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TECHNICAL DATA SHEET

320 New Road Ph:(732) 329-2333
Monmouth Junction, NJ Fax:(732) 329-1143
JOHN C. DOLPH COMPANY
08852 [email protected]
www.dolphs.com

HI-THERM® BC-346-A
CLEAR BAKING VARNISH

PRODUCT DESCRIPTION
BC-346-A is a specially formulated, high temperature varnish, which can be used in a wide range of dip and bake applications.

FEATURES & BENEFITS

 Excellent flexibility
 Military approval - Qualified under
 Excellent adhesion MIL-I-24092, Grade CB, Class 155 and 180
 High film build  UL recognized varnish in systems up to 220°C
 Superior wetting properties

TYPICAL APPLICATIONS

 Transformers  Random Wound Coils

 Stators  Armatures
 Form Wound Coils  Relays

TYPICAL PROPERTIES
Physical

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Color/Appearance Light-Dark Amber

Density @ 77F (25C), Lbs/gal 7.4 - 7.8

Viscosity @ 77°F (25 C), Brookfield Viscometer, cps 150 - 320

Flash Point, F 54

Film Build, mils/side, ASTM D-115 1.0 – 3.0

Thinner (solvent) T-200X or T-100

VOC Content, ASTM D 6053, lbs/gal 3.8

Corrosive Effect on Copper None

Mechanic
al
Bond Strength, Helical Coil Method, lbs to break @25C 28
@150ºC 2.5
Thermal Conductivity, ASTM C 3111, BTU-in./hr-ft2-F 2.4

Electrical
Dielectric Strength ASTM D115, volts/mi Dry 4,000
Wet 2,900

Chemical Resistance
Water Excellent

Acid (10% Sulfuric Acid) Excellent

Alkali (1% Sodium Hydroxide) Excellent

Salt Water Excellent

Oil, ASTM D-115 Passed

Thermal Class (UL-1446)

Twisted Pair MW16 240
MW24 155
MW28 155
MW30 180
MW35 200
MW76 180

APPLICATION GUIDELINES
Following is a suggested dip and bake cycle. Suggested Bake Cycles*
Preheat parts to 250-325°F to remove moisture. 1-2 hours @ 325°F 2-3 hours @ 300°F 2-4 hours @ 275oF
Note: If thermoset tapes are used, preset tapes according to tape manufacturer’s recommendations
*Times are. taken after unit reaches baking temperature
Cool to I30°-140°F
Rev. No.stops
Dip until bubbling 0 (15-30 minutes). Rev. Date : 09.12.2021 Page 2 of 17
Drain between 5-20 minutes
Bake in a preheated oven at recommended time and temperature
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STORAGE AND SHELF LIFE

Shelf life is one year from date of shipment from our plant, when stored in closed containers at 70°F or below.
1. Store in cool, dry place at 70°F/21°C or below.
2. Protect from direct sunlight and sources of heat
3. Keep away from heat, sparks and open flame.

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1.0 Title:
Procedure for vacuum pressure impregnation of transformer and reactors
2.0 Scope:
This following provides workmanship criteria related to application of Vacuum Impregnation process
of UPS - transformer or Reactor and certain other types of workmanship criteria defined herein.
3.0 Responsibility:
In charge QA is responsible for approval and issue of this workmanship standard and subsequent
process.
4.0 Object:
Failures related to inter-turn insulation/ ground insulation can be minimized by doing vacuum
pressure impregnation, thereby making the winding more rigid and preventing vibration/relative
motion between wires/conductors. Moisture and air – voids are also removed from the insulation by
VPI process and thus improving its insulation resistance.
5.0 Typical specification and technical details for VPI Plant
5.1 Typical specification, technical details and plant layout for vacuum impregnation plant are
indicated in annexure - 1
6.0 Impregnation Varnish/Resin:
6.1 Use the following varnishes for VPI
- Resin BC 346A of Von Roll
- Thinner TX 200 of Von Roll
7.0 Vacuum pressure Impregnation procedure:
7.1 Procedure for VPI with resin BC 346A , Thinner TX 200 is given in Annexure – II
8.0 Storage of resin:
8.1 Procedure for storage of resin is given in “annexure – III”
9.0 Precautions while doing ‘VPI’ with solvent-less resin:
9.1 DO’s and DON’T’s while doing ‘VPI’ with solvent-less resin are given in annexure – IV
10.0 Periodicity of implementation:
10.1 Whenever rewinding of transformer and Reactor(choke – AC or DC) is undertaken
11.0 Agency of implementation:
Transformer which manufacture in IN-HOUSE shop.

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Typical Specification and Technical Details for Vacuum-Pressure Impregnation Plant

Dimensions: (a) Impregnation Chamber - 1600 * 1130 mm

(b) Impregnation storage tank - 1540 * 1050 mm

1.0 Impregnation Chamber

1.1 The vessel will be vertical cylindrical dished bottom type
1.2 The dished cover of the impregnation vessel will be provided with a vacuum tight sealing
arrangement of proper design suitable to maintain pressure or vacuum for a long period. The lid
will open or close/clamp manually by hand. Suitable interlocks will be provided to prevent
opening and closing of the cover during the sequence of operation. The system will be complete
including the oil cylinders, valves, cocks, gauges and pipe cork, etc.
1.3 The impregnation vessel will be provided with the supporting legs for mounting suitable height
off the ground.
1.4 Removable filter unit for varnish will be provided between the impregnation vessel and storage
tank, the filter will be easily removable and accessible for cleaning and replacement.
1.5 The impregnation vessel will be equipped with following accessories:
 Suitable visual system attached to the cover for observing the component and the
varnish level during process of impregnation.
 Lamp house, attached to the cover.
 Multifunction meter
 Temperature Controller
 Safety valve
 Drain valve

2.0 Varnish/Resin storage tank – 1 No.

2.1 Treating temperature : 15-25 degree Celsius
2.2 Treating vacuum : Vacuum – 5 mm of Hg

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2.3 The tank will be vertical, cylindrical, dished bottom type and will be constructed with M.S. plate.
Its internal surface will be finished smooth to eliminate the accumulation of the varnish/resin.
2.4 The tank will be provided with a dished cover with locking and vacuum sealing. The sealing
arrangement will be of proven design.
2.5 The tank will be provided with water/cooling tubes/jacket for circulation of cold water. The
cooling tubes suitably located on the tank will be capable of cooling and maintain the temperature of
the varnish stored in the tank to the desired level.
2.6 The tank will be provided with supporting legs For mounting on the ground.
2.7 The tank will be provided with motor operated, vertically operated varnished mixing stirrer or
agitator. The moor will be TEFC type( Flame proof) Stirrer RPM approx. 50
2.8 The storage tank will be equipped with the following accessories:
 Suitable visual system attached to the cover
 Lifting hooks for the cover
 Connection to vacuum pump
 Vacuum gauge
 Drain valve

3.0 Vacuum Pump

3.1 The vacuum pressure impregnating plant will be provided with suitable vacuum pump system for
creating and maintaining vacuum of 5 mm of hg
3.2 The vacuum connections between vessel/tank and pump will include an efficient condenser unit
with adequate capacity to condense moisture

4.0 Compressed Air unit

4.1 The VPI plant will be provided with a compressed air compressor unit with a
regenerative/dehumidifier unit for supply of dry air pressure in the impregnating vessel and
storage tank.

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5.0 Control panel:

The VPI plant is equipped with control panel containing equipment necessary for operation. It will be
possible to operate control operation from this panel. However, the following will be included:
5.1 Vacuum gauges for impregnating vessel and storage tank locally mounted.
5.2 Digital temperature indicator for storage tanks.
5.3 Motor starters for motor are housed in the control panel.
5.4 Push button switches of control of semi automatic operation is done with the help of the panel.
5.5 Indication Lamps is provided on the panel.

6.0 Valves and pipe work:

6.1 The VPI plant is supplied with all valves, pipe connections and flange seals, etc. for varnish
transfer, vacuum application.
6.2 Valves and pipe work for vacuum is of steel and suitably treated for corrosion resistant.
6.3 Pipe work of adequate size and strength will be provided for varnish transfers within short period

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ANNEXURE -I

Please see enclosed schematic diagram of VPI plant

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ANNEXURE - II

Vacuum – Pressure Impregnation Cycle for Transformer / Reactor using Von Roll BC 346A
Solvent-less Impregnation Resin

Principle of operations:
 Ensure that the winding are free from dust, grease, etc. Blow the winding using dry
compressed air
 Pre-heat the Transformer / Reactor for 30 minutes at 100 degree Celsius for moisture
removal and removing stress in the winding.
 Allow the component to cool down to 40 degree Celsius ( nearly room temperature)
 Change the component into impregnation tank of vacuum-pressure impregnation plant. Apply
1vacuum and wait initially it comes in-between -700 to -730 mm Hg, now open the moisture
trap vacuum valve and wait moisture trap cum and main pressure in-between 730 – 760
mmHg @ 1 kg/cm^2 and keep for 10 minutes.
 Admit activated resin slowly to avoid foaming in the tank, until the component is completely
submerged or till bubbles cease to come on the surface for 15 minutes. Release vacuum
present in the tank until it reaches 0kg/cm^2. now open moisture trap to storage tank , create
a vacuum in storage tank, wait until the moisture trap meter comes in-between 400 - 450
mmHg and storage tank vacuum meter comes around -0.5 kg/cm^2.
 Release the air pressure slowly. The resin is forced back into the impregnation storage tank.
This resin should be stored at temperature as low as possible (i.e. below 21°C).
 Remove impregnation component from the impregnation tank and allow resin to drain for 10
– 15 minutes. Transfer the impregnated component to baking oven already maintained at
130°C - 155°C.

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 Cure for 3 – 4 hours at 130°C or 155°C at 2 – 3 hours.

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Storage and Shelf Life:-

Shelf life is one year from date of shipment from our plant, when stored in closed containers at
70°F or below.
 Store in cool, dry place at 70°F/21°C or below.
 Protect from direct sunlight and sources of heat
 Keep away from heat, sparks and open flame.

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ANNEXURE - III

Control of stability of impregnation resin mixture in large storage tank of Von Roll BC 346 A
– solvent-less impregnating un-saturated resin

1.0 Introduction
Von Roll BC 346A resin has a limited storage life and has a shelf life of 12 months at 21°C
when stored in original sealed container. The storage life sharply reduces at higher ambient
temperature.

The impregnation resin mixture in an impregnate storage tank of vacuum impregnation,

conveyorised impregnation or dip impregnation plant, can continuously used, when the
following are adhered to:

1.1 Storage of resin:

Storage temperature should be 21°C or below. The low storage temperature is advantageous
for increasing the pot life of impregnate.

2.0 Control of resin mixture during use:

A very rapid fall in resin storage life and gelling of resin can occur if unforeseen things happen,
such as-
 Reduction in production leading to very low consumption.
 Failure of cooling equipment.
 Occurrence of extreme ambient.
 Addition of foreign substance in the tank.

ANNEXURE – IV

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DO’s and DON’T’s while using solvent-less UP resin for impregnation by

Vacuum Pressure Method

1.0 Plant Design

1.1 The impregnation plant:
 Should have cooling device ( refrigerant or chilled water circulation to maintain
impregnate in the storage chamber between 18 -21° C) Lower temperature than 21° C will
increase resin viscosity and pot life and higher than 21° C will reduce the pot life of
mixture.
 Should not have any valves, part, pipelines which are contact with activated resin made
from non – ferrous metal (Zinc, Brass, Copper, Galvanized Iron, etc) Non- ferrous metal
activated the resin and reduce its pot life.
 Do not apply primer or paint to the inside of plant which comes in contact with resin.

2.0 Storage of un-activated Resin, Hardener:

 Store the containers of Resin & Hardener at 21° C in a cold storage, away from
flammable chemicals. Do not ever expose the resin containers to direct sunlight or high
ambient temperature (>30°C) or fire spots.

3.0 While carrying out impregnation:

 Do not attempt vacuum lower than 10 torr, which is the vapor pressure of mono-styrene
present in Resin. At lower vacuum, styrene will evaporate from Resin, increasing its
viscosity and contaminating vacuum pump oil. Work - out ideal viscosity range for your
components and maintain its viscosity throughout. Ensure sufficient resin consumption of
about 12% of activated impregnate per week. Add freshly activated Resin and Hardener
mixture to the impregnate storage tank periodically. If consumption is low, you run a risk of
getting resin mixture.

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 Measure activated Resin periodically twice or thrice a week for viscosity once a week.
 Do not leave winding immersed in Resin too long. Mono-styrene may chemically attack
the wire coating and other insulations on prolonged contact (generally>0.5 h)

4.0 While curing Resin impregnated jobs.

 Do not keep up Resin impregnated jobs along with the varnish impregnated jobs.
 Do not exceed lower explosive limit (45g/m^3) in the oven particularly during gelling
of the impregnated jobs. Mono-styrene composition above lower explosive may
cause explosion or fire when a spark is produced due to friction or loose electrical
contact.

5.0 General Safety Precautions:

 Vapor of styrene is combustible and toxic when inhaled continuously.
 Styrene vapors being heavier than air, settle down in working area. Styrene vapor level
more than 20ppm cause smell and irritation to the eyes of workman.
 Keep good exhaust conditions at working places to maintain MAK valve less than 20
ppm
 In case of splashing in eyes, wash with plenty of water and take immediate medical
help.

Prepared By Reviewed By Approved By

Vignesh E Manikanda Prabu Sellakarthikeyan R

Engineer Assistant Manager Assistant General Manager

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