Winding-Conductor Selection Can Eliminate Transformer Thermal Margin

What the evidence preview establishes

Electrical and construction comparisons linked the overheated condition to winding conductors that were substantially larger than those in a comparison design. The lower winding resistance was consistent with increased current and loss of thermal margin; dielectric breakdown between windings was not observed.

Why this case matters

A winding change that lowers DC resistance can alter system current and power dissipation even when the transformer appears well made. Electrical requirements, conductor geometry and application-level thermal margin must be reviewed together.