Custom ER70 High Frequency Pulse Transformer For Industrial High Voltage Generator

The ER70 is a high voltage transformer built on a stacked ER70 ferrite core structure, designed to generate a high voltage output from a low voltage switching input in industrial equipment. It steps a switched primary voltage up to the kilovolt range through a high turns ratio secondary, while maintaining full galvanic isolation between the control side and the high voltage output. This is the component that makes it possible to produce several kilovolts from a low voltage DC supply inside equipment that has no mains connection at high potential.

A high voltage transformer is not simply a standard transformer with more secondary turns. The dominant design problem is insulation rather than magnetics. Every layer of the secondary winding sits at a progressively higher potential relative to the core, the primary and its own neighbouring layers, so layer insulation, creepage distance and partial discharge behaviour determine whether the part survives in service. The ER70 addresses this with a segmented high voltage secondary, interlayer insulation, generous creepage separation between primary and secondary sections, and epoxy potting at the critical stress points visible on the assembly.

The stacked ER core structure provides the cross sectional area required to handle the flux without saturating, while keeping the magnetic path closed so that stray field and audible noise stay low. Low acoustic noise is a genuine requirement in this class of product, because a high voltage transformer driven at switching frequency will produce audible magnetostriction and winding movement if the assembly is not properly impregnated and mechanically secured. The winding is tape wrapped, cable tied and bonded so the geometry cannot shift under electrical stress or vibration.

The product is manufactured to order. Output voltage, turns ratio, power rating, insulation system, potting arrangement, lead type and lead length are all defined against the customer circuit, the required output voltage and the safety standard the finished equipment must meet.

Note: output voltage, power rating, turns ratio and insulation specification are defined per application. Approval drawings and samples are issued for your confirmation before mass production.

• Segmented high voltage secondary. The secondary is divided into multiple isolated sections rather than wound as one continuous layer stack. This divides the total output voltage across several segments, so the voltage stress between any two adjacent turns stays low. Segmentation is the single most effective measure against partial discharge, which is the mechanism that erodes insulation from the inside and causes a high voltage transformer to fail months after it passed its initial test.
• Reinforced insulation at the stress points. Polyimide tape provides the interlayer barrier, and epoxy potting is applied where the field concentrates, particularly at lead exits and winding terminations. These are the locations where a high voltage design actually breaks down, so they receive dedicated treatment rather than a uniform coating.
• Generous creepage separation. Primary and secondary sections are physically separated with defined creepage and clearance distances, so surface tracking cannot bridge the isolation barrier over time in a humid or contaminated environment.
• Stacked ER core for flux capacity. Stacking the core increases the effective cross sectional area so the design carries the required flux without approaching saturation, while the closed magnetic path keeps stray field low and reduces coupling into nearby control electronics.
• Low acoustic noise construction. The winding assembly is impregnated, tape wrapped and mechanically secured with cable ties, so there is no free winding movement under electrical stress. In equipment that operates in a laboratory, a medical room or an office environment, audible transformer noise is a product level defect, and it is prevented mechanically at the source.
• Stable output over life. Impregnation locks the winding geometry, so turns ratio and leakage inductance do not drift with vibration or thermal cycling. The output voltage the equipment produces on day one is the output voltage it produces years later.
• Designed around your driver circuit. Topology, input voltage, switching frequency, required output voltage and load current define the design. We do not ask you to redesign your driver around a catalogue part.

• Industrial high voltage power supplies and high voltage generators
• Laser equipment and laser power supply modules
• Ozone generators and air treatment systems
• Electrostatic precipitators and industrial dust collection equipment
• Plasma generation and surface treatment equipment
• X ray and industrial non destructive testing equipment
• Ion generators and electrostatic charging or neutralising systems
• Capacitor charging power supplies
• Industrial ignition and arc starting systems
• Electrostatic spraying and coating equipment
• High voltage test and measurement instrumentation
• Scientific and laboratory instrumentation requiring a stable kilovolt supply

Typical circuit positions include the step up transformer in a flyback or resonant high voltage generator, the transformer feeding a Cockcroft Walton multiplier stage, and the isolation transformer in a capacitor charging supply where output voltage must rise in a controlled manner.

• Established in 2000, with 26 years of continuous experience in magnetic components and power solutions for industrial control and power electronics.
• A 10,000 square metre self owned factory with 8 complete production lines, which keeps capacity, process control and delivery schedule in house rather than subcontracted.
• High voltage and high frequency transformer design are core in house capabilities, supported by a 20 person R&D team and a 20 person quality control team covering incoming material and outgoing product inspection.
• Fast commercial response: quotation within 3 days, sample production within 7 days.
• Low entry barrier for new projects: minimum order quantity of 100 pieces, so a design can be qualified without committing to a large first order.
• Certified management system: ISO 9001 for quality and ISO 14001 for environment. Products comply with RoHS and REACH, with CE, CB, UL and cUL coverage across the product range.
• Annual export value of 42 million USD, serving North America, Northern Europe, South America and Southeast Asia, including established industrial equipment brands.
• An 11 person export team providing direct technical communication in English, so engineering questions are resolved without a trading company in between.

• Built to survive, not just to pass the first test. Segmented winding and targeted potting address partial discharge, which is the real failure mechanism in high voltage magnetics and the reason many low cost designs fail in the field rather than on the bench.
• High efficiency at the operating point. Core grade and winding construction are selected against your switching frequency, so loss is minimised where the equipment actually runs.
• Genuinely low acoustic noise. Mechanical bonding and impregnation eliminate winding movement, which matters in medical, laboratory and indoor industrial environments.
• Stable performance over a long service life. Locked winding geometry keeps output voltage and inductance within specification year after year.
• Backed by a 5 year warranty, extended to 20 years for qualifying special industry applications. The warranty term reflects the construction standard rather than a marketing position.
• Full OEM and ODM customisation. Output voltage, power, insulation system, lead arrangement and mounting are all defined to your requirement.
• Free electrical design service. Send the specification and we will propose core, turns, segmentation and insulation, then confirm the design with samples.

Q1. What is your minimum order quantity?

MOQ is 100 pieces for this product, which allows a new design to be qualified and released without committing to a large first order.

Q2. What payment methods do you accept?

We accept T/T, PayPal and Western Union.

Q3. How quickly can you quote and produce samples?

Quotation is issued within 3 days of receiving your specification, and sample production is completed within 7 days. Mass production lead time is confirmed with the quotation and depends on quantity and complexity.

Q4. What output voltage can you achieve?

Output voltage is defined per design and typically ranges from 1 kV to 30 kV. Tell us the required output voltage, the load current or power, and the input and switching conditions of your driver, and we will confirm feasibility before you order.

Q5. How do you prevent insulation breakdown at high voltage?

Through segmented secondary construction that limits the voltage stress between adjacent turns, polyimide interlayer insulation, defined creepage and clearance separation between primary and secondary, epoxy potting at the points of highest field concentration, and vacuum impregnation to eliminate voids where partial discharge would otherwise initiate.

Q6. Can you design the transformer to match my existing driver circuit?

Yes, this is the normal case. Send us the topology, input voltage, switching frequency, required output voltage and load current, plus the available mechanical space, and our engineers will define core, turns ratio, segmentation and insulation, then confirm the design with samples.

Q7. What warranty do you provide?

We provide a 5 year warranty as standard, extended to 20 years for qualifying special industry applications. Confirm the applicable term for your application with your sales contact when the specification is finalised.

Q8. Can the lead type, lead length and mounting be customised?

Yes. High voltage lead specification, lead length, low voltage termination type, bracket arrangement and overall mechanical envelope are all defined to your drawing.

Q9. Is the transformer suitable for driving a voltage multiplier?

Yes. We regularly design transformers intended to feed a Cockcroft Walton or similar multiplier stage. Tell us the multiplier configuration and the final output voltage target so the transformer output and the multiplier stage are matched correctly.

Q10. How is the transformer tested before shipment?

Inductance, turns ratio, DC resistance and high potential isolation are tested on production equipment before packing. Test voltage and conditions are stated on the approval drawing so your incoming inspection measures the part under the same conditions we do.

Q11. What certifications and material compliance do you provide?

Manufacturing runs under ISO 9001 and ISO 14001. Products comply with RoHS and REACH, and UL recognised insulation materials can be specified on request. Designs follow IEC 61558 and IEC 62368 principles. If your destination market requires an additional approval, tell us the country before ordering.

Q12. Can you reverse engineer a high voltage transformer I am already using?

Yes. Send us a physical sample together with the circuit conditions and the output requirement, and we will produce a matched replacement with the same mechanical envelope and electrical behaviour, confirmed against your equipment with samples before mass production.

Q13. Do you have overseas warehouses or offer drop shipping?

No. All goods ship directly from our factory in Guangdong, China. We support FOB, CIF, DDU and DDP terms.

Q14. Can you provide samples and drawings before mass production?

Yes. We issue approval drawings and physical samples for your confirmation, and mass production does not begin until you approve them.