To a n y l e n g t h

®
MILAN
PRECISION WIRES INDIA LTD.
WINDING WIRES PRECISION
C O N CTO EN TNE NTT SS PRECISION WIRES INDIA LIMITED (PWIL)

QUALITY ASSURANCE

UL RECOGNITION
1

UL RECOGNIZED PRECISION ENAMELLED WINDING WIRES 2

TECHNOLOGY TRANSFER AGREEMENT BETWEEN PWIL AND 2

M/S. ESSEX ITALY S.p.A.

PRECISION WIRES APPLICATIONS AND CUSTOMER PROFILE 2

PRECISION WIRES EXPANSION PLANS 3

PRECISION WIRES CATERING TO EXPORT MARKETS 3

CERTIFICATIONS & RECOGNITIONS 3

PRODUCT RANGE

I) ENAMELLED ROUND WIRES 4

DELIVERY SPOOLS 8

ORDERING INFORMATION 12

II) RECTANGULAR ENAMELLED WIRES 13

DELIVERY SPOOLS 13

ORDERING INFORMATION 13

III) RECTANGULAR INSULATED CONDUCTORS OF 16

VARIOUS TYPES

DELIVERY SPOOLS 17

ORDERING INFORMATION 17

IV) CONTINUOUSLY TRANSPOSED CONDUCTORS (CTC) 18

DELIVERY SPOOLS 25

ORDERING INFORMATION 26
Precision Wires India Limited (PWIL)
PWIL is the largest Indian manufacturer of Enamelled Copper Winding Wires using world standard
technology with the help of foreign trained personnel.

Extremely rigorous and systematic testing procedures are routinely followed to ensure excellence
in the quality of wires. Our installed winding wire both round & rectangular manufacturing capacity
currently is 26000 MT/annum which is the highest in India. This is further being increased to above
30000 MT/annum by 2010. At present PWIL has four plants.

PWIL was promoted in 1989 by (erstwhile) Atlas Wires Limited (AWL) for the manufacture of
Enamelled Copper Winding Wires. (Erstwhile) AWL's first manufacturing facility was established in
1981 at Palej, Gujarat. (Erstwhile) AWL amalgamated into PWIL with effect from 4th May, 2001.
PWIL is the largest manufacturer of its kind in India.

PWIL is a public limited company listed with the BSE and NSE stock exchanges and the promoter
directors of (erstwhile) AWL have been in charge of the management and control of PWIL from the
very beginning.

PWIL's current production range in round wire is between 5 SWG and 47 SWG (including
equivalent in metric and AWG sizes), Rectangular Enamelled Winding Wires with cross sectional
area from 3 sqmm to 75 sqmm and Continuously Transposed Conductors (CTC) from 5 strands to
43 strands in various varieties. PWIL's wires are coated with a variety of enamels.

PWIL produces wires as per various technical specifications including IEC, ISS, BSS, DIN, NEMA,
ASTM & JIS as well as per specific requirements of our customers and also offer winding wires on
returnable tapered plastic spools in pail packings if required.

PWIL's customers include large manufacturers of electrical and electronic equipment, of

international repute. Customers are catered through a well built network of branches and stockists
all over the country.

Quality Assurance
Our quality assurance laboratories are fully equipped to test and certify wire properties according to
national and international specifications such as IS, IEC, NEMA, JIS standards for winding wires. Apart
from these we supply wires meeting customers' stringent additional requirements and specifications.

UL Recognition
Our several Enamelled Wire types are tested and listed by UL (Under Writers Laboratories, USA).
This provides utmost confidence to our Indian and overseas customers regarding reliability and
consistent quality of products supplied.

®
MILAN 1
WINDING WIRES
UL Recognized Precision Enamelled Winding Wires
UL File No. E 174288 Magnet Wire Component
Coat Type (Insulation Type) ANSI Type
PWIL Temperature
Code OC (Over Coat / American/NEMA Class
BC (Base Coat)
Top Coat) Standard MW1000
Preci-1, Preci-3 Polyester Polyamide MW 24 155
Preci-2 Polyester Polyamide MW 76 180
Preci-4 Polyester Polyamide-imide MW 35 200
Preci-5, Preci-6 Polyesterimide Polyamide-imide MW 35, MW 73 200 & 220 (*)
Preci-7 Polyesterimide Polyamide-imide MW 35, MW 73 200 & 220 (*)
Preci-8 Polyesterimide Polyamide MW 24, MW 76 155 & 180
Preci-9 Polyurethane — MW 79 155
(*) Non ANSI type

Technology Transfer Agreement Between PWIL and

M/s. ESSEX Italy S.p.A. :
PWIL has recently entered into a long term Technology Transfer Agreement with ESSEX Italy for
manufacture of Continuously Transposed Conductors (CTC), Enamelled Copper Strips and various
other types of Rectangular Insulated Winding Wires.
ESSEX Italy is a world leader in the manufacture of Rectangular Insulated Conductors and is one
of the largest and most renowned global producers of CTC.
The above Agreement gives PWIL full access to the latest Technology for all the above products as
well as comprehensive training of personnel.
During the last few months, many PWIL personnel have undergone extensive training by ESSEX
Italy both in India and abroad.
On account of the above Agreement, PWIL is assured continuous and constant Technology,
Training, Support and Backup on a long term basis for all the above products which will no doubt
help to increase the level of Customer Confidence.

Precision Wires Applications and Customer Profile

PWIL is today the foremost supplier of Enamelled Winding Wires in India and in many overseas
countries. PWIL wires are widely used by manufacturers of :-
u Rotating machines (manufacturer and repairer)
u Alternators
u Hermetic motors (for refrigeration and air conditioning equipment)
u Power and Distribution Transformers
u Control and Power supply Transformers
u Ballasts
u Auto Electricals
u Electric hand Tools
u House hold appliances
u Fans
u Switchgear, relay and magnet coils
u Instruments and audio coils and many others
®

2
PRECISION
Precision Wires Expansion Plans
PWIL is continuously striving to meet Indian and overseas customers demand for new wire
insulation types and sizes. In order to further expand our wire range, we are planning to
manufacture new types of wires such as :
u Enamelled and glass covered rectangular wires
u Polyimide tape covered wires
u Aromatic Polyamide (Capton) tape covered wires
u Aluminium Round Enamelled Wires
With these expanded range, PWIL will be able to cater to the demands of all rotating & static
electrical equipment manufacturers in India and Overseas.

Precision Wires Catering to Export Markets

Export related production of PWIL is increasing and our current export volumes are about 15% of
the total production.

Certifications & Recognitions

u The high Quality & Consistency of our products has won the confidence of our customers.
Several of our prestigious customers have rated us as the best supplier.
u All our plants are certified for Quality Management System ISO 9001:2000. We are also
certified for ISO TS 16949:2002.
u Our Bare Conductor production unit is in the process of getting certified to ISO 9001:2000
shortly.

DET NORSKE VERITAS

DET NORSKE VERITAS
MANAGEMENT SYSTEM CERTIFICATE MANAGEMENT SYSTEM CERTIFICATE
Certificate No. CERT-12053-2004-AQ-HOU-IATF Certificate No. CERT-07486-2004-AQ-HOU-IATF
IATF Certificate No. 0050684 IATF Certificate No. 0058852
Page 1 of 1 Page 1 of 1
This is to certify that the Quality Management System of This is to certify that the Quality Management System of

PRECISION WIRES INDIA LTD. PRECISION WIRES INDIA LIMITED

(UNIT II ATLAS WIRES SILVASSA) at
at Plot 125/2, Amli Hanuman (66 KVA) Road, Silvassa - 396 230, India
Plot 125 Amli Hanuman Road, Silvassa - 396 230, India Remote Supporting Functions
Site Certification Site Main
Remote Supporting Functions Site Name Site Address Site City
State Body Activities
Name Address Scope
Precision Wires India Ltd. Saiman House, 2nd Floor Marketing, Precision Saiman House, 2nd Floor, . A.
Mumbai -- Marketing,Sales
(Unit II Atlas Wires Silvassa) J. A. Raul Street, Off. sayana road Purchasing Wires India Raul Street, Off. Sayana Road, India DNV
400 025 Purchasing
Prabhadevi, Mumbai 400 025, India Limited Prabhadevi
Has been found to conform to Technical Specification: Has been found to conform to Technical Specification:
ISO/TS 16949:2002 ISO/TS 16949:2002
having been audited in accordance with the: having been audited in accordance with the:
Rules for the registration scheme for ISO/TS 16949:2002 -- 2nd Edition. Rules for the registration scheme for ISO/TS 16949:2002 -- 2nd Edition.
This Certificate is valid for the following products/service ranges: This Certificate is valid for the following products/service ranges:
MANUFACTURE OF ENAMELLED ROUND WINDING WIRES MADE OF COPPER MANUFACTURE OF ENAMELLED ROUND WINDING WIRES MADE OF COPPER
EXCLUSION: 7.3 PRODUCT DESIGN EXCLUSION: 7.3 PRODUCT DESIGN AND DEVELOPMENT
Place and date: This certificate is valid until: Place and date: This certificate is valid until:
Houston, Texas; 23 May 2007 08 May 2010 Houston, Texas; 01 November 2007 30 October,2010
for the Recognized Office: Initial Certification Date:
for the Recognized Office: Initial Certification Date: DET NORSKE VERITAS CERTIFICATION, INC.
Houston, TX USA
31 October,2010
DET NORSKE VERITAS CERTIFICATION, INC. 09 May 2007
Houston, TX USA
L. Umanath
T J Manohar Robert Kozak L. Umanath
Robert Kozak T J Manohar Management Representative Lead Auditor
Lead Auditor Det Norske Veritas Certification, Inc.
Management Representative
Det Norske Veritas Certification, Inc.

Audit Conducted by DNV Office located in Chennai, India

DET NORSKE VERITAS CERTIFICATION INC., 16340 PARK TEN PLACE, HOUSTON, TX 77084, TEL: 281-721-6600-WWW-DNVCERT.COM
Audit Conducted by DNV Office located in Chennai, India

DET NORSKE VERITAS DET NORSKE VERITAS

MANAGEMENT SYSTEM CERTIFICATE MANAGEMENT SYSTEM CERTIFICATE
Certificate No.3450-2007-AQ-IND-RvA Certificate No. 1169-2007-AQ-IND-RvA

This is to certify that This is to certify that

the Quality Management System the Quality Management System
of of

PRECISION WIRES INDIA LIMITED PRECISION WIRES INDIA LIMITED

(UNIT II : ATLAS WIRES, SILVASSA) (Unit I, Atlas Wires - Palej)
at at
Works: Plot Survey 125, Amli Hanuman Road, (66KvA Road), Silvassa - 396 230. Works : National Highway No. 8, Palej, Dist : Bharuch - 392 220, INDIA
U.T. of Dadra & Nagar Haveli, INDIA. Regd. Office: Saiman House, J.L. Raul Road, Off Sayani Road, Prabhadevi, Mumbai - 400 025, INDIA
Regd. Office: Saiman House, J.L. Raul Road, Off Sayani Road, Prabhadevi, Mumbai - 400 025, INDIA

has been found to conform to the Quality Management System Standard: has been found to conform to the Quality Management System Standard:
ISO 9001:2000 ISO 9001:2000
This Certificate is valid for the following product or service ranges: This Certificate is valid for the following product or service ranges:

MANUFACTURE AND SUPPLY OF ENAMELLED ROUND & RECTANGULAR MANUFACTURE AND SUPPLY OF ENAMELLED ROUND
COPPER WINDING WIRES, CONTINUOSLY TRANSPOSED CONDUCTORS AND WINDING WIRES MADE OF COPPER
OTHER INSULATED & TAPED WINDING WIRES FOR ELECTRICAL MACHINES

Original Certification date: Place and date: Original Certification date: Place and date:
2000-05-12 Chennai, 2007-05-24 2000-10-12 Chennai, 2007-10-22

This Certificate is valid until: for the Accredited Unit: This Certificate is valid until: for the Accredited Unit:
2009-05-12 DNV CERTIFICATION B.V., 2009-10-12 DNV CERTIFICATION B.V.,
THE NETHERLANDS THE NETHERLANDS

Compliance to the Standard in respect to the indicated scope Compliance to the Standard in respect to the indicated scope
is verified by the DNV approved registered Team Leader: is verified by the DNV approved registered Team Leader:

Avinash Dhavale Krishnakumar N.R. Avinash Dhavale Krishnakumar N.R.

Lead Auditor Management Representative Lead Auditor Management Representative
Lack of fulfillment of conditions as set out in the Appendix may render this Certificate invalid. Lack of fulfillment of conditions as set out in the Appendix may render this Certificate invalid.

DNV CERTIFICATION B.V. Haastrechtstraat 7. 3079 DC Rotterdam. The Netherlands. TEL.INT.:+31 10 2922 688. FAX:+31 10 4796 768 DNV CERTIFICATION B.V. Haastrechtstraat 7. 3079 DC Rotterdam. The Netherlands. TEL.INT.:+31 10 2922 688. FAX:+31 10 4796 768

®
MILAN 3
WINDING WIRES
Product Range
I) Enamelled Round Wires

PWIL today manufactures wide range of Enamelled Round Winding Wires for use in electrical

machines such as motors, generators, transformers, house hold appliances, auto-electrical,

electrical hand tools, refrigeration (hermetic) motors, fans, switchgears, coils and relays, ballasts

and host of other electrical machines.

Present range of Enamelled Winding Wires manufactured by PWIL covers round copper wire sizes

from 0.050 mm dia to 5.000 mm dia (including equivalent in metric and AWG sizes),

These wire sizes are available with various

insulation coatings, such as :

u Poly Vinyl Acetal, Class 105

u Polyester, Class 130 and 155

u Polyurethane, Class 130, 155 and 180

u Polyesterimide 180

u Dual Coated Polyester (imide) + Polyamide imide, Class 200

u Polyamide imide, Class 200

u Polyesterimide Bondable, Class 155 and 180

u Polyurethane Bondable, Class 130, 155 and 180

u Dual Coated Polyester (imide) + Polyamide, Class 155 and 180

u And other insulation coatings according to customer specifications

4
PRECISION
Product Range Round Wires
1 2 3 4 5 6

High mechanical Self solderable General High mechanical/ High Thermal High
Type of enamelled wire & mechanical/
strength & bondable purpose strength strength temperature

SPECIFICATION IS : 13730-1/ IS : 13730-2/ IS : 13730-3/ IS : 13730-4/ IS : 13730-7/ IS : 13730-8/

IEC-60317-1/ IEC-60317-2 IEC-60317-3/ IEC-60317-4/ IEC-60317-7 IEC-60317-8/
STANDARD* NEMA NEMA NEMA NEMA
MW-15C- MW-5C MW-75C/ MW-30C/
JIS C 3202-PVF JIS C 3202-UEW 72C (Hermetic)
JIS C 3202-EIW

THERMAL CLASS 130 (B) 130 (B) 155 (F) 130 (B) 200 180 (H)

Modified Modified
Chemical base of base coat Polyurethane Polyurethane Polyimide Polyesterimide
Polyvinyl Acetal Polyester
Polyvinyl
Chemical base of top coat Not applicable
butyral/Polyamide
Not applicable Not applicable Not applicable Not applicable

Range of Wire (Diameter) 5.000-0.500 mm 2.000-0.050 mm 5.000-0.050 mm 2.000-0.050 mm 5.000-0.020 mm 5.000-0.050 mm

Insulation Range Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1 & 2 Grade 1, 2 & 3
as per IEC as per IEC as per IEC as per IEC as per IEC as per IEC
(Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single & Heavy (Single, Heavy
& Triple & Triple & Triple & Triple as per NEMA) & Triple
as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA)
Golden Yellow As per Light Brown/ As per Golden Yellow Light Brown/
Standard colour to Light Orange requirements Medium Brown requirements to Light Orange Medium Brown

UL Listed File No. : None File No. : None File No. : None File No. : None File No. : None File No. : None

TECHNICAL PROPERTIES AS PER

IS:13730-0-1 / IEC-60317-0-1

Heat shock (ºC) 155 155 175 155 240 200

Cut through (ºC) 170 170 240 170 400 300

Solderable temperature (ºC) Not applicable 375 Not applicable 375 Not applicable Not applicable

Resistance to Abrasion for 1.00mm >11.3 >9.3 >10.4 >9.3 >6.6 >10.9
dia grade 2 wire (n)
Resistance to refrigerants Very good Not applicable Not applicable Not applicable Very Good Good

Flexibility & Adherence Very good Good Good Good Very Good Good

170/200
Bonding Temperature (ºC) Not applicable depending Not applicable Not applicable Not applicable Not applicable
on overcoat
SPECIAL CHARACTERISTICS High Solderable, Upgraded Self solderable Designed Good
& APPLICATION mechanical thermoplastic thermo property with for using of resistance
properties, bonded by heat mechanical good insulation wire for against
good or solvent, used properties resistance, high product with refrigerants,
transformer oil for all self compared to flexibility used in maximum transformer oil.
resistance,
supported coils ordinary all value of the High burnout
suitable for
130ºC for television, polyesters, communication thermal and resistance,
Hermetic electronics, used in ignition equipments, mechanical used in fhp
applications, small motors, coils, relays, magnetic characteristics motors,
used in oil filled relays, oil filled spools, hermetic
transformers & magnets, transformers, universal & application and
equipments telephones & relays, non- thermal class
requiring high voice coils of all contactors, fhp impregnated 180ºC
mechanical kinds can be motors. This winding of all equipments.
properties such
as auto bonded in forms version can also kinds of
electricals. by heating at be made for transformers.
170 /180ºC upgraded
abrasion.

Delivery Spools Please refer to DELIVERY SPOOLS for Sizes & Respective Spool Types

Can be supplied Can be supplied Can be supplied

Special Notes with Polyamide with Polyamide with Polyamide
(Nylon) (Nylon) topcoated (Nylon)
topcoated for for improved topcoated for
improved high- high-speed improved high-
speed windability, windability, if speed windability,
if required. required. if required.

* IS 13730 and IEC 60317 are completely harmonized standards and identical.
®
MILAN 5
WINDING WIRES
Product Range Round Wires (Contd...)
7 8 9 10 11 12 13 14 15

High Self Self Self High Self High General

temperature solderable solderable solderable temperature solderable temperature purpose

IS : 13730-13/ IS : 13730-19/ IS : 13730-20/ IS : 13730-21/ IS : 13730-22/ IS : 13730-23/ IS : 13730 (Under IS : 13730-26/ IS : 13730-34/
IEC-60371-13/ IEC-60317-19 IEC-60317-20/ IEC-60317-21 IEC-60317-22/ IEC-60317-23 preparation)/ IEC-60317-26/ IEC-60317-34/
NEMA NEMA NEMA NEMA IEC-60317 (Under NEMA JIS C 3202-PEW
MW-35C/ MW-28C MW-79C MW-76C preparation)/ MW-81C
73C (Hermetic) NEMA MW-24C

200 (C) 130 (B) 155 (F) 155 (F) 180 (H) 180 (H) 155 (F) 200 (C) 130 (B)

Theicpolyester / Polyester/
Polyurethane Polyurethane Polyurethane Polyesterimide Polyester Polyamideimide Polyester
Polyesterimide Polyesterimide

Polyamideimide Nylon Not applicable Nylon Nylon Not applicable Polyamide Not applicable Not applicable

5.000-0.050 mm 2.000-0.050 mm 0.800-0.050 mm 1.60-0.050 mm 5.000-0.050 mm 1.60-0.050 mm 1.60-0.254 mm 1.60-0.071 mm 5.000-0.050 mm

Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3
as per IEC as per IEC as per IEC as per IEC as per IEC as per IEC as per IEC as per IEC as per IEC
(Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy
& Triple & Triple & Triple & Triple & Triple & Triple & Triple & Triple & Triple
as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA)
Light Brown As per As per As per Medium Brown Light Brown As per Light Brown Medium Brown
Medium Brown requirements requirements requirements to Dark Brown requirement
File No. : E174288 File No. : E174288 File No. : E174288 File No. : E174288
Thermal Class
200 and 220 Thermal Class 155 Thermal Class 180 Thermal Class 155

220 155 175 175 200 200 175 220 155

320 170 200 200 265 265 240 350 240

Not applicable 375 390 390 Not applicable 470 Not applicable Not applicable Not applicable

>8.1 >7.05
>11.3 >9.3 >9.3 >10.9 >10.9 >10.0 >10.4
(0.8 mm) (for gr.1)

Very good Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable Very good Not applicable

Very good Good Good Good Good Good Good Good Good

Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable

Very good Low coefficient Self solderable Low coefficient Used in all Self solderable Good High burnout Good thermal &
resistance for of friction, property with its of friction, 180ºC class with high mechanical, resistance, electrical
refrigerants & besides low dielectric besides equipment potential both electrical & excellent properties,
chemicals, high properties of dissipation properties of requiring high under the dry chemical windability, low used in general
burnout general factor under polyurethane, speed machine and humid resistance coefficient of purpose
resistance, suitable for friction, high rotating & static
purpose high frequency. winding, low conditions, properties.
excellent
polyurethane. It can be widely winding in coefficient of good properties Improved for slot fill factor, electrical
windability, low
It is suitable for used in small and friction. in heat shock high speed used in special equipments, oil
coefficient of
friction, high winding in small electrical medium and cut through, winding. types of transformers,
slotfill factor, size motors, instruments of electrical it is suitable for FHP motors, motors & control coils.
used in special coils of machine tools, instruments, the coils of coils & relays, electromotive
motors including electrical motors which for high speed various motor audio & tools.
Hermetic motors, instruments, have special winding. appliances, instrument
Armatures, especially of requirements of instruments and coils.
Alternators, high speed this type of telephone
Power Tools and winding. enamel. equipments.
high HP motors,
suitable for high
speed coil
winding.

Please refer to DELIVERY SPOOLS for Sizes & Respective Spool Types

Top coat Can be supplied Can be supplied

Polyamide imide with Polyamide with Polyamide
can be supplied (Nylon) (Nylon) topcoated
of the type Self topcoated for improved
Lubricated, if for improved high-speed
required high-speed
windability, if windability,
required. if required.

* IS 13730 and IEC 60317 are completely harmonized standards and identical.
®

6
PRECISION
Product Range Round Wires (Contd...)
16 17 18 19 20 21

Self solderable/ Self solderable/ Self General General Self solderable

Type of enamelled wire
Self bonding Self bonding bonding purpose purpose High Temperature

SPECIFICATION IS : 13730-35/ IS : 13730-36/ IS : 13730-37/ IS : 13730-45/ IS : 13730-54/ IS : 13730-51/

IEC-60317-35 IEC-60317-36 IEC-60317-37 IEC-60317-45 IEC-60317-54 IEC-60317-51/
STANDARD* JIS C 3202-SBUEW JIS C 3202-SBUEW NEMA
MW-82C

THERMAL CLASS 155 (F) 180 (H) 180 (H) 130 (B) 155 (F) 180 (H)

Chemical base of base coat Polyurethane Polyesterimide Polyesterimide Polyester Polyester Polyurethane

Polyvinyl Polyvinyl Polyvinyl

Chemical base of top coat butyral/Polyamide butyral/Polyamide butyral/Polyamide
Not applicable Not applicable Not applicable

Range of Wire (Diameter) 0.800-0.050 mm 1.60-0.050 mm 1.60-0.050 mm 5.000-0.050 mm 5.000-0.050 mm 1.00-0.050 mm

Insulation Range Grade 1b, 2b & 3b Grade 1b, 2b & 3b Grade 1b, 2b & 3b Grade 1, 2 & 3 Grade 1, 2 & 3 Grade 1, 2 & 3
as per IEC as per IEC as per IEC as per IEC as per IEC as per IEC
(Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy (Single, Heavy
& Triple & Triple & Triple & Triple & Triple & Triple
as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA) as per NEMA)
As per Light Brown / Light Brown/ Light Brown/ Light Brown/ As per
Standard colour requirements Dark Brown Dark Brown Medium Brown Medium Brown requirements

UL Listed

TECHNICAL PROPERTIES AS PER

IS:13730-0-1 / IEC-60317-0-1

Heat shock (ºC) 175 200 200 155 175 200

Cut through (ºC) 200 265 300 240 240 240

Solderable temperature (ºC) 390 470 Not applicable Not applicable Not applicable 450

Resistance to Abrasion for 1.00mm >8.1 >10.9 >10.9 >10.4 >10.4 >7.8
dia grade 2 wire (n)
Resistance to refrigerants Not applicable Not applicable Not applicable Not applicable Not applicable Not applicable

Flexibility & Adherence Good Good Good Good Good Good

170/200 depending 170/200 depending 170/200 depending

Bonding Temperature (ºC) Not applicable Not applicable Not applicable
on overcoat on overcoat on overcoat

SPECIAL CHARACTERISTICS Solderable, Solderable, Class 180ºC General purpose General purpose Good mechanical,
& APPLICATION thermoplastic thermoplastic with self bonding 130ºC polyster. 155ºC polyester electrical &
bonded by heat bonded by heat property and Good thermal & with heat shock chemical
or solvent, used or solvent, used all other electrical at higher mandrel resistant
for all self for all self properties of properties, diameter. Good properties.
supported coils supported Polyesterimide. used in general thermal & Improved thermal
for television, coils for television, purpose electrical resistance. Fast
electronics, small electronics, small rotating & properties, solderability.
motors, relays, motors, relays, static electrical used in general Fractional &
magnets, magnets, equipments, oil purpose rotating integral
telephones & telephones & transformers, & static electrical horsepower
voice coils of voice coils of control coils. equipments, oil motors
all kinds all kinds can be transformers, Class 155.
can be bonded in bonded in control coils. Coils & relays.
forms by heating forms by heating Instrument &
at 170/180ºC at 170/180ºC audio coils.

Delivery Spools Please refer to DELIVERY SPOOLS for Sizes & Respective Spool Types

Can be supplied Can be supplied Can be supplied

Special Notes with Polyamide with Polyamide with Polyamide
(Nylon) topcoated (Nylon) topcoated (Nylon) topcoated
for improved high- for improved high- for improved high-
speed windability, speed windability, speed windability,
if required. if required. if required.

* IS 13730 and IEC 60317 are completely harmonized standards and identical.
®
MILAN 7
WINDING WIRES
Delivery Spools
PWIL make Enamelled Round Winding Wires are supplied on plastic spools, both Cylindrical Barrelled and
Taper Barrelled, as per the customer demand.

These spools are generally according to specifications :

IEC 60264-2-2 : Specification for Cylindrical Barrelled plastic spools, returnable type.
IEC 60264-3-2 : Specification for Taper Barrelled plastic spools, returnable type.
Indian equivalent Cylindrical Barrelled plastic spools, non-returnable type.

Bi-Conical Plastic Spools are available for fine wire between 0.2 mm - 0.05mm upon specific request.

Wire sizes & Respective Spool Types :

Cylindrical Barrelled Spools

Size Range (mm)
IEC 60264-2-2
Indian Equivalent Spools
(Cylindrical Barrelled Spools)
(Refer figure 4)
(Refer figure 1)

5.000 to 0.500 355, 250 & 200 250 mm

0.500 to 0.350 355, 250, 200 & 160 250 & 160

0.350 to 0.200 355, 250, 200, 160 & 125 250, 160 & 125

0.200 to 0.080 250, 200, 160 & 125 250, 160 & 125

Taper Barrelled Spools

IEC 60264-3-2
As per JIS Spools
Size Range (mm) (Taper Barrelled Spools)
(Refer figure 3)
(Refer figure 2)

5.000 to 0.500 200/315, 250/400, 315/500 —

400/630 & 500/800

0.500 to 0.200 200/315, 250/400, 315/500 —

& 400/630

0.200 to 0.120 200/315, 250/400, 315/500 PT-10

& 400/630

0.120 to 0.080 — PT-10 & PT-4

Other Spools available on request.

8
PRECISION
 y A y A

r r

Øz A
a

t2
A
d5
e1

~ 60 o

d1
d4

d2
d3
t1

l2 d6

l1

Figure 1: Cylindrical Barrelled Spool

Table 1 : Dimensions of Cylindrical Barrelled Spools (Returnable) (See Figure 1)

Dimensions
(mm) Net
Spool Weight,
d1 d2 d3 d4 d5 d6 l1 l2 a t1 t2 z y e1 r
Type Max.
(Kg.)
Nom. Tol. Nom. Tol.

125 125 80 16 +0.20 24 7 3 125 100 0.2 1.5 25 8 0.6 0.2 20 3 3

160 160 100 22 +0.20 34 13 3 160 128 0.2 1.5 28 12 0.6 0.3 32 3 7

200 200 125 22 +0.20 34 13 3 200 160 0.3 1.5 32 12 0.6 0.3 32 4 14

250 250 160 22 +0.20 34 13 4 200 160 0.4 2.0 36 12 1.0 0.4 32 5 22

355 355 224 22 +0.50 60 26 4 200 160 0.4 2.5 40 30 1.2 0.5 80 5 48

®
MILAN 9
WINDING WIRES
 d3

60 o

ø100+0.50

s1
3
=
R d4

-0.1
18 o
y A

+
3
=
z A R
5
Datum face

l2

l1
Detail at X (only applicable
to spool types of table 2)
120 min.
y A

X d2
3
=
R
60 o
t1

ø16
ø100+0.50
A
ø106
ø125
d1

Figure 2: Taper Barrelled Spools (IEC 60264-3-2)

Table 2 : Dimensions of Taper Barrelled Spools (Returnable) (See Figure 2)

Dimensions
(mm) Net
Spool Weight,
Type d1 d2 d3 d4 l1 l2 t1 s1 z y Max.
(Kg.)
max. Nom. Tol. max.

200/315 200 125 190 112 315 265 +0.30 7 25 0.4 0.3 25

250/400 250 160 236 140 400 335 +0.50 15 32.5 0.6 0.4 45

315/500 315 200 300 180 500 425 +0.80 20 37.5 1.0 0.6 90

400/630 400 250 375 224 630 530 +1.00 30 50 2.0 1.0 180

500/800 500 315 475 280 800 670 +2.00 30 65 2.5 1.5 400

10
PRECISION
 G
F

D
E
C

125
A B

Figure 3 : Taper Barrelled Spools (PT 4 & PT 10)

Table 3 : Dimensions of Taper Barrelled Spools (See Figure 3)

Spool A B C D E F G Wire Net
Type Size Weight,
(mm) max. (Kg)
PT-4 140 90 15 175 200 70 120 0.050- 4
0.130
PT-10 180 110 15 210 230 100 160 0.050- 10
0.350
PT-11 180 110 22 200 230 95 170 0.050- 11
0.350
PT-15 200 110 30 200 225 95 180 0.130- 15
0.350
PT-20 230 150 32 247 277 132 212 0.130- 20
0.350
PT-25 230 130 30 250 275 110 215 0.130- 25
0.350

®
MILAN 11
WINDING WIRES
 A
B

E
C
60o

Figure 4 : Indian equivalent Cylindrical Barrelled Plastic Spool

Table 4 : Dimensions of Indian equivalent Cylindrical Barrelled Plastic Spool (See Figure 4)

Spool Type A B C D E Net

Weight,
mm mm mm mm mm
Max. (Kg.)

125 125 65 20 70 95 3

160 160 95 35 102 125 7

250 250 115 40 120 150 20

500 500 300 38 240 276 110

Ordering Information
We need the following information from our valued clients to understand fully your requirement and deliver the
right product :
u Wire Size nominal diameter in MM or SWG or AWG.
u Conductor : Copper or Aluminium.
u Type of Insulation and thermal class, e.g. Polyester imide, Class 180 or Dual coated Polyester +
Polyamide imide Class 200 or Polyurethane solderable, Class 155, etc.
u Grade of insulation (thickness), e.g. Grade 1 or 2 or 3, or Single, heavy or triple.
u Specification reference : e.g. IEC 60317-8 or IEC 60317-13 or NEMA MW 1000-Part 24C.
u Packing : Spool size required (for specific Type please refer to Tables 1, 2, 3 and 4).
u Net Quantity : Quantity of Wire required, e.g. 2500 kg.
For any other special requirement, please address your query to our Marketing Department in Mumbai by
e-mail mumbai@pwil.net ®

12
PRECISION
II) Rectangular Enamelled Wires
u Poly Vinyl Acetal, Class 105, 130
u Polyester, Class 130 and 155
u Polyesterimide 180
u Dual Coated Polyester (imide) + Polyamide imide, Class 200
u Polyamide imide, Class 200
u Polyesterimide Bondable, Class 155 and 180
u And other insulation coatings according to customer specifications

Delivery Spools
Dimensions of Drums (All dimensions in mm)

Flange Barrel Traverse Flange Bore Catch hole Slot/hole No. of Wt.
Dia Dia Thick Dia Distance on barrel iron tube Kgs.
450 300 200 18 38 120 15 5 50
450 300 240 18 38 120 15 5 65
500 300 240 18 38 120 15 5 110
560 300 240 18 38 120 15 5 160
650 400 240 20 38 120 15 6 200
710 400 300 20 38 120 15 7 225
710 560 300 20 38 140 15 7 200
760 460 300 22 38 120 15 8 260
760** 560 300 22 38 140 15 8 225
810** 560 300 25 38 140 15 10 240
860** 560 300 25 38 140 15 10 290
910** 560 300 25 38 140 15 10 380

Note : 1) Catch hole dia for all the drums will be 16mm.
2) ** One additional hole of 18mm to be provided on flange at 290mm distance from centre.

Ordering Information
We need the following information from our valued clients to understand fully your requirement and deliver the right product :
u Size : Width X Thickness
u Conductor : Copper or Aluminium.
u Type of Insulation and thermal class, e.g. Polyester imide, Class 180 or Dual coated Polyester + Polyamide imide
Class 200 or Polyurethane solderable, Class 155, etc.
u Grade of insulation (thickness), e.g. Grade 1 or 2 or 3, or Single, heavy or triple.
u Specification reference : e.g. IEC 60317-28, NEMA etc.
u Packing : Spool size required (for specification refer table above).
u Net Quantity : Quantity of Wire required, e.g. 2500 kg.
For any other special requirement, please address your query to our Marketing Department in Mumbai by
e-mail mumbai@pwil.net

®
MILAN 13
WINDING WIRES
Product Range - Rectangular Enamelled Copper Wires
1 2 3 4 5

SPECIFICATION IEC-60317-17 IEC-60317-18 IEC-60317-16 IEC-60317-28 IEC-60317-29/

NEMA NEMA
STANDARD MW-18C MW-36C

THERMAL CLASS 105 120 155 180 200

Chemical base of base coat Polyvinyl Acetal Polyvinyl Acetal Polyester Polyesterimide Polyesterimide

Chemical base of top coat Polyamide-imide

Range of Wire (Diameter) Cross section area up to 80 sp.mm, Thickness : from 1.3-8 mm, Width : from 2.0-16 mm

Insulation Range
IEC Grade 1:0.060-0.110, IEC Grade 2:0.120-0.179;
NEMA Grade Heavy : Increase in thickness : 0.076-0.127,
Grade Quadruple : increase in thickness : 0.127-0.178mm

Standard colour Golden Yellow Golden Yellow Brown Brown Brown

TECHNICAL PROPERTIES AS PER

IEC-60317-0-2

Flexibility & Adherence

Mandrel Bending on thickness

2-3 t & 3-4 W 2-3 t & 3-4 W 3-4 t & 4-6 W 3-4 t & 4-6 W 3-4 t & 4-6 W
on width

Adherence (no crack after

15 15 15 15 15
stretching %)

Heat Shock No cracks after bending

2-3 t/155 2-3 t/155 6 t/175 6 t/200 6 t/260
on thickness / Temperature ºC

Break down voltage at Room

Grade 1 : > 1000, Grade 2: > 2000
temp. (minimum) Volts

Resistance to hot transformer oil Excellent Excellent Not applicable Excellent Excellent

Heat Bonding temperature/Time Not applicable Not applicable Not applicable Not applicable Not applicable

SPECIAL CHARACTERISTICS High mechanical strength, strong Good thermal, High thermal, High thermal,
& APPLICATION adhesion of enamel to copper and and electrical and
conductor, Excellent hydrolysis overall good overall good mechanical,
& oil resistance mechanical, mechanical, properties,
electrical and electrical and excellent heat
chemical chemical shock and
properties resistance burnout

Delivery Spools Please refer to DELIVERY SPOOLS for Sizes & Respective Spool Types

Special Notes Oil filled Oil filled Large rotating Large and special
power & large Machines electrical machines
distribution transformers such as: such as:
transformers, Loco motors,DC generators, alternators,
Inductance transformers, motors,High Motors, HV motors,
coils, etc. chokes & Voltage motors, Dry type
Inductance etc. transformers,
coils, etc. Inductor coils, etc.

14
PRECISION
Product Range - Rectangular Enamelled Copper Wires (Contd...)
6 7 8 9

SPECIFICATION IEC-60317-30 IEC-60317-58

IEC-60317-47 draft
STANDARD NEMA
MW-20C

THERMAL CLASS 220/240 220 120 180

Chemical base of base coat Polyimide Polyamide-imide Polyvinyl Acetal Polyesterimide

Chemical base of top coat Epoxy-Bond coat Epoxy-Bond coat

Range of Wire (Diameter) Cross section area up to 80 sp.mm, Thickness : from 1.3-8 mm, Width : from 2.0-16 mm

Insulation Range
IEC Grade 1:0.060-0.110, In addition to base coat increase
IEC Grade 2:0.120-0.179; in dimensions, additional bond coat
NEMA Grade Heavy : Increase in thickness : 0.076-0.127, increase in thickness of
Grade Quadruple : increase in thickness : 0.127-0.178mm 0.030 - 0.050 mm

Standard colour Light Brown Light Brown Golden Yellow Brown

TECHNICAL PROPERTIES AS PER

IEC-60317-0-2

Flexibility & Adherence

Mandrel Bending on thickness

3-4 t & 4-6 W 3-4 t & 4-6 W 2-3 t & 3-4 W 3-4 t & 4-6 W
on width

Adherence (no crack after

10 15 15 15
stretching %)

Heat Shock No cracks after bending

6 t /260 6 t /240 2-3 t/155 6 t/200
on thickness / Temperature ºC

Break down voltage at Room

Grade 1 : > 1000, Grade 2: > 2000
temp. (minimum) Volts

Resistance to hot transformer oil Not applicable Not applicable Excellent Excellent

Heat Bonding temperature/Time Not applicable Not applicable 110 C/48 h or 120 C/24 h

SPECIAL CHARACTERISTICS Very high thermal Very high thermal Bondable coating Bondable coating
& APPLICATION properties properties with excellent with excellent
mechanical thermal
properties properties

Delivery Spools Please refer to DELIVERY SPOOLS for Sizes & Respective Spool Types

Special Notes Special electrical Large and special Oil filled large transformers, Loco transformers,
machine electrical machines chokes &Inductance coils, particularly
and such as: Generators, with improved mechanical
magnet Motors, HV motors, strength(hoop stress)
coils for Dry type transformers, to resist high short circuit
aerospace Inductor coils ,etc.
industry

®
MILAN 15
WINDING WIRES
III) Rectangular Insulated Conductors of various types

Our Product Range

u Paper Insulated Rectangular Copper Conductors as per IEC 60317-27 as well as Customer
Specification
u NomexTM Insulated Rectangular Copper Conductors
u Mica Tape Insulated Rectangular Copper Conductors
u Special Conductors
• Paper Insulated Twin & Triple Bunched Rectangular Copper Conductors
• NomexTM + Enamelled Insulated Rectangular Copper Conductors
• Bare/Enamelled Rectangular Copper Conductor insulated with Epoxy paper (Single and
Bunched)
[All the above can be offered with controlled Proof Stress]
u Type of Insulating materials
• Kraft papers, Thermally Stabilized papers and Other papers of various types
• KRAFT paper insulation
This is a cellulose based paper which is widely used for conductor insulation in oil filled
transformers. There are various grades of cellulose paper such as:
• Kraft paper
– Thermal class E (120O) as per IEC 554-3-5 in thickness from 50 to 125 microns.
– Thermally Upgraded paper Thermal class E (120O) as per IEC 554-3-5 in thickness from 50
to 125 microns.
– Diamond dotted Epoxy paper in various thicknesses. This improve thermal properties as
compared to normal Kraft paper.
• Mica/Polyester Tapes
– Mica/Polyester Insulation
- Mica-Polyester compounds generally comprise Mica paper on which a polyester
film coat (PETP) is spread using an epoxide resin.
- Mica paper is a type of paper composed only of small strips of Mica with no
admixture or bonding material (100% Mica).
O
- The above materials are of thermal class 155 and are used as insulation for high
voltage motor/generator windings
TM
• Nomex Tapes
TM
– Nomex paper Insulation
O
• Type 410 : This is a 220 C Aramid based calendered paper which offers high
dielectric strength, mechanical toughness, flexibility and resilience. Type 410 is
used in electrical motor, generator and transformer winding due to high temperature
index, excellent chemical resistance and outstanding overall properties.
• Type E188 : This type is used in low, medium and high voltage motors and
generators and power, distribution, dry and welding transformers and also for all
transformers requiring high thermal class.
TM
Non-flammability of Nomex allows it to be used where there are high fire risks.
u Applications
• Oil filled Power and Distribution Transformers
• Dry Type Transformers
• High Tension Motors/Generators
• Traction Equipments

16
PRECISION
 Rectangular / Single / Bunched / Triple Proof Stress Paper Covered Copper Conductor

Bare Width : 3-25 mm

Bare Thickness : 1.2-10 mm

Periphery of Rectangular Conductor : 50 mm max.

Width / Thickness ratio - 1:9

Insulation Thickness : 0.30-6 mm

Types of Lapping : Butt Lapped, 30-50% Overlapped, Interlocked; in various combinations, layers and
tape widths

No. of Layers : 1-36

Delivery Spools
DIMENSIONS OF DRUMS (All dimensions in mm)

Flange Barrel Traverse Flange Bore Catch hole Slot/hole No. of Wt.
Dia Dia Thick Dia Distance on barrel iron tube Kgs.

450 300 240 18 52 125 15 5 70

500 300 240 18 52 125 15 5 105

650 400 240 20 52 125 15 6 200

710 400 300 20 52 125 15 7 240

860** 560 300 25 52 125 15 10 350

910** 560 300 25 52 125 15 10 400

Note : 1) Catch hole dia for all the drums will be 16mm.
2) ** One additional hole of 18mm to be provided on flange at 290mm distance from centre.

Ordering Information
We need the following information from our valued clients to understand fully your requirement and deliver
the right product :
u Size : Width X Thickness.
u Mechanical property of the Conductor.
u Single / Bunched or triple.
u Thickness of Insulation.
u Min. No. of layers of Insulation.
u Length of Conductor
u No. of Bobbins.
For any other special requirement, please address your query to our Marketing Department in Mumbai by
e-mail mumbai@pwil.net
®
MILAN 17
WINDING WIRES
IV) Continuously Transposed Conductors (CTC)
WHAT IS TRANSPOSING ?

1
The enamelled wire conductors within CTC are
5 2
arranged in two parallel stacks. One stack
4 3
having one more conductor that the other. The
5 1 conductors are continuously transposed by
4 2 machine action moving them from position to
3
position in discrete steps :

5
4 1 Step 1 : Conductor 1 is moved from the top of
3 2 the left hand stack to the top of right
hand stack.
4 5
3 1
2
Step 2 : The right hand stack is moved down
one conductor thickness in relation to
4 the left hand stack.
3 5
2 1
Step 3 : Conductor 3 is moved from bottom of

3 4
right hand stack to the bottom of left
2 5 hand stack.
1

Step 4 : The left hand stack is moved up one

3
conductor thickness in relation to the
2 4
1 5 right hand stack.

2 3 At the end of four transposing steps , as shown in

1 4
the figure, the CTC conductors have returned to
5
the original geometry, but each conductor
2 advanced one position clock-wise .
1 3
5 4

1 2
5 3
4

1
5 2
4 3
®

18
PRECISION
 INTRODUCTION OF PRECITRANS™¹ CTC :
PWIL is proud to introduce the PRECITRANS™¹ family of CTC comprising the following :

Sr. Description Type of Enamel Insulation Type of Insulating Paper

No. and Thermal Class 0C
1. PRECITRANS- PVA, Kraft, Thermally Upgraded, Dennison Crepe,
PVA™¹ Class 120 Nomex or others as per Customer request.
Remarks Suitable for large Oil Filled Power and Distribution Transformers
Advantages • Improved transformer performance by reducing eddy current losses.
• Considerable increase in space factor due to very small thickness of single
conductor insulation.
• Uniform temperature distribution throughout winding.
2. PRECITRANS- PVA + Epoxy, Class 120 Kraft, Thermally Upgraded, Dennison Crepe,
BOND™¹ (The epoxy coating is cured Nomex or others as per Customer request.
to B-stage and is tack free)
Remarks Suitable for large Oil Filled Power and Distribution Transformers
Advantages • Improved transformer performance against unstable electrical network and short
circuit risks.
• Exceptional bond between Enamelled rectangular wires offers increased strength.
• Increased short circuit forces resistance due to conductor bonded like a solid beam.
• Excellent B-Stage storage stability.
• Strands bonding during drying process, hence no special treatment necessary at
users end.
0
• Epoxy resin coating cure in the same process as paper drying at 100-120 C.
• Best hot transformer oil resistance.
• Each insulated conductor has improved insulation due to Epoxy.
• Tack free and dust-free surface of insulated conductor for easy handling of Strips
without powder residue.
• No pollution since B-stage Epoxy is free from harmful solvents.
• Small thickness of Epoxy bond coat needed (0.020-0.050 mm)
• Better sliding amongst the strands, improving CTC windability.
3. PRECITRANS- Polyesterimide + Thermally Upgraded, Nomex or others as per
200™¹ Polyamideimide Class 200 Customer request.
Remarks For dry type Transformers requiring high temperature resistance
Advantages • High Temperature Resistance.
• Improved transformer performance by reducing eddy current losses.
• Considerable increase in space factor due to very small thickness of single
conductor insulation.
• Uniform temperature distribution throughout winding.
• Increased short circuit force resistance, particularly with epoxy bond coat
insulation.

Remarks :

(a) The copper conductor used is Electrolytic Tough Pitch (ETP) or Oxygen Free Copper with high
conductivity, for controlled low losses in electrical machines.

(b) The number of strands includes all numbers between 5 to 43; odd numbers can give higher cross
section area in CTC. Paper tapes up to 24 wrapping is applied as external insulation over the
transposed conductor bunch.

(c) Besides fully annealed copper conductor, PRECITRANS CTC is available with copper conductor
with controlled proof stress, for increased mechanical strength for Transformer Winding.
Standard Proof Stress Grade are as under :

®
MILAN 19
WINDING WIRES
 CONTROLLED PROOF STRESS CTC, REF STANDARD EN 13601:2002 OR BS 1432
Grade Rp (0.1%) MPa
CPR-1 140-200 Special grades supplied
against customer
CPR-2 170-220
requirement
CPR-3 220-260
FULLY ANNEALED
Annealed Rp (0.2%) 60-100 Standard grade supplied

PRECITRANS CTC CURRENT MANUFACTURING RANGE :

CONSTRUCTION DETAILS
No of Single conductors (Strands ) in CTC Up to 43 Generally odd nos.
give max C.S area
in CTC
Min. dimensions of conductor (mm) Thickness : 1.25
Width: 4.0
Max. dimensions of the single conductor (mm) Thickness : 3.00
Width : 11.5
Width to thickness ratio (Preferred) for From 2.6 min.
Single Conductor to 6.0 max.
Height to Width ratio (Preferred) of CTC Preferred height to
width ratio of CTC will
be intimated during
contract review stage
Inter column separator 0.1 mm thick Other thickness
on request
Inner paper wrapping 0.050-0.080 mm Kraft Other thickness
paper Max 22 nos. on request
Outer paper wrapping 0.080 mm thermally Other thickness on
upgraded, high request
tensile crepe paper,
last 2 paper coverings
Packing on Wooden drums From 250-4000 kg As per customer
With separators requirement
(Refer to Table on
Page No. 8)

ENAMELLED RECTANGULAR WINDING WIRES USED IN CTC :

Enamelled Rectangular Winding Wires are one of the key ingredients of CTC. Wire Enamel
being a critical input of Enamelled Rectangular Winding Wires is carefully chosen to give
the desired properties like abrasion resistance, transformer oil resistance, temperature
resistance, dielectric strength, etc.

Please refer to the following table for guidelines regarding Enamel Selection and increase
in dimensions due to Enamel insulation.

20
PRECISION
 Designation Enamel Insulation and Class Grade / Increase in
Thickness Dimensions (mm)
of Insulation due to Insulation
PRECIFORM Poly Vinyl Formal, Class 120 1 0.10 ± 0.02
2 0.13 ± 0.02
PRECITHERM- Polyesterimide + Polyamide- 1 0.10 ± 0.02
PLUS imide
2 0.15 ± 0.02
PRECIFORM- Poly Vinyl Formal, Class 120 +
BOND B-stage cured Epoxy 1 0.14 ± 0.02
2 0.17 ± 0.02
Note : The above increase in dimensions can be used as a guideline. Specific requirements can be executed as
per Customer request.

DEFINITIONS :

TRANSPOSING PITCH :
Transposing pitch “P” is the distance between two transposing.

TRANSPOSING LENGTH :
Transposing length “It” is the length measured on the CTC between two points where the
stand goes from one side to the other side of the CTC stack. The transposing length is
generally less than 50% of the Transposing Pitch “P”.

It
It < 0.5 x P P > 56mm, lt > 28mm

MINIMUM WINDING DIAMETER AND TRANSPOSING PITCH:

The first property to be satisfied during the manufacture and use of the CTC is the
windability on the transformers core.

Generally the length in which there is a complete transposing of one strand (called
stranding pitch) should be less than the circumference of the transformer core.

The requirement is due to the flexibility of the CTC in order to avoid any damage of the CTC
structure.

®
MILAN 21
WINDING WIRES
 Minimum winding diameter is in relationship with the dimensional characteristics
and the stranding pitch by the following formula :
x Di = S x n stranding pitch
S=Mx h transposing pitch
Where :
S = Transposing distance (Transposing pitch), distance between two transpositions
M = S/h = Proportionality coefficient - transposing factor (if less than 6, the
maxmimum plus tolerance in redial dimension shall be ‘k’.
If M is lower than 6 it can be difficult to produce the CTC for strand width greater
than 6mm, because the pitch can be too small for the transposing machine. If n is
large, the pitch must be short but not too short to get M lower than 6.

CTC DIMENSIONS

CTC DIMENSIONAL DATA

ENAMEL COPPER
Calculation of the cable outer dimensions
EPOXY
Maximum dimension in axial direction :
ic/2 h
H = 2x(h + iE) + ip + ic + Kh
b
Maximum dimension in radial direction B

B= n +1 x(b + iE) + ic + Kb ip
2 H

Where :
H = Axial cable dimension; B = Radial cable dimension
h = Axial strand dimension; b = Radial strand dimension
Kh = Maximum plus tolerance 0.10 mm for axial dimension
Kb = Maximum plus tolerance for radial dimension (values in table)
n = Number of strands in the cable
iE = Increase in dimensions due to enamel (0.13 fo pva and 0.19 for pva plus epoxy)
ip = Thickness of separator between the strands stacks.
ic = Paper covering (in case of cable without paper ic/2 is the thickness of the plastic wire)

Table : Kb values
Numbers of strands s/h > 7 and b < 2 mm All others cases
and Rp 02 < 180 MPa
Up to 21 0.20 0.30
From 23 to 27 0.25 0.50
Form 29 to 35 0.35 0.60
Greater than 35 0.70 1.00
S = Transposing distance (Transposing pitch), distance between two transpostions.

External dimensions are tested under pressure of IN/mm2 or the value required by the
customer.
®

22
PRECISION
 INTERCOLUMN SEPARATOR :

An intercolumn separator between the two stacks of CTC conductors is inserted, for all
stack heights more than 10 mm, unless otherwise agreed to with the user.

The standard paper thickness for this is 0.100-0.110 mm thick.

Intercolumn paper is generally inserted if :

(n-3) X (b+E)
W = ---------------------- > 10 for PVA CTC or > 25 for PRECITRANS-BOND CTC
2

Standard thickness of intercolumn separator paper, besides 0.100 mm, are 0.20, 0.30, and
0.40 mm

PAPER ARRANGEMENT :
Transposed Enamelled Conductors / Strands are wrapped with multiple layers of oil
resistant Kraft and/or other special papers to give high dielectric and mechanical strength to
the CTC. The paper rolls can be slitted into required width tapes.

TYPES OF PAPERS :
Thickness
Paper Type (Recommended) Application Salient Properties
(mm)
Kraft Paper 0.055-0.080 General purpose, High purity 5A2-1M3
inner layers

Calendered 0.110-0.140 General purpose, High tensile strength

Kraft paper outer layers

Aramid paper 0.050 Thermal Class 200 High temperature

(Nomex®) resistant, for dry type
transformers

Special papers, depending on customers requirement can be used.

Unless otherwise agreed with the customer, the insulation shall consist of at least 3 layers
of 0.080 mm thick Kraft paper.

The paper covering is applied in the following arrangement :

l Papers are wound up to 8 papers in the same direction
l Above 8 papers, in groups of maximum 8 papers
l All inner layers are but lapped and staggered from 25 to 40%
l The two outermost layers are wound interlocked with about 50% overlap

Agreement with customer is required for any change in thickness of papers and the type of
wrapping arrangement, in order to reach required paper insulation thickness.

®
MILAN 23
WINDING WIRES
WINDING GUIDELINES FOR PRECITRANS CTC :
For optimal performance of CTC during the winding it is necessary to follow certain basic
precautions.

Hints for winding Transposed Conductors

CTC drum Core
CTC drum Core

a) b)

c)
d)

During winding operations it is necessary to use some criteria in order to get the best winding of
the Transposed Conductor on the transformer core, particularly if the CTC has a high ratio B/H.
– When the diameter core is greater than 25 times the radial dimension B, it is possible to
wind the CTC leaving it free in the region between CTC and winding core (see figure a).
– In case of core with diameter less than 15 times the radial dimension of the CTC, is
possible to wind the Transposed Conductor using the following hints :
– Distance between transformer core and the drum axis shall be multiple of the stranding
pitch S.
– CTC shall be held up and guided by rollers (see figure b) in order to avoid flexions in the
length between core and drum.
– In order to avoid CTC twisting, rollers shall have adjustable flanges (see figure c and
adjustable flanges d).

DRYING AND HEIGHT ADJUSTMENT PROCESSES AFTER WINDING :

PRECITRANS-Bond CTC generally gives best bonding after curing in the range of
temperature between 110 and 130 degree C. In our Quality Assurance laboratory the
adhesive strength test on Epoxy bond coated conductors is done by heating for 24 h at 120 C.
Many customers use the following drying cycle with great success
l During the transformer manufacturing, drying under vacuum, a pressure of 3-5 N/mm2
(on the spacers of the helical coil winding) is applied and the temperature is raised to
1150C for 48-72 h. (excluding 6-8 h preheating and 10 hours of cooling periods)
l A dimensional adjustment is done at a pressure, in order to reach final dimensions
0
l A vapour phase drying is done at 130 C for 48 hrs. (after 2-3 hrs. preheating to reach the
temperature)
l Before the heat treatment, ensure that at the two ends of the strands are separated
sufficiently, to avoid undesirable bonding between them.

24
PRECISION
 Delivery Spools
PRECITRANS and PRECITRANS-Bond CTC is generally supplied on wooden non-returnable
drums. On agreement with the customer CTC can also be supplied on returnable wooden
spools
CTC is also supplied with separators to permit two or more parallel winding of CTC on
transformer coil, for improved winding efficiency at customer.

Spool Flange Barrel Bore Overall Traverse Capacity

Type Diameter Diameter Diameter Width in Kgs.
P 900 1100 800 82 660 560 990
P 1250 1400 900 82 440 340 1200
P 1750 1400 900 82 580 480 1700
P 2200 1400 900 82 710 610 2200
P 2900 1300 900 82 1150 1050 2900
P 3500 1400 900 82 1110 1010 3500
P 4500 1700 1000 82 900 770 4500

All Dimensions are in mm.

®
MILAN 25
WINDING WIRES
Ordering Information
While ordering PRECITRANS CTC, please use PWIL's contract review form or furnish the information
stated hereunder to ctcenquiry@pwil.net or fax it to 022-24310870

®
CONTRACT REVIEW

PRECISION WIRES INDIA LTD.

PRECISION
TRANSPOSED CONDUCTOR (CTC)

Customer :

Order / Enquiry Ref. : Dated :

Specification :

Number of Conductors N
Conductor Width (mm) mm
Conductor Thickness (mm) mm
Corner radius conductor mm
Mechanical properties N/mm2
Type of Paper
Paper Increase (mm) mm
Number of Papers No
Type of Enamel
Enamel Increase mm
Type of Intercolumn Paper
Thick. of Intercolumn Paper mm
Inner Winding Diameter mm

Overall Maximum Dimensions of CTC Height = mm, Width = mm

N of Length Meters per Length Reel Type No. of Reels Separator details, if any

Total Copper Kg Total CTC Kg

Delivery Returnable
One Way Drum
Comments :

DATE CUSTOMER STAMP

26
 Registered Office :
PRECISION WIRES INDIA LIMITED
SAIMAN HOUSE, J.A. RAUL STREET, OFF SAYANI ROAD, PRABHADEVI, MUMBAI 400 025
TEL : + 22 - 2436 2594 / 2437 6281 / 2436 0089 (EPABX) • FAX : + 22 - 2436 2593 / 2437 0687
E-MAIL : pwil@vsnl.com / awl@vsnl.com / mumbai@pwil.net • WEBSITE : http\\www.precisionwires.com

Printed in January, 2009

Works :
PRECISION WIRES INDIA LIMITED
(PALEJ UNIT : ATLAS WIRES)
PLOT NO. 3, G.I.D.C., NATIONAL HIGHWAY NO. 8, PALEJ 392 220, DIST. BHARUCH, GUJARAT
PRECISION WIRES INDIA LIMITED
PLOT SURVEY NO. 125, AMLI-HANUMAN (66 KVA) ROAD, SILVASSA 396 230, U.T. OF D.N.H.
PRECISION WIRES INDIA LIMITED
(UNIT II : ATLAS WIRES, SILVASSA),
PLOT SURVEY NO. 125, AMLI-HANUMAN (66 KVA) ROAD, SILVASSA 396 230, U.T. OF D.N.H.
PRECISION WIRES INDIA LTD.