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The Stranding Process
The foundation of our PE2+PA insulated wire is the stranded copper conductor, which is manufactured by twisting together multiple individual copper strands to form a single, unified conductor. This stranding process is carefully controlled to ensure consistent electrical and mechanical performance. The individual strands are made from bright-annealed, high-purity copper with more than 99.97% purity, ensuring excellent electrical conductivity.
The stranding operation involves twisting multiple wires together in a helical pattern, with the lay ratio (the ratio of the length of one complete twist to the diameter of the resulting conductor) carefully controlled to achieve the desired balance of flexibility and mechanical integrity. This twisting process creates a conductor that is significantly more flexible than a solid conductor of equivalent cross-sectional area.
Stranded Conductor Specifications
According to industry standards, stranded copper conductors for submersible motor winding wires are available in a wide range of sizes. The stranded conductor diameter typically ranges from approximately 4.5 mm to 17.1 mm, with cross-sectional areas ranging from approximately 3.5 mm² to 150 mm². The strands in the conductor have the same nominal diameter before stranding, ensuring consistent electrical performance across the conductor cross-section.
The flexibility of stranded conductors is particularly valuable in larger motors where the winding wire must be manipulated during the winding process. Solid conductors of equivalent cross-section would be difficult to bend and form into the tight radii required in motor stator slots, making stranded constructions the preferred choice for higher horsepower applications.
The PE2+PA Insulation System
Cross-Linked Polyethylene (PE2) Insulation
The primary insulation layer of our PE2+PA wire consists of cross-linked polyethylene (PE2). Cross-linking is a chemical process that creates bonds between the polyethylene polymer chains, significantly enhancing the material’s thermal and mechanical properties. This cross-linking allows the PE2 insulation to maintain its dielectric integrity at temperatures up to 90°C, compared to standard polyethylene which would soften at lower temperatures.
The PE2 insulation provides the primary dielectric barrier between the stranded copper conductor and the surrounding environment. Its excellent electrical properties include high dielectric strength, low dielectric constant, and minimal power loss even at elevated temperatures.
Polyamide (PA) Sheath
Over the PE2 insulation, we apply a thin but robust polyamide (PA) sheath. The PA sheath serves a different but equally important function: providing mechanical surface protection. This outer layer protects the PE2 insulation from abrasion during the motor winding process and from mechanical stress during motor operation. The PA sheath also provides additional chemical resistance, ensuring the insulation system remains impervious to oils, chemicals, and the varied fluids encountered in submersible applications.
Insulation Thickness
The insulation wall thickness of PE2+PA wires is specified according to the conductor dimensions and operating voltage requirements. Typical insulation thicknesses range from 0.3 mm upward, depending on the specific application requirements. The PA sheath thickness is typically 0.1 to 0.3 mm, determined by the outer diameter of the PE2-insulated conductor.
Advantages of Stranded PE2+PA Wire
Superior Thermal Performance
PE2+PA insulated winding wire is designed for submersible motors operating at elevated temperatures. While standard PVC-insulated wires are typically limited to 70°C to 75°C continuous operation, PE2+PA wires are rated for 90°C continuous operation. This superior thermal performance allows motors to deliver approximately 20% more power than those using standard insulation systems, an advantage that is particularly valuable in high-performance submersible pump applications.
Exceptional Water Resistance
Submersible motors, by definition, operate in direct contact with water or other fluids. The PE2+PA insulation system is engineered to be completely impervious to liquids of any kind. The cross-linked PE2 layer provides excellent water resistance, while the PA sheath adds an additional barrier against moisture penetration. This water resistance ensures long-term reliability in applications ranging from clean water pumping to aggressive chemical environments.
High Voltage Capability
PE2+PA wires are suitable for submersible motors operating at higher voltages. Standard PE2+PA insulation is rated for 1,000V applications, with enhanced configurations available for 3,000V and even 6,000V applications. The high-voltage capability makes these wires suitable for large-scale pumping applications where motor power requirements drive higher operating voltages.
Mechanical Robustness
The combination of the twisted stranded copper conductor and the robust PE2+PA insulation system provides exceptional mechanical durability. The stranded conductor resists fatigue from vibration, while the insulation system withstands the mechanical stresses of winding, insertion into stator slots, and long-term motor operation.
Applications
Water-Filled Submersible Motors
In water-filled submersible motors, the motor cavity is filled with water, and the winding wire operates in direct contact with the cooling fluid. PE2+PA insulated wire is the preferred choice for these applications due to its exceptional water resistance and thermal performance. These motors are commonly used in agricultural irrigation, domestic water supply, and municipal water distribution systems.
Oil-Filled Submersible Motors
Oil-filled submersible motors use transformer oil or other dielectric fluids as both insulation and coolant. The PE2+PA insulation system is fully compatible with these fluids and maintains its electrical and mechanical properties in oil-filled environments. The use of stranded conductors in oil-filled motors provides the flexibility required for complex winding configurations while ensuring long-term reliability.
High-Temperature Applications
PE2+PA wires demonstrate excellent performance at water temperatures up to 50°C. This capability makes them suitable for geothermal applications, hot water pumping, and other applications where the fluid temperature exceeds the capability of standard insulation systems.
High-Power Motors
For higher horsepower submersible motors used in specialized applications such as dewatering, mining, and naval pumping, multi-strand copper conductors with PE2+PA insulation are essential. The multi-strand construction reduces skin effect losses and provides the flexibility required for large-scale motor windings.
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