Precision Copper Winding Conductors for Australian Transformer Manufacturers and Repair Specialists
Global Copper Conductors manufactures precision insulated and bare copper winding conductors for transformer manufacturers and repair specialists across Australia. We supply rectangular strip, round wire, and custom profiles in kraft paper, Nomex, fibreglass, and combined insulation systems.
As one of Australia’s only manufacturers of insulated copper winding conductors, we offer transformer companies a genuine local alternative to imported products: precise dimensions, consistent quality, full material traceability and the fast turnaround that production schedules and repair critical paths demand.
Why Transformer Companies Choose Global Copper Conductors
Australian Manufacturer with Overnight Die Capability
We manufacture in Gateshead, NSW, with the ability to produce custom conductor profiles to order. For transformer manufacturers on production schedules and repair shops working to customer deadlines, this means conductor to your exact specification within days, not weeks.
Exact Dimensional Matching for Any Winding Design
We can manufacture to virtually any rectangular or round profile, matching the conductor specification of any transformer design, including older assets undergoing rewind or imported units requiring non-standard conductor sizes.
99.99% Pure OFHC Copper as Standard
Every conductor we supply is manufactured from OFHC copper with 99.99% purity and greater than 100% IACS conductivity, ensuring low winding losses and strong long-term performance.
Full Insulation Range from One Local Supplier
Kraft paper, Nomex, fibreglass, and combined insulation systems are all available from a single Australian source. This simplifies your supply chain and reduces the lead-time risk of sourcing insulated conductors from offshore.
Our Insulation Systems for Transformer Winding Conductors
Kraft Paper Insulated Copper Conductor
Electrical-grade kraft paper is a traditional and widely used conductor-insulation material for mineral-oil-immersed distribution, power and instrument transformers. After drying and impregnation with compatible mineral insulating oil, it forms part of a combined cellulose–oil insulation system with excellent dielectric properties.
Key properties:
- kraft-paper systems are commonly associated with IEC Class A, 105°C performance.
- Thermally upgraded kraft papers may support higher thermal-system classifications, commonly Class E, 120°C, subject to the specific material and complete transformer insulation-system design.
- Compatible with suitable mineral insulating oils complying with the applicable transformer-oil specification, such as IEC 60296.
- Available in multiple paper thicknesses and wrap configurations to meet the required dielectric and impulse-withstand design.
- Provides good tensile strength, conformability and consistent application when correctly stored, dried and wrapped.
Typical applications:
- Mineral-oil-immersed distribution transformers, including medium-voltage units
- Mineral-oil-immersed power transformers.
- Oil-immersed current and voltage transformers.
- Oil-cooled rectifier, furnace and industrial transformers.
- Rewinding, repair and replacement of insulation on existing oil-immersed transformer assets.
Nomex / Aramid Insulated Copper Conductor
Nomex® is a high-performance, calendered aramid-paper insulation used for conductor, turn, layer and winding insulation in dry-type and selected oil-immersed transformer designs. Its combination of high thermal stability, inherent flame resistance, mechanical toughness, flexibility and high dielectric strength makes it suitable for transformer applications where thermal endurance, fire performance, compact design or high-power density are important.
Key properties:
- High thermal endurance, with Nomex® 410 recognised as a220°C insulation material.
- High short-term AC dielectric strength, typically approximately 18–34 kV/mm, depending on paper thickness.
- Inherently flame resistance: The aramid paper does not readily melt or support combustion.
- A Nomex insulation system may permit higher thermal margins, increased kVA density or reduced transformer size compared with conventional kraft-paper systems, subject to thermal, dielectric, mechanical and cooling design.
- Suitable grades and constructions can be used in both dry-type and liquid-immersed transformer designs, subject to compatibility with the transformer fluid, varnish, adhesive and manufacturing processes.
Typical applications:
- Dry-type transformer conductor and winding insulation.
- Oil-immersed transformers that require enhanced thermal endurance or thermal margins.
- Compact or high-power-density transformer designs.
- Transformer designs that require high overload capability.
- Turn, layer, lead and winding insulation in industrial and power transformers.
Fibreglass Insulated Copper Conductor
Fibreglass-covered conductor provides robust mechanical protection combined with solid thermal performance. It is widely specified for transformer winding applications where conductor durability during winding and forming is a priority, particularly for large rectangular conductors in high-voltage windings.
Key properties:
- Thermal class: F (155°C) to H (180°C) depending on base film specification
- Excellent abrasion and mechanical resistance
- Suitable for round and rectangular conductor profiles
Combined Insulation Systems
For the most demanding transformer winding applications, conductors can be specified with combined insulation systems that layer the dielectric performance of a base film with the mechanical protection and thermal capability of an outer covering. We manufacture combined-insulation conductors to customer specification, with the insulation build selected to match the voltage class, thermal class, cooling medium and winding design requirements.
Conductor Profile and Custom Sizing
| Parameter | Specification |
| Profile | Round or rectangular (strip) |
| Maximum width (rectangular) | 50 mm |
| Maximum cross-sectional area | 200 mm² |
| Custom sizes | Available with overnight die manufacturing capability |
| Insulation options | Kraft paper, Dupont Nomex, fibreglass, combined systems |
Copper Material Specification
| Property | Specification |
| Source Copper Designation | C10200 |
| Standard | AS/NZS 1574:1996 |
| Minimum Purity | 99.99% |
| Electrical Conductivity | Greater than 100.0% IACS |
| Volume Resistivity | No greater than 17.241 nΩ.m at 20°C |
| Test Standard | ASTM B193 |
Frequently Asked Questions
Can you match the conductor specification of an existing transformer?
Yes. Our overnight die manufacturing capability means we can produce conductor in virtually any rectangular or round cross-section, including non-standard profiles from older assets or imported units. Contact us with the conductor dimensions and insulation specification and we will confirm availability and lead time.
How quickly can you supply conductor for a repair job?
For standard sizes from stock, typically 2 to 5 business days. For custom sizes requiring die manufacturing, generally 5 to 7 business days. Contact us early in your repair planning for the quickest delivery.
What is the difference between kraft paper and Nomex insulation for transformer windings?
Electrical-grade kraft and other cellulose papers are traditional and widely used insulation materials for mineral-oil-immersed transformer windings. Standard kraft-paper insulation is commonly associated with IEC Class A, 105°C, while Class B corresponds to 130°C and may require a different or thermally upgraded insulation system. Nomex aramid papers are used where higher thermal endurance, flame resistance or increased power density is required. They are used in both dry-type and liquid-immersed transformers but are not the universal standard for dry-type transformers. In liquid-immersed transformers, a suitably qualified Nomex-based insulation system may permit increased power density or reduced physical size, subject to the complete transformer design and applicable qualification requirements.
Do you supply conductor for both dry-type and oil-immersed transformers?
Yes. We supply kraft paper, Nomex, fibreglass, and combined insulation systems suited to both dry-type and oil-immersed transformer applications, as well as bare annealed conductor for applications where insulation is applied during winding.
Can you supply conductor for instrument transformer rewinding?
Yes. We manufacture conductor in the smaller cross-sections and tight dimensional tolerances required for current and voltage transformer windings. Contact us with your specification and we will confirm what we can supply.
Call Us to Discuss Your Transformer Winding Requirements
Global Copper Conductors supplies precision insulated and bare copper winding conductors to transformer manufacturers, repair specialists and rewind facilities across Australia. Whether you are producing new transformers to a set winding specification or repairing an existing asset, our team can assist with conductor selection, insulation specification, dimensional matching and fast delivery.
Call us: (02) 4943 8244
Email: sales@globalcopper.com.au