MIL-W-5088L - Wiring, Aerospace Vehicle
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JINCH-POUND1 MIL-W-5088L 10 May 1991 SUPERSEDING MIL-1+-5088K 24 December 1984 This specification MILITARY SPECIFICATION WRING, AEROSPACE VEHICLE is amroved for use by all Departments and Agencies of the Dep&rtment of Defense. 1. SCOPE 1.1 Scope. This specification covers all aspects from the selectlon through installation of wiring and wiring devices used in aerospace vehicles. Aerospace vehicles include airplanes, helicopters, lighter-than-air vehicles, and missiles. 1.1.1 Application. This specification establishes design requirements guidance for wiring of aerospace vehicles. Although many of the requirements are written as mandatory and shall be considered as such, there is also con- slderable material which is intended to denote optional, preferential or guidance type requirements. In interpreting the material contained herein, it is intended that the philosophy of the entire document be considered for the wiring of each new type of vehicle. This philosophy Is safety of the personnel, safety of the vehicle, satisfactory performance and reliability of the vehicle and ease of maintenance, and service llfe all at the least cost to the Government. The intent of this document will be fulfilled by tailoring the requirements in each new type or class of aerospace vehicle designed, to the proper application. 2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.1.1 Specifications, standards and handbooks. Unless otherwise specified, the following specifications, standards and handbooks of the Issue llsted in that issue of the Department of Defense Index of Specifications and Standards (DODISS) specified in the solicitation form a part of this speclfl- catlon to the extent speclfled herein. Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to: Commanding Officer, Naval Air Engineer~ng Center, Systems Engineering and Standardization Department (Code 53), Lakehurst, NJ 08733-5100, by using the self-addressed Standardization Document Improvement Proposal (DO Form 1426) appearing at the end of this document or by letter. AMSC N/A AREA GDRQ DISTRIBUTION STATEMENT A. Approved for publlc release; distribution is unlimited. --
Transcript of MIL-W-5088L - Wiring, Aerospace Vehicle
JINCH-POUND1
MIL-W-5088L10 May 1991SUPERSEDINGMIL-1+-5088K24 December 1984
This specification
MILITARY SPECIFICATION
WRING, AEROSPACE VEHICLE
is amroved for use by all Departmentsand Agencies of the Dep&rtment of Defense.
1. SCOPE
1.1 Scope. This specification covers all aspects from the selectlon throughinstallation of wiring and wiring devices used in aerospace vehicles. Aerospacevehicles include airplanes, helicopters, lighter-than-air vehicles, and missiles.
1.1.1 Application. This specification establishes design requirementsguidance for wiring of aerospace vehicles. Although many of the requirements arewritten as mandatory and shall be considered as such, there is also con- slderablematerial which is intended to denote optional, preferential or guidance typerequirements. In interpreting the material contained herein, it is intended thatthe philosophy of the entire document be considered for the wiring of each newtype of vehicle. This philosophy Is safety of the personnel, safety of thevehicle, satisfactory performance and reliability of the vehicle and ease ofmaintenance, and service llfe all at the least cost to the Government. The intentof this document will be fulfilled by tailoring the requirements in each new typeor class of aerospace vehicle designed, to the proper application.
2. APPLICABLE DOCUMENTS
2.1 Government documents.
2.1.1 Specifications, standards and handbooks. Unless otherwisespecified, the following specifications, standards and handbooks of the Issuellsted in that issue of the Department of Defense Index of Specifications andStandards (DODISS) specified in the solicitation form a part of this speclfl-catlon to the extent speclfled herein.
Beneficial comments (recommendations, additions, deletions) and any pertinentdata which may be of use in improving this document should be addressed to:Commanding Officer, Naval Air Engineer~ng Center, Systems Engineering andStandardization Department (Code 53), Lakehurst, NJ 08733-5100, by using theself-addressed Standardization Document Improvement Proposal (DO Form 1426)appearing at the end of this document or by letter.
AMSC N/A AREA GDRQ
DISTRIBUTIONSTATEMENT A. Approved for publlc release; distribution is unlimited.--
MIL-W-5088L
SPECIFICATIONS
MILITARY
MIL-I-631
MIL-I-3190
MIL-C-3607
● MIL-C-3643
MIL-C-3650
MIL-C-3655
MIL-B-5087
MIL-E-6051
MIL-C-6136
MIL-E-7080
MIL-T-7099
MIL-F-7179
MIL-I-7444
MIL-C-7762
MIL-B-7883
MIL-T-7928
MIL-S-8516
Insulation, Electrical, Synthetic-Resin Composi-tion, Nonrfgld
Insulation Sleeving, Electrical, Flexible,Coated, General Specification for
Connector, Coaxial, Radio Frequency, SeriesPulse, General Specification for
Connectors, Coaxial, Radio Frequency, Series HNAssociated Flttlngs, General Speclflcat\on for
Connectors, Coaxial, Radio Frequency, Series LC
Connector, Plug and Receptacle, Electrical(Coaxial, Series Twin), and Associated Fittings,General Speclflcation for
Bonding, Electrical, and Llghtlng Protection,for Aerospace Systems
Electromagnetic Compatibility Requirements,Systems
Conduit, Electrical, Flexible, Shielded,Aluminum Alloy for Aircraft Installations
Electric Equipment, AircraftInstallation of
Terminal, Lug and Splice, Crfor Alumlnum Aircraft N\re
Selection and
mp Style Aluminum,
Finishes, Coatings, and Sealants for theProtectIon of Aerospace ldeapons Systems, GeneralSpeclflcatlon for
Insulation Sleeving, Electrical, Flexible
Compass, Installation of
Brazing of Steels, Copper, Copper Alloys, NickelAlloys, Aluminum and Aluminum Alloys
Terminals, Lug and Splice, Crimp Style, Copper
Sealing Compound, Polysulflde Rubber, ElectrlcConnectors and Electric Systems, Chemically Cured
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SPECIFICATIONS (continued)
MILITARY (continued)
MIL-I-8700
MIL-C-22520
MIL-H-22759
MIL-I-23053
MIL-S-23190
MIL-S-23586
MIL-I-23594
MIL-M-24041
MIL-C-25516
MIL-C-26637
MIL-C-39012
MIL-C-39029
MIL-T-43435
● MIL-C-49142
● MIL-A-5533!I
Installation and Test of Electronic Equipment inAircraft, General Specification for
Crimping Tools, Terminal, Hand or PowerActuated, Wire Termination and Tool Kits,General Specification for
Wire, Electric, Fluoropolymer-i nsulated, Copperor Copper A11oY
Insulation Sleeving, Electrical, Heat Shrink-able, General Speclflcatlon for
Straps, Clamps and Mounting Hardware, Plasticand Metal for Cable Harness Tying and Support
Sealing Compound, Electrical, Sillcone Rubber,Accelerator Required
Insulation Tape, Electrical, High Temperature,Polytetrafluoroethylene, Pressure-sensitive
Molding and Potting Compound, Chemically CuredPolyurethane
Connectors, Electrical, Miniature, Coaxial,Environment-resistant Type, General Specifica-tion for
Connector, Coaxial, Radto Frequency, Series LT,General Specification for
Connectors, Coaxial,Specification for
Contacts, ElectricalIffcatlon for
Radio Frequency, General
Connector, General Spec-
Tape, Lacing and Tying
Connector, Plug and Receptacle, Electrical,Trlaxial, Radio Frequency, General Specificationfor
Adapter, Connector, Coaxial, Radio Frequency,(Between Series and Within Series), GeneralSpecification for
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SPECIFICATIONS (continued)
MILITARY (continued)
MIL-M-81260
MIL-W-81381
MIL-T-81490
MIL-T-81714
MIL-T-81714/11
MIL-T-81714/12
MIL-S-81824
● MIL-C-83517
MIL-S-83519
biIL-C-85049
MIL-C-85485
● MIL-S-85848
STANDARDS
FEDERAL
FED-STD-595
MILITARY
DOD-STD-100
MIL-STD-454
Manual, Technical, Aircraft/System/EquipmentMaintenance
Hire, Electric, Polyimide-i nsulated, Copper andCopper Alloy
Transmission Lines, Transverse ElectromagneticMode
Terminal Junction System (TJS), Environment-reslstant, General Speciflcatlon for
Terminal Junction System (TJS), TerminalJunction Blocks, Sectional, Wire In-LineJunctions, Sfngle, Series I
Terminal Junction System (TJS), TerminalJunction Blocks, Sectional, Hire In-LineJunctions, Double, Series I
Splice, Electric, Permanent, Crimp Style,Copper, Insulated, Environment-resistant
Connector, Coaxial, Radio Frequency for Coaxial,Strip or Mlcrostrip Transmission Line, GeneralSpecification for
Shield Termination, Solder Style, Insulated,Heat-shrinkable, Environment-1Speclflcatlon for
Connector Accessories, ElectrSpeciflcatlon for
Cable, Electric, Fi’Absorptive
Sleeving, For IdentShrinkable, General
esistant, General
cal, General
ter Line, Rad’to Frequency
fication Marking, HeatSpeclficatlon For
Colors Used in Government Procurement
Engineering Drawing Practices
Standard General Requirements for ElectronicEquipment
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STANDARDS (continued)
.. MILITARY (continued)
MIL-STD-681
.
MIL-STD-704
DOD-STD-863
● MIL-STD-889
● MIL-STD-970
MIL-STD-1353
MIL-STD-1388
MIL-STD-1553
MS3373
MS18029
MS21266
MS21919
MS25171
?4S25274
MS25281
MS25435
)4S25436
kiS25437
Identification Coding and Application of Hookupand Lead Hire
A~rcraft Electric Power Characteristics
Wiring Data and System Schematic Diagrams,Preparation of
Dissimilar Metals
Standards and Speclflcat\ons, Order ofPreference for the SelectIon of
Electrical Connectors, Plug-in Sockets andAssociated Hardware, SelectIon and USe Of
Logistfc Support Analysis
Digital Time Division Command/Response,Multiplex Data Bus
Strip, Mounting, Nut Insulating, for MS27212Terminal Board
Cover Assembly, Electrical, for MS27212 TerminalBoard Assembly
Grommet, Plastlc, Edging
Clamp, Loop-Type, Cushioned, Support
Nipple, Electrical Terminal
Cap, Electrical (Hire End, Crimp Style, Type II,Class 1), for 105*C Total Conductor Temperature
Clamp, Loop-Plastic, Hire Support
Terminal, Lug, Crimp Style, Straight Type, forAluminum Aircraft Hire, Class 1
Terminal, Lug, Crimp Style, 90” Upright Type,for Aluminum Aircraft Wire, Class 1
Terminal, Lug, Crimp Style, Left Angle Type, forAluminum Aircraft Wire, Class 1
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STANDARDS (continued)
MILITARY (continued)
MS25438
MS25439
!4S25440
MS27212
MS27488
MS33540
MS35489
MS90376
MS90387
AND1038O
Terminal, Lug, Crimp Style, Right Angle Type,for Aluminum Aircraft Hire, Class 1
Spllce,Aluminul
Masher,
Termina’
Permanent, Crimp Style, 2 Nay Type forAircraft Hire, Class 1
for Use tllthAircraft Aluminum Terminals
Board Assembly, Molded-In Stud, Electric
Plug, End Seal, Electrical Connector
Safety Hiring and Cotter Pinning, GeneralPractices for
Grommet, Synthetic and Silicone Rubber, Hot 011and Coolant Resistant
Cap, Dust, Plastic, Electric Connector
Tool, Hand, Adjustable, for Plastic TiedownStraps
Coupllng Installations, Standard Conduit,Electrical
HANDBCXXS
MILITARY
MIL-HDBK-216 RF Transmlsslon Lines and Fittings
ADDITIONAL DOCUMENTS
Additional documents pertaining to the selection of wire and cables arelfsted In Appendix A.
*(Unless otherwise Indicated, copies of federal and military specifications,standards and handbooks are available from the Standardlzatlon Documents OrderDesk, Bldg. 40, 700 Robbins Avenue. Phtladelphla, PA 19111-5094. )
● 2.2 Non-Government publications. The following documents form a part ofthis document to the extent spec~fied herein. Unless otherwise spec~fled, theissues of the documents which are DOD adopted are those listed in the issue ofthe DODISS cited In the solicitation. Unless otherwise specified, the issuesof documents not listed in the DODISSare the Issues of the documents cited Inthe solicitation (see 6.2).
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AEROSPACE INDUSTRIES ASSOCIATION OF AMERICA, INC. (AIA)
NAS 813 Cap - Protective Electrical ConnectorNAS 820 P?ug - Protective Electrical Connector
(Application for copies should be addressed to the Aerospace IndustriesAssoc’tation of America, Inc., 1250 Eye Street, N.H., Washington, DC 20005.)
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)
Y14.15 1966 Electrical and Electronics Diagrams
Y32 .2 1975 Graphic Symbols for Electrical and ElectronicsDiagrams
Y32.16 1975 Reference Designations for Electrical andElectronic Parts and Equipment
(Application for copies should be addressed to the American NatlfInstitute, Inc., 1430 Broadway, New York, NY 10018-3308.)
(Industry association specifications and standards are generallyreference from libraries. They are also distributed among technand using Federal agencies.)
nal Standards
available forcal groups
2.3 Order of precedence. In the event of a conflict between the text ofthis document and the references cited herein (except for related associateddetail speclficatlons, specification sheets, or military standards), the textof this document takes precedence. Nothing in this document, however,supersedes appl~cable laws and regulations unless a specific exemption hasbeen obtained.
3. REQUIREMENTS
3.? Terminology interpretation. The term “wiring” wherever usedthroughout this specification shall be Interpreted In accordance with 6.3.5.
3.1.1 Oevtations. Deviations from this specification desired by thecontractor (substitution of equipment, material or installation) shall bespecifically brought to the attention of the procuring actlvlty by letterconcurrent with or prior to forwarding the design data for approval. Al 1requests for deviations shall Include-sufficient engineering ‘substantiate the deviations.
3.2 Conflicting requirements. In case of discrepanciesspecification and the type or detail specification for a partpart, the type or detail specification shall prevail.
nformation to
between thiscular vehicle
● 3.3 Selection of parts and materials. Parts and materials covered bydocuments listed herein are standard and shall be used whenever they aresuitable for the purpose. Parts and materials shall be procured fromQPLsources when they exist. Nonstandard parts and materials must be equivalentto or better than similar standard parts and materials. Mhen this specifica----tion fails to provide an applicable specification or standard, the contractorshall use other established speclflcatlons or standards in the order ofprecedence set forth in MIL-STO-970. Parts and materials selected from otherthan this specification are not standard, and approval must be obtained prior
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to their use in aerospace vehicles. Each vendor source for a nonstandard partor mater~al requires approval. When a nonstandard part is used where asuitable standard part exists, the contractor shall reference the standard -part on the drawing, parts lists, or data package, and the Installation shallprovide for replacement with the standard part.
3.3.1 ~ests for approval of nonstandard parts. The data to be sub-mitted with the request for approval of nonstandard parts shall be inaccordance with the terms of the contract.
3.3.2 Connnercial utllltyp arts. (hmnercial utility parts, such asscrews, bolts, nuts, cotter pins, etc., may be used, provided they havesuitable properties and are replaceable by standard parts without alteration.
3.3.3 Contractor’s specifications. Hlr!ng and wirtng devices conformingto contractor’s specifications may be used, provided each contractor’s spec-ification is approved by the procuring activity and provided no militaryspecification exists. The contractor shall provide substantiating test dataand, when required by the procuring activity, shall provide samples for test.The use of contractor’s specifications shall not constitute waiver of Govern-ment inspections. Contractor’s speclflcatlons shall follow the format formilttary specifications. When a detail or general military specificationexists for the class of material required, the contractor’s specificationshall reference the existing mllltary specification and set forth only theneeded new requirements and deviations.
3.3.4 Comnmalltv. An object~ve in the selection of parts shall be tomaxim!ze conmnonallty and m~nimlze the variety of wiring components and relatedservicing tools required In the construction, installation and maintenance ofthe electrical wiring system.
3.3.5 Government-furnished Aircraft Equipment (GFAE). Wlrlng and wiringdevices furnished by the Government shall be Installed without modificationunless otherw!se authorized or directed by the procuring activity.
3.3.6 Modification. The contractor shall not alter, rework or mod~fywiring or wiring dev#ces built to and meeting Government specfficatlons,unless authorized or d~rected by the procuring activity, and such modificationshall be subject to Government InspectIon. Modified parts shall have theGovernment Identlfylng part number removed and shall be identified bycontractor part number.
3.4 Service life. The wiring and associated components used for thewirina Installation shall be so selected and installed to promote ease ofmalnt~nance and highvehicle. The rellab<be determined in theas wI1l the expectedactivity approval.
reliability over the entire expected service life of thellty and maintainability goals for the wiring system willLogistic Support Analysts as delineated in MIL-STD-1388service life. These goals shall be subject to Procur~n9
3.5 Smoke and fire hazards. Wiring and wiring devices shall be selectedand installed In such a manner as to minimize the danger of smoke and firehazards. Adequate protective means, both physical and electrical, shall beemployed to provide reliability and safety commensurate with this requirement.
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3.6 Matertals. Materials used in the installation of wiring and equip-ment shall be suitable for the purpose and shall conform to such Government
.— specifications as are specifically applicable under the contract.
3.6.1 Metals. Metals used in the Installation of wiring shall becorroston resistant or shall be suitably protected to resist corrosion andelectrolytic action during normal service life. Finish and coating shall bein accordance with MIL-F-7179.
● 3.6.1.1 Dissimilar metals. Dlssimllar metals used shall conform to therequirements of MIL-STD-889. This standard establishes requirements for theselectlon and protection of dissimilar metal combinations and othersign!flcant corrosion behavtor factors.
3.6.2 Nonmetals. Nonmetals used, including plastlcs, fabrics andprotective finishes, shall be moisture and flame resistant, shall not supportfungus growth, shall not support combustion, and shall not be adverselyaffected by weathering, applicable fluids and propellants, temperature andambient condlt~ons encountered during operation of the vehicle. hlater~alsthat give off a minimum amount of noxious gases shall be selected. Nonmetalsmay be treated to conform to this requirement.
3.6.2.1 Insulating materials. Insulating materials shall have an arcresistance capability wh~ch will meet the circuit requirements.
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3.6.3 Seallngmaterlals. Only materials that are elastomeric andreversion resistant shall be used. Sealing materials required to seal wirejunctions and terminations shall be selected from MIL-S-8516, NIL-S-23586, orother material specifically approved by the procuring activity. MIL-S-8516 ISthe preferred material. The followlng temperature limlts apply (the upperlimlt Includes ambient plus temperature rise):
MIL-S-8516 -51°C (-60”F) to 93°C (200*F)MIL-S-23586 -65°C (-85°F) to232°C (450°F)
3.6.3.1 Process. Sealtng materials shall be applied In strictconformance with the manufacturer’s instructions. Overage material shall notbe used. The sealtng material shall be held In place by suitable forms duringthe cur!ng process.
3.7 Component select~on and installation. Components and wlrlng devicesshall be suitable for their application and selected and installed inaccordance with the requirements of this specif~cation. In addltlon,selectton and installation considerations shall be made relat~ve to vehicleoperation and servlclng environments to ensure that they are not subjected toconditions exceeding the limits specified in the applicable wiring componentspeclftcations.
3.7.1 Maintenance considerations. The maintainability of the wiringsystem shall be a prime consideration in the selection, design and installa-tion of harnesses, cable assemblies and wiring system components. All wiringshall be accessible, repairable and replaceable at the maintenance levelspeclfled by the procuring activity. Other specific requirements concerningmaintenance are specified in the appropriate paragraph on the subject.
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MIL-14-5088L
3.8 Hiring selection, Wirfng shall be of a type suitable for theapplication. Mire shall be selected so that the rated maximum conductortemperature Is not exceeded for any combination of electrical loadlng, ambienttemperature, and heating effects of bundles, conduit and other enclosures.Typical factors to be considered in the selection are voltage, current,ambient temperature, mechanical strength, abrasion, flexure and pressurealtltude requirements, and extreme environments such as Severe IifndandMotsture Problem (SHAI!P) areas or locations susceptible to significant fluidconcentrations. The wire shall be selected in accordance with Append~x A ofthis speclflcat!on. The wire selectlon shall take tnto account all require-ments of this specification and the followlng design considerations.
3.8.1 Elevated temperature deqradatton. Degradation of tin and stlverplated copper conductors wI1l occur If they are exposed to continuous opera-tion at elevated temperatures. These effects shall be taken \nto account Inthe selectton and application of wlrlng.
3.8.1.? Ttn plated conductors. Tin-copper intermetallics will formresultlng In an increase ~n conductor resistance. The increase js Inverse tos!ze, being up to 4 percent for the smallest gage.
3.8.1.2 Silver plated conductors. Degradation In the form of inter-strand bonding, silver migration, and ox#dation of the copper strands wI1loccur w~th continuous operation near rated temperature, resulting In 10SS offlexlblllty. Due to potential fire hazard, silver plated conductors shall notbe used In areas where they are sub~ect to contamination by ethylene glycolsolutlons. These condltioris should be considered In the aPPllcat~on of wirin9using these conductors.
3.8.1.3 Solderab!llty. Both tin plated and silver plated copperconductors will exhlblt poor solderabtllty after exposure to continuouselevated temperature. Compensating steps shall be Included in maintenanceprocedures for reterminatlon.
3.8.2 Aluminum wire. The use of aluminum wire requires procuringactivity approval. Aluminum wire shall be restricted to size 8 and larger.Alumlnum wire shall neither be directly attached to engine-mounted accessoriesnor \nstalled fn other areas of severe vlbratlon. It shall not be installedwhere frequent connections and disconnections are required. All installationsof aluminum wire shall be relatively permanent. Alum~num wire shall not beused where the length of run Is less than 3 feet, nor In areas where corrosivefumes exist. Aluminum wire shall be terminated only by terminationsspecifically approved for thfs application (see 3.20.2).
* 3.8.3 Deleted.
* 3.8.4 Coaxial cables. Coaxial cables shall be sution and shall be selected in accordance with 30,1.5 ofapplications above 400 MHz and in critical RF circuits,characteristics such as attenuation, capacitance, strut’
table for the applica-Appendlx A. Forcritical electricalural return loss,
-
environmental requirements, short leads and grounding shall be considered Indesign. MIL-HDBi(-216 shall be used as a guide in their selection. Coaxialcable operating in the Transverse Electromagnetic Mode (TEM) and coaxial cable
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MIL-W-5088L
with tubular metal outer surfaces shall be identified by a violet coloredmarker (1 inch nominal width) at intervals not greater than 24 inches of
.. length and within 6 Inches of termination. Transmlsslon llnes In accordancewith MIL-T-81490 need not be identlf!ed by colored markers if the colorrequirements of MIL-T-81490 have been met.
● 3.8.5 Harnesses. Harnesses shall be of either open or protecteddesign. Open harnesses are preferred for maintenance considerations.Harnesses may be designed to meet mechanical or shielding requirements. Theuse of protected harnesses shall be avoided unless wir~ng designconsiderations dictate their use and Is subject to the approval of theprocuring activ~ty. The design details of protected harnesses are alsosubject to the approval of the procuring activity.
3.8.6 Insulation compatlbtllty with sealing and servlcinq. Miringterminations in devices where the wiring must be sealed to provide anenvironment-resistant joint, shall have insulation compatible with the sealingfeature of the device. Elastomer grommets are generally qualified to seal onwires having smooth extruded insulations. Only one wire per gronunet hole ispermitted. Sealing on tape wrapped, braided, striped, or other than smoothcircular insulations shall be specifically tested for compatibility and shallbe subject to procuring activity approval, unless compatibility has beendemonstrated in the qualification of the terminating device. After installa-tion in the vehicle, the Integrity of the sealing features of all such devicesshall be intact, and able to perform their function. A device shall beconsidered as sealed if the outermost sealing feature (web) Is in full contactwith the device when visually inspected. The wiring shall be installed sothat transverse loads will not destroy the integrity of the sealing feature ofthe wire.
3.8.6.1 Wire diameter. The finished wire outside diameter shall bewithin the limits specified for the grommet specified in the appropriatecomponent specification and shall net exceed the capability of contactservicing tools to tnsert and release contacts.
* 3.8.6.2 Pottlncj seal on wire. The potting shall be bonded to the outer-most surface of the wire or cable in such a way to ensure an envlronmental-res!stant seal.
3.8.6.3 Insulation degradation. Wtrlng shall be handled, stripped andInstalled so as not to distort, roughen or damage the insulation on whichsealing is to be effected. Methods-of marking and identification shall beapplled so as not to provide a track for moisture entry. The impression lefton the insulation of shielded and twisted wires can also cause unacceptabledegradation of the insulation in relation to the elastomer seal. Cautionshall be used to avoid this condition.
3.8.7 Corona prevention. In the selection of wiring, considerationsshall be given to the prevention of corona discharge. Useful informationrelating to corona prevention is contained In 6.6 and should be reviewed priorto the selection of all wiring.
MIL-14-5088L
● 3.8.8 MInlmum wire size. This spectficatton permits the use of size 22wire as the minlmurn wire size for a{rr)lanes, helicopters and lighter-than-airvehicles, and prohtbits size 24 and s&ller”gages (see 3.8.8.3 For missiles). -
This restriction in aerospace vehicle applications Is due to maintenancedifficulties.
● 3.8.8.1 Current carrying capac~ty. A guideline for the continuouscurrent in each wire is shown in table 1. Table I assumes an ambient tempera-ture of 70”C, a harness or harness branch of 33 or more wires for sizes 26through 10, and 9 wires for size 8 and larger, carrying 20 percent or less ofrated harness or harness branch current and operating at an altitude of 60,000feet. The use of this tabulation shall not eliminate other requirements forwire selectlon. Data from figures 3, 4 and 5 may be used for determining wiresize for conditions other than those contained In table 1, The use of table Iand figures 3, 4 and 5 shall not eliminate other requirements for wireselectlon.
● 3.8.8. 1.1 Wlrlnq In harnesses. Table I current ratings for wires Inharnesses are based upon 33 or more wires for sizes 26 through 10 and 9 wiresfor stze 8 and larger operating at 60,000 feet altitude, and an ambienttemperature of 70”C. The total current carried by the harness shall not bemore than 20 percent of the numerical total obtained by adding the carryingcapacities taken from table I (or calculated from figures 3, 4 and 5 forambients, altitudes or harness loading factors differing from those assumed intable I), for the appropriate wire construction temperature rating for all thewires in the harness. For example, If a wire harness contains 33 size 20wires rated at 200°C, the numerical total Is 330 amperes, 20 percent of whichIs 66 amperes and the maximum allowable total current in the harness Is 66amperes and the maximum allowable current for any size 20 wire In the harnessis 10 amperes. A cable in a harness shall be treated as a number ofindividual wires equal to the number of conductors In the cable, excludlngshields.
In smaller harnesses, the allowable percentage of total current may beIncreased as the harness approaches the single wire configuration. Theharness ratings contained in table I were derived from figures 3, 4 and 5.Single wires In free alr ratings for copper wire were determined at T(200’C -70’C) (for alumlnum wire derate the free air rating of copper wtre by20 percent) and derated for (a) operation at 60,000 feet altitude, (b)harnesses of 33 wires or more, and (c) carrying 20 percent or less of ratedharness current. For conditions other than (a) through (c), refer to 6.7.
3.8.8. 1.2 Hire terminations. The continuous current ratings of table Iwere derived only for wire application, and cannot be applled directly toassociated wire termination devices (e.g., connector contacts, relays, circuitbreakers, switches). The current ratings are llmited by the design character-istics of the devtce. Care shall be taken to ensure that the continuouscurrent value chosen for a particular system circuit shall not create hotspots within any circuit element which leads to premature failure. Acceptabletemperature levels of circuit components shall be those defined by theparticular circuit component specification.
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MIL-l&5088L
* 3.8.8.2 Amb~ent temperature. The contractor shall ensure that themaximum ambient temperature that the wire bundles will be subjected to, plusthe temperature rtse due to the wire current loads, does not exceed themaximum conductor temperature rating found in Appendix A in tables A-I andA-II . Figures 3, 4 and 5 may be used to determine the appropriate currentloads when the following conditions are known: maximum ambient temperature,maximum conductor temperature, maximum altitude and the number of wires in abundle. See example in 6.7 for method of calculation.
● 3.8.8high tensi’wires.
3.8.8
3 Missile wiring application. For missiles only, use of size 24e strength copper alloy wire is permitted when bundled with other
4 Voltaqe drop. For power distribution circuits, the totalImpedance of supply and return paths shall be such that the voltage at theload equipment terminals is within the limits of MIL-STD-704.
3.8.9 Maintainability. Wire selectlon shall be affected by considera-tions of the types and frequency of maintenance action.
3.8.10 Nirincj selection for special applications. The general purposewires llsted in Appendix A do not perform equally In all applications. Thedetail characteristics of the specific wire’types shall be considered for thefollowing special applications.
● 3.8.10.1 Severe wind and moisture problems (SHAMP). Suitable wire typesin accordance with MIL-W-22759 are Dreferred for severe wind and moistureproblems (SWAMP) or both. Appllcat\ons include wheel wells, near wing flaps,wing folds and pylons.
3.8.10.2 Frequency flexure. Suitable w~re types selected fromMIL-N-22759 are preferred for areas that require repeated bending and flexingof the wiring.
3.8.10.3 Electromagnetic Interference (EMI) and ElectromagneticVulnerabll~ty (EMV) sensitive areas. MIL-C-8S485 Is preferred for use in EMIand EIOIsensltlve areas.
● 3.8.10.4 Thermocouple wlrlng. The followlng is required when usingthermocouple wires (see 6.8):
a. The use of thermocouple contacts is discouraged and should beused only If essential to meet system requirements, such asthermal gradient conditions. Crimp terminations are preferred.
b. TransitIon from thermocouple wires to copper wires are per-mitted with the environmental sealed connectors specified in3.14.1 or MIL-T-81714/12, type 2 in-line junction. Whengold-plated crimping pairs are used, precautions should betaken to ensure that the connector external temperature ambientand internal hotspot temperature is such that both the wire tocontact junctions for the thermocouple wires within theconnector are at the same temperature.
13
MIL-W-5088L
c. Spliclng of thermocouple wire shall be avoided. If splicing isnecessary (see 3.19) a MIL-T-81714/12, type 2 dual in-linejunction (splice) or MIL-T-81714/11 single in-line junctton(spllce) or MIL-S-81824/l spllce shall be used.
d. The connector, in-line junction, or spllce shall provide anenvironmental seal on the thermocouple w!re. The tensilecharacteristics of the contact)thermocouple combination shallbe equal to or greater than the tensile characteristics of thethermocouple wire.
* 3.9 Wire and cable identification. Each wire and cable shall be markedwith an identification code on the jacket or sleeving of the wire and cable.Hot stamp marking of wire and cable shall not be used upless other markingmethods are not compatible with wire or cable insulation.
3.9.1 Assignment of Identification code. The identification code forwiring shall be slqnificant or nonslqn!ficant In accordance with AoDendlx B orC, as-specified by-the procuring act~vity.
3.9.2 Deleted.
3.9.3 Marklnq,
hor8-1
3.9.3.1 The wire identification code shall be printed to readzontally from left to right or vertica’ ly from top to bottom. See figuresand B-2.
d3.9.3.2 The characters shall be legible and permahent and the method of
identification shall not impair the characteristics of the wiring.
● 3.9.3.3 Wiring shall be identified, throughout its length, at intervalsnot longer than 3 inches, as measured from the end of a mark to the begtnningof the next mark.
* 3.9.3.3.1 bihen it Is not possible to print d~rectly upon a wire orcable, an identification marker shall be used. The marker shall be aMIL-S-85848 or MIL-I-23053 heat-shrinkable sleeve; a MIL-S-23190 (MS3368Identification strap, see 3.11.3.8) or a MIL-I-3190 glass braid. The markershall not be used as an electrical insulating device. The markers shall beused as follows:
(NOTE: tIiIL-S-23190(MS3368) identification strap shall notbe used within cables, groups, harnesses or bundles, )
a. Cables upon which identification cannot be printed shall beidentified by printing the identification code (and individualwire color, where applicable) on a markqr placed external tothe outer covering at the term~natlng end or a common jacketshall be identified with printed markers at each end and atintervals not greater than 3 feet. Individual wires within acable shall be identified wlthln 3 inches from theirtermination.
14
MIL-14-5088L
b. Wires on which identification cannot be marked shall beidentified by printed markers at each end and at Intervals notgreater than 3 feet.
c. Wires for which the Identifications are reassigned afterinstallation In the aircraft may be reidentlfied by markers atthe termination of each wire segment. It is not necessary toreidentify such wires throughout their lengths.
3.9.3.3.2 Short wires and cables less than 6 Inches In length need notbe identified In the aircraft, but shall be completely Identified on thedrawing.
3.9.3.3.3 For developmental mdel aircraft, wiring identlf~cat~on may beprovided at junction and termination points only.
● 3.9.3.3.4 For protected harnesses and shielded, jacketed multi-conductorcables and when using nonsignificant wire identiflcatlon, color coding or itsalphanumeric equivalent may be interchanged within the same harness. Thealphanumeric equivalent of the color code shall be in accordance withMIL-STD-681. See paragraph 30.2.3.3 in Appendix C for an example of a}pha-numerlc equivalent of color coding.
3.9.4 Connector Identlficatlon. Connectors shall be identified tofacilitate mating. All plugs shall have a nonmetallic band affixed to thewire group, cable or harness. This band shall bear the P and J numberidentification of both the plug and the mating receptacle and the equ~pmentnomenclature. The band shall be w~thln 6 inches of the plug. All receptaclesshall be Ident!fled with a “J” number on both sides of the structure, adjacentto the receptacle. Receptacles, such as test and power, to which a matfngplug Is not attached, shall have, fn addition, the function of the receptacleidentified on the plug staleof the structure.
● 3.9.5 Hire s~ze color code system. kihenapproved by the procuringactivity, a wire size color code system as specified be?ow may be used tofacilitate control of the wire size. Hhen a wire size color code Is used, thewire Insulation shall be Identified with the appropriate color by one of thefollovdng methods. Only one method may be used for each vehicle.
a. Solid colored.
b. Dlstlnctlvely color banded.
c. Dlstlnctlvely striped.
MIL-ki-5088L
The wire s~ze color code is as follows:
● Size Color Size
26 Black (see 3.8.8) 10Blue (see 3.8.8) 8
:; Green 620 Red 418 White 216 Blue 114 Green o12 Yellow
3.10 Wlrlng installation. Design of the wiring Installatconform to the following precedence:
1st - Safety in fllght.
Co 1or
BrownRedBlueYellowRedWhiteBlue
on shall
2nd - The ease of maintenance, removal and replacement of thew!rlng.
3rd - Cost effective aircraft production.
Wlrlng shall be fabricated and installed so as to achieve the follow!ng:
a. Maximum rellabllfty.
b. Minimum Interference and coupling between systems.
c. Acsesslbillty for inspection and maintenance.
d. PreventIon of damage.
The ease of maintenance, removal and complete replacement of wire harnessesshall be given consideration In the wiring design.
3.10.1 Arranqementof wirlrq. Mrlng shall be arranged in groups andbundles to facilitate installation and maintenance. Indlvldual groups shallbe spot tied, and when these groups are bundled the spot ties shall not beremoved.
● 3.10.2 Bundle and group size. As a design objective, bundles and groupswithin clamps shall be no more than 2 inches in diameter. 141rlng to highdensity connectors may be run as a single group, provided all of the utrlng inthe group is pertinent to a single item, equipment or system.
3.10.2.1 Hlqh density harness size. The number of wires In high densityharnesses shall be llmlted only by efficient and good design. The use of wiresizes larger than 16 is discouraged unless there are also smaller wires in thesame harness.
16
MIL-H-5088L
3.10.3 Inspection and maintenance. In open wiring, groups shall beinstalled to permit replacement of the group without removal of the bundle.High density harnesses-shall be designed so that they are readily replaceablein sect~ons.
3.10.4 Facility for changes. Hhere required by the procuring activity,the wiring for specified systems shall be installed so as to be readilyremoved and wiring for new systems readily installed, when system changes areundertaken. The Installation of the wlrlng shall be such that only the equip-ment and wiring related to the change have to be disturbed.
* 3.10.5 Dead ending. Each undesignated wire end shall be dead ended withMS25274 caps or with Insulation in a manner acceptable to the procuringactivity. Dead ending shall take place within four to SIX inches ofconnectors o~ feedthrough bushings.
3.10.6 Routlnq. Nlrlng shall be routed to ensure reliability and tooffer protection from the following hazards:
a.
b.
c.
d.
e.
f.
9.
h.
t.
Chafing.
Use as handholds or as support for personal equipment.
Damage by personnel moving within the vehicle.
Damage by stowage or shifting of cargo.
Damage by battery or acid fumes and fluids.
Abrasion In wheel wells where exposed to rocks, ice, mud, etc.
Combat damage (to the maximum extent practicable).
Damage by moving parts.
Harsh environments such as SWAMP areas, high temperatures, orareas susceptible to slgnlflcant fluid or fume concentration.
3.10.7 Slack in wlrinq. In addltlon to slack provided for drip loops(3.11.8), slack shall also be provided to meet the requirements of 3.10.7.1through 3.10.7.5. Slack requirements shall be met on every production vehicleas well as experimental models. In production wire harness fabricat~on,provisions shall be incorporated into the harness design and fabricationprocess to ensure that the Installed harness meets these requirements withoutthe need for straining, forcing or modifying the harness.
3.10.7.1 Connector termination. When wtring is terminated In aconnector or terminal junction (excludlng RF connectors), a min~mum of 1 inchof slack for complete connector replacement shall be provided. This slackshall be between the connector and the second wjr~ng support clamp. TheI-Inch slack requirement shall be Interpreted to mean that with the connectorunmated and the first wiring support clamp loosened, the wiring will permit
17
MIL-W-5088L
the front end of the connector shell to extend 1 Inch beyond the pointnormally required to properly mate the connector. Slack for replacement ofpotted connectors shall be, as a minimum, the length of the potting plus one -inch.
3.10.7.2 Lug termination. At each end of a wire terminated by a lug, aminimum length of slack equal to twice the barrel length of the lug shall beprov!ded. For copper wire, size 2 and larger, and alum~num wire, size 4 andlarger, the mlnlmum length of slack shall be equal to one barrel length of thelug. The slack shall be In the vicinity of the lugment of the lug by maintenance personnel.
3.10.7.3 Strain prevention. The wlrlng instato prevent strain on wires, junctions and supports.
3.10.7.4 Free movement. The wiring installatment of shock and v!bration mounted equipment.
and available fo~ replace-
latlon shall be designed
on shall permit free move-
3.10.7.5 Wire shiftlnq. The wlrlng installation shall permit shiftingof wiring and equipment necessary to perform maintenance within the vehicle.
3.10.8 Electromagnetic compatibility. Hiring, including RF and antennacables, shall be routed so as to minimize electromagnetic Interference Inaccordance with MIL-E-6051.
3.10.9 Ignition. Flexlble metallic conduit of a type specificallyapproved by the procuring activity shall be used for magneto cable clrcults.Magneto ground cables (except the induction vibrator output cable) shall not _run through conduit or junction boxes containing other cables.
3.10.10 Compass deviation. Hiring and ground return paths shall beinstalled so as not to cause a compass devlatton exceeding that allowed byMIL-C-7762. Each wire carrying direct current in the area of compasses or thesens~tive pickup elements of compasses shall have a corresponding groundreturn wire twisted with it to neutralize the magnetic field.
3.10.11 Assembly. Lug terminated wire shall be Installed so as toreduce human error In assembly to adjacent terminals, Control of wire lengthfran tfe-down points, fanning strips, or different size stud holes arepreferred to dependence on code Identification.
3.10.12 Sensitive circuits. Sensitive circuits such as low-power levelsignal circuits shall be kept separate from other clrcults at junctions. Thisshall be accomplished by us~ttg separate connectors for the sensitive circuitsand by having at least one grounded terminal stud between sens!tive circuitsand other circuits on a cmn terminal board.
3.10.12.1 Electroexploslve subsystem wlrlnq. All circuits associatedwith electroexDlosive subsystems shall be routed in twisted shielded pairs.All c~rcults and junctions-shall be shielded without discontinuities or gapsIn the shleldlng. Wire shields shall be bonded around the circumference ofconnectors. All firing and control circuits associated with ordnance andexplosive subsystems shall be kept separate from other clrcults at junctions.
18
MIL-14-5088L
3.10.12.2 Electroexploslve subsystem wiring (for Air Force use). Allfiring and control circuits associated with ordnance and explosive subsystemscontained within junction boxes shall be coded with a red stripe in accordancewith FED-STD-595, color 11105.
3.10.13 Power systems. Electrically unprotected wiring of the primaryelectrical power system shall not be bundled or grouped with distributioncircuit wiring. Wiring from two or more sources shall not be in the samebundle or group to prevent a single damage from affecting more than one powersource.
3.10.14 Essential equipment. Hiring to each system which must operateto maintain fllght control of the vehicle under normal or emergency condtt~onsshall be separately routed from other wiring. Essential engine circuits shallhave their wiring so routed as to prevent damage to any circuit for one enginefrom affecting circuits of any other engine. Propeller circuits shall berouted separately from all other circuits.
3.10.15 Parallel circuits. The procuring activity may specify parallelcircuits for specific eauipment circuits and feeders to load centers. Wiringto equipment performing ”duplicate functions shall be run in separate bundlesto prevent damage to one system affecting the other. On airborne vehiclesthat employ dual or multiple redundant MIL-STD-1553 multiplex data bussystems, the redundant data bus cables shall be run in separate bundles androuted to prevent damage to one data bus cable affecting the operation of theredundant data bus or buses.
3.10.16 High-temperature equipment. Hiring shall be kept separate fromhigh-temperature equipment, such as resistors, exhaust stacks, heating ductsand de-icers, to prevent insulation deterloratton.
3.10.17 Nacelle wirinq. Hiring in an engine nacelle. from the point ofdisconnection for removal of the engine, shall be interchangeable between allengine installations having identical equipment and for the same series ofvehicle. A means for positively ascertaining clamp locations shall beprovided for wlrlng that must be unclamped for engine removal. This shall beaccomplished by permanently attaching clamp brackets to supporting parts.
3.10.18 Id\rlnq In bilges. Hiring in bilges shall be installed at least6 inches from the centerline of the aircraft except where attachment to equip-ment located in this area is required. Wire types susceptible to moisturedegradation shall not be used in bilges.
3.10.~9 Enqine mounted accessories. For direct attachment to enginenounted accessories, wire smaller than size 20 shall not be used. Ilhen size20 wires are used, they shall be high-strength alloy conductor and whenterminated in connectors, the connector shall provide support and preventstra!n on terminations. The wires shall be adequately grouped, spot tied andsupported.
3.10.20 Wheel well area!. Conduit or other protection shall be providedfor all wiring in wheel well areas. Flexible tubing, abrasion resistant tapeor braided outer jackets are acceptable for use where wiring is properly
-..
19
MIL++-50B8L
supported. Hhen tubingpoints and at the lowestshall be In accordance wdegradation shall not be
s used, drainage holes shall be provided at all trappoint between each set of support clamps. Tapingth 3.11.6. Hire types susceptible to moistureused In wheel well areas.
* 3.10.21 Sllde mounted equipment. When connecting wires or cable tosllde mounted equipment, sufficient wire or cable shall be provided to permitthe slide mounted equipment to slide in and out without damage, and permitunmating of the connectors.
3.11 Protection and support. Wiring shall be supported to meet thefollow~ng requ~rements:
a.
b.
c.
d.
e.
f.
9“
h.
1.
* 3.11.1
Prevent chafing as deftned in 6.3.8.
Secure wiring where routed through bulkheads and structuralmembers.
Properly group, support and route wlrlng in junction boxes,panels and bundles.
Prevent mechanical strain or work hardening that would tend tobreak the conductors and connections.
Prevent arcing or overheated wiring from causing damage tomechanical control cables, and associated moving equipment.
Facilitate reassembly to equipment terminal boards.
Prevent interference between wiring and other equipment.
Provide support for wiring to prevent excessive movement fnareas of high vlbratlon.
Dress the wiring at connectors and terminating devices In thedirection of the run without deformation of grommet seals.
Primary support. Primary support of wiring shall be provtded bymetal cushion clamps and plastic clamps, in accordance with HIL-S-23190,PlS21919 and !!S2528~, spaced at Intervals not to exceed 24 Inches. Inaddition, where wlr~ng Is routed through cutouts in any aircraft structure,clamps shall be installed as necessary to meet the protection and anti-chafingrequirements of this specification. Open wiring contained in troughs, ductsor conduits is exempt from this requirement. Rigid portions of harnessesshall be supported by clamps spaced at Intervals not to exceed 42 inches.Clamps for harnesses other than round shall be shaped to fit the contour ofthe harness and shall provide a snug fit. Plastic clamps shall not be used tosupport r!gld portions of harnesses. Plastic cable straps shall not be usedas primary supporting devices unless specifically approved by the procuringactivity and then they shall be subject to the restrictions invoked on plasticclamps. The primary support of wiring shall not be attached to adjacentwiring.
-
20
MIL-l&5088L
● 3.11 .1.1 Plastic clamps. Plastlc cable cjamps may be used on horizontalwiring runs provided every fourth clamp is a rubber cushion type. The firstclamp-immediately adjacent to wiring terminations for wire bundles greaterthan .125-inch diameter shall be a metal cushion clamp. The use of plasticcable clamps on other than horizontal wiring runs shall be avoided unless theinstallation is such that slack cannot accumulate between clamping points, andthen every
3.11.’which willaccordanceproper fit
3.11.’
fourth clamp shall be a rubber cushion type.
.2 Clamp size. Primary supporting devices shall be of a sizehold the wirtng In place without damaging the insu?atlon. Tape <with 3.11 .6,1 may be wrapped around groups In order to provide a
n
.3 Support at connectors. Idlrlng terminating In plugs shall besupported to dress the wiring in the direction of the run. This may beaccomplished by adapters, clamps, potting, wire guides, or other meansacceptable to the procuring activity.
● 3.11 .1.4 Metal cushion clamps. bihenmetal cushion clamps are used forprimary support, their physical properties must be compatible with theirinstallation environment. Cushion compounds are formulated to meet specificrequirements and may not be suitable In other applications.
● 3.11.2 Secondary support. Secondary support of wlrlng harnesses,bundles or groups (support between primary supports) shall be provided bydevices selected from 3.11.2.1 through 3.11.2.4.
3.11 .2.1 Tying tape in accordance with MIL-T-43435.
3.11 .2.2 Plastic cable straps In accordance with MXL-S-23190, installedwith tools in accordance with MS90387.
3.11 .2.3 Insulation tape in accordance with MIL-I-23594, Type I.
● 3.11 .2.4 Protective outer covering for a protected harness (see 6.3).
3.11.3 Limltattons on support.
3.11 .3.1 Continuous laclng shall not be used, except In panels andjunction boxes where this practice is optional.
3.11 .3.2 Deleted.
3.11 .3.3 The use of insulating sleeving for the protection of wiringshall be kept to a minimum. Provisions shall be included to eliminate thepossibility of entrapment of liquids.
3.11 .3.4 Deleted.
3.11 .3.5 Wires shall not be tied or fastened together in conduit orInsulating sleeving.
21
MXL-W-5088L
3.11 .3.6 Cable supports shall not restrict the wlrlng in such manner asto interfere with operation of shock mounts.
3.11 .3.7 Tape or cord shall not be used for primary support.
3.11 .3.8 Plastic cable straps shall not be used \n areas when therestrictions of 3.11 .3.8.1 through 3.11 .3.8.7 apply.
3.11 .3.8.1 Where the total temperature (ambient plus rise) exceeds 85°C(185*F).
3.11 .3.8.2 Hhere failure of the strap would permit movement of thewiring against parts which could damage the insulation or allow wiring tomechanical linkages.
3.11 .3.8.3 Hhere failure would permit the strap to fall into movingmechanical parts.
3.11 .3.8,4 In h~gh vibration areas.
foul
3.11 .3.8.5 In areas of severe wind and moisture problems (SWAMP), suchas wheel wells, near wing flags, wing folds, umblllcal or other areasspecified in the detail specification or contract.
3.11 .3.8.6 Where exposure to ultra-violet Ilght might exist, unless thestraps are resistant to such exposure.
3.11.3.8.7 To tie wires, cables, groups or harnesses wlthln bundles.
● 3.11.4 Anti-chafing provisions. Chafing shall be prevented by routingand clamping bundles to prevent contact with edges of equipment andstructure. Hhere physical separation of at least .375 inch cannot be main-tained, the edges shall be covered with suitable, protection strips orgrommets. Grommets and protection strips shall be securely fastened In placewith bonding or other suitable means. Metal braided or shielded harnessesshall have a protective external non-metallic covering except for fire zoneareas where it Is an opt~on.
3.11.5 RF coaxial cable support. Support of individual coaxial cablesand of bundles containing coaxial cables shall be subject to the followingadditional requirements.
a. 8oth primary and secondary support devices shall be tnstalledso as not to exert greater pressure on the cable than theminimum required to prevent sl~pping.
b. Pressure shall be evenly distributed around bundles containingcoaxial cables, or around the coaxial cable If individuallysupported.
c. The support devices shall not deform the cables so thatelectrical characteristics of the cables are degraded,
22
the
MIL-W-5088L
d.
3.11.6items may bement.
3.11 .6.’
Only tape as specified In 3.11 .2.1 shall be used for tyingbundles containing coaxial cables. Selection of the tape andinstallation shall meet the requirements of 3.11.5a, b and c,except that plastic straps In accordance w~th MIL-S-23190installed with tools in accordance with MS90387 may be used fortying bundles containing coaxial cables with solid dielec-trics. The tension adjustment on the MS90387 tool shall be setso that the requirement of 3.ll,5a is met.
General purpose ‘protectIon and suppo rt hardware. The followlngused for the protection and support of wiring and related equip-
Insulation tape. Insulation tape shall be of a type su!tablefor the a~plication, or as called out for the spec~fic use. Insulation tapeshall be used primarily as a filler under clamps and as secondary support.Nonadhesive tape may be used as a wraparound wiring for additional protection,such as in wheel wells. All tape shall have the ends tied or otherwisesuitably secured to prevent unwinding. Tape used for protection shall beapplted so that overlapping layers shed liquids, and shall be provided withdrafnage holes at all trap points, and at each low point between clamps.Plastic tapes that absorb moisture, or that have volattle plasticizers thatproduce chemical reactions with other wiring shall not be used.
3.11 .6.2 Insulation sleevinq. Unless preinsulated, splices and wireterminals shall be protected with insulating sleevtng. Insulating sleev~ngshall conform to MIL-I-7444, NIL-I-631 or MIL-I-3190. The sleeving shall-.cover the splices or terminal barrels and at least .500 inch of the adjacentwire insulation. Non-heat shrinkable sleeving shall be tied in placesecurely: Sleeving temperature ratings shall be compatible with the tempera-ture service requirements of the wire and splices or terminals.
3.11 .6.2.1 Insulating sleeving, heat shrinkable. Heat shrinkableinsulating sleeving shall conform to MIL-I-23053.
3.11 .6.3 Terminal nipples. MS25171 terminal nipples shall be used toprovide overall insulation and protection on terminal lugs and studs.
3.11 .6.4 Grommets. Grommets shall be In accordance with MS21266 orMS35489. MS21266 gronnnets shall be permanently bonded in place and shallprevent the wires from contacting the sides of the holes.
3.11 .6.4.1 Split grommets. The remaining opening In split grommetsshall be no wtder than .063 Inch. The splits shall be diagonal and placed inthe cutouts In such a manner that the wire pressure will be on the oppositeside from the spl~t.
● 3.11.7 Radius of bend measured to Inside surface.
a. Wire, cable and harness. For wiring groups, bundles orharnesses and single wires and cables individually routed andsupported, the rnlnlfnumbend radius shall be ten times the out-side diameter of the largest included wire or cable. At the
23
141L-bi-5088L
point where wiring breaks out from a group, harness or bundle,the minimum bend radius shall be ten times the diameter of thelargest Included wire or cable, provided the wtrlng is suitably -supported at the breakout point. If wires used as shieldterminators or jumpers are required to reverse direction In aharness, the minimum bend radius of the wire shall be threetimes the diameter at the point of reversal providing the wireIs adequately supported.
b. Protected harnesses. The minimum bend radius, as measured onthe Inside radius of a protected harness, shall be six timesits outer diameter. In no case shall the bend radius of aprotected harness be less than ten times the diameter of thelargest Included wire or cable.
c. Coaxial cables. The m!nimum radius of bend shall not adverselyaffect the characteristics of the cable. For flexlble typecoaxial cables, the radius of bend shall not be less than s~xtimes the outsjde diameter. For semt-rigid types, the radiusshall not be less than ten times the outside diameter.
d. These requirements also apply during shipping, handling andstorage.
3.11.8 Drip Iooe. Where wtring is dressed downward to a connector,terminal block, panel or junction box, in addition to the requirement of3.10.7.1, a trap or drip loop shall be provided in the wiring to preventfluids or condensate from runnfng into the above devices. Potted connectorsare exempt from this requirement.
3.11.9 Hiring near moving parts. Hiring attached to assemblies whererelative movement occurs (such as at hinges and rotating pieces, particularlycontrol sttcks, control wheels and columns, and flight control surfaces) shallbe installed or protected in such manner as to prevent deterioration of thewirfng by the relative movement of the assembly parts. This deter!orat!onincludes abrasion of one wire or cable upon another and excess twist!ng andbending. Bundles shall be installed to twist !nstead of bending acrosshinges. Cables in the vlcinlty of line replaceable units (LRUS) and weaponreplaceable assemblies (WAS) shall be protected against damage caused byflexing, pulling, abrasion and other effects of frequent reuwal and replace-ment of equipment.
3.11.10 Special protection. Power feeders, Including wires, cables andbusses shall be given particular mechanical protection such as in the formofextra Insulation, standoff mounting and separation. Bus centers shall belocated wlthln insulated enclosures, isolated in order to prevent a fault toground or phase-to-phase fault that would d!srupt the electrical powersystem. i41rlng installed in locatlons, such as bilges and on decks or floors,shall be so located or protected that they will not be damaged by maintenancepersonnel during normal maintenance or crew movement. Hiring installed Inlocations where fluids may be trapped and the wires and cables contaminated,shall be properly routed and protected against fluld damage.
24
MIL-M-5088L
3.11.11 Gas and fluid carrying l~nes and tubes. kJiring shall besuDoorted lndeDendent of and with the maximum practicable separation from allflu’id-carrying”lines, tubes and equipment. Wiring shall be routed above,rather than below l!quid carrying lines, tubes and equipment to preventcontamination or saturation of the wiring in the event of leakage. 14here thisrouting is not practicable, the wiring shall pass below the lines at an anglerather than parallel to the lines, Terminating devices shall not be placedunder any lines. Wiring shall not be attached to fluld carrying llnes, tubesand equipment unless they require electrical connections or their separationis less than two inches, In areas where separation is less than two Inches,the wiring shall be Installed tomaintatn positive separation of at least.500 inch. Examples: (a) separate the wir~ng from the ltne with a suitableseparation device, (b) attach the wiring to primary support(s) at the closestproxlmlty of the wiring to the line. ldhere lines and wirtng are installedsuch that they are separated by rigid nonmetallic conduit, metal conduit,ribs, webs, frames, channels, extrusions, stringers, or other suitablebarriers, the above minimum separation requirements do not apply.
3.11.12 Hiring through fuel tanks. Wiring should not be routed throughfuel tanks exceDt where there is no alternative. Hiring that must be routedthrough fuel tanks, but that is not part of the fuel ma~agement or controlwiring shall be routed through a dry access channel or passage so as topreclude contact of the wiring insulation and the fuel. The channel orpassage shall be of a size to facilitate the removal and repair of the wiringwithout removal of the fuel tank, and shall have a fluorocarbon liner whichwill preclude electrical contact.
3.11.13 Miring inside fuel tanks. Hiring that is essentfal to theoperation of fuel management or control system, may be routed inside fueltanks only if there is no alternative. Hiring that is Lsed In cirh!ts thatare capable of generating energy levels greater than 0.02 millijoules must beencased in a grounded metal conduit having a fluorocarbon liner. Hiring thatcomes in contact with fuel must have an insulation system which is compatiblewith the fuel and fuel vapor. Clamps and hardware used to attach wlrlnginside fuel tanks must also be compatible with the fuel and fuel vapor. Tietape, string, mechanical straps, or other items that could become loose andclog fuel filters shall not be used Inside fuel tanks.
3.11.14 GFAE equipment wirinq. GFAE equipments furnished with wiringand connectors which are excessive {n length shall not have the wiring lengthreduced. The excess .length shall be grouped and supported in a manner whichwill prevent damage to the wlrlng and possible fouling of moving parts.
3.12 Ground return. The electrical power source ground terminals shallbe connected to the primary metallic structure of the vehicle. The vehiclestructure shall serve as the ground return circuit unless system considera-tions require separate ground return wiring. Equipment that incorporates aground terminal shall be grounded by the shortest suitable ground wire.Equipment that is Internally grounded and that does not Incorporate a groundterminal shall be grounded by the shortest practicable ground wire if suitablegrounding is not provided by the equipment mounts, or if corrosion of thenmunts Is likely to occur. Ground return wiring shall not be connected tomagnesium. Bonding shall be in accordance with MIL-B-5087.
25
MIL-N-5088L
3.12.1 Shielded wire qroundlng. Unless otherwise speclfled by thedetail installat~on sDecificatlon for the equipment Involved, shielded wiresshall have the shields adequately grounded at each end. In clrcultsoperatlngbelow 50 Ktiz,shielded wires may have the shields grounded at one end only.In harness appl~cations, shtelds shall be terminated as close as practicableto the connectors, and specifically wlth~n the booted areas of breakoutterminations. Shields grounded through connector accessories shall begrounded only to connector accessories specifically designed for shieldterminations.
3.12.1.1 Shteld terndnations. MIL-S-83519 specifies the only devices tobe used in terminating shields.
● 3.12.2 kiultlple grounds. No more than four ground wires shall beconnected to a common ground stud. Ground module In accordance withMIL-T-81714 may be used for multiple grounds. No more than 16 ground w~resshall be connected In a ground module. Each ground for electrlc power sources(primary, secondary, conversion, emergency) shall be connected to separateground pojnts. Grounds for utilization equipment may be connected to a commonground point only when supplled from the same power source provided theseequipments do not perform duplicate or overlapping functions.
3.12.3 Insulated equipment boxes. Electrical equipment such as relaysmounted on insulated surfaces shall be Indlvldually connected to ground ratherthan serfes connected and then grounded by a single wire to a ground stud.
3.13 Conduit. Conduit may be used where necessary to protect wiring orto facilitate maintenance ~n inaccessible areas. Use of conduit requ~resprocuring activity approval unless speciftcal?y required elsewhere in thisspecification. Metalllc conduit may be used for shleldlng to meet therequirements of MIL-E-60S1, subject to approval by the procuring activity.
3.13.1 Riqld metal llc. Rigid metallic conduit shall be aluminumoraluminum alloy tubing.
3.13.2 Flexlble metallic. Flexible metallic conduit shall conform toHIL-C-6136 and shall be used only when rigid metalllc conduit Is tmpractlcal.
3.13.3 ?40nmetalllc. !lonmeta?llc condu!t shall be of a material satis-factory for the Installation environment. Polyvlnyl chloride shall not beused.
3.13.4 ~. In determining the diameter of conduit to be used, thewiring which is to be Installed theretn shall be bundled together and themaximum diameter measured. The maximum diameter shall not exceed 80 percentof the Internal diameter of the conduit. Maximum diameter wire and cablepermitted by applicable speclf~cations shall be used or allowed when takingthis measurement.
-
3.13.5 Fittings. Conduit fittings in accordance with AND1038O or otherapplicable drawings shall be used In conjunction with metallic conduit. Non-metallic conduit shall be term~nated with approved AN or MS fittings. Rigidmetallic and nonmetallic conduit used for wiring inaccessible areas need notbe terminated provided the conduit is suitably flared or rounded and sharpedges removed.
26
MIL-i&5088L
3.13.6 Conduit installation. Conduit shall be installed to withstandvibration and normal service abuse.
3.13.7 Suppor~. Conduit shall be supported so that strain on theferrules is relieved.
3.13.8 Drainaqe. Where practicable, metallic and nonmetallic conduitshall be installed so that fluids or condensate will not be trapped. Suitabledrainage holes shall be provided at the low points, except for magneto groundcable conduit and metallic flexible conduit. Tape (nonadhesive) used as awraparound wiring shall also have drainage holes at the low points. Burrsshall be removed from drainage holes In metallic conduit and from the conduitfittings.
3.13.9 Groundinq. Grounding ofaccordance with MIL-B-5087.
3.13.10 Ignition conduit. Theshall be separately routed to preventone engine.
metallic conduit shall be in
gnition ground conduit for each enginea single damage from affecting more than
● 3.?3.11 Radius of bends. The radius of bend of conduit shall allow thebend radius reau!rements of 3.11.7 to be met. Conduit and conduit fittinqbends shall not cause chafing of the wiring.
● 3.14 Connectors. Selection and use of electrical connectors andassociated hardware shall be in accordance with MIL-STD-1353. Connectors
-. shall be environment resisting. Except for hermetic connectors with only pintype design, connectors shall be selected so that contacts on the “live” or“hot” side of the connection are socket type rather than pin type to minimizepersonnel hazard and to prevent accidental shorting of live clrcutts when theconnector is unmated. When using special contacts such as thermocouple orcoaxtal, circular electrical connectors shall be specified on installationdrawings using the A and B suffix when applicable in the connector partnumber. The “A” designation without pins and the “B” designation withoutsockets, lnd~cate special applications for the connector.
● 3.14.1 Moistureproof connectors. Connectors shall be sealed against theingress of water and water vapor under all service conditions includingchanges in altitude, humidity and temperature. The connectors shall have aninterracial seal as well as seallng at wire ends. Environment resistingconnectors having wire sealing grommets are preferred; however, potting may beused where a grommet seal connector would not be suitable (see 3.14.8). Theoutside diameter of the wiring terminated at the connector that has a wiresealing grommet shall comply with the wire diameter range specified for thatconnector (see 3.8.6).
3.14.2 Contacts. Connectors using removable crimp contacts arepreferred to solder contact types. Contacts shall be in accordance withMIL-C-39029. Contractors may use automatic, semi-automatic or hand crimptools for production, provided contacts will give specified performance inaccordance with MIL-C-22520, when crimped with the applicable tool.
21
MIL-h&5088L
3.14.3 Fireproof and flrewall connectors. These connectors shall bethread-coupled. self-lockinq connectors with crimp contacts and corrosion-resistant steel shells. Hh~re It is necessary to”maintain electrical -
continuity for a limited time under continuous flame, both the receptacle andmating plug shall be fireproof. If only flame integrity Is necessalthe need for electrical continuity, only the receptacle needs to beproof. Ftreproof and firewall connectors shall meet the Class K, K“requirements of the applicable military specification.
y withoutfire-or KS
● 3.14.4 coaxial and trlaxial connectors. Coaxial and trlaxlal ‘connectorsshall be suitable for the application and shall be covered by milltary spec-ification. MIL-STD-1353 shall be used as a selectlon guide. Series N, C,BNC, TNS, SC, SMA, SMB and SMC shall be in accordance with MIL-C-39012.Category B connectors of this spectftcation shall be used only on originalequipment. When using Category B connectors, the contractor shall specify anequivalent field replaceable connector as defined on the latest issue ofMIL-C-39012 for replacement as a maintenance or repair item. Category Bconnectors are not recommended for maintenance or repair. Category E and Fconnectors of this specification shall be used for applications usingsemi-rigid coaxial cables. Pulse series connectors shall be in accordancewith MIL-C-3607, HN series with MIL-C-3643, LC series with MIL-C-3650, twinseries with MIL-C-3655, environment resisting series with MXL-C-25516, stripllne with MIL-C-83517, adapters with MIL-A-55339, and triaxial connectors withMIL-C-49142. Where connector parameters beyond the scope of the militaryspecification are required, nonstandard commercial types may be utiltzedprovlcled that they meet the general requirements of the applicable milltaryspeclficat!on and are approved by the procuring activity.
3.14.4.1 Coaxial rlqid lines. Coaxial rigid lines that employ airdielectric shall be provided with air passage bulkhead connectors and pressurefittfng connectors for purging and pressurization of the llnes.
A 3.14.5 Connector installation. Connectors shall be used to join cablesto cables or to equtpment when frequent disconnection is required to remove orservice equipment: c~onents or wtring. Adequate space shall be provtded formating and unmating connectors without the use of tools. At least 314 inchshall be provided around the coupling rings of circular connectors. Ctrcularconnectors, when installed with the axis in a horizontal direction, shall beposittoned so that the master keyway is located at the top. 14hen Installedwith the axis In a vertical direction and master keyway shall be locatedforward in relatlon to the vehicle. Connectors shall be located and Installedso that they will not provide hand holds or foot rests to operattng and main-tenance personnel, or be damaged by cargo and stored material. Both plug andreceptacle shall be visible for engagement and orientation of polarizingkey(s). Mated plugs shall not be strained by the attached wiring. Connectorsin pressurized structures shall preferably be installed with the flange on thehigh pressure side. All circular receptacles with mounting holes shall beinstalled with mounting screws In each hole. Ground power receptacles shallbe installed with the small contacts at the bottom (6 o’clock position).
● 3.14.5.1 In-llne connector installation. Except for coaxial and databus connectors, in-line connectors shall be Installed using primary support(see 3.11.1 and 6.3.13).
28
MIL-W-5088L
● 3.14.6 Locatfons with multiple connectors. Connectors used to provideseparation of or connections to multiple electric circuits in the sameIo&atlon shall be installed so that it will be impossible to mate the wrongconnector In another mating unit. It is preferred that wiring be routed andsupported such that an improper connection cannot be made. The order ofprecedence for making the connector selection for a multiple connectorlocation shall be as follows:
a. First, the connectors shall be different sizes or havedifferent insert arrangements.
b. Second, the connectors withhave alternate insert posit’
c. Third, if none of the aboveconnectors shall have color
the same insert arrangements shalons or keying positions.
requirements can be met, identlcacoded sleeves attached to the
wiring near the connector which identifies the associatedconnector mating half. In cases where one of the connectors ismounted, the connector shall be coded by a color identifier onthe adjacent structure.
3.14.6.1 Connector drainaqe. Receptacles shall be so positioned thatwhen unmated for maintenance operations, fluids and condensate will drain outof and not into the receptacle. Connectors installed external to the vehicleproper, such as In engine compartments, wheel wells, etc., shall be givenspecial attention to protect against entry of 011 and moisture into theconnector such as taping or sealing mated connectors and providing protectivecovers for receptacles and plugs which may be left unmated. Connectors shallnot be mounted or located in a position where they will support standing water.
3.14.7 Safety wlrinq. Non-self-locking threaded coupled connectorslocated in engine nacelles, areas of high vibration (excludtng connectors onshock-mounted equipment), and in areas which are normally inaccessible forperiodic maintenance Inspection, shall have the coupling nut safety-wired orotherwise mechanically locked to prevent opening of the connector due tovibration. When safety wiring Is required on electrical connectors orconnector accessories which use threaded coupling rings, or on plugs whichemploy screws or rtngs to fasten the individual parts of the plug together,they shall be safety-wired with 0.020 Inch diameter corrosion-resistant steelwire in accordance with MS33540.
3.14.8 Pottinq. Connectors that require potting shall be potted withMIL-S-8516 sealant for operating temperatures not exceeding 93°C (200”F).bihereoperating temperatures exceed 93°C but do not exceed 232°C (450”F),sealing compound in accordance with MIL-S-23586 may be used. Hhere resistanceto oil and fuel is required and temperatures do not exceed 125°C (275”F),k!IL-M-24041 molding and potting compound may be used. For higher tempera-tures, potting shall not be used unless specifically approved by the procuringactivity. If protective sleeving, identification sleeves, jacketing orbraiding is terminated at a potted connector, it shall not extend into thepotted material. Insulated sleeving shall not be used within the pottedmaterial of the connector. For Air Force procurement, all p0ttin9 Ofconnectors Is discouraged and requires specific application approval.
29
MIL-k&50881.
3.14.9 Spare contacts. i4hen crimp contact connectors are used, theunused contacts shall be installed. MS27488 or applicable sealing plugs shallbe inserted in unused grommet holes of environment resistant connectors. For -potted connectors, each spare contact shall have a p~gtall attached,consisting of a wire or the largest size that can be accommodated by thecontact and extends 5 to 7 inches beyond the potting material. The plgtallsshall be Identified and dead ended.
3.14.10 Solder type contacts. The soldering of contacts shall be inaccordance with MIL-STD-454, Requirement 5. When a brazing process is used,it shall be in accordance with MIL-13-7883.
3.14.11 Dust protection. Through production (except when uncovered forassembly operat~ons) unmated connectors shall be suitably covered. Plasticdust caps such as those conforming to MS90376, NAS813 and NAS820 may be usedfor this purpose.
3.14.11.1 Final assembly covers. Unmated connectors on final installedassembles. such as those intended for test. future or optional wlrin9 shallbe engaged’to approved vapor-tight covers such as dummy receptacles o; chainedprotective covers In accordance with MIL-STD-1353.
3.14.12 DUMMY receptacles. Dummy receptacles shall be provided withstowlnq unmated plugs or caps or protective covers when the related connectorsare no~ in operatioiial use.. The dummy receptacle shall be conspicuouslymarked and conveniently located to accmdate the unmated connector orprotective cover. The dummy receptacle shall conform to the requ~rements ofthe related connector specification.
3.14.13 Provision pluqs. Connector plugs that are for equipment to beInstalled later or for test purposes shall be secured by clamps, or to dummyreceptacles provided for that purpose, in order that the plugs cannot swing onwir~ng and cause damage to themselves, wlrlng, or adjacent equipment, or foulmechanical linkage.
● 3.14.14 Connector accessories. Circular electrical connectors shall bet)rovidedwith strafn relief accessories In accordance with MIL-C-85049.Accessories shall not be used to terminate ground wires or shields unless theaccessory was spec~fically desfgned to terminate ground wires or shields.Ground wires shall not be terminated to saddle clamp screws.
3.15 Deleted.
3.15.1 Deleted.
3.16 Deleted.
3.17 Junct!ons. An uninterrupted wire is generally preferable to ajunction. Only approved devices, such as permanent splices, feed-thru .bushings, headers, terminal blocks, terminal junction systems and connectors,shall be used for wire junctions. The need and choice of junctions shall bedetermined by consideration of reliability factors, maintenance factors andmanufacturing procedures, in that order of selection. Solderless junctionsare preferred. The use of solder junctions shall be kept to a minimum.
30
MIL-kl-5088L
3.17.1 Junction installations. Electrical junctions shall be installedso that they are adequate both mechanically and electrically. They shall notbe subject to mechanical strain or used to support Insulating mater~als,except for insulation on terminals and splices. Junctions shall not dependupon insulators under compression for maintaining the connection tightness.Circuit continuity shall not depend upon nonmetallic parts retaining originalshape when subjected to compression loading.
● 3.17.2 Preparation for crimp termination. Mires and cables, whenstripped for termination, shall not have more nicked or broken strands thanspecified in table II. 14hen the stripped portion of the conductor Is vls~bleIn the crimp contact inspection hole, no more than .031 ~nch of the conductorshall be exposed at the end of the barrel for size 12 Affiand smaller,.063 inch for size 10 and larger, when the conductor Is terminated. Thesedimensions shall be applicable for contacts, term~nal lugs and spllces. Forterminal lugs, the stripped portion of the conductor shall extend to a pointbeyond the open end of the crimp barrel, which will not Interfere with thestud, washer, nut or similar attachment device. For spllces, the strippedportion of the conductor shall be visible In the Inspection window.
3.17.3 Conductivity. The conductivity of each junction shall not beless than that of an equivalent length of wire equal in size to that beingjoined.
3.17.4 Spac~ng and creepage distance. Electrical junctions shall haveadequate spacing and creepage distance to prevent arcing and detrimentalleakage currents between circuits. Suitable insulating barrier material maybe used to provide necessary creepage distance.
3.17.5 Protection. Special attention shall be given to ensure thatelectrical junctions are adequately protected from damage or short circuitsresulting from nravement of personnel, cargo, shell cases, clips, and otherloose or stored materials. This protection may be provided by covering thejunctions, by installing them in junction boxes, by locating them In suchmanner that additional protection is not required, or by other meansacceptable to the procuring activity.
3.17.6 Exposed junctions. Exposed junctions and buses shall beprotected with insulating materials. Reusable devices are preferred to non-reusable material. Junctions and buses located within enclosed areas con-taining only electrical and electronic equipment are not considered asexposed. Compartments housing electrical and electronic equipment but whichare naturally adaptable as stowage areas or which are not protected againstoccasional debris, etc., shall not be considered as enclosed areas. Terminaljunctions located In wheel wells shall be protected against the effects ofwater thrown by the wheels.
3.17.7 Essential circuit junctions. Junctions in circuits that affectthe operational safety of the vehicle shall be Particularly ~rotected to
.
ensure a maximum degr~e of reliability. These junctions s~all be Individuallyencased with insulating material to insure electrical insulation and isolationfrom foreign material.
31
MIL-H-5088L
alumresu
3.17.8 Aluminum wire junc[ ions. Specianum wire and cable installation to guardt in excessive voltage drop and high res
ultimately lead to failure of the junction. Examples of-such conditions are
attention shall be given toagainst conditions that would
-
stance at junctions that may
improper installation of terminals-and washers, improper torsion (“torquing”)of nuts, and inadequate terminal contact areas.
3.i7.9 Accessibility. All junctions shall be accessible for inspectionand maintenance without r~qulrlng electrical, hydraulic, or other operationalpower for any vehicle system or equipment, This shall Include those junctionsthat are installed for manufacturing convenience.
3.17.10 Nonmetallic covers. Nonmetallic junction covers, such as fabricor plastlc, shall maintatn a high dielectric resistance and shall not absorbor be affected by applicable fluids. They shall be Installed In such a mannerthat mechanical movements are free from interference, that fasteners areunable to cause short circuits, and that proper drainage is provided. tlon-metall~c covers in proximity with high-temperature equipment, such asresistors, shall be capable of withstanding the maximum temperatureencountered without damage.
3.18 Junctton boxes. Junction boxes may be used to provide specialprotection for wire and cable junctions.
3.18.1 Junction box construction. Junction boxes may be made of metalor of nonmetallic material. Metallic junction boxes shall have theirinteriors coated with an insulating material to minimize the possibility ofgrounding faults. The inside of all junction boxes shall be white tofacilitate inspection and maintenance. Except for vapor tight boxes, drainageholes shall be provided, allowing drainage of the boxes with the vehicle onthe ground and in fllght, with wings, wheels, and surfaces both folded andextended, as applicable, Metal junction boxes shall be fabricated from ametal gage size sufficient to provide stiffness and rigidity, to adequatelysupport multiple attachments without flexlng or deforming under serviceconditions, and to provide proper support and alignment for hinged orremovable covers.
3.18.2 H~nqes. Nhen electrical or electronic equipment Is nwnted onjunction box covers, such covers shall be hinged in a manner to prevent damageto cables and equipment when the covers are opened and closed.
3.18.3 Junction boK identificat~on, Junction boxes shall be externallyIdentified to facilitate correlation of the box with the wiring diagrams.Vapor tight junction boKeS shall be externally labeled “Vapor-ttght.”
3.18.4 Junction box wiring. Hiring In junction boxes shall beadequately supported at convenient intervals to meet the following require-ments:
a. Provide neat and orderly arrangement of wiring.
b. Provide ease of inspection and maintenance.
32
MIL4J-5088L
c. Provide relief of \train on terminals.
d. Minimize possibility of faults.
e. Prevent vibration from damaging wiring or terminals.
3.19 Nire splices. Insulated in-line wire splices may be used toassemble subassemblies, to incorporate changes or to facilitate repairs andmaintenance.
3.19.1 Permanent splices. Permanent splices may be used to assemblesubassemblies, to incorporate changes or to facilitate repairs. Splices forcopper conductors shall be In accordance with MIL-T-7928 or MIL-S-81824. Forthe Navy, only MIL-S-81824 environment resistant spllces shall be used.Environment resistant sealed splices shall be used in areas of severe wind andmisture problems (S14AMP), such as wheel wells, near wing flaps, wing foldsand other areas speclfled in the detail speclflcatlon or contract. Splicesfor alumlnum conductors shall be in accordance with MIL-T-7099 and MS25439.
3.19.2 Quick disconnect splices. Quick disconnect splices designed fordisconnection without the use of tools shall not be used.
3.19.3 Terminal junction disconnect spllces. When splices are used forin-llne connections of two or more wires, where disconnect is required,disconnect spllces in accordance with MIL-T-81714/11 and 141L-T-81J14/12 shallbe used. Sealing plugs in accordance with MS27488 shall be Installed inunused grommet holes.
3.19.4 Splice restrictions. Splices are subject to the followingrestrictions:
*
a<
b,
c.
d.
e.
There shall not be more than one splice in any one wire segmentbetween any two connectors or other disconnect points, exceptas allowed by e, g and h, below.
Installation of splices in bundles shall not Increase the sizeof the bundle so as to prevent the bundle from fitting in itsdesignated space or cause congestion which will adverselyaff~ct maintenance,
Spl
Spldev
ces shall not be used to salvage scrap lengths of wire.
ces shall not be used within 12 inches of a terminationce, except for e, below.
Splices may be used within 12 Inches of a termination devicewhen attaching to the pigtail spare lead of a potted termina-tion device, or to”splice multiple wires to a single wire, orto adjust the wire sizes so that they are compatible with thecontact crimp barrel sizes.
..
33
MIL-W-5088L
f. Thesha
applicatiorl of splices shall be under design control and1 be authorized by engineering drawings.
~. Splices may be used to repair manufactured harnesses orinstalled wiring when approved by engineering.
h. (For Air Force use) Splices shall not be used on firing orcontrol circuits associated with ordnance or explosive sub-systems.
3.19.5 Splice areas. Splfces Installed for assembly of subassembliesshall be contained In splice areas and identified as such on all applicabledrawings. Splice areas shall be selected so that they are read~lyaccesslblefor maintenance and inspection including spllces contained in the center ofthe bundle.
3.20 Terminal luqs. 141re terminal lugs shall be used to connect wiringto terminal block studs or equipment terminal studs. No more than fourterminal lugs or three terminal lugs and a bus shall be connected to any onestud (total number of terminal lugs per stud includes a coamxm bus bar joiningadjacent studs. Four terminal lugs plus a common bus bar thus are notpermitted on one stud). 14henthe terminal lugs attached to a stud vary indiameter, the greatest diameter shall be placed on the bottom and smal?estdiameter on top. Terminal lugs shall be selected with a stud hole diameterwhich matches the diameter of the stud. Tightening terminal connections shallnot deform the terminal lugs or the studs. Terminal lugs shall be sopositioned that bending of the terminal lug is not required to remove thefasten~ng screw or nut, and movement of the terminal lugs will tend to tightenthe connection. ..
3.20.1 Copper terminal luqs. Solderless crimp style copper wireterminal lugs shall be used. Terminal lugs shall conform to MIL-T-7928.Spacers or washers are not permitted between the tongues of terminal lugs.
3.20.2 Alum~num terminal luqs. Aluminum terminal lugs conforming toNIL-T-7099 (MS25435, MS25436, MS25437 and 14S25438) shall be crimped toaluminum wire only. The tongue of the aluminum termtnal lugs or the totalnumber of tongues of aluminum terminal lugs when stacked, shall be sandwichedbetween two MS25440 flat washers when terminated on terminal studs. Spacersor washers are not permitted between the tongues of terminal lugs.
3.20.3 Class 2 terminal luqs. Class 2 terminal lugs conforming toMIL-T-7928 may be used for installation by contractors, provided that in suchinstallations Class 1 terminal lugs are adequate for replacement withoutrework of installation or terminal lugs. Class 2 terminal lugs shall be theInsulated type unless the conductor temperature exceeds 105°C, in which caseuninsulated terminal lugs shall be used. Parts lists shall indicate theappropriate Class 1 terminal lugs to be used for service replacement of anyClass 2 terminal lugs Installed.
3.21 Terminal boards and terminal junction modules. Terminal boards orterminal junction mdules shall be used for junctions of wiring requiringinfrequent disconnection or for joining two or more wires to a common point.
34
MIL-M-5088L
3.21.1 Terminal boards. Terminal boards shall be in accordance withMS27212 and shall be Installed with 14S18029 covers. Ammeter shunts shall notbe used as terminal boards.
* 3.21.2 Terminal junction modules. Terminal junction modules and theirmounting tracks and brackets shall be in accordance with 141L-T-81714.Terminal board mounting screw insulators shall be installed in accordance with)4s3373. Sealing plugs In accordance with MS27488 shall be installed in unusedgrommet holes.
* 3.21.3 Terminal board and terminal junction system identification. EachMS27212 terminal board shall be assigned an individual Item number, and thestuds for each board shall be assigned consecutive numbers or lettersbeglnnlng with 1 or A, to correlate wfth the wiring diagrams. For example,TB75-4 shall designate stud #4 of terminal board 75. Each term!nal junctiontrack, per NIL-T-81714, shall also be assigned an }ndlvldual TB number. Forexample, track #76 would be designated as TB76. Individual terminal junct!onmodules shall be identified by numbers or letters permanently applied to theindividual track as specified in NIL-T-81714. The identification of terminalboards, studs and tracks shall be of a permanent nature affixed to the vehicleand shall be so located that the information is readable with minimaldisturbance to wiring or equipment. Tracks shall be positioned so that themodule Identification reads left to right, or top to bottom. Removal of theboard or track shall leave the Identification intact.
3.22 Deleted.
—. 3.22.1 Deleted.
● 3.23 klorkmanshi~. Workmanship shall be In accordance with aerospacevehicle electrical wiring and equipment installation practices to ensuresafety, proper operation and service life. Details of workmanship shall besubject to the inspection and approval of the procuring activity.
3.23.1 Loose parts. Chips, scraps, excess hardware, tcols or otherunessential material that can cause damage to the electrical system byshorting terminals, abrading wiring or puncturing insulation, shall not beleft in the vehicle.
4. QUALITY ASSURANCE PROVISIONS
4.1 Responsiblllty for inspection. Unless otherwise specified In thecontract or purchase order, the contractor Is responsible for the performanceof all ~nspection requirements (examinations and tests) as specified herein.Except as otherwise specified in the contract or purchase order, the con-tractor may use his own or any other facilities suitable for the performanceof the inspection requirements specified herein, unless disapproved by theGovernment. The Government reserves the right to perform any of the inspec-tions set forth in this specification where such inspections are deemednecessary to ensure supplies and services conform to prescribed requirements.
35
MIL-14-5088L
4.2 General. The Inspection checks and tests required herein for wiringinstallation are classified as quallty conformance inspections.
4.3 Nlrinq mockup. 14hen specified in the contract, the contractor shallconduct a wiring mockup for inspection by the procuring activity, prior todelivery of the first vehicle and in time to permit needed changes. On thismockup, the contractor shall demonstrate typical wiring Installations andspecific wiring practices for which deviations are required. This mockup maybe conducted on a production vehicle.
4.4 Inspection of first vehicle. The wiring installation of the firstcomplete vehicle shall be Inspected at the contractor’s plant by the con-tractor under supervision of the procuring activity to determine conformanceto the requirements of this specification, and shall be subject to approval bythe procuring act!vlty.
4.5 Changes In wirlnq. Vehicles in which changes have been made in thewiring shall be inspected at the contractor’s plant by the contractor underthe supervision of the procuring activity to determine compliance with therequirements of this specification.
4.6 Indlvldual tests. Functional checks shall be conducted by thecontractor on each vehicle to ensure proper continuity of all electrical andelectronic circuits, and proper operation of all electrical and electronicequipment.
5. PACKAGING (not applicable)
6. NOTES
●(This section contains Information of a general or explanatory nature thatmay be helpful, but is not mandatory. )
6.1 Intended use. The wiring requirements covered by this specificationare Intended for use In the selection and installation of wlrlng and acces-sories for the interconnection of electr~cal and electronic equipment in aero-space vehicles. The requirements specified herefn are applicable to develop-ment, prototype, production, rework and modification wiring, on new orIn-service vehicles. All wiring that is completely internal to electrical andelectronic equipment, should be in accordance with the applicable equipmentspecifications rather than this specification.
6.2 Orderinq data. Specify the type of identification code inaccordance with Appendix B or C (see 3.9.1). Unless specified otherwise, theidentification code for the Navy shall be “significant” in accordance withAppendix B. When wlrlng data in accordance with DOD-STD-863 is required bycontract, nonsignificant wire identification in accordance with Appendix Cwill be spec~fied by that standard.
6.2.1 Contract data requirements. The selected data requirements insupport of this specification will be reflected in a Contract Data Require-ments List (DD Form 1423) attached to the request for proposal, invitation forbid, or the contract as appropriate.
36
MIL-W-5088L
6.3 Definitions.
6.3.1 Aircraft. An airplane, helicopter or lighter-than-air vehicle.
6.3.2 ~. A single metallic conductor of solid, stranded or tinselconstruction, designed to carry current in an electric circuit, but not havinga metallic covering, sheath or shield. For the purpose of this specification,“wire” refers to “insulated electric wire.”
● 6.3.3 Wire seqment. A length of wire that Is continuous and unbrokenbetween its two intended points of termination. A wire segment that has beenbroken and then repaired is still considered to be one wire segment.
6.3.4 Cable. Two or more Insulated conductors, solid or stranded,contained in a common covering, or two or more insulated conductors twisted ormolded together without common covering, or one insulated conductor with ametallic covering shield or outer conductor.
6.3.5 blirinq. Nit-es,cables, groups, harnesses and bundles, and theirterminations, associated hardware, and support, Installed in the vehicle.When used as a verb it is the act of fabricating and Installing these items inthe vehicle.
6.3.6 Wlrinq devices. Hiring devices are the accessory parts andmaterials which are used in the installation of wiring, such as terminals,connectors, junction boxes, conduit, clamps, Insulation and supports.
-. 6.3.7 Flammable. Capable of bursting Into flame when a spark or openflame Is passed sufficiently near, as with fume% and vapors from hot oils orvolatile combust~ble liquids, and with finely powdered, combustible solids.
6.3.8 Chafing. Repeated relative motion between wiring systemcomponents, or between a wiring system component and structure or equipment,which results In a rubbing action that causes deleterious wear.
● 6.3.9 Grou~. A number of wires and/or cables and their terminationssecured together within the structure of a bundle or harness. Groups nOr~llYcontain wi~e and/or cable pertaining to a single circuit or routed to a s’Itemof equipment.
● 6.3.?0 Harness. An assembly of any number of w!res, cables and/orgroups and their terminations which !s designed and fabricated so as to a’for installation and removal as a unit. A harness may be an open harnessprotected harness.
ngle
1Owor a
+ 6.3.10.1 Hlqh density harness. A protected harness designed to saveweight and space which has a majority of wire types selected from Appendix A,table A-II.
* 6.3.11 Bundle. Any number of harnesses or branches routed and supportedtogether along some distance within the aircraft.
37
MIL-H-5088L
6.3.12 Spot ties. Ties other than secondary support ties used toseparate a number of wires, cables, groups or harnesses within a bundle.
6.3.13 Primary support. Support provided for wiring that carries theweight of the wiring and secures It in the intended position.
-
6.3.14 Severe Wind and Moisture Problem (S14AMP)areas.wheel wells, wing folds and areas near wing flaps, and areasto extended weather conditions are considered SWAMP areas onvehicles.
h 6.3.include a
● 6.3.covering
Areas such asdirectly exposedaerospace
5 Open harness. An assembly of wires and/or cables that does notprotect~ve outer covering.
6 Protected harness. A harness that employs some overall outero provide additional mechanical protection for the wires and/or
cable contained therein. The added protection may consist of an overbraid,tape wrap, conduit or some other form of protection.
d 6.3.17 Branch. A section of harness that divides off and extends to apoint of termination.
● 6.3.18 Connector Pluq. The connector containing the coupllng ring oractive retention device of the mating pair.
● 6.3.19 Connector receptacle. The connector containing the staticretention device of the mating pair.
6.4 Installation of electrical and electronic equipment. The installa- -tion of electrical and electronic equipment Is covered by MIL-E-7080 andMIL-I-8700, respectively.
6.5 Technical manuals. Technical Manual NAVAIR 01-lA-505, USAF T.O.1-1A-14, and Army TM 55-1500-323-24, “Installation Practices for AircraftElectric and Electronic 141rlng,” contains useful information and guidance onaircraft wiring Installation techniques. Guidance on fabrication and instal-lation of R.F. cabling is contained In MIL-HDBK-216.
6.6 Corona prevention related information. In order to prevent ioniza-tion, also referred to as corona, or partial discharges between the outside ofan unsh~elded wire covering and grounded structural elements over which thewire passes, or between the Insulation and a braided shield, the wire coveringshould have adequate “equivalent Insulation thickness” for the conditions ofoperation. “HIre covering” means any combination of extruded or taped insula-tions and Insulating jackets. Ionization causing chemical and mechanicaldeterioration of the cover!ngs, is a source of radio frequency interference,and produces by-products which can corrode adjacent metallic components. ForAC operat!ng voltages not exceed~ng 240 volts RMS, any g~ven thickness offlaw-free insulation is adequate to support this voltage at any pressure ortemperature; thickness is dictated by mechanical requirements, For higher ACvoltages the “equivalent insulation thickness” can be found In figure 1.
38
MIL-W-5088L
Select the appropriate curve for the simultaneous minimum pressure and maximumtemperature of the ambient air to which the wire wI1l be exposed and read the“equivalent insulation thickness” corresponding to the operating RMS voltage.In aircraft and space applications due to partial or complete enclosure forpressurization and due to local heating, the ambient pressures and tempera-tures in the equipment may not correspond to those at the same altitudeoutside of the craft. Equipment operating pressures and temperatures shouldbe used in the determination. The “equivalent insulation thickness” isrelated to the wire covering and is shown in figure 2 where t~, t2, etc., arethe successive thicknesses and kl, k2, etc., are the respective relativedielectric constants of these same wire coverings. The value determined isindependent of power frequency up to at least several kilo- hertz. The valuesof figure 1 and figure 2 are based on the inception voltage (corona startingvoltage). In many Instances once ionization has started it does notextinguish unt~l the applied voltage is lowered to the corona extinctionvoltage, which may be as much as 20 percent lower. Thus, a factor of safetyshould be allowed so that a transient voltage will not initiate Ionlzatlonwhich will not disappear at the operating voltage. For DC, cables can be usedwithout ionization to a maximum voltage of 340 volts independent of the usualpractical range of wire covering thicknesses. Under certain conditions(notably at high ambient temperatures and/or high altitude) some wire typesmay not be free from corona at rated voltage.
● 6.7 Nlre current ratings. The wire current rating in 3.8.8. 1.1 is basedupon the curves of figures 3, 4 and 5. The following examples illustrate theprocedure for using these curves for applications other than 70°C and 33 wireharness for size 26 through 10 gauge, and 9 wire harness for size 8 and largeras referenced for table I values.-.
* 1. Assume a harness (open or protected) consisting of 10 size 20,200”C rated wires and 25 size 22, 200°C rated wires. It willbe installed in an area where the ambient temperature Is 60”Cand the vehicle is capable of operating at 60,000 feetaltitude. Circuit analysis reveals that 7 of the 35 wires inthe bundle (7/35 - 20 percent) will be carrying power currents.
a. Referring to the “single copper wire in free air” curvesin figure 3, determine the T of the wire to determinefree air ratings (for aluminum, derate these values by 20percent). Since the wire will be In an ambient of 60*Cand the wire is rated at 200”C, the T iS 200-60 =140”C. Following the 140”C T line on figure 3, thefree air rating of size 20 is 21.5 amps and the free airrating of size 22 is 16.2 amps.
b. Referring to the “bundle derating curves” in figure 4, the20 percent curve is selected since circuit analysisindicated that 20 percent or less of the wire in theharness would be carrying power currents. Find 35 (on theabscissa) since there are 35 wires in our bundle anddetermine a derating factor of .52 (on the ordinate) fromthe 20 percent curve.
39
MIL-W-5088L
c. Derate the size 22 free air rating of 16.2 amps by .52 toget 8.4 amps harness rating and the size 20 free airrating of 21.5 by .52 to get 11.2 amps harness rating,
-
d. Referring to the “altitude derating curve” of f~gure 5,look for 60,000 feet (on the abscissa) since that is thealtitude the vehicle wI1l be operating at the note thewire must be derated by a factor of ,79 (found on theordinate).
e. f)erate the s~ze 22 harness rating of 8.4 amps by .79 toget 6.6 amps and the size 20 harness rating of 11.2 ampsby .79 to get 8.8 amps.
f. To find the total harness capacity, multiply the totalnumber of size 22 wires by the derated capacity (25 x 6.6= 165.0 amperes) and add to that the number of size 20wires multiplied by the derated capacity (10 x 8.8 - 88amperes) and multiply the sum by the 20 percent harnesscapacity factor. Thus, the total harness capac!ty is(165.0 + 88.0) x 20 = 50.6 amperes.
9- It has been determined that the total harness currentshould not exceed 50.6 amps, no size 22 wire should carrymore than 6.6 amps and no size 20 wire should carry nnrethan 8.8 amps.
2. Assume a harness (open or protected) conslst!ng of 12, size 12, --200”C rated wires. The harness wtll be operated In an ambientof 25°C at sea level and 60”C at 20,000 feet altitude. All 12wires wtll be operated at thetr maximum capactty.
a. Referring to the “single wire In free air” curve In figure3, determine the T of the wire to determine free alrratings. Since the wire will be in an ambient of 25°C and60”C and is rated at 200”C the Ts are 200*C - 25*C-I75”C and ZOO*C - 60”C = 140°C. Following the 175°C andthe 140”C T lines on figure 3, the free air ratings ofsize 12 are 68 amps and 61 amps, respectively.
b. Referring to the “bundle deratlng curves” in figure 4, the100 percent curve !s selected because we know all 12 wireswill be carrying full load. Find 12 (on the abscissa)since there are 12 wires In the bundle and determine aderating factor of .43 (on the ordinate) from the 100percent curve.
, c. Derate the size 12 free alr ratings of 68 amps and 61 ampsby .43 to get 29.2 amps and 26.2 amps, respectively.
d. Referring to the “altitude deratlng curve” of figure 5,look for sea level and 20,000 feet (on the abscissa) sincethese are the conditions at which the load will becarried. The wire must be derated by a factor of 1.0 and.91, respectively.
40
MIL-14-5088L
e. Derate the size 12 bundle ratings of 29.2 amps at sealevel and 26.6 amps at 20,000 feet by 1.0 and .91,respectively, to obtain 29.2 amps and 23.8 amps.
f. The total bundle capacity at sea level and 25°C ambient is29.2 by 12 = 350.4 amps and at 20,000 feet at 60”C ambientis 23.8 x 12 = 285.6 amps. Each size 12 wire can carry29.2 amps at sea level, 25°C amb!ent or 23.8 amps at20,000 feet, 60”C ambient.
● 6.8 Thermocouples. A thermoelectric clrcult consists of two wirescom~osed of dissimilar metals permanently joined at both ends (thermocouple)and one thermocouple Is heated”to a diff~r~nt temperature than the other”. Thesignal from the heated thermocouple is a function of the temperature gradientof the thermocouples and the composition of the two metals.
6.9 Hiring d{agrams. Hiring diagrams when contractually required on theDO 1423 shall be prepared in accordance with 00D-STD-100, ANSI Y14.15, ANSIY32.16 and ANSI Y32.2.
6.9.1 Schematic diagrams (except for Atr Force use). Schematic diagrams(functional) for electrical wiring shall show each circuit and may be onmultiple sheets. The presentation of these circuits in a straight Itne(elementary) form is acceptable. Each electronic wiring diagram of an equip-ment or system shall be included on one sheet, if practicable.
6.9.2 Master dlaqrams (except for Air Force use). Master diagrams and=. wire data lists shall be \n accordance with MIL-M-81260 and DOD-STD-100. Each
system, such as AC power, DC power, exterior llghting and engine control shallbe presented on one sheet, If practicable, without undue crowding.
● 6.9.2.1 Terminal board and terminal module symbols (except for Air Force~. On the master interconnection diagrams, each terminal board stud symboland terminal module contact cavity symbol shall be identified to exactlycorrelate w~th that established In 3.21.1. The wiring diagram shall havecomplete representation for each terminal board, module-track assembly andwire connected thereto, Includlng information as to location of the board orassembly. Terminal boards and module-track assemblies shall be identified Inaccordance with the requirements of ANSI Y32.16.
* 6.10 International standardization agreement. Certain provisions (3.8,Appendix A and Appendix B) of this specification are the subject of inter-national standardization agreement ASCC 104/19, STANAG 3317 and STANAG 3347.When amendment, revision or cancellation of this specification Is proposedthat will affect or violate the international agreement concerned, thepreparing activity will take appropriate action through internationalstandardization channels, including departmental standardization offices, tochange the agreement or make other appropriate accommodations.
41
—
MIL-H-5088L
● 6.11 Subject term (keyword) l~stinq.
CablesCables, coaxialCircuitConduitConnectorsCurrentJunction boxesTerminalsWireHire, aluminumHire, copperHire, electr~cal
6.12 Changes from previous Issue. The margins of this specification aremarked with an asterisk to Indicate where changes from the previous issue weremade. This was done as a convenience only and the Government assumes noliability whatsoever for any Inaccuracies in these notations. Bidders andcontractors are cautioned to evaluate the requirements of this document basedon the entire content irrespective of the marginal notations and relationshipto the previous issue.
Custodians:Army - CRAir Force - 85
Review actlvitles:Alr Force - 11, 17, 19, 99
Preparing activity:Navy - AS
Project GDRQ-0080
.-
—
User activities:Army - ME, AV
.-
42
MIL-14-5088L
TABLE I.
Conductor WireMaterial Size
Copper or 8Copper 6Al loy 4
21
1/02/03/04/0
Aluminum 8642
1}02/03/04/0
Current rating of wires.
105”C
385068’95113128147172204
E547690102117138163
1So”c
5776103141166192222262310
456182113133153178209248
200°c
71
1U179210243285335395
.-
TABLE 11. Flaxlmum allowable nicked and broken strands (see 3.17.2).
Conductor Number of Strands Total Allowable NickedMaterial Per Conductor and Broken Strands
Copper or 2 nicked, none brokenCopper ;; 4 nicked, none brokenAlloy Above 37 6 nicked or broken
Aluminum All numbers of strands None nicked or broken
43
MIL-W-5088L
II
Xx%x% 000 0 0 0::Z0z 0
Omm.* ~gz: ~ s ? 2 :CORONA-START VOLTAGE (VOLTS RMS)
D
u
.
I&
44
MIL-W-5088L
INSULATION7HtCKNESSEs(MtLs)
lRlc CONSTANT
FIGURE 2. Equivalent insulation thickness of wire covering (see b.6).
45
— .—
MIL-W-5088L
N TEMPERATURE DIFFERENCE (WIRE RATINGMINUS THE AMBIENT = T IN C)
.C7
46
MIL-W-5088L
.
l=) m sTEMPERATURE DIFFERENCE (WIRE RATINC
MINUS THE AMBIENT = T IN C)
.
I
L
k
VI
.m
47
MIL-14-5088L
.
?--JLo
—
CURRENT DERATING FACTOR FORWIRES UNBUNDLES
48
MIL-W-5088L
...
--
CURRENT DERATING FACTOR
f’
00
0m
o
0u-l
5?
;
w>L:r. .
LD
K--r +.kJ.ad
L.Wm
v.a)
.
-gel+..- I-4u.
z.m-.
.(-)
.IL
0I--I
-.
49
f’-
..
THIS PAGE I NKNTIONALLY LEFT BLANK
.. ... , ,. ,
50
MIL-14-5088L
APPENDIX A
f
OPEN OR PROTECTED HARNESSES
10. SCOPE
10.1 scope. TtIisappendix governs the selection of electrtc wire andcable to be used for the interconnection of equipment tn aerospace vehicles.This Appendix is a mandatory part of the spectflcatlon. The Informationcontained herein Is intended for compliance.
20. APPLICABLE DOCUMENTS
20.1 Government documents.
20.1,1 Specifications, standards and handbooks. Unless otherwisespecified, the followlng speclflcatlons, standards and handbooks of the Issuelisted in that issue of-Standards (0001SS) specIficatlon to the extent
SPECIFICATIONS
MILITARY
MIL-C-17
MIL-N-22759
MIL-N-25038
MIL-C-27500
MIL-H-81044
the Department of Defense Index of Spectficatlons andfled in the solicitation form a part of this spec-specifled herein.
Cable, Radio Frequency, Flexible and Semi-Rig~d,General Specification for
Hire, Electric, Fluoropolymer-\nsulated, Copperor Copper Alloy
Wire, Electrical, High Temperature and FireResistant, General Spec!ftcation For
Cable, Power, Electrical and Cable SpecialPurpose. Electrical Shielded and Unshielded,General Specification For
Wire, Electric, Crosslinked Polyalkene, Cross-linked Alkane-lmlde Polymer or PolyaryleneInsulated, Copper or Copper Alloy
MIL-W-81381 Hire, Electric, Polyimide-insulated, Copper andCopper Alloy
MIL-T-81490 Transmission Lines, Transverse ElectromagneticMode
MIL-C-85485 Cable, Electric, Filter Line, Radio FrequencyAbsorptive
(Unless otherwise Indicated, copies of federal and military specifications,standards and handbooks are available from the Standardization Documents OrderDesk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.)
51
MIL-W-5088L
APPENDIX A/
30. REQUIREMENTS
30.1 Selection of wire and cable. Unless otherwise approved by theprocuring activity, only wires and cables conforming to one of the documentslisted In table A-I, table A-II, 30.1:3, 30.1.4, 30.1.5, 30.1.6, of thisAppendix shall be used for interconnection of electric and electronicequipment in aerospace vehtcles. The limitations and other select!on crtterlaof Section 3 of this specification shall also be imposed on the selectlon anduse of these w~res and cables. The contractor shall become familiar with allrequirements of this speclflcatlon before any wires and cables are selectedfor use.
30.1.1 Harness wlrinq. Hires shall be selected from table A-I.
h 30.1.2 Protected harnesses. Wires shall be selected from table A-II,but may also Include wires from table A-I. Any harness that uses Wireselect;d from table A-II shall have an outer cover!ng throughout ~ts lengthfor mechanical protection.
● 30.1.3 Use of MIL-H-81381 wire (for Air Force applications only).MIL-H-81381 wire shall be used only when justified to and approved by theresponsible program management office within the procuring actlvlty.
● 30.1.4 Cable. Cable shall be in accordance with MIL-C-27500. Onlyconstructions utllizlng basic wires In accordance with tables A-I and A-IIshall be used. Shielded unjacketed cables shall not be used.
,.30.1.5 Coaxial cable. Coaxial cable shall be in accordance with
MIL-C-17.
30.1.5.1 T.E.M. transmission lines. Transverse electromagnetic modetransmission lines shall be In accordance with MIL-T-81490.
30.1.6 Filter Ilne cable. Radio absorptive filter llne cable shall beIn accordance with ktIL-C-85485.
40. NOTES
-
40.1 Intended purpose. The purpose of this Appendix Is to present thecontractor with a working llst of approved documents to be used In theselection of wire and cable for aerospace vehicle wiring.
52
MIL-I+5088Lv
4
DocumentMIL-14-22759/l
MIL-W-22759/2
MIL-H-22759/3
‘“I
t--
MIL-H-22759/5
MIL-H-22759/6
Voltageratingmaximum)600
600
600
600
600
600
APPENDIX A,/
TABLE A-I. Open wlrinq appllcat!ons ~/.
Ratedwiretemper-ature (“C)200
260
260
200
200
260
InsulationTypeFluoropolymerInsulatedTFE and TFEcoated glass
FluoropolymerinsulatedTFE and TFEcoated glass
FluoropolymerinsulatedTFE-glass-TFE
FluoropolymerinsulatedTFE-glass-FEP
FluoropolymerInsulatedextruded TFE
Fluoropolymerinsulatedextruded TFE
ConductortypeSilver coatedcopper
Nickel coatedcopper
Nickel coatedcopper
Silver coatedcopper
Silver coatedcopper
Nickel coatedcopper
.
ApplicationApproved foruse inArmy, Navyand Air Forceapplications
Approved foruse InArmy, Navyand hir Forceapplications
Approved foruse InArmy, Navyand Air Forceappllcat!ons
Approved foruse inArmy, Navyand Alr Forceapplications
Approved foruse inArmy, Navyand Alr Forceapplications
Approved foruse !nArmy, Navyand Air Forceapplications
~/ For sealing capability of wire, see 3.8.6 and 3.14.I
--
53
DocumentMIL-b&22759/7
MIL-W-22759/8
MIL-H-22759/9
MIL-W-22759/1(
MIL-H-22759/1:
MIL-H-22759/1[
-.
MIL-W-5088L3
APPENDIX A/
TABLE A-I Open wiring applications. (Cont.)
Voltageratingmaximum)600
600
I000
1000
600
600
Ratedwiretemper-ature (“C)200
260
200
260
135
150
InsulationTypeFluoropolymertnsulatedextruded TFE
FluoropolymerInsulatedextruded TFE
FluoropolymerInsulatedextruded TFE
Fluoropolymerinsulatedextruded TFE
FluoropolymerInsulatedFEP PVF2
F]uoropo]Ymerinsulated-extrudedETFE
ConductorTypeSilver coatedcopper
Nickel coatedcopper
Silver coatedcopper
Nickel coatedcopper
Tin coatedcopper
Tln coatedcopper
ApplicationApproved foruse ~nArmy, Navyand Air Forceapplications
Approved foruse InArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Alr Forceapplications
Approved foruse inArmy, Navyand Alr Forceappl!cat!ons
Approved foruse InArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
w
54
MIL-H-5088L
APPENDIX Af’
.—TABLE A-I. Open wiring applications .(Cent.)
I Voltagerating
MIL-W-22759120 1000
MIL-1+22759/35 600
‘M-F
Rated~iretemper-ature (“C)150
200
260
T50
200
200
[nsulationtype~luoropolymerInsulated~xtrudedETFE
FluoropolymerinsulatedextrudedTFE
FluoropolymerInsulatedextrudedTFE
fluoropolymelinsulatedcrossllnkedinodlfled ETF
Fluorcpolymeinsulatedcrossllnkedmodified ETF
Fluoropolymeinsulatedcrosslinked
ConductortypeSilver coatedhigh strengthcopper alloy
Silver coatedhigh strengthcopper alloy
Nickel coatedhigh strengthcopper alloy
Tin coatedcopper
silver coatedhigh strengthcopper alloy
1-Nickel coatedcopper
ApplicationApproved foruse inArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
Approved foruse InArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Alr Forceapplications
Approved foruse !nArmy, Navyand Air Forceapplications
.-
55
——
MIL-H-5088L
APPENDIX AJ’
TABLE A-I. Open wirinq app licatlons.(Cent.)
T- 1 I Rated I I T--7
IVoltage wirerat!ng temper- Insulation Conductor
Uocument (maximum) ature (“C) tYPe type
!41L-ld-22759/42 600 200 Fluoropolwr Nickel coatedInsulated high strength
\ crosslinked copper alloy
I I I modified ETFEI
~IL-H-22759/43 600 200
MIL-H-2503813 600 260~1
MIL-W-81044I6” 600 150
MIL-H-81044/7 600 150
“MIL-w-81044/9 600 150
FluOroDolwer Silver coated
lnsulated- coppercrossl inkedmodified ETFE
See Seespec!f\catlon specification
sheet sheet
Crossl inked Silver coated
polyalkene high strengthcopper alloy
*
2/ For use In circuits where during a fire, maintenance of electricalIntegrity is required for a limlted time.
dJS6 In!rmy, Navyand Air Forceapplications
Approved foruse inArmy, NavYand Air ForceappllcatlOnS
Approved foruse inArmy, Navyand Air ForceapplicationsApproved foruse InArmy, Navyand Air ForceapplicationsApproved foruse inArmy, Navyand Air Forceappl!cat\OnSApproved foruse InArmy, Navyand Alr FOrce
~llcatlon L
56
MIL-W-5088L,
L
APPENDIX A;
TABLE A-I. Open wiring applications.(Cent. )
RatedVoltage w!rerating temper- Insulation Conductor
Document (maximum) ature (“C) type type ApplicationMIL-W-81044/10 600 150 Crossllnked Silver coated Approved for
polyalkene high strength for use Incopper alloy Army, Navy
and Air Forceapplications
MIL-W-81381/11 600 200 Fluorocarbon Silver coated Army: Not forpolyimide copper use
Navy: Not foruse
Alr Force: 31MIL-W-81381112 600 200 Fluorocarbon Nickel coated Army: Not for
polylmlde copper useNavy: Not for
useAir Force: 3/
MIL-H-81381/13 600 200 Fluorocarbon Silver coated Army: Not forpolyimide high strength use
copper alloy Navy: Not foruse
Air Force: 3/MIL-bl-81381/14 600 200 Fluorocarbon Nickel coated Army: Not for
polylmide high strength usecopper alloy Navy: Not for
useAir Force: 3/
MIL-K81381/22 600 150 Fluorocarbon Tin coated Army: Not forpolyimide copper use
Navy: Not foruse
Air Force: 3Ji
~/ MIL-W-81381 ts allowed In Alr Force applications only (See 30.1.3 for restrlctlons).
57
DocumentHIL-H-22759/11
MIL-H-22759/12
MIL-W-22759/14
MIL-H-22759/15
, MIL-H-22759/18
II
~ ML-H-22759115
I
I
—...— —
MIL-b&5088L
APPENDIX A/
TABLE A-II. Protected w!rlng appllcat~ons ~1.
Voltagerating(maximum)600
600
600
600
600
600
Ratedwiretemper-ature (*C)200
260
135
135
150
150
1/ For sealing capability of wire, sec.
Insulation Conductortype typeFluoropolymer Silver coatedInsulated copperextruded TFE
Fluoropolymer Nickel coatedinsulated copperextruded TFE
Fluoropolyme r Tln coatedinsulated copperFEP-PVF2
Fluoropolymer Silver platedinsulated high strengthFEP-PVF2 copper alloy
Fluoropolymer Tin coatedinsulated copperextrudedETFE
Fluoro~olYmerl Silver coatedlnsulated- high strengthextruded copper alloyETFE
.,
1.8.6 and 3.14.1.
ApplicationApproved foruit inArmy, Navyand Alr Forceappl~catlons
Approved foruse inArmy, Navyand Alr Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Alr Forceapplications
Approved foruse inArmy, Navyand Atr Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
-
w
58
r ..-
Document.PIIL-W-22759/22
‘–fiIL-M-22759/23
41L-H-22759133
‘141L-b4-22759/44
‘MIL-1+22759/45
MIL-H-5088L
APPENDIX A,f’
TABLE A-II. Protected wlrlng applications. (Cont.)
Voltageratingmaximum;600
600
600
600
600
600
Ratedwiretemper- Insulationatuie (“C) type200 Fluoropolymer
InsulatedextrudedTFE
--1-EETTFE
150 FluoropolymerInsulatedcrossl inkedmodlfled ETFE
crossl inkedmodified ETFE
I
200 Fluoropolymer!nsulated-crossl inkedmodified ETFE
1
ConductortypeSilver coatedhigh strengthcopper alloy
Nickel coatedh\gh strengthcopper alloy
Tin coatedcopper
Silver coatedhigh strengthcopper alloy
Silver coatedcopper
Nickel coatedcopper
ApplicationApproved foruse inAt-my, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
Approved foruse InArmy, Navyand Alr Forceapplications
Approved foruse inArmy, Navyand Air Forceapplications
59
—
KIIL-H-5088L
Documents
MIL-H-22759/46
MIL-W-81044/12
MIL-W-81044/13
MIL-H-81381/7
MIL-w-81381/B
MIL-1+81381/9
MIL-H-81381/1(
APPENDIX A i#I
TABLE A-II. Protected wiring applications. (Cont.)
Voltageratingmax 1mum
600
600
600
600
600
600
600
Ratedwiretemper-ature (°C)200
150
150
200
200
200
200
InsulationtypeFluoropolymerinsulatedcrosslinkedmodified ETFE
Crossllnkedpolyalkene
Crossl inkedpolyalkene
Fluorocarbonpolylmide
Fluorocarbonpolyimlde
Fluorocarbonpolyimide
Fluorocarbonpolylmide
ConductortypeNickel coatedhigh strengthcopper alloy
Tin coatedcopper
Silver coatedhigh strengthcopper alloy
Silver coatedcopper
Nickel coatedcopper
Silver coatedhigh strengthcopper alloy
Nickel coatedhigh strengthcopper
7A l~catlonApproved foruse InArmy, Navyand Alr Forceapplications
mAkhy, Navy,and Air ForceapplicationsArmy: Not for
useNavy: Not for
use
-.use
Navy: Not foruse I
A!r Force: 2/ IArmy: Not for
useNavy: Not for
use I-w-=+-iuse
Navy: Not foruse I
Air Force: 2/ [
2/ MIL4+-81381 Is allowed for use in Air Force applications only (See 30.1.3 for—restrictions).
60
MIL-H-5088L
APPENDIX A/
TABLE A-II. Protected wiring applications. (Cont.)
[
RatedVoltage wirerating temper- Insulation Conductor
,.Document (maximum) ature (“C) tYpe type Appllcat!on
MIL-H-81381117 600 200 Fluorocarbon Silver coated Army: Not for
polyimide copper useNavy: Not for
useAlr Force: 2/
~ MIL-H-81381/la 600 200 Fluorocarbon Nickel coated Army: Not for
polyimide copper useNavy: Not for
useAir Force: 2/
MIL-W-81381119 600 200 Fluorocarbon St]ver coated Army: Not fOr
polyimide high strength usecopper alloy Navy: Not for
useAlr Force: 2/
MIL-H-81381120 600 200 Fluorocarbon Nickel coated Army: Not for
polyimide high strength usecopper alloy Navy: Not fOr
useAir Force: 2/
MIL-W81381/2 1 600 150 Fluorocarbon Tin coated Army: Not for
polyimide copper useNavy: Not for
useAir Force: 2/
~/ NIL-H-81381 \s allowed for use in Air Force applications only (See 30.1.3 forrestrictions).
=--
MIL-W-50881
APPENDIX A
-
THIS PAGE INTENTIONALLY LEFT BLANK
62
MIL-W-5088L
APPENDIX B ,,
SIGNIFICANT HIRE IDENTIFICATION/
(See 3.9.1)
10. SCOPE
10.1 Scope. This appendix establishes the procedure for assigning theIdentiflcatlon codes for each Individual wire and harness within the scope ofthis speclflcatlon when the type of identlflcatlon code is specified as“significant” in accordance with 3.9.1 and 6.2. The w!re identification is“sign!flcant” in that it Indicates the function of the circuit. ThisIdentlflcation shall be for use in wlrlng data and for physical identificationof Installed wiring. This Appendix is a mandatory part of the specification.The Information contained herein is intended for compliance.
20. APPLICABLE DOCUMENTS
20.1 Government documents.
● 20.1.1 Specifications, standards and handbooks. The followlngspecifications, standards, and handbooks form a part of this document to theextent specified herein. Unless otherwise specified, the issues of thesedocuments are those listed in the issue of the Department of Defense Index ofSpecifications and Standards (DODISS) and the supplement thereto, cited in thesolicitation.
STANDARDS
MILITARY
MIL-STD-196 Joint Electronics Type Destgnatlon System
(Unless otherwise indicated, copies of federal and military specificat~ons,standards and handbooks are available from the Standardization Documents OrderDesk, Bldg. 4D, 700 Robblns Avenue, Philadelphia, pA 19~11-5094.)
30. REQUIREMENTS
30.1 Assignment responsibility. The contractor (installing activity)shall assign the identification code for circuit functions except those listedunder R, S, T and Y in Table B-I. The equipment contractor shall assign theidentification code in accordance with the equipment specification for equip-ments fall!ng under categories R, S, T and Y.
30.2 Hiring identification code. The wiring identification code shallbe in accordance with the pattern illustrated in Figure B-1 or B-2 asapplicable, and as follows:
30.3 Unit number. Hhere two or more identical Items of equipment areinstalled in the same vehicle, the unit numbers “1,” “2,” “3,” “4,” etc.. maYbe prefixed to differentiate between wires when it Is desired that the equip-ment have the same basic identification. To facilitate interchangeabilityrequirements, identical wiring located in left and right wings, nacelles, andmajor Interchangeable structural assemblies may have identical identificationand the unit number is not required.
63
I
MIL-14-5088L
APPENDIX B
.30.4 Circuit function letter. The circuit function Iette is used toLi_cientifythe circuit function specified In Table B-I. Mhere a ire Is used
for more than one circuit function, the circuit function letter of thatcircuitwhich Is functionally predominant shall apply. hlhenfunctional predominanceis questionable, the circuit funct~on letter for the wire having the lowestwire number shall be used.
30.5 Hire number. The wire number consisting of one or more d!gits isused to differentiate between wires In the circuit. A different number shallbe used for wire not having a common terminal or connection.
30.5.1 Wires with the same clrcult function having a common terminalconnection or junctionletters. .
30.5.2 Numbers 2(procur!ng activity to
30.5.3 Beginningeach wire In numerical
30.6 Hire segmen
shall have the same wire number but different segment
00 to 4999, inclusive, shall be reserved for use by thedentify wires installed by service modifications.
with the lowest number, a number shall be assigned tosequence, as far as practicable.
letter. A wire seament is a conductor between twoterminals or connections. - The wire segmen~ letter is used to differentiatebetween conductor segments In a particular circuit. A different letter $hal~be used for wire segments having a cmn terminal or connection. Hire seg-ments shall be lettered In alphabetical sequence and the letter “A” shouldicientlfythe first segment of each clrcult starting at the power source. If acircuit contains only one wire segment, the wire segment shall be marked “A.”The letters “I” and “O” shall not be used as segment letters. Double letters“AA,n “AB,” “AC,” etc., shall be used when more than 24 segments arerequired. Two permanently spliced wires do not require separate segmentletters if the splice Is used for modlflcatlon or repair.
30.7 Hire size number. The wire size number ts used to identify thesize Of the wfre or cable. For coaxial cables and thermocouple wires, thewire size number shall not be Included. For thermocouple wires, a dash (-)shall be used In lieu of the wire size number.
30.8 Ground, phase or thermocouple letter(s).
30.8.1 Unless otherwise specified by the procuring activity, groundcable letter “N” shall be used as a suffix to the wire identification code toIdentify any wiring that completes the circuit to the ground network. Suchwlrlng shall be capable of being connected to the ground network of the atr-craft electrical system without causing malfunctioning of any circuit.Critical and sensitive electronic systems which have Interconnecting “ground”leads, but only one segment actually grounded to the structure shall beidentified with the “N” suffix.
30.8.2 Phase letter “A,” “B” or “C” shall be used as a suffix on thewire Identlflcat!on code to ldent{fy the phase of wires that are in thethree-phase power distribution wtring of AC systems. The phase sequence shallbe “A-B-C.” The letters “A,” “B” and “C” shall indicate the phase sequencecorresponding to “T1,” “T2” and “T3,” ~4spectlvely. For grounded delta
MIL-14-5088L
APPENDIX B $
systems, “T2” shall be considered as corresponding to the groun ed phase.(Examples of wire identification coding, ?as applied to AC powerw iring, areillustrated by Figure B-3.)
30.8.3 Phase letter “V” shall be used as a suffix on the identificationcode to identify the ungrounded wire that is in a single-phase system.
30.8.4applicable.may be used:
For thermocouple wire, the followtng suffixes shall be used asWhere space considerations dictate, the two letter suffixes shown
CHROM - Chromel - CRALML - Alumel - ALIRON - Iron FECONST - Constantan - CNCOP - Copper - CU
● 30.9 Electromagnetic Compatibility (EMC) identification. Hhen EMCcategory number identification is used, it shall be accomplished by markingapplicable category number at the end of each significant-wire code. Categorynumber definition shall be as specifically approved by the procuring activity.
& 30.9.1 Alternate methods for EMC identification. Alternate methods suchas identification sleeving, color codes or other methods may be used for EMCcategory identification when approved by procuring activity.
30.10 Aluminum wire. For alum~num wire, ALUMINUM or ALUM shall be added-.as a suffix to the wire identification code.
30.11 Spare contacts. Hires attached to spare contacts of connectorsshall be identified by the contact designation.
30.12 Harnesses. Each harness shall be identified by the letter “W” anda distinct suffix. Example: H-1, W-2, W-3, H-4, etc.
30.13 Code for type designated equipment. For equipment type designatedin accordance with MIL-STD-?96, the wire identification code shall be derivedutilizing that portion of the rnllitary type designation (AN nomenclature)following the /, but excludlng the hyphen and any suffix letters. The blockof wire numbers for each equipment shall start wtth 1 and continue for as manynumbers as are needed to Identify all wires. For example, wires of anAN/APS-45 would be identified APS45-1A20 --- APS45-975C22; wires of theAN/ARC-52A would be ARC52-1A22 --- ARC52-999C22; and the 14X94would be theMX94-IA20 --- MX94-62D20.
65
MIL-U-5088L
APPENDIX B
THIS PAGE INTENTIONALLY LE17 BLANK
.
66
.—
MIL-M-5088L
APPENDIX B
.—
.
CircuitFunction Letter
A
B
c
D
F
G
TABLE B-I. Circuit function letters.(See 30.1, 30.4 of Appendix B)
/
Circuit
~rmament
~hotographlc -
;ontrol Surface
Instrument (other thanflight or engineinstruments)
Engine Instrument
Fltght Instrument
Landing Gear MingFoldlng
Examples
Stores Management SystemMissiles/RocketsGunChemical
CameraCamera DoorsCamera Heating
AutopilotFlight ControlWing SweepTrim ControlAirbrakesHydraulic System
Position IndicatorPressure GaugeTemperature GaugeClock
Temperature GaugePressure GaugeQuantity MeterFlow MeterTachometerPower IndicatorNozzle Indicator
Gyroscopic InstrumentAttitude IndicatorCompassHead Up DisplayAltitude
Extension and RetractionBrak~ngLockingSteeringAnti-SkidArrestor HookUtilities Hydraulics
--
67
—.—
CircuitFunction Letter
H
I
J
K
L
M
N
o
P
—
MIL-14-5088L
APPENDIX B
TABLE B-I. Circuit function letters (contl~ued).
Circuit
HeatingVentilating andDe-icing
~
HeatingDe-icingCabin conditioningGalleyEquipment Bay Cooling
In order to avoid confusion with the numeral one, the letter“I” shall not be used for clrcult or cable Identlflcatlon.
Ignition
Engine Control
Ltghtlng {Illumination)
Miscellaneous(Electrical)
Unassigned
Engine IgnitionJet-Assisted Take-Off
Vent and FlapPropeller ControlCarburetorSuperchargingPower ControlNozzle ControlThrust ReverserEngine Starting
InternalExternal
Windshield Wiper & SprayDcx3rsHoist and WinchPosition (Seat & Pedal)Auxiliary Power UnitEmergency Power UnitCigarette Lighter
In order to avoid confusion with the numeral zero, theletter “O” shall not be used for circuit or cableiclentificatlon.
DC Power GenerationDistributionBatteryRectifierExternal Power
-
68
--
CircuitFunction Letter
Q
R
s
T
u
MIL-M-5088L
APPENDIX B
TABLE B-I. Clrcult function letters (condlnued).
Circuit
Fuel and Oil
Radio (Navigational andCommunication)
Radar (Pulse Technique)
Special Electronics
Miscellaneous (Electronic)
Examples
ValvesPumpsRefueling/Defue lingTransferDump
Instrument LandingHomingLiai sonMarker BeaconVHF RadioUHF RadioHF RadioIntercommunicationDirection Flndlng
Radar AltimeterInterceptionGun Aim!ngMappingNavigationBomb AimingSearchRecognition (IFF)Terrain Following
Active Electronic CounterInertial NavigationTelevisionMeasuresReconnaissanceComputerWeapon AimingChaff DispensingInfra-Red
Electronic wiring for which the11~,11$[s)lor “T” Identification
is not applicable shall beassigned the circuit functionletter “U,” An example wouldbe common leads to electronicequipments and systems, inter-connection wiring, such asantenna or power circuitscommon to more than oneequipment.
69
MIL-M-5088L
APPENDIX B
TABLE B-I. Circuit functton letters (continuqti).
Circuit -Function Letter Circuit Examples
v Both DC power cables and DC control cables for AC systemsshall be identified by the circuit function letter “V.”
H
x
Y
Warning and Emergency Ball-Out Alarm(except those listed Oxygen Indicatorunder other circuit Passenger S~gnfunctions) Central/Master 14arning
AC Power GenerationDistribution .External Power
Armament SpecialEquipment (exceptthose listed underclrcult function “A”)
L-_z Experimental C!rcuits. 14hen flight test and experimental
research wiring Is Installed, the appropriate CircuitFunction Letter shall be used, preceded by the letter “Z.”When any such clrcult has been adopted and becomes part of astandard Installation, the letter “Z” shall be removed.
70
MIL-k&5088L
APPENDIX BALTERNATE
iI METHODI
02 P 215A 4 N ALUMu
-1--IIII
II
/I1I—— ———— ——-— ———— -.
SUFFIX
GROUND, PHASE, OR THERMOCOUPLE LETTER
WIRE SIZE NUMBER
WIRE SEGMENT LETTER
WIRE NUMBER
CIRCUIT FUNCTION LETTER
UNIT
Applies ti allcircuit functions except
NUMBER
type designated equipment.
FIGURE B-1 . Example of wire Identification coding.(See 3.9.3.1, 30.2)
%.
,
IIII II II—-— ----- ----- ----
PHASE, OR TH
-
2P!2’II
5A4NALuM
ALTERNATEMETHOD
R
ERMOCOUPLE LETTERc
KWIRE SIZE NUMBER
WIRE SEGMENT LETTER
wtRE NUMBER
EQUIPMENT IDENTIFICATION
uNIT NUMBER
2
4.b
BApplies to t~’pe designated equipment.
1210
FIGURE B-2. Example of wire identification cod~.LN
(See 3.9.3.1, 30.2)
71
T1
MIL-W-5088L
APPENDIX B
~x2A20’—
T, ~ ,6’,,, -—1,(a) Slt4GLEPHASE SYSTEM
PHASE SEQUENCE
1=
X34A14A ~
TI=T2=T3 T1
T,
I
T6X17A14N —.11
T3 ~ X5A14B ~
L
)
T3 12~ x29*1K .—o
(b) THREE - PHASE “Y*’ SYSTEM
PHASE SEQUENCE ‘17A16A~
T1- 72- T3T6
13 X65A16N—I II
X2ZA16C ~
(c)THREE- PHASE DELTA SYSTEM
(FOR INVERTIZRSHAVIXG CONNECTORSWITII PHASE ROTATIOX C-B-A AT
THIZ PINS, THE CORRESPONDING TIZRhIINAL DESIGNATIONS zIRE Tl - T2 - T3
AND T13tZ \VIRE IDENTIFICATION PIIASIZ LETTERS SIiOULD BE CONSISTENTWITH FIGURE (C) ABOVE. )
FIGURE B-3. Examples of wire identification as applied to ac power wlr~.(See 30.8.2)
—-.
72
MIL-W-5088L
APPENDIX C
NON-SIGNIFICANTHIRE IDENTIFICATION ~(See 3.9.1)
10. SCOPE
10.? Scope. This appendix establishes the procedure for assigning theindividual codes for each wire, cable and harness wtthiri the scope of thisspecification when the type of ~dentlflcation code Is specified as“non-significant” In accordance with 3.9.1 and 6.2.” The wire identificationis “non-significant” in that it does not Ind!cate the function of thecircuit. This identification shall be for use in wiring data and for physicalIdentification of installed wiring. This appendix Is a mandatory part of thespecification. The information contained herein is intended for compliance.
20. APPLICABLE DOCUMENTS This section is not applicable to thisappendix.
30. REQUIREMENTS
30.1 Harness identification. Each harness shall be identified by theclass letter “N” followed by a distinct wire harness number identifier of notmore than four digits.
30.2 Wire identification, Each wire shall be assigned a uniquealpha-numeric identification (wire number) to distinguish It from all otherwires In the aerospace vehicle. Each wire number shall Include the wireharness identification, a wire identifier, a wire gage number and whereapplicable, special coding for wire color, thermocouple wire and shields.
Example:
The wire number willw 192 - 06 - 22 xx read “H192-06-22XX”
(a) (b) (f) (c) (f) (d) (e)
(a) Hire harness class letter.(b) Hire harness number identifier (maximum of 4 digits, see 30.1).(c) Hire identifier (maxlmumof 4 dlglts, see 30.2.1).(d) Hire gage number (see 30.2.2).(e) Special coding (see 30.2.3).(f) Hyphen separation.
30.2.1 Hire identifier. The wire Identifier shall distinguish each wirefrom all others within a given harness. Harness to harness continuity of thewire identifier is a requirement for wires joined by splices. Harness toharness continuity of the wire identifier is not a requirement for all otherwires but should be considered as a design objective. The wire identifiershall not exceed four digits.
30.2. 1.1 Hire identifiers 900 to 999 and 9000 to 9999 inclusive, shallbe researched for use by the procuring activity to identify wires installed byservice modifications.
73
MIL-I+5088L
APPENDIX C
30.2.2 Hire qage number. The wire gage number ~dentlfte~’ the wireSize. For coaxial cables and thermocouple wires, the wire gagd may be omitted .-from the wire Identification.
30.2
30.2codes sha’
3 Special coding.
3.1 Thermocouple ulre. For thermocouple wire, the following letter1 be used as applicable:
Chrome 1 CRAlumel ALIron FEConstantan - CNCopper Cu
Example: H192-645-CR
30.2.3.2 Color-coded cable. Jacketed, shielded and/or twisted conductorcable consisting of 2 or more wires which are color coded by single strips orbands or by solld colors shall be assigned the same wire Identifier. Thecolor of each conductor shall be identified by using the two letter code shownbelow followlng the wire gauge number.
LetterColor
LetterCode Color Cod e
Black BK Blue BLBrown BR Violet VTRed RD Gray GYOrange OR Hhite HHYellow YE Pink PKGreen GN
See the example In 30.2. 3.3 for a shielded, tri-conductor, color-coded cable.
30.2.3.3 Shields. Shielded cable having ccxnmon wire Identifiersass~gned In accordance with 30.2.3.2 shall be assigned the same number as theconductor(s). Shields over complete harnesses or over groupsdifferent wire Identifiers assigned In accordance with 30.2.1assigned separate wire identifiers. The suffix “SH” shall fo’“wire-identifier.”
a. Example of a shield over wires separately iden’accordance with 30.2.1:
N192-019-Z2W192-020-22N192-600-SH
of wires havingshall below the
ified in
74
MIL-N-5088L
APPENDIX C
b. Example of a shielded s!ngle conductor: /
bi201-019-22W201-019-SH
c. Example of a shielded, color-coded tri–conductor:
W201-363-22 RD14201-362-22 BL14201-362-22 YEW201-362-SH
30.2.3.4 Aluminum wire. For alumlnum wire, “ALUM” (if total number ofdigits exceeds 15, “AM” shall be used) shall be added as a suffix to the wireidentification code.
75
FIIL-W-5088L
APPENDIX C
.
THIS PAGE INTENTIONALLY LEFT BLANK
MIL-W-5088L
1’
Accessibility ......................................................Accessories
Connector ........................................................Engine mounted ...................................................
AluminumTerminals ........................................................Hire .............................................................Wire junctions ...................................................
Amb~ent temperature ................................................Anti-chafl ngprovislons ............................................Arrangement ofwlrlng ..............................................Assembly ...........................................................Bundle and group size ..............................................Cables
Coaxial ..........................................................Caps, dust .........................................................Circuits
Parallel .........................................................Sensitive ........................................................
Clamp size .........................................................Coaxial
Cables ...........................................................Cable support ....................................................Connectors ........Selection .........
CodeAssignment of !dentHire and cable iden
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ficatlon .....................................ification ....................................
Hire size color code .............................................Commonality ........................................................Compass deviation ...0.... ..........................................Component selection and installation ...............................Conduit ............................................................
Flttlngs .........................................................Flexlble metallic ................................................Installation .....................................................Ignition .........................................................Nonmetallic .................4....................................Radius of bends ..................................................Rigid metalllc ...................................................Size .............................................................
Conductivity .......................................................Connectors ........................$................................
Accessories ......................................................Coaxial ..$.......................................................Fireproof and firebal l..... .......................................Identification ...................................................Installation ................$....................................Molstureproof ....................................................Triaxial .........................................................
77
Paragraph
3.17.9
3.14.143.10.19
3.20.23.8.23.17.83.8.8.23.11.43.10.13.10.113.10.2
3.8.43.14.11
3.10.153.10.123.11.1.2
3.8.43.11.s3.14.430.1.5,Appendix A
3.9.13.93.9.53.3.43.10.103.73.133.13.53.13.23.13.63.13.103.13.33.13.113.13.13.13.43.17.33.143.14.143.14.43.14.33.9.43.14.53.14.13.14.4
MIL-14-5088L
INDEX (continued)
Contacts ...........................................................Solder ...........................................................Spare ............................................................
Contractor’ s specification. ........................................Copper terminals ...................................................Corona prevention ..................................................Corona prevention related information ..............................Current carrying capacity ..........................................Current ratings, wire..... .........................................Cushion clamps .....................................................Data requirements, contract ........................................Dead end!ng ........................................................Definitions ........................................................Diagrams
Master ...........................................................Schematic ........................................................Wiring ...........................................................
Dissimilar metals ..................................................Drainage ...........................................................
Conduit ..........................................................Connector .......................................................
Drip loop ..........................................................Dummy receptacles ..................................................Electromagnetic compatibility ......................................
Engine mounted accessories .........................................Equipment
Essential ........................................................Gas and fluldllnes ..............................................GFAE wiring ......................................................High temperature .................................................Installation, electrical and electronic ..........................Insulated boxes ..................................................
GFAE aircraft equipment ............................................GFAEequipment wiring ..............................................Gromnets ...........................................................Ground return ......................................................Grounding ..........................................................Harnesses ..........................................................Hlghdensit yharnesssize ..........................................High-temperatureequlpment .........................................Hinges .............................................................Ignition .........................................................4.
Conduit .........................................................Individual tests ...................................................Inspection and maintenance .........................................Of first vehicle ................................................
Install ationdetai lsforwlri ng ....................................InstallatInstallatInsulated
on of electronicon of connectorsequipment boxes
and electronic equipment ..................................................................................................
Paragraph
3.14.23.14.103.14.93.3.33.20.13.8.76.63.8.8.16.73.11 .1.46.2.13.10.56.3
6.9.26.9.16.93.6.1.13.13.83.13.83.14.6.13.11.83.14.123.10.8,30.9 ApP.B3.10.19
3.10.143.11.113.11.143.10.166.43.12.33.3.53.11.143.11 ,6.43.123.13.!?3.8.53.10.2.13.10.163.18.23.10.93.13.104.63.10.34.43.106.43.14.53.12.3
78
MIL44-5088L
INDEX (continued)
Insulating materials .....Insulation tape ..........Insulation sleeving ......International standardlzatJunction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .on agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boxes ............................................................Box construction .................................................Box identification ...............................................Boxwirlng .......................................................Installation .....................................................
Junctions ..........................................................Alumlnum wire ....................................................Essential circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exposed ..........................................................Llmltations on support .............................................Loose parts ........................................................Ma!ntainabl lity ....................................................Manuals, Technical .................................................Harking ............................................................Master diagrams ....................................................Materials ..........................................................Metals .............................................................M~nimum wire size ..................................................
+. Missile wiring .....................................................Modification .......................................................Molstureproof connectors ...........................................Multiple grounds ...................................................Nacelle w~rlng .....................................................Nonmetal llc covers .................................................Nonmetals ..........................................................Parallel circuits ..................................................Plastic cable straps ...............................................Plastic clamps .....................................................Potting ............................................................Power systems ......................................................Preparation for termination ........................................Primary support ....................................................Protection and support .............................................Provision plugs ....................................................Rad!usOf bend (wire or cable) ..........................................Of bends (conduit) ...............................................
Routing wiring ....-..................,.............................Safety wiring ......................................................Schematic diagrams .................................................Sealing materials ..................................................Secondary support ..................................................Selection of parts and materials ...................................Sensitive circuits ................................................OService llfe .......................................................Shield terminations ................................................
79
Paragraph
3.6.2.13.11 .6.13.11 .6.26.10
3.183.18.13.18.33.18.43.17.13.173.17.83.17.73.17.63.11.33.23.13.8.96.53.9.36.9.23.63.6.13.8.83.8.8.33.3.63.14.13.12.23.10.173.17.103.6.23.10.153.11.2.23.11.1.13.14.83.]0.133.17.23.11.13.113.14.13
3.11.73.13.113.10.63.14.76.9.13.6.33.11.23.33.10.123.43.12.1.1
MIL-W-5088L
INDEX (continued)
Shielded wire grounding ............................................Slack in wiring ....................................................Smoke and fire hazards .............................................Solder type contacts ........Spacing and creepage distanceSpare contacts ..............Special protection ..........Splices .....................Standardlzatlon, lnternationa’
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ------ ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .agreement ...........................
Support at connectors ..........1...................................SWAMP applications .................................................Terminals ..........................................................
Aluminum .........................................................Copper ...........................................................
Terminal boards ....................................................Terminal n~pples ...................................................Terminations, shield ...............................................Thermocouple wiring ................................................Triaxial connectors ................................................Itagedrop .......................................................reAluminum .........................................................Alum! numw!re junctions ..........................................Arrangement of ...................................................Current ratings ..................................................Minimum size .....................................................Rad!us of bend ...................................................Selection for special application ................................Shielded grounding ...............................................Size color code system... ........................................
Wire and cable identification ......................................Hiring .................,.....-...............--..........-...-.....
Changes ..........................................................Diagrams .........................................................Fuel tanks, through ..............................................Fuel tanks, inside ...............................................In bilges ........................................................Filssile ..........................................................Mockup ...........................................................Nacel le ..........................................................Near moving parts ................................................Protection and support ...........................................Routing ..........................................................Safety ...........................................................Selection ........................................................Slack ............................................................Special protection ...............................................Temperature degradation. .........................................Thermocouple .....................................................
Hheel well areas .................................................Wiring selection ................................................. .Workman ship ...........-. ...........................................
80
3.12.13.10.73.53.14.103.17.43.14.93.11.103.196.103.11 .1.33.8.10.13.203.20.23.20.13.213.11 .6.33.12.1.13.8.10.43.14.43.8.8.4
3.8.23.17.83.10.16.73.8.83.11.73.8.103.12.13.9.5
::;.54.56.93.11.123.11.133.10.183.8.8.34.33.10.173.11.93.113.10.63.14.73.83.10.73.11.103.8.’:.:.’
3;83.23
0.420
-
MIL-H-5088L
REFERENCED DOCUMENTS INDEX I
DOCUMENT NO.
MIL-C-17MIL-I-631MIL-I-3190MIL-C-3607MIL-C-3650MIL-C-3643MIL-C-3655MIL-B-5087MIL-E-6051MIL-C-6136MIL-E-7080MIL-T-7099MIL-F-7179MIL-I-7444MIL-C-7762MIL-B-7883MIL-T-7928MIL-S-8516MIL-I-8700MIL-C-22520MIL-C-22759
MIL-I-23053MIL-S-23190MIL-S-23586MIL-I-23594MIL-M-24041MIL-C-25038MIL-C-25516MIL-C-26637MIL-C-27500MIL-C-39012MIL-C-39029MIL-T-43435MIL-C-49142MIL-A-55339MIL-W-81044MIL-M-81260MIL-H-81381MIL-T-81490MIL-T-81714MIL-T-81714/11MIL-T-81714/12MIL-S-81824MIL-C-83517MIL-S-83519MIL-C-85049MIL-C-85485MIL-S-85848FED-STD-595DOD-STD-1OO
PARAGRAPH
30.1.4, Appendix A3.11 .6.23.11.6.2, 3.9.3.3.13.14.43.14.43.14.43.14.43.12, 3.13.93.10.8, 3.133.13.26.43.19.1, 3.20.23.6.13.11 .6.23.10.103.14.103.19.1, 3.20.1, 3.20.33.6.3, 3.14.86.43.14.2Tables A-I & A-II,Appendix A, 3.8.10.1, 3.8.10.23.9.3.3.1, 3. 11.6.2.13.9.3.3.1, 3.11.2.2, 3.11.1, 3.11.5d3.6.3, 3.14.83.11 .2.33.14.8Table A-I, Appendix A3.14.43.14.430.1.4, Appendix A3.14.43.14.23.11 .2.13.14.43.14.4Tables A-I & A-II, Appendix A6.9,2Tables A-I & A-II, Appendix A30.1.5,1, Appendix A, 3.8.43.12.2, 3.21.2, 3.21.33.8.10.4, 3.19.33.8.10.4, 3.19.33.8.10.4, 3.19.13.14.43.12.1.13.14.143.8.10.3, 30.1.6, Appendix A3.9.3.3.13.10. 12.26.9, 6.9.2
81
MIL-M-5088L
REFERENCED DOCUMENTS INDEX I
DOCUMENT NO.
MIL-STD-196141L-STD-454NIL-STD-681MIL-STD-704DOO-STD-863MIL-STD-889MIL-STD-970MIL-STD-1353MIL-STD-1388MIL-STD-1553/4S3368!4s3373MS 18029MS21266MS21919MS25171MS25274MS25281MS25435MS25436t4S25437MS25438)4S25439?4S25440MS27212MS27488MS33540MS35489MS90376MS90387AND10380NAS813NAS820MIL-HDBK-216ANSI Y14.15ANSI Y32.2ANSI Y32.16ASCC 104/19STANAG 3317STANAG 3347ARMY TM 55-1500-323-24NAVAIR 01-lA-505USAF T.O. 1-1A-14
PARAGRAPH
30.13, Appendix B3.14.103.9.3.3.43.8.8.46.23.6.1.13.33.14, 3.14.4, 3.14. 11.13.43.10.153.9.3.3.13.21.23.21.13.11 .6.43.11.13.11.6.3, 3.163.10.53.11.13.20.23.20.23.20.23.20.23.19.13.20.23.21.1, 3.21.33.21.2, 3.19.3, 3.14.93.14.73.11 .6.43.14.113.11 .2.23.13.53,14.113.14.113.8.4, 3.14.4, 6.56.96.96.9, 6.9.2.16.106.106.106.56.56.5
82
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