This document provides an overview of a Canadian manufacturer of power magnetic products. It discusses the company's capabilities including its product offering ranging from power transformers to reactors and enclosures. It highlights the company's key advantages such as its responsive nature, technical expertise, and quality manufacturing processes. The document also provides examples of reference projects demonstrating the company's ability to provide specialized transformer solutions for various industries.

1. 2014 - Company, Product, Capability, & Factory Tour

2. Presentation Topics
• Company overview
• Differentiator: Technical Depth
• Differentiator: Responsiveness
• Differentiator: Quality System
• Not Created Equal
• Efficiency Legislation Explained
• Transformer Construction
– Core types
– Winding & Insulation
– Enclosure types
• Factory Tour
• Testing capability
• Products (Low Voltage)
• Distribution (Green Line)
• Autotransformer
• Transformer Options
• Reactors, Filters, Control, CPT
• Encapsulated, Hazardous location
transformers
• K Factor Rated Transformers
• Harmonic Mitigators
• MPC, VFD, AVR, and other specials
• Products (Medium Voltage)
• Power Distribution Transformers
• Cast Coil transformers
• Air Core Reactor
• Options

3. A stable, profitable and growing Canadian manufacturer of
CSA, UL, & CE approved power magnetic products.
 245 employees, 145 000 ft² centralized facility for sales,
engineering, production, testing, and customer support.
 Privately held, based in Concord Ontario (GTA).
 ISO 9001 registered quality system
 5 warehouses across North America
 Approximately $50 million in sales annually
 Sales: 55% Canada, 40% United States, 5% Overseas
 Sales: 85% “specials”, 15% standard transformers
Company overview

4. Product Offering
Company overview
Power Transformers
(up to 15 MVA, 36 kV class)
Cast Coil, VPE, and VPI Construction
Substation Type, complete with pri. disconnects
Traction Power, Rectifier duty, Crane duty
Special Regulation, Service Station transformer
Specialty Type and Special Voltage
Transformers
K-Rated, Electrostatically Shielded,
Ultra Isolating, Multiple Shielded,
Harmonic Mitigating,
Electro Magnetic Field Shielded,
Encapsulated transformers,
Hazardous Location Duty (Class 1, Div 2),
Marine Duty Types (with applicable certificates)
Mini Power Centres.
Off Load or On Load Tap Switching (Automatic
Voltage Regulators
Control & Machine Tool Transformers
(50 to 7500 VA)
Enclosed, Open, or Potted construction
DIN Rail mountable unit, special fusing.
General Purpose Transformers
Distribution/Isolation, CE Marked
Autotransformers, Drive Isolation,
Motor Starters
Reactors
Input and Output Reactors
Motor Guarding Transient Filters
DC Chokes, Saturable-Core Reactors
High Voltage Iron Core reactors
Air Core Reactors
Enclosures
NEMA -1,-2,-3R,4,-4x,-12, with or without filters.
Stainless Steel, Special Paint,
Custom Switchgear and specialty industrial
electrical enclosures
Switchgear components
Low and Medium Voltage Standoffs, Lightning
arresters, Transformer fans
Transformer Testing, Refurbishment, and
Repair
Replacement of windings, core, insulation, etc.
CSA Category program approved facility

5. Product Offering
Power Transformers
(up to 15 MVA, 36 kV class)
Cast Coil, VPE, and VPI Construction
Substation Type, complete with pri. disconnects
Traction Power, Rectifier duty, Crane duty
Special Regulation, Service Station transformer
Specialty Type and Special Voltage
Transformers
K-Rated, Electrostatically Shielded,
Ultra Isolating, Multiple Shielded,
Harmonic Mitigating,
Electro Magnetic Field Shielded,
Encapsulated transformers,
Hazardous Location Duty (Class 1, Div 2),
Marine Duty Types (with applicable certificates)
Mini Power Centres.
Off Load or On Load Tap Switching (Automatic
Voltage Regulators
Control & Machine Tool Transformers
(50 to 7500 VA)
Enclosed, Open, or Potted construction
DIN Rail mountable unit, special fusing.
General Purpose Transformers
Distribution/Isolation, CE Marked
Autotransformers, Drive Isolation,
Motor Starters
Reactors
Input and Output Reactors
Motor Guarding Transient Filters
DC Chokes, Saturable-Core Reactors
High Voltage Iron Core reactors
Air Core Reactors
Enclosures
NEMA -1,-2,-3R,4,-4x,-12, with or without filters.
Stainless Steel, Special Paint,
Custom Switchgear and specialty industrial
electrical enclosures
Switchgear components
Low and Medium Voltage Standoffs, Lightning
arresters, Transformer fans
Transformer Testing, Refurbishment, and
Repair
Replacement of windings, core, insulation, etc.
CSA Category program approved facility
Complete range of
Dry Type
Power Magnetics, and related
accessories and services.

6. Distinction between Dry type and Liquid filled
• Liquid filled: The dielectric is oil (mineral, or other)
– Between layers, between turns, between PRI and SEC,
between coil and ground
– Use of porous paper
– The oil is also the coolant – Tank may have radiator or fins.
• Dry types: dielectric is a system
– Comprised of air and solid insulation
– Commonly Class 220 “Nomex” paper.
– Others: Dacron, Mylar, Enamel, Epoxy Resin
– The coolant is air, by natural convection. Fan cooling
possible

7. Dry type
Distinction between Dry type and Liquid filled
Oil Filled

8. Dry type
• Virtually maintenance free
• Not flammable – Indoor use
very common
• Easily close coupled to
switchgear – Flexible design
since the enclosure is sheet
metal, and no need to seal it.
• Readily customized to suit
specific application
• Application: Commercial,
industrial, 44 kV and below,
10 MVA and below
Distinction between Dry type and Liquid filled
Oil Filled
• Effective cooling
• Core and coil can be made
compact
•  Easily made efficient
• Regular maintenance required
• Flammable – Normally
mounted outdoors
• Can be customized…
• Application: Utility, 66 kV and
higher, 10 MVA and larger,
mass production.

9. Key Capabilities and Advantages
 Responsive!
 Vertically Integrated production process
 Centralized
 Engaged, empowered flat organization
 Technical Expertise
 Sustained R&D investment
 Overstaffed engineering department
 Ongoing regular training program
 Quality Manufacturing Advantage
 State of the Art equipment
 Mitre-Step-Lap core cutters
 Proprietary Cast-Coil technology
 Highly skilled factory supervisory staff
 Full in-house test capability
Company overview

10. CANADA
Eaton Electrical
WESCO
Westurne / Nedco
Guillevin International
Graybar
Harris & Room
SIEMENS Canada
EECOL Electric
A. C. Dandy Products
I-GARD Corporation
Hydro-Québec
TATA Steel
USA & Overseas
Power Quality International
Eaton Electrical USA
FARGO Electric
Data Technologies
SIEMENS/WESCO Singapore
TEMCO Tower Electric
Utility Systems Technologies
Electrotech
Company overview
Major customers

11. Reference Projects (High Power/Medium Voltage)
PROJECT NAME ENGINEER MVA QTY / Cast Coil / UTILIZATION
TTC Shepard Subway Hatch 1.5 to 3 23 Yes Traction power, Station Svc. Dist’n
Edmonton Power Edmonton Power 1.1 3 No Rectifier. Traction Power LRT
National Elect Systems Penn. Transport Ath. 1.67 2 No Extra Heavy Duty Traction
National Elect Systems Penn. Transport Ath. 3.25 2 No Extra Heavy Duty Traction
ABB ABB 2.2 to .25 15 No Shipyard Crane Duty
NOIBEK Mine ABB 4.75 1 No Mine Hoist Duty
Arrowspeed Ct’ls Arrowspeed 1.5 -1.1 3 No Dual Volt. 12 pulse Rectifier
Rockwell Auto”N Rockwell 1 2 No 12 Pulse Rectifier
FORTIS FORTIS 2.5 1 Yes Outdoor
Beaver Electrical Hatch 0.15 1 Yes BC Hydro
Eaton Genivar 2.0 1 No Wind Turbine power
Eaton MDE 1.5 1 Yes BC Hydro
Maritime Utility DOD 1.5 2 No Halifax, Victoria Navy Yards
Westburne Raffin 2.2 2 Yes Dual Pri/sec. Submarine Shore
ENSCO ABS Specs. 1.5 3 No Oil Rigs
SWTS SWTS 2.0-3.75 42 No Oil Rigs
Dandy Alberta Cronos 1.0 1 No Oil Sands
WESCO Amec 2.0 – 5.0 30 No PCS Allen & Red Cory Potash
Eaton SNC Lavilan 0.5 – 3.75 3 No Agrium Vault Potash mine
Advance Recycling 7.5 1 No Metal Recycling plant
WESCO Stantec/Tworzanski 0.15 – 2.0 3 No Elgin, Waterloo Water treatment
Siemens Sudbury Siemens 2.0 1 No Abitibi water System
Company overview

12. Reference Projects (Special Requirements)
PROJECT NAME ENGINEER MVA QT”Y Cast Coil UTILIZATION LOCATION
Univ. Of Alberta U of A 3 1 Yes Site Power Service
Dep. Of Nat’l Defense CDN Govmn’t 1.5 2 No Outdoor skid Mount. Secondary Disc’t
Eaton Leroux Beaudoin Hurens 4.0 1 No University. Loyola Campus
Eaton MMM Group 2.0 1 Yes UBC Faculty of Law
Eaton Acumen Eng. 2.5 1 Yes UBC Earth Sciences
Wesco Morrison Hershfeild 0.75 – 2.5 4 No University. Keele Campus
Eaton EYP 3.0 2 No Rackforce Data Ctre. Mission Critical
Eaton Applied Eng Soltn’s 1.25 1 No Hotel.
Lizco Hammerserschlag & Jiffe 2.5 2 No Westmount Mall
Siemens 3.75 1 No Winermere Condo
Wesco Nemetz 0.8 – 2.5 3 No Affinity Towers
Wesco H. H. Angus 5.0 2 No Royal Bank
HOSPITAL PROJECTS Shielded
North York General H.H. Angus .6 to .3 4 No Special Regulation
South Lake Regional H.H. Angus .75 to .225 6 yes Special Regulation, X-Ray
Northumberland Health H.H. Angus .75 to .3 4 yes Special Regulation
Toronto Gen’l H.H. Angus 2.5 to .225 7 yes X-ray
St. Michael’s H.H. Angus 3 to .225 8 No X-ray
Wesco H.H. Angus 0.4 – 2.5 6 No Royal Victoria Hospital
Company overview

13. Rex Certifications
• Rex products have a broad range of certifications and we have a product
suitable for nearly every North American application; and many overseas
certifications too
– CSA Approved and UL Listed transformers
– ANSI / IEEE Test methods
– Efficiency: DOE / NRCan MEPS (CSA C802, NEMA TP-1)
– ISO 9001:2008
– CE, ABS, Canadian Coast Guard
• Special Approvals:
– CSA Category Program certification
– OSHPOD Seismic Preapproval
• Seismic Rated for USA Zone 4 and Canada Zone 6
Company overview

14. Seismic Qualification and Certification
Company overview

15. REX Power Magnetics - R&D EXPENDITURES
Since 2004: Average Annual R&D $1.33M to $1.6M
NEW PRODUCTS
•Harmonic Mitigating Transformers
•Cast Coil Transformers
•Encapsulated Control Transformers
•Air Core Reactors
•EMF limiting transformers.
•Energy Efficient Transformers
•CPT-Current Potential Transformers
•Mini Power Centres
•Primary Disconnects
•Hazardous Location
•Auto Voltage Regulator (under load)
NEW IMPROVED PROCESSES
•Conductor insulation Wrapping
•Step Lap Mitre Core cutting
•Semi Auto Multi coil winding
•Coil Support Block manufacturing
•Non flammable resins
•Winding tensioners
•Batch Oven paint curing
•Distributed Gap Core cutting
•Coil Form Manufacturing
•Plasma cutting
•Robotic louvered vent welding
Differentiator: Technical Depth

16. Current Initiatives & Product Developments
Product Expansion and Approvals
• UL approval for Cast Coil Transformers – COMPLETE
• 44 kV (200 kV BIL) Dry Type design – IN PROGRESS
• OSHPOD Seismic pre-approval – COMPLETE
Current Production Improvement & Expansion Projects
• Heavy duty paint option
• Extreme duty bracket option
• New equipment: One new auto winder, one new mitre core cutter
Current Engineering and Marketing Improvements
• Website improved
• Improvements to estimation software
• Improvements to design software
Differentiator: Technical Depth

17. Responsiveness = Vertical Integration
• Design, material preparation, manufacture, test, enclosure fabrication are
all done in house at 65 Basaltic Road
• Why?
– Strict control over quality, reduction of non-conformance
– Permits greater design flexibility – necessary!
– Reduced reliance on deliveries from suppliers helps shorten lead time
– Facilitates experimentation and prototyping
– Designs can be continually optimized as commodity prices fluctuate
DESIGN
PROCESS
MFG
ENCLOSURE
TEST
Differentiator: Responsiveness

18. Quality is no accident
• Made easy thanks to:
– Our centralized, vertically integrated structure
– Owners that are actively involved in business, including production
– Happy employees – Competitive wages, benefits, training, profit share
– Ingrained culture for quality – quality is rewarded!
• Quality through process automation
– Automated core cutters and stackers
– Semi automated winding
– Automatic pre-paint cleaning for steel parts
– Robotic welding of louvre panels
• Quality Inspection Process
– Inspections at every stage
– Traceable order management system
– Pre shipment final inspection
Differentiator: Quality

19. Rex Power Magnetics – Quality Management System
• ISO9001-2008 Quality Manual
– 8 Sections, 23 Documents, 64 pages
• Rex Operating Procedures
– 10 Sections, 117 Documents, 455 pages
– Quality Assurance 20 Sales & Marketing 6
– Procurement 2 Quality Improvement 18
– Manufacturing 17 Engineering 15
– Administration 6 Profit Sharing 2
– Office 6 Health & Safety 25
• Human Resources Manual
– 5 Sections, 53 Documents, 78 pages
We say what we do…. We do what we say!
Differentiator: Quality

20. “Not Created Equal”

21. Efficiency legislation Explained
• Canadian (NRCan) and US (DOE) laws are generally harmonized
• Prior to 2005: No Legislation!
• CSA C802 / NEMA TP-1 / DOE  This describes today’s efficiency levels.
– There is a grid of minimum efficiency levels for every kVA level, in each voltage
class
– There are exceptions (<15 kVA, Autotransformer, other specialty transformers)
• DOE also came up with other “Candidate Standard Levels” (CSL)
– CSL 2 is a good higher-efficiency level in terms of economic pay back
– CSL 3 was considered the level that was likely to be adopted
– NEMA came up with their own proposed levels, for low voltage only
– DOE has published the “2016 10 CFR pt 34” which will take effect in January 1st,
2016. We commonly refer to this level as DOE 2016.
Efficiency Legislation Explained

22. Efficiency Legislation Explained
Efficiency Legislation Explained

23. Core types
DISTRIBUTED GAP CORE (Best Efficiency)
Laminations are bent at corners to form a loop. Two
halves come together to form the magnetic circuit.
Special construction distributes the gaps along the length
of the core leg to reduce crowding.
Transformer Construction: Core Types

24. Winding Types
Transformer Construction: Winding & Insulation

25. Section Wound Coil & VPI Process
• VPI process eliminates moisture, strengthens coil
and improves electrical characteristics.
• Class 220 epoxy resin is used, with a vacuum
chamber process to ensure thorough penetration.
• Additional processes may be applied for special
customer requirements
Transformer Construction: Winding & Insulation

26. Experience counts!
• “wet winding” for better strength
and open air-ways
• Nomex linings and specially designed
winding combs & fixtures for optimal
voltage stress distribution
Transformer Construction: Winding & Insulation

27. Insulation Systems explained…
Transformer Construction: Winding & Insulation
NomexTM,
Epoxy resin,
FHTPolyester
resin, GPO,
DMD
Winding
Temperature Rise
depends heavily
on Current density
and thermal
design of coil
(cooling surfaces)

28. Fan Cooling: «ANN/ANN/ANF»
Fan cooling:
Suitable ONLY for
unexpected or short
time duration
overloads.
Transformer Construction: Winding & Insulation

29. Enclosure Types
NEMA 1 NEMA 2 NEMA 3R NEMA 4 NEMA 4X NEMA12
Indoor √ √ √ √ √ √
Outdoor No No √ √ √ No
Ventilated √ √ √ No No √
Falling Dirt Particles √ √ √ √ √ √
Non Corrosive drip &
light splashing √ √ √ √ √
Snow, Rain,
Sprinkler Proof √ √ √
Windblown Rain,
Snow, Dust. Ice
Damage √ √
Hose-Directed
Water √ √
Corrosion Resistant √
Flying Dust, Lint,
Fibers √ √ √
Enclosure Types

30. NEMA 3R enclosure with filters (Outdoor use)
Filters can be removed without needing to
de-energize transformer.
Enclosure Types

31. NEMA 12 (Dust-tight) Ventilated with filters
• Recently proven design with
certificate achieved
• Allows for dramatically reduced cost
and size for environments requiring
Type 12 (NEMA/UL 12) rating for
dust tight.
• Allows for smaller magnetics
• Filters can be changed without de-
energizing magnetics
Enclosure Types

32. A note on type 3R…
Normally, 112 kVA and larger go
into a #8 box. Other options
impact the enclosure number.
Our website is the best place to
check!
Enclosure Types

33. Rex – Factory and Manufacturing Capability
Factory tour

34. Office – Sales, Customer Service, Engineering, Admin.
• 4 person customer
support team
• 5 person sales support
team
• 9 person engineering team
• 5 person dedicated power
transformer group

35. Control Transformer Area
Factory tour
• Up to 3 kVA – Control trasformer area
• Stamped cores (L225 max)
• In house injection molding of UL approved
terminals
• Motor guarding
transient filters
also assembled
here

36. Standard Distribution Product Line
Factory tour

37. Standard and Special – Core Cutting & Stacking
• Three assembly lines for varying core lamination widths and core types
• Over 8 cutting machines + 2 Distributed Gap machines
• Automatic and manual core stacking
Factory tour

38. State of the Art core cutting
Factory tour

39. State of the Art Core Cutting
Factory tour

40. Fully automated “Distributed Gap” core forming – x2
Factory tour

41. Fully automated “Distributed Gap” core forming – x2
Factory tour

42. Winding
• Broomfield automatic
winders – for uniform,
tightly wound coils.
• 6 Auto winders,
• 12 semi-automatic
winders
• Scale of operation permits:
• Selection of ideal conductor
size.
• Large order handling
capability
Factory tour

43. Final Assembly and Test
• Table height and floor level assembly lines
• Fully traceable production
– Customer support knows what stage of production each tx is in
– Each tx can be traced back to copper shipment and steel stock
• Final inspection, enclosure assembly, and production tests
Factory tour

44. Finished units – Staging area
Factory tour

45. General view – Distribution Side
Factory tour

46. High Power (Medium Voltage) Assembly Bay
Factory tour

47. High Power (Medium Voltage) Assembly Bay
• Core cutting, stacking and
clamping, epoxy coat
• Coil wedging and
blocking,
interconnections
• Bus Bar (Switchgear
coordination),
terminations, other
hardware
• Wiring of fans, thermal
components, control and
grounding components
• Base and lifting
component assembly
Factory tour

48. High Power (Medium Voltage) Assembly Bay
• 4 automatic
core cutters
• Up to 16” wide
lamination
• Cuts: 45°, butt
cuts, notch,
and hole punch
Factory tour

49. High Power (Medium Voltage) Assembly Bay
• Two stacking tables, larger one can handle 5 leg cores
Factory tour

50. High Power (Medium Voltage) Assembly Bay
10 MVA ANN
(13 MVA ANF)
150 kV BIL
Hospital
project
Factory tour

51. High Power (Medium Voltage) Assembly Bay
Factory tour

52. High Power (Medium Voltage) Assembly Bay
2500 kVA ANN, 150 kV BIL (18 kV Primary) – Fitted with MR tapchanger
Factory tour

53. High Power (Medium Voltage) Assembly Bay
• 2000 kVA/2333 ANF tap changer transformer
• Utility application – Reinhausen gear
Factory tour

54. High Power (Medium Voltage) Assembly Bay
Also done in this area:
• Cast coil assembly
• Low voltage units with special
scheduling and/or buswork
Factory tour

55. High Power (Medium Voltage) Assembly Bay
• Cast Coil, non vented
• IP 65 construction
• Corrosion resistant
(galvanized base, 316L
Stainless Steel
enclosure)
• Specialty earthing and
bus bar coordination
with foreign code
compliance
• Wiring compartments
• 12 unit order for
shipment to Australia
(export packaging)
Factory tour

56. High Power (Medium Voltage) Assembly Bay
Factory tour

57. High Power (Medium Voltage) Assembly Bay
• Assembly and wiring of
customer provided
components (breakers,
control boards, etc)
• Assembly of enclosure
• Knock-down enclosures
can be shipped separately
from core and coil
Factory tour

58. Sheet Metal (Fabrication Shop)
• Rex produces its own structural
steel components and enclosures
• Also has a separate product line
for Industrial Electrical Enclosures
• Cutting, stamping, forming,
welding, grinding, and painting
operations all done in house

59. Sheet Metal (Fabrication Shop)
• Programmable Plasma
cutting table
• 6 axis welding robot
configured for 3 standard
parts
• Two turret presses
(STRIPPIT)
Factory tour

60. Sheet Metal (Fabrication Shop)
• Fully continuous three stage
wash, phosphate and rinse cycle
• Continuous powder coat and
bake line
• Over 700 hour salt spray durable
finish – option available for
primer coat which extends
paintlife beyond 800 h salt
spray.
• Colour matching to customer
specified requirement
• Batch wash/paint/bake station
for larger components
Factory tour

61. Lab
• Dedicated temperature and noise
controlled space for our R&D projects
• Temperature Rise tests, Recurrent Surge
Generator testing, Inrush testing, etc
• EMF measurement, dB measurement
Factory tour

62. High Power Test Area
Factory tour

63. Rex Transformer Test Capability
• Ratio, polarity, phase relation
• Resistance measurement, No load / load loss measurement (efficiency)
• Impedance, Excitation current
• Double Induced voltage test, Applied voltage test (Hi-Pot test)
• B.I.L. Test (Basic Impulse Level)
• Megger test (insulation to ground)
• Frequency Response Map
• Corona Test
• Temperature rise testing
• 400 Hz generator
• Sound level testing
• Electro Magnetic Field testing
• Recurrent Surge Generator
Test capability

64. Ratio, polarity, phase relation (Megger PMM)
Test capability

65. Resistance Measurement and PMM
Test capability

66. Partial Discharge Measurement (Biddle)
Test capability

67. Frequency Response Measurement & Hi Pot tester
Test capability

68. BIL Test Set (Test up to 300 kV)
Test capability

69. Impulse Generator & Dr. Strauss Digital Analyzer
Test capability

70. Test Frequency Generators
Test capability

71. Megger tester and Recurrent Surge Generator
Test capability

72. Presentation Topics
• Company overview
• Differentiator: Technical Depth
• Differentiator: Responsiveness
• Differentiator: Quality System
• Not Created Equal
• Efficiency Legislation Explained
• Transformer Construction
– Core types
– Winding & Insulation
– Enclosure types
• Factory Tour
• Testing capability
• Products (Low Voltage)
• Distribution (Green Line)
• Autotransformer
• Transformer Options
• Reactors, Filters, Control, CPT
• Encapsulated, Hazardous location
transformers
• K Factor Rated Transformers
• Harmonic Mitigators
• MPC, VFD, AVR, and other specials
• Products (Medium Voltage)
• Power Distribution Transformers
• Cast Coil transformers
• Air Core Reactor
• Options

73. Distribution Transformers
Distribution Transformers (Green Line)
• “Green Line” – Distribution transformers that meet
or exceed legislated or voluntary efficiency levels (CSA
C802, NEMA TP-1, DOE)
• Three phase 600 or 480 Δ : 208Y120
• Single phase 600 or 480 : 120/240
• kVA ratings up to 2500 kVA
• Copper windings available for all kVA
• Aluminum windings are available in 30 kVA and up
• Indoor sprinkler proof Enclosures provided standard
up to 750 kVA
• Knockouts provided, wall mounting brackets are
provided for easy installation (up to 75 kVA)
• Standard lugs are provided up to 300 kVA
• Z2 level offers enhanced efficiency versus standard,
Z3 level offers next generation of efficiency level
(2016 DOE level)
*NEW* Seismic Rated for USA Zone 4 and Canada Zone 6

74. Distribution Transformer (Green Line) - Construction
Distribution Transformers (Green Line)

75. Distribution Transformers
Distribution Transformers (Green Line)

76. Distribution Transformers
Distribution Transformers (Green Line)

77. Distribution Transformers
Distribution Transformers (Green Line)

78. Calculate Efficiency and Payback (150 kVA, Copper)
Distribution Transformers (Green Line)

79. Calculate Efficiency and Payback (150 kVA, Copper)
Distribution Transformers (Green Line)

80. Calculate Efficiency and Payback (150 kVA, Copper)
Distribution Transformers (Green Line)

81. Calculate Efficiency and Payback (150 kVA, Aluminum)
Distribution Transformers (Green Line)

82. Calculate Efficiency and Payback (150 kVA, Aluminum)
Distribution Transformers (Green Line)

83. Calculate Efficiency and Payback (150 kVA, Aluminum)
Distribution Transformers (Green Line)

84. Calculate Efficiency and Payback (Medium Voltages)
Distribution Transformers (Green Line)

85. • Economical and compact voltage
transformation – without
electrical isolation
• Primary and Secondary windings
have a common section
• For linear loads (motors, electric
heaters, air conditioners etc.)
• Inexpensive – Especially when
Primary and Secondary voltages
are close.
• Three Phase or Single Phase
• All standard enclosure options
• Step-up or step-down, options
available for neutral, lugs, etc.
Autotransformer
Autotransformer

86. Distribution and Autotransformers - Specifying
• Easy-to-understand,
unchanging part numbering
system. Specify your
transformer with confidence!
Autotransformer

87. • Temperature Rise: 80 C, 115 C – or other…
• Specified efficiency / losses
• Special noise level
• EMF shielding
• Special lugs, special terminal strip, special interior arrangement
• Vector/phase offset or relation
• Electrostatic Shielding
• 50 Hz or other frequencies
• Special mounting
• Special markings, paint, appearance
• Additional varnish or epoxy impregnation
• Extreme duty construction and bracing
• Disconnects, breakers, etc
Options
Transformer options

88. Electrostatic Shielding
• Protect your equipment from electrical noise
and reduce parasitic (high frequency) losses
– Hospital/Medical equipment
– Imaging / X-Ray machines
– Data Processing Centres
– Programmable Controller
– Instrumentation
Transformer options

89. Electrostatic Shielding
Transformer options

90. Reactors (inductors, chokes)
• Three phase, input or output reactor (Line reactor, load reactor)
• Single phase chokes available as well
• Motor guarding transient filters (protect against voltage spikes)
• Specially designed tuning reactors designed to customer specifications
• Interphase reactors
• Air core reactors up to 34.5 kV and 150 kV BIL
– (Photos elsewhere in slideshow)
Reactors, Filters, Control, CPT

91. INDUSTRIAL CONTROL TRANSFORMERS
• Open or Enclosed Construction
• Standard VA ratings available up to 3000 VA
• Standard voltage configurations available
• All units are CSA certified and UL listed
• Terminal blocks are provided up to 1000 VA
• Frequencies other than 60 Hz are available
• Various fusing options
• CE marked units are available upon request
• Epoxy encapsulated coils are available
Reactors, Filters, Control, CPT

92. Control Power Transformers
• CPT: Used to supply power to control
circuit in electrical panels.
• Single phase up to 3000 VA
• 7.2 kV, 60 kV BIL
• Insulation Class: 130°C, 155°C, 185°C
• Standard Construction: Open
construction with encapsulated coil
• Optional CSA Enclosures: Type 1, 2,
3R, 4, and 12
• Certification Requirements:
– CSA All of the above, and on custom
made specification
– UL 7200 Volt max and not certified
with Enclosure Type 4 and Type 12
Reactors, Filters, Control, CPT

93. Encapsulated Transformers
• Applicable in cases where dust,
moisture, or fumes may be present.
• Mixture of silica sand and epoxy
resin forms a protective block
encasing the magnetics.
• Nomex insulation + 185 °C class
resin. Encapsulated transformers
have 130 or lower rise
• Enclosure is suitable for Type 3R or 4
applications
• Spacious wiring compartment
• Lugs provided up to 75 kVA
• Floor/wall mount available below 45
kVA – For 45 kVA and larger, use
optional wall bracket kit
Encapsulated, Hazardous Location Transformers

94. Encapsulated Transformers
Encapsulated, Hazardous Location Transformers

95. Transformers for Hazardous Locations
• Hazardous Location Transformers Class I, Div. II. Temperature coded
– CSA and UL approved! **NEW**
– Groups A, B, C, D
– Three constructions avaialble
– Stainless Steel variations for each are available
• IECEx approved Zone 2 transformers also available through special
partnership – consult factory
Encapsulated, Hazardous Location Transformers

96. Epoxy encapsulated,
Wiring inside,
115 rise, 185 C
insulation (T3)
3R box (type 4 with
approved conduit
hubs)
Epoxy encapsulated,
Leads brought out,
115 rise, 185 C
insulation (T3)
Type 4 box
ANN designt, 115 or
150 C rise (T3C, T3, or
T2C)
Transformers for Hazardous Locations
Encapsulated, Hazardous Location Transformers

97. Transformers for Non Linear (K factor) Loads
• High efficiency, as required by CSA C802.2
• K Factors (4, 9, 13, 20…)
• Economical solution for harmonic-rich environments – transformer
operates at a lower flux density in anticipation of harmonic content
• Full rated neutral
• Standard taps, standard enclosure options
• Electrostatic shielding available
• Rex Drive Isolation Transformers:
– K Factor 4, Thermal contacts, braced for mechanical forces of SCR operation
K-Factor Rated transformers

98. Transformers for Non Linear (K factor) Loads
• Switching-mode power supplies echo harmonic components into supply
• Consequence: Overheating, high neutral currents, tripping of breakers
• K-factor is an index of the transformers ability to supply harmonic content
in its load current while operating within it temperature limits.

99. K-Factor: Selecting by load type
K-Factor 1: Motors
Incandescent Lighting
Resistance heating
Motor Generators (w/o solid state drives)
K-Factor 4: HID Lighting
Induction Heaters
Welders
UPS with optional input filtering
PLCs and solid state controls
K-Factor 13: Multiple receptacle circuits in
health care facilities
UPS without input filtering
Production or assembly line equipment
Facilities and classrooms of schools
K-Factor 20: SCR variable speed drives
Circuits with exclusively data processing equipment.
Mainframe computers
Critical care areas and operating rooms of hospitals.
If supplied the harmonic
data, our engineering
department can calculate
the suitable K Factor
level.

100. Harmonic-Mitigating Transformers
• Attenuate the harmful (inefficient) harmonic component that is generated
by switching loads
• High efficiency levels (meet or exceed CSA C802.2)
• Provides a low impedance path to ground for harmonic currents
• One unit can independently treat 3rd order harmonics in its secondary
winding.
• 5th and 7th order harmonics can be treated by load sharing with a separate
supply that is 30° phase-offset
• Single output: 0° or 30°
• Double output: 0°/- 30° or -15°/- 45°
Harmonic Mitigators

101. Attenuation of harmonic currents – Third order
X0X3 X2 X1
H1 H3
H2
X1
X2
X3
X0
• Mitigation of third order harmonic currents
• Multiple secondary windings with interconnections
• All unbalanced loads are cancelled

102. Attenuation of harmonic currents – higher order
• To eliminate 5th, 7th, 17th & 19th harmonics, at a common point of the
source - Phase shift 0° / -30°
• By combining two transformers, with a phase angle of 0 ° / -30 ° & -15 ° / -
45 ° elimination of harmonics 11, 13, 23 & 25 at the common point of the
supply.

103. Mini Power Centres
• Mates an encapsulated
transformer with Primary and
Secondary Disconnects
• Very compact
• 5-50 kVA single phase
• 9-45 kVA three phase
• 480 V to 4160 V Primary
• Available with 24, 30 or 42 branch
circuits (breakers not provided)
• Excellent option for temporary or
permanent installations, job-site,
marine applications, lighting
panels, etc.
• Typical host of options available
MPC, VFD, AVR, and other specials

104. Transformers for Variable Frequency Drives
• High efficiency as per CSA C802.2
• Power (KVA) pre-determined by the drive HP
• Three Phase with delta-star connection,
delta-delta or multiple pulses
• 6, 12, 18 & 24 pulses
• Optimised designs
• Range of voltages available
• Oversized neutral conductor
• Electrostatic shield available
MPC, VFD, AVR, and other specials

105. Other special transformers
• Motor Starting Autotransformers
• Grounding transformers
• Transformers for variable frequency drives
– Single or three phase
– 6 , 12, 18 and 24 pulses
• Potential transformers
• Transformers for higher frequencies (up to 400 Hz)
• Transformers with high current
• Primary Disconnects
• Complete Unit Substations
• Extreme duty transformers
• Special cut cores
• Coil replacement and refurb.
• Standoffs, surge arrestors, fans
MPC, VFD, AVR, and other specials

106. Voltage Regulators (On load / off load)
• Rex offers a host of solutions for applications with voltage fluctuations:
1. Transformers fitted with Reinhausen ON-LOAD Vacuum Tap Changers
• Mechanical operation
• Reliable, established industry standard
• Automatic/Programmable
• Ratio switching done on primary of supply transformer
2. Transformers fitted with OFF-LOAD Tap Changers
• Transformer must be de-energized for tap switching to take place
• Manual or motor driven tap changes
3. Series transformers fitted with semiconductor switching
• Electronic switching
• Rapid immediate switching
• Automatic/programmable
• Voltage bucking/boosting done additively to the line (retrofit able – supply
transformer may remain)

107. Power Distribution Transformers (Medium Voltage)
• Available up to 15MVA
• Primary and Secondary voltages:
5kV – 34,5kV
• BIL available up to 150kV
• Cable or buss coordination for
switchgear
• VPE or CAST COIL construction
*NEW* Seismic Rated for USA Zone 4 and Canada Zone 6

108. Power Distribution Transformers (Medium Voltage)
• Temperature rise: 150 °C, 115 °C
or 80 °C, (or other) as specified
• Copper or Aluminum windings
• Available in Type 1 (NEMA 1),
Type 2 and 3R (or 3R outdoor)
– NEMA 4, 12 and 4X are available
depending on application/kVA
• Option for fan cooling for short-
time ANF rating 33% over ANN
Août 2012

109. Cast Coil Power Transformer
• Available up to 5 MVA
• Voltages up to 34.5kV
• BIL max 150 kV
• Insulation class 185°C
• Excellent short circuit withstand
charactersitics
• Suitable for harsh environments
• Suitable for traction power and other
applications with repeated cycles of
energization
• Ultra low-maintenance design

110. • Higher degree of protection from
dust and other airborn
pollutants
• Long life expectancy
• Enhanced ability to handle
fluctuations in the ambient
temperature. Can be energized
from sub-zero temperatures
• Presently developing a 46 kV
primary (200 kV BIL) insulation
system based on cast coil
approval, with UL certification
pending.
Août 2012
Cast Coil Power Transformer

111. Air Core Reactor

112. Air Core Reactor

113. Commonly specified power transformer options
• Lightning Arresters
• Fan cooling (with/without aux power)
• Neutral Grounding Resistor
• Seismic Anchoring Provision
• Heaters (Anti-condensation)
• Provision for Jack Skid Roll
• Buss work specification (Jacketed, Bare, etc)
• Special temperature sensing
• Flexible connectors