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| | Micro Flex Wire and Cable Reynolds has developed a range of highly flexible cables that are particularly suitable to the aircraft environment. This technology is a direct result of our research into durable and flexible cable assemblies needed for Helmet Mounted Display (HMD) systems. The wire utilized in these cable assemblies has a PFA insulation and all of the conductors are high strand count silver plated copper. They are durable and have excellent tolerance to work hardening environments. They have been designed to operate over a wide temperature range of -55°C to +125°C at their rated voltages and at altitudes up to 70,000 feet (21,000) meters). Micro Flex is available as single wire, twisted pairs or as multicore cable with or without shielding.
Reynolds unique capability to manufacture Micro Flex cable includes special winding tooling to take advantage of the flexibility of the individual cables in laying up a multi-cable bundle. | | Features | - Flexible
- Up to 18 KVDC operation
- PFA insulation
- Small and lightweight
- Durable
- Reliable
- Non-combustible, low smoke rating
- -55°C to +125°C temperature rating
| | Micro Flex Testing | | | The following tests have been performed to MIL-W-22759 Guidelines:| • Wrap test | • Life cycle | • Low temperature (cold bend) | | • Insulation resistance | • Bend test | • Thermal shock | | • Blocking | • Dielectric test | • Humidity |
| | Typical Applications | | | | • HMD CRT Cabling | • Helmet tracker cabling | | • Ejection safe QDC cabling | • Medical instrumentation cabling | | • Communication cabling | • High vibration aircraft cabling | | • NVG ejection cabling | • Flight line or automotive test equipment cabling |
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| Download PDF's of Catalog Pages | |
High Voltage Micro-Flex Wire and Cable | | High Voltage Micro-Flex | Micro Flex wire and cable, like FEP high voltage wire and cable, is available uncoated or with a silicone rubber coating over the PFA insulation. The coated cable is processed with a silicone rubber coating continuously applied to the etched surface of the cable. The coated cable has characteristics similar to silicone rubber cable and a superior dielectric bond to silicone rubber potting or bonding material can be achieved. High Voltage Micro-Flex Attributes| Operating Voltage (KVDC) | Conductor | Plating | Conductor | Ø Over Insulation | Part
Number | | AWG | Strands | Ø In./ mm | In./MM | | 3 | 29 | 51/46 | SPC | .012/0.33 | .019/0.48 | 178-5132 | | 5 | 29 | 51/46 | SPC | .012/0.33 | .025/0.64 | 178-5135 | | 13.5 | 28 | 41/44 | SPC | .014/0.37 | .042/1.07 | 178-5138 | | 18 | 24 | 41/40 | SPC | .022/0.58 | .050/1.27 | 178-5141 | | 25 | 16 | 41/32 | SPC | .059/1.50 | .125/3.17 | 178-5577 |
Silicone Coated High Voltage Micro-Flex Attributes| Operating Voltage (KVDC) | Conductor | Plating | Conductor | Ø Over Insulation | Part
Number | | AWG | Strands | Ø In./ mm | In./MM | | 3 | 29 | 51/46 | SPC | .012/0.33 | .029/0.79 | 178-5134 | | 5 | 29 | 51/46 | SPC | .012/0.33 | .035/0.89 | 178-5137 | | 13.5 | 28 | 41/44 | SPC | .014/0.37 | .052/1.32 | 178-5140 | | 18 | 24 | 41/40 | SPC | .022/0.58 | .060/1.52 | 178-5143 |
Shielded High Voltage Micro-Flex Attributes| Operating Voltage (KVDC) | Conductor | Plating | Conductor | Ø Over Insulation | Ø Over Braid | Part
Number | | AWG | Strands | Ø In./ mm | In./MM | In./MM | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-00 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-01 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-02 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-03 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-04 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-05 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-06 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-07 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-08 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-09 | | 6 | 22 | 65/40 | SPC | .030/0.76 | .041/1.04 | .053/1.35 | 178-5459-10 |
To specify acolor add a hyphen to the Part Number as follows:
-00 Black -01 Brown -02 Red -03 Orange -04 Yellow -05 Green -06 Blue -07 Violet -08 Gray -09 White -10 Natural | | Download PDF's of Catalog Pages | |
HI/Bus High Voltage Bus Line | | HI/Bus - High Voltage Line | An insulated high voltage bus bar for use in densely populated high voltage power supplies. HI/Bus can be bent and will retain its shape prior to soldering and potting. Hi/Bus is rated at 5 KVDC for altitudes up to 70,000 feet (21,000 m)
HI/Bus can be ordered with a silicone coating over the PFA insulation which provides the user with a compatible surface to bond or encapsulate using silicone rubber potting material. The coated surface should be primed in accordance with the instructions of the manufacturer of the potting material. | | HI/Bus Advantages | - Easily formed
- Silver plated solid copper conductor
- Available on spools
- Color options
- Optional silicone rubber coating
| Hi/Bus - High Voltage Bus Line Attributes| Operating Voltage (KVDC) | Conductor | Conductor
Ø In./ mm | Silicone
Coating | Overall | Part
Number | Solid SPC
AWG | Ø In./MM | | 5 | 30 | .010/0.25 | NO | .021/0.53 | 178-5207 | | 5 | 26 | .016/0.41 | NO | .027/0.69 | 178-5208 |
| | Download PDF's of Catalog Pages | |
"Quiet Line" Distributed Loss R.F. Attenuation LineQuiet Line is a continuously extruded, distributed loss, low pass filter line
for high voltage applications. Quiet line is a flexible element offering R.F. power attenuation and can be spliced onto an existing high voltage lead assembly or supplied as an entire high voltage lead assembly.
Quiet Line is available with or without a silicone rubber coating. This continuous thin wall coating is applied over the FEP or PFA jacket and allows the user to achieve a superior dielectric bond when potting or encapsulating with a compatible silicone material.
Quiet Line is available either shielded or non-shielded with or without the silicone rubber coating. Six loss core diameters are offered providing a range of rated voltages and R.F. insertion loss characteristics. The configurations are shown on page 15 and the attributes of each configuration.
Special configurations are available pending a review of your requirements by Reynolds engineering department personnel. | | General Specifications | | Conductor and braid: | Copper, silver plated | | Insulation : | Extruded PFA (fluorocarbon) | | Jacket: | PFA or FEP | | Operating Temperature: | -55°C through +125°C at 70,000 foot altitude | | Voltage stress testing: | 100% test at 140% of rated voltage (room ambient) | | Insertion loss testing: | 100% insertion loss verification performed on each extrusion lot. The swept frequency insertion loss technique is used within the specified frequency range per MIL-C-17F. Test specimens are shielded with a BNC termination. |
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 |  "Quiet Line" Attributes | | Download PDF's of Catalog Pages | |
Cable Conductor Data Size - Stranding - Current Rating | AWG | Stranding | Approx Diameter | Cross Section | DC Resistance | Current Raiting | | mm | inches | mm^2 | Ohms/1000m | (amps) free air. 80º C* | | 30 | 41/46 | 0.3 | 0.012 | 0.051 | 337.3 | 0.4 | | 29 | 51/46 | 0.35 | 0.014 | 0.064 | 271.3 | 0.5 | | 28 | 41/44 | 0.37 | 0.014 | 0.064 | 271.3 | 0.5 | | 26 | SOLID | 0.4 | 0.016 | 0.13 | 133.9 | 1 | | 26 | 11139 | 0.48 | 0.019 | 0.141 | 122.4 | 1 | | 26 | 11962 | 0.51 | 0.02 | 0.13 | 136.2 | 1 | | 26 | 19/38 | 0.5 | 0.02 | 0.151 | 113.8 | 1 | | 26 | 51/42 | 0.56 | 0.022 | 0.16 | 107.3 | 1 | | 26 | 66/44 | 0.48 | 0.019 | 0.131 | 131.9 | 1 | | 24 | SOLID | 0.51 | 0.02 | 0.205 | 84.3 | 1.6 | | 24 | 10409 | 0.61 | .O24 | 0.224 | 76.8 | 1.6 | | 24 | 11231 | 0.64 | 0.025 | 0.201 | 85.6 | 1.6 | | 24 | 16/36 | 0.61 | 0.024 | 0.201 | 85 | 1.6 | | 24 | 19/36 | 0.64 | 0.025 | 0.241 | 71.5 | 1.6 | | 24 | 41/40 | 0.59 | 0.023 | 0.205 | 84 | 1.6 | | 22 | SOLID | 0.64 | 0.025 | 0.326 | 52.8 | 2.5 | | 22 | 34909 | 0.76 | 0.03 | 0.356 | 48.2 | 2.5 | | 22 | 19/34 | 0.8 | 0.032 | 0.383 | 44.9 | 2.5 | | 22 | 26/36 | 0.75 | 0.03 | 0.329 | 52.5 | 2.5 | | 22 | 65/40 | 0.78 | 0.031 | 0.326 | 52.5 | 2.5 | | 20 | SOLID | 0.81 | 0.032 | 0.518 | 33.5 | 4 | | 20 | 34907 | 0.96 | 0.038 | 0.567 | 30.5 | 4 | | 20 | 35001 | 1.02 | 0.04 | 0.509 | 33.8 | 4 | | 20 | 19/32 | 1.01 | 0.04 | 0.609 | 28.2 | 4 | | 20 | 26/34 | 0.94 | 0.037 | 0.524 | 32.8 | 4 | | 20 | 105/40 | 0.99 | 0.039 | 0.526 | 32.8 | 4 | | 18 | SOLID | 1.02 | 0.04 | 0.823 | 21 | 4 | | 18 | 34905 | 1.21 | 0.048 | 0.901 | 19 | 4 | | 18 | 16/30 | 1.23 | 0.048 | 0.815 | 21 | 4 | | 18 | 19/30 | 1.27 | 0.05 | 0.968 | 17.7 | 4 | | 18 | 41/34 | 1.19 | 0.047 | 0.826 | 21 | 4 | | 18 | 65/36 | 1.25 | 0.049 | 0.823 | 21 | 4 | | 18 | 168/40 | 1.34 | 0.053 | 0.842 | 20.3 | 4 | | 16 | SOLID | 1.29 | 0.051 | 1.309 | 14.1 | 10 | | 16 | 34903 | 1.53 | 0.06 | 1.433 | 12.1 | 10 | | 16 | 19/29 | 1.43 | 0.056 | 1.22 | 14.1 | 10 | | 16 | 26/30 | 1.5 | 0.059 | 1.22 | 14.1 | 10 | | 16 | 41/32 | 1.5 | 0.059 | 1.326 | 13.3 | 10 | | 16 | 65/34 | 1.57 | 0.062 | 1.309 | 13.1 | 10 | | 16 | 260/40 | 1.73 | 0.068 | 1.303 | 13.1 | 10 | | 14 | SOLID | 1.63 | 0.064 | 2.081 | 8.2 | 15 | | 14 | 34901 | 1.85 | 0.073 | 2.285 | 7.6 | 15 | | 14 | 19/27 | 1.8 | 0.071 | 1.94 | 8.9 | 15 | | 14 | 41/30 | 1.89 | 0.075 | 2.088 | 8.2 | 15 | | 12 | 34899 | 2.44 | 0.096 | 3.66 | 4.9 | 20 | | 12 | 19/25 | 2.27 | 0.09 | 3.085 | 5.6 | 20 |
*Please refer to Mil-W-5088 for specfic current ratings |
Index by Part Number |
