class155(f) grade 2 pew polyester enameled aluminium wire

Class155(F) Grade 2 PEW polyester enameled aluminium wire is a magnet wire construction for coils that need Class F thermal performance, a defined insulation build and practical winding behavior. PEW usually refers to polyester enamel wire. Grade 2 indicates a heavier enamel build than Grade 1 in many purchasing contexts, giving more insulation margin while increasing outside diameter. For aluminum conductors, those details must be checked carefully because resistance, coil fill and terminal process all affect final performance.

The page title includes several useful product keywords: Class 155, F grade, Grade 2, PEW polyester, enameled aluminium wire and winding wire. A strong product page should explain what each term means for buyers. It should also avoid treating the wire as a generic commodity because a Class 155 Grade 2 wire for a fan motor may not be the right choice for a high-turn relay or a transformer auxiliary coil.

For related polyester aluminum wire topics, compare 155/180 polyester aluminum enamelled wire, modified polyester enamelled coated aluminum magnet wire and SWG34 PEW130 155 enamelled aluminum round wire. These internal links help users move between thermal class, enamel chemistry and gauge-based selection.

Understanding Class 155 F

Class 155, often called Class F, is used when a coil needs more thermal margin than lower-temperature enamel systems but does not require the higher cost or larger insulation build of some Class 180 or Class 200 products. It is common in motors, transformers, appliances, relays, solenoids and industrial coils. The exact suitability depends on the finished equipment temperature, duty cycle, cooling, varnish, bobbin and terminal design.

Thermal class is not a promise that any coil will operate safely at that temperature. It describes an insulation category under controlled conditions. The finished coil must still be tested for temperature rise, insulation resistance and mechanical stability. If the design replaces copper with aluminum, the engineering team must also review current density and resistance.

What Grade 2 changes

Grade 2 enamel build generally gives a thicker insulation layer than Grade 1. This can help breakdown voltage, pinhole resistance and abrasion margin during winding. The tradeoff is outside diameter. A thicker coating can reduce the number of turns in a fixed coil space. For fine wire, the difference can be significant. For larger wire, it can still affect slot fill, cooling and coil dimensions.

The buyer should ask for both bare conductor diameter and outside diameter. If only the bare diameter is quoted, the coil designer cannot know whether the final winding will fit. A sample winding is especially important when the coil window is tight or when the buyer is replacing a previous copper or aluminum wire construction.

PEW polyester enamel behavior

Polyester enamel is valued for general electrical insulation and thermal performance. Depending on the exact formulation, it may offer good adhesion, flexibility and heat resistance for common motor and transformer winding. However, solderability may not be as simple as with some polyurethane enamel systems. Aluminum conductor termination also needs special attention because aluminum oxide can affect contact reliability.

If the finished part requires direct soldering, discuss the terminal method before ordering. The buyer may need mechanical stripping, chemical stripping, welding, crimping or aluminum-to-copper lead transition. A good supplier should not only quote PEW wire; it should help the buyer define how the wire ends will be connected.

Specification table

Typical applications

This wire may be used in fan motors, small motors, transformers, appliance coils, industrial relays, solenoids, inductors and repair winding work. It is most suitable where Class 155 insulation is enough and the design benefits from aluminum's lower weight or cost. It is less suitable when the coil needs the lowest possible resistance in the same space or when the terminal process cannot be adapted for aluminum.

For a transformer coil, the buyer should check insulation margin and temperature rise. For a motor, check current, speed, torque and winding temperature. For a relay or solenoid, check resistance, duty cycle and lead-out reliability. The same wire can behave differently in different devices.

Application case: appliance fan coil

An appliance component factory tested Class155(F) Grade 2 PEW aluminum wire for a fan coil. The Grade 2 enamel improved insulation confidence compared with a thinner build, but the outside diameter slightly changed the winding fill. The engineering team adjusted the winding count and confirmed temperature rise under continuous operation. The terminal was changed from direct soldering to a crimp plus copper lead transition to improve repeatability.

The approved wire became a controlled material for that fan coil only after sample testing. The factory kept the test report, spool label and winding settings as part of its quality file. This kind of approval is more useful than relying on a generic "Class 155" claim.

FAQ

Is Grade 2 always better than Grade 1?

Not always. Grade 2 can improve insulation margin, but it increases outside diameter and may reduce coil fill.

Can PEW aluminum wire be soldered?

It depends on the enamel and aluminum terminal process. Validate stripping and connection before production.

What should be included in a quotation request?

Include conductor diameter, outside diameter limit, Grade 2 requirement, Class 155 thermal class, spool size, application and test documents.

Ordering note

For Class155(F) Grade 2 PEW polyester enameled aluminium wire, the buyer should approve both the material and the process. Confirm enamel build, winding behavior, terminal method and finished-coil temperature before bulk order.

How Grade 2 affects coil production

Grade 2 PEW polyester enameled aluminium wire should be evaluated in the winding machine, not only on a test sheet. The thicker enamel build can improve insulation margin, but it may make the wire slightly less flexible or reduce available winding space. A motor slot or relay bobbin that accepted Grade 1 wire may not accept the same conductor diameter with Grade 2 coating. This is why outside diameter and trial winding should be part of the first approval.

For aluminum conductors, the production team should also watch resistance drift. If winding tension is too high, a smaller aluminum conductor can elongate and resistance can shift upward. If the wire guide is rough, the polyester film can be scratched before the coil is finished. The sample trial should measure resistance before and after winding, then inspect the coil under the same varnish or heat process used in production.

Factory sourcing notes

A factory supplying Class155(F) Grade 2 PEW aluminum wire should be able to state the enamel type, thermal class, diameter tolerance and test standard. It should provide a batch report rather than only a catalog page. Buyers should ask whether the supplier can keep the same enamel build for repeat orders and whether the spool package is suitable for automatic winding. A clean, even spool helps prevent wire breakage and tension spikes.

For export buyers, the product label should show conductor size, PEW, Class 155, Grade 2, net weight and batch number. If the buyer uses AWG or SWG language, add the millimeter diameter to avoid confusion. A well-labeled spool may sound like a small detail, but it helps warehouse teams, repair shops and production workers avoid using the wrong material.

How to approve the finished coil

The wire approval should continue after winding. A finished coil made with Class155(F) Grade 2 PEW aluminum wire should be checked for resistance, turn placement, insulation damage, terminal strength and temperature rise. If the coil is varnished or baked, test after that process, not only before it. Heat can reveal weak adhesion, poor terminal stripping or hidden enamel scratches.

For motors, compare no-load current, running temperature and noise against the approved design. For transformers, compare resistance, insulation resistance and coil dimensions. For relays or solenoids, test duty cycle and lead-out reliability. This application-based approval prevents the buyer from assuming that one Class 155 wire construction is suitable for every product.

If a problem appears, separate material defects from process defects. Exposed conductor, excessive pinholes or wrong outside diameter point toward material control. Broken wire at a guide, scraped enamel at one bobbin corner or loose layers may point toward winding settings. A careful diagnosis helps both sides fix the real issue quickly.

Packaging should also be part of the specification. A Grade 2 PEW wire can still fail in production if the spool is loose, the flange is cracked or the wire layers are crossed. Ask for stable traverse winding, moisture protection and a label that repeats the approved technical description. Incoming inspection should compare the label, test report and measured sample before the material is released to the winding line. Repeat orders should use the same baseline.

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