FEP High Voltage Wire, 18–30 kV DC

FEP high voltage wire for compact equipment leads

FEP high voltage wire is an unshielded, single-conductor wire for internal connections in high-voltage equipment. This family covers 18–30 kV DC configurations with silver-plated stranded copper and a −55 to +200°C operating temperature range. Its distinguishing choice is the insulation surface: plain FEP, pre-etched FEP for epoxy potting, or a silicone coating for RTV and silicone-based potting systems.

Choose the electrical configuration and bonding surface together. A wire that fits a feedthrough may still require a different outer surface at an encapsulated joint. The configuration tables keep voltage, conductor stranding and diameter together, and distinguish the FEP dielectric diameter from the finished diameter of a coated wire.

• Equipment fit: compact leads for power supplies, transformers and laser equipment where the connection remains inside a controlled enclosure.
• Assembly decision: identify the actual potting compound and cure process before selecting an etched or coated surface.
• Routing decision: check the finished diameter at feedthroughs, strain reliefs and bends, especially when adding a coating.

For AC or repetitive-pulse duty, send the waveform, operating duration and termination arrangement so the complete circuit can be assessed. Compare other constructions in High Voltage DC & Test Cables; the wire insulation temperature guide explains how material and complete-wire limits differ.

Construction

Every configuration uses one silver-plated stranded copper conductor with FEP as the electrical insulation. The surface option determines how the wire interfaces with an encapsulant.

Control the bonding surface during assembly

For pre-etched wire, protect the treated surface from ultraviolet light during storage. The stated normal etching shelf life is six months or longer under that protection; check treatment age, handling and bond performance with the intended potting process. A silicone coating changes the finished diameter, so check the coated value before selecting feedthroughs or strain reliefs.

Applications

Use this compact FEP lead family for internal high-voltage connections in equipment where temperature, available space and potting compatibility determine wire selection.

• High-voltage power supplies: internal DC leads between insulated modules and equipment interfaces.
• Transformers: leads requiring a surface compatible with the selected encapsulation compound.
• Laser equipment: compact internal leads where the complete circuit waveform and insulation coordination are reviewed.
• Industrial and medical equipment: internal wiring selected against the end equipment requirements.

Match the potting process and duty

Specify epoxy or RTV/silicone chemistry, cure conditions and the required adhesive bond when choosing plain, etched or silicone-coated FEP. Assess the cable, potting, feedthrough and termination as one insulation system. Include the waveform and operating duration for AC or repetitive-pulse applications.

This family is for equipment and test connections. Include operating duration, continuous-duty requirements and any repetitive-motion conditions with the enquiry, together with the proposed routing radius.

Specifications

FEP high voltage wire is specified by voltage, conductor size and surface option. Dimensions below are nominal. The plain/pre-etched table represents eight plain and six pre-etched configurations; the coated table adds five configurations.

Plain and pre-etched FEP configurations

Silicone-coated FEP configurations

Specify the complete configuration

An enquiry such as “FEP wire, 30 kV DC, 20 AWG, 19/32 stranding, pre-etched surface” identifies the construction more clearly than voltage alone. Add colour, length, operating duration, route and termination details. Include current and ambient conditions for conductor sizing.

Standards

The UL 94 statement concerns the FEP resin. UL explains the scope of UL 94 material flammability ratings; use the equipment specification to establish the required finished-wire and assembly tests.

Include the required inspection documents, dielectric test method, acceptance limits and operating waveform with the technical enquiry. The project test conditions should be agreed for the selected configuration and terminations.