Extension Wire Construction

Thermocouple Extension Wire

Thermocouple extension wire is a single pair wire that cannot be made into a thermocouple, but is used to carry the signal form a thermocouple to the recorder, controller, or instrument reading the signal. Extension grade wire usually has lower ambient temperature specifications. It is used to carry signal representing the higher temperature seen by the sensing location, but extension wire cannot be generally cannot be exposed to those higher temperatures. Extension wire cannot be used to make a thermocouple, but thermocouple wire can be used as extension wire. Insulation is typically PVC, but other option are available.

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Polyvinyl Chloride (PVC)
Suggested operating range:
-15°F to 221°F (-26°C to 105°C)
Also available:  Shielded PVC

Flame retardant PVC insulation provides excellent chemical and abrasion resistance. PVC also has high dielectric strength as well as outstanding insulation resistance to ozone, acid, alkalis, alcohol, oil, gasoline, grease, wax, moisture and most solvents. The individual conductors and outer jacket are extruded.

Nylon
Suggested operating range:
-85°F to 250°F (-65°C to 121°C)

Nylon provides high tensile, impact and flexural resistance. It has excellent resistance to abrasion and is unaffected by most alkalis, oil, grease, dilute mineral acids and most organic acids. It is inert to most organic solvents including hydraulic fluid and aviation oil. The individual conductors and outer jacket are extruded.

Fluorinated Ethylene Propylene (FEP)
Suggested operating range:
-90°F to 400°F (-67°C to 204°C)

FEP retains useful strength and flexibility over broad ranges of environmental temperature or thermal aging.  FEP is flame retardant and non-propagating in fire conditions.  It is moisture and chemical resistant and accepted for use around food and pharmaceuticals. The individual conductors and outer jacket are extruded.

Perfluoroalkoxy (PFA)
Suggested operating range:
-328°F to 500°F (-200°C to 260°C)

Flame retardant PFA provides flexibility and toughness with stress crack resistance, resistance to weather, non-aging characteristics and a low coefficient of friction.  PFA also provides outstanding electrical characteristics, as well as resistance to virtually all chemicals.  The individual conductors and outer jacket are extruded.

Tetrafluoroethylene (TFE)
Suggested operating range:
-328°F to 500°F (-200°C to 260°C)

TFE is flame retardant (passes IEEE 383 & VW-1 flame tests) and has excellent solvent and abrasion resistance.  TFE is unaffected by long term exposure to virtually all chemicals and solder iron temperatures. The individual conductors and outer jacket are insulated with TFE Tape.

Polymide Tape (Kapton)
Suggested operating range:
-400°F to 600°F (-240°C to 315°C)

Kapton is extremely tough.  It has excellent abrasion, impact and cut through resistance, very high resistance to oxidative degradation, weathering, and all chemicals except strong bases.  Kapton also offers high dielectric strength and insulation resistance.  Kapton does not support combustion; even at extremely high temperatures, it decomposes slowly without visible burning.  It is also resistant to radiation. The individual conductors and outer jacket are insulated with Kapton Tape.