Materials Available :Copper,tin,aluminum

1) This coil will go to final assembly with a core, and intend to be submersed in Transformer Oil (Shell 45 or similar), so all insulators, dipping warmish, and materials used to produce coil need to be compatible with above.
2) All dimensions are in millimeters, coil wire – copper.
3) Winding is an open bobbin design or simple core wounding. A bobbin core, flanges need to be made only for winding tooling, polish surfaces where flat bar (wire) is touching. Please advise on total winding tension, and bobbin core design;
4) Please refer to Drawings document (page3) and STEP model (will supply per request) ;
5) Windings done with Rectangular Magnet Wire, copper, flat bus at a 5 x 1.5mm cross-section of 7.5mm2 in fiberglass or electro-technical silk thread insulator or paper covered. Please provide specifications for the wire, insulation;
6) Layer-to-Layer insulation shall be design for not less than 600V. Please provide wire passport or Technical specifications;
7) Total winding layers shall be kept to a minimum of not more than 12mm total thickness, each winding section consist of :
i. 7 layers without insulator;
ii. 15 windings (turns) in each layer;
iii. 105 total windings (turns) per section;
8) Entry wire (marked on drawings “B”) bended according to drawings, open length is 150mm;
9) Finish wire (marked on drawings “E”) bended according to drawings, open length is 150mm;
10) Please pay attention to the “scissor” effect during winding, at layer transitions, on the end of each layer and use appropriate anti-wearing insulator patches (suggested 15x15mm square patch). Please provide details on this with dimensions and place where and how you plan to install this patch;
11) After removing from Tooling fixtures, support winding assembly – suggested place showing by two red lines on the drawings – please advise on details and materials. This support threads will be shipped to us and need to be removed before final assembling;
12) Coils need to be impregnated with varnish by dipping, in a vacuum and processed through appropriate drying/curing complete cycle. We are deep in heated varnish coils with 5min vacuum about ~50micron level, with following decompression to atmospheric pressure and again 10min vacuum to a ~25micron level. This cycle allows the de-gazing deep internal air pockets more efficiently;
Please consult with E2, C2, and F1 standard description.
Please provide a guidelines what you are currently use for similar coils production, for us to familiarize, and comment if we need to follow them or slightly change.
13) Post Production Testing :
a. Resistivity at 20C shall be 32mOHM +/- 2.5% (0.032OHM);
b. Inductance without core 1.8uH +/-0.5uH at no current;
14) Mechanical details:
a. Approximate total copper bus length for coil – about 14.1 meters;
b. Approximate coil weight– 0.95 kg;

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