Mil-W-16878/5 1000V Lead Wire High Voltage PTFE Wire for Industrial Power Systems

Product Overview

The M16878/5 (MIL-W-16878/5 / NEMA HP-3 TYPE EE) is a heavy-duty, thick-wall extruded PTFE insulated wire engineered for high-voltage power distribution and extreme mechanical stress environments. As the 1000V-rated counterpart in the M16878 series, this wire features a robust .015 inch (0.38 mm) insulation wall that delivers superior dielectric strength, arc resistance, and cut-through protection. Designed for demanding applications in aerospace, industrial machinery, and energy infrastructure, the M16878/5 ensures uncompromising safety and long-term reliability where standard 600V wires cannot meet the voltage or durability requirements.

Key Features and Benefits

1000V High-Voltage Capacity: The thick-wall extruded PTFE insulation provides exceptional dielectric strength and arc resistance, safely handling high-voltage power circuits in industrial and aerospace systems where 600V-rated wires are insufficient.

Enhanced Mechanical Durability: With a .015 inch insulation wall, the M16878/5 offers superior resistance to abrasion, cut-through, and mechanical damage — ideal for high-vibration environments, tight routing spaces, and heavy-duty machinery.

Wide Temperature Operating Range: Rated for continuous operation from -60°C to +200°C (silver-plated copper) and up to +250°C (nickel-plated copper), with short-term tolerance up to 300°C.

Superior Chemical and Moisture Resistance: The seamless extruded PTFE insulation is impervious to fuels, hydraulic fluids, solvents, acids, and moisture, maintaining performance in the harshest industrial and aerospace environments.

Flame Retardant and Self-Extinguishing: PTFE material is inherently non-flammable and will self-extinguish immediately upon removal from a flame, meeting critical fire safety requirements for aircraft and industrial equipment.

Solder Heat Resistance: Effectively resists insulation shrinkage and melting during high-temperature soldering, ensuring clean and reliable terminations every time.

Technical Specifications

Extensive Size and Dimension Chart

Target Industries and Equipment

The M16878/5 is engineered for applications where high voltage, mechanical stress, and extreme temperatures converge:

Aerospace Power Systems: Aircraft power distribution, engine control wiring, and ground support equipment requiring 1000V-rated conductors.

Industrial Heavy Machinery: Motor leads, generator windings, high-voltage control circuits, and manufacturing equipment exposed to oils, coolants, and abrasion.

Oil and Gas Equipment: Downhole instrumentation, drilling rig electronics, and pipeline monitoring systems operating in corrosive and high-temperature environments.

Marine and Shipboard Systems: Naval vessel electrical systems, propulsion controls, and communication equipment exposed to saltwater and humidity.

Nuclear Power Control: Monitoring and control systems in nuclear facilities where radiation resistance and high dielectric strength are critical.

Commercial Transportation: Heavy-duty trucks, buses, and rail vehicles requiring robust, high-voltage wiring for power and control systems.

Frequently Asked Questions (FAQ)

What is the key difference between M16878/5 and M16878/4?
The M16878/5 features a thick-wall insulation (.015 inch) rated for 1000V, while the M16878/4 has a medium-wall insulation (.010 inch) rated for 600V. Choose the /5 when your application demands higher voltage capacity or extra mechanical protection against abrasion and cut-through.

Can the M16878/5 be used in high-frequency applications?
While the extruded PTFE insulation offers excellent dielectric properties, the thick-wall design of the M16878/5 is primarily optimized for high-voltage power distribution rather than high-frequency signal transmission.

What conductor plating options are available?
We offer silver-plated copper for standard high-temperature applications up to +200°C, and nickel-plated copper for extreme temperature environments up to +250°C. 

Do you provide free samples for testing?
Yes, we offer free samples of the M16878/5 wire in standard AWG sizes and colors so you can evaluate the quality and performance before placing a bulk order. Simply contact our team with your specifications.

Is the M16878/5 wire compliant with RoHS?
Absolutely. All our wires are manufactured to meet the latest environmental regulations, ensuring they are safe for use in global markets.

Ready to Source Your M16878/5 Wire?

Whether you need a specific AWG size, custom color striping, or a large-volume quote, our team is here to help. We offer fast turnaround times, competitive pricing, and free samples to support your project.