44 wire 44 cable (twisted pair) specifications/approvals mil-w-81044, mil-c-27500 (cables) def stan. 61-12 part 18 issue 4 - type 1 pliable (maintenance range) def stan. 61-12 part 26 issue 2 type 1, 2, 3, 7, 8, 9 & mets 7, 8 & 9 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 conductor primary insulation - radiation crosslinked, extruded polyalkene jacket - radiation crosslinked, modified pvdf ? 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 spec 44 wire and cable 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 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.
spec 44 physical characteristics typical properties environmental performance fire hazard performance small size spec 44 equipment wire, 600 volt rated has a 0.19 mm nominal wall thickness compared to 0.25 mm and 0.38 mm 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/metre max 22awg ptfe equipent wire, mil-w-22759 5.54 grams/metre 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. 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. temperature rating -65 c to +150 c voltage rating (thin wall) 600 v voltage rating (thick wall) 2500 v tensile strength and elongation of insulation 30 n/mm 2 , 230% notch propagation, 0.05mm notch pass solder iron resistance (370 c, 1 minute) pass shrinkage, 200 c <1% low temperature bend -65 c voltage withstand (thin wall) 2500 v insulation resistance (20 c) 1500 m ohms for 1 km resistance: fuels, oils, solvents pass temperature rating spec 44 wire and cable is rated for continuous operation from -65 c to +150 c and for short periods at temperatures as high as 300 c. heat ageing tests are routinely performed at temperatures of 200 c (168 h) and 300 c (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 oxidisers. cold flow radiation cross-linking of spec 44 prevents cold flow of the insulation - a recognised 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. flammability bs4066 vertical flammability pass s424 14751 (swedish chimney) pass nfc 32070 (2) (french chimney) pass iec 332 part 3 (cable ladder) pass smoke/toxicity index smoke index, def stan 61-12 (18) 6 per metre of wire toxicity index, def stan 61-12 (18) 0.8 per metre of wire oxygen index, nes 714 30% oxygen temperature index, nes 715 >300 c
spec 44 spec 44 wire and cable - nominal sizes, strandings and weights primary wires/twisted pair 44a011x (600 v) primary wire 44a021x (1000 v) primary wire 44a031x (2500 v) primary wire 44a081x (600 v) airframe wire 44a012x (600 v) twisted pair size stranding (mm) csa (mm 2 ) od (mm) weight (g/m) od (mm) weight (g/m) od (mm) weight (g/m) od (mm) weight (g/m) od (mm) weight (g/m) 30 7/0.10 0.06 0.68 1.00 1.37 2.12 28 7/0.13 0.09 0.76 1.36 1.49 1.52 2.90 26* 19/0.10 0.15 0.86 1.98 1.02 2.23 1.73 4.10 24 19/0.13 0.25 1.02 2.97 1.17 3.43 1.44 4.18 1.37 3.73 2.03 6.08 22 19/0.16 0.40 1.19 4.38 1.37 4.92 1.75 6.12 1.57 5.52 2.38 8.91 20 19/0.20 0.60 1.40 6.50 1.57 7.30 1.98 8.65 1.78 7.91 2.79 13.30 18 19/0.25 1.00 1.65 9.90 1.85 10.90 2.23 12.38 2.03 11.49 3.30 20.21 16 19/0.29 1.25 1.83 12.58 2.06 13.88 2.46 15.37 2.26 14.32 3.65 25.73 14 19/0.36 2.00 2.26 19.65 2.49 20.90 2.92 23.13 2.74 22.08 4.52 40.15 12 37/0.32 3.00 2.74 30.68 2.98 31.34 3.32 34.32 3.20 32.23 5.48 62.63 10 37/0.40 5.00 3.28 46.28 3.73 50.4 4.09 54.02 3.94 51.80 8 133/0.29 5.23 87.6 5.56 96.20 5.44 92.94 *for 44a0211-26 the stranding is 7/0.16mm screened and jacketed cable 44a111x (600 v) 1 conductor 44a121x (6000 v) 1 conductor 44a181x (600 v) 1 conductor 44a112x (600 v) 2 conductors size stranding (mm) od (mm) weight (g/m) od (mm) weight (g/m) od (mm) weight (g/m) od (mm) weight (g/m) 30 7/0.10 2.23 8.20 28 7/0.13 1.60 5.33 2.38 9.40 26 19/0.10 1.57 5.82 1.73 6.51 2.59 12.05 24 19/0.13 1.83 8.20 1.98 9.18 2.26 11.69 2.99 16.12 22 19/0.16 2.00 10.30 2.24 12.35 2.57 15.39 3.35 21.50 20 19/0.20 2.26 14.02 2.54 17.40 2.77 19.09 3.76 27.97 18 19/0.25 2.62 19.70 2.82 22.61 3.02 23.98 4.32 38.24 16 19/0.29 2.79 23.40 3.02 26.63 3.25 27.97 4.67 44.93 14 19/0.36 3.22 32.50 3.45 36.15 3.73 38.48 5.53 64.28 12 37/0.32 3.70 45.67 4.14 49.55 4.19 52.10 6.50 91.51 size 10 to 4 also available in some constructions depending on conductor type and construction required. spec 44 wire and cable (def stan 61-12 part 18 issue 4 type 1) (maintenance) limited fire hazard equipment wire (pliable) cable electrical - type 1sbm screened and jacketed conductor size stranding (mm) diameter over insulation (mm) weight (gm/m) raychem part number diameter over screen (mm) diameter over jacket (mm) weight (gm/m) raychem part number 30 7/0.10 0.68 1.00 44m9976-30-? 28 7/0.12 0.73 1.40 44m9976-28-? 26 19/0.10 0.88 2.00 44m9976-26-? 1.33 1.80 7.5 44m9995-26-?-? 24 19/0.12 0.98 3.00 44m9976-24-? 1.43 1.90 9.2 44m9995-24-?-? 22 19/0.15 1.13 4.40 44m9976-22-? 1.58 2.05 11.1 44m9995-22-?-? 20 19/0.20 1.40 6.55 44m9976-20-? 1.83 2.30 14.6 44m9995-20-?-? 18 19/0.25 1.65 9.90 44m9976-18-? 2.08 2.55 19.3 44m9995-18-?-? 16 19/0.30 1.90 14.15 44m9976-16-? 2.48 2.95 24.9 44m9995-16-?-? 14 37/0.25 2.25 18.62 44m9976-14-? 2.65 3.13 30.9 44m9995-14-?-? 12 37/0.30 2.60 25.70 44m9976-12-? 3.00 3.48 43.4 44m9995-12-?-? the cable jackets on type 1sbm are specified black to def. stan. 61-12 pt 31, other colours are available. ?colour code suffix - see part numbering system. single and multicore screened and jacketed cables are available using type1 co mponents.
spec 44 all of the above information, including illustrations, is believed to be reliable. users, however, should independently evaluat e the suitability of each product for their application. tyco electronics makes no warranties as to the accuracy or completeness of the information and disclaims any liabi lity regarding its use. tyco electronics only obligations are those in the standard terms and conditions of sale for this product and in no case will tyco electronics b e liable for any incidental, indirect or consequential damages arising from the sale, resale, use or misuse of the product. tyco electronics specifications are subject to change without notice. in addition tyco electronics reserves the right to make changes in materials or processing, without notification to the buyer, which do not affect compliance with any applicable specification. wc0007.0200 raychem and spec 44 are trademarks of tyco electronics corporation. tyco electronics corporation 300 constitution drive menlo park, ca 94025-1164 usa tel: (800)-926 2425 (us and canada) tel: +1 650 361 3860 (all other countries) tyco electronics raychem k.k. 3816 noborito, tama-ku kawasaki kanagawa 214-8533 japan tel: +81 44 900 5102 raychem singapore pte ltd. 26 ang mo kio industrial park 2 singapore 569507 tel: +65 4866151 tyco electronics uk ltd faraday road, dorcan, swindon, wiltshire sn3 5hh tel: (44)-1793-528171 www.tycoelectronics.com part numbering system 44 x x x x x- size- x/x- x typical ordering example 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. ordering information standard equipment wires (44a0111 12 to 30 awg) in most common awgs and colours 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. jacket colour (in accordance with mil-std-681, white preferred) primary wire insulation colour (in accordance with mil-std-681) 0=black 3=orange 7=violet 1=brown 4=yellow 8=grey 2=red 5=green 9=white 2l=pink 6=blue additional number after base colour indicates stripe conductor size conductor type 1 - tin-plated copper 2 - silver-plated copper 4 - silver-plated high strength copper alloy (sphsca) number of conductors 1 - 9 class of wire 1 - 600 v equipment wire 2 - 1000 v equipment wire 3 - 2500 v equipment wire 4 - space wire 600 v 8 - airframe wire - medium weight constructions 0 - primary wire & unscreened, unjacketed cables 1 - round braid screened & jacketed ? 2 - flat braid screened & jacketed ? 3 - round braid, screened, no jacket ? 4 - jacketed, no screen 5 - spirally screened & jacket 7 - 9 special constructions ? screen material same as conductor material except screen for type 4 conductor is tinned copper type a- awg conductor m - metric conductor am - special cd - custom design b - special / - space & specials d - defence standard 61-12 part 26 basic specification number
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