Features of Cast Resin Transformer
- Strong short-circuit resistance and load capacity
- Flame-retardant, oil-free, minimal maintenance
- High mechanical strength and weather resistance
- Prevent dust, moisture, and ultraviolet rays
- Low noise, takes up less space
- ZHONGSHAO cast resin transformer has obtained ISO9001 and ISO45001 certification, and also provides one-stop services
Your Reliable Cast Resin Transformer Supplier in China
ZHONGSHAO’s cast resin transformer represents greater safety, a more competitive price, and more stable long-term performance. We focus on high-quality resin casting technology to ensure that every transformer you receive has excellent insulation strength and reliability.
Please feel free to contact us if you have any questions.
A reliable power distribution with various input voltage, has great cooling method without requiring external source
Ideal power distribution and energy-saving function that ensures the usage of the equipment without malfunction.
Electronic application and large capacity for voltage, a dry-type transformer made with durable materials.
Metallic materials with anti-corrosion, have great power distribution and natural air cooling method.
Has a copper winding material with high-durability, has dry type transformer. Improved to have high efficiency and continuous productivity.
Manufactured with high efficiency and has improved lower noise function. High voltage capacity with natural air cooling method.
Has great power saving and supply with 3-phase distribution, enhanced with flame resistant and explosion proof material.
Dry-type transformer with durable materials used to ensure the fire resistance and environmental friendly advantage.
What is a Cast Resin Transformer
The cast resin transformer is a dry-type transformer with epoxy resin insulation. It does not contain transformer oil and has high fire resistance. Even in harsh environments such as dust and humidity, it operates safely and reliably. Commonly used in commercial buildings, industrial factories, and data centers.
Work Principle of Cast Resin Transformer
The cast resin transformer achieves voltage boosting, decreasing, and isolation through electromagnetic induction. The iron core efficiently concentrates magnetic flux; when the primary winding is energized, a magnetic field is generated, which is then transmitted through the core to the secondary winding, achieving energy conversion.
The resin casting process requires molds and specialized casting equipment to cast the coils under vacuum. Moreover, the resin enhances the transformer’s resistance to short-circuit impacts. Combined with the air-cooling system, it ensures continued safety and reliability under long-term loads.
Construction of Cast Resin Transformer
- Iron Core
The core is usually made of high-quality cold-rolled silicon steel sheets with high magnetic permeability and low loss. Moreover, after the core surface undergoes anti-corrosion and insulation treatment, it effectively reduces eddy current losses, improves efficiency, and thus lowers your long-term operating costs.
- High Voltage Windings
The HV winding is integrally cast with epoxy resin, making its operation more stable. The winding conductors often use high-purity copper or aluminum, which can decrease energy use and enhance heat resistance. Also, heat dissipation channels are arranged properly within the resin casting, further improving heat dissipation efficiency.
- Low Voltage Windings
LV windings are mostly formed by hot pressing copper or aluminum foil. This foil structure dramatically reduces electromagnetic imbalance and minimizes localized overheating problems at their source. It also ensures that the transformer maintains high stability during long-term operation.
- Busbar
Busbars are used to connect low-voltage windings to external power distribution systems and undertake the task of large current transmission. During installation, insulating brackets, heat shrink tubing, epoxy boards, etc., are needed to enhance insulation, thereby preventing short-circuit accidents. It also improves the safety of your entire power distribution system.
- Protective Enclosure
The protective housing protects the transformer’s internal parts from environmental influences and ensures your operator’s safety. The enclosure is generally made of high-strength steel and can provide different levels of protection according to application, reducing your maintenance frequency.
- Cooling System
Resin-cast dry-type transformers often adopt natural cooling by air(AN), heat dissipation is achieved through direct contact between the windings and the air. For high-load or high-temperature environments, forced air cooling (AF) can also be used. By adding fans to enhance heat dissipation efficiency, you can obtain an additional 20% overload capacity.
- Temperature Control
It can monitor the temperature of the high and low voltage windings and the core in real time. Once a preset threshold is reached, it can automatically trigger an alarm, activate the fan, or perform a power-off protection. So, it can help you reduce downtime risks, and the equipment’s life will be extended.
Features and Benefits of Cast Resin Transformer
Compact Structure
If your substation has limited space or you need to allocate space for other equipment, the cast resin transformer is very suitable for you and can save you a lot of space costs.
Cast resin transformers have a compact structure and occupy far less space than oil-immersed transformers, making them ideal for installation in basements, power plants, and commercial buildings. Moreover, this structure also facilitates transportation and allows for more flexible placement, accelerating your project progress.
High Safety
The resin used in the casting is a high-quality, flame-retardant, oil-free material, making your transformer safer. In the event of a fire, oil-immersed transformers are prone to combustion and even explosion, while resin dry-type transformers, due to their self-extinguishing properties, can quickly extinguish the fire after the flames are removed, effectively blocking the spread of fire. This also diminishes the risk of equipment damage and protects surrounding personnel.
If your project must meet standards such as NFPA and IEC, this type of transformer brings stress-free acceptance testing.
Strong Short-Circuit Resistance
In industrial plants, choosing transformers with weak short-circuit resistance is very likely to cause winding damage, resulting in power outages and repair costs.
Cast resin transformers, on the other hand, have coils integrally cast from epoxy resin, providing extremely high mechanical strength and ensuring stability even under short circuits and overloads. When it is confronted with these high stresses, it can still maintain structural stability, guaranteeing your continuous production.
Weather Resistance
Cast resin transformers can operate in ambient temperatures as low as -25°C. You can also use it outdoors with a high-grade IP protective housing.
Compared to oil-immersed transformers, resin dry-type transformers are more suitable for harsh operating conditions. Whether in mountainous areas, coastal regions, sandy areas, or outdoor substations with large temperature differences, the equipment can operate stably for extended periods.
Meanwhile, the resin isolates the transformer from moisture, dust, and corrosive gases, preventing problems such as winding dampness and short circuits.
Easy Maintenance
Cast resin dry-type transformers require minimal maintenance. Routine cleaning of surface dust and dirt is sufficient to maintain stable operation. Furthermore, the modular structure facilitates checks more easily and faster in case of a fault, significantly reducing downtime. Less maintenance finally brings lower hiring costs and a lower total cost of ownership (TCO).
Environmental Friendly
By using casting resin transformers, you don’t need to worry about oil leakage polluting the soil or water sources, nor do you need to build facilities such as oil separation zones. It’s easier to meet environmental protection standards.
At the same time, resin diminishes vibration, making it operate with low noise, which is highly suitable for noise-sensitive scenarios such as hospitals, office buildings, and residential communities. Compared to oil-immersed transformers that require regular testing and waste oil disposal, resin-type transformers are cleaner, safer, and produce almost zero emissions.
Therefore, if you are looking for equipment that combines high performance with eco-friendliness, our cast resin transformer is undoubtedly the best choice.
Applications of Cast Resin Transformer
Industrial
Cast resin transformers are popular in industrial settings due to their high heat resistance, strong insulation properties, and excellent short-circuit resistance. It can effectively prevent dust intrusion and is oil-free, eliminating safety hazards. The equipment can also withstand frequent load fluctuations, making it suitable for high-impact applications such as motor starting and large equipment switching.
Data Centers
A power outage can cause severe business disruptions and financial losses for data centers. Cast resin transformers offer high insulation performance and overload capacity, ensuring stable operation even in high-temperature, high-load-fluctuation machine rooms. And, their high fire resistance makes them ideal for enclosed indoor rooms, reducing your fire safety costs.
Renewable Energy
It can operate stably even in coastal and mountainous areas, and its lifespan will not be shortened by moisture. Their high mechanical strength can withstand the vibration of wind turbines and rapid load changes, ensuring stable power output. Moreover, it is also maintenance-free and is suitable for remote areas, reducing long-term operation costs.
Commercial Building
The cast resin transformers operate with low noise, providing a more comfortable experience for commercial environments. They also have a small footprint, and it can help you save on construction costs and improve space utilization. Furthermore, due to its reliable fire resistance, it can be directly installed indoors, reducing power line length and lowering your energy consumption.
Cast resin transformers are fireproof, explosion-proof, and maintenance-free, so they are ideal for indoor locations with high safety requirements, such as high-rise buildings, subways, and hospitals. Oil-immersed transformers offer good heat dissipation, low cost, and strong overload capacity, but require fire and explosion prevention measures and are suitable for outdoor and harsh environments.
Under normal operating conditions, the life of a resin dry-type transformer can reach 20–30 years. With a good temperature control system, proper ventilation, and avoidance of prolonged overload, the actual lifespan can be even longer.
It relies on air cooling and has weaker heat dissipation capabilities than the oil-immersed type, so it is unsuitable for continuous heavy-duty applications. If it operates for a long time in a high-temperature, poorly ventilated environment will accelerate resin aging. Furthermore, its price is usually higher than that of the oil-immersed type of the same capacity.
VPI transformers offer superior insulation and heat dissipation, are lower cost, and adopt an open winding design for easy localized repairs.
Resin-cast transformers are durable and can withstand extreme environmental conditions. If the environment is humid and maintenance-free is desired, resin-cast transformers are the preferred choice.
Check the sealing condition regularly and ensure good ventilation. When cleaning, first turn off the power, then use a vacuum cleaner or a cloth to wipe away dust and debris adhering to the coil’s casing and other surfaces. You can also clean the coil with a damp cloth. Don’t forget to dry it after cleaning.
