0.020-5.0 mm Polyester Enameled Round Copper Wire Class155
Dimension: 0.020mm – 5mm
Thermal Class: 155℃
Conductor: Copper
Insulation: polyester
Application: transformer, motor,generator
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
5.6 Flexibility and Adherence: The Flexibility and adherence test.
5.7 Heat shock: The heat shock test, the minimum heat shock temperature should be175℃.
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.