SAQA All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.
SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED QUALIFICATION: 

Occupational Certificate: Armature Winder (Heavy Coil Winder) 
SAQA QUAL ID QUALIFICATION TITLE
99254  Occupational Certificate: Armature Winder (Heavy Coil Winder) 
ORIGINATOR
Development Quality Partner - MERSETA 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY NQF SUB-FRAMEWORK
-   OQSF - Occupational Qualifications Sub-framework 
QUALIFICATION TYPE FIELD SUBFIELD
Occupational Certificate  Field 06 - Manufacturing, Engineering and Technology  Manufacturing and Assembly 
ABET BAND MINIMUM CREDITS PRE-2009 NQF LEVEL NQF LEVEL QUAL CLASS
Undefined  540  Not Applicable  NQF Level 04  Regular-ELOAC 
REGISTRATION STATUS SAQA DECISION NUMBER REGISTRATION START DATE REGISTRATION END DATE
Reregistered  EXCO 0425/24  2018-07-01  2025-12-30 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2026-12-30   2029-12-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This qualification does not replace any other qualification and is not replaced by any other qualification. 

PURPOSE AND RATIONALE OF THE QUALIFICATION 
Purpose:
The purpose of this qualification is to prepare a learner to operate as a Heavy Coil Winder.

A Heavy Coil Winder prepares the windings that are used in small to very large transformers that can generate millions of volts of electrical energy. The very large transformers can weigh anything up to 300+ tons and the actual task of preparing the windings can take up to six months for a single large transformer. A Heavy Coil Winder prepares for and produces four different types of windings, namely:
  • Regulator/tapping windings.
  • Screw/helical windings.
  • Continuous disc winding/disc ordinary winding.
  • Disc interleaf/stabilised interleaf disc winding.

    Rationale:
    Heavy Coil Winders manufacture or wind heavy coils for small to very large transformers, the latter are used in power generation. While there are not many companies that manufacture windings for small and large transformers, they play a very significant role in the energy environment.

    Heavy coil winding is distinguished from armature winding in a major way, that being the scale of the operation and the sizes of wound coils that eventually emerge. The large coils are used by massive transformers that weigh in excess of 300 tons.

    The coils are wound in four specific configurations, using machines and equipment by highly skilled Winders. It is also a job with high responsibility as poorly wound coils can cause transformers to be seriously damaged.

    Heavy Coil Winders receive training at their places of work; but the extent of this training cannot be measured in terms of complexity and remains unaccredited. This qualification will have far-reaching implications to those who are in the trade.

    Typical learners are school leavers, Technical Vocational Education and Training (TVET) college graduates and workers who have been employed in the Electro-Mechanical Industry. Once fully qualified, learners are able to wind coils in the four different configurations, depending to a large extent on the nature of the employer's business and the size of the company.

    The work of Heavy Coil Winders is critical to the economy because of the fundamental role that transformers play in electrical energy and power generation. 
    		•

    LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
    Recognition of Prior Learning (RPL):
    RPL for access to the external integrated summative assessment:
    Accredited providers and approved workplaces must apply the internal assessment criteria specified in the related curriculum document to establish and confirm prior learning. Accredited providers and workplaces must confirm prior learning by issuing a statement of result or certifying a work experience record.

    RPL for access to the qualification:
    Accredited providers and approved workplaces may recognise prior learning against the relevant access requirements.

    Entry Requirements:
  • Any NQF Level 2 qualification with Mathematics. 
    		•

    RECOGNISE PREVIOUS LEARNING? 
    Y 

    QUALIFICATION RULES 
    This qualification is made up of the following compulsory Knowledge, Practical Skill and Work Experience Modules:

    Knowledge Modules:
  • 671207001-KM-01, Workplace fundamentals, Level 3, 3 Credits.
  • 671207001-KM-02, The world of heavy coil winding, Level 3, 2 Credits.
  • 671207001-KM-03, Basic first aid, fire-fighting and Hazard Identification and Risk Assessment (HIRA), Level 2, 4 Credits.
  • 671207001-KM-04, Hand and power tools, Level 2, 2 Credits.
  • 671207001-KM-05, Specialised processes and equipment for heavy coil winding, Level 3, 13 Credits.
  • 671207001-KM-06, Electrical fundamentals for heavy coil winders, Level 4, 15 Credits.
  • 671207001-KM-07, Preparation for producing windings, Level 3, 23 Credits.
  • 671207001-KM-08, Tapping/regulator windings, Level 3, 7 Credits.
  • 671207001-KM-09, Helical/screw windings, Level 3, 7 Credits.
  • 671207001-KM-10, Disc continuous or disc ordinary windings, Level 4, 7 Credits.
  • 671207001-KM-11, Disc interleave or stabilised interleave disc windings, Level 4, 9 Credits.
  • 671207001-KM-12, Post-winding processes, Level 4, 6 Credits.
  • 671207001-KM-13, Core stacking, Level 3, 5 Credits.
  • 671207001-KM-14, Active parts assembly, Level 4, 5 Credits.
    Total number of credits for Knowledge Modules: 108.

    Practical Skill Modules:
  • 671207001-PM-01, Mitigate health, safety and fire risks and hazards, Level 2, 4 Credits.
  • 671207001-PM-02, Select, use and care for hand and power tools, Level 2, 7 Credits.
  • 671207001-PM-03, Use a range of equipment, machines and measuring instruments, Level 3, 14 Credits.
  • 671207001-PM-04, Prepare for winding, Level 3, 21 Credits.
  • 671207001-PM-05, Produce, test and unload regulator/tapping winding, Level 3, 15 Credits.
  • 671207001-PM-06, Produce, test and unload helical/screw windings, Level 3, 15 Credits.
  • 671207001-PM-07, Produce, test and unload disc continuous or disc ordinary windings, Level 4, 16 Credits.
  • 671207001-PM-08, Produce, test and unload disc interleave or stabilised interleave disc windings, Level 4, 16 Credits.
    Total number of credits for Practical Skill Modules: 108.

    This qualification also requires the following Work Experience Modules:
  • 671207001-WM-01, Structured planning and communication processes in the workplace, Level 4, 5 Credits.
  • 671207001-WM-02 Processes to prepare for the production of windings, Level 3, 17 Credits.
  • 671207001-WM-03, Regulator or tapping windings production processes, Level 3, 60 Credits.
  • 671207001-WM-04, Helical or screw windings production processes, Level 3, 84 Credits.
  • 671207001-WM-05, Disc continuous or disc ordinary windings production processes, Level 4, 110 Credits.
  • 671207001-WM-06, Disc interleave or stabilised interleave disc windings production processes, Level 4, 48 Credits.
    Total number of credits for Work Experience Modules: 324. 
    		•

    EXIT LEVEL OUTCOMES 
    1. Prepare for regulator or tapping winding.
    2. Produce regulator or tapping winding to specifications, and lift and transport winding.
    3. Prepare for screw or helical winding.
    4. Produce screw or helical winding to specifications, and lift and transport winding.
    5. Prepare for continuous disc or disc ordinary winding.
    6. Produce operational continuous disc or disc ordinary winding to specifications, and lift and transport winding.
    7. Produce disc interleaf or stabilised interleaf disc winding to specifications, and lift and transport winding. 

    ASSOCIATED ASSESSMENT CRITERIA 
    Associated Assessment Criteria for Exit Level Outcome 1:
  • Regulator or tapping winding design documentation is selected and interpreted.
  • Selection and set-up of machine (vertical or horizontal machine), mandrel and cylinder meets documentation requirements and instructions.
  • In-process regulator or tapping winding checks and inspections are carried out correctly and any faults or defects are identified and reported.
  • Set-up and loading of former and pay-off stands is carried out according to requirements.
  • Regulator or tapping winding insulation is set-up to meet documentation requirements.
  • The determination of numbering and winding direction and adjustment of counter meet requirements.
  • Regulator or tapping winding bottom exits (leads) are bent and insulated according to requirements.
  • Safety precautions relevant to the winding of regular or tapping windings are adhered to.
  • The regulator or tapping winding tasks are completed within specified time.
  • Damage to regular or tapping equipment, parts, materials and tools is avoided.
  • An understanding of the preparations for regulator or tapping winding is demonstrated.

    Associated Assessment Criteria for Exit Level Outcome 2:
  • Production of regulator or tapping winding Sling Layer Sling (SLS) and SLL with normal conductor meets design specifications.
  • Regulator or tapping windings are measured and tested to ensure adherence to design specifications.
  • All tolerances are adhered to.
  • Regulator or tapping winding main details assembly are installed, assembled or inserted.
  • Soft soldering, Continuous Transpose Cable (CTC) enamel removal and repair to cable insulation are carried out according to requirements.
  • Lifting of winding demonstrates safe and correct use of slinging techniques and cranes (assessed in work environment).
  • Transportation of winding is carried out safely and without damage using a forklift or pallet truck (assessed in work environment).
  • Relevant safety precautions are adhered to.
  • The tasks are completed within specified time.
  • Damage to regulator or tapping winding equipment, parts, materials and tools is avoided.
  • An understanding of the production of regulator or tapping winding is demonstrated.

    Associated Assessment Criteria for Exit Level Outcome 3:
  • Screw or helical winding design documentation is selected and interpreted (including calculations).
  • Selection and set-up of machine (vertical or horizontal machine), mandrel and cylinder meets documentation requirements and instruction.
  • In-process screw or helical winding checks and inspections are carried out correctly and any faults or defects are identified and reported.
  • Set-up and loading of former and pay-off stands are carried out according to requirements (conductors).
  • Screw or helical winding insulation is set-up to meet documentation requirements.
  • The determination of numbering and winding direction and adjustment of counter meet requirements.
  • Screw or helical winding bottom exits (leads) are bent and insulated according to requirements.
  • Relevant safety precautions are adhered to.
  • The screw or helical winding the tasks are completed within specified time.
  • Damage to screw or helical winding equipment, parts, materials and tools is avoided.
  • An understanding of the preparations for screw or helical winding is demonstrated.

    Associated Assessment Criteria for Exit Level Outcome 4:
  • Production of winding Screw1 sling to Screw2 sling (S1 to S2) with normal conductor meets design specifications.
  • Production of winding S1 to S2 with transposed cable meets design specifications.
  • Screw or helical windings are measured and tested to ensure adherence to design specifications.
  • Screw or helical winding main details assembly are installed, assembled or inserted.
  • Soft soldering, CTC enamel removal and repair to cable insulation are carried out according to requirements.
  • Lifting of winding demonstrates safe and correct use of slinging techniques and cranes.
  • Transportation of screw or helical winding is carried out safely and without damage using a forklift or pallet truck.
  • Relevant safety precautions are adhered to.
  • Damage to screw or helical winding equipment, parts, materials and tools is avoided.
  • An understanding of the production of screw or helical winding is demonstrated.

    Associated Assessment Criteria for Exit Level Outcome 5:
  • Winding design documentation is selected and interpreted.
  • Selection and set-up of vertical machine, mandrel and cylinder meets documentation requirements and instructions.
  • Continuous disc or disc ordinary windingin in-process checks and inspections are carried out correctly and any faults or defects are identified and reported.
  • Set-up and loading of former and pay-off stands are carried out according to requirements.
  • Continuous disc or disc ordinary winding insulation is set-up to meet documentation requirements.
  • Step blocks and edge strips are installed according to procedure.
  • The determination of numbering and winding direction and adjustment of counter meet requirements.
  • Continuous disc or disc ordinary winding bottom exits (leads) are bent and insulated according to requirements.
  • Continuous disc or disc ordinary winding safety precautions relevant to the winding of continuous disc or disc ordinary windings are adhered to.
  • Damage to continuous disc or disc ordinary winding equipment, parts, materials and tools is avoided.
  • An understanding of the preparations for continuous disc or disc ordinary winding is demonstrated.

    Associated Assessment Criteria for Exit Level Outcome 6:
  • Continuous disc or disc ordinary windings are measured and tested to ensure adherence to design specifications.
  • All tolerances are adhered to.
  • Continuous disc or disc ordinary winding main details assembly are installed, assembled or inserted.
  • Soft soldering, CTC enamel removal and repair to cable insulation are carried out according to requirements.
  • Copper filling and tappings are produced according to requirements.
  • Joints and transpositions are made and insulated according to requirements.
  • Lifting of continuous disc or disc ordinary winding demonstrates safe and correct use of slinging techniques and cranes.
  • Transportation of continuous disc or disc ordinary winding is carried out safely and without damage using a forklift or pallet truck.
  • All relevant safety precautions are adhered to.
  • Damage to continuous disc or disc ordinary winding equipment, parts, materials and tools is avoided.
  • An understanding of the production continuous disc or disc ordinary winding is demonstrated.

    Associated Assessment Criteria for Exit Level Outcome 7:
  • Disc interleaf or stabilised interleaf disc windings are measured and tested to ensure adherence to design specifications.
  • Disc interleaf or stabilised interleaf disc winding main details assembly are installed, assembled or inserted.
  • Soft soldering, CTC enamel removal and repair to cable insulation are carried out according to requirements.
  • Copper filling and tappings are produced according to requirements.
  • Joints and transpositions are made and insulated according to requirements.
  • Lifting of Disc interleaf or stabilised interleaf disc winding demonstrates safe and correct use of slinging techniques and cranes.
  • Transportation of Disc interleaf or stabilised interleaf disc winding is carried out safely and without damage using a forklift or pallet truck.
  • Relevant safety precautions are adhered to.
  • Damage to disc interleaf or stabilised interleaf disc winding equipment, parts, materials and tools is avoided.
  • An understanding of the production of disc interleaf or stabilised interleaf disc winding is demonstrated.

    Integrated Assessment:
    Integrated Formative Assessment:
    The skills development provider will use the curriculum to guide them on the stipulated internal assessment criteria and weighting. They will also apply the scope of practical skills and applied knowledge as stipulated by the internal assessment criteria. This formative assessment leads to entrance into the integrated external summative assessment.

    Integrated Summative Assessment:
    An external integrated summative assessment, conducted through the relevant Assessment Quality Partner is required for the issuing of this qualification. The external integrated summative assessment will focus on the exit level outcomes and associated assessment criteria. 
    		•

    INTERNATIONAL COMPARABILITY 
    Qualifications and training in the following countries were investigated:
  • United States.
  • Canada.
  • Australia.

    In Canada the Heavy Coil Winder occupation is listed in the Government of Canada Website, under the title: 9525 Assemblers, Fabricators and Inspectors, industrial electrical motors and transformers.

    This unit group includes workers who assemble, fabricate, fit, wire and inspect heavy-duty industrial electrical equipment. They are employed by manufacturers of industrial electric motors, transformers, control equipment, railway locomotives, transit vehicles and other heavy electrical equipment.

    Among the job titles related to this work category and to the training offered are the following: coil winder, transformer and transformer winder. Among the main duties for this category are the following:
  • Assemble windings into core using overhead cranes.
  • Make electrical connections using crimping, brazing and soldering equipment.
  • Set up and adjust production machinery and equipment.
  • Monitor production and troubleshoot production problems.

    The training offered to this category of worker in Canada is similar in content to that in this Occupational Certificate: Armature Winder (Heavy Coil Winder).

    In Australia, Heavy Coil Winding is a specialisation of the Electrician qualification. Australian and New Zealand Standard Classification of Occupations (ANZSCO) 341111, describes the job as follows: Installs, tests, connects, commissions, maintains and modifies electrical equipment, wiring and control systems.

    Some of the tasks are:
  • Measuring and laying out installation reference points.
  • Selecting, cutting and connecting wire and cable to terminals and connectors.
  • Using electrical and electronic test instruments to trace and diagnose faults.
  • Repairing and replacing faulty wiring and defective parts.

    The training offered to this Australian qualification is similar in content to that in this Occupational Certificate: Armature Winder (Heavy Coil Winder).

    In the United States (US) classification, Heavy Coil Winders are grouped with Coil Winders, Tapers, and Finishers, who wind wire coils used in electrical components, such as resistors and transformers, and in electrical equipment and instruments, such as field cores, bobbins, armature cores, electrical motors, generators, and control equipment.

    They perform the following tasks:
  • Select coil-forming device for specified coil and fastens device onto machine arbor, mandrel, or spindle or fastens device between chuck and tail stock.
  • Thread end of wire from reel through tension device, guides, and spreader, bends wire ends to form lead, and attaches lead to coil core.
  • Turn setscrews to adjust tension on wire and sets counter for number of turns specified.
  • Start machine and manually feeds wire over coil core or spreader to obtain even and uniform winding and shape of coil.
  • Observe counter and stops machine at specified number of coils.
  • Wrap insulation between layers and around wound coil or inserts plastic blocks between turns to form cooling ducts.
  • Cut wire to form leads, using wire or bolt cutters.
  • Strip insulation from end of lead wires, threads lead wires through insulating sleeves or slides sleeves over leads, and solders lead wires to terminals.
  • May test coils for winding continuity, using test lamp.

    All these tasks are reflected in the learning in the Occupational Certificate: Heavy Coil Winder. This in turn is similar to that in the Occupational Certificate: Armature Winder (Heavy Coil Winder).

    Conclusion:
    The South African qualification compares favourably with similar international standards and best practicesin respect of the complexity, similarity, and differences. 
    		•

    ARTICULATION OPTIONS 
    Horizontal Articulation:
  • Occupational Certificate: Armature Winder, Level 4 (ID 94019).
  • Further Education and Training Certificate: Electro-Mechanical Winding, Level 4 (ID 58610).

    Vertical Articulation:
  • National Certificate: N4 Engineering Studies, Level 5 (ID 66881). 
    		•

    MODERATION OPTIONS 
    N/A 

    CRITERIA FOR THE REGISTRATION OF ASSESSORS 
    N/A 

    NOTES 
    N/A 

    LEARNING PROGRAMMES RECORDED AGAINST THIS QUALIFICATION: 
     
    NONE 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS QUALIFICATION: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    NONE 


    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.