Synergy Transformers is a globally trusted manufacturer of high-reliability Furnace Transformers designed specifically for metal reduction, induction melting, arc furnace duty, and heavy industrial heating processes.
Industrial furnaces impose demanding operating conditions, including continuous high current outputs, rapid current swings, severe harmonic distortion, and frequent short-circuit forces. Our furnace transformers are precision-engineered with reinforced core-coil assemblies, heavy-duty LV busbar arrangements, and electrostatic shielding to deliver uninterrupted power supply and extended service life in steel plants, foundries, and metallurgical facilities worldwide.
Built to withstand severe cyclic loading, non-linear harmonic currents, and high-frequency voltage spikes.
Positioned between the primary and secondary windings to divert high-frequency switching surges and primary-side line transients away from secondary rectifiers, safeguarding sensitive thyristor and IGBT units.
Engineered with optimized current densities and low magnetic flux densities to restrict stray losses, prevent localized core overheating, and maintain energy efficiency under severe 6-pulse, 12-pulse, or 24-pulse rectifier loads.
Robust structural clamping frames and high-density radial spacers withstand severe electrodynamic forces generated during furnace short-circuits and rapid melt-down load swings.
Specially configured copper busbar outlets designed to minimize eddy current losses, skin effect, and thermal expansion joints at high secondary amperage outputs.
Available with On-Load Tap Changers (OLTC) or Off-Circuit Tap Changers (OCTC) featuring wide voltage regulation ranges to accommodate changing melt profiles and precise temperature control.
Fully compliant with IEC 60076 series standards, IS 2026, and IS 4540 specifications, supported by complete routine, type, and short-circuit test dossiers.
Each furnace transformer is custom-designed based on furnace kilowatt rating, secondary voltage requirements, duty cycle, and plant layout specifications.
| Parameter | Technical Specification Range |
|---|---|
| Transformer Type | Indoor / Outdoor Pad-Mounted, Oil-Immersed Furnace Transformer |
| Voltage Class | 3.3 kV, 6.6 kV, 11 kV, 22 kV, 33 kV or custom HV voltage input |
| Duty Cycle | Continuous Heavy Industrial Duty (On-Load / Off-Load Tap Changers) |
| Vector Group | Dyn11, Dyn5, Dyn1, YNd11, Star-Delta dual output or customer specified |
| Rectifier Compatibility | 6-Pulse, 12-Pulse, 18-Pulse & 24-Pulse Rectifier Systems |
| Frequency | 50 Hz / 60 Hz |
| Tapping Range | ±10% OLTC / ±7.5% OCTC or custom step taps |
| Winding Conductor | Electrolytic High-Conductivity Copper with thermally upgraded paper insulation |
| Cooling Options | ONAN, ONAF, OFWF (Oil Forced Water Forced) for ultra-compact heavy current duty |
| Standards Compliance | IEC 60076, IS 2026, IS 4540, IEEE C57.18.10 |
Diagrammatic representation of expanded core window and shielded winding configuration for furnace transformers.
Procurement managers and electrical consultants often notice that furnace duty transformers have higher physical weights, larger dimensions, and larger oil volumes compared to standard distribution or power transformers of equivalent kVA ratings. This dimensional increase is an essential engineering requirement for durability:
By refusing to cut corners on active materials, Synergy ensures our furnace transformers operate at low hot-spot temperatures, withstand sudden secondary short circuits during scrap metal bridging, and maintain operational stability across decades of industrial service.
Every unit manufactured at our Rajkot facility undergoes rigorous routine testing prior to dispatch. Customer witness testing and third-party inspections (SGS, TUV, Bureau Veritas, Intertek) are fully supported.
Voltage ratio, vector group verification, winding resistance, insulation resistance, no-load loss, load loss, impedance voltage, and separate-source AC withstand voltage testing.
Temperature rise tests, lightning impulse withstand tests, noise level measurements, and short-circuit withstand capabilities verified at accredited testing laboratories.
Supplied with complete engineering dossiers including approved GA drawings, guaranteed technical particulars (GTP), oil quality reports, and seaworthy export packing.
Share your furnace capacity (kW/kVA), primary input voltage, secondary voltage tap range, and rectifier pulse configuration with our pre-sales engineering team.
Furnace transformers operate under extreme harmonic stresses and cyclic thermal loads. To prevent excessive overheating, Synergy utilizes reduced current densities (larger conductor cross-sections) and reduced magnetic flux densities (larger CRGO core cross-sections). Additionally, internal electrostatic shielding between primary and secondary windings requires wider radial gaps, which increases overall core, copper, oil, and tank dimensions.
We incorporate a grounded electrostatic copper shielding barrier between the primary (HV) and secondary (LV) windings. This shield diverts high-frequency voltage transients and switching surges from entering the secondary circuit, protecting sensitive thyristor and IGBT rectifier components from damage.
Our furnace transformers comply fully with IEC 60076, IS 2026, and IS 4540 standards. We build customized configurations for 6-pulse, 12-pulse, 18-pulse, and 24-pulse rectifier circuits, including dual active core-coil assemblies inside a single tank for compact space footprints.
We offer ONAN (Oil Natural Air Natural), ONAF (Oil Natural Air Forced), and OFWF (Oil Forced Water Forced) cooling configurations. OFWF is particularly advantageous for high-kVA smelting and melting furnaces where space is restricted and high heat dissipation is mandatory.
