Tensility introduces its High Temperature Cable Assemblies, Connectors, and Wire, a series rated to 105°C for higher energy use and heat resistance. These products have spring contacts and are designed for use in heavy duty applications and areas with high ambient temperatures, such as outdoor settings and manufacturing. Custom insulation in the connectors allows this series to be stable at high temperatures with a similar size and footprint as other cable assemblies.

Cable assemblies available in a variety of configurations, including plug or jack to stripped and tinned or plug to jack. Right angle versions are also available. The wire is 18 or 24 AWG, PVC, and rated at VW-1 fire safety.

Connectors are available in both dc plugs and jacks. Connectors come in 5.5x2.1 mm and 5.5x2.5 mm sizes and are rated at 48 V with a current rating of 7.5 A or 8.0 A. All connectors have 2 conductors, a cable mount feature, nickel plating, and spring contacts and custom insulation that creates solid contact and functionality in high heat.

The wire in this series is a flat cable with a VW-1 fire safety and 300 V, ranging from 16 AWG to 28 AWG. The diameter ranges from 2.5 mm to 4.8 mm. Wires in this series are UL 2651 with a PVC jacket.

All models are available for immediate delivery through Digi-Key or Arrow Electronics.  Custom configurations are also welcome.

VIEW HIGH TEMPERATURE CABLE ASSEMBLIES AND CONNECTORS

FAQs

What is the highest temperature a wire can withstand?

The highest temperature a wire can withstand is determined by the temperature rating of its insulator. Above this temperature you risk the insulation melting. As current flows, the wire can get hot due to the natural resistance of the conductor. The current carrying capacity of the wire is thereby determined by the level of current that it can carry without exceeding its insulator temperature limitations.

What is the difference between cables and wires?

A wire is a single strand or multiple strands of a conductor (usually copper), often covered by an outer protective jacket, such as PVC.  A cable has at least one connector attached to the wire, often protected by an overmold. 

Should power cords get hot?

No. The wire will naturally get warmer as current flows. However, the temperature of the wire should never get higher than the rated temperature of its insulation. Above this temperature, you risk the insulation of the wire melting and exposing the inner conductor.

At what temperature does wire insulation melt?

The temperature that wire insulation will melt depends on a multitude of factors, the greatest being the type of material. For example, PVC, a common wire insulator can melt in the range of 100-260°C (212-500°F) depending on the makeup of the PVC. Most commonly, PVC used for electronics manufacturing will melt between 160-190°C (320-374°F). An electronic device should never be run to the point of melting insulation as this increases the risk of electric shock and damage.  

What causes wires to get hot?

As current flows, the wire can get hot due to the natural resistance of the conductor. A wire or connector can overheat if it is run above the current rating for the component.