EPD Cable from TE Connectivity Raychem
EPD stands for Electrical Power and Data and refers to a type of EPD cable from TE Connectivity Raychem. These high-performance cables are specifically developed for the simultaneous transmission of power and data in industrial applications where reliability and safety are essential. Raychem EPD cables combine advanced technology with customized manufacturing according to the highest quality standards.
Characteristics of EPD cables
EPD cables are resistant to mechanical stress, high temperatures and chemical exposure. Thanks to the use of advanced insulation materials, these cables meet strict safety requirements and help minimize the risk of short circuits. This makes them highly suitable for demanding industrial environments.
Variants and applications
TE Connectivity Raychem EPD cables are available in various configurations, including single-core and multicore designs, coaxial cables and fiber optic variants. Depending on the application, these cables can be supplied with additional protection layers such as flame-retardant or waterproof shielding.
The applications of EPD cables are extensive, ranging from aerospace and defense to transportation, power generation and offshore installations. Typical applications include aircraft, trains, ships, wind turbines and oil and gas installations.
Why choose a Raychem EPD cable?
Raychem EPD cables offer a high level of reliability, long service life and resistance to extreme environmental conditions. Thanks to their robust design and industrial certifications, these cables are ideally suited for applications where electrical safety and stable data transmission are critical.
Key features Raychem EPD cables
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Selection guide
Custom cable designs
At Idetrading Electronics, we help you select the right hook-up wire for your specific application. We maintain a large stock of wire sizes, constructions, and colors. All these variants can be used within our custom service for the design and assembly of multicore cables. The selection of the primary wire is the first step in the cable design process and determines the final performance of the cable.
Building blocks for a custom multicore cable
- What is the application or end use?
- What temperature resistance is required?
- How many components are required and what is the function of each component (data, signal, or power)?
- What conductor size is required for each component?
- Are there any requirements regarding electromagnetic shielding (EMI)?
- Are there specific requirements for flexibility, mechanical stress, or resistance to fluids?
- Are specific or continuous lengths required?
Differences in cable jacket selection for multicore cables
There is a wide range of cable jacket materials available with medium to high performance characteristics, suitable for a broad temperature range and various applications. When selecting a cable jacket for multicore cables, two main options can be distinguished depending on the application requirements and production needs:
a. Heat-shrink jacket – For prototypes and short production runs
Ideal for custom designs, prototypes, or small production series. These jackets are shrunk around the cable assembly to accurately encapsulate the components and provide flexibility during development and testing.
b. Extruded jacket – For large-scale production
Suitable for higher production volumes where a consistent and durable cable jacket is required. Extruded jackets provide high mechanical stability and are cost-effective for series production.
In both cases, the combination of the right hook-up wire with a suitable cable jacket provides the optimal solution for your specific cable application.
Step 1a: Select the conductor size
| Conductor Size (AWG) | Number of Strands / Diameter | Nominal Outer Diameter (mm) | Cross-sectional Area (mm²) | Resistance (Ω/km) at 20ºC | Current Carrying Capacity (A) at 30ºC |
|---|---|---|---|---|---|
| 30 | 7/0.10 | 0.30 | 0.06 | 356.0 | 2.2 |
| 28 | 7/0.13 | 0.38 | 0.09 | 225.0 | 2.9 |
| 26 | 19/0.10 | 0.50 | 0.16 | 135.0 | 4.1 |
| 24 | 19/0.13 | 0.63 | 0.24 | 86.0 | 5.5 |
| 22 | 19/0.16 | 0.80 | 0.38 | 53.2 | 7.4 |
| 20 | 19/0.20 | 1.00 | 0.62 | 32.4 | 10.0 |
| 18 | 19/0.25 | 1.25 | 0.96 | 20.4 | 14.0 |
| 16 | 19/0.29 | 1.44 | 1.23 | 15.8 | 15.5 |
| 14 | 19/0.36 | 1.80 | 1.94 | 9.9 | 21.0 |
| 12 | 37/0.32 | 2.24 | 2.97 | 6.6 | 28.0 |
Step 1b: Select the insulation material
| Temperature Range (°C) | Chemical Resistance | Abrasion Resistance | Flexibility | Typical Application |
|---|---|---|---|---|
| -67 to +260 | Excellent | Good | Fair | Aerospace, Industrial Sensors, Thermocouples |
| -65 to +200 | Excellent | Good | Good | Instrumentation, Industrial, Commercial |
| -40 to +150 | Very Good | Fair | Excellent | Aerospace, Motorsport, Defense |
| -55 to +125 | Good | Good | Good | Defense, Industrial, Commercial |
| -30 to +105 | Good | Good | Good | Marine, Railway, and Public Transport |
Step 2a: Cable jacket selection
| Product Type | Temperature Range (ºC) | Chemical Resistance | Abrasion Resistance | Flexibility | Typical Applications |
|---|---|---|---|---|---|
| PTFE | -67 to +250 | Excellent | Good | Fair | Aerospace, industrial sensors, thermocouples |
| RW-200-E | -55 to +200 | Very Good | Good | Good | Military, aerospace, industrial |
| DR-25 | -75 to +150 | Very Good | Fair | Excellent | Aerospace, motorsport, military |
| RNF-100 | -55 to +135 | Good | Good | Good | Military, industrial, commercial |
| ZHTM | -30 to +105 | Fair | Good | Good | Marine, railway, public transport |
| VERSAFIT | -55 to +135 | Fair | Fair | Good | General purpose, commercial |
Step 2b: Production type selection
| Feature | Prototype (Heat-Shrink) | Production (Extruded) |
|---|---|---|
| Application | Prototype / small production runs | Large production volumes |
| Flexibility | High | Medium |
| Mechanical strength | Medium | High |
| Cost efficiency | Lower for high volumes | High for large quantities |
| Lead time | Short (no tooling required) | Longer (tooling required) |
| Development | Ideal for testing & customization | Ideal for stable production |
Idétrading: Expertise in materials for EPD cables
A complete range of custom cable solutions offering a tailored solution to meet your requirements. EPD cables can be manufactured with either a thick-wall or thin-wall jacket.
Thick-wall EPD cable solutions
- Thermorad F, flexible, universal cross-linked polyolefin. A general-purpose material resistant to most common chemicals and solvents. Highly flame-retardant and provides a good balance between physical and chemical properties.
- Thermorad S, rigid cross-linked polyolefin for general applications with improved fluid resistance.
- Thermorad O, oil-resistant cross-linked chlorinated polyolefin.
- FDR-25, highly flexible cross-linked polyester elastomer. Highly flame-retardant and qualified according to VG standards. Originally designed for use in compartments exposed to hot diesel fuels and vibrations. Fluid-resistant, flexible, and suitable for high-temperature environments.
- Thermorad LS, low-smoke and halogen-free cross-linked polyolefin.
- Zerohal, halogen-free cross-linked polyolefin (M24640/M24643). LFH (Low Fire Hazard), a halogen-free cable jacket material developed and approved according to the strictest requirements for fire-safe cables in various countries.
- Raythane C/FR, flexible and abrasion-resistant polyurethane.
- Thermorad NTFR, oil-resistant, flexible chlorinated polychloroprene blend.
Thin-wall EPD cable solutions
- Thermorad 700, high-temperature, nuclear-biological-chemical resistant material.
- Thermorad K, abrasion-resistant PVF2.
- Thermorad HT, solvent-resistant, high-temperature ETFE. A highly temperature-resistant fluoropolymer with excellent fluid resistance. Provides outstanding stability during long-term exposure to high temperatures and aggressive chemical environments. Ideal for use in aircraft fuel tanks and engine wiring applications.
- Thermorad FL, flexible, solvent-resistant ETFE. A general-purpose material resistant to most common chemicals and solvents. Highly flame-retardant and provides a good balance between physical and chemical properties.
EPD cable shielding, control noise for improved signal integrity
Cable shielding is essential in many applications. Shielding helps minimize crosstalk within the cable, prevents interference from external sources, and reduces radiation emitted by the cable itself. Designing cables with effective shielding across a wide frequency spectrum is complex, and cables must be tailored to specific electromagnetic environments. Shielding options range from simple aluminized polyester film, providing electrostatic shielding, to more advanced solutions using plated copper braids and Mu-metal wraps.
The performance of conventional braiding can be significantly improved through computer optimization. This precisely controlled process enhances the shielding effectiveness of a braided base shield while adding minimal weight or increasing optical coverage. Supershielded cables combine Mu-metal wraps with optimized braiding techniques to provide even higher shielding performance, particularly at low frequencies.
EPD cable shielding efficiency
To evaluate shielding effectiveness, TE Connectivity uses the line injection method as described in IEC 1196-1 to measure the surface transfer impedance (Zt) of a cable shield. To determine the surface transfer impedance over a range of frequencies, a drive signal is generated by the internal tracking generator of a spectrum analyzer. The voltage induced on the center conductor of the test sample is amplified and fed back to the signal generator for measurement.
Applications of EPD cable
Military ground systems
- Rotating gun turrets
- Engine compartment wiring
- Bulk wiring for signal and power
- Video feeds for rear-view cameras on large vehicles
Military marine
- Auxiliary equipment, such as weapon systems and radar
- Engine compartment wiring
- Below-deck halogen-free cabling, including water-blocked cables compliant with:
MIL-DTL-24640
MIL-DTL-24643
Rocket technology
- Launch and control systems
- Internal rocket wiring where compact dimensions and flexibility are required due to limited space constraints
Fixed and rotary wing commercial and military aviation
- Open-frame wiring for communication systems
- In-flight entertainment systems
EPD kabel TE Connectivity Raychem
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