Typical Specification For Epoxy Cast Coil Dry-Type Transformers

PO Box 9210 So. Burlington, VT 05407 (800) 292-6792 or (802) 860-7200 info@dynapower.com www.dynapower.com

TYPICAL SPECIFICATION FOR EPOXY CAST COIL DRY-TYPE TRANSFORMERS

This specification is designed to describe a quality cast coil transformer with sufficient detail to insure that true cast coil transformers will be offered. The requirements can be met by adequately equipped and experienced manufacturers with the engineering, production and test capabilities to do so. QUALIFICATIONS The transformer shall be manufactured in the United States by an organization that has been engaged in the production of epoxy cast coil transformers for at least ten years. Transformers shall bear the nameplate of the company who actually built the core and coil assembly and shall not be brand labeled to a third party. Acceptable manufacturers include the following: Dynapower Corporation, South Burlington, VT No other sources will be accepted without written approval from the engineer prior to bid. TECHNICAL DETAILS Example values: 4 1500/2000 kVA AA/FA 3 60 Hz (2) 2.5% FCAN & FCBN 80C 30C avg, 40C max 13.8 kV Delta 95 kV 480Y/277 WYE 30 kV 5.75% +/- 7.5% NEMA 2 Braided flex connections to close coupled switchgear. Air terminal chamber

Quantity Transformer kVA Rating Cooling Class Phases Frequency Taps Temperature rise Ambient Primary Voltage Primary connection Primary BIL Secondary Voltage Secondary connection Secondary BIL Impedance Enclosure Primary Connection Secondary Connection Primary and Secondary Coils

The high voltage and the low voltage coils shall be wound with high conductivity copper conductors and then cast separately in molds. Aluminum windings will not be accepted. Coils shall be separated by a uniform air space that permits free circulation of cooling air between the

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coils. Windings shall be properly sized, insulated and supported for the line and load voltages and currents to be encountered in operation, including short circuits, when the transformer is properly installed and adequately protected. Encapsulation The encapsulation process shall involve pre heating the coils and then filling each mold with degassed and thoroughly mixed epoxy under vacuum. Once filled, the coils shall then be oven cured to insure a solid void free casting. The oven curing process shall be computer controlled and monitored to insure that each coil is properly cured. All coils rated 1200 volts or higher shall be subjected to half and full wave impulse tests as well as partial discharge tests to insure a properly cured and void-free casting. VPI, VPE, or other alternate encapsulation methods will not be accepted. The epoxy shall contain filler material providing characteristics superior to unfilled epoxy including higher temperature rating, better heat conductivity, better arc resistance and adhesion to the conductor, plus a coefficient of expansion closer to that of the conductor material. Unfilled resin will not be accepted. The epoxy shall be macro reinforced with glass fiber mat and micro reinforced with wollastonite fibers. The epoxy resin shall be UL recognized at 200 Deg. C and shall be self-extinguishing. Core The transformer core shall consist of thin, individually insulated sheets of high permeability, grain-oriented, non-aging silicone steel. They shall be miter-corner-cut without burs and hand stacked into a cruciform arrangement of different widths of laminations, to provide a crosssection most nearly resembling the circular cross-section inside the low voltage coil. Laminations shall be cut and stacked utilizing step-lap construction to reduce losses and sound. Designed flux density shall be kept well below saturation. The assembled core shall be braced with heavy (minimum 0.25 inch thick) structural steel angle or channel to apply uniform clamping forces across the entire width, top and bottom. The core shall have steel straps running top to bottom down the front and back of each core leg, inside the coils. Horizontal and vertical bracing shall be through-bolted to insure consistent clamping forces on all parts of the magnetic steel laminations. The core shall be protected from corrosion with a 185 Deg C or higher rated rust-resistant coating. Core and Coil Assembly Construction shall consist of separate high and low voltage coils for each phase, mounted coaxially, with high/low air space between coils adequate for the rated voltage potentials. Coils shall be mounted concentrically and supported in place on the transformer core so as to restrain movement in shipping and in service. Each coil shall be supported on epoxy blocks, top and bottom, with resilient pads to retain the coils while permitting thermal expansion under loading. The core-and-coil assembly shall be designed and manufactured to withstand without damage the short circuit testing as defined in ANSI standards C57.12.01 and C57.12.91. Bus All bus work shall be designed to withstand maximum short circuit stresses when connected to a supply system having a fault capacity of 750 MVA symmetrical at rated voltage, and to meet all

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test voltage requirements, without audible or visible corona. Bus shall be sized to maintain a current density of less than 1000 amps per square inch at 100% nameplate load. a. Low voltage bus shall be high conductivity copper. Connections of coil windings to bus shall be brazed or welded using shielded arc techniques designed to provide high joint integrity. Connection and terminal bolting surfaces shall be tin or silver-plated. Bolted connections shall include spring washers to maintain bolted surface pressure. All bus shall be sized to conform to industry standards and practices, for the amperes involved and maximum specified ambient temperatures. Bus on transformers designated as forced air cooled, or as future forced air cooled, shall be sized for the maximum current to be encountered at full nameplate FA or FFA rating(s). b. High voltage bus shall be high conductivity copper. It shall be supported by glazed porcelain insulators for surge strength (no phenolic, polyester or epoxy supports permitted). It shall have bolt-connected joint and terminal surfaces tin or silver-plated. High voltage leads shall be bus or flexible, insulated cable with industry-accepted types of terminations. Taps shall have flexible cable or solid copper links or jumpers. c. Ground bus shall be 1/4 x 2 inch copper bus or comparable bare conductor extending the full length of the enclosure. It shall have provisions to mount appropriate terminal connections for adjacent switchgear or external grounding. d. Flexible leads shall be offered as option to permit connection to existing switchgear when called for or when the transformer is specified as a retrofit unit. They shall have terminals with holes to match hole pattern(s) in switchgear bus. Enclosure The enclosure shall be a NEMA 2 ventilated enclosure for indoor use and be designed to provide adequate ventilation for the transformer. Panels shall be for bolted installation be capable of being opened, broken down, completely removed from and reassembled to the core-and-coil without cutting or welding. Removable panels shall be located to permit access to high-voltage taps. The enclosure panels shall be of sheet steel with a minimum thickness of 14 gage while the roof and vertical supports shall be formed from minimum 12 gage sheet steel. All steel panels shall be cleaned, primed then painted with a finish coat as required for an indoor installation. Color of the final paint coat shall be ANSI 61 light gray. The core of the transformer shall be visibly grounded to the enclosure by means of a flexible grounding conductor sized in accordance with applicable NEMA, ANSI and NEC standards. Base The transformer base shall be a separate rigid steel weldment capable of supporting the coreand-coil assembly and enclosure. Construction shall include provisions for lifting as well as for jacking and skidding or rolling in both directions. Two stainless steel ground pads with two tapped holes for attaching ground leads shall be provided, one in each diagonally opposite corner of the base. Lifting provisions shall be designed for lifting the transformer and the core-and-coil assembly, separately or together.

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Tests as called for in this Specification shall be made in strict accord with applicable ANSI standards. Certified test reports covering specified testing shall be provided by the manufacturer to the purchaser (or to designated alternate), no later than one week after shipment. Tests may be limited to routine tests, or may include special tests as required by the purchaser. Purchaser reserves the right to witness tests, on negotiated schedule, at additional cost. Test values not specified by standards (such as partial discharge) shall conform to manufacturers' standard practice. a. Routine Tests. Routine tests shall be made on each transformer in accordance with the requirements of ANSI standards for dry type transformers. These shall include the following: Ratio test Polarity test No-load core loss Full load coil loss Impedance measurement Applied voltage test Induced over-potential test Excitation current test Quality control impulse test (half and full wave tests on primary coils prior to assembly) Quality control partial discharge test (performed on primary coils prior to assembly)

b. Special Tests. Special tests (sometimes called design tests) shall be made in accordance with the requirements of ANSI standards for dry type transformers when required. Test results from similar equipment may be accepted in lieu of new unit tests. These shall include the following Temperature rise test. Sound level test. ANSI Impulse test (half, full, and chopped wave impulse tests on the assembled transformer). Partial discharge test (on the assembled transformer) Short Circuit Test.

ACCESSORIES Many options and accessories are available with ULTRACAST transformers. The specific application for which this equipment is being specified will typically dictate which options make sense to purchase with the transformer, but some of the most common options include the following: Temperature Indicator When specified, an instantaneous and maximum temperature-indicating thermometer shall be provided on the front of the transformer. A Cimco model 21A three phase digital temperature monitor or engineer approved equivalent shall be provided for this purpose. The sensors shall be located in wells that extend down approximately 1/3 the height of each low voltage coil and as

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close to the inner lead as practical to most closely indicate the hot spot temperature of each winding. Thermal sensors located in cooling air ducts will not be accepted. Forced Air System The above described temperature monitor can be provided with the forced air system to control fans, and to indicate coil conditions. The forced air system shall consist of a minimum of six propeller type fans for up to 1000 kVA, and 12 fans for larger units directed upwards from the bottoms of the coils. Horizontal wiring for the fan circuits shall be routed through a rigid metal framework near the lower core clamps. The forced air system shall increase to overall kVA of the unit by 33% for transformers between 750 and 3000 kVA, and shall increase the overall kVA by 25% for larger units up to 7500 kVA. Instruction Manuals The manufacturer shall supply with shipment of the transformer complete installation, operation and maintenance instructions/manuals suitable for the specific item(s) being supplied, including information from the manufacturer of each purchased accessory. It shall include interconnection diagrams, drawings and instructions describing procedures for items that are to be shipped disassembled but which are to be assembled and interconnected for operation when installed. These shall contain special rigging instructions as required for unloading, moving by skidding or rolling, and lifting the transformer and accessories. Also included shall be instructions for tap changing, enclosure assembly and disassembly, temperature indicator reading and setting procedures and other information designed to assist in proper operation and periodic maintenance of the equipment being supplied. Key interlocking provisions shall be identified and serial numbers supplied. All manuals, instructions and supporting drawings and parts lists supplied by the manufacturer and supplemental instructions and data supplied by accessory manufacturers shall be in English, clearly readable and arranged in such format as to make the subject items easily identifiable. Each manual shall have an index and/or table of contents identifying each item/subject and shall include the location (name of manual, section, and/or page number) of information therein. All values shall be given in English units and may be in both English and metric values. Fractional values shall be given in decimal form. Drawings Manufacturer shall supply within 30 days after shipment of equipment a complete set of "as manufactured" drawings and wiring diagrams including interconnection diagrams of all components and assemblies of the equipment which will assist in operation and maintenance of the equipment. All drawings shall be prepared in accordance with current industry standards and good industrial practice. A minimum of three sets of hard copy drawings will be furnished along with an e-mailed copy of the AutoCAD files from which the hard copies were printed. All information shall be in the English language, clearly readable, with IEEE, NEMA and ANSI symbols, device numbers and other requirements. Dimensions shall be in inches and may be in both English and metric values if specified. Fractional values shall be given in decimal form.

Specification (continued) General

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The transformer supplied shall include the accessories, type of enclosure, finish and color specified. It shall be designed for service conditions, including storage, ambient, overload and unusual operating conditions (seismic, rectifier, traction, etc.) as specified. Design, construction and testing shall be in strict accord with the latest revisions of applicable industry standards that shall include as a minimum those listed below. Bidder shall be responsible for determining differences in the specified standards and this Specification and shall bring them to the attention of the buyer. Where standards and specifications contain different minimum requirements, the more stringent shall apply. Where Standards conflict with this Specification, this Specification shall take precedence. INDUSTRY STANDARDS AND SPECIFICATIONS 1. 2. ANSI C57.12.01 General Requirements for Dry-type Distribution and Power Transformers Including Those With Solid Cast and/or Resin-Encapsulated Windings. ANSI C57.12.21 Requirements for Pad-Mounted Compartmental-Type, Self-Cooled, Single-Phase Distribution Transformers with High Voltage Bushings; High Voltage, 34,500 GrdY/19,920 V and Below; Low Voltage, 240/120 V; 167 kVA and Smaller ANSI C57.12.22 Requirements for Pad-Mounted, Compartmental-Type, Self-Cooled Three-Phase Distribution Transformers with High Voltage Bushings, 2500 kVA and Smaller: High Voltage, 34,500 GrdY/19,920 V and Below; Low Voltage, 480 V and Below ANSI C57.12.25: Requirements for Pad-Mounted Compartmental-Type, Self-Cooled, Single-Phase Distribution Transformers with Separable Insulated High-Voltage Connectors; High Voltage, 34,500 GrdY/19,920 and Below; Low Voltage, 240/120 V, 167 kVA and Smaller ANSI C57.12.26: Pad-Mounted Compartmental-Type, Self-Cooled, Three-Phase Distribution Transformers for Use with Separable Insulated High Voltage Connectors, High Voltage 34,500 GrdY/19,920 V and Below; 2500 kVA and Smaller ANSI C57.12.28: Pad-Mounted Equipment - Enclosure Integrity ANSI C57.12.50 Requirements for Ventilated Dry-type Distribution Transformers, 1 to 500 kVA, Single Phase, and 15 to 500 kVA Three Phase, with High-voltage 601 to 34 500 Volts, Low-voltage 120 to 600 Volts. ANSI C57.12.51: Requirements for Ventilated Dry-type Power Transformers, 501 kVA and Larger, Three Phase, with High-voltage 601 to 34 500 Volts, Low-voltage 208Y/120 to 4160 Volts. ANSI C57.12.55: Conformance Standards for Dry-Type Transformers Used in Unit Installations, including Unit Substations

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10. ANSI C57.12.57 Ventilated Dry-type Network Transformers 2500 kVA and Below, Three-phase, with High-voltage 34 500 Volts and Below, Low-voltage 216Y/125 and 480Y/277 Volts - requirements. 11. ANSI C57.12.70: Transformers. Terminal Markings and Connections for Distribution and Power

12. ANSI C57.12.80 Terminology for Power and Distribution Transformers. 13. ANSI C57.12.90: Guide for Short Circuit Testing of Distribution and Power Transformers 14. ANSI C57.12/91: Test Code for Dry-type Distribution and Power Transformers. 15. ANSI C57.94: Recommended Practice for Installation, Application, Operation, and Maintenance of Dry-Type general Purpose Distribution and Power Transformers 16. ANSI C57.98: Guide for Transformer Impulse Tests 17. NEMA Type 1 Enclosures for Non-Hazardous Locations, General Purpose - Indoor 18. NEMA Type 3R Rain-Proof and Sleet (Ice)-Resistant - Outdoor 19. NEMA Type 4 Watertight and Dust-Tight - Indoor 20. NEMA ST 20 Dry-Type Transformers for General Applications (referenced for sound levels when not otherwise specified) 21. NEMA Standard No. TR 1 Transformers, Regulators and Reactors. This Standard may be reissued, presumably for liquid-filled only.

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Provided courtesy of Dynapower Corporation, manufacturer of ULTRACAST Transformers This Specification is Available in MS Word format on disk or by email upon request.