magnet wire / winding wire engineering data handbook

1 magnet wire / winding wireengineering data handbook12/2009 datamagnet wire / winding wirei12/2009 warranties do not apply to any Product that was not properly stored or handled by the Buyer, that was repaired or altered or was otherwise subject to abuse, neglect or improper use by Buyer, or that has any stage of processing performed on it which causes the defect. EXCEPT WITH RESPECT TO THE SPECIFIC WARRANTIES SET FORTH IN THIS PARAGRAPH, SELLER MAKES NO OTHER WARRANTIES WHATSOEVER, EXPRESS OR IMPLIED AND SPECIFICALLY DISCLAIMS ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

2 IN NO EVENT WILL SELLER BE LIABLE TO BUYER FOR ANY INDIRECT, INCIDENTAL, SPECIAL, PUNITIVE, DELAY, OR CONSEQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION, LOSS OF DIRECT OR INDIRECT PROFITS, REVENUE, OR USE, WHETHER ARISING IN CONTRACT, TORT, OR OTHERWISE, EVEN IF BUYER OR ANY OTHER PARTY HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. IN NO EVENT WILL SELLER S AGGREGATE LIABILITY TO BUYER EXCEED ALL AMOUNTS ACTUALLY PAID BY BUYER TO SELLER. THESE LIMITATIONS SHALL APPLY NOTWITHSTANDING ANY FAILURE OF ESSENTIAL PURPOSE OF THE LIMITED REMEDY SET FORTH IN THIS statements, technical information and recommendations made herein by Essex Group, Inc.

3 ( Seller ) are based on tests it believes to be reliable, but the accuracy or completeness thereof is not guaranteed, and such information is provided AS IS without any warranties of any kind. Buyer shall determine the suitability of the Products for his intended use, and assumes all risks and responsibility for loss or damage resulting from the handling or use of the Products. Seller warrants that at the time of delivery the Products will be free from material defects in workmanship and materials under normal use and will conform substantially to Seller s applicable specifications.

4 As Buyer s sole and exclusive remedy and Seller s entire liability for any breach of the foregoing warranty, Seller will, at its sole option and expense, either refund the purchase price paid, or repair or replace the Product which fails to meet this warranty upon return of the nonconforming Product; provided, Buyer notifies Seller of noncompliance in writing within sixty (60) days of delivery of such Product. Contents of this book have been revised to reflect NEMA's publishing of ANSI/NEMA MW 1000-2008, Revision 1-2009 magnet wire . Please contact NEMA for information regarding the specific changes to the NEMA MW 1000 publication.

5 magnet wire / winding wireiiengineering dataCONTENTSW eights:(continued)Dimensions:Medium Film Build: CopperPolyester Glass, Bare, Area, Weight and Resistance Whole and Half AWG Sizes and Heavy Film: Copper Physical and Electrical Properties Heavy Build & Self-Bonding, Type : CopperPolyimide and Aromatic Polyimide Tapes Resistance Correction Factors Whole AWG Sizes AWG System Half AWG Sizes Recommended winding Tensions Triple Build & Self-Bonding, Type : CopperWhole AWG Sizes Half AWG Sizes Dimensions:Single Film Build: AluminumHeavy Film Build Whole and Half AWG Sizes Served wire AdditionsMedium Film Build: AluminumDouble Polyester Glass Dimensions:Whole and Half AWG Sizes Single Polyimide Tape Whole and Half AWG Sizes Heavy Film Build: AluminumDouble Polyimide Tape Cross-Sectional Area:Whole AWG Sizes 0 Single Aromatic Polyamide Paper Whole AWG Size Half AWG Sizes Resistance:Half AWG Size Dimensions:Copper, Bare Weights:Self-BondingAluminum, Bare Whole AWG Sizes Type , Whole AWG Sizes Weights.

6 Half AWG Sizes 0 Type , Half AWG Sizes Copper, Bare Resistance:Type , Whole AWG Sizes Aluminum, Bare Copper, Whole AWG Sizes Type , Half AWG Sizes Copper, Half AWG Sizes Aluminum, Whole AWG Sizes Aluminum, Half AWG Sizes Dimensions: Polyester Glass and Polyimide TapePreferred Number Series Summary 0 Whole and Half AWG Sizes Dimensions:Dimensions:Heavy Film Build Single Film BuildServed wire Additions:Whole AWG Sizes Dimensions and Area:Single Polyester Glass Half AWG Sizes Whole and Half AWG Sizes Double Polyester Glass Medium Film BuildResistance and Weight:Whole and Half AWG Sizes Copper, Whole and Half AWG Sizes Bare WireHeavy Film BuildAluminum, Whole & Half AWG Sizes Dimensional Limits & Corner Radii Whole AWG Sizes Weight Corner Losses Half AWG Sizes Triple Film BuildDimensions:Whole and Half AWG Sizes 0 Heavy Film BuildWeights:Weights:Whole and Half AWG Sizes 0 Copper, Bare Single Film Build: CopperAluminum, Bare Whole AWG Sizes Resistance.

7 Half AWG Sizes Copper, Bare Aluminum, Bare Rectangular, Bare Standard SizesCopper & AluminumRectangular WireRound, Served WireSquare, Bare WireSquare, Film-Insulated WireRectangular WireENGINEERING DATAS quare, Served WireDimensions, Area, Weight andResistance ValuesRound, Bare WireRound, Film-Insulated WirePreferred Number Series SizesConductor PropertiesRound, Film-Insulated wire (continued) magnet wire / winding wire engineering dataRound WireFor round conductor, where the cross-sectional area may be moreCircular Mil Area = D2conveniently expressed in Circular Mils, the following formulas areSquare Mil Area = /4 D2 = D2useful:Square Inch Area = x 10-6 D2 General Formula: Ft.

8 = (d) (D2)Where: D= Diameter of bare conductor in mils (1/1000 inches), " Diam. = milsCopper: Ft. = D2 Aluminum: Ft. = D2 Square and Rectangular WireWhere:D = Diameter of bare conductor, Mil Area = (WT )d = Density of conductor metal, Mil Area = WT - for weight are based on density of for copperSquare Inch Area = 1 x 10-6(WT - ), orand for aluminum. = wt , when w, t and r are expressed in : 1 sq. mil = 10-6 sq. Per 1000 FeetWhere: T = Thickness in mils. W = Width in Conductor:R = Corner Radius in Formula: Ohms/1000 Ft.

9 = 1000 RFor square wire : W = rectangular wire with full round edges:Copper: Ohms/1000 Ft. =10371 R = TD22 Note:When calculations involve any of the followingAluminum: Ohms/1000 Ft. =16782standard ASTM corner radii, the values for CornerD2 Area Loss listed below may be substituted for the Where: R = Volume resistivity, ohm x / " " in the above formulas. D = Bare conductor diameter, and Rectangular Conductor:General Formula: Ohms/1000 Ft. = RA AAluminum: Ohms/1000 Ft. = 13180 AWhere: R =Volume resistivity, ohm x circ.

10 Mil / = ohm x circ. mil / ft.* ASTM Standard B 48 for Copper and Aluminum = ohm x circ. mil / ft. ASTM Standard B 324 for = Cross-sectional area, square Per PoundPounds Per 1000 FeetFor any conductor, Ohms/Lb. = Ohms/1000 Formula: Ft. = (d) (A) : Ft. = : Ft. = Per OhmWhere:A = Bare conductor cross-sectional area in square any conductor, Feet/Ohm = 1000d = Density of conductor, grams/cm3 Ohms/1000 volume resistivity factors at 20 C are based on conductivities of 100% copper, and aluminum IACS for soft, annealed conductors.