Class 200 Polyester Glass Fiber Covered Film-Insulated Square Copper Magnet Wire

Wire Types

Polyester Glass Fiber Covered Silicone Treated Bare Square Copper Magnet Wire

Polyester Glass Fiber Covered Silicone Treated Film-Insulated Square Copper Magnet Wire

Polyester Glass Fiber Covered Bare Square Copper Magnet Wire

Polyester Glass Fiber Covered Film-Insulated Square Copper Magnet Wire

Insulating Material

The fiber covering shall consist of a combination of polyester and glass fibers.

The glass fibers shall be electrical-grade continuous-filament glass yarn.

The polyester fiber shall be a high-grade yarn resulting from the linear polymerization of ethylene glycol and terephthalic acid.

The maximum content by weight of polyester fiber in the yarn shall not exceed 50%. The underlying film insulation shall have at least a class 180 rating and comply with the applicable specification of Polyester Glass Fiber Film-Insulated Square Copper Magnet Wire. The polyester glass fiber covering shall be wrapped firmly, closely, evenly, and continuously around the wire. The polyester glass fiber covering shall be fused and treated with a modified silicone insulating varnish. If a tracer is used, one or more ends of glass yarn in the outer layer shall be black or green, and the dye or pigment used for this purpose shall be sufficiently stable so as to retain its color identity after the silicone treatment and subsequent baking.

Thermal Class

200

Conductor

Square Copper Magnet Wire

Dimensions

Table1 (mm) Heavy and Quad Film-Insulated Square Magnet Wire Increase in Dimensions Due to Film Coating

Square AWGSize	Bare Wire Dimensions			Radii (±25%)Nominal	Heavy		Quadruple
					Minimum Increase	Maximum Overall	Minimum Increase	Maximum Overall
	Minimum	Nominal	Maximum
1	7.275	7.348	7.422	1.00	0.080	7.549	0.127	7.600
2	6.477	6.543	6.609	1.00	0.080	6.736	0.127	6.787
3	5.768	5.827	5.885	1.00	0.080	6.012	0.127	6.063
4	5.138	5.189	5.240	1.00	0.080	5.367	0.127	5.418
5	4.575	4.620	4.666	1.00	0.080	4.793	0.127	4.844
6	4.074	4.115	4.155	0.80	0.080	4.282	0.127	4.333
7	3.630	3.665	3.701	0.80	0.080	3.828	0.127	3.879
8	3.231	3.264	3.297	0.80	0.080	3.424	0.127	3.475
9	2.878	2.906	2.934	0.67	0.080	3.061	0.127	3.112
10	2.563	2.588	2.614	0.67	0.080	2.741	0.127	2.791
11	2.278	2.304	2.329	0.50	0.080	2.456	0.127	2.507
12	2.027	2.052	2.078	0.50	0.080	2.205	0.127	2.256
13	1.803	1.829	1.854	0.40	0.080	1.981	0.127	2.032
14	1.603	1.628	1.654	0.40	0.080	1.781	0.127	1.831

Table2 (mm) Single Polyester Glass Fiber Covered Heavy Film-Insulated Square Copper Magnet Wire (Minimum Increase and Maximum Overall Dimensions Due to Insulation)

AWGSize	Bare Wire Dimensions			Radii (±25%) Nominal	Heavy Film-Coated SinglePolyester Glass Covered
					Minimum Increase	Maximum Overall
	Minimum	Nominal	Maximum
1/0	8.176	8.252	8.329	1.00	0.229	8.661
1	7.275	7.348	7.422	1.00	0.229	7.747
2	6.477	6.543	6.609	1.00	0.203	6.909
3	5.768	5.827	5.885	1.00	0.203	6.198
4	5.138	5.189	5.240	1.00	0.203	5.563
5	4.575	4.620	4.666	1.00	0.203	4.978
6	4.074	4.115	4.155	0.80	0.203	4.445
7	3.630	3.665	3.701	0.80	0.203	3.988
8	3.231	3.264	3.297	0.80	0.203	3.581
9	2.878	2.906	2.934	0.67	0.203	3.226
10	2.563	2.588	2.614	0.67	0.178	2.870
11	2.278	2.304	2.329	0.50	0.178	2.591
12	2.027	2.052	2.078	0.50	0.178	2.337
13	1.803	1.829	1.854	0.40	0.178	2.134
14	1.603	1.628	1.654	0.40	0.178	1.930

 Table3 (mm) Double Polyester Glass Fiber Covered, Bare or Heavy Film-Insulated Square Copper Magnet Wire—Minimum Increase and Maximum Overall Dimensions Due to Insulation

Square AWGSize	Bare Wire Dimensions			Nominal Radii±25% mm	BareDouble Glass Covered		Heavy Film-Insulated Double Glass Covered
					Minimum Increase mm	Maximum Overall mm	Minimum Increase* mm	Maximum Overall mm
	Minimum mm	Nominal mm	Maximum mm
1/0	8.171	8.252	8.334	1.00	0.305	8.738	0.381	8.865
1	7.275	7.348	7.422	1.00	0.305	7.823	0.381	7.950
2	6.477	6.543	6.609	1.00	0.305	7.010	0.381	7.137
3	5.768	5.827	5.885	1.00	0.305	6.299	0.381	6.426
4	5.138	5.189	5.240	1.00	0.305	5.639	0.381	5.766
5	4.575	4.620	4.666	1.00	0.279	5.055	0.356	5.182
6	4.074	4.115	4.155	0.80	0.279	4.547	0.356	4.674
7	3.630	3.665	3.701	0.80	0.254	4.064	0.330	4.191
8	3.231	3.264	3.297	0.80	0.229	3.632	0.305	3.759
9	2.878	2.906	2.934	0.67	0.229	3.277	0.305	3.404
10	2.563	2.588	2.614	0.67	0.203	2.921	0.279	3.048
11	2.278	2.304	2.329	0.50	0.203	2.616	0.279	2.743
12	2.027	2.052	2.078	0.50	0.203	2.362	0.279	2.489
13	1.803	1.829	1.854	0.40	0.203	2.134	0.279	2.261
14	1.603	1.628	1.654	0.40	0.203	1.930	0.279	2.057

General Requirements

Properties	Requirement
DIMENSIONS	Square Wire:Radii in accordance with 0.40-1.00mm (±25%)Thickness and width tolerances in accordance with Table1Dimensions and increase in thickness:Single: in accordance with Table2Double: in accordance with Table3
ADHERENCE AND FLEXIBILITY	Single or Double with underlying film: no cracks visible in the film insulation after 20% elongation. Examine with normal vision and without removing the polyester glass fiber covering. *Double without underlying film: not less than 75 V/mil (2950 V/mm) of minimum thickness of the polyester glass fiber covering on one side. *
ELONGATION	Not less than 32% for a thickness less than 0.049 in. (1.25 mm) and greater or 30% for a thickness less than 0.049 in. (1.25 mm)
SPRINGBACK	Polyester glass fiber covered bare: not greater than 5ºPolyester glass fiber covered Heavy film-insulated: not greater than 5.5º
DIELECTRIC BREAKDOWN	Not less than 90 V/mil (3543 V/mm) of the minimum thickness of the glass fiber covering on one side plus the minimum breakdown given in Table4 for the film-insulated wire, if applicable

Table 4 Dielectric Breakdown, Film-Insulated Rectangular and Square Magnet Wire

Film Insulation	Minimum Breakdown Voltage
	Any Three of Four Values	Fourth Value
Heavy	1500	500
Quad	2500	900