82A0111-22-F868-9CS2920 Datasheet 82A0111-22-F868-9CS2920, 82A0111-22-F868-9 | P16-P18

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Page 12 SPECIFICATION 80, ISSUE 1

TABLE 3

MANDREL DIAMETERS FOR CABLES FOR BEND TEST

(POST-ENVIRONMENTAL)

Finished Cable Diameter Mandrel Diameter

inch

≤ 0.083

≤

2.11

.750 19

> 0.083 and ≤ 0.111 >2.11 and

≤

2.82

1.00 25

> 0.111 and ≤ 0.139 >2.82 and

≤

3.53

1.25 32

> 0.139 and ≤ 0.194 >3.53 and

≤

4.93

1.75 44

> 0.194 and ≤ 0.250 >4.93 and

≤

6.35

2.25 57

> 0.250 and ≤ 0.334 >6.35 and

≤

8.48

3.00 76

> 0.334 and ≤ 0.444 >8.48 and

≤

11.3

4.00 102

> 0.444 and ≤ 0.556 >11.3 and

≤

14.1

5.00 127

> 0.556 and ≤ 0.667 >14.1 and

≤

16.9

6.00 152

> 0.667 and ≤ 0.889 >16.9 and

≤

22.6

8.00 203

> 0.889 and ≤ 1.111 >22.6 and

≤

28.2

10.0 254

> 1.111 and ≤ 1.556 >28.2 and

≤

39.5

14.0 356

> 1.556 and ≤ 2.000 >39.5 and

≤

50.8

18.0 457

4.6.2 Conductor and Finished Wire Diameter

Diameter measurements shall be made on a 24-inch (610-mm), minimum, length of finished

wire taken from the end of the sample unit. The conductor shall be made accessible by

stripping and removing the insulation carefully so as not to nick, cut, cold-work, or otherwise

damage the conductor. Three points for measurement shall be located 8 inches (203 mm) apart

along the conductor or finished wire specimen length, as applicable. For AWG 10 and smaller,

measure-ments shall be made at each point at two approximately perpendicular planes or as

required to assure that the minimum and maximum reading is attained at each point. A total of

six measure-ments shall be performed on each specimen. Measurements shall be made with a

micrometer caliper or equivalent device capable of resolving a measurement to 0.0001 inch

(0.0025 mm). For AWG 8 and larger, a circumferential measuring tape may be used in lieu of a

micrometer, and a total of three measurements, taken 8 inches (203 mm) apart, shall be

performed on each specimen. The circumferential measuring tape shall be capable of resolving

a measurement to 0.001 inch (0.025 mm) over a diameter range of 0.200 inch (5.08 mm) and

larger. The average diameter of all applicable measurements shall be calculated and recorded.

4.6.3 Conductor Elongation (High Strand Count)

High-strand-count conductors shall be tested for elongation in accordance with Method 3211

of FED-STD-228, except that the test shall be performed upon the whole conductor for regular

bunch-stranded constructions, and upon one whole member removed from rope bunch-

stranded constructions. In either case, elongation shall be measured upon breakage of the first

strand of the whole conductor or member, as applicable.

4.6.4 Crosslinking Proof Test

Crosslinking proof tests of finished wire and cable shall be conducted in accordance with the

life cycle test method of 4.6.12. The time and temperature specified for the crosslinking proof

test on the applicable specification sheet shall be used.

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SPECIFICATION 80, ISSUE 1 Page 13

4.6.5 Examination of Preparation for Delivery

Preparation for delivery of materials ready for shipment shall be examined to determine

compliance with the requirements of Section 5.

4.6.6 Examination of Product

All samples of wire and cable shall be examined to determine conformance with this specifica-

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

test methods.

4.6.7 Flammability

4.6.7.1 Procedure 1

Procedure 1 flammability testing shall be in accordance with ASTM F 777, with a flame

application period of 30 seconds. The procedure of ASTM F 777 conforms with FAR,

Part 25, Appendix F (g).

4.6.7.2 Procedure 2

(N/A for cable and AWG 8 wire samples)

The test shall be performed in a sheet metal cabinet conforming to FED-STD-191, Method

5903. Two inches (51 mm) of insulation shall be removed from one end of an 18-inch (457-

mm) specimen of finished wire and the specimen shall be mounted as shown in Figure 1. A

1.5-inch (38-mm) high yellow flame from a Bunsen burner conforming to FED-STD-191,

Method 5903, shall be applied to the specimen at the junction of the insulation and the bare

conductor in such a manner that the lower end of the insulation is located 0.75 inch (19 mm)

into the flame. After 12 seconds of flame application, the burner shall be removed from below

the specimen and immediately turned off. The burn length and the time of burning after

removal of the flame shall be recorded. The burn length shall be the distance from the original

bend made in the conductor to the farthest point of damage. Damage shall consist of bare

conductor and charred insulation. Light discoloration of the insulation shall not constitute

failure.

FIGURE 1 - Flammability Test Apparatus, Procedure 2

(shown without metal cabinet)

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Page 14 SPECIFICATION 80, ISSUE 1

4.6.8 Immersion

Specimens of sufficient length to perform the subsequent tests shall be measured at their

midpoints to determine their initial diameters, and shall then be immersed to within 6 inches

(152 mm) of their ends in each of the fluids (using a separate specimen for each fluid) for the

time and temperature specified in Table 4. During immersion, the radius of bend of the

specimens shall be not less than 14, nor more than 35, times the specified maximum diameter

of the wire or cable under test. Upon removal from the fluids, the specimens shall remain for 1

hour in free air at room temperature. The diameters shall then be remeasured at the original

point of measurement and compared to the initial diameters. The percent change in diameter

shall then be calculated. For finished wire, 1 inch (25 mm) of insulation shall be removed from

each end of a 24-inch (610-mm) length of each specimen. For finished cable, 2 inches (51 mm)

of the jacket shall be removed from each end of a 24-inch (610-mm) length of each specimen,

and the shield shall be pushed back and formed into a pigtail at each end of the specimen. One

inch (25 mm) of insulation of each of the primary wires shall then be removed from each end

of the specimen. The specimens shall then be subjected to the bend test (4.6.1 - use the

mandrels and test weights specified on the applicable specification sheet for the Crosslinking

Proof Test), followed by the voltage withstand test (4.6.14).

TABLE 4

IMMERSION TEST FLUIDS

TEST FLUID

TEST TEMPERATURE

IMMERSION

TIME

(a) MIL-L-23699, Lubricating Oil, Aircraft Turbine

Engine,Synthetic Base

48 to 50°C (118 to 122°F) 20 hours

(b) MIL-H-5606, Hydraulic Fluid, Petroleum Base,

Aircraft, Missile and Ordnance

48 to 50°C (118 to 122°F) 20 hours

(d) MIL-T-5624, Turbine Fuel, Aviation, Grade JP-4

or JP-8

20 to 25°C (68 to 77°F) 168 hours

(e) SAE-AS-1241, Fire Resistant Phosphate Ester

Hydraulic Fluid for Aircraft

48 to 50°C (118 to 122°F) 20 hours

(f) MIL-L-7808, Lubricating Oil, Aircraft Turbine

Engine, Synthetic Base; or NATO 148

118 to 121°C (244 to 250°F)

30 minutes

4.6.9 Insulation Elongation and Tensile Strength

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.

4.6.10 Jacket Concentricity

The concentricity of the cable jacket shall be determined by first locating and recording the

minimum wall thickness measured on a cross-section of the jacket. The maximum wall thick-

ness of this same cross-section of the jacket shall also be measured and recorded. The ratio of

the minimum wall thickness to the maximum wall thickness shall define the concentricity. All

wall-thickness measurements shall be made under suitable magnification. The wall thickness

shall be the radial distance between the inner and outer rim of the jacket.

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82A0111-22-F868-9CS2920

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