1General

Non-excitation tap switch applies to oil-immersed transformer with 50Hz or 60Hz of rated frequency. In case of no
excitation in transformer (i.e. no winding is charged), the switch can be operated manually or electrically to change the
tapping position and further to change the transformation ratio, and by this means, secondary voltage can be adjusted or
stabilized.

2Model

Note: when selecting transformer model, users generally emphasize the operating mode, installation mode and outgoing
wiring mode, which are confirmed by transformer manufacturer; at such time, users may select a certain operating mode
from 100, 200, 300, 400 and 500 of 555 series.

3Basic Wiring Diagram

4. Normal Specification Combination

Phase

Voltage class
(kV)

Pressure
regulating
principle

1, D
2, L
S

12, 40.5, 72.5,

126, 170, 252,
363, 550

I, II, III, IV,

V, VI

Rated current (A)

250, 400, 630, 800, 1000,
1250, 1600, 2000, 2500, 3150,
4000, 5000, 6300

5 Performance Parameter

Number of
shunting
tapping

Number of
tapping
positions

Outline character of
switch body

2, 3, 4,
5, 6, 7,
8, 9, 10

2, 3, 4, 5, 6,
7, 8, 9

L: Vertical type
W: horizontal type

main technical performance parameters of typical products

.

Note: all indicators accord with GB10230.1, and many important indicators are much higher than IEC60214-1 and
national standard.
* refers to agreed parameters, which shall be consulted and agreed at the time of goods order. In case that these
parameters are agreed otherwise, the agreement documents shall prevail.

6Operating Conditions
6.1The operating temperature of tap switch in transformer oil shall not be over 100 and lower than 25.
6.2Ambient temperature for tap switch placed in air shall not over 40 and lower than 25 and the relative
humidity shall not be more than 85%.
6.3 The places in which tap switch is used shall be without corrosive or explosive gas.

7 Classification and Application of Tap Switch

Non-excitation tap switches can be classified (according to structures) into four types: drum type, barrel type (new
cage type), in-line type and cage type.
Drum switch: its outline is of barrel shape, and the fixed contact of the switch is with leading wire. The fixed
contact is of column shape, and movable contact is generally of ring rolling type (opposite type is adopted in case of
extreme high voltage between contacts). The switch can be placed between two-phase coils due to its small volume, and
regular switches are mainly applied to power transformer and traction transformer. Special switches are applied to
rectiformer, intermediate transformer and special transformer.
Barrel switch (new cage type): its outline is of barrel shape, and the fixed contact of the switch is with wiring
terminal instead of leading wire. The fixed contact is of column shape, and movable contact is generally of ring rolling
type. It is evolved from drum switch and cage switch. Regular switch applies to three-circle electric transformer with
load, and is placed at the end of oil tank and beside the switch with load. Special switches are applied to rectiformer,
intermediate transformer and special transformer.
In-line switch: its outline is of strip shape, and the movable contact is of clamp type. It applies to transformers of
110kV and below.
Cage switch: its outline is of cage shape, and the movable contact is of clamp type or squirrel-cage type. Regular
clamp type switches are mainly applied to transformer for electric furnace, and squirrel-cage switches are mainly applied
to power transformer with extreme high voltage and high current. Special switches are applied to rectiformer,
intermediate transformer and special transformer.

8Definition
Operating mechanism: it is used to change switch gears and lock the gear.
Drive mechanism: it is used to connect the switch body and operating mechanism.
Mechanical retainer: it is a kind of mechanical device that can prevent the switch from operation exceeding any end
but allow operation towards reverse direction. Regular switch body, operating mechanism and drive mechanism are
respectively equipped with retainers (whether retainers shall be equipped shall be determined based on the switch
structure).
Locating pin and locating hole: they are devices used to lock gear.
Positioner: it helps the movable contract to be in place automatically under no external resistance at the time of gear
shifting.
Movable and fixed contacts: contact devices.
Operating rod: it is a kind of insulating rod which connects the switch body with mechanisms.

9 Structural Feature of Tap Switch

9.1 Structural Feature of Drum Switch
9.1.1 It has independent operating mechanism, which connects with the switch body through operating rod. The
operating rod shall be equipped at the time of transformer assembly.
9.1.2 Contact positioner is installed on the upper wall plate of regular switch body, and it can give you a strong hand
feel at the time of tank cover installation and operation so that you can accurately locate the switch contact to the center,
therefore, accuracy and reliability of installation and location are improved. Gear indicator is equipped on the
positioner, and it indicates 1st gear, 2nd gear, 3rd gearanticlockwise. There are identification numbers on leading wire,
which will provide connivance to you for connecting tapping wire.
9.1.3 Movable contact is of ring rolling type and strong hand feels for operating, and can be back in place
automatically (in case of no undue external resistance). It is generally at the medium gear (at the observation window of
the insulating cylinder) when it leaves factory.
9.1.4 The shaft coupling is with big head (in the direction with high gear number) and small head. The big head and
small head shall be respectively inserted into the big head and small head of operating rod notch. Elastic contact device
is added on the shaft coupling of switch body, and tightly abuts upon the operating rod. By this means, the generation of
floating potential is avoided, and discharge due to operation is eradicated.
9.1.5 Mechanical retainer is installed on the body positioner or on wall plate. Three-phase switch body is generally
equipped with mechanical retainers, while regular 5-gear and 7-gear single-phase switches are not equipped with
mechanical retainers so that they can rotate circularly.

9.1.6 Switch with built-in shielding applies to transformers with high partial discharge requirements and high-voltage
transformers, and it can effectively reduce the volume of transformers.
The structure of regular 5-gear single-phase drum switch body is as shown in Figure 1.
The structure of high-voltage 5-gear single-phase drum switch body (with built-in shielding) is as shown in Figure 2.
The structure of regular 5-gear three-phase drum switch body is as shown in Figure 3.

Guide
cylinder

Shafting
coupling

Small head of
i

Big head of pin

Shield ring

Wall plate
Positioner
gear
Observation
window
Safety

Movable
contact ring
Fixed
contact

Primary
insulating
cylinder
Leading wire and
mark

Fig. 1 Structure of Regular 5-Gear Single-phase Drum Switch

Small head of
pin

Guide cylinder
Primary
cylinder

insulation

Fig. 2 Structure of 5-Gear Single-phase Drum Switch

with Built-in Shielding

Shafting coupling

Big head of
pin

Spacer pin
Positioner
gear indicator

Observation window

Wall plate
Fixed contact

Leading wire and

mark
Movable
ring

contact

Fig. 3 Structure of Regular 5-Gear Three-phase Drum Switch

Drum Switch

9.2 Structural Feature of Barrel Switch

9.2.1 The contact structure and drum switch are annular pure rolling contact structure, which absorbs the merits of
drum switch, such as big working current, automatic arrival in place, small charged body, good stiffness, uniform
electric-field distribution and so on. In combination with the structure of wiring terminal of cage switch, this product is
developed to replace cage switch and has overcome the demerits of cage switch, such as bad stiffness, big volume, small
current-carrying capacity, no operational feel and so on.
9.2.3 Flat-topped and bell type installation manners are mainly adopted for barrel switch. Switch control mechanism
and the body are integral structure without riveting control lever, which makes the installation simpler and more
convenient. Floor type installation can also be adopted with control lever for connection and the installation method is
the same with drum switch.
The structure of regular 5-gear manual flat-topped barrel switch is as shown in the following Figure 4.

Hand
wheel
Grounding
hole

Locating pin for

Flange
installation disc

gears
The state when
being lifted
Gear
indication

Moving
ring

contact

Inspection window
Air relief
cock
Main insulating cylinder
Lifting
ring
Wiring
terminal

Figure 4 Structure of Regular 5-Gear Manual Flat-Topped Barrel Switch

Picures of barrel switch

9.3 Structural Feature of Strip Switch

9.3.1 Clip structure shall be adopted for moving

contact and is hard to carry big current. Screw
drive shall be adopted for the body. The gear shall
be switched over after several revolutions (the rev
olutions of different types shall be different and the
instructions are on the hand grip of control mechanism).
9.3.2The installation shall be carried out at Gear 1. The
limit (joint end) shall be only set at Gear 1 for
the body. Rotate clockwise the joint of switch body to
the limit position as Gear 1 and at that time, the
moving contact touches the Gear 1 position; remove
the protective cover and observe, and when the
moving contact stops at the two adjacent fixed contacts
(when leaving the factory, the fixed contacts of
switch have been labeled with tapping mark) which
are close to the body joint, it is Gear 1.
9.3.3 Just as drum switch, independent control mechanism
is adopted for strip switch. The switch
body is connected through control lever which shall be
prepared during general assembly of transformer.
The structure of regular single-phase strip switch body
is as shown in Figure 5.

Figure 5 Structure of Single-Phase Strip Switch

9.4 Structural Feature of Cage Switch

9.4.1 The clip type structure is applicable to the switch with relatively small current. Circumferential rotation of
moving contact will realize switchover of gears. In general, switchover of gears will happen after rotation of dozens of
degrees.
9.4.2 Squirrel-cage structure is applicable to the switch with especially big current. The rotation of screw stem will
drive moving contact to slide upward and downward axially, so as to realize switchover of gears. Parallel wiring terminal
shall be set on fixed contact.
9.4.3 In general, flat-topped and bell type installation manners shall be adopted without riveting control lever, which
Connecte
makes installation simple and convenient.
d
to
The structure of clip type electric vertical cage switch is as shown in Figure 6. The structure of squirrel-cage vertical
t l
Equaliz
cage switch is as shown in Figure 7.
Cove
er ring

Electric
mechanism
Air

Shiftin
g fork

relief

Moving
contact

Gear
Groove
d pulley

Grounding
Flange

installation

Moving contact
Fixed

Fixed
contact

Manual
cranking
Termina
l lug

Figure 6 Structure of Regular Three-Phase Clip Figure

Type Electric Vertical Cage Switch

Wiring
terminal
Scre
w

Gear
1
Gear 2
Gear 3
Gear 4
Gear 5

7 Structure of Single-phase
Squirrel-Cage Contact Structure Cage Switch

Picture of cage switch

10. Acceptance of Tap Switch

10.1 Acceptance after Arrival of Goods
The packing case shall be without damage or being wetted and the packing quantity shall be correct, otherwise
acceptance shall not be carried out; the type and number of switch and job number of transformer and other marks on
packing case shall be checked whether they are consistent with the order requirement.

10.2 Acceptance after Unpacking

10.2.1 Check whether the packing list, certificate of quality and instruction manual are complete; check whether the
type and size of switch are consistent with design requirement of transformer. Check whether the switches and
accessories are complete. Some switches are packed in different cases. Please check the complete set of mechanism and
body, so as to confirm completeness. After unpacking, keep the switch and its accessories in categories according to
marks and numbers. It is prohibited to use switches and mechanisms of different numbers together.
10.2.2 Check how many cycles there are for console switch body, confirm that no unsmooth transmission exists and
measure DC resistance. Rotate each control mechanism, transmission mechanism, gear box to confirm that no unsmooth
transmission exists. After rotation, restore them to the original state or installation state. Confirm that the indicated
positions of control mechanism and transmission mechanism are the same with the gears of the switch body, and confirm
that marks are aligned at the right places.

11. Installation of Tap Switch

11.1 Relevant Explanation
11.1.1 Under the influence of switch transportation, storage environment and dry environment, after drying of
individual switches, color change may happen on the surface of part of silver-gilt contact. Color change will not affect
the switch performance. When it is serious, you can use eraser to wipe off the contact part.
11.1.2 For drum radial outlet switch, the bending of leading wire during winding displacement will cause the part of
insulating wrapping at the root to be pulled out and it is inevitable. When relatively big part of insulating wrapping is
pulled out, you can suitably wrap during installation, otherwise without treatment the switch performance will not be
affected. As silver-copper or phosphor-copper welding has been adopted at the root of leading wire, during
electrosilvering, part of the welding location at the root of leading wire cannot be plated. The part which cannot be plated
is black brown and will not affect the switch performance in any way.
11.1.3 The bigger the current is, the bigger the rotating torque of switch body, especially drum switch and barrel switch
with positive and negative voltage regulation structure. It is easy to switch over gears with impact force (note: at the limit
position, do not impact in the limit direction). The slower and more uniform the force is, the harder it is to switch over
gears.
11.1.4 If the drum switch is installed at the triangle area of coil, you can add isolation paper tube or cardboard between
the switch and coil and case wall, so as to further improve insulating level.
11.1.5 For the switch with the limit set for the body, the limit shall be fixed on insulators. The strength is limited and
the limit of the body is prohibited to surpass during operating the body. Wrong installation of gears and installation
deviation shall be timely corrected. Otherwise rotating the hand grip of switch mechanism by force may cause damage of
the limit and the switch body will be damaged.
11.1.6 Before installation, check whether the welding direction for welding flange disc and installation support is
consistent with the design direction at first. Especially many linked switches and side control switches, each transmission
shaft shall be ensured to be at the same axis. When the transmission shafts are not at the same axis, you shall reweld
welding flange and installation support in the right direction, otherwise unsmooth transmission will be caused, even
desynchrony of the moving contact of each switch will be caused and the contact performance will be affected.

11.2 Installation of Switch Body

Fix the switch body on transformer according to design requirements, strictly connect correspondingly according to the
leading or terminal mark on the switch, fix tap leading wire and carry out insulating treatment. After measurement of
transformation ratio and DC resistance and they are confirmed as qualified, place the gears of switch body on the
installation positions.
Note:
.The length of tap leading wire shall be suitable and the switch body shall not bear the pulling force of leading wire.
When the switch was leaving the factory, insulation treatment of the leading wire close to fixed contact has been carried
out and there is no need for another treatment.
.The size between the two wooden clips for fixing the switch shall be suitable and the suggested error is 2mm. If the
error is too big, insulating barrel of switch will bear tension or extrusion, in combination with dryness stress, the switch
barrel will be deformed or cracked.
.Before use, vacuum drying treatment shall be carried out on the switch body and control lever (100~110C, 12 hours)
or the switch body and control lever shall be dried along with the drying of transformer (when the exposure time is
exceeded, redrying shall be carried out and the exposure time shall be the same with transformer requirement).After
drying and before oil filling of switch body, do not shift the gears of switch body. When operation is needed, pour
transformer oil lubrication on switch contact and transmission part.
.Insulating bolt and metal bolt with butterfly gasket on the switch may be loosened after being dried. Please check and
suitably fasten the loosened bolts.

11.3 Installation of Control Mechanism and Transmission Mechanism

see Attachment 1 for general setting-out riveting method of control lever and the detailed installation
method shall be conducted according to Guide Book on Installation of Non-excitation Tap Switch.
Note:
.The mechanisms with installation marks shall be installed according to installation mark. Independent mechanisms
shall not be dried, so as to prevent its internal lubrication effect from being lost.
.The minimum length of shortened control lever is suggested as (power frequency withstand voltage to the ground
kV/effective insulating length of control lever mm): 50/250; 100/400; 140/700; 230/800; 325/1100; 395 and above shall
be confirmed). For AC230kV and above levels, relatively short special control lever can be provided and the confirmed
drawing shall prevail.

12. Commissioning After Installation

After installation, the switch shall be operated for several cycles to verify whether the installation is accurate, and this
shall be carried out according to Guide Book on Installation of Non-Excitation Tap Switch. After commissioning and
confirming error-free, measure the transformation ratio and DC resistance. If they are qualified, label corresponding
marks on mechanism installation flange and welding flange to facilitate reinstallation during later core suspending.
Note:
.If the transformer has not been fill oil after drying, do not operate the switch body. When operation is needed, pour
transformer oil lubrication on switch contact and transmission part.
.Each time of reinstallation of switch during core suspending, the switch shall be rechecked: how many cycles are
being operated and measure transformation ratio and DC resistance to confirm that control lever has been inserted into
the body coupling, that each gear is in place and that the contact is normal.

13. Notices for Transformer Transportation

During transportation of transformer, as transmission mechanism of side control switch on transformer body top is
superhigh, it is permitted to remove gear box of transmission mechanism E and G from flange installation disc. The
method of removal and reinstallation and notices are as follows (the removal methods of two mechanisms are the same).
The side gear box shall be directly removed and other mechanisms shall not be removed.
Removal method: remove 3 M12 bolts and lift gear box upward. It is as shown in Figures 8 and 9.
Note:
. Confirm the gear before removal. After removal, There is no gear indication on flange installation disc. You can
write the gears on flange installation disc and gear box with marking pen;
. After removal, mark the position between main shaft and flange installation disc with making pen;
. After removal, it is prohibited to rotate gear box and main shaft;
. Gear box and flange installation disc are one-to-one corresponding and they are not permitted to be interchanged, so
marks shall be labeled.
. After removal, accessories shall be kept correspondingly.
Reinstallation method: reconfirm that gears are consistent and each mark is aligned at the right place. Put seal ring in

place and make gear shaft and main shaft fixed. Fasten 3 bolts.

Gear box
3 M12 bolts

Installation
mark
Before removal,
mark between
gear box and
ball head shaft

Seal ring

Flange installation
disc
Main
shaft

Gear
h ft
Position mark

Internal nut (oil seal)

Figure 8 Transmission Mechanism E (Manual Side Control Switch)

Figure 9 Transmission Mechanism G (Electric

Side Control Switch)

14. Installation, Debugging and Application at Application Site

14.1 Site Installation
14.1.1 Remote location display mechanism: connect the signal wire of remote location display mechanism cable entry
(according to Fig. 11 Gear Signal Terminal Block Identification) to the master-control panel of user control room; when
configuring gear display with switch, connect to the gear display through configured cable and connect the power supply
of the gear display.
14.1.2 Upper electrically operated switch: connect one end of configured cable to CX1 socket of controller and other end
to socket of switch installation flange plate; notice cable plug direction (one end is pin and the other is hole) and connect
controller protective contract and power supply. See Fig. 14 below
14.1.3 Side electrically operated switch: connect power wire and guard wire into electric mechanism box
(TPON-type control mechanism).When configuring controller with switches, connect one end of configured cable
to CX1 socket of controller and other end to CX1 socket of electric mechanism box; notice cable plug direction (one end
is pin and the other is hole) and connect controller power supply. See Fig. 10 below for site installation and debugging of
side electric console switch.
14.1.4 When cable is configured, one shall not pull cable plug and bend joint part of plug and cable during deployment
of wire to avoid break of plug joint and malfunction of operation and display. It is prohibited to cut cable and lengthen or
connect it without permission.
14.1.5 The two pairs of protective contacts action contract and control output of electrically operated switch shall be
correctly connected to closing circuit of transformer; otherwise, switch gear may be mistakenly operated under
electrification of transformer, resulting in major failure.
14.1.5.1 Action contact protective contact: is a pair of normally closed contact provided by auxiliary contact of main
transformer master switch; the contact is open when main transformer operates and electric operation cannot be realized
at this time to avoid electric gear shift under electrification of transformer. Wiring method: action contact must be
connected to a pair of passive normally closed contact provided by high-voltage load switch (or breaker) auxiliary
controlling contact to realized the lock of electrification and voltage regulation of transformer and prevent this contact
from direct short circuit.
14.1.5.2 Control output protective contact: is a pair of normally closed contact provided by electric mechanism to main
transformer; the contact is under open status when electric mechanism operates and the main transformer cannot be
switched on at this time. Wiring method: control output is connected in parallel to a pair of contact provided by
high-voltage load switch auxiliary controlling contact; when controller is under rise or fall operation, the contract is
under open status; the transformer cannot be switched on.
14.1.6 When users require the switch gear signal of the configured controller or display by switch being connected to
user master-control panel or computer, three kinds of output method can be provided on the back plate of controller or
display; users can choose to connect on their own according to their demand (see details in controller or display
specification).(1) One-to-one corresponding signal contact output; (2) BCD code output; (3) RS485 communication
interface.

14.2 Site Debugging

When installing transformer at site, the service personnel of transformer factory shall carry out several circulation of
operation to switches; direct users to carry out variation and DC resistance measurement; check switch operating status,
consistency between electric display gear and body and mechanism gear, and contact status (see Fig. 10, Fig. 11, Fig. 12,
Fig. 13, Fig. 14 and specification in figures for operation method).In case of abnormal situation, place oil tank, oil filter
and other equipments at site to affiliate timely maintenance.

14.3 Site Application

Warning! The operation and maintenance of tap switch shall be carried out under non-excitation status of transformer!
14.3.1 It can be put into application under normal operation of site switch and correct protection wiring of electric switch
and after the transformer is accepted as qualified.
14.3.2 Repeat this step once every three years during normal operation: turn hand shank with wrench for several cycles
(or direct turn by hand wheel) and finally fix locating pin at required gear location hole. Or electrically change gear for
several cycles and then adjust in to required gear. Affirm gear instruction and right location and then carry out DC
resistance measurement under correct operation to check the contact status of transformer and switches; do not operate
beyond gear limit when shifting gear. See Fig. 10, Fig. 11, Fig. 12, Fig. 13, Fig. 14 and specification in figures for
operation method.
CX1 cable socket
TPON side electrical control mechanism

Gear indication
Pointer straightly
points to digit

In place indication
Common switch rotates for one cycle
and pointer points to the top, which
means gear changed

Shift button

Shift
electric
mechanism to
local
and
controller
to
remote

Phase sequence switch RD6:

both lights on are correct. If
yellow light is off, it means
phase sequence is wrong;
change power line of power
supply
Manual shaft
Manually rotates common
switch for 30 cycles for
changing gear

Wiring hole
To power supply and
protection line

19 core control cable

One end is pin and the
other is hole, aligned to
socket
(use
CX1
interface)

Power switch Q1

Terminal block X1 wiring mode:

No. 1, 2, 3 and 4 are three-phase (380v) four-wire power supply; No. 4
is zero line. No. 7, 8, 9 and 10 are protective contacts, preventing electrically
shift switch gear under electrification of main transformer

No.1 and No. 2 are

connected
to
power
supply 220v

During debugging, directly short connect contact No. 7 and No. 8 of

action contact with wire (contact is open when delivering out of factory) to
realize electric shift; control output No. 9 and No. 10 may be not
connected.
Warning: it shall be connected as per methods specified in 14.1.5.1 and

CX5 socket is output contact of remote BCD

code gear signal. CX4 socket is output contact
of RS485 communication interface; user can
connect on his own according to his demand.

Controller installed at
control room

14.1.5.2 at operating site.

Fig. 10

Site Installation and Debugging of Side Electrically Operated Switch

Location pin
Lift and rotate
for 90

Hand wheel
Special wrench

Gear instruction
Hand shank

Location bolt
Location hole

Hand wheel control mechanism

Gear 1

Gear 2

Gear 3

Gear 4

Gear 5

Public terminal

Control mechanism B

Gear signal
Cable entry
Gear signal terminal block of remote display mechanism

Control mechanism C (remote display mechanism)

KTY-3WD tap switch gear display

Operating method (the mechanism in figures are manually operated switch of ring rolling contact structure switch): screw location pin and use special wrench
to rotate hand shank (or direct rotate by hand wheel); it can hear the gear contacted sound by inner switch of body; when the location pin moves to the next
location hole, the gear is changed. After changing required gear, use wrench to sway hand shank in circle and eliminate transmission gap and turn location pin into
location hole. Larger current may result in larger switch rotating torque, especially for three-phase structure switch; use impact force can easily change gear; in
contrary, more even force and more slowly speed may make the gear shift more hard.

Fig. 11
Location groove

Gear observation window

In place instruction

Key hole

Gear instruction
Crank
Hand shank

Gear signal
Cable entry

Operating method (strip-type switch): lift up the handle from the locating slot,
rotate this handle according to the directions and number of turns described on
it, and then put down the handle into the locating slot after proper turns of
rotation and conformity of gear alignment to indications. The strip-type switch
is with sliding contacts of sheet type which is with little moment when shifting.
For such switch, it can not be strongly felt the proper shifting and there is no
sound from the contact shifting.

Fig. 12 Control Mechanism A

Transmission shaft

Operating method: insert the key into the keyhole, rotate it to unlock
state, rotate the crank and then one gear shifting is displayed; the
in-place indication is aligned, and finally the key will return to locking
state automatically; and by then, one gear shifting is completed.
Unlocking shall be performed for each gear shifting, and this
mechanism possesses functions of blocking and long-distance gear
displaying.

Fig. 13 TPON Side Manually Control Mechanism

Gear instruction

Socket

Grooved pulley
Groove of pulley
Shifting fork

Consistence of gear instruction

Upper electrically operated mechanism

Crank

YJK-I Non-excitation Tap Switch Controller

Pin
It shall be out of groove of
grooved pulley and stop
within red arrow scope

Cable

perating method: in case of manual operation, use the crank to rotate the motor rotator, and the
shifting yoke will start to rotate (there is no resistance for the time being). When the shifting
pin enters into the groove of grooved wheel, the grooved wheel will drive the movable contract
of switch to rotate (the torque will increase at this time). When the shifting pin rotate out from
the groove of grooved wheel, the grooved wheel and the movable contract of switch will stop moving
(there is no resistance for the time being). And then rotate it to the middle of scope as indicated
by the arrow, and that the gear changes to another position means one gear shifting is completed.
Refer to the instruction manual of controller for electric debugging. For the protective connection
point of controller, on by directly connecting the actuation contact point with conducting
wire at the time of debugging (the connection point is at off state when the switch leaves factory)
can electric gear shifting can be achieved, and control output may not be connected. Warning!
Connections shall be conducted in accordance with 14.1.5.1 and 14.1.5.2 before putting into
operation.

Fig. 14 Upper Electrically Operated Switch Mechanism

15. Site Maintenance

15.1 Maintenance Notice
15.1.1 When lifting core is needed at site, make re-assembling mark between installation flange and welding flange
before disassembling switch control mechanism.
15.1.2 In case the switch inside is suspected to have problem and lifting core check is needed at site, one shall make
corresponding marks and take photos for each link of disassembling switch, and can inform our company to send
personnel to handle together when necessary.

15.2 Maintenance of Oil Leakage

15.2.1 Oil leaks between the installation flange and welding flange of switch
Screw up installation bolt and if it is ineffective, change seal ring when maintaining transformer.
15.2.2 Oil leaks between switch shaft and installation flange plate
15.2.2.1 Control mechanism B
Appropriately tighten inner nut (oil seal) but not too much. In case the adjustment is ineffective, change seal ring even
without oil drainage. The method is: remove inner nut, upper hand shank and other parts; screw out inner nut; directly
install gasket and re-install inner nut; appropriately screw up and the problem will be solved. If the method is still
ineffective, turn off oil conservator valve and take out gasket and seal ring with small tools; slight oil leakage is normal
at this time; change seal ring and re-disassemble removed parts. Disassembling is as shown in Fig. 15.
15.2.2.2 Hand wheel operating mechanism
Remove M10 bolt from hand wheel and take off hand wheel; take out taper pin and lift display panel upward (pry u
pward if it is tight); screw up inner nut appropriately but not too much. Disassembling is as shown in Fig. 16. Handle it
with method specified in 15.2.2.1 in case the adjustment is ineffective.

15.2.2.3 Upper electrically operated mechanism

Remove four M12 bolts of electric mechanism and take off electric mechanism; remove M10 bolt of grooved pulley
center; lift grooved pulley upward (pry upward if it is tight); pick up end cover; screw up inner nut appropriately but not
too much. Disassembling is as shown in Fig. 17. Handle it with method specified in 15.2.2.1 in case the adjustment is
ineffective.
15.2.2.4 Transmission mechanism G (handle transmission mechanism E and transmission mechanism G with same
method)
The leakage at end cover and cover plate of gear case is resulted by leakage of main shaft of switch body; remove gear
case and screw up inner nut appropriately but not too much tight. Disassembling is as shown in Fig. 18. Handle it with
method specified in 15.2.2.1 in case the adjustment is ineffective.
Taper pin
Notice smaller head and bigger head

M10 bolt
Taper pin
Notice smaller head and bigger head

Hand wheel
Hand shank

Inner nut
Gasket
Seal ring

Display panel
Inner nut
Gasket
Seal ring

Fig. 15 Maintenance Drawing for Oil Leak

of Control Mechanism B
Electric mechanism

Fig. 16 Maintenance Drawing for Oil

Leak of Hand Wheel Operation Mechanism

M12 bolt

M10 bolt
Grooved pulley

Gear box

End cover
Inner nut
Gasket
Seal ring

External seal ring

Inner nut
Gasket
Seal ring

Fig. 17 Maintenance Drawing for Oil Leak of

Upper Electrically Operated Switch Mechanism

Fig. 18 Maintenance Drawing for Oil Leak of

Transmission Mechanism G

15.3 Application site; the following factors may result in abnormal situation of transformer DC
resistance

15.3.1 Installation deviation

The installation deviation of operating mechanism or transmission mechanism and body results in bigger pressure for
one side of moving contact and smaller pressure for the other side.
15.3.1.1 In case the deviation is slight, the contacts side with smaller pressure may endure long-term over current and
result in heating and oxidation; adjust body and mechanism to accordance according to installation fault elimination
method of control mechanism and transmission mechanism; repeatedly change over gear for tens of cycles to wear off
oxide layer; measure DC resistance again.
15.3.1.2 In case the oil quality is changed or it is ineffective after being treated as per 15.3.1.1, lifting core check shall be
carried out; if the contact is found with serious color change or slight burn, these color change and burned contact can be
treated by sanding, and contact pressure can be increased properly. Switches must be changed as for serious situation.
15.3.2 Installation with gear wrong
The measured ration of transformer and resistance is not inconsistent with the gear indicated by control mechanism with
Classification

Fault phenomenon

Analysis of reason

Processing method

Side electrically operted

switch

The manual operation is

normal but local electrically
operated switch does not
work

1. Electrical mechanism is not turned to

local location set.
2. The protective action contacts are
disconnected.
3. Phase sequence of power supply is
wrong.
1. Electrical mechanism is not turned to
local location set.
2. Control cable is not well connected.
1. Control cable is not well connected.
2. The plug and socket of corresponding
gear has rosin joint, sealing-off, broken pin,
etc.
1. 2A protective tube of rear panel is
burned.
2. Check incoming line of power supply.
1. Action contact function is not used or
the status of local/remote control button is
not correct.
2. 0.1A protective tube is burned.
3. The cable aviation plug is not well
plugged or there is rosin joint.
4. The wire on display panel of switch body
exists rosin joint.
5. The contact of incoming line of electrical
machine is bad.

1. Turn electrical mechanism knob from

remote control to local.
2. Connect protective action contacts.
3. Change phase sequence. If the fault still
cannot be solved, it means that the RD6
phase sequence switch is bad.
1. Turn electrical mechanism knob from
local to remote control.
2. Re-plug control cable.
1. Re-plug cable.
2. Check the welding of plug and socket
and the pin.

The remote control does

not work (controller)
Some gears of controller
cannot be displayed
Upper electrically operated
switch

The power supply light of

controller is not no (cannot
display action contact).
The controller cannot rise
or fall.

Controller does not display

gears
(at
that
time,
controller will generate
buzzing sound and the
control contact will be
open).
Certain gear of controller
cannot be displayed and the
gear cannot cease strip stop.

The switch does not work

with controller and control
circuit out of fault.

1. The wire on display panel of switch body

exists rosin joint; public contact 12# and
other gear wires or display contact pin exists
rosin joint;
2. The switch is not at gears; the display
contact pin is worn or with bad contact.
3. The aviation plug is not well plugged or
there is rosin joint.
1. The gear wire exists rosin joint or the
contact of contact pin is bad;
2. The gear wire for aviation plug exists
rosin joint or it is bad connected.
The switch body mechanism is blocked and
it is under status without lubrication.

1. Change protective tube.

2. Correct incoming line of power supply.
1. Connect action contact to the control
loop of transformer and form access;
local/remote control can only be operated
for corresponding status.
2. Change fuse.
3. Repeatedly plug in and out aviation plug
or carry out repair welding; test with
multimeter.
4. Confirm location with multimeter and
carry out repair welding.
5. Use multimeter to test and correct the
connection.
1. Confirm the rosin joint position with
multimeter and carry out welding again.
2. Adjust gear to correct position and
change display contact pin.
3. Re-plug aviation plug; use multimeter to
confirm rosin joint position and carry out
repair welding.
1. Use multimeter to confirm the rosin joint
or sealing-off position and carry out repair
welding.
2. Remove aviation plug and carry out
repair welding towards such gear wire;
tightly plug in aviation plug again.
Confirm the blocked position and repair;
add lubrication oil for each transmission
part.

some gears cannot be changed over: it means body gear is not inconsistent with control mechanism gear; this problem is
caused usually because the core is not re-assembled as per original position after lifting core again; it needs to be
installed again with gear aligned to.
15.3.3 Inconsistence between operating rod and body
In case there is no change-over hand feels when shifting gear and the ratio of transformer and resistance measured at
each gear are the same, it means that control mechanism does not drive body (there is no switch body plugged in
operating rod or the operating rod is short).
15.3.4 There is no application for long time or gear is not shifted for long time
There may form a thin layer of oxidation film on the contact surface. Repeatedly change over the switch for tens of
cycles and then measure the resistance.
15.3.5 Other reasons
The slight color change of switch silver coated contact surface is normal after application, which cannot affect the
contact. If there is large area of black, the DC resistance is unstable and irregular at this time; it may be caused by over
sulfur content of oil; full chemical examination shall be carried out; meanwhile, change switch contact or entire switch.

15.4 See special specification for common faults of controller and display

Notes:
1. Split type switch (connected by control lever); this method is suitable for any operating method and any
mechanism to rivet control lever.
2. The switch body and mechanism shall be confirmed that they are at the same gear, which are usually installed
at intermediate gear; if the mechanism is marked, the marks shall be aligned.
If the mechanism is confirmed
to face this direction, take this
hole as basic hole and draw
datum line with this hole taken
as center.

Installation
flange
mechanism

of

Take this hole as basic hole and draw

mark lines at the side of installation
flange with this hole taken as center
and draw a vertical line to union tube.
Draw datum line outside of the union
tube.

Welding flange

Union tube

Step 1: Find out basis and draw datum line.

Step 2: Lead datum line on welding flange

vertically to control lever. Draw datum line for
length of control lever along the upper plane of
welding flange.

Step 3: Confirm the length of control lever.

After confirming the length of

control lever, insert control lever in
mechanism union tube and align
union tube to the lines on control
lever; use 10 drills for drilling.

Step 4: Align to marked lines and match drills; rivet pins after cleaning up.

The actual length of control lever

L=H-L1+L2-5~10 (clearance)

L1: Length below installation flange plate of control mechanism

L2: Length of control lever inserted into union tube

TPON Tap Changer Electric Operating Mechanism

1. Overview
1.1 TPON tap changer electric mechanism, which mainly acts as the device for
driving and controlling the action of tap changer, switches the tap changer from one tap
position to another to achieve the purpose of adjusting voltage. Other tap changers may also
be selected for use.
Mechanical and electric components necessary for operating tap changer is installed in the
electric mechanism, with electric interlock circuit adopted. Generally speaking, the electric
mechanism serves as a fitted product for tap changer device that is supplied in full set.
Figure 1 lists a form of arranging tap changer and electric mechanism on the transformer
cabinet.
1.2 Using condition for electric mechanism
1.2.1 The temperature of air medium around the mechanism ranges from -25 to +55.
1.2.2 The place where the electric mechanism is used does not exceed 1000m in altitude.
1.2.3 the obliquity of axis for installing the electric mechanism to the vertical plane does
not exceed 5%.
1.2.4 There should not be too much dust, corrosive and explosive gases around the electric
device.

2. Technical Parameters and Major Functions

2.1 Please refer to Table 1 for technical parameters of TPON electric operating
mechanism
S.N.

Table 1
Categorized features
Rated power, W
Rated voltage, V
Parameters of
Rated current, A
motor
Rated frequency Hz
Rotationspeed, r.p.m

5
6

Transmission torque of output shaft, N.m

Number of rotations of output shaft for tap
change at each level
Number of rotations of handle for tap change
at each level
Operation time for tap change at each level, S
Voltage of control loop and heater, V

Excitation power of control loop, VA

3
4

Power of heater, W
Line frequency withstand voltage of control
9
loop, Kv/1min
Protection grade of electric operation
10
mechanism cabinet
11 Service life of mechanism, 10,000 times
12 Weight, kg
*Not including motor, auxiliary contacts of breaker and cable socket

Data
370
380
1.1
50
1400
50
2
30
5
~220
100
30
2.5
IP54
80
40

TPON Tap Changer Electric Operating Mechanism

2.2 Major functions of electric mechanism
The electric mechanism is equipped with various mechanical and electric components
necessary for operating tap changer.
Follow the Stepping principle to operate the electric mechanism, i.e. during the process
when tap changer moves from one working position to another, the electric mechanism is
started by a single control signal, once-for-all switching operation done without interruption.
For tap changer having three middle positions, the mechanism is equipped with
automatic transcending position.
The motor may be either operated electrically with button or manually operated with
handle, having interlock protection device for both manual and electrical operation.
For distant operation, electric operation may be done by using the button installed in the
control room, or automatic operation can be done with automatic voltage controller to be
equipped.
If control voltage is suddenly break off after the mechanism is started, the former
control key must be pressed after the voltage is restored to complete primary tap change.
The electric mechanism has protective loop to prevent disorderly phase sequence.
The electric mechanism has a device for breaker trip signal transmission. The electric
device has contact of indication signal that tap changer is acting.
The electric mechanism has mechanical counter no less than 5 digits, which records
operation times automatically. Record once every two circles for output shaft.
The cabinet of the electric mechanism complies with the requirement for outdoor
product, featuring properties that are free from dust, rain and bugs.
Lubricating grease is spread in the reduction gearbox of the electric mechanism.
Generally user does not have to add or replace the grease.

3. Installation Adjustment
3.1 Please refer to Figure 3 for installing the electric mechanism on transformer cabinet,
overall dimension and installation size of the mechanism.
This electric mechanism should be vertically installed on the side wall of the
transformer cabinet, installed and fastened with M12*60 bolts, nut, spring washer and gasket.
For occasions where vibration is large, it is recommended to adopt the measure of damp
off at installation.
It is required that the output transmission shaft of the electric mechanism be installed
vertically, and adjusted to the same line with bevel gear transmission box of the transmission
shaft.
3.2 Installation of bevel gear box
Please refer to the attached figure 1 for the installation and overall dimension of the
bevel gear box.
The bevel gear transmission box is installed on the support of the transformer box cover
with two M16 bolts. If bolts are loosed, this gear device may be revolved 5 to each left or
right direction.
3.3 Installation of transmission shaft
Please refer to the attached figure 2 for the installation schematic of transmission shaft.
3.4 Electric preparation
1

TPON Tap Changer Electric Operating Mechanism

Connect operation mechanism and cable according to connection table and re-check to
ensure correct wire lead. Before electrifying, insulation resistance must be measured on the
parts with electricity to prevent the occurrence of short circuit.
Check the interlock function of control loop at manual operation.
3.5 Operation test
3.5.1 Check whether the rated value of power source is consistent to the requirement of
electric mechanism before electrifying.
Check whether the phase sequence is correct. When electrifying, if motor rotates
reversely and then positively and stop at the initial position when button S1 or S2 is pressed,
user must adjust the phase sequence of power source.
3.5.2Check for progressive operation
When button S1 or S2 is randomly pressed (pressed several times or keep pressing in
the operation process), electric mechanism should complete only one electric operation
without any disturbance.
3.5.3Test of electric position stop operation
Electric operation moves tap change from one end to the other. At the two limit
positions. When the electric operation toward transcending direction is tested, respectively,
the motor should not be started.
3.5.4 Interlock test of manual and electric operations
When the handle is inserted into manual operation shaft and operation buttons S1 and
S2 are pressed, the motor should not be started.

4. Usage and Maintenance

4.1 Usage
4.1.1 Before being electrified and used, user should make a general check including cleaning
the internal and external surface of electric mechanism, checking whether all the fasteners
are loose and the reliability of the earthing device. Coat grease on the surface of several
visible gears to increase lubrication and reduce wear and tear.
4.1.2, Re-check by doing operation test before official electrifying on site.
Specific check items are the same as those in 4.6.1~4.6.4.
4.2 Maintenance
There has been coated with sufficient grease in the bearings of transmission gearbox and
the motor of the electric mechanism, so check and adding by dismantling is usually not
necessary during the normal use period. Therefore, the maintenance is quite easy. In order to
ensure long-term and reliable running of the mechanism, frequent observations and check
should be done at ordinary times, mainly including the following aspects:
Rain-proofing and dust-proofing conditions of the box;
Lubrication conditions of the surface of the visible gears
Appearance of each electric element in the electric mechanism
During the period of overhaul combined with tap changers, full check and test should
also be done on the mechanism and electric performance on the operation mechanism.

5. Connection Method
5.1 User must do the connections according to connection table 2. No errors are allowed.
5.2 For the power source of this electric mechanism, eiectric motor is adopted. L1 and N are
2

TPON Tap Changer Electric Operating Mechanism

connected to the terminals 1, 2, 3, and 4, respectively.
5.3 Contact:Is the Main Transformer main control switch auxiliary contacts box provided to
the institutions normally closed contact,the contacts as a main transformer at run time must
be disconnected state.(Contact capacity is greater than AC380V2A)
5.4 Control output:Organizations provide for main transformer main control switch box pair
of passive normally closed contact,when Body box shift,the touch Point is broken.(Contact
loadAC380V2A)

6. Instruction for Usage and Ordering

6.1 User should keep record of the operation and maintenance conditions. In case of special
situation, please contact our factory to exchange the experience for operation and
maintenance. User should keep the electric mechanism in a good storage environment to
prevent it from damage and corrosion.
6.2 If abiding by the rules for storage and usage, 12 months from the day when it is installed
and used, and within 18 months from the day when the product is delivered to the user, the
user can have the product repaired by the factory free of charge in case of damage or failure
to work due to production quality.
6.3 Please notice that this electric mechanism is a fitting product for the supply of full set of
tap changer, therefore, the operation levels should be consistent to the corresponding tap
changers. Operation mechanism that is otherwise supplied should be indicated with working
levels.
Connection Table 2 for Electric Mechanism Terminal X1
Electric mechanism terminal X1
Notes
X1-1
X1-2
X1-3
X1-4
X1-5
X1-6
X1-7
X1-8
X1-9
X1-10
X1-11
X1-12
X1-13
X1-14
X1-15
X1-16
X1-17

L1
N
L1
N

Working power
Moisture proof resistance
Action connection
Control output

N1
1N
COM
Digits 1
Digits 2
Digits 3
Digits 4
Digits 5

Action input (passive contact)

Position signal output(passive contact)

COM

TPON Tap Changer Electric Operating Mechanism

Figure 2 Electrical Schematic Diagram of TPON Electric Mechanism

TPON Tap Changer Electric Operating Mechanism