Product Description
The M27500 WR series is a shielded and jacketed multi-core power cable engineered for extreme high-temperature aerospace, defense, and industrial applications, meeting the rigorous requirements of MIL-DTL-22759/92. This cable features nickel-plated copper conductors and a lightweight composite insulation of PTFE/polyimide/PTFE tape, providing exceptional thermal stability and mechanical strength up to 260°C. The outer jacket—composed of FEP/polyimide tape covered by a PTFE tape outer layer—ensures resistance to abrasion, chemicals, and extreme environmental conditions.
With a voltage rating of 600V and continuous temperature rating of -55°C to +260°C, the M27500 WR cable is specifically designed for the hottest zones in jet engines, avionics bays, and high-heat industrial equipment. The nickel-plated copper conductors provide superior oxidation and corrosion resistance at elevated temperatures, while the nickel-plated copper braid shield (85% coverage) protects against electromagnetic interference (EMI), ensuring reliable signal integrity in the most demanding environments.
Key Features
260°C continuous temperature rating – Designed for engine nacelles, exhaust systems, and high-heat zones where standard cables fail
Nickel-plated copper conductors – Provides superior oxidation and corrosion resistance at extreme temperatures, unlike silver-plated alternatives which degrade above 200°C
Lightweight composite construction – PTFE/polyimide/PTFE tape insulation system reduces weight compared to standard extruded insulation, a critical factor for aerospace fuel efficiency
Nickel-plated copper braid shield – 85% coverage provides excellent EMI/RFI protection for sensitive signal transmission
Robust jacketing – FEP/polyimide tape with PTFE tape outer layer offers high tensile strength and resistance to hydraulic fluids, fuels, and solvents
600V voltage rating – Suitable for both power and signal applications in mili-tary and aerospace vehicles
MIL-DTL-22759/92 compliant – Manufactured to strict mili-tary specifications for mission-critical applications
Customization available – Core counts, cut lengths, color coding, and jacket printing available to meet assembly requirements
Specifications
| Standard Reference |
MIL-DTL-22759/92 (Nickel-plated) |
| Conductor Material |
Nickel-Plated Copper |
| Insulation |
PTFE/Polyimide/PTFE Composite Tape |
| Shielding |
Nickel-Plated Copper Braid (85% Coverage) |
| Jacket Material |
FEP/Polyimide with PTFE Tape |
| Temp Rating |
-55°C ~ +260°C |
| Voltage Rating |
600V |
Applications
Jet engine wiring – Continuous 260°C rating withstands engine nacelle temperatures for turbine sensors, exhaust monitoring, and thrust reverser controls
Aerospace propulsion systems – Ideal for the hottest zones near engines where silver-plated conductors would oxidize and fail
Mili-tary avionics – Rugged construction meets MIL-DTL-22759/92 for flight computers, navigation systems, and fly-by-wire controls
High-heat industrial equipment – Furnaces, ovens, and high-temperature processing equipment requiring durable signal cable
Radar and RF systems – Nickel-plated copper braid shield provides excellent EMI protection for sensitive RF communications
Missile guidance systems – Extreme temperature tolerance and chemical resistance for defense electronics
Engine test stands – Reliable signal transmission in high-temperature ground test environments
FAQ
Q: What does the "seamless wrap" insulation mean?
A: The PTFE/polyimide/PTFE composite tape is wrapped around the conductor, creating a thin, lightweight, and tough insulation layer that is lighter than standard extruded PTFE.
Q: What is the continuous temperature rating of M27500 WR cable?
A: -55°C to +260°C. This makes it suitable for engine nacelles and high-heat zones where standard cables are not rated.
Q: Is the cable resistant to aviation fluids?
A: Yes, the FEP/polyimide/PTFE jacket construction provides excellent resistance to hydraulic fluids, jet fuels, oils, and solvents.
Q: What is the difference between M27500 WR and WP?
A: WR uses nickel-plated copper conductors rated for 260°C continuous. WP uses silver-plated copper conductors rated for 200°C. WR is designed for hotter environments where WP cannot survive.
Q: What mili-tary standard does this W27500 WR cable meet?
A: MIL-DTL-22759/92, the specification for high-temperature, nickel-plated copper conductor hook-up wire.
Q: Can these M27500 WR cables be customized?
A: Yes. We offer customization options including core counts, specific cut-to-length services, custom color coding for easy identification during installation, and specific shielding requirements.
