Wire and cable play a crucial role in any engineering venture, and there is no substitute for quality and experience when it comes to identifying the right wire and cable options for your project.
Interconnect Systems has more than 20 years of engineering design and manufacturing experience, and can work with you to find the industrial cable solutions that best meet your unique needs and requirements.
An end to end cable and wire solution
At Interconnect Systems we can offer a complete end to end wire and cable engineering solution, from the initial manufacturing process through to the final supply stage.
Our industrial cable offerings can be manufactured in a variety of conductor types, jacket materials, cable drag chains and constructions, to meet the needs of a range of applications including Commercial, Industrial, Defence, Aerospace and Rail.
We can help supply solutions to a variety of both Commercial and Military specifications, and guarantee our product will meet even the most demanding of power, signal, data or RF needs.
Whether you are looking for standard MV cable or LV cable constructions, custom designed and manufactured multicore cables, coaxial cables, or any other speciality cables, Interconnect Systems can help.
Look to Interconnect Systems for your wire and cable needs
Our completely tailored and individualised end to end service makes Interconnect Systems the number one choice for wire and cable technologies in Australia, New Zealand, Singapore, the UK, and the USA.
For more information, and for advice on selecting the right wire and cable for your project, contact
Interconnect Systems today by calling 1800 812 214.
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1553 Data Bus
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Aircraft Test Equipment
Application Tooling
Backshells and Accessories
Cable Markers
Circular Connectors
Composite Products
Conduit
Fibre Optics
Heat Shrinkable Moulded Parts
Instrument Panels
Interconnect Products
Rectangular Connectors
RF Connectors and Accessories
Screening and Protection
Antennas
Wire and Cable
HI-FLEX Flexible Power Cable
Hi-Flex is a range of highly flexible power cables which meet the increasing power management demands in commercial and military applications. Design initially for use with military Hybrid Electric Drive (HED) vehicles, in order to meet an increasing need for high power ratings without the usual increase in copper size and weight, and it’s associates loss of flexibility, Hi-Flex cables have been successful in a variety of applications within electric drive vehicles. Hi-Flex ZH adds the ability to be coloured, in addition to having low smoke zero halogen (LSZH or LS0H) properties.
Technical Description
Increased Current Carrying Capacity
Using a combination of highly flexible ‘S-Line’ conductors and the latest Omnigard high-temperature insulation material Habia are able to increase the current carrying capacity of our power cables compared to the materials available in standard power cables.
Reduced Cable Size
The higher current carrying capacity of Hi-Flex power cables also enables reductions to be made in the conductor c.s.a. resulting in a smaller lighter cable.
Reduced Maintenance
Hi-Flex cables are designed using materials to ensure a long flex-life and reduced strain on cable terminations, thereby reducing MTBF (Mean Time Before Failure) and providing a highly flexible power cable.
Ease of Installation
When designing in a power cable ease of installation is an important design consideration – the Hi-Flex design and construction eases routing of the cable within confined spaces and gives better access to connectors and equipment. With a product range from 6mm² up to 400mm², Hi-Flex power cables address the design and performance requirements inherent in the latest commercial and military applications.
Hi-Flex ZH
Offering the possibility for a Low Smoke Zero Halogen option and available in a wide range of colours, Hi-Flex ZH maintains the high flexiblity of the original power cable.
NEMA-WC27500 Cable
The NEMA-WC27500 specification has replaced the old MIL-C-27500 specification for cables. This spec covers cables manufactured from SAE-AS22759 and SAE-AS81044 wires.
It is one of the most widely used specifications used in both Military Ground and Aerospace applications, and covers a range of cable constructions.
Technical Description
- Temperature range -65°C to 260°C (depending on the specification)
- Voltage rating 600 and 1000 volts
- A range of conductor types
- A range of insulation materials
- A range of construction types, which include:
- Twisted pair
- Twisted pair with jacket
- Twisted Pair with shield, no jacket
- Single shielded and jacketed
- Multiple conductors with shield and jacket
SAE-AS81044 Wire
Used widely in Military Ground Systems, SAE-AS81044 wires are single conductor wires made as specified in the applicable specification sheet. They are manufactured with a range of conductor coatings and insulation materials.
They consist of either single or dual wall constructions, and offer good chemical resistance and limited fire hazard performance.
Technical Description
- Temperature Rating -65°C to +150°C
- Voltage Rating 600V
- Single and Dual wall constructions available
- Available withTin coated, Silver coated and Nickel coated copper conductors
- Available in a range of insulation materials.
- XL-Polyalkene
- XL-Alkene-imide polymer
- Polyarylene
- These insulation materials can be used in conjunction with other materals
- PVF (Polyvinylidene Fluroide)
- Limited Fire hazard performance
- Good chemical resistance
- The various specification sheets cover sizes from 0 to 30AWG
- Available in a range of colours
Litz Wire
New England Wire Technologies is considered the premier Litz Wire manufacturer in the industry.
They have designed and manufactured thousands of different constructions for use over the ELF through HF frequency ranges.
Typical applications include HF inductors and transformers, inverters, communication equipment, ultrasonic equipment, sonar equipment, radio and television equimment, as well as induction heating.
Technical Description
- Types of Litz wire
- Type 1 (Single twisted)
- Type 2 (Bundles of twisted wire)
- Type 3 (Insulated bundles of twisted wires)
- Type 4 (Bundles of twisted wires around a fibre core)
- Type 5 (Insulated bundles of twisted wires around a fibre core)
- Type 6 (Bundles of Type 4 around a fibre core)
- Type 7 (Insulated wire braided and formed into rectangular profile)
- Type 8 (Single insulated wires twisted and compressed into a rectangulat profile)
- Film Insulation Options
- Polyvinyl Formal
- Polyurethane
- Polyurethane with Nylon overcoat
- Polyester-imide (Solderable)
- Polyester with Polyamide-imide overcoat
- Polyimide
- Tape Insulation options
- Polyester
- Mylar
- Nomex
- Polyimide
- Kapton
- Fibreglass Cloth
- Mica
RailGuard for Rail Systems
Habia’s cost effective range of railway cables for Rail Transport Systems: the RailGuard range of wires and rail cables has been designed and approved for use in protected, fixed installations of Rolling Stock and infrastructure applications. Habia are a highly regarded railway cable and wire manufacturer producing a wide range of rail cables including low smoke, zero halogen (LSOH) & flame retardant wires and cables to enhance performance in rolling stock applications. RailGuard cables are manufactured with additional mechanical and chemical resistance to provide an extended service life.
Technical Description
Habia Cable RailGuard wire and cables are qualified to the following CENELEC Standards;
EN50264-1:2008 EI101-EI104 & EM101-EM104
EN50264-2-1:2008 (0.6/1kV)
EN50264-2-2:2008 (300/500V & 0.6/1kV)
This standard replaces the EN50264-3:2002 and the RTE/STD/024 Type 6 cables).
EN 50264-1:2008 General Requirements
Insulation:
EI 101 Low temperature resistant EI 102 Extra low temperature resistant, oil resistant EI 103 Low temperature resistant, extra oil and fuel resistant
EI 104 Extra low temperature resistant, extra oil and fuel resistant
Sheaths:
EM 101 Low temperature resistant
EM 102 Extra low temperature resistant, oil resistant
EM 103 Low temperature resistant, extra oil and fuel resistant
EM 104 Extra low temperature resistant, extra oil and fuel resistant
EN 50264-2-1:2008 Single Core Cables
300/500V and 600/1000V
EN 50264-2-2:2008 Multi-Core Cables
300/500V and 600/1000V
Habia’s HFI 110 XL insulation and HFS 110 XL jacket material are cross-linked, halogen free, flame retardant, low smoke and oil resistant compounds specially developed for Rolling Stock applications. RailGuard has a wide operating temperature range from -40°C to +107°C and will not emit any corrosive gases in a fire situation.
SAE-AS85485 Filter Line Wire
Filter Line wire and cable is designed to serve as electrical interconnections and low-pass filters. The cables are constructed from an RF-absorptive polymer and Mil-Spec wire insulation.
Filterline wire and cable is compatible with high density Mil-Spec connectors, and meets the performance requirements of SAE-AS85485
Technical Description
• Suppression of EMI above 100 MHz.
• Light weight, small size.
• XL-ETFE insulation.
• 600 V rating.
• Temperature rating of -65°C to +150°C.
Low Smoke Zero Halogen Coaxial Cable
A range of 50 ohm and 75 ohm coaxial cables, designed to conform to Low Smoke and Zero Halogen (LSOH) requirements
Available in several standard RG constructions as well as the Habia Speedflex range, which are dimensionally equivalent to a range of standard RG constructions.
Markets are Marine, Industrial, Off-Shore and Rail and Mass Transit.
Technical Description
Speedflex:
- Temperature Range 40°C to +80°C
- Frequency Range Up to 2.5 GHz
- Flame Retardant
- Low Smoke Zero Halogen
Speedflex XL:
- Temperature Range -40°C to +105°C
- Frequency Range Up to 2.5GHz
- Flame Retardant
- Low Smoke Zero Halogen
Speedflex UL:
- Temperature Range -40°C to +60°C
- Frequency Range Up to 2.5GHz
- Flame Retardant
- Low Smoke Zero Halogen
- UL Approved
SAE-AS22759 Wire
SAE-AS22759 wires are widely used in the Aviation industry. This specification covers fluoropolymer insulated single conductor wires as specified in the applicable specification sheet.
They are available in Tin coated, Silver coated and Nickel coated copper conductors. Construction consists of single wall and dual wall, with extruded and tape wrapped insulations.
Technical Description
- Small size, light weight
- Single and dual wall constructions
- Temperature rating -65ºC to 260ºC
- Voltage rating 600 and 1000 volts
- PTFE and ETFE insulations Laser markable
- Good resistance to wet arc tracking
- Good chemical resistance
- Wire range 30 to 0000 AWG across the range of specification sheets
- Range of conductor types
- Tin coated copper
- Silver coated copper
- Silver coated, high strength copper alloy
- Nickel coated copper
- Nickel coated, high strength copper alloy
- Range of Insulation materials
- PTFE
- ETFE
- XL-ETFE
- FEP
- ECTFE
- Polyalkene
- Polyimide
SeaGuard Naval Cables
With the increasing complexity of modern warships, the necessity to reduce top weight and improve overall performance becomes a major design issue. As most if not all major systems on a warship are electronically/computer controlled, the weight and volume of interconnection cables and associated equipment such as cable trays, bulkhead glands and connectors becomes a significant part of the problem.
SeaGuard is able to offer substantial savings in both weight and size. Comparisons have been made against various standard marine cables (e.g. DIN & VG) and US Mil Spec naval cables, and it has been proven that Habia can, by using thin wall materials, reduce both weight and size by up to 50% depending on the cable design and construction.
Technical Description
- Voltage Rating 600/1000V
- Temperature Range -30°C to +120°C
- Flame Retardant
- Low Smoke Zero Halogen
- RoHS Compliant
- Available in
- Multicore cables – with various screening options
- Multi-pair cables – with various screening options
- Multi-triple cables – with various screening options
- Power cables – with various screening options
- Coaxial cables
- Specifications
- Defence Standard 61-12 (Part 25)