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 ]
Cu-ETP1
Cu-OF1
CuAg 0,04
Cu Ag 0,10
Conductivity @ 20°C
Description
> 58,58 MS/m
> 58,58 MS/m
> 58,00 MS/m > 58,00 MS/m
High conductivity
Oxygen free
Silver alloyed
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)
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
Properties
Application
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
1.510.0
CONDUCTOR
Copper
Aluminium
VARIOUS CONSTRUCTIONS
Twin conductors
Triple, quadruple
conductors
Multiple wire with separator
Cellulose, Aramide,
Pressboard or prepreg
separator
Axial twins
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/cm3
>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/cm3
>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/cm3
>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/cm3
>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/cm3
> 15 %
Hight mechanical strengh
High elongation
Thickness depending to type
Aramide Paper*
0.050 mm
0.080 mm
0.130 mm
0.72 g/cm3
0.80 g/cm3
0.87 g/cm3
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
ca.
30%
3 layers, ca. 30% staggering
ca.
30%
Overlapped insulation
1 layer, ca. 50% overlapped with itself
ca.
50%
Overlapped insulation
3 layers, ca. 20% overlapped with itself
Interlocked insulation
overlapp
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
ElongationSpecific
ThichnessDensity
MDproperties
Very high thermal
resistance, chemical
and mechanical
properties
Aramide
Paper*
0.050 mm
0.080 mm
0.130 mm
0.72 g/cm3
0.80 g/cm3
0.87 g/cm3
9%
11 %
15 %
Polyester
Film
0.023 mm
0.050 mm
1,40 g/cm3
> 110 %
High tensile
strength and
electrical
properties
Polyimide Film 0.038 mm
heat sealable 0.064 mm
1,42 g/cm3
> 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 mm2
120.00 mm2
Ratio Width/Thickness
1.510
FIBER GLASS INSULATION MATERIALS
Standards*
Conductor material*
Glas-Yarn
Polyester-Glas Yan
Glas + Polyester
IEC 60317-0-4
IEC 60317-31
IEC 60317-32
IEC 60317-33
Copper, soft
Copper, soft
Copper, soft
AluminiumAluminium Aluminium
Conductor type*Rectangular
Rectangular
Rectangular
hollow conductor
hollow conductor
hollow conductor
Insulation*
Bare conductor
Magnet Wire (TI 200) G1 or G2
Magnet Wire (TI 220) G1 or G2
Wrapped whith PI-foil
Yarn
E-Glasyarn, free alkali
Bare conductor
Magnet Wire (TI 200) G1 or G2
Magnet Wire (TI 220) G1 or G2
Wrapped whit PI-foil
Bare conductor
Magnet Wire (TI 200) G1 or G2
Magnet Wire (TI 220) G1 or G2
Wrapped whit PI-foil
Glas - Polyester
(TI 155)
Glas - Polyester + E-Glasyarn
impregnated
Layers 1-layer1-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*
Bond Coat*
Epoxy (TI 155)
Possible, but not necessary
Polyester (TI 155)
(see left column)
Polyesterimid (TI 180)
Silicon (TI 200)
Epoxy (TI 155)
Polyester (TI 155)
Polyesterimid (TI 180)
Silicon (TI 200)
Epoxy bi-stage
Epoxy bi-stage
Epoxy bi-stage
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
≤ 80 mm2
≤ 80 mm2
≤ 80 mm2
< 8 : 1
< 8 : 1
<8:1
< 125 Mpa
< 125 Mpa
< 125 Mpa
Sizes*
Cross-section
Ration width / thickness
Proof stress
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
1,00 - 3,30 mm
3,50 - 39 mm2 ≥ 2.5:1 - ≤ 8.0:1
Width
Height
Ratio height Min. Transposing pitch length
7,0 ≤ 26
3,0 ≤ 79
≥ 1:3 - ≤ 8:1
25 mm
3,10 - 12,50 mm
BUNDLE
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
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