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.
Turners Falls, MA USA (800) 545-5833
San Marcos, CA USA (800) 344-5251
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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.
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
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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
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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
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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
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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
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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
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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
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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
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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
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“ 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
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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
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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.
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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
and a member of the Sumitomo Electric Industries group of companies ©2009
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.
