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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
May 2004

1.1

Description

Submersible motors are used as wet motors in fluids, and thus the wires used in submersible motor windings require high-quality insulation that is completely impervious to liquids. NSW winding wires are specially designed to meet the requirements of this application. They have proven their durability and reliability over many decades and ensure trouble-free operation and long motor life. NSW winding wires consist of a solid or multi-stranded bare copper conductor insulated by means of a plastic sheath made of one of the following materials: PVC PE2 HT4 Electric motor manufacturers have found that PVCinsulated winding wires can be used for voltages up to 1,000 V and at conductor temperatures up to a maximum of 75 C*. PE2-insulated winding wires are generally used in submersible motors operating under higher voltages and at conductor temperatures up to a maximum of 90 C*. The increased resistance to heat is achieved by cross-linking the polyethylene.

NSW HT4-insulated winding wires are the most effective solution for conductor temperatures of up to a maximum of 115 C*. To ensure long-term stability with this material NSW recommends a minimum sheath wall thickness of 0.6 mm. The thickness of the sheath wall is a function of the operating voltage. For voltages of 3 kV and more, the use of a semiconducting layer between the copper conductor and the insulating sheath is possible. The surface of winding wires which are insulated with PE2 have a thin sheathing of polyamide (PA) for surface protection. * The temperature specifications are valid for winding wires under normal mechanical stress. The temperatures must be reduced if necessary in the case of winding wires subjected to pronounced mechanical loading.

May 2004

1.2

History

NSW (Norddeutsche Seekabelwerke GmbH & Co. KG) has been developing and manufacturing underwater cables and 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 wires for submersible motors (wet-stator motors) in 1946. Decades of work and research ensure the high quality of this product. NSW manufactures and tests its products in accordance with its own in-house quality management system which has been certified by Lloyds Register Quality Assurance in accordance with ISO 9001:2000.

The PVC blend used in NSW winding wires was developed specially for this purpose, and over the course of many years the materials chosen for NSWs PE2 and HT4 insulation have proved their worth and reliability. A polyamide sheath provides good mechanical protection for NSWs PE2-insulated winding wires. NSWs state-of-the-art laboratories continually test the suitability of new insulating materials for use in its winding wires. 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.

May 2004

2.1

Design

Solid conductor:

Cross section in mm2: 0.283 to 16.6 Cross section in mm2: From approx. 3.5 Depending on dimensions and operating voltage from 0.3 mm

Diameter in mm: 0.6 to 4.6

Stranded conductor:

Insulation wall thickness :

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 wires are, depending on the thickness of the walls, as follows: External diameter in mm Tolerance of external diameter for wall thickness w in mm Maximum excentricity

w 1.0 1.0 < w 1.5 1.5 < w 2.5 2.5 < w 3.5
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

0.05 0.10 0.15 0.20

0.10 0.15 0.20

0.15 0.20 0.20

0.20 0.20 0.20

Half the permissible tolerance of the external diameter

May 2004

2.2

Standard dimensions and weights of winding wires

Cu cross section mm2


0.636 0.785 0.950

Cu diameter mm
0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60 1.60 1.70 1.80 1.90 2.00 2.10 2.20 2.30 2.40 2.50 2.50 2.60 2.60 2.70 2.80 2.90 3.00 3.20 3.40 3.60

PVC diameter mm
1.60 1.70 1.80 1.90 2.10 2.20 2.30 2.30 2.40 2.50 2.60 2.70 2.90 3.10 3.20 3.30 3.60 3.50 3.70 3.60 3.80 3.70 4.00 4.10 4.20 4.40 4.70 5.20

PVC wall thickness mm


0.35 0.35 0.35 0.35 0.40 0.40 0.40 0.35 0.40 0.40 0.40 0.40 0.45 0.50 0.50 0.50 0.60 0.50 0.60 0.50 0.60 0.50 0.60 0.60 0.60 0.60 0.65 0.80

Cu weight kg/km
5.66 6.99 8.46 10.2 11.8 13.7 15.7 17.9 17.9 20.2 22.6 25.2 28.0 30.8 33.8 37.0 40.3 43.7 43.7 47.3 47.3 51.0 54.8 58.8 62.9 71.6 80.8 90.6

Total weight kg/km


7.72 9.22 10.85 12.7 15.0 17.1 19.3 21.1 21.7 24.2 26.8 29.6 33.2 37.0 40.2 43.6 48.7 50.8 52.5 54.6 56.3 58.5 64.4 68.7 73.1 82.3 93.2 107

2.2.1 Solid conductor with PVC insulation

1.13 1.33 1.54 1.77 2.01 2.01 2.27 2.54 2.84 3.14 3.46 3.80 4.15 4.52 4.91 4.91 5.31 5.31 5.73 6.16 6.61 7.07 8.04 8.04 10.2

May 2004

4.1

Physical properties of plastic used for winding wire insulation

Testing characteristics Tensile strength (at (235) C Elongation at break (at (235) C) Tensile strength after aging (7 x 24 h, 80 C) Elongation at break after aging (7 x 24 h, 80 C) Longitudinal shrinkage Testing temperature Shrinkage Hot penetration Testing temperature Penetration depth Dielectric constant r (at 20 C, 800 Hz) Specific insulation resistance (at 20 C) Dielectric breakdown strength (at 20 C, 50 Hz)

Unit

Standards HT4 10

Typical Data PE2 10 100 10 PVC 10 90 10

N/mm2 %

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

100 10

N/mm2

100

100

90

C % C %

IEC 60811-1-3

115 4 115 5 2.6

90 4 90 25 2.3

70 4 70 40 3...4

IEC 60811-3-1 DIN 534483 Supplementary sheet 1 DIN 53483-1 DIN 53483-2

. cm

IEC 60093

10

17

10

18

10

15

kV/mm

DIN VDE 0303-21

85

70

60

Recommended storage and processing temperature: Approx. 20 C May 2004

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