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Conductor Specifications: Solid and Stranded Configurations
The copper conductor forms the electrical foundation of every submersible winding wire. We produce both solid and stranded conductor configurations to accommodate different motor designs and winding methods.
Solid conductors are manufactured in diameters ranging from 0.6 mm to 4.6 mm, corresponding to cross-sectional areas of 0.283 mm² to 16.6 mm² . These dimensions cover the typical requirements for small to medium submersible pump motors. Solid conductors offer advantages in winding density and are simpler to terminate in motor stator assemblies.
Stranded conductors extend the range to larger cross-sections, with diameters from 4.5 mm to 17.1 mm and cross-sectional areas of 3.5 mm² to 150 mm² . Stranded construction provides greater flexibility for larger motors where bending radii and handling considerations favor multi-strand designs.
For standard PE2/PA production, we maintain a core range of 0.8 mm to 3.4 mm in conductor diameter, which covers the majority of submersible pump applications . Conductor diameter tolerances follow the requirements of the applicable product standard, with typical tolerances ranging from ±0.004 mm for 0.4 mm conductors to ±0.019 mm for 1.9 mm conductors, as specified in Indian Standard IS 8783 .
Insulation System: PE2 and PA Layer Dimensions
The double insulation system consists of an inner cross-linked polyethylene (PE2) layer and an outer polyamide (PA) sheath. Each layer has distinct dimensional requirements that affect the wire‘s electrical and mechanical performance.
The PE2 insulation wall thickness depends on the conductor dimensions and the operating voltage for which the wire is designed. Insulation thickness begins at 0.3 mm and increases with conductor size and voltage rating . For standard 600/1000 V applications, thinner insulation walls are acceptable, while 3 kV and higher voltage ratings require proportionally thicker PE2 layers.
The PA sheath is applied over the PE2 insulation as a surface protection layer. Typical PA wall thickness ranges from 0.1 mm to 0.3 mm, depending on the outer diameter of the insulated conductor . The polyamide sheath must be tightly applied with no voids or separation from the underlying PE2 layer.
For HL/PE2/PA construction (high-voltage applications rated 6 kV and above), a semiconducting layer is added between the copper conductor and the PE2 insulation. This HL layer typically measures 0.1 mm to 0.3 mm in thickness, again varying with conductor diameter . The semiconducting layer equalizes the electric field at the conductor surface, preventing localized stress concentrations that could lead to premature dielectric failure.
Dielectric Breakdown Voltage
Breakdown voltage represents the most critical electrical parameter for submersible winding wire. The insulation must withstand the applied voltage plus any transient overvoltages without failing, even after prolonged immersion in water.
PE2/PA winding wire achieves a dielectric breakdown strength of 70 kV/mm when tested at 50 Hz and 20°C in accordance with DIN VDE 0303-21 . This value represents the minimum breakdown voltage per unit of insulation thickness. For a wire with 0.5 mm of PE2 insulation, this translates to a theoretical breakdown voltage of 35 kV, though actual working voltage ratings are substantially lower to provide appropriate safety margins.
The specific insulation resistance measures 10¹⁰ Ω·cm at 20°C per IEC 60093 . This high resistance ensures minimal leakage current even in water-filled motor environments where the insulation is continuously exposed to the surrounding fluid.
The dielectric constant at 800 Hz is 2.3, measured according to DIN 53483 . This relatively low value indicates good insulating characteristics with minimal capacitive losses.
Voltage ratings for our production range include 1,000 V and 3,000 V for standard PE2/PA constructions. The HL/PE2/PA variant extends the rating to 6,000 V for high-voltage submersible motors used in mining and seawater applications .
Finished Product Testing
Every production batch undergoes comprehensive finished product testing to verify compliance with specification requirements. Testing protocols follow the methods specified in the applicable standards, including IEC 60811-1-1 for mechanical properties and IEC 60093 for insulation resistance measurement.
Mechanical testing verifies tensile strength and elongation at break. At 23°C, the minimum tensile strength is 10 N/mm² and minimum elongation is 100% . After aging at 80°C for seven days (7×24 hours), these values must remain at or above the same minimums, demonstrating the long-term stability of the cross-linked insulation .
Electrical testing includes breakdown voltage verification on finished wire samples. Test procedures follow the methods of IEC 60851-5, which specifies Test 13 for breakdown voltage and Test 14 for continuity of insulation . The breakdown voltage test applies increasing voltage across the insulation until failure occurs, with the result expressed in kV/mm.
Dimensional inspection verifies conductor diameter, insulation thickness, and overall wire diameter against specification tolerances. These measurements are performed on samples taken from each production lot.
Water resistance testing is particularly important for submersible applications. Finished wire samples are immersed in water at elevated temperature for extended periods, after which insulation resistance and breakdown voltage are re-measured to confirm that water exposure has not degraded the insulation system.
International Technical Standards
Our submersible winding wires are manufactured in accordance with the relevant national and international standards, depending on customer requirements and destination market.
The primary Chinese standard governing this product category is JB/T 4014.4-2013, “Winding wires for submersible motors – Part 4: Irradiated polyethylene insulated nylon sheathed water-resistant winding wires with rated voltages no more than 600/1000V” . This standard, issued by the Ministry of Industry and Information Technology, specifies the varieties, specifications, and technical requirements for PE2/PA submersible winding wire . The general requirements for the JB/T 4014 series are specified in JB/T 4014.1-2013, which covers test methods, inspection rules, and packaging requirements .
For the Indian market, the applicable standard is IS 8783, “Winding wires for submersible motors – Specification” . Part 4 Section 1 of this standard addresses HR PVC insulated wires, while other sections cover cross-linked polyethylene insulated and polyamide jacketed constructions . The Bureau of Indian Standards maintains this standard through the ETD 33 Winding Wire Sectional Committee.
International standards relevant to winding wire testing include IEC 60851-5, which specifies electrical test methods for winding wires including breakdown voltage and continuity of insulation . The German standard DIN VDE 0303-21 governs dielectric breakdown strength testing at power frequencies . For magnet wire generally, NEMA MW 1000 provides comprehensive requirements for dimensions, constructions, performance, and test methods .
The Chinese national standards referenced by JB/T 4014 include GB/T 3953 for round copper wires and GB/T 6109 series for winding wire test methods . These standards ensure consistency across the domestic supply chain and provide the technical basis for export certification.
Ordering Specifications
When specifying PE2/PA submersible winding wire, customers should provide the following information: conductor diameter or cross-sectional area, conductor construction (solid or stranded), voltage rating, PE2 insulation thickness, PA sheath thickness, and overall wire diameter. For high-voltage applications, specify whether the HL semiconducting layer is required. We produce wire to meet the applicable standard for the destination market and can supply test certificates documenting compliance with the specified requirements.
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