MIL-STD-2003_5B - Electric Plant Installation Standard Methods for Surface Ships and Submarines.pdf

AMSC N/A AREA SESS

DISTRIBUTION STATEMENT A. Approved for public release. Distribution is unlimited.

INCH-POUND

MIL-STD-2003-5B(SH)

6 October 2020

SUPERSEDING

MIL-STD-2003-5A(SH)

3 September 2009

DEPARTMENT OF DEFENSE

STANDARD PRACTICE

ELECTRIC PLANT INSTALLATION

STANDARD METHODS FOR

SURFACE SHIPS AND SUBMARINES

(CONNECTORS)

Downloaded from http://www.everyspec.com

MIL-STD-2003-5B(SH)

ii

FOREWORD

1. This standard is approved for use by the Naval Sea Systems Command, Department of the Navy, and is available for use by all Departments and Agencies of the Department of Defense.

2. This standard disseminates up-to-date information detailing requirements for standard installation methods for connectors employed for submarine and surface ship electrical distribution systems.

3. These criteria are for application to new construction, conversion, and alteration of existing ships.

4. Comments, suggestions, or questions on this document should be addressed to Commander, Naval Sea

Systems Command, ATTN: SEA 05S, 1333 Isaac Hull Avenue, SE, Stop 5160, Washington Navy Yard DC

20376-5160 or emailed to CommandStandards@navy mil, with the subject line “Document Comment”. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla mil.

iii

CONTENTS

PARAGRAPH PAGE

1. SCOPE

1.1 Scope

1.1.1 Application

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

2.2.2 Other Government documents, drawings, and publications

2.3 Non-Government publications

2.4 Order of precedence

3. DEFINITIONS

4. GENERAL REQUIREMENTS

4.1 Instructions for use of MIL-STD-2003-5

4.2 Or equal

4.3 Consideration of electromagnetic shielding

4.4 Use of connectors not covered in MIL-STD-2003-5

4.5 Connector post-installation retests

4.6 Inactive for new design documents

4.7 Workmanship and inspection guidance

4.8 Hazardous materials

4.9 The terms agreement or approval

5. DETAILED REQUIREMENTS

6. NOTES

6.1 Intended use

6.2 Acquisition requirements

6.3 Designation of electric plant installation standard methods figures

6.4 Subject term (key word) listing

6.5 Changes from previous issue

APPENDIX 5A – CABLE LEAD PREPARATION

A.1 SCOPE

A.1.1 Scope

A.2 APPLICABLE DOCUMENTS

A.2.1 General A.2.2 Government documents

A.2.2.1 Specifications, standards, and handbooks A.2.2.2 Other Government documents, drawings, and publications

A.2.3 Non-Government publications A.2.4 Order of precedence

A.3 REQUIRED EQUIPMENT AND MATERIALS

A.3.1 Required equipment and materials

A.4 NOTES AND PROCEDURES

A.4.1 Dimensions A.4.2 Figures

APPENDIX 5B – MIL-C-81511/SAE-AS81511 SERIES 1 AND 2 GANG CONTACT RELEASE

CONNECTOR ASSEMBLY PROCEDURE

B.1 SCOPE

B.1.1 Scope

B.2 APPLICABLE DOCUMENTS

B.2.1 General iv

B.2.2 Government documents B.2.2.1 Other Government documents, drawings, and publications

B.2.3 Non-Government publications B.2.4 Order of precedence

B.3 REQUIRED EQUIPMENT AND MATERIALS

B.3.1 Required equipment and materials

B.4 NOTES AND PROCEDURES

B.4.1 Dimensions B.4.2 Figures

APPENDIX 5C – MIL-DTL-5015/SAE-AS50151 CONNECTORS

C.1 SCOPE

C.1.1 Scope

C.2 APPLICABLE DOCUMENTS

C.2.1 General C.2.2 Government documents

C.2.2.1 Specifications, standards, and handbooks C.2.2.2 Other Government documents, drawings, and publications

C.2.3 Non-Government publications C.2.4 Order of precedence

C.3 REQUIRED EQUIPMENT AND MATERIALS

C.3.1 Required equipment and materials

C.4 NOTES AND PROCEDURES

C.4.1 Dimensions C.4.2 Figures

APPENDIX 5D – MIL-DTL-26482 CONNECTORS

D.1 SCOPE

D.1.1 Scope

D.2 APPLICABLE DOCUMENTS

D.2.1 General D.2.2 Government documents

D.2.2.1 Specifications, standards, and handbooks D.2.2.2 Other Government documents, drawings, and publications

D.2.3 Non-Government publications D.2.4 Order of precedence

D.3 REQUIRED EQUIPMENT AND MATERIALS

D.3.1 Required equipment and materials

D.4 NOTES AND PROCEDURES

D.4.1 Dimensions D.4.2 Figures

APPENDIX 5E – MIL-DTL-28840 CONNECTORS

E.1 SCOPE

E.1.1 Scope

E.2 APPLICABLE DOCUMENTS

E.2.1 General E.2.2 Government documents

E.2.2.1 Specifications, standards, and handbooks E.2.2.2 Other Government documents, drawings, and publications

E.2.3 Non-Government publications E.2.4 Order of precedence

E.3 REQUIRED EQUIPMENT AND MATERIALS

E.3.1 Required equipment and materials v

E.4 NOTES AND PROCEDURES

E.4.1 Dimensions E.4.2 Figures

APPENDIX 5F – MIL-DTL-27599 CONNECTORS

F.1 SCOPE

F.1.1 Scope

F.2 APPLICABLE DOCUMENTS

F.2.1 General F.2.2 Government documents

F.2.2.1 Specifications, standards, and handbooks F.2.2.2 Other Government documents, drawings, and publications

F.2.3 Non-Government publications F.2.4 Order of precedence

F.3 REQUIRED EQUIPMENT AND MATERIALS

F.3.1 Required equipment and materials

F.4 NOTES AND PROCEDURES

F.4.1 Dimensions F.4.2 Figures

APPENDIX 5G – MIL-DTL-22992 CONNECTORS

G.1 SCOPE

G.1.1 Scope

G.2 APPLICABLE DOCUMENTS

G.2.1 General G.2.2 Government documents

G.2.2.1 Specifications, standards, and handbooks G.2.2.2 Other Government documents, drawings, and publications

G.2.3 Non-Government publications G.2.4 Order of precedence

G.3 REQUIRED EQUIPMENT AND MATERIALS

G.3.1 Required equipment and materials

G.4 NOTES AND PROCEDURES

G.4.1 Dimensions G.4.2 Figures

APPENDIX 5H – MIL-DTL-38999 CONNECTORS

H.1 SCOPE

H.1.1 Scope

H.2 APPLICABLE DOCUMENTS

H.2.1 General H.2.2 Government documents

H.2.2.1 Specifications, standards, and handbooks H.2.2.2 Other Government documents, drawings, and publications

H.2.3 Non-Government publications H.2.4 Order of precedence

H.3 REQUIRED EQUIPMENT AND MATERIALS

H.3.1 Required equipment and materials

H.4 NOTES AND PROCEDURES

H.4.1 Dimensions H.4.2 Figures vi

LIST OF TABLES

TABLE PAGE

APPENDIX 5A – CABLE LEAD PREPARATION

TABLE 5AI. Figures for cable lead preparation TABLE 5A1-I. Approved solvents TABLE 5A2-I. Heat shrink tubing TABLE 5A2-II. Telescoping bushings TABLE 5A3-I. Rejection criteria for solder contacts TABLE 5A3-II. Cable lead stripping details TABLE 5A3-III. Ideal wire stripper part numbers TABLE 5A4-I. Wire barrel size TABLE 5A5-I. Soldering iron size TABLE 5A6-I. Cleaning solvents TABLE 5A6-II. Soldering iron size TABLE 5A7-I. Solder ferrule sizes TABLE 5A7-II. Shielded wire terminations: inner ferrule sizes TABLE 5A7-III. Shielded wire terminations: insulated outer ferrule sizes TABLE 5A10-I. Heat shrink tubing (SAE-AS23053) TABLE 5A10-II. Approved solvents TABLE 5A11-I. Solvents

APPENDIX 5B – MIL-C-81511/SAE-AS81511 SERIES 1 AND 2 GANG CONTACT RELEASE

CONNECTOR ASSEMBLY PROCEDURE

TABLE 5BI. Figures for MIL-C-81511 or SAE-AS81511 connector assembly preparation TABLE 5B1-I. Wire barrel depths and minimum separation force TABLE 5B1-II. Crimp tooling information TABLE 5B1-III. Installation and removal tools TABLE 5B2-I. Wire barrel depths TABLE 5B2-II. Crimp tooling information TABLE 5B2-III. Installing and removal tools

APPENDIX 5C – MIL-DTL-5015/SAE-AS50151 CONNECTORS

TABLE 5CI. Figures for MIL-DTL-5015/SAE-AS50151 connector assembly preparation TABLE 5C1-I. Wire barrel contact depth TABLE 5C2-I. Wire barrel contact depth TABLE 5C2-II. Front release TABLE 5C2-III. Rear release TABLE 5C2-IV. Tools for modified MIL-DTL-5015/SAE-AS50151 connectors TABLE 5C2-V. Bendix part numbers

APPENDIX 5D – MIL-DTL-26482 CONNECTORS

TABLE 5DI. Figures for MIL-DTL-26482 connector assembly preparation TABLE 5D1-I. Wire barrel depth TABLE 5D1-II. Crimping tools for series 1 connectors TABLE 5D1-III. Crimping tools for series 2 connectors TABLE 5D1-IV. Insertion and removal tools TABLE 5D1-V. Insertion and removal tools

APPENDIX 5E – MIL-DTL-28840 CONNECTORS

TABLE 5EI. Figures for MIL-DTL-28840 connector assembly preparation

APPENDIX 5F – MIL-DTL-27599 CONNECTORS

TABLE 5FI. Figures for MIL-DTL-27599 connector assembly procedures TABLE 5F1-I. Contact wire barrel depths

APPENDIX 5G – MIL-DTL-22992 CONNECTORS

TABLE 5GI. Figures for MIL-DTL-22992 connector assembly procedures TABLE 5G1-I. Contact wire barrel depths

APPENDIX 5H – MIL-DTL-38999 CONNECTORS

vii

TABLE 5HI. Figures for MIL-DTL-38999 connector assembly procedures TABLE 5H1-I. Contact wire barrel depths TABLE 5H1-II. Crimp tool guide TABLE 5H1-III. Installation and removal tools viii

LIST OF FIGURES

FIGURE PAGE

APPENDIX 5A – CABLE LEAD PREPARATION

FIGURE 5A1. Cable preparation procedures FIGURE 5A2. Cable diameter change procedures FIGURE 5A3. Individual lead stripping techniques FIGURE 5A4. Connector contact crimping techniques FIGURE 5A5. Tinning techniques FIGURE 5A6. Conductor contact soldering techniques FIGURE 5A7. Conductor shield termination procedures FIGURE 5A8. Gross shield termination procedures FIGURE 5A9. Connector lockwiring FIGURE 5A10. Cable transflexing procedure FIGURE 5A11. Cable bifurcation procedure FIGURE 5A12. Glossary of terms FIGURE 5A13. Tooling and materials list FIGURE 5A14. Connector part number nomenclature FIGURE 5A15. Water-proofing coaxial connectors

APPENDIX 5B – MIL-C-81511/SAE-AS81511 SERIES 1 AND 2 GANG CONTACT RELEASE CONNECTOR

ASSEMBLY PROCEDURE

FIGURE 5B1. MIL-C-81511 or SAE-AS81511 series 1 and 2 gang contact release connector assembly procedure FIGURE 5B2. MIL-C-81511 or SAE-AS81511 series 3 and 4 individual contact release connector assembly procedure

APPENDIX 5C – MIL-DTL-5015/SAE-AS50151 CONNECTORS

FIGURE 5C1. MIL-DTL-5015/SAE-AS50151 solder connector assembly procedure FIGURE 5C2. MIL-DTL-5015/SAE-AS50151 (crimp) connector assembly procedure FIGURE 5C3. Multi-cable connector assembly using grommets

APPENDIX 5D – MIL-DTL-26482 CONNECTORS

FIGURE 5D1. MIL-DTL-26482 connector assembly procedure

APPENDIX 5E – MIL-DTL-28840 CONNECTORS

FIGURE 5E1. MIL-DTL-28840 connector assembly procedure

APPENDIX 5F – MIL-DTL-27599 CONNECTORS

FIGURE 5F1. MIL-DTL-27599 connector assembly procedure

APPENDIX 5G – MIL-DTL-22992 CONNECTORS

FIGURE 5G1. MIL-DTL-22992 connector assembly procedure

APPENDIX 5H – MIL-DTL-38999 CONNECTORS

FIGURE 5H1. MIL-DTL-38999 connector assembly procedure

1. SCOPE

1.1 Scope. This standard covers standard methods for connector fabrication on surface ships and submarines.

1.1.1 Application The installation methods in this document are intended to be used by all installing activities as required by contract, ship specifications, or similar implementing documents. These methods do not normally identify ship or type but do establish standards for connector installations in naval ships. The methods in this document are for new construction as well as for conversions, alterations, and repairs. It is the responsibility of the user activity to determine which method satisfies their requirements.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this standard, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-1310 - Shipboard Bonding, Grounding, and Other Techniques for Electromagnetic

Compatibility, Electromagnetic Pulse (EMP) Mitigation, and Safety

(Copies of this document are available online at https://quicksearch.dla.mil.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

NAVAL SEA SYSTEMS COMMAND (NAVSEA) PUBLICATIONS

S9300-A6-GYD-010 - Electrical Workmanship Inspection Guide for Surface Ships and

Submarines

S9407-AB-HBK-010 - Handbook of Shipboard Electromagnetic Shielding Practices

T9070-AL-DPC-020/077-2 - NAVSEA Hazardous Material Avoidance Process

(Copies of these documents are available online via Technical Data Management Information System (TDMIS) at https://mercury.tdmis navy mil/. Refer questions, inquiries, or problems to: DSN 296-0669, Commercial (805) 228-

0669. This document is available for ordering (hard copy) via the Naval Logistics Library https://nll.navsup.navy.mil. For questions regarding the NLL, contact the NLL Customer Service at nllhelpdesk@navy mil, (866) 817-3130, or (215) 697-2626/DSN 442-2626.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

SAE INTERNATIONAL

SAE-AIR6151 - Torque, Threaded Application, Electrical Connector, Accessory and Terminal

Board Installation

(Copies of this document are available online at www.sae.org.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. DEFINITIONS

Refer to figure 5A12.

4. GENERAL REQUIREMENTS

4.1 Instructions for use of MIL-STD-2003-5. This standard is designed to be utilized by a connector assembly technician and is formatted to be utilized as follows:

a. Determine the governing specification for the connector being assembled.

b. Proceed to the applicable Connector Assembly Procedure (figures in appendices 5B through 5H) and review to determine tools and materials required. Each appendix is designed to assemble a connector starting with the basic components and proceeding in a step-by-step manner to the completed assembly.

c. Instructions shown on the figures in appendix 5A identify a sequence of processes common to any connector assembly (for example, lead stripping, crimping, soldering). The conduct of these procedures shall be sequenced by the Connector Assembly Procedures. The technician should review these procedures to become familiar with their content.

d. Terminate the connector/backshell to the cable utilizing the appropriate Connector Assembly Procedure.

e. The technician should keep in mind that to install a cable with connectors onboard a ship, in most instances, at least one end will need to be routed through a kickpipe, standpipe, stuffing tube, etc. and, thus, cannot have a connector installed prior to routing onboard the ship.

These procedures are designed for use with military specification connectors and backshells. Commercial substitutions may result in deviations from these procedures. Manufacturer assembly instructions should be consulted in these cases. Equal tooling and materials (see 4.2) may be substituted provided the intent of the specification is achieved.

4.2 Or equal. MIL-STD-2003 uses the terms “or equal” to permit the use of parts, components, or tools that are equivalent and can perform the same function as the specified products. The use of the equivalent product is allowed as long as the same functional characteristics, performance, equipment safety, personnel safety, suitability for marine service, life cycle cost, maintenance cost, and supportability are attained, and agreement is obtained from

NAVSEA. The request for agreement for the use of “equal” products shall include data that supports that functional and performance equivalence is retained.

4.3 Consideration of electromagnetic shielding. For connector installations where electromagnetic shielding is required, or connectors need to be attached to cable conduit, the practices of S9407-AB-HBK-010 should be used.

Connectors for EMI applications shall be installed to meet the requirements of MIL-STD-1310.

4.4 Use of connectors not covered in MIL-STD-2003-5. MIL-STD-2003-5 does not cover every type of connector installed in ship systems. For other connector types, such as RF, DB, Audio/Video, USB, and RJ connectors, class or specific ship installation drawings, provided by the ship design activity, or connector manufacturer’s instructions should be followed for connector installation. The general requirements of this document should be followed. The specific requirements in Appendix 5A should be followed to the maximum extent practicable. For installation of fiberoptic connectors, see MIL-STD-2042.

4.5 Connector post-installation retests. Pin pull tests, contact push tests, and torque-controlled screwdrivers and wrenches, which were required in the past, are no longer required. However, SAE-AIR6151 or connector manufacturer instructions may be consulted for guidance to determine the proper torque and tightness for assembling and installing electrical connectors.

4.6 Inactive for new design documents. Some of the documents referenced in MIL-STD-2003-5 have been declared as inactive for new design by decision of the Department of Defense. Where replacement documents are designated, the replacement document is normally substituted for the inactive for new design document. Methods that reference inactive for new design documents shall not be used for new ship design unless approved by

NAVSEA. Components and products produced in accordance with the inactive for new design documents shall not be used for new design of systems or equipment; however, this does not prohibit use for maintenance, repair, or resupply purposes. In addition, use of components is not prohibited in cases where connectors must interface with connectors being supplied with Government Furnished Equipment.

4.7 Workmanship and inspection guidance. For workmanship and inspection guidance associated with connector installation, see S9300-A6-GYD-010. For any conflict between this standard and S9300-A6-GYD-010, the requirements of this standard take precedence.

4.8 Hazardous materials. Materials and products utilized to execute installation methods in this standard should avoid chemicals listed on the NAVSEA List of Targeted Chemicals (N-LTC) contained within

T9070-AL-DPC-020/077-2. These chemicals pose significant risk to the user, environment, or both, and are deemed both undesirable and unsustainable by NAVSEA. NAVSEA is minimizing the use of hazardous materials in procedures such as those covered by this standard. Alternative materials should be considered for applications covered in this document to minimize the use of targeted chemicals. NAVSEA should be informed of the need for the use of any of the targeted chemicals prior to procedure execution.

4.9 The terms agreement or approval. Wherever such terms as “approved” or “agreement” are used without further qualification, it is the approval or agreement of the Supervising Authority or NAVSEA, as applicable, that is intended. In these cases, the approval request and the response shall be formal, in writing, and traceable. Existing methods allowed by applicable ship specifications, such as departures from specifications, are acceptable. The

Supervising Authority, also referred to as the Supervisor, is defined in the applicable ship specifications.

5. DETAILED REQUIREMENTS

(See figures.)

6. NOTES

(This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.)

6.1 Intended use. This standard specifies the requirements for standard methods to be employed both on surface ships and submarines. Standard methods identified for electric plant installation are intended for new construction, conversion, and alteration of existing ships. The use of this standard will be specified in the contract, ship specifications, and similar implementing documents (such as COMUSFLTFORCOMINST 4790.3, Joint Fleet

Maintenance Manual (JFMM) and S9086-KC-STM-010/300, Naval Ships’ Technical Manual Chapter 300, Electric

Plant-General).

6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Title, number, and date of this standard.

6.3 Designation of electric plant installation standard methods figures. MIL-STD-2003-5 contains drawings that depict standard methods that are applicable for general electric plant installation on both surface ships and submarines. Each drawing has been assigned a figure number. The methods shown on the figures are grouped together in the following appendices to this standard. Each appendix provides requirements for similar functions.

MIL-STD-2003-5 (Connectors) A. Cable Lead Preparation (Appendix 5A)

B. MIL-C-81511/SAE-AS81511 Series 1 and 2 Gang Contact Release

Connector Assembly Procedure (Appendix 5B)

C. MIL-DTL-5015/SAE-AS50151 Connectors (Appendix 5C)

D. MIL-DTL-26482 Connectors (Appendix 5D)

E. MIL-DTL-28840 Connectors (Appendix 5E)

F. MIL-DTL-27599 Connectors (Appendix 5F)

G. MIL-DTL-22992 Connectors (Appendix 5G)

H. MIL-DTL-38999 Connectors (Appendix 5H)

The methods shown on the figures are identified by the following alphanumeric designation system:

METHOD 5A-14-2: 5 A- 14- 2

Method (always the last number)

Sequential figure number

Appendix number

MIL-STD-2003, part 5

Thus, method 5A-14-2 identifies method 2, sequential number 14 in Appendix 5A of MIL-STD-2003-5.

6.4 Subject term (key word) listing.

Adapter

Backshell

Bifurcation

Cable lead preparation

Clamp

Connector assembly

Crimp

Electromagnetic shielding

Grommet

Heat shrink

Installation retest

Lead strip

Lockwire

Pin

Plug

Shield termination

Socket

Solder

Strain relief

Strip

Tinning

Waterproof transflexing

Wire barrel

6.5 Changes from previous issue. Marginal notations are not used in this revision to identify changes with respect to the previous issue due to the extent of the changes.

APPENDIX 5A

APPENDIX 5A – CABLE LEAD PREPARATION

A.1 SCOPE

A.1.1 Scope. This appendix describes procedures for the preparation of leads for electrical connectors used aboard naval ships and submarines. This appendix is a mandatory part of the standard. The information contained herein is intended for compliance.

A.2 APPLICABLE DOCUMENTS

A.2.1 General. The documents listed in this section are specified in this appendix. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in this appendix, whether or not they are listed.

A.2.2 Government documents.

A.2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL SPECIFICATIONS

MMM-A-189 - Adhesive, Synthetic-Rubber, Thermoplastic, General-Purpose

TT-I-735 - Isopropyl Alcohol

COMMERCIAL ITEM DESCRIPTIONS

A-A-52506 - Clamps, Hose

A-A-59770 - Insulation Tape, Electrical, Pressure Sensitive Adhesive and Pressure Sensitive

Thermosetting Adhesive

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-915 - Cable, Electrical, for Shipboard Use, General Specification for

MIL-DTL-22992 - Connectors, Plugs and Receptacles, Electrical, Waterproof, Quick Disconnect, Heavy Duty Type, General Specification for

MIL-DTL-24640 - Cables, Lightweight, Low Smoke, Electric, for Shipboard Use, General

Specification for

MIL-DTL-24643 - Cables, Electric, Low Smoke Halogen-Free, for Shipboard Use, General

Specification for

MIL-DTL-26482 - Connectors, Electrical, Circular, Miniature, Quick Disconnect, Environment

Resisting, Receptacles and Plugs, General Specification for

MIL-DTL-27599 - Connectors, Electrical, Circular, Miniature, High Density, Quick Disconnect, Environment Resistant, Solder Contacts, General Specification for (see 4.6)

MIL-DTL-28840 - Connectors, Electrical, Circular, Threaded, High Shock, High Density, Shipboard, Class D, General Specification for

MIL-DTL-38999 - Connectors, Electrical, Circular, Miniature, High Density, Quick Disconnect

(Bayonet, Threaded or Breech Coupling), Environment Resistant with Crimp

Removable Contacts or Hermetically Sealed with Fixed, Solderable Contacts, General Specification for

MIL-A-46146 - Adhesives-Sealants, Silicone, RTV, Noncorrosive (for Use with Sensitive

Metals and Equipment)

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-1651 - Insert Arrangements for SAE-AS50151, MIL-DTL-22992 (Classes C, J and R), MIL-DTL-83723 (Series II), and SAE-AS95234 Circular Electrical Connectors

MIL-STD-1669 - Insert Arrangements for MIL-DTL-26482 Environment Resisting, Circular

Electrical Connectors

MIL-STD-1698 - Insert Arrangements for MIL-DTL-28840 High Density High Shock Circular

Electrical Connectors

(Copies of these documents are available online at https://quicksearch.dla.mil.)

A.2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

MILITARY SPECIFICATION SHEETS

MS3116 - Connectors, Plug, Electrical, Solder Type, Straight, Bayonet Coupling, Series 1, Classes E, F, J and P (see 4.6)

MS17344 - Connector, Plug, Electrical, Straight

MS20028 - Connectors, Plug, Electrical, Straight, Solder Type, Bayonet Coupling, Class T, Series I (see 4.6)

MS27467 - Connectors, Plug, Electrical, Straight, Crimp Type, Bayonet Coupling, Series I

(Copies of these documents are available online at https://quicksearch.dla.mil.)

A.2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL

ASTM B286 - Standard Specification for Copper Conductors for Use in Hookup Wire for

Electronic Equipment

ASTM D1193 - Standard Specification for Reagent Water

ASTM D4376 - Standard Specification for Vapor-Degreasing Grade Perchloroethylene

(Copies of these documents are available online at www.astm.org.)

IPC

J-STD-004 - Requirements for Soldering Fluxes

J-STD-005 - Requirements for Soldering Pastes

J-STD-006 - Requirements for Electronic Grade Solder Alloys and Fluxed and Non-Fluxed Solid

Solders for Electronic Soldering Applications

(Copies of these documents are available online at www.ipc.org.)

NATIONAL AEROSPACE STANDARDS COMMITTEE (NA/NAS)

NASM20995 - Wire, Safety or Lock

(Copies of this document are available online at www.aia-aerospace.org.)

SAE INTERNATIONAL

SAE-AS5942 - Marking of Electrical Insulating Materials

SAE-AS18121 - Ferrules, Outer, Insulated, Shield Terminating, Type II Two-Piece, Class I, for Shielded Cable

SAE-AS21608 - Ferrule, Shield Terminating, Crimp Style

SAE-AS21981 - Ferrule, Inner, Uninsulated, Shield Terminating, Type I, Two Piece, Class I, for Shielded Cables

SAE-AS22520 - Crimping Tools, Wire Termination, General Specification for

SAE-AS22520/5 - Crimping Tools, Type 2, Terminal, Hand, Wire Termination, for Coaxial, Twinaxial, Triaxial, Shielded Contacts and Ferrules, Terminal Lugs, Splices and End Caps

SAE-AS22520/6 - Crimping Tools, Terminal, Hand, Wire Termination; In-Service Inspection

Gages for Type II AS22520/5, /10, and MIL-T-22520/32 (Cancel) Crimp

Tools

SAE-AS22520/10 - Crimping Tools, Type 2, Terminal, Hand, Wire Termination, for Coaxial, Twinaxial, Triaxial, Shielded Contacts and Ferrules, Terminal Lugs, Splices, and End Caps

SAE-AS23053 - Insulation Sleeving, Electrical, Heat Shrinkable, General Specification for

SAE-AS23053/5 - Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Flexible, Crosslinked

SAE-AS23053/15 - Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Heavy-Wall, Coated, Flexible, Outer Wall Crosslinked

SAE-AS81765/1 - Insulating Components, Molded, Electrical, Heat Shrinkable Polyolefin, Crosslinked, Semi-Rigid and Flexible

SAE-AS83519 - Shield Termination, Solder Style, Insulated, Heat-Shrinkable, Environment

Resistant General Specification for

SAE-AS85049 - Connector Accessories, Electrical General Specification For

SAE-AS85049/1 - Connector Accessories, Electrical, Backshell, Environmental, Cable

Sealing, Straight, Grounding (Without Strain Relief), Category 1C (for

AS50151 Solder Type, V Thread of AS310XX Classes A, B, C, or K

Connectors, AS95234 Connectors)

SAE-AS85049/2 - Connector Accessories, Electrical, Backshell, Environmental, Cable

Sealing, Straight, Category 1C (for AS50151 Solder Type, V Thread of

AS310XX Classes A, B, C, or K Connectors, AS95234 Connectors)

SAE-AS85049/41 - Connector Accessories, Electrical, Non-Environmental, Strain Relief, Straight, Category 4C (for AS50151 Solder Type, V Thread of MS310X, Classes A, B, C, or K Connectors and AS85049 Accessories)

SAE-AS85049/42 - Connector Accessories, Electrical, Nonenvironmental, Strain Relief, Straight, Category 4A (for AS50151 Solder Type, V Thread of MS310X

Classes A, B, C or K Connectors)

(Copies of these documents are available online at www.sae.org.)

A.2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

A.3 REQUIRED EQUIPMENT AND MATERIALS

A.3.1 Required equipment and materials. The required equipment and materials are specified in the standard methods of this section.

A.4 NOTES AND PROCEDURES

A.4.1 Dimensions. For figures and tables in this appendix, all dimensions are in inches unless otherwise noted.

A.4.2 Figures. Table 5AI provides information for the figures in this appendix.

TABLE 5AI. Figures for cable lead preparation.

Figure number Cable lead preparation Page

5A1 Cable preparation procedures 9

5A2 Cable diameter change procedures 14

5A3 Individual lead stripping techniques 20

5A4 Connector contact crimping techniques 31

5A5 Tinning techniques 35

5A6 Conductor contact soldering techniques 40

5A7 Conductor shield termination procedures 51

5A8 Gross shield termination procedures 61

5A9 Connector lockwiring 68

5A10 Cable transflexing procedure 71

5A11 Cable bifurcation procedure 77

5A12 Glossary of terms 81

5A13 Tooling and materials list 84

5A14 Connector part number nomenclature 86

5A15 Water-proofing coaxial connectors 91

Cable preparation procedures (continued):

(3) Center a ¾-inch to 1-inch length of appropriately sized heat shrink tubing meeting the requirements of SAE-AS23053/5, class 1 over the armor termination point and shrink in place using a heat gun, prior to tightening the saddle clamps.

b. Backshell with armor clinching ferrules.

(1) Measure the length of the assembled backshell (PC 2 through 6) from the connector end to the inner armor clinching RFI ferrule (PC 6) (see illustration 3).

NOTE: On angled backshells, measure the center radius dimension.

(2) Add 2 inches and mark this dimension on the armor. Cut and remove the cable armor at this mark using a cable stripper.

CAUTION: Do not damage the cable jacket beneath the armor.

8. Verify cable diameter is compatible with grommet size for environmental seal.

a. Wipe the cable jacket with an approved solvent from table 5A1-I in order to remove grease, oil, dirt, and other debris.

b. Assemble, in correct order and orientation, the required backshell hardware to compress the grommet to the PVC jacket.

NOTE: Tighten without bottoming of adjoining assemblies (see 4.5).

c. Attempt to push backshell straight along cable, applying moderate pressure (do not twist); backshell shall not move. If satisfactory sealing cannot be obtained, build up or reduce the cable diameter in accordance with figure 5A2.

d. Remove all backshell components from the cable.

9. Jacket preparation for environmental sealing.

a. Measure the length of the assembled backshell from the connector end to the nearest grommet end (PC 3, illustration 3).

b. Add 2 inches and mark this dimension on the jacket.

c. Disassemble and relocate the backshell and clamp components on the cable. Verify that all parts are included and are in correct order and orientation. Assemble the backshell and locate it on the cable so that it will not interfere with connector wiring.

d. Remove the cable jacket to the predetermined length as follows:

NOTE: Ensure the cut does not penetrate the jacket completely (see illustration 5).

FIGURE 5A1. Cable preparation procedures – Continued.

ADJUSTABLE

CUTT NG DEPTH

ILLUSTRATION 4

CABLE STR PPER

Method 5A-2-1

Cable diameter build-up procedures

Procedure:

1. These procedures shall be used when the cable entrance dimension of the backshell is too large for the cable diameter to which the connector backshell assembly is being attached.

2. The material used for cable build-up shall extend completely through the sealing grommet without interruption at completion of connector assembly.

3. The first method depicts the use of heat shrink sleeving as the means to increase the cable diameter. The second method depicts the use of telescoping bushings as the means of cable diameter build-up. Each method is designed such that it can be used individually or in combination with the other as the method for cable build-up.

4. The following method shall be used in conjunction with heat shrink sleeving. The cable diameter build-up shall not exceed the maximum cable entryway diameter (cable range) of the clamp.

a. Build up the cable jacket in the vicinity of the environmental seal or cable clamp or both as follows:

(1) Measure the installed length of the grommet, grommet follower, and cable clamp.

(2) Cut a correctly sized piece of heat shrinkable tubing meeting the requirements of SAE-AS23053/5, class 1 to a length equal to that measured in step 4.a(1).

(a) The size of the heat shrink tubing shall be selected from table 5A2-I such that the inner diameter after shrinkage shall be less than the cable diameter.

FIGURE 5A2. Cable diameter change procedures.

TORQUE SCREWDRIVER

CABLE

1/16" GAP M NIMUM

CLAMP BARS

CENTERING POST

ILLUSTRATION 1

CABLE CLAMP GRIPPING

TABLE 5A2-I. Heat shrink tubing.

Military part number I.D. min. (as supplied) After unrestricted shrinkage

I.D. max. Wall thickness

Class 1

M23053/5-101 0.046 0.023 0.016±0.003

102 0.063 0.031 0.017±0.003

103 0.093 0.046 0.020±0.003

104 0.125 0.062 0.020±0.003

105 0.187 0.093 0.020±0.003

106 0.250 0.125 0.025±0.003

107 0.375 0.187 0.025±0.003

108 0.500 0.250 0.025±0.003

109 0.750 0.375 0.030±0.003

110 1.000 0.500 0.035±0.005

111 1.500 0.750 0.040±0.006

112 2.000 1.000 0.045±0.007

113 3.000 1.500 0.050±0.008

114 4.000 2.000 0.055±0.009

Class 1 over expanded

M23053/5-115 1.000 0.275 0.045±0.005

116 2.000 0.550 0.045±0.005

117 3.000 0.810 0.045±0.005

118 4.000 1.050 0.045±0.005

119 1.000 0.462 0.045±0.005

120 2.375 0.680 0.045±0.005

121 3.000 0.840 0.045±0.005

122 3.750 0.930 0.045±0.005

123 4.500 1.450 0.045±0.005

Cable diameter build-up procedures (continued):

(3) Install the heat shrink tubing on the cable in the area where the environmental seal and cable clamp will be, and shrink in place using a heat gun.

(4) Verify that satisfactory environmental sealing can be obtained without bottoming of adjoining backshell assemblies.

(5) Verify that the clamp securely holds over the sleeving and cable, maintaining a minimum gap of 1⁄16 inch between clamp saddles and support (see illustration 1). The minimum 1⁄16-inch gap requirement applies to all connectors covered by Appendices 5B-5H of this standard. For other connectors, there shall be a discernable gap between the clamp saddles to prevent metal-to-metal contact. All saddle clamp assemblies shall be of sufficient tightness to prevent the cable, harness, or individual wire material from moving and to eliminate strain on the wire/connector terminations.

(6) Continue applying heat shrink tubing until the cable outside diameter is compatible with the cable sealing range of the environmental grommet, cable clamp, or both.

5. Table 5A2-II provides detailed information on the SAE-AS85049 telescoping bushing. The following method shall be used in conjunction with an SAE-AS85049 telescoping bushing (see illustration 2).

FIGURE 5A2. Cable diameter change procedures – Continued.

NOTE: The SAE-AS85049 bushing shall not be installed under the grommet. The SAE-AS85049 bushings are only used to build up cable diameter under the cable clamp. References to SAE-AS85049 specifically refer to specification sheets SAE-AS85049/1, SAE-AS85049/2, SAE-AS85049/41, and SAE-AS85049/42 for particular components of the connector.

BACKSHELL

SADDLE

SAE-AS85049

CABLE CLAMP

SAE-AS85049 BUSHING

SAE-AS85049

CABLE CLAMP

GROMMET FOLLOWER

GROMMET

TELESCOPING

BUSHING (SAE-AS85049)

ILLUSTRATION 2

INSTALLING SAE-AS85049 TELESCOP NG BUSHING

TABLE 5A2-II. Telescoping bushings.

SAE-AS85049

dash number A diameter B diameter C diameter D length

-3 0.130 0.210 0.379 2.875

-4 0.220 0.302 0.505 2.750

-6 0.312 0.427 0.619 2.625

-8 0.437 0.552 0.744 2.500

-10 0.562 0.615 0.889 2.375

-12 0.625 0.740 1.084 2.250

-16 0.750 0.927 1.314 2.125

-20 0.937 1.240 1.598 2.000

-24 1.250 1.365 1.847 1.875

-28 1.375 1.614 2.085 1.750

-32 1.624 1.864 2.335 1.625

-40 1.874 2.364 2.835 1.500

a. Measure the installed length of the grommet, grommet follower, and cable clamp. If measured length is longer than available bushing, use heat shrink tubing to build up cable diameter.

b. Slide a correctly sized SAE-AS85049 telescoping bushing (see illustration 3) on the conductor bundle.

(1) Table 5A2-II provides information on the SAE-AS85049 telescoping bushing in order to select the proper size based on the cable diameter.

C

D

0 062"

0 016±0 002"

B

A

ILLUSTRATION 3

SAE-AS85049

(2) Verify that satisfactory environmental sealing can be obtained without bottoming of adjoining backshell assemblies.

(3) Verify that the cable clamp securely holds over the bushing and cable maintaining a minimum gap of 1⁄16 inch between clamp saddles and support (see illustration 1). The minimum 1⁄16-inch gap requirement applies to all connectors covered by Appendices 5B-5H of this standard. For other connectors, there shall be a discernable gap between the clamp saddles to prevent metal-to-metal contact. All saddle clamp assemblies shall be of sufficient tightness to prevent the cable, harness, or individual wire material from moving and to eliminate strain on the wire/connector terminations.

NOTE: More than one bushing may be used to achieve the desired cable diameter (see illustration 5). However, the cable diameter build-up shall not exceed the maximum cable entryway diameter (cable range) of the clamp.

NOTE: Two design bushings are available. The one has an outside end flange (see illustration 3) while the other has no flange (see illustration 4).

ØA

B

2.000±0.031"

ILLUSTRATION 4

SAE-AS85049 BUSHING

CABLE CLAMP

FIRST TELESCOPING

BUSHING

CABLE

SECOND TELESCOP NG

BUSH NG

ILLUSTRATION 5

USING MORE THAN ONE TELESCOPING BUSHING

Method 5A-2-2

Reducing cable diameter for entry into a connector

General notes:

1. This method includes instructions for reducing a cable diameter for entry into a connector. Only use this method if the cable jacket diameter is too large for the connector to achieve proper strain relief.

2. Heat shrink tubing is required to replace the cable jacket inside a connector to achieve optimal strain relief for the cable and connector.

3. Continually apply layers of heat shrink tubing, as shown in the following illustration, until the diameter of the heat shrink tubing correctly matches the required diameter of the connector strain relief. Ensure that the heat shrink extends past the strain relief location and covers the end of the cable jacket. The heat shrink shall extend past the environmental seal inside of the backshell if backshell contains an environmental seal.

HEAT SHRINK

JACKETPOINT OF

CONNECTOR

STRAIN RELIEF

SEE NOTE 3

CABLE

CONDUCTORS

JACKET STRIPPED

(LENGTH TO SUIT)

TYPICAL APPLICATION OF HEAT SHRINK

TYPICAL CONNECTOR

TYPICAL VIEW ILLUSTRATING COMPLETED CABLE AND CONNECTOR

HEAT SHRINK

JACKET

Individual lead stripping techniques:

1. Thermal stripping is the preferred method when compatible with the insulation type.

2. The following precautions shall be observed when stripping wires with either thermal or mechanical strippers:

a. Ensure the blades or heated stripping elements of thermal strippers are kept clean at all times.

b. Ensure all stripping blades are sharp and free from nicks, dents, and any other mechanical deformities that may prevent proper operation.

c. Ensure the correct stripping hole is used for the corresponding wire size. Illustration 8 of figure 5A3 is provided to show construction of a common conductor.

CAUTION: There are significant differences between Navy and commercial (AWG) wire gauges.

Ensure all comparisons are taken using the same convention.

d. When stripping the lead, hold the wire perpendicular to the cutting or thermal blade (see illustration 2 and illustration 7 on figure 5A3 for examples).

e. Avoid nicking, cutting, or otherwise damaging the wire strands.

f. Ensure there are no frayed or ragged edges after the insulation has been removed.

g. Ensure all insulation has been removed from the stripped area.

h. Conductor strands may be re-twisted if required to restore the natural lay and tightness of the strands.

Avoid bare finger contact with the wire strands.

3. Glass braid or tape and synthetic rubber shall be removed utilizing precision mechanical strippers in accordance with step 6.

4. Strip individual lead using thermal or mechanical stripping method (step 5 or 6). Table 5A3-II contains conductor information for common Navy cables (MIL-DTL-24643) and the recommended stripping method.

Note that table 5A3-II is not a comprehensive list of cables where conductor stripping will be necessary to attach a conductor to a connector contact. For cables not covered in table 5A3-II, consult specification sheets or cable manufacturer’s information. (For information on low smoke cables, refer to MIL-DTL-24643 and

MIL-DTL-24640. For information on non-low smoke cable, refer to MIL-DTL-915.)

a. Strippers shall be tested and adjusted on a test conductor prior to stripping actual cable conductor.

b. Avoid nicking, cutting, or damaging wire strands during stripping.

c. Take care to prevent small particles, especially those which are conductive, from entering into connector contact cavities. Particles may hamper proper seating of contacts and cause short circuits.

FIGURE 5A3. Individual lead stripping techniques.

Individual lead stripping techniques (continued):

d. Adjust the temperature to the insulation melting temperature listed in table 5A3-II for the specific cable type being stripped. If a temperature is not listed, use a precision mechanical stripper in accordance with step 6.

e. Check strip length on several test pieces. Strip length should meet criteria of insulation clearance (see step 7). Adjust strip length as necessary.

f. Insert the conductor to be stripped between the heating elements or stripper blades.

g. Twist the tool slightly or rotate the wire to ring the insulation while applying heat (see illustration 1).

h. Draw the wire from the tool. The insulation slug shall be removed with the heating elements.

6. Precision mechanical stripper (see illustration 3).

a. Ensure stripper is a precision fixed die cutting type (see illustration 3 for an example of a satisfactory stripper). Strippers that permit operator adjustment shall not be used (see illustration 4).

(1) Select the correct stripper blade for the size conductor being stripped utilizing data supplied by the manufacturer. Table 5A3-III is provided as an example of typical Ideal stripper models.

FIGURE 5A3. Individual lead stripping techniques – Continued.

Individual lead stripping techniques (continued):

b. Examine the stripper to ensure the blades line up for proper operation (see illustration 5).

c. Set the wire stop for the depth of the contact wire barrel as specified in the connector assembly procedure for the connector type being assembled, plus the allowable insulation clearance specified in step 7 (see illustration 6).

d. Check strip length on several test pieces.

(1) Strip length shall meet the criteria of insulation clearance (see step 7). Adjust strip length as necessary.

(2) Ensure correct stripping hole is used for corresponding conductor gauge. See table 5A3-II for conductor size.

e. Position the conductor in the stripper jaws (see illustration 7).

f. Squeeze the handles.

ILLUSTRATION 5

STRIPPING BLADE ALIGNMENT

26 24 22222426

IMPROPER ALIGNMENT PROPER ALIGNMENT

Individual lead stripping techniques (continued):

b. Solder contact insulation clearance specification.

(1) Conductor shall be bottomed in contact wire barrel.

(2) Minimum clearance: Insulation shall not be imbedded in the solder joint.

(3) Contour of the conductor shall be visible at the insulation gap.

(4) Maximum clearance: Less than two wire diameters including insulation or 1⁄16 inch, whichever is larger, but shall not permit shorting between adjacent conductors.

8. Examine the wire with a magnifying glass (6X to 10X power) to ensure the strands have not been scratched, nicked, cut, scraped, broken, or otherwise damaged.

a. See table 5A3-I for rejection criteria for solder contacts.

TABLE 5A3-I. Rejection criteria for solder contacts.

Number of strands Maximum allowable nicked or broken strands

Less than 7 0

7-15 1

16-18 2

19-25 3

26-36 4

37-40 5

41 or more 6

b. For crimped contacts, no conductor strand damage is acceptable.

9. Rework rejected conductors as follows:

a. Cut the conductor square where the damage ends.

b. Re-strip the conductor in accordance with step 4.

ILLUSTRATION 8

TYPICAL CONDUCTOR CONSTRUCTION

(SEE TABLE 5A3-II)

CONDUCTOR INSULATION JACKET

(NOT ON ALL CONDUCTORS - SEE TABLE

5A3-II)

CONDUCTOR INSULATION

COPPER CONDUCTOR

TABLE 5A3-II. Cable lead stripping details.

a b le t y p e

,3 o n d u c to r w ir e m a te ri a l

S iz e o f w ir e c o n d u c to r

N o o f st ra n d s p e r c o n d u c to r

M a x w ir e d ia m e te r

M a x c o n d u c d ia m e te r

C o n d u c p im a ry in su la ti n m te r ia l

In su la ti e lt in g t e m p

In su la ti c o m p o si ti te p

C o n d u c la ti ja c k e t m a te ri a l

In su la ti k e t m el ti g p

In su la ti k e t d e c o m p o si ti p

R e c o m m e n d st ip p th

LSDHOF-3

Copper, uncoated

2½(26)

(Navy standard)

26 0.061 0.123 Separator 1/ Undetermined

1/ Undetermined 1/

Synthetic rubber 248 F 248 F Mechanical

LSDHOF-4

Copper, uncoated 4(41) 41 0.077 0.139 Separator 1/

Undetermined 1/

Undetermined 1/ Synthetic rubber 248 F 248 F Mechanical

LSDHOF-6

Copper, uncoated

6(65) (Navy standard)

65 0.097 0.159 Separator 1/ Undetermined

1/ Undetermined 1/

Synthetic rubber 248 F 248 F Mechanical

LSDSGU-3

Copper, uncoated

3(7) (Navy standard) 7 0.060 0.130

Extruded silicone rubber

482 F 530 F Glass braid 1300 F -- Mechanical

LSDSGU-4

Copper, uncoated

4(7) (Navy standard) 7 0.076 0.143

Extruded silicone rubber

482 F 530 F Glass braid 1300 F -- Mechanical

LSDSGU-50

Copper, uncoated

50(19)

(Navy standard)

19 0.254 0.334 Silicone rubber

482 F 530 F Glass tape 1300 F -- Mechanical

LSFHOF-4

Copper, uncoated

4(41)

(Navy standard)

41 0.077 0.139 Separator 1/ Undetermined

1/ Undetermined

Synthetic rubber

248 F 248 F Mechanical

LSFHOF-9

Copper, uncoated

9(90) (Navy standard)

90 0.120 0.182 Separator 1/ Undetermined

1/ Undetermined 1/

Synthetic rubber 248 F 248 F Mechanical

LSFSGU-3

Copper, uncoated

3(7) (Navy standard) 7 0.060 0.096

Extruded silicone rubber

482 F 530 F Glass braid 1300 F -- Mechanical

LSFSGU-4

Copper, uncoated

4(7) (Navy standard) 7 0.076 0.112

Extruded silicone rubber

482 F 530 F Glass braid 1300 F -- Mechanical

LSFSGU-9

Copper, uncoated

9(7) (Navy standard) 7 0.108 0.154

Extruded silicone rubber

482 F 530 F Glass braid 1300 F -- Mechanical

LSFSGU-23

Copper, uncoated

23(7)

(Navy standard)

7 0.171 0.316

Extruded silicone rubber

482 F 530 F Glass braid 1300 F -- Mechanical

LSFSGU-50

Copper, uncoated

50(19)

(Navy standard)

19 0.254 0.334 Silicone rubber

482 F 530 F Glass tape 1300 F -- Mechanical

LSMCOS-2

Copper, uncoated

1½(16) (Navy standard)

16 0.049 0.072 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LSMCOS-6

Copper, uncoated

1(10) (Navy standard)

10 0.038 0.064 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LSTTOP-XX

Copper, uncoated

1(10)

(Navy standard)

10 0.038 0.078 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LSTTRS-XX

Copper, uncoated

1(7) (Navy standard) 7 0.038 0.078 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

TABLE 5A3-II. Lead stripping details – Continued.

a b le t y p e

C o n d u c e m a te ri a l

S iz e o f w ir e c o n d u c to r

N o o f st ra n d s p e r c o n d u c to r

M a x w ir e d ia m e te r

M a x c o n d u c m e te r

C o n d u c im la ti te r ia l

In su la ti lt in g t e m p

In su la ti c o m p o si ti p

C o n d u c la ti k e t m a te r ia l

In su la ti k e t m el ti p

In su la ti k e t d e c o m p o si ti p

R e c o m m e n d ip p th

LSTTSU-XX

Copper, uncoated

3/5(7) (Navy standard)

7 0.030 0.047 Extruded silicone rubber

482 F 530 F Polyamide 325-450

F 700 F Thermal

LS1SMWU-

Copper, tin-coated

22-7

ASTM

B286

7 0.033 0.093 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LS1S50MU-

Copper, tin-coated

22-7

ASTM

B286

7 0.033 0.093 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LS2SJ-16

Copper, tin-coated

16-19

ASTM

B286

19 0.062 0.091 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LS2SJ-20

Copper, tin-coated

20-19

ASTM

B286

19 0.038 0.073 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LS2SU-XX

Copper, uncoated

22-7

ASTM

B286

7 0.033 0.059 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LS2SWAU-

XX

Copper, uncoated

22-7

ASTM

B286

7 0.033 0.059 Separator 1/ Undetermined Undetermined

Cross linked polyethylene or synthetic rubber

-- -- Mechanical

LS2U-XX

Copper, tin-coated

26-7

ASTM

B2…