Omega XT-NN-24 Specification

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Custom Wire and Sleeving

interconnect anode

cathode

interconnect

Cell

Repeat

Unit

electrolyte

for Fuel Cell Applications

In the planar or stack style high temperature Solid Oxide Fuel Cell (SOFC) design the interconnect materials are constantly exposed to both oxidizing and reducing

⻬ Solid Oxide Fuel Cell Anode and

Interconnect Wire

⻬ High Temperature 1200°C (2200°F) ⻬ Nickel, Stainless and Platinum

Based Alloys

⻬ Multiple Shapes, Diameters

and Insulations

⻬ Increased Surface Area, Improved

Electrical Performance

⻬ Low Resistance at High Temperature ⻬ Low Coefficient of Expansion

Fuel cell designs contain various configurations of anode, cathode and electrolyte materials to electrochemically convert a fuel into an electrical current. The power generation of these devices range from milliwatt to megawatts and the performance is dependent upon various factors of efficiency and voltage output of the design itself. Additional factors include the physical configuration including the interconnection or wiring of the cells in a combination of series and parallel circuits.

Basic fuel cell design

conditions, along with temperature gradients and operational temperatures up in the 850 to 1100°C range (1562 to 2012°F). Not only must the interconnect materials perform reliably in these extreme conditions, the interconnect wiring itself must possess the ability to efficiently carry and transfer the generated electricity.

XT-NN-24, round design, shown larger than actual size.

In consideration of the fuel cell operational environments combined with OMEGA’s long term experience in servicing this industry the following anode and interconnect insulated wire, along with braided XC sleeving and our Super OMEGACLAD XL sensors are outlined in following pages as proven high performance product solutions for fuel cell and other advanced power generation related applications.

XT-NNR-08/156-CRG, corrugated design, shown larger than actual size.

Detail of round design.

temperature

Detail of corrugated

design.

The interconnection or interconnect as referred to in fuel cell terminology is an extremely critical consideration and component in the design since the interconnect itself is the electrical connection from the fuel cell and transfers the created energy to the load.

A critical factor involving the interconnect materials is the power or wattage generated by a fuel cell is commonly proportional to the operational temperature of the device. One of the most powerful and efficient designs at this time are high temperature solid oxide fuel cells. These designs have megawatt power generation capabilities, and have achieved 60% plus energy efficiency. They also have the ability to work with various input fuels and are clean energy technology.

Detail of flat design.

XT-NN-24-FLT, flat design, shown larger than actual size.

Detail of star design.

XT-NN-14-STR, star design, shown larger than actual size.

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Custom Wire and Sleeving



for Fuel Cell Applications

⻬ Braided and Wrapped

Insulated Wire Designs

⻬ 3000 Volt Performance ⻬ Multi-Conductor Designs ⻬ High Temperature Wire

Harness and End Connection Sleeving

1.57 to 12.7 mm (1⁄16 to 1⁄2")

Fuel cells like any other power generation device require very high levels of reliability, the design itself including the materials utilized in the device is an extremely critical factor in achieving the expected performance. This is especially true in high powered, high temperature based fuel cells.

XTW-XT-NN-24 passed 60 second 3000 volt high test.

Detail of round design.

In the high temperature Solid Oxide Fuel Cell (SOFC) there are 2 primary designs at this time. The stack or planar orientation is one design where the cells are arranged as stack of plates to form a cube. In the tubular design the cells are multiple layers of tubes. In both cases as the electricity is created from the cells it is necessary to transfer the power from each cell through high temperature insulated interconnect wire and to bundle the multiple wires in a high temperature harness at specific locations or connection points.

OMEGA®XT or XC duplex insulated wire along with the XC braided sleeving has provided the answer to these requirements, and now the new XTW-XT wire design provides the capabilities 3000 volt performance. This new design is a combination of OMEGA’s proprietary wrapping, braiding and other insulation capabilities.

Detail of round design.

XT-NN-NN-24 duplex design, shown larger than actual size.

XTW-XT-NN-24, wrapped/braided design, shown larger than actual size.

XC-38, sleeving design, shown larger than actual size.

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Custom Wire and Sleeving



for Fuel Cell Applications

⻬ Extensive In-House

Product Development and

Precision heat treating on OMEGALLOY®wire.

Manufacturing Capabilities

⻬ Wire Processing Includes

Braiding, Wrapping, Forming, Heat Treating and other Technologies

⻬ Electrical High Pot and CE

Testing

⻬ Long Term and Cycling

Temperature Testing

⻬ ISO Approved Precision

Calibration

OMEGA’s extensive manufacturing and product development capabilities provide ongoing solutions to fuel cells currently in operation along with those in various stages of development and refinement. The industry utilizes both OMEGA’s high volume capacity and technological capabilities to move fuel cell towards a source of competitive, reliable and clean power generation

Horizontal wrapping of alumina fiber insulated wire.

opportunities. The implementation of OMEGA’s product run the full spectrum of fuel cells including PEMFC (Proton Exchange Mechanism), PAFC (Phosphoric Acid),

Vertical wrapping insulation process.

MCFC (Molten Carbonite) SOFC (Solid Oxide) utilized in transportation, military and stationary type power generation and other applications.

AVAILABLE FOR FAST DELIVERY!

To Order (Specify Model Number)

Insulation Conductor Conductor Conductor Overall

Model Number Configuration Material** Configuration Dimensions Dimensions

XT-NN-24-*

XT-NN-24-FLT-*

XT-NN-14-STR-*

XT-NNR-008/156-CRG-*

XTW-XT-NN-24-* Nextel 3000V High Pot OMEGA N

XT-NN-NN-24-*

XC-116 Braided Nextel Sleeving No Wire No wire No wire

XC-38 Braided Nextel Sleeving No Wire No wire No wire

Individually Nextel Braided

Wires and Nextel Overbraid round formed wires (0.088 x 0.132)

Braided

Nextel

Braided Single flat

Nextel

Braided Single star

Nextel

Braided Single corrugated

Nextel

Wrapped and Braided

Performance Test

OMEGA N

Single round 0.5 mm 24 AWG

formed wire (0.020 round)

formed wire

formed wire***

formed wire

Single round

formed wire

Two individual

x 0.76 mm wide

(0.010 x 0.030)

2.56 major

x 1 mm minor

(0.101 x 0.042)

0.017 thick x 3.2 wide x 1.3 mm high

(0.007 x 0.128 x 0.051)

0.5 mm (0.020) 2.5 mm (0.100)

0.5 mm (0.020)

0.25 thick

1.77 mm (0.070)

1 x 1.5 mm

(0.040 x 0.060)

2.9 to 3 mm

(0.115 to 0.120)

3.9 x 2.3 mm

(0.153 x 0.091)

2.2 x 3.3 mm

1.57 ID x 2.3 mm OD (0.062 x 0.91)

9.5 ID x 10.6 mm OD

(0.375 x 0.420)

* Minimum 100 foot order required for the wire based products, long continuous lengths available as well. Ordering Example: XT-NN-24-1000 single layer of braided Nextel insulation on a 24 gage Omega N®round bare wire—Consult Sales

Engineering for pricing. Additional conductor diameter and configurations available—replace the wire size number designation with the desired wire gage—for example

replace the number “24” in XT-NN-24-1000 with the number “20” to create a 20 AWG - 0.8 mm (0.032 diameter) wire. ** Additional conductor materials available—replace the Omega N

or CSS for a custom stainless steel alloy designed for high temperature fuel cells, or PLN for a nickel core platinum coated alloy. Consult sales engineering for details.

*** Note the STR configuration wire cannot be reduced in diameter, it can be increased. Consult sales engineering for details. Sleeving is available in addition diameters and is stocked in 10, 25, 50 and 100 ft lengths, long continuous lengths are available.

NN with appropriate alloy designation—for example NP for Omega P®alloy,

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Page 4

Super OMEGACLAD®XL Probes

00.0

805.0

810.0

815.0

820.0

825.0

830.0

051015202530354045505560

Elasped Time - Weeks

s u

i sle

C s

e e rg

eD ni

er u

ta repme

T tseT

Super OMEGACLAD® XL Inconel® 600 Probe

* Tests conducted using ungrounded probes in an open-air, electric, muffle furnace versus a Type "S", NIST-traceable standar d. Individual results may vary depending on customer application. Inconel

is a registered trademark of Special Metals Corporation.

nconel

600

probe failure

Standard Limits of Error

Special Limits of Error

pecial Limits of Error

Standard Limits of Error

⻬ Super OMEGACLAD XL Thermocouple Probes ⻬ Technological Advance in Temperature Measurement ⻬ High Temperature Utilization up to 1335°C (2440°F) ⻬ Proven Long Term Stability–Low Temperature Drift ⻬ Small Diameters Sensors with Large

Diameter Performance

⻬ Custom and Stock Designs ⻬ K and OMEGALLOY

Omega brings you the Super OMEGACLAD XL Thermocouple sensor family of products, an exclusive development and manufacturing innovation in thermocouple technology. These temperature sensors created with OMEGA’s state of the art proprietary processes for mineral insulated (MI) thermocouple cable and automated sensor manufacturing techniques is an industry leading solution for the high temperature and low drift performance expected in many fuel cell applications. This performance includes increasing the temperature and durability to levels never previously achieved in the fast responding small diameter thermocouple probes.

N Thermocouple Calibrations

ils

Universal connector and clamp included

NMQXL-125U-6,

miniature size

probe, $29.

Products shown

smaller than

actual size.

NQXL-14G-12,

standard size

probe, $30.

Both models

include mating

connector and

cable clamp.

0.8 mm (0.032") Dia., Type K Maintained at 815°C (1500°F)

uper OMEGACLAD

Inconel®600 probe failure

L vs Inconel

Standard Limits of Error

Special Limits of Error

Super OMEGACLAD®XL probe

Special Limits of Error

Standard Limits of Error

00,

Standard Dimension—Quick-Connect Probes

Alloy/ANSI Color Code inches ANSI Color Code G/E U G/E U

MINIATURE CONNECTOR 6" 12"

CHROMEGA®- 0.010" KMQXL-010[*]-[**] $51.00 $71.00 $52.40 $72.40 $1.40 ALOMEGA XL 0.032" KMQXL-032[*]-[**] 31.00 33.00 31.70 33.70 0.70 Sheath 0.040" KMQXL-040[*]-[**] 31.00 33.00 31.70 33.70 0.70

OMEGA-P®- 0.020" NMQXL-020[*]-[**] $31.00 $33.00 $31.70 $33.70 $0.70 OMEGA-N XL 0.040" NMQXL-040[*]-[**] 31.00 33.00 31.70 33.70 0.70 Sheath 0.062" NMQXL-062[*]-[**] 27.00 29.00 27.85 29.85 0.85

Note: Probes with 0.032" diameter and larger are supplied with molded transition joints. Smaller-sized probes are supplied with stainless steel transition joints. Stripped leads standard.

[*]Specify junction type: “G” (Grounded), “E” (Exposed) or “U” (Ungrounded). [**]Specify length in inches: “6”, “12”, “18” or “24”.

Ordering Example: KMQXL-032U-12, Super OMEGACLAD®sheathing type K calibration (CHROMEGA

ALOMEGA®) 0.08 mm (0.032") diameter ungrounded junction thermocouple probe 300 mm (12") length with a miniature Quick–Connect SMPW male connector attached. Female connector and wire clamp hardware included.

Sheath Dia. Model Number Junction Type

0.020" KMQXL-020[*]-[**] 31.00 33.00 31.70 33.70 0.70

0.062" KMQXL-062[*]-[**] 27.00 29.00 27.85 29.85 0.85

0.125" KMQXL-125[*]-[**] 27.00 29.00 28.75 30.75 1.75

0.032" NMQXL-032[*]-[**] 31.00 33.00 31.70 33.70 0.70

0.125" NMQXL-125[*]-[**] 27.00 29.00 28.75 30.75 1.75

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Small Size, Big Performance!

Typical 0.8 mm (0.032") Dia. Type K probes have a maximum tempera ture of 700°C (1260°F). Our Super OMEGACLAD

0.8 mm (0.032") Dia. probe took on 815°C (1500°F) for 3 years and even reached 1000°C (1832°F) for 2 months!

Probes shown ~50%

smaller than actual size.

Approx. response time—ungrounded in water