ZBK Control Transformer

The ZBK control transformer is a dry-type transformer specifically designed for factory automation and electrical control systems. It uses high-quality cold-rolled silicon steel sheets for its core, combined with solid insulating materials. The overall design is compact, has good efficiency, and maintains excellent temperature rise control during operation.
The main task of it is to safely convert the higher voltage in the main circuit (such as the common 380V) into various low-voltage electrical supplies required by the control circuit - like 220V, 110V, or the standard voltages of 36V and 24V. Thus, PLCs, contactors, relays, indicator lights, and various instruments can obtain a stable and reliable power supply.
The product is entirely designed according to the standards of industrial environments. It has a strong ability to withstand overload and is not afraid of common disturbances. It can be used smoothly in various scenarios such as machine tools, production lines, power distribution systems, and various automated control situations. It is truly an indispensable key component behind the control circuit, ensuring safe and stable operation.

Core Materials

The cold-rolled non-oriented silicon steel sheets used are those recognized in the industry as DW470, with a thickness controlled at 0.35 or 0.5 millimeters. This material has high magnetic permeability and low iron loss, and consumes very little electricity when no load is applied.

Coils: T2 grade electrolytic copper

The insulation paint covering them is QZ(G)-2/155/I grade polyester material, which can withstand a temperature of up to 155 degrees Celsius. Even if the ZBK control transformer operates at full load for a long time, it is unlikely to have problems due to overheating.
In terms of insulation treatment, the interlayer is padded with DMD composite foil, which can withstand a voltage of up to 8 kilovolts per millimeter.

Framework: PBT material

The material has a flame retardant grade of UL94 V-0, and cannot catch fire. The entire transformer is finally subjected to vacuum impregnation treatment, using 1032 alkyd resin or H grade organic silicone resin to completely enclose the windings.
By produced in this way, when placed in an environment ranging from -15 degrees Celsius to 40 degrees Celsius, it will not exceed an increase of 85 degrees in temperature, and the insulation resistance will remain above 100 megohms. According to the experience at the Yibaling factory, with normal use for over 100,000 hours, there will be no major problems.
The selection of these materials and the production process ensure that the ZBK control transformers can withstand long-term tests in the factory workshop environment.

FAQ

Q: What is the purpose of the ZBK control transformer? How is it different from ordinary small transformers?
A: The ZBK control transformer is specifically designed for industrial control cabinets. Its main function is to convert the high voltage from the main power supply (such as 380V) into a safe low voltage (usually 24V, 36V, 110V, etc.) that the control circuit requires.
The core difference between the ZBK control transformer and ordinary transformers lies in the industrial-grade design:
The materials are more solid (such as using DW470 silicon steel sheets and T2 electrolytic copper), the protection is better (vacuum impregnation treatment), it can continuously withstand the current impact caused by the contactors closing and the coil actions in the control circuit, and effectively isolate the grid interference to ensure the stable operation of sensitive equipment such as PLCs and instruments.

Q: Is there a difference between the T2 electrolytic copper used in the winding of the ZBK control transformer and ordinary copper wire?
A: There is a fundamental difference. T2 is a high-grade electrolytic copper in the national standard, with a purity of up to 99.9%, and has excellent conductivity.
Using T2 copper for the winding results in a smaller resistance and less heat generation under the same power. This ensures that the ZBK control transformer will not burn out due to excessive winding heat even under full load or short-term overload.
Many cheap transformers use recycled copper with impurities or copper-clad aluminum, which has poor conductivity and is a safety hazard for the equipment operation.

Q: I saw that the parameters include the vacuum impregnation process. Is this important?
A: It is extremely important. This is a key step in the reliability.
This process involves placing the assembled ZBK control transformer core in a vacuum tank, evacuating the air, and then immersing it in insulating paint (such as 1032 resin) to allow the paint to fully penetrate every crevice of the winding.
Then, it is dried and cured. This process has three main functions:
First, it prevents moisture and corrosion, adapting to the workshop environment;
Second, after curing, the winding becomes a single entity, providing better shock resistance and noise reduction;
Third, it fills in the fine gaps, improving the insulation strength and heat dissipation capacity.
Transformers that do not undergo this process are prone to failure in humid or vibrating environments.

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