As part of its continuing research and development efforts, Waukesha Electric Systems has introduced products designed to reduce or simplify power transformer maintenance and extend operating life. Available as retrofits through Waukesha’s Waukesha Service group, the enhancements are also now included as standard equipment on newly manufactured Waukesha transformers.

Worldbox™ Control Enclosure

Waukesha Electric Systems’ Worldbox™ represents the next generation of transformer control technology, designed to simplify maintenance, reduce field service time, and enhance expandability. Worldbox also utilizes IEC standard parts, which are readily available from electrical distributors and generally cost less that NEMA components. All components are either listed or recognized by UL and CSA.

DIN rail mounting of circuit breakers, contactors and relays allows easy replacement and expandability. DIN rail mounted sectional terminal blocks utilize captive screws and accept either bare wire ends or ring tongue terminals.

Overall, the Worldbox wiring layout is organized with wire ducts and offers ample space for accessibility. The cabinet interior is painted white, and dual globe lights provide excellent illumination of all wiring and component areas. A GFCI protected convenience outlet is also included. The single front door panel swings open to a minimum of 115 degrees and is retained in the open position during servicing by an automatic lock.

The Worldbox exterior is primed and painted to 3 mil thickness or greater. Exposed hardware is stainless steel. The enclosure top is crowned to prevent water accumulation, and a drip shield protects door hardware. The standard Worldbox enclosure meets Type 3R weatherproof rating. Type 4 and 4X ratings are available as options.

Galvanized Radiators

Waukesha Electric Systems has now standardized on galvanized radiators for all its medium-power transformers. Compared with conventional painted radiators, galvanized units provide superior protection against rust and corrosion, reducing transformer maintenance time while extending radiator life.

Further, unlike paint, the zinc coating used in the galvanizing process is self-healing if scratched during handling. Galvanized radiators provide thermal performance essentially identical to painted radiators.

Waukesha radiators’ 16-inch-wide fins present a larger surface area and better cooling than typical 15-inch fins. A unique cross-section design puts more oil in closer proximity to the fin’s cooling surface, resulting in significant oil savings.

Maintenance-free radiator shut-off valves, available as an option, feature an exclusive triple o-ring design that eliminates the manual packing gland. This proven o-ring design has been field-proven for more than 20 years.

Maintenance-Free Dehydrating Breather

Used on load tap changers, conservators, control cabinets or elsewhere a breather may be required, the patented Waukesha MFDB Maintenance-Free Dehydrating Breather offers maintenance advantages over conventional silica gel breathers. Using a timer-actuated internal heater, the MFDB renews desiccant automatically, eliminating either manual regeneration or the periodic replacement of the silica gel elements.

By ensuring top-performing desiccant at all times, the MFDB maintains dry air inside the enclosure to which it is attached, extending life and improving reliability.

LTC Oil Filtration System

During normal operation, carbon and metallic particles can contaminate insulating oil in the load tap changer. The Waukesha Electric Systems LTC Oil Filtration System is designed to remove these switching contaminants, along with moisture in the oil, maintaining the oil in peak condition.

Filtering load tap changer oil helps to:

• Extend LTC life
• Minimize routine maintenance
• Reduce oil changes
• Reduce switch contact replacements
• Maintain oil dielectric strength
• Minimize equipment failure and downtime

As part of the Waukesha Oil Filtration System, a seven-day timer allows programmed filtration intervals uniquely tailored to the transformer operating conditions. A convenient indicator light shows when to change the filter cartridge. Economical replacement cartridges can be installed in minutes without shutting down the entire transformer. Alarms are provided for high and low pressure.