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Dry Type Iron Core High Voltage Series Reactor

The Dry Type Iron Core High Voltage Series Reactor is a cutting-edge solution designed to enhance harmonic suppression and voltage stabilization in high-voltage networks. With its innovative, oil-free design, this reactor leverages a robust iron core to deliver efficient reactive power control and reduce harmonic distortion, ensuring stable power flow in demanding systems. Its dry-type construction eliminates the need for oil insulation and cooling, making it an environmentally friendly and safer choice for high-voltage applications. Offering reliable, maintenance-free performance, the Dry Type Iron Core High Voltage Series Reactor is ideal for critical power infrastructure, providing long-lasting, efficient operation in industrial, commercial, and energy applications.

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Product Components

Iron Core (Magnetic Circuit Core)
Constructed from high-permeability silicon steel laminations, forming a closed or segmented magnetic circuit to significantly enhance inductance and reduce volume.
The silicon steel surface is coated with insulating varnish to minimize eddy current losses, and laminations are tightly secured to reduce vibration noise.
Core Types: May feature multi-column or segmented structures to accommodate high-voltage insulation requirements.

Winding (Coil)
Manufactured using copper or aluminum conductors, arranged in single-layer or multi-layer windings with uniform distribution to optimize the magnetic field.
In high-voltage series applications, the winding must withstand high voltage surges and is typically segmented or reinforced with additional insulation measures.
Special Design: Shielding layers, such as grading rings, may be included to improve electric field distribution.

Insulation System
Turn-to-turn insulation: Conductors are wrapped with high-temperature-resistant materials (e.g., mica tape, polyimide film) to ensure dielectric strength.
Main insulation: Achieved through epoxy resin encapsulation or Vacuum Pressure Impregnation (VPI) technology, enhancing overall voltage endurance.
Core insulation: Insulating barriers are placed between the iron core and winding to prevent short circuits.

Mechanical Support Structure
Core fixation: The laminated core is secured using clamping devices, tie rods, or epoxy resin encapsulation to prevent vibration and deformation.
Winding fixation: Windings are stabilized using fiberglass-reinforced strips, epoxy resin bands, or metal frames to ensure mechanical strength.

Cooling System
Natural Air Cooling: Relies on air convection, with ventilation channels integrated into the core and winding structure.
Forced Air Cooling: High-capacity reactors may include fans, though dry-type designs typically do not require additional cooling media.

Connection Terminals & Output Devices
High-voltage output terminals are made of copper, with silver or tin plating to reduce contact resistance.
Output bushings are composed of epoxy resin or ceramic, ensuring sufficient creepage distance and insulation protection.

Enclosure & Protection Devices (Optional)
Protective Cover: A metal or non-metallic enclosure provides dustproof and moisture-proof protection, with ventilation openings to maintain airflow.
Electromagnetic Shielding: Some designs incorporate metal mesh or aluminum housing to suppress magnetic leakage interference.

Monitoring & Protection Components (Optional)
Temperature Sensors (e.g., PT100) are embedded in the winding or core to monitor overheating risks in real time.
Vibration Sensors detect mechanical anomalies, providing early warning of structural instability.

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Key Differences

Feature	Dry-Type Core Low Voltage Series Reactor	Dry-Type Core High Voltage Series Reactor
Design Objective	High Current Limiting, Reactive Power Compensation, Low Voltage Harmonic Mitigation	High Voltage Endurance, Short-Circuit Current Limiting, High Voltage System Harmonic Suppression
Voltage Rating	Typically ≤1kV	Typically ≥6kV (Up to 66kV or higher)
Insulation Requirements	Relatively Low (Main Insulation Thickness is Small, Inter-turn Insulation)	Extremely High (Multiple Layers of Main Insulation, Must Withstand Lightning Surge and Operation Overvoltage)
Winding Structure	Coarse Wire, Fewer Turns, More Inter-layer Heat Dissipation Channels	Fine Wire, More Turns, Segmented Winding for Voltage Equalization, Thicker Insulation Layers
Core Design	Higher Magnetic Flux Density (Near Saturation Point to Reduce Volume)	Lower Magnetic Flux Density (Margin Reserved to Avoid Local Saturation from High Voltage Harmonics)
Loss Characteristics	Copper Losses Dominant (Need to Optimize Wire Cross-section for High Current)	Both Iron and Copper Losses Significant (Hysteresis Losses at High Voltage)
Cooling Method	Primarily Natural Cooling, Relying on Winding Heat Dissipation Channels	Forced Air Cooling or Natural Cooling + Heat Sink Design (To Handle Higher Temperature Rise)
Connection Terminals	Large Cross-Section Copper Busbars/Bolt Terminals, Low Contact Resistance Design	High Voltage Bushings or Epoxy Resin Potted Terminals, Long Creepage Distance Design
Size and Cost	Compact, Material-Centric Cost (High Copper/Aluminum Proportion)	Larger Size, Cost-Centric Insulation Process (Epoxy Potting, Voltage Equalization Shielding, etc.)
Typical Applications	Low Voltage Distribution Cabinets, Inverter Input, New Energy Inverter Output	High Voltage Transmission Networks, Substation Series Compensation, HVDC Converter Stations, Industrial High Voltage Inverter Systems

Product Applications

Economy is more affordable

Enhances voltage stability and reduces harmonic distortion in manufacturing plants.

Industrial Power Quality
Bolsters grid reliability and smooths power delivery in high voltage distribution networks.

Utility Substations
Supports integration of wind and solar installations by mitigating reactive power imbalances.

Renewable Energy Systems
Supplies stable, clean power for data centers, hospitals, and other essential facilities.

Critical Infrastructure

Product Advantages

Enhanced Efficiency

Optimized design minimizes energy losses and boosts overall system performance.

Robust Durability

Constructed with a reinforced iron core and advanced dry insulation for long-term reliability.

Superior Harmonic Filtering

Advanced reactor architecture effectively stabilizes voltage and suppresses electrical disturbances.

WellDone High And Low Voltage Reactor Design Drawing

FAQ

What range of High And Low Voltage Reactor products do you offer and which standards do they meet?

We deliver an extensive portfolio of High And Low Voltage Reactor solutions, including Series Reactors, Air Core Reactors, Filter Reactors, Line Reactors, Output Reactors, Dry Type Iron Core High Voltage Series Reactors, and Dry Type Iron Core Low Voltage Series Reactors. Backed by nearly two decades of industry expertise, our engineering team rigorously designs each reactor to conform with key international guidelines—encompassing ANSI, IEEE, DOE, CSA, AS, AZS, GOST, IEC, among others. Many of our products also carry UL, cUL, and CSA certifications, ensuring they meet stringent global safety and performance benchmarks.
How do you ensure the quality and reliability of your High And Low Voltage Reactors?

Our reactors are manufactured under an all-encompassing quality assurance system that scrutinizes every phase—from the selection of premium materials to exhaustive final testing. Each reactor is supported by a minimum 24-month warranty, reflecting our unwavering commitment to safety, consistency, and long-term performance. This meticulous quality control process has solidified our reputation among international clients and top industry players.
What are your production lead times, customization options, and global market reach?

For our standard reactor models, production typically spans 10 to 25 days. In addition, we provide flexible OEM/ODM services to create tailor-made solutions that precisely match project requirements. Our packaging strategies are adaptable to individual client needs, ensuring safe and efficient delivery. With an expansive global network, our reactors are successfully exported to markets across North America, Europe, South America, Australia, Asia, and Africa. For more detailed information or personalized support, please reach out via email or WhatsApp.