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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 qua-
lity 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 @ 20C 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 @ 20C 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
Thermal
Product designation Insulation class Properties Application
(IEC)

High resistance to abrasion


Distribution and power
Excellent flexibility and adherence
MAGNEFORM F-120 Polyvinylacetal 120 Very resistant against hydrolysis
transformers, supply meters
electrical equipement.
Very good thermal resistance

Control systems, electrical


Excellent resistance against solvents
THEIC-modified equipment, air-cooled and cast
MAGNETEMP C-180 180 and other chemicals
resin dry type transformers, welding
polyesterimide Very good flexibility
transformers

THEIC-modified Excellent thermal characteristics AC and DC motors up to class H, oil


MAGNETEMP CA-200 polyesterimide 200 Outstanding chemical resistance immersed and dry type transformers,
Very good resistance to abrasion hermetic motors, magnet coils
+ polyamide imide

AC and DC motors up to class H, oil


Excellent thermal characteristics
immersed and dry type transformers,
MAGNETEMP A-220 Polyamide imide 220 and ageing resistance
magnet coils and other
Very good resistance to abrasion
electromagnetic applications

Optimum curing is achieved


between 120C and 130C.
MAGNEBOND FX-120 Polyvinyl acetale 120 The bond coat hardens during
Oil immersed transformers up to
operating temperature 130C
with epoxy bond coat (base coat) the usual vapour phase process
for drying of the coil.

Optimum curing is achieved between


Polyvinyl acetale 120 110C and 120C. Oil immersed transformers up to
MAGNEBOND FX2-120 The bond coat hardens during the operating temperature 130C
with epoxy bond coat (base coat) usual vapour phase process or hot
air drying of the coil.

Polyamide imide The temperature range between


220 180C and 230C is ideal for curing. Dry type transformers and
MAGNETEMP AB-220 with aromatic Pressing of the coil during bonding generators up to class F
(base coat)
polyamide bond coat increases the bond strength.

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 mm2 120.00 mm2

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
Elongation Specific
Thickness Density MD Specification properties

0.050 mm
0.065 mm General purpose
Kraft Paper* 0.75 - 0.85 g/cm3 >2% IEC 554-3-5
0.085 mm with high purity
0.105 mm

0.065 mm
Hight density
Kraft Paper Calandered 0.085 mm 0.95 - 1.05 g/cm3 >2% IEC 554-3-5
and dielectric strength
0.105 mm

0.065 mm
Kraft Paper Thermally 0.75 - 0.85 g/cm3 >2% IEC 554-3-5 Hight thermal properties
0.085 mm
Upgraded* 0.105 mm

0.065 mm
Kraft Paper Thermally Hight density, thermal
0.085 mm 0.95 - 1.05 g/cm3 >2% IEC 554-3-5
Upgraded and Calandered and dielectric propertie
0.105 mm

0.050 mm Hight mechanical strengh


Crepe Paper 0.076 mm 1.00 - 1.25 g/cm3 > 15 % High elongation
0.127 mm Thickness depending to type

0.050 mm 0.72 g/cm3 9% Very high thermal


Aramide Paper* 0.080 mm 0.80 g/cm3 11% resistance, chemical
0.130 mm 0.87 g/cm3 15% and mechanical properties

All values are typical values.


* Epoxy coated versions possible.
Other materials or thicknesses possible on request.

INSULATION ARRANGEMENT
Butt wrapped insulation
ca.
3 layers, ca. 30% staggering 30%

ca.
30%
Overlapped insulation
1 layer, ca. 50% overlapped with itself

ca.
50%
Overlapped insulation
3 layers, ca. 20% overlapped with itself

overlapp
Interlocked insulation
2 layer, ca. 50% interlocked

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


Elongation Specific
Thichness Density
MD properties

0.050 mm 0.72 g/cm3 9% Very high thermal


Aramide resistance, chemical
0.080 mm 0.80 g/cm3 11 % and mechanical
Paper*
0.130 mm 0.87 g/cm3 15 % properties

High tensile
Polyester 0.023 mm strength and
1,40 g/cm3 > 110 % electrical
Film 0.050 mm
properties

Excellent physical,
Polyimide Film 0.038 mm electrical and
1,42 g/cm3 > 40 %
heat sealable 0.064 mm 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 mm2 120.00 mm2

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 mm2 80 mm2 80 mm2

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 mm2 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 Special Feature

Kraft 5A2-1H1, general purpose with high purity

Kraf, calendered 5A4-1M2, high density and dielectric strength

Kraft, thermally upgraded 5A2-1M2, high thermal properties

Kraft, thermally upgraded, calendared 5A4-1M1, high density, thermal and dielectric characteristics

Calendered, upgraded, creped Outer layers with very high mechanical strength

Kraft, Epoxy coated Bondable outer layers

Kraft, Epoxy coated, upgraded Bondable outer layers

Aramide Very high thermal resistance, for traction transformers

Aramide, Epoxy coated Bondable outer layers, for traction transformers

Perforated paper CTC with improved cooling of LV windings

Glass fabric tape 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 ESSEX ITALY Spa ESSEX GROUP CANADA inc. ESSEX MAGNET WIRE (Tianjin) Ltd.
Korbacher Str.6 Via Circonvallazione 2 19-20 Gilberson Drive No. 10 MIP Second Road Jingang Road
34454 Bad Arolsen - GERMANY 15028 Quattordio - ITALY Simcoe, ON, N3Y 4L5 - CANADA Tianjin 300385 - CHINA
phone: + 49 (0)5691 894 144 phone: + 39 334 6167411 phone: + 1 416 388 0305 phone: + 86 (0)22 8396 7032/34/36
armin.feickert@spsx.com roberto.salvaggio@spsx.com anthony.ONeil@spsx.com steve.usher@spsx.com

www.essexeurope.com