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TRANSFORMERS
Power Transformers......................................B1
Testing..........................................................B11
Enclosures...................................................B12
B1
DRY TYPE POWER TRANSFORMERS
Applications
Pioneer Electric dry type power transformers are primarily
designed for stepping down high voltages from transmission
and distribution systems to utilization voltages and commercial,
industrial, institutional, or utility applications. They are ideally
suited for both indoor and outdoor applications.
B1
DRY TYPE POWER TRANSFORMERS
B2
DRY TYPE POWER TRANSFORMERS
Silicon Grade
Oriented Core
Material High Voltage Bus
Coil Support
Blocks
Disk Wound
High Voltage
Winding
B3
DRY TYPE POWER TRANSFORMERS
Barrel Windings
This winding is constructed by progressively winding turns
of magnet wire from one end of the coil to the other. Layers
are electrically insulated by solid sheet insulation and cooling
ducts.
Disc Windings
This winding construction is achieved by winding the
conductor into slotted spacers (combs) that are arranged
around the circumference of the coil. The continuous series
connected disc winding provides a high capacitance which
improves the distribution of the impulse wave through the
winding. Cooling efficiency is also maximized by exposing a
large surface area of the conductor to the air.
At the conclusion of the winding process, the completed transformer coil is prepared for
impregnation by preheating to reduce moisture. The drying process is completed when the coil
is subjected to full vacuum in a vacuum chamber removing all the moisture absorbed by the
insulation from the atmosphere.
A clear, low viscosity, high temperature resin (class 220°C) is introduced into the tank under vacuum
eliminating any air bubbles in the resin. When the winding is completely submerged pressure is
applied forcing the resin into all winding spaces and voids in the turn to turn and layer to layer
insulation.
The vacuum/pressurization cycle is repeated four times to achieve full resin penetration the coil is
then removed from the chamber and placed in a baking oven to cure the resin. The entire vacuum
impregnation process is repeated twice, to ensure a uniform protective, hard, and impermeable
coating is formed on all exposed surfaces of the winding.
As an option and for greater protection the coil can be coated with high viscosity epoxy resin
and heat cured.
B4
DRY TYPE POWER TRANSFORMERS
Rectangular Core
This configuration is used mainly for smaller units constructed
with layer wound coils.
Cruciform Core
This configuration is utilized mainly for large round windings.
The core shape is steeped to give as close as possible coupling
with the round coils. This type of design inherently has higher
short circuit capability.
Best Efficiency
B5
DRY TYPE POWER TRANSFORMERS
To prevent interference with sensitive electronic Unshielded transformers 300 - 3000 KVA produce
equipment as well as to satisfy possible health concerns electromagnetic fields in the order of 100 - 500 milligauss in
major magnetic “polluters” can be located in remote the immediate vicinity of the unit. Pioneer Electric specially
areas of a building. However, this is not always possible designed transformers can lower these emissions by a factor
or practical and may add additional costs and limit the of 10 or better depending on the specifications.
useful space.
This allows for the transformers to be located at practically
any location in a building without any restrictions due to
intrusive magnetic fields.
HIGH
LOW
Image 1: Shows a graphical representation of the intensity Image 2: Shows a graphical representation of the intensity
level of the electromagnetic fields outside of the enclosure level of the electromagnetic fields outside of the enclosure
of a typical non-shielded transformer. of a shielded transformer. Due to magnetic shielding of the
enclosure most of the field emission is contained within the
transformer enclosure.
B6
DRY TYPE POWER TRANSFORMERS
B7
DRY TYPE POWER TRANSFORMERS
Description
The unique design and manufacturing process of cast coil dry
type transformers offers several key advantages over liquid filled
or conventional dry type transformers. Specifically, cast coil
type transformers are environmentally safe and provide long
uninterrupted service in the most demanding applications and
under the most severe operating conditions.
Safety
Cast coil type transformers are self-extinguishing which virtually
eliminates the possibility for fire or explosion. Installations do not
require special fire protection systems.
Maintenance
Cast coil type transformers are virtually maintenance free due to
smooth crevice free construction of the coils. With proper precaution
cast coil units can be installed at ambient temperatures as low as
-50°C and can be energized from cold start at full rating.
Environmentally Friendly
Cast coil transformers contain only chemical non-hazardous material.
B8
DRY TYPE POWER TRANSFORMERS
Cast Epoxy
High Voltage
Winding
Cooling Ducts
B9
DRY TYPE POWER TRANSFORMERS
B10
DRY TYPE POWER TRANSFORMERS
Testing
B11
DRY TYPE POWER TRANSFORMERS
Enclosures
NEMA 1
A general purpose indoor ventilated enclosure designed to
provide a limited degree of protection against falling dirt
particles. It is commonly utilized indoors for commercial and
industrial applications.
NEMA 2 NEMA 1
A general purpose indoor ventilated enclosure designed to
provide a degree of protection against dripping and light
splashing of noncorrosive liquids and falling dirt particles.
NEMA 3R
A general purpose ventilated enclosure for either indoor or
outdoor use, designed to provide a degree of protection
against rain, sprinklered water, and snow. Ideal for sprinklered
commercial applications, severe industrial environments, and
outdoor applications.
NEMA 4
A non-ventilated enclosure for either indoor or outdoor
use, constructed to provide a degree of protection against
windblown rain, snow, dust, and splashing water. Hose- NEMA 3R with Filters
directed water, and to be undamaged by the formation of ice
externally. Ideal for industrial and commercial applications in
harsh environments or where severe weather conditions are
likely.
NEMA 4X
A non-ventilated enclosure the same as NEMA 4, but it is
corrosion resistant. Ideal for industrial applications such as
food processing, refineries, and mines.
NEMA 12
An indoor non-ventilated enclosure constructed to provide
a degree of protection against circulating dust, lint, fibers,
and flings. It also provides protection against dripping and
light splashing of noncorrosive liquids. Ideal for industrial
applications such as mills, refineries, or mines.
Sprinkler Proof
B12
DRY TYPE POWER TRANSFORMERS
5 KV (30 KV B.I.L.)
Dimensions for Core and Coil Assembly Enclosure Dimensions Stubs-Up Pads
220°C Insulation (150°C Rise) Arrangement Total
KVA Rating Weight
Width Depth Height Weight Width Depth Height Weight (lbs.)
(in.) (in.) (in.) (lbs.) (in.) (in.) (in.) (lbs.)
300 41 30 39 1900 46 40 60 500 2400
500 51 30 46 2800 60 45 70 700 3500
750 60 35 60 3200 72 45 80 850 4050
1000 62 35 62 4000 72 45 80 850 4850
1500 66 45 66 7000 80 48 91.5 1050 8050
2000 70 45 70 8400 90 60 91.5 1250 9650
15 KV (60 KV B.I.L.)
750 66 42 62 5000 80 48 91.5 1050 6050
1000 68 42 64 6200 80 48 91.5 1050 7250
1500 72 44 68 8000 90 60 91.5 1250 9250
2000 75 44 72 9500 90 60 91.5 1250 10750
2500 78 50 77 10500 100 60 110 1450 11950
3000 84 50 80 12100 100 60 110 1450 13550
3750 90 55 84 17000 110 72 110 1600 18600
5000 100 55 96 19500 120 72 120 1900 21400
18 KV (95 KV B.I.L.)
750 72 45 64 6200 90 60 91.5 1250 7450
1000 78 45 70 6800 100 60 91.5 1300 8100
1500 80 45 76 8200 100 60 110 1450 9650
2000 80 45 80 9600 100 60 110 1450 11050
2500 87 50 82 10800 110 60 110 1550 12350
3000 95 50 86 13000 110 60 110 1550 14550
3750 98 60 88 17700 120 72 120 1900 19600
5000 100 60 92 20500 120 72 120 1900 22400
25 KV (125 KV B.I.L.)
1000 80 48 80 7200 100 60 110 1450 8650
1500 84 48 82 8500 110 60 110 1550 10050
2000 90 50 85 9800 110 60 110 1550 11350
2500 92 50 90 11000 110 60 120 1600 12600
3000 95 50 95 14000 120 60 120 1900 15900
3750 98 55 108 18500 120 72 132 2100 20600
5000 100 60 118 21000 130 72 130 2500 23500
Note: Dimensions may change if co-ordinated with switchgear. Dimensions are estimates. For firm dimensions contact factory.
B13