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The rectifier transformer is a heavy-duty special transformer engineered specifically to supply power to rectifying equipment (thyristors, diodes). Its primary function is to transform high or medium AC grid voltage into the precise AC voltage required by rectifier circuits to produce stable DC power. As a typical high voltage rectifier transformer, it achieves vital galvanic isolation, suppresses harmonic pollution via multi-pulse phase shifting, and aggressively resists DC bias saturation. Tailored for rigorous industrial operating conditions, the rectifier duty transformer is the indispensable power source for electrolysis, electroplating, massive DC drives, and high-power charging systems.
Core Parameters:
• Rated Capacity: 100kVA ~ 100MVA (Built to endure 1.2x~1.5x severe load impacts).
• Voltage Configuration: Grid side 10kV/35kV stepped down to precise operational LV (tens to hundreds of Volts).
• Special Vector Groups: Phase-shifting designs (e.g., 12-pulse, 24-pulse) for harmonic elimination.
Product Features
Rectifier transformers employ advanced multi-winding phase-shifting configurations (like 12-pulse or 24-pulse). This intrinsically cancels out harmful high-order harmonics, keeping the public AC grid clean and improving the power factor, a key strength of a standard high voltage rectifier transformer.
Rectifier loads inject DC components back into the system. Our rectifier duty transformer core design utilizes specialized magnetic flux routing to prevent iron core saturation, eliminating severe overheating and vibration; the second high voltage rectifier transformer variant upgrades this flux routing for extra heavy DC bias loads.
Industrial rectifier systems (like steel electrolysis) generate massive sudden current spikes. The second rectifier transformer adopts a highly braced coil structure that easily withstands these dynamic short-circuit forces without deforming.
This design ensures strict electrical isolation between the high-voltage utility grid and the sensitive low-voltage rectifier valves, protecting critical DC infrastructure from grid-side voltage transients, a non-negotiable design rule for any rectifier duty transformer.
Unlike standard 400V transformers, the secondary winding is custom-engineered to deliver the exact special voltages (e.g., 85V, 600V) required by specific diode or thyristor bridges, fully matching the output demand of metallurgical conversion stations.
Available in diverse cooling modes including ONAN, ONAF, OFAF, and even OFWF (Forced Oil Water Cooling) for immense MVA ratings, ensuring stable 24/7 high-load industrial smelting under continuous heavy conversion operation.
Key Specifications (Rectifier Transformer)
| Parameter | Typical Value | Description |
| Rated Capacity | 100kVA ~ 100MVA | From small charging hubs to massive aluminum smelting plants. |
| Rated Voltage | HV: 10kV / 35kV LV: Custom (e.g., 50V~800V) | Steps down to precise AC voltages dictated by the DC output requirements. |
| Vector Group | Dyn11, Yd11, Z-Type, Multi-Winding | Highly complex phase-shifting to generate 12-pulse or 24-pulse rectification. |
| Short-Circuit Impedance | 6% ~ 12% | Deliberately elevated to buffer thyristors from severe fault currents. |
| Overload Capability | 1.2x ~ 1.5x Rated Capacity | Easily manages the brutal load-cycling typical in electro-chemical processes. |
| Cooling Method | ONAN / ONAF / OFAF / OFWF | Versatile cooling adapted for extremely hot or confined industrial environments. |
Full Series Technical Reference (Rectifier Platform: 100kVA ~ 100MVA)
| Rated Capacity Range | High Voltage (kV) | Low Voltage (V) | Pulse Configuration | Cooling Method | Typical Industrial Application |
| 100kVA ~ 500kVA | 10 / 35 | Custom (e.g., 100~400) | 6-Pulse | ONAN / Dry-Type | Small Electroplating / EV Charging Hubs |
| 500kVA ~ 2500kVA | 10 / 35 | Custom (e.g., 200~600) | 6-Pulse / 12-Pulse | ONAN / ONAF | Medium Chemical Electrolysis / DC Drives |
| 2.5MVA ~ 10MVA | 10 / 35 | Custom (e.g., 400~800) | 12-Pulse / 24-Pulse | ONAF / OFAF | Large Copper / Zinc Smelting |
| 10MVA ~ 31.5MVA | 35 / 110 | Custom | 24-Pulse / 48-Pulse | OFAF / OFWF | Heavy Aluminum Electrolysis Lines |
| 31.5MVA ~ 63MVA | 35 / 110 / 220 | Custom | 24-Pulse / 48-Pulse | OFAF / OFWF | Mega-Scale Electrochemical Plants |
| 63MVA ~ 100MVA | 110 / 220 | Custom | Multi-Winding Phase Shift | OFWF (Water Cooled) | Ultra-High Power DC Transmission (HVDC) |
* The table above illustrates the broad capability of rectifier transformer manufacturing. Because rectifier applications are highly specialized, exact dimensions, weight, and impedance are 100% customized per the specific thyristor bridge design and harmonic suppression requirements.
FAQ
Rectifier equipment (like thyristors) are non-linear loads. When they convert AC to DC, they act as "harmonic generators," pushing massive amounts of distorted, high-frequency currents (harmonics like the 5th, 7th, 11th, and 13th) back into the public power grid. This pollution can overheat lines, destroy capacitors, and crash computers.
The Phase-Shifting Solution (Multi-Pulse): Instead of a simple 6-pulse conversion, we design the rectifier transformer with multiple secondary windings. For example, in a 12-pulse system, the transformer has two secondary windings: one wired in Star (Y) and one in Delta (D). This creates a deliberate 30-degree electrical phase shift between the two outputs.
When the rectifier converts these shifted voltages to DC, the 5th and 7th harmonic currents generated by the Star winding are exactly opposite in phase to those generated by the Delta winding. They mathematically cancel each other out inside the transformer's magnetic core. By extending this to 24-pulse or 48-pulse systems (using zig-zag windings), we eliminate nearly all harmful harmonics before they ever reach the public grid, achieving clean, stable power compliance.
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E-mail: junqiu.wang@czguanghui.cn
jocelyn.duan@czguanghui.cn
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