Design Considerations for ETAC Custom Dry Type Transformers Part I

Discover ETAC’s design considerations for custom dry-type transformers, including core materials, winding configurations, and safety standards.

August 7th, 2024

Custom dry-type transformers are essential components in various applications, offering the flexibility to meet specific requirements and constraints of diverse projects. At ETAC Service & Supply, our custom dry-type transformers are designed with a focus on performance, reliability, and efficiency. This article will highlight crucial design considerations such as core material selection, winding configurations, winding materials, insulation systems, cooling methods, enclosure types, and safety standards, with a special focus on CSA C9.

Core Material Selection

The core material plays a pivotal role in the performance and efficiency of dry-type transformers. At ETAC, we carefully select core materials to ensure optimal functionality:

Silicon Steel: Widely used due to its low cost and adequate performance in many applications. It offers good magnetic properties and is relatively easy to manufacture.
Amorphous Steel: Known for its superior magnetic properties and low core losses, making it suitable for applications requiring high efficiency and minimal energy loss.
Nanocrystalline Core: Provides excellent magnetic properties and is ideal for high-frequency applications. It offers low core losses and high permeability, which can enhance the overall efficiency of the transformer.

Selecting the appropriate core material is critical as it directly impacts the transformer’s performance, efficiency, and cost.

Winding Configurations

Winding configurations determine the electrical characteristics and performance of the transformer. ETAC offers various winding configurations to meet different application needs:

Layer Windings: Consist of multiple layers of conductor wound on the core. This configuration is straightforward and cost-effective but may result in higher losses and lower efficiency.
Helical Windings: Feature conductors wound in a helical fashion, providing better cooling and lower losses. This configuration is suitable for transformers with high current ratings.
Disc Windings: Involve winding conductors in the form of discs. This configuration offers excellent mechanical strength and is commonly used in high-voltage transformers.

The choice of winding configuration depends on factors such as the voltage and current ratings, cooling requirements, and mechanical stress considerations.

Winding Materials

The choice of winding material is crucial for the efficiency, performance, and longevity of the transformer. ETAC uses high-quality winding materials to ensure optimal performance:

Copper: The most widely used winding material due to its excellent electrical conductivity, mechanical strength, and thermal properties. Copper windings provide high efficiency and are suitable for a wide range of applications, from low to high voltage.
Aluminum: A cost-effective alternative to copper, aluminum windings are lighter and less expensive but have lower electrical conductivity. Aluminum windings require larger cross-sectional areas to achieve the same current-carrying capacity as copper, making them bulkier. However, they are still popular in many applications due to their cost benefits.

Choosing the right winding material involves balancing cost, efficiency, mechanical strength, and application-specific requirements.

As we reviewed core material selection, winding configurations, and winding materials, we understood their crucial role in dry-type transformer performance and efficiency. However, dry-type transformers involve more than these aspects. In Part 2, we’ll explore insulation systems, cooling methods, enclosure types, and adherence to safety standards like CSA C9.