All MIL-DTL-27500 cables are designated by a combination of digits and letters (not to exceed 16) which indicates the exact construction of each cable. Please note the following example of a MIL-DTL-27500 cable.
Cable Description: M27500A 22 SB 3 T 23
(1) (2) (3) (4) (5)(6) (7)
Classification: The cable will be of the following types and will be furnished in the basic wire size, type, number of wires, and shield and jacket styles, as specified.
- Unjacketed: 2 to 15 color coded wires, spirally laid without an overall outer jacket.
- Jacketed: 2 to 15 color coded wires, spirally laid with an overall outer jacket.
- Shielded: A single wire, or 2 to 15 color coded wires spirally laid, with one or two overall shields.
- Shielded and Jacketed: A single
Specification Number (1): All cables will carry this prefix.
Identification Method (2):
When 85% minimum shield coverage is required:
| “-“ | designates the preferred identification method (white wire with colored stripes) using Table IIIA; |
| “F” | designates the preferred identification method (white wire with colored stripes) using Table IIIB; |
| “A” | designates optional identification method A (solid colored wires) using Table IIIA; |
| “G” | designates optional identification method A (solid colored wires) using Table IIIB; |
| “B” | designates optional identification method B using Table IIIC; |
| “K” | designates optional identification method C; |
| “L” | designates optional identification method D (see mil spec for band marking specification). |
When 90% minimum shield coverage is required:
| “C” | designates the preferred identification method (white wire with colored stripes) using Table IIIA; |
| “H” | designates the preferred identification method (white wire with colored stripes) using Table IIIB; |
| “D” | designates optional identification method A (solid colored wires) using Table IIIA; |
| “J” | designates optional identification method A (solid colored wires) using Table IIIB; |
| “E” | designates optional identification method B using Table IIIC; |
| “M” | designates optional identification method C; |
| “N” | designates optional identification method D (see mil spec for band marking specification). |
Conductor Size (3): This position identifies the wire size. Wire size depends upon the basic wire specification
(see 4).
Basic Wire Specification (4): The component wires are identified by a one or two letter code. A listing of the
basic wire specifications can be found in Table I.
Number of Conductors (5): M27500 currently specifies from 1 to 15 conductors for shielded or shielded and
jacketed cables, and from 2 to 15 for unshielded unjacketed or unshielded jacketed cables. Cables with 10
to 15 conductors are limited to 12 AWG and smaller.
Shield (6): The specific shield style and material are designated by a single letter code and are detailed in
Table I A.
Jacket (7): Cable jacketing materials are specified by a two digit code and are detailed in Table I B.
Table 1 – Basic Wire Specifications
1 Not for use in aerospace applications.2 Inactive for new design.3 Not for Naval Air Systems Command usage.4 No longer manufactured (no QPL) |
Table 1 A – Shield Material
| Letter Code | Description | Maximum temperature limit for shield material
|
||||
| Single Shield |
Double Shield |
|||||
| U | — | No shield | N/A | N/A | ||
| T | V | Round, tin-coated copper | 150 | 302 | ||
| S | W | Round, silver-coated copper | 200 | 392 | ||
| N | Y | Round, nickel-coated copper | 260 | 500 | ||
| F | Z | Round, stainless steel | 400 | 752 | ||
| C | R | Round, heavy nickel-coated copper | 400 | 752 | ||
| M | K | Round, silver-coated high strength copper alloy | 200 | 392 | ||
| P | L | Round, nickel-coated high strength copper alloy | 260 | 500 | ||
| G | A | Flat, silver-coated copper | 200 | 392 | ||
| H | B | Flat, silver-coated high strength copper alloy | 200 | 392 | ||
| * | # | Flat, nickel-coated copper | 260 | 500 | ||
| J | D | Flat, tin-coated copper | 150 | 302 | ||
| E | X | Flat, nickel-coated high strength copper alloy | 260 | 500 | ||
| I | Q | Flat, nickel-chromium alloy | 400 | 752 | ||
Table 1 B – Jacket Material and Color
| Numeric Code | Description | Temperature Limit for Jacket Material
|
||||
| Single Jacket |
Double Jacket |
|||||
| 00 | 00 | No jacket | N/A | N/A | ||
| 01 | 511 | Extruded white polyvinylchloride (PVC) | 90 | 194 | ||
| 022 | 522 | Extruded clear polyamide in accordance with ASTM-D-4066 | 105 | 221 | ||
| 03 | 53 | White polyamide braid impregnated with clear polyamide finisher over a polyester tape | 105 | 221 | ||
| 04 | 54 | Polyester braid impregnated with high temperature finishers over polyester tape | 150 | 302 | ||
| 05 | 55 | Extruded clear fluorinated ethylene propylene (FEP) | 200 | 392 | ||
| 06 | 56 | Extruded or taped and heat sealed white polytetrafluoroethylene (PTFE) | 260 | 500 | ||
| 07 | 57 | White polytetrafluoroethylene (PTFE) treated glass braid impregnated and coated with polytetrafluoroethylene finisher over presintered polytetrafluoroethylene tape | 260 | 500 | ||
| 083 | 583 | Cross-linked white extruded polyvinylidene fluoride (PVDF)2 | 150 | 302 | ||
| 09 | 59 | Extruded white fluorinated ethylene propylene (FEP) | 200 | 392 | ||
| 103 | 603 | Extruded clear polyvinylidene fluoride (PVDF)2 | 125 | 257 | ||
| 114 | 614 | Tape of natural polyimide combined with clear fluorinated ethylene propylene (FEP) wrapped and heat sealed with (FEP) outer surface | 200 | 392 | ||
| 124 | 624 | Tape of natural polyimide combined with fluorinated ethylene propylene (FEP) wrapped and heat sealed with polyimide outer surface |
200 | 392 | ||
| 14 | 64 | Extruded white ethylene-tetrafluoroethylene copolymer (ETFE) | 150 | 302 | ||
| 15 | 65 | Extruded clear ethylene-tetrafluoroethylene copolymer (ETFE) | 150 | 302 | ||
| 16 | 66 | Braid of aromatic polyamide with high temperature finisher over presintered polytetrafluoroethylene (PTFE) tape | 200 | 392 | ||
| 175 | 675 | Extruded white ethylene chlorotrifluoroethylene (ECTFE) | 150 | 302 | ||
| 185 | 685 | Extruded clear ethylene chlorotrifluoroethylene (ECTFE) | 150 | 302 | ||
| 20 | 70 | Extruded white perfluoroalkoxy (PFA) | 260 | 500 | ||
| 21 | 71 | Extruded clear perfluoroalkoxy (PFA) | 260 | 500 | ||
| 22 | 72 | Tape of polyimide combined with clear fluorinated ethylene propylene (FEP) wrapped and heat sealed with opaque polyimide outer surface | 200 | 392 | ||
| 23 | 73 | Extruded white cross-linked modified ethylene-tetrafluoroethylene copolymer (XLETFE) | 200 | 392 | ||
| 24 | 74 | Tape layer of white polytetrafluoroethylene (PTFE) wrapped over a tape layer of natural polyimide combined with FEP and heat sealed | 200 | 392 | ||
1 Polyvinylchloride (PVC) materials shall not be used for aerospace applications.
2 Jacket material 02/52 is not to be used for cables having a diameter of 0.251 in (6.38 mm) or greater.
3 Jacket materials 08, 10, 58, and 60 are not to be used for cables having a diameter of 0.401 in (10.19 mm) or greater.
4 Not for Naval Air Systems Command usage.
5 Inactive for new design.
2 Jacket material 02/52 is not to be used for cables having a diameter of 0.251 in (6.38 mm) or greater.
3 Jacket materials 08, 10, 58, and 60 are not to be used for cables having a diameter of 0.401 in (10.19 mm) or greater.
4 Not for Naval Air Systems Command usage.
5 Inactive for new design.
Table II – Allowable Shield and Jacket Materials for Each Basic Type Wire
| Cable Type | ||||||
| Basic Wire Specification |
Shielded | Jacketed | Shielded and Jacketed | |||
| Shield Material1 |
Jacket Material |
Shield Material |
Jacket Material |
Shield Material1 |
Jacket Material |
|
| MIL-DTL-5086 | T | 00 | Unshielded | 01, 02, 03, 10 | T | 01, 02, 03, 10 |
| MIL-DTL-8777 | S | 00 | Unshielded | 4 | S | 4 |
| MIL-DTL-22759 slash sheets 1-12,20-23, 28-31 |
T, S, N | 00 | Unshielded | 04, 05, 06, 07, 09, 14-18, 20, 21 |
T, S, N | 04, 05, 06, 07, 09, 14-18, 20, 21 |
| MIL-DTL-22759 slash sheets 13-19 |
T, S, N | 00 | Unshielded | 04, 05, 09, 14-18, 20, 21 |
T, S, N | 04, 05, 09, 14-18, 20, 21 |
| MIL-DTL-22759 slash sheets 32-35, 41-46 |
T, S, N | 00 | Unshielded | 04, 05, 08, 09, 14-18, 20, 21, 23, 24 |
T, S, N | 04, 05, 08, 09, 14-18, 20, 21, 23, 24 |
| MIL-DTL-22759 slash sheets 80-92 |
T, S, N | 00 |
Unshielded
|
04, 05, 06, 07, 09, 11, 12, 14-18, 20, 21, 22, 24 |
T, S, N
|
04, 05, 06, 07, 09, 11, 12, 14-18, 20, 21, 22, 24 |
| MIL-DTL-25038/1 & /3 | F, C | 00 | Unshielded | 06, 07 | F, C | 06, 07 |
| MIL-DTL-81044 | T,S | 00 | Unshielded | 04, 08, 09, 14, 16, 23 | T,S | 04, 08, 09, 14, 16, 23 |
| MIL-DTL-81381 | T, S, N | 00 | Unshielded | 05, 09, 11, 12, 22 | T, S, N | 05, 09, 11, 12, 22 |
See Table I A and Table I B for jacket material cross-reference.
1 T = Tin, S = Silver, N = Nickel, F = Stainless steel, C = Heavy coated nickel
Table III C – Color of Insulation for Identification of Wire Sizes in accordance with MIL-STD-686
|
Wire Size |
261 |
24 | 22 | 20 | 18 | 16 | 14 | 12 | 10 | 8 | 6 | 4 | 2 | 1 | 1/0 | 2/0 |
|
Insulation |
Black | Blue | Green | Red | White2 | Blue | Green | Yellow | Brown | Red | Blue | Yellow | Red | White | Blue | Green |
1 26 AWG is inactive for new design.
2 For MIL-DTL-81381 basic wire, the insulation color may be opaque dark yellow or unpigmented polyimide resin color.
2 For MIL-DTL-81381 basic wire, the insulation color may be opaque dark yellow or unpigmented polyimide resin color.
Table III A – Circuit Identification Colors for Basic Wires in Cable in accordance with MIL-DTL-22759, MIL-DTL-25038, MIL-DTL-81044, or MIL-DTL-81381
| No. of Wires in Cable |
Wire Number | ||||||||||||||
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 | 14 | 15 | |
| 1 | Basic (white) |
||||||||||||||
| 2 | White1 | Blue | |||||||||||||
| 3 | White1 | Blue | Orange | ||||||||||||
| 4 | White1 | Blue | Orange | Green | |||||||||||
| 5 | White1 | Blue | Orange | Green | Red | ||||||||||
| 6 | White1 | Blue | Orange | Green | Red | Black | |||||||||
| 7 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | ||||||||
| 8 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | |||||||
| 9 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | Gray | ||||||
| 10 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | Gray | Brown3 | |||||
| 114 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | Gray | Brown3 | Blue/Blue | ||||
| 124 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | Gray | Brown3 | Blue/Blue | Orange/Orange | |||
| 134 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | Gray | Brown3 | Blue/Blue | Orange/Orange | Green/Green | ||
| 144 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | Gray | Brown3 | Blue/Blue | Orange/Orange | Green/Green | Red/Red | |
| 154 | White1 | Blue | Orange | Green | Red | Black | Yellow2 | Violet | Gray | Brown3 | Blue/Blue | Orange/Orange | Green/Green | Red/Red | Black/Black |
1 Except where preferred color on basic wire specification sheet is not white.
2 Where basic wire is MIL-DTL-81381, a brown helical stripe shall be used.
3 Where basic wire is MIL-DTL-81381, a brown and white helical stripes shall be used.
4 For cables having more than 10 conductors, the wires shall be a white base identified by double color tracers as indicated.
2 Where basic wire is MIL-DTL-81381, a brown helical stripe shall be used.
3 Where basic wire is MIL-DTL-81381, a brown and white helical stripes shall be used.
4 For cables having more than 10 conductors, the wires shall be a white base identified by double color tracers as indicated.
Table III B – Circuit Identification Colors for Basic Wires in Cable in accordance with MIL-DTL-50861, MIL-DTL-8777, MIL-DTL-22759, MIL-DTL-25038, MIL-DTL-81044, or MIL-DTL-81381
| No. of Wires in Cable |
Identification Colors for Respective Wires in Cable |
| 1 | Basic (white) |
| 2 | Red, blue |
| 3 | Red, blue, yellow |
| 4 | Red, blue, yellow, green |
| 5 | Red, blue, yellow, green, basic |
| 6 | Red, blue, yellow, green, basic, black |
| 7 | Red, blue, yellow, green, basic, black, brown |
| 8 | Red, blue, yellow, green, basic, black, brown, orange |
| 9 | Red, blue, yellow, green, basic, black, brown, orange, violet |
| 10 | Red, blue, yellow, green, basic, black, brown, orange, violet, gray |
| 11 | Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2 |
| 12 | Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2 |
| 13 | Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2, yellow/white2 |
| 14 | Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2, yellow/white2, green/white2 |
| 15 | Red, blue, yellow, green, basic, black, brown, orange, violet, gray, red/white2, blue/white2, yellow/white2, green/white2, black/white |
1 Inactive for new design for MIL-DTL-5086.
2 Color designation indicates a solid color with stripe, e.g., red/white – solid red insulation with a white stripe.
2 Color designation indicates a solid color with stripe, e.g., red/white – solid red insulation with a white stripe.