Cast Resin Transformers 08B1-E-0004
Introduction Advantages of Cast Resin Transformer Works Fuji Electric Corporation has two cast resin transformer production bases: Chiba works in Japan, and Shanghai Fuji Electric Transformer Co., Ltd. in China. Fire resistant Epoxy resin is safe against fire since it has self-extinguishing properties and is fire resistant. Our cast resin transformer passed the all tests of IEC 60076-11 in 06. Chiba works Shanghai Fuji Electric Transformer Co.,Ltd. Climatic class: C2 Environmental class: E2 Fire behavior class: F1 Production records Fuji Electric s cast resin transformer works in Chiba was established in 1974, which became the first cast resin transformer works in Japan. Chiba works has produced over 90,000 cast resin transformers of which,000 units were exported to 55 countries all over the world. Exported areas in percentage 7 5 2 1 1 42 Energy saving effects Compact and light Since the beginning of operation in 1998, Shanghai Fuji Electric Transformer has been awarded various certifications including ISO 9001 and has produced over 10,000 cast resin transformers. 16 A sheet coil and wound core construction minimize total loss remarkably, thus reducing the electricity charges and saving energy. Cast resin transformer is made smaller and lighter comparing with oil-immersed transformer. Thus it can be installed in slim type cubicle, which minimizes the installation space. Three-phase 0 kva Three-phase 0 kva Mass, volume and space comparison Primary voltage: 6 kv 26 : 24,000 kva Far East Asia North America Africa Middle Near East Europe Oceania Latin America C O N T E N T S 1. Introduction ------------------------------------------------------1 7. Applications -------------------------------------------------------7 2. Advantages of Cast Resin Transformer ------------------2 8. Specifications ---------------------------------------9. Features of Product-------------------------------------------- 9. 10 kv Series for IEC ------------------------------------------10 4. Design Techniques --------------------------------------------5 10. kv Series for IEC ------------------------------------------11 5. Production Facilities -------------------------------------------6 11. Accessories -----------------------------------------------------12 6. Tests and Inspections -----------------------------------------6 12. Inquiry Specification Sheet ---------------------------------1 Total loss comparison % Oil immersed transformer 65% Cast resin transformer Mass 82% % Volume 9% Easy maintenance % 48% % Cast resin transformer Installation space Oil immersed transformer No insulation oil is required, so maintenance and inspection are easy. 1 2
Features of Product 1. Vacuum-casting 2. Aluminum winding (Optional: copper winding). Sheet-winding 4. Partial discharge free 5. Various product lineups 6. Swift delivery type High efficiency type Low-noise type For rectifier Aluminum winding The aluminum winding weights approximately one half of the copper winding. Conductivity [%] Cross sectional area ratio Gravity [g/cm ] Gravity ratio Copper : Aluminum : 61 1 : 1.64 8.9 : 2.7. : 1 Aluminum s thermal expansion coefficient is close to resin, thus reducing thermal stress effectively. Material Aluminum Copper Epoxy resin Thermal expansion coefficient 2. x 10-5 1.6 x 10-5. x 10-5 [mm/mm.h. ] Mass ratio : Vacuum-casting Cast resin transformer is manufactured with vacuum casting method using metal pattern, its resin layer is thick and the surface is smooth. Thus it has following excellent characteristics. L L 1.64 1.0 Thermal stress acting Aluminum sheet winding Vacuum-casting method realizes highly reliable, voidless molded winding with excellent partial discharge characteristics. Copper > Aluminum Epoxy resin Molded insulated parts are fire resistant since they have selfextinguishing properties. High vacuum condition Resin mold mouth Epoxy resin Sheet winding Sheet winding has high lamination factor. Sheet winding is effective to reduce potential oscillation caused by surge voltage. All winding conductors are molded. They have remarkable humidity resistance which prevents insulation materials from deteriorating due to dust and dirt during operation. Windings Potential distribution Cylindrical winding Sheet winding Molded winging is highly resistant to secondary short-circuit fault and surface cracking. Vacuum-casting process is carried out automatically with advanced customized facilities, to manufacture highly reliable molded winging. Inner pattern Cross section of molded winding (Arrangement of sheet winding) Each part of aluminum sheet winding is sufficiently molded Outer pattern In case of sheet winding, the voltage between turns is only for one turn. Surge voltage Transformer winding C S: Series capacitance C E: Earth capacitance C S C E Earth Partial discharge free We have developed the materials, structures and manufacturing systems that realize excellent partial discharge characteristics. From the viewpoint of cast resin transformer s reliability, the excellent partial discharge characteristics is the most important. Thus we have adopted the following stricter standard than any other standards. Company standard: All units are subject to partial discharge test. Partial discharge is less than 10 pc. Applied voltage is twice the operating voltage. 4
Design Techniques Production Facilities Tests and Inspections Electric field analysis Thermal stress analysis Vacuum-casting plant High voltage foil winding machine The insulation of cast resin transformer is composed of resin-air composite insulation. The distributed voltages of individual transformer parts depend on their respective dimensions. Thus, appropriate dimensions for insulation are designed with electric field analysis of the individual parts of the winding including air space. Molded winding composed of conductor and insulating material (e.g regin) is subjected to thermal stresses due to the difference in the thermal expansion coefficient between conductor and resin, and the thermal distribution in the winding block, where the winding temperature varies with the load fluctuation of the transformer. The stress value obtained in thermal stress analysis is used to design optimum winding structure for high crack-resistance of winding. Core cutting machine Partial discharge measurement The test items: Measurement of insulation resistance Measurement of winding resistance Measurement of voltage ratio and check of phase displacement Measurement of short-circuit impedance and load loss Measurement of no-load loss and current Separate-source AC withstand voltage test ISO9001 Original registration: 2 nd August 1994 Registration date: 2 nd August 09 Induced AC withstand voltage test Partial discharge measurement Lightning impulse test Temperature-rise test Measurement of sound level ISO101 Original registration: 24th March 1996 Registration date: 24th March 07 ISO certifications of Chiba works ISO certification of Shanghai Fuji Electric Transformer Co., Ltd. 5 6
Applications Multistory buildings Hospitals Hotels Laboratories Shopping centers Building complexes Schools Art galleries Theaters Underground shopping centers Petrochemical plants Industrial complexes Underground railways Railway substations Sites where there are airborne contaminants and extremely severe environments (Chemicals, steels, automobiles, underground construction sites etc.) Sites where easy maintenance is required (Power stations, industrial complexes, buildings, underground railways, etc.) Tunnels Cranes Sites where compact size and light weight are required (Urban multistory buildings, etc.) Water and sewerage plants Power supply for construction sites Ships Refuse disposal plants Wind power sites Transformer cubicle for substation in building (00 kva) Sites where high reliability and easy maintenance are required (Public facilities such as museums, airports, etc.) Sites where high reliability is required (Public facilities, etc.) The exterior appearance of transformer (17000 kva, 22/6.6 kv) Sites where fire prevention is the highest priority (Stadiums, hospitals, underground shopping centers, hotels, etc.) The exterior appearance of transformer (2700 kva, /9 kv) Wind power site 7 8
Specifications 10 kv Serries for IEC IEC 60076-11: 04 IEEE Std C57.12.01-1998 specifications Technical data Normal service condition Altitude Number of phases Frequency Highest voltage Separate-source voltage withstand Lightning impulse insulation class Highest [ ] Average [ ] Lowest [ ] (Option) (Option) [m] [Hz] Insulation class Insulation system temp. [ ] Average temp. rise limit [K] /day, /year (Outdoor), 5 (Indoor) Not more than, 60 12 24 28 75 95 (1) F 6 70 145 (170) /day Not more than 60 15 1 (4, 7) 60 (95, 110) 1 90 15 7 (, ) 110 (1, 1) 4.5 (70) 1 (0) Number of phases Frequency [Hz] Rated primary voltage and tap voltage Rated secondary voltage Connection symbol Insulation class Insulation Separate-source Primary levels voltage withstand Secondary Lightning impulse Primary IEC 60076-11: 04 F10.-F10.-R10.00-F9.75-F9. 0.4,, 80,, 1, 160, 0, 2, 15, 0, 0 Yyn0 (Dyn11) F 28 75 6,,, 12,, 00, 20 Dyn11 (Yyn0) 80 1 160 0 2 15 0 0 6 6 12 00 20 No-load loss [W] 190 270 70 0 470 5 6 7 870 980 11 1 10 15 1770 90 24 00 Load loss at 1 [W] 710 180 1570 1 2 27 9 4 5880 5900 6900 81 9600 11700 1 17170 No-load current [%] 2.8 2.0 1.8 1.7 1.4 1.0 1. 0.9 0.7 0.7 0.6 0.6 Impedance voltage [%] 4 6 80 1 160 0 2 15 0 0 6 12 00 20 1 00 00 45 75 112.5 1 2 0 0 7 10 00 20 7 00 Dimensions and masses (without protection enclosure) 80 1 160 0 2 15 0 0 6 UK=4 % 6 UK=6 % 12 00 20 Dimensions X Y 760 480 810 0 810 880 810 880 960 900 1080 9 1 9 11 9 1190 9 1268 9 10 9 9 9 1670 9 1690 9 17 9 18 1170 1170 1170 690 760 810 870 885 927 997 119 129 1299 179 14 189 1444 1654 1699 1854 181 06 4 4 5 5 5 5 5 660 660 660 4 4 4 4 4 8 8 8 8 XH 26 6 272 274 286 8 16 28 2 52 4 479 479 1 5 52 55 609 641 XN 90 90 95 95 1 1 1 1 1 1 1 1 1 1 245 245 245 244 4 26 275 9 27 268 280 279 2 4 455 455 467 471 477 492 5 57 YL 148 158 174 178 165 181 18 190 194 214 187 191 181 196 199 2 211 227 229 5 575 585 645 655 677 765 889 988 1029 101 104 1042 1096 1266 112 1446 142 1578 [mm] L Total mass [kg] Hole[] 72 78 810 870 885 927 997 119 129 1299 179 14 189 1444 1654 1699 1854 181 06 245 48 460 4 55 6 780 9 1080 10 16 1760 1 90 2480 2 4 5 15 Terminals P S Fig. 1 Fig. Fig. 2 Fig. 4 Fig. 5 Fig. 6 60 0 0 120 0 70 0 120 XN XH XH o a b c A B C Nameplate Secondary terminals YL Primary terminals Nameplate XN XH XH o a b c A B C Secondary terminals Primary terminals 000 000 L L : Contact us for any other requests. No-load tap changer No-load tap changer Grounding terminals 1.5 X Grounding terminals Y Install holes X 80 1 Y Install holes φ1 15 t.5 Fig.1 φ1 15 t8 Fig.2 2-φ1 t8 Fig. 4-φ14 t8 Fig.4 4-φ18 t8 Fig.5 8-φ18 t8 Fig.6 M8 φ 9 10
kv Series for IEC Accessories specifications IEC 60076-11: 04 Technical data No-load loss [W] Load loss at 1 [W] No-load current [%] Impedance voltage [%] Lifting lugs Four lifting lugs are provided as standard fixtures on the transformer body. Nameplate The nameplate is easy to read with white letters on a black background. Number of phases Frequency [Hz] Rated primary voltage and tap voltage Rated secondary voltage Connection symbol Insulation class Insulation Separate-source Primary levels voltage withstand Secondary Lightning impulse Primary F21.0-F.5-R.0-F19.5-F19.0 0.4 15-20 Dyn11 F 1 15 0 0 6 12 00 20 960 11 1 1510 17 260 2760 60 4 5760 6 82 97 11480 1790 16280 19270 0.7 0.6 0.4 6 Dimensions and masses (Without protection enclosure) 15 0 0 6 12 00 20 Dimensions X Y 9 9 9 9 1690 9 1 1 00 10 2 1170 21 1170 20 1170 1619 1628 1695 1729 1794 1824 1919 1991 61 67 1 XH 0 0 522 52 552 568 588 628 672 714 XN 1 1 1 260 260 260 587 587 598 607 61 619 6 6 672 692 YL 174 180 18 194 191 8 215 217 26 285 111 1127 1199 1 124 18 1 115 165 14 [mm] YN 289 8 60 Total mass [kg] Hole[] 10 16 1900 2 20 2900 50 60 Terminals P S Fig. 1 Fig. 2 Fig. Fig. 4 Fig. 5 No-voltage tap changing terminals The tap voltage can be changed by switching the shorting bar connector. Warning label A danger label is attached to warn against contacting the surface of the high-potential winding. Nameplate Lifting lugs XH XH XN YN YL Secondary terminals Neutral terminals Primary terminals No-lad tap changer X Grounding terminals Y Install holes Earthing terminals with clamping bolts Two ground terminals are provided at the lower frame ends: one on the primary side and one on the secondary side. (One of these ground terminals is in use.) Protection enclosure An optional simplified protective enclosure can be installed. Thermometer An optional Thermometer can be installed. 60 80 φ1 2-φ1 4-φ14 4-φ18 8-φ18 M8 φ t6 Fig.1 t8 Fig.2 t8 Fig. t8 Fig.4 2-t8 Fig.5 11 12
Inquiry Specification Sheet for Cast Resin Transformer Memo 0)General 1 Delivery date desired 2 Delivery condition Apllication (Purpose to use) Year Month Day FOB Shanghai Other Buildings, Factories, Crane and so on 1)Basic specification(essentials for quotation) 4 Number of units 5 Product type 6 s 7 Ambient temperature 8 Altitude 9 10 Number of phases 11 Frequency 12 Rated primary voltage 1 Rated secondary voltage 14 Tapping range of primary voltage 15 Vector group Connection of primary windings Connection of secondary windings 16 Impedance voltage 17 Cooling method 2)Optional accessories 18 Thermometer 19 Cooling fan Wheels 21 Resistance thermometer bulb(pt Ω) 22 Anti-vibration pads 2 Protection enclosure Degree of protection for enclosure )Special test Option 24 Temperature rise test Lightning impulse test 26 Measurement of sound level 4)Other request items (Option) 27 Witness test 28 Other request item Cast resin transformer IEC60076-11 Other -5 Other 0 m Other kva 1 Hz 60Hz Other kv kv ± 2.5% x 2 Other Dyn11 Yyn0 Other Delta Star Delta Star Star with newtral point Manufacturer standard Other % AN AF No Yes No Yes No Yes No Yes No Yes No Yes IP IP2 Other No Yes No Yes No Yes No Yes Item No.15 Dyn11=Δ(Delta)/Y(Star) Yyn0Y(Star)/Y(Star) Item No.17 ANNaturally-cooed type AFForced-air-cooled type with cooling fan 1 14
Printed on recycled paper Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-002, Japan Phone : (0)545-7111 7 Hangnan Rd., Nanqiao Fengxian, Shanghai, THE PEOPLE S REPUBLIC OF CHINA Phone : Tel +86-21-5718-7705 Internet address : http://www.fujielectric.co.jp Information in this catalog is subject to change without notice. 12-10(J12/J12)KO-H/CTPM Printed in Japan