waterproof transformer

Product Details of High Overload Special Transformer

The High Overload Special Transformer is a specialized power equipment specially developed for scenarios with large load fluctuations, prominent short-term peak loads, and the need to avoid frequent capacity expansion. Its core advantage is that it can withstand long-term short-term high-load operation without affecting the service life of the equipment, balancing power supply reliability, economy, and environmental protection. It is widely used in rural power grids, industry, urban distribution networks and other fields. The following are detailed parameters and characteristic descriptions.

I. Core Performance Parameters (Precisely Adapted to Various Scenario Requirements，customizable)

Overload Capacity (Core Highlight)

Adopting optimized electromagnetic design and heat dissipation structure, the overload performance is far superior to conventional transformers. The typical overload standards are 1.5 times the rated load for 8 hours, 1.75 times the rated load for 5 hours, and 2.0 times the rated load for 1 hour. Some customized models can achieve short-term operation of 2.2 times the rated load for 30 minutes. It can effectively cope with sudden high loads such as seasonal peaks and equipment startup impacts, avoiding equipment burnout and power supply interruptions caused by overload. At the same time, it supports continuous operation at 1.1 times the rated load for a long time, adapting to normalized load fluctuation scenarios.

Insulation Grade and Insulation Performance

The mainstream insulation designs are Class F (maximum allowable temperature 155℃) and Class H (maximum allowable temperature 180℃), which can be upgraded to Class C according to scenario requirements. The core insulation materials adopt DuPont NOMEX® insulating paper, high-quality epoxy resin (dry type) or natural ester insulating oil (oil-immersed type). They have high insulation strength, excellent heat resistance, strong anti-aging and moisture resistance, can maintain stable insulation performance under overload and high temperature conditions, effectively extend the service life of the equipment, and meet the use requirements of harsh environments such as outdoor, humid and high temperature.

Loss and Energy Efficiency Level

The iron core is made of low-loss grain-oriented silicon steel sheet or amorphous alloy material. The no-load loss of the amorphous alloy type is reduced by 30%~50% and the load loss is reduced by 15%~25% compared with conventional transformers, fully complying with the national Level 1 energy efficiency standard, and some products reach ultra-Level 1 energy efficiency. By optimizing the winding structure and selecting oxygen-free copper conductors, circulating current and stray losses are reduced, which can save a lot of electricity expenses during long-term operation and meet the requirements of "dual carbon" energy conservation and consumption reduction.

Temperature Rise and Heat Dissipation System

The oil passages (oil-immersed type) and air passages (dry type) are optimized for overload conditions to ensure rapid heat conduction. Oil-immersed products are equipped with corrugated oil tanks and fin radiators, and can be optionally equipped with forced oil circulation cooling systems (OFAF); dry-type products adopt natural air cooling (AN) or forced air cooling (AF), and some high-end models are equipped with intelligent temperature control fans, which can start and stop automatically according to the winding temperature, strictly control the winding temperature rise during overload within the allowable range, avoid insulation aging caused by high temperature, and ensure the long-term stable operation of the equipment.

Anti-interference and Stability Performance

The mechanical structure is strengthened, the iron core and winding are firmly fixed, and the short-circuit resistance is strong, which can withstand the impact of sudden short-circuit current without damage. It has excellent anti-harmonic and unbalanced load resistance, can adapt to harmonic interference generated by industrial equipment (such as electric furnaces and frequency converters), reduce voltage fluctuations, and ensure power supply quality. It is equipped with complete lightning protection and overvoltage protection devices to reduce the impact of bad weather and grid fluctuations on the equipment, and the failure rate is more than 40% lower than that of conventional transformers.

Noise and Protection Level

The iron core lamination process and winding winding technology are optimized to reduce electromagnetic noise. The noise of dry-type transformers is ≤55dB, and that of oil-immersed transformers is ≤60dB, which is far lower than the relevant national standards, adapting to noise-sensitive scenarios such as residential areas, commercial areas and data centers. In terms of protection grade, the outdoor type can reach IP54, dustproof, moistureproof and foreign object intrusion proof, and the indoor type can be upgraded to IP65 according to requirements to adapt to different installation environments.

II. Structural Design and Core Materials (Lay a Solid Foundation for Equipment Durability)

(I) Core Structural Design

Iron Core Structure

Adopting three-dimensional three-dimensional wound core or stepped laminated core. The three-dimensional three-dimensional wound core has no joints, uniform magnetic circuit, low magnetic loss, low noise and high mechanical strength; the stepped laminated core is tightly bonded, reduces magnetic leakage, improves energy efficiency, and can be flexibly selected according to capacity to adapt to different load requirements.

Winding Structure

Oxygen-free copper conductors (excellent electrical conductivity and low loss) are selected, and multi-layer segmented winding and transposition winding processes are adopted to reduce circulating current and stray loss of the windings and improve the heat dissipation efficiency of the windings. The surface of the winding is wrapped with multiple layers of high-quality insulating materials to strengthen the insulation performance, and insulating spacers are equipped to ensure the insulation distance between the winding and the iron core, and between the winding and the shell, avoid partial discharge, and ensure the safety of the equipment.

Oil Tank/Shell Design

Oil-immersed products adopt fully sealed corrugated oil tanks, which have excellent sealing performance, can effectively prevent the aging and leakage of insulating oil, extend the service life of insulating oil, and do not need frequent oil replenishment. The corrugated sheets can expand and contract with the change of oil temperature, enhance the heat dissipation effect, and have good anti-corrosion performance to adapt to long-term outdoor operation. Dry-type products adopt flame-retardant cold-rolled steel plate shells, the surface is treated with electrostatic plastic spraying, which is dustproof, moistureproof and corrosion-resistant, and is equipped with ventilation louvers to optimize air duct circulation and improve heat dissipation efficiency.

Cooling System Design

Oil-immersed transformers adopt natural cooling (ONAN) by default, and can be upgraded to forced air cooling (ONAF) and forced oil circulation air cooling (OFAF) according to overload requirements. The cooling system is linked with the temperature control device to automatically adjust the cooling intensity; dry-type transformers adopt natural air cooling (AN), and can be optionally equipped with forced air cooling (AF). The fans are designed with low noise, and the start and stop are controlled by the temperature controller, which not only ensures the cooling effect but also reduces energy consumption and noise.

Accessory Configuration

Standard accessories include oil thermometer, oil level gauge (oil-immersed type), temperature controller, pressure relief valve (oil-immersed type), wiring terminals, etc.; optional accessories include on-line oil chromatography monitoring device, on-line winding temperature monitoring device, remote monitoring module, which can realize real-time monitoring of equipment operation status and fault early warning, facilitate remote management by operation and maintenance personnel, and reduce on-site operation and maintenance workload.

(II) Selection of Core Materials (Controllable Quality and Outstanding Durability)

• Iron Core Material: Low-loss grain-oriented silicon steel sheet (conventional type), amorphous alloy (energy-saving type), all selected from well-known domestic brands, with high magnetic permeability, low loss and strong anti-aging ability.

• Winding Material: Oxygen-free copper conductor, with high conductivity, small resistance and high mechanical strength, avoiding conductor deformation and burnout caused by overload and heating.

• Insulation Material: DuPont NOMEX® insulating paper, epoxy resin (dry type), natural ester/mineral insulating oil (oil-immersed type), with excellent insulation performance and strong heat resistance, complying with environmental protection standards.

• Oil Tank/Shell Material: Cold-rolled steel plate, stainless steel (optional), anti-corrosion and rust-proof, adapting to harsh outdoor environments; seals adopt oil-resistant and aging-resistant rubber to ensure sealing performance.

III. Core Product Advantages (Prominent Differentiation, Adapting to Multi-scenario Requirements)

Strong Overload Capacity, Ensuring Power Supply Continuity

The core advantage is that it can withstand short-term high loads far exceeding the rated load for a short time, without blindly increasing capacity due to short-term peak loads, effectively avoiding power supply interruptions caused by overload. It is especially suitable for scenarios such as seasonal high loads during the Spring Festival and busy farming seasons in rural areas, and impact loads of industrial equipment startup, improving power supply reliability and reducing power outage losses. At the same time, the ability to operate at 1.1 times the rated load for a long time can cope with normalized load fluctuations without frequent equipment adjustment.

Long Service Life Design, Reducing Operation and Maintenance Costs

Adopting high-quality insulating materials and optimized heat dissipation structure, the temperature rise is stably controlled under overload conditions, and the service life of the equipment will not be attenuated due to short-term high loads. The normal service life can reach more than 30 years, which is the same as conventional transformers. The equipment has low failure rate, strong anti-interference and anti-aging ability, which can reduce the frequency of on-site inspection and maintenance, reduce the workload and operation and maintenance costs of operation and maintenance personnel, and the long-term comprehensive use cost is 20%~30% lower than that of conventional transformers.

Excellent Economy, Reducing Initial Investment

There is no need to configure equipment according to peak load capacity, only select according to conventional rated capacity to meet short-term overload requirements, which greatly reduces the initial purchase cost of equipment, grid occupancy fee and capacity expansion fee. At the same time, the low-loss design can reduce long-term operating electricity expenses, balancing the economy of initial investment and long-term operation and maintenance. It is especially suitable for scenarios with large load fluctuations and short peak duration, with prominent cost performance.

Wide Adaptability, Comprehensive Scene Coverage

It can be customized into oil-immersed and dry-type according to different scenario requirements, adapting to different voltage levels such as 10kV and 35kV, with a capacity range of 50kVA~20000kVA, which can meet the needs of rural power grids, industrial fields, urban distribution networks, new energy grid connection and other scenarios. Specifically, it can adapt to: short-term high loads during the Spring Festival and busy farming in rural areas; industrial impact loads such as metallurgical, chemical, mining, electric furnaces and motor group startup; fluctuating loads of photovoltaic/wind power grid connection; load regulation with large peak-valley differences in urban residential areas and commercial areas; scenarios with high requirements for power supply stability such as data centers and rail transit.

Green and Environmental Protection, Complying with Policy Requirements

Adopting low-loss and low-noise design, the no-load and load losses are far lower than conventional transformers, which can save a lot of electric energy and reduce carbon emissions during long-term operation. Oil-immersed products can use natural ester insulating oil, which is non-toxic and biodegradable, and will not pollute the environment, and mineral insulating oil can be recycled; dry-type products are oil-free and pollution-free, with excellent flame retardant performance, complying with the national "dual carbon" strategy and environmental protection policies, and adapting to various scenarios with high environmental protection requirements.

Optional Intelligence, More Convenient Operation and Maintenance

Optional intelligent monitoring and remote control modules can be installed to monitor operating parameters such as winding temperature, oil temperature (oil-immersed type), oil level (oil-immersed type), current and voltage in real time, with functions such as fault early warning, data statistics and remote start-stop. Operation and maintenance personnel can check the equipment operation status remotely through computers and mobile phones, without on-duty 24 hours on site, which greatly improves operation and maintenance efficiency and reduces operation and maintenance costs.

IV. Typical Application Scenarios (Precise Matching, Solving Practical Power Supply Pain Points)

Rural Power Grid Scenarios

The load of rural power grids has obvious seasonal fluctuation characteristics. During the Spring Festival, the number of returning people increases, and irrigation equipment starts intensively during busy farming seasons, resulting in short-term high load peaks. Conventional transformers are prone to tripping and burning due to overload. The high overload special transformer can easily cope with such short-term peak loads, without frequent capacity expansion, ensuring the continuity of residential electricity consumption and agricultural production electricity consumption in rural areas, reducing the investment in power grid transformation, adapting to the harsh outdoor environment in rural areas, and reducing operation and maintenance workload.

Industrial Field Scenarios

In industrial fields such as metallurgy, chemical industry, mining and mechanical processing, there are equipment such as electric furnaces, rolling mills, crushers and motor groups, which will generate large impact current when starting, belonging to typical impact loads and easy to cause transformer overload. The high overload special transformer has excellent impact and overload resistance, can withstand the instantaneous large current during equipment startup, avoid power supply interruption, and has strong anti-harmonic and unbalanced load resistance, can adapt to the complex power grid environment on the industrial site, ensure the normal operation of production equipment, and reduce production losses.

Urban Distribution Network Scenarios

In urban residential areas, commercial areas, office buildings and other regions, the load has a large peak-valley difference. During peak hours (such as the peak of air conditioning use in summer and heating peak in winter), the load increases sharply. Conventional transformers need to be configured according to peak load, resulting in low equipment utilization rate and waste of investment during low load hours. The high overload special transformer can be configured according to conventional load capacity to cope with short-term high loads during peak hours, balance load fluctuations, improve equipment utilization rate, reduce the investment in urban distribution network capacity expansion, and at the same time, the low noise and low loss design adapts to the urban residential and commercial environment.

New Energy and Infrastructure Scenarios

When new energy such as photovoltaic and wind power is connected to the grid, the output is volatile, which is easy to lead to grid load fluctuations and high requirements for the overload capacity and stability of the transformer; infrastructure scenarios such as data centers and rail transit have extremely high requirements for power supply continuity and stability, and there are short-term load fluctuations. The high overload special transformer can adapt to the load fluctuations of new energy grid connection, ensure the stable power supply of data centers and rail transit, and the optional intelligent monitoring module can realize real-time monitoring of equipment operation status, meeting the intelligent operation and maintenance needs of infrastructure scenarios.

V. Specification Model and Customized Services (On-demand Adaptation, Meeting Personalized Needs)

(I) Conventional Specifications

• Voltage Grade: 10kV, 35kV (mainstream), customizable special voltage grades such as 6kV and 110kV.

• Capacity Range: 50kVA~20000kVA, which can be flexibly selected according to scenario requirements.

• Connection Group Label: Dyn11, Yyn0 (mainstream), supporting on-load tap changer (OLTC) and no-load tap changer, with customizable voltage regulation range.

• Product Type: Oil-immersed (fully sealed corrugated oil tank), dry-type (epoxy resin casting), can be selected as needed.

• Insulating Oil Type: Mineral insulating oil is default for oil-immersed products, which can be upgraded to natural ester insulating oil (environmental protection type).

• Protection Grade: Outdoor type IP54, indoor type IP65 (optional), can be upgraded according to installation environment.

(II) Customized Services

Comprehensive customized services can be provided according to the specific use scenarios and load requirements of customers, including:

• Overload Multiple Customization: Customize different levels of overload capacity from 1.2 to 2.2 times according to the duration and intensity of peak load.

• Structure Customization: Customize iron core and winding structure to adapt to special installation spaces (such as narrow spaces, high-altitude installation); customize cooling system to adapt to harsh environments such as high temperature and high humidity.

• Accessory Customization: Configure accessories such as oil chromatography monitoring, remote monitoring, lightning protection and grounding on demand to realize intelligent operation and maintenance; customize integrated JP cabinet scheme, integrating transformer, switch and protection device to reduce on-site installation workload.

• Energy Efficiency Customization: Customize amorphous alloy iron core type and ultra-Level 1 energy efficiency products according to energy-saving requirements to further reduce loss.