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CONTINUOUSLY
TRANSPOSED
CONDUCTORS
ISO 9001-2000
CERTIFICATE
CSQ 9125.PIR9
IQNET IT-8970
29.1.2008
inside .....
BONDING PROPERTIES 9
ORDERING 14
This information was prepared to help users in selecting the proper material. We supply this information without representation or
warranty of any kind. ESSEX ITALY SpA therefore assumes no responsibility and shall have no liability of any kind arising from the
supply or use of this information. ESSEX ITALY SpA reserves the right to change this information or to stop the production of its
materials without notice. Errors and omissions excepted.
1
Patent IT01290307 WO9836431 EP859381
ESSEX ITALY SpA Continuously Transposed Conductors – Ed. 3 Rev. 1 29.1.2008 4
CORDEX dimensional properties
n k iC iP cH
11 - 85 1.01 0.45 0.10- 0.30 0.15
b ≥ 2.10 mm h ≥ 9.30 mm k= 1.02
n K' iC cB nX D
11 - 21 1.04 0.45 0.15 0.13 0.15
23 - 27 1.035 0.45 0.15 0.13 0.15
29 - 37 1.03 0.45 0.15 0.13 0.15
39 - 49 1.025 0.45 0.15 0.13 0.15
51 - 85 1.015 0.45 0.15 0.13 0.15
Where:
H = Axial cable dimension (100 N/cm²); B = Radial cable dimension (100 N/cm²)
h = Axial strand dimension; b = Radial strand dimension
k = 1.01 Axial shape factor (for b > 2.10 mm and h > 9.30 mm k =1.02)
k’ = Radial shape factor (values in table ) n = Number of strands in the cable
iE = Increase in dimensions due to enamel (typical values: 0.12 mm for enamelled strands and 0.17 mm for
enamelled + epoxy coated strands)
ip = Thickness of separator between the strands stacks (0.10 up to 0.30 mm according to Customer requirements)
ic = plastic wire covering (typical 1.06 x 0.36 mm - 0.45 mm thickness after 1 N/mm² pressure)
cH = side separator ( 2 calendered crepe papers 0.075 mm ) TOLL = tolerance (axial or radial )
cB = top or bottom separator ( 2 calendered crepe paper 0.075 mm )
nX = adhesive aramid tape - bottom side ( 0.13 mm )
Note: if an aramid tape is required on the CTC bottom side, 2 calendered crepe papers are placed between the
strands and the cordex wire. ( nX + cB )
Please take note that during the measuring under pressure there is a penetration of the plastic monofilament in the
spacer. Then the axial measure is reduced by 0.25-0.30 mm.
There is no experience for cordex CTC less than 11 strands.
Picture 2
Picture 3
or it can be produced according to EN 13601:2002 (CPR Rp0.1% designation) or to other designation (Rp0.2%):
Agreement with the Customer will be required in case of change of thickness of one or more papers or the type of
arrangement, in order to reach the required paper insulation thickness.
Epoxy bonded Transposed Conductors are made covering the enamelled rectangular wires
with special epoxy resins at B-stage (Formicementex wire).
This technique enables the user to strongly bond together the conductors in the same standard thermal
treatment used for drying the paper insulation of the windings.
FORMICEMENTEX® Characteristics
Epoxy is a thermosetting resin.
Enamelled wires are covered with a thin layer of epoxy tack-free cresol-free resin at B-stage.
ESSEX ITALY epoxy system is characterised by the following properties.
• Uniform melting
• High grade curing
• Stability of B-stage (more than 6 months at 32°C)
• Strands bonding during the drying process of the winding
• Available for medium (100-110 °C) and high (110-120 °C) operative temperature
Advantages
• Transformers improve against unstable electrical network and the risks of shorts.
• Formicementex enamelled rectangular wires used in Transposed Conductors provide exceptionally
strong bond strength in the winding.
• Conductors in the winding become like a solid beam and can withstand strong electrodynamic stresses
created during short circuits event.
• Epoxy resin cure in the same thermal treatment for drying paper (100-130°C)
• The best oil resistance
• Each single strand has better insulation
• Tack-free surface and then dust-free and easy handling of the strip without powder residues
• No-pollution because the B-stage resin does not contain residues of harmful solvents
• Small thickness of coating needed in order to achieve very strong bonding (0.02-0.05 mm)
• Better sliding among the strands, improving the CTC windability
10
8
6 Annealed (R0.1=50-80 MPa)
MPa
4 CPR1 (R0.1=140-200MPa)
CPR3(R0.1=220-260MPa)
2
0
7.0 x 1.8 mm conductor
B/H =
(n + 1) × (b + iΕ ) Radial /Axial ratio less or equal
to 7
4 × ( h + iΕ )
All dimensions are in mm
2
dimension without insulation paper
3
depending on the preferred ratio value
ESSEX ITALY SpA Continuously Transposed Conductors – Ed. 3 Rev. 1 29.1.2008 10
CTC DIMENSIONAL DATA
ENAMEL COPPER
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 ( typical value 0.12 mm for pva and 0.17 mm 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
Interleaving paper
According to the axial pressure applied to final winding, if necessary, in order to prevent tilting effect, an
interleaving paper can be used.
This paper is inserted between the two stacks, if required by the Customer.
We suggest 0.11 mm thickness if there is no specified value by the Customer.
0.11 mm paper should be inserted if
W=
(n − 3) × (b + Ε ) > 10 for PVA CTC or > 25 for Formicementex CTC
2
Standard Thickness are 0.10 - 0.20 - 0.30 - 0.40 mm.
Width of the paper is the W value with approximation to the lowest pair unit (example: if W = 7.36 we
select 6 mm paper, but this is the minimum value that we suggest to use).
a)
flange
bore
barrel
b)
d)
c)
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 H/L.
• When the diameter core is greater than 25 times the radial dimension H, 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 25 times the radial dimension of the CTC, it 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
Pc
• CTC shall be held up and driven by pulleys (see figure b) in order to avoid flexions in the
length between core and drum.
• In order to avoid CTC twisting, pulleys shall have adjustable flanges (see figure c and
adjustable flanges d).
ORDERING
When ordering ESSEX ITALY Continuously Transposed Conductors, the following requirements are
necessary:
• number of strands and their nominal dimensions
• type of copper and type of enamelling wires (epoxy or not)
• minimum winding diameter
• total paper thickness, minimum number of layers and type of papers
• interleaving paper and its thickness
• required length and type of drum
Please use our card for Contract Review (see next page) or ask our Sales Dept. for the use of internet
BtoB in www.invexonline.it.
Number of conductors N°
Conductor Width (mm) mm
Conductor Thickness (mm) mm B
Overall dimensions W= B= mm
Comment: