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Essex Wire Product Line Overview
Essex supplies many different kinds of wire, including Soderbond, Solidex, Solidon, or Thermalex lines.
The polyester-imide insulation and polyamide-imide overcoat of GP/MR 200, for example, will allow for an increase in both dielectric properties and chemical resistance to solvents and refrigerants. Soderon 155 as a polyurethane insulation and a polyamide overcoat, increasing the wire's resistance to solvents and giving it a greater windability.
relays, timer &
arts & crafts
Output Coills, Ham
Twist ties, arts
Motors, wound coils,
|Soderbond N||Helical and toroidal
coils, voice coils
|Soderex 155||Small motors, relays
|Soderex 180||Specialty power
|Soderon 180||Bobbin-wound & paper
section coils, molded
& encapsulated coils,
armatures & fields,
pole motor coils,
|Solidon||Shaded pole motor
coils, special control
coils, automotive coils
|Nytherm||Fractional & integral
coils & relays,
control & dry-type
DC field coils
|Polybondex||Clutch & brake
coils, helical &
motor field coils,
deflection yoke coils
fractional & integral
HP motors, hermetic
motors, DC motors,
Class 105 to 200),
control type electronics
(all coil types, Class
105 to 200)
|Thermalex 200||Small appliance &
power tool motors,
|Allex||Fractional & integral
continuous duty coils
& relays, hermetic &
Essex Wire Specifications
Most essex wire will be copper, but aluminum is also available. Copper is the most widely used wire metal and there are numerous reasons for this.
Of all non-precious metals, copper has the highest electrical conductivity. Due to its lower conductivity, aluminum wire needs to have a cross section that is 1.6 times bigger so it can create the same resistance as a copper wire. This makes copper wire less cumbersome than aluminum wire.
In addition, Copper is 300% stronger than aluminum, allowing it to withstand more extreme conditions.
Solid vs. Stranded Essex Wire
One single strand of insulated wire is called solid wire, whereas stranded wire is multiple bare wire strands braided together to make a larger wire.
Solid wires do not have much elasticity, and are found in applications where the wires do not often move. Stranded wires have greater flexibility, which increases as the number of strands goes up;. Stranded wires will have a minimum number of seven wire strands: six wires will be wrapped around one wire in the middle.
Stranded wire is resistant to metal fatigue because of its flexibility. Fatigue happens when a wire is overused, causing the wire to begin to crack. Since it is bendable, stranded wire runs into this problem less frequently.
Solid wire is less likely to experience corrosion, though, due to having less surface area.
The wires that TEMCo sells are solid.
Pictured above: Solid copper wire (left), stranded wire (right)
Essex wires are square, round or rectangular.
The shape determines the tightness of the coil. Square and rectangular copper wires will be wound tighter than round wires since they have less space between the turns when coiled. Square wires are often used in confined spaces and in applications where higher power is required.
Rectangular copper wires can be wound the tightest because they are flat, leaving no spaces between the turns.
Round wire, on the other hand, will have more space between the wires due to the lack of edges.
Pictured above: Rectangular wire (left), round wire (right)
The color of essex wire is purely aesthetic, and neither the insulation, nor any other element of how the wire will function, will be impacted.
In cases where a certain wire color is needed to differentiate wires for soldering, like if there is a need to differentiate wires coming from different circuits, some manufacturers will allow customers to specify a color for their wire.
TEMCo offers red and green Soderon 155, while the GP/MR-200 will be natural/amber.
Insulation protects from having its turns touch. The turns of bare wires, which have no insulation, are not able to come in contact with each other since they would short out. Turns of insulated wire, on the other hand, can be wound so that the wires touch since they have the insulation between them. Insulation is especially important for coils that requires hundreds, possibly thousands, of wire turns.
The American wire gauge (AWG) rating of the wire, used in the U.S. and Canada, represents specific characteristics of round wire, such as diameter, resistance and current.
There are 44 standard wire gauges in total, that range from 0000 to 40. As the wire diameter decreases, the AWG number will increase, so the 0000 gauge wire has a diameter of 11.684 mm, while the 40 gauge wire has a diameter of 0.0799 mm.
Wire weight will also become smaller as the gauge increases.
The 0000 gauge wire will have a weight of 640.5005 lbs per 1000 feet, while the 40 gauge wire has a weight is 0.0299 lbs per 1000 feet.
Temperature Rating/Thermal Class
For a wire to have a 20,000 hour service life there is a maximum temperature at which it will have to be run, called the temperature rating. The service life of the wire increases as the temperature it is being used at decrease; the service life will also decrease if used above the temperature rating.
Thermal class is measured in degrees celsius. 130°, 155°, 180° and 200° are some common temperatures found in different types of insulation.
Bondable Essex Wire
Bondable wire has an adhesive film that can be epoxy, polyester, or polyamide that will be put on top of the regular insulation. The film activates when it is heated up and creates a self-supporting coil which gets rid of the need for the bobbins, which are spindles that the wire is coiled around.
You can bond the wire using either the solvent, oven or resistance method.
- A solvent bonding coat will be applied by dipping the completed coil in a solvent.
- An oven bonding coat will be activated by heat from an oven. This process can take from 10 to 30 minutes depending on the size of the coiled wire.
- A resistance bonding coat is activated by an electric current, the size of the which, as well as how long it will take to complete the process, is determined by coil design. Resistance bonding is used for wire sizes 34 gauge or higher.
When a wire is attached to another wire, or a circuit board it needs to be soldered, or fused a melted down metal with a lower melting point, usually tin or lead.
Whether or not the wire needs to have its insulation removed before being soldered is entirely dependent on the wire being used. Of the wires that TEMCo offers, GP/MR-200 requires that the insulation be removed before soldering, while Soderon 155 does not, as the insulation will act as a flux when it is heated.
Breakdown Voltage and Build
The dielectric strength of the enamel insulation of the wire is also known as the breakdown voltage, of which there are three grades. The breakdown voltage grade goes up as the insulation becomes thicker. Smaller gauges have higher breakdown voltages.
The measurement of the insulation (also known as enamel), which can be calculated by subtracting the total diameter of the wire from the total diameter of the insulation and wire together, is known as the build. Insulation build can be single, heavy, triple or quadruple. Single and heavy are the most common.
The Soderon 155 and GP/MR-200 offered by TEMCo will be heavy build.
Buy Essex Wire
Click the links below to view TEMCo's Essex Wire product offerings. Don't see what you need? Call us for a quote on any other Essex wire lines!
"I needed a 3 phase rotary phase converter to run a DoAll Mill."
The family friend I purchased the mill from had purchased one from TEMCo several years ago, and told me that's the company to deal with. Very competitive price, fast delivery, and a solid, quality product. The shipping was fast, and the phase converter was crated very well and had zero damage from shipping. This thing runs so quietly I hardly know it's running.
I HIGHLY recommend TEMCo!
- mrtriton, 3/15/10
"Excellent advice, service & product".
The staff helped determine exactly the size converter I needed, answered any questions I had thoroughly. The unit was shipped quickly & was very welled packed. The product is so well designed that installation was a breeze & the converter works great.
Got me up and running very quickly.
- Michael Hall, 3/25/11
TEMCo is proud to be an acreddited member of the Better Business Bereau Online Reliability Program.
TEMCo's Phase Converter and Transformer customers include:
American Family Radio
Navy Public Works Center
US Army Executive Service
Stanford Linear Accelerator (SLAC)
Lawrence Livermore National Labs
and many thousands more.
TEMCo products meet the demands of tough industrial applications with dependability and quality.
Since 1968, TEMCo has become a trusted name in Industrial Power Products.
More Customer Feedback
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I had many tech question and they spend about 30 mins on the phone answering all ofthem for me. It is not to often to find service like that!!!!! I am so happy and will definitly purchase from them again. A+++++
- MRZ Contracting, 1/12/12
"Perfect FAST transaction..."
They delivered the 5-HP Electric Motor IMMEDIATELY in Perfect Condition. They bent over backwards to enable us to execute payment using an alternative method, Thank You So Much. We are comming back soon for a Power Converter. ! ! !
- R. A. "BOB" KEMP, NEVADA CENTRAL RAILROAD, Henderson, NV, 11/30/11
"You guys were referred by our electrician as well as our local light/electric company."
Very friendly, very knowledgable.
- Low Country Recyclers LLC, 9/08/11
"Have ordered transformers from this company previously and just ordered again."
Quick order shipment and prompt customer service. When they accidentally sent the wrong transformer on one order they immediately sent a replacement without any hassle at all! Good to do business with.
- m4pilot, 8/13/11
"Not only is the equipment from TEMCo the best, they have been the most helpful and pleasant company we have dealt with."
We bought 2 of the TEMCo phase converters for our machine shop as we did not want to bring in 3 phase power. Not only are their converters the best quality in this type of equipment it is made in North America and the most reasonably priced.
The converters have performed flawlessly with hard use and we expect they will continue to serve us for many years.
Not only is the equipment from TEMCo the best, they have been the most helpful and pleasant company we have dealt with.
If anyone needs the type of equipment TEMCo sells, there should be no hesitation, they are the place to purchase it.
- hydropower, 10/01/10