55PC Spec Sheet Datasheet by TE Connectivity Raychem Cable Protection

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Raychem Wire and Cable
501 Oakside Avenue, Redwood City, CA 94063-3800
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SPECIFICATION: 55PC
THIS ISSUE: Issue 8
DATE: 18 May 2015
REPLACES: Issue 7
PAGE: 1 of 18
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PROCESS-CONTROLLED WIRE AND CABLE,
RADIATION-CROSSLINKED, MODIFIED ETFE*-INSULATED
1. SCOPE
1.1 SCOPE
This specification describes the characteristics, processes, and associated quality assurance
provisions for process-controlled wire and cable products. These products are manufactured
with an extruded insulation and jacket material of radiation-crosslinked, modified ETFE, in
conjunction with various conductor and shield materials.
1.2 DEFINITIONS
This section defines terms, not defined elsewhere, that are used in this specification and
referenced documents.
Cable - Two or more wires twisted together, or one or more wires with an overall shield. Each wire, in
this case, is termed a cable component.
Characteristic - Descriptive and/or measurable features or properties that define the part or process
relative to design, performance, or process.
Conductor - The central, metallic component of an insulated wire, having a single (solid) strand, or
multiple, twisted strands.
Jacket - An extruded layer of insulation applied over a cable. Its function is to provide mechanical
and environmental protection rather than electrical properties.
SCD - The Specification Control Drawing describes a single wire or cable construction in one AWG
size or a range of AWG sizes. It also contains requirements for certain characteristics.
Shield - A braided, or spiral, covering of round or flat metallic strands covering a wire or cable.
Target Value - The central value for a characteristic that reflects the ideal condition for the part or
process.
Tolerance Limits - Values that represent limits of acceptability for a given characteristic.
Wire - A conductor having one or more concentric layers of extruded insulation.
*Ethylene-tetrafluoroethylene
Finished Wire Cable Jackets and Single-Conductor Cable Multiconductor Cable Two or More Comgonents Wire No. Color Wire No. Process Steg Definitions I-v IE (a Color
Page 2 of 18 SPECIFICATION 55PC, ISSUE 8
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1.3 STANDARD INSULATION AND JACKET COLORS
Unless otherwise specified, finished wire and cable products shall be supplied with the
following colors:
1.3.1 Finished Wire, Cable Jackets, and Single-Conductor Cable
Finished wire, cable jackets, and the component wire of single-conductor cable shall be white
in accordance with MIL-STD-104, Class 1 limits.
1.3.2 Multiconductor Cable (Two or More Components)
The insulation color for component wires of multiconductor cable shall be as follows:
Wire No. Color Wire No. Color
1 Red 6 Violet
2 Blue 7 Orange
3 Yellow 8 Brown
4 Green 9 Pink
5 Black
2. MANUFACTURING PROCESS FLOW
This section defines and outlines the essential processes, and their relationships, used in the
manufacture of the wire and cable described herein. Table 1 identifies the manufacturing
process steps used for the basic product constructions offered under this specification.
Table 2 identifies the product characteristics that are established and/or subsequently verified
at these process steps (subsequent X's in the same row for a particular characteristic(s) indicate
steps that have the potential to modify the initially established characteristic, thus the
characteristic is rechecked).
Process Step Definitions:
EXTR. - The process of extruding layers of insulation on a conductor, or a jacket on a
cable.
BEAM - The process of radiation crosslinking the insulation or jacket.
PID - Product Identification (marking or striping).
CABLE - Twisting two or more wires or components together.
BRAID - Application of a braided or spiral metallic shield.
SPOOL - Packaging of wire or cable on final shipping spools, or in-process spooling for
subsequent operations.
SPECIFICATION 55PC, ISSUE 8 Page 3 of 18
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TABLE 1. PRODUCT CONSTRUCTIONS VS. PROCESS STEPS
Construction Incoming Material Extr. Beam PID Cable Braid Spool
Primary Wire Conductor; Compound X X opt --- --- opt
Cable, no shield or
jacket Primary wire --- --- --- X --- opt
Jacketed Cable Unshielded, unjacketed cable;
Compound X X opt --- --- opt
Shielded Cable Unshielded, unjacketed wire or
cable;
Shield strands --- --- --- --- X opt
Shielded and
Jacketed Cable Shielded wire or cable;
Compound X X opt --- --- opt
X = Essential process step
opt = Optional process step depending on final disposition of product (e.g., finished
product or in-process material to be used in another construction)
--- = Not applicable to product
TABLE 2. PRODUCT CHARACTERISTICS VS. PROCESS STEPS
Product Characteristics Extr. Beam PID Cable Braid Spool
Color X X X --- --- ---
Insulation/Jacket Dimensional Properties,
Weight X --- --- --- --- ---
Insulation/Jacket Flaws X --- --- X --- X
Shrinkage X --- --- --- --- X
Workmanship X X X X X X
Crosslinked Verification,
Insulation/Jacket Elongation,
Removability of Insulation --- X --- --- --- ---
Identification of Product,
Identification/Color Striping Durability --- --- X --- --- ---
Cabling --- --- --- X --- ---
Shield Construction and Coverage --- --- --- --- X ---
Conductor and Shield Continuity,
Dielectric Withstand --- --- --- --- --- X
X = Essential process step
--- = Not applicable to product
Characterisxic Codes
Page 4 of 18 SPECIFICATION 55PC, ISSUE 8
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3. REQUIREMENTS FOR CHARACTERISTICS
The requirements for wire and cable characteristics are as specified in Table 3 and as detailed
herein. The SCD and this specification define the requirements for the specified product. In
the event of conflict between the two, the SCD takes precedence.
TABLE 3. WIRE AND CABLE CHARACTERISTICS
Product Characteristics Wire Cable Char.* Requirement Procedure
Blocking X X Q 3.3.1 4.6.1
Cabling --- X P 3.2.1 4.6.6
Color X X P SCD and 1.3 4.6.6
Conductor Diameter X --- M SCD 4.6.6
Conductor Elongation and Break Strength X --- M 3.1.2 4.6.2
Conductor Material X --- M SCD and 3.1.1 4.6.3 and 4.6.6
Conductor Resistance X --- M SCD AS22759
Conductor and Shield Continuity --- X P100 3.2.2 WC 27500
Conductor Stranding X --- M SCD 4.6.6
Copper Mirror Corrosion X X Q SCD 4.6.4
Crosslinked Verification X X P 3.2.3 4.6.5
Dielectric Withstand --- X P100 SCD and 3.2.4 WC 27500
Finished Wire and Cable Diameter X X P SCD 4.6.6
Flammability X X Q 3.3.2 4.6.7
Fluoride Extraction X X Q SCD 4.6.8
Identification/Color Striping Durability X X P SCD and 3.2.5 AS22759
Identification of Product X X P SCD and 3.2.6 4.6.6
Insulation/Jacket Concentricity X X P 3.2.7 ASTM D 3032, Section 16
Insulation/Jacket Construction X X P SCD 4.6.6
Insulation/Jacket Elongation X X P 3.2.8 4.6.9
Insulation/Jacket Flaws X X P100 SCD and 3.2.9 4.6.10
Insulation/Jacket Material X X M 3.1.3 4.6.3
Insulation/Jacket Tensile Strength X X Q 3.3.3 4.6.9
Insulation/Jacket Thickness X X P SCD 4.6.6
Insulation Resistance X --- Q 3.3.4 4.6.11
Low Temperature-Cold Bend X X Q 3.3.5 4.6.12
Removability of Insulation X --- P 3.2.10 4.6.6
Shield Construction and Coverage --- X P SCD and 3.2.11 WC 27500
Shield Material --- X M SCD and 3.1.1 4.6.3 and 4.6.6
Shield Resistance --- X P SCD ASTM B 193
Shrinkage X --- P SCD 4.6.13
Weight X X P SCD 4.6.15
Workmanship X X P 3.2.12 4.6.6
Wraps --- X M SCD and 3.1.4 4.6.3 and 4.6.6
*Characteristic Codes: M = Material Specific Characteristic (see 3.1)
P = Process Specific Characteristic (see 3.2)
P100 = Process Specific Characteristic, 100% tested (see 3.2)
Q = Qualification Specific Characteristic (see 3.3)
Conductor and Shield Materials Conductor Elongation and Break Strength Insulation and Jacket Materials Wraps Cabling Conductor and Shield Continuitx
SPECIFICATION 55PC, ISSUE 8 Page 5 of 18
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3.1 MATERIAL SPECIFIC REQUIREMENTS
These characteristics, noted by the code "M" in Table 3, are initially established and controlled
by the incoming raw materials prior to the first process step (see Table 1). Materials not
specifically designated herein shall be of the quality and form best suited for the purpose
intended. Unless otherwise specified, the materials shall meet the following requirements:
3.1.1 Conductor and Shield Materials
Conductor materials and construction shall be in accordance with AS22759 and the applicable
SCD. Shield strand materials shall conform to the requirements specified in WC 27500 and
the applicable SCD.
3.1.2 Conductor Elongation and Break Strength
Conductor elongation and break strength shall meet the requirements of AS22759 for the
AWG, construction, and material specified in the applicable SCD.
3.1.3 Insulation and Jacket Materials
Insulating materials, used for wire insulation or cable jackets, shall be radiation-crosslinked,
extruded, modified ETFE.
3.1.4 Wraps
Tape wraps, where specified in the applicable SCD, shall be applied with an overlap of
25 percent, minimum, and shall meet the material and construction requirements of the
applicable SCD. Overlap is defined as the percentage of tape width covered by successive
turns of tape.
3.2 PROCESS SPECIFIC REQUIREMENTS
These characteristics, noted by the codes "P" and "P100" in Table 3, are initially established
and controlled by one particular process step (see Table 2). Unless otherwise specified,
requirements for process specific characteristics shall be as follows:
3.2.1 Cabling
Cable components shall be twisted in a left-hand lay with a length of lay 8 to 16 times the
cabled diameter. Cable components shall meet the requirements of the applicable component
SCD prior to cabling.
3.2.2 Conductor and Shield Continuity
One hundred percent of all finished cable shall exhibit no loss of continuity in the conductors
or shields, as applicable.
Crosslinked Verification Crosslinkin Proof Test Dielectric Withstand Identification and Color Striging Durabilitx Identification of Product Insulation or Jacket Concentricity Insulation or Jacket Elongation Insulation or Jacket Flaws
Page 6 of 18 SPECIFICATION 55PC, ISSUE 8
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3.2.3 Crosslinked Verification (Crosslinking Proof Test)
When finished wire is tested in accordance with 4.6.5.1, the insulation shall not crack or fail
dielectrically. When finished cable is tested in accordance with 4.6.5.2, the jacket shall not
crack or, if shielded and jacketed, fail dielectrically.
3.2.4 Dielectric Withstand
One hundred percent of finished cable shall pass the dielectric withstand test with an
application time of 15 to 30 seconds, without breakdown, using the voltage specified in the
applicable SCD.
3.2.5 Identification and Color Striping Durability
There shall be no discontinuity of identification mark or color stripe after subjecting the mark
or stripe to the number of cycles and the test load specified in the applicable SCD.
Additionally, stripes shall not flake or crack when the finished wire, or component wire prior
to cabling, is wound back on itself.
3.2.6 Identification of Product
When specified by the procuring activity, finished wire or cable shall be identified by a
marking applied to the outer surface. The identification shall consist of the appropriate mark
as specified by the contract or the applicable SCD. The mark color shall be in accordance
with MIL-STD-104, Class 1, and shall be contrasting to that of the marking surface.
Identification shall be applied with the vertical axis of the printed characters parallel to the
longitudinal axis of the wire or cable when the nominal diameter of the marking surface is
0.050 inch (1.3 mm) or smaller. The vertical axis of the printed characters may be either
perpendicular or parallel to the longitudinal axis of the wire or cable when the nominal
diameter of the marking surface exceeds 0.050 inch (1.3 mm).
3.2.7 Insulation or Jacket Concentricity
The concentricity of the total wire insulation, or cable jacket, shall be 70 percent, minimum.
3.2.8 Insulation or Jacket Elongation
When finished wire or cable is tested in accordance with 4.6.9, the elongation of the total wire
insulation (for dual-walled insulations, both layers pulled together as a unit), or the cable
jacket, shall be 50 percent, minimum.
3.2.9 Insulation or Jacket Flaws
One hundred percent of finished wire, unshielded and unjacketed cable, and shielded and
jacketed cable shall pass the impulse dielectric test or the spark test specified in 4.6.10 using
the voltage specified in the applicable SCD. Testing shall be performed during the final
winding of the wire or cable on shipment spools or reels.
Removability of Insulation Shield Construction and Coverage Workmanshig Blocking Flammability Insulation or Jacket Tensile Strength
SPECIFICATION 55PC, ISSUE 8 Page 7 of 18
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3.2.10 Removability of Insulation
For AWG 10 and smaller finished wires, 0.5 inch (13 mm) of insulation shall be readily
removable using conventional, hand-operated, wire strippers with properly-sized blades for the
construction. The insulation slug shall not bunch, nor shall any conductor strands break
during the removal process.
3.2.11 Shield Construction and Coverage
The optical coverage of braided or spiral shields shall be 85 percent, minimum. Braided
shields shall have an angle of 18 to 35 degrees relative to the axis of the cable.
3.2.12 Workmanship
Workmanship of finished wire and cable shall be uniform and free of external, or internal,
physical or cosmetic irregularities.
3.3 QUALIFICATION SPECIFIC REQUIREMENTS
These characteristics, noted by the code "Q" in Table 3, are a function of the combination of
materials and processes used to produce a given wire or cable construction. Following
qualification, adherence to material specific and process specific requirements assures that the
product will continue to meet the initial qualification specific requirements. Qualification
specific requirements shall be as follows, when tested on the following constructions:
Wire: 55PC0211-20 and 55PCF0211-20, as applicable
Cable: 55PC1221-22 and 55PCF1221-22, as applicable
Conductor plating and/or shield plating substitutions may be allowed provided the wire or
cable construction is otherwise the same as specified.
3.3.1 Blocking
When finished wire or cable is tested in accordance with 4.6.1, adjacent turns and layers of the
wire or cable shall not block. Blocking shall be defined as a transfer of material between
adjacent surfaces when they are separated.
3.3.2 Flammability
When finished wire or cable is tested in accordance with 4.6.7, the burn length shall not
exceed 3 inches (76 mm), the afterburn time shall not exceed 3 seconds, and there shall be no
flaming of the facial tissue.
3.3.3 Insulation or Jacket Tensile Strength
When finished wire or cable is tested in accordance with 4.6.9, the tensile strength of the total
wire insulation (for dual-walled insulations, both layers pulled together as a unit), or the cable
jacket, shall be 5000 lbf/inch2 (34 N/mm2), minimum.
Insulation Resistance Low Temgerature—Cold Bend Samgling 1or Quality Conformance Insgection
Page 8 of 18 SPECIFICATION 55PC, ISSUE 8
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3.3.4 Insulation Resistance
When finished wire is tested in accordance with 4.6.11, the insulation resistance of the
finished wire shall be 5000 megohms for 1000 feet (1524 M
-1km), minimum.
3.3.5 Low Temperature-Cold Bend
When finished wire or cable is tested in accordance with 4.6.12, there shall be no insulation or
jacket cracking, and no dielectric breakdown.
4. QUALITY ASSURANCE PROVISIONS
4.1 QUALITY ASSURANCE SYSTEM
This section defines the Quality Assurance system that is used to assure that all products
manufactured in accordance with this specification meet all applicable requirements.
4.2 QUALIFICATION INSPECTION
Qualification inspection shall consist of meeting all characteristics listed in Table 1, as
applicable to finished wire or cable. Requalification testing shall be performed any time
changes in materials or processes occur that are deemed to have the potential for significantly
altering the form, fit, function, or appearance of the product.
4.3 QUALITY CONFORMANCE INSPECTION
Quality conformance inspection shall consist of all material specific and process specific
characteristics, represented by the codes "M", "P" and "P100" in Table 3. Quality
conformance inspection shall be performed on every lot of wire or cable procured under this
specification, unless documentation of a statistical nature provides evidence that reduced
inspection is warranted.
4.3.1 Sampling for Quality Conformance Inspection
MIL-STD-1916, inspection level S-3, AQL 1.5 percent, normal inspection, shall apply for all
quality conformance testing. ISO 8402 shall apply for definitions of inspection terms used
herein. For purposes of this specification, the following shall apply:
4.3.1.1 Lot
The inspection lot shall include all wire or cable of one part number or description, exclusive
of color, subjected to inspection at one time.
4.3.1.2 Unit of Product
The unit of product for determining lot size for sampling shall be one continuous length of
wire or cable as offered for inspection.
Control Plan Blocking Conductor Elongation and Break Strength Certification of Materials Copger Mirror Corrosion
SPECIFICATION 55PC, ISSUE 8 Page 9 of 18
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4.3.1.3 Sample Unit
The sample unit for quality conformance inspection shall be of sufficient length to permit all
applicable examinations and tests.
4.4 PROCESS CONTROL
Process control shall be maintained with the use of statistical process control and continuous
improvement techniques.
4.4.1 Control Plan
The Control Plan describes the system for controlling the materials, construction, processes,
and testing required for each wire and cable product.
4.5 DOCUMENTATION
Test reports shall be prepared and kept in the Quality Control Department files for each
manufactured lot of product. The results of the quality conformance inspection (see 4.3) shall
be recorded in these test reports.
4.6 TEST PROCEDURES
4.6.1 Blocking
Finished wire shall be tested in accordance with AS22759 at 230 ± 3°C for 4 hours. Finished
cable shall be tested in accordance with WC 27500 at 230 ± 3°C for 4 hours.
4.6.2 Conductor Elongation and Break Strength
Elongation and tensile strength tests of the conductor shall be tested in accordance with
AS22759, prior to insulation extrusion, except that for high strength alloy conductors, the rate
of jaw separation shall be 2 ± 1/2 inches (51 ± 13 mm) per minute and the tensile strength shall
be reported as the tensile break strength of the conductor rather than in pounds per square
inch.
4.6.3 Certification of Materials
Prior to incorporation in a wire or cable construction, incoming (raw) materials must meet
internal procurement requirements that are not covered in this specification or the applicable
SCD. Certificates of compliance shall be kept on file stating that the specified materials have
been used and that they met all applicable requirements.
4.6.4 Copper Mirror Corrosion
A sufficient number of 3-inch (76-mm) lengths of wire insulation or cable jacket, as
applicable, shall be removed from the finished wire or cable to make up an overall test weight
of 0.90 ± 0.01 grams. The lengths shall be placed into a 19 ml polystyrene test tube
containing 2.5 ml of distilled water. Approximately 1 inch (25 mm) of the insulation or jacket
pieces shall be immersed in the water. Screw on the test tube cap which has been fitted with a
copper alligator clip to which is attached a copper mirror. Please note that the copper mirror
Crosslinked Verification
Page 10 of 18 SPECIFICATION 55PC, ISSUE 8
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should only be handled when wearing gloves. The test tube shall be maintained with the
prepared specimens in the upright position for three weeks at an ambient temperature of
21 ± 3ºC. After this conditioning period, the mirror shall be removed and inspected for any
signs of corrosion which appear as transparent glass. Results can be quantified by imaging the
entire mirror and determining the percentage of surface area which is transparent.
4.6.5 Crosslinked Verification
4.6.5.1 Finished Wire
One inch (25 mm) of insulation shall be removed from each end of a 24-inch (610-mm)
specimen of finished wire. Both ends of the specimen shall be connected together and the test
load specified in Table 4 shall be attached to the connected specimen ends. The specimen
loop shall then be suspended over a stainless steel mandrel with a sintered polytetrafluoro-
ethylene coating. The mandrel shall have the diameter specified in Table 4, and shall be of
sufficient rigidity so as not to flex under load. This specimen, so prepared on the mandrel,
shall be conditioned in an air-circulating oven at 300 ± 3°C for 1 hour. The velocity of air
past the specimen (measured at room temperature) shall not be less than 100 feet (30 m) per
minute. After conditioning, the oven shall be shut off, the door opened, and the specimen
allowed to cool in the oven for at least 1 hour. When cool, the specimen shall be freed from
tension, removed from the mandrel, and straightened. The specimen shall then be subjected to
the bend test (4.6.5.1.1) followed by the voltage withstand test (4.6.14).
4.6.5.1.1 Bend Test
At a temperature maintained between 20 and 25°C, one end of the wire specimen shall be
secured to the mandrel and the other end to a weight equal to one half the test load specified in
Table 4. The mandrel shall be rotated until the full length of the specimen is wrapped around
the mandrel and is under the specified tension with adjoining turns in contact. The mandrel
shall then be rotated in the reverse direction until the full length of the specimen which was
outside during the first wrapping is now next to the mandrel. This procedure shall be repeated
until two bends in each direction have been formed in the same section of the specimen. The
specimen shall then be examined for cracking of the insulation.
4.6.5.2 Finished Cable
Two inches (51 mm) of the jacket shall be removed from each end of a 15-inch (381-mm)
specimen of finished cable, and the shield, if any, shall be pushed back and formed into a
pigtail at each end of the specimen. One inch (25 mm) of insulation from each conductor shall
then be removed from each end of the specimen. The cable specimen shall then be loaded
with sufficient weight to hang straight, and shall be conditioned in an air-circulating oven at
300 ± 3°C for 1 hour. The velocity of air past the specimen (measured at room temperature)
shall not be less than 100 feet (30 m) per minute. After conditioning, the oven shall be shut
off, the door opened, and the specimen allowed to cool in the oven for at least 1 hour. When
cool, the cable specimen shall then be examined for cracking of the jacket. The voltage
withstand test (4.6.14) shall then be conducted on shielded and jacketed cable specimens only.
Examination of Product Flammability
SPECIFICATION 55PC, ISSUE 8 Page 11 of 18
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TABLE 4. MANDRELS AND TEST LOADS FOR FINISHED WIRE
CROSSLINKED VERIFICATION
AWG
55PC011X 55PC021X, 55PC081X 55PC071X
Mandrel OD
(± 3%) Test Load
(± 3%) Mandrel OD
(± 3%) Test Load
(± 3%) Mandrel OD
(± 3%) Test Load
(± 3%)
inch (mm) lbs (kg) inch (mm) lbs (kg) inch (mm) lbs (kg)
30 0.25 (6.4) 0.25 (0.11)
28 0.25 (6.4) 0.25 (0.11)
26 0.38 (9.7) 0.25 (0.11) 0.38 (9.7) 1.0 (0.45)
24 0.38 (9.7) 0.50 (0.23) 0.50 (13) 1.5 (0.68) 1.00 (25) 4.0 (1.8)
22 0.50 (13) 0.75 (0.34) 0.50 (13) 2.0 (0.91) 1.00 (25) 4.0 (1.8)
20 0.50 (13) 1.0 (0.45) 0.50 (13) 3.0 (1.4) 1.00 (25) 6.0 (2.7)
18 0.50 (13) 1.0 (0.45) 0.75 (19) 4.0 (1.8) 1.00 (25) 6.0 (2.7)
16 0.75 (19) 1.5 (0.68) 1.00 (25) 4.0 (1.8) 1.25 (32) 7.0 (3.2)
14 1.00 (25) 2.0 (0.91) 1.00 (25) 6.0 (2.7) 1.25 (32) 7.0 (3.2)
12 1.50 (38) 3.0 (1.4) 1.50 (38) 6.0 (2.7) 2.00 (51) 8.0 (3.6)
10 2.00 (51) 3.0 (1.4) 2.00 (51) 6.0 (2.7) 2.00 (51) 8.0 (3.6)
8 3.00 (76) 4.0 (1.8) 3.00 (76) 8.0 (3.6)
6 4.00 (102) 4.0 (1.8) 4.00 (102) 8.0 (3.6)
4 5.00 (127) 8.0 (3.6)
2 6.00 (152) 12.0 (5.4)
1 8.00 (203) 12.0 (5.4)
0 8.00 (203) 12.0 (5.4)
00 10.0 (254) 16.0 (7.3)
000 10.0 (254) 16.0 (7.3)
0000 10.0 (254) 16.0 (7.3)
4.6.6 Examination of Product
Where requirements are not supported by specific test procedures, products shall be examined
to determine conformance to this specification and the applicable SCD.
4.6.7 Flammability
4.6.7.1 Test Apparatus
The test shall be performed within a test chamber approximately 1 foot (0.30 m) square by
2 feet (0.61 m) in height, open at the top and front to provide adequate ventilation for
combustion but to prevent drafts. The specimen holder shall be so designed that the lower end
of a 24-inch (610-mm) specimen is held by a clamp, while the upper end of the specimen
passes over a pulley and can be suitably weighted to hold the specimen taut at an angle of
60 degrees with the horizontal, in a plane parallel to and approximately 6 inches (152 mm)
from the back of the chamber. The test flame shall originate from a Bunsen type gas burner
with a 0.250-inch (6.4-mm) inlet, a needle valve in the base for gas adjustment, a nominal bore
of 0.375 inch (9.5 mm), and a barrel length of approximately 4 inches (102 mm) above
Page 12 of 18 SPECIFICATION 55PC, ISSUE 8
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the air inlets. The burner shall be adjusted to furnish a 3-inch (76-mm) high conical flame
with an inner cone approximately 1 inch (25 mm) in length and a flame temperature not less
than 954°C at its hottest point, as measured with an accurate thermocouple pyrometer. A sheet
of facial tissue conforming to UU-T-450 shall be suspended taut and horizontal 9.5 inches
(241 mm) below the point of application of the flame to the specimen and at least 0.50 inch (13
mm) from the chamber floor, so that any material dripping from the specimen shall fall upon
the tissue.
4.6.7.2 Test Procedure
A 24-inch (610-mm) specimen shall be marked at a distance of 8 inches (203 mm) from its
lower end to indicate the point for flame application and shall be placed in the specified 60-
degree position in the test chamber. The lower end of the specimen shall be clamped in
position in the specimen holder and the upper end shall be passed over the pulley of the holder
and the applicable weight shall be attached. For wire, the weight shall be equal to one half the
test load specified for the crosslinked verification test of the same wire in Table 4. For cable,
the weight shall be sufficient to hold the specimen taut throughout the test. With the burner
held perpendicular to the specimen and at an angle of 30 degrees from the vertical plane of the
specimen (see Figure 1), the hottest portion of the flame shall be applied to the lower side of
the specimen at the test mark. The period of test flame application shall be 30 seconds and the
test flame shall be withdrawn immediately at the end of that period. The distance of flame
travel upward along the specimen from the test mark and the time of burning after removal of
the test flame shall be recorded; also the presence or absence of flame in the facial tissue due
to incendiary dripping from the specimen. Charred holes or charred spots in the tissue shall be
ignored in the absence of actual flame. Breaking of the wire specimens in size 24 or smaller
shall not be considered as failure, provided the requirements for flame travel limits, duration
of flame, and absence of incendiary dripping are met.
FIGURE 1. FLAMMABILITY TEST APPARATUS
(shown without chamber)
Fluoride Extraction Net F inn gym x Original water weight Insulation or Jacket Elonuation and Tensile Strenclth
SPECIFICATION 55PC, ISSUE 8 Page 13 of 18
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4.6.8 Fluoride Extraction
For finished wire or filler, prior to cabling, or for finished cable, approximately 0.5 gram of
insulation, filler, or jacket material, as applicable, shall be removed, cut into 3-inch (76-mm)
lengths and weighed to the nearest milligram. A polystyrene test tube (without its cap) shall
also be weighed to the nearest 0.1 gram. After filling with approximately 14 ml of distilled
water, the polystyrene test tube shall be reweighed. The insulation, filler, or jacket specimen
shall then be placed into the test tube, making sure that the specimen is fully submerged, and
the test tube cap is tightly attached. The test tube shall then be partially immersed in a
70 ± 2°C water bath so that the water levels of the bath and the test tube are equal. The test
tube shall be so conditioned for 168 hours with the set-up being periodically checked to make
sure that the specimen is still submerged. After conditioning, the test tube shall be removed
from the bath and allowed to cool. The cap shall then be removed from the test tube, and the
tube, water and specimen shall be weighed to determine the water weight loss. If the water
loss is more than 0.5 gram, the test shall be rerun. Otherwise, 5 ml of the test tube water shall
be analyzed for fluoride ion content using an Ion Chromatograph. The fluoride ion content
shall be reported in ppm of water and shall not exceed the amount specified in the applicable
SCD. A blank test in accordance with 4.6.8.1 should also be conducted in case the result is
needed for calculation purposes.
4.6.8.1 Blank Test
A blank test follows the same procedure as 0 except that a specimen is not included. What is
tested is the distilled water and the specimen tube. Ideally, there are no fluoride ions in either
the test tube or the distilled water such that the result for the blank test would be zero.
However, there may be a low non-zero result (i.e. 0.005 ppm). If this occurs, the ppm of
fluoride for the blank test must be subtracted from the ppm of fluoride obtained from the
specimen. A blank test also performs the same function as a calibration as it can indicate a
problem with the test procedure. For example, should the blank test produce a result of 15
ppm of fluoride, this would be an indication that the ion chromatograph is not functioning
correctly, tap water was used in place of distilled water, etc.
4.6.8.2 Calculation
If necessary, the blank test result shall be subtracted from the specimen result to obtain the net
fluoride ion content (ppm). The fluoride ion content of the insulation, filler, or jacket weight
shall then be calculated as follows:
F ion = Net F ion (ppm) x Original water weight
Specimen weight
4.6.9 Insulation or Jacket Elongation and Tensile Strength
For wires, specimens of the entire insulation shall be carefully removed from the conductor
and tested for tensile strength and elongation in accordance with FED-STD-228, Methods
3021 and 3031, respectively, using 1-inch (25-mm) bench marks, a 1-inch (25-mm) initial jaw
separation, and a jaw separation speed of 2 inches (51 mm) per minute. For cables, the method
shall be the same, but only the cable jacket shall be tested.
Insulation or Jacket Flaws Insulation Resistance Specimen resistance (megohms) x Immersed length (feet) (or rim/em) Low Temgerature-Cold Bend
Page 14 of 18 SPECIFICATION 55PC, ISSUE 8
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4.6.10 Insulation or Jacket Flaws
4.6.10.1 Impulse Dielectric Test
Finished wire and cable shall be tested in accordance with ASTM D 3032, Section 13, at the
voltage specified in the applicable SCD with the conductor or shield, as applicable, grounded
at one end or both ends. When specified in the contract or order, insulation or jacket failure,
untested portions, or portions which have been exposed to fewer or more than the specified
pulses may be marked by stripping the insulation or jacket or by any other suitable method of
marking as specified in the contract in lieu of being cut out of the wire or cable.
4.6.10.2 Spark Test
Finished wire and cable shall be passed through a chain electrode spark test device using the
voltage specified in the applicable SCD at a frequency of 60 or 3000 Hz. The conductor or
shield, as applicable, shall be grounded at one or both ends. The electrode shall be of a
suitable bead chain or fine mesh construction that will give intimate metallic contact with
practically all of the wire or cable surface. Electrode length and speed of specimen movement
shall be such that the wire or cable is subjected to the test voltage for a minimum of 0.2
second. Any portion showing breakdown shall be cut out, including at least 2 inches (51 mm)
of insulation or jacket on each side of the failure.
4.6.11 Insulation Resistance
The uninsulated ends of a wire specimen at least 26 feet (7.9 m) in length shall be connected
electrically to a DC terminal. The specimen shall be immersed to within 6 inches (152 mm) of
its ends in a water bath at 25 ± 5°C containing 0.5 to 1.0 percent of an anionic wetting agent.
After 4 hours minimum of immersion, the specimen shall be subjected to a potential of 250 to
500 volts applied between the conductor and the water bath, which serves as the second
electrode. The insulation resistance of the specimen shall be determined after one minute of
electrification at this potential and shall be calculated as follows:
Megohms for 1000 feet =
(or M
-l km) Specimen resistance (megohms) x Immersed length (feet) (or meters)
1000
4.6.12 Low Temperature-Cold Bend
For finished wire, a specimen shall be tested in accordance with the insulation low temperature
resistance test specified in AS22759 at -65 ± 2°C for 4 hours using the applicable mandrel and
test load specified below, except that only 1 specimen shall be tested and the voltage withstand
test shall be as specified herein (4.6.14). Finished cable shall be tested in accordance WC
27500 at -65 ± 2°C for 4 hours using the applicable mandrel and test load specified below,
except the voltage withstand test shall be as specified herein (4.6.14). Dissecting the cable
specimen and testing the individual wires shall not be required.
Wire: 0.75-inch (19-mm) mandrel, 3-lb. (1.4 kg) test load
Cable: 1.50-inch (38-mm) mandrel, 5-lb. (2.3 kg) test load
Volta e Withstand Post Environmental Weight
SPECIFICATION 55PC, ISSUE 8 Page 15 of 18
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4.6.13 Shrinkage
A 12-inch (305-mm) specimen of the finished wire shall be cut so that the insulation and
conductor are flush at both ends. The specimen shall be placed in an air-circulating oven and
maintained for a period of 1 hour at the temperature specified in the applicable SCD. The
velocity of air past the specimen location in the oven shall be between 100 and 200 feet
(30 and 61 m) per minute as determined at room temperature. At the end of the 1-hour period,
the specimen shall be removed from the oven and allowed to return to room temperature.
Shrinkage of the insulation shall be measured as the greatest distance which any layer of the
insulation has receded from either end of the conductor; that is, the measurement obtained at
the end showing the greater shrinkage shall be considered the shrinkage of the specimen.
4.6.14 Voltage Withstand (Post Environmental)
The uninsulated ends of the specimen shall be attached to an electric lead. The specimen shall
be immersed in a 5-percent, by weight, solution of sodium chloride in water at 20 to 25°C,
except that the uninsulated ends and 1.5 inches (38 mm) of insulated wire or cable at each end
of the specimen shall protrude above the surface of the solution. Immediately following
specimen immersion, the voltage specified in the applicable SCD shall be applied at 60 Hz
between all the conductors and shields, tied together, as applicable, and the water bath which
shall be grounded. The voltage shall be gradually increased at a uniform rate from zero to the
specified voltage in 0.5 minute, maintained at that voltage for a period of 5 minutes for
finished wire specimens and 1 minute for finished cable specimens, and gradually reduced to
zero in 0.5 minute.
4.6.15 Weight
The weight of each lot of finished wire or cable shall be determined by Procedure I (4.6.15.1).
Lots failing to meet the weight requirement of the applicable SCD when tested in accordance
with Procedure I shall be subjected to Procedure II (4.6.15.2). All spools or reels failing to
meet the requirements of the applicable SCD when tested to Procedure II shall be rejected.
4.6.15.1 Procedure I
A length of wire or cable, sufficient to produce a measured weight to at least 3 significant
figures, shall be weighed and converted to the weight per unit length shown on the applicable
SCD.
4.6.15.2 Procedure II
The net weight of the finished wire or cable on each spool or reel shall be obtained by
subtracting the tare weight of the spool or reel from the gross weight of the spool or reel
containing the finished wire or cable. The net weight of wire or cable on each spool or reel
shall be divided by the accurately determined length of finished wire or cable on that spool or
reel and the resultant figure converted to the weight per unit length shown on the applicable
SCD. When wood or other moisture absorbent materials are used for spool or reel
construction, weight determinations shall be made under substantially uniform conditions of
relative humidity.
Finished Wire Finished Cable Sgools and Reels Containers
Page 16 of 18 SPECIFICATION 55PC, ISSUE 8
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5. STANDARD PACKAGING
Unless otherwise specified (see 7.1), the following shall define the standard spooling and
labeling requirements for wire and cable furnished under this specification. Standard shipping
tolerance on ordered quantity, for both wire and cable, shall be ± 10 percent.
5.1 SPOOLING REQUIREMENTS
All layers of wire and cable shall be wound on spools or reels (see 5.1.3) with sufficient
tension to prevent shifting of layers and creation of crossovers within layers.
5.1.1 Finished Wire
Finished wire lengths shall be wound on spools or reels with the ends spliced together to
provide one mechanically and electrically continuous length. Unless otherwise specified, the
minimum continuous length between splices shall be in accordance with Table 5.
TABLE 5. FINISHED WIRE LENGTHS
Wire Size Range
(AWG) Minimum Length
30 through 10
8 and larger
100 feet (30 m)
50 feet (15 m)
(NOTE: Metric lengths specified above apply only to those orders placed in metric.)
5.1.2 Finished Cable
Finished cable lengths shall be wound on spools or reels with all ends exposed. There shall be
no more than 5 lengths per spool or reel and no length shall be less than 50 feet (15 m).
5.1.3 Spools and Reels
Spools and reels shall be of a nonreturnable type. Each spool and reel shall have an
appropriate diameter for the respective wire or cable size. In no case shall the barrel of the
spool or reel have a diameter less than 3.5 inches (89 mm). Spools and reels shall be suitably
finished to prevent corrosion under typical storage and handling conditions. Loaded plastic
spools shall not exceed 50 pounds (23 kg). Loaded wooden reels shall have no weight
restriction.
5.1.4 Containers
Unless otherwise specified (see 7.1), finished wire and cable shall be delivered in standard
commercial containers so constructed as to ensure acceptance by common or other carrier for
safe transportation at the lowest rate to the point of delivery.
Deganmem of Defense Federal Military §.dln.mil/ uicksearchl. American Society for Testing and Materials (ASTM) www.aslm.org.
SPECIFICATION 55PC, ISSUE 8 Page 17 of 18
NOTE: ANY PRINTED COPY OF THIS DOCUMENT
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5.2 LABELING REQUIREMENTS
All spools and reels shall be identified with the following information:
Manufacturer's Part Number
Lot Number
Quantity in Feet (or Meters)
Name of Manufacturer
6. APPLICABLE DOCUMENTS
6.1 GOVERNMENT-FURNISHED DOCUMENTS
The following documents, of the issue in effect on date of invitation for bids or request for
proposal, form a part of this specification to the extent specified herein.
6.1.1 Department of Defense
SPECIFICATIONS
Federal
UU-T-450 Tissue, Facial
STANDARDS
Military
MIL-STD-104 Limits for Electrical Insulation Color
MIL-STD-1916 DOD Preferred Methods for Acceptance of Product
(Copies of Department of Defense documents may be obtained from the Naval Publications
and Forms Center, Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Ave.,
Philadelphia, PA 19111-5094; or at http://assist.daps.dla.mil/quicksearch/.)
6.2 OTHER PUBLICATIONS
The following documents, of the issue in effect on date of invitation for bids or request for
proposal, form a part of this specification to the extent specified herein.
6.2.1 American Society for Testing and Materials (ASTM)
B 193 Standard Test Method for Resistivity of Electrical Conductor Materials
D 3032 Standard Test Methods for Hookup Wire Insulation
(Copies of ASTM documents may be obtained from the American Society for Testing and
Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959; or at
www.astm.org.)
International Orqanization for Standardization (ISO) www.iso.org National Electrical Manufacturers Association (NEMA) www.nema.org Society of Automotive Engineers SAE) www.mcorg
Page 18 of 18 SPECIFICATION 55PC, ISSUE 8
NOTE: ANY PRINTED COPY OF THIS DOCUMENT
IS AN UNCONTROLLED COPY.
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6.2.2 International Organization for Standardization (ISO)
8402 Quality Management and Quality Assurance - Vocabulary
(Copies of ISO documents may be obtained from the International Organization for
Standardization; or at www.iso.org.)
6.2.3 National Electrical Manufacturers Association (NEMA)
WC 27500 Standard for Aerospace and Industrial Electrical Cable
(Copies of NEMA documents may be obtained from the National Electrical Manufacturers
Association, 1300 North 17th Street, Rosslyn, VA 22209; or at www.nema.org.)
6.2.4 Society of Automotive Engineers (SAE)
AS22759 Wire, Electrical, Fluoropolymer-Insulated, Copper or Copper Alloy
(Copies of SAE documents may be obtained from the Society of Automotive Engineers,
400 Commonwealth Drive, Warrendale, PA 15096-0001; or at www.sae.org.)
7. NOTES
7.1 ORDERING DATA
Procurement documents should specify the following:
a. Title, number, and revision of this specification
b. Applicable SCD part number and color code (see 1.3)
c. Quantity
d. Special preparation for delivery requirements, if applicable (see Section 5)
7.2 METRIC UNITS
Metric units (where shown in parentheses) are for information only.
7.3 TRADEMARKS
Raychem, TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks.

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