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three-phase HV / LV transformers

mineral oil-immersed distribution models



Instructions for
installation,
commissioning
and maintenance

Contents

taking delivery 3

handling 4

installation 6

HV and LV connections 15

transformer operation in parallel 19

maintenance 20

after-sales service 23

precommissioning checks 24

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Warning

This guide intended for standard
range oil-immersed distribution
transformers as described in
France Transfo product
catalogues.
If in doubt, our After-Sales Service
remains wholly at your disposal.
Tl. (33) 03 87 70 57 72
fax: (33) 03 87 70 56 21

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On receipt of equipment, ensure that it corresponds with your order by checking
machine characteristics indicated on the rating plate (capacity, voltages, etc.)
Distribution transformers are delivered "ready for installation", i.e. completely filled
with oil and with accessories either fitted or delivered separately.
When unloading, check that the transformer has not been damaged during
transport (broken insulators, damaged tank, etc.) and that all accessories ordered
have been delivered.
Also check that the tank lead seal, fixed to one of the cover screws (usually at a
tank corner) is intact, because its breakage causes the transformer guarantee to
lapse.
Should the unit have been damaged or if accessories ordered are found to be
missing:


enter a reservation on the nal haulage contractor's delivery note and conrm
by recorded delivery letter within 3 days.


write a report and send it immediately to your supplier (France Transfo or a
dealer as the case may be).

Taking delivery of equipment and preliminary checking

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Transformers are usually stabilised during transit by heavy timber bearers fixed to
the vehicle bed. It is therefore essential to remove these bearers before lifting the
transformer unit off the vehicle.
Transformer units incorporate specific handling devices.


Lifting by means of slings or a lifting beam

(gure 1)
The unit must be handled using the 2 lifting rings located on the transformer cover.


Hauling

(gure 2)
The transformer must only be hauled from its chassis. 30 mm diameter holes have
been drilled in the ends of chassis members for this purpose, except in the case
of low capacity units or those built to a special specification. Hauling must only
been undertaken in two directions: along and perpendicular to the chassis centre-
line.


Handling using a forklift truck

(gure 2)
Forks must only lift the chassis from within the inverted channel sections, with idler
rollers removed.
o r
1
h o le fo r h a u lin g
2

Handling

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Positioning of idler rollers

(gure 3)


either by lifting with slings or a lifting beam.


or by lifting with a forklift truck.
In this case, position the forks of the truck within the inverted channel sections.
Place heavy timber bearers, which are slightly higher than the idler rollers, cross-
wise beneath the ends of the chassis members and lower the unit onto these tim-
bers.
Position jacks and remove timber bearers one by one.
At the same time, x each idler roller in the required position (idlers swivel in
2 directions) using the locking screw.
Then, remove the jacks and allow the unit to rest on its idler rollers.

Ground clearance due to the idler rollers is essential for transformer cool-
ing.
3
tim b e r b e a re r
id le r ro lle rs

Handling

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Ensure that machine characteristics shown on the rating plate correspond with
installation conditions: primary voltage(s), tapping links.
This plate may be moved and attached to any side of the tank so that it is visible
once the machine is in position.
In general, installation must comply with the requirements of IEC Standard
71-1, 2 and 3 in relation to insulation co-ordination.
E.g.: case of overhead-underground connection to be protected by lightning
arresters installed at both ends of the HV cable.


unit to be installed at a maximum altitude of 1000 m, unless otherwise specied
with order, because air rarefaction adversely affects cooling of the windings.


unless otherwise specied with order, transformers of standard design are
sized in accordance with IEC Standard 76 for the following ambient
temperatures:
maximum : 40C
average daily : 30C
average annual : 20C
minimum : 25C
When the transformer is live, the ambient temperature inside the plantroom must
comply with the above values, unless the transformer has been specially designed
on the basis of a particular specification.

Installation

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Determining the height and cross-sectional areas of
ventilation wall openings (figure 4)

In the general case involving natural cooling (AN), the purpose of the plantroom
ventilation system is to disperse the heat, resulting from the total heat losses
generated by the operating transformer, by natural convection.
An efficient ventilation system comprises a fresh air inlet wall opening of cross-
sectional area S positioned low down in the room, and air outlet opening of cross-
sectional area S' positioned high up on the opposite wall of the room at a height
H above the air inlet opening.
It should be noted that restricted air circulation around the unit causes a reduction
in available power. For this reason, the transformer must be positioned at a
minimum distance of 200 mm from any solid wall.

Design calculation:

P = sum of losses under no load and losses due to load on transformer, expressed
in kW at 75C, plus losses generated by any other unit in the same room.
S = cross-sectional area of fresh air inlet wall opening (deduct possible area
obstructed by grill), expressed in m

2

.
S= cross-sectional area of air outlet wall opening (deduct possible area
obstructed by grill), expressed in m

2

.
H = difference in height between inlet and outlet wall opening centre-lines,
expressed in m.
and
This formula is valid for an average annual ambient temperature of 20C and at a
maximum altitude of 1000 metres.
H
S
S
Groupe Merlin Gerin Usine de Maizires-ls-Metz (Moselle) France n 216540
4
2 0 0 m m
m in i
S
0 18P ,
H
----------------- = S 1 10 S , =

Installation

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Forced ventilation of plantroom (figure 5)

A ventilation system of this type is required for a cramped or poorly ventilated
plantroom, or for a room in which the ambient temperature is much higher than the
temperature outside, in view of the ambient temperatures used for designing the
transformer. Should the transformer be frequently overloaded, a forced ventilation
system can help to disperse the heat generated by the unit, although it will not
reduce the adverse effects of such overloading on the equipment's life.

An air extract fan discharging outside the plantroom

may be fitted to the outlet
wall opening, located at high level, in order to increase natural convection in the
room; this fan can be thermostat-controlled.
Recommended discharge rate (m

3

/s) at 20C = 0.10 P
P = total heat losses to be dispersed, expressed in kW, for all equipment installed.
Groupe Merlin Gerin Usine de Maizires-ls-Metz (Moselle) France n 216540
H
S
S
5
2 0 0 m m
m in i

Installation

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Setting the voltage
commutator

Commutator setting is carried out in the
following way:
- unscrew fully the red locking knob,
- simultaneously pull and turn the
commutator rotating head until the
pointer indicates the right setting,
- push the rotating head back ensuring
that the pointer is engaged in the
notch for the setting required,
- rescrew fully the red locking knob
Tapping links
Set the tapping point
commutator to the required
position:
Pos. 1: upper primary voltage
Pos. 2: rated primary voltage
Pos. 3: lower primary voltage
re d lo c kin g kn o b
c o m m u ta to r ro ta tin g h e a d
in d e x
Adjustments to tapping point or
voltage commutators must be
undertaken with the transformer
off-load and de-energized.
1
2
Double primary voltage
For units using 2 primary
voltages, select position as
required.
Pos. 1: HV1
Pos. 2: HV2

Installation

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Statutory restrictions for oil-immersed transformers

Each country issues its own regulations covering the installation of oil-immersed
transformers on its territory.
These regulations invariably respond to concerns for the protection of people,
property and the environment. Available protection systems depend on the
technology adopted for the transformer concerned.
When the unit is in service, the volume of the dielectric fluid used to cool its coils
(usually mineral oil complying with IEC Standard 296) varies continually, due to
temperature variations in the windings.
These volume changes must be "absorbed" by a suitable expansion system
which has given rise to two distinct technologies:

Hermetically sealed type transformer

The unit's tank, containing the active part, is hermetically sealed: variations in
volume are absorbed by expansion of the cooling fins positioned around the tank,
the dielectric fluid is not exposed to the surrounding air.
Maintenance of this type of unit is thus greatly reduced (see page 20).

Installation

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Protection accessory: the protection relay (figure 6)

Fitted directly to the transformer cover, this relay ensures protection against
internal faults, prolonged overvoltages and fire risks associated with the use of
inflammable dielectric fluids.
The accessory continuously monitors:
- dielectric fluid level,
- tank internal pressure,
- dielectric fluid temperature at two different thresholds.
To operate properly, the protection relay must be fully filled with fluid (level higher
than the float visible in the transparent section of the unit). If this is not the case,
check the instructions which appear inside each casing.
To ensure optimum protection, the following action and adjustments are
recommended:

Finding Recommended
adjustment
Fault detected Action to be taken

Gas emitted or drop in
level
Large oat at the top


Serious fault


De-energize unit
Pressure switch 0.20 bar


Serious fault


De-energize unit
Thermostat threshold 1 90C


Overvoltages


Activate alarm
Thermostat threshold 2 100C


Overvoltages


De-energize unit
6
o il
se n so rs

Installation

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Faults detected on live transformer unit


Dielectric uid level is detected as low
The protection relay is empty and the large oat is at the bottom.
May be due to:
- air entering; there must be a dielectric uid leak and thus oily stains should be
visible on the ground.
Accurately localise the fault, carry out repair, then recheck the level with the
body of uid at a temperature of 20C, before switching the unit live again
(see oil grades, page 20),
- internal gas emission: gas should be sampled using a syringe and then analy-
sed.
Whilst awaiting results, under no circumstances should the transformer be
switched live again because a risk of total destruction exists.
Should gas analysis reveal an inammable gas, contact FRANCE TRANSFO
After-Sales Service (see page 23), or your SCHNEIDER correspondent.


Overheating is detected
This may be due to:
- improper cooling of the transformer (insufcient air ow around unit or plant-
room ventilation),
- continuous overvoltage.


Excess pressure is detected
This may be due to:
- overheating: see above,
- internal gas emission: see above,
- topping up of dielectric uid with the body of uid below 20C; drain the
overow with the transformer de-energised and the dielectric uid at 20C.

Installation

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Breather type transformer with expansion tank (figure 7)

The transformer tank is connected by pipework to an expansion tank, mounted
above the unit, which ensures that the dielectric fluid level remains sufficiently high
in the transformer tank: variations in dielectric fluid volume are absorbed by the
expansion tank which remains at atmospheric pressure.
This type of unit therefore requires maintenance which is both regular and suited
to the climatic conditions in the vicinity of the transformer (see page 21).

Protection accessory : the Buchholz relay

Fitted to the pipework linking the expansion tank to the transformer tank, this
accessory ensures protection against internal faults only, by monitoring dielectric
fluid levels and fluctuations.
To ensure proper operation, the Buchholz relay must be completely bled of air.
Faults detected on live transformer unit


Dielectric uid level is detected as low.
The Buchholz relay is partially empty, the top level oat is at the bottom.
Reasons for this low uid level are the same as those given for the protection
relay (see page 11) but in the present case, the relay will activate automatically
the alarm.


Major discharge of oil towards the expansion tank is detected
A violent emission of gas, resulting in serious electrical faults within the
transformer tank, leads to a large discharge of oil to the expansion tank, which
causes the Buchholz relay bottom oat to pivot; the transformer unit must be
de-energised immediately and permanently.
Contact FRANCE TRANSFO After-Sales Service (see page 23), or your
SCHNEIDER correspondent.
7
o il

Installation

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Dielectric fluid retention system

In an environmental protection context, the retention system used must be
capable of containing the total quantity of dielectric fluid, unless otherwise
specified by local regulations.
It may comprise:
- a raised door threshold if the plantroom oor is oil tight,
- a low oil tight wall around the transformer,
- a steel trough positioned beneath the transformer.
In the last two cases, ensure that the system does not adversely affect transformer
cooling by preventing air circulation around the tank cooling fins.

Installation

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Bushing type

Transformers may be provided with the following connections.

Example of bushing choice for LV = 400 V.
kVA 100 160 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150

LV busbar bushings 1250A 1250A 1250A 1250A 1250A 1250A 1600A 2500A 2500A 3150A 5000A 5000A

LV porcelain bushings

250A 250A 630A 630A 630A 1000A 1000A 1600A 1600A 2500A 2500A 3150A 4000A 5300A
385
M 12
250A
H V c o n n e c tio n s to
p lu g -in b u sh in g s
locking ring locking ring
H V c o n n e c tio n s to
p o rc e la in b u sh in g s D IN 4 2 5 3 1
N.B.: under no circum-
stances should porcelain
HV bushings be used
with cover-protected HV
systems.
with draw-out
angle connector
with draw-out
straight connector 1250A
31,5
63
31,5
12
1
5
5
5
2
11
14,5
31,5
1600A
14,5
11
2
2
1
5
2
12
31,5
31,5
9
7
,
5
31,5
63
31,5
2500A
2
5
0
5
2
12
11
14,5
1
0
6
,
5
31,5
31,5 31,5
100
31,5
3150A
2
5
0
4
5
12
120
50
50
50
18
35
5000A
3
1
0
4
5
20
120
50
50
25
50
135
18
DT 250A
138
M 12
DT 630A
178
M 20
DT 1000A
263
M 30
10
60
26 17
26
14
60
DT 2000A
340
100
50 25
14
15
50
M 42
100
DT 3150A
15
120
372
120
60 30
60 14
M 48
5300A
20
165
465
150
65
150
L V c o n n e c tio n s to b u sb a r b u sh in g s o n ly u se d a b o ve 2 5 0 kVA u n its)
L V c o n n e c tio n s to p o rc e la in b u sh in g s m a n d a to ry fo r 1 0 0 a n d 1 6 0 kVA u n its) D IN 4 2 5 3 0

HV and LV connections

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Assembly and tightening torque

Bushings must not be subjected to stresses resulting from cable or busbar
connections; such loads can cause leaks at various joints.
Furthermore, the following connection details and tightening torque values shall
be complied with:
F
H V o r L V c o n n e c tio n to p o rc e la in b u sh in g
U 5 2 kV - M 1 2 stu d )
nut tightening
torque: 25 Nm
M12 brass stud
load in accordance
with I.E.C. 137:
connecting terminal
inclined < 30, F = 50 daN
connecting terminal
inclined > 30, F = 30 daN
c
l
e
a
r
a
n
c
e
:

a
p
p
r
o
x
.

5

m
m
reminder:
1 N.m = 0.102 mkg
1 mkg = 0.98 daN.m
L V c o n n e c tio n to b u sb a r b u sh in g
steel bolt
locknut
end lug
large diameter metric series
steel plain washers
tin-plated copper busbar bushing
N.B.: end lug, bolt and washers are not supplied.

HV and LV connections

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Table of tightening torque values

Tightening torque given in N.m.
Tightening tolerance 20%.
The above torque values are for assemblies incorporating plain washers.
However, we recommend the incorporation of contact washers behind the plain
washers; the above torque values should be increased by 35% if this is done.
Steel and stainless steel bolts shall be greased prior to fitting.
If aluminium bolts are used, please refer to manufacturer's recommendations.

Bolts Class 6.8
anticorrosion
-treated steel
Class A2-70
and A4-70
stainless steel
Class A2-80
and A4-80
stainless steel
Brass

M8 15.2 15.5 17.7 7.6
M10 30 30 35 15.1
M12 52 53 60 25
M14 83 85 97 41
M16 130 133 152 55

HV and LV connections

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Protection

HV bushings



Draw-out connectors (straight or angle) may be kept plugged into the plug-in
bushings using a padlockable locking device (padlock / lock not supplied);
Release of this locking system may be made conditional on prior isolation of
the transformer from the HV supply (figure 8);


Porcelain bushings may be tted with a sealable protective cover, whose
design will depend on the HV voltages, the conguration and number of cables.

LV bushings


Busbar or porcelain bushings may be protected by a sealable cover.
8

HV and LV connections

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Connection of several transformers in parallel leads to the following constraints:


If their power outputs are different, the total available combined power output
will be slightly less (< 10%) than the sum of the power outputs for each
transformer coupled separately.


The power output of the largest transformer should not be more than twice that
of the smallest unit.


Transformers must be supplied by the same network.


Connections must be of the same length and have similar characteristics
between the LV terminals of the different units and the coupling circuit-breaker
(gure 9).


Couplings must be identical.


Short-circuit voltages must be identical (10%).


Differences in secondary voltages between the different units must not exceed 0.4%.


The switch shall be positioned identically on each unit.
9
re c o m m e n d
to a d vise
L V

Transformer operation in parallel

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Mineral oil and component materials

The transformer is filled with mineral oil complying with ICE Standard 296.
Transformer component materials are free of polychlorobiphenyls (PCB's),
polychloroterphenyls (PCT's) and polychlorobenzyltoluene (PCBT).
Moreover, the PCB content of this unit is guaranteed to be less than the detectable
threshold (2 ppm*) in strict compliance with standards currently in force.

Hermetically sealed type transformer

Under normal operating and environmental conditions, maintenance of this
transformer is reduced. It is in fact limited to regularly checking the tightness of
connections and visual inspection of transformer oil tightness.
Under conditions of extreme pollution (depositing of dust, salt, chemicals, etc.),
cleaning of porcelain or busbar bushings may be required.
As long as the dielectric fluid has not been exposed to the air for a particular
reason (tank opening, repairs, fitting of accessories, topping up of oil, etc.), one
dielectric withstand test, on a sample taken from the bottom of the tank (minimum
breakdown voltage 30 kV), every 10 years is sufficient.
The transformer is hermetically sealed and has no gas cushion. In other words,
filling and closure have been carried out in such a way that pressures are balanced
(internal and external atmospheric pressure) under conditions approaching
normal, i.e. temperature of 20C and pressure of 1013 mbar.
* parts per million.
C
e transfo
rm
ateur est g
aranti ralis avec d
es
constituants neufs et exem
p
ts d
e tout lm
ent d
e
rcup
ration suscep
tib
le d
avoir t p
ollu p
ar
d
es P
C
B
.
W
e w
arrant that this transform
er has b
een
m
anufactured
w
ith new
m
aterial and
is totally free
from
second
hand
p
arts p
olluted
w
ith P
C
B
s.
Lab
el p
laced
on all transform
ers

Maintenance

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If necessary, this transformer may be opened in accordance with the following
recommendations:


Transformer is hot (


> 20C)

The unit's internal pressure is higher than atmospheric and opening it causes
leakage of some dielectric uid which can only be reinjected in full, once its
temperature has returned to 20C.
Until this occurs, the unit can full its functions. However, replacement of all the
dielectric uid lost at the earliest opportunity is preferable.


Transformer is cold (


< 20C)

The unit's internal pressure is lower than atmospheric and opening it causes a
drop in oil level in the tank. After servicing and topping up dielectric uid, if
required, put the unit back into operation and purge when hot.
To prevent excess pressure in the tank, the volume of dielectric uid which may
have been added (during topping up) should be drained, once the unit's
operating temperature has risen to 20C.

Maintenance

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F ra n c e T ra n sfo
Breather type transformer with expansion tank
Because the dielectric fluid is exposed permanently to the surrounding air, the
frequency of oil quality checks must be increased: once a year is an absolute
minimum, which should be further increased if a gradual deterioration of fluid
dielectric withstand is observed (reminder: minimum breakdown voltage: 30 kV).
If an air dehumidifier has been fitted to the expansion tank to filter the incoming air,
the colour of the silica gel it contains should be monitored:
- blue colour : silica gel is in a good condition for ensuring dehumidication,
- pink or white colour : silica gel has absorbed humidity and has become inef-
fective, it should therefore be replaced (supplied by our After-Sales Service,
see page 23).
Also check that the glass, located at the bottom of the dehumidifier, is filled with
oil to the required level, in order that dust carried by the surrounding air flow is
effectively retained.
Maintenance
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F ra n c e T ra n sfo
When making enquiries or ordering spare parts, it is essential to quote the main
characteristics given on the rating plate and, in particular, the unit serial number.
TECHNICAL MEMO
(data to be copied from unit rating plate)
No. :
Year :
Power output : kVA
Frequency : Hz
Cooling :
Coupling :
Rated high
voltage : kV
Low voltage : V
Mass of
dielectric : kg
Total mass : kg
Groupe Schneider Usine de Maizires-ls-Metz (Moselle) France
NAL - 226489
c o m p lyin g re f. H z T R E E P H A S E T R A N S F O R M E R
a c c o rd in g to ye a r
im p e d a n c e
vo lta g e
c o n n e c tio n %
h ig h vo lta g e lo w vo lta g e
p o s 3 V
v
o
l
t
a
g
e
s
p o s 4 V
p o s 1 V
p o s 2 V
p o s 5 V
c u rre n ts A
V
A
k VA N in su la tio n le ve l K V
n a tu re win d in g s
p rim a ry in se rvic e o n
c o o lin g
d ie le c tric
m a ss d ie l. k g
m a ss to ta l k g
After-Sales Service
tel.: (33) 03 87 70 57 72
fax: (33) 03 87 70 56 21
After-Sales Service
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F ra n c e T ra n sfo
Operations prior to connecting transformer
check data given on rating plate in relation to needs (power output, voltage,
etc...)
ensure transformer plantroom is clean and cannot ood
ensure correct ventilation
- plantroom air vents are clear and of suitable area (pages 7 and 8)
- sufcient clearance between unit and solid walls in plantroom (page 7)
- sufcient clearance between unit and oor (unit resting on idler rollers -
page 5)
check general condition and cleanliness of transformer
measure values of insulation resistance using a 2,500 V insulation tester
If the measured values are signicantly less than the usual values, please call
your After-Sales Service (page 22).
check oil tightness of unit (welds, gaskets, valves, drains, plugs).
Checks carried out on: ......................................... by: .........................................
Measuring points Measured values
Usual values for
mineral oil
HV / earth
LV / earth
HV/LV
M
M
M
250 M
250 M
50 M
Precommissioning checks
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F ra n c e T ra n sfo
Operations prior to switching transformer live
ensure there is no foreign body on the unit (metal lings, nuts and bolts, etc.)
if the transformer is an hermetically sealed type unit tted with a protection
relay, check that the large oat is at the top and that the drain is properly
closed (close by turning clockwise). Refer to instructions supplied with each
transformer in relation to testing.
if the transformer is a breather type unit with an expansion tank and Buchholz
relay, check that all air bubbles have been bled from the latter unit and carry
out relay testing using the devices provided for this (rod to be pushed or
pulled to activate alarm or trip).
Check condition of silica gel in the dehumidier and the level of oil in the bot-
tom glass vessel.
ensure that cables and busbars are properly supported; no loads should be
applied to the transformer connection lugs.
check wiring of protection or ventilation auxiliaries with respect to:
- insulation clearances and cable xings,
operation.check tightness of connections (pages 16 and 17)
check earthing continuity - to ensure the safety of operating personnel, the
transformer earthing system must be grounded.
check that rotating switch head is correctly set to, and locked in, the required
position.
ensure that ventilation grills are clear.
- if unit is to operate in parallel, check short-circuit voltage, phase consistency
and voltage ratio (page 19)
Precommissioning checks
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F ra n c e T ra n sfo
notes
GEa220000a Page 26 Mardi, 13. avril 1999 8:40 08
N


i
d
e
n
t
.

T
V
A

:

F
R

7
8

3
5
7
8
0
1
1
0
9


S
A

a
u

c
a
p
i
t
a
l

d
e

1
0

2
8
0

0
0
0

F
R
F


R
C
S

M
e
t
z

B

3
5
7

8
0
1

1
0
9


I
m
p
r
i
m


e
n

F
r
a
n
c
e

France Transfo
BP 10140
F 57281 M aizires-ls-M etz C edex
Tel.: (33) 03 87 70 57 57
fax.: (33) 03 87 51 10 16
GEa 220000 a
Since this manual was edited, a number of alterations may have
been incorporated in the equipment you have received. The sole
reason for this resides in our constant efforts to improve the
quality and performance of our equipment.
Edited by: France Transfo - 03/99
Typesetting and illustrations: COREDIT
GEa220000a Page 28 Mardi, 13. avril 1999 8:40 08

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