Technical Performance

LS Cast Resin Transformers

50kVA Through 15,000kVA
Primary Voltage: 2.3kV Through 36kV
Secondary Voltage: 120V Through 24kV

Power Transmission & Distribution

 Introduction
Great progress has been made in the development and improvement of
distribution transformers over the last decades.
The application of high quality insulation material and suitable selection of the coil
structure for high stress have contribute to the development of LS CAST RESIN
Transformers.
The LS CAST RESIN Transformer has succeeded in combining the advantage of
oil-filled and conventional dry type transformers, which are fabricated with an
epoxy resin. The windings are completely embeded under vacuum conditions.
This casting method makes it possible to assure void-free epoxy penetration of
both the inner layer and turn to turn insulation.

Applications 4
Feature 5
Construction 6
Specification 7
Technical Data(IEC Standard) 9
Manufacturing Process 12
Quality Assurance 13
2Ｉ Ordering Sheet 14
 LV TERMINAL

LIFTING LUG

FRAME

CORE

SPACER

HV TERMINAL

NO VOLT. TAP CHANGER

INTERPHASE LEAD

BED FRAME

Ｉ3
 Applications

LS CAST RESIN Transformers can

be used in various fields.
Here are just a few possible
applications.

● Indoor and outdoor unit substations

● Off-shore flatforms
● Commercial buildings
● Hospitals
● Shopping centers
● Water supplies
● Traction systems
● SCR Power supplies

4Ｉ
Features Cast Resin Transformers

Environmentally safe High overload capability

LS CAST RESIN Transformers will not emit oil or toxic Based on the high thermal time constant factor of the
gases into the atmosphere. Therefore, they do not pollute windings, LS CAST RESIN Transformers can be overloaded
the environment and are strongly recommended as a for a short duration considerably higher than oil-immersed
replacement for askarel(PCB)-filled transformers. transformers. It has a greater capability to withstand sudden
high overloads such as might be encountered in heavy
traction applications.

Moisture proof
The complete casting of coils under vacuum prevents the
High impulse strength
penetration of moisture into the winding.
Therefore, it is suitable for both storage and operation in LS CAST RESIN Transformers are very resistant to impulse
harsh environment and is capable of being switched on voltage.
immediately after such storage without pre-drying. Impulse withstand levels to 200kV are available because of
careful design and special structure.

No partial discharge
Maintenance free
There is no possibility of partial discharge in LS CAST
RESIN Transformers. Maintenance is almost completely eleminated. No checking
Whole core & coil is tested to guarantee the life expectancy of liquid level and no dielectric test for moisture absorption is
of the insulation system. required.
LS CAST RESIN Transformers are free of partial discharge Due to the smooth coil surface, heavy dirt and dust build up
at least up to 1.3 times of the rated voltage. is eleminated even under the worst circumstances.
The recommended routine maintenance is an occasional
visual inspection.

High
frequency Filter Coupling Capacitors
generator
P.T

V Fire resistant
Chopping switch Input transformer Detertors

LS CAST RESIN Transformers have a very excellent

characteristic of self fire-extinguishing and fire resistance.
So there would be no fear of spread of fire even if fire took
place around the electricity room.

Low noise
The coating of the core with an epoxy resin have lead to an
appreciable noise reduction. Noise is also reduced due to
the sound suppresing effect of the step lap cutting.

Ｉ5
 Construction

LS CAST RESIN Transformers take pride in the ability to offer a wide variety of designs and configurations
necessary to satisfy customer needs. Computer and CAD/CAM systems are used for quick and accurate design
and manufacture to meet specific customer requirements.

CORE & FRAME HV & LV Coils

The core is made of highest quality, cold rolled, grain- ● HV COIL (Vacuum Cast type)
oriented, silicon steel and step lap joint. - HV COIL Vacuum Cast in
Three legs of the core are arranged in a single plane and epoxy with a mold.
interconnected with a yoke. - Aluminum / Copper
The legs are circular structure and are carefully interlaced conductor.
with stepwise arranged yokes.
The core is mitred at a 45 degree angle and care-fully stacked
and pressed to obtain low loss, exciting current and noise.
The core is insulated on both side of each lamination and
protected against corrision by a resin coating and grounded
in frame. ● LV COIL (Encapsulated Cast type)- standard
The frame consists of upper and lower steel channels. It - LV COIL Encapsulat- ed
holds the core and coil together. after winding with prepreg
To protect against corrosion, all steel parts are coated with layer insu-lation.
epoxy paint. - Aluminum / Copper
conductor.
5 STEP LAP CORE

● LV COIL (Vacuum Cast type)- optional

- LV COIL Vacuum Cast in
epoxy with a mold.
- Aluminum / Copper
CORE STACKING conductor.

Conductor insulated with a high grade is used in the winding

construction.
CORE ASSEMBLY Turns are arranged in multiple sections and layers in order
to decrease transient maximum voltages. High voltage
windings are cast in a mold under vacuum, using a
computer controlled mixing and vacuum casting process.
So there is no void in the coils. The windings are fiberglass
reinforced to provide additional mechanical strength.
After assembly, all HV coils are partial dischage tested to
verify void free in the coils.

6Ｉ
Specification Cast Resin Transformers

Specification Data Standards

LS CAST RESIN Transformers are normally available with LS CAST RESIN Transformers confirm to the requirements
specification as follows: of IEC 60076-11 (2004).
However we can also meet the requirements of the following
● Rated voltage standards, upon request.
HV COIL : up to 36kV
LV COIL : up to 600V ● ANSI / IEEE C57.12.01 (2005)
* Dual High voltage coils can also be supplied. General requirement for dry-type distribution and power
transformers.
● Standard Tapping range : ±2.5%, ±5%
* Other ratings are available by request
● CSA Standard C9-M1981
Dry type transformers.
● Power capacity
Single phase : 20 ~ 2,000kVA
● HD538.1,2,3(1995)
Three phase : 50 ~ 15,000kVA
3 Phase Dry type distribution transformers.
50Hz from 100kVA to 2500kVA
● Frequency : 50Hz, 60Hz
* Other frequency is available by request
● BS 7806 (1995)
● % Impedance voltage Dry type Power transformers
IEC STD : 4 ~ 8%
● AS 2374 (1982)
ANSI STD : 5.75%
* Other % impedance voltages are available. Power transformers
* Transformers for rectifier applications and other special purposes
can be supplied according to the client’s specification.
● Connections
HV COIL : Delta
LV COIL : Star with neutral point
* Other connections are available to meet requirement.
Certificates
● Temperature class (According to IEC 60076-11)
HV COIL and LV COIL : F CLASS
* H class coils are available by request.

● Conductor
Aluminum (standard)
Copper (optional)

● Noise Level (according to NEMA Std.)

500kVA - 60dB
750kVA - 64dB
1000kVA - 64dB
1500kVA - 65dB
2000kVA - 66dB
2500kVA - 68dB
*Noise reduction TRs are available by request.

Ｉ7
 Specification

HV terminals LV terminals
Accessories
● Normally provided accessories
∙HV & LV terminals
∙Lifting lugs
∙Grounding terminals
∙Name plate
∙Danger label Lifting lugs Grounding terminals
∙Tap terminal link
∙Protection cap for tap terminal
∙Anti-vibration pads

Danger label Tap terminal link

Protection cap Anti-vibration pads

● Optional accessories Wheels Cooling fan

∙Wheels
∙Cooling fan & temp. controller
∙Digital thermometer & PT 100 OHM
(1 Phase)
∙Digital thermometer & PT 100 OHM
(3 Phase)
∙Enclosure
Temperature controller Temperature indicator

8Ｉ
Technical Data (IEC Standard) Cast Resin Transformers

2W 2N 2V 2U

D
1W 1V 1U

2W 2N 2V 2U

1W 1V 1U

Standard : IEC 60076-11

12kV Class, 50Hz
75 BIL Temperature Rise : 100K
Rated Impedance No Load Load Efficiency (%) Dimension (mm)
Weight
Power Voltage Loss Loss 100% 75% 50% Width Depth Height
(kg)
(kVA) (%) (W) (W) Load Load Load (W) (D) (H)
400 4.0 1,150 5,200 98.4 98.6 98.8 1,220 800 1,460 1,320
630 4.5 1,450 7,600 98.6 98.8 98.9 1,305 900 1,620 1,750
1,000 6.0 1,950 11,000 98.7 98.9 99.0 1,520 1,000 1,740 2,500
1,250 6.0 2,450 12,500 98.8 99.0 99.1 1,700 1,000 1,820 3,060
1,600 6.5 2,850 14,500 98.9 99.0 99.2 1,760 1,200 2,000 3,750
2,000 6.5 3,700 16,500 99.0 99.1 99.2 1,940 1,200 2,150 4,750
2,500 7.5 4,200 19,000 99.1 99.2 99.3 2,115 1,200 2,190 5,600
* Other kVA is available according to request.

Ｉ9
 Technical Data (IEC Standard)

2W 2N 2V 2U

D
1W 1V 1U

2W 2N 2V 2U

1W 1V 1U

Standard : IEC 60076-11

24kV Class, 50Hz
125 BIL Temperature Rise : 100K
Rated Impedance No Load Load Efficiency (%) Dimension (mm)
Weight
Power Voltage Loss Loss 100% 75% 50% Width Depth Height
(kg)
(kVA) (%) (W) (W) Load Load Load (W) (D) (H)
400 6.0 1,200 6,000 98.2 98.5 98.6 1,350 800 1,540 1,400
630 6.0 1,650 7,800 98.5 98.7 98.8 1,500 900 1,710 2,060
1,000 6.0 2,300 11,500 98.6 98.8 98.9 1,670 1,000 1,850 2,860
1,250 7.0 2,550 13,000 98.7 98.9 99.0 1,750 1,000 1,900 3,220
1,600 7.0 3,050 16,000 98.8 99.0 99.1 1,810 1,200 2,080 3,840
2,000 7.0 4,050 17,500 98.9 99.0 99.1 1,990 1,200 2,210 4,750
2,500 7.5 4,600 20,500 99.0 99.1 99.2 2,160 1,200 2,250 5,530
* Other kVA is available according to request.

10Ｉ
Technical Data (IEC Standard) Cast Resin Transformers

2W 2N 2V 2U

D
1W 1V 1U

2W 2N 2V 2U

1W 1V 1U

Standard : IEC 60076-11

36kV Class, 50Hz
170 BIL Temperature Rise : 100K
Rated Impedance No Load Load Efficiency (%) Dimension (mm)
Weight
Power Voltage Loss Loss 100% 75% 50% Width Depth Height
(kg)
(kVA) (%) (W) (W) Load Load Load (W) (D) (H)
630 6.0 2,200 7,200 98.5 98.6 98.7 1,720 1,000 1,910 2,650
1,000 6.0 3,000 8,600 98.8 98.9 98.9 1,880 1,200 2,050 3,700
1,250 6.5 3,650 11,000 98.8 98.9 98.9 2,060 1,200 2,100 4,400
1,600 7.5 3,900 14,500 98.8 99.0 99.0 2,110 1,200 2,280 4,900
2,000 7.5 4,850 15,500 98.9 99.1 99.1 2,290 1,200 2,390 6,000
2,500 7.0 6,300 18,000 99.0 99.1 99.1 2,470 1,200 2,460 7,400
* Other kVA is available according to request.

Ｉ 11
 Maunfacturing Process

CORE CUTTING COIL WINDING

CORE STACKING CASTING

ASSEMBLY

TEST

12Ｉ
Quality Assurance Cast Resin Transformers

Routine Test ROUTINE TEST

the following tests are made on all transformer.

● Resistance measurements
● Ratio tests
● Polarity and phase relation test
● Impedance and load loss
● No load loss and exciting current
● Applied potential tests
● Double induced potential tests
● Partial diacharge test(below 10 PC)
IMPULSE TEST

Optional Test
● Impulse test
● Temperature test
Temperature rise test carried out according
to the simulated loading method.
- no load losses
- load losses
The total temperature rise is calculated
in accordance with IEC 60076-11 or ANSI
SHORT CIRCUIT TEST
● Short circuit test
∙3P 1600kVA Certified by KEMA
● Audible sound level test
∙test by IEC 60076-10
∙LS use Pressure Level (Lp).
Lw(A) = Lp(A) + 10 LOG S
S = 1.25 X H X P
H : Transformer height
P : Measurement contour perimeter
● Climatic, environmental and fire behaviour
classes
FIRE BEHAVIOR TEST
- Certificated at CESI according to IEC 60076-11
Fire Behavior Class : F1
Environmental Class : E2
Climatic Class : C1
- Class C2 is available

Ｉ 13
 Ordering Sheet

Ref. No. :
Date. :

End User and Location :

ITEM TR.-1 TR.-2 TR.-3 TR.-4

Rated kVA
Q’ty (sets)
Primary(V)
Rated Voltage(V)
Secondary(V)
Primary
Connection
Secondary
Phase (ф)
% Impedance (%)
1. Frequency � 50Hz � 60Hz � Other
2. Conductor � Maker Standard � Copper � Aluminum � Other
3. Primary Taps � ±2 x 2.5% � ±2.5% � Other
4. Applied standard � IEC � ANSI/IEEE � BS � Other
5. Insulation Class
Primary � Maker Standard(155°C) � Other
Secondary � Maker Standard(155°C) � Other
6. Winding Temperature Rise
Primary � Maker Standard � 80°C � 100°C � 115°C � Other
Secondary � Maker Standard � 80°C � 100°C � 115°C � Other
7. Accessories � Digital Thermometer
� Cooling Fans controller
� Cooling fans � User Spec . ( P V Hz)
� Maker Standard.
8. Protection � IP00 � IP21 � IP31 � Other
9. Attached specification ( � Yes , � No ) , If “Yes” (Total page : pages)
10. Remarks

1.

2.

3.

14Ｉ
Memo Cast Resin Transformers

Ｉ 15
 �For your safety, please read user's manual thoroughly before operating.
�Contact the nearest authorized service facility for examination, repair, or adjustment.
�Please contact qualified service technician when you need maintenance.
Do not disassemble or repair by yourself!
Safety Instructions �Any maintenance and inspection shall be performed by the personnel having expertise concerned.

ⓒ 2001.4 LS Industrial Systems Co.,Ltd. All rights reserved.

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2009. 05 LS Cast Resin Transformers 2001. 04/(12) 2009. 05 Printed in Korea STAFF