MILITARY WIRE (SPEC44/55)
MILITARY WIRE (SPEC44/55)
MILITARY WIRE – SPEC 44
Dual wall Construction
600,1000 & 2500 V rating
Small size - Light weight
Resistant to most chemicals
Resistant to electrical arc tracking
Applications:
SPEC 44 wire has a dual wall construction which combines the outstanding physical and electrical characteristics of radiation crosslinked polyalkene with the excellent mechanical and chemical properties of radiation cross-linked polyvinylidene fluoride (PVDF).
The result is a wire insulation system that offers a 150°C [302°F] temperature rating, small size, light weight, solder iron resist- ance, and resistance to most solvents, fuels and lubricants.
SPEC 44 wire and cable is highly flame retardant, non- melting, does not cold flow, and though mechanically very tough, is easy to handle and install using conventional tools.
Originally developed for aerospace and military requirements in applications of high density and complex circuitry, SPEC 44 wire and cable now finds wide use throughout industry, in commercial and military electronics, avionics, on satellites, aircraft, helicopters, ships, trains, military ground systems, and offshore platforms where environmental conditions demand consistently reliable performance. In airframe applications SPEC 44 constructions can offer a modern dimensional replacement for PVC/Nylon/ Glass braid type wire and cables.
SPEC 44 wire is offered in a wide range of sizes in stranded conduc- tors, standard materials available being tin or silver-plated copper and high strength copper alloy. Voltage ratings of 600, 1000 and 2500 volts are available as standard. Shielded and jacketed versions include single and multi-conductor constructions and flat braid shields where further size and weight savings are achieved.
Physical Characteristics:
- Small Size: SPEC 44 equipment wire, 600 volt rated has a 0.19 [.008] nominal wall thickness compared to 0.25 [.010] and 0.38 [.015] for equivalent PTFE and PVC wires in MIL-DTL-16878, SAE AS22759 or BS 3G210.
- Light Weight: Because of the thin wall and low density of the insulation materials considerable weight savings are made over similarly rated PTFE wires, eg:- 44A0111-22AWG equipment wire 4.45 grams/meter max 22 AWG PTFE equipment wire, AS-81044 5.54 grams/meter max
- General Handling: The flexibility of SPEC 44 and the ease with which it takes a ‘set’ makes it one of the easiest of the ‘high performance’ wires to install. Stripping is done with conventional die blade strippers. The tin-plated conductor usually specified is easily soldered or crimped. The insulation may be easily printed and does not need etching before potting.
- Lengths: SPEC 44 is available in long continuous lengths and can be supplied for use on automatic cut and strip wire preparation machines.
Specifications/Approvals:
- AS-81044, NEMA-WC-27500 (Cables)
- Def Stan. 61-12 Part 18 – Type 1 pliable (Maintenance Range)
- Def Stan. 61-12 Part 26 All types
- VG 95218 Parts 20, 21, 22, 23 and 1000
- NATO Stock Numbers (NSN’s) exist for most standard constructions Civil Aviation
- Authority Accessory Approval E11623
- TE Specification 44
Typical Properties:
- Temperature rating: -65°C to +150°C [-85°F to +302°F]
- Voltage rating (thin wall): 600V
- Voltage rating (thick wall): 2500V
- Tensile strength and elongation of insulation: 28 N/mm2, (4000 PSI), 230%
- Notch propagation, 0.05mm notch: Pass
- Solder iron resistance (370°C, 1 minute): Pass
- Shrinkage, 300°C: <1%
- Low temperature bend: -65°C [-85°F]
- Voltage withstand (thin wall): 2500V
- Resistance: fuels, oils, solvents: Pass
Environmental Performance:
- Tempreture Rating: SPEC 44 wire and cable is rated for continuous operation from -65°C to +150°C [-85°F to +302°F] and for short periods at temperatures as high as 300°C [572°F]. Heat ageing tests are routinely performed at temperatures of 200°C [392°F] (168 hr) and 300°C [572°F] (6 hr). In addition SPEC 44 insulation will not shrink back under repeated cycling.
- Mechanical Performance: SPEC 44 wire provides better cut through resistance than some wires with much thicker walls. 600 volt equipment wire 44A0111 (0.19 mm wall) has 40% greater cut through resistance than 600 volt PTFE insulated wire (0.25 mm wall).
- Solder Iron/Overload Resistance: The radiation crosslinking of the materials used in SPEC 44 makes them nonmelting at high temperature. As a result SPEC 44 wire is resistant to prolonged contact with solder irons and is resistant to current overloads which would melt most thermoplastic insulation.
- Chemical Resistance: The irradiated dual wall construction of SPEC 44 wire is highly resistant to many acids, alkalis, hydrocarbon solvents, fuels, lubricants, water, and many missile fuels and oxidizers.
- Cold Flow: Radiation cross-linking of SPEC 44 prevents cold flow of the insulation — a recognized problem of some uncrosslinked materials.
- Voltage Ratings: Standard available voltage ratings for SPEC 44 wire are 600 volts (0.19 mm wall thickness), 1000 volts (0.28 mm wall) and 2500 volts (0.48 mm wall).
- Electrical Arc Track Resistance: SPEC 44 insulation demonstrates a resistance to arc tracking under both wet and dry conditions at aircraft system voltages.
- Low Outgassing: For use in space applications, special constructions of SPEC 44 wire are available with low outgassing characteristics, for use in an environment of high vacuum and high temperature.
Fire Hazard Perfromance:
- Flammability:
- Federal Aviation Reg FAR-25: Pass
- BS EN 50265 Vertical Flammability: Pass
- S424 14751 (Swedish chimney): Pass
- NFC 32070 (2) (French chimney): Pass
- IEC 60332 part 3 (Cable ladder) Pass
- Smoke/Toxicity Index:
- Smoke Index, Def Stan 61-12 (18): 6 per meter of wire
- Toxicity Index, Def Stan 61-12 (18): 0.8 per meter of wire
- BS EN 1S0-4589 Part 2 /BS EN 1S0-4589 Part 3: 30% Oxygen
- Temperature Index, NES 715: >300°C [572°F]
Part Numbering System:
- Part Numbering System: See Below
- NEMA WC-27500 Cable Part Numbering System: See Below
MILITARY WIRE – SPEC 55
Resistant to electrical arc tracking in wet/dry conditions
Single or dual wall contractions
Small size, ultra light weight
Exceptional chemical resistance
-65°C to 200°C [-85°F to 392°F]
Applications:
SPEC 55 wire is insulated with modified radiation cross-linked ETFE polymer. It has a temperature rating of -65°C to 200°C [-85°F to 392°F] continuous using a silver plated copper conductor, and combines the easy handling of a flexible wire with excellent scrape abrasion and cut-through characteristics.
The dual wall airframe construction of SPEC 55 wire is currently used on numerous aircraft programs. It has a choice of two total wall thicknesses, 0.25 [.010] (55A08XX 10 mil) and 0.2 [.008] (55A02XX 8 mil). Both have a contrasting core color to act as a damage indicator. Chosen for its balance of properties, SPEC 55 wire has outstanding resistance to chemicals and solvents, excellent electrical arc track resistance, and is not susceptible to UV and moisture degradation. Single wall equipment wire constructions
are available in 0.10 [.004] (55/03XX 4 mil) and 0.15 [.006] (6 mil) wall thicknesses for use inside black boxes where flexibility and solder iron resistance make it a wire which is very easy to install reliably.
Both single and dual wall insulated wires are available in twisted pairs, triples, etc., and as shielded and jacketed cables.
Specifications/Approvals:
- SAE AS22759/32-35 and /41 to /46 and NEMA-WC-27500 (Cables)
- Defense Standard 61-12 Part 33 Issue 5
- Part 1001 and Part 1002
- VDE 9426, 9427, 9428
- British Standard 3G233
- Boeing BMS 13-48
- Airbus ABS 0820 to 0826
- NASA preferred product list
- European Space Agency 3901/012, 3901/020 and 3901/022
- TE Specification 55
- Civil Aviation Authority Accessory Approval E11623
Physical Characteristics:
- Size & Weight: SPEC 55 wire provides one of the most comprehensive wiring product ranges for aerospace users, with a wide choice of conductor sizes and insulation wall thicknesses. The dual wall airframe wire has an insulation wall thickness of either 0.2 [.008] or 0.25 [.010] for robustness in unprotected harnesses and has excellent wire to wire abrasion properties. The single wall equipment wire has a 0.15 [.006] wall thickness for use inside equipment and protected harnesses. For high density, interconnect wiring, the 450 volt 55M041X series of equipment wire has a nominal 0.1 [.004] wall and provides considerable weight and size savings over other comparable wires.
- Handling: The excellent flexibility and handleability makes SPEC 55 the ideal wire to install, both in new aircraft and equipment and for maintenance purposes. The wire is easily stripped with conventional tooling. The insulation is readily marked by hot stamp, ink jet or laser, and can be potted without pre-etching.
- SPEC 55PC Wire & Cable Insulation System: This product was originally developed to meet Boeing’s material standard BMS13- 48 for the 777 airliner. SPEC 55PC provides light- weight, compact insulation that matches the proven performance of our SPEC 55 wire. Today, 55PC is specified and utilized on the majority of aerospace platforms worldwide. TE’s rigorous, statistical- process-controlled manu- facturing has produced wiring that is rugged and versatile enough for a wide range of commercial and defense aerospace applica- tions, including electronic hook-ups in harsh, open air- frame environments. SPEC 55PC wire and cable systems feature an 8-mil air- frame wire that is lighter and smaller than typical 10-mil wire, with little reduction in key mechanical perform- ance features. SPEC 55PC wire offers flame resistance superior to FAA standards and also resists scrape abrasion, notch, propaga- tion, cut-through, and electrical arc tracking.
- Meets Boeing material standard BMS 13-48
- Exceeds FAR 25 test requirements for flame resistance and smoke density
Typical Properties:
- Temperature rating: (Tin plated conductor): -65°C to +150°C [-85°F to +302°F] (Silver or nickel plated conductor): -65°C to +200°C [-85°F to +392°F]
- Thermal Endurance: 200 °C [392°F], 10000 h
- Scrape abrasion (BS 3G233): >100 cycles at 150°C [302°F]
- Flexing endurance (Boeing BSS 7324): >1000 cycles
- Voltage rating: 600V,1000V
- Tensile strength + elongation (core only) : (Dual wall wire) 35 N/mm2, 125% min.
- Tensile strength + total elongation (core & primary jacket): (Dual wall wire) 35 N/mm2, 75% min.
- Notch propagation BS 3G230 0.05mm notch: Pass
- Solder iron resistance (370 °C, 1 minute): Pass
- Solderability: Tin plated copper conductor BS 3G233 conditions: <0.8 secs to wet
- Shrinkage: <1%
- Long term water resistance: Will not hyrolyze
- Permitivity 1 KHz (ASTM D150): 2.7
- Dissipation factor (ASTM D150): 0.001
- FAR 25: ⦵
- Afterburn (sec): 30 sec. max.
- Burn length: 75mm {3in.} max.
Environmental Performance:
- Tempreture Rating: SPEC 55 wire and cable is rated for continuous operation from -65°C to +200°C [-85°F to +392°F] and for short periods at temperatures as high as 400°C [752°F].
- Mechanical Performance: Radiation crosslinking of the SPEC 55 insulation signifi- cantly improves the following mechanical characteristics; scrape (sharp edges), cross wire abrasion, cut-through resistance and creep resistance.
- Solder Iron/Overload Resistance: Radiation crosslinking ensures that the insulation resists melting at high temperatures. As a result SPEC 55 wire is resistant to hot solder irons and current overloads which would melt most thermoplastic insulation.
- Chemical Resistance: SPEC 55 is unaffected by all commonly used chemicals, eg. fuels, hydraulic fluids, defluxing agents, cleaners, coolants and de-icers. It also shows excellent resistance to weathering (UV, ozone, pollutants, water).
- Space Wire: SPEC 55 is available in special versions suitable for use in outer space meeting both ESA and NASA requirements for outgassing.
- Flammability: Special additives increase the flame retardance of SPEC 55 compared to unirradiated ETFE so that it meets the latest high performance tests, eg. BS 3G230 and vertical test FAR25.
- Electrical Arc Track Resistance: SPEC 55 insulation demonstrates resistance to arc tracking under both wet and dry conditions at aircraft system voltages.
Part Numbering System:
- Part Numbering System 55A & 55LF – General Purpose: See Below
- Part Numbering System 55/ – Outer Space: See Below
- Part Numbering System 55PC & 55 PLF – Process Control: See below
