Betriebsanl 150556 1431517-EN

OPERATING MANUAL
Rated power 80/120* MVA
Class Power transformer
Type DOTR 120000/110
Serial No. 150 556
Project Trafo für WP Cogealec
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CONTENTS
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CONTENTS
IDENTIFICATIONS DATA
BASIC INFORMATION
SAFETY INSTRUCTIONS
1 ELECTRICAL DATA
2 MECHANICAL DATA
3 TEST REPORTS
4 EMERGENCY OPERATION, STORAGE AND DISPOSAL
4.1 EMERGENCY OPERATION

4.2 STORAGE
4.3 DISPOSAL
5 DESCRIPTION
6 DISASSEMBLY AND TRANSPORT
6.1 DISASSEMBLY
6.2 TRANSPORT
7 UNLOADING, INSTALLATION AND ASSEMBLY
7.1 CHECK FOLLOWING ARRIVAL

7.2 ASSEMBLY
7.3 TIGHTENING TORQUES
7.4 EVACUATION
7.5 FILLING WITH OIL
7.6 TIME TO WAIT AFTER FILLING WITH OIL
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8 GETTING READY FOR OPERATION AND COMMISSIONING
8.1 GETTING READY FOR OPERATION AND COMMISSIONING:

8.2 CHECKLIST FOR COMMISSIONING TRANSFORMERS
9 MAINTENANCE AND INSPECTION
9.1 MAINTENANCE AND INSPECTION

9.2 MAINTENANCE AND INSPECTION CHECKLIST
10 DIMENSION DRAWING AND PART LIST
11 RATINGPLATE, DIAGRAM PLATE
12 RECONNECTING DOM PLATE
13 TRANSPORTPLATE /TRANSPORT DRAWING
14 GENERAL PLAN
15 SIGNAL/CONTROL CABINET
16 MOTOR DRIVE UNIT CONTROL
17 PHOTO H. V. SIDE PHOTO L. V. SIDE FILLING DIAGRAM
18 ADDITIONAL DOCUMENTS ACCORDANG CUSTOMERS SPECIFICATION
19 AA FITTINGS, SLIDE VALVES, COCKS
20 AB TERMINATING ELEMENTS, LOCKING PIECES
21 AC, AE, AN
AC RADIATORS,COOLERS,HEAT EXCHANGERS
AE MOVING, LIFTING,TURNING AND SWIVELLING MECHANISMS
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AN FANS
22 AP, AT, AX
AP PUMP UNITS
AT DRYING AND FILTER EQUIPMENT(DEHYDRATING REATHERS)
AX TESTING AND MONITORING EQUIPMENT
23 BB, BQ
BB CONTAINERS,RESERVOIRS,ACCESSORY CAINETS,TERMINAL BOXES
BQ SUPPORTS,BEARING EQUIPMENT,FRAMEWORKS,CABLE DUCTS
24 BR, BS, BZ
BR PIPELINES,DUCTS
BS NOISE REDUCTION COMPONENTS
BZ MISCELLANEOUS COMPONENTS
25 CE, CF
CE ELECTICAL VARIABLES(E.G. INSTALLATION–TRANSFORMER)
CF FLOW MEASURING EQUIPMENT
(BUCHHOLZ RELAY, PRESSURE/ VACUUM RELAY,
PRESSURE SURGE PROTECTION,OIL AND AIRFLOW
INDICATORS OR WATER FLOW INDICATORS, ETC.)
26 CL, CP
CL LIQUID LEVEL(LEVEL MEASUREMENT)
CP PRESSURE MEASUREMENT
27 CQ, CT, CU
CQ QUALITY VARIABLES (MONITORING, HUMIDITY, AGEING AND QUANTITY)
CT TEMPERATURE MEASUREMENT
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CU COMPOUND MEASURED VARIABLES
28 GD, GE, GF
GD BUSHINGS, RECEPTACLES, CABLE SEALING ENDS ≥ 1 KV ≥ 1 KV
GE BUSHINGS,RECEPTACLES, CABLE SEALING ENDS < 1 KV
GF CABINETS, TERMINAL BOXES (SUB-DISTRIBUTION BOARDS)
29 GH, GS
GH CABINETS FOR PROTECTION, CONTROL AND MONITORING

GS ON-LOAD TAP CHANGERS, OFF LOAD TAP CHANGERS
30 GX FINAL CONTROLLING EQUIPMENT
BKT NUMBERS – COMBINATIONS OF W, X, Y, Z
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IDENTIFICATIONS DATA
Purchaser: S.C.TOMIS TEAM SRL
Customer: S.C.TOMIS TEAM SRL
Projekt: Trafo für WP Cogealec
Substation: -
Order Number: Final Order 4
Date of Purchaser Order: 16.03.2009
Manufacturer: Starkstrom-Gerätebau GmbH

Ohmstraße 10
93 055 Regensburg
Germany
Telephone: +49 941 7841-0
Fax: +49 941 7841-227
E-mail ntv@sgb-trafo.de
Type: DOTR 120000/110
Serial Number: 150 556
Order Number: 1431517
SAP Number: 112010276/20
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BASIC INFORMATION
1 Notes on technical documentation
The operation and maintenance manual contains important information concerning the safe and
fault-free operation of the transformer. Before working on or with the transformer, you must
first have read and understood this O & M manual. Always keep the O & M manual at
the transformer’s place of use.
The O & M manual is aimed at specialist qualified personnel and assumes

that users have the relevant electrical engineering background. It is not intended as a substitute
for providing the specialist personnel with detailed training in how to handle the transformer
safely.
All the requirements of this O & M manual must be observed. This is a prerequisite for ensuring
that
□ The transformer is operated correctly and competently

□ The transformer is maintained, cleaned and inspected correctly
□ Hazards are avoided and the necessary technical safety rules are observed
Conventions and symbols
Procedures that are to be carried out in a particular chronological order are numbered,
grouped into units and the details of the result provided for each.
Lists of items that do not need to be carried out in any particular chronological order
take the form of main bullet points and subpoints preceded by a hyphen.
Safety instructions are identified by means of symbols plus signal words.

The type of hazard is described along with the potential consequences, and information
is provided on how to avert the danger. The meaning of the symbols and signal words used is
explained in the chapter entitled “Safety instructions”.
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2 Appropriate use
The transformer may only be used for the purpose of transforming electrical AC voltage.
It must be operated in accordance with the underlying standards and regulations that are
referred to within the context of the electrical data in Section 3.2.
Using the transformer for any other purpose or beyond the scope of the explanation above
is to be deemed inappropriate and may result in personal injury or damage to property. The
operator alone shall be liable for any resulting injuries or damage.
Appropriate use also involves the following:
□ Complying with all the information in the O & M manual

□ Complying with the inspection and maintenance requirements
Inappropriate use shall invalidate the warranty and free the manufacturer from
all liability.
The following actions in particular constitute unacceptable (and therefore inappropriate) use:
□ Installing monitoring/protective equipment and accessories other than those

specified in the O & M manual
□ Allowing untrained and unqualified personnel to operate and
maintain the transformer
□ Deactivating or bypassing safety equipment
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3 Warranty and liability
The warranty period and term of liability are laid down by the statutory regulations
and the provisions of Starkstrom-Gerätebau GmbH’s “General conditions of sale and delivery”.
The operator shall be provided with these on conclusion of the contract at the very latest.
Deviating from appropriate use as described in this O & M manual will, in the event
of loss or damage, limit or invalidate your right to assert warranty or liability claims.
In the event of personal injury and damage to property, warranty and liability claims
shall not be admitted if they can be attributed to one or more of the following causes:
□ Inappropriate use of the transformer

□ Improper assembly, commissioning, operation and maintenance of the transformer
□ Operation of the transformer when safety equipment is defective or when
safety and protective equipment has not been properly installed
or is not in working order
□ Failure to observe the information in the O & M manual that relates to transporting,
storing, assembling, commissioning, operating and maintaining the transformer
□ Unauthorised structural modifications to the transformer
□ Inadequate monitoring of attachments that are subject to wear
□ Poor-quality repairs
□ Disasters caused by foreign matter and instances of force majeure
□ Errors that can be attributed to a failure to observe this O & M manual
The supplier is liable for defects and non-conformance in respect of the devices supplied as
regards
□ His offer and

□ The Orgalime S2000 General Conditions
4 Scope of supply
The scope of supply includes
□ One Power transformer; type DOTR 120000/110

in accordance with order number Final Order 4
order no. 1431517; serial no. 150 556
□ Comprehensive documentation in English
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SAFETY INSTRUCTIONS
The general safety regulations for operating and working on electrical installations,
as laid down by EN 50110-1 and EN 50110-2 – 1996, apply as a basic principle.
We recommend that the safety instructions applicable to the processes of installing, maintaining
and operating the transformer are kept readily accessible, as these instructions are intended
to inform the personnel involved of any potential injuries (including fatal ones) or damage that
could occur.
These instructions are meant to serve as a general guideline only and are not exhaustive (other
unforeseen risks may arise).
These instructions do not claim to cover every unforeseen type of injury or damage that could occur in
the course of installation, handling, operation or maintenance.
Nor do they claim to be exhaustive in terms of equipment details and variants.
For further information regarding the specific issues associated with installing, operating or
maintaining your equipment, please contact the SGB customer service department.
The transportation, unloading, installing, pre-operational checking and commissioning, maintenance

and inspection of transformers present a source of risk that could lead to serious injury or death
unless appropriate precautions are taken.
DANGERS AND RISKS MAY ARISE:
When transporting and installing the transformer
- Heavy weights and high centres of gravity may cause the transformer to overturn, resulting
in death or very serious injury.
- This can be prevented by keeping the tank base in a horizontal position.
- Free-standing parts may protrude into the working area and cause injury if they are uncovered.
During operation
- High voltages produce electric fields. These are invisible and have an effect over large
distances. Sparkovers can cause injuries, burns or death if an adequate safe distance is
not maintained.
- Magnetic fields are also invisible and have an effect over large distances. These may affect the
function of vital devices such as pacemakers and hearing aids or even stop them functioning
altogether. A risk to life exists if an adequate safe distance is not maintained.
- The transformer is filled with a flammable liquid (mineral oil), which may burn or explode in the
event of a fault. Leaking or burning oil or splinters may result in injury or death if the transformer
is not de-energised and earthed before it is approached.
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During maintenance
- The transformer carries dangerous voltages that may result in serious injuries and damage
to property. Before carrying out any maintenance work, always de-energise and earth the
transformer. Maintenance must only be carried out by qualified personnel.
- The use of unsuitable parts for repairs, unauthorised interventions and a failure to observe the
requirements set out in the manual may result in dangerous situations that could lead to serious
injury or damage to the transformer. The safety requirements described here must be observed.
- Embedded conductors may give the impression than an area can be entered without risk.
Embedded conductors must therefore not be used before the transformer has been
de-energised and earthed.
When working on the transformer.
The use of metal conductors and long metal parts may bridge what would normally be sufficient
safety gaps and cause electrical sparkovers, which could result in injury, damage to the device,
or death. The use of conductors made of metal or other conductive materials should therefore be
avoided. Ensure that the transformer is de-energised before starting any maintenance work.
Persons authorised to work on the device.
Failure to observe the safety requirements may result in injury or damage to the device. Only
qualified personnel may work on the transformer and in its environs, and they must strictly observe
warning signs, safety notices and maintenance regulations. Correct utilisation, installation and
maintenance will ensure smooth operation of the transformer.
Qualified personnel.
For the purposes of this manual and the product labelling, qualified personnel is considered to
mean people who are familiar with the installation, setup and operation of the transformer and
the associated risks.
These personnel must also meet the following criteria:
- Trained and authorised to switch on, switch off, tidy and label circuits and devices in
accordance with customary safety practice.
- Trained in the correct way to maintain and handle protective equipment, e.g. rubber gloves,
hard hats, safety goggles or face shields, high-visibility clothing etc. in accordance with
customary safety practice.
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1. SYMBOLS USED AND SIGNAL WORDS
The symbols and signal words below are used in the instruction
manual to indicate hazards and important information.
The safety instructions always appear before details of a particular action.
DANGER
Indicates imminent danger. Failure to avert the danger
will result in serious injury or death.
WARNING
Indicates a potentially hazardous situation. Failure to avert the situation
may result in serious (crippling) injuries or death.
ATTENTION
Indicates a potential risk of damage. Failure to avert the situation may result
in damage to the product or some other item of equipment within its vicinity.
i
IMPORTANT
Indicates user tips and other very helpful information,
but is not associated with any hazardous situations or potential damage.
ENVIRONMENTAL INFORMATION
Important information about protecting the environment.
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2. WARNING
Please read through all the safety instructions carefully before attempting to
commission, install, use or carry out maintenance on the transformer.
Failure to comply with the safety instructions, with the applicable regulations
and with the industrial standards of the electrical industry may result in serious
injuries or death, as well as in damage to property.
3. DANGER
Electrical transformers generate hazardous voltages that may result in serious

injuries or even death. When using transformers, it is essential to comply with
the relevant regulations covering shutdown/disconnection, blocking/energy lockout,
earthing and all other applicable safety rules.
4. GENERAL WARNINGS
There are a number of potential hazards associated with the processes of installing,
operating and maintaining the transformer, e.g.:
DANGER
WARNING
• Hazardous voltages
• Improper operation of the on-load tap changer
• Moving machine components
• Pressures in the < 2 bar range
• Heavy components
The usual safety precautions must be followed when transporting, inspecting, installing
or maintaining transformers. In addition, the transformer-specific precautions must also
be observed. The equipment referred to in these instructions calls for specialist personnel
who are familiar with electrical safety rules.
These instructions are aimed exclusively at specialist personnel with the requisite training and
experience of using the equipment concerned. They must not be used as a substitute for
appropriate training and experience.
The personnel involved must comply with all the applicable safety precautions
(such as the regulations for operating and working on electrical installations, as laid down
by EN 50110-1 and EN 50110-2 – 1996; the national, regional and local safety rules;
the rules relating to health and safety in the workplace) when transporting, installing,
operating or maintaining the transformer.
They must also exercise caution and good judgement at all times.
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5. General rules to be followed once the transformer has been shut down
In the interests of protecting the personnel, the following safety precautions must
be followed when handling, installing and maintaining power transformers once they
have been shut down.
5.1 Shutting down the transformer
DANGER
The transformer must be shut down in accordance with the safety regulations
for operating and working on electrical installations, as laid down by
EN 50110-1 and EN 50110-2 – 1996.
The safety rules for ensuring safe isolation from the supply, including the requirement
for blocking or energy lockout, must be observed.
5.2 Earthing
DANGER
The transformer tank must remain earthed at all times. If the transformer is shut down
it must be earthed in accordance with the safety regulations for operating and working on
electrical installations, as laid down by EN 50110-1 and EN 50110-2 – 1996.
The windings must be earthed, except when carrying out electrical tests or operating the
transformer. Following installation, the bushings must be earthed, unless electrical tests are
being carried out or the transformers are being put into operation.
All oil-pumping equipment and vacuum pumps must be earthed. All the test equipment
must be properly earthed. Failure to observe any of the points above may result
in static discharges that could injure personnel or damage the transformer.
5.3 Climbing aids
WARNING
Externally mounted fittings, supports and wiring systems must not be used as climbing aids.
In the case of transformers, the only acceptable climbing aids are ladders or platforms that
have undergone a safety inspection.
5.4 Lifting
WARNING
The transformer may only be lifted by the lifting eyes or marked jacking pads.
For details of how to attach lifting gear correctly, please refer to the dimensional drawing,
transport plate or transport drawing supplied with the transformer.
The permissible rope angles for the sling rope must be observed.
Lifting the transformer incorrectly may result in personal injury or damage the transformer.
It will also invalidate the warranty.
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5.5 Moisture
WARNING
Special care must be taken to ensure that no moisture gets into the transformer.
If moisture gets into the insulation or oil, the transformer’s dielectric properties will
be impaired. When the transformer is open (e.g. assembly openings, bushing openings)
the dry air inside the transformer must be kept at a slight positive pressure
(dew point - 50˚C) to prevent moisture from entering.
The moisture will condense on any surface that is colder than the ambient air.
Unless there is dry air present, no work must be carried out inside the transformer
(there is a risk of condensate forming on the interior walls).
In the event of a sudden change in weather conditions (rain or snow), precautions must
be taken by quickly closing the tank to protect the insulation.
5.6 Vacuum
WARNING
To prevent compressive stress during the evacuation process, the on-load tap changer
and transformer chambers must be connected to one another.
Both air chambers are connected by means of a shut-off valve.
The vacuum must be terminated in the transformer chamber and in the
on-load tap changer chamber at the same time.
Transformers that have been in operation for a long period of time must not be placed
under vacuum, as this can result in bubbles in the insulation.
Do not put the transformer into operation immediately after vacuum filling it with oil.
The transformer must be left to stand for some time at atmospheric pressure.
Failure to observe the specified time requirements may result in faults.
i
IMPORTANT
See topic UNLOADING; INSTALLATION AND ASSEMBLY – Time to wait after filling
with oil
5.7 Beware of the transformer lid
ATTENTION
Special care should be taken when walking on the transformer lid.
Certain weather conditions can create a risk of slipping or stumbling on the lid.
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6. General rules to be followed when the transformer is in service
When the transformer is in operation, the following safety precautions must be followed:
6.1 Temperature
The temperature values are defined for each transformer in accordance with the
customer specification, taking into account the agreed temperature rise limits and
maximum ambient temperature.
DANGER
If the hotspot temperature of 140°C is exceeded, gas bubbles may form which could
endanger the transformer’s withstand voltage.
6.2 Working in the vicinity of the active transformer
DANGER
The personnel involved must comply with the regulations for operating and working
on electrical installations, as laid down by EN 50110-1 and EN 50110-2 – 1996;
the national, regional and local safety rules; and the rules relating to health and safety
in the workplace. They are also required to exercise caution and good judgement.
6.3 Oil level
WARNING
You must never switch the transformer on if the oil level inside the transformer,
the conservator or the oil filled cable box (if available) is below the minimum limit.
Take note of the oil level gauge on the conservator.
Do not open any fittings on the transformer while it is switched on, as this may cause
the oil level to drop below the minimum limit.
6.4 Current transformer (if available)
DANGER
The current transformer secondary side, which is not under load, must be short-circuited and
earthed.
6.5 Earthing
DANGER
The transformer tank must be safely earthed.
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7. Transportation and unloading
7.1 Transport rules
WARNING
The applicable and national transport regulations must be observed.
i IMPORTANT
For further information, please see appendices – Transport plate or transport drawing
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8. Unloading and installation requirements.
8.1 Vacuum pumps
The pump and vacuum system should be capable of achieving a priming

pressure of < 0.5 mbar.
8.2 Oil conditioning equipment
Oil conditioning equipment may be required in some cases.
This equipment must be able to supply the transformer with oil in accordance with
the following oil parameters:
Gas content 0.5% max. (volume percentage)

Water content 10 ppm max.
Temperature 50°C, minimum temperature
75°C, maximum temperature
8.3 Dry air
The dry air must have a dew point of -50˚C (-58˚F) or lower and an oxygen content of
between 19.5% and 23%. The pressure cylinders and associated valves for introducing
the dry air into the transformer tank must be used for supplying the dry air.
8.4 Drawings and documents
The shipping documents, operation and maintenance manual (plus transport drawing)
and any other applicable documents supplied with the transformer must be available
during the inspection.
To prevent the warranty from being invalidated, the client’s authorised representative
must complete the following transformer checklists on site for each unit
(does not apply if assembly and steps involved in getting ready for operation are being
carried out by SGB technicians).
MAINTENANCE AND INSPECTION CHECKLIST

GETTING READY FOR OPERATION AND COMMISSIONING CHECKLIST.
Once completed, these should be returned to the address below.
Starkstrom-Gerätebau GmbH
Ohmstraße 10
93 055 Regensburg
Germany
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9. Special transport instructions
9.1 In the event of transport damage or an incomplete delivery
1. Inform the SGB customer service department immediately following delivery.

2. On receipt of the delivery, make a note of any parts that have obviously sustained
damage or are missing on the carrier’s counterfoil.
9.2 Impact recorder (if available)
On request, an impact recorder can be attached to the transformer for the purpose
of monitoring it while in transit.
If the recorder is missing or damaged, if the seal has been broken or if any other
kind of fault has occurred, the carrier must produce a special carrier’s inspection report
to release the client from any liability as far as the equipment is concerned.
Record the date and time when the transformer arrives.

Make sure that the carrier/forwarding company signs to confirm this information.
Return the impact recorder (unless otherwise agreed) to the following address:
Ohmstraße 10
93 055 Regensburg
Germany
9.3 External inspection
Any signs of damage must be reported to the SGB customer service department
before the transformer is unloaded. The customer service team will provide you with
further instructions before the transformer can be unloaded.
The external inspection that is carried out prior to unloading should cover all the
following points:
1. Are all the transportation safety devices secure and in good condition? Is all the
cargo safeguarding equipment secure and free of damage?
2. Is the surface coating damaged?
3. Are there any signs of external damage such as broken glass on the indicators,
damaged weld seams?
4. Are there any signs of oil leaks?
Provided that there are no visible signs of transport damage, the process of unloading
the transformer may begin.
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9.4 Transformer parts
All individual parts that are sent separately must be compared with the
packing list to ensure that all the transformer parts are present and correct
with no visible signs of damage.
The SGB customer service department must be informed about any missing
or damaged parts immediately following delivery via the local authorised dealer.
10. EXCLUSION AND LIMITATION OF LIABILITY

Oriented towards the contractual agreements on which the delivery was based.
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1 ELECTRICAL DATA
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ELECTRICAL DATA
1. Rated power in MVA
80/120* MVA
* Power with fans
2. Definition of power
Acc. to IEC
Without rated capacity reduction on each tapping
3. Rated voltage ratio
110,0 kV ± 11,5 % in 19 positions (± 9 positions) / 33 kV // 15,97 kV
4. Voltages in kV and currents in A
Winding Voltage Current

kV A
Position 19 122,7 376,6/564,9*
H.V. Position 10 110,0 419,9/629,8*
Position 1 97,35 474,5/711,7*
L.V. 33 1400/2100*
T.V. 15,97 557/835*
5. Vector group
YNyn0(d)
6. Impedance voltage in % bei 75°C (guarantee value)
Rated power Winding Position Impedance

MVA voltage %
80 H.V./L.V. 10 12
120* H.V./L.V. 10 18
7. No-load current (calculated value)
No-load current 0,130 %
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8. Short circuit duration in s
5s
9. Insulation level (guarantee value)
Winding Highest voltage for Rated short Rated lightning

equipment duration power frequency impulse withstand
Um withstand voltage voltage
AC LI
kV kV kV
H. V. 123 230 550
H. V. -N 123 230 550
L. V. 36 70 170
L. V. -N 36 70 170
T. V. 24 50 -
10. Neutral loading capacity (if available)
Acc. to IEC
11. No-load loss (guarantee value)
38000 W
12. Load loss at 75°C (guarantee value)
Rated power Winding Position Load loss

MVA W
80 H.V./L.V. 10 435000
13. Total losses (guarantee value)
473000 W
14. Frequency in Hz
50 Hz
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15. Noise level (guarantee value)
No-load noise level

Cooling Distance m LPA dB(A) LWA dB(A) Tolerance dB(A)
ONAN - - 75 -
- - - - -
- - - - -
Short-circuit noise level

Power Distance m LPA dB(A) LWA dB(A) Tolerance dB(A)
- - - - -
- - - - -
- - - - -
Operating noise level

Cooling Power kVA Distance m LPA dB(A) LWA dB(A) Tolerance dB(A)
- - - - - -
- - - - - -
- - - - - -
16. Setting of the ratio
H.V. side: By on-load tap changer

under load.
L.V. side: "not applicable"
17. On-load tap changer (GS 001):
Make MR
Serial number 1110073
Type R III 1200Y-123/C-10 19 1G
Tapping range ± 11,5 %

Number of steps ± 9
Number of positions 19
18. Motor drive (GX 001):
Make MR
Serial number 1110073
Type ED 100-L
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19. Power demand for auxiliaries kVA
ONAN 1,5 kVA

ONAF 4,5 kVA
20. Current transformer (if available)
see under 3 x
21. Temperatures
Temperatur rise (top oil) 60 K
Average winding temperature rise

(measared by resistance rise) 65 K
Hot Spot temperature rise 78 K
Ambient temperature 40 °C
Temperature control in °C
(maximum temperature settings, SGB setting 5° lower)
Contact setting at thermostat (CT001) 90 °C
Contact setting at thermostat (CT002) - °C
Contact setting at dial type thermometer (CT031) 90 / 100 °C
Contact setting at dial type thermometer (CT032) - °C
Contact setting at dial type thermometer (CT036) 55 / 65 °C
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2 MECHANICAL DATA
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MECHANICAL DATA
1. Cooling
ONAN / ONAF*
* Power with fans
2. Weights
Total 115900 kg
Oil 23240 kg
Core and coils 71800 kg
Transport 103400 kg
Conservator tank 750 kg
Bushing for winding H.V. 70 kg
Bushing for winding L.V. – 2U, 2V, 2W 76,7 kg
Bushing for winding L.V. – 2N 35,7 kg
Bushing for stabilizing winding 17,2 kg
Radiators 7200 kg
3. Dimensions
Length 7830 mm
Width 3680 mm
Height 5380 mm
Crane hook clearance 7400 mm
Dimensions for transportation
Length 7000 mm
Width 2850 mm
Height 4165 mm
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4. Surface treatment
See test report
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3 TEST REPORTS
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4 EMERGENCY OPERATION, STORAGE

AND DISPOSAL
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4.1 EMERGENCY OPERATION
Overload and emergency operation in accordance with DIN IEC 60076-7
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4.2 STORAGE
1. Ready-to-use transformer:
Storing the transformer in its ready-to-use state is always the preferred option.
2. Transformer that is not ready to use:
Put the control cabinet heating into operation (if available).
Put the motor drive heating into operation (if available).
Oil-to-water coolers must be protected against frost or completely emptied of water.
Dehydrating breathers with integrated heating must be put into operation (if available).
Air dryers should be put into operation, depending on the type (if available).
i IMPORTANT
See appendices - Documentation relating to integrated air dryer
The following checks must be carried out every 4 weeks: Oil level
Leakage check
Dehydrating breathers
3. Transformer with low oil level (100 mm)

without conservator and with dehydrating breathers mounted:
The points under 2 must be observed.
ATTENTION
Following its arrival, the transformer must not be stored on the project site
for longer than 4 weeks without the checks under point 2 being carried out.
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4. Transformer without oil and conservator:

(filled with dry air)
ATTENTION
Following the transformer’s arrival at the project site, the filling gas topping
up system must be checked.
Filling gas must be present at all times.
The automatic system for topping up the filling gas must be checked
every 2 weeks.
i
IMPORTANT
If available, see appendices of
operation and maintenance manual 53007-810743-EN
The points under 2 must be observed.
The permissible storage temperature range is -20°C to +40°C

or as specified by the client.
5. Storage in excess of 6 months.
ATTENTION
The oil must be analysed for water content and disruptive discharge voltage
prior to starting up.
Limit values to IEC 60422
Highest voltage for equipement

kV
<72,5 72,5 to 170 >170
Breakdown voltage (kV) >55 >60 >60
Watere content (mg/kg) <20 <10 <10
i
IMPORTANT
If the above value is exceeded, we recommend oil reconditioning.
The costs incurred are not part of the warranty costs and must be borne
by the operator.
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4.3 DISPOSAL
1. Materials:
Steel
Copper
Aluminium
Brass
Bronze
Zinc
Tin
Paper
Wood
Ceramics
Casting resin
Glass
Transformer oil
Plastics (seals, insulating material)
Granulated material for the dehydrating breather
2. Components (material allocation):
Tank, lid, conservator, radiators (steel, sealing material, coating materials)

Winding (copper, paper)
Bushings (ceramics, casting resin, copper, brass)
Dehydrating breather (glass, steel, sealing material, Silica gel)
Monitoring devices
(electronic components, plastic, glass, sealing material, copper, brass, bronze, tin)
Sealing materials (plastic)
Insulating and shielding materials (aluminium, steel, paper, pressboard, wood,
transformer oil)
Connections (brass, copper)
Cables (copper, aluminium, tin)
3. Procedure:
Practically all the materials used to make the transformer

(90 to 98% of the overall weight)
can be recycled. This particularly applies to the metals, transformer oil and glass.
However, all waste must be sorted properly according to type.
Oil-impregnated parts, monitoring equipment, electronic components, sealing parts,

plastic parts and granulated materials must be disposed of as hazardous waste.
We recommend that you only ever hand the materials/the entire waste transformer over
to a certified specialist waste disposal company.
All statutory and local environmental regulations must be observed and

complied with.
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5 DESCRIPTION
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DESCRIPTION
i IMPORTANT
The BKT codes in brackets are the item numbers from the transformer dimensional
drawing; see appendices.
1. General:
The transformer has been designed in accordance with the relevant standards
and client specifications.
2. Core:
The core takes the form of a boltless 3 limb-type core.

It consists of cold-rolled, grain-oriented magnetic steel laminations.
3. Windings:
The windings take the form of cylindrical windings (multi-layer or continuous

turned-over windings).
They are dried and pre-pressed before being assembled.
The windings, packing and clamping structure have been designed to withstand
the level of dynamic short-circuit stress involved.
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4. Tank:
The tank, lid and conservator are made from standard, weldable sheet steel
and have a completely vacuum-proof welded design.
Transport rollers (AE 001)

can be adjusted for longitudinal or transverse travel (or for circular travel, if this option is
ordered) by lifting up the transformer; no special tools are required.
The positions are clearly visible.
There is no need to relubricate the rollers.
Lifting bolts (BQ 030)

ensure secure, horizontal lifting.
They have been adequately dimensioned in accordance with the weight.
Jacking pads (BQ 029)

have been provided to facilitate lifting with hydraulic jacks.
You can identify the jacking pads by their colour.
Oil drain plug (AB 240)

This is located at the lowest point of the tank base.
Pulling lugs (BQ 039)

have been provided in sufficient quantities in the area of the base tub for each direction.
Hitching the cables via shackles. Horizontal and paraxial pulling directions
should be used.
The pulling lugs are used as lashing lugs for transport purposes.
Lashing lugs (BQ 034)

have been provided in sufficient quantities in the top area of the bracing.
Throttle valves (AB230)

are welded onto the tank.
Throttle valves can also be fitted with an intermediate flange if ordered as an option.
Connection for vacuum on tank (BZ 101) if available

During evacuation, open:
i
IMPORTANT
For additional information, see appendices
Layout plan of pipelines and fittings
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5. Conservator (BB 085, BB 089)
The conservator is mounted on the transformer tank or lid.

It consists of a main conservator (BB 085) and
a conservator for OLTC oil (BB 089) if available.
Both oil chambers have been adequately dimensioned for the total oil volume variation range.
They are sealed off from one another by means of an air-tight and oil-tight seal.
Each oil chamber has a sufficiently large cleaning aperture (BZ 020, BZ 023) so that the
interior walls can be cleaned and coated.
To avoid compressive stress during evacuation both

oil chambers must be connected via a DN 25 slide valve (AA 349).
The slide valve can also be located between the two
dehydrating breathers (AT 001, AT 005).
Connection for vacuum (BZ 102)

During evacuation, open:
i IMPORTANT
If an air bag is built into the conservator, then

special measures will need to be implemented for filling, etc.
i IMPORTANT
For additional information see filling with oil and appendices.
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6. Cooling (select available cooling method)
ONAN cooling method
Heat is dissipated by means of natural cooling using radiators

in accordance with DIN EN 50216-10-1.
Radiators (AC 600)

are screwed onto the tank via throttle valves to allow for dismounting.
Radiators can also be mounted in groups using a connecting pipe.
i IMPORTANT
For additional information, see appendices.
ONAF cooling method
Fans (AN 701 to AN ...; see dimensional drawing)
Heat is dissipated by using fans that blow air onto the radiators.
i
IMPORTANT
OFAF cooling method
Oil-to-air cooler (AC 681 to AC ...; see dimensional drawing)

Pump (AP 601 to ...; see dimensional drawing)
The heated oil is pumped through the cooler.

The heat is dissipated by using fans to blow air onto the cooler, which results in heat
exchange.
i
IMPORTANT
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OFWF cooling method
Oil-to-water cooler (AC 681 to AC ...; see dimensional drawing)

Pump (AP 601 to AP ...; see dimensional drawing)
The heated oil is pumped through the cooler. In this case, the oil flows roughly perpendicular
to the cooling pipes.
Here, the cooling water flows through multiple pipes in a longitudinal direction,
causing a heat exchange.
i
IMPORTANT
7. Pipelines and fittings
i IMPORTANT
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8. Reconnection dom (if available)
The reconnection dom is not sealed against drips and

is in contact with the transformer oil in the tank.
DANGER
Adjustments should only be made when the equipment is de-energised.
9. Attachments e.g.:
Monitoring devices
Bushings and connectors
On-load tap changer and motor drive
Off-load tap changer, plus drive if applicable
i
IMPORTANT
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6 DISASSEMBLY AND TRANSPORT
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6.1 DISASSEMBLY
Components removed for shipment:

Transport protection must be provided for:
i
IMPORTANT
See appendices – Transport plate or transport drawing
ATTENTION
If the radiators are left on during transport, the lower throttle valves
must be closed.
Before actuating the throttle valves, loosen the packing box screw connections;
tighten them again following actuation.
Throttle valves may only be operated at temperatures above –25°C.
i
IMPORTANT
See appendices – Enclosed operating instructions for throttle valves.
All open flanges must be vacuum-sealed.
If the transformer chamber is filled with dry air for the purpose of transporting it
automatic refilling equipment should be used.
i
IMPORTANT
See appendices - Operating instructions and the automatic refilling
equipment used.
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6.2 TRANSPORT
i IMPORTANT
See appendices – Transport plate or transport drawing
The BKT codes in brackets are the item numbers from the transformer
dimensional drawing; see appendices.
For details of transportation using a heavy road vehicle or a low-loader wagon.
For further information, see transport plate or transport drawing
When shipping transformers with runners (AE 004)
ATTENTION
The runners must be placed on non-slip mats.
When shipping transformers with transport rollers (AE 001)
ATTENTION
Wooden support blocks must be placed centrally under the base tub bracing
on non-slip mats (so that the rollers are clear of the ground).
For further information, see appendices – Transport plate or transport drawing
Lifting bolts (BQ 030)

ensure secure, horizontal lifting.
ATTENTION
For further information, see appendices – Transport plate or transport drawing
WARNING
When loading, never attach lifting gear to the lifting eyes of the lid!
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Jacking pads (BQ 029)

have been provided to facilitate lifting with hydraulic jacks.
You can identify the jacking pads by their colour.
Pulling lugs (BQ 039)

The pulling lugs are used as lashing lugs for transport purposes.
Lashing lugs (BQ 034)

have been provided in sufficient quantities in the top area of the bracing.
Before unloading the transformer, a careful check must be carried out to ensure that no
damage has occurred during transport.
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7 UNLOADING, INSTALLATION
AND ASSEMBLY
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7.1 CHECK FOLLOWING ARRIVAL
Ascertaining mechanical damage
As soon as the equipment arrives at the assembly site, the entire consignment
must be inspected for signs of any possible transport damage.
If the equipment is found to be damaged and oil has been lost as a result,
the following people should be notified immediately: the local site or plant
management, the carrier, the transport insurance company, the relevant
agency or Starkstrom-Gerätebau GmbH.
You should record the damage (insofar as it can be identified) in a log, working in
collaboration with the other parties involved.
Even minor damage that seems completely insignificant must be recorded.
If a complaint is made subsequently, it gets much more complicated from an insurance

perspective.
Any accessories that have been packed into transport boxes or crates should
be stored in a weatherproof location until it is time for them to be assembled.
Return of transport accessories
As contractually agreed, e.g.

impact recorder (if available)
Automatic filling equipment, e.g. dry air (if available)
Compressed air cylinder, e.g. dry air (if available)
Please return to the following address:
Ohmstraße 10
93 055 Regensburg
Germany
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7.2 ASSEMBLY
i IMPORTANT
The BKT codes in brackets are the item numbers from the
dimensional drawing; see appendices.
General
These assembly instructions apply to transformers that have been filled with oil
up to a level of 100 mm below the lid for shipping purposes.
They also apply to transformers that have been emptied completely
prior to transportation and filled with air or nitrogen.
The transformer should always be assembled as soon as possible after

it arrives at the site.
Otherwise, special measures will be required (see STORAGE)
1. Assembly
i IMPORTANT
The transformer must be completely assembled
(see dimensional drawing and layout plan)
ATTENTION
To prevent damp ambient air from getting inside the transformer,
no more than one flange and assembly opening should be opened at once
for the purpose of assembling bushings; they should be opened for as little
time as possible and you will need to work quickly.
Any assembly openings that are not required should remain closed.
In poor weather conditions, the work must be carried out under a canopy.
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2 Preparing for the evacuation process
ATTENTION
Once all the pipelines, radiators or coolers, and the conservator have been
assembled: Open the shut-off valves in accordance with the layout plan
to ensure equal pressure in all these areas during evacuation.
The vacuum line should be connected to the conservator BZ 102

or (if available) to the transformer tank BZ 101.
The oil filling line is connected to the top oil conditioning connection AA 356.
3. In the case of transformers that feature an automatic topping up system,
the automatic topping up system must remain in operation until evacuation takes place.
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7.3 TIGHTENING TORQUES
General:
The tightening torques specified here apply to screwed connections when assembling
attachments.
They do not apply to bushings, connectors, sealing ends, high-current

connections or GRP plates.
In such cases the relevant manufacturer assembly instructions or

the SGB factory standard must be observed and followed.
Thread Tightening torques MA in Nm

Ø For threaded portions
4.8 5.8 8.8 12.9 A2 + A4
4 5 xx) 8 12 x)
M 3 0.6 0.7 1.1 - 1
M 4 1.5 1.8 3 - 2.5
M 5 2.9 3.6 5.7 10 4.9
M 6 5 6.7 10 18 7.8
M 8 11.7 15 24 39 19
M 10 24 31 50 75 38
M 12 40 49 80 128 63
M 16 99 120 200 280 135
M 20 187 235 375 540 175
M 24 320 400 650 950 300
M 30 640 806 1280 1750 605
xx) Welded-on bolt
x) Through bolts, stud bolts, threaded rods
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7.4 EVACUATION
1. General:
These instructions provide the technical data for the process of evacuating
mains transformers before they are filled with oil.
The process described here should be carried out prior to commissioning

at the project site once the transformer has been assembled ready for use.
ATTENTION
Before commencing the evacuation process, you must double-check that all the
necessary valves and slide valves (as per the dimensional drawing or layout plan)
are set to the “operating position”.
In order to achieve the minimum values, it makes a difference whether the transformer
has been filled with oil (a) or with synthetic air (b) for the purpose of transporting it.
Tools and equipment required
Suitable vacuum pump plus connecting hose
Suitable connectors for vacuum pump and connecting flange
Vacuum gauge or recording vacuum gauge
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2. Technical data for vacuum time prior to oil filling
ATTENTION
All data represents minimum values that must be observed.
a) Data for transformer that has been filled with oil for transportation purposes
This means that the transformer has been filled with oil up to a level of approx.
100 mm below the lid.
Um Pressure Minimum time

≤ 170 kV ≤ 1 mbar ≥1h
> 170 kV ≤ 0.5 mbar ≥2h
b) Data for transformer that has been filled with synthetic air for transportation purposes
This means that the oil has been drained and the transformer
has been filled with synthetic air.
Um Pressure Minimum time

≤ 72.5 kV ≤ 0.5 mbar 12 h
≤ 170 kV ≤ 0.5 mbar 16 h
> 170 kV ≤ 0.4 mbar 24 h
The vacuum must be maintained throughout the entire oil filling process
and may only be terminated at the end of the process.
Only at this point may the transformer be aerated.
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7.5 FILLING WITH OIL
General
These instructions describe the process of filling a new transformer with oil
once it has been assembled ready for use.
The oil quantity drained for the purpose of transporting the transformer is
made available in suitable containers.
1. Oil type
Before filling the transformer, you must check that the right
sort of oil has been provided.
For details of the correct oil type for the transformer, please refer to the inspection log.
The oil quantity specified in the dimensional drawing relates to an

oil temperature of +20°C.
Given that other temperatures may apply at the site, the exact
filling quantity will depend on the transformer’s average oil temperature.
The average oil temperature is a mean value calculated on the basis of the “top” and “bottom”
oil samples.
Once the mean value has been calculated, the correct oil level for the conservator can be
read off from the filling curve.
i
IMPORTANT
For filling curve, see appendices
2. Requirements laid down by relevant standards and client specifications
The oil must respect the following parameters.
Flashover voltage > 65 KV
Dielectric loss factor - tan delta < 5‰ = 0.005
3. Filling speed
A filling speed of up to 4000 litres an hour is supported.
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4. Compatibility/Miscibility
ATTENTATION
Mixing is prohibited within the context of performing the contract.
5. Filling quantity for standard conservator
Determine the transformer’s current average oil temperature.

This should be done by taking a sample from the central oil sample and measuring
its temperature. If there is no central oil sample available, the average temperature
should be calculated using the top and bottom oil samples.
Top up the differential oil quantity (e.g. -10°C) up to the average oil temperature
measured/determined on the transformer. The differential quantity can
be determined by referring to the relevant filling curve for the consignment (see appendices).
Example calculation: Oil temperature Oil

-10°C corresponds to 240 l
+30°C corresponds to 950 l
Difference = 950 l –240 l = 710 l *
* This differential oil quantity is the amount that must be put into the conservator.
F illin g c u rv e /fillin g d ia g ra m
110
100
Attention: 95 M AX
90
80
The original filling curve
can be found in the
Oil temperature °C
70
60 appendices to the
50 transformer manual
40
30
20
Sample
10
0
-1 0 -1 0 M IN
-2 0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
O il v o lu m e d m ³
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6. Filling quantity for conservator with air bag
Adjusting the air bag
ATTENTION
The adjustment process must not be interrupted and must not be carried out
during the transformer oil cooling down phase.
The air bag should not be adjusted until the assembly process is
complete/until the transformer has been filled and bled.
Sequence:
6.1 Close the slide valves (AA 346, AA 347).
6.2 Close the slide valve (AA 200) between the conservator and transformer.
6.3 Aerate the conservator, plus DIN 42558-12 locking piece

(if available).
6.4 Check the oil level using the conservator oil gauge glass and adjust it so that it is
in the centre of the glass.
Min-25 °C Ölstand Ölauge
110
6.5 Inflate the air bag with air to a pressure of 0.1 bar.
ATTENTION
The pressure in the air bag must not exceed 0.1 bar.
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6.6 Gradually fill with oil until oil visibly emerges from the bleed plugs of the
conservator, those of the Buchholz relay, and from the DIN 42558-12 locking piece.
ATTENTION
Constantly check the pressure in the air bag during the topping up process.
A rise in pressure is not permitted.
The pressure ust not exceed 0.1 bar; reduce the pressure if necessary.
6.7 Close the bleed plugs and DIN 42558-12 locking piece.
6.8 Aerate the air bag, install dehydrating breathers.
6.9 Determine the transformer’s current average oil temperature.

This should be done by taking a sample from the central oil sample and measuring
its temperature. If there is no central oil sample available, the average temperature
should be calculated using the top and bottom oil samples.
6.10 Top up the differential oil quantity * (e.g. -25°C) up to the average oil temperature
measured/determined on the transformer.
To work out the differential quantity, refer to the filling diagram.
Example calculation: Oil temperature Oil

-10°C corresponds to 240 l
+30°C corresponds to 950 l
Difference = 950 l –240 l = 710 l *
* This differential oil quantity is the amount that must be put into the conservator.
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Filling curve/filling diagram

110
100
95 MAX
90
Attention:
80
The original filling curve
Oil temperature °C
70
can be found in the
60
appendices to the
50
transformer manual
40
30
20
Sample
10
0
-10 -10 MIN
-20
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
Oil volume dm³
Attention
If a drum pump is used, air may get into the system.
Ensure that the oil being conveyed is free of bubbles.
6.11 Reopen the slide valve (AA 200) between the conservator and transformer.
Slide valves (AA 346, AA 347) remain closed.
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7.6 TIME TO WAIT AFTER FILLING WITH OIL
General:
These instructions provide technical data specifying how long you

need to wait before using the mains transformers once they have
been filled with oil.
The values given here are applicable once the transformer has been assembled
ready for use and before it has been commissioned at the project site.
The “time to wait” period is calculated from the moment when the transformer
has been filled with oil and bled.
Technical data for the time to wait before commissioning/connection
ATTENTION
All data represents minimum values that must be observed.
a) Data for transformer that has been filled with oil for transportation purposes
Um Time to wait
170 kV 1 day
> 170 kV 2 days
b) Data for transformer that has been

filled with synthetic air for transportation purposes
Um Time to wait
72.5 kV 3 days
170 kV 3 days
> 170 kV 4 days
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8 GETTING READY FOR OPERATION

AND COMMISSIONING
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8.1 GETTING READY FOR OPERATION AND COMMISSIONING:
Transformers are prepared for commissioning by SGB specialist personnel.

If commissioning is not carried out by SGB, proceed in accordance with the
“Commissioning instructions” below.
The individual steps must be logged in accordance with the commissioning log.
No liability can be assumed for damage caused by third parties as a result
of improper commissioning.
GENERAL
Before commissioning transformers, a check must be carried out to ensure that the
equipment has been assembled properly and that the safety and monitoring devices
are functioning correctly.
The checks to be carried out on the transformer and its protective equipment that are listed
in the commissioning log must be completed (adapted as appropriate for the equipment
supplied).
The checks must be ticked off/the relevant results must be entered.

Prior to actual commissioning, the function of the safety and monitoring equipment
must be checked and the results recorded in the commissioning log.
i
IMPORTANT
For detailed information about operating the safety and monitoring devices,
please refer to the relevant device descriptions, which must be strictly adhered to.
Incorrect operation of the devices can result in serious transformer faults.
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
OPERATION IN ARCTIC AREAS
With the ONAN and ONAF cooling methods, the transformer may be switched on in
the low temperature range up to a uniform oil temperature of –25°C with a maximum
of 0.5 times the load. The load can only be increased after this uniform oil temperature
has been reached.
With the OFAF and OFWF cooling methods, i.e. if an oil pump is operating in the circuit
of the system, the ambient temperature and the uniform oil temperature must not be
lower than –25°C.
Diverter switches may only be switched at an oil temperature of greater than –20°C.
The diverter switch manufacturer’s O & M manual must be followed.The same switching
conditions also apply to off-load tap changers.
i IMPORTANT
see on-load tap changer operation and maintenance manual. MR Technical Data –
General Part TD 61 Point 2.17
ATTENTION
Shut-off valves (valves, slide valves, ball valves etc.) may not be operated until
a uniform oil temperature of greater than –25°C has been reached, i.e. it may not
be possible to operate the throttle valves of the radiators during start-up until the
first warm-up phase to –25°C has taken place.
Seals can be destroyed at ambient temperatures of less than the agreed low
temperature.
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
INSULATION RESISTANCE
DANGER
The sole purpose of this measurement is to reveal any gross assembly errors.
The measurement results depend on several factors (e.g. voltage of the insulation
resistance meter, humidity, how clean the porcelain of the bushings is, temperature).
Under good measuring conditions, a guide value of 1 MΩ/kV is to be expected for
the transformer (reference value is the operating voltage of the terminal being
measured). When the mains supply is connected, the system status is included in
the measurement result. If possible, insulation resistance meters with a voltage
of 5 kV or 2.5 kV should be used to take the measurement. This test voltage (DC)
should not exceed 0.75 x nominal power frequency withstand voltage (AC).
CORE EARTHING (if brought out)
DANGER
This measurement is used to demonstrate that the insulation between the core
and clamping frame is still in order following transportation.
A direct voltage of 500 V should be applied to the bushings in the terminal box
for 1 minute using an insulation resistance meter.
RATIO CHECK
DANGER
This measurement is necessary for the purpose of demonstrating that the
on-load tap changer (off-load tap changer) is functioning correctly from a
mechanical perspective and that the coupling between the motor drive and
on-load tap changer (off-load tap changer) is in order.
i
IMPORTANT
Vor der Inbetriebnahme sollen alle Messwerte mit der Ursprungsmessung der
Werksabnahme verglichen werden.
DANGER
Wenn der Transformator in Betrieb genommen wird, muss in Übereinstimmung
mit den Sicherheitsvorschriften beim Betrieb und Arbeiten an elektrischen
Betriebsmittel nach EN 50110-1 und EN 50110-2 – 1996 sichergestellt sein, daß alle
für die Arbeit getroffenen Sicherheitsmaßnahmen außerhalb der Arbeitsstelle
aufgehoben werden; dazu gehört das Entfernen der Kurzschließung und Erdung
und das Aufheben der Sicherung gegen Wiedereinschalten.
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
COMMISSIONING INSTRUCTIONS
This step does not actually involve checking the exact ratio measurement (as this
will have been done as part of the factory check using precision measuring equipment);
rather, it is a question of ensuring that the voltage changes from the highest to the
lowest number of turns in accordance with the preset ratio and that this happens
continuously in steps without any interruptions.
DANGER
For this purpose, the transformer must be supplied with low voltage
(e.g. 380 V, 500 V) on the HV side. The ratio should be measured using at
least 2 voltmeters on the LV winding; the measurement should be taken at all
on-load (off-load) tap changer positions.
With on-load tap changers, the tapping sequence should be checked
across the entire tapping range to ensure that no interruptions occur
i IMPORTANT
see on-load tap changer operation and maintenance manual.
MOTOR DRIVE AND ON-LOAD TAP CHANGER
The function of the heating must be checked.
Check that the tap changing direction matches the tap position indicator
(phase sequence test).
Overrun block
At the client’s request, a time relay can be integrated into the motor drive or the
control room for the purpose of monitoring the operating time. If the set operating time
of 1 (2) steps is exceeded, the time relay will respond after 8 (13) seconds by tripping
the drive’s motor circuit breaker.
The function of the time relay can be tested by forcing it to respond. This can be achieved
by inhibiting a motor contactor and/or a brake contactor. You need to determine which
contactors will trip the time relay by referring to the circuit diagram concerned.
Step control/continuous cycle
To check the step control, keep the knob/pushbuttons S1 or S2 activated throughout the
entire operating time for a tap changing operation. When the diverter switch switches,
the motor drive should shut down automatically. A new tap changing operation
can only be performed following a new pulse.
At the client’s request, a continuous cycle option can be provided for the purpose
of shutting down step control from the transformer control room in accordance with
requirements.
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
Remote control
Check that tap changing is being executed correctly by sending a pulse from the control
room.
Mechanical end stops
The check should be carried out in manual mode. Move the on-load tap changer into
the penultimate position electrically and then turn the handwheel in order to reach the
end position.Now, if you carry on turning the handwheel by approximately 5-8 revolutions,
the mechanical end stop should be engaged. If the pushbutton is pressed in the same
control direction (the handwheel must be removed first), the drive should not start up.
Now proceed in exactly the same way for the opposite direction.
Electrical limit switch
This check should be carried out after the “mechanical end stop check”. Switch right
through to the end position. When a new pulse is sent, the drive should no longer
start up (it should only start if the pulse is sent in the opposite direction).
The check should be carried out for both end positions.
The mechanical end stop should not engage at this point. Only once the handwheel
has been turned by approximately 1½ additional revolutions, should the
motor circuit breaker trip.
Emergency stop
The “emergency stop” pushbutton should be checked from the control room to
ensure its effectiveness.
The motor circuit breaker in the motor drive should then be reconnected.
Blocking gear
At the client’s request, a blocking gear can be mounted on the input bearing.
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
OFF-LOAD TAP CHANGER (if available)
DANGER
The off-load tap changer may only be actuated when the transformer is de-energised.
Sonst besteht die Gefahr eines Personen- und Transformatorschadens!
POSITION OF THE SHUT-OFF VALVES
Check the position of the slide valves, three-way cocks, ball valves and throttle valves.
i IMPORTANT
See appendices – Layout plan of pipelines and fittings.
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Order No.: 1431517
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OPERATING MANUAL
BLEEDING
All the bleed points provided should be opened until bubble-free oil emerges;
they should then be securely closed again.
Bleed plugs have been fitted to the:
– Bushings (in accordance with DIN or similar type of construction)

– Bushing throats
– Buchholz relay
– Diverter switch for mounting flange (EZ)
– Pressure relief valve
– Radiators
– Oil-to-air/oil-to-water coolers
– Horizontally mounted oil circulating pumps
– Connection pipes between tank and coolers
– Flange over reconnection equipment under transformer lid
– Flange and conductor tube on capacitor bushings

– OLTC oil drain pipe
When arranged vertically (permissible angle of 30° in relation

to the vertical), capacitor bushings have a sealed oil chamber that is isolated
from the transformer oil. The oil chamber must not be bled (merely the area
underneath the bushing flange along with the bushing pipe.
LOCKING DEVICES
If the transformer is installed on wheels, the locking devices (standard 2 diagonal)

must be applied.
INSTALLATION
The transformer is installed horizontally as standard.

The standard design provides the necessary gradient to ensure bleeding
of all the components.
EARTHING (protective earthing)
DANGER
The tank and any cooler present must be earthed, allowing a sufficient
conductor cross-section.
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OPERATING MANUAL
BUCHHOLZ RELAY
ATTENTION
Transformers must not be energised unless there is an activated Buchholz relay
(circuit breakers open/generator de-excited).
If the Buchholz relay has been installed correctly, the arrow will point in the
direction of the conservator.
The ventilation openings of the terminal compartment must allow water through to avoid
the problem of condensate.
The alarm and trip float should be mechanically actuated in accordance with the
device description for the Buchholz relay.
The alarm function check (gassing alarm) should be carried out with the
circuit breakers closed but at zero voltage. If the alarm is triggered
the alarm signal should reach the control room, but the circuit breakers should not trip.
When the tripping function is checked, the circuit breaker/s should open or the generator
should be de-excited. The associated alarms in the control room
will need to be checked.
The tripping elements remain in the response position.

They should be put back into the operating position at the end of the test.
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Order No.: 1431517
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OPERATING MANUAL
DIVERTER SWITCH PROTECTIVE RELAY
ATTENTION
Each diverter switch tank has a diverter switch protective relay integrated into the
pipeline running to the conservator for the diverter switch oil. It responds to the
oil flow (1.5/2.2 m/s) in the direction of the conservator.
If a diverter switch protective relay is installed, the mounting position must be checked
to ensure it is correct. The directional arrow moulded into the housing should point in
the direction of the conservator.
When the diverter switch protective relay responds, the transformer must be shut down.
It is not permissible for it to simply switch to alarm status.
The tripping elements remain in the response position.

They should be put back into the operating position at the end of the test.
At the client’s request, a pressure relief valve can also be installed in the diverter switch tank.
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Order No.: 1431517
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OPERATING MANUAL
PROTECTIVE SPARKING DISTANCE ON BUSHINGS
The protective sparking distance must be set in accordance with the information
in the dimensional drawing packing list or the relevant binding regulation.
A larger distance should be observed when installing the transformer at altitudes

of over 1000 m.
If the transformer terminals are protected by means of surge voltage protectors, there
is no need for the protective sparking distance.
However, if they are required, they should conform to the above requirements as a minimum.
OIL LEVELS
The oil levels in the conservator must be determined via the inspection glasses or oil level
gauges. They must tally with the relevant temperature marks on the indicators in
accordance with the transformer oil temperature.
DEHYDRATING BREATHERS
Dehydrating breathers must be filled with dry silica gel pearls.
When the transformer breathes, air bubbles will become visible in the
oil seal due to differences in temperature.
Dehydrating breathers with heating/air dryers
These must be put into operation by applying the relevant supply voltage.
OIL-TO-WATER COOLER
All coolers must be carefully bled, along with all pipeline systems, before commissioning
the oil and water circuits.
Oil circulation must be commissioned before water circulation.
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Order No.: 1431517
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OPERATING MANUAL
OIL-TO-AIR COOLER
The cooler must be carefully bled, along with all pipeline systems, before
commissioning the oil circuit.
Temperatures in the minus range and poor humidity conditions may result in the guard
on the air inlet side icing up. In this case, the flaps will need to be opened.
The pumps and fans must be checked to ensure that they are running in the right direction.
PUMPS
The arrow moulded into the housing should be used to check that the oil pumps have been
installed correctly. The oil flow direction is set and cannot be changed:
Warm oil is discharged from the tank up towards the cooler.

Cooled oil flows from the cooler into the transformer tank in the base area.
The pumps must be checked to ensure they are running in the right direction.
FANS
All fans must be checked to ensure they are running in the right direction.
Fans must be installed so that they point in the direction for blowing.
OVERCURRENT TRIPPING OF PUMPS AND FANS
PUMPS
In the event of a phase failure during start-up, the motor circuit breaker should respond
within an appropriately short period of time by performing an over current trip.
If the motor circuit breaker trips a message should be sent to the control room.
If oil pumps are put into operation at low temperatures (within the minus range), the
motor circuit breaker may respond due to the viscosity of the transformer oil.
In such cases, the motor circuit breaker can be jumpered when the pump is cold,
provided that cold and viscous oil is being used for the purpose of cooling the pump.
At oil temperatures of + 5°C and above, the jumper must be removed.
OIL FLOW INDICATOR
You should use the arrow markings to check that the oil flow indicator has been installed
in the correct position.
A contacting check must be carried out for each oil flow indicator by closing a valve
when the pump is running.
If there are no valves, the check should be performed by deactivating the pump(s).
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Order No.: 1431517
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OPERATING MANUAL
AIRFLOW INDICATOR
A contacting check must be carried out for the airflow indicators by deactivating the fan.
WATER FLOW
A contacting check must be carried out for the water flow indicators.
Pressure limit
In the case of oil-to-water cooling systems that feature single tubular coolers, the static oil
pressure at the highest point of the cooler must be at least 0.1 bar higher than the water
pressure to ensure that no water can get into the oil circuit if the cooler is not properly sealed.
The water must drain away freely without any back pressure (open water circuit).
OIL LEAKAGE INDICATING POT (only with single tubular coolers)
The water quantity must be set in accordance with the cooler rating plate.
Pressure relief valve
A contacting test must be carried out. The pressure relief valve must be set to the trip
position. The tripping elements remain in the response position. They should be put
back into the operating position at the end of the test.
CABINET HEATING (if available)
The function of the heating must be checked.
TEMPERATURE MONITORING AND FAN CONTROL
The temperature values for triggering an alarm or shutdown, and the temperature data for
switching fan groups on and off in accordance with the temperature, are defined for each
transformer, taking into account the agreed temperature rise limits and the
maximum ambient temperature in the manufacturing plant.
For details of the values to be set, please refer to the operating manual (Technical data).
TEMPERATURE MONITOR
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Serial No.: 150 556
OPERATING MANUAL
DIAL THERMOMETER
RESISTANCE THERMOMETER (if available)
The function of the resistance thermometer must be checked.
WINDING TEMPERATURE INDICATOR (if available)
The winding temperature indicator is adjusted in the SGB test bay and the
temperatures are set.
Details of the setting values can be found under test reports,

factory acceptance test and certificates.
The transformer circuits for the winding temperature indicators must be closed and
must not be opened while the transformer is live. The function of the alarm and
tripping contacts must be checked.
For transportation purposes, the current transformers are short-circuited in the

terminal connection box.
The position of the terminal connection box is given in the dimensional drawing.
The shorting jumper must be removed during commissioning.
Each transformer secondary winding must be earthed at a terminal as per

the circuit diagram. Ideally, terminal “s1” should be earthed.
PAINTWORK
The paintwork must be inspected visually and touched up as necessary.
Sealing check
Finally, the oil tightness of the tank, bushings and cooler, etc. must be checked.
Minimum clearances from nearby components
The distances stipulated by the applicable regulations (e.g. VDE 0532) must be
respected for the clearances between the bushings and connections on the one hand,
and the plant components on the other.
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
CURRENT TRANSFORMERS
DANGER
Integrated current transformers must either be connected to measuring instruments
or be short-circuited and earthed (for the purpose of transporting them, for example).
Each transformer secondary winding must be earthed at a terminal as per the
circuit diagram. Ideally, terminal “s1” should be earthed.
ROOM VENTILATION
If the system is intended for indoor use, adequate room ventilation must be ensured.
If necessary, SGB can provide a dimensioning guideline.
RETURN OF TRANSPORT ACCESSORIES
i
IMPORTANT
See “Check following arrival”.
COMMISSIONING
It is not necessary to gradually increase the voltage with a generator. As soon as

all the checks have been completed, the transformer can be immediately switched on.
There is a chance that the transformer may shut down again as soon as it is switched on
due to spurious tripping of the transformer protection system (e.g. diff. protection,
time overcurrent protection, distance protection, etc.).
Therefore, the transformer should (generally) be connected with the greatest
number of turns: step 1. If the transformer still trips, no attempt should be made to switch it
back on until the cause has been eliminated in order to keep the number of no-load switching
operations to the absolute minimum.
In the case of tap-changing transformers, please note that the on-load tap changer must
be moved into the end position, which corresponds to the greatest transformation
ratio/the lowest level of excitation. Once the transformer has been connected, the
on-load tap changer can be moved into the operating position. However, the transformer
excitation level must not exceed 110% of the nominal excitation value. Once the
transformer has been started up for the first time, you must listen out for any strange
noises (vibrating built-on accessories).
Ohmstraße 10
93 055 Regensburg
Germany
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OPERATING MANUAL
8.2 CHECKLIST FOR COMMISSIONING TRANSFORMERS

Client:
Transformer location:
Type: Job no.: Serial no.:
Transformation ratio: Vector group:
Motor drive: Make: Type: Serial no.:
Persons present:
I. Lower checks: Yes No
1 Transformer earthed on high voltage and low voltage sides?

(Get confirmation from the client!)
2 All labels present?

Missing labels:
3 Wheels secured? (twist protection, wheel protection, runners?).
4 Transformer earthing: diagonally offset? Enquire about cross-section

with client and make a note of it.
Earthing.... x ..........mm². (e.g. 2 x 95 mm²)
5 Signal terminal box : Check lines running to control room to see
whether they are secure (ask client whether operating voltage is available
for checking the devices).
If available, check heating.

Terminal diagram available.
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OPERATING MANUAL
Yes No
6 Lower throttle valves open? Visual inspection.
7 Shock indicator available (yes/no) - Is it OK?

8 Impact recorder available - If "yes", ensure device is switched off and
return it/take it back to SGB.
II. Upper checks:
1 Upper throttle valves open?
2 Sparking distance: HV .............mm , HV-N..............mm.

Sparking distance: MV .............mm , MV-N..............mm.
Sparking distance: LV .............mm , LV-N..............mm.
3 All slide valves checked on the basis of the pipework drawing to

ensure they are in the correct position.
4 Bleed gas inspection nozzles of any compact type transformers
(if available).
5 Bleed high voltage side bushings.

Bleed medium voltage side bushings.
Bleed low voltage side bushings.
Bleed TV bushings.
When bleeding the low voltage side bushings on compact type
transformers, the standpipe will need to be filled first.
Using a suitable container (a clean bucket), pour some oil in
(approx. 10 litres) at the "bottom oil sample" point.
Remove the blank flange from the standpipe.
Reposition the three-way cock.
Fill the standpipe.
Bleed low voltage side bushings.
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OPERATING MANUAL
Yes No
6 Check three-way cock positions (transformer, switch and if available

the three-way cock positions for the bushings and cable connection box).
7 Check tap position on diverter switch

(compare with MA => point I./10.
8 Bleed the diverter switch (2, 3 or 4 x air bleeds)
9 Is there a reconnection dom available - if "yes", bleed it.
10 Is there a reconnection dom available? - If "yes", bleed it.
11 Check that current transformer is connected or short-circuited

in accordance with terminal diagram.
If the current transformers are not wired to the control room, the
transformer bushings will need to be short-circuited and earthed.
If the current transformers are connected, they will need to be
terminated by means of an ammeter.
III. Checking the monitoring equipment:
When checking the monitoring equipment, the following points must be observed:
All monitoring equipment must be in the operating position.
The client must close both circuit breakers before the monitoring
equipment is checked (the disconnectors must of course be open).
Closing the circuit breakers before carrying out the first check
prevents an alarm signal from causing a transformer shutdown.
1 Oil temperature dial thermometer:

Setting ......../.........°C (client setting).
Factory setting: 80/90°C.
2 Fan control and oil temperature dial thermometer:

Setting ........./ ............/ ............/ ............. °C (client setting).
Factory setting: 55/60/85/95°C.
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OPERATING MANUAL
Yes No
3 Winding temperature dial thermometer (different versions):

General: Winding temperature dial thermometers always
require a current transformer.
Consequently, the shorting jumper of the associated
current transformer must be removed,
otherwise, the dial thermometer will only indicate the
oil temperature (and not the winding temperature).
3.1 Winding temp. dial therm.: SGB sett. without fan ctrl. (2 contacts):
100/110°C.
Setting ......... / ......... °C (client setting)
3.2 Winding temp. dial therm.: SGB sett. with fan ctrl. (4 contacts):
75/85/100/110°C.
Setting ........./ ............/ ............/ ............. °C (client setting).
Contact assignment: Signal/signal or signal/shutdown (client).
Contact is actuated by pulling the temperature mark below

the pointer or moving the pointer in the direction that indicates a rise in temperature.
Please do not manually move the pointer in the direction that indicates a drop in
temperature.
2 Thermal relay:
Setting ......... °C.
Factory setting 85°C.
Contact is actuated by turning the knurled screw in the 20°C direction until
the contact audibly switches.
3 Resistance telethermometer connected?
4 Oil level monitor: Main conservator and conservator for OLTC oil
a.) MIN contact only
b.) MIN + MAX contacts
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OPERATING MANUAL
Yes No
5 RS 2001 controller protection:

a. Actuated by pressing the "trigger" knob,
which results in both circuit breakers tripping.
b. Reclosure attempt by client: Either
A. Neither circuit breaker can be closed => OK
B. The circuit breakers can be closed but immediately drop out again => OK
c. Reset controller protection by pressing the "Operation" knob
d. Both circuit breakers can be reclosed.
Contact assignment: Shutdown
6 Buchholz relay transformer:

6.1 "Buchholz alarm (make: Siemens)": press knob down
or alarm as a result of pumping in air with the Buchholz pump.
6.2 "Buchholz alarm (make: EMB/ELMEK)": press knob halfway down
or a alarm as a result of pumping in

air with the Buchholz pump.
6.3 "Buchholz tripping (make: Siemens)": turn and press knob.

Both circuit breakers should trip. Then make a reclosure attempt (keep finger
on knob until the attempt has been made).
6.4 "Buchholz tripping (make: EMB/ELMEK)": Press knob down

fully.
Both circuit breakers should trip. Then make a reclosure attempt.
It should not be possible to close the circuit breaker.
Release the float and make another reclosure attempt.
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Yes No
6.5 If available, release Buchholz disconnection (turn the

knob anticlockwise).
6.6 Bleed Buchholz relay.
7 Buchholz relay bushings (only with compact type transformers):

As for Buchholz relay transformer: (point 6)
8 Blow-off valve/pressure relief valve:

Pull actuating lever outwards - The circuit breaker should trip.
Release actuating lever - Push it inwards.
Reclosure attempt (OK?)
Bleed device.
9 Fans and fan cabinet:
9.1 Check the direction of rotation of the fans (hold a piece of paper at the
bottom of the fans – the piece of paper should be pulled upwards.
9.2 Check to ensure that the fault signals have been wired to the
transformer control room?
9.3 Fan cabinet heating connected? => check.
9.4 Circuit diagram available?

IV. Motor drive:
1. Check tap position indicator on the motor drive and compare

it with the tap position indicator on the diverter switch inspection
glass (top). Do the two indicators match?
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OPERATING MANUAL
Yes No
2. Motor drive checks:
2.1 Centre (e.g.: crank steps 9 - 10 and 11 - 10,

max. deviation of 2 revolutions).
2.2 Crank to mechanical end stop at end positions.
2.3 Supply and control voltages must be present. If not, please ask
the client to specify them. Motor circuit breakers and miniature
circuit breakers must be "CLOSED".
Move to end positions electrically; it must not be possible for the motor drive to be
activated electrically beyond the end positions.
3. Set current intensity of motor circuit breaker ..............A.
4. Checking of motor circuit breaker Q1 to transformer control room?
5. Operation counter reading .............. .
6. Operating time monitoring relay available?
7. Operating time monitoring relay checked?
8. Checking of miniature circuit breakers integrated into the motor drive?
9. Circuit diagram available.

V. Transformer connection:
1. Run motor drive to step 1 (highest high voltage side voltage)

2. Connection of 110 kV circuit breaker:
2.1 Make a note of the connection time: ................ o'clock
2.2 Make a note of the motor drive tap position when the
transformer is connected: .............. .
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OPERATING MANUAL
Yes No
3. Ask someone to set the on-load tap changer to the operating

position (client).
3.1 If possible, the client should adjust the transformer so that
the centre tap position is exceeded (use reverser).
3.2 The client can also increase the secondary voltage until the
"Secondary voltage too high" message is sent (a matter
for the client, but allowed by SGB).
4. Carry out phase comparison (to be done by client):

Record the time .......... o'clock
5. Secondary connection (to be done by client):

Record the time ......... o'clock
6. Transformer subjected to a load of ............... [MW]: (ask client).

VI. Utility company protective equipment:
1. Surge voltage protectors available (ask client).

Details of the phases that have surge voltage protectors installed;
make a note of the phases and the make.
2. Differential protection available?
3. Definite-time overcurrent-time protection available?
................................, Date: ...................... Signature: .................................
a. Commissioning log
b. Approval log
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9 MAINTENANCE AND INSPECTION
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9.1 MAINTENANCE AND INSPECTION
i IMPORTANT
Give priority to the warning information and safety instructions
in the supplier documentation for the individual components.
i IMPORTANT
Additional information (see appendices).
SAFETY INSTRUCTIONS
The general safety regulations for operating and working on electrical installations,
as laid down by EN 50110-1 and EN 50110-2-1996, apply as a basic principle.
The following 5 safety rules must always be observed when working on live and active
components of electrical installations and equipment:
DANGER
WARNING
Isolate
Provide a safeguard to prevent unintentional reclosing
Verify safe isolation from the supply
Earth and short
Cover or fence off any nearby live components.
WHAT TO DO IN AN EMERGENCY
In the event of an accident, the transformer must be immediately isolated from the supply
and earthed.
Reacting quickly can save lives.
The operating and maintenance personnel must be familiar with the

safety equipment and accident and hazard notification procedures,
must know how to perform first aid and must have knowledge of rescue equipment.
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OPERATING MANUAL
GENERAL INFORMATION
To ensure the fault-free operation of the transformer, it is crucial that

inspection and maintenance work is carried out regularly and with the necessary level of
care.
As a general rule, maintenance work may be carried out by the operating personnel.
For detailed information about carrying out maintenance work, please

refer to the relevant parts of the transformer operating manual.
The diverter switch should be inspected/overhauled by the switch manufacturer

or the switch manufacturer’s authorised technicians.
Maintenance and inspection work must only ever be carried out once
the transformer has been disconnected and earthed.
i IMPORTANT
9.2 CHECKLIST FOR MAINTENANCE WORK
Maintenance work must be carried out in accordance with the above checklist.
In the event of any discrepancies between the checklist and the
supplier documentation, priority must be given to the latter.
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OPERATING MANUAL
MAINTENANCE WORK: LEAK TIGHTNESS AND CLEANLINESS
TANK, LID, CONSERVATOR,

CABLE CONNECTION BOX (if available)
ATTENTION
Please note that all applicable accident prevention regulations (particularly
the fire protection measures when working on oil transformers) must be observed.
Check all flanges, sealing points and weld seams for oil tightness.
Any leaks must be rectified immediately by tightening the screws, replacing the
relevant seals, or if necessary by rewelding the affected area.
Rewelding work may only be carried out by specialist SGB personnel or by
a specially trained welder.
PIPELINES, COOLING SYSTEM
Check all flanges, sealing points and weld seams for oil tightness.
With water coolers, the visible surface of the water must

be regularly checked in the oil leakage indicating pot (if available) for any traces of oil.
If any traces of oil are present, a leak may have occurred.
In this case, the coolers should be removed and overhauled.
Then carry out a leak test in accordance with DIN 42 556.
Oil-to-water coolers must be cleaned on the water side, in the case of oil-to-air
coolers, the cooling fins and guards need to be cleaned.
FITTINGS
Check all throttle valves, slide valves and ball valves for oil tightness.
If there is a leak in the packing box, tighten the packing box screw connections.
i
IMPORTANT
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BUSHINGS
Check bushings, bushing domes and pipelines running to the bushings

for leaks.
Depending on the type of construction and make, there may be an oil gauge
glass on the bushing.
The oil level in the glass must be within the specified tolerances.
Cleaning the porcelain of the bushings.

The cleaning intervals will largely be determined by local air pollution levels.
i IMPORTANT
ON-LOAD AND OFF-LOAD TAP CHANGER (if available)
i
IMPORTANT
OIL LEVEL GAUGES
The inspection glasses and contact areas must be checked for leak tightness and corrosion.
Air bleeds and water drains must be cleaned.
i
IMPORTANT
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MONITORING EQUIPMENT MAINTENANCE AND CHECKS
OIL LEVEL GAUGES
The oil level gauge function check should be carried out in

accordance with the device description.
i IMPORTANT
DEHYDRATING BREATHERS FOR CONSERVATOR
Once 50% discolouration of the dehydrating agent has occurred, change the agent.
Weight of filling quantity (DIN 42562)
L1 = 1.2 kg; L2 = 2.4 kg; L3 = 3.6 kg; L4 = 4.8 kg; L5 = 6.0 kg
Weight of filling quantity DIN 42567) = 1.0 kg
Weight of filling quantity (COMEM)

Type 1 = 0.37 kg; Type 2 = 0.76 kg; Type 3 = 2.20 kg; Type 4 = 5.20 kg;
Type 5 = 10.5 kg; Type 6 = 15.2 kg; Type 7 = 25.6 kg; Type 8 = 46.3 kg
Attention:
If the dehydrating agent becomes discoloured in the flange area, the seals
will need to be checked.
Oil seal:
To clean the glass tank, remove the oil seal. Undo the wing nut on the
dehydrating breather base. Remove the glass tank and clean with new (or fully
reconditioned) transformer oil. Do not use any caustic cleaning agents.
For reassembly, follow the steps in reverse.
i
IMPORTANT
For additional information and for a safety data sheet, see appendices.
DEHYDRATING BREATHERS WITH HEATING (if available)
Check external condition for signs of soiling and damage.
i IMPORTANT
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AIR DRYERS (if available)
Check external condition for signs of soiling and damage.
i IMPORTANT
BUCHHOLZ RELAY
The alarm and trip float should be mechanically actuated in accordance with the
device description for the Buchholz relay.
Testing device
The Buchholz relay is equipped with a testing device that allows an external function check to
be
performed separately on both contact systems, even when the relay housing
is completely full of oil.
Alarm: Press the test button.

The alarm function check (gassing alarm) should be carried out with the
circuit breakers closed. If the alarm is triggered the alarm signal should reach the control
room, but the circuit breakers should not trip. Another way of testing the
alarm signal is to slowly pump in air via the air bleed cock.
Shutdown: Turn the test button in the direction of the arrow as far as it will go; then press it
slowly.
The shutdown check should be carried out with the circuit breakers closed.
Turn the test button back to its original position (in the opposite direction to the arrow)
to cancel the locking function.
The associated alarm in the control room will need to be checked.
Oil sludge formation

Oil sludge may form as the oil ages.
This gets deposited on the base of the Buchholz relay and interferes
with the function of the damper and lower float for shutdown.
Terminal compartment
The test and terminal compartments must be checked for condensation.
The ventilation opening of the terminal compartment must allow water through.
i
IMPORTANT
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DIVERTER SWITCH PROTECTION (if available)
The function check for the diverter switch protection should be carried out in
A check should be performed to ensure that the diverter switch protection responds correctly.
When the diverter switch protection responds, a transformer shutdown must be performed.
It is not permissible for it to simply switch to alarm status.
Checking the diverter switch protective relay:

Press the test button. The transformer circuit breakers should trip.
Then perform a reset by pressing the “Operation” button.
The diverter switch protective relay can only be reset on the device itself.
i IMPORTANT
DIAL THERMOMETER
The dial thermometer function check should be carried out in

i
IMPORTANT
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RESISTANCE THERMOMETER (if available)
The resistance thermometer function check should be carried out in

i IMPORTANT
TEMPERATURE CONTROLLER (if available)
The function should be tested by turning the dial to a lower temperature

(below the actual oil temperature).
There will be an audible “click” when the contact responds.
i
IMPORTANT
PRESSURE RELIEF VALVE (if available)
Check the pressure relief valve for the transformer tank

and, if available, the pressure relief valve for the on-load tap changer.
A contacting test must be carried out. The tripping elements must
be put back into the operating position at the end of the test.
i IMPORTANT
FANS (if available)
As a general rule, fans are maintenance-free.

The function of the fans must be checked.
i IMPORTANT
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OIL CIRCULATING PUMP (if available)
ATTENTION
Whenever you are about to carry out any work on the oil circulating pumps,
you must always ensure that they have been disconnected and secured
against unintentional reclosing.
As a general rule, the oil circulating pump is maintenance-free.

Please refer to the manufacturer’s information for details of what maintenance involves.
i IMPORTANT
OIL FLOW INDICATOR (if available)
A contacting check must be carried out for the oil flow indicator.
The function of the oil flow indicator can be checked by closing a slide valve in the
main pipe or by shutting down the pump.
i IMPORTANT
AIRFLOW INDICATOR (if available)
A contacting check must be carried out for the airflow indicator.

This should be down by shutting down the fan.
i IMPORTANT
WATER FLOW INDICATORS (if available)
A contacting check must be carried out for the water flow indicators.
i IMPORTANT
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OIL LEAKAGE INDICATING POT FOR SINGLE-TUBE WATER COOLER

(if available)
The visible surface of the water in the oil leakage indicating pot must be checked regularly for
traces of oil.
If any traces of oil are present, a leak may have occurred. In this case, the coolers should
be removed and overhauled. Then carry out a leak test in accordance with DIN 42556.
i IMPORTANT
LEAKAGE MONITORING (if available)
A contacting check must be carried out for the leakage monitoring system.
i IMPORTANT
FAN AND PUMP CONTROL (if available)
ATTENTION
A check must be carried out to see whether the control is functioning in
accordance with the circuit diagram.
There must not be any problems with the running of fans and pumps.
MAINTAINING AND CHECKING THE OFAF; OFWF; ONAF COOLING SYSTEMS
General:
No general advice can be provided concerning how much operating time should be allowed
to elapse before the components are cleaned; the necessary cleaning intervals will
largely be determined by the local air or cooling water conditions. The components will need
to be cleaned no later than when the oil temperature starts to rise even though
the transformer load is the same and there have been no changes in terms
of the air or water inlet temperature.
i
IMPORTANT
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ON-LOAD TAP CHANGER (if available)
The interval for on-load tap changer inspection and maintenance will depend on the type of
on-load tap changer concerned.
i IMPORTANT
MOTOR DRIVE (if available)
General
Check the door seal and closure for leaks or damage.
Clean air bleeds, if necessary.
Check the function of the heating and if necessary the thermostat setting
(approx. 10°C) or the humidistat (if available).
Check the lighting.
Check the contact decks and position indicators and ensure that all
terminals are securely attached to terminal strips.
If necessary, clean the motor drive.
In cases where the drive housing is subjected to powerful external mechanical vibrations
we recommend checking that all screws are tight; retighten them if necessary.
i
IMPORTANT
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OFF-LOAD TAP CHANGER (if available)
WARNING
The off-load tap changer may only be actuated when the transformer is de
energised; otherwise there is a risk of personal injury or transformer damage.
Switching through all positions

Over time, a tarnishing film will form on the contact components. As a result, the
temperature of the contacts may increase. In the case of the off-load tap changer
it is absolutely essential to find an opportunity (i.e. when the transformer is not in
service and certainly at least once a year) to switch through the entire tapping
range several times in order to rid the contacts of any tarnishing film that may
have accumulated over time.
Electrical interlocks
If the equipment features electrical interlocks, their function must be checked,
i.e. merely attempting to actuate the off-load tap changer should
trigger a transformer shutdown. The end positions are mechanically safeguarded.
Once the off-load tap changer end position has been reached, the only adjustment
possible is in the opposite direction.
Drive
The off-load tap changer can be mechanically actuated using a handle, handwheel or
or motorised drive.
i IMPORTANT
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SWITCHGEAR AND CONTROL GEAR CABINETS
The heating and lighting (door contact) must be checked to ensure that they are functioning
correctly.
The heating temperature must be easily able to prevent condensation.
Switchgear cabinets must be water and dust-tight in accordance with their degree of
protection. The door seals and closure must not be damaged.
The housing air vents must be checked and cleaned.
The electrical connections should make perfect contact.
The ducts and lines must be free of damage, electrical lines must not show any
signs of damage due to ageing.
The measures provided for protecting against electric shock must be completely in place.
i IMPORTANT
ACCESSORIES CABINET (if available)
Accessories cabinets must be water and dust-tight in accordance with their degree of
protection.
The door seals and closure must not be damaged.
The housing air vents must be checked and cleaned if necessary.
CORROSION PROTECTION
The paintwork must be inspected visually.
Damaged paintwork must be professionally repaired.

In the event of major damage to the paintwork, we recommend you consult the manufacturer.
Details of how the paintwork should be applied can be found under test reports, works
acceptance and certificates.
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SPARK GAPS (if available)
The protective spark gaps must be set in accordance with the information in
the dimensional drawing or the relevant binding regulation (e.g. VDE 0532).
Larger gaps should be observed (in accordance with the regulation)

when installing the transformer at altitudes of over 1000 m.
EARTHING CONNECTIONS (protective earthing)
Check that the earthing screws are tight; retighten them as necessary.
OIL SAMPLE
The correct method must be used to take oil samples from the transformer or diverter
switch so that the disruptive discharge voltage can be measured and the chemical
and physical properties of the insulating liquid can be checked.
Samples should be taken in accordance with the procedure recommended in the checklist.
Oil sampling cock in “top” or “central” positions: Sampling position for gas analysis
tests Oil sampling cock in “bottom" position: Sampling position for other tests
i IMPORTANT
See recommendations on the attached "Maintenance and inspection" checklist.
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9.2 MAINTENANCE AND INSPECTION CHECKLIST

SGB - RECOMMENDATIONS In the event of any discrepancies, the specifications of the
transformer operator and component suppliers shall take priority.
Client Location Station
Prod. no. Type Date
Power Ratio Name
MAINTENANCE WORK: LEAK TIGHTNESS AND CLEANLINESS
Years Months Comments

Tank, lid, conservator, cable connection box 1 -
Pipelines, cooling system 1 -
Fittings 1 -
Bushings 1 -
On-load/off-load tap changer 1 -
Oil level gauges 1 -
MONITORING EQUIPMENT MAINTENANCE AND CHECKS
Years Months Comments

Oil level gauges 1 -
Dehydrating breathers - 1
Dehydrating breathers with heating 1 -
Air dryer 1 -
Buchholz relay 1 -
Diverter switch protection 1 -
Oil temperature dial thermometer 1 -
Winding temperature dial thermometer 1 -
Fan control dial thermometer 1 -
Resistance thermometer 1 -
Temperature controller 1 -
Transformer pressure relief valve 1 -
Diverter switch pressure relief valve 1 -
Fan 1 -
Oil circulating pump 1 -
Oil flow indicator - 6
Airflow indicator - 6
Water flow indicator - 6
Oil leakage indicating pot - 6
Leakage monitoring - 6
Fans and pump control 1 -
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GENERAL MAINTENANCE AND CHECKS
Years Variable Comments

Cooling system maintenance/check 1 -
On-load tap changer - X 1) After x number of
operations
Motor drive 1 -
Off-load tap changer - X 2) After x number of
operations
Switchgear and control gear cabinets 1 -
Accessories cabinet 1 -
Corrosion protection 1 -
Spark gaps 1 -
Earthing connections 1 -
Oil sample - X 3)
1) For details of the inspection intervals for the on-load tap changers, please refer to the
relevant operating manual.
2) For details of the inspection intervals for the off-load tap changers, please refer to the
relevant operating manual.
3) Oil sample to be taken in accordance with DIN IEC 475/VDE 0370 Part 3-02.80
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10 DIMENSION DRAWING
AND PART LIST
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10. DIMENSION DRAWING AND PART LIST
DIMENSION DRAWING AND PART LIST 53010-RG814644-EN
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BKT-No. Description
[AA001] Wafer lug pattern butterfly valve DN 80

for transformer tank, bottom
[AA004] Oil drain valve DIN 42568 - 15

for tap changer
[AA021] Sampling valve DIN 42568 - 15

"top"
[AA023] Sampling valve DIN 42568 - 15

"bottom"
[AA026] Oil drain valve DIN 42568 - 32

for conservator tank - transformer
[AA082] Oil filling valve DIN 42568 - 32

[AA086] Oil drain and filling valve DIN 42568 - 15

for conservator tank - tap changer
[AA145] Drain valve DIN 3352 - 40

[AA149] Drain and filling valve DIN EN 12288 - 25

[AA200] Stop valve DIN 3352 - 80

in connecting pipe between Buchholz relay
and conservator tank - transformer
[AA202] Stop valve DIN EN 12288 - 25

in connecting pipe between relay for tap changer
and conservator tank - tap changer
[AA349] Stop valve DIN EN 12288 - 25

between conservator tank - transformer

bottom

top

between transformer tank and radiators
Order No.: 1431516-1518 Date Name Page: 1 / 5

Serial No.: 150555-557 Drawn: 09.07.2009 Amann G.
Checked: 09.07.2009 Li Part list No.53010-G814644-EN
BKT-No. Description
AB020 De-aerator DIN 42558 - 6

on drain pipe DN 25 for tap changer
AB230 Throttle valve DIN 42560 - 80

for radiator
[AB240] Oil drain plug with coverplate DIN 42548 - R
AB600 De-aerator DIN 42558 - 6 for radiator
AB630 Oil drain valve DIN 42558 - 12A for radiator
AC600 Radiator DIN EN 50216-6/092002
AE001 Roller DIN 42561 - L 300
[AN701] Fan for Radiators
[AN726] make SCHORMANN type SK 520 - 6
[AT001] Silica gel breather DIN 42562 - L2

[AT005] Silica gel breather DIN 42562 - L2

BB085 Conservator tank for transformer
BB089 Conservator tank for tap changer
BQ011 Thermometerpocket DIN EN 50216-4-type A1

(spare)
BQ023 Ladder
BQ029 Jacking lug for complete transformer
BQ030 Lifting lugs Ø 160 for complete transformer
BQ031 Lifting lug Ø 60 for active part
BQ033 Lifting lug Ø 40 for conservator tank
BQ039 Haulage lugs Ø 100 for longitudinal and

transverse movement
BQ051 Safety cable

BKT-No. Description
BR001 Filling pipe DN 40 for

conservator tank - transformer
BR005 Drain and filling pipe DN 25 for

conservator tank - tap changer
BR050 Drain pipe DN 40 for conservator tank - transformer
BR090 Drain pipe DN 25 for tap changer
BR107 Connecting pipe DN 80 between transformer tank and

BR109 Connecting pipe DN 25 between tap changer and

BR110 Vent pipe DN 25 between tap changer flange,

bushing fitting and
pipe to the Buchholz relay
BR114 Degassing pipe DN 25 for

BR116 Degassing pipe DN 25 for

BR450 Overflow pipe DN 25 between

transformer tank and conservator tank - transformer
BZ020 Cleaning hole for conservator tank - transformer
BZ023 Cleaning hole for conservator tank - tap changer
[BZ050] Filling hole G 2 A

[BZ054] Filling hole G 2 A

[BZ102] Connecting for vacuum DN 25
BZ115 Fastening for roller

(diagonally mounted)
BZ133 Earthing terminals DIN 48088 - B - 2xM12
BZ150 Manufacturers mark

BKT-No. Description
BZ151 Rating and diagram plate
BZ153 General plan of supervision, pipes and fittings
[CF050] Buchholz relay DIN 42566 - DR 80

for transformer tank
make EMB type 09-26.24.-0236
2 two way contacts
[CF061] Relay for tap changer

make MR type RS 2001
1 two way contact
[CL060] Dial type level gauge

make MESSKO type MTO-STF160
2 two way contacts
[CL064] Dial type level gauge

2 two way contacts
[CT001] Temperature monitors

make STEVANOVIC type STR-WK
1 two way contact
[CT021] Resistance thermometer

for transformer
type 1 PT 100
[CT031] Dial type thermometer for oil temperature control

make MESSKO type MT-ST 160 F
order no. 635081
2 two way contacts
[CT036] Dial type thermometer for fan control

order no. 635081
2 two way contacts
GD001 Bushing for winding H.V. - 1U,1V,1W

make ABB type GOB 550-800 LF 123 061-K
GD002 Bushing for winding H.V. - 1N


BKT-No. Description
GD013 Bushing DIN 42533 - DT20Nf1000

for stabilizing winding - 3U1,3W2
GD209 Bushing for winding L.V. - 2U,2V,2W

make PFISTERER type 4xGr.3, 36kV, 3150A
order no. 827146336
GD210 Bushing for winding L.V. - 2N

make PFISTERER type 2xGr. 3, 36kV, 2200/2500A
order no. 827660001
[GH009] Outdoor kiosk for fan control
GS001 On-load tap changer

make MR type R III 1200Y-123/C-10 19 1G
[GX001] Motor drive

make MR type ED 100-L
[ ] BKT-No. in brackets: designation of the construction parts acc. to DIN 42513

OPERATING MANUAL
11 RATINGPLATE, DIAGRAM PLATE
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11. RATINGPLATE, DIAGRAM PLATE
RATING- AND DIAGRAMPLATE 53021-RG814645-EN
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12 RECONNECTING DOM PLATE
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12. RECONNECTING DOM PLATE
RECONNECTING DOM PLATE "not applicable"
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13 TRANSPORTPLATE /TRANSPORT DRAWING
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13. TRANSPORTPLATE / TRANSPORT DRAWING
TRANSPORTPLATE / TRANSPORT DRAWING 53024-RG814647-EN
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14 GENERAL PLAN
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14. GENERAL PLAN
GENERAL PLAN 53023-RG814646-EN
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15 SIGNAL/CONTROL CABINET
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15. SIGNAL/CONTROL CABINET
SIGNAL/CONTROL CABINET 53025_E502128
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OPERATING MANUAL
16 MOTOR DRIVE UNIT CONTROL
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 146

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
16. MOTOR DRIVE UNIT CONTROL
MOTOR DRIVE UNIT CONTROL 1886506
SAP No.: 112010276/20 Page: 147

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 148

Order No.: 1431517
Serial No.: 150 556
1 2 3 4 5 6 7 8 9 10 11 12
110V DC 230V, 50 HZ
L- L1
L+
PE
A A
X1 PE 6 1 2 3 4 17 19
X1:29
/2.A2
B 21 B
S10
22
1 3 5
Q1
/2.G10
X20 48
2 4 6 X20 4
X2 1 2
C C
41 C
X20 1 2 Q1 S20
X3 1 /2.G10 42 NC NO
C C
S8A S8B
NC NO NC NO 1
1
C C X20 49
S6A S6B PE
R1 E1
NC NO NC NO
D D
Fuer diese technische Unterlage behalten wir uns gemaess
X20 3 2
2
4 4
K1 K2
/2.G4 3 /2.G7 3
DIN 34 Abschnitt 2.1 und 2.2 alle Rechte vor.
TAP-CHANGER IN OPERATION
X2 4 5 X3 2
5 5
SIGNAL MOTOR CIRCUIT

K1 K2
/2.G4 6 /2.G7 6
E 2 2 71 E
X20 5
K2 K1 K1
/2.F7 1 /2.F4 1 /2.G4 72
K1:A2
/2.E2
X20 32 33 34 35
71
D1 C2 K2
/2.G7 72 X1 7 8 9 18 20
A1 E1
M N
F M1 = F
E2 D2 PE
U4
1
2
3
X20 36 4
/1.G2 5
1 8 4 6 3 7 2 5 6
- + 7
U4 8
/1.G5 10
/2.B6 11
G G
DRIVE BRAKING HEATER LIGHTING

DO NOT MODIFY MANUALLY
DRAWING BY CAD
H H
DATE 23.01.2008 LANGUAGE: PROJECT: =
EXEC. KONFIG MOTOR DRIVE UNIT EN +
VERIFIED BLE SHEET 1
NO. MODIFICATION DATE NAME STANDARD ORIGIN. REPL. REPL.BY
1886506_00 5 SH.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
TO POS. 1 RAISE WITH STEP-BY-STEP OPERATION TO POS. 19 LOWER Q1 "OFF"
A A
X1 29 30 10 11 12 13 14 15
X1:2
/1.A5
33 2 4
Q1 S3
/2.G10 34 1 3
B 53 11 53 B
K1 U4 K2
/2.G4 54 /1.G5 10 /2.G7 54
21 13 73 43 31
K20
/2.G6 22 14 74 44 32
X20 6 7 8
C C
C C C C C C
S14 S4 S13A S13B S5 S12
NC NO NC NO NC NO NC NO NC NO NC NO
C C
S1 S2
NC NO NC NO
D X20 9 10 11 12 13 D
61 83 83 61
K1 K2
/2.G4 62 84 /2.G7 84 62
112 122 84 62
E K2 K1 K20 E
/2.G7 111 /2.G4 121 /2.G6 83 61
A1 A1 A1 C1
K1 K20 K2 Q1
/2.F4 A2 /2.F6 A2 /2.F7 A2 /2.G10 C2
/1.E5
X1:7
TO POS. 1 RAISE X1 16 TO POS. 19 LOWER
F F
K1 K20 K2 Q1
/2.E4 A1 A2 /2.E6 A1 A2 /2.E7 A1 A2
/1.E3 1 2 /2.C5 13 14 /1.E3 1 2 1 2

/1.D3 3 4 /2.C5 21 22 /1.D3 3 4
/1.E3 5 6 /2.C7 31 32 /1.E3 5 6 3 4
/1.C2
/2.B5 53 54 /2.C7 43 44 /2.B7 53 54
/2.D9 61 62 53 54 /2.D10 61 62 5 6
/1.E4 71 72 /2.E10 61 62 /1.F4 71 72
/2.D9 83 84 /2.C6 73 74 /2.D10 83 84
/2.B3 33 34
/2.E7 121 122 /2.E9 83 84 /2.E4 111 112
G /1.C11 41 42 G
/2.E10 C1 C2
DRAWING BY CAD
H H
DATE 23.01.2008 CONTROL LANGUAGE: PROJECT: =
1886506_00 5 SH.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
S38M S38P
1
A b a A
1
2
2
3 1
3
2
4
3
5
4
6
5
7
B 6 B
8
7
9
8
10
9
11
10
12
11
13
12
C 14 C
13
18 X 10 OHM
15
14
16
15
17
16
18
17
19
18
20
D 19 D
21
22
23
24
25
26
E 27
E
28
29
30
31
32
33
F F
34
35
36
37
G G
DRAWING BY CAD
H H
DATE 23.01.2008 REMOTE POSITION INDICATION LANGUAGE: PROJECT: =
1886506_00 5 SH.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
S61M S61P
1
A A
2 1
20 10 8 4 2 1
+ -
3 2 X 1
4 4 X 2
5 8 X X 3
6 10(-) X 4
7 20(+) X X 5
B X X 6 B
X X X 7
X 8
X X 9
X 10
X X 11
X X 12
C C
X X X 13
X X 14
X X X 15
X X X 16
X X X X 17
X X 18
D X X X 19 D
E E
BCD
F F
G G
DRAWING BY CAD
H H
DATE 23.01.2008 REMOTE POSITION INDICATION LANGUAGE: PROJECT: =
1886506_00 5 SH.
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
E1 HAND LAMP
33 1 2 3 4 5 6 - 11 - 15 16 17 18 - 24 25 26 27 28 29 30 31 32 33 1 2 3 4
A K1 MOTOR CONTACTOR A
K2 MOTOR CONTACTOR
S1/C-NO
K20 AUXILIARY CONTACTOR
S1/C-NC
M1 MOTOR
S2/C-NO
Q1 MOTOR PROTECTIVE SWITCH
S2/C-NC
R1 HEATER S12,S14/C-NO
S1 CAM-OPERATED SWITCH S13A,S13B/C-NO
S10 DOOR CONTACT
S12 CAM-OPERATED DIRECTIONAL SWITCH
B S13A CAM-OPERATED DIRECTIONAL SWITCH B
S13B CAM-OPERATED DIRECTIONAL SWITCH
S14 CAM-OPERATED DIRECTIONAL SWITCH
S2 CAM-OPERATED SWITCH
S20 CAM-OPERATED NON-DIRECTIONAL SWITCH
S3 RAISE/LOWER CONTROL SWITCH
S38M POSITION TRANSMITTER MODULE, RESISTOR-TYPE
S38P POSITION TRANSMITTER BOARD
S4 END POSITION SWITCH
C S5 END POSITION SWITCH C
S61M MODULE WITH DIODE MATRIX
S61P POSITION TRANSMITTER BOARD
S6A END POSITION SWITCH
S6B END POSITION SWITCH
S8A HAND CRANK SAFETY SWITCH
S8B HAND CRANK SAFETY SWITCH S20/C-NO
U4 THYRISTOR BRAKE S20/C-NC
X1 TERMINAL
D X2 TERMINAL D
X20 TERMINAL
X3 TERMINAL
E E
S4,S5/C-NC
F F
S6A,S6B/C-NC
G G
/2.A10
/1.A12
/2.A11
/1.A11
/1.F12
/1.F11
/1.A2
/1.A2
/1.A2
/1.A3
/1.A5
/1.A7
/1.A9
/1.A3
/1.A2
/2.A4
/2.A7
/2.A9
/2.A9
/2.A3
/2.A3
/1.F5
/1.F7
/1.F9
/2.F5
X1 :29
K1 :A2
K2 :53
Q1 :C1
K20 :14
Q1 :42
X20 :48
X20 :49
Q1 :33
S10 :21
Q1 :41
X2 :4
S3 :4
Q1 :5
X20 :5
S3 :3
X1 :2
X2 :1
Q1 :1
S3 :1
X1
3
5
6
7
8
9
2
4
PE
PE
PE
30
1
20
29
10
11
12
13
15
16
17
18
19
14
PE :
L+ :
L1 :
L- :
N:
DRAWING BY CAD
H H
NO. MODIFICATION DATE NAME STANDARD ORIGIN. REPL. REPL.BY 1886506_00 5 SH.
1 2 3 4 5 6 7 8 9 10 11 12
OPERATING MANUAL
17 PHOTO H. V. SIDE
PHOTO L. V. SIDE
FILLING DIAGRAM
SAP No.: 112010276/20 Page: 149

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 150

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
17. PHOTO H. V. SIDE, PHOTO L. V. SIDE, FILLING DIAGRAM
PHOTO H. V. SIDE
PHOTO L. V. SIDE
FILLING DIAGRAMM 1431517
SAP No.: 112010276/20 Page: 151

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 152

Order No.: 1431517
Serial No.: 150 556
Oilvolume-oiltemperature
discharge oil for transport at + 20°C order no.

transformer tank (100mm discharge ) 1051 dm3 925 kg 1431517
oil volume radiator 2146 dm3 1888 kg
tap changer 25 dm3 23 kg oil level f. bottom
oil volume conservator at + 20°C 955 dm3 840 kg 429 mm
0 dm3 0 kg
Total 4177 dm3 3676 kg
conservator
diameter = 1100 mm tank L= 2689 mm oil level f. bottom oil level gauge
oil volume min. Temp -25 °C 41 dm3 36 kg 50 mm float rod S= 562 mm
oil volume Max. Temp 100 °C 2514 dm3 2212 kg 1032 mm
Filling diagram
110 °C
100 °C
90 °C 100 °C
80 °C
70 °C
60 °C
Oiltemperature °C
50 °C
40 °C
30 °C
20 °C
10 °C
0 °C ‐25 °C
-10 °C
-20 °C
-30 °C
-40 °C
-50 °C
0 dm3
100 dm3
200 dm3
300 dm3
400 dm3
500 dm3
600 dm3
700 dm3
800 dm3
900 dm3
1000 dm3
1100 dm3
1200 dm3
1300 dm3
1400 dm3
1500 dm3
1600 dm3
1700 dm3
1800 dm3
1900 dm3
2000 dm3
2100 dm3
2200 dm3
2300 dm3
2400 dm3
2500 dm3
2600 dm3
2700 dm3
Oilvolume dm³
Füllkurve_1431517.xls page 1 printed:14.01.2010

OPERATING MANUAL
18 ADDITIONAL DOCUMENTS
ACCORDANG CUSTOMERS
SPECIFICATION
SAP No.: 112010276/20 Page: 153

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Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 154

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
19 AA FITTINGS, SLIDE VALVES, COCKS
SAP No.: 112010276/20 Page: 155

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 156

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
19. AA Fittings, slide valves, cocks
BKT Nr. are numbers from the part list of the dimension drawing
AA 001 Wafer lug pattern butterfly valve DN 80
for transformer tank, bottom
Drawing or description 594161-RM225589
AA 004 Oil drain valve DIN 42568 - 15
for tap changer
AA 021 Sampling valve DIN 42568 - 15
"top"
AA 023 Sampling valve DIN 42568 - 15
"bottom"
AA 026 Oil drain valve DIN 42568 - 32
AA 082 Oil filling valve DIN 42568 - 32
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
AA 086 Oil drain and filling valve DIN 42568 - 15
AA 145 Drain valve DIN 3352 - 40
Drawing or description 214120-HP0001
AA 149 Drain and filling valve DIN EN 12288 - 25
AA 200 Stop valve DIN 3352 - 80
in connecting pipe between Buchholz relay
and conservator tank - transformer
AA 202 Stop valve DIN EN 12288 - 25
in connecting pipe between relay for tap changer
AA 349 Stop valve DIN EN 12288 - 25
between conservator tank - transformer
SAP No.: 112010276/20 Page: 158

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
bottom
top
between transformer tank and radiators
SAP No.: 112010276/20 Page: 159

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Order No.: 1431517
Serial No.: 150 556
S.Mat.No.: Pos: Page 1 of 2
15.01.2010 12:50:51
***Engineering Parts List*** SB: LODERMEIER
No Drwg.Pos. Quantity QU Standard Mat.No Weight(kg)
Text Basic Data/Addition. Pos. Text SO DB GEB HL
===========================================================================
0010 1 1 ST 214911 RM225409 7,250
20
DROSSELKLAPPE DN 80/40-A2 -40°C
Flansch: Ø 200 x 40
Befestigung: 8 Loch (Ø18) TK=160
A2 =Flansch A2
Klappe: GG-20 (einseitig gelagert)
Inneres Dichtsystem: Stahl-Stahl
Äusseres Dichtsystem (Welle):
O-Ring+Konus
Betriebsdrehmoment: <10 Nm
Schließdrehmoment: <70 Nm
Öffnungsdrehmoment: <40 Nm
*
min. Umgebungstemp. -40°C +125°C
Öldicht < 8,5cc/60" =
< 0,5 l/h entsprechend EN50216-8
*
Bedienung:Montageanleitung für
Drosselklappe beachten
*
Hersteller:Fa.MAIER
___________________________________________________________________________
0020 2 2 ST 161621 RM225411 0,260
20
FLACHDICHT DIN 86071-DN 80-NP815
D1=90 D2=200 K=160 L=22 S=3.00
ANZ. DER LÖCHER=8
___________________________________________________________________________
0030 3 1 ST 594045 RM225565 4,870
20
B-FLANSCH M.VERSCHLUSSSTUECK-DN 80/6
Öldicht geschweißt mit
Anstrich C4 RAL7033
EMC 182 80µm + HV43X 80µm
Bestehend aus:
Pos 1 M205593
(B-FLANSCH DIN 2527-B 80-ND16-tZn)
Pos 2 M200437
(VERSCHL-STUECK DIN 42558- 6 -ST-VZn)
___________________________________________________________________________
0040 4 8 ST 032454 RM225560 1,392
20
GEW-BOLZ DIN 976-1- M16* 130-B-A2-70
___________________________________________________________________________
0050 5 16 ST 110354 HF2115 0,528
20 X
Hexagon nut ISO 4032-M16-A2-70
(formerly DIN 934)
___________________________________________________________________________
***************************************************************************
Custom. order: 112010276/000020 Applicat. : 1 Order : 1431517
Valid from SO DB Quantity QU Weight(kg) WN/MNr: 594161
15.12.2009 50 X 1 ST 14,636 RM225589
Cre/Mod./Ind: 15.12.2009/KNORR / / /
Cont.: Mod: DOTR 120000 / 110
Prec.: Clie.: S.C.TOMIS TEAM SRL
15.01.2010 12:50:51
===========================================================================
0060 6 16 ST 120253 HF0050 0,176
20 X
washer ISO 7090- 16-140HV-A2
(formerly DIN 125-B)
___________________________________________________________________________
0070 7 8 ST 110454 HF2026 0,160
20 X
Hex. thin nut ISO 4035-M16-A2-70
(formerly DIN 439)
___________________________________________________________________________
***************************************************************************
15.12.2009 50 X 1 ST 14,636 RM225589
Cre/Mod./Ind: 15.12.2009/KNORR / / /
Cont.: Mod: DOTR 120000 / 110
MOUNTING INSTRUCTION BUTTERFLY/THROTTLE VALVE
Required tool:
Open-ended or ring spanner size 17* for valve position indicator
Open-ended or ring spanner size 36* for pressure screw
Open-ended or ring spanner size 24* for mounting of radiators
* Metric
Close the Butterfly/throttle valve correct by following work operations:
1. Loosen the pressure screw with an open-ended or ring spanner size 36*
2. Close the valve in clock-wise direction with an open-ended or ring spanner size
17* and hold this position until you have finished point 3.
3. Tighten the pressure screw.
4. Seal the Butterfly-/ Throttle valve with B-flange and discharge the air from
the oil chamber
Apply reversed sequence to open valve. Valve needs to be turned counter-clockwise
ATTENTION The trottle valve do not provide an abslutely tight seal. Therefore
when removing the blind flanges it is possible that sam oil leakage will run out.
Do not use force on the valves in trying to obtain a tight seal otherwise.
15.01.2010 11:15:58
===========================================================================
0010 1 1 ST 214210 HP0010 1,030
20 YGEB
OUTLET VALVE DIN 42568-DN 15-CuZn
___________________________________________________________________________
0020 2 2 ST 161621 RM205402 0,024
20 X
fl. gasket DIN 86071-DN 15-NP815
D1=22 D2=80 K=55 L=14 S=1.50
number of holes=4
___________________________________________________________________________
0030 3 4 ST 110354 HF2112 0,048
20 X
(formerly DIN 934)
___________________________________________________________________________
***************************************************************************
01.07.2009 50 X 1 ST 1,102 RM203513
Cre/Mod./Ind: 01.07.2009/SCHECK / / /
Cont.: Mod: DOTR 120000 / 110
outlet valve complete-DN 15-A2
15.01.2010 11:16:03
===========================================================================
0010 1 1 ST 214210 HP0011 2,300
20 YGEB
OUTLET VALVE DIN 42568-DN 32-CuZn
___________________________________________________________________________
0020 2 2 ST 162621 RM205409 0,038
20 X
gasket-DN 32-NP815
A=90 D=34 K=90 L=16 R=13 S=1.50
___________________________________________________________________________
0030 3 4 ST 110354 HF2113 0,068
20 X
(formerly DIN 934)
___________________________________________________________________________
***************************************************************************
01.07.2009 50 X 1 ST 2,410 RM203514
Cont.: Mod: DOTR 120000 / 110
outlet valve complete-DN 32-A2
15.01.2010 12:50:46
===========================================================================
0010 1 1 ST 214911 RM225408 11,580
20
DROSSELKLAPPE DN125/40-A2 -40°C
Flansch: Ø 250 x 40
Befestigung: 8 Loch (Ø18) TK=210
A2 =Flansch A2
Klappe: Stahl GG20
(einseitig. gelagert)
Inneres Dichtsystem: Stahl-Stahl
Äusseres Dichtsystem (Welle):
O-Ring+Konus
Betriebsdrehmoment: <30 Nm
Schließdrehmoment: <100 Nm
Öffnungsdrehmoment: <50 Nm
*
min. Umgebungstemp. -40°C +125°C
Öldicht <16,6 cc/60" =
< 1,0 l/h entsprechend EN50216-8
*
Bedienung:Montageanleitung für
Drosselklappe beachten
*
Hersteller:Fa.MAIER
___________________________________________________________________________
0020 2 2 ST 161621 RM225410 1,450
20
FLACHDICHT DIN 86071-DN125-NP815
D1=141 D2=250 K=210 L=22 S=3.00
ANZ. DER LÖCHER=8
___________________________________________________________________________
0030 3 1 ST
*HINWEIS:
*B-Flansch_DN125
*8 Stück
*Bestandteil Stücklister RTR
___________________________________________________________________________
0040 4 8 ST 032454 RM225560 1,392
20
GEW-BOLZ DIN 976-1- M16* 130-B-A2-70
___________________________________________________________________________
0050 5 16 ST 110354 HF2115 0,528
20 X
(formerly DIN 934)
___________________________________________________________________________
***************************************************************************
15.12.2009 50 X 1 ST 15,286 RM225587
Cre/Mod./Ind: 15.12.2009/KNORR / / /
Cont.: Mod: DOTR 120000 / 110
15.01.2010 12:50:46
===========================================================================
0060 6 16 ST 120253 HF0050 0,176
20 X
___________________________________________________________________________
0070 7 8 ST 110454 HF2026 0,160
20 X
Hex. thin nut ISO 4035-M16-A2-70
(formerly DIN 439)
___________________________________________________________________________
***************************************************************************
15.12.2009 50 X 1 ST 15,286 RM225587
Cre/Mod./Ind: 15.12.2009/KNORR / / /
Cont.: Mod: DOTR 120000 / 110
MOUNTING INSTRUCTION BUTTERFLY/THROTTLE VALVE
Required tool:
Open-ended or ring spanner size 17* for valve position indicator
* Metric
Close the Butterfly/throttle valve correct by following work operations:
2. Close the valve in clock-wise direction with an open-ended or ring spanner size
17* and hold this position until you have finished point 3.
4. Seal the Butterfly-/ Throttle valve with B-flange and discharge the air from
the oil chamber
Apply reversed sequence to open valve. Valve needs to be turned counter-clockwise
ATTENTION The trottle valve do not provide an abslutely tight seal. Therefore
when removing the blind flanges it is possible that sam oil leakage will run out.
OPERATING MANUAL
20 AB TERMINATING ELEMENTS,
LOCKING PIECES
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OPERATING MANUAL
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
20. AB Terminating elements, locking pieces
BKT No. are numbers from the part list of the dimension drawing
AB 020 De-aerator DIN 42558 - 6
on drain pipe DN 25 for tap changer
AB 230 Throttle valve DIN 42560 - 80
for radiator
AB 240 Oil drain plug with coverplate DIN 42548 - R
Drawing or description 594175-RM203511-K296

594175-RM203511
AB 600 De-aerator DIN 42558 – 6
for radiator
AB 630 Oil drain valve DIN 42558 - 12A
for radiator
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OPERATING MANUAL
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Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
MOUNTING INSTRUCTION THROTTLE VALVE
Required tool:
Open-ended or ring spanner size 17* or 22* for valve position indicator
* Metric
Close the throttle valve correct by following work operations:
2. Close the valve in clock-wise direction with an open-ended or ring spanner size 17*
or 22* and hold this position until you have finished point 3.
Apply reversed sequence to open the throttle valve.

Throttle valve needs to be turned counter-clockwise
ATTENTION
The trottle valve do not provide an abslutely tight seal. Therefore when removing
the radiator or blank flanges it is possible that sam oil leakage will run out.
ATTENTION
Prior to energization throttle position must be checked.
(Arrow to point towards the radiator)
Date: JUN.2008 Name: MAUNTING INSTRUCTION page: 1

Author’s name: Gerstl THROTTLE VALVE
Checked: Götz Docu. no. 53007-G812924-EN
---- 11.06
Weight: Part 1 to 4 = 2,620 kg

Part 5 to 8 = 0,210 kg
15.01.2010 11:15:54
===========================================================================
0010 5 1 ST 161050 RM200652 0,002
20 X
RING- 52.0* 60.0*2.00-Pa6
D1=52 D2=60 S=2
___________________________________________________________________________
0020 6 2 ST 162621 RM207935 0,038
20 X
gasket-oil drain plug-NP815
A=100 D=62 K=110 L=16 S=1.50
___________________________________________________________________________
0030 7 4 ST 120253 HF0049 0,024
20 X
___________________________________________________________________________
0040 8 4 ST 113254 HF2162 0,112
20 X
cap nut DIN 1587-M12-A2-70
___________________________________________________________________________
***************************************************************************
01.07.2009 50 X 1 ST 0,920 RM203511-K296
Cont.: Mod: DOTR 120000 / 110
oil drain plug DIN 42548-R-A2
(part 5 to 8)
15.01.2010 11:15:46
===========================================================================
0010 1 1 ST 594176 RM203512 1,470
20
connecting flange DIN 42548-1-RSt 37-2
(with thread holes)
___________________________________________________________________________
0020 2 4 ST 106654 HF1665 0,100
20
Studs DIN 938-M12* 25-A2-70
___________________________________________________________________________
0030 3 1 ST 105111 RM204254 0,302
20
screw plug DIN 908-M52*2-St A4H
L=21 D=60 I=16 S=24 E=27.4
___________________________________________________________________________
0040 4 1 ST 594177 RM203504 0,750
20 YGEB
blind-flange DIN 42548-2-tZn
___________________________________________________________________________
***************************************************************************
18.08.2009 50 X 1 ST 1,870 RM203511
Cre/Mod./Ind: 18.08.2009/REHMANI / / /
Cont.: Mod: DOTR 120000 / 110
oil drain plug DIN 42548-R-A2
(part 1 to 4)
OPERATING MANUAL
21 AC, AE, AN
SAP No.: 112010276/20 Page: 165

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 166

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
AC RADIATORS,COOLERS,HEAT EXCHANGERS
AE MOVING, LIFTING,TURNING AND SWIVELLING MECHANISMS
AN FANS
AC 600 Radiator DIN EN 50216-6/092002
Drawing or description 210100-R3000126
AE 001 Roller DIN 42561 - L 300 S
AN 701 Fan for Radiators type SK 520-6
- make SCHORMANN
AN 726 Drawing or description 211654-HV0054
SAP No.: 112010276/20 Page: 167

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Order No.: 1431517
Serial No.: 150 556
15.01.2010 11:16:56
===========================================================================
0010 AC600 1 SA 210100 R3000126 7.189,880
DB
RADIATORSATZ DIN EN 50216-6/092002
Radiatorenfabrikant: frei
Wanddicke: 1,0 mm
Ausführungsrichtlinie für Radiatoren
Design guideline for radiator
210001-NTTK-RL
*
Anzahl der Radiatorglieder = 468
Total number of radiator elements
*
Pos. 1 / 2 Stück/Pieces
FG 1400* 65*18
*
FG 1400* 65*18
*
FGSl 1400* 65*18* 5
*
FGSr 1400* 65*18* 5
*
Vierkantmutter 210002-NTTK-RL
Square nuts
Pos.1,2,3,4
Abb./Fig. 2.1 u 2.6
*
Verschlußstück 210003-NTTK-RL
Plugs and oil drain mechanisms
Pos.1,2,3,4
Abb./Fig. 3.1 Gr. 6 + 12A
*
Temperaturmessstelle 210011-NTTK-RL
Position of temp. measuring point
Pos.1
Abb./Fig. 11.1 Gr. 12A
*
Schildertafelanbau 210004-NTTK-RL
Position of fixings for plates
Pos.1
Abb./Fig. 4.4 A= 100 B= 440
*
Ventilatorenanbau 210005-NTTK-RL
Position of ventilator fixings
Pos.1,2,3,4
Abb./Fig. 5.1 A=200 B=433
*
Bezeichnung der Rad. 210006-NTTK-RL
Designations of radiators
***************************************************************************
Valid from SO DB Quantity QU Weight(kg) WN/MNr:
17.06.2009 52 1 ST 7.575,794 RRAD
Cre/Mod./Ind: 17.06.2009/PANGERL / / /
Cont.: 114 NTTKE Andreas Scheck Mod: DOTR 120000 / 110
15.01.2010 11:16:56
===========================================================================
Pos.1: 6,25
Pos.2:
1,2,3,9,10,21,22,28,29,30,41,42,43,44,45,
46
Pos.3: 4,7,23,26
Pos.4: 5,8,24,27
*
Dichtungsmaterial: Pa6
Seals
*
Umgebungstemperatur: min. = -25°C
Ambient temperature
*
Korrosionsschutz:
Corrosion protection
ANSTRICH FV-A1/C4-RAL7033
___________________________________________________________________________
0020 AC600. 4 ST 594153 RM220149 4,240
20 YGEB
SPACING STRIP FOR 2 RADIATOR-585-665-tZn
FL DIN 1017- 40* 5* 705-RSt 37-2
*
before storage paint with
RAL7033-AC/IC in cost center 1350K
___________________________________________________________________________
0030 AC600. 6 ST 594153 RM220150 12,060
20 YGEB
SPACING STRIP FOR 3 RADIATOR-605-645-tZn
FL DIN 1017- 40* 5*1330-RSt 37-2
*
before storage paint with RAL7033-AC/IC
in cost center 1350K
___________________________________________________________________________
0040 AC600. 4 ST 594154 RM220151 6,520
20 YGEB
SPACING STRIP FOR 2 RADIATOR-585-665-M.
VA-tZn
FL DIN 1017- 40* 5*1135-RSt 37-2
*
___________________________________________________________________________
***************************************************************************
17.06.2009 52 1 ST 7.575,794 RRAD
15.01.2010 11:16:56
===========================================================================
0050 AC600. 6 ST 594154 RM220152 15,240
20 YGEB
SPACING STRIP FOR 3 RADIATOR-605-645-M.
VA-tZn
FL DIN 1017- 40* 5*1760-RSt 37-2
*
___________________________________________________________________________
0060 AN701 26 ST 211654 HV0054 338,000
20
VENTILATOR-SK520- 6-G804021-KST-7033-C5M
0,37 KW; 50 HZ, 240 V/415 V;
2,30 A/1,35 A; 370 W; 950 1/MIN;
1,95 M3/S FREIBLASEND; 65,0 DB(A)/1M
FABRIKAT: Schormann
ZEICHNUNG: 3 SA6598
BEFESTIGUNGSBOHRUNGEN NACH
ZEICHNUNG: G804021
ANSTRICH: Stoff-Nr.15 RAL7033
Korrosionsschutz: C5M
WERKSTOFFE:
-LAUFRAD: KUNSTSTOFF
-GEHÄUSE: SILUMIN
-MOTORGEHÄUSE: ALUMINIUM
-MOTORAUFHÄNG.: ALUMINIUM
-SCHUTZGITTER: NICHTROSTENDER STAHL
-VERB-ELEMENTE: A2
-VERBINDUNGSELEMENTE FÜR ELEKTRISCHE
ANSCHLÜSSE: CU2/VNI
___________________________________________________________________________
0070 AN701. 26 ST 53450 RK514203 9,854
50 X
LUEFTERBEFESTIGUNG KPL.
___________________________________________________________________________
***************************************************************************
17.06.2009 52 1 ST 7.575,794 RRAD
211654_M______1_
Schormann GmbH
Transformers – Accessories – Edition : 01/09/09
DIN EN ISO 9001
Zertificate 01 100 00012
OPERATING AND SERVICING INSTRUCTIONS FOR FANS

SIMILAR TO DIN 42565
TYPE : SK 350, SK 400, SK 450, SK 470, SK 520, SKS 470, SKS 520
GENERAL
This type of fan does not require any special serving during operation. Its construction
is shown on the attached drawing.
However, it is recommended to treat the fan in accordance with the instruction as given.
Due to mint conditions of the fan, motor might be noisy at first start up of operation.
For the new bearings, gaskets and grease, a run-in period of approx. 2 hours is required.
Fan must be in operation from time to time.
If the fan is stationary for long periods, it should be switched ON for minimum of two
hours every month to remove any moisture that may have condensed within the motor.
To avoid condensation water inside of the motor, special measures must be taken if long
storage is necessary. Huge differences in temperature and the possibility that water can
infiltrate are to eliminate.
OPERATING INSTRUCTIONS
1. TRANSPORT
When transporting the fan avoid jolts and vibrations as far as possible so the bearings
of the drive motor will not get damaged.
2. MOUNTING
When mounting the fans make sure that the direction of the air stream is vertical upwards
i.e. from the motor towards the fan-wheel. Otherwise interchange the connections at the
terminal box at the bottom of the motor.
For motors mounted with shaft vertical, the condensation water drain must be open.
3. ELECTRICAL CONNECTION
The fan is connected by means of the terminal box provided at the motor. The terminal
box is equipped with 2 glands PG 16 to enable several fans to be connected in parallel
and to simplify the wiring.
The fan casing is provided with a rating plate containing the datas of the fan.
4. PROTECTION
Fan quards are fitted in both sides of the fan blade.
CAUTION ! Only remove the fan quards when the fan is turned off.
5. MAINTENANCE AND LUBRICATION
5.1. FANS
Maintenance of the fan is confined to an occasional cleaning because of the closed

type of construction.
However , in cases of longer intervals during operation in the winter time check the
fan to make sure the fan - wheel is free from ice and snow as otherwise undue
out-of-balance forces may be caused.
5.2. MOTOR
The motor does not require any special maintenance. However , it is recommended
to check the motor from time to time for smooth running.
Damaged bearings make themselves noticed by noisy running of the motor. Because
of the danger of pollution it is advised when testing the play of bearing not to dismont
the caps of the bearings and not to remove the sealing sleeves . When the motor is
dismantled and the rotor removed it can be determined without difficulty whether the
bearings are in order or if they have to be exchanged.
The fan motor is designed for continous operation with amply proportioned encased
ball bearings.
Lubrication is sufficient for approx. 35 000 working hours , that is equal to an

uninterrupted running time of approx. 4 years. Consequently no lubricating facilities
are provided for the bearings . For repair or checking of bearings the fan must be
dismounted and the motor disanssembled.
Remove the draining plug at the bottom of the motor when the fan is in operation.
To secure the drain of condensate the drain hole must be open when the fan is in
operation.
6. DISASSEMBLING AND ASSEMBLING
Dismantle the motor only when the fan is dismounted . Remove the screws by means
of which the motor is fastened to the fan casing and take out the motor with fan-wheel.
For further dismounting it will be useful to put the motor on an adequately clean
surface.
Remove the cap nut on the fan-wheel. Loosen the pinch screw and the loocking screw
and withdraw the fan-wheel by means of an extractor.
Remove the srews of the bearing plate and remove each bearing plate loosening it by
slight blows with a wooden or rubber hammer. Withdraw the rotor from either side,
making sure not to damage the stator windings in the process . Only remove the
encased ball-bearings from the motor shaft if it is necessary to exchange them
because of damage.
For withdrawing ball-bearings only use an extractor. Take special care when pushing
new bearings onto the shaft. Under any circumstances avoid fitting the bearing edges,
shoulder , cages or rollers as hereby the bearings could be damaged.
Crease or oil the bearing seats before fitting new bearings .
Use only identical bearings.
Following methodes may be applied for fitting new bearings :
a) Driving bearings onto the shaft means of hammer and soft metal punch or tube .
Strike evenly with the hammer so bearing does not tilt.
Preferably use tubes having a cap with rounded-off impact surface, as these warrant
concentric application of power.
b) With the aid of mechanical or hydraulic presses, especially where a large number
of bearings is concerned . For this purpose use similar tube as described under a ).
c) By warming up the bearings to approx. 80° C . This may be done in an oil bath
in an oven.Hereby make sure that the temperature in any section of the bearings does
not exceed 90° C, as otherwise the degree of hardness will be reduced or the sealing
sleeves will be damaged. Both the container and the oil must be absolutely clean.
The bearings should be hanging free inside the oil bath . For handling the bearings
use only use clean, not fuzzing rags or suitable tongs.
When pushing the warmed up bearings onto the shaft make sure it fits properly at the
shaft collar.
Reassemble the motor after repair or cleaning in reversed order.
Place the motor into the casing. Adjust the motor and the fan-wheel so that there is a
symmetrical clearance between the rotating blades and the fan casing . The srews
should not be tightened before . Check once more the clearance between the blade
tips and the fan casing.
7. CLEANING AND LUBRICATION OF THE BEARINGS
Encased ball bearings do not require cleaning and re-lubrication. Do not remove the
bearings from the shaft when checking.
Check the bearing cage and bearing balls for damage and wear . Check the bearing
play, i.e. the space between ball race and cage. Make sure that the sealing sleeves of
the bearings do not get damaged when checking.
Damaged and worn bearings must be exchanged.
Bearing type : A-side : Nr. 6202-Z , B-side : Nr. 6202
Machinenfabrik Schormann GmbH

Greisberger Straße 43 – 45 ; 51399 Burscheid
Phone +49 (0)2364 9385-0
Fax +49 (0)2364 9385-50
e-mail info@schormann.de
hompage http : //www.schormann.de
Installation Instruction
1 . 7 . 1 - 8 . 16 Process: Outdoor installation
Title: Terminal box lids on fans
Created: QW Effective: 17/07/2006
Released: QW
Distribution: Intranet, QW, NTVS, NTTK
General:
This work must always be performed prior to commissioning but not until after the equipment has
been set up on site. If the transformer is to be store for an extended period (i.e. idle, out of service
for more than 4 weeks) then the drain plugs are to remain in the lid and must be subsequently
removed by the customer.
Horizontally mounted fans (hanging under the radiators):
The drain plugs on the fans' terminal boxes are to be removed.
Vertically mounted fans:
These plugs may not be removed. Because of this, if the labels are not painted over then the
labels are to be removed.
Replaces: MA_2.050 Page 1 of 1

Revision: -
Starkstrom-Gerätebau GmbH Montageanweisung_Lüfter 1.7.1-8.16-
Englisch
OPERATING MANUAL
22 AP, AT, AX
SAP No.: 112010276/20 Page: 169

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OPERATING MANUAL
SAP No.: 112010276/20 Page: 170

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
AP PUMP UNITS
AT DRYING AND FILTER EQUIPMENT(DEHYDRATING REATHERS)
AX TESTING AND MONITORING EQUIPMENT
AT 001 Silica gel breather DIN 42562 - L2
AT 005 Silica gel breather DIN 42562 - L2
SAP No.: 112010276/20 Page: 171

Order No.: 1431517
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SAP No.: 112010276/20 Page: 172

Order No.: 1431517
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OPERATING MANUAL
23 BB, BQ
SAP No.: 112010276/20 Page: 173

Order No.: 1431517
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SAP No.: 112010276/20 Page: 174

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
BB CONTAINERS,RESERVOIRS,ACCESSORY CAINETS,TERMINAL BOXES
BQ SUPPORTS,BEARING EQUIPMENT,FRAMEWORKS,CABLE DUCTS
BQ 011 Thermometerpocket DIN EN 50216-4-type A1
(spare)

594284-RM220002
BQ 051 Safety cable
SAP No.: 112010276/20 Page: 175

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OPERATING MANUAL
SAP No.: 112010276/20 Page: 176

Order No.: 1431517
Serial No.: 150 556
15.01.2010 11:16:25
===========================================================================
0010 1 1 ST 105211 HF1155 0,195
20 X
Screw plug DIN 910 G1A -St A4H
___________________________________________________________________________
0020 2 1 ST 161321 RM200670 0,001
20 X
fl.gasket-33-39-NP815
D1=33 D2=39 S=1.50
___________________________________________________________________________
***************************************************************************
22.09.2009 50 X 1 ST 0,196 RM220002
Cre/Mod./Ind: 22.09.2009/KNORR / / /
Cont.: Mod: DOTR 120000 / 110
bolt assembly for thermometer jacket-
St A4H/NP815
OPERATING MANUAL
24 BR, BS, BZ
SAP No.: 112010276/20 Page: 177

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 178

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
BR PIPELINES,DUCTS
BS NOISE REDUCTION COMPONENTS
BZ MISCELLANEOUS COMPONENTS
BZ 050 Filling hole G2A
BZ 054 Filling hole G2A
BZ 115 Fastening for roller
(diagonally mounted)
BZ 133 Earthing terminals DIN 48088 - B - 2xM12
Drawing or description 594075-RYM203636
SAP No.: 112010276/20 Page: 179

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 180

Order No.: 1431517
Serial No.: 150 556
15.01.2010 11:16:35
===========================================================================
0010 1 1 ST 594372 RM223391 0,300
20 X
cap-G2 MS -(6KT)
surface for seal(outside-ø= 60 mm)
turn off - including thread cutting
*
back-up for M221245
___________________________________________________________________________
0020 2 2 ST 161121 RM200580 0,010
20
fl.gasket DIN 42539-O - 250-NP815
D1=38 D2=60 S=1.50
___________________________________________________________________________
***************************************************************************
22.09.2009 50 X 1 ST 0,310 RM221244
Cre/Mod./Ind: 22.09.2009/KNORR / / /
Cont.: Mod: DOTR 120000 / 110
filler base complete-G2 A-MS
15.01.2010 11:16:39
===========================================================================
0010 1 2 ST 597517 RM223162 1,580
20
fastening for roller-tZn
Position 1-3 hot-dip galvanized
___________________________________________________________________________
0020 2 2 ST 032454 RM221697 0,350
20 X
Threaded rod DIN 976-1- M10* 350-A-A2-70
___________________________________________________________________________
0030 3 4 ST 120153 HF0040 0,016
20 X
(formerly DIN 125-A)
___________________________________________________________________________
0040 4 4 ST 110354 HF2112 0,048
20 X
(formerly DIN 934)
___________________________________________________________________________
***************************************************************************
01.07.2009 50 X 1 ST 2,000 RM223161
Cont.: Mod: DOTR 120000 / 110
fastening for roller F. K,L,M
15.01.2010 11:17:02
===========================================================================
0010 1 1 ST
*HINWEIS FUER KT
*GEWINDEAUGE-M12-nrSt (M203630)
**
*Kontaktfläche "blank" und beim
*spritzen abgedeckt
___________________________________________________________________________
0020 2 1 ST 120253 HF0049 0,006
20 X
___________________________________________________________________________
0030 3 1 ST 100254 HF1536 0,034
20 X
Hexagon head screw ISO 4017-M12* 25-A2-70
(formerly DIN 933)
___________________________________________________________________________
***************************************************************************
22.09.2009 50 X 1 ST 0,040 RYM203636
Cre/Mod./Ind: 22.09.2009/KNORR / / /
Cont.: Mod: DOTR 120000 / 110
earth complete-M12
(without part1)
OPERATING MANUAL
25 CE, CF
SAP No.: 112010276/20 Page: 181

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 182

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
CE ELECTICAL VARIABLES(E.G. INSTALLATION–TRANSFORMER)
CF FLOW MEASURING EQUIPMENT
(BUCHHOLZ RELAY, PRESSURE/ VACUUM RELAY,
PRESSURE SURGE PROTECTION,OIL AND AIRFLOW
INDICATORS OR WATER FLOW INDICATORS, ETC.)
CF 050 Buchholz relay DIN 42566 - DR 80
for transformer tank
make EMB type 09-26.24.-0236
2 two way contacts
CF 061 Relay for tap changer
make MR type RS 2001
1 two way contact
Drawing or description 059/07/01/0
SAP No.: 112010276/20 Page: 183

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 184

Order No.: 1431517
Serial No.: 150 556
223013_M215330
Elektromotoren und
Gerätebau Barleben GmbH
Transformer Protection Relays

(Buchholz Principle)
1
Elektromotoren und
Content
Item No. Heading Page
Firm’s history 3
Preface 3
1. Design features 4
2. Function 6
3. Tests 7
4. Type list 8
4.1. Single-float Buchholz relays with thread connection 8
4.2. Single-float Buchholz relays with flange connection 8
4.3. Single-float Buchholz relays – possible switching system designs 9
4.4. Double-float Buchholz relays with thread connection 10
4.5. Double-float Buchholz relays with flange connection (round) 11
4.6. Double-float Buchholz relays with flange connection (square) 13
4.7. Buchholz relays according to Chinese norm 13
4.8. Buchholz relays according to French norm 14
4.9. Buchholz relays according to British standard 15
4.10. Double-float Buchholz relays – possible switching system designs 16
5. Technical data 20
6. Special designs 21
6.1. Explanations to identif. no. 32 22
6.2. Explanations to identif. no. 60 22
7. Ordering data 23
8. Additional devices for Buchholz relays 24
9. Further protection devices 27
2
Firm’s history Preface
Since its foundation the company has been The Buchholz relay was developed in 1921 by Max
passed through an eventful history with regard Buchholz, Oberrat at the Prussian Electric supply
to ownership, affiliation and connected with this company - PLC in Kassel.
changes of firm names. Since that time it has been an important protection and
monitoring device for liquid-cooled transformers and
choke coils. It is known for its easy operation, high
reliability, maintenance-free operation and extremely long
1863 Foundation of the company life.
as sugar factory It is built in the cooling cycle of the appliances to be
protected and responds in the event of troubles like gas
1943 Establishment of SIEMENS accumulation, loss as well as high flow of the insulation
Magdeburg liquid. Furthermore single-float Buchholz relays are used
as “Air Cell Failure Relay” for monitoring the tightness of
1948
1
VEB Elektromotorenwerk a rubber bag (air bag) inside the expansion vessel.
Barleben; VEM
(state-owned firm)
The company has had for more than 50 years experience
1951 1
VEB Starkstromanlagenbau in producing Buchholz relays and other protection
Magdeburg devices for liquid-cooled appliances. It ranks among the
(state-owned firm) most distinguished manufacturers of this kind of
equipment.
1951 Start of manufacturing Experiences collected and profound know-how are the
Buchholz relays at site sound basis for a high product quality. References from
in Barleben reputed transformer manufacturers and further users are
proof of the high level of the products.
1970 VEB1 Elektrotechnik und The company is ISO 9001/2000 certified.
Gerätebau Magdeburg;
EGEM
(state-owned firm) The staff of highly qualified engineers and experienced
skilled workers do their best to guarantee top quality
1980 VEB1 Kombinat high-precision products.
Elektromaschinenbau Dresden The mechanical working of the casings is done on
VEB1 Elektromotorenwerk modern CNC-controlled machine tools. The final tests,
Barleben; VEM; ELMO where all the functions of the Buchholz relays are
(state-owned firm) checked, are done with each device by using special test
equipment.
1990 VEM Antriebstechnik AG Each device is delivered with a test certificate.
Dresden
Elektromotorenwerk Barleben
GmbH; VEM; ELMO The type diversity of the Buchholz relays is tailored to
(public limited company) norms and standards as well as to special customer
demands.
1993 Elektromotoren und EMB-Buchholz relays are in compliance with EN 50216.
Gerätebau Barleben GmbH;
EMB The type of relay to be used depends on nominal rating
(privately owned company) and construction features of appliance to be protected.
Our range of products permits optimum adaptation to
actual requirements.
Buchholz relays may be used in open-air or also in indoor

equipment.
1
VEB = nationally owned firm
3
Elektromotoren und
1. Design features
Casing
(Figures 1A and 1B)
The casing is a weather-resistant
casting of light alloy and is provided
with a paint coat. It is supplied either
with screwed or flanged ends (1).
The variants of casings are shown
under para. 4, further are possible on
request.
The casing has sightglasses (2) for
inspection of function of the switching
systems. The sightglasses with scale 2
divisions permit reading of collected
gas volume. 3
The relays can be equipped with lids
(3, may be folded up) before the 1
sightglasses.
Figure 1A: casing with
flange connection
Figure 1B: casing with
thread connection
Cover (Figure 2)
8
The cover is a weather-resistant casting
of light alloy and is provided with a paint
7 coat. Terminal box (1), test valve (2) and
5 test key, covered by a cap nut (3) as well
as a plate for operation of the test key (4)
are arranged above the cover. The
terminal box has an earthing contact (5)
9 and at most eight electrical connectors
9
(6). By the number of these connectors
6 the design of the switching systems
concerning kind and quantity of the
1 magnet contact tubes is determined.
The aluminium cap (7) seals the terminal
box. If the cap is opened the contact
setting (8) can be seen.
The cable may be optionally brought in
3 through one of both cable glands (9).
2
4
Figure 2: cover with dismantled cap
4
Switchgear (Figures 3A and 3B)
The switchgear has the following main components:

Switching system
Carrier, frame
Mechanical testing device.
Whereas the single-float Buchholz relay has only one switching system, the double-float Buchholz relay
has an upper and a lower switching system.
Permanent magnet and float are rigidly linked forming an unit that is movably fitted to the frame together
with mechanical testing device and magnet contact tube(s).
Switchgear of a single-float
Buchholz relay:
float (1)
permanent magnet (2)
one or two magnet contact tubes (3)
frame (4)
mechanical testing device (5)
damper (6)
1
5 The damper is hold by permanent magnets.
2
6 3
Figure 3A: Switchgear of a single-float

Buchholz relay
Switchgear of a double-float
Buchholz relay:
upper float (1)

lower float (1a)
permanent magnet for upper float (2)
permanent magnet for lower float (2a)
one or two magnet contact tubes for
upper switching system (3)
one or two magnet contact tubes for 1
lower switching system (3a)
frame (4) 5
2
mechanical testing device (5)
damper (6)
3
The damper is hold by permanent magnets and acts
on the lower switching system. 6 3a
4 1a
2a
Figure 3B: Switchgear of a double-float

Buchholz relay
5
Elektromotoren und
2. Function
In the following the operation of a Buchholz relay is explained using the example of a double-float
Buchholz relay.
The relay is built in the connecting pipe between the transformer tank and the conservator. During
normal operation it is filled completely with insulating liquid. Due to buoyancy the floats are at their top
position. If a fault occurs inside the transformer, the Buchholz relay responds as follows:
Gas accumulation (Figure 4)
Fault: Free gas is available in the insulating

liquid.
Gas
Response: The gas in the liquid moves
upwards, accumulates in the Buchholz relay
and displaces the insulating liquid level. The
moving float actuates a switch element (magnet Oil
contact tube).
An alarm signal is tripped.
The lower float is not affected as from a certain
gas volume the gas flows through a piping to
the conservator.
Figure 4: Gas accumulation
Insulating liquid loss (Figure 5)
Fault: Insulating liquid loss due to leakage.

Response: As the liquid level falls the top float
moves downward. An alarm is tripped. If the
liquid loss continues, conservator and piping as
well as the Buchholz relay will be emptied.
Air
As the liquid level falls, the lower float moves
downward. The moving float actuates a switch
element so that the transformer is Oil
disconnected.
Figure 5: Insulating liquid loss

Insulating liquid flow (Figure 6)
Fault: A spontaneous incident generates a

pressure wave moving in the direction of the
conservator.
Response: The liquid flow reaches a damper
arranged in the liquid flow. If the flow rate
exceeds the operating threshold of the damper, Oil
the latter moves in flow direction. Due to this
movement a switch element is actuated so that
the transformer is disconnected.
Figure 6: Insulating liquid flow
The upper and lower switching system form a functional unit in the single-float Buchholz relay. In case
of a fault, the single-float Buchholz relay normally isolates the transformer immediately from the mains
system.
6
3. Tests
To each Buchholz relay a works-number is given mentioned in the test certificate. Furthermore, the
tests made with each Buchholz relay are documented in the test certificate:
- Dielectric strength test

(AC 2000 V against casing)
- Leakage test
(25 min with 80o C warm Transformer oil at 0.25 MPa)
- Functional test
(damper setting, switching systems).
The Buchholz relays are delivered in transport

cardboards. In the cap nut of the test key there is a
temporary lock for the switching system. This temporary
lock has to be removed before the device is taken into
operation.
With each device we deliver

in the agreed language:
- operating instructions
- test certificate.
DIN EN ISO 9001:2000 certificate
Flow test Functional and leakage test
7
Elektromotoren und
4. Type list
4.1. Single-float Buchholz relays with thread connection
Type code no. Mode of DN Flange Device weight Suited for

Works-design. connection of pipe dimensions dimensions (kg) transformer
DIN-design. (mm) (mm) (mm) ratings of
d1 d2 d3 d4 d5 f l h1 h2
01 Connection
(AG 25) thread 25 - - - - 16 185 170 62 3.1 < 1600 KVA
(CG 25) G 11/2 “
4.1.1. Type 01
170
250
300
350
3
cm
f
d1
l
G 11/ 2"
4.2. Single-float Buchholz relays with flange connection

d1 d2 d3 d4 d5 f l h1 h2
02
Flange
(AF 25/6) 4-holes 25 100 75 60 12 12 185 195 62 3.6 <1600 KVA
(-)
03
Flange
(AF 25/10) 4-holes 25 115 85 68 14 16 200 205 62 4.0 < 1600 KVA
(-)
25
Flange
(AF 25) 4-holes 25 100 75 -- 12 10 160 195 62 3.3 < 1600 KVA
(-)
(These types are also used as „Air Cell Failure Relay“.)
4.2.1. Type 02, 03, 25

1 70
250
300
350
cm3
f d1
l d4
d3
d2
8
4.3. Single-float Buchholz relays - possible switching system designs
As switching elements are used magnet contact tubes. There are normally-closed (NC), normally-
open (NO) or change-over (CO) versions.
For coding of the switching system version see point 7. ordering data, page 23.
The magnet contact tube version is coded by the last figure of the ordering number.
...01 ...02 ...03 ...04 ...05 ...06

1 NO 1 NC 2 NO 2 NC 1 NO and 1 NC 1 CO
13 11
13 23 11 21 13 11 1
14 12 14 24 12 22 14 12 2 4
...07 ...08 ...09

2 CO 1 NO and 1 CO 1 NC and 1 CO
21 11 23 11 21 11
22 24 12 14 24 12 14 22 12 14
Explanation of symbols: not occupied
Example: coding „ ...0 6 “
Magnet contact tube version (1 CO)
Note:
1 The switching system is shown
1 change-over
in its normal position, i.e. with
(CO) --- Graphical symbol with
the Buchholz relay filled
terminal marking
completely with insulating
2 4 liquid corresponding to trouble-
free operation of the device to
be monitored.
Terminal assignment
---
in terminal box
A plate showing the connection diagram and the terminal assignment is arranged inside the
cap of each Buchholz relay delivered by EMB.
9
Elektromotoren und
4.4. Double-float Buchholz relays with thread connection

d1 d2 d3 d4 d5 f l h1 h2
Connection
04 thread
(BG 25) 25 - - - - 16 185 235 90 4.2 < 5000 KVA
(DG 25) 1
G 1 /2 “
Connection
21 thread
(BG 25 S) 25 - - - - 16 185 235 90 3.6 < 5000 KVA
(-) 1
G 1 /2 “
4.4.1. Type 04
170
250
300
350
cm 3
l d1
G11 /2"
4.4.2. Type 21
1 50
250
300
350
3
cm
d1
l
10
4.5. Double-float Buchholz relays with flange connection (round)

d1 d2 d3 d4 d5 f l h1 h2
05
Flange
(BF 25/6) 4-holes 25 100 75 60 12 12 185 235 90 4.4 < 5000 KVA
(-)
06
(BF 25/10) Flange
(DR 25) 4-holes 25 115 85 68 14 18 200 235 90 4.8 <5000 KVA
23
Flange
(BF25/10S) 4-holes 25 115 85 68 14 18 200 235 90 4.4 < 5000 KVA
(-)
07
Flange > 5000 KVA
(BF 50/6) 4-holes 50 140 110 90 14 12 185 235 80 4.6
< 10000 KVA
(-)
08
Flange > 5000 KVA
(BF 50/10) 4-holes 50 165 125 102 18 16 195 250 80 5.9
< 10000 KVA
(DR 50)
09
Flange
(BF 80/10) 4-holes 80 200 160 138 18 15 195 265 80 6.2 > 10000 KVA
(-)
09-26.
Flange 18
(BF80/10/8) 8-holes 80 200 160 138
M16
15 195 265 80 6.2 > 10000 KVA
(DR 80)
24
Flange
(BF 80/6) 4-holes 80 190 150 130 18 15 195 260 80 6.0 > 10000 KVA
(-)
11
Elektromotoren und
4.5.1. Type 05, 06, 07, 08, 09, 24
4.5.2. Type 23
1 50
250
300
350
cm3
f d1
l d4
d3
d2
4.5.3. Type 09-26.

17 0
250
300
350 M 16
cm3
f
l d1
d4
d3
d2
12
4.6. Double-float Buchholz relays with flange connection (square)
d1 b d3 d4 d5 f l h1 h2
10 Flange
(BF 80/Q) square
4-holes
80 125 132 - 18 20 200 235 80 5.0 > 10000 KVA
(DQ 80)
4.6.1. Type 10
4.7. Buchholz relays according to Chinese norm
Type code no. Mode of DN Flange dimensions Device weight Suited for
Works-design. connection of pipe (mm) dimensions (kg) transformer
Chinese Type (mm) (mm) ratings of
d1 b d3 d4 d5 f l h1 h2
63 Flange
(BC 80) square
4-holes
80 160 160 - 18 15 185 245 80 5.0 > 10000 KVA
(QJ-80)
Further types according to Chinese norm on request.
4.7.1. Type 63
13
Elektromotoren und
4.8. Buchholz relays according to French norm

(mm) (mm) (mm) ratings of
d1 d2 d3 d5 f l h1 h2
41 Flange
(NF 25) 4-holes 25 115 85 14 8 240 235 90 4.2 < 5000 KVA
42 Flange >5000 KVA

(NF 50) 4-holes 50 165 125 18 11 240 250 80 5.1
< 10000 KVA
43 Flange
(NF 80) 4-holes 80 200 160 18 11 240 265 80 5.5 > 10000 KVA
4.8.1. Types 41, 42, 43
1 50
250
300
350
cm 3
f
d1
240
d3
d2
14
4.9. Buchholz relays according to British standard
Type code no. Mode of DN Flange dimensions Device dimensions weight Suited for
Works-design. connection of pipe (mm) (mm) (kg) transformer
(inch) (inch)
(mm) ratings of
d2 d3 d5 f l h1 h2 h3
(inch)
d1
Flange
51 - 72 M10 127 235 90 80
(BS 25)
square 25 - 2.83 M10
-
5 9.25 3.54 3.15
3.7 < 5000 KVA
4-holes
52 Flange 140 110 12 12 185 235 80 80 > 5000 KVA

(BS 50) 6-holes 50 5.51 4.33 0.47 0.47 7.28 9.25 3.15 3.15
4.8
< 10000 KVA
53 Flange 160 130 12 13 185 240 80 80

(BS 80) 6-holes 80 6.30 5.12 0.47 0.51 7.28 9.45 3.15 3.15
5.0 > 10000 KVA
4.9.1. Type 51
4.9.2. Types 52, 53
15
Elektromotoren und
4.10. Double-float Buchholz relays - possible switching system designs
As switching elements are used magnet contact tubes. There are normally-closed (NC), normally-
open (NO) or change-over (CO) versions.
For coding of the switching systems version see point 7. ordering data, page 23.
The magnet contact tube version is coded by the last two figures of the ordering number.
...11 BS 25...11 ...12 ...13 ...14 ...15

Alarm Alarm Alarm Alarm Alarm Alarm
1 NO 1 NO 1 NO 1 NO 1 NO 1 NO
13 13 13 13 13 13
14 14 14 14 14 14
Disconnection Disconnection Disconnection Disconnection Disconnection Disconnection

1 NO 1 NO 1 NC 2 NO 2 NC 1 NO and 1NC
23 11 23 33 11 21 23 11
23
12 24 34 12 22 24 12
24 24
...16 ...17 ...19 ...21 ...22

Alarm Alarm Alarm Alarm Alarm
1 NO 1 NO 1 NO 1 NC 1 NC
13 13 11 11
23
24 14 14 12 12
Disconnection Disconnection Disconnection Disconnection Disconnection

1 CO 2 CO 3 NO 1 NO 1 NC
11 21 31 23 33 43 13 21
22 24 32 34
12 14 24 34 44 22
14
16
...23 ...24 ...25 ...26 ...27 ...31
1 NC 1 NC 1 NC 1 NC 1 NC 1 CO
11 11 11 11 21
21
12 12 12 12 22 24
22

2 NO 2 NC 1 NO and 1 NC 1 CO 2 CO 1 NO
13 23 21 31 13 21 11 21 31
13
22 24 32 34 14
14 24 22 32 14 22 12 14
...32 ...33 ...34 ...35 ...36 ...41

1 CO 1 CO 1 CO 1 CO 1 CO 2 NO
21 21 21 21 21 13 23
22 24 22 24 22 24 22 24 22 24 14 24

1 NC 2 NO 2 NC 1 NO and 1 NC 1 CO 1 NO
11 33 43 31 41 13 11 11 33
12 34 44 32 42 14 12 12 14 34
14 13 34 33
17
Elektromotoren und
...42 ...43 ...44 ...45 ...46 ...51

2 NO 2 NO 2 NO 2 NO 2 NO 1 NC and 1 NO
13 23 13 23 13 23 13 23 23 33 11 13
14 24 14 24 14 24 14 24 24 34 12 14

1 NC 2 NO 2 NC 1 NO and 1 NC 1 CO 1 NO
33 43 11 21 33 11 11 23
11
34 44 12 22 34 12 12 14 24
12
...52 ...53 ...54 ...55 ...56

Alarm Alarm Alarm Alarm Alarm
1 NC and 1 NO 1 NC and 1 NO 1 NC and 1 NO 1 NC and 1 NO 1 NC and 1 NO
11 13 11 13 11 13 11 13 21 23
12 14 12 14 12 14 12 14 22 24
Disconnection Disconnection Disconnection Disconnection Disconnection

1 NC 2 NO 2 NC 1 NC and 1 NO 1 CO
21 23 33 21 31 21 23 11
22 24 34 22 32 12 14
22 24
18
Explanation of symbols: Magnet contact tube version
Upper switching system - Alarm
Example: coding „ ...1 2 “
Magnet contact tube version

Lower switching system - Disconnection
13
Alarm
1 NO
14
--- Graphical symbol with
terminal marking
11
Disconnection
1 NC
12
Terminal assignment
---
in terminal box
Note:
The switching systems are shown in their normal position, i.e. with the Buchholz relay filled
completely with insulating liquid corresponding to trouble-free operation of the device to be
monitored.
A plate showing the connection diagram and the terminal assignment is arranged
inside the cap of each Buchholz relay delivered by EMB.
19
Elektromotoren und
5. Technical data
The technical data listed in table 1 are valid for all Buchholz relays manufactured by EMB.
More options are mentioned in table 2 on page 21. These additional special designs should
be coded with the relevant identification number when ordering Buchholz relays.
Table 1
Parameter Data Notes
Nominal voltage AC 230 V 12 V to 250 V

DC 230 V 12 V to 250 V
Nominal current AC 2 A 0.05 A to 2 A
DC 2 A 0.05 A to 2 A
Contact voltage capacity AC 1000 V --
Insulation voltage capacity AC 2000 V Contact against casing
Temperature range:
- ambient temperature -40oC to +55o C Climate acc. to
-40o F to +131o F DIN EN 60068-2-78: 2002-09
- working range
* temperature of the insulation liquid -40oC to +115oC Others on request
-40o F to +239o F
* viscosity of the insulation liquid < 1100 mm2/s

Shock resistance class 4M6
- Earthquake / Vibration 2g (peak value) frequency --

range 2Hz to 200 Hz
- Impact 25g / shock duration 11 ms --

Resistance to pressure 0.25 MPa --
Resistance to vacuum < 2.5 kPa --
Insensitivity to 25 mT --
magnetic fields
Switching system:
- Number of switching elements per
switching system 1 More on request
- Switching element magnet contact tube --
- damper hold by magnets --
- Response time of damper < 0.1 s --
Response of switching system in

case of:
3 3
- Gas accumulation 200 cm to 300 cm --
- Flow of insulation liquid

nominal diameter (DN) 25 mm 1.00 m/s + 15%
Others on request
nominal diameter (DN) 50 mm 1.00 m/s + 15%
Please, see also ordering data
nominal diameter (DN) 80 mm 1.00 m/s + 15% or on page 23.
1.50 m/s + 15% or
2.00 m/s + 15%
Cable gland M 20x1.5 Others on request
Nominal installation position 1o ascending towards 0o to 5o
expansion vessel
Degree of protection IP 54 Others on request
20
6. Special designs
Table 2
Explanation Identif. no.
Insulation liquid silicone oil * 20

Insulation liquid based on ester * 21
Climatic version (extreme frigidal open-air climates below - 40 °C) * 34

Climatic version (sea climate) * 36
Degree of protection IP 56 38
Degree of protection IP 66 39
Special design approved by RWE, Germany 24

With premounted Harting connector 59
Casing colour RAL 7001 (silver-grey) * 41

Casing colour RAL 7012 (basalt-grey) * 42
Casing colour RAL 7022 (umber-grey) * 43
Casing colour RAL 7033 (cement-grey) * 44
Casing colour RAL 7038 (agate-grey) * 45
Casing colour RAL 7035 (light-grey) * 46
Casing colour RAL 7016 (anthracite-grey) * 47
Casing colour RAL 9002 (grey-white) * 48
Casing colour RAL 7032 (siliceous-grey) * 49
Upper switching system equipped with two magnet contact tubes 35

Lower switching system equipped with two magnet contact tubes 25
Upper and lower switching system each equipped with two magnet contact tubes 33
Lower switching system equipped with three magnet contact tubes 99
Testing of the switching systems by means of compressed-air and test key 32

Damper hold in response position 23
With oil drain plug (only double-float Buchholz relays) 28
Special request (on special agreement with customer) * 29
NM series – Buchholz relay with analog measurement of the gas volume 60
* These identification numbers you also can use for ordering gas sampling device ZG 1.2.
Casing colour: two-component polyurethane-based structural coating
Attention: For constructional reasons the following special designs are not combined possible in
the same device.
identif.no. with identif.no. identif.no. with identif.no.

23 32 99 23
23 33 99 32
32 33 99 33
32 25 99 35
32 35
21
Elektromotoren und
6.1. Explanations to identif. no. 32
For Buchholz relays of special design (identif. no. 32), the
2 3 1 mechanical function of the two switching systems can be tested
by means of test button (1), and the upper switching system
(alarm) can be tested by pumping in air via the test valve (2)
using a suitable test pump. Additionally, the switching systems
can be tested pneumatically. To this end, air is supplied via an
air supply nipple (3) provided with a check valve.
Pneumatic test of the upper switching system (alarm)
using compressed air:
Air is introduced slowly into the Buchholz relay until the alarm
contact is tripped when the upper float is lowered.
4 Pneumatic test of the lower switching system
(disconnection) using compressed air:
Through the air supply nipple and the pipe (4) air is applied
suddenly to the damper. When the damper responds the
disconnection contact is tripped. The response value of the
damper is not checked.
After any test using air, bleed the Buchholz relay through the
test valve (2).
The functional test using compressed air results from British Standard B.E.B.S. T2 of 1966.
6.2. Explanations to identif. no. 60

The principal construction of the Buchholz relay with
floats and damper as well as their electro-mechanical
functions have been maintained.
Buchholz relays of series NM are equipped
additionally with a capacitive sensor (1). The
sensor is installed in the cover of the Buchholz relay.
The cover of the terminal box accommodates the 1
electronic amplifier of the measuring unit. Sensor and
amplifier are connected by a cable connector.
The measured value is based on capacitance
variation of the sensor caused by variation of the
insulating liquid level in the Buchholz relay.
Analog measurement of the gas volume is possible 350

between 50 cm3 and 300 cm3. Lower gas volumes
300
cannot be measured reliably because of high
[cm³]
inaccuracies. Measurements beyond this range are

volumeinin[cm³]
250
not necessary as in this case the upper switching 200

system will respond. Besides, the construction of the
Gasvolume
150
Buchholz relay (larger gas volumes escape towards
Gas
the expansion tank) does not allow such 100
measurements. The operating point of the upper 50

switching system (upper float) is a gas volume of
200-300 cm3. 0
0 5 10 15 20
Output signal of the messuring unit [mA]
Further information:
“Technical information and Operating instructions

Transformer Protection Relay
(Buchholz principle)
Series NM”
22
7. Ordering data
For placing orders, please, use the following key:
Single-float Buchholz relays Double-float Buchholz relays
XX - XX ... XX .- X 0 X XX - XX ... XX .- XX X X
Type code no. Type code no.
(see para. 4) (see para. 4)
Special design
Special design
(see table 2)
(see table 2)
(There are several
(There are several
identif. no. possible,
always separated by
always separated by
a dot.)
a dot.)
Damper setting (m/s) Damper setting (m/s)

1= 0.65 01= 0.65 11 = 1.20
2 = 1.00 02 = 1.00 12 = 1.25
3 = 1.50 03 = 1.50 13 = 1.30
04 = 2.00 14 = 1.40
05 = 2.50 15 = 1.80
06 = 3.00
0 = not occupied
Contact setting of upper
switching system
(alarm)
Contact setting of
1 = one NO-contact
switching system
2 = one NC-contact
1 = one NO-contact 3 = one CO-contact
2 = one NC-contact 4 = two NO-contacts
3 = two NO-contacts 5 = one NO- and
4 = two NC-contacts one NC-contact
5 = one NO- and one
NC-contact Contact setting of lower
6 = one CO-contact switching system
7 = two CO-contacts (disconnection)
8 = one NO- and
one CO-contact 1 = one NO-contact
9 = one NC- and 2 = one NC-contact
one CO-contact 3 = two NO-contacts
4 = two NC-contacts
5 = one NO- and
one NC-contact
6 = one CO-contact
7 = two CO-contacts
9 = three NO-contacts
For possible switching system designs, please, see for single- Important remark:
float Buchholz relays on page 9 and for double-float Buchholz NO = normally-open
relays on pages 16-18. NC = normally-closed
CO = change-over
Ordering example:
Buchholz relay 10-25.28.-0313 10 = designation of a double-float Buchholz relay type 10 (BF 80/Q)
25 = lower switching system equipped with 2 magnet contact tubes
28 = oil drain plug
03 = damper setting 1.50 m/s
1 = contact setting of upper switching system - 1 NO-contact
3 = contact setting of lower switching system - 2 NO-contacts
23
Elektromotoren und
8. Additional devices for Buchholz relays

designation description
ZG 1.2. Gas sampling device

The gas sampling device is mounted at the transformer
and connected to the Buchholz relay by means of a pipe.
It allows to sample the relay gas at normal operating level.
The length of the tube (pipe) will be as requested by
customer. The device can be delivered with a lockable box.
Technical data:
Gas outlet opening: R 1/8“ others on request
Oil outlet opening: R 1/8“ others on request
Viscosity of the insulation liquid: <1100 mm²/s
Temperature of the insulation liquid: -40°C to +115°C others on request
Ambient temperature: -40°C to +55°C others on request
Weight without tubing: 2.2 kg
Tubing dimension: Ø 6x1 copper tubing others on request

Tubing length: < 15 m others on request
Dimensions:
Ordering data: 90 XX ... XX . X XX,XXm

Type code
Special design 0 = without box Tubing length
for ZG 1.2. 1 = with box in meter
(see Table 2, page 21)
(There are several
always separated by
a dot.)
Ordering example:
Gas sampling device 90-34.44.-0-10,50m 90 = ZG 1.2.

34 = climatic version (extreme frigidal)
44 = colour RAL 7033
0 = without box
10,50m = tubing length 10,50 m
24
Gas testing device

The gas testing device is used to test the gas
ZG 3.1. accumulated in the Buchholz relay. It can be installed directly
on the test valve of the Buchholz relay or on the gas
outlet tap of the gas sampler. The Buchholz gas flows through two
different chemical solutions and their colour
reactions allow conclusions with regard to the type of
fault.
Testing by means of the gas testing device is no substitution
for a chromatographic analysis.
Ordering data: ZG 3.1.
Reflux lock
The device prevents that the insulation liquid gets into the
ZG 4.1. gas testing device.
The device is arranged between the Buchholz relay or
gas sampling device and gas testing device.
Test pump
ZG 5.1. The test pump (manual or pedal operated) serves to check
the function of the upper switching system (warning) of the
ZG 5.2.
Buchholz relay by pumping in air.
The test can be performed directly on the Buchholz
relay. For that purpose, the test pump is connected to
the test valve of the Buchholz relay.
When the test is performed with the help of the gas
sampling device, the test pump is connected to the gas outlet
tap of the gas sampling device.

ZG 5.2.
Oil sampling device

The oil sampling device is connected with the
ZG 6.1. Buchholz relay via a pipe and serves to take oil
samples from the Buchholz relay
(suitable for Buchholz relays with oil drain plug).
The pipe is supplied as requested by customer.
25
Elektromotoren und
BGS
Buchholzgas - Sampler
The Buchholz gas sampler serves to safely take and
transport gas samples from the Buchholz relay
or the gas sampling device.
Its capacity is 100 ml.
The gas sampled can be stored up to five days.
Ordering data: BGS
BGT Buchholzgas - Tester

The Buchholz gas tester serves to measure the
hydrogen concentration of Buchholz gases.
Measurement can be performed directly on site.
For any other gas testing equipment, please, contact us.
Ordering data: BGT
For any other information, please, ask for special reference material.
26
9. Further protection devices
ÜRF 25 Monitoring relay for tap changer

The monitoring relay for tap changers or oil
flow relay is installed in the pipe between the tap
ÜRF 25/10
changer head and the oil expansion vessel. It is
tripped in the case of inadmissibly high oil flows
towards theexpansion vessel caused by tap
changer faults.
Pipe diameter : 25 mm (1“)

Connection : flange
Flow indicator
SG 25 The flow indicator is a protective relay monitoring
circulating oil lubrication or circulating oil cooling
SF 25 of machines and equipment. It indicates faults of
circulating oil systems or shuts down the machine
or equipment, hence preventing damage.
SF 25/10 The flow indicator operates at a very low service
pressure so that it can be also installed in an oil
return pipe where the oil flow is ensured by the
sloping oil pipe.
Pipe diameter : 25 mm (1“)

Connection: thread or flange
For any other information or data required for placing an order, please, ask for
special catalogues.
27
Elektromotoren und
Bahnhofstraße 27/28
39179 Barleben / Germany
Phone : +49 39203 790

Telefax : +49 39203 5330
Telefax : +49 39203 5450
E-mail : info@emb-online.de
Internet : http://www.emb-online.de
Edition: Catalogue Buchholz relays 01/01/08/02 English
Due to technical improvement of our products, the information contained in this brochure may be
subjected to change without notice.
28
Elektromotoren und
OPERATING INSTRUCTIONS
Transformer Protection Relay

(Buchholz Principle / RWE approved)
Elektromotoren und
CONTENT
Item No. Heading Page
1. Installation 3
1.1. Installation in piping 3
1.2. Filling the Buchholz relay 4
1.3. Draining the Buchholz relay 4
1.4. Electrical connection 4
2. Functional test 6
2.1. Testing by means of test button 6
2.1.1. Single-float Buchholz relay 6
2.1.2. Double-float Buchholz relay 6
2.2. Testing by means of test pump 7
3. Maintenance 7
2
Elektromotoren und
1. Installation
1.1. Installation in piping (Figure 1)
The Buchholz relay (2) is installed in the piping (4) connecting the tank (1) of the device to be
protected (transformer, reactor) with the conservator (5).
0°...5° 0°...5°
R
5
2
>
50
0°...5°
4
R>
50
1 2 3 4 1
Figure 1 Installation in piping
Make sure that

- the red arrow on the Buchholz relay points to the conservator
- the slope of the piping to the conservator is neither below 0° nor above 5°
- oblique position of the Buchholz relay transverse to the direction of flow does not exceed 5°
related to the perpendicular
- the piping has no elbows, and bends are formed preferably with an inside pipe radius of
R>50mm
- the free pipe length between the Buchholz relay and the nearest reference point does not
exceed the following values:
Nominal pipe diameter DN 25 DN 50 DN 80

Distance (m) 0.5 0.7 1.0
Should the distance exceed the above values, a support has to be provided in the immediate
vicinity of the Buchholz relay.
During installation make sure that no dirt, moisture or foreign matter penetrates in the relay.
3
Elektromotoren und
1.2. Filling the Buchholz relay (Figure 2)
• Remove small cap nut (1) from test valve (2)
• Open test valve and let the air escape from the
Buchholz relay
• Close test valve as soon as insulating liquid comes
out
• Screw small cap nut onto test valve and tighten
Figure 2
1.3. Draining the Buchholz relay (Figure 1) Filling the Buchholz relay
• Close shutoff valve (3) on the conservator (5) side.

Open the Buchholz relay. Remove the Buchholz relay.
Lower the insulating liquid level Lower the insulating liquid level
to the top inspection glass marking to the lower interior wall of the pipe
1.4. Electrical connection (Figure 3)

The terminal box is safe to touch and protected against pollution.
To connect the cables, proceed as follows:
• Loosen screw (2)
• Swing up hinged cover (1)
• Insert cable through cable gland (3)
• Connect cable to the marked terminal stud (4)
(wire range: max. 4mm²)
• Close hinged cover
• Tighten screw
Figure 3
Note: Remove temporary lock (Figure 5, Page 6) Electrical connection
● Remove large cap nut (1)

● Remove temporary lock (2) from large cap nut
● Fit large cap nut without temporary lock
Terminal assignment is shown in the following diagrams.
4
Elektromotoren und
Single-float Buchholz relay Double-float Buchholz relay
Contact setting, Contact setting,

switching system upper switching system
(disconnection) (warning)
1 change-over contact 1 change-over contact
1 21
2 4
22 24
2 1 4
Contact setting,
lower switching system
(disconnection)
1 change-over contact
11
14 12
24 21 22 12
14 11
Explanation of symbols:
Example: Single-float Buchholz relay
11 Graphical symbol with

--- terminal marking and
identification number
12
12 11
Terminal assignment
---
in terminal box
5
Elektromotoren und
Note: The switching systems are shown in their normal position, i.e. with the Buchholz relay
filled completely with insulating liquid corresponding to trouble-free operation of the
device to be monitored.
A plate showing the connection diagram and the terminal assignment is arranged
inside the cover.
Connected load: Voltage AC 12 volts to 250 volts

DC 12 volts to 250 volts
Current AC 2 amps cos f ≥ 0.4
DC 2 amps τ = L/R ≤ 75 ms
2. Functional test
2.1. Testing by means of test button
2.1.1. Single-float Buchholz relay (Figure 4)

• Remove large cap nut (1)
• Press test button (3) down to position 1 (stop position),
keep depressed
• Obtain verification of correct function from
control room Figure 4
Operation/testing
• Release test button
• Fit large cap nut
2.1.2. Double-float Buchholz relay (Figure 5)

• Remove large cap nut (1)
• Press test button (3) down to position 1 and keep
depressed (functional test of upper switch system)
control room
• Press test button down to position 2 (stop position) and
release (functional test of lower switching system)
• Check locking mechanism of lower switching system
(damper)
• Obtain verification of correct function from control room
• Turn test button counterclockwise
x = Actuator travel
• Fit large cap nut and tighten
Figure 5 Operation/testing
6
Elektromotoren und
2.2. Testing by means of test pump (Figure 6)
• Remove small cap nut (1) from test valve (2)

• Screw adapter (4) of hose (3) providing the
connection to the test pump onto valve nozzle
(5)
• Open test valve
• Pump air into the Buchholz relay until falling of the
(upper) float causes the magnetic switch to respond
control room
• Close test valve
• Unscrew adapter from valve nozzle
• Open test valve and let air escape
• Close test valve when insulating liquid starts to Figure 6 Testing by means of test pump
flow out
• Screw small cap nut onto test valve and tighten
3. Maintenance
Buchholz relays are almost insensitive to ambient conditions. Hence, no continuous maintenance
is required.
When renewing the paint coat, make sure that the openings provided for condensate drainage and
ventilation are kept free. The opening for drainage of condensate is located on the right side below
the flanged connection of casing and cover. The vent hole is provided on the rear side of the
hinged cover.
Buchholz relays have to be inspected and checked in accordance with the maintenance
instructions of the plant operators. The functional tests described have to be performed in
connection with such inspections.
Gas accumulations can be analysed using the gas analyser. An auxiliary device allows gas
sampling at normal service height.
7
Elektromotoren und
ELEKTROMOTOREN UND
GERÄTEBAU BARLEBEN GmbH
Bahnhofstraße 27/28
39179 BARLEBEN/ GERMANY
Phone: +49 39203 79-0

Fax: +49 39203 53 30
Fax: +49 39203 54 50
e-mail: info@emb-online.de
Website: http://www.emb-online.de
Buchholz relay – 04/02/04/02 – Englisch RWE

The parameters given in this technical information are subject to changes due to technical modifications.
8
www.reinhausen.com
Protective relay RS 2001
Operating Instructions BA 59/07
NOTE
Changes may have been made to a product after going to press with this documentation.
We expressly reserve the right to make changes to a product’s technical data and design as well as changes to
the scope of delivery.
In all cases, the information submitted and agreements concluded during processing of the quotation and order
in question shall be binding.
Contents
Contents
1 General .......................................................................................................................................................................................... 4
1.1 Safety instructions ........................................................................................................................................................ 4
1.2 Designated application ............................................................................................................................................... 4
1.3 Function ......................................................................................................................................................................... 4
2 Design ............................................................................................................................................................................................ 5
2.1 Housing ........................................................................................................................................................................... 5
2.2 Relay ................................................................................................................................................................................. 5
3 Mode of operation ................................................................................................................................................................... 5
4 Installation instructions ........................................................................................................................................................... 6

4.1 Assembly ........................................................................................................................................................................... 6
4.2 Electrical connection ..................................................................................................................................................... 7
5 Commissioning ........................................................................................................................................................................... 8
6 Response of the protective relay .......................................................................................................................................... 8

6.1 Flap valve in position "IN SERVICE" ........................................................................................................................... 8
6.2 Flap valve in position "IN SERVICE" ........................................................................................................................... 8
7 Technical Data ....................................................................................................................................................................... 9
8 Special designs ...................................................................................................................................................................... 10

8.1 Protective relay with change-over contact CO ...................................................................................................... 10
8.2 Protective relay with two reed switches ................................................................................................................... 10
9 Appendix ........................................................................................................................................................................................ 10
059/07/01/0
3
1 General
1 General
1.1 Safety instructions Installation, electrical connection and function check of

the protective relay must be carried out exclusively by suitably
All personnel involved in installation, commissioning,
qualified personnel and under strict observation of these
operation, maintenance or repair of the equipment must:
Operating Instructions.
- be suitably qualified and
- strictly observe these Operating Instructions.
Improper operation or misuse can lead to
WARNING
- serious or fatal injury,
- damage to the equipment and property of the user
It is the responsibility of the user to ensure that the relay is
and
used exclusively for the designated application and that the
- a reduction in the efficiency of the equipment.
protective relay is correctly dimensioned, particularly its
Safety instructions in this manual are presented in three tripping value.
different forms to emphasize important information. The non-observance of these Operating Instructions and
work carried out inappropriately during the installation,
electrical connection and function test of the protective
relay can put the on-load tap-changer and transformer at
WARNING risk and lead to damage to the equipment and serious injury.
This information indicates particular dangers to life and

health. Disregarding such a warning can lead to serious or
1.3 Function
fatal injury.
The protective relay is used to protect the on-load tap-
changer and the transformer when a malfunction occurs in
the diverter switch or selector switch oil compartment. It is
CAUTION triggered when the specified oil flow between the on-load
tap-changer head and oil conservator is exceeded due to a
malfunction. Connect the protective relay so that the trans-
This information indicates particular dangers to the equip-
former is immediately disconnected when the protective relay
ment or other property of the user. Serious or fatal injury
is tripped. Install the protective relay in the pipe between on-
cannot be excluded.
load tap-changer head and oil conservator considering the
installation instructions.
Since the protective relay is part of an oil on-load tap-changer
NOTE and its properties are subject to IEC 60214-1 publications in
the applicable version or a future subsequent standard, it is
This note gives important information on a certain subject. part of the scope of our delivery.
WARNING
1.2 Designated application
It is absolutely essential that the protective relay be adjusted to Connect the protective relay in such a way to ensure that
the on-load tap-changer for which it will be used. the transformer is immediately disconnected when the
protective relay is tripped.
See assignment of the tripping values to the specific MR on- Systems which only generate an alarm signal are not
load tap-changer types as stated in section 7. permitted.
If you intend to use the protective relay on other types of on-
load tap-changer and on-load tap-changers of other manu-
facturers, you can obtain the applicable tripping values from
MR.
4 059/07/01/0
2 Design
3 Mode of operation
2 Design
2.1 Housing (fig. 1: front view

fig. 2: rear view) MR
The housing consists of corrosion-proof light-metal and is

provided with flanges for the connection of pipes leading to
the on-load tap-changer head and to the oil conservator.
An inspection window is located on the front side of the
housing to check the flap valve position.
The terminals of the reed switch are housed in a terminal box,
sealed from the oil chamber of the relay by oil-tight seals. The
terminal box is ventilated by a covered opening.
In addition, two test buttons in the terminal box serve for
checking the tripping function of the protective relay as well
as for resetting the flap valve.
The terminals are protected by a clear plastic screen. 1 KHW 848-4.1
2.2 Relay (fig. 3: protective housing open) 1

The actuating element of the relay consists of a flap valve with 2
a permanent magnet. 3
This magnet serves for actuating the reed switch and for fixing
the flap valve in position "IN SERVICE". F.N 192 443
1.2 - NO
An intermediate position of the flap valve is not possible.
1 - Cable gland M25

2 - Ventilation for terminal box
3 Mode of operation 3 - Identification label KHW 851-4
2
The protective relay responds only if oil flows occur from the
on-load tap-changer head to the oil conservator. The flowing
oil actuates the flap valve which tips over into position "OFF". MR
The reed switch is thereby actuated, the circuit breakers are 2

tripped and the transformer is deenergized.
NOTE
Switching operations at rated switching capacity or at

permissible overload will not result in a response of
the protective relay.
1
1 - Flap valve 3
2 - Permanent magnet
3 3 - Reed switch KHW 852-4
059/07/01/0
5
4 Installation instructions
4.1 Assembly Test button Test button OFF

IN SERVICE
Install the protective relay in the pipe leading from the on-
load tap- changer head to the oil conservator – located as
near as possible to the on-load tap-changer head. BETRIEB AUS
RESET TRIP
SERVICE DÉCLENCHÉ
SERVIZIO INTERROTTO
SERVICIO DESCONEXION
Install the protective relay in a horizontal position and

with the test buttons upwards. The reference arrow on the
terminal box cover must point towards the oil
conservator.
Use a pipe of at least 25 mm nominal width between protec-
tive relay and on-load tap-changer head/oil conservator.
Take care to install the protective relay well supported and
protected against vibrations in this pipe connection.
KHW 853-4
NOTE 4 Cover open
The pipe from the protective relay to the oil conservator

MR
must be placed with an inclination of at least 2 % to ensure
free escape of switching gas.
Provide a stop valve between protective relay and oil conser-

vator (fig. 7).
NOTE
Install the protective relay in a place where the influcence

of magnetic fields (bushings, busbars etc.) is felt as little as
possible.
Prior to mounting check the function of the protective relay.

Open the cover of the terminal box at the 3 bolts M6/w. s. 10 5 Position "OFF" KHW 849-4
(fig. 4) and actuate:

Test button "OFF": MR
flap valve is inclined (line marker appears in the middle of the

inspection window, fig. 5).
Test button "IN SERVICE":
flap valve is vertical (fig. 6).
NOTE
Do not press both test bottons at the same time.
The associated contact positions for checking of the electrical

continuity are evident from the drawing 899084 in the
appendix.
6 Position »IN SERVICE" KHW 850-4
Always check the position of the flap valve.
6 059/07/01/0
Inclination at least a continuous 2 %
a b c d e
a – On-load tap-changer
oil compartment
b – On-load tap-changer head
c – Protective relay RS 2001
d – Stop valve
e – Oil conservator
7 899759
4.2 Electrical connection

The reed switch of the protective relay can either be provided Replace the clear plastic screen and lock the cover of the ter-
as NO or as NC contact. Other contact combinations are minal box (3 bolts M6/w. s. 10, max. torque 5 Nm).
available as special design (see section 8).
CAUTION
CAUTION
Do not dry the protective relay together with the active
Connect the protective relay into the tripping circuit of the part of the transformer.
circuit breakers of the transformer to be protected so that
the transformer is immediately disconnected by the circuit
The protective relay responds to oil flow, not to gas accumu-
breakers when the protective relay of the transformer is
lated in the protective relay. It is not necessary to bleed the
tripped.
protective relay when filling oil into the transformer tank.
Gas accumulation in the protective relay is normal.
For entering the leads use the thread-hole at the most suitable
side of the terminal box. Fit the cable gland and close the
other hole by the blind screw. The cable gland (M25 x 1.5)
WARNING
is adequate for leads with an outside dia. of 10 ...19 mm.
Potentially explosive gases (switching gases) collect in the
Remove the cover of the terminal box (3 bolts M6). protective relay while the on-load tap-changer is in
Connect the leads (terminal bolt M6, max. torque 2 Nm). operation.
Connect the protective conductor to the ground screw M6 in When you open the protective relay, make sure that there
the terminal box (max. torque 5 Nm). are no open fires or sparks in the vicinity. Otherwise a danger
of explosion exists. Wait approx. 15 minutes before you
begin further work on the protective relay so that the gases
have a chance to volatize.
059/07/01/0
7
5 Commissioning
6 Response of the protective relay
5 Commissioning
Repeat the test of the protective relay according to section 4.1 6.1 Flap valve in position "IN SERVICE"
when commissioning the transformer.
If the flap valve is in position "IN SERVICE", there may be a
In addition, check to make sure that the circuit breakers dis- fault in the tripping circuit. Check the tripping circuit. If this
connect on all sides the transformer to be protected when the does not clarify the cause, remove and check the diverter
"OFF" test button is pressed. switch insert or tap selector insert (visual check), see sec-
tion 6.2.
During the test make sure that
• the transformer stays disconnected,
• the grounding for work has not been removed on the 6.2 Flap valve in position "OFF"
transformer and If the flap valve is in position "OFF", it is essential to remove
• the automatic fire extinguishing device is deactivated. and examine the diverter switch insert/tap selector insert and
examine according to the relevant maintenance instructions.
Ensure that switch-on is not possible again until after the
protective relay is placed in the „IN SERVICE“ position by Check the tripping force of the flap valve.
pressing the other test button.
Contact MR and inquire about the tripping force, indicate the
serial no. of the on-load tap-changer.
Furthermore, the following questions must be clarified:
6 Response of the protective relay • What was the load of the transformer at the instant of
tripping?
• Was a tap-change operation performed right before or
WARNING during the tripping?
• Did any other protective devices of the transformer
Make sure to check on-load tap-changer and transformer
respond at the instant of tripping?
after the protective relay has been tripped.
Remove the diverter switch insert or the tap selector insert • Were switching operations in the network performed at
and check as described in the relevant maintenance manual. the instant of tripping?
Do not put into service before having made sure that there • Were overvoltages registered at the instant of tripping?
is no damage to on-load tap-changer and transformer. In addition to the measures described under 6.1 and 6.2,
Safety concerns prohibit to reconnect the transformer Maschinenfabrik Reinhausen or the authorized MR
without prior check as this can result in considerable representative and the transformer manufacturer should
damage to the on-load tap-changer and transformer. be informed whenever the protective relay has responded.
When the circuit breakers have been tripped by the protec-

tive relay, proceed as follows:
• Determine the instant of tripping.
• Determine the operating position of the on-load tap-
changer.
• As a precaution, block the motor-drive unit by tripping the
motor protective switch to prevent the on-load tap-
changer being actuated by remote control.
• Examine the on-load tap-changer cover. If oil leaks out,
shut the oil conservator stop valve immediately.
• Check the flap valve of the protective relay if it is in
position "OFF" or in position "IN SERVICE".
8 059/07/01/0
7 Technical Data
7 Technical Data
Housing: Tripping switch:

Outdoor design Reed switch, available on request as NO (version 1) or NC
switch (version 2). Designations of versions, see dimension
Protection:
drawing 899084 in the appendix. Other contact combina-
IP 54
tions available as special design on request, see section 8.
Relay actuation:
Electrical data for reed switches, NO contact or NC
Flap valve with aperture
contact
Vibration immunity: Switching capacity:
up to max. 3 g
• Switching capacity AC: 1.2 VA to 400 VA
Weight: • Switching capacity DC: 1.2 W to 250 W
ca. 3.5 kg Maximum admissible voltage AC/DC:
Oil flow speed of available types on response • Maximum admissible voltage: 250 V
(oil temperature 20°C): • Minimum admissible voltage: 24 V
0.65 ± 0.15 m/s Switched current AC/DC:
1.20 ± 0.20 m/s
• Maximum switched current: 2 A
3.00 ± 0.40 m/s
• Minimum switched current: 4.8 mA at 250 V
4.80 ± 0.60 m/s
Power-frequency voltage test:
Assignation of response values to the relevant on-load • Between all voltage-carrying connections and the
tap-changer type grounded parts: minimum of 2500 V, 50 Hz, test
duration: 1 min.
On-load tap-changer - current delivery program
• Between the opened contacts: minimum of 2000 V,
50 Hz, test duration: 1 min.
Frequency Response value
[Hz] [m/s] OLTC type
0.65 A, V V (without OF)
V, V V (with OF), VRC, VRE, MS,

50/60 1.20
M (without M I 1203, M I 1503)
R, RM, T, G,
3.00
M I 1203, M I 1503
G-16 2/3 Hz,

16 2/3 4.80
M-16 2/3 Hz,
On-load tap-changer - not current delivery program
Frequency Response value

[Hz] [m/s] OLTC type
0,65 A
50/60 1,20 H
3,00 M I 1800, T
059/07/01/0
9
8 Special design
9 Appendix
8 Special Designs 9 Appendix

(on request, at extra cost)
8.1 Protective relay with change-over contact CO Protective relay RS 2001,

dimension drawing .................................................................. 899084
The protective relay can be supplied with a reed switch,
including change-over contact CO (version 3). Designation of
versions, see dimension drawing 899084 in the appendix.
Other contact combinations available as special design on
request (see section 8.2).
Electrical data for reed switches, NO contact or NC

contact
Switching capacity:
• Switching capacity AC: 1.2 VA to 200 VA
• Switching capacity DC: 1.2 W to 130 W
Maximum admissible voltage AC/DC:
• Maximum admissible voltage: 250 V
• Minimum admissible voltage: 24 V
Switched current AC/DC:
• Maximum switched current: 1 A
• Minimum switched current: 4.8 mA at 250 V
Power-frequency voltage test:
• Between all voltage-carrying connections and the
grounded parts: minimum of 2500 V, 50 Hz,
test duration: 1 min.
• Between the opened contacts:
minimum of 1150 V, 50 Hz,
test duration: 1 min.
8.2 Protective relay with two reed switches

The protective relay can be supplied on request with two
independent reed switches (versions 4…6). These can be
designed as NO or as NC contacts and are galvanically isolated
from each other. See appendix, dimension drawing 899084.
Electrical data identical to versions 1 and 2 (see section 7).
059/07/01/0
10
8990842E
(Standard)
Cable gland
Inspection M25 x 1.5
window
Identification label
Gasket Gasket
Test push buttons

IN SERVICE OFF
(reset) (test tripping)
Dummy plug M25 x 1.5
The arrow must always point towards the oil pipe leading to the Plan view of test push buttons
oil conservator of the transformer. (cover removed)
Key of versions
Reed Contact positions

Version Relay designation1) switch Arrangement of terminals Design
In service Off
0.65 - NO
1 1.2 - NO A
Standard design
3.0 - NO
4.8 - NO
0.65 - NC
2 1.2 - NC B
3.0 - NC
4.8 - NC
0.65 - CO
3 1.2 - CO C
3.0 - CO
4.8 - CO
Special design against surcharge
0.65 - 2NO
4 1.2 - 2NO 2A
3.0 - 2NO
4.8 - 2NO
0.65 - 2NC
5 1.2 - 2NC 2B
3.0 - 2NC
4.8 - 2NC
0.65 - NO + NC
6 1.2 - NO + NC 1 A and 1 B
3.0 - NO + NC
4.8 - NO + NC
1)
NO - normally open, NC - normally closed, CO - change-over contact
The protective relay is to be connected in such a way that if it is energized, the power transformer is switched off immediately by the corresponding circuit breakers.
059/07/01/0
11
© Maschinenfabrik Reinhausen GmbH Phone +49 941 40 90-0
www.reinhausen.com Falkensteinstrasse 8 Fax +49 941 40 90-111
93059 Regensburg, Germany E-mail sales@reinhausen.com
BA 059/07 en • 1005/3000 • 059/07/01/0 • F0015205 • Printed in Germany

OPERATING MANUAL
26 CL, CP
SAP No.: 112010276/20 Page: 185

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 186

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
CL LIQUID LEVEL(LEVEL MEASUREMENT)
CP PRESSURE MEASUREMENT
CL 060 Dial type level gauge
2 two way contacts
CL 064 Dial type level gauge
2 two way contacts
SAP No.: 112010276/20 Page: 187

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 188

Order No.: 1431517
Serial No.: 150 556
RM225343
MESSKO MESSKO
TEMPERATURE MEASURING INSTRUMENTS

FOR TRANSFORMERS
MTO-ST(F)160 With or without fixed or adjustable limit switches,
7. Inspections Microswitches radial drive
7.1 Check for leaks Types of switches: Firmly set or adjustable MTO-ST(F)160 G With or without fixed or adjustable limit switches,
To protect the environment and maintain the microswitches
Quantity: 1 or 2 microswitches
radial drive
transformer’s operational safety it is very important to
make sure that there are no oil leaks. It is therefore Contact material: Silver-cadmium-oxide MTO-ST(F)160D With or without fixed or adjustable limit switches,
imperative to check the installation point for leaks after Rated current: Firmly set microswitches radial drive as per DIN 42 569
filling the expansion vessel. Please drain the expansion AC: 250V / 15A / cosö = 1 (black dial, yellow inscription)
vessel if leaking oil is noted. Proceed by disassembling DC: 220V / 0.25A
the oil level indicator in reverse order. Clean all parts and Adjustable microswitches 1 General Operating Instructions BA 2036
reassemble the oil level indicator with a new seal as AC: 250V / 5A / cosö = 1
specified above DC: 220V / 0.4A
1.1 Safety instructions
7.2 Limit switches Setting: Firmly set microswitches:
Remove the bayonet fixing ring. Move the pointer over 5 deg. before the MAX and MIN
the switching mark against the force of the magnetic markings
operation, maintenance or repair of this equipment must:
coupling. Perform an electrical measurement of the Different in-factory settings are
circuit state. Move the pointer by hand back into the available on request
-be suitably qualified and
home position without letting go of it. Should the Adjustable microswitches:
-strictly observe these operating instructions.
measurement not confirm the diagram, check the supply Freely adjustable over the dial range
-Improper operation or misuse can lead to
lead and related pin allocation. Now put the bayonet Line terminal: Required cable cross-sectional area
-serious or fatal injury,
fixing ring back on Min. 0.25mm²
-damage to the equipment and property of the user
Max. 2.5mm²
8. Service -a reduction in the efficiency of the equipment.
If the measures specified above do not yield the desired
results, please get in touch with our factory. CAUTION Safety instructions in this manual are presented in three
9. Maintenance High voltage peaks may occur when disconnecting different forms to emphasize important information.
The oil level indicator is low-maintenance. inductive reactances. The use of fuses should
therefore be considered. Implementation of a fuse
Technical data would reduce contact erosion. WARNING
WARNING
Materials
Mounting ring and housing:Steel plate, galvanized and 1 Microswitch MIN (red) This information indicates particular danger to life and
2 Microswitch MAX (blue) All relevant fire protection regulations must be strictly
varnished with RAL shade health. Disregarding such a warning can lead to serious
observed.
7033 or fatal injury.
Housing bottom: Aluminium 1 2 1 2
Mounting flange: Aluminium
Inspection glass: Reinforced safety glass CAUTION
Dial: Anodized aluminium
Cable gland connection: M25x1.5, galvanized brass Installation, electrical connection and commissioning
CAUTION
Float rod: Aluminium of the equipment may only be carried out by qualified,
Float: Rohacell 110, oil-resistant, skilled personnel and only in accordance with these
heat resistant up to 160 deg. Fig. 5 Terminal no. as per DIN 46 199 This information indicates particular danger to the operating instructions.
Celsius equipment or other property of the user. Serious or
Characteristic data: fatal injury cannot be excluded. It is the responsibility of the user to make sure that
Display: MIN + 20 deg. Celsius MAX the equipment is used for the specific application
Inscription: Black lettering, (for all
models designed in MESSKO only.
accordance with DIN 42 569 For safety reasons, any unauthorized and improperly
the dial is black and the NOTE executed works during installation, modification,
writing is yellow ) alteration of the equipment, electrical connection, or
Installation sites: Suitable for indoor and © Messko GmbH
Gablonzer Strasse 25 - 27 These notes give important information on a certain commissioning of the equipment, are forbidden without
outdoor installation, tropic- first consulting MESSKO!
61440 Oberursel subject.
proof. Germany
Ambient temperature: -40….+80 deg. Celsius Telephone:(+49) 6171 / 63 98-0
Degree of protection: IP 55 according to DIN VDE Facsimile: (+49) 6171 / 63 98-98
Internet: http://www.messko.de NOTE
0470-1
Email: info@messko.de
Ventilation: Fan, inspection glass non- Data contained herein may differ in details from the equipment delivered.
fogging up to 80% relative BA 2036/01/01 We reserve the right to make alterations without notice.
humidity Printed in Germany
BA2036/01/01 BA2036/01/01
MESSKO MESSKO
Insert the float rod into the borehole of the float shaft
IMPORTANT (Fig. 3.1, Pos. 7) all the way to the end stop. Please be
It is important to protect all elements against fall, shock sure to properly align the float shown in Fig. 3.1 before
and impact. Please be sure to keep the maximum tightening it to ensure that the float will be mobile as
ambient temperature at 80 degrees Celsius. shown in Fig. 3.2. Now please proceed by carefully
tightening the clamping screw (Fig. 3, Pos. 9) and
securing it with the counternut (Fig. 3, Pos. 10).
NOTE Now please separate the display element from the
sensor element at the rear of the housing edge by
Strict observation of the installation and operating removing the four screws (Fig. 2, Pos. 6). Insert the float
conditions advised in these operating and installation and float rod into the expansion vessel. Paying special
instructions is imperative. attention to the „TOP“ marking (Fig. 2, Pos. 11), please
proceed by mounting the sensor element to a seal and
3. Measuring principle carefully tightening the four fixing screws. Now plug the
The float rod (Fig. 2, Pos. 8) transmits the float’s lifting display element back onto the sensor element. Lock the
movements to a shaft (Fig. 3, Pos. 7). This shaft is magnetic coupling home by lightly rotating and jiggling it
connected via magnetic coupling to the pointer spindle in back and forth. Tighten the four screws at the rear of the
the display element. There are two different float drive housing edge.
Fig. 1 Fig. 2
modes for the oil expansion vessel (see Fig. 3):
IMPORTANT
Breathing bag -Float movement in radial direction (radial drive)
radial axial The display element and the sensor element are
-Float movement in axial direction (axial drive)
perfectly adjusted to each other. Please use only the
original display element for its counterpart sensor
The design featuring float movement in axial direction element.
(axial drive) is best suited for use in narrow or flat
expansion vessels allowing only minimal float 5.2 Electrical installation
movements. Float movements can be rendered at a ratio (with incorporated limit switches)
of 1:1, 1:2, 1:3, or 1:4.
WARNING
4. Microswitches (Fig. 1, Pos. 1
Oil level indicators can be equipped with up to two limit
Electrical voltage! Life-threatening electrical shocks!
Fig. 3.2 switches. There are two models available:
Disconnect the power supply before folding up the
4.1 Firmly set limit switches terminal cover.
Firmly set limit switches are indicated by a line
Overhang Remove the bayonet fixing ring (Fig. 1, Pos. 3). Fold up
(switching mark) located 5° before the MAX/MIN printing.
the terminal cover (Fig. 1, Pos. 4). Remove approx.
The color of both switching marks is yellow for all models
160mm of the sheath of the required flying leads and
designed in accordance with DIN 42 569. Firmly set limit
Fig. 3 Fig. 3.1 push the flying leads through the cable gland connection
switches are set in the factory, adjustments are a later
(Fig. 1, Pos. 5). Keep twisting tight the pressure nut of
date are no longer possible.
the cable gland connection until the cable is closed off
The following combinations are possible: liquid-tight by the sealing ring. The individual flying leads
Either MAX or MIN only, or MAX and MIN. are then connected as shown in the schematic diagram
(Fig. 5) printed on the inside of the terminal cover. Now
4.2 Adjustable limit switches fold down the terminal cover and put the bayonet fixing
2. Product description ring back on.
Adjustable limit switches are recognized by their colored
Magnetic oil level indicators are used for measuring the
switching deltas on the dial. These switching deltas can
oil level in the expansion vessel of transformers. The oil 6. Setting the microswitches
Fig. 4 be adjusted over the entire dial range. Colors of the
level indicator is composed of two separably connected Remove the bayonet fixing ring. Move the limit switch
switching deltas: MAX = blue, MIN = red.
elements. manually to the desired position by shifting the limit
Oil leakage from the expansion vessel is safely prevented switch at the housing, not at the switching deltas. Now
- Sensor element (Fig. 3) with float and float arm by the separate arrangement of sensor element and display 5 Installation put the bayonet fixing ring back on.
(on the inside of the expansion vessel) element. The sensor element is equipped with an oil-proof 5.1 Mechanical installation
flange plate and is incorporated directly in the vessel wall. The float rod (Fig. 2, Pos. 8) may be shortened to the
- Display element (Fig. 4), optionally with limit switches Both elements are connected by four screws (Fig. 2, desired length, if necessary (although no shorter than IMPORTANT
(on the outside of the expansion vessel) Pos. 6). Magnetic oil level indicators can optionally be 200mm). Please do not shorten the float rod containing Please do not move the limit switches at the colored
equipped with limit switches. the gear unit (axial) shown in Fig. 3.1. switching deltas.
BA2036/01/01 BA2036/01/01
MESSKO MESSKO
Insert the float rod into the borehole of the float shaft
IMPORTANT (Fig. 3.1, Pos. 7) all the way to the end stop. Please be
It is important to protect all elements against fall, shock sure to properly align the float shown in Fig. 3.1 before
and impact. Please be sure to keep the maximum tightening it to ensure that the float will be mobile as
ambient temperature at 80 degrees Celsius. shown in Fig. 3.2. Now please proceed by carefully
tightening the clamping screw (Fig. 3, Pos. 9) and
securing it with the counternut (Fig. 3, Pos. 10).
NOTE Now please separate the display element from the
sensor element at the rear of the housing edge by
Strict observation of the installation and operating removing the four screws (Fig. 2, Pos. 6). Insert the float
conditions advised in these operating and installation and float rod into the expansion vessel. Paying special
instructions is imperative. attention to the „TOP“ marking (Fig. 2, Pos. 11), please
proceed by mounting the sensor element to a seal and
3. Measuring principle carefully tightening the four fixing screws. Now plug the
The float rod (Fig. 2, Pos. 8) transmits the float’s lifting display element back onto the sensor element. Lock the
movements to a shaft (Fig. 3, Pos. 7). This shaft is magnetic coupling home by lightly rotating and jiggling it
connected via magnetic coupling to the pointer spindle in back and forth. Tighten the four screws at the rear of the
the display element. There are two different float drive housing edge.
Fig. 1 Fig. 2
modes for the oil expansion vessel (see Fig. 3):
IMPORTANT
Breathing bag -Float movement in radial direction (radial drive)
radial axial The display element and the sensor element are
-Float movement in axial direction (axial drive)
perfectly adjusted to each other. Please use only the
original display element for its counterpart sensor
The design featuring float movement in axial direction element.
(axial drive) is best suited for use in narrow or flat
expansion vessels allowing only minimal float 5.2 Electrical installation
movements. Float movements can be rendered at a ratio (with incorporated limit switches)
of 1:1, 1:2, 1:3, or 1:4.
WARNING
4. Microswitches (Fig. 1, Pos. 1
Oil level indicators can be equipped with up to two limit
Electrical voltage! Life-threatening electrical shocks!
Fig. 3.2 switches. There are two models available:
Disconnect the power supply before folding up the
4.1 Firmly set limit switches terminal cover.
Firmly set limit switches are indicated by a line
Overhang Remove the bayonet fixing ring (Fig. 1, Pos. 3). Fold up
(switching mark) located 5° before the MAX/MIN printing.
the terminal cover (Fig. 1, Pos. 4). Remove approx.
The color of both switching marks is yellow for all models
160mm of the sheath of the required flying leads and
designed in accordance with DIN 42 569. Firmly set limit
Fig. 3 Fig. 3.1 push the flying leads through the cable gland connection
switches are set in the factory, adjustments are a later
(Fig. 1, Pos. 5). Keep twisting tight the pressure nut of
date are no longer possible.
the cable gland connection until the cable is closed off
The following combinations are possible: liquid-tight by the sealing ring. The individual flying leads
Either MAX or MIN only, or MAX and MIN. are then connected as shown in the schematic diagram
(Fig. 5) printed on the inside of the terminal cover. Now
4.2 Adjustable limit switches fold down the terminal cover and put the bayonet fixing
2. Product description ring back on.
Adjustable limit switches are recognized by their colored
Magnetic oil level indicators are used for measuring the
switching deltas on the dial. These switching deltas can
oil level in the expansion vessel of transformers. The oil 6. Setting the microswitches
Fig. 4 be adjusted over the entire dial range. Colors of the
level indicator is composed of two separably connected Remove the bayonet fixing ring. Move the limit switch
switching deltas: MAX = blue, MIN = red.
elements. manually to the desired position by shifting the limit
Oil leakage from the expansion vessel is safely prevented switch at the housing, not at the switching deltas. Now
- Sensor element (Fig. 3) with float and float arm by the separate arrangement of sensor element and display 5 Installation put the bayonet fixing ring back on.
(on the inside of the expansion vessel) element. The sensor element is equipped with an oil-proof 5.1 Mechanical installation
flange plate and is incorporated directly in the vessel wall. The float rod (Fig. 2, Pos. 8) may be shortened to the
- Display element (Fig. 4), optionally with limit switches Both elements are connected by four screws (Fig. 2, desired length, if necessary (although no shorter than IMPORTANT
(on the outside of the expansion vessel) Pos. 6). Magnetic oil level indicators can optionally be 200mm). Please do not shorten the float rod containing Please do not move the limit switches at the colored
equipped with limit switches. the gear unit (axial) shown in Fig. 3.1. switching deltas.
BA2036/01/01 BA2036/01/01
MESSKO MESSKO
TEMPERATURE MEASURING INSTRUMENTS

FOR TRANSFORMERS
MTO-ST(F)160 With or without fixed or adjustable limit switches,
7. Inspections Microswitches radial drive
7.1 Check for leaks Types of switches: Firmly set or adjustable MTO-ST(F)160 G With or without fixed or adjustable limit switches,
To protect the environment and maintain the microswitches
Quantity: 1 or 2 microswitches
radial drive
transformer’s operational safety it is very important to
make sure that there are no oil leaks. It is therefore Contact material: Silver-cadmium-oxide MTO-ST(F)160D With or without fixed or adjustable limit switches,
imperative to check the installation point for leaks after Rated current: Firmly set microswitches radial drive as per DIN 42 569
filling the expansion vessel. Please drain the expansion AC: 250V / 15A / cosö = 1 (black dial, yellow inscription)
vessel if leaking oil is noted. Proceed by disassembling DC: 220V / 0.25A
the oil level indicator in reverse order. Clean all parts and Adjustable microswitches 1 General Operating Instructions BA 2036
reassemble the oil level indicator with a new seal as AC: 250V / 5A / cosö = 1
specified above DC: 220V / 0.4A
7.2 Limit switches Setting: Firmly set microswitches:
Remove the bayonet fixing ring. Move the pointer over 5 deg. before the MAX and MIN
the switching mark against the force of the magnetic markings
operation, maintenance or repair of this equipment must:
coupling. Perform an electrical measurement of the Different in-factory settings are
circuit state. Move the pointer by hand back into the available on request
-be suitably qualified and
home position without letting go of it. Should the Adjustable microswitches:
-strictly observe these operating instructions.
measurement not confirm the diagram, check the supply Freely adjustable over the dial range
-Improper operation or misuse can lead to
lead and related pin allocation. Now put the bayonet Line terminal: Required cable cross-sectional area
-serious or fatal injury,
fixing ring back on Min. 0.25mm²
-damage to the equipment and property of the user
Max. 2.5mm²
8. Service -a reduction in the efficiency of the equipment.
If the measures specified above do not yield the desired
results, please get in touch with our factory. CAUTION Safety instructions in this manual are presented in three
9. Maintenance High voltage peaks may occur when disconnecting different forms to emphasize important information.
The oil level indicator is low-maintenance. inductive reactances. The use of fuses should
therefore be considered. Implementation of a fuse
Technical data would reduce contact erosion. WARNING
WARNING
Materials
Mounting ring and housing:Steel plate, galvanized and 1 Microswitch MIN (red) This information indicates particular danger to life and
2 Microswitch MAX (blue) All relevant fire protection regulations must be strictly
varnished with RAL shade health. Disregarding such a warning can lead to serious
observed.
7033 or fatal injury.
Housing bottom: Aluminium 1 2 1 2
Mounting flange: Aluminium
Inspection glass: Reinforced safety glass CAUTION
Dial: Anodized aluminium
Cable gland connection: M25x1.5, galvanized brass Installation, electrical connection and commissioning
CAUTION
Float rod: Aluminium of the equipment may only be carried out by qualified,
Float: Rohacell 110, oil-resistant, skilled personnel and only in accordance with these
heat resistant up to 160 deg. Fig. 5 Terminal no. as per DIN 46 199 This information indicates particular danger to the operating instructions.
Celsius equipment or other property of the user. Serious or
Characteristic data: fatal injury cannot be excluded. It is the responsibility of the user to make sure that
Display: MIN + 20 deg. Celsius MAX the equipment is used for the specific application
Inscription: Black lettering, (for all
models designed in MESSKO only.
accordance with DIN 42 569 For safety reasons, any unauthorized and improperly
the dial is black and the NOTE executed works during installation, modification,
writing is yellow ) alteration of the equipment, electrical connection, or
Installation sites: Suitable for indoor and © Messko GmbH
Gablonzer Strasse 25 - 27 These notes give important information on a certain commissioning of the equipment, are forbidden without
outdoor installation, tropic- first consulting MESSKO!
61440 Oberursel subject.
proof. Germany
Ambient temperature: -40….+80 deg. Celsius Telephone:(+49) 6171 / 63 98-0
Degree of protection: IP 55 according to DIN VDE Facsimile: (+49) 6171 / 63 98-98
Internet: http://www.messko.de NOTE
0470-1
Email: info@messko.de
Ventilation: Fan, inspection glass non- Data contained herein may differ in details from the equipment delivered.
fogging up to 80% relative BA 2036/01/01 We reserve the right to make alterations without notice.
humidity Printed in Germany
BA2036/01/01 BA2036/01/01
OPERATING MANUAL
27 CQ, CT, CU
SAP No.: 112010276/20 Page: 189

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 190

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
CQ QUALITY VARIABLES (MONITORING, HUMIDITY, AGEING

AND QUANTITY)
CT TEMPERATURE MEASUREMENT
CU COMPOUND MEASURED VARIABLES
CT 001 Temperature monitors
make STEVANOVIC type STR-WK
1 two way contact order no. 1745 4 1115 810
CT 021 Resistance thermometer type 1xPT 100-4L
for transformer
CT 031 Dial type thermometer for oil temperature control
order no. 635081
2 two way contacts
CT 036 Dial type thermometer for fan control
order no. 635081
2 two way contacts
SAP No.: 112010276/20 Page: 191

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 192

Order No.: 1431517
Serial No.: 150 556
STABTEMPERATURREGLER
Typ STR-WK, Temperaturwächter mit Kappe
Anwendung:
Der Regler wird zur Temperaturüberwachung in Transformatoren
eingesetzt. Die Einbauvorschriften des Transformatorenherstel-
lers sind zu beachten.
Technische Daten:
Temperaturbereiche: 0 – 140°C
Schalttemperatur-Differenz: ca. 5 K, je nach Ausführung
max. zul. Umgebungstemperatur: -50 bis + 150°C
max. zul. Schaltstrom: AC 250 V 10 (2,5) A
Betriebsspannung: AC 24 V bis AC 230 V
Elektrische Lebensdauer: mind. 2 · 105 Schaltspiele
Schaltleistung: 2,5 kW
Kontaktart: 1 Wechsler
Sollwerteinstellung: Innenskala
Fühlstab: ø 9 mm
Einbaulänge: 145 mm
Gehäuse:
Material: Alu-Guss, lackiert
Schutzart: siehe Tabelle
Befestigung: G 1" Gewinde
Gewicht: ca. 800 g
Bestellangaben:
Typ Schutzart Belüftung Artikel / Bestell-Nr.:
STR-WK IP 65 Entlüftungskappe (abgedichtet) 1745 4 0900 006

STR-WK IP 44 Entlüftungskappe 1745 4 1115 810
Stevanovic Elektrotechnik GmbH | Hohenbuckstr. 5 | 90425 Nürnberg | Tel.: +49 (0) 911 51 05 917 | Fax: +49 (0) 911 51 05 918 | www.stevanovic-elektrotechnik.de 63
Important References Important Refernces
Resistance thermometers in pipe or mineral insulated construction Thermocouples in pipe or mineral insulated construction
consist in principle of three major components : consist in principle of two major components :
1. TTemperature
emperature sensitive section 1. TTemperature
emperature sensitive section
Contains the thermal sensing element in form of a glass or ceramic platinum resistor This is in priciple the entire length of the thermocouple ( TC ). The front tip of course must be
located at the point of measuring.
2. Interconnection section
Interconnects the sensing with the cable connection section. 2. Cable connection section
Connection point for the cable necessary for further signal processing
3. Cable connection section
Connection point for the cable necessary for further signal processing TC‘s in pipe construction ( metal or ceramic protection tube ) must not be bended.
Mineral insulated metal sheathed thermocouples may be bende under following asumptions:
Measuring resistors of glass are usually suitable for temperatures up to approx. 400 °. Special
constructions can be designed for higher temperatures. A ) The bending radius must no be below 5 times outside diameter in mm.
Measuring ceramic resistors in chip design are suitable for temperatures up to 500 °. Special B ) The measuring tip must not be bent on a length of min. 20 mm.
construction can be designed for higher temperatures. C ) The area of approximately ca. 50 mm beyond the connection sleeve resp. the connection
Ceramic measuring resistors in wire-wound design can be used up to 650 °. See also EN 60751. socket must not be bent in any case.
Special construction can be designed for higher temperatures. D ) In the area of the measuring tip ( approx. 25 mm ) no welding or soldering is allowed. By
The temperature compatibility of the protective tube and the inner conductors using soldering processes at mineral insulatet cables outside this section, the temperature
must be taken into consideration ! See also DIN 43772. may not exeed 900 °C.
If the interconnection part is constructed from a pipe with inner ceramic capillary rod, this part E ) In the area of the measuring tip ( approx. 20 mm ) squeeze - and /oder sticking screw joints
may not bent in any case! must not be used .
F) TC‘s, especially mineral insulated metal sheathed TC‘s, can not shortened by the customer
If the interconnection part is constructed as a mineral insulated cable, this part can be bent under
following assumptions : The min. and max. temperature rang of the specific TC is given by the standard DIN EN 60584.
Guidlines for the operating temperature range are given in DIN 43712 and DIN EN 61515.
A ) The bending radius may not be beyond 5 to 7 times the outside diameter in mm.
B ) The measuring tip may not be bent in any case on a length of min. 75 mm. The operating temperature range may be deviate from this significantly depending of the
protection tube material used. See also DIN 43772 and DIN 43734
C ) In the area of the measuring tip ( approx. 75 mm ) no welding or soldering is allowed.
Squeeze - and /oder sticking screw joints must not be used in this area. In the case of connecting the cables to the connector, the local rules and safety guidelines are
D ) The area of approximately ca. 50 mm beyond the connection sleeve resp. the connection always to be considered .
socket must not be bent in any case. In case of that the connection section is constructed as a sleeve with firmly connected cable (WL /
In the case of connecting the cables to the connector, the local rules and safety guidelines are WLS - construction), the temperature at the sleeve may not exeed 100 °C. In special constructions
always to be considered . temperatures up to 240 °C are allowed here.
In case of that the connection section is constructed as a sleeve with firmly connected cable (WL / Constructions with firmly mounted pin connectors ( jacks or plugs ), the temperature at that point
WLS - construction), the temperature at the sleeve may not exeed 100 °C. In special constructions may not exeed 100 °C. While using TEFLON - insolated cables and special potting resin tem-
temperatures up to 240 °C are allowed here. peratures up to 180 °C for mini - or standard plugs and up to 240 °C for round connectors are
allowed.
Constructions with firmly mounted pin connectors ( jacks or plugs ), the temperature at that point
may not exeed 100 °C. While using TEFLON - insolated cables and special potting resin tem- The connection scheme to the measuring equipment is depending to the connection diagram
peratures up to 180 °C for mini - or standard plugs and up to 240 °C for round connectors are resp. the marking on the connection socket.
allowed.
The connection scheme to the measuring equipment is depending to the connection diagram
resp. the marking on the connection socket.
RÖSSEL-Messtechnik GmbH & Co RÖSSEL-Messtechnik GmbH RÖSSEL Nederland RÖSSEL-Messtechnik GmbH & Co RÖSSEL-Messtechnik GmbH RÖSSEL Nederland
Lohstrasse 2; DE-59368 Werne Spenerstrasse 1; DE-01309 Dresden Eikenlaan 253d; NL-2404BP Alphen a/d Rijn Lohstrasse 2; DE-59368 Werne Spenerstrasse 1; DE-01309 Dresden Eikenlaan 253d; NL-2404BP Alphen a/d Rijn
Fon: +49 (0) 2389 409-0 Fon: +49 (0) 351 31225-0 Fon: +31 (0) 172 49 31 41 Fon: +49 (0) 2389 409-0 Fon: +49 (0) 351 31225-0 Fon: +31 (0) 172 49 31 41
Fax: +49 (0) 2389 409-80 Fax: +49 (0) 351 31225-25 Fax: +31 (0) 172 49 50 43 Fax: +49 (0) 2389 409-80 Fax: +49 (0) 351 31225-25 Fax: +31 (0) 172 49 50 43
Mail: info@roesselwerne.de Mail: info@roesseldresden.de Co Mail: info@rossel.nl Co Mail: info@roesselwerne.de Mail: info@roesseldresden.de Co Mail: info@rossel.nl Co
Contents
1. General…………………………………………………………………………………… 2
2. Thermocouples……………………………………………………………………………. 2
3. Resistance Thermometers…………………………………………………………………. 2
4. Thermometers with head-mounted Transmitter…………………………………………... 2
5. Mounting and Operation

5.1 Installation ………………………………………………………………………………… 3
5.2 Connecting wires …………………………………………………………………………. 3
5.3 Instructions for explosion proofed Components ………………………………………... 3
5.4 Protection Tubes ………………………………………………………………………….. 4
6. Maintenance……………………………………………………………………………….. 4
7. Troubleshooting……………………………………………………………………………. 5
7.1 Quick Check …………………………………………………………………………….. 5
7.2 Error Table for Thermocouples and Resistance Thermometers ………………………… 5
8. Wiring diagram and colour coding ………………………………………………………. 8
page 1
1 . General
We are capable of supplying complete thermometer assemblies ready for immediate use.
These thermocouples or resistance thermometers are sensitive devices which contain either glass or ceramic parts. They
must therefore be handled with due care.
On receiving the thermometer assembly, please make sure to unpack all supplied articles, including those that may be
delivered in dismantled form.
Long thermometers must be supported at various points, and lifted up or transported in appropriate manner. The same
care must be taken during the actual installation of the device. Prior to installation, please check the thermometers (see
5.1) to ensure that the device has suffered no transportation damages.
2. Thermocouples
Thermocouple assemblies are delivered with 1, 2, or sometimes 3 thermocouple elements. The measuring point is
usually insulated but can still be connected to the protecting tube.
The connection of the thermocouple to the measuring instrument is established with a compensation lead (CL). Only the
right type of compensation leads suiting the thermocouple and possessing the right polarity should be used for the
connection. The leads should be at least 0.5 m away from the power cables, preferably laid in their own cable trays.
Twisted and shielded cables suppress magnetic and electrical parasitical interferences. (connection see page 9)
3. Resistance Thermometers
Resistance thermometers are supplied with 1, 2, or sometimes with 3 measuring resistors.
The measuring point is isolated. The connection between resistance thermometer and measuring instrument is mostly of
the 2wire type (the sum and compensation of line resistance become part of the measurement). To obtain accurate
measurements, the 3-wire technique is used. lf highly accurate measurements are desired, the 4-wire technique with
constant current and high resistance voltage pick-up are used.
Conventional copper cables usually found on the market, preferably with 1.5MM2 cross-section should be laid, possibly
at about 0.5 m away from the power cables, at best on their own cable trays.
Twisted and shielded cables suppress magnetic and electrical parasitical interferences.
Depending on the type, care must be taken not to exceed the measuring currents of 0.1 to 10 mA, recommended by the
manufacturer (errors may result from inherent heating).
4. Thermometer with head-mounted Transmitter
The afore mentioned problems which could eventually be caused by transfer resistances in the cable and EMC can be
prevented by installing a 2-wire transmitter (output signal 4 ... 20 mA) in the sensor head. Required is only a 2-core
copper cable. Multiple wire circuits for resistance thermometers and compensation cables for thermocouples are not
necessary.
When using the transmitter, please take notice of the following:

- the contents of these instructions or the operating manual provided with the transmitter
- the relevant rules involving the installation and operation of electrical systems, in some cases
the regulations and directives for explosion protection.
page 2
5. Mounting and Operation
5.1 Installation
The thermometer (thermocouple, resistance thermometer) must be brought into contact with the medium to be measured
in the best possible manner.
To avoid thermal conduction errors, the immersion depth should be:

in fluids 6...8 times greater
in gases 10 ... 15 times greater
than the protective tube diameter. lf only very short insertion lengths are possible, special designs should be applied. lt is
often helpful to install in a pipe bend, whereby the protective tube must be positioned against the flow of the medium.
5.2 Connecting wires
For all connecting wires it is important to ensure that proper contact has been established and that corrosion, humidity,
pollution, electrical parasitic interferences of power cables etc. are avoided.
The cables should be insulated to counter the ambient influences (dry, humid, chemically aggressive, hot), whereby the
ambient temperature of both the cable and the connection head may not exceed 100 IC.
Please pay attention to the valid standards and regulations when selecting the types of cables to be used.
lf possible, all measuring systems should be operated in ungrounded condition, or only grounded at one point.
When using thermocouples connected to protective tubes, these should be the only ground/mass connection.
5.3 Instructions for explosion prooved Components
1 In accordance with of ElexV, maintenance work (repairs) may be conducted only under the following conditions
stated below:
1.1 lf a part of an electrical device which is important for explosion protection is repaired, this may
be put into operation only after a technical expert has determined that the main explosion
protection characteristics still correspond to the required standard and after issuing a certificate or
awarding a test mark.
1.2. Item 1.1 shall not be valid if the component has been individually tested by the manufacturer and it is confirmed
that the main characteristics for application in hazardous areas comply with the stipulated technical requirements.
2. The ElexV is only valid within the Federal Republic of Germany. In foreign countries, the relevant
binding regulation corresponding to ElexV must be adhered to.
3. Repair work may only be carried out using original

components of the original manufacturer, otherwise the standards stipulated in the certificate of conformity shall
not be fulfilled.
4. When ordering spare parts, exact information on previous delivery such as type of protection
(Exd, Exi), No. of the certificate of conformity, serial and item No.s must be supplied.
5. Ex-protected thermometers only fulfil the required safety requirements as a unit component,
as determined by the certficate of conformity. Measuring insets or connecting heads alone do not satisfy the
explosion-protection requirements.
page 3
6. lf RÖSSEL supplies thermometers destined for operation in hazardous areas without protecting
tubes, it will be the responsibility of the owner to see to it that.
6.1. These thermometers are deployed only in zones which are permissible in accordance with the certificate of con-
formity or with the manufacturer's declaration (e.g. zones 1 or 2).
6.2 A protecting tube is provided for an eventually necessary separation of a zone (e.g. zone 0
from zone 1). Such a tube must correspond fully to the "special conditions" spelled out in the respective certficate
of conformity.
7. RÖSSEL shall inform the plant owner of the above subject matter in appropriate form, e.g. by drawing attention to
this leaflet of instructions.
5.4. Protection Tubes
Thermometers can be installed in any mounting position, preferably hanging vertically, up to temperatures reaching
about 500°C.
Ceramic protection tubes must be protected from mechanical stress (bumps, bends), including temperature shocks e.g.
through direct flame contact.
If they are applied to hot processes (e.g. when changing the thermocouple), they must be either prewarmed or inserted
very slowly (1…2 c,/min at 1600°C, 10…20 cm/min at 1200°C). This also applies when removing the hot protecting
tube. Care must be taken to avoid suspending lengths >500 mm for temperatures >1200°C.
6. Maintenance
The thermometer and the entire temperature measuring circuit must be checked at regular intervals for
- wear and tear of protecting tube or chemical activity,
- drifts of the measuring element caused by ageing,
- reduction of insulation resistance through humidity and pollution
- improper contact of the wire connections and
- mechanical and chemical damage of the thermometer and wires.
Resistance thermocouple circuits can be checked by replacing the measuring element with a known defined resistance,
thereby simulating a specific temperature.
Thermocouple measuring circuits can be checked by connecting a mV voltage of a known variable to the measuring
circuit, instead of the thermocouple.
In both cases, substantial deviations from the set point can be determined, also if the thermometer or the instrumentation
is the cause of function errors.
The insulation resistance of the entire ungrounded measuring circuit (wires and thermometer) against ground should be
> 1 MQ (measured with 100 V DC).
page 4
7. Troubleshooting
7.1 Quick Check
of thermocouples and resistance thermometers, including their associated measuring circuits in dismantled form.
Required instruments: mV-meter, Q-meter or resistance bridge, insulation meter with 60 ... 100 V voltage (all
measurements at room temperature)
In the case of room temperature the throughput and insulation are checked by "knocking" to see if any wire breaks have
occurred.
A thermocouple is regarded as being in order if R < 20 ? (wire > 0.5 mm diameter); the value depends on the wire
cross-section and the length. Risol 100 m? (for insulated thermocouples).
A resistance thermometer is considered to be in order if R is about 100 ? (for Pt100), Risol > 100 M? .
A heating up of the thermocouples or resistance thermometers to between 200 and 400 °C (without temperature control)
gives further clues to interruptions, polarity errors (for thermocouples), and low insulation resistance etc.
The accuracy of thermometers according to ISO 9000 can only be checked by a reference element.
Therefore in most cases the thermometers has to be removed and checked by a heating device.
7.2 Error Table for Thermocouples and Resistance Thermometers
The entire temperature measuring circuit should be routinely checked.
The following tables contain an illustration of the most important errors and provide suggestions towards their solution.
fault probable cause remedy

errors in the measuring signal electrical/magnetic pick-up - at least 0.5 m spacing between the
measuring cable and power cables
supply lines if laid in parallel
- electrostatic shielding caused by a
metal foil/braiding grounded at one
point
- twist the core wires (in pairs) to
combat magnetic pick-up
- right-angled crossing of electrode
with interfering power cables
grounded loops - only one grounding point in circuit or
“floating" measuring system (un-
grounded)
drop in insulation resistance - humidity has eventually penetrated
the thermometer/inset; in such case
dry up and reseal
- replace inset
- check to see if thermometer is ther-
mally overloaded
page 5
response times too long, incorrect wrong location for installation; there is a - change the point of installation so
readouts heat source within the flow path that the medium can transmit its
temperature to the thermometer
without interference
wrong installation: - immersion depth approximately tem
- insufficient installation depth perature sensitive length + 6 x
- excessive loss of warmth (fluids) up to 10 x (gases) d (d
external protecting tube diameter)
- ensure that thermal contacts, espe-
cially for surface measurements are
established with matching contact
surfaces and/or heat conducting ma
terials
protecting tube too thick, drilled hole for - select the smallest possible protec-
protecting tube too big ting tube for the process; response
time at first exposure should be pro-
portional to the cross-section or the
volume of the thermometer, depen-
ding on the tentative thermal figures
and air gaps within the assembly.
Fill any such gaps with contact
agent (oil, grease) if possible.
deposits on the protecting tube - remove during inspections
- if possible, select another protecting
tube, another installation point
thermometer interruptions vibrations - reenforced springs on inset
- shorten inset insertion length
- change the measuring point (if pos-
sible)
- special construction of inset and pro-
tecting tube
highly corroded protecting tube - composition of the medium is not as - check the medium , eventually ana-
assumed, or has changed lyze the defective protecting tube
- unsuitable material chosen for pro- and select a more suitable material,
tecting tube whilst providing additional surface
protection
- in certain circumstances the protec-
ting tube must be replaced from time
to time, since it is subject to wear
Typical Thermocouple Faults

fluctuating temperature readout even reference junction temperature or vol- - temperature or supply voltage must
though thermocouple circuit is faultless tage is not constant be kept constant at < 0.1 %; check
instruments
- for non-precious metal-thermocou-
ples use the full value for measure-
ment; use only about half the value
of thermocouples made of precious
metals
temperature display highly deviates improper material combinations, check thermocouples and wires for
from the table values for bad electrical contacts, - correct pairing
thermocouples parasitic voltages (thermostatic - correct compensation lead
voltages, galvanic voltage), - correct pinup
page 6
wrong compensation cable - permitted ambient temperature at
connection head
Typical Resistance Thermometer Faults

too high or fluctuating temperature - wire resistance too high, uncom- if still possible:
readout despite known cross-section, pensated - select 2-wire leads with bigger
accurate sensor of the resistance ther- - supply lead resistance altered by cross-sections eventually move to a
mometer high temperature more accessible point
- shorten wire
- lead adjustment
- change to 3 or 4 wire system
- use the head transmitter
fluctuating temperature readout even voltage or power supply is not constant Must be kept constant at <0.1%. Fully
though measuring circuit of the resis- affects the measurement when tuned
tance thermometer off bridge and current/voltage measure-
ments (4-wire).
page 7
8. Wiring diagram and colour coding Pt100
page 8
Wiring diagram and colour coding Thermocouples
page 9
Our information regarding our products, equipment, plants and processes is based on extensive research and experience in the field
of applied engineering. We are making such information available, to the best of our knowledge and in written form, without
assuming any liabilty over and above the terms of this contract but reserving the right to make technical changes of our products at
any time without prior notification. In addition, our applications engineers are available on request to provide further consultation
and cooperation in solving production and application-related problems.
This however does not relieve the user from the obligation to verify the suitability of our information and recommendations before
putting our products to use.
This applies particularly to deliveries destined for customers in foreign countries, especially in their obligation to ensure that no
patent rights of third parties are infringed upon, including applications and processing methods which we have not expressly spelled
out in writing. In case of damage or quality deficiencies, our liabilities and indemnities are limited to the same volumes as stipulated
in our General Terms of Supply and Delivery.
Subject to technical changes.
This technical documentation is protected by copyright. Translating, photocopying and diseminating it in any form whatsoever - even
editings or excerpts thereof - especially as reprint, photomechanical or electronic reproduction or storage on data processing
systems or networks is not allowed without the permission of the copyright owner and non-compliance will lead to both civil and
criminal prosecution.
page 10
www.messko.com
Zeigerthermometer/Pointer Thermometer
Betriebsanleitung/Operating Instructions 2046
Trasy-Serie: MT-ST160F
Trasy-Series: MT-STW160F2
Messko
Inhaltsverzeichnis/Contents
Inhaltsverzeichnis Contents
1 Sicherheit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Sicherheitshinweise. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Bestimmungsgemäße Verwendung . . . . . . . . . . . . . . . 3 1.2 Specified application . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Hinweise für den Betrieb des Geräts . . . . . . . . . . . . . . 3 1.3 Important notes on equipment operation . . . . . . . . . 3
2 Produktbeschreibung . . . . . . . . . . . . . . . . . . . . . . . .4 2 Product specification. . . . . . . . . . . . . . . . . . . . . . . . .4

2.1 MT-ST160F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2.1 MT-ST160F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 MT-STW160F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 MT-STW160F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Montage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1 Montage des Geräts . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.1 Mounting the device. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Kapillarleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.2 Capillary tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Temperaturfühler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.3 Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Tretschutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.4 Kick protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Schleppzeiger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3.5 Maximum pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Elektrischer Anschluss . . . . . . . . . . . . . . . . . . . . . . .6 4 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . .6

4.1 Anschluss der Mikroschalter . . . . . . . . . . . . . . . . . . . . 6 4.1 Connecting the microswitches. . . . . . . . . . . . . . . . . . . 6
4.2 Verstellen und Prüfen der Mikroschalter . . . . . . . . . . 7 4.2 Checking and adjusting the microswitches . . . . . . . . 7
5 Anzeigekontrolle und Nachjustierung . . . . . . . . . . .8 5 Indication control and readjustment . . . . . . . . . . . .8
6 Wartung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
7 Technische Daten . . . . . . . . . . . . . . . . . . . . . . . . . . .8 7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8 Anhang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 8 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

8.1 Anbauzeichnung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 8.1 Installation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.2 Kabelverschraubung . . . . . . . . . . . . . . . . . . . . . . . . . . 10 8.2 Cable gland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HINWEIS Note
Die in dieser Betriebsanleitung enthaltenen Angaben The data contained herein may differ in details to the
können von dem gelieferten Gerät abweichen. equipment delivered.
Änderungen bleiben vorbehalten. Subject to change without prior notice.
Für zukünftige Verwendung aufbewahren! Please keep this manual for future reference!
2 BA 2046/00/05
1 Sicherheit/Safety Messko
1 Sicherheit 1 Safety
1.1 Sicherheitshinweise
Alle Personen, die mit der Montage, Inbetriebnahme, Bedie-
nung, Wartung und Instandhaltung des Geräts zu tun haben,
operation or maintenance of this equipment must:
müssen
- fachlich ausreichend qualifiziert sein und
- strictly observe these operating instructions.
- diese Betriebsanleitung genau beachten.
Bei Fehlbedienung oder Missbrauch drohen Gefahren für
- serious or fatal injury,
- Leib und Leben,
- damage to the equipment and other property of the user
- das Gerät und andere Sachwerte des Betreibers und
- a reduction in the efficiency of the equipment.
- die effiziente Funktionsweise des Geräts
Safety instructions in this manual are presented in three
In dieser Betriebsanleitung werden drei Arten von Sicher-
different forms to emphasize important information.
heitshinweisen verwendet, um wichtige Informationen
hervorzuheben.
WARNUNG WARNING
weist auf besondere Gefahren für Leib und Leben hin. This information indicates particular danger to life and
Ein Nichtbeachten dieser Hinweise kann zu schwersten health. Disregarding such a warning can lead to serious
Verletzungen oder Tod führen. or fatal injury.
ACHTUNG CAUTION
weist auf Gefahren für das Gerät oder andere Sachwerte This information indicates particular danger to the
des Betreibers hin. Ferner können Gefahren für Leib und equipment or other property of the user. Serious or fatal
Leben nicht ausgeschlossen werden. injury cannot be excluded.
HINWEIS NOTE
weist auf wichtige Informationen zu einer konkreten These notes give important information on a certain
Thematik hin. issue.
1.2 Bestimmungsgemäße Verwendung 1.2 Specified application

Das Zeigerthermometer dient der Temperaturmessung an Pointer thermometers are used to measure temperatures on
Leistungstransformatoren, Drosselspulen oder ähnlichen power transformers, reactors or similar equipment.
Geräten. It is important to read and observe the limit values for
Vor Inbetriebnahme des Geräts sind die auf dem Typenschild operation indicated on the nameplate and in the operating
und in der Betriebsanleitung angegebenen Grenzwerte in der instructions prior to commissioning the device.
Anwendung zu beachten und unbedingt einzuhalten.
1.3 Hinweise für den Betrieb des Geräts 1.3 Important notes on equipment operation
Die nationalen Unfallverhütungsvorschriften hat der Anwen- The user is obliged to comply with the national health and
der unbedingt einzuhalten. safety regulations.
Es wird besonders darauf hingewiesen, dass das Arbeiten an It is especially emphasized that works performed to live, e.g.
aktiven, d.h. berührungsgefährlichen Teilen nur zulässig ist, dangerous-contact components, are permissible only while
wenn diese Teile spannungsfrei sind oder gegen direktes these components are either de-energized or protected
Berühren geschützt sind. against direct contact.
BA 2046/00/05 3
2 Produktbeschreibung/Product specification
Bei der elektrischen Installation sind die nationalen Vor- Electrical installation is subject to the relevant national safety
schriften zu beachten. Um einen störungsfreien Betrieb zu regulations. It is imperative to connect the ground wire in
gewährleisten, ist der Schutzleiter unbedingt anzuschließen. order to ensure trouble-free operation.
ACHTUNG CAUTION
Einbau, elektrischer Anschluss, Inbetriebnahme und War- Installation, electrical connection, commissioning, and
tung des Geräts dürfen ausschließlich von qualifiziertem, maintenance of the device may only be carried out by
ausgebildetem Personal gemäß dieser Betriebsanleitung qualified, skilled personnel and only in accordance with
durchgeführt werden. these operating instructions.
Der Betreiber hat für die bestimmungsgemäße Verwen- It is the responsibility of the user to make sure that the
dung des Geräts Sorge zu tragen. device is used for the specified application only.
Eigenmächtig und unsachgemäß durchgeführte Arbeiten For safety reasons, any unauthorized and improperly
bei Ein- und Umbau, elektrischem Anschluss, Inbetrieb- executed work, i.e. installation, modification, alteration
nahme und Wartung – ohne Rücksprache mit Messko – of the equipment, electrical connection, or commis-
sind aus Sicherheitsgründen verboten! sioning of the equipment, are forbidden without first
consulting Messko!
WARNUNG WARNING
Beachten sie unbedingt die nationalen Brandschutzvor- All relevant fire protection regulations must be strictly
schriften. observed.
2 Produktbeschreibung 2 Product specification

Zeigerthermometer werden zur Temperaturanzeige an Trans- Pointer thermometers are used to indicate temperatures on
formatoren, Drosselspulen oder ähnlichen Geräten eingesetzt. power transformers, reactors or similar equipment.
Sie bestehen grundsätzlich aus einem Temperaturfühler, der They always consist of a temperature sensor which is
durch eine Kapillarleitung mit dem Messwerk verbunden ist. connected to the measuring device with a capillary tube.
An dem Messwerk ist ein Zeiger angebracht, der über eine The measuring device is equipped with a pointer which turns
Drehbewegung den Temperaturwert auf einer Skala anzeigt. to show the temperature on a scale. The measuring system
Das Messsystem, bestehend aus Fühler, Kapillarleitung und consisting of sensor, capillary tube and measuring device is
Messwerk, ist mit einer Flüssigkeit gefüllt. filled with a liquid.
ACHTUNG CAUTION
Messgeräte sind empfindlich. Alle Teile vor Fall, Schlag Measuring instruments are sensitive. All parts should
oder Stoß schützen. therefore be protected against falling and against knocks
and vibrations.
Die Kapillarleitung darf nicht gekürzt werden, das Mess-
system steht unter Druck und wird dadurch zerstört. The capillary tube may not be shortened otherwise the
pressurized measuring system will be destroyed.
Die in dem Messsystem verwendete Flüssigkeit ist
gesundheitsschädlich. The liquid used in the measuring system is hazardous to
health.
2.1 MT-ST160F 2.1 MT-ST160F

Zeigerthermometer mit verstellbaren Mikroschaltern zur An- Pointer thermometers with adjustable microswitches for indi-
zeige der Öltemperatur. Die angezeigte Temperatur entspricht cating the oil temperature. The indicated temperature is the
der Öltemperatur am Fühler des Gerätes. Das mechanische oil temperature at sensor location. The mechanical measuring
Messsystem funktioniert selbstständig und energieunabhängig. system functions independently and requires no power input.
Gemäß der Applikation, kann der Fühler in den Zusatzgerä- According to the type of applikation, the temperature sensor
ten Einbauhülse und Kombihülse montiert werden. Weitere can be assembled into such accessory equipment as the ther-
Informationen für das Zusatzgerät Kombihülse finden sie in mal well and combi well. Futher information on the combi
der Betriebsanleitung BA2032 well can be found in the operating instructions BA2032
4 BA 2046/00/05
3 Montage/Installation Messko
2.2 MT-STW160F2 2.2 MT-STW160F2

Zeigerthermometer mit verstellbaren Mikroschaltern zur These types of pointer thermometers with adjustable
Anzeige der Wicklungstemperatur (thermisches Abbild). Der microswitches are used to indicate the winding temperature
Temperatursprung zwischen Kühlflüssigkeit (Öl) und Wicklung (thermal image). The temperature difference between the
hängt u.a. vom Strom in der Wicklung ab. Der Wandler-Se- cooling medium (oil) and the winding depends, among
kundärstrom ist dem Strom in der Wicklung des Transfor- other things, on the current flowing in the winding. The
mators verhältnisgleich. Der Wandler-Sekundärstrom speist CT secondary current is proportional to the winding of the
einen Heizwiderstand im Zusatzgerät ZT-F2 das dadurch eine transformer. The CT secondary current feeds a heating resistor
der Transformatorbelastung entsprechende Anzeigeerhöhung inside the additional device ZT-F2. This provides an appropri-
der tatsächlich gemessenen Öltemperatur (Sprungtemperatur) ate increase (heat gradient) to the actual indication of the
bewirkt. measured oil temperature, corresponding to transformer load.
For further details please refer to the operating instructions
Weitere Informationen für das Zusatzgerät ZT-F2 finden Sie
BA 2033 for the ZT-F2.
in der Betriebsanleitung BA2033.
3 Montage 3. Installation
ACHTUNG CAUTION
Die in dieser Montage- und Betriebsanleitung vorge- The operating and installation conditions demanded
schriebenen Betriebs- und Montagebedingungen müssen by this installation and operating instructions must be
strikt eingehalten werden. strictly complied with.
3.1 Montage des Geräts 3.1 Mounting the device

The pointer thermometer is attached to the transformer by its
Das Zeigerthermometer wird mit der Befestigungsplatte (Bild
mounting plate (Fig.1/11). The spacing between the fixing holes
1/11) am Trafo montiert. Der Abstand der Befestigungslöcher
is 140mm and the diameter of the holes is 9mm. The thermo-
beträgt 140mm, der Lochdurchmesser 9mm. Die Einbaulage
meter should be installed vertically. The location of the device
muss senkrecht sein. Der Einbauort ist so zu wählen, dass weder
must be chosen to avoid any irregular vibrations or electroma-
Vibrationen noch Netzschwingungen auftreten.
gnetic fields which are above the pertinent electromagnetic
Die Einbaulage muss senkrecht sein.
compatibility standards.
3.2 Kapillarleitung (Bild 1/12)
3.2 Capillary tube (Fig. 1/12)
Rollen Sie die Kapillarleitung knick- und verwindungsfrei
Roll out the capillary tube avoiding kinks and loops. Do not rip,
aus. Das Zeigerthermometer darf nicht an der Kapillarleitung
pull, squeeze or bend this tube. Never carry the thermometer
getragen werden! Verlegen und fixieren Sie die Kapillarleitung,
by the capillary tube. Route the capillary tube and fix it in
überschüssige Kapillarleitung aufwickeln und im Bereich nicht
position. Roll up excess tube and store it in a position not sub-
zu hoher Temperaturen (max. 60° C) befestigen. Minimaler
ject to excessive temperatures (max. 60°C). Minimum winding
Biegeradius 10mm. Minimaler Aufwickeldurchmesser 80mm
diameter is 80 mm (see fig. 1).
(siehe Bild 1).
3.3 Temperature sensor (Fig.1/13)
3.3 Temperaturfühler (Bild 1/13)
Fill the transformer thermometer pocket (e.g. acc. to EN50216-4,
Trafo-Thermometertasche (z.B. nach EN 50216-4 vormals
formerly DIN 42554 or similar) up to two thirds full with oil or
42554 oder ähnlich) zu 2/3 mit Öl oder Wärmeleitpaste füllen
heat conducting paste and screw the thermowell as shown in
und die Einbauhülse (Bild 2/2) einschrauben. Die Kapillarleitung
Fig. 2/2 into place. Insert the temperature sensor and capillary
mit dem Temperaturfühler bis zum Anschlag in die Einbauhülse
tube into the thermowell as far as possible and tighten it up
einschieben und Kabelverschraubung M16 festschrauben.
using the M16 cable gland. If the thermometer is to be used
Wird das Thermometer mit einer Kombihülse oder einem with either a combi well or a transformer transmitter type
Trafo-Temperaturgeber ZT-F2 eingesetzt, siehe hierzu BA2032 ZT-FZ, please refer to the operating instructions BA2032 or
(Kombihülse) bzw. BA 2033 (ZT-F2). BA2033 respectively.
BA 2046/00/05 5
4 Elektrischer Anschluss/Electrical connection
3.4 Tretschutz (Bild 2/1) optional 3.4 Kick protection (Fig.2/1) optional
Falls gewünscht, Tretschutz auf die Verschraubung der If required, fit the kick protection to the adapter of the
Schutzhülse (Bild 2/2) aufsetzen und die Kapillarleitung thermowell (Fig. 2/2) and route the capillary tube inside the
innerhalb des Tretschutzes verlegen. Ziehen Sie die Befesti- kick protection. Tighten the fixing screw (Fig. 2/4, wrench size
gungsschraube (Bild 2/4) des Tretschutzes an einer Schlüssel- 13mm) of the kick protection to a flat side of the thermowell
fläche der Verschraubung der Schutzhülse an. adapter.
1. Tretschutz/Kick protection
2. Schutzhülse/Thermowell 3
3. Temperaturfühler/Temperature sensor
4. Befg-Schraube/Fixing screw
Bild 1/Fig. 1 Bild 2/Fig. 2

3.5 Schleppzeiger (Bild 1/9) 3.5 Maximum pointer (Fig.1/9)
Der Schleppzeiger wird vom Zeiger betätigt und kennzeichnet The maximum pointer is operated by the pointer and records
dessen Maximalausschlag. Die Rückstellung des Schleppzei- the maximum reading of a temperature measurement. The
gers erfolgt über den Knopf (Bild 1/10). maximum pointer can be reset using the knob (Fig. 1/10).
4 Elektrischer Anschluss 4 Electrical connection
WARNUNG WARNING
Elektrische, lebensgefährliche Spannung! Electrical voltages, danger to life!
Vor dem Öffnen des Gerätes müssen alle Anschlussleitungen All connecting wiring must be free of voltage before
stromlos sein. opening the device.
Zum Anschließen der elektrischen Leitungen, Einstellen und The bayonet fixing ring must be removed in order to connect,
Prüfen der Mikroschalter muss das Gerät geöffnet werden. set and check the microswitches. Turn the ring anti-clockwise
Hierzu den Bajonettverschlussring bis zum Anschlag gegen as far as possible and then lift it off.
den Uhrzeigersinn drehen und abheben.
When closing the device, make sure that the maximum
Beim Verschliessen des Geräts ist auf die richtige Stellung des pointer (Fig. 1/9) is in the correct position. It must be to the
Schleppzeigers (Bild 1/9) zu achten. Dieser muss rechts vom right of the pointer (Fig. 1/4). Replace the ring and turn it
Zeiger (Bild 1/4) stehen. Den Bajonettverschlussring wieder clockwise as far as it will go.
aufsetzen und bis zum Anschlag im Uhrzeigersinn drehen.
4.1 Connecting the microswitches (Fig. 3)
4.1 Anschluss der Mikroschalter (Bild 3)
To connect the microswitches flip up the covering plate (Fig.
Zum Anschließen klappen Sie die Abdeckblende (Bild 1/2) 1/2). Remove the outer sheaths of the connecting cables to
hoch. Entfernen Sie jeweils den Mantel der Anschlussleitun- a length of approx. 160 mm and then the insulation of the
gen auf einer Länge von ca. 160mm und die Isolierung der individual conductors to a length of approx. 6 mm. Install
benötigten Litzen auf einer Länge von ca. 6mm. Montieren the cable glands provided loosely to the incoming cables and
6 BA 2046/00/05
4 Elektrischer Anschluss/Electrical connection Messko
Sie die beiliegenden Kabelverschraubungen mit den An- housing. This must be done as shown in the appendix Fig. 8.
schlusskabeln entsprechend der Zeichnung im Anhang Pay close attention to cable gland assembly and ensure
(Bild 8). Achten Sie darauf, dass die Kabelverschraubungen that the seal is properly fitted to avoid any water ingress.
die Kabel flüssigkeitsdicht umschliessen. Schließen Sie die Connect the incoming wiring to the terminal strip (Fig. 3/1)
einzelnen Litzen entsprechend dem auf der Abdeckblende in accordance with the connection diagram (Fig. 3/3) printed
aufgedruckten Anschlussschema (Bild 3/3) an der Klemmleiste on the cover plate.
(Bild 3/1) an.
4.2 Verstellen und Prüfen der Mikroschalter (Bild 4) 4.2 Checking and adjusting the microswitches (Fig. 4)
Zum Verstellen eines Mikroschalters, schieben Sie diesen von To set a microswitch, slide it by hand to the desired position.
Hand in die gewünschte Position.
ACHTUNG CAUTION
Die Mikroschalter dürfen nicht an den farbigen Anzeige- Do not slide the microswitches on the colored indicator
spitzen verschoben werden. Die Anzeigespitzen können points. The indicator points may break off or be bent.
abbrechen oder verbogen werden.
Zum Prüfen der Mikroschalter, die sich rechts vom Zeiger To check the microswitches which are located to the right
befinden, drehen Sie den Zeiger von Hand im Uhrzeigersinn of the pointer, turn the pointer clockwise by hand past the
an den Mikroschaltern vorbei und anschließend wieder microswitches and back. A return spring pulls the pointer
zurück. Eine Rückholfeder zieht den Zeiger wieder in seine back to its original position (Fig. 4).
Ausgangsposition zurück (Bild 4).
ACHTUNG CAUTION
Der Zeiger darf hierzu nicht losgelassen werden, er muss Do not release the pointer here. It must be slowly retur-
langsam in seine Ausgangsposition zurückgeführt werden. ned to its original position. If the pointer snaps back, the
Schnellt der Zeiger zurück, können die Mikroschalter microswitches may be damaged.
beschädigt werden.
Mikroschalter, die sich links vom Zeiger befinden, sind zum To check the microswitches which are located to the left of
Prüfen im Uhrzeigersinn am Zeiger vorbeizuschieben (wie the pointer, slide them clockwise past the pointer, in the same
beim Verstellen der Mikroschalter). Nach dem Prüfen müssen way as when setting the microswitches. After checking, the
die Mikroschalter wieder auf ihren ursprünglichen Wert microswitches must be reset to their original positions.
eingestellt werden.
BA 2046/00/05 7
5 Anzeigekontrolle und Nachjustierung/Indication control and readjustment
6 Wartung/Maintenance
7 Technische Daten/Technical data
ACHTUNG CAUTION
Der Zeiger darf nie gegen den Uhrzeigersinn hin zu The pointer must never be turned anti-clockwise to lower
tieferen Temperaturen verdreht werden. Das Messsystem temperatures. This will damage the measuring system.
wird dadurch beschädigt.
5 Anzeigekontrolle und Nachjustierung 5 Indication control and readjustment

Die Zeigerthermometer werden im Werk kalibriert. Sollte es The pointer thermometers are calibrated at the factory. If it
dennoch erforderlich sein, die Anzeige neu zu justieren, so is necessary to readjust it, indication control and comparison
sollten Anzeigekontrollen und Vergleichsmessungen nur in measurements should only be carried out in agitated water
bewegten Wasserbädern vorgenommen werden, die über baths in witch the temperature remains constant for several
einige Minuten (ca. 15 Min.) temperaturkonstant bleiben. minutes (approx. 15 min.). Readjustments are possible. The
Eine Nachjustierung ist möglich. Die Justierschraube (Bild 1/3) adjustment screw (Fig. 1/3) is on the front of the instrument.
befindet sich auf der Vorderseite des Instruments.
ACHTUNG CAUTION
Das Gerät ist werkseitig kalibriert. Durch eine Nachjus- The pointer thermometers are calibrated and set at the
tierung erlischt die Garantie für die ordnungsgemäße factory. Readjusting them results in the loss of accuracy
Funktion des Geräts. as well as the guarantee for the device.
Weiterhin kann es durch eine nachträgliche Nachjustier- Furthermore, a later readjustment can lead to deviations
ung zu Abweichungen zwischen dem Zeigerthermometer between the pointer thermometer and the analog
und den Analogausgängen der Temperaturgeber ZT-F2 outputs of the transformer temperature transmitter type
kommen. ZT-F2.
6 Wartung 6 Maintenance
Eine regelmäßige Wartung ist nicht erforderlich. Regular maintenance is not required.
Bei den turnusmäßigen Überprüfungen des Transformators During the regular check of the transformer, we recommend
empfehlen wir folgende Kontrollen durchzuführen: checking the following.
- Überprüfen Sie den äußeren Zustand des eingebauten - Check the exterior of the installed device for damage.
Gerätes auf Beschädigungen.
ACHTUNG CAUTION
Die in dieser Betriebsanleitung gemachten Angaben sind The details made within these operating instructions are valid
für Standardgeräte gültig. Bei Sonderausführungen sind die for standard products only. For special designs refer to the
Angaben des Typenschilds und der Bestellung zu beachten. details of the nameplate as well as the order confirmation.
7 Technische Daten 7 Technical data

Abmessungen siehe Bild 7 Dimensions refer to Fig. 7
Werkstoffe Materials
Frontring und Gehäuse: Stahlblech, verzinkt, Ring and casing: Sheet steel, galvanized,
Pulverbeschichtung RAL 7033 powder coating RAL 7033
Sichtscheibe: Verbundsicherheitsglas Glass: Laminated safety glass
Temperaturfühler: Messing, blank Temperature bulb: Brass, bright
Befestigungsplatte: Edelstahl Mounting plate: Stainless steel
Kapillarleitung: Kupfer-Kapillare mit Capillary tube: Copper capillary tube
Schutzmantel with protective sheath
Kabelverschraubungen: 4x M25x1,5 Messing, Cable glands: 4x M25x1,5, nickel-plated
vernickelt
8 BA 2046/00/05
7 Technische Daten/Technical data Messko
Kenndaten Specifications
Meßbereich: -20...140°C Typ MT-ST160F, Measuring ranges: -20...140°C Typ MT-ST160F,
0........160°C Typ MT-STW160F2, 0........160°C Typ MT-STW160F2,
Messtoleranz: ±3°C nach EN 13190 Klasse 1 Tolerances: ± 3°C according to EN 13190
und DIN 16196 class 1 and DIN16196
Aufstellung: Innenraum und Freiluft, Location: indoor and outdoor, tropics
tropenfest Ambient temperature: -50 to 80 °C
Umgebungstemperatur: -50... 80°C Degree of protection: IP55 in accordance with
Schutzart: IP55 nach IEC 60 529 IEC 60 529
Belüftung: Belüftungseinrichtung, Ventilation: Ventilation unit, no conden-
beschlagfrei bis 80% rel. sation up to 80% humidity
Feuchte
Schleppzeiger: Rückstellbarer Maximumzeiger Drag hand: Resetable maximum pointer
Mikroschalter Microswitches
Anzahl: 1 bis 6 verstellbare Number: 1 to 6 adjustable
Mikroschalter microswitches
Belastbarkeit: 5A bei 250VAC (110VAC) Rated current: 5A at 250VAC (110VAC)
cosw=1 cosw=1
0,4A bei 250VDC 0,4A at 250VDC
0,6A bei 110VDC 0,6A at 110VDC
Schalterstellung: siehe Bild 5 und 6, Switch positions: Refer to Fig. 5 and 6,
andere auf Anfrage others on request
Schalterabstand: 6% des Meßbereiches Switching distance: 6% of measuring range
Schalthysterese: ca. 5°C Switching hysteresis: approx. 5°C
(bei sinkender Temperatur) (at decreasing temperatures)
Kontaktmaterial: Silber-Cadmium-Oxid Contact materials: Silver-Cadmium-Oxide
Nennisolationsspannung: 2500VAC/1min-Schaltkontakte Rated insulation voltage: 2500VAC/1min-switching
und Heizkreis gegeg Erde contacts and heating circuit
500VDC/1min-Analogausgang to ground
gegen Erde 500VDC/1min-analog output
to ground
1+2 eng, Standard 1+2/3+4 eng

1+2 close switching, standard 1+2/3+4 close switching
rot blau grün gelb rot blau grün gelb
red blue green yellow red blue green yellow
BA 2046/00/05 9
8 Anhang/Appendix
8.1 Anbauzeichnung 8.1 Installation diagram
Bild 7/Fig. 7
8.2 Kabelverschraubung 8.2 Cable gland
Bild 8/Fig. 8
10 BA 2046/00/05
Messko
BA 2046/00/05 11
01-08 Esser
© Messko GmbH Phone: +49 (0)6171/6398 - 0
www.messko.com Gablonzer Straße 25-27 Fax: +49 (0)6171/6398 - 98
61440 Oberursel E-Mail: info@messko.de
Bitte beachten: Die in allen unseren Publikationen enthalte-

nen Angaben können in Details von dem gelieferten Gerät
abweichen. Änderungen bleiben vorbehalten.
Important note: The information contained in all of our

publications may differ in detail from the actual equipment
delivered. Subject to change without prior notice.
Messko
BA2046/00/05 • Art.Nr./Art. no. 990448 • Printed in Germany
12 BA 2046/00/05
OPERATING MANUAL
28 GD, GE, GF
SAP No.: 112010276/20 Page: 193

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 194

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
GD BUSHINGS, RECEPTACLES, CABLE SEALING ENDS ≥ 1 KV ≥ 1 KV
GE BUSHINGS,RECEPTACLES, CABLE SEALING ENDS < 1 KV
GF CABINETS, TERMINAL BOXES (SUB-DISTRIBUTION BOARDS)
GD 001 Bushing for winding H.V. - 1U,1V,1W
GD 002 Bushing for winding H.V. - 1N
GD 013 Bushing DIN 42533 - DT20Nf1000
for stabilizing winding - 3U1,3W2
GD 209 Bushing for winding L.V. - 2U,2V,2W
make PFISTERER type 4xGr.3, 36kV, 3150A
order no. 827146336
GD 210 Bushing for winding L.V. - 2N
make PFISTERER type 2xGr. 3, 36kV, 2200/2500A
order no. 827660001
SAP No.: 112010276/20 Page: 195

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 196

Order No.: 1431517
Serial No.: 150 556
1ZSE 2750-102 en, Rev. 7
Transformer bushings, type GOB

Technical guide
This Technical Guide has been produced to allow transformer manufacturers, and their
designers and engineers, access to all the technical information required to assist them
in their selection of the appropriate Transformer Bushing. The Guide should be used in
conjunction with the Selection Guide to allow the optimum selection to be made.
The technical information pertaining to bushings manufactured by ABB has been divided
into separate documents, with one document for each type.
The information provided in this document is intended to be general and does not cover
all possible applications. Any specific application not covered should be referred directly
to ABB, or its authorized representative.
ABB makes no warranty or representation and assumes no liability for the accuracy of
the information in this document or for the use of such information. All information in this
document is subject to change without notice.
Contents
Design________________________________________ 4
Test tap__________________________________ 5
Testing________________________________________ 5
Test tap adapter____________________________ 5
Electrical data__________________________________ 6
Common specifications___________________________ 6
Conductor loading_______________________________ 7
Overloading of bushings_____________________ 7
Short-time current__________________________ 7
52 – 170 kV
Dimensions____________________________________ 8
Bushings without oil level gauge_______________ 8
Shed form________________________________ 9
Dimensions____________________________________ 10
Bushings with oil level gauge_ ________________ 10
Shed form________________________________ 11
Ordering particulars______________________________ 12
Bushings without oil level gauge_______________ 12
Bushings with oil level gauge_ ________________ 14
Connection details_______________________________ 16
Inner terminal_ ____________________________ 16
Solid rod conductor_________________________ 16
Outer terminal_____________________________ 17
Separate terminal plate with bolts______________ 17
Arcing horns_ _____________________________ 17
300 kV
Dimensions____________________________________ 18
Type GOB 1050____________________________ 18
Shed form________________________________ 18
Type GOB 1050____________________________ 19
Recommendations for positioning___________________ 20
Design
The bushing is built up around a centre tube on which the condenser body
is wound. The upper insulator, lower insulator and mounting flange are held
between the end plates by the centre tube. Sealing is accomplished by oil-
resistant rubber gaskets in grooves.
The annular space between the condenser body and the porcelain is filled
with transformer oil. A gas-filled expansion space is left at the top. For GOB
bushings without oil level gauge the oil level can be checked by means of a
dipstick in the oil filling hole.
The lower end is shielded by an epoxy resin insulated aluminium shield.
The shield is integrated for 52–170kV, and separate for 300 kV bushings.
The inner terminal is attached to the centre tube by means of a through-
going resilient pin which becomes locked when the outer terminal is
screwed on. This design, patented by ABB, ensures effective electrical
contact between the inner and outer terminals. The inner terminal can be
chosen for connection to leads either by brazing or crimping.
The outer terminal is available in aluminium or copper alloy and can be
supplemented by terminal plates of corresponding material.
The upper insulator is made in one piece of high quality electrical porcelain.
The mounting flange is manufactured of corrosion-resistant aluminium alloy.
The mounting flange, the top housing and the top washer are protected
by painting with a two-component primer and a grey-blue finishing coat of
paint. The standard colour is Munsell 5.5B 55/1.25.
Outer terminal stud
Oil filling holes

with sealing plug Top
washer
Expansion space
Oil Top
housing
Porcelain insulator
air side
Test tap
Mounting flange
Flange extension
Top
Porcelain insulator housing
oil side
Prism
Condenser body glass
Insulated shield Oil filling

(integrated or holes with
separate) sealing plug
Fig. 1. Transformer bushing type GOB
4
The bushings are delivered oil-filled and ready for use.
If the bushing is mounted with an inclination of more than 45° from the
vertical, special measures may have to be taken to ensure the condenser
body is fully submerged in oil. Further information can be obtained on
request.
Test tap
The outer conducting layer of the
condenser body is connected to
an insulated test tap on the flange.
During operation the test tap cover
must be screwed on, in order to earth
the bushing. The max. test voltage of
the tap is 2 kV, 50 Hz for 1 minute.
Max. service voltage is 600 V.
goh_0010
Fig. 2. Test tap.
Testing
During the manufacture and on its completion the bushing is subjected
to a number of routine tests, in compliance with IEC 60137. A tightness
test is carried out on the assembled bushing after the final drying and
impregnation. The test is made with an oil overpressure of 180 kPa (1.8
bar) for 12 hours at ambient temperature. No sign of leakage is allowed.
Each bushing is subjected to a final electrical routine test. The test
is made at room temperature with the bushing submerged in oil.
Capacitance and tan δ are measured in steps up to the power frequency
withstand voltage, which is maintained for one minute. Capacitance and
tan δ are also measured at decreasing voltage at the same voltage levels
as before the one minute test.
Measurements for detection of internal partial discharge (PD
measurements) are also made. These measurements are carried out at
the same time as the power frequency withstand test. PD measurements
are made in steps up to the full test voltage and down. It is always
demonstrated that the PD value is max. 5 pC at test voltage equal to the
rated system voltage.
GOB 1050 is also routine tested with a dry lightning impulse voltage
withstand test.
Type tests have been carried out according to IEC 60137 and IEEE. Type
test reports are available on request.
Test tap adapter

For permanent connection of the
test tap to measuring circuits,
a test tap adapter is required.
Catalogue number 2769 531-D.
Fig. 3. Test tap adapter. goh_0011
5
Electrical data
Type GOB Rating Routine test Design data
Highest Phase-to- Dry lightning Wet power 1 min. dry Dry Wet
voltage for earth voltage impulse frequency AC 50 Hz switching switching
equipment Um Uy kV, peak kV, RMS kV, RMS impulse impulse
kV, RMS kV, RMS kV, peak kV, peak
250-800 52 52 250 105 120 230 -
250-1250 52 52 250 105 120 230 -
325-800 72.5 72.5 350 140 160 300 -
380-800 100 72.5 380 150 162 330 -
380-1250 100 72.5 380 150 162 330 -
450-800 123 90 450 185 195 410 -
550-800 170 123 550 230 260 470 -
550-1250 170 123 550 230 260 470 -
650-1250 170 145 650 275 300 580 -
750-1250 170 170 750 325 365 670 -
1050-1100 300 173 1050 510 510 810 750
Common specifications
Application: Transformers
Classification: Oil impregnated paper, capacitance graded, outdoor-immersed bushing
Ambient temperature: +40 to -40 °C, minimum value as per temperature class 2 of IEC 60137
(-60 °C according to GOST 10693-81 item 2.26)
Altitude of site: < 1 000 m
Level of rain and humidity: 1-2 mm rain/min horizontally and vertically, as per IEC 60060-1
Pollution level: According to specified creepage distance and IEC 60815 1
Type of immersion medium: Transformer oil. Maximum daily mean oil temperature 90 °C. Maximum temporary oil temperature
115 °C
Oil level below bushing flange: Maximum 30 mm
Max. pressure of medium: 100 kPa overpressure
Markings: Conforming to IEC/ IEEE
1) IEC 60815 "Guide for selection of insulators with respect to polluted conditions."
6
Conductor loading
The rated currents listed in this catalogue are the standardised values
according to IEC 60137 which, with the largest possible conductor, fulfil
the temperature rise test.
The GOB bushings fulfil the temperature rise test requirements according
to IEC 60137 and IEEE C57.19.00-1991.
Rated current of Conductor 52 – 170 kV 300 kV

bushing Permissible current Permissible current
A
IEC, A IEEE, A IEC, A IEEE, A
800 Solid rod LF 170 019 800 730
1100, 1250 Solid rod LF 170 052 1250 1200 1100 1000
800, 1100, 1250 Stranded cable 50 mm2 165 150 155 130
2
800, 1100, 1250 Stranded cable 70 mm 225 210 190 160
2
800, 1100, 1250 Stranded cable 95 mm 300 285 240 195
800, 1100, 1250 Stranded cable 150 mm2 475 415 330 275
2
1100, 1250 Stranded cable 185 mm 530 460 380 320
1100, 1250 Stranded cable 285 mm2 665 570 540 450
Overloading of bushings
If the conductor for the bushing is selected with 120 % of the rated current
of the transformer, the bushing is considered to be able to withstand the
overload conditions stated in IEC 60354 without further clarifications or
tests, according to IEC 60137.
Short-time current
The rated thermal short-time current (Ith) is calculated according to IEC
60137. Read more in product information 2750 515-118.
For draw-lead of stranded copper, values are given for 100 mm2. For other
areas the short-time current is directly proportional to the area.
Conductor Rated Area Short-time current (Ith) Dynamic
current mm2 current (Id)
1s 2s
A kA, peak
kA, RMS kA, RMS
Solid rod 800 - 30 21 52
Solid rod 1100/1250 - 70 50 125
Stranded draw-lead 365 100 9.6 6.8 17
7
52 – 170 kV
Dimensions
Bushings without
oil level gauge
Draw
lead
length = Fig. 4.2. Fig. 4.3
Top design Top design
Fig. 4.1. GOB design Fig. 4.4

1)
The bushings can be provided
n1 Holes
with a longer shield L9 + 50 mm,
D = 16
in which case dimensions L, L1
and L5 also increase by 50 mm.
Type Rated Cat. No. Space Net Top Dimensions in mm

GOB current for mass design L1) L11) L2 L3 L4 L51) L6 L7 L8 L91)
A current kg acc. to
trans- Fig. 6
former
mm
250 800 LF 123 013- - 23 2 998 240 590 65 555 60 - 480 70 15

015- 300 25 2 1258 500 590 555 260
083- 500 27 3 1558 700 690 655 460
250 1250 LF 123 017- - 26 2 1063 255 605 65 580 75 - 480 70 25
019- 300 29 2 1323 515 605 580 260
085- 500 31 3 1623 715 705 680 460
325 800 LF 123 025- - 27 2 1198 295 735 93 700 60 - 625 70 15
027- 300 31 2 1458 555 735 700 260
089- 500 35 3 1758 755 835 800 460
380 800 LF 123 037- - 33 2 1303 345 790 98 755 60 - 680 70 15
039- 300 37 2 1543 585 790 755 240
095- 500 39 3 1843 785 890 855 440
380 1250 LF 123 041- - 37 2 1368 360 805 98 780 75 - 680 70 25
043- 300 39 2 1608 600 805 780 240
097- 500 43 3 1908 800 905 880 440
450 800 LF 123 049- - 42 2 1473 345 960 98 925 60 - 850 70 15
051- 300 45 2 1713 585 960 925 240
053- 500 48 3 2013 785 1060 1025 440
550 800 LF 123 061- 100 70 2 1823 495 1160 60 1125 90 95 1050 60 25
063- 300 73 3 2108 680 1260 1225 280
107- 500 77 3 2308 880 1260 1225 480
550 1250 LF 123 065- 100 105 2 1868 495 1170 68 1145 100 95 1050 60 30
067- 300 109 3 2153 680 1270 1245 280
109- 500 115 3 2353 880 1270 1245 480
650 1250 LF 123 073- 150 116 2 2153 580 1370 60 1345 100 120 1250 60 30
075- 300 122 3 2413 740 1470 1445 280
113- 500 126 3 2613 940 1470 1445 480
750 1250 LF 123 077- 200 180 2 2468 685 1580 70 1555 100 165 1460 60 30
078- 300 190 3 2683 800 1680 1655 280
079- 500 200 3 2883 1000 1680 1655 480
8
52 – 170 kV
Shed form
The shed form is of the anti-fog type with alternating long and short
sheds. For each pair of sheds the ratio between nominal creepage
distance and the axial length is 3.43
and the ratio between protected and
nominal creepage distance is 0.40.
According to IEC 60815 the creepage
factor C.F. is <3.2 and the profile factor
P.F. is >1.1.
For special customer demands
regarding creepage distance, other
shed forms may be used.
Fig. 4.5. Shed form, GOB 52 – 170 kV.
Dimensions are subject to modification without notice.

Creepage distance Cantilever load
D1 D2 D3 D4 D5 D6 D7 D8 D10 n1 R1 R2 T total protected Max. 60 s
mm mm permitted Test
loading N
perpendicular
to the
terminal
N
86 22 86 115 88 185 225 230 46 6 8 6 16 1500±50 580 1800 2340
101 34 112 120 101 250 290 245 70 8 12 10 16 1500±50 580 3000 4000
95 22 86 115 96 185 225 230 46 6 8 6 16 1980±50 775 1500 1950
95 22 86 115 96 185 225 240 46 6 8 6 16 2210±70 870 1400 1800
112 34 112 120 112 250 290 245 70 8 12 10 16 2210±70 870 2900 3750
95 22 86 115 96 185 225 245 46 6 8 6 16 2720±80 1060 1150 1500
126 22 118 145 150 250 290 280 50 8 12 12 18 3430±100 1350 1300 1700
160 34 140 175 200 290 335 300 70 12 15 15 20 3430±100 1350 2400 3100
160 34 140 175 200 290 335 305 70 12 15 15 20 4080±110 1620 2600 3380
184 34 140 230 184 290 335 350 70 12 15 15 20 4800±150 1700 2600 3350
9
52 – 170 kV
Dimensions
Bushings with
oil level gauge
Draw
lead
length =
Fig. 5.2. Fig. 5.3
Top design Top design
Fig. 5.1. GOB design. Fig. 5.4

n1 Holes
1)
D = 16 The bushings can be provided
with a longer shield L9 + 50 mm,
in which case dimensions L, L1
and L5 also increase by 50 mm.
Type Rated Cat. No. Space Net Top Dimensions in mm

GOB current for mass design L1) L11) L2 L3 L4 L51) L6 L7 L8 L91)
A current kg acc. to
trans- Fig. 6
former
mm
250 800 LF 123 171- - 24 2 1138 240 730 65 695 60 - 480 70 15

173- 300 26 1398 500 260
175- 500 28 1598 700 460
250 1250 LF 123 167- - 28 2 1203 255 745 65 720 75 - 480 70 25
168- 300 30 1463 515 260
169- 500 33 1663 715 460
325 800 LF 123 177- - 28 2 1338 295 875 93 840 60 - 625 70 15
179- 300 32 1598 555 260
181- 500 36 1798 755 460
380 800 LF 123 183- - 34 2 1443 345 930 98 895 60 - 680 70 15
185- 300 38 1683 585 240
187- 500 40 1883 785 440
380 1250 LF 123 101- - 38 2 1508 360 945 98 920 75 - 680 70 25
102- 300 41 1748 600 240
103- 500 44 1948 800 440
450 800 LF 123 145- - 43 2 1613 345 1100 98 1065 60 - 850 70 15
147- 300 46 1853 585 240
149- 500 49 2053 785 440
550 800 LF 123 189- 100 71 2 1963 495 1300 60 1265 90 95 1050 60 25
190- 300 74 2148 680 280
191- 500 78 2348 880 480
550 1250 LF 123 142- 100 106 2 2008 495 1310 68 1285 100 95 1050 60 30
143- 300 110 2193 680 280
144- 500 116 2393 880 480
650 1250 LF 123 192- 150 118 2 2293 580 1510 60 1485 100 120 1250 60 30
193- 300 124 2453 740 280
194- 500 128 2653 940 480
750 1250 LF 123 104- 200 187 3 2718 685 1830 70 1805 100 165 1460 60 30
105- 300 197 2833 800 280
106- 500 207 3033 1000 480
10
52 – 170 kV
Shed form
distance and the axial length is 3.43
and the ratio between protected and
nominal creepage distance is 0.40.
According to IEC 60815 the creepage
factor C.F. is <3.2 and the profile factor
P.F. is >1.1.
regarding creepage distance, other
shed forms may be used.
Fig. 5.5. Shed form, GOB 52 – 170 kV.

Creepage distance Cantilever load
D1 D2 D3 D4 D5 D6 D7 D8 D10 n1 R1 R2 T total protected Max. 60 s
mm mm permitted Test
loading N
perpendicular
to the
terminal
N
86 22 86 140 88 185 225 230 46 6 8 6 16 1500±50 580 1800 2340
101 34 112 140 101 250 290 245 70 8 12 10 16 1500±50 580 3000 4000
95 22 86 140 96 185 225 230 46 6 8 6 16 1980±50 775 1500 1950
95 22 86 140 96 185 225 240 46 6 8 6 16 2210±70 870 1400 1800
112 34 112 140 112 250 290 245 70 8 12 10 16 2210±70 870 2900 3750
95 22 86 140 96 185 225 245 46 6 8 6 16 2720±80 1060 1150 1500
126 22 118 200 150 250 290 280 50 8 12 12 18 3430±100 1350 1300 1700
160 34 140 265 200 290 335 300 70 12 15 15 20 3430±100 1350 2400 3100
160 34 140 265 200 290 335 305 70 12 15 15 20 4080±110 1620 2600 3380
184 34 140 265 184 290 335 350 70 12 15 15 20 4800±150 1700 2600 3350
11
52–170 kV
Ordering particulars
When ordering, please state:
Bushings without oil level gauge ■■ Type and catalogue number for bushings.
■■ Catalogue number for inner and outer terminal
assembly.
■■ Additional accessories or modifications.
■■ Test required, in addition to the normal routine tests.
■■ Test tap adapter, if required.
Note:
The catalogue number should have one of the following
letters added to it, to indicate the type of insulator and
oil end shield:
–K Normal oil end shield, brown porcelain
–L Normal oil end shield, light grey porcelain
–M Longer oil end shield, brown porcelain
–N Longer oil end shield, light grey porcelain
Oil end
shield
Bushings Connection details, Cat. No. LF 170

Type Rated Cat. No. Space for Bushing tube Inner terminal stud
GOB current current (See fig.) For crimping or brazing For brazing Undrilled
A transformer D2, mm Conductor area Conductor area with pilot
mm 50 mm2 70 mm2 95 mm2 <150 mm2 <285 mm2 hole
250 800 LF 123 013- - 22 010-M 010-N 010-L 010-S - 011-U
015- 300
083- 500
250 1250 LF 123 017- - 34 - - - - 011-T 011-V
019- 300
085- 500
325 800 LF 123 025- - 22 010-M 010-N 010-L 010-S - 011-U
027- 300
089- 500
380 800 LF 123 037- - 22 010-M 010-N 010-L 010-S - 011-U
039- 300
095- 500
380 1250 LF 123 041- - 34 - - - - 011-T 011-V
043- 300
097- 500
450 800 LF 123 049- - 22 010-M 010-N 010-L 010-S - 011-U
051- 300
053- 500
550 800 LF 123 061- 100 22 010-M 010-N 010-L 010-S - 011-U
063- 300
107- 500
550 1250 LF 123 065- 100 34 - - - - 011-T 011-V
067- 300
109- 500
650 1250 LF 123 073- 150 34 - - - - 011-T 011-V
075- 300
113- 500
750 1250 LF 123 077- 200 34 - - - - 011-T 011-V
078- 300
079- 500
12
52–170 kV
LF 170 019- LF 170 052-

800 A 1250 A
Outer terminal assembly
Stud with O-ring and locking pin Separate terminal plate with bolts Solid rod conductor Arcing horns
Aluminium Copper alloy Aluminium Tin-plated copper Alt. 1 Alt. 2 Mass kg
001-A 002-A 014-A 021-A 019 -A 019 - 2.6 004 -A
-D -B 3.3 -A
-E -C 4.2 -B
001-B 002-B 014-A 021-A 052 -A 052 - 6.8 004 -A
-D -B 8.4 -A
-E -C 10.6 -B
001-A 002-A 014-A 021-A 019 -F 019 - 3.1 004 -A
-K -G 3.9 -A
-L -H 4.7 -B
001-A 002-A 014-A 021-A 019 -M 019 - 3.5 004 -A
-R -N 4.2 -A
-S -P 5.0 -B
001-B 002-B 014-A 021-A 052 -V 052 - 8.6 004 -B
-Z -X 10.4 -B
-AA -Y 12.7 -B
001-A 002-A 014-A 021-A 019 -BL 019 - 4.0 004 -B
-BM -BN 4.7 -B
-BP -BR 5.5 -C
001-A 002-A 014-A 021-A 019 -T 019 - 4.9 004 -B
-X -U 5.7 -C
-Y -V 6.3 -C
001-B 002-B 014-A 021-A 052 -AM 052 - 12.0 004 -B
-AN -AP 14.1 -C
-AR -AS 15.5 -C
001-B 002-B 014-A 021-A 052 -F 052 - 14.0 005 -A
-K -G 15.9 -B
-L -H 17.5 -B
001-B 002-B 014-A 021-A 052 -M 052 - 16.3 005 -B
-R -N 18.0 -E
-S -P 19.5 -E
13
52–170 kV
Bushings with oil level gauge ■■ Type and catalogue number for bushings.
■■ Catalogue number for inner and outer terminal
assembly.
Note:
letters added to it, to indicate the type of insulator and
oil end shield:
–K Normal oil end shield, brown porcelain
–L Normal oil end shield, light grey porcelain
–M Longer oil end shield, brown porcelain
–N Longer oil end shield, light grey porcelain
Oil end
shield
Bushings Connection details, Cat. No. LF 170

Type Rated Cat. No. Space for Bushing tube Inner terminal stud
GOB current current (See fig.) For crimping or brazing For brazing Undrilled
A transformer D2, mm Conductor area Conductor area with pilot
mm 50 mm2 70 mm2 95 mm2 <150 mm2 <285 mm2 hole
250 800 LF 123 171- - 22 010-M 010-N 010-L 010-S - 011-U
173- 300
175- 500
250 1250 LF 123 167- - 34 - - - - 011-T 011-V
168- 300
169- 500
325 800 LF 123 177- - 22 010-M 010-N 010-L 010-S - 011-U
179- 300
181- 500
380 800 LF 123 183- - 22 010-M 010-N 010-L 010-S - 011-U
185- 300
187- 500
380 1250 LF 123 101- - 34 - - - - 011-T 011-V
102- 300
103 500
450 800 LF 123 145- - 22 010-M 010-N 010-L 010-S - 011-U
147- 300
149- 500
550 800 LF 123 189- 100 22 010-M 010-N 010-L 010-S - 011-U
190- 300
191- 500
550 1250 LF 123 142- 100 34 - - - - 011-T 011-V
143- 300
144- 500
650 1250 LF 123 192- 150 34 - - - - 011-T 011-V
193- 300
194- 500
750 1250 LF 123 104- 200 34 - - - - 011-T 011-V
105- 300
106- 500
14
52–170 kV
LF 170 019- LF 170 052-

800 A 1250 A
Outer terminal assembly
Stud with O-ring and locking pin Separate terminal plate with bolts Solid rod conductor Arcing horns
Aluminium Copper alloy Aluminium Tin-plated copper Alt. 1 Alt. 2 Mass kg
001-A 002-A 014-A 021-A 019 -AM 019 - 3.0 004 -B
-AS -AT 3.7 -B
-BB -BC 4.3 -B
001-B 002-B 014-A 021-A 052 -BC 052 - 7.7 004 -B
-BF -BD 9.3 -B
-BG -BE 10.8 -B
001-A 002-A 014-A 021-A 019 -AN 019 - 3.5 004 -B
-AU -AV 4.3 -B
-BD -BE 4.8 -B
001-A 002-A 014-A 021-A 019 -AP 019 - 3.9 004 -B
-AX -AY 4.6 -B
-BF -BG 5.1 -B
001-B 002-B 014-A 021-A 052 -BK 052 - 9.6 004 -B
-BN -BL 11.4 -B
-BP -BM 12.6 -B
001-A 002-A 014-A 021-A 019 -BS 019 - 4.4 004 -C
-BT -BU 5.1 -C
-BV -BX 5.6 -C
001-A 002-A 014-A 021-A 019 -AR 019 - 5.3 004 -C
-AZ -BA 5.8 -C
-BH -BK 6.4 -C
001-B 002-B 014-A 021-A 052 -AT 052 - 13.0 004 -C
-AU -AX 14.4 -C
-AV -AY 15.8 -C
001-B 002-B 014-A 021-A 052 -AD 052 - 14.9 005 -B
-AE -AF 16.1 -B
-AG -AH 17.7 -B
001-B 002-B 014-A 021-A 052 -AZ 052 - 18.0 005 -F
-BA -BB 19.0 -F
-AK -AL 20.5 -F
15
52 – 170 kV
Connection details
Inner terminal
Stud made of copper for connection of draw lead.
The inner terminal must be provided with an outer
terminal.
Fig. 6. Inner terminal.
Material and Conductor area Cat. No. Dimensions Mass

design mm2 mm kg
D1 D2 L
Copper for 50 LF 170 010 -M 11 14.5 35 0.3
crimping or
brazing 70 -N 13 17 35 0.3
95 -L 15 20 35 0.3
Copper for < 150 LF 170 011 -S 18 20 35 0.3
brazing only
undrilled -U 5 20 35 0.3
< 285 -T 29 32 20 0.6
undrilled -V 5 32 20 0.6
Solid rod conductor

The rod is produced from electrolytic copper and is divided into two parts.
For the 800 A conductor the two parts are held together by a centre bolt
with a resilient locking pin. For the
1100/1250 A conductor the two
parts are connected by counter-
sunk screws.
The lower part of the solid rod is
designed to enable connection by
brazing.
The solid rod conductor can be
divided either:
Alt. 1: 20 mm below the bushing
flange, or
Alt. 2: 20 mm below the upper end
of the bottom porcelain.
The solid rod conductor must be
provided with an outer terminal.
Fig. 7. Solid rod conductor.
Rated current 800 A Rated current 1100/1250 A

LF 170 019- LF 170 052-
16
52 – 170 kV
Outer terminal
Stud made of copper alloy or aluminium with O-ring and
locking pin. Other types can be provided on request.
Fig. 8. Outer terminal assembly.
Width across flats N
Material Cat. No. Dimensions Mass For bushings

mm kg with D2
mm
D L N
Aluminium LF 170 001 -A 30 170 55 0.5 22
-B 30 205 66 0.8 34
Copper alloy LF 170 002 -A 30 170 55 1.2 22
-B 30 205 66 2.3 34
Separate terminal plate with bolts

The separate terminal plate is used for connecting
the bushing to the line conductor.
Fig. 9. Separate terminal plate with bolts.
Material Cat. No.
Aluminium LF 170 014-A
Nickel-plated copper LF 170 021-A
Arcing horns
Arcing horns of galvanised steel can be
mounted on the bushing.
The lower rod is fastened onto the flange with
one of the fixing screws and the upper rod by
means of a bracket on the outer terminal.
The gap distances for standard arcing horns
are shown in the table. Other gap distances
on request.
Fig. 10. Gap distances.
Type GOB K C H
mm mm mm
250 230–440 315 112
325 320–580 315 112
380 400–620 315 112
450 400–780 315 112
550 620–960 315 114
650 700–1080 380 224
750 820–1290 380 224
1050 950–1840 420 410
17
300 kV
Dimensions D=265
D=355
Type GOB 1050
■■ Type and catalogue number for bushings.
■■ Catalogue number for inner and outer terminal assembly.
L2
L7
L4
L
Note:
letters added to it, to indicate the type of insulator and oil
L6 180
end shield:
–K Brown porcelain D=200
20
–L Light grey porcelain
L1
L3
D=34
D=450
D=400
12 holes
D=23
gob_0020
Rated Cat. No. Space for Net Creepage Cantilever

current current mass Dimensions in mm distance load
A transformer kg
L L1 L2 L3 L4 L6 L7 total protected Max Test
mm
mm mm N N
1100 LF 123 281- 300 335 3690 930 2555 49 2530 300 2066 7500 3200 1250 3200
LF 123 280- 600 350 3990 1230 2555 49 2530 600 2066 7500 3200 1250 3200
Shed form
distance and the axial length is 3.97 and the ratio between protected and
nominal creepage distance is 0.4. 67.5
R8
According to IEC 60815 the
creepage factor C.F. is 3.7 and the
profile factor P.F. is >1.1.
18°
31
10°

regarding creepage distance, 70
other shed forms may be used.
Fig. 11.5. Shed form, GOB 300 kV. R10
52.5 R4.5
gob_0021
18
300 kV
Type GOB 1050
M8
M8
D=7
20
D=32 L4 D=7
gob_0022
Fig. 11.1. Inner terminal.
Alt. 1 - 3
D=30
66
205
D=32
gob_0023
Fig. 11.2. Outer terminal.

28
D=28 gob_0025
156 R160
107 Fig. 11.3. Solid rod.
The solid rod can be divided:

R1 Alt. 1: 20 mm below the bushing flange
5
R6
D=105
Alt. 2: 20 mm below the upper end of the bottom porcelain
D=176
Alt. 3: 210 mm above the bottom end of the bushing
gob_0024
Fig. 11.4. Oil end shield.

Dimensions refer to the epoxy insulated shield. The thickness of the pressboard is 3 mm.
Connection details Cat. No. LF 170

Cat. No. Inner terminal stud Solid rod conductor Oil end shield Arcing
horns
For brazing Stud with O-ring and
locking pin
Conductor Undrilled Aluminium Copper Alt. 1 Alt. 2 Alt. 3 Epoxy Pressboard
area with pilot alloy insulated insulated
<285 mm2 hole
LF 123 281– 011-T 011-V 001-B 002-B 052 -FD 052 -FE 052 -FF 092-B 092-D 005-G
LF 123 280– -FA -FB -FC
19
Recommendations for positioning
The maximum stresses in
the oil at the surface of the
shield insulation must be
limited to those values normal
for insulated conductors and
similar components in the same
transformer. Earthed
layer
The adjacent recommendations
Distance to
are intended as guide lines when uninsulated detail Distance to flat
complete calculations are not surface e.g. tank or
carried out. core clamp
Type GOB Internal insulation level R (mm)

of transformer (kV)
250–800 170–70 65
250–95 75
250–1250 170–70 75
250–95 85
325–800 250–95 75
325–140 100
380–800 325–140 100
380–150 105
380–1250 325–140 105
380–150 110
450–800 380–150 105
450–185 125
550–800 450–185 130
550–230 155
550–1250 450–185 140
550–230 160
650–1250 550–230 160
650–275 185
750–1250 650–275 185
750–325 210
1050–1100 850–360 240
950–395 260
1050–460 300
ABB Ludvika, Sweden

GOB 250 LF 123 013-K
No. 1ZSC 257 007
Um/Uy 52/52 kV Ir 800 A 50/60 Hz Nameplate with
LI / AC 250/120 kV marking example.
M 23 kg L 240 mm 0-90 °
C1 128 pF Tan δ 0.33 %
C2 80 pF Tan δ 0.45 %
20
1ZSE 2750-102 en, Rev. 7, 2007-10-15
ABB AB
Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com/electricalcomponents
2750 515-12 en, Rev. 9
Transformer bushings, type GOB

Installation and maintenance guide
This document must not be copied without our written permission, and the
contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Safety information
Keep this instruction available to those responsible for the installation, maintenance,
and operation of the bushing.
The installation, operation, and maintenance of a bushing present numerous potential
unsafe conditions, including, but not limited to, the following:
■ High pressures
■ Lethal voltages
■ Moving machinery
■ Heavy components
■ Slip, stumble or fall
Specialized procedures and instructions are required and must be adhered to when
working on such apparatus. Failure to follow the instructions could result in severe
personal injury, death, and/or product or property damage.
Additionally, all applicable safety procedures such as regional or local safety rules and
regulations, safe working practices, and good judgement must be used by the person-
nel when installing, operating, maintaining and/or disposing such equipment.
Safety, as defined in this instruction, involves two conditions:
1. Personal injury or death.
2. Product or property damage (includes damage to the bushing or other property,
and reduced bushing life).
Safety notations are intended to alert personnel of possible personal injury, death or
property damage. They have been inserted in the instructional text prior to the step in
which the condition is cited.
The safety conditions are headed by one of the three hazard intensity levels which are
defined as follows:
DANGER
Immediate hazard which will result in severe personal injury, death, or property
damage.
WARNING
Hazard or unsafe practice which could result in severe personal injury, death, or pro-
perty damage.
CAUTION: Hazard or unsafe practice which could result in minor personal injury, or
property damage.
Contents
1 Description_______________________________________________ 6
1.1.1 Design_ _________________________________________________ 6
1.1.2 Design of horizontally mounted bushings_______________________ 8
1.2 Operating conditions_______________________________________ 9
1.3 Mechanical loading________________________________________ 9
1.4 Spare parts_______________________________________________ 10
2 Installation_______________________________________________ 10
2.1 Tools____________________________________________________ 10
2.2 Consumables_ ____________________________________________ 10
2.3 Transport and handling_ ____________________________________ 11
2.4 Lifting from the box________________________________________ 11
2.5 Mounting________________________________________________ 12
2.5.1 Mounting of oil-end shield___________________________________ 12
2.5.2 Inner terminal / Stranded cable_ ______________________________ 13
2.5.3 Solid rod conductor________________________________________ 14
2.5.4 Horizontal mounting of bushing_ _____________________________ 15
2.6 Mounting of outer terminal__________________________________ 15
2.7 Flange earthing____________________________________________ 16
2.8 Waiting time before energizing_______________________________ 16
2.9 Recommended tests before energizing_ ________________________ 17
2.9.1 Tightness test between transformer and bushing__________________ 17
2.9.2 Tightness test of bushing outer terminal_ _______________________ 17
2.9.3 Measurement of capacitance and tan δ_ ________________________ 18
2.9.4 Check of through resistance__________________________________ 20
3 Maintenance______________________________________________ 21
3.1 Recommended maintenance and supervision_ ___________________ 21
3.1.1 Cleaning of insulator surface_________________________________ 21
3.1.2 Measurment of capacitance and tan δ_ _________________________ 21
3.1.3 Thermovision (infrared camera) check for local overheating
on connectors_____________________________________________ 21
3.1.4 Check for leakage_ ________________________________________ 21
3.1.5 Checking and adjustment of the oil level________________________ 22
3.1.6 De-mounting of horizontally mounted bushing___________________ 23
3.2 Disposal after end of service life______________________________ 23
1 Description
1 Description
1.1.1 Design
The design and dimensions of bushings type GOB are given in the Technical Guide,
1ZSE 2750-102. The design principle is also shown in Figs. 1a–d. For bushings with
a relatively small oil quantity the expansion space at the top of the insulator is suf-
ficient. For bushings with larger oil quantity the expansion space has been increased
with at top housing according to Fig. 1b. An alternative design, with an oil level glass
of prisma type according to Fig. 1c is also available. All GOB bushings are equipped
with a test tap, see Fig. 2, connected to the outer layer of the condenser body. The test
tap can be used for checking of the bushing insulation by capacitance and dissipation
factor measurements. The maximum test voltage for the test tap is 2 kV, one minute at
50 to 60 Hz. It serves as a test tap, and in connection with an external capacitance it
can be used as a voltage tap. The operation voltage is limited to 600 V. An adapter is
available for permanent connection to measuring circuits, see Fig. 3.
Fig. 1. Design principle

1) Outer terminal stud
2) Oil filling holes with sealing plug M8,
2522 731‑A
3) Oil
4) Expansion space
5) Prism type glass
a) GOB 250 ‑ 650
2911 720‑2
b) GOB 750 - 1050
2911 730‑1
6) Gasket
a) GOB 250 ‑ 650
O‑ring 49.5 x 3
2152 2012‑416 Fig. 1b
b) GOB 750 - 1050
O‑ring 34.2 x 3
2152 2011‑410
7) Porcelain insulator, air side
8) Test tap
9) Mounting flange
10) Condenser body
11) Insulated shield (integrated or separate)
12) Flange extension
13) Porcelain insulator, oil side
gob_0001
Fig. 1a
Fig. 1c
2750 515-12 en, Rev. 8

1 Description
gob_0018
Fig. 1d. Sealing plug, 2522 731-A

1) Bolt with flange DIN 6921, 2121 738-18
2) Gasket, 2152 899-132
Fig. 2. Test tap 2769 531-B (not self-earthing) 2

1) Bushing for test tap
2) Disc spring
3) Press nut
4) Cover 2749 528-B with O-ring 2152 484-2
5) Contact pin, 4 mm
6) O-ring
7) O-ring
8) Cable
gob_0015
Fig. 3. Adapter for permanent connection to measur-

ing circuits 2769 531‑D
1) Cover
2) Box
3) Cable gland Pr (screwed steel conduit) 22.5
(Pg 16 acc. to DIN 40430)
4) Protecting resistor, 10 kW, 5 W
5) Earthing connection (to be removed before con- goh_0008
nection of outer cable)

6) Nut
7) Belleville spring washer
8) Connector to test tap
9) O-ring
2750 515-12 en, Rev. 8

1 Description
1.1.2 Design of horizontally mounted bushings

If a bushing shall be mounted in horizontal position this must be clearly stated in the
order. The bushing flange is then supplied with an oil hole at the oil side of the flange
for connection of the bushing oil system to the transformer oil. As horizontally moun-
ted bushings must be completely oil filled this hole will provide the necessary oil
expansion for the bushing.
At delivery the hole is covered by a flat rubber gasket and a steel plate as shown in the
figure below. This arrangement makes sure that the hole is opened before mounting of
the bushing. It is important to check that the gasket on the transformer flange does not
cover this hole in service. The hole is located between two mounting holes and at a
distance B from the flange edge.
Table 1.
Type GOB Dimension B
250/800 54
250/1250 78
325/800 54
380/800 54
380/1250 78
450/800 54
550/800 60
550/1250 65
650/1250 65
750/1250 60
gob_0013
Fig. 1g.
gob_0012
Fig. 1f. Design principle - horizontally mounted bushing.
2750 515-12 en, Rev. 8

1 Description
1.2 Operating conditions

The table below show the standard technical specifications for the GOB Oil - Air
bushings. For conditions exceeding the below values, please contact ABB.
Common specifications:
Application: Transformers
Classification: Oil impregnated paper, capacitance graded, outdoor-im-
mersed bushing
Ambient temperature: +40 to -40 °C, minimum value as per temperature class 2
of IEC 60137
Altitude of site: < 1 000 m
Level of rain and humidity: 1-2 mm rain/min horizontally and vertically, as per IEC
60060-1
Pollution level: According to specified creepage distance and IEC 60815
("Guide for the selection of insulators in respect of pol-
luted conditions")
Type of immersion medium: Transformer oil. Maximum daily mean oil temp. 90 °C.
Maximum temporary oil temperature 115 °C
Oil level below bushing flange: Maximum 30 mm
Max. pressure of medium: 100 kPa overpressure
Markings: Conforming to IEC/ IEEE
1.3 Mechanical loading

The bushings are designed for the following cantilever loads applied to the midpoint
of the top end terminal, perpendicularly to the bushing axis. The bushing mounting
angle can be 0 – 45° from vertical or horizontal (if the bushing is ordered for horizon-
tal mounting).
In axial direction, the GOB bushings can be loaded with 10 kN continuously. The
bushing can withstand 30 Nm torque on the outer terminals.
Table 2. Mechanical loading
Bushing Type test load 1 minute (N) Max. service load (N)
GOB 250/800 2340 1800
GOB 250/1250 4000 3000
GOB 325/800 1950 1500
GOB 380/800 1800 1400
GOB 380/1250 3750 2900
GOB 450/800 1500 1150
GOB 550/800 1700 1300
GOB 550/1250 3100 2400
GOB 650/1250 3380 2600
GOB 750/1250 3350 2600
GOB 1050/1100 3200 1250
2750 515-12 en, Rev. 8

2 Installation
1.4 Spare parts

In case of major damage to the bushing we recommend that it is sent back to ABB
for possible repair and re-testing. Certain parts (Figs. 1, 2, 7, 8 and 9), which may be
damaged or lost during transport or installation, can be ordered from ABB.
2 Installation
2.1 Tools
■ Soft slings
■ Lifting eye screw M12 (DIN 580) for mounting at an angle, 2183 2001-3
■ Pull-through cord with M8 swivel, 9760 669-A
■ Torque wrench key for hexagon head screws, head width 16 mm (M10) and ad-
justable up to 66 mm
■ Key for hexagon socket head cap screw 6 mm (Only for previous design of test
tap cover)
2.2 Consumables
■ Water free vaseline, Mobilgrease 28 or other lubricant not harmful to the transfor-
mer oil, to lubricate screws that come into contact with the transformer oil.
■ Mobilgrease 28 or other suitable grease to lubricate and protect the earthing screw
and the outer terminal o-ring gasket.
10 2750 515-12 en, Rev. 8

2 Installation
2.3 Transport and handling

CAUTION: The bushing may be transported and stored horizontally up to 6 months.
For storing over 6 months it is recommended to raise the bushing to vertical position
with the top end upwards or inclined position with the top end upwards and at an
angle of at least 7°. Keep the bushings dry and clean and protected against mechani-
cal damage.
Keep the bushings protected from penetrating water when stored outdoors. This means
that the case must not be stored in areas where it can be foreseen that the ground will
be wet and muddy during heavy rains. Shelter the case from rain and snow with a
tarpaulin or roofing.
Carefully inspect the bushing on receiving with regard to shipping damage. Please
note that the bushing has been routine tested in oil and some oil may be left, especially
in the narrow openings between porcelain and metal. Vaseline is used for lubrications
of threads, and at some temperatures the vaseline may appear as oil
The bushings are normally delivered from ABB in boxes with the bushing supported
by blocks and fibre boards. The boxes are marked with "Top End".
"Top End"
Min. 7°
Fig. 4. Long-term storage.
2.4 Lifting from the box

WARNING
For lifting the bushing from the box, apply two clean lifting slings as shown in the
figure below. Support the bushing at the same points as in the box if placed on the
ground or block it under the flange and the metal top piece. Light bushings may be
handled manually.
Fig. 5.
Lifting from the box.
gob_0011
2750 515-12 en, Rev. 8 11

2 Installation
2.5 Mounting
CAUTION: Bushings mounted horizontally must be specially ordered for that, and
mounted according to section 2.5.4. If additional requirements are not fulfilled, the
bushing can be damaged.
WARNING
Light bushings may be handled manually. Lift heavier bushings with the aid of a lifting
tool, see section 2.1 Tools. Lift the bushing to vertical position and to an angle accor-
ding to the figures below. Use a soft bedding under the bottom end of the bushing, e.g.
a rubber mat.
The mass of the bushing is stated on the marking plate. Carefully clean and inspect the
oil end of the bushing and the inside of the centre hole before mounting on the trans-
former.
F
Lifting sling
arrangement
Soft sling
F
gob_0010
Soft sling
Lifting eye
2183 2001-3
Soft bedding Soft bedding
gob_0011 gob_0011
Fig. 6. Mounting.
2.5.1 Mounting of oil end-shield

CAUTION: If the bushing is lowered in transformer oil, the air cushion in the end-
shield must be vented by a hose.
The shield is packed in a plywood box with the fastening screws and the washers
included.
The end-shield is mounted on the bottom end of the bushing according to Fig. 7.
Fig. 7. Mounting of end-shield.

1) End-shield
2) Washer 6.4 x 12 x 1.5
3) Socket screw M6 x 16
gom_0006
12 2750 515-12 en, Rev. 8

2 Installation
2.5.2 Inner terminal / Stranded cable

CAUTION: Mounting of the conductor must be performed according to the procedure
below. The contact surfaces must be clean. The oxide on brazed terminals is to be
removed by brushing.
1. Stretch the stranded cable with the brazed or crimped inner terminal, normally
fastened to the cover plate. Avoid making any loops.
2. Drop the pull-through cord through the bushing centre hole.
3. Lift the bushing above the opening.
4. Fasten the M8 swivel to the inner terminal at the end of the stranded cable. Lower
the bushing into the transformer while directing the stranded cable by keeping the
pull-through cord taut.
5. Fix the bushing to the cover. Torque M12 to 50 ±5 Nm, 1/2" UNC to 55 ±5 Nm.
Ensure to tighten the bolts evenly crosswise in order to avoid damages to the
flange.
6. Lock the inner terminal with the locking pin according to Fig. 8.
7. Gently release the pull-through cord so the conductor rests on the locking pin.
8. Remove the pull-through cord.
9. Proceed immediately to section 2.6 Mounting of outer terminal.
60-80 Nm
M8 Grease with vaseline

or similar compound
Lubricate the o-ring
gob_0005
Fig. 8. Outer and inner terminal stud.

1) Outer terminal
2) Inner terminal
3) O‑ring 800 A: 2152 2011‑412; 39.2 x 3
1100/1250 A: 2152 2012‑420; 59.2 x 3
4) Locking pin 800 A: 2111 764‑A
1100/1250 A: 2111 764‑B
5) Width across flats 800 A: 55 mm
for wrench 1100/1250 A: 66 mm
2750 515-12 en, Rev. 8 13

2 Installation
2.5.3 Solid rod conductor

CAUTION: Mounting of the conductor must be performed according to the procedure
below. The contact surfaces must be clean.
If turning of the conductor is needed to line up the holes for the locking pin in the
conductor tube with the hole in the conductor, the conductor must definitely be turned
clockwise. Turning in opposite direction may loosen the current carrying joint in 800
A conductors.
The lower part of the solid conductor is normally fastened to the cover plate of the
transformer. The top part is usually delivered to site with the bushing.
1. Drop the pull-through cord through the bushing centre hole.
2. Fasten the M8 swivel to the top part of the solid conductor.
3. Partly pull the top part of the solid rod up into the bushing centre hole, leaving the
part with the jointing hole(s) sticking out.
N = 17
(for wrench
with gap 17 mm)
Tightening torque
35 ‑ 40 Nm
Tightening torque
35 ‑ 40 Nm
gob_0006
Fig. 9. Solid conductor 800 A Fig. 10. Solid conductor 1100/1250 A

1) Upper conductor 1) Upper conductor
2) Lower conductor 2) Lower conductor
3) Locking pin, 2111 764‑A 3) Locking pin, 2111 764‑B
4) Locking pin, 2111 764-C 4) Hexagon head screw M10 x 20
5) Screw, 2122 751‑2 Previous non-captive design, 2121 2033-490
New captive design, 2121 738-19
5) Belleville spring washer, 2154 717‑5
14 2750 515-12 en, Rev. 8
2 Installation
4. Secure the pull-through cord so the solid rod conductor top part cannot fall out of
the bushing.
5. Lift the bushing with the solid rod attached above the opening.
6. Lower the bushing until the two solid conductor parts meet.
7. Lubricate 1 x M12 (800 A) or 3 x M10 (1100/1250 A) screws with water-free va-
seline, Mobilgrease 28 or other lubricant not harmful to the transformer oil. Insert
and tighten to 35-40 Nm.
8. Lower the bushing into the transformer while directing the assembled solid rod
conductor by keeping the pull-through cord taut.
9. Fix the bushing to the cover. Torque M12 to 50 ±5 Nm, 1/2" UNC to 55 ±5 Nm.
Ensure to tighten the bolts evenly crosswise in order to avoid damages to the
flange.
10. Lock the solid rod with the locking pin according to Figs. 9 and 10.
11. Gently release the pull-through cord so the conductor rests on the locking pin.
12. Remove the pull-through cord.
13. Proceed immediately to section 2.6 Mounting of outer terminal.
2.5.4 Horizontal mounting of bushing

A horizontal GOB bushing normally has the tap to the left, seen from the air side when
the bushing is mounted according to the instructions below.
Alternative 1. At vacuum filling of transformer.
Open the oil hole in the flange. Mount the bushing with the hole upwards. The bushing
will be completely oil filled at the filling of the transformer.
Alternative 2. Filling of transformer without vacuum.
Place the bushing vertically and open one of the filling plugs at the top. Add clean and
dry transformer oil until the bushing is completely filled. Put back and tighten the plug
and place the bushing horizontally with the opening in the flange upwards. Remove
the covering plate or plug immediately and mount the bushing in the transformer wit-
hout turning or tilting it.
2.6 Mounting of outer terminal

CAUTION: Before connection of conductor clamps, the outer terminals of aluminium
must be carefully wire brushed and greased with a contact compund or vaseline.
In order to obtain the correct pressure and a low contact resistance, the following must
be carried out:
1. Clean the contact and gasket surfaces carefully.
2. The inner terminal / solid rod thread is to be lubricated with vaseline or other lub-
ricant not harmful to the transformer oil.
3. Lubricate the o-ring before putting it into the groove.
4. Screw on the outer terminal and tighten with 60-80 Nm according to Fig. 8.
2750 515-12 en, Rev. 8 15

2 Installation
2.7 Flange earthing

WARNING
Proper earthing is essential!
The bushing flange is provided with a tapped hole M12. After tightening the bolts
fixing the bushing to the transformer tank, the flange should be earthed. This prevents
electrical discharges between bushing flange and transformer tank under normal ser-
vice conditions.
Alternative 1
Insert a heavily greased (Mobilgrease 28 recommended) pointed set screw M12 (stain-
less steel A4-80 preferrably). Tighten to 40 Nm, penetrating the paint of the transfor-
mer tank down to the metal underneath. This makes an electrical connection between
the bushing and the transformer tank, keeping them at the same voltage.
Alternative 2
Apply a flexible cable between the M12 earthing hole in the bushing flange and a
corresponding connection point in the transformer. Grease the screw (Mobilgrease 28
recommended) and tighten the M12 in the bushing to 40 Nm. Connect the other end of
the cable to the transformer.
2.8 Waiting time before energizing

CAUTION: When a bushing has been stored horizontally, it must be raised with the
top up for at least 12 hours before service voltage is applied and 24 hours before test
voltage is applied. If, by mistake, the bushing has been stored horizontally more than
one year, it must be placed in the vertical position for at least one week before energi-
zing. Some waiting time may be necessary before energizing in order to avoid flasho-
vers or partial discharges due to airbubbles at the bushing surface. Choose a suitable
procedure below.
Vacuum filled transformer

No waiting time is necessary from the bushing point of view.
De-gassed oil-filled transformer

During mounting, use a clean and dry paintbrush to release surface bubbles. Wait 6
hours before energizing.
Gas-saturated oil-filled transformer

During mounting, use a clean and dry paintbrush to release surface bubbles. Wait 24
hours before energizing.
De-gassed oil filled transformer with reduced oil-level
After restoring the oil-level, wait 24 hours before energizing.
For all alternatives except vacuum-filled transformer, the oil should be allowed to
enter the centre tube to at least flange height by releasing the outer terminal sealing
system and allowing air to escape this way.
16 2750 515-12 en, Rev. 8

2 Installation
2.9 Recommended tests before energizing

The following tests may be performed to check the insulation, sealing and current path
of the bushing. The tests should be made after mounting, but before connecting the
outer terminal of the bushing to the rest of the switchyard power circuit.
1. Tightness test between transformer and bushing flange.
2. Tightness test of bushing outer terminal.
3. Measurement of capacitance and tan δ.
4. Check of through-resistance.
2.9.1 Tightness test between transformer and bushing flange

Several different methods may be used and we thus refer to instructions given by the
company responsible for the field erection. As a simple example, the tightness of the
seal between transformer and bushing flange may be checked when the transformer is
oil-filled by using chalk or, perhaps easier, with paper strips.
2.9.2 Tightness test of bushing outer terminal

Since the top terminal is often situated above the oil level of the transformer expansion
system, a leak at this point is extremely serious, because water could enter directly
into the transformer insulation this way. It is thus recommended to make a tightness
test after assembly, preferably both with vacuum and over‑pressure. Several different
methods may be used and we refer to instructions given by the firm responsible for the
field erection.
One possible method is the tracer gas method:
1. Put a tracer gas into the centre tube before mounting the outer terminal. The oil
level of the transformer must be above the bottom end of the bushing but below
the bushing flange.
2. Increase the pressure in the center tube by increasing the oil level as much as pos-
sible.
3. Search with a gas detector (sniffer) for leaking gas at the gasket.
2750 515-12 en, Rev. 8 17

2 Installation
2.9.3 Measurement of capacitance and tan δ

WARNING
The test tap is not self-earthing.
Since C2 usually is relatively small, the test tap must never be open‑circuited when
applying a voltage to the bushing. It shall always be earthed or connected to an ex-
ternal impedance. No connection may destroy the bushing. Recommended maximum
voltage for C1 is 10 kV and for C2 500 V.
CAUTION: When not measuring, always make sure that the cap nut is properly tigh-
tened with the gasket in place. This is to prevent dust and water from coming in to the
test tap.
After mounting, a capacitance measurement is recommended. Connect a measuring
bridge between the outer terminal and the test tap by using a ø 4 mm lead coupler or
ABB's test tap adapter 2749 510-U. This is possible without removing the bushing as
the bushing has an insulated test tap, see Fig. 2. More details can be found in product
information 2750 515-142, "Bushing diagnostics and conditioning".
With the transformer de‑energized and the bushing outer terminal disconnected, the
test tap cover is removed. The measuring equipment is connected to the test tap and
the measuring voltage source to the bushing terminal.
The capacitances C1 between the centre tube and the tap, and the capacitance C2, bet-
ween the test tap and earth are marked on the marking plate. The nominal capacitances
C1 of the different bushing types are listed in Table 3. C2 is highly dependent on the
surrounding parts inside the transformer and it is not possible to give a nominal value
valid for all service conditions.
18 2750 515-12 en, Rev. 8

2 Installation
Table 3. Nominal capacitances in pF (Manufacturing tolerances for C1 ± 10%).

Type Catalogue No. Nominal capacitance (pF)
LF 123 C1 C2
GOB 250 013, 014, 171, 172 125 90
015, 016, 173, 174 205 500
017, 167 165 110
019, 168 270 750
083, 084, 175, 176 275 800
085, 169 375 1200
GOB 325 025, 026, 177, 178 135 95
027, 028, 179, 180 200 200
089, 090, 181, 182 260 425
GOB 380 037, 038, 183, 184 145 110
039, 040, 185, 186 200 335
041, 101 185 150
043, 102 265 550
095, 096, 187, 188 245 550
097, 103 320 1150
GOB 450 049, 050, 145, 146 145 125
051, 052, 147, 148 200 570
053, 054, 149, 150 245 770
GOB 550 061, 189, 062 150 156
063, 190, 064 170 400
107, 191, 108 210 750
065, 142 170 150
067, 143 195 320
109, 144 240 575
GOB 650 073,192 205 200
075, 193 235 340
113, 194 280 550
GOB 750 077, 104 205 390
078, 105 235 565
079, 106 275 950
GOB 1050 281 310 450
280 367 700
2750 515-12 en, Rev. 8 19

2 Installation
The dissipation factor varies with the temperature of the bushing body, and the mea-
sured value should thus be multiplied with the correction factor (multiplier) given in
Table 4.
Table 4. Dissipation factor variations as a function of temperature.
Bushing body temperature °C Multiplier to 20 °C
0-2 0.80
3-7 0.85
8-12 0.90
13-17 0.95
18-22 1.00
23-27 1.05
28-32 1.10
33-37 1.15
38-42 1.20
43-47 1.25
48-52 1.30
53-57 1.34
58-62 1.35
63-67 1.35
68-72 1.30
73-77 1.25
78-82 1.20
83-87 1.10
2.9.4 Check of through resistance

This method can be used to detect very large faults in the current path, such as disrup-
tions, and is not a tool for diagnostic of the bushing.
The through resistance measurement method depends on the design of the transformer.
Generally, a current is applied from bushing to bushing. The voltage drop from outer
terminal to outer terminal is measured. The resistance is calculated with Ohm’s law, U
= R·I. (U: Measured voltage drop. I: Through current. R: Total circuit resistance.)
The total through resistance is the sum of the transformer winding and lead resistance
and the bushing conductor and contact resistance. The additional resistance from he
bushing conductor should not be more than 150 mΩ. Since the through resistance of
the HV winding of a typical power transformer is in the order of 0.1 ..1 Ω, this is a
very rough method.
Less-than-perfect contacts can only be detected by making a sensitive measurement
across each connection point, or by measuring the temperature increase during opera-
tion with an infrared sensitive camera (thermovision).
20 2750 515-12 en, Rev. 8

3 Maintenance
3 Maintenance
The GOB bushings are maintenance-free. For bushings with oil-level glass, it is re-
commended to note the oil level during normal routine inspections in the plant.
DANGER
No work at all can be performed on the bushing while it is energized or not
earthed.
3.1 Recommended maintenance and supervision

1. Cleaning of insulator surface
2. Measurement of capacitance and tan δ
3. Thermovision (infrared camera) check for local overheating on connectors
4. Check for leakage
5. Checking and adjustment of the oil level
3.1.1 Cleaning of insulator surface

CAUTION: Avoid having solvent on the bushing gasket and porcelain joints.
Under conditions of extreme pollution it may be necessary to clean the porcelain
insulator surface. This should be done by water-jet or by wiping with a moist cloth. If
necessary, ethyl-alcohol or ethyl-acetate may be used.
3.1.2 Measurement of capacitance and tan δ

Please refer to Chapter 2 Installation.
3.1.3 Thermovision (infrared camera) check for local

overheating on connectors
At maximum rated current, the bushing outer terminal normally takes a temperature of
about 35 to 45 °C above the ambient air. Significantly higher temperatures, especially
at lower current loading, can be a sign of bad connections.
2750 515-12 en, Rev. 8 21

3 Maintenance
3.1.4 Check for leakage

Make a visual inspection for oil leakage during normal station supervision.
3.1.5 Checking and adjustment of the oil level

CAUTION: Oil sampling and dissolved gas in oil analysis.
Normally we do not recommend taking oil samples or opening our bushings. The
bushing is sealed and tightness tested at the time of manufacturing. An oil sampling
means that the bushing has to be opened. Thus, there is also a risk of improper sealing
after the sampling is finished. However, when a problem is known, for example high
power factor over C1 or visible leakage, there might be a need for oil sampling and
gas analysis or oil level check. In this case, ask for product information 2750 515-142
"Bushing diagnostics and conditioning".
Bushings with one oil level glass should show the oil level in the middle of the glass at
20 °C. The oil level change is approximately 3 mm per 10 °C.
GOB 750 and 1050 has two glasses and the oil level at 20 °C is to be at the oil level
plug between the two glasses. The oil level change is approximately 6 mm per 10 °C.
The oil level in bushings without oil level glass may be checked through one of the
two oil filling holes at the top end. A dry and clean dipstick should be used. In one of
these holes there is a rubber plug. This plug may be pressed down into the bushing so
that checking of the oil level can be carried out. Correct oil level is shown in Table
5. For bushings mounted at an angle it may be necessary to check at both holes and
calculate the average. If the oil level is too high, oil can be sucked out by means of a
narrow hose. If the oil level is too low, clean and dry transformer oil must be added.
Adjustment of oil level is allowed only when the temperature of the bushing is +5 °C
to +35 °C. It is recommended to provide the sealing plug with a new gasket after the
check. The sealing plug is to be tightened with 20 Nm. For further information on oil
sampling, see product information 2750 515-142.
For topping-up of the bushing, any clean and dry transformer oil available at site may
be used.
Table 5. Oil level for bushings without oil level gauge

Type GOB Oil level A mm at 20 ±10 °C Oil level change mm/10 °C
Fig. 1a Fig. 1b (The bushing in vertical position)
250 110 ±8 165 ±10 4
325 110 ±8 165 ±10 5
380 110 ±8 165 ±10 5
450 110 ±8 165 ±10 6
550 170 ±10 270 ±15 7
650 175 ±10 275 ±15 9
750 275 ±15 330 ±15 11
22 2750 515-12 en, Rev. 8

3 Maintenance
3.1.6 De-mounting of horizontally mounted bushings

When the bushing is removed from the transformer it is completely filled with oil.
Drain a small volume of oil and tighten the flange hole with the gasket and cover plate
or plug. Place the bushing vertically and adjust the oil level according to 3.1.5.
3.2 Disposal after end of service life

The bushing consists of the following material:
- Conductor of copper or low-alloy aluminium.
- Terminals of copper, brass or low-alloy aluminium may be plated with for instan-
ce silver, tin, gold or nickel in layer thickness up to 20 µm.
- Transformer oil as per IEC 60296, class 2.
- Transformer oil impregnated condenser body consists of paper and 1 % alumi-
nium foils.
- Centre tube, on which the condenser body is wound, consists of aluminium alloy.
- Top washer, top housing, flange, top nut, flange extension and end-shield consist
of aluminium alloys.
- Press ring for oil level glass and previous design of test tap cap consist of plated
brass. New design of test tap consists of stainless steel.
- Prism glass consists of glass.
- Insulators consist of quartz or alumino silicated based porcelain.
2750 515-12 en, Rev. 8 23

2750 515-12 en, Rev. 9, 2006-10-15
ABB AB
Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com/electricalcomponents
15.01.2010 11:16:08
===========================================================================
0010 1 1 ST 230450 RM200720 8,700
20
insulator DIN 42533-20NF-1000
___________________________________________________________________________
0020 2 1 ST 230460 RM207236 5,540
20
connecting bolt DIN 42533-20NF-1000
M30*2, l= 615mm
piece/material see part list
___________________________________________________________________________
0030 3 1 ST 230470 RM212271 0,700
20 X
cap DIN 42533-E 1000
edits
___________________________________________________________________________
0040 4 1 ST 230471 RM212274 0,800
20 X
washer DIN 42533-F 1000
___________________________________________________________________________
0050 7 1 ST 164010 RM200615 0,033
20
pack. ring DIN 42533-J -1000-NBR120
D1=30 D2=54 S=24
___________________________________________________________________________
0060 8 1 ST 163021 RM200605 0,004
20 X
spacer DIN 42533-O-1000-NP815
D1=32 D2=56 D3=48 D4=12 S=1.50
___________________________________________________________________________
0070 9 1 ST 161121 RM200579 0,012
20 X
fl. gasket DIN 42533-M -1000-NP815
D1=36 D2=80 S=1.50
___________________________________________________________________________
0080 10 1 ST 161110 RM207956 0,060
20 X
fl. gasket DIN 42533-N -1000-NBR120
D1=110 D2=149 S=5 -0 +0.5
*dimension do not correspond DIN*
material:NBR QUAL. S-1057
transformer oil is endurable
temperature area +120°C -25°C
___________________________________________________________________________
***************************************************************************
01.07.2009 50 X 1 ST 17,140 RM213043
Cont.: Mod: DOTR 120000 / 110
DT DIN 42533-20NF-1000-A2
a=462
15.01.2010 11:16:08
===========================================================================
0090 11 1 ST 161050 RM222399 0,048
20
ring 160*148MM diameter 4MM thick
turned and deburrs
gen. tol. according to DIN 2768 m
material PTFE virginal
___________________________________________________________________________
0100 14 1 ST 110304 HF2136 0,242
20 X
Hexagon nut ISO 8673-M30*2.0-CU2
(formerly DIN 934)
___________________________________________________________________________
0110 16 1 ST 230379 RM202316 0,006
20 X
ventilate screw DIN 42533-R-CU2
according to drawing 230379-M______
___________________________________________________________________________
0120 17 1 ST 161050 RM200645 0,001
20 X
ring- 6.4* 12.5*2.00-Pa6
D1=6.4 D2=12.5 S=2
___________________________________________________________________________
0130 23 1 ST 230475 RM202313 0,002
20 YGEB
link ring DIN 42533-U 1000
___________________________________________________________________________
0140 25 1 ST 230493 RM200973 0,150
20 X
flanged ring DIN 42538-C-Alu
___________________________________________________________________________
0150 26 6 ST 230496 RM200976 0,282
20 X
thrust piece DIN 42538-F
___________________________________________________________________________
0160 27 6 ST 110354 HF2113 0,102
20 X
(formerly DIN 934)
___________________________________________________________________________
0170 28 6 ST 120253 HF0049 0,036
20 X
___________________________________________________________________________
0180 30 4 ST 230478 RM207042 0,172
20 X
socket head screw M12* 42-8.8-blank
(design after drawing 2.3.04.78)
___________________________________________________________________________
***************************************************************************
01.07.2009 50 X 1 ST 17,140 RM213043
Cont.: Mod: DOTR 120000 / 110
DT DIN 42533-20NF-1000-A2
a=462
15.01.2010 11:16:08
===========================================================================
0190 31 4 ST 121018 HF0147 0,048
20 X
Conical spring washer DIN 6796-12-1.4568
1.4568 = Stainless spring steel
___________________________________________________________________________
***************************************************************************
01.07.2009 50 X 1 ST 17,140 RM213043
Cont.: Mod: DOTR 120000 / 110
DT DIN 42533-20NF-1000-A2
a=462
OPERATION AND MAINTENANCE MANUAL
INSTALLATION INSTRUCTIONS BUSHING DIN 42 533
1. Removal
Drain the insulant 100 mm (max.) below the tank flange.

(Stop valve AA 356)
Unscrew hexagon nut pos. 14.
Remuve the washer pos. 4, sealing ring pos. 7, link ring pos. 23, cap pos. 3
and sealing washer pos. 9.
Undo the fixing element from the insulator base pos. 25-28.
Remove the insulator pos. 1.
Unscrew the terminal stud pos. 2.
2. Replacing
Assemble in the reverse order.
Venting
3. Undo the screw pos. 16 and retighten is after the insulant has emerged.
page: 1/1
15.01.2010 11:16:20
===========================================================================
0010 1 1 ST 232665 RM213795 76,000
20
quadruple elbow bushing-827146336-
4* size 3-36kV-3150A (KAW 6328)
make.:PFISTERER
*
checking certificate above partial
discharge to include
___________________________________________________________________________
0020 2 1 ST 161110 RM207957 0,056
20 X
D1=133 D2=165 S=5 -0 +0.5
___________________________________________________________________________
0030 3 1 ST 161050 RM222398 0,048
20 X
ring 177*165mm diameter 4mm thick
turned and deburrs
___________________________________________________________________________
0040 4 1 ST 230493 RM200974 0,180
20 X
flanged ring DIN 42538-D-Alu
___________________________________________________________________________
0050 5 6 ST 230496 RM200976 0,282
20 X
___________________________________________________________________________
0060 6 6 ST 110354 HF2113 0,102
20 X
(formerly DIN 934)
___________________________________________________________________________
0070 7 6 ST 120253 HF0049 0,036
20 X
___________________________________________________________________________
***************************************************************************
19.06.2009 50 X 1 ST 76,710 RM213825
Cont.: Mod: DOTR 120000 / 110
15.01.2010 11:16:15
===========================================================================
0010 1 1 ST 232655 RM213792 35,000
20
2F-angle socket contact-827660001-
2*GR.3-36kV-2200/2500A (KAW 6301)
make:PFISTERER
*
checking certificate above partial
discharge to include
___________________________________________________________________________
0020 2 1 ST 161110 RM207957 0,056
20 X
D1=133 D2=165 S=5 -0 +0.5
___________________________________________________________________________
0030 3 1 ST 161050 RM222398 0,048
20 X
ring 177*165mm diameter 4mm thick
turned and deburrs
___________________________________________________________________________
0040 4 1 ST 230493 RM200974 0,180
20 X
flanged ring DIN 42538-D-Alu
___________________________________________________________________________
0050 5 6 ST 230496 RM200976 0,282
20 X
___________________________________________________________________________
0060 6 6 ST 110354 HF2113 0,102
20 X
(formerly DIN 934)
___________________________________________________________________________
0070 7 6 ST 120253 HF0049 0,036
20 X
___________________________________________________________________________
***************************************************************************
19.06.2009 50 X 1 ST 35,710 RM213822
Cont.: Mod: DOTR 120000 / 110
Umschlag 4 10.04.2003 11:09 Uhr Seite 1
Konzeption und Gestaltung: Vischer & Bernet GmbH, Agentur für Marketing und Werbung, Stuttgart Für Druckfehler übernehmen wir keine Haftung / Technische Änderungen vorbehalten We Can Assume no Liability for Printing Errors / Subject to Technical Modification
Kontaktsysteme für Energienetze Contact systems for power networks
Kabelgarnituren für Mittel- und Hochspannungsnetze

Cable fittings for medium and high voltage networks
Kontaktsysteme GmbH & Co. KG

Rosenstraße 44
73650 Winterbach
Germany
042 380 400 / 2003
Telefon +49 (0)71 81 / 7005-0

Telefax +49 (0)71 81 / 7005-565
Email dialog@pfisterer.de
www.pfisterer.de
Ein Unternehmen der PFISTERER Gruppe

04.1 CONNEX 10.04.2003 11:50 Uhr Seite 26
4.1 CONNEX-Trafoanschlußteile CONNEX Transformer Bushings
CONNEX-Trafo-Anschlussteile, CONNEX Transformer Bushings,

gerade, bis 24 kV Straight up to 24 kV
Der Einbau der Trafoanschlussteile These transformer bushings are in-
erfolgt anstelle der DIN-Porzellan- stalled on the medium-voltage side
Durchführungen auf der Mittel- in place of DIN porcelain bushings.
spannungsseite.
To fit different transformer designs,
Um der Beschaffenheit des Trans- the insulating part projecting into
formators Rechnung zu tragen, ist the transformer (dimension l1 and
das in den Traforaum hineinragen- l2) is available in various lengths.
de Isolierteil (Maß l1 und l 2 ) in ver- The cables are connected with metal-
schiedenen Längen lieferbar. Die enclosed CONNEX separable connec-
Kabel werden mit metallgekapsel- tors.
ten CONNEX-Kabelanschlussteilen For the 0.4 kV side, appropriate insu-
angeschlossen. lating covers are available which
Auf der 0,4 kV Seite stehen entspre- provide complete protection against
chende Isolierhauben zur Verfü- electric-shock hazard.
gung, die einen vollkommenen Be-
rührungsschutz bieten.
Nr. Größe Maße mm Anschluß- Nenn- Gewicht

Gewinde Strom ca. kg
No. Size Dimensions mm Threaded Nominal Weight
Connection Current approx. kg
l1 l2 d e f IN/A
1 827 115 004 0 133 128 74 127 M8 250 2,1

1 827 115 002 0 178 173 77 127 M8 250 2,8
2 827 158 001 0 68 – 75 130 M12 250 3,4
2
2 827 159 001 1 68 – 75 130 M12 630 3,3
26 www. .de
CONNEX-Trafoanschlußteile CONNEX Transformer Bushings 4.1
CONNEX-Winkeladapter bis CONNEX Elbow Adapters up to

24 kV 24 kV
Steckbar, freiluftbeständig. Plug-in type. Suitable for outdoor
use.
Der metallgekapselte CONNEX-Win- The metal-enclosed CONNEX elbow

keladapter ist ein Bauteil, mit dem adapter is a component allowing
gerade CONNEX-Geräteanschlus- straight CONNEX bushings to be con-
steile in CONNEX-Winkel-Gerätean- verted into CONNEX elbow bushings.
schlussteile umgerüstet werden The system permits a 90° offset con-
können. Das System bietet einen um nection.
90° versetzten Anschluss.Eine Seite One side of the adapter is designed
ist als CONNEX-Kabelanschlussteil as CONNEX separable connector size
Größe 0 bzw. 1 ausgebildet, die an- 0 or 1, the other side is designed as a
dere Seite als CONNEX Gerätean- CONNEX bushing of the same size.
schlussteil gleicher Größe.Das geer- The grounded metal housing provi-
dete Metallgehäuse bietet einen des absolute protection against elec-
absoluten Berührungsschutz. tric-shock hazard.
Nr. Größe Nenn-Strom Gewicht ca. kg

No. Size Nominal Current Weight approx. kg
IN/A 2
1 827 176 001 0 250 4,3
2 827 180 001 1 630 5,4
www. .de 27
CONNEX-Trafo-Winkelanschlus- CONNEX Transformer Elbow

steile bis 36 kV Bushings up to 36 kV
Winkelanschlussteile sind im einge- When installed, elbow bushings can
bauten Zustand bis 260° schwenk- be swiveled by 260°. After fixing the
bar. Nach dem Befestigen des CONNEX separable connector, the el-
CONNEX-Kabelanschlussteiles kann bow bushing can be locked. The
das Winkelanschlussteil arretiert grounded metal housing provides
werden. Das geerdete Metallge- absolute protection against electric-
häuse bietet einen absoluten Berüh- shock hazard.
rungsschutz.
Mit einer Presshülse und einer Cu- A compression sleeve and a copper
Litze muß eine flexible Verbindung strand wire serve to establish a
von dem um 260° schwenkbaren flexible connection between the 260°
Winkelanschlussteil zur Trafo- swivel-type elbow bushing and the
wicklung hergestellt werden. transformer winding.
Erdungslitze
Grounding wire
Nr./No. 556 800 013
Presshülsen und Erdungslitze sepa- Compression sleeves and grounding

rat bestellen. wire to be ordered separately.
Nr. Größe Maß Nenn- Max. Betriebs- Gewicht

Strom spannung ca. kg
No. Size Dimension Nominal Max. Operating Weight
Current Voltage approx. kg
l1 mm G IN Um/kV
827 107 064 0 64 M10 250 A 12 + 24 4,4

827 107 107 0 107 M10 250 A 12 + 24 4,5
827 107 168 0 168 M10 250 A 12 + 24 4,8
827 117 064 1 64 M16 630 A 12 + 24 4,8
827 117 107 1 107 M16 630 A 12/24/36 5,0
827 117 168 1 168 M16 630 A 12/24/36 5,2
Presshülsen Compression Sleeves
Größe / Size Nr. Größe Maß Cu-Litze nach DIN 46438 Sechskant- Preßwerkzeug
Querschnitt max. ø Gewinde G Cu Litze H
No. Size Dimension Copper Strand Wire Hexagonal Compr. Die for
DIN 46438
Cross Section max. ø Thread G Cu Strand Wire H
0 G l2 mm mm2 mm
560 320 001 0 M10 35 10 5,0 KZ 14 KZ 8

560 320 007 0 M10 42 35 10,0 KZ 16 KZ 14
1 560 320 005 0 M10 70 70 14,2 KZ 16 KZ 18
560 320 002 1 M16 38 10 5,0 KZ 20 KZ 8
560 320 003 1 M16 42 35 10,0 KZ 20 KZ 14
560 320 004 1 M16 42 50 12,0 KZ 20 KZ 16
560 320 006 1 M16 70 120 19,5 KZ 22 KZ 25
28 www. .de
Ortsnetztransformatoren, bis 36 kV
Local Plant Transformers, up to 36 kV
www. .de 29
CONNEX-Mehrfach-Winkelan- CONNEX Multi-Contact Elbow

schlussteile Bushings
Der Einbau der Mehrfach-Winkel- Multi-contact elbow bushings are in-
anschlussteile erfolgt anstelle der stalled on the medium voltage side
DIN-Porzellandurchführungen auf of power transformers in the place of
der Mittelspannungsseite des DIN porcelain bushings.
Leistungstrafos.
Die Mehrfach-Winkelanschlussteile Multi-contact elbow bushings com-

bestehen aus einem Isolierkörper, prise an insulating body that is inte-
der in einem Metallgehäuse integrated within a metal housing and
griert ist und mit maximal 2 oder 4 connected to maximum 2 or 4 cables
Kabeln mit CONNEX-Kabelanschluss- with CONNEX separable connectors
teilen der Größen 2 oder 3 ange- size 2 or 3.
schlossen wird. The grounded metal housing provi-
Das geerdete Metallgehäuse bietet des absolute protection against elec-
einen absoluten Berührungsschutz. tric-shock hazard. Bushings that are
Nicht belegte Anschlussteile müssen not occupied must be closed with
mit Blindsteckern spannungsfest dummy connectors assuring a vol-
verschlossen werden. tage-proof seal.
Äußere Umwelteinflüsse – wie z.B. External environmental influences,
Kleintiere, Vögel – können keine e.g. small animals and birds, cannot
Kurzschlüsse verursachen. Steck- cause any short circuits. Plug-in type
bare Überspannungsableiter kön- surge arresters can be mounted in-
nen anstelle eines Kabelanschlusses stead of a cable termination. The e-
montiert werden. Die elektrischen lectric connections inside the trans-
Anschlüsse im Trafo können ge- former can be either of clamping or
klemmt oder gesteckt ausgeführt of plug-in type.
werden.
Für Leistungstrafos passend zur Be- For power transformers. Designed to

festigung nach DIN 42538, freiluft- fit fixings acc. DIN 42538. Suitable
beständig.*1) for outdoor use.*2)
Anschlussteil gesondert bestellen. Connecting part to be ordered
separately.
Kälteschockprüfungen nach Cold-shock tests acc. VDE 0441.

VDE 0441.
Achtung: Note:
Die CONNEX-Kabelblindstecker ge- CONNEX dummy connectors are not
hören nicht zum Lieferumfang, und included and must be ordered sepa-
müssen separat bestellt werden. rately.
Auf Anfrage auch 52 kV Ausführung 52 kV design is available upon

lieferbar. request.
*1) Befestigungsteile auf Anfrage *2) Fixing materials on request
30 www. .de
www. .de 31
CONNEX-2-fach-Winkelan- CONNEX Double-Contact Elbow

schlussteile bis 36 kV Bushings up to 36 kV
Für gesteckte Ausführung. For plug-in construction.
Nr. Größe Nenn-Strom Maße mm Gewicht

Anschluss im Trafo ca. kg
gesteckt
No. Size Nominal Current Dimensions m Weight

Internal Transformer approx. kg
Connection Plug-In Type
max. IN/A a b c d f g h
827 661 003 2 x 2 1600 200 135 35 125 388 215 303 38
827 660 005 2 x 3 2200 200 135 35 125 451 146 380 64
Sonderausführungen auf Anfrage. Special design on request.

C Steckbares Anschlussteil. C Plug-in type connecting part.
Nr. Steckbares Länge Gewinde Gewicht ca. kg

Anschlussteil
No.Plug-In Type Length Thread Weight approx. kg
Connecting Part
1 827 197 001 127 M16 2,3

1 827 197 002 149 M16 2,4
2 827 197 003 149 M12 2,6
2 827 197 004 149 M16 2,9
1 2 827 197 195 195 M12 3,4
Prüfdaten Anschluss im Trafo

gesteckt
Test Data Internal Transformer
Größe/Size 2 x 2 Größe/Size 2 x 3
2 Nenn-Strom/Nominal Current IN 1600 A 2200 A

Max. Betriebsspannung/Max. operating voltage Um bis/up to 36 kV bis/until 36 kV
Nenn-Steh-Wechselspannung 50 Hz/ 1 min. 75 kV 75 kV
Rated power frequency withstand voltage
Nenn-Steh-Blitzstoßspannung 1,2/50 µs 170 kV 170 kV
Rated lightning impulse withstand voltage
Gleichspannungsprüfung / 15 min. 6 x U0 108 kV 108 kV
D.C. voltage test
Teilentladung/Partial discharge 2 x U0 ≤ 10 pC ≤ 10 pC
Nenn-Kurzzeitstrom/ 50 kA/1 sec. 50 kA/1 sec.
Rated short-time withstand current
Nenn-Stoßstrom/Rated impulse current 125 kA 125 kA
32 www. .de
CONNEX-2-fach-Winkelan- CONNEX Double-Contact Elbow

schlussteile bis 52 kV Bushings up to 52 kV
Für gesteckte bzw. geklemmte Aus- For plug-in and clamping type con-
führung. struction, respectively.
B Klemmbares Anschlussteil B Clamping type connecting part

(liefert Trafohersteller). (supplied by the transformer
manufacturer).
Nr. Größe Nenn-Strom Maße mm Gewicht Max. Betriebs-
Anschluss im Trafo ca. kg spannung
gesteckt geklemmt
No. Size Nominal Current Dimensions mm Weight Max. operating
Internal Transformer Connection approx. kg voltage
Plug-In Type Clamping Type
max. IN/A max. IN/A a b c d e f g h
827 661 002 2x2 1250 1250 180 110 30 125 90 388 215 303 41 36
827 661 001 2x2 1600 1600 200 135 35 125 125 388 215 303 47 36
827 660 001 2x3 2200 2500 200 135 35 125 125 451 146 380 62 36
827 660 004 2x3 2200 2500 200 135 35 125 125 451 146 380 62 52
Sonderausführung auf Anfrage. Special design on request.

A Steckbares Anschlussteil. A Plug-in type connecting part.
Nr. Steckbares Für CONNEX-2- und Gewicht ca. kg

Anschlussteil 4-fach-Winkelanschlussteile
No. Plug-In Type For CONNEX Multi-Contact Weight approx. kg
Connecting Part Elbow Bushings
827 128 710 827 661 002 2,5

827 128 730 827 661 001 2,8
827 128 730 827 660 001 2,8
Prüfdaten Anschluss im Trafo Anschluss im Trafo

gesteckt geklemmt
Test Data Internal Transformer Internal Transformer
Connection Plug-In Type Connection Clamping Type
Größe/Size 2 x 2 Größe/Size 2 x 3 Größe/Size 2 x 2 Größe/Size 2 x 3
Nenn-Strom/Nominal Current IN 2200 A 2200 A 1600 A 2500 A

Max. Betriebsspannung/Max. operating voltage Um bis/up to 36 kV bis/up to 52 kV bis/up to 36 kV bis/up to 52 kV
Nenn-Steh-Wechselspannung 50 Hz/ 1 min. 75 kV 95 kV 75 kV 95 kV
Nenn-Steh-Blitzstoßspannung 1,2/50 µs 170 kV 250 kV 170 kV 250 kV
Gleichspannungsprüfung / 15 min. 6 x U0 108 kV 108 kV 108 kV 108 kV
D.C. voltage test
Teilentladung/Partial discharge 2 x U0 ≤ 10 pC ≤ 10 pC ≤ 10 pC ≤ 10 pC
Nenn-Kurzzeitstrom/Rated short-time withstand current 50 kA/1 sec. 50 kA/1 sec. 50 kA/1 sec. 50 kA/1 sec.
Nenn-Stoßstrom/Rated impulse current 125 kA 125 kA 125 kA 125 kA
www. .de 33
Leistungstrafo bis 145 kV, unterspannungsseitig mit Mehrfachwinkelanschlußteilen bis 52 kV

Power Transformers up to 145 kV, on the low-voltage side with multi-contact elbow bushings up to 52 kV
34 www. .de
Leistungstrafo bis 145 kV, unterspannungsseitig mit Mehrfachwinkelanschlußteilen bis 52 kV

Power Transformers up to 145 kV, on the low-voltage side with multi-contact elbow bushings up to 52 kV
www. .de 35
CONNEX-4-fach-Winkelan- CONNEX Quadruple-Contact El-

schlussteile bis 36 kV bow Bushings up to 36 kV
Für gesteckte Ausführung. For plug-in construction.
Nr. Größe Nenn-Strom Maße mm Gewicht

Anschluss im Trafo ca. kg
gesteckt
No. Size Nominal Current Dimensions m Weight

Internal Transformer approx. kg
max. IN/A a b c d f g h
827 124 527 4 x 2 2200 200 135 35 125 387 345 286 66
827 146 436 4 x 3 2200 200 135 35 125 449 390 347 73
Sonderausführungen auf Anfrage. Special design on request.

C Steckbares Anschlussteil. C Plug-in type connecting part.
Nr. Steckbares Länge Gewinde Gewicht ca. kg

Anschlussteil
No.Plug-In Type Length Thread Weight approx. kg
Connecting Part
1 827 197 001 127 M16 2,3

1 827 197 002 149 M16 2,4
1 2 827 197 003 149 M12 2,6
2 827 197 004 149 M16 2,9
2 827 197 195 195 M12 3,4
Prüfdaten Anschluss im Trafo

gesteckt
Test Data Internal Transformer
2
Größe/Size 4 x 2 Größe/Size 4 x 3
Nenn-Strom/Nominal Current IN 2200 A 2200 A

Max. Betriebsspannung/Max. operating voltage Um bis/until 36 kV bis/until 36 kV
Nenn-Steh-Wechselspannung 50 Hz/ 1 min. 75 kV 75 kV
Nenn-Steh-Blitzstoßspannung 1,2/50 µs 170 kV 170 kV
Gleichspannungsprüfung / 15 min. 6 x U0 108 kV 108 kV
D.C. voltage test
Teilentladung/Partial discharge 2 x U0 ≤ 10 pC ≤ 10 pC
Nenn-Kurzzeitstrom/ 50 kA/1 sec. 50 kA/1 sec.
Rated short-time withstand current
Nenn-Stoßstrom/Rated impulse current 125 kA 125 kA
36 www. .de
CONNEX-4-fach-Winkelan- CONNEX Quadruple-Contact El-

schlussteile bis 52 kV bow Bushings up to 52 kV
Für gesteckte bzw. geklemmte Aus- For plug-in and clamping type con-
führung. struction, respectively.
B Klemmbares Anschlussteil B Clamping type connecting part

(liefert Trafohersteller). (supplied by the transformer
manufacturer).
Nr. Größe Nenn-Strom Maße mm Gewicht Max. Betriebs-

Anschluss im Trafo ca. kg spannung
gesteckt geklemmt
No. Size Nominal Current Dimensions mm Weight Max. operating
Internal Transformer Connection approx. kg voltage
Plug-In Type Clamping Type
max. IN/A max. IN/A a b c d e f g h
827 124 716 4x2 1250 1250 180 110 30 125 90 387 345 286 61 36
827 124 727 4x2 2200 3150 200 135 35 125 125 387 345 286 55 36
827 146 336 4x3 2200 3150 200 135 35 125 125 449 390 347 75 36
827 146 337 4x3 2200 3150 200 135 35 125 125 449 390 347 75 52
Sonderausführung auf Anfrage. Special design on request.

A Steckbares Anschlussteil. A Plug-in type connecting part.
Nr. Steckbares Für CONNEX-2- und Gewicht ca. kg
Anschlussteil 4-fach-Winkelanschlussteile
No. Plug-In Type For CONNEX Multi-Contact Weight approx. kg
Connecting Part Elbow Bushings
827 128 710 827 124 716 2,5

827 128 730 827 124 727 2,8
827 128 730 827 146 336 2,8
Prüfdaten Anschluss im Trafo Anschluss im Trafo

gesteckt geklemmt
Test Data Internal Transformer Internal Transformer
Connection Plug-In Type Connection Clamping Type
Größe/Size 4 x 2 Größe/Size 4 x 3 Größe/Size 4 x 2 Größe/Size 4 x 3
Nenn-Strom/Nominal Current IN 2200 A 2200 A 3150 A 3150 A

Max. Betriebsspannung/Max. operating voltage Um bis/up to 36 kV bis/up to 52 kV bis/up to 36 kV bis/up to 52 kV
Nenn-Steh-Wechselspannung 50 Hz/ 1 min. 75 kV 95 kV 75 kV 95 kV
Nenn-Steh-Blitzstoßspannung 1,2/50 µs 170 kV 250 kV 170 kV 250 kV
Gleichspannungsprüfung / 15 min. 6 x U0 108 kV 108 kV 108 kV 108 kV
D.C. voltage test
Teilentladung/Partial discharge 2 x U0 ≤ 10 pC ≤ 10 pC ≤ 10 pC ≤ 10 pC
Nenn-Kurzzeitstrom/Rated short-time withstand current 50 kA/1 sec. 50 kA/1 sec. 50 kA/1 sec. 50 kA/1 sec.
Nenn-Stoßstrom/Rated impulse current 125 kA 125 kA 125 kA 125 kA
www. .de 37
OPERATING MANUAL
29 GH, GS
SAP No.: 112010276/20 Page: 197

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 198

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
GH CABINETS FOR PROTECTION, CONTROL AND MONITORING
GS ON-LOAD TAP CHANGERS, OFF LOAD TAP CHANGERS
surge voltage protectors, protective capacitors
GH 009 Outdoor kiosk for fan control

see under 15.
GS 001 On-load tap changer
make MR type R III 1200Y-123/C-10 19 1G

1888073
8969735E
119/04/01/0
TD 61
SAP No.: 112010276/20 Page: 199

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 200

Order No.: 1431517
Serial No.: 150 556
1 2 3 4 5 6 7 8
DIVERTER SWITCH
A A
1U1 2
1U2 1W2
OUTPUT TERMINAL 1N 2
1V1 1W1
1V2 2
FUER DIESE TECHNISCHE UNTERLAGE BEHALTEN WIR UNS GEMAESS
B B
1U,1V,1W
DIN 34 ABSCHNITT 2.1 UND 2.2 ALLE RECHTE VOR.
10 6 I/II
I TAP SELECTOR PLANES 19 6 1
C C
3 18 7 2
12 14 17 8 3
16 9 4
15 10 5
5-3
4
14 11 6
3
4 COARSE TAP SELECTOR 13 12 7
12 13 8
5 5 11 14 9
D 6 10 4 10 D
7 9 6 11
7
8 7 12
9 4 7 8 13
II
6 9 14
5-4
SERVICE POSITIONS 19
5 10 15
11 13
4 11 16
DIFFERENT VOLTAGES 19
3 12 17
12
2 13 18
ADJUSTING POSITION 10
E 13 1 14 19 E
14
POSITION OF COARSE TAP SELECTOR

SERVICE POSITION
DRAWING BY CAD
DESIGNATION OF TAP SELECTOR CONTACTS
DESIGNATION OF POSITIONS
F F
EXEC. ALKOFER +
ON-LOAD TAP-CHANGER EN 1888073_00
VERIFIED BLA SHEET 1
NO. MODIFICATION DATE NAME STANDARD ORIGIN. REPL. REPL.BY R III 1200-C/D-10191G/1061016 1 SH.
1 2 3 4 5 6 7 8
On-Load
Tap-Changer
Type R
Operating Instructions
119/04/01/0
2
Contents
Contents
1 General ......................................................................................................................................... 5
1.1 Safety instructions ............................................................................................................... 5
1.2 Specified application ........................................................................................................... 5
2 Design ....................................................................................................................................... 6
3 Shipment ................................................................................................................................... 6
4 Installation of the on-load tap-changer for cover attachment .............................................. 8

4.1 Mounting flange ................................................................................................................... 8
4.2 Attaching the on-load tap-changer head to the transformer cover .................................... 8
4.3 Mounting the tap selector and the diverter switch oil compartment .................................. 9
5 Installation of the on-load tap-changer into the bell-type tank ............................................. 11

5.1 Assembly of diverter switch oil compartment and tap selector,
connection of tap selector connecting leads ..................................................................... 11
5.2 Installation of the on-load tap-changer into the supporting structure ................................. 11
5.3 Preparations ..................................................................................................................... 12
5.4 Mounting the bell-type transformer cover ......................................................................... 13
6 Connection of tap winding and tap-changer take-off leads .................................................. 16

6.1 Tap selector ...................................................................................................................... 16
6.2 Parallel bridges for R I 2002 an R I 3000 .......................................................................... 17
6.3 Connecting the tap-changer take-off lead ......................................................................... 17
7 Transformer ratio test .............................................................................................................. 18
8 Drying procedure and filling with oil ...................................................................................... 18

8.1 Drying procedure .............................................................................................................. 18
8.1.1 Vacuum-drying process .......................................................................................... 18
8.1.1.1 Drying in the autoclave .............................................................................. 18
8.1.1.2 Drying in the transformer tank ................................................................... 18
8.1.2 Vapor-phase drying process ................................................................................... 19
8.1.2.1 Drying in the autoclave .............................................................................. 19
8.1.2.2 Drying in the transformer tank ................................................................... 19
8.1.3 Operating the OLTC ............................................................................................... 19
8.2 Filling with oil .................................................................................................................. 20
9 Pipe connections ...................................................................................................................... 20

9.1 Pipe connection R for protective relay RS 2001 ............................................................... 20
9.2 Pipe connection S for suction pipe ................................................................................... 20
9.3 Pipe connection Q ............................................................................................................ 20
9.4 Connection flange E2 ....................................................................................................... 20
NOTE
Data contained herein may differ in details from the tap-changing equipment delivered.
We reserve the right to make alterations without notice.
119/04/01/0 3
Contents
10 Mounting the motor drive unit, the bevel gear and the drive shaft ...................................... 21
10.1 Mounting the motor drive unit ........................................................................................... 21
10.2 Mounting the bevel gear ................................................................................................... 21
10.3 Mounting the drive shaft (square tube) ............................................................................. 21
11 Putting the on-load tap-changer into operation at the transformer factory ........................ 22
11.1 Operational tests .............................................................................................................. 22
11.2 Final oil filling .................................................................................................................. 22
11.3 Ground connections ......................................................................................................... 23
11.4 Electrical transformer tests ............................................................................................... 23
12 Transport to the operating site ................................................................................................ 24
13 Putting into service at the operating site ............................................................................... 24
14 Supervision during service, failures ....................................................................................... 25
15 Inspections ............................................................................................................................... 25
16 Appendix ................................................................................................................................... 27
119/04/01/0
4
1
General
1 General
1.1 Safety instructions 1.2 Specified application

operation, maintenance or repair of the equipment
must: CAUTION
- strictly observe these Operating Instructions. Only use the on-load tap-changer with the transfor-
mer specified in the order. Installation, electrical
Improper operation or misuse can lead to connection and commissioning of the on-load tap-
changer may only be carried out by qualified, skilled
- a reduction in the efficiency of the equipment
personnel and only in accordance with these operat-
- damage to the equipment and property of the
ing instructions.
user
- serious or fatal injury. It is the responsibility of the user to make sure that
the on-load tap-changer is used for the specified
Safety instructions in this manual are presented in three application only.
different forms to emphasize important information. For safety reasons, any unauthorized work, i.e. in-
stallation, modification, alteration of the tap-changing
equipment, electrical connection or commissioning of
the equipment is forbidden without first consulting MR!
WARNING The trouble-free operation of the drive, the on-load
tap-changer and the transformer may be put at risk.
This information indicates particular danger to life and
health. Disregarding such a warning can lead to
serious or fatal injury.
CAUTION
All relevant fire protection regulations must be strictly

CAUTION
observed.
This information indicates particular danger to the

equipment or other property of the user. Serious or
fatal injury cannot be excluded.
NOTE
These notes give important information on a certain

subject.
119/04/01/0 5
2 Design
3 Shipment
2 Design 3 SHIPMENT
The on-load tap-changer (OLTC) consists of the diver- On-load tap-changer and motor drive are shipped in the
ter switch with the tap selector mounted below (fig. 1). adjustment position. The on-load tap-changer is packed
in two parts, diverter switch and tap selector, and is well
The diverter switch is installed in its own oil compart-
protected against moisture. Both the diverter switch and
ment.
the tap selector are blocked in the adjustment position.
The on-load tap-changer is attached to the transformer
The tap-changing equipment is shipped as follows:
cover by means of the tap-changer head.
Diverter switch oil compartment with tap-changer head
If required, the tap selector may be equipped with a
and diverter switch unit (max. weight approx. 210 kg),
change-over selector.
fig. 2.
The change-over selector of all type R OLTCs is
Tap selector (max. weight approx. 270 kg), fig. 3.
laterally attached to the fine tap selector.
Motor drive unit ED-S (approx. 80 kg) fig. 4.
OLTC models without change-over selector are avail-
able for max. 18, and with change-over selector for Drive shaft with coupling parts and bevel gear (max.
max. 35 operating positions. weight approx. 20 kg), fig. 5.
The design of the on-load tap-changer and the designa- Protective relay RS 2001(weight 3.5 kg), fig. 6.
tion of its main parts are shown in the installation draw- Check shipment against documents.
ing 896 705 in the appendix. Store all parts in a dry place until installation.
These Operating Instructions contain all information The tap-changer parts must be left wrapped in their
regarding installation and operation of the following airtight cover, unwrap just before installation.
OLTC standard models, which are available with and
without change-over selector.
Three-phase OLTC:
R III 1200 (see fig. 1)
Single-phase OLTC:
R I 2000/2002/2402, R I 3000/3600.
All single-phase OLTCs are also available as a group
3 x R I 2002/2402 or
3 x R I 3000/3600
A
with a common motor drive.
V2 W1
3 1
U1
4 2
U21
3 1
V1
4 2
V2
3 1
W1
4 2
W2
1 KHW 1086-4
119/04/01/0
6
3
Shipment
NOTE
In general, drive shaft, bevel gear and protective

relay are packed with the on-load tap-changer.
4 KHW 915-4
MR
V2 W1
2 KHW 1087-4
5 KHW 766-4
MR
3 1
4 2
3 1
4 2
3 1
4 2
3 KHW 1097-4 6 KHW 848-4
119/04/01/0 7
4
Installation of the on-load tap-changer for cover attachment
4 Installation of the on-load tap-

changer for cover attachment (fig. 7)
4.1 Mounting flange

To mount the tap-changer head to the transformer cover M12
a mounting flange is necessary. This mounting flange
25
should meet the requirements of the tap-changer head
45
gasket surface (see fig. 7, and section 16, drawing
15
896 705).
To position the thread studs (M12, max. length = 45 mm)
we recommend the use of a drilling template (see
fig. 8 and section 16, dwg. 890 183). If requested, the
drilling template will be supplied without charge with the
15°
0
first on-load tap-changer type R. 74
710
7,5°
15°
4.2 Attachment of the tap-changer
65
0
head to the transformer cover
The diverter switch oil compartment is lowered through
the cover aperture (= mounting flange) of the trans- 7 KHW 770-4
former. The tap-changer head is attached to the mount-
ing flange by means of bolts.
7,5°
Then, the tap selector is fastened to the diverter switch
15°
oil compartment (see section 4.3). 24
x1
5°
=3
5
Proceed as follows: 60
°
1. Place the diverter switch oil compartment on a level

surface.
0
0
74
2. Clean sealing surfaces of mounting flange and tap- 71
changer head.
650
3. Put an oil-proof gasket on the mounting flange of
60
20
the transformer cover.

200 200
4. Lift the diverter switch oil compartment by hooking
up the tap-changer head. Lower the oil compartment
cautiously into the mounting flange.
Take care of screening rings (with Um ≥ 170 kV only).
5. Check position of tap changer head. 8 8 KHW 769-4
6. Attach the tap-changer head to the mounting flange

with bolts.
NOTE
Remove the blocking plate from the coupling (fig. 9)

of the oil compartment bottom.
119/04/01/0
8
4
4.3 Mounting the tap selector and the

diverter switch oil compartment
Raise the tap selector to the oil compartment and

attach. At the same time the mechanical coupling for
the tap selector drive has to be performed. Finally,
connect the tap selector connecting leads to the
diverter switch oil compartment.
Proceed as follows:
1. Put the tap selector down on a level surface. Get
ready 4 lock nuts M12 with washers.
NOTE
Remove the blocking strip from the tap selector

coupling (fig. 10).
The coupling must not be displaced afterwards.
2. Put the tap selector on an appropriate lifting device. 9 KHW 1111-4

rh-1111-4-0/1
Remove the ring nuts.

3. Raise the tap selector to the diverter switch oil
compartment. Be sure that tap selector connecting
leads clear the diverter switch oil compartment and
remain undamaged.
4. Position coupling parts and attachment points of
tap selector and oil compartment to match properly.
5. Raise the tap selector to its final height (fig. 11).
6. Bolt tap selector attachment points to the oil
compartment bottom:
4 lock nuts M 12/w.s.19, washers,
max. torque 60 Nm (fig. 12).
7. Remove the wooden support from the laterally
attached change-over selector.
10 KHW 1098-4
rh-1098-4-0/1
1500
11 KHW 1102-4
119/04/01/0 9
4
Connection of the tap selector connnecting leads to

the diverter switch oil compartment:
CAUTION
All connections must be carried out carefully. The

tightening torques indicated must be applied. Be
sure that bolts are tightened carefully and screened
by the screening caps supplied with the equipment
(fig. 13).
OLTCs R III 1200 and R I 3000/3600

6 connecting leads to oil compartment terminals
according to fig. 14.
Each one attached by 1 bolt M12 (w.s.19) lock nut and 13 KHW653-3
screening cap, torque 60 Nm.
OLTC R I 2002/2402
4 connecting leads to oil compartment terminals
according to fig. 15.
Each one attached by 1 bolt M12, lock nut and screen-
ing cap, torque 60 Nm. A
1V1 1V2
14 KHW 1088-4
3 4
12 KHW 1091-4 15 KHW 1093-4
119/04/01/0
10
5
Installation of the on-load tap-changer into the bell-type tank
5 Installation of the on-load tap-

changer into the bell-type tank 5.2 Installation of the on-load tap changer
into the supporting structure
To install the on-load tap-changer into a transformer Lift the assembled on-load tap-changer, according to
with bell-type tank the on-load tap-changer must be section 4.1, into the supporting structure. Make sure
mounted onto a supporting structure. that the on-load tap-changer is in proper mounting
For this purpose, the OLTC is equipped with a sup- position and fasten it there safely.
porting flange at the diverter switch oil compartment
(= special design, section 16, dwg. 896 762).
Firstly, lift the on-load tap-changer into the supporting NOTE
structure and connect it to the tap winding. The OLTC
must be attached to the supporting structure in such a In the supporting structure the on-load tap-changer
way that it cannot be displaced. The supporting flange must be in an exactly vertical position. The on-load
is provided with through-holes which allow it to be fixed tap-changer must be mounted to the supporting
to the supporting structure. It is advisable to put spacer structure ensuring that it need not be lifted by more
blocks temporarily between supporting structure and than 5 to 20 mm to reach its final position after the
supporting flange and to remove them before the bell- bell-type cover is set up.
type cover is set up.
It is of advantage to install spacer blocks between
Once the bell-type cover is attached, lift the on-load tap-
supporting structure and supporting flange in such a
changer (with the diverter switch unit removed) by
way that the on-load tap-changer is in its final position
means of the lifting traverse (see section 16, drawing
after the bell-type cover is set up. This measure helps
890 180) and fix it to the bell-type cover together with
to cut the tap leads to their correct lengths. Remove the
the top part of the head.
spacer blocks after the leads have been connected.
To attach the tap-changer head to the bell-type cover,
we recommend using a mounting flange as described in To connect the tap winding and the tap-changer take-off
section 4.1. terminal follow the instructions according to section 6.
5.1 Assembly of diverter switch oil com- CAUTION

partment and tap selector, attachment
of tap selector connecting leads The connected leads must not exercise any force on
the on-load tap-changer. Moreover there must be
sufficient clearance so that it is possible to lift the on-
load tap-changer in its final installation position after
The assembly of diverter switch oil compartment and the bell-type tank has been mounted.
tap selector as well as the connection of tap selector
connecting leads has to be carried out according to
section 4.3. The drying procedure and the transformer ratio test are
to be performed in accordance with sections 7 and 8.
119/04/01/0 11
5
5.3 Preparations
Prior to setting up the bell-type tank the tap-changer

head must be removed from the on-load tap-changer.
1. For this purpose, open the tap-changer head cover
(24 hexagonal head screws M10, w.s.17, with lock
washers).
2. Take care of the cover gasket
(round rubber gasket, fig. 16).
3. Remove the position indicator dial (remove the clip
from the shaft end, fig. 17).
4. Take note of the red-marked area not covered by
the supporting plate of the diverter switch unit
(fig. 18).
5. Remove the fixing nuts of the supporting plate (4
nuts M8, w.s.13, lock washers, fig. 19).
17 KHW 1101-4
rh-1101-4-0/1
6. Withdraw the diverter switch unit carefully from the
oil compartment (fig. 20). Keep the diverter switch
unit in a vertical position.
7. Remove the suction pipe. The pipe connection has
to be withdrawn from within the tap-changer head
(fig. 21). Take care of O-rings.
8. Unscrew the remaining nuts in the tap-changer head
(fig. 22), 17 nuts M8, w.s.13, lock washers.
Lift off the tap-changer head from the supporting
flange. Take care of the gasket.
18 KHW 1103-4
rh-1103-4-0/1
16 KHW 762-4
19 KHW 1105-4
rh-1105-4-0/1
119/04/01/0
12
5
5.4 Mounting the bell-type

transformer cover
1. Before mounting the bell-type transformer cover

clean the sealing surface of the oil compartment
supporting flange. Place the gasket onto the flange
(fig. 23). Withdraw the spacer blocks (see section
5.2).
2. Lift the bell-type cover over the transformer active
part and lower it to its final position.
3. Before mounting the tap-changer head clean the
sealing surfaces (bottom of tap-changer head,
mounting flange). Put an oil-resistant gasket on the
mounting flange.
21 KHW 1106-4
22 KHW 1110-4
rh-1110-4-0/1
20 KHWrh-1109-4-0/1
1109-4 23 KHW 1107-4
rh-1107-4-0/1
119/04/01/0 13
5
4. Place the tap-changer head on the mounting flange.

Check the mounting position of the tap-changer
head by means of 2 adjusting bolts (fig. 23) and the
marks of the supporting flange and tap-changer
head (fig. 24) which allow assembly in the correct
position only. Depending on the final height
adjustment leave a clearance of 5 to 20 mm
between tap-changer head and supporting flange
5. Lift the on-load tap-changer slightly by means of the
lifting traverse (see fig. 25 and section 16, drawing
890 180). Make sure that all supporting flange studs
easily slide through the fixing holes of the tap-
changer head.
CAUTION
24 KHW 1100-4
Take care not to drop any parts into the diverter

switch oil compartment. Otherwise the diverter
switch can block and cause severe damage to the
on-load tap-changer and transformer.
Therefore, make sure that the number of small
parts is complete when disassembling and
reinstalling. Count them to be sure.
25 KHW 1108-4
119/04/01/0
14
5
6. Attach the tap-changer head in the red marked area

not covered by the supporting plate of the diverter
switch (fig. 26, see also section 5.3). Use 17 nuts
M8 (wrench size 13, max. torque 14 Nm, lock
washers). Attach the tap-changer head to the
mounting flange.
7. Remount the suction pipe. Make sure that the O-
rings are placed properly. The O-rings should slightly
be greased before being mounted.
8. Remount the diverter switch unit. Make sure that the
diverter switch supporting plate is in its proper
position within the tap-changer head (the red marked
areas must be left free). Attach the supporting plate
by means of 5 nuts M8 (wrench size 13, max. torque
14 Nm, lock washers).
9. Attach the position indication dial: 26 KHW 1110-4
rh-1110-4-0/1
Put the clip onto the shaft end.
The dial can be mounted in correct position only by
means of its coupling pin (fig. 27).
10.Mount the cover on the tap-changer head. Make
sure that the rubber gasket (O-ring) in the cover is in
proper position.Fasten the 24 screws M10 (wrench
size 17) equally, max. torque 34 Nm (fig. 28).
27 KHW 1101-4
rh-1101-4-0/1
28 KHW 1104-4
rh-1104-4-0/1
119/04/01/0 15
6
Connection of tap winding and tap-changer take-off leads
6 Connection of tap winding and tap-

changer take-off leads
The tap winding has to be connected to the on-load tap-

changer according to the connection diagram supplied
with the particular tap-changer equipment.
CAUTION
3 1
All connections to the on-load tap-changer must be 4 2
made carefully and locked safely. The tap leads must

3 1
be assembled in such a way to allow for connecting

all leads to the on-load tap-changer without tension. 4 2
If necessary, lead ends must be shaped in form of

3 1
expansion loops.
4 2
Single-phase OLTCs R I 2002 and R I 3000 require the 29 KHW 1096-4

parallel connection of the tap selector terminals with
identical terminal numbers in order to avoid over-
voltages between parallel contacts.
If requested, bridges for the parallel connection of tap A10
selector terminals according to dwg. 896 706 (see ap-
pendix) can be supplied.
In case of OLTCs R I 2402 and R I 3600 the parallel
connection of tap selector terminals by means of
parallel bridges is not applicable as the enforced current B9
splitting of tap leads is provided by two or three isolated
winding branches on each tap selector terminal.
B10
6.1 Tap selector (fig. 29)

C9
Fine tap selector terminals
with through-hole for M12 screws(fig. 30). If reques- 30 KHW 1090-4
rh-1090-4-0/1
ted, screening caps (MR part number 078 957) will be

supplied with the delivery.
Change-over selector terminals
Reversing switch: terminals (+) and (–) like the fine
tap selector terminals, terminals (0) as terminal lug of
the connecting lead (0/K) with through-hole for M12
screws (see fig. 31).
Coarse tap selector: terminals (0) and (–) like the fine
tap selector terminals, terminals (+) as terminal lug of
the cranked connecting lead (+/K) with through-holes
for M12 screws (see fig. 31).
31 KHW 1089-4
rh-1089-4-0/1
119/04/01/0
16
6
Connection of tap winding and tap-changer take-off leads
6.2 Parallel bridges for R I 2002

and R I 3000 (fig. 32)
Parallel bridges for the fine tap selector and change-

over selector according to dwg. 896 706 (see appendix)
can be supplied on request.
Parallel bridges consist of two identical parts which are
joined by a single M12 bolt with lock nut (wrench size
19, max. torque 60 Nm). They are provided with two
through-holes to accommodate connection of tap leads.
6.3 Connecting the tap-changer

take-off lead
The tap-changer take-off lead is to be connected to 33 894 490 0M
the bus bar ring of the diverter switch oil compartment

(fig. 33). The screw connection must be locked safely
(Md = 60 Nm).
OLTC type R III 1200 (starpoint connection)
One throughhole each for M12 bolts is provided on
different points of the bus bar ring displaced by 120° A
(fig. 34).
OLTC type R I 2002/2402 and R I 3000/3600
Three or four throughholes each for M12 bolts are pro-
vided on different points of the bus bar ring displaced 1V1
by 120° (fig. 35).
1V2
34 KHW 1094-4
rh-1094-4-0/1
3 4
32 KHW 1099-4 35
rh-1099-4-0/1 KHW 1095-4
119/04/01/0 17
7 Transformer ratio test
8 Drying procedure and filling with oil
7 Transformer ratio test 8 Drying procedure and filling with oil

8.1 Drying procedure
We recommend to ratio-meter the transformer with a The dielectric properties of the on-load tap-changer can
low AC voltage before drying. only be guaranteed, if the on-load tap-changer is sub-
jected to a drying treatment according to the following
To operate the drive shaft in the tap-changer head a
instructions (8.1.1 or 8.1.2).
short tube of nominal width 25 mm with an insert
coupling bolt of 12 mm dia. together with a hand wheel
or a hand crank may be used. 8.1.1 Vacuum-drying process
In case of OLTC set 3 x R I 2002 ... 3600 all three tap- 8.1.1.1 Drying in the autoclave
changer heads have to be coupled by the horizontal
drive shafts (see section 10).
NOTE
When using an ED, 16.5 drive shaft revolutions of the
tap-changer drive shaft are required for one tap-change
operation. The diverter switch action can be heard When drying the transformer in the autoclave remove
distinctly. the tap-changer cover and store it outside the vacuum
autoclave.
To operate the change-over selector a higher torque is
necessary.
• Heating up
The end positions shown on the connection diagram the on-load tap-changer in air of atmospheric
supplied with the delivery must never be overrun. It is pressure with a temperature rise of approx. 10 °C/
therefore necessary to check the operating position hour to a final temperature of at most 110 °C.
through the inspection glass in the tap-changer head
• Preparatory drying
cover (fig. 36). Keep the number of tap-change opera-
in circulating air at 110 °C max. applied to the on-
tions to a minimum as long as the on-load tap-changer
load tap-changer for a duration of 20 hours.
has not been immersed in oil. After the transformer ratio
test the on-load tap-changer has to be set back to the • Vacuum drying
adjustment position in which it was delivered by MR. at a temperature of 110 °C max. applied to the on-
The position is indicated in the connection diagram load tap-changer and a residual pressure of at most
delivered with the equipment. 10-3 bar for a duration of at least 50 hours.
8.1.1.2 Drying in the transformer tank

NOTE
If the transformer is to be vapor-phase dried in its own

tank, open the kerosene drain plug (see section 8.1.2). NOTE
If the transformer is to be dried in its tank the interior

of the diverter switch oil compartment must be con-
nected to vacuum, as the tap-changer head cover
remains closed during the entire drying process.
The tap-changer head cover is vacuum-proof.

To ensure sufficient drying of the interior of the oil
compartment and the diverter switch insert, connect a
by-pass tube of 25 mm nominal width between the
transformer tank and the connecting flange which leads
into the oil compartment.
For ease of handling connect the bypass tube either
b
9
between flanges E2 and Q or flanges E2 and R of the

tap-changer head (for position of connecting flanges
see section 9 and dwg. 893 899 of appendix).
Procedure, temperature, pressure and duration of the
36 KHW 764-4
drying process are as described in section 8.1.1.1.
119/04/01/0
18
8
Drying procedure and filling with oil
8.1.2 Vapor-phase drying process

8.1.2.1Drying in the autoclave
NOTE NOTE
Before starting the drying procedure, open the When drying in the autoclave remove the tap-changer
kerosene drain plug (fig. 37) to drain the condensate head cover first and store it outside the vacuum
from the oil compartment. autoclave.
The kerosene drain plug has an hexagonal recess • Heating up

screw (w.s. 8) and is easily accessible between oil by admitting the kerosene vapor at a temperature of
compartment bottom and tap selector gear. It can be about 90°C. Keep this temperature constant for 3 to
unscrewed from the outside. The thread of the kerosene 4 hours.
drain plug has a plastic coat so that it can only be
turned with some force. • Drying
by increasing the kerosene vapor temperature by
about 10°C per hour to the desired final temperature
NOTE with not more than 125 °C applied to the on-load tap-
changer. The duration of the drying procedure is
normally the same as that of the transformer.
Do not continue turning the kerosene drain plug
beyond the point where it starts moving tightly.
8.1.2.2 Drying in the transformer tank

When drying the transformer in its own tank (see
section 8.1.2.2) the drain plug, in general, is not If the transformer is to be dried in its own tank, the tap-
accessible from outside and can only be opened changer head cover remains closed during the entire
from inside the oil compartment. drying process. The tap-changer head cover is vacuum-
In this case the diverter switch unit must be removed proof. To ensure sufficient drying of the interior of the
and the kerosene drain plug must be unscrewed with a diverter switch oil compartment and of the diverter
socket wrench (see section 16, dwg. 890 182). Then switch unit connect a common tube of at least 50 mm
reinstall the diverter switch unit. width between the vapor lead and two connecting
flanges of the tap-changer head leading into the oil
CAUTION compartment.
Use flanges Q and R for OLTCs type R. (For position of
The kerosene drain plug must be closed again after connecting flanges see section 9 and 16, dwg. 893 899).
the drying process to ensure that no oil from the Procedure, temperature and duration of the drying
diverter switch oil compartment can flow into the process are described in item 8.1.2.1.
transformer tank!
8 mm
8.1.3 Operating the OLTC
CAUTION
Do not operate the on-load tap-changer without oil

after drying otherwise bearings and gaskets will be
damaged.
8 mm
The on-load tap-changer must not be operated before
the diverter switch oil compartment has been filled with
Coating oil and the tap selector has been completely immersed
37 KHW 831-4 in the transformer oil.
119/04/01/0 19
8 Drying procedure and filling with oil
9 Pipe connections
9 Pipe connections
8.2 Filling with oil
The tap-changer head is provided with 3 pipe connec-

CAUTION tions for different purposes. After loosening the thrust
collar (4 bolts M10, w.s. 17) these pipe connections can
be swivelled (see fig. 38 and appendix, dwg. 893 899).
The tap-changer oil compartment and the associated
oil conservator must only be filled with new mineral
insulating oil for transformers according to IEC 296.
The use of other oil affects the trouble-free operation
9.1 Pipe connection R for
of on-load tap-changer and transformer. protective relay RS 2001
The mounting of the protective relay RS 2001 (see
Place the cover on the tap-changer head. Tighten all section 16, dimension drawing 892 608) is pursuant to
24 cover bolts M10 (wrench size 17, max. torque 34 Nm). our Operating Instructions No. 59.
On-load tap-changer and transformer are filled simul-
taneously with new oil under vacuum.
NOTE
For this purpose use pipe connection S or R. To eva-
cuate, a by-pass tube between connections E2 and Q is
to be installed in order to apply vacuum to both diverter The relay serial number must be the same as that of
switch oil compartment and transformer tank simultane- the on-load tap-changer.
ously. The relay must be mounted in horizontal position and
as near to the tap-changer head as possible.
The arrow on the relay should point towards the oil
conservator when mounted.
The pipe to the oil conservator must be installed with
an inclination of at least 2%.
9.2 Pipe connections S for suction pipe

This is the connection for the feeding pipe of a sta-
tionary oil filter. If there is no filter, the pipe connection
should be provided with a pipe with a drain cock easily
accessible on one side of the transformer tank.
9.3 Pipe connection Q

R S Q (special design, required for
stationary oil filter only)
This is the pipe connection for the return pipe of a
stationary oil filter.
If no oil filter is provided, a dummy plug is mounted
instead of the pipe connection.
E2
9.4 Connection flange E2
In general, this flange is covered by a dummy plug.
The flange hole is open to the transformer tank directly
beneath the tap-changer head.
38 If necessary, it may be connected to the gas accumulat-

KHW 805-4
ing tube for the Buchholz relay.
119/04/01/0
20
10
Mounting the motor drive unit, the bevel gear and the drive shaft
10 Mounting the motor drive unit,

the bevel gear and the drive shaft
10.1 Mounting the motor drive unit (see 10.3 Mounting the drive shaft
appendix, dwg. 898 801, 898 802)
You may find comprehensive mounting instructions in
The drive shaft must be assembled according to our
our Operating Instructions No. 138 for motor drive ED.
Operating Instructions No. 42. The drive shaft is the
mechanical connection between the motor drive and the
tap changer head.
NOTE The bevel gear diverts the driving force from the vertical
to the horizontal direction.
Serial number of motor drive unit and on-load tap-
changer must be identical (nameplate). Accordingly, the vertical part of the drive shaft is to be
mounted between motor drive unit and bevel gear,
Motor drive unit and on-load tap-changer must be in whereas the horizontal part of the drive shaft is to be
the same operating position. The adjustment position mounted between bevel gear and tap-changer head.
is indicated in the connection diagram supplied with
the equipment. The drive shaft itself consists of a square tube and is to
be connected on both ends to the respective equipment
The motor drive unit must be mounted at the provided by two coupling brackets and one coupling bolt.
place on the transformer tank in a vertical position
and protected against excessive transformer
vibrations. NOTE
When mounting the drive shaft make sure that the

shaft ends to be connected are aligned properly.
10.2 Mounting the bevel gear
The bevel gear is to be attached to a support on the Square shafts, coupling brackets, coupling bolts,
transformer cover by means of 2 bolts (through-holes screws, nuts and lock tabs are made of corrosion-proof
18 mm dia., see section 16, drawing 892 916). steel. We recommend, however, to apply the same
outside coating here as to the transformer tank.
The square shafts and the guard plate for the footstep
protection for the horizontal drive shaft at the trans-
NOTE former cover are supplied in oversize (various standard
lengths).
Make sure that bevel gear serial number and on-load These parts must be cut to the required size before
tap-changer serial number are identical. mounting.
The horizontal drive shaft must be in proper alignment Finally equalize the rotation lag between on-load tap-
with the trunnion in the tap-changer head. changer and motor drive unit (according to Operating
Instructions No. 138 for ED).
After loosening the thrust collar (6 bolts M8, w.s. 13)
the upper gear unit can be swivelled (fig. 39). After
adjusting the upper gear unit, the thrust collar must be
re-tightened (max. torque 15 Nm).
Tab-lock the screws.
In case of bevel gears in special design and
intermediate bearings of the vertical or horizontal
drive shaft above instructions apply analogously.
39 KHW 767-4
119/04/01/0 21
10 Mounting the motor drive unit, the bevel gear and the drive shaft
11 Putting the OLTC into operation in the transformer factory
11 Putting the OLTC into operation in

the transformer factory
11.1 Operational tests
OLTCs 3 x R I 2002 ... 3600 Before applying voltage to the transformer check the
mechanical operation of on-load tap-changer and motor
The following procedure is also recommended for
drive.
OLTC R III 1200.
For these test operations the on-load tap-changer has
Due to the special arrangement of the tap-changer
to be run through the complete operating cycle.
phases in three columns, the horizontal drive shaft must
be mounted between the three tap-changer heads Make sure that in each operating position the indi-
above the tank cover. Since a swivelling of the upper cators of motor drive and on-load tap-changer (tap-
gear unit will initiate a switching action, make sure that changer head) read the same position.
the adjustment position of the diverter switch is re-
gained after the alignment of the gear units.
For this purpose proceed as follows: CAUTION
1. Check that the operating positions of all columns Misalignment between on-load tap-changer and
are identical (tap-changer head, inspection win motor drive unit exists, if on-load tap-changer and
dow). Each one of the one-phase OLTCs must be motor drive unit show different operating positions.
in the adjustment position. Misalignment of coupling between on-load tap-
2. Turn the upper gear unit of the tap-changer heads changer and motor drive unit leads to severe damage
into the desired installation position and fix them of on-load tap-changer and transformer, if operation
there (tighten thrust collars and tab-lock the is continued. The transformer must not be taken in
screws). operation.
Take note of the arrow on the drive shaft flange
Make sure that in both end positions the electrical and
below the punched serial number. The direction of
mechanical limit stops function automatically (see
the arrow indicates the rotation sense when crank-
Operating Instructions No. 138 for ED).
ing the motor drive clockwise and must be identical
on all gear units.
3. Operate the tap-changer poles separately by one
step by rotating the trunnions counter-clockwise 11.2 Final oil filling
until the diverter switch operates once.
Check coincidence of operating positions of all Fill up the on-load tap-changer completely with trans-
tap-changer heads. former oil via the oil conservator and evacuate.
4. Mount the horizontal drive shaft between the tap- • Bleed the tap-changer head via the bleeder valve in
changer heads. the head cover (E1):
Remove screw cap M30/w.s. 36 (fig. 40), lift valve
5. Return the OLTC set, that is all tap-changer tappet by means of a screw driver.
poles together, into the adjustment position.The
adjustment position is reached by turning the drive • Bleed the suction pipe (S) via the bleeder screw of
shaft in clockwise direction. the elbow: cap nut M16 (w.s. 22, max. torque 9 Nm),
slotted bleeder screw M6 (max. torque 2 Nm,
Check simultaneous operation of all diverter
fig. 41).
switches.
Check coincidence of position of all tap-
changer heads and the motor drive unit.
6. Mount the vertical drive shaft.
CAUTION
Caution
The supervisory control must be installed according
to the connection diagram of the relevant motor drive Make sure that the suction pipe has been bled
unit. Incorrect installation will cause damage of both completely. The insulation capability of the on-load
on-load tap-changer and transformer in case of tap-changer to ground is otherwise significally
malfunction. impaired.
119/04/01/0
22
11
Putting the OLTC into operation in the transformer factory
11.3 Ground connections
Connect the ground screws (2 screws M12 with nuts,

w.s. 19, max. torque 60 Nm, fig. 42) of the tap-changer
head to the transformer cover.
Connect the ground screw (M12, w.s. 19, max. torque
60 Nm) of the motor drive housing to the transformer
tank.
11.4 Electrical transformer tests
After the afore mentioned steps the necessary electrical

acceptance tests of the transformer can be performed.
40 KHW 773-4
41 KHW 811-4
42 KHW 811-4
119/04/01/0 23
12 Transport to the operating site
13 Putting into service at the operating site
12 Transport to the operating site 13 Putting into service at the operating

site
If the transformer is to be transported without the motor Before putting the transformer into service, operational
drive unit, set the motor drive to the adjustment position tests of on-load tap-changer and motor drive have to be
and uncouple. performed according to section 11.1. At the same time
check the function of the protective relay.
CAUTION
NOTE
Do not operate the motor drive unit while the on-load
tap-changer is uncoupled.
The protective relay has to be inserted into the trip-
ping circuit of the circuit breakers so that energiza-
tion of the protective relay switches off the trans-
To remount the motor drive unit follow the instructions former immediately (see Operating Instructions
according to section 10.1 and 10.3. No. 59 for protective relay RS 2001).
Make sure that the circuit breakers switching off the

NOTE
transformer operate when the test push button »OFF«
is pressed. Be sure that they energize the transformer
If the transformer is filled with oil but stored or trans- only after push button »IN SERVICE« of the protective
ported without oil conservator, a bypass tube must be relay has been pressed.
installed between the interior of the tap changer and
the transformer tank to compensate the static
pressure caused by expansion of oil. CAUTION
Install this by-pass tube between pipe connections E2 Check whether all stop valves between oil
and Q of the tap-changer head. conservator and tap-changer head are open.
For short time conditions of 2 to 4 weeks without oil
conservator, lower the oil level by approx. 5 litres. After the transformer has been energized, tap-change
If the transformer is to be transported or stored without operations under load can be performed. Gas accumu-
oil filling, drain the oil of the on-load tap-changer com- lating under the cover of the tap-changer head will
pletely. cause minor oil displacement and/or escape via the oil
conservator.
The interior of the on-load tap-changer should be
conserved and protected in the same way as the
transformer itself (nitrogen-sealing).
If a prolonged stand-by period is expected, the heater of
the motor drive unit must be connected to the suitable
power supply.
119/04/01/0
24
Supervision during service, failures 14
Inspections 15
14 Supervision during service, failures 15 Inspections
It is only necessary to inspect the tap-changer head, the

protective relay and the motor drive unit occasionally.
Pay special attention to:
• oil tightness of sealings of the tap-changer head, the NOTE
protective relay and the pipe connections,
• sealings at the motor drive housing, The tap-changing equipment must be inspected at
regular intervals to maintain a high level of operating
• proper function of the electrical space heater inside reliability.
the motor drive unit,
• the condition of the control devices in the motor drive
In general, the inspection can be carried out by
unit.
qualified and MR-trained personnel within one day,
provided it is well prepared and organized.
We strongly recommend to have inspections performed
WARNING by our Technical Service. This guarantees a professio-
nal performance including all the latest updating
If the protective relay operates, do not reset until the measures.
on-load tap-changer and the transformer have been
checked. For this purpose also withdraw the diverter Inquire for spare parts when preparing an inspection
switch unit and check it according to our Inspection which will not be carried out by MR personnel (please
Instructions. Proceed in detail according to our indicate OLTC number and number of operations).
Operating Instructions No. 59 for the protective relay The number of tap-change operations determining the
RS 2001. inspection intervals indicated in table II and table III are
figures based on experience with oil qualities normally
Before returning to energized operation, make sure
used.
that the cause of the trouble has been corrected and
that the on-load tap-changer and the transformer are The tap selector of the on-load tap-changer is generally
free of damage. maintenance-free. In special cases, however, if OLTCs
are used in industrial transformers where high operating
Never reconnect the transformer without prior numbers are to be expected, our technical service
checking. Continued operation of the on-load tap department must be contacted after about 1,000,000
changer can result in severe damage of on-load tap- operations. The diverter switch insert of the OLTC is to
changer and transformer. be replaced after 800,000 operations.
If the number of operations per year is 15,000 or higher,
In case of serious trouble with on-load tap-changer or the use of our oil filter plant type OF100 with paper filter
motor drive – provided that the repair cannot easily be insert (see Operating Instructions No. 18) is recommen-
done at site and in case of a tripping of the protective ded. The use of our oil filter plant type OF100 with
relay please contact the authorized MR representative, combination filter insert is obligatory for OLTC type R
the transformer manufacturer or directly with insulation to ground Um > 300 kV.
Maschinenfabrik Reinhausen GmbH Filtering of switching oil allows to extend the inspection
Technical Service intervals.
Postfach 12 03 60
The user should regularly test the transformer insulating
D-93025 Regensburg
oil according to the relevant standards.
Phone: (+49) 9 41 / 40 90-0
Telefax:(+49) 9 41 / 40 90-5 01 If inspection has not been performed by MR-personnel,
Telex: 65881 please give us your report for data collecting purposes.
119/04/01/0 25
15
Inspections
CAUTION
Inspections of the tap-changer equipment are obliga-

tory. Disregarding the inspection intervals endangers
the trouble-free operation of on-load tap- changer and
transformer.
Standard values for oil testing according to CIGRE report 12-13 (1982)
applying to transformer oil at service temperature:
On-load tap-changer Water content*) Dielectric strengh**)
Neutral-end tap-changers < 40 ppm > 30 kV/2,5 mm
Single-pole tap-changers < 30 ppm > 40 kV/2,5 mm
*) measured according to Karl-Fischer method based on IEC Publication 814 (1985)

**) measured according to DIN 57370 Teil1/VDE 0370 Teil 1/12.78 Teil 1
Table I Guide values for monitoring the tap-changer oil
On-load tap-changer Transformer Number of tap-change operations

rated current without MR oil filter with oil filter
R III 1200 up to 600 A 80 000 100 000

up to 1200 A 60 000 100 000
R I 1201 up to 600 A 80 000 100 000

up to 1200 A 60 000 100 000
R I 2002 up to 2000 A 40 000 80 000
R I 2402 up to 2400 A 40 000 80 000
R I 3000 up to 3000 A 40 000 80 000
R I 3600 up to 3600A 40 000 80 000
Table II Inspection intervals for

– OLTC type R in star-point connection (Y)
– One-phase OLTC with Um < 245 kV used in autotransformers or for regulation at the line end of
winding of the transformer.
First inspection and further inspections: after 7 years or the number of operations indicated in Table II, depending on
what is reached first.
119/04/01/0
26
Inspections 15
Appendix 16
On-load tap-changer Transformer Number of tap-change operations

rarted current without MR oil filter with MR oil filter
R I 1201 up to 600 A 40 000 50 000

up to 1200 A 30 000 50 000
R I 2002 up to 2000 A 20 000 40 000
R I 2402 up to 2400 A 20 000 40 000
R I 3000 up to 3000 A 20 000 40 000
R I 3600 up to 3600 A 20 000 40 000
Table III Inspection intervals for one-phase OLTCs type R with Um ³ 245 kV and used in autotransformers
or for the regulation at line end of winding of the transformer.
First inspection: after 2 years or 20,000 operations, depending on what is reached first.
Next inspections: without MR filter plant after every 4 years, with MR filter plant (combination filter) after
every 6 years or the number of operations indicated in table III – whatever is reached first.
16 APPENDIX
Installation drawing _____________________________________________________________________ 896 705

OLTCs R I 2002 / R I 3000, bridges for parallel connection of tap selector terminals ___________________ 896 706
Tap-changer head ______________________________________________________________________ 893 899
Drilling template for tap-changer head ______________________________________________________ 890 183
Supporting flange for the installation into bell-type tank _________________________________________ 896 762
Lifting traverse _________________________________________________________________________ 890 180
Socket wrench for kerosene drain plug ______________________________________________________ 890 182
Protective relay RS 2001, dimension drawing _________________________________________________ 899 084
Motor drive unit ED-S, dimension drawing ___________________________________________________ 898 801
Motor drive unit ED-L, dimension drawing ____________________________________________________ 898 802
Bevel gear CD 6400, dimension drawing ____________________________________________________ 892 916
119/04/01/0 27
16
Appendix
Flat
surface
max. withdrawal height 1750 mm
Protective
relay
Take-off
terminal
11 Mounting flange on transformer cover

12 Fixing bolt M12
13 Gasket for tap-changer head
14 Position indicator
15 Inspection window
16 Drive shaft for position indicator
17 Through-hole 15 mm dia.
21 Tap-changer head
22 Bolt for tap-changer head cover
23 Gasket for tap-changer head cover
24 Tap changer head cover
25 Centric gear unit with drive shaft 25a
26 Pipe connection R for protective relay
27 Pipe connection S for suction pipe
28 Pipe connection Q for return pipe
(with oil filter only)
29a Bleeder valve of tap-changer head cover
29b Bleeding facility for transformer oil
29c Bleeder screw for suction pipe
31 Diverter switch oil compartment
32 Bottom of oil compartment
33 Grading ring (with Um = 170/245 kV)
34 Terminal of diverter switch oil compartment
35 Tap-changer take-off terminal (with R III 1200 neutral)
36 Suction pipe
41 Suspension of tap selector
42 Tap selector gear
43 Fine tap selector
44 Change-over selector
45 Tap selector terminals.
see corresponding dimension drawing
46 Change-over selector terminals.
see corresponding dimension drawing
48 Connecting lead for tap selector
48a Holding strip for 48
51 Diverter switch unit
52 Supporting cylinder
See also variants of tap selector 53 Gear plate
bottom 896 702 provide sufficient 54 Fixing bolt
55 Lifting Lug
clearance!
56 Transition resistors
Transformer tank bottom
Tap selector drive side
On-load tap-changer type R 896 705:5E

Installation drawing
119/04/01/0
28
16
Appendix
On-load tap-changer type R

Bridges for parallel connection of tap selector terminals 896 706:5E
for OLTCs R I 2002, R I 3000
(not applicable in case of enforced current splitting)
119/04/01/0 29
16
Appendix
width of
gasket
Detail at A
Connection flange
for Q, S, R
16
Thickness
E1 = Bleeding facility for tap- changer head

E2 = Bleeding facility for space under the head outside the tap-changer oil compartment
(same pipe connection as R, S, Q or bleeder screw can be used)
Q = Connection for oil return pipe (only for oil filter)
S = Connection for suction pipe Connections orientable
O-Ring R = Connection for protective relay (exchangeble with connection Q) through 360°
44.2 - 5.7
= Earth connection M12
On-load tap-changers type MS, M, T, R 893 899:9E

Tap-changer head
119/04/01/0
30
16
Appendix
3 thick
Marks to be pounded
On-load tap-changers type MS, M, T, R 890 183:6E

Drilling template
119/04/01/0 31
16
Appendix
O-Ring 44.2 - 5.7 Lifting device
Suction pipe
Drilling hole represented

in the sectional plane
Transformer cover
Gasket
Level traverse
Grading ring with

Um170/245/300 kV only
Supporting flange
Level traverse
Z = Guiding pin
On-load tap-changer type R

896 762:6E
Special design for installation into bell-type tank
119/04/01/0
32
16
Appendix
Sheet steel
St 37-2 DIN 17 100
On-load tap-changer type R 890 180:3E

Lifting traverse
119/04/01/0 33
16
Appendix
Item-No. 014 820 Item-No. 017 660

Socket wrench L = 1350 mm L = 1860 mm
To be used Type M (except M ∆) M III 350/600 ∆

for OLTC Typ MS Type T, R, G
On-load tap-changer type MS, M, T, R

Socket wrench for kerosene draining screw 890 182:7E
119/04/01/0
34
16
Appendix
Cable gland
Inspection PG 16
window
Gasket Gasket
Test push buttons

IN SERVICE OFF
Metal - dummy plug PG 16
The arrow must always point towards the oil pipe leading Plan view of test push buttons
to the oil conservator of the transformer. (cover removed)
Key of variants
Contact positions
Variant Relay designation1) Reed Arrangement of terminals Design
contact In service Off
0.65 - NO
Standard design
1 1.2 - NO A
3.0 - NO
4.8 - NO
0.65 - NC
2 1.2 - NC B
3.0 - NC
4.8 - NC
0.65 - CO
3 1.2 - CO C
3.0 - CO
4.8 - CO
0.65 - 2NO
4 1.2 - 2NO 2A
3.0 - 2NO
4.8 - 2NO
0.65 - 2NC
5 1.2 - 2NC 2B
3.0 - 2NC
4.8 - 2NC
0.65 - NO + NC
6 1.2 - NO + NC 1A &1B
3.0 - NO + NC
4.8 - NO + NC
1)
The protective relay is to be connected in such a way that if it is energized, the power transformer is switched off immediately by the corresponding
circuit breakers.
Protective Relay RS 2001

899 084:0E
(STANDARD)
119/04/01/0 35
16
Appendix
Vertical guard plate with

spacing ring
Hand crank
* for design with

intermediate bearing
3 dummy plates for packing glands

special design with OLTC monitoring required
Wall of transformer tank

Shim
Attachment of protective housing
The cover can be opened

to the left or to the right
depending on the arrange-
ment of the hinge pins.
ca. 690 if opened 130°
Aperture of fixing holes on protective housing Aperture in protective housing for cables
(rear view) (underside view)
Motor Drive ED-S

898 801:2E
Protective Housing
119/04/01/0
36
16
Appendix

spacing ring Hand crank
* for design with


special design with OLTC monitoring
required
Wall of transformer tank Shim

ca. 690 if opened 130° ment of the hinge pins.
Motor Drive ED-L

898 802:2E
Protective Housing
119/04/01/0 37
16
Appendix
e2 = 215 for design with ball joint

e1 = 205 for standard design
Bevel gear CD 6400

892 916:6E
Dimension drawing
119/04/01/0
38
© Maschinenfabrik Reinhausen GmbH 2001
Postfach 12 03 60
93025 Regensburg
Deutschland
Telefon: (+49) 9 41 / 40 90-0
Fax: (+49) 9 41 / 40 90-111
Email: sales@reinhausen.com
Internet: http://www.reinhausen.com
BA 119/04 en - 1102/500
119/04/01/0
F0002201
Printed in Germany
119/04/01/0 39
www.reinhausen.com
Technical Data – General Section
Technical Data TD 61
Survey
Survey
This general section pertains to the following technical data.
VACUTAP® V T ........................................... TD 124
VACUTAP® V V ........................................... TD 203
VACUTAP® V R ........................................... TD 237
OILTAP® V ........................................... TD 82
OILTAP® MS ........................................... TD 60
OILTAP® M ........................................... TD 50
OILTAP® RM ........................................... TD 130
OILTAP® R ........................................... TD 115
OILTAP® G ........................................... TD 48
DEETAP® U ........................................... TD 51
NOTE
These technical data are intended for the calculator and designer of the transformer. This release replaces all previous releases
which then become invalid.
Dimensional drawings and connection diagrams are subject to change without prior notice.
Drawings submitted during bidding and ordering are always binding.
Since the on-load tap-changer is delivered to the specifications of the transformer manufacturer, the manufacturer
is responsible for selecting the correct properties of the on-load tap-changer so that the requirements of the
transformer are met.
2 TD 61/02 061/02/01/0
Table of Contents
Table of Contents
1 General .................................................................................................................................................................................................................. 5
1.1 How it functions .................................................................................................................................................................................... 5
1.2 Basic connections of the tap winding ............................................................................................................................................ 6
2 Characteristic properties of the on-load tap-changer ..................................................................................................................... 7

2.1 Designations of the on-load tap-changer .................................................................................................................................... 7
2.2 Through-current, step voltage and step capacity ....................................................................................................................... 10
2.3 Insulation ................................................................................................................................................................................................. 11
2.4 Overload .................................................................................................................................................................................................. 11
2.4.1 Through-currents greater than rated through-current .............................................................................................. 11
2.4.2 Operation at increased transformer power with improved cooling ....................................................................... 11
2.4.3 Required specifications for modes which are not defined by IEC 60354 or ANSI C57.91 ............................... 12
2.5 Short-circuit stress on on-load tap-changers and off-circuit tap-changers .................................................................... 12
2.6 Forced current division ........................................................................................................................................................................ 12
2.7 Permissible overexcitation .................................................................................................................................................................. 13
2.8 Multiple-column on-load tap-changers ........................................................................................................................................ 13
2.9 On-load tap-changer applications with variable step voltage ............................................................................................... 13
2.10 Coarse tap winding/tapped winding, leakage inductance ....................................................................................................... 14
2.11 Potential connection of the tap winding ...................................................................................................................................... 14
2.12 On-load tap-changer in transformers for arcing furnaces (cf. also ordering sheets) ..................................................... 19
2.13 Installing the on-load tap-changer and off-circuit tap-changer ......................................................................................... 19
2.14 Activating the on-load tap-changer during the transformer test ........................................................................................ 19
2.15 Special applications .............................................................................................................................................................................. 19
2.16 Insulation oils ......................................................................................................................................................................................... 19
2.17 Service in arctic areas .......................................................................................................................................................................... 19
2.18 Hermetically sealed transformer with gas cushion .................................................................................................................... 19
2.19 Parallel jumpers for parallel connection of tap selector planes ............................................................................................ 19
3 Important information on design and installation ............................................................................................................................ 20

3.1 Designation of the terminal contacts of the tap selector and operating positions ........................................................ 20
3.2 Oil suction pipe ...................................................................................................................................................................................... 21
3.3 Oil filter unit ........................................................................................................................................................................................... 21
061/02/01/0
TD 61/02 3
Table of Contents
Table of Contents
4 Protective relay RS 2001 ............................................................................................................................................................................... 21
5 Motor-drive units ED-S, ED-L ..................................................................................................................................................................... 22
5.1 Function .................................................................................................................................................................................................. 22

5.2 Type designations .................................................................................................................................................................................. 22
5.3 Technical data of the motor-drive unit ......................................................................................................................................... 23
6 Drive shaft ............................................................................................................................................................................................................ 24
7 Selecting the on-load tap-changer ............................................................................................................................................................ 24

7.1 Selection principle ................................................................................................................................................................................ 24
7.2 Examples of selecting the on-load tap-changer ......................................................................................................................... 25
8 Appendix ............................................................................................................................................................................................................... 28
4 TD 61/02 061/02/01/0
1 General
1 General
1.1 Function principle On-load tap-changer (diverter switch-tap selector

principle)
The on-load tap-changer provides uninterrupted voltage
regulation of transformers under load. The voltage is The tap selector selects the desired tap which is then con-
regulated by changing the voltage ratio. This is done in steps. nected to the no-load side of the diverter switch. This tap
The transformer is equipped with a tap winding whose then accepts the service current with the next diverter switch
tappings are connected with the tap selector of the on-load operation.
tap-changer.
The functions of the diverter switch and tap selector are
This is the reason the on-load tap-changer is designed for time-correlated during the tap change, see fig. 2a for
immersed installation in the transformer tank (fig. 1) to keep connection principle.
the distances from the tap winding terminals to the tap
selectors short. The on-load tap-changer is activated by a
motor-drive. Drive shafts and bevel gear units mechanically
connect the motor-drive to the on-load tap-changer head.
Exception: The on-load tap-changer VACUTAP® VT is fixed to
the active part of the dry-type transformer.
Tap selector
Diverter switch
KHW 370 - 4
Fig. 2a
Connection principle of the on-load tap-changer
consisting of diverter switch and tap selector
8997590D
Fig. 1 Transformer with on-load tap-changer, drawing

1 - On-load tap-changer
2 – Motor-drive
3 – Protective relay
4 – Oil conservator
061/02/01/0
TD 61/02 5
1 General
On-load tap-changer (selector switch principle) 1.2 Basic connection of the tap winding (see fig. 3)
It combines the characteristics of a diverter switch and a tap For possible basic connections, see the technical data of the
selector. The change-over from one tap to the next takes pertinent tap-changer type.
place in only one switching process, see fig. 2b for connec-
tion principle.
a b c
KHW 114-4
EV1004
Fig. 3 Basic connections
Fig. 2b a – Without change-over selector
Connection principle of the on-load tap-changer based on b – With reversing switch
the selector switch principle c – With coarse tap selector
6 TD 61/02 061/02/01/0
2 Characteristic properties of the on-load tap-changer
2.1 Designations of the on-load tap-changer M I 601 – 123 / B – 10 19 1 W
Each type of on-load tap-changer is available in many

designs, varying by number of poles, maximum rated
through-current, highest voltage for equipment Um, tap
selector size, and basic connection diagram. For this reason, Type
the designation of a certain on-load tap-changer model Basic connection diagram
must also indicate these features (see fig. 4). This gives the Number of
on-load tap-changer an unique identification. poles
Tap selector size
Max. rated
Number of steps and basic connection diagram through-current in A
and additional
Highest voltage for
The tap selector can be extensively adjusted to the required identification of
equipment Um
the design
number of steps and the connection of the tap winding. in kV
The applicable basic connection diagrams are differentiated
by tap selector contacts (10 to 18), number of operating
positions, number of mid-positions, and the change-over Fig. 4
selector design. Fig. 5 shows the designation of the basic Designation of the on-load tap-changer
connection diagram. Example: On-load tap-changer, type M, 1-pole, max. rated
through-current 600 A, highest voltage for equipment
The adjustment position is the position in which the on-load Um = 123 kV, tap selector size B, tap selector in acc. w. basic
tap-changer is delivered. The on-load tap-changer must be in connection diagram 10 19 1 W
„adjustment position“ mode during maintenance work (re-
moval or installation of the on-load tap-changer unit).
For further details, see the pertinent operating/maintenance
instructions. 10 19 1 W
Each design connection diagram of the on-load tap-changer
explicitly specifies the adjustment position.
The mid-position is the position in which the „K“ contact is
connected in the reversing switch or coarse tap design. Tap selector pitch Mid-position(s) Change-over selector
The mid-position is usually also the adjustment position (see
design connection diagram of the on-load tap-changer).
0
1 mid-position: With 1 mid-position, there is no position 1
10 Max. 3 G W
with the same voltage before or after the „K“ contact. 12 operating positions Coarse Reversing
14 tap selector switch
3 mid-positions: With 3 mid-positions, there is no change in 16
voltage before and after the „K“ contact. 18
Jumpered contacts are not considered as mid-positions.

without change- with change-over
over selector selector
10 09 19
12 11 23
14 13 27
16 15 31
18 17 35
Fig. 5
Designation of the basic connection diagram
Example:
Tap selector pitch 10, max. of 19 operating positions,
1 mid-position, change-over selector designed as
reversing switch
061/02/01/0
TD 61/02 7
On-load tap-changer designations
x x xxxx x - xxx / x - xx xx xx
Type ® Basic connection diagram
OILTAP V
®
OILTAP M / MS
®
OILTAP R / RM
®
OILTAP G
®
VACUTAP VT
®
VACUTAP VV
No. of poles I 1 pole
II 2 pole
III 3 pole
I Um A
200 V (not V I)
250 V (special design, not V I), VV
300 MS
350 M, V
400 V (special design), VV
500 M, VT I
600 M, RM, VV
800 MI
1200 MI, RMI; R
1500 MI, RMI
1600 G
2000 RI
2400 RI (forced current division)
3000 RI, GI
No. of configured 1 1 sector
sectors 2 2 sectors
(only 1-pole) 3 3 sectors
Application Y Application with neutral point
D Application not with neutral point
Not for single-pole tap-changers
Um kV
36 VT
40 V, VV
72,5 MS, M, RM, R, G,
76 V, VV
123/76 V III D
123 MS, M, RM, R, G, VIII Y
145 VV
170 MS, M, RM, R, G
245 M, MS, RM, R, G
300 MI, RMI, RI, GI
362 On request
Tap selector size B M, MS
C M, RM, R
D M, RM, R, G
DE M, RM
E R, G
Not with selector switches and VACUTAP® VV
Contacts without change-over with change-over selector
9 VT
10 M, MS, R, RM, G, V, VV M, MS, R, RM, G, V, VV
12 M, MS, R, RM, G, V, VV M, MS, R, RM, G, V, VV
14 V, M, MS, R, RM, G V, M, MS, R, RM, G
16 M, R, RM, G M, R, RM, G
18 M, R, RM, (G) M, R, RM, (G)
22 M
Number of max. without change-over with change-over selector
operating positions 9 9
10 10 19
12 12 23
14 14 27
16 16 31
18 18 35
22 22
Mid-positions 0 0 mid-positions (without change-over selector)
1 1 mid-position
3 3 mid-positions
Reversing switch / W Reversing switch
coarse tap 1) G Coarse tap
1) Up to max. 107 operating positions (only type M)
8 TD 61/02 061/02/01/0
Off-circuit tap-changer designations

x x xxxx - xxx - xx xx xx
Basic connection diagram
Off-circuit tap-changer U
Number of poles III 3 poles
Max. rated through- 300 300 A
current 600 600 A
800 800 A
1000 1000 A
>1000 on request
Highest voltage for 17.5
equipment Um [kV] 36
72.5
123
170
>170 on request
Contact circle pitch 06 Contact circle Æ 350 mm,
max. of 5 operating positions
12 Contact circle Æ 550 mm,
18 Contact circle Æ 750 mm,
Max. number of 05 5 operating positions
operating positions 11 11 operating positions
17 17 operating positions
Type of connection Y Linear off-circuit tap-changer for neutral application
D Linear off-circuit tap-changer for delta application
ME Single bridging off-circuit tap-changer
MD Double bridging off-circuit tap-changer
SP Series-parallel off-circuit tap-changer
YD Star-delta off-circuit tap-changer
S Special connection
061/02/01/0
TD 61/02 9
2.2 Through-current, step voltage and step capacity The rated step capacity PStN is the product of rated
through-current Iu and related rated step voltage Ui:
The through-current is the current flowing through the on-
P = Iu x Ui
load tap-changer and off-circuit tap-changer while in service. StN
The through-current of an on-load tap-changer usually
varies along the voltage regulating range (e. g., while the
rated power of the transformer remains the same).
The maximum through-current which a transformer can
handle continuously must be used for the rating of the on-
load tap-changer and off-circuit tap-changer. This maximum Ui = Uim
continuously permissible through-current of the transformer
is the rated through-current Iu of the on-load tap-changer
or of the off-circuit tap-changer. Ui
The step voltage is the operating voltage between adjacent

taps. The step voltage can remain the same or vary over the
entire setting range. If the step voltage varies, the maximum
step voltage Ust of the transformer is used to rate the on-
load tap-changer and the off-circuit tap-changer.
Iu = Ium
The maximum rated through-current Ium varies with the
design and is the maximum through-current of an on-load
tap-changer and off-circuit tap-changer to which the cur-
KHW 371-3
rent-related type tests refer.
Iu
The rated step voltage Ui of an on-load tap-changer is the
highest permissible step voltage for a certain value of the Fig. 5 Rated step capacity diagram of a diverter switch
rated through-current Iu. Together with a rated through- 1 - upper limit point
current, it is known as the related rated step voltage. 2 - lower limit point
The max. rated step voltage Uim varies with the design and Fig. 5 shows the typical load limits of a diverter switch.
is the max. permissible step voltage of an on-load tap- This means that the permissible range on the voltage side is
changer and off-circuit tap-changer. limited by the max. rated step voltage Uim and, on the
current side, by the max. rated through-current Ium.
The transition resistors of the on-load tap-changer are de-
signed for the existing values of the maximum step voltage The points of the curve located between limit points 1 and 2
Ust and the rated through-current Iu of the transformer for are determined by the permissible rated switching capacity.
which the on-load tap-changer is to be used. The permissible switching capacity between limit points 1
and 2 corresponds to related pairs of values for Iu and Ui
Since the permissible rated through-current Iu and the
and may be constant or varying.
permissible step voltage Ust vary with the value of the tran-
sition resistors, these rated values refer to the particular The rated step capacity diagram as well as individual values
application. for Iu and Ui in limit points 1 and 2 are specified separately
for each type of on-load tap-changer (see TD of the parti-
If an on-load tap-changer is to be used with values for
cular type).
step voltage and through-current other than those
declared in the order (e. g., transformer power increased due The limit step capacity is the greatest step capacity which
to improved cooling or use of the on-load tap-changer in can be safely transferred. Every MR on-load tap-changer can
another transformer), MR must determine whether this is switch at least twice the rated through-current Iu at step
possible or whether the transition resistors must be changed. voltage Ust for which the on-load tap-changer was designed.
This also applies when the desired new rated values Iu and This limit switching capacity is documented with the type
Ust are below the original values since the design of the test as prescribed by IEC 60214. Tap change operations with
transition resistors not only affects the switching capacity currents greater than twice the rated through-current Iu
stress of the contacts but uniform contact wear is also must be prevented with suitable measures.
desired.
10 TD 61/02 061/02/01/0
2.3 Insulation 2.4 Overload

The insulation strength of the various insulation distances of 2.4.1 Through-currents higher than rated through-
the on-load tap-changer and off-circuit tap-changer is de- current
termined by the individual technical data of the particular
MR on-load tap-changers and off-circuit tap-changers can
type of tap-changer. The specified rated withstand voltages
be used for all transformer loads as described in IEC
of the insulation apply to new, thoroughly dried insulating
60354:1991 („Loading guide for oil-immersed transformers“)
material in treated transformer oil (at an ambient
and ANSI C57.91-1995 („Guide for loading mineral-oil-
temperature of at least 10 °C).
immersed transformers“).
Selection of an on-load tap-changer and off-circuit tap-
IEC 60354 differentiates between three modes.
changer requires the following information.
- Normal cyclic loading
- The maximum network-frequency voltages during service
- Long-time emergency cyclic loading
- The power frequency test voltages occurring during the
transformer test - Short-time emergency loading
- The impulse voltages (lightning impulse, switching im- ANSI C57.91 differentiates between four modes:
pulse, wave cut off at the back and wave cut off at the - Normal life expectancy loading
front) occurring during the transformer test
- Planned loading beyond nameplate rating
The transformer manufacturer is responsible for the correct
selection of the rated withstand voltages as required by on- - Long-time emergency loading
site insulation coordination. The required rated withstand - Short-time emergency loading
voltages must be provided for the different insulation
distances. Suitability of an on-load tap-changer for the above modes is
documented with the type test in accordance with IEC
- Against ground 60214-1989.
- With multiple-phase types, between the phases With „normal cyclic loading“ or „normal life expectancy
- Between contacts of one phase loading“ mode, through-currents greater than the rated
through-current may occur during a daily load cycle. If the
The required specifications depend on the type of regulation operating conditions described by IEC 60354 or ANSI C57.91
(e.g., with on-load tap-changers: regulation without change- are adhered to (i.e., duration and power during a daily cycle,
over selector, reversing switch arrangement, coarse tapping transformer oil temperature, and so on), this constitutes
arrangement) and the type of tap-changer. The relevant normal service and not an extraordinary load. For this
insulation distances and their relation to the voltages of the reason, through-currents greater than the rated through-
transformer windings are described in the technical data of current which may occur briefly in the above modes do not
the particular tap-changer type. need to be given special consideration when selecting the
on-load tap-changer.
061/02/01/0
TD 61/02 11
2.4.2 Operation at increased transformer load with All MR on-load tap-changers and off-circuit tap-changers
improved cooling meet at least the requirements of IEC 60214:1989 pertaining
to short-circuit strength. Calculation of permissible short-
Keep the following points in mind when specifying the
circuit duration with stress of short-time currents lower than
required rated through-current of an on-load tap-changer.
the rated short-time withstand current, or calculation of the
When a transformer is run with different capacities due to permissible short-time current for short-circuit durations
different conditions (e.g., type of cooling, ambient temper- longer than the rated short-circuit duration is possible with
ature), the greatest load must be taken as the basis for the the help of the following equation.
rated power when selecting the on-load tap-changer. Ix² * tx = IK² * tK
See also IEC 60076-1:1993. This is necessary since the oil
with
temperature in the transformer is not reduced despite in-
creased transformer cooling due to the increased load and, IK : Rated short-time withstand current
in contrast to the transformer, the external conditions of the tK : Rated short-circuit duration
on-load tap-changer are not improved. Another reason is Ix : Permissible short-time current for
the design of the transition resistors of on-load tap-changers short-circuit duration tx (with tx
based on the greatest through-current so that the switching always greater than tk)
capacity stress on the contacts of the on-load tap-changer is tx : Permissible short-circuit duration for
limited to permissible values. stress with Ix (with Ix always smaller
than Ik)
2.4.3 Required specifications for modes which are not Due to the dynamic stress alone from the impulse current, an
defined by IEC 60354 or ANSI C57.91 impulse current greater than the rated peak withstand cur-
rent is not permitted. This is the reason that recalculation of
When asked about overload conditions, MR requests a the rated values for higher impulse currents and short-time
definition based on the above modes to avoid currents for shorter short-circuit durations is not permitted!
misunderstandings and to clearly describe the conditions of
service. If the requested mode cannot be defined in relation Short-circuit stresses usually occur only rarely on transfor-
to IEC 60354 or ANSI C57.91, the following specifications mers in service. With applications with very frequent short-
become necessary. circuit stresses (e.g., special test transformers), this must be
allowed for by selecting an on-load tap-changer with greater
- Through-currents and related load duration during one short-circuit resistance. Information on amount and fre-
day’s cycle quency of the expected short-circuit stresses is necessary for
- Oil temperature of the transformer during one day’s cycle this.
- Expected number of tap changes during the load phases
of one day’s cycle (only for on-load tap-changers) 2.6 Forced current division
- Duration of overload service in days/weeks/months With single-pole on-load tap-changers and off-circuit tap-
changers for large rated through-currents, current paths are
- Frequency of this overload service (e. g., „once a year“ or connected in parallel. A distinction is made between applica-
„rarely, only when other transformers fail“) tions with and without „forced current division.“
Applications with and without „forced current division“ with
2.5 Stress on on-load tap-changers and off-circuit the same rated through-current require different on-load
tap-changers due to short circuit tap-changer and off-circuit tap-changer designs. The mean-
Permissible stress due to short circuits is listed below. ing of „forced current division“ differs for on-load tap-chan-
gers and off-circuit tap-changers.
- Rated short-time withstand current as r.m.s. value of
permissible short-circuit current On-load tap-changer
During the change-over operation of the diverter switch,
- Rated peak withstand current as highest permissible peak uniform division of the current on the parallel contacts must
value of the short-circuit current be ensured. This always requires a divided tap winding and a
- Rated short-circuit duration as permissible short-circuit divided main winding. Leakage impedance between the
duration during stress with rated short-time withstand parallel main windings must be at least three times the value
current of the transition resistor of the on-load tap-changer.
12 TD 61/02 061/02/01/0
It is imperative that MR be consulted about these When different value pairs of step voltage and related
applications. You will need a drawing of the complete through-current are required for an on-load tap-changer,
winding arrangement with all parallel winding parts. the combination must consist of maximum step voltage and
maximum through-current within the permissible switching
Off-circuit tap-changer:
capacity range of the pertinent on-load tap-changer type,
The tap winding must be completely divided. In addition,
even when the step voltage and this through-current do not
some windings on the tap winding next to the main winding
occur at the same time.
must also be divided.
Example:
In arrangements with forced current division, parallel
A transformer is being run at constant power within a large
contacts may not be jumpered. The voltage between the
range of fluctuating line voltage. Then the highest step
parallel tap windings when stressed with impulse voltage
voltage occurs with highest system voltage together with a
must be considered. The transformer manufacturer must
low through-current in relation to the transformer load, and
specify the required impulse voltage strength between the
the greatest through-current occurs together with the lowest
parallel tap windings.
step voltage at the lowest system voltage.
The on-load tap-changer must then be designed as if the
2.7 Permissible overexcitation highest step voltage occurs together with the highest
through-current.
MR on-load tap-changers meet the requirements of IEC
60076-1:1993 (5% overexcitation) and ANSI IEEE C57.12.00- The reason for this is the necessary adjustment of the tran-
2000 (10% overexcitation) . sition resistance to both the step voltage and the through-
current. In general, the following applies to this adjustment:
2.8 Multiple-column on-load tap-changers High step voltages require high values for the transition
resistance. In contrast, high through-currents require low
Regardless of whether activated by one or more motor- values for the transition resistance.
drives, multiple-column on-load tap-changers (e.g., 3 x M I)
Therefore, a solution to transition resistance adjustment is
do not switch synchronously. When delta connections with a
only possible if there is a resistance value which is suitable
very large regulation range and very low voltage in an end
both for the highest step voltage and the highest through-
position are regulated where the voltage can then only be
current. Otherwise, the value of the transition resistance in
generated from a few taps, this can cause excessively high
the above example would have to be continuously adjusted
circulating currents in the delta winding (varies with con-
to the different system voltages.
nection group and short-circuit impedance of the transfor-
mer). In such cases, the transformer manufacturer must There is always a suitable resistance value if the value pair of
specify the circulating current for different positions of the highest step voltage and highest through-current is within
on-load tap-changer in the three phases so that MR can the permissible switching capacity. If this pair of values is
consider the required increased switching capacity when located just outside the permissible switching capacity range,
selecting the on-load tap-changer and designing the MR must check individual cases to determine whether a
transition resistors. solution for the adjustment of the transition resistance is still
possible. When the permissible switching capacity range is
2.9 On-load tap-changer applications with variable significantly exceeded, an on-load tap-changer type with
step voltage greater switching capacity must be used.
In applications with variable step voltage, the greatest

possible step voltage must always be specified for the
selection of the on-load tap-changer. Examples of such
applications include:
- Variable magnetic flow
- Tap windings with different numbers of turns
- Load and position-dependent step voltage for phase-
shifter transformers
- Service under unusually great fluctuation of the system
voltage
061/02/01/0
TD 61/02 13
2.10 Coarse tap winding/tapped winding, leakage 2.11 Potential connection of the tap winding
inductance
The tap winding is briefly galvanically isolated from the main
During the change-over operation from the end of the winding during the change-over operation of the reversing
tapped winding to the end of the coarse tap winding (mid- switch or coarse tap selector. It assumes a potential resulting
position, see fig. 6) and the reverse switching direction, all from the voltages of the adjacent windings and the coupling
turns of the coarse tap winding and the entire tapped capacities to these windings or to grounded parts. This po-
winding are located between the selected and pre-selected tential shift of the tap winding generates corresponding
tap. voltages between the breaking change-over selector contacts
With these switching operations, this results in a much since one contact is always connected with the tap winding
higher leakage inductance for the circuit of the on-load tap- and the other contact is always connected with the main
changer as the internal resistance of the step voltage than winding.
for all other switching operations during which only the This voltage is called the recovery voltage Uw. When the
leakage inductance of a step takes effect and this induc- change-over selector contacts open, a capacitive current
tance can be ignored for the function of the on-load tap- caused by the above coupling capacities of the tap winding
changer. must be interrupted. This current is called the breaking cur-
rent Is. The recovery voltage Uw and the breaking current Is
The leakage inductance described above for coarse tap wind-
may cause excessive discharges on the change-over selector.
ing/tapped winding generates a phase shift between break-
The permissible range of recovery voltage Uw and breaking
ing current and recovery voltage on the resistor contacts of
current Is is shown in fig. 7 for the various on-load tap-
the diverter switch which may cause longer arcing times.
changer types.
This leakage inductance must be specified for adjustment of
the on-load tap-changer to these operating conditions.
In extreme cases, this leakage inductance can be the deter- Without tie-in resistors
mining factor for selecting the on-load tap-changer type.
50.00
45.00
Recovery voltage Uw (kV)
40.00
35.00
30.00 M, MS, RM
25.00
20.00 VV
R, G
15.00
10.00
5.00 V
0.00
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
Breaking current Is [mA]
Fig. 7 Standard values without tie-in resistors
KHW 447-4
Fig. 6 Leakage inductance in the mid-position
14 TD 61/02 061/02/01/0
If appropriate calculations result in values outside the per- Due to the potential connection of the tap winding with a
missible range shown in fig. 7, the tap winding must be tie-in resistor, the recovery voltage Uw is decreased on the
connected to a fixed potential during the switching opera- change-over selector contacts while the breaking current Is is
tion. This is accomplished with the following measures increased by the additional current via the tie-in resistor. Fig.
(see fig. 8). 9 shows for the different on-load tap-changer types the
range of recovery voltage Uw and breaking current Is which
can be used without consulting with MR when tie-in resistors
are used.
This figure applies to all cases where the breaking current Is
is primarily determined by the tie-in resistor.
With tie-in resistors

40.00
35.00
Recovery voltage Uw (kV)
30.00 M, MS, RM
25.00
20.00 VV
R, G
15.00
10.00
V
5.00
0.00
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
Breaking current Is [mA]
Fig. 9 Standard values for tie-in resistor, breaking

current Is primarily determined by tie-in resistor.
a b
Since the recovery voltage Uw and breaking current Is are
KHW 164-2 not the only important criteria for evaluating the permissible
Fig. 8 Potential connections
switching capacity of a change-over selector, an evaluation
(Reversing switch is in mid-position) by MR is required when the ranges in fig. 7 and fig. 9 are
a – Tie-in resistor Rp exceeded.
b – With potential switch Sp
and tie-in resistor Rp Since a decrease in the recovery voltage Uw due to the tie-in
resistor is always accompanied by an increase in the breaking
current Is, a solution with permissible change-over selector
a – Connection to potential of the tap winding by a per-
capacity cannot always be found for winding arrangements
manently installed ohmic resistor (tie-in resistor)
with poor capacitive coupling. If this is true, a change-over
b – Potential switch selector with a higher permissible breaking current must then
Connection to potential of the tap winding by a be used or the winding arrangement must be changed. This is
ohmic resistor which is only inserted (by a potential why prompt examination of the change-over selector capa-
switch) during the change-over selector operation. city is particularly important for high-power transformers
The constructive solutions for a and b vary depending on the (i.e., large coupling capacities) and high operating voltages
type of on-load tap-changer. For additional details pertain- (i. e., great potential shift of the tap winding during change-
ing to our delivery program, see TD 48, TD 50, TD 60, TD 82, over selector operation).
TD 115, TD 130, TD 203 and TD 237.
061/02/01/0
TD 61/02 15
Calculation of the recovery voltage Uw and the breaking Example of the estimated calculation of the recovery
current Is as well as the design of the possibly necessary tie- voltage on the change-over selector
in resistor can be handled by MR.
Transformer
The following information is required for this. Rated power: 13 MVA
High voltage winding: 132 kV + 10%
- Winding arrangement (i.e., location of the tap winding
Delta connection: 50 Hz
with respect to the adjacent windings)
Tap winding with reversing switch
- Capacitance of the tap winding to the adjacent windings (fig. 10)
or capacitance of the tap winding against ground or
adjacent grounded windings Double concentric arrangement of the high voltage winding
- A.c. operating voltage across windings or the positions of with inside main winding (disk-type coils) and outside tap
the windings which are adjacent to the tap winding winding (see page 17, fig. 11).
Winding capacities:
In addition, the following information is needed to C1 = 1810 pF (between main and tap winding)
dimension the tie-in measure. C2 = 950 pF (between tap winding and ground)
- Expected stress due to lightning impulse voltage across On-load tap-changer:
half the tap winding MS I 301/MS II 302 - 170/B-10 19 3 W
- A.c. voltage across half the tap winding under operating
and test conditions can usually be deduced from the
normal ordering specifications for the on-load tap-
changers.
Fig. 10 Connection of the high voltage winding
16 TD 61/02 061/02/01/0
Assuming that winding capacities C1 and C2 are effective in Core Tank

the middle of the winding, the following equation applies to
recovery voltages Uw+ and Uw- (see fig. 12 below).
as well as for voltage exceeding C1
US OS
Fig. 11 Winding arrangement with the related winding

capacities
and consequently, the vector variable and the corresponding

absolute value can be calculated as follows:
Fig. 12 Vectorial diagram for calculation of the

recovery voltages on change-over selector
contacts (+) and (-)
061/02/01/0
TD 61/02 17
For C1 = 1810 pF – C2 = 950 pF – U1 = 132 kV – UF = 13,2 kV

the following computational values result for the amount of recovery voltages UW+ and UW-:
The breaking currents Is+ und Is– are:

U1
. . . w (C1 + C2)
U1 + UF
Is+ = wC2 + j
2 Ö3 2

. . . w (C1 + C2)
U1 U1 – UF
Is-- = wC2 + j
2 Ö3 2
Using the above number values, the following results:
Is+ = 63.97 mA
Is– = 52.75 mA
Due to the high values for Uw a tie-in resistor is required.

After a tie-in resistor Rp = 280 kW is installed, the following values are obtained:
Uw+ = 19.6 kV Uw– = 14.4 kV

Is+ = 72.0 mA Is– = 53.0 mA
18 TD 61/02 061/02/01/0
2.12 On-load tap-changer in transformers for arcing 2.17 Service in artic areas
furnaces (cf. also ordering sheets)
If on-load tap-changer oil temperatures of less than -25 °C
When in service, overloads of up to 2.5 times the rated are expected, this must be specified on the ordering sheet so
transformer load occur in on-load tap-changers which are that a temperature control can be provided for reliable
used in transformers for arcing furnaces. The on-load tap- service. The temperature control consists of the thermo
changers must be adjusted to these operating conditions. sensor and the measuring amplifier. The thermo sensor is
Types V V, MS, M, RM, R and G: The permissible step voltage is installed in the on-load tap-changer head cover. It records
reduced for the required rated through-current to 80 % of the temperature of the oil in the on-load tap-changer.
the relevant rated step voltages specified in the applicable TD. The measuring amplifier is installed in the motor-drive. It is
connected to the control current circuit so that the motor-
Type V: V 200 (250) is not designed for this type of service. drive is blocked for electrical service when the temperature
With V 350 (400) the rated through-current is limited to control is activated.
200 A.
Remember that ambient temperatures below -45 °C may
destroy the gaskets of on-load tap-changers and accessories.
2.13 Installing the on-load tap-changer and off-circuit
tap-changer 2.18 Hermetically sealed transformer with gas cushion
The on-load tap-changer and off-circuit tap-changer must This is available on request. Requests to MR for information
be installed vertically. The maximum deviation is 1°. on implementation must contain the maximum gas cushion
density below the transformer cover.
2.14 Activating the on-load tap-changer during the
transformer test 2.19 Parallel jumpers for parallel connection of tap
When the transformer is excited, the on-load tap-changer selector planes
may only be activated under rated frequency. This also a) With forced current division:
applies to no load service. Parallel jumpers are not permitted
2.15 Special applications b) With unforced current division:

Parallel jumpers on the tap selector terminals are still
Examples: High voltage direct current, generator operation, mandatory even when the tap winding was wound in two
phase shifter, traction transformer, portion of the harmonic or more wires and each of these coil taps is connected as
waves > 10 % a tapping connection to the terminal contacts.
Please see extra ordering sheet. This reliably prevents the following:
– Introduction of circulating currents into the current
2.16 Insulation oils paths of tap selector and diverter switch
– Arcing on movable tap selector contacts due to
To fill the oil compartment and the related oil conservator,
commutation
use only new mineral oil for transformers in accordance with
IEC 60296 (specification for unused mineral insulating oils – Overvoltages between adjacent tap selector terminals
for transformers and switchgear) and IEC 60422 (supervision connected in parallel
and maintenance guide for mineral insulating oils in electri- The parallel jumpers are also required to ensure the tie-in
cal equipment). resistor takes effect for all parallel connected winding
parts when tie-in measures are used.
061/02/01/0
TD 61/02 19
3 Important information on transformer design and tap-changer installation
3 Important information on transformer design and tap-changer installation
3.1 Designation of the tap selector terminals and Example:

operating positions Fig. 13 shows the contact designation of the two tap selector planes as seen
from above with 1 to 9, K (clockwise).
A connection diagram is individually prepared for every on- The on-load tap-changer is in position 2 at the moment and the change-
over selector connects contacts 0 and +.
load tap-changer. This diagram is the sole binding
Position 1 is reached by activating the other tap selector contact bridges
document for connection of the on-load tap-changer to counterclockwise (seen from above).
the transformer. In addition to the electrical connections, With manual drive, this means: turning the hand crank to the right
this diagram contains a drawing of the physical arrangement (clockwise).
of the terminals as seen from above. This diagram specifies With motor-drive, this means: activating motor contactor K2
the designation of the tap selector terminals and the The direction of rotation on the on-load tap-changer remains unchanged
regardless of which arrangement of the drive shaft is selected.
operating positions for the related on-load tap-changer
in accordance with customer specifications. Special design
The contact designations used in the dimensional drawings If necessary, the following parts of the standard design can
for on-load tap-changers comply with MR’s standard be changed:
designations.
1. The designation of the operating positions,
The position designation of the on-load tap-changer is 2. The specification of the activation directions „higher“/
identical to that of the motor-drive. “lower“ on the motor-drive
MR standard designation If desired, connection designations in accordance with IEC-

Publ. 445 and DIN 42 402 can be used.
In the MR standard designation of the tap selector terminals
and operating positions, tap selector terminal 1 is current-
carrying in operating position 1. Operating position 1 is at
the same time an end position and is reached by running
through the regulating range with the movement of the tap
selector contact bridges counterclockwise.
Position 19 18 17 < > 11 10 9 < > 3 2 1

Current-carrying
selector switch 9 8 7 < > 1 K 9 < > 3 2 1
terminal
Change-over 0– 0– 0– > 0– 0– 0+ > 0+ 0+ 0+
selector connects < 0– 0+ 0+ <
Operation > »Raise« >
in direction < »Lower« <
Hand crank > Clockwise >
rotation < Counterclockwise <
Tap selector > Counterclockwise >
contact bridge < Clockwise <
Motor drive > by motor contactor »K2« >
control < by motor contactor »K1« <
8997890D
Fig. 13
Relationship of the direction of rotation of motor-drive,
hand crank and switching direction of the tap selector
contact bridges, assignment of the position designation and
contact designation on the tap selector (standard design)
20 TD 61/02 061/02/01/0
3 Important information on construction and installation
4 Protective relay
4 Protective relay
3.2 Oil suction pipe For information, see manual BA 59.

OILTAP® on-load tap-changers are usually equipped with an
oil suction pipe (see fig. 14) .
On-load tap-changer VACUTAP® are equipped with suction
pipe connection S, but not with an oil suction pipe.
KHW 379-2
Fig. 14
Suction pipe connection S and draining cock
E = bleeding valve
3.3 Oil filter unit

The oil filter unit is used to clean or clean and dry the switching
oil in the on-load tap-changer.
The unit can be fitted with a paper filter (only for cleaning) or a
combi filter (for cleaning and drying). For more information, see
manual BA 18.
061/02/01/0
TD 61/02 21
5 Motor-drive units ED-S, ED-L
5.1 Function Motor

drive
The modularly designed motor-drive unit ED is used to adjust
the operating positions of on-load tap-changers/off-circuit
tap-changers in regulating transformers to the particular Tap
service requirements. selector
The on-load tap-change operation is initiated by activating

Diverter
the motor-drive unit (single control pulse, from a device of switch
operation
the TAPCON® series, for example). This tap changing opera-
tion is always concluded regardless of whether additional
control pulses are output during the tap changing operation.
Another tap change is not possible until all control devices
33 sections
are at rest.
Fig. 15 shows the switching sequence of an on-load tap-
change operation. Winding
The dimensional drawings for motor-drive unit ED-S/ED-L

(898801/898802) are listed in appendix 8.
Diverter switch
contact
movement
KHW 220
from KHW 938
Fig. 15 Switching sequence of an on-load tap-change

operation
5.2 Type designations

The different basic designs of the ED motor-drive unit are identified with clear product designations.
Type designation Description Versions
ED 100-ST Product designation Electric Drive
ED 100-ST Transmission gear design 100 = Small transmission gear (motor, 6.5 Nm)
200 = Large transmission gear (motor, 13/18 Nm)
ED 100-ST Protective housing design S = Small protective housing

L = Large protective housing
ED 100-ST Special applications = None

M = Monitoring
C = Plunger coil design
T = Voltage regulator TAPCON® 240
22 TD 61/02 061/02/01/0
5.3 Technical data of the motor-drive unit

The technical data apply to the standard design but may differ from the delivered model. Subject to change without prior
notice.
Motor-drive unit ED 100/200-S/L
Motor power 0.75 kW 2.0 kW 2.2 kW
Voltage 3 AC/N 230/400 V
Current 1.9 A 5.2 A 6.2 A
Frequency 50 Hz
Synchronous speed 1500 1/min
Rotation of the drive shaft per switching operation 16.5
Running time per tap change operationg ca. 5.4 s
Rated torque of the drive shaft 45 Nm 95 Nm 130 Nm
Hand crank rotations per switching operation 33 54
Max. number of operating positions 35

Voltage of the controller and heater AC 230 V
Power consumption of the control current circuit

(control/operation) 100 VA/25 VA
Heating capacity 50 W with ED 100/200 S – 60 W with ED 100/200 L
Temperature range (ambient temperature) -30 °C to +50 °C
Test voltage against ground 2 kV
Weight ED 100 S: 80 kg ED 200 S: 80 kg

ED 100 L: 130 kg ED 200 L: 130 kg ED 200 L: 130 kg
061/02/01/0
TD 61/02 23
6 Drive shaft
7 Selecting the on-load tap-changer
6 Drive shaft 7 Selecting the on-load tap-changer
For information, see manual BA 42. 7.1 Selection principle

Optimum technical and economic results are obtained by
selecting an on-load tap-changer which just meets the
requirements of the service and test conditions of the
transformer. Safety margins for the individual on-load
tap-changer data are generally not required.
To select the on-load tap-changer, the following important
data on the transformer winding to which the on-load tap-
changer will be connected must be available.
Data of the transformer winding

1 – Rated power PN
2 – Connection (star-point, delta, single-phase connection)
3 – Rated voltage, setting rang: UN (1 ± x %)
4 – Number of steps, basic connection of the tap winding
5 – Rated insulation level
6 – Voltage stress of the tap winding during test with
lightning impulse voltage and induced a.c. voltage
The following values for phase values are calculated from

the above for the on-load tap-changer.
Basic data of the on-load tap-changer

From 1, 2 und 3: Max. tapping current Imax
From 3 und 4: Step voltage USt
Switching capacity PSt = USt . Imax
The suitable on-load tap-changer is determined by the

following characteristics.
Determination of the on-load tap-changer -

1st step
On-load tap-changer type
Number of poles
Max. rated through-current
24 TD 61/02 061/02/01/0
Further designation of the on-load tap-changer in 7.2 Example of selecting the on-load tap-changer
accordance with TD 61/section 2.1 must be completed by
specification of the following characteristics. Example 1 (for connection, see fig. 16)
We are looking for the right on-load tap-changer for a
three-phase power transformer with the following data.
Determination of the on-load tap-changer - Rated power PN = 80 MVA,
2nd step Star connection
Highest voltage for equipment Um of the on-load tap- Rated voltage and setting range of the high voltage winding
changer UN = 110 (1 ± 11 %) kV, ± 9 Stufen,
Tap selector size Reversing switch
Basic connection diagram Rated insulation level of the high voltage winding for
Note: The technical data for the above determined Up = 230 kV, 50 Hz /550 kV, 1.2|50
on-load tap-changer must be used. See TD 48, TD 50, Voltage stress on the tap winding across the setting range of
TD 60, TD 82, TD 115, TD 124, TD 130, TD 203 or TD 237. one phase (250 kV, 1.2|50/16 kV, 50 Hz, 1 min.) between two
phases of the tapped winding (220 kV, 1.2|50/24 kV, 50 Hz,
1 min.)
If necessary, we recommend checking the following
specifications of the on-load tap-changer. On-load tap-changer data:
Breaking capacity of the diverter switch Imax = 80 . 103 /110 (1 – 11 %) . Ö3 = 472 A
Temporary overload USt = 110 . 103 . 11 % / 9 . Ö3 = 777 V
Permissible short-circuit current PSt = 472 . 777 . 10–3 = 367 kVA
Contact lifespan of the diverter switch
110 (1 ± 11 %) kV
Fig. 16 KHW 376o-3
061/02/01/0
TD 61/02 25
Determination of the on-load tap-changer:
1st step 2nd step
In acc. w. table 1:: In acc. w. TD 50/section 1.2 (Survey: Examples of design

On-load tap-changer type: M connection diagrams):
Number of poles: 3 Um of the on-load tap-changer: 123 kV
Max. rated through-current: 500 A Tap selector size: B
On-load tap-changer design: M III 500 Y Basic connection diagram: 10 19 1 W
On-load tap-changer M III 500 Y–123/B–10 19 1 W is selected
Rated power, Connection Rated voltage, Insulation On-load

maximum setting range tap changer,
tapping change-over
current selector
to across the
ground setting range
± 9 steps,
80 MVA Star 550 kV 1.2I50 250 kV 1.2I50 reversing switch
472 A connection 110 (1 ± 11 %) kV 230 kV 50 Hz 16 kV 50 Hz
Type, number of poles,

Um, tap selector size Basic connection diagram
rated through-current
M III 500 Y 123 / B 10 19 1 W
26 TD 61/02 061/02/01/0
Example 2 (see fig. 17) On-load tap-changer data:
We are looking for the right on-load tap-changer for a Imax = 600 . 103 /220 (1 – 18 %) . Ö3 = 1920 A
three-phase current auto-transformer with the following USt = 220 . 103 . 18 % / 11 . Ö3 = 2078 V
data.: PSt = 1600 . 1759 . 10–3 = 3990 kVA
Rated power PN = 600 MVA,
Star connection 220 (1 ± 18 %) kV
Rated voltage and setting range of the high voltage winding
UN = 220 (1 ± 18 %) kV/110 kV, ± 11 steps,
Reversing switch 110 kV
Rated insulation level of the intermediate voltage winding
for Up = 230 kV, 50 Hz/550 kV, 1.2I50.
Voltage stress on the tap winding along the setting range
480 kV, 1. 2I50/49kV, 50 Hz, 1 min.
KHW 376u-3
Bild 17
Determination of the on-load tap-changer:
1st step 2st step
In acc. w. table 1: In acc. w. TD 115/section 1.2 Survey:
On-load tap-changer type: R Examples of design connection diagrams:
Number of poles: 3x1 Ub of the on-load tap-changer: 110 kV
Max. rated through-current: 2000 A Um (required): 170 kV
On-load tap-changer design: 3 x R I 2002 Tap selector size: D
Basic connection diagram: 12 23 1 W
On-load tap-changer 3 x R I 2002–170/D–12 23 1 W is selected
Rated power, Connection Rated voltage, Insulation On-load

setting range tap-changer,
maximum
change-over
tapping
selector
current to across the
ground setting range
auto
transformer ± 11 steps,
star 550 kV 1.2I50 480 kV 1.2I50 reversing switch
600 MVA 220 (1 ± 18 %) kV
connection 230 kV 50 Hz 49 kV 50 Hz
1920 A
Type, number of poles

Um, tap selector size Basic connection diagram
rated through-current
3 x R I 2002 170 / D 12 23 1 W
061/02/01/0
TD 61/02 27
8 Appendix
8 Appendix
Oil filter plant OF 100, dimension drawing ..................................................................................................................................................... 898718

Oil filter plant OF 100, control cabinet, dimension drawing ..................................................................................................................... 897688
Protective relay RS 2001, dimension drawing ................................................................................................................................................. 899084
Motor-drive unit ED-S, protective housing ...................................................................................................................................................... 898801
Motor-drive unit ED-L, protective housing ...................................................................................................................................................... 898802
Bevel gear CD 6400 .................................................................................................................................................................................................. 892916
Motor-drive unit ED-S, motor-drive unit ED-L, limit dimensions of the vertical drive shaft .......................................................... 898598
Electronic voltage regulator TAPCON 230®, flush and projected panel mounting ............................................................................. 899564
Electronic voltage regulator TAPCON® 240, 19-inch module rack ........................................................................................................... 899580
LED display panel, dimension drawing ............................................................................................................................................................... 899144
Position indicating instrument with square front frame, dimension drawing ..................................................................................... 897897
Position indicating instrument with rectangular front frame, dimension drawing and connection diagram ........................... 898105
Power supply unit for position indicator, dimension drawing ................................................................................................................... 898106
Digital remote position indicator, signal transmitter, dimension drawing ............................................................................................ 898699
Digital remote position indicator, 7-segment display, dimension drawing ........................................................................................... 899700
Digital remote position indicator, connection diagram ............................................................................................................................... 707281
Digital remote position indicator by selsyn transmitter, dimension drawing ................................................................................... 00711TM
28 TD 61/02 061/02/01/0
8987182E
Oil filter plant OF 100
Dimension drawing
061/02/01/0
TD 61/02 29
8976882M
Oil filter plant OF 100
Control cabinet, dimension drawing
30 TD 61/02 061/02/01/0
8990841E
Dimension drawing
Cable gland
Inspection PG 16
window
Gasket Gasket
Test push buttons

IN SERVICE OFF
Metal - dummy plug PG 16
The arrow must always point towards the oil pipe leading Plan view of test push buttons
to the oil conservator of the transformer. (cover removed)
Key of variants
Contact positions
Variant Relay designation1) Reed Arrangement of terminals Design
contact In service Off
0.65 - NO
Standard design
1 1.2 - NO A
3.0 - NO
4.8 - NO
0.65 - NC
2 1.2 - NC B
3.0 - NC
4.8 - NC
0.65 - CO
3 1.2 - CO C
3.0 - CO
4.8 - CO
0.65 - 2NO
4 1.2 - 2NO 2A
3.0 - 2NO
4.8 - 2NO
0.65 - 2NC
5 1.2 - 2NC 2B
3.0 - 2NC
4.8 - 2NC
0.65 - NO + NC
6 1.2 - NO + NC 1A &1B
3.0 - NO + NC
4.8 - NO + NC
1)
The protective relay is to be connected in such a way that if it is energized, the power transformer is switched off immediately by the corresponding
circuit breakers.
061/02/01/0
TD 61/02 31
8988012E
Motor-drive unit ED-S
Protective housing

spacing ring
Hand crank
* for design with



Shim

ca. 690 if opened 130° ment of the hinge pins.
32 TD 61/02 061/02/01/0
8988022E
Motor-drive unit ED-L
Protective housing

spacing ring Hand crank
* for design with


special design with OLTC monitoring
required
Wall of transformer tank Shim

061/02/01/0
TD 61/02 33
8929166E
Bevel gear CD 6400
Dimension drawing

34 TD 61/02 061/02/01/0
8985980E
Motor-drive unit ED-S/ED-L with CD 6400
Limit dimensions of the vertical drive shaft
061/02/01/0
TD 61/02 35
8995640E
Electronic voltage regulator TAPCON® 230
Flush and projected panel mounting
Remove crimp cable-

entries for flush
mounting
Bracketing fishplate
for panel mountig
Clamp for
flush mounting
Panel cutout for

flush mounting
36 TD 61/02 061/02/01/0
8995800E
Electronic voltage regulator TAPCON® 240
19-inch module rack
061/02/01/0
TD 61/02 37
8991440E
LED display panel
Dimension drawing
38 TD 61/02 061/02/01/0
8978973M
Position indicating instrument with square front frame
Dimension drawing
061/02/01/0
TD 61/02 39
8981053M
Position indicating instrument with rectangular front frame
Dimension drawing and connection diagram
40 TD 61/02 061/02/01/0
8981062M
Power supply unit for position indicator
Dimension drawing
061/02/01/0
TD 61/02 41
8986990M
Digital remote position indicator
Signal transmitter, dimension drawing
42 TD 61/02 061/02/01/0
8987000M
7-segment display, dimension drawing
061/02/01/0
TD 61/02 43
70728100
Connection diagram
44 TD 61/02 061/02/01/0
00711TM
Digital remote position indicator by selsyn transmitter
Dimension drawing
061/02/01/0
TD 61/02 45
93059 Regensburg, Germany E-Mail sales@reinhausen.com
Please note: The data in our publications may differ from the data of the devices delivered.
We reserve the right to make changes without notice.
TD 61/02 en • 0203/1000 • 061/02/01/0 • F0017401 • Printed in Germany
OPERATING MANUAL
30 GX FINAL CONTROLLING EQUIPMENT
SAP No.: 112010276/20 Page: 201

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 202

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
GX FINAL CONTROLLING EQUIPMENT AND
BKT NUMBERS – COMBINATIONS OF W, X, Y, Z
BKT NO. ARE NUMBERS FROM THE PART LIST OF THE DIMENSION DRAWING
GX 001 Motor drive
make MR type ED 100-L

138/05/01/0
042/06/01/0
SAP No.: 112010276/20 Page: 203

Order No.: 1431517
Serial No.: 150 556
OPERATING MANUAL
SAP No.: 112010276/20 Page: 204

Order No.: 1431517
Serial No.: 150 556
www.reinhausen.com
TAPMOTION® ED
Contents
Contents
1 General ......................................................................................................................................................................................... 5
1.1 Safety instructions ....................................................................................................................................................... 5
1.2 Specified application .................................................................................................................................................. 5
1.3 Function ......................................................................................................................................................................... 6
1.4 Type designations ......................................................................................................................................................... 6
2 Design ........................................................................................................................................................................................... 7
2.1 Mechanical equipment ............................................................................................................................................... 7
2.1.1 Protective housing ..................................................................................................................................... 7
2.1.2 Protective housing cover ......................................................................................................................... 7
2.1.3 Swing frame ................................................................................................................................................. 7
2.1.4 Hand crank ................................................................................................................................................... 7
2.1.5 Indication field ............................................................................................................................................ 9
2.1.6 Hand lamp .................................................................................................................................................... 9
2.1.7 Control elements ........................................................................................................................................ 9
2.1.8 Anti-condensation heater ....................................................................................................................... 9
2.2 Gearing ......................................................................................................................................................................... 10
2.2.1 Transmission gear ....................................................................................................................................... 10
2.2.2 Control gear ................................................................................................................................................. 10
2.2.3 Indicating equipment gear ...................................................................................................................... 10
2.2.4 Position transmitter equipment ............................................................................................................ 11
2.2.5 Transmission gear, control gear, motor unit wiring ........................................................................ 11
2.2.6 Covering for transmission gear, control gear, motor unit ............................................................. 11
2.3 Driving motor ................................................................................................................................................................ 11
2.4 Electrical equipment ................................................................................................................................................... 12
2.4.1 Swing frame ................................................................................................................................................. 12
2.4.2 Position transmitter equipment ............................................................................................................ 12
2.4.3 Terminal rails ................................................................................................................................................ 13
3 Installation .................................................................................................................................................................................. 14
3.1 Installing the motor-drive unit onto the transformer tank ........................................................................... 14
3.2 Installing the drive shafts and the bevel gear .................................................................................................... 14
3.3 Coupling on-load tap-changer and motor-drive .............................................................................................. 14
3.4 Electrical connection of the motor-drive ............................................................................................................. 17
4 Commissioning ........................................................................................................................................................................... 18
4.1 Function test .................................................................................................................................................................. 18
4.1.1 Preparations ................................................................................................................................................. 18
4.1.2 Checking the step-by-step operation .................................................................................................. 18
4.1.3 Checking the end position switches and the protective device against
passage of positions .................................................................................................................................. 18
4.1.4 Checking the motor protective switch ................................................................................................ 18
4.2 Commissioning on site ................................................................................................................................................ 18
138/05/01/0 BA 138/05 – TAPMOTION® ED 3

Contents
5 Transport .......................................................................................................................................................................................... 19
6 Maintenance .................................................................................................................................................................................. 19
7 Special designs .............................................................................................................................................................................. 20

7.1 Special designs based on on-load tap-changer features and operating conditions .................................... 20
8 Appendix .......................................................................................................................................................................................... 21
8.1 Technical data: motor-drive unit .................................................................................................................................. 21
8.2 Technical data: position transmitter equipment ..................................................................................................... 22
8.3 Dimension drawings ........................................................................................................................................................ 23
NOTE
Data contained herein may differ in small details from the motor-drive unit delivered.
We reserve the right to make alterations without notice.
4 BA 138/05 – TAPMOTION® ED 138/05/01/0

1 General
1 General
1.1 Safety Instructions 1.2 Specified application

All personnel involved in installation, commissioning, The TAPMOTION® ED is to be used exclusively for operating
operation, maintenance or repair of the equipment must: on-load tap-changers and off-circuit tap-changers in regu-
- be suitably qualified and lating transformers as well as for operating plunger-core
- strictly observe these Operating Instructions. earth-fault neutralizers.

- a reduction in the efficiency of the equipment CAUTION
- damage to the equipment and property of the user
- serious or fatal injury.
The motor-drive unit may only be used to operate the
Safety instructions in this manual are presented in three on-load tap-changer/off-circuit tap-changer of the same
different forms to emphasize important information. serial number. All safety devices have been adjusted to this
specific application.
It is the responsibility of the user to make sure that the
WARNING equipment is used for the specified application only.
For safety reasons, unauthorized work, i.e. installation,
This information indicates particular danger to life and modification, alteration, electrical connection or com-
health. Disregarding such a warning can lead to serious or missioning of the equipment must not be carried out
fatal injury. without first consulting MR !
The trouble-free operation of the motor-drive, the on-load
tap-changer/off-circuit tap-changer and the transformer
may be put at risk.
CAUTION
This information indicates particular danger to the Lock the motor-drive unit using a padlock (not included) to
equipment or other property of the user. Serious or fatal prevent operation by unauthorized personnel.
injury cannot be excluded.
CAUTION
NOTE
All relevant fire protection regulations must be strictly
observed.
These notes give important information on a certain
subject.
138/05/01/0 BA 138/05 – TAPMOTION® ED 5

1 General
1.3 Function
The modular-designed TAPMOTION® ED works by adjusting the
operating position of on-load tap-changers and off-circuit Motor-
drive
tap-changers in regulating transformers to the individual
operating requirements (figs. 2, 3).
The tap-change operation is activated by starting the motor- Tap
selector
drive (for example by a single control pulse triggered by a
regulator of the TAPCON®-series). This operation is always
completed regardless of any other control pulses emitted Diverter
during the operating time. The next tap-change operation switch
operation
can only proceed once the control devices have been
adjusted to their rest positions.
Fig. 1 shows the sequence of a tap-change operation. ca. 5,4 s
33 sections
Wicklung
Diverter
switch
contact
movement
1.4 Type designation

The various basic designs of the TAPMOTION® ED are clearly identified by explicit product definitions.
Type designation Description Types
ED 100-ST Product definition Electric Drive
ED 100-ST Type of transmission gear 100 = small transmission gear (motor, 6.5 Nm)
200 = large transmission gear (motor, 13/18 Nm)
ED 100-ST Type of protective housing S = small protective housing

L = large protective housing
ED 100-ST Special designs = without

C = Plunger-core earth-fault neutralizer design
T = TAPCON® and/or TAPGUARD®
6 BA 138/05 – TAPMOTION® ED 138/05/01/0

2 Design
2 Design
2.1 Mechanical equipment 2.1.3 Swing frame

2.1.1 Protective housing
The TAPMOTION® ED is characterized by two main features: WARNING
its uniform construction for all motor-drive designs and its
modular drive concept. Before opening the swing frame the relevant safety
instructions must be observed in order to avoid
The motor-drive is available in two types of protective
serious or fatal injury.
housing with the same arrangements for the attachment
points and the drive shaft (fig. 2 ED 100/200 S and fig. 3
ED 100/200 L ). All control elements are installed in a closed swing-frame
The protective housing, which will be finished with an anti- panel located behind the protective housing cover. This panel
corrosive paint (standard colour RAL 7033), consists of two protects all electrical and mechanical parts of the motor-
parts, the housing and the cover, both of which are made of drive against accidental contact.
non-corroding cast-aluminium. The closing system of the swing frame is designed to prevent
The spaces between the housing and the cover, as well as all the frame from banging against the base or cover. The closed
apertures required for operation (driven shaft, inspection swing frame is attached to the protective housing by two
window, aperture for hand crank in special arctic design, etc.), spring-supported door bolts. The standard design of the
are thoroughly sealed. Thus protection against dust and jets of swing frame always opens to the left.
water is ensured (IP 66).
The protective housing is ventilated by two labyrinth vents,
with metal filters on both sides of the housing. The bottom 2.1.4 Hand crank
of the housing is made up of three plates providing entries The hand crank is used to manually operate the motor-drive
for the cables. in emergencies or for adjustment purposes. It is attached to
the upper cover plate inside the protective housing.
2.1.2 Protective housing cover
In the standard design, the cover is attached to the base by
two hinges and it opens to the left. The standard cover has CAUTION
an opening angle of 130°.
There is a pocket attached to the inside of the protective When manually operating the motor-drive unit only use
housing cover to hold the connection diagrams. the built-in hand crank. Otherwise, there is a risk of serious
or fatal injury.
The safety switch in the hand crank disconnects the motor-
drive circuit at two poles; however, it does not disconnect
the control circuit.
2 3
138/05/01/0 BA 138/05 – TAPMOTION® ED 7
2 Design
4
8 BA 138/05 – TAPMOTION® ED 138/05/01/0
2 Design
2.1.5 Indication field 2.1.7 Control elements

A clearly arranged indication field (fig. 5) is installed in the The standard design contains the following control elements
upper part of the control panel cover (fig. 4). mounted in the upper part of the swing frame (see fig. 4):
The data displayed and the displays are detailed as follows:
– Door contact for switching on the lamp
– Motor protective switch
– Control switch “RAISE/LOWER“ to initiate a tap-change
2 operation electrically.
2.1.8 Anti-condensation heater
4 CAUTION
3
Do not touch the panel heater as it becomes very hot
during operation.
1 The anticondensation heater, fig. 4 (ED 100/200 S:

50 W, ED 100/200 L: 60 W) is designed as a panel heater
5 which also acts as the front cover of the swing frame.
1 - The mechanical operation counter shows the overall

number of operations performed by the motor-drive. NOTE
2 - The position indicator shows the position of the motor-
drive and the on-load tap-changer (standard, This new heater design:
max. 35 positions) / off-circuit tap-changer). - is a complete anti-condensation heater suitable
3 - The two drag hands indicate the regulating range for all climate regions except the arctic.
currently used. - does not require a thermostat or a hygrometer.
4 - The tap change indicator shows the current position of
the control cam (33 sections per tap-change operation)
Pointer and operations counter are mechanically driven and

indicate the switching sequence of the motor-drive.
The reset-wheel on the operations counter is lead-sealed at
the factory.
2.1.6 Hand lamp

There is a 4 W tubular fluorescent lamp (cable length ca. 1 m)
inside the protective housing which is switched on via a door
contact when the door is opened.
138/05/01/0 BA 138/05 – TAPMOTION® ED 9

2 Design
2.2 Gearing It contains cam discs which are used to mechanically trigger
the cam switches. The modular-designed position indicator
2.2.1 Transmission gear
equipment and the additional cam-operated contacts are
Transmission gear, control gear and the gear for the indi- driven by the control gear, the indicating equipment gear is
cating equipment are located in the upper part of the pro- driven by a cam shaft (fig. 8).
tective housing. They are protected against accidental
contact by a cover plate.
8 KHW 929
Electrical limit switches prevent overrunning of the end

positions. In addition to this, mechanical and electrical
6 limiting devices prevent tap-change operations beyond the
regulating range.
The entire gearing system (fig. 6) is located behind the upper
control panel in the upper part of the housing. The transmis- 2.2.3 Indicating equipment gear
sion gear is a low-noise, single-stage belt-type gear which has
unchanging 16.5 revolutions (= 33 hand crank rotations) per
switching operation. The transmission is a wear-resistant belt.
NOTE
The transmission gear belt must not come into contact

with lubricants.
2.2.2 Control gear

The control gear (fig. 7) (step-by-step device with cam-
operated contacts) is installed below the transmission gear.
9
The indicating equipment gear (fig. 9) mechanically reflects

the tap position on the indicator panel.
7 KHW 935
10 BA 138/05 – TAPMOTION® ED 138/05/01/0

2 Design
2.2.4 Position transmitter equipment 2.3 Driving motors

The position transmitter equipment comprises: The TAPMOTION® ED is equipped with a three-phase motor
- the position transmitter, which covers a wide voltage range as well as covering the 50/
60 Hz frequencies. The motor unit is installed below the trans-
- the position transmitter module and
mission gear.
- a plug-in connecting cable.
The on-load tap-changers and their corresponding motor-
The position transmitter is installed below the control gear. drive unit designs are listed in a separate selection table.
The position transmitter module for the connection by the
customer is located on the terminal rails (fig. 12).
2.2.5 Transmission gear, control gear, motor unit

wiring
The transmission gear, control gear and motor unit are wired
using black, flexible line material (1.5 mm2).
2.2.6 Covering for transmission gear, control gear,

motor unit
The touch-protected covering of the transmission gear,
control gear and motor unit is provided with an opening for
the hand crank used for manual operation (fig. 10).
The covering is equipped with fixing clamps and hooks to
hold the hand lamp and the hand crank.
10
138/05/01/0 BA 138/05 – TAPMOTION® ED 11

2 Design
2.4 Electrical equipment 2.4.2 Position transmitter equipment

2.4.1 Swing frame In the standard model, the following designs of the position
transmitting equipment are available:
- resistor-type position transmitter device
- N/O contact position transmitter device
• break before make-type
• make before break-type
– position transmitter module, diode matrix
11
The electrical equipment is mounted on the back of the

swing frame (fig. 11). Mounting rails and clamping rails
(some two-sided) allow for an easy installation of
components.
The individual devices are clearly marked with designations
for easier identification on the connection diagram kept in
the pocket of the door.
In the standard design, the swing frame is equipped with the
following components:
- anti-condensation heating: designed as a panel
heater (temperature increase in relation to ambient
temperature by ΔT ≈ 7 K)
- motor protection with trip coil
- control switch for RAISE/LOWER control
- contactors for RAISE/LOWER
- auxiliary contactor for step-by-step operation
- door contact for hand lamp
The cable connection bundle between the swing frame and
the terminal rails has a zip and a strain relief device on both
sides.
12 BA 138/05 – TAPMOTION® ED 138/05/01/0

2 Design
2.4.3 Terminal rails The wiring is easily connected using vertically arranged
clamping rails and terminal bars.
The terminal board facilitates an easy electrical connection
of the motor-drive unit (fig. 12).
7
2
6 5
4 1 3
1 - cable entries 6 - connection bundle

(closed by 3 bottom plates) swing frame – terminal rails
2 - terminal bar X1 7 - connection bundle
3 - cable duct terminal rails - transmission gear,
4 - clamping rail control gear, motor unit
5 - position transmitter module
KHW 1168
12
138/05/01/0 BA 138/05 – TAPMOTION® ED 13
3 Installation
3 Installation
3.1 Installing the motor-drive unit onto the 3.3 Coupling on-load tap-changer and motor-drive
transformer tank
The motor-drive unit is installed using 4 stud bolts (not in-
cluded in MR delivery) attached to the transformer tank. CAUTION
The necessary drill holes are located outside on the brackets
of the protective housing. The drill hole arrangement in all Make sure that the on-load tap-changer completes the
ED motor-drive designs is identical. tap-change operation before the motor-drive stops by
For correct attachment of the 4 stud bolts onto the trans- correctly coupling the motor-drive to the on-load tap-
former tank see the dimension diagram in paragraph 8.3. changer and also ensuring that the position indication of
the on-load tap-changer and the motor-drive are the same
for each operating position. These measures can prevent
damage to the motor-drive, on-load tap-changer and the
CAUTION transformer.
The motor-drive’s protective housing must not be warped

or deformed in any way when fixing it to the transformer
The above-mentioned requirements are met by setting the
tank.
time at which the operation of the on-load tap-changer
Make sure the motor-drive is mounted vertically and that
occurs 1.5 – 2 sections before the grey area of the tap
its driven shaft is correctly aligned with the vertical drive
change indicator (fig. 13).
shaft of the bevel gear in order to prevent damage to the
motor-drive, the on-load / off-circuit tap-changer and the Centre mark Resting range of
transformer. the motor-drive
If the transformer causes extremely strong mechanical vibra-

tions, the use of vibration absorbers is recommended (MR
special design).
3.2 Installing the drive shafts and the bevel gear

Further information on attaching these drive components
can be found in the Operating Instructions No. BA 42.
13 aus KHW 934
The centre mark in the grey field of the tap-change indica-

tion will be used as reference for the following procedures.
One tap-change operation is represented by one rotation of
the pointer on the tap change indicator. This indicator is
divided into 33 sections where one section corresponds to
one rotation of the hand crank.
The number of sections from the beginning of the diverter
switch action until the pointer reaches the centre mark of
the resting range should be equal in both directions.
14 BA 138/05 – TAPMOTION® ED 138/05/01/0

3 Installation
A slight asymmetry of a max. of 1 section is permissible.

To obtain a symmetrical coupling, proceed as follows: WARNING
Before starting any coupling work make sure that the

motor protective switch is tripped to prevent an unin-
tentional start of the motor-drive.
Procedure Example
Carry out any adjustment work by manual operation only.
Attach the hand crank in the motor-drive to the shaft end located in the upper cover
plate. This activates a safety switch which disconnects the motor-drive at two poles.
Make sure the on-load tap-changer and the motor-drive are in their adjustment
positions before commencing any adjustment work.
When adjusting, make sure the position indicators on the on-load tap-changer and
on the motor-drive are identical.
Couple the motor-drive and vertical drive shaft by mounting the coupling brackets.
Turn hand crank in one direction until the diverter switch operation begins.
When operating the motor-drive manually, observe the tap change
indicator which mechanically reflects the progress of the tap-change
operation.
Instant of diverter ect

ion
s
Once the diverter switch operation begins, turn the hand crank in the switch operation A=
5s Centre
mark
same direction while counting the sections required for the pointer to
reach the centre mark of the tap-change indicator.
Note the determined value A and the direction of rotation.
The tap-change operation is completed.
138/05/01/0 BA 138/05 – TAPMOTION® ED 15

3 Installation
Procedure Example
Turn the hand crank in the opposite direction, until the diverter switch
operation occurs.
B=
3 sec
Rest position tions
Count the remaining sections from the time the diverter switch (centre mark)
operation occurs until the pointer reaches the centre mark of Instant of diverter
the tap-change indicator. switch operation
Note the determined value B and the direction of rotation.
If the values obtained for both directions are identical, the on-load tap-changer and the
motor-drive are correctly coupled. A=B
As a control measure, carry out several tap-change operations in both directions.
If the values for A and B are not equal, proceed as follows:
Determine the correction value C by

dividing the difference between A C = A-B
and B by 2. 2
Uncouple the motor-drive and the vertical drive shaft by removing the coupling
brackets
Operate the motor-drive using the hand crank in direction of the higher value, either A or B by the number of sections on
the tap-change indication which equals C.
Re-couple motor-drive and on-load tap-changer and check the coupling using the above procedure.
Make sure that the pointer of the tap-change indicator is in centre position within the grey
field once the manual operation is finished.
Check the coupling after adjustment work by carrying out a few tap-change operations in both directions.
Check that the operating positions of the on-load tap-changer and the motor-drive are identical.
16 BA 138/05 – TAPMOTION® ED 138/05/01/0

3 Installation
3.4 Electrical connection of the motor-drive
WARNING
Before connecting the motor-drive to the mains supply,

the relevant safety instructions must be observed in order
to prevent serious or fatal injury.
Connect the motor-drive to the mains supply according to

the connection diagram in the pocket of the swing frame
door. The standard terminal block illustrated in fig. 14 on the
terminal rail X (fig. 12) is used for this purpose.
Terminal bar X1
14
138/05/01/0 BA 138/05 – TAPMOTION® ED 17

4 Commissioning
4 Commissioning
4.1 Function test 4.1.3 Checking the end position switches and the
protective device against passage of positions
4.1.1 Preparations
- To check the end position switch, operate the motor
drive to the penultimate position by turning the control
switch S3. Using the hand crank, manually operate the
WARNING motor-drive to its end position.
- When the S3 switch is turned further in the same direc-
The function test must be performed with the supply tion, the motor-drive must not continue to operate.
voltage connected. Make sure that the on-load/off-circuit Check to make sure.
tap-changer completes the tap-change operation before
the motor-drive stops by properly coupling the motor- - Using the same procedure, operate the motor-drive to the
drive to the on-load/off-circuit tap-changer. Also ensure other end position and repeat the above check.
that the position indications of the on-load/off-circuit Check that the pointer of the tap-change indication is in the
tap-changer and the motor-drive are the same for each grey field.
operating position. These measures can prevent damage to To check the protective device against passage of positions,
the motor-drive, the on-load/off-circuit tap-changer and operate the motor-drive using the hand crank while the
the transformer. motor protective switch is activated.
The relevant safety instructions must be strictly observed Check that the motor protective switch trips after a max. of
to prevent serious or fatal injury. 4 sections.
4.2 Commissioning on site

CAUTION The function tests as per 4.1 are to be repeated before the
transformer is commissioned.
Electrical mains supply
Make sure that the mains supply fulfils all the connection
requirements of the motor-drive unit. WARNING
Phase sequence test Under no circumstances is the transformer to be com-

When checking the motor circuit voltage, make sure that missioned, if the devices described in 4.1 do not pass the
voltage applied to the connecting terminals has a clockwise function test. Otherwise serious or fatal injury may result.
phase sequence.
4.1.2 Checking the step-by-step operation

- Initiate a tap-change operation by turning the control CAUTION
switch S3 (fig. 15) and keeping it turned while the
motor-drive is in operation. The motor drive housing must always be kept tightly closed.
- Check that the motor-drive switches off automatically When standstill time before commissioning exceeds 8 weeks
after performing one operation of the on-load/off-circuit or operation is interrupted for longer than 2 weeks, the
tap-changer and that the pointer of the tap-change indi- heater must be connected and turned on to prevent the
cator stops within the grey field. condensation of moisture inside the housing. If this is not
- Carry out this test in both directions. possible (e. g., during transportation of the motor drive),
a sufficient amount of dehydrating agent must be placed in
the housing.
15
18 BA 138/05 – TAPMOTION® ED 138/05/01/0
5 Transport / 6 Maintenance
5 Transport 6 Maintenance
If it is neccessary to remove the motor-drive for transporting The ED motor-drive unit does not require regular main-
the transformer, proceed according to section 3 of these tenance. However, if used with industrial transformers, our
Operating Instructions when re-installing the unit. Technical Service department must be contacted after the
unit performs 500.000 tap-change operations.
NOTE
WARNING
To prevent damage to the motor-drive unit during trans-
portation use the packing material provided by the MR The control checks must be performed with the supply
delivery. voltage connected.
If the motor-drive has to be removed for transporting the
The relevant safety instructions must be strictly observed.
transformer from the factory to the site of operation,
Failure to do so can lead to serious or fatal injury.
operate the on-load/off-circuit tap-changer and the
motor-drive to the adjustment position beforehand.
Reinstall the motor-drive according to section 3 of these We recommend that the following control checks be carried
Operating Instructions. out on the motor-drive unit during routine transformer
inspections:
- checking that the sealing of the protective housing is
water-proof,
- checking that the built-in electrical heater is functioning
trouble-free,
- checking the exterior condition of the equipment
installed in the motor-drive.
When inspecting the on-load tap-changer, also carry out a
functional test of the motor-drive according to 4.1.
138/05/01/0 BA 138/05 – TAPMOTION® ED 19

7 Special designs
7 Special designs
The standard design of the TAPMOTION® ED can be modified to accommodate specific operating requirements.
7.1 Special designs based on on-load tap-changer features and operating conditions
Feature
Number of mid-positions of on-load tap-changer >1 Automatic passage of positions

Device for automatic passage of positions through
one or more operational positions
On-load/off-circuit tap-changer with specified Monitoring of drive shafts and tap-change operations
synchronism control
On-load tap-changer type M-delta;
off-circuit tap-changer type U, UR
On-load tap-changer type VT Recovery time delay (60 s)
On-load tap-changer with change-over selector for Monitoring of drive shafts, tap-change operation and
star-delta change-over operation star-delta change-over operation
Furnace and electrolysis operation Additional input terminals for "operation without step-by
step switch".
Possibility to install position indication modules with
N/O contact range, 10 A (make-before-break) for the
control of external current matching transformers.
Thermoswitch for on-load tap-changers Measuring amplifier with break contact for the
control circuit
Higher max. number of operating positions Control gear + position indicator for 71 operating positions
Control gear + position indicator for 107 operating positions
Special on-load tap-changer arrangement

AB-arrangement Control gear for AB arrangement, operating time = 2.7 s
ABC-arrangement Control gear for ABC arrangement, operating time = 1.8 s
Temperature range < -30 °C Externally-located control elements,

main switch for disconnecting all circuits except
the heating circuit
thermostatically-controlled additional heater
20 BA 138/05 – TAPMOTION® ED 138/05/01/0

8 Appendix
8 Appendix
8.1 Technical data: motor-drive unit

The technical data is relevant to the standard design and may vary depending on the design delivered. It is subject to change
without notice.
Motor-drive unit ED 100/200-S/L
Motor power 0.75 kW 2.0 kW 2.2 kW
Voltage 3 AC/N 230/400 V
Current 1.9 A 5.2 A 6.2 A
Frequency 50 Hz
Synchronous speed 1500 1/min
Rotations of the drive shaft per tap-change operation 16.5
Duration of the tap-change operation ca. 5.4 s
Rated torque of the drive shaft 45 Nm 90 Nm 125 Nm
Rotations of the hand crank per tap-change operation 33 54
Max. number of operating positions 35

Control and heater voltage AC 230 V
Power input of the control circuit 100 VA / 25 VA

(control / operation)
Heating power 50 W for the ED 100/200 S – 60 W for the ED 100/200 L
Temperature range (ambient temperature) -30 °C to +50 °C
Test voltage to ground 2 kV / 60 s
Weight max. 130 kg
138/05/01/0 BA 138/05 – TAPMOTION® ED 21

8 Appendix
8.2 Technical data: position transmitter equipment

Resistance-type position transmitter
Standard resistance: 10.0 : (0,6 W, +/-1 %) per step
The maximum load on the module is determined by the number of resistors loaded and can be inferred from the capability
curve below. The permissible supply voltage is calculated from these power ratings and the total resistance value. However, the
supply voltage should not exceed DC 220 V.
Load on the resistance-type position transmitter

Permissible load in relation to the number of resistors
load on the module [W]
Number of resistors loaded
N/O contact position transmitter (break-before-make contact)

AC: 250 V, 0.5 A (ohmic load)
DC: 220 V, 0.2 A (ohmic load)
Minimum voltage level for signal and data processing: 24 V
N/O contact position transmitter (make-before-break contact)

AC, DC: 250 V, 0.02 A (ohmic load)
AC, DC: 24 V, 0.20 A (ohmic load)
N/O contact position transmitter, 10 A (make-before-break contact) for controlling current matching transformer in
industrial applications.
AC/DC: 250 V, 10 A (ohmic load)
Position transmitter, diode matrix

DC: 220 V, 0.2 A (ohmic load)
22 BA 138/05 – TAPMOTION® ED 138/05/01/0

8 Appendix
8.3 Dimension drawings

TAPMOTION® ED-S, protective housing ......................................................................................................................................................... 8988013E
TAPMOTION® ED-L, protective housing .......................................................................................................................................................... 8988023E
138/05/01/0 BA 138/05 – TAPMOTION® ED 23

8988013E
TAPMOTION® ED-S
Protective housing

spacing ring
Hand crank
* for design with



Shim

24 BA 138/05 – TAPMOTION® ED 138/05/01/0

8988023E
TAPMOTION® ED-L
Protective housing

spacing ring
Hand crank
* for design with


Wall of tansformer tank Shim

138/05/01/0 BA 138/05 – TAPMOTION® ED 25

93059 Regensburg, Germany E-Mail sales@reinhausen.com
Please note: The data in our publications may differ from the data of devices delivered.
We reserve the right to make changes without notice.
www.reinhausen.com
Drive shaft
Contents
Contents
1 General .......................................................................................................................................................................... 3
1.1 Safety labels .................................................................................................................................................. 3
1.2 Safety instructions ....................................................................................................................................... 3
1.3 Specified application ................................................................................................................................... 3
2 Design/Types ................................................................................................................................................................. 4
3 Installation of the drive shaft .................................................................................................................................... 5
4 Installation of the drive shaft covering.................................................................................................................... 6

4.1 Installation of the guard plate for the horizontal drive shaft .............................................................. 6
4.2 Installation of the telescopic protective tube for the vertical drive shaft .......................................... 7
4.3 Installation of the protective tube for vertical drive shaft with isolator ............................................ 7
5 Installation of the drive shaft with cardan joints ................................................................................................... 8

5.1 Installation of the drive shaft with cardan joints ................................................................................... 8
5.2 Installation of the telescopic protective tube for drive shafts with cardan joints (fig. 10) ............. 10
6 Installation of the drive shaft with insulator .......................................................................................................... 12
NOTE!
The product may have been modified after this document went to press.
We expressly reserve the right to make changes to the technical data, the design or the scope of
delivery.
In general, the information provided and the arrangements agreed during processing of the relevant
offers and orders are binding.
2 BA 42/06 – Drive shaft 042/06/01/0

1 General
1 General
1.1 Safety labels 1.2 Safety instructions

The following safety labels relating to the operation of the • All warnings and safety instructions must be observed at
drive shaft are used in these operating instructions. all times!
Failure to follow the safety instructions may lead to acci-
These labels must be observed at all times!
dents and severe personal injury.
• Please read these operating instructions before commis-
sioning the equipment!
WARNING! Please read the operating instructions before putting the
drive shaft into service. As the operator, you are responsible
Refers to a potentially hazardous for ensuring that users of the equipment have fully under-
situation that may result in death stood the operating and safety instructions.
or severe injury. • Train your staff!
Before asking staff to work with the drive shaft, provide
training regarding general and special safety instructions
and accident prevention regulations.
ATTENTION!
1.3 Specified application
Refers to a potentially harmful si-
tuation that may result in damage
to the the product or adjacent
equipment. WARNING!
Failure to motor drive, on-load
tap-changer and transfomer!
NOTE! Installation and commissioning of
the drive shaft may only be carried
Contains important information out by qualified, skilled personnel
and special notes. and under strict observation of
these Operating Instructions.
It is the responsibility of the user to
ensure that the drive shaft is used
for the specified application only.
For safety reasons, do not carry out
any unauthorized work, i. e. during
installation, modification, commis-
sioning and alteration of the drive
shaft without first consulting MR!
The trouble-free operation of mo-
tor drive, on-load tap-changer and
transformer may be put at risk.
NOTE!
The serial numbers of motor-drive,
on-load tap-changer or off-circuit
tap-changer, drive shafts and bevel
gear must correspond.
042/06/01/0
BA 42/06 – Drive shaft 3
2 Design/Types
2 Design/Types
The drive shaft is the mechanical connection between motor- Graded standard lengths of square tubes, see table 1
drive and on-load tap-changer head or off-circuit tap-chan-
ger head. The change from the vertical to the horizontal direc-
tion is performed by the bevel gear (see dimension drawing Standard length Motor-drive Manual drive
892916). 400 • •
Accordingly, the vertical drive shaft has to be mounted bet- 600 • •
ween motor-drive and bevel gear and the horizontal drive shaft 900 • •
between bevel gear and on-load tap-changer or off-circuit 1300 • •
tap-changer.
1700 • •
The drive shaft is designed as a square tube and is coupled at 2000 • •
both ends by two coupling brackets and one coupling bolt to
2500 not admissible •1)
the driving end of the drive shaft ends of the unit to be con-
nected. 3000 not admissible •1)
ATTENTION! Maximum total shaft length of the drive - last pole = 15 m!
When mounting the drive shaft
make sure that the shaft ends to be Table 1
connected are exactly aligned. 1)
l> 2000 only possible for vertical installation without shaft
Otherwise the trouble-free opera- protection! Telescopic protective tubes for manual drives with
tion of the motor-drive and the on- vertical dimensions V1>2462 should be delivered vertically,
load tap-changer off-circuit tap- similar to the motor drive unit with intermediate bearing.
changer cannot be guaranteed.
Minor axial displacement can be tolerated as long as it does

not exceed 35 mm per 1000 mm square shaft length (that
corresponds to 2°).
Square tubes, coupling brackets, coupling bolts, screws, and
locking washers are corrosion-resistant. We therefore recom-
mend not to apply the same external coating to these parts as
to the transformer tank.
The square tubes and the vertical guard plate are supplied in
overlengths (graded standard lengths). These parts must be cut
to the correct length when mounted on the transformer. In
rare cases the inner tube of the telescopic protective tube has
to be cut.
4 BA 42/06 – Drive shaft 042/06/01/0

3 Installation of the drive shaft
3 Installation of the drive shaft
Proceed for installation as follows (see fig. 1): • Insert the coupling bolt into the lower shaft end and slide the
square shaft over it together with the coupling piece
(fig. 2). Provide the opposite end with a coupling bracket and
ATTENTION! the coupling bolt. Fit in the square shaft by the end and con-
nect it with the second coupling bracket below by 4 self-
Check to make sure that the motor locking screws M6/w.s. 10 and 4 locking washers.
protective switch is tripped before • Set an axial clearance of 3 mm between the coupling bolt
starting the coupling procedure, and the upper coupling piece (fig. 3).
otherwise the motor drive can start • Preliminary tightening of the screws at approx. 6 Nm in
up accidentally. preparation for the alignment.
• Carry out final tightening of the screws only after aligning
• Determine dimension A between the two shaft ends. the on-load tap-changer and the motor drive unit (see
• Cut the square tube to the dimension LR = A - 9 mm. BA 138, chapter 3.3 "Coupling on-load tap-changer and
Deburr the cut. motor drive"). Tighten the screws M6/w. s. 10 with a max.
• Loosely attach one coupling piece (2 coupling brackets) with torque of 9 Nm.
4 screws M6 x 25/w. s.10 and 4 locking washers and slide it
onto the square shaft up to the dead stop. Tighten the screws
with a torque of 9 Nm. See section 4.2 for installation of the
telescopic protective tube!
NOTE! NOTE!
Grease the coupling bolts, the cou-
The middle bore holes of the coup-
pling brackets and the ball heads
ling brackets can be used for lead
(e. g. with adhesive grease ISOFLEX
seals.
TOPAS L 32).
Axial clearance of 3 mm
Set axial clearance of 3 mm at one end!
A - Dimension
between shaft
ends
LR - Length of square
tube
1 8900564M 2 3
042/06/01/0
4 Installation of the drive shaft covering
ATTENTION!
According to IEC standard 60214,
all driving shafts located on the
outside of the transformer need to
be protected with safety coverings.
To protect the vertical drive shaft, it needs to be covered with

a telescopic protective tube. The horizontal drive shaft needs A – Dimension between
to be protected with a guard plate. shaft ends
LSR – Length of the extended
telescopic protective tubes
4.1 Installation of the guard plate for the horizontal B - Inside width between
the housings
drive shaft LSB - Length of the guard
Proceed for installation of the guard plate as follows (fig. 4): plate
• Determine dimension B over the connecting flanges of the LSB = B - 2

housings.
• Cut down the guard plate to dimension LSB = B - 2 mm,
Deburr the cut and protect it against corrosion by a coat of
paint.
• To install the horizontal guard plate (uniform lengths
between 400 and 2,300 mm), please pay attention to the
following: 4
Slide the guard plate over the connecting flanges on the on-
load tap-changer and the bevel gear and fasten at each end
with a hose clip (fig. 5).
MR
6 BA 42/06 – Drive shaft 042/06/01/0

4.2 Installation of the telescopic protective tube for 4.3 Installation of the protective tube for vertical
the vertical drive shaft drive shaft with isolator
To install the telescopic protective tube (uniform lengths The procedure for the installation with isolator is similar to
between 200 and 1150 mm) please pay attention to the follo- section 4.2, except that in addition to the adapter ring at the
wing (fig. 6). bevel gear an insulated spacer ring must be positioned on the
bearing collar of the motor drive before the drive shaft is in-
• Determine dimension A (V1 = A + 453) between the shaft end
stalled.
of the ED and the bevel gear.
• Now shorten the inner tube on the non-slotted side as
follows without deforming it. Ensure that it is deburred
properly so that it can slide easily in the outer tube:
for dimension A = 170-190 mm shorten inner tube to size
200 (outer tube = 200)
for dimension A = 191-1130 mm shorten inner tube to size
A + 20 (outer tube = 200)
for dimension A = 1131-1598 mm use size 700 inner tube Adapter ring
without shortening (outer tube = 1150)
for dimension A = 1599-2009 mm use 1150 size for both
tubes without shortening
• Before the vertical drive shaft is installed, the adapter ring
must be located around the bearing neck of the bevel gear
and the coupling bolts must be pushed in (fig. 6).
• Now the two lower coupling brackets must be screwed onto
the drive shaft.
• The two protective tubes (inner tube with slot facing down-
wards and outer tube pushed over inner tube) must now be
pushed over the drive shaft mounted on the driven shaft of
the motor-drive unit and this must be aligned with the bevel
gear. 6
• Push in the upper coupling bolts. Then mount the upper
coupling brackets with four self-locking screws (M6 x 25/w.
s. 10) to the drive shaft with an axial play of 3 mm. Now
attach the lower protective tube (inner tube) with a hose clip
on the bearing collar of the motor drive. Then push the upper
protective tube over the adapter at the bevel gear and attach
on both slotted sides with hose clips.
042/06/01/0
5 Installation of the drive shaft with cardan joints
5.1 Installation of the drive shaft with cardan joints

Installation of the drive shaft with cardan joints is designed
NOTE!
as vertical drive shaft between motor-drive and bevel gear. Make sure that the position of the
Technically, horizontal design is also possible. opposite cardan joint straps corre-
To install the cardan joints, please proceed as follows sponds!
(fig. 10, page 10): Do not allow the expansion bellows
to be damaged when the cardan
• The included cardan joint with the inner hub diameter of joint folds up.
24.6 mm must be connected to the ball head of the motor-
drive unit via cardan joint bolts. The second cardan joint with
the inner hub diameter of 25 mm must be installed on the • Provisionally connect the loose shaft ends of the joints to a
bevel gear. For all other types of installation, a cardan joint piece of angle bar and align (fig. 7).
with an inner hub diameter of 25 mm must be used. The • Determine dimension A between the shaft ends.
cardan joint bolt is secured with the hose clip on the • Cut down the square tube shaft to LR = A + 106 mm
expansion bellows. and deburr the cuts.
7 8 9
8 BA 42/06 – Drive shaft 042/06/01/0
NOTE! ATTENTION!
Grease the coupling bolts, the cou- By the correct coupling of motor-
pling brackets and the ball heads drive and on-load tap-changer or
(e. g. with adhesive grease ISOFLEX off-circuit tap-changer you ensure
TOPAS L 32). that the on-load tap-changer is sure
to switch over before the motor-
drive stops so that the position of
• Mount lower coupling brackets loosely on the square tube. the on-load tap-changer or off-cir-
Mount coupling bolt(s). Put in square tube and push com- cuit tap-changer and motor-drive
pletely down so that no axial play remains between coupling are the same in any operating posi-
bolt and coupling bracket. tion.
Screw both coupling brackets with 4 self-locking screws M6 Otherwise there is a danger to mo-
x 25/w. s.10) and 4 locking washers with a tightening torque tor-drive, on-load tap-changer and
of 9 Nm (fig. 8). This securely connects (no clearance) end of transformer.
shaft and coupling piece.
• See section 5.2 for installation of the telescopic protective
tube!
• Provide the upper shaft end with a coupling bolt.
• Connect the square tube and the shaft end by 2 coupling
brackets and 4 self-locking screws M6 x 25/w. s.10 and
4 locking washers (fig. 9).
• Set an axial clearance of 3mm at one end between the
coupling bolts and upper coupling brackets.
• Preliminary tightening of the bolts at approx. 6 Nm in prepa-
ration for the alignment.
• Carry out final tightening of the screws only after aligning
the on-load tap-changer and the motor drive unit (see BA
138, chapter 3.3 "Coupling on-load tap-changer and motor
drive"). Tighten the screws M6/w. s. 10 with a max. torque of
9 Nm.
042/06/01/0
5.2 Installation of the telescopic protective tube for Before finishing installation, the following components have
drive shafts with cardan joints (fig. 10) to be threaded from below onto the square tube, following
the sequence as per description:
Before beginning installation, each of the two telescope tubes
must be shortened to dimension A/2 + 120 mm (A is the di- 1. upper flexible protective tube (item 5), with the long end of
mension between the ends of the cardan joint). the tube pointing up
2. adapter (item 3)
The adapter (item 1) on the bearing collar of the ED and the
3. outer tube (item 7), with the slit side pointing down
adapter (item 4) of the bevel gear must be mounted.
4. inner tube (item 6)
Now slide the deburred and shortened (according to chapter
Now slide the adapter (item 2) and the lower flexible protec-
5.1) square tube over the upper cardan joint end as far as it
tive tube (item 5) with the long end of the tube pointing up
will go.
over the inner tube.
Set axial clearance of 3 mm at one end!
Bevel gear
LR = A + 106
LR - Length of square tube

A - Distance between shaft ends
Pos. Designation Unit

1 Adapter d82 x 102 1
5 flexible protective tube 2
6 inner tube 1
7 outer tube 1
8 hose clip 87 - 112 5
Motor-drive
890063
10
10 BA 42/06 – Drive shaft 042/06/01/0
Mount a screw clamp on the square tube in order to avoid that

the components slide off during the installation of the coup-
ling brackets of the shaft tubes.
To finish the installation of the telescope tube all the above
mentioned components must be tightened. Proceed from top
to bottom.
For this purpose be sure that the plastic adapters are located
on the respective end of the flexible protective tube and that
the telescope tube is only slid into the upper or the lower
flexible protective tube as far as the adapter is wide (item 3).
Slide the flexible protective tube over the adapter (item 4)
between the protective tube and the bevel gear. Then fit the
adapter (item 3) between the flexible protective tube and the
outer tube and secure the protective tube on both sides with
hose clips (item 8).
The installation of the lower protective tube between the ED
and the inner tube has to be carried out with an adapter (item
2) and two hose clips (item 8).
1. Slide the flexible protective tube over the adapter (item 1)
between the protective tube and the motor drive unit.
2. Fit the adapter (item 2) between the flexible protective tube
and the inner tube .
3. Secure the protective tube on both sides with hose clips.
At the end, secure the two telescope tubes towards each other
with a hose clip.
042/06/01/0
6 Installation of the drive shaft with insulator
6 Installation of the drive shaft with insulator
A model with insulator of the vertical drive shaft is available The insulator can also be used in connection with the joint
(fig. 11) for insulating installation of the drive shaft. shaft (fig. 12).
Type with insulator (D max. = 2°) Type with insulator (D max. = 20°)
§
§
from 898598 from 898598
11 12
042/06/01/0
12 BA 42/06 – Drive shaft
8929166E Bevel gearing
Dimension drawing

042/06/01/0
Falkensteinstrasse 8 Fax +49 941 40 90-111
www.reinhausen.com 93059 Regensburg, Germany E-Mail sales@reinhausen.com

Rated power Rated power Rated power
80/120* MVA 80/120* MVA 80/120* MVA
Class Class Class
Power transformer Power transformer Power transformer
Type Type Type
DOTR 120000/110 DOTR 120000/110 DOTR 120000/110
Serial No. Serial No. Serial No.
150 556 150 556 150 556

Betriebsanl 150556 1431517-EN

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Betriebsanl 150556 1431517-EN

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OPERATING MANUAL

Rated power 80/120* MVA

Class Power transformer

Type DOTR 120000/110

Serial No. 150 556

Project Trafo für WP Cogealec

SAP No.: 112010276/20 Page: 1

SAP No.: 112010276/20 Page: 2

SAP No.: 112010276/20 Page: 3

SAP No.: 112010276/20 Page: 4

4 EMERGENCY OPERATION, STORAGE AND DISPOSAL

4.1 EMERGENCY OPERATION

6 DISASSEMBLY AND TRANSPORT

7 UNLOADING, INSTALLATION AND ASSEMBLY

7.1 CHECK FOLLOWING ARRIVAL

SAP No.: 112010276/20 Page: 5

8 GETTING READY FOR OPERATION AND COMMISSIONING

8.1 GETTING READY FOR OPERATION AND COMMISSIONING:

9 MAINTENANCE AND INSPECTION

9.1 MAINTENANCE AND INSPECTION

10 DIMENSION DRAWING AND PART LIST

11 RATINGPLATE, DIAGRAM PLATE

12 RECONNECTING DOM PLATE

13 TRANSPORTPLATE /TRANSPORT DRAWING

16 MOTOR DRIVE UNIT CONTROL

17 PHOTO H. V. SIDE PHOTO L. V. SIDE FILLING DIAGRAM

18 ADDITIONAL DOCUMENTS ACCORDANG CUSTOMERS SPECIFICATION

19 AA FITTINGS, SLIDE VALVES, COCKS

20 AB TERMINATING ELEMENTS, LOCKING PIECES

AE MOVING, LIFTING,TURNING AND SWIVELLING MECHANISMS

SAP No.: 112010276/20 Page: 6

AT DRYING AND FILTER EQUIPMENT(DEHYDRATING REATHERS)

AX TESTING AND MONITORING EQUIPMENT

BB CONTAINERS,RESERVOIRS,ACCESSORY CAINETS,TERMINAL BOXES

BQ SUPPORTS,BEARING EQUIPMENT,FRAMEWORKS,CABLE DUCTS

BS NOISE REDUCTION COMPONENTS

CE ELECTICAL VARIABLES(E.G. INSTALLATION–TRANSFORMER)

CF FLOW MEASURING EQUIPMENT

(BUCHHOLZ RELAY, PRESSURE/ VACUUM RELAY,

PRESSURE SURGE PROTECTION,OIL AND AIRFLOW

INDICATORS OR WATER FLOW INDICATORS, ETC.)

CL LIQUID LEVEL(LEVEL MEASUREMENT)

CQ QUALITY VARIABLES (MONITORING, HUMIDITY, AGEING AND QUANTITY)

SAP No.: 112010276/20 Page: 7

CU COMPOUND MEASURED VARIABLES

GD BUSHINGS, RECEPTACLES, CABLE SEALING ENDS ≥ 1 KV ≥ 1 KV

GE BUSHINGS,RECEPTACLES, CABLE SEALING ENDS < 1 KV

GF CABINETS, TERMINAL BOXES (SUB-DISTRIBUTION BOARDS)

GH CABINETS FOR PROTECTION, CONTROL AND MONITORING

30 GX FINAL CONTROLLING EQUIPMENT

BKT NUMBERS – COMBINATIONS OF W, X, Y, Z

SAP No.: 112010276/20 Page: 8

Purchaser: S.C.TOMIS TEAM SRL

Customer: S.C.TOMIS TEAM SRL

Projekt: Trafo für WP Cogealec

Order Number: Final Order 4

Date of Purchaser Order: 16.03.2009

Manufacturer: Starkstrom-Gerätebau GmbH

Telephone: +49 941 7841-0

Fax: +49 941 7841-227

Type: DOTR 120000/110

Serial Number: 150 556

Order Number: 1431517