Engineering Design Handbook: Electrical Wire and Cable - Defense

296 Pages·2014·10.77 MB·English

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AMCP-706-125
AMC PAMPHLET AMCP 706-125
>NES( INFORMATION E
/
5 0510
ENGINEERING DESIGN
HANDBOOK
Rt'DSTOi.'S •:■
ELECTRICAL
WIRE AND CABLE
HEADQUARTERS, U.S. ARMY MATERIEL COMMAND SEPTEMBER 1969
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
Paragraph Page
LIST OF ILLUSTRATIONS XI
LIST OF TABLES xiii
LIST OF EQUATIONS - QUICK REFERENCE. xvi
PREFACE xix
CHAPTER 1 CONDUCTORS
1-1 Material Elements 1-
1-1.1 Copper (ETP and OFHC) 1-
1-1.2 Copper (Hot Rolled) 1-
1-2 Wire Size (Solid) 1-
1-2.1 Gaging Systems 1-
1-2.2 Circular Ml Area (CMA) 1-
1-2.3 Copper Wire Dimensions 1-2
1-2.4 DC Resistance 1-2
1-3 Coatings 1-2
1-3.1 Methods of Coating 1-2
1-3.1.1 Tin 1-2
1-3.1.2 Silver 1-3
1-3.1.3 Nickel 1-4
1-3.2 Dual Coating 1-4
1-3.3 Claddings 1-5
1-4 Aluminum 1-5
1-4.1 Uses 1-5
1-4.2 Coatings 1-5
1-5 Alloys 1-5
1-5.1 General Properties 1-5
1-5.2 High Conductivity Types 1-5
1-5.3 High Conductivity-High Strength Types 1-6
1-6 Stranding 1-6
1-6.1 Bunched Stranding 1-8
1-6.2 Concentric Stranding 1-8
1-6.3 Rope Stranding 1-8
1-7 Soldering 1-8
1-7.1 Soldering Stranded Wire 1-9
1-7.2 Heavy Tinned Stranding 1-9
1-7.3 Silver-coated Stranding 1-9
1-7.4 Nickel-coated Stranding 1-10
1-7.5 Composite Stranding 1-10
1-8 Terminations 1-10
1-8.1 Crimp Termination 1-10
1-8.2 Wire Wrap Termination 1-10
1-9 Shielding 1-11
1-9.1 General 1-11
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1—9.2 Braid Terminology 1-11
1-9.3 Computation of Braid Angle and Coverage 1-12
1-9.4 Served Shields 1-13
1-9.5 Shielding Effectiveness 1-13
1-10 Flex-life Comparison—Copper vs Alloy 63 1-19
1-10.1 Test Method 1-19
1-10.2 Comparative Data 1-19
References 1-25
CHAPTER 2 INSULATION MATERIALS
2—1 Introduction 2-1
2-2 Thermoplastic Insulation Materials . . . 2-1
2-2.1 Polyvinylchloride 2-1
2-2.2 Polyolefins 2-2
2-2.2.1 Low-density Polyethylene 2-2
2—2.2.2 High-density Polyethylene 2-2
2-2.2.3 Polypropylene 2-3
2-2.3 Cross-linked Polyolefins 2-3
2-2.4 Nylon 2-6
2-3 Fluorocarbons 2-7
2-3.1 Polytetrafluoroethylene (TFE) 2-7
2-3.2 Copolymer of Tetrafluoroethylene and
Perfluoropropylene (FEP) 2-7
2-3.3 Polychlorotrifluoroethylene (CTFE) . 2-8
2-3.4 Polyvinylidenefluoride (VF-2) 2-8
2-4 Polyurethanes 2-8
2-4.1 Physical Properties 2-8
2-4.2 Thermal Properties 2-9
2-4.3 Uses 2-9
2-5 Rubber 2-9
2--5.1 Natural Rubber (Polyisoprene) 2-9
2-5.2 Styrene-butadiene Rubbers 2-9
2-5.3 Chloroprene Rubber 2-10
2-5.4 Butyl Rubber 2-10
2-5.5 Silicone Rubber 2-10
2-5.6 Chlorosulfonated Polyethylene 2-13
2-5.7 Ethylene Propylene Rubber 2-13
2—5.8 Fluorocarbon Rubber 2-13
2-6 Films 2-14
2-6.1 Cellulosics 2-14
2-6.2 Polyesters 2-14
2-6.3 Fluorocarbons 2-16
2—6.4 Polyimide 2-16
2-7 Fibers 2-17
2-7.1 Cotton 2-17
2-7.2 Rayon 2-17
2-7.3 Nylon 2-17
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2-7.4 Polyester 2-17
2-7.5 Glass 2-17
2-7.6 Ceramic 2-18
2-7.7 Asbestos 2-18
2-7.8 Fiber Combinations 2-18
2-7.9 Coated Fibers 2-18
2-8 Lacquers 2-18
2-8.1 Cellulose Acetate Butyrate 2-18
2-8.2 Nylon 2-18
2-8.3 Fluorocarbons 2-20
2-8.4 Silicones 2-20
2—8.5 Specialized Coatings 2—20
2—8.6 Bondable Coatings 2-20
2-8.7 Polyimide Coatings 2-20
2-9 Potting Compounds 2-21
2-9.1 Types of Potting Compounds 2-21
2-9.2 Potting .Design Criteria 2-21
2—9.2.1 Surface Preparation 2—21
2-9.2.2 Mechanical Factors 2-21
2-9.2.3 Chemical Factors 2-21
2—10 Inorganic Insulations 2—21
2—10.1 Magnesium Oxide Insulation 2—23
2-10.2 Magnesium Oxide Beads 2-23
2—11 Special Environments 2—23
2-11.1 Fungus Resistance 2—23
2—11.2 Radiation Resistance 2—23
References 2—27
CHAPTERS
DESIGN FACTORS _HOOK-UP AND INTERCONNECTING WIRE
3-1 Scope 3-1
3-2 Factors Influencing Design 3-1
3-2.1 Environmental Factors 3-1
3-2 1 1 High Temperature 3-1
3-2.1.2 Low Temperature 3-1
3-2.1.3 Flammability 3-1
3-2 1 4 Moisture and Fungus . 3-2
3-2 2 Chemical Factors 3-2
3-2 2 1 Liquid 3-2
3-2 2 2 Ultraviolet 3-2
3-2 2 3 3-2
3-2 2 4 3-2
3-2 2 5 Outgassing 3-2
3-2 3 3-2
3-2 3 1 Flex-life 3-2
3-232 3-3
3-2.3.3 3-3
III
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3-2.3.4 Tensile Strength 3—3
3-2.3.5 Elongation 3—3
3-2.4 Electrical Factors 3—3
3-2.4.1 Dielectric Constant 3—3
3-2.4.2 Dielectric Strength 3—3
3-2.4.3 Gradient (Electrical) 3—3
3-2.4.4 Insulation Resistance 3-4
3-2.4.5 Loss Factor 3—4
3-2.4.6 Current-carrying Capacity 3-4
3-2.4.7 Voltage Drop 3-4
3-2.5 Identification 3—5
3-3 Design Considerations 3—5
3-3.1 Conductor Choices 3—5
3-3.1.1 Mechanical Factors 3—5
3-3.1.2 Thermal Factors 3-5
3-3.2 Insulation Choices 3—6
3-3.2.1 Mechanical Considerations 3-6
3-3.2.2 Electrical Considerations 3—6
3-4 Testing To Prove Design 3-6
3-4.1 Electrical Tests 3-7
3-4.2 Physical Tests 3—7
3^.3 Aging Tests 3—7
3-4.4 Thermal Tests 3—7
3-4.5 Mechanical Tests 3—7
3-4.6 Chemical Tests 3-7
3-5 Hook-up vs Interconnecting Wire 3-7
3-5.1 Hook-up Wire 3—7
3-5.2 Interconnecting Wire and Cable 3-8
3-6 Comparison of Hook-up Wire Types 3—8
3-6.1 MIL-W-76 3-8
3-6.2 MIL-W-16878D 3-11/3-12
3-6.3 MIL-W-81044 3-11/3-12
3-6.4 MIL-W-27300 3-11/3-12
3-6.5 MIL-W-22759 3-11/3-12
3-7 Comparison of Interconnecting Wire Types 3—11/3-12
3-7.1 MIL-W-5086 3-11/3-12
3-7.2 MIL-W-81044 3-11/3-12
3-7.3 MIL-W-7139 3-1 1/3-12
3-7.4 MIL-W-8777 3-11/3-12
References 3 — 15/3 — 16
CHAPTER 4 BUNDLED WIRES
4-1 Laced Bundles 4—1
4-1.1 Lacing 4—1
4-1.2 Usage — Laced Bundles 4—1
4-2 Prefabricated Bundles 4—1
4-2.1 Construction 4—1
4-2.2 Components 4—2
IV
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4-2.3 Color Code 4-2
4-2.4 Shield 4-2
4-2.5 Jacket 4-2
4-3 Derating Factors for Bundled Wires 4-2
4-3.1 Introduction 4-2
4-3.2 Basic Considerations 4-2
4-4 Derating Calculations 4-6
4-4.1 Symbols and Their Definitions 4-6
4-4.2 Rating Procedure 4-6
4-4.3 Usage Xurrent Rating Procedure 4-7
4-5 Ribbon Cable 4-21
4-5.1 Introduction 4-21
4-5.2 Usage 4-21
4-5.3 Construction 4-21
4-5.3.1 Adhesive Bonding 4-21
4-5.3.2 Thermal Fusing 4-21
4-5.3.3 Direct Extrusion 4-21
4-5.3.4 Envelope 4-21
4-S.3.5 Braided or Woven 4-21
4-6 Comparison _Ribbon Cable vs Round Multiconductor Cable. 4-21
4-6.1 Advantages _Ribbon Cable 4-21
4-6.2 Disadvantages -Ribbon Cable 4-22
4-7 Tape Cable 4-22
4-7.1 Introduction 4-22
4-7.2 Usage 4-22
4-7.3 Flat Wire 4-22
4-7.3.1 Constructional Factors 4-23
4-7.3.2 Construction 4-23
4-7.3.3 Disadvantages -Flat Wire 4-23
4-7.4 Constructional Considerations 4-23
4-7.5 Testing 4-23
4-7.5.1 Folding Test 4-24
4-7.5.2 Roll Flexure Test 4-24
4-7.5.3 Straight Flexure Test 4-24
4-7.6 Installation 4-26
References 4—27
CHAPTER 5 COAXIAL CABLE
5-1 Introduction 5_i
5-2 Types of Coaxial Cable 5—1
5-2.1 Definitions 5_i
5-2.1.1 Coaxial 5-1
5-2.1.2 Twin Coaxial 5_i
5-2.1.3 Dual Coaxial 5_i
5-2.1.4 Double Shielded 5_i
5-2.1.5 Triaxial 5_1
5-3 Materials 5_i
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5-4 Electrical Properties of Coaxial Cable 5—1
5-4.1 Basic Parameters 5—1
5—4.1.1 Capacitance 5—2
5-4.1.2 Phase Angle 5-5
5_4.1.3 Power Factor 5-5
5—4.1.4 Dielectric Constant 5—5
5-4.1.5 Velocity of Propagation 5-5
5—4.1.6 Characteristic Impedance 5—5
5-4.1.7 Propagation Constant 5-8
5-4.1.8 Attenuation and Phase Shift 5-8
5—4.1.9 Corona and Voltage Rating 5—14
5_5 Air-spaced Cables 5 -20
5—5.1 General Constructional Details 5—20
5-5.2 Uses 5-20
5-6 Voltage Standing Wave Ratio (VSWR) 5-20
5-6.1 Reflection .Coaxial Cable System 5—20
5-6.2 Reflection Causes -Coaxial Cable Systems 5-22
5-7 Power Rating 5-22
5-7.1 Power Handling Capacity 5-22
5-7.2 Power Rating Due to VSWR 5-23
5-8 Shields 5-23
5-8.1 Picks 5-23
5-8.2 Carriers 5-23
5-8.3 Ends 5-23
5_9 Shielding Effectiveness 5-25
5-9.1 Surface Transfer Impedance 5—25
5-9.2 Reference 5-26
5—10 Transmission Unbalance 5—26
5-10.1 General 5-26
5—10.2 References for Test and Measurement 5—27
5-11 Coverings and Sheaths 5-27
5-11.1 Uses 5-27
5—11.2 Fibrous or Textile 5—27
5-12 Special Purpose Coaxial Cables 5-28
5-12.1 Pulse Cables 5-28
5—12.2 Delay Lines 5—28
5—12.3 Low Noise Cable 5—29
5-13 Practical Constructional Considerations 5-29
5-13.1 Size 5-29
5—13.2 Concentricity and Eccentricity 5—30
5-13.3 Abrasion 5-30
5—13.4 Contamination 5—30
5—14 Environmental Conditions 5—30
5—14.1 General Considerations 5—30
5—14.2 Insulation Guide 5—30
5-15 Discussion of Application JVIajor Usage 5-30
References 5-31/5-32
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CHAPTER 6 CONTROL AND SIGNAL CABLES
6-1 Introduction 6-1
6-2 Applications of Control and Signal Cables 6-1
6-3 Constructional Design Factors 6-1
6-3.1 Physical Considerations 6-1
6-3.2 Electrical Considerations 6-2
6-4 Cable Types 6-2
6-4.1 Portable 6-2
6-4.2 Nonportable 6-2
6-5 Multiconductor Cable Design 6-2
6-5.1 General Considerations 6-2
6-5.2 Specific Construction Considerations 6-3
6-6 Multiconductor Construction 6-3
6-6.1 Conductors and Components 6-3
6-6.2 Component Strandings 6-6
6-6.3 Basic Insulated Wire 6-6
6-6.4 Component Shielding 6-6
6-6.5 Component Shield Covering and Component Jacket Dimensions 6-7
6-6.6 Cabling 6-7
6-6.6.1 Lay 6-8
6-6.6.2 Pitch Diameter 6-9
6-6.6.3 Lay Construction 6-9
6-6.7 Cable Fillers 6-9
6-6.8 Color Coding Control and Signal Cables 6-10
6-6.8.1 Color Coding Methods 6-10
6-6.8.2 Color Code Application 6-10
6-6.8.3 Color Code and Related Numbers 6-11
6-6.8.4 Specifications 6-11
6-6.9 Cable Binders 6-12
6-6.10 Cable Sheaths 6-13
6-6.11 Sheath Application 6-13
6-6.12 Armor 6-13
6-6.13 Cable Identification Marking 6-15
6-7 Multiconductor Cable Testing 6-16
6-7.1 Cable Cross-talk 6-16
6-7.2 Tests and Test Methods 6-16
6-7.3 Multiconductor Cable Tests 6-16
6-7.3.1 Cold Bend Test 6-17
6-7.3.2 Impact Test 6-17
6-7.3.3 Torque Test 6-17
6-7.3.4 Twist Test 6-17
6-7.3.5 Bend Test 6-18
6-7.3.6 Dielectric and Pulse Dielectric Tests 6-19
6—7.3.7 Insulation Resistance Test 6-22
6-7.3.8 Measuring Capacitance in a Multiconductor Cable 6-23
6-7.3.9 Abrasion Resistance 6-25
6-7.3.10 Tensile Strength of Multiconductor Cable 6-27
References 6-29
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CHAPTER 7 POWER CABLES
7_1 Introduction 7-1
7-1.1 Usage 7-1
7_1 2 General Design Factors 7-1
7_2 Major Constructional Design Factors 7-1
7-2.1 Conductor 7-1
7_2.1.1 Conductor Material 7-1
7-2.1.2 Conductor Size 7-1
7-2.1.3 Conductor Form 7-2
7-2.2 Insulation 7-2
7-2.3 Sheath 7-2
7_3 Miscellaneous Constructional Design Factors 7-2
7--3.1 Shields 7-2
7-3.2 Cabling 7-2
7_3 3 Ground Wires 7-2
7_4 Voltage Drop 7-3
References 7-25
CHAPTER 8 SPECIAL PURPOSE CABLES
8-1 Introduction 8-1
8-1.1 General Types 8-1
8-1.2 Design Factors 8-1
8-2 Hybrid Cable Design Factors
8-3 Construction Check List
8-3.1 Basic Insulated Wires 8-1
8-3.2 Component Lay-up 8-2
8—3.3 Core Binder 8-2
8_3.4 Outer Covering 8-2
8-3.5 Cable Identification 8-2
8-3.6 Protective Braid 8-2
8-4 Sample Hybrid Cable Configuration 8-2
8-4.1 Sample Cable Requirements 8-2
8-4.2 Sample Cable Constructional Factors 8-3
8-4.3 Sample Cable Lay-up 8-4
8_4.3.1 Component Construction 8-4
8—4.3.2 Component Color Coding 8-5
8-4.3.3 Component Precabling Tests 8-7
8-4.3.4 Cable Core Lay-up 8-7
8_4.3.5 Core Binder 8-7
8-4.3,6 Core Diameter Calculation 8-8
8^.3.7 Core Shielding 8-8
8-4.3.8 Cable Separator 8-8
8-4.3.9 Cable Sheath 8-9
8-4.3.10 Cable Identification 3-10
8-5 Choice of Cable for Equipment Design 3-10
8-5.1 Light-or Medium-duty Cables 3-11
8-5.2 Heavy-duty Cables 3-11