Comments for page: Better Hookup Wire

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Posted by Steve p December 25, 2022 - 05:53 pm
Lookup TEFZEL MIL SPEC WIRE, CONFORMS TO M22759/32 SPECIFICATION. SOLID COLOR, CHOOSE FROM MENU. M22759/32 is a lightweight, high temperature airframe and avionics wire insulated with a single layer of cross-linked, modified ethylene-tetrafluoroethylene (ETFE) coating

Posted by Steve L. April 30, 2017 - 10:49 am
Hi Lloyd, Sorry that you weren't able to find what you wanted. (The Rolling Stones had a song about that :) Best wishes with your project.

Posted by Lloyd B April 28, 2017 - 04:50 pm
Hi Steve

No reply from Flex Wires to my email so eventually I phoned them. Bill, in sales there, was very helpful but had to direct me to Allied Wire and Cable in Pennsylvania as Flex sells 10,000-foot drums. Unfortunately I'd already checked Allied: it sells XLPVC on-line, but only one size and rating in solid core. Worse from my PoV, its checkout only accepts US shipping addresses. I think I've exhausted the possibilities for now. Will check out Keynar - thanks for the suggestion - and others such as PTFE, or may simply have to use ordinary PVC and be very careful.

Posted by Steve L. April 25, 2017 - 06:30 am
Yeah, I much prefer solid-strand hookup wire too, though after being forced to use stranded in a recent project, I have to admit some softening on that position. (Had 60+ wires going to a PCB which needed to be able to flip over for servicing, so flexibility was essential.) You might want to consider Kynar, as mentioned in the November, 2011 comments below. I only found it up to 20AWG but that was long ago and I didn't search widely. Don't know about 600V in that though. Hope you find what you need.

Posted by Lloyd B April 25, 2017 - 02:27 am
Hi again Steve. Yes, that looks like a good product and I was't aware of it - thanks. Raychem's TE Connectivity seems to be the mfr.: No solid-core and limited colours, so I'll keep chasing the XLPVC for what I need and let you know how I get on.

Posted by Steve L. April 24, 2017 - 07:33 pm
Hi Lloyd, I appreciate the kind words. Recently, I discovered a great, new-type wire and will be adding an addendum to the "Better Hookup Wire" article as soon as I get time. Depending on your requirements, it may be superior to IPVC. The product is Raychem's type 400R wire: I needed 600V wire for my application but the diameter of the #22, 600V version is just 49mils, versus about 100mils for the IPVC I had been using. (It seems about the same diameter as PVC 300V wire.) The dielectric constant is just 2.3, versus 3.5 to 8 (5 typ) for PVC. That's good for reducing parasitic capacitance. It's rated to 125C. My 5-sec test of 750F soldering iron against the insulation showed almost no effect! Whereas PVC melts "to the bone" and IPVC shows slight surface charring. Unlike PTFE, it's easy to strip and doesn't outgas corrosive fluorine. Best of all, (as quality hookup wire goes at Mouser) it's CHEAP. I paid $8.80 for 100ft. They cut it to the length you order and I didn't see a minimum but I try not to pester them with nuisance orders.

I was looking for stranded wire and don't know about availability of a solid version. As a starting point, you can see what I found (in various AWG values) at Mouser by searching there on 400R0111. The primary insulation used is irradiated polyolefin and it also has a 3-mil coating of irradiated fluoropolymer. (PTFE is one of many fluoropolymers.) I speculate that the coating is the reason that the soldering iron test came through so impressively. The only downside I've noticed is quite minor: it seems slightly stiffer than PVC but I don't think I would have noticed if I hadn't already researched the insulation characteristics.

Hope you find what you're looking for. Please post here if you find something nice. Thanks, Steve

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