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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
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
2.3.1 Solid conductor with PE2 insulation and PA sheathing
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
2.2. Standard dimensions and weights of winding wires for operating voltages of up to 690 V
November 2001
2.2.3 Solid conductor with PE2 insulation and PA sheathing
2.2. Standard dimensions and weights of winding wires for operating voltages of up to 690 V
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
2.2. Standard dimensions and weights of winding wires for operating voltages of up to 690 V
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
2.2. Standard dimensions and weights of winding wires for operating voltages of up to 690 V
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
2.3.1 Solid conductor with PE2 insulation and PA sheathing
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:
Delivery lengthsin m:
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
Delivery lengthsin m:
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
Mean value (µ)Limit of variation (µ-3)*)
November 2001
4.2.2 PE2-insulatedwinding 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)*)
4.2 Electrical properties of plastic-insulated winding wires
Ω. c
m
kVkV
/mm
Mean value (µ)Limit of variation (µ-3)*)
t /°C
t /°C
t /°C
November 2001
4.2.3 HT4 -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 1.8 / 3.0 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)*)
Mean value (µ)Limit of variation (µ-3)*)
4.2 Electrical propertiesof plastic-insulated winding wires
Ω. c
m
kVkV
/mm
t / °C
t /°C
t /°C
November 2001
Specific insulation resistance ; Ω . cm
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
Absolute insulation resistance
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