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Copper Bare Round and Rectangular Wire

Copper bare round and rectangular wires are wires without any kind of insulation these are widely used for busbars, alternator, special motors and switch gears. Copper busbars are widely used in distribution panels and circuit breakers. Switchgears on the other hand are used to isolate electrical equipments.

Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Copper Rod. Chemical properties confirming to Cu-Cath-1 of BSEN 1978:1998/ ASTM B-115:2000 and Physical properties confirming to ASTM B49-2009

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 0.315 mm ( 30 SWG) / 0.320 mm (29 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Specifications/ Standards

IS 6160                           


Aluminium Bare Round and Rectangular Wire:
Aluminium Bare Round and Rectangular Wire are mainly used as connectors in control panels. A recent technological advance in the industry has led to use of aluminium as an alternative to copper. Nowadays industries are changing their design and incorporating aluminium as it is cost effective when compared to copper.


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Aluminium Wire Rod ( Conductivity > 61% ) confirming to EN10204,3.1.b and EN485/1/2/4, 515, 573

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 0.508 mm ( 25 SWG) / 0.510 mm (24 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Specifications/ Standards

IS 6160                            


Copper Double Paper Covered Round and Rectangular Wire (DPC)
Copper double paper covered round and rectangular wire (DPC) are conductors which are an important element in oil cooled transformers, these transformers are vintage styled oil cooled transformer. The DPC conductors have a low thermal index compared to other insulations. Copper DPC round and rectangular wires are mainly used in distribution, power transformers as well as in large power grids.  


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Copper Rod. Chemical properties confirming to Cu-Cath-1 of BSEN 1978:1998/ ASTM B-115:2000 and Physical properties confirming to ASTM B49-2009

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 0.508 mm ( 25 SWG) / 0.510 mm (24 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

Electrical Grade Kraft paper

Thermal Class

105’C

Insulation Thickness (Round Wire)

DPC: 0.100 mm – 0.300 mm
MPC: 0.300 mm – 3.000 mm

Insulation Thickness (Rectangular )

DPC: 0.300mm – 0.600 mm

Specifications/ Standards

IS   7404-1/ IS 13730-27
IEC 60317-27                        

Aluminium Double Paper Covered Round and Rectangular Wire (DPC) are also used in oil cooled low voltage transformers. Use of aluminium is on a rise, as an alternative to copper because of cheap metal price as well as technological advances in producing high quality EC grade high conductive aluminium wire rods.


Aluminium Double Paper Covered Round and Rectangular Wire (DPC)


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Aluminium Wire Rod ( Conductivity > 61% ) confirming to EN10204,3.1.b and EN485/1/2/4, 515, 573

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 0.508 mm ( 25 SWG) / 0.510 mm (24 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

Electrical Grade Kraft paper

Thermal Class

 

Insulation Thickness (Round Wire)

DPC: 0.100 mm – 0.300 mm
MPC: 0.300 mm – 3.000 mm

Insulation Thickness (Rectangular )

DPC: 0.300 mm – 0.600 mm

Specifications/ Standards

IS   6162-1 / IS 6162-2 


Copper Double Fibre Glass Insulated Round and Rectangular Wire (DFGC)
Copper Double Fibre Glass Insulated Round and Rectangular Wire (DFGC) have been in use since early 2000. New regulations by the authorities to use dry type transformers instead of the oil cooled transformers in city limits to reduce electrical short circuit disaster, had put industry designers on the drawing board, after several tests at their R&D a new product was introduced to address this issue. This is when Fibre glass conductor was introduced. Fibre glass conductor is a combination of Glass Fibre Yarn and Varnish bonding, Fibre yarn is an insulator lapped on the conductor with a primary insulation of varnish of different class.  These conductors would withstand high temperature with naturally air cooled and is more efficient than conventional conductors.



Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Copper Rod. Chemical properties confirming to Cu-Cath-1 of BSEN 1978:1998/ ASTM B-115:2000 and Physical properties confirming to ASTM B49-2009

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 3.657 mm ( 9 SWG) / 3.664 mm (7 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

E – Type Fibre Glass Yarn with low alkali content and high strength, corrosion resistant, good thermal conductivity, high heat and fire resistant.
Varnish Bonding is primarily a polyester base raisin which is a good insulator with good physical, electrical and mechanical properties

Thermal Class

Class – F ( 155Degree)/ Class – H (180 Degree)/ Class – C ( 200 Degree)

Insulation Thickness (Round Wire)

0.080 mm – 0.150 mm

Insulation Thickness (Rectangular )

0.100 mm – 0.500 mm

Specifications/ Standards

IS 4685-1 / IS 4685-2
IEC 60317-0-4/ IEC 60317-32


Aluminium Double Fibre Glass Insulated Round and Rectangular Wire (DFGC)
Aluminium Double Fibre Glass conductor is been increasingly in use nowadays. Good Electrical, Thermal and mechanical properties of Copper Fibre Glass conductor has inspired designers to try Aluminium instead of copper, and were successful in creating it. Aluminium Double Fibre Glass is feasible, cost effective and has good thermal, electrical and mechanical properties. Aluminium Double Fibre Glass conductors are used in small and medium dry type transformers, power reactor as well as UPS transformers. 

Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Aluminium Wire Rod ( Conductivity > 61% ) confirming to EN10204,3.1.b and EN485/1/2/4, 515, 573

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 3.657 mm ( 9 SWG) / 3.664 mm (7 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

E – Type Fibre Glass Yarn with low alkali content and high strength,  corrosion resistant, good thermal conductivity, high heat and fire resistant.
Varnish Bonding is primarily a polyester base raisin which is a good insulator with good physical, electrical and mechanical properties

Thermal Class

Class – F ( 155Degree)/ Class – H (180 Degree)/ Class – C ( 200 Degree)

Insulation Thickness (Round Wire)

0.080 mm – 0.150 mm

Insulation Thickness (Rectangular )

0.100 mm – 0.600 mm

Specifications/ Standards

IS 13730-31/ IS 13730-32/ IS 13730-33
IEC 60317-31/ IEC 60317-32/ IEC 60317-33


Copper Enamel Insulated Round and Rectangular Winding (Magnet Wires)
Copper Enamel wire (Magnet Wires) is classed as the sole of the electric motor. The copper enamel wire in a coil form (Stator) carries electric current which then generates a magnetic field making the rotor to rotate. Electric motors are used in diverse applications, such as fans, washing machines, blowers, industrial machinery and many more. Electric motors come in different types and in different capacities to suit different industrial and domestic needs. Most popularly used electric motors in the industry are ABB Motors, Marathon Electric, WEG Electric Corp, Kirloskar, Siemens, L&T, Crompton Greaves Ltd, Bharat Bijlee Limited and many more.
Rectangular Copper Enamel wires on the other hand are widely used in alternators as well as in some dry type transformers. High thermal endurance of Polyesterimide/ THEIC Polyesterimide chemical base enamel has excellent flexibility and adhesion properties.


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Copper Rod. Chemical properties confirming to Cu-Cath-1 of BSEN 1978:1998/ ASTM B-115:2000 and Physical properties confirming to ASTM B49-2009

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 0.193 mm ( 36 SWG) / 0.190 mm (32.5 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

Superior quality enamel, Polyester (130’); Modified Polyester (155’); Polyurethane (155’) solderable; Polyesterimide (180’); Polyamide-Imide (200’) 

Thermal Class

Class – B ( 130 Degree) Class – F ( 155Degree)/ Class – H (180 Degree)/ Class – C ( 200 Degree)

Insulation Thickness (Round Wire)

0.050 mm – 0.110 mm

Insulation Thickness (Rectangular )

0.080 mm – 0.110 mm

Specifications/ Standards

Wire : IS 13730-45/IS 13730-03/IS 13730-08/IS 13730-    13/ IS 13730-20/-23 IS13730-29
IEC 60317-20 / IEC 60317-51/ IEC 60317-12
Flat Wire: IS 13730-16/IS 13730-28/IS13730-29
IEC 60317-18/ IEC 60317-29/ IEC 60317-47
                 


Aluminium Enamel Insulated Round and Rectangular Winding Wire
Aluminium Enamel wires are widely been used since early 2010. These wires were earlier used in electrical chokes. Nowadays it is also used in low voltage transformers for primary winding. Technological advances in the chemicals industry has led to discover new polyester base enamel to suit base metal like aluminum. The enamels used in aluminium enameled wires possess high adherence properties. These enamels also have high electrical, thermal as well as mechanical properties. The rectangular wires on the other hand have been specifically designed for low voltage transforms, these low voltage transformers are extensively used in online UPS, Stabilizer, Reactor, DC converters, Inductors, Transformer rectifier and many more applications.           


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Aluminium Wire Rod ( Conductivity > 61% ) confirming to EN10204,3.1.b and EN485/1/2/4, 515, 573

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 1.016 mm ( 19 SWG) / 1.023 mm (18 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

Superior quality enamel, Polyester (130’); Modified Polyester (155’); Polyurethane (155’) solderable; Polyesterimide (180’); Polyamide-Imide (200’) 

Thermal Class

Class – B ( 130 Degree) Class – F ( 155Degree)/ Class – H (180 Degree)/ Class – C ( 200 Degree)

Insulation Thickness (Round Wire)

0.050 mm – 0.110 mm

Insulation Thickness (Rectangular )

0.080 mm – 0.110 mm

Specifications/ Standards

Wire : IS 13730-45/IS 13730-03/IS 13730-08/IS 13730-    13/ IS 13730-20/-23
IEC 60317-20 / IEC 60317-51/ IEC 60317-12
Flat Wire: IS 13730-16/IS 13730-28/IS13730-29
 IEC 60317-18/ IEC 60317-29/ IEC 60317-47
                 


Copper Enamel Fibre Glass Insulated Round and Rectangular Wire (ENFGC)
Copper Enamel Fibre Glass insulated wires are primarily a combination of enamel coating over which fibre glass yarn covering is done. Higher capacity transformers which are used in large power stations as well as in substations require higher thermal and corrosion resistant conductors, enameled fibre glass conductors are used in such conditions due to the benefit of both polyester enamel covering as well as fibre yarn covering which are high quality insulators. Copper enamel fibre glass are mainly used in Roebel bars, power and distribution dry type transformers.


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Copper Rod. Chemical properties confirming to Cu-Cath-1 of BSEN 1978:1998/ ASTM B-115:2000 and Physical properties confirming to ASTM B49-2009

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 3.657 mm ( 9 SWG) / 3.664 mm (7 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

Primary insulation: Superior quality enamel, Polyesterimide (180’); Polyamide-Imide (200’)
Secondary insulation: Glass lapped fibre yarn with varnish bonding 

Thermal Class

Class – H (180 Degree)/ Class – C ( 200 Degree)

Insulation Thickness (Round Wire)

0.050 mm – 0.110 mm

Insulation Thickness (Rectangular )

0.250 mm – 0.500 mm

Specifications/ Standards

IS 11184 / IS 13730-0-16
IEC 60317-16


Aluminium Enamel Fibre Glass Insulated Round and Rectangular (Flat) Wire (ENFGC)
Aluminium enamel fibre glass insulated conductors are primarily a combination of enamel coating over which fibre glass yarn is lapped. Aluminium enamel fibre glass is less used compared to its copper counterpart because of its low conductivity. Aluminium enamel fibre glass is mainly used in electric welding transformer, medium voltage transformers, reactors, output filter and DC choke.   


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Aluminium Wire Rod ( Conductivity > 61% ) confirming to EN10204,3.1.b and EN485/1/2/4, 515, 573

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 3.657 mm ( 9 SWG) / 3.664 mm (7 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

Primary insulation: Superior quality enamel, Polyesterimide (180’); Polyamide-Imide (200’)
Secondary insulation: Glass lapped fibre yarn with varnish bonding 

Thermal Class

Class – H (180 Degree)/ Class – C ( 200 Degree)

Insulation Thickness (Round Wire)

0.050 mm – 0.110 mm

Insulation Thickness (Rectangular )

0.080 mm – 0.110 mm

Specifications/ Standards

IS 11184 / IS 13730-0-16
IEC 60317-16


Taped Round and Rectangular (Flat) Copper/ Aluminium Wires
Taped conductors are produced in various types, amongst those Mica, Nomex, Kapton and Polyfilm are widely used in the industry. These high quality insulators are wound on the conductors and have formidable thermal resistant capacity, some insulators like Mica and Kapton can resist from 500’ C to 1000’ C. The conductors are mainly used for high voltage motors, windmill generator, inverter driven motors, safety motors and transaction motors.


Metal Type

Electrical Conductivity Grade (EC Grade) Continuous Cast Copper Rod. Chemical properties confirming to Cu-Cath-1 of BSEN 1978:1998/ ASTM B-115:2000 and Physical properties confirming to ASTM B49-2009

Round Wire Dimension

7.62 mm ( 1 SWG/ 1 AWG) To 3.657 mm ( 9 SWG) / 3.664 mm (7 AWG)
Special size accommodated, subject to condition 

Rectangle Wire Dimensions

Width: 3.00 mm To 16.00 mm
Thickness : 0.80 mm To 5.00 mm
Cross sec area: 3.00 Sq.mm To 80 Sq.mm
Special sizes accommodated, subject to condition

Insulation

Mica, Nomex, Kapton and Polyfilm tapes. Each made of different material and possess unique characteristic with high thermal resistant property.

Thermal Class

Class – C ( 155 Degree) to Class – D ( 220 Degree)

Insulation Thickness (Round Wire)

0.050 mm – 0.110 mm

Insulation Thickness (Rectangular )

0.080 mm – 0.500 mm

Specifications/ Standards

IS   11174