Manufacturing
MAGNETIC CIRCUIT
It is a core-type design, manufactured from oriented silicon alloy sheets of 0.30, 0.25, and 0.23 mm thickness, designated M5, M4, and M3, respectively. Sheets with a 45-degree beveled cut are used in the transition zones of the magnetic circuit. All sheets used in the magnetic circuit are cut on a CNC-controlled cutting machine, stacked, and arranged to form the magnetic circuit. The cutting and assembly of the magnetic circuit are performed using a method called “step-lab,” which minimizes iron losses. The core is assembled using both crosswise and longitudinal step-lab applications.
ACTIVE PART
In order to form the active part of the transformer with ready core and coils, the coils are mounted by being compressed against the core and each other by means of slats in order to carry radial forces and the upper yoke is arranged. At the same time, the coils are equipped with a protection system against axial forces. The necessary welding and connections of the adjustment ends going to the commutator or step switch are made with silver electrodes and the active part is made ready for the furnace.
WINDINGS
Distribution Transformer Windings: The low-voltage winding conductor is made of copper. In sheet windings, layer insulation is provided by thermally enhanced resin-impregnated paper (DPP).
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TANK
Used in oil-filled transformers to cool the transformer and protect the insulating material. Depending on the cooling surfaces, transformers up to 3,150 KVA are manufactured with corrugated walls, while transformers with higher power ratings are manufactured with radiator-equipped tanks.
DRYING AND OIL FILLING
Transformers whose active components have been fully assembled are dried in drying ovens at a temperature of 120 degrees, then placed in the tank and filled with oil in the vacuum chamber. In the vacuum chamber, any air remaining inside the transformer’s tank is extracted, ensuring that the insulating oil fully penetrates the active part. The oil provides both insulation and cooling.
PAINTING
Once manufacturing is complete, the tanks are painted using a spray method. The standard paint job consists of one coat of primer and two coats of topcoat. The total film thickness is no less than 105p. The standard transformer color is RAL 7033, known as “cement gray.” Upon customer request, painting can be performed using different finishes (such as zinc coating), in different thicknesses, and in different color codes.