Step Up Dry Type Transformer Copper Winding High Overload Capacity
The Step Up Dry Type Transformer Copper Winding High Overload Capacity is a robust, oil-free power solution designed to increase (step up) voltage from lower primary levels to higher secondary outputs for efficient power transmission in indoor applications. This three-phase cast resin dry type transformer features premium high-conductivity copper windings fully encapsulated in epoxy resin under vacuum pressure, paired with low-loss grain-oriented silicon steel cores to achieve superior energy efficiency (typically 98%+), minimal no-load and load losses, and excellent partial discharge performance (<10pC). Compliant with IEC 60076-11, IEEE/ANSI, and relevant efficiency standards, this transformer commonly steps up voltages such as 0.4kV/480V primary to 6.6kV, 11kV, 13.8kV, 22kV, or 35kV secondary (Dyn11 or custom vector group), with capacities from 100kVA to several MVA, making it ideal for renewable energy systems, generator step-up, industrial processes, and utility indoor substations prioritizing safety, sustainability, and overload resilience.
- Primary Voltage Ratings 0.4kV, 0.48kV, 0.69kV or custom
- Secondary Voltage Ratings 6.6kV–35kV or custom
- H.V. Tap Range ± 2×2.5% HV taps or others
- Type Dry type transformer
- BIL 30/95kV
- Standards IEEE, ANSI, NEMA,IEC,GB
- Application office buildings, transportation facilities
- Power Rating 50kVA - 7500kVA
- Certificate IEC 60076-11, IEC 60076-1, IEC 60076-3, UL 1561
- Cooling Method OA/OF
- Opeartion Step Down & Step Up
Technical Specifications
Customization Optional
Packing and Shipping
Manufacturer Test
Routine Testing
Application
Technical Specifications
Step Up Dry Type Transformer Copper Winding High Overload Capacity
Technical Specifications
Accessories
| Rated Power | 50kVA - 7500 kVA | |
| Rating Primary Voltage | 2.4-34.5kV | |
| Secondary Voltage | 480/277V 400/230V 380/220V Customized |
|
| Frequency | 50/60Hz | |
| Vector Group | Dyn11,Yyn0,Dyn5 | |
| Winding Material | Aluminum/Copper | |
| Efficiency | As IEEE,Doe 2016,CAS Std or Customized | |
| Impedance Voltage | Nominal 2% or Customized 1.1-5.75% | |
| Altitude | ≤1,000m or Customized | |
| Enclosure material | 304 Stainless Steel | |
| HV Bushing |
| LV Bushing |
| Tap changer connector |
| Lifting hook for complete transformer |
| Name plate |
Customization Optional
Step Up Dry Type Transformer Copper Winding High Overload Capacity
Step up dry type transformers with copper windings offer extensive customization to match specific voltage boost requirements, overload demands, and site conditions in indoor power systems. Primary voltages cover low-voltage inputs (e.g., 0.4kV/480V, 0.69kV) stepping up to medium/high-voltage outputs (6.6kV, 11kV, 13.8kV, 22kV, 33kV, 35kV, or custom), with capacities from 100kVA to 5000kVA+. Copper windings are standard for superior conductivity, thermal endurance, and high overload handling; aluminum alternatives reduce weight and cost. Tap changers include off-circuit ±2×2.5% to ±10% or on-load (OLTC) for dynamic voltage adjustment. Insulation upgrades to Class H (180°C) and low-temperature-rise designs (80K/100K) support elevated ambients or extended overloads (e.g., 150% continuous or 200% short-term). Cooling enhancements feature forced air (AF) fans, ducted systems, or hybrid cooling for enhanced overload capacity, with enclosure protection from IP00 open to IP54/IP55 dust/water-resistant designs including filters or louvers.
Further options encompass vector groups (Dyn11 standard, YNd1, Dyn5, or custom) for harmonic mitigation and system compatibility, integrated fiber-optic temperature monitoring, partial discharge sensors, Modbus/Ethernet smart interfaces for predictive maintenance, electrostatic shielding, anti-vibration isolators reducing noise below 55–70dB, and specialized resin formulations for enhanced fire behavior or chemical resistance. Seismic qualification, marine-grade coatings, and high-current bushings accommodate demanding generator step-up or renewable applications. These tailored features ensure optimal performance and overload resilience, boosting search visibility for "custom high overload step up dry type transformers copper winding."
Packing and Shipping
Step Up Dry Type Transformer Copper Winding High Overload Capacity
Packaging step up dry type transformers with copper windings prioritizes protection of resin-encapsulated windings, core, and accessories during transit. The unit is securely bolted to a reinforced wooden pallet with anti-vibration pads, corner braces, and lifting provisions for crane/forklift handling. Terminals, bushings, and sensors receive foam padding and rigid caps, while the assembly is wrapped in multi-layer moisture-barrier film and breathable covers. A sturdy, ISPM 15-compliant wooden crate fully encloses it, reinforced with internal supports, desiccant packs, humidity indicators, and shock/tilt recorders to monitor conditions and ensure dry-type integrity.
Shipping offers flexible, secure options worldwide. Ocean freight in 20ft/40ft containers provides economical delivery with secure bracing (typically 20–60 days to ports). Air freight handles urgent needs in 5–12 days. Domestic/regional trucking uses enclosed trailers with weatherproofing and tie-downs for compliant movement. Full-value insurance covers risks end-to-end.
The transformer is mounted on a reinforced wooden pallet or steel skid designed for forklift and crane handling, wrapped in multi-layer stretch film and moisture-barrier material. Desiccant packs are included to control humidity, critical for cast-resin units that must remain dry before energization. The entire unit is then placed in a sturdy export-grade wooden crate (ISPM-15 heat-treated) with foam corner protectors, wooden bracing, and steel strapping for stability. Clear markings include gross/net weight, center of gravity, lift points, dimensions (approx. 2.2–3.5 m L × 1.5–2.5 m W × 2.2–3.0 m H depending on rating), and handling instructions (“Fragile – Electrical Equipment – No Tipping”).
Export documentation includes invoices, packing lists, origin certificates, test reports, and IEC compliance for smooth customs. Sustainable practices feature recyclable materials and optimized routing. Clients get real-time GPS tracking with alerts and dedicated support.
Arrival assistance offers optional unpacking supervision, insulation checks, and packaging recycling to speed installation. Bulk orders enable consolidated shipments and phased delivery. This process guarantees reliable arrival, optimizing SEO for "step up dry type transformer copper winding logistics."
Shipping offers flexible, secure options worldwide. Ocean freight in 20ft/40ft containers provides economical delivery with secure bracing (typically 20–60 days to ports). Air freight handles urgent needs in 5–12 days. Domestic/regional trucking uses enclosed trailers with weatherproofing and tie-downs for compliant movement. Full-value insurance covers risks end-to-end.
The transformer is mounted on a reinforced wooden pallet or steel skid designed for forklift and crane handling, wrapped in multi-layer stretch film and moisture-barrier material. Desiccant packs are included to control humidity, critical for cast-resin units that must remain dry before energization. The entire unit is then placed in a sturdy export-grade wooden crate (ISPM-15 heat-treated) with foam corner protectors, wooden bracing, and steel strapping for stability. Clear markings include gross/net weight, center of gravity, lift points, dimensions (approx. 2.2–3.5 m L × 1.5–2.5 m W × 2.2–3.0 m H depending on rating), and handling instructions (“Fragile – Electrical Equipment – No Tipping”).
Export documentation includes invoices, packing lists, origin certificates, test reports, and IEC compliance for smooth customs. Sustainable practices feature recyclable materials and optimized routing. Clients get real-time GPS tracking with alerts and dedicated support.
Arrival assistance offers optional unpacking supervision, insulation checks, and packaging recycling to speed installation. Bulk orders enable consolidated shipments and phased delivery. This process guarantees reliable arrival, optimizing SEO for "step up dry type transformer copper winding logistics."
32
32 years of industry experience
Manufacturer Test
Step Up Dry Type Transformer Copper Winding High Overload Capacity
Progress Test
Progress tests for the step up dry type transformer are conducted at every critical manufacturing stage to ensure material quality and specification conformance. Core lamination stacking is inspected for precise alignment, clamp pressure uniformity, and inter-lamination insulation integrity to minimize no-load losses and audible noise. Winding fabrication progress verifies exact turn counts using automated counters, consistent conductor tension, correct transposition, and adequate insulation thickness between layers for balanced impedance and thermal distribution. After core-coil assembly, preliminary DC resistance, turns ratio, polarity, and inductance measurements are taken to confirm correct phasing, no shorted turns, and electrical symmetry before encapsulation. Cast resin encapsulation progress monitors resin mixing ratios, vacuum pressure levels, curing temperature profiles, and partial discharge testing during cure to ensure void-free insulation. Enclosure assembly checks verify fit-up, ventilation openings (if ventilated), grounding continuity, and surface preparation for paint adhesion. These incremental checks enable early identification and correction of nonconformities, ensuring the finished transformer meets efficiency, dielectric, and reliability targets.
Design Tests
All transformer will be test after finished the production, test items as below:
♦ Insulation Power Factor
♦ Winding Resistance
♦ Impulse Tests
♦ On load Loss Test
♦ No Load Loss Test
♦ Leak Test
♦ DC Insulation Resistance Test
♦ Transformer Turns Ratio/TTR (All Tap Voltages)
♦ Impedance Voltage & Load Loss (Rated Voltage)
♦ Excitation & No-Load Loss (Rated Voltage)
♦ Applied Voltage
♦ Insulation Resistance (Rated Voltage)
♦ Temperature Rise
Transformer Factory Acceptance Test
Factory acceptance testing (FAT) for the step up dry type transformer strictly follows IEC 60076-11, IEEE C57.12.91, and UL 1561 protocols to confirm full compliance before shipment. Routine visual and mechanical inspections verify enclosure finish, weld quality (if applicable), nameplate data accuracy, accessory mounting, and terminal tightness. Winding resistance is measured across all tap positions at reference temperature to confirm conductor uniformity and match calculated loss values. Turns ratio (TTR) testing is performed on every tap to ensure ratio accuracy within 0.5% and correct vector group alignment. Polarity and phase relation checks confirm proper connection. Insulation resistance (megger at 2500–5000 V) evaluates winding-to-winding and winding-to-ground paths for multi-gigohm readings. Applied potential withstand test applies one-minute power-frequency voltage to HV and LV separately per insulation class without breakdown or excessive corona. Induced voltage test at double frequency stresses inter-turn and layer insulation with sensitive partial discharge monitoring to confirm corona-free operation. No-load loss and excitation current are measured at rated voltage to validate core performance against efficiency targets.
Routine Test - DC Insulation Resistance Test
Purpose of Testing
The purpose of DC insulation resistance testing is to measure the insulation resistance of a device by applying a DC voltage, thereby evaluating the health of the insulation material and the voltage withstand capability of the electrical device. This test helps detect potential insulation aging, moisture or damage, preventing electrical failures in the device.
Testing Equipment
Insulation resistance tester (e.g. Megger, Fluke, Hioki, Klein Tools, etc.)
Voltage source (usually 500V, 1000V, 2500V, or customized according to customer requirements)
Temperature and humidity meter (used to record the ambient temperature and humidity during the test to ensure that the test conditions meet the standard requirements.)
Voltage source (usually 500V, 1000V, 2500V, or customized according to customer requirements)
Temperature and humidity meter (used to record the ambient temperature and humidity during the test to ensure that the test conditions meet the standard requirements.)
Pre-Test Preparation
Make sure the device is properly grounded and fully discharged to prevent residual charge in the device from affecting the test results.
Perform the test under suitable environmental conditions. It is recommended to have a relative humidity below 75%, no rain, and a temperature range of 20-30°C to avoid moisture or temperature fluctuations affecting the test results.
Perform the test under suitable environmental conditions. It is recommended to have a relative humidity below 75%, no rain, and a temperature range of 20-30°C to avoid moisture or temperature fluctuations affecting the test results.
Test Progress
Connect the Test Instrument:
Connect an insulation resistance tester to the high voltage terminal of the device under test and to ground.
Apply Test Voltage:
Select an appropriate test voltage based on the rated voltage of the equipment .
Connect an insulation resistance tester to the high voltage terminal of the device under test and to ground.
Apply Test Voltage:
Select an appropriate test voltage based on the rated voltage of the equipment .
Measure and Record
Start the test and record the following parameters:
Insulation resistance value (MΩ)
Applied voltage
Ambient temperature and humidity during testing
Insulation resistance value (MΩ)
Applied voltage
Ambient temperature and humidity during testing
Temperature Correction
The measured insulation resistance values are corrected to a reference temperature (usually 20°C) for accurate evaluation.
Repeat Testing (if necessary)
Measure different windings (high voltage, medium voltage, low voltage) or each bushing separately, and conduct comparative analysis to ensure the insulation status of all parts.
Evaluation Criteria (Reference)
nsulation resistance ≥ 1000 MΩ (excellent)
500 MΩ ≤ Insulation resistance < 1000 MΩ (good)
100 MΩ ≤ Insulation resistance < 500 MΩ
Insulation resistance < 100 MΩ
500 MΩ ≤ Insulation resistance < 1000 MΩ (good)
100 MΩ ≤ Insulation resistance < 500 MΩ
Insulation resistance < 100 MΩ
Test standard
IEEE C57.12.01 & IEEE C57.12.91 (Dry-Type)
*These comprehensive tests ensure that each transformer meets performance standards and operates
reliably under various conditions.
Application
Frequently deployed in industrial cogeneration plants, combined heat & power (CHP) systems, emergency backup generators, and large-scale EV charging hubs needing reliable step-up from low-voltage generation/supply to medium-voltage distribution. Also supports mining operations, railway traction feeders, data center UPS tie-ins, and remote industrial sites demanding high reliability, harmonic tolerance, zero oil risk, and long-term operation in controlled indoor conditions.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
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What is a Transformer?A transformer is an electrical device used to change the voltage of alternating current (AC). It works on the principle of electromagnetic induction, converting high-voltage current into low-voltage current or low-voltage current into high-voltage current. Transformers are widely used in power transmission, distribution systems, and various electronic devices.
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What are the main uses of a transformer?The main use of a transformer is voltage conversion. Transformers are used in power transmission systems to help transfer electricity from power plants to consumers. In addition, transformers are also used in electronic devices such as chargers, televisions, power adapters, etc., to adjust the voltage to meet the requirements of different devices.
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Do you have UL listed?Yes, our transformer has UL listed. We have exported to America many pad mounted transformer,substation transformer and HV.
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