Winding Wires

Reference Standards IS 13778 1993/IEC 851 - 1985 Methods of tests for winding wires IS 13730 1993/IEC 60317 - 1990 Specifications for particular types of winding wires

Part I 1993 General Part II 1993 Determination of dimensions Part III 1993 Mechanical properties Part IV 1993 Chemical properties Part V 1993 Electrical properties Part VI 1993 Thermal properties

IS 13778: Methods of tests for winding wires

IS 13778 Part 2 (1993)

Determination of dimensions Overall Dimensions Conductor Dimensions Out of roundness of the conductor for round wires Increase in dimensions due to the insulation Rounding of corners (For rectangular wires)

IS 13778 Part 3 (1993)

Mechanical Properties Elongation Test Flexibility & Adherence Test Springiness Test Resistance to Abrasion Test Heat and solvent bonding tests

IS 13778 Part 4 (1993)

Chemical properties: Solvent Test Tests for wires for use in refrigerants Solder test Resistance to transformer oil in the presence of water

IS 13778 Part 5 (1993)

Electrical properties Break Down Voltage Test Continuity of Covering Electrical Resistance Test Dielectric loss tangent Test

IS 13778 Part 6 (1993)

Thermal properties : Cut Through Test Heat Shock Test Thermal endurance test Loss of mass High temperature failure test

IS 13730

Part 0 / Section 1 -- 1993 General requirements, Enamelled round copper wire Part 0 / Section 2 -- 1993 General requirements, Enamelled rectangular copper wire Part 0 / Section 3 -- 1993 General requirements, Enamelled round aluminium wire Part 0 / Section 4 -- 1993 General requirements, Glass fibre wound bare or enamelled rectangular copper wire

Dimensions: Diameter Tolerance 1% Out of roundness Tolerance 1% Flexibility and Adherence Test : a) Mandrel winding Test (For Conductor Diameter up to and including 1.6 mm)

IS 13730 Part 0 / Section 1 -1993

Diameter of conductor in mm Over -0.05 Up to and Including 0.05 1.6

Elongation before winding on mandrel 20% --

Mandrel Diameter 0.15mm D

IS 13730 Part 0 / Section 1 -1993

b) Stretching Test (For Conductor Diameter over 1.6mm) The coating shall show no cracks after the wire has been elongated 32% c) Jerk Test (For Conductor Diameter up to and including 1 mm) The coating shall show no cracks

IS 13730 Part 0 / Section 1 -1993

c) Peel Test (For Conductor Diameter over 1mm) The coating shall show no loss of adhesion after the specimen has been subjected to the number of revolutions R where R=K/d (K constant, d- diameter)

Elongation Test
Over 0.5 0.56 0.63 0.8 0.9 1.12 1.25 1.8 2.5 3.15 4

IS 13730 Part 0 / Section 1 -1993

Diameter of Conductor in mm Up to and Including 0.56 0.63 0.8 0.9 1.12 1.25 1.8 2.5 3.15 4 5 %Elongation (Min) 26 27 28 29 30 31 32 33 34 35 36

IS 13730 Part 0 / Section 1 -1993

Heat Shock Test: a) Conductor Diameter up to and including 1.6 mm Diameter of conductor in mm

Over -0.04 0.16 0.25 1 Up to and Including 0.04 0.16 0.25 1 1.6 0.15mm 3D 4D 2D 3D

Mandrel Diameter

D is diameter of conductor

IS 13730 Part 0 / Section 1 -1993

b) Conductor Diameter over 1.6 mm: The sample shall be elongated by 25% Testing temperature will be given in relevant standards. Resistance to solvents: Using a pencil of hardness H, the coating shall not be removed.

Continuity of Insulation: The number of faults in 30meters wire shall not exceed the values given in table

IS 13730 Part 0 / Section 1 -1993

Diameter of conductor in mm Over -0.05 0.08 0.125 Up to and Including 0.05 0.08 0.125 1.6

Max. faults 24 24 15 5

IS 13730 Part 0 / Section 2 -1993

Width or Thickness in mm Over -3.15 6.3 12.5 Up to and Including 3.15 6.3 12.5 16

Dimensions: Tolerance

Tolerance mm 0.03 0.05 0.07 0.1

IS 13730 Part 0 / Section 2 -1993

Dimensions Corner Radius
Thickness of conductor in mm Over Up to and Including -1 1 1.6 1.6 2.24 2.24 3.55 3.55 5.6
T is thickness of conductor

Corner radius in mm 25% 0.5*T 0.5 0.65 0.8 1

IS 13730 Part 0 / Section 2 -1993

Increase in Dimensions:
Increase in Dimensions (mm)

Grade Minimum 1 2 -0.11 Maximum 0.11 0.16

IS 13730 Part 0 / Section 2 -1993

Electrical Resistance: The method used to find Electrical Resistance shall provide an accuracy of 0.5% Resistivity shall be less than 1/58mm2/m Springiness: Maximum spring back is 5 Degrees

IS 13730 Part 0 / Section 2 -1993

Thickness of conductor in mm Over -2.5 Up to and Including 2.5 5.6

Elongation:

Minimum %Elongation 30 32

IS 13730 Part 0 / Section 2 -1993

Wire bent on Width

Flexibility and Adherence Test a) Mandrel Winding Test

Mandrel diameter 4xwidth 5xwidth 4xthickness

Size up to and including 10mm Over 10mm

Thickness

All sizes

b) Adherence Test: The wire shall be stretched by 15%. The distance of loss of adhesion shall be less than 1xwidth.

IS 13730 Part 0 / Section 2 -1993

Heat shock Test: The coating shall show no cracks after the wire has been bent flat wise on a mandrel with a diameter of six times the thickness.

IS 13730 Part 0 / Section 2 -1993

Break Down Voltage

Minimum B.D.V in Volts At Room Temperature 1000 2000 At Elevated Temperature 750 1500

Grade

1 2

IS 13730 Part 0 / Section 3 -1993

Dimensions: Tolerance 1% Flexibility and Adherence Test : a) Mandrel winding Test (For Conductor Diameter up to and including 1.6 mm) Mandrel Diameter shall be 3x Diameter of wire b) Stretching Test (For Conductor Diameter over 1.6mm) The coating shall show no cracks after the wire has been elongated 15% c) Jerk Test (For Conductor Diameter up to and including 1 mm)

Elongation Test
Over -0.4 1 2

IS 13730 Part 0 / Section 3 -1993

Diameter of Conductor in mm Up to and Including 0.4 1 2 5 %Elongation (Min) 10 12 15 15

Continuity of Insulation: The number of faults in 30meters wire shall not exceed the values given in table
Diameter of conductor in mm Over Up to and Including -1.6 Max. faults 10

IS 13730 Part 0 / Section 3 -1993

Increase in Dimensions due to insulation

Nominal Width of the Conductor (mm)
Over -3.15 6.3 12.5 Up to and including 3.15 6.3 12.5 16

13730 Part 0 / Section 4 -1993

Increase in Dimensions (mm) Glass fibre wound over bare conductor Single Covering
Min 0.13 0.14 0.16 0.18 Max 0.20 0.22 0.28 0.32

Glass fibre wound over grade 2 enamelled conductor Single Covering

Min 0.24 0.25 0.27 0.28 Max 0.36 0.38 0.44 0.48

Double Covering
Min 0.20 0.22 0.25 0.27 Max 0.32 0.37 0.41 0.45

Double Covering
Min 0.31 0.34 0.36 0.38 Max 0.48 0.52 0.56 0.61

13730 Part 0 / Section 4 -1993

Flexibility and Adherence Test a) Mandrel Winding Test

Wire bent on Width Thickness Size up to and including 8mm Over 8mm All sizes

Mandrel diameter 10xwidth 15xwidth 10xthickness

b) Adherence Test: The wire shall be stretched by 10%. There shall be no loss of adhesion of the fibre covering.

IS 13730 Part 0 / Section 4 -1993

Type of Insulation Bare conductor with

Break Down Voltage

Single Covering Double Covering

B.D.V (min) in Volts 350 560 1500 2000

Grade 2 Single Covering enamelled wire Double Covering with

IS 13730 Specifications for particular types of winding wires

Part 1 - 1993 Polyvinyl acetal enamelled round copper wire, class 105 Part 2 1996 Solderable polyurethane enamlled round copper wire, class 130 with a bonding layer. Part 3 1996 Polyester enamelled round copper wire, class 155 Part 4 - 1993 Solderable polyurethane enamelled round copper wire, class 130

IS 13730 Specifications for particular types of winding wires

Part 6 - 1994 Oleo-resinous enamelled round aluminium wire, Class 180 Part 7 - 1993 Polyimide enamelled round copper wire Class 220 Part 8 - 1996 polyesterimide enamelled round copper wire class 180 Part 9 1994 Polyester enamelled round aluminium wire, Class 130 Part 13 - 1993 Polyester or polyesterimide over coated with polyamide-imide enamelled round

IS 13730 Specifications for particular types of winding wires

Part 15 1994 Polyesterimide enamelled round aluminium wire, Class 180 Part 16 - 1996 Polyester enamelled rectangular copper wire, Class 155 Part 17 - 1996 Polyvinyl acetal enamelled rectangular copper wire, Class 105 Part 20 1993 Solderable polyurethane enamelled round copper wire, Class 155 Part 26 1996 Polyamide-imide

IS 13730 Specifications for particular types of winding wires Part 27 1996 Paper covered rectangular copper wire Part 28 - 1997 Polyesterimide enamelled rectangular copper wire, Class 180 Part 29 - 1997 Polyester or polyesterimide over coated with polyamide-imide enamelled rectangular copper wire, Class 200 Part 31 1997 Glass-fibre wound, polyester or polyesterimide varnish- treated, bare or enamelled rectangular copper wire, temperature index 180

IS 13730 Specifications for particular types of winding wires Part 32 1997 Glass-fibre wound, polyester or polyesterimide varnish-treated, bare or enamelled rectangular copper wire, temperature index 155 Part 33 1997 Glass-fibre wound, silicone varnish-treated bare or enamelled rectangular copper wire, temperature index 200 Part 34 2000 Polyester enamelled round copper wire, Class 130 (first revision) Part 45 1999 Polyester enamelled round copper wire , class 130

IS 13730 Part 1 - 1993 Polyvinyl acetal enamelled round copper wire, class 105

Peel Test: Revolutions R=K/d (K constant, d is diameter) Constant K= 175 Heat shock test: Heat shock temperature is 155C Cut Through test: No failure shall occur within 2 min at 170C

IS 13730 Part 8 1996 Polyesterimide enamelled round copper wire class 180

Peel Test: Revolutions R=K/d (K constant, d is diameter) Constant K= 110 Heat shock test: Heat shock temperature is 200C Cut Through test: No failure shall occur within 2 min at 300C

IS 13730 Part 13 1993 Polyester or polyesterimide over coated with polyamide-imide enamelled round copper wire, Class 200

Peel Test: Revolutions R=K/d (K constant, d is diameter) Constant K= 110 Heat shock test: Heat shock temperature is 220C Cut Through test: No failure shall occur within 2 min at 320C

enamelled rectangular copper wire, Class 155

Heat shock test: Heat shock temperature is 175C

IS 13730 Part 17 1996 Polyvinyl acetal enamelled rectangular copper wire, Class 105
Heat

shock test: Heat shock temperature is 175C

IS 13730 Part 27 1996 Paper covered rectangular copper wire

Dimensions:
Increase in dimensions due to the paper covering

Increase in dimensions due to the paper covering in mm Over -2 4 Up to and Including 2 4 16

Tolerance % -10 to 0 -7.5 to 0 -5 to 0

IS 13730 Part 34 2000 Polyester enamelled round copper wire, Class 130 (first revision)

Peel Test: Revolutions R=K/d diameter) Constant K= 130

(K constant, d is

Cut Through test: No failure shall occur within 2 min at 240C

IS 13730 Part 34 2000 Polyester enamelled round copper wire, Class 130 (first revision) Heat shock test: Heat shock temperature is 155C
Conductor Diameter up to and including 1.6 mm
Diameter of conductor in mm Over -0.05 0.16 0.25 1 Up to and Including 0.05 0.16 0.25 1 1.6

Mandrel Diameter 0.15mm 3D 4D 6D 7D

D is overall diameter of conductor

For Conductor Diameter over 1.6 mm Sample shall be elongated by 10%

IS 13730 Part 45 1999 Polyester enamelled round copper wire, Class 130

Peel Test: Revolutions R=K/d (K constant, d is diameter) Constant K= 150 Heat shock test: Heat shock temperature is 155C Cut Through test: No failure shall occur within 2 min at 240C

Paper Covered Alluminium Conductors

Reference Standards: IS 6162 (Part 1) 1971 : Specifications for Paper Covered Alluminium Round Conductors. IS 6162 (Part 2) 1971 : Specifications for Paper Covered Alluminium Rectangular Conductors.

IS 6162 (Part 1) 1971

Test Condition Dimensions Tolerance: 1%

Tolerance % -10 to 0 -7.5 to 0 -5 to 0 Up to and Including 0.5 1.3 16

Increase in dimensions due to the paper covering in mm Over 0.25 0.5 1.3

Resistivity : 0.028mm2/m

IS 6162 (Part 1) 1971

Tensile Strength: Minimum: 69MN/m2 Maximum: 100MN/m2 %Elongation: 15 (min)

Test Condition Dimensions Tolerance:

IS 6162 (Part 2) 1971

Increase in dimensions due to the paper covering in mm Over 0.25 0.5 1.3

Tolerance % -10 to 0 -7.5 to 0 -5 to 0

Up to and Including 0.5 1.3 --

Resistivity : 0.028mm2/m

IS 6162 (Part 2) 1971

Tensile Strength: Maximum: 100MN/m2 %Elongation: 25 (min)

Paper Covered Round Copper Conductors

Reference standard: IS 7404 (Part 1) 1991 This standard covers the requirements and tests for round copper conductors covered with two or more layers of paper.

IS 7404 (Part 1) 1991

Dimensions: Conductor Tolerance : 1% Increase in dimensions due to the

paper covering in mm Over 0.25 0.5 1.3 Up to and Including 0.5 1.3 --

Tolerance % -10 to 0 -7.5 to 0 -5 to 0

COPPER WIRE RODS

Reference standard: IS 12444 - 1988 This standard covers the requirements of EC grade copper rod up to 18mm diameter.

IS 12444 - 1988

Chemical Composition:
Percent 99.90 0.001 0.005 0.03

Element Copper + Silver (min) Bismuth (Max) Lead (Max) Total of all impurities except oxygen (Max)

Note:Reference standard IS 440-1964

IS 12444 - 1988

Tolerance on Diameter:
Diameter in mm Up to and Including 9 12 18 Tolerance in mm 0.5 0.7 0.9

Over 6 9 12

IS 12444 - 1988
Mechanical Properties : Tensile Test Tensile Diameter in mm

Over 6 9 12

Up to and Including 9 12 18

strength (MPa) min 210 205 200

%Elongation (min) 32 40 46

Alluminium Rod

Reference standard: IS 5484 - 1997 This standard covers the requirements of EC grade alluminium rod of 7.6mm & 9.5mm diameter. Tensile Strength : 65 to 100MPa

IS 5484 - 1997

Resistivity at 20C : 0.028264 (max) Conductivity : 61% (min) Dimensions Tolerance:

Tolerance in mm 0.4 0.5

Diameter in mm 7.6 9.5

Sampling : For every coil

Glass Fibre covered Round Copper wire

Reference Standard: IS 11184-1984 This standard covers requirements of round copper wires coated with enamel and covered with single or double glass fibre.

IS 11184-1984
Flexibility : 10xdiameter Mandrel Break Down Voltage
Nominal Diameter of the Conductor (mm)
Over -0.85 0.95 1.12 1.32 1.6 Up to and including 0.85 0.95 1.12 1.32 1.6 4

Break down voltage (Volts) Single Covering

Min 1050 1100 1150 1200 1250 1300

Double Covering
Min 1100 1150 1200 1250 1300 1350

IS 11184-1984
Increase in Dimensions due to fibre glass insulation (mm)
Nominal Diameter of the Conductor (mm)
Over -2 3.35 Up to and including 2 3.35 4

Glass fibre wound over grade 2 enamelled conductor Single Covering

Min 0.085 Max 0.125 -

Double Covering
Min 0.15 0.2 0.25 Max 0.2 0.25 0.3

Reference standard: IS 11171 1985 IEC 726 1982 This standard applies to Dry-Type Power Transformers having values of highest voltage for equipment up to and including 36KV.

Dry-Type Power Transformers

Section 1 - General Section 2 - Rating Section 3 - Cooling methods and Temperature rise Section 4 - Insulation Levels Section 5 - Tests Section 6 - Enclosures

IS 11171 1985

IS 11171 1985
1)

(Section

Types of Dry-Type Power Transformers a) Sealed Dry-Type Transformers b) Totally Enclosed Dry-Type Transformers c) Enclosed Dry-Type Transformers d) Non-Enclosed Dry-Type Transformers

IS 11171 1985
1)

(Section

Service Conditions: Altitude : height above MSL not exceeding 1000m Ambient Temperature Terminal markings, tappings and connections : As specified in IS 2026 (Part 4)-1977 Preferred taps are 5% in steps of 2.5%

IS 11171 1985
2)

(Section

Rating : Same as IS 2026 (Part 1)1977 Operation at other than rated voltage: The transformer can be operated at its rated KVA at any voltage with in 10% Rated frequency: 50Hz 1.5 Rating Plate

IS 11171 1985
3)

(Section

Identification according to cooling method: Kind of cooling medium Symbol Air A Gas G Kind of circulation Symbol Natural N Forced F

IS 11171 1985
3)

(Section

Temperature rise limits:

Part

Winding

Temperature Temperature Class of Insulation Rise (C) A 50 E 65 B 70 F 90 H 115 C 140

IS 11171 1985
4)

(Section

Insulation Levels:

Voltage power frequency Lightning impulse class withstand voltage (KV) withstand voltage (KV) 1.1 3 -3.6 10 40 7.2 20 60 12 28 75 17.5 38 95 24 50 125 36 70 170

IS 11171 1985
5)

(Section

Tests: Classification of Tests: a) Type Tests b) Routine Tests c) Special Tests

IS 11171 1985
5)

(Section

Type Tests Measurement of winding resistance Measurement Voltage ratio and check of voltage vector relationship Measurement of impedance voltage, short circuit impedance and load loss Measurement of no-load loss and

IS 11171 1985
5)

(Section

Type Tests SSVW test IOVW test Lightning impulse test Temperature rise test

IS 11171 1985
5)

(Section

Routine Tests Measurement of winding resistance Measurement Voltage ratio and check of voltage vector relationship Measurement of impedance voltage, short circuit impedance and load loss Measurement of no-load loss and current SSVW test IOVW test

IS 11171 1985
5)

(Section

Special Tests Partial Discharge measurement Measurement of acoustic sound level Short Circuit Test