1 Introduction
Fiberglass covered wire is composite insulated winding wire formed by wrapping electrical grade continuous filament glass yarn on enameled copper wire, enameled aluminum wire, copper wire, aluminum wire conductor, is the core winding material for motor, transformer, home appliance, special equipment and other key electrical equipment. Fiberglass covered wire by insulation layer structure is divided into fiberglass covered round copper wire, fiberglass covered flat copper wire, fiberglass covered enameled wire, fiberglass paper covered wire four major categories, by heat resistance class divided into B class 130℃, F class 155℃, H class 180℃, C class 200℃, N class 220℃, R class 240℃ six grades.
Fiberglass covered wire international standard is the authoritative specification for product specification, quality control, detection method. Based on NEMA MW 1000-2018, IEC 60317 series, GB/T 7672, JIS C 3202, EN 60317 and other international and domestic standards, this article systematically describes the technical system, parameter specification, application selection and development trend of fiberglass covered wire international standard from six dimensions including standard system overview, NEMA MW 1000-2018 interpretation, IEC 60317 system, regional standard comparison, parameter detailed explanation, standard selection application notes.
2 Fiberglass Covered Wire Standard System Overview
2.1 International Standard Classification
Fiberglass covered wire international standard by issuing organization is divided into five major categories. IEC, IEC 60317 series, IEC 60851, IEC 60172. NEMA, MW 1000-2018 Magnet Wire, MW 43-C fiberglass covered copper wire, MW 44-C, MW 45-C, MW 46-C. CENELEC, EN 60317, HD 555. JIS, C 3202 enameled copper wire, C 3211 enameled aluminum wire, C 3216 fiberglass covered copper wire.
China GB, GB/T 7672 fiberglass covered winding wire, GB/T 11021, GB/T 10580, JB/T 5331, JB/T 4074, JB/T 5268.
2.2 Standard System Structure
Standard structure covers general specification, product specification, test method, inspection rule four major levels.
General specification, general technical requirement, terminology, classification, naming. NEMA MW 1000-2018 is comprehensive general specification, covering fiberglass, enameled, paper, film covered wire.
Product specification, specifies specific product technical requirement, performance index, detection rule. IEC 60317-0 series is subdivision specification, IEC 60317-X is specific product specification.
Test method, IEC 60851 series is international universal method, GB/T 4074 equivalently adopts.
Inspection rule, GB/T 2828.1 counting sampling, ASTM E540.
2.3 Standard Selection Principle
Fiberglass covered wire standard selection principle covers technical specification, market access, customer requirement, product positioning four major dimensions.
Technical specification, NEV drive motor commonly uses IEC 60317, special equipment commonly uses NEMA MW 1000-2018.
Market access, export to America select NEMA MW 1000-2018, export to European Union select EN 60317, export to Japan select JIS C.
Customer requirement, customer specified standard must be satisfied.
Product positioning, high end product selects IEC 60317 plus NEMA MW 1000 dual standard certification.
3 NEMA MW 1000-2018 Standard Interpretation
3.1 NEMA MW 1000-2018 Overview
NEMA MW 1000-2018 Magnet Wire is comprehensive enameled wire standard, covering fiberglass covered wire, enameled wire, paper covered wire, film covered wire full product series. Structure divided into Part 1 general specification, Part 2 test method, Part 3 product specification.
Part 1 general specification, terminology, naming, classification, technical requirement general principle. Part 2 test method, conductor resistance, varnish film thickness, varnish film continuity, breakdown voltage, tensile strength, elongation, thermal shock, thermal aging. Part 3 product specification, MW number 1-C to 100-C.
3.2 NEMA MW 43-C to 46-C Fiberglass Covered Wire Series
NEMA MW 43-C fiberglass covered round copper wire, conductor 0.50 to 5.00 mm, Thermal Class 155, adopts electrical grade continuous filament glass yarn insulation, suitable for motor and transformer.
MW 44-C fiberglass covered flat copper wire, width 1.00 to 16.00 mm, thickness 0.50 to 5.60 mm, Class 155. MW 45-C fiberglass covered enameled round copper wire, conductor 0.20 to 4.00 mm, Class 180 or 200. NEMA MW 46-C fiberglass covered enameled flat copper wire, width 1.00 to 12.50 mm, thickness 0.80 to 5.60 mm, Thermal Class 180 or 200.
3.3 NEMA MW 1000-2018 Heat Resistance Class Classification
NEMA MW 1000-2018 by heat resistance class is divided into Class 130, 155, 180, 200, 220, 240 fiberglass covered enameled copper wire six classes.
Class 130, 155, 180, 200, 220, 240 corresponding to 130 to 240℃ long term working temperature, each class corresponding to different varnish film system, fiberglass layer number, insulation structure.
3.4 NEMA MW 1000-2018 Key Technical Parameters
NEMA MW 1000-2018 key technical parameters cover conductor, varnish film, fiberglass, mechanical, electrical, thermal six major categories.
Conductor, round 14 to 30 AWG, 0.255 to 1.628 mm, flat 0.045 to 0.500 by 0.025 to 0.250 inch. Varnish film Grade 1, 2, 3, fiberglass single layer, double layer, four layer.
Mechanical, tensile 200 to 280 MPa, elongation greater than or equal to 25%. Electrical, resistivity less than or equal to 1.724×10⁻⁸ Ω·m, breakdown greater than or equal to 5000 V. Thermal, Class 155 life 20000 to 50000 hours.
4 IEC 60317 Standard System
4.1 IEC 60317 Standard Overview
IEC 60317 series is International Electrotechnical Commission published enameled wire subdivision specification, IEC 60317-0-X is general requirement, IEC 60317-X is specific product specification.
IEC 60317-0-1 round copper wire, 0-3 round aluminum wire, 0-4 round copper stranded wire, 0-7 fully insulated FIW, 0-8 130 class, 0-11 round copper stranded wire.
Specific specification includes 60317-13 130 class polyester round copper, -16 180 class polyester imide flat copper, -27 200 class polyamide imide flat copper, -46 200 class round copper.
4.2 IEC 60317-0-X Subdivision Specification
IEC 60317-0-1 round copper wire general requirement, conductor 0.018 to 5.000 mm, varnish film Grade 1 to 3.
IEC 60317-0-3 round aluminum wire, published in 2008, conductor 0.250 to 5.000 mm, Grade 1 to 3, resistivity less than or equal to 2.826×10⁻⁸ Ω·m.
4.3 IEC 60317 Enameled Plus Fiberglass Combined Specification
IEC 60317-0-7 fully insulated FIW, no pinhole no bubble, used for transformer inductor coil, fiberglass covered plus FIW is NEV drive new direction.
IEC 60317-15 fiberglass covered enameled round copper wire, NEV drive, rail transit. IEC 60317-26 fiberglass covered enameled flat copper wire, MW 44-C plus IEC 60317.
4.4 IEC 60851 Test Method Specification
IEC 60851 is enameled wire test method international standard, covering conductor resistance, varnish film thickness, varnish film continuity, breakdown voltage, tensile strength, elongation, thermal shock, thermal aging, softening breakdown all test methods.
IEC 60851-1 general, -2 dimension, -3 mechanical, -4 chemical, -5 electrical, -6 thermal. GB/T 4074 equivalently adopts.
5 Regional Standard Comparison
5.1 European Standard EN 60317 and IEC 60317
EN 60317 and IEC 60317 equivalent, adopt double numbering form.
EN 60317-0-1 equivalent to IEC 60317-0-1. HD 555 is CENELEC harmonization document. Export to European Union must satisfy EN.
5.2 Japanese Standard JIS C 3202 and IEC 60317
JIS C 3202 enameled copper wire, based on IEC 60317 developed, equivalently adopted.
JIS C 3211 enameled aluminum wire equivalent to IEC 60317-0-3. C 3216 fiberglass covered copper wire based on IEC plus MW 43-C.
5.3 China National Standard GB/T 7672 and IEC 60317
GB/T 7672 glass fiber covered winding wire, equivalently adopted IEC 60317 plus MW 43-C.
GB/T 7672, conductor 0.30 to 5.00 mm, fiberglass layer 0.10 to 0.80 mm, Class 130, 155, 180, breakdown greater than or equal to 3000 V. JB/T 5331 equivalent to MW 44-C plus IEC 60317-26.
5.4 Regional Standard System Features
Regional features, NEMA motor application, IEC varnish film chemical, JIS dimension precision, GB transformer application, IS low cost, KS electronic, NBR home appliance.
Standard relation, IEC 60317 as foundation, NEMA MW harmonizes with IEC, EN and JIS equivalently adopt, GB/T equivalently adopts.
6 Standard Parameter Detailed Explanation
6.1 Conductor Specification Standard Parameter
Conductor specification covers material, diameter, cross section area, tolerance four items.
Conductor, copper TU1, TU2, T2, aluminum 1060, 1050, 1350. Round copper 0.018 to 5.000 mm, round aluminum 0.250 to 5.000, flat copper 0.45 to 6.00 by 0.016 to 7.00.
Cross section area, round 0.0003 to 19.635 square mm, flat width thickness ratio 2:1 to 30:1. Tolerance, round plus minus 1% to 3%, flat plus minus 0.05 to 0.15 by plus minus 0.03 to 0.10 mm.
6.2 Insulation Thickness Standard Parameter
Insulation thickness standard parameter covers varnish film thickness, glass fiber layer thickness, insulation total thickness, varnish film thickness grade four items.
Varnish film, Grade 1 thin, 0.02 to 0.06 mm. Grade 2 standard, 0.04 to 0.10. Grade 3 thick, 0.06 to 0.15.
Fiberglass layer, single layer 0.10 to 0.30, double layer 0.20 to 0.50, four layer 0.40 to 0.80 mm.
Insulation total thickness, 0.15 to 1.00 mm, breakdown greater than or equal to 5000 V. Varnish film thickness grade, Grade 1 G1, Grade 2 G2, Grade 3 G3 universal three grades.
6.3 Mechanical Performance Standard Parameter
Mechanical performance standard parameter covers tensile strength, elongation, softness, wear resistance four items.
Tensile, copper 200 to 280 MPa, aluminum 70 to 110 MPa, fiberglass layer 2000 to 3500 MPa, overall 250 to 400 MPa.
Elongation, round copper 25% to 40%, flat copper 25% to 35%, round aluminum 15% to 25%.
Softness, round copper wire less than or equal to 5 times diameter bending, flat copper wire less than or equal to 10 times thickness bending, winding without crack.
Wear resistance, varnish film wear resistance times greater than or equal to 50, fiberglass covered wire wear resistance times greater than or equal to 80, adhesion.
6.4 Heat Resistance Performance Standard Parameter
Heat resistance performance covers heat resistance class, thermal stability, thermal shock, thermal aging four items.
Heat resistance, Class 130 B, 155 F, 180 H, 200 C, 220 N, 240 R.
Thermal stability, H 180℃ long term 20000 to 50000 hours, C 200℃ 10000 to 30000, N 220℃ 5000 to 20000, R 240℃ 3000 to 10000 hours.
Thermal shock, H class 180℃ to room temperature 5 times without crack, C class 200℃ to room temperature 10 times without crack.
Thermal aging, H class 180℃ aging 5000 hours, tensile retention rate greater than or equal to 80%, breakdown voltage retention rate greater than or equal to 70%.
6.5 Electrical Performance Standard Parameter
Electrical performance covers conductor resistance, insulation resistance, breakdown voltage, PDIV four items.
Conductor resistance, copper less than or equal to 1.724×10⁻⁸ Ω·m, aluminum less than or equal to 2.826×10⁻⁸ Ω·m.
Insulation resistance, dry state greater than or equal to 1000 MΩ·km, oil immersed greater than or equal to 10000 MΩ·km.
Breakdown voltage, Grade 1 greater than or equal to 3000 V, Grade 2 greater than or equal to 5000 V, fiberglass greater than or equal to 8000 V, Nomex greater than or equal to 12000 V.
PDIV, greater than or equal to 2 times rated, transformer greater than or equal to 1.5 times.
7 Standard Selection and Application Notes
7.1 Standard Selection Key Points
Selection key points cover application, customer, technical, market, certification five major dimensions.
Application, motor NEMA MW 1000, transformer IEC 60317, home appliance GB/T 7672, special AS9100. NEV dual certification MW 1000 plus 60317-15.
Customer, Nissan MW plus IEC, Volkswagen EN 60317, Bosch ISO 9001 plus IATF 16949.
Technical, H class motor MW 45-C or GB/T 7672 H, damp heat IEC 60851-6.
Market, America NEMA, European Union EN, Japan JIS C 3216, China GB/T 7672.
Certification, UL North America, CE European Union, RoHS plus REACH environmental.
7.2 Application Notes
Notes cover standard understanding, process, detection, document, change five major dimensions.
Standard understanding, such as IEC 60317-0-1 annex B resistance, ASTM D149 dielectric breakdown, IEC 60851-3 tensile test.
Process matching, Grade 2 varnish film thickness, fiberglass overlap rate 50% plus minus 10%.
Detection compliance, detect according to standard specified test method, judge according to sampling rule, handle non-conforming product according to standard. Such as GB/T 2828.1 counting sampling.
Document management, save complete standard version, process document, inspection record, traceability record. Each batch product unique number, traceable, traceability response time less than or equal to 24 hours.
Change management, standard update timely revise product specification. Such as NEMA MW 1000 every 5 to 8 years update one edition.
7.3 Future Trends
Fiberglass covered wire standard future development trend embodies five major directions, intelligent, environmental, high end, international, digital.
Intelligent, add intelligent sensor fiberglass covered wire standard, IEC 60317-X add intelligent monitoring, optical fiber sensor life monitoring.
Environmental, environmental material, degradable covered wire, vegetable oil impregnation, RoHS, REACH.
High end, N 220, R 240, S 250℃ heat resistance, PDIV greater than or equal to 3 times, tensile greater than or equal to 400 MPa.
International, IEC 60317 plus NEMA MW 1000 dual standard certification becomes mainstream, Europe America Japan Korea China five country standard mutual recognition, reduce technical barrier.
Digital, standard document digitalization, online query tool, intelligent standard library, artificial intelligence assist standard interpretation.
8 Summary
Fiberglass covered wire international standard covers IEC 60317, NEMA MW 1000-2018, EN 60317, JIS C, GB/T 7672, JB/T 5331 and other systems.
Standard system covers five major standards, four major levels, general specification, product specification, test method, inspection rule.
NEMA MW 1000-2018 includes MW 43-C, 44-C, 45-C, 46-C, six major heat resistance classes Class 130 to 240℃.
IEC 60317 includes 0-1 to 0-11 subdivision specification, -13 to -46 specific product, IEC 60851 test method.
Regional standard comparison, EN and JIS equivalent to IEC, GB equivalently adopts. Selection principle, technical, market, customer, positioning.
Standard parameter covers conductor, insulation, mechanical, heat resistance, electrical five major categories. Conductor TU1 99.97%, resistance less than or equal to 1.724×10⁻⁸ Ω·m, varnish film Grade 1, 2, 3, tensile 200 to 280 MPa, breakdown greater than or equal to 5000 V, PDIV greater than or equal to 2 times.
Future trend, intelligent, environmental, high end, international, digital five major directions.
Reference standards: NEMA MW 1000-2018, NEMA MW 43-C, IEC 60317 series, IEC 60851 series, EN 60317 series, JIS C 3202, JIS C 3216, GB/T 7672, GB/T 11021, JB/T 5331, JB/T 4074.
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