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    Litz Wire Termination Guide

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    fd
    This document discusses various termination methods for litz wire, including: 1) Soldering litz wire with a solderable enamel using factors like solder pot choice and temperature, heat sinks, immersion time, and cleaning. 2) Removing the enamel from non-solderable litz wire using mechanical, chemical, or fused salts methods. 3) Applying terminals by tinning the ends, crimping terminals on, and backfilling terminals with solder.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Litz Wire Termination Guide

    Uploaded by

    fd
    176 views5 pages
    This document discusses various termination methods for litz wire, including: 1) Soldering litz wire with a solderable enamel using factors like solder pot choice and temperature, heat sinks, immersion time, and cleaning. 2) Removing the enamel from non-solderable litz wire using mechanical, chemical, or fused salts methods. 3) Applying terminals by tinning the ends, crimping terminals on, and backfilling terminals with solder.

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    Litz-Wire-Termination-Guide

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    This document discusses various termination methods for litz wire, including: 1) Soldering litz wire with a solderable enamel using factors like solder pot choice and temperature, heat sinks, immersion time, and cleaning. 2) Removing the enamel from non-solderable litz wire using mechanical, chemical, or fused salts methods. 3) Applying terminals by tinning the ends, crimping terminals on, and backfilling terminals with solder.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    176 views5 pages

    Litz Wire Termination Guide

    Uploaded by

    fd
    This document discusses various termination methods for litz wire, including: 1) Soldering litz wire with a solderable enamel using factors like solder pot choice and temperature, heat sinks, immersion time, and cleaning. 2) Removing the enamel from non-solderable litz wire using mechanical, chemical, or fused salts methods. 3) Applying terminals by tinning the ends, crimping terminals on, and backfilling terminals with solder.

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    You are on page 1of 5

    Termination Methods for Litz Wire

    Part 1 Soldering
    Part 2 Varnish removal methods
    Part 3 Applying Terminals

    Part 1

    Solderable Litz Wire


    Solderable Litz wire is constructed from Magnet wire that has a solderable enamel.

    Soldering
    A number of factors affect the quality of the soldered termination of a litz conductor
    manufactured with solderable wire. The following provides general guidelines for these
    factors.

    Choice of solder Pot


    Quantity of solder should be large enough so that solder temperature is not lowered
    significantly during sample immersion. For example a solder pot with a five lb
    capacity would be sufficient for Litz up to an approximate diameter of .250”, being
    immersed 1 inch. For larger conductors or for higher production capabilities a solder
    pot with a nine lb capacity or larger is recommended.

    Choice of solder
    At the high temperatures used to remove the enamel from each insulated strand of
    the conductor, replacement of copper by the tin element of the solder can be a factor.
    A 50/50 tin lead solder or 60/40 tin lead solder is recommended as a general rule.

    Heat Sink
    A heat sink is used to prevent soldering heat from migrating up the cable and
    affecting the litz wire strength and flexibility. The heatsink is sized to the wire and
    clamped onto the wire just above the portion to be immersed. pliers with brass jaws
    or brass bars attached to the jaws work well and also provides a means of holding the
    sample.

    07APRIL05 – Issue 3
    Solder Temperature
    Typical solder temperature is 700° F for soldering litz conductors, however
    experience with a particular construction may suggest raising as high as 800° F or
    lowering (slightly), the solder pot temperature.
    The solder temperature varies with the type of magnet wire being soldered the size
    of the overall construction and the size of the individual wires. A finely stranded
    conductor requiring only a very few seconds of immersion time can be safely and
    cleanly soldered at the higher temperatures. A heavier cable such as .250” diameter
    or large rectangular type 7 or 8 may have to be soldered at a lower temperature, due
    to the time required to boil off all the enamel, get a good solder bond and not lose
    copper strands to tin replacement.

    Immersion Time
    This has to be determined on each construction, but should be kept to a minimum to
    avoid tin replacement of copper. Times range from 2 seconds up to A maximum of
    60 seconds. Even on the larger constructions the enamel will all boil to the surface of
    the solder pot within a 60 second period.

    Flux
    The use of flux to ease the tinning process may not be necessary in all cases,
    however for larger constructions, the use of flux may decrease the immersion time
    required and produce a cleaner , brighter solder termination. Type R Non activated
    flux, or type RA fully activated flux may be used again depending on the magnet
    wire being used the size of the construction and the single end size. The end of the
    cable should be immersed in the liquid flux no more than the length of cable to be
    tinned or as experience dictates.

    Cleaning
    Wipe tinned length of litz cable, immediately upon removal from solder pot, with a
    clean cloth. Excess flux may be removed if necessary with isopropyl alcohol.

    Safety
    Make sure that adequate protection and safety measures are taken.
    Wear safety gloves, eye and face protection. Adequate ventilation or breathing
    protection should be used to avoid breathing of fumes. Soldering should be done
    under a retaliated fume hood.

    For More Information on Flux contact


    Litton
    Kester Solder
    (708) 297-1600
    www.kester.com

    07APRIL05 – Issue 3 2
    Part 2

    Non-solderable Litz Wire


    Non-solderable classes of magnet wire must first be stripped of the enamel. The
    constructions can then be soldered or mechanically terminated.

    Mechanical Method
    Physically abrade the enamel material off the magnet wire strands, works best for larger
    single end sizes. This can be done manually with sand paper or automatically with Nylon
    or Steel brushes being used depending on AWG size and number of ends.

    For more information contact


    The Eraser Company, INC.
    P.O. Box 4961 Oliva Drive
    Syracuse, NY 13221
    www.eraser.com

    Chemical Method
    This is a chemical magnet wire insulation stripper available in both a Jell and Liquid
    formulae. The ends of the litz constructions are dipped into the chemical solvent until the
    enamel is dissolved. Ends are then rinsed and wiped clean. Can be used on most sizes and
    insulation films.

    For more information contact


    Ambion Corp.
    37 Naugatuck Drive
    Naugatuck Industrial Park
    Naugatuck, CT 06770
    (203) 723-1437

    Salts Method
    Fused Salts are melted in a pot similar to a solder pot. The ends of the litz constructions
    are dipped into the melted salts until the enamel is dissolved. Ends are then rinsed and
    wiped clean. Can be used on most sizes and insulation films.

    For more information contact


    The Eraser Company, INC.
    P.O. Box 4961 Oliva Drive
    Syracuse, NY 13221
    www.eraser.com

    07APRIL05 – Issue 3 3
    Pinch terminals
    For use with a limited number of strands of magnet wire
    These are special connectors with teeth that punch through the enamel when applied.
    Possible suppliers AMP, Molex (contact info in connectors section)

    SN – Fusing (also works for solderable magnet wire’s)


    This process uses a combination of heat and pressure to replace the enamel with
    tin/solder.

    For more information contact


    Joyal Products, INC.
    1233 West Saint George Ave
    Linden, NJ 07036
    Phone 908-486-6100
    www.joyalusa.com

    Torch
    A Torch is sometimes used on larger single end sizes to burn away the enamel.

    Laser Striping
    This works well for single end wire only.

    Sonic Welding, Induction stripping,


    No information at this time.

    07APRIL05 – Issue 3 4
    Part 3

    Applying terminals to litz wire

    Tin the ends


    Tin the ends of the litz wire following the guidelines above.
    Wipe the tinned area with a rag.
    Visually inspect the end for any un-tinned wires re-tin if necessary.

    Crimping the terminals


    Follow the manufactures recommendations for the crimping process.

    Back Fill the terminals


    A hanger to hold the terminated litz wire is recommended. Use a large hand held
    soldering iron (250 Watt) and reheat the terminal area by touching the soldering iron and
    roll solder to the end of the Litz. (should be done in a vented area)

    Fill the terminal with solder until the face of the terminal is filled and and solder is
    flowing out the rear of the terminal.

    Cleaning
    Use an acid brush and isopropyl Alcohol to clean any residual flux dirt or other
    contaminants from the termination’s.

    07APRIL05 – Issue 3 5

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