44 terms

The words on a cable drawing, explained

Name: Reyansh International
Address: J-61, Sector-63, Noida, Uttar Pradesh, 201301, IN
Telephone: +918810272579

From copper rod to the HV tester — the terms buyers, engineers and auditors use, defined in a sentence or two by the people who make the parts.

Copper and conductor

Copper rod: Thick copper wire, usually supplied in large coils, that is the starting material for wire drawing. Reyansh draws its conductor from rod in its own plant. Backward integration →
Wire drawing: Pulling copper through a series of progressively smaller dies to reduce it to the diameter needed, from rod down to fine wire.
Annealing: Heat-treating drawn copper so it becomes soft and flexible again after drawing has hardened it. Flexible cords need annealed copper.
Bunching: Twisting many fine copper wires together into one flexible conductor. The finer and more numerous the wires, the more flexible the cable.
Conductor: The copper that carries the current, either a single solid wire or many fine wires bunched together.
Flexible conductor: A conductor made of many fine wires, used where a cable must bend repeatedly — power cords, appliance leads, battery cables. Indian Standard IS 8130 groups conductors into classes; flexible cords use the fine-stranded classes.
Cross-section (sq mm): The conductor's copper area in square millimetres. It sets how much current the cable can carry; the appliance designer chooses it from the appliance's rating and the applicable appliance standard.

PVC compound: PVC resin blended with plasticisers, stabilisers and fillers into granules with the properties a cable needs — flexibility, heat and age resistance, colour. Reyansh has made PVC compound since 1987. PVC compound →
Insulation: The PVC layer extruded directly over each conductor to keep it electrically separate from the others.
Core: One insulated conductor. A 3-core cable has three insulated conductors inside one sheath.
Extrusion: Forcing molten PVC compound through a die around the conductor (for insulation) or around the laid-up cores (for the sheath), then cooling it in a water trough.
Laying up: Twisting insulated cores together into a round bundle before the sheath goes on, so the cable stays round and flexes evenly.
Sheath: The outer PVC jacket over the laid-up cores. It protects the cores from abrasion, moisture and handling.
Flat cable: Cores laid side by side in a flat sheath instead of a round bundle — the usual form for submersible pump cable, which lies flat against the pump pipe. Submersible cables →
Cable marking (legend): Text printed along the sheath at intervals — maker's name or brand, size, standard. Reyansh marks REYCORD, or the customer's brand with written approval.
450/750 V: A cable's rated voltage, written as voltage to earth / voltage between conductors. IS 694:2010 covers PVC insulated cables up to and including 450/750 V. Standards →

Power cord (mains lead): A length of flexible cable with a moulded plug on one end and a prepared free end on the other, fitted to an appliance to connect it to the supply. Reycords power cords →
Moulded plug: A plug formed directly onto the cable by injection moulding, so plug and cable become one piece that cannot be opened or rewired.
Inner mould: The first moulding shot, which locks the pins and conductor joints in position. Reyansh moulds the inner in PP.
Outer mould: The second moulding shot that forms the visible plug body over the inner mould. Reyansh moulds the outer in PVC.
Grommet (strain relief): The tapered sleeve where the cable leaves the plug. It spreads bending over a length of cable so the conductors do not fatigue at the plug.
Pin welding: Joining each conductor to its brass plug pin before moulding.
2-pin and 3-pin plugs: A 2-pin plug carries live and neutral; a 3-pin plug adds a protective earth pin. In India both are made to IS 1293, in 6 A and 16 A ratings.
Free end: The appliance end of a power cord — stripped and tinned, fitted with crimped terminals, or fitted with a connector, to the appliance maker's drawing.
Appliance coupler (IEC connector): A detachable connector at the appliance end, such as the C13 kettle-type connector on computer and equipment leads. Appliance cables →

Wiring harness: A set of wires cut to length, terminated and grouped so it can be fitted into a product in one step. Built to the customer's drawing. Wiring harnesses →
Crimping: Pressing a metal terminal onto a stripped wire end so the two are joined mechanically and electrically without solder.
Terminal: The metal fitting on a wire end — a ring, spade, pin or socket — that connects to a screw, tab or connector.
Connector housing: The plastic shell that holds several terminals in fixed positions so they mate with a matching connector.
Harness jig (board): A board laid out to the harness drawing with pegs and fixtures, on which wires are routed and tied so every harness comes out the same.
Ring lug: A crimped terminal with a round eye that fits over a stud or bolt — common on battery and power cables. Battery cables →

High-voltage (HV) test: Applying a high voltage between conductors, and between conductors and earth, to confirm the insulation holds. Reyansh HV-tests every power cord before packing, not a sample from the lot. Quality →
Continuity test: Checking that each conductor connects end to end to the right pin or terminal, with no breaks or cross-wiring.
BIS (Bureau of Indian Standards): India's national standards body. It publishes Indian Standards and licenses manufacturers to mark products as conforming to them. Standards →
CM/L number: The number of a BIS product licence. Reyansh's are CM/L 8800110115 (IS 694:2010 cables) and CM/L 8800188617 (IS 1293 plugs).
ISI mark: The certification mark a BIS licensee prints on a product that conforms to the licensed Indian Standard.
IS 694: Indian Standard for PVC insulated cables up to and including 450/750 V. Standards →
IS 1293: Indian Standard for plugs and socket-outlets for household and similar purposes, up to 250 V and 16 A. Standards →
RoHS: Restriction of Hazardous Substances — limits on substances such as lead and cadmium in electrical products. Reyansh is RoHS certified.

OEM: Original equipment manufacturer — the company that makes the finished product the cable or cord goes into. OEM solutions →
Private label: Products made by one company and sold under another's brand. Reyansh prints the customer's brand on cable and packing, only with written approval. Custom solutions →
Counter sample: An approved sample kept by both buyer and maker as the reference that every later lot is checked against.
Copper-linked price: A price that moves with the copper market on an agreed formula. Reyansh shares the formula, so the buyer can see what moved the rate. Why Reyansh →
Backward integration: Making your own inputs instead of buying them. For a cable maker, drawing your own copper and compounding your own PVC. Backward integration →

Send the drawing. We'll tell you what it means for the part — and whether we can make it.