Technical Construction File Transformer

Engineering Speci
Superseded by T HR EL 17 Engineering Specification

Electrical
EP 17 00 00 11 SP
LOW VOLTAGE ISOLATING

TRANSFORMER
Version 4.1
Issued November 2012
Owner: Chief Engineer Electrical
Approved Neal Hook Authorised Neal Hook

by: Chief Engineer, Electrical by: Chief Engineer, Electrical
Disclaimer
This document was prepared for use on the RailCorp Network only.
RailCorp makes no warranties, express or implied, that compliance with the contents of this document shall be
sufficient to ensure safe systems or work or operation. It is the document user’s sole responsibility to ensure that the
copy of the document it is viewing is the current version of the document as in use by RailCorp.
RailCorp accepts no liability whatsoever in relation to the use of this document by any party, and RailCorp excludes
any liability which arises in any manner by the use of this document.
Copyright
The information in this document is protected by Copyright and no part of this document may be reproduced, altered,
stored or transmitted by any person without the prior consent of RailCorp.
UNCONTROLLED WHEN PRINTED Page 1 of 20

by T HR E
Superseded 24/05/201 RailCorp Engineering Specification — Electrical
Low Voltage Isolating Transformer EP 17 00 00 11 SP
Document control
Version Date Summary of change
3.0 May 2010 Application of TMA 400 format
4.0 February 2012  Last Technical Review
 Updated suitable transformer rated range from
25kVA - 315kVA to 5kVA - 315kVA
 Updated reference to Australian Standards and
Railcorp Standard
 Updated RailCorp Drawings list
 Additional sub section for References
 Updated the following performance characteristics
(No load ratio, Inrush current, Impedance voltage
and Tolerances)
 Additional sub section for Technical Characteristics
 Updated IP rating requirements for indoor
transformer case from IP33 to IP21
 Updated section - Reliability, Availability and
Maintainability
 New section - Quality Management System
 New Appendix B - Information to be supplied by
tenders
Add Appendix C - Requirements for Technical Aspects of
4.1 November 2012 Tender Evaluation
© RailCorp Page 2 of 20
Issued November 2012 UNCONTROLLED WHEN PRINTED Version 4.1
by T HR E
Contents
1 Introduction............................................................................................................................ 5
2 References............................................................................................................................. 5
2.1 Australian Standards............................................................................................................... 5
2.2 RailCorp Documents............................................................................................................... 6
2.3 RailCorp Drawings................................................................................................................... 6
3 Definitions and Abbreviations.............................................................................................. 6
4 Functional Characteristics.................................................................................................... 7
4.1 General.................................................................................................................................... 7
5 Performance Characteristics................................................................................................ 7
6 Technical Characteristics...................................................................................................... 8
6.1 General 8
6.2 Core 8
6.3 Winding 8
6.4 Protective Screen.................................................................................................................... 9
6.5 Internal Connections................................................................................................................ 9
6.6 Terminals & Terminal Enclosure.............................................................................................. 9
6.6.1 Terminal Enclosure Mounting Positions..................................................................10
6.7 Transformer Case.................................................................................................................. 11
6.7.1 Indoor Type 11
6.7.2 Outdoor Type 11
6.7.3 Mounting 11
6.7.4 Lifting and Lashing Attachments.............................................................................12
6.7.5 Surface Finish 12
6.8 Rating Plate 12
6.9 Labelling 12
6.10 Environment12
7 Reliability, Availability and Maintainability........................................................................12
7.1 RAM Targets......................................................................................................................... 12
7.2 RAM Requirements............................................................................................................... 13
7.3 Maintenance Concept............................................................................................................ 13
8 Tests..................................................................................................................................... 13
8.1 Routine Tests........................................................................................................................ 13
8.2 Type Tests............................................................................................................................. 14
9 Quality Management System.............................................................................................. 14
9.1 Supplier’s Accreditation......................................................................................................... 14
9.2 Inspection and Test Plan....................................................................................................... 14
10 Data Set associated with the Equipment...........................................................................14
10.1 Equipment Manuals............................................................................................................... 15
10.2 Drawings and Information...................................................................................................... 15
10.3 Test Results........................................................................................................................... 15
10.4 Life Cycle Costing.................................................................................................................. 15
10.5 Technical Schedule............................................................................................................... 15
by T HR E
Appendix A Technical Schedule.............................................................................................. 16

Appendix B Request for Tender Checklist..............................................................................19
Appendix C Requirements for Technical Aspects of Tender Evaluation.............................20
by T HR E
1 Introduction
This document details the design, manufacture and whole of life performance
requirements for single and three phase low voltage isolating transformers for use in the
RailCorp electrical network.
The transformers described in this document are associated with Local Electricity
Distributor supplies, the 120/415Vac signalling systems and supplies to equipment in
contact with the RailCorp 1500V dc system. Specific applications of the isolation
transformer are detailed in Section 4.1.
The design is suitable for transformers rated from 5kVA to 315KVA, inclusive. For
signalling transformers with ratings below 5kVA, it shall comply with the requirements of
RailCorp Specification Single Phase Air Cooled Isolating Transformers for Signalling
Applications SPG1133.
The intention of this document is that the transformers will be dry-type. Oil filled
transformers are not acceptable.
The requirements of this document apply to all new single and three phase low voltage
isolating transformers.
2 References
2.1 Australian Standards

The following Australian Standards are either referenced in this document or can provide
further information.
AS 1627.4:2005 Metal finishing – Preparation and pre-treatment of surfaces,

Abrasive blast cleaning.
AS 1939:1990 Degrees of protection provided by enclosures for electrical
equipment (IP Code).
AS 60076.1:2005 Power transformers– General
AS 2374.5:1982 Power transformers – Ability to withstand short-
circuit. AS/NZS 60076.10:2009 Power transformers – Determination of sound
levels. AS 2700:2011 Colour standards for general purposes.
AS 60076.11:2006 Power transformers – Dry-type transformers.
AS/NZS 3000:2007 Electrical installations (known as the Australian/New Zealand
Wiring Rules.
AS/NZS 3100:2009 Approval and test specification – General requirements for
electrical equipment.
AS/NZS 61558.1:2008 Safety of power transformers, power supplies, reactors and
similar products – General requirements and test
AS/NZS 61558.2.4:2009 Safety of power transformers, power supply units and similar –
Particular requirements for isolating transformers for general
use.
AS/NZS 3750.15:1998 Paint for steel structures – Inorganic zinc silicate paint
AS/NZS 4680:2006 Hot-dip galvanised (zinc) coatings on fabricated ferrous
articles AS/NZS 60137:2008 Insulated bushings for alternating voltages above 1000 V
by T HR E
2.2 RailCorp Documents

The following RailCorp documents are either referenced in this document or can provide
EP 02 00 00 01 SP Transformer Loss Evaluation

EP 12 10 00 20 SP Low Voltage Distribution Earthing
EP 12 10 00 21 SP Low Voltage Installations Earthing
EP 12 30 00 01 SP Electrolysis From Stray DC Current
SPG 1133 Single Phase Air Cooled, Isolating Transformer for
Signalling Applications
2.3 RailCorp Drawings

The following RailCorp drawings are either referenced in this document or can provide
EL0035272: General – Distribution Padmount Substation 415/415 or 240/240 Whole

Current Metering General Arrangement Internal Details
EL0474159: General – Distribution Padmount Substation Type R Kiosk
Assembly General Arrangement
EL0497871: General – Distribution Padmount Substation LV Kiosk – 25kVA XFMR With
Remote Metering General Arrangement
EL0170330: General – Low Voltage Double Insulated Point of Supply General
Arrangement
EL0494646: General – Distribution Padmount Substation 415V/415V Isolation
Transformer Schematic Diagram 3 Phase
EL0474470: Distrbution Power Supply Signals Power Supply with UPS
EL0494650: Distribution Padmount Substation Railcorp Dual Supply Arrangement
EL0282072: Distribution Power Supply Railcorp & Backup Power Supply with
UPS EL0480479: Distribution Radmount Substation 415V/415V Isolation
Transformer
3 Definitions and Abbreviations

For the purpose of this specification the definitions specified in the referenced Australian
Standards apply. The following definitions should particularly be noted:
Dry-Type Transformer: A transformer of which the core and windings are not immersed
in an insulating liquid (from AS 60076.11).
Isolating Transformer: A transformer with protective separation between the input and
output windings.
Primary Winding: The winding that receives the active power from the supply system.
Principal tapping: Is the mean tapping position. It is also the tapping to which the rated
quantities are related.
Secondary winding: The winding that delivers the active power to the load circuit.
Protective separation Denotes separation between circuits by means of basic and

supplementary protection (basic insulation plus either supplementary insulation or
protective screening) or by an equivalent protective provision (for example, reinforced
insulation).
by T HR E
Protective screening Denotes separation from live parts by means of an interposed

conductive screen, connected to the means of connection for an external protective
conductor.
4 Functional Characteristics
4.1 General
Isolating transformers are used in the RailCorp network to ensure separation of different
earth systems for electrolysis mitigation purposes and IT system of earthing, in particular:
 Provide galvanic isolation between the local electricity distributor’s MEN earth
system and RailCorp’s earth system. RailCorp’s earthing system has been
designed for a dc traction environment.
 Provide for the unearthed 120Vac and 415Vac signalling IT power system.
 Provide galvanic isolation to low voltage equipment in contact with RailCorp’s
1500Vdc traction system.
For further information on the background for these requirements refer to

‘EP 12 10 00 20 SP - Low Voltage Distribution Earthing’, ‘EP 12 10 00 21 SP - Low
Voltage Installations Earthing’ and ‘EP 12 30 00 01 SP – Electrolysis from Stray DC
Current’.
5 Performance Characteristics
Applicable standards AS 60076, AS61558.2.4
Transformer type Dry type
No. of winding Two winding
No. of phases 1 phase or 3 phase

240V (single phase), 415V (phase to phase, 3
Rated voltage
phase)
240/240V 1 phase
415/415V 3 phase
240/120V 1 phase (Signals)
No load ratio
1 phase: 25kVA
Rated power (preferred ratings, other sizes 3 phase: 75kVA, 200kVA, 315kVA
subject to RailCorp’s approval) Signals only (1 phase): 5kVA, 10kVA, 15kVA,
20kVA
Frequency 50Hz
≤ 10 In
Inrush current
≤ 8 In (For signals isolation transformer)
Star point or neutral of lower voltage winding
Neutral terminal shall be connected to bushing and fully insulated
from earth.
Type of cooling AN
by T HR E
Vector group Dyn1 (for 3 phase transformers)

Full kVA tappings on the primary winding at
Tapping on primary winding
±2.5% and ±5% of the principal tapping
System highest voltage 1.1Kv
Insulation Windings double insulated from earth
Rated insulation level for 1 minute 5kVrms
Insulation Class Class A to AS 60076.11

Maximum winding temperature rise limit at rated
65 oC
kVA over ambient
3.3% for 5kVA – 25kVA
Impedance voltage
4% for 75kVA – 315kVA
As per “Standard Limits” of Annex ZA of AS
Minimum sound power level
60076.10
Tolerances
 Load loss
 No load loss As per Table 1 of AS 60076.1
 Voltage ratio
 Voltage Regulation
6 Technical Characteristics
6.1 General
Each transformer shall be so constructed as to be unaffected by normal handling during
transport, installation, inspection and repair
6.2 Core
The core of the transformer is to be isolated from the external metal parts of the
transformer with an insulation level of at least 5 kV rms for 1 minute. A test point for the
application of high voltage test and insulation resistance test is to be provided on the
core. Suitable insulators shall be used to mount the core onto the frame of the
transformer.
All nuts used in the construction of the core shall be adequately locked by means of
spring washers, locknuts, or other approved locking devices.
6.3 Winding
The transformer winding shall be made of copper or aluminium. The preferred method of
winding varnish impregnation is under vacuum. However, the method applying varnish
through baking is also acceptable.
by T HR E
6.4 Protective Screen

Each transformer shall be provided with a protective screen of copper or aluminium at
least 0.5 mm in thickness with an insulation level of at least 5 kV rms for 1 minute,
located between the primary and secondary windings.
The protective screen is to be connected to a special insulated terminal (5 kV rms

insulation level) in the same enclosure as the primary terminals of the transformer. The
terminal shall be suitably marked.
The protective screen shall be arranged to prevent leakage from any part of the primary
windings to any part of the secondary windings of the transformer.
The protective screen shall withstand a 5 kV rms voltage test applied for one minute
between the screen terminal and primary and secondary windings.
The insulation level between the protective screen and the core and the frame shall be
5 kV rms for one minute.
For further information on the connection of the screen, refer to ‘EP 12 10 00 20 SP –

Low Voltage Distribution Earthing’ for supplies from a Local Electricity Distributor or
‘EP 12 10 00 21 SP – Low Voltage Installations Earthing’ for Signalling supplies or
supplies to buildings or structures in contact with the RailCorp 1500 V system.
6.5 Internal Connections

The leads between the windings and the terminals (including protective screen terminal)
shall be double insulated, in accordance with the requirements of the Section 5.4.1.1(b)(i)
covering Double Insulation in AS/NZS 3000.
The leads shall be secured to prevent contact with the transformer casing if the
connection becomes loose or breaks away from the terminal. The method of securing the
leads shall be detailed in Appendix A.
Flexible leads shall be provided between the windings and terminals where the cross
sectional area of the leads are less than 25 mm².
6.6 Terminals & Terminal Enclosure

The primary and secondary windings of the transformer shall be terminated onto screwed
terminal studs suitably sized for the power rating of the transformer. The hardware used
shall provide secure cable connections, ‘locked’ against loosening, for example by the
use of star washers and nickel-plated brass nuts.
The terminals shall be arranged so that all required interconnections of windings and
adjustments of taps can be accomplished by the alteration of accessible tinned copper
bolted links. The links shall be rated at the full transformer kVA rating. Access to the
terminals and adjustment of links shall only be possible by the use of appropriate tools.
The links shall be supplied with the transformer.
The primary and secondary terminals shall be located within individual weatherproof
polycarbonate enclosures. The polycarbonate enclosures are to be suitably sized to
accommodate the appropriate installation of the terminals, links, glands and cables fitted
with crimp lugs. The degree of protection to be provided from the exterior environment by
the polycarbonate enclosure is to comply with AS 1939 Table II and Table III as IP56.
Removal of the terminal enclosure cover shall only be possible by the use of appropriate
tools.
by T HR E
The terminal enclosures must be
a) Mounted on the outside and close to the top of the transformer casing.
b) Located to provide suitable access for electrical connection and ongoing

maintenance.
c) Located to minimise possible touch potentials between the primary and

secondary terminals.
d) All terminals shall be appropriately labelled for the purpose.
6.6.1 Terminal Enclosure Mounting Positions
by T HR E
6.7 Transformer Case
6.7.1 Indoor Type

The preferred location of the terminal enclosures mounting is Type A. Where physical
limitations requires it, the terminal enclosure mounting may be type "B".
The casing shall be fabricated with minimum 1.5mm galvabond or equivalent galvanised
steel sheets. The casing shall provide a minimum protection of IP21 as per AS 1939.
This design is for use indoors, such as within a traction substation or signalling hut, or
within a fibreglass padmount structure.
6.7.2 Outdoor Type

The terminal enclosure mounting shall be type "A". A metal vandal resistant casing must
then enclose the terminal enclosure. This casing shall be the full height of the transformer
casing and contain a facility to support cables within the casing. Removal of the casing
shall only be possible by the use of appropriate tools.
The transformer casing shall comply with AS 1939 as IP56. The IP56 rating must be
maintained between the transformer casing and the terminal enclosure. The casing shall
be vermin, insect and vandal resistant.
Where the casing design uses a flat construction, the thickness of the steel sheet shall
not be less than 3mm. Where the casing design uses a folded construction (corrugated or
square, etc), thickness of the steel sheet shall not be less than 1.5mm. Only galvabond or
equivalent galvanised steel sheets shall be used to fabricate.
6.7.3 Mounting
The transformer shall normally be ground mounted and it shall be fitted with “C” channel
type mounting brackets suitable for floor mounting. However, where transformers are
specified for wall mounting, a suitable mounting bracket for wall mounting shall be
supplied.
The mounting brackets shall
a) Be hot dipped galvanised.
b) Structurally support the weight of the transformer.
c) Enable the transformer to be dragged across hard surfaces, without damaging

the structural integrity of the transformer and or mounting brackets.
d) Be capable of being removed if required.
e) Include 15mm diameter mounting holes that are accessible when the
transformer is mounted against a wall.
f) Allow for mounting without the removal of the transformer cover.
g) Ensure that the clearance between the transformer enclosure and the mounting
surface allows for sufficient ventilation to meet the heat rise requirements. Refer
to Section 8.2 for heat rise tests.
by T HR E
6.7.4 Lifting and Lashing Attachments

Suitable lifting lugs for attaching lashings shall be provided external to the transformer
enclosure. They shall be affixed near the top of the transformer enclosure for securing it
to a transport vehicle and for lifting the transformer.
6.7.5 Surface Finish

All external surfaces shall have welds made smooth, rough edges rounded and weld
splatter removed. The transformer shall remain corrosion free for the life of the
transformer.
All external steelwork shall be hot-dipped galvanised to AS/NZS 4680. For indoor
transformers, the transformer casing shall be textured powder coated after fabrication to
colour N42 “storm grey” as per AS 2700.
6.8 Rating Plate

The rating plate shall meet the requirements of AS 60076.1, Section 7, and shall include
a diagram of connections including the primary tappings. The rating plate shall also
indicate that a protective screen is fitted between the primary and secondary windings.
A terminal marking plate complying with the requirements of AS 60076.1, Section ZB7
shall also be attached to the transformer.
The plates shall not be attached to a removable cover.
As the transformer is a double insulated isolating transformer complying with AS/NZS

61558.2.4, the labelling shall include the following marking:
“DOUBLE INSULATED ISOLATING TRANSFORMER TO AS/NZS 61558.2.4

DO NOT EARTH”
If the transformer has an actual design rating exceeding the rating ordered, the rating
plate shall show the actual design rating and not the rating ordered.
6.9 Labelling
Labelling of the transformer shall be as per the requirements of Section 4.9 of RailCorp
Standard EP 00 00 00 15 SP.
6.10 Environment
The installation may be located in close proximity to railway tracks that is subject to
significant vibrations, dust and dirt ingress. The transformer shall not be adversely
affected when operating under these environments.
7 Reliability, Availability and Maintainability
7.1 RAM Targets

Reliability, availability and maintainability targets shall be specified by RailCorp to
RailCorp Engineering Procedure EPD 0009 on a project to project basis.
by T HR E
7.2 RAM Requirements

The transformer shall exhibit a high level of reliability, consistent with the achievement of
availability targets specified for the equipment. Manufacturers shall provide details of
reliability claimed for each major element of the transformer in the specified operating
environment including the source of reliability data. If claimed reliability performance is
based on calculation, the basis and methodology for the calculation should be quoted. If
based on actual field operating performance, the source of data, including details of the
installation and, where possible, methods of verification should be provided.
Reliability performance is to be expressed in the form of a mean time between failure

(MTBF), where failure is defined as a condition which will prevent the item performing its
intended primary functions.
Estimates should include a clear statement about whether the mean time to repair
(MTTR) quoted include any allowance for response times and waiting times to obtain
suitable spares and other equipment necessary for the task.
7.3 Maintenance Concept

The transformer shall be designed and constructed to require no maintenance.
8 Tests
8.1 Routine Tests

Routine tests as listed in AS 60076.1 Section 10.1.1 and routine tests listed in Section 19
and Section 20 of AS 60076.11 shall be carried out on each transformer. The routine test
of Section 6.2 of EP 00 00 00 15 SP shall also be carried out on each transformer. These
tests shall be carried out in conjunction with the following requirements:
1 2 3 4 5 6 7
Applied HV Min. 500 V
(Frame)
Test Input Output Protective Test insulation
Core External
No. Winding Winding Screen 1 minute resistance
Metal Parts
(kV) (Megohms)
1 HV E F F E 5.0 100
2 E HV F F E 5.0 100
3 E E F HV E 2.5 10
4 E E HV F F 2.5 10
5 F F HV F E 5.0 10
6 F F E HV E 5.0 100
Notes:
a) "HV” indicates that the high voltage test or the insulation resistance test is to be
applied to the part.
b) "E” indicates that the part is to be connected to earth during the high voltage
test and the insulation resistance test.
c) “F” indicates that the part is not to be connected to any supply or earth, ie, to be
floating during the high voltage test and the insulation resistance test.
d) If the core is to be connected to the external metal parts (frame) delete Test
Nos. 4 and 5 and Column 3.
by T HR E
The protective screen shall withstand a 5 kV voltage test applied for one minute between
the screen terminal and primary and secondary windings. (Test 3)
The insulation level between the protective screen and the core and the frame shall
withstand 5 kV applied for one minute. (Test 5)
8.2 Type Tests

Temperature rise type tests shall be carried out on one transformer of each type and
rating in accordance with Section 23 of AS 60076.11.
The method of loading is to be either by the direct loading method (described in

AS 60076.1 Section 23.2.3) or by the back-to-back method (described in Section 23.2.2).
The simulated load method (described in Section 23.2.1) is not acceptable by RailCorp.
The winding temperature rise is to be determined by the change of resistance method.

The resistance is to be determined by d.c. volts/amps in which the current is to be
substantial (ie greater than 10% of the current rating of the winding).
Type test certificates for each of these tests will be accepted where it can be
demonstrated that the transformer supplied is of a similar design to a previously type
tested transformer.
BLOCK DIAGRAM FOR MANUFACTURING
ELECTRICAL CIRCUIT DIAGRAM

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Technical Construction File Transformer

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Engineering Speci

Superseded by T HR EL 17 Engineering Specification

LOW VOLTAGE ISOLATING

Issued November 2012

Owner: Chief Engineer Electrical

Approved Neal Hook Authorised Neal Hook

UNCONTROLLED WHEN PRINTED Page 1 of 20

Appendix A Technical Schedule.............................................................................................. 16

2.1 Australian Standards

AS 1627.4:2005 Metal finishing – Preparation and pre-treatment of surfaces,

2.2 RailCorp Documents

EP 02 00 00 01 SP Transformer Loss Evaluation

2.3 RailCorp Drawings

EL0035272: General – Distribution Padmount Substation 415/415 or 240/240 Whole

EL0494650: Distribution Padmount Substation Railcorp Dual Supply Arrangement

UPS EL0480479: Distribution Radmount Substation 415V/415V Isolation

3 Definitions and Abbreviations

Protective separation Denotes separation between circuits by means of basic and

Protective screening Denotes separation from live parts by means of an interposed

For further information on the background for these requirements refer to

Transformer type Dry type

No. of winding Two winding

No. of phases 1 phase or 3 phase

Vector group Dyn1 (for 3 phase transformers)

Insulation Windings double insulated from earth

Rated insulation level for 1 minute 5kVrms

Insulation Class Class A to AS 60076.11

6.4 Protective Screen

The protective screen is to be connected to a special insulated terminal (5 kV rms

For further information on the connection of the screen, refer to ‘EP 12 10 00 20 SP –

6.5 Internal Connections

6.6 Terminals & Terminal Enclosure

The terminal enclosures must be

b) Located to provide suitable access for electrical connection and ongoing

c) Located to minimise possible touch potentials between the primary and

d) All terminals shall be appropriately labelled for the purpose.

6.6.1 Terminal Enclosure Mounting Positions

6.7 Transformer Case

6.7.1 Indoor Type

6.7.2 Outdoor Type

The mounting brackets shall

a) Be hot dipped galvanised.

b) Structurally support the weight of the transformer.

c) Enable the transformer to be dragged across hard surfaces, without damaging

d) Be capable of being removed if required.

f) Allow for mounting without the removal of the transformer cover.

6.7.4 Lifting and Lashing Attachments

6.7.5 Surface Finish

6.8 Rating Plate

The plates shall not be attached to a removable cover.

As the transformer is a double insulated isolating transformer complying with AS/NZS

“DOUBLE INSULATED ISOLATING TRANSFORMER TO AS/NZS 61558.2.4

7 Reliability, Availability and Maintainability

7.1 RAM Targets

7.2 RAM Requirements

Reliability performance is to be expressed in the form of a mean time between failure

7.3 Maintenance Concept

8.1 Routine Tests

8.2 Type Tests

The method of loading is to be either by the direct loading method (described in

The winding temperature rise is to be determined by the change of resistance method.

ELECTRICAL CIRCUIT DIAGRAM

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