essex fine wire brochure-html.html

Essex

Fine Wire Copper Products

Note:
1. Special builds, additional sizes and colors available upon request.For additional details or specific requests, please contact Essex Magnet Wire

Marketing at

finewire@spsx.com

or by one of the phone numbers listed on the back of this brochure.

2. Products listed are UL recognized with the exception of Formvar.

* MW 102 for Polybondex

Bond E and Bond S products.

105°C

MW 15

IEC 60317-1

Formvar

–

Polyvinyl Acetal

Excellent flexibility, adhesion, and abrasion scrape resistance.

Oil-filled transformers, motors, solenoids.

155°C

MW 136

–

Soderbond

N / 155

–

Polyurethane / Nylon / Butvar

Excellent bond strength at room temperature.

Helical and toroidal coils, solenoid coils, voice coils.

155°C

MW 131

IEC 60317-35

–

Magnebond

UV-155

Polyurethane / Polyvinylbutyral

Very low bonding temperature (low energy), solvo-bonding can be used,

Watch coils, sensors for medical, optics, acoustic measurement

155°C

MW 131

IEC 60317-35

–

Magnebond

UL-155

Polyurethane / Aliphatic Polyamide

Bonding at low temperature and good solderability.

Small motors, electromagnetic coils.

155°C

MW 79

IEC 60317-20

Soderex

/ 155

Magnesol

U-155

Polyurethane

Polyurethane insulation allows soldering without prior removal of

Appliance motors, relays, timers and clock coils, encapsulated coils,

155°C

MW 80

IEC 60317-21

Soderon

/ 155

Magnesol

UN-155

Polyurethane / Polyamide

Same characteristics as Soderex with the advantages of a nylon topcoat.

Appliance motors, relays, timers and clock coils, encapsulated

180°C

–

IEC 60317-37

–

Magnebond

CL-180

THEIC Polyesterimide / Aliphatic Polyamide

High thermal properties, good chemical resistance, low bonding temperature.

Small motors, RFID coils.

180°C

–

IEC 60317-35

–

Magnebond

UL-180

Polyurethane / Aliphatic Polyamide

Bonding at low temperature and good solderability.

Deflection yokes for monitors, small motors, electromagnetic coils.

180°C

MW 30, MW 72

IEC 60317-8

–

Magnetemp

C-180

THEIC Polyesterimide

High thermal properties, good chemical resistance.

Small motors, ignition coils, transformers.

180°C

MW 77

IEC 60317-23

Solidex

Magnesol

E-180

Solderable Polyester(imide)

Soderability is coupled with a need for high thermal resistance.

Automotive controls, relays, ABS coils, ignition coils, solenoids,

180°C

MW 78

–

Solidon

Magnesol

EN-180

Solderable Polyester(imide) / Polyamide

Good solderability at high temperatures. Enhanced by addition of a

Applications submitted to high thermal stresses: automotive

180°C

MW 82

IEC 60317-51

Soderex

/ 180

Magnesol

U-180

Polyurethane

180°C

MW 83

IEC 60317-55

Soderon

/ 180

Magnesol

UN-180

Polyurethane / Polyamide

Designed for applications requiring both high thermal resistance and low

Bobbin wound and paper section coils, molded and encapsulated coils,

180°C

Reference

–

Polybondex

–

Modified Polyester /

Different constructions of bondable wire having a GP/MR-200

MW1000

(with or without Polyamideimide) /

or Thermalex 200

for dimension

Bondcoat

Bondcoat allows the use of resistance, induction, or radiant

data only *

200°C

MW 35, MW 73

IEC 60317-13

GP/MR-200

Magnetemp

CA-200

THEIC Polyester or Polyester(imide) /

Standard of excellence for motor repair with high moisture resistance

Applications submitted to high stresses (thermal, chemical

Polyamideimide

200°C

MW 74

IEC 60317-42

Thermalex 200

–

THEIC Polyester

200°C

–

IEC 60317-38

–

Magnebond

CAB-200

THEIC Polyesterimide /

Polyamide-imide / Aromatic Polyamide

220°C

MW 81

IEC 60317-26

Magnetemp

A-220

Polyamideimide

Provides unsurpassed scrape and abrasion resistance. The combination

Applications submitted to high thermal stress or to radiations especially,

240°C

MW 16

IEC 60317-46

Allex

Magnetemp

Y-240

Polyimide

Exceptional resistance to chemical solvents and burn-out, outstanding

Aerospace, nuclear, medical, fractional and integral horsepower

Thermal NEMA

IEC

Insulation Characteristics

Applications

Class

Designation

North America / Far East

Europe / Far East

Product Name

All Fine Wire Products are exclusively subject to Essex’s product warranties set forth in Essex’s Standard Terms and Conditions of Sale Pertaining to
Magnet/Winding Wire Products and Services which can be located on Essex’s website at www.superioressex.com.

The information provided in this chart is provided for convenience only and is intended to identify products available within the corresponding thermal
classes and NEMA and IEC designations. No representations or comparisons as to the quality, attributes, reliability or performance of the listed products
are intended or expressed.

Excellent flexibility, adhesion, and abrasion scrape resistance.

Oil-filled transformers, motors, solenoids.

Good thermal shock resistance.

Excellent bond strength at room temperature.

Helical and toroidal coils, solenoid coils, voice coils.

Very low bonding temperature (low energy), solvo-bonding can be used,

Watch coils, sensors for medical, optics, acoustic measurement

excellent performance for ultra-fine applications.

equipment, hearing aids.

Bonding at low temperature and good solderability.

Small motors, electromagnetic coils.

Polyurethane insulation allows soldering without prior removal of

Appliance motors, relays, timers and clock coils, encapsulated coils,

the film from the wire. Excellent resistance to moisture and most common

bobbin wound coils, small motors, automotive coils, toroidal coils.

solvents. Excellent solderability and elevated thermal properties.

Same characteristics as Soderex with the advantages of a nylon topcoat.

Appliance motors, relays, timers and clock coils, encapsulated

The nylon topcoat helps provide improvement in the windability and

coils, bobbin wound coils, small motors, toroidal coils,

tolerates more severe winding operations.

transformers, components for automotive.

High thermal properties, good chemical resistance, low bonding temperature.

Small motors, RFID coils.

Bonding at low temperature and good solderability.

Deflection yokes for monitors, small motors, electromagnetic coils.

High thermal properties, good chemical resistance.

Small motors, ignition coils, transformers.

Soderability is coupled with a need for high thermal resistance.

Automotive controls, relays, ABS coils, ignition coils, solenoids,

appliance controls, coils, small motors, small transformers.

Good solderability at high temperatures. Enhanced by addition of a

Applications submitted to high thermal stresses: automotive

polyamide overcoat. Excellent resistance to thermal stress.

components, ignition coils, small motors, solenoids, appliance

controls, small transformers.

Designed for applications requiring both high thermal

Relays, automotive coils, specialty power transformers,

resistance and low soldering temperatures.

appliance controls, automotive controls, solenoids, motors.

Designed for applications requiring both high thermal resistance and low

Bobbin wound and paper section coils, molded and encapsulated coils,

soldering temperatures. The nylon topcoat helps provide improvement

small motors, armatures and fields, toroidal coils, linear motors, relays,

in the windability and tolerates more severe winding operations.

transformers, watch coils, components for automotive, ignition coils.

Different constructions of bondable wire having a GP/MR-200

Armatures, bobbinless coils, brake, clutch and ignition coils,

or Thermalex 200

base insulation with a thermoplastic bondcoat.

motors, relays, sensors, solenoids, stators, transformers.

Bondcoat allows the use of resistance, induction, or radiant

heating to flow the bond.

Standard of excellence for motor repair with high moisture resistance

Applications submitted to high stresses (thermal, chemical

and ease of insertion. Film insulation has physical toughness, excellent

and/or mechanical). Fractional and integral horsepower motors,

dielectric properties, and superior chemical resistance to common

hermetic motors, DC motors, automotive alternators and generators,

solvents and refrigerants.

power tool motors, dry type transformers (Class 105 through 200).

Thermally stable, modified polyester film and has excellent

Small appliance and power tool motors, continuous operation coils,

physical, chemical and electrical properties for small coils

encapsulated coils, sub-fractional instrument and servo-motors,

operating at high temperatures.

DC motors, fractional and integral horsepower motors.

High bonding strength and high resoftening temperature.

Stators and rotors, dry transformers.

Provides unsurpassed scrape and abrasion resistance. The combination

Applications submitted to high thermal stress or to radiations especially,

of high moisture and chemical resistance makes it suited for the most

adapted to nuclear needs. Fractional and integral horsepower motors,

demanding of applications. Excellent resistance to thermal

high temperature continuous duty coils and relays, hermetic and

and chemical stresses.

sealed units, heavy duty hand tool motors, encapsulated coils.

Exceptional resistance to chemical solvents and burn-out, outstanding

Aerospace, nuclear, medical, fractional and integral horsepower

thermoplastic flow and ability to withstand excessive overloads in extreme

motors , high temperature continuous duty coils and relays, hermetic

conditions. Excellent resistance to thermal and chemical stresses.

and sealed units, heavy duty hand tool motors, encapsulated coils.

Used when particulary high termal resistance is required:

special relays, transformers, generators, motors.

Characteristics

Applications

To ensure the best performance with Essex

fine wire, please be sure to

exert special care when handling. We suggest the following guidelines:

URING

NCOMING

HIPMENTS

All incoming shipments should be checked for damage during
transportation. The inspection should occur while the freight carrier is
present at your location. Any damage should be properly noted on the
delivery receipt.

When using a fork lift or hand cart, be careful not to bump the outside
of the packaging as this may damage the magnet wire.

URING

IRE

TORAGE

Avoid double stacking the wire pallets.

Store packages on their original pallets and keep unused spools safely
stored in their original packages until needed. Store the wire package
in a dry, non-corrosive location. Keep the wire protected from dust
and other contaminants.

Spools should be placed back into their original packaging and
maintained in a manner to prevent damage with other items,
including other spools.

Bare Wire Diameter

Standard Enameled Copper wire

Bondable Enameled

Copper Wire

Nom.

Tolerance

Section

Mass

Resistance at 20°C

Grade 1

Grade 2

Grade 3

Min Inc.

Grade 1B

Grade 2B

Dia.

+/-

Nom.

Max

Insulation

Max

Insulation

Max

Insulation

Max

Bonding

Max

Thickness

Dia.

Thickness

Dia.

Thickness

Dia.

Layer

Dia.

(mm)

(mm

)

(g/m)

(Ohm/m) (Ohm/m)

(Ohm/m)

(mm)

0,200

+/-0.003

0,03142

0,27930

0,5237

0,5441

0,5657

0,014

0,226

0,027

0,239

0,039

0,252

0,011

0,243

0,256

0,190

+/-0.003

0,02835

0,25210

0,5794

0,6029

0,6278

0,014

0,216

0,027

0,228

0,039

0,240

0,011

0,233

0,245

0,180

+/-0.003

0,02545

0,22620

0,6444

0,6718

0,7007

0,013

0,204

0,025

0,217

0,036

0,229

0,010

0,220

0,233

0,170

+/-0.003

0,02270

0,20180

0,7211

0,7531

0,7871

0,013

0,194

0,025

0,205

0,036

0,217

0,010

0,210

0,221

0,160

+/-0.003

0,02011

0,17870

0,8122

0,8502

0,8906

0,012

0,182

0,023

0,194

0,033

0,205

0,010

0,197

0,209

0,150

+/-0.003

0,01767

0,15710

0,9219

0,9673

1,015

0,012

0,171

0,023

0,182

0,033

0,193

0,010

0,186

0,197

0,140

+/-0.003

0,01539

0,13690

1,055

1,110

1,170

0,011

0,160

0,021

0,171

0,030

0,181

0,010

0,175

0,186

0,132

+/-0.003

0,01368

0,12170

1,184

1,249

1,319

0,011

0,152

0,021

0,162

0,030

0,171

0,010

0,167

0,177

0,125

+/-0.003

0,01227

0,10910

1,317

1,393

1,475

0,010

0,144

0,019

0,154

0,028

0,163

0,009

0,158

0,168

0,118

+/-0.003

0,01094

0,09720

1,474

1,563

1,660

0,010

0,136

0,019

0,145

0,028

0,154

0,009

0,150

0,159

0,112

+/-0.003

0,00985

0,08760

1,632

1,735

1,848

0,009

0,130

0,017

0,139

0,026

0,147

0,008

0,143

0,152

0,106

+/-0.003

0,00882

0,07850

1,816

1,937

2,069

0,009

0,123

0,017

0,132

0,026

0,140

0,008

0,136

0,145

0,100

+/-0.003

0,00785

0,06980

2,034

2,176

2,333

0,008

0,117

0,016

0,125

0,023

0,132

0,007

0,129

0,137

0,095

+/-0.003

0,00709

0,06300

2,247

2,412

2,594

0,008

0,111

0,016

0,119

0,023

0,126

0,007

0,123

0,131

0,090

+/-0.003

0,00636

0,05660

2,495

2,687

2,900

0,008

0,105

0,015

0,113

0,022

0,120

0,007

0,117

0,125

0,085

+/-0.003

0,00567

0,05040

2,787

3,012

3,265

0,008

0,100

0,015

0,107

0,021

0,114

0,007

0,112

0,119

0,080

+/-0.003

0,00503

0,04470

3,133

3,401

3,703

0,007

0,094

0,014

0,101

0,020

0,108

0,007

0,105

0,112

0,075

+/-0.003

0,00442

0,03930

3,547

3,869

4,235

0,007

0,089

0,014

0,095

0,020

0,102

0,007

0,100

0,106

0,071

+/-0.003

0,00396

0,03520

3,941

4,318

4,747

0,007

0,084

0,012

0,091

0,018

0,098

0,006

0,094

0,101

0,067

+/-0.003

0,00353

0,03130

4,848

4,461

5,236

0,007

0,080

0,012

0,088

0,018

0,095

0,006

0,090

0,098

0,063

0,00312

0,02770

5,045

5,484

5,922

0,006

0,076

0,012

0,083

0,017

0,090

0,005

0,085

0,092

0,060

0,00283

0,02510

5,502

6,046

6,590

0,006

0,072

0,012

0,079

0,016

0,085

0,005

0,081

0,088

0,056

0,00246

0,02190

6,316

6,94

7,565

0,005

0,067

0,011

0,074

0,015

0,081

0,005

0,075

0,082

0,053

0,00221

0,01960

7,051

7,748

8,446

0,005

0,064

0,011

0,070

0,015

0,076

0,005

0,072

0,078

0,050

0,00196

0,01750

7,922

8,706

9,489

0,005

0,060

0,010

0,066

0,014

0,072

0,005

0,068

0,074

0,048

0,00181

0,01610

8,530

9,447

10,36

0,005

0,059

0,010

0,065

0,014

0,069

0,005

0,067

0,073

0,045

0,00159

0,01410

9,705

10,75

11,79

0,004

0,055

0,010

0,061

0,013

0,066

0,004

0,062

0,068

0,043

0,00145

0,01290

10,63

11,77

12,91

0,004

0,052

0,009

0,058

0,012

0,063

0,004

0,059

0,065

0,040

0,00126

0,01120

12,28

13,60

14,92

0,004

0,049

0,008

0,054

0,012

0,058

0,004

0,055

0,060

0,038

0,00113

0,01010

13,61

15,07

16,53

0,004

0,046

0,008

0,051

0,011

0,055

0,004

0,052

0,057

0,036

0,00102

0,00900

15,16

16,79

18,42

0,003

0,044

0,008

0,049

0,011

0,053

0,004

0,050

0,055

0,034

0,00091

0,00810

16,94

18,83

20,71

0,003

0,041

0,008

0,046

0,010

0,050

0,003

0,047

0,052

0,032

0,00080

0,00710

19,13

21,25

23,38

0,003

0,039

0,007

0,043

0,010

0,047

0,003

0,044

0,048

0,030

0,00071

0,00634

21,77

24,18

26,60

0,003

0,037

0,007

0,041

0,009

0,044

0,003

0,042

0,046

0,028

0,00062

0,00549

24,99

27,76

30,54

0,003

0,034

0,006

0,038

0,009

0,042

0,003

0,038

0,042

0,027

0,00057

0,00511

26,87

29,86

32,84

0,003

0,033

0,006

0,036

0,009

0,040

0,002

0,037

0,040

0,025

0,00049

0,00438

31,34

34,82

37,31

0,003

0,031

0,005

0,034

0,008

0,037

0,002

0,034

0,037

0,024

0,00045

0,00404

34,01

37,79

41,57

0,002

0,029

0,005

0,032

0,008

0,035

0,002

0,032

0,035

0,023

0,00042

0,00372

37,03

41,14

45,26

0,002

0,028

0,005

0,031

0,007

0,035

0,002

0,031

0,034

0,022

0,00038

0,00339

40,47

44,97

49,47

0,002

0,027

0,005

0,030

0,008

0,033

0,002

0,030

0,033

0,021

0,00035

0,00309

44,42

49,35

54,29

0,002

0,026

0,005

0,028

0,007

0,031

0,001

0,029

0,031

0,020

0,00031

0,00280

48,97

54,41

59,85

0,002

0,024

0,004

0,027

0,007

0,030

0,001

0,026

0,029

0,019

0,00028

0,00253

54,26

60,29

66,32

0,002

0,023

0,004

0,026

0,007

0,028

0,018

0,00025

0,00227

60,46

67,18

73,89

0,002

0,022

0,004

0,024

0,006

0,026

0,016

0,00020

0,00179

76,52

85,02

93,52

0,002

0,020

0,004

0,022

0,005

0,025

0,014

0,00015

0,00137

99,94

111,04

122,15

0,002

0,018

0,004

0,020

0,005

0,023

IEC Dimensional Characteristics

Note: Data from NEMA Standards Publication MW 1000, NEMA doesn't cover half sizes finer than 30 AWG.
For metric size information, please consult Magnet Wire Marketing.
*Theoretical nominal bare diameter for sizes finer than 45 AWG.

SINGLE BUILD DIMENSIONS

HEAVY BUILD DIMENSIONS

AWG

Bare Wire Diameter

Increase in Diameter

Overall Diameter of

Increase in Diameter

Overall Diameter of

SIZE

Due to Film Coating

Film Coated Wire

Due to Film Coating

Film Coated Wire

Minimum

Nominal

Maximum

Minimum

Maximum

Minimum

Maximum

Inches

0.0099

0.251

0.0100

0.254

0.0101

0.257

0.0007

0.018

0.0112

0.285

0.0013

0.033

0.0121

0.307

30 1/2

0.0094

0.239

0.0095

0.241

0.0096

0.244

0.0006

0.015

0.0106

0.270

0.0013

0.033

0.0114

0.291

0.0088

0.224

0.0089

0.226

0.0090

0.229

0.0006

0.015

0.0100

0.255

0.0012

0.030

0.0108

0.275

31 1/2

0.0083

0.211

0.0084

0.213

0.0085

0.216

0.0006

0.015

0.0095

0.242

0.0012

0.030

0.0103

0.261

0.0079

0.201

0.0080

0.203

0.0081

0.206

0.0006

0.015

0.0090

0.229

0.0011

0.028

0.0097

0.247

32 1/2

0.0074

0.188

0.0075

0.191

0.0076

0.193

0.0005

0.013

0.0086

0.216

0.0011

0.028

0.0093

0.234

0.0070

0.178

0.0071

0.180

0.0072

0.183

0.0005

0.013

0.0081

0.205

0.0010

0.025

0.0087

0.222

33 1/2

0.0066

0.168

0.0067

0.170

0.0068

0.173

0.0005

0.013

0.0077

0.194

0.0010

0.025

0.0083

0.210

0.0062

0.157

0.0063

0.160

0.0064

0.163

0.0005

0.013

0.0072

0.183

0.0009

0.023

0.0078

0.199

34 1/2

0.0058

0.147

0.0059

0.150

0.0060

0.152

0.0004

0.010

0.0068

0.174

0.0009

0.023

0.0074

0.188

0.0055

0.140

0.0056

0.142

0.0057

0.145

0.0004

0.010

0.0065

0.164

0.0009

0.023

0.0070

0.178

35 1/2

0.0052

0.132

0.0053

0.135

0.0054

0.137

0.0004

0.010

0.0061

0.156

0.0008

0.020

0.0067

0.169

0.0049

0.124

0.0050

0.127

0.0051

0.130

0.0004

0.010

0.0058

0.147

0.0008

0.020

0.0063

0.160

36 1/2

0.0046

0.117

0.0047

0.119

0.0048

0.122

0.0004

0.010

0.0055

0.139

0.0007

0.018

0.0060

0.152

0.0044

0.112

0.0045

0.114

0.0046

0.117

0.0004

0.010

0.0052

0.132

0.0007

0.018

0.0057

0.144

37 1/2

0.0041

0.104

0.0042

0.107

0.0043

0.109

0.0003

0.008

0.0049

0.125

0.0007

0.018

0.0054

0.136

0.0039

0.099

0.0040

0.102

0.0041

0.104

0.0003

0.008

0.0047

0.118

0.0007

0.018

0.0051

0.129

38 1/2

0.0036

0.091

0.0037

0.094

0.0038

0.097

0.0003

0.008

0.0044

0.112

0.0006

0.015

0.0048

0.122

0.0034

0.086

0.0035

0.089

0.0036

0.091

0.0003

0.008

0.0042

0.106

0.0006

0.015

0.0045

0.116

39 1/2

0.0032

0.081

0.0033

0.084

0.0034

0.086

0.0003

0.008

0.0039

0.100

0.0006

0.015

0.0043

0.109

0.0030

0.076

0.0031

0.079

0.0032

0.081

0.0003

0.008

0.0037

0.095

0.0005

0.013

0.0041

0.104

40 1/2

0.0029

0.074

0.0030

0.076

0.0031

0.079

0.0003

0.008

0.0035

0.090

0.0005

0.013

0.0039

0.098

0.0027

0.069

0.0028

0.071

0.0029

0.074

0.0003

0.008

0.0033

0.085

0.0005

0.013

0.0037

0.093

41 1/2

0.0025

0.064

0.0026

0.066

0.0027

0.069

0.0002

0.005

0.0032

0.080

0.0005

0.013

0.0035

0.088

0.0024

0.061

0.0025

0.064

0.0026

0.066

0.0002

0.005

0.0030

0.076

0.0005

0.013

0.0033

0.083

42 1/2

0.0023

0.058

0.0024

0.061

0.0025

0.064

0.0002

0.005

0.0028

0.072

0.0005

0.013

0.0031

0.079

0.0021

0.053

0.0022

0.056

0.0023

0.058

0.0002

0.005

0.0027

0.068

0.0004

0.010

0.0029

0.075

43 1/2

0.0020

0.051

0.0021

0.053

0.0022

0.056

0.0002

0.005

0.0025

0.065

0.0004

0.010

0.0028

0.071

0.0019

0.048

0.0020

0.051

0.0021

0.053

0.0002

0.005

0.0024

0.061

0.0004

0.010

0.0026

0.067

44 1/2

0.0018

0.046

0.0019

0.048

0.0020

0.051

0.0002

0.005

0.0023

0.058

0.0004

0.010

0.0025

0.064

45*

0.00169

0.043

0.00176

0.0447

0.00183

0.0465

0.00020

0.0051

0.00220

0.0559

0.0004

0.0010

0.0024

0.0610

46*

0.00151

0.038

0.00157

0.0399

0.00164

0.0417

0.00020

0.0051

0.00200

0.0508

0.0003

0.0076

0.0021

0.0533

47*

0.00135

0.0343

0.00140

0.0356

0.00146

0.0371

0.00010

0.0025

0.00170

0.0432

0.0003

0.0076

0.0019

0.0483

48*

0.00119

0.0302

0.00124

0.0315

0.00129

0.0328

0.00010

0.0025

0.00150

0.0381

0.00020

0.0051

0.00170

0.0432

49*

0.00107

0.0272

0.00111

0.0282

0.00116

0.0295

0.00010

0.0025

0.00130

0.0330

0.00020

0.0051

0.00150

0.0381

50*

0.00095

0.0241

0.00099

0.0251

0.00103

0.0262

0.00010

0.0025

0.00120

0.0305

0.00020

0.0051

0.00140

0.0356

51*

0.00085

0.0216

0.00088

0.0224

0.00092

0.0234

0.00010

0.0025

0.00110

0.0279

0.00020

0.0051

0.00130

0.0330

52*

0.00075

0.0191

0.00078

0.0198

0.00081

0.0206

0.00010

0.0025

0.00100

0.0254

0.00020

0.0051

0.00115

0.0292

53*

0.00067

0.0170

0.00070

0.0178

0.00073

0.0185

0.00005

0.0013

0.00085

0.0216

0.00010

0.0025

0.00103

0.0262

54*

0.00060

0.0152

0.00062

0.0157

0.00065

0.0165

0.00005

0.0013

0.00075

0.0191

0.00010

0.0025

0.00095

0.0241

Essex

Fine Wire Handling Suggestions

URING

IRING

ANDLING

Do not stack spools outside of the original Essex packaging.

When removing spool from its original packaging, be sure that it can
be freely removed without the risk of touching anything, including the
packaging itself.

To protect the wire enamel, do not remove the spool wrapper until
ready to load the spool onto the winding equipment. Use extreme
caution when removing the tape from the wrapper and place
wrappers back in cartons for reuse.

Care should be taken when handling spools near jewelry, metal
objects, or chemicals; contact may damage the wire enamel.

Avoid placing your fingers too far into the packaging handling slots;
contact may damage the wire enamel.

Carry the spools by using the provided hand holes or handles.

URING

ANUFACTURING

ROCESS

Check top flanges for any damage; use very fine grit sand paper to
remove minor nicks on the flanges.

If the spool is to be returned to its original packaging for later
usage, please secure the loose end by tying it to the flange.

Keep the spool as straight as possible when inserting into a
payoff shroud.

Maintain proper tension control during wire payoff.

URING

IRE

ETURNS

If the magnet wire must be returned, please contact your Essex
representative.

NEMA Dimensional Characteristics

Pkg

Size -

Dimensions (inches)

Nom. Pounds

Number of

Package

Code

Package Design

Copper

Aluminum

Per Spool-

Spools/Reels

Containers

(AWG)

Copper

Per Carton

per Pallet

DIN 125/45

35-47

27-30

4.921

2.795

2.559

4.921

45°

0.630

4.5

6" x 3 1/2" Spool Box

28-47

27-30

6.000

0.408

3.500

4.32

3.500

0.630

8.5

6" x 3 1/2" Spool Bulk Pack

28-47

27-30

6.000

0.408

3.500

4.32

3.500

0.630

8.5

6" x 6" Spool Box

28-47

27-30

6.000

0.516

5.968

3.750

0.630

12.0

6" x 6" Spool Bulk Pack

28-47

27-30

6.000

0.516

5.968

3.750

0.630

12.0

DIN 160/45 Spool

40-47

27-30

6.299

3.543

3.346

6.299

45°

0.630

13.5

DIN 200/45 Spool

29-44

27-30

7.874

4.409

4.173

7.874

45°

0.630

23.0

8 1/2" x 9 1/4" Taper Spool

28-39

27-30

8.500

9.250

0.521

9.000

10.0625

5.500

6.500

1.531

40.0

8 1/2" Pail

28-47

8.500

9.250

0.521

9.000

10.0625

5.500

6.500

1.531

40.0

DIN 200 Pail

7.874

4.409

9.173

7.874

45°

0.630

23.0

DIN 250/45*

9.843

5.512

5.236

9.843

45°

0.630

50.0

Taper Flange TF 80 (Pail)

28-37

27-30

10.000

10.875

6.000

6.800

12.634

8.230

45°

1.531

75.0

Taper Flange TF 80 (Box)

28-37

27-30

10.000

10.875

6.000

6.800

12.634

8.230

45°

1.531

75.0

Reel-Pak 250*

15.000

16.000

1.218

12.000

14.375

7.960

9.000

1.531

260.0

C D

D E

Essex has the capabilities to match spool weights to fit your application requirements.

Note: Aluminum nominal pounds per spool information available upon special request.

*Available upon special request, please consult Magnet Wire Marketing for more information.

Essex

Fine Wire Packaging Reference Guide

Straight Flange / Barrel – 1

Pkg

Size -

Dimensions (mm)

Covers (mm)

Ave. Weight

Number of

Package

Code

Package Design

Copper

Aluminum

(kg) per Spool

Spools

(mm)

-Copper

per Pallet

D 80

614

5 <

0,040

0,5

288

D 100

613

0,040 - 0,1

100

1,1

144

D 125

607

0,040 - 0,1

125

100

D 160

608

0,040 - 0,3

160

100

160

128

D 200

609

0,040 - 0,3

200

125

200

160

305

295

D 250

610

0,040 - 0,3

250

160

200

160

305

295

HK 76

615

< 0,030

44,4

0,3

450

HK 100

654

< 0,030

100

0,8

144

HK 125

645

< 0,040

125

HK 160

652

0,040 - 0,150

160

HK 200

636

0,040 - 0,150

200

112

200

106

305

295

HK 250

637

0,040 - 0,150

250

140

250

133

305

350

A 250/4

612

0,101 - 0,5

250

160

100

236

140

400

335

315

500

A 315/5

611

0,151 - 1,0

315

200

100

300

180

500

425

400

630

A 400/6

617

0,151 - 3,0

400

250

100

375

224

630

530

500

800

160

Tapered Flange / Tapered Barrel – 4

Taper Flange / Straight Barrel – 3

Straight Flange / Tapered Barrel – 2

Cylindrical – 5

Biconical – 6

Conical / Taper – 7

Cover

Note: This table is provided as a general guide only; the appropriate winding
tensions may vary depending on a number of factors including product application.
The type of winder, payoff device, and type of coil may vary the tensions to be used.
In general, use the minimum tension that provides a good winding. Some minor
variations in the softness of the wire from one lot to another may also dictate minor
adjustments in winding tension.
1. Using the yield strength of fully annealed wire as a point of reference, tensions

beyond these may cause excessive stretching and high coil resistance.

2. Maximum recommended tensions are based upon 10,000 p.s.i. for copper.
3. Theoretical dimensions for sizes 45 AWG and finer.
Note: Start-up acceleration surge can produce tensions well in excess of

production tensions and need to be taken into consideration.

Inches

Grams

0.0100

358

0.0089

282

0.0080

228

0.0071

180

0.0063

142

0.0056

112

0.0500

0.0045

0.0040

0.0035

0.0031

0.0028

0.0025

0.0022

0.0020

0.00176

0.00157

8.8

0.00140

7.0

0.00124

5.5

0.00111

4.4

0.00099

3.5

0.00088

2.8

0.00078

2.2

0.00070

1.7

0.00062

1.4

Recommended Winding Tensions

North America Headquarters

Fort Wayne, Indiana

Tel: 260 461 4000 • Fax: 260 461 4690

Europe Headquarters

Compiegne, France

Tel: +33 (0)3 44 30 52 00 • Fax: +33 (0)3 44 30 52 96

Asia Pacific Headquarters

Shanghai, P.R.C.

Tel: +8621 5253 1100 • Fax: +8621 6228 8816

WHOLE AWG

NEMA NOM. BARE

Maximum

1,2

SIZE

O.D.

Tension

0,200

268,8

0,190

242,0

0,180

211,9

0,170

190,7

0,160

166,8

0,150

150,2

0,140

131,5

0,132

119,0

0,125

105,0

0,118

95,7

0,112

85,3

0,106

76,6

0,100

66,7

0,095

59,4

0,090

51,0

0,085

45,9

0,080

40,2

0,075

36,9

0,071

33,4

0,067

30,1

0,063

26,5

0,060

23,7

0,056

20,6

0,053

18,7

0,050

16,7

0,048

14,8

0,045

12,8

0,043

11,8

0,040

10,8

0,038

10,7

0,036

10,6

0,034

10,4

0,032

10,1

0,030

9,8

0,028

9,2

0,027

0,025

7,4

0,024

6,8

0,023

6,3

0,022

5,7

0,021

0,020

4,7

0,019

4,2

0,018

3,8

0,016

3,0

0,014

2,3

NOMINAL

IEC

Maximum

DIAMETER

MINIMUM

Tension

(mm)

ELONGATION

(cN)

finewire@spsx.com

www.superioressex.com