INCH-POUND MIL-DTL-24640/16D 22 August 2002 SUPERSEDING MIL-C-24640/16C 26 June 1995 DETAIL SPECIFICATION SHEET CABLE, ELECTRIC, 600 VOLTS, LIGHT-WEIGHT, MULTI-PAIR, AWG 18, TYPE 2XSW (INCLUDING VARIATION TYPE 2XSOW) This specification is approved for use by all Departments and Agencies of the Department of Defense. The requirements for acquiring the product described herein shall consist of this specification sheet and the issue of MIL-DTL-24640 listed in that issue of the Department of Defense Index of Specifications and Standards (DoDISS) specified in the solicitation. Construction (Watertight) First - 7-strand, tin-coated copper conductor, AWG size and dimensions in accordance with Table I. Second - Insulation material and basic construction requirements shall be in accordance with MIL-W-81044/12 and tested in accordance with the component wire ratings and requirements listed on this slash sheet. Quality conformance testing shall be in accordance with MIL-W-81044, prior to cabling. Third - Two conductors, one black and one white, twisted together. The pitch shall be 1 + ¼ inch. Fourth - Binder tape applied helically with overlap, at manufacturer's option. Fifth - Braided shield of # 38 AWG tin coated copper strands. Braid coverage shall be no less than 90 percent determined in accordance with WC-27500 Sixth - Shield insulation of two polyester tapes or polyester tape and extruded jacket. Identification codes applied using Method 2. (NOTE: This step is not required for type 2XSW1) Seventh - The required number of shielded, twisted pairs shall be cabled together. Cabling sequence shall be consecutive, starting with number 1 from center outward. Fillers may be used as necessary, to form a round cable. Eighth - Binder tape applied helically with overlap. AMSC N/A 1 of 6 FSC 6145 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. MIL-DTL-24640/16D CONSTRUCTION VARIANT FOR TYPE 2XSW Ninth - Crosslinked polyolefin jacket. (See Table II for thickness). CONSTRUCTION VARIANT FOR TYPE 2XSOW Ninth - Braided shield, tin coated copper strands. Braid must be constructed to meet Surface Transfer Impedance requirements as listed herein. Tenth - Binder tape applied helically with overlap. Eleventh -Cross-linked polyolefin jacket. (See Table III for thickness). TABLE I. Component wire details. Watertight conductor Finished wire Test load life Low temp. at -40° C Wire size Stranding Diameter Diameter cycle accelerated Mandrel (AWG) (no. x AWG) nominal (inches) aging tests diameter Test load (inches) (lbs. + 3%) (inches) (lbs) 18 7 x 26 0.048 0.065 0.250 1.0 1.0 + 0.003 TABLE II. Construction details. Jacket Cable Cable weight Number of thickness diameter (pounds per PIN Type number pairs (inch) (inch) 1000 feet) M24640/16 (min) (min) (max) (max) -01UN 2XSW-1 1 0.034 0.240 0.258 52.9 -02UN 2XSW-3 3 .041 .436 .470 175.0 -03UN 2XSW-7 7 .044 .573 .617 330.0 TABLE III. Construction details - overall shield. Diameter Jacket Cable weight PIN Number of over shield thickness Cable diameter (pounds per M24640/16 Type number pairs (inch) (inch) (inch) 1000 feet) (nom) (min) (min) (max) (max) -01UO 2XSOW-3 3 0.374 0.041 0.487 0.525 227.0 -02UO 2XSOW-7 7 .514 .044 .608 .656 401.0 -03UO 2XSOW-12 12 .702 .047 .802 .864 665.0 -04UO 2XSOW-19 19 .844 .050 .938 1.010 950.0 -05UO 2XSOW-30 30 1.080 .057 1.180 1.270 1442.0 2 MIL-DTL-24640/16D REQUIREMENTS: Qualification required. Construction details: See Tables I, II, and III. Component wire: The component wire shall be per MIL-W-81044 and shall be tested in accordance with the following wire ratings and additional requirements. o o Temperature rating: 135 C (275 F) maximum conductor temperature Voltage rating: 600 volts (rms) at sea level. o o Accelerated aging: Oven temperature, 250 + 2 C (482 + 3.6 F) for 6 hours. o o Low temp.-cold bend: -40 C (-40 F) for 4 hours o o Blocking: 150 + 2 C (302 + 3.6 F) Color: In accordance with MIL-STD-104, class 1; white preferred Flammability: 30 seconds (max); 3.0 inches (max); no flaming of tissue paper. Humidity resistance: 5000 megohms for 1000 feet, minimum insulation resistance after humidity exposure. Identification, striping or banding durability: 125 cycles (250 strokes) (min), 500 gram weight. Impulse dielectric test: Primary insulation (when tested in lieu of spark test): 6.0 kilovolts (peak) 100 percent test. Finished wire: 8.0 kilovolts (peak), or 3 kHz spark test 5.5 kV, 100 percent test. Insulation resistance: 5000 megohms for 1000 feet (min). o o Life cycle: Oven temperature, 200 + 2 C (392 + 3.6 F) for 120 hours. Physical properties of primary insulation: 2 Tensile strength, 2500 lb/in (min). Elongation, 150 percent (min). o o Shrinkage: 0.125 inch maximum at 250 + 2 C (482 + 2 F). Spark test primary insulation: 1500 volts (rms), 60 Hz or 3 kHz, 100 percent test. Surface resistance: 500 megohms inches (min), initial and final readings. o o Thermal shock: Oven temperature, 150 + 2 C (302 + 3.6 F). Maximum change in measurement: 0.060 inch. Wet dielectric test: 2500 volts (rms). Wrap test: Mandrel wrap test required. EXAMINATION AND TESTS: Basic electrical: Requirements o Conductor Resistance - ohms/1000 feet at 25 C, maximum.....................................7.11 Voltage withstand - volts, root mean square, minimum Conductor to conductor and shield ................................................................1000 Component Shield to Component Shield.......................................................200 Component Shield to overall shield (Type 2XSOW only)... .........................500 Insulation resistance – megohms-1000 feet, minimum 3 MIL-DTL-24640/16D Conductor to conductor and shield ................................................................2500 Shield to shield (component shield only) ......................................................100 Shield to shield (component shield to overall shield) Type 2XSOW only....100 Conductor and shield continuity........................................................No failure Jacket flaws (type 2XSOW only).................… .................................No failure Group A: Visual and dimensional .................................................................................No failure Capacitance: Mutual capacitance - at 1 MHz, picofarads/foot (pF/ft), maximum..60 Capacitance unbalance - percent, maximum .....................................15 Characteristic impedance - at 1 MHz, ohms.............................................30 min, 53 max Watertightness (see Table IX of MIL-DTL-24640 for limits of water leakage)......................................................................No failure Weight ...........................................................................................................No failure Group B: Cold bending..................................................................................................No failure Drip ...............................................................................................................No failure Cross link proof test (percent maximum) Jacket.............................................................................................................50 Tear - pounds per inch thickness, minimum..............................................................35 Physicals (unaged) Jacket 2 Tensile strength - lb/in , minimum. ...................................................1300 Elongation - percent, minimum .........................................................160 Attenuation - at 3 MHz, dB/100 feet, maximum ...........................................Not applicable Gas flame (1 hour) .........................................................................................Not applicable Group C: Physicals (aged) Jacket Air oven Tensile strength - percent of unaged, minimum ....................60 Elongation - percent of unaged, minimum ............................60 Permanence of printing (conductor) - cycles, minimum ...............................Not applicable Permanence of printing (jacket) - cycles, minimum..................................................125 Shield - conformance to material, construction and coverage.......................No failure Heat distortion - percent of unaged, maximum .........................................................30 Cable sealant removability.............................................................................No failure Shrinkage.......................................................................................................No failure Mutual inductance - dB/1000 feet, maximum ...............................................Not applicable Surface transfer impedance (type 2XSOW only) Milliohms per meter, maximum ................................................................................700 EMP response, dB, minimum ....................................................................................60 Pulse response time - ms/500 feet 4 MIL-DTL-24640/16D Rise time, maximum ..........................................................................Not applicable Decay time, maximum .......................................................................Not applicable QUALIFICATION INSPECTION: Qualification inspection shall include basic electrical, all of groups A, B, C and D, plus the following: Flame propagation .........................................................................................No failure Aging and compatibility (cable) ....................................................................No failure Acid gas equivalent - percent, maximum Jacket.............................................................................................................2 Fillers.............................................................................................................2 Insulation.......................................................................................................18 Halogen content - percent, maximum Jacket.............................................................................................................0.2 Fillers.............................................................................................................0.2 Hot oil immersion Tensile strength - percent of unaged, minimum ............................................50 Elongation - percent of unaged minimum .....................................................50 Smoke index, maximum Jacket.............................................................................................................25 Fillers.............................................................................................................45 Insulation.......................................................................................................10 Toxicity index, maximum Jacket ............................................................................................................5 Fillers.............................................................................................................5 Insulation.......................................................................................................1.5 Durometer (jacket) - (type A) hardness, minimum....................................................80 Weathering (jacket)........................................................................................No failure Fungus Resistance..........................................................................................No failure Abrasion resistance ........................................................................................No failure Gas Flame (3 hour) ........................................................................................Not applicable Component wire ...........................................................................................No failure Unit ordering length: 3 - 12 500 feet nominal. 19 & 30 250 feet nominal. 5 MIL-DTL-24640/16D Custodians: Preparing Activity: Army - MI Navy - SH Navy - SH (Project 6145-2307-016) Review Activities: Army - AR, AV, CR, CR4 Navy - CG, EC DLA - IS 6