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08B1-E-0004Internet address : http://www.fujielectric.co.jpInformation in this catalog is subject to change without notice.
Printed on recycled paper
2012-10(J2012/J2012)KO-H/CTP3M Printed in Japan
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, JapanPhone : (03)5435-7111
1557 Hangnan Rd., Nanqiao Fengxian, Shanghai, THE PEOPLE’S REPUBLIC OF CHINAPhone : Tel +86-21-5718-7705
Cast Resin Transformers
Exported areas in percentage
●Maximum rating Three-phase 500 kVA Three-phase 500 kVA
Total loss comparison
Oil immersed transformer
Cast resin transformer
Mass, volume and space comparison
Oil immersedtransformer
Cast resintransformerMass
VolumeInstallation space
100%100%100%
65%48%39%
82%
100%
1 2
•Climatic class: C2•Environmental class: E2•Fire behavior class: F1
Fuji Electric Corporation has two cast resin transformer production bases:Chiba works in Japan, and Shanghai Fuji Electric Transformer Co., Ltd. in China.
1. Introduction ------------------------------------------------------12. Advantages of Cast Resin Transformer ------------------23. Features of Product--------------------------------------------34. Design Techniques --------------------------------------------55. Production Facilities -------------------------------------------66. Tests and Inspections -----------------------------------------6
7. Applications -------------------------------------------------------78. Standard Specifications ---------------------------------------99. 10 kV Series for IEC------------------------------------------10
10. 20 kV Series for IEC------------------------------------------1111. Accessories -----------------------------------------------------1212. Inquiry Specification Sheet ---------------------------------13
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 3,000 units were exported to 55 countries all over the world.
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.
C O N T E N T S
Chiba works Shanghai Fuji Electric Transformer Co.,Ltd.
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 2006.
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.
No insulation oil is required, so maintenance and inspection are easy.
42
Far EastAsiaNorth America
26
75 2 11
16
Primary voltage: 36 kV
Rated capacity: 24,000 kVA
Start of fire-test After test (completely extinguishing)
Works
Production records
IntroductionIntroduction Advantages of Cast Resin TransformerAdvantages of Cast Resin Transformer
Fire resistant
Energy saving effects Compact and light
Easy maintenance
OceaniaLatin America
AfricaMiddle Near EastEurope
1.0
L
L
1 2 3
CS
CS: Series capacitance
CE
CE: Earth capacitance
123456789
242322212019181716151413
121110
1.64
3 4
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.
(1) Weight reduction The aluminum winding weights approximately one half of the copper winding.
Vacuum-casting method realizes highly reliable, voidless molded winding with excellent partial discharge characteristics.
Void-less
All winding conductors are molded. They have remarkable humidity resistance which prevents insulation materials from deteriorating due to dust and dirt during operation.
Resistance to humidity and dust
Molded winging is highly resistant to secondary short-circuit fault and surface cracking.
Robust construction
Vacuum-casting process is carried out automatically with advanced customized facilities, to manufacture highly reliable molded winging.
High reliability
Molded insulated parts are fire resistant since they have self- extinguishing properties.
Fire prevention
1. Vacuum-casting2. Aluminum winding (Optional: copper winding)3. Sheet-winding4. Partial discharge free5. Various product lineups6. Swift delivery
Standard typeHigh efficiency typeLow-noise typeFor rectifier
High vacuum conditionResin mold mouth
Inner pattern
Epoxy resin
Windings
Outer pattern
Cross section of molded winding(Arrangement of sheet winding)
Each part of aluminum sheet winding is sufficiently molded
Condition of molding epoxy resin
(3) Downsizing Sheet winding has high lamination factor.
(5) Surge stability Sheet winding is effective to reduce potential oscillation caused by surge voltage.
(4) High insulation reliability In case of sheet winding, the voltage between turns is only for one turn.
(2) Large mechanical strengthAluminum’s thermal expansion coefficient is close to resin, thus reducing thermal stress effectively.
Copper : Aluminum
100 : 61 1 : 1.64
8.9 : 2.7 3.3 : 1
100 : 50
Material
Aluminum
Copper
Epoxy resin
Thermal expansion coefficient [mm/mm.h.℃]
2.3 x 10-5
1.6 x 10-5
3.3 x 10-5
Copper > Aluminum
Thermal stress acting
Aluminum sheet winding
Thermal stress acting on winding
Potential distribution Cylindrical winding
Sheet winding
Transformer winding
Surge voltage
Earth
Epoxy resin
Sheet winding Cylindrical winding
Sheet windingCylindrical winding
Company standard: ● All units are subject to partial discharge test. ● Applied voltage is twice the operating voltage.
● Partial discharge is less than 10 pC.
Aluminum winding
Sheet winding
Vacuum-casting
Features of ProductFeatures of Product
Partial discharge freeWe 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.
Comparison of the weight in the same resistance
Conductivity [%]Cross sectional area ratio
Gravity [g/cm3]Gravity ratio
Mass ratio
5 6
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.
a) Routine tests: ・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 ・Induced AC withstand voltage test ・Partial discharge measurement
b) Type tests: ・Lightning impulse test ・Temperature-rise test ・Measurement of sound level
ISO9001Original registration: 23nd August 1994Registration date: 23nd August 2009
ISO14001Original registration: 24th March 1996Registration date: 24th March 2007
ISO certifications of Chiba works
Vacuum-casting plant High voltage foil winding machine
Core cutting machine Partial discharge measurement
Electric field analysis
The test items:
Design TechniquesDesign Techniques Production FacilitiesProduction FacilitiesTests and InspectionsTests and Inspections
Thermal stress analysis
ISO certification of Shanghai FujiElectric Transformer Co., Ltd.
7 8
● Multistory buildings● Hospitals● Hotels● Laboratories● Shopping centers● Building complexes● Schools● Art galleries● Theaters● Underground shopping centers● Petrochemical plants● Industrial complexes● Underground railways● Railway substations● Tunnels● Cranes● Water and sewerage plants● Power supply for construction sites● Ships● Refuse disposal plants● Wind power sites
Sites where there are airborne contaminants and extremely severe environments (Chemicals, steels, automobiles, underground construction sites etc.)
Sites where compact size and light weight are required(Urban multistory buildings, etc.)
Sites where high reliability is required (Public facilities, etc.)
Sites where fire prevention is the highest priority(Stadiums, hospitals, underground shopping centers, hotels, etc.)
The exterior appearance of transformer (17000 kVA, 22/6.6 kV)
Sites where easy maintenance is required (Power stations, industrial complexes, buildings, underground railways, etc.)
Transformer cubicle for substation in building(5000 kVA)
Sites where high reliability and easy maintenance are required (Public facilities such as museums, airports, etc.)
The exterior appearance of transformer(2700 kVA, 33/0.59 kV)
Wind power site
ApplicationsApplications
Fig.2
1520
40
φ13
t8
XSX
o a b c
B C
XN XH XH
A
YL YH
YS
ZL
ZH
Z
YXSX
o a b cXN XH XH
A B C
YSY
ZLZ
ZH
YH YH
1520
31.5
φ13
t3.5 Fig.1
2040
40
25
2-φ13
t8 Fig.3
4080 100
100
2040
25
4-φ14
t8 Fig.4
50 2550
30
4-φ18
t8 Fig.5
120
50100
50100
2550
30
8-φ18
t8 Fig.6
50
M8
φ25
Nameplate Nameplate
Primaryterminals
Primaryterminals
Secondary terminals
No-load tapchanger
No-load tapchanger
Groundingterminals
Groundingterminals
Install holes Install holes
Secondary terminals
109
※: Contact us for any other requests.
Standard
Normal servicecondition
Altitude [m]
Number of phases
Frequency [Hz]
Highest voltage [kV]
Separate-source voltage withstand
Lightning impulseinsulation class
Insulation class
Insulation system temp. [℃]
Average temp. rise limit [K]
Rated capacity [kVA]
Standard
Number of phasesFrequency [Hz]Rated primary voltage and tap voltage [kV]Rated secondary voltage [kV]Rated capacity [kVA]
Connection symbolInsulation classInsulationlevels[kV]
IEC 60076-11: 2004
40
30/day, 20/year
−25 (Outdoor), −5 (Indoor)
Not more than 1000
3
50, 60
12
28
75
F
155
100
30
50
80
100
125
160
200
250
315
400
500
630
800
1000
1250
1600
2000
2500
3150
4000
5000
6300
8000
10000
12500
16000
20000
IEEE Std C57.12.01-1998
40
30/day
−30
Not more than 1000
3
60
15
31(34, 37)
60(95, 110)
−
150
90
15
30
45
75
112.5
150
225
300
500
750
1000
1500
2000
2500
3750
5000
7500
10000
12500
15000
20000
Highest [℃]
Average [℃]
Lowest [℃]
Standard [kV](Option)
Standard [kV](Option)
24
50
95(125)
36
70
145(170)
25
37(40, 50)
110(125, 150)
34.5
50(70)
150(200)
Rated capacity [kVA]
30 50 80 100 125 160 200 250 315 400 500 630 630 80010001250160020002500
Rated capacity [kVA]
30 50 80 100 125 160 200 250 315 400 500 630 UK=4 % 630 UK=6 % 80010001250160020002500
Total mass [kg]
24534846050453563078092510801300162017601800209024802800342042005100
Dimensions [mm]X76081081081096010801100115011901268150016001600167016901740184020502050
No-load loss [W]
190 270 370 400 470 550 630 720 870 980115013501300152017702090245033204000
No-load current [%]
2.82.01.81.71.41.01.30.90.70.70.50.60.60.50.50.50.50.50.5
Impedance voltage [%]
4
6
Load loss at120℃ [W]
710 1000 1380 1570 1800 2100 2530 2750 3400 3950 4800 5880 5900 6900 8130 9600117001420017170
IEC 60076-11: 2004
350F10.50-F10.25-R10.00-F9.75-F9.500.430, 50, 80, 100,125, 160, 200, 250,315, 400, 500Yyn0 (Dyn11)F28375
Separate-source Primaryvoltage withstand SecondaryLightning impulse Primary
Y480500880880900920920920920920920920920920920920117011701170
Z690760810870885927997113912391299137914041389144416541699185418312006
XS450450550550550550550660660660820820820820820820107010701070
YS420420420420420840840840840820820820820820820820107010701070
XH236256272274286308316328332352433479479501505523553609641
XN90909595140140140140140140130130130130155155245245245
YH244254263275259273268280279302433455455467471477492525537
YL148158174178165181183190194214187191181196199202211227229
ZL723783810870885927997113912391299137914041389144416541699185418312006
TerminalsPFig. 1
Fig. 2
SFig. 3
Fig. 4
Fig. 5
Fig. 6
ZH5255755856456556777658899881029103110341042109612661312144614231578
630, 800, 1000,1250,1600, 2000, 2500Dyn11 (Yyn0)
●30 to 400 kVA ●500 to 2500 kVA
Standard specifications
Standard SpecificationsStandard Specifications 10 kV Serries for IEC10 kV Serries for IEC
Technical data
Dimensions and masses (without protection enclosure)Hole[φ]
15
20
Primary terminals
Secondary terminals
Install holes
Lifting lugs
Nameplate
No-lad tap changer
Grounding terminals
Neutral terminals
11 12
Rated capacity [kVA]
315 400 500 630 80010001250160020002500
Total mass [kg]
1500165019002100250029003400450055006500
Dimensions [mm]X1600160016001600169018002000210021502200
TerminalsP SFig. 1 Fig. 2 Fig. 3
Fig. 4
Fig. 5
Y92092092092092011001200117011701170
Z1619162816951729179418241919199120612067
XS820820820820820820820107010701070
YS82082082082082010001100107010701070
XH500500522532552568588628672714
XN155155130130130155155260260260
YH587587598607613619630650672692
YL174180183194191208215217236285
ZH1113112711991203124312081303131513651450
YN
289308360
XSX
XH XH XN YHYN
YL
Z
ZH
YSY
20
2025 40
4080
501004060
25
2040
25
2550
30
50 50100
50100
2550
30
M8
2-φ13φ13 4-φ14 4-φ18 8-φ18 φ25
t6 Fig.1 t8 Fig.2 t8 Fig.3 t8 Fig.4 2-t8 Fig.5
Technical data
20 kV Series for IEC20 kV Series for IEC
Standard specifications
Dimensions and masses (Without protection enclosure)
Nameplate The nameplate is easy to read with white letters on
a black background.
No-voltage tap changing terminals The tap voltage can be changed by switching the shorting bar connector.
Lifting lugs Four lifting lugs are provided as standard fixtures on the transformer body.
Protection enclosure An optional simplified protective enclosure can be installed.
Thermometer An optional Thermometer can be installed.
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.)
Warning label A danger label is attached to warn against contacting the surface of the high-potential winding.
AccessoriesAccessories
Rated capacity [kVA]
315 400 500 630 80010001250160020002500
No-load loss [W]
960114013301510173020402360276032003820
No-load current [%]
0.70.6
0.5
0.4
Impedance voltage [%]
6
Load loss at120℃ [W]
4060 4820 5760 6800 8220 973011480137901628019270
Standard
Number of phasesFrequency [Hz]Rated primary voltage and tap voltage [kV]Rated secondary voltage [kV]Rated capacity [kVA]Connection symbolInsulation classInsulationlevels[kV]
IEC 60076-11: 2004
350F21.0-F20.5-R20.0-F19.5-F19.00.4315-2500Dyn11F503125
Separate-source Primaryvoltage withstand SecondaryLightning impulse Primary
Hole[φ]
20202020202020202020
Notes)Notes)
13 14
Item No.15 Dyn11=Δ(Delta)/Y(Star) Yyn0=Y(Star)/Y(Star)
Item No.17 AN;Naturally-cooled type AF;Forced-air-cooled type with cooling fan
0)General
1 Delivery date desired
2 Delivery condition
3 Apllication (Purpose to use)
1)Basic specification(Essentials for quotation)
4 Number of units
5 Product type
6 Standards
7 Ambient temperature
8 Altitude
9 Rated capacity
10 Number of phases
11 Frequency
12 Rated primary voltage
13 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
20 Wheels
21 Resistance thermometer bulb (Pt 100Ω)
22 Anti-vibration pads
23 Protection enclosure
Degree of protection for enclosure
3)Special test (Option)
24 Temperature rise test
25 Lightning impulse test
26 Measurement of sound level
4)Other request items (Option)
27 Witness test
28 Other request item
Year Month Day
□ FOB Shanghai □ Other
Buildings, Factories, Crane and so on
Cast resin transformer
□ IEC60076-11 □ Other
□ Standard -5~ 40 ℃ □ Other
□ Standard 0~ 1000 m □ Other
kVA
□ 1 □ 3
□ 50Hz □ 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
□ IP20 □ IP23 □ Other
□ No □ Yes
□ No □ Yes
□ No □ Yes
□ No □ Yes
Inquiry Specification Sheet for Cast Resin TransformerInquiry Specification Sheet for Cast Resin Transformer MemoMemo
08B1-E-0004Internet address : http://www.fujielectric.co.jpInformation in this catalog is subject to change without notice.
Printed on recycled paper
2012-10(J2012/J2012)KO-H/CTP3M Printed in Japan
Gate City Ohsaki, East Tower, 11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, JapanPhone : (03)5435-7111
1557 Hangnan Rd., Nanqiao Fengxian, Shanghai, THE PEOPLE’S REPUBLIC OF CHINAPhone : Tel +86-21-5718-7705
Cast Resin Transformers
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