{"id":2834,"date":"2024-01-25T17:00:24","date_gmt":"2024-01-25T16:00:24","guid":{"rendered":"https:\/\/schupp.ch\/p\/kd500-winding-wires-with-ceramic-insulation-500c\/"},"modified":"2025-12-28T12:50:49","modified_gmt":"2025-12-28T11:50:49","slug":"kd500-winding-wires-with-ceramic-insulation-500c","status":"publish","type":"product","link":"https:\/\/schupp.ch\/en\/p\/kd500-winding-wires-with-ceramic-insulation-500c\/","title":{"rendered":"KD500 winding wires with ceramic insulation ( 500\u00b0C )"},"content":{"rendered":"

 <\/p>\n

Applications:<\/strong><\/p>\n

Special windings for transformers, chokes, coils or sensors that have to function continuously in the low-voltage range at elevated temperatures of up to 500\u00b0C (peaks up to 1000\u00b0C). Various safety applications that have to withstand a fire of up to 600\u00b0C without destruction (mechanical heating, short circuit, heat risks, etc.).<\/p>\n

Structure:<\/strong><\/p>\n\n\n\n\n\n\n\n\n\n
Conductor:<\/strong><\/td>\nCopper\/nickel plating 27%<\/td>\n<\/tr>\n
<\/td>\nOther conductor materials on request. Special conductor materials provided by the customer can also be processed. Corresponding tests are carried out in the factory<\/td>\n<\/tr>\n
Insulation:<\/strong><\/td>\nCeramic in thicknesses of 5-20 \u00b5m<\/td>\n<\/tr>\n
Color:<\/strong><\/td>\ngray<\/td>\n<\/tr>\n
Dimensions:<\/strong><\/td>\nAWG 41 to AWG 18 or 0.07 mm to 1.0 mm<\/td>\n<\/tr>\n
Linear density:<\/strong><\/td>\nLike that of copper = 8.92 kg\/dm3 per km<\/td>\n<\/tr>\n
Nickel migration:<\/strong><\/td>\nAt temperatures >315\u00b0C, the KD500 is subject to nickel penetration into the copper. This effect is negligible with larger diameters but considerable with wire diameters <0.15 mm (AWG 34) after an operating time of 48 hours with the consequence of an increase in resistance.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

 <\/p>\n

Heat resistance:
\n<\/strong>Permanent -90\u00b0C to +500\u00b0C (2500 hours min.) Short-term up to 800\u00b0C (tested for 10 days or 240 hours) and peaks up to 1000\u00b0C.<\/p>\n

Electrical values:
\n<\/strong>Test voltage 150V AC, corresponding to 212V DC, test with rolled wire Bending radius = 20 x diameter. For bending radius < 20 x diameter please enquire Breakdown voltage >150V AC Resistance max. 3.10-6 \u03a9.cm at 20\u00b0 C after ageing at 500\u00b0C<\/p>\n

Further properties<\/strong><\/p>\n\n\n\n\n\n\n\n\n\n
Moisture resistance<\/td>\nThe ceramic is sensitive to moisture. It may need to be impregnated in the finished state.<\/td>\n<\/tr>\n
Chemical resistance:<\/td>\nThe ceramic is highly resistant to solvents and organic oils<\/td>\n<\/tr>\n
Radiation resistance<\/td>\nHigh Resistance.<\/td>\n<\/tr>\n
Flammability:<\/td>\nNon-flammable. At temperatures >1000\u00b0C the wire can melt but not burn.<\/td>\n<\/tr>\n
Bending radius:<\/td>\n5x outer diameter (see table)<\/td>\n<\/tr>\n
Halogen-free:<\/td>\nYes<\/td>\n<\/tr>\n
Outgassing:<\/td>\nNone<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

 <\/p>\n

Processing instructions
\n<\/strong>Ceramic is very different from conventional wire insulations. It is very hard and sensitive to moisture. It therefore requires special care during processing.<\/p>\n

    \n
  • KD 500 must be stored and processed in a dry environment.<\/li>\n
  • The winding must not be subjected to shocks or impacts.<\/li>\n
  • No higher tensile forces than those specified in the table below may be used for winding.<\/li>\n
  • The bending radius must not exceed 5 x the outer diameter of the wire (see table).<\/li>\n
  • The wire should not be unwound overhead but axially, preferably with a constant tensile force.<\/li>\n
  • The wires must not be kinked under any circumstances. Visually check the winding.<\/li>\n
  • A bending radius that is too tight or a kink in the wire can generally be recognized by cracks in the ceramic insulation, which become visible as a white discoloration of the surface.<\/li>\n<\/ul>\n

    Stripping of Insulation
    \n<\/strong>The ceramic coating on the KD500 is very thin and adheres to the conductor. Conventional stripping tools can therefore not be used. Stripping can be carried out with fine sandpaper.<\/p>\n

    Please note<\/strong>:
    \nWhen mechanically stripping nickel-coated wires, this coating must not be removed, otherwise good welding is no longer guaranteed.<\/p>\n

    Connecting
    \n<\/strong>The ceramic wires are connected either by soldering with silver solder, crimping or wrapping.<\/p>\n

    Dimensions:<\/strong><\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
    Item number<\/strong><\/td>\nDiameter [mm]<\/td>\nAWG Size<\/td>\nOutside diameter [mm]<\/td>\nWeight [g\/km]<\/td>\nLength [m kg]<\/td>\n<\/tr>\n
    KD500\/007RR<\/strong><\/td>\n0,07<\/td>\n41<\/td>\n0,086<\/td>\n34<\/td>\n29 800<\/td>\n<\/tr>\n
    KD500\/010RR<\/strong><\/td>\n0,10<\/td>\n38<\/td>\n0,116<\/td>\n71<\/td>\n14 000<\/td>\n<\/tr>\n
    KD500\/012RR<\/strong><\/td>\n0,12<\/td>\n36<\/td>\n0,136<\/td>\n101<\/td>\n9 901<\/td>\n<\/tr>\n
    KD500\/015RR<\/strong><\/td>\n0,15<\/td>\n34<\/td>\n0,167<\/td>\n161<\/td>\n6 210<\/td>\n<\/tr>\n
    KD500\/017RR<\/strong><\/td>\n0,17<\/td>\n33<\/td>\n0,186<\/td>\n202<\/td>\n4 950<\/td>\n<\/tr>\n
    KD500\/020RR<\/strong><\/td>\n0,20<\/td>\n32<\/td>\n0,217<\/td>\n286<\/td>\n3 500<\/td>\n<\/tr>\n
    KD500\/025RR<\/strong><\/td>\n0,25<\/td>\n30<\/td>\n0,268<\/td>\n446<\/td>\n2 240<\/td>\n<\/tr>\n
    KD500\/030RR<\/strong><\/td>\n0,30<\/td>\n28<\/td>\n0,318<\/td>\n637<\/td>\n1 570<\/td>\n<\/tr>\n
    KD500\/035RR<\/strong><\/td>\n0,35<\/td>\n27<\/td>\n0,368<\/td>\n862<\/td>\n1 160<\/td>\n<\/tr>\n
    KD500\/040RR<\/strong><\/td>\n0,40<\/td>\n26<\/td>\n0,418<\/td>\n1 136<\/td>\n880<\/td>\n<\/tr>\n
    KD500\/045RR<\/strong><\/td>\n0,45<\/td>\n25<\/td>\n0,468<\/td>\n1 433<\/td>\n698<\/td>\n<\/tr>\n
    KD500\/050RR<\/strong><\/td>\n0,50<\/td>\n24<\/td>\n0,518<\/td>\n1 754<\/td>\n570<\/td>\n<\/tr>\n
    KD500\/055RR<\/strong><\/td>\n0,55<\/td>\n23<\/td>\n0,568<\/td>\n2 105<\/td>\n475<\/td>\n<\/tr>\n
    KD500\/060RR<\/strong><\/td>\n0,60<\/td>\n22<\/td>\n0,619<\/td>\n2 500<\/td>\n400<\/td>\n<\/tr>\n
    KD500\/065RR<\/strong><\/td>\n0,65<\/td>\n22<\/td>\n0,669<\/td>\n2 899<\/td>\n345<\/td>\n<\/tr>\n
    KD500\/070RR<\/strong><\/td>\n0,70<\/td>\n21<\/td>\n0,719<\/td>\n3 356<\/td>\n298<\/td>\n<\/tr>\n
    KD500\/075RR<\/strong><\/td>\n0,75<\/td>\n20<\/td>\n0,769<\/td>\n3 846<\/td>\n260<\/td>\n<\/tr>\n
    KD500\/080RR<\/strong><\/td>\n0,80<\/td>\n20<\/td>\n0,820<\/td>\n4 348<\/td>\n230<\/td>\n<\/tr>\n
    KD500\/090RR<\/strong><\/td>\n0,90<\/td>\n19<\/td>\n0,920<\/td>\n5 814<\/td>\n172<\/td>\n<\/tr>\n
    KD500\/100RR<\/strong><\/td>\n1,00<\/td>\n18<\/td>\n1,020<\/td>\n7 194<\/td>\n139<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

     <\/p>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
    Diameter [mm]<\/strong><\/td>\nMax. permissible tensile force (N)<\/td>\nMinim. Bending radius [mm]<\/td>\nResistance at 20\u00b0C [\u03a9\/m]<\/td>\n<\/tr>\n
    7\/100<\/td>\n0,23<\/td>\n0,45<\/td>\n7,795<\/td>\n<\/tr>\n
    10\/100<\/td>\n0,47<\/td>\n0,60<\/td>\n3,818<\/td>\n<\/tr>\n
    12\/100<\/td>\n0,67<\/td>\n0,70<\/td>\n2,652<\/td>\n<\/tr>\n
    15\/100<\/td>\n1,06<\/td>\n0,85<\/td>\n1,697<\/td>\n<\/tr>\n
    17\/100<\/td>\n1,36<\/td>\n0,93<\/td>\n1,322<\/td>\n<\/tr>\n
    20\/100<\/td>\n1,88<\/td>\n1,10<\/td>\n0,954<\/td>\n<\/tr>\n
    25\/100<\/td>\n2,95<\/td>\n1,35<\/td>\n0,611<\/td>\n<\/tr>\n
    30\/100<\/td>\n4,24<\/td>\n1,60<\/td>\n0,424<\/td>\n<\/tr>\n
    35\/100<\/td>\n5,77<\/td>\n1,85<\/td>\n0,312<\/td>\n<\/tr>\n
    40\/100<\/td>\n7,54<\/td>\n2,10<\/td>\n0,239<\/td>\n<\/tr>\n
    45\/100<\/td>\n9,55<\/td>\n2,35<\/td>\n0,189<\/td>\n<\/tr>\n
    50\/100<\/td>\n11,78<\/td>\n2,60<\/td>\n0,153<\/td>\n<\/tr>\n
    55\/100<\/td>\n14,25<\/td>\n2,85<\/td>\n0,126<\/td>\n<\/tr>\n
    60\/100<\/td>\n16,96<\/td>\n3,10<\/td>\n0,106<\/td>\n<\/tr>\n
    65\/100<\/td>\n19,91<\/td>\n3,35<\/td>\n0,090<\/td>\n<\/tr>\n
    70\/100<\/td>\n23,09<\/td>\n3,60<\/td>\n0,078<\/td>\n<\/tr>\n
    75\/100<\/td>\n26,51<\/td>\n3,85<\/td>\n0,068<\/td>\n<\/tr>\n
    80\/100<\/td>\n30,16<\/td>\n4,10<\/td>\n0,059<\/td>\n<\/tr>\n
    90\/100<\/td>\n38,17<\/td>\n4,60<\/td>\n0,047<\/td>\n<\/tr>\n
    100\/100<\/td>\n47,12<\/td>\n5,10<\/td>\n0,038<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n","protected":false},"excerpt":{"rendered":"

     <\/p>\n

    This ceramic wire was developed to produce windings with high functional reliability, i.e. windings that retain their functionality even under thermal overload (peaks of up to 1000\u00b0C).<\/h5>\n
    The KD500 owes the ever-increasing demand to its unique properties, which enable it to be used in numerous high-tech applications, often preventively in high-temperature safety elements.<\/h5>\n

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