Comprehensive Technical Overview of Bronze Vise Connectors
We are one of the leading manufacturers and exporters of Bronze Vise Connectors, Electrical Vise Connectors, and Heavy-Duty Connection Systems from India. We have been supplying high-quality Bronze Vise-Type Connectors, Parallel Groove Vise Connectors, Vise-Type Clamps, Electrical Vise Connectors, Custom Vise Connectors, and Special Application Vise Connectors to the world market for many decades. Our state-of-the-art manufacturing facility specializes in producing premium Bronze Vise 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 Vise Connector manufacturing, we serve diverse industries including electrical power distribution, transmission utilities, renewable energy projects, industrial power systems, telecommunications, railway electrification, and critical infrastructure development. 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 Vise Connectors in current ratings from 200A to 3000A, conductor sizes from 25mm² to 800mm², maintaining temperature ratings from -40°C to 120°C, excellent electrical conductivity (minimum 20% IACS), compliance with IEC 61284, IS 2505, ANSI C119.4, ASTM B283 standards, and reliable performance in demanding electrical applications.
Types of Bronze Vise Connectors
Parallel Groove Vise Connectors
Heavy-Duty Vise-Type Clamps with parallel jaw design for main conductor to tap conductor connections, featuring spring-loaded mechanism and uniform pressure distribution. Available in single-phase and three-phase configurations with current ratings from 200A to 1200A. These Universal Vise Connectors provide reliable branching connections for overhead distribution lines, service drops, transformer taps, and line extensions where secure parallel conductor joining is required.
Single-Bolt Vise Connectors
Compact Vise-Type Clamps with single-bolt design for space-constrained applications, featuring streamlined profile and easy installation. Current ratings from 200A to 600A with conductor compatibility from 25mm² to 185mm². These Space-Saving Connectors are essential for compact installations, retrofit projects, temporary supplies, and maintenance work where space optimization is critical.
Double-Bolt Vise Connectors
Enhanced Security Vise Clamps with dual-bolt design for increased clamping force, featuring wider contact surface and balanced pressure distribution. Current ratings from 400A to 2000A with robust bronze construction. These High-Pressure Connectors are designed for heavy conductors, main connections, critical applications, and high-current systems where maximum clamping security is necessary.
Reducing Vise Connectors
Step-Down Vise Connectors with different jaw sizes for connecting dissimilar conductors, featuring smooth transition and optimal current flow. Available in common size combinations including 120mm² to 70mm², 185mm² to 120mm², and 240mm² to 150mm². These Size Adaptation Connectors solve compatibility issues in system modifications, retrofit applications, design changes, and material availability situations.
High-Temperature Vise Connectors
Thermal Resistant Vise Connectors with special bronze alloy construction, featuring enhanced temperature capability and thermal stability. Temperature range from -40°C to 200°C with maintained mechanical properties. These Elevated Temperature Connectors are crucial for furnace connections, heating systems, high-temperature equipment, and thermal process applications.
Material Specifications & Properties
Bronze Alloy Composition & Mechanical Properties
| Alloy Type | Composition | Conductivity (% IACS) | Tensile Strength (MPa) | Yield Strength (MPa) | Rockwell Hardness |
|---|---|---|---|---|---|
| Gunmetal Bronze LG2 | 85% Cu, 5% Zn, 5% Sn, 5% Pb | 25% | 240-300 | 120-150 | B65-B80 |
| Phosphor Bronze PB4 | 90% Cu, 10% Sn, 0.2% P | 18% | 350-450 | 200-250 | B80-B95 |
| Aluminum Bronze AB2 | 85% Cu, 10% Al, 3% Fe, 2% Ni | 20% | 600-750 | 300-400 | B90-B105 |
| High-Strength Bronze | 88% Cu, 8% Sn, 2% Zn, 2% Pb | 22% | 400-500 | 180-220 | B75-B90 |
Performance Specifications & Ratings
| Parameter | Standard Range | Heavy-Duty Range | Test Standard |
|---|---|---|---|
| Current Rating | 200A – 1000A | 800A – 3000A | IEC 61284 |
| Short Circuit Withstand | 16kA – 40kA | 40kA – 80kA | IEEE 80 |
| Contact Resistance | <15μΩ | <8μΩ | IEC 61238 |
| Clamping Force | 5kN – 20kN | 20kN – 50kN | IS 2505 |
| Corrosion Resistance | 1000+ hours salt spray | 2000+ hours salt spray | ASTM B117 |
Manufacturing Excellence
Advanced Manufacturing Process
Sand Casting Technology: Precision sand casting for complex geometries and superior surface finish
Hot Forging Process: 600-ton forging presses for high-strength components
CNC Precision Machining: 5-axis CNC machining centers maintaining tolerances of ±0.03mm
Heat Treatment: Solution treatment and precipitation hardening for optimal mechanical 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 current cycling tests
Performance Validation: Salt spray testing, thermal cycling, and accelerated aging
Technical Specifications & Performance Data
Current Carrying Capacity & Mechanical Specifications
| Connector Model | Conductor Size | Current Rating | Clamping Force | Bolt Size | Torque Value | Weight |
|---|---|---|---|---|---|---|
| BVC-S-200 | 25-50mm² | 200A | 5-8kN | M10 | 25-30Nm | 0.35kg |
| BVC-S-400 | 50-120mm² | 400A | 8-12kN | M12 | 40-50Nm | 0.65kg |
| BVC-S-630 | 120-240mm² | 630A | 12-18kN | M16 | 70-80Nm | 1.10kg |
| BVC-D-400 | 70-120mm² | 400A | 15-20kN | M12 | 40-50Nm | 0.85kg |
| BVC-D-630 | 120-185mm² | 630A | 20-25kN | M16 | 70-80Nm | 1.35kg |
| BVC-D-800 | 185-300mm² | 800A | 25-35kN | M20 | 100-120Nm | 2.00kg |
| BVC-D-1000 | 240-400mm² | 1000A | 35-45kN | M24 | 150-180Nm | 2.80kg |
Electrical Performance Specifications
| Performance Parameter | Standard Value | Enhanced Value | Test Condition |
|---|---|---|---|
| Contact Resistance | <15μΩ | <8μΩ | At 100A DC |
| Temperature Rise | 45°C at rated current | 35°C at rated current | Ambient 25°C |
| Short Circuit Withstand | 25kA for 1s | 50kA for 1s | IEEE 80 Standard |
| Voltage Drop | <2.5mV per 100A | <1.2mV per 100A | Steady State |
| Frequency Response | Up to 100MHz | Up to 500MHz | RF Applications |
Installation Tools & Accessories
Recommended Installation Tools
| Connector Size | Torque Wrench | Socket Size | Installation Tool | Special Requirements |
|---|---|---|---|---|
| M10 | 10-60Nm | 17mm | Standard wrench | Contact cleaner |
| M12 | 20-100Nm | 19mm | Ratchet wrench | Anti-seize compound |
| M16 | 50-150Nm | 24mm | Torque multiplier | Alignment tool |
| M20 | 80-200Nm | 30mm | Hydraulic wrench | Pressure gauge |
| M24 | 120-250Nm | 36mm | Hydraulic torque | Calibration certificate |
Installation Accessories
Contact Paste: Special antioxidant compound for bronze-to-copper connections
Cleaning Kits: Wire brushes and contact cleaner for surface preparation
Alignment Tools: Precision fixtures for perfect conductor alignment
Torque Calibration: Regular calibration services for installation tools
International Standards & Certifications
Global Compliance & Approvals
IEC 61284: Overhead lines – requirements and tests for fittings
IS 2505: Indian standard for metal fittings for overhead power lines
ANSI C119.4: Electric connectors – connectors for use between aluminum-to-aluminum conductors
ASTM B283: Standard specification for copper and copper-alloy die forgings
IEC 61238: Compression and mechanical connectors for power cables
Testing & Certification Standards
Short Circuit Testing: IEC 61238 for short circuit withstand capability
Temperature Rise Testing: IEEE 80 for current carrying capacity verification
Mechanical Testing: IS 2505 for mechanical strength validation
Environmental Testing: IEC 60068 for environmental conditions assessment
Industry Applications
Electrical Power Distribution
Overhead Distribution Lines: Main conductor connections and branching points
Service Installations: Customer service connections and meter installations
Transformer Connections: HV and LV transformer terminal connections
Line Maintenance: Emergency repairs and routine maintenance operations
Transmission Systems
Substation Connections: Busbar connections and equipment terminations
Line Taps: Transmission line tapping for substation feeds
Jumpers: Cross connections and phase-to-phase connections
Tension Sections: Dead-end terminations and anchor points
Industrial Applications
Manufacturing Plants: Heavy equipment power connections and busbar systems
Process Industries: Chemical and petrochemical plant electrical systems
Mining Operations: High-current equipment connections and power distribution
Steel Plants: Furnace connections and heavy power distribution
Installation Guidelines & Maintenance
Professional Installation Procedure
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Conductor Preparation: Clean conductor surfaces using wire brush and contact cleaner
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Connector Selection: Verify connector rating matches conductor size and current requirements
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Alignment Check: Ensure proper conductor alignment within connector jaws
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Torque Application: Use calibrated torque wrench with specified torque values
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Contact Verification: Check for proper contact and pressure distribution
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Final Inspection: Verify installation quality 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: 25-year recommended service life with proper maintenance
Frequently Asked Questions
Q1: What are the advantages of bronze vise connectors over other types?
Bronze vise connectors offer superior corrosion resistance, excellent electrical conductivity, high mechanical strength, thermal stability, and long-term reliability. The vise-type design provides uniform pressure distribution and secure connections even under vibration and thermal cycling.
Q2: Can these connectors be used for both copper and aluminum conductors?
Yes, our bronze vise connectors are suitable for both copper and aluminum conductors. The bronze material is electrochemically compatible with both metals, preventing galvanic corrosion and ensuring reliable connections.
Q3: What is the maximum installation temperature for these connectors?
The connectors can be installed in ambient temperatures from -40°C to 50°C. For operation, they are rated for continuous service from -40°C to 120°C, with special versions available for higher temperature applications up to 200°C.
Q4: Do you provide connectors with different surface treatments?
Yes, we offer various surface treatments including natural bronze, tin plating (5-15μm), silver plating (8-20μm), and special passivation treatments to suit different environmental conditions and application requirements.
Q5: What is the expected service life of your bronze vise connectors?
Our bronze vise connectors have a minimum service life expectancy of 25+ years when properly installed and maintained, with proven performance in various industrial and utility applications worldwide.
Q6: What testing do you perform on finished connectors?
We perform 100% dimensional inspection, visual examination, mechanical strength testing, contact resistance measurement, and sample corrosion testing. Additionally, we conduct type tests including temperature rise, short circuit, and environmental testing.
Contact Us Today – Request Quote for Bronze Vise Connectors
Ready to discuss your Bronze Vise Connector requirements for electrical power systems, industrial applications, transmission projects, or custom electrical connection solutions?
Request a Quote: Send your specifications including connector type, conductor sizes, 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 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
