Comprehensive Technical Overview of Bronze Transformer Clamps
We are one of the leading manufacturers and exporters of Bronze Transformer Clamps, Transformer Connection Clamps, and Electrical Transformer Fittings from India. We have been supplying high-quality Bronze Busbar Clamps, Transformer Terminal Clamps, HV/LV Connection Clamps, Transformer Grounding Clamps, Custom Transformer Clamps, and Special Application Transformer Fittings to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing premium Bronze Transformer Connection Systems using advanced copper alloy formulation, precision sand casting, hot forging technology, CNC machining, heat treatment processes, surface finishing, automated assembly, electrical testing, and comprehensive quality assurance systems. With over three decades of global experience in Bronze Transformer Clamp 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 bronze alloys including Gunmetal Bronze (BS 1400 LG2), Phosphor Bronze (BS 1400 PB4), Aluminum Bronze (BS 1400 AB2), and High-Strength Bronze Alloys. We manufacture Bronze Transformer Clamps in current ratings from 200A to 5000A, voltage ratings up to 36kV, conductor sizes from 25mm² to 1000mm², maintaining temperature ratings from -40°C to 150°C, excellent electrical conductivity (minimum 18% IACS), compliance with IEC 60076, IS 2026, ANSI C119.4, ASTM B283 standards, and reliable performance in demanding electrical power applications.
Types of Bronze Transformer Clamps
HV Transformer Bushings Clamps
High Voltage Bushing Connectors specifically designed for transformer HV bushings, featuring precision-machined contact surfaces and superior dielectric properties. Available for bushings from 11kV to 33kV with current ratings from 400A to 2000A. These High Voltage Connection Clamps provide reliable connections for power transformer bushings, HV cable terminations, substation connections, and transformer incomer systems where high dielectric strength is critical.
LV Transformer Terminal Clamps
Low Voltage Terminal Connectors for transformer LV side connections, featuring heavy-duty construction and optimized current distribution. Current ratings from 600A to 5000A with multiple conductor configurations. These High Current Clamps are essential for transformer LV terminals, busbar connections, cable terminations, and distribution systems where high current carrying capacity is required.
Grounding Transformer Clamps
Transformer Grounding Connectors for neutral and body grounding applications, featuring enhanced conductivity and corrosion resistance. Available in various configurations including strap clamps and rod connectors. These Grounding System Clamps are crucial for transformer neutral grounding, tank grounding, core grounding, and safety grounding systems where reliable earth continuity is mandatory.
Tap Changer Connection Clamps
Tap Changer Terminal Connectors with precision design for tap changer connections, featuring fine adjustment capability and secure contact. These Adjustable Connection Clamps are designed for transformer tap changers, voltage regulation systems, OLTC connections, and tap selector switches where precise and reliable connections are critical.
Radiator and Coolant Pipe Clamps
Cooling System Clamps for transformer radiator and pipe connections, featuring thermal stability and mechanical strength. These Thermal Resistant Clamps provide secure connections for transformer radiators, coolant pipes, bushing connections, and cooling system components where thermal cycling resistance is important.
Material Specifications & Properties
Bronze Alloy Composition & Electrical Properties
| Alloy Type | Composition | Conductivity (% IACS) | Tensile Strength (MPa) | Yield Strength (MPa) | Maximum Service Temperature |
|---|---|---|---|---|---|
| Gunmetal Bronze LG2 | 85% Cu, 5% Zn, 5% Sn, 5% Pb | 25% | 240-300 | 120-150 | 150°C |
| Phosphor Bronze PB4 | 90% Cu, 10% Sn, 0.2% P | 18% | 350-450 | 200-250 | 180°C |
| Aluminum Bronze AB2 | 85% Cu, 10% Al, 3% Fe, 2% Ni | 20% | 600-750 | 300-400 | 200°C |
| High-Strength Bronze | 88% Cu, 8% Sn, 2% Zn, 2% Pb | 22% | 400-500 | 180-220 | 160°C |
Performance Specifications & Ratings
| Parameter | LV Clamp Range | HV Clamp Range | Test Standard |
|---|---|---|---|
| Current Rating | 600A – 5000A | 400A – 2000A | IEC 60076 |
| Voltage Rating | Up to 1.1kV | 11kV – 33kV | IEC 60137 |
| Short Circuit Withstand | 25kA – 100kA | 16kA – 50kA | IEC 61439 |
| Contact Resistance | <15μΩ | <20μΩ | IEC 61238 |
| Mechanical Strength | 20kN – 100kN | 15kN – 60kN | IS 2026 |
Manufacturing Excellence
Advanced Manufacturing Process
Sand Casting Technology: Precision sand casting for complex geometries and superior surface finish
Hot Forging Process: 800-ton forging presses for high-strength components
CNC Precision Machining: 5-axis CNC machining centers maintaining tolerances of ±0.02mm
Heat Treatment: Solution treatment and precipitation hardening for optimal properties
Surface Treatment: Tin plating, silver plating, or passivation treatments
Quality Testing: 100% dimensional, visual, and electrical inspection
Quality Assurance Protocols
Material Certification: Mill certificates with full chemical composition analysis
Dimensional Control: CMM inspection with statistical process control
Mechanical Testing: Tensile testing, compression testing, and fatigue testing
Electrical Testing: Contact resistance measurement and dielectric testing
Performance Validation: Thermal cycling, salt spray testing, and accelerated aging
Technical Specifications & Performance Data
Current Carrying Capacity & Mechanical Specifications
| Clamp Type | Transformer Rating | Current Rating | Conductor Size | Bolt Size | Torque Value | Weight |
|---|---|---|---|---|---|---|
| BTC-LV-630 | 630kVA | 630A | 185-300mm² | M16 | 80-100Nm | 1.2kg |
| BTC-LV-1000 | 1000kVA | 1000A | 300-500mm² | M20 | 120-150Nm | 2.0kg |
| BTC-LV-1600 | 1600kVA | 1600A | 400-630mm² | M24 | 150-180Nm | 3.2kg |
| BTC-LV-2500 | 2500kVA | 2500A | 630-800mm² | M27 | 180-220Nm | 4.8kg |
| BTC-HV-11 | 11kV | 400A | 150-240mm² | M12 | 60-70Nm | 0.8kg |
| BTC-HV-22 | 22kV | 630A | 185-300mm² | M16 | 80-100Nm | 1.4kg |
| BTC-HV-33 | 33kV | 800A | 240-400mm² | M20 | 120-150Nm | 2.2kg |
Electrical Performance Specifications
| Performance Parameter | LV Clamp Value | HV Clamp Value | Test Condition |
|---|---|---|---|
| Contact Resistance | <15μΩ | <20μΩ | At 100A DC |
| Temperature Rise | 65°C at rated current | 55°C at rated current | Ambient 40°C |
| Short Circuit Withstand | 50kA for 1s | 25kA for 1s | IEC 61439 |
| Partial Discharge | <5pC | <3pC | 1.1 x rated voltage |
| Dielectric Strength | 3kV for 1min | 70kV for 1min | IEC 60137 |
Transformer Compatibility & Applications
Distribution Transformers (11kV/433V)
Pole Mounted Transformers: HV and LV bushing connections for 25kVA to 250kVA transformers
Pad Mounted Transformers: Complete clamping solutions for 315kVA to 1000kVA units
Compact Substations: Integrated clamping systems for pre-fabricated substations
Power Transformers (33kV and above)
Substation Transformers: Heavy-duty clamps for 5MVA to 50MVA power transformers
Generator Transformers: Special clamps for large generator transformer applications
Auto Transformers: Custom clamps for auto transformer applications
Special Application Transformers
Rectifier Transformers: Clamps for high-harmonic applications
Furnace Transformers: High-temperature clamps for furnace applications
Traction Transformers: Vibration-resistant clamps for railway applications
International Standards & Certifications
Global Compliance & Approvals
IEC 60076: Power transformers
IS 2026: Indian standard for power transformers
ANSI C119.4: Electric connectors
ASTM B283: Copper-alloy die forgings
IEC 60137: Insulated bushings
Testing & Certification Standards
Temperature Rise Test: IEC 60076 for current carrying capacity
Short Circuit Test: IEC 61439 for dynamic stability
Dielectric Test: IEC 60137 for insulation coordination
Mechanical Test: IS 2026 for mechanical strength
Installation Guidelines & Maintenance
Professional Installation Procedure
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Surface Preparation: Clean transformer bushings and clamp surfaces thoroughly
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Clamp Selection: Verify clamp rating matches transformer specifications
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Alignment Check: Ensure proper alignment with transformer terminals
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Torque Application: Use calibrated torque wrench with specified values
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Contact Verification: Check for proper contact and pressure distribution
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Final Inspection: Verify complete installation and electrical continuity
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: 30-year recommended service life with proper maintenance
Frequently Asked Questions
Q1: Why use bronze clamps for transformer connections instead of aluminum?
Bronze offers superior mechanical strength, better corrosion resistance, higher temperature capability, excellent arc resistance, and proven long-term reliability in transformer applications, making it ideal for critical power connections.
Q2: Are these clamps compatible with all transformer manufacturers?
Yes, our bronze transformer clamps are designed to be compatible with major transformer manufacturers including ABB, Siemens, Schneider, Toshiba, and other international brands. We also provide custom solutions for specific requirements.
Q3: What is the maximum short-circuit current your clamps can withstand?
Our LV clamps can withstand up to 100kA for 1 second, while HV clamps are rated for up to 50kA for 1 second, complying with international standards for transformer applications.
Q4: Do you provide complete transformer connection kits?
Yes, we provide complete transformer connection kits including all necessary clamps, hardware, and installation accessories. These kits are customized for specific transformer ratings and configurations.
Q5: What is the expected service life of your bronze transformer clamps?
Our bronze transformer clamps have a minimum service life expectancy of 30+ years when properly installed and maintained, with proven performance in utility applications worldwide.
Q6: What testing do you perform on finished transformer clamps?
We perform 100% dimensional inspection, mechanical strength testing, contact resistance measurement, and sample destructive testing. Additionally, we conduct type tests including temperature rise, short circuit, partial discharge, and dielectric testing.
Contact Us Today – Request Quote for Bronze Transformer Clamps
Ready to discuss your Bronze Transformer Clamp requirements for power distribution, transformer manufacturing, substation projects, or custom electrical connection solutions?
Request a Quote: Send your specifications including transformer rating, voltage class, current rating, 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 clamp 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
