1

CAMTECH/E/2002/AT/1.

CHAPTER 1

GENERAL
1.1

INTRODUCTION
Auxiliary Transformer in Electrified section is required for CLS equipment for
signal light, switching stations and traction sub stations. Auxiliary Transformer provides
240 volt supply for cabins, cable huts, SPs, SSPs, level crossings, RRIs etc.

1.2

CONSTRUCTION

1.2.1 General Construction

Auxiliary Transformer transfers power from
25 kV system to 240 volt system. Thus an Auxiliary
Transformer have a HV winding and a LV winding.
Both windings are separated electrically but
magnetically coupled. Primary and secondary
windings are wound on a common magnetic core.
One end of primary winding is connected to 25 KV
system through a bushing and other end is connected
to tank (Earth) through bushing and link. Secondary
terminals (both) are mounted on the tank through
FIGURE 1.1
bushings. One terminal is used as phase and other is
GENERAL LAYOUT OF
earthed and used as neutral. Windings along with core AUXILIARY TRANSFORMER
are immersed in insulating oil in a tank. For
contraction and expansion of air in conservator tank, there is silica-gel breather. Oil level
indicating glass window is provided on the side of conservator tank. Two nos. of valves
are provided on top & bottom side of tank for centrifusing of oil or drainage. There is tap
changer on primary or on secondary side of AT for suitable out-put voltage as OHE
voltage is varying in nature.
1.2.2 Transformer tank
The tank for the auxiliary transformer shall be constructed from good commercial
grade low carbon steel suitable for welding with a single tier construction, so as to reduce
welding to the minimum while fabricating. The tank shall be adequately strengthened
with lifting lugs to permit hoisting of the transformer filled with oil through lifting lugs
by a crane or other means.

FIGURE 1.2
TRANSFORMER TANK

Maintenance Handbook on Auxiliary Transformer

February, 2002

CAMTECH/E/2002/AT/1.

1.2.3 Silica Gel Container

Silica gel breather shall be suitably clamped to the tank. The silicagel container
shall be made of a seamless tough acrylic transparent tube and so designed as to facilitate
easy replacement and filling or removal of silicagel. The colour of silica gel shall be
visible to a person standing on the ground.
1.2.4 Core
The core shall be made of high permeability cold
rolled grain oriented/non aging electrical silicon steel
laminations conforming to IS:3024. The flux density in
any part of the core and yoke with the primary winding
excited at the rated voltage and rated frequency shall not
exceed 1.55 Tesla.
The laminations used for stacking the core shall
be free from defects due to storage/atmospheric effects.
Both sides of the laminations shall be coated with
suitable insulation capable of withstanding stress relief
annealing. In assembling the core, air gaps shall be
avoided.
The core shall be electrically connected to the
tank to drain off any electrostatic potential that may
have built up.
1.2.5

Windings

FIGURE 1.3
CORE

The primary and secondary winding shall be

of spiral/helical type.
The windings shall be made of continuous
electrolytic copper conductor, paper insulated to class
A insulation. The conductor shall not have sharp
edges, which may damage the insulation.
Normally, no joint shall be used in the
winding conductor. If a joint becomes inescapable, it
shall be brazed with high silver alloy grade Ba, Cu
Ag6 conforming to IS: 2927 or electrically buttwelded.
The ratio of width to thickness of copper
conductor used for winding shall be as small as
possible but shall not exceed 5:1 so as to avoid tilting
of conductors when the windings are subjected to axial
and radial forces during short circuits.

Maintenance Handbook on Auxiliary Transformer

FIGURE 1.4
WINDING

February, 2002

CAMTECH/E/2002/AT/1.

The auxiliary transformer winding shall have the following insulation levels.

a.

Primary

Secondary

25 kV

240 kV

Rated voltage between

winding and earth.

b.

Rated short duration power

frequency withstand voltage 70kVrms 3 kVrms

c.

Rated lighting impulse

withstand voltage

190 kV peak

Induced over voltage

withstand.

80 kV rms

d.

1.2.6 Bushings and Terminals Arrangement

The bushing shall comply with IS: 2099 and IS:
3347. The line terminal of the primary winding shall be
brought out through a 36 kV class bushing for connection to
the overhead equipment and the neutral terminal brought out
through a 3.6 kV class bushing and connected to the tank
externally be means of a suitable tin coated copper link. The
steel enclosure of the AT shall be connected to earth during
service.
The 3.6 kV bushing and connection of the link to the
tank shall be covered by sheet steel of not less than 2 mm
thickness welded on to the tank and should have a captive
bolted cover.
The porcelain housing of both bushing shall comply
with the requirements laid down in IS: 5621 and shall be of
a single piece construction i.e. there shall be no joint in the
porcelain housing. The shed profile shall have a lip at the
extremities, but free from ribs on the underside so as to
avoid accumulation of dust and pollutants and the to
permit easy cleaning.
The bushing shall be free from corona.

FIGURE 1.5
BUSHING

Primary and secondary bushing shall

be provided with identical tinned copper
stems of 20mm diameter for 36 kV class
bushing and 12 mm diameter for 3.6 kV class
bushing. The stem shall be threaded to metric
size at suitable places as per IS: 1367.
FIGURE 1.6
TERMINAL

Maintenance Handbook on Auxiliary Transformer

February, 2002

CAMTECH/E/2002/AT/1.

The bushings shall withstand the following test voltages.

Primary
a.
b.

c.
d.

Secondary

Highest voltage for

equipment .

36 kV rms

3.6 kV rms

Rated short duration

wet power frequency
withstand voltage

70 kV rms

10 kV rms

Rated lightning impulse

withstand voltage

190 kV peak 40 kV peak

Minimum creepage
distance

900 mm

90mm

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Maintenance Handbook on Auxiliary Transformer

February, 2002