TESTS PROCEDURES FOR

DISTRIBUTION TRANSFORMERS

CHERYONG INDUSTRIAL CO., LTD.

 Test Items
1. General Test 2. Form Test

1.1 Construction and Appearance Check 2.1 Temperature Rise Test

1.2 Winding Resistance Measuring 2.2 Impulse Withstand Voltage Test
1.3 Insulation Resistance Measuring
1.4 Transformer Turn Ratio Measuring
1.5 Phase Displacement Measuring
1.6 No-load Current and No-load Loss Measuring
1.7 Load Loss and Impedance Voltage Test
1.8 Power-frequency Withstand Voltage Test
1.9 Induction Withstand Voltage Test
1.10 Efficiency Calculation
1.11 Voltage Regulation Calculation

Applied Standard : IEC 60076

 Test Purpose Check whether they comply with the standard based on orderer-maker approved specifications.

Measure checking points with naked eyes and measuring instruments, and check whether they comply
Test Method
with the standard.

1. naked eyes
Use Instrument 2. steel tape
3. vernier calipers

Cautions Check whether measuring error is within allowable error.

1.1 Construction 1. appearance and dimension

and Appearance 2. standard, nameplate and terminal indication status
Check Checking Point
3. insulating oil leakage, gasket, painting and color, and other appearance
4. option goods' attachment status, indication, and part attachment status, etc

Test Circuit Diagram -

 Test Purpose Check cold resistance to calculate characteristics and temperature rise.

Apply DC current between two terminals of 1st and 2nd windings, and measure each winding resistance
Test Method
by using a micro ohmmeter.

Use Instrument Micro Ohmmeter

1) Leave winding at constant ambient temperature for 3 hours at least, and then record its temperature.
2) Put a sensor to a main position, and then measure winding temperature. Winding resistance and
Cautions
winding temperature should be measured at the same time.
1.2 Winding
3) Pay attention to making the magnetic induction effect minimized.
Resistance
Measuring Checking Point Check whether each winding's measuring value are similar.

Test Circuit
Diagram
 Test Purpose Check insulation performance in 1st and 2nd coils

By using an insulation ohmmeter, measure insulation resistance between 1st-2nd coils, between 1st coil
Test Method
and the ground, and between 2nd coil and the ground.

Use Instrument Insulation Ohmmeter (DC 1000V or DC2500V)

Cautions -

Checking Point P-S : 1000㏁ or more

1.3 Insulation
Resistance
Measuring

Test Circuit Diagram

 Test Purpose Check the number of 1st coil's windings and the number of 2nd winding's coils.

Test Method By using a transformer turn ratio meter, measure the transformer turn ratio (polarity and displacement)
in all taps, and check whether they are within allowable error.

Use Instrument Transformer Turn Ratio Meter

Cautions Check 1st voltage and 2nd voltage

Checking Point ±0.5% or less

1.4 Transformer
Turn Ratio
Measuring

Test Circuit Diagram

 Test Purpose Check a single-phase transformer's polarity and a three-phase transformer's connection.

1. Single-phase : Connect high/low voltage U terminals mutually by voltmeter method and galvanometer
method, apply about 200V to the high-voltage terminal, and then measure voltage
between high/low voltage V terminals.
Test Method
2. Three-phase : Connect high/low voltage U terminals mutually, apply about 200V to the high-voltage
terminal, and then measure and record voltage between high/low voltage V terminals.
Depict the vector diagram for the measured values, and check them.

Use Instrument Transformer Turn Ratio Meter

Cautions -

1.5 Phase The single-phase transformer should be subtractive polarity and the three-phase transformer should
Checking Point
Displacement conform to approved specifications.
Measuring

Test Circuit Diagram

 Test Purpose Check the transformer's no-load current/loss.

Open 1st circuit at any ambient temperature, apply 2nd rated voltage in rated frequency and sine wave
Test Method between 2nd terminals, and measure the current to indicate it at percentage. And measure no-load loss,
and indicate it at watt (W). (the average of each phase current for a three-phase transformer)

Use Instrument Characteristic Test Stand, Meter Transformer, Digital Power Meter

Cautions Apply 100% of rated voltage

Checking Point 1) No-load Current : +30%, 2) No-load Loss : +15%

1.6 No-load Current

and No-load Loss
Measuring

Test Circuit Diagram

 Test Purpose Check the transformer's load loss and impedance.

Short 2nd circuit at any ambient temperature, apply sine wave voltage at rated frequency between 1st
terminals, generate current equivalent to this output to 2nd circuit (For a three-phase transformer, the
average of each phase currents different mutually), and measure the loss. And correct it at the reference
Test Method winding temperature in 75℃, and then indicate the corrected value at watt(W).

When measuring load loss for rated capacity, measure voltage between 1st terminals, correct the
measuring value at the reference winding temperature in 75℃, and then indicate the corrected value at
voltage (V) or percentage (%) of 1st rated voltage.

Use Instrument Characteristic Test Stand, Meter Transformer, Digital Power Meter

Cautions Measure quickly that error due to temperature rise cannot occur.
1.7 Load Loss and Checking Point Supply current must be equal to rated current but not be its 50% or less.
Impedance Voltage
Test

Test Circuit Diagram

 Test Purpose Check whether the transformer is insulated between phase and ground.

Apply power-frequency single-phase AC current equivalent to voltage to one winding for 60 seconds, and
Test Method
ground other winding and the ground (core and frame, etc).

Use Instrument Power-frequency Withstand Voltmeter

Cautions Check attached parts's status before test.

1. Sudden current rise must not occur.

Checking Point 2. Flashover must not occur.
3. The transformer's structures must not be damaged.

1.8
Power-frequency
Withstand Voltage
Test

Test Circuit Diagram

 Test Purpose Check whether the transformer's winding is normally insulated.

Drop voltage to two times voltage of rated voltage at 120~500Hz, and check whether winding
Test Method
withstands it. The test time should be max 60 seconds through min 15 seconds.

Use Instrument Induction Withstand Voltmeter

Cautions Comply with safe rules for the high-voltage test.

1. Sudden current rise must not occur.

Checking Point
2. The transformer's structures must not be damaged.

1.9 Induction
Withstand Voltage
Test

Test Circuit Diagram

 Test Purpose Check whether it complies with the guaranteed value in approved specifications.

Measure loss by the no-load / load loss tests, and then calculate the efficiency for any output by the
following equation.

A
Test Method Efficiency η (%) = × 100
( A + B + C)
1.10 Efficiency
Calculation A: capacity (kVA),
B: no-load loss (W)
C: load loss (W) (corrected by the reference winding temperature in 75℃ )

Use Instrument Computer

Cautions -

Checking Point Guaranteed value-(100-measuring value)/10 or more

Test Purpose Check whether it complies with the guaranteed value in approved specifications.

Measure loss by the no-load / load loss tests, and then calculate the efficiency for any output by the
following equation.

Test Method If power factor is COS Φ, voltage regulation is calculated by the following equation.
1.11 Voltage
Regulation (% IX ) 2
Voltage regulation ε (%) = % IR +
Calculation 200

Use Instrument Computer

Cautions -

Checking Point Guaranteed value +10% or less

 Test Purpose Check whether the transformer normally operators without overheat under rated load.
1. Loading Method
Consecutively load until the transformer's temperature rise is constant. To shorten the test time, the
transformer may be properly overloaded in the beginning of the test. Loading-back method is used in
principle.
2. How to Measure the Transformer's Temperature
Measure winding temperature by the resistance method; oil temperature by the thermometer method. The
transformer's winding temperature (t2) is calculated by the following equation based on winding
resistance.

t 2 (°C ) =
(R2 − R1 ) × (235 + t ) + t
1 1
R
Test Method t : winding temperature in the beginning of the test (℃ )
R1: winding resistance in t1 ℃ (Ω )
2.1 Temperature R2: winding resistance in t2 ℃ (Ω )
Rise Test
- How to Decide the Reference Ambient Temperature
Whichever following methods are available.
(1) Place a thermometer to some spots which are 1/2m in height and 1~2m in distance from the test
target transformer, measure the air temperature, and take the average of values measured every 30
minutes for 3 hours in the last.
(2)The idle transformer in the almost same size to the test target transformer is used. When the idle
transformer's cooling status is regarded to be almost same to that of the test target transformer, the
idle transformer's oil temperature in the last of the test is taken as the reference ambient temperature.
Use Instrument Characteristic Test Stand, Temperature Gauge, Double Bridge, Stopwatch

Cautions Load current should be constantly supplied.

Checking Point Check whether the measuring value complies with the guaranteed winding temperature rise value.
Test Circuit Diagram -
 Test Purpose Check whether the insulation in and out the transformer has the strength to withstand impulse voltage.

By using the impulse voltage generator, apply voltage according to the specified test sequence. However
this test is allowed for specially designated cases only.
Test Method
voltage waveform : -(1.2×50)µs
voltage peak value : 125kV for full wave voltage 22.9kV(Y); 145kV for chop wave voltage 22.9kV(Y)

Use Instrument Impulse Voltmeter

Cautions Comply with safe rules in the high-voltage test.

Checking Point Check the connection status again.

2.2 Impulse
Withstand Voltage
Test

Test Circuit Diagram