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Construction and Characteristics
The HL/PE2/PA winding wire consists of a solid copper conductor with a multi-layer insulation system. The conductor is manufactured from high-conductivity copper, with diameters typically ranging from 0.8 mm to 3.4 mm for submersible motor applications. The solid construction offers advantages in slot fill factor and simplifies termination in motor stator assemblies.
The semiconducting layer (HL) is applied directly over the copper conductor. This layer performs a critical function at higher operating voltages: it equalizes the electric field distribution at the conductor surface. Without this layer, localized electrical stress concentrations at surface irregularities would create initiation points for partial discharge, leading to progressive insulation degradation. The HL layer is typically applied with a thickness ranging from 0.1 mm to 0.3 mm.
The PE2 insulation layer provides the primary dielectric barrier. Cross-linking transforms the polyethylene from a thermoplastic to a thermoset material, creating a three-dimensional molecular network that maintains its properties at continuous operating temperatures up to 50°C for standard constructions, with higher ratings available for specialized applications. The cross-linked structure also provides enhanced resistance to water penetration, a critical requirement for submersible motor windings that operate in direct contact with the surrounding fluid.
The PA outer sheath, typically applied with a wall thickness of 0.1 mm to 0.3 mm, provides mechanical protection for the PE2 insulation. The polyamide material resists abrasion during winding and service, contributes to the wire‘s smooth surface finish for ease of slot filling, and adds a secondary barrier against water ingress.
Polish Manufacturers Using HL/PE2/PA Winding Wire
Several Polish companies manufacture or supply submersible motors that utilize PE2/PA or HL/PE2/PA insulation systems. While the specific “HL” designation is typically reserved for higher-voltage applications, the PE2/PA construction forms the foundation of this insulation family.
Hydro-Vacuum S.A. , based in Grudziądz, Poland, is a major Polish manufacturer of submersible motors and pumps. The company‘s 6“, 8”, and 10“ submersible motors are available with stator windings using PA-PE2 (SMP) thermoplastic insulation, which the company identifies as increasing motor longevity compared to PP-insulated windings . Hydro-Vacuum‘s motors are designed for drinking water supply, wells, agriculture, drainage, pressure boosting, and industrial water applications, with maximum submersion depth of 200 meters .
DAB Pumps Polska offers 6” submersible motors that are available with PE2+PA winding on request for use with variable frequency drives . The standard version uses PVC windings, but the PE2+PA option is specified for applications requiring higher thermal performance or VFD compatibility. The motors feature NEMA 6“ flange connections and are designed for maximum submersion depth of 300 meters .
Franklin Electric , through its European operations, supplies 8” and 10“ rewindable submersible motors to the Polish market that feature PE2/PA winding insulation rated for maximum ambient temperatures up to 45°C or 50°C depending on the model . The company’s 8” rewindable motors in the 30-93 kW range are available with PE2/PA insulation as an option for higher water temperature applications . Franklin Electric‘s Polish-language product documentation confirms the use of “wysokiej jakości uzwojeniem z tworzywa PE2/PA sieciowanego promieniowaniem” (high-quality radiation-crosslinked PE2/PA winding) in their larger motors .
Panelli Pumps , an Italian manufacturer whose products are distributed in Poland, specifies PE2+PA winding wire as an option for its 10” and 12“ submersible motors. The company notes that “with PE2+PA winding up to 50°C” water temperature is achievable, compared to the 30°C maximum for standard thermoplastic insulation . Panelli’s 12” motors are available with PE2+PE winding wire on request for higher water temperatures .
Suitable Pumps for Repair
The HL/PE2/PA winding wire is designed for high-power submersible motors where the combination of electric field control and reliable insulation is essential. Polish motor repair facilities that service these pumps should be familiar with the appropriate rewinding procedures.
Deep well water supply pumps operating in municipal, agricultural, and industrial settings represent the primary application. These pumps often operate at significant depths where water pressure and temperature place demands on the insulation system. Hydro-Vacuum‘s submersible motors are specifically designed for “dostarczania wody pitnej” (drinking water supply), “studniach” (wells), and “rolnictwie” (agriculture), with maximum submersion depth of 200 meters .
High-temperature water applications benefit from the PE2/PA construction. Where standard PVC-insulated motors are limited to 30°C water temperature, PE2/PA insulation extends the operating range to 50°C, making it suitable for applications where geothermal or industrial process water reaches elevated temperatures.
Variable frequency drive (VFD) applications require insulation systems that can withstand the voltage stresses imposed by PWM output waveforms. DAB Pumps specifies PE2+PA winding for their motors when used with frequency converters, acknowledging that the insulation system must handle the additional electrical stress .
Rewindable motors in the 6” to 12“ range are specifically designed for repair rather than replacement. Franklin Electric’s rewindable motors with PE2/PA insulation are designed for “dependable operation in 8” diameter or larger water wells“ with “water lubricated thrust and radial bearings” enabling maintenance-free operation . When these motors fail, rewinding with appropriate PE2/PA or HL/PE2/PA wire restores them to service.
Polish motor repair companies serving these applications include Albeco, which offers comprehensive repair and refurbishment services including electric motor rewinding, bearing replacement, and rotor balancing from facilities in Plewiska, Katowice, and Olsztyn . ZWiK Szczecin provides pump repair and motor rewinding services up to 50 kW, holding authorizations for Hydro-Vacuum, Grundfos, Sulzer (ABS), and ITT Flygt pumps . Villtek EMSZ Ltd. , with over 35 years of experience, specializes in winding, repair, and overhaul of industrial and agricultural electric motors, including FLYGT submersible and sewage pump refurbishment .
Technical Standards
The PE2/PA insulation system is manufactured and tested in accordance with international standards. Tensile strength and elongation are verified per IEC 60811-1-1, with minimum values of 10 N/mm² and 100% respectively at 23°C, maintained after aging at 80°C for seven days . Dielectric breakdown strength reaches 70 kV/mm when tested at 50 Hz and 20°C according to DIN VDE 0303-21 . Specific insulation resistance measures 10¹⁰ Ω·cm at 20°C per IEC 60093, and the dielectric constant is 2.3 at 800 Hz per DIN 53483
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