MUKESH TRADERS

Andheri East, Mumbai, Maharashtra

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.

The mechanical, electrical and chemical characteristics of aluminium magnet wire differ from those of copper magnet wire because of the inherent differences in the conductor materials. These differences are reflected in certain test procedures and/or performance requirements for aluminium magnet wire, such as elongation, adherence and flexibility, heat shock, scrape resistance, continuity and thermal endurance.

Large round sizes, all rectangular film coated and all fibrous covered wire shall have yield strength not less than 9000 PSI.

We offer a superior range of super enamelled copper wire that is manufactured using E.C Grade copper rods that is extruded or drawn by dies of special size and is further repeatedly coated with enamel. Our assortment of enamelled copper wire comprises Polyester, Polyesterimide and Self-Soderable wires.

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 equipment's. 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.

International/Customised Standard : IEC, DIN, IS

Packing Details : Cylindrical & PT4 , PT10 , PT25 , PT45 , Pt90 Pt190 & as per Customers Requirements

Electrical Motors, CT / VT Transformers, Generator, Integrated Circuits, Power Supplies, Alternator, Gauges And Meters, Ignition Electronic System, Switchgear, Consumer & Industrial Electronics, Auto Electrical, Pumps & Fans.

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.

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.

• Polyurethane class 130, 155, 180 – Natural / Coloured
•  Polyesterimide class 180
•  Dual Coated class 200

Bunching / twisting can be customized as per customer drawing

Uncertainty and higher metal cost in copper have raised the need for alternate conductor metal in various electrical applications. Aluminum being the next good conductive material is most popular as replacement of copper. In certain applications like transformer windings this transition is happening rapidly.

The manufacturing of bare aluminum strips is critical process, being the soft metal characteristics of aluminum. At the same time the insulation strength and flexibility have to be excellent to withstand the winding stresses bending / shaping etc. RR Shramik, Jalan amongst other companies has most advanced technique machinery to make the aluminum conductors with precision controls in conductor dimensions and better surface properties. Also, they provide very special attention towards the flexibility and adherence of the insulation film of enameled strips.

• Automated machines for Aluminum strip making enameling
• Online quality monitoring through blister and pin hole detectors
• Variety of Class of insulations and Variety in packing spools
• Stringent test procedures for consistent quality

We 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.

Fine and Ultrafine Enamelled Copper Wires are mainly used in Small Transformers, Relays, IgnitionCoils, Transformers& Small Motors

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.

Submersible Winding Wires are used in submersible pumps motors of all sizes for domestic and industrial application.

There is very low voltage difference between turn to turn (approx 2V) hence less Insulation properties are required. Cotton, soaked in epoxy resin and cured, gives required insulation and toughness to the winding. It has better performance than Enameled wires for this application. As during the grinding application the cotton covering does not chip off. This is mainly used in variacwindings above the range of enameled wires windings (thicker wires)

• SWG 0 to 15 (8.23mm to 1.8mm)

• 10 to 75sq mm copper (Width 3mm to 25mm-Thickness 1.5mm to 4mm)

First layer of Fibre glass yarn covered with Second layer of cotton yarn

Can be supplied in range of 0.30 to 0.80 as per customer requirement.

Dry, wrapped around tightly over copper conductor without varnish treatment.

As per IS:7391 part 1 for round copper wires

This product is exclusively used in Dimmer stat windings of 40, 50, 75, 80, 90Amp 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 Variac Dimmer Coil.

Variac Dimmer Coil, Welding Machines & Rectifiers, Electroplating Rectifiers, Battery Chargers, and High frequency coils.

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.

Glass Fibre Covered Strips are used in Motor Stators, Generators, Special Transformers and High Volatage Motors

• CLASS : 155 : IEC 60317-32 (IS 13730-32)
• CLASS : 180 : IEC 60317-31 (IS 13730-31)
• CLASS : 200 : IEC 60317-33 (IS 13730-33)

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. 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.

• Modified Polyster 155 C ( IS 13730-16 & IEC 60317-16 )
• Polystermide Class H 180 C ( IS 13730-28 & IEC 60917-28 )
• Dual Coated Polyester (imide) + Polyamideimide (Overcoat) DC (PEI + PAI) Class 200 C ( IS 13730-29 & IEC 60317-29 )

Super Enameled Copper Strips are used in various types of transformers.

Fits perfect required Grommet As per IS dimension Perfect sheathing for under water application.

Conductor: Compactly bunched high purity bright, electrolytic grade, plain annealed copper with superb lexibility according to BS 8130 Class 2 & 5 available in various sizes. Unilay conductor in the core will be provided on special order from 1 to 4 sq. mm.Insulation & Sheathing: Generally available with 70C insulation and normal PVC sheathing, Choice of insulation and sheathing is available on special order.

• Current derating factors as per IS 3961 part 5 shall be applicable for different usage conditions.
• Standard Sheath Colours: Black.
• Standard Packing: 100 mtr. Longer lengths supplied on order.

SALIENT FEATURES:

• Dimensional accuracy
• High strength
• Superior finish

APPLICATION

• Winding Wire
• Cables
• Transformers
• Earthing

• Dimensional accuracy
• High strength
• Superior finish

Many Industrial Sectors and Application of ETP Copper Strips : Automotive Radiator, Electrical Fittings, Terminals, Electronic Components, Flashlights, Handicraft, Decorative Items, Domestic Appliances, Connectors, Springs Heat Exchangers & Condensers, Electric transformers, Earthing, Power Plants, Welding transformers etc.

Beico Industries entire range of electrical insulation laminates, for Temp Class B, F, H, and C.

• DuPont Nomex Paper-based Laminates (NPN Class F, NKN Class H)
• Pure Nomex Paper T410/T411, rolls as well as slitted tapes
• Fleece Polyester Laminates (FPF/DMD) Class B
• Electrical Grade Milky PET film, UL approved (rolls as well as slitted tapes)
• Polyimide film (rolls as well as slitted tapes)

All materials are available in slitting Rolls as per requirement.

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 by an 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.

Their applications cover most switching transformers, information and telecommunications equipment, game machines, consumer goods, inverters and other similar devices.

• SMPS for units of printer, facsimile, memory, computer, monitor, inverter, game machine.
• Battery Charger for assemblies of digital camera, portable telephone, 8 mm VCR, AC adapter, personal computer, DVD.
•  Operating Frequencies: Typically 85 kHz to 200 kHz but level with a maximum of 500 kHz
• SPECIFICATIONS

  Conforms to Japanese standard JIS 3005

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 automotive industry. Where, 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.

Mainly used in Automobile industry in various component coils. Starter motors, alternators, fuel pumps and ABS systems. The insulation is capable of withstanding harsh environments like extreme temperatures, chemicals, oils greases, fuels, 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.

IEC 60317-26, Polyamide-imide round copper wires Class 200

Product Range:- 0.070 to 2.00mm Grade 1, Grade-2

Coloured Wires:– We offer AIW wires in green OR black colour, as per customer requirements. This is helpful in colour coding and identification of AIW wound components at assembly lines.

•  Excellent high temperature characteristics
•  Resistance to harsh chemicals and fuels
•  High burnout resistance
•  Lower dissipation factor at high temperature – Tan Delta values >240°C
•  Easily replaceable to Dual coated Class 200°C wires
•  Durability

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 it's 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. More over it has poor adhesion to most of the resins. 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”.

Dual coated wire, with Polyesterimide as the base coat and Polyamideimide as the topcoat has been the most commonly used for applications up to thermal class 200. As discussed earlier, even these types of wires are susceptible to corona related failures. In order to overcome this deficiency, base coat is replaced with special corona resistant enamel.

• Basecoat of Corona resistant wire enamel class 200°C
• Top coat of Polyamide-imide (PAI) class 200°C +

We process Corona resistant wire in the range 3 mm to 0.63 mm. We can extend this range up to 0.3 mm by suitably modifying our machines. These corona resistant wires were tested for higher proof voltage and at elevated temperatures. There are certain guide lines about the voltage endurance test by RDSO. Our products conform to requirements of standards.

Further to this, the wire was impregnated with class vinyl toluene based class 200 impregnating varnish (resin) and tested for proof voltage at elevated temperatures. Test results were found satisfactory.

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.

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.

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.

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.

Nomex covering corresponds to class H insulation is mainly used in the construction of condensers and capacitors. Main application of it is in shielding of cables in high temp. environments (200C) such as dry type transformers, military and aerospace cables. Nomex covered conductors are more effective in condition where temperature resistance and dielectric strength requirements are high.

Kapton in KAPTON COVERED COPPER STRIPis the condensation product of an aromatic tetra basic acid and an aromatic diamine. It has no melting point, is infusible and self-extinguishing (does not support combustion).

Kapton(Brand Name of DuPonts PolyamideFilm) Covered Wires offers a wide range of applications in the construction of motors (specially in traction motors), aerospace equipments. It provides insulation with high electrical, thermal and mechanical properties over a temperature range of -196C to +250C. It provides higher Break Down Voltage (more than 8 KV BDV) as well as Temperature Class (220 C) as compare with other insulated conductors.

Insulating materials in traction motors have to withstand high temperatures and frequent changes of load and temperature. Standard materials applied for conductor insulation in Traction Motor application is polyimide film. It has excellent chemical resistance; there are no known organic solvents for the film.

Kapton does not melt or burn as it has the highest flammability rating. The outstanding properties of Kapton permit it to be used at both high and low temperature extremes where other organic polymeric materials would not be functional. Kapton gives conductors space saving, which ultimately yields more power without increasing motor size. Kapton provides exceptional overload protection and long motor life, even in the most demanding applications and envornments.

Busbars& Tapes are made from LME registered cathodes of Grade A typehaving copper purity of 99.99%. This high purity input give RR products high electrical conductivity of 100% IACS (International Annealed Copper Standard). This level of high conductivity is desirable for accurately designing electrical instruments.

We use smart process controls which impart fine grain structure to the final product. This fine grain structure gives good formability to bus bars, shows no cracks on bending and is suitable for making intricate parts of electrical machines.

Our products have glittering surface finish, a twist & bend free flatness. The extrusion drawing dyes angle design, drawing machine and high quality dyes gives our products a flawless shiny surface finish, matching all international standards and the right flatness for jointing purpose making it a perfect for connection application.