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Spec 55 wire is insulated with modified radiation cross-linked ETFE polymer. It has a temperature rating of -65C to 200C continuous, 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 Specifications
* Resistant to electrical arc tracking in wet or dry conditions * Single or dual wall constructions * Small size, ultra light weight * Exceptional chemical resistance
Spec 55
Wire and cable
Spec 55 Insulation system - Single wall
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MIL-W-22759/32-35 and /41 to /46 and MIL-DTL-C-27500 (Cables) Defence Standard 61-12 Part 33 VG95218 Part 20, Type D; Part 21, Type A; Part 22, Type A; Part 23, Type A, Part 1001 and Part 1002 VDE 9426, 9427, 9428 British Standard 3G233 Boeing BMS 13-48 Civil Aviation Authority Accessory Approval E11749 Airbus ABS 0820 to 0826 Underwriters Laboratory Style 3467 NASA preferred product list Raychem Specification 55 European Space Agency 3901/012, 3901/020 and 3901/022
Conductor Insulation Radiation Crosslinked, Modified ETFE Conductor
numerous aircraft programmes. It has a choice of two total wall thickness, 0.25 mm and 0.2mm, both have a contrasting core colour 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 mm and 0.15 mm wall thicknesses for use inside black boxes where flexibility and solder-iron resistance make it a wire which is very easy to reliably install. Both single and dual wall insulated wires are available in twisted pairs, triples, etc., and as screened and jacketed cables.
Spec 55 Insulation system - Dual wall
Insulations Radiation Crosslinked, Modified ETFE Innerlayer coloured blue
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Spec 55
Physical characteristics
Size and 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 thickness. The dual wall airframe wire has an insulation wall thickness of either 0.2mm or 0.25 mm for robustness in unprotected harnesses and has excellent wire to wire abrasion properties. The single wall equipment wire has a 0.15 mm 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 mm wall and provides considerable weight and size savings over other comparable wires. Handling The excellent flexibility and low resilience 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 preetching. For full descriptions of the appropriate tools see separate wire handling guide.
Typical properties
Temperature rating (Tin plated conductor) (Silver or nickel plated conductor) Thermal endurance Scrape abrasion (BS 3G233) Flexing endurance (Boeing BSS 7324) Voltage rating Tensile strength + core elongation Tensile strength + total elongation Notch propagation BS 3G230 0.05 mm notch Solder iron resistance (370C, 1 minute) Solderability - Tin plated copper conductor BS 3G233 conditions Shrinkage Long term water resistance Permittivity 1 KHz (ASTM D150) Dissipation factor (ASTM D150) -65C to +150C -65C to +200C 200C, 10000 h >100 cycles at 150C >1000 cyles 600 V, 450V (Airframe wire only) 35 N/mm2, 125% (All primary wire) 35 N/mm2, 75% Pass Pass <0.8 secs to wet <1% Will not hydrolyse 2.7 0.001
Environmental performance
Temperature rating Spec 55 wire and cable is rated for continuous operation from -65C to +200C and for short periods at temperatures as high as 400C. Mechanical performance Radiation crosslinking of the Spec 55 insulation significantly 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 does not melt at high temperature. As a result Spec 55 wire is resistant to hot solder irons and current overloads which would melt most thermoplastic insulations. 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 vertical test FAR 25. Electrical arc tracking resistance Spec 55 insulation demonstrates resistance to arc tracking under both wet and dry conditions at aircraft system voltages.
Spec 55
Spec 55 wire & cable: Standard constructions, nominal sizes, strandings, diameters and weights
Conductor Primary wire Twisted pair Single Screened & jacketed Pair
55A - AWG conductor: Equipment/Interconnect wires & cables
Stranding (mm) 7/0.102 7/127 19/102 19/127 19/0.16 19/0.203 19/0.25 19/287 19/0.36 37/0.32 37/0.403 133/0.287 55A011X OD (mm) 0.61 0.68 0.81 0.94 1.09 1.27 1.52 1.73 2.2 2.62 3.25 4.77 Weight (g/m) 0.98 1.35 2.1 2.98 4.2 6.4 9.7 12.4 19.4 29.35 47.4 87.6 55A012X OD (mm) 1.27 1.42 1.67 1.93 2.23 2.66 3.2 3.58 4.47 5.38 6.65 9.8 Weight (g/m) 1.94 2.68 4.2 5.96 8.6 13.26 19.57 25.8 39.6 60/0 96.7 178.8 55A111X OD (mm) 1.51 1.59 1.71 1.84 1.99 2.2 2.45 2.67 3.1 3.55 4.2 5.8 Weight (g/m) 5.1 5.8 6.85 8.2 10.3 13.4 17.88 21.75 30.4 42.46 62.7 110.5 55A112X OD (mm) 2.12 2.27 2.53 2.8 3.07 3.5 4.1 4.43 5.3 6.3 Weight (g/m) 7.74 8.9 11.32 13.86 17.9 23.8 32.6 39.7 57.0 81.2 -
Size 30 28 26 24 22 20 18 16 14 12 10 8
55A - AWG conductor: Airframe wires & cables
Stranding (mm) 19/102 19/127 19/0.16 19/0.203 19/0.25 19/287 37/0.36 37/0.32 37/0.403 55A081X OD (mm) 1.01 1.14 1.27 1.47 1.78 1.95 2.4 2.82 3.4 Weight (g/m) 2.5 3.4 4.8 7.0 10.7 13.4 20.5 30.5 48.3 55A082X OD (mm) 2.1 2.33 2.64 3.07 3.63 4.06 4.9 5.8 7.1 Weight (g/m) 5.1 6.84 9.98 14.75 21.9 27.5 42.3 63.0 99.1 55A111X OD (mm) 1.71 1.84 1.99 2.2 2.45 2.67 3.1 3.55 4.2 Weight (g/m) 6.85 8.2 10.3 13.4 17.88 21.75 30.4 42.46 - 62.7 55A112X OD (mm) 2.63 2.8 3.07 3.5 4.1 4.43 6.3 6.3 Weight (g/m) 11.32 13.86 17.9 23.8 32.6 39.7 57.0 81.2 -
Size 26 24 22 20 18 16 14 12 10
55PC - AWG conductor: Statistical Process Controlled Airframe wires & cables
55PC042X 55PC021X Weight Weight OD Stranding OD (mm) (g/m) (mm) (g/m) (mm) 19/102 0.087 1.8 19/127 1.00 3.2 2.0 6.3 19/0.16 1.15 4.56 2.31 9.12 19/0.203 1.37 6.8 2.74 13.66 19/0.25 1.61 10.3 3.22 20.6 19/287 1.8 12.96 3.6 26.0 19/.036 2.18 19.86 4.36 39.9 37/0.32 2.66 30.2 5.3 60.8 37/0.403 3.27 47.9 - Tin plated copper conductor. - Silver plated high strength copper alloy conductor. (Recommended for size 24 & 26in airframe applications). 55PC141X OD (mm) 1.52 1.65 1.80 2.00 2.23 2.44 2.79 3.30 3.98 Weight (g/m) 6.32 7.63 9.55 12.47 16.72 20.05 28.08 40.45 61.16 55PC142X OD (mm) 2.33 2.89 2.89 3.30 3.78 4.16 4.92 5.92 7.39 Weight (g/m) 10.75 13.27 17.28 23.00 31.33 38.05 54.25 78.80 128.06
Size 26 24 22 20 18 16 14 12 10 X= 1 4
55PC - extra light weight constructions
For applications where weight is critical, light weight tight tolerance conductors and insulations are available. These are manufactured using statistical process control methods and achieve weights that are equal or lighter than the equivalent polyimide/ PTFE constructions. Contact Wire & Cable Division for further details.
Spec 55
Part numbering system
55 X X X X XSize- X/X- X 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 3 - Nickel-plated copper 4 - Silver-plated high strength copper alloy 6 - Nickel-plated high strength copper alloy Number of conductors 1 to 9 Class of wire 1 - 600 V equipment wire, light weight 2 - 600 V airframe wire, light weight 4 - 450 V equipment wire (55M Only sizes 20-30) 8 - 600 V airframe wire, normal weight Constructions 0 - Primary wire & unscreened, unjacketed cables 1 - Round braid screened & jacketed cable 2 - Flat braid screened & jacketed cable 3 - Round braid, screened cable, no jacket 4 - Jacketed cable, no screen 5 - Spiral screened and jacketed cable 8 - Special constructions (part numbers not coded) 9 - Special constructions including light weight Screen material same as conductor material except all flat screens and screen for conductor types 4 and 6 shall be tinplated copper. Other combinations are special. (Refer to Wire and Cable Division). Type A- AWG conductor M - Metric conductor / - Space wire Basic specification number
Typical ordering example Ordering information
3 conductors, red, yellow, blue, 600 volt equipment wire with overall round braid, 20 AWG tinned conductor and white jacket: total part number is 55A1131-20-2/4/6-9. A list of stock policy items can be identified by contacting the relevant Product Specialist or Sales Order Office. Stock policy items are recognized by the use of a suffix, such as (300) defining the pack size, typically 55A0111-22-9(300).
Raychem and Spec 55 are trademarks of Tyco Electronics Corporation. Tyco Electronics Raychem 305 Constitution Drive Menlo Park, CA 94025 U.S.A Tel: (650)-361 3860 Tyco/Electronics/Raychem Cheney Manor Industrial Estate Swindon, Wiltshire SN2 2QE UK Tel: (44)-1793 573762 Tyco/Electronics/Raychem 3816 Noborito, Tama-ku Kawasaki 214-8533 Japan Tel: (81)-44 9005102 Tyco/Electronics/Raychem No. 26 Ang Mo Kio Ind. Park Singapore 569507 Tel: (65)-4866151
WC0026.1200

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