Engineered to Withstand Harsh Environments
Modern control equipment faces relentless exposure to moisture, dust, thermal cycling, and mechanical vibrations. Standard open-type transformers frequently suffer from insulation degradation, short circuits, and mechanical fatigue under these demanding conditions.
At Dezhou Xinping Electronics, our encapsulated epoxy potting transformers are engineered specifically to solve these critical failure modes. By sealing the magnetic core and copper windings in a vacuum-impregnated epoxy resin matrix, we provide an impenetrable barrier against environmental hazards.
Whether deployed in outdoor smart energy meters, high-vibration industrial machinery, or moisture-prone home appliances, our PCB-mount safety isolation transformers deliver steady, uninterrupted power.
Moisture-Proof
Hermetically sealed to prevent moisture ingress and oxidation in humid environments.
Anti-Vibration
Solid potting compound dampens mechanical shocks and prevents wire fatigue.
High Insulation
Achieve isolation voltages up to 4500VAC and beyond for maximum operator safety.
Thermal Stability
Class B to Class H insulation ratings designed to handle extreme temperatures.
Versatile Mounting Formats for Every PCB Layout
We design and manufacture encapsulated transformers in multiple configurations to fit your physical space and power delivery requirements.
Vertical Pin Type
Optimized for applications with restricted board surface area. The vertical pin architecture minimizes the footprint on the PCB.
- Power range: 0.5VA to 15VA
- Ideal for dense control boards
- Standard pitch layout for auto-insertion
Horizontal Through-Hole
Designed for superior stability in high-vibration applications. The lower center of gravity reduces mechanical stress on solder joints.
- Power range: 15VA to 100VA
- Low profile clearance designs
- Robust mechanical anchoring
Terminal Block Connection
Engineered for high-power industrial control panels. Features screw-type or pluggable terminal blocks for quick wiring and maintenance.
- Power range: Up to 150VA
- No direct PCB soldering required
- Heavy-duty industrial housing
Core Pre-Selection Factors for PCB Mount Encapsulated Transformers
Selecting the right encapsulated transformer requires balancing electrical, thermal, and mechanical parameters. Below is a detailed breakdown of the critical factors our engineering team considers for your application.
1. Working Voltage & Dielectric Withstand Voltage (Hipot Test)
Dielectric strength is the primary indicator of safety isolation quality. Depending on your industry and end product, you must select the appropriate test voltage:
- Low-voltage household PCBs: 2kVAC to 3kVAC hipot testing is typically sufficient for standard white goods and control boards.
- Medical, industrial control, & smart meter PCBs: Require ≥4500VAC isolation voltage to protect sensitive microprocessors and human operators.
- High-voltage power supply boards: Custom designs with 6kV to 12kV insulation strength are available for utility-scale electrical grids.
*Design Tip: Potting epoxy greatly improves insulation, so confirm PCB isolation clearance and creepage distances first before selecting the potting type.
2. Operating Temperature & Insulation Class
The thermal environment dictates both the choice of copper wire insulation and the type of potting compound used:
- Standard potting transformers: Utilizes Class B (130°C) epoxy, supporting an operating temperature range of -20℃ to 70℃.
- Outdoor / automotive PCB boards: Requires Class F (155°C) or Class H (180°C) high-temperature resistant potting compounds, withstanding -40℃ to 125℃.
Heat dissipation reminder: The fully encapsulated structure has poorer heat dissipation compared to open-type transformers. If your PCB has continuous high-load operation, we recommend reserving a power margin of 1.2 to 1.5 times the rated power.
3. Potting Material Type Selection
Epoxy resin is not a one-size-fits-all material. We formulate and select our potting compounds based on your specific application environment:
- Normal black epoxy potting: Cost-effective, excellent dustproof and moisture-proof properties. Perfect for general home appliances and smart meter PCBs.
- White epoxy potting: Excellent heat reflection and aesthetic integration. Highly suited for PCBs containing concentrated heat sources.
- Flame-retardant V0 grade epoxy: Mandatory for medical power supplies, industrial control, and EV charging modules. Must pass the UL94-V0 fire resistance test.
- Soft glue potting (Polyurethane/Silicone): Excellent anti-vibration and anti-cracking properties. Best suited for vehicle-mounted PCBs subjected to constant vibration.
4. PCB Installation Structure & Layout
Physical placement on the PCB affects mechanical stability and assembly efficiency:
- Vertical pin type encapsulated transformer: Small footprint, ideal for low-power PCBs (below 15VA).
- Horizontal through-hole pin transformer: Enhanced mechanical stability, designed for medium-power PCBs (15VA to 100VA).
- Terminal block potting transformer: Easy wiring and maintenance, preferred for high-power industrial control boards.
*Key Check: Confirm pin spacing, pin length, and overall height after potting to avoid physical collision with adjacent components on the PCB.
Electrical Performance Key Indicators
Our standard product specifications. We also offer customization options for non-standard voltages, taps, and physical dimensions.
| Model Series (XP) | Rated Power (VA) | Primary Voltage (V) | Secondary Voltage (V) | Hipot Isolation (VAC) | Insulation Class | Certifications |
|---|---|---|---|---|---|---|
| XP-EE20-01 | 0.5VA - 1.2VA | 115V / 230V | Single/Dual 6V - 24V | 3750V / 4500V | Class B (130°C) | UL, CE, RoHS |
| XP-EE30-05 | 1.5VA - 3.0VA | 115V / 230V | Single/Dual 6V - 24V | 4500VAC | Class B / Class F | UL, CE, RoHS |
| XP-EE38-10 | 3.2VA - 5.0VA | 115V / 230V / 380V | Single/Dual 6V - 24V | 4500VAC | Class F (155°C) | UL, CE, RoHS |
| XP-EE48-18 | 6.0VA - 12.0VA | 115V / 230V / 380V | Single/Dual 6V - 24V | 4500VAC | Class F / Class H | UL, CE, RoHS |
| XP-EE54-25 | 15.0VA - 25.0VA | 230V / 380V / 400V | Custom Tap Options | ≥4500VAC | Class H (180°C) | UL, CE, RoHS |
| XP-EI60-50 | 30.0VA - 60.0VA | 230V / 380V / 480V | Custom Tap Options | ≥4500VAC | Class H (180°C) | UL, CE, RoHS |
*Rated Power (VA): Always calculate maximum continuous load plus safety margin before selection.
Request Custom Data SheetWhy Choose Dezhou Xinping Electronics?
As a dedicated manufacturer of magnetic components, Dezhou Xinping Electronics combines advanced automated production with strict quality control systems. We understand that a transformer is the heart of your PCB's power supply, and its reliability is non-negotiable.
Our facility features state-of-the-art vacuum epoxy potting machines that eliminate air pockets within the transformer housing. This guarantees uniform dielectric properties and prevents internal corona discharges under high voltage stress.
Every single batch undergoes 100% automated testing, including turns ratio, inductance, leakage inductance, DC resistance, and high-voltage dielectric tests.
Automated Winding
High-precision winding tension control prevents wire stretching and micro-fractures.
Vacuum Impregnation
Ensures complete penetration of epoxy resin, leaving zero air bubbles inside the module.
100% Hipot Testing
Every unit is tested at rated dielectric voltage to guarantee field reliability.
Global Compliance
Materials used comply with RoHS, REACH, and UL94-V0 flammability standards.
Powering Critical Equipment Across Sectors
Our encapsulated transformers are trusted by leading manufacturers in industries where failure is not an option.
Smart Energy Meters
Utility meters are exposed to outdoor elements for decades. Our Class F/H encapsulated transformers withstand extreme temperature swings and high-voltage surges, ensuring continuous power to measurement circuits.
Industrial Automation
In factory environments, heavy machinery creates constant vibration and electromagnetic interference. Our potted construction isolates control electronics from electrical noise and physical shock.
High-End Home Appliances
Washing machines, dishwashers, and HVAC units operate in damp, warm environments. Flame-retardant V0 potting ensures compliance with household safety regulations (such as IEC/EN 60335).
Technical FAQ: Encapsulated Epoxy Transformers
Get answers to the most common engineering queries regarding PCB-mount encapsulated transformers.
Why is vacuum potting preferred over standard open encapsulation?
Vacuum potting removes all air bubbles (voids) from the resin. Under high voltages, air bubbles can cause partial discharge, leading to insulation breakdown. Vacuum potting also ensures the epoxy completely coats every winding layer, enhancing thermal transfer and mechanical resistance to shock.
What is the difference between Class B and Class F insulation?
Class B insulation is rated for a maximum operating temperature of 130°C, suitable for standard indoor control systems. Class F insulation is rated up to 155°C, offering a higher safety margin and suitability for hot environments like industrial machinery enclosures or outdoor power cabinets.
How do I calculate the power safety margin for my PCB design?
Since encapsulated transformers have lower heat dissipation than open-frame units, we recommend operating them at 70% to 80% of their rated VA capacity. For example, if your circuit draws 7VA continuously, select a transformer rated for at least 10VA (1.4x margin) to prevent heat buildup.
When should I choose soft glue potting over hard epoxy resin?
Hard epoxy resin provides superior mechanical protection and chemical resistance, but it can crack under extreme thermal cycling or constant heavy vibration. Soft glue potting (like polyurethane or silicone) remains flexible, absorbing vibrations and accommodating thermal expansion without cracking.
Are Dezhou Xinping Electronics transformers compliant with UL94-V0?
Yes. Upon request, we use flame-retardant epoxy resins that comply with UL94-V0 flammability standards. This is critical for safety certification in home appliances, medical equipment, and industrial power supplies.
Can you customize the pin layout or physical size?
Yes, customization is one of our primary strengths. We can modify bobbin designs, pin configurations, housing sizes, and electrical parameters (such as secondary voltages, multi-taps, and shielding) to fit your exact specifications.
Ready to Optimize Your PCB Power Design?
Contact the engineering team at Dezhou Xinping Electronics today. We provide free design consultations, samples for testing, and competitive volume pricing.
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