Bharat Insulation Company (BIC)

Enamelled Round Copper Winding Wires

Enamelled Round Copper Winding Wires

Copper winding wires (also referred to as super enamelled/enamelled wire, magnet wire, armature wire, or copper winding wire) serve as the unseen yet essential backbone of electric motors, transformers, industrial and home appliances, and various other critical electrical systems. Designed with a thin but yet durable layer of enamel insulation, these wires allow for enable tightly wound coils that ensure high electrical efficiency with minimal space requirements.

Whether you are an original equipment manufacturer, rewinder, or electrical engineer, choosing the right copper winding wire is crucial for optimal performance, energy efficiency, and long-term reliability for in rotating machinery/motors, transformers, automobile electrical systems, switchgears, and home or industrial appliances.

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Enamelled Round Copper Winding Wires
What is an Enamelled Copper Winding Wire?

A winding wire is a copper conductor coated with a thin film of synthetic polymer-based insulation, making it ideal for coiling in confined spaces. It is commonly referred to as:

  • Super Enamelled / Enameled Wire made of copper
  • Magnet Wire
  • Winding wire made of copper wire
  • Armature Wire
Why Choose Copper Over Other Metals?

Copper is the most preferred material due to its

  • High conductivity: Excellent electrical and thermal transfer.
  • Flexibility and ductility: Suitable for precision winding.
  • Heat resistance: Essential for high-temperature applications.
  • Corrosion resistance: Long-term durability in harsh environments.
Types of Enamelled Round Copper Winding Wires and Their Applications
Polyvinyl Acital Modified Polyvinyl Acital (For hermetic applications) Polyeurethane Polyeurethane + Bandai Polyester Modified Polyester Modified Polyurethane Polyurethane + Polyamide Polyester - Imide Polyesterimide +Epoxy Bandai Polyester (lmide) + Polyamide Polyamide - Imide Dual coated Polyester (Imide) Polyamide Imide Polyimide
Property PVA 105 Mod. PVA 120 PU 130 PU + Bond. 130 PE 130 Mod. PE 155 PU 155 PU + PA 155 PEI 180 PEI +PA 180 PEI + PA 180 PAI 200 DC(PEI+PAI) 200 PI 220
Standard IS : 13730 Part 1 Part 12 Part 4 Part 2 Part 34 Part 3 Part 20 Part 21 Part 8 Part 37 Part 22 Part 26 Part 13 Part 7
IEC - 60317 Part 1 Part 12 Part 4 Part 2 Part 34 Part 3 Part 20 Part 21 Part 8 Part 37 Part 22 Part 26 Part 13 Part 7
NEMA 1000 MW 15 C - MW 75 C MW 130 C - MW 5 C MW 79 C MW 80 C MW 30 C MW 102 C MW 76 C MW 81 C MW 35 C, 73 C MW 16 C
Size 1.00 1.00 0.30 0.30 1.00 1.000 / 18.5 AWG 0.300 / 29 AWG 0.300 / 29 AWG 1.000 / 18.5 AWG 1.000 / 18.5 AWG 1.000 / 18.5 AWG 1.000 / 18.5 AWG 1.000 / 18.5 AWG 1.000 / 18.5 AWG
Covering Grade G2 G2 G1 G1B G2 G2 G1 G1B G2 G1B G2 G1 G2 G2
Elogation (%) IS/IEC - Min. 32 32 26 26 32 32 26 26 32 32 32 32 32 32
NEMA - Min. 32 32 26 26 - 32 26 26 32 - 32 32 32 32
BIC Value 36 36 30 30 36 36 30 30 36 36 36 36 36 36
Springness (Deg.) IS/IEC - Max. 45 45 50 50 45 45 50 50 45 45 45 42 45 45
NEMA - Max. 58 - 58 - - 58 58 61 58 - 58 58 58 58
BIC Value 38 38 43 47 38 38 43 43 38 38 38 36 38 38
Flexibility (No Crack) IS/IEC 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D 1 X D
NEMA 20% +3d - 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d 20% +3d
BIC Value 10% +1d 10% +1d 10% +1d 10% +1d 10% +1d 10% +1d 15% +1d 15% +1d 10% +1d 10% +1d 10% +1d 10% +1d 10% +1d 10% +1d
Abrasion (N) IS/IEC - Min. 9.6/11.3 9.6/11.3 2.3/2.7 2.3/2.7 8.8/10.4 8.8/10.4 2.3/2.7 2.65/3.2 9.2/10.9 5.75/6.75 9.6/11.3 5.95/7.05 9.6/11.3 6.6/7.8
NEMA - Min. 945/1110 - 240/285 - - 980/1150 235/275 265/310 945/1110 - 945/1110 530/620 945/1110 710/835
BIC Value 10.6/12.4 10.6/12.4 2.7/3.7 2.7/3.7 9.7/11.4 9.7/11.4 2.7/3.7 3.2/4.2 10.1/12.0 6.8/7.8 10.6/12.4 7.9/8.9 10.6/12.4 7.3/8.6
Heat Shock (1/2 Hr.) IS/IEC 155 - 1d 155 - 1d 155 - 0.71mm 155 - 0.71mm 175 - 2.24mm 175 - 2.24mm 175 - 0.71mm 175 - 0.71mm 200 - 2.24mm 200 - 2.24mm 200 - 2.24mm 220 - 2.24mm 220 - 2.24mm 240 - 2.24mm
NEMA 175 - 20% +3d - 175 - 6d 175 - 20% +3d 175 - 20% +3d 175 - 20% +3d 175 - 20% +3d 175 - 20% +3d 200 - 20% +3d - 200 - 20% +3d 240 - 20% +3d 220 - 20% +3d 280 - 20% +3d
BIC Value 175 - 1d 175 - 6d 175 - 0.71mm 175 - 0.71mm 175 - 2.24mm 200 - 2.24mm 200 - 0.71mm 200 - 0.71mm 220 - 2.24mm 220 - 2.24mm 220 - 2.24mm 240 - 2.24mm 240 - 2.24mm 260 - 2.24mm
Cut Through (Deg. C) IS/IEC 170 170 170 170 240 240 200 200 300 300 320 350 320 400
NEMA 180 - 200 200 260 250 200 200 300 - 325 325 300 450
BIC Value 190 190 190 190 260 260 220 220 320 320 340 370 340 420
HV Pin Hole (V DC) IS/IEC 1500 - 5 1500 - 5 750 - 25 750 - 15 1500 - 5 1500 - 5 750 - 25 750 - 25 1500 - 5 1000 - 25 1500 - 5 1000 - 25 1500 - 5 1500 - 5
NEMA 1500 - 5 - 750 - 15 1000 - 5 1500 - 5 1500 - 5 750 - 15 750 - 15 1500 - 5 1500 - 5 1500 - 5 1000 - 15 1500 - 5 1500 - 5
BIC Value 1500 - 2 1500 - 2 750 - 5 750 - 5 1500 - 2 1500 - 2 750 - 5 750 - 5 1500 - 2 1000 - 5 1500 - 2 1000 - 5 1500 - 2 1500 - 2
B D V (V) IS/IEC - Min. 5000 5000 2200 2200 5000 5000 2200 2200 5000 2700 5000 2700 5000 5000
NEMA - Min. 5620 - 2410 4330 - 5620 2380 2380 5620 - 5620 3130 5620 5620
BIC Value 8000 8000 4500 4500 8000 8000 4500 4500 8000 5500 8000 5500 8000 8000
Range SWG 5 - 45 5 - 45 21 - 45 21 - 45 4 - 45 4 - 45 21 - 45 21 - 45 4 - 45 16 - 45 4 - 45 16 - 45 4 - 45 4 - 45
Applications For E Class Oil, Synthetic liquid filled transfer Systems For B Class Motors for hermetic, Refrigeration & Air cond. For B Class Direct soldering and bonding small motors, Ignition coils, Low voltage transformers, Relays, Solenoids and TV deflection coils. For B Class Direct soldering and bonding small motors, Ignition coils, Low voltage transformers, Relays, Solenoids and TV deflection coils. For B Class Dry type transformers, Stator winding fractional and HP motors, DC fields, Armature winding ballasts, Ele. meter coils, Portable tools & Domestic appliances. For F Class Dry type transformers, Stator winding fractional and HP motors, Contactor coils, Motors for domestic appliances. For F Class Direct soldering and bonding small motors, Ignition coils, Low voltage transformers, Relays, Solenoids and TV Deflection coils. For F Class Direct soldering and bonding small motors, Ignition coils, Low voltage transformers, Relays, Solenoids, Deflection coils & used on high speed automatic coil winding machine. For H Class Dry type transformers, Stator winding, fractional and HP & Armature winding, Hand tools Contactor coils, Motors for domestic appliances. For H Class Direct bonding clutch & brake coils, Helical & toroidal DC coils, Deflection yoke coils. For H Class Dry type transformer, stator winding fractional and HP motors, DC & Armature winding, Encapsulated coils & used on high speed automatic coil winding machine. For W Class Motors for atomic power station, and Hermetic tools, Chemical industries, Furnaces and Working in radioactive atmosphere. For W Class Dry type transformer, Stator winding fractional and HP motors, DC & Armature winding, Hand tools contactor coils, Motors for chemical industries, Automotive alternator stators, Solenoids, Television play-back transformer. For C Class Dry type transformers, Fractional and integral HP motors, High temp continuous duty coils, Relays, Hermetic and sealed units, Heavy duty hand tool motors.

Diameters, Increase in Diameters, and Resistance of Enamelled Round Copper Winding Wires Based on IS 13730-0-1

Nominal Conductor Diamete Conductor Tolerance ± Grade 1 Grade 2 Grade 3 Conductor Resistance at 20 Deg. C for 1 meter (Ohms)
Min. increase Max. overall dia Min. increase Max. # overall dia Min. # increase Max. # overall dia
(SWG) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Nominal (mm) (mm)
4 5.893 0.059 0.054 5.986 0.098 6.034 0.146 6.079 0.000617 - -
5 5.385 0.054 0.052 5.478 0.096 5.526 0.144 5.571 0.000751 - -
6 4.877 0.049 0.05 4.97 0.094 5.018 0.142 5.063 0.000915 - -
7 4.47 0.045 0.049 4.561 0.092 4.607 0.138 4.651 0.00109 - -
8 4.064 0.041 0.048 4.155 0.091 4.197 0.137 4.245 0.00132 - -
9 3.658 0.037 0.047 3.746 0.089 3.791 0.134 3.834 0.00163 - -
10 3.251 0.033 0.046 3.336 0.086 3.38 0.13 3.422 0.00206 - -
11 2.946 0.029 0.045 3.029 0.084 3.072 0.127 3.112 0.002508 - -
12 2.642 0.026 0.043 2.722 0.081 2.764 0.123 2.803 0.003118 - -
13 2.337 0.023 0.042 2.415 0.079 2.455 0.119 2.493 0.003985 - -
14 2.032 0.02 0.041 2.108 0.077 2.147 0.116 2.184 0.005271 - -
15 1.829 0.018 0.04 1.903 0.075 1.941 0.113 1.977 0.006506 - -
16 1.626 0.016 0.039 1.698 0.073 1.735 0.11 1.77 0.008232 - -
17 1.422 0.014 0.038 1.492 0.071 1.528 0.107 1.562 0.01076 - -
18 1.219 0.012 0.035 1.285 0.067 1.318 0.1 1.35 0.01465 - -
19 1.016 0.01 0.034 1.08 0.065 1.113 0.098 1.144 0.02108 - -
20 0.914 0.009 0.034 0.976 0.063 1.008 0.095 1.038 0.02605 0.02686 0.02526
21 0.813 0.008 0.032 0.872 0.06 0.902 0.09 0.931 0.03293 0.03396 0.03194
22 0.711 0.007 0.03 0.766 0.056 0.795 0.085 0.822 0.04305 0.04442 0.04175
23 0.61 0.006 0.027 0.659 0.05 0.684 0.075 0.708 0.05848 0.06017 0.05687
24 0.559 0.006 0.025 0.605 0.047 0.629 0.071 0.652 0.06965 0.07178 0.0676
25 0.508 0.005 0.025 0.554 0.047 0.578 0.071 0.601 0.08434 0.08711 0.08168
26 0.457 0.005 0.024 0.501 0.045 0.523 0.067 0.544 0.1042 0.1075 0.1011
27 0.417 0.005 0.022 0.458 0.042 0.48 0.064 0.5 0.1252 0.1293 0.1212
28 0.376 0.005 0.021 0.417 0.04 0.435 0.06 0.454 0.1539 0.1595 0.1487
29 0.345 0.004 0.02 0.382 0.038 0.401 0.057 0.418 0.1829 0.1888 0.1772
30 0.315 0.004 0.019 0.349 0.035 0.367 0.053 0.384 0.2193 0.2269 0.2121
31 0.295 0.004 0.019 0.329 0.035 0.347 0.053 0.364 0.2501 0.2592 0.2414
32 0.274 0.004 0.018 0.306 0.033 0.323 0.05 0.339 0.2899 0.3011 0.2792
33 0.254 0.004 0.018 0.286 0.033 0.303 0.05 0.319 0.3374 0.3512 0.3242
34 0.234 0.004 0.017 0.265 0.032 0.281 0.048 0.296 0.3974 0.4149 0.3809
35 0.213 0.003 0.015 0.241 0.029 0.255 0.043 0.269 0.4798 0.4978 0.4625
36 0.193 0.003 0.014 0.219 0.027 0.232 0.039 0.245 0.5842 0.6081 0.5618
37 0.173 0.003 0.013 0.197 0.025 0.21 0.036 0.222 0.7271 0.7596 0.6967
38 0.152 0.003 0.012 0.174 0.023 0.186 0.033 0.197 0.9418 0.9888 0.8982
39 0.132 0.003 0.011 0.152 0.021 0.162 0.03 0.171 1.2496 1.3192 1.1841
40 0.122 0.003 0.01 0.141 0.019 0.151 0.028 0.16 1.4623 1.5502 1.3811
41 0.112 0.003 0.009 0.13 0.017 0.139 0.026 0.147 1.7354 1.8477 1.6318
42 0.102 0.003 0.009 0.119 0.017 0.128 0.026 0.136 2.0923 2.2398 1.9574
43 0.091 0.003 0.008 0.107 0.016 0.115 0.023 0.122 2.6283 2.8348 2.4423
44 0.081 0.003 0.008 0.096 0.015 0.103 0.022 0.11 3.3173 3.6082 3.0584
45 0.071 0.003 0.007 0.084 0.012 0.091 0.018 0.097 4.3176 4.7475 3.9409
Types of Enamelled Copper Winding Wires

Based on Insulation Material

. Modified Polyester
  • Improved thermal performance over standard polyester
  • Used in motors, transformers, & domestic appliances
  • Heat resistance - 155°C
. Polyester or polyetherimide overcoated with polyamide imide
  • Dual-coated insulation for superior heat and chemical resistance
  • Applications - Dry-type transformers, stator windings, encapsulated coils
  • Heat resistance - 180°C
. Polyester or polyetherimide overcoated with polyamide-imide, with a bonding layer
  • Enhanced mechanical strength and thermal bonding capability
  • Enhanced mechanical strength and thermal bonding capability
  • Heat resistance - 180°C
. Polyester or polyetherimide overcoated with polyamide
  • Combines flexibility and mechanical resistance
  • Used in fractional HP motors, relays, and tools
  • Heat resistance - 180°C
. Solderable Polyetherimide
  • Can be soldered without stripping insulation
  • Suitable for ignition coils, low-voltage transformers, and relays
  • Heat resistance - 180°C
. Polyetherimide
  • High dielectric strength with general-purpose use
  • Used in DC motors, stator windings, & armatures
  • Heat resistance - 180°C
. Polyetherimide with a bonding layer
  • Enables coil bonding during heating
  • Useful in high-speed automatic winding machines
  • Heat resistance - 180°C
. Polyester-amide-imide
  • Need more information
. Solderable Polyurethane Enamelled (130°C)
  • Direct solderability without insulation removal
  • Ideal for relays, clocks, and small transformers
  • Heat resistance - 130°C
. Solderable Polyurethane overcoated with Polyamide (155°C)
  • Combines easy soldering with mechanical robustness
  • Suitable for solenoids, ignition coils, & high-speed winding
  • Need more information
  • Heat resistance - 155°C
. Solderable Polyurethane with a Bonding Layer (130°C)
  • Solderable and bondable in one insulation system
  • Used in compact coils and automatic machines
  • Heat resistance - 130°C
. Solderable Polyurethane Enamelled (155°C)
  • Higher class version for extended temperature performance
  • Suitable for electronics requiring easy solderability and thermal endurance
  • Heat resistance - 155°C
. Solderable polyurethane overcoated with polyamide (155°C)
  • Enhanced abrasion and heat resistance
  • Used in ignition coils, TV deflection coils
  • Heat resistance - 155°C
. Solderable Polyurethane with a Bonding Layer (155°C)
  • Combines solderability and bonding for dynamic winding needs
  • Used in relays and small bonded coil applications
  • Heat resistance - 155°C
. Polyamide-Imide Enamelled
  • Very high thermal endurance and mechanical resilience
  • Suitable for chemical industries, automotive alternators, & furnaces
  • Heat resistance - 200°C
. Polyvinyl Acetal
  • Traditional insulation for oil-filled transformers and hermetic motors
  • Cost-effective for general B-class applications
  • Heat resistance - 105°C
Enamelled Round Copper Winding Wires
Key Applications of Enamelled Copper Wires

These wires are used in virtually all electromagnetic applications, including.

  • Electric Motors
    Whether AC or DC, copper winding wire for motors ensures efficient operation with minimal heat loss.
  • Transformers
    Transformer winding wire requires exceptional dielectric strength and thermal resistance, both of which copper enamelled wires provide.
  • Inductors and Chokes
    Essential for noise suppression and voltage regulation in electronic circuits.
  • Automotive & EV Industry
    Used in alternators, ignition coils, and now EV drive systems.
  • Fans, Compressors & White Goods
    Electrical copper wire is commonly used in consumer appliances for durability and performance.
Key Features & Benefits
  • High Dielectric Strength
  • Excellent Thermal Stability
  • Precision Diameter Tolerances
  • Flexible Coating for Tight Coils
  • Custom Enamel Formulations Available

Whether you need a heat-resistant copper wire for high-temperature machinery or a solderable magnet wire for compact electronics, there's a type of enamelled wire to match your application.

Quality Standards and Compliance

Top manufacturers in India ensure that their varnished copper wire meets:

  • IS 13730 – Indian Standard for Winding Wires
  • IEC 60317 – Global standards for enamelled wires
  • NEMA MW 1000 – American standard for magnet wire
  • RoHS/REACH Compliance – For eco-friendly and safe products
Manufacturing & Testing Process

Every high-quality enamelled copper winding wire undergoes:

  • Conductor purity test (99.99% copper)
  • Enamel adhesion & flexibility test
  • Thermal shock test
  • Breakdown voltage test
  • Solderability test (for PU-coated wires)
  • Scrape resistance & elongation tests

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