plastic-insulated winding wires

November 2001

Plastic-Insulated Winding Wires

Norddeutsche Seekabelwerke GmbH & Co. KG

P.O. Box 14 64

D-26944 Nordenham

Germany

Tel: +49 4731 82 0

Fax: +49 4731 82 1520

www.nsw.com

November 2001

Plastic-Insulated Winding Wires

1. General Information

2. Design, Dimensions and Weights

3. Delivery Lengths and Packaging

4. Physical Properties

5. Testing

The following information is intended to describe the product NSW delivers to its customers. It is not a guarantee of properties.

November 2001

1. General Information

1.1 Description

1.2 History

November 2001

Submersible motors are used as wet motors in fluids, andthus the wires used in submersible motor windings requirehigh-quality insulation that is completely impervious toliquids. NSW winding wires are specially designed to meetthe requirements of this application. They have proventheir durability and reliability over many decades andensure trouble-free operation and long motor life. NSWwinding wires consist of a solid or multi-stranded barecopper conductor insulated by means of a plastic sheathmade of one of the following materials:

PVCPE2HT4

Electric motor manufacturers have found that PVC-insu-lated winding wires can be used for voltages up to 1,000 Vand at temperatures up to 60 °C. PE2-insulated windingwires are generally used in submersible motors operatingunder higher voltages and at temperatures of up to approx-imately 85 °C. The increased resistance to heat is achievedby cross-linking the polyethylene. NSW HT4-insulatedwinding wires are the most effective solution for operatingtemperatures of up to approximately 115 °C. To ensurelong-term stability with this material NSW recommends aminimum sheath wall thickness of 0.6 mm. The thickness

1.1. Description of the sheath wall is a function of the operating voltage.For voltages of 3 kV and more NSW recommends the useof a semiconducting layer between the copper conductorand the insulating sheath.

The surface of winding wires which are insulated with PE2 have a thin sheathing of polyamide (PA) forsurface protection.

November 2001

NSW (Norddeutsche Seekabelwerke GmbH & Co. KG)has been developing and manufacturing underwater cablesand wires since the company was founded in 1899. Initially,NSW produced wires for transoceanic telegraph and telephone cables. On the basis of this experience the company began producing plastic-insulated winding wiresfor submersible motors (wet-stator motors) in 1946.Decades of work and research ensure the high quality ofthis product.

NSW manufactures and tests its products in accordancewith its own in-house quality management system whichhas been certified by Lloyd’s Register Quality Assurance inaccordance with ISO 9001.

1.2. History The PVC blend used in NSW winding wires was developed specially for this purpose, and over the course ofmany years the materials chosen for NSW´s PE2 and HT4insulation have proved their worth and reliability.

A polyamide sheath provides good mechanical protectionfor NSW´s PE2-insulated winding wires.

NSW´s state-of-the-art laboratories continually test the suitability of new insulating materials for use in its windingwires. NSW has broad experience in the manufacture of special wires, and for many decades its partners have trusted the high quality and performance which they have- justifiably - come to expect.

November 2001

2. Design, Dimensions and Weights

2.1 Design

2.2 Standard dimensions and weights of winding wires for operating voltages of up to 690 V

2.2.1 Solid conductor with PVC insulation

2.2.2 Stranded conductor with PVC insulation

2.2.3 Solid conductor with PE2 insulation and PA sheathing

2.2.4 Stranded conductor with PE2 insulation and PA sheathing

2.2.5 Solid conductor with HT4 insulation

2.2.6 Stranded conductor with HT4 insulation

2.3 Standard dimensions and weights of winding wires for operating voltages of 3 kV


2.4 Standard dimensions and weights of winding wires for operating voltages of 6 kV

2.4.1 Solid conductor with semi-conductive layer, PE2 insulation and PA sheathing

Tolerance of external diameterfor wall thickness w in mm

Up to 2.5

Above 2.5 up to 7.0

Above 7.0 up to 12.0

Above 12.0 up to 15.0

w≤ 1.0

± 0.05

± 0.10

± 0.15

± 0.20

1.0 < w≤ 1.5

-

± 0.10

± 0.15

± 0.20

1.5 < w≤ 2.5

-

± 0.15

± 0.20

± 0.20

2.5 < w≤ 3.5

-

± 0.20

± 0.20

± 0.20

Half the permissible tolerance ofthe external

diameter

Maximumeccentricity

November 2001

Solid conductor: Cross section in mm2: Diameter in mm:0.283 to 16.6 0.6 to 4.6

Stranded conductor: Cross section in mm2:From approx. 3.5

Insulation wall thickness : Depending on dimensions and operating voltagefrom 0.3 mm

PA sheathing: From 0.1 mm to 0.2 mm wall thickness, depending on external diameter of the insulated conductor

Special dimensions available on request

Tolerance levels:

The permissible tolerance levels for the external diameter of NSW plastic-insulated winding wiresare, depending on the thickness of the walls, as follows:

2.1. Design

External diameterin mm

November 2001

Cu crosssection

mm2

Cudiameter

mm

PVCdiameter

mm

PVC wall thickness

mm

0.6360.7850.950

1.131.331.54

1.772.012.01

2.272.542.84

3.143.463.80

4.154.524.91

4.915.315.31

5.736.166.61

7.078.048.04

10.2

1.601.701.80

1.902.102.20

2.302.302.40

2.502.602.70

2.903.103.20

3.303.603.50

3.703.603.80

3.704.004.10

4.204.404.70

5.20

0.350.350.35

0.350.400.40

0.400.350.40

0.400.400.40

0.450.500.50

0.500.600.50

0.600.500.60

0.500.600.60

0.600.600.65

0.80

2.2.1 Solid conductor with PVC insulation

2.2. Standard dimensions and weights of winding wires for operating voltages of up to 690 V

Cuweightkg/km

5.666.998.46

10.211.813.7

15.717.917.9

20.222.625.2

28.030.833.8

37.040.343.7

43.747.347.3

51.054.858.8

62.971.680.8

90.6

Total weightkg/km

7.729.22

10.85

12.715.017.1

19.321.121.7

24.226.829.6

33.237.040.2

43.648.750.8

52.554.656.3

58.564.468.7

73.182.393.2

107

0.901.001.10

1.201.301.40

1.501.601.60

1.701.801.90

2.002.102.20

2.302.402.50

2.502.602.60

2.702.802.90

3.003.203.40

3.60

November 2001

Cu crosssection

mm2

DesignCu

diametermm

PVCdiameter

mm

PVC wallthickness

mm

Cuweightkg/km

Total weightkg/km

7.95

9.0810.012.1

13.214.014.9

16.118.120.1

21.225.7

19 x 0.73

19 x 0.7819 x 0.8219 x 0.90

19 x 0.9419 x 0.9719 x 1.00

19 x 1.0419 x 1.1019 x 1.16

27 x 1.0027 x 1.10

3.65

3.904.104.50

4.704.855.00

5.205.505.80

6.156.80

4.90

5.205.405.90

6.106.406.60

6.907.207.40

7.808.50

0.625

0.6500.6500.700

0.7000.7750.800

0.8500.8500.800

0.8500.850

71.5

81.790.2

109

119126134

145162180

191232

84.1

95.6105126

136147156

169188205

218263

2.2.2 Stranded conductorwith PVC insulation


November 2001



Cu crosssection

mm2

PE2 wallthickness

mm

Cudiameter

mm

PE2diameter

mm

Externaldiameter

mm

Cuweightkg/km

1.541.772.01

2.272.542.84

3.143.463.80

4.154.524.91

5.315.736.16

6.617.078.04

9.0810.211.3

12.613.916.6

0.400.400.40

0.400.400.40

0.450.450.45

0.450.500.50

0.500.550.55

0.550.600.60

0.650.650.65

0.700.750.75

1.41.51.6

1.71.81.9

2.02.12.2

2.32.42.5

2.62.72.8

2.93.03.2

3.43.63.8

4.04.24.6

2.22.32.4

2.52.62.7

2.93.03.1

3.23.43.5

3.63.83.9

4.04.24.4

4.74.95.1

5.45.76.1

2.42.52.6

2.72.82.9

3.13.33.4

3.53.73.8

3.94.14.2

4.34.54.7

5.05.25.4

5.76.16.5

PA wallthickness

mm

0.100.100.10

0.100.100.10

0.100.150.15

0.150.150.15

0.150.150.15

0.150.150.15

0.150.150.15

0.150.200.20

13.715.717.9

20.222.625.2

28.030.833.8

37.040.343.7

47.351.054.8

58.862.971.6

80.890.6

101

112123148

Totalweightkg/km

16.518.721.0

23.526.128.8

31.535.738.8

42.246.249.8

53.558.062.1

66.371.280.4

90.7101112

124138164

November 2001

2.2.4 Stranded conductor with PE2 insulation and PA sheathing


Cu crosssection

mm2

PA external diameter

mmDesign

Cudiameter

mm

PE2diameter

mm

PA wallthickness

mm

7.959.08

10.012.1

13.214.0

16.118.1

21.225.7

5.305.60

5.806.30

6.506.80

7.307.60

8.208.90

19 x 0.7319 x 0.78

19 x 0.8219 x 0.90

19 x 0.9419 x 0.97

19 x 1.0419 x 1.10

27 x 1.0027 x 1.10

3.653.90

4.104.50

4.704.85

5.205.50

6.156.80

4.905.20

5.405.90

6.106.40

6.907.20

7.808.50

PE2 wallthickness

mm

0.6250.650

0.6500.700

0.7000.775

0.8500.850

0.8250.850

0.200.20

0.200.20

0.200.20

0.200.20

0.200.20

Cuweightkg/km

Totalweightkg/km

71.581.7

90.2109

119126

145162

191232

83.594.9

104125

135145

165185

216260

November 2001

2.2.5 Solid conductor with HT4 insulation


Cu crosssection

mm2

Cuweightkg/km

Cudiameter

mm

HT4diameter

mm

HT4 wall thickness

mm

1.542.01

2.272.84

3.143.80

4.526.16

7.079.08

10.2011.90

13.717.9

20.225.2

28.033.8

40.354.8

62.980.8

90.6106

1.41.6

1.71.9

2.02.2

2.42.8

3.03.4

3.63.9

2.42.8

2.93.1

3.23.4

3.64.0

4.55.0

5.25.5

0.500.60

0.600.60

0.600.60

0.600.60

0.750.80

0.800.80

Totalweightkg/km

18.824.9

27.633.2

36.342.8

49.965.7

77.998.8

109126

November 2001

2.2.6 Stranded conductor with HT4 insulation

2.2. Standard dimensions and weights of winding wires for operating voltages ofup to 690 V

Cu crosssection

mm2

HT4 wallthickness

mmDesign

Cudiameter

mm

HT4diameter

mm

Totalweightkg/km

7.9513.2

16.118.1

21.225.2

0.6750.700

1.0501.050

0.8250.850

19 x 0.7319 x 0.94

19 x 1.0419 x 1.10

27 x 1.0019 x 1.30

3.654.70

5.205.50

6.156.50

5.006.10

7.307.60

7.808.20

Cuweightkg/km

71.5119

145162

191227

89.0142

184203

227266

November 2001


2.3. Standard dimensions and weights of winding wires for operating voltages of 3 kV

Cu crosssection

mm2

PE2 wallthickness

mm

Cudiameter

mm

PE2diameter

mm

PA externaldiameter

mm

Cuweightkg/km

3.804.524.52

5.315.735.73

6.167.078.04

9.0810.210.8

11.313.213.2

13.913.914.5

15.215.916.6

1.401.151.40

1.401.151.40

1.151.401.50

1.151.401.40

1.401.151.40

1.151.401.15

1.401.401.40

2.202.402.40

2.602.702.70

2.803.003.20

3.403.603.70

3.804.104.10

4.204.204.30

4.404.504.60

5.004.705.20

5.405.005.50

5.105.806.20

5.706.406.50

6.606.406.90

6.507.006.60

7.207.307.40

5.305.005.50

5.705.305.80

5.406.106.60

6.006.806.90

7.006.807.30

6.907.407.00

7.607.707.80

PA wallthickness

mm

0.150.150.15

0.150.150.15

0.150.150.20

0.150.200.20

0.200.200.20

0.200.200.20

0.200.200.20

33.840.340.3

47.351.051.0

54.862.971.6

80.890.695.7

101118118

123123129

135142148

Totalweightkg/km

50.954.458.2

66.166.270.3

70.583.696.1

98.7115121

126139144

145151152

164170177

November 2001

2.4.1 Solid conductor with semi-conductive layer, PE2 insulation and PA sheathing

2.4. Standard dimensions and weights of winding wires for operating voltages of 6 kV

Cu crosssection

mm2

PAdiameter

mm

Cudiameter

mm

HLdiameter

mm

PE2diameter

mm

3.804.524.52

5.315.316.16

7.078.048.04

8.048.049.08

10.210.211.3

12.612.616.6

7.606.507.60

6.707.707.90

8.308.407.60

9.108.509.50

9.008.909.20

9.209.509.60

Cuweightkg/km

33.840.340.3

47.347.354.8

62.971.671.6

71.671.680.8

90.690.6

101

112112148

Totalweightkg/km

72.667.078.3

75.185.794.7

107116107

125117138

140139152

162166200

2.202.402.40

2.602.602.80

3.003.003.20

3.203.203.40

3.603.603.80

4.004.004.60

2.802.802.80

3.002.903.10

3.503.603.70

3.603.604.00

4.204.004.20

4.404.505.00

7.206.207.20

6.407.307.50

7.808.007.10

8.608.009.00

8.608.408.80

8.809.009.20

HLmm

PE2mm

Wall thickness

0.300.200.20

0.200.150.15

0.250.200.25

0.200.200.30

0.300.200.20

0.200.250.20

2.201.702.20

1.702.202.20

2.152.201.70

2.502.202.50

2.202.202.30

2.202.252.10

PAmm

0.200.150.20

0.150.200.20

0.250.200.25

0.250.250.25

0.200.250.20

0.200.250.20

November 2001

3. Delivery Lengths and Packaging

3.1 Standard delivery lengths

3.2 Delivery forms and packaging

3.2.1 Reel and drum dimensions

November 2001

3.1. Standard delivery lengths

When packed on reels with conical cores

Delivery lengths for winding wires with stranded conduc-tors are agreed upon individually with the customer.

Deliveries can contain a portion of short lengths down tominimum lengths of 400 m for solid conductors and 200 mfor stranded conductors.

Ø of winding wire in mm:

1.60 to 2.202.302.402.502.602.702.802.903.003.103.30

Delivery lengthsin m:

up to 3500up to 3200up to 2900up to 2700up to 2500up to 2300up to 2100up to 2000up to 1900up to 1700up to 1500

When packaged in coilsInternal diameter of coil: 300 mm

When packed on reels with cylindrical cores

The standard delivery lengths for winding wires withsolid conductors are:


up to 700up to 1150up to 600up to 500up to 400

Ø of copper conductor in mm:

0.40 to 0.650.70 to 1.001.10 to 1.601.70 to 2.702.80 to 2.90


up to 2000up to 1800up to 1500up to 1000up to 2000up to 1500

or wooden drums

Reel type (size)

350350350350500500800

Ø of copper conductor

in mm:0.40 to 0.901.00 to 1.101.20 to 1.301.40 to 1.601.70 to 2.002.10 to 2.50over 2.50

November 2001

As a rule, winding wires are delivered on reels.As a special form of delivery, they can also be supplied as coils.

The packaging used is selected to provide the most suitableprotection against damage or impairment.

Examples of packaging:

- Wire coils wrapped individually in crepe paper

- Reels protected by a layer of cardboard

- Wooden drums protected with a layer of cardboard or panelled with boards.

For the dimensions of the reels and drums used, please see Section 3.2.1

3.2. Delivery forms and packaging

November 2001

3.2.1 Reel and drum dimensions

Reel type d4 l1 l2 s Nominal weight in kg

350

500

800

400 KS

355

500

800

400

224

250

400

260 / 175

36

30

78

80

200

300

510

463

160

260

440

400

20

20

35

38 / 25

Approx. 1.8

Approx. 7.0

Approx. 24

Approx. 2.6

Reel dimensions in mm:

d1 d2 / d3

Drum type d4 l1 l2 s Nominal weight in kg

07

08

09

10

710

800

900

1000

355

400

450

500

80

80

80

80

520

520

690

710

400

400

560

560

48

48

48

48

Approx. 25

Approx. 31

Approx. 47

Approx. 71

Drum dimensions in mm:

d1 d2

November 2001

4. Physical Properties

4.1 Physical of plastics used for winding wire insulation

4.2 Electrical properties ofplastic-insulated winding wires

4.2.1 PVC-insulated winding wire

4.2.2 PE2-insulated winding wire

4.2.3 HT4-insulated winding wire

4.2.4 Summary of some of the electrical properties of plastic-insulated winding wires

November 2001

4.1. Physical properties of plastics used for winding wire insulation IEC 60811-1-1

IEC 60811-1-1

IEC 60811-1-1IEC 60811-1-2

IEC 60811-1-1IEC 60811-1-2

IEC 60811-1-3

IEC 60811-3-1

DIN 534483Supplementary sheet 1DIN 53483-1DIN 53483-2

IEC 60093

DIN VDE 0303-21

HT4

≥ 10

≥ 100

≥ 10

≥ 100

115≤ 4

115≤ 5

2.6

1017

85

PE2

≥ 10

≥ 100

≥ 10

≥ 100

90≤ 4

90≤ 25

2.3

1018

70

PVC

≥ 10

≥ 90

≥ 10

≥ 90

70≤ 4

70≤ 40

3...4

1015

60

UnitTypical Data

Recommended storage and processingtemperature: Approx. 20 °C

Testing characteristics

Tensile strength(at (23±5) °C

Elongation at break (at (23±5) °C)

Tensile strength after aging(7 x 24 h, 80 °C)

Elongation at break after aging(7 x 24 h, 80 °C)

Longitudinal shrinkageTesting temperatureShrinkage

Hot penetration Testing temperaturePenetration depth

Dielectric constant r(at 20 °C, 800 Hz)

Specific insulationresistance(at 20 °C)

Dielectric breakdownstrength(at 20 °C, 50 Hz)

N/mm2

N/mm2

%

%

%°C

%°C

Ω . cm

kV/mm

Standards

November 2001

4.2 Electrical properties of plastic-insulated winding wires

4.2.1 PVC-insulated winding wire

Specific insulation resistance ; Ω . cm

Instantaneous breakdown voltage U; kV, 50 Hz

Instantaneous breakdown field strength E; kV/mm, 50 Hz

Voltage increase: 100 V/sWire 1.1 / 2.0 mm ø

*) Limit of variation (µ-3) : 99.7% of all breakdown

values are above the given limit

Absolute insulation resistance

Mean value (µ)Limit of variation (µ-3)*)

t /°C

t /°C

t /°C

Ω. c

mkV

kV/m

m


November 2001

4.2.2 PE2-insulatedwinding wire









4.2 Electrical properties of plastic-insulated winding wires

Ω. c

m

kVkV

/mm


t /°C

t /°C

t /°C

November 2001

4.2.3 HT4 -insulated winding wire










4.2 Electrical propertiesof plastic-insulated winding wires

Ω. c

m

kVkV

/mm

t / °C

t /°C

t /°C

November 2001


Average value of instantaneous breakdown voltage E; kV/mm, 50 Hz

Voltage increase : 100 V/sPE2, PVC wire 1.1 / 2.0 mm øHT4 wire 1.8 / 3.0 mm ø


4.2.4 Summary of some of the electrical properties of plastic-insulated winding wires

4.2 Electrical propertiesof plastic-insulated winding wires

Ω. c

m

kV/m

m

Average value of instantaneous breakdown voltage U; kV, 50 Hz

kV

t / °C

t /°C

t /°C

5. Testing

5.1 Final testing

5.1.1 Dimensions and mechanical tests

5.1.2 Electrical tests

5.2 Extended duration testing

5.3 Type tests

November 2001

November 2001

Routine tests at room temperature

• Diameter, wall thickness, concentricity, surface characteristics

• Tensile strength, elongation at break, shrinkage

Routine testing in mains water bath

• High-voltage testing

The test is carried out with alternating current (50 Hz)after the winding wire has been in a bath of water at atemperature of approx. 15°C for 24 hours.

Test voltage and test duration for standard dimensions:

For operating voltages of up to 1 kV:

Utest = 4 kV Test duration = 1 minute

For operating voltages of over 1 kV:

Utest = 2 Uop + 1 kV Test duration = 10 minutes

5.1 Final testing

5.1.1 Dimensions and mechanical tests

5.1.2 Electrical tests

Directly after the alternating current test, the insulationresistance of the winding wire is tested using a direct current of at least 500 V.

Comments:

If a customer´s specifications have been agreed upon in a contract, the customer’s requirements apply.

If desired by the customer, a test certificate 3.1 B inaccordance with the German industrial standard DINEN 10204 can be issued certifying that the product hassuccessfully passed the final test.

November 2001

5.2 Extended durationtesting

Time-dependent characteristics of the specific insulationresistance under an alternating current load of 600 V in a water bath at a temperature of 80 °C

PE2-insulated Winding WireWire 1.1 / 2.0 mm ø

PVC-insulated Winding WireWire 1.1 / 2.0 mm ø

HT4-insulated Winding WireWire 1.8 / 3.0 mm ø

Hours

Hours

Hours

Ω. c

mΩ

. cm

Ω. c

m

November 2001

At regular intervals, samples of wire are taken from the current production batch and subjected to type testing.

During type tests the

Specific insulation resistanceInstantaneous breakdown voltageInstantaneous breakdown field strength

are tested as a function of the temperature (t).

Testing procedure

Winding wire samples are stored in a tempered testing basinfilled with water. Starting at 20 °C, the temperature in the testing basin is increased in steps of 20 °C . The samples remain at each temperature level until the insulation resistance is constant.

The specific insulation resistance of the samples is monitored over the entire duration of the test. In order to determine the immediate disruptive voltage and the immediate disruptive field strength, some of the samples aredestruction-tested at the end of each temperature level.

5.3 Type tests

plastic-insulated winding wires

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