NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Wire and Cable
501 Oakside Avenue, Redw ood Ci ty, CA 94063-3800
CABLE, HIGH-FREQUENCY AND CONTROLLED ELECTRICAL
1. SCOPE
This specification covers inspection methods, procedures and requirements for high-
frequency and controlled electrical cables.
2. APPLICABLE DOCUMENTS
2.1 GOVERNMENT-FURNISHED DOCUMENTS
The following documents, of the issue in effect on the date of invitation for bids or
request for proposal, form a part of this specification to the extent specified herein.
2.1.1 Military
SPECIFICATIONS
MIL-C-17 Cables, Radio Frequency, Flexible and Semirigid, General
Specification for
MIL-C-915 Cable and Cord, Electrical, for Shipboard Use, General
Specification for
MIL-W-22759 Wire, Electric, Fluoropolymer-Insulated, Copper or Copper Alloy
MIL-W-29606 Wire, Electrical, Stranded, Uninsulated Copper, Copper Alloy, or
Aluminum, or Thermocouple Extension, General Specification for
MIL-C-85485 Cable, Electric, Filter Line, Radio Frequency, Absorptive
STANDARDS
MIL-STD-202 Test Methods for Electronic and Electrical Component Parts
2.1.2 Federal
SPECIFICATIONS
UU-T-450 Tissue, Facial
(Copies of government-furnished documents may be obtained from the Defense
Automation and Production Service, 700 Robbins Avenue, Bldg. 4/D, Philadelphia,
Pennsylvania 19111-5094; or at http://astimage.daps.dla.mil/quicksearch.)
SPECIFICATION: 1200
THIS ISSUE: Issue 10
DATE: 5 November 2001
REPLACES: Issue 9
PAGE: 1 of 38
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 2 SPECI F ICATION 1200, ISSUE 10
2.2 OTHER PUBLICATIONS
The following documents form a part of this specification to the extent specified herein.
Unless otherwise indicated, the issue in effect on date of invitation for bid or request for
proposal shall apply.
2.2.1 American National St andar d (ANSI)
ANSI/ASQC Z1.4 Sampling Procedures and Tables for Inspection by Attributes
(Copies of ASQC documents may be obtained from the American Society for Quality
Control, 611 E. Wisconsin Avenue, Milwaukee, Wisconsin 53202; or at www.asqc.org.)
2.2.2 American Society f o r Testing and Materials (ASTM)
B 193 Standard Test Method for Resistivity of Electrical Conductor Materials
D 3032 Standard Methods of Testing Hookup Wire Insulation
D 4566 Standard Test Methods for Electrical Performance Properties of
Insulations and Jackets for Telecommunications Wire and Cable
E 595 Standard Test Method for Total Loss and Collected Volatile Condensable
Materials from Outgassing in a Vacuum Environment
(Copies of ASTM documents may be obtained from the American Society for Testing and
Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103; or at www.astm.org.)
2.2.3 Canadian Standards Association ( CSA)
C22.2 No. 0.3 Test Methods for Electrical Wires and Cables
(Copies of CSA documents may be obtained from CSA International, 178 Rexdale
Boulevard, Toronto, Ontario, Canada M9W 1R3; or at www.csa-international.org.)
2.2.4 Department of Tr ansportation, Feder al Aviation Administ r ation
FEDERAL AVIATION REGULATIONS (FAR)
Part 25 Airworthiness Standards: Transportation Category Airplanes
(Copies of Department of Transportation, Federal Aviation Administration documents
may be obtained from the Superintendent of Documents, Government Printing Office,
Washington, D.C. 20402; or at www.faa.gov.)
2.2.5 International Org anization for Standardization (ISO)
8402 Quality Management and Quality Assurance – Vocabulary
(Copies of ISO documents may be obtained from the International Organization for
Standardization, or at www.iso.ch.)
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 3
2.2.6 National Electrical Manufacturers Associat ion ( NEMA)
WC27500 Standard for Aerospace and Industrial Electrical Cable
(Copies of NEMA documents may be obtained from NEMA, 1300 North 17th Street,
Rosslyn, VA; or at www.nema.org.)
2.2.7 Society of Automotive Engineers, I nc. ( SAE)
J1128 Low Tension Primary Cable
(Copies of SAE documents may be obtained from SAE, 400 Commonwealth Drive,
Warrendale, PA 15096-0001, or at www.sae.org.)
2.2.8 Underwriters Laborat or ies ( UL)
UL 1581 Reference Standard for Electrical Wires, Cables, and Flexible Cords
(Copies of UL documents may be obtained from Underwriters Laboratories Inc.,
Publications Stock, 333 Pfingsten Road, Northbrook, Illinois 60062-2096; or at
www.ul.com.)
3. REQUIREMENTS
3.1 SPECIFICATION SHEETS
The requirements for the cables furnished under this specification shall be as specified
herein and in accordance with the applicable specification sheet. The requirements of the
specification sheet shall govern.
3.2 MATERIALS
3.2.1 Conductor Materials
Conductor materials shall be in accordance with MIL-W-29606 and the applicable
specification sheet.
3.2.2 Shield Materials
Shield materials shall conform to the requirements of NEMA WC27500 and the
applicable specification sheet.
3.2.3 Insulating and Jacket Materials
Insulating and jacketing materials shall be in accordance with the applicable specification
sheet.
3.3 PROCESS-CONTROL
3.3.1 Conductor Splices
Splices shall be in accordance with MIL-W-29606.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 4 SPECI F ICATION 1200, ISSUE 10
3.4 CONSTRUCTION
Construction of the finished cable shall be as specified herein and on the applicable
specification sheet.
3.4.1 Conductor
Unless otherwise specified on the applicable specification sheet, the conductor
construction shall be in accordance with MIL-W-29606.
3.4.1.1 Conductor Elong ation and Breaking Streng th
Prior to dielectric extrusion, tensile strength and elongation of the conductor shall be in
accordance with MIL-W-29606 as applicable. Other materials not covered by MIL-W-
29606 shall be in accordance with the applicable specification sheet.
3.4.2 Shield
The shield shall be constructed so as to meet all physical and surface transfer impedance
requirements of the applicable specification sheet. The shield shall be free of
irregularities, discontinuities and whole braid splices.
3.4.3 Insulation and Jacket s
All insulating and jacket materials shall be constructed as specified in the applicable
specification sheet.
3.5 DETAIL REQUIREMENTS
Finished cable shall conform to the requirements of Table I and those of the specification
sheet, as applicable.
3.5.1 Conductor and Shield Continuity
One hundred percent of all finished cable shall be tested for continuity prior to shipment.
There shall be no discontinuity in any of the component wires or shields, as applicable.
3.5.2 Dielectric Concentricity
Where required, the dielectric concentricity shall be in accordance with the applicable
specification sheet when tested in accordance with 4.4.9.
3.5.3 Dielectric Flaws
When specified, one hundred percent of the dielectric insulation shall be tested after
application of the dielectric and prior to the application of any other material to the wire.
Testing shall be in accordance with the jacket flaws test of 4.4.18 and best manufacturing
practice.
3.5.4 Flammability
Finished cable shall be tested in accordance with 4.4.14 for the appropriate method as
specified on the applicable specification sheet. Unless otherwise specified on the
applicable specification sheet, finished cable shall meet the following requirements:
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 5
3.5.4.1 Method A, Vertical T est , Inclined Burner
60 seconds (maximum)
25 percent (maximum) of flag burned
No flaming of cotton
3.5.4.2 Method B, 60° Test, Inclined Burner
30 seconds (maximum)
3 inches (76 mm) (maximum)
No flaming of facial tissue
3.5.4.3 Method C, Horizontal Test, Vertical Burner
No flaming of indicator papers.
3.5.4.4 Method D, 45° Test, Inclined Burner
70 seconds maximum
3.5.5 Jacket Concent r icit y and Wall Thick ness
Unless otherwise specified in the applicable specification sheet, the jacket concentricity
shall be 70 percent, minimum, when tested with 4.4.17. The jacket wall thickness shall be
as specified in the applicable specification sheet.
3.5.6 Jacket Flaws
One hundred percent of the finished cable shall pass the impulse test or spark test of
4.4.18, using the voltage specified in the applicable specification sheet. Jacket flaws
testing shall be performed during the final winding on shipment spools or reels.
3.5.7 Low Temperature Cold Bend
When finished cable is tested in accordance with 4.4.19, there shall be no cracking and no
breakdown.
3.5.8 Workmanship
All details of workmanship shall be in accordance with high-grade wire and cable
manufacturing practice. The insulation shall be free of cracks, splits, irregularities and
imbedded foreign material.
4. QUALITY ASSURANCE PROVISIONS
4.1 RESPONSIBI LITY FOR INSPECTION
The supplier is responsible for the performance of all tests specified herein. The supplier
may utilize internal or any other inspection facility and services acceptable to the buyer.
Inspection records of the examinations and tests shall be kept complete and available to
the buyer as required.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 6 SPECI F ICATION 1200, ISSUE 10
4.2 QUALITY-CONFORMANCE INSPECTION
Quality-conformance inspection shall consist of all applicable examinations and tests
listed in Table 1. Quality-conformance inspection shall be performed on every lot of
cable procured under this specification.
4.2.1 Inspection Classifications
a. Vendor Control (V) - Requirements for raw materials such as conductor and
insulation materials over which the vendor has control and responsibility.
b. Process Control (P) - Inspections performed on samples taken from the lots of cable.
Inspections may be performed on finished cable or after the process which establishes
the specified characteristic. The Quality Control Plan establishes the frequency of
inspection based on process control data.
c. One hundred Percent (100%) - Test performed on the total length of each cable. Tests
may be performed on the finished product or “in process” as applicable.
4.2.2 Inspection Definitions
ISO 8402 shall apply for definitions of inspection terms used herein. For the purposes of
this specification, the following shall apply:
4.2.2.1 Lot
The inspection lot shall include all cable(s) of one part number subjected to inspection at
one time.
4.2.3 Nonconform ing Inspection Lots
Disposition of inspection lots found unacceptable under initial quality-conformance
inspection shall be in accordance with ANSI/ASQC Z1.4.
4.3 INSPECTION CONDITIONS
Unless otherwise specified herein, all test inspection conditions shall be in accordance
with the test conditions specified in the “General Requirements” of MIL-STD-202, as
follows:
a. Temperature: 25°C ± 10°C
b. Relative humidity: 60 percent ± 15 percent
c. Atmospheric pressure: 725 mm ± 75 mm of mercury
4.4 TEST METHODS
NOTE: Where more than one test method is given for determining a particular property
required by the applicable specification sheet, Method A shall be used unless otherwise
specified by the applicable specification sheet.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 7
TABLE 1
PROPERTIES OF FINISHED CABLE
Examination or Test Requirement Method Inspection
Class
Adhesio n of Conductor Specification Sheet 4.4.1 P
Attenuation Specification Sheet 4.4.2 P
Blocking Specification Sheet 4.4.3 P
Cabling Specification Sheet 4.4.13 P
Capacitance Specification Sheet 4.4.4 P
Capacitance Unbalance Specification Sheet 4.4.5 P
Characteristic Impedance Specification Sheet 4.4.6 P
Conductor Elongation and Breaking Strength 3.4.1.1 MIL-W-29606 V
Conductor and Shield Continuity 3.5.1 4.4.7 100%
Conductor and Shield Resistance Specification Sheet 4.4.8 P
Conductor Splices 3.3.1 4.4.13 V
Construction and Materials Specification Sheet, 3.2 and 3.4 4.4.13 P
Dielectric Concentricity 3.5.2 4.4.9 P
Dielectric Flaws Specification Sheet and 3.5.3 4.4.18 100%
Dielectric/Jacket Elongation and Tensile Strength Specification Sheet 4.4.10 P
Dimensional Stability Specification Sheet 4.4.11 P
Dimensions Specification Sheet 4.4.12 P
Flammability Specification Sheet and 3.5.4 4.4.1 4 P
Heat Shock Specification Sheet 4.4.15 P
Insulation Resistance Specification Sheet 4.4.16 P
Jacket Concentricity and Wall Thickness 3.5.5 4.4.17 P
Jacket Flaws 3.5.6 4.4.18 100%
Low Temperature Cold Bend Specification Sheet and 3.5.7 4.4.19 P
Outer Space Environmental Testing Specification Sheet 4.4.20 1/
Partial Discharge (Corona) Specification Sheet 4.4.21 P
Propagation Delay Specification Sheet 4.4.22 P
Shield Coverage Specification Sheet 4.4.23 P
Skew Specification Sheet 4.4.24 P
Structural Return Loss Specification Sheet 4.4.25 P
Surface Transfer Impedance Specification Sheet 4.4.26 P
Time Delay Specification Sheet 4.4.27 P
Velocity of Propagation Specification Sheet 4.4.28 P
Voltage Withstand (Dielectric) Specification Sheet 4.4.29.1 100%
Voltage Withstand (Post-Environmental) Specification Sheet 4.4.29.2 P
Weight Specification Sheet 4.4.30 P
Workmanship 3.5.8 4.4.13 P
1/ Outer Space testing shall be performed at a frequency that has been agreed upon between the
customer and Raychem.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 8 SPECI F ICATION 1200, ISSUE 10
4.4.1 Adhesion of Conduct or
4.4.1.1 Specimen Preparation
Two specimens shall be cut to the length shown in Figure 1 using shear-type cutters to
minimize cross-sectional distortion. The jacket and shield shall be cut and carefully
removed without bending or flexing the cable. The dielectric shall be removed using a
razor blade without disturbing the remaining dielectric.
Conductor Dielectric
3.0 ± 0.25 inch
(
76 ± 6.4mm
)
3.0 ± 0.25 inch
(
76 ± 6.4mm
)
Figure 1. Conductor Adhesion Dimension
4.4.1.2 Apparatus
A test fixture capable of being held in a tensile testing machine and providing a hole for
the conductor to pass through shall be used. Clearance holes for conductors shall be no
smaller than the diameter of the conductor plus 0.002 inch (0.5 mm) and no larger than the
smallest practicable numerical drill size.
4.4.1.3 Procedure
With the conductor passing through the appropriate hole, the conductor shall be clamped
in one set of jaws while the test fixture is held or supported by the other set of jaws. The
jaws shall be separated at a rate of 0.5 inch (13 mm) per minute and the force recorded
while the conductor is pulled out of the dielectric. The maximum force recorded shall be
designated as the strip force and shall meet the requirements of the applicable
specification sheet.
4.4.1.4 Test Method Derivation
The preceding test method is derived from the Adhesion of Conductor test method in
MIL-C-17.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 9
4.4.2 Attenuation
4.4.2.1 Specimen
The specimen shall be of sufficient length to exhibit at least 3 dB of attenuation at the
lowest frequency required. The specimen shall be short enough to ensure that the
measured signal is at least 10 dB higher than the measuring system noise floor. If the
frequency range is such that one specimen cannot fulfill this requirement, then an
additional specimen of suitable length shall be used. For coaxial-type cables, suitable
connectors shall be attached to both ends of the cable. For twisted pairs, a connector
board with insulation displacement connectors may be used.
4.4.2.2 Procedure
An appropriate test set shall be used to measure the attenuation of the sample. Calibration
and specimen measurements shall be made in accordance with the analyzer or system
procedures. The attenuation at any frequency shall be expressed by the formula:
()
Attenuation in dB /100 feet ( / ) = Measured Attenuation dB 100
Specimen length in feet ( )
or dB m x
meters
100
4.4.2.3 Determinat ion of Compliance
Within the frequency range(s) specified on the applicable specification sheet, the
attenuation shall not exceed the specified value. Due to reflections, it may be necessary
to perform an standard regression analysis on the raw data. The regression polynomial
used shall be:
Af a f af()=+
12
Where:
f = Frequency in MHz
a1, a2 = Coefficients determined by regression analysis
A(f) = Attenuation in dB/100 feet (or dB/100 m) at frequency (f)
The regression analysis is used to smooth out SWR effects. To determine compliance, the
frequency (or frequencies) listed on the specification sheet shall be substituted into the
above equation, along with the regression coefficients a1 and a2, and the attenuation A(f)
calculated.
4.4.2.4 Test Method Derivation
The preceding test method is derived from the Attenuation test methods in MIL-C-17 and
ASTM D4566.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 10 SPECI F ICATION 1200, ISSUE 10
4.4.3 Blocking
One end of a continuous length of finished cable shall be fixed to a mandrel specified in
the applicable specification sheet. The cable shall then be spirally wound around the
mandrel so at least three turns are in close contact with one another. The winding shall be
continued until there are three layers of turns with each layer in close contact with one
another. The mandrel and cable shall then be placed within an air oven for the time and at
the temperature specified in the applicable specification sheet. After removal from the
oven, the mandrel and cable shall be cooled to room temperature and the cable shall be
unwound. There shall be no adhesion or sticking of adjacent turns or layers during the
unwinding process.
4.4.3.1 Test Method Derivation
The preceding test method is derived from the Blocking test method in NEMA WC27500.
4.4.4 Capacitance
4.4.4.1 Specimen Preparation
For measuring a frequency of 1 MHz, the specimen shall consist of an approximate 10-
foot (3-m) length of finished cable with all shields removed for a distance of 1 inch (25
mm) from each end and the insulation removed for a distance of 0.5 inch (13 mm) from
the end of all conductors. The length of the specimen shall be the shielded length. For
measuring frequencies other than 1 MHz, the sample shall be prepared as above except
that the specimen length shall be less than 1/40 wavelength.
4.4.4.2 Configuration
For coaxial and triaxial cables only, capacitance shall be measured with a capacitance
bridge at 1 kHz unless otherwise specified on the applicable specification sheet. For pair
and triad cables, the frequency shall be 1 MHz unless otherwise specified. If the frequency
specified for shielded or unshielded pairs or triads is 1 kHz, an appropriate capacitance
bridge that performs measurements in accordance with ASTM D4566 may be used.
4.4.4.3 Procedure
4.4.4.3.1 Coaxial Cables
The capacitance (C) shall be measured between the inner conductor and outer conductor
(shield) with the outer shield grounded.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 11
4.4.4.3.2 Shielded Pair Cables
The capacitance between the two inner conductors shall be measured by the two-terminal
method. With the outer conductor (shield) connected to the ground terminal of the
capacitance bridge, the mutual capacitance shall be determined as follows:
Designate:
Ca = Capacitance between no. 1 conductor and no. 2 conductor, with no. 2 conductor
connected to the outer conductor.
Cb = Capacitance between no. 2 conductor and no. 1 conductor, with no. 1 conductor
connected to the outer conductor.
Cc = Capacitance between no. 1 and no. 2 conductors connected together and the outer
conductor.
The mutual capacitance (Cm) per unit length for each shielded pair shall be determined by
the formula:
CCC C
mab c
=+−2
4()
(Length of specimen)
4.4.4.3.3 Shielded Triad Cables
The capacitance shall be measured by the two-terminal method. With the outer conductor
(shield) connected to the ground terminal of the capacitance bridge, the mutual
capacitance shall be determined as follows:
Designate:
Ca = Capacitance between no. 1 conductor and all other conductors connected to the
outer conductor.
Cb = Capacitance between no. 2 conductor and all other conductors connected to the
outer conductor.
Cc = Capacitance between no. 3 and all other conductors connected together and the
outer conductor.
Cd = Capacitance between no. 1, no. 2 and no. 3 conductors connected together and the
outer conductor.
The mutual capacitance (Cm) per unit length for each shielded triad shall be determined by
the formula:
()
()
CCCC C
mabc d
=++ −3
12 Length of specimen
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 12 SPECI F ICATION 1200, ISSUE 10
4.4.4.3.4 Unshielded Pair Cables
For unshielded pairs, the procedure shall be the same as given for shielded pair cables
except that the overall shield, if any, and all the conductors of the specimen, except the
pair under test, shall be connected together and treated as the outer conductor when
making measurements. The mutual capacitance (Cm) for each pair shall be determined by
the formula specified for the shielded pairs.
4.4.4.3.5 Unshielded Triad Cables
For unshielded triad cables, the procedure shall be the same as given for shielded triads
except that the overall shield, if any, and all conductors of the specimen, except those of
the triad under test, shall be connected together and treated as the outer conductor when
making measurements. The mutual capacitance (Cm) for each triad shall be determined by
the formula specified for shielded triads.
4.4.4.4 Test Method Derivation
The preceding test methods are derived from the Capacitance test methods in MIL-C-17,
MIL-C-915 and ASTM D4566.
4.4.5 Capacitance Unbalance
4.4.5.1 Capacitance Unbalance to Shield
4.4.5.1.1 Capacitance Unbalance Pair-t o- Shield
The capacitance shall be determined in accordance with 4.4.4. The capacitance unbalance
(Cu) in percent shall be determined from the following formula:
()
CCC
CCC
uab
abc
=-
+-
400
2%
4.4.5.1.2 Capacitance Unbalance Triad-t o- Shield
The capacitance shall be determined in accordance with 4.4.4. The capacitance unbalance
(Cu) in percent shall be determined from the following formula:
()
()
()
CCC
CC
CCC
CC
CCC
CC
uab
ab
ubc
bc
uac
ac
1
2
3
200 %
200 %
200 %
=-
+
=-
+
=-
+
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 13
4.4.5.1.2 Capacitance Unbalance Triad-t o-Shield (cont’d)
Where:
Cu1 = Percent of capacitance unbalance of conductor no. 1 in relation to conductor no. 2.
Cu2 = Percent of capacitance unbalance of conductor no. 2 in relation to conductor no. 3.
Cu3 = Percent of capacitance unbalance of conductor no. 3 in relation to conductor no. 1.
4.4.5.1. 3 Test Met hod Der ivation
The preceding test methods are derived from the Capacitance Unbalance test method in
MIL-C-17, and the Capacitance test method in MIL-C-915.
4.4.5.2 Capacitance Unbalance Pair-t o-Pair
Capacitance unbalance between the pairs of a finished cable shall be measured using a
suitable meter or bridge specifically designed for use with telephone cable. The cable
sample shall be connected to the measuring instrument in accordance with the instrument
manufacturer’s procedure. The measurement frequency shall be 1 kHz. The capacitance
unbalance of all adjacent and alternate pairs shall be measured as well as the capacitance
unbalance between the pairs in adjacent layers. A lesser number of measurements may be
made if allowed by the applicable specification sheet. The measured value of the
capacitance unbalance for the particular sample under test shall be converted to an
unbalance per 1000 feet (or km) by use of the following formula:
CC L
uuL
=1000
Where:
Cu = Capacitance unbalance in pF/1000 feet (or pF/km).
CuL = Measured capacitance unbalance of sample in picofarads (pF).
L = Length of sample in feet (or meters).
4.4.5.2. 1 Test Met hod Der ivation
The preceding test method is derived from the Capacitance Unbalance Pair-to-Pair section
of ASTM D4566.
4.4.5.3 Capacitance Unbalance Pair-t o- Ground
Capacitance unbalance between the pairs of finished cable and ground shall be measured
using a suitable meter or bridge specifically designed for use with telephone cable. The
cable sample shall be connected to the measuring instrument in accordance with the
instrument manufacturer’s procedure. The measurement frequency shall be 1 kHz. If a
capacitance unbalance bridge is not available, the pair-to-ground capacitance unbalance
shall be calculated using the following formula:
()()
CCCCC
upg ag ap bg bp
=+−+
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 14 SPECI F ICATION 1200, ISSUE 10
4.4.5.3 Capacitance Unbalance Pair-t o- Ground (cont ’d)
Where:
Cupg = Capacitance unbalance between pair and ground of sample in picofarads (pF).
Cag = Capacitance between conductor ‘a’ and ground.
Cap = Capacitance between conductor ‘a’ and all other pairs in the cable connected
together and grounded.
Cbg = Capacitance between conductor ‘b’ and ground.
Cbp = Capacitance between conductor ‘b’ and all other pairs in the cable connected
together and grounded.
The measured value of the capacitance unbalance for the particular sample under test
shall be converted to an unbalance per 1000 feet (or km) by use of the following formula:
YY
X
11000
=
Where:
Y1 = Unbalance corrected to 1000 feet (or km)
Y = Unbalance of cable length
X = Cable length in feet (or meters)
4.4.5.3. 1 Test Met hod Der ivation
The preceding test method is derived from the Capacitance Unbalance Pair-to-Ground
section of ASTM D4566.
4.4.6 Characteristic Impedance
4.4.6.1 Characteristic I mpedance - Method A
This method shall be used for cables whose nominal impedance is within 20 percent of
Zref, where Zref is the impedance of the calibrated air line (CRAL). However, if the Time
Domain Reflectometer (TDR) has the capability of displaying ohms at cursor, this method
may also be used for cables whose nominal impedance falls outside 20 percent of the
impedance of the CRAL.
4.4.6.1.1 Specimen Preparation
For coaxial cable, attach a suitable connector at one end of the cable. For twisted pairs,
the measurement is made wire-to-wire. Designate one wire as the inner conductor and the
other wire as the outer conductor and attach a suitable connector at one end.
4.4.6.1.2 Apparatus
The apparatus shall consist of a TDR with a maximum rise time of 150 picoseconds. A
calibrated reference air line (CRAL) of suitable impedance and suitable connectors shall
be used.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 15
4.4.6.1.3 Procedure
Attach the CRAL to the TDR output. If the TDR displays ohms at cursor, follow the
instrument manufacturer’s procedure. If not, designate the resulting trace as Zref and
adjust horizontal magnifier control until Zref extends through at least six horizontal
divisions. The sample cable shall then be attached and the resulting addition to Zref shall
be designated as Zc. With the cable attached, the Reflection Coefficient dial shall be
adjusted so that Zref and Zc are both on the graticule portion of the screen, but as far apart
vertically as possible. Record the setting on the dial as ARC. Determine the vertical
spacing between Zref and Zc in vertical divisions and designate as ρu. If Zref is higher than
Zc, then ρu is negative. If Zref is lower than Zc, then ρu is positive.
Define ρ as:
ρ
ρ
=uRC
A*
Characteristic impedance, Zo, shall be determined from the following formula:
ZZ
oref
=+
−
1
1
ρ
ρ
4.4.6.1. 4 Test Met hod Der ivation
The preceding test method is derived from the Characteristic Impedance test method in
MIL-C-17.
4.4.6.2 Characteristic I mpedance - Method B
This method shall be used for the determination of the characteristic impedance of coaxial
cables only.
4.4.6.2.1 Procedure
The velocity of propagation (Vp) shall be determined in accordance with 4.4.28. The
capacitance (C) shall be determined in accordance with 4.4.4. The characteristic
impedance shall be determined from the relation:
ZVCpFft
op
=∗
101670
(%) ( / )
4.4.6.2. 2 Test Met hod Der ivation
The preceding test method is derived from the Characteristic Impedance test method in
MIL-C-17.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 16 SPECI F ICATION 1200, ISSUE 10
4.4.6.3 Characteristic Impedance - Method C
This method is appropriate for determination of the characteristic impedance of cables at
specified frequencies of 1 MHz or higher.
4.4.6.3.1 Procedure
Using a 1 MHz bridge, determine the capacitance (C) in accordance with 4.4.4. The end
of the specimen used to determine the capacitance shall then be shorted and the
inductance (L) of the specimen determined using a 1 MHz bridge. Determination of the
capacitance and inductance may also be made at other specified frequencies by use of a
suitable bridge. For determining the characteristic impedance at frequencies higher than 1
MHz, the sample length should be shortened in order to minimize the effect of resonance.
The characteristic impedance, at the specified frequency, shall be determined from the
relation:
ZLC
o=
Where: Zo is the characteristic impedance in ohms
when L is the inductance in henries
and C is the capacitance in farads
For multiconductor cables, the capacitance (C) shall be the mutual capacitance (Cm).
4.4.6.3. 2 Test Met hod Der ivation
The preceding test method is derived from the Characteristic Impedance test method in
MIL-C-915.
4.4.6.4 Characteristic Impedance - Method D
This method is appropriate for determination of the characteristic impedance of data bus
(balanced pair) cables at specified frequencies of 772 kHz or higher.
4.4.6.4.1 Procedure
Using an appropriate bridge or measurement system, the open circuit impedance (Zoc) and
short circuit impedance (Zsc) shall be measured. For determining the characteristic
impedance at frequencies higher than 1 MHz, the sample length should be shortened in
order to minimize the effect of resonance. The characteristic impedance, at the specified
frequency, shall be determined from the relation:
ZZZ
oocsc
=
Where:
Zo = Complex characteristic impedance in ohms
Zoc = Complex open circuit impedance in ohms
Zsc = Complex short circuit impedance in ohms
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 17
4.4.6.4.1 Procedure (cont’d)
For electrically long lines (more than 1/8 of a wave length), the presence of structural
variations influences the impedance observed at the measured end considerably, so that it
is not actually Zo but rather an input impedance (Zin). For this situation, least squares
function fitting techniques can be used to extract the characteristic impedance from the
input impedance.
4.4.6.4. 2 Test Met hod Der ivation
The preceding test method is derived from the Characteristic Impedance test method in
ASTM D4566.
4.4.7 Conductor and Shield Continuity
To establish continuity, 25 volts dc maximum shall be applied to both ends of each
conductor and shield of the cable through an appropriate indicator, such as an ohmmeter,
light, or buzzer. The test voltage may be applied to the conductors and shields
individually or in series.
4.4.7.1 Test Method Derivation
The preceding test method is derived from the Continuity test method in MIL-C-17.
4.4.8 Conductor and Shield Resistance
Electrical resistance shall be determined on conductors or shields, as applicable, as
specified on the applicable specification sheet. The test procedure shall be in accordance
with ASTM B193. All test results shall be corrected to 20°C, unless otherwise specified.
4.4.9 Dielectric Concentricity
The concentricity of the dielectric insulation shall be determined by first locating and
recording the minimum wall thickness measured on a cross-section of the dielectric
insulation. The maximum wall thickness of this same cross-section of dielectric shall also
be located and recorded. All wall thickness measurements shall be made under suitable
magnification. The wall thickness shall be the shortest distance between the outer rim of
the dielectric insulation and the outer rim of the underlying strand of the conductor. The
ratio of the minimum wall thickness to the maximum wall thickness, multiplied by 100,
shall define the percent concentricity.
4.4.9.1 Test Method Derivation
The preceding test method is derived from the Concentricity test method in MIL-W-22759.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 18 SPECI F ICATION 1200, ISSUE 10
4.4.10 Dielectric/Jacket Elongat ion and Tensile Strength
Specimens of the dielectric insulation or cable jacket, as applicable, shall be carefully
removed and tested for tensile strength and elongation in accordance with ASTM D3032
using one-inch (25-mm) bench marks, a one-inch (25-mm) initial jaw separation, and a
jaw separation speed of two inches (50 mm) per minute, unless specified otherwise on the
applicable specification sheet.
4.4.11 Dimensional Stability
4.4. 11.1 Specim en Preparation
A 5-foot (1.5-m), minimum, specimen shall be cut. The ends of the specimen shall be cut
squarely and the specimen formed into an 18-inch (457-mm) coil.
4.4. 11.2 Pr ocedur e
Place the specimen in an air-circulating oven and condition for six hours at the applicable
test temperature. After the conditioning period, remove the specimen from the oven and
condition at room temperature for four hours. Measure both ends of the specimen for
protrusion or contraction of the inner conductor.
4.4.11.3 Test Method
The preceding test method is derived from the Dimensional Stability test method in
MIL-C-17.
4.4.12 Dimensions
Measurements shall be made on a 12-inch (305-mm), minimum, length of cable. Inner
components shall be made accessible by stripping and removing the outer components
carefully so as not to nick, cut, or otherwise damage the component to be measured. Four
points for measurement shall be located 3 to 4 inches (76 to 102 mm) apart along the
component or finished cable specimen length, as applicable. Measurements shall be made
at each point at two approximately perpendicular planes or as required to assure that the
minimum and maximum reading is attained at each point. A total of eight measurements
shall be performed on each specimen. The minimum, maximum, and average values shall
be recorded, as applicable. Measurements shall be made with a micrometer caliper or any
other instrument of equal accuracy.
4.4.12.1 Test Method Derivation
The preceding test method is derived from the Diameter Measurements test method in
MIL-C-17.
4.4.13 Examination of Pr oduct
All samples shall be examined carefully to determine conformance to this specification
and to applicable specification sheets with regard to requirements not covered by specific
test methods.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 19
4.4.14 Flammability
Flammability shall be tested in accordance with one of the following procedures, as
specified in the applicable specification sheet.
4.4.14.1 Flammability - Method A, Ver tical Test, Inclined Burner (VW-1)
The test shall be performed in accordance with Underwriters Laboratories Subject 1581,
Section 1080.
4.4.14.2 Flammability - Method B, 60° Test, I nclined Bur ner
4.4.14.2.1 Test Apparatus
The test shall be performed within a test chamber approximately 1 foot (0.3 m) square by
2 feet (0.6 m) in height, open at the top and front to provide adequate ventilation for
combustion but to prevent drafts. The specimen holder shall be so designed that the lower
end of a 24-inch (610-mm) specimen is held by a clamp, while the upper end of the
specimen passes over a pulley and can be suitably weighted to hold the specimen taut at
an angle of 60 degrees with the horizontal, in a plane parallel to and approximately 6
inches (152 mm) from the back of the chamber. The test flame shall originate from a
Bunsen-type gas burner with a 0.250-inch (6.4-mm) inlet, a needle valve in the base for
gas adjustment, a nominal bore of 0.375 inch (9.5 mm), and a barrel length of
approximately 4 inches (102 mm) above the air inlets. The burner shall be adjusted to
furnish a 3-inch (76-mm) high conical flame with an inner cone approximately 1 inch (25
mm) in length and a flame temperature not less than 954°C at its hottest point, as
measured with an accurate thermocouple pyrometer. A sheet of facial tissue conforming
to UU-T-450 shall be suspended taut and horizontal 9.5 inches (241 mm) below the point
of application of the flame to the specimen and at least 0.50 inch (13 mm) from the
chamber floor, so that any material dripping from the specimen shall fall upon the tissue.
60°
3 in. (75 mm )
Pulley
Weight
Specim e n clamped
in p la c e
8 in. (200 mm )
Figure 2. Flammability, Test Apparatus — Method B, 60° Test, Inclined Burner
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 20 SPECI F ICATION 1200, ISSUE 10
4.4.14.2.2 Test Procedure
A 24-inch (610-mm) specimen shall be marked at a distance of 8 inches (203 mm) from its
lower end to indicate the point for flame application, and shall be placed in the specified
60-degree position in the test chamber. The lower end of the specimen shall be clamped
in position in the specimen holder and the upper end shall be passed over the pulley of the
holder and the appropriate weight shall be attached. Weight shall be sufficient to hold the
specimen taut throughout the test. With the burner held perpendicular to the specimen
and at an angle of 30 degrees from the vertical plane of the specimen (see Figure 2), the
hottest portion of the flame shall be applied to the lower side of the specimen at the test
mark. The period of test flame application shall be 30 seconds and the test flame shall be
withdrawn immediately at the end of that period. The distance of flame travel upward
along the specimen from the test mark and the time of burning after removal of the test
flame shall be recorded; also the presence or absence of flame in the facial tissue due to
incendiary dripping from the specimen. Charred holes or charred spots in the tissue shall
be ignored in the absence of actual flame. Breaking of the specimens shall not be
considered as failure, provided the requirements for flame travel limits, duration of flame,
and the absence of incendiary dripping are met.
4.4.14.2. 3 Test Method Derivation
The preceding test method conforms to FAR Part 25, Appendix F, Part I, and includes a
provision for the detection of incendiary dripping.
4.4.14.3 Flammabilit y - Method C, Hor izontal T est, Vert ical Bur ner
4.4.14.3.1 Apparatus
The test shall be performed within a test chamber approximately 14 inches (365 mm)
square by 24 inches (610 mm) in height, open at the top and front to provide adequate
ventilation for combustion but to prevent drafts. The chamber shall be equipped with
supports 12 inches (305 mm) apart, designed to hold a 15-inch (381-mm) specimen in
a taut, horizontal position during the test, and located in a plane parallel to and
approximately 6 inches (152 mm) from the back of the chamber. The test flame shall
originate from a Tirrill-type gas burner with an 0.25-inch (6.4-mm) inlet, a needle valve
in the base for gas adjustment, a nominal bore of 0.38 inch (9.5 mm) and a barrel length
of approximately 4 inches (102 mm) above the air inlets. The burner shall be adjusted to
furnish a 5-inch (127-mm) high conical flame with an inner cone approximately 1.5 inches
(38 mm) in height.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 21
4.4.14.3.2 Procedure
A 15-inch (381-mm) specimen shall be placed in a horizontal position in the chamber on
supports 12 inches (305 mm) apart. Two strips of indicator paper shall be attached to the
specimen 10 inches (254 mm) apart, each paper being 5 inches (127 mm) from the point
on the specimen where the inner blue cone of the flame is to be applied. The indicator
paper shall be moistened sufficiently for proper adhesion and wrapped once around the
specimen, with the gummed side towards the specimen, and the ends pasted evenly
together and projected 0.75 inch (19 mm) from the specimen on the opposite side to which
the flame is to be applied. The Tirrill burner shall be placed in a vertical position and the
flame adjusted to 5 inches (127 mm) in height with the inner blue cone 1.5 inches (38 mm)
in height. The burner, in a vertical position, shall be placed so that the inner cone just
touches the underside of the specimen at a point midway between the two indicator
papers. The flame shall be directed against the specimen for exactly 30 seconds and then
removed. After flaming of the specimen has ceased, the indicator papers shall be
examined to determine the maximum distance the flame extended in either direction from
the center point of application of the flame.
4.4.14.3. 3 Test Method Derivation
The preceding test method is derived from the Flame Retardance Horizontal test method
of CSA Standard C22.2 No. 0.3.
4.4.14.4 Flammability - Method D, 45° Test, I nclined Bur ner
4.4.14.4.1 Apparatus
A gas burner having a 0.5-inch (13-mm) inlet, a nominal core of 0.4 inches (10 mm), and a
length of 4 inches (102 mm) above the primary inlets shall be used. The gas burner shall
be adjusted to produce a 4-inch (102-mm) gas flame with an inner cone one-half of its
height.
4.4.14.4.2 Procedure
Suspend a 24-inch (610-mm) test specimen in a draft-free chamber such that the specimen
is at a 45-degree angle to the vertical wall of the test chamber. The burner shall
perpendicular and in the plane of the specimen. The tip of the inner cone shall be
positioned 4 inches (102 mm) from the bottom of the specimen. The flame shall be
applied to the specimen for 15 seconds. The afterburn time shall be recorded.
4.4.14.4. 3 Test Method Derivation
The preceding test method is derived from the Flame Resistance test method in SAE
J1128.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 22 SPECI F ICATION 1200, ISSUE 10
Figure 3. Flammability, Test Apparatus — Method D, 45° Test, Inclined Burner
4.4.15 Heat Shock
A 4-inch (102-mm) specimen of finished cable shall be suspended for four hours in an air-
circulating oven at the temperature specified in the applicable specification sheet. The
oven shall have between 8–20 or 100–200 air changes per hour, and the velocity of air
past the specimens shall be between 100 and 200 feet (30 and 61 m) per minute. After
conditioning, the specimen shall be removed, cooled to room temperature, and visually
examined for evidence of melting or flowing.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 23
4.4.16 Insulation Resistance
Insulation resistance shall be measured on samples of finished cable at least 25 feet (7.6
m) in length. A dc potential between 200 and 500 volts shall be applied between each
conductor or shield in the cable and all the other conductors and shields. The leakage
current shall be measured after a 2-minute electrification period. However, a stable, or
an increasing reading indicating compliance with the specification requirement obtained
before the 2-minute period shall be acceptable. The insulation resistance of the test
specimen shall be calculated from the formula:
RMxL
=1000
Where:
R = Insulation resistance for 1000 feet in megohms.
M = Reading in megohms.
L = Test specimen length, in feet, measured between outer conductor ends.
4.4.16.1 Test Method Derivation
The preceding test method is derived from the Insulation Resistance test method in
MIL-C-17.
4.4.17 Jacket Concent r icit y and Wall Thick ness
The concentricity and wall thickness of the cable jacket shall be determined by first
locating and recording the minimum wall thickness measured on a cross-section of the
jacket. The maximum wall thickness of this same cross-section of jacket shall also be
measured and recorded. The wall thickness shall be the radial distance between the inner
and outer rim of the jacket as measured under suitable magnification. The ratio of the
minimum wall thickness to the maximum wall thickness, multiplied by 100, shall define
the percent concentricity.
4.4.17.1 Test Method Derivation
The preceding test method is derived from the Concentricity test method in NEMA
WC27500.
4.4.18 Jacket Flaws
4.4.18.1 Impulse Test
Finished cable shall be tested in accordance with ASTM D3032 at the voltage specified in
the applicable specification sheet with the conductor and shield, as applicable, grounded at
one end or both ends. When specified in the contract or order, dielectric or jacket failure,
untested portions, or portions which have been exposed to fewer or more than the specified
pulses may be marked by stripping the insulation or jacket or by any other suitable method
of marking as specified in the contract in lieu of being cut out of the cable.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 24 SPECI F ICATION 1200, ISSUE 10
4.4.18.2 Spark Test
Finished cable shall be passed through a bead chain electrode spark test device using the
voltage and frequency specified in the applicable specification sheet. (Note: 3000 Hz
may be used as an alternative for specification sheets specifying a test frequency of 60
Hz. If no frequency is specified, then either 60 or 3000 Hz may be used.) The conductor
and shield, as applicable, shall be grounded at one or both ends. The electrode shall be of
a suitable bead chain or fine mesh construction that will give intimate metallic contact
with practically all the jacket surface. Electrode length and speed of specimen movement
shall be such that the jacket is subjected to the test voltage for a minimum of 0.2 second.
Any portion showing jacket breakdown shall be cut out including at least 2 inches (51
mm) of cable on each side of the failure.
4.4.18.2. 1 Test Method Derivation
The preceding test method is derived from the Jacket Flaws test method in NEMA
WC27500.
4.4.19 Low Temperature Cold Bend
One end of the cable specimen shall be secured to the mandrel specified in the applicable
specification sheet and placed in the cold chamber. One full turn shall be wrapped around
the mandrel and the opposite end shall have sufficient weight attached to keep the cable
vertical and tangent to the mandrel during the bending operation. The chamber shall be
lowered to the temperature specified in the applicable specification sheet at a rate not to
exceed 50°C per minute. The specimen and the mandrel shall be conditioned at this
temperature for four hours. At the end of this period, and while both the specimen and
mandrel are still at this low temperature, the cable shall be wrapped around the mandrel
for 180 degrees without opening the chamber. The time for bending around 180 degrees
of the mandrel shall be one-half minute at a uniform rate of speed. A revolving mandrel
operated externally from the chamber shall be used. The specimen shall then be removed
from the mandrel and visually examined, without magnification, for cracks. The
specimen shall then be subjected to the voltage withstand test specified in 4.4.29.2.
4.4.19.1 Test Method Derivation
The preceding test method is derived from the Cold Bend test method in NEMA
WC27500.
4.4.20 Outer Space Environment al Testing
4.4.20.1 Radiation Resistance
A specimen of the finished cable shall be subjected to the electron radiation dosage
specified in the applicable specification sheet at an average rate of between 5 and 10
megarads per minute. Following exposure, the center portion of the specimen shall be
wound around a mandrel whose diameter is specified in the applicable specification sheet.
The ends of the specimen shall extend at least 6 inches (152 mm) beyond the wound
portion. The specimen shall be removed from the mandrel without unwinding and shall
be subjected to the voltage withstand test of 4.4.29.2.
4.4.20.2 Vacuum Stability
Specimens of finished cable shall be tested in accordance with ASTM E595.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 25
4.4.21 Partial Discharge (Corona)
Partial discharge extinction voltage (PDEV) shall be defined for this test method as the
voltage at which the apparent discharge level falls to 5 picocoulombs or less as the
applied voltage is decreased from a value exceeding the inception voltage.
4.4.21.1 Specimen Preparation
A length of cable shall be selected such that the sensitivity of the detecting equipment
will permit observation of discharges of 5 picocoulombs or less. The specimen shall be as
shown in Figure 4. Similar preparation should be made on triaxial cables.
Figure 4. Partial Discharge (Corona) Sample Preparation
4.4.21.2 Procedure
Connect the specimen to the voltage source so that the voltage is between the conductor
and the shield. Triaxial cables shall be connected between the conductor and the first
braid. In all cases, the high voltage shall be connected to the conductor or inner shield of
the triaxial cable. The frequency of the test voltage shall be between 48 and 62 Hz. The
specimen shall be connected to the detecting equipment with the specimen ends immersed
in oil until the shield is at least 0.25 inch (6.4 mm) below the surface of the oil.
Measurements shall not be made with air bubbles still visible in the oil. Apply the voltage
at a maximum rate of 50 volts per second to specimens having a specified PDEV of 3 kV
or less, and 100 volts per second for specimens having a specified PDEV above
3 kV. Increase the voltage until partial discharges are detected by the equipment. Then
lower the voltage at the same rate until the partial discharges cease. This voltage shall be
recorded as the PDEV.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 26 SPECI F ICATION 1200, ISSUE 10
4.4.21.3 Test Method Derivation
The preceding test is derived from the Corona Extinction Voltage test method in
MIL-C-17.
4.4.22 Propagation Delay
Using an appropriate set-up, follow the equipment manufacturer’s procedure for
measuring propagation delay in nanoseconds per unit length at the frequency specified in
the applicable specification sheet.
4.4.23 Shield Coverage
4.4.23.1 Braided Shields
The percent optical coverage (OC) of the braided shields shall be determined by the
following formula:
()
OC F F x=−2 100
2
Where:
FEPd ECd
L
==
sin sin
αα
2
Where:
E = Number of strands per carrier
α = Angle of strands with axis of cable
P = Picks per inch of cable length
d = Diameter of strands (or width, if flat strands are used)
C = Number of carriers
L = Length of lay of strands along cable
and
()()
tan = 2+2=+2
α ππ
DbP
CDb
L
Where:
b = Diameter of strands (or thickness, if flat strands are used)
D = Average diameter of cable under shield (see 4.4.12)
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 27
4.4.23.2 Spiral Shields
The percent optical coverage (OC) of the spiral shield shall be determined by the
following formula:
OC Fx=100
Where:
FEd
L
=sin
α
Where:
E = Number of strands
d = Diameter of strands (or width, if flat strands are used)
L = Length of lay of strands along the cable
α = Angle of strands with axis of cable
and
()
tan = +
απ
Db
L
Where:
b = Diameter of strands (or thickness, if flat strands are used)
D = Average diameter of cable under the shield (see 4.4.12)
4.4.23.3 Tape Shields
The coverage of a tape shield shall be expressed as the percentage by which one turn of
the tape overlaps the previous turn, and shall be determined by the following formula:
Overlap a
bx=100%
Where:
a = Distance, measured perpendicular to the edge of the tape, by which one turn of the
tape overlaps the next
b = Width of the tape
Alternatively:
Overlap c
dx
=−
1 100%
Where:
c = Distance between adjacent visible tape edges measured along the axis of the cable
d = Width of the tape measured along the axis of the cable
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 28 SPECI F ICATION 1200, ISSUE 10
4.4.23.4 Test Method Derivation
The preceding test methods are derived from the Shield Coverage test method in NEMA
WC27500.
4.4.24 Skew
A sample of appropriate length shall be tested for skew in accordance with the equipment
manufacturer’s procedure. Skew shall be reported in nanoseconds per unit length at the
frequency shown in the specification sheet.
4.4.25 Structur al Ret u r n Loss
4.4.25.1 Specimen Preparation
The specimen shall be of sufficient length to exhibit at least 3 dB attenuation at the lowest
frequency required, unless otherwise specified. The specified connectors shall be
attached to both ends of the specimen and the assembly connected to a TDR that is
capable of producing a step-function rise-time of 150 picoseconds or less. With the far
end of the specimen connected to a matched load, the impedance variation exhibited by
each cable connector-cable interface shall not be greater than the maximum impedance
variation permitted for the cable itself.
4.4.25.2 Procedure
An appropriate test set shall be used to measure the structural return loss of the sample.
Calibration and specimen measurements shall be made in accordance with the analyzer or
system procedures. The return loss shall be recorded over the specified frequency range.
4.4.25.3 Determinat ion of Compliance
Within the frequency range(s) specified on the applicable specification sheet, the
structural return loss shall not be greater than the specified value. (Note: Structural
Return Loss is measured in dB. This measurement may be reported as SWR or VSWR
and expressed as a ratio.)
4.4.25.4 Test Method Derivation
The preceding test method is derived from the Structural Return Loss test method in
MIL-C-17.
4.4.26 Surface Transf er Impedance
4.4.26.1 Sample Preparation
Approximately 4 feet (1.2 m) of the cable shall be prepared in the manner described
below. Any method of shield termination may be used provided the method is shown to
produce results of equal accuracy to that obtained with the method described below.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 29
4.4.26.1.1 End A Preparation
(See Figure 5). Approximately 3 inches (75 mm) of the cable jacket shall be removed
from one end of the cable and the shield pushed back to expose the insulated conductor.
The insulation shall be removed from the conductor to within 1 inch (25 mm) of the
pushed-back shield as shown in Figure 5, Step 1. For a multiconductor cable, connect all
the conductors together to form a single “conductor”. The shield shall then be pulled
forward over the remaining insulation and soldered to the conductor. The shield shall
completely enclose the insulated conductor, shall be soldered around 360 degrees of the
conductor, and all disturbed portions of the shield shall be well soldered. The conductor
shall extend beyond the soldered joint with the shield and shall be formed and trimmed so
as to be able to be soldered into the center pin of a BNC female-female adapter as shown
in Figure 5, Step 2. Excess shield beyond the solder joint shall be removed, and the
center pin of the adapter shall be attached to the conductor so that the pin is within 0.5
inch (12.5 mm) of the soldered joint. From the soldered joint, measure 1 meter and make
an appropriate mark on the jacket insulation. A piece of shrink tubing or other
appropriate material shall be applied over the soldered joint to insulate the joint as shown
in Figure 5, Step 3. The adapter pin shall then be inserted into the BNC adapter as shown
in Figure 5, Step 4. A metallic outer braid shall be pulled over the entire length of cable
and shall extend one-third over the BNC adapter. The outer braid shall then be soldered
to the BNC adapter, making sure that a 360-degree solder joint is formed as shown in
Figure 5, Step 5.
4.4.26.1.2 End B Preparation
(See Figure 6). At the other end of the cable, push back the outer braid, over the cable, to
expose the mark made 1 meter from the end A conductor solder joint. At the mark, the
cable jacket shall be window-stripped for a distance of 0.5 inch (12.5 mm), 0.25 inch (6
mm) on either side of the mark as shown in Figure 6, Step 1. The outer shield shall then
be pulled taut back over the cable and twisted at the end of the cable to hold the outer
braid in place. The outer braid shall be soldered to the underlying exposed shield for 360-
degrees around the cable at the window cut. Excess outer braid between the solder joint
and the end of the cable shall be removed as shown in Figure 6, Step 2. Shrink tubing
shall be applied over the entire length of outer braid ensuring that the braid is pressed
firmly to the jacket as shown in Figure 5, Step 6. Excess heat shrink tubing shall be
removed. The end of the cable shall then be cut and prepared for termination to the N-
male connector such that the distance from the installed connector to the window in the
cable jacket is as close as possible as shown in Figure 6, Step 3 and Figure 6, Step 4. For
multiconductor cables, one conductor shall be prepared for termination to the N
connector, the other conductors shall be floating. (Floating conductors in a
multiconductor cable is achieved by applying shrink tubing to the exposed ends of the
unused conductors.)
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 30 SPECI F ICATION 1200, ISSUE 10
Figure 5. Preparation of Cable End A
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 31
Step 1
Step 2
Step 3
Step 4
Figure 6. Preparation of Cable End B
4.4.26.2 Configuration
An appropriate test set shall be used to measure the surface transfer impedance of the
sample.
Signal
Generator 10 dB Pad Specimen Detector
A B
Figure 7. Configuration of the measurement system for determining surface
transfer impedance. The letters “A” and “B” refer to the A and B
ends of the specimen as described in paragraph 4.4.26.1.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 32 SPECI F ICATION 1200, ISSUE 10
4.4.26.3 Procedure
This measurement procedure is suitable for use with a spectrum analyzer and tracking
generator. The measurement procedure may be modified as needed if other instruments
are used, provided the results are shown to be of equal accuracy to those obtained when
the measurements are performed as described below. With the measuring system
configured as shown in Figure 7, adjust the output of the signal generator to produce a
trace on the spectrum analyzer, which at its highest point is near the top graticule line on
the screen. Remove the specimen and insert a calibrated variable attenuator in its place.
Adjust the attenuator until a trace is obtained which approximates the top graticule on the
screen. The position of the trace shall be recorded, either by storage on the screen or in
any other suitable manner. Designate this trace A0, where A0 is the setting of the
attenuator in dB. Increase the attenuator setting by 20 dB, and record the position of this
trace, designated A20, where A20 is the setting of the attenuator in dB. Increase the
attenuator further by 20 dB, and record the position of a trace designated A40. Continue in
this manner until the calibration traces have covered the entire height of the screen.
Remove the attenuator, and reconnect the specimen as shown in Figure 7. Designate the
resulting trace on the screen as S and record its position. The value of S at any frequency
shall then be calculated using the following equation:
SA y
hdB m
u
=+20
Where:
Au = Attenuator setting used to produce the calibration trace immediately above trace S.
y = Distance on the screen between the traces Au and S.
h = Distance on the screen between trace Au and the calibration trace immediately
below trace S.
The power of attenuation P of the shield is:
PS
=10 10
The surface transfer impedance Zt, at the frequency chosen, is given by:
ZZP
t=0
2 ohms/ meter
Where:
Z0 = Characteristic impedance of the spectrum analyzer and tracking generator.
Unless otherwise specified, 100 points uniformly spaced throughout the decade of
frequency, and including the beginning and end of the decade, shall be taken for each
decade of frequency range specified on the specification sheet.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 33
4.4.26.4 Determinat ion of Compliance
The values of Zt, as determined from measurements made in accordance with 4.4.26.3,
shall not exceed the maximum specified values of Zt as shown on the applicable
specification sheet in any of the following ways:
a. A single maximum value of Zt may be specified at a discrete frequency or over a
range of frequencies.
b. The maximum value of Zt over a range of frequencies may be specified by a plot of
the maximum value of Zt versus frequency.
c. The maximum value of Zt over a range of frequencies specified by a curve defined by
the maximum value of Zt at given frequencies.
d. The maximum value of Zt over a range of frequencies may be specified by the
equation:
()
Maximum specified Z milliohms/ meter,
t=AB
zf z
Where:
f = Frequency in MHz
Az, Bz = Zt calculation parameters given on the specification sheet
4.4.26.5 Test Method Derivation
The preceding test method is derived from the Surface Transfer Impedance test method in
MIL-C-85485.
4.4.27 Time Delay
Time delay (TD), in nanoseconds per foot, shall be determined by the formula:
TD Vp
=10167.
(%)
Where:
Vp = Velocity of propagation as determined by 4.4.28.
4.4.28 Velocity of Pr opagation
4.4.28.1 Specimen Preparation
The sample cable shall be of suitable length, 10 feet (3 m), minimum. At one end of the
cable, the center conductor and shield shall be connected together. For a twisted pair, the
conductors shall be twisted together and the shield left unconnected. At the other end of
the cable, one conductor shall be designated as the center conductor and the other
conductor as the outer conductor. The sample length shall be defined as the length of
cable covered by the shield. For an unshielded twisted pair, tape the components together
one-half inch (12.5 mm) from each end of the cable. The sample length shall be defined
as the length of cable between the outside edges of the tape. The sample length shall be
measured and designated as L.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 34 SPECI F ICATION 1200, ISSUE 10
4.4.28.2 Procedure
The free end of the cable shall be attached to a ‘T’-type connector. One leg of the T shall
be attached to a detector and the other leg to a signal generator. The signal generator shall
be adjusted to a frequency of 1 MHz and the frequency shall then be increased until a
sharp decrease in the detector reading is observed. The frequency generator shall be
adjusted until a minimum in the detector reading is achieved. This frequency shall be
recorded to the nearest 0.1 MHz. Designate this reading as f1. The frequency of the
signal generator shall be increased further until another decrease in the detector reading is
observed. The frequency of the minimum detector reading shall be recorded as f2. This
procedure shall be repeated until at least four different frequencies are recorded.
4.4.28.3 Calculations
At each recorded frequency, the frequency in MHz shall be divided by the subscript
number and the results recorded.
ff
ff
ff
ff
etc
101
202
303
404
1=
2=
3=
4=
.
The mean value of all the resulting frequencies shall be calculated and designated as f
_.
The velocity of propagation (Vp) shall be determined from the formula:
VLf Lf
pmf
=2
2998
2
__
. or 983.6 %
Where:
Lm = Specimen length in meters
Lf = Specimen length in feet
4.4.28.4 Test Method Derivation
The preceding test method is derived from the Time Delay test method in MIL-C-17.
4.4.29 Voltage Withstand
Voltage withstand tests shall be made using an ac source with a frequency of 50 to 60 Hz.
The voltage applied shall be as specified on the applicable specification sheet and shall be
applied for one minute.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 35
4.4.29.1 Voltage Withstand ( Dielect r ic)
Voltage withstand (dielectric) tests shall be performed upon finished cable by applying
the specified voltage between each conductor or shield in turn, and all other conductors
and shields which shall be tied together and grounded.
4.4.29.2 Voltage Withstand ( Post - Environment al)
Voltage withstand (post-environmental) tests on the outer jacket shall be performed after
the finished cable has been immersed in water for at least one hour and while the cable is
still immersed. The specified voltage shall be applied between all the conductors and
shields, tied together, and the water bath which shall be grounded.
4.4.29.3 Test Method Derivation
The preceding test methods are derived from the Dielectric Withstand and Voltage
Withstand, Jacket, test methods in NEMA WC27500.
4.4.30 Weight
The weight of each lot of finished cable shall be determined by Procedure I (4.4.30.1).
Lots failing to meet the weight requirement of the applicable specification sheet when
tested in accordance with Procedure I shall be subjected to Procedure II (4.4.30.2). All
reels or spools failing to meet the requirements of the applicable specification sheet when
tested by Procedure II shall be rejected.
4.4.30.1 Procedure I
A length of cable, sufficient to produce a measured weight to at least 3 significant figures,
shall be weighed and converted to the weight per unit length shown on the applicable
specification sheet.
4.4.30.2 Procedure II
The net weight of the finished cable on each reel or spool shall be obtained by subtracting
the tare weight of the reel or spool from the gross weight of the reel or spool containing
the finished cable. The net weight of cable on each reel or spool shall be divided by the
accurately determined length of finished cable on that reel or spool and the resultant
figure converted to pounds per 1000 feet (kg/km). When wood or other moisture
absorbent materials are used for reel or spool construction, weight determinations shall be
made under substantially uniform conditions of relative humidity.
4.4.30.3 Test Method Derivation
The preceding test methods are derived from the Wire Weight test methods in
MIL-W-22759.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 36 SPECI F ICATION 1200, ISSUE 10
5 PREPARATION FOR DELIVERY
5.1 PACKAGI NG AND PACKING
Cable shall be delivered wound on reels or spools in accordance with 5.1.1 and in such a
manner that all ends are accessible. Only identical type cable lengths shall be contained
in any one package unit.
5.1.1 Reels and Spools
Reels and spools shall be of a nonreturnable type. Each reel and spool shall have an
appropriate diameter for the respective cable size. In no case shall the barrel of the reel
or spool have a diameter less than 3 inches (76 mm). Reels and spools shall be suitably
finished to prevent corrosion under typical storage and handling conditions.
5.1.2 Containers
Unless otherwise specified (see 6.1), cable shall be delivered in standard commercial
containers, so constructed as to ensure acceptance by common or other carrier for safe
transportation at the lowest rate to the point of delivery.
5.2 MARKING OF SHIPMENTS
Unless otherwise specified in the contract or purchase order, each reel or spool shall be
legibly marked with the following information:
Manufacturer’s Part Number
Lot Number
Quantity in Feet (or Meters)
Name of Manufacturer
6 NOTES
6.1 ORDERING DATA
Procurement documents should specify the following:
a. Title and number of this specification
b. Applicable specification sheet part number
c. Quantity
d. Special preparation for delivery requirements, if applicable
6.2 METRIC UNITS
Metric units, where shown in parentheses, are for information only.
6.3 TEST METHOD DERIVATIONS
Test method derivations contained in test methods are shown for information only.
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
SPECI FICATION 1200, ISS UE 10 Page 37
6.4 SYMBOLS
The following symbols and prefixes are used in this specification and are listed below for
information.
6.4.1 Standard Prefixes
Symbol Prefix Multiplier
M mega 106
k kilo 103
d deci 10-1
c centi 10-2
m milli 10-3
µ micro 10-6
n nano 10-9
p pico 10-12
f femto 10-15
6.4.2 Standard Symbols
Symbol Name
B bel
Bm bel (relative to 1 milliwatt)
C coulomb
°C degrees, Celsius
°F degrees, Fahrenheit
eV electron-volt
ft. foot
F farad
g gram
Hz hertz
in. inch
m meter
psi pounds per square inch
s second
V volt
Ω ohm
NOTE: ANY COPY OF THIS DOCUMENT THAT DOES NOT HAVE A
RED "CONTROL" STAMP IS AN UNCONTROLLED COPY.
Page 38 SPECI F ICATION 1200, ISSUE 10
6.4.4 Electrical Symbols
Symbol Description
a1, a2 Attenuation formula coefficients
ac Alternating current
A0, A20,… Calibrated attenuator settings, dB
A(f) Attenuation at frequency (f)
Au Calibrated attenuator setting, dB
Az Z
t calculation parameter
Bz Z
t calculation parameter
C Calculated or measured capacitance
Ca, Cb, Cc, Cd Measured capacitances
Cag, Cbg Measured capacitance, conductor to ground
Cap, Cbp Measured capacitance, conductor to pair
Cm Mutual capacitance, calculated
Cu Capacitance unbalance, calculated
Cu1, Cu2, etc. Capacitance unbalance, %
CuL Pair-to-pair capacitance unbalance, measured
Cupg Pair-to-ground capacitance unbalance, calculated
CRAL Calibrated reference air line
dc Direct current
f Frequency (MHz)
f1, f2,… Resonant frequency (MHz)
h Measurement on spectrum analyzer screen
L Calculated or measured inductance
M Leakage current reading in megohms
P Power ratio
PDEV Partial discharge extinction voltage
R Insulation resistance, calculated
S Calculated attenuation
SWR Standing wave ratio
TD Time delay
TDR Time domain reflectometer
VSWR Voltage standing wave ratio
Vp Velocity of propagation, %
y Measurement on spectrum analyzer screen
Y Pair-to-ground capacitance unbalance, measured
Y1 Pair-to-ground capacitance unbalance per 1000 feet (km)
Zin Input impedance
Zo Characteristic impedance
Zos Open circuit impedance, measured
Zsc Short circuit impedance, measured
Zref Reference characteristic impedance
Zt Surface transfer impedance
ρ Reflection coefficient, calculated
ρu Reflection coefficient, un-scaled
