High-temperature insulated wire is not a one-size-fits-all product. Based on the application, different factors will go into selecting the most appropriate form of wire to have the job finished right. On this page, we'll take particular notice at what these 4 elements are and how they are able to aid in selecting the right high-temperature insulated wire for the specific situation.

Factor #1: Meaning of Electrical Requirements - Operating voltage, conductor temperature rating and current-carrying capacity (aka ampacity) must all be met when selecting high-temperature insulated wire. Such wiring is labeled having a temperature rating, that's driven by a mixture of ambient heat and current-generated heat. Ambient heat stems from the approval being performed whereas current-generated heat is calculated by matching conductor material and diameter to service amperage. It is important to note that due to the difficulty in pinning down exact current-carrying capacity, manufacturers often specify higher capacity conductors than theoretical calculations would indicate.



Factor #2: Environmental Conditions - What's going on inside the wire isn't the only consideration in terms of selecting the right high-temperature insulated wire. External environmental factors will also be important. Like they are able to possess a damaging effect on both wire's insulation as well as its interior circuitry. Ambient heat, moisture, abrasion, thermal stability, chemical attach, mechanical abuse, cold, flame resistance, easy stripping terminating and routing are typical environmental problems that has to be paid for when choosing high-temperature insulated wire. Some factors are discussed in greater detail further on on this page.

Factor #3: Conductor Material Type - The wire's conductor material will determine the absolute maximum temperature it could withstand. Situations that want the wire to have the highest of temperatures, like high-rise alarms in the event of a fireplace, could be more reliably served with nickel-coated copper and nickel conductors, as both versions can endure temperatures up to 550 degrees Celsius. Copper, nickel-plated and iron conductors alternatively hold up under only a maximum variety of 200 to 250 degrees Celsius.

Factor #4: Current-Carrying Capacity or Ampacity - A portion of the environmental conditions pointed out above also provide an effect on high-temperature insulated wire's power to carry current. Therefore, they should be weighed in to the equation. Ampacity is measured as the current a conductor can hold prior to combined temperature of both conductor and insulation rises above a permitted limit.

Conductor size and material, amperage, ambient temperature and insulation type will all be the cause is the wire's ampacity. The conductor's diameter and mass will be the most influential size considerations. Smaller these are, the low the high-temperature insulated wire's ampacity. As previously stated inside the Factor #3 section, a conductor's material features a strong relating just how much temperature the wire can withstand which temperature range varies widely. Likewise, different materials produce wide fluctuations in the current-carrying capacity in the wire as well.

Finally, the sort of insulation found in the wire determines just how much heat it dissipates and, in turn, the ampacity. The dissipation problem becomes even more complicated when wire is enclosed inside a tightly confined space, so fire alarms in high-rise ductwork, for example, pose additional challenges when looking at high-temperature insulated wire options.

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