JUDD WIRE, INC. Aerospace 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. Contents SuperComposite(R) 200 . . . . . . . . . .2 JWXLT . . . . . . . . . . . . . . . . . . . . . . .3 Fiber Optic Cables for Commercial Aircraft Applications . . . . . . . . . . . . . . . . . .4 Hybrid Conductors . . . . . . . . . . . .5 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. Low Voltage Lightweight XLETFE . . . . . . . . . . .5 SAE-AS-22759/32 SAE-AS-22759/33 SAE-AS-22759/34 SAE-AS-22759/35 SAE-AS-22759/41 SAE-AS-22759/42 SAE-AS-22759/43 SAE-AS-22759/44 SAE-AS-22759/45 SAE-AS-22759/46 . . . . . . . . . . . . .6 . . . . . . . . . . . . .6 . . . . . . . . . . . . .7 . . . . . . . . . . . . .7 . . . . . . . . . . . . .8 . . . . . . . . . . . . .8 . . . . . . . . . . . . .8 . . . . . . . . . . . . .9 . . . . . . . . . . . . .9 . . . . . . . . . . . . .9 SAE-AS-85485-Filter Line . .10, 11 NEMA WC 27500 . . . . . . . . .12, 13 Custom Designs . . . . . . . . . . . . .13 JUDD WIRE INC. 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. 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. 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 www.juddwire.com Turners Falls, MA USA (800) 545-5833 San Marcos, CA USA (800) 344-5251 1 SuperComposite 200 (R) Judd Wire's newest hybrid insulation system is the SuperComposite(R) 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. Judd Wire's SuperComposite(R) 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 200C capability (260C 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. 2 Turners Falls, MA USA San Marcos, CA USA (800) 545-5833 (800) 344-5251 www.juddwire.com JWXLT 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. 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. www.juddwire.com Turners Falls, MA USA (800) 545-5833 San Marcos, CA USA (800) 344-5251 3 Fiber Optic Cables for Commercial Aircraft Applications 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. 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 Diameter Cable Weight Cable Flexibility Specification Reference ARINC 802 Table 2-1 ARINC 802 Section 2.1.1 ARINC 802 Section 2.2.3.1 Frictional torque applied 20% of max ARINC 802 Section 2.2.3.2 TIA/EIA - 455-104A ARINC 802 Section 2.2.3.4 ARINC 802 Section 2.2.3.7 TIA/EIA - 455-25C ARINC 802 Section 2.2.3.8 TIA/EIA - 455-3A Test Condition C-3 Requirement(s) 1.80mm 0.16mm Lowest Weight Possible Angle: 90 0.20 dN x m (min) 0.85 dN x m (max) Angle: 180 0.20 dN x m (min) 1.13 dN x m (max) Change in 10,000 cycles 0.25 Transmittance dB (max) Change in 0.25 dB (max) Transmittance No Cracking, 20 drops No Fiber Breakage Change in 1.3% (45mm) (max) Strip Length Cable to Cable Abrasion ARINC 802 Section 2.2.3.11 300,000 cycles (min) No exposure of any layer Fiber movement under compression Smoke and Toxicity ARINC 802 Section 2.2.3.13 Change in Transmittance 0.10 dB (max) Flexure Endurance Cable Bend Radius Impact Resistance Jacket Shrinkage ARINC 802 Section 2.2.4.7 Boeing Specifications: BSS 7238 BSS 7239 Low and High ARINC 802 Section 2.2.5.4 Temperature Cable Bend TIA/EIA - 455-37A Temperature Life 4 Turners Falls, MA USA San Marcos, CA USA ARINC 802 Section 2.2.5.5 TIA/EIA - 455-4C (800) 545-5833 (800) 344-5251 www.juddwire.com Smoke and Toxicity limits specified Change in Transmittance 500hrs at 125C (275F) Change in Transmittance 0.25 dB (max) No cracking (10x magnification) 3.0 dB/Km (max) at 1300m 6.0 dB/Km (max) at 850m Product Test Results 1.90mm 4.61Kg/Km 0.22 dN x m 0.27 dN x m 0.11 dB 0.00 change (negligible) 147 drops No Fiber Breakage 4.57mm (No added change in jacket shrinkage after 23 cycles) Greater than 50,000,000 cycles 0.03 dB Meets Smoke limits Meets Toxicity limits 0.04 dB No cracks (10x magnification) 1.15 dB/Km 3.58 dB/Km Hybrid Conductors 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. Aluminum Hybrid Conductors AWG 14 19/27 12 37/28 10 37/26 8 133/29 6 133/27 4 133/25 2 665/30 1 817/30 0 1045/30 00 1330/30 000 1665/30 Nominal Diameter (inches) .218 .218 .107 .218 .267 .325 .407 .471 .504 .553 .630 Plated Copper- Insulated Values DCR Weight LBS/KFT (max.) (max.) 3.000 1.980 1.240 .694 .436 .275 .177 .149 .113 .089 .071 11.3 17.2 27.9 70.8 107.0 170.0 261.0 332.0 429.0 530.0 634.0 Plated Hybrid- Insulated Values DCR Weight LBS/KFT (max.) (max.) 3.470 2.440 1.530 .803 .504 .318 .205 .167 .131 .103 .088 8.3 11.1 17.9 51.7 78.1 121.3 195.0 245.3 296.2 375.0 403.3 Weight Savings DCR Rise 27% 36% 36% 27% 27% 29% 25% 26% 31% 29% 36% 16% 23% 23% 16% 16% 16% 16% 12% 16% 16% 24% Low Voltage - Lightweight XLETFE 450 Volts - 150C 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 Judd Part No. H4503302**01 H4503282**01 H4503264**01 H4503244**01 H4503224**01 H4503204**01 H4503184**01 H4503164**01 H4503144**01 H4503126**01 Wire AWG/Strand 30 7/38 28 7/36 26 19/38 24 19/36 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 Resistance at 20C OHMS 1000' Max. 156.00 74.40 44.80 28.40 15.10 9.19 5.79 4.52 2.88 1.90 Maximum Diameter Inches Millimeters .021 .024 .029 .034 .041 .051 .061 .068 .083 .103 .534 .610 .737 .864 1.042 1.300 1.550 1.730 2.083 2.620 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers .54 .81 1.23 1.79 2.70 4.27 6.56 8.33 12.80 19.71 .80 1.21 1.83 2.67 4.02 6.36 9.76 12.40 19.05 29.33 www.juddwire.com Turners Falls, MA USA (800) 545-5833 San Marcos, CA USA (800) 344-5251 5 Tinned Copper Conductor SAE-AS-22759/32 150C 600 Volts Single Insulation of Crosslinked Ethylene-Tetrafluoroethylene (ETFE) Judd Part No. H3832302-* H3832282-* H3832264-* H3832244-* H3832224-* H3832204-* H3832184-* H3832164-* H3832144-* H3832126-* Military Part No. M22759/32-30-* M22759/32-28-* M22759/32-26-* M22759/32-24-* M22759/32-22-* M22759/32-20-* M22759/32-18-* M22759/32-16-* M22759/32-14-* M22759/32-12-* Wire AWG/Strand Resistance at 20C OHMS 1000' Max. 30 7/38 28 7/36 26 19/38 24 19/36 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 108.4 68.6 41.3 26.2 16.2 9.88 6.23 4.81 3.06 2.02 Nominal Diameter Inches Millimeters .024 .027 .032 .037 .043 .050 .060 .068 .085 .103 .610 .686 .813 .940 1.092 1.270 1.524 1.727 2.159 2.616 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers .66 .91 1.4 2.0 2.8 4.3 6.5 8.3 13.0 19.7 .98 1.35 2.08 2.98 4.17 6.40 9.67 12.35 19.35 29.32 Silver Coated High Strength Copper Alloy Conductor SAE-AS-22759/33 200C 600 Volts Single Insulation of Crosslinked Ethylene-Tetrafluoroethylene (ETFE) Judd Part No. H3833302-* H3833282-* H3833264-* H3833244-* H3833224-* H3833204-* Military Part No. M22759/33-30-* M22759/33-28-* M22759/33-26-* M22759/33-24-* M22759/33-22-* M22759/33-20-* Wire AWG/Strand 30 7/38 28 7/36 26 19/38 24 19/36 22 19/34 20 19/32 *Replace the asterisks with numeric color code designations 6 Turners Falls, MA USA San Marcos, CA USA (800) 545-5833 (800) 344-5251 www.juddwire.com Resistance at 20C OHMS 1000' Max. 117.4 74.4 44.8 28.4 17.5 10.7 Nominal Diameter Inches Millimeters .024 .027 .032 .037 .043 .050 .610 .686 .813 .940 1.092 1.270 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers .66 .91 1.4 2.0 2.9 4.4 .98 1.35 2.08 2.98 4.32 6.55 Tinned Copper Conductor SAE-AS-22759/34 150C 600 Volts Dual Insulation of Crosslinked Ethylene-Tetrafluoroethylene (ETFE) Judd Part No. H3834244-* H3834224-* H3834204-* H3834184-* H3834164-* H3834144-* H3834126-* H3834106-* H3834088-* H3834068-* H3834048-* H3834029-* H3834019-* H3834109-* H3834209-* Military Part No. Wire AWG/Strand M22759/34-24-* M22759/34-22-* M22759/34-20-* M22759/34-18-* M22759/34-16-* M22759/34-14-* M22759/34-12-* M22759/34-10-* M22759/34-8-* M22759/34-6-* M22759/34-4-* M22759/34-2-* M22759/34-1-* M22759/34-01* M22759/34-02* Resistance at 20C OHMS 1000' Max. 24 19/36 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 10 37/26 8 133/29 6 133/27 4 133/25 2 665/30 1 817/30 1/0 1045/30 2/0 1330/30 26.20 16.20 9.88 6.23 4.81 3.06 2.02 1.26 .701 .445 .280 .183 .149 .116 .091 Nominal Diameter Inches Millimeters .045 .050 .058 .070 .077 .094 .111 .134 .195 .241 .310 .405 .445 .485 .545 1.143 1.270 1.473 1.778 1.956 2.388 2.819 3.404 4.953 6.121 7.874 10.287 11.303 12.319 13.843 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 2.3 3.2 4.7 7.2 9.0 13.8 20.5 32.4 60.3 94.5 150.0 239.0 290.0 377.0 487.0 3.42 4.76 6.99 10.71 13.39 20.54 30.51 48.21 89.73 140.63 223.22 355.68 431.57 561.05 724.75 Silver Coated High Strength Copper Alloy Conductor SAE-AS-22759/35 200C 600 Volts Dual Insulation of Crosslinked Ethylene-Tetrafluoroethylene (ETFE) Judd Part No. H3835264-* H3835244-* H3835224-* H3835204-* Military Part No. M22759/35-26-* M22759/35-24-* M22759/35-22-* M22759/35-20-* Wire AWG/Strand 26 19/38 24 19/36 22 19/34 20 19/32 Resistance at 20C OHMS 1000' Max. 44.8 28.4 17.5 10.7 Nominal Diameter Inches Millimeters .040 .045 .050 .058 1.016 1.143 1.270 1.473 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 1.7 2.3 3.3 4.8 2.53 3.42 4.91 7.14 *Replace the asterisks with numeric color code designations www.juddwire.com Turners Falls, MA USA (800) 545-5833 San Marcos, CA USA (800) 344-5251 7 Nickel Coated Copper Conductor SAE-AS-22759/41 200C 600 Volts Dual Insulation of Crosslinked Ethylene-Tetrafluoroethylene (ETFE) Judd Part No. H3841264-* H3841244-* H3841224-* H3841204-* H3841184-* H3841164-* H3841144-* H3841126-* H3841106-* H3841088-* H3841068-* H3841048-* H3841029-* H3841019-* H3841109-* H3841209-* Military Part No. M22759/41-26-* M22759/41-24-* M22759/41-22-* M22759/41-20-* M22759/41-18-* M22759/41-16-* M22759/41-14-* M22759/41-12-* M22759/41-10-* M22759/41-8-* M22759/41-6-* M22759/41-4-* M22759/41-2-* M22759/41-1-* M22759/41-01* M22759/41-02* H3842264-* H3842244-* H3842224-* H3842204-* Military Part No. H3843264-* H3843244-* H3843224-* H3843204-* H3843184-* H3843164-* H3843144-* H3843126-* H3843106-* H3843088-* H3843068-* H3843048-* H3843029-* H3843019-* H3843109-* H3843209-* 8 Turners Falls, MA USA San Marcos, CA USA 26 19/38 24 19/36 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 10 37/26 8 133/29 6 133/27 4 133/25 2 665/30 1 817/30 1/0 1045/30 2/0 1330/30 42.2 25.9 16.0 9.77 6.10 4.76 3.00 1.98 1.24 .694 .436 .275 .177 .144 .113 .089 Wire AWG/Strand M22759/42-26-* M22759/42-24-* M22759/42-22-* M22759/42-20-* Military Part No. M22759/43-26-* M22759/43-24-* M22759/43-22-* M22759/43-20-* M22759/43-18-* M22759/43-16-* M22759/43-14-* M22759/43-12-* M22759/43-10-* M22759/43-8-* M22759/43-6-* M22759/43-4-* M22759/43-2-* M22759/43-1-* M22759/43-01* M22759/43-02* (800) 545-5833 (800) 344-5251 Nominal Diameter Inches Millimeters .040 .045 .050 .058 .070 .077 .094 .111 .134 .195 .241 .310 .405 .445 .485 .545 1.016 1.143 1.270 1.473 1.778 1.956 2.388 2.819 3.404 4.953 6.121 7.874 10.287 11.303 12.319 13.843 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 1.7 2.3 3.2 4.7 7.2 9.0 13.8 20.5 32.4 64.2 96.8 163.0 246.0 314.0 421.0 518.0 2.53 3.42 4.76 6.99 10.71 13.39 20.54 30.51 48.21 95.54 144.05 242.56 366.09 467.29 626.53 770.88 26 19/38 24 19/36 22 19/34 20 19/32 Resistance at 20C OHMS 1000' Max. 49.4 30.1 18.6 11.4 Nominal Diameter Inches Millimeters .040 .045 .050 .058 1.016 1.143 1.270 1.473 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 1.7 2.3 3.3 4.8 2.53 3.42 4.91 7.14 Silver Coated Copper Conductor SAE-AS-22759/43 Judd Part No. Resistance at 20C OHMS 1000' Max. Nickel Coated High Strength Copper Conductor SAE-AS-22759/42 Judd Part No. Wire AWG/Strand Wire AWG/Strand 26 19/38 24 19/36 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 10 37/26 8 133/29 6 133/27 4 133/25 2 665/30 1 817/30 1/0 1045/30 2/0 1330/30 www.juddwire.com Resistance at 20C OHMS 1000' Max. 38.4 24.3 15.1 9.19 5.79 4.52 2.88 1.90 1.19 .658 .418 .264 .170 .139 .108 .085 Nominal Diameter Inches Millimeters .040 .045 .050 .058 .070 .077 .094 .111 .134 .195 .241 .310 .405 .445 .485 .545 1.016 1.143 1.270 1.473 1.778 1.956 2.388 2.819 3.404 4.953 6.121 7.874 10.287 11.303 12.319 13.843 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 1.7 2.3 3.2 4.7 7.2 9.0 13.8 20.5 32.4 61.9 94.5 158.0 239.0 305.0 385.0 487.0 2.53 3.42 4.76 6.99 10.71 13.39 20.54 30.51 48.21 92.11 140.63 235.12 355.68 453.90 572.95 724.75 Silver Coated Copper Conductor SAE-AS-22759/44 200C 600 Volts Single Insulation of Crosslinked Ethylene-Tetrafluoroethylene (ETFE) Judd Part No. H3844282-* H3844264-* H3844244-* H3844224-* H3844204-* H3844184-* H3844164-* H3844144-* H3844126-* Military Part No. M22759/44-28-* M22759/44-26-* M22759/44-24-* M22759/44-22-* M22759/44-20-* M22759/44-18-* M22759/44-16-* M22759/44-14-* M22759/44-12-* SAE-AS-22759/45 Judd Part No. H3845282-* H3845264-* H3845244-* H3845224-* H3845204-* H3845184-* H3845164-* H3845144-* H3845126-* Military Part No. M22759/45-28-* M22759/45-26-* M22759/45-24-* M22759/45-22-* M22759/45-20-* M22759/45-18-* M22759/45-16-* M22759/45-14-* M22759/45-12-* SAE-AS-22759/46 Judd Part No. H3846282-* H3846264-* H3846244-* H3846224-* H3846204-* Military Part No. M22759/46-28-* M22759/46-26-* M22759/46-24-* M22759/46-22-* M22759/46-20-* Wire AWG/Strand Resistance at 20C OHMS 1000' Max. 28 7/36 26 19/38 24 19/36 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 63.8 38.4 24.3 15.1 9.19 5.79 4.52 2.88 1.90 Nominal Diameter Inches Millimeters .027 .032 .037 .043 .050 .060 .068 .085 .103 .686 .813 .940 1.092 1.270 1.524 1.727 2.159 2.616 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers .91 1.4 2.0 2.8 4.3 6.5 8.3 13.0 19.7 1.35 2.08 2.98 4.17 6.40 9.67 12.35 19.35 29.32 Nickel Coated Copper Conductor Wire AWG/Strand Resistance at 20C OHMS 1000' Max. 28 7/36 26 19/38 24 19/36 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 67.9 42.2 25.9 16.0 9.77 6.10 4.76 3.00 1.98 Nominal Diameter Inches Millimeters .027 .032 .037 .043 .050 .060 .068 .085 .103 .686 .813 .940 1.092 1.270 1.524 1.727 2.159 2.616 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers .91 1.4 2.0 2.8 4.3 6.5 8.3 13.0 19.7 1.35 2.08 2.98 4.17 6.40 9.67 12.35 19.35 29.32 Nickel Coated High Strength Copper Alloy Conductor Wire AWG/Strand 28 7/36 26 19/38 24 19/36 22 19/34 20 19/32 Resistance at 20C OHMS 1000' Max. 79.0 49.4 30.1 18.6 11.4 Nominal Diameter Inches Millimeters .027 .032 .037 .043 .050 .686 .813 .940 1.092 1.270 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers .91 1.4 2.0 2.9 4.4 1.35 2.08 2.98 4.32 6.55 *Replace the asterisks with numeric color code designations www.juddwire.com Turners Falls, MA USA (800) 545-5833 San Marcos, CA USA (800) 344-5251 9 SAE-AS-85485 - Filter Line "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-85485/9 Judd Part No. Tinned Coated Copper Conductor Military Part No. H9009224-* H9009204-* H9009184-* H9009164-* H9009144-* H9009126-* H9009106-* M85485/9-22-* M85485/9-20-* M85485/9-18-* M85485/9-16-* M85485/9-14-* M85485/9-12-* M85485/9-10-* SAE-AS-85485/10 Resistance at 20C OHMS 1000' Max. 22 19/34 20 19/32 18 19/30 16 19/29 14 19/27 12 37/28 10 37/26 16.20 9.88 6.23 4.81 3.06 2.02 1.26 Judd Part No. Military Part No. Wire AWG/Strand Resistance at 20C OHMS 1000' Max. H9010244* M85785/10-24-* 24 19/36 28.40 Military Part No. M9002222* M9002224* M9003222* M9003224* (800) 545-5833 (800) 344-5251 .051 .059 .070 .078 .095 .112 .136 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 1.30 1.50 1.78 1.98 2.41 2.84 3.45 4.0 5.8 8.7 11.2 16.1 24.0 37.0 6.0 8.6 13.0 16.7 24.0 35.7 55.1 Nominal Diameter Inches Millimeters .045 1.14 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 3.0 4.5 M85485/9 Components Twisted, No Shield, No Jacket: "T" Designation Judd Part No. Turners Falls, MA USA San Marcos, CA USA Nominal Diameter Inches Millimeters Silver Coated High Strength Copper Alloy Conductor SAE-AS-85485/11 10 Wire AWG/Strand M85485/11-22T2* M85485/11-20T2* M85485/11-22T3* M85485/11-20T3* www.juddwire.com Number of Components 2 2 3 3 Nominal Diameter Inches Millimeters .102 .118 .110 .127 2.59 3.00 2.79 3.23 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 8.2 11.8 12.2 17.7 12.2 17.6 18.2 26.3 Filter Line continued SAE-AS-85485/11 M85485/10 Components Twisted, No Shield, No Jacket: "M" Designation Judd Part No. Military Part No. Number of Components M9002268* M9003268* M85485/11-24M2* M85485/11-24M3* 2 3 SAE-AS-85485/12 Judd Part No. C9001302* C9001304* C9001308* SAE-AS-85485/12 Judd Part No. M9002302* M9002304* M9002308* M9003302* M9003304* M9003308* SAE-AS-85485/12 Judd Part No. C9001348* SAE-AS-85485/12 Judd Part No. M9002348* M9003348* Nominal Diameter Inches Millimeters .090 .097 2.29 2.46 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 6.1 9.2 9.1 13.7 M85485/9 Component, Tin Coated Copper Shield, Jacketed: "T" Designation Military Part No. M85485/12-22T1* M85485/12-20T1* M85485/12-16T1* Number of Components 1 1 1 Nominal Diameter Inches Millimeters .083 .091 .110 2.11 2.31 2.79 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 8.8 11.2 18.0 13.1 16.7 26.8 M85485/9 Components Twisted, Tin Coated Copper Shield, Jacketed: "T" Designation Military Part No. M85485/12-22T2* M85485/12-20T2* M85485/12-16T2* M85485/12-22T3* M85485/12-20T3* M85485/12-16T3* Number of Components 2 2 2 3 3 3 Nominal Diameter Inches Millimeters .134 .150 .188 .142 .159 .201 3.40 3.81 4.78 3.61 4.04 5.11 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 16.0 20.5 34.0 20.9 27.6 47.0 23.8 30.5 50.6 31.1 41.1 69.9 M85485/10 Component, Silver Coated High Strength Copper Alloy Shield, Jacketed: "M" Designation Military Part No. Number of Components M85485/12-24M1* 1 Nominal Diameter Inches Millimeters .077 1.96 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 7.3 10.9 M85485/10 Components Twisted, Silver Coated High Strength Copper Alloy Shield, Jacketed: "M"Designation Military Part No. Number of Components M85485/12-24M2* M85485/12-24M3* 2 3 Nominal Diameter Inches Millimeters .122 .129 3.10 3.28 Maximum Weight Pounds/ Kilograms/ 1000' Kilometers 13.0 17.0 19.3 25.3 www.juddwire.com Turners Falls, MA USA (800) 545-5833 San Marcos, CA USA (800) 344-5251 11 NEMA WC 27500 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. M2750 0 - 22SB2T23 1 2 3 4 5 6 7 Example: seven digit code 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. Table A Identification Codes Identification method of cable (within 85% shield coverage) Optional identification method (with 90% shield coverage) Statement taken from NEMA WC 27500 - C F H A D G J K M Optional identification method C L N Optional identification method D 12 Turners Falls, MA USA San Marcos, CA USA (800) 545-5833 (800) 344-5251 Preferred identification method using table III A Preferred identification method using table III B Optional identification method A, Table III A Optional identification method A, Table III B www.juddwire.com Judd Wire description of the requirement from NEMA WC 27500 All wires are colored white with spiral stripes for identification. All wires are colored white with spiral stripes for identification, but different stripe color sequence is used. All solid colors are used instead of white striped wires. All solid colors are used instead of white striped wires, but a different color sequence is used. All wires are the same solid color determined by the Table to denote the AWG. Numbers are added for individual conductor identification. All wires are white and numbers are added for individual conductor identification. Table B Letter Code Base Description Code Base Specification Description SB SC SD SE SM SN SP SR SS ST SAE-AS-22759/32 SAE-AS-22759/33 SAE-AS-22759/34 SAE-AS-22759/35 SAE-AS-22759/41 SAE-AS-22759/42 SAE-AS-22759/43 SAE-AS-22759/44 SAE-AS-22759/45 SAE-AS-22759/46 Single Insulation, Tin Coated Copper Single Insulation, Silver Coated High Strength Copper Alloy Dual Insulation, Tin Coated Copper Dual Insulation, Silver Coated High Strength Copper Alloy Dual Insulation, Nickel Coated Copper Dual Insulation, Nickel Coated High Strength Copper Alloy Dual Insulation, Silver Coated Copper Single Insulation, Silver Coated Copper Single Insulation, Nickel Coated Copper Single Insulation, Nickel Coated High Strength Copper Alloy Wire AWG Table C Table D Shield Letter Code Shield Letter Code Single Shield Double Shield U T S N M V W Y K P L G H A B * J E # D X Description Single Jacket Double Jacket No Shield Round, Tin Coated Copper Round, Silver Coated Copper Round, Nickel Coated Copper Round, Silver Coated High Strength Copper Alloy Round, Nickel Coated High Strength Copper Alloy Flat, Silver Coated Copper Flat, Silver Coated High Strength Copper Alloy Flat, Nickel Coated Copper Flat, Tin Coated Copper Flat, Nickel Coated High Strength Copper Alloy 00 09 00 59 14 64 23 73 30-12 30-20 24-2/O 26-20 26-2/O 26-20 26-2/O 28-12 28-12 28-20 Description Temp. Rating No Jacket Extruded white fluorinated 260C (500F) ethylene propylene (FEP) Extruded white, 150C (302F) Ethylene-tetrafluoroethylene Copolymer (ETFE) White, Crosslinked, 200C (392F) extruded, modified, Ethylene Tetrafluoroethylene Copolymer (XLETFE) Custom Designed Aerospace Wires & Cables 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 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. www.juddwire.com Turners Falls, MA USA (800) 545-5833 San Marcos, CA USA (800) 344-5251 13 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 INC. 870 Los Vallecitos Boulevard San Marcos, CA 92069 USA tel (760) 744-7720 (800) 344-5251 fax (760) 744-0689 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. 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 and a member of the Sumitomo Electric Industries group of companies (c)2009