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Distribution authorized to U.S. Gov't. agencies and their contractors; Critical Technology; SEP 1969. Other requests shall be referred to Army Materiel Command, Attn: AMCRD-TV, Washington, DC 20315.

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usamc ltr, 14 jan 1972

THIS PAGE IS UNCLASSIFIED

'AN

CPAMPHLET

AMCP 706-125

ENGINEERING DESIGN HANDBOOK

ELECTRICAL
WIRE AND CABLE
Reproduced by the

'A

_4
FEB 19 19 S

tor

lntormation Springfield Va. 22151

Federal Scientific & Techn;cal

11STATWARIT

.... #2 UNCLASS&IID to spe..- il export controls SX4 ~1adocument is Sbet trausm4ttal to flTreign '.n ri,,nZentL or foreign nationals xmqr W , made I ggyj with prior approval o:1----------------

HEADQUARTERS, U.S. ARMY MATERIEL COMMAND

SEPTEMBER 1969

. ... ;L6
A

DISCLAIMER NOTICE
THIS DOCUMENT IS BEST QUALITY PRACTICABLE. THE COPY FURNISHED TO DTIC CONTAINED A SIGNIFICANT NUMBER OF PAGES WHICH DO NOT REPRODUCE LEGIBLY.

drJ

HEADQUARTERS UNITED STATES ARMY MATERIEL COMMAND WASHINGTON, D.C. 20315

30 September 1969

AMC PAMPHLET No. 706-125

ENGINEERING DESIGN HANDBOOK ELECTRICAL WIRE AND CABLE

Page LIST OF ILLUSTRATIONS .................. ..... LIST OF TABLES ............................ LIST OF EQUATIONS - QUICK REFERENCE ........ ... PREFACE .............................. CHAPTER 1 CONDUCTORS xi xiii xvi xix

Paragraph "

1-1 1--1.1

1--1.2
1-2 1-2.1 1-2.2 1-2.3 1-2.4

Material Elements .. .......................... Copper (ETP and OFHC) .. ..................... Copper (Hot Rolled) .. ........................ Wire Size (Solid) .. .......................... Gaging Systems ........................... Circular Mil Area (CMA) ....................... Copper Wire Dimensions ....................... DC Resistance .. ...........................

1-1 1-1

1-1
1-1 1-1 1-1 1-2 1-2

1-3
1-3.1 1-3.1.1 1-3.1.2 1-3.1.3 1-3.2 1-3.3 1-4 1-4.1 1-4.2 1-5 1-5.1 1-5.2 1-5.3 1-6 1-6.1 1-6.2
1-6.3 1k

Coatings ...

...............................
:

1-2
1-2 1-2 1-3 1-4 1-4 1-5 i-5 1-5

I, "

1-7

Methods of Coating ........................... Tin ... .................................. Silver .......... ........................ Nickel .. ................................. Dual Coating ............................... Claddings .. ............................... Aluminum ........... ................. Uses .. .................................. Coatings ................................ Alloys ................................. General Propeties .. ......................... High Conductivity Types ....................... High Conductivity-High Strength Types ............. Stranding ...... ........................... Bunched Stranding .. ......................... Concentric Stranding .......................... Rope Stranding ........................... Soldenng ...............................

1-S
1-5 1-5 1-5 1-6 1-6

I1-8 1-8 1-8

1-7.1 1-7.2 1-7.3 1-7.4 1-7.5 1-8 1-8.1 1-8.2 1-9 1-9.1

Soldering Stranded Wire .. ...................... 1-9 Heavy Tinned Stra.iding .. ...................... 1-9 Silver-coated Stranding ........................ 1-9 Nickel-coated Stranding . ...................... 1-10 Composite Stranding ......................... 1-10 Terminations .............................. 1-10 Crimp Termination...........................1-10 Wire Wrap Termination ......................... 1-10 Shielding .................................. 1-11 General .. ................................ 1-11

AMCP 706-125

Paragraph 1-9.2 1-9.3 1-9.4 1-9.5 1-10 U.1-10.1 1-10.2 Braid Terminology........................... Computation of Braid Angle and Coverage............. Served Shields.............................. Shielding Effectiveness......................... Flex-life Comparison-Copper vs Alloy 63..............1-19 Test Method........................ ....... Comparative Data ................... References. .. .. .. .. .. .. .. .. ... .. ... ....

Page 1-11 1-12 1-13 1-13 1-19 1-19 1-25V

..

CHAPTrER 2 INSULATION MATERIALS 2-1 2-2 2-2.1 2-2.2 2-2.2.1 2-2.2.2 2-2.2.3 2-3 2-3.1 2-3.2 Introductioa............................... The.zmiplastic Insulation Materials.................. Polyvinylchioride............................ Polyolefins................................ Low-density Polyethylene....................... High-density Polyethylene....................... Polypropylene.............................. Cros.Iinked Polyolefins........................ Nylon.................................... Fluorocarbons.............................. Polytetrafluoroethylene (TFE).................... Copolymtr of Teirafluoroethylene and Perfluoropropylene (FEP)...................... 2-1 2-1 2-1 2-2 2-2 2-2 2-3

.12-2.3 2-2.4
2-3.4
2-3.3 2-4 2-4.1 2-4.2 2-4.3 2-5 2-5.1 2-5.2 2-5i.3 2-5.4 2-5.5 2-5.6 2.-5.7 2-5.8 2-6 2-6.1 2-6.2 2-6.3 2-6.4 2-7 2-7.1 2-7.2 2-7.3

2-3
2-6 2-7 2-7 2-7 2-8 2-8 2-8 2-9 2-9 2-9 2-9 2-9 2-10 2-10 2-10 2-13 2-13 2-13 2-14 2-14 2-14 2-16 2-16 2-17 2-17 2-17

Polyvinlidenetfluorie (F)...................2-8C
Polyvihlroerifluorehy e (TFE.................... Polyurethanes:.............................. Physical Properties .......................... Thermal Properties........................... Uses..................................... Rubber................................... Natural Rubber (Polyisoprene).................... Styrene-butadiene Rubbers. .. .. .. .. .. .. .. .. .. ... Chloroprene Rubber. .. .. .. .. .. .. .. .. .. .. .. ... Butyl Rubber. .. .. .. .. .. .. .. .. .. .. .. .. .. ... Silicone Rubber............................. Chlorosulfonated Polyethylene..................... Ethylene Propylene Rubber...................... Fluorocarbon Rubber......................... Films................................... Cellulosics................................ P31lvcsters................................ Fluorocarbons............................. Polyimide................................ Fibers................................... Cotton....................................2-17 Rayon.................................. Nylon...................................

I
V

AMCP 706-125

Paragraph 2-7.4 2-7.5 2-7.6 2-7.7 2-7.8

$

Page Polyester .. ............................... Class .. ................................ Ceramina ................................ Asbestos ............................... " ""2-18 Fiber Combination?........................... Coated Fibers..............................2-18 Lacquers ................................... Cellulose Acetate Butyrate ......................... Nylon ..................................... Bondable Coatings ............................. PolySImide Coatings ......................... Typesiaof PottingCompounds ..................... Potting - Design Criteria .. ...................... 2-17 2-17 2-18 2-18 2-18 2-18 2-18 2-20 2-20 2-2 1 2-21 2-21 2-21 2-21 2-21 2-23 2_23 2-23 2-23 2-23 2-27

2-7.9 2-8 2-8.1 2--8.2 2-8.6 2-8.7 2- 9. 2-9.2 2-9.2.1 2-9.2.2 2-9.2.3 2-10 2-10.1 2-10.2 2-11.2

..... ........

hJ2-11
S2-11.1

... Surface Preparation ......................... ..... .. Mechanical Factors .................... Chemical Factors .......................... ... Inorganic Insulations. .. .. .. .. .. .. .. .. .. .. .. ... Magnesium Oxide Insulation .. .. .. .. .. .. .. .. .. ... Magnesium Oxide Beads . . . . . . . . . . . . . . . . . . . .. ". Special Environments .. .. .. .. .. .. .. .. .. .. .. .... Fungus Resistance .. .. . . . . . . . . . . . . . . . . . . . . . . ... Radiation Resistance ........................ References .............................. ... CHAPTER 3

i,

DESIGN FACTORS - HOOK-UP AND INTERCONNECTING WIRE 3-1 3-2 3-2.1 3-2.1.1 3-2.1.2 3-2.1.3 3-2.1.4 3-2.2 3-2.2.1 3-2.2.3 3-2.2.4 Scope ..... ............... ................... Factors Influencing Design........................... Environm-mial Factors .. .. .. .. .. .. .. .. .. .. ..... High Temperature. .. .. .. .. .. .. .. .. .. .. .. .. ... Low Temperatui . .. .. .. .. .. .. .. .. .. .. .. .. ... I-lammabiity .. .. .. .. .. .. .. .. .. .. .. .. .. .... Moisture and Fung.s . .. .. .. .. .. .. .. .. .. .. .. ... Chemicali Factors ... .......................... Liquid................................... Gaseous................................. Corrosion.................................. 3-I 3-I 1 3-1 3--1 3-1 3-1 3-2 3-2 3-2 33-2

3-2.2.5
3-2.3 3.-2.3.1 3-2.3.2 3-.2.3.3

O'.!tassing.................................
Mechanical Factois............................ Fl ' ex ife ............................... Abrasion Resistance........................... Penetiation................................

3-2K.
3-2 3-2 3-3 3-3

Wikl

AMCP 706-125

Paragraph
3-2.3.4 3-2.3.5 Tensile Strength ..... .......................... Elongation ..... ............................

Page
3-3 3,-3

3-2.4
3-2.41 3-2.4.2 3-2A.3 3-2.4.4 3.2.4.5 3-2A4.6 3-2.4.7 3-2.5 3-3 3-3.1 3-3.1.1 3-3.1,2 3-3.2 3-3.2.1 3-3.2.2 3-4 3-4.1 3-4.2 3-4.3 3-4.4 3-4.5 3-4.6 3-5 3-5.1 3-5.2 3-6 3-6.1 3-6.2 3-6.3 3-6.4 3-6.5 3-7 3--7.1 3-7.2 3-7.3 3-7.4

Electrical Factors..............................
Dielectric Constant ......................... Dielectric Strength ......................... Gradient (Electrical) ........................ Insulation Resistance ........................ Loss Factor ............................. Current-carrying Capacity ..................... Voltage Drop ............................ Identification ............................ Design Considerations ....................... Conductor Choices ..... ....................... Mechanical Factors ..... ........................ Thermal Factors .............................. Insulation Choices ......................... Mechanical Considerations ..................... Electrical Considerations ...................... Testing To Prove Design ...................... Electrical Tests ........................... Physical Tests ............................ Aging Tests ..... ............................. Thermal Tests ............................ Mechanical Tests .......................... Chemical Tects ........................... Hook-up vs Interconnecting Wire ................ Hook-up Wire ................................ Interconnecting Wire and Cable .................. Comparison of Hook-up Wire Types .... .............. MIL-W-76 ..... .............................. MIL-W-16878D ........................... MJL-W-81044 .............................. M__L.W-27300 ............................ MIL-W-22759 ............................ Comparison of Interconnecting Wire Type, ........... MIL-W-5086 .............................. M1L-W4;1044 . ............................ MIL-W,7139 . ............................. MIL-W-8777 ............................. References ................ .............. CHAPTER 4 BUNDLED WIRES ..... ..... ..... ..... ..... ..... . ...

3-3
3-3 3-3 3-3 3-4 3-4 3-4 3-4 .. 3-5 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3-7 3-8 3-8 3-8 3-11/3-12 3-11/3-12 3-11/3-12 3-11/3-12 3-11/3-12 3-11/3-12 3-11/3-12 3-11/3-12 3-11/3-12 3-15/3-16

..... .... .... .... ..... ..... ..... ..... ..... ..... ....

. . ..

4-1 4-1.1 4-1.2 4-2 4-2.1 4-2.2

Laced Bundles ................................. Lacing ............................. Usage - Laced Bundles ....................... Prefabricated Bindles ..... ..................... Construction .................................. Components ..... ...........................

..

4-1 4-1 44-1 4-2

iv

Fm

AMCP 706125

Paragraph 4-2.3 4-2.4 4-2.5 4-3 4-3.1 4-3.2 4-4 4-4.1 4-4.2 4-4.3 4-5 4-5.1 4-5.2 4-5.3 4-5.3.1 4-5.3.2 4-5.3.3 4-5.3.4 4-5.3.5 4-6 4-6.1 4-6.2 4-7 4-47'.1 4-7.2 4-7.3 4-7.3.1 4-7.3.2 4-7.3.3 4-7.4 4-7.5 4-7.5.1 4-7.5.2 4-7.5.3 4-7.6

Page Color Code .................................. 4-2 Shield ... ................................. 4-2 Jacket ... ................................. 4-2 Deraiing Factors for Bundled Wires .................. 4-2 Introduction ............................. 4-2 Basic Considerations ... ........................ 4-2 Derating Calculations ........................... 4-6 Symbols and Their Definitions ... .................. 4-6 Rating Procedure ... .......................... 4-6 Usage -Current Rating Procedure .................. 4-7 Ribbon Cable ... ............................ 4-21 Introductioa .. ............................. 4-21 Usage ... ................................. 4-21 Constnction ............................... 4-21 Adhesive Bonding ............................. 4-21 Thermal Fusing ... ........................... 4-21 Direct Extrusion ... .......................... 4-21 Envelope ......... ......................... 4-21 Braided or Woven ............................. 4-21 Comparison - Ribbon Cable vs Round Multiconductor Cable. 4-21 Advantages - Ribbon Cable ...................... 4-21 Disadvantages - Ribbon Cable .................... 4-22 Tape Cable ................................ 4-22 Introduction ............................. 4-22 Usage ... ................................. 4-22 Flat Wire ... ............................... 4-22 Constructional Factors ......................... 4-23 Construction ............................... 4-23 D'advantages - Flat Wire ....................... 4-23 Constructional Considerations ...................... 4-23 Testing ... ................................ 4-23 Folding Test ............................. ... 4-24 Roll Flexure lest .......................... ... 4-24 Straight Flexure Test ........................ 4-24 Installation .............................. ... 4-26 References ................................. 4-27 CHAPTER 5 COAXIAL CABLE 5-1 5-1 5-I 5-1 5-1 5-1 5-1 5-1 5-1

5-1 5-2 5-2.1 5-2.1.1 5-2.1.2 5-2.1.3 5-2.1.4 5-2.1.5 5-3

Introduction .... ............................ Types of Coaxial Cable .... ..................... Definitions .... ............................. Coaxial ................................ Twin Coaxial ............................ Dual Coaxial ............................. Double Shielded ............................... Triaxial ..... ............................. Materials ...............................

-~_____

)f

-AMCP

706-125

Paragraph 5-4 5-4.5-4.1.1 5-4.1.2 5-4.1.3 5-4.1A 5-4.1.5 5-4.1.6 5-4.1.7 5-4.1.8 5-4.1.9 5-5 5-5.1 5-5.2 5-6 5-6.1 5-6.2 5-7 5-7.1 5-7.2 5-8 5-8.1 5-8.2 5-8.3 5-9 5-9.1 5-9.2 5-10 5-10.1 5-10.2 5-11 5-11.1 5-11.2 5-12 5-12.1 5-12.2 5-12.3 5-13 5-13.1 5-13.2 5-13.3 5-13.4 5-14 5-14.1 5-14.2 5-15 Electrical Properties of Coaxial Cable ................ Basic Parameters .... ......................... Capacitance .... ............................ Phase Angle .... ............................ Power Factor .... ........................... Dielectric Constant ........................... Velocity of Propagation ... ..................... Characteristic Impedance ..................... Propagation Constant ........................ Attenuation and Phase Shift ................... Corona and Voltage Rating .................... Air-spaced Cables .......................... General Constructional Details ................. Uses .................................. Voltage Standing Wave Ratio (VSWR) .............. Reflection - Coaxial Cable System ................ Reflection Causes - Coaxial Cable Systems ........... Power Rating ... ............................ Power Handling Capacity ... ..................... Power Rating Due to VSWR ..................... Shields ... ................................ Picks ......... : ....................... Carriers ... ................................ Ends ... ................................. Shielding Effectiveness .......................... Surface Transfer Impedance ....................... Reference ... .............................. Transmission Unbalance ........................ General ................................ References for Test and Measurement .............. Coverings and Sheaths ....................... Uses .................................. Fibrous or Textile ... ......................... Special Purpose Coaxial Cables .................... Pulse Cables ... ............................. Delay Lines ... ............................. Low Noise Cable ... .......................... Practical Constructional Considerations ............... Size ... .................................. Concentricity and Eccentricity .................. Abrasion ............................... Contamination ............................ Environmental Conditions ....................... General Considerations ......................... Insulation Guide ............................ Dissussion of Application - Major Usage ............. References .............................

Page 5-1 5-1 5-2 5-5 5-5 5-5 5-5 .... 5-5 .... 5-8 .... 5-8 ... 5-14 .... 5-20 .... 5-20 .... 5-20 .. 5 -20 .. 5-20 5-22 5-22 5-22 5-23 5-23 5-23 5-23 5-23 5-25 5-25 5-26 5-26 .... 5-26 .. 5-27 ... 5-27 .... 5-27 5-27 5-28 5-28 5-28 5-29 5-29 5-29 ... 5-30 .... 5-30 ... 5-30 5-30 5--30 5-30 5-30 . 5-31/5-32

viC

r-

18

AMCP 706-125

Paragraph CHAPTER 6 6-1 6-2 6-3 6-3.1 CONTROL AND SIGNAL CABLES

Page

'0

Introduction ... ............................. Ar-lications of Control and Signal Cables ............. Cor itructional Des.gn Factors .. .................. Physical Considerations ... ......................

6-1 6-1 6-1 6-1

6-3.2
6-4 6-4.1 6-4.2 6-5 6-5.1 6-5.2 6-6

Electrical Considerations ........................

Cable Types ................................ Portable ... ............................... Nonportable ... ............................. Multiconductor Cable Design ..................... General Considerations ......................... Specific Coastruction Considerations ....... Multiconductor Construction .....................

6-2
6-2 6-2 6.-2 6-2 6-2 6--3 6-3

........

6-6.1
6-6.2 6-6.3 6-6.4 6-6.5 6-6.6 6-6.6.1 6-6.6.2 6-6.6.3 6-6.7 6-6.8 6-6.8.1 6-6.8.2 6-6.8.3 6-6.8.4 6-6.9 6-6.10 6-6.11 6-6.12 6-6.13 6-7 6-7.1 6 7.2 6-7.3 6-7.3.1 6-7.3.2 6-7.3.3 6-7.3.4 6-7.3.5 6-7.3.6 6-7.3.7

Conductors and Components .....................

6-3

IW

Component Strandings ......................... 6-6 Basic Insulated Wire ... ........................ 6-6 Component Shielding ........................... 6-6 Component Shield Covering and Component Jacket Dimensions 6-7 Cabling ... ................................ 6-7 Lay .. ................................... 6-8 . 6-9 ......................... Pitch Diameter ... Lay Construction .. .......................... 6-9 Cable Fillers ... ............................. 6-9 Color Coding Control and Signal Cables .............. 6-10 Color Coding Methods ....................... .. 6-10 Color Code Application ...................... ... 6-10 Color Code and Related Numbers ................ .. 6-I1 Specifications .. ............................ 6-11 Cable Binders . ............................. 6-12 Cable Sheaths .. ............................ 6-13 Sheath Application ........................ 6-13 Armor ... ................................ 6-13 Cable Identification Marking .. ................... 6-15 Multiconductor Cable Testing .................... 6-16 Cable Cross-talk ........................... 6-16 Tests and Test Methods .. ...................... 6-16 6-16 Multiconductor Cable Tests ..................... 6-17 Cold Bend Test ........................... Impact Test .. ............................. 6-17 Torque Test .. ............................. 6-17 Twist Te. . ............................... 6-17 Bend Test ... .............................. 6-18 Dielectric and Pulse Dielectric Tests ................ 6-19 Insulation Resistance Test ...................... 6-22

6-7.3.8
6-7.3.9 6-7.3.10

Measuring Capacitance in a Multiconductor Cable..........6-23

Abrasion Resistance .. ........................ Tensile Strength of Multiconductor Cable ............. References ..............................
__vii_

6-25 6-27 6-29

i'-

AMCP 706-126

Paragraph CHAPTER 7 POWER CABLES 7-1 7-1.1 7-1.2 7-2 7-2.1 7-2.1.1 7-2.1.2 7-2.1.3 7-2.2 7-2.3 7--3 7-3.1 7-3.2 7-3.3 7-4 Introduction ... ............................. Usage .................................... General Design Factors .......................... ...... Major Constructional Design Factors ........ ............................. Conductor .... Conductor Material ............................ .......................... Conductor Size .... Conductor Form .... ......................... Insulation .... .............................. ................................ Sheath .... Miscellaneous Constructional Design Factors .......... ............................... Shields .... Cabling .... ............................... Ground Wires ... ............................ Voltage Drop .... ........................... References ... .............................. CHAPTER 8 8-1 8-1.1 8-1.2 8-2 8-3 8-3.1 8-3.2 8-3.3 8-3A 8-3.5 8-3.6 8-4 8-4.1 8-4.2 8-4.3 8-4.3.1 8-4.3.2 8-4.3.3 8-43.4 8-4.3.5 8-43.6 8-4.3.7 8-4.3.C 8-4.3.9 8-4.3.10 8-5 8-5.1 3-5.2 viii SPECIAL PURPOSE CABLES

Page

7-1 7-1 7-1 7-1 7-1 7-1 7-1 7-2 7-2 7-2 7-2 7-2 7-2 7-2 7-3 7-25

Int:oduction ................................ General Types ... ............................ Design Factors ............................... Hybrid Cable Design Factors ...................... Construction Check List ......................... ........................ Basic Insulated Wires ... Component Lay-up ............................ ............................ Core Binder .... Outer Covering .............................. Cable Identification ............................ Protective Braid ... ........................... Sample Hybrid Cable Configuration ................. Sample Cable Requirements ....................... Sample Cable Constructional Factors ................. Sample Cable Lay-up .......................... Component Constnction ... ..................... Component Color Coding ........................ Component Precabling Tests ... ................... Cable Core Lay-up ... ......................... Core Binder .... ............................ Core Dkmneter Calculation ..................... Core Shi4ding ................................ Cable Separator .............................. Cable Sheath ................................. Cable Identification ............................ Choike of Cable for Equipment Design ............... Light- or Medium-duty Cables ..................... ... Heavy-duty Cables ........................

8-1 8-1 8-1 8-1 8-1 8-1 8-2 8-2 8-2 8-2 8-2 8-2 8-.2 8-3 8-4 8-4 8-5 8-7 8-7 3-7 8-3
6-8

8-8 8-9 8-10 8-10 8-11 8-11

AFACP 7OG.125

Pararap

Page Nonhosing or Waterbiock Cables................... General Description........................... Nanhosing Cable Applicationm.................... Thermocouple Cables.............. ............ Introduction................................ General Operational Factors...................... Thermocouple Materials........................ Thermocouple Procurement...................... Calibration................................. 1Ibermocouples vs Lead Wires..................... Construction................................ Cunductors................................ Insulation.............................. .. Constructional Examples. .. .. .. .. .. .. .. .. .. .. ... hIstalatio. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... Electromotive Force .. .. .. .. .. .. .. .. .. .. .. ..... Ignition Wire - High Voltage .. .. .. .. .. .. .. .. .. ... Introduction. .. .. .. .. .. .. .. .. .. .. .. .. .. ..... Design Considerations.......................... Conductor................................. Insulation................................. Reinforcing Braid ............................ Outer Protective Fiber Braid..................... Shield.................................... Specifications............... ............... References................................. CHAPTER 9 TELEPHONE CABLES 8-4i2 8-12 8-13 8-13 8-13 8-14 8-15 8-15

-I

8-6 8-6.1 8-6.2 8-7 8-7.1 8-7.2 8-7.3 8-7.4 8-7.5 8-8 8-8.1 8-8.1.1 8-8.1.2 8-8.2 8-8.3 8-8.4 8-9 8-9.1 8-9.2 8-9.2.1 8-9.2.2 8-9.2.3 8-9.2.4 8-9.2.5 8-9.3

8-15
8-15 8-16 8-16 8-16 8-16 8-16 8-17 8-17 8-17 8-17 8-1-1 8-19 8-19 8-19 8-19 8-19 8-20

9-1 9-2 9-3 9-3.1 9-3.2 9-3.2.1 9-3.2.2

Introduction................................ Major Categories............................. Audio Cord............................... Basic Design................................ Tinsel Cord ............................... Basic Design .. .. .. .. .. .. .. ... .. .. .. .. ..... Construction and Tests .. .. .. .. .. .. .. .. .. .. ......

9-1 9--i 9-1 9-1 9-1 9-2 9.2

9-3.31
__

9-3.3.2 9-3A3 9-3.3.1 9-3.2 9-3.5 9-35.1 9-35.2 9-3.5.3 9-3.5.4 9-3.6

Maiiat Caleostpcti Prse.................. Tests..............................................[ Renitre (HCal) Crs.-.....urpo....................9-4 Basic Design andCo.truti...............'** *'* .... 9-4 Tests.............................. ...... 9-7 Multiconductor Cord (Retractile).................. 9Usage....................................9-7 Basic Design................................ 9-7 Retractile Construction...........................9-8 Retractile Testing........................... 9Specifications............................... 9-9

Ix

AMCP 706-125

Parar,aph 9-3.7 9-4 9-4.1 9-4.2 9-43 9-4.4 9-4.5 9-4.6 9-4.6.1 9-4.6.2 9-4.7 9-5 9-5.1 9-5.2 9-5.3 9-5.4 9-5.5 9-5.5.1 9-5.5.2 9-5.6 9-5.7 9-5.8 9-6 9-6.1 9-6.2 9-6.3 9-6.4 9-6.4.1 9-6.4.2 9-6.5 9-6.6 9-6.6.1 9-6.6.1.1 9-6.6.1.2 9-6.6.1.2.1
9-6.6.1.2.2

Page Alternate Constructions ... ...................... Field Wire ... .............................. Usage ... ................................. Installation Factors ... ......................... Field Wire Types ... .......................... Construction ................................ Test Data .................................. Packaging .................................. Canvas Dispenser Construction .................... Plastic Dispenser Construction .. .................. Specifications .... ......................... Multipair Telephone Cabks....................... Us g .................................... Cable Requirements .. ........................ Reasons fcr Testing .................. ....... Basic Design .. ............................. Electical Chara, Ieristics ......................... Mutual Capacitance (Pair) ..................... ... Capacitance Unbalance (Pair) .................. .... Construction ............................. ... Tests for Cable .. ........................... Specifications .. ............................ Telephone Multicnannei Communication Cables ........ Usage .. ................................. Construction ............................... Tests for Cable ... ........................... Pulse Code Modulation Cables .. .................. FDM and PCM Systems ...................... Cable Requirements .. ........................ Construction 'and Performance Data ................ Cable Testing ............................ .... Test Procedures and Requirements ................ .. Test Procedures ........................... .... ........ Shielding Effectiveness .............. Framing Test ... ............................
....................... Radiation from Cabl . ..

I
"

9-9 9-9 9-9 9-9 9-9 9-10 9-13 9-13 9-14 9-14 9-16 9-17 9-17 9-17 9-20 9-20 9-,20 9-20 9-21 9-21 9-22 9-23 9-23 9-23 9-23 9-24 9-24 9-2.A 9-24 9-25 9-25 9-25 9-25 9-25 9-25
9-28

9-6.6.1.2.3 9-6.6.1.3 9-6.7 9-6.8

Calculation of Shielding Effectiveness .............. 9-29 Tensile and Sag .. ........................... 9-30 Lightning P:otection of Cable Systems ...... ........ . Q-31 References for PCM and Multichannel Cables and Systems . . 9-31 References .. .............................. 9-34
GLOSSARY ............. ................. G-1

BIBLIOGRAPHY ............................. APPENDIX .... ............................ INDEX ..... ..............................

B-1 A-i -.

ing

AMCP 706-125

LIST -OF ILLUSTRATIONS

Figure
1_-i 4-1 4-2 4 -3

Title
Shield - Constructional Details.................... Calculation of Free Convective Heat Dissipation ........ Calcul.,ion of Bundling Factor for 105 0C...............4-9 Wrapping Factor vs Ratio of Unwrapped to Wrapped Cross-sectional A-ea for Typical Bundle

Page1 1-12
-

01:
TITK

~4-4
4-5 4-6 4-7 4-8 4-9 5-1 5-2 5-3 5-4

Diameters. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ...

4-12

le, I

I5-5

5-6

,5-7

5-8 5_-9 5-10

5-1

Calculation of Bwaidling Factor .. .. .. .. .. .. .. .. .... 4-12 Calculation of Radiant Heat Dissipation ............... 4-14 Bonded Ribbon Cable Configuration ......... 4-22 Laminated Flat Conductor Cable .. .. .. .. .. . ..... .....24 4-25 Rol-.d Flex Test. .. .. .. .. .. .. .. .. .. .. ...... Straightl Flex Test. .. .. .. .. .. .. .. .. .. .. .. .. ... 4-25 Coaxial Cable .. .. .. .. .. .. .. .. .. .. .. .. .. ..... 5-2 Twin Coaxial (Parallel)......................... S-3 Twin Coaxial (Twisted)........................ 5DiA Coaxial (Parallel).......................... 5-3 Dual Coaxial (Twisted)......................... 5-4 Double Shielded Coaxial .......................... 5-4 Triaxial Cable............................... 5-4 Basic Parameters of a Transmission Line.............. 5-7 Rc-lationship of Diameters to Dielectric Constant......... 5-9 Changes hi Z, Due to Dld Ratio Change............... 5-10

5-11 5-13 5-14 5-15 5-16 5-17 5-18 6-1

Ti

Twin Coaxial Cross Section...................... 5-11 Attenuation vs Frequency - Polyethylene Cable...........5-15 Average Power Ratings of 50.ohm Polyethylene Cables.................................. 5-24 Average Power Ratings of 50.ohin Teflon Cables .......... 5-25 Pewer Rating Due to VSW-vR - Teflon Cable ............. 5-26 Power Rating Due to VSWR - Polyethylene Cable ......... 5-2.7 Shield - Constructional Details.................... 5-28L Typical Multiconductor Cable Design................. 6-3 Brehil La............................ g 6-8 Braided hieldaAngl.............................6-8 Pitch Diameter.............................. 6-10 Contrahelical Lay............................ 6-10 Reinforced Sheath Configuration................. 6-15 Impact Test Fixture........................... 6-18 Twist Test Fixture............................ 6-19 Ninety-degree Bend Test Fixture................... 6-20 Pulse Dielectric Test Fixture..................... 6-21

oxa rs eto

.. . . . . . . . .

54

I6-11

6-3 6-23 6-4 6 -5 6-6 6-7 6-8 6-9 6-10

6-12
6-13

Capacitance of a Pair (Schematic)..................

Pair-to-palr Capacitance Unbalancc (Schematic).......... Pair-to-shield Capacitance Unbalance (Schematic) ..........

6-23

6-25

6-24

xi

i-

.CP-705-I25

LIST OF ILLUSTRATIONS (CONT.)

Figure 6-14 6-15 6-16 8-1 8-2 8-3 8-4 8-5 9-1 9-2 9-3 9-4 9-5 9-6 97 9.-8 9-9 9-10 9-11 9-12 9-13 Ttle Sandpaper Abrasion Test Apparatus ............... .. Tungsten Carbide Rod Abrasion Test Apparatus ........ . Tensile or Breaking Strength Test Methods ........... .. Hybrid Configuration - Component Placement ........ ... Hybrid Configuration - Component Placement ........ ... Hybrid Configuration - Filler Placement ............ Hybrid Configuration - Completed Cable ............ Typical Thermocouple Application ................ Spcial Purpose Cable - WD 27 A/U ................ Special Purpose Cable - WM 69 B/U .............. Special Purpose Cable - WM 70 B/U .............. Special Purpose Cable - WM Ill A/U .............. Field Wire Comparison - Attenuation vs Frequency ..... Field Wire Comparison - Characteristic Impedance vs Frequency .. ............................ Field W-he Comparison - Phase Constant vs Frequency .... Field Wire Comparison - Velocity of Propagation vs Frequency .. ............................ Field Wire Comparison - Transmission Range vs Frequency ............................ ... Canvas Dispenser - Field Wire .................. ... Semi-rigid Dispenser - Field Wire .................. Field Test Set-up for Transmission and Shielding Effectiveness .. ...................... Low Frequency Shielding Effectiveness Test Set-up .. ............................. Page 6-26 6-27 6-28 8-8 8-9 8-10 8-12 8-15 9-6 9-6 9-6 9-7 9-14 9-15 9-16 9-17 9-18 9-18 9-19 9-28 9-32

iti

[V
I'

IL
-

-_

V
.W

AMCP 706. 25

LIST OF TABLES
Table No. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 2-1 2-2 2-3 2-4 2-5 2--6 2-7 2-8 2-9 3-1
1 U "3--2

Title Data - Copper-clad Steel Conductors ............... Design Guide - Shield Wire Si7e .................. Shielding Effectiveness - Various Matrials and Constructions ......................... ... Wire Chart - Solid Conduc, ors ................... .. Flex-life of Copper vs Alloy 63 .................. Wire Chart - Stranded Conductors ................ .. General Properties of Conductor Materials ........... .. Stranding Lay Lengths - Stranded Conductors ......... . Typical Applications for Polyolefin Resins ........... ... Typical Properties of Thermoplastic Materials ........ . Typical Properties of Elastomeric Compositions ........

Page 1-6 1-12 1-13 1-15 1-19 1-20 1-22 1-24 2-3 2-4 2-11

4-1 4-2 4-3

4-4 4-5 4-6

z ,.,

2-15 Typical Properties of Films . ..------------------2-19 Typical Properties of Fibers .................... 2-22 Properties of Typical Potting Compounds -------------2-24 Properties of Typical Inorganic Insulating Materials ...... Relative Radiation Resistance of Insulating Materials in Air ..........................- 2-25 2-26 Relative Costs of Insulating Materials .............. Existing Military Specifications for General 3-9/3-10 Purpose Wire (Hook-up) --------------------Existing Military Specifications for Interconnecting Wire ..................... 3-13/3-14 4-3 Bundle Shield Material Selection Chart ............. Core and/or Sheath Material Selection for 4-4 Bundled Wires ................... ........ Values of Ideal Heat Dissipation for Horizontal Cable at Standard 4-10 Atmospheric Air Pressure ....-........... 4-11 Temperature Factors (Derating) .................Cabled Wire Current Rating - Example No.1-4-13 Bundled Wire Current Rating ................... 4-7 Cabled Wire Current Rating-Example No.2 (First Calculation) ................... ...... Cabled Wire Current Rating - Example No. 2 (Second Calculation) ....................... Cabled Wire Current Rating - Example No. 2 (Third Calculation) ........................ Dielectric Constant and Velocity of Insulating Materials .................. ...... Characteristics of Standard RF Cables .............. Characteristics of Semi-solid RF Cab!es .. .. .. .. .. .. . Shielding Effectiveness K, @ I MHz for Various Shield Materials and ConstructIons .......... Component Twist - Diameter Multiplying Factor ....... Diameter Increase Due to Shield Application .......... Average Wall Thickness - Shield CoverLig (Light- and Medium-duty) .................... 4-15 4-17 4-18 4-19 5-7 5-16 5-21 5-29 6-4 6-7 6-8

' 4-8 4-9 5-1 5-2 5-3 5-4 6-1 6-2 6-3

AMCP 706.125

LIST OF TABLES (CONT.)

Tabit No. 6-4 6-5 6-6 6-7 6-8 6-9 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9
Tile

C,
Page 6-11 6-12 6- 14 6-15 6-16 6-22 7-4 7-5 7-6 7-7 7-8 .K 7-9 7-10 7-11

Striping - Lay Length ......................... Color Code and Related Numbers .................. Sheathing Materials and Their Properties .............. Common Overall Polychloroprene Sheath - Wall Thickness ................................. Standard Constiiction of Twisted Pair Multilayer Cable for Reduction of Cross-talk ................................. Electrical Constants - Insulation Materials ............. Current.carrying Capacity in Underground Ducts, One Single-conductor Cable Per Duct, 0.600 volts, 0-60 Hz .................... ... Current-carrying Capacity in Underground Ducts, Three Single Ccnductors Per Duct, 0-600 volts, 0-60 Hz .................... ... Current-carrying Capacity in Underground Ducts, One Three-conductor Cable Per Duct, 3-600 volts, 0-60 Hz ................. .... Current-iarrying Capacity in Enclosed or Exposed Conduit, Single-conductor Cables, 0-600 volts, 0-60 Hz ................... Current-carrying Capacity in Enclosed or Exposed Conduit, Three-conductor Cable, 0-600 volts, 0-60 Hz ....................... Current Rating Correction Factors for Cables in Various Groupings of Conduits ............................. Current-carrying Capacity in Air, Single-conductor and Three-conductor Cables, 0-600 volts, 0-60 Hz ................... Current Rating Correction Factors for Various Groupings of Cables in Air ........................... Current-carrying Capacity of Cables Buried Directly in Earth, Three Single-conductor Cables Spaced 6 Inches Apart, Buried 3 Feet Underground ........... Current-carrying Capacity of Cables Buried Directly in Earth, Three-Conductor Cables, Spaced 18 Inches Apart, Buried 3 Feet Underground ....................... Current-carrying Capacity, Portable Power Cable, Rubber-insulated, Rubber-sheathed ..-....... "Flexible" Conductor Strandings of Annealed Copper Wire ...................... "Extra Flexible" Conductor Strandings of Annealed Copper Wire ...................... Conductor Strandings, Aluminum Wire (EC, Hard-drawn) ......................... Physical Properties of Insulation ................. Recommended Insulation Wall Thicknesses ...........

7-12

7-10

7-13 7-14 7-15 7-16 7-17 7-18 7-19

7-11 7-12 7-13 7-14 7-15 7-16

l~v

11

____________ _______

AMCP 706-125

LIS! OF TABLES (CONT.)

Table No. 7-17 7-18 7-19 7-20 Title Cabw Sheaths - Physical Prope,ties ................. Recommended Sheath Thicknesses - Polyhloroprene . . . 'ize of Ground Wires, Annealed Coppr............... Constructional Details of Annealed Copper Ground Wires for "Flexible" and "Extra Plexible" Cable Construction .................. ... Estimated Maximum Line Length for 1-volt Drop Copper Conductors at 60C ................ Helical Wrap Tape Width Selection Guide ............ Light- and Medium-duty Cables - Average Overall Sheath Wall Thicknesses, in ............... .. Light- and Medium-duty Cables - Average Jacket Wall Thicknesses for Shielded Components, in .............................. Heavy-duty Cables - Aveiage Jacket Wall Thicknesses for Shielded Componernts, in ............ Heavy-duty Cables - Average Oveall Reinforced Sheath Wall Thickness, in .............. Thermocouple Insulation and Jacket Selection Guide ................................... Thermocouple-Temperature-EMF Cozrelation Chart ...... Conductor Chart - Audio Cords .................... Cibling Chart - Audio Cords .................. .... Installation Factors - Field Wire ...................... Comparison Chart - Field Wire .................. .. Cable Construction Comparison Chart .............. Multipair Cable - Electrical Characteristics (Pair)-------9.-22 Construction and Performance Data - PCM Cables ...... Framing or Susceptibility Data - PCM Cables (Radio Set Operating at 2.304 MHz) .............. Radiation from Cable Data - PCM Cables (Radio Set Operating at 2.304 MHz) .............. Sag Data - Spiral Four and PCM Cables ............ .. Sag at Various Temperatures - Spiral Four Cable ....... Page 7-20 7-21 7-22

7-23 7-24 8--11 8-11

7-21 8-1 8-2 8-3

8-13 8-14 8-14 8-17 8-18 9-5 9-6 9-10 9-11 9-13 9-26 9-27 9-29 9-32 9-33

8-4 8-5 8-6 8-7 9-1 9-2 9-3 9-4 9-5 9-6 9-7

S,9 9-10 9-! 1

IL

i"v

i Na._-

AMCP 706-125

LIST OF EQUATIONS
Equation No. 1-1 1-2 1-3 1-4 3-1 3-2 3-3 5-2 5-31 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-4 5-15 5-16 5-17 5-18 5-i9 5-20 5-21 5-22 5-23 5-24 5-25 5-26 5-27 5- 28 5_29 5-30 5-31 5-32 5-33 5-34

QUICK REFERENCE
Page

(
1-2 1--7 1-7 1-12 3-3 3-4 3-4 5-5 5-6 5-6 5-6 5-6 5-6 5-7 5-7 5-7 5-8 5-8 5-9 5-9 5-9 5-9 5-9 5-11 5-12 5-12 5-13 5-13 5-13 5-43 5-13 5-13 5-13 5-14 5-14 5-20 5-20 5-20

Strand Weight.-diameter Proportion ................ DC Resistance (0.010 in. and larger strand) ............ DC Resistance (0.0099 in. and smaller strand) ........ Shield Braid-Coverage and Angle ................ Electrical Stress (Gradient) Of Insulation ............ Corrected Conductor Resistivity At Other Than 20 0C Referenced Temperature ..................... Coefficient of Resistivity-Conductor .............. Velocity of Propagation ..................... Characterii.- ImpedanceL > R ) .................

... ... ... ... ...

Capacitance-Concentric Cylindce ................ .... Inductance-C ancentric Cylinder .......... ....... . .. Characteristic Impedance-Concentric Cylinder ......... Characteristic Impedance - Coaxial In RF Range.......... Characteristic Impedance-Dual Conductor Coaxial ...... Capacitance-Dual Conductor Coaxial .............. Inductance-Dual Conductor Coaxial .............. ... Propagation Constant ........................ .. Propagation Constant (using input ) ............ Attenuation (using quantities R, L, C, and G) ......... Phase Constant (using quantitiesR, L, C, and G) ....... Attenuation At High Frequency ................. Phase Constant At High Frequency ............... Attenuation Due To Conductor Loss (see Eq. 3-24) ........................... High Frequency Resistance (solid and tubular :4,in Depth (nonmagnetic material) ............... .... ... RCsLM,:c of Coaxial Cable (per unit length) ......... Resistan-* of Copper Coaxial Cable (per 100 ft) ....... .. High Frequency Resistance (stranded or braided ... conductors) ............................. ... Conductor Loss Foi Eq. 5-18 .................. Attenuation Due To Dielectric Loss (db/unit length) ........................... Conductance Of The Dielectric (for Eq. 5-25) .......... Attenuation Due To Dielectric Loss ... (db/unit length) .......................... Beta (P)Calculation For Eq. 5-21 ................ .. Attenuation Due To Dielectric Loss (db/100 it) ........ .. Total Attenuaion DueTo Dielectric Loss ................ Maximum Voltage Stress-Insulation (perfect cylinder ;n air) ........................... ... .... Reflection Coefficient (VSWR) ................. .. Reflection Coefficient (as a complex quantity) ........ Relation-Reflected Current To Incident Curront (VSWR) .......................... ...

xvi

AMCP 706-125 .

LIST OF EQUATIONS
EquationNo. 5-35 5-36 5-37 5--38 5-39 5--40 5-41 6-1 6-2 6-3 6-4 6-5 6-6 6-7
9-1

QUICK REFERENCE (CONT.)

Page

Loss Due To Reflection (VSWR) ................. Magnitude Of Refleztion Coefficient (VSWR) ......... Peak Power Rating-Coaxial Cable ................ Heat Generated Within A Coaxial System (expressed in terms of attenuation) ....................... Heat Generated Within A Coaxial System (expressed in watts/unit length) ......................... Average Power Rating-Coaxial Cable .............. Power Rating Due To VSWR .................. Calculated Diameter of Twisted Components ........... Establishing An Insulation Res-,iance Value .......... Insulation Resistance-Direo't Measurement ........... Direct Capacitance (paii) ..................... Mutual Capacitance (pair) ....................... Pair-to-pair Capacitance Unbalance ................ Pair-to-shield Capacitance Unbalance ...............
Mutual Capacitance (pair within paired cable) ......... ..

5-22 5-22 5-22 5-22 5-22 5-23 5-23 6-3 6-22 6-22 6-23 6-23 6-24 6-25
9-20

('

9-2

9-3

Capacitance Unbalance (pair within paired -able) ....... Shielding Effectiveness ....................... Sag Factor (aerial installation) .................. Tension In Unsupported Cable Span (aerial installation) ........................ Sag For Any Span Length Other Than In Tables 9-10 and 9-11 ...................... ... .... ...

9-21
9-29

9-4 9-.5 9-6

9-30 9-30 9-31

Li"
xvii/xviii

'p.

I.!
5.

AMCP 706-125

PREFACE

This Engineering Design Handbook, Eiectrical Wire and Cable, contains basic information and fundamental data in the design, usage, and development of ire and cable used in Army materiel and systems. The hndbook contains a wide variety of useful information and quantitative facts as well as authoritative references helpful in the design, development, usage, and maintenance, of wi.es and cables used in modem Army electronic and electrical systems. The information contained herein will enable the systems engineer, technician, buying agency, and user, to meet the tactical and technical needs of the Armed Forces. The highly technical nature of today's Army, together with the demands placed upon it, have greatly enhanced the need for a wire and cable handbcok of this scope. Information which has been amassed through wide experiences of both manufacturer and user has been systematically recorded so a to expedite the search for the necessary technical data. The objective cf thi-handbook is to provide a practical guide to correct design of equipment to meet the exacting transmission requirements of the many and varied aspects of today's electronic and electrical systems Tbe dsignr who (onsiders the proper technology of wire and cable design can alleae--' many problems in proper transmission and installation techniques; whereas, he designer who ignores this technology can and does greatly multiply the proble MEW. T,,lhis handbook contains information on the structure, application, usage, and installation of most of the wires and cables utilized by the Army. Also included are a glossary of terms; a listing of equations for quick reference; and an appendix which presents the applicable Military Specifications, Standards, and Publications.

-.

'1

This handbook was prepared by International Telephone and Telegraph Corporation Wire and Cable Division under subcontract to the Engineering Handbook Office of Duke University, prime contractor to the Army Research Office-Durham for the Engineering HandLcok Series. The Handbooks are readily available to all elements of AMC including personnel and contractors having a need and/or requirement. The Army Materiel Command policy is to release these Engineering Design Handbooks to other DOD activities and their contractors, and other Government agencies in accordance with current Army Regulation 70-31, dated 9 September 1966. Procedures for acquiring these Handbooks follow: a. Activities widtin AMC and other DOD agenciis should direct their request on an official form to: Publications Distribution Branch Letterkenny Army Depot

ii

ATTN: AMXLE-ATD Cllambersburg, Penrsylvania 17201

"

ii

'

I ...
AMCP 706.125

PREFACE (CONT.)
b. Contractors who have Department of Defense contracts should submit their 'request, through their contracting officer with proper justification, to the address indicated in par. a. c. Government agencies other than DOD having need for the Handbooks may submit their request directly to the Letterkenny Army Depot, as indicated in par. a above, or to: Commanding Genzral U.S. Army Materiel Command ATTN: AMCAD-PP Washington, D. C.20315
or

Director Defense Documentation Center ATTN: TCA Cameron Station Alexandria, Virginia 22314 d. Industry not having a Government contrac, (this includes Universities) must forward their request to: Commanding Genera! U. S. Army Materiel Command ATTN: AldCRD-TV Washington, D. C.20315 e. All foreign reqests must be submitted through the Washington, D. C. Embassy to: Office of the Assistant Chief of Staff for Intelligence ATTN: Foreign Liaison Office Departmtent of the Army Washington, D.C 20310

All requests, other than those originating witiin the DOD, .must be accompanied by a-valid justification. Comments and suggestions oa this handbook are encouraged, and should be addressed to Army Research Office-Durham, Box CM, Duke Station, Durham, N. C. 27706.

,@

-I

7!

AMCP 706-I

CHAPTER 1 CONDUCTORS
1-1 MATERIAL ELF ;,ENTS Conductors have the function of getting electricity from one point to another in an electric l circuit. For this handbook, copper and aluminum will be the main materials discussed because of their balance between high conductivity and reasonable price, 1-1.1 COPPER (ETP and OFHC) There are two main divisions of copper used for conductor purposes, electrolytic tough pitch (ETP) copper, and oxygen-free high conductivity (OFHC)* copper which is similar, except that the molten copper is protected by an inert gas cover fior melt to casting in OFHC. Both varieties have similar properties (tensile strengthl, elongation, melt pAint, etc.) except that with ETP when exposed to reducing gases (illuminating gas and hydrogen) at high temperatures (1000*F and above) embrittlement takes place. The manufacture of OFHC within an inert atmosphere adds to its cost and only imparts rerfstance to embrittlement way aboie operating temperature of wire and cable. The'efrie, the piemium price paid for OFHC is wasted in rrost wire and cable applications except where copper wire has to be welded, 1-2 WIRE SIZE (SOLID) 1-2.1 GAGING SYSTZMS While dhere are several gage systems for classifying wire size, the Amieican Wire Gage (AWG) or Brown and Shai'e series of size designations is used for conductor materials in the United States. Table 1-4 Ls arranpd by AWG size and flhows diameters, areas, weighta, and resistances. Ths gage system is a geometric progression whereby each gage cize represents a 20% reduction in area or roughly a 10% reduction in diameter. On this basis every 3 gage sizes approximately doubles the area and every 6 gage sizes apjroximately doubles the diameter. 1-2.2 CIRCULAR MIL AREA (CMA) The arei of round conductors is usually expressed in circular nul. A circular mil is the area of a circle 1 mil in diameter or -2- times a square mil. Therefore, the area of any c4ile is simply the square of the diameter (in mils) expressed in circular mils. There is an easy rule of thumb which imay be used to obtain approximate siz4s of wire if one remembers that #10 AWG wire is approximate!y 1/10 in. in diameter and has approximately 10,000 crcular mils and approximately 1 ohm/1000 ft of length. ExamapL: What is approximate size, weight, area, and, resistance of #22 AWG wire? 22 is 12 sizes smaller than #10, therefore, ilK area has been halved 4 times (#13, #16, #19, #22) making the area ap)roimately 625 circular mils. The diameter has been halved twice (#16, #22) and is approximately 0.025 in. Since resistspe is ;nversely proportional to area, it has been 6doubled 4 times and
Registered Trademark American Metals Climax is approximately lo ohm/1000 ft.

1-1.2 COPPER (HOT ROLLED) Hot rolled copper rod used for drawing into wire usually has embedded in its surface, oxides, scale, dirt. When fine gage stiids (0.025 in. or less) areand to
A be dravn from such rod, the rod thould be prnc .by pickling and die jlhaicd to insure round rod and remove troublesome rolled-in oxides, particles, and scales.

'3) I

1.

AM'W 71r,-125 1-2.3 COPPER WIRE DIMENSIONS The dimensions of soft drawn bare copper wire are normally controlled by Federal, Military, and ASTMY* Specifications, and Haitdbook 100 - National Burect of the diameter for sizes larger of~ Standards, to *1l% 0.010 in. and to 0.0001l i. for sizes 0.010 in. and smaller. 1-2.4F.DC RESISTANC~i Zempcratures tin rapidly oxidizes, turning black, and cood. Histori~ally, tin was appicd to copper first by the hot dip method. With this technique, impurities of the molten tin bath remain in the coating deposited on the hurface of the wire. The control of the thickness of tin coatina by this meto4 is relatively poor, varying from molten tin bath on adjacent spools.

4thwt

:1

The ,naxiimurn resistance figures shown, in TableI lc4ulated L'3ing minimum diameter values. 1-4 wer Forothr esitane aloy, my b clcuate, i % cenductivity is kiown. Fo1t e l o s e.t nc a e c l ua e , i
1-3 COATINGS Copper is -zrely used or, spmeiallzed applictions in ofth oxd~io tht ake pac itsbae ~ecns sa~~ on o ai. eposre Oidaion r oher~orrsio 15 accelerated by the presence of heat, aoisture, and some insulation materials such as rubboar. To prevent nd ehane txutntin, bre cppe is q coroson coated h a metal" sucetil oxidtioan corrosion.
'

A more accur-ate method of applying a ti coating to a conductor is by the elentroplating rnethod. Here a concentric, high purity, uniform layer of tin deposit on the copper is assured. Th eplating should be done at rod or in!ermediate size and redrawn to compact and reflow the relatively porous coating formed by jelating. The electroplating method of tin coating wire is chosen so that very accurate control of the deposit can be maintained after final redraw, and the resulting icnswllb sualefrheeqrd pltn applicatior This method allows the same diameter toermc har up (0.0001 in. on 0.010 in. or tlrnea.br smaller strand, cnd 1% for large; strand) on tin-cvated The ASTM, Federal, and Military Specifications( -]% permit 9 +0.0003 in. -0.0001 in. and +3% tolerance 1.o allow for added tin when processed by the hot lin d~p method. This tolerance difference can beoea significant factor in applications in aircraft and space- craft where weight is critical. Example: dineteen sWands of #08AWG (#26 equivalent) ir a large usage itzim in such vehicles. 'Ile maa~ixum strand diameter with such a wire, and the 0,0001 fin. tolerance would be 0.0041 in.; with the

{I

1-3.1METHDS O COAIN{

~wire.

Coatings may be applied by one of s-everal methods. The-more common are: a. Electroplating: ap electrolytic anodic coating er dhise mea.commnoa

B i f

d iI
mea

rocss f rrtang he ire dppig: he b. Ht wire the cof ning bthe oes thouh oltepn: thrugha motenbat of he oatng mteral.0.0003

in. tolerance, 0.0043 in. The weight is

da tr

~ ~~~c. Cladding: the process of welding under heat and

protinlo ran.hefrtot squared as depicted in Eq. : -1. sapressuie, ieioverh a base outer coatintg omdit ste a heavy producing hc

1Tin 1-3.1.1
to0 1200~~~~~~~~~ FoAmrc ociey forg teest aexpMaersiveal in isti.

d, p,4 +d,

aW+ Xi)2

.wj

ox

ocx

%weigh inisnsgebcasraeihasednitoti, smale dW2ee _ oW ice n

=

large diameter, tomlerne n.

x___

mllrd-mtr

oe-ace

Ainrim

Soit

etn

AMtras=lre

-o

imtrtlrne

AMCP 706-125 Note Eq. 1-1, is used for #30 AWG strands and smaller. To cite an example, and using the #38 AWG stranding as above, we would determine t e weight proportion as follows.

d, W2 +d2

[(V X,.

x)-I

i 0

8.9.004004
.9

. 04

+73

. k.(.004 +0.0001)

0.003

_0 .004

x10

10.6

We now see that the maximum weight with the looser, or larger, tolerance is hs.26% greater than the maximum weight of the lighter, or smaller, tolerance. In addition, needed. the size is larger, hience more insulation :AS

1.-3.1.2 Silver Silver-coated conductors are reliable for continuous through 2000C. At temperature applications temperatures in the order of"3500C silver will rapidly tarnish and corrode. The silver and copper tend to migrate through te boundary layer and form an alloy with copper, which rises to the surface. Silver is aipplied by the electrodeposit method which allows . -0.0001 in. and tl% tolerance on final wire size. In this case ASTM, Federal, etc., Specifications require these tolerances. Silver-coated wire has the same tests applied to it as to tin-coated wire with the addition of a thickness measurement. The parameters of these tests are specified in AS'TM Standard B-298. Many specifications require a minimum thickness of 40 uin. of silwr coating on Lie finished strand while others cell for 50, ASTM De298 specifies several classes of plating thickness by %weight of silver to that of total wire weight and only recommends by note that a minimum of 40 pin. be used. This does not help the end user who is only concerned that sufficient thickness be required to prevent corrosion. Example: Class B ASTM B-298 requires 2.50% silver. On a 0.010 in. (#30) wire this yields 53 gin. of siver. On a 0.004 in. (#38) wire this yields only 2) 14n. of silver.
* ASTM Special Technical Publication #319

Tin-coated wire is normally tested for tensile strength and elongation, resistivity, continuity of coating, and adherence of coating and finish. ASTM Standard B-33 specifies parameters for these tests. --Tin thickness for normal applications is 25-30 gin. on the finished wire. For special applications, heavy coatigs of from 125 to 175juin. are applied. Testing for continuity and adhesion of coating should be done prior to stranding because, due to the softness of the coating, minor scratches are inevitable during future operations. Tests should be made to insure that the coating is applied evenly and adheres firmly to the base metal.* There is some evidence that pure tin can traiv(hrm to a grey tin powdery structure when subjected to a sub-zero environment for pr6longed perio6s. The addition of nr!Jll amounts of antimony and/or bismuth will inhibit this tansfornation. Antimony and bismuth can be added to both the hot dip and electroplating process. This phenomenon has been thcrdugh!y investigated by experts and transformation of tin has been observed on tin-coated wire in laboratoiy studies; however, there is not sufficient evidence that there is a generally serious problem.**
ASTM Standard 13-33 (tin) ASTM Standard B-298 (silver), ASTM Standard B-355 (nickcl)

1-3

;,! AMCP 706-125 This Class B wire is totally inadequate for #38 wire. Example: Class D ASTM B-298 requires 6.10% silver, On a 0.010 in. (#30) wire this yields 129 pin. of silver. On a 0.004 in,. (#38) wire this yields 52 pin. of silver, Obviously far too much silver is present on the #30 wire, resulting in excess cost. The various classes of A. ..... t!erefore, are only academic since in practical use sufficient silver must be applied so that after redraw ;he required amount is present. In spite of its large usage, silver-coated copper has some limitations as follows:
-

1-3.1.3 Nickel Nickel plating was developed for continuous service up to 3000 C. The nickel does not tamish at elevated temperatures as does silver. Nickel is electropositive tcopper, therefore, nickel does not exhibit the oxides that are sometimes found when using silvei. In a phenomenon of electrolytic action, a flaw in the nickel coating will actually heal, preventing the cuprous oxide from forming. Nickel is much harder than silver, and passes through stranding machinery with less surface scratching.

ftkerefore,

'- ,

a. Silver tarnishes, giving poor appearance and 'frequently causes misunderstandings with inspectors expecting a brilliant finish. eNickel b. Silver wets very easily with molten solder, and solder will wick up into the strands by capillary action to form a solid conductor at the soldered joint where flexibility and flex life are most needed. This has caused conductors to break under conditions of repeated flexing or vibration. It can be overcome by controlled soldering techniques- controlling such parameters as solder pot temperature, time and amount of immersion during dip, use of heat sinks, and soldering iron temperature. A much more satisfactory solution is fuund in the use of nickel coating which reduces wicking. c. With silver, in proximity to copper and moisture being present, electrolytic corrosion can take place with copper protecting the silver. Copper is electropositive to silver so that the corrosion can be progressive if conditions remai, conducive. A red cuprous oxide formation, sometimes referred to as "red plague", has occurred. Usually this is the result of poor manufacturing procedures, where tither insufficient silver was applied or excessive heating has caused the copper to migrate to the surface and form sites for electrolysis. Fifty microinches of silver is very much morer effective than forty in minimizing this problem. An effective way of eliminating this oxidation is dual coating (see par. 1-3.2). 1-4

Again, as in the case of tin coatings, the electrodeposit method of nickel coating gives assurance of a highpurity, concentric, uniform layer of deposit. The tolerance on finished nickel-coated wire strands in ASTM B-355 are +0.0003 iii.-0.0001 in. and +3%--1% for tin-coated copper. Since nickel-coated wire is redrawn through dies after coating, ths extra tolerance is not needed and normal manufacturing controls can hold this to -+0.0001 in. and 1%. This smaller tolerance should be specified to save weight as illustrated in par. 1-3.1.1 for tin-coated strands. coating solders readily with approved noncorrosive solders but requires higher temperatures. Solder pots and irons should iue run in excess of 6750F for adequate wetting. Testing of nickel-coated copper wire includes tensile strength, resistivity, continuity, coating adherence, weight, and finish. The parameters of these tests are specified in ASTM B-355. The normal thickness applied ib 50 pin. minimum. The plating of nickel is more difficult to accomplish than silver or tin, therefore, the nickel-coated wire has the additional coating adhesion test and resistence check. This adhesion test consists of heat cycling which, because of the differences in coefficients of thermal expansion of nickel and copper, causes the nickel and copper to separate if not thoroughly bonded. This is a very useful and revealing test, and should be part of every specification requiring the use of nickel plating. The resistivity test is utilized to assure that excessive amounts of nickel ,are not present on the wire. 1-3.2 DUAL COATING In order to provide silver coating with the corrosiop protection of nickel, a corrosion-resistant coating with excellent solderability has been developed consisting of (

"ie

f
that layer of nickel, and over that a coating of silver. These combine to giv, the advantages of both materials. This coating is usually applied with 10 gin. of nickel and 40 gin. of silver (minimum). This construction should include testing for resistance, thickness of coating, continuity of coating, adhesion of coating. tensile strength, and elongation, 1-3.3 CL G 1-3.3 CLADDINGS Copper-clad steel consists of a steel core surrounded by a coppe.r cylinder, the two meals coninuously fused or bonded together undei heat and pressure. Nickel-clad copper is similarly formed. When being drawn to fine wire, it is important that the cladding process be accomplished at a small wire 3ize instead of at the billet stage. When the cladding is done in billet size (4 in. to 6 in. diameter) and drawn to 0.003 in.-O.0l0 in. diameter range, the coating will no longer be u.1iform may even be exposed. nieial and, in fact, ani at the h core oem ailmyee eepsd Resistances will vary along the length of the wire and the product is unsatisfactbry. Table 1-1 shows data of copper-clad steel conductors. coppetopGtunity Nickel is normally applied by the electrodeposit method, but may be clad. When applied by cladding, the nickel coating must be heavier than a plated coating. This normally runs 15% or greater by weight which is undesirable since the conductivity of nickel is much lower than that of copper. 1-4 ALUMINUM 1-4.1 USES Aluminum is frequently used as a conductor material because of its good conductivity and light weight. Large diameter transmission lines made of aluminum with a steel reinforcement are the main uses of aluminum conductors. High purity (99.45%) EC giade alurnintum is used, however, it is necessary to use a conductor two gage sizes larger, where aluminum is substituted for copper, to have equal current-carrying capacity because of the increase in resistivity over that of copper (see Table 1-4). Therefore, because he aluminum conductor ir larger, more insulation has to be provided to assure equivalent protection. Even though the size of the aluminum configuration is from 20% to 50% larger than that of copper, the breaking strength is less due to the much lower tensile strength of aluminum, 1-4.2 COATINGS

AMCP 76-125

Aluminum should not be coated by zny other metals even though the techniques exist to do it. Aluminum is very active, high in the EMF series, and positive, so that electrolytic corrosion between aluminum and other metls such as, copper, tin, silver, or nickel is very rapid and destructive at fihe interface in the presence of moisture, especially if polar salts are involved. 15ALY 1- ALLOYS 1-5.1 GENERAL PROPERTIES Alloying of copper with small amounts of other metals can increase the hadness, tensile strength, flex endurance, and resisance to elevated temperatures, with only a small sacrifice of electrical conductivity (see Table 1-71). Reduction of conductor size offers the greatest for weight and size reductions where current and voltage drops permit. In small gages (#26 AWG or smaller) copper does not have sufficient physical strength to be completely reliable. The substitilion of hard drawn materials is an unsatisfactory method of increasing strength because they have little or no elongation which would make breakage due to high stress a very serious problem. Obviously, hard drawn conductors with no elongation, bound into harnesses of cable, must break if the cable is bent since there is no stretch available. This rules out the use of cadmium copper, beryllium copper, or hard drawn copper to increase the strength of fine wire since in the annealed siate they offer little or no improvement in physical properties over soft coppei. 1-5.2 HIGH CONDUCTIVITY TYPES Flex-life is improved vastly with the use of high conductivity copper alloy conauctors as compared to similar soft copper constructions. It is -ossible to selact a conductor #2 AWG sizes smaller in an alloy construction, for weight saving designs, while retaining the breaking strength, elongation, and flex-life characteristics of the larger and heavier soft copper conductor. See Table 1-4 for flex-life comparisons. These alloys can. ue acquired with the same protective'-,* coatings as described for copper. 1-5

,.

J4
,,, i .JL , ' __.,-.-

AMCP 706-125 TABLE 1-1 DATA-COPPER-CLAD STEEL CONDUCTORS*

Dia, in. AWG# Max DC Resistance, ohm/ 1000 ft @20"C, Conductivity Max DC Resistance, ohm/1000 ft @20C, Conductivity

AWG#

Dia, in.

40 39 38 37 36 35 34 33 32 31
30

0.003145 0.003531 0.003965 0.004453 0.006000 0.005614 0.006304 0.007080 0.007950 0.008928
0.01003

2978.0 2324.0 1787.0 1408.0 1143.0 910.0 720.0 567.0 447.0 361.0
286.0

40%

3955.0 3135.0 2490.0 1974.0 1566.0 1242.0 984.0 780.0 619.0 491.0
392.0

30%

18 17 16 15 14 13 12 11 10 9
8

0.04030 0.04526 0.05082 0.05707 0.06408 0.07196 0.08081 0.090"74 0.1019 0.1144
0.1285

17.58 13.96 11.00 8.77 6.96 5.52 4.37 3.47 2.75 2.18
1.73

40%

24.10 19.10 15.15 12.02 9.53 7.56 6.00 4.76 3.77 2.99
2.37

30%

29 28 27 26 25 24 23 22 21 20 19
Material

0.01126 0.01264 0.01419 0.01590 0.01790 0.02010 0.02257 0.0253. 0.02846 '0.03196 0.03589

224.0 180.0 142.0 113.5 89.2 70.7 56.0 44.7 35.2 27.9 22.2
Conductiv'ty AICS** Based op DCResistivity 40% 40% 30%

308.0 245.0 194.0 154.0 122.2 97.0 76.8 60.8 48.4 38.3 30.4

7 6 5 4 3 2 1 0 00 000 0000
Tensile Strength, psi

0.1443 0.1620 0.1819 0.2043 0.2294 0.2576 0.2893 0.3249 0.3648 0.4096 0.4600

1.372 1.088 0.864 0.684 0.542 0.431 0.341 0.271 0.215 0.170 0.135
Elongation, % in 10 in.

1.88 1.492 1.183 0.938 0.744 0.590 0.467 0.371 0.294 0.233 0.185

Min 110,000 55,000 127,000

Max 120,000 60,000 135,000

Min 1 8

Nom 2 12 .2

Copper-Covered Steel 40 Hard Drawn 30%Hard Drawn

30% Soft

30%

60,000

65,000

12

* Copper-covered Steel or Copperweld are other common names. ** International Annealed Copper Standard.

1-5.3 HIGH CONDUCTIVITY-HIGH TYPES

STRENGTH

alloys can be exposed to 750"F with no change in properties. 1-6 STRANDING The majority of high quality, specialized wire is stranded in order to give it flexibility, long flex-life, and to improve its reliability.

The high conductivity-high strength alloys can be subjected to much higher temperatures than can copper, either in processing or in use, without effect on breaking strength or flex-life. Copper, cadmium bronze, etc., anneal at temperatures as low as 4500 F, whereas the.

1-6

AMCP 706.125 Nonstandard strand sizes may be selected so :hat the finished wire will have a certain cross-sectional area as defined by a standard wire gage, or a standard strand size may be selected so that the finished wire, with a specified number of strands, does not match the standard wire gage exactly, but is a close approximation. Table 1-6 shows a typical comparison of strandings specified in Specification QQ-W-343 and ASTM B.286. The ASTM Specification calls for the measurements of zesistivity as a control of the finished size of a conductor. This is more realistic and is more readily measured on an insulated conductor than circular mil area. These values may be controlled more closely by careful wire processing techniques to cut down on the amount of cold working of the conductor during stranding, and stretching in subsequent operations. Table 1-6 shows typical wire resistance values for stranded and solid wires of various materials. ASTM B-286 furnishes Eq. 1-2 for -alculating the maximum D-C resistance of coated and uncoated electrical conductors. Eq. 1-2 applies to 0.010 in. and larger strand sizes. Eq. 1-3 is used for computation of -maximum resistance for 0.0099 in. and smaller strand size. R x 105.35 xfxm
d

f = 1.02 for bunch or concentric stranding through 27 strands 28 or more strandscn f = 1.04 for rope lay conductors with 7 members f = 1.05 for rope lay conductors with 19 members stretch allonc m = 1.02 a nominal strand diameter, mils (i.e., 0.001 in. 1 mi) = minimum allowable strand diameter, mils (same as above). Note For strandsstrand use 0.0002 in. less than nickeI-coated mlinimum allowable diameter. 0.98 = cross-sectional area factor for minus tolerance allowance in single end wire. S.G. specific gravity 8.89 for copper and Alloy 63 2.7 for aluminum fctor tocen

--ohm (max)/1000 ft @ 20C (1-2)

xG

Rx105.35xfxm (drin)2 x N x S.G.

2 @20CN R = resistivity, ohm-lb/mi

"(13) N
=

7.9 for steel number of strands

R = 875.20 for bare Copper R = 939.51 for tinned copper 0.0111 in. to 0.0030 in. diameter 9configurations. = 929.52 for tinned copper 0.0201 in.to 0.0111 in. diameter R =910.15 for tinned copper0.103 in.to 0.0201 in. diameter R = 875.20 for silver-coated copper 105.35 = constant conversion factor f = stranding lay factor In the stiariding of conductors there are specific numbers of strands which lend themselves to round These round configurations may be made up with 7, 12, 19, 27, or 37 and Irrger numbe.rs of strands. NormaUv the 37 grouping is the largest one utilized without .miaking %if a rope out of 7 or 19 groups of stranded conduc,.ors. When insulating conductors, it is extremely d';sirable to use these configurations which yield round conductors because the insulation is ext-uded from a circular die and is in itself round. If the conductor is not round, then excessive insulation requiring additional space and weight must be utilized, or there will be insufficient insulation on the thin spots to properly carry the rated voltage without breakdown,

["

1-7

AMCP 706-.125 Wire is stranded in 3 basic configurations - bunched, concentric, and rope. 1-6.1 BUNCHED STRANDING directions for each successive layer (true concentric). As with concentric stranding, each layer in a unidirectional construction must have a different lay length if the roundness is to be maintaintA. Unidirectional lay is preferred to true concentric because o.'better flexibility and greater flex life. The lay lengths for each lay should be between 8 and 14 times the pitch diameter of that layer for best compromise between flexibility and flex life. See Table 1-8 for stranded conductor lay lengths. 1-7 SOLDERING Since soldering is a mutual union involving an action between two metals, it is essential that the metal being soldered be as hot as the molten solder for proper alloying to transpire. If hot solder is dropped on a cold metal, the solder will only freeze to produce a "cold joint", and no alloying action will take pla e - the result is a poor electrical connection. Therefore, the soldering iron or other source of heat that is employed must be of adequate capacity to heat the metal being soldered to a temperature that will melt and alloy the solder. succetsful, effective soldering, the soldering iron must be "tinned" before use. The purpose of this is to provide a completely metallic surface through which the heat may flow readily from the iron to the metal being soldered. If tinning is not present, the hot iron will oxidize and the heat will not flow readily through the surface oxide film +o the %,ork. Even the metals - tin, silver, and nickel - which are added to enhance solderability, will form an oxide surface, which must be removed before a good joint can be ach ved. This is accomplished by chemical fluxes which must be noncorrosive at the operating temperature of the finished product. The flux may be applied by brush, dipping, or most commonly by incorpoiating as a core in the solder. Wheen using flux-core solder, it is important to remember that this product consists of two substances (solder and flux) that are physically and chemically dissimilar. For instance, the flux in most cases is liquid or semi-liquid at room temperatures with a tendency to volatilize at 100C .212 0F), while the solder does not become liquid bHlow 183C (361"F) to 327C (620 0 F). For thi; reason the soldering flux, whch is contained within the solder core, has a tendency to volatilize or decompose while the solder is being melted. Flux-core solder must, therefore, be applied not on the top or side

" Bunched stranding consists of twisting a group of wires of any number together, all at once - in the bunching machine, wih the same length of lay for all strands - without regard to roundness or geometric arrangement. When configurations - such as 7, 12, 19, etc., which may be round - are twisted in this manner, the bunch stianding has been called "Unilay". "Unilay" stranding is still a bunched stranding with all its inherernt problems, such as strands popping out and sliding from layer to layer. In order to attempt to minimize this strand migration, bunched stranding is sometimes passed S. through a closing die too small for the conductors and "mashed" into shape. During this process the round strands are pressed into polygons. This results in excessive work hardening, loss of flex life, and scraped coating. 1-6.2 CONCENTRIC STRANDING 6 CFor Concentric stranding consists of a central core surrounded by distinct layers of strands. The onily way such a stranding can be guaranteed to stay round is to either reverse the direction of the successive layers of strands, or have a different length of lay for each layer, so that the inner layer will support the outer layer and prevent the strand migrt.... encountered in a bunched colifiguration. When the lay in each layer is reversed, concentric stranding is called true concentric, and when the layers are in the same direction, each with a different lay length, it is called unidirectional coascentric. Unidirectional concentric has an advantage of much greater flexibility and flex life than the true concentric. Lay lengths close to, but not greater than, those specified in Table 1-8 are important for flexibility and flex life. Concentric stranding is preferred to bunched to achieve more uniform wall thickness ofinsulatim1 . 1--6.3 ROr-STRANDING Rope stranding consists of twisted groups of stranded conductors. Each group may be either bunched or concentrically stranded. In rope stranding it is staadard to use a number of groups that lead to round constructions (7, 12, 19, 27, etc.) - 7 and 19 being most common. These groups may be twisted in the same direction in all layers (unidirectional) or in alternate

-(

AMCP 706-125

of the hot :ron where it will volatilize and lose its offectivencss, but rather at the exact junction be.ween the metal assembly and the soldering iron in order that solder and flux may be liberated simultaneously at the specific joint where solder is desired and where it is needed. The primaiy purpose of soldeng is not to secure mechanica! strength, but to secure a permanently sound, nonporous, and rontinuously metallic connection that is not affected by temperature change; that lends itself to minor torsional strain and stress without rupture; and that has a constant and permanent electrical value. A joint must be mechanically secure before soldering, and allowed to remain undisturbed until it is completely solid. It is of no value to add solder to a joint after adequate alloy action has taken place. The alloy attachment lies in the thin film of solder between the two metals that are joined together. This film of solder is preferably in the order of 0.004 in. in thickness, Some metals solder readily, some solder with difficulty, and some will not solder. The type of solder and flux depends on the particular metal being soldered. 1-7.1 SOLDERING STRANDED WIRE have been many problems in connection withi the soldering of stranded wire. The conventional procedure has been to cut and strip conductors, either by hand or mechanized equipment, twist the stripped ends together and dip in a solder pot to tin the conductors and hold the strands together. This being a hand operation, it becomes very costly and presents problems such as melting of the insulation and the wicking of solder up into the strands. An attempt to avoid this may be made by running tinned stranded wire through a hot tin dip in order to fuse all the strands together conthiuously throughout the length of the wire prior to insulating. This approach is costly and results in a stiff stranded conductor similai to a solid conductor. A second approach is to lightly tack the strands together s that, on flexing, these strands will break away on the first bend and will then act as strahded conductors. However, this has the disadvantage that, when it is bent with tools to insert into lugs or wrap around terminals, the strands will break open defeating the purpose of fusing. Neither of these methods is approved under the governig specifications for hookup wire, MIL-W-76 or MIL-W-16878D, because of the

obvious implications of reduced flex life compared to the stranded conductor specified. 1-7.2 HEAVY TINNED STRANDING The most practical solution to enable this tinning to be done without sacrifice to wire characteristics is by the use of stranded wire made with heavy tinned strands utilizing 100-150 pin. of tin. Heavy tinned, insulated, stranded wire utilizing such a conductor may be passed through a coil on a radio frequency induction heater, and if the correct amount of radio frequency current is passed through the coil, it will heat the conductor through the insulation and fuse together the heavy tinned strands in a section approximately equal to the coil length. The coil length should be such that when the fused section is cut in the center and stripped, a tinned and fused section of conductor will be exposed where the insulation is stripped off, with the remainder of the conductor unfised. This technique may be utilized with either heavy tin or silver coating to uliminate the tedious hand dipping operation. In practice the coil ;s located an integral number of cutting lengths from the cutting and sl ripping machine so that when the wire stops for cutting a pulse of current is passed through the coil fusing a spot which will later be cut and stripped. Example: A run of 9 in. pieces are to be made with 1/2 in. stripped length at each end. A coil will be chosen to fuse 3/4 in. of condoctor and the machine set so that the center of the coil is i8 in., 27 in., 36 in., or other convenient multiple of 9 in. from the cutter. As the machine operates, the cut will be made in the center of the fused portion and stripped, leaving 3/8 in. of fused and 1/8 in. of unfused conductor exposed. 1-7.3 SILVER-COATED STRANDING Considerable breakage has been ,.xperienced by equipment manufacturers utilizing silver-coated strandings, paiticularly with Teflon insulation. In most instances, the breakage was due to careless soldering operations which caused the solder to wick up into the strands, yielding a solid conductor where the insulation is stripped and the *flexibility is needed most. This probably occurred for the following reasons: (1) Teflon being resistant to the heat of soldering causes operators to become extremely careless and actually dip the Teflon it! alf into the solder pot, and (2) silver has a great affinity for 3older, and as long as the temperature of the silver-eated wire is hot enouigh to keep the solder

)There

1-9

__

______

1
! .'AMCP 706"125

melted, it will continue to wick up by capilnrxy action higher and higher into the stranded wire rider the insulation. This condition can be cotrolled by exercising extremely careful regulation of solder pot temDerature, immersion time, immersion depth, solder iron temperature, and use of heat sinks,

1-8 TERMINATIONS 1-8.1 CRIMP TERMINATION A crimp termination can be definied as the joining together of conductor and terminal through the proper mechanikal displacement of the materials by squeezing the connector sleeves onto the conductor. The process is realized through a mechanical bond in lieu of thermal alloying. The primary concern in the selection of this termination method is proper execution of the crimp. This can only be realized through selection of proper tools and terminals, including contacts, lugs, etc., and wire sizes. Tcols are now available which will properly execute the termination by means of ratchet, preset, positive cycle mechanisms. These tools will function properly over extended periods of time, with the augmentation of thorough test sampling cycles. This method lends itself well to semi- and fully-autornated production methods. Crimp terminations offer the advantages of the selection of wire, insulation, and terminals without concern for thermal characteristics. This method also permits miniaturization and subiniaturization of circuitry with excellent mechanical and environmental parameters. The greatest single advantage of crimping, compared to soldering, is elimination of the human element always present in soldering. When proper tooling is sed, crimps are as consistent as the tolerances that can be maintained on the joined parts.
1-9-.2 WIRE WRAP TERMI1NATION

1-7.4 NICKEL-COATED STRANDING A more satisfactory solution is to avoid the problem completely by using nickel.plated wire in place of silver. While nickl, does not have the great affinity for solder that siver does, it will solder nicely with ordinary approved noncorrosive fluxes. It does require slightly higher temperatures for the solder pot, in the order of 3200C (6080F) to 360 0 C (6800F). Experience has shown, both in production and the laboratory, that the flex life of nickel-plated, stranded conductor terminations is superior to those of si'ver-plated terminations. This can oe traced to the greatly reduced amount of solder wicking which occurs with a nickel-platd strand.

1-7.5 COMPOSITE STRANDING An unsatisfactory attempt at a solution to wire breakage was offered several years ago - before
adequate alloy materials were available. Strandings

made of composite materials - such as copper mixed with stainless steel, copper-covered steel strands, or other reinforcement - were tried. If composite strands are stretched or jerked in some manner, the copper will elongate, and the more springy, harder materials will retract more readily, causing basket effects a,'d kinking of the adjacent copper strands. When materials such as A'ainless steel are used, they %io not solder; and, therefore, are useless in adding strength at the solder joint where the strength is most needed. Also, they can become a source of electrical noise oince they are free to move within the solder joint under conditions of ibration or stress. These composite withoit regard for their solderability. In M1L-W-16878D this was modified, and if composite strandings are used, the steel or other material must be coated with a solierable surface similar to the copper coating for the particular wire in question.

A relatively recent method of making a reliable solderless termination, rapidly and adapiable to automation, is the wire wrapping technique. The principle of this method involves the wrapping of a solid wire under tension, 4 to 8 complete turns in the form of a closed helix, around a rectangular termination pin made from a relatively harder material than the wire being used. The wire is bent sharply around the corners of the pin under enough tension that the corners displace metal in the wire and form an increased area of contact. For this reason, the wire used for wire wrapping must be very ductile and by raising the minimum elongation values of copper wire 5% above the normal. In some cases an added restriction of maximum tensile strength is desirable. Present u~sge involves #22 through #30 AWG. Stranded wire cannot be used for wrap terminations.

1-10

I
AMCP 706-125 1-9 SHIELDING 1-9.1 GENERAL Shielding is used to 1'revent electrical interference, whether from the protected circuit to other circuits, or from other circuits into the protected rircuit. Shielding is also helpful in reducing damage to wire insulations from elecarical discharges, due to lightning, built up on the outside of the insulation and serves as a safety measure to prevent injury if the insulation is accidentally pierced or otherwise penetrated or broken, A shield is applied over the insulated conductor and is usually grounded while the wire or cable is in operation. An external shield or armor may be appiihd over the jacket and primarily serves the function of protecting the wire or cable from external physical damage. For low frequency electrostatic shielding, seraicunductive coatings, either extruded or tepe wrapped, have been used. Usually this semico.ductive coatihg is applied over an uninsulated drain wire which is used for termination purposes. The electrical effectiveness of those semiconductors leaves much to be desired, and in fact, the drain wire alone will furnish the major portion by capacitive coupling. Shieiding may be provided by metallic (usually copper or tluminum) sheaths in various forms. The metal may be either spirally or longitudinally applied in tape form. When sufficient thickness is applied to furnish effective electrical shielding, the construction is very stiff - the spirally wrapped version being slightly more flexible because the layers can slide as the cable is bent. The most effective shield, electrically, is a solid meta. tube applied either by drawing down over the conductor or by wrapping a sheet of material around the conductor and welding the seam. This construction, of course, is very stiff and will only Mt -4 limited bending. Itis utilived a great deal fo permanent installaticns of coaxial cable, Thin solid metal coatings may be applied by electroplating directly to the dielectric. These are unsatisfactory, because, if sufficient plating is applied to give an electrically .effective shield, the resulting metal is so brittle it will fracture under bending around small radii. Thin metal foils applied by tape wrapping suffer the same lack of electrical shielding capability as thin plating, This is especially true at low frequencies where current penetration is greater. Tiis would pply particularly to metal-backed plastic films where the metal is etpecially thin. Again, as with semi-conductors, most of the shielding would result from capacitive coupling to a drain wire wrapped under the foil. Flat wire has been applied by braiding over the insulated wire in an attempt to reduce costs through weight saving and labor, and improve coverage. One end of wire per carrier is used. It has been found that coverage measurements average about the sami. as round wire braids and the flat wire adds considerably to the stiffness of the cable. On sharp bends the flat wire has a "endency to kink with the relatively sharp edges cutting into te insulation. The most satisiactory shield technique is the use of braided wires. This yields a high conductivity, flexible, mechanically sound structure giving an effective electrostatic and electromagnetic shield at the price of a weight increase. The size of wire used depends on the dia-meter to be shielded, and ib chosen on the basis of machine limitations and mechanical structures. A tu typical shield is pictured in Fig. 1-l.I 1-9.2 BRAID TERMINOLOGY In braid terminology the number of ends refers to the number of parallel wires in a group (C in Fig. 1-i in this case). The number of carriers refers to the total number of groups of wircs in the braid (total number of spools on the braiding machine). The number of picks refers to the number of group cross-overs measured longitudinally along the cable in any distance, usually 1 in., (P, Fig. 1-1 in this case). The ends/carrier is shown as N in Fig. 1-l. An indication (although not mathematically proportional) of the shield effectiveness is given by the % of optical covtags. of Lte siieid. it is usual to specn, a braid by the degree of angle, %coverge, and shield wire gage size; and leave the actual design up to the manufacturer. In order t facilitate terminations, a shielded conductor or complex must have good push back qualities. The use of a 200 to 400 angle, angle a in Fig, 1-1, with the axis of the conductor will assure these

IA

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AMCP 7064126 N

CARRIER

Figure 1-1. Shield-Constructional Details

qualities. It is nt* always~ possible to maintain this angle range hsoweief, particuliarly where the cable OD

tna taC C
t

2ir(D +-24 nme 346 .11 fcrjr

~~2
-600

hgood attenuation charateiistics.

ecn Vi conzptted by oeag

in,,excess ~~is of 0.400 in.; on such cables the shield angle shall be the best porsible. For a high cove.age, tightly adhering shield, ant angle of between 400 and is preferable. This is sometimes used to assum
1-9.3 COM'.PUTATION OF BRAID ANGLE AND COVERAGE ftemyb

diameter of core under shield, in.(

W.ire gage generally used for shielding is #36 AWG or #34 AWG for single conducton, and up to #30 AWG for overall cable shield depending on size. The percent coverage range is usually between 85% and 9 , by specification requirement, and is dependent on the number of carriers, number of ends per carriar, and the pieVks per inch as shown by Eq. -4. Table 1-2 is a guide to good design for -. Weld diameter.

K-(2F-P) 100 Ihere1 '7 wherewire

(1.4)

Kcoverage,%
sin a

TAL117
DESIGN GUIDE -$HIELD WIRE SIZE
Shield Wire Size #38 AWG #36 AWG #-32 3 AW1 W 430 AWG r
--

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P
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=diameter, =angle

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caier, single end, in.

of shield with axis of conductor, dey,

.41A

AMCP 706-125 1-9.4 SERVED SHELDS 1-9.6 SHIELDING EFFECTIVENESS Table 1-3 gives measured values of typical shields utilizing the method of U.S. Amiy Electronics Command Technical Requirement SCL,1476. In this table the shielding effectiveness number is nondimensional: 0 = perfect shielding I =No shielding. The values listed in Table 1-3 for shield effectiveness Ke at 5 MHz are those obtained experimentally.

In order to save weig t, shield wires are sometimes served in one direction. This cuts down cn,iderably on electrical effective.ness due to the inductance introduced as currents spiral around the corc. It also presents some minor problem, in fraying if the outer plastic jacket is removed,

TABLE 1-3 SHIELDING EFFECTIVENESS-VARiOUS MATERIALS AND CONSTRUCTIONS Shield Description 1.

2.50%

Relative Shield Effectivettess Ke @_ 6 5 MHz*

2.9 x 10 1.06 x I0" '

#36 #36 #3 #36 #36

#36

AWG Tinned Copper Braid

Coverage

2. 3. 3. 4. 5. 6. 7.

AWG Tinned Copper Bnaid 75% Coverage AWG Tinned Copper Braid 85% Coverage AWG Tinned Coper Braid 95% Coverage
AWG Tinned Copper Served

0.850x o G.336 x 10

Shield 100% Coverage riat Wire Braid-0.002 in. 'Thick 48% Coverqe #36 AWG Tinnedl Copper Braid 85% Coverage (2 conauctors

7.65 x 10-3 1A.90x 10-3

twisted together - overall U shield) 8. Extruded Semiconductive UThermoplastic (with no

C.4352 x 10

,j

9. 10.

i.

12. 13.

drain wire) Extruded Serniconductive Thermoplastic (with drain -wire) Double-faced Aluminum on Mylar Backing. Spirally Wrapped Tape - 56 Overlap 1/4 in. Alcoa Aluminum Foil 0.005 in. Thick Impregnated Semiconductivn Cioth Tapp (Ho drain wire) Semiconductive Black Cloth Tape with #30 Drain Wire

No Apparent Ohielding No Apparent Shielding

5.2x 0

24.0 x IV" 0.353 (very poor shield)

0.900 (no shieLd effectiveness)

I1_13

IAMCP

706-125

TABLE 1-3 (CONT.)

Shield Description

Felative Shield Effect iveness

IK@M~

IDener I
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0.350 (very poor shield) 0.291I (veiy poor shield)

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1-14(

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1-10 FLEX-LIFE COMPARISON - COPPER VS ALLOY 63 1-10.1 TEST METHODR Wire is flexed through an arc of 1200 ( 600 from vertical) between parallel horizontal mandrels - having a diameter 4 x the wire diameter and set 90' to the

AMCP 706-125 plane of flexure. One complete cycle represents the swing of the wire from vertical to 600 one way, 1200 the opposite way, and 600 back to vertical. The load is attached to the bottom of the wire. 1-10.2 COMPARATIVE DATA: Table 1-5 .shows comparative figures.

TABLE 1-3 FLEX-LIFE OF COPPER VS ALLOY 63

Load Material*,

Soft

Alloy

psi
1300 5000 10,000 15,000

Copper
160 cycles 36 cycles 16 cycles 1" cycle

63
2000 + cycles 249 cycles 30 cycles

14 cycles

* Load psi exceeds material yield strength

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AMCP 706-125

TABLE 1-8 STRANDING LAY LENGTHS-STRANDED CONDUCTORS

Strand Diameter
AWG No. of Each Strand, Stranded Diameter,

(
in.
Length of Lay,
i17.

#
0000 000 00 0

Wires
2109 1665 1330 1045 817 665 133 133 133 37 49 37 19 37 19 19 19 16 19 7 19 7 19 7 19 7 7 7

in.
0.010l 0.0100 0.0100 0.0100 0.0100 0.0100 0.0179 0.0142 0.0113 0.0159 0.0142 0.0142 0.0179 0.0126 0.0142 0.0113 0.0100 0.0100 0.0080 0.0126 0.0063 0.0100 0.0050 0.0080 0.0040 0.0063 0.0050 0.004.)

Min
0.580 0.515

Max
C.605 0.540 0.480

Min
*5.24 *4.32 *3.84 *3.40 *3.04 *2.72 "2.19 *174 *1.38 0.91 *1.02 0.80 0.74 0.72 0.58 0.46 0.41 0.38 0.33 0.31 0.26 0.25 0.21 0.20 0.17 0.16 0.13 0.10

Max
8.47 7.56 6.72 5.95 5.32 4.76 3.84 3.04 2.42 1.82 1.79 1.60 1.47 1.44 1.17 0.93 0.82 0.77 0.66 0.62 0.54 0.50 0.42 0.40 0.34 0.32 0.26 0.23

0.455
0.405 0.360 0.320 0.250 0.192 0.157 0.103 0.118 0.090 0.083 0,082 0.066 0.052 0.046 0.045 C.037 0.037 0.029 0.029 0.023 0.023 0.019 0.018 0.0147 0.0117

0.425
0.380 0.340 0.274 0.217 0.173 0.114 0.128 0.100 0.092 0.090 0.073 0.058 0.051 0.048 0.041 0.039 0.033 0.031 0.026 0.025 0.021 0.020 0.016 0.013

1
2 4 6 8 10 12

14 16 18 20 22 24 26 28 30
*

I(

Rope Strandings - Lay Lengths are a mini aum of 8 times, and a maximum of 14 times, the maximum stranded diameter All other stranding lay lengths are 8 times minimum and 16 times maximum stranded diameter.

1-24

11.2

____

__

__________________

____________________________________________________

AMCP 706-1263 P

REFERENCES
6. MlL-W-76, Wire and Cable ins-tated.
fit'.,k-up

I.-AST11 Reference, Special Technical Publication # 319. *2. ASTM-STD-B33. ;'Izned Soft or Annealed Copper Wi.'eJbr Electric! Purposes. 3. ASTM-STD.B286, Specification for Coypp Conductors for Use in Hook-up Wire for Electronic Equipment (Tentative). 4. ASTM-STD-B298, Specification for Silver Coated Soft or Annmealed Copper Wire. 5. ASTM-STD-B355, Specification for Nickel Coated Soft or Annealed Copper Wire (Tentative).

Electrical,

7. MILAV-16878D), Wire, Electrical, Insulated, High Temperature (Napyyj

8. QQ-;V-343, Wire, Electrical and Nonelectrical, CpeUhslid 9. Final R 2port on Extra Flexible Tactical Ccble, USAECOM Contract No. DA-28.043-AMC. 00043(E) with Martin-Marietta Corp., November 1967.

1-5

,AlaCP 706-125

~) CHAPTER 2 INSULATION MATERIALS

2-1 INTRODUCTION Over the past thirty yea;,s or so, the complexity of materials available for use as primary insulations and as jackets or sheaths for wire and cable constructions has vastly increased. The technology associated with the application of these materials to wire and cable has also become more sophisticated. This chapter, howevcr, is a presentation of only the salient characteristics of the most prominent classes of insulation materials. The thermal ratings and other characteristics assigned to the materials hereinafter discussed are those generally accepted by the military. Throughout the chapter, tables and figures will be found which list typical properties of the various insulating materials under consideration. (Table 2-9 indicates the relative costs of insulating materials.) The data herein should not be utilized for specification limiting values because appreciable variation from the given values may result fiom varying wall thicknesses, conditions of processiiug, and methods of testing. 2-2 THERMOPLASTIC MATERIALS INSULATION drawn through a sizing die simultaneously. The coated wire or cable is then drawn thiough a water bath which returns the plastic to its solid state. The coated wire is wound on reels. The thermoplastic resins most commonly used as insulation and jacketing for wire and cable are discussed in the paragraphs which follow. See Table 2-2. 2-2.1 POLYVINYLCHLOrFIDE The terms "vinyl" or "PVC" are commonly applied to polyvinylchloride resins. Polyvinylchloiide resins alor.e would be useless as wire insulations even if they could be applied to wire. They are extremely hard and rigid, and are subject to autocatalytic degradation at tenperatures required for processing. Therefore, the resins must be compounded with various ingredients in crder to prepare useful products. The compounding ingredients thus bccome controlling factors in determining naterial properties for the finished vinyl formulation. Compounds having temperature ratings from a low ,f -65 0 C to a high ef 1050C are available, although unfortunateiy, no single .ompound is known which five typical range. Therefore, this can range of. a widecompounds whidch cover selected been havecover applications. Their typical properties are listed in Table

.1

heterm "thermoplastic" is applied to thsc and An become materials whici behoe s ofhet p l solten t, he s w i repeatedly fomaerpa application ofthermoplasticamaterialsnasfwiretanI tcable heira aplctio of tholatic mteals as insulation and jacketing, advantage is taken of their semi-fluid nature at elevated temperature to form them around cable cores by means of n, ., for curing." extrusion,conductors without theor process consists of feeding solid resin into a heated barrel in which turns a vorm or screw which forces the resin along the barrel. As the resin picks up heat it melts into a viscous fluid, The screw forces the molten plastic into the "head" on the end of the barrel where it is formed into a tube. The item to be covered is also introduced through the head where it contacts the molten resin, and both are

2-2.
hsid

With reference to the compounds shown in Table 2--2" a. Compound I is a hiah-grade compound capable of being used at temperatures up to 105 0 C as a primary insulation toz wires made to MIL-W-16878D and NAS-702. It can also be used as a sheath over shielded single and multiconductoi cable configurations not exceeding 0.250 in. in diameter. b. Compound 2 is a "semi-rigid" compound utilized as the primary insulation over small size conductors 2-1

I!
i

AMCP MO6125

(approximately #20 AWG) and in thin walls (approx. imately 0.010 in.) for application as appliance wire or instrument wire where small diameter combined with insulation toughness is required. c. Compound 3 is a typical 80C compound which rinds application as a primary insulation and jacketing compound in wires and cables to such specifications as MIL-W-76, MIL-C-1 1311, and MIL-C-91S. d. Compound 4 is a typical extreme low temperature compound utilized as a jacketing material for -65 0 C environments. Its electrical properties are generally considered to be insufficient for its use in [r -yinsulaLons. e. Compound 5 is the mnaerial widely used as a "noncontaminating" jacket for MIL-C-17 cable constructions. It is compounded with a special nonliquid (nilrile rubber polymer) plasticizer which will not migrate into the cable dielectric and thereby affect its electrical parameters. Vinyl compounds can be made which are fairly resistant to embrittlement in hot oils, but all vinyls are subject to swelling in ketones, chlorinated hydrocarbons, and esters. They are generally resistant to water and dilute acids and bases. Nearly all vinyl compounds can be made to be flame retardant. The dielectric properties of vinyl compounds vary considerablj, with temperature and signal frequency. They are not considered adequate for use as primary insulations in applications rcquiring the use of low loss dielectric material, 2-2.2 POLYOLEFINS The term "polyolefin" relates to polymers similar to paraffinic oils and waxes in their basic chemical structure. The most important of the thermoplastic polyolefins as regards insulating and jacketing materials are polyethylene and polypropylene.

and softening temperature increase with increasing resin density; while such properties as elongation, impact strength, and cold temperature flexibility decrease with increasing resin density. Some of the established applications for the polyolefins, together with pertinent governing specifications, are listed in Table 2-I. Where the polyolefins are to be used in applications which require exposure to sunlight, it has been found necessary to add small amounts of carbon black to protect the resin against ultraviolet degradation. These compounds quite naturally have higher dielectric constants and dissipation factors than the natural resins. to Indeed, it these is generally true that the addition of fillers any of resins, as for example, to impart flame retardance or to reduce stress cracking, will result in the sacrifice of some physical properties and electrical parameters. 2-2.2.1 Low-density Polyethylene Low-density polyethylene exhibits good fluid resistance at room temperature. it also has very low water absorption. Its general temperature rating is on the order of -65' io 750 C. The upper temperature limrit is dictated by the softening of the resin as it approaches its melting point of 970 to 110C. Low.density polyethylene is flammable, but it can be compounded so as to be "flLme-retardant" at some sacrifice of physical and electrical properties. The mechanical properties of low-density polyethylene are not outstanding. Generally, wheie mechanical abuse is anticipated on relatively thin-walled hook-up wire constructions, a nylon jacket or some other suitable outer covering is usually recommended to improve abrasion and cut-through resistance. The electrical properties of low-density polyethylcne are outstanding. It is a low loss material and is used as cables the dielectric for many Itcoaxial frequency applications. exhibits goodinvolving resistancehigh to breakdown under corona and is often used in high voltage applications. 2-2.2.2 High-density Polyethylene High-density polyethylene has chemical and electrical properties similar to the low-density resi-;.
Ls fluid resistance is somewhat better. Its melting

Polyethylene resins are generally classified by density and are roughly grouped into three types: low.density resins having a density of 0.910 to 0.925 g/cc, medium.density resins having a density of 0.926 to 0.940 g/cc, and high-density resins having a density of 0.941 to 0.965 g/cc. In general, such properties as stiffness, hardness,
tensile strength, abrasion resistance, dielectric constant,

2-2

AMCP 706-125 TABLE 2-1 TYPICAL APPLICATION FOR POLYOLEFIN RESINS

Resin Polyethylene, Low-density

Application Coaxial Cable Dielectric (WF-8and CX-4245/G) Hook-up Wire Multiconductor Cable Field Wire (WD-I/TT)

Specification MIL-C-17; L-P-390 MIL-W-76 MIL-C-13777; MIL-C-915 MIL-C-13294 L-P-390 MIL-C-55036 Pending

Polyethylene, Medium-density Polyethylene, High-density Polypropylene

Telephone Wire Tolephone Singles (WM-130A/I) Telephone Wire (CX-1 1230( )/G)

point is generally in the range of 1210 to 135 0C. rhe major difference between the two types lies in the mechanical area. High-density resins are harder, stiffer, and better in abrasion and cut-through resistance than the low-density resins. These resins are suitable for jackets or sheaths since they have good resistance to enviranmental degradation. Although the electrical properties of high-density polyethylene are similar to those of the low-density resins, the fact that its dielectric constant is highei than that of low-density polyethylene combined with the added stiffness of the high-density resin generally results ;- making it impractical for use in coaxial cables involving heavy insulation walis. 2 The chemical, physical, and electrical ,iopcrties of medium-density resins, in general, csn be regarded as compromises between those of the high- and lowdensity polyethylenes.

is flammable, but flame-retardant grades have been made available. Its melting point is on the order .. 1550 to 168 0C. Its dielectric constant is somewhat lower than that of low density polyethylene. The primary difference between polypropylene and polyethylene lies in their mechanical properties. Polypropylene is even harder and stiffer than high-density polyethylene. For this reason, its abrasion and cut-through resistance is superior to the high-density polyethylene resins. However, its use in heavy-walled coaxial cable or sheathing material is decidedly limited by its high degree of stiffness. One other major drawback to the use of polypropylene is its relatively poor low-temperature flexibility. 2-2.3 CROSS-LINKED POLYOLEFINS Cross-linking is a term used to describe the process wherein individunl polymer molecules are tied together to form a network structure. There are two ways to cross-link polyolefins: (1) by irradiation, and (2) by chemical means. The end effect of either methoJ is the
creation of a tLruc-diniensional network, or "gel", of

2-2.2.3 Polypropylene

F;
X2-3
*7

Polypropylene has the lowest density of the polyolefin resins, approximately 0.905 g/cc. The chemical and electrical properties of these resins are similar to those of the polyethylenes. Its fluid resistance i somewhat superior to the polyethylenes. It

the resin molecules. The c:,lss-linked material no longer has a true melting poiu . The effects of this cross-linkage on the properties of the resins are: a. The electrical properties are essentially unchanged.

~AMCP

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II
2-

AMCP 706-125 b. The chemical properties are enhanced as regards oil resistance at .levated temperatures. c. Certain mechanical properties are markedly improved. The resins will not melt or drip even at soldoe-iron temperatures. This does not mean that it does not soften at these temperatures, only that the g l structure introduced by cross.linking is such that the resin will not melt or drip away. The polyolcfins cross-linked by irradiation may be compounded to improve heat aging characteristics, therefore, taking advantage of the increased flow resistance so as to be rated at I I0 to 135 0C.The low temperature properties are essentially unaffected by 'ross-linking, so that the-65C rating for polyethylene still applies. In gNylon In general, only the polyethylene resins have been successfully cross-linked commercially. Polypropylene reons tend to embrittle when subjected to the cross-linking processes. As to the relative merits of chemical cros-linking versus irradiation, it might be stated that although irradiation is the more expensive procass, it has the advantages of: even from the atmosphere, and for this reason it is not suitable for primary insulation incitical applications. Nylon is used in wire applications because of its resistance to abrasion and cut-through and its excellent resistance to hydraulic fluids including Skydrol. It is the most inert to fungus of the tbermoplastics. It finds wide use as a protective jacket over polyvinylchloride primary insulations in wire constructions, such as those MIL-W-5086 and MIL-W-16878D and over polyethylene in constructions as typified in MIL-C-13777E, ML-W-76, and MIL-C-13294. Although nylon is listed in the literature as "slow burt.ing", or even as "self-extinguishing", the fact remains that in the relatively thin walls in which it is used as a jacketing for wire, it must be considered flammable. generally carries a high temperature rating of 0 1O C for continuous service. Its low temperature limit is dependent upon the wall thicknes!, and the diameter of the construLtion. As both of these parameters increase, the susceptibility to cracking or flexing at low temperatures also increases. For this reason, nylon fiber braid is substituted for ex.ruded nslon on the larger conductor sizes of most wire constructions. In general, in older to achieve a -550 C rating, extruded nylon jacketing is utilized in wall thicknesses less than 6 mils over construction, less than 0.150 in. in diameter. Although nylon has been ut'lized as a ja,.keting material over 3nall shielded wire constri'ctio:3., t should be pointed out thal. there is a tendency ft. cracking of the nylon to occur when such constructions are exposed to temperatures near the upper rated limit of 105 0 C. The combination of the drying effect, which reduces the elongation of the nylon, together with the presence of the braided metallic shield which provides points of stress concentrations due to i relatively uneven vrrface, is believed to be the cause for the development of cracks. The use of a heat-sealed, tap.,-wrapped, poiyester/polyethylene jacket (see pa3r. 2-6) to replace extruded nylon is often recommendtd for this type of construction. Where nylon is to be exposed to considerable outdoor weathering and sunlight, the addition of a small amount of carbon black is recommended for stabilization again t ernbrittement.

1of

ii"-

a. wals o wthot dager ion i o inslaton Phin a. Pocesingthi of deformation h Versatility c.Better process control ,. d. Freedom from contamination from peroxide residues Chemical cross-,Rking has been confined generally to applications involving relatively heavy walls of insulation in which electrica! parameters, sucl, as didectric constant and power factor, are not critical, 2-2A NYLON i The terra "Pylon" is applied to polyamide resins. In and cab'. conbtuction nylo, is used almost exclusively a a jacketing material. Its electrical properties are generally adequate for 60-cycle 3ervice at low voltages but it does absorb appreciable moisture,

-wire

'

. . ..2

-6

I1
-

AMCP 706-125 Table 2-2 shows some typical properties for the most widely used nylon resin, a "610" polymer described by Type III Grade E of MIL-M-20693. Other nylon polymers and copolymers are utilized in wire jacketing for specialty applications, but the 610 polymer is by far the n.ost popular resin for electrical applications because it absorbs appreciably less moisture than other types. 2-3 FLUOROCARBONS There are presently four fluorocarbon resins which are of importance as insulating and jacketing materials for wirc and cable: (1) polytetrafluoroethylene or "TFE", (2) a copolymer of tetrafluoroethylene and perfluoropropylene or "FEP", (3) a resin based upon polychlorotrifluoroethylene or "CTFE", and (4) polyvinyiidenefluoride or "VF-2". All of these resins are nonflammable in the sense that they will not support combustion. They are considered to be inert to fungus. However, in many other properties these resins are significantly different from each other as will be .oted in the ensuing discussion. 2-3.1 POLYTETRAFLUOROETHYLENE (TFE) ifaster TFE is probably the most widely utilized fluorocarbon resin. It possesses unexcelled fluid resistance and is attacked only by alkali metals and by fluorine at high temperatures and pressures. TFE has excellent thermal stbility and a wide range of operating temperatures, being rated for continuous operation from -650 to +260PC. It is useful at temperatures as low as -2650C anc' also for short time exposures to temperatures is digh as 320C. TFE does not ,oa.as, partcularly good mechanica! properties at loom ten'peatute with regard to abrasion resistance or cut-througi resistance. Howe'- r, TFE at elevated temperatures, even up to 2000 C, retains a significant of3270C, m- chanical strength. above its melting degree point of TIFF exists as a Even remarkably tough, form-stable gel which imparts to the resin the abIlity to withstand contact with a hrt solder iron withont damage. The electrical propertie3 of TArE are alsoI. outstanding. The dielectric constant is low and remains stable over a wide range of temperatures and frequencies. It is an extremely low loss material. It Is not suitable for high voltage applications oecaase of its 2-3.2 COPOLYMER OF TETRAFLUOROETHYLENE AND PERFLUOROPROPYLENE (FEP) The copolymer of tetrafluoroethylene and perfluoropropylene (FEP) has fluid resistance properties similar to those of TFE up to about 2000 C. It possesses excellent thermal aging properties. However, because it does soften at lowjr temperatures than TFE, becoming a melt at approximately 2900 C, the maximum temperature rating is generally accepted to be 175 0 C. The low temperature properties of FEP ate similar to TFE and result in a-650 C rating. The mechanical properties of FEP are similar to TFE, but fall off with increasing temperature at a rate than TFE. FEP will, of course, melt and flow on contact with a hot solder iron. The electrical properties of FEP are nearly identical with TFE and remain constant over a wide range of temperatures and frequencies. However, at frequencies of around 2000 MHz and higher, FEP starts to exhibit higher losses than TFE. The primary differences between TFE and FEP lie in the melting point phenomena. The fact that PEP will melt into a fluid state permits its extrusion in a manner similar to that employed for many hermoplastic materials. TFE, since it "melts" into a tough gel, cannot melt-extruded and at must be paste-extruded and be sub.-.queil*y sitered 3270C lisinp techniques approaching those of powder metallurgy. Therefore, FEP becomes a somewhat more versatile resin to process than TFE. poor corona resistance in the presence of air or oxygen, which limits its use to about 100-volt rms constructions. As might be expected, TFE finds wide application in hook-up wire as specified in MIL-W-168/8D and MIL-W-22759, and in coaxial cable dielectrics and jackets per MIL-C-17.

FEP finds application as primary insultion in hook-up wires, typically specified in MIL-W-16878D, and as jackuting over many shielded high-temperature coaxial cables similar to thrse of MUL.C-17.

2-7

~I

AMCP 706-125 f 2-3.3 POLYCHLOROTRIFLUOROETHYLENE (CTFE} There is a series of polymers based upon monochlorotrifluoroethylene. This resin, which is most commonly utilized as primary insulations and jacketing for wire and cable, has a melting point of approxhnately 210 0C. This CTFE rfsin is generally rated for continuous service over a temperature range life falls off rapidly at of .650 to 135 0C. Its useful temperatures exceeding 1350C however, resulting in a short term rating of 96 hours at 150 0 C. The chemical resistance of CTFE is very good, but not as universally excellent as TFE and FEP. CTFE exhibits excellent resistance to a wide variety of acids, bases, oils, and alcohols ac room temperature. it is swollen somewhat by halogenated solvents and some oxygenated solvents (ketones, esters, ethers) and is severely attacked by the hydrazines at mildly elevated tempeiatures, by alkali metals, and by liquid halogens. which imparts CTFS is a hzrd, tough material excellent cut-through resistance and good abrasion resistance to insulations fabricated from it. The electrical properties of CTFE are excelentc t has a hih voluma resistivity, a low dielectric constant, and a good dissipation factor over a wi;de frequency range. Like FEP and TFE, CTFE is not generally ,,seful as a high voltage insulation because it is degraded under corona conditions. size CTFE is used as a jacketing material over small coaxial cables and as primary insulation on hook-up wire made to MIL-W.12349. It also finds application as primary insulation for hook-up wire in automatic wire wrapping equipment. 2-3.4 POLY';iNYLIDENE-LUORIDE (VF-2) VF-2 is a relatively new polymer. The present resin has a melting point of 171 0C and is tentatively rated for continuous ue o'er a temperature rangeof from .-65 to 135 0 C.The relatively high temperature rating, with relation to the melting point of VF-2, is wade possible by the unique retention of its physical properties .t elevated temperatures. The chemical resistance of VF-2 is such that the resin is resirtant to attack or penetration by most corrosive ch,,micals anl organic solvents including
2-8

inorgaaic acids, oxidants, alkalies, halogens, and hydrocarbons. Strongly polar solvents, such as dimethylacetamide, tend to react with and embrittle the rein. VF-2 is a very hard material with high tensile strength which results in insulations having excellent cut-through resistance and good abrasion resistance. The material is notch-sensitivd, however, and some drawbacks result when it is extruded over large, rope-stranded conductors, in that a sharp blow will cause the insulation to shatter. However, when used on solid conductors, o,,er otner extruded insulations, or on small gage, concentrically stranded conductors; the notch-sensitivity of VF-2 doe, not appear to be a handicap. VF.2 has the lowest spt cific gravity of the fluorocarbon polymers. The dielectric strength of VF-2 is excellent. lowever, its dielectric constant and power factor are quite high, and it is not to be recommended for high frequency, low loss applications. VF-2 can be cross-linked by irradiation so as to impart a udegrcc of i: tlow at temperatures above its normal melting point. In lais form, it is used as a jacketing suan fo rame wire specified in MIL-W-81044. The regular polymer is also adaptable to uses as primary insulation for hook-up wire, and for wire utilized in automatic wire-wrapping equipment. Table 2-2 gives some typical properties of thfluoroarbonpolymers discussed above. 2-4 POLYURETHANES 2-4.1 PHYSICAL PROPERTIES The thermoplastic polyurethane resins are unique in that at room temperature they have the physical properties of a very tough rubber, although ,hey are esseitially true thermoplastic materiaib. These resins have excellent tensile and elongation propcrties and provide the toughest, most abeesion-resistant, jacketing material presently available. Polyurethanes possess good resistance to most liquid fue's and oils, but are attacked, ..nd swollen or dissolved, by hal, :enated solvents and a vari.,ty of ketones, esters, and polar solvents. Some e.cer types are subject to hydrolysis on water immersion, and, although propely compounded polymers will be useful

I-)for
ma,y years of continuous immersion in water at or belchi room temperature, any potential application in, olving continuous immersion iti water at t. mperatures exceeding SO0 should be carefully evaluated, 2-4.2 THERMAL PROPERTIES Polyurethane thermoplastics have not been assigned specific thermal ratings, but indications are that a continuous operating range of from -550 to 7SC is realistic. The upper temperature limit is dictated by the thennoplastic nature of these resins which soften appreciably at temperatures of 1000 to 1200C. The,. resins have outstanding ozone resistance and resistance to radiation damage. The electrical poperties of the polyurethane formulations are entirely adequate for jacketing applications, but marginal for primary insulations. 2-4.3 USES The polyurethane thermoplastics are used almost exclusively as jacketing, typified by the requirements specified in MIL.C-23020 for RG 2641/U. it general, ether type urethanes have superior fungus and freeze resistance and hydiolytic stability to ester types. Some typical properties of a polyurethane thermoplastic formulation are given in Table 2-2. 2-5 RUBBER

AMCP 706-125 compounded to impart specific properties pertinent to the end.use of the finished product. The additives .to the elastomer itself include fillers, plasticizers, extrusion aids, vulcanizing ugents, accelerators, activators, antioxidants, and antiozonants. Finished rubber compounds for wire and cable, then, may contain as little as perhaps 10% actual elastomer to perhaps as much as 90% elastomer, depending upon desired properties and cost factors. It is obvious that a considerable number of compounds having a wide range of chemical, electrical, and physical properties can be made from any given elastomer. Since this handbook is not intended to be a treatise on the compounding of elastomers, it will be confined to a very general discussion of the salient properties of tht elastomeric polymers, together with some typical properties of some of the compounds which find use as wire and cable insulation or jacketing materials. 2-5.1 NATURAL RUBBER (POLYISOPRENE) The physical properties of natural rubber are excellent and offer a wide range of compounding possibilities. Compounds with thermal ratings of from -55' to 750C can be prepared. The electrical properties of specifically compounded natural rubbc. are good. It is generally resistant to water, but its resistance .to liquid fuels and oils is inferior to i ome of the synthetic elastomers. The heat aging, resistance to ox; ation, and ozone resistance are only fair. The current trends appear to be toward using natural iubber only when it offers price advantage over SBR elastomers, or wher, some special end use seems to require its exceptional high strength and resiliency. Typical properties for natural rubber compounds are

Rubber, are thermoset elastomers. This means that the application of heat reults in the formation of a inattrial which cannot be reformed or melted; it is Natural rubbe; compounds have application as sprimary insulations for power cables, portable cords, "set". Hence, although these materials are extruded, utcnutrfedabtislweaduiig

shown in Table 2-3.

or only mildly heated, an they are extruded cold, lter bjec ed oheatingccl d r

whily caeate, ao later subjected to a heating cycle which causes them to "cross-link" or ",ulcanize" into their familiar form. difier from other thermosettinp polymers - such as phenolics, epoxies, etc. - in that they have the properties of being able to stretch and retract rapidly, exhibit high strength and modules while stretched, and recover on release of the stress. As in the case with PVC insulating and jacketing applieatiou, the basic polyner is extensively

multiconductor field cable, tinsel wire, axid building

wire. It is used: as jacketing over flexible cords and in sone heavy duty applications. The use of natural ,ubber as insulation material is becoming obsolete, specia elastomers i military applications, ince synthetic aturas pol y et aplic ca p ely i r ns polyisoprenes can replace the natural polymer. 2-5.2 STYRENE-BUTADIENE RUBBERS These copolymers are also known by the designations GR-S, Buna S, and SBR. The most

--

2-9

I'_

AMCP 706-125
common monomer ratio is approximately 75/25 formulations have excellent electrical properties and

butadiene/styrene, but some copolymers of lower strene content (10-15%) are used for special low-temperature compounds. Compon:nds with thermal 0C can be prepared. The ratings of from -550 to 90 electrical properties of .pecifically compounded SBR are good. It is superior to natural rbber in resistance
to aging, but somewhat inferior in gtneral physical properties. Its water and solvent resistance is generally comparable to rattural rubber. . =-

can be used as primary insulations on high-voltage power cables having voltage rrtings in excess of 25,000 volts. Butyl rubhers are characterized by generally superior weathering ana ozone resistance, low water
absorption, and good tesistance to heat aging. They are considerably inferno. to neoprene it, oil resistance. which canwith" be Specific be prepared thermally compounds rated as lowcan as -550C, and some ,nthers thermal ratings as high as 90C. The mechanical properties of buty) are not as good a3 neoprene or natural rubber, but can be made to be adequate for many jacketing applications in which its excellent ozone resistance and resistanLt, to water absorption are important factors. Butyl rubber is also utilized as a inulticonductor cable jacket on s, mie ground support cables for missiles fueled wii:i "i-i ger, tetroxide and the hydrazines bezause of its 5- eriority to other elastomers in its resistance to these chemicals. Typical properties of butyl rubber compounds are listed in Table 2-3.

Typical prorerties for SBR compounds art, shown in Table 2-3. SBR compounds are used as primary insulation and as jacketing in much the same areas as natural rubber. The deciding factors as to which is used ie in the majority of cases material cost anO proce,:ssng considerations, 2-5.3 CHLOROPRENE RUBBER These elastomers are better known under their commercial name of "Neoprene" (duPont). Compounds made from these rubbers are generally characterized by poorer electrical properties than natural rubber, SBR, and butyl compounds; and, therefore, their use as primary electrical insulations is confined to noncritical applications. However, the neoprenes have good weathering properties, oil resistance, flame resistance, ozone resistance, and good mechanical toughness. This combination of properties has led to its being currently the most widely used jacketing material within ils temperature limitations. Specially compounded neoprene formulations can 'e prepared which will permit thermal ratings as low as -55 0 C, while other formulations can be made which will permit thermal ratings as high as 90C.

2-5.5 SILICONE RUBBER Tie silicone elastomeis can be boadly divided into three classifications. The first two are based upon polymer differences which result in noLable differences in low-t ,mperature properties. Hnce, one might be designated as "standard" and the second as "extreme low temperature", for want of b ,ter designations. The third class would be the fluorinated silicones. Silicones have the widest thermal operating range of the elastomers. The -standard" elastomers are capable of being compounded into formulations having thermal ratings from a low of about -55C to a high of 2000C. The "extreme low temperature" elastomers remain flexible at teinpeatuies of -90 0 C, and possibly somewhat lower without sacrifice of other properties, but are more expensive. The fluorinated silicone differs fiom the other two grades primarily in its improved resistance to oils and liquid fuels in which the other types are severely 3wollen. Its thermal ratings would be about the same as the "st.ndard" elastomers.

Il [
M

' Typical properties for neoprene compounds are shown in Table 2-3. The so called "arctic" (-550 C) neoprene compounds are uted specifically in multiconductor cable jackets to MIL-C-13777, MIL-C-3432, and telephone drop wires. 2-5.4 BUTYL RUBBER Butyl elastomers are copolymers of isobutylene and small amoinzts of isoprene. Specifically compounded

J
P

:2-10

J%

AMCP 706-125 TABLE 2-3 TYPICAL PROPERTIES OF ELASTOMERIC COMPOSITIONS Base Polymer Specific Gravity Ultimate Tensile Strength, psi Ultimate Elongation, % Rated Max Use Tenp , 0C Rated Min Use Temp, 0 C Voluie Resistivity, ohm-cm Dielectric Constant, I kHz i3ipation Factor, 1 kHz Resistance to: Water Absorption Natural 1.3 to 1.7 1500 to 4000 300 to 700 75 -55 1013 to 1015 3.3 to 5 0.01 to 0.035 excellent poor poor poor poor poor fair SBR 1.15 to 1.55 800 to 2500 350 to 650 90 -55 Is 1012 to l0 3.5 to 5 0.006 to 0.035 excellent poor poor poor fair poor fair Neoprene 1.4 to 1.65 1200 to 2700 300 to 700 90 -55 1011 to i013 5 to 7 0.02 to 0.05 good good poor good good good poor Butyl 1.15 to 1.5 500 to 100 300 to 800 90 -55 1013 to 1016 3.2 to 5 0.038 to 0.035 excellent poor poor excellent excellent poor poor Silicone
1.10 to 1.55

500 to 1530 100 to 600 200 -55 to -100 1013 to 1016 2.9 to 3.5 0.002 to 0.02 good poor poor excellent excellent fair good

Oil and Gasoline Chlorinated Hydrocarbon Weathering Ozone Flame Radiation

Notes With the exception of the electrical properties, Table 2-3 shows typical properties of both insulating and jacketing compounds. The electrical properties shown are typical of insulati.ng compounds containing little o[ no carbon black, but are not typical of many jacketing compounds which way contain vurying amounts of back as reinforcing filler which can produce considerable variation of electrical properties.

r
Ftt

2-1
i
[
2.11

LI

AMCP 706-125

TABLE 2-3 (CONT.) Fluoinatd Bae oymrSilicone Specific Gravity Ulti mate Tensile Strength, psi Ultimate Elongation, % Rated Max Use Temp, 0 C 1.4 to l.& 500 to 1000 100 to 250 200 [ . Hypalon (du Pont) 1.35 to 1.7 1200 to 2200 300 to 600 90

EPR 1.25 to 1.45 1000 to 2500 350 to 600 90

Fluorocarbon 1.9 to 2.0 10CO to 2000 200 to 400 200

Rated Min Use Temp, oC

Volume Resistivity, ohm.cm Dielectric Constant, 1 kHz

-55
1012 to 1014 6 to 7.5

-55
1012 to 1014 9 to 11

-55
1013 to lo 3.2 to 5

-30

1012 to 1014

7 to 9

Dissipation Factor, I kHz

Resistance to:

0.03 to 0.06 good

excellent good excellent excellent fair good

0.05 to 0.08 good

good poor excellent excellent good fair

0.007 to 0.03S good

poor poor excellent excellent poor fair

0.02 to 0.05 good

excellent excelient excellent excellent good fair

Water Absorption
Oil and Gasoline Chlorinated Hydrocarbon Weathering Ozone Flame Radiation

Notes With the exception of the electrical properties, Table 2-3 shows typical properties of both insulating and jacketing compounds. The el.ctrical properties shown are typical of insulating compounds containing little or no carbon black, but are not typical of many jacketing compounds which may contain varying amounts of black as reinforcing filler which can produce considerable variat'on of electrica! properties.

Ii

AMCP 706-125 All silicone elastomers are flammable, but their iinique structure is such that a nonconductive ash remains after burning. If this ash is contained by a glass braid, itwill function as an insulator for short time emergency use. Tis property has facilitated its use in many military applications, The mechanical properties of silicone elastomers are not exceptional. Its abrasion resistance and cut-through resistance is inferior to that of many of the other elastomers. The electrical propertie3 of silicone rubber compounds are very good. They can be compounded to have a relatively low dielectric constant and dissipation factor. Their ability to resist corona and ozone is excellent. These properties mahe silicone rubber a useful high-voltage insulation where temperature or fexibility requirements rule out the use of butyl rubber or polyethylene. Silicone rubber also possesses good ability to resist radiation damage. Properly compounded silicone rubbers have been utilized in hook-up and interconnecting wires made to MIL-W-8777 and MIL-W-i6878D. They are also used as primary insulation and jacketing to MJL-C-2194 and MIL-C.23206, power, control, and thermocouple cables aboard niu.',-ir-powered naval vessels. Another application is that or primary insulation and jacketing for ignition cable made in accordance with MIL.C-3702. Typical properties of silicone rubber compounds are shown in Table 2-3. 2-5.6 CHLOROSULFONATED POLYETHYLENE These elastomers are better known under the (ditPont). Compounds trade-name, "Hypalon" formulated from these elastomers are characte.i2ed by their excellent resistance to ozone, common oil., Liqud fuels, weathering, flame, and corona. Pioperlv compounded formulas have been prepared which indicate a probable thermal range for continuous usage from a low of -4W'" to a high of 90C, and possibly fo 1050 C, in wire and cable applications. Special compounding can reduce the low-temperature rating to perhaps-55 at some sacrifice in the high-ten,prature raitig. Hypalon vulcanizates have reasonably good physical properties, but are not particularly resilient. Their electrical properties are adequate for low frequency applications, but their high, dielectric constant and dissipation factor make them unsuitable for use as high frequency dielectrics. Hypalon compounds are finding appli,;ation in, mining cable, power cable, motor lead and appliance wiring, automotive ignition wire, and cord jacketing. Typical properties of chlorosulfonated polyethylene compounds are shown in Table 2-3. 2-5.7 ETHYLENE PROPYLIkNE RUBBER These elastomers art. copolyraers of ethylene and propylene, or more recently, terpolymers of ethylene, propylene, and a diene. The latter offers vulcanization with more conventional curing systems. Comnounds made from these elastomers offer excellent resistance to ozone and weathering, good heat resistance, good low-temperature properties, and good resilience. Specif-c compounds can be made which appear to offer wire and cable applications having thermal ratings from a low of about-550 C to a high of 9OC. Chemical resistanc. is generally geod, but oil resistance is poor. Electrical properties of specific compounds are very good. It is expected that compounds based on ethylene propylene rubber may find application as primary irstilation and sheathing for power cables and flexible cords, in place of butyl rubber. Typical properties of ethylene propylene rubber compounds are given in Table 2-3. 2-5.8 FLUOROCARBON RUBBER The outstanding properties of pr iperly compounded fluorocarbon elastomers xre its high temperature resistance and its excellent oil resistance. Temperature ratings for continuous se-vice worid appear to be 0 approximately-3 0 *C to a high of 200 C. The physical characttristics of compounds based upon these elastomers are good. They have good resistance to ozone and we.thering.

2-13

~it

4I

AMCP 706-125 The electrical properties are generally poor. The compounds have a high dielectric constant and dissipation factor, The high cost of the fluorocarbon elastomers has ;mited their use to specialty jacketing applications requiring a combination of high temperature resistance, gogd chemical r'esistance, and good mechanical poopertic, a triacetate- made from cellulose derivatives that have had some use as wire insulation in low voltage, noncritical applications when high humidity is not encountered.

a. Cellulose Acetate is one of the first plastic films to be used as an electrical insulating tape. It has good electrical properies and good physical properties. Its resistance to aging makes it useful for continuous operation over a temperature range of -300 to 600C. It is flammable. Cellulose acetate has been used ac a film Typical properties compounds based un oaa c pinsulation for lead wire and switchboard wiring. fluorocarbcn elastomers are listed in Table 2-3. 2-6 FILMS b. Cellulose Acetate Butyrate has somewhat lower water absorption than cellulose acetate. It has good Film can be defined as sheeting less than 10 mils in thickness. In his p'ragraph only those films which are used as primary insulations or as jacketing will be considered. Nnrm~ily, film insulations are used only when processing factois make extruded insulation impractical, as ;n the attainment of extremely thin film insulation walls, or in the instances where the material cannot be obfained in a form suitable for extrusion. The principal reason for the use of films as insulations is the ieduction in size and weight where the end-use requirements, in combination with the film properes, I permit the utilization of thinner walls than can be achieved by extrusion. The application of films, as wire insulation and jacketing, is done by either spiral wrapping or longitudinal wrapping of the film as a tape, followed by come subsequent operation designed to hold the wrap in place. Such an operation might consist of the application of a coating from solution of dispersion, an overbraid of some suitable fiber, a thermoplastic or elastomeric extruded jacket, or by heat-sealing. The most desirable holding method, from the standpoint of maintaining thin walls togethe, with dielectric integrity, is that of heat sealing. In the paragraphs which follow, typical properties of those films most commonly considered suitable for application as insulating materials for wire and cable are presented. Typical properties of these fils arc listed in fable 2-4. 2-6.1 CELLULOSICS There are three principal types of film - cellulose acetate, cellulose ucetate butyrate, and cellulose electrical properties and good physical properties. It has good aging properties and can be considered useful over a tempera(ure range of -400 to 600 C. It is somewhat softer an4 more flexible than cellulose acetate. It is flammable. Cellulose acetate butyrate films have been used as insulation for switchboard h ave e. hook-tp wire. c. Cellulose Triacetate also has good electical and physical properties. It is the most resistant to heat distortion of this group of cellulosics and can be considered to have a thermal operating range of-300 to 75C. It is flammable. Cellulose tr~acetate film has been used as insulation for range wire and lead wire.

2-6.2 POLYESTERS The polyester films utilized in tie wire and cable industry are based upon terephthalic ester resins. All of these products are chaiacterized by excellent physical properties, good chemical resistance, good electrical properties, and a wide range of service temperatures (-60C to 150C). The most useful polyester film, as regards applications for primary insulation and insulation over shields, is a heat-sealable composite film of polyethylene and polyester The composite, made from I mail polyester and 0.5 mil polyethylene, when properly double-wrapped and heat-sealed (6.mil nominal wall) results in an insulation of exceptional mechanical toughness, abrasioni resistance, cut-through resistance, and puncture res;stance. Long lengths of both insulated conductors and shields have been made and subjected to the "tank test" dielectric requirement of MIL-W-16878D without failure.

2-14

(
________

__

_________

AMCP 706-125

CD

~C.0

4i

LU

C1
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W

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00g
-50

00

00SOi

0
CC

Ce.)

CC

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00

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2-1 G

AMCP 706-125

TALE 2-4 (CONT.)

General Type Specific Compound TFE Fluorocarbon FEP Poiyinidc Kapton (du Pnnt)

Specific Gravity

2.2

2.15

1.42

Ultimate Tensile Strength, psi

UltimatelElongation, %

3300
300

3000
300

20,000
70

Volume Resistivity, ohm-cra

1 x 1018

1 x 1018 2.1 0.0003

1x 101 7

Dielectric Constant, I kHz Dissipation Factor, I kHz

2.1 0.0003

3.5 0.003

2-6.3 FLUOROCARBONS The fluorocarbon resins described in the paragraphs

on Thermoplastic Insulation Materials (pars. 2-2

temperatures in excess of the resin melting point of 3270 C. Unsintc-ed tapes are most commonly used in thicknesses of hom 3 to 7 mils. They find wide use as
both primary 'wire insulation and as jacketing over

through 2-2.4) arc also available in tape form and have

rijlds in a variety of applications and constructions.

2-6..t POLYIMIDE

properties essentilly the same as those given in those

prg h

Of the group of fluorocarbons, polytetrafluoroethylene (TFE) is the resin most used in tape form for insulating purposes. TFE tape is available in several forms:
a.Cast Tape: This tape is usually required where

A new film, trade-amed "Kapton" (duPont), made from an aromatic polyimide resin has recently become available. The film has good physical properties, excellent thermal properties, and good electrical properties over a very wide temperature range. In an
aging test the film has an extrapolated life of 10 years

thicknesses from 0.25 mil to about 3 mils are involved, These tapes are used for extremely thin-walled, wrapped insulations where resistance to mechanical damage is arot a consideration in the end use of the wire. b. Skived Tape: This tape (literally shaved or skived continuously from the surface of a cylindrical block of moldtd TFE) is generally used where 5- to lO-mil tape lhicknemss are useful, as in the wrapped dielectric for some large size coaxial cables, c. Unsintered Tape: This is a tape which can be wrapped into place and sintered or fused at

at 250 0C, 1 year at 2750C, 1 month at 300fC, and about 1 day at 400'C. It exhibits excellent cut-through resistance at temperatures in excess of 2500 C and maintains its electrical properties at elevated temperatures. It has excellent solvent resistance. It is degraded by concentrated acids and alkalies, and has relatively poor sunlight resistance in its precsnt form. For purposes of its use as primary insulation, heat sealability would be required. The polyimide film itself cannot be heat-sealed. However, composite films of "polyimide" and FE? fluorocarbon resin are available which can be heat-sealed. The resulting composite insulation, combining properties of FEP and polyimide,

2-16

L___ ___
____ ____
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____

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__ ___

--

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AMCP 706-125

can properly be rated for service over 200WC, while maintaining and even enhancing the electrical, phys'cal, and chemical resistance properties of the polyimide film alone, Properties of the composito films are dapendent upon the relative amounts of polyimide and FEP, and can be approximated by calculating a weighted average of the respective properties of each. 2-7 FIBERS The principal uses of fibers in the wize and cable industry are in the form of protective co'erings, reinforcements, and fillers. They are usually applieJ by serving or braiding, followed by a lacquer coatin3 or possibly by an extruded jacket of some material either subsequent to, or in place of, the lacquer coating. See MIL-E.572 for data on fibers. Although extruded jackets offer far better protection egainst fluid penetration and a greater contribution to the overall dielectric strength of a wire construction than do fiber braids, there axe good reasons for using the latter. First, fiber braids provide wire constructions with a more flexible covering than extruded jacketing, particularly on the larger wire sizes. Second, in the case of braids utilizing glass yarns, some degree of physical separation of adjacent conductors is provided should the insulation be burned out in a fire, thereby permitting low-voltage circuits to continue functioning in critical situations. Finally, fiber braids do mechanically reinforce and strengthen overall constructions, particularly heavy-duty elastomeric cable jackets, but also to some degree, even on small size, jacketed hook-up wires such as type 3 of MIL.W-5086, The charac:eristics of braided coverings are dependent upon the combintion of the properties of the fiber and the lacquer or saturant. The contribution of the fiber is one primarily of mechanical strength. The function of the saturant is the impregration of the braided fibers in order to bond them together for effective abrasion Tesistance and to minimize fraying and wicking. A brief de.iption of some ot the most commonly used fibers and lacquers is given in the paragraphs which follow. Typical properties of the fibers to be discussed are given hi Table 2-5.

2-7.1 COTTON Cotton is a relatively strong and flexible fiber with good abrasion resistance and resiliency. It is highly water absorbent, and has poor fungus res:,stance unles; treated. It is flammable. It has moderate heat resistance. Cotton finds its principal application as a reinforcement for elastomeric jacketing typified in MIL-C-13777E.
2-7.2 RAYON

Rayon is a regenerated cellulose. It is somewhat lower in .ensile strwngth than cotton, but has abrasion resistance and resiliency similar to that of cotton. It is not fungus-resistant unless trea:ted. It is flammable. It is less water absorbent than cotton. It, has moderat. thermal capabilities, on the order of 80C. Saponified acetat, rayon is commonly used.
2-7.3 NYLON

-i

N.lon is a strong, tough fiber which has excellent abrasion resistance. In fact, in combination with nylon lacquer, it forms probably the best braid lacquer team in this respect. Nylon is inert to fungus. Nylon is flammable, but much slower burning than other organic fibers. It has thermal properties which permit its continuous usc at 1050 C.Nylon is widely uked both as a reinforcement for elastomeric jacketed cables and as outer coverings for many wire constructions, such as those specified in MIL-W-5086. 2-7.4 POLYESTER The polyester most commonly utilized is a polyethylene terephdhalnte resin. It possesses good strength and abrasion resistance. It is flammable. It is fur.gus-resistant. Its Oermal properties are sufficient to permit its use a an outer covering in wire constructions rated at 200'C, such as those of MIL-W-8777. 2-7.5 GLASS Glass fibers are very strong but brittle. Hence, their abrasion resistance is relatively poor. The nonflammability of glass is one of its major :!iaracteristics. It is fungus in.rt. The thermal capabilities of glass are'excelled only by those of some of the ceramic fibers and asbestos. Glass is useful at

"

2-17

AMC? 70Wi2F tem. atures up to about 3200C. Glass braids are 2-7.9 COATED FIB8ERS Of the many possible coated yams, those of glass coated with polytetrafluoroethylene (TFE) are probably the most widely used. The fact the TFE completely surrounds the fiber results in a finished braid having improved abrasion resistance over that resulting from applying TFE dispersion to a regular glass braid. To obtain the ultimate properties of this braid, it must Le heated to the sintering temperature of TFE t-. cause the resin particles to fuse together. This, of "ourse, limits its use to those constructions capable of withstanding ths processing temperature, gcneTally, TFF of the insulating resins. This fiber has been widely used in hook-up wire constructions made to MIL-W-7139.

utlized in a number of wire constructions including MIL-W-5086, MIL-W.16878D, MIL-W-87')7, and many others too numerous to list. 2-7.6 CERAMIC There is a growing number of ceramic fibers some of which are reputed to have heat resistance to temperatures of 15000 to 1700 0 C. However, only one of these, a quartz fiber, has seen much application in the wire and cable field. This quartz fiber is characterized by being weak and btittle, thus requiring relatively bulky yams to obtain sufficient strength for braiding, This fiber finds its principal application in the so-called "fire.vall ' wire of MIL-C-25038 where its resistance to an 1100PC flame is required. 2-7.7 AtAESTOS a ie asbestos fiber commonly used for electrical applicationsapplied principally cormposed of hydrous silicates of magnesia. Individual fibers have extremely high tensile strength, but are not amenab~e to a spinning process. Hence, pure asbestos yarns are relatively weak and must be quite bulky in order to be adaptable to braiding and serving operations. Asbestos yam is characterized by

2-8 LACQUERS Lacquers are generally solutions of soluble polymers or dispersions of insoluble polymers. Thus they are to braids as liquids, dried, and in some cases baked or fused, to o.sm a polymer film. The a m er fom. Te fse of baer characteristiucs of some of the most commonly used lacquers or braid saturants are briefly dscussed. 2-8.1 CELLULOSE ACETATE BUTYRATE

poor mechanical properties, but excellent thermal properties, making it useful at temperatures up to about 4800C. It is nonflammable. It is used for low

Lacquers made from solutions of this polymer are generally compounded with additives to impart fungus

voltage applications in lead wire, range wire, appliance

wires and cords, apparatus cable, and thermocouple leads.
2-7.8 FIBER COMBINATIONS Of the many combinations

resistance. They form good-looking films with good

abrasion resistance and good oil re.sistance. The thermal capabilities of these films are limited to about 80C.

The film is affected by solvents, particularly those in

of fibers that are which it was originally dissolved to form the lacquer. Cellulose acetate butyrate lacquers are used over cotton, rayon, and glass braids. A typical construction inwhich this lacquer is often used is MIL-W-76.

possible, only a few are commonly used. One example

is the. combination of cotton with rayon, or nylon

with asbestos. The obvious reason for this latter combination of fibers is to increase the physical
strength of the asbestos. Such combinations must be
d ra"d

2-8.2 NYLON
Solutions of nylon make excellent lacquers. Nylon

thr ,ally. Industrial practice .-at. s the.,adheres well to all fibers and forms films which have thermal use, temperature to type and quantity, of excellent abrasion resistance. It is fungus inert. It is ncnasbestos content. A second example is the resistant to oils and solvents with the exception of the combip~ation of polyester and glass. The obvious alcohols. Its thermal use limit is about 1050C. Nylon compromise of properties is that of the abrasion lacquers or braid saturants are widely used over many re.istance of the polyester with the nonflammability of fibers. Typical of the wire constictions in which it is glass. used are those of MIL-W-5086.

2-18

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706-125

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AMCP 706-125 2-8.3 FLUOROCARBONS There are several fluorocarbou resins which have 6een utilized as lacquer coatings in the form of solutions or dispersions. The two most widely used are a solution of a specific fluorocarbon resin and a dispersion of TFE. The fluorocarbon resin solution is generally applied over polyester braids and glass braids. It has fair abrasion resistance and is flame-retardant. It has good thermal resistance and is used in wire constructions rated at 200 0C, typical of those specified in MIL.W-8777. The TFE dispersion results in a coating which must be heated to the sintering tempeiature of the resin (327*C) to form a film. This fact imposes a limitation in ils use to materials which will withstand this processing temperature - such as glass oi ceramic fiber and TFE primary insulation. The thermal, mechanical, and chemical resistance capabilities of the film are typical of the resin. As previously noted, this coating is used in wire constructions typical of those specified in MIL-W-7139. 2-8.4 SILICONES Solutions of silicone resins are available for use a4 high temperature braid saturants heving thermal use capabilities up to 2500C. To achieve their optimum properties, however, they must be baked at high temperatures. As a result, their applications are generally confined to glass braids and high temperature primary insulation material. There are some so.called "silicone" lacquers which do not require this extreme baking cycle. However, these coating solutions can contain considerable proportions of nonsilicone resins and are not capable of the high temperature usage of the straight silicones. These solutic.s must be derated to pehaps i 1350 to 180 0C%, dcpi....g. upon their silicone resin content. 2-8.5 SPECIALIZED COATINGS In addition to the braid saturants or lacquer coatings described above, there are some specialized coatings which ate designed for use specifically with wires insulated with extruded polytetrafluoroethylene MTFE) and polyfluorinated ethylene propylene (FEP) resins. The,. cn be categorized as bondable coatings and polyimide, coatings.

2--8.6 BONDABLE COATINGS Both TF8 and FEP resins are characterized by having surfaces which are extremely inert and nonwettable. Normally this is an advantageous feature for an electrical insulation, because it results in a high degree of surface resistivity. However, it becomes a distinct disadvantage when it becomes desirable to obtair, an adhesive bond to the surface as, for example, in potting connector assemblies. There are two ways to obtain a bondable surface. One is the sodium etching process. This process results in excellent bondability, but has the disadvantage of blackening the. surface, particularly of TFE. and rendering any color coding ;ndiscernible. Additionally, it is a rather hazardous opetation requiring strict safety precautions. A number of manufacturers have developed proprietary bondable coatings applied over TFE and aEheinsulated s cpalo po viing dequhte ain mmo pttig striped,opond coatings dc ds nott mask printed, or solid These color identifications and can be procured with a thermal endurance equivalent to that of the potting compounds themselves. 2-8.7 POLYIMIDE COATINGS The development of a polyimide resin solution and the process for applying it in thin films (about 1 mil thick) to wires insulated with relatively thin wall- (5-6 mils thick) of extruded FEP have resulted in a ,ast improvement of mechanical properties, such as cut-through resistance over the uncoated insulation. The polyimide coating, when properly applied and processed, has properites similar to that of the polyinide film listed in par. 2-6, "Films", of this chapter. The presence of the film permits the use of thinner walls of FEP in areas subject to more mechanical abuse, without reducing its thermal rating, than the fluorocarbon resin could be expected to withstand by itself. Currei tly, techniques for the application of the polyimide resin to TFE insulated wires have not been developed to the point where a consistently satisfactory product can be manufactured on a commercial scale.

2.20

--

It

wr

Wires having this coating arv. expected to be especially valuable in space application where reduced size and weight are iital consideratons. 2-9 POTTING COMPOUNDS Potting compounds are usually low viscosity liquids which cure to a thermoset polymer t room, or moderately elevated, temperatures. Their major function is to provide a moisture-tight seal around the embedded components; however, an important secondary functico is one of providing mechanical protectioi, and reinforcement. 2-9.1 TYPES Or POTTING COMPOUNDS There are three major types of potting compounds: epoxy resin fom.ulatiops, polyurethane formulatiops, and room temperature vulcanizing (RTV) silicone rubber compounds; also some less frequently used types, such as polystyrene and unsaturated polyester formulations. Tlzire are literally hundreds, and verhaps thousands, of possible formulations of potting compounds commercially available with a resulting wide range of physical, thermal, and electrical properties. Tab!e 2-5 which lists pioperties of some typicai potting compounds, should be utilized therefore only in a very general way, particularly in case of the epoxy resin compounds. It is usually a relatively simple mu.tter to select a potting compound having the required thcrmal and electrical properties for a potting application. The major p'oblems involved in achieving a saftfactory potted connection are those which can ba clasified as problems of adhesion. The problems can be narrowed even further by considering that adhesion to the metallic components of the connection are relatively easily resolved, thus leaving the vdhesive bonds between the potting compound and wile or cable insulation or jacket materials as the most critical. 2-9.2 POTTING - DESIGN CRITERIA Some suggestions which should be considered in the design of potted wire and cable terminations are the following: 2-9.2.1 Surface Preparation a. Rely upon the advica, )f the potting compound supplier with regard to surface preparation and priming,

b. In the case of bonding TFE or FEP, either sodium-etch the area to be bonded or use wires having a bondable coating. c. In the case of polyethylene, some method of oxidizing the surface is usually required. The simplest method i6 that of "ame-treating". d Once having prepared the surfaces to be bonded, keep them clean. 2-9.2.2 Machanical Factors a. Utilize a potting compound having as low a volume shrinkage on curing as possible. b. Ideally, the moduli of elasticity of the potting compound and the surface to which it is bonded should be equal. In actual wire and cable applications, however, this is rarely possible and the best rule of thumb to follow is hJat the potting compound, when cured, should have a lower elastic modulus than that of the insulation to which it is adhered, c. If poscible, fillet the potting compound around the wire or cable to help distribute stresses. 2-9.2.3 Chemical Factors a. Be aware of the fact that those potting compounds which are exothermic (generate heat) during cure should be used in sufficiently small quantities so that th, hieat generated does not exceed the thermal capabilities )f the insulation. b. Check with thn supplier of the p-otting compound To be sure it -tnone of the compound components will affect components of the potted connection. c. Select compositions which do not readily volatilize or change composidon ratio during vacuum degassing. 2-10 INORGANIC INSULATIONS In addition to the inorganic fibers, such as glass, asbestos, and quartz discussed in par. 2.7 "Fibers", other inorganic materials are utilized as insulations in the form of compressad powders which may or may not be fused. Cablcs and wire- using this form of insulation consist of one or more conductors surrounded by the peformed insulation and enclosed

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AMCP 7W6125

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AMCP 70G-125 Jin a liquid and gas tight metallic sheath. Such constructions, being completely inorganic, are very heat-resistant, inert to most environments, and fireproof. Although such wires and cables can be bent, it is obvious that they are not truly flexible. Further, their lengths are limited, because the application of the insulation is not amenable to a continuous process. 2-10.i MAGNESIUM OXIDE INSULATION materials are subject to fungus attack when ambient conditions are favorable for fungus growth. This attack can ultimately severely deteriorate or even destroy the insulating material. Mildew is an example of one type ot fungus. Generally, warm, damp, and shaded areas provide the most ideal conditions for fungus growth. The obvious way to avoid insulation deterioration arising from fungus attack is to utilize materials which are non-nutrient, or "inert", to fungus. It is possible, however, to utilize fungus nutrient m-terials if adequate concentrations of additives which a.e poisons for fungi (fungicides) are incorporated to render the in'alation fungus-resistant. A typical test method for determining fungus resistarce is that given in MIL.STD-454 and MIL-STD-810. 2-11.2 RADIATION RESISTANCE The effect of nuclear radiation upon insulating and jacketing materials is of concern where wires and cables must operate in environments which may expose them to such radiation. All polymeric insulation materials are adversely affected by exposure to radiation. The mechanics of the attack upon polymer structure are either cross-linking or chain scission. The former results in eventual embrittlement, the latter results in loss of physical properties. In general, radiation in a vacuum or in an inert atmosphere is less sev re in its effects than radiation in air. The inorganic insulations are quite resistant to radiation damage, and high exposures are required to effect significant changes in physical properties. Materials containing boron are an exception. They are not resistant to thermal-neutron bombardment, although they are resistant to damage by high energy electrons. Conversely, therml-neutrons have not been found to contribute significantly to the degradation of organic polymeri. 2-8 shows the approximate, relative gamma radiation resistance in air of the materials commonly used as wire and cable insulations and jackets. The table is only indicative of the relative service life of the materials listed and should not be interpreted as actual service life. Factois such as dose rates, temperatures, wall thicknesses, compounding variables, and ventilation conditions will combine to affect actual service life. 2-23 "S,

'

The most common inorganic insulation is magnesium oxide. It finds use in "mineral insulated" cables as a compressed powder. Such cables are used at voltages up to 600 volts rms under continuous operating temperatures of 2500 C.Short time overloads, or higher operating temperatures at lower voltage ratings, are possible depending upon the melt temperature of the sheath or conductor (copper melts at 1080C). The insulation is physically stable to 28000 C, although its insulation resistance is very low at that temperature. Other inorganic materials which have found some use as wire and cable insulations are aluminum oxide and boron nitride. Some of the properties of these materials are given in Table 2-7. 2-10.2 MAGNESIUM OXIDE BEADS Donble-sneathed, multironductor cables for unusual Rpplication& may be fabricated by threading the conductors through preformed magnesium oxide beads which in turn are placed inside a sheath of the appropriate dinieter Lnd length. The assembly is then subjected to a process which compresses the magnesium oxide. The cable is built up by repeating the operation of "stringing" and compression.

[I

2-11 SPECiAL ENVIRONMENTS

P~Table
2-11.1 FUNGUS RESISTANCE Fungi are defined as being saprophytic and parasitic lower plants which lack chlorophyll, Certain insulating materials, notably cellulose derivatives and some lubber and plastic compounding ingredients, are fungus nutrients. Therefore, these

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AMCP 706125

TABLE 2-7

PROPERTIES* OF TYPICAL INORGANIC INSULATING MATERIALS

Material Melting Point, 0 C

Magnesium Oxide

kiutainurn Oxide

Boron Nitride

2830

2015

2730
lol 100

Volume Resistivity, ohm-cm @ 30C @ 10o0c @1S000 C Specific Gravity Dielectric Constant, I MHz Dissipation Factor, 1 MHz

1 '.0
10 107
9

106

10

....

3.6 9.7 0.002

3.8 9.5 0.008

2.2 4.2 0.001

* The properties listed are those expected of a void free construction, and in the case of compressed powders, would

vary appreciably with the degree of compaction, particularly with regard to dielectric constant.

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1AMCP
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TABLE 2-8 RELATIVE RADIATION RESISTANCE OF INSULATING MATERIALS IN AIR

706-125

Material Thermoplastic

Radiation Resistance, Gamma Exposure, rad

Polyvinylchdoride Polyethylene, Low-density Polyethylene, High-density Polypropylene Nylon Fluorocarbon, TFE Fluorocarbon, FEP Fluorocarbon, CTFE Fluorocarbon, VF-2 Polyurethane Elastom eric Natural Rubber
SBR

107 _10l 9 108 - 10 7

10
-

10

106
4 10

_J 0 106 _ i0 7

10s _ 106
106 _ 107 106 _ 107 108 -10
107

_ 10/

/
/

Chloroprene Butyl Silicone Rubber Chlorosulfonated Polyethylene EPR Fluorocarbon Rubber Polyester

107 - l08 106 - 107

10 -

l0s - 106
7 10 - 108

106 - 107
106
106 l0s
-

107
10
7

9Cel;l osic

7 - 10 106 - 101

Polyimide

108 . 1010

2-25

AMCP 706-125 TABLE 2-9 W

RELATIVE COSTS OF INSULATING MATERIALS Material

PVC Polyolefin Nylon TFE FEP .CTFE Cost =Weight x Specific Gravity* 0.4 0.4 1.2 10.0 12.0 12.9

VF-2
Polyurethane Natural Rubber

9.0
1.8 0.6

SBR Rubber
Neoprene Rubber

0.5
0.9

Butyl Rubber
Silicone Rubber Silicone Rubber, Fluorinated Hypclon Rubber EPR Rubber Fluorocarbon Rubber Cellulosics

0.5
3.8 25.0 0.8 0.5 19.0 0.3

Polyester Films
Polyimide Films

1.7
40,0

Since wire and cable are sold by length rather than by weight, it is necessary to multiply weight by specific gravity to reflect the true cost relationship of insulating materials. This table does not include costs imparted by processing characteristics of the varioui materials which, in some cases, are a major factor in the cost of finished wire and cable.

2-26

6C
____________________________ _____________________________ _ _

I.

I"

~AMCP
REFERENCES
p

706-125

1. Effects of Radiation on Materials and Components, Kircher and b.,wman, Reinhold, N.Y., 1964. 2. Handbook of Design Data on El,'tomeric Materials Used in Aero Space Systems, ASD.TR-61.234. 3. High Polymers, Volume XI, Polyethylene, Raff and Allison, Interscience, N.Y., 1956. and Engineeiing 4. Insulating Materials for Design Practice, Clark, Wiley, N.Y., 1962. 5. Insulation Directory - Encyclopedia 1-ue, Lake Publishing Co., Libertyville, Ill., 1966. F.W. Bi.meyer, 6. Textbook of Polymer Chemistry, Interscience. N.Y., 1957. 7. The Vanderbilt Rubber Handbook, R.T. Vanderbilt Co., N.Y., 1958. 8. Vinyl and Related Polymers, Schildknecht, Wiley,

19. MIL.C.23206, Cable, Electric, Thermocouple. 20. MIL-C-25038, Cable, Electric, Aircraft, High Temperature and Fire Resistant. 21. MIL.C-55036, Cable, Telephone, WM-130# #/". 22. MIL-E-572, Environmental Testing, Aeronautcal and Associated Equipment, General Specification

For.

23. MIL-M-20693, Molding, Plastic Material,Polyamide (Nylon) Rigid. 24. MIL-STD-202, Selected Standards for R.F. and Acoustical Parts. 25. MIL-STD-810, Environmental Test Methods For Aerospace and Ground Equipment. 26. MIL-W-76, Wire and Cable, Hook.up, Electrical,

Insulated. N.Y., 1952. 9. CX-4245/G, Aerial Installation of Cable Assembly, Special Purpose. 10. CX-1 1230 ( )/G, Evaluation of PreliminaryEngineering Development Models of Cable Assembly, Special 27. MIL-W-5086, Wire, Electrical, 600 Volt, Copper, Aircraft. 28. MIL-W-7139, Wire, Electrical Polytetrafluoroethylene Insulated, Copper, 600 Volt. 29. MIL-W-8777, Wire, Electrical, Silicone Insulated,

PurposeElectrical.
11. MIL-C-17, Cables, Radio Frequency, Coaxial, Dual Coaxial, Twin Conductorand Twin Lead. !2. MIL-C.915, Cable, Cord, and Wire, Electrical (Shipboard Use).
13. MIL-C-2194, Cables, Power, Electric' Reduced

30. MIL-W12349, Wire, Hook-up, Monochlorotrifluoro. ethylene Insulated. 31. MIL-W-16878D, Wire, Electrical, Insulated, High
Temperature (Navy).

Diameter Type, Naval Shipboard. 14. MIL-C-3707. Cable, Power, Electrical, Ignition,
High Tension.

32. MIL-W-22759,

Wire, Electrical, Fluorocarbon

Insulated, Copper. 33. NAS-702, Wire, Electrical. hsulated, Copper Hook-up and General Purpose (For 105C Service). 34. Guide to Test Meihods for Plastics and Related Materials Picatinny Arsenal, Dover, N.J., AD-662

15. MIL-C.1311, Cables, Telephone, WVD 31/U and WTr 241U

(Inside Telephone Station).

16. MIL-C-13294, an d

Cable, Telephone, iWD.I/TT

Electrical

attdWD-1/TT.049.

17. MIL-C.13777E, Cable, Sp,?cial Purpose, Electrical. 18. MIL-C-23020, Cable, Coaxial (For Submarine Use).
"

35. Engineering Design for Plastics, E. Baer, Case Inst. of Tech., Reinhold P-iblishing Corp.. 1964 (LO# 64.15356).2
2-27

AMCP 706-125 REFERENCES (CONT.) 36. MIL-HDBK-700(MR), Plastics, Army Materials Research Agency, Watertown, Mass., 1965. 37. Electrical Properties of Plastic Materials, Plastic Report 23, Plastics Technical Evaluation Center, Picatinny Arsenal, Dover, N.J., July 1965. 43. Mechanical 1ropertie of Polymers, Pol)mer Conference Series, Wayne State University. 44. "Materials", Scientific American, Sept 1967. 45. Electro-Technology's Basic Science & Engineering Series, C-M Technical Publications Corp. a. The Fundamented Properties of Plastics, T.D. Callinan & A.E. Javitz, Aug 1959. b. Electrical Insulation Deterioration, T.W. Dakin, Dcc 1960. c. Electrical Breakdovn in Solids and Liquids, A.H. Sharbaugh and J.C. Devi:,s, Oct 1961. d. Mlecuar Bhapo f Composite Eetia lnsulatior C.R. Bh Vail, Feb 1962. 46. "Materials--impact on Design," Electro-Technology, Vol 79, No. 6, June 1967.

'

38. Dielectric Materials and Applications, A.R. Von Hippel, Editor, Technology Press of MIT and John Wiley & Sons, 1954 39. Subject Index, Bibliography, and Code Description of Technical Paperson Plastics,10 Mar 66 - 18 May 67, Plastic Report 31, Plastics Technical Evaluation Center, Picatinny Arsenal, Dover, N.J., July 1967. 40. Insulation Engineering Fundamentals, Graham Les

Moses, Lake Publishing Co., 1958

'

41. InsulatingFundamentalScrics, Insulation Magazine, Lake Publishing Corp., Ot 1967. 42. ASTM Standards on Electrical Insulating MaterialsASTM Comm. D.9, Oct 1959.

2-2
I
2-28

'II

AMCP 706-125

)
CHAPTER 3

DESIGN FACTORS - HOOK-UP AND INTERCONNECTING WIRE

3-1 SCOPE Conductor materials, coatings, and configurations were presented in Chapter 1. Insulating materials, their ratings, properties, and limitations, were presented in Chapter 2. This chapter proceeds with the choice of materials and design criteria to meet requirements of application tor single conductor insulated wires, 3-2 FACTORS INFLUENCING DESIGN 3-2.1 ENVIRONMENTAL FACTORS 3-2.1.1 High Temperature One of the chief factors contributing to the degradation of electrcal insulation in service is that of temperature. Temperature degradation is a function of time, so that the maximum permissible temperature is higher for a short time than that permissible for continuous service, The total temperature of a system determines the rate of aging and establishes its thermal endurance. This total temperature is based on two prime factors; ambient operating temperature and temperature rise due to internal conductor heatings. The conductor "hot spot" (the temperature of the conductor at the hottest spot in the system) should be used as the total temperature for insulation selection. Chapter 2.should be referenced for the selection of insulating materials for continuous upper limit thermal ratings. 3-2.1.2 Low Tempcratura As discussed in Chapter 2, the low temperature characteristics of the many insulation systems - and even different compounds of the same system - differ greatly, depending on the ingredients, method of processing, and method of testing to verify suitability for handling at extrene temperatures.

Insulations, both primary and jacketing types, will withstand extreme low temperatures well below their "rating", usually down to absolute zero, provided they are not disturbed or flexed in any manner. Such being the case, storage at temperatures below the specified limits will present no problems if the wire or cable is returned to a safe handling ten'perature before unreeling, flexing, or installation. Low-temperature ratings or limitations should be specified in terms of the actual usage expected, and where applicable should include: (1) mechanical and electrical performance expected at the temperatures to be encountered in service, (2) temperature of installation and maintenance, (3) maximum permissible variation of properties under temperature cycling throughout the entire operating range, and (4) vibration and operational flexing expected within the operating range. Specifying only a general low-temperature rating can be dangerous due to the many adverse conditions and environments that cannot be duplicated or simulated by test in the laboratory. Present test methods employed for low temperature rating define controlled test conditions, including mandrel sizes for bending or wrapping, motor driven sheaves at constant speeds, specific load weight, and controlled temperature duration. These methods should only be utilized for comparison in selection of materials, and as a quality control measure on the material. Chapter 2 lists the low-temperature ratings of the more commonly used insulating materials. 3-2.1.3 Flammability Flame-rmtardant properties, as discussed in Chapter 2, will vary greatly depending on the ingredients, the compounding, the construction, and method of test. Most insulations, except for the fluorocarbons, will support combustion and convey flame if extensive flame is present or applied continuously This is

3-1

I1

)!

AMCP 706-125

particularly true if the wire or bundle of wires run vertically. Again, all adversc conditions and environments cannot be duplicated in the laboratory, and the test method should be utilized only as a guide to determine ad compare the flame-retardant properties of the materials and construction of the wire. Self-extiaguishing properties, and flame travel and burring rate. in air at sea level can be entirely different from those hi oxygen at zero gravity,
3-2.1.4 Moisture and Fungus

los, of dielectric strengdi, and discoloration resulting in loss of identity.

Ozone concentration must aho be considered, particularly with vulcanized rubber and rubber-like materials. Conditions affecting insulating materials are the concentration of ozone togeth:r with temperature, stress, additives, sunshine, and rainil'. 3-2.2.4 Corrosion Corrosion for the most part, are but some rubber withproblems, the basic conductor, n u ai gmaterials mt r a s( a t c l r y those t o ehaving h v n sulfur u f r ii insulating (particularly the curing system) can accelerate this condition. Heat and moisture also contribute. Corrosive atmospheres should be evaluated to insulating the extentmaterials th,, theyand may be by both basic conductor metals.
3-2.2.5 Outgassing

~concerned w ire and cables th at are is to especially be used intrue warmfor , dam p, or wet installations. This use in
tropical or semitropical areas, The materials that are fungus inert are fluorocarbons, nylon, and some vinyls information refer to (see MIL-STD.454). Fo, further (seter 2.o uencountered

Fungus-resistant materials should be utilized for

3-2.2 CFJEMICAL FACTORS 3-2.2.1 Liquid

The mutual compatibility of the basic insulations with chemicals should be evaluated tc the extent that they will be encountered. Immersion in, or contact with, fluids, solvents, ols, fuels, acids, salt water, and

moisture, that may result in mechanical or electrical degradation be examined throughout the entire temperature should range to be encountered in operation. e is, however, notnecessary to boil the wire in tests when only occasional splashing may be encountered s room temperature. Some of the degrading effects of immersion are swelling, cracking, splitting, protrusion, dielectric breakdown, and irsulation resistance loss.
3-2.2.2 Ultraviolat

Insulation systems containing volatiles (particularly plasticizers) can outgas, at low pressures in airborne equipment and space vacuum, to form condensible film or fog on critical optical and electrical surfaces. PVC, polyethylenes, irradiated polyolefins, and compounds containing additives - with the exception of the fluorocarbons TFE and FEP, and polyimides - are known to outgas the additives, such as flame retardants or thermal stabilizers, that are frequently used in these materials. Some plasticizers, such as used in 60PC PVC compounds, can form a caductive gas in a closed (unrented) system.
3-2.3 MECHANICAL FACTORS

Ultraviolet produces (I)- ozone, causing degradation,

usually on the surface and, (2) attacks most plastic materials directly. The materials may be protected by

3-2.3.1 Flex-life
Flex-life refers prinarily to the conductor, relating

for direct exposure to sunlight. Plastics should be pigmented (black preferred) to exclude penetration. Infrared raises the temperatur, of dark materials above that of the atmosphere.
1ivb:tor;

3-2.2.3 Gaseous Oxidation is a predominant cause for deterioration in plastic materials and can lead to deterioration of properties - such as stiffening and loss of elongation,
3-2

to is ability to withstar.d specific bending or flexing without breakage. Flex-life is very dependent on installation techniques- such as type of lug or termination, whether soldered or crimped, whether the insulation is supported by the termination, and how the wire is fastened and secured within the equipment. The insulation system can contribute greatly as a strain relief, particularly when utilized with insulation grip type terminations. Some plastics, particularly the polycarbonates, exhibit poor flex-ife.

.Ip

LIU
AMCP 706-125

"

moisture absorption, weathering, deterioration, and electrical history. Dielectri," constant is of utmost " importance in a shielded construction (coaxial) for abrasion flammability, and temperature low with As resistance characteristics are difficult to assess with radio frequency application. It is generally desirable to laboratory methods because of the many forms of have the capacitance, and hence the dielectric constant, abrasion encountered in practice. Abrasion is a very as small as possible. important problem and a control must be established, again on a comparative basis, even though the tests do 3-2.4.2' Dielectric Strength The fundamental requirement of insulation is to ofthe rand(maufacurer ; always simulate practice. a change in the Even brasvealthugh not cloe to he conductor as brand (manufacturer) of the abrasive, althoughas required by the end voltages all applied under possible can change siz, and grit material same the supposadly the results use. The dielectric strength test is necessary to prove performance as a qualiy measure. In service there my be many deteriorating influences-such as heat. 3-2.3.3 Penetration mechanical stress, manufacturing defects, corona and its products, contaminants, etc.-which may reduce Mechanical problems of penetration, cut-through, the breakdown voltage of the insulation below the slow compression, cold flow, or deformation are really one and the same, i.e., amounting to stress under load. value as originally installed. Some of these effects can the laboratory, and followed by a These again are depeiident on conditions of installation be simulated itn dielectric test, to obtain an estimate of material and mechanrcal abuse during service. It is important, however, to specify cut-through testing to simulate use performance under adverse conditions. In dielectric conditions at the maximum use temperature where the testing it is important that the voltage be raised from zero at a uniform rate to prevent transients (500 voIts insulation material is softer than at room temperature. Specific test methods and test equipment again per second is usually specified). determine only the relative capabilities of the 3-2.4.3 Gradient (Elactrical) insulation system. Gradient is generally expressed as the quotient of 3-2.3.4 Tensile Strength 3-2.3.2 Abrasion Resistance Tensile strength per se has no real importance to the finished wire except to serve as a control of the mt.erial chosen. 3-2.3.5 Elongation Elongation is also used as a control of material but differs from tensile strength in that a certain minimum value must be retained for adequate performance. Conductor materials should always have greater than elongation at rupture (while maintaining a yield o6% point of 0.5% at elongation) to prevent conductor breakage. Insulation should have greater than 50% elongation to eliminate possible cracking on flexure. For specific materia) control however, values in excess of these may be specified as minimum.
3-2.4 ELECTRICAL FACTORS

the applied voltage divided by the insulation thickness between two oppositely charged conducting members. The electrical stress of a single coe cable with a conducting cylindrical outer surface may bo Lalculated at any point in the insulation in terms of the applied voltage and cable dimensions by Eq. 3-1. S
e

3)

x log, (Rir) S = electrical stress, volt/mil x = distance from center of th'e conductor to point of stress calculation, mil r = radius of center conductor, mil
. -

= radius of core (or inner radius of outer

'"

conductor), mil E
=

3-2.4.1 DIelectric Constant Factors affecting the dielectric constant of a given material are signal frequency, temperature, voltage,
__ ' '.--

voltage between inner comductor and outer conductor, volt

Gradient calculations are important in the design of high voltage cables.

3-3
... . . . _l l~l lIm v S.."

it

AMCP 706-125 3-2.4.4 Insulation Resistance Insulation resistance is a measure of volume resistivity of ins, lation and depends on the length of time of electrification and on the value of the applied voltage (in addition to the usual material and environmental variables). This is due to a combination of polar migration, linear resistance, and displacement current. It is usual to use the value achieved after one minute of eiectrification. Insulation resistance is lower at high temperature ofincressed molecular activity e bncause The insulation resistance required can be accurately determined from circuit considerations and should be specified encounter at d. the highest operating temperature to be 3-2.4.5 Loss Factor The loss factor is an indication of the power loss in the insulation system and should be small to reduce insulation heating and signal degradation. It is usually of importance only in audio and radio frequency cables. Factors affecting loss characteristics are identical to those affecting the dielectric constant. 3-2.4.6 Current-carrying Capacity Reliable current ratings are one of the prerequisites for the design of any electrical system. There are two general criteria by which the current-carrying capacity of a cable is determined: (1) the maximum permissible voltage drop in the conductor, and (2) the maximum insulation temperature of the conductor. Since the maximum conductor temperature is limited by the insulation, the maximtumn current wil depend upon the maximum operating, or "hot spot", temperature and ambient temperature. The higher ,the ,mbient, the lower the allowable temperature rise will be. Under conditions of thermal equilibrium, the ,ate at which heat is produced in the conductor is equal to the rate at which the heat is removed from the insulation ana dissipated lo the surroundings by conduction, convection, and radiation. d -teminationof current-carrying capacity
in the Inasmuch as there are many factors involved and its

technical prerequisites, no attempt will be made to( define all the parameters involved in the selection and ratings of single conductors here. The current-carrying capacity can be determined experimentally, and can be accurately calculated using formulas on current and temperature rise in cables in Refs. 1-3. These techniques have been verified experimentally in several laboratories, and are accurate and usable. (For bundling see Chapter 4.) 3-2.4.7 Voltage Drop of Another size criterion that influences selection operating conductor is the voltage drop the under aircraft is often found in conditions. This condition cable installations containing low voltage, high current, and long wiring runs. This factor may be more important than current-carrying capacity. Voltage drop, when excessive, can be reduced to a practical value by resorting to a conductor larger than necessary to carry the necessary circuit current. For direct current and 60-Hz circuits (except long interstate power circuits) the voltage drop may be calculated from Ohm's Law. For 400-Hz and high-voltage systems, particularly 3-phase, the calculations become involved beyond the scope of this handbook. Skin effect must also be taken into consideiation. Techniques for these calculations may be found in Ref. 4. Cognizance must be taken of the increase in resistance with operating temperature according to the fundamental relation:
RT
=

R 20 [1 + a2o(7 -20)]

(3-2)

where RT
R 20

resistance at measurement temperature, ohm resistance P20 0C the refercnce tmperature, ohm
t t
=

T a?(

teml.-ratL-e coefficient of resistivity per C @ 10C

The value of temperature coefficient of resistivity will depend on the conductivity of the conductor as well as the temperature and may be obtained from the equation
__a__

(3-3)

_1_(3-3)

n(0.0393)

(T-20)

\' I

~3-4

AMCP 706-125

whre a = coefficient of resistivity

n = percent conductivity of conductor expressed decimally (99% 0.99) 0.00393

=

copper (100% conductivity)

3-2.5 IDENTIFICATION Basically there are three requisites for identification: manufacturer, temperature, and circuit identification, Manufacturer identification may b . accomplished by the use of color-coded threads placed either within the strands or under the insulation, braid, or jacket, and surface printing or Federal Code designation,
Sb

Flex-life is primarily a function of the number and size of the individual strands, the, strongth of the *:.cductoi r..eial, and the length and direction of strading lay employed. A great,-r number of smaller size strands will increase the flex-life considerably. The use of a solid conductor should not be considered when flex-life or flexibility is impotant. Cold working due to mehanital vibration, physical abuse in installation and service, and uncontrolled manufacturing processes can lead to premature breakage of solid conductors. See Chapter 1 for details and particulars affecting construction and design of the basic conductor. 3-3.1.2 Thermal Factors Following the requirements of tensile strength, elongation, and flex-life of the basic conductor, consideration must be given to its thermal operating environment. Selection of a coating, if required, must made. Many factors are involved in the selection of tin, silver, nickel, the coating material, to i.e.,Chapter 1 will aid or in dual the Reference coatings. selection and determiration of the proper coating. The following examples are typical of conductor selection: EXAMPLE NO. 1: Reanuired Tensile Strength Elongation Flex-lfe
Wire Size

identification may also be hbe r accomplished by a color-coded thread system or by surface printing. STemperature Circuit identification is accomplished by the use of

color coding or printed numbers. Color coding includes or solid colored insulation, helical striping, continuous slash or broken horizontal striping, "hash-mark" striping, and, in some instances, a series of dashes. Color coding by spiral striping is the most common and least expensive. Circuit identification may also be accompiishea by the surface printing method utilizing a c or code number system. 3-3 DESIGN CONSIDERATIONS
3-3.1 CONDUCTOR CHOICES

39,000 psi (max) 20% (min) Essential

4-" AWG

The selection of the basic conductor involves many factors which are essential to the satisfactory operation of an electrical system. The following is a discussion of the most important of these factors. 3-3.1.1 Mechanical Factors From the engineering information available, the tensile strength and elongation of the basic -.onductor should be specified.

Maximum Conductor Temperature Coating DC Resistance Conductivity Corrosion

1050C Tin 10.5 ohm/1000 ft @200C 0C 99% No problem

For applications involving wire sizes #24 AWC. .nd smaller, consideration should be given to the use of alloy materials for improved strength and flex-life.

The following selection would be more than adequate fe, Example No. 1: 19 strands of #32 AWG tin
3-5 V

AMCP 706-125 copper, or 27 of #34, or 37 of #36, depending on the degree of flexibility. (As opposed to a solid or 7 strands of #28 AWG.) Eich stranding ha a tensile strength of approximately 37,000 psi, an elongation of approximately 25%, z coating thickness of approximately 40 pin., and a DC resistance of less than the maximum 10.5 ohm/1000 ft @ 2OTC specified.
EXAMPLE NO. 2: Factors affecting the mechanical performance of an

a. Temperature (high): Refer to par. 3-2.1. b. Temperature (low): Refer to par. 3-2.1.2 c. Chemical Factors: Refer to par. 3-2.2 d. Electrical Factors: Refer to par. 3-2.4 3-3.2.1 Mechanical Considerations

Reuured Tensile Strength Yield Strength (at 0.5% strain) Elongation i.-lJife Wire Size 1Maximiun Conductor Temperatue Coating DC Resistance Conductivity Corrosion 50,000 psi (min) 45,000 psi 8%(rain) Essential #26 AWG 2600C High Temperature 49.00 ohm/1000 ft @ 200 C 85% -90% Possibility

insulation are elongation, flexibility, abrasion, resistance to penetration, cold flow, and deformation. All of thse properties are desirable, but the cost factors involvwd usually dictate an acceptable compromise. A zareful evaluation of the necessary properties requited for sa'dsfactory operation should be made and applicable test methods shoidd be specified to insure sufficient wall thickness for the mechanical abuse that may be encountered, or exis!, under normal ope-ating condition.i. 3-3.2.2 Electrical Considerationc The primary function of wall thickness, in relation to the electrical prope-rties of a single wire, is to provide a capability of withstanding the electrical etress imposed upon it during the application of the nominal operating voltages and frequencies. The dielectric stress at any point is a function of the applied voltage, conductor size, and insulation thickiess. It will be maximum at the surface of the conductor and will progressively decrease towards the outer surface of the insulation, and will vary with the size of the conductor. From this it is obvious that for a given voltage rating he wall thickness will be dependent on the physical size of the conductor. When the wall thickness is increased, for mechanical reasons or special service conditions, the test voltage and fiequency should be determined by the size of the corductor and the rated voltage, not the apparent thickness of the insulation. Minimum wall thicknesses -nay be limited by permissible interferpn ,e due to capacitive coupling. Reference to Chapter 7 should ue made for details involved in voltage ratings vs insulation thickn.ss. 3-4 TESTING TO PROVE DESIGN The culmination of all engineering work is in the practicable application of the materials selected. The

The following selection would be more than adequate for Example No. 2: 19 strands of #38 AWG high strength, nickel-coated copper alloy, with a tensile strength of approximately 63,000 psi, a yield strength of 55,000 psi (at 0.5% slain), an elongation of approximately 10% at rupture, a nickel coating thickness of 50 pin. minimum, a conductivity of 90% rrinimum, and a DC resistance of approximately 47.8 ohm/1000 ft @20 0C. 3-3.2 'PJMULATION tVHOICES of the The following factors govern the choice correct insulating material for the prescribed installation,

3-6C

AMCP 703-1'5 most expert and knowledgeable selection is only one step toward the final objective. Another step is the establishment of suitable test methods which insure that the end product will perform in accordance w ith the requirements to be. encountered under operating conditions for the service life expected. A general outline of specific tests is presented that may be utilized in the writing of specifications for control of production processes, quality control, and acceptance test procedures. This listing does not include special test methods applicable to certain wire and cable that may be described in appropriate detail specifications, nor does it include all the test methods 3-4.3 AGING TESTS Air Oven Life Cycle Accelerated Aging Oxygen Test Air Pressure Test Humidity Resistance

3-4.4 THERMAL TESTS Heat Shock Deformation

for wire and cable used in the industry.

Reference to established Military Specifications, ASTM Standards, and Federal Test Specifications should be made for detailed descriptions of the indicated tests. For additional information refer to the Appendix. 3-4.1 ELECTRICAL TESTS: Dielectric Strength DC Resistance Tes A/D RFFlexibility

Heat Distortion
Flammability Brittleness 3-4.5 MECHANICAL TESTS Cold Bend

Melt Point
Shrinkage (insulation)

Penetration Slow Compression

Test AC/D, /RF

Spark Test, Insul=tion Defect Corona Level

Conductivity

Flex-life Abrasion Resistance

Flow Under Stress

Capacitance

3-4.6 CHEMICAL TESTS Water Absorption Ozone Resistance Resist an So Resistance to Oils and Solvents Resistance to Acids and Alkalies 3-5 HOOK-UP WIRE VS oating cont;nuity conductor) Sodium Polysulfide duPyui

Insulation Resistance Surface Resistance Power Factor Volume Resistance PoerFctrVoum essane Dielectric Constant (capacitive coupling in multiconductor cable) Electrical Stress Smoke

INTERCONNECTING

3-4.2 PHYSICAL TESTS Tensile Strength Elongation Tension Set Tear Test Tensile Stress Solder Accelerated Aging Thickness of Insulation Concentricity Specific Gravity Wicking

3-5.1 HOOK-UP WIRE Major uses of hook-up include internal wiring of meters, panels, electronic computers, aircraft and instrumentatien wiring, military ground support wire, industrial and domestic appliances, automotive industry, telephone equipment, "black boxes" for aircraft and missile components, and other automated equipment. As opposed to interconnecting wire, most hook-up wire is utilized in (1) mechanically protected areas such as chassis wiring, or (2) as basic components _____3-7

,.

AMCP 706-125 h, nulticonductor cables protected by either individual shields or overall shields and outer protective coverings such as extruded jackets or sheaths and armor braids. Most hook-up wires manufactured in accordance with individual specifications are suitable as component parts of milticonductor cables. However, it should be of the individual noted that the test requirements hook-up wire do nct necessarily covcr the performance requirements if those wires are incorporated in multiconductor cables. Tests required for completed cable constructions, to assure suitability for operating conditions, should be agreed upon between the purchaser and manufacturer. relatively fragile and easily are bms, 250-300 volts damaged, and, therefore, should not be used where :ubjected to mechanical stress or abrasive envirormant. 2onductors employing hiIn-wail insulations are very susceptible to damage and, consequently, may not be suitable for circuits requiring the highest dtugree of reliability. This problem can be minimized by employing high strength copper alloy conductors in sizes #24 AWG and smaller in order to insure greater tensile strength, elongation, and flexibility. In order to appear consistent, thin-well insulations are assigned the same rated values as those rated values assigned to heavier walls of the same dielectric material. Care must be taken with these thin-wall insulations during installation to avoid damage to the dielectric - e.g., the use of hot soldering irons or leaving residual strain on the dielectric wall - that may cause thermoplastic flow and subsequent failures. Thin-wall insulations should be used only where space and weight limitations preclude the use of more spbstantial and reliable insulation thickness. Most hook-up wire specifications allow, or make provisions for, alternate strandings and additional outer coverings such as braids, shields, and jackets that may by the purchaser for mechanical specified be from abrasives, JAs, fluids. and moisture protection environments. 3-5.2 INTERCONNECTING WIRE AND CABLE Thc term "intercunnecting" indicates wire or cable utilized as harnesses between "black boxes", electrical equipment, and operational units where they are exposed to mechanical abuse. This means that a more rugged construction is necessary than for hook-up wire. There are innumerable types and designations of interconnecting wire or cable, both in the commercial and military fields. Major uses of interconnecting wire include aircraft, aerospace and missile wire, mining and refinery installations, grounded transportation equipment, communications, and electronic computers. Other uses are for the interconnection of various interior units of space vehicles, and exterior ground network systems in multiconductor configurations. Due to the rapid increase and growth of electronic equipment and automation, it was necessary thai specifications for more rugged and compatible constructions and insulation systems be designed to meet both the new mechanical and the environmental encountered. These conditions service conditions to be necessitated the 105 0C temperature range. It was

Thin-wall insulations below 10 mils, usually rated at

ncsiae

imperative that more rugged constructions be designed to meet the mechanical and installation problems that could not be handled by the more fragile types of hook-up wire. 3-6 COMPARISON TYPES OF HOOK-UP WIRE

00

eprtr

ag.I

Characteristics and ratings of hook-up wire are uually given in detailed specifications, applicable individual desig, data sheets, or Miltary Standards. See Table 3-1 for comparison of wire types per various Specifications. Specifications are ubjeut to frequent revision and their citation in this handbook are for reference only. Latest issue should be consulted. 3-6.1 MIL.W-76 MIL-WV-76 coveis synthetic resin insulated hook-up wire for temperatures of 80'C for internal wiring of electrical and electronic equipment. Specifications have been made for five basic types of 80 0 C hook-up wire, including provisions for jackets, shields, braids, outer jackets, or combinations thereof. The wire covered by this specification is not Ted ed e trs aplications t The 80C intended for high-temperature applications. rating is approximate, applies to the insulated wire without covering, and may be raised slightly when the construction includes a covering over the insulation. The rating is ambient temperature plus temperature rise due to conductor current. When a nylon jacket is used, the temperature rating may be raised to 90C. This is possible because the extruded nylon jacket will prevent the escape of plasticizer, allowing the basic material to maintain its properties and characteristics for a much greater service life. In direct current circuits the wire covered by this specification may be used at voltages 1.4 times the rms voltage rating specified.

I.

3-8(

11b

TABLE 3-1
EXISTING MILITARY SPECIFICATIONS FOR GENERAL PURPOSE WIRE (HOOK-UP)

Copper
Military Specifications Military Designations Temperature Rating, 0C Voltage Rating,rms Wire Size Range, AWG Conductor Coating Primary Insulation

MIL-W-16878D MIl.-W-16878D MII.W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-16878D MIL-W-76 i L-W-76 MIL-W-76 MIL-W-76 MiL-W-76 MIL-W-27300 MIL-W-81044 MIL-W-81044 MIL-W-81044 MIL-W-81044 MIL-W-22759 MIL-Y-22759 MIL-W-22759 MIL-W-22759 MIL-W-22759 MiLAW-22759 MIL-W-22759 MIL-W-22759

Type B Type C Type D Type E Type EE Type ET Type F Type FF Type FFW Type J Type K Type KK Type KT Type LW Type MW Type HW Type FX Type HF MS-24284 M-81044/1 M-81044/2 M.31044/3 M-81044/4 MS-21985 MS-21986 MS-18113 MS-18114 MS-18104 MS-18105 MS-18032 MS-18033

-54 to 105 -54 to 105 -54 to 105 -65 to 200/260 -65 to 200/260 -65 to 200,260 -54 to 200 -54 to 200 -54 to 200 -65 to 75 -65 to 200 -65 to 200 -65 to 200 -40 to 80 -40 to 80 -40 to 80 -54 to 80 -40to 80 -65 to 260 -65 to 135 -65 to 135 -65 to 135 -65 to 135 -65 to 200 -65 to 260 -65 to 200 -65 to 260 -65 to 200 -65 to 260

600 1000 3000 600 1000 250 600 1000 1000 600 600 1000 250 300 1000 2500 600 500 1000 600 600 600 600 600 600 600 1000 1000 600 1000 600
1000

#32-#14 #26 -#12 #24 -#1/0 #32 - #10 #32 - #8 #32 - #20 #24 -#12 #24 - #4/0 #24 - #8 #24 - #4/0 #32 -#10 #32 -#8 #32 -#20 #30 - #20 #24 - #12 #22 - #16 #14 #30 - #00 #24- #16 #26 - #12 #24 .#4 924 -#4 #30 - #12 #30 - #12 #28 - #12 #28 - #12 #28 - #8 #28 -#8 #28 - #8 #12-#14 #28-#10 #1*2 -#14 #30-#2 430- #2

Tin Tin Tin Silver Nickel Silver Nickel Silver Nickel Silver Nickel Silver Nickel Silver Nickel Tin Silver Silver Silver Tin Tin Tin Tin Tin Nickel Silver Tin Silver Tin Silver Nickel Silver Nickel Silver Nickel Silver Nickel

PVC PVC PVC TFE TFE TFE SE SE SE HF FEP FEP FEP PVC PVC PVC PVC HF TFE PE/PVF-2 PE/PVF-2 ")E/PVF-2 PE/PVF-2 TFE TFE TFE kTFE TFE/ML TFE/ML TFE/Tape TFE/Tape

Gene Gene Gene: HighHighHighHigh-1 High-1 High-1 Ultra-] High-t High-t High-t Gener Gener, Gener, Specia Radio Aircra Aerosi Aerosi Aeros, Aerosl Aerost Aerosr Aerosf Aerosp Aerosp Aerosp Aetosp Aerosp

-65 to 200 65 to 260

600 600

7,,

AMCP 706-125

HOOK-UP)

pper
ductor ating Primary Insulation APPLICATION AND USE

er Nickel er Nickel ver Nickel er Nickel erNickel er Nickel

er er

PVC PVC PVC TFE TFE TFE SE SE SE HF FEP FEP FEP PVC PVC PVC PVC HF TFE PE/PVF-2 PEFPVF-2 PE/PVF-2 PE/PVF-2 TFE TFE TFE TFE TFE/ML TFE/ML TFE/Tape TFE/Tape

General purpose, excellent resistance to moisture, oils, and solvents. General purpose, excellent resistance to moisture, oils, and solvents.

General purpose, excellent resistance to moisture, oils, and solvents, high-voltage.

High-temperature, ultra-high frequency use, good resistance to hot solder irons, general purpose. High-temperature, ultfa-high frequency use, good resistance to hot solder irons, high-voltage. High-temperature, ultra-high frequency use, low voltage. Note: thin-wall precautions. High-temperature, medium frequency range, solder-iron-resistant, contained during fire, will serve as dielectric. High-temperature, medium frequency range, solder-iron-resistant, high-voltage. High-temperature, encapsulated coil lead wire, water-blocked stranding, high-voltage. Ultra-high frequency, relatively poor resistance to environmental cracking, protect with polyamide jacket. High-temperature, ultra-high frequency, does not resist hot solder irons, general purpose. High-temperature, ultra-high frequency, does not resist hot solder irons, h'gh-voltage. High-temperature, ultra-high frequency, does not resist hot solder ions, low-voltage. General purpose, internal wiring of electrical and electronic wiring. General purpose, internal wiring of electrical and electronic wiring, high-voltage. General purpose, internal wiring of electrical and electronic wiring, high-voltage (#14 - #6 AWG). Special purpose, internal wiring of electrical and electronic wiring. Radio frequency, internal wiring of electrical and electronic wiring, high-voltage. Aircraft and missiles, nin size, min weight, smooth outer surface for use with grommet-type seals. Aerospace electrical systems, general purpose. Aerospace electrical systems, general purpose. Aerospace electrical systems, general purpose. Aerospace electrical systems, general purpose. Aerospace electrical systems, general purpose, high-temperature. Aerospace electrical systems, general purpose, high-temperature. Aerospace electrical systems, general purpose, high-temperature, high-voltage. Aerospace clecrical sy-tems' general purpose, high-tempcrature, high-voltage. Aerospace elet trical systems, general purpose, high-temperature, polyimide-coated. Aerospace eiectrical systems, general purpose, high-temperature, polyimide-coated. Aerospace electrical systems, general purpose, high-temperature, fused, laminated .nsulation. Aerospace electrical systems, general purpose, high-temperature, fused, laminated insulation.

kel er er er el ver k! er kel ver ckel

3-9/3-10

___________

_________-__-

AMCP 706-125 3-.6.2 MIL-W456878D MIL-W-16878D at the presenit tin., 'e; hook-up wire employing several types of .-imary insulation systems. Provisions are made for jackets, shields, and oute, covering such as polyimide (nylon), glass braid or synthetic yarns, polyvinyl, FEP-fluorocarbon and TFE-fluat ocarbon jackets. 3-6.3 MIL-W-81044 MIL-W-81044 is a new specification with temperature rating in the mid-temperature rangi (1350C), utilizing a combination t.f two cross-linked materials and offers to the industry four designs, two of which are sufficiently rugged to be used as aircraft interconnecting wire and are tuitable replacements for MIL-W-5086 type wire with improved properties and high temperature rating. 3-6.4 MIL-W-27300 MIL-W-27300 covers extruded polytetrafluoroethylene primary insulation only. This Specification covers nickel-coated copper conductor and incorporates features of minimum size, weight, and smooth outer surface suitable for use in grommet-type seals. Care should be exercised in harnessing and outing this wire. Mechanical abuse, abrasion, and concentrated loads should be avoided. 3-6.5 MIL-W.22759 MIL-W-22759 covers both TFE- and FEP-fluotocarbon insulation systems, alone, or in combination with outer insulating materials. It covers both book-up and interconnecting or airframe wires. 3-7.2 MIL-W-81044 MIL-W-81044 a relatively new specification issued in 1964, has made available to the industry two new "interconnecting" wire types sufficiently rugged for replacement of MIL-W-5086. These constructions provide, a long-needed improvement in the MIL-W-5086 type wires. They offer improved resistance to fluids, higher tep.?erature rating, much improved resistance to flow duo to momentary overloading of conductors or short term heat aging, physical stability at elevated t.rnperatures, and improved abrasion resistance (both t4rape and sandpaper tests) which is maintained at maximum rated temperatures. Of all the aircraft types, it offers the ligh.test weight for interconnecting service. 3-7.3 MIL-W-7139 MIL-W-7139 covers two classes: Class 1, silver copper conductor with polytetrafluoroethylene primary insulation, rated at 200C, 600 volt rms, and Class 2, rated at 260'C, 600 volt rms, with nickel.copper conductor. This specification allows the use of polytetrafluoroethylene tapes or extruded polytetrafluoroethylene, glass tapes impregnated withm polytetrafluoroethylene, or glass braids which are impregnated. This particular type of construction has presented many problems, due to wickiig of the outer glass braid, cau=ing electrical surface arcs and termination failures. Ia addition, the irregular surface mahes sealing in grommet-type connections, such as those described in MIL-C-26506, difficult.

.,.Jof

:1

3-7 COMPARISON OF INTERCONNECTING WMIL-W-8777 WIRE TYPES Characteristics and ratings of interconnecting, or "airframe", wire types are given in detailed specifications, individual applicable design date sheets, or Militan, Standard Sheets (see Table 3-2).

3-7.4 MIL-W-8777 employs silicone rubber primary insulation in two constructions. These are covered by MS-25471 and MS-27110. Both MS types are rated for 600 volts rms, 200"C, with the basic difference being the outer jackets. MS-25471 employs a double braid jacket, glass inner braid, and a polyester outer braid. Both finishes. braids are impregnated with high temperature MS-27110 employs a tan glass braid impregnated with an extruded fluorinatad-ethylenepropylene jacket to make it more fluid-and moisture-resistant. Basic problems with these types have been with the glass braid construction.

3--7.1 MI LAVI-5GS6
MIL-W-5086 was drawn up primarily for use as airframe and missile 'iterconncc ing wire. This specification at the present time consists of four types of PVC insulation covered by MS-25190.

~3-11/3-12

TABLE 3-2 EXISTING MILITARY SPECIFICATIONS FOR INTERCONNECTING WIRE

Copper Conductor Material Tin

Military Specifications MIL-W-5086

Military Designations Type 1 (MS25190-A) Type 2 (MS-25190-B) Type 3 (MS-25190-C) Type 4 (MS-25190-D) Class 1 Class 2 MS-25471 MS-27110 MS-17410 MS-17411 MS-17412 MS-17331 MS-17332 MS-18000 MS-18001 M-81044/1 M.81044/2

Temperature Rating, 0 C -55 to 105

Voltage Rating, (tis) 600

Wire Size Range, (AWG) #22 - #12

Primary Insulation

PVC
PVC

Aircraft clectrica

MIL-W-5086

-55 to 105

600

#22 - #0000

Tin

Aircraft clectrica protection. Aircraft elechica protection and v Aircraft clectrica

MIL-W-5086

-55 to 105

600

#22 - #0000

Tin

PVC PVC

MIL-W-5086

-55 to 105

3000

#22 - #16

Tin

MIL-W-7139 MIL-W-7139 MIL-W-8777 MIL-W-8777 MIL-W-22759 MIL-W-22759 MIL-W-22759 MIL-W-22759 MIL-W-22759 MIL-W-22759 MIL-W-22759 MIL-W-81044 MIL-W-81044

-65 to 200 -65 to 260 -55 to 200 -55 to 200 -65 to 200 -:5 to 200 -65 to 260 -65 to 200 -65 to 260 -65 to 200 -65 to 260 -65 to 135 -65 to 135

600 600 600 600 600 600 600 600 600 600 600 600 600

#22 - #0000 #22 - #0000 #22 - #00 #22 - #4 #22 - #00 #26 - #4 #26 - #4 #22 - #8 #22 - #8 #24
-

Silver Nickel Silver Silver Silver Silver Nickel Silver Nickel Silver Nickel Silver Tin

TFE TEE SE SE TFE TFE TFE TFE TFE TFE TFE PE/PVF2 PE/PVF2

Aircraft and mis, Aircraft and miss Aircraft and miss Aircraft and miss Aerospace vehicle Aerospace vehicle Aerospace vehicle Aerospace vehicle Aerospace vehicle! Aerospace vehicle Aerospace vehicles Aerospace electric Aerospace electric

#4

#24 - #4 #24 - #4 #24 - #4

_ _ __

_ _ _

_ __

_ _

_ _ _ _

_ _ _ _ _ _ _ _ _ _

I_

AMCP 706-125

Primary Insulation
PVC

APPLICATION AND USE

Aircraft electrical systems per MIL-W-5088, MIL-C-27500, and general purpose within specification limits. Aircraft electrha systems per MIL-W-5088, MI-C-27500, and general purpoa, employing glass brid for overload rprotection. Aircraft electrical systems per MIL-W-5088, MIL-C-27500, and general purpose, employing glass braid for overload protection and vinyl jacket with nylon or ,iylon braid for mechanical protection. Aircraft electrical systems per MIL-W-5088, MIL-C-27500, and general purpose, heavy wail, high-voltage. Aircraft ind mnissile wiring aid genera! purpose, within specification limits, not fire-resitant. Aircraft and missile wiring and general purpose, within specification limits, not fire-resistant. Aircraft and missile wiring and general purpose, within specification limits, not fire-resislunt, polyeste jacket. Aircraft and missile wiring and general purpose, within specification limits, not fire-resistant, FEP jacket. Aerospace vehicles and general purpose, within specification limits, TFE, FEP, and fibrous plass combination. Aerospace vehicles and general purpose, within specification limits, homogeneous, extruded TFE, abrasion-rcsistant. Aerospace vehicles and gneral purpose, within specification limits, homogeneous, extruded TFE, abrasion-resistant. Aerospace vehicles and general purpose, within specification limits, abrasion-resistant, asbestos reinforead, combination. Aerospace vehicles and general purpose, within specification limits, abrasion-resistant, asbestos reinforced, combirvition. Aerospace veh'cles and general purpose, within specification limits, bomogencous, extruded TFE, abrasion-resistant, inedium weight. Aerospace vehicles and general purpose, within specification limits, homogeneous, extruded TFE, abr,--in-resistant, medium weight. Aerospace electrical systems, general purpose.

PVC

PVC

PVC

TFE TFE SE SE TFE TFE TFE TFE TFE TFE TFE PE/PVF2

PE/PVF 2

Aerospac~e electrical systems, general purpose.

3-IM3-14

AMCP 706.125

REFERENCES
1. Milton Shach, "Continuouy Current and Temperature Rise in Aircraft Cables" AIEE Trans. 71, Part ,197-233 (1952). 2," (9. 2. Milton Shach, Current and Temperature Rise In Aircraft Cables, NRL Report 3587, Part 1, 1949. 3. Milton Shach and Robert E. Kidwel, Jr., C4rrent and Temperature Rise in Aircraft Cables, NRL Report 3936, 1952. 8. MIL-W-5086, Wire, Electrical, 600 Volt, Copper, Aircraft. MIL-W-5088, Wiring Aircraft, InstallationOf 10. MIL-W-7139, Wire, Electrical, Polytetrafluoroethylene Insulated,Copper, 600 Volt. 11. MIL-W-8777, Wire, Electrical, Silicone Insulated, Copper, 600 Volt. 12. MIL-W-16878D, Wire, Electrical, Insulated, High Temperature(Navy). 13. MIL-W-22759, Wire, Electrical, Fluorocarbon Insulated, Copper. 14. MIL-W.27300, Wire, Electrical,Polytetrafluoroethylene insv ated, Copper, 600 Volt. 15. MIL-W-81044, Wire, Electric, Crosslinked Polyalkene Insulated Copper. 16. MIL-STD-454, General Requirements for Electronic Equipment.
3A

![2

4. Stephenson, Elements of Power System Analysis, 'McGraw-Hll. 5. Method for Calculation of Cun-nt Rating of Hook-up Wire, EIA Standard RS.214, November 1958.

V
6. MILeC-7500, Cable, Electrical, Shielded and Unshielded Airraft and Misik 7. MIL-W-76, Wire and rable, floo,-up, Electrical, Insulated.

1 "

1
~,,

3-15/3-16

i4

LAs

AMCP 706-125

CHAPTER 4 BUNDLED WIRES

4-1 LACED BUNDLES 4-1.1 LACING Bundled and laced cables referred to in this chapter will be two or more single, insulated conductors, laid parallel, held by a lacing cord, wrapped and tied intermittently along ,iie bundle. In lacing, it is very difficult to control the tension applied to the cord' this is of majo, concern in the fabrication of these cable types. A too tight tension during application causes cut-through and insulation flattening, while a too loose tension will not hold the bundl.-d conductors in place after repeated flexing. Usually nylon cordage is used because it is ffingus inert, strong, and resists the usual fluids found in aircraft and other vehicles. When nylon lacing is applied under tension it stretches, and when heated, due either to increased ambient temperature or current flow, it will tend to relax. This constant tensing and relaxing will apply a great deal of force to the bundled wires tending to cut-through the insulation. For this reason, especially when used with a PVC-insulated wire, and particularly with- thin-wall insulation on the oder of 0.015 in. or less, the nylon cordage used should be a flat braid rather than a round monofilament. This flat braid should be between 1/16 in. and 3/16 in. wide. Also available, as alternate bundling ties, are blown-on or shrinkable plastics tubes, metal or plastic clamps, and various types of tie wraps made of various materials, 4-42 USAGE-LACED BUNDLES The major reason for employing a laced, bundled cable of this type is that a great many breakouts may be permitted. These cables are normally used for relatively short run assemblies ,vhare numerous breakouts of one or more cond'.tors from the main bundle occur at frequent intervals. Where fewer breakouts ,ccur, a much more satisfactory assembly would be factory assembled cables, u discussed under prefabricated bundles later in this chapter and the chapter on inulticonductor cables. Laced bundles frequently contain, within a given harness, a multiplicity of wire sizes and frequently more than one wire type; e.g., coaxial cable intermixed with interconnecting wires. Laced bundles are utilized for either hook-up or interconnecting applications, dependent upon whether the assembly is to be enclosed within the chassis or exposed. Laced bundles utilizing hook-up wire within "black boxes" have been largely replaced by the printed circuit. Laced bundles are used in aircaft or missile applications where size and weight are of major concern. 4-2 PREFABRICATED BUNDLES Within modern large aircraft there are several relatively long runs of interconnecting wire without breakouts. Here a much more satisfactory assembly results from factory constructed bundles or cables terminated in juction boxes at either end of the run. These cables are usually confined to 7 or less conductors and consist of the assembled, insulat- d conductors twisted on a planetary twisting machine to insure smooth, even component lay-up within the cable. Conductors are usually twisted with a left hand lay, and the individual conductor lay ranges between not less than 16 nor more than 28 times the diameter of the individual basic cable component. These preasserabled bundles, or cables, have an advantage in that they are more flexible due to the twisted construction; are less costly because the hand labor of lacing is eliminated; the danger of cut-through is eliminated; and they are more rugged and substantial because of the outer protective jacket. The Military Specifications covering this type of cable are MILC-7078 and MIL-C-27500, both of ,hIch art similar in the latest revision. 4-2.1 CONSTRUCTION Thee cables catagories: are fabricated in four genaral

(I) Two or more spirally wires - unshielded, unjacketed.

laid,

coded

4-1

AMCP 70S-125 (2) Two or wires -jacketed. (3) Two or

wires - shielded,

more more

spirally laid, coded spirally laid, coded

(4) Extruded or taped TFE is used where extreme temperatures or acid environments are of major concern. Extruded FEP would be used at slightly lower temperature environments and for added flexibility
over TFE.

(4) Two or more spirally wires- shielded and jacketed, 4-2.2 ONThese

laid, coded

the The cable components are all constructed from specified insulated wires as described in Chapter 2. 4-2.3DOLOR CODE Color coding should be performed, where possible, using a colored ink, spiral stripe on the individual conductor insulation. 4-2A SHIELD

(5) Extruded materials, based on monochlorotrifluoroethylene (CTFE), would be used where extreme abrasion factors are encountered. specifications allow freedom of design to optimize cost and performance. Table 4-2 will aid in the selection of the proper jacketing material for each cable and environment. It must be emphasized that the minimum temperature indicated refers only to bundled wire which remains in a relatively stationary position. 4-3 DERATING FACTORS FOR BUNDLED WIRES 4-3.1 INTRODUCTION

A metallic braid over the bundle should be employed, where shielding is required, to reduce elictrical interference. This shield may be fabricated from bare copper, silver-plated copper, nickel-plated or nickel.clad copper, or stainless steel dependent on the temperature environment and corrosion resistance needed. The metallic braid should be so applied that a 200 to 40" angle occurs between the braid carriers and the bundle axis; this is desirable in order to give a push back quality to the shield for greater flexibility and easkr termination characteristics. Table 4-1 will aid in the selection of a correct shield wire material for a particular envionment. 4-2.5 JACKET The jackets provided for these cabic types are as follows: (1) Extruded, clear nylon for cables not over 0.25 in. diameter under the jacket. Braided, satuated nylon where temperature is not a major factor and good abrasive qualities are desired, (2) Braided, szturated Fiberglas is used where temperature and abrasion factors are encountered. (3) Extruded PVC is used, where possible, because of the cost savings incurred over the other type jackets.

A great deal of information has been compiled on the current-catying capacity of bundled insulated wires, but it has had very little use. This is true because the calcuations arm complex and differ for each particular assembly or circumstance. The following describes the most accurate method of aetermining current ratings of bundled wires. This method should not be used in calculating wire size for signal circuits since mechanical strength is usually the determining factor in this type circuit. The basic document referenced for many of the procedures is Cu,-rcnt Rating For Bundled Wire - A Step by Step Procedure, A.M. Samborsky, U.S. Navy Elect.onio: Lab., San Diego, Calif.
4-3.2 BASIC CONSIDERAT!ONS

The bimiting factor for current-carrying capacity is the maximum allowable wire temperature. Current rating is, therefore, dependent on the ability of the bundled wire, or wire configuration, to dissipate internal heat losses emanating from the current being transmitted. These losses are determined by cabling design parameters, physical size of :onductor or bundle, and thermal limits and properties of 'the insulation. A hat balance is ca!culated for the configuration in question.

4-2

AMCP 706125

40

co

Iul

oi
__________ _______________

IIt-

4-

AMCP 7098-125

09

~0
-CD

0 0

z
-L

-0A

C-.

U.

for

C-

w0

>,~

0%*

I
0'0

U.

.2L3

0. 0-

0~~~

-0

a;l

---------

AMCP 706-125

80

LL. E

0.4 0

V:V
*uMM0 00

fl

44 tx.

%D~

z8
-C*

Ei(
.F con

.2:b w

uo Lr~rL.O '~

&.9-2

40

44

4)4-5

AMCP 706-125 assumed, follows, and verified experimentally be wires have to been qualities of cabled aer Certainasbasic true: a. The difference in temperature between the ambient and the cabled wires is very large i, comparison with the temperature difference between te highest and lowest wiro temperature within the bundle. This being true, nominal heat transfer equations apply - heat in equals heat out. b. The heat transfer is calculated as a combination of free convection and radiation. Conduction will assist in cooling, but is not considered in the calculations because of the variation in parameters along the run throughout, giving a conservative result. c. The insulating material is inportant to determine the temperature level above which the insulation will degrade. Caculations, verified by test, show that a 100% change in insulation thermal resistance can result in as low as 5%change in maximum current rating of any given conducto- over the entire operating temperature span. d. The cabling lay-up, or configuration, greatly affects the efficiency of the heat dissipation within the cable. 4-4 DERATING CALCULATIONS 4-4.1 SYMBOLS AND THEIR DEFINITIONS A a surface area per unit length of a cylinder with diameter equal to Db, i. 2/ft temperature coefficient of resistance per *C@ 250C Fw= wrapping factor, ratio of the allowabh heat dissipation of a sheathed or wrapped cable, of a given physical size, to the heat dissipation of a cylinder, of the same physical size, under the same environmental conditions I = maximum allowable current, amp N = number of conductors of diameter d which can be contained in a bundle of diameter Db (if all conductors are of diameter d) n = actual number of conductors of diameter d in the cable p = absolute air pressure, in. Hg Q = heat dissipation ability of bundled condutor per unit length, watt/ft q = neat dissipation under ideal conditions, watt/in. 2 qc = free convective heat dissipation under ideal conditions, watt/in. 2 q, = radiant heat disipation under ideal conditions, watt/in. 2 R = resistance per unit length @25"C, ohm/ft 3 = sum of the series resistances per unit length of N cabled conductors @ t., ohm/ft t,
=

" = temperature temperature t,factor. to tew-.rature at 25C Ratio of resistance at F,

maximum anticipated ambient temperature, 0 C

Db= bundle diameter, in. Dwj d

=

ts = maximum specified wire temperature, 'C W = ratio of unwrapped cross-sectional area to wrapped cross-sectional area 4-4.2 RATING- PROCEDURE Following is a general case current-rating cabled conductors. procedure for

internal diameter of sheath, wrap, or other covering, in. individual wire diameter over insulatidn, in.

Fb= bundling factor, ratio of the allowable heat dissipation of an unsheathed or unwrapped cable, of a given physical cize, .o the heat dissipation of a cylinder, of equai physical size, under ideal.conditions

a. Ascertain maximum ambient temperature ta wire will encounter.

4--

1~"!

.
op AMCP 706-125

maximum allowable temperature r, of b. cabled condu.,ctors; value should be lowest rated maximum temperature for any component. c. Specify nominal wire diameterd. If more than one size wire, used,, d2 , etc. of size d conductors used in more than one wire size, use nj , n2 ,etc. cable. If e. Calculate bundle diameter: Db = 1.1A
" -

in. Determine the bundling factor Fb ftor Rig. 4-4. For often used values of t,, a sitpler figure such as Fig. 4-2 may be constructed. (1) Where the bundled or cabled conductors are properly sheathed, using a close fitting extruded sheath or tightly applied wrap, use the sheath outside dianeter for Db in steps f and g, and Fw = 1. (2) For unsheathed bundles
w = 1,

also.

n*(dd 2
I.gid

pipe or zipper tubing, the current must be further

(3) When the sheath is loose fitting, such as a

f. Determine the heat dissipation under conditions:

b:q

ideal

derated with the use of a calculated F,. n. For loosely wrapped or sheathed cables, calculate cross-sectional area ratio of unwrapped to wrapped the cbe cable.
= D
p'2

'

= qc

qr

Fig. 4-2, respectively.

where qc aid e, are obtained from Fig. 4-1 and

For common values of the variables, a table such as Table 4-3 may be derived, g. Calculate the surface area per foot length of cylinder of diameter Db:
A =
37 7

where Dw is the inner diameter of the wrap, or outer diameter of the cabled conductors. o. Determine the wrapping factor Fw fror,. Fig. 4-3 (F, 1 for unwrapped cables).

. Db,

in.2/ft

h. Calculate the heat dissipation ability of the bundled conductors: Q = A x q, watt/ft i. Calculate the number of conductors of size d that could be circumscribed by a circle of diameterDb: Db) 2 N = 0.75 (round to the nearest integer) j. Calculate the temperature factor: F I +a (t, - 25)

p. Compute the current rating for each wire size.

'

(FwXFbXQIS)

4-4.3 USAGE - CURRENT RATING PROCEDURE The two more common uses of this current rating procedure are: 1.Calculating a safe current rating for any given bundle of conductors. 2. Determining the minqimum wirc size for the required current ratings. The folloing examples typify these applications and illustrate the use of the procedure and graphs. EXAMPLE NO. 1: LeterinLe the current ratings for each of three wire types in a single bundle. 1.Given: a. 55 conductors, cabled and sheathed.
4-

For often used valucs of "s and a, a table such as Table 4-4 may be calculated. k.Specify the resistance per foot length @2SC R for each wire type and size. I. Calculate the sum of the resistance per foot length for each wire type and size, as if the cable contained only that type, from: S = NxFxR

1
"

1"

... _

AMCP 706-125

26

30 -3

z 0 ~3.0

00 cc
UJ

0U
W
U

POIN X

020
031.
.2

lo
-8 V

16

0 1.0
L01

0.3

I
:14

Point X may L~e in the left or right family of curves in quadrant. The value of q, is read fromi the le.l )r right hand scales, respectively. D,-.hed lines indicate sample calculation for Table 4-5.

Figure 4-1. Calculation of Free Convective Heat Dissipation

b. Bundled core diameter is 1.79 in., and the bundle is enclosed in a 7dpper tubing having an ID of 2 plcdinhrnotlat.ue c. Bundle isplcdi
:.

(2) Fifteen (15) D - 6 per MIL.W.16878 (3) Thirty (30) E - 10 per MIL-W-16878 2. Data:

oiot)aitue a.The three wires P.nd jacket-, have the following maximum temperature ratings: (1) Type SHFS Wire
-

Ambient temperL.ture is 500C eThe three types of wire involved are: (1) Ten (10) SHFS - 9 per MIL-915

~2~V

125 0C

4-8

AMCP 7M8125 (2) Type D Wire - 105 0C (2) Type D -6=0444 x

1iy3

A [j
I80

ohm/ft

(3) Type E Wire -

2000

C(3Tpe-0=.x

Ooh/f

(4) Jacket Type - 1050C2 b. Since 1050C2 is maximum for type D and d. The nominal diameters for the three wire $Acket, this is the maximum temperature the bundle is types are: allowed to re ach. T here fore , t ,= 10 50(2.( 1 Ty e S F - 9 =0 . 4 i n c. The maximum D-C resistances for the thrcee()Tp ~F .4 n wire types at 250(2 are: (2) Type D - 6= 0.290 in.
(1) Type SHFS - 9 1.25 x 1(T"ohm/ft (3) Type E - 10= 0. 137 in.

i70
.0/

z
I

I.

20 V

302.5

2.0

1.5

1.0

0.50

BUNDLE DIAMETER Db, In

Figure 4-2. Calculation of Sundllng Factor for 1 050 C. Dashed lines indicate samrple calculation for Table 4-5.

4-0

AMCP 706-125

C"

Ci

0Cl

08
00 tm

e NI

in, q

rtN'

a, N

Cq~ Vn

c'i

ei

-J

o 0
0I
CL0

o 0

It *

m
0

r-

in~

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Cd

CIS

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II

lu

ii

4.4

v~

4-10

AMCP 706-125

)TABLE
Specified Temperature ts, 0C 105
125

4-4 TEMPERATURE FACTORS (DERATINr

Temperature Fac 'or F Copper
a = 0.00385
-

Aluminum
a = 0.00396

1.308
1.385

1.317
1.396

200
Calculated using equation: Ft

1.674 1 + a (t - 25)

1.693

3. Solution: Ratings are worked aut in Table 4-5. a. Steps a through e are accomplished by reference to data and given information.

d. Step m ray be obtained from either Fig. 4-3 or Fig. 4-4. The value of Fb is obtained in 4 steps, as shown by the dashed lines in Fig. 4-4, as follo'vs (the 127 conductor case is used to illustrate the procedure):

'I

b. Step f may be obtained either from Figs.4-1 (1) Follow the 105'C ordinate up to an and 4-5 or from Table 4-3. The value of q. is obtained in 5 steps, as shown by the dashed lines L'1 interpolated curve for 127 conductors. Fig. 4-1 as follows: (2) Proceed to the right to the reference line 0 a 2-in. cabled diameter (Note: Chart is representing abscissa C the 105 Follow I: (1) Quadrant 0 based on this 2-in. ID). left to the curve representing an ambient of 50 C. (2) Quadrant IV: Proceed down to the line representing 30 in. Hg absolute air pressure. (3) Quadrant III: Proceed left to the line representing horizontal attitude. (3) Draw a curve parallel to t, to a diameter of 1.79 in. i05*C curve,

(4) Read the value of the bundle factor, Fb = 0.50, from the vertical scale.

(4) Quadrant II:

(a) Proceed up to an interpolated line representing a 1.79 in. bundled diameter. (b) Then, read q= 0.24 watt/in.2 , from the right hand scale, c. Step j may be either calculated or interpolated from Table 4-4. The calculation of the current rating for given wire sizes, but using a close fitting sheath or wrapping of 2.20 in. overall diameter, is now performed. From Table 4-6, it can easily be seen that the use of a close fitting sheath will noticeably increase the current-carrying capabilities of a given conductor or conductor group over that same conductor or conductor group utilizing a loose fitti:g sheath such as zipper tubing.

4-11

AMCP 706-125_C

.8

~0.70.7

4:b
0.6

CROSS-SECTIONAL AREA RATIO W

Figule 4-3. Wrapping Factor vs Ratio of Unwrapped to Wrapped Cross-sectional Area for

Typical Bundle Diameters.1

1'

.85

.75

~(
-0 -

10 2m 800
-

200

160

1201

80

-0

25

20

15

10

SPECIFIED TEMP. Is, OC

30

SUNOLE DIAMETER Ob, -

Figure 4-4. Calculation of Bundling Factor. Dashed linev indicate sample calculatioi"for ~12 Table 4-5.

442

AMCP 706-125 TABLE 4-5 CABLED WIRE CURRENT RATING-EXAMPLE NO. 1

a. t, b. t, . d,

0 = 50 C

= 1050C = 0.24 in. da

n2 =

, 0.29 in. d3
n3

0.137 in.

d.

1= 0

15

= 30

e. Db = 1.15

F= n,(dj2 1.15V 10(0.24) 2 15(0.29) 2 + 30(0.137)2 = !.15-,j0.-576 +1.261.5+60.5631 = 1.15-V2.409"= 1,15 (1.5494)
= 1.782 in.

f. q g. A h. Q i. N, N2

= q,

q, = 0.24 + 0.35 = 0.59 watt/in.2

= 37.7 (Db) = 37.7 (1.782) = 67.18 in.2 /ft = A(q) = 67.18 (0.59) = 39.64 watt/ft
=

0.75 (Db/dl)2
2

= 0.75 (Dbd2)

0.75 (1 .7.4) = 0.75 (1.782/0.29)2

41 (to nearest integer)

= 28 (to nearest integer)

"

N3

0.75 (Db/d3)2

0.7S (1.782/0.137)2

= 127 (to nearest integer)

j.

1;'= ! +a(t-25) = 1+0.00385(10S-25) = 1+0.3080=1.308 1.25 x 10' ohm/ft ohm/ft

R2

k. R,

- 0.444 x

10, 3

ohm/ft

A. = 1.24 x 10' 1. 81 S2 ,.

= NI(FtXRI) = 41 (1.308) (1.25 x 10-3) = 0.067 ohm/ft = N2(FtXR 2 ) = 28 (1.308) (0.444 x 10-3) 127 (1.308) ~3
=

i
p

0.01626 ohm/ft "

'

8~~~ m. Fb, = 0.56

(1.24 X ,0-3*=0.206 om. Fb3

.

0.59

0.50

n.
o. F,

(Db/Dw)2
0.63

- (1.782/2.0)2

0.794 '

. .. -. 3

........

AMCP 706-125 TABLE 4-5 (CONT.)

P. I,

= JAF)

-(,,) (Q!Yi

/(0.3) (56) (39.64/0.067)

= 14.45 amp

F1
216 0

= ,/(O5j3) (0.56) (591.642) = F28.3 =

=

,(F.,)

-(Fb 2 ) (Q/S2 ) = \(0.6-3) (0.59) (39.64T/0.01626)

= \/9-6.12

(063) (0.59) (2439.884)

-- 30.10 amp

=
=

(F) () (FN(Q/S 3)

= (0.63j*(0.50) (39.64/0.2G6)
v60 615 0
=7.78

vf{).3) (0.50) (192.427)

amp

170
1

_____-

IISO I20
CLU

.140_

90
40A

II20

I I I I
I

0I0.

00.0.101214
RDINT EA DSSIATONq~,wlU1

iue -.

cacltino Rdat etDispton

forTabl 4-5

ahe1Tesidcaesmpeclclto

40

4-14C

I
S L,

Ii
TABLE 4-6 BUNDLED WIRE CURRENT RATING

AMCP 70-125

~a.
b.

ta ts

= 50C 10_'_
=
_

c. d,
d.

0.24 is.

d2
n2

0.29 in.
15
2

d3
n3

0.137 in.
30

it1

= 10
=

e. Db

115
35

.n,(dl)

2 = 1.15 /10(0.24)2 + 15(0.29) + 30(0.137)2

=-

.576 + 1.2615 + 0.5631 = 1.1

V2.5w

1.15(1.5494)

= 1.782 M.
Sq

= q + qr

0.22 + 0.35

0.57 watt/in.2

g. 4

= 37.7 (Db) = 37.7 (2.2) = 82.94 in. 2/ft

h. q
i. N,
N2 N3

= A(q) = (82.94) (0.57)

=

47.276 watt/ft
= 0.75 (55.13) 41 (to nearest integer)

0.75 (9/d 1 )2 = 0.75 (1.782/0.24)2

= 0.75 (Db/d2) 2 = 0.75 (1.782/0.29)2

= 0.75 (37.759) = 28 (to nearest integer)

= 0.75 (Dbld3) 2 = 0.75 (1.782/0.137)2 z 0.75 (169.182) = 127 (to nearest integer) + a(ts
10

Ftj. = :. R,

25) =
-3

+ 0.00385 (105 -25)

1 +0.3080

= 1.308

= 1.25 x

ohm/ft

R2 = 0.444 x 10" ohn/ft

R3 = 1.24 x i0 - ohm/ft I. S1
S2 S3 =
=

N, (Ft) (Rl) = (41) (1.308) (1.25 x 10- 3)

N2 , (Ft)
(R 2 )

0.'.'halun/ft 0.0162 ohm/ft

= (28) (1.308) (0.444 x

10-3) =

I.
4-15

N3 (Ft) (R3) = (127) (1.308) (1.24 : u"3) = 0.206 ohm/ft 0.56 Fb 2 0.59

m. Fb, n. W

Fb3

0.50

(unnecessary for tight sheathing)

=

o. F

1.0

.!.--.-.- - -----.-- - -

AMCP 706-125 TABLE 4-6 (CONT.) p

I = (Fw)

(Fb) (Q/S)

('0(0.56) (47.276/,.067)

=vri)(o.s6)(705.6n2) Vrn
12 = V/(F)

.88 amp

(Fb 2 ) (Q/S2) -/I) (0.59) (4.276/0.0163) -) = 41.37 amp

= \/(1) (0.59) (2900.368) =,/1 7

13 IVIF ) (Fb 3 ) (Q!S 3 ) =\/I) (0.50) (47.276/0.206) =\/i) (0.50) (229.495) =\/I14.748 = 10.71 amp

FXAMPLE NO. 2: Determine a minimum wie size for three different current ratings.

2. Solution: a. Use an inverse current density of 300 circular mils per ampere for initial conditions. Therefore: (1) For a 6-ampere current, a conductor with 1800 circular mils is needed; try Type E, #16 AWG.

t. Given: a. Currcnt Ratings:

(2) For a 15-ampere current a conductor with

4500 circular mils i;required; try Tvn-.1, #12 AWG. (3) For a 9-a.pere curret, a eo".uctor with 2700 circular mils is required; try Type E, #14 AWG. Observe from Table -- 7 that the current ratings are

( ) Twelve (12) currents of six (6) amperes

each. (2) Seven (7) currents of fifteen (15) amperes

each.
e (3) Ten (10) currents of nine (9) amperes each.(1)

eigniticantly

;her than the requirements. We must

change the conductor sizes accordingly. b. Therefore, try: Type E, #18 AWG (for 6 amp) (2) Type E,#14 AWG (for 15 amp) (3) Type E, #16 AWG (for 9 arp). Observe from Table 4-8 that these are satisfactory sizes from tN performance figures obtained. c. Obse: ,a from Table 4-9 that wire size is too small using Type i wire sizes #20 AWG (6 amp), #14 AWG (15 amp), and #16 AWG (9 amp).

b. Antient temperature of 700 C. c. Conductors are tightly tape wrapped. . Mi'nimum voltage ratings of 600 volts rms.

e.Type E wire per MIL-W. 46878, silver-plated copper (t s = 200*C).

4-16

F
TABLE 4-7

AMCP 706-125

CABLED WIRE CURRENT RATING - EXAMPLE NO. 2 (FIRST CALCULATION) (#16 AWG FOR 6 AMP, #12 AWG FOR 15 AMP, #14 AWG FOR 9 AMP)

a. t,
b. t3 c. d1 d. nj

= 70 0C
=

200 0C d2 = 0.113 in.

n2 = 7 = 1.15,12

= 0.080 in.

d 3 = 0.094 in.
n3
=

= 12
b 1

e.

ng(d1)
(d

= 1.54

(0.080)2
(0.08;

10 + 7 (0.113)2 + 10(0.094)2

= 1.150.0768 + 0.0894 + 0.0884 = 1.15 JU46

= 1.15 (0.5046) = 0.5803 in. f"q g. A = qe + qr = 0.90 + 1.33
=

2 2.23 watt/in.

= 37.7 (Db) = 37.7 (0.5803) = 2x.877 in.2 /ft

Si.
,
'N2

Q
i2 i. N1

= A(q) = 21.877 (2.23) = 48.786 watt/ft

=
=

0.75 (Dbidl )2 = 0.75 (0.5803/0.080)2

2 0.75 (Db/d2) =

0.75 (52.6 18)

39 (to ncarest integer)

0.75 (0.5803/0.113) = 0.75 (26.372) = 20 (to nearest integer)

N3

= 0.75 (Db/d23)
2

= 0.75 (0.5803/0.094)2 = 0.75 (38.111) = 29 (to nearest integer)

j. Ft = I + a(t s k. R,

5)

= I

+0.00385(200-25)=1.674
R
2

= 4.85 x 10-3 ohm/ft

R3
=

= 1.92 x I0-3 ohm/ft

3.05

x 10

-3

ohm/ft

1. S 1
.5

= N, (Ft ) (RI) = (39) (1.674) (4.85 x 10- 3 ) = 0.317 ohm/ft = N2 (Ft ) (R2 ) = (20) (1.674) (1.92 x 10 ., = 0.064 ohm/ft

m.

y3 .'p : ()(R)=(29) (1674) (3.674

Fb 2
.4

- ,,.-,A ol
01
'T

111

m. Fb 1 = 0.73
n. Wt

F3--07 r

(Not Applicable).'

o. F, = 1.0

4.17

AMCP 706-125 TABLE 4-7 (CONT.) P. !i = V(F) (Fbl) (Q/S 1 ) =/(1.0) (0.73) (48.786/0.317)

= V/0'.) (0.73) (153.899) 12

=

/112.346 = 10.60 amp

VI(F w ) (Fb,) (Q/S2) =V/(1.0) (0.74) (48.786/0.064)

v/ 10) : (0.74) (762.28) =6 = 23.75 amp

13

V(F

) ((QIS,)

=V/(I.O) (0.73) (48.786/0.148) 4 = 15.51 amp

= /0.0) (0.73) (35.635) =/24

TABLE 4-8
CABLED WIRE CURRENT RATING - EXAMPLE NO. 2 (SECOND CALCULATION) (#18 AWG FOR 6 AMP, #14 AWG FOR 15 AMP, 16 AWG FOR 9 AMP)

a. t,
b. ts c. d, d. nj

= 70
= 200C = 0.068 in. d2
n
2

0.094 in.

d 3 = 0.080 in.
n 3 = 10

= 12 e =.

= 7
=

n(d ) 2

1.15./12 (0.068)2 , 7 (0.094) + 10 (0.080)2

= 1.15,/(0.055) + (0.062) + (0.064) = 1.15V/.181 = 1.15 (0.4254) = 0.489 in.

f. q
g. A h. Q i. N,

2 = qc + qr = 0.90 + 1.26 = 2.26 watt/in.

= 37.7 (Db) = 37.7 (0.489) = 18.435 in. 2 /ft = A (q) = 18.435 (2.26) = 41.663 watt/ft = 0.75 (Db/dl)2 = 0.75 (0.489/0.068)2 = 0.75 (51.713)
=

39 (to nearest integer) 20 (to nearest integer-

IN 2
N3

0.75 (Q5b/d)

0.75 (0.489/0.094)2

0.75 (27.061)

= 0.75 (Db~d3) 2

= 0.75 (0.489/0.080)2

= 0.75 (37.363) = 28 (to nearest integer)

j.

Ft

I + a (t, -25)=1
= 6.57 x 10- 3 ohm/ft

+0. 1 00385(200.-25)= 1.674

k. R,

R 2 = 3.05 x 1

-3

ohm/ft

R 3 = 4.85 x 10- 3 ohm/ft

F
, AbA MCP 706-126

TABLE 4-8 (CONT,

1. S, (39) (1.674) (6.57 x 10-3) = C.429 ohm/ft N1 - Ft).(R 2 ) = (20) (1.674) (3.05 x 10- 3 ) = 0.102 ohm/ft
N3 (Ft)(0 3 ) = (28) (1.674) (4.85 x 10-3)

N, (Ft)(R 1 )

133

= 0.227 ohm/ft

M.

Fbt
W

0.75

Fb 2 = 0.75

Fb3

0.75

n.

(Not Applicable) 1.0 = / l (F ,)(Q/Sl) 1 =4i .O (0.75) -(41.663/0.429)

o. F w p.

,1'0) (0.75) (97.117) 1 =i v/7.H = ;.53 amp

2

/w)

(Fb2 ) (Q/S.)

(l.0) (0.75) (41.663/0.102)

=V()(0*7 )(408461)
13

17.5 amp

//w) (.b') (Q/S)

4

= /(.0) (0.75) (41.6630.227)

3

1= .o) (0.75) (183.537) =V=/i76 TA3LE

11.73 amp

4-9 CABLED WIRE CURRENT RATING EXAMPLE NO. 2 (THIRD CALCULATION) (#20 AWG FOR 6 AMP, #14 AWG FOR 15 AMP, #16 AWG FOR 9 AMP)
a. ta = 700C

b. t, = 2000C

c. di d..n c. Db

= 0.058 in.

d2 = 0.094 in.
2

d3

0.080 in.

=12
=

=7

3= 10

.I5

" ni~d)2 = 1.15,2

(.058)

+ 7(0.094)2 + 10(0.080)2

'v5 /- "
=0.469

00621 0064

i iS/0.166

1.15 (0.4075)

in.

4-19

AMCP 706-12

TABLE 4-9 (CONT.)

f" q = q, + q,
2 0.94 + J.34 = 2.28 watt/in.

g. A
h. Q i. N,

= 37.7 (Db) = 37.7 (0.469) = 17.681 in.2/ft = A(q) = 17.681 (2.28) = 40.313 watt/ft = 0.75 (b/dl
)2
2

= 0.75 (0.469/0.058)2

= 0.75 (65.387) = 49 (to nearest iateger)

N 2 = 0.75 (Db/d2) N3 j. Ft
k. R,
=

= 0.75 (0.469/0.094)2 = 0.75 (24.894) = 19 (to nearest integer) = 0.75 (34.369) = 26 (to nearest integer)

0.75 (Dbd3) 2 = 0.75 (0.469/0.080)2

-

= I+a(s

25) = I+0.00385(200-25) = 1.674

R2 =

= 10.5 x10- 3 olhn/ft

3.05 x

10 - 3 ohm/ft

R3 = 4.85 x 10 - 3 ohm/ft

1. S1
S2 S3

= (NI) (Ft ) (RI) = (49) (1.674) (10.5 x 10- 3 ) = 0.861 ohm/ft

-

) (Ft) (R 2 ) (N 3 ) (FtXR3)

= (19) (1.674) (3.05 x 10-3)

0.097 ohm/ft

(26) (1.674) (4.85 x 10- 3 ) Fb2

=

0.211 ohm/ft 0.82

m. Fb1 = 0.74 n. W = (Db/Dw)

2

0.84

Fb 3

= Not Applicable

o.F
p.

= I.0
(Fw) () (Q/S) = (0.74) (40.313/0.861)

1
12=

V/0) (0.74) (46.821) =V/ /(F) (Fb2 ) (Q/SI)

8= 5.89 amp

=,/(1) (0.84) (40.313/0.097)

= V(I) (0.84) (415.598) -3.

13

= 18.68 amp

= /(FW) (Fb3) (Q/S3) = V(I) (0.82) (40.313/0.211) = V(1) (0.82) (191.057) =V/15.66 12.51 amp

4-20

II
_________

I..__________

_________________________

___

AMCP 7064i25

4-5 RIBBON CABLE 4-5.1 INTRODUCTION Ribbon cable is a construction where a number of individually insulated conductors are- bonded together in a flat parallel cable. This construction can be seen in Fig. 4-6. insulated wires, and shielded and jacketed wires -- may be manufactured into a ribbon-type construction. The only criterion is that the two materials to be joined must be bondable, 4-5.2 USAGE A ribbon-type construction is generally designed when a multiconductor construction is to be located in a limited space or where great flexibility in one plane is needed and no flex:bility is needed in the perpendicular plane. A good example is in the "drawer" or accessibie front of a rack panel where the "drawer" must be continually opened and closed for repair and adjustment. A ribbon cable is ideal for a loop connection from drawer to complex because of its flexibility and flatness. 4-5.3 CONSTRUCTION There are five basic ways to construct a ribbon-type cable after the individual constructions, or insulated conductors, have been selected.
4-5.3.1 Adhesive Bonding

together under pressure. The most common materials used in this type construction are polyvinylchloride and polyethylene. Care must be exercised here to not overheat the insulation - allowing the conductors to cut-through the soft, heated material and short circuit. Insufficient heat will cause poor bonding with resultant separation.
4-5.3.3 Direct Extrusion

By use of a number of bare conductors and the use of a multi-die, the ribbon cable may be actually extruded as one integral unit. Nearly any type insulation may be used for this type construction. This is by far the best way to produce ribbon cable, but the tooling is very expensive. This method, therefore, allows a smaller flexibility in the selection of conductors without retooling, while still maintaining a reasonable cost. 4-5.3.4 Envelope With Teflon*, an "envelope" type construction is usually employed since it cannot be cemented or melted. A number of individual Teflon insulated wires are run parallel through a-very carefully matched roll calendar which encloses them in a thin Teflon film, or "envelope", formed from two Teflon tapes introduced onto the roils, between the rolls and the conductors. This technique is aiso very costly and inflexible because of the tooling invc!ved, but is the only way of producing a high quality Teflon ribbon cable.
4-5.3.5 Braided or Woven

Using individually insulated conductors, an adhesive is applied to the bonding area of the insulation and the two insulations glued together within a guide or closing die. The most common materials used in this type construction are polyvinylchoride or nylon. Extreme care must be used in the selection of the adhesive because most adhesives are solvents which leech out the plasticizer, thus greatly lowering the electrical properties and tending to make the insulation brittle.
4-5.3.2 Thermal Fusing

By modifying conventional braiding machines, a flat fabric braid may be woven about parallel conductors to hold them in place. W4hile the product, as manufactured, can be made to be presentable, it is very difficult to install without severe fraying and resultant poor appearance. The fabric braids will also wick moisture and other fluids. -abrics used include cotton, nylon, glass, and Dacron*. 4-6 COMPARISON - RIBBON CABLE VS ROUND MULTICONDUCTOR CABLE 4-6.1 ADVANTAGES - RIBBON CABLE a. Can be placed through narrow, rectangular openings where round cable might miot fit.
*

Thermal fusiig also uses individually insulated conductors, and by :he application of heat to tli, insulation' the components are bonded. The bonding edges of the insulation are heated and the wires are
passed through a closing die which fuses the ,nsulation

RTM duPont.

4-21

AMCP 706-125
BOND-1

CONDUCTOR-j
INSULATION

Figure 4-6. Bonded Ribbon Cable Configuration b. Greater flexibility in one plane. c. High current rating.
4-7.2 USAGE

a thin wall of insulating material. The conductors are not individually insulated first.

d. More precise and fixed capacitance between conductors. 4-6.2 DISADVANTAGES

-

RIBBON CABLE

The usage is for the same applications as ribbon cable, -xcept the tape cable is much lighter in weight for the same current ratings as 'ompared to conventional cables.
4-7.3 FLAT WIRE

a. Flexible in only one plane. b. More delicate. Careful handling is required to prevent separations, and other inherent problems. c. Much less flexible for design. To be practical, conductors used in a given cable must be nearly the same physical size. There ate practical limitations to the number of conductors in a given cable (approximately 3 in. in width in a single layer). A.For the same mechanical protection the ribbon cr.ole may be larger and heavier. AD shielded constructions must be jacketed, except woven types. e. Ahesve my bndig derad inslaton.b e.Adhesive bonding may degrade insulation. f. Heat bonding may reduce dielectric strength. g. The direct extrusion and envelope techmiques are inflexible and expensive for short runs. 4-7 TAPE CABLE 4-7.1 INTRODUCTION Tape cable is similar to ribbon cable, except the conductors are usually flat, metailic strips covered with An increasing demand for smaller and lighter electronic component systems has resulted i the development of a cable utilizing a flat flexible copper conductor sandwiched between plastic film. The flat wire cable possesses some unique qualities; among them are: a. Two-dimensional cable harnessing can be achieved with flat wire, parallel conductor, cables which are compatible with lome of the newly developed microminiaturiz"v systems and techniques. A flat wire cable construction can be bondedI to the equipment chassis o; wali to secure the cable harness. This, in effect, achieves efficient shielding and/or heat dissipation at the expense of high
capacitance per fout.

c. The precise geometry of flat wire cable requires greater circuit design accuracy due to the specifically established capacitance between conductors and/or ground. d. Corrugating a flat conductor cable can provide an extremely flexible harness for drawer-type applications.

4-22

I--

AMCP 706-125 4-7.3.1 Constructional Factors The laminated, flat conductor cable has parallel, flat, metallic, specifically spaced, conductors, laminated between two sheets of insulating material, which are either hat-sealable or bondable to each other by adhesive. This configuration is shown in Fig. 4-7. 4-7.3.2 Construction Flat copper, or plated metallic, ribbons varying from 0.001 in. to 0.003 in. in thickness and 0.010 in. to 0.050 in. in width, are laid paiallel between two sheets of plastic film, usually between 0.002 in. and 0.005 in. thick, the plastic film being heat-sealed or cemented together around and betwjen the conductors. Insulation material may be polyethyleneteraphthalate (Mylar*), pclyimide (K apt on *) , T e flon*, FEP, or polychlorotrifluoroethylene (CTFE). These cables have the same advantages as ribbon cable plus being smaller in size, lighter in weight, and more flexible. 4-7.3.3 Disadvantages - Flat Wire . a. Flexible in only one plane. b. Solid condudor is susceptible to nicks and breakage. c. For some methods of termination special precision tooling is required to strip the chosen configuration, making field repairs difficult. d. Shielded flat cables losc a great deal of their flex characteristics, due to shield breakage and shield -penetration of insulation, after repeated flexing. This is particularly true in the straight flexure rather than the roll flexure. a. The difficulty in manufacturing to maintain the stringent conductor spacig tolerances rec tivd. 4 -7A CONSI RUCTIONAL CONSIDERATIONS The cable can be fabricated as described in any
desired width and reasonably long lengths, utilizing as

of 25 mils (i.e., 25-50-75-10015-etc.). This spacing controls the number of conductors contained within a specified cable width. Of major concern in the manufacture of flat the physical dimensional stability of laminated cables is the conductor spacing throughout any given length of wire, and/or wie taken from different manufacturing runs. There ar. many reasons for this concurn, among them are: a. Connector designs demand a high degree of dimensional integrity. b. Electrical parameters depend on equal spacings for repeated values. Flat laminated cables may also be of a shielded construction. The shielding normaly consists of a spirally served wire, or group of wires; a spirally wrapped metallic foil; or two foils laid parallel, one on each side of the cable core. An overall jacket is applied using the extrusion process, or the same lamination construction used in the cable core, sealing the edges in an "envelope" type configuration. 4-7.5 TESTING Most of the tests performed on flat laminated cable are common to any cable configuration, such as: a. Dielectric strength b. Isulation resistance c. Conductor resistance d. Moisture resistance e. Shrinkage f. Accelerated aging g. Thermal shock h. Tensile strength and elongation i. Vibration tests j. Noise tests

, 0,,

many conductors as is physically feasible. The cable is normally manufactured in one.half inch increments, v,ith conductor center-to-center spacing in increments
RTM duPont

4-23

---

----

--

AMCP 706-125

'--CONUCTOR

\-INSULATION

where: A = total width B = conductor width C = conductor spacing D = conductor thickness E = total thickness F = insulation thickness

Figure 4-7. Laminated Flat Conductor Cable There are, however, some very important tests performed which are more or less unique to flat cable due to the nature of the job expected from the installatiou for which these cables were designed. These tests are p.esented in the paragraphs which follow. 4-7.5.1 Folding Test This test is designed primarily to ascertain the physical and/or electrical degradation of a tape cable coistruction at a point of extreme bend. The test is absorb before failure in a panel mounted "drawer" type installation. The test is peformed as shown in Fig. 4-8. The rate of flexure is approximately 30 cycles per minute, and the tests performed at room temperature. These two factors will, of course, vary with the cable construction and installation environment to be encountered. All conductors in the cable are series connected and monitored to detect short circuits or breaks.

performed as follows: A length of cable, approximately

two feet in length, is folded 1800 transversely and a pressure of 30 psi applied to the folded specimen for 15 minutes. After the 15-minute interval the specimen is unfolded, laid flat, and the pressure reapplied for 15 minutes. This series, constitutes one complete cycle. A total of two to three cycles is normally applied to a specimen. The specimen is then subjected to the insulation resistance and dielectric strength (conductor-to-conductor and conductor-to.ground) tests. 4-7.5.2 Roll Flexure Tests This test is designed primarily to determine the amount of opening and shutting action a cable can 4-7.5.3 Straight Flexure Test This test is designed primarily to determine the normal flex-life of a tape cable construction under conditions wheie the cable is continuously bent at a fixed point. The test is performed as shown in Fig. 4-9. This being a much more stringent test than the roll flexure test, the flexure rate will nccessarily be reduced to approximately 1/3 as many cycles per minute. Here again, all conductors are series connected and monitored for conductor breakage or short circuits.

'i

4-24

___

'

I
1.2 In.LOW FRICt ION PIVOT BEARINGS

AMCP 706-125

[
1/8 in. R

/n.

3 in. TRAVEL-

Figure 4-8. Rolled Flex Test

~-

LINEAR MOTION--.

5%I 5in.r-NYLON -T I In FRELNT

yI inl.

U
1)

i[Figure
4-R. Straight Flex Test

4-25

AMCP 706-125 4-7.6 INSTALLATION It would appear that flat tape cables may have a value in .ertain specifically designed nmilitary installationv. If installed and used properly, they have some advantages over conventional designs. specifically in the savings of space and weight. If improperly uied or installed, the troubles encountered can quickly overcome these advantages and highly unsatisfactory Ferformance will result. Highly selective cable design and equipment design is a must when flat cables are to be utilized.

it

4-26(

AMCF 706-125

REFERENCE03
I. Andiew Saxnborsky, Cur.-eit Rating for Bundled Wire-A Step by Stop ,rocedure, U. S. Nav'y Electronics Laboratory, San Diego, California. 2. MIL..C-7078, Cable, Electric. Acrospace Vehicle. 3. MIL-C-27S00, Ca~k, L'Iectrk'al, Shielded and Unshielded, Aircraft and Missile. 4. Milton Schach, "Continuous Current and Temperature Rise in Aircraft Cables", AJEE Trans. 71, Part 2, 197-203 (19S2). S. Milton Schach, Current and Temperature Rise in Aircraft Cables, NRL Report 3587, Part 1, 1949. Kidwell, Jr., Currfent 6. Milton Scihach and Robert E3. and Temperature Rise in Aircraft Cables, NRL Report 3936, 19S2. 9. W. Angelo, "Fiat Conductor Cable Manufacture and Instf-Ilation Technique.,", presented at 15th Annual Wre and Cable Symposium, December 1966. 10. Multilayer Printed Circuit Boards Technical Manual, The Institute of Printed Circuits, March 1~6 11. Flexprint Circuit Design Handbook, Bulletin FT-169, Sanders Assoc., Inc., Nashua, N. H., 1965. 7. EIA Staqdard RS-2 14, Method for Calculation of Current Rating of Hook-up Wire, 1958. 8. E. F. Godwin, "Materiris for Flat Cable, Thc' Interconnecting Systen! of Tomorrow", IEEE Trans. PMP-3, No. 4 (1967).

4-27,/4-28

I0

F
CHAPTER 5 COAXIAL CABLES
5-1 INTRODUCTION The term "coaxial cable" usually cable is to be used to transmit radio (500 kHz to 10,000 MHz). Coaxial used at frequencies lower than 0.5 implies that the frequency energy cables are often MHz, and have 5-2.1.3 Dual Coaxial

AMCP 706-125

many applications in the audio frequency range. How-.ver, at frequencies lower than 0.5 MHz, coaxial ca~le is normaly designated as merely shielded and jacketed wire. A more accurate distinction between shielded wires and coaxial cable is that a coaxial cable is an RF transmission line for propagation of electromagnetic energy in the transverse electrical magnetic (TEM) mode. In shielded wire. the outer conductor serves only as a screening ground plane to

A dual coaxial able is two individual coaxial cables, either laid parallel to one another or twisted around one another, and placed concentrically within a common sheath or an additional cylindrical shield and sheath. See Figs 5-4 and 5-5. 5-2.1.4 Double Shielded A double shielded coaxial cable is sometimes specified when small improvements over single shielding are required. This type of cable has one shield braided over Zhe othe" ith no insulating barrier between them. See Fig. 5-6. 5-2.1.5 Triaxial

xninimize electrical interference.

-

In most applications, for tie types of coaxial and triaxial cab'e described, the outer shields are covered with an insulating sheath which is often referred to as the outer jacket. This sheath serves to isolate the shield from adjacent metallic surfaces and to repel moisture, solvents, and other contaminants, 5-2 TYPES OF COAXIAL CABLE 5-2.1 DEFINITIONS 5-2.1.1. Coaxial A coaxial cabl. may be defined as two concentric wires, lindrical in shape, separated by some type of dielectric material; one wire being the center conductor and the other wire the outer conductor. See Fig. 5-I. U-2.a.2 Twin Coaxial

A triaxial cable is very similar to a coaxial cable and is used in place of the coaxial cable when- further shielding effectiveness is required. Tius cable is cylindrical in shape, having a center conductor located concentrically withi he -;ble core or dielectric, but having two Aheids separated by a nonconducting m-terial such as polyethylene (PE), or polytetrafluoroethylene (TFE) tape or extrucion. See Fig. 5-7. 5-3 MATERIALS Conductor materials are defined in Chapter 1, dielectric materials ;n Chapter 2. The important electrical parameters required of these materials will be evident from the required electrical characteristics of 5-4 ELQJJ1CCAL PRffOPERTIES
OF
GO-'

A twin coaxial cable consists of two individually insulated conductors, within a common shield. These insulated conductors are either laid parallel to one another or twisted around each othar, and placed concentrically within an additional cylindrical cable core or dielectric. The shield, or ground, is plat.d ovei this cable dielectric. Se, Figs 5-2 and 5-3.

AXIAL CABLE
5-4.1 BASIC PARAMETERS A transmission line has four line parameters, which consist of (I) sh n'! capacitance C between wires, (2) shunt conductance G, (3) series resistance R, (4) and

)5-1

AMCP 706-125 series or self-inductance L. Any uniform line, regardless frequencies the current is crowded into an area nearer

of length, has these parameters uniformly distributed along the entire length. The line ur cable may be
represented as in Fig. 5-8, where an infinite number of infinitesimally small sections are connected end to

the outer Derimeter of the conductor, this is due to the internal magnetic field. The rnagnetk. tiux
determines the inddctance; therefore, when current penetration is large, some of the flux is within the frequency increases, the flux forces the current toward the outer perimeter of the conductor, and the inductance decreases somewhat. Inductance may be considered to have a constant value (maximum) at lower frequencies, varying as "skin effect" takes over, and again returning to a constant value when "skin effect" no longer varies the value of inductance. In other words, the "skin effect" has reached its maximum value and no longer changes the value of inductance. This constant value is approximately 20 percent less than that of the constant value before the influence of "skin effect". The frequency range in which inductance varies from maximnm to minimum is nominally between 100 kHz and 10 MHz. Variations of inductance will depend largely on the type of cab'e, its size, and conductor configuration.

Ihese parameters depend upon the materials used and their pnysical configurations, which in turn regulate the electrical performance of the cable. 5-4.1.1 Capacitance Capacitance is that property o" two electrodes whitkh builds up charges caused by a difference in potential. The amount of charge built up by a given voltage, and hence the capacitance, is firectly proportional to a property of the dielectric called the "dielectric constant" e. When a potential (voltage) is placed across a dielectric, a certain amount of current will flow between center conductor and shield, Part of this "current" charges up the electrodes through which the potential is applied, and part is pure current flow inversely pioportional to the resistance of the dielectric, or directly proportional to its conductance.

Since the depth of current penetration into the conductor is re 'uced, the effective area of conductor is reduced, therefore, the conductor resistance has increased with frequency. The resistance becomes approximately proportional to the square root of the The seriea resistance R is the loop resistance of the frequency when skin effect depth becomes very small. center and outer conductors, and the inductance L is The use of stranded conductors will not eliminate due to the magnetic flux linkages set up by current "skin effect", but will reduce it and will increase the flow in these conductors. The resistance R is inversely upper limit of the inductance change region. The high proportional to the area e6"copper through which the frequency resistance i, influenced by the type and current flows. The behavior of both the resistance and composition of conductor, thickness, size, type, and inductance is influenced by "skin effect". At high quality of conductor plating. ARMOR r'OUTER CONDUCTOR
CORE

FJACKET-CABLE

INNER CONDUCTOR

Figure 5-1. Coaxial Cable 7 5.2

iI
i

LZ
m

-.

AMCP 706-125 s FJACKE T OUTER CONDUCTOR CABLE CORE COAXIAL CORE

INNER CONDUCTOR

Figure 5-2. Twin Coaxial (Parallel) JACKET

OUTER DIELECTRIC r"CABLE CORE INNER DIELECTRIC

CONDUCTOR

Figure 5-3. Twin Coaxial (Twisted) . -ARMOR -JACKET

ANKER '

COMMON OUTER BRAID BRAID OUTER CCNDUCTOR / -CABLE CORE [COMM[INNER BRAID

"

COREINNER CONDUCTOR

Figure 5-4. Dual Coaxial (Parallel)

5.3

I.AMCP70-2
f
OUTER

JACKET
CONDUCTOR LNNER JACKETS [INNER CONDUCTORS

OUTER

'1
~ ~I.

CABLE COR4ES

INNER CONDUCTORS

COAXIAL SHIELDS

INDIVIDUAL

Figure 5-5. Dual Coaxial (Twisted)

JACKETFiue56DobeSileCoxa
ORBADOUTER CONDUCTOR

CALJCR INNER CONDUCTOR

Figure 5-.
JACKE

TrblSixilde Cal

I ~~~

~~UE

CONDUCTOR_____________________

AMCP 70e 125

_ ,

5-4.1.2 Phase Angle

The dielectric phase angle is the t;me difference between the sinusoidal alternating voltage applied to a dielectric and the resulting alternating current, as referred to one cycle or 3600. 5-4.1.3 Power Factor The power factor P is the cosine of the dielectric phase angle and the dissipation factor is defined as the cotangent of the phase angle of the dielectric material, Therefore, when the phase angle approaches 900 the power factor and the dissipation factor are both small. Coaxial cables for radio frequency RF transmission require a dielectric material which has a dielectric constant e and a low dissipation factor, both of which are essentially consut fron t audio frequencies to microwave frequencies. Three such dielectrics are polyethylene (PE), tetrafluoroethylene (TFE), and fluorinatedethylenepropylene (FEP). In these materials the shunt capacitance and the dissipation factor are constant, except that with FEP-type insulation the dissipation factor increases above 2000 MHz. Rubberand PVC-type insulations have a high loss, and the value of capacitance is not constant with frequencies. Because of their high attenuation, or loss characteristics, these latter materials are not normally used for radio frequency transmissions. 5-4.1.4 Dielectric Constant The dielectric constant of 9:r, as a dielectric, is one (1); this value yields the theoretical limitation in coaxial cable design. The closer the dielectric constant is brought to one, the higher the velocity of propagation (and lower the car~acitrnace). It is po~s-ble to introduce air into the dielectric space and furhcr reduce the effective dielectric constant. This may be done by supporting the conductor on beads of dielectric material spaced intermittently along the conductor, or by a spirally applied, round monofilament of dielectric material separating the center conductor from the outer conductor. A foamed diclectric material may also be formen by introducing unicellular gas pockets into the solid insulating material. This may be done with polyethylene, polypropylene, and Teflon FEP. With any of these foams a dielectric constant as low as 1.40 may be achieved. However, meclanical and electrical strength is sacrificed. Table 5-I lists some of the more common ', of a dielectric material

dielectric constant and velocity of propagation. 5-4.1.5 Velo%:ity of Propagation

dielectric

materials, and shows

comparisons

of

The velocity of propagation of electrical energy through a cable is a function of dielectric constant only; therefore, the value of velocity would remain the same regardless of size or configuration of the dielectric material being used. The dielectric constant of insulating material is generally a known factor. An accurate method of determining the dielecLic constant of any insulating material is the method described in ASTM-D-150-59T. The velocity of propagation may be directly measured per MIL-C.17, or calculated from one of the following equations: V
=
-

(5-1)

_ - /

(5-2)

where V = ratio of velocity of propagation to speed of light e L dielectric constant

= inductance, p/ft

C = capacitance, pF/ft 5-4.1.6 Characteristic Impedance Assume thlat a line composed of the basic parameters R, L, C, and G is infinitely long so that factors at the receiving end of the line cannot be measured at the sending enu. Obviously, this line has an inpnt impedance of some definite value due to the distributed R, L, C, and G. If a short section of line is cut off the sending end, the remaining infinite length it is oi, still has the same innut impedance str.. infinitely long. If the piece cut off the front enid is now terminated in the impedance of the infinite line, the sending end must have the same impedance it did originally. Since this short piece is made up of a series of R, L, C, and G elements, any other termination would reflect a diffetert input value. This value of impedance, when use1 as a termination to a '5-5

eA
_ _ _

AMCP 706-125 transmission line, yields the snme value of input impedance. This is called the "characteristic Capacitance C = 7

.(c)
D

(
(55)
ffft(5-6) f

impedance" of the cable. When a cable is terminated in

lo 10 1d

j.
I

i- characteristic impcdance -li energy transmitted down the line is absorbed in the termination. Any other termination causes 6ntrgy to be reflected. A line terminated in its characteristic impedance is said to be matched. The characteristic impedance may be detenpined by the following equation used at any frequency, high or

Inductance I = 0.140 logDo

Characteristic Impedance

138
Z

D
logo)"-

ohm

low:
where

Ie

(5-7)

z,,0

R+

L(5-3)
D = inner diameter of the outer conductor d = diameter of inner conductor

G+ jc.C

where e = dielectric constant Z, R L C G w f i[ = characteristic impedance, ohm = resistance, ohm/unit length = inductance, H/unit length = capacitance, F/unit length = conductance, mhos/unit length = 27rf, rad/sec = frequency, Hz = "1Z, - Z0100 -v , ohm (5-8) The characteristic impedance of a coaxial line in the radio frequency range is primarily determined by iKs physical dimensions and the dielectric constant of the insulating material used. Fig. 5-10 is a representation of the changes in the characteristic impedance when the ratio Did was varied from 3.33 to 33.33. Plots Fr, the three most commonly used insulating mate,.ls used for coaxial cable were derived from Eq. 5-7. From Eqs. 5-1 and 5-5 impedence may be expressed as 'he characteristi"

Obviously the characteristic impedance varies with frequency and must be ascertained az the frequency of application. At frequencies where L is much greater ,than t, and C much greater than G (approximately i~MHz) Eq. 5-3 reduces to the ioilowing: P C
=

velocity of piopagation, % (See Table 5-1) capacitance, pF/ft ,

1
5-6

This leaas to a simple experimental det, imination of the high frequency characteristic ipedance. The
\0.

VO +vW

" /C

(5-4)

either measured or calculated from the dielectic

constant.

Fig. 5-11 may be used for approximations of Zo, C, Since the parameters L and C are a function of the electrode geometry, the following equations apply to concentric cylinders, as in coaxial cahle. and L of a twin coaxial cable where the conductor insulation and cable core dielectric are of the same insulating naterial.

5.6

It
it_

AMCP 706-125

IC 7R G

Figure 5-8. Basic Parameters of a Transmission Line

ABLE 5-1 DIELECTRIC CONSTANT AND VELOCITV OF INSULATING MATERIALS Dielectric Material Polyethylene TFE Foam Polyethylene Foam FF.P Silicone Dielectric Constant, e 2.25 2.00 1.65 -1.60 1.60 3.0 1.0 Velocity of Propagation, % 67 71 78-81 80 58 100

lAir

276 l

( -

Inductance L51,: 28.07bgl 1 x 1 II I d \1 +h2 ) wh.re D

d

+ h2)jo

PH

(5-Il)

Capacitance
C

diameter of cable core

diameter of conductor

3.68c dkl +h2) ]x

pFft FI,

(5-10)

distanca, center to center, between the two corductors, in.

5-7

I
__I.

AMCP 706-125 h=ratio, x1D e

=

Nepers may be converted to decibels by multiplying( by 8.686, and radians to degrees by muitiplying by 57.3. The propagation constant may also be determined by input impedance measurements. This method is of coaxial cables are when long lengths usedpropagation commonly available. The constant is calculated from the following equation
, tan (y'2)V- -:

dielectric constant of insulation

Eqs. 5-8 through 5-11 are used as approximations at frequencies of 10 MHz and higher. Fig. 5-12 illustrates one type of a dual coaxial cable. As each component is an individual coaxial cable, L. 5-3 through 5-6 are used to determine Z, and Eqs.
5-4.1.7 Propilahon Consitanlt

-!C,
:.-?:'i

= a+ip 1

(5-13)

If a line is terminated into its characteristic impedance, and a signal is transmitted down the line, there will be a change in both magnitude and phase of the voltage and current continuously along the line. The real part of th- propagation constant (attenuatien constant) represents the change in magnitude due to line loss, and the imaginary part represents the phase shift from the end of the line. The propagation constant - may be determined by the following equations which are valid at any frequency when R, L, C, and G are known and

where 3 propagation constant = length of cable, ft

=

ZC = input impedance,with far end short circuited

Zo7= input impedance, with far end open ,.ircuited Eq. 5-13 is valid at all frequencies and any line length. The same length must be used for both open and short circuit masjremcnt. 5-4.1.8 Attenuation and Phase Shift All transmission lines, or coaxial cables, experience losses. Those losses, termed attenuation, will decrease the efficiency of the line, which in turn limits the power c.ipabilities. Tht loss of electrical power in coaxial cbles can be attributed to two causes - the cause being the conductor resistance that results in power :oss due to conductor heating by radic frequency cu:rents passing through the conductors. The second eauz isthe dielectric loss caused by poor dielectric materials. It is, therefore, desirable to use dielectric compounds having a low power factor and a low dielectric constant in order to minimize the losses. On !he assumption that the best conductor material is used, the ;esistance loss in the conductor then may be minimized only at the expense of -ize and weighl. The larger the conductors, the lower the resistance, which results in lower losses. Again, considering a cable as having many small sections - vth each section consisting of the lumped parameters R, L, C, and G, which give a propagation ccnstant y = a + i 3 (Eqs. 5-12 and 5-13) - then the total atteauation is equal to the number of sections times a. Likewise, the total phase shift is equal to the number of sections times/3.

4(R ""]L)(G+iw C) = a+ip3 where y = propagation constant sa h n efirst R R = resistance, chn/unit length w= 21rfrad/see = 3.14

(5-12)

:1

f =frequency, Hz L = inductance, H/unit length G = conductance, ohm/unit icngti, C = capacitance, F'unit length a. = attenuation constant, neper/unit length

13= phase constant, rad/unit length

5-8

___________
_____________________________
______________

AMCP 706-125

F
a +I
=

dD

Figure 5-9. Reiationship of Diameters to Dielectric Constant By use of unit quantities R, L, C, and G the attenuation and phase constants may be obtained at any frequency by Eq. 5-12 as follows:

I(R +jwL) (G +joC)

By expanding and equating the real and imag-nary components, Ihe attenuation becomes:
2 2 2 2 2 2

R +cW L )(G

+c0

C)

+RG

W L

(5-14)

and the phase constant becomes:

2 (G + 2C ]() ) 2 + W 20) -RG SL

If w is sufficiently large, and RG is very small compared to c.,2LC, the following are good approximations at high frequency (approximately I MH4). R C a +2' + .L C" R -.-- - 2 ,noper/unit length (5-16)

cr since one decibel = 8.686 nepers a 4.343 7 + GZo dp/unit length.

[=
I

, t,
The attenuation due to conductor loss ac is (for conductor loss refer to Eq. 5-24) a,
=

(5-17)

'.

4.343 L

db/unit length

(5-18)

59

AMCP 706-125

--

co 0'0

-J

-~

~:-

L 0 r0

C4

'0 3NVO]3dVfl D3t1ISIOVUVHO

5-10

AMCP 706-125

f0

I F
I

Figure 5-11. Twin Coaxial Cross Section

FILLER

d Dn

Figure 5-12. Dual Coaxial Cross Section conductors is:

High frequency resistance for solid and tubular Re= _

2irS(d/2)

+
2ir5(D/2)

r
+

2irs[

,ohm/unit length ,dh)m/un (5-19)

For any nonmagnetic mateial, the skin depth 6 is: 6 where k-I]__ ,unit length
(5-20)

i 1.

AMCP 708-125 The:efore, Eq. 5-19 bacomes:

2k

2+

= f

jo

,ohnjunit length

(5-21)

where 2rk Values of K for various nonmagnetic materials are: K = 41.6 x I0 for copper

= 40.2 x 10- 5 for silver

= 83 x 10- 9 for brass (approximate!y) For other nonmagnetic materials, K is proportional to the square root of the resistivity. For a copper cable, te resistance R per x00 ft can be expressed as:

R =0.

'

,ohm/100 ft

(5-22)

The notation for Eqs. 5-18 throtgh S-22 follows:

d = diameter of center cornductor, in.

D = diameter of outer conductcr, in. fo = frequency, Hz f - frequency, MHz Re= resistance of coaxial cable, ohm/unit length R = resistance of coxial cable, ohm/100 ft 8 = skin depth, unit length
" it = absolute permeability, 1.257 x I0 6 H/m (if nonmagnetic)

'i

p = conductor resistivity, ohm-unit length

-1 5-12

(
_________

4._________________________

II

AMCP 706-125 When the conductors are stranded or braided, the resistance becumes:

IR r'
1.

f (

0.
where, KS Kb
=

k, KP-3 IU J
+d

(5-3

stranding factor (approximately 1.3 for 7 strands) braiding factor 2.0 for 0.25 in. diameter core 2.5 for 0.50 in. diameter core 3.0 f'jr 0.75 in. d-ameter core 4.0 for 1.00 in. diameter core 5.0 for 1.50 in. diameter core

KP

resistivity factor when outer condutor material diffeiw from center conductor.

(Kp=

:
Te d

By use of Eqs. 5-7 and 5-23 the conductor loss of Eq. 5-18 becomes

- + Kb Pdb/100 ft - JT- K$ a. =30.4-343 D c 1 3 8 190D (d

K5 U-3 xlT~~ 3.14 lef Kdgc

/100 ft db

(-4

The attenuation due to dielectric loss 2,4 is

Sad

= 4.343 GZ, db/unit length The conductance of the dielectric G is G= w C (Pe), mhos/unit length ad 4.343,,,(PF)J-= 4.343.
2-r

(5-25)

(S-26) ) rZ(P9 4.343a(PF),db/unit length (5-27)

(5-28)

t -=X 2r
ad
=

- "=j V0
(Pf),dbI00ft

2.78 f/

(5-29)

"no

5-13

F!
AMCP 706-125

where

frequency, MHz

V o = velocity in free space, ft/sec

IO
a a.+ ad =

= wavelength

= wavelength in free space, ft

e = dielectric constant PF= power factor of dielectric Total attenuation in db/100 ft then becomes

Kb K 3.14 x10-3vJ, _K
Iogio D/d d +
D _+27feP)

~ '50
(-0

3 is a graphical repiesentation of 5-13 Pig.. 5 some of the more attenuation versus frequency for having nominal cables coaxial common radio frequency impedances of 50, 75, 95, and 125 ohms. 5-4.1.9 Corona and Voltae Ratnj Corona is the ionization of air that may exist within a coaxial cable. This corona effect is produced by self sustained electrical discharges in thesu limited air spaces. These electrical discharges are caused by the influence of the electrical field in this region; therefore, sinall voids resultinS from improper manufacturing techniques will initiate corona at a much lower voltage than that fe. a cable of proper manufacture. Corona has three effects on the performance of coaxial cable in that it will: premature electrical failure of the

may which voltage at by maximum extinction corona cable thea coaxial is determined operated be The peat. point. The voltage that can safely be applied to a coaxial transmission line is limited by the onset of corona, i.e., the ionization of air spaces in the immediate vicinity of a hi! ly localized stress. The intrinsic surge stiength of the dielectric materials used for support is extremely high in comparison with gases. For perfect cylindrical conductors in air the maximum voltage stress ema occurs directly at the face of the inner conductor awd is given by the following equation: 0.g68 emX= d 0.go Dd ,kV/in. or volt/mil (5-31) where d = diameter of center conductor, in. D = diameter of dielectric, in. The maximum peak voltage Vp which exists at any point along the line will generaliy diffei froin the input voltage when the line is not terminated properly. The exact value will depend upon the degree of mismatch, the electrical length, and the attenuation of the line. Howeiver, the ratio of Lhe maximum voltage to the input voltage cannot exceed the actual value of the voltage standing vave ratio (VSWR) which should be used as a conservative derating factor. Table 5-2 shows the voltage rating and other characteristics of some of the more commonly used SO- and 75-ohm (polyethylene and Teflon dielectrics) coa.ial cables.

1. Cause dielectric.

2. Cause interference with electrical communication, measurements, and control. 3. Cause a reduction in effiziency, due to the energy loss. A slightly higher voltage is required to initiate corona than to sustain it. The corona voltage specified for coaxial cable is the voltage at which corona, once initiated, will stop, and is termed "corona extinction voltage" 5..14

rc

itH 64
I

4n

tI

,:

CLC

------------

AMCP 106125

C14

7. 1
oo

-, ol

cq
C'!.

v O

C')c 0

00.
a-

00

00
Cs!

01

00

0t

C2.

u.

d.n

.0U0

t-

C'a

co

5-16

AMCP MG6*2!i

CIL
C11 N tn 0 0

CL

)40
e'i D p z

m
cn 0 00~ 5 Jc0

oA!

~.

ci

OR
di 0

9
:

10

0V

1Pw

o
Q.

0
-6
d

04

~
0

10
.
.

LrJ

V~r~.
0 0 s

13,

C.Q) - w.
=

t0
4/

C;
r

Ii

."sen

I
-

00 0

'0

o~zo 6---0-0-0

0-

AMCP 706-126

*1 ~ /
8n 8q
tn %D

(
8 8
~C

-P. un Cn %AV) 0
(1 t,-. 0

Oo0

00

en

il0

uo

C!
tQ ! !

5-18C

I- -----

f
&0-c.'
I N t

AMCP 706-125

40%

96

43

00

0!0 00

Om

000

oo

I~I

i)

AMCP 706-125 5-5 AIR-SPACED CABLES 5-5.1 GENERAL CONSTRUCTIONAL DETAILS Table -3 lists the characteistics of some typical semi-solid, air-spaced coaxial cables which incorporate a variety of dielectric designs and outer conductor materials. The dielectric core may be in the form of thread wraps, braided threads, taped or solid helixes, multiple tubes, splines, or foams. The outer conductor most frequently is a copper braid, either sir.gle or doubie, but is often a solid aluminum tube. The exact construction for a particular csable is specified on its appropriate drawing, Standard, or Specification, and is selected for use on the basis of the desired electrical ormance consistent with the required physical and mechanical properties of.its application, where Z. is the characteristic impedance of the uniform line and Zr is the load impedance. Alo, the current reflected may be related to the incident current by the equation: tq -1r (-4 (534) 6-

where I is the incident current and I, is the reflected current. The voltage at the load is the vector sum of Vi and V., and the load current is the vector sum of Ii and I4. The reflected voltage and current are subject to the same propagation constant (attenuation and phase shift) in traveling back along the line toward the sending end as is the incident wave in traveling from sending end to receiving end. At any point on tie line the actual voltage is made up of the vector sum of the and the traveling incident backdown alongthe theline line. Since reflected voltage voltage wave traveling both these voltages are shifting in phase along the line, there will be points where the incident and reflection voltages will adi in phase to give a voltage maximum. There will also be points along the line, half way between voltage maximum, wiere the voltage will add out of phase to give a voltage minimum. If an AC volt meter is :moved along the line, it will rise and fall between these maxima and minima, therefore, the ratio ofV 4 is called the voltage stanaing wave ratio Vmin (VSWR). Obviously there will be current maxima and minima, and the minimum will be displaced 900 along the line from a voltage maximum (the current maxima voltage maximum).

: ai~spaed Th ableis tilied hereoneof tree following characteristics is desired: 1. Low capacitance and/or attenuation, 2. Smaller inphysical size over cables using other dielectric materials, and of equal impedance. 3. Weight savings, but with some sacrifice in dielectric strength. 5-6 VOLTAGE STANDING WAVE RATIO

VS-WR VS.

,i

iir

j!

Whenever an electrically uniform - R, L, C,and G line is constant throughout the line - transmission ten..inated in its characteristic impedance, any energy sent down the line will be completely absorbed by the 56.1 REFLECTION-COAXIAL CABLE SYSTEM termination. If the line is terminated in any other impedance, there will be reflections retransmitted from I is desirable to minimize reflection in a coaxial te termination - the sending end of the line. Thereasons, some of which are: reflected voltage V, is related to the incident voltage 1. The reflection can cause echos that will transmit Vi arriving at the load by the relationship of Eq. S-32. false information. In a digital transmission system a V (5-32) reflected pulse may not be distinguishable from a ieflection coefficient = 6t = V, transmitted pulse, and cause improper registration. In tiV or visual data transmission the echo can caise a complex quantity. double pictures. In both magnitude and phase, 6 i3
6

Z7 - " zr + Zo

(5-33)

2. Reflectcd energy iep.esents energy that does not reach the intended load (attenuation is increased).

5-20

1,

___AMCP700-125

\0

'(S

'(S

0 \0

(ift%

0 cc

0~

0t

0*

0*

[I

~ ~

_____ I , j cc

0________________0__ M___________ No

inN

CsC

C1

00

-n

^I (1 C4

C14

r~ -

wc

5-21

'It

AMCP 706-125 3. The high voltage standing wave ratio can cxceed the voltage rating of the line if the line is beng used close to its ma:iLnum rated voltage. 4. The current maxima can overheat the conductor and insulation. The loss due to reflection may be calculated from Eq. 5-35. Reflection lo1 = 10 logic db (5-35) 5-7 POWER RATING The maximum RF power a coaxial line may safely transmit can be limited either by the voltage introduced to the peak power or the thermal heating due to the average power. Which of these is the predominating factor will vary according to opcrating conditions and the design of the transmission line. The peak power PP rating is determined directly by the voltage rating, and is expressed by Eq. 5-37 Pv = r 220 (5-37)

The magnitude of reflection coefficient can be calculated if measurements of VSWR have been made e r= VSWR + (5-36)

The peak is affected by any of the design features, mechanical imperfections, or external factors which tend to degrade the corona level. For continuous wave (CI), dielectric losses may limit the power to a level below that of Eq. 5-36. 5-7.1 POWER HANDLING CApACJTY

The phase angle is equal to 2,b, where 0 is the electrical angle to the nearest voltage maximum on the generator side of the point where 6 is measured. Mea3uring VSWR and 0 gives a powerful tool for determining impedances at high frequency when a known line Z, is used.

The average power handling capacity will be 5-6.2 REFLECTION CAUSES - COAXIAL CABLE determined by the attenuation of the line, and the minimum "hot spot" temperature that the dielectric or SYSTFMr% can withstand continuously. Excessive ui b e dconductor e can recult in conductor migration due to teriperature its in Even though a coaxial cable is terminated softening of the dielectric material, mechanical damage characteristic impedance, there may be multiple reflections set up along the .,ntire line. This is due to due to differential expansion, or shortened life due to chemical deterioration. The amount of heat generated ronuniformity of the cable itself. One principal cause W in a matched system is the difference between the cable the of diameter the in variation the would be input power P, and the output power F2 , watts/unit changes. impe:1ance in esults core dielectric, which length (generally in ft), and can be expressed in terms Other reasons could be poor concentricity of the of attenuation a as follows: conductor within the dielectric, variations in braid, and rising sharp bend, during installation. If impedance (5-38) -, variations or discontinuities exist and if they occur at a = small very a only causing each intenals, spaced evenly reflection, a very high VSWR could be obtained at a (5--39) P, particular frequency where these discontinuities are IV P, -- P2 = P1 - antilogo(a/lO) one half wave length apart on the line. so that each adds in phase to all the rest. If a transmission line is to he used over a band of fiequancies where these reflections could cause trouble, it is important that the I;-,- be measured for VSWR over the entire frequency range to be used. This is most convriently done by sweep measurement techniques, where the frequency is autmatically shifted over '.he range 9nd the reflections shown on a cathot'e ray tube display. The rate of heat dissipation from the line depends on the diameter, materials, color of the outer covering, and the ambient temperature and altitude. The amount of heat which flows radially from the line will depend on the composite thermal resistivity RTH of the dielectric, any jacketing materials used, and the temperature gradients present therein. Heat is generated internally, at the center conductor, in direct

F
L__

5-22

-~

--

--

AMCP 706-125 proportion to its individual attenuation. By equating the heat generated, from Eq. 5-39, to the heat dissipated for a given temperature rise AT between the center conductor and the ambient temperature, the maximum average power rating PT can be established from Eq. 5-40. W = A T _PT [i STy 1 anti logio(aflO) 5-40) PT =_ RT11 . AT I 1 0 antilogio(al1) 5-8 SHI ELDS There are many type of sbields used in the construction of coaxix cables. The more popudar types are the braided shield, slyeved or metallic tubing, and a conductive spiral or longitudinal wrap, The shield acts to confine the dielectric field inside the cable insulation; provide a barrier to any external energy or radiation; and in the case of high voltage operaion, provide ;ncreased safety to human life. The most conmuonly used wire gage sizes for individual shield wires in a braid are from #34 AWQ through #38 AWG inclusive. The braid is constructed with machines having 16 or 24 carriers, with the number of wires per carrier ranging from 2 to 8, and the number of picks per inch ranging between 10 and 30. The nominal braid angle is approximately 30 to 35 degrees. 5-8.1 PICKS The point at which two carers cross is called the pick. The number of these picks per inch in a line parallel to the axis of the conductor isreferred to as
picks per inch.

The temperature rise will depend on many factors such as the dielectric material used, dimensions, convection and radiation conditions, etc. Polyethylene (low density) coaxial cables are rated for use at a maximum temperature of 800C on the center conductor. When a higher temperature or an increase in power ratings is desired, a Teflon insulated coaxial cable ib uied. Teflon is recommended for temperatures up to 25 0 C (4820F) for cables classified as miniature cables. Figs. 5-14 and 5-15 show average power curves for some of the more commonly used 50.,hm polyethylene and Teflon cables, respectively,
5-7.2 POWER RATING DUE TO VSWR

Longitudinal variations in voltage and -current as a result of a mismatched load will reduce the average permissible power. When attenuation is small, so the VSWR is nearly constant over the entire length, then: Average power lost in the line with VSWR Average power lost in the line (matched) S11 "VSWR + 2VSWRJ

5-8.2 CARR.ERS. The carrier is the spool which ,arries a group of parallel wires that are woven to form the shield. In the weaving process half the carriers spiral in one direction around the cable and half spiral in the opposite direction.

-(S-1)

Axial heat flow, particularly in the center condutor, tends to reduce its temperature for short wavelengths. When the wavelength is very long, the power rating for the match." !ine should be divided directly by the VSWR. The maximum temperature rise occurs at the point of the VSWR minimum.

5-8.3 ENDS 1lie ends are the number of parallel wires on each carrier. Four ends per carrier are shown in Fig. 5-18. The factors d, N, C,and P can b. varied to give the desired percent of coverage for the cabl, being shielded. See Eq. 1-4, par. 1-9.3.
5-23

I.

The amounts by which tl., power handling ability of Teflon and polyethylene cables decrease with VSWR, altitude, and temperature are shown in Figs. 5-16 and 5-17. .)

AMCP 706-125 Although solid type sheaths, such as copper or aluminum tubes, provide low attenuation and good shielding effectiveness, there is a distinct disadvantage due to the loss of flexibility. stiffer than a braid. Tapes are usually considered when( the cables are expected to encounter severe mechanica. abuse, or in some cases, to prevent rodent damage. Foils - such as aluminum, copper, or laminates-are mostly used in shields foi low frequency applications. This type of shielding is not recommended for use when the cable will be subjected to great amounts of flexing. Under extreme flexing th:s type of shield may break and the continuity of the shield will be lost.

Copper, steel, and alu, unum tapes .d foils are also used for shielding purposes, but .hey too are much

1,000

2,0

,700

1100

30_____*~ U 4015 AMINTTMP_

50 '1
w "

ccI
ISOT | .

__.

40

20SW.304

60

10

200

50

100

10FREQUENCY,

MHz

Figure 5-14. Average Power Ratings of 50ohm Polyethylene Cables 5-24

*AMCP

706-125

30

20 15

400 C AMBIENT TEMP 2500 C HOT SPOT TEMP VSWR= 1.0

10

5 3

j0
,
>

LI-

1.0

0.2

0.3

.i

I
100 2G0 300 500 1K 2K 3K 4K 5K

FREQUENCY, MHz

Figure 5-15. Average Power Ratings of 50-ohm Teflon Cables

5-9 SHIELDING EFFECTIVENESS

5-9.1 SUBfACE3RANSFERIMPEDANE

extent, however, some radiation of ekctrical energy may occur at microwave frequencies through the interstices of the shielding braids. The use of a triaxial
construction (two shields insulated from one another)

The surface transfer impedance is the most practical unit of measuring the relative effectiveness of shielding. It is defined as the ratio of voltage on the surface of the outer conductor, to the total current carried by the inner conduictor. It is a function only of frequency and the design parameters of the line. Therefore, at higher frequencies (above 1000 MHz), the shieiding effectiveness becomes an important factor. A braided double shield improves the quality of shielding to some

improves the effectiveness of the ..hielding eoasiderably. The effect of dus type constniction is two individual shields operating separately. To obtain the best shielding performance using this type construction, both shields wrust be brought to the termination point with the in-ulatiag material separating them. Table 5-4 provides data on shielding effectiveness for various types of shields which have been used in the construction of shielded wires or coaxial cable.
5-25

AMCP 706-125

DIAMETER, IN.

In1
SE VE

VSWR 111 19 111 1 1 11 1 11 1 'O0$,"I 111-11 1 '

1.5 1.4

1.3 1.2

1.1

1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 1.0 0

POWNER RATING FACTOR

Figure 5-16. Power Rating Due to VSWR-Te f/on Cable

5-9.2 -9EFR NL For additional information on shielding, shielding effectiveness, and power rating refer to Refs. 15 and 16.

5-10 TRANSMISSION UNJBALANCE

In most cases, with the use of dual or twin coaxial cable, it is required thiat the line be as perfectly
____

~5

-6_

_--_

AMCP 706-125

OVERALL CABLE DIAMETER, IN.'

.-

VSWR
-i

q (qOR 0 N IV:
SEA LEVEL

15
*

3 4 5
0F

10

0 ANBA-Lk I

250 F

500 F i50

F'

1 0F

175 o F

3.0 2.8

2.6 2.4

2.2

2.0 1.8

1.6 1.4

1.2

1.0

0.8 0.6 0.4

0.2

POWER RATING FACTOR

Figure 5-1Z Power Rating Due to VSWR-Polyethylene Cable

balanced as possible. This means that a cable of a certain physical length must have both lines equal in electrical length. If one line differs ;n characterisic impedance from the other, then the electrical length also differs, which will cause both a voltage drop and phase angle variation between the lines 5-10.2 REFERENCES FOR TEST AND MEASURE. MENT Ref. 14 describes the test set-up and method of measurement. A more comprehensive discussion of the test and test procedures may be found in Ref. 11.

5-11 COVERINGS AND SHEATHS 5-11.1 USES It is commop practice to provide a nonma IC covering or sheath over the cable shield. This prevents the shield from coming in contact with other live electrical circuits, acts as a barrier to moisture, provides mechanical protvction, and reduces self-generated noise. 5-11.2 FIBROUS OR TEXTILE Fibrous or textile braids - such as acetate, rayon, nylon, Dacron and Fiberglas - provide good flexibility.
5-27

AMCP 706-.125

N(

(P) ONECKC PICKONE CARRIER SING~LE STRAND DIAMETER

Di-tails Figure 5-18. -Shield-Constructonal

where a N P C d D
= = = = =

braid angle, deg (relative to cable axis) number of ends per carrier pick carrier diameter of single shield end d'aneter of cable core under braid WhendfieJ shieds re sed extude nyon,

conductor or sheath, is necessary to eliminate air pockets. Polyethylene is used as a dielectric for cables with moderate powers; for higher operating temperatures and power levels, rubber-type insulations are used. The flexibility of the cable is increased, and because the rubber-type insulation adheres better to the inner and outer conductor, voltage stresses during flexing will be minimized. Most pulse cables are constructed in tiaxial form. Because of the very high powers involved, a reduction of spurious electromagnetic radiation is mandatory. The attenuation and average power handling capacity under pulse conditions is dependent directly on the duty cycle, and is established by the system requirements and limitations. For a more complete discussion and additional information refer to Refs. 9, 10, and 12. 5-12.2 DELAY LINES Delay lines are prima:ily used in pulse forning circuits and systems, and for matching high impedance of these cables is achieved circuits. The high impedanceinductance of the center by increasing the series conductor and the cable capacitance, which results in phase and attenuation characteristics similar to a low These characteristics remain fairly constant pass filter. frequency cut.cff is reached. The center conductor consists of a fine enameled wire which is closely wound around a hollow insulating core. A thin tepe, or extruded dielectric, is placed over

polyethylene, polyvinylcloride, Teflon, or other Lasulation should be used to electrically isolate the shield from the surroundings. 5-12 SPECIAL CABLES 5-12.1 .PU SE CABLES Because pulse cables must be capable of transmitting high voltage, direct current pulses, with the order of megawatts, peak powers in the more strinlgent than that of requirements are much conventional coaxial cables. The more important requirements are in respect to corona levels, shielding attenuation. effectiveness, and low frequency ec auntil nu To provide a cable with a high corona level, a good physical bond between center conductor and the dielectric, and between the dielectric and outer 5-28 PURPOSE

COAXIAL

,1

r1
. -

AMCP 706.125

TABLE 5-4 SHIELDING EFFECTIVENESS Ke @ 1 MHz * FOR VARIOUS SHIELD MATERIALS AND CONSTRUCTIONS
Where Ke = 0 for perfect shielding K e = I for_ no shielding Type of Shield Tinned Copper #36 AWG 5001 Coverage Tinned Copper #36 AWG 75% coverage Flat Braid Tinned Copper 0.002 in. thick, 50% coverag-, Sen-d-conductor material only Double faced aluminum on Mylar backing 100 coverage 1/4 in. aluminum foil, 0.005 in. thick 100% coverage Relative Shielding Effectiveness at 1 MHz 3.4 x 10-3 1.42 x 10' 8.26 x 10-3 No apparent shielding ,

22.7 x 10-3 16.3 x 103

i,

Triax (shields separated with

polyvinyl extrusion)
See par. 1-9.5

0.200 x 10

this spiraled conductor. The thickness of the wrap or extrusion will detcrmine the capacitance of the cable. This is followed by a served or braided outer

polyethylene - and placed over the dielectric core. This semi-conductive barrier, between the dielectric and shield, tends to suppress mechanical noises which f,
'

conductor. Protection is usually provided by the use of

a vinyl covering or sheath. Construction of such cables can provide delays of 0.040 to 1.1 psec/ft, with surge impedance values of 900 to 3000 ohms. Applications for this type cable are in radar, timing circuits in conjunction with computors, and television systems. For a more complete discussion and additional information refer to Ref. 12. 5-12.3 LOW NOISE CABLE Low noise cables have constructions very similar to conventional coaxial cables except that a semi.conductive material, such as carbon, is disper,,ed with another compatible material - such as vinyl or

develop from unusual mechanical abuses - such as the

cable dropping onto a hard surface or receiving a sharp blow. For a more complete discu.%ton and additional information refer to Ref. 12. 5-13 PRACTICAL COSTRUCTIONAL CONSIDERATIONS 5-13.1 SIZE In selecting the size of a coaxial cable the three prime factors which must be kept in mind are attenuation, characteristic impedance, and the capacitance. Determination of attenuation is a funct(on of the power losses in the conductor and dielectric, and with low loss dielectrics, is primarily the 12 R

)5-29

mmo

W__ _

__

))

AMCP 706.125 losses. Therefore, the smaller the center conductor, the larger the attenuation. The ratio D/d - where D is the diameter of insulation or core, and d is the diameter of 'd he conductor - is the prime determining factor of Zo and capacitance. The capacitance for a given length will decrease as the ratio D/d increases and, at the same time, the Z, will increase. This is readily understandable by Eqs. 5-2 through 5-4. The most often used values of characteristic impedance in the 4pplication of coaxial cables are 50, 75, and 95 ohms. Values exceeding 125 ohms are very impractical since they will necessitate the use of a very small and fragile center conductor, or a very large core and overall diameter, . Cthe 5-13.2 CONCENTRICITY AND ECCENTRICITY properties of the coaxial cable over the specified operating temperature range. It is extremely important that the sheaths be truly a moisture barrier because water, having a very high dielectric constant, will s'riously affect the performance of coaxial cable should moisture enter into the cable. See Chapter 2, "Insulation" 5-14 ENVIRONMEYAL CQNDITIONS 5-14.1 GENERAL CONSCIDERATIONS The environmental conditions to which a coaxial cable will be subjected is a prime consideration before actual design of such a cable can be considered. The morefrom import.nt factors the temperature reaction contact wih are foreign agents and limits, fluids, humidit ,an altitude or vacuum. Each gage size used in the construction of a center conductor is limited by the amount of current it will pass (see Chapter I "Conductors"). The heat that the passing current will generate is also a consideration since it must be kept within the temperature range of the cab!e core insulation material. Chapter 2 "Insulation" lists the thermal limits of many insulation types available which are presently being used. t

To nisure against variable electrical characteristics, a co al cable should be constructed as concentrically as possible. A mechanically perfect cable would be 100% concentric and 0% eccentric. Since capacitance is a function of Did, the capacitance would vary along a line length if the coneentricity were varyng, and -consequently, the characteristic impedance would also have irregularities. These impedance variations stemming from eccentricity are lower, or much less, than those from diameter variation. A 50% concentricity change produces less than a 10% 5-14.2 INSULATION GUIDE impedance change. guide to the selection of the proper insulation 5 3 ABRASION hangeA 5-13.3 AB . materials with respect to immersion, humidity, and The selection of the cable sheath, in respect to i abrasion resistance qualities, would largely depend on the environmental conditions to which the cable would be subjected. Reference should be made to Chapter 2, "Insulation", in selecting the proper insulation material for specified abrasion-resistant requirements.
5-13.4 .CONTAMINATION

altitude will also be found in Chapter 2 "Insulation. Coaxial cables will withstand lower dielectric breakdown values, and will exhibit lower corona extinbtion points, in a partial vacuum. The lowest co.ona values occur in a vacuum corresponding to approximately 100,000-foot altitude. If environmental fictors other than atmospheric are to be encountered, the dielectric properties .'1 the cable should be investigated. 6;-15 DISCUSSION OF APPLICATION MAJOR USAGE
-

in son cases there is an additional requirement for a coaxial cable sheath; it must be noncontaminating. Over a period of time, within the operating temperature range of the cable, any sheath materials used must not leech or exude any material which will pass thiough the braid or shield and contaminate the primary dielectric material to the extent that it will affect the power factor of thu dielectric material. This limits some of the sheath material selkction possibilities when using plasticized materials such as vinyl sheaths. The choice of a vinyl sheath material must be such that the ingredients will not damage the electrical

The application of coaxial cables is found in all phases of electronics today. Some of the major uses of coaxial cable are as follows: a. Construction of electronic equipment b. Innerconnection for electronic systems of all types

6(

__

_-

_ _ __0

AMCP 706-125 - Pantenna c. Lead in for antennas and interconnection of arrays. Specially constructed coaxial cables with foam dielectrics (low dielectric constant) are adaptable to feed antenna systems for broadcast communications and closed circuit television. d. Audio frequency applications, because of low cross-tak oualities e. High voltage pulse applications f. Low noise cable. Noise may be caused from capacitarce changes, and electrical shield noise caused by the resistance of the shield. Some remedies for this self-generated noise are the use of a good condictor i. Multiconductor cables having coaxial cable components for control systems j. High impedance cable, commonly called delay cable material, and the use of semi-conductive materials between the cable core (dielectric) and ground or shield or a mechanically tight shield made with a noncorrosive material sach as sllver.coated copper. g. Radar and sonar applicdioams h. Computer and data processing

REFERENCES 1. H.L. Woodbury, Appli-d Research & Development of Hgh Temperature, High Power RF Coaxial Transmission Lines, Andrew Corp., ASD-TDR-62-976, Air Force Systems Command WPAFB, Ohio. , ""\ 8. H.H. Skilling, Electric Transmission .

Lines, McGraw-Hill Book Co., N.Y., 1951. 9. General Elect ric Contract, DA-28-043.AMC-00296E, 25 June 1965. 10. General Electric Contract, DA-36-039-SC-88974, 12 March 1964. 1I. Measurement of Transmission Unbalance- Dual Coaxial and Twin Conductor Cable, Tech. Memo. M-1344, U.S. Signal Corps Engineering Laboratories, Ft. Monmouth, N.J., 26 Dec 1950. 12. "RF Transmisrion Lines and Waveguides", Techniques for Application of Electronic Component Parts in Military Equipment, Volume 2, Chapter 8, McGraw.Hill Book Co. is. Refere,.ce Data fcr Radio Engineers, Fourth Ed:'ion, International Telepaone and Telegraph Corp. 14. MIL-C-17, Cables, Radio Frequency, Coaxial,Dual Coaxial, TwIn Conductorand Twin Lead. 15. R. C. Miidner, "The Power Rating of RF Cables", AIEE Proceedings T978, 1949. 16. G. A. Dummer, Wires and R" Cables, Sir Isaac Pitman, London, England,

2. Final Report or. High Power, Noise Free Pulse Cable, Signal Corps Contract DA 36-039SC-42669 with Okonite Co. 3. Final Report on Thermoplaste Insulated Pulse Cables, Signal Corps Contract W-36-039SC-44519 with Federal Telecommunications Labs. (ITT). 4. f uarterly Reports An Investigation of Interference from Raaar Modulators, Air Force Contract AF-30(602).401 with Rensselaer Polytechnic Institute. S. Final Engineering Rep. t on Study of Tubular Shielding and Develop nent of Flexible Shielding Conduit, Rpt #hNS-F2 Vol II., June 29, 1949 prepared by Technicraft Laboratories, Inc. under Contract NOa(S)-8098. 6. ASTM-D-150-59T, Tests for A-C Capacizance, Dielectric Constant, atid Loss Characteristics of Electrical InsutatingMaterials. 7. Ware and Reed, Communications Circuits, Third Edition, John Wiley & Sons, N.Y.

F
*

5-31/5-32

1~'

___h

AMCP 706125

CHAPTER 6 CONTROL AND SIGNAL CABLES

6-1 INTRODUCTION Military control and signal cables are defined as multiconductor cables, shielded and unshieldi-d, for use in circuits 300 and 600 volts root mean square (rms). This chapter considers all component parts, regardless of the number, as being identical In construction (#11 AWG and small,;r). Cables utilizing component parts that are not identical are discussed in Chapter 8
"Special Purpose Cables".

c. All electrical requirements (such as voltage and current ratings, DC re.istance, attenuation, impedance, insulation resistance, capacitance, cross.talk. etc. (Chaps. 3 to 5) d. Cable use - portable or norportable e. All mechanical and environmental conditions to which the cable will be subjected. The required cable may be a simple twisted pair-designed in a similar manner to cables listed in MIL-C-27072, MIL-C-55021, MIL-C-13777, and MIL.C-3432 - or it might be a large multiconuctor cable applicable to the same specifications. Some engineers deem it good practice to provide for 2 or 3 extra circuits, to be used as spares, when designing a cable. The main functions to be c4;nsidered in the design of a multiconductcr cable are discussed in detail later in this chapter. 6-3.1 PHYSICAL CONSIDERATIONS If it is known a cable w. b qubjected to great amounts of flexing, then a strzded type conductor should be considered rather than a solid type. Selected conductors must also be capable of carrying the required current. Conductor insulations are rain'ily selected considering temperature limits, voltage ratings, current ratings, size, and cost. Voltage rating for ccntrol and signal cable is nominally 300 and 600 volts (rms). By taking advantage of the high volt-per-nil rating of insulating materials a.,Aable today, minimum diameters can be obtained. A great amount of basic insulated wire, constructed for cable use, is made in accordance with MIL-W.16878D. Control rad signsl ;ables are nominally operated usin: low values of uurrent, however, it should be kept in mind that the current capacity of an insulated wire is !imited by temperature. The operating temperature i' :he rire, which is the ambient temperature plus the temperature increase due to current flow, should not exceed the tmperature ra.Ing of the insulation. For example,

6-2 APPLICATIONS OF CONTROL SIGNAL CABLES

AND

Control and signal cabls are sometimes termed "supervisory cable" and arc used for monitoring data recordings and for conveyance of information e.g., communications, telemetering temperature, pres.iure, flow, indicating lights, and operation of inner connections of protective devices, such as relays, circuit breakers, motor controllers, transformers, pdnel board control switches, and other current sensing devices. Control and signal cables are used extensively in the aircraft, missile and space programs, radar, ground support, data processing, etc. 6-3 CONSTRUCTIONAL DESIGN FACTORS Control and signal cables are, in a great aniwy cases (except when made to a particular MIL-Spec), designed to be incorporated into a particular electrical and electronic circuit and system. Threfore, prior to the actual cable design, the engineer must know, or be able to select, information from the items listed below, Each will be discussed only briefly in this chapter since each has been fully detailed in previous chapters. a. Number of circuits needed b. Selection of conductors and insulation (Chaps. I and 2)

+.. . .. ... .F . .

ii

AMCP 706-125 using an insulation rated at 105 0C,and operating the wire or cable in a 90*C ambient temperature, the maximum allowable increase in temperature due to current flow will be 150C. For more detailed information on conductors refer to Chapter 1. For insulation, refer to Chapter 2. 6-3.2 ELECTRICAL CONSIDERATIONS Electrical parameters - such as DC resistance, attenuation, and impedance-may or may not be 9 specific consideration. If these were definite requirements, then other parameters -such as capacitance, dielectric constant, and velocity of the properifcable propagationthe paticularly treinto holdenter would also design. This would required cable were tc be a multiconductor cable consisting of a group, or groups, of coaxial cable whose primary function is to match sime type of input cable, and output is to be matched to a particular characteristic impedance. Mirdmum attenuation may also be a requirement in this case, and because attenuation is primarily affected by tht JR losses of the line, the resistance of the line should also the low time, same At thefast a minimum. kept to signals be and time, travel may require attenuated since the velocity of a propagation is mainly affected by dielectric constant of be the selected. insulatingChapter materials, 5, must compound the the proper "Coaxial Cables", disusses all these electrical parameters in detail and is a helpful guide in the design of the cable type discussed here. Cable "cross-talk" may be minimized by cabling technique of multic, iiducior cables and is discussed par. 6-7. 6-4 CABLE TYPEC; 6-4CABE TC~6-5.1 are classified in two Control and signal cables distinct types: "portable" and " nonportable", each of which is discussed,
6-4.1 PORTABLE

encountered in its use. (Impact, bend, and twist testing and test fixtures are discussed in par. 6-7. Cables constructed to MIL-C-3432 ae actuhly closely related to commercial type cable. This specification covers the design data for low-, medium-, and heavy-duty cables. These cables are also of an all rubber construction which is rapidly becoming obsolete and being replaced by polychloroprene sheathed cables which are superior to rubber for environmentsl and mechanical reasons, Polychloroprene is more resistant to oil-based fluids, less affected by ozone, and is less susceptible to damage due to temperature and humidity changes. Cables constructed to MIL-C-3432 cables are not recommended. use as portable-type for and mechanical guarantees, such as Enviionmental given with cables constructed to MIL-C-13777E, cannot be expected. 6-4.2 NONPOF. ABLE Nonportable types are those cables specified in MI1C-27072. Nonportable types of cable are used in a permanent installation where the cable is not intended any great extent; therefore, or abused to moved requirement to would not be as stringent as physical thebe for the portable types. otb, rnnotbe factors which mechnical and there are environmental shoal ', e given consideration. Pars. 6-5 and 6-7, "M'oiti',nductor Cable Design" and "Multiconductor .Cable Testing", cover these requirements in detail. Rgrl R o h ye 6-5 MULTICONDUCTOR CABLE DESIGN GENERAL CONSIDER'.ATIONS A multiconductor cable may be interpreted as two or more conductors in any one complex. Normally speaking, a two-conductor cable is called a pair;
three-conductor, a triplicate; four-conauctor, a

Portable types are those cables specified in MIL-C-13777E. Portable cable is a configuration that may be moved many times or used in temporary installations which might impart abusive handling. The portable cable construction muct employ a much more flexible and tougher sheathing, such as polychloropre. w, and may possibly require special constructional trngineering to enable the configuration to withstand the impacting, bending, and/or twisting

quadruplicate; and five-conductor, a quintuplicate. In this chapter we will be concerned mostly with the larger configurations of tei and more conductors. Multiconductor control cables have a large number of ideptical components cabled together to form a complex. The overall cable must be as physically round as possible, light weight as possible, small as possible in overall diameter, and not contain a great number of large air spaces or voids. All these consideradons plus the flexing quality, physical abuse, and electrical

6-2

1-.

AI

---

--

'.

AMCP 706-125 parameters- must be taken into consideration inthe , or components, Table 6-i considers all conductors

design of the completed complex, taken t be S 6-5. 6-5.2 CNSTRCTIN SPCIFC CNSIER TIONS The following is a breakdown of the main functions to be considered in the design and manufacture of a multiconductor cable complex: a. Insulated conductor components

as being equal in size, and will be helpful in

determining the overall size of various configurations. A multiplying factor is used, multiplied by the

diamezer of one condutor or component, to give D

the calculated diameter of the twisted components

D where f b. Cabling or twisting of conductor components
=
=

= fd, in.

(6-1)

multiplying factor from Table 6-1 diameter of single component, in.

c. Shielding or braiding d. Fillers

e.Binders f. Sheathing
g. Armor

6-6 MULTICONDUCTOR

CONSTRUCTION

We shall now consider each of these categories individually, explaining the functions and design criteria of each separately.
6--6.1 CONDUCTORS AND COMPONENTS

Fig. 6-1 is a typical multiconductor cable design

showing the relative location and us. 3f ez.h of the above-mentioned categories,

First, it is nec ssary to understand that a cabie

component is not could necessarily insulatecf the component be one a group of conductor; insulated

FLLER-

JACKET

FIRST LAYER

SHIELD

14 COMONENT SECOND LAYER "

10BINDER

Figure6-1. Typical Multiconductor Cable Design

AMCP 70S-1?5 TABLE 6-1

(
COMPONENT TWIST-DIAMETER MULTIPLYING FACTOR Cable Design Configuration No. Conductors Multiplying Factor

21.0

2.15

2.41

2.70

I6
64

3.0

'II

AMCP 706-125

TABLE 6-1 (CONT.) Cable Design No. Conductors Multiplying Factor

@7
8 9

3.0

3.35

4.0

[10

4.0

AMCP 706-125 conductors. To define the term "cable component", we could say a component is any completed, member that is to be placed within the complete unit. For example, a cable may contain sixty (60) conductors divided into twelve (12) components of five (5) conductors each, every component having the same construction; or it could contain five (5) components, consisting of two components of eight (8) conductors each, two components of fourteen (14) conductors each, and one component of sixteen (16) conductors, each component containing a different construction, Component conductors are chosen with regard to (1) the environmental and performance requirements such as flexibility, thermal environment, cold bend qual.ties, voltage current and (2) installation need. such as solderability, potability, etc. 6-6.2 COMPONENT STRANDINGS Generally, there are three basic strandings used in the construction of cable components (see Chapter 1). 1. Concentric.The concentric stranding is recommended for sizes equal to and smaller than #10 AWG where flexibility and conductor concentricity are essential. This is almost mandatory if thin-wall insulations are to be used. 2. Bunch.The bunch stranding may be used for conductor sizes ol #10 AWG and smaller where heavy wall insulations are needed and economy is a prime factor. Bunch stranding, however, shoula only be employed where medium or heavy insulations are specifierd oecause it is not a truly round construction and may have high strands which would result in a dangerously thin wall at the high stiand point. 3. Rope. Rope stranding is recommended for the larsxo AWG sizes in order to maintain good flexibility,
6-.3 BASIC INSULATED WiRE

extruded nylon' as an insulation covering is recommended, and particularly for conductors used in temperatures up to 105 0C where excellent cut-through resistance and abrasion resistance is required. In shielded components, where insulation walls are less than 0.015 in. thick, the use of nylon or a high temperature equivalent protective insulation covering is necessary to preveut short circuits from developing due to the braid ends puncturing the thin insulation. This type of protective covering has been highly successful for use in cables where physical abuse is hWgh, and is particularly effective in the protection it affords shielded components. Even though the nylon insulation covering used in multiconductor cables adds to the stiffness of the component, it does not decrease the overall flexibility; on the contrary, increased flexibility is usually obtained due to the extremely smooth surface of the nylon, which tends to reduce the binding effect between adjacent layers when the cable is flexed. Extruded nylon would normally be found on #12 AWG conductor size and smaller. For the larger AWG sizes a saturated nylon braid may be used, but generally. a heavier wall of insulation is supplied with no additional covering. Refer to Table 7-16. 6-6.4 COMPONENT SHIELDING In many components, and in many overall configurations, the use of a shield may be required. In the majority of components the generally accepted AWG size wire used for shielding is #38, #36, or #34. For larger overall 3hields the use of AWG #32 or #30 wire may be required to obtain the correct coverage. The #38 AWG wire for shields, in general practice, is only used for very small components or cables where a minimum size is a definite requirement. Table 6-2 lists the recommended shield braid wire sizes for specified core diameters, or the overall shielding over the assembled components. Also listed is the approximate increase in size due to the shield application. The overall shield coverage usually specified on cable components, and overail shields, is between 85 and 90 percent, and is dependent on the cable core size, number of carriers, number of picks per inch, and number of ends per carrier. It has been found, however, that a sh-eld coverage i.f 75 percent is usually adequate and results in lower cost aad lighter weight. The equations for calculating shield coverage and braid angle can be found in Chapter 1, "Conductors."

The conductor insulation can be one or a combination of materials, dependent on basic overall cable construction, environment, and function. All environmental and electrical factors must be considered in the proper selection of the basic insulation. Refur to Chapter 2, "Insulating Materials," for selection of the best insulation. Where the wall thickness of the primary insulation if 0.015 in. or less, the use of

6-6

V,,

AMCP 706-125

TABLE 6-2 DIAMETER INCIPEASE DUE TO SHIELD APPLICATION Core Diameter, in. Shield Braid Size, AWG
Added Increase in Diameter, in.

Inae

0-0.05 0.051 - 0.300 0.301 - 0.900 0.901 - 1.700

#38 #36 #34 #32

0.017 0.022 0.027 0.034

1.700 and up

#30

0.044

In order to facilitate terminating a shielded conductor or component, it should have good shield "push back" qualities; i.e., the shield must easily push back, or slide away, from the cut end of the conductor or component. This quality is obtained by the use of a axis of the conductor. It has been found that a 200 to 40" angle will assure adequate push back of the shield for termination purposes. Fig. 6-2 pictorially shows this angle. Itcovering denote the braid angle relative to the axis of the

correct braid angle which is calculated relative to the

and unshielded components, which in time may actually wear through the insulation causing a short circuit. Another reason is the prevention of random noise generation and elecrical interference that may occur when the cable is flexed. This covering will also help prevent electrical distortion and cross-talk in a conductor, caused by ground loops within the cable complex. It also prevents abrasion between the shields of adjacent conductors. The two must common shield coverings for low temperature applications ,ae extruded nylon and a lacquered nylon braid. A shield must not be confused with a shield insulation for driven shields. Neither of the above materials is

conductor; it can readily be seen that the wider the angle, or closer to 900 this angle becomes, the more
difficult it becomes to push or slide back the shield, On larger cable core diameter- it is not always possible to maintain a braid angle in the 200 to 400 range, therefore, in cables with a core diameter in excess of approximately 0.400 in. the rhield angle shall be the lowest possible. 6-6.5 COMPONENT SHIELD COVERING AND

,onsidered good for dielectric insulation protection. For dielectric protection, or shield insulation, a heavier
wall of an insulating material--such as polyethylene, vinyl, or polyester/polyethyiene-would be recommended. Dimensions of component jackets for ight- and medium-duty cables should be in accordance with

Table 6-3. The minimum wall thickness at any cross COMPONENT JACKET DIMENSIONS
I. a multiconductor construction, it is advisable that a shield covering be used for various reasons. This is felt to be necessary even though the shields may be electriclly common at point of termination. One of the reaons for a shield covering is to protect unshieldea, insulated conductors from mechanical damage by adjacent shields. TIs is necessary because of the abrasion produced between shielded components

section should not be less than 70% of the average wall

tickness at the cross section,

6-6.6 CABLING ,
..

The cabling, or twisting, operation is a very important function, Its primary effects are felt in the mechanical perormance of the cable. In the decilpi of a multiconductor complex thc conductors should be so arranged in the overaJl design that a flexible, circular, cross section, with the smalest possible overall

6-7

AMI'P 706-125

flB
~900

BRAID
ANGLE _A
CONDUCTOR AXIS

Figure 6-2. Braided Shield Angle diameter will be obtained. !'he planetary-type cabling or twisting machine keeps all components in the same plane and eliminates any twisting action of the individual components of a complex. 6-6.6.1 Lay In the design of a cable complex, cabling lay length is important. "Cable lay length" is the distance of advance, measured axially, of one turn of any one coraponent within the cabled group. For good cable design, lay length should be eight to sixteen times the "pitch d~tmeter" of the layer in which the component is a member. A longer lay causes excessive stiffness; a shorter lay is expensive and may contribute to conductor or component damage during cabling. In the select;on of the lay length, t.se as long a lay as possible consistent with flexibility and electrical parameteis required. Use a short lay when hard core cable is desirable for flexibility, or to allow adjacent layers to be cabled without the components falling into the component interstices of the underlying layer.

TABLE 6-3 AVERAGE WALL THICKNESS-SHIELD COVERING (LIGHT- AND MEDIUM-DUTY) Component OD, in. Shield Covering, in. Nylon Nylon Ext. Wall '_Tape 0.000-0.100 0.101 - 0.200 0.201 - 0.250 0.251 -0.500 0.501 - 0.750 0.751 -1.0000.004 0.006 0.008
-

Folyester/ Polyethylene 0.006 0.006 0.006 0.006 0.006 0.006

Shield Insulation, in. PVC 0.010 0.013 0.013 0.018 0.027 0,035 PE 0.010 0.013 0.013 0.018 0.027 0.035

TFE or FEP 0.008 0.010 0.012 0.015 0.020 0.025

Braid Wall

0.007 0.007 0.007

16S

*%,,

L
S6-6.6.2

___'

AMCP 706.125 cable interstices, or voids, in the under layers caused by poor component spacing. Each succeeding layer should have a different lay length to keep the layers concentric. 6--6.7 CABLE FILLERS
Fillers in a cable are used for various reasons. The

Pitch Diametar

"Pitch diameter" refers to that diameter which is twice the distance measured to the centor of any conductor or component from the center of the cabled core. Fig. 6-3 depicts lay length and Fig. 6-4 shows pitch diameter.
6-6.6.3 Lay Construction

Cable lay may be either of two constructions: 1. Unidiiecticnal Lay-meaning all component layers twisted in one direction, with either a right or left hand lay. 2. Contrahelical Lay-(Fig. 6-3) indicating all cor:ponent layers twisted so that each component layrr has a lay that is opposite in direction from each preceding component layer. Unidirectional lay, or all layers twisted in the same direction, is recommended for cables that are required to withstand physical abuse, or where maximum flexibility is required. Where physical abuse or flexibility is not a problem, cables utilizing contrahelical lays may be used. In a contrahelical type construction the use of filers is held to a minimum because of the opposite direction lapping of the zomponents in adjacent layers. When using the idirectional lay, each layer must be full and round vith no large voids. This must be done to prevent omponents of the above layers from falling into the

two most comramon are as a center core and as a replacement fbr missing or unnecessary components in order to maintain the firm and full outer perimeter of a layer. Filler materials are available in many forms, and are composed of nearly every known material. Some of the more common forms and materials used are jutl, cotton-polyethylene tubes, rods, or twisted film, polyvinylchcride rods or tubes, Fiberglas, nylon, and asbestos yarns. The filler material must, of course, be compatible with the rest of the cable materials used and must perform the requirements of the pertinent specification. As an example a PVC filler material would not ordinarily be used in a cable employing Teflon componente because a Teflon-type construction would be expected to have a high temperature requirement. A fibrous type filler-i.e., cotton, nylon, etc.-is most fxequently used as a core filer or to fill the larger cable interstices, because of their softness, ability to crush into place, and low cost. This is particularly tree when cables must withstand severe flexing and/or abuse. Fibrous fillers, however, have the disadvantage that they will wick moisture into the cable; twisted

,.

LENGTH OF LAY

Figure 6-3. Length of La 6.9

K
AMCP 706-125 cable construction will determine the method of color

coding.
6-6.8.1 Color Coding Mediods A few of the more common methods of color coding are: a. Color coding the primary dielectric or jacket using colored compounds.
P;TCH

DIA

b. Single, solid color extrusion, usually white, and then ink striping-using vari-colored, spiral, longitudinal, or hash mark stripes. c. Where textile braids are used, the use of vari-colored textile strands or carriers in order to weave in a colored stripe. d. The use of printed words or numbers to denote the color des-red. e. The use of a worded or numbered tape, applied spirally or longitudinally to the primary dielectric, or under the shield or sheath. 6-6.8.2 Color Code Application When using the striping method of color coding, the stripe sequence is designated as follows: a "base stripe",

Figure 6-4. Pitch Diameter polyethylene fi type fillers, if exposed, will also wick moisture into the cable. 6-6.8 COLOR CODING CONTROL AND SIGNAL CABLES The use of color coding in a cable is frequently required for circuit identification where it is impractical to electrically check both ends of the cable after installation. There are many metliodi of color coding a multiconductor cable, and in many, cases !he

I.,

RIGHT HAND LAY

LEFT HAND LAY

RIGHT HAND LAY

Figure 6-5, Contrahelical Lay

S-10

AMCP 706-125 or wide stripe, will be applied as a continuous helical stripe. The base stripe may also be the main body color of the primary insulation. The base stripe is distinguishably wider than any of the succeeding stripes in the color group. The succeeding stripes in the group are called tracer stripes. All stripes will be separated from each other, and from each group, by not less thai' the width of the succeeding stripe. >A The application of the colored stripe will be accomplished by the use of inks or materials containing pigments or dyes which are least affected by sunlight or the various plasticizers used in the manufacture of the plastic material being striped. They must remain fast under the effects of operating temperature and humidity, and be free from fading under normal operating conditions and handling. They must be impervious to abrasion during handling, be unmistakably readable under incandescent lighting, and be nonconductive. The length of "lay" of the colored stripe should be as indicated in Table 6-4. The stripe width is measured perpendicularly to the axis of the stripe. The width of the base stripe, or widest stripe, will be 0.031 in. minimum when the striping surface is 0.047 in. or larger. When the striping surface is 0.046 in. or smaller, the base stripe must be not less than 2/3 tho nominal diameter of the striping surface. The narrow, or tracer stripe, will in all cases be not less than 1/2 the width of the base stripe when single stripe coloring is used. The spacing between stripes should be not iess than twice the width of the base stripe. The color coding sequence - using numbers to designate colored stripes - is: if three stripes are required, the second narrow, or tracer, stripe is of a higher numerical wlue than the first narrow, or tracer, stripe. As an example, the numbers shown in Table 6-5 would be used as follows: A solid black wire would be number 0, a solid red wire, number 2, etc. Numerical number 92 would indicate a white insulation with a red base stripe. Numerical number 936 would indicate a white insulation, an orange base stripe, and a blue tracer stripe. A three stripe color coding would follow the same pattern, i.e., numerical number 9147 would indicate a white insulation, a brown base stripe, and tracer stripes of yellow and violet, in that order. 6-6.8.4 Specifications Standards have been set on the depth and shade of the coloring used in the striping of wire. The standards used on wire for military use are usually MIL-STD-104, MIL-STD-686,and MIL-STD-681, in which the limits for eketrical insulation colors are established. The light and dark colors, as established by these Specifications, are the extremes within which the color of the insulation must fall, when so required. The Military Specifications regarding color coding or marking are: a. MIL.STD.104 b. MILC-13777E* c. MIL-STD-686
6-6.8.3 Color Code and Related Numbers

"

Standard colors and their related numerical values should be as shown in Table 6--5.

*This specificatinn spells out color coding methods and values for cables pertinent to this specification.

TABLE 6-4 STRIPING-LAY LENGTH Diameter of Striped Surface Leigth of lay Maximum Up to 0.088 in. 0.089 in. - 0.11C in. 0.111 irn. and up

1.0 in.

1.5 in.

2.0 in.

6-11

ii

AMCP 706-125'

TABLE 6-5C
COLOR CODE AND RELATED NUMBERS* Color Number 0 1 2 3 4 5 6 7 8 9 From Ref. 6 6-6.9 CABLE BINDERS When twisting components, or goups of components, together into a completed cable over which an outer shield or sheach is to bc placed, it is important for this core to be held together so (1) the original cabled shave will be preserved, (2) the electrical properties of the component groups will not be disturbed, and (3) the outer extruded sheath material will not adhere to the inner components, making the cable nearly inflexible and vety difficilt to strip for termination. This material, or layer, is called a binder or serarator, and may be applied in various methods. The most common rr.thod utilizes a tape which must be of a material which is compatible with both the c'bed conuponcrnts and outer sheafii:, material. The more common tapes used for this purpose are polyethylene terephthalate (Mylar), polyvirylchloride (PVC), poly'ihylene, Teflon, polypropylene, silicone-impregnated glass, PVCimpregnated cotton, laminated Mylar and aluminum and Teflon-impregnated glass. Dapending upon the cabled construction, snd/or cable requirements, this tape is usually heli.aly wound with the overlap from 75 percent to open. The most common tape wrap utilizes a 50 percent overiap. The percent overlap, is determined as the amount the Jeading edge of one wrap overlaps the trailing edge of the preceding wrap, expressed as a percent of tape width. A butt wrap is where the trailing edge of one wrap just meets the leading edge of the preceding wrap, giving 100 percent coverage, but no overlap. An open wrap is where a space is left between the trailing and leading edges of the tape, giving less than 100% coverage. Another application method of a binder or separator is using a fibrous, woven or braided material, such as cotton, nylon, or glass. In some instances this method is required because of the rough surface fornied by the woven or braided binder. The rough surface offers excellent bonding qualities to the outer sheath extrusion. Normally, the braided fiber-type binder or separator is used in cables which are required to absorb heavier abusive treatment. In many instances a Mylar tape binder is used to hold the cabled components in place during manufacture since it can be aplied immediately at tie cabling machine; this application is followed by a braided fibe, separator. Color Indicated Black Brown Red Orange Yellow Green Blue Violet Gray White

6-12

E,
6-6.10 CABLE SHEATHS The overall covering of a cable is a very important feature of the overall cable design, both from a service and appearance standpoint. There are many extruidable sheatidng materials inuse today. Some of the more common materials are polyethylene, polyvinylchloride, polyckioroprene, tetrafl-.oroethylene (TFE), flunrinatedethylene propylea. (FEP), silicone rubber, natural rubber, bityl rubber, and nylon. There are varied reasons why certain materials are required, or would be chosen, for an overal! cable sheath. A few of the more conmmon reasons for a certain sheathing mateiial seiection are fleyibiity, abusive treatment protectioyn, moisture ;csistanca, underground or under water in.,talation, exposure to unusual climatcs or en-ironmenrs. weight of overall cable constructions, relative costs, etc. Fci further detailed informatic ,on physical and clectrical espects of sheathing compounds refer to Chapter 2. Shown in Table 6 -6 are some ef ,he more common sheathing materials and their properties,. 6-6.11 sHEiA'H APPLICATION There ar several methods fcr applicatinn of sheaths or outer jackets on control and signal cables. It is found, however, that the conventional extrusion method, using thermoplastics and rubber compounds is the most satisfactory and most often used. With this method the tooling is adjusted to produce a tight extrusion. The tubing method is also used. Unlike the conventional extrusion process, the tubing method does iiot impregnate the corstruction beneath the sheath, but does follow the general contour or shape of th,- underlying core. Thi method produces a slightly looser sheath construrtion than thie extrusion method. Polyester tape wraps are sometimes used as cable sheaths or jackets. Heat sealing of the wrap to produce a continuous sheath may or may not be ,equired. This of course will depend upon the environmental and mechanical conditions encountered. In most cases this tape wrap is followed by an additio~ial extruded sha-th. The method of applying "blown-on tubing" has become obsolete, except for cable harnssing. This method requires the forcing of air into a length of tubing which expands it to a p)int where the underlying core may be passed through. The air pressure is then removed and the tubing (smaller Ti than the OD of the core) allowed to return to its normal size. Th.is method is frequently used with harnesses which require many breakout poi.ns. Because

AMCP 706-125 the sheath will be broken at these breakout points, molding processes around these breakout areas are normally employed. A primary objection to this method is that the sheath is continuously under stress and, therefore, any nicks or splits will propagate down the cable length. Construction of elastomeric cable sheaths falls basically into one of two categories, i.e. reinforced or nonreinfoiced. See Table 6-7. A reinforced construction has a reinforcing layer composed of an oper braid between two layers, or walls, of sheathing compound. The two layers of sheathing compound join and vulcanize together in the open spaces between threads and adhere to the thread yarns. The most common reinforced sheath employs cotton or seine twine biaid, or a laft and right serving of reinforcing agent. The construction czi be seen pictured in Fig. 6-6. As noted in Fig. 6-6 the reinforcement would be the seine twine braid. 6-6.12 ARMOR Because of the extreme abuse a cable is required to absorb during or after install. lion. more protection. is often required than any sheath alone can give. In this case an overall armor i, applied. Since the armor ,hill be continuously exposed to the elements, it must not rust or corrode under any condition or climate; it nmut absorb unusual punishment without t-pture or fraying and still afford protection to the outer sheath; and it must be flexible enough to be usable in any normal installation. The armor on a cable is usually constructed utilizing one or more of the following: aluminum, stainless steel, galvanized steel, or beryllium.copper. The armor may be in a braided form, serving in either single or double lqyer, or in a solid tube (smooth or corrugated). When aluminum braid is used, it should be painted with an aluminum paint to prevent oxidation and deterioration of the aluminum strands. It is not considered practical to apply armor to cables of less than 03 in. in diameter. It is recommended that a #28 AWG wire strand be used to construct the armor braid. When employing aluminum armor and paint, it is very important that the aluminum paint chosen be chemically compatible with the baderlying sheath material u:ed. The characteristics of an armor, such as percent coverage and braid angle, are calculated using the same formula-i.e., Eq. 1-4-as any inner shield. 6-13

L
-

4!

AMCP 7OC-125

JOL

Kw.l I3

a C14 n

03~
CIS)

0i 0
. t

U))
CD

o
-

0
-

00
LU

0~4
0

C.C4)~

o~~

~"

J.S

C4o

OF I
z C3'

o
)

o o rA

~0

~X

00-.5

tz(

"\U

AMCP 706-125

TABLE 6-7 COMMON OVERALL POLYCHLOROPRENE SHEATH-WALL THICKNESS Diameter of Cable Under Sheath, in. 0.4,5 o, less 0.426 t o 0.700 G.)01 to 1.000 1.001 to 1.500 1.501 to 2.000 2.COI & lager Minimum Sheath Thickness, in. Nonreinforced 0.040 0.050 0.070 0.090 0.11O) 0.125 Reinforced 0.090 0.090 0.110 U.123 0.Ji ,4 0.155

1
-

"

It has been found that an armor coverage of approximately 80% will give adequate physical protection to a cable under moderately heavy abusive conditions and an armor braid angle of approximately 5U "o 5,0, especially on the larger cabies, allows sz.f'cient flexibility during normal installation, For very severe abuse, as experienced in submarine telephone cable or oil well down hole cable, - double serve of very heavy steel strands, laid contrahelically with 95%-100% coverage on each layer, is used over the sheath. These strands may be up to 0.25 in. in diameter,
JACKET

6-6.13 CABLE IDENTIFICATION MARKING In most cases a cable is required to have a manufacturer's identification and cable nomenclature information as an integral part of the cable construction. This may be done by one of two basic methods: (1) tae outer sheath of the cable may be printed, using an indented marking, an ink marking or print applied longitudinally, or (2) if this is impractical because of an overall armor or unprintable sheathing material or contour, a printed tape is inserted in the cabled core or under the outer sheath. This printed tap? is generally made of a material that will conform to the cable test requirements. Printed tapes of Mylar, cotton, glass, and Teflon-impregnated glass are some of the more common types used. In add;tion to using these tapes as identification markers, it sometimes becomes necessary for a user to have a serially

OUTER SEINE TWINE

CORE

numbered foot--,-e m'avrer tape insertced

COTTON BRAID BINDER

for installation convenience. These tapes usually have a width of 1/8 in. They are also manufactured in 3/16 in. and 1/4 in. widths although any width down to 1/16 in. can be obtained with the desired printed information.

into thec cable'ab

Figure 6- 6. Reinforced Sheath Configuration

With some materials, such as PVC, the indent method is sometimes injurious to the sheath because the depth of the letter indentions onto the sheathing compound cuts the wall of the sheath down to the

Ii6)15

iI
AMCP 706-125

fJ

depth of the embossing and thus may affect cold bend properties.
6-7 MULTICONDUCTOR CABLE TESTING

A typical example of a twisted pair, multiconductor complex is shown in Table 6-8. The cable construction shown in this table cmploys the lay
varianca method, with unidirectional lay, which may

6-7.1 CABLE CROSS-TALK 6 cableist i auicnctor hCrss-talk in a multiconductor cable is the phenomenon of any conductor, or group of conductors, having sufficient electrical or --agnetic
coupling to induce the signal into another conductor, or group of conductors, adjacent to it. The solution to

be accomplished on covcntional twisting machines and is as effective as the opposite direction l3y method in cables employing two or more layers. Control cables usually do not have cross-talk requirements.
5-7.2 TESTS AND TEST 'ETHODS The requirenekrs of a multiconductor cable dictat

]
.

this type of problem is to either contain the signal or to insure that the ginduced voltages will cancel as much cs possible within the given conductor, or group of conductors. With single condt ctors this is nccomplished by the application of a shield over the individual conductor. Shielding is considered in Chapter 5. The cross-talk, or leakage, in a cable component becomes increasingly worse with the increase in frequency and/or level of the inducing signal. Adequate cross-talk reduction may frequently be

the tests needed. Listed are the t're common tests called for in multiconductoi cable construction. A discussion of the te.ts, methods, aad the effects they have on constructional design engineering follows. 6-7.3 MULTICONJDUCTOR CABLE TESTS Tests to be considered are: a. Cold Bend

achieved in paired constructions without the expense

of shielding by carefully controlling capacitance unbalance, and by varying the lay of adjacent twisted components within any layer and from layer to layer. Changing the direction of lay from right hand lay to left hand lay in adjacent components within any one
layer also is helpful.

b. Impact
c. Torque d. Twist
e. Bend

TABLE 6-8

STANDARD CONSTRUCTION OF TWISTED PAIR MUL,' LAYER CABLE FOR REDUCTION OF CROSS-TALK Pair Location
Core

Pair No.
1 2 3
4 - 6*- 8 - 10 5.-7-9-11 12 13 - 15 - 17 - 19 - 21 - 23 - 25 14 - 16 - 1F -70 -22 - 24 26

Right Hand Lay, in.

2.00 2.50 3.00
2.75 2.25 3.25 2.50 2.00 3.50

First Layer

Second Layer

6-16

I..

AMCP 706-125
f. Dielectric (AC and DC) 6-7.3.2 Impact Test

g. Insulation Resistance h. Capacitance (Mutual and Unbalance) i. Abri.sion Resistnce j. Tensile or Bieaking Strengths k. Cross-tak j-7.3.1 Cold Bend Test A cold bend test is performed on a cable to determine if all materials used are compatible with the lowest operating temperature required, and whethel processing has been correct, i.e., is the cable structurally engineered to withstand a bend at the required lowest operating temperature, and what effect will the sub-zero temperatures and severe bendi"g have :n the sable electrically? The majority of cold bend tests require a mandrel diameter that is ten times ihe overall cable diameter. The cable is usually arvanged so that one end Fs attached to a mandrel and a otefully specified weight attached to the free end of the cable. This weight is enough to keep the free end of the cable straight at the required temperature while *he cabl3 is undergoing the bend test. The attached end of the cable should be wound at least one turn op the mandrel prior to reducing the temperature to be sure of a smooth start. It is important to remember, when evaluating ccld bend test results, that data received on cable cold bends are from a controlled be!nding rate. Sudden sharp bends, or rapid unreeling of cable at lowered temperatu.es, may shatter a cable that has passed the cold bend test at identical temnperateres under controlled speeds. It is essential, for test reproductibdity,. that ilhe bending rates be maintained by power driven apparatus. Hand bending is useless because of the variability of rate. It is necessary, then, to specify the greatest anticipated benu rAte and incorporat this in the cold bend test required. Bending must also be conducted within the cold chamber without opering the doors. A very slight exposue to a room temperature draft invalidates the test; this exposure causes the surface of the wire to warm and greatly 1 mproves the cable's chance of passing.

The impact test-whether performed at room t,.znperature, elevated temperatures, or loweied temperatures-is designed to show the result of a continuous, measured impact on the cable materials, and how this concrolled impact affects a cable clertrically. In some cases an impact on a cable would show no injurious effects to the cable sheath but, with improper irternal construction, could break or damage one or more of the internal components, causing electrical short circuits or conductor opens due to internal component damage. A typical impact test jig is pictured in Fig. 6-7. This test simulates vehicular traffic over a cable, backfilling with stones over directly buried cable, and other physical abulse. As noted in Fig. 6-7, a cable design is engineered to withstand a certain specified weight in pouids, dropping a specified distance, and impacting a specified area at a specified rate of impacts per minute. During impact all cable conductors, including any inner or outer metallic shields, are electrically tied in series and a specified electrical load imposed throughout the cable configuration. The testing apparatus is equipped with a courter, and any conductor or shield short or open circuit automatically stops the impact testing apparatus, thowing exactly how many impacts were absorbed in the given area before breakdown. 6-7.3.3 Torque
Test

Torque tests and twist tests are very similar in technique, the only differen,.e being the information so"3ht. A torque test is designed to find the force required to twist or bend a cable at a specified temperature, usually the lowest temperature at which the cable will be handled. The test data sought are how flexible a cable construction is at a given teamperature. This is generally accomplished by use of a torque wrench attached to a mandrel end outside the environmental test chamber, with the cable arranged as for a cold bend test. This test must be run through once at a specified temperature, without the cable, to determine the amount of friction of the apparatus. 6-7.3.4 Twist Test
.

A twist test is concerned with how many twists ofagiven nature can be absorbed by a specimen before 6-17

4---

-------

r)

AMCP 706-125

CABLE SPECIMEN

CONTROLLED RADIUS

1
C

VISE TYPE CLAMP ONE EACH SIDE OF IMPACT AREA

FREE RUNNING ARM MOTOR DRIVEN ARM

CABLE SPECIMEN
ELECTRICAL MONITOR

Figure 6-7. Impact Tett Fixture

aestruction. This test i, accomplished by attaching a 1800 twist (900 from center) and a 1800 bend'

givej wcigh. to the free end of the specimen, and twisting the weight, which in turn rotates one end of the specimen a given amount with respect to the other end. Fig. 6-8 shows a common twist apparatus which is especially severe because bending occurs over the top sheave, while twisting occurs between the sheave and the weight. As can be seen by Fig. 6-8, the weight slides a p.:edetermined distance at a given rate, inflicting both a
8.18

simultaneously. During this test voltage is imposed between all conductors and slields, with alternate wires tied electrically in series, to determine when conductor failur- or short between conductors occurs. This test may also be conducted at any required temperature. 6-7.3.5 Bend Test The majority of multiconductor flex tests are run on the basis of a 900 bend in one direction and a 900

(
____________________

II"
AMCP 706-125

!.

VCABLE
SPECIMEN

1!/

WEIUHT

MOTOR DRIVEN

Figure 6-8. Twist Test Fixture

bend in the opposite direction. This seoies of bends, or flexes, constitutes one cycle. This test is used to ascertain how many extreme bends a cable construction will absorb before destruction. The first deteriorations likely to appear are conductor breakage or sheath cracking. Shown in Fig. 6-9 is a typical 900 bend test fixture. A combinati'u of twist test and bend test very well simulates actual handling of portable cable in the field where frequnt reeling and unreeling with the ilherent kinking and pulling occur. 6-7.36 Dielectric and Pulse Dielectric Tea Dielectric tests should be given to all completed cables and componefnts in the course of quality assurance procedures. There are numerous methods of applying either alternating (AC) or direct (DC) voltage to a specimen, dependung on the configuration. 6-19

__

_ _ _ _ _ _ _

_1

j
11 I

AMCP "0-125(

... ..................

WHE

LA~REACBE58n

STANDARD LENGTH 45 in.

TEST SPECIMEN

RADIUS INSERT LARGE DIA CABLE 5/8 in. RAD It 3/8in. RAD SMALL 1

LB 20 25 30 35 40 45 50

CIR. MIL. AREA 14,000 17,500 21,000 24,500 28,000 31,000 35,000

Figure 6-9. Ninet-dogre Bend Test Fixture . If a cable hs no shield, or outer conductor, the
specimen" may be immersed in water and voltage applied between the conductor and water, using titr water as a ground potential. With a shielded wire the voltage is applied between conductor and shield,

generally using the shicld an a ground potential. In a

two-conductor pair, voltage is applied from conductor to conductor. If a shield is required, voltage is then applied from conductor to conductor and each conductor to shield, again using the shield as ground

6-20

AMCP 706125

potential. The voltage and length of test vary with different specifications. A general rule of thumb for most dielectric applications is a 60 Hz, alternating te t voltage of twice sated voltage plus 1000 volts. Direct current test voltage? are generally from 2 to 5 times the ins alternating voltages, depending on the material used.

A recently devised test method, which is a 100 percent substitute for tank testing, is the pulse dielectric test method. This new dielectric test method is used on all unshielded wires vp to appioximately 0.375 in. in diameter. This 'lislectric test may also be useful in testing for Paws in the outer jacket of the coaxial type component where the coaxial component diameter is no larger than 0.375 in. This test procedure has been incorporated in MIL-C-13777E, and is expected to be included hi other pertinent specifications very shortly. The pulse dielectric test fixture is shown in Fig. 6-10.

The wav form of the voltage consists of a sharp rise pulse followed by a damped wave train. The pulse repetition rate is such that at least three pulses shall occur while any : ortion of the wire specimen is within the electrode; this iactor governs the speed of the wirreeling through die -lectrode. The equipment includes a fault finding ap, aratus which, in case of failare, automatically shuts )ff the high voltage, stops reeling mechanism, and gives a visible indication of failure. It has been ascertained that this metsod of test has many advaptages over the tank test method. Among these advantages are: a. The testing is done as a final operation, at either cabling or spooliag, prior to shipment, and not as an extra operation. This reduces costs, facilitates eas.e and spee' of manufacture, and, due to the elimination of

/5/ /
.. *.

fELECTRODE

'S.'.

152
SECTION UNIT ACPOSS

' '/

/"-r

, ""I1 I

.I

I
BODY

LUCITE BODY

' JJ

!1/2

-.--

HIGH VOLTAGE LEAD

SECTION ALONG LENGTH OF ELECTRODE
UNIT

f1

Figure 6-10. Pulse Dielectric Test Fixture

6-21

AMCP 706-125 reeling and unreeling, assures the high quality of the win just prior to use or shipment. b.When test , a reel of wire in tank test, and when a dielectr'- failure occurs, the resulting sudden power surge emanating from the failure through the insulation has a tendency to damage adjacent layers of wire. This proves costly in time and material. ThisD disadvantage is overcome using the pulse dielectric test rmethod, c. The pulse dielectric method does not destroy the conductor or insulation in the flaw, or failure, area, therefore, this area can be examined and the cause of the flaw determined and consequently eliminated or repaired. This is especialy valuable if certain predetermined lhngths of wire are required. d. Water is not used, eliminating the wicking of water up into the conductor and possible conductor corrosion. 6-7.3.7 Insulation Resistance Test An intuiation resistance test ,s a method of determinag the loss of a given electrical charge through a, ipsulation, whether it be a primary insulation or an outer sheath. Insulation resistance is measured by enclosing the insulated conductor, or conductors, within a conducting material (shield, water, etc.) in intimate contact with the conductor intulation, and measuring the leakage current between the center conductor and the conducting material. Since the insulation resistance consists of many( parallel paths, increasing the length decreases the insulation resistance; and increasing the outer diameter of the insulation increases the resistano, since the leakage path is increased. To establish a value for insulation r.-sistanco R Eq. 6-2 may be used. m where D = outer diani... -of insulation d = inner diameter of insulation *K =resistivity constant for each insulation Insulation resistance is normally determined by a direct measurement, using a high quality megohmeter, with voltage from 200 to 500 volts DC. Results are given in megohm-1000 ft from the following formula. rxL (6-3) R= r
1000
*

where R = insulation resistance, megohm-1000 ft r = megohuneter reading, megohm L = lcn-gt of specimen, ft

*It is general practice to use the constant K 'isted in Table 6-9
lo determin- imulation resistance.

TABLE 6-9 ELECTRICAL CONSTANTS-INSULATION MATERIALS Resistivity Constant K for lsulation Material 950 2000 10,000 500 20,000 106 30,000

Insulating Material Rubber, Code Grade Rubber, ASTM-D-755 Rubber, Bitvl Polyvinylchloride Polyethylene Tetrafluoroethylene (Teflon) Monoclorotrifluoroethylene (Kel-F)

Dielectric Constant e 4-6 3.5 -5.5 2.4 3.5 - 6.0 2.3 2.0 2.3 - 3.0

6-22

ID

AMCP 706-125

a good quality control check on material This test is used, the value set for the requirement being a function of the mnsuletinq compound. With the exception of rubber insulations, the test value is us, ally far in excess of circuit requirements. In materials having polar iigredients, such as rubber and PVC, a factor of 2 or 3 difference on caf'erent material batches is common, and changes under one order of magnitude are barely significant. The ,rompounds are also very tem.c rature sensitive tid measurements must be made at the specified temperature. 6-7.3.8 Measuring Capacitance in a Multiconductor Cabie In the measurement of capacitance, in a multiconductor cable, there are many methods of taking the measurements, depending on the information desired and the cable configuration. Capacitance of a single, shielded conductor is explained in Chapter 5, "Coaxial Cable." In the measurement of multiconductor cables; direct capacitance, mutual capacitance, capacitance uniformity, and capacitance unbalance may be important depending on the application. Fig. 6-11 illustrates the capacitances in a pair within a multiconductor configuration. Referring to Fig. 6-11: a. 1C3 represents the direct capacitance of the pair. b. Mutual capacitance = C3 in parallel with C 1 + C2 in series, and is the actual capacitance seen by the circuit, unless C, + C2 are grounded out. Direct capacitance can be measured using CA, CB, and CC by Eq. 6-4. (C
3

C3

Figure 6-11. Capacitanceofa Pair (Schematic) Direct measurement using guarded bridge Pircuit may aLo be utilized. The mutual capacitance C. on this type cable would be measured on each pair individually. The measurements would be taken as follows, using Eq. 6-5.

)=
Cm
where

c + Cb)

(6-5)

C,

capacitance between the No. 1 conductor of a pair, and the No. 2 conductor of a pair tied to all other conductors in the cable. capacitance between No. 2 conductor of a pair, and the No. 1 conductor of a pair ted all other conductors in cable.

Cb

-to 2 Cc

where (in Fig. 6-ii1

capacitance between No. I and No. 2 conductors tied together, and all other corductors in cable. Capacitance unbalance should be low to prevent

CA =C1 +C3
CB =C2 +C3 C= C + C2

interference or cross-talk between circuits of multipair cable. The capacitance unbalance of a paired conductor cable shall be measured as the unbalance of any selected pair against any adjacent pifr; this includes

CcCIC 2

)V

6-23

'

t
AMCP 706-12.5 botween pairs, layer-to-laysr. adjacent to each other, and of condlictors in this case are left out of the circuit, or hanging open. The same method would be used reguading CrC, CMD, and CAC. When the cable confi mration has an overall metallic shield placed over the cabled conductors and under the outer sheath, the capacitance urbalance, pair-to-shield, is measured as in Fig. 6-13. Note: Direct capacitance is defined in Amaricar Standard Definition of Electrical Terms (1941 - Def. 05.15.080) The two conductors of a pair are represented by a andb in Fig. 6-13. Cag = direct capacit' ico between a a id.shield Cbg Cap direct capacitance between b and shield dircct capacitance between a and all other pairs

i)

The capacitance involved and definition pair-to-pair unbalance are shown in Fig. 6-12.

For insulated conductors, lstters A ai-d B in Fig. 6-12 represent the two conductors of a pair, C and D the two conductors of any other adjacei;t pair. The capacitances CAC, CAD, CBC, CBD, and CCD are direct capacitances. Capacitances CA, CBg, C, and CDg, 'ire direct and D, capacitances between wires A, B, C 3 respectiveiy, and the other three conduct-rs groui- ed.

The pair-to-pair capacitance unbalance C. for these measurements is deterrrdned using Eq. 6-6. Cu= (CAD + CBC)
-

(CAC + cBD)

(6-6)

CAD represents the capacitance from wire A in one pair, to wire D in the adjacent pair only, all other

"

CAg

CAC CABIg

CAD

tCBC

It
Cg

Ii >
CBD

Figure 6-12. Pair-to-pair Capacitance Unbalance (Schematic)

6-24(

jAMCP
CONNECTED TOGE fHERt eBUT NOT GROUNDED.
ALL (CTHER PAIRF

1
706-125

I.Cap
a

b
Cab
b

GROUNDED~
SHIELD

Figure 6-13. Pair-to-shield Capacitance Unbalance (Schemathd)

=

Cbp

direct %;apacitance between b and all other pairs

Cc

= capacitance between No. 1 and No. 2 conductors tied together, md shield.

CPg

direc. capacitance between all othr pairs and =shields

6-7.3.9 Abrasion Resistance The abrasion resistance of a wire or cable is another way of determining how much abrasive abuse the insulation or sheath will absorb before destruction or failure under the specified conditions. There are three commoni nethods for determining cable abrasion resistaxce:

Then. pair-to-shield capacitance unbalance is determniued as Ca - Cbg. For pair-to-par unbalancw, the mna.urement is made exactly as for unshielded pair to pair, except the shield is connected to the grounded conductors in all cases. If the cable is constructed of

twisted, slhelded, sheathed pairs, the aame holds true in mesuring mutual capacitance C,, except the shield is substituted for all other pairs !n the cable as follows: Cm
where Ca = capacitance between No. 1 conductor, and No. 2 conductor tied to shield. = capaci,V.e between No. 2 conductor, and No, I conductor tied to shield, .v 3 4

1.A machine utilizing a moving sandpaper strip applying the abra.ive action. This method is described
ii. MIL-T-5438 wid ihown in Fig 6-14.

2.'1he secoqi wf.hed ;. a ,hccl cimploying tungsten carbide roi. is the abrasive, the rods being mounted in a rotai q w'eel, or squirrel cage configuration, as shown i'Fig. 6-15. 3. The third method is ,he scrape test. This method utilizes a metal rod of specified diameter, the diameter being dependent on the cable diameter under test. The rod is laid flat and in the same plane as the specimen, 6-25

Cb

AMCP'706-125

(
SPECIMEN-.* WI REP S O
7

CNUTV

-NDUCWIE

GROUND
Figure 6-14. Sandpaper Abrasion Test Apparatus but at right angles to the specimen. This rod is then moved forward and backward ovcr the specimen surface a specified distance at a given rate under a specified load; or, in other words, "scrnped" along the surface of the insulation. This test is usually performed to test ihe durability of striping or ink printing, As c=n be seen from Fig. o-14, the sandpaper drags under the cable specimen, at a given speed, while the specimcn is pressed down over a given area by a given force on the moving sandpaper belt. The sandpaper has conductive painted strips spaced evenly over the surface. When the sandpaper wears through the insulation, and the conductive strip comes in contact with the conductor, it breaks an electrical circuit, thus stopping the machine and indicating the number of inches of sandpaper needed to abrade th.ough the insulation. As can be seen in Pig. 6-15, the squirrel cage nethod is quite similar to the sandpaper method, -xcept the rods act as the abrasive. Here again the wheel is driven at a given speed and the cable specinpen is held with given force onto he abrasive rod surface. When break-throgh occurs, a circuit is broken causing the fixture to stop. A counter counts the wheel revolutions. Usually, the sandpaper test fixture and scrape abrader are used forsmaller single conductors or shielded and jacketed components, whereas the squirrel cal. type is used on larger configurations where sheath abrasion resistance is the only in;'ormation sought.

II,

I
I

Most of these abrasion tests do not simulate exactly the service conditions, but do provide a basis for comparative measurements. The sandpap.r abrasion test of MIL-T-5438, utilizing the #0000 grit paper, does not simulaie use conditions to any degree; but with #.00 grit aluminum oxide paper-as used in M1lW-27300, MIL-W-22759, and others-the test is simi.ar to wire being abraded on anodized aluminum or oxidized aluminum surfaces, as in an airplane wiring bundle, and is therefore much loser to use conditions than i: the #0000 grit paper. The scrape abrasion tester is the closest to ust conditio,s because it simulates d-agging wire past a chassis edge or over aircraft structural members. Most abra.:ion of wire cccurs in t:-s fashion during.installation, rather than in and later if the installation terlhniques are "operation, Lni, roper

:-626

6-2

AMCP 706-125

CABLE

NONCON/UCTIVE MATERIAL

SPECIMEN CLAMP Gr OUNDED

TO CABLE CONDUCTOR

SCARNDRIVE

MOTOR DRIVEN

Figure 6-15. Tungsten Carbide Rod Abrasion Test Apparatus

6-7.3.10 Tensile Strength of Multiconductor Cable In considering the tensile, or breaking, strength of a multiconductor cable, many problems are faced by the design engineer. It can be said of this type test that, as in a chain, the weakest link will break first. In other words it is entirely possible that, with improper engineering design, the innermost conductor of a multiconductor cable could break first under a tensile load even though the load be applied to the outer sheath. Usually, in a cable that is required to withstand severe tensile load. it is best to insert a strength member such as a stainless steel stranded rope as the center core or, in a woven or served configration, incorporated into the outer sheath. This is much the ,,s a telephone aerial cable which uses a carrier for strength in installation. Steel strands incorporated within the stranded copper conductor component, such as is required in MIL-C.13777, is another good cable reknforcing method. An alternate method utilizes a

braided, strong, metal shield over the entire cable Core, incorrorated as a sheath reinforcement, or applied as an overall armor. It must be noted, wtl.n applying a shield for tensile strength purposes, that the braid angle should be kept extremely low so as not to crush or stretch the cable excessively under tensile load. In testing cables for tensile strength or breaking strength, the test method used is a very important factor in order to gain correct data. Shown in Fig. 6-16 are the correct and incorrect methods of test. As noted by Fig. 6-16, the incorrect method uses a clamp on each cable end; this allows sheath slippage and great force on the clamps which pull unevenly on the cable core. The correct method, as shown, has the cable ends clamped to the cable itself and around a manzlrel, allowing most of the force, or pull, to be exacted in the center of the cable specimen and away from the ends thus allowing equal force to be exerted around the entire cable perimeter.

fsame

j:

6-27

AMCP 706-125
INCORRECT CORRECT(

I.

I
FORCE

RCE F

CABLECAL CABLE CLAMP SPECIMEN SPCIMLEN SEIE

FORCE

0j

FORCE(

Figure 6-16. Tensile or Breaking Strength Test M4ethods

AMD" 706-125

REFERENCES

1. American Standard Definition of Electrical Terms, Definition 05.15.080, "Direct Capacitance". 2. MIL.C-3 432, Cable and Wire, Electrical (Powver and Control, Flexible and Extra flexible, 300 and 600 volts). 3. MIL,.C.13777E, Cable, Special Purpose, Electrical 4. MIL.C-27072, Cable, Special Purpose, Electrical, Multi-Conductor. 5. MIL-STD-104, Limits for Electrical Insulation Color.

7. MIL-STD.686, Cable and Cord, Electrical, Identification Marking and Color Coding Of 8. MIL.T-S438, Tester, Abrasion, Electrical Cable 9. MIL-W-16878D, Wire, Electrical, Insulared, High Temperature (Navy). 10. MIL.W-22759, Wire, Electrical, Fluorocarbon Insulated, Coppcr 11, MIL-W-27300, Wire, Electrical, Polytetrafluoroethylene Insulated, Copper, 600 Volt. 12. MIL.C-55021, Cables, Electrical Twisted Pair and Tiples, Internal Hook-Up, General Specification

[Application of Hook-Up and Lead Wire.

6. 1IL.TD.8 Idntiicaion Codng nd 6. ML-SD-61, denifictio Coingand

For.

5.29/C-30

AMCP 706-125

3)
CHAPTER 7 POWER CABLES

7-1 INTRODUCTION 7-1.1 USAGE Power cables are named for their function - the transmission of large quantities of electrical power. Further classifications often include the voltage rating; the number of conductors; the specific application, i.e., switchboard, lighting, etc.; and environmental conditions of use, i.e., portable, light-duty, heavy-duty, etc. 7-1.2 GENERAL DESIGN FACTORS Most military power cables are designed for use at low voltages (up to 600 volts). The current may be DC or low frequency AC (usually not over 60 Hz).* In general, conductor sizes for military, primary power cables fall within the range of #10 AVG to #40 AWG.

7-2.1 CONDUCTOR Thcre are three major decisions affecting the selection of the conductor for a power cable: (1) the conductor material, (2) the conductor size, and (3) the conductor form, i.e., whether solid or stranded, and if stranded, the number of strands. 7-2.1.1 Conductor Material Copper is the most commonly used conductor material for power cables, although aluminum has found some use in application where flex requirements are minimal. 7-2.1.2 Conductor Size There are three factors to

be considered in

7-2 MAJOR CONSTRUCTIONAL FACTORS

DESIGN

Power cables have three basic components; namely a condictor, insulation, and a protective covering or sheath. The factors to be.considered in arriving at a correct choice of each of these basic components, in order to design a useful power cable for a given application, are discussed in this chapter. For the sake of simplicity, eacih component will be considered Eeparately, although it mist be realized that there may be instances of interdependence or incompatibility which must be comprorsed in the final de3ignFor aircraft and shipboard cable, some power circuits are operated from 400 to 1600 Hz. The basic design considerations remain the same as with 60 'Tz, except that in larger conductors ihe current-carrying capLities may need to be derated. At this writing isfrequencies. no agreement as to the degree of derating required at there higher

determining conductor size: physical strength, required current-carrying capacity, and allowable voltage drop or resistance. Voltage drop is discussed in some detail in par. 7-4. Physical strength, as a criterion of conductor size, requires that the conductor be large enough to withstand the forces to be encountered in installation and service. Current-carrying capacity is determined by the electrical resistance of the conductor, the maximum allowable temperature for the insulation, and the ability of the installed system to dissipate heat. Chapter 4 lists methods for calculating current-carrying capacity vs temperature rise, and may be utiliLed to determine the current-carrying capacities of power cable. The temperature limits on insulated materials are defined in Chapter 2. Normally, tho conductor is sized to facilitate efficient ttransmission with accptablc cnergy loss due to resistance heating. The referenced tables will indicate ibe temperatures at which various cables cu

can be expected to operate under the given current

loading aad environment. Type of installation is a factor because of its influence on the ability of the cable to dissipate heat. Tables 7-1 through 7-11 showI

I
E

.[

I.

.. . ...

AMCP 706.121 the current-carrying capacities of the principal sizes and types of power cables under various conditions of environment 7-2.1.3 Corductor Form In the size'range normally used in power cables, conductors must be stranded to be flexible enough for installation. Flexibility is of particular importance for portable cables and field cables which must be repeatedly reeled out and re-reeled during their use. Generally speaking, the finer the strand that is used to ,ueke up the conductor, the more flexible the finished conductor will be. However, the finer the strand, the more costly the conductor is to manufacture. Also, in an insulated cable, the conductor contributes only a portion of the flexibility (or stiffness) to the total cable. There is a point beyond whirh the insulation stiffness becomes a contributing factor and a more flexible conductor stranding will make very little practical difference in the flexibility of the complete cable. Tables 7-12 through 7-14 list the commonly accepted stiandings for "flexible" and the accepted "extra flexible" copper conductors, and strandings for aluminum conductors. 7-2.2 INSULATION The most important properties of insulation material used in 600.volt rms military power cables are the mechanical properties which contribute to thtoughness and flexibility of the cable. For the ultimate in flexibility, elastomers such as SBR, butyl rubber, and EPR are the usual selections. :'.wever, cross-linked polyethylene or polyethylene witti a protective jacket of nylon are being utilized as inaulations. Polyvinylchloride compounds are useful in some applications. For elevated temperature environments, silicone rubber, TFE, and FEP have been utilized as primary insulation in special power cables. Generally speaking, in order to assure adequate mechanical protection, a minimum wall thickness is specified as w.ll as minimum physical propertlis of the insulation, Tables 7-15 and 7-16 list typical physical properties specified for the most commoitly used insulation materials and the wall thicknesses recommended for military power cables. Although some consideration must be given to the electrical properties of tha insulation, it should be recognized that at the low voltage levels and low frequencies under discussion here, such parameters as 7-2 corona resistance, dielectric constant, and voltage bre3kdown are of relatively minor importance to the overall performance of the cable. 7-2.3 SHEATH Polychloroprene compounds are by far the most commonly used sheath or jacket materials. Some use is also made of chlorosufonated polyethylene, PVC, polyurethane polymers, ethylenepropylene rubber, and SBR for this purpose. Butyl rubber has been used where resistance to certain missile fuels is a requirement Table 7-17 lists the requirements normally specified for sheath compounds. Table 7-18 gives a guide to the wall thickness considered satisfactory for polychloroprene sheaths of power cables. Reference is made to Charter 2 for further information on the properties of insulating, jacketing, and sheathing materials. 7-3 MISCELLANEOUS CONSTRUCTIONAL DESIGN FACTORS 7-3.1 SHIELDS Shielding is not generally required for voltage stress distribution or current leakage drain in 600-volt rms power cables. Occasionally, shielding may be specified as a barrier to radio frequency interference outside the cable, or in the case where switching transients may result in surge voltages in excess of 2000 volts rms and require external grounding for safety. 7-3.2 CABLING Reference is made to Chapters 6 and 8 for a discussion of good cabling practices. 7-3.3 GROL'ID WIRES It is common practice to incorporate ground wires where required, directly into the power cable, very much as though they were added conductors to multiconductor cable. In some instances, ground wires are the same size as the power conductors. However, in order to reduce cost, weight, and size, it is general practice to use somewhat smaller gage conductors as ground wires than those used as the power lines. Table 7-19 shows the minimum recommended size of ground wires to be utilized with given power conductors.

_ i

illll _

1_

_.

....

--

1,

AMCP 70125 In all cases, it is mandatory that the ground wires be insulated, or at least physically separated, from the other conductors in the cable. Ground wires should also be stranded as in Table 7-20 to maintain the flexibility of the finished cable. 7--4 VIf While a cable may be designed to carry the necessary amperes, and have sufficient insulation for mechanical protection, larger conductors may be required because of voltage drop due to the conductor resistance. After determining the proper cable size, it Is necesry to check the length .of run required and determine that the voltage drop will not be excemsive. it is, larger cable mut be used. Table 7-21 iows Vmximum cable length for single phase system on power cable gage which result in a voltage drop of one volt.

)7-

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AMCP 706-125

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AMCP 706-125

I f
I
Conductor

TABLE " 7-5

CURRENT-CARRYING CAPACITY IN ENCL.SED OR EXPOSED CONDUIT THREE-CONDUCTOR CABLE, 0-600 VOLTS, 0-60 Hz
op er

Temperature______________

Size, AWG# 10 8 6 4 2 1 0 00 000 0000

60

75oc
IAmperes per Conductor

90C

27 33 44 57 74 84 97 110 128 145

35 44 57 73 95 109 125 143 165 188

40 50 65 85 110 130 146 166 193 219

Correction Factors for Various Ambient Air Temperatures

10 0 C

20 C 30 0 C 40P C 50uC Assumptions: "conduits

-

158 1.41 !.22 1.00 0.71

1.36

1.25 1.13 1.00 0.85

1.27 1.18 1.10 .00 0.90

All ratings based on nonmetallic conduits. All rativs based on one isolated conduit only. Correction factors for groups of are given in Table 7-6. Load Factor: 100%. All conductors of a given 3-conductcr cable are the same size. Cc,rection factor for aluminum conductors: 0.78.

Note: 7.

II
(

V178

AMCP 70r-125

TABLE 7-6

1.

iCURRENT

RATING CORRECTION FACTORS FOR CABLES IN (VARIOUS GROUPINGS OF CONDUITS)

Number of Conduits

Horizon tally

Vertically 1 2 3 4 5 6 Note: 1.00 0.92 0.85 0.82 0.80 0.79

2 0.94 0.87 0.81 0.78 0.76 0.75

3 0.91 0.84 0.78 0.74 0.72 0.71

4 0.88 0.81 0.76 0.73 0.71 0.70

5 0.87 0.80 0.75 0.72 0.70 0.69

6 0.86 0.79 0.74 0.72 0.70 10.69

These correction factors apply only when the spacing between conduit surfaces is not greater than conduit diameter, or less than one-fourth of conduit diameter.

I.!

7-9

FII

AMCP 706-125 TArBLE 7-7 CURRENT-CARRYING CAPACITY IN AIR SINGLE-CONDUCTOR AND THREE-CONDUCTOR CABLES,0-600 VOLTS, 0-60 Hz Conductor Copper Temperature

size,
AWG#

60 0C

75C

9C
Amperes per Conductor

600C

750C
Three-Conductor

9 0C

Single-Conductor

10 8 6 4 2 1 0 00 000 0000

35 47 64 86 117 135 158 183 212 245

4A 61 83 110 150 172 202 235 273 315

50
7C 95 130 175 200 235 275 320 370

29 39 50 67 88 100 114 132 150 171

38 50 65 86 113 129 147 171 194 221

45 60 75 100 130 150 170 200 225 260

Correction Factors for Various Ambient Air Temperatures IOC 20PC 30PC 40P C 50C 1.58 1.41 1.22 1.00 0.71 1.36 1.25 1.13 1.00 0.85 1.2'7 1.18 1.10 1.00 0.90 1.58 1.41 1.22 1.00 0.71 1.36 J I5 1.13 1.00 0.85 1.27 1.18 1.10 1.00 0.90

Assumptions:

Only single, isolated cables are considered. For groups of cables see correction factors listed in Table 7-8. All conductors of 3-conductor cubles are same size. Load Factor: 100%.

Note:

Correction factor for aluminum conductors: 0.78.

-1

71
7-10

I
I
___ _ ____

-AMCP

706-125

TABLE 7-8 CURRENT RATING CORRECTION FACTORS FOR (VARIOUS GROUPINGS OF CABLES IN AIR) Number of Cables Horizontally 1 1.00 2 3 4 5 6 Note: 0.89 0.80 0.77 0.75 0.74 2 0.93 0.83 0.76 0.72 0.70 0.69 3 0.87 0.79 0.72 0.69 0.66 0.64 4 0.84 0.76 0.70 0.67 0.65 0.63 5 0.83 0.75 0.69 0.66 0.64 0.62 6 0.82 0.74 0.68 0.65 0.63 0.61

Number of Cables
Vertically

These correction factors apply only when the spacing between cables surfaces is not greater than the cable diameter, nor less than one.fourth of the cable diameter.

")

7-11

Ii..
;i .. .. . .

AMCP 706-125

TABLE 7-9 CURRENT-CARRYING CAPACITY OF CABLES BURIED DIRECTLY IN EARTH THREE SINGLE-CONDUCTOR CABLES SPACED 6 INCHES APART, BURIED 3 FEET UNDERGROUND, 0-600 VOLTS, 0-60 Hz
Conductor Siz6, AWG# 8 6 4 2 1 0 00 000
COO

Copper Temperature 600C Amperes per Conductor 70 90 115 145 165 190 220 245 280 80 105 130 170 190 220 250 280
315

75 0C

90oC

90 115 145 185 210 240 275 310

350

Correction Factors for Various Ambient Earth Temperatures 150C 200 C 250 C 30C 350C 400 C Assumption: Note: 1.06 1.00. 0.94 0.87 0.79
0.71

1.04 1.00 0.95 0.90 0.85 0.80

1.03 1.00 0.96

'1

0.93 0.89
0.85

J
(

Load Factor: I" )% Correction factor for aluminum conductors: 0.78.

7-12

AMP?7M6I25

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AMCP 706-125 TABLE 7-11 CURRENT-CARRYING CAPACITY, PORTABLE POWER CABLE RUBBER-INSULATED, RUBBER-SHEATHED Conductor Number of Conductors

Size,
AWG# 8 6 4 2 1

One..
45 60 85

Two
40 50 70 95 1 it

Three
35 50 65 90 100

Four
30 40 55 75 85

Five
25 35 45 65 75 20 30 35 55 65

Amperes per Conductor

110
130

0
00 000 0000 Assumptions:

150
175 205 235

130
150 175 200

120
135 155 180

100
115 130 150

8S
95 110 125

70
75 85 100J

Maximum conductor temperature, 60 C All conductors in given cable are the same size. Ambient temperature: 400 C. For other ambient temperatures, use the following correction factors:
0 10 C 200 C 30PC 400 C 500 C

i
Note:

1.58 1.41 1.22 1.00

0.7'

When the cab'es ar- used with one or m1t-e ;ayers on a gathering reel, the Above currentcarrying capacity should be corrccted as follows: Layers on Reel 1 2 3 4 and more Correction Factor 0.85 0.65 04 0.35

7-14

-A

______________________________

AMCP 706-125

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AMCP 706-125

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AMCP 706-125

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AMCP 706-125

TABLE 7-18 RECOMMENDED SHEATH THICKNESSES - POLYCHLOROPRENE Sheath Wall Thickness, Nominal in. Core Diameter, in. 0.125 and Under 0.126 to 0.155
0.156 to 0.219

Light-di'ty* 0.020 0.022

0.024

Medium.duty* 0.027 0.031

0.039

Heavy-duty* 0.035 0.040

0.045 ,. ,

0.220 tv 0.234 0.235 to 0.290 0.291 to 0.300 0.301 to 0A30

0.431 to 0.540

0,026 0.031 0.031 0.050

-

0.039 0.047 0.047 0.063

0.070

0.078 0.078 0.094 0.094

0.094

0.541 to 0.640 0.641 to 0.740 0.741 to 0.850 0.851 to 1.100 1.101 to 1.320 1.321 to 1.550

0.078 0.094 0.109

0.109 0.125 0.141 0.156

0.172

I
--

0.125
0.156

j
-

0.172

0.188 0.203

"

1.551 to 1.820

Note:

K
,

Double-layer sheaths shall be used on cables who z Eheath wall thickness, as specified, is 0.109 hi. or over. Such double-layer sheaths should be applied in two concentric layers so cured or vulcanized that they are strongly bonded together; the cut r .yer to be at le,of ^50% the t thickc:^.._ A .^:.1 . . . , of an open braid, or two layers applied in reverse directions, of seine twine, or the equivalent, shall be provided between the layers of the sheath.

SSee note inTable 7-16.

7-21

AMCP 706-125

TABLE 7-19

'iV
Conductor

SIZE OF GROUND WIRES, ANNEALED COPPER Nurnber of Conductors

Size,

Two
10 10 8 6 5 4 3 2

Three _Four _
12 10 8 8 7 6 5 4 12 12 10 9 8 7 6 5 "!

AWG# 8 6 4 2 1 0 00 000

Min Ground Wire Size, AWG

Vd

ooo

II
00 17 3.~ 4

II
7-22

AMCP 706.125

TABLE 7-20 CONSTRUCTIONAL DETAILS OF ANNEALED COPPER GROUND WIRES FOR "FLEXIBLE" AND "EXTR"
Ground

FLEXIBLE" CABLE CONSTRUCTION

_

Flexible

Extra Flexible
Number of Strands Nominal Nominal Dia of Conductor Each OD, in.

Wire Size, AW"P

-

t_ _ _I__Strand,
Concentric Concentric Conceittric Conceatric Rope Concentric Concentric 19 19 7x7 7x7 7W7 19x7 19x7 0.0l8 0.0234 0.0164 0.0184 0.0206 0.0140 0.0158

'iype Stranding

Number cf Strands

Nominal Dia Nominal Conductor Type of Each Strand, in. OD, in. Stranding

12 10 9 8 " 6 5

0.092 0.117 0.148 0.166 0.185 0.210 0.237

Bunch Bunc, Bunch Rope Bunch Bunch Bunch

65 104 7x19 7x24 7x30 7x38 7x48

0.010 0.010 0.010 0.010 0.010 0.010 0.010

0.101 0.126 0.146 0.157 0.179 0.202 0.235

4
3 2 1

Concentric
Concentric Concentric Concentric

19x7
19x7 19x7 37x7

0.0177
0.0199 0.0233 0.0180

0.266
0.299 0.335 0.378

Bunch
-.-.-

7x60

0.010

0.272
-

7-23

AMCP 706-126~

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7-24(

AMCP 70M-125

TABLE 7-21 (CONT.)

(Note 4 continued) Conductor Temperature, 0 C 25 410 50 Correction Factor 1.14 U,7 1.04 1.00 0.95

6C
75

90

0.91

REFERENCES

1. MIL-C-1958, Cable, Cord, and Wire, Electrical (Shipboard Use). 2. MIL-C-3432C, Cable and Wire, Electrical (Power and Control, Flexible and Extra Flexible, 300 and 600 volts). 3. M.L-C-13777E, Cable, Spcal Purpose, F,4tricaL

4. MIL-1-393uC, Insulating and Jacketing Compounds, Electrical (For Cables, Cord: and

Wires).
5. Standard Handbook For Electricaw Engineet, McGraw-Hill Book Co., N.Y.

2/

I
AMCP 706-125

CHAPTER 8 SPECIAL PURPOSE CABLES

8-1 INTRODUCTION 8-1.1 GENERAL TYPES This chapter discusses special purpose cables, including multiconductor design and application, ignition wire, and thermoconple cables. Special purpose cables are defined as cables degigned with a specififb use or application in mind. Thtis chapter includes hybrid cables embodying principles utilized in Chapter 6, "Control and Signal Cables", and Chapter 7, "Power Cables". 8-1.2 DESIGN FACTORS This chapter discusses the following two aspects of design criteria: 1. Desirpi of cable 1.j 2. Choice of cable fo, equipment design 8-2 HYBRID CABLE DESIGN FACTORS

b. Strand selection for each a. par. 8-3.1 (See Chapter 1). (1) Strand material determination (copper, plated coppl., steel, aluminum, etc.). More than one type of strand may be desired in any one stranding; for example, steel may be used with copper within a given stranding, the steel strands giving the desired strength, the copper strands giving the desired conductivity. A bare copper stranding may incorporate a silver-platnd copper strand for circuit identification. (2) Strand AWG size selection (dependent on stranded AWG size). More than one strand AWG size may be incorporated in any one completed stranding, i.e, the steel strands used as strength members may need to be a larger AWG size for the desired strength. c. Stranding choice (See Chapter 1). (1) Stranded AWG size selection (dependent on desired resistance, current, physical strength, etc.).

(2)Type of stranding selected (concentric, The design factors of amulticonductor hybrid ca !e bunch, rope, etc.). configi'ation are essentially the same as those used for control ani signal cable (Chapter 6), except that the (3) Determine physical size of completed emphasis isplaced on those points dependent on the stranding. cable end uage. The following is a general check list used in the design of a multiconductor hybrid (4) Stranding lay (dependent on flexibility, flex complex life, etc.). 8-3 CONSTRUCTION CHECK LIST
3--3.1 BASIC INSULATED WIRES

d. Insulation selection for each of a, par. 8-3.1 (See Chapter 2). (1)Insulation material (PE, PVC, SE, TE, etc.). Note that the strand material selection may be dependent on insulation selected, or vice versa (See Chapter 1). (2) Determine insulation thickness and physical size of each bas-o insulated wire (See Chapter 2). (3) Determine thickness of nylon, or other covering, over basic insulated wire (nylon covering, or 8.1

a.Determine type and number of basic insulated wires (there may be several types within a gien component or complex). As an example, a single hybrid complex may contain any given number of hook-up wires, coaxial cables, power cable?, twitr pairs, triplicates, quads, etc., shielded or unshielded, jacketed or "injacketed, all cabled to form a round, uniform, oveizil cable.

AMCP 706-125

ibCa e. Calculate overall cable diameter. 8-3.5 CABLE IDENTIFICATION Manufacturei's identification (See Chapter 6). a. Determine what type of manufacturer's identification is required - print, embossing, tape, etc. b. Determine where manufacturer's identification is to be located within cable complex. 8-3.6 PROTECTIVE BRAID Armor (See Chapter 6). a. Determine type of armor material to be used aluminum, galvanized steel, etc. b. Calculate percent coverage and braid angle if armor is of a braided construction. c. CaicuLate overall diameter of cable. 8-4 SAMPLE HYBRID CABLE CONFIGURATION or

equal, is recommended in ;nulticonductor cable for all insulations other than Toflon and polyester tapes). Determine overall diameter of each basic wire (See Chapter 2). 8-3,2 COMI-ONENT LAY-UP Cabling (See Chapter 6). a. Determine loction of each component within overall configuration. Ideally, the hrger components will be located in the center, and each successive layer will employ progressively smaller components. This method of conductor lay-up is desirable for the two following major reasons: (1) To gain as much flexibility as possible without sharp bend damage to any component. (2) It is usually easier to obtain a well rounded, outer perimeter, thus enhancing the completed cable appearance as well as making the sheath application process easier and, in many cases, less expensive. b. Calculate the diameter of each layer and the overall construction. c. Determine the lay length and lay direction of each cabled layer.
8-3.3 CORE BINDER

Binder (See Chapter 6). a. Determine binder material to be used.

Par. 8-3 presents the basic design criteria to be considered in the design and lay.up of a typical hybrid multiconductor cable configuration. We shall now take as an example the following requirements and follow them through to cable lay.up and design,
8-4.1 SAMPLE CABLE REQUIREMENTS

a. Number of conductors total = 71 b. Determin. binder application (tape, braid, etc.). c. Calculate overall diameter over binder, 8-3.40UTEF COVERING . Sheath (See Chapter 2). a. Determine Ae-ath material to be used. b. Determine tube, etc. method of application - extrude, The 71 total conductors are to be broken up as follows: (1) 13 shielded,jacketed pairs #16 AWG C,) 4 siglcs, ushielded (3) 14 shielded, jacketed ':irgles (4) 2 singles, unshielded (5) 3 shielded, jacketed groups of five (6) 2 shielded, jacketed triples #16 AWG #16 AWG #8 AWG #16 AWG #16 AWG

c. Determine if sheath should be reinforced, d. Calculate wall thickiess.

8-I

ARMCP 706.125 (7) 1 shielded, jacketed group of four # 16 AWG 1000 complete cycles on each specimen, without failure, urlng an 85 !b weight at each cf the following temperatue.: (a) 3 specimens at -55"C (b) 3 specimens at +70C h. Minimumn overall diameter to meet other requirements. 8-4.2 SAMPLE CABLE FACTORS CONSTRUCTIONAL

Wire sizes were determined by curz-at to be carried and allowable voltage drop for required lengths of cable. Shielding is determined by :.;gnals to be carried and isolation needed.
0 b. Temperature Range: -50 to 70 C,ambient.

c. Cable Flexibility: flexibility must be maintained at -55 0 C. d. Component identification required. e. Manufactuier's identification required. f. Voltage Requirements: (1) Up to 1000 volts rms between conductors (300 volts rms test voltage). t v s t e(1) (2) Up to 300 volts rms between shields (1000 volts rms test voltage). g. Medium Mechanical Handling (Portable) (See Chapter 7). (1) Impact test (See Chapter 6). 100 complete cycles on emch specimen, without failure, using a 27.5 lb weight at each of the following temperatures:
(a) 6 specimens at -5501

The cable would be laid up as follows, with some of the more important reasons for the selection of materials. a. Selection of Strandings (Ref. Tables 1-4 and 1-6). #16 AWG: 19 strands of #29 AWG, tinplated, diameter of each strand = 0 0113 in. (a) Diameter of 19/29 stranding=0.0113 in. x S = 0.057 in. (rounded to nearest mil). From Table 1-6, diameter is 0.057 in. co b) Tinned copper is adequate for temperatures encountered arsl improves solderability over bare (2) 48 AWG: 133 strands of #29 AWG, tinned copper, diameter of each strand = 0.0113 in.
(a) Diameter of 133/29 stranding=rope

(1') 6 specimens at +70'C (2) Berl test (See Chapter 6).

stranded in 19 groups of 7 strands each =0.0113 in. x 3 = 0.0339 in x 5 =0.170 in. diameter. From Table 1-6, diameter is 0.169 in. (b) Conductors are tranded for flexibility.

1000 complete cycles on each specimen, without failure, using an 85 lb weight at each of the following temperatures: (a) 3 specimens at -55C (b) 3 specimcns at +70C (3) 7vAst test (See Chapter 6).

(c) Conductors are plated resistance.

for corrosion

b. Selection of primary Insulat'on. Polyethylene (low-density normally) was selected for both primary insulations because oi environmental temperatures and dielectric properties. c,Selection of Insulation Coverings.

[
AMCP 706-125 (1) #16 ,.MVG: All conductor insul-tions covered with extruded nylon. (2) 8 AWG" Conductor insulation covered with impregnated nylon braid. Conductor insulations are covered for physical protpction from internal cable injury such as shield end puncture, abrasion of component to component or conductor insulation to shield, and for performance under mechanical environment,
/Extruded

(c) Primary dielectric: polyethylene, diameter 0.077 in. (d) Dielectric covering: extruded nylon 0.009 in. wall, diameter 0.095 in. (e) 'Wist: two above cabled together with a 2 in. right hand lay, diameter 0.190 in. (f) Shield: 6 ends #36 AWG tinnted copper, 24 carrier, 8.2 picks/in. (g) Braid coverage: 91%, braid angle 20.2, diametet 0.212 in. (h) Jdcket: polyethylene (clear), 0.017 in. wall, diameter 0.246 in. Note Cable components will be exposed for five feet at either end, when term;.',ated. This requirement necessitated the heavy wall of protective nylon (0.009 in.) over individual components. Normally, a 0.004 in. wall is sufficient and gives adequate internal protection. ( (2) Component 2: (a) Number of conductors: 4 singles (b) AWG size: #16 (19/29) tinned copper, diameter 0.057 in. (c) Primary dielectric: polyethylene, diameter
0.077 in.
s

nylon was u !d, except where ,hysical size of the conductor diamler was prohibitive. d. Braided Shield Seleciions. (1) Shield material in all cases will be tinned copper. (2) Shields will have a minimum coverage of 75%. (3) Shields will have minimum practical braid angle (less than 350) for good flexibility and termination -qualities. e. Selection of Component Jackets. All jackets shall be polyethylene (high- or lowdensity dependent upon applications). Polyethylene was selected for jacketing because of environmental tempervture range and physical qualities (twist, bend, impact, etc.) desired in overall cable.
8-4.3 SAMP&,i CABLE LAY-UP

Witl the preceding information available, it is now possible to lay up the individual cable zomponents. 8-4.3.1 Component Construction (Refer to par. 8-') (1) Component 1: (a) Number of conductors: 13 shielded, jacketed pairs (b) AWG size: di-,rneter 0.057 in. #!6(19/29) tinned coppr

(d) Dizzlectric covering: extruded nylon 0.009 in. wall, diameter 0.095 in. (3) Component 3: (a) Number of conductors: 14 shielded, Jacketed singles (b) AWG size: diameter 0.057 in. #16 (19/29) tinned copper,

(c) Primary dielectric: polyethylene, diameter 0.077 in.

8.4

,/1

1 F

-.

AMCP 706-125

(d) Dielectric covering: ex.ruded nylon 0.009 in. wall, diameter 0.095 in. (e) Shield: Z ends #36 AWG tinned copper, 16 carrier, 9 picks/in. (f) Braid coverage: 87%, braid anglu 20A, diameter 0.117 in. 0 (g) Jacket: polyethylene (clear), 0.015 wall, diameter 0.147 in. (4) Component 4: (a) Number of conductors: 2 singles

0) Jacket. polyethylene (clear), 0.025 in. wall, diameter 0.330 in.

(6) Component 6: (a) Number of conductors: 2 shielded, jacketed groups of 3 (b) AWG size: #16 (19/29) tinned copper, diameter 0.057 in. (c) Primary dielectric: polyethylene, diameter 0.077 in. (d) Dielectric covering: extruded nylon 0.009 in. wall, diameter 0.095 in. (e) Twist: three above cabled together with a 2 in. right hand lay, diameter 0.204 in. (f) Shield: 6 ends #36 AWG tinned copper, 24 carrier, 12 picks/in. (g) Braid coverage: 87.5%, braid angle 30.70, diameter 0.251 in. (h) Jacket: polyethylene (clear), 0.072 in. wall, diameter 0.295 in. T o g
8-4.32 Component Color Coding (Refer
to

(b) AWG size: #8 (133/29) diameter 0.170 in.

tinned copper,

(c) Primary dizlcctric: polyethylene, diameter 0.230 in. (d) Dielectric covering: saturated, braided nylon fiber, diameter 0.247 in. (5) Component 5: (a) Numbe of conductors: 3 shielded, jacketed
grup o

par.

~~diameter 0.057 in.

r "

(b) AWG

siz,: #16

(19/29)

tinned copper,

84.1) With a cable of this complex nature it is mandatory io have a clearly understandable color coding for circuit identifi cation. The following is one suggestion, although others may serve as well. (i) Component 1: (a) 13 shielded, jacketed pairs. (b) Each hielded, jacketed pair shall contain I biack and I wh'i.te conductor. (c) Each shideld, jacketed pai: will contain a 1/3 in. wide x 0.001 in. thick, printed Mylar markr" tape placed longitudinally between the outer jacket and shield. This tape shall be legible through the clear outer jacket. The tape shall be printed every two inches as follows:
. Pair #1 - 1

" "'

(q) Primary dieleciric: polyethylene, diameter 0.077 in. (d) Dielectric covering: extruded nylon 0.009 in. wall, diameter 0.095 in. (e) Twist: five above cabled together with a 2.5 in. right hand lay, dihmneter 0.256 in.

.1

cotton filler in cole.

() Filler: Place one 0.075 in. farigus-resistant

(g) binder: 0.0005 in. thick x 3/4 in. wide Mylar tape wrap 507 overlap, diameter 0.258 in. (h) Shield: 8 ends #36 AWG tinned copper, 24 carrier, 8 picks/in. (i) Braid coverage: 88%, braid angle 29.10, diameter 0.280 in.

2. Pair #2 - 2 - etc. to cover the 13 pair 8-5

AMCP 706125

(2) Component 2: (a) 4 singles : (b) All coyeri. s, shall ()Eahll (c) Each ink every 2 in.

7. white primary

black stripe

3. wifite primary - yellow stripe

primary dielectrics, or dielectric 4. white primary - blue scripe be colored white. coluor hitle with k5. white primary - gray stripe conductor shall be prin',d with black (c) Each shielded, jacketed group shall contain a as follows: 1/8 in. wide x 0.001 in. thick printed Mylar marker tape placed longitudinally between the outer jacket and shield. The tape shall be lefible through the clear outer jacket. The tape shall be printed every 2 in. as follows: 1. #1 - 34 2. #2 - 35 or dielectric 3. 3 - 36

1.I. #1 - 14

2. #2

15, etc. to cover the 4 singles,

(3) Component 3: (a) 14 shielded, jacketed singles. (b) All primary dielectrics, coverings, shall be colored white.

(c) Each jacket shall be printed with black ink every 2 in. as foU,,ws: 1. #1 - 18 2. #2 - 19, etc. to cover the 14 singles. (4) Component 4: (a) 2 singles (b) Primary dielectric is clear. (c) Nylon braid shall be white. Steope (d) Extruded'nylon jacket shall be clear, jacket shall be printed with black ink Each every (e) 2 in. as follows:ollows: #1 -- 32 2.2. 2. #2 - 33
1.

(6) Component 6: (g (a) 2 shielded, jacketid groups of 3. (b) Each shielded, jacketed group of 3 shall contin conductors with white primary dielectrics, or nylon coverings, and helical ink striping as follows: 1. white primary 2. white primary - orange stripe 3. white primary - brown stripe (c) Each shielded, jacketed group shall cuntaii: a 1/8 in. wide x 0.001 in. thick printed Mylar marker placed longitudinally between the outer jacket and shield. The tape shall be legible through the clear outer jacket. The tape shall be printed every 2 in. as 1. #1-37 2-3 2 #2-38 (7) Component 7: Ashielded, jacketed group of 4 (b) The shielded, jacketed group of 4 shall contain conductos with d white primary dielectrics, or nylon coverings, and helical ink striping as follows: 1. white primary
-

o (a) 3 shielded, jacketed groups of S conductors.

(b) All primary dielectrics, or nylon coverings, white with helical ink striping as follows: j., white primary
8-6

AMCP 706-125

2. white primary - green stripe

Component 2: 4, of diameter 0.095 in.

h3.

white primary

black stripe

Component 3:14, of diameter 0.147 in.

Component 4: 2, of diameter 0.247 in. Component 5: 3, of diameter 0.330 in. Component 6: 2, of diameter 0.260 in. Component 7: 1, of diameter 0.295 in. With this information displayed in this fashion, select the group, or groups, of largest diameter components and form them in a circle as close to the center as possible. In this case these groups consist of compo. nent numbers 4, 5, 6, and 7. This configuration is shown in Fig. 8-I. As seen in Fig. 8-1, the components are laid out in a basic circle and balanced, component 5 opposite component 5, component 6 opposite component 6, etc. With this basic part of the cable laid out in this manner, the next step is mostly arrived at by trial and error, i. e., fitting in the remainder of the components as well as possible while maintaining cable balance and minimum diameter. This is made easier only by experience and common sense. The best possible solution to this particular cable is shown in Fig. 8-2. The next step is to fill all the larger cable voids with filters. This is especially necessary around the outside perimeter in o-der that a true, round perimeter will be obtained. If thus is not done, the cable -when sheathed - will have large irregularities in the sheath, making the application of the sheath difficult and presenting a very poor appearance. The placement and size of fillers in this cable will be as shown in Fig. 8-3.

4. white primary - yellow stripe (c) The shielded jacketed group shall contain a 1/8 in. wide x 0.001 in. thick printed Mylar marker tape placed longitudinally between the outer jacket and shield. The tape shall be legible through the clear outer jarciet. The tape shall be printed every 2 in. with the marking "#1 - 39." 8-4.3.3 Coponent Precabling Tests The components for the cable are now complete. It is suggested that after completion, the components be given a precabling test to preclude any faulty components from being cabled into the complete complex. This test normally consists of a few very simple control checks such as conductor continuity, voltage checks, diameter checks, color coding conformance, etc. 8-4.3.4 Cable Core Lay-up e, With the component parts completed, the next step is the calculation of cable core lay-up. The cable core, in this instance, means the cabling of rJl the componcnts out to the binder tape. The major points to keep in mind for this phase are: a. Keep larger conductors or components in as close to the center of the complex as possible, for the reasons mentioned previously in this chapter under Construction Check List, par. 8-3. b. Keep overall core diameter to a minimum,

I,

c. Distribute components throughout the complex to evenly distribute the weight, and obtain a well balanced and rounded cable. d. Cable should employ the least amount of fillers feasible. A list of component diameters and how many of each, will help in the calculation, The list could be drawn up as follows: Component 1: 13, of diameter 0.246 in.
__-_

8-4.3.5 Core Binder As noted in Fig. 8-3 a binder has been applied to the overall core, in this case the. binder is to be a 0.001 in. thick x 1.5 in. wide Mylar tape, helically wrapped with a 50% overlap. The choice of tape width is dependent on these three basic factors: 1. Core diameter 2. The speed at which the cabling is performed

AMCP 7MI,25
5

The cable core diameter, in this case, comes to 1.614 in. over the biader tape. 8-4.3.7 Core Shielding

0.330

'

The next item to consider is the application of a shield. In most cases a core of this diameter will employ a #30 AWG size (see Chapter 1) shield wire, and the while shield still will maintaining utilize a braid angle as low as feasible a good percent of coverage. The braid used in this cable construction is: 1. 9 ends of #30 AWG tinned copper wire Oem 2. 64 carrier braider . s

DIMNSIONS IN RICHES

Figure 8-1. HybddiConfiguration-Componen7t Plcemeont Placement

3. The an-.junt of overlap desired Table 8-1 is a general guide to help in the selection ftape widths for secierd iaete. iwill p d f e e i einto The thickness of tape used is entirely dependent on thecablendesign engineer's judgmet, butdsept to

When calculated, using Eq. 1-4, the braid angle is 32.70 and the coverage 88.5%. 8-4.3.8 Cable Separator The next step is application of a separator. This separator is used primarily under a neoprene or rubber sheathing material so that the sheath, when applied, strip easily from the shield and not imbed itself the shield strands. The separator also affcrs extra strength and flexibility to the overall cable structure. The separator is usually composed of a braided or

Siominimum

thickness where possible, to save weight and ed -rus material- such as cotton, glass, nylon, lower cost. The main function of this binder is to etc. - or a tape wrap such as Mylar, polyethylene, etc. maintain the cable ibrm until an outer covering, either In this sample cable a 26/2 cotton braid will be shield or sheath, can be epplied. If a shield is to be applied. The 26/2 denotes a 2-ply, 26-count cotton, and use is normally purchasedmachine wound on applied over the cabled core, the bi~ider is of some suitable for with a braiding or bobbins wrapping head. or apcoveao e typ a braidd usig We shield stray from components the protecting in value ndspunturng he uterpernleer nsuatins.When using a braided-type separator, a coverage of pciPmenan90% is desirable. Using the braid formula, Eq. 1-4, a 90% minimum coverage braid is calculated, and the 8--4.3.6 Cor C lfollowing braid is applied as a separator: With the cable laid up to this point, the diameter of the cabled core can be calculated in one of two basic methods: and the diameter I. A scale drawing can be made, measured. 2. By taking a cioss section of the cable, and addir.;g up all component plus void diameters in a straight line through the cross section. Methol I is by far the most reliable and accurate. I1.8 ends of 26/2 cotton 2. 48 carriers 3. 10 .,icks/in.14 This braid gives: 1. 91.2% coverage 2. 65.40 angle 3. 1.688 in. diameter over braid separator

! 8

--

i A
0.246
0.246

AMCP 706-125

047

0246
3

1
0.246 60.246

0.330

2
0.09 0.4 33 0.4

0.260
0.147 07017 33

0.247

2
0.A 0.147

10.295
0.246

U.147 3 01.147

0.147
30.246 0.147 6 050

0.3301

4 10.247 0.246 33 2.9 0.4 0.147

6

0.246 0.330 3 0.147 2 0.0

"4

0.246

0.246 0.246DIMENSIONS

N INCHES

Figure 8-2. Hybrid CL-onfiguration-Component Placement

8-4.3.9 Cable Sheath The method for calculating overall cable diameter follows: In Table 8-2 the polychloroprene sheath wall thickness recommended for a 1.688 in. core diameter is 0.135 in. Tuierefore, 1.688 in. core diaxneter+ 2(0.135 verll1958 dameerforced n. diameter overall in.) = 1.958 in.in.)= When determining a sheath or jacket wall thickness from a known overall diameter, calculate as follows: 1.958 in. overall sheath or jacket diameter -1.688 in. core diameter under sheath 0.270 in. total of two jacket or sheath wall thicknesses Then: 0.270 in . .35 1 in. jacket or sheath wall 2 thickness

1II

When the cable sheath is of the reinforced type, the walls are calculated similar to a nonreinforcd type reinapplying when thumb A good sheath. sheath is rule 407o of and 6075, i.e., the sheath a wall is divided by the reinforcement, leaving 40% of the total wall thickness next to the core, and 60% of the total over the reinforcement layer. The heavier portion of sheath wall is almost always on the outside to afford greater protection and abrasive resistant qualities to the cable structure. Generally, the reinforcement is of a wide open brid or serve, and can be ignored in the calculation o. the sheath wall thickness. 8-9

AMCP 706-125

D2

BINDER

FF SF F 0075 0125 F 07

~
007

009F

0 075

1 25F

0125

0 205

LI
s-4.10

DIMENSIONS IN INOHES

Figure 8-3. Hybrid Configuration-Filler Placement

caus~l ',u,.tcation

8-5 CHOICE OF CABLE FOR EQUIPMENT

DESIGN

The manufacturer's identification on t cable of this type i,"usually an ink print applied to the outside of the l, ih during the sheathing operation. If the conlo " .s such that printing is not feasble, or if an
ovein. -moris pplied, or the customer does not wish printE a suicable printed manufacturer's marker tape is longitudinally laid in, usually under the metallic shield. These tapes are discussed in Chapter 6.

With tile correct choice of cable construction to perform a certain function over a usable length of
tune, the user may be assured of elatively trouble-free operation. There are countless applications or environments that will be encountered and, therefore, countless cable configurations. For this chapter the cable choices will be broken into two broad categories: (1)

The cable construction discussed hereto will, when

completed, be as shown in Fig. 8-4.

light- or medium-duty cables and (2) heavy-duty

cables.
(

0125

F
TABLE 8-1 HELICAL WRAP TAPE WIDTH
_

AMCP 706-125 8-5.1 LIGHT- OR MEDIUM-DUTY CABLES The intended usage of this type cable is for elec-

GUtIical , SELEC1 ON GUIDE Core Diameter, in.

0.Jo 0.100 0.101 - 0250 0.251 - 0.400 0.401 - 0.750

and electronic applications in protected areas.

These cibles are flexible multiconductcr cables for use tunnels, trailers, or buildings, and in protected

_within

Minimum Tape Width, in.*

3/8 1/2 3/4 1 1-1/4 1-1/2 1-3/4 2 Aheavier 2-1/2

runways between buildings. The cables will ba used for

data transmission, audio and video signals, control power, and radio frequency signals for electronic equipment. The general construction of these cables is to omit any reinforcing agents and limit the insulations and sheath wall thicknesses to meet in use, operational demands. These cables will be small, light in weight, and less expensive than heavy-duty cables. 8-5.2 HEAVY-DUTY CABLES

0.751 - 1.000 1.001 - 1.300 1.301

-

1.750

1.751 - 2.250 2.251 and larger

Widths are for a 50%overlap of tape over specified core.

The intended usage is for iortable cables not permanently inbtalled. These cables will be laid in the open where they may ba subjected to vehicular traffic, direct burial, abuse in back filling, of shifting soil conditions caused by frost, heay pedestrian traffic, etc. For the most part these cables are. strengthened for extreme abuse by installing steel strands within the conductors, reinforcing the outer sheath, applying walls of insulation and dienthing, and, occa.

sionally, the application of ar. ovarall armor. The

majority of the cables designed for heavy duty, or

____TABLE

8-2 LI GHT- AND MEDIUM-DUTY CABLES-

AVERAGE OVERALL SHEATH WALL THICKNESSES, in.

Core Diameter, in. 0.000- 0.250 0.251 -0.500 0.501 - 1.000 1.001 - 1.500

PVC 0.025 0.040 0.065 0.085

Polyethylene 0.025 0.040 0.065 0.085

Polychloroprene 0.072 0.087 0.100 0.115

IEP
0.010 0.015 0.021 0.025

1.501 - 2.000 2.001 - 2.500 2.501 - 3.000

0.110 0.125 0.125

0.110 0.125 0.125

0.135 0.152 0.195

I8-__

. _ _

_2__

_1_

13-11I

AMCP 700-125
... _. -. . SHEATH -SE'PARATOR

SHEL
WHT 13 21 i

BIDE

Figure 8-4. Hybrid Configuration-CompletedCable ! extreme abuse, will employ a reinforced palychF'-"o,
prene sheath. Tables 8-3 through 8-5 will aid in the selection of insulation and sheath wail Thicknesses for light., meedium-, and heavy-duty cables, .6NON ORWATEBLOKCABE OSIN

types

found

in

MIL-C-915B,

MIL-C-2194,

MIL-C-23020, MIL-C-24 145, etc. The generail construc-. tion of these cables is very .,,milar to any conventional multiconductor or coaxial type cable, except for one unique difference; the nonhosing cable type is capable of withstanding water pressures from 25 psi to 3,00" psi, tlke pressure being dependent on the construction and materias. The appropriate water prssure, when

~-6 OW-OSIN ORWATRBLOK CBLE

8-6.1 GENERAL DESCRIPTION *A
8-12

applied to one open end of a cable specimen, shall allow no longitudinal passage of water through the test specimen length for this type cable
for longit.udinal hydrostatic leakage
-

special purpose cable briefly discussed in the next

few ishe aragaph ubmaineor nonhsin", cble

when testing

is five feet, and

CL

AMCP 706-125

rA
TABLE 8-3

[
I'IPolyester/
0.000 -0.100 0.01 -0.200 0.201 -0.250 0.251 - 0.500 0.501 -0.750 0.751 -1.000 --Nylon Core Diameter, in. (Extruded) 0.004 0.006 0.008

LIGHT- AND MEDIUM-DUTY CABLESAVERAGE JACKET WALL THICKNESSES FOR SHIELDED COMPONENTS, in. Nylon (Braid)
-

PVC 0.012 0.015 0.015

Polyethylene 0.012 0.015 0.015

0.020

FEP 0.008 0.010 0.012

0.015

Polyethylene Tape 0.006 0.006 0.006

0.006

C.007 .-3.007 0.007

0.020

0.030 0.040

0.030 0.040

0.020 0.025

0.006 0.006

the time of pressure application varies from two to six hours. The nonhosing properties of this cable type are accomplished by inserting a "blocking compound" in .ll air voids of the cable during manufacture. This inclides: (1) blocking the conductor stranding and then extruding the primary insulation very tightly over the blocked stranding, (2) blocking all interstices between components of a multicondutor configuration, and (3) blocking all braids, both metallic and fibrous. There must also bo an integral adherence of all insulating layer; i.e., binder to core, sheath to binder, etc. A very important purt of a waterblock cable is the selection of the blo;kng compound. This compound must be physically onipatible with all the materials found in the cable structure; it must be ':a-ible of passing all the dectrical and environxiental tests required of the cable; and, very important, it must last the required cable shelf, or service, life without losing any of the inhirent bkcking qualities for which it was ,lpH,,I. 8- 8.2 NONHOSING CABLE APPLICATIONS It, e 4pplications of the cable are for any area where th "'able may pass through a liquid - not necessarily vatey;, or wet installation - such as undexround duct work. The blocked construction of the cable prevents the internal passage of liquid through the cable caus'ig

damage to the "black box" unit being controlled by the cable, or flooding of adjacent areas if the cable is cut or damaged during use.

8-7 THERMOCOUPLE CABLES 8-7.1 INTRODUCTION When two wVres of dissimilar metal are joined together to form an electrical circuit, and when one junction is maintained at a higher temperature than the will be generated. other, an electromotive force (EMF) This EMF is due to the temperature differential between the junctures. If the circuit is closed, and as long as there iemains a temperature gradient from the "hot" to the "cold" junctions, current produced by this thermal EMF will continue to flow witin the circuit. The principles which evolve from this phenomenon provide the basis for thermoelectric thermometry. The basic factors producing the thermoelectric output of thes, thermoelechic materials can be reproducedly controlled by alloying and heat treatment of the metals involved. As a result of the degree of this control, thermocouple wires and cables have become one of the most reliable and widely used means of accurate temperature measurement.

m8-13

IJ
AMCP 706-125

TABLE 8-4 HEAVY-DUTY CABLESAVERAGE JACKET WALL THICKNESSES FOR SHIELDED COMPONENTS, in.
Core Diameter, in. 0.000 -0.100 0.101 -0.200 0.201 -0.250
0.251 ' - 0.500 0.501 -0,750 0.751 - 1.000

Nylon 0.007 0.009 0.010

-

PVC 0.015 0.018 0.018

0.024 0.034 0.045

Poly ethylene 0.015 0.018 0.018

0.024 0.034 0.045

FEP &TFE 0.010 0.015 0.015

0.021 0.025 0.030

PE Tape 0.008 0.010 0.012

0.015 0.020 0.025

TABLE 8-5
HEAVY-DUTY CABLES-

8.-4.2 GENERAL OPERATIONAL FACTORS

A thermoelectric thermometer, or thermocouple, consists essentially of a pair of dissnilar metallic -

AVERAGE OVERALL REINFORCED

SHEATH WALL THICKNESS, in.
_ _"_data.

conductors usually joined by welding. The introduction

of other materials or metals, such as in soldering,

usually results in erroneous and misleading temperature In order for the circuit to function as a thermocouple there must be a temperature difference between the "hot" and "cold" junctions, and one of the must be accurately .known in order to act as a reference point. In extending from one temperatire to the other, the conductor materials selected must span the needed temperature range or "temperature gradient". most applications the drop or rise in temperature is very abrupt, often taking place through a few inches of insulation. A typical thermocouple application is shown in Fig. 8-5. If the thermocouple wires are initially homogeneous, and remain homogeneous during service, a sharp

Core Diameter, in. . 0.000 -0.250 05 0|00temperatures 0.251 -0.500 0.501 - 1.000
1.001 - 1.500

Polychioroprene 0.092 0.102 0.120

0.140

10 -In 1.501 2.000 2.001 -2.500 2.501- 3.000 ,

0.165 0.187 0.235

8-14(

.!

AMCP 705-125

FURNACE INSULATION

NBLOCK

HEAT ZONE

-011 THEMOCLOCK

0
EX NIO
EXTENSION LEAD WIRES

PROTECTION TUBE

COLD ZONE
ROOM TEMPERATURE)

Figure 8-5. Typial Thermocouple Applicuaion temperature gradient has no harmful effect upon the accuracy of the thermocouple unit. Under certain conditions, however, inhomogfneities may gradualtly develop in a pair of thermocouple wires due to oxid, tion, corrosion, evaporation, contamination, or metallurgical change, and thus create an EMF differece which may result in erroneous readings. |
8-7.3 THERMOCOUPLE MATERIALS 8-7.4 THERMOCOUPLE PROCUREMENT

gradient change per degree at the lowered temperatures. Frequently there are long runs from the thermocouple device to the instrumentation. These runs are normally made using copper conductors, but a much higher accuracy is obtained if the thermocouple metals are canried all the way. These long runs,.or extensions, are called thermocouple lead cable, and are discussed in ensuing paragraphs.

The five mos. commonly used metals for use in thermocouple work are copper, iron, constantan, Chrome* and Alumel*. When united into thermocouples, the pairing would be as follows: Pairs a. Copper - Constantan b. Iron - Constantan c. Chromei - Alumei orTl** - T2** Temperature limits 1900 to 4000 C - 1900 to 750 0C
-

In the procurement of randcm lengths of singleconductor, insulated, extension wire, it muJt be recognized that such wire is commercially combined in matching pairs conform establishea calibration curves. For hijsto reason it is to imperative that all singleconductor, insulated extension, or lead, wires be procured in the pairs to be installed, at the same time, and from the same source. For in this reason couple wires are usually furnished cable formthermowith P' number of matched pairs of thermocouple lead wires. 6-7.5 CALIBRATiON All thermociuple cables and lead wire3 mnut be carefully calibrated against known temperature standards and certificatcs of calibration furnshedi. 8--8 T1ERMOCOUPLES VS LEAD WIRES

- 190 Gto 13600 C

Many other alloy combinations are available for special purpose applications. Chromel and Alumel are not normally preferred for temperatures below O C bnt nse of the small EMF

Chromel and Alun.ci are trade nraes of Hoskins Mfg. Co.

** Ti and T2 are trade names of Driver Harris Co.

To differentiate L.,weei thermocouple cables and thermocouple lead wires in locurement, it must be 8-15

AMCP 706-125 remembered that the the.mocouple lead wires do not meet, and are not required to meet, as rigid an FMF tolerance as th.eimocouples, and should not be used as high accuracy measuring devices. Usually on lead wires and cables the insulation is the temperature limiting factor, whereas, on thermocouples the conductor is the tempeirature limiting factor. Thermocouple lead wires are used to run from the thermocouple to the instrument, and should have the same metals as the thermocouple in order to eliminate stray thermal EMF caused by junctions of dissimilar metals. 8-8.1 CONSTRUCTION c. Insulation:( (1) Iron c',nductor: PVC - white j2) Constantan conductor: PVC - red d. Insulation over pair: extruded nylon - black 2. Conductor sin: #18 AWG solid a. Wire type: Chromel - Alumel b. Cbne: Twisted pair c. Insulation: (I) Chronel conductor: extruded TFEwhite - yellow spiral stripe (2) Alumel conductor: extruded TFE - Ahite - red spiral stripe d. Insulation ov-r pair: extruded FEP - clearyellow spiral stripe 8-8.3 INSTALLATION Thermocouples and thermocouple lead wires are nonally installed with o;,ly the conside.tion due conventional electrical wiring. There is one very important, and often overlooked, difference in the installation of a thermocouple circuit, i.e., thermocouple cables and lead wires should always be twisted together when any outside electrical interference exists which could generate EMP variations, the result o.' which would be erroneous temperature readings. Selection of conductor size. in thermocouples and lead wi:es is made for mechanical considerations only. amount of heat is to be masu-ed in z relatively short period of time. In this case, using a large size conductor would act as a heat sink and give erroneous readings; accordingly, z smaller condutor would be much preferable in this inetance. In Gther cases there is no . connection between the selected AWG conducto" sizt and temperature values or accuracy. A #40 AWG size conductor will record the same temperature 1 ad with cc'yt21 accuracy, as a #8 AWG conductor size under the same exaca conditions, but may not physically give the servic fe required simply because

I'

8-8.1.1 Conauctors Thermocouple cables and lead wires may be constxucted with either solid or stranded conductors in any Pf the thermocouple metals. The AWG size normally ranges from #16 AWG to #36 AWG, but any gage size is available from approximately #8 AWG solid to #42 AWG solid. 8-3.1.2 Insulation There axe eany number of insulations, or combirations of insulat-ons, available for thermocot pie wires and cables. Becaue of the low voltage hwided in therntocouple work, low grade, electrically adeuuate insulation systems exist. This is 5enerally true because the major concern in thermocouple woe- is environmental conditions. Shown in Table 8-6 is a typical cross section of some thermocouple insulations and their rccommended, accompanying, overall insulations, The two general categories looked for when choosing insulations or jacketi.,g are wicking or nonwicking properties of the materials. "rabl- 8-6 shows the constructiona that fall into these general areas.

:'

..

"

8--.2 CONSTRUCTIONAL EXAMPLES Two constructional examples showing typical cables 2nd colo coding methods are: 1. Conductor sze - #18 AWG stranded (7 strands #26 AWGI. a. Wire type: Iron - Constntan b. Cabling: Parflel conductors

8.16

F
TABLE 8-6
THERMOCOUPLE INSULATION AND JACKET SELECTION GUIDE
Single-conductor Insulation Lacquered glass Nylon lacquered glass Teflon tape - hli teinperature varnished glass Lacquered glass Lacquered glass - nylon Lacquered glas3 - polyviylchloiide Lacquered glas., Moisture-proofed asbestos Moisture-proofed asbestos Nylon hi temperature varnished asbestos/glass Nylon hi temperature vsrnishel asbestos/glass Teflon tape - hi temperature vzrnisned asbestos Moisture proofed asbestos Nylon Polyvinylchloride - nylon Glass polyvinylchloride
-nylon

AMCP 706-125

Overall Insulation

Wicking Propertics Lacquered glass Lacquered glass Hi-temperature varnished glass Lacquered cotton Lacquered glass Lacquered glass Lacquered glass - polyvinyichIoride Moisture proofed asbestos Lacquered glass Hi temperature varnished glass Stainless steel braid 1-ii temperature varnished glazs Lacquered cotton Lacquered .otton Lacquered cotton Nylon
glass - nylon

Polyvinylehloridc

________Lacquered

Nonwicking Properties Teflon tape Nylon Polyvinylchlloride Polyvinyichiodide - nyloGn Nylon Extruded tetrafluoroahye-ne Extruded fiuorinatedethyltmepropylene Teflurta~.pe Nylon Nylcn Nylon Polyvinyichloride ExAtruded tetraflusoroethylene Extruded fluorinatedethylenepropylene

the smaller size will niot stand !he abuse likely to occur. 8.--W.4 ELEIOA0W ~ FOsiaui RCE

transfo.-mer to a spark plug. The elcetrircal encigy carbe considered to flow in the form of a high voltage pulse of low zriperage, followed by a low frequencey, damped wavetrain. T7he major applicationas ate, of osbhiratnduomivigtonyte, 8-49.2 DF.SiGN CONSIDERATIONS 8-9.1 Con~ductor The electrical properties of the usually not of ptime umportance. The are relatively short and the circuit ;nhecnt rusistance of several hundred conductor are lengths of wire has an initial thousand ohm

Table 8-7 shows the tempcrdture EMPF correlation for the three most widely uscd thermocouple capbles. 8-9 IGNITION WIRE - HIGH VOLTA8GE 8-9.1 INTRODUCTION The function of an ignition wire is the transmission of high-impulse voltage, electrical energy from a coil or

--

AMcP 7oW*2S

TABLE 8-7 THERMOCOUPLE-TEMPERATURE-EMF CORRELATION CHART*

EMF, Absolute Milivolts

Temp rature, 0C Reference ;gnctions OC Thermocouples

Temperature, 0C -156

Copper-Constantan -5.411 @-193C -4.603

Iron-Constantan -7.78 @-195 0C -6.50

Chromel-Alumel -5.75 @-200C -4.81

-100
-50 0 50 100 150 200 250 300 350 400 450 500 550 600
650

-3.349
-1.8304 0 2.035 4.277 6.703 9.288 12.015 14.864 17.821 20.874

-4.63
-2.43 0 2.58 5.27 8.00 10.78 13.56 16.33 19.09 21.85 24.61 27.39 30.22 33.11

-3.49
-1.86 0 2.02 4.10 6.13 8.13 10.16 12.21 14.29 16.40 18.51 20.65 22.78 24.91
27.03

---

36.08

700
750

39.15
42.32

29.14
31.23

800 850

45.53

33.30 2.34

900
950
1000

....
--

37.36
39.35
4131
--

1050
1100 1200 , ,1250 1300 1350 1400 *Taken from NBS Mcla S61, Ref. 6 ------.... l~qO -

43.25
47.04 4... 50.69 52/#6 54.20 54.88 @1370PC

--

45.16

'"8-18C

F
AMCP 706-125

i.
at the spark gap, hence even a few thousand ohms, more or less, in the conductor does not significantly ignition performance. In fact, a high-resistance conductor is often very desirable in helping to suppress radio noise by damping out oscillations sooner. The physical properties of the conductor are an important feature of ignition wire. Becau4 this is considered a permanent type installation, the physical strength prop. erties required would only be dependent oji the anticipated forces or abuse inflicted during installation and maintenance. Resistance to flex fatigue should be considered since there is generally appreciable vibration around an engine. Generally, the same conductor material and construction is used for ignition wire as for conventional cables, however, there is one construc. tion that is uniqne to ignition-type cable; this is the carbon-impregnated fiber type of conductr. 'This type construction Ias excellent thermal properties and flex life. If copper is used as a conductor material, plating should be used because of the corrosion caused by the thermal conditions around the installation (see Chapter 1,"Conductors").
8-9.2.2 Insulation

ratect

end.use requirement with regard to installation abuse in pulling the cable through onduits, ducts, etc. The choice of fiber is largely dependent upon the anticipated thermal environment and costs. Here again, a protective covering is recommended over the butyl sheath. A recent dvvelopment utilizes a single extrusion of ethylene-propylenc rubbp- serving as both primary insulation and sheathing. 7his material combines good electrical properties, giod corona resistante, nuid adequate oil resistanc,.. Cost savings are realized here by the single extrsion and the phyacal amount of material used. 8-9.2.4 Outer Protective Fiber Braid An outer fiber brai permissble in some specifications. However, this application shoald be avoided whenever possible. Wicking and fraying problems arc inherant in this type of outer covering, and with the advent of the newer sheathing materials, the outer fiber braid is becoming increasingly unnecessary as well as beh-g very undesirable.
8-9.2.5 Shield

The primary insulation material mus. have good electrical properties, be resistant to deterioration due to corona, and have as low a capacitance value as is feasible with construction and usage. Butyl and neoprene rubber, polyethylene, and silicone rubber, for high temperature, are possible materals. The governing factors in 'he choice of these insulating materials are usually the thermal environment, flexibility, and cost. In the case of butyl rubber, this material is not considered as good in a high temperature, oil-saturated envhonment as some of the other choices, and would th.refore function more efficiently with a protective
sheathing.

A metallic shield, whether bra.ded or otherwise, should be used only wbhn absolutely necessary, and is required to screen out 7adio interference. It is generally used on aircraft ignition wiring, but the shield is not usually desirable because it contribut s to the system capacitance and increaser the required output needed from the igh voltage source. The shielding material is usually copper with a tin, silver, or nickel plating. In some instances solid nickel or stainless steel ,nay be used when extreme thermal or acid envi2ncimt are to be encountered.
8-9. PECIFICATIONS _

8-9.2.3 Rsinforcing &aid is optional; the braid would bf dependent upon the
A reinforcing braid in most constructions

MIL.C-3702 is an active Military Specification for ignition wire covering three temperature ranges; -54v
to 121"C, -54 to 2320C, -540 to 3160C. Only the

latter two ate considered for aircraft application.

S)

8-19

A.MCP 706125

REFERENCES
1. MIL-C-915B, Cable, Cord and Wire, ElectKal (Shipboard Use). 4. MIL.C.23020, Cable, Coaial (For Submrne Use). 5. MIL.C-24145, Cable, Electrical, Special Purpose For Shipboard Use 6. National Bureau of Standards Circular 561, Reference Tables for Thermocouples.

1
i!8

2. MI.C-2194, Cables, Power, Electricad Reduced

Diameter Type, Naval Shipboard 3. MftX-3702, Cable, Power, Electrical; Ignition, Hih Tetsion.

II
1,

I1*

8.20

(
. .. -....

*1 I

-,

[m

AMCP 706-12E

j-

CHAP-ER 9 TELEPHONE CABLES 9-1 INTRODUCTION

The term "telephone cables" covers a myriad of constructions and uses in the wire and cable field; therefore, for purposes of this handbook, telephone cables will be broken down into four major categories... 9-2 MAJOR CATEGORIES The categories of components to be discussed are.
1. Audio Cord
I.

T ere are many and varied audio cord designs for various special use&. The basic design for all audio cords and cables, however, is very similar, and incorporates the previously cited basic qualities to the required degree needed for performance conformance. . 9-3.1 BASIC DESIGN

1. Conductor The relatively small whs and retractile cords used in telephone handsets and headsets. 2. Field Wire Wire used to provide tactical units in the field with relatively portable communications systems. The equipments are rugged, can be installed and removed rapidly, and are comparatively easy to maintain. 3. Mutipair Telephone Covering from two- to twenty-six pair czble and used in relatively short distance teleconmunications systems. 4. Multichannel Communications Covering special purpose telephone cables for long distance telecommunications systems.
I

Stranded wire, or tinsel ribbon, for flexibility. Strand material dependent on electrical andIor physical properties required. 2. Separator Applied over conductor and under insulation, when needed, to insure free stripping quality of primary insulation. Separator material is usually an organic, synthetic fiber or yarn. 3. Shields Shields are used in audio cords for shielding out electrical intererence. A shilld does add to the overall diameter and we'-ht, but is sometimes deemed necesr for the reasons stated. 4. Prmary Inidation A specially compounded, vulcanized, elastemer;
asnl^; ".+-Itb o.n ..

'

Thesz four categories cover the major applications in rilitary commun-nication1 s5ia4W. 9-3 AUDIO CORD

.,,

vinyl or polyethylene material.

b1lend. or a *hrmnnol

unh

9-3.2 TINSEL CORD (MIL-C-3849A) An audio cord is defined as a wire or cable ussembly designed for use on communication equipment at audio frequencies. The basic considerations required in an audio cord or cable are ruggedness, conductor resistance, compatibility with equipment, and mechanical and environmental performance. Normally, in the manufacture of tin.l cord there are four basic steps to be followed. These four steps can be considerd standard n the manufacture of tinsel cords, although there aire ramy variations of each.

9.1

__..

_..

AMCP 706-125

9-3.2.1

Basic Design

The four basic proceduree and the terminology used are given in the paragraphs which follow, I. Tinsel Ribbon The single, flat, metalic, conducting material used as the basic conductor. 2. Ynsel Strand Made up of one or more tinsel ribbons spirally wound on a flexible fabric thread strength member. 3.Tinsel Conductor Consisting of 2 or more tinsel strands around a fabric thread strength member. 4. Tinsel Cord The completed product consistiag of insulated tinsel conductors, usually wrapped around a flexible yarn staycord, with an overal! protective covering, 9-3.2.2 Construction and Tests The paragraphs which follow describe the four basic manufacturing and testing procedures of the above components. 1. Tinsel Ribbon Tinsel ribbor is usually fabricated by rolling a piece of sound wire to a desired thickness and width consistent with physical and electrical properties desired. The metals employed to fabricate the tinsel ribbon are usually pure copper, pure silver, tinned or silver.plated copper, or a copper alloy (usually tinned) designed to meet the required properties. The three main properties of tinsel ribbon are: a. DC resistance b. Breaking strength c. Flexure characteristics 2. Tinsel Strand The tinsel strand is constructed using a selected fibrous yarn core and helicafly wrapping one o! mole" 9-2

tinsel ribbons around this core with a specified lay length, The fibrous core must he of a strength to meet the tensile and elongation requirements, and must not contaminate or corrode: the tinsel ribbon under the specified environmental conditions. High tenacity rayon is frequently used because of its high strength and low stretch qualities. 3. 7nsel Conductor The tinsel conductor is composed of a specified number of individua;y insulated tinsel strands cabled around a fibrous core. The tinsel strands are covered with a protective, close-knit, fibrous braid or serve, and insulated with an extruded plastic or ela3tomer covering. This insulation is color coded by using colored compounds or ink striping. 4. Tinsel Coid The completed tinsel cord is constructed by twisting the selected number of insulated tinsel conductors into a smooth uniform core (usually around a staycord) and covering it with an extruded plastic or rubber sheath overall. The tinsel cord is now complete except for the jacket, and if required, is now ready for electrical extensile/retractile cord construction. 9-3.3 RETRACTILE (HELICAL) CORDS
9-3.3.1 Basic Design and Construction

Retractile cords are accomplished by forming a precut length of the cord into a helical, spiral form (except for each end) with adjacent turns contiguous, and heat-setting the plastic jacket or curing the rubber jacket in this form to attain a permanent set in the configuration. The cables, particularly those with a vulcanized jacket, are then reverse twisted for improved* retractile properties. The sheath selection in this type of cable is very important for the following reasons: 1. Sheathing com.-'ound cannot become v'icky or tacky under operating conditions because extensiie and/or retractile properties will be affected. 2. Sheath must remain very flexible over entire operating temperature. 3. Sheath must maintain its elastic properties after repeated flexing over operating temperature range.

!I

\4

AMCP 706-125 9-3.3.2 Tests After the helical retractile cord has beer designed and constructed, the tests are basic for normal ueage. The basic tests are given in the paragraphs which follow, (Othet tests may be umployed for special cables or special usage.) 1. Eixtension Qualities A specified cable length must extend to a specified distance, at a specific temperature, under a specified load, and remain for a specified time period. After this time, period has expired and the load is removed, the cable coil must retract to its original length or a specified percentage thereof. 2. Retracile Qalities (Low Temperture) The completed elec~rial cord is placed i a cold chamber at a specified temperature, in a horizontal position, for a specified length of time. At the conclusion of the time period the cord is extended a specified distance and rate while at this temperature. No fracture of the jacket, conductor insulation, or conductors shall occur. While still at this reduced temperature, the cord is released, and within a speciflied time must retract to within a certain percentage of the original retracted position. 3. Low Temperature Impact Resistance After a specified time at a specified temperature ("cold soak"), and while in the cold chamber, a specified weight is dropped a given distance on the retractile cord helix. The jacket and insulation are then examined for cracks or other defects, 4. Static Loading i The cord is suspended vertically at roe 1 temperature, with aem, specified attached to the fre p::fi~ fra tme weight od.hev'eihttall bre suffient o etendt a sp d e cfed ertsae be sufficient to extend the cord a specified percentage of original retracted state.the After time andits with the weight removed, cordthe is laid at period, rest in a horizontal plane; within a specified time the cord should return to a specified percentage of its original retracted form. S. Continuity Each conductor of the cord shall be continuous upon final completion. When conducting the 9. DilectricStrength NoA specified voltage is applied between each conductor, one at a time, with the remaining conductors at ground potential, for a specified time. No dielectric failure or breakdown of any conductor salocr shall occur. 10. InsulationResistance A specified insulation resistance shall be realized when a potential is applied between each conductor of the cable, one at a time, when other conductors are at ground po)ntial. 9-3, continuity test, many times the cord conductor will indicate contiruity when the conductor is actually broken. One test procedure to overcome this situation is to run a noise level test on the cord length. If the conductor is actually broken, even though the two broker ends of the conductor are touching and indicating continuity, the noise level will increase above the specified limit. 6. DC Resistance Upon cord completion, the DC resistance of each conductor shall be as specified. 7 Extension-retraction Flex-life At a specific temperature the cord is extended a certain multiple of its relaxed length and allowed to retract. This action, in this sequence, constitutes one flex cycle. Rate of extension and retraction per cycle is specified. After a given number of cycles, the cord may be given one turn about its longitudinal axis and the test continued. Upon completion of the Specified number of cycles, continuity and/or conductor resistance is measured. 8. Flex-life Retractile cords are'usually of a specified length in inches, and contain a specified number of turns, with straight -sections at each end for emse 3f terminating the individual insulated conductors. The straight section is placed under tensile load and bent 1800 back and forth around a mandrel of specified diameter at a specific temperature, for a specified number of bend cycles. Thi most sensitive indicator for flex-life failure is the noise level tea.t.

*1

AMCP 706-125 9-3.4 MINIATURE CABLES (SPECIAL PURPOSE)

(MIL--03928.j

These types of straight cables are used at potentials up to 300 volts rms; utilize a reduced diameter; are very flexible and light weight; and have excellent tensile properties for their size. These cables are designed for an operating temperature range of -400 to 60 0C. 9-34.1 Basic Design of Some of these miniature special in purpose cables and the paragraphs are outlined constructions their which follow, 1. Conductors The conductors for the various cables in MIL-C-10392B are as shown in Table 9-1. 2. Conductor Construction

Stay cords shall co,sist of a fiber core tightly overlaid with a closely woven fiber braid. Thcse should act as flexible strength members and should be incorporated within the multiconductor configuration. Stay cords should be as follows for the specified cables: a. Cables: WD 27 A/U, WM 69 B/U, two stay cords - 25 lb minimum breaking strength each. b. Cables: WT 15 A/U, WF 11 A/U, WM 59 AU, WM 61 WM 64 cord-M641 oWe62 62aA/U, A/U, WM 61IA/U, B/U, WM 60 A/U, WM 60 A/U, WM minimum bieakiig strength. 7. Cabling a. The ir.sulated conductors of cables WT 15 A/U, WF 11 A/U, WM 59 A/U, WM 60 A/U, WM 61 A/U, WM 62 A/U, WM 63 A/U, and WM 64 A/U should be twisted concentrically aronnd a central staycord in the color-coded sequence of MIL-C-10392B, with the lay length as shown in Table 9-2. Cable WD 27 A/U should be twisted with two stay ,cords and a maximum lay length of 0.500 in. c. Cable WM 69 B/U should be twisted with two stay cords and a maximum lay length of 0.875 in. d. Cable WM 70 B/U should be twisted, around a central stay cord, with a maximum lay length of 0.875 in. e, Cable WM II1 A/U should be twisted around a central stay cord and shall employ three fibrous fillers. The cable shall have a maximum lay length of 0.875 in. Figs. 9-1 through 9-4 show cable configurations of cable types B.,C,D and E, and indicate color coding sequences for cable types A,B,C,D, and. 8. Separator An outer, braided, fibrous separator should be loosely applied over the cabled conductors. '-ven though this braid shall be loosely applied, it should afford excellent coverage.

6. Stay Cords (MIL.C.572)

"

! a. The 404 circular nil area conductors will consist of 41 strands of #40 AWG (0.0031 in.) tinned, annealed, cadmium copper, bunch-stranded (see Chapter I.b. 1). b. The 1620 circdilar mai area conductors will consist of 168 strands of #40 AWG (0.0031 in.) tinned, annealed, cadmium copper, rope-stranded (See Chapter 1). 3. Separator A fibrous yarn (rayon or nylon) should be closely served over the conductor if the insulating compound is not free-stripping, 4. Insulation rhe insulation should be a specially compounded elastomeric material ineeting the requirement of Type IS*, MIL-I-3930* (Buria S or Buna S and natural rubber) extruded over the conductor or separator. The insulation should have a minimum 0.0!0 in. wall thickness and a maximum 0.097 in. diameter over the 1620 circular ril conductor. 5. Color Coding The conductors should be color-coded using differently colored insulating compounds. For color coding sequence oti cables refer to MIL-C-10392B.
" This C* may eventually be changed to Type IS-L for -55 to 9-4
__ __ __ __ __ _

_.4

__

AMCP 706-125

TABLE 9-1 CONDUCTOR CHART-AUDIO CORDS

No. of No. of Conductors 2 3 4 5 6 6 Conductots of Each Size 2 3 4 5 6 2 4 AWG Size (Nominal) 24 24 24 24 24 18 24 Circular Mils (Nominal) 404 404 404 404 404 1620 404

Cable Diameter, in. (Nominal) 0.146 0.212 0.212 0.212 0.252 0.262

Cable Type WD 27 A/U " is AM

WF 11 A/U WM 59 A/U WM 60 ,/U WM 69 B/U

WMIIIA/U

2
5

18
24 24

1620
404 404

0.280

VM 61 A/U

0.252

WM 62 A/U WM 70B/U

8 8

8 2
6

24 18
24 24 24

404 1620
404 404 404

0.262 0.285

WM 63 A/U WM 64 A/U

9 10

9 10

0.280 0.297

,t

1~~

AM(,

/06-1251

TABLE 9-2C CABLNG CHART-AUDIO CORDSSTYOS

Cable ',VT 15 A/U *7i 11 A/U WM 59 A/U WM 60 A/U WM 61 A/U WM 62 A/U WM 63A/U WM. 64 A/U Max Lay Length, in. 0.500 0.875 1.125 1.250BRW 1.250 1.62S .750Figure 2.250 BU E YLO

9-2. Special Purpose Cable-W 69 B/U

STAYCORUS

WIESTAYCORD
YELLOW

(
WHITE ORANGE BL.ACK

BLUE

Figure 9-1. Special Purpose Cuable-WD 27 A/U 9. hethGREEN The sheath, in all cases, should be composed of a
specially compounded SBR, meeting the requirements of Type JS* per MJL4.3930. The sheath wall should beBRW 0.015 in. minimum for Cable WD 21:' 4U, and 0.020 in. for all other cables. 10. IdentificationMarking for identification. ismay eventually bc changed to Type JS-L for -5 C
(zt.lzcr than Ad'o~C operation.Fiue93SpcaPros

RED

*
0/

iu093

pca

uroeCbeW
blWM7Bu

Ak-A

AMCP 706-125

*
YELLOW WHITE , LEsize BLAC

NOTE:
Due to the development of new and different conductor and insulating materials a contract has been issued by the U.S.Arny Electronics Command for the development of subminiatue retractile cords to reduce and weight ovet existing cords. For frther information on the progress of these subminiature cords reference should be made to the following US. Aimy Electron;-cs Command Contracts: (E), Subminiature Cords. Light.

IfLLE SGREEN

STAY-

RED

) O' NDA-28-043-AMC-00471
9-3.5.1 Usap

DA-28-043-AMC-00045 (E), Extra Flexible, weight, Tactical Cable. Figure 9-4. Specia! Purpose Cable-WM 111 A/U 9-3.4.2 Tests -- VC) I. DC Resisrance I (at a. #24 AWG: 39.k ohm/iooo ft maximum. b. #18 AWG: 9.7 ohm/1000 ft maximum. 2. Dielectric Strength* a. Dry: 1000 volts rrms for I sec. b. Wet: 500 volts rms for I sec. 3. Insulation Resistance * ft (atmilmum, 15.6 0C): Conductor 600 megolums/1000 Insulation 4. Flex-life**: Conductor continuity should remain unaffected ater 30,000 cycles. 5. Cold Bend**: No cracking of conductor 0 insulation or sheath when tested at -40 C. WMLTICONDUCTOR CORD (RETRACTLE (MIL-C-13273) (I--23conductor The paragraphs which follow discuss the tonfigur,tions and requirements for three typical multiconduetor,retrac.tile, electrical cords.
Tests conducted per J-C-98. 4/U
-

Thesa cables are designed for basically theAme applications as the existing cords, but are lighter in weight and smaller in size. The cords to be discussed are: 1. Cord WD 9/U (2-conductor) 2. Cord WT 2/U (3-conductor) 3. Cord WF 4/U (4-conductor) The cord types indicated are for use on communications equipment at audio0 frequencies in. a temperature range from -55" to + 85 C for ccntinuous operation. The cables are designed for extension, in normal service, to five times their normal retra-ted lengths.

9-3.5.2 Basic Design Conductors The three cables

all utilize the same cadmium copper alloy
-

WD 9/7J, WT 2/U, and WF

2 d 2.Insulation The insulating material should be a specially compounded elastomer. The extruded minimum wall should be 0.010 in., and the maximum diameter over the insulated conductor should be 0.080 in.
9-7

'

*Tests conducted per MIL-C-10392B.

APACP 706-125 3. Color Coding 9-3.5.3 Retractile Construction the completed electrical cord should be helical in form. Thie helix shall be left hand iMits lay with a maximum diameter of 7/8 in. for WD 9/U (2-conductor), and 1-1/8 in. for WT 2/U and WF 4/0 (4-conductor).
-3.5.4 Retractile Testing

1.

Color coding shall be attained by use of colored insua tg material as follows: a. WD 9/U (2 conductor): ((3-ccwlactor) (1) Conductor #1-White (2) Conductor #2-Black b. WT 2IT (3 conductor) (1) Conductor #-White (2) Conductor #2-Black (3) Conductor #3-Red
c. WF 4/U (4 conductor)

t. Extensile and RetractileProperties At room temperature the finished cords shall be extended t, five times their retracted length and allowed to retract freely. After a total of six extensile and retractile cycles, the adjacent coils shall remain cuntiguous when the cord is placed on a horizontal surface.
2. Stretch

(1) Conductor #I-White (2) Conductor #2-Black (3) Conducirr #3-Red "h (4) Conductor #4-Green The conductors must be capabl of free stripping. 4. Cabling 4 All conductars should be cabled together, in the specified coltr code sequence, with a right hand lay of 1.5 int. maximum.

The helical cord shall be capable of 60,000 cycles of stretching to 4 times its retracted length at 40 cycles/minute. After this cycling the DC resistance of any conductor shall not have changed by more than 10% of its original value, aad the cord shall return to within 20% of its original retracted length. 3. Extension The helix, when suspended, suall be capable of extension to a. minimum of 2-1/2 times its retracted length at room temperature under an 8-oz load for two-conductor cables, and a !0-oz load for three- and four-crductor cables. 4. Other Tests

S. So.eat'
S I

a. Low Temperature Extension b. Retraction After Static Load c. DC Resistance d. Dieiectric Strength e.Insulation Resistance f. Continuity All tests shall be performed per MIL-C-13273 (Signal Corps). Tinsel cords may also be used mn

The sheath shall consist of a specially compour.ded elastomer (SBR or SBR--natural rubher blend). When extruded, the average sheath wall on any cioss section should be 0.010 in. and the mihmum thickness on the Araight sheath thickness shall be 0.020 in. The average overall diamet.ers s)houL,' be as ikvows: a, WD 9/U (2-conductor) 0.220 in.

~b.

WF 2iU (3-conductor) 0.250 in. c r,. WF 4/U (4- ondiictor) 0.250 in.

____

_-'"

1-

AMCP 70e0125

multiconductor configurations where great flexibility is required. A cable containing a number of tinsel cords has great flex-life, but is not considered appropriate where undue physical abuse is a factor. Very good tensile, or breaking, strength qualities can be incorporated in a multi,:onductor tinsel cable but abuse, such as impacting, will very rapidly cause damage and deterioration of cable operation. 9-3.6 SPECIFICATIONS Specfficationm for tekephore retractile cables, cords, And cord asseznb'.es inc!ule: a. MIL-C.,3885A, < able Assemlles and Cocrd

9-4 FIELD WMRE 9-4.1 USAGE Field wice is manufactured in relatively long lengths (usually 0.5 - or I - mile pack~.ge) and is desig'ied for use in communication systems in the field. Tiuds means it must necessarily be rugged, very portable and light weight, of minimum cost, and W~ compact in package. Atypical field wire communication ;ystem coi sists of fletd telephones, teltypewriters, switchboards, and radio wire integration staticns all interconnected by field wire lines. The paragraphs which follow describe somne typical fteld wire constructions, installations, and usages, along with somne typical physcal and electrical characteristics. 9-4.2 INSTALLATION FACTORS There are three basic methods for th'e installation of a field telephone communication system: 1. Surface constitutes simply laying the cable, or cables, the ground between equipments in as straight a line as feasible. 2.BIP

A.,semblies,

Eleetrical (For use in electronic, communication, and associated electrical equipmertj. b. MIL.C-3884, Cord, Electrical(Short Lay). c. MIL.C-l 199Th. (Signal C~orps), Ceid Assembly, Electrical, C.Y-215 ( )/Z1 (Retrartile). WreEletricl (insl).This d. ML-W379A, d. MLW-395A, Wie, Eectover a. MIL.C-13273 (Signal Corps), Cord, Flectrical (Retractile 2, 3 and 4 C'onductor, WD 9/U, WT 2/U,

WT' 4/ U).

~
This method employs a ditcll' where a cable, or cab'. s, are laid, with or without ducts, and covered over.

I(Miniature),

f. MIL.C-10392B, Cables, Special Purpose, Electrical

g. MIL.C-3883, Cord, Electrical (Audio lRequency.~ 3. Aerial h. rt'iA2.3849A, Cord, Electrical (Tinsel, This method of installation strings the cable framQ trees or preinstalled poles. 9-3.7 ALTERNATE CONSTRUCTIONS types of insulation, such as polyethylene or Iolyvinylchloridt:, may be used with success in the asheavy a wall of isulating compound, therefore, creatin~g a cost and veliht savings. It must be noted that the polyvinylcbloride used in this operation must be for either the cold temperature range, to -55 0C, or the high temperature range, to +850C. A single poyvirnylchloride compound to c.over this temperature has not been comparable features of each. rd tg toec

[1

Iimanufactuac
-D

IOther

Table 9-3 are the installation method. Listed in

of retrartile cords. They may not require

9-4.3 FIELD WIRE TYPES

The cables discussed cover the typi-al range of construction and usage; they are: 1. Electrical Telephone Cable (infantry Field Wire) Twisted Pair, No.'s WD-1/TT (Std A) and WD-141'T
-

Irange

da oloped to date.

(Std B) 9.9

SII

AMCP 71)6-125

TABLE 9-3(
t I

INSTALLATION FACTORS-FIELD WIRE

I, Line Type
Su;face

Advantages Easy to install.

Disadv'nutages Subject to damage by iehicles, fire, weapons, pelsorriet, and rodents.

Fastest to install. Easy to maintain and repair.

Affeaed by weath-r PPJ :limate. Reqaires more rugged cablk construction, affecting weight and cost.

1.

~Easily
Buried

recovered. Less s:bject to damage than surface or aerial. Least affected by weather and clinatL.

I
Most difficult to rapair. More tiiu= and equipment fc, installation. Difficul! to recover, cannot be installed in some-terrain. More construcion time than surface lines. Affectei by weather and climate. Requixcs greater cable tensile and/or break;ng streagth quality. _

Aerial

Less subject to damage than surface lines. Easy to maintain and repair.(

i
_

2. Telephone Cable No. Wr--I b/U 3. Tetephone Cable Nc. WD-36/TfT Shown in Table 9-4 are some nomparative data on fiald cable characteristics. Notes with respect to this table are: 1. WD-I/TT is standard field wire for U.S. Army. _WD-14TT could be used as a substitute for WD-/TT WD-/TT is in short supply. - when 2. WD-36/TT, because of its small size and aluminum conductor construction, has application limitations. This cable, because of its light weight, is excellent for a quick, temporary, nonrecoverable installation only-such as demolition or assault operations, WD-36/TT should not he considered as a

replacemcnt fcr WD-l/TT or WD-,4/TT cables which are more rugged. WD-36/TT is uoed only in dispenser forn, and is not buried or installed on poles. 9--4.4 3ONSTAUCTION With the advent of new materials, such as high-density or cross-linked polyethylhia, new communication cables can be developed to rerlace the in operation. The use of high-dersity now improves stardards polyethylene ihe electrical and physical capabilities while lowering the cost and weight in a comparable cable. Lowering the cost and weight are, in a great part, due to the possiblity of omitting the protective nylon or fiber braid coverng over the primary insulation when using high density polyethylene.

9-10

A
_

ci

C-If

.L AI

%01F'

Cl))

00

InS
r-+) 0 0

C11. C.) .9.-

-4--

AMCP7012

II
t, CC-4

+
oq
o

t
0

% 0
W;_ n0

2N

00

I.-

.0ti.

CD

9-12(

'I)

F
A comparison was made using standard cables and cables utilizing high-density polyethylene. The cable constructions and some comparative electrical and physical characteristics are shown in Table 9-5.

AMCP

768-125

well as wire packaging, and contain 0.25 or 0.5 wiuile lengths. Dispensers such as those pictured in Figs 9-10 anfd 9-11 haVe many useful featies, among them are: 1.Very inexpensive. portable, lightweight, and relatively

9-4.5 TEST DATA In Figs 9-5 through 9-9 some comparative test data are plotted oa the cable constructions shown in Table 9-5.

2. Capable of high speed pay out (40 mph or greater). 3. The wire will lay flat, without xinks or coils, after pay-out. 4. No special mounting devices are necessary for use. 5. Two or more dispensers may be mounted in tandem for extended wire lengths if required.

9-4.6 PACKAGING Field cables of the types described are normally ordered in lengths ranging from 0.25 mile to 2.5 miles when supplied on reels. There is often a special packaging requirement other than coiling the wire on a spool or reel. These packages are called dispensers and are normally equally concerned with wire pay-off as

TABLE 9-5 CABLE CONSTRUCTION COMPARISON CHART Cable A* Conductor Insulation Material Inbulation diameter Jacket Material Jacket diameter Cabling Weight, lb/mile Avg. Tensile strength, lb I.R. (minimum), ohms Dry Wet AfterHumidity DC Resistance, ohm/mile Dielectric Strength, rms/l minute
*

Cable B** 7 Strands/0.011 in. 4 copper 3 steel Hi-density poly. 0.070 in. ea. cond. None Twisted pair 40 202 5x1012 5 x 101 2 2x 10' 220 1000

Cable Cf 7 Strands/0.01 I in. 4 copper 3 steel Hi-density poly. 0.070 in. x 0.140 in. None Parallel pair 40 203 5x101 2 5 x 102 lx l01 220 1000

Cable D * #23 AWG solid Aluminum Polyethylene 0.036 in x 0.072 in None Parallel pair 8.5 27.5 2x10 12 5 x 1012 3x 10' 620
1000

7 Strands/0.01 I in. 4 copper 3 steel Polyethylene 0.070 in. ca. cond. Ext. nylon 0.085 in. ea. cond. Twisted pair 50 200
2 4x!01 2 x 10"2 lx l0 s

220
1000

-[

Standard WD-1

* Twiste- pair WD-I (no nylon jacket) t Paralel pair WD-1 (no uylon jacket)

-I Standard WD-36

9-1

ANv,,V706-125

1~2
CABLE D (DRY) 24 24 200 18 CABLE C (DRY) CABLE A (DRY) CABLE B (DRY) CABLE B (WET)

S16
1412in800 .

6(
.5 1.0 3.0 5.0 10 20 50

FREQUENCY,.

Figure 9-5. Fijeld Whe Comparison-Attenuation vs Frequency

9-4.6.1 Canvas Dispenser Construction 4. Trape, double-backed (white' and single-backed

JFig.

9-10 indicates these features:(oieda)

9-4.6.2 Plastic Dispenser Construction

1. "D" rings
-

steel, used for dispenser mounting.

-

i:

2. Side repellant.

panels

duck, moisture

and

mildew

Fig. 9-11 shows another type of dispenser similar to the one illustrated ;n Fig. 9-40 but lighter in weight, more compact, and affording the wire more

3. Grommet compound.

hi strength,

flex~blc,

elastamer

physical protectimx. In this type of dispenser .the wire

is wound on a plastic mandrel attached to one side of the cs.ie. After the wire has been formed over the

9-14

AMC? 706-125 I mandrel, the entire coil is then encased in a heat shrunk, vacuum preformed, plastic cover. When the package is complete, it foms a semi-rigid, sealed casing which can withstand much physical abuse.

1200

1100

*11
'.

CABLE CABLE CABLE CABLE

D (DRY) B (DRY) A (DRY) C (DRY)

WOO

.-

CABLE D(WET)

900 CABLE A (WET) .CABLE C (WET) CABLE 8 (WEr-

800 7

600

500

<

400

300

.5

1.0

10

20

50

FREQUENCY, kHz

Figure 9-6. Field Wire Comparison-Characteristic Impedance vs Frequency 9-15

I
AMCP 706-125

.?

7r
CABLE B (WET) 6 CABLE A&C (WET) CABLE D (DRY) CABLE D (WET) CABLE C (DRY) CABLE A (DRY) /

5-

CABLE B (DRY) "

'IZ 4

II1_

_ ___

_ _ _ __

_ _ _ _/

.5

1.0

10

20

50

FREQUENCY,kHz

Figure 9-7 Field Wire Comparison-Phase Constant vs Frequency

9-4.7 SPECIFICATIONS

1ome

c. Cable MX.6895( )/7T. 2. MIL-C-55425(EL), Cable, Telephone, WFi 6/LU.

pertinent specifications that refer to field wire

and cable, and field wire and cable packaging are: 1. MIL-C-55462(EL), a. Cable, Telephone, WD-36 [TT Dispenser. a. C4. b. Cable MX-6894( /T and Dispenser.
9-6

3. MIL-C-10369, Cable, Telephone, Field, for Rapid Payout (MX 306-A/G. ECOM Technical Report 2657, Laboratory Evaluation of Field and Assault Cable.

AMCP 7A6-125

140

F
.
GABLE

~~120'
B (DRY1 -

I
0

CABLE A (DRY)

100

CABLE C(DRY)
CABLE B (WET)

80

CABLE A&C (WET) CABLE D (DRY)--\ OF

60

CABLE D (WET)

0
40

20

II
0 .5 1.0

L., I fII
3.0 5.0 10.0 20 FREQUENCY, kHz

..
50

Figure 9-8. Field Wire Comparison- Velocity of Propagation vs Frequency

5. FM 24.20, Tchniques.

Field Wire

and Field Cable

in work such as switchboard connection cables, where a great many wires are utilized in a relatively small space. The construction for multipair telephona cables is much the same as is required in any oter multiconductor for fact that all components are cable, twisted except pairs and arethe normally all the same physical size. 9-5.2 CABLE REQUIREMENTS The requirements of multiconductor telephone cables are much the same as any other multiconductor

6. MIL.-C-13294B and Amendment 3 (EL), Cable, Telephone, Electrical (Infantry Field Wire, Twisted Pair, Wire WD-1/TTand WD141TT). 9-5 MULTIPAIR T"LEPHONE CABLES 9-5.1 USAGE

Multipair telephone cables are normally used insidc

a building or in a protected area. They find great use

cable, except for the following:

9-17

II

(
AMCP 706-125 35

~30---CABLE
:30
u
2a

----/ ,

B (DRY) CABLE A (DRY) -CABLEC(DRY) D C (WET) CABLE A AN CABLE B (WET) D (DRY' CABLE D (WET)

0 to

2CABLE

020

(9 ' " i

15 10 /

/
,I--

-.....

0.5

1.0

3.0 FREQUENCY, kHz

5.0

10.0

20

50

Range vs Frequency Fiqure9-9. Field Wire Comparison-Transmission " RINGS _ /-WIRE COILS

f-SIDE PANELS
GROMMET

Figure 9-ia. Canvas Dispenser-Field Wire

9-18

AMCP 706-125

L~

6in.
_6i.-,_ -

---

App.ox, 6%in." %A)

PREFORMED PLASTIC SHEET COVE;.

~MANDREL
-Approx. 11 in.

MANDREL WITH WIRE COIL

/D N ~SECURE

f- FABRIC TAPS TO "D" RINGS

D" RING

(C) MANDREL WI ,. WIRE COIL ENCASED IN PLASTIC SHEET COVER Figure 9-11. Semi-rigid Dispenser.-F/eld Wire

II

9-19

',

AMCP 706-125

a. Voltages carried are normally very "miall, and the same emph is is not placed or, the voltage breakdown quality of the insulations as on those insulations used for power circuits. b. In the paired component construction, the
capacitance unbalance, mutual capacitance and

d. Attenuatior. The attenuation requirement is limited to insure aga!ist high electrical los&rcs. vNith correct attenuation, the desired operating sigial will reach the termination in afficient strength t&be detected. e. Mutual Capacitance The mutual capacitance of each pair in the multiconductor configuration is checked, one against the other, to assure capacitance uniformity throughout tle phired cable. Capacitance Unbalance capacitance unbalance

cross-talk qtualities are very important for efficient operation of the system. The mare impertant electrical characteristics in a imultipair telephone cable are: a. DC Resistance b. If. b u s r. Dielectric Strength d. Attenuation
e. Mutual C:apacitance

Z,,

cThe

of conductor

to

conductor in a pair, and pair to pair in the cable, is checked to minimize cross-talk between circuits within the cable.
9-5.4 BASIC DESIGN

f. Capacitance Unbalance 9-53 REASONS FOR TESTING

_-_.3_RASON __F__TESTIN

The majority of telephone cables employ 4 basic AWG-sized conductors: 426 AWG, #24 AWG, #22
AWG, and #19 AWG, and usually utilize solid wires.

An explanation of why the cited electrical characteristics are important to cable operation and.the reason for testing follows:
a. DC Resistance
, measured The DC resistance of each conductor ito determine conductor size, material uitiformity, and as a control on attenuation.

These conductors are normally bare copper. but are sometimes tinned copper. When a stranded conductor is desired, steel strands should be integrated with the copper Etrands to give added strength.
9-5.5 ELECT.3iCAL CHARACTERISTICS

Table 9-6 gives some typical characteristics of a pair within a multipair cable for the various conductor AWG sizes. A:l the data are based on a nominal 0.010 in. wall of polyethylene primary insulation.
9-5.5.1 Mutual Capacitance (Pair)

b.

sulation Resistance The mutual capacitance of a pair is defined as that capacitance measured betweena the two wires of a pair with the remainder of the conductors within a cable connected to shield or sheath and grounded. Mutual capacitance Cm is computed u.sing Eq. 9-1.

The insulation resistance is important to assure dielectric material unifor'ity and quality, and for a check on moisture penetration, c. DielectricS:rength for dielectric Cables shuld be checked 100% str.ength integrity L) assure that the installed cable will trsmit the desired signal in a trouble-free manner. Th;s is the reason that ihe required dielectric test voltage volag. is many tirrv. greater than the oprating

CM

2(Ca + 4(-) Cb) Cc

(9-1)

9-20

>--- -

__

_
(

AMCP 706-125

where Ca
=

polyethylene. The diameter over each insulated conductor shall be 0.044 in. Capacitance between No. I conductor and No. 2 conductor. No. 2 conductor connected to all remaining conductors (and shield if any) and ground. Capacitance between No. 2 conductor and No. I conductor. No. 1 conductor connected to all ren'aining conductors (and shield if any) and ground.
=

3. Color Code The 26-pair cable shall be fully color coded, as in MIL-C-55036 (Signal Corps), using the insulation material for the base color, wiJ, a circumferential ink stripe for the band. 4. PairTwist The insulated conductors shall be twisted into pairs, utilizing the varied pair lay for reduction of cross-talk as shown in Table 6-8.
5. Cabling

Cb

Cc

Capacitance of No. l and No. 2 conductors connected together, against all remaining conductors (and shield if any) and ground.

9-5.5.2 Capacitance Unbalance (Pair)

The capacitance unbalance of a pair may be determined using Eq. 6-6. This measurement is often referred to as the Coefficient of Asymmetry.
400(C, - Cb)

The varied lay pairs shall then be cabled together to form a three-layer construction with a left hand lay of not more than 5 in. 6. Marker A manufacturer's marker ef material, denoting the manufacturer's nonhygroscopic name, shall be laid parallel with the cabled core axis under the core binder, or under the core wrap if no binder is used. 7. Binder At manufacturer's option an open serve of nylon yarn may be applied over the core with a right hand lay. 8. Core Wrap The core shall be coveted with a 0.001 in. thick Mylar tape wrap with a n;nimum of 15% overlap. 9. Inner Sheath An extruded process, tightly applied, polyvinylchloride or polyethylene sheath, of a nornai . 0.1 n al hl epae vrtecr rp

where

Cu , 2(c+ 1 (9-2) Ca, Cb, and Cc are defined as in Eq: 9-I for capacitance,

-mutual

9-5.6 CONSTRUCTION The description of a multipair telephone cable which follows typifies the construction and material used in this type of cable as specified inMIL.C-55036. example As an pair.use of 26 be composed we shall construction, The #24 AWG shall of acable typical .tranded, tin-coated copper conductors, insulated with polyethylene, color-coded, cabled, binder-wrapped, sheathed with either a polyvinylchlonde or polychloroprene compound, and armored with a galvanized steel braid.
I. Conductors

.:

Each conductor shall consist of 6 strands of tin-coated copper wire, concentrically stranded around a single galvanized steel strand. Each strand has a nominal diameter of 0.008 in., and the stranded diameter is 0.024 in

10. Braid
A galvanized steel braid consisting of 2 ends #28 The conductor shalt be insulated with a nominpi 0.010 in. wall thickness of extruded higb-,4.-sty AWG wire, 16 carriers, 3 picks/in, shall be applied over the inner sheath.

9-2

AMCP 70S-125

TABLE 9-6 MULTIPAIR CABLE-ELECTRICAL CHARACTERISTICS (PMIR)

AWG Size

Electrical Characteristics
Nominal Conductor Resistance,

#26 221 442

#24 138 276

#22 86 172

#19 43 86

ohm/mi @20*C
Nominal Conductor Resistance,

oL/loop mi @20oC Minimum Insulation Resistance, megohm/mi

Dielectric Strength, DC Voltage conductor-to-conductor for 3 sec

1000
2400

1000
3000

100
3600

1000
4500

Nominal Attenuation @I kHz, db/loop mi Average Mutual Capacitance, PF/mi @1 kHz Nominal Capacitance Unbalance, pair-to-pair @I kHz/1000 ft

2.85 0.083 0.007 40

2.28 0.083 0.007 40

1.79 0.083 0.007 40

1.25 0.083 0.007 40

11. Outer Sheath An extruded process, tightly applied, polyvinylchloiide or polyehloroprene outer sheath, of an 0.047 in. wall, shall be applied over the galvanized braid. 12. Identification Marking ~minimum outer sheath shall have ink printed cable identification markings at specified intervals. 0 -5.7 TESTS FOR CABLE

b. Breaking Strength: 800 lb minimum c. DC Resistance: 62 ohm/1000 loop ft, maximum each conductor d. Dielectric Strergth: 3 kVDC (3 sec) e. Insulation Resistance: 10,000 megohm/l000 ft f. Conductor Resistance Unbalance: 4% maximum each pair g. Mutual Capacitance: 0.090 pF/mile maximum

IThe
I
a

a. Low Temperature:
T p th. (1) Cold Bend @.-40 0C,1.Sin. mandrel (2) Cold Bend @-50 0C,3.75 in. mandrel Capacitance maximum Unbalance: 160 pWtF1000 ft

i. Attenuation: 2.7 db/mile maximum

9-22

)(

f)
AMCP 706-125 9-5.8 SPECIFICATIONS Some of the specifications now in effect for the manufacture and procurement of military multipair telephone cables are: a.MIL-C-55425(EL), Cable. Telephone, WF-16/U. b.MIL-C-55036 (Signal Corps), 26 pair Cable, Telephone, IVM-130( )/G. c. MIL-C-13268 (Signal Corps), Cable, Telephone t#19 A WG and #20 A WG Switchboard Cable). 9-6 TELEPHONE MULTICHANNEL COMMUNICATION CABLES conductors at the opposite end. This cable assembly is
used for connections to equipments that are not

provided with connectors; for example, when making local tests on equipments, for connectors to open-wire lines, or when making tests on cable line. d. Phase 4 With some carrier telephone systems a telephone loading coil assembly is used to reduce system attenuation and thus permit greater spacing of repeaters. This loading coil is connected in the cable system at the junction of two Phase 1 cable lengths. A loading coil assembly is a metallic cylinder approximately 6 in. in length with a universal connector at each end and containing one or more loading coils to suitably decrease the system attenuation over thc system's usable frequency range. 9-6.2 CONSTRUlTION The information which follows describes the constructional details of a typical cable used in a multi-channel communication system as specified in MIL-C-10581. The cable to be described is a telephone field carrier cable of the "Spiral Four" type. "Spiral Four" means a star quad, long distance communication cable, and of portable type construction. 1. Conductor The conductors shall be stranded, annealed, bare copper. The stranding shall be concentric and each strand diameter shall be 0.0136 in. 2. Insulation in. Polyethylene, heat-sabilized, extruded, with a 0.014 minimum wall. 3. Cable Core

9-6.1 USAGE In general telephone multichan.nel communication cables are used to form a transmission line to link stations of a military carrier to telephone communication systems over relatively long distances, The assemblies are to be used in any climate. The lines are laid on the ground, under water, buried, or strung aerially from trees or poles. In a tranmission system there are various phases used to form the completed system. In general these phases are as felows: a. Phase I A multiconductor cable of specified length (the main, or longest length of the assembly) with a univeral connector at each end for quick assembly or disassembly. One or more of these lengths are connected together to form the length desired.
,tb.

Phase 2 A multiconductor cable of approximately 100 feet in length, the same construction as in Phase I, with a universal connector at each end. This shorter assembly is used to span short distances between equipments, between equipment and the end of a line, or betwee;a two cabled assemblies. c. Phase 3 A multiconductor cable of approximately 12 feet in length, a universal connector at one end and exposed

Solid polyethylene rod, heat-stabilized. 4. Cabling Four conductors, two brown-colored (pair #1) and two natural-colored (pair #2), cabled around the core with a 2 in. right hand lay. When cabling, the two conductors constituting a pair shall not be zdjacent, but diagonally opposite when viewed from cross section.

9-23

AMCP 706-125 S. Inner Jacket Extruded natural polyethylene. The jacket shall be extrusion applied. Extrusion application is mandatory in order to fill all cable core voids and consequently hold core in above cabled position. Jacket shall have a round, smooth, outer perimeter, 6. StabilizLng Tape A capacity stabilizing tape shall be applied over the inner jacket, either longitudinally or in a helical wrap, at manufacturer's option. The tape shall have a surface resistivity of less than 10,000 ohms per square unit of material used. 7. Identfication MaTker A standard manufacturer's identification marker tape shalt be inserted over the stabilizing tape, as well marker tape denoting year of as a separate additional manufatureexhibited 9-6.4 PULSE CODE MODULATION CABLES 9-6.4.1 FDM and PCA Systems such as For many years Spiral Four cables, previously described, were used as standard equipment in field telephone communication systems. These systems were referred to as FDM (Frequency Division Multiplex) systems. These systems operated at a frequency of upproximately 400 kHz. Recently a more refined system has come into use utilizing two coaxial cables instead of the usual four wire systems. This system is called a PCM (Pulse Code Modulation) system. Cables used in PCM systems are Signal Corp cables CX-4245 and CX-1 1230; these two cables are described and discussed later in this chapter. 9-6.4.2 Cable Requirements A recent PCM system cable, Signal Corps No. and tested. the cable CX-4245/G, two was major developed deficiencies, although the electrical characteristics were satisfactory. Accordingly, this cable was considered only as a limited standard. The two major deficiencies noted were as follows: 1. Inadequate tensile strength to resist breakage during typical installation and payout. 2. Excessive weight and stiffness for easy field handling and payout. This configuration and the corresponding test results did, however, point up the necessity and importance of the shielding qualities of the construction. In PCM systems this quality is considered a major portion of the effectiveness of the installed system. Highlighted also were weight and the tensile properties r.eeded, especially in aerial installations where the cable is strung from pole to pole over appreciable spans. With these points "n mind, a second cable configuration was developed to try to overcome the deficiencies noted in the CX-4245/G cable. The second cable, CX-1 1230 ( )/G (Reference c - par. 9-6.8) was fabricated utilizing smaller coaxial cable constructions with an extruded, foamed, polypropylene dielectric. Thin extrudeJ, polyethylene jackets were applied over each coaxial shield in order to isoiate each coaxial cable, affording better shielding qualities and still using the same shield configuration. The two coaxial cables were then twisted and a Mylar binder tape, a shielding braid, and an overall sheath were applied to the twisted coaxial cables.

8. Braid An open-weave stainless steel braid shall be applied over the stabilizing tape. 9. Sheat.h The outer sheath shall be composed of a tough, tight fitting, nonfiee stripping, low temperature, plastic compound. 9-6.3 TESTS FOR CABLE a. Breaking Strength b. Low Temperature Range to -55 0 C c. DC Resistance d. Dielectric Strength e. Insulation Resistance f. Capacitance Unbalance (pair-to-pair) g. Capacitance Uralance (pair-to-ground) h. AC Resistance i. Mutual Capacitance (conductor-to-conductor) 9-24

AMCP 706-125 9-6.5 CONSTRUCTION AND PERFORMANCE DATA Comparative construction and performaace data of CX-4245/G and CX-11230 ( )/G are given in Table 9-7. To improve the shielding effectiveness and strength of the cable, and at the same time reduce the weight of the cable, a shield consisting of a closely woven #32 AWG, 30% conductive, copperweld strand was used on the CX-11230 ( )/G. Furthermore, the shield of the cable was carried through the shell of the dual coaxial connector in the termination of the CX-11230 ( )/G; whereas, the shield of the CX-4245/G was terminated approximately two feet from the back of each single coaxial connector. This shield construction and carry-throuh accomplished three things: 1. It increased the shielding effectiveness by the increased shielding coverage of the cable core, the increased conductivity of the wires used in the shield configuration, and the direct shield termination to the shell of the connector. 2. It increased the flexibility and tensile properties of the cable. 3. It reduced the weight of the cable. An extruded, black polyethylene sheath was applied overall with smaller major and minor diameters. 9-6.6 CABLE TESTING The qualification tests performed on each cable are described in the paragraphs which follow, 9-6.6.1 Test Procedures and Requirements For procedures and requirements for the following tests refer to Specification No. 2$.'71606 ITT Federal Laboratoies: aoaois a. Dielectric Strength b. Dimensional Stability c. Flow Test d. Tubing Test e. -55 0 CBend Test The framing, or susceptibility, criterion was the ability to operate a radio set transmitting at full causing "loss of frame" of the PCM terminal equipment. The radiation from the cable criterion was to have no pickup of the PCM signal greater than 3 db above ambient noise level, by a suitable detector, at a distance as close as fifty feet to the system. 9-25 f. Low Temperature After Aging
g. Breaking Strength - Static

h. Breaking Strength - Dynamic i. Attenuation j. Impedance k. Shielding Effectiveness 1. Tensile Strength m. Sag 966.1 TsPo The following is a more detailed discussion of the attenuation, shielding effectiveness, tensile, and sag qualities of the aforementioned cables. 9-6.6.1.2 Shielding Effectivenea The shielding effectiveness of the PM ystem was tested in the following two major areas. 1. Framing tests, or susceptibility of. #stem to pickup of electromagnetic radiation from outside transmitters. 2. Radiation, or interference, from systcn* which could affect outside receivers. The basic cable communication configuratioi for field testing the system consisted of two halftmile cable lengths with connector assemblies, mated at .the half-mile point and installed on a pole line. The terminal ends were connected to PCM equipment which was housed in shelters one mile apart. 9-6.6.1.2.1 Framiny Ts

[1

N,

if

AMCP 76-25

TABLE 9-7

ONSTR CTlON AND PERFORMANCE DATA-PCM CABLES

Coaxial Cable Construction: Conductor Primary Insulation Shield

CX-4245/G

CX-1 1230( )/G

#X2AWG (710.010 iin.), 0.030 in. annealed bare copper Solid polyethylene, 0.108 in. #36 AWG, Copper Alloy 85, 0.138 in. Hi-density polyethylene, 0.170 in. 6 in. right hand lay None #30 AWG, Copper, 0.400 in. (major dia) Hi.density polyethylene, 0.440 in. (major dia)

#22 AWG (7/0.010 in.), 0.030 in. annealed bare copper Foamed propylene, 0.090 in. #36 AWG, Copper, 0.117 in.

Jacket Twist Binder Shield Overall Jacket

Low-density polyethylene, 0.139 in. 6 in. right hand !ay Mylar tape, 0.001 in., 25% overlap #32 AWG, 30% conductivity copperweld, 0.324 in. major dia Medium.density polyethylene, 0.364 in. (major dia)

Performance Data: Weight, lbimi Strength, lb Connector Retention, lb Shielding RFI dist, ft Vehicle Crossings Handling 500 450 308 750

140 <100 25f)00 Stiff

40G <100 30,000 Flexible

*Provisions

were made in the test set up to allow

b. TD-206 Pulse Restorer modified with tev.foot

"pigtail" cables terminated with connectors which mated with the CX.1 1230( )/G Cable. c. AN/GRC - 26 Radio Set transmitting at full power.

evaluation of the eflects of various shieldig and grounding configurations. Shown in Table 9-8 are test results obtained on cable CX-1 1230 ( )IG for seven different test conditions. The equipments used were:

a. AN/TCC - 46 PCM equipment housed in the shelters and connected to cable terminal ends.

Shown in FiE. 9- -,1. is a schematic of field test set up for transmission sn, shielding tests.

9-26

AIVICP 706.123

TABLE 9-8 FRAMING OR SUSCEPTIBILITY DATA-PCM CABLES

(RADIO SET OPERATING AT 2.304 MHz)

Test
Point
C A B 0 130 100 90 85 5 110 100 85 74 200 300(G) 150(O,) 300(U)
-

Test Condition Nuimber

4 55(G,U) 50(GU) 40(r,,U 35(GU) 5U 48(U) 45(GU) 50(U) 50(GU) 6 65(U) 55(U) 50(U) 20(GUI

C
D

S0(0,)

10(GU) 10(G,) 10(G,U)

In Frame Distance (Feet from Cable)

Note:

C-=Shield braids grounded at both shelters.

U=Shield braids ungrounded at both shelters.

Test Conditions Condition 1. Without restorer. Coaxial and shield braids not shorted at connectors. Shield braids not continuuus from cable to cable.

Condition 4. Without restorer. Other conditions same as in condition 3. Condition 5. Without restorer. Coaxial and shield oraids not shorted at connectors. Shield braids

continuous from cable to cable. Condition 2. lead WithOter restorer. Restorer sae and restorer a in cndiion unhieded
leads unshielded. Other conditions same as in

Cond~ition 6.

With restorer. Restorer and restorer

Conditiorn 1.
With restorei. Coaxial and shieid Condition 3. braids shorted at connectors. Other conditions same as in Condition 2.

leads shielded. Other conditions same as in Condition 5. 5 Condition 7. With restorer. Coaxial and slield braids shorted at connetors. Shield braids continuous from cable to cable.

I--

9-27

AMCP 706-125

(
Mile Mile %a

CX-11230( )/G

CX-11230( )/G

CONNECTORS SHELTER SHELTER

2ft

ft

UNSHIELDED PIGTAIL LEADS Figure 9-12. Field Test Set.up for Transmission and Shielding Effectiveness

The conclusions, based on the Table 9-8 data, show that the one significant factor of Conditions 4 through 7 is that the shield braids are continuous from cable to cable. It is important then, that the connector utilized provide a means for preserving the continuity of the 4hield braid from assembly to assembly.

9-6,6.1.2.2 Radiation from Cable Measurements were obtained using the same PCM cable and system set up as in framing tests. The measurements were made with an NM-20B, RI-FL meter at 2.304 MHz. TJ.1 results of these tests are shown in Table 9-9 under four different test conditions, all without continuity of shield braids from cabic to cable.

'1

9-28

('5

I
AMCP 706-125

)TABLE

9-9 RADIATION FROM CABLE DATA-PCM CABLES (RADIO SET OPERATING AT 2.304 MHz)

rest Point
12 A B C D
-

Test Condition Number 34 0 0 0 0 2 0 1 1

10 12 7 7 Radiation

20 23 20 21 (db above ambient)

Note: Radiation was measured at a distance of 50 feet from cable.

Test Conditions Condition I 0 Without restorer. Coaxial and shield braids not shorted at connectors. Shield braids not continuc uw from cable to cable. Condition 20 With restorer. Restorer and restorer leads unshielded. Other conditions same as in Condition 1. Condition 30 With restorer. Coaxial and shield braids shorted at connectors. Other conditions same as in Condition 2. Condition 4* Without restorer. Other conditions same as in Condition 3. 9-6..1.2.3 Calculation of Shielding Effectiveness (References a and d of Dar. 9-6.81 The equation, put in written form, for cvaluating the relative shielding effLvezness of a cable configuration is presented as: Shielding Etfectiveness(SE) = Energy transmitted into inner coaxial (9-3) Energy leakage into outer coaxial as expressed in equtation mathematical The r'esulting logarithmic form is:

SE

20 logo

'\VL)Z

+1010g

10

+\20"g

7n

-10 logo

L2Z~ R

+OCD

R)

+3, db

(9-3a) 9-29

""

AMCP 706-125 where a. Determine Sag Factor by Eq. 9-4

V, VL
R Z,

= =

voltage inputSa voltage outputT

resistance across output characteristic cable characteristic impedance
t impedance of triaxial tes er discontiuity capacitance

Sag Factor

Sa a

(9-4)

F ctr - P b. With the Sag Factor calculated by Eq. 9-4, enter the Sag Table 1, Rome Cable Co. Manual, for the given parameter and determine a corresponding value x, the numerical equivalent of the Sag Factor. c. Determine T by Eq. 9-5 T = SPW (9-5)

= =

Zt = CD =
=

phase constant of cable radian length of triaxial test-r

where S S1 W T
X

o) L

= =

=
= =

span, ft sag, ft cable weight, lb/ft tension in unsupported cable span, lb numcrical equivalent of sag factor (from Sag Table 1).

Z0 , Zt, 'P,, and CD are all dependent on the physical and dimensional characteristics of the various test specimens and the tester. Therefore, from the standpoint of comparison evaluations of a narticular cable type, the only portion of the equation that varies with external The values of braid type is the 20 loglo

=
=

VL

relation. Shown in

Sample calculation:

Fig 9-13 is a schematic diagram of a typical test set up for low frequency (0.2 to 10 MHz) shielding effectiveness measurements.

Span = 150 ft Sag in 150 ft span = 2 ft b. Solution:

9-6.6.1.3 Tensile and Sag (References b and e, par.

be used in aerial installations are the tensile or b,:ing strength qualities which, in a great part, determine the sag factors which can be allowed over a span. Determining the cable tension over a specified sagging span (such as between two poles) is calculated according to the following procedure:

Sag Factor 150

0.0133

I.30

r
From Sag Table I, Rome Cable Co. Manual, determine x (150)(0.0964) for sag factor of 0.0133 T T 0.106 (from Sag Table 1).

AMCP 706-125

=(150)

.0964)

0.106 T
=

a c

= srog given in table for span length A, in. = sag given in table for span length C, in. PROTECTION OF CABLE

136.4 lb tension

9-6.7 LIGHTNING
SYSTEMS

1
t

It is important to note that the tension T as determined in the calculations, is not the only determining factor in the amount of tension a cable span may have to withstand. Environment - or where the cable is installed - will have a great bearing on the tension, or tensile properties, of installed aerial systems. Some factors which must be taken into consideration are ice and/or snow loading, wind whip, rain, temperature, etc. Table 9-10 shows minimum sag for Spiral Four and PCM cable aerial spans based on tensions of 100 lb at 60PF. The table shows sag for various span lengths of self-supported cables carried on poles or frames in medium loading areas. Cables that are attached directly to trees should hav a greater sag allowance. Normally, wires and cables increase in length (sag) with a temperature increase but, because of its construction, Spiral Four cable will decrease in length, or sag, as temperatures increase. For this reason greater sags are provided for Spiral Four cable type at lower temperatues. Table 9-11 indicates minimum sag for self-supprted Spiral Four cables calculated for different temperatures. The sag for any span length other than thos shown arTables 9-10 and 9-11 may be found by substituting values from the tables and using Eq. 9-.6. UnknoC sag = (B--A). xC - A) a 9-6 where B A C = = = span length for which sag is required, ft span length in table just before B, ft span length in table just after B, ft

See Electrical Report of Tactical Communications Systems, Contract DA-36-039-SC-73089, U. S. Army Sigra Research and Development Laboratory, Fort Monmouth, Now Jersey. 9-6.8 REFEREP!CES FOR PCM AND MULTICHAHJWEL CABLES AND SYSTEMS

The following specifications and documents are recommended for further information on PCM cables and systems, and multichannel communications cables. a. ECOM Technical Report Effectiveness of PCM Cable System. telephone

2788, Shielding

b. ECOM Technical Report 2711, Aerial Installation of Cable Assembly, Special Purpose, Electrical CX-4245 ( JIG. c. ECOM Technical Report DA Task 1E640306D48706 Evaluation of Pretmitry Engineering Development Models of Cable Assembly, Special Purpose, Electrical CX-11230 ( #/G. S d. J. A. Allen of USAECOM, Technical Paper, A Proposed Standard for Testing the Shielding Effectiveness of Coaxial Cables and Shielding Material. e. TM 11-381, Cable Assembly CX-1065G, Telephone Cable Assemblies .Y-1606/G and CX.1512/U, and Telephone Loading Coil A:.embly CU-260/G. f. MIL-C-10581 (Signal Corps), Cable, Telephone; Cable Assemblies, Telephone; Coil Assembly, Teleph-.one Loading; Dwg SC-A-46846-B, Cable Assembly, Special Purpose, Electrical CX.4245( )/G. 9-31

_______________

AMCP 706-125
COAX SWITCHER (DPDT) BIRD ELECTRIC CORP. TYPE 72-Rl

-I

---

II

SN

G
' -

Al

URM-85

GEN. ROD.1001-A

01~

WICV-1101

A2

R2

,L.

TRIAXIAL TESTER DWG#ES-DL-172775 MOD-#ES-C-172780

1.(
Figure 9-13. Low Frequency Shielding Effectiveness Test Set-up TABLE 9-.10 SAG DATA-SPIRAL FOUR AND PCM CABLES CX-42451G CX-1 12301 )Ij Sag, in. Span, ft
100

Spiral

WF-8/G

at 60F 16 24 36 48 72

Sag, in. at 60F 11 17 25 37 64

125 150 175 200

q -3( .o-32
i
--_____ ______

AMCP 706-125

TABLE 9-11 SAG AT VARIOUS TEMPERATURES--SPIRAL FOUR CABLE

Span Length, ft

Ojj OF]

Th~

W0F
Minimum Sag, in.

90-F

120*F

100

13

12

11

11

10
is

125
150 175 200

19
28 40 68

18
26 38 66

17
25 37 64

16
24 35 62

23 34 61

250
300

139
224

137
222

136
221

134
219

132
217

q
S-_

i-i

"

AMCP 706-125

REFERENCES
1. USAJECOM Contract No. DA.28.043.AMC.00045 (E), Extra Flexible, Lightweight, Tactical Cords. 2. USAECOM Contract No. DA-28.043-AMC-00471 (E), Subminiature Cords. 3. FM 24.20, Field Wire and Field Cable Techniques. 4. J.C-98, Wire and Cable, Insulated; Methods of Sampling and Testing. 5. MIL4-572, Cords, Yarns and Monofilaments; Organic Synthetic Fiber. 6. MILC-3849, Cord, Electrical (Tinsel). 7. MIL-3883, Cord, Electrical (Audo Frequency). 8. MILd2-3884, Cord, Electrical(Short ay). 9. MIL4.3885,Cable Assemblies and CordAssemblies. 12. MIL-C-10581, Cable, Telephone; Cable Assemblies, Telephone; Coil Assemblies, Telephone Loading. 13. MIL-C-11997, Cord Assembly. Electrical, CX-2151 /U (Retractile). 14. MIL.C.13268, Cable, Telephone (No. 19 A WG and 20 A WG) Switchboard Cable. r S 2 MIL-C-13273, Cord, Electrical (Retractile2, 3, and 15. 4 Conductor, WD-9/U, WT-2/V, WF-4/U). 16. MIL.C-13294, Cable, Telephone, Electrical, (Infantry Field Wire) Twisted Pair, Wire WD-1/TT and WD-14/7T. 17. MIL-C-55036, Cable, Telephone, WF-130( )UG. 18. MIL-C-55425, Cable, Telephone, WF-16 (
J1U.

10. MIL-C-10369, Cables, Telephone, Field, For Rapid

19. MIL-C-55462, Cable, Telephone WD-36 ( )/TT Dispersion, Cable VX-6894 ( )/TT and Dispersion, CableMX-6895 ( )/TT 9 ) M

Payout, (AIX-306 AIG).

11. MIL.4-10392, Cables, Special Purpose, Electrical (Miniature).

20. MIL-W-3795, Wire, Electrical Tinsel).

21. USAECOM Technical Report 2657, Laboratory Evaluation of Field and Assault Cable.

9-3

'*1

(/

AMCP 706-125

APPENDIX
Document ASTM-B-33 ASTM-B-286 Title Tinned, Soft or Annealed Copper Wire for Electrical Purposes. Specification For Copper Conductors For Use In 1Hook-up Wire for Electronic Equipment. Specification for Silver-Coated, Soft or Annealed Copper Wire. 3pecification for Nickel-Coated, S'oft or Annealed Copper Wire. Tests for A-C Capacitance, Dielectric Constant, and Loss Characteristics of Electrical Invulating Materials. Special Technical Publication #319 Aerial Installation of Cable Assembly, Special Purpose. Evaluation of Preliminary EngineeringDevelopment Models of Cable Assembly, Special Purpose, Electrcal. Wire and Cab. ., Insulated; Methods of Sampling and Testing. Cables, Radio Frequency, Coaxial, Dual Coaxial, Twin Conductim and Twin Lead. Cords, Yarns, and Monofilaments; Organic Synthetic Fiber. Cable, Cord, and Wire, Electrical (Shipboard Use). Cables, Power, Electrical Reduced Diameter Type, Naval Shipboard. Cable and Wire, Electrical(Power and Control, Flexible and Extra Flexible, 300 and 600 Vots). Cable, Power, Electrical;Ignition,High Tension Cord,Electrical(Tinsel). Cord,Electrical(Audio Frequency). Cord,Electrical(Short Lay). Cable Assemblies and CordAssemblies. Specification For Jable,Electric,Aerospace Vehicle.

ASTM-B-298 ASTM-B-355 ASTM-D-150-59T ASTM.Reference CX-4245/G CX-l 1230 ( )iG

J-C-98 MIL-C-17 MIL-C-572 MIL-C-915B MIL-C-2194 MIL-C-3432C

MIL-C-3702 MIL-C-3849A MIL-C-3883 MIL-C-3884 MiL-C-3885 MiL-C-7078

-)

A-1

____

AI1,CP 706-125

APPENDIX (CONT.)
Document MIL-C-10369 MIL-C-10392B MIL-C-10581 MIL.C-11311 MIL.C-11997A MIL-C-13268 MIIC-13273 MIL-C-13294B Title Cables, Telephone, Field,ForRapid Payout(MX-306 AIG). Cables, SpecialPurpose,Electrical(Miniature). Cable Telephone; Cable Assemblies, Telephone; Coil Assemblies, Telephone Loading. Cables, Telephone, WD-31/U and WT-24/U (Inside Telephone Station). CordAssembly, Electrical,CX.2151 (/U (Retractile). Cable, Telephone (No. 19 A WG and 20 A WG) Switchboard Cable. Cord,Electrical(Retractile2, 3, and 4'Conductor, WD-9/U, WT-2/U, WF.4/U). Cable, Telephone, Electrical (Infantny Feld Wire) Twisted Pair, Wire WD-117T and

WD-)4/T.
MIL-C-13777E MIL.X-23020 MIL-C-23206 MIL-C-24145 MIL.C-25038 MIL.C-27072 MIL-C-27500 MIL-C-55036 MIL-C-55425 MIL-C-55462 Cable, Special Purpose,Electrical. Cable, Coaxial (ForSubmarine Use). Cable, Electric, Thermocouple. Cable, Electrical,Secial Purpose,ForShipboard Use. Cable, Electric,Aircraft, High Temperatureand Fire Resistant. Cable, Special Purpose,Electrical,Mdti-Conductor. Cable,Electrical,Shielded and Unshielded,Aircraft and Missile. Cable, Telephone, WM.13 ( )IG. Cable, Telephone, WF-16/U. Cable, Telephone, WD-36/TT Dispenser, Cable, MIX-6894 ( )/TT and Dispenser, Cal
,

MX.6895 ( #T
MIL-E-572 MIL-I.3930C Env.ironmental Testing, Aeronautical and Associated Equipment, General Specification For. Insulatingand JacketingCompounds, Electrical(Wor Cables, Cords, and Wires). Molding, Plastic Materal, Polyamide (Nylon) Rigid. Limits ForElectricalInsulation Color. Selected Standardsfor RFand Acoustical Parts.

MI-M-20693 MIL-STD-104 MIL-STD-202

A-2

-i

AMCP 706-125 2APPENDIX Document MII.-ST1Z 454 MIL-STD.681 MIL-STD-686 MIL-STD.810 MIL-T.5438 MIL-W-76 MIL.W.3795A MIL-W.5086 MIL-W-5088 MIL-W-7139 M.-W-8777 MILW-12349 * MIL.W 16878D MII,-W22759 MIL-W-27300 MIL-W-81044 MSFC-332 NAS-702 QQ:W.343

(CONT.)
Title GeneralRequirements For ElectronirEquipment. 'dentificatin Codingand Application ofHook-up and Lead Wire Ocble and Cord,Electrical;IdentificationMarkingand Color CodingOf Environmental Test Methods ForAerospace and GroundEquipment. Tester, Abrasion, ElectricalCable. Wire and Cable, Hook-up, Electrical, Insulated. Wire, Electrical(Tinsel). Wire, Electrical, 600 Volt, Copper,Aircraft. Wiring,Aircraft, InstallationOf Wire, Electrical,PolytetrafluoroethyleneInsulated, Copper,600 Volt. Wire, Electrical,Silicone Insulated,Copper, 600 Volt. Wi,'e, Hook-up Monochlororifluoroethylene Insulated. Wire, Electrical,Insulated,High Temperature (Navy). Wire, Electrical,FluorocarbonInsulated,Copper. Wire. Electrical,PolytetrafluoroethyleneInsulated, Copper, 600 Volt. Wire, Elrciric, CrosnkedPolyalkeneInsulated, Copper. Cables, Electrical,GeneralSpecification For. Wire. Electrical,Insulated, Copper, Hook-up and GeneralPurpose (For105 C Service). Wire, Electricaland Nonelectrical.Copper, Uninsulated.

I
I

A-3/A.4

-.___

IL
AMCP 706-125

BIBLIOGRAPHY

1. American Standard Definition of ElectricalTerms,

1941.

15. Handbook of Design Data on ElastomericMaterials

Used in Aero Space Systems, ASD-TR-61-234.

2. Communications Circuits, Third Edition, Ware and Reed, John Wiley & Sons, N.Y. I * 3. "Continuous Current and Temperature Rise in Aircraft Cables", Miltop Schach, AIFIE Trans. 71, Part 2, 197-203 (1952). 4. Copper and Copper Alloys, ASf M,Part 5. . *l 5. Current and Temperature Rise in Aircraft Cables, Milton Schach, NRL Report 3587, Part 1, 1949. 6. Current and Temperature Rise in Aircraft Cables, Milton Schach and Robert E. Kidweil, Jr., NRL Report 3936, 1952. 7. Current Rating for Bundled Wire - A Step by Step Procedure, Andrew Samborsky, U. S. Navy Electronics Laboratory, San Diego, California. ' i 8. Effects of Radiation on Materials and Components, Kircher and Bowman, Reinhold, N.Y., 1964. 9. Electic Transmission Lines, H. H. Skilling, McGraw-Hill Book Co., N.Y. 1951. 10. Elements of Power System Analysis, Stephenson, McGraw-Hill Book Co., N.Y. 11. Extra Flexible, Lightweight, Tactical Qords, USA EC0 M C ntract No DA28.043AMC.00045(E). 12. Field Wire and Field Cable Techniques,FM 24-20. Con tract 13. G3eneral Elec tric DA.28.043.AMC.OO296(E), 25 June 1965.

16. High Polymers, Volume X1, Polyethylene, Raff and Allison, Interscience, N.Y., 1956. 17. Insulating Materials for Design and Engineering Practices, Clark, John Wiley & Sons, N.Y., 1962. ;lation Directory - Encyclopedia Issue, Lake 2 , '-. Publishing Co., Libertyville, Ill., 1966. 19. KWIC Index. of Technical Papers (USA ECOM), Wire and Cable Symposia 1952-1966, November 1967, AD-6E1 308. 20. Laboratory Evaluation of Field and Assault Cable, USAECOM Technical Report 2657. 21. Measurement of Transmission Unbalance- Dual Coaxial and Twin Conductor Cable, Tech. Memo. M. 1344, U.Ft. S. Signal 26 Corps Enginearing Laboratories, Monmouth, December 1950. 22. Method for Calculation of Current Rating of Hookip Wire, EIA Standard RS-214, November 1958. 23. Rcfeence Data for Radio Engineers, Fourth Editioi,, International Telephone and Telegraph Corp. 24. ,eference Tables for Thermocouples, National Bureau of Standards Cicular 561. 25. Standard Handbook for Eletrical Engineers, McGraw-Hill Bok Co., N.Y. 26. Techuaa R SignalCorps. 27. Techniques for Application of Electronic Component Parts i, Military Equipment, Volume 2, Chapter 8, "RF Transmission Lines and Waveguides", McGraw-Hill Book Co., N.Y. em,.ent SC-1476, U. S. Army -

. "

14. General Electric Contract DA-36.039.SC-88974, 12 March 1964.

fil

B-1

|'!

AMCP 706-120

BIBLIOGRAPHY (CONT.)
31. Vinyl and Related Polymers, Schildknecht, John Wiley & Sons, N.Y., 1952. 32 rsadR CblG.ADumSiIac 32. iVires and RF Cables, G. A. Duniner, Sir Isaac London. Publishers, Pitman

28. Textbook of Polymer Chemistry, F. W. Billmeyer, Interscience, N.Y., 1957. 29. "The Power Rating of RIF Cables", AJEE Pmoceedings T978, R. C.Mildner, 1949. !

/2

30. The Vanderbilt Rubber Handbook, R. T. Vanderbilt Co., N.Y., 1958.

Ai

B-2

I
____

__________

AMCP 706-125

GLOSSARY
(In general, terms are defined with specific reference to their use in conjunction with electrical wire and cable)
-A-

abrasion resistance. Ability of material or cable to resist surface wear. accelerated aging. A test performed on material or cable meant to duplicate long time environmental conditions in a relatively short space of time. accelerator. A chemical additive which hastens a chemical reaction under specific conditions.
activator. A chemical additive used to initiate the

audio frequency. Pertaining to that band of frequency which is audible to the human ear. Usually 20 to 20,000
Hz.

autocatalytic degradation. Pertaining to degradation of certain materials, whereby the breakdown products of the initial phase of their degradation accelerate the rate at which subsequent degradation proceeds.
-.

B-

chemical reaction in a specific chemical mixture. adjacent conductor. Any conductor next to another conductor, either in the same multiconductor cable layer or in adjaceit layers.
V

binder. Usually a spirally served tape or thread wrap used for holding assembled cable components in place awaiting further manufacturing operati.'s. braid. A fibrous or metallic group of filaments interwoven in cylindrical form to form a protective covering over one or more wires. braid angle. A term used in the determination of the braid configuration relating to the angle of the braided filaments or fibers in relationship to the axis of the cable core being braided. braid carrier. A spool or bobbin on a braiding machine holding one group of strands or filaments consisting of a specified number of ends. The carrier revolves during the braiding operation. braid eids. In a braid, the given number cf strands used to make up one carrier. The strands are wound side by side on the carrier bobbin and lay parallel in the finished braid. braider. A machine used to apply a woven fibrous or metallic braid over a cable diameter. breakout. A term used to define a wire or group of wires in a multiconductor configuration which terminates somewhere other than at the end of the configuration. building wire. Wire used for light and power in permanent installation utilizing 600 volts or less. Olsuaily G.1

alternating current resistance. The resistance offered by any circuit to the flow of alternating current. ambient temperature. Any all-encompassing temperature existing within the given area. American wire gage. A standard used in the determidnation of the physical size of a conductor determined by its circular mil area. Usually expressed as AWG. ampere. The unit used for measuring the quantity of an electric current flow. One ampere represents a flow of one coulomb per second. antioxidant. A substance which prevents or slows down oxygen decomposition of a material, antiozonant. A substance which prevents or slows dowa material degradation due to ozone reaction. armor. Mechanical prot.ection, usually accomplished by a metallic layer of tape, braid, or served wires. Normally found only over the outer sheath. attenuation. Power loss ina an electrical system. In cables the loss is t:-pressed in decibels per unit lrngth of cable.

U'

AMCP 70C,125 in an enclosure and which will not be exposed to outdoor environments. bunch strand. Any number of conductor strands twisted together in one direction with the same lay length. butt wrap. A spirally wrapped tape over a cable core, where the trailing edge of one wrap just meets the leading edge of th- preceding wrap with neither overlap nor spacing. cold flow. Permanent deformation of the insulation due to mchanical forces, without the aid of heat softening of the i-isulating material. cold joint. A soldered joint made with insufficient heat. cold work. The hardening and embrittlcment of a metal by repeated flexing action. color code. A colored identification m; rk applied t.o the outside of a wire or cable componeiht, usually in the form of a stripe, to identify a given component within a

C-

complex.
compound. A teim used to designate an insulating material made by mixing two or more ingredients. To compound: the mixing together of two or more different materials t o make one material. concentricity. In a wire or cable, that measurement which is the location of the center of the conductor with to the geometric center of the circular insulation. concentric stranding. A group of uninsulated wire twisted so as to contain a center core with one or mor distinct layers of spirally wrapped, uninsulated wires lak. overall to form a single conductor. When more than one layer is present each layer must have a different lay legh( conductance. A measure of the ability of any material to conduct an electrical charge. Conductance is a ratio of the current flow to the pot.ntial difference causing the curreat flow at i s ends. conductivity (electrical). A term used in describing the capability of a material to carry an electrical chaige, i.e., conductance of a unit cube of any material. Conductivity of metals is usually expressed as a percentage of copper conductivity-copper being one hundred percent (IM0%). conductor. Any material capable of easily cairying an electrical charge. contrahelical. A terrm meaning t!e application of two or more layers of spiraily twisted, served, or wrapped materials, where each successive layer is wrapped in the opposite direction to the preceding layer. control cable. A multiconductor cable made for operation in control or signal circuits, usually flexible, small in size, and with relatively small current ratings. convection. A conveying, or transference, of heat or electricity by moving particles of matter.

cible. An insulated conductor or twisted group of c ,ndu.:tors used for the transmission of electrical ,.nergy. cabling. The act of twisting together two or more insulated components by machine to form a cable. capacitance The ratio of the electrostatic charge on conductor to the potential difference between the conductors required to maintain that charle. capacitive coupling. Eleftrical interaction between two conductors caused by the capacitance between them. capillary action. The phenomenon of liquid rising in a small interstice due to surface tension, cast tape. A macrial which is formed directly into a tape by means of flowing or "casting" a solution or dispersion of the film-forming material onto a suitable carrier, then removing the solvent-as epposed to skiving or slicing a block of material into a tape form. ceramic. Pertaining to a product made from inorganic, nonmetallic materials fused or fired at high temperatures; jsed as an insulation in cables when extremely high temperatures are to be encountered. cir".ular mil. A measurement used in determining the area of wire. The area of a circle one ooe-thousandth inch in diameter. cladding. A method of applying a layer of metal over another metal, whereby the junction of the two metals is contiruously welied, -- =relatively coaxial. A cable configuration having two cylindrical conductors with coincidental axes; such as a conductor with a tubular shield surrounding the conductor and insulated from i . G-2

I,.

. . -

ii

AMCP 706.125

copolymer. A term used to designate that two or more monomers are polymeri:ed together to form a dif rent material. core. In cables, a term used to deucte a component, or assembly of components, over which other materials are applied-such as additional components, shield, sheath, or armor. corona. A discharge due to ionization of a gas (usually air) due to a potential gradient exceeding a certain critical value. corona initiation point. The critical value, in the application of an electrical potential, where corona is first noticed by the detection device, crimp termination. A wire termination that is applied by physical pressuripg of terminal to wire. crosslinked. Inter-molecular bonds produced between long che'i molecules in a material to increase molecular size by chemical or electron bombardment, resulting in a change in physical properties in the material -- usually improved properties.

denier. A term describing the weight of a yar,, which in turn determines its physical size. deratinZ factor. A factor used to reduce P current carrying capacity of a wire when tho, wire is used in other envir mmunts from that for which the value was established. dielectric. An insulating material, usually haiing a very low loss factor. dielectric constant. That property K of an insulating material which is the ratio of the parallel capacitance C of a given configuration of electrodes with the nmaterial as the dielectric, to the capacitance of the same electrode configuration with a vacuum as the dielectric. dielectric phase angle. Angular difference in phase between the sinusoidal alternating potential difference applied to a dielectric, and the component of the resulting alternating current. dielectric strength. A term used to describe the limit, without damage, of an insulating material to an applied voltage potential. direct capacitance. The capacitance measured directly from conductor to conductor through a single insulating layer. direct current resistance. The resitance offered by any circuit to the flow of direct current. direction of lay. The direction of tist, either clockwise or counterclockwise, of a component, or group of components, when looking axially down the length. dissipation factor. The ratio of the conductance of a capacitor, in which the material is the dielectric, to its susceptance; or, the ratio of its parallel reactance to its parallel resistance; or, the ratio of the power loss to the circulating KVA. drain wire. In a cable, an uninsulated wire laid over the component, )r components, and used as a ground connection. it drain wire is frequently plaued under a shield. rawng. In the .mnufactur of wirc, pulling the maial through a die, or series of dies, for reduction of diameter to specifiedsize. dual coaxial cable. A configuration c-nsisting of two individually insulated conductors, parallel or twisted, placed within an overall shield and sheath. duct. Aw underground or overhead tube used for carrying electrical conductors.
G.3

cross-sectional area. The area of the cut surface of an object cut at right angles to the long axis of the object. Electrical interference betwean two adjacent cross-talk. insulated conductors, whereby a signal in one of the conductors will be picked up by the adjacent conductor. current-carrying capacity. The current a conductor of given size and length is capable of carrying safely without exceeding its temperature limitations, current penetration. The depth a current of a given frequency will penetrate into the surface of a conductor carrying the current. cut.through resistarce. The ability of a material to withstand mechanical pressure, usually a sharp edge of prescribed radius, without separation.

Id
")

-D decibel. Unit to express differences of power level, Example: The decibel is 10 times the common logarithm of the power ratio. It is used to express power gain in amplifiers or power loss in passive circuits or cables. delay line. A cable made to provide very low velocity of propagation with long electrical delay for transmitted signals.

.,

AMCP 706-125

durometer. A measurement used to denote the hardness of a substance. E% ifibrous eccentricity. Like concentricity, a measure of the center of a conductor's location with respect to the cicular cross section o? the insulation; expressed as a percentage of center displacement of one circle within the other. elastomer. Any elastic, rubber-like substance, such as natural or synthetic rubber. electric gradient. The space rate of change of potential at a point in the direction of the greatest change. electrical length. That length of cable expressed as degrees of a cycle, or fraction of a wavelength, for the signal transmitted. The equivalent electrical length of a cable equals the physical length times the square root of the dielectric constant. electrode. A conductor through which a current enters or leaves art electrolytic ce!, arc furnace, vacuum tube, gas discharge tube, or other nonmetallic conductor. electrolytic corrosion. Corrosion electrochemical erosion. by means of

-F-

farad. A unit of electric capacity. filler. A material used to fill interstices in cables, made from fibers such as cotton, glass, etc. field wire. A term defining a small, light, wire type, usually produced in long lengths for use in communications in the field. filler. (a) A material used in tue cable to fill large interstices where there are no electrical components. (b) A substance, often inert, added to a compound to improve properties and/or decrease cost. film. Another terni to describe thin plastic sheeting. flat conductor. A wire manufactured in a flattened form, as opposed to round or square. flex-life. Ability of a conductor wire or cable to withstand rep' ated bending. flux. (a) A material that helps produce fusion, as solder flux. (b) A continuous flowing or passing, as in the field . created by a magnet. fraying. In cabling, a term -ised to describe the unraveling of a fibrous braid. Of an alternating electric current that number of hertz (cycles per second), or completed alternations, per second. - Ggage. A term used to denote the phyrical size of a wire. giga-. A numerical prefix denoting one billion, as a gigahertz is one billion cycles per second. ground. An electrical term meaning to connect to the earth, or other large conducting body to serve as an earth, thus making a complete electrical circuit. giound support cable. A cable construction, usually rugged and heavy, for use in ground support control or power systems.

electrolytic tough pitch. A term describing the method of raw copper preparation to ensure a good physical and electrical grade copper finished product. s Te pfrequency. ele electrolysis. The production of chemical changes by passage of current through an electrolyte. electromagnetism. Magnetism caused by the flow of an electric current. electromotive force. That force which determines the flow of electricity; a difference of electric potential. electroplate. The term used to indicate the application of a metallic coating on a surface by means of celctrolytic action. embossing. A means of marker identification, the thermal molding of lettering in the sheath material of cable. ends. In braiding, a term used to denote the number of wires or threads wound side by side on a braider carrier. exothermic. Characterized by the liberation of heat.

G.

....

_,__________________________-

...-- - - , -

:,

--"

- ' -

-r

- ...

..

Cb
AMCP 701-125
-H-l-

hard drawn copper wire. Copper wire that has been drawn to size and not annealed. harness. A term used to describe a group of conductors laid parallel or twisted by hand, usually with many breakouts, laced together or pulled into a rubber or plastic sheath, used to interconnect electrical circuits. aash mark stripe. A noncontinuous, helical stripe, applied to a conductor for circuit identification. heat distortion. Distortion or flow of a material or configurat; n due to the application of hcat. heat seal. In cabling, a method of sealing a tape wrap jacket by means of thermal fusion, heat shock. A test to determine stability of a material by sudden exposure to a high temperature for a short period of time. helical stripe. A continuous, colored, spiral stripe applied over the outer perimeter of an insulated conductor for circuit identification purposes. helix. A spiral winding, ' the inductance of a henry. An electrical unit denoting circuit in which a current varying at the rate of one ampere per second produces an electromotive force of one volt. hertz. A designation of electrical frequency meaning cycles per second. hook-up wire. A wire used for low current, low-voltage (under 1000V) applications, internally within enclosed electronic equipment. horizontal stripe. A colored stripe running horizontally with the axis of a conductor, sometimes called a longitudinal stripc, uscdl as a means of circuit identification, hot dip. A term denoting the covering of a surface by dipping the surface to be coated into a molten bath of the coating material. hybrid cable. A multiconductor cable containing two or more types o' conductors,

ignition cable. A cable designed primarily for automoive ignition systems. impact strength. A test designed to ascertain the punishment a cable configuration can abscrb, without physical or electrical breakdown, by impacting with a given weight, dropped a given distance, in a controlled environment. impedance. The ratio of the effective value of the potential difference between two terminals to the effective value of the current flow produced by that potential difference. inductance That property of an electrical circuit by virtue of which a varying current induces an electromotive force in that circuit, or in an adjacent circuit. insulation. A nonconductive material usually surrounding or separating two conductive materials. Often called the dielectric in a radio frequency cable. insulation resistance. That property of an "nsulating material which resists electrical current flow through the insulating material when a potential difference is applied. integral belt. In a cable, a layer of insulation or semi-conductive material applied usually by extrusion over two or more insulated, twisted or parallel conductors, to form a round smooth cylinder. interconnecting wire. A type of wire for external use in electronic equipments where exposed to physical abuse. Interconnecting wire encompasses both control and power circuits. interstice. In a cable construction, the space or void left between or around the cabled components. ionization. The act of splitting into, or producing, ions irradiation. The exposure of a material to high energy emissions. In insulations for the purpose of favorably altering the molecular structure. -J
-

jacket. A material covering over a wire insulation or an assembly of components. An overall jacket on a complex cable grouping is also often referred to as a sheath.
G-5

)
___. _...... - .. ----

I
't AMCP 706-125

I/
-Kcaused by capacitance changes or self generated noise, induced by either physical abuse or adjacent circuitry. lug. A term commonly used to '.ascribe a termination, usually crimped or soldered to the conductor, with provision for screwing down to a terminal. - Mmagnetic field. The region within which a body or current experiences magnetic force.
L

kilocycle. A term denoting one thousand cycles. kilohertz. A term denoting tme thousand cycles per second. kilovolt. A term denoting one thousand volts. kilowatt. A term denotipg one thousand watts.

magnetic flux. The rate of flow of magnetic energy across or througa a surface (real or imaginary). lacquer. 'Ihe term used in cable manufacture to designate the liquid resin, or compound, applied to a fibrous braid to prevent fraying, wicking, moisture absorption, etc., in the braid. laminated tape. A term used to describe a tape consisting of two or more sealed layers,orusually each layer being a different mateiial, laminated together to form one tape. lay. A term used in cable manufacturing to denote the distance of advance of one member of a group of spirally twisted members in one turn, measured axially. life cycle. A test performed on a material or configuration to cetermine the length of time before failure, in a controlled, usually acce!erated, environment. litz wire. A conductor m.de up of several insulated, twisted wires to reduce skin effect and lower radio frequency losses. longitudinal wrap. A tape applied longitudinally with the axis of the core being covered, as opposed to a helical, o spiral, tape-wrapped core. loop resistance. The total resistance of two conductors measured round trip from one end (twisted pair, shield and conductor, etc.). loss factor. The loss factor of an insulating material is equal to the product of its dissipation and dielectric constant. low loss dielectric. An insulating material, such as polyethylene, that has a relatively low dielectric loss, making it suitable for transmission of radio frequency energy. low noise cable. A cable configuration specially constructed to eliminate spurious electrical disturbances, megacycle. One million cycles. megahertz. One million cycles per second. megavolt. One mllion volts. megawatt. One million watts. nmegohr. One million ohms.

melt extrude. To heat a material above its crystalline melt point and extrude it through an orifice. mho. An electrical unit of conductivity, being the conductivity of a body with the resistance of one ohm. microfarad. One millionth of a farad. microhenry. One millionth of a henry. mictoinch. One millionth of an inch. microwave. A short electrical wave, usually a wavelength of less than 30 cm. microwave frequency. The frequency of a microwave, usually above 1000 hertz. ml!. One one.thousandth of onc inch. millivolt. One one-thousandth of one volt. mining cable. A flame-retardant cable especially constructed to withstand long time immersion for underground use in the environment of a mine or tunnel. mismatch. A termination having a different impedance than that for which a circuit or cable is designed.

G-6

I
A!

iiAMCP
-

706-125
P-

modulus of elasticity. The ratio of stress to strain in an elastic material. monofilament. A term denoti . single strand filament as opposed to a braided or twisted filament. monomer. A term denoting a single property or ingredient. A molecule or' low molecular weight used as a starting material for polymerization to produce molecules of larger molecular weight, called polymers. uldkonductor. More thac, one component within a single cable complex. mutual capacitlce. Capacitance between two conductors when all other conductors, including ground, are connected together and then regarded as an ignored ground.

paste extru&d. An extrusion method whereby the extrudable material is in a fine powder form, mixed with a lubricant, and forced through a die of given size, without heat, as opposed to melt extrude. peak voltage. The maximum instantaneous voltage. percent conductivity. The conductivity of a material expressed as a percentage of that of copper. phase. A particular stage, or point of advancement, in an electrical cycle. The fractional part of the period through which the time has advanced, measured from some arbitrary point, usually expressed in electrical degrees, where 3600 represents one cycle. phase shift. A change in phase of a voltage or current after passing through a circuit or cable. pick. In a braid, a pick is the open area left by the crossing of any two carriers in the weave, axially along the weave. picofarad. One trillionth of a farad. pin. Denoting an electrical terminal, usually in a connector. Normally a smaller termination than a lug. pitch diameter. The diimeter of a circle passing through the centers of the conductors in any layer of a multiconductor cable. planetary twister. A twisting machine whose payoff spools are mounted in rotating cradles that hold the axis of the spool in a fixed direction as the spools are revolved about one another so the wire will not kink as it is twisted. plasticizer. A chemical agent added in compounding plastics to make them softer and more flexible. plating. The electrolytic application of one metal over another. polar ingredient. Any ingredient in a material or complex capable of ionization. polymer. A material having molecules of high molecular weight, formed by polymerization of lower molecular weight molecules. potting. The sealing of a cable termination, or other component, with a liquid which thermosets into an elastomer or solid compound to exclude moisture. G3-7

-N

neper. An electrical unit similar to decibel, used to express the ratio between two amounts of power existing at two distinct points. A neper is 8.686 decibels. noncontaminating compound. A compounded material that will not 1h ach ingredients, so as to contaminate or degrade adjacent materials, under given environmental conditions.

-0

ohm. A unit of electrical resistance, the resistance of a circuit in which a potential difference of c-'e volt produces a current of one ampere. ohm-poundimile. A unit of weight resistivity expressing the resistance of a wire one pound in weight and one mile in length. organic fiber. A fiber derived or composed of matter originating in plant or animal life, or composed of chemicals of hydrocarbon origin, either natural or synthetic.

overlap. The amount the trailing edge laps over the leading edge of a spiral tape wrap. ozone test. Exposure of material to a h;gh concentration of ozone to give an accelerated indication of degradation expected in normal environments.

6X7

AMCP 706-125 power factor. The atio of the power to the effective values of the electromotive force multiplied by the effective value of current, in volts and amperes, respedively. The cosine of the angle between voltage applied and the current resulting. primary insulation. The layer of material which is designed to do the electrical insulating, usually tMe first layer of materi3 app'ed over the conductor. propagation constant. A complex quantity, characteristic of a radio frequency transmission line, which indicates the effect of the line on the transmitted wave. The real part indicates the attenuation, the imaginary part the phase shift. cable specifically constructed to pulse cable. A withstand and transmit repeated high voltage pulses without undue physical or electrical degradation. push back. That property of a braid or shield which allows the braid or shield to be pushed back along the cable core easily. rope strand. A conductor composed of a center group of twisted strands surrounded by one or more layers of similar groups of twisted strands. round wire. A wire circular in cross section, as opposed to flat, square, etc. rupture. In the breaking strength or tensole strength tests, the point at which a material physically comes apart, as opposed to yield strength, elongation, etc.

' ,!

]
!i
,R

semi-rigid. A cable containing a flexible inner core and a relatively inflexible sheathing material, such as a metalli. tube, but which can be bent for coiling, spooling, or placing in a duct or cable run. series resistance. Any sum of resistances, installed in sequential order, within one circuit. serve. Any filament, or group of filaments, such as wires or fibers, helically wound around a central core. sheath. The material, usually an extruded plastic or elastomer, applied outermost to a wire or cable. Very often referred to as a jacket.,o shield. In cables, that metallic layer applied over the dielectric, or group of dielectrics, composed of woven, braided, or served wires, foil wrap or tubular metallic construction, to prevent electrostatic or electromagnetic interference between the enclosed wires and external fields. shunt. A device used to divert part of an electric current. signal. An electric current used to -',nvey information; digital, analog, audio, or video. sinter. To thermally cure or treat a material. skived tape. Tape shaved in a tbin layer from a cylindrical block of material. spark test. A test designed to locate pin.holes in an insulated wire by application of an electrical potential across the material for a very short period of time while the wire is reeled through an electrode. specific gravity. The ratio of the weight of any volume of substance to a weight of an equal volume of some substance taken as a standard, usually water for liquids. spiral wrap. A term given to describe the helical wrap of a tape or thread over a core.

rated voltage.

That voltage at which an electrical

component can operate for extended periods without undue degradation or safety hazard. 7actance. That part of the impedance of an alternating current circuit which is due to capacitance or inductance, reflection loss. That part of a signal which is lost due to reflection of power at a line discontinuity, reinforced sheath. The outermost covering of a cable, or that cable sheath which is constructed in layers, with a reinforcing material, usually a braided fiber, molded in place between layers. resistance. The property of an electric circuit which determines, for a given current, Ihe rate at which electric energy is converted into heat, and has a value such that the cu-ent squared multiplied by the resistance gives the power converted, ribbon cable. A cable consisting of two or more conduct(trs laid parallel in one plane and held in place by some means. root mean square. The effective value of an alternating periodic voltage or current.. G.8

-_L

.- ..

,s .

'

2 .

' -

"

" ...

.-

"-...

AMCP 706-125

square mil. The area of a square, one mil by one mil. strand. A single uninsulated wire. strand lay. The distance of advance, of one strand of a spiral? e stranded conductor, in one turn, measured axially.

thermal aging. Exposure to a give, thermal condition or a programmed series of conditions for prescribed periods of time.

thermal allDying. The act of uniting two diffeient metals to make one common metal by the use of heat. thermal expansion. The expansion of a material when subjected to beat. surface resistivity. The surface resistivity of a material is therma rafirg. The maximum or minimum temperature the ratio of the potential gradent parallel to the current at which a material will perform its function without along its surface to the curient per unit width of the undue degradation. surface, usually expressed in ohms. in the electrical That change thermal resitance. to hetr ucondctors he subjected o aheaterialw resistance Note:. Surface resistivity of a material is numerically to heat. when a material fro resistance of mteral s umeicaly Not: esitiityof Srfce equal to the surface resistance between two electrodes forming opposite sides of a sqt.are, the sqtare size being inunaterial.
-

Resistance to heat flow from conductors to outer surface of insulation or sheath in a wire or cable. thermal xesistivity. Thermal resistance of a unit cube-&F material.
thermocouple. A thermocouple wire joined at one end

T-

tesgand tank tesi A term used to describe a voltage dielectric a test, where the specimen to be tr :ed is submerged in liquid and a voltage potential placed between the conductor and the liquid os ground. tape wrap. A terni denoting a spirally or longitudinally applied tape material wrapped around the either insulated or uninsulated wire, and used as an insulation

used in conjunction with a thermoelectric temperature measuring device. When a temlperature difference exists between the junction and the device, a voltage is generated which can be calibrated to irdicate temperature. thermocouple wire. A two-c:onductor cable, each conductor employing a dissimilar metal, made up specifically for temperature measurements. thermocouple except the measurements themiocouple lead wire. Similar to thermocouple wire, degree of accuracy in- temperature is not as high, and it is used to transmit information to remote indicators.

or mechanical barrier, tarnish. A term used to describe a discolored or stained conductor or shield wire, caused by exposure to the atmosphere. tear test. A test to determine the tear strength of an insulating material, temperature coefficient of resistivity. T'he amount of resistance change of a material per degree of temperature rise. temperature stress. The maximum stress which can be applied to a material at a given temperature without physical deformation. tcimle strejigth. A term denoting the greatest longitudinal tensile stress a substance can bear without tearing apart or rupturing, tensile stress. Force, per unit cross-sectional area, applied to elongate amaterial. tension set. The condition when a plastic material shows permanent deformation caused by a stress, after the stress is removed.

thermosetting. The act of a material changing from a liquid, paste. er plastic form, to an elastomeric or rigid form, due to thc application of heat. tinsel wire. A very flexible conductor made by serving one or more very small, flat conductors over a fibious core, such vs a high tenacity rayon or glass fibers. torque test. A test designed to ascertain the stiffness of a material under given environmental conditions. tracer stripe. W.en mole than one color coding stripe is required, the first (widest) stripe is the base stripe, the others, usually narrower stripes, being termed tracer stripes. triaxial. A cable construction, having three coincident axes, such as conductor, first shield, and second shield, all insulated from one another. true concentric. A true concentric stranding, or twisted cable, occurs when each successive layer has a reversed direction of lay from the preceding layer. -

)G.9

FI
AMCP 706-125 twin coaxial. A configuration containing two separate, complete coaxial laid parallel or twisted around each other, in one cables, complex. volume resistivity. The volume resistance between two electrodes unit and unit apart, that are in contact of with, orarea imbedded in,distance a specimen, is the ratio of the direct voltage applied to the electrodes to that portion of the current between them that is distributed the volume of the specimen. Usually expressed in ohms/centimeter.

U -through ultraviolet degradation. The degradation caused by long time exposure of a material to sunlight or other containing radiation.' ultraviolet r as unidirectional concentric stranding. A unidirectional stranding3 is where each successive layer has a different lay length, thereby retaining a circular form without migration of strands from one layer to another. unidirectional stranding. A term denoting, that in a stranded conductor, all layers have the same direction lay. unilay stranding. A bunched construction having 19, 27, 37, or any number of strands, which might be found in a concentric stranding.

-Wwall thickness. A term exp'essing the thickness of 2 layer of applied insulation. water absorption ttst. A method to determine the water penetration through an insulating material after a given water immesion period. waterblocked cable. A cable specially constructed with no internal voids, to allow no longitudinal water passage under a given pressure. watt. A unit of electrical power; the power of one ampere of current pushed by one volt of electromotive force. wavelength. The distance, measured in the direction of propagation, of a repetitive electrical pulse or waveform between two successive points that are characterized by the same phase of vibration. wetting. The ability of a material to absorb moisture. wicking. The logitudinal flow of a liquid in a wire or cable construction due to capillary action. wire. (a) A single piece of slender, flexible metal, ranging in approximate size from a piece that is difficult to bend by hand, to a fine thread. (b) Several wires as in (a) twisted together (c) Wires as in (a) or (b) insulated. - Yyield strength. The minimum stress at which a material will start to physically deform without further increase in lead.

velocity of propagation. In cable measurements, a function of dielectric constant. The transmissior speed of an electrical signal down a length of cable compared to speed in free space - expressed as a percentage of speed in free space. ,, volt. A unit of electromotive force, voltage drop. A term expressing the amount of voltage loss from original input in a conductor of given size and length. " :| ,effective voltage standing wave ratio. The ratio of the maximum voltage to the minimum effective voltage measured along the length of a mismatched radio frequency transmission line. voltage stress. That stress found within a material when subjected to an electrical charge.

I,

AMCP 706125f

INV)EX

-AAbrasion Resistance coaxial cable. .. .. .. .. .. .. .... hook-up and interconnecting wire . .. sandpaper method test fixture .. .. ..... soecifications. .. .. .. .. .. .. .. ... test methods .*. .. .. ...... tungsten carbide rod method test fixture. .. .. .. .. .. .. .. ... Acetate Rayon, Saponified .. .. .. .. ..... Adhiesive Bonded Ribbon Wire .. .. .. ..... Aerial Installation cable sag calculation. .. .. .. .. .. ... cable tension calculation .. .. .. .. ... Aging Test, Hook-up and !a~terconnecting Wire. .. .. .. .. .. ...
AAir-spaced

5-30 3-1 6-26 6-26 6-25 6-27 2-17 4-21 9-31 9-30 3-7 5-5 1-5 1-6

Arm,~........................ braid coverage................. hybrid cable................... materials. .. .. .. .. .. .. .. .. .... paint, aluminum. .. .. .. .. .. .. ... uses .. .. .. .. .. .. .. .. .. .. .... Asbestos Fiber .. .. .. .. .. .. .. .. ... uses .. .. .. .. .. .. .. .. .. .. .... Attenuation .. .. .. .. .. .. .. .. .. ... calculation. .. .. .. .. .. .. .. .. ... due to conductor loss. .. .. .. .. .... vs frequency, coaxial cable .. .. .. .... vs frequency, field wire .. .. .. .. .... Audio Cord basic design .. .. .. .. .. .. .. .. ... conductor. .. .. .. .. .. .. .. .. ... table. .. .. .. .. .. .. .. .. ..... insulation .. .. .. .. .. .. .. .. ..... miniature special purpose .. .. .. .. ... cable configuration .. .. .. .. .. ... cabling. .. .. .. .. .. .. .. ..... cabling table .. .. .. .. .. .. .. ... color code .. .. .. .. .. .. .. .... conductor construction. .. .. .. ... design .. .. .. .. .. .. .. .. ..... identification .. .. .. .. .. .. ..... insulation .. .. .. .. .. .. .. ..... separator .. .. .. .. .. .. .. ... sheath .. .. .. .. .. .. .. .. ..... stay cord .. .. .. .. . ............ separator .. .. .. .. .. .. .. .. .. ... shield .. .. .. .. .. .. .. .. .. ..... AGWr ie...........-

6-13 6-15 8-2 6-13 6-13 6-15 2-18 2-18 5-8 5-9 5-13 5-15 9-14 9-1 9-1 9-5 9-1 9-4 9-4 9-4 9-6 9-4

Coaxial Cable. .. .. .. .. ..... Alloy Conductor .. .. .. .. .. .. .. ..... high strength, high conductivity .....

Ijvs

copper conductor, flex-life .. .. . . ....

Alternate Constructions, Retractile Multiconductor Cord. .. .. .. .. .. .... Aluminum C2onductor. .. .. .. .. .. ..... stranding table -power cable .. .. .. ... Angle, Braid .. .. .. .. .. .. .. .. ... and coverage calculation .. .. .. .. ... configuration .. .. .. .. .. .. .. .....

_19
9-9 1-4 7-17 1-Il 1-12 6-6 6-1, 6-10 2-14 2-3 6-13

conductor. .. .. .. .. .. .. .. ...

9-4

9-4 9-4 9-6 9-4 9-4 9-6 9-4 9-1 9-1

~~Application
bindei .. .. .. .. .. .. .. .. .. ..... color code. .. .. .. .. .. .. .. .. ... filmn. .. .. .. .. .. .. .. .. .. .. ... polypropylene insulation. .. .. .. ..... sheath, multiconductor cable. .. .. ..... Area, Circular Mil. .. .. .. .. .. . . . ....

B9-1 9-20 9-7 9-2

Basic Design audio cord. .. .. .. .. .. .. .. .. ... niultipair telephone cable. .. .. .. .... retractile multiconductor cord ...... tinsel cord. .. .. .. .. .. .. .. .. ...

INDEX (CONT.)
Basic Insulated Wire hyrdcable .. .. .. .. .. .. .. .. ... insulation selection, hybrid cable . . .. multiconductor cable. .. .. .. .. ..... selection, hybrid cable ...... Bend Test. .. .. .. .. .. .. .. .. .. ... ninety degree .. .. .. .. .. ... Binder application. .. .. .. .. .. .. .. ..... butt wrap. .. .. .. .. .. .. .. .. ... helical wrap, tape width selection tzble . hybrid cable .. .. .. .. .. .. .. .. ... materials .. .. .. .. .. .. .. .. .. ... multiconductor cable. .. .. .. .. .... multipair telephone cable. .. .. .. ..... open wrap. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. ... Bonduble Coating, Braid. .. .. .. .. . ... Bonded Ribbon Cable Configuration .... Braid angle .. .. .. .. .. .. .. .. .. .. ... carnier .. .. .. .. .. .. .. .. ....... coverage .. .. .. .. .. .. .. .. .. ... coverage and angle calculation ...... .. .. .. .. .. .. .. .. .. .. ... outer protective fiber, ignition wire .. .. .. .. .. .. .. .. .. ... reinforced, ignition wire .. .. .. .. ..... terminology .. .. .. .. .. .. .. .. ...
..

4.--strand F
.fixture,

8-1 8-1 6-6 8-i 6-18 6-20 6-12 6-12. 8-11 8-2 6-12 61 9-21 6-12 6-12 2-20 4-22 1-11A 1-11 1-12 1-12 1-11 8-19 1-11 8-19 1-11

Bundle, Prefabricated (cant.) jacket. .. .. .. .. .. .. .. .. .. .... lay .. .. .. .. .. .. .. .. .. .. ..... shield. .. .. .. .. .. .. .. .. .. ..... Specifications .. .. .. .. .. .. .. ..... Bundled Wire .. .. .. .. .. .. .. .. ..... core/sheath material selection table . .. derating. .. .. .. .. .. .. .. .. ..... insulation .. .. .. .. .. .. .. .. ... laced. .. .. .. .. .. .. .. .. .. ..... lacing. .. .. .. .. .. .. .. .. .. ..... references. .. .. .. .. .. .. .. .. ... shield selection table. .. .. .. .. .. .... uses .. .. .. .. .. .. .. .. .. .. ..... Bundling Ties. .. .. .. .. .. .. .. .. .. Butt Wrap Binder .. .. .. .. .. .. .. ... Butyl Rubber. .. .. .. mechanical properti.s thermal properties .. uses. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. ... .. ... .....

4-2 4-1 4-2 4-1 4-1 4-4 4-2 4-1 4-1 4-1 4-27 4-1 4-1 46-12 2-10 2-10 2-10 2-10

Luses.

CCable choice for equipment dosign. .. .. ..... coaxial .. .. .. .. .. .. .. .. .. ..... control and signal. .. .. .. .. .. ..... references. .. .. .. .. .. .. .. ... hybrid .. .. .. .. .. .. .. .. .. ..... multichannel communications .. .. ..... multipair telephone. .. .. .. .. .. ... nonhosinglwaterblock. .. .. .. .. ..... power .. .. .. .. .. .. .. .. .. ..... references. .. .. .. .. .. .. .. ... pulse code modulation. .. .. .. .. ... ribbon. .. .. .. .. .. .. .. .. .. ... special purpose .. .. .. .. .. .. .. ... references. .. .. .. .. .. .. .. ... 8-18 5-1 6-1 6 -29 8-1 9-23 9-17 8-12 7-1

Aend.

J.pick.

Braided armor, coverag . .. .. .. .. . . . . . . ... or woven ribbon cable. .. .. .. .. ..... shield .. .. .. .. .. .. .. .. . . . . .... Breaking/Tensile Strength, Test Method, Multiconductor Cable .. .. .. .. .. ..... Brown .and Sharpe, Wire Size .. .. .. ..... Bunch Strandiing .. .. .. .. .. .. .. ..... Bundle, l-efabricated. .. .. .. .. .. ..... color code .. .. .. .. .. .. .. .. ..... components. .. .. .. .. .. .. .. ..... construction .. .. .. .. .. .. .. .. ...

7-25
9-24 4-21

Isheath.

4-21 1 6-28 1-1 1-8 4-1 4-2 4-2 4-1

.. .. .. .. .. .. .. .. .. ...

6-13

8-1 8-20

tape .. .. .. .. .. .. .. .. .. .. ...
telephone .. .. .. .. .. .. .. .. ..... references .. .. .. .. .. .. .. .... thermocouple. .. .. .. .. .. .. .. ... triaxial.. .. .. .. .:. .. .. .. .. ..... Cabled Wire current rating procedure .. .. .. .. ... heat dissipation table .. .. .. .. .. ...

4-22I
9-1 9-34 8-13 5-1 4-6 4-19

1-2(

IDI

zt
AMCP 700-125 f

C)nINDEX
Cabling hybrid cable .................. miniature special purpose audio cord .. multichannel communications cable ... .... .nulticonductor cable ........... multipair telephone cable ......... .. .... power cable ................. retractile mutcoriductor cord ...... table-miniature special purpose ... audio cord ................ 8-1 9-4 9-23 6-7 9-21 7-2 9-8 9-6

(CONT.)
Capacitance (cont.) of a pair ...................... unbalance .................... ... pair .................... ... pair.to.shield .............. Carrier braid ..................... shield ..................... ... Cast Fluorocarbon Tape ........... ...

6-23 6-23 9-21 6-25 1I-1 5-23 2-16 5-22 2-14 2-18 2-14 2-14 2-18 5-16 S-20 2-16

Calculation ... . 5. -_9 attenuation ................. ... 1-12 braid coverage and angle ......... .. 9-30 cable sag, aerial intallation ........ 9-30 cable tension, aerial installation ..... .5-6 capacitance ................. 5-7 twin conductor coaxial cable ..... 3-7 core diameter, multiconductor cable . . 1-7 DC resistance ................. .... 3-3 electrical gradient ............. 5- 11 .. high frequency resistance ......... impedance .................. .... 5-5 5-6 ... inductance .................. 5-7 twin conductor coaxial cable ..... ... 6-22 insulation resistance ............ .... 5-9 phase constant ............... 5-9 ... phase shift .................. power rating ................ ... 5-22 5-8 ... propagation constant ........... ... 5-20 reflectien loss ............... 8-9 sheath thkkness-multiconductor cable . 9-29 ... shielding effcctiveness ........... 3-4 tomperature coefficient of resistivity .. 5-5 velocity of propagation .......... ... Calibration, Thermocouple Cable ...... Canvas Dispenser construction, field wire .......... field wire ..................
...

Causes, Co.Jial System Reflections ..... Cellilose Acetate Butyrtte filin, theimal properties .......... lacquer .................... Cellulose Acetate FHi, Thermal Properties .................. Cellulosic Film ................. Ceramic Fiber, Uses .............. .. ... ... ... ..

Characterisics Table .. radio frequency cable ........... seri-solid radio frequency cable ..... Chemical Cross-ilking vs Irradiation
....

8-15 9-14 9-i8 5-6 5-7 5-2 6-23 6-23 6-23 9-20

...

Capacitance calculation .................. .. twin conductor coaxial cable ..... .... coaxial cable ................ ... direct ..................... multiconductor cable ........... ... ... mutual .................... pair ................... .

Chemical Factors corrosion, hook.up and intercomecting wire ............ gaseous, Iiiok-up hiid .. interconnecting wire ........... insulation, hook-up and .... interconnecting wie.......... liquid, hook, up and ... interconnecting wire .......... outgassing, book-up and interconnecting wire ......... .... ... potting .................... ultraviolet, hook-up and interconnecting wire .......... ... Chemical Properties chloroprene ruober ............. ethylene propylene rubber ........ fluorocarbon rubber ............ natural rubber ............... .. ... ..

3-2 3-2 3-1 3-2 3-2 2-21 3-2 2-10 2-13 2-13 2-9

1-3

AMCP706-125

INDEX (CONT.)
Chemical Properties (cont.) polychiorotrifluoroethylene .. .. .. ..... 2-8 *polytetrafluoroathylene. .. .. .. .. ... 2-7 polyurethane .. .. .. .. .. .. .. ..... 2-8 polyvinylidene fluoride. .. .. .. .. ... 2-8 rubber .. .. .. .. .. .. .. ... 2-10 Cht-,mical Tests, Hook-up and 3-7 Interconnecting Wire. .. .. .. .. .. .... Chliooprene Rubber .. .. .. .. .. .. .... Achemical properties. .. .. .. .. .. ... electrical properties.... .. .. .. .. ..mechanical properties. .. .. .. .. ..... thermal properties .. .. .. .. .. .. ... 2-10 2-10 0 2-10 2-10 Coaxial Cable.................... abrasion resistance .. .. .. .. .. ..... air-spaced. .. .. .. .. .. .. .. ..... attenuation vs frequency .. .. .. ..... capacitance. .. .. .. .. .. .. .. .... construction .. .. .. .. .. .. .. ..... constructional considerations ...... contamination .. .. .. .. .. .. ..... coverings and sheaths .. .. .. .. ..... delay line. .. .. .. .. .. .. .. ..... double shielded .. .. .. .. .. .. ..... cnruto..........5-4 dual. .. .. .. .. .. .. .. .. .. .... dual parallel, construction dual twisted, construction ....... 5-1 5-30 5-20 5-15 5-2 5-3 5-29 5-30 5-27 5-28 5-1 5-1 5-3 5-4

4silicone

1;Chlorosulfonat
electrical properties. mechanical properties thermal properties .. uses. .. .. .. .. ..

Polyethylene
.. .. .. ..

.. .. .. ..

.. .. .. ..

.. .. .. ..

.. ... .. ... .. ... .....

2-13 2-13 2-13 2-13 1-1

electrical properties .. .. .. .. .. ....

Circilar Mil Area. .. .. .. .. .. .. .. ... Cladding. .. .. .. .. .. .. .. .. .. ..... conductor .. .. .. .. .. .. .. .. ..... conductor coating. .. .. .. .. .. ..... Coated Fibes . .. .. .. .. .. .. .. .. ... Coating braid, bondable, specialized .. .. .. ..... cladding, conductor .. .. .. .. .. ..... conductor .. .. .. .. .. .. .. .. ..... conductor, weight proportions ...... dual, conductor .. .. .. .. .. .. .. .... testfig. .. .. .. .. ... .. ...... .. .. .. .. .. .. .. ..

1-5 1-5 1-2 2-18

2-20 1-2 1-2 1-2 1-4 1-5 1-5 1-2 1-2 1-2 1-4 1-4 1-4 2-20 1-3 1-3 1-3 1-2 1-3

5-30 environmental conditions. .. .. .. .... impedance. .. .. .. .. .. ...... 5-1 introduction .. .. .. .. .. .. .. ..... low noisc. .. .. .. .. .. .. .. ..... 5-29 5-1 niaterials .. .. .. .. .. .. .. .. ..... power rating. .. .. .. .. .. .. ..... 5-22 5-28 pulse .. .. .. .. .. .. .. .. .. ..... reflerences. .. .. .. .. .. .. .. ... 5-31/5-32 sinle . .. .. .. .. .. .. .. .. ...... 5-1 special purpose .. .. .. .. .. .. ..... 5-28 5-22 system, reflection causes .. .. .. ..... twin conductor .. .. .. .. .. .. ..... 5-1 5-1 capacitance calculation ....... inductance calculation .. .. .. ..... 5-7 parallel construction. .. .. .. ..... 5-3 twisted construction. .. .. .. ..... 5-3 types. .. .. .. .. .. .. .. .. .. .... 5-1 5-$0 uses. .. .. .. .. .. .. .. .. .. .... 5-5 velocity of propagation. .. .. .. ..... voltage rating. .. .. .. .. .. .. ......-

5-1

~1ithickness .. ..

14 6-17 6-10 6-10 8-5 6-10 9-4 9-21 6-1l 9-8 6-11

elctroplate, conductor .. .. .. .. ..... hot dip, conductor .. .. .. .. .. .. ... Jmethods, conductor .. .. .. .. .. ..... nickel. .. .. .. .. .. .. .. .. ...... Ithermal properties. .. .. .. .. ..... thickness .. .. .. .. .. .. .. .. ... polyin-ide. .. .. .. .. .. .. .. ..... silver. .. .. .. .. .. .. .. .. .. ..... thermal properties. .. .. .. .. ..... thickness ... I... .. .. .. .. ..... thermal properties. .. .. .. .. ..... thickness .. .. .. .. .. .. .. .. ...

Cold Bend Test. .. .. .. .. .. .. .. ... Color Code application .. .. .. .. .. .. .. ... control and signal cable .. .. .. .. ... hybrid cable component .. .. .. ..... methods .. .. .. .......... miniature special purpose audio cord multipair telephone cable. .. .. .. ... numerical. .. .. .. .. .. .. .. ..... retractile multiconductor cord ..... sequence. .. .. .. .. .. .. .. .. ...

1-C

r
INDEX (CONT.)
Color Code (cant.) 6-11 60 Specifi4tations .. .. .. .. .. .. .. ... 6-12 striping. .. .. .. .. .. .. .. .. ..... table, related numbers .......... 2-18 Comintins Fier .. .... .. . CobntinFiesmethods. 1Comparison field wire constructions .. .. .. .. .... 9-10 hook-up wire types .. .. .. .. .. .... 3-8 interconnecting wire types .. .. .. .. 3-11/3-12 table, field wire cons~r'ictions ..... 9-13 9-11 table, field wire types. .. .. .. .. .... Complete Hybrid Cable Configuration
.

AMCP 706-125

8-12

Component and conductor, multiconductor constrniction .. .. .. .. .. .. ..... cabling, hybrid cable. .. .. .. .. ...... color code, hybrid cable ........ construction sample, hybrid cable . .. jacket dimnensions, multiconductor cable. .. .. .. .. .. .. .. .. .... placement, hybrid cable .. .. .. .. ... precabling test. .. .. .. .. .. .. .... prefabricated bundle. .. .. .. .. ..... shield covering thickness table ..... shielding, multiconductor cable . . . . twist, diameter multiplying factor table .. .. .. .. .. .. .. .. .... Compound, Potting. .. .. .. .. .. ..... epoxy resin. .. .. .. .. .. .. .. .....polysulf ide. .. .. .. .. .. .. .. .... polyurethdne . .. .. .. .. .. .. ..... proeris tabl . .. .. .. .. .. .. ... temperaturo vulcanizing ..... usyes.

6-3 8-2 8-5 8-4

Conductor (cont.) coating .. .. .. .. .. .. .. .. .. ..... cladding. .. .. .. .. .. .. .. ..... electroplate. .. .. .. .. .. .. ..... hot dip .. .. .. .. .. .. .. .. ..... .. .. .. .. .. .. .. ..... nickel .. .. .. .. .. .. .. .. .. ... nickel, thermal properties .. .. .. ... nickel, thickness .. .. .. .. .. ..... silver. .. .. .. .. .. .. .. .. ..... silver, thermal properties .. .. .. ... silver, thickness .. .. .. .. .. .. ... tin .. .. .. .. .. .. .. .. .. ..... tin, thermal properties .. .. .. .. .... tin, thickness .. .. .. .. .. .. ..... weight proportions .. .. .. .. .. ... construction, miniature special purpose audio cord .. .. .. .. ...... c'.pper .. .. .. .. .. .. .. .. .. . . copper-covered steel. .. .. .. .. .. ... data table .. .. .. .. .. .. .. ..... design, hook-up and interconnecting wire. .. .. .. .. .. .. .. .. .. ... diameter tolerances .. .. .. .. .. ..... dual-coated. .. .. .. .. .. .. .. ..... testing .. .. .. .. .. .. .. .. ..... electrolytic tough pitch (ETPO) copper form, power cable .. .. .. .. .. .. ... ignition wire. .. .. .. .. .. .. .. ... material elements .. .. . . . . . . . . . . material, power cables .. .. .. .. .. ... mechanical factors, hook-up and interconnecting wire. .. .. .. . . ... miniature special purpose audio cord multichannel communications cable multicconductor component construction .. .. .. .. .. .. .. ... raultipair telephone cable. .. .. .. ....
. -

1-2 1-2 1-2 1-2 1-2 1-4 1-4 1-4 1-3 1-3 1-3 1-2 1-2 1-2 1-2 9-4 1 1-5 1-6

6-7 8-8,8-9 8-7 4-2 6-8 6-6 6-4,6-5 2-21 ?1 2-22 2-21 2-22 2-21

3-5 1-1 1-4 1-5 1-1 7-2 8-17 7-1 9-4 9-23 6-3 9-21

5room
.'

~~1

.. .. .. .. .. .. .. .. .. ....

2-21

types.......................2-21 .. 1-8 Co:centic Stranding True. .. .. .. .... Concenteicity.....................5.30 Conductors

tetn......... nickel-coated, soldering.........-

1ikkotd A

~..

(OFHC) coper .. .. .. .. .. .. ... .1-1 cabl.............. .. .. .. .. .. .. .. .. 1-8S trndigmulticonductor cable ..... stranding table, aluminum, power cable .. ............ stranding table, flexible copper, power cable .. .. .. .. .. .. .. ..... 6-6 7-17 7-15

-S .... .... .. ally ...... allo.....................15 aluminum. .. .. .. .. .. .. .. . .... 15 audio cord .. .. .. .. .. .. .. .. .... 91 cladding. .. .. .. .. .. .. .. ...... 1-5

-1J

AMCP 706-125

INDEX (CONT.)
Conductor (cont.) table, audio cord .............. .... thermal factors, hook-up and interconnecting wire .......... .... thermocouple cable ............ ... tinsel ....................... Construction and performance table, pulse code modulation cable ................ canvas field wire dispenser ............ check list, hybrid cable .............. coaxial cable ............... .... comparison, field wire .......... ... comparison table, field wire ...... conductor, miniature special purpose audio cord ................. double-shielded coaxial cable ...... dual parallel conductor coaxial cable dual twisted condw'tor coaxial cable examples, thermocouple cable ..... field wire ................. dispenser ..................... flat wire tape caole ........... .... lay ..................... .... multichannel communications cable . . nulticonductor cable .......... .... multiconductor construction for cross.talk reduction ......... .... multipair telephone cable ........ ... prefabricated bundle ............... retractile multiconductor cord ..... ribbon cable ................ .... sample, hybrid cable ........... .... hybrid cable oomponent ....... shield .................... .... tape cable ................. .... thermocouple cable ........... .... tinsel conductor cord .................. .... ribbon ................. .... strand ................. .... triaxial cable ............... .... twin parallel conductor coaxial cable . twin twisted conductor coaxial cable . 9-5 3-5 8-13 9-2 Constructional (cont.) details, shield ................ factors, hybrid cable ............ ... ... 1-11 8-3 5-30 9-3 6-9

Contamination, Coaxial Cables......... .... Continuity, Retractile Cord ......... Contrahelical Lay ............... .... Control and Signal Cable color code .................. ... constructional design factors ....... ... electrical considerations .......... ... introduction ................. ... nonportable ................. ... physical consi'erations .......... ... portable ................... .... references .................. ... specifications ................ ... types ..................... .... uses ...................... .... Copper conductor .................. .... electrolytic tough pitch (ETP) ...... hot rolled .................. .... oxygen.free high conductivity (OFHC) ................ ... stranding table, flexible, power cable ............... ... voltage drop table ........... ... covered steel conductor .......... ... data table ................ ... ground wire size table, power cable . . . rod ...................... .... vs alloy conductor, flex-life ........ .. wire, dimensions .............. ... Cord audio ..................... ... miniature special purpose ....... ... .... retractile .................. multiconductor ............... stay ....................... tinsel .................... .... Core and sheath material selection table, bundled wire .............. .... binder, hybrid cable ........... .... diameter calculation, multiconductor cable .......... ...

9-26 9-14 8-1 5-2 9-10 9-13 9-4 5-4 5-3 5-4 8-16 9-9 9-13 4-23 6-8 9-23 6-3 6-16 9-21 4-1 9-8 4-.21 8-2 8-4 5-23 4-22 8-16 9-2 9-2 9-2 5-4 5-3 5-3

6-10 6-1 6-2 6-1 6-2 6-1 6-2 6-29 6-29 6-2 6-1

1-1 1-1 1-1 1-1 7-15 7-24 1 -5

I

7-2
1-1 1-19 1-2 9-1 9-4 9-2 9-7 9-4 9-1 4-4 8-7 8-8

Constructional considerations, coaxial cable ...... 5-29 flat wire tape cable .......... ... 4-23 data, hook-up wire ............ 3-8 interconnecting wire ......... 3-11/3-12
1.6

AMCP 706-123

)
Core (cont.) l,4y-up, hybrid cable ............ multichannel communications cable shield, multiconductor cable ....... wrap, multipair telephone cable .....
Corona .....................
.

INDEX (CONT.)
8-7 9-23 8-8 9-21 5-14 8-18 ... .. ... ... .. ...
. .

Current Rating correction factors, power cable in air .. correction factors, ... power cable in conduit ......... .... procedure, cabled wire .......... procedure usage .............. ....
- D-

7-11 7-9 4-6 4-7

...

Correlation Table, Temperature/Electromotive Force. . .. Corrosion, Hook-up and Interconnecting Wire ............ Cotton Fiber, Uses ............... Coverage armor braid ................. braid, calculation .............. C Coverings and sheaths, coaxial cables ........ shielded components, multiconductor cable. .. .. .. .. thickness table, shielded components Crimp Terminations .............. Cross -linked polyolefin. properties ...... -linking, chemical vs irradiation ..... -talk reduction, multiconductor conshuction .............. Current-carrying Capacity
hook-up and interconnecting wire . . .

DC Resistance calculation .................. retractile cord ................... Delay Line ................... Derating basic considerations ............ cabled conductors ............. introduction ................. nomenclature ................ procedure .................. Design Factors control and signal cable .......... flammability, hook-up and interconnecting wire .......... high temperature, hook-up and interconnecting wire ..........
hook-up and interconnecting wire .
.

... ... ... ... ... ... .... ... .... ..

. .

1-7 9-3 5-28 4-2 4-2 4-2 4-6 4-6 6-1 3-1 3-1
3-1

3-2 2-17 6-13 1-12 5-27 6-7 6-8 1-10

...

2-3 2-6 6-16

3-4

hybrid cable ................. ignition wire ................ low temperature, hook-up and interconnecting wire........... miniature special purpose audio cord multiconductor cable ........... potting ....................
power cable .................

... ... .. . ... ... ...

8-1 8-17 3-1 9-4 6-2 2-21

7-1

portable power cable ........... single-and three-conductor power cable in air ............ single-conductor power cable, underground duct ............... three-conductor power cable enclosed/exposed conduit ....... direct burial ............... underground duct ........... three siiigle-conductor power cable

... ..

7-14 7-10 7-4

retractile cord ................

9-2 8-8 6-7 6-4 6-9 1-1 5-2,5-9 3-3,3-6

Diameter calculation, multiconductor cable core . increase due to shield application . . .. multiplying factor table, component twist ............. pitch ..................... tolerances, conductor ........... ...

...

7-8 7-13 7-6 7-12 7-S

direct burial .. .. .. .. .. .. . .. underground duct ........... ....

constant .. .. .. .. .. .. .. .. . .. hook-up and interconnecting wire .

1-7

AMCP 706-125_ INDEX (CONT.)

Dielectric (cont.) constant insulating materials ............ value table, insulating materials .. strength, hook-up and interconnecting wire.......... strength, retractile cord ............
tank test vs impulse dielectric test ....

5-5 6-22 3-3, 3-6 9-3

6-22

Electrical (cont.) characteristics table, multipair telephone cable ....... .. considerations, control and signal cable. gradient, calculation ............ .... properties chloroprene rubber ........... ..
chlorosulfonated polyethylene . .

9-22 6-2 3-3 2-10

2-13

test ...................... ... fix~ture, impulse ...... ....... impulse .................. .. Diamensions, Component Jacket, Multiconductor Cable ........... copper wire ................. Direct Burial Power Cable, Current-carrying Capacity ......... Direct Capacitance ............... .... ... ... ..

6-19 6-21 6-21 6-7 1-2 7-12 6-23

--23

coaxial cable .............. fluorinatedethylenepropylene . .... .. fluorocarbon rubber .......... ... ... high-density polyethylene ....... insulation, hook-up and ... interconnecting wire ......... low-density polyethylene ....... polychlorotrifluoroethylene ...... polytetrafluoroethylene ........ ... .... .... ... silicone rubber ............. requirements, multipair telephone cable tests, hook-up and interconnecting wire Electro,Itic Tough Pitch (ETP) Copper . Electromotive, Force/Temperature Correlation Table .............. Electroplate, Shielding ............ polyurethane .............. polyvinylidene fluoride ........

5-1 2-7 2-14 2-2 3-6 2-2 2-F 2-7 2-8 2-8
2-13

Disadvantages, Flat Wire Tape Cable ... .

Dispenser canvas, field wire .............. canvas, field wire, construction ..... construction, field wire .......... operatibns factors, field wire ....... plastic,' ield wire ....... .... ... Double-shielded Coaxial Cable ........ construction ................. Dual coated conductor .............. coating, conductor tests .......... coating thickness, conductor ...-.... conductor coaxial cable .......... parallel conductor coaxial cable ..... twisted conductor coaxial cable ..... ,-;E.Eccentricity ................... Elastomer, Insulation .............
Elastomer Material, Properties Table .. ..

9-18 9-14 9-13 9-13 9-14 5-1 5-4 1-4 1-5 1-5 5-1 5-3 5-4

9-20 3-7 1-1

-

8-18 1-11 1-2 3-3 1-11 5-23 4-21 5-30 2-21 9-8
9-3

Electroplated Conductor, Coated ...... Elongation, Hock-up and Interconnecting Wire ............ End, Braid ................... shield ..................... Envelope Construction, Ribbon Cable ... Environmental Conditions, Coaxial Cable

5-30 2-9
2-11

Epoxy Resin Potting Compound

......

Extensie and Retractile Properties, Retractile Multiconductor Cord ......

Extension Qualities, Retractile Cord ... .

Electrical characteristics, multipair telephone cable .............

9-20

Extension, Multiconductor Retractile Cord ...............

9-8

I-8

. .

AMCP 706-125

INDEX (CONT.)
Extension/Retraction
Flex-life, Retractile Cord .......... 9-

Film ...

....................... .. ... ... ... ... ... .. ... ... ... ... ... ... ... ... ... ... ... ... .. .... ...

2-14
2-14

cellulose acetate, thermal properties ...

Extra Flexible Copper Conductor Stranding Table, Power Cable ....... Extra Flexible/Flexible Copper Ground Wire Construction Table, Power Cable Extrusion Process ............... -F Fiber ....................... asbestos ................... ceramic ................... coated .................... combinations ................ cotton ...................... glass ..................... nylon ..................... polyester .................. properties table ............... rayon ..................... uses ......................

..

7-16 7-23 2-1

cellulose acetate butyrate, thermal properties ............ cellulosic ................... fluorocarbon ................ cast tape ................. skived tape ...............
unsintered tape ................

2-14 2-14 2-16 2-16 2-16

2.-16

....

insulation .................. application ................ uses .................... polyester ................... thermal properties ........... uses .................... polyimide .................. thermal properties ........... uses .................... properties table ............... Fixture impact test ................. impulse dielectric test ........... ninety-degree bend test .......... sand paper abrasion resistance test tungsten carbide rod abrasion resistance test ......... twist test .................. Flammability, Hook-up and Interconnecting Wire ............

2-14 2-14 2-14 2-14 2-14 2-14 2-16 2-16 2-16 2-15 6-17 6-21 6-20 6-26 6-27 6-19 3-1 4-23 1-11 4-22 4-23 4-23 4-23 4-24 4-24 4-23 1-19
3-2

... ... .... ... ... .... ... .... ... ... ...

2-17 2-18 2-18 2-18 2-18 2-17 2-17 2-17 2-17 2-19 2-17 2-17 9-9 9-14 9-14 9-10 9-13 9-13 9-13 9-18 9-13 9-14 9-15 9-9 9-10 9-13 9-16 9-16 9-18 9-9 9-11
9-9

Field Wire .................... .... attenuation vs frequency ......... ... canvas dispenser construction ...... construction ................. ... comparison ............... ... comparison table ............ ... dispenser ................... ... canvas .................. ... operations factors ........... ... plastic .................. .. impedance vs frequency .......... installation ................. .... ... factors table ............... packaging .................. ... phase constant vs frequency ....... ... ... Specifications ................ transmission range vs frequency ..... types ..................... ... ... comparison table ............
uses ......................

Flat Wire laminated tape cable ............ .. shielding ................... ... tape cable .................. ... .. construction ............... constructional considerations ..... ... disadvantages .............. folding tests ............... ... roll flexure test ............. .. .... tests ................... Flex-life copper vs alloy conductor retractile cord .................. test method ................. ........ ... ...

hook-up and interconnecting wire . . . .

velocity vs frequency ........... Filler, Multiconductor Cable ......... Filler Placement, Hybrid Cable .......
...

9-17 6-9 8-10

9-3 1-19 7-15

...

Flexible Copper Conductor Stranding Table, Power Cabl........

)1-9

,I
AMCP 706-125

INDEX (CONT.)
Flexible/Extra Flexible Copper Ground Wire Construction Table, Power Cable
..

7-23
2-7 2-7 2-7 2-7 2-7 2-16 2-16 2-7 2-20 2-13 2-14 2-14 2-13 2-14 2-16 2-16 4-24 9-27 5-14 9-14 9-15 9-16 9-18 9-17 2-23 2-23

General Data, Pulse Code Modulation Cable .............. General Design F, tors, Power Cable .... Glass Fiber .................... uses ......................... Gradient, Electrical calculation ..................
hook.up and interconnecting wire ....

9-24 7-1 2-17 2-17 3-3

3-3

Fluorinatedethylenepropyleno electrical properties .............. insulation ..................... mechanical properties............. thermal properties ............. vs polytetrafluoroethylene ........
Fluorocarbon

cast tape ................... film insulation ............... insulaticn ................. lacque ...................... rubber ...................... chemical properties ........... electrical properties .......... thermal properties ........... uses .................... skived tape ................. unsintered tape ...............

... ... ..... .. ... ... ... ... ...

Graph attenuation vs frequency, field wire ... impedance vs frequency, field wire ... phase constant vs frequency, field wire . power derating, polyethylene cables . .. power derating, Teflon cables ...... .. power rating, 50.ohm polyethylene coaxial cable ....... .. power rating, 50.ohm Teflon coaxial cable ........... .. transmission range vs frequency, field wire ......... .. velocity vs frequency, field wire ..... Ground Wire constbuction table, flexible/extra flexible copper, power cable ...... power cable ................... size table, copper, power cable ....... Guide, Shield Wire Size............. -H9-14 9-15 9-16 5-25 5-24 5-26 5-27 9-18 9-17

Folding Tests, Flat Wire Tape Cable .... Framing Test Result Table, Pulse Code Modulation Cable ....... Frequency vs attenuation, coaxial cable ......... attenuation, field wire ............. impedance, field wire ............. phase constant, field wire ......... transmision range, field wire ....... velocity, field wire ............. Fungus Resistance Test ............ Fungus-resistant Insulation ..........
-

7-23 7-2

7-22
1-12

Heat Dissipation Table, Cabled Components .................

Heavy.duty Multiconductor Cable ......

4-19
8-11

G-

Gaging Systems, Solid Wire .......... Gaseous Chemical Factors, Hook-up and Interconnecting Wire .... General Considerations, Multiconductor Cable Design ....... ...

1-1

ie!nforced sheath wall thickness table.. shielded cumponent jacket wall thickness table ............. Heavy Tinned Stranding ............. Halical Wrap Binder Tape Width Selection Thble ........... ...

8-14 8-14 1-9 8-11

3-2 6-2

1-10

] .

AMCP 706-125

INDEX (CONT.)
High 1-6 conductivity-high strength alloy . ... 2-2 -density polyethylene ............... 2-3 electrical properties ............ mechanical properties...........22-3 ther-mal properties .. .. .. .. .. ... 1 . . . . calculation *frequency resistasice strength-high conductivity alloy . . . . 1-6 temperature design factors, ho-votg niowire.. .. .. .. .. .. .. .. -votae wre gniio .. . .. . 8-1 817 Hook-up Wire (cont. lotepatrdsgn........3-1 low temperature din......... leowitemperateslt..............3-1 tabl........3-93-70 MiliaySiicatsts 3-20 .. .. ........ MiltarSeificatons.... 3-2 t. .. .. .. .. .. .. .. .... pentain physical tests .. .. .. .. .. .. .. .... 3-7 references. .. .. .. .. .. .. .. ... 3-I13-16 Specifications MIL-W-76 .. .. .. .. .. .. .. .... 3-8 ..3-11/3-12 MIL-W-22700---------------. ...3-11/3-12 MIL-WV-26700-------------.3-1 1/3-12 MIL-W-1878D .---------------. ..... 3-11/3-12 Speifiai-W----------------. ------- 3-14 Seiecstength------------.. .. . 're stength--.----.-.-.-.-..-.-.-.-. -36 3-6 . ... . tests---------------------tera

Hook-up Wire . . ---abrasion resistance-------------;,ging tests. .. .. .. .. .. .. .. .. ..... 3-1 and interconnecting wire. .. .. .. ..... 3-6 chemical tests. .. .. .. .. .. .. .. ...

Imechanical Ithernal

design .. .. .. .. .. .. .. .. ..........

Tdielectric
Ielectricai
Iloss

. 3-5 35 properties ........... 3-8 constructional data .. .. .. .. .. .. ..... corso 4 3 current-carrying capacity ......... .3-1 ... .. .. .. .. .. .. .. design factors.

properties .. .. .. .. ...

thrates ...............

3-

3-8 .. types comparison------------------3-2 . ultraviolet properties-----------------. uses-----------------------.. .....3-13/3-14 ..3-4 vsoite ron ctp wire----------------. 3vsitroncngw e .........

dielectric strength. .. .. .. .. .. .....

.. 3-3 constant------------------.
3-3

. 1-2 Hot Dip Conductor Coating-------------1-1 .. Hot Rolled Copper-------------------Hybrid Cable armor--------------------------. .. 8-2 basic insulated wire------------------a-I. 8_ cabling--------------------------. . .. 8-2 color code .. .. .. .. .. .. .. .. ..... 8-S complete configuration. .. .. .. .. ... 8-12 components. .. .. .. .. .. .. .. ..... 8-4 crinstruction------------------.....8-2, 8-4 check list------------------....8-1, 8-7 factors .. .. .. .. .. .. .. .. ..... 8-3 core binder-----------------------. .. 8-2 8-7 core lay-up .. .. .. .. .. .. .. . ..... design factors---------------------. .. V-I 8-10 filler placement. .. .. .. .. .. .. .... 8-2 identificatilon .. .. .. .. .. .. .. .....

.. 3-3 Igradient-----------------------.

Ifla-rmability----------------------..
Igaseous
Ihigh

Itests------------------------. .. 3-7

factor .. .. .. .. .. .. .. .....

3-4

Idesign
[insulation

elongation .. .. .. .. .. .. .. .. ..... 3-3 .. 3-1 flex-life. .. .. .. .. .. .. .. .. ..... 3-2 chemidcal properties. .. .. .. .... 3-2 h tigh temperature design. .. .. .. ..... 3-1 temperature insulation------------. 3-6 considerations. .. .. .. .. ..... 3-5 chemical factors .. dielectric Constant. dielectric strength. electrical factors .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..... ..... ..... ..... 3-7 3-3 3-3 3-3 3-4 3-4 3-6 3-3 3-2

Finsulation

loss factor----------------------.. .. resistance .. .. .. .. .. .. .. ..... thickness. .. .. .. .. .. .. .. ..... voltage gradient .. .. .. .. .. .. ...

resistante----------------. . 3-4

insulation selection------------------. .. 8-1

multiconductor cable. .. .. .. .. ..... ....8-8, placement--------------------. precabling tests .. .. .. .. .. .. .. ... sheath .. .. .. .. .. .. .. .. .. ..... strand selection .. .. .. .. .. .. .. ...

8-9 8-9 8-7 8-2 8-1

liqilhi chemical properties .. .. .. .. ....

AMCP 706-125 INDEX (CONT.)( I -Installation fators table, field wire ............ ............ field wire ..... tape cable .. .................. thermocouple cable .......... 9-10 9-9 4-26 8-16

Identification hybrid cable .................... ... interconnecting wire ............ marker, multichannel .. communications cable .......... marker, multipair telephone cable .... marking, multiconductor cable ...... .. miniature special purpose audio cord . Ignition Wire conductor .................. design considerations ........... high voltage .................... insulation .................... introduction ................. outer protective fiber braid ........ reinforcing braid .............. shield ..................... Specifications ................ Impact resistance, retractile cord ......... test ...................... test fixture ................. Impedance
calculation .
. . . ...

8-2 3-5 9-24 9-22 6-15 9-6 8-17 8-17 8-17 8-19 8-17 8-19 8-19 8 -19 8-19 9-3 6-17 6-18
5-6

.8-15,

... ...

Insulation and jacket selection table, ... tiermocouple cable ........... ... audio cord .................. .... bundled wire ................ ... butyl rubber ................ chemical factors, interconnecting wire .. chloroprene rubber ............. chorosulfonated polyethylene ........ cross.linked polyolefin ............. design, interconnecting wire ....... dielectric constant, interconnecting .... wire .................... dielectric strength, interconnecting .... wire .................... .... elastomer .................. electrical factors, interconnecting wire electrical loss factor, ... interconnecting wire ........... ... ethylene propylene rubber ........ ... film ...................... flammability, interconnecting wire .. ... fluorinatedethylenepropylene ....... .... fluorocarbon ................ ... fluorocarbon rubber ............ ... fungus-resistant ............... ... high-dcnsity polyethylene ......... high temperature, interconnecting wire . .... ignition wire ................ ... information sources ............ ... inorganic ................... ... inorganic properties table ......... .... low.density polyethylene ......... low temperature, interconnecting wire ... magnesium oxide .............. material ................... .... ... dielectric constant ............ .. dielectric constant table ........ introduction ............... .... velocity of propagation ........ .... miniature special purpose audio cord .
multichannel communication cable

8-17 9-1 4-1 2-10 3-2 2-10 2-13 2-3 3-6 3-3 3-3 2-9 3-3 3-4 2-13 2-14 3-1
2-7

... .. ... ... ... ... ... ...

......

). ratio change ...... .. change due 1, .... coaxial cable ................ .... surface transfe ............... ... vs frequency, fidd wie .......... Impulse Dielectric Test ........... fixture .................... vs tank test dielectric ........... .... ... ...

5-10 5-5 5-25 9-15 6-21 6-21 6-21 5-2 5-6 5-7 2-27

.... Inductance ................... .... calculation .................. twin conductor coaxial ........ .... Information Sources, Insulation ....... ..

Inner Jacket multichannel communications ...... multipair telephone cable ......... .. Inorganic Insulation .............. magnesium oxide .............. properties table ...............
1-12

9-24 9-21 2-21 2-23 2-24

2-7 2-13 2-23 2-3 3-1 8-17 2-27 2-21 2-24 2-3 3-1 2-23 2-1 5-7 6-22 2-1 5-5 9-4
9-23

... ... ...

multipair telephone cable ......... natural rubber ............... nylon .....................

. .

... .... ....

9-21 2-9 2-6

(
_-__

AMCP 706-125

INDEX (CONT.)
Insulation (cont.) physical properties table, power cable polychlorotrifluoroethylene ........ .. polyolefin .................. ... polypropylene ............... .... polytetrafluoroethylene .......... ... polyurethane ................ .... polyvinylchloride .............. ... polyvinylidenefluoride .......... .... power cable ................. radiation resist.nce table ......... radiation.resistant ............. ... .. ... 7-18 2-8 2-2 2-3 2-7 2-8 2-1 2-8 7-2 2-25 2--23 2-27 2-26 6-22 6-22 3-7 9-3 6-22 9-7 2-9 8-1 2-10 2-23 2.-10 8-16 2-1 3-6 3-6 3-6 7-19 3-3 Interconnecting Wire (cont.) electrical gradient ................ .... loss factor ............... tests .................. .... elongation ................. .... flammability .............. ..... flex-life .................. .... gaseous chemical properties ....... high temperature design ......... how to design ............... identification ............... .... .... .... 3-3 3-4 3-7 3-3 3-1 3-2 3-2 3-1 3-5 3-5 3-2 3-3 3-3 3-3 3-4 3-4 3-4 3-6 3-6 3-6 3-3 3-2 3-1 3-7

'

,special

referen:es .................. ... relative costs table ............. .. resistance ..................... calculation ................ .. interconnecting wire .......... ... retractile cord .............. ... uses .................... ... retractile multiconductor cord ...... rubber .................... .... selection, basic insulated wire, hybrid cable ............... .... silicone rubber ............... ... environment . .. .. .. .. . .. styrene-butadiene ,uber ......... .. pthermocouple cable .................. thermoplastic . .............. thickness electrical factors, .

insulation chemical factors ........... .... dielectric constant .............. dielectric strength .......... .... electrical factors ........... .... electrical loss factor ......... ... insulation resistance ......... .... resistance ............... .... thickness ................ .... thickness, electrical factors ..... thickness, mechanical factors .... voltage gradient ............ .... liquid chemical properties . .. .. . .. low temperature design ......... .... mechanical tests . es............

Mlitary Specifications table ...... .3-13/3-14 outgassingest.................. 3-2 penetration test . .. .. .. .. .. . .. ... 3-3 physical tests ............... references .. .. .. .. .. .. .. Specifications MIL-W-5086 .............. MIL-W-7139 .............. MIL-V-8777 .............. MIL-W-81044 ............. Specifications ............... tensile strength .............. testing ................... thermal tests ............... thermocouple cable ........... thermoplastic ............... thickriess electrioil factovs, interconnectinr wire ........ interconnecting wire ......... mechanical factors, interconnecting wire ........ table, power cable .......... types compari.n ............. 3-7 . .. 3-15/3-16 .3-11/3-12 .3-11/3-12 .3-11/3-12 .3-11/3-12 .3-13/3-14 .... 3-3 .... 3-6 .... 3-7 .... 8-16 .... 2-1 ... .... . 3-6 3-6

interconnecting wire ......... interconnecting wire . .. .. .. . .. mechanical factors, interconnecting wire ......... .. table, pcwer cable ........... ... voltage gradient, interconnecting wire . Interconnecting Wire abrasion restance................3-3 aging test .................. and hook.up wire ............. chemical tests . .............. conuctor design .................. mcchanical farctors ........... thermal factors ............. corrorion .................. current-carrying capacity ........ design factors ................ *iielectric constant ............. aielectricstrongth .............

.... .... .... .... .... .... .... .... .... .... ....

3-7 3-I 3-7 3-5 3-5 3-5 3-2 3-3 3-1 3-3 3-3

... . 3-6 .... 7-19 . 3-11/3-12

>1
_ _ _ _ _

1.3

__,_

AMCP 706-125

INDEX (CONT.)
Interconnecting Wire (cont.) ultraviolet properties ........... uses ..................... voltage drop ................ voltage pradient ................ vs hook-up wire ................ Introduction coaxial cable ............... control and ssgnal cable ......... [ :,d',rating..................... S.Lead 3-2 .... .3-13/3-14 3-4 .... 3-3 3-7 .... .... 5-1 6-1 4-2 2-3 Length of Lay'. .. .. .. .. .. .. .. ..... ... table, stranding ............... ... ................ table, stiping 8-17 9-24 7-20 4-2 7-21 8-14 '3-13 Light/Medium-duty Multiconductor Cable .. sheath thic.kness table ........... jacket component shielded .. .. .. .. .. . '14O!e wall thickness Liquid Chemical Properties, Lay (cont.) ... special purpose cables ........... .... telephone cable .............. ... thermocouple cable ............ ... contrahelical ................ .... length .................... .. length table, stranding ........... .. length table, striping ............ ... prefabricated bundled wire ........ ... ................ unidirectional Wire vs Thermocouple Wire ...... .. 8-1 9-1 8-14 6-10 6-9 1-24 6-11 4-1 6-9 8-15 6-8
1-24

Irradiation vs Chemical Cross-linking . . .

-

J-

Jacket and insulation selection table, .... thermocouple cable .......... .. cable telephone iner, multichannel cable power table, properties physical r(fabricated bundled wire .. .. . .. thickness table poly(hloroprene, power cable
shielded component, heavy-duty

6-11 8-11 8-11 8-3

Hook-up and interconnecting Wire .

...

33-2

multiconductor cable ........ .... shielded component, light/medium duty multiconductor cable .....

Loop Resistance ................ Loss Factor, Electrical,

Hook-up and Interconnecting Whe . . . . 3-4

L-

Low-density Polyethylene

Laced Bundled Wire ............. Lacing, Bundled Wire . ........... Lacquer .................... cellulose acetate butyrate ........ fluorocarbon ............... nylon .................... ........ i]* uss ................... silicone ........... Laminated Flat Wire Cable ......... Lay censtruc ion ................ ignition wire ............... insulation materials ........... power cable ................ ribbon cable ............ 144

4-1 4-1 2-18 2-18 2-20 2-18 2-18 2-20 4-22 6-8 8-17 2-1 7-1 4-21

electrical properties ............ mechanical properties ........... thermal properties ............. Low Frequency Test Set-up, Shielding Effectiveness .......... Low Noise Coaxial Cable ........... - MMagnesium Oxide Insulation ......... Marufacturer's Marker, Multipair Telephone Cable ......... Materials and constructions, shielding effectiveness table ....... armor ....................

.... ...

2-2 2-2 2-2

9-32 .. 5-29

2-23 . 9-21

....

5-29 6-13
I

41

__________

--

____

__--

AMCP 706-125

rMeterials

INDEX (CONT.)
6-12 1-1 Miniature Special Purpose Audio Cord (cont.) color code.......... .......... conductor ..................... conductor construction............ 9-4 9*-4 9-4

17insulation.....................
properties table elastorner. .. .. .. .. .. .. ..... fiber .. .. .. .. .. .. .. .. .. ... film .. .. .. .. .. .. .. .. .. .... inorganic insulation. .. .. .. .. ... potting compound. .. .. .. .. ..... sheath. .. .. .. .. .. .. .. .. ... thermoplastic. .. .. .. .. .. .. ... selection table, bundled wire core/sheath material.. thermocouple cable. .. .. .. .. .. ...

(cont.) binder...................... coaxial cable...................5-1 elements, conductor..............

2-1
2-11 2-19 2-15 2-24 2-23 6-14 2-4 4-4 8-15

design.......................
identification .. .. .. .. .. .. .. ..... insulation .. .. .. .. .. .. .. .. ..... separator .. .. .. .. .. .. .. .. .. ... sheath .. .. .. .. .. .. .. .. .. ..... stay cord .. .. .. .. .. .. .. .. ..... tests. .. .. .. .. .. .. .. .. .. ..... Mlihne omnctosCbe.... cabling. .. .. .. .. .. .. .. .. .. ... conductor. .. .. .. .. .. .. .. .. ... construction. .. .. .. .. .. .. .. .... core. .. .. .. .. .. .. .. .. .. .....

9-4
9-6 9-4 9-4 9-6 9-4 9-7 92 9-23 9-23 9-23 9-23

I:high-density
polyethylene .. .. .. .. .... 2-2
low-density polyethylen. . ...... .. .... polychlorotrifluoroethyleiie ....... polytetrafluoroethylene. .. .. .. ..... polyurethane .. .. .. .. .. .. .. .... polyvinylidene fluoride .. .. .. .. ..... potting. .. .. .. .. .. .. .. .. .. ... silicone rubber .. .. .. .. .. .. .. ... 2-2 2-8 2-8 2-8 2-8 2-21 2-13 Mechanical Tests, Hook-up and Interconnecting Wire. .. .. .. .. .. ....

Mechanical Properties butyl rubber. .. .. .. .. .. .. .. ... 2-10 chloroprene rubber. .. .. .. .. .. .... 2-10 chflorosulfonated polyethylene .. .. ..... 2-V? fluorinatedethylenepiopylene .. .. .. .... 2-7

identification marking. .. .. .. .. ..... 9-24 inner jacket .. .. .. .. .. .. .. .. ... 9-24 insulation. .. .. .. .. .. .. .. .. ... 9-23 sheath. .. .. .. .. .. .. .. .. .. ... 9-24 shield. .. .. .. .. .. .. .. .. .. . ... 9-24

stabdtin tape .. .. .. .. .. .. .. ...

tests. .. .. .. .. .. .. .. .. .. .....

9-24
9-24

(1color
Li

II

Metal Foil, Shielding .. .. .. .. .. .. ... 1-11 Methods abrasion resistance tests... .. .. .. .. .b ) code. .. .. .. .. .. .. .. .. ... cndutorcoatng................A flex-life test. .. .. .. .. .. .. .. .......... ultsiconductor cable 6-28 tensile/breaking strength test. .. .. ... shielding. .. .. .. .. .. .. .. . . . . ... Military Specifications Table hook-up wire .. .. .. .. .. .. .. ... 3-9/3-10 interconnecting wire .. .. .. .. .. .. 3-13/3-14

4shield

3-7

iicabling

Miniature Special Purpose Audio Cord

. ..

9-4 9-4

Multiconductor Cable basic insulated wire .. .. .. .. .. ..... binders. .. .. .. .. .. .. .. .. .. ... cabling .. .. .. .. .. .. .. .. .. ..... capacitance .. .. .. .. .. .. .. .. ... choice for equipment design. .. .. ..... component jacket dimensions. .. .. .. .. .. .... covering. .. .. .. .. .. ..... shielding. .. .. .. .. .. .. .. ..... conductor and component. .. .. .. .... conductor stranding .. .. .. .. .. .... construction .. .. .. .. .. .. .. .. ... construction for cross-talk reduction core diamieter calculation .. .. .. .. ... care sh,.e!d .. .. .. .. .. .. .. . . . ... design .. .. .. .. .. .. .. .. .. ..... fillers. .. .. .. .. .. .. .. .. .. ..... general dIesign considerations .. .. .. .... heavy-duty. .. .. .. .. .. .. .. ..... reinforced sheath wiall thdckness table. .. .. .. .. .. ... shielded component jacket wall thickness table .. .. .. .. ...
.

6-6 6-12 6-7 6-22 8-10 6-7 6-7 6-6 6-3 6-6 6-6 6-16 8-8 6-2 6-9 6-2 8-11 8-14 8-14 8-10

cabling .. .. .. .. .. .. .. .. .. .....

identification. .. .. .. .. .. .. .. ...

table .. .. .. .. .. .. .. .....

9-6

identification marking. .. .. .. .. .....

6-15
1-16

AMCP 706-125

INDEX (CONT.)
Multiconductor Cable (cont.) Slight/medium-duty ............. sheath wat thickr .os table ...... .. shie!ded component jacket wall thickness table ......... .. vnety.degree bend test fixture ...... .. round vs ribbon construction ....... .. ... separator ................... .... sheath .................... application ................ .. thickness calculation .......... specific design considerations ....... ... tensile strenth ............... .... tensile/breaking strength test method . tests ..................... Multiconduc*or Retractile Cerd ....... alternate constrctions . ....... 8-11 8-11 8-13 6-20 4-21 8-8 8-9
6-11

(
9-23 9-22 9-17 6-4 6-23 9-20 ... ... .. .... ...

Multip:air Telephone Cable (cont.) Specifications ... ............. tests ..................... uses ...................... Multiplying Factor Table, Twisted Component Diameter ....... .......... Mutual Cpacitance ... of a pair ...................
- N -

8-9 6-3 6-27 6-28 6-17 9-7 9-9

Natural Rubber ................. ... chemical prorcrties ............ .... thermal properties............. uses ...................... .... Nickel Nce -coated conductor, soldeying ...... .. . -coated conductor, testing ........ .... conductor coating ............. thermal prcperties ........... .... thickness ................. ... Ninety-degree Bend Tect Fixture, Multicondutor Cable ........... Nomenclature, Derating ............ ... ...

2-9 2-9 2-9 2-9

9-7 basic design ....................... . 9-8 ... cabling .................... 9-8 .... color code .................. con ruction ................. ... 9-8 extensile/retractile properties ......... 9-8 extension .................. .... 9-8 insulation ..................... 9-7 98 sheath................ . . . . Specifications ................ .... 9-9 stretch....................... 9-8 testing ....................... 9-8 uses ...................... ... . 9-7 Use .... . .. . .. . .. . . . -7 Multipair Telephone Cable .......... ... 9-17 basic design ................. ... 9-20 binder....................... 9-21 cabling ..................... ... .21
color code ..................

1-4 -4 1-4 1-4 1-4 6-20 4-6 2-2 6-2 6-11 2-6 2-17 2-18 2-6 2-6

Noncontaminating Polyvinylchloride Insulation ........ Nonportable, Control and Signai Cable . .. Numericai Color Code ............. Nylon ...................... fiber ..................... lacquer .................... thermal propertie. ............. uses ...................... .. .... ... ... ... ...

conductor .................. construction ................. core wrap .................. electrical characteristics table ....... electrical requirements ........... identification marking ........... inner sheath ................. insulation .................. . manufacturer's marker ........... .. o iier sheath ................. ... pair twist .................. ... reasons for test ............... ... ... requirements ................ shield ..................... ...

... ... ... ... .. .. ... ...

9-21

9-21 9-21 9-21 9-22 9-20 9-22 9-21 -21 9-21

9-22

. 9-21 9-20 9-17 9-21

Open Wrap, Binder ..............

...

6-12 8-14

Operational Factors, Thermocouple Cable

-1

-,'-

AMCP 706-125

INDEX (CONT.)
Operations Factors, Field Wire.......... Outer Protective Fiber Braid, Igriition Wire. .. .. .. .. .. .. .. ... Outer Sheath, Multipair telephone Cable Outgassing, Hook-up and Interconnecting Wire. .. .. .. .. .. ... Oxygen-free High Conductivity (OFHC) Copper .. .. .. .. .. .. .. .....
-

9-13

Pitch Diameter.................... configuration.................. Plastic Dispenser, Field Wire. .. .. .. ..... Polychloroprene jacket thickness table, power cable ... sheath, reinforced .. .. .. .. .. .. ... sheath thickness table. .. .. .. .. ..... Polychlorotrifluoroethylene chemical properties .. .. .. .. .. ..... electrical properties .. .. .. .. .. . ..... mechanical properties .. .. .. .. .. ... thermal properties .. .. .. .. .. .. .... Uses .. .. .. .. .. .. .. .. .. .. .....

6-9 6-10 9-14

8-19 9-22

3-2 1-1

7-21 6-15 6-15 2-8 8 2-8 2-8 2-8

Packaging, Field Wire .. .. .. .. .. .. ... Paint, Aluminum. .. .. .. .. .. .. .. ... Pair capacitance unbalance. .. .. .. .. ..... mutual capacitance ....... -to-shield capacitaice unbalance . . . multipair telephone cable .....

9-13 6-15

)twist,

9-21 9-20 6-25 9-21

Polyester fiber .. .. .. .. .. .. .. .. .. .. ... 2-17 film---------------------------.. . .. 2-14 thermal properties------------------. .. 2-14 uses---------------------------.. . .. 2-14 Polyethylene cables, power derating--------------.. 5-25 lo%%-density-----------------------. .. 2-2 ei.cctrical properties----------------. . 2-2 m.-chanical properties--------------. . 2-2 thermal properties-----------------. . 2-2 high-density-----------------------. .. 2-2 electrical properties----------------. . 2- 2 mechanical properties--------------. 2-3 hra rpris ........... 2-3
oymd

Penetration Test, Hook-up and Interconnecting Wire----------------.. 3-3 Performance and Construction Table, Pulse Code Modulation Cable----------. 9-26 Phase angle . constant, calculations. .. .. .. .. ..... constant vs frequency, field wire .
-...

5-9 9-16

shift. .. .. .. .. .. .. .. .. .. ..... shift calculation ..............

5-8 59

Poyie . .. 2-20 coatings------------------------.

... 2-16 . 6-1---------------------------------Control and Signal Cable---------------. Physicl Hookup andPolyisoprene Test, Rubber------------------.. 2-9 Pick, Braid-------------------------.. .. shield ..................... 5-23 1-11 Polyolefin--------------------------. . .. 2-2 cross-liked, properties---------------. . 2-3

1-17

if
AMCP 106--125

Polypropylene application .................... properties .................... P.lysulfide Potting Compound ........ Polytetrafluoroethylenc ... cable, power derating ........... .... chemical properties ............ .... electrical properties ............ ... mechanical properties ........... ... thermal properties ............. vs fluorinatedethylenepropylene ..... Polyurethane .... chemical properties ............ .... electrical properties ............ ... mechanical properties ........... .. potting compound ............. thermal properties ...... ....... uses ...................... Polyvinylchloride noncontaminating ............. semi-rigid .................. temperature rated at ............ 80 0C ................... 105 0C .................. -65 0C ................... Polyvinylidene Fluoride chemical properties ............ electrical properties ............ mechanical properties ........... thermal properties ............. ...

INDEX (CONT.)
2-3 2-3 2-21

Potting (cont.) compound room temperature vulcanizing .... types .. ................... uses ....................... design criteria ................ mechanical factors ............. ... .. surface preparation ............. Power Cable aianinum conductor stranding table . .... cabling .................... .... conductor .................. .... form ................... ... materi. ................. .... size .................... copper conductor, voltage drop table .. copper ground wire size table ...... current.varrying capacity single- and three.conductor in air ... single-conductor, underground duct three-conductor, direct burial ..... three-conductor, enclosed/exposed conduit ..... three.conductor underground duct . three single.conductor, direct burial three single-conductor, enclosed/exposed conouit ..... three single-conductor, ... underground duct .......... factors current rating correction ... nair ................... .... in conduit ................ "erating, polyethylene cable ....... ... ... derating, Teflon cable ........... ... design factors ................ extra flexible copper conductor stranding table ....... .. flexible copper conductor ... stranding table ............. flexible/extra flexible copper
ground wire construction table . . ..

2-21 2-21 2-21 2-21 2-21 2-21 7-17 7-2 7-1 7-2 7-I 7-1

5-24 2-7 2-7 2-7 2-7 2-7

2-8 2-9 2-8 2-21 2-9 2-9

7-24 7-22
7-10 7-4 7-13 7-8 7-6 7-12 7-7 7-5 7-I1 7-9 5-24 5-25 7-1 7-16 7-15 7-23 7-I 7-2 7-2 7-18 7-20 7-1 7-21

.... .... ... .... .... ...

2-1 2-2 2-1 2-2 2-I 2-2

.... .... ... ....

2-8 2-8 2-8 2-8

-{

Portable ... control and signal cable .......... power cable, current.carrying capacity Potting chemical factors .............. compound ..................... epoxy resin ............... polysulfide ................ polyurethane .............. properties table ............. 1-18 ... . ....... ... ...

6-2 7-14

2-21 2-21 21 2-21 2-21 2-21

general design factors ........... ground wire ................. insulation .................. properties table ............. thickness table ............. introduction ................. jacket properties table ...........

... .... .... ... ... ... ..

AMCP 706-125

j
Power Cable (cont.) p'lychloroprene jacket thickness table portable, current-carrying capacity .. ... references .................. .... sheath .................... .... shieid ..................... uses ...................... .... voltage drop ................... .... Power Factor .................. Power Rating cables, due to VSWR ........... calculations ................. coaxial cable ................ 50-ohm polyethylene cables ....... 50-ohm Teflon cables ...........
Precabling Tests, Multiconductor Cable
.

INDEX (CONT.)
Pulse Cable ..................... 5-28 7-22 7-14 8-20 7-2 7-2 7-1 7-3 5-5 Pulse Cod- Modulation Cable construction and performance table ... ... framing test results table ......... ... general .................... radiation from cable ............ .. ... results table ............... ... requirements ................ .. shielding effectiveness ........... .. tests and procedures ............ transmission and shielding .. effectiveness tests set-up ........ Purpose shielding ................... soldering ................... Push Back Shield Properties ......... R .... .... ...

9-26 9-27 9-24 9-28 9-29 9-24 9-25 9-25 9-28

... ... ... .. ..

..

5-23 5-22 5-22 5-26 5-27

8-7

-11 1-9 6-6

Prefabricated Bundle

.. .... ....... .. .... ... .... .... ... ...

4-1
4-2

color code ..................

comporients ................. construction ................. jacket .................... lay ...................... shield ..................... Specifications ................ Procedure cable current rating ............ derating ................... usage, cable current rating ........ Procurement Information, Thermocouple Cable ............

4-2 4-1 4-2 4-1 4-2 4-1

.... ... ...

4-6 4-10 4-7

Radiation fom cable, pulse code modulation cable ................... from cable, results table-pulse code modulation cable ......... resistance table, insulations ........ resistant insulation .............

... .. .. ..

9-28 9-29 2-25 2-23 5-1 5-16 5-21 5-23 2-17

..

8-15 5-8 2-11 2-19 2-15 2-21 2-22 7-18 7-20 6-14 -4

... Radio Frequency Cable ............ characteristics table ............ ... semi-solid, characteristics table ...... .. Rating, Power, Due to VSWR ........ Rayon Fiber .................. Reasons for Test, Multipair Telephone Cable ......... References bundled wire .................. coaxial cable ............... conductors ................. .. ...

Propgation Constant, Calculation ...... Properties Table clastomeric materials ............ fibers ..................... films ..................... inorganic insulations ............ potting compounds ............ power cable insulations .......... power cable jackets ............ sheath materials . ........... thermoplastic materials .......... .. ... ... .. ... ... ... .... . . ..

..

9-20

4-27 .5-31/5-32 ... 1-25

1-19

!I
AMCP 706-125

INDEX (CONT.)
References (cont.) control and signal cable ......... hook-up wire ............... insulating materials ............ interconnecting wire............ ... 6-29 .3-15/3-16 ... 2-27 3-15/3-16 Retractile Multiconductor Cord (cont.) Specifications ................ ... stretch .................... .... testing .................... .... uses........................ Ribbon Cable adhesive-bonded .............. bonded .................... braided or wwen .............. construction ................. direct extrusion ............... envelope construction ........... introduction ........... thermal fused ................ uses ...................... vs round multiconductor cable ...... Resistance abrasion ................... DC calculation .............. high frequency ................. insulation .................. loop ..................... Retractile Cord ................. ... .... ... .... ... 6-25 1-7 5-9 6-22 5-2 9-2 9-3 9-3 9-2 9-3 9-3 9-3 9-3 9-3 9-3 9-3 9-3 9-3 9-7 9-9 -7 9-7 ... ... 9-8 Ribbon, Tinsel ................. Rod, Copper ..................... Roll Flexure Test, Flat Wire Tape Cable Rope Stranding ................ .... 9-9 9-8 9-8 9-7

power cable ................. ... special purpose cable ........... ... telephone cable ................. Reinforced Polychloroprene Sheath ..... Reinforcing Braid, Ignition Wire ....... Related Numbers, Color Code ........ Relative Costs Table, Insulations ...... .. ..

7-25
8-20 9-34 6-13 8-19 6-11 2-26

... ... ... .. .. ..... ... ... ... ..

4-21 4-21 4-2 4-21 4-21 4-21 4-21 4-21 4-21 4-21 9-2 1-1 4-24 1-8

continuity .................. ... DC resistance ............... .... design .................... .... dielectric strength ............. .... extensiorn/retraction flex-life ....... extension qualities ............. ... flex-life .......... ........ .... impact resistance .............. ... insulation resistance ............ ... retractile qualities ............... static loading ................ tests ....................... Retractile Multiconductor Cord ....... alternate constructions .......... basc ... dsig... .. ... basic design....................... color code .................. construction ................. extensile/retractile properties ........ insulation .................... insuaio n ............... .

Rubber ..................... butyl ..................... chloroprene ................. ethylene propylene ............. fluorocarbon ................. natural .................... polyisoprene ................ silicone .................... styrene-butadiene .............. -SSag a calculation, 'eriaI installation .......... data cable, telephone cable ........ properties, telephone cable ........

.... ... ... .. .. .... .... ... ...

2-9 2-10 2-10 2-13 2-13 2-9 2-9 2-10 2-9

... ..

9-31 .. .. 9-32 9-30

9-8 Abrasion Resistance 9-8 e n . .. Sandpaper 9 Method Test Fixture ............ 9-8 Saponified Acetate Rayon .......... 9-8 Semi-rigid Polyvinylchloride .........

.. ... ...

6-25 2-17 2-I

1-20

_1

I..

AMCP 706-125

INDEX (CONT.)
Semi-solid Radio Frequency Cable Characteristics Table .. .. .. .. .. ..... Separator "N Fminiature 5-21 Shield (con,.) ignition wire. .. .. .. .. .. .. .. ... multi channel communications cable .... conductor cable .. .. .. .. .. .. ... conductor cable component pair, telephone cable............ pick........................ power cable.................... prefabricated bundle .............. push back .. .. .. .. .. .. .. .. ..... selection table, bundled wire .. .. .. ... Shielded Component Jacket Thickness Table heavy-duty multiconductor cable ... light/medium-duty multiconductor cable .. .. .. .. .. .. .. .. .. ... braided. .. .. .. .. .. .. .. .. .. ... 8-19 9-24 8-8 6-6 9-22 5-23 7-2 4-1 6-7 4-3

~audio cord. .. .. .. .. .. .. .. .. ...

special purpose audio cord multiconductor cable..............
.

9-1 9-4 8-8 6-12 1-13

Sequence, Color Code............... Served Shield. .. .. .. .. .. .. .. .. ... Sheath and covering, coaxial cables ........... and core material selection table, bundled wire .. .. ..... application, multiconductor cable ....

5-27 4-2 6-13

'1cable :]Imaterial

8-14 8-13 1-11

.. .. .. .. .. .. .. .. .. .. ...

6-13
9-21 9-6 9-24 8-9

inner, multipair telephone cable ..... miniature special purpose audio card . . multichannel communications table ... multiconductor cable. .. .. .. .. .....

and properties table------------. . 6-14

constructional details .. .. .. .. .. ...

Imultipair

effectiveness .. .. .. .. .. .. .. .. ... and transmission test set-up, pulse code modulation cable . . ..

1-12
1-13 9-28

. .. 7-2 power cable---------------------. 6-14 reinforced polychioroprene------------. retractile multiconductor cord ...... 9-8 thickness

. 9-22 telephone cable-------------.

calculation---------------------.9..

Icalculatidn---------------------.
..

low frequency test set-up----------. 9-32 9-25 pulsz code modulation cable ..... table, various materials and constructions. .. .. .. .. .. .1-13, 5-29

-29

8-9

.. 1-11 electroplated---------------------.
flat wire-----------------------.... 1-11 metal foil-----------------------.... 1-11 methods------------------------. . .. 1-11 1-11 purpose------------------------. ..

U [multiconductor
)

table, light/mediumn-duty multiconductor cable------------. . 8-11 table, polychloroprene-------------. . 6-15 table, reinforced heavy-duty

cable------------. . 8-14

served--------------------------. . .. 1-13
solid tube. .. .. .. .. .. .. .. .. ... wire size guide--------------------.. .. 1-4Il 1-11

Shield---------------------------.. . .. 5-23 ....-.-.-..-.-.-.-.-.--.-.-.-.-.-. 6-7 audio cord----------------------. .. 9-1 ca"ir .. .. . . .. .. .. . 5-23 3 construction .. .. .. .. .. .. .. .. .... coverage calculation----------------.. 1-12 6-7 covering, multiconductor components covering thickness table, 6-7 inulticonductor components .. .. .. .... end. .. .. .. .. .. .. .. .. .. .. ... 5-23
-

Signal and Control Cable---------------.. 6-1 Silic.,ne Lacquer. .. .. .. .. .. .. .. ... Silicone Rubber chemical properties. .. .. .. .. .. ... electrical properties. .. .. .. .. .. ... mechanical properties .. .. .. .. .. ... 2-20

2-13 2-13 2-13

1.21

L
AMCP 706.125

INDEX (CONT.)
Silicone Rubber (cont.) thermal properties ............ uses ..................... Silver Coating conductor ................. thermal properties .............. . . . .......... hickness .... Single Coaxial Cable ............. Skin Effect .................... Skived Fluorocarbon Tape ......... Soldering nickel-co ted conductor ......... purpose .................. stranded conductors ........... temperatures ............... wicking .................. Solid Tube Shielding ............ 1-4 .... 1-9 .... 1-9 .... . 1-8, 1-10 .... 1-9 .... 1-11 1-15 ...... 2-23 Strand Selection, Basic Insulated Wire, .... Hybrid Cable ................ Strand, Tinsel .................. Stranded Conductor Soldering ........ Specialized Coatings bondable .................. polyimide ................. Specifications .. .... .... 2-20 2-20 Stranded Wire Table .............. Stranding .................... bunched ................... ..................... .e. ................ heavy tinned.... ... ... .. .... .... 8-1 9-2 1-9 1-20 1-6 1-8
1-8

... ... .I... .

2-10 2-13 1-3 1-3 1-3 5-1 5-.1

Specifications (cont.) MIL-W-81044 ............. ignition wire ............... interconnecting wire ........... iuIL-W-5086 ............... MIL-W-7139 .............. MIL.W-8777 .............. MIL-W-81044 .............

.3-11/3-12 .... 8-19 .3-13/3-14 3-11/3-12 3-11/3-12 3-11/3-12 .3-11/3-12

...

2-111

9-23 multipair telephone cable ........ 8-12 nonhosing/waterblock cable ...... 4-1 prefabricated bundle .............. 9-9 retractile multiconductor cord ..... .3-9/3-10 table, hook-up wire ........... .3-13/3-14 table, interconnecting wire .......

Stabilizing Tape, Multichannel Communications Table ........... Static Loading, Retractile Cord ....... Stay Cord, Miniature Special Purpose Audio Cord .................

.. ...

9-24 9-3

Solid Wire Table.................. Special Environment Insulation Special Purposes Cables coaxial...................... multiconductor ................ references ................. ....

.... ..

9-4 4-24

Straight Flexure Test, Tape Cable ......

5-28 8-1 8-20

color code .................

field wire ................. hook-up wire ............... MIL-W-76 ............... MIL-W-22759 ............. MIL-W-27300 .............

.........

. . .

6-25 6-11

1-9

control and signal cable .........

...

6-1

lay length table ...............

..

1-24
6-5 1-8 7-17

9-16 .... . 3-8 .... 3-8 .... .3-11/3-12 .3-.11/3-12

multiconductor cable construction . . .... rope ..................... table aluminum conductor, power cable . extra flexible copper condaictor,

MIL-W-16878D ............

.3-11/3-12

power cable .............

...

7-16

1.22
1

AMCP 70G,125

A'INDEX

(CONT.)
Stranding (cont.)
table
flexible copper conductor, field -dire

Table (cont.)
7-15 1-8 1-8 9. 8
-i 1-8

power cable .............. .... true concentric ............... :,

unidirectional ................ ... ~unilay.......................
.

construction comparison .......... .. type comparison ..............

flexible copper strandhg, power cable

9-13 9-11
7-15

Stretch, Retractile Multiconductor Cord

Striping, Color Code ..............

feil/xr lxbeprgon flexible/extra flexible copper ground wire, power cable .............
framing test results, pulse code modulation cable .............

7-23
.. 9-27

..
..

Striping, Lay Length Table, Color Code Styrene.butadiene Rubber thermal properties ..... .......... uses ...................... Surface Preparation, Potting .........

6-11 2-10 2-10 2-21 5-25

... ... ..

Surface Transfer Impedance .........

T Table
-

"cable

conductor strandig, power aluminum ................... audio cord conductor ........... bundled wire core sheath material selection .... .. heat dissipation ............. .. .. .. .. .. ... selection shield sield seci cabling, miniature special purpose audio cord.................... color code numbers ............

7-17

helical wrap binder tape width selection ................... 8-11 9-10 installation factors, field wire ......... Military Specifications 3-9/3-10 hook-up wire .............. interconnecting wire ......... 3-13/3-14 6-15 polychloroprene sheath thickness ... properties elastomeric material ............ 2-11 2-19 fiber...................... 2-15 fibm ...................

...... film gai

......

.....

2-15

7-17inorganic insulations ............. 9-5 potting compounds ........... power cable insulation ......... power cable jackets.......... ....thrmoplasticmaterials ........ 4-18 tempatcmtras........ 4-3 radiation from cable test results, pulse .9-6 6-11 code modulation cable ......... radiation resistance, insulation ......

2-24 2-22 7-18 7-20 24

k2

9-29 2-25

component shield covering thickness

..

6-8
9-20

radii frequency cable characteristics

..

5-16
8-14 2-26
9-32

construction and performance, pulse code ... modification cable ........... copper ground wire size, power cable . .
copper-covered steel conductors
.

7-22
1-6

reinforced sheath thickness, heavy-duty .. multiconductor cable .......... .. redAtive cost, insulations ..........
sag data, telephone cables ......... ..

diameter increase due to shield application ................ ... 6-7 diameter multiplying factor, component 6-4 .... twist ................... dielectric constants for insulating . . . . . . . . . . . . . . .. . . . . 6 -22 m ate rials electrical characteristics, multipair 9-22 ... telephone cable ............. extra flexible copper stranding, power ... 7-16 c-ble ...................

seini.solid radio frequency cable characteristics ............. .... sheath materials and properties sheath thickness, lightmediumduty multiconductor cable............8c nt a ke thic kness s h i co n shielded component jacket thickness heavy-duty multiconductor cable ihit/mediutr-duty multiconductor ... cable ..................

5-20 6-13

8-14 8-13

-22

V.

AMCP 706-12b

INDEX (CONT.)
Table (cont.) shielding effectiveness of =-ious materials and constructions ........ solid wire .................. ... ... stranded wire ................ .. stranding lay lengths ............
striping lay length thcrmocouple cable ............. insulation and jacket

(
9-32 9-30 9-1 34

5-29 1-15 1-20 1-24

6-11

Telephoiie Cable (cont.) sag data table .................. tensile and sag ............... ... types ..................... .... Temperature Coefficient of Resistivity,
Temperatures, Soldering ...........

.1-8/1-10

material selection ............ ... thermocouple/temperature/electromotive force correlation ............ ... thickness, power cable insulation . . thickness, power cable insultion ... thickness, power cable polychioroprene jacket ................... ... voltage drop, copper conductor, ... power cable ............... Tank Test Dielectric vs Impulse Dieletric Test ..................... .... Tape cast, fluorocarbon ............. skived, fluorocarbon ............
unsintered, fluorocarbon .........

8-17 8-18 7-19 77-21 7-24 6-18 2-16 2-16

2-16

Tensile and/or breaking strength test method, multiconductor cable .......... .. ... and sag, telephone cable ......... strength, hook-up and interconnecting wire ....................... strength, multiconductor cable ...... .. Tension Calculation, Aerial Cable Installation ................. Terminations crimp ..................... wire wrap .................. Terminology, Braid .............. Tests aging, hook-up and interconnecting wire ............ bend ..................... chemical, hook-up and interconnecting wire ............ cold bend .................. component, precabling .......... dielectric ................... dual coated conductor ........... electrical, hook-up and interconnecting wire ............ fixture impact .................. iipulse dielectric ............ ninety.degree bend, multiconductor cable ........ sandpaper method, abrasion resistance .......... tungsten carbide rod method, abrasion resistance .......... twist ................... folding, tape table ............. fungus resistance ..............

6-28 9-30 3-3 6-27

.... ... ... ...

9-30 1-10 1-10 1-11-

... ...
...

width selection table, helical wrap binder ........... ... Tape Cable construction ................. ... flat wire ................... ... construction ............... ... constructional considerations ..... disadvantages .............. ... laminated .. ............. .... tests ................... .... folding tests ................. ... installation ................. .... laminated, flat wire ............ ... roll flexure test ............... ... straight flexure test .............. uses ...................... ... Telephone Cable audio cord .................. ... introduction ................. ... multichannel communication ....... .. multipair ................... .... pulse code modulation .......... ... references .................. ...

8-11 4-23 4-22 4-23 4-23 4-23 4-23 4-23 4-24 4-26 4-23 4-24 4-2 4-21 9-1 9-1 9-23 9-17 9-24 9-34

... ... .... ... ...

3-7 6-18 3-7 8-16 8-7 6-19 1-4 3-7

... .. .. .. .. ... ... ...

6-18 6-20 6-20 6-26 6-27 6-19 4-24 2-23

1.24

II

AMCP 7065

INDEX (CONT.)
Tests (cont.) hook-up and interconnectint, wire .... 3-7 impact. .. .. .. .. .. .. .. .. .. ... 6-17 impulse dielectric .. .. .. .. .. .. .... 6-21 mech iical, hook-up and interconnecting wire. .. .. .. .. ... 3-7 methods abrasion resistance. .. .. .. .. ..... 6-2S flex-life. .. .. .. .. .. .. .. .. ... 1-19 tensile/breaking strength, multiconductor cable .. .. .. ... 6-27 miniature special purpose audio cord 9-7 multi channel, communications cable . . . . 9-24 conductor cable. .. .. .. .. .. .... 6-16 pair, telephone cable--------------. . 9-22 nickel-coated conductor .. .. .. .. . ... 1-4 physical, hook-up and interconnecting wire. .. .. .. .. .... 3-7 procedures, pulse code jr-odu~ation cable .. .. .. .. .. .. .. .. .. ... 9-25 piulse code modulation cable. .. .. ..... 9-2S retractile cord. .. .. .. .. .. .. .. ... 9-3 retractile tnulticond-jctor cord ...... 9-8 roll flexure, tape cable. .. .. .. .. ... 4-24 set-up, low frequency shielding effectiveness .. .. .. .. .. .. .. .... 9-32 straight flexure, tape cable .. .. .. ..... 4-24 tape cable. .. .. .. .. .. .. .. .. ... 4-23 thermal, hook-up and interconnecting wire. .. .. .. .. .... 3-7 torque........ .. ..... 5-16 transmission and shielding effectiveness,
-

Thermal Properties (cant.) naua ubr..........2-9 nickel coating. .. .. .. .. .. .. .. ... 1-4 nylon .. .. .. .. .. .. .. .. .. .. ... 2-6 polychlorotrifluoroethylene .. .. .. ..... 2-8B polyester film .. .. .. .. .. .. .. .... 2-14 polyinide film .. .. .. .. .. .. .. ... 2-16 polytetyafluoroethylene. .. .. .. .. ... 2-7 polyurethane .. .. .. .. .. .. .. ..... 2-9 polyvinyl-,dene fluoride---------------. . 2-8 silicone rubber .. .. .. .. .. .. .. ... 2-10 silver coating---------------------. .. 1-3 styrene-butadiene rubober-------------. . 2-10 *ests, hook-up and interconnecting wire---.-----------------------. . .. 3-7 tin coating-----------------------. . .. 1-2 'rhiermocouple Cable calibration .. .. .. .. .. .. .. .. .... 8-15 conductor----------------------. .. 8-16 construction. .. .. .. .. .. .. .. .... 8-16 constructional examples-------------.. 8-16 installation .. .. .. .. .. .. .. ... 8-15/8-16 insulation----------------------. .. 8-16 insulation anti jacket material selection teble------------------------. . ..8-17 introduction. .. .. .. .. .. .. .. .... 8-13 materials------------------------. . .. 8-15 operational factors----------------..8-14 procurement data------------------. .. 8-15 temperature/electromotive force, correlation table-------------. . --- 1-8 vs lend wire---------------------. .. 8-15 Thermoplastic Insulation .. .. .. .. .. .... Thermoplastic Material, Properties Table
--

1pulse

twist---------------------------. . .. 6-16 Thermal Factors, Condu~tor, Hook-up and Interconnecting Wire--------------. . ---

code modulation cable .. .. .....

9-28

2-1 2-4
-

Thermal Fused, Ribbon Cable . .. .. ...... 4-21 Thermal Pioperties 210 .... .. . .. butl.rbbr .. 2-10 raeld .. ..... rbr...... cluoeeaebuty celulseactae utrae il 214 cellulose acetate film .. .. .. .. .. ... 2-14 .. 2-10 chioroprene rubber----------------chlorosulfonated polyethylene .. .. ..... 2-13 ethylene propylene rubber. .. .. .. .. .2-13 fluorinatedethylenepropylene-----------. 2-7 fluorocarbon rub~ber. .. .. .. .. .. ... 2-13 high-density polyethylene .. .. .. .. .... 2-3 low-density polyethylene--------------. . 2-2

Thickness calculation, muiticonductor sheath . . dual coating .. .. .. .. .. .. .. ..... insulation, hook-up and interconnecting wire. .. .. .. .. ..... nce otn-----------silver coating .. .. .. .. .. .. .. ..... tinve coating .. .. .. .. .. .. .. ... tico in .................. Ties, Uutndlin . .. .. .. .. .. .. .. ..... Tin Coating conductor .. .. .. .. .. .. .. .. .....

8-9 1-4 3-6

1-43 3 14-1 1-2

'7)

1-25

ii
AMCP 706-125

.1
I

INDEX (CONT.)
Tin Coating (cont.) thermal properties ............. thicknec ..... ............. Tinsel condctor, .. .. .. . .. design .. .. .............. , ,ord, bpic construction construction ............... ribbon, construction ............ s rand .................... Tolerance, Conductor Diameter ....... Torque Test ................... ... ... .... ... .. 1-2 1-3 -U Ultraviolet Properties, Hook-up and Interconnecting Wire ............ 9-2 9-1 9-2 9-2 9-2 1-2 6-17 Unbalance, Capacitance ............. pair to shield ................ Unidirectional Stranding ........... Unilay Stranding ................ Unsintered Fluorocaibon Tape ........ Usage, Current Rating Procedure 9-28 ...... .... ... ... .... .... ... . .... ... ... .... .... ... .... .... .. 3-2 6-24 6-25 1-8 1-8 2-16 4-7 6-13 2-18 6-12 4-1 2-10 2-18 2-13 5-30 6-I 2-17 2-17 9-9 I

Transmission and Shielding Effectiveness Test Set-up, Pulse Code Modulation ... Cable ...................

Uses armor .................... asbestos fiber ................ Transmission Range vs Frequency, binder tape ................. 9-18 ... Field Wire .................. bundled wire ................ Unbalane................5--26 STransmission i Ubutyl rubber ................ ceramic fiber ................ 5-1 Triaxial Cable ...................... rubber contrcton .. . .. . .. .. 5coaxial chlorosulfonated cable . .. .. .. .......... .. .. .. construction....................5-1 True Concentric Stranding ...... Tubular Shielding ............... ... ... 1-8 1-11 5-1 .control and signal cable .......... cotton fiber ................. ............ fibers ........ field wire ..................

Twin Conductor Coaxial Cable ....... .2-14 capacitance calculation.......... Twin Parallel Condudtor, Coaxial Cable Construction ..................... Twin Twisted Condtictor, Coaxial Cable .. Construction ................ Twist Test .................... fixture .6-18 Types coaxial cable ................ comparison field wire ................ hook-up wire .............. interconnecting wire ......... control and signal cable .......... field wire.......................retractile potting compound ............. telephone cable ............... 1-26 ...

I
5-3 5--3 6-17

.5..

S--I

9-11 .... 3-8 .... .3-11/3-12 6-2 .... ... .... 2-21 9-1

.. 2-14 film ...................... fluorocarbon rubber ............. 2-17 ... gisz fiber .................. .3-9/3-10 hook-up wire ................ 6-22 ... insulation resistance ............ .3-13/3-14 interconnecting wire ........... 2-18 ... lacquer .................... multichannel conununic.'tions cable .. " 9-23 9-17 ........ .... multipair telephone c2-9 .... natural rubber .. ............ 8-13 no.-h osi...wat erblock cable ....... ... .... 2-6 nylon ..................... 2-17 ... nylon fiber ................. 2-8 ... polychlorotrifluoroethylene ........ 2-14 ... ................ film polyester 2-16 ... polyinide film ............... 2-8 .... polyurethane ................ 2-21 ... potting compound ............. 7-1 .... power cable ................. multiconductor cord ...... 9-7 ribbon cable ................. silicone rubber............... ... 4-21 2-10

__

____

-L____

._..llP

.... II_

II

[ ILI
L
Uses (cont.) styrene.butadiene rubber .......... tape cable ..................
-

AMCP 706.125

iNDEX (CONT.)
.2-10 4-22 Weight Proportion, Conductor Coating to Conductor ................ ....
Wicking, Solder .................

..

1-2
1-9

V-

....

Velocity of Propagation
calculation ........ .

Width Selection, Helical Wrap Binder Tape ................. ... .. 5-5 9-17 Wire bundled ................... .... .... field ..................... gaghig systems.................. hook:p and interconnecting ....... .. ignitin ...................... size AWG ..................... Erown and Sharpe ........... guide, shielding ............. solid ...................
table

8-7

coaxial cable ................ vs frequency, field wire ..........

Voltage drop hook-up and interconnecting wire power cable ................. table, copper conductor ... power cable ............. gradient, hook-up and interconnecting .. wire insulation .............. ... rating, coaxial cable ............
Voltage Standing Wave Ratio (VSWR)
-. ..

3-4 7-3 7-24 3.-3 5-14

5-20

4-1 9-9 1-i 3-1 8-17 1-1 1-1 1-12 1-1 1-15
1-20

... .. .... ... .. .

WWaterblock/Nonhoshig Cable Specifications . .. .. .. .. .. .. . .. ... uses ......................

8--42 .- 13

solid ................... stranued . .................. wrap termination .............. Woven or Braided Ribbon Cable ........

1-10 4-21

1-2711-28

ENGINEERING IR

DESIGN HANBOOK

Listed below are the Handbooks which have been published or are currently being printed. Handbooks with publication dates prior to i August 1962 were published as 20-series Ordnance Corps pamphlets. AMC Circular 310-38, 19 July 1963, redesignated those publications as 706-series AMC pamp.,lets (i.e., ORDP 20-138 was redesignated AMLP 706-139). All new, reprinted, ar revised Handbooks are being published as 706-series AMC pamphlets. No. Title No. 212(S) 213(S) 214(S) 215(C) Fuzes, Fuzes, Fuzes, Fazes, Title Proximity, Proximity, Proximity, Proximity, Electrical, Electrical, Electrical, Electrical, Part Part Part Part Two (U) Three (U) Four (U) Five (U)

106 107 108 110 Ill 112 113 114

Ele,,ents of Armament Engineering, Part One, Soirces of Energy Elements of Armament Engineering, Part Two, Ballistics Elements of Aninirant Engineering, Part Three, Weapon Systems 4nd Ccmponents Experimental Statistics, Section 1, Basic Concepts and Analysis of Measurement Data Experimental Statistics, Section 2, Analysis of Erumerative and Classificatory Data Experimental Statistics, Section 3, Planning and Analysis of Comparative Experiments Experimental Statisti^s, Sectijn 4, Special Topics Experimental Statistics, Section 5, Tables

240(C) 242 244

Grenades (U) Design .or Control of Projectile Flight Characteristics Ammunition, Section 1, Artillery haitnitiori-General, with Table of Contents, Glsztary and Index for Series Ammunition, Section 2, Design for Terminal Effects (U) Av..unition, Section 4, Design for Projection Ammunition, Section 5, Inspection Aspects of

245(C) 24? 248 249 250 251 252 255

*115
121 *125 130 134 135 136 137 138 139 140 150 16O(S)

Basic Environmental Concepts

Packaging and Pack Engineering Electrical Wire and Cable Design for Air Transport and Airdrop of Materiel Maintainability Guide for Design Inventions, Patents, and Related Matters Servomechanisms, Section 1, Theory Servomechanisms, Section 2, Measurement and Signal Converters Servomachaniss, Section 3, Amplification Servomechanisms, Section 4, Power Element-, and System Design Trajectories, Differential Effects, and Uata for Projectiles

Artillery Ammunition Design

Ammunition, Section 6, Manufacture of Metallic Components of Artillery Ammunition Guns--Gcneral Muzzle Devices Gun Tubes Spectra' Characteristics of Muzzle Flash

270 Propellant Actuated Devices 280 Design of Aerodynamically Stabilized Free Rockets 281(S-RD)Weapon System Effectiveness (U) 282 283 284(C) *285 286 290(C) 291 292 293 294(S) 295(S) 2S6 297(S) 327
3?9

Interior Ballistics of Guns Elements of Terminal Ballistics, Part One, Kill Mechanisms and Vulnerability (U) 161(S) Elements of Terminal Ballistics, Part Two, Collection and Analysis of Data Concerning Targets (U) 162(S-RD)Elements of Terminal Ballistics, Part Three, Application to Missile and Space Targets (U)

Propulsion and Propellants Aerodynamics Trajectories(U) Elements of Aircraft and Missile Propulsion Structures Warheads--General (U) Surface-to-Air Missiles, Part One, System Integration Surf-ce-to-Air Missiles, Part Two, Weapon Control Surface-to-Air iMis..ies, Part Three, Co.puters Surface-to-Air Missiles, Part Four, Missile Armement (U) Surface-to-Air Missiles, Part Five, Countermeasures (U) Surface-to-Air Missiles. Part Six, Structures

165
170(C) 175 176(C) 177 179 185 186 187 189 *210 211(C)

Liquid-Filled Prolectile

esi,

il

and Power Sources

Surface-to-Air Missiles, Part Sevep, Samnple rroblem (U) Fire Control Systems--General

Armor and Its Applica ion to c (U) Solid Propellants, Dart One Solid Propellants, Part Two (U) Properties of Explosives of Milit ry Interest Explosive Trains Military Pyrotechnics, Part One, Theory and Application Military Pyic~echnics, Part Two, Safety, Procedure: =nd Glossary Military Pyrotechnics, Part Three, Properties of Materials Used in Pyrotechnic Compositions Military Pyrotechnics, Part Five, Bibliography Fuzes Fuzes, Proximity, Electrical, Part One (U)

Fire Control Computing Systems

Compensating Elements Carrlagcs and iounts--Genekal Cradles Recoil Systems Top Carriages Bottom Carrlies Equilibrators Elevating Mechanisms Traversing Mechanisms The Automotive Assembly Automotive Suspensions

331 340 341 34? 343 344 345 346 347 355 356

*currently being printed.

__

____________________

___