Product Information

Continuously Transposed Cable

© Essex Revision 2014-05

Product Information CTC 2014-05; Page 2 of 13

Inhaltsverzeichnis

1 Introduction ................................................................................................................... 3
2 Quality ........................................................................................................................... 3
3 Technical restrictions .................................................................................................... 3
3.1 Overview ................................................................................................................ 3
3.2 Conductor ............................................................................................................... 4
3.2.1 Materials..................................................................................................................................... 4
3.2.2 Mechanical characteristics of conductor ................................................................................... 4
3.2.3 Sizes ............................................................................................................................................ 5
3.3 Enamelled strand.................................................................................................... 5
3.3.1 Strand Insolation ........................................................................................................................ 5
3.3.2 Thickness of enamel ................................................................................................................... 5
3.3.3 Epoxy bond coat ......................................................................................................................... 5
3.4 Continuously transposed cable .............................................................................. 6
3.4.1 Transposition .............................................................................................................................. 6
3.4.2 Size calculation ........................................................................................................................... 6
3.4.3 Determination of size ................................................................................................................. 7
3.5 Cable Insulation ...................................................................................................... 7
3.5.1 Cellulose insulation .................................................................................................................... 7
3.5.2 Thickness and width of paper .................................................................................................... 8
3.5.3 Minimum number of paper layers ............................................................................................. 8
3.5.4 Tolerance of insulation ............................................................................................................... 9
3.5.5 Arrangement of layers ................................................................................................................ 9
3.5.6 Inter column separator............................................................................................................... 9
3.5.7 Special insulation ........................................................................................................................ 9
3.5.8 Special solutions for low voltage winding ................................................................................10
4 Test certificate ............................................................................................................. 11
5 Packaging ................................................................................................................... 11
5.1 Drum types ........................................................................................................... 11
5.2 Storage and transport condition ........................................................................... 12
6 Ordering specification ................................................................................................. 12
7 Marking ....................................................................................................................... 12
8 Appendix: order specification form .............................................................................. 13
8.1.1 .........................................................................................................................................................13
8.1.2 .........................................................................................................................................................13

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Product Information CTC 2014-05; Page 3 of 13

1 Introduction
Continuously transposed cables are used in power transformers. They offer decisive
advantages in the design of transformers compared to the conventional paper-insulated solid
conductors:
• shorted winding time during the production of power transformers
• increased space factor resulting in decreased size and costs of transformer
• reduced electrical losses
A large selection of various materials for insulation and special covering of continuously
transposed cables is available.
Furthermore, the patented manufacturing process of Essex offers additional specific
advantages:
• precise transposition enabling limited tolerance in measuring
• extreme flexibility through short pitches
• excellent windability and simple handling
• no necessity of paper insulation because of high stability
This Product Information provides general technical information on continuously transposed
cable made of high conductivity enamelled copper or copper silver alloy strip made up of odd
or even number of 5 to 84 individual strips for use in transformer winding.
Please contact us for any special request you may have.

2 Quality
Continuously transposed cables are used in electrical machines at very high cost per unit.
For this reason the quality is strictly controlled during the entire production, e.g.:
• Bare wire drawing continuous monitoring of dimensions
surface condition
geometry
• Enamelling dielectrics
surface condition
• Transposing accuracy of transpositions
insulation between strands
The process-oriented quality system of Essex is based on ISO 9001 and ISO TS 16949

3 Technical restrictions
3.1 Overview
Table 1: Overview technical restrictions

Single Strips
Number of Single Strips 5 - 84
Width of Single Strip [mm] 3,10 - 12.50
Thickness of Single Strip [mm] 1,00 - 3,30
Ratio Width/Thickness of Single Strip ≥ 2.5:1 - ≤ 8.0:1
Cross Section of Single Strip [mm²] 3,5 - 39
Bundle
Width of Bundle (axial) [mm] 7,0 ≤ 26
Height of Bundle (radial) [mm] 3,0 ≤ 79
Interleaving Paper [yes/no] yes

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Ratio Height/Width of Bundle ≥ 1:3 - ≤ 8:1

Transposing Factor 5 - 14
Min. Transposing pitch length [mm] 25
Mechanical Properties
Proof stress (Rp 0.2) - Soft annealed [N/mm²] 80 - 120
Proof stress (Rp 0.2) - Mechanical hardened [N/mm²] 120 - 220
Proof stress (Rp 0.2) - silver alloyed [N/mm²] 220 - 350
Restrictions
Proof Stress
Width of Single Strip [mm] 3,10 - 12.50
170 N/mm² < Rp 0.2 <
220 N/mm² Thickness of Single Strip [mm] 1,00 - 3,30
Cross Section of Single Strip [mm²] 3,5 ≤ 39
Width of Single Strip [mm] 3,10 - 12.50
220 N/mm² < Rp 0.2 <
Thickness of Single Strip [mm] 1,00 - 2,80
280 N/mm²
Max. Cross Section of Single Strip
[mm²] 3,5 ≤ 30
Transposing Factors < 7
Width of Single Strip [mm] 3,10 - 10,00
Thickness of Single Strip [mm] 1,00 - 2,00
Proof Stress (Rp 0.2) [N/mm²] 80 - 200
Other dimensions on request !

3.2 Conductor
3.2.1 Materials
Table 2: Conductor material
Copper
type description norm purity conductivity @ specific resis- remarks
20°C* tance @ 20 °C*
Cu-ETP1 high conductivity EN 1977 Cu min 99,99 % > 58,58 MS/m < 0,01707 µΩ m
copper

Cu-OF1 oxygen free copper EN 1977 Cu min 99,99 % > 58,58 MS/m < 0,01707 µΩ m copper with high conductivity and
resitance against hydrogen
embrittlement
CuAg0,04 silver alloyed copper EN 1977 Ag: 0,03 - 0,05 % > 58,00 MS/m < 0,01724 µΩ m material for high yield points up to
380 Mpa

CuAg0,10 silver alloyed copper EN 1977 Ag: 0,08 - 0,12 % > 58,00 MS/m < 0,01724 µΩ m material for high yield points up to
380 Mpa

Aluminium
type description norm purity conductivity @ remarks
20°C*
EN AW 1370 Aluminium for DIN EN 573-3 Al min 99,70 % > 36,7 MS/m < 0,02725 µΩ m
electrical application

3.2.2 Mechanical characteristics of conductor

The mechanical characteristics of conductor are adjusted to the customer specification at
Rp0,1 or Rp0,2.

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Table 3: Typical proof stress for copper conductor

Yield point
Condition Grade
MPa
Soft annealed Cu ETP 1 of Cu-OF 1 ≤ 120
Hardened Cu ETP 1 of Cu-OF 1 140 - 220
Silver alloyed CuAg > 220

For Aluminium conductor the proof stress is typically ~ 100 MPa and has to be agreed for
each order. In the following brochure all given values are for copper if not especially
mentioned.

3.2.3 Sizes
Table 4: Conductor sizes, tolerances and corner radii acc. IEC 60317-0-2
Conductor size for variation Conductor size for Corner radius
width and thickness thickness
From To incl. from to incl.
- 3,15 mm ± 0,030 mm - 1,00 mm 0,5 x thickness
3,15 mm 6,30 mm ± 0,050 mm 1,00 mm 1,60 mm 0,50 mm ± 25 %
6,30 mm 12,50 mm ± 0,070 mm 1,60 mm 2,24 mm 0,65 mm ± 25 %
2,24 mm 3,55 mm 0,80 mm ± 25 %

3.3 Enamelled strand

3.3.1 Strand Insolation
Magneform ® F-120 Polyvenylacetale (PVA) Conforms to IEC 60317-18 with TI of
120 °C. Compatible with transformer
oil and resistant against hydrolysis

Magnetemp ® CA 200 polyester imide base coat Corresponding IEC 60317-29 with TI
with polyamide imide over of 200 °C. Compatible with
coat transformer oil and resistant against
hydrolysis.

3.3.2 Thickness of enamel

The increase due to enamelling shall be 0,10 mm for grade 1 or 0,14 mm for grade 2
respectively.

3.3.3 Epoxy bond coat

If required, the PVA shall be over coated with bondable epoxy.
Magneform ® FX-120 Polyvenylacetale (PVA) Quick curing < 24 hrs at 120°C
+ Epoxy Bond Coat Expanded shelf life ≥ 12 months
Excellent chemical resistance
Smooth surface
Magnetemp ® FX2-120 Polyvenylacetale (PVA) Curing temperature < 120 °C
+ Epoxy Bond Coat Post curing at operating temperature
Easy stripping in lightly volatile solvents
The appropriate type of epoxy could be selected according to the drying process, handling of
winding leads, etc.

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Enamelling of epoxy can be done by different methods, either concentrically with an increase
of 0,05 mm or as Radial Bond. For Radial Bond the size will increase axially by 0,01 mm and
0,05 mm in radial direction.
Please contact us for any further request you may have.

3.4 Continuously transposed cable

The majority of continuously transposed cables consist of an uneven number of individual
strands due to geometrical advantages in the manufacturing of transformer windings. Even-
numbered continuously transposed cables are produced at Essex as well. Twin- or triple-
continuously transposed cables made by Essex, can reduce winding time in certain
applications, where large section conductors are needed.
Our patented manufacturing equipment allows maximum stack size axially 26 mm and
radially 79 mm prior to paper covering. Because of easy windability the radial dimension
should not exceed 6 times of the axial size
Each CTC is supplied with electrically continuous strands for the entire length of the cable on
the drum.
Prior to shipment the insulation of strips is tested. Electrical failures between each and every
strand are not permitted. All CTC are delivered without shorts.

3.4.1 Transposition
In one turn on the smallest winding diameter all
strands change their position at least once. The
pitch P may be shorter than calculated:
D×π
P=
n
Part of the pitch is the crank length (c) which is the
area of bending.
For geometric reasons the pitch can not be
chosen at random. The transposing factor
considers the width of the individual conductor.
The transposing factor (FT) should not be less Figure 1: Crank length and pitch
than 5:
D ×π
FT =
b×n
The applicable maximum transposition factor in individual cases will be set to ensure
mechanical stability of the CTC during processing.

3.4.2 Size calculation

Nominal axial width is calculated as
BA = 2 * (b + E ) + I + Z
The radial dimension of odd numbered CTC is calculated as
HR =
(n + 1) (a + E ) + Z
2
or for CTC with an even number of strands Figure 2: CTC Section
HR =
(n + 2 ) (a + E ) + Z .
2
Where n Number of strips
a Thickness of bare wire
b Width of bare wire
E Nominal increase due to enamel
I Inter column separator, if specified in order 0.10 mm
Z Nominal paper insulation
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3.4.3 Determination of size

Measurement of size of CTC is done on straight specimen of approximately 40 cm
length with free ends under a pressure of 100 N/cm².

Table 5: Radial tolerances

Transposing factor FT ≥ 7 Transposing factor FT ≥ 5
thickness of strand ≤ 2,00 mm or thickness of strand > 2,00 mm or
yield point Rp0,2 ≤ 170 MPa yield point 170 MPa < Rp0,2 ≤ 220 MPa
No. of strands Tolerance No. of strands Tolerance
≤ 21 - 0,10 / +0,20 mm ≤ 21 - 0,10 / +0,30 mm
≤ 35 - 0,15 / + 0,30 mm ≤ 35 - 0,15 / + 0,50 mm
≤ 55 - 0,20 / + 0,80 mm ≤ 55 - 0,20 / + 1,30 mm
> 55 - 0,50 / + 1,10 mm > 55 - 0,50 / + 1,40 mm

Table 6: Axial tolerances

Size Tolerance
All sizes - 0,10 / + 0,05 mm

In case of transposing factors FT < 5 or yield point Rp0,2 > 220 MPa please contact
ESSEX for technical support.

3.5 Cable Insulation

Table 7: Overview of typical wrapping materials

Wrapping Material Special Feature, application

Kraft 5A2-1H1, general purpose with high purity
Kraft, calendared 5A4-1M2, high density and dielectric strength
Kraft, thermally upgraded 5A2-1M2, high thermal properties
Kraft, thermally upgraded, calendared 5A4-1M1, high density, thermal and dielectric characteristics
Calandered, upgraded, creped Outer layers with very high mechanical strength
Kraft, Epoxy coated Bondable outer layers
Kraft, Epoxy coated, upgraded Bondable outer layers
Aramide Very high thermal resistance, for traction transformers
Aramide, Epoxy coated Bondable outer layers, for traction transformers
Perforated paper CTC with improved cooling of LV windings
Glass fabric tape External protection for cast resin transformers

This brochure describes the most common materials and arrangements used for CTC in
transformers. Further types and combinations are always possible. Please contact us.

3.5.1 Cellulose insulation

For the insulation of CTC designed for use in oil immersed transformers only insulating paper
corresponding to IEC 554-3-5 is used. Available grades of cellulose paper are described
below.

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High density crepe papers are often recommended as outermost layers to improve
mechanical strength of the insulation. Crepe papers are thermally upgraded.

Table 8: Cellulose Papers acc. IEC 554-3-5

Standard Kraft Calandered Upgraded Upgraded
Kraft calendared
5A2-1H1 5A4-1M2 5A2-1M2 5A4-1M1
Colour natural brown natural brown green green
Air permeability µm/Pa*s 0,5 -1,0 0,1 - 0,2 0,1 - 0,2 0,05 - 0,1
Air resistance Guerley 128 – 255 640 – 1279 640 – 1279 1280 – 2560
s
Thickness mm 0,065 to 0,100 0,065 to 0,105 0,065 to 0,105 0,065 to 0,105
Density g/cm³ 0,80+/-0,05 1,00 +/- 0,05 0,80 +/- 0,05 1,00 +/- 0,05
Tensile index MD Nm/g > 93 > 93 > 93 > 93
CD > 34 > 35 > 35 > 35
Elongation MD % >2 >2 >2 >2
CD >4 >4 >4 >4
Ash content % < 0,5 < 0,5 < 0,5 < 0,5
pH 6,0 - 8,0 6,0 - 8,0 6,0 - 8,0 6,0 - 8,0
Conductivity mS/m <4 <4 <4 <4
Capillary rise mm >5 >5 >5 >5
Dielectric in air kV/mm >7 >8 >7 >7
Dielectric in oil kV/mm >40 >60 >50 >60
Nitrogen content % - - 1,1-2,6 1,1-2,6
Degree of polymerisation >1000 >1000 >1100 >1100

Table 9: Crepe Papers, thermally Upgraded High Density, typical properties

Dennison Dennison Cindus Cottrell
22 HCC 32 HCC 42 HCF K 125 TU
Air permeability Guerley s 750 750 >800 n.a.
Thickness mm 0,076 0,076 0,076 0,127
Density g/cm³ 1,02 1,04 1,12 1,05-1,25
Tensile strength MD N/mm >5 >5 >7 >6
Elongation MD % >15 >15 >15 >15
Ash content % <1 <1 <1 0,75
pH 7,50 7,50 6,5-7,5 n.a.
Conductivity mS/m <4 <4 <250 n.a.
Nitrogen content % 1.3-2.5 1.3-2.5 1,3-2,6 1,3-2,6
Dielectric in air kV/mm > 10 >9 >9 > 12
Dielectric in oil kV/mm 74 68 74 n.a.
Degree of polymerisation >1200 >1200 ~1200 n.a.

3.5.2 Thickness and width of paper

The preferred width of paper is between 15 mm and 30 mm, its thickness between 65 µm
and 105 µm. Thicker papers are applied as outer layers.

3.5.3 Minimum number of paper layers

A minimum number of layers will be applied according to Table 8.

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Table 10: Minimum number of paper layers

Nominal increase Z Min. Nominal increase Z Min.
mm layers mm layers
≥ 0,5 3 ≥ 2,1 14
≥ 0,7 4 ≥ 2,2 15
≥ 0,8 5 ≥ 2,4 16
≥ 0,9 6 ≥ 2,5 17
≥ 1,1 7 ≥ 2,7 18
≥ 1,2 8 ≥ 2,8 19
≥ 1,3 9 ≥ 3,0 20
≥ 1,5 10 ≥ 3,1 21
≥ 1,6 11 ≥ 3,3 22
≥ 1,8 13 ≥ 3,4 23
≥ 1,9 13 ≥ 3,6 24

3.5.4 Tolerance of insulation

Table 11: Tolerance of paper insulation
Nominal increase Z Tolerance
mm %
up to 0,50 +0/-10,0
>0,50 up to 1,25 +0/-7,5
>1,25 +0/-5,0

3.5.5 Arrangement of layers

All layers are applied in the same direction. All layers are butt wound. The gap between
butted edges will be maximum 0,5 mm.
Two outermost layers are interlocked wound with staggering of approximately 50 % of the
width of paper.
The position of butt joints of any layer relative to the layer below will be progressively
displaced by approximately 30 % of the paper width.
In case of low insulation build up to four 4 layers the papers should preferably be wrapped
with 10 – 20 % overlap.
Based on dielectric requirement the transposed cable can be equipped with additional
insulation on a defined length of the CTC.

3.5.6 Inter column separator

Due to the movement of strands during transposing an inter column separator can only be
provided on request if its width exceeds 8 mm, i.e.
 n −3
  × (a + E ) ≥ 8
 2 
Press board P.2.1 B according to IEC 60641-3-2 with a thickness of 0, 10 mm is the standard
material, others are subject to agreement.

3.5.7 Special insulation

Different grades of aramide paper are available for insulation of CTC for e.g. use in traction
transformers at higher service temperature.
CTC designed for cast resin transformers are covered with glass fabric tape to ensure good
interconnection with the encapsulation resin used.

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3.5.8 Special solutions for low voltage winding

For low voltage windings Essex developed many patented solutions. These new types of
continuously transposed cable offer significant advantages:
• No bulging of paper insulation, oil pockets are avoided
• Improved heat dissipation allows reduction of oil ducts and results in better space
factor

Cordex
Cordex CTC is wrapped with a oil resistant
polyester monofilament. The cable is delivered
with a protection paper which will be removed
prior to the winding. Different types are available:
• Cordex: monofilament
• Cordex 1: monofilament + 2 paper in radial
direction
• Cordex 2: monofilament + 2 paper in axial
direction
• Cordex 3: monofilament + 2 paper in radial
direction + outer aramide tape for easy
winding

Perforated Insulation
This product gives excellent heat dissipation and
is suitable for Epoxy application. The cable is
wrapped with a perforated tape. Different
materials like Aramide or stabilized PE can be
used.
Perforated CTC is delivered without protection
paper.

Diamond wrap
This covering consists of two opposing wraps of
tape to allow free oil flow through the CTC
strands. A linear protection paper is normally
inserted on the underside of the cable.
Diamond wrapped CTC is delivered without
protection paper.

Please contact us for further technical information.

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Product Information CTC 2014-05; Page 11 of 13

4 Test certificate
A test certificate will be submitted if agreed upon.

5 Packaging
5.1 Drum types
The continuously transposed cable shall be wound on wooden drum according to DIN 46391
with metal inserts for the centre bore. The drum shall comply with the dimensions given in
Table 12.
Suitable protection on the outside layer of the cable shall prevent from moisture and foreign
matter during storage and transport. An overall protection shall be obtained by wooden
battens. Flanges and partitions shall be smooth and not cause any damage to the conductor
during winding operation.
One or multiple length of cable per drum may be ordered. When multiple lengths per drum
are required each length shall be wound into different compartments. When quantities or
design on any partition differ length wise they shall be supplied as per Figure 3. In such case
the width may differ from sizes given in table 10.
The conductor ends shall be arranged that an electrical test between strips can be carried
out without unwinding. It should be noted that the ends of each length of the cable must be
suitably insulated for this test and adequately protected for transport.
The finished conductor shall be lightly and evenly wound without twist on the drum.

d2 d3 d1

b2

b1

Figure 3: Drum dimension Figure 4: Arrangement on drum

Table 12: Standard Drums for delivery of CTC (*)
Flange Core Width Traversing Centre bore Volume (**) Max. gross
d1 d2 b1 b2 d3 65% weight
mm mm mm mm mm dm³ kg, ca.
1000 800 630 530 82 97 575
1000 800 830 730 82 134 800
1000 800 1050 930 82 171 1050
1250 900 630 500 82 192 1200
1250 900 830 700 82 269 1650
1250 900 1050 900 82 346 2150
1400 900 630 500 82 294 1800
1400 900 830 700 82 411 2500
1400 900 1050 900 82 528 3200
1600 1000 630 500 82 398 2300
1600 1000 830 700 82 557 3250
1600 1000 1050 900 82 717 4400

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(*) Other types are subject to agreement.

(**) By experience it may be suggested to calculate the filling from 65 % usable volume of
the geometrical space.

5.2 Storage and transport condition

All reels have to be transported and stored only with horizontal axis. Care should be taken to
ensure that all loads are secured and unable to move during transportation. Forklifts have to
be used carefully not to destroy the flanges of the reel and the protection paper.

The storage temperature should not exceed 50 °C for a longer time, especially when the wire
is coated with Epoxy bond coat. High humidity, condensate water or aggressive agents
should be avoided.
Recommended conditions are between 15 - 25 °C at 60 % humidity and no direct solar
radiation. Under these conditions the shelf life of Epoxy coated CTC is 6 month.

6 Ordering specification
Following details to be furnished in Purchase Order
• Conductor size
• Number of strands
• Nominal insulation increase due to paper covering
• Inter column separator, if applicable
• Smallest winding diameter of transformer coil
• Length per drum and compartment
• Number of drum
• Approximate total weight of cable
• Number and issue of this Product Information
Enclosed order form contains all relevant information. We recommend using it for your
enquiries, requests or orders.

7 Marking
Each drum is to be clearly marked clearly with following information
• Supplier’s name
• Number and size of strands
• Drum number
• Gross weight
• Length of cable

© Essex
8 Appendix: order specification form

Continuously Transposed Cable

Order / Inquiry Specification

............................ Order No ...............................

Customer
Specification Product Information CTC 2009-05
Size of CTC ............................ Winding diameter ............. mm
Length ......... m Number ..... Total length ............. m
Weight ......... kg per length Total weight ............. kg
Reel type ............................ Number of reels .............
Number of CTC per reel ......
Cu ETP CuAg 0,1
Conductor Aluminium
Proof stress Soft annealed min. .......... MPa
Rp 0,2 Rp 0,1
Increase Grade 1 Grade 2
Enamel
Magneform ® F-120 IEC 60317-18
Magnetemp ® CA-200 IEC 60317-29
Epoxy resin Magnebond ® FX-120 FX2-120
Magnebond ® FX-120 RB FX2-120 RB
Insulation Increase ............. mm
No. of inner layers, min. No. of outer layers, min.
Kraft, standard 5A2 1H1 ............ ............
Kraft, calendared 5A4 1M2 ............ ............
Upgraded, standard 5A2-1M2 ............ ............
Upgraded, calendared 5A4-1M1 ............ ............
Cindus or Dennison ............ ............
Glass fabric tape ............ ............
Nomex 410 ............ ............
Epoxy coated paper ............ ............
Inner layers butt to butt, ca. 35 % staggering;
Arrangement of paper
2 outer layers 50 % interlocked
4 papers, 10 – 20 % overlap
Other …………………………………..
No Yes
Inter column separator
Press board P 2.1B Other ....................
Thickness ............ mm
radial mm ......................... min. ........................... max.
Overall dimension
axial mm ......................... min. ........................... max.
Other requirements …………………………………………………………
…………………………………………………………
…………………………………………………………
Approved by Date/Signature
© Essex 2014-05