RR Shramik Worli, Mumbai, Maharashtra

TIW, a unique product for small transformers. Three layer extruded coatings of high performance polymer resins gives excellent dielectric properties to this type of winding wires. Unlike enamelled wires, three layers of insulation are extruded over the copper conductor with automated manufacturing process ensure perfect central position of conductor. The conventional enamelled wire winding coils requires insulation between the primary and secondary coils by means of barrier tape or interlayer tape to isolate primary and secondary windings. Since three layers coating is having very high dielectric strength, it has very less creepage factor. This positive feature of TIW serves to downsize switching transformers and promises high production efficiency and cost reduction. Depending on the design, the transformer size can be reduced up to 40% and weight up to 60% as compared to transformers made up of enamelled wires.

We offer a superior range of enamelled copper wires aiming to cater the wide variety of applications in the industry ranging from a common motor rewinding to most critical applications like in automobiles. Enamelled winding wire is a film insulated copper (or aluminium) electrical conductor used in form of coil windings in motors, transformers, generators and other electromagnetic equipments. When wound into coils, and energized, enamelled winding wire creates an electromagnetic field, which is utilized to generate the required output form of energy – viz electrical to mechanical (or vice versa) electrical to electrical, and electrical to magnetic energy

Enamel film insulated rectangular copper conductors are known as enamelled copper strips. The manufacturing process of enamelled strips, are essentially same as round wires, but most critical. The rectangular shape of copper conductors with nominal corner radii, helps to pack maximum copper in small space. This characteristic is beneficial in design aspect of the transformer windings. At the same time the insulation strength and flexibility has to be excellent to withstand the winding stresses, bending / shaping etc. At Salasar Copper, we provide very special attention towards the flexibility and adherence of the insulation film of enamelled strips. We have many esteemed and satisfied customers using enamelled strips for critical applications. Application Super Enameled Copper Strips are used in various types of transformers. Size Range Width-14 mm max.Thickness-5 mm max.Cross Sectional Area-65 mm2 max

The demand of aluminium magnet wires in many industrial applications has sky rocketed due to unprecedented increase in copper rates. To cater this demand, we proudly declare the addition of super enamelled aluminium magnet wires in the product armory. These are manufactured as per Indian as well International standards and as per the specifications given by the customers. The product is available in different sizes, types and grades of coverings to cater to specific needs for special fields of applications. The latest technology is adopted for manufacturing to offer high quality products. Application Aluminium is an excellent electrical conductor after copper. The super enamelled aluminium wire can be used to replace the copper enamelled wires with proper design modifications. Mainly it is used in electronic circuits, television degaussing coils and so on for many more applications including washing machine motors, fans and AC compressors. The conductor properties of these wires differ from that of enamelled copper wires. Our products have a smooth surface and a very good elongation. Size Range,Types and Specifications  Wire Dia Sizes from 4.0 to 0.25 mm (8 to 33 SWG), Grade – 1, 2, and 3 • Modified Polyesters, Class 130, 155. As per IS 13730 part 9 / IEC 60317 part 9 • Hermetic Grade, Class 180. As per IS 13730 part 15 / IEC 60317 part 15 • Dual Coated, Class 200. As per IS 13730 part 25 / IEC 60317 part 25 and NEMA MW 35A

We also offer poly wrapped winding wire commonly known as “Submersible Copper Winding Wire”. The copper conductor is wrapped with thin polyester film and Biaxial oriented poly propylene (BOPP) films. The most modern plant with sophisticated wrapping heads and in line continuous heat shrinkage furnace is installed to get uniform covering. A complete quality assurance testing by instruments covering all governing standards is available. Application Submersible Winding Wires are used in submersible pumps motors of all sizes for domestic and industrial application.   Size Range 0.40mm- 3.00 mm  

We also offer poly wrapped winding wire commonly known as “Submersible Copper Winding Wire”. The copper conductor is wrapped with thin polyester film and Biaxial oriented poly propylene (BOPP) films. The most modern plant with sophisticated wrapping heads and in line continuous heat shrinkage furnace is installed to get uniform covering. A complete quality assurance testing by instruments covering all governing standards is available.

The application of Polyamide-Imide top coat over Polyester / Polyester-imide base coat, is well known to the user industry. The Polyamide-imide is class 200+ insulation which gives added thermal properties and chemical resistance to the substrate base coat. However, for certain applications the thermal, mechanical and dielectric properties are highly demanding. A typical example is in the automotive industry where the reliability of components is the crucial factor. The development of sole coat Polyamide-imide (PAI or AIW) wires, have cutting edge advantages over previous dual coated class 200 wires. Application AIW Enameled wires are mainly used in automobile industry in various component coils. The insulation is capable of withstanding harsh environments like extreme temperatures, chemicals, oils, greases, mechanical stresses and vibrations. The insulation thickness grade can be selected as grade 1, 2 and 3 depending upon the component design and slot filling factor. Size Range 0.070 mm to 2.00 mm grade 1, grade 2

Normally enamelled copper conductors are used as coil components of various electrical products such as motors / transformers / home appliances / auto electrical components / chokes / AC compressors. Apart from AC compressors all other copper windings undergo secondary insulation coating and curing of the same. The process is called impregnation. The secondary insulation is used to get a firm compact winding, that can withstand vibration and all the copper conductors are held firmly together. The voids in coil are also filled by the secondary insulation. It also prevents direct contact of moisture with the primary (enamel) insulation film. The basic property of secondary insulation (varnish) is to hold the winding together. However for certain applications (where the secondary insulation is not practical) self-bonding enamelled wires can be used. These wires have an outer layer of bondable material which is usually thermoplastic and bonds the wires surfaces with each other once heated to the bonding temperature of the outer layer. Bondable wires, thus, benefits in reduction of cycle time and elimination of process of secondary insulation application / baking / curing cycle etc. Application Bondable wires can be used in power tools armature coils, electronics, miniature coils, TV yoke coils, continuous-transposed conductors etc. The bondable layer is applied over variety of primary insulation like polyester, polyester-imide, dual coated and solderable polyurethanes of class 130, 155 and 180. Size Range 0.20 mm to 1.00 mm grade 1B, 2B Types Epoxy ResinsPolyamideAromatic Polyamide

Kraft paper insulation is most commonly used in oil-filled transformers. The plain kraft papers are wrapped in a number of layers around conductors, to acquire the needed insulation strength. However, plain kraft paper has limitations of the flexibility and leads to breakage of insulation in tight shaping of the coils. For this purpose, kraft papers are fabricated or creped. The folds made in creping process, increases the elasticity and flexibility during shaping of coils. It also enlarges the surface area of insulation and absorbs insulating oils resulting in better insulation and heat dissipation during operation.

Kraft paper insulation is most commonly used in oil-filled transformers. The plain kraft papers are wrapped in a number of layers around conductors, to acquire the needed insulation strength. However, plain kraft paper has limitations of the flexibility and leads to breakage of insulation in tight shaping of the coils. For this purpose, kraft papers are fabricated or creped. The folds made in creping process, increases the elasticity and flexibility during shaping of coils. It also enlarges the surface area of insulation and absorbs insulating oils resulting in better insulation and heat dissipation during operation. Application Crepe Kraft Paper Insulated Copper Cables are mainly used as an insulation in oil cooled transformers, current transformers of type IMB, CT, CVT as leads and shields. Crepe paper has 300% more strength in machine and cross machine direction and hence is more resistant to breakage. It can also take various shapes of the surface being insulated. The cable is wound on FRP Rings, 3 to 12 turns as per transformer application. This is also most suitable as lead wire and terminal wires of PT windings. Size Range & Types 70 sq mm to 150 sq mm. Copper flexible cables. Specifications FLEXIBLE COPPER CABLES WITH CREPE KRAFT PAPER MULTI LAYERED INSULATION    

Kraft paper insulation is most commonly used in oil filled transformers. The plain kraft papers are wrapped in number of layers on conductors, to acquire the needed insulation strength. However, plain kraft paper has limitations of the flexibility and leads to breakage of insulation in tight shaping of the coils. For this purpose, kraft papers are fabricated or creped. The folds made in creping process, increases the elasticity and flexibility during shaping of coils. It also enlarges the surface area of insulation and absorbs insulating oils resulting in better insulation and heat dissipation during operation.

Nylon top coat is used over the regular enamelled copper wires to enhance the mechanical properties of insulation coat. Normal enamelled coating is stressed in coil winding applications like high speed auto winding and auto coil insertions in slots. Nylon top coat exhibits a smooth and tough, slippery surface of top layer of insulation, thus, reducing chances of insulation damage and failures related to mechanical abuse of the thin insulation layer. Application Nylon top coat wires can be used in high speed windings for armature coils of home appliances, power tools, auto coiling machines for switch gears miniature coils in electronics etc.Nylon top coat applied over variety of primary insulation like polyester, polyester-imide, dual coated and solderable polyurethanes of class 130, 155 and 180 Size Range 0.020 mm to 0.800 mm

Litz wire is a type of cable used in electronics to carry alternating current. The wire is designed to reduce the skin effect and proximity effect losses in conductors used at frequencies up to about 1 MHz. It consists of many thin wire strands, individually insulated and twisted bunched, grouped or braided woven together, as per the specific design and application. This often involves several levels (groups of twisted wires are twisted together etc.). This winding pattern equalizes the proportion of the overall length over which each strand is at the outside of the conductor. The individually insulated copper strands are basically the insulated magnet wires laid in form of cable strands.

Litz wire is a type of cable used in electronics to carry alternating current. The wire is designed to reduce the skin effect and proximity effect losses in conductors used at frequencies up to about 1 MHz. It consists of many thin wire strands, individually insulated and twisted / bunched, grouped or braided / woven together, as per the specific design and application. This often involves several levels (groups of twisted wires are twisted together etc.). This winding pattern equalizes the proportion of the overall length over which each strand is at the outside of the conductor. The individually insulated copper strands are basically the insulated magnet wires laid in form of cable strands. Application Typical applications for litz wire conductors include high-frequency inductors and transformers, motors, relays, inverters, power supplies, AC/DC converters, communication equipment, ultra-sonic equipment, sonar equipment, television equipment and heat induction equipment. The new innovations in information technology and communication devices have opened tremendous opportunities of usage of litz wires. A latest example can be a wireless mobile charger. Size Range 0.050 to 0.500mm Types Polyurethane class 130, 155, 180 – Natural / ColouredPolyesterimide class 180Dual Coated class 200

Kraft paper insulation is most commonly used in oil filled transformers. The plain kraft papers are wrapped in number of layers on conductors, to acquire the needed insulation strength. However, plain kraft paper has limitations of the flexibility and leads to breakage of insulation in tight shaping of the coils. For this purpose, kraft papers are fabricated or creped. The folds made in creping process, increases the elasticity and flexibility during shaping of coils. It also enlarges the surface area of insulation and absorbs insulating oils resulting in better insulation and heat dissipation during operation.

The glass in glass fibre conductor may be applied in woven tape form or as a continuous fibre. It has proven to be an efficient insulator, providing coil winders with thermal stability, and equate electrical properties and good resistance to abrasion after varnishing. The glass fibre is bonded with a varnish, to improve dielectric strength and mechanical properties. Glass fibre-lapped conductors (bare or enamelled) are very suitable for windings of electric motor stators, generators, special transformers and high voltage motors, heavy magnet coils etc. In general this insulation can be applied where high mechanical strength and high insulation properties are required. Most common application is in traction motors. It exhibits a very high degree of mechanical and thermal stability; either for class F and H insulation, when impregnated with polyester, polyester-imide or epoxy based impregnating varnishes. For higher thermal class, the glass fibre-lapped conductors can be impregnated with silicone based resins of thermal class 200. The production machinery includes high speed double six spindle fibre lapping and varnish application with inline heating oven and automatic take up reeling Application Glass Fibre Covered Strips are used in Motor Stators,Generators,Special Transformers and High Volatage Motors

RR Shramik offers an industry-leading range of high quality fine and ultra-fine enamelled copper wires. The enamelled wire properties governing proper selection not only require consideration of the end use conditions but system compatibility and ease of use in production. Solderablility, abrasion resistance, bondability, flexibility, insulation builds, etc. are all typical production and design considerations.Higher temperature requirements and more complex systems dictate the need for knowledgeable selectivity of enamelled wires. In addition to the product featured in this catalogue, we can manufacture custom insulated wires to meet your requirements.

Cotton is one of the most useful naturally occurring insulators and is used from ancient time for its also has moderate electrical insulation properties in dry condition. in certain low voltage applications, cotton yarns are used wrapped around insulators., which proved to be long lasting.

Cotton is one of the most useful, naturally occurring insulators and is used from ancient time for heat resistance. However, it also has moderate electrical insulation properties in dry condition. In certain low voltage applications, cotton yarn is used as wrap-around insulators, which proved to be long lasting, flexible and tough insulation. Cotton yarn soaked in impregnating resins and cured properly can be used for critical applications like servo stabilizer windings, magnet coils etc. Application Cotton Covered Copper Conductors are exclusively used in dimmer stat windings of 40, 50, 75, 80, 90 Amp or even higher capacity. SWG 6, 9, and 11 are commonly used for this application. The wires are wound in form for toroid windings, which is further dipped in epoxy resins and cured / baked to form a solid, hard, tough insulation. Size Range SWG 5 to 15 (5.4 mm to 1.8 mm)6 to 80 sq. mm. copper (Width 3 mm to 15 mm – Thickness 1.6 mm to 5 mm) Specifications As per IS 7391 part 1 for round copper wires, IS 7391 part 2 for rectangular copper conductors.

In inverter driven motors, excessive surges and voltage peaks during speed variation, creates corona discharge in the stator windings, which induce extra thermal stress on the insulation, causing excessive thermal ageing there by weakening and even decomposing of the insulation, leading to premature failure of motors. Corona induced failure is a typical phenomenon. Mica based products are used in certain application where corona resistance is required. Mica is naturally occurring and is available easily. But it has its own inherent weakness. It has poor flexibility and large area and as such, the space required is more for any mica based application. This result by increasing the size of the motor, making it unusable where space constraints are there. Moreover it has poor adhesion to most of theresins. Improved dielectric materials having resistance to corona discharge-induced deterioration would therefore be highly necessary. M/s. Dupont has been manufacturing corona resistant Wire enamel under the brand name “Voltatex”. Corona Resistant Winding Wires are used in Inverter drives & Stator Windings.