• Just like oil filled t ransfor m ers , t here are variet ies of windings in cast

resin t ransform ers t oo.

• Reliabilit y & ease of m anufact uring is aslo t o be considered while
deciding on any winding m et hod.
• Maj or t ypes in cast resin t ransform er windings m et hods are..
• Low volt age winding
• Foil winding using t hin st rip
• Layer winding by using Rect angular wires.
• High Volt age winding
• Foil disc winding
• Layer winding by using Round/ Rect angular wire
LV Foil winding:
• I t uses a single piece of t hin st rip as conduct or. Widt h of t he foil is equal t o lengt h
of t he winding.
• This conduct or st rip ( foil) wound along wit h a pre- im pregnat ed int erlayer
insulat ion. During curing process foil and insulat ion are bonded t oget her t o form a
rigid block. The LV coil becom es self support ing against forces.
• Lat er t he coil is im pregnat ed wit h resin for environm ent al prot ect ion.
• Eddy losses in t he t hin foil are very less com pared t o t hick rect angular wires,so
windings m ade wit h foil are cooler t han ot her t ypes.
• Foil winding m inim izes t he axial forces during short circuit , since curr ent s in t he
winding are adj ust ed t o t he am pere t urns in t he high volt age winding.
• I s sim ple int roduce cooling duct wit hout decreasing t he m echanical st regnt .
• I t is easy and quick t o m anufact ure t his t ype of winding.
LV layer winding:
• Mult iple st rands of rect angular wire is used in t his m et hod.
• Conduct or t hickness is generally high t o lim it num ber of st rands. So
eddy & st ray losses are high in t his const ruct ion.
• Transposit ion of conduct ors is m andat ory t o avoid t he cir culat ing
current s in t he windings.
• Transposit ion is a t edious and sensit ive process. I f not done car efully
int er- st rand fault s cause dielect ric failures and hot spot s in t he winding.
• Manufact uring t he m ult ist rand layer winding is com plicat ed.
• Winding is not balanced ver y well wit h t he High volt age winding. Ax ial
forces present during short circuit condit ions.
• I t is not a self st anding const ruct ion, r equires support by cylinder s.
som et im es it is cast ed wit h m oulds.
Layer Winding Foil Winding
HV Foil disc winding:

• Even dist r ibut ion of volt age along t he height of t he winding is im port ant
for High Volt age winding.
• Foil disc winding is a winding t echnique which achives t his requirem ent .
• Thin foils of r equired widt h are w ound w it h int erlayer insulat ion bet w een
t hem . Each layer is a t urn , so volt age st ress is m inim ized.
• Tot al t urns are devided bet ween m any discs , so volt age gradient
bet ween discs is also low.
• This can be m ade on aut om at ed m achines , which gives accuracy &
speed.
HV Foil disc winding :
HV wire winding:
• Several winding m et hods are followed in wire winding
• Mult ilayer w inding , random winding , wire discs winding et c. are som e
m et hods.
• Generally r ound w ire/ rect angular w ire is used for winding based on t he
rat ing.
• What ever t he m et hod followed , unifor m volt age dist ribut ion is not
possible in wire t ype windings.
• This affect s t he im pulse wit hst and st rengt h.
• Volt age st ress increases progressively t owards t he end of layer.
 Foil discs
Random Wire discs Mult ilayer
 Foil disc winding Wire disc winding
Hom ogeneous dist ribut ion Non Hom ogeneous dist ribut ion
What TMC Follows:
• TMC follows Foil disc winding t echnique conisdering it s uniform volt age dist ribut ion.

• Example of 1600kVA transformer 36kV class.

• Impulse level 170kV
• Maximum voltage between discs , in case of impulse , 17kV with 14mm of resin.
Unfilled Sy st em :
• Unfilled syst em , as t he nam e suggest s, does not use any t ype of fillers. Resin
and Hardner are t he m ain com ponent s.
• Unfilled syst em is used where very low viscosit y is a requirem ent .
Ex: very sm all coils used in elect rionics
• Unfilled syst em can have sm aller gaps in t he coils , since t he resin has low
viscosit y.
• Cast ed block in t he unfilled syst em is m anufact ure wit h glass Fibres.
• Fibres needs t o be com plet ely im pregnat ed for achieving t he desirable dielect ric &
m echanical st rengt h.
• Fibres , if not im pregnat ed properly , causes voids in t he coil t hat result s in
dielect ric failures.
• This syst em can be used wit h good result s up 12 kV class. When t he volt age st ress
is not very high.
Filled Syst em :
• Filled syst em m eans , resin & hardner are added wit h fillers like
quart z/ silica/ alum inium hydroxide et c.
• Fillers provide
• Flam e ret ardency, self ext inguishing & arc resist ance
• I ncreases Therm al conduct ivit y
• I ncreases Therm al shock resist ance
• Reduce t he shrinkage
• I m prove adhesion t o t he conduct or
• Brings t he coefficient of t herm al expansion m ore close t o conduct or
m at erial.
• Adding fillers increases t he viscosit y. But viscosit y can be reduced by
warm ing t he resin m ixt ure.
What TMC Follows:

• Filled syst em ( or) Unfilled syst em is t o be decided based on t he product

requirem ent s.
• TMC uses Filled r esin syst em t o fulfill t he pr oduct r equirem ent s as
m ent ioned above.
• TMC product s has C2- E2- F1 cert ificat ed.
• TMC supplies t ransfor m er s suit able for st orage upt o - 50° C , which proves
t he st rengt h of filled syst em .
• I nsulat ion m at erial used in t he filled syst em are self sufficient for dielect r ic
st rengt h. I m pregant ion by resin is not required.
I m pregnat ed windings :
• Ot her nam es for t his const r uct ion are Openwound/ Openvent ilat ed
windings/ VPI / VPE
• Does not require any m oulds for winding. Flexibilit y in design.
• The w inding const ruct ion is sim illar t o disc w indings of oil filled
t ransform ers.
• Windings are im m ersed in resin and t hen cur ed. Resin coat ing on
conduct ors is less t han a m illi m et er.
• provides clear view of t he windings. Fault locat ion is easy.
• Heat dissipat ion direct ly from windings.
• St rengt h aganist short circuit s is poor.
• I nt erspace bet ween w inding discs is air. Lim it ed dielect ric st rengt h due
t o presence of air bet ween discs.
....cont d
• Since w indings are exposed t o at m osphere around t hem , dust collect ion
on surface of conduct ors is possible.
• Mosit ure accum alt es on windings , if t ransform ers are st ored.
• Transfor m ers can not be swit ched on im m edialt ely aft er long shut
downs.
• Part ial discharges possibilit y as air is t he insulat ing m edium .
• Open wound t ransform ers are not conisdered as m aint enance free.
Filled Cast Unfilled Cast
windings windings
Filled Cast windings :
• Unique feat ur e of cast resin t ransfor m er is conduct ors of HV winding ar e
com plet ely encapsulat ed in a cast resin block which has a sm oot h surface.
• They require m oulds t o encapsule t he windings.
• Uses round/ rect angular wire ( or) Foil as t he winding conduct ors.
• Can use bot h Alum inium / Copper conduct ors.
• Foil disc is m ost widely used opt ion for HV winding.
• Windings are m ade on m andrel ,m oulds are fit t ed, Resin is filled and
t hen cured.
• Cast resin coils are non hygroscopic.Transfor m er can be swit ched on
aft er long shut downs.
...cont d
• Cast Coils ar e perfect ly m osit ure proof , dust proof & has very high
reliabilit y.
• Very st rong against short circuit s as windings are encapsulat ed.
• Heat dissipat ion surface area increases due t o t he encapsulat ion of t he
windings.
• Low Part ial discharges since gap bet ween disc is filled wit h resin.
• Cast resin t ransform ers are pract ically m aint enance free.
• Cast winding conduct ors are not visible t o naked eyes.
• Repairabilit y of windings is not an issue , if a t ransform er fails it is
never repaired by an user.
What TMC Follows:
• TMC m anufact ures HV windings using m ould
• LV w inding is m ade wit h AL/ CU Foil. Mould are not used for cast ing.
They are I m pregnat ed.
• Being low volt age , LV winding does not require cast ing
• I nsulat ion used in LV w inding is pre im pregnat ed wit h resins. During
cur ing of LV winding insulat ion and conduct or for m s a rigid block . Lat er LV
winding is im pregant ed wit h resin for environm ent al prot ect ion.
• Such LV windings are suit able for inst allat ion under t ropical or saline
environm net s.
• I f cust om er requires cast LV winding , TMC supplies.
• Bot h are used as conduct or s of elect r icit y & long hist ory of being used as
winding conduct ors for t ransform es.
• Copper is t he preferr ed conduct or during init ial days of t ransfor m er
m anufact uring, due t o it ’s ready availabilit y.
• AL usage becam e prom inent during w orld war2 due t o non availabilit y of
Copper & im provem ent in m et ullargical processes of Alum inium .
• We can achieve sam e perfor m ance param et er s by using Allum ninum
( or) Copper windigs.
• We can com pare bot h conduct ors by
• Elect rical Propert ies
• Therm al Propert ies
• Mechanical Propert ies
Elect rical Propert ies:
• Copper has lesser resist ivit y. To achive sam e ohm ic losses 1.5 - 1.8 t im es
higher cross sect ion of Alum inium t o be used.
• Core cross sect ion t o be increased t o offset t he volum e incr ease due t o
Alum inium conduct or.
• Specific weight of Alum inium is m uch lesser t han copper. So weight of
Alum inium is 50- 55% of weight of copper.
• I ncrease in core weight is com pesat ed by reduct ion in conduct or weight .
• AL t ransforer will have alm ost equal weight as t he copper t ransform er.
• Volum e is slight ly higher t han t he copper t ransform er. ( 5- 10% )
• We can achieve sam e perform ance param ent er s like noload/ load losses,
I m pedance , t em perat ure rise of windings using AL conduct or.
Therm al Propert ies:
• Melt ing point of Alum inium ( 665°C) is considerably lower t han of
Copper ( 1085°C) .
• The serv ice t em pearat ure of cast resin t ransfor m er is 155°C for class F
and 180° C for class H t ransfor m ers.So,Melt ing point is not of
im port ance.
• Therm al conduct ivit y of Alum inium is lower t han copper.But while
calculat ing t herm al gradient s bet ween winding and am bient air w hole coil
is t ake as a block . So heat dissipat ion does not depend solely on t he
Therm al conduct ivit y.
• Surface area of Alum inium is higher t han Copper for sam e losses.
Moreover, specific heat of Alum inium is m ore t han copper.
• Higher surface area and higher specific heat m akes Alum inium coils
cooler t han copper coils for sam e losses.
....cont d
• This is an advant age for longer life of insulat ion and also dur ing shor t
t im e overloads.
•I ncase of resin encapsulat ed t ransfor m ers , it is very im port ant t hat t he
co- efficient of t her m al expansion of conduct or and resin block needs t o be
close. I f t hey differ t oo m uch, cracks develop during varying load cycles.
• Alum inium co- efficient is close t o t he resin m ixt ur e, w hich m akes t his
conduct or m ore suit able for cast coils.
Mechanical Propert ies :
• Conduct ors in t he t ransform ers are st ressed during t he fault condit ions.
• The for ces generat ed dur ing fault s are expressed as com pression ,
t esion and bending bet ween coil support s.
• Breaking st rengt h of Alum inium is lesser t han t he copper. I t is
com pensat ed by t he higher cross sect ion of Alum inium used for sam e
current .
• Furt her High volt age w indings are encapsulat ed in t he resin block .
Hence , t he m echanical st rengt h is provided by t he resin.
• For Low volt age Foil windings, using pr eim pr egnat ed insulat ion and
curing it subsequent ly m akes t he coil as a rigid block t o wit hst and forces.
 .... cont d
• Alum inium windings can be designed t o have sam e m echanical int egr it y
as of copper windings.
Ot her Considerat ions:
• Larger surface area of t he Alum inum windings im pr oves t he ser ies
capacit ance , which is favourable for I m pulse volt age wit hst and.
• I m provem ent s in j oint ing t echniques has m ade Alum inum t o easily and
reliably j oin wit h copper ( or ) ot her Alum inium conduct ors.
• Price of Copper is very m uch volat ile and ~ 3,5 t im es of t he price of
Alum inium .
What TMC Follows:
• I t can be concluded t hat m edium power t ransfor m ers upt o 20 MVA can
be m anufact ured wit h Alum inium windings wit hout any difficult y.
• Alum inium windings are default for TMC.
• Alum inium winding t ransfor m ers are cheaper by 50 - 60 % for sam e
perform ance.
• Copper w inding t ransfor m ers w ill be supplied by TMC , if cust om er
requires t hem .