• Resistant to electrical arc tracking
in wet or dry conditions
• Single or dual wall constructions
• Small size, ultra light weight
• Exceptional chemical resistance
Spec 55
Wire and cable
Spec 55 wire is insulated with modified
radiation cross-linked ETFE polymer. It has
a temperature rating of -65
°
C to 200
°
C
continuous, and combines the easy
handling of a flexible wire with excellent
scrape abrasion and cut-through
characteristics.
The dual wall airframe construction of
Spec 55 wire is currently used on
numerous aircraft programmes. It has a
choice of two total wall thickness,
0.25 mm and 0.2mm, both have a
contrasting core colour to act as a
damage indicator. Chosen for its balance
of properties, Spec 55 wire has
outstanding resistance to chemicals and
solvents, excellent electrical arc track
resistance, and is not susceptible to UV
and moisture degradation. Single wall
equipment wire constructions are
available in 0.10 mm and 0.15 mm wall
thicknesses for use inside black boxes
where flexibility and solder-iron resistance
make it a wire which is very easy to
reliably install.
Both single and dual wall insulated wires
are available in twisted pairs, triples, etc.,
and as screened and jacketed cables.
Specifications
MIL-W-22759/32-35 and /41 to /46 and MIL-DTL-C-27500 (Cables)
Defence Standard 61-12 Part 33
VG95218 Part 20, Type D; Part 21, Type A; Part 22, Type A; Part 23, Type A,
Part 1001 and Part 1002
VDE 9426, 9427, 9428
British Standard 3G233
Civil Aviation Authority Accessory Approval E11749
Boeing BMS 13-48
Airbus ABS 0820 to 0826
Underwriters Laboratory Style 3467
NASA preferred product list
European Space Agency 3901/012, 3901/020 and 3901/022
Raychem Specification 55
Spec 55 Insulation system - Single wall
Conductor
Insulation -
Radiation Crosslinked, Modified ETFE
Spec 55 Insulation system - Dual wall
Conductor
Insulations -
Radiation Crosslinked, Modified ETFE
Innerlayer coloured blue
Spec 55
Physical characteristics
Size and weight
Spec 55 wire provides one of the most
comprehensive wiring product ranges for
aerospace users, with a wide choice of
conductor sizes and insulation wall thickness.
The dual wall airframe wire has an insulation
wall thickness of either 0.2mm or 0.25 mm for
robustness in unprotected harnesses and has
excellent wire to wire abrasion properties. The
single wall equipment wire has a 0.15 mm wall
thickness for use inside equipment and
protected harnesses. For high density
interconnect wiring, the 450 volt 55M041X
series of equipment wire has a nominal 0.1 mm
wall and provides considerable weight and size
savings over other comparable wires.
Handling
The excellent flexibility and low resilience
makes Spec 55 the ideal wire to install, both in
new aircraft and equipment and for
maintenance purposes. The wire is easily
stripped with conventional tooling. The
insulation is readily marked by hot stamp, ink
jet or laser, and can be potted without pre-
etching.
For full descriptions of the appropriate tools
see separate wire handling guide.
Typical properties
Temperature rating (Tin plated conductor)
(Silver or nickel plated conductor)
Thermal endurance
Scrape abrasion (BS 3G233)
Flexing endurance (Boeing BSS 7324)
Voltage rating
Tensile strength + core elongation
Tensile strength + total elongation
Notch propagation BS 3G230 0.05 mm notch
Solder iron resistance (370
°
C, 1 minute)
Solderability - Tin plated copper conductor
BS 3G233 conditions
Shrinkage
Long term water resistance
Permittivity 1 KHz (ASTM D150)
Dissipation factor (ASTM D150)
-65
°
C to +150
°
C
-65
°
C to +200
°
C
200
°
C, 10000 h
>100 cycles at 150
°
C
>1000 cyles
600 V, 450V
(Airframe wire only) 35 N/mm
2
, 125%
(All primary wire) 35 N/mm
2
, 75%
Pass
Pass
<0.8 secs to wet
<1%
Will not hydrolyse
2.7
0.001
Environmental performance
Temperature rating
Spec 55 wire and cable is rated for continuous
operation from -65
°
C to +200
°
C and for short
periods at temperatures as high as 400
°
C.
Mechanical performance
Radiation crosslinking of the Spec 55 insulation
significantly improves the following
mechanical characteristics; scrape (sharp
edges), cross wire abrasion, cut-through
resistance and creep resistance.
Solder iron/Overload resistance
Radiation crosslinking ensures that the
insulation does not melt at high temperature.
As a result Spec 55 wire is resistant to hot
solder irons and current overloads which would
melt most thermoplastic insulations.
Chemical resistance
Spec 55 is unaffected by all commonly used
chemicals, eg. fuels, hydraulic fluids, defluxing
agents, cleaners, coolants and de-icers. It also
shows excellent resistance to weathering
(UV, ozone, pollutants, water).
Space wire
Spec 55 is available in special versions suitable
for use in outer space meeting both ESA and
NASA requirements for outgassing.
Flammability
Special additives increase the flame retardance
of Spec 55 compared to unirradiated ETFE so
that it meets the latest high performance tests,
eg. BS 3G230 vertical test FAR 25.
Electrical arc tracking resistance
Spec 55 insulation demonstrates resistance to
arc tracking under both wet and dry conditions
at aircraft system voltages.
Spec 55
Spec 55 wire & cable: Standard constructions, nominal sizes, strandings, diameters and weights
Conductor
Primary wire
Twisted pair
Single
Screened & jacketed
Pair
55A - AWG conductor: Equipment/Interconnect wires & cables
Stranding
(mm)
7/0.102
7/127
19/102
19/127
19/0.16
19/0.203
19/0.25
19/287
19/0.36
37/0.32
37/0.403
133/0.287
55A011X
OD
(mm)
0.61
0.68
0.81
0.94
1.09
1.27
1.52
1.73
2.2
2.62
3.25
4.77
Weight
(g/m)
0.98
1.35
2.1
2.98
4.2
6.4
9.7
12.4
19.4
29.35
47.4
87.6
55A012X
OD
(mm)
1.27
1.42
1.67
1.93
2.23
2.66
3.2
3.58
4.47
5.38
6.65
9.8
Weight
(g/m)
1.94
2.68
4.2
5.96
8.6
13.26
19.57
25.8
39.6
60/0
96.7
178.8
55A111X
OD
(mm)
1.51
1.59
1.71
1.84
1.99
2.2
2.45
2.67
3.1
3.55
4.2
5.8
Weight
(g/m)
5.1
5.8
6.85
8.2
10.3
13.4
17.88
21.75
30.4
42.46
62.7
110.5
55A112X
OD
(mm)
2.12
2.27
2.53
2.8
3.07
3.5
4.1
4.43
5.3
6.3
-
-
Weight
(g/m)
7.74
8.9
11.32
13.86
17.9
23.8
32.6
39.7
57.0
81.2
-
-
Size
30
28
26
24
22
20
18
16
14
12
10
8
55A - AWG conductor: Airframe wires & cables
Stranding
(mm)
19/102
19/127
19/0.16
19/0.203
19/0.25
19/287
37/0.36
37/0.32
37/0.403
55A081X
OD
(mm)
1.01
1.14
1.27
1.47
1.78
1.95
2.4
2.82
3.4
Weight
(g/m)
2.5
3.4
4.8
7.0
10.7
13.4
20.5
30.5
48.3
55A082X
OD
(mm)
2.1
2.33
2.64
3.07
3.63
4.06
4.9
5.8
7.1
Weight
(g/m)
5.1
6.84
9.98
14.75
21.9
27.5
42.3
63.0
99.1
55A111X
OD
(mm)
1.71
1.84
1.99
2.2
2.45
2.67
3.1
3.55
4.2
Weight
(g/m)
6.85
8.2
10.3
13.4
17.88
21.75
30.4
42.46
- 62.7
55A112X
OD
(mm)
2.63
2.8
3.07
3.5
4.1
4.43
6.3
6.3
-
Weight
(g/m)
11.32
13.86
17.9
23.8
32.6
39.7
57.0
81.2
-
Size
26
24
22
20
18
16
14
12
10
55PC - AWG conductor: Statistical Process Controlled Airframe wires & cables
55PC042X
55PC021X
Weight
Weight
OD
Stranding
OD
(mm)
(g/m)
(g/m)
(mm)
(mm)
19/102
0.087
1.8
-
-
19/127
1.00
3.2
2.0
6.3
19/0.16
1.15
4.56
2.31
9.12
19/0.203
1.37
6.8
2.74
13.66
19/0.25
1.61
10.3
3.22
20.6
19/287
1.8
12.96
3.6
26.0
19/.036
2.18
19.86
4.36
39.9
37/0.32
2.66
30.2
5.3
60.8
37/0.403
3.27
47.9
-
-
- Tin plated copper conductor.
- Silver plated high strength copper alloy conductor.
(Recommended for size 24 & 26in airframe applications).
55PC141X
OD
(mm)
1.52
1.65
1.80
2.00
2.23
2.44
2.79
3.30
3.98
Weight
(g/m)
6.32
7.63
9.55
12.47
16.72
20.05
28.08
40.45
61.16
55PC142X
OD
(mm)
2.33
2.89
2.89
3.30
3.78
4.16
4.92
5.92
7.39
Weight
(g/m)
10.75
13.27
17.28
23.00
31.33
38.05
54.25
78.80
128.06
Size
26
24
22
20
18
16
14
12
10
X= 1
4
55PC - extra light weight constructions
For applications where weight is critical, light
weight tight tolerance conductors and
insulations are available. These are
manufactured using statistical process
control methods and achieve weights that are
equal or lighter than the equivalent polyimide/
PTFE constructions.
Contact Wire & Cable Division for further
details.
Spec 55
Part numbering system
55 X X
X
X
X-
Size- X/X- X
Jacket colour
(in accordance with MIL-STD-681,
white preferred)
Primary wire insulation colour
(in accordance with MIL-STD-681)
0=Black
3=Orange
7=Violet
1=Brown
4=Yellow
8=Grey
2=Red
5=Green
9=White
2L=Pink
6=Blue
Additional number after base colour
indicates stripe
Conductor size
Conductor type
1 - Tin-plated copper
2 - Silver-plated copper
3 - Nickel-plated copper
4 - Silver-plated high strength copper alloy
6 - Nickel-plated high strength copper alloy
Number of conductors
1 to 9
Class of wire
1 - 600 V equipment wire, light weight
2 - 600 V airframe wire, light weight
4 - 450 V equipment wire
(55M Only sizes 20-30)
8 - 600 V airframe wire, normal weight
Constructions
0 - Primary wire & unscreened,
unjacketed cables
1 - Round braid screened & jacketed cable
†
2 - Flat braid screened & jacketed cable
†
3 - Round braid, screened cable, no jacket
†
4 - Jacketed cable, no screen
5 - Spiral screened and jacketed cable
†
8 - Special constructions
(part numbers not coded)
9 - Special constructions including
light weight
†
Screen material same as conductor
material except all flat screens and screen
for conductor types 4 and 6 shall be tin-
plated copper. Other combinations are special.
(Refer to Wire and Cable Division).
Type
A- AWG conductor
M - Metric conductor
/ - Space wire
Basic specification number
Typical ordering example
Ordering information
3 conductors, red, yellow, blue, 600 volt equipment wire with overall round braid,
20 AWG tinned conductor and white jacket: total part number is 55A1131-20-2/4/6-9.
A list of stock policy items can be identified by contacting the relevant Product Specialist or Sales
Order Office. Stock policy items are recognized by the use of a suffix, such as (300) defining the
pack size, typically 55A0111-22-9(300).
Raychem and Spec 55 are trademarks of Tyco Electronics Corporation.
Tyco Electronics Raychem
305 Constitution Drive
Menlo Park, CA 94025
U.S.A
Tel: (650)-361 3860
Tyco/Electronics/Raychem
Cheney Manor Industrial Estate
Swindon, Wiltshire SN2 2QE
UK
Tel: (44)-1793 573762
Tyco/Electronics/Raychem
3816 Noborito, Tama-ku
Kawasaki 214-8533
Japan
Tel: (81)-44 9005102
Tyco/Electronics/Raychem
No. 26 Ang Mo Kio Ind. Park
Singapore 569507
Tel: (65)-4866151
WC0026.1200
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