C a s t C o i l Tr a n s f o r m e r s

100 kVA to 30 MVA

2 3kV tto 34
2.3kV 34.5kV
5kV

Extraordinary Quality, Reliability and Service

Energy Efficient
Low Total Owning Cost
“ Proven World Class Leader”
“ World Class Cast Coil Transformers with Credentials”

This brochure is an overview of why Over this period, we have value the opportunity to discuss your
JST can qualify
lif as your prime
i source d
demonstrated
t t d a reliability
li bilit andd service
i needs
d and d any other
th questions
ti you
for Cast Coil Transformers. JST has record of the highest level globally. may have about JST Cast Coil
served the North American market This is the core of JST’s credentials. transformers.
since 1998 and brings extensive We welcome the inspection of our
experience of over 25 years serving claims and comparison against any
other major world markets. other sources. We appreciate and

Credentials Related Comments Re f. Pages

Experience record -Over
Over 20,000
20 000 MVA installed in a diverse range of duty and in the most demanding 2
applications and environments

Standards and Designs -Meets All US or IEC Standards 3

-Proven “May Christie” technology
-Ratings through 15,000 kVA and 34.5kV
-185 ℃ / 115 and 80 ℃ rise; and 150 ℃ / 80 ℃ rise
Product Performance -Meets or exceeds all standard and customer specifications 3,4
Reliability -A reliability record superior on a global comparison (99.9%)
Performance
Design and -State of the Art, automated, design (CAD), core, coil, casting manufacturing and 5, 6, 7, 8
Manufacturing testing systems.
Systems and Facilities - Clean, orderly facilities, precise and consistent, cost effective

Quality Systems -Philosophy… Highest possible quality standards followed throughout all operations 4,8
T ests and Certification -All C57.12.91 tests plus many optional tests
-Certification: ISO9001, ISO14001, KEMA
UL & cUL listed

Fit-Finish and Features - Superior by design and it shows 9

Order/ Customer -95% of quotes within 2 days 10,11
Service
Product Service -Competitive US factory and field service
Delivery Service -Competitive lead times
-99% on-time delivery record
T otal
t lOOwning
i C Costt “L
“Lowest
t T otal
t l Owning
O i Cost
C t – Efficiency
Effi i + all
ll other
th costs”
t ” 11
(T OC)

All add up to superior performance, and a high confidence level,

critical in reliable application of Cast Coil Transformers.
JST Served Market… Experience

JST Cast Coil Transformers offer the ultimate in performance and reliability while serving the most severe and demanding
applications and environments
environments. Solid cast resin construction of primary and secondary coils have demonstrated superior
capability and exceptional reliability.

•Low installation cost – no need for liquid containment

•Withstand extreme impact and short circuit loads
•Impervious to Moisture, contaminants and other hostile environments
•Exceptionally long life with minimal maintenance

Windpower Airports Trains and Subways

Universities Cast Coil Transformer Computer Data Centers

Hospitals Power Systems Office Buildings

Standard and Optional Ratings and Features

Sizes Available kVA 150 300

150, 300, 500
500, 750
750, 1000
1000, 1250
1250, 1500
1500, 2000
2000, 2500
2500, 3000
3000, 3250
3250, 3750
3750, 5000
5000, 7500
7500,
10000, 12000, 15000, 20000
Primary Voltage Classes, kV 2.3, 5, 8.7, 15, 25, 34.5

Secondary Voltage, kV 0.208, 0.24, 0.48, 2.4, 4.16, 6.9, 12.47, 13.2, 13.8

Basic Impulse Levels

Levels, kV Standard Optional
1.2 10 20,30
2.5 30 45
5.0 60 75
8.7 75 95
15 95 110
25 125 150
34.5 150 170

Winding Temperature Rise, oC 80 115

Impedance 5.5% through 7.5% depending on HV, HV and LV ratings

Forced Air Rating 133% 140%

300-15,000kVA

Conductor Material Copper Aluminum

Range oC
Ambient Operating Range, -40
40 to 30 avg/40 max to 50

Standard Features Options

•Windings Cast in vacuum in a mold •Aluminum windings
•Copper windings •80Ԩ average temperature rise
•Step-lap mitered/cruciform core •NEMA 3R, NEMA 4, stainless steel enclosure
•185Ԩ insulation system 115Ԩ rise •Forced air cooling
•Four full capacity tap on HV winding rated 2 1/2%, 2-FCAN - FCBN on •Three phase electronic temperature monitor
units with voltage above 601V •Higher BIL
•NEMA 1 heavy-gauge ventilated enclosure with removable panels •Loss optimized designs (TOC)
front and rear •Humidity control / Heaters
•Provisions for lifting core and coil •R-C Snubber
•Vibration isolation pads between core and coil and enclosure •Triplex Design
•Base equipped with Jack pads and designed for rolling or skidding in
any direction Standard Certification
•Diagrammatic aluminum nameplate •UL 1562
•Partial discharge free (< 10 pc@120% rated voltage) •ANSI C57.12.01, C57.12.91
•ANSI ANSI N45.2-1977
•NRC 10CFR50 Appendix B
•ISO9001
•NEMA std20
•CSA Z 299.3
Quality and Reliability Assurance

Superior JST Cast Coil quality and reliability is the result of many key ingredients.

Corporate JST’s foundation is built on the fundamental philosophy that customer satisfaction and long-term
Foundation success depends on consistently supplying transformers on-time and of the highest possible quality,
and that will perform well and reliably in the most severe applications and environments.

Standards & Quality standards and practices per ISO 9001 are clearly documented, communicated and rigorously
Practices followed throughout all aspects of the business.

Certifications

ISO9001 ISO14001 OHSAS18001 KEMA UL

Computer Aided The most advanced computer aided design (CAD) systems are
Design operated by highly trained engineers, assuring accurate, optimized
designs, exact fit of all parts, plus providing programs for automated
core cutting and stacking, coil winding and testing.

Highest Quality All materials meet the highest standards with assurance per ISO 9001
Materials - Core steel of high efficiency, high permeability grain oriented silicon steel
- Insulation materials are used to meet UL certification

State-of-the-Art Automated, state-of-the-art manufacturing systems are used in all stages of production – core
Manufacturing cutting and stacking, coil winding and casting, assuring precise, consistent transformers, with high
efficiency,
ffi i low
l losses
l and
d noise
i

Testing Each transformer is 100% tested to assure compliance with all customer specifications and to all
US Standards per ANSI C57.12.91, and in accordance with ISO 9001 procedures.

Routine Tests Optional Tests

•1. Polarity and phase-relation tests • Temperature Rise
•2. Ratio test • ANSI Impulse
•3. Winding resistance measurements • Sound Level
•4. Separate-source AC withstand voltage test
•5. Induced AC withstand voltage test
•6. No-load loss and excitation current Design Type Tests
•7. Load loss and impedance • Short Circuit
•8. Partial discharge measurements • Seismic Qualifications
•9. Insulation resistance measurements
•10. Auxiliary control circuitry test
Core Manufacturing Process

State-of-the-art manufacturing with CAD optimized designs. The design

systems are used throughout JST’s
JST s process computerized automatic precision
process,
entire operations. First is a detailed cutting, stacking and handling, and the highest
computer aided design defining the quality high permeability, grain oriented silicon
entire transformer and all of its steel, all contribute to achieve a consistently
components in exact detail. high core quality with the lowest possible losses
GEORG automated cutting and and sound levels, and at an economic cost.
stacking line is computer programmed

3D CAD modeling insures parts fit

exactly prior to assembly

Core Cutting Equipment Core Stacking Equipment

Cruciform construction, nearly stacking also assures minimal stress, transferring along natural grain
round, enables minimal dimensions for consistent quality with higher efficiency and oriented lines, enhancing efficiency
lowest losses and optimal coil fit, lower noise. by reducing joint fringing, thereby
thereby optimizing total transformer Mitered step-lap construction with reducing losses and exciting current
material utilization and operating precision joints allow efficient flux and yielding the lowest sound levels.
energy cost. Automatic, precise

Core Assemblies Mitered Step-lap construction

Coil Manufacturing Process

JST’s coils are produced with state-of-the-art, computer automated, winding and casting equipment from Germany using the
highest quality copper or aluminum conductor and insulation materials used in UL certified insulation systems
systems.

Stollberg secondary winding machine, is computer Stollberg primary winding machine is computer controlled
automated and features conductor under constant and features controlled tensioning and precision wire laying
tensioning, and precision, automated welding of copper or ensuring consistently high quality coils.
aluminum strip and LV terminal, ensuring consistently
hi h quality
high lit coils.
il

perfect, solid, void-free castings,

Casting is the most critical step for process is made possible by a modern, with the resin completely saturating
ensuring coil winding quality and computer controlled, high capacity, all of the insulation and tightly
integrity and the guarantee that a casting system supplied by Hubers of holding the winding in place,
transformer will perform reliably, long- Germany, the most proven technology assuring long-term reliable
term, under the most demanding globally. This state-of-the-art vacuum operations, under the most
applications and severe casting system employs static mixing, crushing forces of short circuit and
environmental conditions. Extensive a process that delivers a constant Di l t i iintegrity,
power surges. Dielectric t it
testing and JST's extremely high viscosity, uniform, gas free resin important for basic impulse level
reliability record clearly demonstrate mixture to pre-heated molds, which (BIL) and lightning or switching
that JST's vacuum cast resin are filled from the bottom, under surge applications, is assured by
transformers meet all criteria for vacuum, all in a climate-controlled the solid resin block being
serving under the most demanding room. Curing in time-temperature impervious to moisture and
conditions. Consistency of the casting controlled ovens results in environmental contaminants.

HV Coil

Coil Cross-Section

Hubers computer controlled casting system

Coil top view

Manufacturing Facilities...
Manufacturing Facilities...

Inspection of JST’s manufacturing facilities

clearly reveals key ingredients for
exceptional quality. Cleanliness throughout.
Strict attention to process and quality control
procedures. Planned, orderly flow.
Design and testing to either ANSI or IEC
specification. Extra protection for safe
shipment to customers around the world.
Features… Quality is Built In… . And It Shows

JST’s
JST’ transformers
f are known
k for
f their
h i superior Fit… .
i Fi
Finish … and Functionality.
JST Core-Coil assemblies are designed for optimized
performance and value. For greater cooling capacity needed
in higher power transformers, axial ducts are added in HV
coils providing more cooling surface thus enabling greater
optimization. Photos show higher kVA ducted and lower kVA
non-ducted coils.
Coils are supported on the top and bottom with epoxy blocks,
cushioned with resilient pads to permit expansion and
contraction.

Upper jack-bolt assemblies provide uniform pressure to

contain coil movement. Details make JST’s transformers
better. For example, bottom coil blocks are pinned to the
lower core clamps to prevent them from shifting or falling out.

Top coil blocks are recessed to capture the jack-bolt plates.

T and
Top d bottom
b tt blocks
bl k are machined
hi d tto provide
id permanentt
“high-low space” separation of the coils, helping to maintain
consistent dielectric performance.

Fan superiority is also evident. Fans are constructed of

stainless steel and with squirrel cage air delivery system, and
can deliver up to 50% additional transformer capacity, the
highest in the industry.

We can comply with Buy America and ARRA requirements

WITNESS
TESTING

We can
provide
Witness
Testing
(including
all routine
tests) in
our
Carlstadt,
NJ facility
Cast Coil Specification Guide

1.0 General National Electrical Manufacturer’s perform all ANSI required tests
The transformer shall be cast coil
coil, dry- Association (NEMA) and the American including impulse
impulse, temperature rise
type construction, manufactured and National Standards Institute (ANSI). and sound level, and have at least
tested in accordance with applicable Manufacturer shall be ISO certified, five years experience.
industry standards prepared by the have complete in-house capability to

2.0 Ratings
kVA, _______AA, ______ /______ AA/FA, _______/______ AA/FFA, Conductor & bus _______ copper or aluminum
Primary coils are vacuum cast with Secondary coils___ vacuum cast or ___ eNcast (hermetically sealed epoxy)
Primary volts_______ delta or wye connected, BIL ___kV, Phase __, Frequency _ _, Taps__ standard 2+/-
2.5%
2.5%_____other
other
Primary terminals connect to __ customer cables inside transformer case, __ HV ATC, __ HV switch/ breaker, ___ busduct
Secondary volts ____ delta or wye connected, BIL ___ kV Impedance % __ standard tolerance), __+/-10% tolerance
Secondary terminals connect to __ customer cables inside transformer case, __ LV ATC, __ LV switchgear, __ busduct
Sound Level ____ dB (AA), ____/___ dB (AA/FFA or AA/FA) ____dB (standard)
Temperature rise 115°C, or 80°C, or 80/115°C with continuous 15% overload capacity without exceeding maximum
operating temperature,
Ambient temperature ____ °C , ____(standard 30/40 °C )
Special accessories ________________________________________________________________________________
Enclosure _________ Indoor (NEMA 1 or NEMA 2), or _________ Outdoor (NEMA 3R)
Total Owning Cost evaluation, ____ standard losses and efficiency or ____NEMA TP1 high efficiency rating or
Special loss evaluation @ ______% load, “A” or NL value $______ /kW, “B” or LL value $______/kW

3.0 Construction
3.1 HV & LV Coils The assembled core shall be braced with air provisions shall include bus sized for the
The transformer shall be constructed of heavy steel angle to provide uniform maximum FA rating, and provisions for
individually cast, co-axially mounted, clamping pressure. Core and clamping mounting fans and controls.
primary and secondary coils. Primary coils structure shall be coated with high 3.4 Enclosure
shall be wound with copper or aluminum temperature enamel for environmental As specified, a heavy gauge sheet steel
conductor as specified. High voltage taps protection. The top and bottom of the coils NEMA 1 indoor, NEMA 2 indoor
shall be provided on the front of the coils
coils, shall be supported on epoxy blocks
blocks, drip-proof,
drip proof, or NEMA 3R outdoor enclosure
2-2.5% full capacity above nominal (FCAN) cushioned with resilient pads, to secure them shall be supplied. The design shall permit
and 2-2.5% full capacity below nominal while permitting them to expand under the enclosure to be disassembled and
(FCBN), and are changed only when the loading. Bottom coil blocks shall be pinned reassembled, and the core-and-coil assembly
transformer is de-energized. Threaded brass to bottom core clamps to prevent blocks removed from its base in the field without
tap inserts imbedded in the epoxy and bolted from moving. Manufacturer shall mark all cutting or welding. Resilient pads mounted
solid tin-plated bus tap links shall be bolted torque connections. The transformer below the core-and-coil assembly shall
furnished. Drilled bus tabs extending core and coil design and construction must effectively dampen vibrations to the
through the epoxy are not permitted. High be verified by short circuit testing on similar transformer enclosure. Equip enclosures
voltage windings are cast in epoxy, in a units, performed in accordance with the with removable bolted panels on the front
mold, using pre-heat and vacuum cycles and latest revisions of ANSI Standards and rear for internal access. Indoor
a bottom injection filling process to assure C57 12 01 and C57.12.91.
C57.12.01 C57 12 91 ventilated openings or outdoor louvers shall
optimal saturation of the epoxy. The epoxy, 3.3 Accessories comply with NEMA and NEC standards.
rated for the same temperature as the Fan cooling, if specified shall increase base The heavy steel enclosure base shall include
insulation system, shall be reinforced with kVA rating by 33 1/3% on units up to provisions for rolling, skidding, lifting, and
fiberglass. Secondary coils utilizing wire or 3750kVA and 25% on units over 3750kVA jacking. A flexible grounding strap shall be
sheet conductor are wound separately, and at the rated temperature rise. If 80/115°C is used to visibly ground the core to the frame.
are either vacuum cast as the high voltage specified, base ratings will increase 50% up Enclosure finish shall be ANSI 61utilizing
coils or eNcast construction, a non-vacuum to 3750kVA and 40% on units over dry powder, electro-static process.
process with oven cured epoxy layer to layer 3750kVA when operating at the maximum 4.0 Testing
insulation and epoxy caps on both ends of temperature rise. Thermal sensors placed in Testing shall comply with the latest
the coil. HV and LV coils shall be designed tube wells adjacent to the leads of all three revisions of ANSI C57.12.01 and ANSI
to operate in a 30°C average, 40° C LV coils shall automatically regulate C57.12.91. Each transformer shall receive
maximum ambient temperature in a 24-hour forced-air cooling. Complete forced air the following tests: Ratio, Polarity, Phase
period. equipment includes flush mounted Relation, No Load Loss, Excitation Current,
3.2 Core & Coil Assembly three-phase electronic temperature Impedance Voltage, Load Loss, Applied
The transformer core shall be designed to monitor-controller with contacts for fan, Potential, Induced Potential and Partial
maintain flux density well below saturation alarm and trip function, fail safe maximum Discharge test (for coils over 600 volt).
and consist of Grade M-5 (minimum), high temperature recording, internal alarm with Windings shall be tested for partial
permeability, grain-oriented, non-aging automatic or manual reset, programmable discharge at 120% of rated voltage, with 10
silicone steel. Core shall be step-lap, fan exerciser feature and blackbox, bus sized Pico-Coulomb maximum extinction level.
cruciform construction with mitered joints. for the maximum FA rating, fans and control Impulse, sound level, temperature and short
Too assure
assu e reduced
educed sou
sound d levels
e esa and
d lowest
o est wiring.
g After exiting
g the LV tube wells,, circuit test results shall be available upon
p
losses, core legs shall be insulated and thermal sensors are to be routed in metal request from previously tested similar
banded with stainless steel straps and top conduit-tray to prevent damage. Plastic designs.
and bottom core clamps shall utilize an tie-wraps are not permitted for securing the
insulated through-core bolting process. thermocouple. At a minimum, future forced
Transformer Selection

Selecting the best transformer for an application requires consideration of several factors.
• Choice between types
types, Liquid -filled,
-filled Dry-type
Dry-type, or Cast Coil
• Choice between transformer suppliers
• Choice between price and total life cycle costs, as basis for purchase

Choice between types:

Choice between types is usually based on how and where the transformer is being applied, plus weight given to relative
cost between types. Cast coil usually is the best choice where duty, and environment are most severe and where the
highest confidence of reliable, long-term operation is critical. First cost of a cast coil is usually higher than other
technologies, however this premium is offset by product advantages, superior operating performance, and lower operating
costs .

Choice between suppliers:

Choice of supplier is highly influenced by relative price, plus some price allowance for how well suppliers compare in
meeting customer specification, and in the degree of customer confidence in product reliability and overall service.
However, increasingly, customers are becoming much more aware of the importance of evaluating total life cycle cost
when choosing transformer type, and suppliers.

Selection of transformer type and supplier based on Total Life Cycle Owning Costs (TOC)
TOC is a combination of (First Cost or Price + Operating Costs). Operating Cost consist of all cost invoLVed from sourcing,
through installation,
installation insurance
insurance, maintenance; repair
repair, cost of electrical losses related to transformer efficiency (normally
referred to Cost of Losses or COL), and finally disposal at life’s end. Selection of transformer type and supplier based on
TOC evaluation requires determination of the TOC for each transformer under consideration and then comparing TOC of
each. Type and supplier with the lowest TOC and best reliability should win if TOC is the basis of selection.

Cast Coil Transformer TOC Evaluation:

When comparing cast coil transformers to other types, it becomes apparent that there are other economic advantages:
1. Low installation cost – no dykes or walls for liquid containment or dry out procedure
2. Very low maintenance – immune to moisture, fumes and most contaminated environments
3. Superior operating safety – coils are flame retardant, with self extinguishing properties
4. High reliability, low service downtime and repair. Superior strength and durability of solid epoxy resin castings
ensure maximum dielectric, thermal, and mechanical performance and continuity under demanding operating
conditions, like switching, lightning surges, short circuits and life cycle loading.
5. Low disposal cost – no fluids to leak during operation and no fluids to dispose of at life’s end.
6. Low insurance cost – associated with fire properties, and no fluid spill exposure

Cast Coil Transformers win in more applications when relative performance is measured …
In addition, JST cast coil transformers offer even more…

Superior reliability – 99.9% + Worth… immeasurable for critical applications

Standard core losses typically 20 to 25% lower. Worth … 10-12% price advantage. (@$4/watt NLL)
Higher FA performance 140% or more vs 133%. Worth… over 5% price advantage

JST wins when efficiency, reliability and performance advantages are evaluated…

Jinpan International USA Limited

390 Veterans Boulevard
Carlstadt,, NJ 07072
201-460-8778-tel 201-460-8775-fax
www.jstusa.net
sales@jstusa.net