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How to repair AGI Wire Reels

Wire and plugs can be replaced on AGI wire reels to optimize data quality and minimize field downtime

Wire Specification: Use 18 AWG copper wire with 16 or more strands and insulation rated to 600V which is polyvinyl chloride (PVC). If you specify TFFN, it will have two layers with PVC inside and a harder nylon (polyamide) outer jacket to help it slip over objects that may snag it. Avoid solid core wire. TFFN is going to be more robust. It is normal to see small cracks in the outer nylon jacket if it kinks or bends tightly. The inner layer is the primary insulation.

Splicing: It is possible to splice in new wire with a technique involving a locking type knot before you twist the wire and heat shrink over it. This will create a splice which is close to the same strength as the nearby uncut wire. The technique is beyond the scope of this article. Simply twisting wire is not recommended. Use of crimp connectors is also possible but crimp connectors will eventually loosen in this application and AGI does not recommend using them. It is best to completely replace all wire with no splices.

Spool Sizes: To avoid very long sections, it is beneficial to  join smaller reels together in series from one to the next to avoid very long and heavy singular wire reels. Heavier reels promote dragging wire which tends to damage it faster.

Plugs: You can replace the male banana plug with any full size banana plug that will fit 18 AWG wire and is rated to 600V.  These are very common and easy to find. Models with a slip over cover and small set screw are easier to work with and do not require soldering.

Noise: It is very important to avoid using unshielded reels.  All AGI reels with plastic and metal housings are shielded and tested.  In general, off the shelf plastic reels will induce noise from EM primarily  if they are not properly shielded and tested. On the field side, you can test your reels for various noise issues with a reciprocal test found HERE. AGI Reels are found HERE