SPEC 44

Wire and cable

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 150C temperature rating, small size, light weight, solder iron resistance, 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, 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 conductors, 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.

Features and benefits

Dual wall construction. 600, 1000 and 2500 voltage rating. Small size, light weight. Low smoke and low corrosive gas generation. Resistant to most chemicals and electrical arc tracking.
Available in: 44 wire Americas Europe Asia Pacific 44 cable (twisted pair)

Conductor

Primary Insulation Radiation Crosslinked, Extruded Polyalkene 9-0 Wire and Cable

Jacket Radiation Crosslinked, Modified PVDF

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Physical characteristics
Small size SPEC 44 equipment wire, 600 volt rated has a 0.19 mm (.008 in) nominal wall thickness compared to 0.25 mm (.010 in) and 0.38 mm (.015 in) for equivalent PTFE and PVC wires in MIL-W-16878, MIL-W-22759 or BS G210. 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 4.62 grams/meter max 22AWG PTFE equipment wire, MIL-W-22759 5.54 grams/meter max
Specifications/approvals
MIL-W-81044, NEMA-WC-27500 (Cables) Def Stan. 61-12 Part 18 Issue 4 - Type 1 pliable (Maintenance Range) Def Stan. 61-12 Part 26 Issue 3 Type 2, 3, 8 & 9 & METS 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 Lloyds Register of Shipping NASA Preferred Product List Raychem Specification 44

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. For details of appropriate tools see separate wire handling guide. The tin-plated conductor usually specified is easily soldered or crimped. The insulation may be hot stamp marked or 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.

Typical properties
Temperature rating Voltage rating (thin wall) Voltage rating (thick wall) Tensile strength and elongation of insulation Notch propagation, 0.05mm notch Solder iron resistance (370C, 1 minute) Shrinkage, 200C Low temperature bend Voltage withstand (thin wall) Insulation resistance (20C) Resistance: fuels, oils, solvents -65C to +150C 600 V 2500 V 30 N/mm2 , 230% Pass Pass <1% -65C 2500 V 1500 M ohms for 1 km Pass

Users should independently evaluate the suitability of the product for their application. Before ordering check with factory for most current data.

Wire and Cable 9-1

SPEC 44 (contd.)
Wire and cable

SPEC 44 wire and cable Primary wires/twisted pair 44A011X (600 V) primary wire 44A021X (1000 V) primary wire

Size
30 28 26* 24 22 20 18 16 14 12 10 8

Stranding (mm)
7/0.10 7/0.13 19/0.10 19/0.13 19/0.16 19/0.20 19/0.25 19/0.29 19/0.36 37/0.32 37/0.40 133/0.29

#/AWG
7/38 7/36 19/38 19/36 19/34 19/32 19/30 19/29 19/27 37/28 37/26 133/29

CSA (mm2)
0.06 0.09 0.15 0.25 0.40 0.60 1.00 1.25 2.00 3.00 5.00

Nom. OD (mm)
0.68 0.76 0.86 1.02 1.19 1.40 1.65 1.83 2.26 2.74 3.28

(in)
0.027 0.03 0.034 0.04 0.047 0.055 0.065 0.072 0.089 0.108 0.129

Max. Weight (g/m)

1.00 1.36 1.98 2.97 4.38 6.50 9.90 12.58 19.65 30.68 46.28 5.23

lb/kft
0.71 0.96 1.4 2 3 4.5 6.8 8.6 13.2 20.2 31.1

Nom. OD (mm) (in)

Max. Weight (g/m) lb/kft

1.02 1.17 1.37 1.57 1.85 2.06 2.49 2.98 3.73 87.6

0.04 0.046 0.054 0.062 0.073 0.081 0.098 0.117 0.146 0.206

2.23 3.43 4.92 7.30

1.6 2.4 3.5 5.1

10.90 7.7 13.88 9.8 20.90 14.7 31.34 22.1 50.4 5.56 35.6 61.8

*For 44A0211-26 the stranding is 7/0.16mm 7/34 AWG

Screened and jacketed cable 44A111X (600 V) 1 conductor 44A121X (600 V) 1 conductor

Size
30 28 26 24 22 20 18 16 14 12

Stranding (mm)
7/0.10 7/0.13 19/0.10 19/0.13 19/0.16 19/0.20 19/0.25 19/0.29 19/0.36 37/0.32

#/AWG
7/38 7/36 19/38 19/36 19/34 19/32 19/30 19/29 19/27 37/28

Nom. OD (mm)

(in)

Max. Weight (g/m)

lb/kft

Nom. OD (mm) (in)

Max. Weight (g/m) lb/kft

1.57 1.83 2.00 2.26 2.62 2.79 3.22 3.70

0.065 0.072 0.076 0.089 0.103 0.11 0.127 0.146

5.82 8.20 10.30 14.02 19.70 23.40 32.50 45.67

4.6 5.8 7.2 9.9 13.9 16.5 22.9 32.1

1.73 1.98 2.24 2.54 2.82 3.02 3.45 4.14

0.068 0.078 0.088 0.100 0.111 0.119 0.136 0.155

6.51 9.18

4.6 6.5

12.35 8.3 17.40 11.7 22.61 15.2 26.63 17.9 36.15 24.3 49.55 33.3

Other sizes are also available in some constructions depending on conductor type and construction required.

9-2 Wire and Cable

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44A031X (2500 V) primary wire

44A081X (600 V) airframe wire

44A012X (600 V) twisted pair

Nom. OD (mm)

(in)

Max. Weight (g/m) lb/kft

Nom. OD (mm)

(in)

Max Weight (g/m) lb/kft

Nom. OD (mm) (in)

1.37 1.52 0.054 0.060 0.068 0.080 0.094 0.110 0.130 0.144 0.178 0.216

Max. Weight (g/m) lb/kft

2.12 2.90 4.10 6.08 8.91 13.30 20.21 25.73 40.15 62.63 1.6 2.1 3 4.5 6.6 9.9 15 19.1 29.8 46.5

1.22 1.44 1.75 1.98 2.23 2.46 2.92 3.32 4.09 96.20 0.057 0.069 0.078 0.088 0.097 0.115 0.131 0.161 0.219 4.18 6.12 8.65 12.38 15.37 23.13 34.32 54.02 5.44 3.0 4.3 6.1 8.7 10.9 16.2 24.2 36.5 65.0 1.37 1.57 1.78 2.03 2.26 2.74 3.20 3.94 92.94

0.048 0.054 0.062 0.07 0.08 0.089 0.108 0.126 0.155 0.214

2.28 3.73 5.52 7.91 11.49 14.32 22.08 32.23 51.80

2.0 2.6 3.8 5.4 8.0 9.9 14.9 21.9 35.0 62.8

1.73 2.03 2.38 2.79 3.30 3.65 4.52 5.48

44A181X (600 V) 1 conductor

44A112X (600 V) 2 conductors

Nom. OD (mm)

(in)

Max. Weight (g/m) lb/kft

Nom. OD (mm)
2.23 2.38 2.59

(in)
0.088 0.094 0.102 0.118 0.132 0.148 0.170 0.184 0.218 0.256

Max. Weight (g/m) lb/kft

8.20 9.40 12.05 16.12 21.50 27.97 38.24 44.93 64.28 91.51 5.8 6.6 8.1 11.3 14.5 18.8 25.7 30.2 43.2 61.5

2.26 2.57 2.77 3.02 3.25 3.73 4.19

0.089 0.101 0.109 0.119 0.128 0.147 0.165

11.69 15.39 19.09 23.98 27.97 38.48 52.10

7.9 10.4 12.9 16.2 18.9 26 35.2

2.99 3.35 3.76 4.32 4.67 5.53 6.50

Users should independently evaluate the suitability of the product for their application. Before ordering check with factory for most current data.

Wire and Cable 9-3

SPEC 44 (contd.)
Wire and cable

NEMA WC-27500 Cable Part Numbering System

M27500 - AWG XX X X XX Jacket style and material 00 = no jacket 08 = crosslinked, white PVDF 23 = crosslinked, white, modified ETFE Shield material and style U = no shield T = tin-coated copper, round J = tin-coated copper, flat S = silver-coated copper, round G = silver-coated copper, flat N = nickel-coated copper, round Number of components. 1 through 9; 10 components = 0. Basic wire spec (MIL-W-81044) and slash sheet MD = /5 (44A0712) ME = /6 (44A0711) MF = /7 (44A0714) MG = /8 (44A0812) MH = /9 (44A0811) MJ = /10 (44A0814) MK = /11 (44A0112) ML = /12 (44A0111) MM = /13 (44A0114)

Example:
M27500-22ML3T08 = 44AM1131-22-9/96/93-9

Military part no. Raychem part no.

9-4 Wire and Cable

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Environmental Performance
Temperature rating SPEC 44 wire and cable is rated for continuous operation from -65C to +150C and for short periods at temperatures as high as 300C. Heat ageing tests are routinely performed at temperatures of 200C (168 h) and 300C (6 h). In addition SPEC 44's 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 non-melting 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 insulations. 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 total 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.

Users should independently evaluate the suitability of the product for their application. Before ordering check with factory for most current data.

Wire and Cable 9-5

SPEC 44 (contd.)
Wire and cable

Fire hazard performance Flammability

Federal Aviation Reg FAR-25 BS4066 vertical flammability S424 14751 (Swedish chimney) NFC 32070 (2) (French chimney) IEC 332 part 3 (Cable ladder)

Pass Pass Pass Pass Pass 6 per meter of wire 0.8 per meter of wire 30% Oxygen >300C

Smoke/Toxicity Index

Smoke Index, Def Stan 61-12 (18) Toxicity Index, Def Stan 61-12 (18) Oxygen Index, NES 714 Temperature Index, NES 715

9-6 Wire and Cable

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Part numbering system

44 X X X X X- Size- X/X- X Jacket color (in accordance with MIL-STD-681,white preferred) Primary wire insulation color (in accordance with MIL-STD-681) 0=Black 1=Brown 2=Red 2L=Pink 3=Orange 4=Yellow 5=Green 6=Blue 7=Violet 8=Grey 9=White Additional number after base color indicates stripe Conductor size Conductor type 1 - Tin-plated copper 4 - Silver-plated high strength 2 - Silver-plated copper copper alloy (SPHSCA) 3 - Nickel-plated copper 6 - Nickel-plated high strength copper alloy (NPHSCA) Number of conductors 1 to 9 0 = 10 conductor Class of wire 1 - 600 V equipment wire 7 - 600 V nominal weight wire 2 - 1000 V equipment wire 8 - 600 V medium weight wire 3 - 2500 V equipment wire Constructions 0 - Primary wire and unscreened, unjacketed cables 1 - Round braid screened and jacketed 2 - Flat braid screened and jacketed 3 - Round braid, screened, no jacket 4 - Jacketed, no screen 5 - Spirally screened and jacketed 7-9 - Special constructions
Screen material same as conductor material except screen for type 4 conductor is tinned copper.

Type I - 135C space wire B - Radiation crosslinked modified A - AWG conductor ETFE jacket in place of PVDF CD - Custom Design AM - Designation for M27500 cables M - Metric conductor D - Defense Standard 61-12 Part 2b Issue 3 Basic specification number
Typical ordering example Ordering information
3 conductors, brown, yellow with green stripe, blue, white jacket. If 600 volt, round braid, 20 AWG tinned conductor, total part number is 44A1131-20-1/45/6-9. Standard equipment wires (44A0111 12 to 30 AWG) in most common AWGs and colors are kept in stock. In addition, many of the most commonly used single/pair and triple screened cables are also stock items, as are some airframe constructions*. Other constructions and custom designed wire and cable are available on request.

*Europe only.

Users should independently evaluate the suitability of the product for their application. Before ordering check with factory for most current data.

Wire and Cable 9-7