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qxp:Datasheet Ideas 9/24/08 6:23 AM Page 1

Essex® ULTRASHIELD® PLUS


Magnet Wire / Winding Wire

NEMA MW 35-C or MW 73-C


Class 200 Copper - Round Conductors - Polyester/Polyamideimide coated magnet wire / winding wire.
APPLICATION ENGINEERING HIGHLIGHTS
ULTRASHIELD® PLUS magnet wire, which is specifically designed for 1. THERMAL CLASSIFICATION
use in motors that may be subjected to higher voltage spikes ULTRASHIELD® PLUS magnet wire on copper conductor is UL listed at
present in inverter duty applications, has been enhanced for easy Class 200, and is recommended for NEMA MW 35-C and
identification and differentiation. The enhanced product has exhibit- MW 73-C wire applications with higher burnout requirements.
ed increased resistance to partial discharges and improved abrasion 2. THERMOPLASTIC FLOW
resistance to repeated scrape. The combination of the modified ULTRASHIELD® PLUS magnet wire has excellent thermoplastic flow
polyester basecoat and polyamideimide topcoat provides an (cut-thru) properties, with typical test values of 390°C.
insulation system with outstanding toughness and excellent
dielectric properties. ULTRASHIELD® PLUS magnet wire has 3. WINDABILITY
improved voltage endurance and thermal properties, compared to ULTRASHIELD® PLUS magnet wire has been extensively wound in
standard NEMA MW 35-C magnet wire, while retaining superior various motor applications and has been highly commended for its
chemical resistance to common solvents and refrigerants. superior windability performance.
ULTRASHIELD®PLUS conforms to all of the requirements of 4. ELECTRICAL
NEMA MW 35-C and MW 73-C. The electrical properties for ULTRASHIELD® PLUS have been
ULTRASHIELD® PLUS is recommended but not limited to the measurably improved. Voltage endurance for the enhanced
following applications : ULTRASHIELD® PLUS magnet wire at 3000V and room
temperature increased by 20% and at 1000V and 200C increased by
• Inverter Duty Drive Motors 30%. Testing with sinusoidal and with inverter waveshapes
• Rotating Machines shows that ULTRASHIELD® PLUS magnet wire lasts many times
• Hermetic Motors longer than standard NEMA MW 35-C and MW 73-C insulation
• DC Motors (see graph at lower left). While no standards for this type of testing
have been universally accepted, our testing shows dramatic improve-
• Power Tools
ment in insulation life, especially under severe duty applications at
• Automotive Alternators and Generators
higher temperatures.
• Transformers, All Dry Types through Class 200
• Electronics, All Types of Coils through Class 200 5. CHEMICAL
ULTRASHIELD® PLUS magnet wire has been tested for resistance
to R-22 refrigerant and the results show it to be compatible for
hermetic systems.
Wire Life on 575 V Inverter Test Set ***
Successful results are also seen with samples tested for 24
1000 hours at room temperature in a wide variety of other solvents
such as petroleum naphtha, toluene, ethanol, 5% sulfuric acid,
1% potassium hydroxide, butyl acetate, and acetone.
100
Average Life, Hours

6. TERMINATION
Insulation piercing, mechanical stripping, and flame welding
processes can all be used successfully with ULTRASHIELD® PLUS
10
magnet wire. If the connection is to be soldered, it is recommended
that mechanical stripping be used to remove the insulation prior
to soldering.
1
7. NORMAL AVAILABILITY
• Round Copper Sizes:
0.1 9 - 30 AWG, Heavy Build
Heavy Triple Quad Heavy
ULTRASHIELD ® PLUS
Please consult Magnet Wire Marketing for additional size
GP/MR-200 ®
(including metric) and build information.
58875_UltrashldPlus.qxp:Datasheet Ideas 9/24/08 6:23 AM Page 2

Essex® ULTRASHIELD® PLUS


Magnet Wire / Winding Wire

Performance data is representative of 18 AWG heavy build copper. **


THERMAL PROPER TIES PHYSICAL PROPER TIES (cont’d)

HEAT SHOCK RESISTANCE ADHESION AND FLEXIBILITY


TYPICAL PERFORMANCE: No topcoat or basecoat cracks TYPICAL PERFORMANCE: No topcoat or basecoat cracks
REQUIRED PERFORMANCE: 20%, 3XD, no cracks† REQUIRED PERFORMANCE: 20%, 3XD, no cracks†
THERMAL AGING COEFFICIENT OF FRICTION
TYPICAL PERFORMANCE: 215°C TYPICAL PERFORMANCE: Dry Lube: 0.02 - 0.06*
REQUIRED PERFORMANCE: 200°C, minimum†
ELONGATION
THERMOPLASTIC FLOW TYPICAL PERFORMANCE: 38%
TYPICAL PERFORMANCE: 390°C REQUIRED PERFORMANCE: 32%, minimum†
REQUIRED PERFORMANCE: 300°C, minimum†
SPRINGBACK
TYPICAL PERFORMANCE: 48 degrees
18 AWG Heavy Build ULTRASHIELD PLUS Thermal Aging ®
REQUIRED PERFORMANCE: 58 degrees, maximum†
100,000 1
9
8
7
6
5
ELECTRICAL PROPER TIES
4

3
CONTINUITY
20,000 2
TYPICAL PERFORMANCE: ≤ 1 fault/100 ft.
10,000 1
REQUIRED PERFORMANCE: 5 faults/100 ft., maximum†
9
8
7
6
5
DIELECTRIC BREAKDOWN VOLTAGE
4
ROOM TEMPERATURE
Average Life, Hours

2
TYPICAL PERFORMANCE: 12,900 volts, avg.
REQUIRED PERFORMANCE: 5,700 volts, minimum†
1,000 1
9
8
7
RATED TEMPERATURE
6
5

4
TYPICAL PERFORMANCE: 10,982 volts, avg.
3
REQUIRED PERFORMANCE: 4,275 volts, minimum†
2

CU CHEMICAL PROPER TIES


100 1
9
8
7
6
5
REFRIGERANT RESISTANCE (R-22)
4 EXTRACTION
3
TYPICAL PERFORMANCE: 0.02%
2
REQUIRED PERFORMANCE: 0.25%, maximum†
1

180 200 220 240 260 280 300 320 DIELECTRIC BREAKDOWN VOLTAGE
Temperature °C (1/°k) TYPICAL PERFORMANCE: 11,686 volts
REQUIRED PERFORMANCE: 5,700 volts, minimum†
PHYSICAL PROPER TIES SOLUBILITY
TYPICAL PERFORMANCE: Passes
ABRASION RESISTANCE: REPEATED SCRAPE REQUIRED PERFORMANCE: 580 g. scrape, minimum†
TYPICAL PERFORMANCE: 496 strokes, avg.*
* Tests not indicated as NEMA are Essex® Standards.
ABRASION RESISTANCE: UNIDIRECTIONAL ** The values shown represent typical average results and are not intended to be
TYPICAL PERFORMANCE: 2100 g., avg. used as design data or specification limits.
REQUIRED PERFORMANCE: 980 g., minimum; 1150 g., *** Data obtained from standard 18 AWG twisted pairs tested at 150°C, with a 575
minimum avg.† volt drive and motor (phase-to-phase).
† Requirements of NEMA MW 1000; Section MW 35-C or MW 73-C, as applicable.

Essex Group, Inc. All sales are subject to Essex® Standard Terms and Conditions as posted on
1601 Wall Street www.superioressex.com. Copies are available upon request.
Fort Wayne, IN 46802
260.461.4000
® © Essex Group, Inc. 2008

ESSEX GROUP® www.superioressex.com


Essex® ULTRASHIELD® PLUS
Magnet Wire / Winding Wire

NEMA MW 36-C
Class 200 Copper - Rectangular Conductors - Polyester/Polyamideimide Coated Magnet Wire / Winding Wire.

APPLICATION 3. ELECTRICAL
The electrical properties of ULTRASHIELD® PLUS are
ULTRASHIELD® PLUS rectangular magnet wire is
one of the superior attributes of this product. Overall
designed specifically for use in motors & generators
product quality was key in the development of this
that may be subjected to higher voltage spikes product. Due to the design of the insulation system and
present in inverter applications. ULTRASHIELD® PLUS manufacturing process, AC dielectric breakdown
rectangular magnet wire provides significant values consistently average 6,000V. Inverter life testing
resistance to abrasion while maintaining flexibility. The of the rectangular ULTRASHIELD® PLUS insulation
combination of a modified polyester basecoat and system shows a 24X increase in life over the standard
polyamideimide topcoat provides an insulation system MW 36-C insulation system when tested at 200°C on a
with outstanding toughness and excellent dielectric 575V inverter.s While no standards for this type of
properties. ULTRASHIELD® PLUS conforms to all of the testing have been universally accepted, our testing
requirements of NEMA MW 36-C. shows dramatic improvement in insulation life,
especially under severe duty applications at higher
ULTRASHIELD® PLUS magnet wire is recommended but temperatures.
not limited to the following applications:
• Motors and Generators for Hybrid and 4. CHEMICAL
Electric Vehicles ULTRASHIELD® PLUS magnet wire has been tested for
• Wind Generators resistance to R-22 refrigerant and the results show it to
• Inverter Duty Drive Motors be compatible for hermetic systems. Successful results
• Low, Medium & High Voltage Rotating Machines are also seen with samples tested for 24 hours at room
• Hermetic Motors temperature in a wide variety of other solvents such as
• Large Industrial Motors in Corona Applications petroleum naphtha, toluene, ethanol, 5% sulfuric acid,
1% potassium hydroxide, butyl acetate, and acetone.
ENGINEERING HIGHLIGHT S
5. TERMINATION
1. THERMAL CLASSIFICATION
Mechanical stripping and flame welding processes
ULTRASHIELD® PLUS magnet wire on copper conductor can be used for removing the insulation prior to
is UL listed at Class 200, and is recommended for termination.
NEMA MW 36-C wire applications with higher burnout
6. NORMAL AVAILABILITY
requirements.
• Rectangular Copper Size Ranges:
2. THERMOPLASTIC FLOW 0.081-0.257 Thickness (inches)
ULTRASHIELD® PLUS magnet wire has excellent 0.091-0.300 Width (inches)
thermoplastic flow (cut-thru) properties, with typical Please consult Magnet Wire Marketing for additional
test values of 405°C. sizes (including metric) and product availability.
Essex® ULTRASHIELD® PLUS
Magnet Wire / Winding Wire

Performance data below is representative Performance data below is representative of 18 AWG


of 0.102" x 0.204" heavy build copper.t heavy build copper using rectangular enamels.u
THERMAL PROPER TIES THERMAL PROPER TIES
HEAT SHOCK RESISTANCE HEAT SHOCK RESISTANCE
TYPICAL PERFORMANCE: No cracks TYPICAL PERFORMANCE: No cracks
REQUIRED PERFORMANCE: 220°C 30 min, 15%, no cracks† REQUIRED PERFORMANCE: 20%, 3XD, no cracks‡
THERMOPLASTIC FLOW THERMAL AGING
TYPICAL PERFORMANCE: 405°C TYPICAL PERFORMANCE: 215°C
REQUIRED PERFORMANCE: 200°C, minimum‡
PHYSICAL PROPER TIES THERMOPLASTIC FLOW
ADHERENCE AND FLEXIBILITY TYPICAL PERFORMANCE: 381°C
TYPICAL PERFORMANCE: No topcoat or basecoat cracks REQUIRED PERFORMANCE: 300°C, minimum‡
REQUIRED PERFORMANCE: 30%, no cracks†
ELECTRICAL PROPER TIES PHYSICAL PROPER TIES
DIELECTRIC BREAKDOWN VOLTAGE – NEMA ABRASION RESISTANCE: REPEATED SCRAPE
TYPICAL PERFORMANCE: 6,000V TYPICAL PERFORMANCE: 300 strokes, avg.*
REQUIRED PERFORMANCE: 10%, Flat & Edge Bend Foil Method: ABRASION RESISTANCE: UNIDIRECTIONAL
1500V, minimum, Any 3 of 4 values; 500V, minimum, 4th Value† TYPICAL PERFORMANCE: 2,100 g., avg.
DIELECTRIC BREAKDOWN VOLTAGE – SHOTBOX REQUIRED PERFORMANCE: 980 g., minimum; 1,150 g., minimum avg.‡
TYPICAL PERFORMANCE: 6,000V*; 10%, Flat & Edge Bend ADHESION AND FLEXIBILITY
TYPICAL PERFORMANCE: No cracks
®
18 AWG Heavy Build ULTRASHIELD PLUS Thermal Aging REQUIRED PERFORMANCE: 20%, 3XD, no cracks‡
100,000
ELECTRICAL PROPER TIES
1
9
8
7
6
5

4
DIELECTRIC BREAKDOWN VOLTAGE
3 ROOM TEMPERATURE
20,000 2 TYPICAL PERFORMANCE: 12,900 volts, avg.
REQUIRED PERFORMANCE: 5,700 volts, minimum‡
10,000 1
9
8
RATED TEMPERATURE
7
6
TYPICAL PERFORMANCE: 10,982 volts, avg.
5

4
REQUIRED PERFORMANCE: 4,275 volts, minimum‡
Average Life, Hours

2 CHEMICAL PROPER TIES


1,000 1
REFRIGERANT RESISTANCE (R-22)
9
8
7
EXTRACTION
6
5
TYPICAL PERFORMANCE: 0.02%
4
REQUIRED PERFORMANCE: 0.25%, maximum‡
3
DIELECTRIC BREAKDOWN VOLTAGE
2
TYPICAL PERFORMANCE:11,686 volts
CU REQUIRED PERFORMANCE: 5,700 volts, minimum‡
100 1
9
8
7
6
SOLUBILITY
5

4
TYPICAL PERFORMANCE: Passes
3 REQUIRED PERFORMANCE: 580 g. scrape, minimum‡
2

s
Data obtained from standard 18 AWG twisted pairs tested at 200°C, with a 575 volt drive and motor
1
(phase-to-phase).
180 200 220 240 260 280 300 320 u
Data from 18 AWG ULTRASHIELD® PLUS is included in this document to provide material characteristics &
Temperature C (1/k) properties related to the enamel insulation system for tests that are not typically performed or cannot be
performed on rectangular magnet wire.
Thermal classifications for rectangular and square magnet wires are based on * Tests not indicated as NEMA are Essex® Standards.
t
The values shown represent typical average results and are not intended to be used as design data or
the thermal endurance results of round wire sizes 10-18 AWG. The preferred specification limits.
round wire size for evaluation is 18 AWG round heavy build insulation. † Requirements of NEMA MW 1000; Section MW 36-C, as applicable.
‡ Requirements of NEMA MW 1000; Section MW 35-C, as applicable.
Essex Group, Inc. All Sales are subject to Essex Standard Terms and Conditions as posted
1601 Wall Street on www.superioressex.com.
Fort Wayne, IN 46802
260.461.4000
© 2012 Essex Group, Inc.

ESSEX GROUP® www.superioressex.com