What makes 1000 V wire different from regular wire?

[duragezic]

At work we've started into some high voltage applications so we now stock 1000 V wire. It seems quite similar to the "regular" cheap GXL wire but has a teflon coating and the wire strands inside are shiny (coated with tin I believe). Of course we have non-high voltage teflon wire that is tin coated as well due to its temp rating of up to 150° C.

Why is there a need for 1000 V wire if the voltage doesn't actually travel through it? If we're using higher voltages I'd assume the currents are lower thus less heat, plus the 1000 V wire is only 18ga, while some of our 12 and 24 V applications require 12ga due to higher currents.

 

[duragezic]

cmon you wire experts!

 

[miniMUNCH]

dielectric specfications of the insulation are different for low voltage and high voltage wire. Teflon isn't exactly the cheapest insulation but it is better insulator and has better chemical resistance than cheaper alternatives.

 

[Antisocial Virge]

Not sure if I know the answers but I know that running higher voltage is more efficient and thus has less voltage drop than the same size wire at lower voltage. Thats why 240 wire is usually thicker than 480 wiring for the same distance, the 240 has a larger voltage drop. I know the battery backup in cellular towers use like 12 runs of 4aug for a 24V system. Its nuts.