Complete Technical Reference for Military & Aerospace Specification Cables
By Anhui Feichun Special Cable Co., Ltd. (安徽飞纯特种电缆有限公司)
MIL-DTL-27500 (NEMA WC27500) Cable Designation Guide
Complete Technical Reference for Military & Aerospace Specification Cables
By Anhui Feichun Special Cable Co., Ltd. (安徽飞纯特种电缆有限公司)
Understanding MIL-DTL-27500 Military Specification
MIL-DTL-27500, also known as NEMA WC27500, is a comprehensive United States military specification that defines requirements for special purpose electrical and power cables used in aerospace, aviation, defense, and military applications. This specification was originally designated as MIL-C-27500 before transitioning to the MIL-DTL nomenclature, with the NEMA WC27500 standard adopted in 2012 to harmonize commercial and military requirements[1].
Key Specification Highlights:
- Current Designation: MIL-DTL-27500 / ANSI/NEMA WC27500-2012
- Legacy Designation: MIL-C-27500 (superseded)
- Application: Aerospace, military avionics, airframe wiring, defense systems
- Voltage Rating: 600V AC/DC (standard configurations)
- Temperature Range: -55°C to +260°C (depending on materials)
- QPL Requirement: All manufacturers must be listed on Qualified Products List (QPL-27500)
The specification covers requirements for both power and special-purpose cables ranging from 1 to 15 conductors, with construction options including unjacketed, jacketed, shielded, and shielded-jacketed configurations[2]. These cables are specifically engineered to withstand extreme environmental conditions, including temperature extremes, vibration, electromagnetic interference, and exposure to aviation fuels and hydraulic fluids.
⚙️ Military & Aerospace Applications:
- Aircraft Avionics: Flight control systems, navigation equipment, communication systems
- Military Vehicles: Armored personnel carriers, tanks, naval vessels
- Missile Systems: Guidance systems, telemetry, launch control
- Satellite Systems: Power distribution, signal transmission in space applications
- Ground Support Equipment: Maintenance vehicles, test equipment, radar systems
- Unmanned Systems: Drones, UAVs, robotic platforms
Cable Designation System Explained
The Seven-Position Code Structure
Every MIL-DTL-27500 cable is designated by a precise combination of up to 16 alphanumeric characters that completely define its construction. This systematic approach ensures complete traceability and eliminates ambiguity in procurement and installation.
Position-by-Position Breakdown:
(1) M27500 – Specification Number
All cables carry this mandatory prefix identifying the specification
(2) A – Identification Method
Designates color coding system and shield coverage percentage (85% or 90%)
(3) 22 – Conductor Size
AWG wire gauge (26, 24, 22, 20, 18, 16, 14, 12, 10, 8, 6, 4, 2, 1, 1/0, 2/0)
(4) SB – Basic Wire Specification
One or two letter code referencing component wire specification (e.g., MIL-DTL-22759/32)
(5) 3 – Number of Conductors
1-15 conductors for shielded cables; 2-15 for unshielded cables
(6) T – Shield Material
Single letter code for shield type and material (or “U” for no shield)
(7) 23 – Jacket Material
Two-digit code specifying jacket material and color (or “00” for no jacket)
Example Interpretation:
M27500A22SB3T23
- M27500 = MIL-DTL-27500 specification
- A = Optional identification method A with 85% shield coverage (solid colored wires)
- 22 = 22 AWG conductor size
- SB = MIL-DTL-22759/32 component wire (PTFE/Polyimide insulation, 260°C rated)
- 3 = Three conductors
- T = Tin-coated copper round shield (150°C max)
- 23 = Extruded white cross-linked modified ETFE jacket (200°C max)
Contact Anhui Feichun Special Cable Co., Ltd.
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References and Citations
- WireMasters. “Cable Guide: M27500 Specification – NEMA WC 27500 2012 Part Anatomy.” https://www.wiremasters.com/guides/m27500-anatomy-guide
- Standard Wire & Cable Co. “MIL-DTL-27500 (NEMA WC27500) Cable Designations.” Technical specification document. https://standard-wire.com
This comprehensive technical guide is provided for informational purposes by Anhui Feichun Special Cable Co., Ltd. While every effort has been made to ensure accuracy, specifications are subject to change. Always consult the latest version of MIL-DTL-27500 and applicable military standards for contractual requirements.
