1. Scope

This specification covers polyester enameled round copper wire, class 155 to be used in winding and wiring of transformer, motor,generator and so on. (Hereinafter referred to as wire)

2. Polyester enameled round copper wire: class 155

3.Conductor and Insulating Film

3.1 Conductor
The conductor shall be transformed into annealed copper wire.

3.2 Insulating Film
Baking Polyester insulating varnish shall make the insulating film of the wire Class155 on the conductor uniformly and perfectly.

4. Characteristics

The characteristics of wire shall comply with table 2, when tested by 5.0.

Item Characteristics Test Method
Appearance (1)To comply with IEC60317-0-1 clause 3.3 requirements 5.1
Dimensions To comply with IEC60317-0-1 clause 4 requirements. 5.2
Conductor resistance To comply with IEC60317-0-1 clause 5 requirements 5.3
Elongation To comply with IEC60317-0-1 clause 6 requirements 5.4
Springiness To comply with IEC60317-0-1 clause 7 requirements 5.5
Flexibility and Adherence To comply with IEC60317-0-1 clause 8 requirements, Film free from cracks such as to expose the conduct. 5.6
Heat shock To comply with IEC60317-0-1 requirements, Film free from cracks such as to expose the conduct 5.7
Cut-through No failure shall occur within 2 min at a temperature of 270 ℃ 5.8
Resistance to abrasion (nominal conductor diameter from 0.25 up to and including 2.5 mm) The wire shall meet the requirement given in Table 3 5.9
Resistance to solvent To comply with IEC60317-0-1 clause 12 requirements, No bubble or blister in film 5.10
Broken-down voltage comply with IEC60317-0-1 clause 13 requirements 5.11
Continuity of insulation comply with IEC60317-0-1 clause 14 requirements 5.12
Temperature index comply with IEC60317-0-1 clause 15 requirements 5.13
Pine hole test comply with IEC60317-0-1 clause 23 requirements 5.14

5. Test methods

5.1 Appearance
The appearance shall be examined, as wound on bobbin, for existence of flaw and stain; by naked eye to determine its appearance.
No flaws; Smooth surface and uniform color; Not Sticky
IEC60317-0-1 3.3
The film coating shall be essentially smooth and continuous, free from streaks, blisters and foreign material when examined with normal vision, as wound on the original spool or reel.
When agreed upon between the user and supplier,examination using 6x to 10x magnificationshall be used for wires with a nominal diameter less than 0.1 mm.
5.2 Dimensions. The dimensions shall be measured by using of a micrometer.
The series of preferred nominal conductor diameters shall correspond to series R 20 accordingto ISO 3. The actual values and their tolerances are given in Tables IEC standard Enameled copper wire size IEC-317-0-1.
5.3 Conductor Resistance The electrical resistance test

Nomimal conductor diameter(mm) Resistance Ω/m Nomimal conductor diameter(mm) Resistance Ω/m
Minimum Maximum Minimum Maximum
0.018 60.46 73.89 0.036 15.16 18.42
0.020 48.97 59.85 0.040 12.28 14.92
0.022 40.47 49.47 0.045 9.705 11.79
0.018 60.46 73.89 0.036 15.16 18.42
0.025 31.34 38.31 0.050 7.922 9.489
0.028 24.99 30.54 0.056 6.316 7.565
0.032 19.13 23.38 0.063 5.045 5.922

5.4 Elongation. The elongation test

Nomimal conductor diameter(mm) Elongation % Nomimal conductor diameter(mm) Elongation % Nomimal conductor diameter(mm) Elongation %
0.018 5 0.180 20 1.800 32
0.020 6 0.200 21 2.000 33
0.022 6 0.224 21 2.240 33
0.025 7 0.250 22 2.500 33
0.028 7 0.280 22 2.800 34
0.032 8 0.315 23 3.150 34
0.036 8 0.355 23 3.550 35
0.040 9 0.400 24 4.000 35
0.045 9 0.450 25 4.500 36
0.050 10 0.500 25 5.000 36
0.056 10 0.560 26
0.063 12 0.630 27
0.071 13 0.710 28
0.080 14 0.800 28
0.090 15 0.900 29
0.100 16 1.000 30
0.112 17 1.120 30
0.125 17 1.250 31
0.140 18 1.400 32
0.160 19 1.600 32

5.5 Springiness test

enameled wire Springiness test

5.6 Flexibility and Adherence: The Flexibility and adherence test.

The Flexibility and adherence test

5.7 Heat shock: The heat shock test, the minimum heat shock temperature should be175℃.
Heat shock
5.8 Cut-through: The cut-through test. No failure shall occur within 2 min at a temperature of 270 ℃.
5.9 Resistance to abrasion (nominal conductor diameter from 0.25 up to and including 2.5 mm)

5.10 Resistance to solvent: The resistance to solvent test. Standard Solvent Using a pencil of hardness of “H”the coating shall not be removed.
5.11 Broken-down voltage: The broken-down voltage test. The high temperature should be 155℃

5.12 Continuity of insulation: The continuity of insulation test.

5.13 Temperature index The minimum temperature index should be 155
5.14 Pine hole test

6. Inspection.

The inspection shall be carried out using the test methods 5, on the items specified from 3, 4. If the purchaser and the supplies have an agreement, some items can be omitted.
(1)Appearance
(2)Dimensions
(3)Flexibility
(4)Adherence
(5)Broken-down voltage
(6)Resistance to Solvent
(7)Heat shock
(8)Electrical Resistance
(9)Elongation

7. Packing

7.1 Packing requirement. The wire shall be wound uniformly and compactly on the spool, without tangle.
7.2 Packing size

Spool Type MEASUREMENT
d1 d2 D1 D2 H1 H2
PT-30 22.2 110 24.7 130 24.5 28.5
PT-60 269 150 296 178 350 400

Spool Type MEASUREMENT
d1 d2 D1 D2 H1 H2
PT-90
PCZ-315
300 180 315 200 425 500
PT-200
PCZ-400
375 225 400 250 530 630
PT-270 435 225 460 280 528 628

8.Designation

The wire shall be designated by class and conductor dimension or by symbol and conductor dimensions. Example Enameled Round copper wire, temperature Class 180℃, 0.15mm

9. Marking

The spool and container shall be marked at a specified place with the following items: (1)Designation; (2 Dimensions; (3)Manufacturing Lot number;(4)Net weight; (5)Manufacturer.

10.Attention, storage method in handling, and attention in period and abandonment
1) Attention in handling
*Please note use in the place where the ignition source by the fire, static electricity, and the impact spark, etc. is caused enough.
*Please avoid contact with the medicines such as a strong acid, strong alkali, and organic solvents. *Please wear protective glasses at the coil winding.
*The harmful gas is generated from the insulation film when removing the insulation film by heat or solder. Please use the exhaust equipment, and do not inhale directly.
*Please follow the instruction concerning handling, when you use the medicines for removing. *Please do not roll bobbin to generate loosening and the tangle of the wire.
* There is a possibility of causing a minute crack on the insulation film when touching it to moisture, water, the solvent, and the medicine, while suffering stress to the insulation film. Therefore, we recommend heat-treating it after the coil is built or before the varnish is processed.
*Please note handling when you move the wire, and do not treat the product by the hand that attaches the moist hand and the hand cream.
2 )Attention in keeping
*Please store it in a room, avoid it being under the high temperature and humidity environment or exposed directly to the sunshine.
*Please mind the pile height.

3)Storage:
Storage temperature: 5~35℃
Relative humidity: 85% or less (Do not generate the dewy on the surface of the wire.)

4) Attention in Recycle
Please recycle if it is possible because copper is main material in this product. When recycling is impossible, please process as industrial waste.