TFE-WIRE

Supported Applications

The Omega TFE Insulated Thermocouple Duplex Wire series provides temperature measurement extension and connection solutions using fused tape insulation. The product line encompasses two distinct construction types: TFE insulated wire, which offers superior abrasion, moisture, and chemical resistance; and Kapton® duplex insulated wire (KK), noted for excellent moisture and abrasion resistance, high dielectric strength of 7 kV/mil, and the ability to retain physical integrity after gamma radiation. Both series utilize FEP as an adhesive binding agent that melts at approximately 260°C.

Operating Conditions & Performance

The documented maximum operating temperature for both TFE Insulated and Kapton® Duplex Insulated thermocouple wire is 260 °C (500 °F). The series supports multiple calibration types, including J, K, T, and E. Conductor configurations are available in solid or stranded formats; the AWG No. suffix 'S' denotes stranded wire options such as 7 x 28 and 7 x 32.

Physical dimensions vary by gauge and construction:

• AWG 20 (Solid): Nominal size 1.5 x 2.5 mm (0.060 x 0.100 inch)
• AWG 20S (Stranded, 7 x 28): Nominal size 1.5 x 2.7 mm (0.060 x 0.105 inch)
• AWG 24 (Solid): Nominal size 1.3 x 1.9 mm (0.050 x 0.075 inch)
• AWG 24S (Stranded, 7 x 32): Nominal size 1.3 x 2.2 mm (0.050 x 0.085 inch)
• AWG 30 (Solid, Kapton® only): Nominal size 1.0 x 1.4 mm (0.040 x 0.055 inch)

Weight per 1000 feet is listed as 5 kg (11 lb) for AWG 20 variants and 3 kg (6 lb) for AWG 24 and 30 variants, with values rounded up to the next highest pound excluding packing material.

Configuration Options

The series offers extensive configuration options across insulation type, calibration, conductor construction, gauge, spool length, and special features. Model numbers follow a generalized guide structure: <Calibration>-<AWG No.>, with examples including TFE-J-20, TFE-K-20S, KK-J-20, and KK-K-20S.

Key configurable attributes include:

• Insulation Material: Fused TFE Tape (TFE series) or Fused Polyimide Tape (Kapton®/KK series).
• Calibration Types: J, K, T, and E.
• Conductor Construction: Solid wire or stranded options (e.g., 7 x 28 for AWG 20S; 7 x 32 for AWG 24S).
• Gauge Sizes: AWG 20, 24, and 30 (AWG 30 available only in Kapton® Duplex Insulated wire).
• Spool Lengths: Standard lengths include 25', 50', 100', 200', 500', and 1000'. Metric options such as 7.5M, 30M, 60M, 150M, and 300M are also available.
• Special Limits of Error: To order special limits of error wire, add the suffix "-SLE" to the model number before the spool length designation.

Metal overbraiding is available as an option for protection against wear and abrasion. This addition provides durability and electrical shielding for improved performance; consult sales for details on this configuration.

Key Product Differences

The series distinguishes between two primary insulation technologies with specific identification methods:

• TFE Insulated Wire: Features color-coded or fused tape insulation applied to conductors and jackets. The model prefix is "TFE" followed by the calibration letter (e.g., TFE-J, TFE-K).
• Kapton® Duplex Insulated Wire: Uses Fused Polyimide Tape for both conductor and overall insulation. This series uses a "KK" prefix in model numbers (e.g., KK-J-20). Kapton® wire is neither ANSI nor IEC color-coded; the positive leg is identified by a string embedded within the insulation.

Stranded variants are indicated by an 'S' suffix on the AWG number (e.g., 20S, 24S). The Kapton® series includes an additional gauge option of AWG 30 in solid construction, which is not listed for the TFE Insulated wire tables.