Cables Submersible Winding Wires – PE2/ PA China Manufacturer

Product Structure and Materials

PE2/PA winding wire consists of three essential components arranged concentrically:

Copper Conductor: The core is a solid or stranded bare copper conductor with a purity of at least 99.97% (oxygen-free copper). Single-strand conductors range from approximately 0.6 mm to 4.6 mm in diameter, corresponding to cross-sectional areas of 0.283 mm² to 16.6 mm². Multi-stranded configurations are available for larger cross-sections, with typical constructions such as 7-strand or 19-strand arrangements.

PE2 Insulation Layer: The inner insulation is made from cross-linked polyethylene (PE2). The cross-linking process enhances the polyethylene‘s thermal resistance, enabling the wire to operate at conductor temperatures up to 90°C. The PE2 layer provides the primary dielectric strength and low water permeability essential for submerged operation.

PA Sheath: The outer layer is a thin polyamide (nylon) sheath, typically 0.1 mm to 0.2 mm in wall thickness. The PA sheath delivers mechanical protection, abrasion resistance, and chemical resistance against water, oil, acids, and alkalis. It also protects the softer PE2 layer during winding and installation.

Key Technical Parameters

The following parameters define the performance envelope of standard PE2/PA submersible winding wire:

Rated Voltage: Standard products are rated for 450/750V (U₀/U) under JB/T 4014.2. Higher-voltage variants, including those with a semiconducting layer, are available for 600/1000V, 3 kV, and 6 kV applications.

Temperature Rating: The maximum continuous conductor operating temperature is 90°C for PE2/PA wire. Some manufacturers specify a maximum ambient operating temperature of 50°C for the complete submersible motor assembly.

Conductor Dimensions: Solid copper conductors range from 0.6 mm to 4.6 mm in diameter. Insulation wall thickness starts from 0.3 mm and increases with conductor size and voltage rating. PA sheath thickness ranges from 0.1 mm to 0.3 mm depending on the outer diameter of the insulated conductor.

Dielectric Properties: The dielectric breakdown strength of the PE2 insulation is specified at ≥ 70 kV/mm (at 20°C, 50 Hz). The specific insulation resistance is ≥ 10¹⁴ Ω·cm at 20°C. The dielectric constant at 800 Hz is approximately 2.3.

Mechanical Properties: Tensile strength of the insulation is ≥ 10 N/mm² at 23°C, with elongation at break ≥ 100%. After aging at 80°C for 7 days (168 hours), these values must remain at ≥ 10 N/mm² and ≥ 100% respectively.

Test Items for PE2/PA Winding Wire

Comprehensive testing ensures that PE2/PA winding wire meets the stringent requirements of submersible motor applications. Third-party inspection and manufacturer testing typically cover the following categories:

Dimensional Tests: Conductor structure and dimensions; PE2 insulation thickness; PA sheath thickness; overall diameter; eccentricity (concentricity of insulation around the conductor).

Electrical Tests: DC resistance of conductor at 20°C; insulation resistance measurement; dielectric breakdown voltage test (withstand voltage test); dielectric constant measurement.

Mechanical and Physical Tests: Tensile strength and elongation of insulation and sheath; adhesion of insulation to conductor; flexibility and mandrel bend test; surface finish inspection.

Thermal and Aging Tests: Heat aging resistance (typically at 80°C for 7 days); thermal endurance evaluation; accelerated life testing.

Environmental and Performance Tests: Water pressure resistance test; water absorption test; chemical resistance (to water with pH 6.5–8.5, oil, and mild chemicals).

Special Tests: Voltage fluctuation resistance; long-term submersion performance; compatibility with motor impregnating varnishes and fluids.

These test items align with the requirements of JB/T 4014.2-2013, the Chinese industry standard specifically governing polyethylene-insulated nylon-sheathed water-resistant winding wires.

Technical Standards Governing PE2/PA Winding Wire

Chinese Industry Standards

The primary standard for PE2/PA submersible winding wire in China is JB/T 4014.2-2013: “Winding wires for submersible motors — Part 2: Polythene insulated nylon sheathed water-resistant winding wires with rated voltages no more than 450/750V” . This standard specifies the品种 (varieties), specifications, and technical requirements for the product. It is part of the broader JB/T 4014 series, which includes Part 1 (General Regulations), Part 3 (PVC-insulated), and Part 4 (XLPE-insulated) .

Supporting standards include GB/T 3048.4 (Test methods for electrical properties — DC resistance of conductors), GB/T 2951.11 (General test methods for insulation and sheath materials — mechanical properties), and GB/T 2951.12 (Thermal aging test methods) .

International Standards

At the international level, winding wires are governed by the IEC 60317 series, developed by IEC Technical Committee TC 55 (Winding Wires). While IEC 60317-0-1 provides general requirements for enamelled round copper wire, the PE2/PA construction for submersible motors is addressed through manufacturer-specific specifications and national standards that build upon IEC test methodologies.

Key IEC test standards referenced for PE2/PA wire include:

• IEC 60811-1-1: Measurement of thickness and overall dimensions; mechanical properties

• IEC 60093: Methods of test for volume resistivity and surface resistivity of solid electrical insulating materials

• IEC 60250: Recommended methods for the determination of the permittivity and dielectric dissipation factor of electrical insulating materials

Research and Application by Global Companies

PE2/PA winding wire has been the subject of extensive research and application development by leading submersible motor manufacturers worldwide.

Franklin Electric has conducted intensive laboratory and field testing of winding wire insulation systems for submersible motors. The company‘s research demonstrated that radiation-crosslinked PE2/PA winding delivers “superior insulation properties and suitability” for variable frequency drive (VFD) operation and high-temperature applications up to 50°C ambient. Franklin Electric continues to specify PE2/PA as the standard winding for its synchronous and 12-inch rewindable motors, confirming its position as the high-quality reference insulation for demanding applications.

Vansan (Turkey), a submersible motor manufacturer, produces PE2/PA winding wire in its own factory under ISO 9001:2015 certification. Their published testing data confirms the wire’s dielectric breakdown strength of 70 kV/mm and its suitability for continuous operation at 50°C ambient. Vansan positions PE2/PA as the wire that gives submersible motors a “safety factor” beyond standard motors.

Grundfos (Denmark) specifies PE2/PA winding wire with polyamide sheathing for surface protection in its submersible motor documentation, noting its suitability for conductor temperatures up to 90°C.

Nidec Corporation (Japan), a global leader in motor technology, has conducted extensive research on winding wire space factors and insulation systems for electric motors, contributing to the broader body of knowledge on winding wire performance and reliability