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