Cast Resin Transformer for Railway

The Cast Resin Transformer For Railway is a high-reliability power transmission and transformation device tailored for electrified railways and rail transit systems. It is widely used in railway traction substations, switchgear stations, automated transmission stations, substations, and along-line signaling systems, power and lighting systems, and other power supply applications. Utilizing an advanced epoxy resin vacuum casting process, this product features a single-phase design, flame retardancy and explosion-proofing, maintenance-free operation, energy conservation, and environmental protection. It meets the railway system's stringent requirements for power supply safety, stability, and environmental adaptability, making it a critical component for ensuring railway power transmission and signal control.

1. High-Voltage Winding
The high-voltage winding utilizes a multi-layer cylindrical structure, with high-purity oxygen-free copper conductors and fully insulated interlayers, molded by vacuum casting. The winding is vacuum impregnated and cast with a special epoxy resin in a mold to effectively eliminate internal bubbles, resulting in low partial discharge (≤10pC) and excellent resistance to moisture, mildew, and salt spray.

2. Low-Voltage Winding
The low-voltage winding utilizes a copper foil winding structure with interlayer cooling ducts and is integrally resin-cast and cured. This provides high mechanical strength, balanced ampere-turn distribution, and strong short-circuit withstand capability. Flexible wiring options support direct copper busbar or cable connections, and the joints are highly reliable.
 

3. Vacuum Casting Process
Fully automated vacuum casting equipment ensures precise and uniform resin mixing. Strict vacuum control during the casting process eliminates bubbles and defects, resulting in a dense, high-strength winding structure with excellent electrical insulation and mechanical resistance.
 

4. Core Structure
The core is constructed from high-quality, high-permeability, cold-rolled, grain-oriented silicon steel sheets with 45°, fully beveled joints. This ensures low no-load losses and current, and minimizes noise and vibration. The core surface is coated with rust-proof resin, ensuring overall strength and reliability, suitable for the frequent vibration and shock loads encountered in railway applications.
 

5. Voltage Regulation and Insulation Design
Off-excitation voltage regulation is supported, with a typical tapping range of ±2 × 2.5%, which can be expanded based on user needs. The insulation system is designed for F- or H-class heat resistance. After curing, it resists moisture absorption and aging, ensuring a long service life.
 

6. Enclosure and Protection
The enclosure can be made of cold-rolled steel with plastic spraying or aluminum alloy, with protection levels up to IP20, IP21, or higher, suitable for a variety of installation environments, including indoors, in tunnels, and outdoors. The compact structure and minimal footprint allow for wall mounting or integration with switchgear.

High Safety and Reliability: Flame retardant and self-extinguishing, explosion-proof and fireproof, with no toxic gas emissions, it can be installed directly at the load center.
Energy Saving and Environmental Protection: The low-loss design ensures no-load and loaded losses are far below national standards, resulting in significant energy savings.
Strong Environmental Adaptability: Moisture-, mildew-, and salt spray-resistant, making it suitable for harsh environments such as coastal areas and tunnels.
Low Temperature Rise and High Overload: F/H-class insulation with strict temperature rise limits (coil ≤ 95K, core ≤ 85K) provides excellent overload capacity. Low Noise and Low Partial Discharge: Optimized magnetic flux density and structural design achieve noise levels 3-5dB(A) lower than national standards, and partial discharge levels less than 5pC.
Maintenance-Free Design: Fully sealed cast structure eliminates the need for regular maintenance, reducing overall lifecycle costs.
Intelligent Options: Configurable temperature control and air cooling systems, supporting remote monitoring and intelligent linkage.

Rated Voltage: 27.5kV / 0.23kV (or customized)
Rated Capacity: 20-8000kVA
Frequency: 50Hz / 60Hz
Voltage Regulation: Off-circuit Voltage Regulation
Tapping Range: ±2 x 2.5%
Impedance Voltage: 4%-6% (customizable)
Insulation Class: F or H
Protection Class: IP20 / IP21 (higher options available)
Cooling Method: AN / AF
Partial Discharge: ≤5pC
Compliant Standards: IEC 60310, IEC 60076, TB Series Railway Industry Standards

This Cast Resin Transformer For Railway is widely used in:
Electrified railway traction power supply systems
Railway signal control power supply
Power systems for switchgear, automatic transmission (AT) stations, and substations
Lighting and power distribution for rail transit stations and tunnels
Other industrial power distribution applications with stringent safety and reliability requirements
With its outstanding reliability, energy efficiency, and environmental adaptability, this product has become an indispensable core device in modern railway and rail transit power supply systems.