Magnet wire is a copper wire coated with high-quality enamel. It appears quite straightforward, right?
If you want to learn more, please visit our website Hengfeng.
Yet, a minor variation in the quality and quantity of the conductor or insulation can make it unfit for a specific application. Be it a high-performing electric vehicle motor or an energy-efficient BLDC fan motor.
Let us see what happens when proper insulation is not there in the magnet wire. Defects like small cracks in the enamel insulation can lead to problems such as electrical breakdown, overheating, and mechanical failure of the motor. Or in other words, your customer finds the product (motor) less reliable, affecting the brand perception.
So, to win customer satisfaction with better efficiency and longer life of the motor, the winding wire has to meet the required enamel specifications. Quality-focused magnet wire manufacturers follow a series of quality checks to affirm the same. Tan Delta test is one such test that ensures the quality of enamel insulation in magnet wire.
What is Tan Delta?
Tan delta indicates the degree of curing of the magnet wire. Every enamel has a recommended tan delta which is best suited for wire properties.
During the curing process, the enamel insulation is heated to a high temperature to crosslink the polymer molecules and form a continuous, protective layer around the wire. If the enamel is not fully cured, it may have defects such as voids, cracks, or contamination. These can affect the electrical insulation properties of magnet wire, viz:
Tan Delta testing is an accurate way to identify such defects in the insulation in magnet wires.
Quality Testing for Magnet Wires ' Tan Delta Testing
Tan delta testing, also known as dielectric loss tangent testing or dissipation factor testing, is a method used to measure the electrical insulation properties of winding wires.
It involves applying a high-frequency alternating voltage to the winding wire and measuring the resulting current. The ratio between the alternating voltage and current is known as the 'tan delta' value. It indicates the amount of energy lost due to resistance and capacitance within the wire.
This value can be used to determine the condition of the wire. Specifically, to identify any defects or damage that may be present in the insulation.
A low tan delta or dissipation factor indicates that the insulation of the winding wire is good. In other words, it has a low level of electrical resistance. On the other hand, high values indicate that the insulation is not performing well, due to improper curing.
Right Way to Measure Tan Delta in Winding Wire
Tan delta can be measured using 2 types of techniques
The latter is the correct way, as it indicates any trapped solvents or cross-linking which hasn't taken place during manufacturing. In the former, since the sample is pre-heated to a higher temperature, there is a tendency to hide these defects.
Likewise, the R&R (Repeatability and Reproducibility) of the Tan delta is also of utmost importance. Above all, for accurate results, the usage of quality measuring instruments is a must.
Tan Delta Testing at Geekay to ensure high-quality insulation
At GEEKAY we use the Tan Delta with Graphite method and we have Tan Delta testing equipment from one of the best manufacturers in the world known for quality instruments. We also do a few more quality tests for concentricity, inline diameter and pinhole to ensure the consistency of enamel coating throughout. We are proud to say that we source our enamel from reliable sources ' Elantas, Fupao and Huber.
By ensuring quality controls at every step of the manufacturing process, we can provide high-quality magnet wires of exact electric specifications customised for your products.
Get in touch with us with your requirements for some samples.
This article was originally published on the GEEKAY blog as Tan Delta- Importance, Significance and Relevance for Magnet Wires
Profile
WGSL-
5
Tan delta tester
is used to measure dissipation factor (PF) in heavy interference site such as power plants or power substations. It can also be used in laboratory for high accurate test. The set is whole in one designed: including precision digital bridge, power unit, reference capacitor (CN), step-up transformer and other electronic circuits. It's also using frequency shift technology, FFT (Fast Fourier Transform algorithm) and digital filtering. It adopts frequency conversion anti-interference and Fourier transform digital filtering technology, fully automatic and intelligent measurement, and the measurement data is very stable under strong interference.When started, it's running automatically and then outputs results on LCD display and prints results automatically.
M
easurement modes:
UST
(Ungrounded
specimen
test)
,
GST
(Grounded
specimen
test)
,
GS
T
-g
(Grounded
specimen
test
with
guard
)
,CVT self-excitation.
Advantage
1.Variable frequency anti-interference
Frequency conversion anti-interference technology can still accurately measure under 200% interference, and the test data is stable, which is suitable for the field anti-interference dielectric loss test.
2.High precision measurement
-Using frequency floating, digital waveform analysis and Bridge self calibration
technology, combined with high-precision three terminal standard capacitor,
high-precision dielectric loss measurement is realized, and the accuracy and stability of
forward / reverse wiring measurement are consistent.
-Input resistance of all ranges <2Ω, which eliminates the influence of additional
capacitance of test cables.
-Oil Dielectric loss test if external connecting oil cup and solid material measuring electrode.
3.Good compatibility
-Automatic identification of 50 Hz / 60 Hz system power supply, support generator power supply, even if the frequency fluctuation is large, it can also be measured normally.
-Built-in series and parallel dielectric loss measurement modes, it can be fully compatible with the calibration bench and dielectric loss standard, which is convenient for instrument verification.
4.Multi-level safety protection to ensure personal and equipment safety
-High voltage protection: short circuit, breakdown or high voltage current fluctuation of the test object can cut off the output at high speed in short circuit mode.
-Low voltage protection: wrong connection of 380V, power fluctuation or sudden power failure, starting protection, will not cause overvoltage.
-Grounding protection: when the instrument is not well grounded and the shell has dangerous voltage, the grounding protection is started.
-CVT: high voltage voltage and current, low voltage voltage and current four protection limits, will not damage the equipment; wrong selection menu will not output excitation voltage. There is no 10kV High voltage output during CVT measurement.
-Anti misoperation: two-stage power switch; real-time monitoring of voltage and current; multiple key confirmation; clear high / low voltage of wiring terminal; slow speed boost, rapid voltage reduction, sound and light alarm.
-Anti "capacitance rise": when measuring large capacity test object, the voltage rise effect will appear. The instrument can automatically track the output voltage and keep the test voltage constant.
-Prevent vibration: the instrument adopts unique anti-shock design, which can withstand strong long-distance transportation vibration and bumps without damage.
-High voltage cable: high voltage resistant insulated conductor, HV cable can be used for touching the ground.
5.Technical breakthrough and powerful function
(1) External standard capacitor interface, it can automatically track the frequency of external test power supply from 40Hz to 70Hz, and support power frequency power supply and series resonant power supply for large capacity and high voltage dielectric loss test.
(2) It has discharge prompt function for poor contact circuit, so as to judge whether the wiring is reliable or not.
(3) CVT self excitation measurement function, C1 / C2 can be connected at the same time, automatic compensation of bus grounding and the impact of standard capacitor partial voltage, no need to change lines and external connection of any accessories, and high-voltage connection line can be dragged to the ground.
(4) It has the function of reverse wiring and low-voltage shielding (GST-g). Under the condition of 220kV CVT bus grounding, C
11
dielectric loss can be measured without disconnecting 10kV reverse connection, and the primary and secondary capacitance can be measured at the same time by primary wiring.
(5) Menu operation, large screen backlight LCD display.
(6) Built-in thermal printer, printing data is clear and fast, no noise.
(7) Calendar clock, it can store 100 groups of measurement data.
(8) RS232 interface (optional).
Panel
1)High voltage output
2)C
x
: I
nput of test object
3)C
n
: Input of
standard capacitance
4)CVT1 terminal
5)CVT2 terminal
6)Power input
7)Power switch
8)Menu button
9)Printer
10)LCD Display
11)RS232 interface
12)Grounding
Technical parameter
1
Accuracy
Cx
±(reading×1%+1pF)
PF
±(reading×1%+0.)
2
Anti-
Interference
Variable frequency anti-interference, it can still achieve the above accuracy under 200%
Interference
3
Capacitance Range:
Internal HV
:
3pF~pF /
1
2
kV,
60pF~1µF
/
0.5kV
External HV
:
3pF~
1.
5
µF
/
10kV
60pF~
30
µF
/
0.5kV
Resolution
0.001pF, 4 digit
s
4
tgδ Range
No limit, Resolution 0.001%, C/L/R
automatic recognition
5
Test mode
UST, GST,
GST-g
,
CVT self-excitation
6
Input current range
10μA~
5
A
7
Internal HV
Voltage range:
0.5~1
2
kV
Current:
200mA (max)
Voltage up/down
: continuous smooth adjustment
Voltage accuracy: ± (1.5% × reading + 10V)
Voltage resolution: 1V
8
Test frequency
45~65Hz
integer
Frequency
;
45/55Hz,
49
/
51
Hz
automatic dual variable frequency
Frequency accuracy: ±0.01Hz
9
External HV
UST
:
max test current
:1
A
(
40-70Hz
If you are looking for more details, kindly visit capacitance and tan delta tester supplier.
);
GST
:
max
test current1
0
kV/
1
A
(
40-70Hz
).
10
CVT self-excitation
O
utput voltage
:
3 ~ 50V
, o
utput current
:
3 ~ 30A
11
HV Accuracy
±(
1.5% x
reading×1%+10V
),
Resol
ution:
1V
12
Test Time
Approx
4
0S
,
It is related to measurement m
ode
13
PC connection
RS232 (for optional)
14
Printer
Built-in thermal printer
1
5
Power Supply
180V~270V 50Hz/60Hz
, mains or generator power supply
1
6
Operating Temperat
ure
-1
0ºC~
50
ºC
1
7
Humidity
<90%
, no condensation
1
8
Dimesion
42
0×
3
6
0×
32
0
m
m
1
9
Net Weight
2
6
kgs
Measurement & display
Type of specimen
Display result
Note
Capacit
ance
Cx,tgδ,U,I,Φ,P,F,t
|tgδ|>
1: C
apacitance and series/parallel resistance.
|Q|<1
: I
nductance and series resistance.
Inducti
on
Lx,Q,U,I,Φ,P,F,t
Resist
ance
Cx(Lx),Rx,U,I,Φ,P,F,t
CVT self-excitation
C1,tgδ,C2,tgδ,U1,U2,F,t
C1
is
connected to CX
;
C2
is
connected to
HV
.
U1 is the
C1
voltage
;
U2 is the
C2
voltage
.
CVT ratio
K,Φ,F,t,U,I,Cx,tgδ
C
x
and tgδ
are the results
of
GST
connection
at
high voltage
side
(Just for Model no.WGSL-
5
F)
Accessories
1.
Host
1 unit
2.
HV cable (8m)
1 unit
3.
LV cable (6m)
2 units
4
.
Power
supply cable
1 unit
5
.
Earth line (5m)
1 unit
6
.
CVT
wire
2 units
7
.
5A
fuse
2 units
8.
Print paper
2 units
9.
Canvas bag for cables
1 unit
10.
Operating Manual
1 unit
11
.
Factory
'
s
Calibration
report
1 unit
Are you interested in learning more about DC dielectric test equipments? Contact us today to secure an expert consultation!