Transportation, Installation, Commissioning and Maintenance of SGB Cast Resin Transformers

TITt 12/95

Contents
1. General Information 2. Packaging 3. Transport 4. Storage 5. Installation 6. Commissioning 7. Operation 8. Maintenance

1. General Information
According to national regulations (VDE 0532, part 6) and international regulations IEC 726), cast resin transformers are classified as dry-type transformers. Characteristic technical values and constructive design conform generally to DIN 42523 and especially to customer specification for each order. Special characteristics of the cast resin transformers are their HV windings, cast completely in resin, and their LV windings, which are insulated in synthetic resin and come most often in the form of foil windings. These features differentiate cast resin transformers from other dry-type transformers in that they enable better partial discharge, short circuit and electric strength (especially switching impulse voltage and lightning impulse voltage strength) and higher resistance to detrimental environmental conditions such as humidity, dampness and dust. All other technical details are either visible (since cast resin transformers do not have tanks) or can be found on the following sources: - rating plate and connection diagram (on the transformer) - dimension drawing and item list (upon request) - measurement and test sheets - information about transformer enclosures (where applicable) - wiring diagram for temperature control

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2. Packaging
Cast resin transformers are not sensitive to natural humidity. Domestic transportation over short distances on covered vehicles generally does not required packaging. For long distance or overseas transportation, the transformers are wrapped in protective covering and placed in containers or wooden crates. Packaging details are decided in each individual order either acc. to customer specification or by SGB, based on the transport route.

3. Transportation
3.1 When lifting the transformer, all 4 lifting lugs must be used simultaneously. Lifting directly by the yoke is not permissible ! 3.2 Lift crates and containers only where indicated. 3.3 Use only pneumatic suspension vehicles for street transportation. 3.4 For short distance transportation by truck, place the undercarriage of the transformer on squared timber and secure these against sliding on the loading area. Use the 4 lugs in the upper clamping beams to fasten the transformer with lashes. Adjust the tension with the lash control device at a minimum of 30 slack angle above the lash belts. Rates are given on the plate near the lugs Levels for acceleration during transport must not exceed 0,8g in driving direction and 0,5 g in transverse direction. 3.5 In case of damage or visible shifts of the winding positions in the transformer, submit complaints immediately to the forwarding agent; if necessary, contact SGB. 3.6 Transport with fork lifts, for example, should only be carried out with lifting gear when the 4 lifting lugs are used (see 3.1).

4. Storage
Temporary storage during transportation or prior to installation must be done only in rainproof storage areas. Plastic coverings should be fitted over the transformer in such a way that condensed water is prevented from forming, for example by rear ventilation. The same applies to transformers already installed in enclosures.

5. Installation
5.1 Remove packaging and transportation materials and clean the transformer. Special care should be given to the cooling ducts and the spaces between the windings. 5.2 Position the transformer free from wobble in the station. Lock the wheels. When using anti-vibration supports be sure to position them exactly in relation to the transformer. 5.3 Make sure there is a properly dimensioned ventilation system in the room where the transformer is installed. (Take higher load losses

-3into account under AF operation.) For this set up, guidelines in the worksheet J 11 Transformer Substations" can be used. This will be sent upon request. 5.4 Unpack and remove parts that have been packed separately for transportation, such as connecting leads, control boxes, etc., and mount them (see 7.3). 5.5 The undercarriage must not be dismantled from the bottom yoke clamping beams ! 5.6 lf protection enclosures have also been delivered, mount them according to the instructions enclosed with them. 5.7 lf there is to be a great deal of time between installation and commissioning of a transformer, and if there is a danger of the transformer becoming dirty during this time, use plastic coverings (see 4.). 5.8 Connecting the Temperature Control Thermistors are used in the LV windings and for each control system connected in series. Each control system (e.g. for alarm, tripping, fan control) has a separate thermistor row with different nominal response temperatures (NRT) marked by the color of the individual leads. When one thermistor reaches his NRT, the tripping relay is operated. This way, single-phase overloads are also prevented. The terminal strip which connects the thermistor rows with the tripping relays is generally located on the upper clamping beam. The tripping relays are usually packed separately when delivered, have screws and snaps for clamping and are for control panel installation. See separate diagram for temperature control wiring.

6. Commissioning
Before starting, do the following: 6.1 Remove plastic coverings. 6.2 Connect earthing properly and check them. 6.3 Check transformer for dirt and foreign bodies; clean again if necessary. 6.4 Make sure the upper coil supports are tight. The 20 mm thick artificial rubber supports must be pressed a little bit. Tighten axial clamping bolts if necessary. 6.5 Connect temperature control systems and check them by interrupting the sensor circuit on the terminal strip (see 7.2). 6.6 lf fans are included, check that propellers turn in the proper direction and that the control device works (see wiring diagram, temperature control). 6.7 Do phase connection according to connection diagram (see 6.9). lf the tapping connection installed by the manufacturer has to be changed to another tap position, complete according 7.3.

-46.8 Check and tighten all screws/bolts in electrical connections! See last page for torque values. 6.9 Check clearances: Place all connections and control leads, as well as support devices and fastenings with sufficient distance from the HV cast resin windings. We recommend clearances such as those for bare conductors, as in VDE 0532 : Um = 12 kV - 115 mm) Um = 24 kV - 215 mm) installation height Um = 36 kV - 300 mm) =1000 m above sea level CAUTION! The HV cast resin windings are insulated by a coat of cast resin, but they are not safe to touch in the sense that the VDE regulations provide. This means that work on the transformer or in its immediate vicinity is only permissible when the transformer is off-circuit and earthed.

7. Operation
The general regulations and conditions of operation in VDE 0532/IEC 676 apply to cast resin transformers, provided that customer specifications do not deviate from them. Cast resin transformers differ from fluid filled transformers in their overload capacity. Since common guidelines for loading are missing, the following guidelines should be observed: 7.1 Overload Capacity Compared to oil-filled distribution transformers, cast resin transformers have different thermal capacities, temperature of the insulating system and the thermal time constants, which determine the overload capacity depending on the pre-load, temperatures of the coolants and time. Because of the various constructions and models, general guidelines for loading cannot be applied. They must be calculated individually and are available upon request. 7.2 Temperature Control The thermistors (thermistor rows) are connected in series and built into the LV windings. They generally consist of two systems with a difference in nominal response temperature (NRT) of 20 degrees Celsius, whereby the lower NRT is used as an alarm and the higher NRT to trip the transformer. When the higher NRT for tripping is reached, the temperature limit of the insulation system is usually exceeded and life expectancy of the transformer is thus reduced. The lower NRT for alarm reacts at an ambient temperature of 20C if the continuous rated load temperature has been reached. In this case the load must be prevented from increasing.

-5Causes for overheating may be: - overload - ambient temperature higher then 40C at rated load - insufficient cooling of the transformer (check ventilation) Under no circumstances may the thermistors be replaced by thermistors with a higher rated operation temperature ! 7.3 Changing the tap links Tap change only when the transformer is off-circuit ! Change the HV tap links individually, without changing the position of the delta connection: - loosen the connection between tap link and delta connection - remove fastening bolt from the terminal insert - slide tap link over the newly chosen terminal, insert and refasten tightly with bolt - reconnect the tap link to the delta connection Counter-moment must be applied to the HV tap links with an open ended spanner, size 20-21, when loosening or tightening the connections (see sketch) ! See last page for torques.

8. Maintenance
Cast resin transformers are largely maintenance free. 8.1 Function of fans and fan controi must be checkend approx. every six months. 8.2 Check pollution of transformer surfaces within self selected intervals and clean them if dirty. After installation in a new place with unknown pollution risk we recommend a first check latest six months after. lf pollution is unimportant check intervals can be lengthened without problems. lf transformer surfaces are especially dirty, cleaning should be more frequent according to the extent of the dirt, and preventive measures should be taken to reduce the amount of dirt in the future. When cleaning, special attention must be paid to the cooling ducts and to the spaces between the windings. Cleaning is done with vacuums, dry compressed air, and cleaning cloths. lf dirt is very persistent, cleaning cloths can be impregnated with a special cleaning fluid (e.g. Rivolta S.L.X.-Top, supplier Bremer & Leguil GmbH). In that case we recommend you to put the treated surface under seal again (should be done with plunged into varnish type 3H, supplier Dr. Wiedeking or into shellac varnish). 8.3 The function of the temperature control must be checked every 6 months by interrupting the thermistor row on the terminal strip. If the resistance of the thermistors is checked, the voltage used with the measurement device must not exceed 2.5 V!

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Torques for copper bar connections Thread size M 10 M 12 M 16 Torques *) 40 Nm 70 Nm 140 Nm *) without lubricant

Torques for tap links and threaded inserts Thread size M8 M10 M12
1

Torques *) 10 Nm 20 Nm 35 Nm

*) without lubricant

)apply counter-moment to the HV tap link with open ended spanner, size 20-21 (see sketch)

STARKSTROM-GERTEBAU GMBH
D-93055 Regensburg - Ohmstrae 10
Telephone (+49 941) 78 41 0 - Teletex 9418 192 SGBR - Fax (+49 941) 7 17 21 eMail : sgb@sgb-trafo.de Internet: www.sgb-trafo.de