ENERGY WIRE Continuously Transposed Cable Flat enamelled wire Flat wrapped wire
WELCOME TO ESSEX EUROPE Essex Europe is the European division of Superior Essex, global leader for winding wire products. As a leading supplier in Europe, Essex supplies its customers a large range of products: round wires, fine and ultra-fine wires, flat enamelled or wrapped wires and Continuously Transposed Cable ("CTC"). A complete offer 80 Years of know-how in winding wire A global presence Since 1963 producer of CTC A strong investment policy
A COMPLETE RANGE OF ENERGY WIRES AND SPECIALTIES Flat enamelled wire Flat wrapped wire Special flat insulated wire Continuously Transposed Cable 1
FOCUS ON QUALITY & INNOVATION To bring the customers the most efficient solutions in winding wire and CTC. HIGH QUALITY Essex employees are strongly focused on delivering to customers the right products at the right time, with the lowest impact on the environment. The Essex plants are equipped with state of the art equipment and are operating in compliance with norms ISO TS16949, ISO 9001, ISO 14001 and according to international standards. Furthermore, a robust continuous improvement program fine tunes the processes, the quality level and the flexibility of the plants year after year. INNOVATION IS KEY To face the challenge of our customers looking for a better power efficiency of their products, a dedicated R & D team for transformers and generator wires is working alongside them. New enamels, new wire design, innovative constructions, the R & D team will find the best solution to improve the performance of the customers product.
A FULL INTEGRATED PROCESS Because raw material quality and performance of enamels are key. VARNISH INTEGRATION Essex is the only European winding wire producer also manufacturing its enamels. First, it guarantees the perfect adaptation of the enamel characteristics to the Essex winding wire production line to deliver the best quality and efficiency. Besides, Essex engineers from the winding wire and enameling departments team up continuously to define the best and innovative solutions for the customers. COPPER ROD PRODUCTION Copper rod quality is essential to reach the required winding wire performance. Essex follows a strict quality process from the supplier selection to the control of copper characteristics and surface conditions of each delivery. In addition, Essex develops its own rod production to guarantee the best raw material possible. COPPER AND ALUMINIUM INFORMATION COPPER [EN-1977 ] Conductivity @ 20 C Description Cu-ETP1 > 58,58 MS/m High conductivity Cu-OF1 > 58,58 MS/m Oxygen free CuAg 0,04 > 58,00 MS/m Silver alloyed Cu Ag 0,10 > 58,00 MS/m Silver alloyed ALUMINIUM [DIN-EN 573-3] Conductivity @ 20 C Description EN AW 1370 > 36,7 MS/m Aluminium for electrical application 3
FLAT ENAMELLED WIRES Wide range of product for motors, distribution and power transformers. TYPE OF ENAMEL PVA:... Polyvinylacetal THEIC-PEI:... Modified polyesterimide THEIC-PEI + PAI:... Modified polyesterimide + polyamide imide PAI:... Polyamide imide PVA + Epoxy:... Polyvinylacetal with epoxy bond coat PVA + Epoxy type 2:... Polyvinylacetal with epoxy bond coat type 2 PAI + PA:... Polyamide imide with aromatic polyamide bond coat CONDUCTOR Copper Aluminium PRODUCTION RANGE Width: 2.00-25.00 mm Thickness: 0.80-5.00 mm Cross section: max 80 mm2
FLAT ENAMELLED WIRE PRODUCT RANGE Product designation Insulation Thermal class (IEC) Properties Application MAGNEFORM F-120 Polyvinylacetal 120 High resistance to abrasion Excellent flexibility and adherence Very resistant against hydrolysis Very good thermal resistance Distribution and power transformers, supply meters electrical equipement. MAGNETEMP C-180 THEIC-modified polyesterimide 180 Excellent resistance against solvents and other chemicals Very good flexibility Control systems, electrical equipment, air-cooled and cast resin dry type transformers, welding transformers MAGNETEMP CA-200 THEIC-modified polyesterimide + polyamide imide 200 Excellent thermal characteristics Outstanding chemical resistance Very good resistance to abrasion AC and DC motors up to class H, oil immersed and dry type transformers, hermetic motors, magnet coils MAGNETEMP A-220 Polyamide imide 220 Excellent thermal characteristics and ageing resistance Very good resistance to abrasion AC and DC motors up to class H, oil immersed and dry type transformers, magnet coils and other electromagnetic applications MAGNEBOND FX-120 Polyvinyl acetale with epoxy bond coat 120 (base coat) Optimum curing is achieved between 120 C and 130 C. The bond coat hardens during the usual vapour phase process for drying of the coil. Oil immersed transformers up to operating temperature 130 C MAGNEBOND FX2-120 Polyvinyl acetale with epoxy bond coat 120 (base coat) Optimum curing is achieved between 110 C and 120 C. The bond coat hardens during the usual vapour phase process or hot air drying of the coil. Oil immersed transformers up to operating temperature 130 C MAGNETEMP AB-220 Polyamide imide with aromatic polyamide bond coat 220 (base coat) The temperature range between 180 C and 230 C is ideal for curing. Pressing of the coil during bonding increases the bond strength. Dry type transformers and generators up to class F 5
FLAT WRAPPED WIRES Full range of paper covered wires in various constructions and insulation materials to fulfill the customers requirements for their transformers and other electrical equipment. DIMENSIONS Min. Max. Thickness of bares 1.00 mm 10.00 mm Width of bares 4.00 mm 25.00 mm Cross section 8.00 mm 2 120.00 mm 2 Ratio Width/Thickness 1.5 10.0 CONDUCTOR Copper Aluminium VARIOUS CONSTRUCTIONS Twin conductors Triple, quadruple conductors Multiple wire with separator Axial twins Cellulose, Aramide, Pressboard or prepreg separator
TYPE OF INSULATION MATERIALS Thickness Density Elongation MD Specification Specific properties Kraft Paper* 0.050 mm 0.065 mm 0.085 mm 0.105 mm 0.75-0.85 g/cm 3 > 2 % IEC 554-3-5 General purpose with high purity Kraft Paper Calandered 0.065 mm 0.085 mm 0.105 mm 0.95-1.05 g/cm 3 > 2 % IEC 554-3-5 Hight density and dielectric strength Kraft Paper Thermally Upgraded* 0.065 mm 0.085 mm 0.105 mm 0.75-0.85 g/cm 3 > 2 % IEC 554-3-5 Hight thermal properties Kraft Paper Thermally Upgraded and Calandered 0.065 mm 0.085 mm 0.105 mm 0.95-1.05 g/cm 3 > 2 % IEC 554-3-5 Hight density, thermal and dielectric propertie Crepe Paper 0.050 mm 0.076 mm 0.127 mm 1.00-1.25 g/cm 3 > 15 % Hight mechanical strengh High elongation Thickness depending to type Aramide Paper* 0.050 mm 0.080 mm 0.130 mm 0.72 g/cm 3 0.80 g/cm 3 0.87 g/cm 3 9 % 11% 15% Very high thermal resistance, chemical and mechanical properties All values are typical values. * Epoxy coated versions possible. Other materials or thicknesses possible on request. INSULATION ARRANGEMENT Butt wrapped insulation 3 layers, ca. 30% staggering ca. 30% Overlapped insulation 1 layer, ca. 50% overlapped with itself ca. 30% Overlapped insulation 3 layers, ca. 20% overlapped with itself ca. 50% Interlocked insulation 2 layer, ca. 50% interlocked overlapp ca. 50% 7
SPECIAL FLAT INSULATED WIRE Essex proposes special insulation materials such Aramide paper, polyimide and polyester film, with a complete product range in Glass yarn or Polyester Glass yarn for tractions motors, motors and generators. FILM INSULATION MATERIALS Thichness Density Elongation MD Specific properties Aramide Paper* 0.050 mm 0.72 g/cm 3 9 % 0.080 mm 0.80 g/cm 3 11 % 0.130 mm 0.87 g/cm 3 15 % Very high thermal resistance, chemical and mechanical properties Polyester Film 0.023 mm 0.050 mm 1,40 g/cm 3 > 110 % High tensile strength and electrical properties Polyimide Film 0.038 mm heat sealable 0.064 mm 1,42 g/cm 3 > 40 % Excellent physical, electrical and mechanical properties All values are typical values. * Epoxy coated versions possible. Other materials or thicknesses possible on request. CONDUCTOR Copper soft Aluminium DIMENSIONS Min. Max. Thickness of bares 1.00 mm 10.00 mm Width of bares 4.00 mm 25.00 mm Cross section 8.00 mm 2 120.00 mm 2 Ratio Width/Thickness 1.5 10
FIBER GLASS INSULATION MATERIALS Glas-Yarn Polyester-Glas Yan Glas + Polyester Standards* IEC 60317-0-4 IEC 60317-31 IEC 60317-32 IEC 60317-33 Conductor material* Copper, soft Copper, soft Copper, soft Aluminium Aluminium Aluminium Conductor type* Rectangular Rectangular Rectangular hollow conductor hollow conductor hollow conductor Insulation* Bare conductor Bare conductor Bare conductor Magnet Wire (TI 200) G1 or G2 Magnet Wire (TI 200) G1 or G2 Magnet Wire (TI 200) G1 or G2 Magnet Wire (TI 220) G1 or G2 Magnet Wire (TI 220) G1 or G2 Magnet Wire (TI 220) G1 or G2 Wrapped whith PI-foil Wrapped whit PI-foil Wrapped whit PI-foil Yarn E-Glasyarn, free alkali Glas - Polyester Glas - Polyester + E-Glasyarn (TI 155) impregnated Layers 1-layer 1-layer 2-lapped layer, same direction 2-lapped layer, same direction 2-lapped layer, same direction 2-lapped layer, cross directio 2-lapped layer, cross direction 2-lapped layer, cross direction Impregnation* Epoxy (TI 155) Possible, but not necessary Epoxy (TI 155) Polyester (TI 155) (see left column) Polyester (TI 155) Polyesterimid (TI 180) Polyesterimid (TI 180) Silicon (TI 200) Silicon (TI 200) Bond Coat* Epoxy bi-stage Epoxy bi-stage Epoxy bi-stage Sizes* Width 3.00-20.00 mm 3.00-11.00 mm 3.00-20.00 mm Thickness 0.80-12.00 mm 0.80-8.00 mm 0.80-12.00 mm Cross-section 80 mm 2 80 mm 2 80 mm 2 Ration width / thickness < 8 : 1 < 8 : 1 < 8 : 1 Proof stress < 125 Mpa < 125 Mpa < 125 Mpa All values are typical values. * Futher sizes, geometries and insulation types possible. Please contact us. 9
CONTINUOUSLY TRANSPOSED CABLE Continuously Transposed Cable offers significant advantages in the design of Transformers compared to conventional paper insulated conductors. 50 YEARS OF EXPERTISE IN CTC Since 1963 Essex has been a key supplier to the transformer industry. This expertise in CTC allows Essex to propose innovative solutions which see it selected for the most technical global projects. A GLOBAL APPROACH Superior Essex is the largest CTC producer worldwide. With four manufacturing facilities on three different continents, our sales and engineering teams are dedicated to supporting the customers on a global and regional level. CANADA GERMANY ITALY CHINA
5 to 84 single strips. Transposition enables windability Flat enamelled wire Paper insulation determines dielectric characteristics Separator improves pressure resistance SIZE RANGE SINGLE STRIPS Width Thickness Section Width/Thickness 3,10-12,50 mm 1,00-3,30 mm 3,50-39 mm 2 2.5:1-8.0:1 BUNDLE Width Height Ratio height Min. Transposing pitch length 7,0 26 3,0 79 1:3-8:1 25 mm TYPE OF ISOLATION Type of Paper Kraft Kraf, calendered Kraft, thermally upgraded Kraft, thermally upgraded, calendared Calendered, upgraded, creped Kraft, Epoxy coated Kraft, Epoxy coated, upgraded Aramide Aramide, Epoxy coated Perforated paper Glass fabric tape Special Feature 5A2-1H1, general purpose with high purity 5A4-1M2, high density and dielectric strength 5A2-1M2, high thermal properties 5A4-1M1, high density, thermal and dielectric characteristics Outer layers with very high mechanical strength Bondable outer layers Bondable outer layers Very high thermal resistance, for traction transformers Bondable outer layers, for traction transformers CTC with improved cooling of LV windings External protection for cast resin transformers More informations page 6-7 11
A WIDE RANGE OF SPECIALTIES To answer the needs of specific solutions. CORDEX Cordex CTC is a special Transposed Cable without paper insulation. It is wrapped with a transformer oil resistant polyester monofilament. Different types of Cordex are available. PERFORATED PAPER This product gives excellent heat dissipation and is suitable for epoxy application with radial or concentric Bond. The cable is wrapped with perforated aramide paper. DIAMOND WRAP This covering currently consists of two opposing wraps of aramide paper arranged to allow free oil flow through the CTC strands for cooling purposes. A linear protection crepe paper is normally inserted on the underside of the cable.
ESSEX GERMANY GmbH Korbacher Str.6 34454 Bad Arolsen - GERMANY phone: + 49 (0)5691 894 144 armin.feickert@spsx.com ESSEX ITALY Spa Via Circonvallazione 2 15028 Quattordio - ITALY phone: + 39 334 6167411 roberto.salvaggio@spsx.com www.essexeurope.com ESSEX GROUP CANADA inc. 19-20 Gilberson Drive Simcoe, ON, N3Y 4L5 - CANADA phone: + 1 416 388 0305 anthony.oneil@spsx.com ESSEX MAGNET WIRE (Tianjin) Ltd. No. 10 MIP Second Road Jingang Road Tianjin 300385 - CHINA phone: + 86 (0)22 8396 7032/34/36 steve.usher@spsx.com