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Electrical Wire and Cable Engineering Design Handbook

Electrical, Instrumentation, Electronic Design and Engineering

Electrical Wire and Cable, Engineering Design Handbook
International Telephone and Telegraph Corporation Wire and Cable Division
295 pages

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Preface

This Engineering Design Handbook, Electrical Wire and Cable, contains basic information and fundamental data in the design, usage, and development of wire and cable used in Army materiel and systems. The handbook contains a wide variety of useful information and quantitative facts as well as authoritative references helpful in the design, development, usage, and maintenance, of wires and cables used in modern Army electronic and electrical systems. The information contained herein will enable the systems engineer, technician, buying agency, and user, to meet the tactical and technical needs of the Armed Forces.

The highly technical nature of today's Army, together with the demands placed upon it, have greatly enhanced the need for a wire and cable handbook of this scope. Information which has been amassed through wide experiences of both manufacturer and user has been systematically recorded so as to expedite the search for the necessary technical data.

The objective of this handbook is to provide a practical guide to correct design of equipment to meet the exacting transmission requirements of the many and varied aspects of today's electronic and electrical systems. The designer who considers the proper technology of wire and cable design can alleviate many problems in proper transmission and installation techniques; whereas, the designer who ignores this technology can and does greatly multiply the problems.

This handbook contains information on the structure, application, usage, and installation of most of the wires and cables utilized by the Army. Also included are a glossary of terms; a listing of equations for quick reference; and an appendix which presents the applicable Military Specifications, Standards, and Publications.

TOC

LIST OF ILLUSTRATIONS
LIST OF TABLES
LIST OF EQUATIONS - QUICK REFERENCE.
PREFACE
CHAPTER 1 CONDUCTORS
Material Elements
Copper (ETP and OFHC)
Copper (Hot Rolled)
Wire Size (Solid)
Gaging Systems
Circular Ml Area (CMA)
Copper Wire Dimensions
DC Resistance
Coatings
Methods of Coating
Tin
Silver
Nickel
Dual Coating
Claddings
Aluminum
Uses
Coatings
Alloys
General Properties
High Conductivity Types
High Conductivity-High Strength Types
Stranding
Bunched Stranding
Concentric Stranding
Rope Stranding
Soldering
Soldering Stranded Wire
Heavy Tinned Stranding
Silver-coated Stranding
Nickel-coated Stranding
Composite Stranding
Terminations
Crimp Termination
Wire Wrap Termination
Shielding
Braid Terminology
Computation of Braid Angle and Coverage
Served Shields
Shielding Effectiveness
Flex-life Comparison—Copper vs Alloy 63
Test Method
Comparative Data

CHAPTER 2 INSULATION MATERIALS
Introduction
Thermoplastic Insulation Materials . . .
Polyvinylchloride
Polyolefins
Low-density Polyethylene
High-density Polyethylene
Polypropylene
Cross-linked Polyolefins
Nylon
Fluorocarbons
Polytetrafluoroethylene (TFE)
Copolymer of Tetrafluoroethylene and
Perfluoropropylene (FEP)
Polychlorotrifluoroethylene (CTFE) .
Polyvinylidenefluoride (VF-2)
Polyurethanes
Physical Properties
Thermal Properties
Rubber
Natural Rubber (Polyisoprene)
Styrene-butadiene Rubbers
Chloroprene Rubber
Butyl Rubber
Silicone Rubber
Chlorosulfonated Polyethylene
Ethylene Propylene Rubber
Fluorocarbon Rubber
Films
Cellulosics
Polyesters
Fluorocarbons
Polyimide
Fibers
Cotton
Rayon
Nylon
Polyester 2-17
Glass 2-17
Ceramic 2-18
Asbestos 2-18
Fiber Combinations 2-18
Coated Fibers 2-18
Lacquers 2-18
Cellulose Acetate Butyrate 2-18
Nylon 2-18
Fluorocarbons 2-20
Silicones 2-20
Specialized Coatings 2—20
Bondable Coatings 2-20
Polyimide Coatings 2-20
Potting Compounds 2-21
Types of Potting Compounds 2-21
Potting .Design Criteria 2-21
Surface Preparation 2—21
Mechanical Factors 2-21
Chemical Factors 2-21
Inorganic Insulations 2—21
Magnesium Oxide Insulation 2—23
Magnesium Oxide Beads 2-23
Special Environments 2—23
Fungus Resistance 2—23
Radiation Resistance 2—23
References

CHAPTER 3
DESIGN FACTORS HOOK-UP AND INTERCONNECTING WIRE
Scope
Factors Influencing Design
Environmental Factors
High Temperature 3-1
Low Temperature 3-1
Flammability 3-1
Moisture and Fungus . 3-2
Chemical Factors 3-2
Liquid 3-2
Ultraviolet 3-2
Gaseous
Corrosion
Outgassing 3-2
Mechanical Factors
Flex-life 3-2
Abration Resistance
Penetration
Tensile Strength 3—3
Elongation 3—3
Electrical Factors 3—3
Dielectric Constant 3—3
Dielectric Strength 3—3
Gradient (Electrical) 3—3
Insulation Resistance 3-4
Loss Factor 3—4
Current-carrying Capacity 3-4
Voltage Drop 3-4
Identification 3—5
Design Considerations 3—5
Conductor Choices 3—5
Mechanical Factors 3—5
Thermal Factors 3-5
Insulation Choices 3—6
Mechanical Considerations 3-6
Electrical Considerations 3—6
Testing To Prove Design 3-6
Electrical Tests 3-7
Physical Tests 3—7
Aging Tests 3—7
Thermal Tests 3—7
Mechanical Tests 3—7
Chemical Tests 3-7
Hook-up vs Interconnecting Wire 3-7
Hook-up Wire 3—7
Interconnecting Wire and Cable 3-8
Comparison of Hook-up Wire Types 3—8
MIL-W-76 3-8
MIL-W-16878D 3-11/3-12
MIL-W-81044 3-11/3-12
MIL-W-27300 3-11/3-12
MIL-W-22759 3-11/3-12
Comparison of Interconnecting Wire Types 3—11/3-12
MIL-W-5086 3-11/3-12
MIL-W-81044 3-11/3-12
MIL-W-7139 3-1 1/3-12
MIL-W-8777 3-11/3-12
References 3 — 15/3 — 16

CHAPTER 4
BUNDLED WIRES
Laced Bundles 4—1
Lacing 4—1
Usage — Laced Bundles 4—1
Prefabricated Bundles 4—1
Construction 4—1
Components 4—2
Color Code 4-2
Shield 4-2
Jacket 4-2
Derating Factors for Bundled Wires 4-2
Introduction 4-2
Basic Considerations 4-2
Derating Calculations 4-6
Symbols and Their Definitions 4-6
Rating Procedure 4-6
Usage Current Rating Procedure 4-7
Ribbon Cable 4-21
Introduction 4-21
Usage 4-21
Construction 4-21
Adhesive Bonding 4-21
Thermal Fusing 4-21
Direct Extrusion 4-21
Envelope 4-21
Braided or Woven 4-21
Comparison Ribbon Cable vs Round Multiconductor Cable. 4-21
Advantages Ribbon Cable 4-21
Disadvantages -Ribbon Cable 4-22
Tape Cable 4-22
Introduction 4-22
Usage 4-22
Flat Wire 4-22
Constructional Factors 4-23
Construction 4-23
Disadvantages -Flat Wire 4-23
Constructional Considerations 4-23
Testing 4-23
Folding Test 4-24
Roll Flexure Test 4-24
Straight Flexure Test 4-24
Installation 4-26
References 4—27

CHAPTER 5 COAXIAL CABLE
Introduction 5_i
Types of Coaxial Cable 5—1
Definitions 5_i
Coaxial 5-1
Twin Coaxial 5_i
Dual Coaxial 5_i
Double Shielded 5_i
Triaxial 5_1
Materials 5_i
Electrical Properties of Coaxial Cable 5—1
Basic Parameters 5—1
Capacitance 5—2
Phase Angle 5-5
Power Factor 5-5
Dielectric Constant 5—5
Velocity of Propagation 5-5
Characteristic Impedance 5—5
Propagation Constant 5-8
Attenuation and Phase Shift 5-8
Corona and Voltage Rating 5—14
Air-spaced Cables 5 -20
General Constructional Details 5—20
Voltage Standing Wave Ratio (VSWR) 5-20
Reflection .Coaxial Cable System 5—20
Reflection Causes -Coaxial Cable Systems 5-22
Power Rating 5-22
Power Handling Capacity 5-22
Power Rating Due to VSWR 5-23
Shields 5-23
Picks 5-23
Carriers 5-23
Ends 5-23
Shielding Effectiveness 5-25
Surface Transfer Impedance 5—25
Transmission Unbalance 5—26
General 5-26
References for Test and Measurement 5—27
Coverings and Sheaths 5-27
Fibrous or Textile 5—27
Special Purpose Coaxial Cables 5-28
Pulse Cables 5-28
Delay Lines 5—28
Low Noise Cable 5—29
Practical Constructional Considerations 5-29
Concentricity and Eccentricity 5—30
Abrasion 5-30
Contamination 5—30
Environmental Conditions 5—30
General Considerations 5—30
Insulation Guide 5—30

CHAPTER 6
CONTROL AND SIGNAL CABLES AMCP 706-125

6-1 Introduction 6-1
6-2 Applications of Control and Signal Cables 6-1
6-3 Constructional Design Factors 6-1
6-3.1 Physical Considerations 6-1
6-3.2 Electrical Considerations 6-2
6-4 Cable Types 6-2
6-4.1 Portable 6-2
6-4.2 Nonportable 6-2
6-5 Multiconductor Cable Design 6-2
6-5.1 General Considerations 6-2
6-5.2 Specific Construction Considerations 6-3
6-6 Multiconductor Construction 6-3
6-6.1 Conductors and Components 6-3
6-6.2 Component Strandings 6-6
6-6.3 Basic Insulated Wire 6-6
6-6.4 Component Shielding 6-6
6-6.5 Component Shield Covering and Component Jacket Dimensions 6-7
6-6.6 Cabling 6-7
6-6.6.1 Lay 6-8
6-6.6.2 Pitch Diameter 6-9
6-6.6.3 Lay Construction 6-9
6-6.7 Cable Fillers 6-9
6-6.8 Color Coding Control and Signal Cables 6-10
6-6.8.1 Color Coding Methods 6-10
6-6.8.2 Color Code Application 6-10
6-6.8.3 Color Code and Related Numbers 6-11
6-6.8.4 Specifications 6-11
6-6.9 Cable Binders 6-12
6-6.10 Cable Sheaths 6-13
6-6.11 Sheath Application 6-13
6-6.12 Armor 6-13
6-6.13 Cable Identification Marking 6-15
6-7 Multiconductor Cable Testing 6-16
6-7.1 Cable Cross-talk 6-16
6-7.2 Tests and Test Methods 6-16
6-7.3 Multiconductor Cable Tests 6-16
6-7.3.1 Cold Bend Test 6-17
6-7.3.2 Impact Test 6-17
6-7.3.3 Torque Test 6-17
6-7.3.4 Twist Test 6-17
6-7.3.5 Bend Test 6-18
6-7.3.6 Dielectric and Pulse Dielectric Tests 6-19
6—7.3.7 Insulation Resistance Test 6-22
6-7.3.8 Measuring Capacitance in a Multiconductor Cable 6-23
6-7.3.9 Abrasion Resistance 6-25
6-7.3.10 Tensile Strength of Multiconductor Cable 6-27
References 6-29

CHAPTER 7 POWER CABLES
7_1 Introduction
7-1.1 Usage
7_1 2 General Design Factors
7_2 Major Constructional Design Factors
7-2.1 Conductor
7_2.1.1 Conductor Material
7-2.1.2 Conductor Size
7-2.1.3 Conductor Form
7-2.2 Insulation
7-2.3 Sheath
7_3 Miscellaneous Constructional Design Factors
7--3.1 Shields
7-3.2 Cabling
7_3 3 Ground Wires
7_4 Voltage Drop
References

CHAPTER 8 SPECIAL PURPOSE CABLES
8-1 Introduction
8-1.1 General Types
8-1.2 Design Factors
8-2 Hybrid Cable Design Factors
8-3 Construction Check List
8-3.1 Basic Insulated Wires
8-3.2 Component Lay-up
8—3.3 Core Binder
8_3.4 Outer Covering
8-3.5 Cable Identification
8-3.6 Protective Braid
8-4 Sample Hybrid Cable Configuration
8-4.1 Sample Cable Requirements
8-4.2 Sample Cable Constructional Factors
8-4.3 Sample Cable Lay-up
8_4.3.1 Component Construction
8—4.3.2 Component Color Coding
8-4.3.3 Component Precabling Tests
8-4.3.4 Cable Core Lay-up
8_4.3.5 Core Binder
8-4.3,6 Core Diameter Calculation
8^.3.7 Core Shielding
8-4.3.8 Cable Separator
8-4.3.9 Cable Sheath
8-4.3.10 Cable Identification
8-5 Choice of Cable for Equipment Design
8-5.1 Light-or Medium-duty Cables
8-5.2 Heavy-duty Cables
Nonhosing or Waterblock Cables 8-12
General Description 8-12
Nonhosing Cable Applications 8-13
Thermocouple Cables 8-13
Introduction 8-13
General Operational Factors 8-14
Thermocouple Materials 8-15
Thermocouple Procurement 8-15
Calibration 8-15
Thermocouples vs Lead Wires 8-15
Construction 8-16
Conductors 8-16
Insulation 8-16
Constructional Examples 8-16
Installation 8-16
Electromotive Force 8-17
Ignition Wire -High Voltage 8-17
Introduction 8-17
Design Considerations 8-17
Conductor 8-17
Insulation 8-19
Reinforcing Braid 8-19
Outer Protective Fiber Braid 8-19
Shield 8-19
Specifications 8-19
References 8-20

CHAPTER 9 TELEPHONE CABLES
Introduction 9-1
Major Categories 9-1
Audio Cord 9-1
Basic Design 9-1
Tinsel Cord 9-1
Basic Design 9-2
Construction and Tests 9-2
Retractile (Helical) Cords 9_2
Basic Design and Construction 9_2
Tests 9-3
Miniature Cables (Special Purpose) 9_4
Basic Design 9_4
Tests 9-7
Multiconductor Cord (Retractile) 9_7
Usage 9-7
Basic Design 9_7
Retractile Construction 9_g
Retractile Testing 9_g
Specifications 9_9
9-3.7 Alternate Constructions 9-9
9_4 Field Wire 9-9
9-4.1 Usage 9-9
9-4.2 Installation Factors 9-9
9-4.3 Field Wire Types 9-9
9-4.4 Construction 9-10
9_4.5 Test Data 9-13
9-4.6 Packaging 9-13
9-4 6.1 Canvas Dispenser Construction 9-14
9-4.6.2 Plastic Dispenser Construction 9-14
9-4.7 Specifications 9-16
9-5 Multipair Telephone Cables 9-17
9-5.1 Usage 9_17
9-5.2 Cable Requirements 9-17
9-5.3 Reasons for Testing 9-20
9-5.4 Basic Design 9-20
9—5.5 Electrical Characteristics 9—20
9-5.5.1 Mutual Capacitance (Pair) 9-20
9-5.5.2 Capacitance Unbalance (Pair) 9_2^
9-5.6 Construction 9_2j
9-5.7 Tests for Cable 9-22
9-5.8 Specifications 9-23
9-6 Telephone Multichannel Communication Cables 9-23
9-6.1 Usage 9-23
9-6.2 Construction 9-23
9-6.3 Tests for Cable 9-24
9-6.4 Pulse Code Modulation Cables 9-24
9-6.4.1 FDM and PCM Systems 9_24
9-6.4.2 Cable Requirements 9-24
9—6.5 Construction and Performance Data 9-25
9-6.6 Cable Testing 9-25
9-6.6.1 Test Procedures and Requirements 9-25
9-6.6.1.1 Test Procedures 9-25
9-6.6.1.2 Shielding Effectiveness 9-25
9-6.6.1.2.1 Framing Test 9-25
9-6.6.1.2.2 Radiation from Cable 9-28
9-6.6.1.2.3 Calculation of Shielding Effectiveness 9-29
9-6.6.1.3 Tensile and Sag 9-30
9-6.7 Lightning Protection of Cable Systems 9-31
9-6.8 References for PCM and Multichannel Cables and Systems . . 9-31