ANSI NEMA MW 1000-2003 Rev.1.2005

Approved as an American National Standard
ANSI Approval Date: October 25, 2005
ANSI/NEMA MW 1000-2003
Revision 1, 2005
Magnet Wire
Published by
National Electrical Manufacturers Association

1300 North 17th Street, Suite 1752
Rosslyn, Virginia 22209
www.nema.org
Copyright 2005 by the National Electrical Manufacturers Association. All rights including translation into
other languages, reserved under the Universal Copyright Convention, the Berne Convention for the
Protection of Literary and Artistic Works, and the International and Pan American Copyright Conventions.
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MW 1000-2003, Revision 1, June 16, 2005
Page i
CONTENTS
Page
Foreword ...................................................................................................................................xi
How to Use this Publication......................................................................................................xii
Part 1 GENERAL
1.1 Scope......................................................................................................................................... 1
1.2 Normative References and Authorized Engineering Information (AEI) .................................... 1
1.3 Definitions .................................................................................................................................. 2
1.4 Materials .................................................................................................................................... 4
1.4.1 Conductors Round, Square, and Rectangular, Copper and Aluminum .................... 4
1.4.2 Insulating Materials....................................................................................................... 5
1.5 Manufacturing............................................................................................................................ 5
1.5.1 Application of Insulation ............................................................................................... 5
1.5.2 Intermediate Sizes........................................................................................................ 6
1.5.3 Joints ............................................................................................................................ 6
1.5.4 Packaging..................................................................................................................... 6
1.6 Test Conditions and Parameters............................................................................................... 7
1.6.1 Safety Statement .......................................................................................................... 7
1.6.2 Selection of Specimens ................................................................................................ 7
1.6.3 Ambient Conditions of Test .......................................................................................... 7
1.6.4 Power Frequency ......................................................................................................... 7
1.6.5 Mandrels....................................................................................................................... 7
1.6.6 Rectangular and Square Wire ...................................................................................... 8
1.6.7 Round Wire................................................................................................................... 8
1.6.8 Periodic Conformance.................................................................................................. 8
1.6.9 Retests ......................................................................................................................... 8
1.7 Units of Measure ....................................................................................................................... 9
1.8 Thermal Class of Magnet Wire.................................................................................................. 9
1.9 Ordering Information.................................................................................................................. 9
1.9.1 Product Identification Number ...................................................................................... 9
1.9.2 Minimum Ordering Data ............................................................................................. 10
Tables
1-1 Dimensions for Bare and Film Insulated Round Magnet Wire ................................................ 11
1-2 Round Copper Wire, Ultra Fine Sizes by Resistance ............................................................. 17
1-3 Dimensions for Round Film Insulated Self-Bonding Magnet Wire .......................................... 18
1-4 Dimensions for Single Glass Fiber Covered Round Bare,
Single Film Coated and Heavy Film Coated Wire................................................................... 20
1-5 Dimensions for Double Glass Fiber Covered Round Bare,
1-6 Dimensions for Single Polyester Glass Fiber Covered Round Bare,
1-7 Dimensions for Double Polyester Glass Fiber Covered Round Bare,
1-8 Dimensions and Radii for Rectangular Bare Wire................................................................... 28
1-9 Bare Rectangular Conductor Tolerances................................................................................ 28
Copyright 2005 by the National Electrical Manufacturers Association.

MW 1000-2003, Revision 1, June 16, 2005
Page ii
1-10 Film Insulated Rectangular Magnet Wire

Increase in Thickness and Width Due to Film Coating ........................................................... 28
1-11 Dimensions of Square Bare Wire ............................................................................................ 29
1-12 Heavy and Quadruple Film Insulated Square Magnet Wire
Increase in Dimensions Due to Film Coating .......................................................................... 30
1-13 Range of Increase in Dimensions, Inches
Single Glass Fiber Covered Heavy Film Insulated Rectangular Copper Wire........................ 31
Double Glass Fiber Covered Bare Rectangular Copper Wire ................................................ 32
Double Glass Fiber Covered Heavy Film Coated Rectangular Copper Wire ......................... 33
Single Polyester Glass Fiber Covered Heavy Film Insulated Rectangular Copper Wire ....... 34
Double Polyester Glass Fiber Covered Bare Rectangular Copper Wire ................................ 35
Double Polyester Glass Fiber Covered Heavy Film Coated Rectangular Copper Wire ......... 36
1-19 Single Glass Fiber Covered, Heavy Film Insulated Square Copper Magnet Wire
Minimum Increase and Maximum Overall Dimensions Due to Insulation............................... 37
1-20 Single Polyester Glass Fiber Covered Heavy Film Insulated Square Copper Magnet
Wire-Minimum Increase and Maximum Overall Dimensions Due to Insulation ...................... 38
1-21 Double Glass Fiber Covered, Bare or Heavy Film Insulated Square Copper Magnet Wire
Minimum Increase and Maximum Overall Dimensions Due to Insulation............................... 39
1-22 Double Polyester Glass Fiber Covered, Bare or Heavy Film Insulated Square Copper
Magnet WireMinimum Increase and Maximum Overall Dimensions Due to Insulation ........ 40
1-23 Comparison Between AWG and IEC R-40 Series Bare Wire Diameters ............................... 41
1-24 Comparison Between NEMA and IEC Increases and Overall Diameters............................... 43

MW 1000-2003, Revision 1, June 16, 2005
Page iii
CONTENTS (continued)
Part 2 PROPERTIES AND REQUIREMENTS

Specification Thermal Round Rectangular Page
Number Class and Square No.
MW 2-C Polyurethane for solderable applications 105 X 2
(Single and Heavy)
MW 3-C Polyurethane with self-bonding overcoat for 105 X 3
solderable applications (Types 1 and 2)
MW 5-C Polyester (Single and Heavy) 155 X 4
MW 6-C Polyamide (Single and Heavy) 105 X 5
MW 9-C Epoxy (Single, Heavy, and Triple) 130 X 6
(OBSOLETE)
MW 14-C Epoxy (Heavy and Quadruple) (OBSOLETE) 130 X 7
MW 15-A Polyvinyl Acetal (Single and Heavy) 105 X 8
MW 15-C Polyvinyl Acetal (Single, Heavy, Triple and 105 X 9
Quad)
MW 16-C Polyimide (Single Heavy, Triple, and 240 X 1017
Quadruple)
MW 17-C Polyvinyl acetal overcoated with polyamide 105 X 18
(Single and Heavy)
MW 18-A Polyvinyl acetal (Heavy and Quadruple) 105 X 19
MW 18-C Polyvinyl acetal (Heavy and Quadruple) 105 X 20
MW 19-C Polyvinyl acetal with self-bonding overcoat 105 X 21
(Types 1, 2 and 3)
MW 20-C Polyimide (Heavy and Quadruple) 240 X 22
MW 24-A Polyester (amide) (imide) overcoated with 155 X 23
polyamide (Single and Heavy)
MW 24-C Polyester (amide) (imide) overcoated with 155 X 24
polyamide (Single, Heavy and Triple)
MW 26-C Polyester (imide) for solderable applications 155 X 25
(Single and Heavy)
MW 27-C Polyester (imide) overcoated with polyamide 155 X 26
for solderable applications (Single and Heavy)
MW 28-A Polyurethane overcoated with polyamide for 130 X 27
solderable applications (Single and Heavy)
MW 28-C Polyurethane overcoated with polyamide for 130 X 28
MW 29-C Polyurethane overcoated with polyamide and 105 X 29
self-bonding overcoated for solderable
applications (Types 1 and 2)
MW 30-C Polyester (amide) (imide) (Single, Heavy, and 180 X 30
Triple)
MW 31-C Paper covered 90 or X 31
105
MW 32-C Double paper single cotton covered 90 or X 3233
(OBSOLETE) 105
MW 33-C Paper covered 90 or X 34
105

MW 1000-2003, Revision 1, June 16, 2005
Page iv
Part 2 PROPERTIES AND REQUIREMENTS

MW 35-A Polyester (amide)(imide) overcoated with 220 X 35

polyamideimide (Single and Heavy)
MW 35-C Polyester (amide)(imide) overcoated with 200 X 36
polyamideimide (Single, Heavy Triple, and
Quad)
polyamideimide (Heavy and Quadruple)
polyamideimide (Heavy and Quadruple)
MW 37-C Polyester (amide)(imide) overcoated with 220 X 38-1
polyamideimide (Heavy)
MW 38-C Polyester (amide)(imide) overcoated with 220 X 38-2
polyamideimide (Heavy)
MW 41-C Glass fiber covered (Single and Double) 155 X 39
MW 42-C Glass fiber covered (Single and Double) 155 X 40
MW 43-C Glass fiber covered silicone treated 200 X 41
(Single and Double)
MW 44-C Glass fiber covered silicone treated 200 X 42
(Single and Double)
MW 45-C Polyester glass fiber covered 155 X 43
(Single and Double)
MW 46-C Polyester glass fiber covered 155 X 44
(Single and Double)
MW 47-C Polyester glass fiber covered silicone treated 200 X 45
(Single and Double)
MW 48-C Polyester glass fiber covered silicone treated 200 X 46
(Single and Double)
MW 50-C Glass fiber covered, High Temperature 180 X 47
organic varnish treated (Single and Double)
MW 51-C Polyester glass fiber covered, High 180 X 48
Temperature organic varnish treated (Single
and Double)
MW 52-C Glass fiber covered, High Temperature 180 X 49
organic varnish treated (Single or Double)
MW 53-C Polyester glass fiber covered, High 180 X 50
Temperature organic varnish treated (Single
and Double)
MW 60-A Aromatic polyamide paper covered (Paper) 220 X 5253
MW 60-C Aromatic polyamide paper covered (Paper) 220 X 5455
MW 61-A Aromatic polyamide paper covered (Paper) 220 X 5657
MW 61-C Aromatic polyamide paper covered (Paper) 220 X 5859
MW 62-C Aromatic Polyimide tape covered 220 X 60
MW 63-C Aromatic Polyimide tape covered 220 X 61
MW 72-C Polyester (amide)(imide) for Hermetic 180 X 62

MW 1000-2003, Revision 1, June 16, 2005
Page v
Part 2 PROPERTIES AND REQUIREMENTS (continued)

Applications (Heavy)
polyamideimide for Hermetic Applications
(Heavy)
polyamideimide for Hermetic Applications
(Heavy, Triple, and Quad)
MW 74-A Polyester (amide)(imide) (Single and Heavy) 220 X 65
MW 74-C Polyester (amide)(imide) (Single and Heavy) 200 X 66
(Single and Heavy)
polyamide (Single and Heavy)
polyamide (Single, Heavy, and Triple)
MW 77-C Polyester (imide) for solderable applications 180 X 70
(Single and Heavy)
MW 78-C Polyester (imide) overcoated with polyamide 180 X 71
for solderable applications (Single and Heavy)
(Single, Heavy and Triple)
MW 80-A Polyurethane overcoated with polyamide for 155 X 73
solderable applications (Single, Heavy, Triple)
MW 81-C Polyamideimide (Single and Heavy) 220 X 75
(Single, Heavy and Triple)
solderable applications (Single, Heavy,
Triple)
polyamideimide and self-bonding overcoat
(Type 1 and Type 2)
(Type 1 and Type 2)
MW 130-C Polyurethane with self-bonding overcoat 130 X 80
(Type 1 and Type 2)
MW 131-C Polyurethane with self-bonding overcoat 155 X 81
(Type 1 and Type 2)
self-bonding overcoat (Type 1 and Type 2)
self-bonding overcoat (Type 1 and Type 2)

MW 1000-2003, Revision 1, June 16, 2005
Page vi
Tables
S (MW 16-C) Polyimide Single Film Insulated Round Copper Magnet Wire, Thermal Class 240 ......... 11
H (MW 16-C) Polyimide Heavy Film Insulated Round Copper Magnet Wire, Thermal Class 240 ......... 13
T (MW 16-C) Polyimide Triple Film Insulated Round Copper Magnet Wire, Thermal Class 240 .......... 15
Q (MW 16-C) Polyimide Quadruple Film Insulated Round Copper Magnet Wire, Thermal Class 240 .. 17
PR (MW 60-A) Increase in Dimensions of Rectangular Wire Due to Paper Covering.............................. 53
PSQ (MW 60-A) Dimensions 14/0 AWG .................................................................................................. 53
PR (MW 60-C) Increase in Dimensions of Rectangular Wire Due to Paper Covering............................... 55
PSQ (MW 60-C) Dimensions 14/0 AWG .................................................................................................. 55
PR (MW 61-A) Dimensions 4/09 AWG ..................................................................................................... 57
PR (MW 61-C) Dimensions 4/09 AWG..................................................................................................... 59
TR (MW 63-C) Insulated Wire Dimensions................................................................................................. 61
Part 2
PROPERTIES AND REQUIREMENTS LISTING BY THERMAL CLASS, INSULATION, COATING AND FORM
Thermal Class Insulation, Covering and Form See Part 2, Section

Aluminum Copper Page No.
FILM INSULATED ROUND MAGNET WIRE

105 Polyamide - MW 6-C 5
105 Polyvinyl acetal MW 15-A MW 15-C 8, 9
105 Polyvinyl acetal overcoated with polyamide - MW 17-C 18
105 Solderable Polyurethane - MW 2-C 2
105 Solderable Polyurethane and self-bonding overcoat - MW 3-C 3
105 Solderable Polyurethane overcoated with polyamide and self- - MW 29-C 29
bonding overcoat
105 Polyvinyl acetal and self-bonding overcoat - MW 19-C 21
130 Solderable Polyurethane overcoated with polyamide MW 28-A MW 28-C 27, 28

130 Solderable Polyurethane with self-bonding overcoat - MW 130-C 80
bonding overcoat
155 Polyester - MW 5-C 4
155 Polyester (amide)(imide) overcoated with polyamide MW 24-A MW 24-C 23, 24
155 Solderable Polyester (imide) - MW 26-C 25
155 Solderable Polyester (imide) overcoated with polyamide - MW 27-C 26
155 Solderable Polyurethane overcoated with polyamide MW 80-A MW 80-C 73, 74
155 Solderable Polyurethane with self-bonding overcoat - MW 131-C 81
bonding overcoat
180 Polyester (amide)(imide) - MW 30-C 30
180 Polyester (amide)(imide) overcoated with polyamide MW 76-A MW 76-C 68, 69
180 Polyester (amide)(imide) overcoated with MW 102-A MW 102-C 78, 79

MW 1000-2003, Revision 1, June 16, 2005
Page vii
Part 2

180 Solderable Polyester (imide) - MW 77-C 70
180 Solderable Polyester (imide) overcoated with polyamide - MW 78-C 71
180 Hermetic Polyester (amide)(imide) - MW 72-C 62
180 Solderable Polyurethane overcoated with Polyamide - MW 83-C 77
200 Polyester (amide)(imide) overcoated with - MW 35-C 36
polyamideimide
200 Polyester (amide)(imide) - MW 74-C 66
200 Hermetic Polyester (amide)(imide) overcoated with - MW 73-C 64
polyamideimide
220 Polyester (amide)(imide) overcoated with MW 35-A - 35
polyamideimide
220 Polyester (amide)(imide) overcoated with - MW 37-C 38-1
polyamideimide
220 Polyester (amide)(imide) MW 74-A - 65
220 Hermetic Polyester (amide)(imide) overcoated with MW 73-A - 63
polyamideimide
220 Polyamideimide MW 81-C 75
240 Hermetic Polyimide - MW 16-C 1017
FILM INSULATED RECTANGULAR AND SQUARE WIRE

105 Polyvinyl acetal MW 18-A MW 18-C 19, 20
200 Polyester (amide)(imide) overcoated with - MW 36-C 38

polyamideimide
220 Polyester (amide)(imide) overcoated with MW 36-A - 37
polyamideimide
220 Polyester (amide)(imide) overcoated with - MW 38-C 38-2
Polyamideimide
240 Polyimide - MW 20-C 22
FIBROUS COVERED ROUND MAGNET WIRE
90 or 105 Paper covered - MW 31-C 31
155 Glass fiber covered - MW 41-C 39
155 Polyester glass fiber covered - MW 45-C 43
180 Glass fiber covered, High temperature organic - MW 50-C 47
varnish treated
180 Polyester glass fiber covered, High temperature - MW 51-C 48
organic varnish treated
200 Glass fiber covered, silicone treated - MW 44-C 42
200 Polyester glass fiber covered, Silicone treated - MW 47-C 45
220 Aromatic polyamide paper covered MW 61-A MW 61-C 5659
220 Aromatic polyimide tape covered - MW 63-C 61
FIBROUS COVERED RECTANGULAR & SQUARE MAGNET WIRE

MW 1000-2003, Revision 1, June 16, 2005
Page viii
Part 2

90 or 105 Paper covered - MW 33-C 34
155 Glass fiber covered - MW 42-C 40
155 Polyester glass fiber covered - MW 46-C 44
180 Glass fiber covered, High temperature organic - MW 52-C 49
varnish treated
180 Polyester glass fiber covered, High temperature - MW 53-C 50
organic varnish treated
200 Glass fiber covered, Silicone treated - MW 43-C 41
200 Polyester glass fiber covered, Silicone treated - MW 48-C 46
220 Aromatic polyamide paper covered MW 60-A MW 60-C 5255
220 Aromatic polyimide tape covered - MW 62-C 60

MW 1000-2003, Revision 1, June 16, 2005
Page ix
Part 3 TEST PROCEDURES

3.1 Safety Statement ....................................................................................................................... 1
ROUTINE TESTS
3.2 Dimensions................................................................................................................................ 1
3.2.1 Round Wire................................................................................................................... 1
3.2.2 Rectangular and Square Wire ...................................................................................... 3
3.3 Adherence and Flexibility .......................................................................................................... 3
3.3.1 Elongation and Mandrel Wrap Method......................................................................... 3
3.3.2 Mandrel Wrap Method .................................................................................................. 4
3.3.3 Elongation Method........................................................................................................ 4
3.3.4 Circumferential Cut and Elongation Method ................................................................ 4
3.3.5 Bend and Shot Dielectric Method................................................................................. 4
3.3.6 Flat and Edge Bend Method......................................................................................... 4
3.4 Elongation.................................................................................................................................. 4
3.5 Heat Shock ................................................................................................................................ 6
3.6 Reserved ................................................................................................................................... 6
3.7 Springback (Specified for Copper Conductors Only) ................................................................ 6
3.7.1 Mandrel Wrap Method .................................................................................................. 6
3.7.2 Deflection Method (All Rectangular and Round Sizes Larger than 14 AWG)............ 10
3.8 Dielectric Breakdown............................................................................................................... 11
3.8.1 Test ProcedureGeneral .......................................................................................... 11
3.8.2 Foil Electrode Method................................................................................................. 11
3.8.3 Twisted Pair Method................................................................................................... 12
3.8.4 Wound Pair Method.................................................................................................... 14
3.8.5 Layer Method.............................................................................................................. 14
3.8.6 Bend Method .............................................................................................................. 14
3.8.7 Cylinder Method ......................................................................................................... 15
3.9 Continuity................................................................................................................................. 17
3.9.1 General ....................................................................................................................... 17
3.9.2 High-Voltage Direct Current Continuity (14-44 AWG)................................................ 17
3.9.3 Low-Voltage Direct Current Continuity (45-56 AWG) ................................................ 18
3.10 Dissipation Factor.................................................................................................................... 20
3.10.1 Principle of Test.......................................................................................................... 20
3.10.2 Equipment .................................................................................................................. 20
3.10.3 Preparation of Specimen............................................................................................ 20
3.10.4 Procedure ................................................................................................................... 21
3.10.5 Result.......................................................................................................................... 22
3.11 Reserved ................................................................................................................................. 22
3.12 Coverage ................................................................................................................................. 22
3.12.1 Mandrel Wrap Method ................................................................................................ 22
3.12.2 Flat Bend Method ....................................................................................................... 22
3.13 Solderability ............................................................................................................................. 22
3.13.1 General ....................................................................................................................... 22
3.13.2 Self-Supported Specimen Method (14-36 AWG) ....................................................... 23
3.13.3 Fixture-Supported Specimen Method (37-56 AWG) .................................................. 23

MW 1000-2003, Revision 1, June 16, 2005
Page x
PERIODIC CONFORMANCE TESTS
3.50 Thermoplastic Flow ................................................................................................................. 24

3.50.1 Apparatus ................................................................................................................... 24
3.50.2 Procedure ................................................................................................................... 24
3.51 Solubility .................................................................................................................................. 25
3.51.1 Round Film Insulated Wire (10 AWG and Finer)........................................................ 25
3.51.2 Round Wire Larger than 10 AWG, Rectangular and Square Wire ............................ 25
3.52 Dielectric Strength at Rated Temperature............................................................................... 26
3.52.1 Test Procedure ........................................................................................................... 26
3.53 Toluene/Ethanol Compatibility..............................................................................................26-1
3.53.1 Principle of Test.......................................................................................................26-1
3.53.2 Equipment & Materials ............................................................................................26-1
3.53.3 Specimen Preparation .............................................................................................26-1
3.53.4 Procedure ................................................................................................................26-1
3.53.5 Result.......................................................................................................................26-1
3.54 Transformer Oil Resistance and Hydrolytic Stability ............................................................26-2
3.54.1 Principal of Test.......................................................................................................26-2
3.54.2 Test Apparatus ........................................................................................................26-2
3.54.3 Short Term Exposure Test ......................................................................................26-2
3.54.4 Long Term Exposure Test.......................................................................................... 27
3.55 Refrigerant (R-22) Extraction .................................................................................................. 27
3.55.1 Preparation of Specimens .......................................................................................... 28
3.55.2 Environmental Conditioning ....................................................................................... 28
3.55.3 Collecting Residue...................................................................................................... 29
3.55.4 Determination of Results ............................................................................................ 30
3.56 Dielectric Breakdown after R-22 Conditioning ........................................................................ 30
3.57 Bond ........................................................................................................................................ 31
3.57.1 Preparation of Specimens .......................................................................................... 31
3.57.2 Heat and Solvent Bonding.......................................................................................... 31
3.57.3 Room Temperature Bonding ...................................................................................... 32
3.57.4 Elevated Temperature Bond Test Procedure............................................................. 32
3.58 Thermal Endurance ................................................................................................................. 33
3.58.1 Test Procedure ........................................................................................................... 33
3.59 Scrape Resistance .................................................................................................................. 33
3.59.1 Apparatus ................................................................................................................... 33
3.59.2 Test Procedure ........................................................................................................... 34
Tables
3.2.1 Specification for Micrometer Anvil Diameter and Spindle Force............................................... 2
3.3.1 Adherence and Flexibility: Elongation and Mandrel Diameters ................................................ 3
3.4.1 Minimum Percent Elongation, Square and Rectangular Wire................................................... 4
3.4.2 Minimum Percent Elongation, Round Wire ............................................................................... 5
3.7.1 Springback - Mandrel Wrap Method.......................................................................................... 9
3.8.2 Minimum Dielectric Breakdown VoltageFoil Method ........................................................... 12
3.8.3.1 Twisted Pair Method: Tensions and Rotations........................................................................ 12
3.8.3.2 Minimum Dielectric Breakdown VoltageTwisted Pair Method ............................................. 13

MW 1000-2003, Revision 1, June 16, 2005
Page xi
3.8.6 Bend Method Mandrel Sizes ................................................................................................... 14

3.8.7.1 Rate of Increase in VoltageCylinder Method ....................................................................... 15
3.8.7.2 Cylinder Method Test Loads ................................................................................................... 16
3.8.7.3 Minimum Dielectric Breakdown VoltageCylinder Method.................................................... 16
3.9.2.1 Test Voltage (DC Volts 5%) and Maximum Fault Count per 100 Feet ................................. 17
3.9.2.2 Threshold Fault Current .......................................................................................................... 18
3.9.3 Low-Voltage ContinuityMaximum Fault Count per 100 Feet............................................... 19
3.50.2 Thermoplastic Flow Test Loads .............................................................................................. 24
3.54.4 Pressure Vessel Components................................................................................................. 27
3.55.1 Recommended Turns/Coil....................................................................................................... 28
3.55.2 Typical Siphon Cup Dimensions ............................................................................................. 28
3.57.1 Bond Test Parameters............................................................................................................. 31
3.59.1 Standard Scrape Resistance of Round Film Insulated Magnet Wire...................................... 35
3.59.2 Reduced Scrape Resistance of Round Film Insulated Magnet Wire...................................... 35
Figures
3.7.1.1 Details of Springback Scale ...................................................................................................... 7
3.7.1.2 Springback Tester After Winding a Coil Under Tension ........................................................... 8
3.7.1.3 Example of Springback Scales.................................................................................................. 8
3.7.2 Apparatus for Springback Deflection Method.......................................................................... 10
3.8.4 Wound Pair Specimen Winder ................................................................................................ 14
3.8.7 Test Apparatus for Cylinder Method........................................................................................ 15
3.9.3 Bath of Mercury or Other Suitable Material ............................................................................. 19
3.10.2 Electrode and Specimen Arrangement for Dissipation Factor Test ........................................ 21
3.13.3 Solderability Test Specimen Fixture........................................................................................ 23
3.51.1 Machine for Solubility Scrape.................................................................................................. 25
3.55.1 Refrigerant Extractable Siphon Cup........................................................................................ 28
3.55.2 Condenser Coil........................................................................................................................ 29
3.55.3 Condenser Coil Siphon Cup Assembly ................................................................................... 29
3.57.1 Bond Coil Prep Fixture ............................................................................................................ 31
3.57.3.1 Bond Strength Test Fixture...................................................................................................... 32
3.57.3.2 Bond Test Fixture .................................................................................................................... 32
3.59.1 Machine for Scrape Resistance .............................................................................................. 34
Appendices
A Reference Test Conditions and Procedures for Film-Insulated Magnet Wire....................................A1
B Magnet Wire Packaging and Labeling................................................................................................B1
C Cross Reference of NEMA, Cancelled Federal J-W-1177, and IEC Magnet Wire Specifications C1

MW 1000-2003, Revision 1, June 16, 2005
Page xii
Foreword
NEMA MW 1000-2003 and its revisions supersede NEMA Standards Publication MW 1000-1997. It has
been approved as an American National Standard.
The standards contained in this publication are periodically reviewed by the NEMA Magnet Wire Section
for revisions considered to be necessary to keep them up to date with changes in technology. Proposed
or recommended revisions should be submitted to:
Vice President, Engineering

Rosslyn, Virginia 22209
These standards were developed by the Magnet Wire Section of NEMA, working closely with
representatives of various industries that use magnet wire. At the time they were approved, the Magnet
Wire Section had the following members:
Bridgeport Insulated Wire CompanyBridgeport, CT

Elektrisola, Inc.Boscawen, NH
Essex Group, Inc.Fort Wayne, IN
MagnekonSan Nicolas, NL, Mexico
NexansMarkham, ON, Canada
Phelps Dodge Magnet Wire CompanyFort Wayne, IN
Rea Magnet Wire Company, Inc.Fort Wayne, IN
Universal Lighting TechnologiesGallman, MS

MW 1000-2003, Revision 1, June 16, 2005
Page xiii
How to Use This Publication
Part 1 (blue, if in print) of this publication deals with information common to all types of magnet wire,
that is, ordering information, general material requirements, general test conditions, definitions and
manufacturing data in support of thermal rating. This part also includes dimensions with metric
equivalents for all bare, minimum insulation increase, and overall dimensions for all Part 2 MW
specification requirements. The exception to this is MW 16, where the dimensional and other
requirements are provided in Part 2.
Part 2 (yellow, if in print) consists of product specifications requirements (other than dimensions) for
magnet wire with different types of coatings and/or coverings. Insofar as possible, the product
specifications are complete on one sheet since they are arranged to include only one insulation or
covering per sheet. The title on each individual sheet identifies the product. (Example: MW 15-C,
Polyvinyl Acetal Round Copper Magnet Wire. MW 15-A covers the aluminum version of the same
generic product).
Part 3 (green, if in print) contains the test procedures to be followed and corresponding tables of
specific test values to be attained in determining compliance with the requirements given in Part 2. The
requirements are consolidated with the test procedures and testing parameters for a given property. An
index of the main test paragraphs is given beginning on page viii of the Table of Contents.
Appendix A (tan, if in print) provides a cross reference between test procedures in this Standards
Publication and those published by the American Society for Testing and Materials (ASTM).
Appendix B (tan, if in print) consists of definitions, requirements, and recommended test procedures
for reusable magnet wire packaging, standardized dimensions for spools and reels, and formatting for the
labeling of magnet wire products.
Appendix C (tan, if in print) provides a cross reference between NEMA, cancelled J-W-1177 Federal,
and IEC magnet wire specifications.
First, review Part 1 for general information. Then in Part 2 locate the specification for the type of
insulation and conductor of interest. Part 2 is arranged in numerical order as shown beginning on page ii.
The dimensions for each Part 2 MW type are provided in Part 1 beginning with Table 1-1. The
specification in Part 2 will indicate the requirements to be met and will refer to the test procedures and
corresponding test values to be attained in Part 3.

MW 1000-2003, Revision 1, June 16, 2005
Page xiv
<This page is intentionally left blank.>

MW 1000-2003
Part 1Page 1
Part 1
GENERAL
1.1 SCOPE
This publication is designed to present, in concise and convenient form, all of the existing NEMA
Standards for magnet wire. This publication is classified as a NEMA Standard unless otherwise indicated.
It contains standards for round, rectangular, and square film insulated and/or fibrous covered copper and
aluminum magnet wire for use in electrical apparatus. Included are the definitions, type designations,
dimensions, constructions, performance, and test methods for magnet wire generally used in the winding
of coils for electrical apparatus.
1.2 NORMATIVE REFERENCES AND AUTHORIZED ENGINEERING INFORMATION (AEI)

The following references apply to Parts 1, 2 and 3 only. Reference is made to the current revision of each
of the standards or AEI listed below:
American National Standards Institute

11 West 42nd Street
New York, NY 10036
American Society for Testing Materials

100 Barr Harbor Drive
West Conshohocken, PA 19428-2959
ASTM B 3 Standard Specification for Soft or Annealed Copper Wire

ASTM B 32 Standard Specification for Solder Metal
ASTM B 48 Standard Specification for Soft Rectangular and Square Bare Copper Wire for
Electrical Conductors
ASTM B 193 Standard Test Method for Resistivity of Electrical Conductor Materials
ASTM D 149 Standard Test Method for Dielectric Breakdown Voltage and Dielectric
Strength of Solid Electrical Insulating Materials at Commercial Power
Frequencies
ASTM D 1676 Standard Methods for Testing Film-Insulated Magnet Wire
ASTM D 1711 Standard Terminology Relating to Electrical Insulation
ASTM D 1932 Standard Test Method for Thermal Endurance of Flexible Electrical
Insulating Varnishes
ASTM D 2307 Standard Test Method for Relative Thermal Endurance of Film-Insulated
Round Magnet Wire
ASTM D 3353 Standard Methods for Testing Fibrous-Insulated Magnet Wire
ASTM D 5423 Standard Specification for Forced-Convection Laboratory Ovens for Evaluation of
Electrical Insulation
ASTM E 8 Standard Methods of Tension Testing of Metallic Materials
ASTM E 29 Standard Recommended Practice for Indicating Which Places of Figures Are
to Be Considered Significant in Specified Limiting Values
Institute of Electrical and Electronics Engineers

45 Hoes Lane, P.O. Box 1331
Piscataway, NJ 08855-1331
ANSI/IEEE Std 1 General Principles for Temperature Limits in the Rating of Electric
Equipment and for the Evaluation of Electrical Insulation
ANSI/IEEE Std 4 Techniques for High Voltage Testing

MW 1000-2003, Revision 1, June 16, 2005
Part 1Page 2
International Electrotechnical Commission

3, rue de Varemb
Case postale 131
CH-1211 Geneva 20
IEC 60317-0-1 Specifications for particular types of winding wires - Part 0-1
General requirements - Enamelled round copper wire
IEC 60317-0-2 Specifications for particular types of winding wires - Part 0-2
General requirements - Enamelled rectangular copper wire
National Institute for Standards and Technology

Gaithersburg, MD
Handbook 100 Copper Wire Tables

Rosslyn, VA 22209
MW 750 (AEI) Dynamic Coefficient of Friction of Film-Insulated Magnet Wire

MW 785 (AEI) Simulated Insertion Force Test
MW 790 (AEI) AC Overload Test
1.3 DEFINITIONS
build: The increase in wire dimension (diameter, thickness, width) due to the insulation.
single build: A reference terminology denoting the lowest of four standard NEMA film builds.
The minimum insulation increases in mils for single build in the 8-13.5 AWG size range are defined
by the formula:
0.600 AWG
B1 = 0.5 x 10 135

The minimum insulation increases in mils for single build in the 14-29.5 AWG size range are defined
by the formula:
AWG
0.518
B1 = 10 44.8
The minimum insulation increases in mils for single build in the 30-46 AWG size range are defined
by the formula:
B1 = (46.7 x (nominal bare diameter in inches x 25.4)0.75)/25.4
heavy build: A reference terminology denoting standard NEMA film builds which are approximately
two times the increases specified for single builds.
The minimum insulation increases in mils for heavy build in the 4-13.5 AWG size range are defined
by the formula:

MW 1000-2003, Revision 1, June 16, 2005
Part 1Page 3
AWG
0.600
B 2 = 10 135
The minimum insulation increases in mils for heavy build in the 14-29.5 AWG size range are defined
by the formula:
AWG
0.819
B 2 = 10 44.8
The minimum insulation increases in mils for heavy build in the 30-46 AWG size range are defined
by the formula:
triple build: A reference terminology denoting standard NEMA film builds which are approximately
three times the increases specified for single builds.
The minimum insulation increases in mils for triple build in the 14-29.5 AWG size range are defined
by the formula:
AWG
0.995
B3 = 10 44.8
The minimum insulation increases in mils for triple build in the 30-46 AWG size range are defined by
the formula:
quadruple build: A reference terminology denoting standard NEMA film builds which are
approximately four times the increases specified for single builds.
The minimum insulation increases in mils for quad build in the 10-13.5 AWG size range are defined
by the formula:
0.600 AWG
B 4 = 2 x 10 135

The minimum insulation increases in mils for quad build in the 1429.5 AWG size range are defined
by the formula:
AWG
1.12
B 4 = 10 44.8
The minimum insulation increases in mils for quadruple build in the 30-46 AWG size range are
defined by the formula:
type 1 self-bonding: A single build insulated magnet wire with a self-bonding outer coating. The
maximum overall diameter does not exceed the maximum overall diameter of heavy build.

MW 1000-2003, Revision 1, June 16, 2005
Part 1Page 4
type 2 self-bonding: A heavy build insulated magnet wire with a self-bonding outer coating. The
maximum overall diameter does not exceed the maximum overall diameter of triple build.
type 3 self-bonding: A triple build insulated magnet wire with a self-bonding outer coating. The
maximum overall diameter does not exceed the maximum overall diameter of quadruple build.
conductor: A substance used to transmit electrical current.
covering: A fibrous or tape insulating material that is wound, wrapped, or braided around a bare or film
coated conductor.
crack in film coating: An opening in the coating that exposes the bare conductor to view at the
magnification specified in Part 3.
film coating: A continuous barrier of polymeric insulation.
film insulated wire: A film-coated conductor.
insulation: A dielectric medium that is applied to the conductor.
magnet wire: An insulated wire used primarily for the winding of coils in order to provide an
electromagnetic field (also known as winding wire).
self-bonding overcoat: A material that is applied as an outer coating to insulated wire that, when
activated, serves as a bonding agent.
visual examination: Normal vision shall be defined as 20/20 vision, with corrective lenses, if
necessary.
1.4 MATERIALS
1.4.1 ConductorsRound, Square, and Rectangular, Copper and Aluminum
1.4.1.1 Surface Condition
Bare conductors shall be smooth, clean and free of dirt, discoloration, corrosion, scales or slivers
consistent with good commercial practice. Rectangular and square conductors shall be free from sharp,
rough or projecting edges. The corners on rectangular and square conductors shall be rounded so that
the arcs of the radii merge smoothly into the flat surfaces. Wire with slight oxidation shall not be a cause
for rejection.
1.4.1.2 Dimensions and Resistivity

The conductor, after insulating, shall comply with the requirements given for dimensions in the applicable
section in Part 2. These resistivities correspond to a conductivity, in percent International Annealed Copper
Standard (IACS) of 100 for copper, 61.8 for aluminum, and 60.6 for aluminum alloys at 20C (68F)(See
NIST Handbook 100). The resistivity shall be determined in accordance with ASTM B193 and shall not
exceed the following values:
Maximum Resistivity
2
Conductors Ohm-circular mil/ft Ohm-mm /m
Copper 10.371 0.017241
Aluminum 16.782 0.027898
Aluminum Alloys* 17.114 0.028450
* The use of aluminum alloys with a minimum conductivity 60.6% of the IACS is allowed in place of aluminum if agreed upon between
the supplier and user.

MW 1000-2003, Revision 1, June 16, 2005
Part 1Page 5
This standards publication specifies a minimum conductivity for copper of 100 percent IACS and shall not
exclude the possibility of the use of coppers over 100 percent IACS. Likewise, a conductivity of 61.8
percent for aluminum and 60.6 percent for aluminum alloys shall not exclude the use of aluminum or
aluminum alloys with higher conductivities in either case. The current state of conductor processing has
made possible the use of higher conductivity metals.
1.4.1.3 Characteristics of Aluminum

The mechanical, electrical, and chemical characteristics of aluminum magnet wire differ from those of
copper magnet wire because of the inherent differences in the conductor materials. These differences are
reflected in certain test procedures and/or performance requirements for aluminum magnet wire, such as
elongation, adherence and flexibility, heat shock, scrape resistance, continuity, and thermal endurance.
Film coated aluminum round wire sizes 10 through 14 AWG (2.59 through 1.63 mm) shall have a yield
strength not less than 7,000 psi (48.3 MPa) and a tensile strength not less than 13,000 psi (89.6 MPa); sizes
15 through 25 AWG (1.450 through 0.455 mm) shall have a yield strength not less than 8,000 psi (55.2
MPa) and a tensile strength not less than 13,000 psi (89.6 MPa). Large round sizes, all rectangular film
coated and all fibrous covered wire shall have a yield strength not less than 9,000 psi (62.1 MPa). The yield
strength shall be determined in accordance with the 0.2 percent offset method described in ASTM E 8.
NOTEThe testing procedure may include a pre-stretch of the specimen of 0.25 percent, which may remove small kinks, waves, and
bends in the specimen prior to the test.
1.4.2 Insulating Materials

1.4.2.1 Film and fibers shall conform to the latest revisions of the applicable standards of ANSI, ASTM,
or NEMA.
1.4.2.2 Various resins are referred to under insulating materials in Part 2. The resins specified may be
modified. A modified resin is defined as a resin that has undergone a chemical change, or contains one
or more additives to enhance certain performance or application characteristics. It must retain the
essential chemical identity of the original resin and the coated conductor must meet all specified test
requirements of the appropriate MW standard.
1.4.2.3 Various resins are identified under the insulating materials headings in Part 2. These resin
descriptions are given with the primary generic type listed first and optional types listed in parentheses.
Combinations of the primary generic resin with one or more of those in parentheses, which have been
found by experience to meet all specified requirements, shall also be permitted.
1.4.2.4 Some magnet wire products described in Part 2 are constructed of multiple coats of different
insulating materials. The requirements in Part 2 shall be met regardless of resin modifications or the
amounts applied.
1.5 MANUFACTURING
1.5.1 Application of Insulation
Wire shall be coated or covered with insulation that meets the applicable requirements in Part 2 when the
wire is taken directly from the spool, reel, or container.
Film coatings shall be essentially smooth and continuous, free from streakiness, blisters, and foreign
material in accordance with good commercial practice.
When the wire is to be both film coated and fibrous or tape covered, the film-coated wire shall meet the
applicable requirements of Part 2 before it is covered.

MW 1000-2003, Revision 1, June 16, 2005
Part 1Page 6
Fibrous coverings shall be wrapped firmly, closely, evenly, and continuously around the wire. When more
than one layer of fibrous covering is applied, adjacent layers shall be wound in opposite directions.
When more than one layer of tape covering is applied, adjacent layers shall be permitted to be wound in
the same or in opposite directions. The relation of the degree of lapping of the tape to the number of
layers of tape is shown as follows:
Lap Description Maximum Number

Percentage of Lap of Tape Layers
0 1
Greater than 0 but less than or equal to 50 2
1.5.2 Intermediate Sizes

1.5.2.1 Round and Square
For wire sizes between AWG sizes, the increase in dimension due to the film coating shall be calculated
according to the applicable formula presented in the definition for build, clause 1.3. The increase in
dimension due to the fibrous or tape covering shall be the same as for the next lower AWG size (next
larger diameter). Test procedures and values for all wire sizes between AWG sizes, for all insulation
types, if not present in the appropriate test requirement table, shall be the same as for the next higher
AWG size (next smaller diameter size).
1.5.2.2 Rectangular
The increase in dimensions due to the insulation for rectangular wires having dimensions not shown in
the applicable Part 1 table or Part 2 specification shall be the same as that specified for the next larger
thickness or width.
1.5.3 Joints
All magnet wire shall be one continuous length for each spool, reel, or container. Joints when present
shall be either brazed with silver solder or welded. The number of joints shall be minimized. The surface
of the wire at the joints shall be smooth and suitably insulated.
The dimensions of the wire at the joints shall be within the tolerances specified in Part 2.
For 30 AWG (0.254 mm) and larger diameter wire, the tensile strength of the joints shall be not less than
80 percent of the tensile strength of the wire 3 feet (914 mm) from the joint.
For 31 AWG (0.226 mm) and finer copper wire, the tensile strength of the joint shall be at least 20,000 psi
(138 MPa).
1.5.4 Packaging
The wire shall be packed in such a manner as to protect it from damage during transit, and labeled in
accordance with Appendix B as applicable.
The wire shall be wound evenly and compactly on spools or reels in accordance with Appendix B, or shall
be deposited in containers uniformly and compactly and free from kinks. A minimum amount of neutral
lubricant consistent with good packaging may be applied to the surface of film insulated wire.

MW 1000-2003
Part 1Page 7
1.6 TEST CONDITIONS AND PARAMETERS

1.6.1 Safety Statement
It is not the intent of this standard to address all of the safety issues associated with its use. It is the
responsibility of the user of this standard to train personnel, establish proper health and safety
procedures and be aware of local, state and national regulatory restrictions that may apply.
Some tests use materials which local, state, and national regulatory agencies have determined to be
hazardous. These tests shall be performed under controlled conditions where the safety and protection of
personnel shall be of prime consideration. Information and instructions contained in the Material Safety
Data Sheets (MSDS) for handling and working with such products, shall be followed. Discharge of these
chemicals to the environment must be controlled in accordance with all applicable regulations.
Certain test procedures require high voltage. It is important that the equipment be designed to comply
with relevant electrical codes. Safety must be an integral part of the design. In such cases necessary
precautions must be taken and test equipment manufacturers' recommendations shall be followed.
Some tests utilizing mechanical equipment may expose the operator to mechanical hazards. Care must
be exercised to protect eyes, fingers, hands, and other body parts from injury.
In tests requiring elevated temperatures, precautions must be taken in handling materials exposed to
heat to avoid skin burns.
1.6.2 Selection of Specimens

The requirements in Part 2 are applicable only to the size ranges indicated or as shown in Part 3.
If there is evidence that the wire on the surface of the package has been damaged, the damaged wire
shall be discarded before specimens are taken for testing. Wire specimens shall be removed from the
package in such a way as to prevent damage such as bending, stretching, kinking, etc.
As dielectric breakdown, dissipation factor and high voltage continuity test results are affected by the
presence of skin oils, acids, salts, dust, dirt, etc., care should be exercised in the handling of test
specimens.
1.6.3 Ambient Conditions of Test

Unless otherwise specified, all tests shall be made at room temperature, which shall be between 15C
(59F) and 40C (104F).
1.6.4 Power Frequency

Tests shall be conducted using 60-hertz power unless otherwise specified.
1.6.5 Mandrels
Mandrel diameters are expressed in multiples of "d" (the nominal round bare wire diameter or thickness
or width of rectangular and square bare wires). The mandrel diameter shall be expressed in decimal
dimensions to the nearest mil (0.001 in.) (0.025 mm).
For diameters smaller than 30 AWG (0.0100 in.) (0.254 mm), the mandrel diameter shall not vary from
the specified diameter by more than one mil (0.025 mm). For diameters equal to or larger than 30 AWG,
the mandrel diameter shall not vary from the specified diameter by more than 1 percent as measured to
the nearest mil (0.025 mm).

MW 1000-2003
Part 1Page 8
1.6.6 Rectangular and Square Wire

References to rectangular wire in the test procedures in Part 3 include square wire unless otherwise
indicated.
The dimension tables for rectangular and square copper and aluminum wire (Tables 1-8 through 1-11) for
the applicable Part 2 specifications are based on a series of standardized AWG size subdivisions for
thickness and width.
1.6.7 Round Wire

1.6.7.1 AWG Size
The nominal AWG bare wire diameters, in inches, in Table 1-23 were calculated using the basic
mathematical characteristics of the American Wire Gauge:
X = (0.0050)(1.1229322)(36-N)
Where:
X = nominal bare wire diameter in inches to be determined
0.0050 = nominal base diameter in inches for 36 AWG
1.1229322 = 3992 = the ratio of the diameter of any AWG size to the (smaller) diameter of the
next larger AWG size.
36 = the AWG number of the base diameter
N = the equivalent AWG number of X, where N is normally a whole number
For sizes 4/0 to 2/0 AWG, N is a negative number from -3 to -1.
1.6.7.2 Ultra Fine Dimensions

Theoretical nominal bare copper wire diameters of sizes 45 56 AWG are in accordance with ASTM B 3.
Conductor diameter tolerances in the applicable sections in Part 2 are shown as resistance values and
shall be determined by measuring resistance of the wire in accordance with ASTM B 193.
1.6.7.3 Comparison Between AWG and IEC R-40 Series

The International Electrotechnical Commission has adopted the Preferred Number series for round and
rectangular wire. Mathematically, the preferred numbers form a geometrical series (with a constant ratio
between adjacent numbers) based on the 20th or 40th root of 10. These series are known as the R-20
and R-40 series. Preferred number series values in inches (rounded to the nearest 0.001 inch) represent
a conversion from original computations in mm.
NOTEThe preceding paragraph is classified as Authorized Engineering Information.
Table 1-23 illustrates the relationship between the metric diameters in mm based on the IEC R-40 Series
and the diameter of AWG sizes converted to mm.
1.6.8 Periodic Conformance

Periodic conformance tests as described in Part 3 (numbered 3.50 and higher) are performed at extended
intervals. This assures continuing levels of certain inherent characteristics of materials and processes.
1.6.9 Retests
When a sample fails to meet a Part 2 requirement, the full test procedure in Part 3 shall be repeated twice.
The wire shall be regarded as meeting the requirement if the results of both additional tests are satisfactory.

MW 1000-2003
Part 1Page 9
1.7 UNITS OF MEASURE

For this standard, units are expressed in the inch-pound system, however temperatures are given in
degrees Celsius. Where their approximate metric equivalents are included, they are given as information
only. For direct conversion of inches to millimeters, multiply inches by the factor 25.4 (exact).
Rounding shall be in accordance with ASTM E 29.
All product dimensions listed in this publication are significant only to the number of digits shown to the
right of the decimal point.
1.8 THERMAL CLASS OF MAGNET WIRE

The thermal class of magnet wire shall be based upon:
a. Temperature index in accordance with 3.58.1

b. Heat shock capability as required in individual specifications in Part 2. This shall be at least 20C higher
than the Thermal Class temperature.
The thermal class given in each product specification in Part 2 is the class of the magnet wire and is not
intended to be the class of the electrical equipment in which the wire is used.
It is expected that the magnet wire producer will supply the user, upon request, with test data in support of
the thermal class of the magnet wire offered as meeting the requirements of Part 2 of this Standard. These
data points should be given in such form as in accord with the provisions of ASTM D 2307.
The tests described in ASTM D 2307 are considered as design tests on a given insulation composition. It is
not intended that they will be performed as production tests or on individual shipments.
NOTE 1Copper will oxidize at an increasing rate at temperatures of 200C and above and will also pit and become brittle at such
temperatures. This oxidation will eventually damage the film coating and failure of the winding may result. Where extended life is
desirable at temperatures exceeding 200C, it is advisable to protect the copper conductor with a material such as silver or nickel,
provided the material is compatible with the film coating or covering.
NOTE 2Aluminum magnet wire products often exhibit a higher thermal index and different heat shock properties in comparison with film
coated copper magnet wire. These differences should be considered when assigning the thermal class to film coated aluminum magnet
wire.
1.9 ORDERING INFORMATION

1.9.1 Product Identification Number
When a description of an individual magnet wire product is needed the following format shall be used: the
MW designation shall occupy the first two spaces, the type of insulation based on the NEMA MW
specification shall occupy the 3rd through 5th spaces, the conductor type shall occupy the 6th space, the
insulation build shall occupy the 7th space, additional information about the insulation (e.g. single fiber)
shall occupy the 8th space, the size description shall occupy the 9th through 14th spaces. In the case of
1/2 sizes, a decimal point is used in the thirteenth place and a five in the fourteenth place. The external
lubricant type shall occupy the 15th space. The film insulation color shall occupy the 16th and 17th
spaces. Please refer to the following NEMA Product Identification Number (PIN) Table for more detailed
information for use in developing NEMA Product Identification Numbers.

MW 1000-2003
Part 1Page 10
NEMA MW Product Identification Number Table

PIN Column NEMA MW Type of Type of Insulation Additional Type of Lubricant Insulation
Information Symbol Insulation Conductor Build Insulation Size Color
Information
PIN Spaces 2 3 1 1 1 6 1 2
PIN Position 1-2 3-5 6 7 8 9-14 15 16-17
PIN Data MW NEMA MW C- Copper B - Bare x Round P - paraffin wax bl blue
Standard A- Aluminum S Single a Start at far O - mineral oil bk black
(Number) H Heavy c right with S - special br brown
T Triple d last digit. N - none gd - gold
Q Quad e U - unspecified gn green
1 - Type 1 f gy - gray
2 - Type 2 g Square iv ivory
3 - Type 3 h Actual Size nc - *
i (Decimal or orange
j Nom. Bare pk pink
k x 1000) rd red
l Rectangular tn tan
n Actual Size tq turquoise
(Decimal vt violet
Nom. Bare wh white
x 1000) yl - yellow
* no color added
Explanation of additional insulation information

x: film coated only
a: single glass fiber
c: single polyester glass fiber
d: double polyester glass fiber
e: single tape .002 0 to 1/2 lap
f: single tape .002 1/2 to 2/3 lap
g: double tape .002 0 to 1/2 lap
h: double tape .002 1/2 to 2/3 lap
i: single tape .003 0 to 1/2 lap
j: single tape .003 1/2 to 2/3 lap
k: single tape 1/2 to 2/3 lap
l: double tape 1/2 to 2/3 lap
n: double paper single cotton
Examples: 18 AWG Round Single Build MW 80-C red with paraffin wax lubrication would have a PIN of: MW080CSx000018Prd
16-1/2 AWG Round Heavy Build MW 35-C green with paraffin wax lubrication would have a PIN of: MW035CHx0016.5Pgn
6 AWG Square Heavy Build MW 36-C natural with oil lubrication would have a PIN of: MW036CHx162162Onc
0.100 x 0.230 Single Glass Fiber over Heavy Film, MW 42-C would have a PIN of: MW042CHa100230Nnc
1.9.2 Minimum Ordering Data

Orders for materials in this Standards Publication should include the following information:
a. Quantity: total number of pounds (kilograms)
b. Product Identification Number (PIN)
c. Packaging: spool, reel, or container nomenclature in accordance with Appendix B
d. Other requirements as agreed to between supplier and user

Table 1-1 (Inch)
DIMENSIONS FOR BARE AND FILM INSULATED ROUND MAGNET WIRE
Bare Wire Diameter Single Build Heavy Build Triple Build Quad Build
AWG Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum AWG
Size Minimum Nominal Maximum Increase in Overall Increase in Overall Increase in Overall Increase in Overall Size
Diameter Diameter Diameter Diameter Diameter Diameter Diameter Diameter
4/0 0.4554 0.4600 0.4646 4/0
3/0 0.4055 0.4096 0.4137 3/0
2/0 0.3612 0.3648 0.3684 2/0
1/0 0.3170 0.3249 0.3281 1/0
1 0.2864 0.2893 0.2922 1

2 0.2550 0.2576 0.2602 2
3 0.2271 0.2294 0.2317 3
4 0.2023 0.2043 0.2057 0.0037 0.2098 4
4.5 0.1909 0.1928 0.1941 0.0037 0.1982 4.5

5 0.1801 0.1819 0.1832 0.0037 0.1873 5
5.5 0.1700 0.1717 0.1729 0.0036 0.1769 5.5
6 0.1604 0.1620 0.1631 0.0036 0.1672 6
6.5 0.1514 0.1529 0.1540 0.0036 0.1579 6.5

7 0.1429 0.1443 0.1453 0.0035 0.1492 7
7.5 0.1348 0.1362 0.1372 0.0035 0.1410 7.5
8 0.1272 0.1285 0.1294 0.0017 0.1314 0.0035 0.1332 8
8.5 0.1201 0.1213 0.1221 0.0017 0.1241 0.0034 0.1258 8.5

9 0.1133 0.1144 0.1153 0.0017 0.1173 0.0034 0.1190 9
MW 1000-2003, Revision 1, June 16, 2005

9.5 0.1069 0.1080 0.1089 0.0017 0.1109 0.0034 0.1125 9.5
10 0.1009 0.1019 0.1027 0.0017 0.1047 0.0034 0.1064 0.0068 0.1098 10
10.5 0.0952 0.0962 0.0970 0.0017 0.0990 0.0033 0.1007 0.0066 0.1039 10.5
11 0.0898 0.0907 0.0914 0.0017 0.0934 0.0033 0.0952 0.0066 0.0983 11
11.5 0.0847 0.0856 0.0863 0.0016 0.0882 0.0033 0.0900 0.0066 0.0932 11.5
12 0.0800 0.0808 0.0814 0.0016 0.0833 0.0032 0.0851 0.0064 0.0881 12
12.5 0.0755 0.0763 0.0769 0.0016 0.0788 0.0032 0.0805 0.0064 0.0836 12.5
13 0.0713 0.0720 0.0726 0.0016 0.0745 0.0032 0.0762 0.0064 0.0793 13
13.5 0.0672 0.0679 0.0684 0.0016 0.0703 0.0032 0.0720 0.0064 0.0751 13.5
Part 1Page 11
14 0.0635 0.0641 0.0647 0.0016 0.0666 0.0032 0.0682 0.0048 0.0698 0.0064 0.0714 14
14.5 0.0599 0.0605 0.0611 0.0016 0.0629 0.0031 0.0645 0.0047 0.0661 0.0063 0.0676 14.5
15 0.0565 0.0571 0.0577 0.0015 0.0594 0.0030 0.0610 0.0046 0.0625 0.0061 0.0640 15
15.5 0.0534 0.0539 0.0544 0.0015 0.0563 0.0030 0.0578 0.0045 0.0592 0.0059 0.0607 15.5
16 0.0503 0.0508 0.0513 0.0014 0.0531 0.0029 0.0545 0.0043 0.0560 0.0058 0.0574 16
16.5 0.0475 0.0480 0.0485 0.0014 0.0502 0.0028 0.0516 0.0042 0.0530 0.0056 0.0545 16.5
Part 1Page 12
MW 1000-2003, Revision 1, June 16, 2005
17 0.0448 0.0453 0.0458 0.0014 0.0475 0.0028 0.0488 0.0041 0.0502 0.0055 0.0516 17
17.5 0.0423 0.0427 0.0431 0.0013 0.0449 0.0027 0.0462 0.0040 0.0476 0.0054 0.0489 17.5
18 0.0399 0.0403 0.0407 0.0013 0.0424 0.0026 0.0437 0.0039 0.0450 0.0052 0.0464 18
18.5 0.0376 0.0380 0.0384 0.0013 0.0400 0.0025 0.0413 0.0038 0.0426 0.0051 0.0441 18.5
19 0.0355 0.0359 0.0363 0.0012 0.0379 0.0025 0.0391 0.0037 0.0404 0.0050 0.0418 19
19.5 0.0336 0.0339 0.0342 0.0012 0.0359 0.0024 0.0371 0.0036 0.0383 0.0048 0.0397 19.5
20 0.0317 0.0320 0.0323 0.0012 0.0340 0.0024 0.0351 0.0035 0.0363 0.0047 0.0377 20
20.5 0.0299 0.0302 0.0305 0.0011 0.0321 0.0023 0.0332 0.0034 0.0344 0.0046 0.0358 20.5
21 0.0282 0.0285 0.0288 0.0011 0.0303 0.0022 0.0315 0.0034 0.0326 0.0045 0.0340 21
21.5 0.0266 0.0269 0.0272 0.0011 0.0287 0.0022 0.0298 0.0033 0.0309 0.0044 0.0323 21.5
22 0.0250 0.0253 0.0256 0.0011 0.0270 0.0021 0.0281 0.0032 0.0292 0.0043 0.0306 22
22.5 0.0237 0.0239 0.0241 0.0010 0.0257 0.0021 0.0267 0.0031 0.0277 0.0041 0.0291 22.5
23 0.0224 0.0226 0.0228 0.0010 0.0243 0.0020 0.0253 0.0030 0.0263 0.0040 0.0277 23
23.5 0.0211 0.0213 0.0215 0.0010 0.0230 0.0020 0.0240 0.0030 0.0249 0.0039 0.0264 23.5
24 0.0199 0.0201 0.0203 0.0010 0.0217 0.0019 0.0227 0.0029 0.0236 0.0038 0.0250 24
24.5 0.0188 0.0190 0.0192 0.0009 0.0206 0.0019 0.0215 0.0028 0.0224 0.0037 0.0238 24.5
25 0.0177 0.0179 0.0181 0.0009 0.0194 0.0018 0.0203 0.0027 0.0212 0.0036 0.0226 25
25.5 0.0167 0.0169 0.0171 0.0009 0.0184 0.0018 0.0193 0.0027 0.0202 0.0036 0.0215 25.5
26 0.0157 0.0159 0.0161 0.0009 0.0173 0.0017 0.0182 0.0026 0.0191 0.0035 0.0204 26
26.5 0.0149 0.0150 0.0152 0.0008 0.0165 0.0017 0.0173 0.0025 0.0182 0.0034 0.0194 26.5
27 0.0141 0.0142 0.0143 0.0008 0.0156 0.0016 0.0165 0.0025 0.0173 0.0033 0.0185 27
27.5 0.0133 0.0134 0.0135 0.0008 0.0148 0.0016 0.0156 0.0024 0.0164 0.0032 0.0175 27.5
28 0.0125 0.0126 0.0127 0.0008 0.0140 0.0016 0.0147 0.0023 0.0155 0.0031 0.0167 28
28.5 0.0118 0.0119 0.0120 0.0008 0.0132 0.0015 0.0140 0.0023 0.0147 0.0030 0.0158 28.5
29 0.0112 0.0113 0.0114 0.0007 0.0126 0.0015 0.0133 0.0022 0.0141 0.0030 0.0151 29
29.5 0.0105 0.0106 0.0107 0.0007 0.0118 0.0014 0.0126 0.0022 0.0133 0.0029 0.0143 29.5
Table continued on next page.
Table 1-1 (Inch) Continued
30 0.0099 0.0100 0.0101 0.0007 0.0112 0.0013 0.0119 0.0020 0.0128 0.0026 0.0136 30
31 0.0088 0.0089 0.0090 0.0006 0.0100 0.0012 0.0108 0.0018 0.0114 0.0024 0.0124 31
32 0.0079 0.0080 0.0081 0.0006 0.0091 0.0011 0.0098 0.0017 0.0103 0.0022 0.0113 32
33 0.0070 0.0071 0.0072 0.0005 0.0081 0.0010 0.0088 0.0015 0.0092 0.0020 0.0102 33
34 0.0062 0.0063 0.0064 0.0005 0.0072 0.0009 0.0078 0.0014 0.0082 0.0019 0.0091 34
35 0.0055 0.0056 0.0057 0.0004 0.0064 0.0009 0.0070 0.0013 0.0074 0.0017 0.0082 35
36 0.0049 0.0050 0.0051 0.0004 0.0058 0.0008 0.0063 0.0012 0.0067 0.0016 0.0074 36
37 0.0044 0.0045 0.0046 0.0004 0.0053 0.0007 0.0057 0.0011 0.0060 0.0014 0.0067 37
38 0.0039 0.0040 0.0041 0.0003 0.0047 0.0007 0.0051 0.0010 0.0054 0.0013 0.0060 38
39 0.0034 0.0035 0.0036 0.0003 0.0041 0.0006 0.0045 0.0009 0.0048 0.0012 0.0053 39
40 0.0030 0.0031 0.0032 0.0003 0.0037 0.0005 0.0040 0.0008 0.0043 0.0011 0.0047 40
41 0.0027 0.0028 0.0029 0.0003 0.0034 0.0005 0.0036 0.0008 0.0040 0.0010 0.0043 41
42 0.0024 0.0025 0.0026 0.0002 0.0030 0.0005 0.0033 0.0007 0.0036 0.0009 0.0039 42
43 0.0021 0.0022 0.0023 0.0002 0.0026 0.0004 0.0029 0.0006 0.0032 0.0008 0.0035 43
44 0.0019 0.0020 0.0021 0.0002 0.0024 0.0004 0.0027 0.0006 0.0030 0.0008 0.0033 44
Theoretical Nominal Bare

Diameter
45 0.00176 0.00020 0.00220 0.0004 0.0024 0.0005 0.0027 0.0007 0.0029 45

46 0.00157 0.00020 0.00200 0.0003 0.0021 0.0005 0.0024 0.0007 0.0026 46
47 0.00140 0.00010 0.00170 0.0003 0.0019 47
48 0.00124 0.00010 0.00150 0.0002 0.0017 48
49 0.00111 0.00010 0.00130 0.0002 0.0015 49
50 0.00099 0.00010 0.00120 0.0002 0.0014 50
51 0.00088 0.00010 0.00110 51
52 0.00078 0.00010 0.00100 52
Part 1Page 13

MW 1000-2003
53 0.00070 0.00005 0.00085 53
54 0.00062 0.00005 0.00075 54
55 0.00055 0.00005 0.00070 55
56 0.00049 0.00005 0.00065 56
* See Table 1-2 for equivalent dimensions in mm
Theoretical nominal bare wire diameter by resistance, see 1.6.7.2.
See Table 1-3 for resistance metric equivalents.
Part 1Page 14
MW 1000-2003, Revision 1, June 16, 2005
Table 1-1 (mm)
DIMENSIONS FOR BARE AND FILM INSULATED ROUND MAGNET WIRE
4/0 11.567 11.684 11.801 4/0
3/0 10.300 10.404 10.508 3/0

2/0 9.174 9.266 9.357 2/0
1/0 8.171 8.252 8.334 1/0
1 7.275 7.348 7.422 1

2 6.477 6.543 6.609 2
3 5.768 5.827 5.885 3
4 5.138 5.189 5.225 0.094 5.330 4
4.5 4.849 4.897 4.931 0.094 5.035 4.5

5 4.575 4.620 4.666 0.094 4.757 5
5.5 4.318 4.361 4.392 0.091 4.494 5.5
6 4.074 4.115 4.155 0.091 4.246 6
6.5 3.846 3.884 3.911 0.091 4.012 6.5

7 3.630 3.665 3.701 0.089 3.790 7
7.5 3.424 3.459 3.484 0.089 3.581 7.5
8 3.231 3.264 3.297 0.043 3.338 0.089 3.383 8
8.5 3.051 3.081 3.103 0.043 3.153 0.086 3.196 8.5

9 2.878 2.906 2.929 0.043 2.980 0.086 3.023 9
9.5 2.715 2.743 2.765 0.043 2.816 0.086 2.859 9.5
10 2.563 2.588 2.609 0.043 2.660 0.086 2.703 0.173 2.789 10
10.5 2.418 2.443 2.463 0.043 2.514 0.084 2.557 0.168 2.638 10.5
11 2.281 2.304 2.322 0.043 2.373 0.084 2.418 0.168 2.497 11
11.5 2.151 2.174 2.192 0.041 2.240 0.084 2.287 0.168 2.367 11.5
12 2.032 2.052 2.069 0.041 2.117 0.081 2.163 0.163 2.239 12
12.5 1,918 1.938 1.954 0.041 2.002 0.081 2.045 0.163 2.124 12.5
13 1.811 1.829 1.843 0.041 1.892 0.081 1.934 0.163 2.014 13
13.5 1.707 1.725 1.738 0.041 1,787 0.081 1.829 0.163 1.909 13.5
14 1.613 1.628 1.643 0.041 1.692 0.081 1.732 0.122 1.773 0.163 1.814 14
14.5 1.521 1.537 1.552 0.041 1.598 0.079 1.638 0.119 1.679 0.160 1.717 14.5
15 1.435 1.450 1.466 0.038 1.509 0.076 1.549 0.117 1.588 0.155 1.626 15
15.5 1.356 1.369 1.382 0.038 1.430 0.076 1.468 0.114 1.504 0.150 1.542 15.5
16 1.278 1.290 1.303 0.036 1.349 0.074 1.384 0.109 1.422 0.147 1.458 16
16.5 1.207 1.219 1.232 0.036 1.275 0.071 1.311 0.107 1.346 0.142 1.384 16.5
17 1.138 1.151 1.163 0.036 1.207 0.071 1.240 0.104 1.275 0.140 1.311 17
17.5 1.074 1.085 1.095 0.033 1.140 0.069 1.173 0.102 1.209 0.137 1.242 17.5
18 1.013 1.024 1.034 0.033 1.077 0.066 1.110 0.099 1.143 0.132 1.179 18
18.5 0.955 0.965 0.975 0.033 1.016 0.064 1.049 0.097 1.082 0.130 1.119 18.5
19 0.902 0.912 0.922 0.030 0.963 0.064 0.993 0.094 1.026 0.127 1.063 19
19.5 0.853 0.861 0.869 0;030 0.912 0.061 0.942 0.091 0.973 0.122 1.009 19.5
20 0.805 0.813 0.820 0.030 0.864 0.061 0.892 0.089 0.922 0.119 0.958 20
20.5 0.759 0.767 0.775 0.028 0.815 0.058 0.843 0.086 0.874 0.117 0.909 20.5
21 0.716 0.724 0.732 0.028 0.770 0.056 0.800 0.086 0.828 0.114 0.863 21
21.5 0.676 0.683 0.691 0.028 0.729 0.056 0.757 0.084 0.785 0.112 0.819 21.5
22 0.635 0.643 0.650 0.028 0.686 0.053 0.714 0.081 0.742 0.109 0.778 22
22.5 0.602 0.607 0.612 0.025 0.653 0.053 0.678 0.079 0.704 0.104 0.738 22.5
23 0.569 0.574 0.579 0.025 0.617 0.051 0.643 0.076 0.668 0.102 0.704 23
23.5 0.536 0.541 0.546 0.025 0.584 0.051 0.610 0.076 0.632 0.099 0.669 23.5
24 0.505 0.511 0.516 0.025 0.551 0.048 0.577 0.074 0.599 0.097 0.635 24
24.5 0.478 0.483 0.488 0.023 0.523 0.048 0.546 0.071 0.569 0.094 0.605 24.5
25 0.450 0.455 0.460 0.023 0.493 0.046 0.516 0.069 0.538 0.091 0.575 25
25.5 0.424 0.429 0.434 0.023 0.467 0.046 0.490 0.069 0.513 0.091 0.546 25.5
26 0.399 0.404 0.409 0.023 0.439 0.043 0.462 0.066 0.485 0.089 0.519 26
26.5 0.378 0.381 0.386 0.020 0.419 0.043 0.439 0.064 0.462 0.086 0.493 26.5
27 0.358 0.361 0.363 0.020 0.396 0.041 0.419 0.064 0.439 0.084 0.469 27
27.5 0.338 0.340 0.343 0.020 0.376 0.041 0.396 0.061 0.417 0.081 0.446 27.5
28 0.318 0.320 0.323 0.020 0.356 0.041 0.373 0.058 0.394 0.079 0.423 28
28.5 0.300 0.302 0.305 0.020 0.335 0.038 0.356 0.058 0.373 0.076 0.423 28.5
29 0.284 0.287 0.290 0.018 0.320 0.038 0.338 0.056 0.358 0.076 0.382 29
29.5 0.267 0.269 0.272 0.018 0.300 0.036 0.320 0.056 0.338 0.074 0.363 29.5
MW 1000-2003, Revision 1, June 16, 2005

Part 1Page 15
Part 1Page 16
MW 1000-2003
Table 1-1 (mm) Continued
30 0.251 0.254 0.257 0.018 0.284 0.033 0.302 0.051 0.325 0.066 0.345 30
31 0.224 0.226 0.229 0.015 0.254 0.030 0.274 0.046 0.290 0.061 0.315 31
32 0.201 0.203 0.206 0.015 0.231 0.028 0.249 0.043 0.262 0.056 0.287 32
33 0.178 0.180 0.183 0.013 0.206 0.025 0.224 0.038 0.234 0.051 0.259 33
34 0.157 0.160 0.163 0.013 0.183 0.023 0.198 0.036 0.208 0.048 0.231 34
35 0.140 0.142 0.145 0.010 0.163 0.023 0.178 0.033 0.188 0.043 0.208 35
36 0.124 0.127 0.130 0.010 0.147 0.020 0.160 0.030 0.170 0.041 0.188 36
37 0.112 0.114 0.117 0.010 0.135 0.018 0.145 0.028 0.152 0.036 0.170 37
38 0.099 0.102 0.104 0.008 0.119 0.018 0.130 0.025 0.137 0.033 0.152 38
39 0.086 0.089 0.091 0.008 0.104 0.015 0.114 0.023 0.122 0.030 0.135 39
40 0.076 0.079 0.081 0.008 0.094 0.013 0.102 0.020 0.109 0.028 0.119 40
41 0.069 0.071 0.074 0.008 0.086 0.013 0.091 0.020 0.102 0.025 0.109 41
42 0.061 0.064 0.066 0.005 0.076 0.013 0.084 0.018 0.091 0.023 0.099 42
43 0.053 0.056 0.058 0.005 0.066 0.010 0.074 0.015 0.081 0.020 0.089 43
44 0.048 0.051 0.053 0.005 0.061 0.010 0.069 0.015 0.076 0.020 0.084 44
Theoretical Nominal Bare Diameter
45 0.0447 0.005 0.0559 0.0010 0.0610 0.0127 0.0686 0.0178 0.0737 45

46 0.0399 0.005 0.0508 0.0076 0.0533 0.0127 0.0610 0.0178 0.0660 46
47 0.0356 0.0025 0.0432 0.0076 0.0483 47
48 0.0315 0.0025 0.0381 0.0051 0.0432 48
49 0.0282 0.0025 0.0330 0.0051 0.0381 49
50 0.0251 0.0025 0.0305 0.0051 0.0356 50
51 0.0224 0.0025 0.0279 51
52 0.0198 0.0025 0.0254 52
53 0.0178 0.0013 0.0216 53
54 0.0157 0.0013 0.0191 54
55 0.0140 0.0013 0.0178 55
56 0.0124 0.0013 0.0165 56
Theoretical nominal bare wire diameter by resistance, see 1.6.7.2.
MW 1000-2003
Part 1Page 17
Table 1-2
ROUND COPPER WIRE, ULTRA FINE SIZES BY RESISTANCE
Resistance per foot
AWG Ohms per foot at 20C at 100% IACS

Size Minimum Nominal Maximum
45 3.080 3.348 3.616
46 3.870 4.207 4.544
47 4.868 5.291 5.714
48 6.205 6.745 7.285
49 7.744 8.417 9.090
50 9.734 10.58 11.43
51 12.32 13.39 14.46
52 15.69 17.05 18.41
53 19.48 21.17 22.86
54 24.82 26.98 29.14
55 31.54 34.28 37.02
56 39.73 43.19 46.64
Resistance per meter
AWG Ohms per meter at 20C at 100% IACS

Size Minimum Nominal Maximum
45 10.11 10.98 11.86
46 12.70 13.80 14.91
47 15.97 17.36 18.75
48 20.36 22.13 23.90
49 25.41 27.62 29.82
50 31.94 34.71 37.50
51 40.42 43.93 47.44
52 51.48 55.94 60.40
53 63.91 69.46 75.00
54 81.43 88.52 95.60
55 103.5 112.5 121.5
56 130.3 141.7 153.0

MW 1000-2003
Part 1Page 18
Table 1-3 (Inch)

DIMENSIONS FOR ROUND FILM INSULATED SELF-BONDING MAGNET WIRE
Type 1 Self-Bonding Type 2 Self-Bonding Type 3 Self-Bonding

Minimum Increase Maximum Minimum Increase Maximum Minimum Increase Maximum
AWG Bare Wire Diameter Film Self- Overall Film Self- Overall Film Self- Overall AWG
Size Minimum Nominal Maximum Coating Bond Diameter Coating Bond Diameter Coating Bond Diameter Size
14 0.0635 0.0641 0.0647 0.0016 0.0006 0.0682 0.0032 0.0006 0.0698 0.0048 0.0006 0.0714 14
15 0.0565 0.0571 0.0577 0.0015 0.0006 0.0610 0.0030 0.0006 0.0625 0.0046 0.0006 0.0640 15
16 0.0503 0.0508 0.0513 0.0014 0.0006 0.0545 0.0029 0.0006 0.0560 0.0043 0.0006 0.0574 16
17 0.0448 0.0453 0.0458 0.0014 0.0006 0.0488 0.0028 0.0006 0.0502 0.0041 0.0006 0.0516 17
18 0.0399 0.0403 0.0407 0.0013 0.0006 0.0437 0.0026 0.0006 0.0450 0.0039 0.0006 0.0464 18
19 0.0355 0.0359 0.0363 0.0012 0.0006 0.0391 0.0025 0.0006 0.0404 0.0037 0.0006 0.0418 19
20 0.0317 0.0320 0.0323 0.0012 0.0005 0.0351 0.0024 0.0005 0.0363 0.0035 0.0005 0.0376 20
21 0.0282 0.0285 0.0288 0.0011 0.0005 0.0315 0.0022 0.0005 0.0326 0.0034 0.0005 0.0339 21
22 0.0250 0.0253 0.0256 0.0011 0.0005 0.0281 0.0021 0.0005 0.0292 0.0032 0.0005 0.0305 22
23 0.0224 0.0226 0.0228 0.0010 0.0005 0.0253 0.0020 0.0005 0.0263 0.0030 0.0005 0.0277 23
24 0.0199 0.0201 0.0203 0.0010 0.0005 0.0227 0.0019 0.0005 0.0236 0.0029 0.0005 0.0250 24
25 0.0177 0.0179 0.0181 0.0009 0.0005 0.0203 0.0018 0.0005 0.0212 0.0027 0.0005 0.0226 25
26 0.0157 0.0159 0.0161 0.0009 0.0005 0.0182 0.0017 0.0005 0.0191 0.0026 0.0005 0.0204 26
27 0.0141 0.0142 0.0143 0.0008 0.0005 0.0165 0.0016 0.0005 0.0173 0.0025 0.0005 0.0184 27
28 0.0125 0.0126 0.0127 0.0008 0.0005 0.0147 0.0016 0.0005 0.0155 0.0023 0.0005 0.0165 28
29 0.0112 0.0113 0.0114 0.0007 0.0004 0.0133 0.0015 0.0004 0.0141 0.0022 0.0004 0.0151 29
30 0.0099 0.0100 0.0101 0.0007 0.0004 0.0119 0.0013 0.0004 0.0128 0.0020 0.0004 0.0136 30
31 0.0088 0.0089 0.0090 0.0006 0.0004 0.0108 0.0012 0.0004 0.0114 31
32 0.0079 0.0080 0.0081 0.0006 0.0004 0.0098 0.0011 0.0004 0.0103 32
33 0.0070 0.0071 0.0072 0.0005 0.0003 0.0088 0.0010 0.0003 0.0092 33
34 0.0062 0.0063 0.0064 0.0005 0.0003 0.0078 0.0009 0.0003 0.0082 34
35 0.0055 0.0056 0.0057 0.0004 0.0003 0.0070 0.0009 0.0003 0.0074 35
36 0.0049 0.0050 0.0051 0.0004 0.0003 0.0063 0.0008 0.0003 0.0067 36
37 0.0044 0.0045 0.0046 0.0004 0.0003 0.0057 0.0007 0.0003 0.0060 37
38 0.0039 0.0040 0.0041 0.0003 0.0002 0.0051 0.0007 0.0002 0.0054 38
39 0.0034 0.0035 0.0036 0.0003 0.0002 0.0045 0.0006 0.0002 0.0048 39
40 0.0030 0.0031 0.0032 0.0003 0.0002 0.0040 0.0005 0.0002 0.0043 40
41 0.0027 0.0028 0.0029 0.0003 0.0002 0.0036 0.0005 0.0002 0.0040 41
42 0.0024 0.0025 0.0026 0.0002 0.0002 0.0033 0.0005 0.0002 0.0036 42
43 0.0021 0.0022 0.0023 0.0002 0.0001 0.0029 0.0004 0.0001 0.0032 43
44 0.0019 0.0020 0.0021 0.0002 0.0001 0.0027 0.0004 0.0001 0.0030 44
Diameter
45 0.00176 0.0002 0.0001 0.0024 0.0004 0.0001 0.0027 45
46 0.00157 0.0002 0.0001 0.0021 0.0003 0.0001 0.0024 46
47 0.00140 0.0001 0.0001 0.0019 0.0003 0.0001 0.00210 47
48 0.00124 0.0001 0.0001 0.0017 0.0002 0.0001 0.00185 48
49 0.00111 0.0001 0.0001 0.0015 0.0002 0.0001 0.00170 49
50 0.00099 0.0001 0.0001 0.0014 0.0002 0.0001 0.00160 50
51 0.00088 0.0001 0.0001 0.0013 51
52 0.00078 0.0001 0.00005 0.00115 52
Theoretical nominal bare wire diameter by resistance, see 1.6.7.2

MW 1000-2003
Part 1Page 19
Table 1-3 (mm)

DIMENSIONS FOR ROUND FILM INSULATED SELF-BONDING MAGNET WIRE
Type 1 Self-Bonding Type 2 Self-Bonding Type 3 Self-Bonding

Minimum Increase Maximum Minimum Increase Maximum Minimum Increase Maximum AWG
AWG Bare Wire Diameter Film Self- Overall Film Self- Overall Film Self- Overall Size
Size Minimum Nominal Maximum Coating Bond Diameter Coating Bond Diameter Coating Bond Diameter
14 1.613 1.628 1.643 0.041 0.015 1.732 0.081 0.015 1.773 0.122 0.015 1.814 14
15 1.435 1.450 1.466 0.038 0.015 1.549 0.076 0.015 1.588 0.117 0.015 1.626 15
16 1.278 1.290 1.303 0.036 0.015 1.384 0.074 0.015 1.422 0.109 0.015 1.458 16
17 1.138 1.151 1.163 0.036 0.015 1.240 0.071 0.015 1.275 0.104 0.015 1.311 17
18 1.013 1.024 1.034 0.033 0.015 1.110 0.066 0.015 1.143 0.099 0.015 1.179 18
19 0.902 0.912 0.922 0.030 0.015 0.993 0.064 0.015 1.026 0.094 0.015 1.062 19
20 0.805 0.813 0.820 0.030 0.013 0.892 0.061 0.013 0.922 0.089 0.013 0.955 20
21 0.716 0.724 0.731 0.028 0.013 0.800 0.056 0.013 0.828 0.086 0.013 0.861 21
22 0.635 0.643 0.650 0.028 0.013 0.714 0.053 0.013 0.742 0.081 0.013 0.775 22
23 0.569 0.574 0.579 0.025 0.013 0.643 0.051 0.013 0.668 0.076 0.013 0.704 23
24 0.505 0.511 0.516 0.025 0.013 0.577 0.048 0.013 0.599 0.074 0.013 0.635 24
25 0.450 0.455 0.460 0.023 0.013 0.516 0.046 0.013 0.538 0.069 0.013 0.574 25
26 0.399 0.404 0.409 0.023 0.013 0.462 0.043 0.013 0.485 0.066 0.013 0.518 26
27 0.358 0.361 0.363 0.020 0.013 0.419 0.041 0.013 0.439 0.064 0.013 0.467 27
28 0.318 0.320 0.323 0.020 0.013 0.373 0.041 0.013 0.394 0.058 0.013 0.419 28
29 0.284 0.287 0.290 0.018 0.010 0.338 0.038 0.010 0.358 0.056 0.010 0.384 29
30 0.251 0.254 0.257 0.018 0.010 0.302 0.033 0.010 0.325 0.050 0.010 0.345 30
31 0.224 0.226 0.229 0.015 0.010 0.274 0.030 0.010 0.290 31
32 0.201 0.203 0.206 0.015 0.010 0.249 0.028 0.010 0.262 32
33 0.178 0.180 0.183 0.013 0.008 0.224 0.025 0.008 0.234 33
34 0.157 0.160 0.163 0.013 0.008 0.198 0.023 0.008 0.208 34
35 0.140 0.142 0.145 0.010 0.008 0.178 0.023 0.008 0.188 35
36 0.124 0.127 0.130 0.010 0.008 0.160 0.020 0.008 0.170 36
37 0.112 0.114 0.117 0.0010 0.008 0.145 0.018 0.008 0.152 37
38 0.099 0.102 0.104 0.008 0.005 0.130 0.018 0.005 0.137 38
39 0.086 0.089 0.091 0.008 0.005 0.114 0.015 0.005 0.122 39
40 0.076 0.079 0.081 0.008 0.005 0.102 0.013 0.005 0.109 40
41 0.069 0.071 0.074 0.008 0.005 0.091 0.013 0.005 0.102 41
42 0.061 0.064 0.066 0.005 0.005 0.084 0.013 0.005 0.091 42
43 0.053 0.056 0.058 0.005 0.003 0.074 0.010 0.003 0.081 43
44 0.048 0.051 0.053 0.005 0.003 0.069 0.010 0.003 0.076 44
Diameter
45 0.0447 0.005 0.0025 0.0610 0.0010 0.0025 0.0686 45
46 0.0399 0.005 0.0025 0.0533 0.0076 0.0025 0.0610 46
47 0.0356 0.0025 0.0025 0.0483 0.0076 0.0025 0.0533 47
48 0.0315 0.0025 0.0025 0.0432 0.0051 0.0025 0.0470 48
49 0.0282 0.0025 0.0025 0.0381 0.0051 0.0025 0.0432 49
50 0.0251 0.0025 0.0025 0.0356 0.0051 0.0025 0.0406 50
51 0.0224 0.0025 0.0025 0.0330 51
52 0.0198 0.0025 0.0013 0.0292 52
Theoretical nominal bare wire diameter by resistance; see 1.6.7.2.

MW 1000-2003
Part 1Page 20
Table 1-4 (Inch)

DIMENSIONS FOR SINGLE GLASS FIBER COVERED ROUND BARE,
SINGLE FILM COATED AND HEAVY FILM COATED WIRE
Minimum Increase Maximum Overall Diameter,

AWG Bare Wire Diameter Single glass fiber Single glass fiber covered AWG
Size Minimum Nominal Maximum covering Bare Single Film Heavy Film Size
4/0 0.4554 0.4600 0.4646 0.0045 0.4716 4/0
3/0 0.4055 0.4096 0.4137 0.0045 0.4207 3/0
2/0 0.3612 0.3648 0.3684 0.0045 0.3754 2/0
1/0 0.3170 0.3249 0.3281 0.0045 0.3351 1/0
1 0.2864 0.2893 0.2922 0.0045 0.2992 1
2 0.2550 0.2576 0.2602 0.0045 0.2672 2
3 0.2271 0.2294 0.2317 0.0045 0.2387 3
4 0.2023 0.2043 0.2063 0.0045 0.2133 0.2168 4
5 0.1801 0.1819 0.1837 0.0045 0.1907 0.1942 5
6 0.1604 0.1620 0.1636 0.0045 0.1706 0.1741 6
7 0.1429 0.1443 0.1457 0.0045 0.1527 0.1561 7
8 0.1272 0.1285 0.1298 0.0045 0.1368 0.1402 8
9 0.1133 0.1144 0.1155 0.0045 0.1225 0.1259 9
10 0.1009 0.1019 0.1029 0.0040 0.1089 0.1121 10
11 0.0898 0.0907 0.0916 0.0040 0.0976 0.1008 11
12 0.0800 0.0808 0.0816 0.0040 0.0876 0.0907 12
13 0.0713 0.0720 0.0727 0.0040 0.0787 0.0817 13
14 0.0635 0.0641 0.0647 0.0040 0.0707 0.0726 0.0742 14
15 0.0565 0.0571 0.0577 0.0040 0.0637 0.0654 0.0669 15
16 0.0503 0.0508 0.0513 0.0040 0.0573 0.0591 0.0605 16
17 0.0448 0.0453 0.0458 0.0040 0.0518 0.0535 0.0548 17
18 0.0399 0.0403 0.0407 0.0040 0.0467 0.0484 0.0497 18
19 0.0355 0.0359 0.0363 0.0040 0.0423 0.0439 0.0451 19
20 0.0317 0.0320 0.0323 0.0040 0.0383 0.0399 0.0411 20
21 0.0282 0.0285 0.0288 0.0040 0.0348 0.0363 0.0374 21
22 0.0250 0.0253 0.0256 0.0040 0.0316 0.0330 0.0341 22
23 0.0224 0.0226 0.0228 0.0040 0.0288 0.0303 0.0313 23
24 0.0199 0.0201 0.0203 0.0025 0.0243 0.0257 0.0267 24
25 0.0177 0.0179 0.0181 0.0025 0.0221 0.0234 0.0243 25
26 0.0157 0.0159 0.0161 0.0025 0.0201 0.0213 0.0222 26
27 0.0141 0.0142 0.0143 0.0025 0.0183 0.0196 0.0204 27
28 0.0125 0.0126 0.0127 0.0025 0.0167 0.0180 0.0187 28
29 0.0112 0.0113 0.0114 0.0025 0.0154 0.0166 0.0173 29
30 0.0099 0.0100 0.0101 0.0025 0.0141 0.0152 0.0159 30

MW 1000-2003
Part 1Page 21
Table 1-4 (mm)

DIMENSIONS FOR SINGLE GLASS FIBER COVERED ROUND BARE,

AWG Bare Wire Diameter Single glass fiber Single glass fiber covered AWG
4/0 11.567 11.684 11.801 0.114 11.979 4/0
3/0 10.300 10.404 10.508 0.114 10.686 3/0
2/0 9.174 9.266 9.357 0.114 9.535 2/0
1/0 8.171 8.252 8.334 0.114 8.512 1/0
1 7.275 7.348 7.422 0.114 7.600 1
2 6.477 6.543 6.609 0.114 6.787 2
3 5.768 5.827 5.885 0.114 6.063 3
4 5.138 5.189 5.240 0.114 5.418 5.507 4
5 4.575 4.620 4.666 0.114 4.844 4.933 5
6 4.074 4.115 4.155 0.114 4.333 4.422 6
7 3.630 3.665 3.701 0.114 3.879 3.965 7
8 3.231 3.264 3.297 0.114 3.475 3.561 8
9 2.878 2.906 2.934 0.114 3.112 3.198 9
10 2.563 2.588 2.614 0.102 2.766 2.847 10
11 2.281 2.304 2.327 0.102 2.479 2.560 11
12 2.032 2.052 2.073 0.102 2.225 2.304 12
13 1.811 1.829 1.847 0.102 1.999 2.075 13
14 1.613 1.628 1.643 0.102 1.796 1.844 1.885 14
15 1.435 1.450 1.466 0.102 1.618 1.661 1.699 15
16 1.278 1.290 1.303 0.102 1.455 1.501 1.537 16
17 1.138 1.151 1.163 0.102 1.316 1.359 1.392 17
18 1.013 1.024 1.034 0.102 1.186 1.229 1.262 18
19 0.902 0.912 0.922 0.102 1.074 1.115 1.146 19
20 0.805 0.813 0.820 0.102 0.973 1.013 1.044 20
21 0.716 0.724 0.731 0.102 0.884 0.922 0.950 21
22 0.635 0.643 0.650 0.102 0.803 0.838 0.866 22
23 0.569 0.574 0.579 0.102 0.732 0.770 0.795 23
24 0.505 0.511 0.516 0.064 0.617 0.653 0.678 24
25 0.450 0.455 0.460 0.064 0.561 0.594 0.617 25
26 0.399 0.404 0.409 0.064 0.511 0.541 0.564 26
27 0.358 0.361 0.363 0.064 0.465 0.498 0.518 27
28 0.318 0.320 0.323 0.064 0.424 0.457 0.475 28
29 0.284 0.287 0.290 0.064 0.391 0.422 0.439 29
30 0.251 0.254 0.257 0.064 0.358 0.386 0.404 30

MW 1000-2003
Part 1Page 22
Table 1-5 (Inch)

DIMENSIONS FOR DOUBLE GLASS FIBER COVERED ROUND BARE, SINGLE FILM COATED AND
HEAVY FILM COATED WIRE

AWG Bare Wire Diameter Double Glass Fiber Double Glass Fiber Covered AWG
Size Minimum Nominal Maximum Covering Bare Single Film Heavy Film Size
4/0 0.4554 0.4600 0.4646 0.0070 0.4756 4/0
3/0 0.4055 0.4096 0.4137 0.0070 0.4247 3/0
2/0 0.3612 0.3648 0.3684 0.0070 0.3794 2/0
1/0 0.3170 0.3249 0.3281 0.0070 0.3391 1/0
1 0.2864 0.2893 0.2922 0.0070 0.3032 1
2 0.2550 0.2576 0.2602 0.0070 0.2712 2
3 0.2271 0.2294 0.2317 0.0070 0.2427 3
4 0.2023 0.2043 0.2063 0.0070 0.2173 0.2210 4
5 0.1801 0.1819 0.1837 0.0070 0.1947 0.1982 5
6 0.1604 0.1620 0.1636 0.0070 0.1746 0.1781 6
7 0.1429 0.1443 0.1457 0.0070 0.1567 0.1601 7
8 0.1272 0.1285 0.1298 0.0070 0.1408 0.1442 8
9 0.1133 0.1144 0.1155 0.0070 0.1265 0.1299 9
10 0.1009 0.1019 0.1029 0.0060 0.1119 0.1151 10
11 0.0898 0.0907 0.0916 0.0060 0.1006 0.1038 11
12 0.0800 0.0808 0.0816 0.0060 0.0906 0.0937 12
13 0.0713 0.0720 0.0727 0.0060 0.0817 0.0847 13
14 0.0635 0.0641 0.0647 0.0060 0.0737 0.0726 0.0772 14
15 0.0565 0.0571 0.0577 0.0060 0.0667 0.0654 0.0699 15
16 0.0503 0.0508 0.0513 0.0060 0.0603 0.0621 0.0635 16
17 0.0448 0.0453 0.0458 0.0060 0.0548 0.0565 0.0578 17
18 0.0399 0.0403 0.0407 0.0060 0.0497 0.0514 0.0527 18
19 0.0355 0.0359 0.0363 0.0060 0.0435 0.0469 0.0481 19
20 0.0317 0.0320 0.0323 0.0060 0.0413 0.0429 0.0441 20
21 0.0282 0.0285 0.0288 0.0060 0.0378 0.0393 0.0404 21
22 0.0250 0.0253 0.0256 0.0060 0.0346 0.0360 0.0371 22
23 0.0224 0.0226 0.0228 0.0060 0.0318 0.0333 0.0343 23
24 0.0199 0.0201 0.0203 0.0045 0.0263 0.0277 0.0287 24
25 0.0177 0.0179 0.0181 0.0045 0.0241 0.0254 0.0263 25
26 0.0157 0.0159 0.0161 0.0045 0.0221 0.0233 0.0242 26
27 0.0141 0.0142 0.0143 0.0045 0.0203 0.0216 0.0224 27
28 0.0125 0.0126 0.0127 0.0045 0.0187 0.0200 0.0207 28
29 0.0112 0.0113 0.0114 0.0045 0.0174 0.0186 0.0193 29
30 0.0099 0.0100 0.0101 0.0045 0.0161 0.0172 0.0179 30

MW 1000-2003
Part 1Page 23
Table 1-5 (mm)

DIMENSIONS FOR DOUBLE GLASS FIBER COVERED ROUND BARE, SINGLE FILM COATED AND
HEAVY FILM COATED WIRE

AWG Bare Wire Diameter Double Glass Fiber Double Glass Fiber Covered AWG
4/0 11.567 11.684 11.801 0.178 12.080 4/0
3/0 10.300 10.404 10.508 0.178 10.787 3/0
2/0 9.174 9.266 9.357 0.178 9.637 2/0
1/0 8.171 8.252 8.334 0.178 8.613 1/0
1 7.275 7.348 7.422 0.178 7.701 1
2 6.477 6.543 6.609 0.178 6.888 2
3 5.768 5.827 5.885 0.178 6.165 3
4 5.138 5.189 5.240 0.178 5.520 5.613 4
5 4.575 4.620 4.666 0.178 4.945 5.034 5
6 4.074 4.115 4.155 0.178 4.435 4.524 6
7 3.630 3.665 3.701 0.178 3.980 4.067 7
8 3.231 3.264 3.297 0.178 3.576 3.663 8
9 2.878 2.906 2.934 0.178 3.213 3.299 9
10 2.563 2.588 2.614 0.152 2.842 2.924 10
11 2.281 2.304 2.327 0.152 2.555 2.637 11
12 2.032 2.052 2.073 0.152 2.301 2.380 12
13 1.811 1.829 1.847 0.152 2.075 2.151 13
14 1.613 1.628 1.643 0.152 1.872 1.844 1.961 14
15 1.435 1.450 1.466 0.152 1.694 1.661 1.775 15
16 1.278 1.290 1.303 0.152 1.532 1.577 1.613 16
17 1.138 1.151 1.163 0.152 1.392 1.465 1.468 17
18 1.013 1.024 1.034 0.152 1.262 1.306 1.339 18
19 0.902 0.912 0.922 0.152 1.151 1.191 1.222 19
20 0.805 0.813 0.820 0.152 1.049 1.090 1.120 20
21 0.716 0.724 0.731 0.152 0.960 0.998 1.026 21
22 0.635 0.643 0.650 0.152 0.879 0.914 0.942 22
23 0.569 0.574 0.579 0.152 0.808 0.846 0.871 23
24 0.505 0.511 0.516 0.114 0.668 0.704 0.729 24
25 0.450 0.455 0.460 0.114 0.612 0.645 0.668 25
26 0.399 0.404 0.409 0.114 0.561 0.592 0.615 26
27 0.358 0.361 0.363 0.114 0.516 0.549 0.569 27
28 0.318 0.320 0.323 0.114 0.475 0.508 0.526 28
29 0.284 0.287 0.290 0.114 0.442 0.472 0.490 29
30 0.251 0.254 0.257 0.114 0.409 0.437 0.455 30

MW 1000-2003
Part 1Page 24
Table 1-6 (Inch)

DIMENSIONS FOR SINGLE POLYESTER GLASS FIBER COVERED ROUND BARE, SINGLE FILM
COATED AND HEAVY FILM COATED WIRE
Minimum Increase,
Single Polyester Maximum Overall Diameter,
AWG Bare Wire Diameter Glass Fiber Single Polyester Glass Fiber Covered AWG
4/0 0.4554 0.4600 0.4646 0.0040 0.4696 4/0
3/0 0.4055 0.4096 0.4137 0.0040 0.4187 3/0
2/0 0.3612 0.3648 0.3684 0.0040 0.3734 2/0
1/0 0.3170 0.3249 0.3281 0.0040 0.3331 1/0
1 0.2864 0.2893 0.2922 0.0040 0.2972 1
2 0.2550 0.2576 0.2602 0.0040 0.2652 2
3 0.2271 0.2294 0.2317 0.0040 0.2367 3
4 0.2023 0.2043 0.2063 0.0040 0.2123 0.2158 4
5 0.1801 0.1819 0.1837 0.0040 0.1897 0.1932 5
6 0.1604 0.1620 0.1636 0.0040 0.1696 0.1731 6
7 0.1429 0.1443 0.1457 0.0040 0.1517 0.1551 7
8 0.1272 0.1285 0.1298 0.0040 0.1358 0.1392 8
9 0.1133 0.1144 0.1155 0.0040 0.1215 0.1249 9
10 0.1009 0.1019 0.1029 0.0035 0.1079 0.1111 10
11 0.0898 0.0907 0.0916 0.0035 0.0966 0.0998 11
12 0.0800 0.0808 0.0816 0.0035 0.0866 0.0897 12
13 0.0713 0.0720 0.0727 0.0035 0.0777 0.0807 13
14 0.0635 0.0641 0.0647 0.0035 0.0697 0.0716 0.0732 14
15 0.0565 0.0571 0.0577 0.0035 0.0627 0.0644 0.0569 15
16 0.0503 0.0508 0.0513 0.0035 0.0563 0.0581 0.0595 16
17 0.0448 0.0453 0.0458 0.0035 0.0508 0.0525 0.0538 17
18 0.0399 0.0403 0.0407 0.0035 0.0457 0.0474 0.0487 18
19 0.0355 0.0359 0.0363 0.0035 0.0413 0.0429 0.0441 19
20 0.0317 0.0320 0.0323 0.0035 0.0373 0.0389 0.0401 20
21 0.0282 0.0285 0.0288 0.0035 0.0338 0.0353 0.0364 21
22 0.0250 0.0253 0.0256 0.0035 0.0306 0.0320 0.0331 22
23 0.0224 0.0226 0.0228 0.0035 0.0278 0.0293 0.0303 23
24 0.0199 0.0201 0.0203 0.0025 0.0253 0.0267 0.0277 24
25 0.0177 0.0179 0.0181 0.0025 0.0231 0.0244 0.0253 25
26 0.0157 0.0159 0.0161 0.0025 0.0211 0.0223 0.0232 26
27 0.0141 0.0142 0.0143 0.0025 0.0193 0.0206 0.0214 27
28 0.0125 0.0126 0.0127 0.0025 0.0177 0.0190 0.0197 28
29 0.0112 0.0113 0.0114 0.0025 0.0164 0.0176 0.0183 29
30 0.0099 0.0100 0.0101 0.0025 0.0151 0.0162 0.0169 30

MW 1000-2003
Part 1Page 25
Table 1-6 (mm)

DIMENSIONS FOR SINGLE POLYESTER GLASS FIBER COVERED ROUND BARE, SINGLE FILM
Minimum Increase,
Single Polyester Maximum Overall Diameter,
AWG Bare Wire Diameter Glass Fiber Single Polyester Glass Fiber Covered AWG
4/0 11.567 11.684 11.801 0.102 11.928 4/0
3/0 10.300 10.404 10.508 0.102 10.635 3/0
2/0 9.174 9.266 9.357 0.102 9.484 2/0
1/0 8.171 8.252 8.334 0.102 8.461 1/0
1 7.275 7.348 7.422 0.102 7.549 1
2 6.477 6.543 6.609 0.102 6.736 2
3 5.768 5.827 5.885 0.102 6.012 3
4 5.138 5.189 5.240 0.102 5.392 5.481 4
5 4.575 4.620 4.666 0.102 4.818 4.907 5
6 4.074 4.115 4.155 0.102 4.308 4.397 6
7 3.630 3.665 3.701 0.102 3.853 3.940 7
8 3.231 3.264 3.297 0.102 3.449 3.536 8
9 2.878 2.906 2.934 0.102 3.086 3.172 9
10 2.563 2.588 2.614 0.089 2.741 2.822 10
11 2.281 2.304 2.327 0.089 2.454 2.535 11
12 2.032 2.052 2.073 0.089 2.200 2.278 12
13 1.811 1.829 1.847 0.089 1.974 2.050 13
14 1.613 1.628 1.643 0.089 1.770 1.819 1.859 14
15 1.435 1.450 1.466 0.089 1.593 1.639 1.674 15
16 1.278 1.290 1.303 0.089 1.430 1.476 1.511 16
17 1.138 1.151 1.163 0.089 1.290 1.334 1.367 17
18 1.013 1.024 1.034 0.089 1.161 1.204 1.237 18
19 0.902 0.912 0.922 0.089 1.049 1.090 1.120 19
20 0.805 0.813 0.820 0.089 0.947 0.988 1.019 20
21 0.716 0.724 0.731 0.089 0.859 0.897 0.925 21
22 0.635 0.643 0.650 0.089 0.777 0.813 0.841 22
23 0.569 0.574 0.579 0.089 0.706 0.744 0.770 23
24 0.505 0.511 0.516 0.064 0.643 0.678 0.704 24
25 0.450 0.455 0.460 0.064 0.587 0.620 0.643 25
26 0.399 0.404 0.409 0.064 0.536 0.566 0.589 26
27 0.358 0.361 0.363 0.064 0.490 0.523 0.544 27
28 0.318 0.320 0.323 0.064 0.450 0.483 0.500 28
29 0.284 0.287 0.290 0.064 0.417 0.447 0.465 29
30 0.251 0.254 0.257 0.064 0.384 0.411 0.429 30

MW 1000-2003
Part 1Page 26
Table 1-7 (Inch)

DIMENSIONS FOR DOUBLE POLYESTER GLASS FIBER COVERED ROUND BARE, SINGLE FILM
Minimum Increase,
Double Polyester Maximum Overall Diameter,
AWG Bare Wire Diameter Glass fiber Double Polyester Glass Fiber Covered AWG
4/0 0.4554 0.4600 0.4646 0.0060 0.4736 4/0
3/0 0.4055 0.4096 0.4137 0.0060 0.4227 3/0
2/0 0.3612 0.3648 0.3684 0.0060 0.3774 2/0
1/0 0.3170 0.3249 0.3281 0.0060 0.3371 1/0
1 0.2864 0.2893 0.2922 0.0060 0.3012 1
2 0.2550 0.2576 0.2602 0.0060 0.2692 2
3 0.2271 0.2294 0.2317 0.0060 0.2407 3
4 0.2023 0.2043 0.2063 0.0060 0.2153 0.2188 4
5 0.1801 0.1819 0.1837 0.0060 0.1927 0.1962 5
6 0.1604 0.1620 0.1636 0.0060 0.1726 0.1761 6
7 0.1429 0.1443 0.1457 0.0060 0.1547 0.1581 7
8 0.1272 0.1285 0.1298 0.0060 0.1388 0.1422 8
9 0.1133 0.1144 0.1155 0.0060 0.1245 0.1279 9
10 0.1009 0.1019 0.1029 0.0055 0.1109 0.1141 10
11 0.0898 0.0907 0.0916 0.0055 0.0996 0.1028 11
12 0.0800 0.0808 0.0816 0.0055 0.0986 0.0927 12
13 0.0713 0.0720 0.0727 0.0055 0.0807 0.0837 13
14 0.0635 0.0641 0.0647 0.0055 0.0727 0.0746 0.0762 14
15 0.0565 0.0571 0.0577 0.0055 0.0657 0.0674 0.0689 15
16 0.0503 0.0508 0.0513 0.0055 0.0593 0.0611 0.0625 16
17 0.0448 0.0453 0.0458 0.0055 0.0538 0.0555 0.0568 17
18 0.0399 0.0403 0.0407 0.0055 0.0487 0.0504 0.0517 18
19 0.0355 0.0359 0.0363 0.0055 0.0443 0.0459 0.0471 19
20 0.0317 0.0320 0.0323 0.0055 0.0403 0.0419 0.0431 20
21 0.0282 0.0285 0.0288 0.0055 0.0368 0.0383 0.0394 21
22 0.0250 0.0253 0.0256 0.0055 0.0336 0.0350 0.0361 22
23 0.0224 0.0226 0.0228 0.0055 0.0308 0.0323 0.0333 23
24 0.0199 0.0201 0.0203 0.0045 0.0268 0.0282 0.0292 24
25 0.0177 0.0179 0.0181 0.0045 0.0246 0.0259 0.0268 25
26 0.0157 0.0159 0.0161 0.0045 0.0226 0.0238 0.0247 26
27 0.0141 0.0142 0.0143 0.0045 0.0208 0.0221 0.0229 27
28 0.0125 0.0126 0.0127 0.0045 0.0192 0.0205 0.0212 28
29 0.0112 0.0113 0.0114 0.0045 0.0179 0.0191 0.0198 29
30 0.0099 0.0100 0.0101 0.0045 0.0166 0.0177 0.0184 30

MW 1000-2003
Part 1Page 27
Table 1-7 (mm)

DIMENSIONS FOR DOUBLE POLYESTER GLASS FIBER COVERED ROUND BARE
Minimum Increase,
Double Polyester Maximum Overall Diameter,
AWG Bare Wire Diameter Glass Fiber Double Polyester Glass Fiber Covered AWG
4/0 11.567 11.684 11.801 0.152 12.029 4/0
3/0 10.300 10.404 10.508 0.152 10.737 3/0
2/0 9.174 9.266 9.357 0.152 9.586 2/0
1/0 8.171 8.252 8.334 0.152 8.562 1/0
1 7.275 7.348 7.422 0.152 7.650 1
2 6.477 6.543 6.609 0.152 6.838 2
3 5.768 5.827 5.885 0.152 6.114 3
4 5.138 5.189 5.240 0.152 5.469 5.558 4
5 4.575 4.620 4.666 0.152 4.895 4.983 5
6 4.074 4.115 4.155 0.152 4.384 4.473 6
7 3.630 3.665 3.701 0.152 3.929 4.016 7
8 3.231 3.264 3.297 0.152 3.526 3.612 8
9 2.878 2.906 2.934 0.152 3.162 3.249 9
10 2.563 2.588 2.614 0.140 2.817 2.898 10
11 2.281 2.304 2.327 0.140 2.530 2.611 11
12 2.032 2.052 2.073 0.140 2.276 2.355 12
13 1.811 1.829 1.847 0.140 2.050 2.126 13
14 1.613 1.628 1.643 0.140 1.847 1.895 1.935 14
15 1.435 1.450 1.466 0.140 1.669 1.712 1.750 15
16 1.278 1.290 1.303 0.140 1.506 1.552 1.558 16
17 1.138 1.151 1.163 0.140 1.367 1.410 1.443 17
18 1.013 1.024 1.034 0.140 1.237 1.280 1.313 18
19 0.902 0.912 0.922 0.140 1.125 1.166 1.196 19
20 0.805 0.813 0.820 0.140 1.024 1.064 1.095 20
21 0.716 0.724 0.731 0.140 0.935 0.973 1.001 21
22 0.635 0.643 0.650 0.140 0.853 0.889 0.917 22
23 0.569 0.574 0.579 0.140 0.782 0.820 0.846 23
24 0.505 0.511 0.516 0.114 0.681 0.716 0.742 24
25 0.450 0.455 0.460 0.114 0.625 0.658 0.681 25
26 0.399 0.404 0.409 0.114 0.574 0.605 0.627 26
27 0.358 0.361 0.363 0.114 0.528 0.561 0.582 27
28 0.318 0.320 0.323 0.114 0.488 0.521 0.538 28
29 0.284 0.287 0.290 0.114 0.455 0.485 0.503 29
30 0.251 0.254 0.257 0.114 0.422 0.450 0.467 30

MW 1000-2003
Part 1Page 28
Table 1-8
DIMENSIONS AND RADII FOR RECTANGULAR BARE WIRE*
Dimensions in inches
Nominal Thickness Nominal Width Radii 25% Nominal Width Radii 25%
0.025 - 0.063 All FRE
0.064 - 0.088 0.065 - 0.187 0.020 0.188-0.750 0.031**
0.089 - 0.124 0.090 - 0.187 0.026 0.188-0.750 0.031**
0.125 - 0.157 All 0.031
0.158 - 0.280 All 0.039
Dimensions in mm
Nominal Thickness Nominal Width Radii 25% Nominal Width Radii 25%
0.64 1.60 All FRE
1.63 2.24 1.65 - 4.75 0.50 4.78 19.05 0.80**
2.26 3.15 2.29 4.75 0.67 4.78 19.05 0.80**
3.18 3.99 All 0.80
4.01 7.11 All 1.00
NOTE 1FRE - Fully Rounded Edges (Radius = half the thickness of the wire)
NOTE 2The ratio of the width dimension to the thickness dimension shall not exceed 10.
* This table is similar to ASTM B 48.
** Rectangular wire with a thickness in the .064-.124 inch (1.63- 3.15 mm) range and a width in the 0.188-0.750 inch (4.78-19.05
mm) range may be manufactured with the corner radii specified for widths less than 0.188 (4.78 mm).
Table 1-9
BARE RECTANGULAR CONDUCTOR TOLERANCES
Thickness Tolerances
Nominal Thickness Permissible Variations in Thickness
Range Inches Range mm Inches mm Percent
0.025 - 0.098 0.64 - 2.49 0.001 0.03
>0.098 - 0.280 >2.49 - 7.11 1 percent
Width Tolerances
Nominal Width Permissible Variations in Width
Range Inches Range mm Inches mm Percent
0.063 - 0.098 1.60 - 2.49 0.001 0.03
>0.098 - 0.315 >2.49 - 8.00 1 percent
>0.315 - .492 >8.00 - 12.5 0.003 0.08
>0.492 inch >12.5 1 percent
Table 1-10
FILM INSULATED RECTANGULAR MAGNET WIRE
INCREASE IN THICKNESS AND WIDTH DUE TO FILM COATING
Increase in Width Increase in Thickness
Minimum Maximum* Minimum Maximum*
Build inches mm inches mm inches mm inches mm
Heavy 0.0025 0.064 0.0045 0.114 0.0030 0.076 0.0050 0.127
Quadruple 0.0040 0.102 0.0060 0.152 0.0050 0.127 0.0070 0.178
*The maximum increase shall be permitted to be exceeded provided the maximum overall dimension of the coated wire does not
exceed the sum of the maximum dimensions of the bare wire plus the maximum increase due to the coating.

MW 1000-2003
Part 1Page 29
Table 1-11
DIMENSIONS OF SQUARE BARE WIRE
AWG Minimum Nominal Maximum Nominal Corner Radius 25%

1/0 0.3219 0.3249 0.3281 0.039
1 0.2864 0.2893 0.2922 0.039
2 0.2550 0.2576 0.2602 0.039
3 0.2271 0.2294 0.2317 0.039
4 0.2023 0.2043 0.2063 0.039
5 0.1801 0.1819 0.1837 0.039
6 0.1604 0.1620 0.1636 0.031
7 0.1429 0.1443 0.1457 0.031
8 0.1272 0.1285 0.1298 0.031
9 0.1133 0.1144 0.1155 0.026
10 0.1009 0.1019 0.1029 0.026
11 0.0897 0.0907 0.0917 0.020
12 0.0798 0.0808 0.0818 0.020
13 0.0710 0.0720 0.0730 0.016
14 0.0631 0.0641 0.0651 0.016
Dimensions in mm
AWG Minimum Nominal Maximum Nominal Corner Radius 25%
1/0 8.176 8.252 8.334 1.00
1 7.275 7.348 7.422 1.00
2 6.477 6.543 6.609 1.00
3 5.768 5.827 5.885 1.00
4 5.138 5.189 5.240 1.00
5 4.575 4.620 4.666 1.00
6 4.074 4.115 4.155 0.80
7 3.630 3.665 3.701 0.80
8 3.231 3.264 3.297 0.80
9 2.878 2.906 2.934 0.67
10 2.563 2.588 2.614 0.67
11 2.278 2.304 2.329 0.50
12 2.027 2.052 2.078 0.50
13 1.803 1.829 1.854 0.40
14 1.603 1.628 1.654 0.40

MW 1000-2003
Part 1Page 30
Table 1-12
HEAVY AND QUADRUPLE FILM INSULATED SQUARE MAGNET WIRE
INCREASE IN DIMENSIONS DUE TO FILM COATING
Square Heavy Quadruple
AWG Bare Wire Dimensions Radii ( 25%) Minimum Maximum Minimum Maximum
Size Minimum Nominal Maximum Nominal Increase Overall Increase Overall
1 0.2864 0.2893 0.2922 0.039 0.0030 0.2972 0.0050 0.2992

2 0.2550 0.2576 0.2602 0.039 0.0030 0.2652 0.0050 0.2672
3 0.2271 0.2294 0.2317 0.039 0.0030 0.2367 0.0050 0.2387
4 0.2023 0.2043 0.2063 0.039 0.0030 0.2113 0.0050 0.2133
5 0.1801 0.1819 0.1837 0.039 0.0030 0.1887 0.0050 0.1907
6 0.1604 0.1620 0.1636 0.031 0.0030 0.1686 0.0050 0.1706
7 0.1429 0.1443 0.1457 0.031 0.0030 0.1507 0.0050 0.1527
8 0.1272 0.1285 0.1298 0.031 0.0030 0.1348 0.0050 0.1368
9 0.1133 0.1144 0.1155 0.026 0.0030 0.1205 0.0050 0.1225
10 0.1009 0.1019 0.1029 0.026 0.0030 0.1079 0.0050 0.1099
11 0.0897 0.0907 0.0917 0.020 0.0030 0.0967 0.0050 0.0987
12 0.0798 0.0808 0.0818 0.020 0.0030 0.0868 0.0050 0.0888
13 0.0710 0.0720 0.0730 0.016 0.0030 0.0780 0.0050 0.0800
14 0.0631 0.0641 0.0651 0.016 0.0030 0.0701 0.0050 0.0721
Dimensions in mm
Square Heavy Quadruple
AWG Bare Wire Dimensions Radii ( 25%) Minimum Maximum Minimum Maximum
Size Minimum Nominal Maximum Nominal Increase Overall Increase Overall
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

MW 1000-2003
Part 1Page 31
Table 1-13
RANGE OF INCREASE IN DIMENSIONS, INCHES
SINGLE GLASS FIBER COVERED HEAVY FILM INSULATED RECTANGULAR COPPER WIRE
(Applies to MW 42-C Single, MW 43-C Single, and MW 52-C Single)
The increases in the table below apply to the total insulation (film coating plus glass fiber)
Nominal Nominal Width Nominal
Thickness Thickness
2.05
2.18
2.30
2.44
2.59
2.74
2.91
3.08
3.26
3.46
3.66
3.88
4.12
4.36
4.62
4.90
5.19
5.50
5.83
6.18
6.54
6.93
7.35
7.79
8.25
8.74
9.27
9.82
10.40
11.03
11.68
12.38
13.12
mm mm
0.081
0.086
0.091
0.096
0.102
0.108
0.114
0.121
0.128
0.136
0.144
0.153
0.162
0.172
0.182
0.193
0.204
0.217
0.229
0.243
0.258
0.273
0.289
0.307
0.325
0.344
0.365
0.387
0.410
0.434
0.460
0.487
0.517
Inches Inches
1.02 0.040 0.040 1.02

1.15 0.045 0.045 1.15
1.29 0.051 0.008-0.012 0.009-0.013 0.010-0.014 0.011-0.015 0.011-0.016 0.051 1.29
1.45 0.057 0.057 1.45
1.63 0.064 0.064 1.63
1.83 0.072 0.072 1.83
2.05 0.081 0.081 2.05
2.30 0.091 0.091 2.30
2.59 0.102 0.102 2.59
2.91 0.114 0.114 2.91
3.26 0.128 0.128 3.26
3.66 0.144 0.144 3.66
4.12 0.162 0.162 4.12
4.62 0.182 0.182 4.62
5.19 0.204 0.204 5.19
5.83 0.229 0.229 5.83
6.54 0.258 0.258 6.54
NOTE 1 The maximum increase in thickness or width due to the glass fiber covering and treating varnish shall be permitted to be
exceeded, provided the overall thickness or width of the covered wire does not exceed the sum of the maximum thickness or
width of the bare wire plus the maximum increase in dimension given in the table above.
NOTE 2 The increase due to the heavy film insulation shall be in accordance with the applicable section for film insulated wire in Part 2.
NOTE 3 The minimum increases in dimensions in the table above apply only to the increase in thickness.
NOTE 4 The equivalent mm increases in dimensions are shown below.
Inch 0.008 0.009 .010 0.011 0.012 0.013 0.014 0.015 0.016
mm 0.20 0.23 0.25 0.28 0.30 0.33 0.36 0.38 0.41

MW 1000-2003
Part 1Page 32
Table 1-14
DOUBLE GLASS FIBER COVERED BARE RECTANGULAR COPPER WIRE
(Applies to MW 42-C Double, MW 43-C Double, and MW 52-C Double)

Thickness Thickness
2.05
2.18
2.30
2.44
2.59
2.74
2.91
3.08
3.26
3.46
3.66
3.88
4.12
4.36
4.62
4.90
5.19
5.50
5.83
6.18
6.54
6.93
7.35
7.79
8.25
8.74
9.27
9.82
10.40
11.03
11.68
12.38
13.12
mm mm
0.081
0.086
0.091
0.096
0.102
0.108
0.114
0.121
0.128
0.136
0.144
0.153
0.162
0.172
0.182
0.193
0.204
0.217
0.229
0.243
0.258
0.273
0.289
0.307
0.325
0.344
0.365
0.387
0.410
0.434
0.460
0.487
0.517
Inches Inches
1.02 0.040 0.040 1.02

1.15 0.045 0.045 1.15
1.29 0.051 0.008-0.012 0.009-0.013 0.010-0.014 0.011-0.015 0.011-0.016 0.013-0.018 0.051 1.29
1.45 0.057 0.057 1.45
1.63 0.064 0.064 1.63
1.83 0.072 0.072 1.83
2.05 0.081 0.081 2.05
2.30 0.091 0.091 2.30
2.59 0.102 0.102 2.59
2.91 0.114 0.013- 0.114 2.91
3.26 0.128 0.012-0.017 0.019 0.128 3.26
3.66 0.144 0.144 3.66
4.12 0.162 0.162 4.12
4.62 0.182 0.182 4.62
5.19 0.204 0.204 5.19
5.83 0.229 0.229 5.83
6.54 0.258 0.258 6.54
exceeded, provided the overall thickness or width of the covered wire does not exceed the sum of the maximum thickness
or width of the bare wire plus the maximum increase in dimension given in the table above.
NOTE 2 The minimum increases in dimensions in the table above apply only to the increase In thickness.
Inch 0.008 0.009 .010 0.011 0.012 0.013 0.014 0.015 0.016 0.017 0.018 0.019
mm 0.20 0.23 0.25 0.28 0.30 0.33 0.36 0.38 0.41 0.43 0.46 0.48

MW 1000-2003
Part 1Page 33
Table 1-15
DOUBLE GLASS FIBER COVERED HEAVY FILM COATED RECTANGULAR COPPER WIRE
The increases in the table below apply to the total insulation (film coating plus glass fiber)
Thickness Thickness
2.05
2.18
2.30
2.44
2.59
2.74
2.91
3.08
3.26
3.46
3.66
3.88
4.12
4.36
4.62
4.90
5.19
5.50
5.83
6.18
6.54
6.93
7.35
7.79
8.25
8.74
9.27
9.82
10.40
11.03
11.68
12.38
13.12
mm mm
0.081
0.086
0.091
0.096
0.102
0.108
0.114
0.121
0.128
0.136
0.144
0.153
0.162
0.172
0.182
0.193
0.204
0.217
0.229
0.243
0.258
0.273
0.289
0.307
0.325
0.344
0.365
0.387
0.410
0.434
0.460
0.487
0.517
Inches Inches
1.02 0.040 0.040 1.02

1.15 0.045 0.045 1.15
1.29 0.051 0.012-0.017 0.013-0.018 0.013-0.019 0.014-0.020 0.015-0.021 0.016-0.023 0.051 1.29
1.45 0.057 0.057 1.45
1.63 0.064 0.064 1.63
1.83 0.072 0.072 1.83
2.05 0.081 0.081 2.05
2.30 0.091 0.091 2.30
2.59 0.102 0.102 2.59
2.91 0.114 0.017- 0.114 2.91
3.26 0.128 0.015-0.022 0.024 0.128 3.26
3.66 0.144 0.144 3.66
4.12 0.162 0.162 4.12
4.62 0.182 0.182 4.62
5.19 0.204 0.204 5.19
5.83 0.229 0.229 5.83
6.54 0.258 0.258 6.54
exceeded, provided the overall thickness or width of the covered wire does not exceed the sum of the maximum thickness or
width of the bare wire plus the maximum increase in dimension given in the table above.
NOTE 3 The minimum increases in dimension in the table above apply only to the increase in thickness.
Inch 0.012 0.013 0.014 0.015 0.016 0.017 0.018 0.019 0.020 0.021 0.022 0.023 0.024
mm 0.30 0.33 0.36 0.38 0.41 0.43 0.46 0.48 0.51 0.53 0.56 0.58 0.61

MW 1000-2003
Part 1Page 34
Table 1-16
SINGLE POLYESTER GLASS FIBER COVERED HEAVY FILM INSULATED RECTANGULAR COPPER
WIRE
(Applies to MW 46-C Single, MW 48-C Single, and MW 53-C Single)
The increases in the table below apply to the total insulation (film coating plus polyester glass fiber)
Thickness Thickness
2.05
2.18
2.30
2.44
2.59
2.74
2.91
3.08
3.26
3.46
3.66
3.88
4.12
4.36
4.62
4.90
5.19
5.50
5.83
6.18
6.54
6.93
7.35
7.79
8.25
8.74
9.27
9.82
10.40
11.03
11.68
12.38
13.12
mm mm
0.081
0.086
0.091
0.096
0.102
0.108
0.114
0.121
0.128
0.136
0.144
0.153
0.162
0.172
0.182
0.193
0.204
0.217
0.229
0.243
0.258
0.273
0.289
0.307
0.325
0.344
0.365
0.387
0.410
0.434
0.460
0.487
0.517
Inches Inches
1.02 0.040 0.040 1.02

1.15 0.045 0.045 1.15
1.29 0.051 0.007-0.010 0.008-0.011 0.008-0.012 0.009-0.013 0.051 1.29
1.45 0.057 0.057 1.45
1.63 0.064 0.064 1.63
1.83 0.072 0.072 1.83
2.05 0.081 0.081 2.05
2.30 0.091 0.091 2.30
2.59 0.102 0.102 2.59
2.91 0.114 0.114 2.91
3.26 0.128 0.128 3.26
3.66 0.144 0.144 3.66
4.12 0.162 0.162 4.12
4.62 0.182 0.182 4.62
5.19 0.204 0.204 5.19
5.83 0.229 0.229 5.83
6.54 0.258 0.258 6.54
NOTE 1 The maximum increase in thickness or width due to the polyester glass fiber covering and treating varnish, if used shall be
permitted to be exceeded, provided the overall thickness or width of the covered wire does not exceed the sum of the maximum
thickness or width of the bare wire plus the maximum increase in dimension given in the table above.
Inch 0.007 0.008 0.009 0.010 0.011 0.012 0.013

mm 0.18 0.20 0.23 0.25 0.28 0.30 0.33

MW 1000-2003
Part 1Page 35
Table 1-17
DOUBLE POLYESTER GLASS FIBER COVERED BARE RECTANGULAR COPPER WIRE

Thickness Thickness
2.05
2.18
2.30
2.44
2.59
2.74
2.91
3.08
3.26
3.46
3.66
3.88
4.12
4.36
4.62
4.90
5.19
5.50
5.83
6.18
6.54
6.93
7.35
7.79
8.25
8.74
9.27
9.82
10.40
11.03
11.68
12.38
13.12
mm mm
0.081
0.086
0.091
0.096
0.102
0.108
0.114
0.121
0.128
0.136
0.144
0.153
0.162
0.172
0.182
0.193
0.204
0.217
0.229
0.243
0.258
0.273
0.289
0.307
0.325
0.344
0.365
0.387
0.410
0.434
0.460
0.487
0.517
Inches Inches
1.02 0.040 0.040 1.02

1.15 0.045 0.045 1.15
1.29 0.051 0.008-0.011 0.008-0.012 0.009-0.013 0.010-0.014 0.011-0.015 0.011-0.016 0.051 1.29
1.45 0.057 0.057 1.45
1.63 0.064 0.064 1.63
1.83 0.072 0.072 1.83
2.05 0.081 0.081 2.05
2.30 0.091 0.091 2.30
2.59 0.102 0.009-0.013 0.102 2.59
2.91 0.114 0.114 2.91
3.26 0.128 0.128 3.26
3.66 0.144 0.011-0.015 0.144 3.66
4.12 0.162 0.162 4.12
4.62 0.182 0.182 4.62
5.19 0.204 0.204 5.19
5.83 0.229 0.229 5.83
6.54 0.258 0.258 6.54
Inch 0.008 0.009 0.010 0.011 0.012 0.013 0.014 0.015 0.016
mm 0.20 0.23 0.25 0.28 0.30 0.33 0.36 0.38 0.41

MW 1000-2003
Part 1Page 36
Table 1-18
DOUBLE POLYESTER GLASS FIBER COVERED HEAVY FILM COATED RECTANGULAR COPPER
WIRE
Applies to MW 46-C Double, MW 48-C Double, and MW 53-C Double
The increases in the table below apply to the total insulation (film coating plus polyester glass fiber)
Thickness Thickness
2.05
2.18
2.30
2.44
2.59
2.74
2.91
3.08
3.26
3.46
3.66
3.88
4.12
4.36
4.62
4.90
5.19
5.50
5.83
6.18
6.54
6.93
7.35
7.79
8.25
8.74
9.27
9.82
10.40
11.03
11.68
12.38
13.12
mm mm
0.081
0.086
0.091
0.096
0.102
0.108
0.114
0.121
0.128
0.136
0.144
0.153
0.162
0.172
0.182
0.193
0.204
0.217
0.229
0.243
0.258
0.273
0.289
0.307
0.325
0.344
0.365
0.387
0.410
0.434
0.460
0.487
0.517
Inches Inches
1.02 0.040 0.040 1.02

1.15 0.045 0.045 1.15
1.29 0.051 0.011-0.016 0.012-0.017 0.013-0.018 0.013-0.019 0.014-0.020 0.015-0.021 0.051 1.29
1.45 0.057 0.057 1.45
1.63 0.064 0.064 1.63
1.83 0.072 0.072 1.83
2.05 0.081 0.081 2.05
2.30 0.091 0.091 2.30
2.59 0.102 0.013-0.018 0.102 2.59
2.91 0.114 0.114 2.91
3.26 0.128 0.128 3.26
3.66 0.144 0.014-0.020 0.144 3.66
4.12 0.162 0.162 4.12
4.62 0.182 0.182 4.62
5.19 0.204 0.204 5.19
5.83 0.229 0.229 5.83
6.54 0.258 0.258 6.54
NOTE 3 The minimum increases in dimension in the table above apply only to the increase in thickness.
Inch 0.011 0.012 0.013 0.014 0.015 0.016 0.017 0018 0.019 0.020 0.021
mm 0.28 0.30 0.33 0.36 0.38 0.41 043 0.46 0.48 0.51 0.53

MW 1000-2003
Part 1Page 37
Table 1-19
SINGLE GLASS FIBER COVERED, HEAVY FILM INSULATED SQUARE COPPER MAGNET WIRE
MINIMUM INCREASE AND MAXIMUM OVERALL DIMENSIONS DUE TO INSULATION
Applies to MW 42-C Single, MW 43-C Single and MW 52-C Single
Dimensions in Inches
Heavy Film Coated
Single Glass Covered
AWG Bare Wire Dimensions Radii ( 25%) Minimum Maximum
Size Minimum Nominal Maximum Nominal Increase Overall
1/0 0.3219 0.3249 0.3279 0.039 0.011 0.344
1 0.2864 0.2893 0.2922 0.039 0.010 0.307
2 0.2550 0.2576 0.2602 0.039 0.010 0.275
3 0.2271 0.2294 0.2317 0.039 0.010 0.247
4 0.2023 0.2043 0.2063 0.039 0.010 0.221
5 0.1801 0.1819 0.1837 0.039 0.009 0.198
6 0.1604 0.1620 0.1636 0.031 0.009 0.178
7 0.1429 0.1443 0.1457 0.031 0.009 0.159
8 0.1272 0.1285 0.1298 0.031 0.009 0.143
9 0.1133 0.1144 0.1155 0.026 0.009 0.129
10 0.1009 0.1019 0.1029 0.026 0.009 0.116
11 0.0897 0.0907 0.0917 0.020 0.008 0.104
12 0.0798 0.0808 0.0818 0.020 0.008 0.094
13 0.0710 0.0720 0.0730 0.016 0.008 0.085
14 0.0631 0.0641 0.0651 0.016 0.008 0.077
Dimensions in mm
Heavy Film Coated
Single Glass Covered
1/0 8.176 8.252 8.329 1.00 0.279 8.738
1 7.275 7.348 7.422 1.00 0.254 7.798
2 6.477 6.543 6.609 1.00 0.254 6.985
3 5.768 5.827 5.885 1.00 0.254 6.274
4 5.138 5.189 5.240 1.00 0.254 5.613
5 4.575 4.620 4.666 1.00 0.229 5.029
6 4.074 4.115 4.155 0.80 0.229 4.521
7 3.630 3.665 3.701 0.80 0.229 4.039
8 3.231 3.264 3.297 0.80 0.229 3.632
9 2.878 2.906 2.934 0.67 0.229 3.277
10 2.563 2.588 2.614 0.67 0.229 2.946
11 2.278 2.304 2.329 0.50 0.203 2.642
12 2.027 2.052 2.078 0.50 0.203 2.388
13 1.803 1.829 1.854 0.40 0.203 2.159
14 1.603 1.628 1.654 0.40 0.203 1.956

MW 1000-2003
Part 1Page 38
Table 1-20
SINGLE POLYESTER GLASS FIBER COVERED HEAVY FILM INSULATED SQUARE COPPER MAGNET
WIREMINIMUM INCREASE AND MAXIMUM OVERALL DIMENSIONS DUE TO INSULATION
Applies to MW 46-C Single, MW 48-C Single and MW 53-C Single
Heavy Film Coated Single
Polyester Glass Covered
1/0 0.3219 0.3249 0.3279 0.039 0.009 0.341
1 0.2864 0.2893 0.2922 0.039 0.009 0.305
2 0.2550 0.2576 0.2602 0.039 0.008 0.272
3 0.2271 0.2294 0.2317 0.039 0.008 0.244
4 0.2023 0.2043 0.2063 0.039 0.008 0.219
5 0.1801 0.1819 0.1837 0.039 0.008 0.196
6 0.1604 0.1620 0.1636 0.031 0.008 0.175
7 0.1429 0.1443 0.1457 0.031 0.008 0.157
8 0.1272 0.1285 0.1298 0.031 0.008 0.141
9 0.1133 0.1144 0.1155 0.026 0.008 0.127
10 0.1009 0.1019 0.1029 0.026 0.007 0.113
11 0.0897 0.0907 0.0917 0.020 0.007 0.102
12 0.0798 0.0808 0.0818 0.020 0.007 0.092
13 0.0710 0.0720 0.0730 0.016 0.007 0.084
14 0.0631 0.0641 0.0651 0.016 0.007 0.076
Dimensions in mm
Heavy Film Coated Single
Polyester Glass Covered
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

MW 1000-2003
Part 1Page 39
Table 1-21
DOUBLE GLASS FIBER COVERED, BARE OR HEAVY FILM INSULATED SQUARE COPPER MAGNET
WIREMINIMUM INCREASE AND MAXIMUM OVERALL DIMENSIONS DUE TO INSULATION
Applies to MW 42-C Double, MW 43-C Double and MW 52-C Double
Bare Heavy-film-coated
Double-glass-covered Double-glass-covered
Square Bare Wire Dimensions Nominal Minimum Maximum Minimum Maximum
AWG Minimum Nominal Maximum Radii 25% Increase Overall Increase* Overall
Size inches inches inches Inches Inches inches inches inches
1/0 0.3219 0.3249 0.3279 0.039 0.013 0.346 0.016 0.351
1 0.2864 0.2893 0.2922 0.039 0.012 0.309 0.015 0.314
2 0.2550 0.2576 0.2602 0.039 0.012 0.277 0.015 0.282
3 0.2271 0.2294 0.2317 0.039 0.011 0.248 0.014 0.253
4 0.2023 0.2043 0.2063 0.039 0.011 0.222 0.014 0.227
5 0.1801 0.1819 0.1837 0.039 0.011 0.199 0.014 0.204
6 0.1604 0.1620 0.1636 0.031 0.011 0.179 0.014 0.184
7 0.1429 0.1443 0.1457 0.031 0.010 0.160 0.013 0.165
8 0.1272 0.1285 0.1298 0.031 0.010 0.144 0.013 0.149
9 0.1133 0.1144 0.1155 0.026 0.009 0.129 0.012 0.134
10 0.1009 0.1019 0.1029 0.026 0.009 0.116 0.012 0.121
11 0.0897 0.0907 0.0917 0.020 0.008 0.104 0.011 0.109
12 0.0798 0.0808 0.0818 0.020 0.008 0.094 0.011 0.099
13 0.0710 0.0720 0.0730 0.016 0.008 0.085 0.011 0.090
14 0.0631 0.0641 0.0651 0.016 0.008 0.077 0.011 0.082
* Minimum increase including film insulation
Dimensions in mm
Bare Heavy-film-insulated
Size mm mm mm mm mm mm mm mm
1/0 8.176 8.252 8.329 1.00 0.330 8.788 0.406 8.915
1 7.275 7.348 7.422 1.00 0.305 7.849 0.381 7.976
2 6.477 6.543 6.609 1.00 0.305 7.036 0.381 7.163
3 5.768 5.827 5.885 1.00 0.279 6.299 0.356 6.426
4 5.138 5.189 5.240 1.00 0.279 5.639 0.356 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 0.254 3.658 0.330 3.785
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 0.229 2.946 0.305 3.073
11 2.278 2.304 2.329 0.50 0.203 2.642 0.279 2.769
12 2.027 2.052 2.078 0.50 0.203 2.388 0.279 2.515
13 1.803 1.829 1.854 0.40 0.203 2.159 0.279 2.286
14 1.603 1.628 1.654 0.40 0.203 1.956 0.279 2.083

MW 1000-2003
Part 1Page 40
Table 1-22
DOUBLE POLYESTER GLASS FIBER COVERED, BARE OR HEAVY FILM INSULATED SQUARE COPPER
MAGNET WIREMINIMUM INCREASE AND MAXIMUM OVERALL DIMENSIONS DUE TO INSULATION
Applies to MW 46-C Double, MW 48-C Double and MW 53-C Double
Bare Heavy-film-coated
Size inches inches inches Inches Inches inches inches inches
1/0 0.3219 0.3249 0.3279 0.039 0.012 0.344 0.015 0.349
1 0.2864 0.2893 0.2922 0.039 0.012 0.308 0.015 0.313
2 0.2550 0.2576 0.2602 0.039 0.012 0.276 0.015 0.281
3 0.2271 0.2294 0.2317 0.039 0.012 0.248 0.015 0.253
4 0.2023 0.2043 0.2063 0.039 0.012 0.222 0.015 0.227
5 0.1801 0.1819 0.1837 0.039 0.011 0.199 0.014 0.204
6 0.1604 0.1620 0.1636 0.031 0.011 0.179 0.014 0.184
7 0.1429 0.1443 0.1457 0.031 0.010 0.160 0.013 0.165
8 0.1272 0.1285 0.1298 0.031 0.009 0.143 0.012 0.148
9 0.1133 0.1144 0.1155 0.031 0.009 0.129 0.012 0.134
10 0.1009 0.1019 0.1029 0.026 0.008 0.115 0.011 0.120
11 0.0897 0.0907 0.0917 0.020 0.008 0.103 0.011 0.108
12 0.0798 0.0808 0.0818 0.020 0.008 0.093 0.011 0.098
13 0.0710 0.0720 0.0730 0.016 0.008 0.084 0.011 0.089
14 0.0631 0.0641 0.0651 0.016 0.008 0.076 0.011 0.081
Dimensions in mm
Bare Heavy-film-insulated
Size mm mm mm mm mm mm mm mm
1/0 8.176 8.252 8.329 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

MW 1000-2003
Part 1Page 41
Table 1-23
COMPARISON BETWEEN AWG AND IEC R-40 SERIES BARE WIRE DIAMETERS
Nominal Nominal Nominal ** Nominal % Difference

Bare Wire Dia. R-40 AWG R-40 Series Nominal Nominal
AWG Diameter Series Area Area Diameter Area AWG
Size inches mm* mm mm mm R-40 to AWG R-40 to AWG Size
4 0.2043 5.189 5.000 21.149 19.635 -3.6 -7.2 4
4.5 0.1928 4.897 4.750 18.835 17.721 -3.0 -5.9 4.5
5 0.1819 4.620 4.500 16.766 15.904 -2.6 -5.1 5
5.5 0.1717 4.361 4.250 14.938 14.186 -2.5 -5.0 5.5
6 0.1620 4.115 4.000 13.298 12.566 -2.8 -5.5 6
6.5 0.1529 3.884 3.750 11.846 11.045 -3.4 -6.8 6.5
7 0.1443 3.665 3.550 10.551 9.898 -3.1 -6.2 7
7.5 0.1362 3.459 3.350 9.400 8.814 -3.2 -6.2 7.5
8 0.1285 3.264 3.150 8.367 7.793 -3.5 -6.9 8
8.5 0.1213 3.081 3.000 7.456 7.069 -2.6 -5.2 8.5
9 0.1144 2.906 2.800 6.631 6.158 -3.6 -7.1 9
9.5 0.1080 2.743 2.650 5.910 5.515 -3.4 -6.7 9.5
10 0.1019 2.588 2.500 5.261 4.909 -3.4 -6.7 10
10.5 0.0962 2.443 2.360 4.689 4.374 -3.4 -6.7 10.5
11 0.0907 2.304 2.240 4.168 3.941 -2.8 -5.5 11
11.5 0.0856 2.174 2.120 3.713 3.530 -2.5 -4.9 11.5
12 0.0808 2.052 2.000 3.308 3.142 -2.5 -5.0 12
12.5 0.0763 1.938 1.900 2.950 2.835 -2.0 -3.9 12.5
13 0.0720 1.829 1.800 2.627 2.545 -1.6 -3.1 13
13.5 0.0679 1.725 1.700 2.336 2.270 -1.4 -2.8 13.5
14 0.0641 1.628 1.600 2.082 2.011 -1.7 -3.4 14
14.5 0.0605 1.537 1.500 1.855 1.767 -2.4 -4.7 14.5
15 0.0571 1.450 1.400 1.652 1.539 -3.5 -6.8 15
15.5 0.0539 1.369 1.320 1.472 1.368 -3.6 -7.0 15.5
16 0.0508 1.290 1.250 1.308 1.227 -3.1 -6.2 16
16.5 0.0480 1.219 1.180 1.167 1.094 -3.2 -6.3 16.5
17 0.0453 1.151 1.120 1.040 0.985 -2.7 -5.3 17
17.5 0.0427 1.085 1.060 0.924 0.882 -2.3 -4.5 17.5
18 0.0403 1.024 1.000 0.823 0.785 -2.3 -4.6 18
18.5 0.0380 0.965 0.950 0.732 0.709 -1.6 -3.1 18.5
19 0.0359 0.912 0.900 0.653 0.636 -1.3 -2.6 19
19.5 0.0339 0.861 0.850 0.582 0.567 -1.3 -2.6 19.5
20 0.0320 0.813 0.800 0.519 0.503 -1.6 -3.1 20
20.5 0.0302 0.767 0.750 0.462 0.442 -2.2 -4.4 20.5
21 0.0285 0.724 0.710 0.412 0.396 -1.9 -3.8 21
21.5 0.0269 0.683 0.670 0.367 0.353 -1.9 -3.8 21.5
22 0.0253 0.643 0.630 0.324 0.312 -2.0 -3.9 22
22.5 0.0239 0.607 0.600 0.289 0.283 -1.2 -2.3 22.5
23 0.0226 0.574 0.560 0.259 0.246 -2.4 -4.8 23
23.5 0.0213 0.541 0.530 0.230 0.221 -2.0 -4.0 23.5
24 0.0201 0.511 0.500 0.205 0.196 -2.1 -4.1 24
24.5 0.0190 0.483 0.475 0.183 0.177 -1.6 -3.1 24.5
25 0.0179 0.455 0.450 0.162 0.159 -1.0 -2.0 25
25.5 0.0169 0.429 0.425 0.145 0.142 -1.0 -2.0 25.5
26 0.0159 0.404 0.400 0.128 0.126 -1.0 -1.9 26
26.5 0.0150 0.381 0.375 0.114 0.110 -1.6 -3.1 26.5
* These diameters are rounded numbers calculated from the inch values.
** The nominal area of AWG wires have been calculated in square inch units and then converted to square millimeters.
The differences in diameter and area have been calculated from values more precise than those shown in the table.

MW 1000-2003
Part 1Page 42
Table 1-23 Continued

Nominal Nominal Nominal ** Nominal % Difference
Bare Wire Dia. R-40 AWG R-40 Series Nominal Nominal
AWG Diameter Series Area Area Diameter Area AWG
2 2
Size inches mm* mm mm mm R-40 to AWG R-40 to AWG Size
27 0.0142 0.361 0.355 0.102 0.0990 -1.6 -3.1 27
27.5 0.0134 0.340 0.335 0.0910 0.0881 -1.6 -3.1 27.5
28 0.0126 0.320 0.315 0.0804 0.0779 -1.6 -3.1 28
28.5 0.0119 0.302 0.300 0.0718 0.0707 -0.8 -1.5 28.5
29 0.0113 0.287 0.280 0.0647 0.0616 -2.4 -4.8 29
29.5 0.0106 0.269 0.265 0.0569 0.0552 -1.6 -3.1 29.5
30 0.0100 0.254 0.250 0.0507 0.0491 -1.6 -3.1 30
30.5 0.0095 0.241 0.236 0.0457 0.0437 -2.2 -4.3 30.5
31 0.0089 0.226 0.224 0.0401 0.0394 -0.9 -1.8 31
31.5 0.0084 0.213 0.212 0.0358 0.0353 -0.7 -1.3 31.5
32 0.0080 0.203 0.200 0.0324 0.0314 -1.6 -3.1 32
32.5 0.0075 0.191 0.190 0.0285 0.0284 -0.3 -0.5 32.5
33 0.0071 0.180 0.180 0.0255 0.0254 -0.2 -0.4 33
33.5 0.0067 0.170 0.170 0.0227 0.0227 -0.1 -0.2 33.5
34 0.0063 0.160 0.160 0.0201 0.0201 0.0 0.0 34
34.5 0.0059 0.150 0.150 0.0176 0.0177 0.1 0.2 34.5
35 0.0056 0.142 0.140 0.0159 0.0154 -1.5 -3.1 35
35.5 0.0053 0.135 0.132 0.0142 0.0137 -1.9 -3.9 35.5
36 0.0050 0.127 0.125 0.0127 0.0123 -1.6 -3.1 36
36.5 0.0047 0.119 0.118 0.0112 0.0109 -1.2 -2.3 36.5
37 0.0045 0.114 0.112 0.0103 0.00985 -2.0 -4.0 37
37.5 0.0042 0.107 0.106 0.00894 0.00882 -0.7 -1.3 37.5
38 0.0040 0.102 0.100 0.00811 0.00785 -1.6 -3.1 38
38.5 0.0037 0.094 0.095 0.00694 0.00709 1.1 2.2 38.5
39 0.0035 0.089 0.090 0.00621 0.00636 1.2 2.5 39
39.5 0.0033 0.084 0.085 0.00552 0.00567 1.4 2.8 39.5
40 0.0031 0.079 0.080 0.00487 0.00503 1.7 3.2 40
40.5 0.0030 0.076 0.075 0.00456 0.00442 -1.6 -3.1 40.5
41 0.0028 0.071 0.071 0.00397 0.00396 -0.1 -0.3 41
41.5 0.0026 0.066 0.067 0.00343 0.00353 1.5 2.9 41.5
42 0.0025 0.064 0.063 0.00317 0.00312 -0.8 -1.6 42
42.5 0.0024 0.061 0.060 0.00292 0.00283 -1.6 -3.1 42.5
43 0.0022 0.056 0.056 0.00245 0.00243 0.2 0.4 43
43.5 0.0021 0.053 0.053 0.00223 0.00221 -0.6 -1.3 43.5
44 0.0020 0.051 0.050 0.00203 0.00196 -1.6 -3.1 44
44.5 0.0019 0.048 0.048 0.00183 0.00177 -0.6 -1.1 44.5
* These diameters are rounded numbers calculated from the inch values.
** The nominal area of AWG wires have been calculated in square inch units and then converted to square millimeters.
The differences in diameter and area have been calculated from values more precise than those shown in the table.

Table 1-24
COMPARISON BETWEEN NEMA AND IEC INCREASES AND OVERALL DIAMETERS
(inches)
Single Heavy Triple IEC Grade 1* Grade 2* Grade 3*
AWG Nominal Minimum Maximum Minimum Maximum Minimum Maximum Nominal Minimum Maximum Minimum Maximum Minimum Maximum AWG
Size Bare Increase O.D. Increase O.D. Increase O.D. Diameter** Increase O.D. Increase O.D. Increase O.D. Size
14 0.0641 0.0016 0.0666 0.0032 0.0682 0.0048 0.0698 0.0630 0.0015 0.0657 0.0028 0.0672 0.0042 0.0685 14
15 0.0571 0.0015 0.0594 0.0030 0.0610 0.0046 0.0625 0.0551 0.0014 0.0578 0.0027 0.0591 0.0041 0.0604 15
16 0.0508 0.0014 0.0531 0.0029 0.0545 0.0043 0.0560 0.0492 0.0014 0.0518 0.0026 0.0531 0.0039 0.0544 16
17 0.0453 0.0014 0.0475 0.0028 0.0488 0.0041 0.0502 0.0441 0.0013 0.0466 0.0026 0.0479 0.0039 0.0491 17
18 0.0403 0.0013 0.0424 0.0026 0.0437 0.0039 0.0450 0.0394 0.0013 0.0418 0.0025 0.0431 0.0037 0.0443 18
19 0.0359 0.0012 0.0379 0.0025 0.0391 0.0037 0.0404 0.0354 0.0013 0.0378 0.0024 0.0389 0.0035 0.0401 19
20 0.0320 0.0012 0.0340 0.0024 0.0351 0.0035 0.0363 0.0315 0.0012 0.0337 0.0022 0.0348 0.0335 0.0359 20
21 0.0285 0.0011 0.0303 0.0022 0.0315 0.0034 0.0326 0.0280 0.0011 0.0300 0.0021 0.0311 0.0031 0.0320 21
22 0.0253 0.0011 0.0270 0.0021 0.0281 0.0032 0.0292 0.0248 0.0011 0.0267 0.0020 0.0277 0.0030 0.0287 22
23 0.0226 0.0010 0.0243 0.0020 0.0253 0.0030 0.0263 0.0220 0.0010 0.0239 0.0019 0.0248 0.0028 0.0257 23
24 0.0201 0.0010 0.0217 0.0019 0.0227 0.0029 0.0236 0.0197 0.0009 0.0214 0.0018 0.0223 0.0026 0.0231 24
25 0.0179 0.0009 0.0194 0.0018 0.0203 0.0027 0.0212 0.0177 0.0009 0.0193 0.0017 0.0202 0.0025 0.0210 25
26 0.0159 0.0009 0.0173 0.0017 0.0182 0.0026 0.0191 0.0157 0.0008 0.0173 0.0016 0.0181 0.0024 0.0188 26
27 0.0142 0.0008 0.0156 0.0016 0.0165 0.0025 0.0173 0.0140 0.0008 0.0154 0.0015 0.0162 0.0022 0.0169 27
28 0.0126 0.0008 0.0140 0.0016 0.0147 0.0023 0.0155 0.0124 0.0007 0.0137 0.0014 0.0144 0.0021 0.0151 28
29 0.0113 0.0007 0.0126 0.0015 0.0133 0.0022 0.0141 0.0110 0.0007 0.0123 0.0013 0.0130 0.0020 0.0136 29
30 0.0100 0.0007 0.0112 0.0013 0.0119 0.0020 0.0128 0.0098 0.0007 0.0111 0.0013 0.0117 0.0019 0.0123 30
31 0.0089 0.0006 0.0100 0.0012 0.0108 0.0018 0.0114 0.0088 0.0006 0.0099 0.0011 0.0105 0.0017 0.0110 31
32 0.0080 0.0006 0.0091 0.0011 0.0098 0.0017 0.0103 0.0079 0.0006 0.0089 0.0011 0.0094 0.0015 0.0099 32
33 0.0071 0.0005 0.0081 0.0010 0.0088 0.0015 0.0092 0.0071 0.0005 0.0080 0.0010 0.0085 0.0014 0.0090 33
34 0.0063 0.0005 0.0072 0.0009 0.0078 0.0014 0.0082 0.0063 0.0005 0.0072 0.0009 0.0076 0.0013 0.0081 34
35 0.0056 0.0004 0.0064 0.0009 0.0070 0.0013 0.0074 0.0055 0.0004 0.0063 0.0008 0.0067 0.0012 0.0071 35
36 0.0050 0.0004 0.0058 0.0008 0.0063 0.0012 0.0067 0.0049 0.0004 0.0057 0.0007 0.0061 0.0011 0.0064 36
37 0.0045 0.0004 0.0053 0.0007 0.0057 0.0011 0.0060 0.0044 0.0004 0.0051 0.0007 0.0055 0.0010 0.0058 37
38 0.0040 0.0003 0.0047 0.0007 0.0051 0.0010 0.0054 0.0039 0.0003 0.0046 0.0006 0.0049 0.0009 0.0052 38
39 0.0035 0.0003 0.0041 0.0006 0.0045 0.0009 0.0048 0.0035 0.0003 0.0041 0.0006 0.0044 0.0009 0.0047 39
40 0.0031 0.0003 0.0037 0.0005 0.0040 0.0008 0.0043 0.0031 0.0003 0.0037 0.0006 0.0040 0.0008 0.0043 40

* Minimum increases and maximum overall diameters based upon IEC 60317-0-1 and converted to inches using the factor 25.4, exact.
** Nominal diameters are based upon the ISO R-20 series.
NOTENo minimum increases are given for grades 2 and 3 for nominal sizes smaller than 0.071 mm in IEC 60317-0-1.
Part 1Page 43
MW 1000-2003
Part 1Page 44
MW 1000-2003
(inches)
41 0.0028 0.0003 0.0034 0.0005 0.0036 0.0008 0.0040 0.0028 0.0003 0.0033 0.0005 0.0036 0.0007 0.0038 41
42 0.0025 0.0002 0.0030 0.0005 0.0033 0.0007 0.0036 0.0025 0.0002 0.0030 ... 0.0033 ... ... 42
43 0.0022 0.0002 0.0026 0.0004 0.0029 0.0006 0.0032 0.0022 0.0002 0.0026 ... 0.0029 ... ... 43
44 0.0020 0.0002 0.0024 0.0004 0.0027 0.0006 0.0030 0.0020 0.0002 0.0024 ... 0.0026 ... ... 44
45 0.00176 0.0002 0.0022 0.0004 0.0024 0.0005 0.0027 0.0018 0.0002 0.0022 ... 0.0024 ... ... 45
46 0.00157 0.0002 0.0020 0.0003 0.0021 0.0005 0.0024 0.0016 0.0002 0.0019 ... 0.0021 ... ... 46
47 0.00140 0.0001 0.0017 0.0003 0.0019 ... ... 0.0014 0.0002 0.0017 ... 0.0019 ... ... 47
48 0.00124 0.0001 0.0015 0.0002 0.0017 ... ... 0.0013 0.0001 0.0015 ... 0.0017 ... ... 48
49 0.00111 0.0001 0.0013 0.0002 0.0015 ... ... 0.0011 0.0001 0.0013 ... 0.0015 ... ... 49
50 0.00099 0.0001 0.0012 0.0002 0.0014 ... ... 0.0010 0.0001 0.0012 ... 0.0013 ... ... 50
51 0.00088 0.00010 0.00110 ... ... ... ... 0.0009 0.0001 0.0011 ... 0.0012 ... ... 51
52 0.00078 0.00010 0.00100 ... ... ... ... 0.0008 0.0001 0.0009 ... 0.0011 ... ... 52
53 0.00070 0.00005 0.00085 ... ... ... ... 0.0007 0.0001 0.00087 ... 0.00094 ... ... 53
54 0.00062 0.00005 0.00075 ... ... ... ... ... ... ... ... ... ... ... 54
55 0.00055 0.00005 0.00070 ... ... ... ... ... ... ... ... ... ... ... 55
56 0.00049 0.00005 0.00065 ... ... ... ... ... ... ... ... ... ... ... 56
* Minimum increases and maximum overall diameters based upon IEC 60317-0-1 and converted to inches using the factor 25.4, exact.
Table 1-24
COMPARISON BETWEEN NEMA AND IEC INCREASES AND OVERALL DIAMETERS
(millimeters)
14 1.628 0.041 1.692 0.081 1.732 0.122 1.773 1.600 0.038 1.670 0.071 1.706 0.107 1.740 14
15 1.450 0.038 1.509 0.076 1.549 0.117 1.588 1.400 0.036 1.468 0.069 1.502 0.103 1.535 15
16 1.290 0.036 1.349 0.074 1.384 0.109 1.422 1.250 0.035 1.316 0.067 1.349 0.100 1.381 16
17 1.151 0.036 1.207 0.071 1.240 0.104 1.275 1.120 0.034 1.184 0.065 1.217 0.098 1.248 17
18 1.024 0.033 1.077 0.066 1.110 0.099 1.143 1.000 0.034 1.062 0.063 1.094 0.095 1.124 18
19 0.912 0.030 0.963 0.064 0.993 0.094 1.026 0.900 0.032 0.959 0.060 0.989 0.090 1.018 19
20 0.813 0.030 0.864 0.061 0.892 0.089 0.922 0.800 0.030 0.855 0.056 0.884 0.850 0.911 20
21 0.724 0.028 0.770 0.056 0.800 0.086 0.828 0.710 0.028 0.762 0.053 0.789 0.080 0.814 21
22 0.643 0.028 0.686 0.053 0.714 0.081 0.742 0.630 0.027 0.679 0.050 0.704 0.075 0.728 22
23 0.574 0.025 0.617 0.051 0.643 0.076 0.668 0.560 0.025 0.606 0.047 0.630 0.071 0.653 23
24 0.511 0.025 0.551 0.048 0.577 0.074 0.599 0.500 0.024 0.544 0.045 0.566 0.067 0.587 24
25 0.455 0.023 0.493 0.046 0.516 0.069 0.538 0.450 0.022 0.491 0.042 0.513 0.064 0.533 25
26 0.404 0.023 0.439 0.043 0.462 0.066 0.485 0.400 0.021 0.439 0.040 0.459 0.060 0.478 26
27 0.361 0.020 0.396 0.041 0.419 0.064 0.439 0.355 0.020 0.392 0.038 0.411 0.057 0.428 27
28 0.320 0.020 0.356 0.041 0.373 0.058 0.394 0.315 0.019 0.349 0.035 0.367 0.053 0.384 28
29 0.287 0.018 0.320 0.038 0.338 0.056 0.358 0.280 0.018 0.312 0.033 0.329 0.050 0.345 29
30 0.254 0.018 0.284 0.033 0.302 0.051 0.325 0.250 0.017 0.281 0.032 0.297 0.048 0.312 30
31 0.226 0.015 0.254 0.030 0.274 0.046 0.290 0224 0.015 0.252 0.029 0.266 0.043 0.280 31
32 0.203 0.015 0.231 0.028 0.249 0.043 0.262 0.200 0.014 0.226 0.027 0.239 0.039 0.252 32
33 0.180 0.013 0.206 0.025 0.224 0.038 0.234 0.180 0.013 0.204 0.025 0.217 0.036 0.229 33
34 0.160 0.013 0.183 0.023 0.198 0.036 0.208 0.160 0.012 0.182 0.023 0.194 0.033 0.205 34
35 0.142 0.010 0.163 0.023 0.178 0.033 0.188 0.140 0.011 0.160 0.021 0.171 0.030 0.181 35
36 0.127 0.010 0.147 0.020 0.160 0.030 0.170 0.125 0.010 0.144 0.019 0.154 0.028 0.163 36
37 0.114 0.010 0.135 0.018 0.145 0.028 0.152 0.112 0.009 0.130 0.017 0.139 0.026 0.147 37
38 0.102 0.008 0.119 0.018 0.130 0.025 0.137 0.100 0.008 0.117 0.016 0.125 0.023 0.132 38
39 0.089 0.008 0.104 0.015 0.114 0.023 0.122 0.090 0.008 0.105 0.015 0.113 0.022 0.120 39
40 0.079 0.008 0.094 0.013 0.102 0.020 0.109 0.080 0.007 0.094 0.014 0.101 0.020 0.108 40

* Minimum increases and maximum overall diameters based upon IEC 60317-0-1.
Part 1Page 45
MW 1000-2003
Part 1Page 46
MW 1000-2003
(millimeters)
41 0.071 0.008 0.086 0.013 0.091 0.020 0.102 0.071 0.007 0.084 0.012 0.091 0.018 0.097 41
42 0.064 0.005 0.076 0.013 0.084 0.018 0.091 0.063 0.006 0.076 ... 0.083 ... ... 42
43 0.056 0.005 0.066 0.010 0.074 0.015 0.081 0.056 0.006 0.067 ... 0.074 ... ... 43
44 0.051 0.005 0.061 0.010 0.069 0.015 0.076 0.050 0.005 0.060 ... 0.066 ... ... 44
45 0.0447 0.0050 0.0559 0.0100 0.0610 0.0127 0.0686 0.045 0.005 0.055 ... 0.061 ... ... 45
46 0.0399 0.0050 0.0508 0.0076 0.0533 0.0127 0.0610 0.040 0.004 0.049 ... 0.054 ... ... 46
47 0.0356 0.0025 0.0432 0.0076 0.0483 ... ... 0.036 0.004 0.044 ... 0.049 ... ... 47
48 0.0315 0.0025 0.0381 0.0051 0.0432 ... ... 0.032 0.003 0.039 ... 0.043 ... ... 48
49 0.0282 0.0025 0.0330 0.0051 0.0381 ... ... 0.028 0.003 0.034 ... 0.038 ... ... 49
50 0.0251 0.0025 0.0305 0.0051 0.0356 ... ... 0.025 0.003 0.031 ... 0.034 ... ... 50
51 0.0224 0.0025 0.0279 ... ... ... ... 0.022 0.002 0.027 ... 0.030 ... ... 51
52 0.0198 0.0025 0.0254 ... ... ... ... 0.020 0.002 0.024 ... 0.027 ... ... 52
53 0.0178 0.0013 0.0216 ... ... ... ... 0.018 0.002 0.022 ... 0.024 ... ... 53
54 0.0157 0.0013 0.0191 ... ... ... ... ... ... ... ... ... ... ... 54
55 0.0140 0.0013 0.0178 ... ... ... ... ... ... ... ... ... ... ... 55
56 0.0124 0.0013 0.0165 ... ... ... ... ... ... ... ... ... ... ... 56
* Minimum increases and maximum overall diameters based upon IEC 60317-0-1.
MW 1000-2003
Part 2Page 1
Part 2
PROPERTIES AND REQUIREMENTS
All properties and requirements for magnet wire contained in Part 2 shall be as indicated in the following
specification sheets.

MW 1000-2003
Part 2Page 2
MW 2-C
POLYURETHANE FILM INSULATED ROUND COPPER MAGNET WIRE
FOR SOLDERABLE APPLICATIONS, THERMAL CLASS 105
INSULATING MATERIAL The coating is based on polyurethane resins (1.4.2).

THERMAL CLASS 105 as defined in Part 1, Clause 1.8, and when tested in accordance with Part 3,
Clause 3.58.1.
GENERAL REQUIREMENTS See Part 1.
Properties Procedure, Requirement

Part 3, Clause
DIMENSIONS 3.2.1.1 Single 2556 AWG; Heavy 2550 AWG in accordance with Table 1-1
ADHERENCE AND FLEXIBILITY 3.3.1 No cracks visible in the film coating
ELONGATION 3.4 Not less than value in Table 3.4.2
HEAT SHOCK 3.5 No cracks visible in the film coating after conditioning at 150C, following a
20% sudden jerk elongation, using a 6d mandrel for sizes 2544 AWG
SPRINGBACK 3.7.1 Not greater than the value in Table 3.7.1
DIELECTRIC BREAKDOWN 3.8.3 2537 AWG Not less than the value in Table 3.8.3.2
3.8.7 3856 AWG Not less than the value in Table 3.8.7.3
CONTINUITY 3.9.2 2544 AWG Max allowable discontinuities in accordance with Table 3.9.2.1
3.9.3 4556 AWG Max number of discontinuities in accordance with Table 3.9.3
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time
specified at 360C:
AWG Size Single and Heavy
2529 6 seconds
3036 5 seconds
3746 4 seconds
4756 3 seconds

THERMOPLASTIC FLOW 3.50 Median not less than 170C
SOLUBILITY 3.51 Specimens immersed in xylene shall not soften sufficiently to expose the
bare conductor
DIELECTRIC BREAKDOWN AT 3.52 Wire shall not average not less than 75% of the value in Table 3.8.3.2
RATED TEMPERATURE
SCRAPE RESISTANCE 3.59 Lowest "grams-to-fail" load for any one of the three tests and the average of
the three tests shall not be less than the values in Table 3.59.2

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 3
MW 3-C
POLYURETHANE WITH SELF-BONDING OVERCOAT, FILM INSULATED ROUND COPPER MAGNET
WIRE FOR SOLDERABLE APPLICATIONS, THERMAL CLASS 105
INSULATING MATERIAL The conductor shall be coated with a dual film. The underlying coating is
based on polyurethane resins (1.4.2). The superimposed coating is based on
resins that are self-bonding in character.
Clause 3.58.1.

Part 3,
Clause
DIMENSIONS 3.2.1.1 Type 1: 2552 AWG; Type 2: 2550 AWG in accordance with Table 1-3
HEAT SHOCK 3.5 No cracks visible in the film coating after conditioning at 150C, following a
20% sudden jerk elongation, using a 6d mandrel for sizes 2544 AWG
CONTINUITY 3.9.2 2544 AWG Max number of discontinuities in accordance with Table 3.9.2.1
specified at 360C:

2529 6 seconds
3036 5 seconds
3746 4 seconds
4752 3 seconds

DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of the value in Table 3.8.3.2
RATED TEMPERATURE
BONDROOM TEMPERATURE 3.57.3 No separation of turns with Type 2 film insulated 26 and 36 AWG

MW 1000-2003
Part 2Page 4
MW 5-C
POLYESTER FILM INSULATED ROUND COPPER MAGNET WIRE THERMAL CLASS 155
INSULATING MATERIAL The coating is based on polyester resins (1.4.2).

Clause 3.58.1.

Part 3,
Clause
DIMENSIONS 3.2.1.1 Single and Heavy 2550 AWG in accordance with Table 1-1
HEAT SHOCK 3.5 No cracks visible in the film coating after conditioning at 175C
SPRINGBACK 3.7.1 2530 AWG Not greater than the value in Table 3.7.1
SOLUBILITY 3.51 Specimens immersed in xylene shall not soften sufficiently to expose the bare
conductor
RATED TEMPERATURE

MW 1000-2003
Part 2Page 5
MW 6-C
POLYAMIDE FILM INSULATED ROUND COPPER MAGNET WIRE THERMAL CLASS 105
INSULATING MATERIAL The coating is based on polyamide resins (1.4.2).

Clause 3.58.1.

Part 3,
Clause
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time and at
the temperature specified:
AWG Size Temperature Single and Heavy
1419 430C 10 seconds
2023 430C 8 seconds
2429 360C 6 seconds
3036 360C 5 seconds
3744 360C 4 seconds

conductor
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 6
MW 9-C
EPOXY FILM INSULATED ROUND COPPER MAGNET WIRE THERMAL CLASS 130
INSULATING MATERIAL The coating is based on epoxy resins (1.4.2).

Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Single 1450 AWG; Heavy 450 AWG; Triple 1430 AWG
In accordance with Table 1-1
3.7.2 413 AWG Not greater than 5
DIELECTRIC BREAKDOWN 3.8.2 49 AWG Not less than the value in Table 3.8.2
conductor
RATED TEMPERATURE
TRANSFORMER OIL 3.54 18 AWG Heavy film insulated wire shall not average not less than 5700 volts
RESISTANCE
SCRAPE RESISTANCE 3.59 Lowest "grams-to-fail" load for any one of the three tests and the average of the
three tests shall not be less than the values in Table 3.59.1

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 7
MW 14-C
EPOXY FILM INSULATED RECTANGULAR AND SQUARE
COPPER MAGNET WIRE THERMAL CLASS 130
INSULATING MATERIALS The coating is based on epoxy resins (1.4.2).

Clause 3.58.1.

Part 3, Clause
DIMENSIONS Bare Wire 3.2.2.1 Rectangular: Table 1-8, Square: Table 1-11
Insulation 3.2.2.1 Rectangular: Table 1-10, Square: Table 1-12
ADHERENCE AND FLEXIBILITY 3.3.3 No cracks visible in the film coating after 30 percent elongation
ELONGATION 3.4 Not less than 32 percent for a thickness less than 0.049 inch (1.25 mm)
and greater; 30 percent for a thickness less than 0.049 inch (1.25 mm)
HEAT SHOCK 3.5 No cracks in the film coating after 30 percent elongation followed by
conditioning at 150C
SPRINGBACK 3.7.2 Not greater than 5
DIELECTRIC BREAKDOWN 3.8.2 Minimum Breakdown Voltage
Film Any three of four Fourth electrode
Insulation electrodes
Heavy 1500 500
Quadruple 2500 900

THERMOPLASTIC FLOW 3.50 Median not less than 170C, when tested as MW 9-C Heavy Build.
SOLUBILITY 3.51.2 Specimens immersed in xylene or 50/50 xylene/butyl Cellosolve shall
not soften sufficiently to expose the bare conductor
DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of the room temperature dielectric breakdown
RATED TEMPERATURE requirement in Table 3.8.3.2, when tested on MW 9-C Heavy Build
TRANSFORMER OIL 3.54 18 AWG MW 9-C Heavy film insulated wire shall not average not less
RESISTANCE than 5700 volts

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 8
MW 15-A
POLYVINYL ACETAL FILM INSULATED ROUND ALUMINUM
MAGNET WIRE THERMAL CLASS 105
INSULATING MATERIALS The coating is based on a blend of polyvinyl acetal and phenolic resins (1.4.2).
Clause 3.58.1.
Properties Procedure, Part Requirement

3, Clause
conductor
RATED TEMPERATURE
TOLUENE /ETHANOL 3.53 No swelling or blistering in the film coating
COMPATIBILITY
RESISTANCE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 9
MW 15-C
POLYVINYL ACETAL, FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 105
INSULATING MATERIAL The coating is based on a blend of polyvinyl acetal and phenolic resins (1.4.2).
Clause 3.58.1.

3, Clause
DIMENSIONS 3.2.1.1 Single 856 AWG; Heavy 450 AWG; Triple 1430 AWG; Quad 1036 AWG
conductor
RATED TEMPERATURE
COMPATIBILITY
RESISTANCE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 10
MW 16-C (Single)
POLYIMIDE SINGLE FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240
INSULATING MATERIAL The coating is based on aromatic polyimide resins (1.4.2).

Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 1450 AWG in accordance with Table S (MW 16-C)

ELONGATION 3.4 Not less than value in Table S (MW 16-C)
HEAT SHOCK 3.5 No cracks visible in film coating after conditioning at 280C
SPRINGBACK 3.7.1 1430 AWG Not greater than the value in Table S (MW 16-C)
DIELECTRIC BREAKDOWN 3.8.3 1437 AWG Not less than the value in Table S (MW 16-C)
3.8.7 3850 AWG Not less than the value in Table S (MW 16-C)
DISSIPATION FACTOR 3.10 Not greater than 0.60 percent.
SOLUBILITY 3.51 Specimens immersed in xylene or 50/50 xylene/butyl Cellosolve shall not soften
sufficiently to expose the bare conductor
DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of value in Table S (MW 16-C)
RATED TEMPERATURE
SCRAPE RESISTANCE 3.59 Lowest grams-to-fail load for any one of three tests and the average of the three
tests shall not be less than the values in Table S (MW 16-C)

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 11
Table S (MW 16-C)

POLYIMIDE SINGLE FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240
Insulation
Minimum Maximum Springback, Dielectric
Increase in Overall Elongation, Scrape Resistance, Maximum Breakdown,
AWG Diameter, Diameter, Minimum Grams to Fail Degrees Minimum AWG
Size Inches Inches Percent Average Minimum per Turn Voltage Size
14 0.0016 0.0666 33 545 465 42 3525 14
15 0.0015 0.0594 33 510 430 46 3425 15
16 0.0014 0.0531 33 475 405 50 3325 16
17 0.0014 0.0475 32 445 380 54 3250 17
18 0.0013 0.0424 32 420 355 58 3175 18
19 0.0012 0.0379 31 390 335 62 3075 19
20 0.0012 0.0339 30 370 315 66 3000 20
21 0.0011 0.0303 30 345 295 53 2925 21
22 0.0011 0.0270 29 325 275 58 2850 22
23 0.0010 0.0243 29 300 255 62 2775 23
24 0.0010 0.0217 28 285 245 67 2700 24
25 0.0009 0.0194 28 265 225 72 2625 25
26 0.0009 0.0173 27 245 210 76 2550 26
27 0.0008 0.0156 27 230 200 50 2500 27
28 0.0008 0.0140 26 215 185 55 2425 28
29 0.0007 0.0126 26 200 170 61 2375 29
30 0.0007 0.0112 25 190 160 66 2300 30
31 0.0006 0.0100 24 2075 31
32 0.0006 0.0091 24 1850 32
33 0.0005 0.0081 23 1675 33
34 0.0005 0.0072 22 1500 34
35 0.0004 0.0064 21 1325 35
1200
36 0.0004 0.0058 20 36
37 0.0003 0.0052 20 1075 37
38 0.0003 0.0047 19 500 38
39 0.0002 0.0041 18 500 39
40 0.0002 0.0037 17 425 40
41 0.0002 0.0033 17 425 41
42 0.0002 0.0030 16 375 42
43 0.0002 0.0026 15 325 43
44 0.0001 0.0024 14 300 44
45 0.00010 0.00205 11 275 45
46 0.00010 0.00185 10 250 46
47 0.00010 0.00170 8 225 47
48 0.00010 0.00150 7 190 48
49 0.00010 0.00130 6 170 49
50 0.00010 0.00120 5 150 50
For bare wire dimensions, see Table 1-1.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 12
MW 16-C (Heavy)
POLYIMIDE HEAVY FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240

Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 450 AWG in accordance with Table H (MW 16-C)

ELONGATION 3.4 Not less than value in Table H (MW 16-C)
SPRINGBACK 3.7.1 1430 AWG Not greater than the value in Table H (MW 16-C)
DIELECTRIC BREAKDOWN 3.8.3 437 AWG Not less than the value in Table H (MW 16-C)
3.8.7 3850 AWG Not less than the value in Table H (MW 16-C)
SOLUBILITY 3.51 Specimens immersed in xylene or 50/50 xylene/butyl Cellosolve shall not
soften sufficiently to expose the bare conductor
DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of value in Table H (MW 16-C)
RATED TEMPERATURE
REFRIGERANT R22 EXTRACTION 3.55 1424 AWG Not greater than 0.25% of weight of film insulation
DIELECTRIC BREAKDOWN AFTER 3.56 1424 AWG Average not less than the value in Table H (MW 16-C)
R22 CONDITIONING
SCRAPE RESISTANCE 3.59 Lowest grams-to-fail load for any one of three tests and the average of the
three tests shall not be less than the values in Table H (MW 16-C)

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 13
Table H (MW 16-C)

POLYIMIDE HEAVY FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240
Insulation
4 0.0037 0.2098 38 3700 4
5 0.0036 0.1872 37 3600 5
6 0.0035 0.1671 37 3500 6
7 0.0034 0.1491 36 3400 7
8 0.0033 0.1332 36 3300 8
9 0.0032 0.1189 36 3200 9
10 0.0031 0.1061 35 1090 925 6200 10
11 0.0030 0.0948 35 1090 925 6000 11
12 0.0029 0.0847 34 1090 925 5800 12
13 0.0028 0.0757 34 1090 925 5600 13
14 0.0032 0.0682 33 1090 925 42 6325 14
15 0.0030 0.0609 33 1015 865 46 6175 15
16 0.0029 0.0545 33 955 810 50 6000 16
17 0.0028 0.0488 32 890 755 54 5850 17
18 0.0026 0.0437 32 835 710 58 5700 18
19 0.0025 0.0391 31 785 665 62 5550 19
20 0.0023 0.0351 30 740 630 66 5400 20
21 0.0022 0.0314 30 695 595 53 5250 21
22 0.0021 0.0281 29 650 550 58 5125 22
23 0.0020 0.0253 29 605 515 62 5000 23
24 0.0019 0.0227 28 565 485 67 4850 24
25 0.0018 0.0203 28 530 450 72 4725 25
26 0.0017 0.0182 27 495 425 76 4600 26
27 0.0016 0.0164 27 460 395 50 4500 27
28 0.0016 0.0147 26 435 370 55 4375 28
29 0.0015 0.0133 26 405 340 61 4250 29
30 0.0014 0.0119 25 380 325 66 4150 30
31 0.0013 0.0108 24 3825 31
32 0.0012 0.0098 24 3525 32
33 0.0011 0.0088 23 3250 33
34 0.0010 0.0078 22 2975 34
35 0.0009 0.0070 21 2750 35
36 0.0008 0.0063 20 2525 36
37 0.0008 0.0057 20 2325 37
38 0.0007 0.0051 19 950 38
39 0.0006 0.0045 18 900 39
40 0.0006 0.0040 17 850 40
41 0.0005 0.0036 17 700 41
42 0.0004 0.0032 16 700 42
43 0.0004 0.0029 15 650 43
44 0.0004 0.0027 14 600 44
45 0.0003 0.0023 11 550 45
46 0.0003 0.0021 10 475 46
47 0.0003 0.0019 8 425 47
48 0.0002 0.0017 7 375 48
49 0.0002 0.0015 6 325 49
50 0.0002 0.0014 5 300 50

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 14
MW 16-C (Triple)
POLYIMIDE TRIPLE FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240

Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 1444 AWG in accordance with Table T (MW 16-C)

ELONGATION 3.4 Not less than value in Table T (MW 16-C)
SPRINGBACK 3.7.1 1430 AWG Not greater than the value in Table T (MW 16-C)
DIELECTRIC BREAKDOWN 3.8.3 1437 AWG Not less than the value in Table T (MW 16-C)
3.8.7 3844 AWG Not less than the value in Table T (MW 16-C)
DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of value in T (MW 16-C)
RATED TEMPERATURE
DIELECTRIC BREAKDOWN AFTER 3.56 1424 AWG Average not less than the value in Table T (MW 16-C)
R22 CONDITIONING
SCRAPE RESISTANCE 3.59 Lowest grams-to-fail load for any one of three tests and the average of the
three tests shall not be less than the values in Table T (MW 16-C)

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 15
Table T (MW 16-C)

POLYIMIDE TRIPLE FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240
Insulation
14 0.0048 0.0700 33 1360 1150 46 8450 14
15 0.0045 0.0627 33 1270 1080 49 8225 15
16 0.0043 0.0562 33 1190 1010 53 8000 16
17 0.0041 0.0504 32 1115 945 58 7800 17
18 0.0039 0.0452 32 1045 890 62 7600 18
19 0.0037 0.0406 31 980 830 66 7400 19
20 0.0035 0.0364 30 920 785 70 7200 20
21 0.0033 0.0326 30 865 735 55 7025 21
22 0.0032 0.0293 29 810 690 60 6850 22
23 0.0030 0.0264 29 755 645 64 6675 23
24 0.0029 0.0238 28 710 605 69 6500 24
25 0.0027 0.0214 28 665 565 74 6325 25
26 0.0026 0.0193 27 620 530 80 6150 26
27 0.0024 0.0173 27 575 490 55 6000 27
28 0.0023 0.0156 26 540 460 60 5850 28
29 0.0022 0.0142 26 505 425 65 5700 29
30 0.0021 0.0128 25 470 395 70 5550 30
31 0.0017 0.0114 24 4600 31
32 0.0016 0.0103 24 4275 32
33 0.0014 0.0092 23 3950 33
34 0.0013 0.0082 22 3675 34
35 0.0012 0.0074 21 3425 35
36 0.0011 0.0067 20 3175 36
37 0.0010 0.0060 20 2950 37
38 0.0009 0.0054 19 1400 38
39 0.0008 0.0048 18 1300 39
40 0.0008 0.0043 17 1200 40
41 0.0007 0.0039 17 1100 41
42 0.0007 0.0035 16 1025 42
43 0.0006 0.0032 15 950 43
44 0.0006 0.0029 14 875 44

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 16
MW 16-C (Quadruple)
POLYIMDE QUADRUPLE FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240

Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 See Table Q (MW 16-C)

ELONGATION 3.4 Not less than value in Table Q (MW 16-C)
SPRINGBACK 3.7.1 Not greater than the value in Table Q (MW 16-C)
DIELECTRIC BREAKDOWN 3.8.3 Not less than the value in Table Q (MW 16-C)
CONTINUITY 3.9.2 The number of discontinuities shall not exceed 3
DISSIPATION FACTOR 3.10 Not greater than 0.60 percent
DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of the value in Table Q (MW 16-C)
RATED TEMPERATURE
DIELECTRIC BREAKDOWN AFTER 3.56 1424 AWG Average not less than the value in Table Q (MW 16-C)
R22 CONDITIONING
the three tests shall not be less than the values in Table Q (MW 16-C)

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 17
Table Q (MW 16-C)

POLYIMIDE QUADRUPLE FILM INSULATED ROUND COPPER MAGNET WIRE, THERMAL CLASS 240
Insulation
Increase in Overall Elongation, Scrape Resistance, Maximum Breakdown
14 .0049 .0709 33 1390 1185 46 8680 14

15 .0048 .0638 33 1350 1150 49 8640 15
16 .0046 .0572 33 1275 1090 53 8395 16
17 .0045 .0515 32 1225 1045 58 8325 17
18 .0044 .0464 32 1115 955 62 8250 18
19 .0042 .0418 31 1060 905 66 7980 19
20 .0040 .0376 30 990 845 70 7700 20
21 .0039 .0339 30 945 810 55 7605 21
22 .0037 .0305 29 870 745 60 7310 22
23 .0036 .0277 29 805 690 64 7200 23
24 .0035 .0250 28 745 635 69 7090 24
25 .0034 .0226 28 710 605 74 6970 25
26 .0032 .0204 27 655 570 80 6640 26
27 .0030 .0184 27 635 545 55 6300 27
28 .0029 .0165 26 585 500 60 6160 28
29 .0028 .0151 26 550 470 65 6020 29
30 .0027 .0136 25 500 425 70 5870 30

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 18
MW 17-C
POLYVINYL ACETAL OVERCOATED WITH POLYAMIDE, FILM INSULATED ROUND COPPER MAGNET
WIRE THERMAL CLASS 105
INSULATING MATERIAL The conductor shall be coated with a dual film. The underlying coating is based
on a blend of polyvinyl acetal and phenolic resins (1.4.2). The superimposed
coating is based on polyamide resins (1.4.2).
Clause 3.58.1.

3, Clause
conductor
RATED TEMPERATURE
COMPATIBILITY

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 19
MW 18-A
POLYVINYL ACETAL, FILM INSULATED RECTANGULAR AND SQUARE
ALUMINUM MAGNET WIRE THERMAL CLASS 105
INSULATING MATERIALS The coating is based on a blend of polyvinyl acetal and phenolic resins
(1.4.2).
Clause 3.58.1.

Part 3, Clause
DIMENSIONS Bare Wire 3.2.2.1 Rectangular and square in accordance with Tables 18 and 1-11
Insulation 3.2.2.1 Rectangular and square in accordance with Tables 1-10 and 1-12
ADHERENCE AND 3.3.3 No cracks visible in the film coating after 15 percent elongation
FLEXIBILITY
ELONGATION 3.4 Not less than 15 percent
HEAT SHOCK 3.5 No cracks visible in the film coating after 10 percent elongation followed
by conditioning at 150 3C
DIELECTRIC BREAKDOWN 3.8.2
Minimum Breakdown Voltage
insulation electrodes
Heavy 1500 500
Quadruple 2500 900

bare conductor
RATED TEMPERATURE requirement in Table 3.8.3.2, when tested on MW 15-A Heavy Build
COMPATIBILITY
TRANSFORMER OIL 3.54 18 AWG MW 15-A Heavy Build film insulated wire shall not average not
RESISTANCE less than 5700 volts

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 20
MW 18-C
POLYVINYL ACETAL, FILM INSULATED RECTANGULAR AND SQUARE
INSULATING MATERIALS The coating is based on a blend of polyvinyl acetal and phenolic resins
(1.4.2).
Clause 3.58.1.

Part 3, Clause
ELONGATION 3.4 Not less than 32 percent for a thickness 0.049 inch (1.25 mm) and greater
or 30 percent for a thickness less than 0.049 inch (1.25 mm)
by conditioning at 150 3C
Heavy 1500 500
Quadruple 2500 900

THERMOPLASTIC FLOW 3.50 Median not less than 180C, when tested as MW 15-C Heavy Build.
bare conductor
COMPATIBILITY
TRANSFORMER OIL 3.54 18 AWG MW 15-C Heavy film insulated wire shall not average less than
RESISTANCE 5700 volts

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 21
MW 19-C
POLYVINYL ACETAL WITH SELF-BONDING OVERCOAT, FILM INSULATED ROUND COPPER MAGNET
WIRE THERMAL CLASS 105
on a blend of polyvinyl acetal and phenolic resins (1.4.2). The superimposed
coating is based on resins that are self-bonding in character.
Clause 3.58.1.

Part 3,
Clause
DIMENSIONS 3.2.1.1 Type 1 and Type 2: 1444 AWG, Type 3: 1430 AWG
CONTINUITY 3.9.2 Max number of discontinuities in accordance with Table 3.9.2.1

RATED TEMPERATURE
COMPATIBILITY
BOND ROOM TEMPERATURE 3.57.3 No separation of turns in Type 2 specimens of 18, 26 and 36 AWG

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 22
MW 20-C
POLYIMIDE, FILM INSULATED RECTANGULAR AND SQUARE COPPER MAGNET WIRE THERMAL
CLASS 240
INSULATING MATERIALS The coating is based on aromatic polyimide resins (1.4.2).

Clause 3.58.1.

Part 3, Clause
ELONGATION 3.4 Not less than 32 percent for a thickness 0.049 inch (1.25 mm) and greater
or 30 percent for a thickness less than 0.049 inch (1.25 mm)
HEAT SHOCK 3.5 No cracks in the film coating after 15 percent elongation followed by
conditioning at 280C 3C
Heavy 1500 500
Quadruple 2500 900

THERMOPLASTIC FLOW 3.50 Median not less than 450C, when tested on MW 16-C Heavy Build.
SOLUBILITY 3.51 Specimens immersed in xylene and 50/50 xylene/butyl Cellosolve shall
RATED TEMPERATURE requirement in Table H (MW 16-C), when tested on round wire

MW 1000-2003
Part 2Page 23
MW 24-A
POLYESTER (AMIDE) (IMIDE) OVERCOATED WITH POLYAMIDE
FILM INSULATED ROUND ALUMINUM MAGNET WIRE THERMAL CLASS 155
based on polyester (amide) (imide) resins (1.4.2). The superimposed coating
is based on polyamide resins (1.4.2).
Clause 3.58.1.

Part 3, Clause
DIELECTRIC BREAKDOWN 3.8.3 Not less than the value in Table 3.8.3.2
SOLUBILITY 3.51 Specimens immersed in xylene and 50/50 xylene/butyl Cellosolve shall not
RATED TEMPERATURE

MW 1000-2003
Part 2Page 24
MW 24-C
FILM INSULATED ROUND COPPER MAGNET WIRE THERMAL CLASS 155
based on polyester (amide) (imide) resins (1.4.2). The superimposed coating
is based on polyamide resins (1.4.2).
Clause 3.58.1.

3, Clause
SOLUBILITY 3.51 Specimens immersed in xylene and 50/50 xylene/butyl Cellosolve shall not soften
RATED TEMPERATURE

MW 1000-2003
Part 2Page 25
MW 26-C
POLYESTER (IMIDE), FILM INSULATED ROUND COPPER MAGNET
WIRE FOR SOLDERABLE APPLICATIONS THERMAL CLASS 155
INSULATING MATERIAL The coating is based on polyester (imide) resins (1.4.2).
Clause 3.58.1.

3, Clause
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time specified
at 470C.

2529 6 seconds
3036 5 seconds
3746 4 seconds
4756 3 seconds

conductor
RATED TEMPERATURE

MW 1000-2003
Part 2Page 26
MW 27-C
POLYESTER (IMIDE) OVERCOATED WITH POLYAMIDE
FILM INSULATED ROUND COPPER MAGNET WIRE FOR SOLDERABLE APPLICATIONS
THERMAL CLASS 155
on polyester (imide) resins (1.4.2). The superimposed coating is based on
polyamide resins (1.4.2).
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Single and Heavy: 2544 AWG in accordance with Table 1-1
specified at 470C.
2529 6 seconds
3036 5 seconds
3744 4 seconds

bare conductor
RATED TEMPERATURE

MW 1000-2003
Part 2Page 27
MW 28-A
POLYURETHANE OVERCOATED WITH POLYAMIDE FILM INSULATED
ROUND ALUMINUM MAGNET WIRE FOR SOLDERABLE APPLICATIONS
THERMAL CLASS 130
on polyurethane resins (1.4.2). The superimposed coating is based on
Clause 3.58.1.

Part 3,
Clause
DIMENSIONS 3.2.1.1 Single and Heavy: 1430 AWG in accordance with Table 1-1
SOLDERABILITY 3.13 Insulation completely removed after immersion within the time and at the
temperature specified:
2023 430C 8 seconds
2430 390C 6 seconds

bare conductor
DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of value in Table 3.8.3.2
RATED TEMPERATURE
SCRAPE RESISTANCE 3.59 Lowest "grams-to-fail" load for any one of the three tests and the average
of the three tests shall not be less than the values in Table 3.59.1

MW 1000-2003
Part 2Page 28
MW 28-C
POLYURETHANE OVERCOATED WITH POLYAMIDE
THERMAL CLASS 130
on polyurethane resins (1.4.2). The superimposed coating is based on
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Single: 1444 AWG, Heavy: 944 AWG in accordance with Table 1-1
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time and
at temperature specified:
AWG Temperature Single Heavy
Size
913 430C 12 seconds
1419 430C 10 seconds 10 seconds

bare conductor
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 29
MW 29-C
POLYURETHANE OVERCOATED WITH POLYAMIDE AND SELF-BONDING OVERCOAT
THERMAL CLASS 105
INSULATING MATERIAL The conductor shall be coated with a multiple film. The underlying coating is
based on polyurethane resins (1.4.2). The intermediate coating is based on
polyamide resins (1.4.2). The superimposed outer coating is based on resins
which are self-bonding in character (1.4.2).
Clause 3.58.1.

Part 3,
Clause
DIMENSIONS 3.2.1.2 Type 1 and Type 2: 1444 AWG in accordance with Table 1-3
DIELECTRIC BREAKDOWN 3.8.3 1437 AWG Not less than the value in Table 3.8.3.2 (polyamide col.)
3.8.7 3844 AWG Not less than the value in Table 3.8.7.3 (polyamide col.)
and at the temperature specified:
2023 430C 8 seconds
2429 390C 6 seconds
3036 390C 5 seconds
3744 390C 4 seconds

DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of the value in Table 3.8.3.2 (polyamide col.)
RATED TEMPERATURE
BONDROOM TEMPERATURE 3.57 No separation of turns in Type 2 specimens of 18, 26 and 36 AWG

MW 1000-2003
Part 2Page 30
MW 30-C
POLYESTER (AMIDE) (IMIDE) FILM INSULATED ROUND COPPER MAGNET WIRE
THERMAL CLASS 180
INSULATING MATERIAL The coating is based on polyester (amide)(imide) resins (1.4.2).

Clause 3.58.1.

3, Clause
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 31
MW 31-C
PAPER COVERED BARE OR FILM INSULATED ROUND COPPER MAGNET WIRE
THERMAL CLASS 90 OR 105
INSULATING MATERIALS The insulating material shall be rope paper or Kraft paper, or both. The paper
covering shall be one or more tape layers wrapped firmly, closely, evenly, and
continuously around the wire. The use of suitable adhesive material shall be
permitted.
THERMAL CLASS 90 unimpregnated or 105 impregnated or in oil, when tested in accordance with
Part 3, Clause 3.58.1.

Part 3,
Clause
DIMENSIONS 3.2.1.3 Bare and film insulated wire dimensions in accordance with Table 1-1
The increase in thickness for the paper covering shall be as follows:
Min. thickness increase = 2(Equiv. No. of Layers 1)(Nom. tape thickness)

Max. thickness increase = 2(Equiv. No. of Layers + 1)(Nom. tape thickness)
ADHERENCE AND FLEXIBILITY 3.3.2 No openings sufficient to expose the bare or film insulated conductor, when
wound on the following mandrel:
AWG Size Mandrel Wrap Method Elongation Method

8 13 5d 15% (+2, -0)
14 22 4d 10% (+2, -0)
23 32 3d 8% (+2, -0)
3.3.3 No openings sufficient to expose the bare or film coated wire, following
elongation in accordance with 3.3.3.
Paper Covered Wire
AWG Diameter of Single Heavy
Size Mandrel, inches Bare Film Film
89 None 115 --- 1490
10 1.00 330 --- 2980
11 15 0.75 265 1820* 3065
16 20 0.50 265 1630 2750
21 24 0.50 265 1495 2475
25 28 0.25 200 1305 2200
29 32 0.25 200 1030 1790
*Sizes 14 and 15 AWG only.
NOTE 1 The calculated maximum increase due to the paper covering may be exceeded provided the measured overall diameter of the
covered wire does not exceed the sum of the nominal conductor diameter + 1% (for paper covered bare products), or maximum film insulated
diameter (given in Table 1-1), plus the maximum increase due to the paper.
NOTE 2 The number of paper tapes, type of paper, paper tape thickness, and the degree of overlap shall be agreed upon between the
user and supplier.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 32
MW 32-C
DOUBLE PAPER SINGLE COTTON COVERED BARE RECTANGULAR AND SQUARE COPPER MAGNET
WIRE THERMAL CLASS 90 OR 105
INSULATING MATERIALS The insulating material shall be rope paper or Kraft paper, or both. The cotton
shall be of good quality and substantially free from knots, ravelings, foreign
matter, and other irregularities. The paper covering shall be two thicknesses of
tape applied using one or two tapes wrapped firmly, closely, evenly, and
continuously around the wire. The use of suitable adhesive material shall be
permitted. The cotton covering shall be wrapped firmly, closely, evenly, and
continuously around the wire and in the direction opposite to that in which the
paper was spirally wrapped.

Part 3, Clause
DIMENSIONS 3.2.2.2 a. Radii in accordance with Table 1-8

b. Thickness and width tolerances in accordance with Table 1-9
c. Dimensions and increase due to insulation in accordance with Table PC
(MW 32-C)
ELONGATION 3.4 Not less than 32 percent for a thickness of 0.049 inch (1.25 mm) and
greater, or 30 percent for a thickness less than 0.049 inch (1.25 mm)
SPRINGBACK 3.7.2 Not greater than 5.5
COVERAGE 3.12.2 Covering shall not loosen sufficiently to expose the bare wire
Ratio of Mandrel Diameter to

Thickness of Bare Wire
Nominal Thickness Paper and Cotton Paper Covered
of Bare Wire, Inches Covered
0.220 0.098 6 6
0.088 0.049 4 6
0.044 0.025 3 6
NOTE 1 The maximum increase due to the double paper single cotton covering may be exceeded provided the measured overall dimension
of the covered wire does not exceed the sum of the specified maximum conductor thickness plus the maximum increase due to the double
paper single cotton covering.
NOTE 2 The type of paper tape, the paper tape thicknesses, the degree of tape overlap, type of cotton, and use of adhesive materials
shall be agreed upon between the user and supplier.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 33
TABLE PC (MW 32-C)

DUE TO DOUBLE PAPER SINGLE COTTON COVERING

Thickness Thickness
Millimeters Millimeters
10.40
11.03
11.68
12.38
13.12
2.05
2.18
2.30
2.44
2.59
2.74
2.91
3.08
3.26
3.46
3.66
3.88
4.12
4.36
4.62
4.90
5.19
5.50
5.83
6.18
6.54
6.93
7.35
7.79
8.25
8.74
9.27
9.82
Inches Inches
0.081
0.086
0.091
0.096
0.102
0.108
0.114
0.121
0.128
0.136
0.144
0.153
0.162
0.172
0.182
0.193
0.204
0.217
0.229
0.243
0.258
0.273
0.289
0.307
0.325
0.344
0.365
0.387
0.410
0.434
0.460
0.487
0.517
1.02 0.040 0.040 1.02
1.15 0.045 0.013-0.019 0.014-0.020 0.015-0.021 0.015-0.022 0.045 1.15
1.29 0.051 0.051 1.29
1.45 0.057 0.057 1.45
1.63 0.064 0.064 1.63
1.83 0.072 0.072 1.83
2.05 0.081 0.081 2.05
2.30 0.091 0.091 2.30
2.59 0.102 0.014-0.020 0.102 2.59
2.91 0.114 0.114 2.91
3.26 0.128 0.015-0.021 0.015-0.022 0.016-0.023 0.128 3.26
3.66 0.144 0.144 3.66
4.12 0.162 0.162 4.12
4.62 0.182 0.182 4.62
5.19 0.204 0.016-0.023 0.017-0.024 0.204 5.19
5.83 0.229 0.229 5.83
NOTEThe equivalent mm increases in dimensions are shown below
Inch 0.013 0.014 0.015 0.016 0.017 0.018 0.019 0.020 0.021 0.022 0.023 0.024
mm 0.33 0.36 0.38 0.41 0.43 0.46 0.48 0.51 0.53 0.56 0.58 0.61

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 34
MW 33-C
PAPER COVERED BARE RECTANGULAR AND SQUARE COPPER MAGNET WIRE
THERMAL CLASS 90 OR 105
INSULATING MATERIALS The insulating material shall be rope paper or Kraft paper, or both. The paper
covering shall be of one or more tapes wrapped firmly, closely, evenly, and
continuously around the wire. The use of a suitable adhesive material shall be
permitted.

Part 3, Clause
DIMENSIONS 3.2.2.2 a. Radii in accordance with Table 1-8

c. Increase in thickness due to the paper covering shall be as follows:
Min. thickness increase = 2(Equiv. No. of Layers* 1)(Nom. tape thickness)
Max. thickness increase = 2(Equiv. No. of Layers* + 1)(Nom. tape thickness)
d. The increase in width due to the paper covering shall be equal to or less
than the increase in thickness
* See table in Part 1, Clause 1.5.1
ELONGATION 3.4 Not less than 32 percent for a conductor thickness of 0.049 inch (1.25 mm)
and greater, or 30 percent for a conductor thickness less than 0.049 inch
(1.25 mm)
COVERAGE 3.12.2 Paper covering shall not loosen sufficiently to expose the bare wire, when
bent around a mandrel 6 times the thickness of the bare wire.
NOTE 1 The calculated maximum increase due to the paper covering may be exceeded provided the measured overall dimension of the
covered wire does not exceed the sum of the specified maximum conductor thickness plus the maximum increase due to the paper.
NOTE 2 The number of paper tapes, type of paper, paper tape thickness, and the degree of overlap shall be agreed upon between the user
and supplier.

MW 1000-2003
Part 2Page 35
MW 35-A
POLYESTER (AMIDE) (IMIDE) OVERCOATED WITH POLYAMIDEIMIDE
on polyester (amide)(imide) resins (1.4.2). The superimposed coating is based
on polyamideimide resins (1.4.2).
Clause 3.58.1.

3, Clause
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 36
MW 35-C
POLYESTER (AMIDE)(IMIDE) OVERCOATED WITH POLYAMIDEIMIDE
INSULATING MATERIALS The conductor shall be coated with a dual film. The underlying coating is based
Clause 3.58.1.

3, Clause
DIMENSIONS 3.2.1.1 Single 1444 AWG; Heavy 444 AWG; Triple 1444 AWG; Quad 1030 AWG
RATED TEMPERATURE

MW 1000-2003
Part 2Page 37
MW 36-A
POLYESTER (AMIDE)(IMIDE) OVERCOATED WITH POLYAMIDEIMIDE, FILM INSULATED
RECTANGULAR AND SQUARE ALUMINUM MAGNET WIRE THERMAL CLASS 220
Clause 3.58.1.

Part 3,
Clause
by conditioning at 240C
Heavy 1500 500
Quadruple 2500 900

RATED TEMPERATURE requirement in Table 3.8.3.2, when tested on MW 35-A Heavy Build

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 38
MW 36-C
FILM INSULATED RECTANGULAR AND SQUARE COPPER MAGNET WIRE
THERMAL CLASS 200
Clause 3.58.1.

Part 3, Clause
HEAT SHOCK 3.5 No cracks visible in the film coating after 15% elongation followed by
Heavy 1500 500
Quadruple 2500 900
Applicable to Heavy film insulated sizes having a thickness of less than

0.049 inch (1.25 mm) or a width greater than 0.492 inch (12.5 mm), or a
width-to-thickness ratio greater than 5:1, and all quadruple. Other Heavy
film insulated sizes shall be tested in accordance with 3.8.6.
3.8.6 Heavy film insulated sizes having a thickness 0.049 inch (1.25 mm) or
greater; a width of 0.492 inch (12.5 mm) or less; and a width-to-thickness
ratio not more than 5:1, shall have a dielectric breakdown voltage not less
than in the table above after bending.
THERMOPLASTIC FLOW 3.50 Median not less than 300C when tested as MW 35-C Heavy Build
SOLUBILITY 3.51.2 Specimens immersed in xylene and 50/50 xylene/butyl Cellosolve shall

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 38-1
MW 37-C
Clause 3.58.1

Part 3,
Clause
CONTINUITY 3.9.2 1444 AWG Max number of discontinuities in accordance with Table
3.9.2.1
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 38-2
MW 38-C
FILM INSULATED RECTANGULAR AND SQUARE COPPER MAGNET WIRE
THERMAL CLASS 220
Clause 3.58.1

Part 3, Clause
HEAT SHOCK 3.5 No cracks visible in the film coating after 15% elongation followed by
Heavy 1500 500
Quadruple 2500 900
Applicable to Heavy film insulated sizes having a thickness of less than

0.049 inch (1.25 mm) or a width greater than 0.492 inch (12.5 mm), or a
width-to-thickness ratio greater than 5:1, and all quadruple. Other Heavy
film insulated sizes shall be tested in accordance with 3.8.6.
3.8.6 Heavy film insulated sizes having a thickness 0.049 inch (1.25 mm) or
greater; a width of 0.492 inch (12.5 mm) or less; and a width-to-thickness
ratio not more than 5:1, shall have a dielectric breakdown voltage not less
than in the table above after bending.
THERMOPLASTIC FLOW 3.50 Median not less than 325C when tested as MW 37-C Heavy Build
SOLUBILITY 3.51.2 Specimens immersed in xylene and 50/50 xylene/butyl Cellosolve shall

MW 1000-2003
Part 2Page 39
MW 41-C
GLASS FIBER COVERED, BARE OR FILM INSULATED
ROUND COPPER MAGNET WIRE THERMAL CLASS 155
INSULATING MATERIALS The glass fiber shall be electrical grade continuous filament glass yarn. If an
underlying film coating is used, it shall have at least a Class 130 rating. The
glass fiber covering shall be wrapped firmly, closely, evenly, and continuously
around the wire. The glass fiber covering shall be treated with an insulating
varnish to provide a tough outer finish.
THERMAL CLASS 155 as defined in Part 1, Clause 1.8 and when tested in accordance with Part 3,
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.3 Single 4/030 AWG in accordance with Table 1-4

Double 4/030 AWG in accordance with Table 1-5
ADHERENCE AND FLEXIBILITY 3.3.2 Covering shall not open sufficiently to expose the bare or film insulated
wire after bending on mandrel sizes as follows:
AWG Size Mandrel Diameter
1/0 and larger 15d
1 to 30 10d
ELONGATION 3.4 Not less than the following:

Minimum Elongation Percent
AWG With Glass Fiber Glass Fiber
Size Covering Covering Removed
4/01/0 35.0 35.0
18 30.0 30.0
915 20.0 30.0
1621 15.0 25.0
2228 20.0
29 and 30 15.0
SPRINGBACK 3.7.2 4/013 AWG Glass fiber covered bare: Not greater than 5
413 AWG Glass fiber covered film insulated: Not greater than 5.5
DIELECTRIC BREAKDOWN Not less than the following:
Minimum
AWG Size Mandrel Diameter Breakdown, Volts*
Inches mm Single Double
3.8.2 4/09 170 315
3.8.4 or 1023 1.00 25.4 360 540
3.8.5 2430 0.25 6.3 225 400
3.8.4 or *For glass fiber covered wire having an underlying film insulation, add the
3.8.5 minimum breakdown voltage given in Part 3 for the film insulated wire

MW 1000-2003
Part 2Page 40
MW 42-C
GLASS FIBER COVERED, BARE OR HEAVY FILM INSULATED
RECTANGULAR AND SQUARE COPPER MAGNET WIRE THERMAL CLASS 155
around the wire. The glass fiber covering shall be treated with an insulating
varnish to provide a tough outer finish.
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.2.2 Rectangular Wire:

a. Radii in accordance with Tables 18
c. Dimensions and increase in thickness:
Singlein accordance with Table 1-13
Doublein accordance with Table 1-14 or 1-15
Square Wire:
Doublein accordance with Table 1-21
ADHERENCE AND FLEXIBILITY 3.3.3 Single or Double with underlying film: No cracks visible in the film
insulation after 20 percent elongation. Examine with normal vision and
without removing the glass fiber covering.
3.3.5 Double without underlying film: Not less than 75 V/mil (2950 V/mm) of
minimum thickness of the glass fiber covering on one side.
NOTEThe minimum thickness of the glass fiber covering is 35% of the maximum
increase in dimensions calculated from:
Rectangular: Table 1-14
Square: Table 1-21
SPRINGBACK 3.7.2 Glass fiber covered BareNot greater than 5
Glass fiber covered Heavy Film InsulatedNot greater than 5.5
DIELECTRIC BREAKDOWN 3.8.2 Not less than 90 Volts/mil (3543 V/mm) of the minimum thickness of the
glass fiber covering on one side plus the minimum breakdown given in
Part 2 for the film insulated wire, if applicable.
Single: Rectangular: Table 1-13
Square: Table 1-19
Double: Rectangular: Table 1-14
Square: Table 1-21

MW 1000-2003
Part 2Page 41
MW 43-C
GLASS FIBER COVERED SILICONE TREATED BARE OR HEAVY FILM INSULATED
around the wire. The glass fiber covering shall be treated with a modified silicone
insulating varnish or silicone compound to provide a tough outer finish. If a tracer
is used, one or more ends of glass yarn 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.
Clause 3.58.1.

Part 3, Clause

Single in accordance with Table 1-13
Double in accordance with Table 1-14 or 1-15
Square Wire:
ADHERENCE AND FLEXIBILITY 3.3.3 Single or Double with underlying film: No cracks visible in the film insulation
after 20 percent elongation. Examine with normal vision and without
removing the glass fiber covering.
3.3.5 Double without underlying film: Not less than 75 Volts/mil (2950 V/mm) of
minimum thickness of the glass fiber covering on one side.
Square: Table 1-19
Glass fiber covered Heavy Film Insulated Not greater than 5.5
glass fiber covering on one side plus the minimum breakdown given in Part
2 for the film insulated wire, if applicable.
Square: Table 1-19
Double: Rectangular without underlying film: Table 1-14
Square: Table 1-21

MW 1000-2003
Part 2Page 42
MW 44-C
GLASS FIBER COVERED SILICONE TREATED, BARE OR HEAVY FILM INSULATED
INSULATING MATERIALS The glass fiber shall be electrical grade continuous filament glass yarn. If
underlying film insulation is used, it shall have at least a Class 180 rating. The
around the wire. The glass fiber covering shall be treated with a modified
silicone insulating varnish or silicone compound to provide a tough outer finish.
If a tracer is used, one or more ends of glass yarn in the outer layer should 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 as defined in Part 1, Clause 1.8 and tested in accordance with Part 3,
Clause 3.58.1.

Part 3, Clause

1/0 and larger 15d
1 to 30 10d
ELONGATION 3.4 Not less than the values in Table 3.4.2.
Minimum
3.8.2 4/09 170 315
3.8.4 or 3.8.5 1023 1.00 25.4 360 540
3.8.4 or 3.8.5 2430 0.25 6.3 225 400
*For glass fiber covered wire having an underlying film insulation, add the
minimum breakdown voltage given in Part 3 for the film insulated wire

MW 1000-2003
Part 2Page 43
MW 45-C
POLYESTER GLASS FIBER COVERED, BARE OR HEAVY FILM INSULATED
INSULATING MATERIALS 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 percent. If
underlying film insulation is used, it shall have at least a Class 130 rating.
The polyester glass fiber covering shall be wrapped firmly, closely, evenly,
and continuously around the wire. The polyester glass fiber covering shall be
fused; when required it may treated with an insulating varnish of compound to
provide a tough outer finish.
Clause 3.58.1.

Part 3, Clause

4/09 10d
1030 5d
3.3.3 After a specimen has been elongated 25% or to its breaking point,
whichever is less, there shall be no loosening, fraying or loss of
adherence of the covering except at the point of rupture.
SPRINGBACK 3.7.2 4/013 AWG Polyester glass fiber covered bare:

Not greater than 5
413 AWG Polyester glass fiber covered film insulated:
Not greater than 5.5
Minimum
3.8.2 4/09 150 270
3.8.4 or 3.8.5 1023 1.00 25.4 360 540
3.8.4 or 3.8.5 2430 0.25 6.3 225 400
*For polyester glass fiber covered wire having an underlying film insulation,
add the minimum breakdown voltage given in Part 3 for the film insulated
wire

MW 1000-2003
Part 2Page 44
MW 46-C
POLYESTER GLASS FIBER COVERED, BARE OR HEAVY FILM INSULATED
INSULATING MATERIALS The fiber covering shall consist a combination of polyester and glass fibers.
polyester glass fiber covering shall be wrapped firmly, closely, evenly, and
continuously around the wire. The polyester glass fiber covering shall be
fused; when required it may be treated with an insulating varnish or
compound to provide a tough outer finish.
Clause 3.58.1.

Part 3, Clause

Single in accordance with Table 1-16
Double in accordance with Table 1-17 or 1-18
Square Wire:
removing the polyester glass fiber covering.
minimum thickness of the polyester glass fiber covering on one side.
NOTEThe minimum thickness of the polyester glass fiber covering is 35% of the
maximum increase in dimensions calculated from:
Square: Table 1-22
SPRINGBACK 3.7.2 Polyester glass fiber covered BareNot greater than 5
Polyester glass fiber covered Heavy Film Insulated Not greater than 5.5
Square: Table 1-20
Square: Table 1-22

MW 1000-2003
Part 2Page 45
MW 47-C
POLYESTER GLASS FIBER COVERED SILICONE TREATED, BARE OR FILM INSULATED
fused; when required it may treated with an insulating varnish of compound to
provide a tough outer finish.
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.3 Single 430 AWG in accordance with Table 1-6

Double 430 AWG in accordance with Table 1-7
49 10d
1030 5d
3.3.3 After a specimen has been elongated 25% or to its breaking point,
whichever is less, there shall be no loosening, fraying or loss of
adherence of the covering except at the point of rupture.
ELONGATION 3.4 Not less than the values in Table 3.4.2
SPRINGBACK 3.7.2 4/013 AWG Polyester glass fiber covered bare:

Not greater than 5

Minimum
3.8.2 49 150 270
3.8.4 or 3.8.5 1023 1.00 25.4 360 540
3.8.4 or 3.8.5 2430 0.25 6.3 225 400
wire

MW 1000-2003
Part 2Page 46
MW 48-C
POLYESTER GLASS FIBER COVERED SILICONE TREATED BARE OR
HEAVY FILM INSULATED RECTANGULAR AND SQUARE COPPER MAGNET WIRE
THERMAL CLASS 200
polymerization of ethylene glycol and terephthalic acid. The maximum content
by weight of polyester fiber in the yarn shall not exceed 50 percent. If
underlying film insulation is used, it shall have at least a Class 180 rating. 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 should 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.
Clause 3.58.1.
Part 3, Clause
Square Wire:
Square: Table 1-22
ELONGATION 3.4 Not less than 32 percent for a thickness less than 0.049 inch (1.25 mm)
and greater or 30 percent for a thickness less than 0.049 inch (1.25 mm)
Square: Table 1-20
Square: Table 1-22

MW 1000-2003
Part 2Page 47
MW 50-C
GLASS FIBER COVERED HIGH TEMPERATURE ORGANIC VARNISH TREATED,
BARE OR FILM INSULATED ROUND COPPER MAGNET WIRE
THERMAL CLASS 180
INSULATING MATERIALS The glass fiber shall be electrical grade continuous filament glass yarn. If
The glass fiber covering shall be wrapped firmly, closely, evenly, and
continuously around the wire. The glass fiber covering shall be treated with a
high temperature non-silicone organic insulating varnish.
Clause 3.58.1.

Part 3, Clause

1/0 and larger 15d
1 to 30 10d
Minimum
3.8.2 4/09 170 315
3.8.4 or 3.8.5 1023 1.00 25.4 360 540
3.8.4 or 3.8.5 2430 0.25 6.3 225 400
*For glass fiber covered wire having an underlying film insulation, add the
minimum breakdown voltage given in Part 3 for the film insulated wire

MW 1000-2003
Part 2Page 48
MW 51-C
POLYESTER GLASS FIBER COVERED HIGH TEMPERATURE ORGANIC VARNISH TREATED
BARE OR FILM INSULATED ROUND COPPER MAGNET WIRE
THERMAL CLASS 180
fused and shall be treated with a high temperature non-silicone organic
insulating varnish.
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.3 Single 430 AWG in accordance with Table 1-6

Double 430 AWG in accordance with Table 1-7
49 10d
1030 5d
ELONGATION 3.4 Not less than the values in Table 3.4.2
SPRINGBACK 3.7.2 413 AWG Polyester glass fiber covered bare:

Not greater than 5

Minimum
3.8.2 49 150 270
3.8.4 or 3.8.5 1023 1.00 25.4 360 540
3.8.4 or 3.8.5 2430 0.25 6.3 225 400
wire

MW 1000-2003
Part 2Page 49
MW 52-C
GLASS FIBER COVERED HIGH TEMPERATURE ORGANIC VARNISH TREATED
HEAVY FILM INSULATED RECTANGULAR AND SQUARE COPPER MAGNET WIRE
THERMAL CLASS 180
INSULATING MATERIALS The glass fiber shall be electrical grade continuous filament glass yarn. The
underlying film insulation shall have at least a Class 155 rating. The glass
fiber covering shall be wrapped firmly, closely, evenly, and continuously
around the wire. The glass fiber covering shall be treated with a high-
temperature non-silicone insulating varnish.
Clause 3.58.1.

Part 3, Clause

c. Dimensions and increase in thickness in accordance with:
SingleTable 1-13
DoubleTable 1-14 or 1-15
Square Wire:
c. Dimensions and increase in thickness in accordance with
SingleTable 1-19
DoubleTable 1-21
3.3.5 removing the glass fiber covering.
Double without underlying film: Not less than 75 Volts/mil (2950 V/mm) of
Square: Table 1-21
greater, or 30 percent for a thickness of less than 0.049 inch (1.25 mm)
Glass fiber covered Heavy Film Insulated Not greater than 5.5
Square: Table 1-19
Square: Table 1-21

MW 1000-2003
Part 2Page 50
MW 53-C
POLYESTER GLASS FIBER COVERED HIGH TEMPERATURE ORGANIC VARNISH TREATED
BARE OR HEAVY FILM INSULATED RECTANGULAR AND SQUARE COPPER MAGNET WIRE
THERMAL CLASS 180
polyester fiber covering shall be a high grade yarn resulting from the linear
fused and treated with a high-temperature non-silicone insulating varnish.
Clause 3.58.1.

Part 3, Clause
Square Wire:
Square: Table 1-22
Square: Table 1-20
Square: Table 1-22

MW 1000-2003
Part 2Page 51
<This page intentionally left blank.>

MW 1000-2003
Part 2Page 52
MW 60-A
AROMATIC POLYAMIDE PAPER COVERED RECTANGULAR AND SQUARE ALUMINUM
INSULATING MATERIALS The insulating material shall be an aromatic polyamide paper. The paper
covering shall consist of one or more tapes, each wrapped firmly, closely,
evenly, and continuously around the wire in a configuration necessary to
provide the specified number of tape layers (thicknesses of paper). The
paper covering shall consist of at least two thicknesses of paper with not less
than 40-percent overlap. If an adhesive is used, this material shall perform in
the applicable insulation system as required in Part 3, Clause 3.58.
Clause 3.58.1.

Part 3, Clause

a. Radii in accordance with Table 1-8
c. Increase in thickness due to paper covering in accordance Table PR
(MW 60-A).
Square Wire:
Bare wire dimensions and tolerances, radii and increase in dimensions due to
paper covering in accordance with Table PSQ (MW 60-A) for two or three
thicknesses of paper, whichever applies.
The increase in thickness for coverings having more than three thicknesses of
paper shall be as follows:


paper covering on one side (one half the minimum increase)
COVERAGE 3.12.2 Covering shall not loosen appreciably nor open sufficiently to expose the bare
wire after bending around a mandrel having a dimension 6 times the thickness
of the bare wire.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 53
MW 60-A
AROMATIC POLYAMIDE PAPER COVERED RECTANGULAR AND SQUARE
ALUMINUM MAGNET WIRE THERMAL CLASS 220
Table PR (MW 60-A)
INCREASE IN DIMENSIONS OF RECTANGULAR WIRE DUE TO PAPER COVERING
Nominal Tape Thickness = 0.002 in. (.051 mm) Nominal Tape Thickness = 0.003 in. (.076 mm)
Number Minimum Maximum Minimum Maximum
of Tapes inches mm inches mm inches mm inches mm
2 0.004 0.102 0.012 0.305 0.006 0.152 0.018 0.457
3 0.008 0.203 0.016 0.406 0.012 0.305 0.024 0.610
NOTE 1 The calculated max. increase due to polyamide paper covering may be exceeded provided the measured overall dimension of covered wire does not exceed the sum of
the specified maximum conductor thickness plus maximum increase due to covering.
NOTE 2 The increase in width due to the paper covering shall be equal to or less than the increase in thickness.
NOTE 3 Number of paper tapes, paper tape thickness, and degree of overlap shall be agreed upon between user and supplier.
Table PSQ (MW 60-A)Dimensions 1/014 AWG

(Inches)
Two Tape Thicknesses Three Tape Thicknesses
Square Nom. Tape = 0.002 in. Nom. Tape = 0.003 in. Nom. Tape = 0.002 in. Nom. Tape = 0.003 in.
AWG Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum
Size Increase Overall Increase Overall Increase Overall Increase Overall
1/0 0.004 0.3399 0.006 0.3459 0.008 0.3439 0.012 0.3519
1 0.004 0.3042 0.006 0.3102 0.008 0.3082 0.012 0.3162
2 0.004 0.2722 0.006 0.2782 0.008 0.2762 0.012 0.2842
3 0.004 0.2437 0.006 0.2497 0.008 0.2477 0.012 0.2557
4 0.004 0.2183 0.006 0.2243 0.008 0.2223 0.012 0.2303
5 0.004 0.1957 0.006 0.2017 0.008 0.1997 0.012 0.2077
6 0.004 0.1756 0.006 0.1816 0.008 0.1796 0.012 0.1876
7 0.004 0.1577 0.006 0.1637 0.008 0.1617 0.012 0.1697
8 0.004 0.1418 0.006 0.1478 0.008 0.1458 0.012 0.1538
9 0.004 0.1275 0.006 0.1335 0.008 0.1315 0.012 0.1395
10 0.004 0.1149 0.006 0.1209 0.008 0.1189 0.012 0.1269
11 0.004 0.1037 0.006 0.1097 0.008 0.1077 0.012 0.1157
12 0.004 0.0938 0.006 0.0998 0.008 0.0978 0.012 0.1058
13 0.004 0.0850 0.006 0.0910 0.008 0.0890 0.012 0.0970
14 0.004 0.0771 0.006 0.0831 0.008 0.0811 0.012 0.0891
(mm)
Square Nom. Tape = 0.051 Nom. Tape = 0.076 Nom. Tape = 0.051 Nom. Tape = 0.076
1/0 0.102 8.633 0.152 8.786 0.203 8.735 0.305 8.938
1 0.102 7.727 0.152 7.879 0.203 7.828 0.305 8.031
2 0.102 6.914 0.152 7.066 0.203 7.015 0.305 7.219
3 0.102 6.190 0.152 6.342 0.203 6.292 0.305 6.495
4 0.102 5.545 0.152 5.697 0.203 5.646 0.305 5.850
5 0.102 4.971 0.152 5.123 0.203 5.072 0.305 5.276
6 0.102 4.460 0.152 4.613 0.203 4.562 0.305 4.765
7 0.102 4.006 0.152 4.158 0.203 4.107 0.305 4.310
8 0.102 3.602 0.152 3.754 0.203 3.703 0.305 3.907
9 0.102 3.239 0.152 3.391 0.203 3.340 0.305 3.543
10 0.102 2.918 0.152 3.071 0.203 3.020 0.305 3.223
11 0.102 2.634 0.152 2.786 0.203 2.736 0.305 2.939
12 0.102 2.383 0.152 2.535 0.203 2.484 0.305 2.687
13 0.102 2.159 0.152 2.311 0.203 2.261 0.305 2.464
14 0.102 1.958 0.152 2.111 0.203 2.060 0.305 2.263
NOTEThe maximum overall dimensions have been calculated in accordance with the values in Table PR (MW 60-A)

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 54
MW 60-C
AROMATIC POLYAMIDE PAPER COVERED RECTANGULAR AND SQUARE COPPER
Clause 3.58.1.

Part 3, Clause

a. Radii in accordance with Table 1-8
c. Increase in thickness due to paper covering in accordance with Table PR
(MW 60-C)
Square Wire:
Bare wire dimensions and tolerances, radii and increase in dimensions due to
paper covering in accordance with Tables PSQ (MW 60-C) for two or three
thicknesses of paper, whichever applies.
The increase in thickness for coverings having more than three thicknesses
of paper shall be as follows:

ELONGATION 3.4 Not less than 32 percent for thicknesses of 0.049 inch (1.25 mm and greater
or 30 percent for thicknesses less than 0.049 inch (1.25 mm)
wire after bending around a mandrel having a dimension 6 times the
thickness of the bare wire.
NOTE 1 The calculated maximum increase due to the polyamide paper covering may be exceeded provided the measured overall dimension
of the covered wire does not exceed the sum of the specified maximum conductor thickness plus the maximum increase due to the covering.
NOTE 3 The number of paper tapes, the paper tape thickness, and the degree of overlap shall be agreed upon between the user and
supplier.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 55
MW 60-C
AROMATIC POLYAMIDE PAPER COVERED RECTANGULAR AND SQUARE
Table PR (MW 60-C)
INCREASE IN DIMENSIONS OF RECTANGULAR WIRE DUE POLYAMIDE PAPER COVERING
Nominal Tape Thickness = 0.002 in. (.051 mm) Nominal Tape Thickness = 0.003 in. (.076 mm)
Number Minimum Maximum Minimum Maximum
of Tapes inches mm inches mm inches mm inches mm
2 0.004 0.102 0.012 0.305 0.006 0.152 0.018 0.457
3 0.008 0.203 0.016 0.406 0.012 0.305 0.024 0.610
NOTE 1 The calculated maximum increase due to the polyamide paper covering may be exceeded provided the measured overall dimension of the covered wire does not exceed
the sum of the specified maximum conductor thickness plus the maximum increase due to the covering.
NOTE 3 The number of paper tapes, the paper tape thickness, and the degree of overlap shall be agreed upon between the user and supplier.
Table PSQ (MW 60-C)Dimensions 1/014 AWG

(Inches)
Square Nom. Tape = 0.002 in. Nom. Tape = 0.003 in. Nom. Tape = 0.002 in. Nom. Tape = 0.003 in.
1/0 0.004 0.3399 0.006 0.3459 0.008 0.3439 0.012 0.3519
1 0.004 0.3042 0.006 0.3102 0.008 0.3082 0.012 0.3162
2 0.004 0.2722 0.006 0.2782 0.008 0.2762 0.012 0.2842
3 0.004 0.2437 0.006 0.2497 0.008 0.2477 0.012 0.2557
4 0.004 0.2183 0.006 0.2243 0.008 0.2223 0.012 0.2303
5 0.004 0.1957 0.006 0.2017 0.008 0.1997 0.012 0.2077
6 0.004 0.1756 0.006 0.1816 0.008 0.1796 0.012 0.1876
7 0.004 0.1577 0.006 0.1637 0.008 0.1617 0.012 0.1697
8 0.004 0.1418 0.006 0.1478 0.008 0.1458 0.012 0.1538
9 0.004 0.1275 0.006 0.1335 0.008 0.1315 0.012 0.1395
10 0.004 0.1149 0.006 0.1209 0.008 0.1189 0.012 0.1269
11 0.004 0.1037 0.006 0.1097 0.008 0.1077 0.012 0.1157
12 0.004 0.0938 0.006 0.0998 0.008 0.0978 0.012 0.1058
13 0.004 0.0850 0.006 0.0910 0.008 0.0890 0.012 0.0970
14 0.004 0.0771 0.006 0.0831 0.008 0.0811 0.012 0.0891
(mm)
Square Nom. Tape = 0.051 Nom. Tape = 0.076 Nom. Tape = 0.051 Nom. Tape = 0.076
1/0 0.102 8.633 0.152 8.786 0.203 8.735 0.305 8.938
1 0.102 7.727 0.152 7.879 0.203 7.828 0.305 8.031
2 0.102 6.914 0.152 7.066 0.203 7.015 0.305 7.219
3 0.102 6.190 0.152 6.342 0.203 6.292 0.305 6.495
4 0.102 5.545 0.152 5.697 0.203 5.646 0.305 5.850
5 0.102 4.971 0.152 5.123 0.203 5.072 0.305 5.276
6 0.102 4.460 0.152 4.613 0.203 4.562 0.305 4.765
7 0.102 4.006 0.152 4.158 0.203 4.107 0.305 4.310
8 0.102 3.602 0.152 3.754 0.203 3.703 0.305 3.907
9 0.102 3.239 0.152 3.391 0.203 3.340 0.305 3.543
10 0.102 2.918 0.152 3.071 0.203 3.020 0.305 3.223
11 0.102 2.634 0.152 2.786 0.203 2.736 0.305 2.939
12 0.102 2.383 0.152 2.535 0.203 2.484 0.305 2.687
13 0.102 2.159 0.152 2.311 0.203 2.261 0.305 2.464
14 0.102 1.958 0.152 2.111 0.203 2.060 0.305 2.263
NOTEThe maximum overall dimensions have been calculated in accordance with the values in Table PR (MW 60-C)

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 56
MW 61-A (Paper)
AROMATIC POLYAMIDE PAPER COVERED ROUND ALUMINUM
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.2 4/09 AWG: See Table PR (MW 61-A) for wire having two or three
thicknesses of paper. The increase in diameter for coverings having more
than three thicknesses of paper shall be specified as follows:

NOTE 1 The calculated maximum increase due to the polyamide paper covering may
be exceeded provided the measured overall diameter of the covered wire does not
exceed the sum of the nominal conductor diameter + 1% plus the maximum increase
due to the covering.
NOTE 2 The number of paper tapes, the paper tape thickness, and the degree of
overlap shall be agreed upon between the user and supplier.
ADHERENCE AND FLEXIBILITY 3.3.1 89 AWG: Covering shall not open sufficiently to expose the bare wire, nor
shall it be possible to slide the paper along the wire, after the specimen is
elongated 15% (+2, -0) and wound around a 5d mandrel
3.3.3 4/07 AWG: Covering shall not open sufficiently to expose the bare wire, nor
shall the covering show any tearing
wire after bending around a 6d mandrel.

MW 1000-2003
Part 2Page 57
MW 61-A
AROMATIC POLYAMIDE PAPER COVERED ROUND ALUMINUM
Table PR (MW 61-A)Dimensions 4/09 AWG
(inches)
Nom. Tape = 0.002 in. Nom. Tape = 0.003 in. Nom. Tape = 0.002 in. Nom. Tape = 0.003 in.
4/0 0.004 0.4766 0.006 0.4826 0.008 0.4806 0.012 0.4886
3/0 0.004 0.4257 0.006 0.4317 0.008 0.4297 0.012 0.4377
2/0 0.004 0.3804 0.006 0.3864 0.008 0.3844 0.012 0.3924
1/0 0.004 0.3401 0.006 0.3461 0.008 0.3441 0.012 0.3521
1 0.004 0.3042 0.006 0.3102 0.008 0.3082 0.012 0.3162
2 0.004 0.2722 0.006 0.2782 0.008 0.2762 0.012 0.2842
3 0.004 0.2437 0.006 0.2497 0.008 0.2477 0.012 0.2557
4 0.004 0.2173 0.006 0.2233 0.008 0.2213 0.012 0.2293
5 0.004 0.1948 0.006 0.2008 0.008 0.1988 0.012 0.2068
6 0.004 0.1748 0.006 0.1808 0.008 0.1788 0.012 0.1868
7 0.004 0.1570 0.006 0.1630 0.008 0.1610 0.012 0.1690
8 0.004 0.1412 0.006 0.1472 0.008 0.1452 0.012 0.1532
9 0.004 0.1270 0.006 0.1330 0.008 0.1310 0.012 0.1390
(mm)
Nom. Tape = 0.051 mm Nom. Tape = 0.076 mm Nom. Tape = 0.051 mm Nom. Tape = 0.076 mm
4/0 0.102 12.106 0.152 12.258 0.203 12.207 0.305 12.410
3/0 0.102 10.813 0.152 10.965 0.203 10.914 0.305 11.118
2/0 0.102 9.662 0.152 9.815 0.203 9.764 0.305 9.967
1/0 0.102 8.639 0.152 8.791 0.203 8.740 0.305 8.943
1 0.102 7.727 0.152 7.879 0.203 7.828 0.305 8.031
2 0.102 6.914 0.152 7.066 0.203 7.015 0.305 7.219
3 0.102 6.190 0.152 6.342 0.203 6.292 0.305 6.495
4 0.102 5.519 0.152 5.672 0.203 5.621 0.305 5.824
5 0.102 4.948 0.152 5.100 0.203 5.050 0.305 5.253
6 0.102 4.440 0.152 4.592 0.203 4.542 0.305 4.745
7 0.102 3.988 0.152 4.140 0.203 4.089 0.305 4.293
8 0.102 3.586 0.152 3.739 0.203 3.688 0.305 3.891
9 0.102 3.226 0.152 3.378 0.203 3.327 0.305 3.531
NOTEThe maximum overall diameters have been calculated in accordance with the formulas given in this specification:

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 58
MW 61-C
AROMATIC POLYAMIDE PAPER COVERED ROUND COPPER
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.2 See Table PR (MW 61-C) for wire having two or three thicknesses of paper.
The increase in diameter for coverings having more than three thicknesses of
paper shall be specified as follows:

NOTE 1 The calculated maximum increase due to the polyamide paper covering may
be exceeded provided the measured overall diameter of the covered wire does not
exceed the sum of the nominal conductor diameter + 1% plus the maximum increase
due to the covering.
NOTE 2 The number of paper tapes, the paper tape thickness, and the degree of
overlap shall be agreed upon between the user and supplier.
ADHERENCE AND FLEXIBILITY 3.3.1 89 AWG: Covering shall not open sufficiently to expose the bare wire, nor
shall it be possible to slide the paper along the wire, after the specimen is
elongated 15% (+2, -0) and wound around a 5d mandrel
3.3.3 4/07 AWG: Covering shall not open sufficiently to expose the bare wire, nor
shall the covering show any tearing
ELONGATION 3.4 Not less than the following:
Minimum Elongation
AWG Size Percent
4/0-1/0 35
19 30
wire after bending around a 6d mandrel.

MW 1000-2003
Part 2Page 59
MW 61-C
AROMATIC POLYAMIDE PAPER COVERED ROUND COPPER
Table PR (MW 61-C)Dimensions 4/09 AWG
(inches)
Nom. Tape = 0.002" Nom. Tape = 0.003" Nom. Tape = 0.002" Nom. Tape = 0.003"
4/0 0.004 0.4766 0.006 0.4826 0.008 0.4806 0.012 0.4886
3/0 0.004 0.4257 0.006 0.4317 0.008 0.4297 0.012 0.4377
2/0 0.004 0.3804 0.006 0.3864 0.008 0.3844 0.012 0.3924
1/0 0.004 0.3401 0.006 0.3461 0.008 0.3441 0.012 0.3521
1 0.004 0.3042 0.006 0.3102 0.008 0.3082 0.012 0.3162
2 0.004 0.2722 0.006 0.2782 0.008 0.2762 0.012 0.2842
3 0.004 0.2437 0.006 0.2497 0.008 0.2477 0.012 0.2557
4 0.004 0.2173 0.006 0.2233 0.008 0.2213 0.012 0.2293
5 0.004 0.1948 0.006 0.2008 0.008 0.1988 0.012 0.2068
6 0.004 0.1748 0.006 0.1808 0.008 0.1788 0.012 0.1868
7 0.004 0.1570 0.006 0.1630 0.008 0.1610 0.012 0.1690
8 0.004 0.1412 0.006 0.1472 0.008 0.1452 0.012 0.1532
9 0.004 0.1270 0.006 0.1330 0.008 0.1310 0.012 0.1390
(mm)
Nom. Tape = 0.002" Nom. Tape = 0.003" Nom. Tape = 0.002" Nom. Tape = 0.003"
4/0 0.102 12.106 0.152 12.258 0.203 12.207 0.305 12.410
3/0 0.102 10.813 0.152 10.965 0.203 10.914 0.305 11.118
2/0 0.102 9.662 0.152 9.815 0.203 9.764 0.305 9.967
1/0 0.102 8.639 0.152 8.791 0.203 8.740 0.305 8.943
1 0.102 7.727 0.152 7.879 0.203 7.828 0.305 8.031
2 0.102 6.914 0.152 7.066 0.203 7.015 0.305 7.219
3 0.102 6.190 0.152 6.342 0.203 6.292 0.305 6.495
4 0.102 5.519 0.152 5.672 0.203 5.621 0.305 5.824
5 0.102 4.948 0.152 5.100 0.203 5.050 0.305 5.253
6 0.102 4.440 0.152 4.592 0.203 4.542 0.305 4.745
7 0.102 3.988 0.152 4.140 0.203 4.089 0.305 4.293
8 0.102 3.586 0.152 3.739 0.203 3.688 0.305 3.891
9 0.102 3.226 0.152 3.378 0.203 3.327 0.305 3.531
NOTEThe maximum overall diameters have been calculated in accordance with the following:

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 60
MW 62-C
AROMATIC POLYIMIDE TAPE COVERED RECTANGULAR AND SQUARE
INSULATING MATERIALS: The insulating material shall be aromatic polyimide tape coated one or both
sides with an adhesive layer of fluorinated ethylene propylene (FEP). The
covering shall be one or two tapes wrapped spirally around the wire. After
wrapping, the tape shall be heat sealed.
THERMAL CLASS: The temperature index shall meet or exceed 240C, as defined in Part 3,
Clause 3.58.1.
GENERAL REQUIREMENTS: See Part 1; degree of overlapping and number of tapes as agreed upon
between purchaser and supplier.

Part 3, Clause
DIMENSIONS 3.2.2.2 a. Dimensions and radii:

Rectangular Wire in accordance with Table 1-8
Square Wire in accordance with Table 1-11
b. Thickness and width tolerances:
Rectangular Wire in accordance with Table 1-9
Square Wire in accordance with Table 1-12
c. Increase in thickness and width due to tape covering shall be as
follows:
Minimum Increase = 2(n1T1min + n2T2min)
Maximum Increase = 2[(n1+1)T1max +(n2+1)T2max]
Where:
n1 = the minimum number of tape thicknesses per side
(See 1.5.1) achieved using the specified degree of
overlap for tape 1, the tape closest to the conductor.
For overlaps of 0 up to but not including 1/2, n1=1

1/2 up to but not including 2/3, n1=2
2/3 up to but not including 3/4, n1=3
T1min = minimum tape thickness including adhesive of tape 1.

T1max = maximum tape thickness including adhesive of tape 1.
n2, t2min and T2max = same as above for tape 2 when used
NOTE 1 The calculated maximum increase due to the polyimide tape covering may
be exceeded provided the measured overall dimension of the covered wire does not
exceed the sum of the specified maximum conductor thickness plus the maximum
increase due to the covering.
NOTE 2 The number of tapes, the tape thickness, sides of application of FEP
adhesive, and the degree of overlap shall be agreed upon between the user and
supplier.
ADHERENCE AND FLEXIBILITY 3.3.6 No loss of adherence between tape to conductor or between layers of tape
greater, or 30 percent for a thickness of less than 0.049 inch (1.25 mm)

DIELECTRIC BREAKDOWN 3.8.2 Not less than 1000 Volts/mil (39370 V/mm) of the minimum thickness of

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 61
MW 63-C
AROMATIC POLYIMIDE TAPE COVERED BARE ROUND COPPER MAGNET WIRE
THERMAL CLASS 220
INSULATING MATERIALS: The insulating material shall be aromatic polyimide tape coated one or both
sides with an adhesive layer of fluorinated ethylene propylene (FEP). The
covering shall be one or two tapes wrapped spirally around the wire. After
wrapping, the tape shall be heat sealed.
THERMAL CLASS: The temperature index shall meet or exceed 240C, as defined in Part 3,
Clause 3.58.1.
GENERAL REQUIREMENTS: See Part 1This standard is based on one or two tape layers. The degree of
overlapping and tape thickness shall be agreed upon between purchaser and
supplier.

Part 3, Clause
DIMENSIONS 3.2.1.3 Bare Wire 414 AWG in accordance with Table 1-1
Tape Covered Wire in accordance with Table TR (MW 63-C)
The increase in dimensions due to the tape covering shall be as follows:
Minimum increase = 2 (n1T1min +n2T2min)

Maximum increase = 2[(n1+1)T1max + (n2+1)T2max]
Where:
n1 = the minimum number of tape thicknesses per side, achieved
using the specified degree of overlap for tape 1, the tape
closest to the conductor (See 1.5.1).
For overlaps of 0 up to 1/2, n=1

For overlaps of 1/2 up to 2/3, n=2
T1min = min. tape thickness including adhesive of tape 1.
T1max = max. tape thickness including adhesive of tape 1.
n2, T2min and T2max = same as above for tape 2 when used.
NOTE 1 The calculated maximum increase due to the polyimide tape covering may be exceeded provided the
measured overall diameter of the covered wire does not exceed the sum of the nominal conductor diameter + 1%
plus the maximum increase due to the covering.
NOTE 2 The number of tapes, the tape thickness, sides of application of FEP adhesive, and the degree of overlap
shall be agreed upon between the user and supplier.
ADHERENCE AND FLEXIBILITY 3.3.4 No loss of adherence between tape to conductor or between layers of tape
ELONGATION 3.4 Not less than 30 percent.
SPRINGBACK 3.7.2 Not greater than 5.5 degrees
DIELECTRIC BREAKDOWN 3.8.2 Not less than 1000 Volts/mil (39370 V/mm) of the minimum thickness of tape
covering on one side (one half the minimum increase)
TABLE TR (MW 63-C)

INSULATED WIRE DIMENSIONS
(Based on .0015 inch, 10% thick tape; .0010 inch tape thickness, with .0005 inch adhesive one side)
One Tape Layer Two Tape Layers

Minimum Additional Increase, Maximum Additional Increase, Minimum Additional Increase, Maximum Additional Increase,
Overlap Overlap Overlap Overlap
0 up to 1/2 1/2 up to 2/3 0 up to 1/2 1/2 up to 2/3 0 up to 1/2 1/2 up to 2/3 0 up to 1/2 1/2 up to 2/3
inch mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm
.0026 .066 .0052 .132 .0064 0.16 .0096 0.24 .0052 .132 .0104 .264 .0128 0.33 .0192 0.49
NOTEMax. OD = maximum bare wire diameter + maximum addition.

MW 1000-2003
Part 2Page 62
MW 72-C
POLYESTER (AMIDE)(IMIDE) FILM INSULATED ROUND COPPER MAGNET WIRE
FOR HERMETIC APPLICATIONS, THERMAL CLASS 180
INSULATING MATERIAL The coating is based on polyester (amide)(imide) resins (1.4.2).

Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Heavy 1430 AWG in accordance with Table 1-1

RATED TEMPERATURE
REFREIGERANT 22 EXTRACTION 3.55 Not greater than 0.25 percent of the weight of the film insulation
RETAINED DIELECTRIC AFTER 3.56 18 AWG Heavy Build specimens shall average not less than 5700 V
R-22 CONDITIONING
SCRAPE RESISTANCE 3.59 Lowest "grams-to-fail" load for any one of the three tests and the
average of the three tests shall not be less than the values in Table
3.59.1

MW 1000-2003
Part 2Page 63
MW 73-A
POLYESTER (AMIDE) (IMIDE) OVERCOATED WITH POLYAMIDEIMIDE FILM INSULATED ROUND
ALUMINUM MAGNET WIRE FOR HERMETIC APPLICATIONS, THERMAL CLASS 220
based on polyester (amide)(imide) resins (1.4.2). The superimposed coating
is based on polyamideimide resins (1.4.2).
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Heavy 1228 AWG in accordance with Table 1-1

RATED TEMPERATURE
REFREIGERANT 22 EXTRACTION 3.55 Not greater than 0.25 percent of the weight of the film insulation
R-22 CONDITIONING
3.59.1

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 64
MW 73-C
POLYESTER (AMIDE) (IMIDE) OVERCOATED WITH POLYAMIDEIMIDE FILM INSULATED ROUND
COPPER MAGNET WIRE FOR HERMETIC APPLICATIONS, THERMAL CLASS 200
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Heavy and Quad 1430 AWG in accordance with Table 1-1
RATED TEMPERATURE
REFRIGERANT 22 EXTRACTION 3.55 Not greater than 0.25 percent of the weight of the film insulation
R-22 CONDITIONING
3.59.1

MW 1000-2003
Part 2Page 65
MW 74-A
POLYESTER (AMIDE) (IMIDE), FILM INSULATED ROUND ALUMINUM
INSULATING MATERIAL The conductor is based on polyester (amide)(imide) resins (1.4.2).

Clause 3.58.1.

3, Clause
RATED TEMPERATURE

MW 1000-2003
Part 2Page 66
MW 74-C
POLYESTER (AMIDE) (IMIDE), FILM INSULATED ROUND COPPER
INSULATING MATERIAL The conductor is based on polyester (amide)(imide) resins (1.4.2).

Clause 3.58.1.
Properties Procedure, Part 3, Requirement

Clause
RATED TEMPERATURE

MW 1000-2003
Part 2Page 67
MW 75-C
POLYURETHANE, FILM INSULATED ROUND COPPER MAGNET WIRE
FOR SOLDERABLE APPLICATIONS THERMAL CLASS 130

Clause 3.58.1.

3, Clause
HEAT SHOCK 3.5 No cracks visible in the film coating after conditioning at 175C,
Exceptionuse 6d mandrel for all sizes
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time specified at
360C:
2529 6 seconds
3036 5 seconds
3746 4 seconds
4756 3 seconds

conductor
RATED TEMPERATURE

MW 1000-2003
Part 2Page 68
MW 76-A
based on polyester (amide)(imide) resins (1.4.2). The superimposed
insulation is based on polyamide resins (1.4.2).
Clause 3.58.1.

Part 3, Clause
RATED TEMPERATURE
SCRAPE RESISTANCE 3.59 Lowest "grams-to-fail" load for any one of the three tests and the average
of the three tests shall not be less than the values in Table 3.59.1

MW 1000-2003
Part 2Page 69
MW 76-C
based on polyester (amide)(imide) resins (1.4.2). The superimposed
insulation is based on polyamide resins (1.4.2).
Clause 3.58.1.

3, Clause
RATED TEMPERATURE

MW 1000-2003
Part 2Page 70
MW 77-C
POLYESTER (IMIDE) FILM INSULATED ROUND COPPER MAGNET WIRE
INSULATING MATERIAL The coating is based on polyester (imide) resins (1.4.2).

Clause 3.58.1.

3, Clause
ADHERENCE AND 3.3.1 No cracks visible in the film coating
FLEXIBILITY
470C:
AWG Size Single Heavy
2529 6 seconds 6 seconds

conductor
RATED TEMPERATURE

MW 1000-2003
Part 2Page 71
MW 78-C
POLYESTER (IMIDE) OVERCOATED WITH POLYAMIDE, FILM INSULATED ROUND COPPER MAGNET
INSULATING MATERIAL The conductor shall be coated with dual film. The underlying coating is based
on polyester (imide) resins (1.4.2). The superimposed coating is based on
Clause 3.58.1.

3, Clause
470C:
1415 10 seconds
1619 8 seconds
2029 6 seconds
3036 5 seconds
3744 4 seconds

conductor
RATED TEMPERATURE

MW 1000-2003
Part 2Page 72
MW 79-C
POLYURETHANE FILM INSULATED ROUND COPPER MAGNET WIRE FOR SOLDERABLE
APPLICATIONS THERMAL CLASS 155

Clause 3.58.1.

3, Clause
in accordance with Table 1-1
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time and at the
AWG
Temperature Single Heavy Triple
Size
2529 390C 4 seconds 5 seconds 5 seconds

conductor
RATED TEMPERATURE
SCRAPE RESISTANCE 3.59 Lowest "grams-to-fail" load for any one of the three tests and the average of the three
tests shall not be less than the values in Table 3.59.2

MW 1000-2003
Part 2Page 73
MW 80-A
POLYURETHANE OVERCOATED WITH POLYAMIDE FILM INSULATED ROUND ALUMINUM MAGNET
INSULATING MATERIAL The conductor shall be coated with a dual film. The underlying insulation is
Clause 3.58.1.

Part 3, Clause
SOLDERABILITY 3.13 Insulation completely removed after immersion within the time and at the
temperature specified
2023 430C 8 seconds
2430 390C 6 seconds

bare conductor
RATED TEMPERATURE

MW 1000-2003
Part 2Page 74
MW 80-C
POLYURETHANE OVERCOATED WITH POLYAMIDE FILM INSULATED ROUND COPPER MAGNET WIRE
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Single, Heavy and Triple 1444 AWG in accordance with Table 1-1
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time and at
the temperature specified
AWG
Size

bare conductor
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 75
MW 81-C
POLYAMIDEIMIDE FILM INSULATED ROUND COPPER MAGNET WIRE
THERMAL CLASS 220
INSULATING MATERIAL The coating is based on polyamideimide resins (1.4.2).

Clause 3.58.1.
Properties Procedure, Part 3, Requirement

Clause
RATED TEMPERATURE

MW 1000-2003
Part 2Page 76
MW 82-C
POLYURETHANE FILM INSULATED ROUND COPPER MAGNET WIRE FOR SOLDERABLE
APPLICATIONS THERMAL CLASS 155

Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Single 2556 AWG, Heavy 2550 AWG and Triple 3044 AWG in accordance with
Table 1-1
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion within the time and at the
AWG
Size
2529 390 6 seconds 6 seconds
3036 390 5 seconds 5 seconds 5 seconds
3746 390 4 seconds 4 seconds 4 seconds
4756 360 3 seconds 3 seconds

conductor
RATED TEMPERATURE
SCRAPE RESISTANCE 3.59 Lowest "grams-to-fail" load for any one of the three tests and the average of the three
tests shall not be less than the values in Table 3.59.2

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 77
MW 83-C
POLYURETHANE OVERCOATED WITH POLYAMIDE FILM INSULATED ROUND COPPER MAGNET WIRE
Clause 3.58.1.

Part 3, Clause
DIMENSIONS 3.2.1.1 Single and Heavy 1444 AWG, Triple 2544 AWG in accordance with
Table 1-1
SOLDERABILITY 3.13 Covered with continuous film of solder after immersion for the time and
temperature specified
AWG
Size

bare conductor
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 78
MW 102-A
POLYESTER (AMIDE) (IMIDE) OVERCOATED WITH POLYAMIDEIMIDE, AND SELF-BONDING
OVERCOAT FILM INSULATED ROUND ALUMINUM MAGNET WIRE
THERMAL CLASS 180/BOND STRENGTH PERFORMANCE 180C
based on polyester (amide) (imide) resins (1.4.2). The intermediate coating is
based on polyamideimide resins (1.4.2), and the superimposed outer coating
is based on resins, which are self-bonding in character (1.4.2).
THERMAL CLASS 180 with the above construction as defined in Part 1, Clause 1.8, and tested
in accordance with Part 3, Clause 3.58.1.
BOND PERFORMANCE Determined by the retained bond strength at 180C in accordance with 3.57.4

Part 3, Clause
RATED TEMPERATURE
BOND STRENGTH 3.57.3.1 Minimum 30 lbs. (134 N) of helical coil bond strength of 18 AWG copper
ROOM TEMPERATURE Type 2 after processing at bond conditions agreed upon between customer
and supplier.
BOND STRENGTH 3.57.4 Minimum of 3 lbs. (13 N) of retained helical coil bond strength of 18 AWG
ELEVATED TEMPERATURE copper Type 2 tested at 180 3C after processing at bond conditions
agreed upon between customer and supplier.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 79
MW 102-C
POLYESTER (AMIDE) (IMIDE) OVERCOATED WITH POLYAMIDEIMIDE, AND SELF-BONDING
OVERCOAT FILM INSULATED ROUND COPPER MAGNET WIRE
THERMAL CLASS 180/BOND STRENGTH PERFORMANCE 180C
based on polyester (amide) (imide) resins (1.4.2). The intermediate coating is
based on polyamideimide resins (1.4.2), and the superimposed outer coating
is based on resins, which are self-bonding in character (1.4.2).
THERMAL CLASS 180 with the above construction as defined in Part 1, Clause 1.8, and tested
in accordance with Part 3, Clause 3.58.1.
BOND PERFORMANCE Determined by the retained bond strength at 180C in accordance with 3.57.4

Part 3, Clause
DIELECTRIC BREAKDOWN 3.8.3 1437 AWG: Not less than the value in Table 3.8.3.2
3.8.7 3840 AWG: Not less than the value in Table 3.8.7.3
RATED TEMPERATURE
BOND STRENGTH 3.57.3.1 Minimum 30 lbs. (133 N) of helical coil bond strength of 18 AWG copper
ROOM TEMPERATURE Type 2 after processing at bond conditions shall be as agreed upon
between customer and supplier.
BOND STRENGTH 3.57.4 Minimum of 3 lbs. (13 N) of retained helical coil bond strength of 18 AWG
ELEVATED TEMPERATURE copper Type 2 tested at 180 3C after processing at bond conditions
agreed upon between customer and supplier.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 80
MW 130-C
POLYURETHANE WITH SELF-BONDING OVERCOAT, FILM INSULATED ROUND COPPER MAGNET
resins that are self-bonding in character (1.4.2).
Clause 3.58.1

Part 3,
Clause
AWG Size Temperature Type 1 Type 2
2529 390 C 4 seconds 5 seconds

RATED TEMPERATURE
BOND STRENGTH 3.57.3.1 18, 26 AWG Type 2No break in the coil specimen when subjected to the
ROOM TEMPERATURE load specified in Table 3.57.1.
3.57.3.2 36 AWG Type 2No separation of turns other than the first or last turn.
BOND STRENGTH 3.57.4 Bond conditions and strength requirements as agreed upon between
ELEVATED TEMPERATURE customer and supplier.

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 81
MW 131-C
POLYURETHANE WITH SELF-BONDING OVERCOAT, FILM INSULATED ROUND COPPER MAGNET WIRE
resins that are self-bonding in character (1.4.2).
Clause 3.58.1

Part 3,
Clause
CONTINUITY 3.9.2 2544 AWG Max number of discontinuities in accordance with Table
3.9.3 3.9.2.1
4552 AWG Max number of discontinuities in accordance with Table 3.9.3

RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 82
MW 135-C
THERMAL CLASS 130
polyamide resins (1.4.2). The superimposed coating is based on resins that
are self-bonding in character (1.4.2).
THERMAL CLASS 130 is defined in Part 1, Clause 1.8, and when tested in accordance with Part 3,
Clause 3.58.1

Part 3, Clause
at the temperature specified:
AWG Size Temperature Type 1 and Type 2

2023 430C 8 seconds
2429 390C 6 seconds
3036 390C 5 seconds
3744 390C 4 seconds

DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of the value in Table 3.8.3.2 (Polyamide column)
RATED TEMPERATURE

MW 1000-2003, Revision 1, June 16, 2005
Part 2Page 83
MW 136-C
THERMAL CLASS 155
polyamide resins (1.4.2). The superimposed outer coating is based on resins
that are self-bonding in character (1.4.2).
THERMAL CLASS 155 is defined in Part 1, Clause 1.8, and when tested in accordance with Part 3,
Clause 3.58.1

Part 3, Clause
at the temperature specified:

DIELECTRIC BREAKDOWN AT 3.52 Average not less than 75% of the value in Table 3.8.3.2 (Polyamide column)
RATED TEMPERATURE

MW 1000-2003
Part 2Page 84

MW 1000-2003
Part 3Page 1
Part 3
TEST PROCEDURES
(See Part 1, Clause 1.3 for Definitions, and Clause 1.6 for Test Conditions and Parameters)
3.1 SAFETY STATEMENT

It is not the intent of this standard to address all of the safety issues associated with its use. It is the
responsibility of the user of this standard to train personnel, establish proper health and safety procedures and
be aware of local, state and national regulatory restrictions that may apply.
chemical hazard: Some tests use materials that local, state, and national regulatory agencies have
determined to be hazardous. These tests shall be performed under controlled conditions, which allow for
proper safety and protection of personnel. Information and instructions contained in Material Safety Data
Sheets (MSDS) for handling, working and disposal of hazardous chemicals shall be followed. Furthermore,
discharges of these chemicals to the environment, that is, the air, water or ground must comply with the latest
applicable regulations.
electrical hazard: Certain test procedures require high voltage. It is important that the equipment be
designed to comply with good engineering practices with safety being an integral part of the design. To avoid
electric shocks in such cases, necessary precautions must be taken and test equipment manufacturers'
recommendations shall be followed.
mechanical hazard: Some tests utilizing mechanical equipment may expose the operator to mechanical
hazards. Care must be exercised to protect eyes, fingers, hands, and other body parts from injury.
thermal hazard: In tests requiring elevated temperatures, precautions must be taken in handling materials
exposed to heat to avoid skin burns.
ROUTINE TESTS
3.2 DIMENSIONS
The increase in dimensions due to the insulation shall be determined in accordance with 3.2.1 or 3.2.2.
3.2.1 Round Wire

3.2.1.1 Film Insulated
3.2.1.1.1 Optical Micrometer Method (Preferred)
The overall diameter of the film-insulated wire shall be measured at a minimum of four different positions
evenly spaced around one half of the circumference. The average of these readings shall be recorded as the
overall diameter.
The insulation shall be removed at approximately the same position on the wire by means not injurious to the
conductor, and the measurements shall be repeated around the bare wire. The average of the readings shall
be recorded as the diameter of the conductor. The increase in diameter due to the insulation shall be
calculated in accordance with the following equation:
(Increase in diameter due to insulation) = (Overall diameter) - (Diameter of bare wire)
3.2.1.1.2 Hand or Bench Mechanical Micrometer Method (Alternative)

The film insulated wire shall be measured at a minimum of four points, evenly spaced around one half of the
circumference. The largest and smallest readings shall be recorded, and the average of these two readings
shall be taken as the overall diameter. The insulation shall then be removed at approximately the same
position on the wire by means not injurious to the conductor and the measurements repeated around the
bare wire. The average of the largest and smallest readings shall be taken as the diameter of the bare wire.
The use of measuring instruments such as pressure type micrometers or electronic meters shall be

MW 1000-2003
Part 3Page 2
permitted in measuring diameters in accordance with Table 3.2.1. The increase in diameter due to the
insulation shall be calculated in accordance with the following equation:
3.2.1.2 Self Bonding Over Coated
The increase in diameter due to the self-bonding overcoat shall be determined in the following manner. The
overall diameter shall be measured in accordance with 3.2.1.1.1 or 3.2.1.1.2. The result shall be recorded as
the overall diameter. The self-bonding overcoat shall then be removed by immersing the wire for 2 minutes
in a solvent which will remove the outer coating without swelling or softening the underlying film coating and
then wiping the wire with a wipe dampened with solvent. The diameter of the underlying film coating shall be
measured by the same method used for determining the overall diameter. The result shall be taken as the
diameter of the underlying film coated wire. The increase in the diameter due to the self-bonding overcoat
shall be calculated according to the following equation:
(Increase in diameter due to self-bonding overcoat) = (Overall diameter) - (Diameter of underlying film coated wire)
The underlying film insulation shall be removed at approximately the same position on the wire by means
not injurious to the conductor and the measurements shall be repeated around the bare wire. The
average, determined in accordance with either 3.2.1.1.1 or 3.2.1.1.2 shall be recorded as the diameter of
the conductor. The increase in diameter due to the underlying film coating shall be determined according to
the following equation:
(Increase in diameter due to underlying film coating) = (Diameter of underlying film coated wire) - (Diameter of bare wire)
3.2.1.3 Fibrous and Tape Covered

A pressure type micrometer shall be used to measure the diameters in accordance with Table 3.2.1.
Fibrous covered wire shall be measured at three locations, spaced approximately 1 foot (305 mm) apart. In
each set of measurements, the diameter shall be measured at two points on the circumference,
approximately 90 degrees apart. The average of these readings shall be taken as the overall diameter.
When measuring tape covered wire, care shall be exercised to make measurements at the maximum overall
diameter. The insulation shall then be removed at approximately the same positions on the wire by means
not injurious to the bare wire and the measurements repeated around the bare wire.
Table 3.2.1
SPECIFICATION FOR MICROMETER ANVIL DIAMETER AND SPINDLE FORCE
Test Parameters Wire Type Film Coated Fibrous Covered Tape Covered
Anvil Diameter Round and 0.250 .001 in. 0.250 .001 in. 0.250 .001 in.
Rectangular (6 .03 mm) (6 .03 mm) (6 .03 mm)
Spindle Force Round 25 AWG and Smaller Same as Film Coated ...
35 oz. (0.81.4 N)
Spindle Force Round Larger than 25 AWG Same as Film Coated ...
810 oz. (2.22.8 N)
Spindle Force Rectangular All sizes 810 oz. Same as Film Coated ...
(2.22.8 N)
Spindle Force Round and All Sizes
Rectangular ... ... (2.53.0 lb.)
(11.213.4 N)
In the case of glass fiber or polyester glass covering over film coated wire, the film coating as well as the
glass fibers shall be removed and the measurements repeated around the bare wire. In each set of
measurements, the diameter shall be measured at two points on the circumference, approximately 90
degrees apart. The increase in diameter due to the insulation shall be calculated in accordance with the
following:

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 3
3.2.2 Rectangular and Square Wire

3.2.2.1 Film Insulated
The overall dimension shall be measured on three carefully straightened specimens, each a minimum of 3
inches (76 mm) long, taken from the reel at approximately 1-foot (305-mm) intervals. Straightening shall be
accomplished by stretching the wire not more than 1 percent to remove bends or kinks. One measurement
of the dimension shall be made over the insulation of each specimen for both the thickness and width. The
average of the three readings for thickness and width shall be taken as the overall dimension for thickness
and width. The insulation shall then be removed at these points by means not injurious to the bare wire, the
same measurements made, and then the average taken as the dimensions of the bare wire. A pressure type
micrometer shall be used to measure the thickness and width dimensions (See Table 3.2.1). The radii of
bare wire shall be measured with a standard radius gauge.
thickness and width: The increase in the thickness and width dimensions due to the insulation shall be
calculated in accordance with the following:
Increase in dimension due to insulation = (Overall dimension) (Dimension of bare wire)
3.2.2.2 Fibrous and Tape Covered
The dimensions shall be measured in accordance with 3.2.2.1. A pressure type micrometer shall be used
to measure overall dimensions (See Table 3.2.1). In the case of glass fiber or polyester glass covering
over film coated wire, the film coating as well as the glass fibers shall be removed and the measurements
repeated to determine the overall increase due to the insulation. When measuring tape covered wire,
care shall be exercised to make measurements at the maximum overall dimensions.
3.3 ADHERENCE AND FLEXIBILITY

Warning: Mechanical Hazard Equipment must be designed to contain any flying pieces of wire. Operator
should wear proper safety equipment.
3.3.1 Elongation and Mandrel Wrap Method
A specimen having an effective length of 10 1/4 in. (254 6 mm) shall be elongated, wound ten turns (or
until the specimen is consumed) around a mandrel, and examined in accordance with Table 3.3.1.
Table 3.3.1
ADHERENCE, FLEXIBILITY AND HEAT SHOCK: ELONGATION AND MANDREL DIAMETERS
Material Elongation Mandrel Total
AWG Size Elongation Rate Percent (+2,-0) Diameter Elongation Examined With
Copper
Rectangular 12 1 in (305 25 mm) per min See Part 2 None See Part 2 Normal vision
49 Round 12 1 in (305 25 mm) per min 30 None 30 Normal vision
1013 12 1 in (305 25 mm) per min 25 5d 36.7 Normal vision
1430 Sudden jerk** 20 3d 45 Normal vision
3144 Sudden jerk** 20 3d 45 6x10x magnification
4556 Sudden jerk** 5 0.006 in 33 10x15x magnification
(0.150 mm)
Aluminum
Rectangular 12 1 in (305 25 mm) per min See Part 2 None See Part 2 Normal vision
49 Round 12 1 in (305 25 mm) per min 15 None 15 Normal vision
1015 12 1 in (305 25 mm) per min 15 5d 26.7 Normal vision
** 12-15 ft./sec. (3.7-4.9 m/sec.)
Or to its breaking point, whichever is less
Applies to Adherence and Flexibility testing only

MW 1000-2003
Part 3Page 4
Round wire test specimens shall be evenly wound in a close helix around the mandrel and under sufficient
tension to ensure a compact winding. Care shall be exercised not to introduce an axial twist into the
specimen. Any failures on the first and last turns of the round wire mandrel specimens shall be disregarded.
3.3.2 Mandrel Wrap Method

A specimen of sufficient length shall be tightly wound three turns around a mandrel equal to the diameter
specified in Part 2. Round wire test specimens shall be evenly wound in a close helix around the mandrel
and under sufficient tension to ensure a compact winding. Care shall be exercised not to introduce an axial
twist into the specimen. The specimen shall be examined with normal vision.
3.3.3 Elongation Method

A specimen having an effective length of 10 inches (254 mm) shall be elongated by the percentage specified
in Part 2, at a rate of 12 1 inches (305 25 mm) per minute. The elongation shall be 30 percent (+2, -0) for
copper or 15 percent (+2, -0) for aluminum if an elongation percentage is not specified in Part 2. The
specimen shall be examined with normal vision.
3.3.4 Circumferential Cut and Elongation Method

The insulation of a test specimen having an effective length of 10 inches (254 mm) shall be circumferentially
cut at approximately its mid-point and then elongated at least 10% at a rate of 12 inches 1 inch per minute
(305 mm 25 mm). The specimen shall then be examined with normal vision.
3.3.5 Bend and Shot Dielectric Method

A specimen shall be wound flatwise 180 degrees around a mandrel having a diameter 10 times the
thickness of the bare wire, and the bent portion shall be buried in lead, nickel or nickel-plated shot, 0.080 to
0.110 inch (2.0 to 2.8 mm) in diameter. The specimen shall then be tested in accordance with 3.8.1,
applying the voltage between the conductor and the shot.
3.3.6 Flat and Edge Bend Method

A specimen shall be bent flatwise and edgewise 90 degrees around a mandrel having a diameter 4 times
the thickness or width respectively. The specimen shall be examined with normal vision.
3.4 ELONGATION
A specimen having an effective length of 10 inches 1/4 inch (254 mm 6 mm) shall be elongated to its
breaking point at a rate of 12 1 inches (305 25 mm) per minute. The specimen gripping jaws shall be
such that a break will not occur within 1/4 inch (6 mm) of either jaw. The travel distance of the jaw at the
instant of break shall be noted and the percentage of elongation calculated. The minimum percent
elongation values listed in Table 3.4.1 or 3.4.2 shall apply to the wire size range specified in Part 2. In case
of failure of glass fiber covered wire sizes 21 AWG and larger, the fibrous covering shall be removed from
another specimen and the wire tested. On sizes 22 AWG and smaller, the fibrous covering shall be removed
from the specimens prior to testing.
Table 3.4.1
MINIMUM PERCENT ELONGATION, SQUARE AND RECTANGULAR WIRE
Copper Aluminum
Glass Fiber
Wire Film Paper, With Glass Polyester/ Aromatic Aromatic Film Fibrous
Size Insulated Paper- Glass Removed Glass Fiber Polyamide Polyimide Insulated Covered
Cotton Paper Film
MW Specification 18, 20, 36 33 42, 43, 52 46, 48, 53 60 62 18, 36 60
Square and T 0.049 32 32 32 n/a 32 32 32 15 15
Rectangular T < 0.049 32 30 30 n/a 30 30 30 15 15

MW 1000-2003
Part 3Page 5
Table 3.4.2
MINIMUM PERCENT ELONGATION, ROUND WIRE
Copper Aluminum
MW Specification * 31 41, 44, 50, 52 45, 47, 51 61 63 * 61
AWG Film Paper, With Glass Polyester/ Aromatic Aromatic Film Fibrous
Size Insulated Paper-Cotton glass removed Glass Fiber Polyamide Polyimide Insulated Covered
Paper Film
4/01/0 32 35 35 35 35 15 15
13 32 30 30 30 30 30 15 15
4 38 30 30 30 30 30 15 15
5 37 30 30 30 30 30 15 15
6 37 30 30 30 30 30 15 15
7 36 30 30 30 30 30 15 15
8 36 25 30 30 30 30 30 15 15
9 36 25 20 30 20 30 30 15 15
10 35 25 20 30 20 30 15
11 35 25 20 30 20 30 15
12 34 25 20 30 20 30 15
13 34 25 20 30 20 30 15
14 33 20 20 30 20 30 15
15 33 20 20 30 20 15
16 33 20 15 25 15 15
17 32 20 15 25 15 15
18 32 20 15 25 15 15
19 31 20 15 25 15 15
20 30 20 15 25 15 14
21 30 20 15 25 15 14
22 29 20 20 10 14
23 29 10 20 10 14
24 28 10 20 10 13
25 28 10 20 10 13
26 27 10 20 10 13
27 27 10 20 10 13
28 26 10 20 10 12
29 26 10 15 10
30 25 10 15 10
31 24 10
32 24 10
33 23
34 22
35 21
36 20
37 20
38 19
39 18
40 17
41 17
42 16
43 15
44 14
45 11
46 10
47 8
48 7
49 6
50 5
* See Table of Contents for a list of MW specification numbers for these constructions.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 6
3.5 HEAT SHOCK
Warning: Thermal Hazard Care must be exercised in removing test specimens from the oven to avoid
skin burns.
A specimen having an effective length of 10 inches 1/4 inch (254 mm) shall be elongated at the rate given
and wound not more than ten turns around a mandrel equal to the diameter given in Table 3.3.1, unless
otherwise specified in Part 2. Round wire test specimens shall be evenly wound in a close helix around the
mandrel and under sufficient tension to ensure a compact winding. Any failures on the first and last turns of
the round wire mandrel specimens shall be disregarded. Care shall be exercised not to introduce an axial
twist into the specimen.
The specimen shall be removed from the mandrel and placed in a circulating air oven for 30 (+5, -0) minutes
at not less than the temperature specified in Part 2. The specimen shall be allowed to cool to room
temperature and shall then be examined in accordance with Table 3.3.1.
3.6 (RESERVED)
3.7 SPRINGBACK (COPPER CONDUCTORS ONLY)
3.7.1.1 Principle of Test
The springback of a wire specimen quantifies the amount of elastic memory remaining in a wound coil by
measuring the angular displacement of its free end as it is allowed to slowly unwind.
NOTEA soft wire will exhibit less of a tendency to spring back. Hence the degrees return (springback) will be less than that for harder wire.
3.7.1.2 Scale Description

The springback scales are graduated into 120 segments representing degrees per turn since the wire is
wrapped three times around the specified mandrel, as shown in Figure 3.7.1.1. The marked segments on the
scales are drawn from the theoretical centers of the relaxed coils.
The theoretical centers of the relaxed coils are determined using the following calculations:
Dnew = 360 * Dinitial / [360 ( / 3)]
Where:
Dnew = New diameter of the relaxed coil
Dinitial = Initial diameter of the mandrel upon which the wire was wrapped
= The angle that the mark on the last turn of wire travels in the relaxed coil
Thus the new center Cnew:
Cnew = Dnew / 2 measured from the top of the original mandrel diameter.

MW 1000-2003
Part 3Page 7
0
5
115
10
110
15
105
20
25 100
30 95
35
90
40
85
45
80
50 75
55
70
65
60
Figure 3.7.1.1
DETAILS OF SPRINGBACK SCALE

MW 1000-2003
Part 3Page 8
3.7.1.3 Procedure
Using a Springback tester (see Figures 3.7.1.2 and 3.7.1.3), a specimen shall be wound for three turns
around a mandrel having the diameter shown in Table 3.7.1 under the tension indicated.
Figure 3.7.1.2 Figure 3.7.1.3

SPRINGBACK TESTER AFTER WINDING A EXAMPLE OF SPRINGBACK SCALES
COIL UNDER TENSION
Springback test equipment shall be operated in accordance with the following procedure:
a. The instrument shall be mounted with the shaft of the mandrel horizontal and at a height sufficient to allow
a 4.0-ft (1.22-meter) sample to hang freely.
b. The mandrel shall be locked in position so that the hole for fastening the wire is in a vertical position to
correspond with zero on the dials.
c. The wire to be tested shall be removed carefully from the package in such a way that the wire will not be
subjected to extra bends or tension and shall be wound onto the mandrel in the same direction as
originally coiled.
d. One end of the wire shall be inserted into the mandrel hole provided using the mandrel diameter and
weight specified in Table 3.7.1.
e. The wire shall be layer-wound by turning the mandrel counter-clockwise through exactly three revolutions
at a rate of 5 to 10 rpm.
f. A mark shall be made on the last turn opposite the zero mark on the dial.
g. The wire shall be held in place on the mandrel and the weight removed soon after the coil is wound.
h. The wire shall be cut leaving approximately inch (12 mm) of wire past the zero mark. This inch (12
mm) length shall be bent into a vertical position.
i. Placing a pencil or other supporting device to the left of the vertical end of the wire the coil shall be
allowed to unwind slowly without jerking.
NOTEIf the wire is permitted to spring back suddenly, erroneous results are obtained.
j. The indicating point on the free end of the coil shall come to rest on the curve on the dial.
k. The springback value is read from the indicating dial on the mandrel, which aligns with the mark on the
last turn.

MW 1000-2003
Part 3Page 9
Table 3.7.1
SPRINGBACKMANDREL WRAP METHOD
Mandrel Diameter Tension ( 2%) Springback Maximum Degrees per Turn
AWG inches mm Single and Heavy Triple and Quad
Size ( 0.005) ( 0.127) Ounces Newtons Build, and Type 1 Build, Types 2 and 3
14 3.25 82.6 16 4.45 42 46
15 3.25 82.6 16 4.45 46 49
16 3.25 82.6 16 4.45 50 53
17 3.25 82.6 16 4.45 54 58
18 3.25 82.6 16 4.45 58 62
19 3.25 82.6 16 4.45 62 66
20 3.25 82.6 16 4.45 66 70
21 1.88 47.6 4 1.11 53 57
22 1.88 47.6 4 1.11 58 60
23 1.88 47.6 4 1.11 62 64
24 1.88 47.6 4 1.11 67 69
25 1.88 47.6 2 0.56 72 74
26 1.88 47.6 2 0.56 76 80
27 0.75 19.0 2 0.56 50 55
28 0.75 19.0 2 0.56 55 60
29 0.75 19.0 2 0.56 61 65
30 0.75 19.0 2 0.56 66 70

MW 1000-2003
Part 3Page 10
3.7.2 Deflection Method (All Rectangular,

and Round Sizes Larger than 14 AWG)
3.7.2.1 Principle of Test
The test consists of bending a specimen over a
given angle, then removing the load and measuring
the Springback in degrees.
3.7.2.2 Specimen
The sample shall be at least 48 inches (1219 mm)
long and shall be removed from the spool with as
little bending as possible. It shall be carefully
straightened by hand and cut into 16-inch (406-
mm) specimens. Work hardening shall be
minimized. Elongation by machines shall NOT be
used for straightening.
3.7.2.3 Test Apparatus

The Springback is determined by means of the
apparatus shown in Figure 3.7.2, consisting
essentially of two smooth jaws, one fixed (2), the
other moveable (1), and a sector graduated in
degrees (5) with the 0-10 sector of the scale
graduated in 0.5 increments.
The test apparatus shall be placed in a horizontal

position on a table. The graduated sector is an arc
placed in a plane 90 to the clamp faces. Its center
is located at the outer edge of the fixed jaw (3). The
lever arm whose fulcrum is placed at the center of
the arc can move over the graduated sector in the
horizontal plane. The lever arm shall have a marker
to clearly indicate the Springback. There is a
movable slider (4) located on the lever arm which
has a 12 inch (305 mm) length scaled off in tenths
of an inch (or 0.25 mm).
3.7.2.4 Test Procedure

The test shall be made by bending the wire
specimens in the same direction that the wire was
bent when wound on the spool. A lever arm slider is
provided to compensate for differences in
thicknesses or diameter of the test specimen. The
bare wire thickness (or round wire diameter) shall
be measured to determine the actual position of
the slider. The calculated distance from the fulcrum Figure 3.7.2
to the lever arm slider pointer is determined by APPARATUS FOR SPRINGBACK DEFLECTION METHOD
multiplying the thickness (or diameter) of the wire
by 40. The wire is moderately tightened between
the jaws with the direction of the former curvature
up, or away from the operator, to leave a free
length of specimen extending approximately 0.5
inches (13 mm) beyond the slider knife edge.

MW 1000-2003
Part 3Page 11
By means of the lever arm, starting at the horizontal position (the 30 scale mark, position 1), the wire is
gently bent 30 (to the 0 scale mark, position 2). The time of this bending shall be not less than 2 seconds
nor more than 5 seconds. The specimen is held at the 0 point (a 30 bend) for a maximum of 2 seconds.
3.7.2.5 Value of Springback
The lever arm is gently returned in the reverse direction at the same angular rate at which it was raised until
the slider knife edge moves away from the wire specimen. The lever arm is then raised until the slider knife
edge again just contacts the wire specimen without moving it. The point where the lever arm pointer aligns
with the graduated sector scale indicates the Springback value
The value of Springback is read directly on the scale shown by the position of the lever arm marker on the
graduated sector (in position 3).
The operator shall test three specimens per sample. The results of the three specimens must not differ by
more than 0.5 over a consecutive length of sample or a new sample shall be selected and tested. The final
result shall be the average of the three specimens.
3.8 DIELECTRIC BREAKDOWN
Warning: Electrical Hazard Extremely high voltages may be present. Personnel performing the test must
be adequately trained and qualified. The design of the test equipment must comply with good engineering
practice and incorporate safety features. This includes grounding of metal parts to avoid electric shock and
burns to operators performing the test.
Warning: Chemical Hazard Ozone gas may be generated under high voltage conditions during testing.
Test area must have adequate ventilation.
3.8.1 Test Procedure General
A source of 60-hertz voltage of a substantially sinusoidal waveform shall be applied separately and
consecutively between a specified electrode and the conductor or between two conductor legs.
The testing transformer shall have a rating of 500 volt-amperes or more and shall provide an essentially
undistorted waveform under test conditions.
Fault current of the circuit shall be a minimum of 1.5 milliamperes.
The voltage shall start at zero and shall be increased uniformly at the rate of 500 volts per second ( 10%)
until breakdown occurs. In the event that breakdown occurs in less than 5 seconds, the rate of increase in
voltage shall be reduced sufficiently so that breakdown occurs in not less than 5 seconds. The breakdown
voltage (ASTM D 149) shall be measured with a meter calibrated in rms. (root mean squared) volts in
accordance with one of the methods described in ANSI/IEEE Std 4.
In case of failure, additional specimens of wire in an unbent and un-stretched condition shall be dried for 20
1 minutes in a forced air oven at 60C 3C (140 4.5F). The sample shall be cooled to room
temperature and tested in accordance with the foregoing procedure.
Dielectric breakdown values are affected by the presence of skin oils, acids, salts, dust, dirt, etc. Gloves
shall be worn when preparing test specimens or during handling of magnet wire for this test.
3.8.2 Foil Electrode Method
Electrodes shall be prepared by applying a 1/4-inch (6-mm) wide thin metal foil to the center of a 1/2-inch
(13 mm) wide pressure-sensitive tape. The tape shall be cut into strips each about three inches (76 mm)
long. Four of these electrodes shall be applied at right angles to the specimen at intervals approximately 2
inches (51 mm) and wrapped smoothly and firmly around the specimen a minimum of 1-1/2 complete turns,
with the metal surface of the foil in contact with the insulation. The test voltage shall be applied separately
and consecutively between each electrode and the conductor. The minimum breakdown voltage shall be in
accordance with Table 3.8.2 for round film insulated wire, or as indicated in Part 2 for other wire to which this
test applies.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 12
Table 3.8.2
DIELECTRIC BREAKDOWN, MINIMUM VOLTAGEFOIL METHOD
Standard Round Film Insulated Copper Wire

AWG Single Heavy Heavy Build with Polyamide Topcoat
Size Build Build Round Film Insulated Copper Wire
4 3700
5 3700
6 3600
7 3500
8 1870 3500
9 1870 3400 3060
3.8.3 Twisted Pair Method

A specimen of wire shall be formed into a "U" shape and the two legs twisted together the number of 360
rotations specified in Table 3.8.3.1 to form an effective sample length of 4.75 0.25 inches (121 mm 6
mm). The total tension on the two legs, and the total number of rotations shall be as shown in Table 3.8.3.2.
The closed end loop of the twisted specimen shall be cut and the ends shall be carefully and adequately
separated. There shall be no sharp bends in the specimen or damage to the insulation. A source of 60-hertz
voltage of a substantially sinusoidal waveform shall be applied between the two conductor legs. Three
specimens shall be tested and each specimen shall be in accordance with Table 3.8.3.2 for the particular
wire specification in Part 2.
Table 3.8.3.1
TWISTED PAIR METHOD: TENSIONS AND ROTATIONS
AWG Total Tension on Total Number of
Size Specimen ( 2%) Rotations
89* 24 Pounds (107N) 3
1011 24 Pounds (107N) 3
1214 12 Pounds (53 N) 4
1517 6 Pounds (27N) 6
1820 3 Pounds (13N) 8
2123 1.5 Pounds (7N) 12
2426 340 Grams (3.3 N) 16
2729 170 Grams (1.7 N) 20
3032 85 Grams (0.8 N) 25
3335 40 Grams (0.4 N) 31
3637 20 Grams (0.2 N) 36
* Aluminum only

MW 1000-2003
Part 3Page 13
Table 3.8.3.2
DIELECTRIC BREAKDOWN, MINIMUM VOLTAGETWISTED PAIR METHOD
Single Build or Type 1 Heavy Build or Type 2 Triple Build or Type 3 Quad Build**
Standard Polyamide Standard Polyamide Standard Polyamide Standard Polyamide
AWG topcoat topcoat topcoat topcoat
Size
8 3740* 7000*
9 3740* 6800*
10 3740 6800 6120
11 3740 6600 5940
12 3520 6400 5760
13 3520 6400 5760
14 3520 3170 6330 5690 8450 7600 11000 9900
15 3430 3090 6160 5550 8230 7410 10720 9650
16 3340 3010 6000 5400 8020 7220 10440 9400
17 3250 2930 5850 5260 7810 7030 10170 9150
18 3170 2850 5700 5130 7610 6850 9910 8920
19 3090 2780 5550 4990 7410 6670 9650 8690
20 3010 2710 5410 4870 7220 6500 9400 8460
21 2930 2640 5270 4740 7030 6330 9160 8240
22 2850 2570 5130 4620 6850 6170 8920 8030
23 2780 2500 5000 4500 6670 6010 8690 7820
24 2710 2440 4870 4380 6500 5850 8470 7620
25 2640 2370 4740 4270 6330 5700 8250 7420
26 2570 2310 4620 4160 6170 5550 8040 7230
27 2500 2250 4500 4050 6010 5410 7830 7040
28 2440 2200 4380 3950 5860 5270 7630 6860
29 2380 2140 4270 3840 5700 5130 7430 6690
30 2380 2140 4220 3800 5640 5080 7340 6600
31 2040 1840 3900 3510 5080 4570 6770 6100
32 2040 1840 3570 3210 4800 4320 6210 5590
33 1700 1530 3250 2920 4230 3810 5640 5080
34 1700 1530 2920 2630 3950 3560 5360 4830
35 1360 1220 2920 2630 3670 3300 4800 4320
36 1360 1220 2600 2340 3390 3050 4520 4060
37 1360 1220 2270 2050 3100 2790 3950 3560
* Aluminum only
** Excludes MW 16-C (Quad)

MW 1000-2003
Part 3Page 14
3.8.4 Wound Pair Method

A wire shall be bent over the hook of the served wire specimen winder
(see Figure 3.8.4) and wound in a manner similar to that described in
3.8.3, but without axial twist in the conductor, for a distance of 4.75
0.25 inches (121 6 mm). The tension on each wire of the pair shall be
one-half that given in Table 3.8.3.1. The total number of rotations shall
be as shown in Table 3.8.3.1. The ends shall be carefully and
adequately separated, and there shall be no sharp bends in the
specimen or damage to the insulation. A source of 60-hertz voltage of a
substantially sinusoidal waveform shall be applied between the two
conductor legs. Three specimens shall be tested and each specimen
shall meet the requirements of Table 3.8.3.2.
3.8.5 Layer Method
Two specimens shall be wound, one on top of the other, for a distance of
approximately 1 inch (25 mm) on a smooth mandrel of an insulating
material. The diameter of the mandrel shall be in accordance with Part
2. The ends of each of the windings shall be secured in such a manner
that the two layers are maintained in intimate contact, and there is no
loosening of the convolutions. A source of 60-hertz voltage of a
substantially sinusoidal waveform shall be applied between the two
wound layers.
3.8.6 Bend Method
Two undamaged 10-inch (250 mm) specimens of wire shall be
elongated 10 percent and bent approximately 4 inches (10 mm) from
each end, one flatwise and one edgewise, on a 90-degree angle over a
mandrel as specified in Table 3.8.6 in the form of a . The specimen
shall be bent around the mandrel perpendicular to the axis of the
mandrel and under sufficient tension to ensure a uniform bend. During
the bending operation, extreme caution shall be observed to prevent
external damage to film coating such as may occur due to scraping,
cutting, etc. A strip of 1/4-inch (6-mm) wide conductive adhesive metal Figure 3.8.4
foil tape shall be wrapped around the wire smoothly and firmly a WOUND PAIR SPECIMEN
minimum of 1-1/2 complete turns at the center of each bend. A source of WINDER
60-hertz voltage of a substantially sinusoidal waveform shall be applied
separately and consecutively between each foil electrode and the
conductor.
Table 3.8.6
BEND METHOD MANDREL SIZES
Flatwise Bend-Thickness Edgewise Bend-Width Mandrel (1%)
inches mm inches mm inches mm
Less than 0.050 Less than 1.27 0.200 5.08
0.0500.063 1.301.60 0.250 6.35
0.0640.075 1.631.90 0.300 7.62
0.0760.088 1.932.24 0.0760.088 1.932.24 0.350 8.89
0.0890.100 2.262.54 0.0890.100 2.262.54 0.400 10.2
0.1010.125 2.573.18 0.1010.125 2.573.18 0.500 12.7
0.1260.150 3.203.81 0.1260.150 3.203.81 0.600 15.2
0.1510.187 3.844.75 0.1510.187 3.844.75 0.750 19.1
0.1880.219 4.785.56 0.1880.219 4.785.56 0.900 22.9
0.2200.250 5.596.35 0.2200.250 5.596.35 1.00 25.4
0.2510.310 6.387.87 0.2510.310 6.387.87 1.25 31.8
0.3110.375 7.909.52 1.50 38.1
0.3760.435 9.5511.1 1.75 44.4
0.4360.500 11.112.7 2.00 50.8

MW 1000-2003
Part 3Page 15
3.8.7 Cylinder Method

A straight piece of wire with the insulation removed from one end shall be connected to the upper terminal as
shown in Figure 3.8.7 and wound once around the cylinder. The cylinder shall be made of metal with a
polished contact surface and shall have a diameter of 25.0 0.5 mm (0.98 0.02 in.). In addition the cylinder
shall be mounted horizontally and electrically connected to one terminal of the AC test supply voltage.
Upper terminal
Wire specimen
Voltage
Source
Cylinder electrode
Insulating
material
Load
Figure 3.8.7
TEST APPARATUS FOR CYLINDER METHOD
A load, as specified in Table 3.8.7.2 shall be applied to the lower end of the wire to maintain close contact with
the cylinder surface. Each individual value shall meet or exceed the minimum voltages specified in Table
3.8.7.3 for a given insulation build. The test voltage shall be started at zero and increased at a uniform rate of
20 to 500 V/s, according to Table 3.8.7.1, so that breakdown does not occur in less than 5 seconds. The test
shall be conducted at room temperature. Five specimens shall be tested. The five individual results shall be
reported.
Table 3.8.7.1
RATE OF INCREASE IN VOLTAGE CYLINDER METHOD
Breakdown Voltage
(Volts) Rate of Increase
Over Up to and including (V/Sec)
500 20
500 2,500 100
2,500 500

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 16
Table 3.8.7.2
CYLINDER METHOD TEST LOADS
AWG Load (grams) Load (N)

10%, 10%
38 39 0.400
39 29 0.300
40 25 0.250
41 20 0.200
42 15 0.150
43 12 0.120
44 12 0.120
45 10 0.100
46 6.0 0.060
47 6.0 0.050
48 4.0 0.040
49 3.0 0.030
50 2.5 0.025
51 2.0 0.020
52 1.5 0.015
53 1.3 0.013
54 1.3 0.013
55 1.3 0.013
56 1.3 0.013
Table 3.8.7.3
MINIMUM DIELECTRIC BREAKDOWN VOLTAGE CYLINDER METHOD
Single Build or Type 1 Heavy Build or Type 2 Triple Build or Type 3 Quad Build
Standard Polyamide Standard Polyamide Standard Polyamide Standard Polyamide
AWG topcoat topcoat topcoat topcoat
Size
38 500 450 950 850 1400 1250 1835 1650
39 500 450 900 800 1300 1175 1695 1525
40 425 375 850 750 1200 1075 1550 1395
41 425 375 700 650 1100 1000 1410 1270
42 375 350 700 650 990 890 1270 1145
43 325 300 650 600 845 760 1130 1015
44 300 275 600 550 845 760 1130 1015
45 275 250 550 500 760 685 990 890
46 250 225 475 425 690 620 990 890
47 225 200 425 375
48 190 170 375 350
49 170 150 325 300
50 150 130 300 275
51 130 110 275 250
52 120 100 250 225
53 110 100 225 200
54 100 90 200 175
55 100 90 200 175
56 90 80 175 150

MW 1000-2003
Part 3Page 17
3.9 CONTINUITY
Warning: Electrical Hazard Extremely high voltages may be present. The design of the equipment must
comply with good engineering practices and incorporate safety features. This includes grounding of metal
parts to avoid electric shock and burns to trained personnel who are operating the equipment.
3.9.1 General
3.9.1.1 Definitions
fault (or discontinuity): Any defect (or series of defects) in 1 inch (25 mm) of wire that allows sufficient
current flow to activate the fault detection circuit.
test voltage: open circuit DC voltage ( 5%) applied across the film insulation.
fault detection current: current flowing ( 10%) from the electrode sheave through the fault detection
circuit.
sensitivity: minimum current that will activate the fault counter in the fault detection circuit.
3.9.1.2 Retesting
In case of failure under prevailing laboratory conditions, two additional specimens of wire shall be dried for
20 1 minutes in a forced air oven at 60C 3C (140F 4.5F). The sample shall be cooled to room
temperature and testing in accordance with the foregoing procedure. Gloves shall be worn when preparing
test specimens or during handling of magnet wire for this test.
3.9.1.3 Note on Transition to New Electrodes

Until December 31, 2004, the use of dual electrode sheave electrodes as described in NEMA MW 1000-
1997 shall be considered acceptable as an alternative to the graphite fiber brush electrodes as described in
3.9.2. In the case of differences in test values between the two types of electrodes, the values obtained
using graphite fiber brush electrodes shall prevail.
3.9.2 High-Voltage Direct Current Continuity (14-44 AWG)
One hundred (+2, -0) feet (30.5 +0.6, -0 mm) of film-insulated wire shall be passed through a graphite fiber
brush electrode at a speed of 60 3 feet (18 1 m) per minute. Grounded freely rotating metallic guide
sheaves shall be used, one before and one after the graphite fiber brush electrode assembly. The conductor
shall be electrically grounded by means of either a ground terminal or a grounded take-up drum. The pay-off
equipment shall be designed to prevent damage to the wire being tested and shall provide sufficient tension
to straighten the wire for complete contact with the entire length of graphite fiber brush. The open circuit test
voltage maintained between the energized (positive polarity) graphite fiber brush electrode and the
grounded conductor shall be indicated in Table 3.9.2.1.
Table 3.9.2.1
TEST VOLTAGES (DC VOLTS 5%) AND MAXIMUM FAULT COUNT PER 100 FEET
Build Single Heavy Triple
Self-Bonding Type 1 Type 2 Type 3 Quad
Material/AWG Range
Copper
1424 1000 1500 2000 2500
2530 750 1000 1500 2000
3135 500 750 1000 1500
3644 350 500 750 1000
Maximum Fault Count per 100 feet 15 5 3 3
Aluminum
1424 750 1500
2528 500 1000
Maximum Fault Count per 100 feet 25 10

MW 1000-2003
Part 3Page 18
The high voltage power supply shall be regulated and shall provide filtered direct current voltage up to 3000
volts, free of transient over-voltage spikes. All voltage settings shall be checked with a high impedance
device, such as an electrostatic voltmeter. Sufficient internal resistance shall be provided so that rapid
collapse of the applied voltage occurs when a fault is detected. Rapid recovery of the voltage to the test level
is also required.
A surge dampening resistor of 4.7 megohms 10 percent shall be installed in the high voltage line at the
electrode connection. No shielding shall be used on the high-voltage lead since a minimum capacitance to
ground is sought during switching and counting events.
The graphite fiber brush electrode assembly shall be constructed so that the conductive brushes completely
surround and contact the wire surface for a length of 1 0.1 inches (25.4 2.5 mm). The graphite fiber
brush electrode shall be inspected, cleaned, or replaced if excessive wear or accumulation of foreign
material is present.
The graphite fiber brush electrode assembly shall be electrically isolated for the duration of the test to
prevent false readings at the specified voltages.
The test device shall include such wire handling equipment as will provide the specified wire speed
stipulated and shall be capable of handling wire sizes 14 through 44 AWG. A length indicator with a preset
shut-off feature shall be included so that exact lengths can be monitored. The drive shall have sufficient
power to maintain speed under the heaviest load.
The steady state short circuit current shall be limited internally by series resistance to 25 5 microamperes
at any test voltage setting. A 50-megohm fault resistance at the electrode sheaves shall not cause more
than a 75 percent drop in voltage at the graphite fiber brush electrode at any voltage setting.
The sensitivity of the fault detection circuit shall be such that the threshold fault current will be as shown in
Table 3.9.2.2. The speed of response of the fault circuit to a single fault pulse or to the accumulated time of
multiple, closely spaced fault pulses (all occurring within 83 milliseconds) shall be 4 to 6 milliseconds. The
fault counter circuit shall be designed to repeat at a rate of 450 45 counts per minute when bare wire is
passing through the graphite fiber brush electrode.
Table 3.9.2.2
THRESHOLD FAULT CURRENT
DC Test Voltage, Volts Threshold Fault Current Microamperes
3000 16
2500 14
2000 12
1500 10
1000 8
750 7
500 6
350 5
The fault counter shall be a digital readout device such as an electromechanical counter or its electronic
equivalent. Means for resetting the counter to zero shall be included.
The maximum number of discontinuities (faults) shall be in accordance with Table 3.9.2.1, as applicable
for the particular requirements in Part 2.
3.9.3 Low-Voltage Direct Current Continuity (45-56 AWG)

Warning: Chemical Hazard Mercury has been recognized to be a hazardous substance by regulatory
agencies. Primary routes of exposure are through inhalation and ingestion. The information contained in the
Material Safety Data Sheet (MSDS) for Mercury must be adhered to while using, handling, or disposing this

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 19
material. Mercury spills need to be treated with great caution. Information on how to handle spills can be
obtained from the supplier.
A 100 (+2, -0) feet (30.1 +0.6, -0 meters) of film coated wire shall be passed through a bath of mercury or
other suitable material (see Figure 3.9.3) at a speed of 100 10 feet per minute (30.5 3 meters). The test
circuit shall be so arranged that the discontinuity indicating device will operate when the resistance between
the conductor and the bath of mercury or other suitable material is 5,000 ohms or less but will not operate
when the resistance is 10,000 ohms or more. The test circuit shall include a repeating circuit that will indicate
600 breaks per minute 10 percent when a bare wire is passed through the bath of mercury or other suitable
material. The direct current test voltage of 20 1 volts shall be applied between the bath and the conductor.
The number of discontinuities shall be recorded, and shall not exceed the values in Table 3.9.3.
Table 3.9.3
LOW VOLTAGE CONTINUITY MAXIMUM FAULT COUNT PER 100 FEET
Film Insulation Build Single Heavy
Self-Bonding Type 1 Type 2
Material/ AWG Range
Copper/ 4556 AWG 25 10
Figure 3.9.3
BATH OF MERCURY OR OTHER SUITABLE MATERIAL

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 20
3.10 DISSIPATION FACTOR
Warning: Chemical Hazard Mercury has been recognized to be a hazardous substance by regulatory
agencies. Primary routes of exposure are through inhalation and ingestion. The information contained in
the Material Safety Data Sheet (MSDS) for mercury must be adhered to while using, handling, or disposing
this
material. Mercury spills need to be treated with great caution. Information on how to handle spills can be
obtained from the supplier.
3.10.1 Principle of Test

A wire specimen is treated as a capacitor where the insulation is the dielectric, and the conductor acts as one
electrode and a conducting medium as the second electrode. This capacitor is connected into a circuit, which
operates at the required frequency and is suitable for measurement of the capacitive and resistive
components from which the dielectric dissipation factor is obtained.
3.10.2 Equipment
- An automatic RLC bridge producing a sinusoidal frequency at 1.0 0.1 kHz, or equivalent;
- A circulating air oven capable of maintaining a temperature within 3C;
- Test method A
a) Metal blocks either maintained at 25 5C, or having a heating system that controls the
temperature to 1C
b) Conducting suspension
- Test method B - Metal bath according to Figure 3.10.2, containing a suitable liquid metal (alloy)
maintained at 25 5C, or having a heating system that controls the temperature to 1C.
3.10.3 Preparation of Specimen

Gloves shall be worn when preparing test specimens or during handling of magnet wire for this test.
3.10.3.1 Specimen for Metal Bath Electrode

A straight piece of wire shall be bent into a U-shape to fit into the metal bath as shown in Figure 3.10.2.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 21
1 Plug
2 Insulating material
3 Metallic container
4 Specimen
5 Electrode
6 Terminal
7 Insulated clamp
Figure 3.10.2
ELECTRODE AND SPECIMEN ARRANGEMENT FOR
DISSIPATION FACTOR TEST
3.10.3.2 Specimen for Conductive Suspension Electrode

3.10.3.2.1 Round wire, 38 AWG and Finer
A straight piece of wire approximately 150 mm (6 inches) in length shall be wound around a straight piece of
1218 AWG copper wire and subsequently coated with a conductive suspension, for example by brushing a
layer of an aqueous graphite dispersion on the specimen. The coated length shall be 100 6 mm (4 0.25
inches) The specimen shall then be dried.
3.10.3.2.2 Round wire, Larger than 38 AWG, and Rectangular and Square Wire
A straight piece of wire approximately 6 inches (150 mm) in length shall be coated with a conductive
suspension, for example, by brushing a layer of an aqueous graphite dispersion on the wire. The coated
length shall be 4 0.25 inches (100 6 mm). The specimen shall then be dried.
3.10.4 Procedure
3.10.4.1 Test Method A
The specimen shall be placed between the two metal blocks, with the conductively coated section within
the edges of the blocks. On rectangular wire specimens, the dissipation factor of the film shall be
measured on the wider sides of the magnet wire.
NOTEIn order to obtain accurate readings, it is essential to establish intimate contact between the surface electrode and the outer surface
of the magnet wire specimen being tested.
3.10.4.2 Test Method B

The specimen shall be connected into the metal bath as shown in Figure 3.10.2.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 22
3.10.4.3 Measurement
For either method, the specimen shall be connected to the RLC bridge and shall be allowed to reach the test
temperature, and the dissipation factor read.
3.10.4.4 Retesting
In the case of nonconformance, another specimen shall be wiped with a soft cloth or tissue and conditioned
in a circulating air oven for 20 1 minutes at 60 3C. The wire specimen shall be removed from the oven,
cooled to room temperature, and tested.
3.10.5 Result
The dissipation factor and the test temperature shall be recorded.
3.11 RESERVED
3.12 COVERAGE
The specimen shall be wound ten turns around the mandrel having the diameter specified in Part 2, and
examined with normal vision. Round wire test specimens shall be evenly wound in a close helix around the
mandrel and under sufficient tension to ensure a compact winding. Care shall be exercised not to introduce
an axial twist into the specimen.
3.12.2 Flat Bend Method

The specimen shall be bent flatwise 180 degrees around a mandrel having the diameter specified in Part 2,
and examined with normal vision. The specimen shall be bent around the mandrel perpendicular to the axis
of the mandrel and under sufficient tension to ensure a uniform bend.
3.13 SOLDERABILITY
Warning: Chemical Hazard Lead has been recognized to be a hazardous substance by regulatory
agencies. Primary routes of exposure are by inhalation and ingestion. The information contained in the
Material Safety Data Sheet (MSDS) for lead, tin, flux, and alcohol must be adhered to while using, handling,
or disposing of these products. Adequate ventilation or forced exhausting of solder pot vapors and products
of decomposition from various solderable insulations may be necessary to comply with environmental
regulations.
Warning: Thermal Hazard Care must be exercised in removing test specimens from the solder part to
avoid skin burns.
3.13.1 General
A 60/40 tin-lead solder conforming to ASTM B 32, Grade B shall be used for all tests. Any dross that forms
must be removed from the surface of the solder before each test.
The solder pot shall have a volume sufficient to ensure maintenance of a uniform solder temperature during
specimen immersion. The temperature shall be measured within 1/4 inch (6 mm) from the immersed end of
the specimen. The temperature must be controllable within 5C (9F) of the relevant specification
temperature indicated in Part 2.
In the event the specimen being tested does not meet the requirements of Part 2 at the specified solder
time, a new specimen shall be dipped in a suitable rosin-alcohol flux (10 parts of Grade WW water white
rosin mixed with 90 parts of denatured ethyl alcohol by weight) prior to retesting.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 23
3.13.2 Self-Supported Specimen Method (9-36 AWG)
A single-strand, straight length of wire shall be cut to a 6-inch (150-mm) test specimen. The specimen
prepared for test shall be immersed vertically to a depth of 1-1/4 to 1-15/16 inches (32 to 33 mm) at the
center of the solder pot for the time equal to or less than indicated in Part 2. After removal from the pot, the
lower 1/2 inch (13 mm) of the segment immersed in the pot shall be examined under 6x to 10x
magnification.
3.13.3 Fixture-Supported Specimen Method (37-56 AWG)
A specimen of wire shall be supported by means of a suitable carrier that allows the wire to be held free for
at least 1.3 inches 0.2 inches (33.0 5.1 mm) between the points of support. The material used for the
carrier shall be such that the solder bath does not undergo any contamination. The dimensions of the carrier
shall not lead to appreciable changes in the bath temperature during immersion. A suggested carrier
configuration is shown in Figure 3.13.3.
The specimen and fixture so prepared shall be immersed vertically to a depth of 1.25 to 1.50 inches (32 mm
to 38 mm) at the center of the solder pot for the time equal to or less than that indicated in Part 2. After
removal from the pot, examination shall be made under the 15x magnification and shall be restricted to the
center 1.0 0.1-inch (25.4 2.5-mm) free length section between the supports. Wire specimens finer than
52 AWG may be double stranded and twisted two to five times to avoid breakage during immersion.
Minimum Bend
Radius (typical)
Solderability
Evaluation
Section
Figure 3.13.3
SOLDERABILITY TEST SPECIMEN FIXTURE

MW 1000-2003
Part 3Page 24
3.50 THERMOPLASTIC FLOW

Warning: Thermal Hazard Care must be exercised in removing test specimens from the oven to avoid skin
burns.
3.50.1 Apparatus
The thermoplastic flow tester shall be capable of exerting a constant load perpendicular to, and directly over, the
right-angle crossover of the specimen. The tester shall include a control thermocouple of suitable temperature
range and a pyrometer to indicate the temperature measured by the control thermocouple. The actual specimen
temperature at each test position under the load at the crossover position shall be measured throughout the
expected temperature range by a calibrated thermocouple-pyrometer or other suitable measuring device, and
compared to the control or indicated temperature. The resulting temperature differences shall be used to
appropriately correct the indicated thermoplastic flow temperature. The testing chamber shall be of suitable size
to maintain a temperature rise at a rate of 10C (18F) to 45C (81F) per minute to not less than 50C (90F)
below the temperature specified in Part 2 and 5 1C (9 2F) per minute temperature rise from that point to
failure. The failure detector shall be so constructed that a current flow of 20 10 milliamperes at 115 volts 60
hertz between the crossed wires of the specimen will indicate failure.
3.50.2 Procedure
The thermoplastic flow values for all round 14 AWG and finer film insulated magnet wire shall be evaluated
according to the conditions specified in Table 3.50.2. The thermoplastic flow values for round film insulated wire
larger than 14 AWG and square and rectangular film insulated magnet wire shall be based on the test results of
that same insulation system on 18 AWG copper heavy build magnet wire.
The specimen shall consist of two lengths of wire crossed at right angles to each other in the apparatus. The
intersection of the two lengths of wire shall be carefully loaded as specified in Table 3.50.2. The temperature shall
be increased at 10C (18F) to 45C (81F) per minute until 55 5C (99 9F) below the thermoplastic flow
temperature specified in Part 2 is attained and then raised 5 1C (9 2F) per minute until failure of the
specimen occurs. The indicated temperature, corrected in accordance with 3.50.1, shall be taken as the
thermoplastic flow temperature of that specimen. For wire sizes 1435 AWG, five specimens shall be tested per
sample, and the median (the third highest value) shall be the thermoplastic flow temperature. For 36 AWG and
finer wire sizes, nine specimens shall be tested per sample, and the median (the fifth highest value) shall be the
thermoplastic flow temperature.
Table 3.50.2
THERMOPLASTIC FLOW TEST LOADS
Test Loads 2%
Size Ranges, AWG Test Load (grams) Test Load (Newtons)
1418 2000 19.60
1924 1000 9.80
2526 600 5.88
2729 300 2.94
3036 250 2.45
3740 150 1.47
4144 100 0.98

MW 1000-2003
Part 3Page 25
3.51 SOLUBILITY
Warning: Chemical Hazard Follow Material Safety Data Sheets (MSDS) instructions on using, handling, and
disposal of solvents specified in Part 2.
3.51.1 Round Film Insulated Wire (10 AWG and Finer)

3.51.1.1 Preparation of Specimens
Specimens of un-stretched and unbent film coated wire, each 12 inches (305 mm) long, which have been stress
annealed for 10 (+1, -0) minutes at 150 3C (302 5F) shall be immersed for at least 6 inches (152 mm),
without bending, for 30 (+5, -0) minutes in the liquids specified in Part 2 and maintained at 60 2C (140 4F).
A separate specimen is required for each liquid.
3.51.1.2 Needle Scrape (1030 AWG)

The specimens shall then be removed from
the solvent and tested within 2 minutes, but
not less than 1 minute, on a device which
scrapes the surface of the film coating at right
angles to the length of the wire with a 0.016
inch (0.406 mm) diameter steel needle. The
needle shall be loaded to 50% of the
minimum average grams-to-fail unidirectional
scrape load as specified in the
corresponding table in Part 2 (See Figure
3.51.1). The specimens shall be wiped with a
clean cloth or tissue to remove any liquid and
shall be straightened by hand, without
stretching, to remove kinks. After the wire is
inserted in the test apparatus, the weighted
needle shall be lowered gently to the surface
of the film coating and the wire scraped at 2
inches (51 mm) per second 10% along the
portion that was immersed. Exposure of the Figure 3.51.1
bare conductor shall be indicated by an MACHINE FOR SOLUBILITY SCRAPE
electrical circuit having a potential of 7.5 1.5
volts between the needle and the conductor.
3.51.1.3 Cheesecloth Wipe (Finer than 30 AWG)

The specimens shall then be removed from the solvent and, within 2 minutes but not less than 1 minute, drawn
once between the folds of four thicknesses of cheesecloth pressed firmly between the forefinger and the ball of
the thumb. Any removal of the coating caused by kinks or mechanical injury shall not be considered as failure to
meet the requirements of Part 2.
3.51.2 Round Wire Larger than 10 AWG, Rectangular and Square Wire
Specimens of un-stretched and unbent film coated wire, each 12 inches (305 mm) long, which have been stress
annealed for 30 (+5,-0) minutes at 150 3C (302 5F) shall be immersed at least 6 inches
(150 mm), without bending, for 30 (+5,-0) minutes in the liquids specified in Part 2 and maintained at
60 2C, (140 4F). Each specimen shall be immersed in one liquid only. The specimens shall then be tested
in accordance with 3.51.1.3

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 26
3.52 DIELECTRIC BREAKDOWN AT RATED TEMPERATURE

Warning: Electrical Hazard Extremely high voltage may be present. Personnel performing the test must be
adequately trained and qualified. The design of the test equipment must comply with good engineering practices
and incorporate safety procedures. This includes grounding of metal parts to avoid electric shock and burns to
operators performing the test.
Warning: Thermal Hazard Care must be exercised in handling the wire samples at elevated temperatures to
avoid skin burns.
Warning: Chemical Hazard Ozone gas may be generated under high voltage conditions during testing. Test
area must have adequate ventilation.
3.52.1 Test Procedure

Each of five specimens, prepared in accordance with Clause 3.8.3, shall be placed in a suitable holder or holders,
then placed in a circulating air oven and connected to high-voltage feed-through connectors.
The temperature of the oven shall be raised to the temperature equivalent to the thermal class rating (see Part 2)
of the specimen 2C (4F).
Fifteen minutes, but not more than 30 minutes, after the oven reaches the temperature equivalent to the thermal
class rating of the specimen 2C (4F), a source of 60-hertz voltage as described in 3.8.1 shall applied to the
specimen through the feed-through connector at the oven. To determine compliance with the Part 2 specification,
the breakdown voltage shall be measured in accordance with 3.8.3 and the five results averaged.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 26-1
3.53 TOLUENE / ETHANOL COMPATIBILITY

Warning: Chemical Hazard Regulatory agencies have established permissible exposure levels for toluene and
ethyl alcohol. Primary routes for exposure are through absorption and inhalation. Consult Material Data Safety
Sheets (MSDS) for proper handling, use, and disposal of these products.
3.53.1 Principle of Test
This test evaluates the chemical compatibility of polyvinyl formal insulation with a 30/70 mixture of toluene and
ethyl alcohol that is at its boiling point.
3.53.2 Equipment & Materials
- Circulating air oven capable of maintaining a temperature within 3C;

- Erlenmeyer flask or suitable vessel
- Boiling chips or glass beads
- Reflux condenser
- Heating plate
- Toluene: Commercial grade 3 degree
- Ethyl Alcohol: Denatured with Methanol and Methyl Isobutyl Ketone: SDA formula 3A or equivalent
3.53.3 Specimen preparation
A straight length of magnet wire shall be conditioned by heating the wire specimen in a re-circulating oven for 10
(+1, -0) minutes at 125 3C (257 5F).
3.53.4 Procedure
An Erlenmeyer flask shall contain a mixture of 30 percent commercial grade 3 degree toluene and 70 percent
denatured ethyl alcohol by volume. Boiling chips or glass beads shall be added to the flask to control the boiling
as well as a reflux condenser to prevent the loss of solvents from the mixture. The flask shall be heated on a hot
plate until the mixture is boiling.
Immerse the previously conditioned wire specimen 4 to 5 inches (102 to 127 mm) in the mixture without bending
for 5 (+0.5, -0) minutes.
After removal from the mixture, square and rectangular specimens, and round wire specimens sizes 4 through 29
AWG shall be examined with normal vision. Sizes 30 through 44 AWG shall be examined by 6x to 10x
magnification.
3.53.5 Result
No swelling or blistering shall be visible in the film coating. Swelling of the film within 1/2 inch (12.7 mm) of the
immersed end shall not constitute failure. When testing self-bonding wire, the swelling, blistering, or removal of
the self-bonding outer coating shall not be considered as failure.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 26-2
3.54 TRANSFORMER OIL RESISTANCE AND HYDROLYTIC STABILITY

Warning: Thermal Hazard Care must be exercised in handling the apparatus and wire samples at elevated
temperatures, to avoid skin burns.
3.54.1 Principal of Test

The transformer oil resistance and hydrolytic stability of all film insulated sizes and shapes shall be evaluated
using 18 AWG heavy build magnet wire. It is recognized that water, a breakdown product of cellulose, is the
primary agent that causes deterioration of the magnet wire film-insulation in liquid-filled electrical equipment.
Sufficient time and temperature are required to break down the cellulose. This test method measures the effect of
this generated moisture in a sealed test environment.
3.54.2 Test Apparatus

This test requires the following equipment: tubes 1 in. by 12 in. (25 mm by 305 mm) capable of being sealed, a
forced air oven in compliance with ASTM D 2436, a pressure vessel, stainless steel, glass or glass-lined capable
of withstanding a minimum pressure of 870 psi (6.0 MPa) and equipped with a pressure tube assembly
containing a rupture disk set at 800 psi (5.5 MPa) maximum. The inside dimensions must be such that the
specimens are completely immersed in the insulating liquid. The forced air oven must be capable of providing a
constant temperature of 150 3C (302 5F) for 1000 10 hours.
3.54.3 Short Term Exposure Test

Prepare two tubes with 80 1 ml of transformer oil and to only one tube add 0.19 to 0.24 ml (approximately 4 or 5
drops) of distilled water. The tube containing no water will provide the control data. Place six straight 8 0.5 in.
(203 12 mm) unelongated specimens of 18 AWG heavy film-insulated magnet wire in each tube, seal the tubes,
and place in an oven set at 150 3C (302 5F) for 24 0.5 hours. After conditioning for 24 hours, remove the
tubes and cool to room temperature before opening. After removal from the tubes inspect the specimens for loss
of film integrity.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 27
3.54.4 Long Term Exposure Test

This procedure is written for a 400 ml vessel1, which requires approximately 302 in. (7671 mm) of 18 AWG heavy
film-insulated magnet wire. Table 3.54.4 shows the pressure vessel components as a percent of the vessel
volume.
Prepare 10 dielectric twisted pair specimens in accordance with 3.8.3: five flexibility specimens elongated by
sudden jerk to 20% and wrapped on a 3d mandrel in accordance with 3.3.1, and five specimens elongated to
10% in accordance with 3.4.
Table 3.54.4
PRESSURE VESSEL COMPONENTS
Component Pressure Vessel Volume %
Transformer Oil 65
Kraft Paper 4
Film Insulation 0.26
Steel 0.5
The pressure vessel shall contain the above prepared wire samples and the components listed in Table 3.54.4.
NOTEIt is necessary to add the remaining quantity of film insulated magnet wire from the original 302 in. wire sample in order to bring the
total volume of enamel to the specified value of 0.26% volume.
Dry a quantity of insulating liquid, in excess of 65% of the total volume of the pressure vessel by heating to 110
3C (230 5F) and hold for 30 0.5 min. and then de-aerate under a vacuum system at 15 0.5 mm of mercury
for 10 1 min. Process dielectric liquids that vaporize readily with controlled degassing.
Place the clean pressure vessel containing the test specimens, the Kraft paper, and metal in an oven at 105
3C (221 5F) for 240.5 hrs. to dry and then place under the vacuum system at 45 1 mm of mercury for 10
1 min. Open the pressure vessel while still hot, and carefully add the dry de-aerated insulating liquid. Ensure all
test materials are immersed in the insulating liquid. Close the vessel and either evacuate to remove the air above
the oil, or evacuate and fill with nitrogen or other inert atmosphere and seal. Age the sealed system in an oven at
150 3C (302 5F) for 1000 10 hours.
At the end of 1000 hours, cool the pressure vessel to room temperature, open, and remove one-half of the
dielectric specimens, test to breakdown and record the results. Remove the remaining dielectric specimens from
the pressure vessel, dry for 30 (+5, -0) min. at 125 3C (257 5F), and then test to breakdown for determining
compliance with Part 2 requirements.
NOTEHydrolytic degradation or water absorption can cause loss of dielectric breakdown strength of insulating films. If only absorption
occurs, drying the specimens prior to dielectric measurement will produce a recovery in dielectric strength.
Remove the flexibility and elongation specimens from the pressure vessel, wipe clean of excess oil, and visually
inspect for film-insulation defects.
3.55 REFRIGERANT (R-22) EXTRACTION

Warning: Mechanical Hazard For safe operation of this test, an autoclave having a pressure capacity of up to
3000 psi (20.7 MPa) is recommended. The heating systems should be equipped with a device designed to
deactivate the system when the pressure inside the pressure vessel approaches a prescribed critical value.
The autoclave should be equipped with a pressure relief / rupture disk system for emergency relief of
excessive pressures. A device designed to deactivate the heating system when the water flow through the
condenser coil is interrupted should also be a consideration.
Warning: Chemical Hazard Chemicals used in this test have been classified as hazardous by regulatory
agencies. Primary routes of exposure are through absorption and inhalation. Follow instructions provided in the
Material Safety Data Sheets (MSDS) for the safe handling, use, and disposal of these chemicals.
1
For different sized vessels, refer to ASTM D 1676 to determine the volume of the components.
MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 28
NOTEDue to environmental concerns, alternate refrigerants are being proposed for the replacement of R-22. These alternate materials will
most likely have different parameters, i.e., critical temperature, and cannot be substituted directly for R-22 in the test method described below.
In all probability, different time and temperature requirements will be necessary to satisfactorily complete the procedure. For additional
information, please contact the refrigerant manufacturer, or your magnet wire manufacturer, or both.
3.55.1 Preparation of Specimens

14-24 AWG round magnet wire shall be wound into eight coils having the dimensions of approximately 5/8 inch
(16 mm) diameter and 1 5/8 inches (41 mm) high. The recommended number of wire turns per coil shall be
according to Table 3.55.1, and should result in a total film insulation weight of 0.6 0.1 gram.
Table 3.55.1
RECOMMENDED TURNS/COIL
AWG Heavy Build Triple Build Quad Build
14 35 24 18
15 42 28 21
16 49 33 25
17 59 39 29
18 68 46 34
19 81 54 40
20 93 64 47
21 111 74 55
22 134 89 64
23 153 104 74
24 180 122 87
The eight coils shall be conditioned in a forced draft oven at 150 3C

(302 5F) for 15 (+1,-0) minutes, cooled to room temperature,
thoroughly washed in methylene chloride (Dichloromethane, ACS grade,
99.5% min by GC) and dried in a forced draft oven at 150 3C (302
5F) for 15 (+1,-0) minutes. After cooling for 30 (+5,-0) minutes, the eight
coils shall be weighed together to the nearest 0.0001 gram. The
combined weight of the eight specimens shall be the "total initial weight.
3.55.2 Environmental Conditioning

The eight specimens shall be placed in a 450-milliliter modified Wiley
siphon cup (see Figure 3.55.1). Care shall be taken to ensure that the
specimen coils do not block the siphon tube opening. Typical dimensions
are provided in Table 3.55.2. The specimens shall be suspended from
the condenser coil (see Figure 3.55.2) in the top portion of a 2000-milliliter
pressure vessel (similar to Parr autoclave #4632) below the condenser
(See Figure 3.55.3). The pressure vessel shall be assembled and
charged with 700 25 grams of monochlorodifluoromethane (R-22). The
pressure vessel shall be placed in a controlled heating system, and the
condenser water supply and drain line properly connected. The
Figure 3.55.1
temperature of the controlled heating system and the water flow running
REFRIGERANT
through the condenser shall be adjusted to maintain a reflux rate of 20 to
EXTRACTABLE SIPHON CUP
25 cup discharges per hour for six hours.
NOTEA pressure control range of 500 to 580 psig. (3.4 to 4.0 MPa) has been experienced with R-22.
The autoclave pressure shall be kept at last 60 psig (0.4 MPa) below the critical pressure of R-22 (722 psi
absolute) (4.98 MPa).
Table 3.55.2
Typical Siphon Cup Dimensions
Description mm inches (approximate)

Height of cup 82 3.23
Diameter of cup 84 3.31
Diameter of tubing 5 0.20

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 29
Figure 3.55.2
CONDENSER COIL
Figure 3.55.3
CONDENSER COIL SIPHON CUP ASSEMBLY
3.55.3 Collecting Residue
After completion of the environmental conditioning, the pressure vessel shall be removed from the heating source
and cooled with refrigeration or solid carbon dioxide (dry ice) to below 30 C to liquefy the refrigerant. The
cooled pressure vessel shall be carefully opened. The coils and siphon cup shall be rinsed with methylene
chloride and the rinse shall be poured into the pressure vessel. The refrigerant shall be evaporated slowly to
within approximately 1/4 inch (6 mm) of the bottom of the vessel. The walls of the pressure vessel shall be
washed with two successive rinses of 100 milliliters each of methylene chloride. The solvents shall be evaporated
under a hood or in a well-ventilated area to within 1/4 inch (6 mm) of the bottom of the vessel. The liquid sample
shall then be transferred to a pre-weighed, pre-dried, aluminum weighing dish, using a rinse consisting of 15
milliliters of methylene chloride. The liquid shall then be evaporated to dryness at 150 3C (302 5F) for 60
(+5, -0) minutes, then cooled to room temperature in a desiccator.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 30
3.55.4 Determinations of Results

The aluminum dish, with a residue, shall be weighed to the nearest 0.0001 gram. The initial tare weight of the
aluminum dish shall be subtracted. The difference is the "total residue weight" of the original coils.
The insulation shall be removed from the original coils by a suitable chemical means that will not damage the
conductor, and the bare conductors dried for 15 (1, -0) minutes at 150 3C (302 5F). The conductors shall be
cooled to room temperature in a desiccator and weighed immediately to the nearest 0.0001 gram. The sum of the
weights of the coils is the "total conductor weight."
The percent extractables shall be calculated as follows:
Total residue weight

Percent Extractables = 100
Total initial weight Total conductor weight
3.56 DIELECTRIC BREAKDOWN AFTER R-22 CONDITIONING

Warning: Mechanical Hazard For safe operation of this test, an autoclave having a pressure capacity of up to
3000 psi (20.7 MPa) is recommended. The heating systems should be equipped with a device designed to
deactivate the system when the pressure inside the pressure vessel approaches a prescribed critical value.
The autoclave should be equipped with a pressure relief / rupture disk system for emergency relief of
excessive pressures.
Warning: Chemical Hazard Chemicals used in this test have been classified as hazardous by regulatory
agencies. Primary routes of exposure are through absorption and inhalation. Follow instructions provided in the
Material Safety Data Sheets (MSDS) for the safe handling, use, and disposal of these chemicals.
Adequate ventilation is necessary since ozone gas may be generated during the dielectric strength test.
NOTEDue to environmental concerns, alternate refrigerants are being proposed for the replacement of R-22. These alternate materials will
most likely have different parameters, i.e., critical temperature, and cannot be substituted directly for R-22 in the test method described below.
In all probability, different time and temperature requirements will be necessary to satisfactorily complete the procedure. For additional
information, please contact the refrigerant manufacturer, or your magnet wire manufacturer, or both.
Five dielectric twisted pairs of (1424 AWG) film insulated wire shall be prepared in accordance with 3.8.3 and
conditioned in a forced draft oven at 150 3C (302 5F) for 4 hours (+5, -0) minutes.
3.56.2 Environmental Conditioning
The conditioned specimens shall be loaded in a pressure vessel (Parr autoclave #4632, or the equivalent) having
a 2000-milliliter capacity, and an inside diameter of approximately 4 inches (102 mm). The loaded pressure
vessel shall be scaled, weighed, and evacuated to 200 20 mm of mercury (30 3 Pa).
The pressure vessel shall then be filled with 3.1 0.1 lbs. (1.4 kg 50 g) of monochlorodifluoromethane (R-22).
The loaded pressure vessel shall be heated to obtain a pressure gage reading of 600 50 psig (4.20 0.35
MPa). The pressure shall be maintained for 72 1 hours, after which time the pressure vessel shall then be
removed from the heat source and cooled with refrigeration or solid carbon dioxide (dry ice) to below 30 C to
liquefy the refrigerant. After completion of the environmental conditioning, the pressure vessel shall be removed
from the heating source and cooled with refrigeration or solid carbon dioxide (dry ice) to below 30 C to liquefy
the refrigerant.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 31
3.56.3 Evaluation of Specimens
When the pressure in the vessel falls to 10 psig. (0.007 MPa) or less, the cover shall be carefully removed and
the twisted pairs transferred within 60 seconds to a forced draft oven at 150 3C (302 5F). The specimens
shall remain in the oven for 10 +1,-0 minutes.
After the specimens have been removed from the oven and cooled to room temperature, the dielectric
breakdown voltage of the twisted pairs shall be determined in accordance with 3.8.3. The five readings shall be
recorded and averaged.
3.57 BOND
3.57.1.1 Sizes 18 and 26 AWG
The appropriate mandrel shall be selected from Table 3.57.1 and
sprayed with a suitable release agent.
NOTEFluorocarbon or silicone sprays have been found to be satisfactory.
The wire shall be de-reeled over the end of the spool as a 3-inch
single-layer coil is wound onto the prepared mandrel, using a winding
tension not to exceed that shown in Table 3.57.1. The coil and
mandrel shall be vertically mounted in a suitable holder with the free
end of the coil at the top. The specified bonding weight from Table
3.57.1 shall be placed on the vertically mounted coil, providing a
downward force during bonding. (See Figure 3.57.1.) Three coils
shall be prepared.
3.57.1.2 Size 36 AWG Figure 3.57.1

The appropriate mandrel shall be selected from Table 3.57.1 and BOND COIL PREP FIXTURE
sprayed with a suitable release agent (see 3.57.1.1). The wire shall
be dereeled over the end of the spool as a coil of fifty continuous
turns is wound onto the prepared mandrel. The coils and mandrel
shall be vertically mounted in a suitable holder. The specified
bonding weight from Table 3.57.1 shall be placed on the vertically
mounted coils as described in 3.57.1.1. Three coils shall be
prepared.
Table 3.57.1
BOND TEST PARAMETERS
Maximum Test Load*
Mandrel Diameter* Winding Tension Bonding Load* After Heat Bonding After Solvent Bonding
AWG inches mm grams newtons grams newtons kilograms newtons kilograms newtons
18 0.250 6.35 1220 12.0 408.0 4.00 9.0 88.3 4.5 44.1
26 0.157 3.99 200 2.0 76.0 0.75 1.6 15.7 0.80 7.85
36 0.039 0.99 12.2 0.12 15.3 0.15 0.025 0.25 0.0122 0.12
* Tolerance 2%
3.57.2 Heat and Solvent Bonding

3.57.2.1 Heat Bonding Sizes 18, 26, and 36 AWG
Warning: Thermal Hazard Care must be exercised in removing the holder assembly from the oven at elevated
temperatures to avoid skin burns.
The holder assembly shall be placed in a forced air oven for 60 minutes (+5, -0) minutes at 150 3C
(302 5F) or as specified in Part 2. The assembly shall be removed from the oven and cooled to room
temperature.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 32
The coils shall be removed from the mandrels, inspected for breaks or physical damage, and tested in
accordance with 3.57.3 and/or 3.57.4.
3.57.2.2 Solvent Bonding Sizes 18,26, and 36 AWG

Warning: Chemical Hazard Adequate ventilation must be provided to remove hazardous fumes generated
from the solvents used for bonding. Primary routes of entry are by absorption and inhalation. Consult Material
Safety Data Sheets (MSDS) of the solvent being used to determine proper handling, use, and disposal
procedures.
The specimen shall be dipped into the specified solvent for approximately 5 seconds. The bonded coil shall be
immediately placed in the holder with the specified bonding weight from Table 3.57.1 and allowed to dry for 60
minutes (+5, -0) minutes at room temperature.
The coils shall be removed from the mandrels, dried for 15 (+1, -0) minutes at 100 3C (212 5F), inspected
for breaks or physical damage, and tested in accordance with 3.57.3.
3.57.3 Room Temperature Bonding

3.57.3.1 Sizes 18 and 26 AWG
Each 3-inch test coil shall be placed in a test fixture
identical to that shown in Figure 3.57.3.1 with regard
to all dimensions and radii shown. The appropriate
test weight, as shown in Table 3.57.1 shall be the
total load to be applied to the center of the coil, which
includes the knife edge, support, and added weight.
The load shall be lowered gently and allowed to hang
for 5 seconds.
The use of a stress-strain analyzer shall be permitted

to apply an increasing load. The cross-head speed
shall be between 0.5 and 1 inch (12 mm and 25 mm)
per minute. Separation of the first or last turn shall be
disregarded.
3.57.3.2 Size 36 AWG

Each coil shall be hung by one of its ends and loaded
with the weight indicated in Table 3.57.1 (See Figure Figure 3.57.3.1
3.57.3.2). When attaching the load, any additional BOND STRENGTH TEST FIXTURE
shock must be avoided. The weight shall be allowed
to hang for 5 seconds. Separation of the first or last
turn shall be disregarded.
3.57.4 Elevated Temperature Bond Test
Procedure
The bond test fixture as shown in Figure 3.57.2 shall
be placed in a re-circulating oven capable of
maintaining 250 2C. The oven temperature should
be stabilized at the set temperature specified in Part 2
2C. The specimen to be tested shall then be
placed in the fixture in the oven. 15 minutes but not
more than 30 minutes after the oven again reaches
set temperature 2C, the sample shall be tested in
accordance with 3.57.3.1. Use of a stress strain
analyzer shall be permitted to apply an increasing
load until the sample is broken. The cross-head
speed shall be between 0.5 and 1 inch (12 and 25
Figure 3.57.3.2
mm) per minute. The peak load is recorded.
BOND TEST FIXTURE
MW 1000-2003
Part 3Page 33
3.58 THERMAL ENDURANCE

The thermal endurance of all film insulated sizes and shapes shall be evaluated using 18 AWG heavy (or Type 2)
magnet wire.
Thermal class ratings shall be based upon tests performed on unvarnished specimens of 18 AWG round wire
with a heavy film coating, prepared and tested in accordance with ASTM D 2307. Wire size 28 AWG shall be
permitted for use as a substitute for 18 AWG where the specification's size range is limited to 25 AWG and finer.
The "end point" chosen for purposes of this publication is 20,000 hours. This means that the graph of the test
data that is obtained when following the test procedure given in ASTM D 2307 must show an extrapolated life for
the wire of 20,000 hours or more at or above the thermal class rating.
The philosophy established in ANSI/IEEE Std. 1 was followed in setting the 20,000-hour end point.
The tested life of the specimen being evaluated shall be not less than 5000 hours at least 20C above the thermal
class rating.
The thermal class of fibrous covered or tape wrapped wire shall be based on experience.
The Institute of Electrical and Electronics Engineers has not established test procedures for the thermal
evaluation of fibrous covered or tape wrapped magnet wire. However, ANSI/IEEE Std. 1 points out that the
thermal rating of insulation can be established either by experience or by accepted tests.
For example, glass fiber insulation has, by experience, become established as a component in both Class 130
and 155 insulation systems.
Glass fiber silicone treated insulation has, by experience, become established as a component in Class 200
insulation systems.
Polyester-glass-fiber insulation is more than 50 percent inorganic material and has, by experience, become
established as a component in Class 155 insulation systems and in Class 200 when silicone treated.
Glass fiber and polyester-glass-fiber insulations, when treated with high-temperature, non-silicone organic
varnish have, by experience, become established as components in Class 180 insulation systems. In this case
the high temperature organic varnish must also exceed a 180C temperature index when tested in accordance
with ASTM D 1932.
3.59 SCRAPE RESISTANCE

This test procedure is applicable to round film insulated wire sizes 10 through 30 AWG.
3.59.1 Apparatus
Scrape resistance of the wire specimen shall be determined using a machine such as that shown in Figure
3.59.1. The machine shall provide a scraping action in one direction along the longitudinal axis of the film
insulated wire to be tested, at a rate of 16 inches (406 mm) 10 percent per minute.
The machine shall automatically apply an increasing scraping force by the movement of the scraping device
along a pivoted loading arm whose lower edge is graduated to provide a multiplying factor.
The weighted scraping device shall contain a polished 0.009 inch (0.23 mm) diameter steel piano wire or needle
located between two jaws which support the steel piano wire or needle rigidly, without sagging or curvature, at
right angles to the direction of stroke.

MW 1000-2003
Part 3Page 34
Figure 3.59.1
MACHINE FOR SCRAPE RESISTANCE
The machine shall be equipped with two adjustable clamping jaws that can be indexed at each 120 position to
rotate the specimen, and with a supporting anvil that can be suitably adjusted to support the specimens.
The machine shall be equipped with an electrical circuit which limits the current to 20.0 milliamperes at 7.5 1.5
volts, between the conductor and the piano wire or needle scraper. The circuit shall be so designed that the
machine stops when the film insulation is removed and the bare conductor exposed for approximately 1/8 inch (3
mm).

A specimen of film insulated wire shall be wiped with a clean cloth or tissue, placed in the machine, and
straightened by elongating it not more than 1 percent to remove kinks. The specimen shall then be secured in the
clamping jaws, and the supporting anvil adjusted to contact the underside of the specimen.
An initial load of approximately 90 percent of the minimum individual "grams-to-fail" value specified in Table
3.59.1 or 3.59.2 shall be applied to the loading arm. This initial device shall be lowered gently onto the surface of
the film insulation and the scraping action started. The scraping action shall continue until the conductor is
exposed and the machine stops.
The multiplying factor at which the machine shuts off shall be read from the scale on the loading arm. The
product of this factor and the initial load applied shall be recorded as the "grams-to-fail" value.
The test procedure shall be repeated twice, indexing the clamps holding the wire to expose the wire surface 120
and 240 from the original position, and the same information recorded. The three individual "grams-to-fail" values
shall then be averaged. The average and individual grams-to-fail shall not be less than the values given in Table
3.59.1 or 3.59.2, as applicable to the particular wire specification in Part 2.

MW 1000-2003, Revision 1, June 16, 2005
Part 3Page 35
Table 3.59.1
STANDARD SCRAPE RESISTANCE OF ROUND FILM INSULATED MAGNET WIRE
MW 5, 9, 15, 17, 24, 28, 30, 35, 72, 73, 74, 76, 80, 81, 83
Copper, minimum grams-to-fail Aluminum, minimum grams-to-fail
AWG Single Build Heavy Build Triple Build Quad Build* Single Build Heavy Build
Size Average Individual Average Individual Average Individual Average Individual Average Individual Average Individual
10 1490 1270 895 760
11 1490 1270 895 760
12 1490 1270 895 760
13 1490 1270 895 760
14 840 715 1490 1270 1735 1475 505 430 895 760
15 780 665 1400 1190 1620 1375 470 400 840 715
16 735 625 1310 1115 1525 1295 440 375 785 670
17 690 585 1230 1045 1425 1210 415 350 740 625
18 645 550 1150 980 1335 1135 390 330 690 590
19 600 510 1070 910 1255 1065 360 305 640 545
20 560 475 1000 850 1180 1000 335 285 600 510
21 525 445 940 800 1115 945 315 265 565 480
22 490 415 880 750 1045 890 295 250 520 450
23 460 390 820 700 975 830 275 235 490 420
24 430 365 770 655 910 770 260 220 460 395
25 400 340 720 615 850 720 245 205 430 370
26 380 325 675 575 795 675 230 190 405 350
27 355 300 635 540 735 625 215 175 385 325
28 335 285 595 510 690 585 200 160 360 310
29 310 265 560 480 645 550 185 145 340 290
30 295 250 525 450 605 515 170 130 320 270
*Under investigation
Table 3.59.2
REDUCED SCRAPE RESISTANCE OF ROUND FILM INSULATED MAGNET WIRE
MW 2, 26, 27, 75, 77, 78, 79, 82
Copper, minimum grams-to-fail

AWG Single Build Heavy Build Triple Build
Size Average Individual Average Individual Average Individual
14 740 630 1310 1120
15 685 585 1230 1045
16 645 550 1155 980
17 605 515 1080 920
18 570 485 1010 860
19 530 450 940 800
20 495 420 880 750
21 460 390 825 705
22 430 365 775 660
23 405 345 720 615
24 380 320 680 575
25 350 300 635 540 745 630
26 335 285 595 505 700 590
27 310 265 560 475 645 550
28 295 250 525 450 605 515
29 275 235 495 420 565 480
30 260 220 460 395 530 450

MW 1000-2003
Part 3Page 36

MW 1000-2003
Page A-1
Appendix A
Reference test conditions and procedures
for film-insulated magnet wire
ASTM ASTM ASTM NEMA Standards Publication MW 1000

D 1676 D 2307 D 3353 Clause Number
Paragraph Paragraph Paragraph Round Rectangular
Film Film Fibrous Film Fibrous Film Fibrous
Title of Test Insulated Insulated Covered Insulated Covered Insulated Covered
Dimensions 100106 7.17.6 3.2.1.1 3.2.1.3 3.2.2.1 3.2.2.2
Adherence and flexibility 141148 8.18.5 3.3.1 3.3* 3.3.3 3.3*
Elongation 122129 4.14.6 3.4 3.4 3.4 3.4
Heat shock 156162 3.5 3.5
Springback 154155 3.7 3.7.2 3.7.2 3.7.2
Dielectric breakdown 6975 9.19.6 3.8 3.8 3.8 3.8
Continuity, high-voltage 3845 3.9.2
Continuity, low voltage 4653 3.9.3
Completeness of cure 5460 3.10 3.10
Solderability 178185 3.13
Thermoplastic flow 6168 3.50
Solubility 2228 3.51.1 3.51.2
Dielectric breakdown at rated 8389 3.52 3.52

temperature
Transformer oil resistance 186195 3.54 3.54
and hydrolytic stability
Refrigerant 22 extraction 130140 3.55
Retained dielectric after 9099 3.56

Refrigerant 22 conditioning
Bond 412 3.57
Thermal endurance 113 3.58.1 3.58.1 3.58.1 3.58.1
Scrape resistance 170177 3.59
* The appropriate Adherence and Flexibility test depends on the product specification and size. See Part 2.

MW 1000-2003
Page A-2

MW 1000-2003
Page B-1
Appendix B
MAGNET WIRE PACKAGING AND LABELING
(This Appendix supersedes NEMA Standards Publications MW 700, MW 755, MW 760, and MW 770)
B.1 GENERAL
B.1.1 Scope
This Appendix covers the following:
Dimensional, physical, and visual characteristics of newly molded, straight and tapered flange plastic spools
and reels for packaging of magnet wire (See B.2).
Recommended test procedures (See B.3).
Guidelines for size of printing format, data items, and the application of data labels to magnet wire spools,
reels and cartons (See B.4).
B.1.2 Normative References
B.1.2.1 Packaging
The following normative documents contain provisions that, through their references, constitute provisions of
this part. By reference herein, these publications are adopted in whole or in part. And are available form the
organizations listed below.
Deutsche Elektrotechnische Kommission im DIN und VDE (DKE)

Stresemannallee 15
D-6000 Frankfurt AM Main 70
DIN 46399-1 Delivery Spools for Bare and Insulated Wires: Dimensions
DIN 46399-2 Delivery Spools for Bare and Insulated Wires:

Technical Terms of Delivery for Spools of Plastic
International Electrotechnical Commission (IEC)

3, rue de Varembe
Case postale 131
CH-1211 Geneva 20
IEC 60264-2-1 Packaging of Winding Wires-

Part 2 - Cylindrical Barreled Delivery Spools
Section 1 Basic Dimensions
IEC 60264-4-1 Packaging of Winding Wires-

Part 4 Methods of Test
Section 1 delivery spools made from thermoplastic material
B.1.2.2 Labeling
The following normative documents have been adopted in whole or in part, and are available from the
organizations listed below:

MW 1000-2003
Page B-2
American National Standards Institute (ANSI)

11 West 42nd Street
New York, NY 10036
ANSI X12.3-1986 Standards for Electronic Data Communication
Automated Identification Manufacturers (AIM)

1326 Freeport Road
Pittsburgh, PA 15238
Uniform Symbology Specification Manual for Code 39-1986
Automotive Industry Action Group (AIAG)

North Park Plaza, Suite 830
17117 West Nine Mile Road
Southfield, MI 48075
AIAG-B-1-1988 Bar Code Symbology

AIAG-B-3-1990 Shipping Parts Identification Label
AIAG-B-10-1995 Shipping Parts Identification Label
Federation of Automated Coding Technologies

1326 Freeport Road
Pittsburgh, PA 15238
FACT-1, 1989 FACT Data Identifier Standard
National Electrical Manufacturers Association (NEMA)

Rosslyn, VA 22209
Electrical Industry Bar Code Application Guidelines1987
B.1.3 Definitions
Definitions that are applicable to magnet wire products are found in Part 1 of this Standards Publication. The
following definitions apply to this Appendix only. See Figure B-1 for an illustration of selected terms.
arbor hole: The hole in a flange through which the arbor shaft passes (Figure B-1).
drive slot: The hole or slot in either or both flanges, which serves as the means for driving the reel on the
machine take-up (Figure B-1).
finger holes: Holes in the top flanges that serve as a means for lifting reels by using fingers.
flange: The part of the spool/reel that is perpendicular to the barrel, which defines the traverse length.
Several different flange spool/reel arrangements are described in the indented section below.
double taper flange, straight barrel spool/reel: A spool/reel that contains two tapered flanges with a
straight barrel within the winding area, as shown in Figure B-5.
double taper flange, tapered barrel reel: A spool/reel that contains two tapered flanges with a tapered
barrel within the winding area, as shown in Figure B-6.
single tapered flange tapered barrel spool/reel: A spool/reel that contains one tapered flange with a
tapered barrel within the winding area, as shown in Figure B-7.

MW 1000-2003
Page B-3
straight flange straight barrel spool/reel: A spool/reel that contains two straight flanges, and a straight
barrel within the winding area, as shown in Figures B-2 and B-3
straight flange tapered barrel reel: A spool/reel that contains two straight flanges, and a tapered barrel
within the winding area, as shown in Figure B-4.
TRAVERSE
LENGTH
Figure B-1
PARTS AND FEATURES OF TYPICAL MAGNET WIRE SPOOLS/REELS
flange wobble: A condition where the flange, when rotated fails to track in a true plane, which is at the
appropriate angle (90 or 45 degrees) to the arbor shaft axis.
flash: Excessive material projections that protrude at mold parting lines.
inside flange face: The surface at the flange adjacent to the barrel surface.
inside flange radius: The radius located at the junction of the inside flange surface and the barrel.
inspection slots: Slots in the flange that leave a portion of the winding exposed, in order to provide a means
for visual inspection of the winding.
outside flange radius: The radius of the flange edge and the outside flange face.
reel: A cylindrical device with a top and bottom flange having diameter of 8 inches or larger, that extend
beyond the cylinder surface, for the purpose of holding wire for packaging, transportation, and de-reeling.
spool: A spool is defined as having a flange diameter of less than 8 inches.

MW 1000-2003
Page B-4
start ribs: Indentations and molded protrusions in the barrel of a spool/reel, which serve as a gripping surface
for wire on the initial layer of the winding.
sink: A depression in the molded surface resulting from the cooling process of the plastic. It generally does
not affect the strength of the item.
tare weight: The weight of the empty spool/reel, with no wire applied.
tie-off holes: Holes at the junction of the barrel and flange, or on the outside edge of the flange, which serves
as a means to tie off the start or end of the reel of wire.
traverse length: The distance between the flanges parallel to the barrel (Figure B-1).
B.2 REQUIREMENTS FOR SPOOLS AND REELS

B.2.1 Material
All spools/reels shall be fabricated of plastic material specified by the magnet wire producer. Glued
spools/reels shall be of a single material type.
B.2.2 Marking
Spools/reels shall be permanently marked in a visible location. The spool/reel shall carry a marking denoting
the country of origin and type of plastic. Spools/reels made of multiple types of plastic shall have their
individual parts marked.
B.2.3 General Features

All spools/reels shall provide a means for lifting as well as include a method for driving by means of a pin
through the spool/reel flange, or by another suitable means agreed upon between the magnet wire producer
and the spool/reel supplier.
B.2.4 Physical Appearance
B.2.4.1 Flanges
Flanges shall be smooth and free from all material flash that are likely to interfere with over-the-flange de-
reeling or cause wire damage.
B.2.4.2 Flash
Flash shall be kept to a minimum in the arbor hole in order facilitate spool/reel removal on oven and rewind
take-ups.
B.2.4.3 Flange Wobble

Flange wobble shall not exceed the following total indicator readings (TIR), when tested in accordance with
B.5.1.3:
Spools TIR
Equal to or less than 3 inches (76.2 mm) 0.005-inch (0.13 mm)
Greater than 3-inches (76.2 mm) 0.010-inch (0.25 mm)
Reels
8-inch (203 mm) and greater to less than 11-inch (279 mm) 0.015-inch (0.38 mm)
11-inch (279 mm) and greater to less than 23-inch (584 mm) 0.020-inch (0.51 mm)
Greater than 23-inch (584 mm) as specified by wire producer

MW 1000-2003
Page B-5
B.2.4.4 Flange Diameter and Inner Flange Surface

Flange diameter and inner flange surfaces, and the related radius between these two surfaces shall be free of
nicks, scratches, burrs, solvent splash, or solvent runs which will or likely to interfere with wire de-reeling and
automatic winding.
B.2.4.5 Barrel
B.2.4.5.1 The barrel of the spool within its winding areas shall be smooth in order to prevent damage to
magnet wire. The barrel, of tapered barrel reels, shall permit within its winding area, a surface and /or ribs to
prevent pull-down.
B.2.4.5.2 Solvent/adhesive runs along the barrel shall not raise or depress the as-molded
surface of the barrel by more than 0.002 inch (0.05 mm).
B.2.4.5.3 Barrel concentricity shall not exceed the following total indicator readings (TIR), when tested in
accordance with B.5.1.2.
Straight Flange TIR

6 inches (152 mm) or less 0.010 (0.25 mm)
6 (152 mm) to less than 8 inches (203 mm) 0.015 (0.38 mm)
8 (203 mm) to less than 12 inches (305 mm) 0.020 (0.51 mm)
12 inches (305 mm) and greater 0.025 (0.63 mm)
Tapered Flange
Less than 8 inches (203 mm) 0.015 (0.38 mm)
8 inches (203 mm) to less than or equal to 12 inches (305 mm) 0.020 (0.51 mm)
Greater than 12 inches (305 mm) 0.025 (0.63 mm)
B.2.4.6 Solvent/Adhesive Weld Length

The solvent/adhesive weld length shall be such that it shows signs that at least 90 percent of the bond area
has been covered and solvent applied
B.2.4.7 Butt Surface and Bond Line

There shall be no gap between the butt surfaces and the bond line. The line at this butt area shall not exceed
an outward extension of 0.002 inch (0.05 mm) or recess of 0.002 inch (0.05 mm) for spools, or 0.005 inch
(0.13 mm) and 0.002 inch (0.05 mm) respectively for reel
B.2.4.8 Sinks
Sinks in the winding area shall be kept to a minimum and shall not be greater than 0.010 inch (0.25 mm) deep
for 3 inch (76 mm) and larger spools, except that 3 inch (76 mm) and smaller spools used for 44.5 AWG and
finer wire applications shall be a maximum of 0.005 inch (0.13 mm). The 60-degree cone area shall not have
sinks, which affect barrel concentricity or flange run-out. Sinks in the non-winding area shall be acceptable as
long as other properties of the spool are in compliance of specified limits.
B.2.4.9 Appearance and Color

Appearance and color of spools/reels shall be as specified by the magnet wire producer.
B.2.4.10 Reel Size

Reel sizes are defined nominally in Table B-3 as:
Top Flange/Bottom Flange X Traverse Length

MW 1000-2003
Page B-6
B.2.4.11 Straight Flange

B.2.4.11.1 Non-tapered Barrel
Typical dimensions and tolerances for standard non-tapered barrel spools/reels are in accordance with Tables
B-1, B-2, and B-4 and Figures B-2, and B-4.
NOTEInformation contained in Figures B-2 and B-4, and Table B-2 is adopted from IEC 60264-2-1, and shall be considered Authorized
Engineering Information.
B.2.4.11.2 Tapered Barrel

Typical dimensions for tapered barrel reels shown in Figure B-4 are as indicated in Table B-3.
B.2.4.12 Tapered Flange

Typical dimensions and tolerances for available tapered flange barrel spools/reels as indicated in Tables B-4,
B-5 and B-6 are shown in Figures B-5, B-6 and B-7.
B.2.4.13 Strength
Spool/reel strength shall be determined in accordance with B.3.2. Performance requirements shall be based
upon agreement reached between individual spool/reel supplier and the magnet wire producer.

MW 1000-2003
Page B-7
Table B-1
DIMENSIONS AND TOLERANCES FOR STRAIGHT BARREL SPOOL/REELS
(Dimensions in inches)
Nominal Nominal Nominal

Weight Tare Flange Flange Traverse Overall Barrel Bore
Standard Copper Weight Diameter Thickness Length Length Diameter Diameter
Nomenclature (lbs.) (lbs.)
2 or 2-1/2 0.75 0.15 2.5 0.01 0.184 0.01 3.00 0.01 3.38 1.75 0.01 0.629 +0.010, -0.000
3 2 0.17 3.00 0.010 0.25 0.01 3.48 0.01 4 1.75 0.01 0.629 +0.010, -0.000
5 6 0.38 4.88 0.02 0.25 0.01 3.50 0.01 4 3.00 0.01 0.629 +0.010, -0.000
5WF 6 0.46 5.00 0.02 0.31 0.01 3.50 0.01 4.13 3.00 0.02 0.629 +0.010, -0.000
6IF 9 0.6 6.00 0.02 0.31 0.01 3.50 0.01 4.13 3.50 0.02 0.629 +0.010, -0.000
6WF 9 0.67 6.00 0.02 0.41 0.01 3.50 0.01 4.32 3.50 0.02 0.629 +0.010, -0.000
6TF 9 0.48 6.00 0.02 0.25 0.01 3.50 0.01 4 3.50 0.02 0.629 +0.010, -0.000
6X6 14 1.03 6.00 0.02 0.50 0.01 6.00 0.01 7 3.75 0.02 0.629 +0.010, -0.000
8X6 25 1.43 8.00 0.03 0.68 0.01 6.00 0.01 7.38 4.63 0.02 **
12 75 2.92 11.75 0.03 0.65 0.02 7.00 0.01 8.25 6.56 0.03 **
24 250 16.9 24.00 0.04 1.38 0.01 6.00 0.02 8.75 14.00 0.03 **
(Dimensions in mm)
Nominal Nominal
Nominal
Standard Weight Tare Flange Flange Traverse Barrel Bore
Overall
Nomenclature Copper Weight Diameter Thickness Length Diameter Diameter
Length
(kg) (kg)
2 or 2-1/2 0.3 0.1 63.5 0.3 4.7 0.3 76.2 0.3 85.9 44.5 0.3 16.0 + 0.3 - 0.0
3 0.9 0.1 76.2 0.3 6.4 0.3 88.4 0.3 101.6 44.5 0.3 16.0 + 0.3 - 0.0
5 2.7 0.2 124.0 0.5 6.4 0.3 88.9 0.3 101.6 76.2 0.3 16.0 + 0.3 - 0.0
5WF 2.7 0.2 127.0 0.5 7.9 0.3 88.9 0.3 104.9 76.2 0.5 16.0 + 0.3 - 0.0
6IF 4.1 0.3 152.4 0.5 7.9 0.3 88.9 0.3 104.9 88.9 0.5 16.0 + 0.3 - 0.0
6WF 4.1 0.3 152.4 0.5 10.4 0.3 88.9 0.3 109.7 88.9 0.5 16.0 + 0.3 - 0.0
6TF 4.1 0.2 152.4 0.5 6.4 0.3 88.9 0.3 101.6 88.9 0.5 16.0 + 0.3 - 0.0
6X6 6.4 0.5 152.4 0.5 12.7 0.3 152.4 0.3 177.8 95.3 0.5 16.0 + 0.3 - 0.0
8X6 11.3 0.6 203.2 0.8 17.3 0.3 152.4 0.3 187.5 117.6 0.5 **
12 34.0 1.3 298.5 0.8 16.5 0.5 177.8 0.3 209.6 166.6 0.8 **
24 113.4 7.7 609.6 1.0 35.1 0.3 152.4 0.5 222.3 355.6 0.8 **

MW 1000-2003
Page B-8
Figure B-2
STRAIGHT BARREL SPOOL/REEL

MW 1000-2003
Page B-9
Table B-2
DIMENSIONS AND TOLERANCES FOR IEC CYLINDRICAL STRAIGHT BARREL SPOOL/REELS
(Dimensions in mm)
Inside Outside
Spool Flange Barrel Bore Bore Overall Traverse Traverse Barrel Flange
Type Diameter Diameter Diameter Tolerance Length Length Tolerance Radius Radius
40 40 25 11 +0.1, -0.0 50 38 0.10 0.4 1.0

50 50 32 11 +0.1, -0.0 50 38 0.15 0.4 1.0
63 63 40 11 +0.1, -0.0 63 49 0.15 0.4 1.6
80 80 50 16 +0.2, -0.0 80 64 0.15 0.6 2.0
100 100 63 16 +0.2, -0.0 100 80 0.20 0.6 3.0
125 125 80 16 +0.2, -0.0 125 100 0.20 0.6 3.0
160 160 100 22 +0.2, -0.0 160 128 0.20 0.6 3.0
200 200 125 22 +0.2, -0.0 200 160 0.30 0.6 4.0
250 250 160 22 +0.2, -0.0 200 160 0.40 1.0 5.0
355 355 224 36 +0.5, -0.0 200 160 0.40 1.2 5.0
500 500 315 36 +0.5, -0.0 250 180 0.50 1.6 5.0
710 710 500 51 +0.5, -0.0 250 180 0.80 2.0 6.0
1000 1000 800 51 +0.5, -0.0 250 180 1.00 3.0 6.0
Inside Outside
Spool Flange Barrel Bore Bore Overall Traverse Traverse Barrel Flange
Type Diameter Diameter Diameter Tolerance Length Length Tolerance Radius Radius
40 1.6 1.0 0.4 +0.04, -0.0 2.0 1.5 0.004 0.02 0.04
50 2.0 1.3 0.4 +0.04, -0.0 2.0 1.5 0.006 0.02 0.04
63 2.5 1.6 0.4 +0.04, -0.0 2.5 1.9 0.006 0.02 0.06
80 3.1 2.0 0.6 +0.08, -0.0 3.1 2.5 0.006 0.02 0.08
100 3.9 2.5 0.6 +0.08, -0.0 3.9 3.1 0.008 0.02 0.12
125 4.9 3.1 0.6 +0.08, -0.0 4.9 3.9 0.008 0.02 0.12
160 6.3 3.9 0.9 +0.08, -0.0 6.3 5.0 0.008 0.02 0.12
200 7.9 4.9 0.9 +0.08, -0.0 7.9 6.3 0.01 0.02 0.16
250 9.8 6.3 0.9 +0.08, -0.0 7.9 6.3 0.02 0.04 0.20
355 14.0 8.8 1.4 +0.20, -0.0 7.9 6.3 0.02 0.05 0.20
500 19.7 12.4 1.4 +0.20, -0.0 9.8 7.1 0.02 0.06 0.20
710 28.0 19.7 2.0 +0.20, -0.0 9.8 7.1 0.03 0.08 0.24
1000 39.4 31.5 2.0 +0.20, -0.0 9.8 7.1 0.04 0.12 0.24

MW 1000-2003
Page B-10
Figure B-3
IEC CYLINDRICAL BARRELED DELIVERY SPOOLS

MW 1000-2003
Page B-11
Table B-3
DIMENSIONS AND TOLERANCES FOR TAPERED BARREL, STRAIGHT FLANGE SPOOL/REELS
Nominal Bottom Bottom Nominal Barrel Barrel

Standard Copper Reel Top Flange Flange Traverse Flange Overall Top Bottom
Nomenclature Weight Size Diameter Diameter Length Thickness Length Diameter Diameter
50 40 lbs. 8.5/9.25x9 8.5 0.02 9.25 0.02 9.00 0.01 0.53 0.01 10.06 5.75 0.02 6.50 0.02
100 85 lbs. 10/11x12 10.0 0.02 11.0 0.02 12.01 0.01 0.69 0.01 13.38 6.05 0.02 7.00 0.01
250 275 lbs. 15/16x12 15.00 0.04 16.00 0.04 11.96 0.02 1.25 0.01 14.50 8.00 0.02 9.00 0.02
500 550 lbs. 15/16x24 15.00 0.04 16.00 0.04 23.86 0.02 1.19 0.01 26.38 7.96 0.02 9.00 0.02
550 525 lbs. 16.5/19.5x18 16.5 0.04 19.5 0.04 17.96 0.02 1.19 0.01 20.25 7.96 0.02 9.26 0.02
650 650 lbs. 16.5/19.5x18.5 16.5 0.04 19.5 0.04 18.39 0.02 1.19 0.01 20.75 7.96 0.02 9.00 0.02
750 750 lbs. 16.5/19/.5x24 16.5 0.04 19.5 0.04 23.86 0.02 1.19 0.01 26.19 7.96 0.02 9.00 0.02
1000 925 lbs. 16.5/19.5x30 16.5 0.04 19.5 0.04 29.86 0.02 1.19 0.01 32.19 7.96 0.02 9.26 0.02
NOTEBore diameter or arbor hole size shall be as specified by the magnet wire producer.
(Dimensions in mm)
Nominal Bottom Bottom Nominal Barrel Barrel

Standard Copper Reel Top Flange Flange Traverse Flange Overall Top Bottom
Nomenclature Weight Size Diameter Diameter Length Thickness Length Diameter Diameter
50 18.1 kg 216/235x229 216 0.5 235 0.5 229 0.3 0.53 0.3 256 146 0.5 165 0.5
100 38.6 kg 254/279x305 254 0.5 279 0.5 305 0.3 0.69 0.3 340 154 0.5 178 0.3
250 124.7 kg 381/406x305 381 1.0 406 1.0 304 0.5 1.25 0.3 368 203 0.5 229 0.5
500 249.5 kg 381/406x609 381 1.0 406 1.0 606 0.5 1.19 0.3 670 202 0.5 229 0.5
550 238.1 kg 419/495x457 419 1.0 495 1.0 456 0.5 1.19 0.3 514 202 0.5 235 0.5
650 294.8 kg 419/495x470 419 1.0 495 1.0 467 0.5 1.19 0.3 514 202 0.5 229 0.5
750 340.2 kg 419/495x609 419 1.0 495 1.0 606 0.5 1.19 0.3 665 202 0.5 229 0.5
1000 419.6 kg 419/495x762 419 1.0 495 1.0 758 0.5 1.19 0.3 818 202 0.5 235 0.5

MW 1000-2003
Page B-12
Figure B-4
TAPER BARREL SPOOL/REEL

MW 1000-2003
Page B-13
Table B-4
DIMENSIONS FOR DOUBLE TAPERED FLANGE/STRAIGHT BARREL SPOOLS/REELS
(Dimensions in mm)
Outside
Spool/Reel Flange Barrel Bore Angle of Overall Barrel
Type Diameter Diameter Diameter Flange Length Length
DIN-100/45 100 56 16 45 100 49
DIN-125/45 125 71 16 45 125 65
DIN-160/45 160 90 22 45 160 85
DIN-200/45 200 112 22 45 200 106
DIN-250/45 250 140 22 45 250 133
Outside
Spool/Reel Flange Barrel Bore Angle of Overall Barrel
Type Diameter Diameter Diameter Flange Length Length
DIN-100/45 3.94 2.20 0.630 45 3.94 1.93
DIN-125/45 4.92 2.80 0.630 45 4.92 2.56
DIN-160/45 6.30 3.54 0.866 45 6.30 3.35
DIN-200/45 7.87 4.41 0.866 45 7.87 4.17
DIN-250/45 9.84 5.51 0.866 45 9.84 5.24
Figure B-5
DOUBLE TAPERED FLANGE, STRAIGHT BARREL SPOOL

MW 1000-2003
Page B-14
Table B-5
DIMENSIONS FOR TAPERED BARREL REELS WITH DOUBLE TAPERED FLANGES
Nominal Bottom Bottom Nominal Barrel Barrel Nominal

Standard Top Flange Traverse Bore
Copper Flange Flange Overall Top Bottom Overall
Nomenclature Diameter Length Diameter
Weight Diameter Thickness Length Diameter Diameter Length
TF80 80 lbs. 10.0 0.03 10.03 0.03 0.44 0.02 10.06 6.00 0.02 6.80 0.02 12.63 8.23 1.53+.010,-0.000
TF600 600 lbs. 17.8 0.02 19.36 0.02 NA NA 13.38 7.96 0.02 9.00 0.02 22.79 12.00 NA
TF1000 1000 lbs. 17.8 0.02 19.36 0.02 NA NA 14.50 7.96 0.02 9.00 0.02 29.18 18.19 NA
(Dimensions in mm)
Nominal Bottom Bottom Nominal Barrel Barrel Nominal

Standard Top Flange Traverse Bore
Copper Flange Flange Overall Top Bottom Overall
Nomenclature Diameter Length Diameter
Weight Diameter Thickness Length Diameter Diameter Length
TF80 36.3 kg 254.8 0.8 254.8 0.8 11.2 0.5 255.5 152.4 0.5 172.7 0.5 320.8 209.0 38.9+0.3,-0.0
TF600 272.2 kg 452.4 0.5 491.7 0.5 NA 339.9 202.2 0.5 228.6 0.5 578.9 304.8 NA
TF1000 453.6 kg 452.4 0.5 491.7 0.5 NA 368.3 202.2 0.5 228.6 0.5 741.2 462.0 NA
Figure B-6
DOUBLE TAPERED FLANGE, TAPERED BARREL SPOOL/REEL

MW 1000-2003
Page B-15
Table B-6
DIMENSIONS AND TOLERANCES FOR SINGLE TAPERED FLANGE TAPERED BARREL REELS
Standard Nominal Bottom Top Flange Bottom Top Bottom

Nomenclature Copper Top Flange Flange Edge Flange Overall Barrel Barrel Barrel Bore
Weight Diameter Diameter Radius Thickness Length Length Diameter Diameter Diameter
85# 85 lbs. 10.00 0.02 11.00 0.02 0.25 0.63 0.01 0.69 0.01 8.00 5.50 6.05 0.02 1.281 0.010
325# 325lbs. 18.95 0.01 20.00 0.02 0.50 1.50 0.02 13.32 6.36 9.02 0.02 9.93 0.02 1.531 0.015
650# 650lbs. 19.99 0.02 20.00 0.02 0.50 1.50 0.02 21.00 13.80 9.02 0.02 9.95 0.02 1.531 0.015
990# 821 lbs. 17.75 0.01 19.5 0.01 NA 1.18 0.01 30.35 23.71 7.75 0.05 9.00 0.05 1.536 0.015
1000# 925lbs. 19.05 0.01 20.00 0.02 0.50 1.50 0.02 26.37 19.15 9.02 0.02 9.95 0.02 NA
(Dimensions in mm)
Nominal Bottom Top Flange Bottom Bottom

Standard Top Flange Overall Barrel Top Barrel Bore
Copper Flange Edge Flange Barrel
Nomenclature Diameter Length Length Diameter Diameter
Weight Diameter Radius Thickness Diameter
85# 38.6 kg 254.0 0.5 279.4 0.5 6.4 16.0 0.3 271.50.3 203.2 139.7 153.7 0.5 32.5 0.3
325# 147.4 kg 481.3 0.3 508.0 0.5 12.7 38.1 0.5 338.3 161.5 229.1 0.5 252.2 0.5 38.9 0.4
650# 294.8 kg 507.7 0.5 508.0 0.5 12.7 38.1 0.5 533.4 350.5 229.1 0.5 252.7 0.5 38.9 0.4
990# 372.4 kg 450.9 0.3 495.3 0.3 NA 30.0 0.3 770.9 602.2 196.9 1.3 228.6 1.3 39.0 0.4
1000# 419.6 kg 483.9 0.3 508.0 0.5 12.7 38.1 0.5 669.8 486.4 229.1 0.5 252.7 0.5 NA
Figure B-7
SINGLE TAPERED FLANGE, TAPERED BARREL

MW 1000-2003
Page B-16
B.3 TEST METHODS

B.3.1 DIMENSIONAL MEASUREMENTS
Measurement methods used by spool/reel manufacturers shall be reproducible.
B.3.1.1 Flange thickness
For measuring flange thickness, the spool/reel shall be placed on a surface plate in a vertical position. The
flange thickness measurement shall be taken 0.25 inch (6.4 mm) from the barrel, by suitable equipment
capable of measurements to within 0.001 inch (0.03 mm).
B.3.1.2 Barrel Concentricity

With the exception of the 1000-pound reels, barrel concentricity shall be measured by engaging the 60-degree
countersink of the arbor holes with a 60-degree conical center. The pick-up point of a calibrated measuring
device shall rest on the barrel, approximately 0.125 inch (3.2 mm) away from the flange. The spool/reel shall
be rotated using live conical centers.
Barrel concentricity shall not exceed the total indicator reading (TIR) specified in B.2.4.5.3.
B.3.1.3 Flange Wobble

Flange wobble shall be measured using the holding apparatus described in B.3.1.2. The pick-up point of the
calibrated measuring device shall track on the traverse side of the flange 0.25 inch (6.4 mm) down from the
flange outer diameter.
B.3.1.4 Barrel Diameter

Barrel diameter on all 2-piece spools shall be measured 0.0625 inch (1.6 mm) from either side of the bond
line, allowing for 0.004-inch (0.10 mm) bond built to be added to the diameter of the barrel.
B.3.1.5 Straight Flange Spools/Reels

B.3.1.5.1 Flange Angle
The flange angle shall not exceed 90 degrees, nor be less than 89 degrees 30 minutes. The total
accumulation in traverse reduction (flange toe-in) at the outer edge of the flange (measured 0.125 inch inward
from the maximum flange diameter) shall not exceed 0.020 inch (0.5 mm) for spools.
B.3.1.5.2 Traverse Length

Traverse length shall be the distance measured flange-to-flange, 0.125 inch (3.2 mm) out from the maximum
barrel dimension, parallel to the centerline of the arbor holes.
B.3.2 STRENGTH
B.3.2.1 Principle of Test
This test method applies only to spools/reels for magnet wire products. It provides guidelines for the testing of
10/11x12 or smaller straight or tapered barrel spools and reels, and is to be used in conjunction with all other
testing procedures for magnet wire spools and reels.
Safety Statement: Mechanical Hazard - Some tests using mechanical equipment may expose the operator to
mechanical hazards. Care must be exercised to protect eyes, fingers, hands, and other body parts from injury.

MW 1000-2003
Page B-17
B.3.2.2 Preparation of Test Specimens

Flange and barrel strengths shall be determined by using a tensile test machine having a minimum capacity of
10,000 lbs. and the capability of measuring jaw speed in inches per second. The spool shall be held in a set
of pulling jaws as shown in Figure B-8. The test fixture or jaws shall have a rate of jaw travel of 1 0.25 inch
per second.
Tests shall be made at room temperature 7279F (2226C). Spools or reels for test shall be held at the test
temperature for at least 24 hours prior to testing. Spools or reels that are solvent bonded shall not be tested
prior to 7 days after assembly.
Load L
Figure B-8
PREPARATION OF SAMPLE FOR STRENGTH TEST
B.3.2.3 Straight Flange Spools/Reel

B.3.2.3.1 Methods
Method A Flange Test
The load L is applied to the flanges by a semi-circular fixture with an inside diameter D equal to the spool or
reel barrel diameter plus 1.5 times the flange overhang, less 1/4 (6.4 mm) inch. The jaws should be designed
to allow the flange to slide during testing, and should not contact the flange inside the specified diameter.
Method B Barrel Test

The load L is applied to the flanges by a semi-circular ring fixture, positioned equidistant around the center of
the barrel. The inside diameter of the ring D shall be equal to the spool or reel barrel diameter plus 1/4 inch
(6.4 mm). The jaws should be designed to allow the flanges to slide during the test.

MW 1000-2003
Page B-18
B.3.2.3.2 Evaluation
Minimum or range of performance values shall be determined by mutual agreement between the supplier and
the wire producer.
B.3.2.4 Tapered Flange Spools/Reels

B.3.2.4.1 Method
For testing of tapered top tapered barrel spools and reels, a fixture similar to the one used for straight flange
and barrel reels is used. The load is applied to the flanges at a diameter equal to the spool or reel barrel
diameter plus 1/8 inch (3.2 mm) on the radius. For example, if the diameter at the barrel is 5 inches, (127 mm)
the opening in the fixture shall be 5-1/4 inches (133 mm). With a tapered barrel the fixture openings at the top
and bottom will be of different diameters. The opening at the top shall be cut at a 45-degree angle or an angle
to match the angle of the top flange. Where spools or reels have double taper of both flanges, the bottom of
the fixture shall be designed in the same manner as the plate or ring holding the top flange.
The load shall be applied by means of the semi-circular ring fixture. The jaws should be designed to allow the
flange to slide during the test and should not contact the flange inside the diameter specified above.
B.3.2.4.2 Evaluation
The value from the testing and the minimum or range for the spool/reel performance shall be determined by
mutual agreement between the supplier and the wire producer.
B.3.3 CHEMICAL COMPATABILITY

B.3.3.1 Principle of Test
As magnet wire is wound on plastic spools or reels, the plastic spool or reel comes in contact with chemicals
used to treat the wire such as lubricants, cleaners, coatings etc. Some of these chemicals may not be
compatible with the plastic used in the construction of the reel and may adversely affect the performance of
the plastic reel. Cracks may develop in the reel, which can trap or break the wire during the de-reeling
process, or the reel may break.
Chemical incompatibility or attack is referred to as an environmental stress cracking (ESC). The degree of
ESC present in actual application on spools and reels is directly influenced by the type of plastic resin, by the
amount of chemical added to the wire, evaporation rates of the chemical, wire temperature at the point of
application of the chemical, winding speed, distance from the point of application to the spool or reel, winding
tension, and the amount of time a wound spool or reel is stored before use.
B.3.3.2 Safety Statements
It is not the intent of this document to address all of the safety issues associated with its use. It is the
responsibility of the user to train personnel, establish proper health and safety procedures and to be aware of
local, state and national regulatory restrictions that may apply.
WARNING: Chemical HazardThis test shall be performed under controlled conditions that allow for safety
and protection of personnel. The chemicals being evaluated may be hazardous. Information and instructions
contained in Material Safety Data Sheets (MSDS) for handling, working with, and disposal of hazardous
chemicals shall be followed. Furthermore, discharges of these chemicals to the environment must be
performed in compliance with current Federal, state and local regulations.
WARNING: Mechanical HazardAs test specimens are placed in the test fixture under tension, they can
break at any time. The sudden release of energy could propel parts of the specimen, the chemical being
evaluated, or the fixture itself in a hazardous way or into hazardous circumstances. The hydraulic test

MW 1000-2003
Page B-19
apparatus to be used may also expose the operator to mechanical hazards. Care must be exercised to
protect eyes, fingers, hands, and other body parts from injury.

Test specimens, referred to as a dog bone due to their shape (Figure B-9a), are molded from the same
thermoplastic resin used in molding the spool or reel to be evaluated. The dog bone measures 1 inch (25 mm)
wide X 5 inches (127 mm) long X 0.110 inch (2.8 mm) thick overall and necks down to 1-3/4 inches (44.5 mm)
long and 3/8 (9.5 mm) inch wide X 0.110 inch (2.8 mm) thick, with 0.055 inch (1.4 mm) radius edges in the test
section (0.0373 in sq. (24 mm sq.) cross-sectional area) with a 3/8 inch (9.5 mm) diameter mounting hole and
bosses 0.150 inch (3.8 mm) high on both sides of the dog bone.
Figure B-9a Figure B-9b

DOG BONE DOG BONE WITH PAPER TOWELLING
For each chemical tested, four dog bone specimens are required. Two specimens shall be tested at a tensile
load of 2030 p.s.i. (1.43 kg/sq mm) and two tested at 3030 p.s.i. (2.13 kg/sq mm) All four-dog bones will be
measured, covered with paper toweling (Figure B-9b), and saturated with the chemical being tested. Two of
these will also be wrapped in polyethylene film to slow the evaporation rate (See Table B-7).
Table B-7
PREPARATION OF DOG BONE TEST SPECIMENS
Specimen Tensile Load Paper Toweling Paper Toweling and

Number p.s.i. kg/sq mm Only Polyester Film
1 2030 1.43 X
2 2030 1.43 X
3 3030 2.13 X
4 3030 2.13 X
B.3.3.4 Evaluation
The four specimens shall be examined every four hours the first day, then daily for up to 21 days to determine
if breakage has occurred. The date and time that breaks are found shall be recorded. At the end of seven
days, the specimens are measured for elongation and re-saturated with the chemical being tested, unwrapping
those specimens wrapped in polyethylene film and re-wrapping them. At the end of 14 days, the previous step
is repeated. After 21 days, the specimens are measured for elongation and removed.
B.3.3.5 Performance Requirements

After 21 days, the four dog bone specimens must not break or elongate more than 10% in order for the
chemical to be considered compatible with the plastic resin used in molding the specimens. For specimens
that do not meet this acceptance standard, the time before failure or percentage of elongation after 21 days is
simply a relative measure of the degree of chemical incompatibility.
B.3.3.6 Discussion
This procedure is purposely designed as a severe test in that the amount of chemical used is acknowledged
as being significantly greater than that which is used in actual application conditions. It is intentional because

MW 1000-2003
Page B-20
the tensile load applied to the dog bone does not simulate all loads and stresses likely to be applied to the
spool or reel by the wire and other variables mentioned in the Introduction, which are not present in this test.
The specimens are tested at two tensile loads because environmental stress cracking is directly influenced by
the load stresses present.
B.3.3.7 Test Procedures
Four dog bone specimens shall be molded per Figure B-9a from the same thermoplastic resin used in molding
the spool or reel to be evaluated. Double ply paper toweling, 2 inches X 3-3/4 inches (51 mm X 95 mm) long,
in to be folded in half lengthwise around the neck of each dog bone, and stapled as close to the edge of the
dog bone as possible, one staple beside the other, in accordance with Figure B-9b.
Clean four test fixtures and their clevis pins of all chemicals to which they have been previously exposed (See
Figure B-10)
Mount a test fixture on the hydraulic test stand mounting plate using a hex head screw (See Figure B-10)
Figure B-10
APPARATUS FOR CHEMICAL COMPATIBILTY TEST
Install a dog bone specimen (with paper toweling) in the test fixture. Loosen the test fixture stop nut (Figure B-
10, item 8) to provide sufficient travel to install the dog bone. The ends of the dog bone are to be fitted in the
clevis clamp and the clevis pins inserted to hold the dog bone in place. The head end of both clevis pins must
be on the same side.
Screw the threaded square nut end of the cylinder rod connector (Figure B-10, item 4) three or four turns in the
threaded rod of the test fixture by turning the square nut clockwise.
Turn on the power to the hydraulic power supply and turn the directional control valve to extend the hydraulic
cylinder. Pivot the latch (Figure B-10, item 6) of the cylinder rod connector to engage the cylinder rod yoke

MW 1000-2003
Page B-21
(Figure B-10, Item 7) and then reverse the direction of the cylinder to retract the cylinder rod. At the same
time, adjust the pressure regulator to the prescribed pressure.
Two samples shall be set at 12 p.s.i (8.43 grams/sq. mm) (the equivalent of 75.4 lbs. (335.5 N) of force on the
0.0373 in sq. (24 sq mm) cross-section of the neck of the dog bone, and 2030 p.s.i. (1.43 kg./sq. mm) tensile
load on the dog bone) and two at 18 p.s.i. (12.65 grams/sq. mm) (the equivalent of 113.1 lbs. of force (503.3
N) and 3030 p.s.i. (2.13 kg./sq. mm) tensile load on the dog bone).
When the prescribed pressure is reached, the cylinder will stop moving. Then screw the stop nut (Figure B-10,
Item 8) by hand until it contacts the test fixture surface. Do not use a wrench to turn the stop nut, as this will
increase the tensile load above the value preset by the hydraulic cylinder. Turn off the hydraulic power supply
and unscrew the square nut from the test fixture threaded rod.
The distance between the inserted ends of the clevis pins shall be recorded to three decimal places with a 6-
inch dial or digital caliper. Specimens shall be saturated with the chemical agent being tested for compatibility
using a clean, unused eyedropper. After saturation, two of the four specimens, as indicated in Table B-7, shall
be wrapped with 1-1/2 mil (.038 mm) polyethylene film strip inch wide X 8 inches (12 X 203 mm) long. The
polyethylene film strip is applied by holding one end of the strip at the start of the dog bone neck, and tightly
wrapping the film strip in a spiral-wound fashion around the paper toweling, progressing toward the opposite
end of the dog bone, stopping at the neck and looping the film strip end to prevent unwinding.
Remove the fixture for storage.
Repeat the above procedure to produce four specimens.

1 2030 p.s.i. (1.43 kg/sq mm) tensile load- saturated
2 2030 p.s.i (1.43 kg/sq mm) tensile load- saturated and wrapped with polyethylene film
3 3030 p.s.i. (2.13 kg/sq mm) tensile load- saturated
4 3030 p.s.i. (2.13 kg/sq mm) tensile load- saturated and wrapped with polyethylene film
The four specimens shall be examined every four hours during the first day, and daily thereafter for 21 days to
determine if breakage has occurred. The date and time that breaks are found shall be recorded. At the end of
7 days, the specimens are measured for elongation and re-saturated with the chemical being tested;
unwrapping those wrapped in polyethylene film and rewrapping them. At the end of 14 days, the previous step
is repeated. At the end of 21 days, the specimens are measured for elongation and removed.
B.3.4 INSERT PULLOUT STRENGTH
B.3.4.1 Scope
This clause provides two methods for determining the ability of a magnet wire spool/reel insert to withstand a
pulling force. The destructive force method determines the breaking point of an insert as a steadily increasing
pullout force is applied (See Figure B-11), while the Specified Pullout Force method evaluates the ability of an
insert to withstand a specified pulling force (See Figure B-12).
Tests shall be made at room temperature 7279F (2226C). Spools or reels for test shall be held at the test
temperature for at least 7 days prior to testing. Solvent bonded products shall be held 7 days after assembly
to ensure a complete bond before they are tested.

MW 1000-2003
Page B-22
B.3.4.3 Test Method
B.3.4.3.1 Destructive Force Method
Safety Statement: Mechanical Hazard - The mechanical equipment used in this test may expose the operator
to mechanical hazards. Care must be exercised to protect eyes, fingers, hands, and other body parts from
injury.
Adjust a tensile test machine to the desired setting for testing of insert.
Cut approximately two inches (51 mm) off the bottom of three reels
Load the test plates and the insert strain rod fixture, as shown in Figure B-11, and attach the strain rod tee bar
onto the movable side of the tensile fixture.
Adjust the tee bar to 0 backlash and reset the dial indicator to zero.
Stretch the assembly to the breaking point, observing the pressure gauge and dial indicators.
Repeat this procedure with thee two additional reels.
B.3.4.3.2 Specified Pullout Force Method
Safety Statement: Mechanical Hazard Mechanical equipment used in this test may expose the operator to
mechanical hazards. Care must be exercised to protect eyes, fingers, hands, and other body parts from injury.
Further, the test weight employed in this method should be contained in an enclosure to protect personnel
from a sudden release of the weight in case of specimen failure.
Turn the reel to an inverted position so that the insert is facing upward (See Figure B-12).
Affix a weight that is two times the suggested weight-carrying capacity of the reel to the top of the flange. A
device that attaches through the bore and canters the load should be utilized.
A similar attachment device is affixed to the bore of the insert. This upper attachment device is connected to a
means of lifting the reel and the test weight assembly, which may be mechanical, hydraulic, or pneumatic.
The test is initiated by applying a tensile load sufficient to lift the test weight one inch (25 mm) off the surface
on which it is resting. The reel shall remain in tension for two minutes.
B.3.4.4 Evaluation
B.3.4.4.1 Destructive Force Method
The minimum tensile load that the insert must withstand shall be determined by mutual agreement between
the spool/reel supplier and the magnet wire producer.
B.3.4.4.2 Specified Pullout Force Method
Any movement of the insert during the time the reel is suspended from its resting surface shall constitute a
failure.

MW 1000-2003
Page B-23
Figure B-11
APPARATUS FOR PULLOUT OF INSERT TEST Figure B-12
DESTRUCTIVE FORCE METHOD ATTACHMENT LIFTING DEVICE FOR
PULLOUT OF INSERT TEST
SPECIFIC FORCE METHOD
B.3.5 IMPACT TESTING

Safety Statement: Mechanical Hazard Some tests using mechanical equipment may expose the operator
to mechanical hazards. Care must be exercised to protect eyes, fingers, hands, and other body parts from
injury.
B.3.5.1 Summary
This procedure provides guidelines for impact testing of spools and reels from small 3 fine wire spools to the
larger 1000 lb. Capacity reel. Tests are performed to destruction or damage.
B.3.5.2 Preparation of the Specimens

Flange strengths shall be determined by using an impact device, in most cases comprising a weight with a
dart attached that is intended to strike the flange at specified positions.

MW 1000-2003
Page B-24
Tests shall be made at room temperature 7279F (22-26C). Spools and/or reels to be tested shall be held at
the test temperature for at least 24 hours prior to testing. Spools and reels that are solvent bonded shall not
be tested prior to 7 days after assembly.
B.3.5.3 Test Equipment

The test shall consist of a free falling weight that will impact the spool or reel flange. The weight shall be held
in a track in order to provide a straight fall. A scale graduated in inches shall be attached to the track
measuring the distance from the release point to the impact point on the reel. The end of the weight shall
constitute a dart having a flat surface that is 1 inch in diameter. Two weights, one of 5 pounds, and one of 50
pounds, which include the weight of the dart, shall be used for the test.
Smaller spools and reels shall be subjected to the impact from a 5-pound weight, and larger reels shall be
subjected to the impact of a 50-pound weight. The weight selection shall be at the discretion of the tester.
B.3.5.4 Test Procedure

The spool or reel shall be tested along three (3) axes. For each test a new reel shall be used.
B.3.5.4.1 The spool or reel shall be held firmly in the fixture by means of a long bolt through the arbor hole and
into a threaded hole in the fixture shown in Figure B-13, to prevent the item from moving during the test. The
impact will be at 0 degrees to the axis of the reel.
B.3.5.4.2 The weight shall be raised to an estimated position on the scale and released. If the flange fails, a
new spool or reel shall be placed in the fixture and the weight shall be raised to a lesser height. If the flange
does not fail, the weight shall be raised to a higher level and again allowed to impact the flange. This
procedure shall be repeated until the flange fails, at which time the distance shall be recorded.
B.3.5.4.3 The test procedure described in B.3.5.4.2 shall be repeated with the spool or reel held in positions
that are at 45 degrees and 90 degrees to the axis of the spool or reel.
B.3.5.5 Test Data

The data gathered from these tests shall be used only for comparative purposes. They do not reflect positive
values that can in any manner be compared to field conditions. The three axes of testing reflect an attempt to
give a reliable indicator of strength.
B.3.5.6 Alternative Procedure

Some tests are performed following production to indicate the flange impact or break strength. These utilize a
pendulum weight that strikes the flange at a 0-degree angle to the spool or reel axis. This is referred to an
Izod impact test because of the use of the pendulum. Such a test is not a part of this procedure.

MW 1000-2003
Page B-25
Figure B-13
FLANGE IMPACT TEST

MW 1000-2003
Page B-26
B.4 CUSTOMER LABELING OF MAGNET WIRE SPOOLS AND REELS
B.4.1 Bar Code Symbology---Code 39

These guidelines do not apply to the manufacturers primary product label, only the secondary label needed to
provide customers with data needed for efficient capture of data for warehouse input and output, receiving,
and other inventory controls.
B.4.1.1 All bar coded data shall use (AIM) Uniform Symbol Specification for Code 39-1986.
B.4.1.2 The four characters $,/,+,%, of the symbology shall not be used on the identification label.
B.4.1.3 The width of the narrow elements shall be within the range of 0.013 to 0.017 inch (0.33 to 0.43 mm).
The ratio of the nominal width of the elements to the nominal width of the narrow elements shall be 2:8:1 to
3:2:1.
B.4.1.4 Check digits shall not be added in the bar code.
B.4.1.5 Printed bar code symbols shall meet the reflectivity and contact requirements specified in AIAG-B-1,
Section 4.1
B.4.2 Secondary Label Placement

B.4.2.1 Labels on reels shall be placed on the reel wrapper. The secondary identification label shall be at
least one inch from the suppliers primary product label.
B.4.2.2 Labels on cartoned products shall be placed on the front of the carton no less than one inch from any
other bar coded label. The front of the carton shall be considered the side with the suppliers logo and primary
label.
B.4.2.3 If label protection is applied to the label, the method of protection shall allow the data to be scanned
with contact and non-contact devices.
B.4.3 Secondary Label Specifications

B.4.3.1 The label shall be 4 inches (102 mm) high by 6 inches (152 mm) long. This size will accommodate all
known conditions such as long part numbers.
B.4.3.2 Pressure sensitive adhesive backed labels are recommended. Other types of labels are acceptable
as long as adherence to the carton or wrapper is wrinkle free.
B.4.4 Data Area Characteristics

B.4.4.1 The magnet wire industry endorses the use of all data identifiers (DI) developed by the Federation of
Automated Coding Technology (FACT). The FACT DI indicated the general category of intended use of the
data that follows.
B.4.4.2 A FACT DI shall be at the beginning of each field. This character is not to be included in the human
readable line, but is shown in human readable characters under the title for the appropriate area.
B.4.4.3 The customer part number, quantity, and supplier number shall be included on each label in the
designated areas and shall be displayed in both human readable characters and bar code symbology. Data
characters shall be as follows:
Part Number: Not to exceed 5.5 inches (140 mm) in length

Quantity: Six characters, plus Data Identifier
Supplier: Nine characters, plus Data Identifiers

MW 1000-2003
Page B-27
B.4.4.4 Special data items such as serial number and purchase order number may be added.
B.4.4.5 Each data area shall be separated by thin lines and shall contain its title in the upper left-hand corner
(see Figure B-14). Titles shall be printed in 1.50 mm (0.06-inch) high letters.
B.4.5 Label Format

B.4.5.1 Each data item shall contain human readable and bar code data.
B.4.5.2 The bar code symbols shall be directly below the human readable characters and shall be a minimum
of 0.4 inches (10.16 mm) in height.
B.4.5.3 Human readable characters shall be bold, with the following heights:
Part number: 0.4 inches (10.16 mm)

Quantity: 0.4 inches (10.16 mm)
Supplier: 0.2 inches (5.08 mm)
B.4.6 Pallets Summary Label

B.4.6.1 A Pallet Summary Label, also known as a Master Label (See Figure B-15), should be used when
supplier and customer agree that the total contents of a multiple, common item pack should be identified. The
total multiple pack should be identified with a master label in a location specified by the customer.
B.4.6.2 At the top of this label, the heading Master Label should be printed in bold, one inch (25.4 mm)
letters. This may be a separate label applied above the standard 6 inch (152 mm) by 4-inch (102 mm) unified
pallet label. The balance of the label format should conform to the specifications for Section B.4.1, B.4.3,
B.4.4, and B.4.5 except that the data identifier for serial number shall be M instead of S.

MW 1000-2003
Page B-28
6.00 in. (152 mm)
1.20 in.
(30 mm)
1.10 in,
(28 mm) 4.00
0.80 in.
(20 mm)
0.90 in.
(23 mm)
Figure B-14
DATA AREA CHARACTERISTICS
MASTER LABEL
(M)
Figure B-15
MASTER LABEL

Appendix C
CROSS REFERENCE OF NEMA, CANCELLED FEDERAL J-W-1177, AND IEC MAGNET WIRE SPECIFICATIONS
Round Build Rectangular/ Square Federal

(Bond Build) Build J-W-1177
Description (Cancelled) IEC Specifications
NEMA Thermal
Standard Thermal Heavy Triple Quad. Heavy Class if
Basecoat/Overcoat/Bond Overcoat Number Class Single (Type 1) (Type 2) (Type 3) Single (Double) Quad. / No. Type IEC No. Different
Polyurethane MW 2-C 105 X X - - - - - 2 U 60317-4 130
Polyurethane/self-bonding MW 3-C 105 - X X - - - - 44 SUB 60317-2 130
Polyester MW 5-C 155 X X - - - - - 10 L 60317-3 -
Polyamide MW 6-C 105 X X - - - - - 3 N - -
Polyvinyl acetal MW 15-A 105 X X - - - - - - - 60317-14 -
Polyvinyl acetal MW 15-C 105 X X X - - - - 4 T 60317-1 -
Polyimide MW 16-C 240 X X X X - - - 15* M 60317-46 -
Polyvinyl acetal/polyamide MW 17-C 105 X X - - - - - 5 TN - -
Polyvinyl acetal MW 18-A 105 - - - - - X X - - - -
Polyvinyl acetal MW 18-C 105 - - - - - X X 16 T 60317-17 -
Polyvinyl acetal/self-bonding MW 19-C 105 - X X X - - - 6 TB - -
Polyimide MW 20-C 240 X X 18* M 60317-47 -
Polyester (amide)(imide)/polyamide MW 24-A 155 X X - - - - - - - 60317-24 180
Polyester (amide)(imide)/polyamide MW 24-C 155 X X X - - - - 11 LN 60317-22 180
-
Polyester (imide) solderable MW 26-C 155 X X - - - - 28 SPE 60317-23 180
Polyester (imide)/polyamide solderable MW 27-C 155 X X - - - - - 29 SPEN -
MW 1000-2003, Revision 1, August 16, 2005

Polyurethane/polyamide MW 28-A 130 X X - - - - - - - - -
Polyurethane/polyamide MW 28-C 130 X X - - - - - 9 SUN 60317-19 -
Polyurethane/polyamide/self-bonding MW 29-C 105 - X X - - - - 30 SUNB - -
Polyester (amide)(imide) MW 30-C 180 X X X - - - - 12 H 60317-8 -
Paper covered (also 90'C) MW 31-C 105 X X - - - - - - - - -
Paper covered (also 90'C) MW 33-C 105 - - - - X X - - - 60317-27 -
Polyester (amide)(imide)/polyamideimide MW 35-A 220 X X - - - - - - - 60317-25 200
Polyester (amide)(imide)/polyamideimide MW 35-C 200 X X X - - - - 14 K 60317-13 200
Polyester (amide)(imide)/polyamideimide MW 36-A 220 - - - - - X X - - - -
Polyester (amide)(imide)/polyamideimide MW 36-C 200 - - - - - X X 13 K 60317-29 -
Page C-1
Page C-2
NEMA Thermal
-
Glass fiber/varnish MW 41-C 155 X X - - - - - 19 GV 60317-48
Glass fiber/varnish MW 42-C 155 - - - - X X - 22 GV 60317-32 -
Glass fiber/silicone varnish MW 43-C 200 - - - - X X - 23 GK 60317-33 -
Glass fiber/silicone varnish MW 44-C 200 X X - - - - - 21 GK 60317-50 **
Polyester glass fiber covered MW 45-C 155 X X - - - - - 20 DGV - -
Polyester glass fiber covered MW 46-C 155 - - - - X X - 25 DGV - -
Polyester glass fiber/silicone varnish MW 47-C 200 X X - - - - - 24 DGH - -
Polyester glass fiber/silicone varnish MW 48-C 200 - - - - X X - 26 DGH - -
Glass fiber/high temperature varnish MW 50-C 180 X X - - - - - 31 GO 60317-49 -

Polyester glass fiber/high temperature varnish MW 51-C 180 X X - - - - - 32 DGO - -
Glass fiber/high temperature varnish MW 52-C 180 - - - - - X X 33 GO 60317-31
Polyester glass fiber/high temperature varnish MW 53-C 180 - - - - - X X 34 DGO - -
Aromatic polyamide paper covered MW 60-A 220 - - - - - X - - - - -
Aromatic polyamide paper covered MW 60-C 220 - - - - - X - 35 PAP 60317-53 -
Aromatic polyamide paper covered MW 61-A 220 - X - - - - - - - - -
Aromatic polyamide paper covered MW 61-C 220 - X - - - - - - - 60317-52 -
Aromatic polyimide tape covered MW 62-C 220 - - - - X X - - - 60317-44 240
Aromatic polyimide tape covered MW 63-C 220 X X - - - - - - - 60317-43 240
Aromatic polyimide tape covered MW 64-C 240 - - - - X X - - - 60317-44
Aromatic polyimide tape covered MW 65-C 240 X X - - - - - - - 60317-43
Polyester(amide)(imide) Hermetic Applications MW 72-C 180 - X - - - - - - - 60317-10 PEI only
Polyester(amide)(imide)/polyamideimide
Hermetic Applications MW 73-A 220 - X - - - - - - - 60317-25 200
Polyester(amide)(imide)/polyamideimide
Hermetic Applications MW 73-C 200 - X - - - - - - - 60317-13 -
Table continued on following page
NEMA Thermal
180, PEI
Polyester(amide)(imide) MW 74-A 220 X X - - - - - - - 60317-15 only
Polyester(amide)(imide) MW 74-C 200 X X - - - - - 43 PEAI 60317-42 -
Polyurethane MW 75-C 130 X X - - - - - 37 SP 60317-4 -
Polyester(amide)(imide)/polyamide MW 76-A 180 X X - - - - - - - 60317-24 -

Polyester(amide)(imide)/polyamide MW 76-C 180 X X X - - - - - - 60317-22 -
Polyester (imide) solderable MW 77-C 180 X X - - - - - 39 SPEI 60317-23 -
Polyester (imide)/polyamide solderable MW 78-C 180 X X - - - - - 40 SPEIN - -
Polyurethane MW 79-C 155 X X X - - - - 41 SPU 60317-20 -

Polyurethane/polyamide MW 80-A 155 X X - - - - - - - - -
Polyurethane/polyamide MW 80-C 155 X X X - - - - 42 SPUN 60317-21 -
Polyamideimide MW 81-C 220 X X - - - - - - - 60317-26 200
Polyurethane MW 82-C 180 X X X - - - - - 60317-51 -

Polyurethane/polyamide MW 83-C 180 X X X - - - 60317-55 -
-
Polyester/Polyamideimide w/ Self-Bonding
Overcoat MW 102-A 180 - X X - - - -
Polyester/Polyamideimide w/ Self-Bonding
Overcoat MW 102-C 180 - X X - - - - - - 60317-38

Polyurethane/self-bonding MW 130-C 130 - X X - - - -
Polyurethane/polyamide/self-bonding MW 131-C 130 - X X - - - -
Polyurethane/self-bonding MW 135-C 155 - X X - - - - 60317-35
Polyurethane/polyamide/self-bonding MW 136-C 155 - X X - - - -
Page C-3
Page C-4
IEC Materials - With No US Equivalent
IEC Build Grades
IEC Build Grades G1 G2, G1B G3, G2B G1 G2
Polyimide - 220 X X - - - - - - - 60317-7 -
Polyurethane bunched with silk 130 60317-11
Polyvinyl acetal - 120 X X - - - - - - - 60317-12 -
Polyester - 155 - - - - X X - - - 60317-16 -
Polyvinyl acetal - 120 - - - - X X - - - 60317-18 -
Polyesterimide - 180 - - - - X X - - - 60317-28 -
Polyimide - 220 - - - - X X - - - 60317-30 -
Polyester - 130L X X - - - - - - - 60317-34 -
Polyester (imide) w/ Self bonding Overcoat

Solderable - 180 - X X - - - - - - 60317-36 -
Polyester (imide) w/ Self bonding Overcoat - 180 - X X - - - - - - 60317-37 -
Glass Fiber Braided Polyester (imide) Varnish
treated Bare or Enameled - 180 - - - - X X - - - 60317-39 -
Glass Fiber Braided Silicone Varnish treated
Bare or Enameled - 200 - - - - X X - - - 60317-40 -
Polyester Solderable - 130L X X - - - - - - - 60317-41 -
Polyester - 155L X X - - - - - - - 60317-54 -
* Thermal Class 220

** Silicone varnish not specified

ANSI NEMA MW 1000-2003 Rev.1.2005

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Approved as an American National Standard

ANSI Approval Date: October 25, 2005

National Electrical Manufacturers Association

Copyright 2005 by the National Electrical Manufacturers Association.

1-10 Film Insulated Rectangular Magnet Wire

Copyright 2005 by the National Electrical Manufacturers Association.

Part 2 PROPERTIES AND REQUIREMENTS

Copyright 2005 by the National Electrical Manufacturers Association.

Part 2 PROPERTIES AND REQUIREMENTS

MW 35-A Polyester (amide)(imide) overcoated with 220 X 35

Copyright 2005 by the National Electrical Manufacturers Association.

Part 2 PROPERTIES AND REQUIREMENTS (continued)

Copyright 2005 by the National Electrical Manufacturers Association.

Thermal Class Insulation, Covering and Form See Part 2, Section

FILM INSULATED ROUND MAGNET WIRE

130 Solderable Polyurethane overcoated with polyamide MW 28-A MW 28-C 27, 28

Copyright 2005 by the National Electrical Manufacturers Association.

Thermal Class Insulation, Covering and Form See Part 2, Section

FILM INSULATED RECTANGULAR AND SQUARE WIRE

200 Polyester (amide)(imide) overcoated with - MW 36-C 38

Copyright 2005 by the National Electrical Manufacturers Association.

Thermal Class Insulation, Covering and Form See Part 2, Section

Copyright 2005 by the National Electrical Manufacturers Association.

Part 3 TEST PROCEDURES

Copyright 2005 by the National Electrical Manufacturers Association.

PERIODIC CONFORMANCE TESTS

3.50 Thermoplastic Flow ................................................................................................................. 24

Copyright 2005 by the National Electrical Manufacturers Association.

3.8.6 Bend Method Mandrel Sizes ................................................................................................... 14

Copyright 2005 by the National Electrical Manufacturers Association.

Vice President, Engineering

Bridgeport Insulated Wire CompanyBridgeport, CT

Copyright 2005 by the National Electrical Manufacturers Association.

How to Use This Publication

Copyright 2005 by the National Electrical Manufacturers Association.

<This page is intentionally left blank.>

Copyright 2005 by the National Electrical Manufacturers Association.

1.2 NORMATIVE REFERENCES AND AUTHORIZED ENGINEERING INFORMATION (AEI)

American National Standards Institute

American Society for Testing Materials

ASTM B 3 Standard Specification for Soft or Annealed Copper Wire

Institute of Electrical and Electronics Engineers

Copyright 2005 by the National Electrical Manufacturers Association.

International Electrotechnical Commission

National Institute for Standards and Technology

Handbook 100 Copper Wire Tables

National Electrical Manufacturers Association

MW 750 (AEI) Dynamic Coefficient of Friction of Film-Insulated Magnet Wire

B1 = (46.7 x (nominal bare diameter in inches x 25.4)0.75)/25.4

Copyright 2005 by the National Electrical Manufacturers Association.

B2 = (93.3 x (nominal bare diameter in inches x 25.4)0.75)/25.4

B3 = (140.0 x (nominal bare diameter in inches x 25.4)0.75)/25.4

B4 = (186.7 x (nominal bare diameter in inches x 25.4)0.75)/25.4

Copyright 2005 by the National Electrical Manufacturers Association.

conductor: A substance used to transmit electrical current.

film coating: A continuous barrier of polymeric insulation.

film insulated wire: A film-coated conductor.

insulation: A dielectric medium that is applied to the conductor.

1.4.1.2 Dimensions and Resistivity

Copyright 2005 by the National Electrical Manufacturers Association.