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    Wires and Cables1

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    S.Dharanipathy
    Shielded wires have multiple layers of covering and conductors to protect the wire. They are constructed with a central core, insulation layer, shield layer made of a metal-coated tape, and outer sheath. Thermostat wires connect thermostats to HVAC systems and are made of solid copper conductors insulated with PVC. Winding wires are important for electrical devices and are often copper conductors insulated with polymer coatings to withstand high temperatures.

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    Wires and Cables1

    Uploaded by

    S.Dharanipathy
    127 views7 pages
    Shielded wires have multiple layers of covering and conductors to protect the wire. They are constructed with a central core, insulation layer, shield layer made of a metal-coated tape, and outer sheath. Thermostat wires connect thermostats to HVAC systems and are made of solid copper conductors insulated with PVC. Winding wires are important for electrical devices and are often copper conductors insulated with polymer coatings to withstand high temperatures.

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    Shielded wires have multiple layers of covering and conductors to protect the wire. They are constructed with a central core, insulation layer, shield layer made of a metal-coated tape, and outer sheath. Thermostat wires connect thermostats to HVAC systems and are made of solid copper conductors insulated with PVC. Winding wires are important for electrical devices and are often copper conductors insulated with polymer coatings to withstand high temperatures.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    127 views7 pages

    Wires and Cables1

    Uploaded by

    S.Dharanipathy
    Shielded wires have multiple layers of covering and conductors to protect the wire. They are constructed with a central core, insulation layer, shield layer made of a metal-coated tape, and outer sheath. Thermostat wires connect thermostats to HVAC systems and are made of solid copper conductors insulated with PVC. Winding wires are important for electrical devices and are often copper conductors insulated with polymer coatings to withstand high temperatures.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    of 7

    Wires and cables

    Shielded Wires
    A shielded wire is a type of electrical wire made of several layers
    of covering and conductors. It is useful for different types of
    applications where protecting covering of conductor is needed.
    Due to the specific characteristics it has found varieties of
    applications in different fields. It shows preferable electric
    attributes. Each of its cores is protected and the ground wire is
    closely contacted with the shield layer.

    Construction of Shielded Wires


    A shielded wire must have a protecting coat of layer outside it. It
    has a central core and an insulation
    layer provided. Then there is a shield layer which separates the
    insulation layer from a ground wire. This layer is made by a
    composite tape having a metal surface along with an adhesive
    surface. The metallic surface of the wire is longitudinally folded so
    that it can cover a portion of the adhesive surface. Then this tape
    is helically binded with the folded layer on the outer cover so that
    to form alternate helical patterns of the metal and adhesive
    layers. A sheath is used to wrap the shielded layer and the ground
    wire. After it the sheath layer is attached to the adhesive layer

    1
    while the ground wire remains in touch with the outer metallic
    layer. The metal surface used inside makes the shield.

    Metal Wires
    A metal wire is generally circular in cross section and is flexible.

    Most metal wires are made of several small twisted or woven


    strands available in varying lengths and diameters. These wires
    are often insulated carrying current and conducting electricity.

    Wire Production Method


    Metals wires for various applications are processed and reduced
    to the desired diameter and properties by repeatedly drawing it
    through smaller dies, or traditionally through holes in draw plates.
    The wires are heated in an inert atmosphere for softening and
    then they are cooled, this process is commonly known as
    annealing. An inert atmosphere prevents oxidation, although
    some amount of scaling always occurs and is removed by
    'pickling' before the wire is redrawn.

    Electrical wires are covered with different insulating materials,


    including plastic or rubber-like polymers. Two or more insulated
    wires are again wrapped in a concentric manner and wrapped
    with paraffin for further protection. Wire insulation and jacketing

    2
    is done by making them pass through extruders. There are
    different methods and materials used for manufacturing different
    types of wires.

    Thermostat Wires
    Thermostat wires or cables are used to connect a thermostat to
    the cooling, heating, and ventilating system. They are used for
    joining heat pumps, air conditioning controls, thermostats,
    heating controls and bell / alarm systems
    too. The thermostat wires are general purpose multi conductor
    low voltage control cables. They come in different varieties and
    are generally numbered or colored to do the correct installation.

    There are various types of controls and components in a


    thermostat and the wires for these controls run into the
    thermostat. The wires are multi-colored. The controls are usually
    complex and in order to run properly each wire must go to the
    correct terminal on the thermostat otherwise it will not work
    properly.

    Construction of Thermostat Cables


    Thermostat cables are usually made of a solid uncovered copper
    conductor. Mostly copper is used in these applications. Then it is
    insulated with polyvinyl chloride (PVC). The insulation
    is done without filler and it is surrounded by a fire and sunlight
    resistant PVC jacket.

    3
    Winding Wires
    Winding wires are among one of the most important types of wire
    used in electrical industries. They are used in the production of
    various types of electromagnetic devices like generators,
    transformers, pumps, control devices and motors. Though a lot of
    materials are available and suitable for constructing winding wires
    but copper is the most widely accepted metal for it.
    Winding wires are either enameled or coated with various types
    of varnish and other insulating materials.
    Copper is the most common conductor used in winding
    wires. It may be either solid or stranded. It offers very low
    resistance. The insulation used in these winding wires are made
    of special and tough grade polymer compounds. These materials
    make the wire impervious to water, oil, grease, and chemicals.

    Applications of Winding Wires


    Winding wires are applied in several industries. They are used as
    very fine wires in electronics and telecommunications
    applications. Winding wires are used as large insulated and
    covered wires for large motor and power transformation
    industries. The use and demand of winding wires are increasing
    rapidly as the economy of developing countries as well as the
    developed countries are recovering and surging. So the demand
    for electricity as well as winding wires is rapidly increasing in
    these nations. Some of the most important industries where
    winding wires are used are:

    • Automotive
    • Domestic appliances

    4
    • Electrical rotating machinery
    • Transformers
    • Other electrical equipment

    Varnishing of Winding Wires


    Varnishing of winding wires provide a layer of insulation on these
    wires. The varnishes must have the capability to resist high
    temperatures. The winding wires are generally composed of a
    conductive material which is usually copper. This conductor is
    covered with one or more layers of varnish. Varnishes are
    comprised of a copolymer which is obtained from a thermoplastic
    or thermosetting resin. These layers can withstand temperatures
    up to 200°C. The resin is made of any of the followings materials
    like

    • Polyamide imide (PAI)


    • Polyester imide (PEI)
    • Polyimide (PI)
    • Polyester (PE)
    • Polyurethane (PU)
    • Polyvinyl acetal (PVA).

    Need of varnishing
    Varnishes add an extra stability and strength to the winding
    wires. They improve their ability to withstand partial discharges
    and voltage peaks at very high temperatures. These insulated
    varnished winding wires are used in the manufacturing of coils for
    variable frequency controllers and converters.

    Winding Wire Industry


    Winding wire is used as semi finished material for generating
    electromagnetic fields and transforming electrical energy. The
    industry of winding wire is a mature industry and its market is on
    the rise. Its use in making different types of electromagnetic
    devices make them one of the important wires in the electrical
    industry. The motors, transformers, and generators are the

    5
    building block of any type of industries, plant or systems. So their
    uses in diverse areas are spreading its market by leaps and
    bounds.

    Double Insulated Submersible Pump Motors


    Winding Wires
    The double insulated winding wires are used for the purpose of
    winding & re-winding of submersible pumps motors. The
    especially double insulation of wires is to operate the submersible
    pumps motor under water over long periods.

    Flat Cables
    Flat cables, sometimes also known as ribbon cables, are a well
    known name in the field of electronics industry. They are used to
    interconnect the inner electrical systems especially in computers
    to connect peripherals. As these cables are flat, they distribute
    the mechanical load over the total width of the cable. Flat cables
    help them to increase heat dissipation and thus eliminate the
    need for large conductors.

    Flat ribbon cables consist of highly stranded, individually


    insulated conductors that are laid parallel and then fused in a flat,
    flexible ribbon form. These flat cables don't need repetitious
    insulating material like the traditional round wire cables. The
    electrical characteristics like capacitance, impedance, attenuation
    remain uniform because of the uniform geometry in these cables.

    6
    Construction of Flat cables:
    Flat cables are typically made of plastic substrates. They have a
    number of electrical conductors fixed to the plastic substrate.
    There may be 3 or 4 conductors to more than 50 conductors in a
    single cable. The axial distance between the adjacent conductors
    is usually 0.05 inches. The combination of substrate and plastic is
    flexible and flat. The width of conductors varies according to the
    device requirement.

    Plastic substrates are made from different types of plastics. They


    are:

    • Polyvinyl
    • Polyamide
    • Plyetherimide
    • Polyethylene
    • Naphthalate
    • Polycarbonate

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