M39012/25-0009 - CORSAIR ELECTRICAL CONNECTORS INC.

JUDD WIRE, INC.

Aerospace

Judd Wire’s Aerospace wiring

is currently used in a wide range of

commercial and military airframes, avionics, satellites, missile

guidance systems, Fly-By-Wire cables, in-flight communication and

entertainment cables, and military electronics ground equipment.

Judd Wire

is approved for installation in the world’s largest

transports built by the Boeing Commercial Airplane Group, and

numerous other military and OEM programs.

Manufacturers of Superior Insulation Systems for Electrical Aerospace Wire & Cable

Judd Wire

is an integrated designer, manufacturer and test facility for

Aerospace wire and cable. We work to create a combination of design

choices for our customers that allow them the best choice of materials

and performance attributes for their unique applications.

Our products include both military and commercial airframe wiring,

lightweight avionics wiring, data bus cables, non-halogenated

jacketed cables for in-flight entertainment systems, Fly-By-Wire flight

control cables, reduced diameter cables for satellites, commercial

aircraft grade Fiber Optic cables, Filter Line wiring and custom cables

for military ground equipment and missiles.

Designing for Excellence

Engineering expertise in the design of unique Aerospace products

has made

Judd Wire

a leading supplier to the newest aircraft platforms

being built today. Our engineers work in multi skilled teams to utilize

the most effective choices among materials, designs, manufacturing

processes and test verifications.

Product designs from simple discrete wire to complex cables carry

with them the same involvement of engineering expertise and

dedication to precise design elements.

Product engineers utilize an on-line design system to tie together

customer specifications into our design efforts from the

manufacturing process through the Quality Assurance documentation.

Give us the opportunity to enhance the design of your requirements.

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

Judd Wire Specification Approvals

Judd Wire

is approved to both SAE AS 22759 (/32-/46) XLETFE and SAE

AS 85485 (Filter Line) QPL specifications. We also manufacture to the

corresponding NEMA WC 27500 cable requirements for related styles.

Judd Wire’s

OEM approvals include designs used at Boeing Commercial

Airplane, Boeing Military, Raytheon, Lockheed Martin, Bombardier,

Embraer, Sikorsky, Northrop Grumman, and Fokker.

These designs are used on commercial aircraft built throughout the

world as well for the United States military.

Quality Assurance and Testing

Judd Wire

is registered to ISO-9000 and AS9100. Our quality record

allows customers to create a “ship-to-stock” program that saves them

considerable time and money in the receiving and inspection of our

product.

Judd Wire

has also achieved registration to the Automotive

IS/TS1649 and Environmental ISO 14000 certifications.

Other companies may manufacture product for Aerospace use,

however few can offer the complete laboratory and material test facilities

that

Judd Wire

provides.

Among the specialized testing for airframe products that

Judd Wire’s

laboratory routinely performs are Insulation and Conductor Flexure

Endurance, Wet Arc Tracking Resistance, Dry Arc Tracking Resistance, Wire

to Wire Abrasion, Circuit Breaker Overload testing, Shielding

Effectiveness, Surface Transfer Impedance, and Dynamic Cut-Through.

Specialized material analysis testing is available as DSC or TGA

measurements, hot modulus benchmarking, viscosity analysis, volatile

particulate measurements and FT-IR examinations.

Through this program, both Judd Wire and

its vendors guarantee to always provide

the very best products backed by the very

best quality assurance network.

JUDD WIRE INC.

Contents

SuperComposite®200 . . . . . . . . . .2

JWXLT . . . . . . . . . . . . . . . . . . . . . . .3

Fiber Optic Cables

for Commercial Aircraft

Applications . . . . . . . . . . . . . . . . . .4

Hybrid Conductors . . . . . . . . . . . .5

Low Voltage

Lightweight XLETFE . . . . . . . . . . .5

SAE-AS-22759/32 . . . . . . . . . . . . .6

SAE-AS-22759/33 . . . . . . . . . . . . .6

SAE-AS-22759/34 . . . . . . . . . . . . .7

SAE-AS-22759/35 . . . . . . . . . . . . .7

SAE-AS-22759/41 . . . . . . . . . . . . .8

SAE-AS-22759/42 . . . . . . . . . . . . .8

SAE-AS-22759/43 . . . . . . . . . . . . .8

SAE-AS-22759/44 . . . . . . . . . . . . .9

SAE-AS-22759/45 . . . . . . . . . . . . .9

SAE-AS-22759/46 . . . . . . . . . . . . .9

SAE-AS-85485– Filter Line . .10, 11

NEMA WC 27500 . . . . . . . . .12, 13

Custom Designs . . . . . . . . . . . . .13

Qualified Vendor Listing

In an effort to provide customers with the highest quality products

through our distributors,

Judd Wire

has developed a Qualified Vendor

Listing (QVL) program for its Military and Aerospace wire and cable

distributors. To become a QVL distributor of

Judd Wire

, vendors were

audited to the standards outlined in ISO 9001:2000 and AS9100-B which

are in accordance with AS9104 and AIR5359B, and certified to have met

or exceeded all of the expectations within those standards.

Judd Wire’s

QVL program provides customers with:

■A distribution source that utilizes accredited methods for record keeping,

certification and traceability of all factory documentation

■A value added packaging system that complies with Aerospace regulatory agency

requirements

■A visible and defined link between

Judd Wire

and the end customer

Judd Wire’s

newest hybrid insulation system is the SuperComposite®200, a combination of dual walls

using an enhanced ultra thin layer of PTFE/Polyimide tape with an extruded XLETFE outer layer.

This robust and proven combination of materials produces a .006” dual wall product with performance

properties that exceed every current design materials used in the Aerospace community today.

The design emphasis has been on using the strengths of each material to compliment and improve

the overall performance of the insulation.

We believe that the mechanical performance for cut-through (at both room temperature and at

elevated temperatures), wire to wire abrasion resistance, moisture resistance, resistance to arc

tracking, and deformation all have been measured as equal to the best materials in use today.

This wire also exhibits superb contrast levels when marked with current laser processors and can be

cut and stripped with all types of hand held and automated equipment.

We invite you to ask more about what

Judd Wire

sees as the natural progression to the next

generation Aerospace wiring insulation system.

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

SuperComposite®200

Judd Wire’s SuperComposite®products offer:

■Truly edge-free outer insulation layer

■Extruded layer (no edges/seams)

■Improved laser contrast vs. tape

■Equivalent Wet Arc-Track Resistance

■Durable/Abrasion resistant outer layer

■Improved Dynamic Cut-Through Resistance

■200˚C capability (260˚C version available)

■Improved strippability (insulation removal) vs. tape

■Equivalent forced Hydrolysis Resistance

■Potential for weight savings

Please contact Judd Wire for complete test and data information.

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

JWXLT is an improved lightweight XLETFE insulations system with enhanced properties for airframe

wiring applications.

Judd Wire

is pleased to offer to the general aviation industry the same superior wires and cables which

are currently used on the largest commercial aircraft in the world. JWXLT is used in commercial, regional

aircraft, business jets and on aircraft developed for the United States Armed Forces.

The unique attributes of this insulation allow it to meet the requirements of the Military Specification

SAE AS 22759 for crosslinked modified Ethylene Tetrafluoroethylene Copolymer (XLETFE) and the

additional testing requirements imposed by the OEM standards used in these programs.

JWXLT

Design Enhancements of JWXLT

■Superior wire to wire abrasion resistance

• Over 6 million average cycles

■Lower weights and diameters due to thinner

dual wall insulations

• 20% Thinner insulation layers than

standard Mil Spec XLETFE

■Outstanding resistance to wire bundle damage due to

arc tracking from overloaded circuits

• Qualifies to industry standards for both wet and

dry arc propagation

■Enhanced markability contrasts when processed by

Excimer Lasers

• Exceeds 60% contrast measurements

■Excellent results when tested for fusing characteristics in

Circuit Breaker Overload Current Compatibility Test

■Improved flexure endurance for conductor and insulation

■Excellent outgassing measurements for Toxic Emissions

and Smoke Density

Please contact Judd Wire for complete test and data information.

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

Judd Wire

has developed a flexible, abrasion and crush resistant, temperature stable Fiber Optic cable

that is made in compliance with ARINC standard 802. This cable is suitable for installation in both the

pressurized and non pressurized cabin environments of all commercial aircraft.

Fiber Optic Cables for

Commercial Aircraft Applications

Superior Performance and Strength of Support

■In-Flight Entertainment Systems

■Commercial Aircraft Cabin Data Collection

■Electronic Flight Bag (Downloadable Data)

■Military Systems

Please contact Judd Wire for complete test and data information.

Test Description Specification Reference Requirement(s) Product Test Results

Diameter ARINC 802 Table 2-1 1.80mm ± 0.16mm 1.90mm

Cable Weight ARINC 802 Section 2.1.1 Lowest Weight Possible 4.61Kg/Km

Cable Flexibility ARINC 802 Angle: 90˚ 0.20 dN x m (min) 0.22 dN x m

Section 2.2.3.1 0.85 dN x m (max)

Frictional torque applied Angle: 180˚ 0.20 dN x m (min) 0.27 dN x m

20% of max 1.13 dN x m (max)

Flexure Endurance ARINC 802 Section 2.2.3.2 Change in 10,000 cycles ± 0.25 0.11 dB

TIA/EIA - 455-104A Transmittance dB (max)

Cable Bend Radius ARINC 802 Change in ± 0.25 dB (max) 0.00 change

Section 2.2.3.4 Transmittance (negligible)

Impact Resistance ARINC 802 Section 2.2.3.7 No Cracking, 20 drops 147 drops

TIA/EIA - 455-25C No Fiber Breakage No Fiber Breakage

Jacket Shrinkage ARINC 802 Section 2.2.3.8 Change in 1.3% (45mm) (max) 4.57mm (No added

TIA/EIA - 455-3A Strip Length change in jacket

Test Condition C-3 shrinkage after

23 cycles)

Cable to Cable Abrasion ARINC 802 Section 2.2.3.11 300,000 cycles (min) No exposure of any layer Greater than

50,000,000 cycles

Fiber movement ARINC 802 Section 2.2.3.13 Change in ± 0.10 dB (max) 0.03 dB

under compression Transmittance

Smoke and Toxicity ARINC 802 Section 2.2.4.7 Meets Smoke limits

Boeing Specifications: BSS 7238 Smoke and Toxicity limits specified Meets Toxicity limits

BSS 7239

Low and High ARINC 802 Section 2.2.5.4 Change in ± 0.25 dB (max) 0.04 dB

Temperature Cable Bend TIA/EIA - 455-37A Transmittance No cracking No cracks

(10x magnification) (10x magnification)

Temperature Life ARINC 802 500hrs at 125˚C 3.0 dB/Km (max) 1.15 dB/Km

Section 2.2.5.5 (275˚F) at 1300µm

TIA/EIA - 455-4C Change in 6.0 dB/Km (max) 3.58 dB/Km

Transmittance at 850µm

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

AWG Nominal Plated Copper- Insulated Values Plated Hybrid- Insulated Values Weight DCR

Diameter DCR Weight LBS/KFT DCR Weight LBS/KFT Savings Rise

(inches) (max.) (max.) (max.) (max.)

14 19/27 .218 3.000 11.3 3.470 8.3 27% 16%

12 37/28 .218 1.980 17.2 2.440 11.1 36% 23%

10 37/26 .107 1.240 27.9 1.530 17.9 36% 23%

8 133/29 .218 .694 70.8 .803 51.7 27% 16%

6 133/27 .267 .436 107.0 .504 78.1 27% 16%

4 133/25 .325 .275 170.0 .318 121.3 29% 16%

2 665/30 .407 .177 261.0 .205 195.0 25% 16%

1 817/30 .471 .149 332.0 .167 245.3 26% 12%

0 1045/30 .504 .113 429.0 .131 296.2 31% 16%

00 1330/30 .553 .089 530.0 .103 375.0 29% 16%

000 1665/30 .630 .071 634.0 .088 403.3 36% 24%

Judd Wire

offers a unique reduced wall (.004”) avionics wire for enclosed panels and systems that require

the smallest wire possible for unique applications. Although not listed under a specific military specification,

this wire is routinely used in satellite systems, optical systems and other miniaturized control devices.

Low Voltage – Lightweight XLETFE

450 Volts - 150°C

Judd Wire

offers a number of design options for weight reductions and performance enhancements.

One of those alternatives is the development of an insulated hybrid conductor, utilizing both aluminum

and copper stranding. Customers requiring a balance of properties can take advantage of weight savings

afforded by the aluminum while keeping the conductivity and mechanical strength properties of the copper.

Designs to date have used 1350 EC aluminum as the center bunch with plated copper strands forming

the outer layer.

Full design (including calculated weight savings) and test performance data is available upon request.

Hybrid Conductors

Aluminum Hybrid Conductors

Low Voltage Lightweight XLETFE

Judd Wire Resistance at Maximum Maximum Weight

Part No. AWG/Strand 20˚C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H4503302**01 30 7/38 156.00 .021 .534 .54 .80

H4503282**01 28 7/36 74.40 .024 .610 .81 1.21

H4503264**01 26 19/38 44.80 .029 .737 1.23 1.83

H4503244**01 24 19/36 28.40 .034 .864 1.79 2.67

H4503224**01 22 19/34 15.10 .041 1.042 2.70 4.02

H4503204**01 20 19/32 9.19 .051 1.300 4.27 6.36

H4503184**01 18 19/30 5.79 .061 1.550 6.56 9.76

H4503164**01 16 19/29 4.52 .068 1.730 8.33 12.40

H4503144**01 14 19/27 2.88 .083 2.083 12.80 19.05

H4503126**01 12 37/28 1.90 .103 2.620 19.71 29.33

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3832302-* M22759/32-30-* 30 7/38 108.4 .024 .610 .66 .98

H3832282-* M22759/32-28-* 28 7/36 68.6 .027 .686 .91 1.35

H3832264-* M22759/32-26-* 26 19/38 41.3 .032 .813 1.4 2.08

H3832244-* M22759/32-24-* 24 19/36 26.2 .037 .940 2.0 2.98

H3832224-* M22759/32-22-* 22 19/34 16.2 .043 1.092 2.8 4.17

H3832204-* M22759/32-20-* 20 19/32 9.88 .050 1.270 4.3 6.40

H3832184-* M22759/32-18-* 18 19/30 6.23 .060 1.524 6.5 9.67

H3832164-* M22759/32-16-* 16 19/29 4.81 .068 1.727 8.3 12.35

H3832144-* M22759/32-14-* 14 19/27 3.06 .085 2.159 13.0 19.35

H3832126-* M22759/32-12-* 12 37/28 2.02 .103 2.616 19.7 29.32

SAE-AS-22759/32

Tinned Copper Conductor

150°C 600 Volts

Single Insulation of

Crosslinked Ethylene-Tetrafluoroethylene (ETFE)

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3833302-* M22759/33-30-* 30 7/38 117.4 .024 .610 .66 .98

H3833282-* M22759/33-28-* 28 7/36 74.4 .027 .686 .91 1.35

H3833264-* M22759/33-26-* 26 19/38 44.8 .032 .813 1.4 2.08

H3833244-* M22759/33-24-* 24 19/36 28.4 .037 .940 2.0 2.98

H3833224-* M22759/33-22-* 22 19/34 17.5 .043 1.092 2.9 4.32

H3833204-* M22759/33-20-* 20 19/32 10.7 .050 1.270 4.4 6.55

SAE-AS-22759/33

Silver Coated High Strength

Copper Alloy Conductor

200°C 600 Volts

Single Insulation of

Crosslinked Ethylene-Tetrafluoroethylene (ETFE)

*Replace the asterisks with numeric color code designations

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3834244-* M22759/34-24-* 24 19/36 26.20 .045 1.143 2.3 3.42

H3834224-* M22759/34-22-* 22 19/34 16.20 .050 1.270 3.2 4.76

H3834204-* M22759/34-20-* 20 19/32 9.88 .058 1.473 4.7 6.99

H3834184-* M22759/34-18-* 18 19/30 6.23 .070 1.778 7.2 10.71

H3834164-* M22759/34-16-* 16 19/29 4.81 .077 1.956 9.0 13.39

H3834144-* M22759/34-14-* 14 19/27 3.06 .094 2.388 13.8 20.54

H3834126-* M22759/34-12-* 12 37/28 2.02 .111 2.819 20.5 30.51

H3834106-* M22759/34-10-* 10 37/26 1.26 .134 3.404 32.4 48.21

H3834088-* M22759/34-8-* 8 133/29 .701 .195 4.953 60.3 89.73

H3834068-* M22759/34-6-* 6 133/27 .445 .241 6.121 94.5 140.63

H3834048-* M22759/34-4-* 4 133/25 .280 .310 7.874 150.0 223.22

H3834029-* M22759/34-2-* 2 665/30 .183 .405 10.287 239.0 355.68

H3834019-* M22759/34-1-* 1 817/30 .149 .445 11.303 290.0 431.57

H3834109-* M22759/34-01* 1/0 1045/30 .116 .485 12.319 377.0 561.05

H3834209-* M22759/34-02* 2/0 1330/30 .091 .545 13.843 487.0 724.75

SAE-AS-22759/34

Tinned Copper Conductor

150°C 600 Volts

Dual Insulation of

Crosslinked Ethylene-Tetrafluoroethylene (ETFE)

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3835264-* M22759/35-26-* 26 19/38 44.8 .040 1.016 1.7 2.53

H3835244-* M22759/35-24-* 24 19/36 28.4 .045 1.143 2.3 3.42

H3835224-* M22759/35-22-* 22 19/34 17.5 .050 1.270 3.3 4.91

H3835204-* M22759/35-20-* 20 19/32 10.7 .058 1.473 4.8 7.14

SAE-AS-22759/35

Silver Coated High Strength

Copper Alloy Conductor

200°C 600 Volts

Dual Insulation of

Crosslinked Ethylene-Tetrafluoroethylene (ETFE)

*Replace the asterisks with numeric color code designations

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3841264-* M22759/41-26-* 26 19/38 42.2 .040 1.016 1.7 2.53

H3841244-* M22759/41-24-* 24 19/36 25.9 .045 1.143 2.3 3.42

H3841224-* M22759/41-22-* 22 19/34 16.0 .050 1.270 3.2 4.76

H3841204-* M22759/41-20-* 20 19/32 9.77 .058 1.473 4.7 6.99

H3841184-* M22759/41-18-* 18 19/30 6.10 .070 1.778 7.2 10.71

H3841164-* M22759/41-16-* 16 19/29 4.76 .077 1.956 9.0 13.39

H3841144-* M22759/41-14-* 14 19/27 3.00 .094 2.388 13.8 20.54

H3841126-* M22759/41-12-* 12 37/28 1.98 .111 2.819 20.5 30.51

H3841106-* M22759/41-10-* 10 37/26 1.24 .134 3.404 32.4 48.21

H3841088-* M22759/41-8-* 8 133/29 .694 .195 4.953 64.2 95.54

H3841068-* M22759/41-6-* 6 133/27 .436 .241 6.121 96.8 144.05

H3841048-* M22759/41-4-* 4 133/25 .275 .310 7.874 163.0 242.56

H3841029-* M22759/41-2-* 2 665/30 .177 .405 10.287 246.0 366.09

H3841019-* M22759/41-1-* 1 817/30 .144 .445 11.303 314.0 467.29

H3841109-* M22759/41-01* 1/0 1045/30 .113 .485 12.319 421.0 626.53

H3841209-* M22759/41-02* 2/0 1330/30 .089 .545 13.843 518.0 770.88

SAE-AS-22759/41

Nickel Coated Copper Conductor

200°C 600 Volts

Dual Insulation of

Crosslinked Ethylene-Tetrafluoroethylene (ETFE)

SAE-AS-22759/42

Nickel Coated High Strength Copper Conductor

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3842264-* M22759/42-26-* 26 19/38 49.4 .040 1.016 1.7 2.53

H3842244-* M22759/42-24-* 24 19/36 30.1 .045 1.143 2.3 3.42

H3842224-* M22759/42-22-* 22 19/34 18.6 .050 1.270 3.3 4.91

H3842204-* M22759/42-20-* 20 19/32 11.4 .058 1.473 4.8 7.14

SAE-AS-22759/43

Silver Coated Copper Conductor

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3843264-* M22759/43-26-* 26 19/38 38.4 .040 1.016 1.7 2.53

H3843244-* M22759/43-24-* 24 19/36 24.3 .045 1.143 2.3 3.42

H3843224-* M22759/43-22-* 22 19/34 15.1 .050 1.270 3.2 4.76

H3843204-* M22759/43-20-* 20 19/32 9.19 .058 1.473 4.7 6.99

H3843184-* M22759/43-18-* 18 19/30 5.79 .070 1.778 7.2 10.71

H3843164-* M22759/43-16-* 16 19/29 4.52 .077 1.956 9.0 13.39

H3843144-* M22759/43-14-* 14 19/27 2.88 .094 2.388 13.8 20.54

H3843126-* M22759/43-12-* 12 37/28 1.90 .111 2.819 20.5 30.51

H3843106-* M22759/43-10-* 10 37/26 1.19 .134 3.404 32.4 48.21

H3843088-* M22759/43-8-* 8 133/29 .658 .195 4.953 61.9 92.11

H3843068-* M22759/43-6-* 6 133/27 .418 .241 6.121 94.5 140.63

H3843048-* M22759/43-4-* 4 133/25 .264 .310 7.874 158.0 235.12

H3843029-* M22759/43-2-* 2 665/30 .170 .405 10.287 239.0 355.68

H3843019-* M22759/43-1-* 1 817/30 .139 .445 11.303 305.0 453.90

H3843109-* M22759/43-01* 1/0 1045/30 .108 .485 12.319 385.0 572.95

H3843209-* M22759/43-02* 2/0 1330/30 .085 .545 13.843 487.0 724.75

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3844282-* M22759/44-28-* 28 7/36 63.8 .027 .686 .91 1.35

H3844264-* M22759/44-26-* 26 19/38 38.4 .032 .813 1.4 2.08

H3844244-* M22759/44-24-* 24 19/36 24.3 .037 .940 2.0 2.98

H3844224-* M22759/44-22-* 22 19/34 15.1 .043 1.092 2.8 4.17

H3844204-* M22759/44-20-* 20 19/32 9.19 .050 1.270 4.3 6.40

H3844184-* M22759/44-18-* 18 19/30 5.79 .060 1.524 6.5 9.67

H3844164-* M22759/44-16-* 16 19/29 4.52 .068 1.727 8.3 12.35

H3844144-* M22759/44-14-* 14 19/27 2.88 .085 2.159 13.0 19.35

H3844126-* M22759/44-12-* 12 37/28 1.90 .103 2.616 19.7 29.32

SAE-AS-22759/44

Silver Coated Copper Conductor

200°C 600 Volts

Single Insulation of

Crosslinked Ethylene-Tetrafluoroethylene (ETFE)

SAE-AS-22759/45

Nickel Coated Copper Conductor

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3845282-* M22759/45-28-* 28 7/36 67.9 .027 .686 .91 1.35

H3845264-* M22759/45-26-* 26 19/38 42.2 .032 .813 1.4 2.08

H3845244-* M22759/45-24-* 24 19/36 25.9 .037 .940 2.0 2.98

H3845224-* M22759/45-22-* 22 19/34 16.0 .043 1.092 2.8 4.17

H3845204-* M22759/45-20-* 20 19/32 9.77 .050 1.270 4.3 6.40

H3845184-* M22759/45-18-* 18 19/30 6.10 .060 1.524 6.5 9.67

H3845164-* M22759/45-16-* 16 19/29 4.76 .068 1.727 8.3 12.35

H3845144-* M22759/45-14-* 14 19/27 3.00 .085 2.159 13.0 19.35

H3845126-* M22759/45-12-* 12 37/28 1.98 .103 2.616 19.7 29.32

SAE-AS-22759/46

Nickel Coated High Strength Copper Alloy Conductor

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H3846282-* M22759/46-28-* 28 7/36 79.0 .027 .686 .91 1.35

H3846264-* M22759/46-26-* 26 19/38 49.4 .032 .813 1.4 2.08

H3846244-* M22759/46-24-* 24 19/36 30.1 .037 .940 2.0 2.98

H3846224-* M22759/46-22-* 22 19/34 18.6 .043 1.092 2.9 4.32

H3846204-* M22759/46-20-* 20 19/32 11.4 .050 1.270 4.4 6.55

*Replace the asterisks with numeric color code designations

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

“ This specification covers the requirements for radio frequency absorptive component wires and

finished cables which function electrically as distributed low-pass filters.”

Judd Wire’s

Filter Line products offer a flexible alternative for traditionally metal shielded products.

The reduced size, weight and increased flexibility can be critical in applications were those

performance requirements are paramount.

Filter Line products offer excellent design solutions in areas where power and signal wires run in

close proximity, or in areas where space and weight limitations restrict the use of metallic braids.

These filtered layer wires are used today in numerous environments including helicopter harnesses,

satellite systems and other secure electrical communication networks.

SAE-AS-85485 – Filter Line

SAE-AS-85485/9

Tinned Coated Copper Conductor

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H9009224-* M85485/9-22-* 22 19/34 16.20 .051 1.30 4.0 6.0

H9009204-* M85485/9-20-* 20 19/32 9.88 .059 1.50 5.8 8.6

H9009184-* M85485/9-18-* 18 19/30 6.23 .070 1.78 8.7 13.0

H9009164-* M85485/9-16-* 16 19/29 4.81 .078 1.98 11.2 16.7

H9009144-* M85485/9-14-* 14 19/27 3.06 .095 2.41 16.1 24.0

H9009126-* M85485/9-12-* 12 37/28 2.02 .112 2.84 24.0 35.7

H9009106-* M85485/9-10-* 10 37/26 1.26 .136 3.45 37.0 55.1

SAE-AS-85485/10

Silver Coated High Strength Copper Alloy Conductor

Judd Military Wire Resistance at Nominal Maximum Weight

Part No. Part No. AWG/Strand 20°C OHMS Diameter Pounds/ Kilograms/

1000’ Max. Inches Millimeters 1000’ Kilometers

H9010244* M85785/10-24-* 24 19/36 28.40 .045 1.14 3.0 4.5

SAE-AS-85485/11

M85485/9 Components Twisted, No Shield, No Jacket: “T” Designation

Judd Military Number of Nominal Maximum Weight

Part No. Part No. Components Diameter Pounds/ Kilograms/

Inches Millimeters 1000’ Kilometers

M9002222* M85485/11-22T2* 2 .102 2.59 8.2 12.2

M9002224* M85485/11-20T2* 2 .118 3.00 11.8 17.6

M9003222* M85485/11-22T3* 3 .110 2.79 12.2 18.2

M9003224* M85485/11-20T3* 3 .127 3.23 17.7 26.3

Turners Falls, MA USA (800) 545-5833

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SAE-AS-85485/11

M85485/10 Components Twisted, No Shield, No Jacket: “M” Designation

Judd Military Number of Nominal Maximum Weight

Part No. Part No. Components Diameter Pounds/ Kilograms/

Inches Millimeters 1000’ Kilometers

M9002268* M85485/11-24M2* 2 .090 2.29 6.1 9.1

M9003268* M85485/11-24M3* 3 .097 2.46 9.2 13.7

SAE-AS-85485/12

M85485/9 Component, Tin Coated Copper Shield, Jacketed: “T” Designation

Judd Military Number of Nominal Maximum Weight

Part No. Part No. Components Diameter Pounds/ Kilograms/

Inches Millimeters 1000’ Kilometers

C9001302* M85485/12-22T1* 1 .083 2.11 8.8 13.1

C9001304* M85485/12-20T1* 1 .091 2.31 11.2 16.7

C9001308* M85485/12-16T1* 1 .110 2.79 18.0 26.8

Filter Line

continued

SAE-AS-85485/12

M85485/9 Components Twisted, Tin Coated Copper Shield, Jacketed: “T” Designation

Judd Military Number of Nominal Maximum Weight

Part No. Part No. Components Diameter Pounds/ Kilograms/

Inches Millimeters 1000’ Kilometers

M9002302* M85485/12-22T2* 2 .134 3.40 16.0 23.8

M9002304* M85485/12-20T2* 2 .150 3.81 20.5 30.5

M9002308* M85485/12-16T2* 2 .188 4.78 34.0 50.6

M9003302* M85485/12-22T3* 3 .142 3.61 20.9 31.1

M9003304* M85485/12-20T3* 3 .159 4.04 27.6 41.1

M9003308* M85485/12-16T3* 3 .201 5.11 47.0 69.9

SAE-AS-85485/12

M85485/10 Component, Silver Coated High Strength Copper Alloy Shield, Jacketed: “M” Designation

Judd Military Number of Nominal Maximum Weight

Part No. Part No. Components Diameter Pounds/ Kilograms/

Inches Millimeters 1000’ Kilometers

C9001348* M85485/12-24M1* 1 .077 1.96 7.3 10.9

SAE-AS-85485/12

M85485/10 Components Twisted, Silver Coated High Strength Copper Alloy Shield, Jacketed: “M” Designation

Judd Military Number of Nominal Maximum Weight

Part No. Part No. Components Diameter Pounds/ Kilograms/

Inches Millimeters 1000’ Kilometers

M9002348* M85485/12-24M2* 2 .122 3.10 13.0 19.3

M9003348* M85485/12-24M3* 3 .129 3.28 17.0 25.3

432 5 6 71

Turners Falls, MA USA (800) 545-5833

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1 Military Specification 27500

is used to designate NEMA WC 27500

2 Shield Coverage and Color Identification-

a slash followed by a dash (-) or letter code

indicates both shielding coverage and the method of color identification of primary core

insulation as detailed in

Table A.

The example (left) indicates 85% and white primaries with

colored stripes.

3 Conductor Size-

This position identifies the wire AWG. Judd Wire can manufacture cables

using AWG’s of 30-2/O, depending on basic wire specification.

4 Basic Wire Specification-

The component wire are identified by a two letter code. Cables

utilizing Judd Wire’s components are detailed in

Table B.

5 Number of Conductors-

27500 currently specifies from 1 to 15 conductors for shielded and

jacketed cables, and from 2 to 15 for unshielded unjacketed or unshielded jacketed cables.

6 Shield-

The specific shield style and material are designated by a single letter code.

Detailed in

Table C.

7 Jacket-

Cable jacketing materials are specified with a two digit code. Detailed in

Table D.

NEMA WC 27500

Table A

Identification Codes

Identification Optional identification

method of cable method (with 90% Statement taken from NEMA WC 27500 Judd Wire description of the requirement

(within 85% shield coverage) from NEMA WC 27500

shield coverage)

- C Preferred identification method All wires are colored white with

using table III A spiral stripes for identification.

F H Preferred identification method All wires are colored white with spiral

using table III B stripes for identification, but different

stripe color sequence is used.

A D Optional identification method A, All solid colors are used instead of

Table III A white striped wires.

G J Optional identification method A, All solid colors are used instead of

Table III B white striped wires, but a different

color sequence is used.

K M Optional identification method C All wires are the same solid color

determined by the Table to denote the

AWG. Numbers are added for

individual conductor identification.

L N Optional identification method D All wires are white and numbers are

added for individual conductor

identification.

M27500 – 22SB2T23

Example: seven digit code

All NEMA WC 27500 cables are designated by a seven digit code that includes the exact construction of each cable.

The tables used in this brochure represent only some of the material and design choices available.

These designs are those used most often with

Judd Wire

produced materials. You must consult the

actual cable document for full design and performance requirement information.

Turners Falls, MA USA (800) 545-5833

San Marcos, CA USA (800) 344-5251

www.juddwire.com

Judd Wire

builds hundreds of wire and cable designs that could not be included in a single brochure. Those designs use

all of the required testing and manufacturing elements of our obligations to the Aerospace industry.

We invite you to ask us about recommending a unique design for your application, or working with you to create a

design that can match your specific requirements.

Custom Designed Aerospace Wires & Cables

Table B

Letter Code Base Description

Code Base Specification Description Wire AWG

SB SAE-AS-22759/32 Single Insulation, Tin Coated Copper 30-12

SC SAE-AS-22759/33 Single Insulation, Silver Coated High Strength Copper Alloy 30-20

SD SAE-AS-22759/34 Dual Insulation, Tin Coated Copper 24-2/O

SE SAE-AS-22759/35 Dual Insulation, Silver Coated High Strength Copper Alloy 26-20

SM SAE-AS-22759/41 Dual Insulation, Nickel Coated Copper 26-2/O

SN SAE-AS-22759/42 Dual Insulation, Nickel Coated High Strength Copper Alloy 26-20

SP SAE-AS-22759/43 Dual Insulation, Silver Coated Copper 26-2/O

SR SAE-AS-22759/44 Single Insulation, Silver Coated Copper 28-12

SS SAE-AS-22759/45 Single Insulation, Nickel Coated Copper 28-12

ST SAE-AS-22759/46 Single Insulation, Nickel Coated High Strength Copper Alloy 28-20

Table C

Shield Letter Code

Single Double Description

Shield Shield

U - No Shield

T V Round, Tin Coated Copper

S W Round, Silver Coated Copper

N Y Round, Nickel Coated Copper

M K Round, Silver Coated

High Strength Copper Alloy

P L Round, Nickel Coated

High Strength Copper Alloy

G A Flat, Silver Coated Copper

H B Flat, Silver Coated

High Strength Copper Alloy

* # Flat, Nickel Coated Copper

J D Flat, Tin Coated Copper

E X Flat, Nickel Coated

High Strength Copper Alloy

Table D

Shield Letter Code

Single Double Description Temp.

Jacket Jacket Rating

00 00 No Jacket -

09 59 Extruded white fluorinated 260˚C (500˚F)

ethylene propylene (FEP)

14 64 Extruded white, 150˚C (302˚F)

Ethylene-tetrafluoroethylene

Copolymer (ETFE)

23 73 White, Crosslinked, 200˚C (392˚F)

extruded, modified,

Ethylene Tetrafluoroethylene

Copolymer (XLETFE)

Custom Manufactured Cables

Judd Wire

manufactures a wide array of custom designed cables for unique Aerospace applications

requiring very specific matching of material and electrical performance.

Judd Wire

offers a wide range of

material and design combinations to create cost-effective solutions in these fields:

■

Data Bus Cables- Judd Wire

has OEM approvals for numerous cables designed for multiplexing requirements of the data

bus architecture of Mil-STD-1553.

■

In-Flight Entertainment Systems- Judd Wire

cabling systems are used on the largest and most modern commercial aircraft

in the world and have been approved by the leading manufacturers of in-flight video delivery equipment.

■

Fly-By-Wire Cables-

These cables combine the electrical integrity and performance required by this flight critical system

combined with a very flexible and tough insulation system to withstand the rigors of their physical environment.

JUDD WIRE INC.

Defines, Designs, and Delivers High Value Solutions for our Customers

Judd Wire Inc. is an ISO 9001, IS/TS 16949, AS 9100, and ISO 14001 registered firm

JUDD WIRE INC.

870 Los Vallecitos Boulevard

San Marcos, CA 92069 USA

tel (760) 744-7720

(800) 344-5251

fax (760) 744-0689

JUDD WIRE INC.

Headquarters and Manufacturing Facility

124 Turnpike Road

Turners Falls, MA 01376-2699 USA

tel (413) 863-4357

(800) 545-5833

fax (413) 863-2305

www.juddwire.com

Judd Wire’s two modern facilities are part of the Sumitomo Electric

Industries (SEI) worldwide family of companies.

With over 300,000

square feet of production space, and state-of-the-art equipment,

Judd Wire provides irradiation cross-linking processes on both

coasts, supporting the product diversity our customers require.