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Cables & Cable AssembliesStandard & Custom Flexible Flat Cables
LEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMAS9100CERTIFIEDStandard Wire Common Flexible Wire Cicoil® Ultra-Flexible WireCombine power, signal, video, air & liquid in a crystal-clear at cable.Built-In FlexibilityIn addition to the strong, exible cable jacketing, every Cicoil cable incorporates nely stranded, ultra-exible wire conductors. Conductors and shields are also specially heat-treated and plated to maximize their exibility, while providing extremely long ex life in the most demanding applications. Cicoil at cables are rated for over ten million cycles, and our cables have performed for hundreds of millions of exing cycles in some of the most demanding robotic, continually exing equipment applications.Complete Cable AssembliesCicoil can provide complete cable assemblies, with any connectors required by the customer. Every cable assembly is 100% tested by our automated test equipment, so reliability and performance is guaranteed. Our award-winning quality system is certied to ISO 9001 standards, including the strict AS9100 aerospace specication. Cicoil cable assemblies are used on the space shuttle, supersonic missiles, and industrial robotics, in some of the most demanding applications possible. So you can rest assured that your cable assembly will receive the same dedication and care, ensuring reliable, high performance operation.Visit Cicoil.com to learn more, or call (661) 295-1295 to speak directly to an Application Engineer.Standard or Custom CablesCicoil’s patented extrusion process makes custom cables easy, so you can quickly get the exact cable you want. Try our Online Congurator, where you can design your own cable in minutes and get an immediate drawing and quote!Check out our many standard cables and assemblies, all available from stock for immediate delivery.Cicoil high-ex at cables are the Future of Cabling. Our patented extrusion technology produces the most high performancerformance at cables available with the superior attributes you’re looking for:J Ultra exible: Tens of millions of ex cycles in the tightest bend radius applicationsJ Unlimited variation: Micro size to 400mm wide cables, wires from 4 to 44 gauge, also including ber also including ber optics, tubing, or coax, so you can get the exact cable you needoptics, tubing, or coax, so you can get the exact cable you needJ Extreme Environments: Our cables perform from -65°C to +260°C, and under exposureexposure to water, steam, chemicals, and oilsStandard 24 AWG wire has 7 base strands, ‘flexible’ wire has 19 base strands, while Cicoil High-Flex wire has 66 base strands. All Cicoil wire has base stranding of 40 AWG minimum, versus 36 AWG and larger in other ‘flexible’ wires.REACHCOMPLIANTFAAFLAME TESTEDThe of is Here...
1661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesTable of Contents / p1of1 / 2021-08-25Motion Control Cables 3Motion Series Cable 4Motion Series Plus Cable 5EZ-Flexx™ Motion Series Plus Cable 6Hi-Flex Motor Power Cable 7Hi-Flex Shielded Signal Cable 8Data & Video Cables 9Cat 5e Ethernet Cable 10Cat 6a Ethernet Cable 11Camera Link® Cable 12Controlled Impedance Cable 13USB Cable 14Flexible Coaxial Cable 15FireWire Cable 16HDMI Cable 17Unshielded Cables: Multi and Single Conductor 19Hi-Flex Unshielded Cable 20Hi-Flex, Hi-Temp IDC Ribbon Cable 22Ultra Flexible Micro IDC Ribbon Cable 23Flexx-Sil™ Hi-Temp Festoon Cable 24Hi-Flex Unshielded Single Conductor Cable 25Thermocouple Cable 26Customizing Cicoil Flat Cables 27Unlimited Flat Cable Design 28Online Cable Congurator 29Low Friction Options 30StripMount™ Integrated Mounting Strip 30Flat Cables with Tubing 31SuperTu™ Jacketing 31Colored Flat Cable 31Cable End Preparation 31Cicoil Cable Assemblies 33Custom Cable Assemblies from Cicoil 34-35Cicoil Cable Technology 37Patented Extrusion Process | Key to Flexibility 38Top 10 Reasons to Use Flat Cable 38Flat Cable vs Round Cable 39Flexx-Sil™ Cable Technology 40Cleanroom Cables | Outgassing Performance 41Cicoil Flat Cables vs Alternatives 42-49Harsh Environments | Bend Radius and Life Cycles 50-51Certications and Approvals 52Current Ratings for Wire 53Table of ContentsPage
Cicoil Invents the Ribbon CableCicoil was founded in 1956 with an innovative new product for the early mainframe computers - the flat ribbon cable. The ribbon cable allowed companies like IBM to replace bulky, stiff round cables with sleek, flexible ribbon cables. Cicoil’s innovative engineers figured out how to use a new material, silicone rubber, to ‘mold’ a flat cable containing multiple conductors of the same size. Named ribbon cables, variations of these flat cables are still used today in most computers, printers, and many electronic devices..Cicoil’s ribbon cables helped America put a man on the moon, as the lightweight cables were integral to the first space walk in 1965, and the Lunar landing in 1969. In the decades that followed, Cicoil flat cables have performed on every US fighter jet, most commercial airplanes, and in many demanding missile and land-based applicationsFlexx-Sil™ Material and Patented Extrusion ProcessServo-controlled automation systems need cables that are able to continuously flex for millions of cycles, are lightweight, and that fit in increasingly compact spaces. To meet these new needs, Cicoil developed a new extrusion process, able to make continuous lengths of flat cable with a unique, crystal clear material named Flexx-Sil™. Representing a quantum leap from Cicoil’s original molded flat cables, the new Flexx-Sil™ material and extrusion process created a wide variety of high performance, cost-effective flat cable solutions for the semiconductor, motion control and medical automation industries worldwide.Cicoil Today – Innovating for the FutureCicoil continues its proud history of innovation, with the company’s automated, state-of-the-art facility in Valencia, California. By implementing the latest lean manufacturing production techniques, Cicoil continues to design and manufacture the highest quality products, with fast, responsive lead times for our customers. Our efforts have earned numerous customer and industry awards for quality, delivery, and continuous improvement, and our continued R&D has resulted in multiple US and worldwide patents. Cicoil cables perform awlessly in mission-critical applications in the Aerospace, Semiconductor, Medical, and Factory Automation industries. When you need high performance cable solutions, Cicoil is ‘The Clear Choice.’2661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesA History of Innovation / p1of1 / 2021-08-25Cicoil – A History of Innovation
Motion Control3661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesMotion Control / p1of1 / 2021-08-25Motion Control CablesIdeal for high performance motion applications, shielded power and signal conductors are combined into a single, high-exibility cable. Available in 1, 2 or 3 servo axis versions, in multiple power ratings for all standard rotary and linear servo motors. Due to the at construction, a cable carrier is often not needed. Cables are available in continuous lengths, or as cable assemblies, complete with connectors.Motion Series Cable 4Motion Series Plus Cable 5EZ-Flexx™ Motion Series Plus Cable 6Hi-Flex Motor Power Cable 7Hi-Flex Shielded Signal Cable 8Low Friction Options 30 Halogen Free & Flame Retardant Available from Stock Available as Bulk Cable or Complete AssembliesTailor Your OrderTo create a custom version of any standard cable, call our engineers at 661-295-1295.Low Friction OptionsWhen cables need to be stacked together, or where a lower friction surface is desired, Cicoil features two low-friction cable finishes: GlideRite™ and SlideRite™. View on Page 30.
Motion ControlBAAAABPOWER SHIELDED 4XSIGNAL, SHIELDED 8XBAAAABPOWER SHIELDED 4XSIGNAL, SHIELDED 8XBAAAABPOWER SHIELDED 4XSIGNAL, SHIELDED 8XPOWER SHIELDED 8XSIGNAL, SHIELDED 16XPOWER SHIELDED 12XSIGNAL, SHIELDED 24XBBNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-04Flexible Flat Cables & Cable AssembliesOptions PageUnlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Cable SpecificationsAll engineering values are nominal and subject to change.661-295-1295 Cicoil.comMotion Series / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53CablePower RatingAmp Rating1No. of AxesConductor Gauge Dimensions [inches]Part NumberPower Signal Width Height1KW 81 22 AWG/4c 28 AWG/8c 0.85 0.10 MC-1000-12 22 AWG/8c 28 AWG/16c 1.68 0.10 MC-1000-23 22 AWG/12c 28 AWG/24c 2.52 0.10 MC-1000-32KW 151 18 AWG/4c 28 AWG/8c 0.95 0.14 MC-2000-12 18 AWG/8c 28 AWG/16c 1.89 0.14 MC-2000-23 18 AWG/12c 28 AWG/24c 2.83 0.14 MC-2000-33KW 271 14 AWG/4c 28 AWG/8c 1.10 0.20 MC-3000-12 14 AWG/8c 28 AWG/16c 2.19 0.20 MC-3000-23 14 AWG/12c 28 AWG/24c 3.27 0.20 MC-3000-3Notes1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Ideal for Hi-Flex Motion Applications Designed for 1KW, 2KW and 3KW Servo Motors Shielded Power and Signal Wires for 1, 2 or 3 Servo Axes Halogen Free Flame Retardant (HFFR)Cicoil’s Motion Series cable is available in three designs for 1, 2 or 3 axes of servo motion with multiple power ratings. Each Motion Series cable incorporates four shielded power cables and eight signal cables for each axis of motion. The Flexx-Sil™ encapsulation provides a solid, one-piece construction that creates a highly durable, flexible flat cable package.Motion Series CablePOWER, SHIELDED, 4XSIGNAL, SHIELDED, 8XHEIGHTWIDTHWIDTHWIDTH1 AXIS2 AXES3 AXESApplications Linear Motors, Servo and Stepper MotorsDimensions Cable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: MC-1000-1-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): D-Sub 9-Pin, P/N L717-DB25P Shell P/N 5748677-3J1 J1P1 P1CABLE LENGTHWire Gauge Power (P1)18-22Tin Contacts - TE, P/N 770904-19-Pos Housing - TE, P/N 172169-114Gold Contacts - MOLEX, P/N 02-09-611015-Pos Housing - MOLEX, P/N 19-09-2159
Motion Control5Flexible Flat Cables & Cable AssembliesUnlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Options PageMechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm) See Electrical Rating Chart on Page 53Cable SpecificationsAll engineering values are nominal and subject to change.661-295-1295 Cicoil.comMotion Series Plus / p1of1 / 2021-08-25Assembly DimensionsNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-0CableAmp Rating1No. of AxesConductor Gauge Dimensions [inches]Part NumberPower Signal Width Height81 22 AWG/3 pr 28 AWG/10 pr 0.75 0.20 MCP-2000-12 22 AWG/6 pr 28 AWG/20 pr 1.50 0.20 MCP-2000-23 22 AWG/9 pr 28 AWG/30 pr 2.25 0.20 MCP-2000-3Notes1. Amp rating is the maximum value for each power conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Ideal for Hi-Flex Motion Applications Shielded Power and Signal Wires in a Compact Flat Cable For 1, 2 or 3 Servo Axes Halogen Free Flame Retardant (HFFR)Cicoil’s Motion Series Plus cable is available in a single axis design that may be ganged for 1, 2 or 3 axes servo motion. Each Motion Series Plus cable integrates 6 power conductors and 20 signal wires in a compact flat cable measuring just 0.75” wide by 0.2” thick. The Flexx-Sil™ encapsulation provides a solid, one-piece construction that creates a highly durable, flexible flat cable package. Motion Series Plus Cable0.420.750.63 0.751.502.25MOTOR POWER & AUX (22 AWG TWISTED PAIR SHIELDED) X3MOTOR FEEDBACK & AUX (28 AWG, TWISTED PAIR SHIELDED X5) X20.210.751 AXIS2 AXES3 AXESDimensionsCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: MCP-2000-1-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Connectors• Power (P1): Tin Contact - TE, P/N 770904-1 9-Pos Housing - TE, P/N 172169-1• Signal (J1): 25-Pin - Amphenol, P/N L717-DB25P Metallized Shell - TE, P/N 5748677-3CABLE LENGTHJ1 J1P1 P1Applications Linear Motors, Servo and Stepper MotorsCABLES ARE NOT BONDEDCABLES ARE NOT BONDED
Motion ControlAssembly DimensionsNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-06Flexible Flat Cables & Cable AssembliesOptions PageUnlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Cable SpecificationsAll engineering values are nominal and subject to change.661-295-1295 Cicoil.comEZ-Flexx™ Motion Series / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53 Ideal for Hi-Flex Motion Applications Shielded Power and Signal Wires in a Compact Flat Cable For 1, 2 or 3 Servo Axes Rated for More Than 10 Million Flexing Cycles Easy to Separate and Strip Halogen Free Flame Retardant (HFFR)Cicoil’s EZ-Flexx™ Motion Series Plus cable is available in a single axis design that may be ganged for 1, 2 or 3 axes servo motion. Each EZ-Flexx™ Motion Series Plus cable integrates 6 power conductors and 20 signal wires in a compact flat cable measuring just 0.84” wide by 0.19” thick. The Flexx-Sil™ encapsulation provides a solid, one-piece construction that creates a highly durable, flexible flat cable package. EZ-Flexx™ Motion Series Plus0.360.551.682.52MOTOR POWER & AUX (22 AWG TWISTED PAIR SHIELDED) X3700X-70, CLEAR FLEXX-SIL RUBBERMOTOR FEEDBACK & AUX (28 AWG, TWISTED PAIR SHIELDED X5) X20.190.841 AXIS2 AXES3 AXESDimensionsCable axes are not bonded, so may be grouped laterally or in stacked positions as shown below.Cable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: MCZ-1000-1-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Connectors• Power (P1): Tin Contact - TE, P/N 770904-1 9-Pos Housing - TE, P/N 172169-1• Signal (J1): 25-Pin - Amphenol, P/N L717-DB25P Metallized Shell - TE, P/N 5748677-3CABLE LENGTHJ1 J1P1 P1Applications Linear Motors, Servo and Stepper MotorsCableAmp Rating1No. of AxesConductor Gauge Dimensions [inches]Part NumberPower Signal Width Height81 22 AWG/3 pr 28 AWG/10 pr 0.84 0.19 MCZ-1000-12 22 AWG/6 pr 28 AWG/20 prSee Dimensional DrawingsMCZ-1000-23 22 AWG/9 pr 28 AWG/30 pr MCZ-1000-3Notes1. Amp rating is the maximum value for each power conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases.
Motion ControlP1 P1CABLE LENGTHNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-07Flexible Flat Cables & Cable AssembliesUnlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Options PageCable SpecificationsAll engineering values are nominal and subject to change.661-295-1295 Cicoil.comMotor Power / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53Applications Linear, Servo and Stepper Motors, AC and Variable Frequency Drives Ideal for Hi-Flex Servo Power Applications Rated for More Than 10 Million Flexing Cycles 4 Power Conductors in Shielded and Unshielded Versions Halogen Free Flame Retardant (HFFR)Cicoil’s line of Hi-Flex Motor Cables provides the advantages of all Cicoil flexible flat cables in a standard, low-cost package. Ultra-flexible, finely stranded wire conductors are used for maximum flexibility and long life in dynamic, flexing applications. Shielded conductors add tinned copper braiding over PFA insulation. Cicoil’s patented extrusion process encapsulates the wire conductors in a crystal clear, flexible, yet extremely durable insulation.Hi-Flex Motor Power CableDimensionsNon-Shielded ShieldedCableAmp Rating1Volts DCConductor GaugeDimensions [inches]Part NumberWidth HeightNon-Shielded7 12,000 24 AWG 0.27 0.09 969M101-24-4-MC8 18,000 22 AWG 0.32 0.11 969M101-22-4-MC10 18,000 20 AWG 0.36 0.12 969M101-20-4-MC15 20,000 18 AWG 0.43 0.14 969M101-18-4-MC19 20,000 16 AWG 0.48 0.15 969M101-16-4-MC27 20,000 14 AWG 0.61 0.19 969M101-14-4-MC36 20,000 12 AWG 0.75 0.24 969M101-12-4-MC47 20,000 10 AWG 0.92 0.29 969M101-10-4-MC65 20,000 8 AWG 1.26 0.35 969M101-8-4-MC95 20,000 6 AWG 1.47 0.40 969M101-6-4-MC125 20,000 4 AWG 1.77 0.47 969M101-4-4-MCShielded7 12,000 24 AWG 0.36 0.12 969M101-24-4-SMC8 18,000 22 AWG 0.41 0.13 969M101-22-4-SMC10 18,000 20 AWG 0.45 0.14 969M101-20-4-SMC15 20,000 18 AWG 0.52 0.16 969M101-18-4-SMC19 20,000 16 AWG 0.57 0.17 969M101-16-4-SMC27 20,000 14 AWG 0.70 0.21 969M101-14-4-SMC36 20,000 12 AWG 0.84 0.26 969M101-12-4-SMC47 20,000 10 AWG 1.01 0.31 969M101-10-4-SMCNotes1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases.HEIGHT HEIGHTWIDTH WIDTHCable AssembliesCable Length (feet) Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: 969M101-24-4-MC-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Wire Gauge Power Connector (P1)22-24 Tin Contacts - TE, P/N 770902-1; 9-Pos Housing - TE, P/N 172169-116-20 Tin Contacts - TE, P/N 171639-1; 9-Pos Housing - TE, P/N 172169-114 Gold Contacts - MOLEX, P/N 02-09-6110; 9-Pos Housing - MOLEX, P/N 30920924-10 Ring Lugs - TypicalPlease contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• See Table to the left
Motion ControlJ1 J1CABLE LENGTHNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-08Flexible Flat Cables & Cable AssembliesOptions PageUnlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Cable SpecificationsAll engineering values are nominal and subject to change.661-295-1295 Cicoil.comShielded Signal / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53Applications Sensors, Encoders, Actuators, Resolvers Ideal for High Performance Data Transmission Applications Ultra Flexible for Conned Area and Continuous Motion Twisted Shielded Signal Pairs for Excellent EMI/RFI Protection Halogen Free Flame Retardant (HFFR)Cicoil’s Hi-Flex Shielded Signal cables are ideal for the most demanding data transmission applications. Cicoil’s patented extrusion process allows individually shielded pairs to be placed in a highly flexible flat profile, while exceeding electrical and signal requirements. These flat cable designs are an excellent alternative to bulky round and stiffer PVC or Teflon flat cable designs.Hi-Flex Shielded Signal CableCableConductor GaugeAmp Rating1No. of PairsDimensions [inches]Part NumberWidth Height28 AWG 51 0.12 0.12 969M101-28-1TPS2 0.21 0.12 969M101-28-2TPS3 0.31 0.12 969M101-28-3TPS5 ∅0.21 ∅0.21 969M101-28-5TPS26 AWG 61 0.13 0.13 969M101-26-1TPS2 0.23 0.13 969M101-26-2TPS3 0.32 0.13 969M101-26-3TPS24 AWG 71 0.14 0.14 969M101-24-1TPS2 0.25 0.14 969M101-24-2TPS3 0.36 0.14 969M101-24-3TPS22 AWG 81 0.15 0.15 969M101-22-1TPS2 0.27 0.15 969M101-22-2TPS3 0.40 0.15 969M101-22-3TPS18 AWG 15 1 0.21 0.21 969M101-18-1TPS2 0.38 0.21 969M101-18-2TPS3 0.56 0.21 969M101-18-3TPSNotes1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases.DimensionsHEIGHTHEIGHTHEIGHTWIDTHWIDTHWIDTH1 Discreet Twisted Pair5X TWISTED PAIR2 Discreet Twisted Pair3 Discreet Twisted PairØ 0.21˝Cable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: 969M101-28-1TPS-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectorsWire Gauge Signal (J1)2825-Pin - Amphenol, P/N L717-DB25PMetallized Shell - TE, P/N 5748677-322-26Gold Contacts - TE, P/N 745254-225-Pos D-SUB Housing - TE, P/N 5205208-118Gold Contacts - MOLEX, P/N 02-09-61109-Pos Housing - MOLEX, P/N 3092092
Data & Video9Flexible Flat Cables & Cable Assemblies661-295-1295 Cicoil.comData & Video / p1of1 / 2021-08-25Data & Video CablesVideo/data communications cables using standard industry protocols in a at, exible package. Due to Cicoil’s patented Flexx-Sil™ jacketing, these cables feature superior durability in harsh environments and long cycle life in dynamic, exing applications. Cables are available in continuous lengths, or as cable assemblies, complete with connectors.Cat 5e Ethernet Cable 10Cat 6a Ethernet Cable 1 1Camera Link® Cable 12Controlled Impedance Cable 13USB Cable 14Flexible Coaxial Cable 15FireWire Cable 16HDMI Cable 17Low Friction Options 30 Halogen Free & Flame Retardant Available from Stock Available as Bulk Cable or Complete AssembliesTailor Your OrderTo create a custom version of any standard cable, call our engineers at 661-295-1295.Low Friction OptionsWhen cables need to be stacked together, or where a lower friction surface is desired, Cicoil features two low-friction cable finishes: GlideRite™ and SlideRite™. View on Page 30.
Data & Video10Flexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34661-295-1295 Cicoil.comEthernet 5e / p1of1 / 2021-08-25RJ 45RJ 45SHIELDED PAIRS0.450.14SHIELDINGø0.21SHIELDED PAIRS0.450.14SHIELDINGø0.21SHIELDED PAIRS0.450.14SHIELDINGø0.21NEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-0EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantClean Room Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height/diameter for intermediate ex - 10x cable height/diameter for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)Applications PLC and DCS Automation Networks, Field Level Networking and Ethernet Networks Ideal for Motion and Harsh Environment Applications Exceeds ANSI/TIA/EIA-568-A and TIA/EIA-568-B Cat 5e Specs Supporting Data Rates to 1 Gb/second Halogen Free Flame Retardant (HFFR)Cicoil’s Cat 5e Ethernet Cable meets the increased demand of professionals who need a rugged, reliable, portable, flexible and harsh environment ready network cable solution. Cicoil’s patented extrusion process allows individually shielded wires to be placed in a highly flexible flat profile for clear, high speed data transmission.Cat 5e Ethernet CableDimensionsFlat Section Round Section Cable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: DC-500-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsJ1 J1CABLE LENGTHConnectors• Signal (J1): RJ45CableAmp Rating1No. of PairsConductor GaugeCross-Section ProleDimensions [inches]Part NumberWidth Height Diameter3 430 AWG Flat 0.45 0.14 — DC-50028 AWG Round — — 0.21 DC-501Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Color Code – DC-501a. BRN/WHI with BRN stripeb. ORG/WHI with ORG stripec. GRN/WHI with GRN striped. BLU/WHI with BLU stripe
Data & VideoNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-011Flexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34661-295-1295 Cicoil.comEthernet 6A / p1of1 / 2021-08-25EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)Applications PLC and DCS Automation Networks, Field Level Networking and Ethernet Networks 500 MHz Performance Speeds Ideal for 100BASE-TX and 10GBASE-T (10-Gigabit Ethernet) Rated for More than 10 Million Flexing Cycles Exceptional EMI/RFI Suppression Rated for Temperatures from -104°C to +165°C Halogen Free Flame Retardant (HFFR)Cicoil’s Cat 6A Ethernet Cable meets the increased demands of professionals who need a rugged, flexible and high performance Ethernet cable solution. Cicoil’s patented extrusion process allows individually shielded, twisted pairs to be placed in a flexible flat profile for high speed data transmission, with exceptional EMI/RFI suppression. Cicoil’s Cat 6A Flat Cable delivers the ultimate in electrical performance, extreme ruggedness, and a Flex rating of over 10 Million cycles.Cat 6A Ethernet CableDimensionsWiring DiagramCableAmp Rating1Conductor Gauge No. of PairsDimensions [inches]Part NumberWidth Height1.4 28 AWG 4 0.52 0.15 DC-601Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. 0.520.15SHIELDED PAIRSCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: DC-601-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsRJ 45RJ 45J1 J1CABLE LENGTHConnectors• Signal (J1): RJ45POSITION 3 & 6POSITION 1 & 2POSITION 7 & 8POSITION 4 & 587654321
Data & VideoFLEXX-SIL™ JACKETTWINAX, TINNED ULTRAFLEX COPPER, SHIELDED0.031.500.030.17BRAID SHIELDPFA JACKETFOIL SHIELDWIRE STRANDSDRAIN WIRENEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-012Flexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34661-295-1295 Cicoil.comCamera Link / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53Applications Aerospace, Robotics, Medical, Semiconductor, Automation Ideal for Motion Video, Vision and Frame Grabber Applications Exceeds Camera Link® Standards Separately-Shielded Conductors in Flat Package Provides Fastest Data Speeds Halogen Free Flame Retardant (HFFR)Cicoil Camera Link® cable is ideal for motion video and frame grabber applications that require an extremely durable and harsh environment resistant design. This design features a 10 million flex cycle life and high flexibility through the use of ultra-flex copper stranded wire in the 11 twinax, dual-shielded cables that comprise the Cicoil Camera Link® cable. Also, individually-shielded conductors in a flat cable create a constant, clear signal path for the highest data speeds available.Camera Link® CableDimensionsCableAmp Rating1Conductor Gauge No. of PairsDimensions [inches]Part NumberWidth Height5 28 AWG 11 1.50 0.17 CL-1000Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Cable AssembliesConnector Type Temperature RatingCable Length (feet)Part Number AdditionMetal -55°C to +105°C3 -M-CA0036 -M-CA00612 -M-CA012Plastic -20°C to +85°C3 -P-CA0036 -P-CA00612 -P-CA012Notes1. Append onto base cable Part Number for complete assembly. Example: CL-1000-M-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsJ1 J1CABLE LENGTHConnectors• Signal (J1): Camera Link
Data & VideoNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-013661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Impedance / p1of1 / 2021-08-25EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A) Individually Controlled Impedance Signals with Frequencies Up to 1 GHz Excellent Alternative to Coaxial Cables in Many Applications Choice of 1 - 8 Individually Shielded 100 Ohm Twinax Conductors Halogen Free Flame Retardant (HFFR)Cicoil’s Controlled Impedance Cable is a highly flexible cable with individually controlled impedance signals. This 30 AWG/1 twisted shielded pair cable can be used as a more durable and flexible alternative to standard twisted pair and coaxial cables. Unlike bulky round and non-flexible woven cables, the Cicoil design can be used in applications requiring submersion in water, exposure to harsh weather and rugged environments. And the flat cable construction guarantees clear, high speed data transmission.Controlled Impedance CableDimensionsCableAmp Rating1Conductor GaugeNo. of PairsNo. of ConductorsDimensions [inches]Part NumberWidth Height3 30 AWG1 2 0.15 0.15 CIM-100-012 4 0.28 0.15 CIM-100-024 8 0.54 0.15 CIM-100-046 12 0.81 0.15 CIM-100-068 16 1.07 0.15 CIM-100-08Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Applications Sensors, Encoders, Actuators, ResolversJ1J1J1J1CABLE LENGTHCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: CIM-100-01-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): D-SUB, P/N 205203-8WIDTHHEIGHT
Data & VideoNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27J1J2CABLE LENGTHRoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-014Flexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34USB / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53 USB 2.0 and 3.0 Available Ideal for High Performance Data Transmission Applications Ultra Flexible Cable for Conned Area and Continuous Motion Halogen Free Flame Retardant (HFFR)Comprised of 2 individually shielded power wires and 1 twisted shielded pair of 100 ohm twinaxial configuration for USB 2.0 and 3 twisted pairs of 100 ohm twinaxial configuration for USB 3.0, Cicoil’s Flexx-Sil™ jacketed USB cables are designed for highly demanding applications. Unlike typical USB cables, the Cicoil cable has been designed for high flexibility, mechanical stress, temperature extremes and harsh environments. And the flat cable construction guarantees clear, high speed data transmission, even in the toughest of environments.USB CableCableTypeAmp Rating1Conductor Gauge Dimensions [inches]Part NumberPower Signal Power Signal Width HeightUSB 2.0 7 3 24 AWG/2c 30 AWG/1 pr 0.31 0.15 USB-2000USB 3.0 10 5 24 AWG/2c 28 AWG/3 pr 0.62 0.18 USB-3000Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases.Applications Indoor and outdoor USB applications0.310.1524 AWG, SINGLE SHIELDED, WIRE, 2 PLACES30 AWG, 100 OHM TWINAX0.180.6224 AWG, POWER CONDUCTOR SHIELDED, 2 PLACES28 AWG, SIGNAL CONDUCTOR, IMPEDANCE MATCHED, SHIELDED, 3 PLACES0.310.1524 AWG, SINGLE SHIELDED, WIRE, 2 PLACES30 AWG, 100 OHM TWINAX0.180.6224 AWG, POWER CONDUCTOR SHIELDED, 2 PLACES28 AWG, SIGNAL CONDUCTOR, IMPEDANCE MATCHED, SHIELDED, 3 PLACESDimensionsUSB 2.0USB 3.0J1J1CABLE LENGTHCable AssembliesCongurationCable Length (feet)Part Number AdditionHost to Host3 -CAH0036 -CAH00612 -CAH012Host to Peripheral3 -CAP0036 -CAP00612 -CAP012Notes1. Append onto base cable Part Number for complete assembly. Example: USB-2000-H-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): USB Type A, P/N A-USBPA-3-R• Signal (J2): USB Type B, P/N B-USBPB-3-RHost to HostHost to Peripheral
Data & VideoNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-015661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Coax / p1of1 / 2021-08-25EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)Applications Aerospace Surveilance, Surgical Robotics, Medical Diagnostics, Automated Test Systems Ideal for High Performance Video Transmission Applications Ultra Flexible Cable for Conned Area and Continuous Motion 1 - 8 Individual 50 or 75 Ohm Coax Conductors Halogen Free Flame Retardant (HFFR)Cicoil Flexible Coaxial Cables are ideal for high speed data and video applications that require flexibility, high & low temperature resistance and protection from very rugged environments. These 50 ohm and 75 ohm low capacitance cables feature low line to line skew, maximum signal integrity, low EMI and suppress crosstalk. And the flat cable construction guarantees clear, high speed data transmission, even in the toughest of environments.Flexible Coaxial CablesCableOhms Amp Rating1Conductor GaugeNo. of ConductorsDimensions [inches]Part NumberWidth Height50 3 30 AWG1 0.12 0.12 FC50-012 0.25 0.12 FC50-024 0.50 0.12 FC50-048 1.01 0.12 FC50-0875 3 30 AWG1 0.18 0.18 FC75-012 0.36 0.18 FC75-024 0.73 0.18 FC75-048 1.47 0.18 FC75-08Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Dimensions50 OhmJ1J1J1J1J1J1J1J1CABLE LENGTHCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: FC50-01-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): SMA MaleWIDTHWIDTHHEIGHTHEIGHT75 Ohm
Data & VideoNEED CUSTOMS?NEED CUSTOMS?See Page27See Page2722 AWG, POWER CONDUCTOR, SHIELDED, 2 PLACES28 AWG, SIGNAL CONDUCTOR, IMPEDANCE MATCHED, SHIELDED, 2 PLACESRoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-016661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34FireWire / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53CableAmp Rating1Conductor Gauge Dimensions [inches]Part NumberPower Signal Power Signal Width Height8 5 22 AWG/2c 28 AWG/2 pr 0.38 0.12 FW-1000Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Ideal for High Performance Data Transmission Ultra Flexible Cable for Conned Area and Continuous Motion Exceed FireWire Specs in a Flat, Compact Package Halogen Free Flame Retardant (HFFR)Comprised of 2 individually shielded 22 AWG power wires and 2 individually twisted shielded pairs of 28 AWG 100 ohm twinaxial configuration, Cicoil’s Flexx-Sil™ jacketed FireWire cables are designed for highly demanding applications. Unlike typical FireWire cables, the Cicoil cable has been designed for high flexibility, mechanical stress, temperature extremes and harsh environments. And the flat cable construction guarantees clear, high speed data transmission, even in the toughest of environments.Applications Indoor and Outdoor FireWire ApplicationsFireWire CableDimensions0.380.12J1 J1CABLE LENGTHCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: FW-1000-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): FireWire, P/N 154-FWW15-E
Data & Video17661-295-1295 Cicoil.comOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Flexible Flat Cables & Cable AssembliesHDMI / p1of1 / 2021-08-25NEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-0Applications High Denition Multimedia Interfaces Ideal for High Denition Multimedia Interface Applications Ultra Flexible Cable for Conned Area and Continuous Motion Meets HDMI 1.3 Digital Audio/Video Specications Halogen Free Flame Retardant (HFFR)Comprised of 4 individually dual shielded 100 ohm and one bundle of 5 twisted 28 AWG pairs with an overall shield, Cicoil’s Flexx-Sil™ jacketed HDMI cables are designed for highly demanding high resolution video signal transmission applications. Cicoil’s design is an excellent alternative to standard HDMI cables where resistance to mechanical stress, temperature extremes, vibration, tight bending and harsh environments is required.HDMI CableDimensionsCableAmp Rating1Conductor Gauge No. of PairsDimensions [inches]Part NumberWidth Height5 28 AWG 9 0.77 0.21 HDMI-2000Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. 0.770.21CAMERA LINK, 100 OHM TWINAX, 4 PLACESØ 0.106˝28 AWG, 5 TWISTED PAIRS, SHIELDEDØ 0.135˝Cable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: HDMI-2000-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsJ1 J1CABLE LENGTHConnectors• Signal (J1): HDMIEnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 51MechanicalConductors: Ultra exible, nely stranded, tinned copperShielding: Ultra exible, braided shields, with 90% nominal coverageMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exFlex Life: 10,000,000 cycles nominalOuter Jacket Durometer Rating: 65 (Shore A)
Motion Control18661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesUAVs Soar with Flat CablesCicoil flat cables can include power, signal, data and video conductors in one compact, lightweight package, saving valuable space and weight on UAVs. And the silicone jacket operates in extreme conditions, including temperatures from -65°C to +260°C, and it also cushions the conductors against vibration and turbulence.Withstand 10,000 Gs of ShockThis projectile’s guidance system sustains 10,000 Gs of shock force when fired. That’s why Cicoil high performance flat cables have been specified to form the Control Systems Actuator Harness. Cicoil’s unique StripMount feature saves space while providing a strong, anti-vibration mounting.Save Space with Custom Flat CablesCicoil custom cables solve many critical space, weight, and assembly issues. Packaging many conductors using flat cables provides solutions in high performance, tight-fitting military and aerospace applications. And Cicoil’s unique cable forming capability means cables can take virtually any shape, eliminating costly flex circuits or wiring costs.Bring on the Heat...and Cold!Cicoil delivers exceptional reliability under a broad range of temperatures. Our cables retain their electrical properties and flexibility in temperatures from -104°C to +260°C. They also withstand exposure to high levels of ultraviolet, radiation and ozone with no adverse effects.Approved by NASA for space flight, Cicoil flat cables exceed outgassing specifications for vacuum and space use. They provide very broad temperature capability, ranging from -65°C to +260°C, and also deliver exceptional resistance to radiation and ozone.Certied for Space TravelCicoil flat cables are used extensively within a variety of modern guided missiles and their delivery systems. Their flat profile saves space and weight, while a seamless silicone encapsulation provides incredible shock absorption. When one launch can make the difference rely on Cicoil.Every Launch Counts - Rely on Cicoil661.295.1295 • www.cicoil.comCicoil® High Flex Flat Cableswww.Cicoil.comSophisticated, Versatile, Mission Ready... Cicoil cable assemblies are used in thousands of mission-critical aircraft, missile and space applications. Our AS9100 certied quality system ensures that each cable assembly is rigorously tested to perform in the toughest places. Our in-house cable production and assembly capabilities allow us to respond quickly to prototype or production needs. Visit our website or call today to speak to an engineer.And that’s just the Cicoil Cables! The ghter is pretty cool too.nPerform in temperatures from -65°C to +260°Cn Enables compact, lightweight assembliesn Flexible silicone at cables t in tight spaces nComplete assemblies, including any connectors, made in-housenAS9100 certied quality
Unshielded19661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesUnshielded Cables / p1of1 / 2021-08-25Unshielded Cables: Multi and Single ConductorCicoil has multiple variations of high ex, unshielded cables and assemblies in at, exible congurations all available from stock. Ranging from 1 to 64 conductors in exible at cables, standard IDC, festoon or thermocouple variations, Cicoil’s selection of standard cables provides the highest variety available anywhere. All cables are jacketed in Cicoil’s exclusive, clear Flexx-Sil™ material, delivering the highest exibility in the most extreme environments. Cables are available in continuous lengths, or as cable assemblies, complete with connectors.Hi-Flex Unshielded Cable 20Hi-Flex, Hi-Temp IDC Ribbon Cable 22Ultra Flexible Micro IDC Ribbon Cable 23Flexx-Sil™ Hi-Temp Festoon Cable 24Hi-Flex Unshielded Single Conductor Cable 25Thermocouple Cable* 26Low Friction Options 30 Low Smoke/Zero Halogen (LSZH)* Halogen Free & Flame Retardant Available from Stock Available as Bulk Cable or Complete AssembliesTailor Your OrderTo create a custom version of any standard cable, call our engineers at 661-295-1295.Low Friction OptionsWhen cables need to be stacked together, or where a lower friction surface is desired, Cicoil features two low-friction cable finishes: GlideRite™ and SlideRite™. View on Page 30.* All Unshielded Cables have passed testing for smoke, toxicity, flammability, and halogen content except for Thermocouple Cable, which is Halogen Free & Flame Retardant like all other Cicoil Standard Cables.
Unshielded.035”.037”AABBBBABBABBABBABBBBAA.050” Pitch1mm PitchNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-020661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesUnshielded Multi / p1of2 / 2021-08-25 Ideal for High Performance Power & Control Applications Ultra Flexible Cable for Conned Area and Continuous Motion 4 AWG - 28 AWG Conductors Available in 2 - 12 Conductors Low Smoke/Zero Halogen (LSZH)Cicoil’s line of Hi-Flex Unshielded Cables provides the advantages of all Cicoil flexible cables in a standard, low-cost package. Ultra-flexible, finely stranded wire conductors are used for maximum flexibility and long life in dynamic, flexing applications. Cicoil’s patented extrusion process encapsulates the wire conductors in a crystal clear, flexible, yet extremely durable Flexx-Sil™ insulation. Hi-Flex Unshielded CableCableAmp Rating1Volts DCConductor GaugeNo. of ConductorsDimensions [inches]Part NumberWidth Height5 12K 28 AWG2 0.13 0.08 969M101-28-23 0.18 0.08 969M101-28-34 0.23 0.08 969M101-28-46 0.33 0.08 969M101-28-68 0.43 0.08 969M101-28-810 0.53 0.08 969M101-28-106 12K 26 AWG2 0.14 0.09 969M101-26-23 0.19 0.09 969M101-26-34 0.25 0.09 969M101-26-46 0.35 0.09 969M101-26-68 0.46 0.09 969M101-26-810 0.57 0.09 969M101-26-108 12K 24 AWG2 0.15 0.10 969M101-24-23 0.21 0.10 969M101-24-34 0.27 0.10 969M101-24-46 0.38 0.10 969M101-24-68 0.50 0.10 969M101-24-810 0.62 0.10 969M101-24-1012 0.74 0.10 969M101-24-1211 18K 22 AWG2 0.18 0.11 969M101-22-23 0.25 0.11 969M101-22-34 0.32 0.11 969M101-22-46 0.45 0.11 969M101-22-68 0.59 0.11 969M101-22-810 0.73 0.11 969M101-22-1012 0.87 0.11 969M101-22-12Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. Dimensions2-12 ConductorsApplications Aerospace, Festoon Systems, Robotics, Medical, Oil Drilling, PackagingCable Assemblies – 22-28 AWGCable Length (feet) Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: 969M101-28-2-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.J1 J1CABLE LENGTHAssembly DimensionsConnectors for 28 AWG• Signal (J1): 25-Pos D-SUB - Amphenol, P/N L717-DB25P Metallized Shell - TE, P/N 5748677-3Connectors for 22-26 AWG• Signal (J1): Gold Contacts - TE, P/N 745254-2 25-Pos D-SUB Housing - TE, P/N 5205208-1WIDTHHEIGHT
Unshielded21661-295-1295 Cicoil.comOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Unshielded Multi / p2of2 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantLow Smoke/Zero Halogen (LSZH): Has passed testing for smoke, toxicity, ammability and halogen content, by UKAS certied labElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53Flexible Flat Cables & Cable AssembliesCable (continued)Amp Rating1Volts DCConductor GaugeNo. of ConductorsDimensions [inches]Part NumberWidth Height13 18K 20 AWG2 0.20 0.12 969M101-20-23 0.28 0.12 969M101-20-34 0.36 0.12 969M101-20-46 0.51 0.12 969M101-20-68 0.67 0.12 969M101-20-810 0.83 0.12 969M101-20-1012 0.99 0.12 969M101-20-1220 20K 18 AWG2 0.24 0.14 969M101-18-23 0.33 0.14 969M101-18-34 0.43 0.14 969M101-18-46 0.62 0.14 969M101-18-68 0.81 0.14 969M101-18-810 1.00 0.14 969M101-18-1012 1.19 0.14 969M101-18-1226 20K 16 AWG2 0.26 0.15 969M101-16-23 0.37 0.15 969M101-16-34 0.48 0.15 969M101-16-46 0.70 0. 15 969M101-16-68 0.92 0. 15 969M101-16-810 1.14 0. 15 969M101-16-1012 1.36 0. 15 969M101-16-1227 20K 14 AWG3 0.47 0.19 969M101-14-34 0.61 0. 19 969M101-14-48 1.16 0. 19 969M101-14-836 20K 12 AWG3 0.58 0. 24 969M101-12-34 0.75 0.24 969M101-12-447 20K 10 AWG 4 0.92 0.29 969M101-10-465 20K 8 AWG 4 1.17 0.35 969M101-8-495 20K 6 AWG 4 1.47 0.40 969M101-6-4125 20K 4 AWG 4 1.64 0.47 969M101-4-4Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. J1J1J1J1J1J1J1J1J1J1CABLE LENGTHCABLE LENGTHCable Assemblies – 4-20 AWGCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: 969M101-20-2-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors for 4-12 AWG• Signal (J1): Ring Lugs - TypicalConnectors for 14-20 AWG• Signal (J1): Gold Contacts - MOLEX, P/N 02-09-6110 15-Pos Housing - MOLEX, P/N 19-09-2159
UnshieldedAABBNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-022661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34IDC Ribbon / p1of1 / 2021-08-25EnvironmentalTemperature Rating: -104°C to +260°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantLow Smoke/Zero Halogen (LSZH): Has passed testing for smoke, toxicity, ammability and halogen content, by UKAS certied labElectricalOperating Voltage: 300Outer Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)MechanicalConductors: Ultra exible, nely stranded copperMinimum Bend Radius: - 6x cable height for intermediate ex Outer Jacket Durometer Rating: 65 (Shore A)See Electrical Rating Chart on Page 53Dimensions Ultra Flexible Ribbon Cable for standard IDC Connectors Available with up to 64 Conductors in .050˝ or 1mm Pitch -104°C to +260°C Rating – Ideal for the Harshest Environments Low Smoke/Zero Halogen (LSZH)Cicoil’s high performance line of flat ribbon cable is ideal for electronic applications that require better flexibility, broader temperature and harsh environment capabilities than those offered by PVC or other ribbon cables. Cicoil’s patented Flexx-Sil™ jacket provides the highest flex, highest performance ribbon cable available.Hi-Flex, Hi-Temp IDC Ribbon CableCableGauge PitchAmp Rating1No. of ConductorsDimensionsPart NumberWidth Span Height28 AWG .050˝510 0.50˝ 0.45˝ 0.04˝ max. 310J101-1014 0.70˝ 0.65˝ 0.04˝ max. 310J101-1416 0.80˝ 0.75˝ 0.04˝ max. 310J101-1620 1.00˝ 0.95˝ 0.04˝ max. 310J101-2026 1.30˝ 1.25˝ 0.04˝ max. 310J101-2628 1.40˝ 1.35˝ 0.04˝ max. 310J101-2830 1.50˝ 1.45˝ 0.04˝ max. 310J101-3034 1.70˝ 1.65˝ 0.04˝ max. 310J101-3440 2.00˝ 1.95˝ 0.04˝ max. 310J101-4044 2.20˝ 2.15˝ 0.04˝ max. 310J101-4450 2.50˝ 2.45˝ 0.04˝ max. 310J101-5060 3.00˝ 2.95˝ 0.04˝ max. 310J101-6064 3.20˝ 3.15˝ 0.04˝ max. 310J101-6428 AWG 1mm510 10 mm 9 mm 0.94 mm 666K101-1016 16 mm 15 mm 0.94 mm 666K101-1620 20 mm 19 mm 0.94 mm 666K101-2026 26 mm 25 mm 0.94 mm 666K101-2630 30 mm 29 mm 0.94 mm 666K101-3034 34 mm 33 mm 0.94 mm 666K101-3440 40 mm 39 mm 0.94 mm 666K101-4044 44 mm 43 mm 0.94 mm 666K101-4450 50 mm 49 mm 0.94 mm 666K101-50Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. HEIGHTSPANWIDTHApplications Aerospace, Robotics, Medical, Semiconductor, Packaging, Surgical SystemsJ1 J1CABLE LENGTHCable AssembliesCable Length (feet) Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: 310J101-10-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): Berg or equivalent (XX = Position Quantity) .050˝ Pitch: P/N 71602-00XX 1mm Pitch: P/N 89361-1XX
UnshieldedAABBRoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-0NEED CUSTOMS?NEED CUSTOMS?See Page27See Page2723661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34MechanicalConductors: Ultra exible, nely stranded, bare copperMinimum Bend Radius: - 6x cable height for intermediate ex Outer Jacket Durometer Rating: 65 (Shore A)See Electrical Rating Chart on Page 53EnvironmentalTemperature Rating: -104°C to +260°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantLow Smoke/Zero Halogen (LSZH): Has passed testing for smoke, toxicity, ammability and halogen content, by UKAS certied labElectricalOperating Voltage: 300Outer Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)Micro IDC Ribbon / p1of1 / 2021-08-25Dimensions Light, exible design routes easily in tight spaces .025˝ Pitch works with any Micro IDC connector Standard sizes available with up to 34 conductors Rated for Temperatures from -104°C to +260°C Low Smoke/Zero Halogen (LSZH)Cicoil’s .025˝ Micro IDC Cable is excellent for tight spacing applications that require dependable signal density. The Ultra Flexible cable performs exceptionally well in harsh environments, including high/low temperatures, and under exposure to moisture and most chemicals.Ultra Flexible Micro IDC Ribbon CableCableGauge PitchAmp Rating1Volts DCNo. of ConductorsDimensionsPart NumberWidth Span Height30 AWG .025˝0.2 3K10 0.250˝ 0.225˝ 0.026˝ 482W101-1014 0.350˝ 0.325˝ 0.026˝ 482W101-1416 0.400˝ 0.375˝ 0.026˝ 482W101-1620 0.500˝ 0.475˝ 0.026˝ 482W101-2026 0.650˝ 0.625˝ 0.026˝ 482W101-2628 0.700˝ 0.675˝ 0.026˝ 482W101-2830 0.750˝ 0.725˝ 0.026˝ 482W101-3034 0.850˝ 0.825˝ 0.026˝ 482W101-34Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. HEIGHTSPANWIDTHApplications Aerospace, Robotics, Medical, Semiconductor, Surgical Systems, Printer Head, Satellites, Board-to-BoardJ1 J1CABLE LENGTHCable AssembliesCable Length (feet) Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: 482W101-10-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): CnC Tech or equivalent (XX = Position Quantity) .025˝ Pitch: P/N 3230-XX-0103-00
UnshieldedNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-024661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Festoon / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°C (higher temperatures available)Moisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantLow Smoke/Zero Halogen (LSZH): Has passed testing for smoke, toxicity, ammability and halogen content, by UKAS certied labElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53Dimensions Rated from -104°C to +165°C Ultra Flexible Alternative to PVC & Neoprene Festoon Cables Available in 18 AWG to 4 AWG Congurations Low Smoke/Zero Halogen (LSZH)Cicoil’s line of Flexx-Sil™ Festoon Cables are designed for continuous flexing, extreme temperature and higher voltage requirement applications. These UV-radiation resistant cables are an excellent alternative to PVC and Neoprene jacketed flat cables that do not provide reliability in severe environments. The clear Flexx-Sil™ jacket makes the cables highly flexible and ideal for extreme temperatures and harsh environments.Flexx-Sil™ Hi-Temp Festoon CableCableAmp Rating1Volts DCConductor GaugeNo. of ConductorsDimensions [inches]Part Number2Width Height15 20K 18 AWG 4 0.43 0.14 CFC-18-419 20K 16 AWG4 0.48 0.15 CFC-16-48 0.92 0.15 CFC-16-812 1.36 0.15 CFC-16-1227 20K 14 AWG4 0.61 0.19 CFC-14-48 1.16 0.19 CFC-14-836 20K 12 AWG 4 0.75 0.24 CFC-12-447 20K 10 AWG 4 0.92 0.29 CFC-10-465 20K 8 AWG 4 1.17 0.35 CFC-8-495 20K 6 AWG 4 1.47 0.40 CFC-6-4125 20K 4 AWG 4 1.64 0.47 CFC-4-4Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. 2. High tensile, bare copper, silver plated conductors and insulated wires with specic color codes are available by request. Minimums may apply.HEIGHTWIDTHApplications Festoon Systems, Gantries, Telescoping Jetways, Conveyors, Car WashesJ1 J1CABLE LENGTHCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: CFC-18-4-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectorsWire Gauge Signal (J1)18Gold Contacts - MOLEX, P/N 02-09-61109-Pos Housing - MOLEX, P/N 309209214-16Gold Contacts - MOLEX, P/N 02-09-611015-Pos Housing - MOLEX, P/N 19-09-21594-12 Ring Lugs - Typical
UnshieldedBANEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-025661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Unshielded Single / p1of1 / 2021-08-25MechanicalConductors: Ultra exible, nely stranded, tinned copperMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +165°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantLow Smoke/Zero Halogen (LSZH): Has passed testing for smoke, toxicity, ammability and halogen content, by UKAS certied labElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53 Ideal for Power Applications Requiring Voltages up to 42,000 Volts DC Excellent Alternative to PVC & Teon Wire in Conned Area and Motion Applications Available from 4 AWG to 30 AWG Low Smoke/Zero Halogen (LSZH)Cicoil’s Hi-Flex Unshielded Single Conductor Cable is ideal for high voltage and extreme temperature applications. Ultra-flexible, finely stranded wire conductors are used for maximum flexibility and long life in dynamic, flexing applications. Cicoil’s patented extrusion process encapsulates the wire conductor in a crystal clear, flexible, yet very durable Flexx-Sil™ insulation.Hi-Flex Unshielded Single Conductor CableCableAmp Rating1Volts DCConductor GaugeDiameter [inches]Part Number23 10K 30 AWG 0.21 969M101-30-15 12K 28 AWG 0.21 969M101-28-16 12K 26 AWG 0.22 969M101-26-17 12K 24 AWG 0.22 969M101-24-18 31K 22 AWG 0.23 969M101-22-110 31K 20 AWG 0.24 969M101-20-115 42K 18 AWG 0.25 969M101-18-119 42K 16 AWG 0.26 969M101-16-127 42K 14 AWG 0.28 969M101-14-136 42K 12 AWG 0.30 969M101-12-147 42K 10 AWG 0.33 969M101-10-165 42K 8 AWG 0.39 969M101-8-195 42K 6 AWG 0.44 969M101-6-1125 42K 4 AWG 0.50 969M101-4-1Note1. Amp rating is the maximum value for each conductor at room temperature of 70°F (21°C). Amp rating decreases as temperature increases. 2. High tensile, bare copper and silver plated conductors, insulated wires with specic color codes are available by request. Minimums may apply.DimensionsDIAMETERApplications Aerospace, Solar Panel, Robotics, Medical, Oil Drilling, Wind Turbine, WeldingJ1 J1CABLE LENGTHCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: 969M101-30-1-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Signal (J1): Ring Lug
UnshieldedNEED CUSTOMS?NEED CUSTOMS?See Page27See Page27RoHSCOMPLIANTREACHCOMPLIANTFAAFLAME TESTEDULMEETS 94V-026661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOptions PageCable SpecificationsAll engineering values are nominal and subject to change.Unlimited Cable Design 28Low Friction Options 30StripMount™ Integrated Mounting Strip 30Integrated Tubing 31SuperTuff™ Jacket 31Colored Jacketing 31Strip and Tin Cable Ends 31Complete Assembly 34Thermocouple / p1of1 / 2021-08-25MechanicalConductors: - Type J: Ultra Flexible Iron and Constantan- Type K: Ultra Flexible Chromel and AlumelMinimum Bend Radius: - 6x cable height for intermediate ex - 10x cable height for continuous exOuter Jacket Durometer Rating: 65 (Shore A)EnvironmentalTemperature Rating: -104°C to +260°CMoisture Rating: Submersible, Salt Water ResistantCleanroom Rating: Class 1, Zero ParticulatesExtreme Environments: Sunlight, UV Light, Alcohol, Chemical and Oil ResistantElectricalOuter Jacket Dielectric Strength: 450 volts/mil (17.7 kv/mm)See Electrical Rating Chart on Page 53 Ideal for Control Instrumentation & Temperature Sensing Applications Rated from -104°C to +260°C Available in Type J & Type K Versions with 1 - 8 Conductors Halogen Free Flame Retardant (HFFR)Cicoil Thermocouple Cables are ideal for high performance temperature sensing applications, where flexibility and reliability are needed. Available in flat cables, with up to 8 thermocouples, and encased in Cicoil’s clear Flexx-Sil™ jacketing, these cables provide high performance and compact packaging for the most demanding thermocouple applications.Thermocouple CableCableTypeConductor GaugeNo. of ConductorsDimensions [inches]Part NumberWidth HeightJ 28 AWG1 0.14 0.14 TC-J-012 0.27 0.14 TC-J-024 0.54 0.14 TC-J-048 1.08 0.14 TC-J-08K 28 AWG1 0.14 0.14 TC-K-012 0.27 0.14 TC-K-024 0.54 0.14 TC-K-048 1.08 0.14 TC-K-08DimensionsWIDTHHEIGHTApplications Temperature Sensing, Heating & Air Conditioning, Cooking EquipmentJ1J1J1J1J1J1J1J1CABLE LENGTHCable AssembliesCable Length (feet)Part Number Addition3 -CA0036 -CA00612 -CA012Notes1. Append onto base cable Part Number for complete assembly. Example: TC-J-24-CA0032. Connector ratings may dier from cable ratings; refer to manufacturer specications.Please contact Cicoil for other connectors and length options.Assembly DimensionsConnectors• Type J Signal (J1): Omega, P/N SMPW-CC-J-M• Type K Signal (J1): Omega, P/N SMPW-CC-K-M
Customizing27661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCustomizing / p1of6 / 2021-08-25Customizing Cicoil Flat CablesCicoil’s patented extrusion process enables the production of virtually any at cable conguration. But it doesn’t end there. Within a single cable you can integrate power wire, signal wire, hollow tubing, and ber optics. Add elements to provide special attributes, such as GlideRite™ for low friction, FlexRail™ for carrier-free repetitive motion, or StripMount™ for fast and easy installation. This sections covers the basics. Unlimited Flat Cable Design 28Online Cable Configurator 29Low Friction Options 30StripMount™ Integrated Mounting Strip 30Flat Cables with Tubing 31SuperTuff™ Jacketing 31 Colored Flat Cable 31Cable End Preparation 31
Customizing28661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCustomizing / p2of6 / 2021-08-25Cicoil Patented TechnologiesCicoil invented the highest performance, most versatile flat cables on the planet, and we are extremely proud to have received numerous US and worldwide patents for our unique technologies and products. Cicoil’s ongoing innovations enable us to design and manufacture high performance cables that exceed the demands of our customers’ toughest applications.Unlimited Flat Cable DesignCreate exactly the cable needed, in the smallest possible package. Save space and reduce cost. The flexible cable jacket and finely-stranded wire conductors combine to make Cicoil’s cables the most flexible on the market. Tested for tens of millions of cycles, Cicoil flat cables deliver reliable performance and long life.For repetitive motion, vibration, tough environments, and temperature extremes there is simply no better option than Cicoil flat cables.Any Wire or Cable ElementCicoil’s patented extrusion process allows the addition of an unlimited variety of conductors, such as coaxial, video, and fiber optics. Design your own cable with our easy-to-use Configurator (See next page). Bare Wire, Insulated and Shielded Conductors, Twisted Pair, Coax, Fiber Optics, TubingThese patented flat cables are available with wire gauges from 4 to 44 AWG, in virtually any configuration required. Cicoil’s patented extrusion process allows multiple wires to be placed in a flat cable, precisely controlling the wire spacing, the insulation thickness, and the overall cable shape. Specify Cicoil Flat Cables when… PVC will melt, break, or burn PTFE is too sti for repetitive motion Operation is in temperature and environmental extremes Cables must withstand medical or industrial chemicals Repetitive motion, vibration, or shock will damage other cables Cables must be soft to the touch Application must meet NASA or ESA outgassing requirementsAnd any connector!Flat Cables with TubingAdd hollow tubing to cables for transporting fluid and gasses or make a flat cable with only tubes. Standard PTFE, Tygon® and PVC tubes can be integrated in any cable Most diameter sizes supported Specify any location and number of tubes in combination with other conductors More information on Page 30
Customizing29661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCustomizing / p3of6 / 2021-08-25Online Cable Configurator – Easy as 1-2-3!Add Conductors & Tubing to Your CableDesign Your Own Flat Cable in Just Minutes! Over 10 Million Potential Configurations. Try It Today!Remove or Rearrange Parts as Needed and SubmitGet a Drawing with PricingCustom design your own cable in real time at Cicoil.com with our online Cable Configurator. It features drag & drop simplicity to design any flat cable, and get an immediate drawing and quote.Cables can be constructed of many elements, including shielded Power conductors, shielded Signal conductors, Video and Coax wires, Tubing for Fluids or Gases, and other design elements like Cicoil’s patented StripMount™ fastening strip. Immediately after constructing a flat cable design, you will receive an engineering drawing and a price quotation. Try out the Cicoil Flat Cable Configurator today. Find it at:https://www.cicoil.com/flat-cable/configurator123
Customizing30661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCustomizing / p4of6 / 2021-08-25GlideRite™: The lowest friction available, the cable is as slippery as Teon® Compound is chemically bonded to the cable, and will not rub or peel o Cable retains all performance characteristics, including temperature range and exibility (See Tech Note). Continuous lengths not available, cable needs to be supplied in 30-80 foot lengthsSlideRite™: Reduced friction, similar to a PVC cable jacket Compound is chemically bonded to the cable, and will not rub or peel o Cable retains all performance characteristics, including temperature range and exibility Continuous lengths can be coated Makes cables slightly cloudy in colorLow Friction OptionsFlexx-Sil™ JacketWire Conductors of Your ChoiceUse common hardware such as screws, rivets or 1/4-turn fasteners to secure cable Fiberglass-Reinforced StripMount™ RibbonStripMount™ Integrated Mounting StripCicoil’s StripMount™ design makes it quick and easy to mount cables to any surface. The patented design allows for holes to be easily punched or drilled through the StripMount™ cable reinforcement at whatever intervals you need. Use any fasteners to attach the cable to any surface. Rather than using expensive, difficult cable management systems, StripMount™ lets you attach cables anywhere. You can even stack up and drill through multiple cables!When cables need to be stacked together, or where a lower friction surface is desired, there are two different cable finishes available: GlideRite™ and SlideRite™. Benefits: Standard fasteners mount cables to any surface Saves space by eliminating cable conduit and cable tie systems Fiberglass-reinforced strip has 250 lbs. holding force Stackable: Multiple cables can be stacked and secured by a single fastenerStripMount™ is available with any Cicoil cable.
Customizing31661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCustomizing / p5of6 / 2021-08-25.5”1”.5”1”Cable End PreparationSelect this option to have Cicoil prepare one or both ends of cable for connectors or other termination. Cable will be stripped as illustrated. Cable jacket is removed 1” from end of conductors. Insulation (if present) is stripped 0.5” from end of conductors.SuperTuff™ Cable JacketingStandard Cicoil Flexx-Sil™ jacketing carries a Durometer Rating of 65 (Shore A), and is very strong and durable. For more rugged environments, where cable is to be subject to impact or abrasion, we recommend that you specify Cicoil’s SuperTu™ formulation to deliver a Durometer Rating of 85. Available with any at cable.Colored Cable JacketingCicoil produces colored cable jackets upon request. Black, white and lots of colors in between. Let us know what you need. Flat Cables with TubingCicoil excels at incorporating tubing into our flat cables. Flat cables can include tubing for gases and/or liquids, right alongside power, signal, data or video conductors. We also manufacture many cables that are 100% tubing, in a wide variety of sizes, configurations and tubing materials.Versatility & Performance PTFE, PFA, Polyurethane, Tygon® and PVC Tubes can be used in Cicoil at cables Multiple tube diameters are available, including a variety of tube diameters in a single at cable Tubing can be included virtually anywhere, in any quantity, in any at cable ‘Tubing Only’ cables also available, in multiple variations Simplify design and packaging by combining tubing with power, signal, data and video conductors, all in a single at cable Custom shaped cables with tubing Class 1 Cleanroom Rated; Free of Halogens, Contaminants and Particulates™
Customizing32661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCustomizing / p6of6 / 2021-08-25Tiny Cables. Flex Circuit Alternative.Soft and pliable cables encapsulated in medical grade Flexx-Sil™ jacketing encapsulates wires as small as 44 AWG. Resists alcohol and chlorine bleach washes, and easily withstands autoclaving. Compatible with all medical connectors. Bring on the Heat...and Cold!Cicoil delivers exceptional reliability under a broad range of temperatures. Our cables retain their electrical properties and exibility in temperatures from -104°C to +260°C. They also withstand exposure to high levels of ultraviolet, radiation and ozone with no adverse eects.Any Wire...Any Shape...Any Size...Cicoil crystal-clear at cables deliver unsurpassed versatility & performance! Bare Wire, Insulated and Shielded Conductors, Twisted Pair, Coax, Fiber Optics, TubingWet and WildThe water-repellent characteristics of Flexx-Sil™ jacketing make our cables immune to immersion, high humidity, fungus, and damp operating environments. Ideal for washdown, auto-clave, and other wet applications.Flexibility: The King of MotionFlexibility and at prole make them the undisputed champion of motion control applications. Also available with our Gliderite coating that prevents binding in densely packed carriers. Our Motion Series cables are ready for 1-, 2- or 3-axes systems. Bulk cables are available in continuous lengths; or have Cicoil provide a complete assembly, 100% tested and ready to install.Go to Cicoil.com and see how easy it is to design the specic cable you need. Combine signal, power, tubing, video into a single high-ex at cable, then get an instant engineering drawing and price for your own cable! Plus Cicoil will deliver your custom at cable in two week or less. Check out this great design tool at Cicoil.com.Online Congurator661.295.1295 • www.cicoil.comnPerfect Fit: Cicoil’s patented extrusion process gives you exactly the cable you need, in the smallest possible package.nFlexible: The most exible cable you can buy, for the toughest motion applications.nExtreme Environments: Excels in temperatures from -65°C to 260°C, and under exposure to water, oil and the harshest chemicals. nQuality: Jet ghters rely on Cicoil cables, and so can you. Our ISO 9001 (AS9100) quality system ensures “mission-critical” reliability.Save Space with Custom Flat CablesCicoil custom cables solve many critical space, weight, and assembly issues. Packaging many conductors using at cables provides solutions in high performance, tight-tting military and aerospace applications. And Cicoil’s unique cable forming capability means cables can take virtually any shape, eliminating costly ex circuits or wiring costs.
Assemblies33661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Assemblies / p1of4 / 2021-08-25Cicoil Cable AssembliesCicoil will produce complete cable assemblies to your specications with the connectors of your choice.Cicoil has designed and manufactured thousands of custom cable assemblies. Our experienced engineers work closely with our customers, designing assemblies to meet the most demanding requirements, often in mission-critical applications. Challenge us with your toughest specs and give Cicoil’s design engineers an opportunity to show you why “Specials Are Standard at Cicoil.”Each and every cable assembly is 100% tested for electrical performance and physical dimensions before shipment to a customer. Our new, automated cable testing equipment is capable of inspecting 2,000 point-to-point connections, as well as hi-pot, resistance, and other electrical tests. Sophisticated SPC software allows rigorous six-sigma and Pareto analysis, for continuous improvement of our processes and products.Custom Cable Assemblies from Cicoil 34-35
Assemblies34661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Assemblies / p2of4 / 2021-08-25Cable Assemblies – “Specials Are Standard at Cicoil”Any Connector ‘D’ Sub, Micro ‘D’, and Nano connectors for small gauge wire Circular connectors, Mil-Spec and Industrial Lightweight Fiberglass ‘Header’ Connectors machined in-house Assemblies available with virtually any connector Custom Shapes – Formed Cables Custom shaped cable assemblies t precisely into compact spaces Complex formed shapes possible, using our 3D modeling software Formed cables retain all performance characteristics, including exibilityCicoil’s experienced engineering team works with customers to design cable assemblies that meet the specific needs of the toughest applications. Using advanced Solid Modeling and Cable Design Software, our engineers are able to meet the most difficult requirements of the most challenging, mission-critical applications. Custom-shaped cables, with complex molding, tubing, or vacuum requirements, utilizing a wide variety of connectors, are standard at Cicoil.See below for examples of our custom assemblies. Please call Cicoil to speak to an engineer about your application.Torsional FlexCables are easily slit for Torsional Flexing.
Assemblies35661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Assemblies / p3of4 / 2021-08-25Molding Molded connector backshells from hard or exible Mil-Spec materials Complex molding capabilities, including PCBs, metal plates, and insulated junctions All tooling designed and manufactured in-house, for fast prototypingTubing Tubing can be incorporated into any Cicoil Flat Cable Teon®, PVC, Polyurethane or Tygon® Tubing Options available, in standard sizes up to .375” diameter Flat ‘Tubing Only’ cables available, with a mix of virtually any tubing types and sizes Tubing Assemblies with Tri-Clamp Fittings, Barbed connectors or Luer Adapters availableSpace/Vacuum Space/Vacuum Cables meet NASA and ASTM E-595 Low Outgassing Requirements of <1% TML (Total Material Loss), and <0.1% CVCM (Collected Volatile Condensable Material) Cables are 100% tested and certied to be low outgassing Cables meet Class 1 Cleanroom requirements, with zero particulatesComplex 3D Mold-Making Capabilities
Assemblies36661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Assemblies / p4of4 / 2021-08-25Touch It! We’ll Send You a SamplePictures and words can’t fully describe Cicoil Flexible Flat Cable. We want you to have a sample in your hands to discover the flexibility and suppleness! Your cable sample will arrive neatly wrapped in our latest full color information kit. Use the request form at Cicoil.com to receive your Info Kit and Sample.Wet and WildThe water-repellent characteristics of patented Flexx-Sil™ jacketing make our cables immune to immersion, high humidity, fungus, and damp operating environments. Ideal for washdown, auto-clave, and other wet applications.High Flex Cables for Surgical RoboticsUnsurpassed flexibility, compact size, and custom shapes deliver the precision for medical robotics. Our patented Flexx-Sil™ flat cable jacketing is “self-healing” and halogen-free, so will not delaminate or degrade due to exposure to steam, water, alcohol, UV light, mechanical abuse, autoclave and many chemicals. Deliver Signal, Power, Liquid and Gas in a single, unified, highly flexible flat cable. PTFE tubing available for Motion Series Plus cables adds fluid dispensing or pneumatic control capabilities. Applications include medical diagnostic equipment, wafer-handling robots, painting robots, and automated pick-and-place equipment, etc. One Cable to Rule Them All!Our patented extrusion process allows wire gauges from 4 to 44 AWG, in virtually any configuration required. Power, Signal, Video, Coax, Cat 5e, plus Fiber Opitics and tubing for liquids and gases. Multiple wires and conduits are placed in the flat cable, with precise control of the wire spacing, the insulation thickness, and the overall cable shape. Designers can create exactly the cable needed.Any Wire. Any Shape. Any SizeGo to Cicoil.com and see how easy it is to design the specific cable you need. Combine signal, power, tubing, video into a single high-flex flat cable, then get an instant engineering drawing and price for your own cable! Plus Cicoil will deliver your custom flat cable in two weeks or less. Check out this great design tool at Cicoil.com.Online Congurator – Design Your CableThe Clear Choice 661.295.1295 • www.cicoil.comnWater, steam (autoclave) and chemical resistantn Combine power, signal, video and tubing in a single at cablen Conductors as small as 44 AWG support miniature electronics n10 million+ exing cycle lifenEliminate cable carrier tracksn Online Congurator delivers instant price quotesCicoil® High Flex Flat CablesFlexx-Sil™ Cables forMedical DevicesSoft, Supple, Inert& VersatileCicoil Flexx-Sil™ encapsulated cables are used in a wide variety of medical applications, including medical robotics, testing equipment, and also human medical devices like hearing aids. Flexx-Sil™, Cicoil’s patented silicone formulation, is approved for most medical applications, and medical grade cables for human implant use are also available.Find out how to simplify your product design and packaging with ultra exible at cables by visiting Cicoil.com today. www.Cicoil.com
Technology37661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p1of17 / 2021-08-25Cicoil Cable TechnologyCicoil Flat Cables are The Clear Choice™ for repetitive motion, vibration, harsh environments, temperature extremes, and conned spaces. They provide unsurpassed exibility, while simultaneously providing superior durability and the ability to operate in extreme environments. This section covers the many technical reasons why Cicoil at cables are The Clear Choice™ for the most demanding applications.Patented Extrusion Process | Key to Flexibility 38Top 10 Reasons to Use Flat Cable 38Flat Cable vs Round Cable 39Flexx-Sil™ Cable Technology 40Cleanroom Cables | Outgassing Performance 4 1Cicoil Flat Cables vs Alternatives 42-49Harsh Environments | Bend Radius and Life Cycles 50 Certifications and Approvals 52Current Ratings for Wire 53
Technology38661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p2of17 / 2021-08-25The Key to Superior Flexibility: Finer Base StrandsMost industrial wire is made up of multiple wire strands, called ‘base strands’, rather than being made of a solid piece of metal. Multiple strands make the wire more flexible, allowing it to bend and flex more easily than solid metal.The finer the base strand, the more flexible the wire. As shown above, standard 24 AWG wire has 7 base strands, ‘flexible’ wire has 19 base strands, while Cicoil High-Flex wire has 66 base strands. All Cicoil wire has base stranding of 40 AWG minimum, versus 36 AWG and larger in other ‘flexible’ wires. Cicoil wire conductors have2x to 3x more base strands than competitive ‘exible’ wire. This makes Cicoil wire extremely flexible, as wires with smaller base stranding will have a much smaller bend radius than wires with larger stranding. In addition, finer stranded wire has significantly longer life in flexing applications, as bending stresses are distributed across many more wires strands, thereby dissipating the strain on the overall wire conductor.Cicoil flat cables only use High-Flex, finely stranded wires, which are the most flexible wires available. The combination of our high-flex wire and the ultimate flexibility of our Flexx-Sil™ insulation make Cicoil flat cables the most flexible flat cable you can buy.When you need the ultimate in exibility, you need Cicoil.Cicoil High-Flex WireCicoil 24 AWG Wire has66 x 42 AWG Base StrandsCommon Flexible WireOther flexible wire has19 x 36 AWG Base StrandsStandard WireStandard 24 AWG Wire has7 x 32 AWG Base StrandsPatented Extrusion ProcessThe exclusive, patented Cicoil extrusion process produces flat cables in continuous lengths. Cicoil’s process combines multiple elements into a single flat cable, including: Single Conductor Shielded Conductors Tubing Cat 5e Camera Link™ Fiber Optics Coax and TwinaxThis capability can save you space and reduce much of complexity of your current cabling requirements.Cicoil Patented Technologies Cicoil invented the highest performance, most versatile flat cables on the planet, and we are extremely proud to have received numerous US and worldwide patents for our unique technologies and products. Cicoil’s ongoing innovations enable us to design and manufacture high performance cables that exceed the demands of our customers’ toughest applications.CURING PROCESSPROPRIETARYCOMPOUNDSFLEXX-SIL™ RUBBERPNEUMATIC TUBINGTWISTED TRIAD, SHIELDEDSINGLE CONDUCTOROPTIC FIBERSCOAXPatented Cicoil Extrusion Process®1. ReliabilityThe simplicity of flat cable with its parallel conductor geometry eliminates many of the common sources of wiring error and malfunction. Registration of the conductors is one-to-one with the terminating connector or board so that proper contact assignment is almost automatic.2. Weight ReductionThe use of flat cable often eliminates much of the conventional wire weight. Such things as redundant insulating materials, fillers and tapes are not required. In addition, the composite flat cable construction is so mechanically strong that it is not necessary to have large conductors for strength. The copper cross-section can thus be reduced to what’s required to carry the current load or to satisfy voltage drop requirements.3. Space EfficiencyEliminating unnecessary insulating, fillers and tapes reduces the bulk and physical volume of flat cables. In addition, their low profile enables them to hug surfaces and take advantage of tight, or normally-unused space. A rectangular cross-section allows flat cables to stack, or layer, with almost no wasted dead space between cables, providing maximum conductor density for a given volume.4. FlexibilityFlat cable is extremely flexible when bent in the plane of its thin cross-section. This flexibility has been utilized in applications where continuous or high flexing is necessary, e.g. drawers, doors, rotating arms, etc.5. Greater StrengthStrength is enhanced by the fact that all conductors and insulation equally share tensile loads.Top 10 Reasons to Use Flat Cables
Technology39661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p3of17 / 2021-08-25Flat Cables VS Round CablesCicoil flat cables have many advantages over round flex cables. Round cables feature insulated wires in a bundle which is surrounded by several layers of other material. The bundle is usually wrapped in either a textile material or a polymer chosen to minimize frictional heating as the cable moves. A PVC jacket surrounds these layers. In shielded cables, there is an additional set of layers consisting of another low-friction wrap, braided copper, and an overall jacket of PVC or other material selected for abrasion resistance. A problem with this construction is its use of multiple layers of insulation and special low-friction materials necessary to reduce the friction that arises as cables go through numerous cycles of repetitive motion.Cicoil’s Flat Cables make more efficient use of insulating material. It needs no low-friction tapes and fillers because conductors don’t move within the Flexx-Sil™ material that forms the outer jacket. And when bent in the plane of its thin cross section, Cicoil Flat Cables have inherently more flexibility than round cable. The flat form factor of Cicoil cables also provides better heat dissipation than round cables because there is more surface area for a given volume. The larger surface area lets flat cables carry a higher current level for a given temperature rise and for conductors of a given cross section. Conductors in flat cable also have a fixed geometry that makes for consistent and non-varying electrical qualities. The spacing of conductors in the extruded Flexx-Sil™ jacketing never changes as the cable moves. Thus cable impedance, inductance, capacitance, time delay, crosstalk, and attenuation all remain constant. Similarly, the conductors in the cable all have the same physical and electrical length. This, coupled with the fact that the dielectric dimensions stay constant, means that signal skewing and differential time delays between signals in the cable stay at a minimum.Cicoil flat cables form an inherently high-density interconnect system. Packing density of flat cable is higher than is possible with round cables. The fact that conductors can be visible in the clear Flexx-Sil™ extrusion simplifies coding, inspection, and tracing circuits for trouble shooting.Overall PVC Jacket Tinned Copper Braided Shield Textile Wrap PVC Inner Jacket Inner Textile Wrap Round Flex Cable Primary Insulation Copper Conductors Using Cicoil Flat Cable vs Round Cable allows an equivalent number of conductors in a much smaller space. When compactness is one of the attributes you are striving for, Cicoil Flat Cable is your best option.Flat Cables for Efficient PackagingCicoil Flat CableCommon Round Cable6. Consistent Electrical CharacteristicsBecause the conductor spacing is fixed and the geometry of the cable is constant, the electrical characteristics, such as impedance, capacitance, inductance, time delay, crosstalk and attenuation, are consistent.7. Greater Current Carrying CapacityFlat cables have greater surface-to-volume ratio than their round cable counterparts, consequently having higher efficiency in dissipating heat. This allows a higher current level for a given temperature rise and conductor cross-section.8. Reduced Skewing EffectsDue to the conductors having the exact physical and electrical length, along with a continuous and consistent dielectric, time delays between signals within a given flat cable are minimized.9. High-Density InterconnectionsThe cabling density achievable using flat cable is superior to that using conventional cable because of the high wire-to-cable cross-sectional density. Layers of flat cable are more effectively packed for higher conductor density than round cable.10. Ease of HandlingFlat cable folds and bends readily, conforms to the mounting area, fastens easily with clamps, adhesive, or double-faced tape, and eliminated the installation and lacing difficulties associated with round wire cabling. Visible conductor in a fixed position within the dielectric simplify coding, inspection and circuit tracing.Top 10 Reasons to Use Flat Cables
Technology40661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p4of17 / 2021-08-25Chemical ResistanceFor more information visit: http://www.cicoil.com/PDF/chemc2.pdf (11 page document)Durometer of Cicoil Flexx-Sil™ CablesCicoil’s Flexx-Sil™ Cable Jacket has a rating of Shore A65. This rating offers a tough yet flexible jacket that can resist impacts and other physical abuse. See the chart below for a simple way to relate shore ratings to common objects.Flexx-Sil™ CompositionThe description and composition of Cicoil Flexx-Sil™ jacket is as follows:Generic Description: Ultra pure, zero additives and no contaminants.Physical Form: Flexible yet durableColor: Translucent clearOdor: NoneNFPA Prole: Health 0 Flammability 1 Instability/ReactivityProperty Unit Test Method ValueTemperature range ºC ASTM D2137 & UL 94HB -104 to 260Hardness Shore A ASTM D2240 65-70Water Absorption % vol. change ASTM D471 <+5Tensile Strength PSI ASTM D412 >800Elongation at Break % ASTM D412 >400Tear Strength lb/in Die B ASTM D624 280Brittle Point ºC ASTM D2137 -70Flame Retardant Temp. ºC UL94HB & IEC332 260 minDecomposition Temp. ºC PTL 13057 446.2Combustion Temp. ºC PTL 13057 710.3EXTRA SOFTChewingGumRacquetBallRubberBandFLEXX-SIL™ JACKET SUPERTUFF™ JACKETPencilEraserTireTreadShoeHeelShoppingCart WheelHard HatSHORE A 10 20 30 40 50 60 70 80 90 95 100SHORE D 22 25 35 45 55 65 7520SHORE OO30 3540 50 55 60 70 80 90 95 98SOFTMEDIUMSOFTMEDIUMHARDHARD EXTRA HARDFlexx-Sil™ Cable Jacketing – Simply SuperiorCicoil invented the ribbon cable in 1956, and we have continually perfected and improved our technology to make high performance flat cables. After years of extensive R&D, Cicoil achieved a breakthrough in the method and materials used in making our flexible flat cables. In combination with our patented extrusion process, Cicoil developed an exclusive material which is ideally suited to high flex, high performance flat cable applications. This unique material is called Flexx-Sil™, and it combines the best aspects of the silicone rubber polymer with our exclusive extrusion process, to make the most advanced cable jacketing material available in the marketplace.Flexx-Sil™ cable jacketing provides the following high performance features:Rubber Hardness — The Shore ScalePhysical and Chemical Properties – physical and mechanical, per ZZ-R-765E Temperature Extremes – Operates at temperatures from -104°C to +260°C. Also stays exible in temps as low as -100°C. Flexibility – Has the natural exibility of silicone rubber, which is more than twice as exible as PVC or PTFE insulation. Crystal Clear – Flexx-Sil™ is crystal clear, and virtually translucent, clearly showing the purity and the cleanliness of the material Low Outgassing – The purity of Flexx-Sil™ means that it has very low outgassing characteristics, as the molecular bond is extremely strong, and the extrusion process results in virtually zero impurities. Durable – Flexx-Sil™ has a Durometer of 65 (Shore A), and can be provided in a SuperTu™ version with a Durometer of 85 (Shore A). Zero Particulates – The purity of Flexx-Sil™ results in a Class 1 Cleanroom rating, as the insulation material has zero particulates Halogen Free – Flexx-Sil™ jacketing is 100% Halogen Free Water/Chemical/UV Resistant – Flexx-Sil™ jacketing is water proof (including immersion), is resistant to most chemicals, and can operate for years in intense UV and sunlight conditions.
Technology41661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p5of17 / 2021-08-25Cicoil Cables Outgassing PerformanceCicoil outgassed cables meet the following outgassing requirements:DetailsCertied to Total Mass Loss (TML): <1.00% CVCM (Collected Volatile Condensable Materials): <0.10% Vacuum Bake (PSI): 10-6 torr Vacuum Bake (Temp): +160ºC Vacuum Duration (h): 48 hoursOther Ratings:NASA Outgassing Specication: Spec 1124 Standard Test Method for TML and CVCM: ASTM E595-93Notes: 1. Outgassing certificates available upon request. 2. Additional outgassing fee may apply, contact Cicoil for details.Cicoil Cleanroom CablesCicoil cables are suitable for use in class 1 to 100,000 cleanroom environments. No particulates are generated from Cicoil cables during use in static or dynamic applications.Product Type: Cicoil Ultraflex cables Product Family: Flat and round cables using Flexx-Sil™ jacket Eectivity: Cicoil flat and round cables Applicable Standard: ISO 14644-1 (ISO 3 - 8) Applicable Standard: FED STD 209E Verication Detail: Optical Particle counter and logging Time duration testing = 120 minutes Static and dynamic* specimen testing*Dynamic speed testing velocities varied from 0.2 to 10 ft./min.Air Flow Verication: Airow volume control baseline veried Air velocity control baseline veried Unidirectional ow area baseline veried Room air exchange rates baseline veried HEPA lter integrity veried Temperature / relative humidity baseline veriedDATAParticleStatic/Dynamic SIZEμmCOUNTParticles/cu-ft.Static 5.0 0Dynamic (0.2-10ft/min) 5.0 0Static 1.0 0Dynamic (0.2-10ft/min) 1.0 0Static 0.5 0Dynamic (0.2-10ft/min) 0.5 0Static 0.3 0Dynamic (0.2-10ft/min) 0.3 0Static 0.2 0Dynamic (0.2-10ft/min) 0.2 0Static 0.1 0Dynamic (0.2-10ft/min) 0.1 0
Technology42661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p6of17 /2021-08-25Extruded Flat Cables VS PTFE Flat Cables2-Piece Construction Extruded in continuous lengths Automated, climate controlled process Easy setup of wide variety of cables Flexx-Sil™ jacket has complete integrity, totally surrounding the cable elements in a durable one-piece construction1. 2-Piece Construction: Two PTFE shell halves are bonded together to produce the at cable jacket for the enclosed wires.PTFE Flat CablesExtruded Flat Cables2. Loose Wires: Wires are loose inside the two-piece cable jackets, rubbing against each during exing cycles, and requiring clamping devices to hold in place.3. High Stiness: PTFE jacketing is fairly sti, resulting in less exibility and higher bend radiuses than highly exible Flexx-Sil™ jacketing. Image above shows the greater natural exibility of Cicoil extruded at cable.4. Limited Variation. Manufacturing process to produce two-piece PTFE at cables results in a limited number of variations, and limited cable widths and lengths. Cable shape customizable and innitely repeatable -104°C to +260°C (-155°F to +500°F). Our at cable temperature capability exceeds even specialized PTFE jacketed cables.a. Coaxb. Optic Fibersc. Single Conductord. Twisted Triad, Shieldede. Gas or Liquid TubingCURING PROCESSPROPRIETARYCOMPOUNDSFLEXX-SIL™ RUBBERPNEUMATIC TUBINGTWISTED TRIAD, SHIELDEDSINGLE CONDUCTOROPTIC FIBERSCOAXPatented Cicoil Extrusion Process®abcde
Technology43661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p7of17 / 2021-08-25Extruded Flat CablesSTRENGTH & PERFORMANCEPTFE Flat CablesCable is solid, one-piece construction, due to the continuous extrusion process.Two-piece construction is an inherent weakness, as cable bonding is more likely to separate during operation, flexing, or under exposure to heat, cold, and/or chemicals.Each element in Cicoil cables are completely surrounded by a Flexx-Sil™ jacket, ensuring that they do not rub against each other and wear during operation.Conductors are loose inside the cable halves, which can lead to premature wear as they rub together during operation.Cicoil Flexx-Sil™ material is naturally much more flexible than PTFE, allowing tighter bend radiuses and longer flex life.PTFE is stiff, requiring larger bend radiuses, which takes up more space and limits flex life.Cicoil flat cables handle extreme heat and cold.PTFE cables burn and melt under exposure to fire, and become very stiff and crack in extremely cold temperatures.Flexx-Sil™ is ‘self-healing’ from small punctures, and cable damage can easily be repaired in the field.Any damage to PTFE shell can’t be repaired, necessitating a new replacement cable.Extruded Flat CablesVERSATILITY & COSTPTFE Flat CablesVirtually any outside cable profile can be created, exactly as the application requires.Pre-formed PTFE shells limit the cable profile and design.Wide variety of wire conductors, tubing, mounting strip, even fiber optics can be easily incorporated into the cable.Existing cable shells limit the variety of conductors, and range of sizes, that can be incorporated into a single cable.Cable conductors are completely surrounded by the Flexx-Sil™ jacket, requiring limited clamping.Loose wires require extensive clamping, adding weight, inertia, and cost to overall cable.Quickly and easily make new cables, virtually unlimited in width and length. New cables require only 100 foot minimum, and a small tooling cost.Existing cable shells limit cable width and length. For new cable designs, there are often high minimums and/or tooling costs.SummaryThe results are clear: Cicoil’s extrusion technology is the modern, automated way to produce high quality flat cables. PTFE flat cables are limited in reliability and performance, while often resulting in higher design and equipment costs.
Technology44661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p8of17 / 2021-08-25Extruded Flat Cables VS Molded Flat Cables Extruded in continuous lengths Automated, climate controlled process Easy setup of wide variety of cable and tubing Flexx-Sil™ cable jacket is produced with complete integrity and without any breaches through the encapsulation1. Wires are stretched between pins in a mold, and then liquid silicone plus additives are poured over the wires.Molded Flat CablesExtruded Flat Cables2. Multiple pours are needed to get proper thickness, and the molded cable takes 24-48 hours to fully cure.3. The cured cable is cut out of the mold, leaving sharp edges and multiple holes.4. The holes are lled in by hand, and the cable needs to be cured again. Cable shape customizable and innitely repeatablea. Coaxb. Optic Fibersc. Single Conductord. Twisted Triad, Shieldede. Gas or Liquid TubingCURING PROCESSPROPRIETARYCOMPOUNDSFLEXX-SIL™ RUBBERPNEUMATIC TUBINGTWISTED TRIAD, SHIELDEDSINGLE CONDUCTOROPTIC FIBERSCOAXPatented Cicoil Extrusion Process®abcde
Technology45661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p9of17 / 2021-08-25Extruded Flat CablesQUALITYMolded Flat CablesCable thickness precisely controlled to within .005˝, and conductor spacing accuracy to within .002˝.Large variation in thickness, and inaccurate conductor spacing. Gravity causes molded cables to be thicker at the bottom, and thinner at the top. Thickness will vary throughout the length of the cable.Computer-controlled extrusion process means entire cable exactly the same.Manual pouring and curing method means each cable will be unique, and there will be large variations among different cable batches.Continuous cable lengths, as long as neededLimited by physical mold, usually no longer than 6 feetExtruded cable cured continuously, with no debris or material contamination.Molded cables take many hours to fully cure. While curing, the gooey cable will collect dust, metal chips, and other airborne debris.Extruded Flat CablesSTRENGTH & RELIABILITYMolded Flat CablesCable is solid, one-piece construction, due to the continuous extrusion process.‘Bed of Nails’ in tool leaves many holes in cable when pulled from the mold. These holes are then filled by hand, and the cable is cured again, resulting in a weaker cable construction.Cicoil cables have rounded radiuses on each end, making them stronger and also more flexible.Molded cables are cut from the mold with Exacto blades, resulting in sharp, square edges. This greatly lessens the strength and the flexibility of the cable.Extruded Flat CablesVERSATILITY & COSTMolded Flat CablesVirtually any outside cable profile can be created, exactly as the application requires.Manual pouring process does not allow complex or variations in profile, as the molding material will conform to the shape of the conductors.Wide variety of wire conductors, tubing, mounting strip, even fiber optics can be easily incorporated into the cable.Conductor variation is limited, and tubing, fiber optics, etc., are not available.Quickly and easily make new cables, only $250 tooling cost.Expensive tooling for new cables, with long lead times.SummaryThe results are clear: Cicoil’s extrusion technology is the modern, automated way to produce high quality flat cables. The old fashioned method of hand pouring liquid to make molded cables is inefficient, inconsistent, and results in a lower quality flat cable.
Technology46661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p10of17 / 2021-08-25Extruded Flat Cables VS Round CablesExtruded Flat CablesQUALITYRound CablesThe use of flat cable often eliminates much of the conventional wire weight. Its low profile allows them to hug surfaces and take advantage of tight, or normally unused space. Flat cables occupy just 50% of the space of comparable round cables.Round cables require redundant insulating materials, fillers, tapes, textile wraps, additional layers, and lubricating agents, such as talc. Round cables tend to be bulkier than flat cables and take up more space.Composite flat cable construction is so mechanically strong that it is not necessary to have large conductors for strength. The copper cross section can thus be reduced to what’s required to carry the current load or to satisfy voltage drop requirements.Round cables have lesser surface-to-volume ratio than flat cables, resulting in the need for larger conductor sizes to handle higher current requirements due to increased heat.Computer controlled flat cable extrusion process allows for the same exact cable every time you order it and the crystal clear jacket is free of convolutions. Cable is cured continuously, with no debris or material contamination in an automated, climate-controlled environment.Round cable extrusion does not produce the exact cable every time it is manufactured. In addition, the outer jacket needs to have color additives to hide imperfections and convolutions. Most round cables are manufactured in open air environments exposed to contaminants, such as dirt and dust.Extruded Flat CablesSTRENGTH & PERFORMANCERound CablesCable is solid, one-piece construction. Strength is enhanced by the fact that all conductors and insulation equally share tensile loads. Rounded edges of cable absorb stress as well.Non-parallel conductors in a round cable contribute to unequal load sharing among all of the internal conductors, which limits the overall strength of the cable.The flat form factor of Cicoil cables provides better heat dissipation than round cables because there is more surface area for a given volume.Round cables incorporate multiple layers of wires, insulation, and fillers, so heat dissipation can be problematic, especially during repetitive motion cycles.Each element in Cicoil flat cables are completely surrounded by Flexx-Sil™ rubber, ensuring that they do not rub against each other and wear during operation.Internal wires found inside of round cables can rub against each other, which will wear and, in some cases, impede the overall functionality of the cable in flexing applications.Extruded Flat CablesVERSATILITY & COSTRound CablesFlexx-Sil™ jacketing is self-healing from small punctures, and cable damage can easily be repaired in the field.Any damage to PVC, polyurethane, PTFE, and silicone can’t be repaired, necessitating a new replacement cable.When bent in the same plane of its thin cross section, Cicoil Flat Cables have inherently more flexibility than round cables. The spacing of conductors never changes as the cable moves, so each conductor flexes the same amount in the same plane.When bent, the inner conductors of a round cable are not held securely within the round bundle causing wires to impede each other’s movement, resulting in sticking, friction, and corkscrewing. Unlike a flat cable, the round cable tends to move in a different sequence during each flex cycle.
Technology47661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p11of17 / 2021-08-25Extruded Flat Cables VS Woven Braid CablesExtruded Flat CablesQUALITYWoven Braid CablesComputer controlled flat cable extrusion process allows for the same exact cable every time you order it and the crystal clear jacket is free of convolutions. Cable is cured continuously, with no debris or material contamination in an automated, climate-controlled environment.Woven design provides an outer textile material to cover a flat layer of inner wires and twisted pairs. However, the inner components are not separately encased, so they will not be in the exact same place every time. Inner components can be exposed to contaminants.The tear-resistant outer Flexx-Sil™ rubber jacket is also self-healing from small punctures. Anti-kinking design is tangle free and excellent in constant motion and extremely tight bend radius applications.The textile material is exposed to harsh operating environments. During flexing and tight bend radius applications, the woven cables are prone to kinking and fatigue.Extruded Flat CablesSTRENGTH & PERFORMANCEWoven Braid CablesCable is solid, one-piece construction. Strength is enhanced by the fact that all conductors and insulation equally share tensile loads. Rounded edges of cable absorb stress as well.Flat woven cables do not have rounded edges and lack the mechanical strength of a solid, one-piece extruded design. Conductors don’t share equal tensile loads.Each element in Cicoil flat cables are completely surrounded by Flexx-Sil™ rubber, ensuring that they do not rub against each other and wear during operation.Inner components are not separately encased within their flat profile. They will rub against each other during any movement, which results in wear and tear.Outer jacket with a durometer of Shore A65 is similar to the heel of a shoe, and provides excellent mechanical protection to inner wires.The outer sleeving may provide some protection of the inner wires, but they do not provide resistance to shock, vibration, and mechanical stress.Extruded Flat CablesVERSATILITY & COSTWoven Braid CablesFlexx-Sil™ jacketing is self-healing from small punctures, and cable damage can easily be repaired in the field.Once the outer woven wrap is damaged, the inner components are exposed, leading to damage, failure, and replacement.When bent in the same plane of its thin cross section, Cicoil Flat Cables have inherently more flexibility than round cables. The spacing of conductors never changes as the cable moves, so each conductor flexes the same amount in the same plane.Woven cables are not made for constant motion applications. When flexed, the inner components will corkscrew, tangle, and kink, leading to cable failure.The crystal clear Flexx-Sil cable is easy to inspect and provides excellent aesthetics.With the exception of air gaps, woven wraps cover the inner components, providing no visibility and leaving the cable prone to undetectable defects.
Technology48661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p12of17 / 2021-08-25Extruded Flat Cables VS Loose WiresExtruded Flat CablesQUALITYLoose WiresThe simplicity of flat cable with its parallel conductor geometry eliminates many of the common sources of wiring error and malfunction. Registration of the conductors is one-to-one with the terminating connector or board so that proper contact assignment is almost automatic.Loose wires, aka spaghetti wires, in bundles become very messy, are hard to identify and are prone to wiring errors and malfunction.Computer controlled flat cable extrusion process allows for the same exact cable every time you order it and the crystal clear jacket is free of convolutions. Cable is cured continuously, with no debris or material contamination in an automated, climate-controlled environment.Wires are exposed to harsh environments, pulling, abrasion, and damage.The tear-resistant outer Flexx-Sil™ rubber jacket is also self-healing from small punctures. Anti-kinking design is tangle free and excellent in constant motion and extremely tight bend radius applications.Wires are exposed to punctures, kinking, entanglement, and impede each other’s performance in flexing and bending applications, which leads to damage and failure.Extruded Flat CablesSTRENGTH & PERFORMANCELoose WiresCable is solid, one-piece construction. Strength is enhanced by the fact that all conductors and insulation equally share tensile loads. Rounded edges of cable absorb stress as well.Scattered wires in a loose bundle operate independently of each other. Individual wires are exposed to greater tensile loads and added stress.The flat form factor of Cicoil cables provides better heat dissipation than round cables because there is more surface area for a given volume.Wires wound into a bundle plus an outer protective covering, so exposure to heat dissipation can become an issue and cause wire failure.Outer jacket with a durometer of Shore A65 is similar to the heel of a shoe, and provides excellent mechanical protection to inner wires.Wires and pairs are exposed to mechanical stress and abrasion.Extruded Flat CablesVERSATILITY & COSTLoose WiresFlexx-Sil™ jacketing is self-healing from small punctures, and cable damage can easily be repaired in the field. Inner wires are completely encased in Flexx-Sil™ jacket.Loose wires can easily be damaged from exposure to the application they are utilized in, so require expensive tubing, sleeving, or conduit to protect them as well.Simple Plug-n-Play cable saves time and money.Expensive cable management products are required to organize loose wire bundles, which involves more time-consuming labor, costs, and potential for error.The crystal clear Flexx-Sil cable is easy to inspect and provides excellent aesthetics.Inspection of bundled wires takes time, and additional materials required to hide the unorganized bundle increase costs.
Technology49661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p13of17 / 2021-08-25Extruded Flat CablesQUALITYFlex CircuitsEach wire can have its own shield. Shielding attained by using adjacent conductors or flat shield planes above and below the circuit trace layer; results in larger and stiffer assemblies.High strand count, high flexibility and flex life. Can be withstand >10 million+ flex cyclesHave solid, flat conductors and flex life below a million cycles.Extruded Flat CablesSTRENGTH & RELIABILITYFlex CircuitsCICOIL flat cable is durable and will withstand severe impact and rough handling.Flex circuits are very ridged and susceptible to micro- cracks and failure in severe vibration applicationsCICOIL flat cable is durable and will withstand severe impact and rough handling.Flex circuits are more fragile. They can be easily dented, bent and damaged from minor impact or improper handling.Extruded Flat CablesVERSATILITY & COSTFlex CircuitsCan include twinax, coax, digital communications, power and twisted pair wires. Pneumatics and fiber optics can also be included.Single conductors only (typical).Can be formed to custom fit in equipment to aid installation to make installation a quick task.Can be shaped to fit the installation path. This eases assembly and maximizes real estate use.Inexpensive custom cable tooling of $250. Tooling is made in-house in less than a day.Large initial tooling costs. Once made, tooling is expensive to change or new tooling may be required.Short lead time of 1- 2 weeks using wire from our large inventory.Long lead times are typical and flex circuits does not lend itself to rapid prototyping.Cable is produced in continuous lengths (bulk) that can be cut to suit various applications.Flex circuits are individually made and the size is fixed according to the tooling.Flat cable can be installed in tight spaces where equivalent round cable won’t fit.Flex circuits can be used in small spaces where equivalent round cable won’t fit.Extruded Flat Cables VS Flex CircuitsFlex circuits have some useful properties; however, many designers try to make use of them beyond the limits of the flex circuit’s capability. The reality is that despite the name, flex circuits have limited flexing capability. Over flexing and stress can cause cracks and breaks in the brittle circuit tracing. When failure is not an option, Cicoil flat cable provides true flexibility and tremendous resilience to shock and vibration. And our flat cables are available in miniature configurations, with wires as small as 44 AWG.
Technology50661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p14of17 / 2021-08-25Handling Harsh EnvironmentsCicoil’s patented extrusion process is at the heart of manufacturing extreme environment cables that retain electrical properties and exibility over a long life.Chemical ResistantFlexx-Sil™ jacketing produces cables that are resistant to acids, bases, alcohol, de-ionized water, fuels, oils, and more.Cleanroom UseCicoil flexible flat cable is non-particulating, and is suitable for Class 1 cleanroom and vacuum environments.Low OutgassingCicoil cables meet NASA Outgassing Specification 1124. Certified Total Mass Loss (TML) is <1.00%, and Collected Volatile Condensible Material (CVCM is <0.10%.)SaltwaterCicoil Flexx-Sil™ jacketed flat cables suffer no degradation from the corrosive effects of salt spray or seawater exposure, meeting all applicable specifications for shipboard use and marine environments.Low HumidityNeither extremely dry conditions nor low humidity will adversely affect either the flexibility or life of the Flexx-Sil™ jacketing on Cicoil flat cables and cable assemblies.WaterproofFlexx-Sil™ jacketing enjoys inherent water repelling characteristics and produces superior water resistant cables. Cicoil waterproof cables are impervious to immersion, high humidity, fungus, and damp operating environments, making our cables ideal for washdown, autoclave, and other wet applications. Low TemperatureTemperature to: -104°C (-155°F). Cicoil flat cable exceeds the low temperature capability of typical PVC jacketed cables and even specialized PTFE jacketed cables.High Temperature Temperature to +260°C (+500°F). Cicoil flat cable exceeds the high temperature capability of typical PVC jacketed cables and even specialized PTFE jacketed cables.
Technology51661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p15 of17 / 2021-08-25Bend Radius and Life CyclesSpecifying cable in applications characterized by repeated motion should allow for two key qualities: allowable bend radius and life cycles under constant exing.The bend radius of Cicoil Flat cable, like that of any flat cable, depends on the gauge of the wire and type of conductors used in the cable. In general, the finer the gauge of the conductors, the smaller the allowable bend radius. To calculate the bend radius of Cicoil flat cable, simply multiply the cable thickness by a factor 4-6x. Most industrial automation equipment today operates 24/7, often with robotic elements that execute rigorous motions repeatedly, sometimes thousands of times a day. These applications stress the electrical cabling. Standard cabling will not last in these applications, as the cables are not designed to flex continuously. Flat cables are best for continuous flexing. Their wire conductors can individually flex in a single plane, which provides optimum flex life.Under continuous flexing, conductors containing multiple strands of fine-gauge wire will last the longest. Wire in Cicoil cables are typically composed of 40 AWG wire (or even finer gauge). The finer-gauge base wire exhibits less coldworking under constant flexing. And minimal cold-working enables Cicoil cables to last through tens of millions of exing cycles.2x1xPTFE Jacket CableSilicone Extruded Cable. Twice the natural flexibility.T = CABLE THICKNESSR = BENDING RADIUS = B x TFunctionally comparable flat cables using PTFE jackets have a bend radius more than twice as large as Cicoil flat cables. Fitting in a more compact space, Cicoil flat cables serve in uses that may not be suitable for PTFE cables.Ultraviolet ResistantOur Flexx-Sil™ formulation enables ultraviolet resistant cables that withstand exposure to high levels of ozone with no adverse effects. Cicoil cables will perform well even after 50+ years in direct sunlight.Extreme Radiation ResistantCicoil cables are radiation-hardened components, able to withstand up to 7 Mrads of gamma radiation exposure without severe degradation. This was proven in a test that measured the mechanical properties of Flexx-Sil™ material after undergoing 2.5, 5, and 7 Mrads of gamma radiation.See the gamma radiation test results.Cicoil on the MoonCicoil Flat Cables have been enduring the harshest environment there is for over 60 years. NASA chose Cicoil ribbon cables to serve astronauts of the Apollo 11 mission in 1969, and have been a valued client of Cicoil ever since.Cicoil’s Biomedical Harnesses reached the Moon with the first steps of Neil Armstrong and Buzz Aldrin. Every U.S. Astronaut in the history of NASA has worn a Cicoil Biomedical Harness.
Technology52661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p16of17 / 2021-08-25Reach Declaration of ConformanceCicoil products do not discharge (during normal use and disposal) any dangerous substances defined in REACH and for human health nor the environment. Cicoil complies with the conditions of Article 7 paragraph 1, Chapter 1 / Title 11.Cicoil declares that our products meet or exceed the requirements set out by Regulation (CE) No. 1907/2006, called REACH.Cicoil Flexx-Sil™ and Compliance to European Directives RoHSCicoil Flexx-Sil™ jacket is compliant to the ROHS directive.This declaration is made regarding the following directives of the European Parliament: European Commission Directive 2002/96/EC relating to Waste Electrical & Electronic Equipment (WEEE Directive) European Commission Directive 2002/95/EC relating to the Restriction of the use of certain Hazardous Substances in electrical & electronic equipment (RoHS Directive) European Commission Directive 2003/11/EC relating to restrictions on the marketing and use of certain dangerous substances and preparations (pentabromodiphenyl ether, octabromodiphenyl ether) Furthermore, Cicoil Flexx-Sil™ jacket does not utilize ozone-depleting substances (low molecular weight CFCs, HCFCs, HFCs or HCs) as additives or within the manufacturing process.The prohibited substances are not normally present in the product(s) mentioned above at or above the specified guide concentrations* 0.1% (by weight) lead, mercury, hexavalent chromium, PBB, PBDE, PentaBDE or OctaBDE; and 0.01% (by weight) cadmium.LEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMLEAD FREERoHSCOMPLIANTCICOILSMCicoil Flammability Testing ApprovalsUL 94V-0 — Cicoil cable has been tested at UL Laboratories and shown to:A. Not have any specimens that burn with flaming combustion for more than 10 seconds after either application of the test flame.B. Not have a total flaming combustion time exceeding 50 seconds for the 10 flame applications for each set of five specimens.C. Not have any specimens that burn with flaming or glowing combustion up to the holding clamp.D. Not have any specimens that drip flaming particles that ignite the dry absorbent surgical cotton located 12 inches below the test specimen.E. Not have any specimens with glowing combustion that persists for more than 30 seconds after the second removal of the test flame.FAA — FAA Flammability TestingCicoil cable has been tested and complies with FAA Title 14 CFR, PART 25—Subpart D, § 25.853 (a) compartment interiors, [Amdt. 25-116, 69 FR 62788, Oct. 27, 2004] Appendix F to Part 25, Part I (a)(1)(ii).Cicoil cable is confirmed to be self-extinguishing. The average after-flame time must not exceed 15 seconds: and flaming drippings must not continue to burn for more than 5 seconds after falling to the cabinet floor. This test was conducted in accordance with the standards established by The Federal Aviation Administration, as described above.Cicoil’s Quality System is ISO 9001 certified, to the rigorous AS9100 Aerospace standard. Our average customer quality rating is 99.98%, and our quality system received an extremely high 96.4% score during a recent AS9100 quality audit.Each and every cable assembly is 100% tested for electrical performance and physical dimensions before shipment to a customer. Our new, automated cable testing equipment is capable of inspecting 2,000 point-to-point connections, as well as hi-pot, resistance, and other electrical tests. Sophisticated SPC software allows rigorous six-sigma and Pareto analysis, for continuous improvement of our processes and products.Certificates of compliance, including actual test data, are available upon request. We retain all inspection and quality records for at least ten years, so customers can be confident that the products they receive meet every specification and quality standard required, and that we have documentation to back it up.Almost every aircraft flying today uses Cicoil cables, in mission-critical flight control and instrumentation functions. For over fifty years, Cicoil cables have performed flawlessly in thousands of flight, aerospace, space, medical and industrial applications Mission-critical equipment, and often human life, depends on the quality of Cicoil cables, and each and every person at Cicoil is justly proud of our flawless quality record.Certificate of RegistrationThis certifies that the Quality Management System ofCicoil, LLC24960 Avenue TibbittsValencia, California, 91355, United Stateshas been assessed by NSF-ISR and found to be in conformance to the following standard(s):AS9100D with ISO 9001:2015*Audited in accordance with AS9104/1:2012 Requirements for Aviation, Space, and Defense Quality Management System Certification Programs. NSF-ISR is accredited under the Americas Aerospace Quality Group Registration Management Committee.Scope of Registration:Manufacturer of flexible flat cables and cable assemblies.Tom Chestnut,Sr Vice President - ISR, NSF-ISR, Ltd.Certificate Number: C0392251-AS3Certificate Decision/Re-Issue Date: 17-OCT-2019Certificate Issue Date: 04-NOV-2019Expiration Date *: 03-NOV-2022QualityCicoil cables exceed the most stringent regulatory requirements. Approvals from laboratories such as UL and compliance to worldwide standards including FAA, CE, CSA, RoHS, REACH, and others demonstrates the superiority of Cicoil technologies.
Technology53661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesCable Technology / p16of17 / 2021-08-25Current Rating Guide for WirePlease see the current rating guide below. You may use this guide to obtain estimated current ratings for wire.This guide is for reference only. Current ratings will vary depending on each individual application. Careful calculations must be taken to assure proper current loads on wire. Always implement circuit interruption for the protection of wire and cable.Wire Gauge (AWG)Diameter Inches Diameter mm Ohms/ 1000 ftOhms/kmMaximum amps for chassis wiringOOOO 0.46 11.684 0.049 0.16072 380OOO 0.4096 10.40384 0.0618 0.202704 328OO 0.3648 9.26592 0.0779 0.255512 2830 0.3249 8.25246 0.0983 0.322424 2451 0.2893 7.34822 0.1239 0.406392 2112 0.2576 6.54304 0.1563 0.512664 1813 0.2294 5.82676 0.197 0.64616 1584 0.2043 5.18922 0.2485 0.81508 1355 0.1819 4.62026 0.3133 1.027624 1186 0.162 4.1148 0.3951 1.295928 1017 0.1443 3.66522 0.4982 1.634096 898 0.1285 3.2639 0.6282 2.060496 739 0.1144 2.90576 0.7921 2.598088 6410 0.1019 2.58826 0.9989 3.276392 5511 0.0907 2.30378 1.26 4.1328 4712 0.0808 2.05232 1.588 5.20864 4113 0.072 1.8288 2.003 6.56984 3514 0.0641 1.62814 2.525 8.282 3215 0.0571 1.45034 3.184 10.44352 2816 0.0508 1.29032 4.016 13.17248 2217 0.0453 1.15062 5.064 16.60992 1918 0.0403 1.02362 6.385 20.9428 1619 0.0359 0.91186 8.051 26.40728 1420 0.032 0.8128 10.15 33.292 1121 0.0285 0.7239 12.8 41.984 922 0.0254 0.64516 16.14 52.9392 723 0.0226 0.57404 20.36 66.7808 4.724 0.0201 0.51054 25.67 84.1976 3.525 0.0179 0.45466 32.37 106.1736 2.726 0.0159 0.40386 40.81 133.8568 2.227 0.0142 0.36068 51.47 168.8216 1.728 0.0126 0.32004 64.9 212.872 1.429 0.0113 0.28702 81.83 268.4024 1.230 0.01 0.254 103.2 338.496 0.8631 0.0089 0.22606 130.1 426.728 0.732 0.008 0.2032 164.1 538.248 0.53Metric 2.0 0.00787 0.200 169.39 555.61 0.5133 0.0071 0.18034 206.9 678.632 0.43Metric 1.8 0.00709 0.180 207.5 680.55 0.4334 0.0063 0.16002 260.9 855.752 0.33Metric 1.6 0.0063 0.16002 260.9 855.752 0.3335 0.0056 0.14224 329 1079.12 0.27Metric 1.4 .00551 .140 339 1114 0.2636 0.005 0.127 414.8 1360 0.21Metric 1.25 .00492 0.125 428.2 1404 0.2037 0.0045 0.1143 523.1 1715 0.17Metric 1.12 .00441 0.112 533.8 1750 0.16338 0.004 0.1016 659.6 2163 0.13Metric 1 .00394 0.1000 670.2 2198 0.12639 0.0035 0.0889 831.8 2728 0.1140 0.0031 0.07874 1049 3440 0.09
Technology54661-295-1295 Cicoil.comFlexible Flat Cables & Cable AssembliesOnline Cable Configurator – Easy as 1-2-3!Add Conductors & Tubing to Your CableDesign Your Own Flat Cable in Just Minutes! Over 10 Million Potential Configurations. Try It Today!Remove or Rearrange Parts as Needed and SubmitGet a Drawing with PricingCustom design your own cable in real time at Cicoil.com with our online Cable Configurator. It features drag & drop simplicity to design any flat cable, and get an immediate drawing and quote.Cables can be constructed of many elements, including shielded Power conductors, shielded Signal conductors, Video and Coax wires, Tubing for Fluids or Gases, and other design elements like Cicoil’s patented StripMount™ fastening strip. Immediately after constructing a flat cable design, you will receive an engineering drawing and a price quotation. Try out the Cicoil Flat Cable Configurator today. Find it at:https://www.cicoil.com/flat-cable/configurator123Cable Configurator / p1of1 / 2021-08-25
World HeadquartersCicoil24960 Avenue Tibbitts Valencia, CA 91355 Contact us directly for Quotes, Sales and Support. Phone: 1-661-295-1295 Email: atcable@cicoil.comWebsite: www.cicoil.comReps | DistributorsTo find your local Cicoil Rep or Distributor, please call: 1-661-295-1295 Or look up on our website:cicoil.com/repsTechnical SupportFind detailed technical documentation, How-To videos, and much more at: cicoil.com/techsupportOr call:1-661-295-1295Worldwide Availability, Sales and SupportCicoil Products Also Available Through:Digi-Key Corporationwww.digikey.com1-800-344-4539Electro Sonic Groupwww.e-sonic.com1-800-567-6642Master Electronicswww.masterelectronics.com1-888-473-5297Onlinecomponents.comwww.onlinecomponents.com1-602-685-390055Cicoil Flat Cable and Cable Assemblies are available worldwide through a network of sales offices, representatives and distributors.
CofiguratorPromoHere24960 Avenue Tibbitts Valencia, CA 91355 661.295.1295 • www.cicoil.comOur cables and cable assemblies are used in a wide variety of medical applications, including automated medical equipment, medical robotics, testing equipment, and also human medical devices like hearing aids.Semiconductor EquipmentMilitary/AerospaceIndustrial Automation/Motion ControlMedicalOur high performance cable assemblies are used in a wide variety of extremely demanding motion control and industrial automation applications. Linear motor stages, multi-axis motion systems, robotic equipment, servo axes, and packaging equipment all use Cicoil flexible cables to achieve optimum, reliable performance.Cicoil has thousands of cable assemblies operating in the most sophisticated missile, fighter aircraft, commercial aviation, and space applications. Cicoil’s Flexx-Sil™ cables are ideal for mission-critical military and aerospace applications.Cicoil Flexx-Sil™ Cables and Cable Assemblies have been used by most major semiconductor equipment manufacturers, in some of the most demanding applications in the industry. Wafer robots, deposition equipment, cleaning robots, and wafer inspection are some of the applications that use Cicoil cables.Cicoil has been the leader in high performance at cable technology for over fty years. Our cables are used in thousands of demanding applications, in a multitude of industries. Whenever high performance at cables are needed, Cicoil is The Clear Choice.#5000 8/21 15MPRINTED IN U.S.A.