Transformer Manufacturing Capabilities

Olsun has the design and manufacturing capabilities under one roof to build the custom transformer solution to your specific design requirements. While many transformer companies have converted to strictly stock items, we have remained the premier choice for customers’ most sophisticated electrical needs.

Those capabilities extend to being able to handle retrofits. We make the replacement a simple process and actually have forms available that you can fill out to jumpstart the process and ensure it moves forward smoothly.

Like our tagline states: We Can Do That!

Olsun is aggressively embracing the emerging Electric Vehicle (EV) market as well. We’ve been working directly with the engineering staffs of EV charging system organizations–resulting in successful Olsun engineered-solutions encompassing both low voltage and medium voltage substations.

Our Distinguishing Power Factor is Craftsmanship

With a long history of bringing very intricate designs to life, Olsun is recognized in the industry as a brand of transformer craftsmanship. Our team of professionals applies the best methods to the best designs and the best materials. The end result is a high quality, standards compliant product.

Well Grounded Flexibility

Although uncommon applications are common for us and we have the unique ability to design specialty, one-of-a-kind transformers, we can also manufacture standard units. In reality, it’s all about giving you a proven solution rather than a simple product—no matter how complex.

See How We Have Been Winding Our Way To Excellence for Over 60 Years By Watching Our Building Process

Design Engineering - Our engineering design expertise provides transformer solutions to fit your specific needs, when an off the shelf transformer just won't do.
Coil Winding - Our coil winders have decades of experience with winding of barrel, disc and block coils with wire and foil on equipment for all shapes, sizes and ratings.
VPI Varnish System - All coils are either impregnated with epoxy varnish in a vacuum pressure chamber or coated with epoxy varnish in a dip tank. This coating is cured at a high temperature to provide excellent environmental protection.
Miter & Butt Lap Cores - The transformer cores are fabricated on our miter and butt lap core cutters and assembled on stacking table fixtures.
Core & Coil Assembly - The coils are positioned on the legs of the transformer core and the yokes are assembled to the legs with core clamps.
Enclosure Fabrication - The three dimensional model of the assembled enclosure is converted to flat layouts for each of the sheet metal parts. The programs are completed to shear, punch and form the parts on our computer controlled equipment.
Base & Clamp Fabrication - The structural steel components for welded cabinet bases and assembled core clamps are fabricated from steel channel, angle and bar stock.
Powder Coat Paint System - Olsun utilizes a multi-stage wash and pretreat system to clean and prepare steel surfaces for the electrostatically applied and oven cured powder coat paint finish.
Encapsulated Cores - The core and coil assembly is encapsulated with a mixture of polyester resin and silica sand in the welded enclosures to provide superior heat transfer and environmental protection.
Bus Bar Fabrication - The different sections of the assembled bus from the coil terminations to the customer connection are fabricated from aluminum or copper flat stock and designed to meet the current rating and electrical clearances.
Final Assembly - Our assemblers install the core and coil assembly with the assembled bus in the assembled enclosure with other purchased components and electrical connections. The different designs include interrupter switches, rotary tap switches, breaker panels, current transformers, meters, fans and heaters.
Transformer Test Systems - The ratio, insulation, loss, current and voltage tests as required by ANSI/IEEE standards are completed for all transformers before shipment to the customer.

Scene 1: Design Engineering
Scene 2: Coil Winding
Scene 3: VPI Varnish
Scene 4: Miter & Butt Lap Cores

Scene 5: Core & Coil Assembly
Scene 6: Enclosure Fabrication
Scene 7: Base & Clamp Fabrication
Scene 8: Powder Coat Paint System

Scene 9: Encapsulated Cores
Scene 10: Bus Bar Fabrication
Scene 11: Final Assembly
Scene 12: Transformer Test Systems

Download Transformer Manufacturing Capabilities Brochure