Documente Academic
Documente Profesional
Documente Cultură
1.0 SCOPE
This standard covers requirements of enamelled round copper wires of Polyster and Polysterimide enamel for use at elevated temperatures.
ORDERING SPECIFICATIONS
REQUIREMENTS
a) General: The conductor shall be of high conductivity annealed copper and be completely and uniformly covered with
a durable , flexible synthetic enamel. the enamel shall have a clean, smooth surface free from embedded
particles such as dust & other deleterious material. It shall also be free from slivers, cracks, spills and other
harmful defects. Each batch shall be accompanied by a batch test certificate .
b) Material:
b.1 Conductor:
i) Breakdown Voltage at room temperature: As per values given in Table-1, when tested as per Appendix I
ii) Breakdown Voltage at elevated temperature: When tested as per Appendix I the value shall not be less than 75% of the BDV at
room temperature as specified in Table-I.
iii) Elongation: Shall be as given in Table-I, when tested as per Appendix II.
iv) Springiness: (Applicable to sizes >0.05mm ≤ 1.60mm) Shall be as given in Table-I, when tested as per Appendix III.
REVISION M N O
DATE
31.12.98 31.12.99 30.09.2000
PAGE NO
7,8 & 10 3 6
v) Continuity of covering: (Applicable to sizes upto 0.85mm). Not more than 15 faults in a length of 50m,
when tested as per Appendix IV.
vi) Heat shock test: The covering shall show no cracks, when tested as per Appendix V.
vii) Flexibility and Adherence: the covering shall show no cracks when tested as per Appenix VI.
ix) Abrasion Resistance: (Applicable sizes >0.25mm. 2.50mm).Shall satisfy the values given in the
Table-2, when tested as per AppendixVIII.
x) Cut-Through test: No breakdown shall occur within 2 minutes when tested as per Appendix IX.
xi) Softening temperature test: No breakdown shall occur when tested as per Appendix X
.
xii) Compatibility: shall satisfy the requirements for performance when tested as per Appendix XI.
6.0 TESTING
The enamelled copper wires shall be tested for :
This test shall be done for approval of new vendor of enamel or varnish application.
xii) Test certificate as per the format given by L&T and shall be enclosed alongwith the supply challan.
7.0 INSPECTION
After ascertaining that a valid batch test certificate is available, inspection shall be carried out for :
8.0 PACKING
The wires shall be wound evenly and compactly on plastic/wooden spools without any deformation. The
spools shall be packed in suitable cartons. Dimensions of the spools shall be as per table given below :
i) The material used for the construction of the spool shall have the required mechanical strength so that the
spool does not warp on actual usage or storage.
ii) The material shall have no deleterious effect on enamel or other coverings of wire.
iii) No portion of spool shall warp when kept in an oven at 70°C for an hour.
iv) The spool shall be of any light colour (Black excluded)
v) Imbalance and axial throw of the flange shall be negligible.
vi) Eccentricity of the spool when measured by dial gauge shall be within 0.35 mm.
8.1 At least 80% supply of 40 G fine cov. wire shall be min. 3 kg. per spool.
9.0 MARKING
Each spool & carton shall be labelled with the following with indelible ink :
10.0 STORAGE
The spools shall be stored on racks and in dry atmosphere.
31.12.1999 No copying or Extraction from this Document without L&T’s Permission Page 3 of 30
LTS 3216
TABLE-2
NOTE:
i) IN = 102 gms.
ii) Load values for polyester & polyesterimide wires are same.
SWG Nominal Dia OVERALL DIA (mm) Electrical Spool Net weight of
Of conductor Fine Medium Thick Resistance at type wire in spool
Covering Covering Covering 20°° C per Plastic or (kg.)
metre (ohms) wooden
mm Tol Min Max Min Max Min Max Min. Max. Min. Max.
±)
(± Incre O.D. Increa O.D. Incre O.D.
ase se ase
0.020 0.002 0.025 0.003 0.027 46.63 65.31 No.12 0.5 --
0.025 0.025 0.031 0.004 0.034 -- -- 30.55 41.09 No.12 0.5 --
0.032 0.003 0.040 0.006 0.043 -- -- 18.87 24.44 No.12 0.5 --
0.040 0.004 0.050 0.008 0.054 -- -- 12.21 15.37 No.12 0.5 --
0.050 0.005 0.062 0.010 0.068 -- -- 7.903 9.559 No.12 0.5 --
46 0.060 0.003 0.007 0.076 0.013 0.083 -- -- 5.369 6.431 No.12/PT-1 0.5 --
0.063 0.007 0.078 0.013 0.085 -- -- 5.033 6.029 No.12/PT-4 0.5 --
45 0.071 0.003 0.008 0.088 0.015 0.095 -- -- 3.985 4.725 No.12 0.5 --
0.080 0.003 0.009 0.098 0.016 0.105 0.024 0.116 3.156 3.704 No.12 0.5 --
44 0.081 0.013 0.009 0.099 0.016 0.106 0.024 0.117 3.078 3.614 No.12/PT-1 0.5 --
0.090 0.003 0.010 0.110 0.017 0.117 0.026 0.128 2.507 2.913 No.12 0.5 --
43 0.091 0.003 0.010 0.111 0.017 0.118 0.026 0.129 2.452 2.850 No.12 0.5 --
0.095 0.003 0.018 0.123 2.254 2.619 PT-4 3.0 --
0.100 +0.000 0.111 0.116 2.041 2.349 PT-4 3.0 --
-0.003
0.100 0.003 0.011 0.121 0.019 0.129 0.028 0.141 2.041 2.349 No.12/PT-4 0.5 --
42 0.102 0.003 0.011 0.123 0.019 0.131 0.028 0.143 1.974 2.259 No.12/PT-4 0.5 --
41 0.112 0.003 0.012 0.134 0.020 0.143 0.029 0.155 1.646 1.864 PT-4 3.0 --
40 0.122 0.003 0.013 0.146 0.023 0.156 0.032 0.168 1.393 1.564 PT-4 3.0 --
0.125 0.003 0.013 0.149 0.022 0.159 0.032 0.171 1.328 1.488 No.12/PT-4 0.5 --
39 0.132 0.003 0.015 0.157 0.024 0.168 0.034 0.180 1.194 1.331 No.12/PT-4 0.5 --
0.140 0.003 0.015 0.166 0.024 0.176 0.034 0.189 1.064 1.180 No.12/PT-4 0.5 --
0.147 0.002 0.161 0.165 0.968 1.065 PT-4 3.0 --
38 0.152 0.003 0.016 0.179 0.025 0.190 0.034 0.203 0.9056 0.9974 PT-4 3.0 --
30.06.98 No Copying or Extraction from this Document without L&T’s Permission Page 6 of 30
LTS 3216
SWG Nominal Dia OVERALL DIA (mm) Electrical Spool Net weight of
Of conductor Fine Medium Thick Resistance at type wire in spool
Covering Covering Covering 20°° C per Plastic or (kg.)
metre (ohms) wooden
mm Tol Min Max Min Max Min Max Min. Max. Min. Max.
±)
(± Incre O.D. Increa O.D. Incre O.D.
ase se ase
0.152 0.003 0.016 0.170 -- -- -- -- 0.9056 0.9974 No.12/PT 0.5 --
0.160 0.003 0.016 0.187 0.025 0.199 0.037 0.213 0.8192 0.8983 No.12/PT-4 0.5 --
0.170 0.003 0.017 0.198 0.027 0.211 0.040 0.226 0.7272 0.7940 No.12 0.5 --
37 0.173 0.003 0.017 0.201 0.026 0.214 0.039 0.229 0.7026 0.7662 No.12/PT-4 0.5 --
0.180 0.003 0.017 0.209 0.027 0.222 0.040 0.237 0.6499 0.7068 No.12 0.5 --
0.190 0.003 0.018 0.220 0.028 0.234 0.043 0.248 0.5843 0.6332 No.12 0.5 --
36 0.193 0.003 0.017 0.223 0.027 0.237 0.040 0.253 0.5666 0.6134 No.12/PT-4 0.5 --
0.195 0.003 0.018 0.225 0.028 0.239 0.043 0.255 0.5552 0.6007 No.12 0.5 --
0.200 0.003 0.018 0.230 0.028 0.245 0.043 0.261 0.5282 0.5706 No.12 0.5 --
0.212 0.003 0.019 0.244 0.030 0.258 0.046 0.275 0.4708 0.5069 No.12 0.5 --
35 0.213 0.003 0.018 0.244 0.028 0.260 0.043 0.277 0.4666 0.5022 No.12/PT-4 0.5 --
0.224 0.004 0.019 0.256 0.030 0.272 0.046 0.290 0.4224 0.4534 No.12/PT-4 0.5 --
34 0.234 0.004 0.019 0.267 0.030 0.282 0.046 0.300 0.3875 0.4150 No.12/PT-4 0.5 --
0.236 0.003 0.020 0.269 0.031 0.283 0.048 0.310 0.3810 0.4079 No.12 0.5 --
0.243 0.004 0.020 0.276 0.031 0.293 0.048 0.310 0.3567 0.3876 No.12 0.5 --
0.250 0.004 0.020 0.284 0.031 0.301 0.048 0.320 0.3374 0.3659 No.12/PT-4 0.5 --
33 0.254 0.004 0.020 0.288 0.031 0.305 0.048 0.334 0.3270 0.3526 No.12/PT-4 0.5 --
0.265 0.004 0.021 0.300 0.032 0.317 0.051 0.335 0.3008 0.3251 No.12 0.5 --
0.273 0.004 0.021 0.309 0.032 0.326 0.051 0.344 0.2837 0.3060 No.12 0.5 --
32 0.274 0.004 0.021 0.309 0.032 0.328 0.049 0.347 0.2816 0.3037 No.12/PT-4 3.0 --
31 0.295 0.004 0.021 0.331 0.033 0.350 0.052 0.369 0.2435 0.2615 No.12/PT-4 0.5 --
0.300 0.004 0.022 0.337 0.034 0.355 0.053 0.374 0.2355 0.2527 No.12 0.5 --
30 0.315 0.004 0.022 0.352 0.034 0.371 0.053 0.391 0.2139 0.2289 No.12/PT-4 0.5 --
31.12.98 No Copying or Extraction from this Document without L&T’s Permission Page 7 of 30
LTS 3216
SWG Nominal Dia OVERALL DIA (mm) Electrical Spool type Net weight
Of conductor Fine Medium Thick Resistance at Plastic or of wire in
Covering Covering Covering 20°° C per metre wooden spool (kg.)
(ohms)
mm Tol Min Max Min Max Min Max Min. Max. Min. Ma
±)
(± Incre O.D. Increa O.D. Incre O.D. x.
ase se ase
29 0.345 0.004 0.024 0.385 0.036 0.404 0.056 0.424 0.1784 0.1904 No.12 0.5 --
0.355 0.004 0.024 0.395 0.036 0.414 0.056 0.435 0.1689 0.1797 No.12 0.5 --
0.376 0.004 0.025 0.416 0.038 0.436 0.058 0.459 0.1515 0.1609 No.12 0.5 --
28 0.376 0.005 0.024 0.417 0.037 0.437 0.057 0.458 0.1499 0.1609 No.12/PT-4 0.5 --
0.400 0.005 0.025 0.442 0.038 0.462 0.058 0.483 0.1327 0.1419 No.12 0.5 --
0.412 0.005 0.026 0.455 0.040 0.476 0.060 0.497 0.1252 0.1337 No.12 0.5 --
27 0.417 0.005 0.025 0.459 0.038 0.479 0.058 0.500 0.1222 0.1305 PT-4/K-160 0.5/5.0 14.0
0.450 0.005 0.027 0.495 0.041 0.516 0.062 0.538 0.1051 0.1118 No.12/PT-4 0.5 --
26 0.457 0.005 0.027 0.502 0.041 0.523 0.062 0.545 0.1020 0.1084 PT-4/K-160 0.5/5.0 14.0
0.500 0.005 0.029 0.548 0.044 0.569 0.591 0.650 0.08534 0.09037 No.12 0.5 --
25 0.508 0.005 0.029 0.556 0.044 0.577 0.065 0.599 0.0827 0.0875 PT-4/K-160 1.5/5.6 14.0
24 0.559 0.006 0.030 0.610 0.046 0.631 0.071 0.655 0.0682 0.0724 PT-4/K-160 1.5/5.0 14.0
0.560 0.006 0.030 0.611 0.046 0.632 0.067 0.656 0.06794 0.7215 No.12 0.5 --
0.600 0.006 0.032 0.653 0.049 0.676 0.071 0.699 0.05927 0.06276 No.12/ W8/P8 0.5 --
23 0.610 0.006 0.032 0.664 0.049 0.686 0.071 0.719 0.0574 0.0607 No.12 1.5 14.0
0.630 0.006 0.032 0.684 0.049 0.706 0.071 0.730 0.05381 0.05687 W-8/P-8 5.0 14.0
0.710 0.007 0.034 0.767 0.051 0.791 0.074 0.815 0.04234 0.04481 W-8/K-160/P-8 5.0 14.0
22 0.711 0.007 0.034 0.768 0.051 0.791 0.074 0.816 0.0422 0.0447 W-8/K-160/P-8 5.0 14.0
0.750 0.008 0.035 0.809 0.052 0.832 0.075 0.858 0.03788 0.04022 W-8/P-8 5.0 14.0
0.800 0.008 0.036 0.861 0.054 0.885 0.078 0.911 0.03334 0.03530 W-8/P-8 5.0 14.0
21 0.813 0.008 0.037 0.874 0.055 0.889 0.079 0.924 0.0323 0.0342 W-8/P-8 5.0 14.0
0.850 0.009 0.037 0.913 0.055 0.937 0.079 0.964 0.02950 0.03131 W-8/P-8 5.0 14.0
31.12.98 No Copying or Extraction from this Document without L&T’s Permission Page 8 of 30
LTS 3216
SWG Nominal Dia OVERALL DIA (mm) Electrical Spool Net weight of
Of conductor Fine Medium Thick Resistance at type wire in spool
Covering Covering Covering 20°° C per metre Plastic (kg.)
(ohms) or
wooden
mm Tol Min Max Min Max Min Max Min. Max. Min Max.
±)
(± Incre O.D. Increa O.D. Incre O.D. .
ase se ase
0.900 0.009 0.038 0.965 0.057 0.990 0.081 1.017 0.02634 0.02789 W-8/P-8 5.0 14.0
20 0.914 0.010 0.039 0.979 0.058 1.003 0.082 1.030 0.0256 0.0270 W-8/P-8 5.0 14.0
0.950 0.010 0.039 1.017 0.058 1.041 0.082 1.070 0.02362 0.02506 W-8/P-8 5.0 14.0
0.965 0.010 0.039 1.032 0.059 1.057 0.084 1.084 0.02290 0.02428 W-8/P-8 5.0 14.0
1.000 0.010 0.039 1.068 0.059 1.093 0.084 1.123 0.02134 0.02259 W-8/P-8 5.0 14.0
19 1.016 0.010 0.039 1.084 0.059 1.109 0.084 1.139 0.0207 0.0219 W-8/P-8 5.0 14.0
1.030 0.010 0.040 1.099 0.060 1.124 0.085 1.151 -- -- W-8/P-8 5.0 14.0
1.060 0.011 0.040 1.130 0.060 1.155 0.085 1.184 -- -- W-8/P-8 5.0 14.0
1.120 0.011 0.041 1.192 0.061 1.217 0.087 1.246 -- -- W-8/P-8 5.0 14.0
1.180 0.012 0.042 1.254 0.062 1.279 0.088 1.308 -- -- W-8/P-8 5.0 14.0
18 1.219 0.011 0.042 1.293 0.063 1.319 0.089 1.340 0.0143 0.0152 W-8/P-8 5.0 14.0
1.250 0.013 0.042 1.325 0.063 1.351 0.089 1.381 -- -- W-8/P-8 5.0 14.0
1.320 0.013 0.043 1.397 0.064 1.423 0.091 1.453 -- -- W-8/P-8 5.0 14.0
1.400 0.014 0.044 1.479 0.066 1.506 0.093 1.535 -- -- W-8/P-8 5.0 14.0
17 1.422 0.014 0.044 1.501 0.066 1.528 0.093 1.557 0.0105 0.0112 W-8/P-8 5.0 14.0
1.500 0.015 0.045 1.581 0.067 1.608 0.094 1.638 -- -- W-8/P-8 5.0 14.0
1.600 0.016 0.046 1.683 0.068 1.711 0.096 1.741 -- -- W-8/P-8 5.0 14.0
16 1.626 0.014 0.047 1.710 0.069 1.738 0.097 1.768 0.0081 0.0085 W-8/P-8 5.0 14.0
1.700 1.017 0.047 1.785 0.069 1.813 0.097 1.844 -- -- W-8/P-8 5.0 14.0
1.800 1.018 0.048 1.888 0.071 1.916 0.099 1.947 -- -- W-8/P-8 5.0 14.0
15 1.829 0.018 0.048 1.917 0.071 1.945 0.099 1.976 0.0064 0.0068 W-8/P-8 5.0 14.0
2.000 0.020 0.049 2.092 0.073 2.120 0.101 2.152 -- -- W-8/P-8 5.0 14.0
30.06.98 No Copying or Extraction from this Document without L&T’s Permission Page 9 of 30
LTS 3216
SWG Nominal Dia OVERALL DIA (mm) Electrical Spool Net weight of
Of conductor Fine Medium Thick Resistance at type wire in spool
Covering Covering Covering 20°° C per Plastic or (kg.)
metre (ohms) wooden
mm Tol Min Max Min Max Min Max Min. Max. Min. Max.
±)
(± Incre O.D. Increa O.D. Incre O.D.
ase se ase
14 2.032 0.020 0.049 2.124 0.073 2.152 0.101 2.182 0.0051 0.0054 W-10/P-10 10.0 25.0
2.120 0.021 0.050 2.124 0.074 2.243 0.103 2.275 -- -- W-10/P-10 10.0 25.0
2.240 0.022 0.051 2.336 0.075 2.366 0.104 2.398 -- -- W-10/P-10 10.0 25.0
2.360 0.024 0.051 2.459 0.076 2.488 0.105 2.522 -- -- W-10/P-10 10.0 25.0
2.500 0.025 0.052 2.601 0.077 2.631 0.107 2.665 -- -- W-10/P-10 10.0 25.0
2.650 0.027 0.053 2.754 0.078 2.784 0.108 2.819 -- -- W-10/P-10 10.0 25.0
2.800 0.028 0.054 2.907 0.080 2.938 0.110 2.972 -- -- W-10/P-10 10.0 25.0
3.150 0.032 0.056 3.263 0.082 3.294 0.113 3.330 -- -- W-10/P-10 10.0 25.0
3.245 0.034 0.057 3.359 0.083 3.392 0.115 3.428 -- -- W-10/P-10 10.0 25.0
3.350 0.034 0.057 3.466 0.083 3.498 0.115 3.534 -- -- W-10/P-10 10.0 25.0
3.550 0.036 0.058 3.670 0.085 3.702 0.117 3.738 -- -- W-10/P-10 10.0 25.0
3.660 0.038 0.059 3.701 0.086 3.814 0.118 3.851 -- -- W-10/P-10 10.0 25.0
3.750 0.038 0.059 3.873 0.086 3.905 0.118 3.942 -- -- W-10/P-10 10.0 25.0
4.000 0.040 0.060 4.127 0.087 4.160 0.120 4.196 -- -- W-10/P-10 10.0 25.0
4.250 0.043 0.060 4.380 0.088 4.414 0.122 4.451 -- -- W-10/P-10 10.0 25.0
4.500 0.045 0.061 4.634 0.090 4.668 0.124 4.705 -- -- W-10/P-10 10.0 25.0
4.750 0.048 0.062 4.889 0.091 4.923 0.126 4.961 -- -- W-10/P-10 10.0 25.0
5.000 0.050 0.063 5.142 0.092 5.177 0.128 5.215 -- -- W-10/P-10 10.0 25.0
1.900 0.019 0.049 1.990 0.072 2.018 0.100 2.049 -- -- W-10/P-10 10.0 25.0
3.000 0.030 0.055 3.110 0.081 3.142 0.112 3.176 -- -- W-10/P-10 10.0 25.0
31.12.98 No Copying or Extraction from this Document without L&T’s Permission Page 10 of 30
LTS 3216
APPENDIX - I
BREAKDOWN VOLTAGE TEST
1. SCOPE
To determine the maximum voltage which the enamelled wire can withstand.
2. APPARATUS
i) Test voltage device : Nominal frequency 50 Hz of sine wave form, peak cycle shall be √2±5%
(i.e. 1.34 to 1.48), capacity to supply current of 5mA
iii) Oven
3. PROCEDURE
i) Twist two 400 mm sample lengths of wire together for a length of 125 mm with a device as
shown in the figure given on the next page. Tension in wire pairs while being twisted and
number of twists are in the table given along with.
ii) Cut the loop at the end of the twisted section at two places, to provide maximum spacing
between cut ends. avoid sharp bends and damages to insulation.
v) Repeat the test on fresh samples, if any one of the samples fails to withstand required value.
ii) Apply test voltage 15 minutes after placing the sample in an oven or on
reaching the specified temperature, whichever is later.
i) BDV at room temperature: The BDV shall not be less than the value specified in
the Table-1 of LTS 3216.
ii) BDV at elevated temperature: The BDV shall not be less than 75% of the value
specified at room temperature.
ELONGATION TEST
1 SCOPE
2 APPARATUS
3 PROCEDURE
iii) Stretch at the rate of 5mm/sec(300mm / minute) upto the breaking point
of the conductor material.
Dimensions Grooves
Conductor Winding
dia Diameter
SWG a b c d Depth (c) Width (f)
45-47 3.0 6.0 6.0 30 0.25 0.04 0.15
42-44 5.0 6.0 7.5 32 0.25 0.08 0.30
39-41 7.0 6.0 9.0 34 0.40 0.12 0.50
35-38 10.0 6.0 9.0 34 0.60 0.16 0.70
31-34 12.5 6.0 9.0 40 0.80 0.20 0.80
27-30 19.0 10.0 11.0 45 1.20 0.30 1.20
24-26 25.0 12.5 12.5 45 2.00 0.15 0.75
21-23 37.5 12.5 14.5 47 2.40 0.25 1.25
17-20 50.0 12.5 17.5 50 2.80 0.40 2.00
3. PROCEDURE
a. Attach specified weight to one end of sample wire. Insert the other end through the transverse hole in
the mandrel and hold firmly.
b. Apply tension to wire by means of weight in such a manner that the mandrel is aligned with dial
zero vertically downwards.
c. Hold the free end of wire securely and rotate the mandrel counter clockwise until 5 complete turns
of the wire have been wound.
e. Bend this end in a vertical position in line with zero mark on the dial to act as a pointer.
f. Unlatch the winding head & allow the coil to unwind slowly without jerking.
i. In the case of very springy wire, the pointer may rotate through more than one revolution. It is
necessary to add 72 to the reading for each completed revolution.
APPENDIX -V
2. APPARATUS
3. PROCEDURE
Take 3 samples of at least 200 mm long.
i) The wire shall be wound for 10 turns, touching one another, around a polished metal mandrel of
diameter as given in the table below:
The wires shall be pre-stretched to 20% or breaking, whichever is less, before winding on the mandrel. The pre-
stretching shall be done between grips, placed 200mm to 250mm apart, at the rate of approximately 300
mm/minute.
ii) Immerse the test specimen into a hot, electrically heated, forced air circulating oven having following
temperatures for a period of 30 minutes:
iii) Remove the sample from oven and allow it to be cooled to room temperature.
a) Visual : Enamelled wire shall be examined for cracks, flaking off etc., after the test, under 10-15
magnification.
b) Practical observation (for wire dia < 1.6 mm)
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 17 of 30
LTS 3216
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 18 of 30
LTS 3216
APPENDIX - VI
FLEXIBILITY & ADHERENCE
1. SCOPE
2. APPARATUS
i) Polished mandrel.
ii) Stretch terst apparatus.
iii) Bath with NaCl solution.
iv) 24 V DC supply.
3. PROCEDURE
ii) Wind the wires upto 10 continuous turns around a polished mandrel of following dia.
iii) Rotate the mandrel between 1 & 3 turns per sec. Avoid twisitng on elongation on of wires.
Stretch test
(Applicable to sizes > 1.60mm)
i) Grip the specimen in elongation testing fixtures and stretch steadily at a rate of 300 mm/
minute to the breaking point of the conductor material.
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 19 of 30
LTS 3216
b) Jerk test & peel test:
Jerk test
(Applicable to sizes ≤ 1.00mm)
i) Take sample specimen of 250 mm and hold it in jerk testing machine as shown in the
figure-1 (see next page)
Discard the portion of 2 mm from the broken ends for calculating elongation.
Peel test
i) Take sample length of 600 mm and place it in jerk testing machine as shown in the figure-2
(See next page).
ii) Remove the enamel by means of a scraper shown in the figure-3. (see next page).
iii) The load as given in the Table on the next page shall be sufficient to remove the enamel and leave a
smooth, clean surface without removing any significant quantity of conductor material.
iv) The enamel removal shall be started approximately 10 mm away from fixing device.
i) Enamel flexibility.
The condition of enamel insulation can be examined by any one of the following methods:
Enamel wire shall be examined for cracks, flaking off etc., after the test under 10 - 15
magnification.
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 20 of 30
LTS 3216
APPENDIX - VII
STRETCH TEST
(Applicable for conductor sizes > 1.60 mm)
1. SCOPE
2. APPARATUS
Tensile test equipment
3. PROCEDURE
i) Grip the wire in the tensile test apparatus.
ii) Stretch at the rate of 5 mm/sec. (300 mm/minute) upto the breaking point of the conductor material.
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 23 of 30
LTS 3216
viii) Apply load steadily and increase it until the conductor is exposed and the device stop.
ix) Do not apply a initial force of more than 90% of the minimum force to failure as specified in
Table-2 of LTS 3216.
x) Read the value on the graduated scale when the device stops.
xi) Repeat the test by turning the sample wire axially through approximately 120° and then
through 240°.
i) The product of the value on the graduated scale and the initial load applied shall be recorded as
a force of failure.
c) For observation disregard 0.50mm distance from both ends of the sample.
d) Establishes whether enamelled wire alone (unimpregnated) has satisfactory heat ageing.
This has no significance for compatibility with impregnant. A ratio below 0.8 shows
unsatisfactory wire, which is unsuitable for further impregnation and tests.
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 25 of 30
LTS 3216
APPENDIX - IX
CUT - THROUGH TEST
1. SCOPE
To evaluate the capacity of the enamel to withstand high temperature when underload.
2. APPARATUS
3 PROCEDURE
ii) Insert these in pre-heated compression testing device. The temperatures shall be
iii) These two pieces shall be carefully inserted in the apparatus in such a manner that they cross
each other at right angles. The crossing point shall lie centrally under the piston.
In case of wire dia.less than 0.20mm two wires be placed side by side below the top wire.
iv) Keep the specimen in the apparatus for time specified in the Table-1, prior to loading.
v) Apply load given in the Table-2 gently to the upper wire by means of piston. the load includes weight
of the piston.
vi) Apply a voltage of 100 ± 10V between upper and lower wires.
vii) Circuit shall be so designed that an indication is given when a current of approximately 5 m A flows
between the wires. Excessive current (more than 50m A ) should be avoided.
No cut-through shall occur due to thermoplastically of the enamel at the specified temperature.
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 26 of 30
LTS 3216
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 27 of 30
LTS 3216
APPENDIX - X
2. APPARATUS
3. PROCEDURE
ii) Insert these wires in compression device carefully in such a manner that the wires cross each other at
right angles. The crossing point shall lie centrally under the piston. In case of wire dia. less than 0.20
mm two wires shall be placed side by side below the top wires.
iv) Start heating and increase the temperature at the rate of 15°C/minute.
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 28 of 30
LTS 3216
APPENDIX - XI
COMPATIBILITY TEST
1. SCOPE
To determine the compatibility of enamel for copper wire with impregnation varnish used.
2. APPARATUS
3. PROCEDURE
ii) BDV test, at room temperature shall be carried out as per method specified in Appendix A.
Follow the chart given below for preparation of test specimen for the test :
Temperature T shall be :
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 29 of 30
LTS 3216
Calculate the average reading for each test and find out the following :
IG 0 IG 1 IG 2 NIG 2
R0= R1= R2= & R3 =
NIG 0 NIG 1 NIG 2 NIG 0
The performance compatibility between enameled copper wire and impregnating varnish is estimated from
above ratios by means of following criteria:
31.12.97 No Copying or Extraction from this Document without L&T’s Permission Page 30 of 30