04 Essex Wires

WIRES AND TRANSPOSED CABLES IN TRANSFORMERS
Dr. Stefan Beckmöller
ESSEX Germany GmbH
TRANSFORM Partner
Vita
Dr. Stefan Beckmöller
Studies at University
„Metallurgy with focus metal forming“ at RWTH Aachen
PhD at RWTH Aachen
Professional Carreer
Quality Engineer at Kabelwerke Rheydt
Project Engineer at Lackdraht Union GmbH, Arolsen
Head of R&D Lacroix & Kress GmbH, Bramsche
Head of R&D Essex Germany GmbH, Arolsen
Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 2

Continuous Transposed Cables
Energy Efficient Transformers
CTC
Continuous Transposed Cable
Source: Siemens AG

A brief history
1912 Ludwig Roebel invents single insulated and

transposed strands to replace the large
cross-section conductors that were currently
in use within generator designs
Since 1940 Transformer designs using the idea of

Ludwig Roebel
new challenges relating to efficiency, profitability and

environmental compatibility
CTC requirements

Why do we use CTC?
high flexibility Fast and efficient

winding of the active
part of the
power transformer
length due to transposition.
compensation
reduced electrical Reduced impact of S e1

I
losses magnetic field by A1
increased surface due E
to single isolated strips B
and transposition. A2
improved cooling (skin + proximity effect) e2
S i

Requirement to wires in Transformer
Conductivity
Conductor
Mechanic strength
Varnish-insulation
Chemical strength
Cable-insulation
Electric strength
Construction
Lifetime
Windability Process

CTC construction
CTC – build up Properties influenced by
Conductor
Cost pressure
Insulation
Insulation
Bond Coat
Bond Coat
Construction
Construction
Process
Reel-type
Process
Reel-type

Conductor
Varnish-insulation
Cable-insulation
Construction
Process

Conductor: Material
Rod
Soft Cu-ETP1
Copper Cu-OF1
Hard E.g. CPR1, CPR2, CPR3
CuAg 0,03
Conductor Copper alloys Hard
CuAg 0,10
+ low cost
Aluminium - low conductivity and stiffness

Conductor: Material
Copper Aluminium CCA* (15 %)
Aspect red-orange metallic Bi-Metall

% of geosphere 0,01 % 7,75 % ---
Density 8,92 g/m³ 2,70 g/m³ 3,63 g/m³
Melting point 1083 ºC 658 ºC 658 ºC
Linear heat expansion 17,0 x 10-6 1/K 23,5 x 10-6 1/K
Young-modulus 13,0 x 104 MPa 7,1 x 104 MPa
Thermal conductivity 385 W/mK 230 W/mK 240 W/mK
Electric conductivity > 58,58 m/(Ω mm²) > 35,67 m/(Ω mm²) > 37,35 m/(Ωmm²)*
Price (15.04.2013) 5,741 € / kg 1,416 € / kg metall+forming
General remarks ↑ welding ↓ welding ↑ welding
↑ forming high oxidation rate ↓ recycling
low oxidation rate ↓ bending ↓ bending
↓ plastic flow * ↑ = copper @ 5 MHz
Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 10

Page 10
Conductor: Material
Electric Conductivity
Conductivity
60  Copper > 58,58
Cd
Ag, Zn  pure Copper ≈ 60
55 Sn  Silver ≈ 62
electric conductivity [m/Omm²]
AL
 Aluminium ≈ 36
50 Mn
Impurities reduces conductivity

45
Silver has less impact to conductivity
Co
40
Hardening reduces conductivity
Fe
35 Cu-ETP1 and Cu-OFE 99,99 %
P
copper content
30
0 ,0 0 0 ,0 2 0 ,0 4 0 ,0 6 0 ,0 8 0 ,10 0 ,12
m ixture in m ass-%
source: DKI

Conductor: Material
Mechanical strength
creep behavior of materials after
1.000 h
OF-Cu Ag
material begins to anneal with
temperature
impurity silver enhances
mechanical behavior without
dramatic impact to the
conductivity
OF-Cu
Typical alloy CuAg0,03 and
CuAg0,10
source: DKI

Conductor: Material
Copper Rod Production
Metallurgy Electrolyse Continuous Rod Casting
Up-Cast Verfahren
Source: Aurubis Source: Aurubis

Conductor: Material
Rectangular Wire Production
Pre-material Drawing Rolling

Conductor: Material
Conform Technology
Advantage Disadvantage
• Direct production from rod to square • “Slow” production process
size • Sensitive to cleanness off pre-material
• No annealing necessary • Soft material sensitive to scratches and
• Clean surface of the pressed material oxidation
(no fat, flaks, …) • Increased copper scrap
• Set up times low
• Flexible in dimension and shape
• No emulsion necessary

Conductor
Varnish-insulation
Cable-insulation
Construction
Process

Varnish insulation: Material
Polyvinylacetal Excellent adhesion, flexibility and oil resistance
Polyesterimid + Increased heat resistance

Polyamidimid Comparable with impregnation varnishes
strand
Standard Concentric
Epoxy-
Bond coat Improved Partial
PET- foil, Aramid- paper,

Specials Prepreg, glass yarn, …

Electric Insulation Insulation types
today 90 % PVA - class 120 Introduction of isolation types

break down voltage > 50 V/µm
reduced contact failure
insulation resistance > 500 M km 240°C Polyimid 1958
Polyamidimid 1964
Polyesterimid 1962
better workability
higher temperature class Polyester 1955
higher abrasion withstand
higher bond strength Polyurethane 1950
120°C Polyvinylacetal 1938

Varnish Insulation: possible solutions
Polyvinylacetal Polyurethan T. Poly. (imid) Polyamidimid Polyimid

+
Polyamidimid
Temperature-index Temperature-index Temperature-index Temperature-index Temperature-index
120 ºC 180 ºC 200 ºC 220 ºC 240 ºC
Heat shock Heat shock Heat shock Heat shock Heat shock
155 ºC 200 ºC 220 ºC 240 ºC 260 ºC
Resoftening temp. Resoftening temp. Resoftening temp. Resoftening temp. Resoftening temp.
> 215 ºC > 250 ºC > 340 ºC > 400 ºC > 500 ºC
soldering Soldering soldering soldering soldering
no yes no no no
Chem. Resistance Chem. Resistance Chem. Resistance Chem. Resistance Chem. Resistance
very good good good very good very good

Bond Coat (Epoxy) Mechanical strength

(bond coat)
increased strength at working 6000
condition (5 x stiffness @ 120 °C) 5000

bonded
4000
Force [N]
compatibility with transformer oil 3000
2000
hardening during drying process 1000 not bonded
(start @ 90 °C depending on type 0

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
Bending [m m ]
in hot air or vapour phase)
30
different application possible:
25 26,6
Stiffness factor
24,8
20
all around radial bond
15
simple usage 12,5
10
shelf life min. 6 month depending 5 7,8

6,4
bond type and climate 0

20°C 60°C 80°C 105°C 120°C
Temperatur

Varnish insulation: Application
Process Product
~ 26 m
Isolation increase:
~ 0,10 mm
10 layers with 0,005 mm
thickness
Bdv > 2 kV
Source MAG

Conductor
Varnish-insulation
Cable-insulation
Construction
Process

Cable insulation: Material
smooth But to but wrapping

Cellulose
Micro crepe staggering
High thermal resistance, high mechanic strength,

Aramid Resistance against oil,
Protection
Without wrapping paper *
Without inter column separator
Continuous Perforated* Aramid Gap

Transposed Cable
Cordex * PET Filament
Diamond* Aramid
* Essex Patente
Specials Glass yarn, …

Electric Insulation Paper types for electric insulation

advantage: Papertype Remarks
- thick insulation Kraft- Paper 5A2-1H1, paper with high purity

- dielectric strength Kraft- Paper, calendared 5A4-1M2, high density and break down voltage
in oil
Thermo stabilized 5A2-1M1, increased thermal resistance
different types: Thermo stabilized, 5A4-1M2, high density and break down voltage,
calendared increased thermal resistance
- Cellulose Thermo stabilized, Paper with high mechanical strength, used for outer
- Aramid calendared, crepe layers
Epoxy coated,
Bondable outer layers
Thermo stabilized
disadvantage:
Aramid High thermal resistance, used for traction transformers
- cooling behavior
- thermal aging Epoxy coated Aramid Bondable outer layers for traction transformers
Transformer- Pressboard P 2.1, inter column separator
Glass woven fabric Winding used for resin cast transformers

Electric Insulation CTC with improved cooling (low voltage winding)

for low voltage perforated Paperless CTC diamond Cordex
winding with
increased heat
transfer
increased filling
factor
reduced cooling
higher efficiency
in power transformers

Cable insulation: Process
Paper wrapping process Typical paper set up for CTC

application of inner layers
2 outer layers, 50 % staggering
inner layers but to but, ~ 30 % shifted
outer layer
inner layer
CTC

Conductor
Varnish-insulation
Cable-insulation
Construction
Process

Cable insulation: Construction
d n 1
pitch SR Radial Size HR = a E Z
n (odd numbers) 2
SR n 2
Transposing factor fR Radial Size HR = a E Z
b (even numbers) 2
d = Winding diameter Axial Size BA = 2 b E I Z
n = number of strands
n 1
b = width of conductor Intercolumn Paper I = b E
c = crank length (min. 8 mm) 2

Dimension range of strands in CTC Limits of Transposed Cable
Transposition head
3,10 12,50 Radial size mm < 79

3,50
3,15 Axial size mm < 26
3,00
thickness [mm]
2,50
3,5 … 39 mm² Crank length mm 15 - 50
2,00
1,50 Geometry
1,00 1,00
Transposing factor >5
0,50
0,00 ratio width/thickness <8
1,00 3,00 5,00 7,00 9,00 11,00 13,00
width [mm]
Other dimension on request possible

Limits of Transposed Cable Limits of Transposed Cable

the crank length increases with the the radial size is depended from
width of the strand ratio pitch / crank length
CTC with a high ratio width / Small transposing factors
height incline to tilt increases the radial size
c
HR
b SR/c

Conductor
Varnish-insulation
Cable-insulation
Construction
Process

CTC Production Process
Pay off Transposing Paper Wrapping Caterpillar Winder

head

CTC Production Process
Work principle
Stack pusher
Production
Counter holder*
Strand pusher
Rotation

Test and specification

Tests and specification
specification
Copper DIN 1977

Aluminium DIN EN 573-3
Rectangular magnet wire – general requirements IEC 60317-0-2
Magnet wire – specific requirements IEC 60317-..
Magnet wire – test method IEC 60851-..
Magnet wire – temperature index IEC 60172
Cellulosic paper IEC 60554
Aramid - Paper IEC 60819
Pressboard IEC 60641
Drums and spools DIN 46391/1, IEC 60264

Product test
Shorts in CTC
Bonding Elongation
Sizes Spring Back
CTC
Snap test Yield strength
Abrasion tan delta
Break Down
Adhesion
Voltage
Staggering;
Heat Shock
bulging
Oil Compatibility El. Resistance
Softening
Temperature
Test depending to magnet wire

Summary
Continuous Transposed Cable look simple but are a “high tech”

product
Continuous Transposed Cable are a customized product
A lot of things are possible with a close work together of the CTC
producer and the transformer producer
If the others belief, you're at the end,

now you really have to start.
Konrad Adenauer

Superior Essex
23 plants in 9 countries
in
America, Europe and Asia
Cable for telecomunication

Round and flat enameled wires out of
copper and aluminium
Covered products
Continuous Transposed Cables
Isolation varnishes
Copper – Rod
Member of the LS-Cable Group

Thank you very much
for your attention

04 Essex Wires

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04 Essex Wires

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WIRES AND TRANSPOSED CABLES IN TRANSFORMERS

Dr. Stefan Beckmöller

ESSEX Germany GmbH

Dr. Stefan Beckmöller

„Metallurgy with focus metal forming“ at RWTH Aachen

PhD at RWTH Aachen

Quality Engineer at Kabelwerke Rheydt

Project Engineer at Lackdraht Union GmbH, Arolsen

Head of R&D Lacroix & Kress GmbH, Bramsche

Head of R&D Essex Germany GmbH, Arolsen

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 2

Energy Efficient Transformers

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 3

1912 Ludwig Roebel invents single insulated and

Since 1940 Transformer designs using the idea of

new challenges relating to efficiency, profitability and

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 4

high flexibility Fast and efficient

reduced electrical Reduced impact of S e1

improved cooling (skin + proximity effect) e2

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 5

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 6

CTC – build up Properties influenced by

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 7

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 8

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 9

Copper Aluminium CCA* (15 %)

Aspect red-orange metallic Bi-Metall

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 10

Impurities reduces conductivity

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 11

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 12

Copper Rod Production

Metallurgy Electrolyse Continuous Rod Casting

Source: Aurubis Source: Aurubis

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 13

Rectangular Wire Production

Pre-material Drawing Rolling

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 14

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 15

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 16

Polyvinylacetal Excellent adhesion, flexibility and oil resistance

Polyesterimid + Increased heat resistance

PET- foil, Aramid- paper,

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 17

Electric Insulation Insulation types

today 90 % PVA - class 120 Introduction of isolation types

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 18

Polyvinylacetal Polyurethan T. Poly. (imid) Polyamidimid Polyimid

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 19

Bond Coat (Epoxy) Mechanical strength

condition (5 x stiffness @ 120 °C) 5000

hardening during drying process 1000 not bonded

(start @ 90 °C depending on type 0

shelf life min. 6 month depending 5 7,8

bond type and climate 0

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 20

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 21

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 22

smooth But to but wrapping

High thermal resistance, high mechanic strength,

Continuous Perforated* Aramid Gap

Cordex * PET Filament

Dr. Stefan Beckmöller, Essex Germany GmbH 06.06.2013 Page 23