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Insulation & Conductor

   

Insulation Material

We work with extrudable plastics and braidable fibres which can be continuously used as electrical insulations for temperatures of +90°C and upwards.

Below we have listed our processed materials depending on operating temperature (20,000h).

For further information on that material just klick on its name.

PVC (Thermoplast) +90°C
TPE (Thermoplastic Elastomer) +125°C
ECTFE (Fluoropolymer) +135°C
ETFE (Fluoropolymer) +155°C
Silicone Rubber (Elastomer) +180°C
FEP (Fluoropolymer) +205°C
PFA (Fluoropolymer) +260°C
E-Glass (Glass Fibres) +350°C
R-Glass (Glass Fibres) +650°C
Quartz Glass (Ceramic Fibres) +1.000°C
Nextel (Ceramic Fibres) +1.200°C
Auxiliaries (Metal Braids, Tapes, Varnishes)  

Please note:
Our cables and tubes fulfil the „RoHS“ requirements as detailed by the EU Directives 2002/95/EC, 2002/96/EC and 2003/11/EC.

PVC

(Polyvinylchlorid), VDE: "Y"
Operating temperature: +90°C
Garnisch denomination: "J" (e.g. JXFJ 2x0,75)
Remarks: contains halogens, low-priced polymer, versions for 70 -105°C

TPE

(Thermoplastic Elastomer), e.g. TPV, TPE-E
Operating temperature: up to +125°C
Garnisch denomination: "A, A1, A2" (e.g. T1XA 4x0,50)
Remarks: silicone-free, suitable for the automotive industry

ECTFE

(Ethylen-Trifluorochlorethylen), "Halar"
Operating temperature: +135°C
Garnisch denomination: "T3" (e.g. T3XFJ 4x0,75)
Remarks: fluoropolymer, contains halogens, non-flammable (LOI >30%), very good resistance to chemical substances and mechanical stress, very high electric strength, small wall thickness possible

ETFE

(Ethylen-TetraFluor-Ethylen) "Tefzel", VDE: "7Y"
Operating temperature: +155°C
Garnisch denomination: "T1" (e.g. T1XCS 2x1,50)
Remarks: fluoropolymer, contains halogens, non-flammable (LOI >30%), very good resistance to chemical substances and mechanical stress, very high electric strength (small wall thickness possible), exceptionally high resistance to ionising radiation (nuclear industry, aerospace)

Silicone Rubber

VDE: "2G"
Operating temperature: +180°C
Garnisch denomination: "S" (e.g. SXCS 2x1,50)
Remarks: synthetic rubber, very elastic, many versions for special applications

FEP

(Fluor-Ethylen-Propylen), VDE: "6Y"
Operating temperature: +205°C
Garnisch denomination: "T" (e.g. TXCT 3x0,75)
Remarks: fluoropolymer, contains halogens, non-flammable (LOI >95%), very good resistance to chemical substances and mechanical stress, very high electric strength, small wall thickness possible

PFA

(Pefluoro-Alcoxy Copolymer), VDE: "51Y"
Operating temperature: +260°C
Garnisch denomination: "T2" (e.g. T2XFS 4x0,75)
Remarks: fluoropolymer, contains halogens, non-flammable (LOI >95%), very good resistance to chemical substances and mechanical stress, very high electric strength, small wall thickness possible

E-Glass

Operating temperature: +350°C, fixed +400°C
Garnisch denomination:: "G" (e.g. GGNi 0,75)
Remarks: glass fibres for wraps and braids

R-Glass

Operating temperature: +650°C, fixed +700°C
Garnisch denomination: "R" (e.g. RRNi 6,00)
Remarks: glass fibres for wraps and braids

Quartz Glass

Operating temperature: +1.000°C
Garnisch denomination: "Q" (e.g. QQNi 0,22)
Remarks: heat-resistant ceramic fibres, braids only

Nextel

(Trademark of 3M)
Operating temperature: +1.200°C
Garnisch denomination: "N" (e.g. NN-Ni 0,75)
Remarks: exceedingly heat-resistant ceramic fibres, braids only

Auxiliaries

Metal braids made of tin or nickel plated copper wires, galvanized steel wires, stainless steel wires. Tapes made of polyester, aluminium plated polyester, polyimide, pre-sintered PTFE.
Varnishes based on silicone, polyurethane or acryl.

Conductor Material

As conductor material we mainly use electrolytical copper or pure nickel (>99.2%).
Depending on operating temperature our copper conductor are bare (“Cb“), tin-plated (“Cv“), silver-plated (“Cs“) or nickel-plated (“Cn”) strands.
For thermocouples and resistance wires we use alloys including Cu, Ni, Fe, Cr, Al and Mn.

With our own range of stranding machines we are capable to manufacture customized strands.
Of course we also work with solid wires.

INFO: for determination of the copper weight of a conductor just multiply the cross section by 9.6.

   
Ampacity and Resistance by Temperature

An increasing operating temperature alters the conductor’s electrical properties, decreasing its ampacity while increasing its electrical resistance. As a help to determine the appropriate cross section for a certain operating temperature we have added an Excel file with the proper formulas, factors and example calculations:

Metric Sizes

Most conductors we use are metric bunched strands, which are mostly according to VDE class 5. Of course we also work with metric high-flexible strands and solid wires.

The following table lists the most common metric bunched strands in our production:

Cross Section
mm²
Diameter
mm
Construction
X x mm
0,10 0,42 13 x 0,10
0,14
0,14
0,48
0,49
7 x 0,16
18 x 0,10
0,18 0,54 10 x 0,15
0,22 0,60 7 x 0,20
0,25
0,25
0,66
0,65
14 x 0,15
32 x 0,10
0,34 0,75 7 x 0,25
0,38 0,80 19 x 0,16
0,50
0,50
0,50
0,90
0,95
0,90
7 x 0,30
16 x 0,20
19 x 0,18
0,75
0,75
1,15
1,15
24 x 0,20
19 x 0,23
1,00
1,00
1,32
1,30
32 x 0,20
19 x 0,26
1,50
1,50
1,63
1,61
48 x 0,20
37 x 0,23
2,50
2,50
2,07
2,03
50 x 0,25
37 x 0,29
4,00 2,61 56 x 0,30
6,00 3,19 48 x 0,40
10,0 4,16 80 x 0,40
16,0 5,76 126 x 0,40
25,0 7,48 196 x 0,40
AWG Sizes

AWG stranded wires (AWG = American Wire Gauge) are geometrically round shaped conductors with non-metric sizes since it is based on the American measure of length „mil“ (milli-inch, 1 mil = 0.0254 mm).

Following table lists the AWG stranded wires with which we work:

AWG
no.
Construction
X x mm
Cross Section
mm²
Diameter
mm
10 7 x 15 x 0,254
7 x 7 x 0,361
37 x 0,404
5,32
5,01
4,74
3,30
3,35
2,92
12 65 x 0,254
37 x 0,320
19 x 0,455
3,29
2,97
3,09
2,51
2,31
2,36
14 41 x 0,254
19 x 0,361
2,08
1,93
2,06
1,85
16 26 x 0,254
19 x 0,287
1,28
1,23
1,57
1,50
18 26 x 0,203
19 x 0,254
7 x 0,404
0,84
0,93
0,90
1,27
1,32
1,27
20 19 x 0,203
10 x 0,254
7 x 0,32
0,60
0,51
0,56
1,06
1,01
0,99
22 19 x 0,16
7 x 0,254
0,38
0,34
0,84
0,78
24 19 x 0,127
7 x 0,203
0,24
0,22
0,68
0,63
26 19 x 0,102
7 x 0,160
0,16
0,14
0,56
0,51
28 19 x 0,079
7 x 0,127
0,09
0,09
0,43
0,41
30 7 x 0,102 0,06 0,33
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