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EQUIPMENT WIRES PER
U.S.A. MIL-W-16878
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 PTFE WIRES & CABLES

 WIRES PER U.S.A. MIL-W-16878
  - ADVANTAGES
  - APPLICATIONS
  - SPECIAL EQUIPMENT WIRES
  - QUALITY FEATURES
  - CAUTION
  - ADVANTAGES OF TWS
  - LIST OF MIL-W SPEC SHEETS
  - CONDUCTOR SIZE TABLE
  - INSULATED WIRE SIZES

 COAXIAL CABLES PER MIL-C-17
  - TABLE OF COAXIAL CABLES

 MULTI-CORE CABLES

 HIGH VOLTAGE WIRES & CABLES
  - HVCR SELECTION GUIDELINES
  - HVCR QUALITY ASSURANCE
  - HVCR SIZE TABLE

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  - WIRES FOR FLOOR HEATING

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PTFE Insulated Hook-up/Equipment Wires as per US Navy's MIL-W-16878 (click here for listing of specification sheets) or British BS-2G-210 or Indian JSS 51034 are used for internal wiring of professional high-performance electronic/electrical equipment.

On this page, you will find:
  1. Advantages of PTFE insulation
  2.Applications of PTFE insulated Wires & Cables
  3. PTFE Insulated Special Equipment Wires
  4. Special Features -- Quality Assurance, Test Voltages
  5.Caution

PTFE insulated wires

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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