At Satellite Cable there is a new passion for quality. No longer is it restricted to the end product - In the transformed perspective that rules the company, Quality is viewed as a consequence of a number of processes, checks and balances that make it an every time phenomenon and a visible hallmark across all manufacturing processes.
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Equipment or hook-up wires are small insulated wires which are used extensively in all types of electrical apparatus. Originally developed for use in aircraft, PTFE equipment wires, due to their performance and reliability are now widely used throughout the industry, where environmental condition preclude the use of ordinary PVC insulated wires. The small size of PTFE insulated equipment wire coupled with high voltage rating saves valuable weight and space in miniaturization and the high temperature limits of PTFE enables soldered connections to be made without damaging adjacent wires.

We manufacturer PTFE insulated silver plated copper wire as per American Military Specification W-16878. Our PTFE wires are as per JSS specifications 51034. These PTE insulated hook-up wires are manufactured in different sizes and different voltages. We manufacture these wires according to American Wire gauge system. Normal size of wires varies from AWG 32 to AWG 12 in single strand as well as multistrand. Insulation thickness of these wire depend upon voltage ratings. Generally three different voltage codes for each type of voltage ratings.

Voltage Rating
(Volts A.C.R.M.S)                   MIL – W-16878

TYPE
JSS-51034

BSG 210

250 volts                                     ET

WE 1 TD

A

600 volts                                       E

WE 2 TD

B

1000 volts                                   EE

WE 3 TD

C


We can also supply the material for higher voltage for specific requirements. Chart sowing diameter of base conductor and diameter and diameter of insulated wires having different voltage rating are given SPECIFICATION

 

PTFE INSULATED SPECIAL EQUIPMENT WIRES
Please refer to table for commonly available sizes. Within the normal range, larger number of strands are available to improve flexibility and flex-life; 19 strands up to AWG 30, 37 strands up to AWG 20 and 60 strands for AWG 9, 10, 11, 12 and 13. In the two larger sizes AWG 6 and 8, compact 61 strands true concentric constructions (compared to Rope lay 19 x 7) are about 15% lower in OD, weight and cost, although slightly stiffer.

We offer finer sizes, having thin-wall PTFE insulation, highly flexible (with flex-life) constructions using Silver Plated High Strength Copper Alloy (SPHSCA). Sizes as small as AWG 37/7/45 (0.43 mm). Even such fine sizes are 100% tested.

For Wire-Wrap wire, advantages of PTFE insulation are now available in single strand size up to AWG 36 (OD 0.43 mm), and multi-strand 3607 or 3707 with OD 0.38 mm.

SPECIAL FEATURES -- QUALITY ASSURANCE

100% Physical and Electrical testing (see below for test voltages )
A minimum of 3 layers of PTFE tape, wrapped and sintered, provides balanced bi-axially oriented, concentrically placed insulation (for more details about advantages of TWS method, click here)
Minimum shrinkage/deformation and no `run-away' problem at soldering-iron temperatures
Surface as good as extruded wire without the disadvantages of extruded PTFE insulation in fine-gauge thin-wall types
Certified minimum BREAK DOWN VOLTAGE (on samples) to ensure higher, uniform and predictable performance
Controlled tigher tolerance on weight, PTFE density and conductor resistance
Test voltages for the three common working voltages are:
Type Working Voltage
AC RMS Dielectric Test
Voltage for 1 minute Spark Test Voltage for for 1 second
ET 250 1500 2500
E 600 2000 3400
EE 1000 3000 5000

CAUTION
Thin-wall insulation is not recommended for higher soldering iron temperatures and for gauges larger than AWG 20
Stripping of Tape-Wrapped-Sintered (TWS) PTFE insulation is generally difficult on automatic high-speed machines, more so, for thin-wall finer sizes

ADVANTAGES OF PTFE INSULATION

PHYSICAL/CHEMICAL

  • Inert to practically all chemicals even at elevated temperatures
  • Excellent Resistance to Ultra-Violet radiation and stress-cracking
  • Non-contaminating, Non-toxic and bio-compatible
  • Resistant to fungus and mould growth
HIGH TEMPERATURE
  • Excellent thermal stability -- suitable for use from -200°C to 260°C
  • Fire (flame) proof
  • Soldering iron resistant and suitable for high density wiring
ELECTRICAL
  • Suitable for very wide frequency range (DC to above 10,000 MHz) over wide temperature range
  • Lowest dielectric constant (2.1)
  • Lowest dissipation factor (below 0.0003)
  • Highest volume and surface resistivities (in Teraohms)
  • Corona Resistance is fair (CR PTFE is available for severe corona conditions)
MECHANICAL
  • Smaller size, lighter weight and much higher reliability
  • Cold-flow and cut-through resistance -- fair (good mechanical strength)
  • Excellent flex-life
APPLICATIONS OF PTFE INSULATED WIRES & CABLES
  • Electronic Test Equipment
  • Communication Equipment (mobile and manpack wireless sets)
  • Equipment for Aircraft, Radar, Navigation, Electro-mechanical applications, Satellites, Research Equipment for Aerospace, Navy & Meteorology
  • Control Equipment for Atomic Energy, Satellite Launching, Ground Control, Reactors and Process Control, Telephone Exchange, Lifts
  • Computers, Flight simulators
  • High performance motors, transformers and rectifiers
  • Infra-red sensing equipment
  • Thermo-couple and compensating cables
  • Air-field lighting equipment
  • High temperature lighting fittings (sodium lamps etc.)
  • Refrigeration equipment
  • Load cells and pressure transducers
  • Electro-medical/Neuro-surgical equipment
  • High temperature control valves
  • Furnace and oven wiring
PTFE INSULATED SPECIAL EQUIPMENT WIRES

Please refer to table for commonly available sizes.  Within the normal range, larger number of strands are available to improve flexibility and flex-life; 19 strands up to AWG 30, 37 strands up to AWG 20 and 60 strands for AWG 9, 10, 11, 12 and 13.  In the two larger sizes AWG 6 and 8, compact 61 strands true concentric constructions (compared to Rope lay 19 x 7) are about 15% lower in OD, weight and cost, although slightly stiffer.

We offer finer sizes, having thin-wall PTFE insulation, highly flexible (with flex-life) constructions using Silver Plated High Strength Copper Alloy (SPHSCA).  Sizes as small as AWG 37/7/45 (0.43 mm).  Even such fine sizes are 100% tested.

For Wire-Wrap wire, advantages of PTFE insulation are now available in single strand size up to AWG 36 (OD 0.43 mm), and multi-strand 3607 or 3707 with OD 0.38 mm.

SPECIAL FEATURES -- QUALITY ASSURANCE

  • 100% Physical and Electrical testing (see below for test voltages )
  • A minimum of 3 layers of PTFE tape, wrapped and sintered, provides balanced bi-axially oriented, concentrically placed insulation (for more details about advantages of TWS method, click here)
  • Minimum shrinkage/deformation and no `run-away' problem at soldering-iron temperatures
  • Surface as good as extruded wire without the disadvantages of extruded PTFE insulation in fine-gauge thin-wall types
  • Certified minimum BREAK DOWN VOLTAGE (on samples) to ensure higher, uniform and predictable performance
  • Controlled tigher tolerance on weight, PTFE density and conductor resistance
  • Test voltages for the three common working voltages are:
     
    Type
    Working Voltage
     AC RMS
    Dielectric Test 
    Voltage for 1 minute
    Spark Test Voltage for for 1 second
    ET
    250
    1500
    2500
    E
    600
    2000
    3400
    EE
    1000
    3000
    5000
CAUTION
  • Thin-wall insulation is not recommended for higher soldering iron temperatures and for gauges larger than AWG 20
  • Stripping of Tape-Wrapped-Sintered (TWS) PTFE insulation is generally difficult on automatic high-speed machines, more so, for thin-wall finer sizes

 

 

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