Mil Spec Wire and Cable

M27500 Wire Specification Breakdown

 

The M27500 specification allows for a wide variety of construction choices. Simply build your cable from the tables below, or contact Ryan Electronics for more information.


M27500 PART NUMBER EXAMPLE: M27500-20TG5T18

Mil-spec #

Color
Designator
(Table 3)

Conductor
Size

Basic Wire
Specification
(Table 1)

Number of 
Conductors

Shield Style
& Material
(Table 1A)

Jacket
Material
(Table 1B)

M27500 - 20 TG 5 T 18

TABLE 1: BASIC WIRE SPECIFICATION

Mil spec #

Type

Mil spec #

Type Mil spec # Type

Mil spec #

Type

MIL-W-5086/1 A MIL-W-81044/5 MD MIL-W-5086/4 P MIL-W-22759/20 TK
MIL-W-5088/5 AA MIL-W-81044/6 ME MIL-W-22759/3 RA MIL-W-22759/21 TL
MIL-W-5086/6 AB MIL-W-81044/7 MF MIL-W-22759/4 RB MIL-W-22759/22 TM
MIL-W-5086/7 AD MIL-W-81044/8 MG MIL-W-22759/11 RC MIL-W-22759/23 TN
MIL-W-5086/2 B MIL-W-81044/9 MH MIL-W-22759/12 RE MIL-W-22759/6 WA
MIL-W-5086/3 C MIL-W-81044/10 MJ MIL-W-22759/7 SA MIL-W-22759/80 WB
MIL-W-22759/13 CA MIL-W-81044/11 MK MIL-W-22759/32 SB MIL-W-22759/81 WC
MIL-W-22759/14 CB MIL-W-81044/12 ML MIL-W-22759/33 SC MIL-W-22759/82 WE
MIL-W-22759/15 CC MIL-W-81044/13 MM MIL-W-22759/34 SD MIL-W-22759/83 WF
MIL-W-22759/2 E MIL-W-81381/7 MR MIL-W-22759/35 SE MIL-W-22759/84 WG
MIL-W-22759/1 EA MIL-W-81381/8 MS MIL-W-22759/41 SM MIL-W-22759/85 WH
MIL-W-8777
(MS27110)
F MIL-W-81381/9 MT MIL-W-22759/42 SN MIL-W-22759/86 WJ
MIL-W-8777
(MS25471)
H MIL-W-81381/10 MV MIL-W-22759/43 SP MIL-W-22759/87 WK
MIL-W-25038/1 JA MIL-W-81381/11 MW MIL-W-22759/44 SR MIL-W-22759/88 WL
MIL-W-22579/28 JB MIL-W-81381/12 MY MIL-W-22759/45 SS MIL-W-22759/89 WM
MIL-W-22579/29 JC MIL-W-81381/13 NA MIL-W-22759/46 ST MIL-W-22759/90 WN
MIL-W-22579/30 JD MIL-W-81381/14 NB MIL-W-22759/8 TA MIL-W-22759/91 WP
MIL-W-22579/31 JE MIL-W-81381/17 NE MIL-W-22759/16 TE MIL-W-22759/5 VA
MIL-W-25038/3 JF MIL-W-81381/18 NF MIL-W-22759/17 TF ---------------------- ------
MIL-W-22579/9 LE MIL-W-81381/21 NK MIL-W-22759/18 TG ---------------------- ------
MIL-W-22579/10 LH MIL-W-81381/22 NL MIL-W-22759/19 TH ---------------------- ------

TABLE 1A: SHIELD STYLE & MATERIAL

Single Shield
Symbol

Double Shield
Symbol

Shield Material
Description

Max. Temp. for
Shield Material

U - No shield N/A
T V Tin-coated copper, round 150°C
S W Silver-coated copper, round 200°C
N Y Nickel-coated copper, round 260°C
F Z Stainless steel, round 400°C
C R Nickel-clad copper, round 400°C
M K Silver-coated high strength copper alloy, round 200°C
P L Nickel-coated high strength copper alloy, round 260°C
G A Silver-coated copper, flat 200°C
H B Silver-coated high strength copper 200°C
* # Nickel-coated copper, flat 260°C
J D Tin-Coated copper, flat 150°C
E X Nickel-coated high strength copper alloy, flat 260°C
I Q Nickel-chromium alloy, flat 400°C

TABLE 1B: JACKET MATERIAL

Single Jacket
Symbol

Double Jacket
Symbol

Jacket Material
Description

Max. Temp for
Jacket Material

00 00 No jacket N/A
01 51 Extruded PVC, white 90°C
02 52 Extruded nylon, clear  105°C
03 53 White nylon braid over mylar 105°C
04 54 Polyester briad over mylar 150°C
05 55 Extruded clear FEP 200°C
06 56 Extruded or taped heat sealed white PTFE 260°C
07 57 PTFE coated  glass braid over PTFE 260°C
08 58 Crosslinked extruded PVDF, White 150°C
09 59 Extruded FEP, White 150°C
10 60 PVDF, clear 125°C
11 61 Polymide Tape, FEP 200°C
12 62 Polymide tape, FEP, polymide 200°C
14 64 Extruded ETFE, white 150°C
15 65 Extruded ETFE, clear 150°C
16 66 Polymide braid, PTFE tape 200°C
17 67 Extruded ECTFE, white 150°C
18 68 Extruded ECTFE, clear 150°C
20 70 PFA, white 260°C
21 71 PFA, clear 260°C
22 72 Polymide tape, clear FEP wrap 200°C
23 73 Crosslinked, extruded, modified ETFE 200°C
24 74 PFTE tape over FEP and polymide tape 200°C

Allowable Shield and Jacket Materials for Each Basic Wire Type

Cable Type

Basic Wire
Specification

Shielded
Jacketed
Shielded & Jacketed
Shield
Material*
Jacket
Material
Shield
Material
Jacket
Material
Shield
Material*
Jacket
Material
MIL-W-5086 T 00 U 01, 02, 03, 10 T 01, 02, 03, 10
MIL-W-8777 S 00 U 04 S 04
MIL-W-25038/1 & /3 F, C 00 U 06, 07 F, C 06, 07
MIL-W-81044 T, S 00 U 04, 08, 09,
14, 16, 23
T, S 04, 08, 09,
14, 16, 23
MIL-W-81381 T, S, N 00 U 05, 09, 11, 12, 22 T, S, N 05, 09, 11, 12, 22
MIL-W-22759
slash sheets
1-12, 20-23, 28-31
T, S, N 00 U 04, 05, 06, 07, 09
14-18, 20, 21
T, S, N 04, 05, 06, 07, 09,
14-18, 20, 21
MIL-W-22759
slash sheets
13-19
T, S, N 00 U 04, 05, 09,
14-18, 20, 21
T, S, N 04, 05, 09,
14-18, 20, 21
MIL-W-22759
slash sheets
32-35, 41-46
T, S, N 00 U 04, 05, 08, 09
14-18, 20, 21
23, 24
T, S, N 04, 05, 08, 09,
14-18, 20, 21
23, 24
MIL-W-22759
slash sheets
80-92
T, S, N 00 U 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

*T = Tin, S = Silver, N = Nickel, F = Stainless Steel, C = Heavey Coated Nickel


TABLE 3: SHIELD COVERAGE & COLOR CODING

Color Code for Shield Coverage
M27500 Cable Terminology
Component Wire
Identification Method
85%
90%
- C Preferred method, Table 3A White wires with colored stripes - stripe color per Table 3A
F H Preferred method, Table 3B White wires with colored stripes - stripe color per Table 3B
A D Optional method A, Table 3A Solid colored wire - colors per Table 3A
G J Optional method A,  Table 3B Solid colored wire - colors per Table 3B
B E Optional method B, Table 3C Wires are all same color, based on AWG size (per Table 3C). Bands of contrasting color denote wire number (per table 3D)
K M Optional method C Wires are all same color, based on AWG size (per Table 4C). Numbers of contrasting color printed to denote wire number
L N Optional method D  White wires with numbers of contrasting color printed on each wire to denote wire number

 

TABLE 3A: COLOR CODING

  • For "preferred method" color coding, colors are stripes on white insulation (wire #1 has no stripe). Wires 11 - 15 have double stripes as indicated.
  • For "optional method A" color coding, colors are solid insulation color. Wires 11 - 15 have a stripe in lighter shade of base color.

Wire Number

Color

Wire Number

Color

Wire Number

Color

1 White 6 Black 11 Blue/Blue
2 Blue 7 Yellow 12 Orange/Orange
3 Orange 8 Violet 13 Green/Green
4 Green 9 Gray  14 Red/Red
5 Red 10 Brown 15 Black/Black

 

TABLE 3B: COLOR CODING

  • For "prferred method" color coding, colors are stripes on white insulation (wire #5 has no stripe), for wires 1 - 10. For wires 11 - 15, color pairs indicate insulation of the first color, with a stripe of second color.
  • For "optional method A" color coding, colors are solid insulation color, for wires 1 - 10. For wires 11 -15, color pairs indicate insulation of the first color, with a stripe of the second color.

  • For either method the color of the wire in a one conductor cable is white.

# of Wires

Identification Colors
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/white
12 Red, Blue, Yellow, Green, Basic, Black, Brown, Orange, Violet, Gray, Red/white, Blue/white
13 Red, Blue, Yellow, Green, Basic, Black, Brown, Orange, Violet, Gray, Red/white, Blue/white, Yellow/White
14 Red, Blue, Yellow, Green, Basic, Black, Brown, Orange, Violet, Gray, Red/white, Blue/white, Yellow/White, Green/white
15 Red, Blue, Yellow, Green, Basic, Black, Brown, Orange, Violet, Gray, Red/white, Blue/white, Yellow/White, Green/white, Black/white

 

TABLE 3C: COLOR CODING

  • For "optional method B" color coding, wire insulation color is based on AWG size, with color bands per Table 4D to indicate wire number (circuit ID).
  • For "optional method C" color coding, wire insulation color is based on AWG size, with numbers printed on each wire to indicate wire number (circuit ID).

AWG
Size

Color

AWG
Size

Color

AWG
Size

Color

AWG
Size

Color
26 Black 18 White 10 Brown 2 Red
24 Blue 16 Blue 8 Red  1 White
22 Green 14 Green 6 Blue 1/0 Blue
20 Red 12 Yellow 4 Yellow 2/0 Green

 

Table 3D: COLOR CODING

  • For "optional method B" color coding, band groups are printed on wires to indicate wire number (circuit ID).

Wire
Number

Band
Configuration

Wire
Number

Band
Configuration

Wire
Number

Band
Configuration

1 None 6 6 Narrow 11 1 Wide, 4 Narrow
2 2 Narrow 7 7 Narrow 12 1 Wide, 5 Narrow
3 3 Narrow 8 1 Wide, 1 Narrow 13 2 Wide, 1 Narrow
4 4 Narrow 9 1 Wide, 2 Narrow 14 2 Wide, 2 Narrow
5 5 Narrow 10 1 Wide, 3 Narrow 15 2 Wide, 3 Narrow