enamelled copper wire testing PDF

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ENAMELLED ROUND COPPER WIRES LTS 3216 1.0 SCOPE This standard covers requirements of enamelled round copper wires of Polyster and Polysterimide enamel for use at elevated temperatures. ORDERING SPECIFICATIONS POLY-Polyster, POLYAMIDE- Polyestrimide. EN-Enamelled, CU-Copper & Covering FC-Fine, MC...

Description

ENAMELLED ROUND COPPER WIRES 1.0

LTS 3216

SCOPE

This standard covers requirements of enamelled round copper wires of Polyster and Polysterimide enamel for use at elevated temperatures.

ORDERING SPECIFICATIONS POLY-Polyster, POLYAMIDE- Polyestrimide. EN-Enamelled, CU-Copper & Covering FC-Fine, MC-Medium, TC-Thick, CC-Coarse

APPLICATIONS It is intended to be used as winding wires in electrical and electronics apparutus.

REQUIREMENTS a)

General:

b)

Material:

b.1

Conductor:

i)

The conductor shall be of high conductivity annealed copper and be completely and uniformly covered with a durable , flexible synthetic enamel. the enamel shall have a clean, smooth surface free from embedded particles such as dust & other deleterious material. It shall also be free from slivers, cracks, spills and other harmful defects. Each batch shall be accompanied by a batch test certificate .

Coefficient of linear expansion :0.000017m/°C over temperature range of 0°C to 150°C.

ii)

Density:

8.89gm/cc at 20°C

iii)

Resistivity :

0.017241 ohm mm 2/m at 20° C

b.2

Enamelled wire:

i)

Breakdown Voltage at room temperature: As per values given in Table-1, when tested as per Appendix I

ii)

Breakdown Voltage at elevated temperature: When tested as per Appendix I the value shall not be less than 75% of the BDV at room temperature as specified in Table-I.

iii)

Elongation: Shall be as given in Table-I, when tested as per Appendix II.

iv)

Springiness: (Applicable to sizes >0.05mm ≤ 1.60mm) Shall be as given in Table-I, when tested as per Appendix III.

NOTE : Table No.3 expanded to include metric sizes.

REVISION

M

N

O

31.12.98

31.12.99

30.09.2000

3

6

DATE PAGE NO 7,8 & 10

ADOPTED BY L&T STANDARDIZATION COMMITTEE REVISION A B C D DATE PAGE NO

31.10.93 3

07.01.94 4,5

31.03.94 4,5,6,10, 11

30.06.94 ALL

PREPARED & RELEASED BY STANDARDS CELL, CMD E 30.09.94 1,2,6

F 31.03.95 4,6,7

G 30.06.95 4,6,7

H 30.09.95 1,2

I 31.12.95 2,3

J 30.06.97 3,7

30.10.92 K 31.12.97 Released

L 30.06.98 3,6,8,9

LARSEN & TOUBRO LIMITED, POWAI, MUMBAI - 400 072 PAGE : 1 OF 30 No copying or Extraction from this Document without L&T’s Permission

LTS 3216 v)

Continuity of covering: (Applicable to sizes upto 0.85mm). Not more than 15 faults in a length of 50m, when tested as per Appendix IV.

vi)

Heat shock test: The covering shall show no cracks, when tested as per Appendix V.

vii)

Flexibility and Adherence: the covering shall show no cracks when tested as per Appenix VI.

viii)

Stretch test: To satisfy requirements given in Appendix VII.

ix)

Abrasion Resistance: (Applicable sizes >0.25mm. 2.50mm).Shall satisfy the values Table-2, when tested as per AppendixVIII.

given

x)

Cut-Through test: No breakdown shall occur within 2 minutes when tested as per Appendix IX.

xi)

Softening temperature test: No breakdown shall occur when tested as per Appendix X

xii)

Compatibility: shall satisfy the requirements for performance when tested as per Appendix XI.

in

the

.

5.0

DIMENSIONS AND TOLERANCES As per Table-3 enclosed

6.0

TESTING The enamelled copper wires shall be tested for : i)

Breakdown voltage : As per Appendix I.

ii)

Elongation : As per Appendix II.

iii)

Springiness : As per Appendix III.

iv)

Continuity of covering : As per Appendix IV.

v)

Heat shock test : As per Appendix V.

vi)

Flexibility and Adherence : As per Appendix VI.

vii)

Stretch Test : As per Appendix VII.

viii)

Abrasion Resistance : As per Appendix VIII.

ix)

Cut-Through test : As per Appendix IX.

x)

Softening temperature test : As per Appendix X.

xi)

Compatibility : As per Appendix XI. This test shall be done for approval of new vendor of enamel or varnish application.

xii)

7.0

Test certificate as per the format given by L&T and shall be enclosed alongwith the supply challan.

INSPECTION After ascertaining that a valid batch test certificate is available, inspection shall be carried out for : i) ii)

Dimensions and Tolerances as per clause 5.0. Visual/General requirements as per clause 4.0.

31.12.1997

No copying or Extraction from this Document without L&T’s Permission

Page 2 of 30

LTS 3216 8.0

PACKING The wires shall be wound evenly and compactly on plastic/wooden spools without any deformation. The spools shall be packed in suitable cartons. Dimensions of the spools shall be as per table given below : Flange ∅

SPOOL

Traverse

Material

Type

(mm) Approx.

PLASTIC

No.12

125 x 125 mm

70

PLASTIC

PT-1

95 x 104 mm

99

PLASTIC

PT-4

125 x 140 mm

170

PLASTIC

P-8

8” x 8”

120

PLASTIC

P-10

10” x 10”

120

PLASTIC

K-160

160 x 160 mm

135

WOOD

W-8

8” x 8”

120

WOOD

W-10

10” x 10”

120

Spool shall conform to following : i) The material used for the construction of the spool shall have the required mechanical strength so that the spool does not warp on actual usage or storage. ii) The material shall have no deleterious effect on enamel or other coverings of wire. iii) No portion of spool shall warp when kept in an oven at 70°C for an hour. iv) The spool shall be of any light colour (Black excluded) v) Imbalance and axial throw of the flange shall be negligible. vi) Eccentricity of the spool when measured by dial gauge shall be within 0.35 mm.

8.1

At least 80% supply of 40 G fine cov. wire shall be min. 3 kg. per spool.

9.0

MARKING Each spool & carton shall be labelled with the following with indelible ink :

10.0

i)

Manufacturer’s Name and / or Trade mark.

ii)

Material 10 digit code No.

iii)

Type of enamel.

iv)

Type of covering.

v)

Size of wire in swg/mm.

vi)

Net weight of wire.

vii)

BIS certification mark: if any.

viii)

Batch No.

STORAGE The spools shall be stored on racks and in dry atmosphere.

31.12.1999

No copying or Extraction from this Document without L&T’s Permission

Page 3 of 30

LTS 3216 TABLE 1 : ELONGATION, SPRING BACK AND BREAKDOWN VOLTAGE

Nom.dia of Conductor SWG mm

46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14

0.060 0.071 0.081 0.091 0.100 0.102 0.112 0.122 0.125 0.132 0.152 0.173 0.180 0.193 0.213 0.224 0.234 0.250 0.254 0.274 0.295 0.315 0.345 0.376 0.417 0.450 0.457 0.508 0.559 0.610 0.711 0.813 0.914 1.016 1.219 1.422 1.626 1.829 2.032

31.12.1997

Elongation minimum

Spring back, maximum (Degree)

%

Fine Covering

Medium Covering

Thick Covering

12.0 13.0 14.0 15.0 16.0 16.0 17.0 17.0 17.0 17.0 18.5 19.5 20.0 20.5 21.0 21.0 21.5 22.0 22.0 22.0 22.0 23.0 23.0 23.5 24.5 25.0 25.0 25.0 26.0 26.5 28.0 29.0 29.0 30.0 31.0 32.0 32.0 32.0 33.0

68 65 70 67 64 64 64 62 62 59 59 57 57 54 51 51 51 49 49 47 50 50 48 47 45 44 44 43 41 46 44 41 45 42 36 32 -

82 77 80 77 73 73 73 70 70 67 67 65 65 62 59 59 59 56 56 53 55 55 53 52 50 48 48 47 44 50 47 43 48 45 38 34 -

94 90 90 88 84 84 79 78 75 75 72 68 68 68 65 65 61 62 62 59 57 55 53 53 51 48 53 50 46 51 47 40 34 -

TENSION N

0.1

0.25

0.5

1.0

2.0

4.0

8.0

12.0

15.0

-

Breakdown voltage at room temp. minimum (Volt.) Fine Covering

Medium Covering

Thick Covering

500 500 600 600 600 600 700 700 700 800 800 900 900 900 1000 1000 1000 1200 1200 1200 1200 1200 1400 1400 1600 1600 1600 1800 1800 1800 1900 1900 2000 2100 2200 2300 2400 2400 2500

800 950 1200 1200 1200 1200 1300 1300 1300 1500 1500 1700 1700 1700 2000 2000 2000 2200 2200 2200 2200 2200 2400 2400 2500 2800 2800 3100 3100 3100 3500 3500 3700 3800 3900 4000 4300 4300 4400

1000 1400 1800 1800 1800 1800 1800 1800 1800 2200 2200 2500 2500 2500 3000 3000 3000 2390 3300 3300 3300 3300 3700 3700 4000 4000 4000 4400 4400 4400 4700 4700 5100 5300 5600 5900 5900 5900 6300

No copying or Extraction from this Document without L&T’s Permission

Page 4 of 30

LTS 3216 TABLE-2

Conductor size in SWG 33

FINE COVERING Average force Minimum force to failure in to failure in N N 2.70 2.30

MEDIUM COVERING Average force Minimum force to failure in to failure in N N 4.50 3.80

32

2.90

2.45

4.80

4.10

31

3.01

2.54

5.00

4.25

30

3.15

2.65

5.20

4.40

29

3.40

2.85

5.60

4.75

28

3.51

2.93

5.77

4.90

27

3.65

3.05

6.00

5.10

26

3.90

3.30

6.45

5.45

25

4.20

3.55

6.90

5.85

24

4.50

3.80

7.40

6.25

23

5.85

4.10

7.90

6.70

22

5.20

4.40

8.50

7.20

21

5.60

4.70

9.10

7.79

20

6.05

5.10

9.70

8.20

19

6.55

5.50

10.40

8.80

18

7.38

6.23

11.55

9.80

17

8.20

6.95

12.70

10.80

16

8.90

7.55

13.70

11.80

15

9.60

8.15

14.70

12.40

14

10.30

8.75

15.70

13.30

NOTE: i)

IN = 102 gms.

ii)

Load values for polyester & polyesterimide wires are same.

31.12.1997

No copying or Extraction from this Document without L&T’s Permission

Page 5 of 30

DIMENSIONS & TOLERANCES FOR ENAMELLED COPPER WIRES – TABLE NO.3

LTS 3216

SWG

Net weight of wire in spool (kg.)

Nominal Dia Of conductor

mm

46 45 44 43

42 41 40 39

38

30.06.98

OVERALL DIA (mm) Medium Thick Covering Covering

Min Incre ase

Max O.D.

Min Increa se

Max O.D.

0.020

0.002

0.025

0.003

0.027

0.025 0.032 0.040 0.050 0.060 0.063 0.071 0.080 0.081 0.090 0.091 0.095 0.100

0.025 0.003 0.004 0.005 0.007 0.007 0.008 0.009 0.009 0.010 0.010

0.031 0.040 0.050 0.062 0.076 0.078 0.088 0.098 0.099 0.110 0.111

0.004 0.006 0.008 0.010 0.013 0.013 0.015 0.016 0.016 0.017 0.017 0.018

0.034 0.043 0.054 0.068 0.083 0.085 0.095 0.105 0.106 0.117 0.118 0.123

-------0.024 0.024 0.026 0.026

0.111

0.116

0.011 0.011 0.012 0.013 0.013 0.015 0.015 0.161 0.016

0.121 0.123 0.134 0.146 0.149 0.157 0.166 0.165 0.179

0.019 0.019 0.020 0.023 0.022 0.024 0.024

0.129 0.131 0.143 0.156 0.159 0.168 0.176

0.028 0.028 0.029 0.032 0.032 0.034 0.034

0.141 0.143 0.155 0.168 0.171 0.180 0.189

0.025

0.190

0.034

0.203

0.100 0.102 0.112 0.122 0.125 0.132 0.140 0.147 0.152

Tol (± ±)

Fine Covering

0.003 0.003 0.003 0.013 0.003 0.003 0.003 +0.000 -0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.002 0.003

Min Incre ase

Max O.D.

-------0.116 0.117 0.128 0.129

Electrical Resistance at 20°° C per metre (ohms) Min. Max.

Spool type Plastic or wooden

46.63

65.31

30.55 18.87 12.21 7.903 5.369 5.033 3.985 3.156 3.078 2.507 2.452 2.254 2.041

41.09 24.44 15.37 9.559 6.431 6.029 4.725 3.704 3.614 2.913 2.850 2.619 2.349

No.12 No.12 No.12 No.12 No.12

2.041 1.974 1.646 1.393 1.328 1.194 1.064 0.968 0.9056

2.349 2.259 1.864 1.564 1.488 1.331 1.180 1.065 0.9974

No Copying or Extraction from this Document without L&T’s Permission

Min.

Max.

0.5

--

PT-4 PT-4

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 3.0 3.0

--------------

No.12/PT-4 No.12/PT-4 PT-4 PT-4 No.12/PT-4 No.12/PT-4 No.12/PT-4 PT-4 PT-4

0.5 0.5 3.0 3.0 0.5 0.5 0.5 3.0 3.0

----------

No.12/PT-1 No.12/PT-4

No.12 No.12 No.12/PT-1

No.12 No.12

Page 6 of 30

LTS 3216 SWG

37

36

35 34

33

32 31 30

31.12.98

Nominal Dia Of conductor

Fine Covering

OVERALL DIA (mm) Medium Thick Covering Covering Min Increa se

Max O.D.

Min Incre ase

Max O.D.

Electrical Resistance at 20°° C per metre (ohms) Min. Max.

Spool type Plastic or wooden

Net weight of wire in spool (kg.)

mm

Tol (± ±)

Min Incre ase

Max O.D.

0.152

0.003

0.016

0.170

--

--

--

--

0.9056

0.9974

No.12/PT

0.5

--

0.160 0.170 0.173 0.180 0.190 0.193 0.195 0.200 0.212 0.213 0.224 0.234 0.236 0.243 0.250 0.254

0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.003 0.004 0.004 0.003 0.004 0.004 0.004

0.016 0.017 0.017 0.017 0.018 0.017 0.018 0.018 0.019 0.018 0.019 0.019 0.020 0.020 0.020 0.020

0.187 0.198 0.201 0.209 0.220 0.223 0.225 0.230 0.244 0.244 0.256 0.267 0.269 0.276 0.284 0.288

0.025 0.027 0.026 0.027 0.028 0.027 0.028 0.028 0.030 0.028 0.030 0.030 0.031 0.031 0.031 0.031

0.199 0.211 0.214 0.222 0.234 0.237 0.239 0.245 0.258 0.260 0.272 0.282 0.283 0.293 0.301 0.305

0.037 0.040 0.039 0.040 0.043 0.040 0.043 0.043 0.046 0.043 0.046 0.046 0.048 0.048 0.048 0.048

0.213 0.226 0.229 0.237 0.248 0.253 0.255 0.261 0.275 0.277 0.290 0.300 0.310 0.310 0.320 0.334

0.8192 0.7272 0.7026 0.6499 0.5843 0.5666 0.5552 0.5282 0.4708 0.4666 0.4224 0.3875 0.3810 0.3567 0.3374 0.3270

0.8983 0.7940 0.7662 0.7068 0.6332 0.6134 0.6007 0.5706 0.5069 0.5022 0.4534 0.4150 0.4079 0.3876 0.3659 0.3526

No.12/PT-4 No.12 No.12/PT-4 No.12 No.12 No.12/PT-4

No.12 No.12/PT-4 No.12/PT-4 No.12/PT-4 No.12 No.12 No.12/PT-4 No.12/PT-4

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

-----------------

0.265 0.273 0.274 0.295 0.300 0.315

0.004 0.004 0.004 0.004 0.004 0.004

0.021 0.021 0.021 0.021 0.022 0.022

0.300 0.309 0.309 0.331 0.337 0.352

0.032 0.032 0.032 0.033 0.034 0.034

0.317 0.326 0.328 0.350 0.355 0.371

0.051 0.051 0.049 0.052 0.053 0.053

0.335 0.344 0.347 0.369 0.374 0.391

0.3008 0.2837 0.2816 0.2435 0.2355 0.2139

0.3251 0.3060 0.3037 0.2615 0.2527 0.2289

No.12 No.12 No.12/PT-4 No.12/PT-4 No.12 No.12/PT-4

0.5 0.5 3.0 0.5 0.5 0.5

-------

No Copying or Extraction from this Document without L&T’s Permission

Min.

No.12 No.12

Page 7 of 30

Max.

LTS 3216 SWG

29

28

27 26 25 24

23

22

21

31.12.98

Nominal Dia Of conductor

Fine Covering

OVERALL DIA (mm) Medium Thick Covering Covering

Electrical Resistance at 20°° C per metre (ohms) Min. Max.

Spool type Plastic or wooden

mm

Tol (± ±)

Min Incre ase

Max O.D.

Min Increa se

Max O.D.

Min Incre ase

Max O.D.

0.345 0.355 0.376 0.376 0.400 0.412 0.417 0.450 0.457 0.500 0.508 0.559 0.560 0.600

0.004 0.004 0.004 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.005 0.006 0.006 0.006

0.024 0.024 0.025 0.024 0.025 0.026 0.025 0.027 0.027 0.029 0.029 0.030 0.030 0.032

0.385 0.395 0.416 0.417 0.442 0.455 0.459 0.495 0.502 0.548 0.556 0.610 0.611 0.653

0.036 0.036 0.038 0.037 0.038 0.040 0.038 0.041 0.041 0.044 0.044 0.046 0.046 0.049

0.404 0.414 0.436 0.437 0.462 0.476 0.479 0.516 0.523 0.569 0.577 0.631 0.632 0.676

0.056 0.056 0.058 0.057 0.058 0.060 0.058 0.062 0.062 0.591 0.065 0.071 0.067 0.071

0.424 0.435 0.459 0.458 0.483 0.497 0.500 0.538 0.545 0.650 0.599 0.655 0.656 0.699

0.1784 0.1689 0.1515 0.1499 0.1327 0.1252 0.1222 0.1051 0.1020 0.08534 0.0827 0.0682 0.06794 0.05927

0.1904 0.1797 0.1609 0.1609 0.1419 0.1337 0.1305 0.1118 0.1084 0.09037 0.0875 0.0724 0.7215 0.06276

0.610 0.630 0.710 0.711 0.750 0.800 0.813 0.850

0.006 0.006 0.007 0.007 0.008 0.008 0.008 0.009

0.032 0.032 0.034 0.034 0.035 0.036 0.037 0.037

0.664 0.684 0.767 0.768 0.809 0.861 0.874 0.913

0.049 0.049 0.051 0.051 0.052 0.054 0.055 0.055

0.686 0.706 0.791 0.791 0.832 0.885 0.889 0.937

0.071 0.071 0.074 0.074 0.075 0.078 0.079 0.079

0.719 0.730 0.815 0.816 0.858 0.911 0.924 0.964

0.0574 0.05381 0.04234 0.0422 0.03788 0.03334 0.0323 0.02950

0.0607 0.05687 0.04481 0....