GE
Industrial Solutions
Wave Cast
Dry-type Power Transformers
GE
GE is a diversified organization covering a myriad of market segments, including infrastructure, finance and media.
From energy, water, transportation and health to access to money and information, GE serves customers in more than
100 countries and employs more than 300,000 people worldwide.
The company traces its beginnings from Thomas A. Edison, who established the Edison Electric Light Company in 1878.
In 1892, a merger of Edison General Electric Company and Thomson-Houston Electric Company created the General
Electric Company. GE is the only company listed in the Dow Jones Industrial Index today that was also included in the
original index in 1896.
Industrial Solutions
GE Industrial Solutions, a division of GE Energy Management, is a global leading provider in power distribution, offering a
wide range of products which include medium and low voltage power distribution equipment and components, and
motor & control systems that are safe, reliable and offer high performance. Its innovative solutions can improve energy
efficiency and environmental impact in power plants, power grids, oil & gas, mining, data center, overseas EPC,
industrial manufacturing, rail transportation, commercial buildings, residential houses, renewable energy and many
other industries.
GE is one of the worldwide partners of the Olympic Games. In 2008, GE assisted
Beijing with this tremendous event, which was unprecedented in scale and
first-class in its use of science and technology, offering a series of innovative
solutions and products for around 400 Olympic infrastructure projects, covering
fields in electricity distribution, lighting, security, water processing, benefiting
some 37 Olympic venues and 168 commercial buildings. GE also brought its
experiences to the 2010 Expo in Shanghai, Asia Games in Guangzhou,
Vancouver Olympic Games and continued through to the London 2012 Olympic
Games.
2010 World's Most Innovative Companies
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Contents
Wave Cast Transformers ……………………………… 01
Vacuum cast windings ………………………………… 02
Winding assembly ……………………………………… 03
Cores …………………………………………………… 04
Enclosures ……………………………………………… 04
Accessories ……………………………………………… 05
Technical specifications ………………………………… 06
Tests …………………………………………………… 10
Certificates ……………………………………………… 11
Handling ………………………………………………… 12
Foundation ……………………………………………… 13
Wave Cast Transformers
Reliability, flexibility, efficiency and safety
Wave Cast coil transformers from GE are characterized by proven technology, application
flexibility, lower installation cost, operating efficiency and environmental acceptability.
Advanced design of the winding assembly establishes superior performance to meet
today’s exacting needs. Indoors or out, they are designed for use in the most demanding
and diverse environments and in all applications requiring reliable electrical power.
Typical applications of cast coil transformers include:
• Steel mills
• Industrial critical power solutions
• Windmills
• Offshore drilling platforms
• Pulp & paper mills
• Chemical plants
• Cement & mining operations
• Automotive industry
• High rise building & water-side installations
Cast coil transformers boast several advantages over alternative transformer technologies.
• Mechanical strength. Because of the strong protection provided by the vacuum cast
epoxy encapsulated coils, Wave Cast transformers are stronger than either liquid or
ventilated dry-type transformers. Short circuit tests have proven this strength well beyond
IEC and ANSI requirements. GE designs and manufactures its cast coils to be among the
strongest in the industry. The strength of Wave Cast transformers makes them ideal for
such applications as impact loading, mobile machinery and transit systems.
• Impervious to adverse atmospheric conditions. Unlike ventilated dry-type transformers
and in a manner similar to liquid filled transformers, GE Cast Coil transformers are optimal
for application in harsh environments. The epoxy casting is extremely inert and renders
the windings impervious to moisture, dirt and most corrosive elements.
• Suitability for simple indoor installations. Unlike the case with liquid filled transformers,
indoor installations do not require an automatic fire extinguishing system or fire vault, oil
checking or replacing, or a liquid confinement area.
• Extended ratings. GE cast coil transformers can be provided with the highest self-cooled
and fan-cooled extended ratings of any transformers in their size class.
• High efficiency and environmental safety. Wave Cast coil transformers have several
distinct advantages over dry and liquid filled transformer. The main advantage of a cast
coil transformer is that the polyester glass and epoxy resin provides excellent mechanical
strength and eliminates conductor movement since both the primary and secondary
windings are completely capsulated in the epoxy resin. As with other dry transformer,
the electromagnetic force under short circuit conditions tends to push the secondary
winding into the core, while driving the primary winding away from the core. In addition
to using the strength of the conductor material and winding geometry, the cast coil
design incorporates the concrete-like epoxy-conductor matrix. Wedging sticks are placed
between the secondary windings and the core legs to center the coils on the core legs.
The primary winding is completely embedded in a block of epoxy, which prevents any
winding movement.
The epoxy resin essentially makes the cast coil transformer impervious to harsh
environments and has no potential adverse affects on the environment. Thus it can be
used virtually in any application. Another advantage is that the cast coil transformer has
a higher efficiency rating than liquid or dry transformer.
1
Vacuum cast windings
Tough epoxy provides the strength.
The principal advantage of solid vacuum cast construction is
Wave Cast vacuum cast windings are highly engineered
that the cast coils seal out harmful fumes, air and moisture,
components, requiring specific expertise in electrical,
preventing them from entering the windings. The solid cast
material, thermal and mechanical engineering. The process of
transformer achieves a maximum degree of resin impregnation
measuring, mixing, heating and vacuum casting materials into
during the casting process.
the windings is equally critical.
Cast coils are solid vacuum cast with epoxy resin compound.
Other advantages of vacuum cast construction include:
The epoxy is applied under vacuum to hermetically seal the
• Dielectric strength - Windings are corona-free at twice the
windings in a highly durable epoxy. Quartz filler is included,
2
rated voltage.
which provides increased viscosity to the resin, better
• Mechanical strength - Short circuit capability meets and
impregnation and increased capability to withstand short
exceeds the requirements of IEC60076-11:2004 and IEEE
circuits. The epoxy mixture is carefully designed to provide
standard C57.12.91-2001.
maximum strength and environmental protection and yet
• Thermal strength - Withstands fluctuating operating
minimize the temperature differential through the coil thickness.
temperatures ranging from -40℃ to 180℃ without damage
Process control ensures that the coils are void-free and
to the epoxy insulation.
prevents partial discharges within the resin material or cracking
• Insulation system - Tested to ANSI/NEMA and IEC standards,
of the epoxy over a wide range of ambient and operating
turn-turn and layer-layer electrical insulation components
temperatures
(polyimide film) are recognized at 180℃.
Winding assembly
High and low voltage windings are vacuum cast in metal molds as separate concentric cylinders.
High voltage windings are wound using strip foil technology. Multiple layers of polyimide film (180℃ system) provide turn insulation.
Individual coil sections are wound directly onto the HV winding form and then connected in series by welding. Molds are assembled
around the completed high voltage coils and placed in a vacuum chamber. Coils are pre-heated under high vacuum to remove trapped
moisture. A special mixture of epoxy resin and quartz powder flows into the mold through an opening in the molding assembly. After
pouring, the molds are cured in a time-temperature process controlled oven. The result is a reliable, vacuum cast winding with an
unusually high-strength essentially void free assembly capable of withstanding high electrical stress.
Low voltage windings use sheet conductor construction. A fiberglass mesh provides support for the inside of the winding. Full-width
sheet conductor and SCC layer insulation is wound onto the cylinder. Start and finish lead bars are TIG welded to the sheet conductor.
Low voltage windings are also vacuum cast in a metal mold using the same technique as the high voltage windings.
Why strip foil windings?
• High power frequency and impulse-voltage strength
• Virtual absence of partial discharges
• High short-circuit strength
• Low noise levels
• Low hotspot temperature rise differential
3
Cores
Construction ensures optimal performance.
Transformer cores utilize mitered step-lap technology to optimize performance and
minimize sound levels. Cores are constructed of non-aging, high permeability, grainoriented silicon steel laminations without punched holes offering high magnetic
permeability.
Core laminations are free of burrs and stacked without gaps, resulting in the lowest
possible losses from magnetic hysteresis and eddy currents. The core clamping brackets
are designed to provide an even distribution of clamping forces to the core yokes and
legs and are rigidly braced to reduce sound levels and losses.
Other core construction benefits include:
• Magnetic flux densities, kept well below saturation point
• Surfaces of the core, clamps and tie rods are all treated against corrosion
Enclosures
Withstands the harshest indoor and outdoor environments.
Enclosures are suitable for lifting, jacking, rolling or skidding with provisions for lifting the
transformer from its base. The standard indoor enclosures are IP20, IP30 and NEMA 1,
Category C construction.
While core and coil technologies have been enhanced to combat caustic and humid
environments, Wave Cast transformers are further protected by properly designed
enclosures. GE enclosures are custom fabricated using heavy gauge sheet steel. Optional
aluminum and stainless steel enclosures are available.
Additional protection against harsh outdoor or indoor environments is provided through
electrostatically deposited dry powder paint baked onto a phosphate treated surface. The
paint finish is neat, clean and highly resistant to corrosion.
A variety of optional enclosures is available: drip proof roofs, supplemental filters, screens,
hinged panels and special hardware. Other modifications can also be made to extend the
enclosure, add bottom plates, add end sheets and/or include special cutouts for specific
applications.
4
Accessories
Temperature monitor/fan controller
The controller can display the operating temperature of windings, control
fans and provide temperature alarm, ensuring effective monitoring and
protection of the transformer.
The PT100 sensors are inserted into each LV winding to send the temperature
signal, which can be displayed on the panel.
Main function:
• Setting alarm temperature level
• Record the maximum temperature in non-volatile memory,
Controller Panel
• Send fault signal and alarm
• Send audible over-temperature alarm, alarm signal and trip signal
• Start and stop fans automatically or manually (optional)
• Provide communication interface (optional)
Cross flow fan
The low noise cross flow fan can reduce the winding temperature, enhance
the overload ability, and prolong the service life of transformer.
The rated power of transformer can be increased by 25-40% when forced
air-cooling is used.
Cross flow Fan
Roller
4 rollers can be equipped under a transformer or enclosure to facilitate
moving in two directions.
5
Technical specifications
Standard products
IEC
ANSI / IEEE
Phases
3
Conductors
Copper or Aluminum
Frequency (Hz)
50
60
Primary Voltages (kV)
Up to 35
Secondary Voltages (kV)
Up to 10
Power (kVA)
160 - 10,000
Off-load tapping range
±2×2.5%, ±5% *
Insulation class
Ambient temperature (℃)
F (155℃) or H (180℃)
Max
Min
≥-5 (indoor), ≥-25 (outdoor)
Altitude (m)
≥-30
≤1,000
Connection
Cooling
150℃or 180℃
≤40
Dyn5, Dyn11, YNd11, Yyn0 and others
AN, AN/AF, AF
* Other taps are available on request.
Accessories / options
• Enclosures: IP20, IP21, IP23, NEMA 1, NEMA
3R and others
• Space heaters
• Thermostat for space heaters
• 120/240V fans for forced-air cooling ratings
• Temperature monitor/fan controller
• Rollers
Applicable standards
• IEC 60076-11:2004
Dry-type transformers
• IEEE C57.12.01-2005
General requirements for dry-type distribution
and power transformers including those with
solid-cast and/or resin-encapsulated windings.
6
Special design or application
•
•
•
•
•
•
•
•
•
Larger power
Higher secondary Voltage
Special ambient
Special altitude
On-load tap changing
High overload capacity
Low loss
Special short-circuit impedance
Special usage
AA, AA/FA, AFA
Technical specifications
Phase number
Frequency
Service condition
Tapping range of
HV winding
Connection symbol
Insulation class
Temperature rise
limit
3
50 Hz
Normal condition according to
IEC60076-11: 2004
±2×2.5% or ±5%
Dyn, Yyn,
Yd, YNd
F
100K
Copper windings, distribution transformers
HV Um=12kV LV Um≤1.1kV
Rated Power
No-load Loss
Load Loss 75℃
Load Loss 120℃
Short-circuit Impedance
Noise LPA
Length
Width
Height
Weight
Distance Between Rollers
kVA
W
W
W
%
dB
mm
mm
mm
kg
mm
200
700
2280
2600
4
46
1170
750
930
1040
660
315
1000
2990
3400
4
46
1230
750
1040
1330
660
400
1080
3520
4000
4
46
1260
750
1110
1500
660
500
1250
4100
4650
4
48
1310
750
1160
1750
660
630
1300
5300
6000
6
48
1410
750
1170
2010
660
800
1550
6500
7350
6
50
1470
920
1280
2310
820
1000
1800
7210
8100
6
50
1500
920
1400
2710
820
1250
2000
8570
9600
6
50
1580
920
1440
3190
820
1600
2600
10700
12000
6
52
1700
920
1570
3920
820
2000
3400
12800
14400
6
54
1890
920
1570
4930
820
2500
4000
15400
17000
6
56
2010
1170
1620
5730
1070
3150
5000
20000
22000
6
58
1970
1270
1960
6400
1070
kVA
W
W
W
%
dB
mm
mm
mm
kg
mm
315
1100
2990
3400
6
48
1380
750
1220
1520
660
400
1200
4050
4600
6
48
1370
750
1290
1620
660
500
1400
4920
5600
6
50
1400
750
1360
1850
660
630
1500
6020
6800
6
50
1530
750
1360
2080
660
800
1800
6500
7350
6
52
1590
920
1400
2550
820
1000
2100
7470
8400
6
52
1650
920
1500
3050
820
1250
2400
9440
10600
6
52
1710
920
1650
3570
820
1600
2600
10700
12000
6
54
1850
920
1760
4500
820
2000
3500
12800
14400
6
56
2010
1170
1800
5450
1070
2500
4300
15400
17000
6
58
2100
1170
1830
6070
1070
3150
5000
20000
22000
6
60
2130
1270
2060
7050
1070
630
1840
6020
6800
6
54
1670
920
1560
2600
820
800
2100
7100
8000
6
56
1680
920
1580
2800
820
1000
2450
8000
9000
6
58
1770
920
1620
3500
820
1250
2800
11600
13000
6
60
1800
920
1900
3900
820
1600
3200
12900
14500
6
60
1890
1270
1960
4600
1070
2000
3900
13900
14600
6
62
1950
1270
2180
5700
1070
2500
4600
17500
20000
6
62
2100
1270
2180
6700
1070
3150
5500
21500
23500
6
62
2280
1270
2180
7700
1070
HV Um=24kV LV Um≤1.1kV
Rated Power
No-load Loss
Load Loss 75℃
Load Loss 120℃
Short-circuit Impedance
Noise LPA
Length
Width
Height
Weight
Distance Between Rollers
HV Um=40.5kV LV Um≤1.1kV
Rated Power
No-load Loss
Load Loss 75℃
Load Loss 120℃
Short-circuit Impedance
Noise LPA
Length
Width
Height
Weight
Distance Between Rollers
kVA
W
W
W
%
dB
mm
mm
mm
kg
mm
Other powers and voltages are available on request.
7
Technical specifications
Aluminum windings, distribution transformers
HV Um=12kV LV Um≤1.1kV
Rated Power
No-load Loss
Load Loss 75℃
Load Loss 120℃
Short-circuit Impedance
Noise LPA
Length
Width
Height
Weight
Distance Between Rollers
kVA
W
W
W
%
dB
mm
mm
mm
kg
mm
315
900
3100
3500
4
46
1310
750
1090
1300
660
400
1000
3500
4000
4
46
1320
750
1200
1500
660
500
1200
4200
4800
4
48
1350
750
1300
1700
660
630
1300
5380
6100
6
48
1520
750
1310
1880
660
800
1600
6600
7500
6
50
1560
920
1410
2200
820
1000
1800
7100
8100
6
50
1610
920
1550
2580
820
1250
2150
8400
9600
6
50
1680
920
1640
3060
820
1600
2600
10800
11600
6
52
1740
920
1800
3760
820
2000
3300
12800
14000
6
54
1860
920
1840
4300
820
2500
4000
14500
16000
6
56
2070
1170
1890
5500
1070
3150
5000
19500
21000
6
58
2130
1170
2050
6400
1070
kVA
W
W
W
%
dB
mm
mm
mm
kg
mm
315
1200
3100
3500
6
48
1470
750
1350
1550
660
400
1300
3500
4000
6
48
1470
750
1390
1650
660
500
1500
4300
4900
6
50
1490
750
1410
1900
660
630
1600
6350
7300
6
50
1590
920
1420
2000
820
800
1700
7700
8700
6
52
1620
920
1520
2150
820
1000
2000
7400
8400
6
52
1780
920
1650
2650
820
1250
2400
9300
10600
6
52
1770
920
1770
3300
820
1600
3000
11200
12500
6
54
1890
920
1930
4060
820
2000
3500
12800
14400
6
56
1980
1170
1960
4850
1070
2500
4000
14500
16000
6
58
2130
1170
2040
5800
1070
3150
5000
19500
21000
6
60
2210
1170
2180
6900
1070
5000
8300
3000
34000
8
63
2760
1675
2300
11500
1475 (W)
1475
2040 (L)
6300
9000
34000
38000
8
63
2780
1675
2370
13200
1475 (W)
2040 (L)
8000
11000
40000
47000
9
65
3000
1675
2660
15300
1475 (W)
2040 (L)
10000
12800
46000
55000
9
65
3150
1675
2750
18100
1475 (W)
2040 (L)
12500
14500
55000
62000
9
67
3300
1675
2950
22500
1475 (W)
2040 (L)
HV Um=24kV LV Um≤1.1kV
Rated Power
No-load Loss
Load Loss 75℃
Load Loss 120℃
Short-circuit Impedance
Noise LPA
Length
Width
Height
Weight
Distance Between Rollers
Other powers and voltages are available on request.
Copper windings, power transformers
HV Um=40.5kV LV Um>1.1kV
Rated Power
No-load Loss
Load Loss 75℃
Load Loss 120℃
Short-circuit Impedance
Noise LPA
Length
Width
Height
Weight
kVA
W
W
W
%
dB
mm
mm
mm
kg
1000 1250 1600 2000
2700 3200 3600 4300
8500 10600 11200 13500
9600 12000 12800 15000
6
6
6
7
58
60
60
61
1950 2010 2070 2150
920
920
920
1270
1700 1800 1880 1960
3700 4500 5100 6150
2500
4500
16000
18000
7
61
2100
1270
2180
6650
3150
5400
21000
24000
8
62
2430
1270
2130
7850
Distance Between Rollers
mm
820
1070
1070
820
820
1070
4000
6500
25000
28000
8
62
2500
1270
2260
9250
Other powers and voltages are available on request. Aluminum windings are available as well.
8
IP23 outdoor enclosure
IP30 enclosure
Technical specifications
Enclosures
Nominal Outline Dimension
Rated
power
(kVA)
1600
1800
2000
2200
315
①
②
②
Length (mm)
Width (mm)
Height (mm)
2400 2600 2800 3000 3200 1200 1400 1600 1800 2000 1800 2000
①②
①②
2200
2400
2800
400
①
②
①②
①②
500
①
②
①②
①
②
630
①
②
②
③
①
①②
③
①
①②
③　800
①
①
②
③
①②
③
①
①
②③
1000
①
①
②
②
③
③
①②
③
①
①②③
1250
①
②
②
③
③
①②
③
①
①②
③
1600
①
①
②
③
③
③
①②
③
①
①②③
2000
①
①
②
③
③
①
①
②③
③
①
①②
③
2500
①
①
②
③
③
③
①
②③
③
①
①②
③
3150
①
②
②
③
③
①
②③
③
①
①②③
Notes: ① – HV Um=12kV, ② – HV. Um=24kV, ③ – HV Um=40.5kV;
Outline dimensions of enclosure are related with not only rated power and primary voltage of transformer, but also conductor material
used. Please contact us for your specific application.
• Cable top in-coming or out-going
• Cable bottom in-coming or out-going
• Busbar top out-going
• Busbar lower side out-going
• Busbar upper side out-going
Other connecting methods, Please contact us.
Height
Available connecting method
Standard enclosure type
• IP23, NEMA 3R for outdoor installation
• IP20, IP21, IP30, NEMA 1 for indoor installation
Width
Len
gth
9
Tests
Standard insulation level
Tests are performed in accordance with IEC60076-11:2004 or
IEC
IEEE C57.12.91-2001.
Routine tests
Each cast coil transformer is submitted to a complete set of
routine tests for ensuring transformer reliable.
• Measurements of winding resistance
• Measurement of voltage ratio and check of phase
displacement
• Measurement of insulation resistance
• Measurement of short circuit impedance and load losses
• Measurement of no-load losses and current
• Separate-source AC voltage withstand voltage test
• Induced AC withstand voltage test
• Measurement of partial discharge
Highest Voltage for
equipment Um
(r.m.s)
(kV)
Rated short duration
separate source AC
withstand voltage
(r.m.s)
(kV)
Rated lightning
impulse withstand
voltage (peak value)
(kV)
≤1.1
3.6
7.2
12
17.5
24
36
3
10
20
28
38
50
70
40
60
75
95
125
170
ANSI/IEEE
Nominal Voltage
(kV)
Type tests
Type test is performed in case of new design or important
design modification in order to confirm that the quality of
transformer is compliance to related standard. They can be
carried out according to custom request.
1.2
2.5
5
8.7
15
25
34.5
Low-frequency voltage Basic lightning impulse
insulation levels (r.m.s) insulation level (crest)
(kV)
(kV)
4
10
10
20
12
30
19
45
31
60
37
110
50
150
• Temperature-rise test
• Lightning impulse test
ANSI/IEEE standard sound leveL
Special tests
Can be performed upon request
• Sound level test
• Short-circuit test
Wave Cast had pass the following tests:
• Short-circuit test at KEMA Holand on one 2.5MVA
transformer
• All the routine, type and special tests at CTQC witnessed
by KEMA on both one 1600kVA 11/0.4kV copper winding
transformer and one 2000kVA 20/0.4kV aluminium winding
transformer. (KEMA report)
• All the routine, type and special tests at CTQC (China
Transformer Quality Center) on one 2MVA distribution
transformer
• All the routine, type and special tests at CTQC on one
10MVA power transformer
• The C2 climatic class, E2 environmental class, F1 fire
behaviour class tests at CTQC
• Vibration test withstand the acceleration ag of the horizontal
0.6g and vertical 0.3g at Tongji University
10
Rated power (kVA)
Self cooled (db)
Fan cooled (db)
300
500
800
1000
1600
2000
2500
3150
5000
55
60
64
64
66
66
68
70
71
67
67
67
67
68
69
71
71
73
Certificates
ISO 9001:2000 Certification awarded
by Bureau Veritas Certification (BVQI)
Hongkong
2.5MVA 12.47kV power transformer
short-circuit test report at KEMA USA
1 6 0 0 k VA 1 1 k VC o p p e r w i n d i n g
transformer test report of KEMA
2000kVA 20kV Aluminium winding
transformer test report of KEMA
10MVA 35kV power transformer test
report at CTQC
Vibration test report at Tongji University
11
Handling
Handling transformer
Transporting by fork-lift truck
1. 4 hoisting joint hinges are installed on the upper clamps
1. The fork shall be symmetrically placed under the enclosure
(channel-section) of transformer.
base to avoid declining and overturn.
2. It is suggested to hoist the body integrally by 4 steel cables.
3. The included angle between steel cables is not more than 60
2. The fork end shall be over the enclosure center to avoid
declining and overturn.
3. The speed shall be limited to avoid tossing.
degree.
Hoisting hanger
Steel cable
≤60°
Enclosure
Joint hinge
Fork-lift truck
Transformer
Enclosure center & Forks center Enclosure center
Handling transformer with enclosure
Enclosure
Fork-lift truck
Enclosure
1. The 4 lifting pads are fixed on the base of enclosure.
Fork-lift truck
2. It is suggested to hoist the enclosure by 4 steel cables and
spreader bar (or similar tools) as below.
3. The included angle between steel cables is not more than 60
degree.
Fork end (over the enclosure center)
4. The special handling way, please refer to the sketch map on
the enclosure.
Storage
1. Transformer in storage and non-running period shall be
away from severe moisture.
≤60°
2. The relative humidity of the surrounding air shall be less than
93%. No drops of water shall be present on the surface of the
coils.
3. The details refer to the Wave Cast Manual.
Handling transformer with enclosure
12
Foundation
Enclosure
A
B
C
Enclosure
Concrete
Concrete
Cable trench
(If applicable)
Channel steel
(inserted in concrete foundation)
Fix holes
100
100
Fix holes
100
Concrete
Channel steel
(inserted in concrete foundation)
Enclosure bottom
Cable trench
(If applicable)
Fix holes
Transformer support channel steel
Fix holes
100
4-ø22
Fix holes
13
Greater China
Shanghai
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Australia & New Zealand
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Italy
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Germany
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Hungary
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Latin America
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and
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Brazil
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T: +55 11 36141900
Mexico
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T: (01-800) 800-1968
Russia
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P.O. Box 76672 Wendywood 2144
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United Kingdom
Houghton Centre, Salthouse Road, Blackmills,
Northampton
NN4 7EX
T: +44 (0)800 587 1239
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