Comprehensive Technical Overview of Aluminium Stud Mount Transformer Connectors
We are one of the leading manufacturers and exporters of Aluminium Stud Mount Transformer Connectors, Transformer Terminal Connectors, and Electrical Power Connectors from India. We have been supplying high-quality Aluminium Transformer Connectors, Stud Mount Cable Lugs, Transformer Bushings Connectors, Heavy Duty Electrical Connectors, HV Transformer Connectors, Custom Aluminium Connectors, and Power Distribution Connectors to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing premium Aluminium Electrical Connection Systems using advanced aluminum alloy formulation, precision die casting, CNC machining, heat treatment processes, electroplating, automated assembly, electrical testing, and comprehensive quality assurance systems. With over three decades of global experience in High Voltage Electrical Connector manufacturing, we serve diverse industries including power transmission and distribution, electrical utilities, renewable energy, industrial power systems, railway electrification, substation equipment, transformer manufacturing, and electrical infrastructure projects. Our expertise encompasses working with various aluminum alloys including Aluminum 1350, Aluminum 6061, Aluminum 6101, and Special Electrical Grade Alloys. We manufacture Aluminium Stud Mount Transformer Connectors in current ratings from 200A to 5000A, voltage ratings up to 36kV, stud sizes from M8 to M30, maintaining temperature ratings from -40°C to 120°C, excellent electrical conductivity (minimum 55% IACS), compliance with IEC 61238, IS 1255, ASTM B316, ANSI C119.4 standards, and reliable performance in demanding electrical power applications.
Types of Aluminium Stud Mount Transformer Connectors
Single Stud Mount Transformer Connectors
Standard Single Stud Connectors designed for individual cable termination, featuring precision-machined contact surfaces and optimized current path design. Available in straight and angled configurations with current ratings from 200A to 2000A. These Heavy Duty Single Connectors provide reliable connections for distribution transformers, power capacitors, reactor terminals, and electrical equipment where single cable termination is required.
Double Stud Mount Transformer Connectors
Dual Connection Transformer Connectors with two cable termination points, featuring balanced current distribution and enhanced mechanical strength. Current ratings from 400A to 3000A with stud sizes from M10 to M24. These Parallel Connection Connectors are essential for power transformer bushings, substation equipment, busbar connections, and multiple cable terminations where parallel connections are necessary.
Four Stud Mount Transformer Connectors
Multi-Point Transformer Connectors with four cable termination points in square or rectangular configuration, featuring uniform current distribution and robust construction. Current ratings from 800A to 5000A with heavy-duty stud arrangements. These High Current Connectors are designed for large power transformers, generator terminals, substation busbars, and high current applications requiring multiple parallel connections.
Angled Stud Mount Transformer Connectors
45° and 90° Angled Connectors with precision bending and optimized contact geometry, featuring stress-free design and smooth current transition. Available in single and double stud configurations. These Directional Connection Connectors solve space constraints in compact substations, pad-mounted transformers, underground distribution, and confined electrical enclosures.
Custom Configuration Transformer Connectors
Application-Specific Connectors with custom hole patterns, special angles, and unique configurations, featuring engineered solutions for specific requirements. These Tailored Design Connectors address unique challenges in special transformer designs, retrofit applications, overseas projects, and proprietary equipment interfaces.
Material Specifications & Properties
Aluminum Alloy Composition & Electrical Properties
| Alloy Grade | Composition | Conductivity (% IACS) | Tensile Strength (MPa) | Yield Strength (MPa) | Applications |
|---|---|---|---|---|---|
| Aluminum 1350 | 99.5% Al, 0.1% Si, 0.05% Fe | 61% | 85-110 | 30-40 | High conductivity applications |
| Aluminum 6061 | 97.9% Al, 0.6% Si, 1.0% Mg | 55% | 310 | 275 | Structural applications |
| Aluminum 6101 | 98.9% Al, 0.5% Mg, 0.4% Si | 57% | 220 | 195 | Electrical bus conductors |
| Special Electrical Grade | 99.0% Al, 0.6% Cu, 0.3% Mg | 58% | 250 | 200 | High performance connectors |
Mechanical & Electrical Performance Specifications
| Parameter | Standard Range | High Performance Range | Test Standard |
|---|---|---|---|
| Current Rating | 200A – 5000A | Up to 6000A | IEC 61238-1 |
| Voltage Rating | 1kV – 36kV | Up to 52kV | IEC 61439 |
| Temperature Rating | -40°C to 120°C | -60°C to 150°C | IEC 60512 |
| Contact Resistance | <15μΩ | <10μΩ | IEC 61238 |
| Mechanical Strength | 50-500 Nm torque | 75-750 Nm torque | ASTM B316 |
Manufacturing Excellence
Advanced Manufacturing Process
High Pressure Die Casting: 800-1000 ton pressure casting machines for dense, pore-free aluminum components
CNC Precision Machining: 5-axis CNC machining centers maintaining tolerances of ±0.02mm
Heat Treatment: Solution heat treatment and artificial aging for optimal mechanical properties
Surface Treatment: Tin plating, silver plating, or chromate conversion coating
Quality Testing: 100% electrical testing and dimensional verification
Quality Assurance Protocols
Material Certification: Mill certificates with full chemical composition analysis
Dimensional Control: CMM inspection with statistical process control charts
Electrical Testing: Contact resistance measurement and current cycling tests
Mechanical Testing: Torque testing, pull-out force testing, and fatigue testing
Performance Validation: Thermal cycling, salt spray testing, and accelerated aging
Technical Specifications & Performance Data
Current Carrying Capacity & Temperature Rise
| Connector Size | Current Rating (Amps) | Temperature Rise at Rated Current | Maximum Short Circuit Current (1 sec) |
|---|---|---|---|
| 200A | 200 | 45°C | 16kA |
| 400A | 400 | 50°C | 25kA |
| 630A | 630 | 55°C | 40kA |
| 800A | 800 | 60°C | 50kA |
| 1000A | 1000 | 65°C | 63kA |
| 1600A | 1600 | 70°C | 80kA |
| 2000A | 2000 | 75°C | 100kA |
| 3150A | 3150 | 80°C | 125kA |
| 4000A | 4000 | 85°C | 160kA |
| 5000A | 5000 | 90°C | 200kA |
Dimensional Specifications & Stud Sizes
| Current Rating | Stud Size (mm) | Torque Value (Nm) | Cable Range (sqmm) | Overall Dimensions (LxWxH mm) |
|---|---|---|---|---|
| 200A | M8 | 25-30 | 25-50 | 60x40x25 |
| 400A | M10 | 40-50 | 70-120 | 80x50x30 |
| 630A | M12 | 60-70 | 150-240 | 100x60x35 |
| 800A | M12 | 70-80 | 185-300 | 120x70x40 |
| 1000A | M16 | 100-120 | 240-400 | 140x80x45 |
| 1600A | M20 | 150-180 | 500-630 | 180x100x55 |
| 2000A | M20 | 180-200 | 630-800 | 200x120x60 |
| 3150A | M24 | 250-300 | 800-1000 | 250x150x70 |
| 4000A | M27 | 350-400 | 1000-1250 | 300x180x80 |
| 5000A | M30 | 450-500 | 1250-1600 | 350x200x90 |
International Standards & Certifications
Global Compliance & Approvals
*IEC 61238-1*: Compression and mechanical connectors for power cables
IEC 61439: Low-voltage switchgear and controlgear assemblies
ANSI C119.4: Electric connectors – connectors for use between aluminum-to-aluminum conductors
IS 1255: Indian standard for aluminum conductors for overhead power transmission
ASTM B316: Standard specification for aluminum busbar and connector alloys
Testing & Certification Standards
Short Circuit Testing: IEC 61439-1 for short circuit withstand capability
Temperature Rise Testing: IEC 60512 for current carrying capacity verification
Environmental Testing: IEC 60068 for environmental conditions
Quality Management: ISO 9001:2015 certified manufacturing processes
Industry Applications
Power Transmission & Distribution
Distribution Transformers: LV and MV transformer bushings and terminals
Substation Equipment: Circuit breakers, disconnectors, and busbar connections
Power Capacitors: Power factor correction capacitor bank connections
Reactors & Chokes: Current limiting reactor and smoothing choke terminations
Renewable Energy Systems
Solar Power Plants: Inverter output connections and transformer terminations
Wind Farms: Generator terminals and power collection systems
Energy Storage: Battery energy storage system power connections
Hydroelectric Plants: Generator terminals and excitation system connections
Industrial Power Systems
Manufacturing Plants: Main power distribution and process equipment connections
Data Centers: Critical power distribution and UPS system connections
Railway Electrification: Traction substations and power supply systems
Mining Operations: High power equipment and distribution system connections
Installation Guidelines & Maintenance
Professional Installation Procedure
-
Surface Preparation: Clean contact surfaces using wire brush and contact cleaner
-
Torque Application: Use calibrated torque wrench with specified torque values
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Contact Lubrication: Apply antioxidant compound to aluminum contact surfaces
-
Cable Preparation: Strip cable insulation to recommended length
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Connector Assembly: Assemble components in correct sequence
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Final Inspection: Verify torque values and contact alignment
Maintenance Best Practices
Regular Inspection: Annual thermal imaging and visual inspection
Preventive Maintenance: Triennial torque verification and contact cleaning
Performance Monitoring: Continuous temperature monitoring in critical applications
Replacement Schedule: 20-year recommended service life with proper maintenance
Frequently Asked Questions
Q1: Why choose aluminum over copper for transformer connectors?
Aluminum offers significant cost savings (40-60% lower cost), excellent corrosion resistance, lighter weight (approximately 70% lighter than copper), and adequate electrical conductivity (61% IACS for pure aluminum) for most power applications, making it the preferred choice for large power connectors.
Q2: What is the service life expectancy of your aluminum connectors?
Our aluminum stud mount transformer connectors have a minimum service life expectancy of 30 years when properly installed and maintained, with proven performance in utility applications worldwide.
Q3: Do you provide custom-designed connectors for specific applications?
Yes, we specialize in custom connector design and manufacturing. We can create connectors with specific hole patterns, angles, current ratings, and special features to meet unique application requirements.
Q4: What surface treatments do you offer for corrosion protection?
We offer tin plating (5-8μm), silver plating (8-12μm), chromate conversion coating, and clear anodizing depending on the application environment and performance requirements.
Q5: Can you provide connectors for overseas voltage standards?
Yes, we manufacture connectors for all international voltage standards including 11kV, 22kV, 33kV, 66kV, 132kV, and custom voltage ratings up to 36kV and beyond.
Q6: What testing do you perform on finished connectors?
We perform 100% dimensional inspection, contact resistance testing, torque testing, and sample destructive testing. Additionally, we conduct type tests including temperature rise, short circuit, and environmental testing.
Contact Us Today – Request Quote for Aluminium Stud Mount Transformer Connectors
Ready to discuss your Aluminium Stud Mount Transformer Connector requirements for power distribution, renewable energy, industrial applications, or custom electrical connection solutions?
Request a Quote: Send your specifications including current rating, voltage rating, stud size, configuration, quantity, and application details to sales@jambrass.com for a detailed quotation within 24 hours.
Technical Support: Email your application requirements or technical drawings for connector selection guidance, material recommendation, and certification assistance.
Call Us: +91-22-43449300 / +91-22-43449323 (Monday-Friday, 9:00 AM – 6:00 PM IST)
Office Address: 1406, 14th Floor, Dalamal Tower, Nariman Point, Mumbai – 400021, Maharashtra, INDIA
Factory Address: Plot 10B, GIDC Industrial Estate, Shanker Tekari, Udyognagar, Jamnagar, Gujarat, India – 361004
Contact Person: Mr. Mehul Vora
Email: sales@jambrass.com
