The H-J Family of Companies

Introduction to Tap Changers & Dual Voltage Switches Application

O. Giraldo, Rev. 0, April 2018
Tap Changers
Why to use them ?
•  Due to voltage regulation in transformers and in
transmission and distribution lines, it is not practical to
have a fixed transformer turns ratio !!
•  Tap changers allow changes of the turns ratio by adding
or subtracting turns, in certain % (typically less than
10%) of the rated number of turns.
•  This variation in number of turns in made typically in
the higher voltage winding.
Why ? :
Less current, less cost, larger number of turns (easy to
have low % variations)
From basic equation of transformers
Volts per turn are constant

•  V1 / N1 = 4.44 * f * Sn * Bn * 10-8

•  V2 / N2 = 4.44 * f * Sn * Bn * 10-8
Tap Changers
Prinzip of operation – Transformer 13200 +/- 2 * 2.5 %, 240V
7
POS V1 Delta N V2 N2 N1 Delta N N1/N2 Join
1 13860 240 40 2310 57.7500 1-2
2 13530 -330 240 40 2255 -55 56.3750 2-3
1045e 6270 3 13200 -330 240 40 2200 -55 55.0000 3-4
4 12870 -330 240 40 2145 -55 53.6250 4-5
5 12540 -330 240 40 2090 -55 52.2500 5-6

5
55e 330v
3
55e 330v
1

  POSITION
2
  N1 + 5% 1
55e 330v
4 40e 240v N1 + 2.5% 2
55e 330v
  V1 / V2 = N1 / N2 N1 3
6
  N1 - 2.5% 4
  N1 - 5% 5

1045e 6270

8
Tap Changers
Prinzip of operation

h"ps://www.youtube.com/watch?v=ATyXK0YmZqk
Tap Changers
Prinzip of operation
Tap Changers
Why to use them ? - Cases
•  CASE A:
•  System voltage higher than transformer rated primary voltage
•  => Secondary Voltage higher than rated
•  => Increase N1/N2 to reduce secondary voltage
•  => Move tap changer to positions 1 or 2

•  CASE B:
•  System voltage lower than transformer rated primary voltage
•  => Secondary Voltage lower than rated
•  => Reduce N1 / N2 to increase secondary voltage
•  => Move tap changer to positions 4 or 5
•  Transformer secondary voltage higher than needed => Same as CASE A
•  Transformer secondary voltage lower than needed => Same as CASE B
Tap Changers
Types
•  NO-LOAD (NLTC):
•  Operates at de-energized condition:
•  No voltage, no current
•  Manual operation
•  Used mainly for distribution transformers
•  Normally located at the HV side

•  ON-LOAD (OLTC):
•  Operates with voltage and current
•  Automatic operation
•  Used mainly for power transformers
•  May be located either at the HV or LV side
•  (Arc in HV contains a lot of energy)

https://www.youtube.com/watch?v=f3uQQBDI1o4
Dual Voltage Switches
Why to use them ?

•  It is mainly a transformers’ inventory issue

•  When transformer is required to be installed in a
facility with two different voltage sources, using the
dual voltage switch allows to connect the transformer
to anyone of the sources
•  It’s like having “two transformers in one”
•  HV winding is designed accordingly to be connected,
generally in series-parallel arrangement, to both
sources.
Dual Voltage Switches
Connection Configurations Analysis

Terms for analysis in this presentation:

•  Dual Voltage Switch is always connected in the HV

winding of the transformer
•  Analysis is done in “per phase” basis, regardless
winding connection (delta or wye or single phase)
•  Analysis is same regardless transformer type or kVA size
Dual Voltage Switches
Examples of Connections
Most typical connections H-J uses to sell DV switches for:

•  2400 x 4160
•  2400 x 7200
•  4160 x 13200
•  6300 x 13200
•  11400 x 13200
•  13200 x 33000
•  Delta x Wye Switch
•  There are many other possibilities
Dual Voltage Switches
2:1 DV Switches Applications

Used when the ratio of the voltages is 2:1 or less, under

following conditions:

•  Only 1 deck
•  Single phase transformers
•  50 amps max continuous rating in series
•  100 amps max in parallel position
•  125kV BIL
•  40kV, 60Hz, 1min withstand
•  Fault Current: 1000 amps, 1 second
Dual Voltage Switches
3:1 DV Switches Applications
Used when the ratio of the voltages is 3:1 or less, under
following conditions:
•  1 to 4 decks – Back switches if needed
•  Single or 3-phase transformers
•  Heavy Duty
•  150 amps max continuous rating in series
•  300 amps max in parallel position
•  150kV BIL (125kV between adjacent
contacts)
•  50kV, 60Hz, 1min withstand
•  Fault Current: 7500 amps, 0.5 second
3750 amps, 2 seconds
Dual Voltage Switches
Generalities for 2:1 and 3:1
•  Always connected to HV side of transformer. Advantages of it are:
•  Less Current
•  Smaller size
•  Much cheaper
•  DV Switches are also known like
series/parallel switches
•  External operating handle to switch
between position 1 and 2
•  Maximum tank wall thickness: 0.25”
•  To be operated under no load conditions (transformer de-energized)
•  Remember for amps capacities larger than explained here, Quality
Switch can provide special Dual Voltage Switches. Principles of
operation are same as explained in this presentation
 H1 H2

2400 volts Tap changer

Winding 1 Deck 1

7200 volts 2400 volts Tap changer

3x windings Winding 2 Deck 2
in series

Dual Voltage Switches

4

2400 volts Tap changer

Winding 3 Deck 3

S E R I E S C O NNE CT I O N
POS I T I O N A

Example of series-parallel connection

2400 x 7200 Connection (3:1 case) – Series Connection
H1 H2

2400 volts Tap changer

Winding 1 Deck 1

VOLTS POS CONNECT

2

2-3
7200 A 4-5
7200 volts 2400 volts Tap changer
3x windings Winding 2 Deck 2
in series

5
Make sure which switch positions have terminal
connectors and which switch positions don’t !!
2400 volts Tap changer
Winding 3 Deck 3

Some applications might need to ask CM to

6
put connectors in any terminal(s) !!
S E R I E S C O N N E C T I O N
P O S I T I O N A
Dual Voltage Switches
Example of series-parallel connection
2400 x 7200 Connection (3:1 case) – Parallel Connection

H1 H2

1 3 5
VOLTS POS CONNECT

2400 volts 1-3-5

3x windings 2400 B 2-4-6
in parallel

2 4 6

2400 volts 2400 volts 2400 volts Number of turns between H1 and H2 is now 1/3 of
Winding 1 Winding 2 Winding 3
the series case and so does the voltage…
P A R A L L E L C O N N E C T I O N ….
P O S I T I O N B

But each turn has now 3 times the cross section…,

why ??
 Dual Voltage Switches
Example of series-parallel connection
2400 x 7200 Connection (3:1 case) – 500kVA Case
H1 H2

H1 H2
2400 volts Tap changer
Winding 1 Deck 1
I7200 = 500 / (1.732 * 7.2)
1 3 5
= 40.1 A
2

3 I/3 I/3 I/3

2400 volts
3x windings
7200 volts 2400 volts Tap changer
in parallel
3x windings Winding 2 Deck 2
in series
I2400 = 500 / (1.732 * 2.4)
4
2 4 6
= 120.3 A
5
2400 volts 2400 volts 2400 volts
Winding 1 Winding 2 Winding 3

Current for every winding

2400 volts Tap changer
Winding 3 Deck 3
P A R A L L E L C O N N E C T I O N

is the same either in series

P O S I T I O N B

S E R I E S
P O S I T I O N
6

C O N N E C T
A
I O N
or in parallel connection !!
Dual Voltage Switches
Example of series-parallel connection
H1 H2 H3

What happens when the voltages are 2 2 2

not exact multiples ? 6600v = 33000v – 2 * 13200v 8 8 8

Between 8-6 6 6 6

13200 x 33000 Connection (2.5:1 33000v

case) – Series Connection 5
4
5
between
4
8-1 5
4

1 1 1

13200v
between 6-5
S E R I E S C O N N E C T I O N
and also P O S I T I O N 2
between 4-1
4 5
VOLTS POS LIGA

6 1
4-5
33000 2 2-8
2
8

POSICION 2
Dual Voltage Switches
Example of series-parallel connection
H1 H2 H3

What happens when the voltages are 2 2 2

not exact multiples ? 6600v

8 8 8

X 6 6 6

13200 x 33000 Connection (2.5:1

case) – Parallel Connection 5
4
5
4
5
4

1 1 1

13200v
P A R A L L E L C O N N E C T I O N
P O S I T I O N 1

4 5
VOLTS POS LIGA

6 1 2-4 -6
13200 1 5-1

2
8

POSICION 1
Dual Voltage Switches
Special Applications - Delta & Wye commutation
H1 H2 H3

CONEX POS

DELTA B

CONEX POS

WYE A

Hacia No 4 Hacia No 7 Hacia No 4 Hacia No 7

4 7 4 7

6 6

Hacia No 6 Hacia No 6

POSICION B POSICION A
Dual Voltage Switches
Special Applications
Using DV Switch like inverter to add Voltage regulation positions to a
tap changer – Additive sense of current
H1 H0
POS CONNECTS CONNECTS GROUNDED

A 2 - 3 4 - 5
B 2 - 4 3 - 5
IHV
- Main winding turns +

<---------- V ---------->

T1 +
2 T2 x IHV
3 T3 x TAP
DV Switch T4 Tap Changer CHANGER VOLTAGE JOIN
4 T5 x POSITION
1 V + 4 x T3 - T4
5 T6 x
2 V + 3 x T4 - T2
-
3 V + 2 x T2 - T5
4 V + x T5 - T1
5 V T1 - T6
Dual Voltage Switches
Special Applications
Using DV Switch like inverter to add Voltage regulation positions to a
tap changer – Subtractive sense of current
H1 H0
POS CONNECTS CONNECTS GROUNDED

A 2 - 3 4 - 5
B 2 - 4 3 - 5
IHV
- Main winding turns +

<---------- V ---------->

T1 +
2 T2 x IHV
3 T3 x TAP
DV Switch T4 Tap Changer CHANGER VOLTAGE JOIN
4 T5 x POSITION
5 T6 x 1 V - 4 x T3 - T4
- 2 V - 3 x T4 - T2
3 V - 2 x T2 - T5
4 V - x T5 - T1
5 V T1 - T6
Dual Voltage Switches
Special Applications
DV Switches with back-deck 2 decks per phase
Dual Voltage Switches
Special Applications
DV Switches with back-deck Example of application
H1 H2 H3

4B 6, 7B B Q C R

2 L M

5 F G
4 I J

1 N N

VOLTS POS LIGA

2-4-6
6300 B 5-1

VOLTS POS LIGA

4-5
13200 A 4B - 7B
Dual Voltage Switches H1 H2

Special Applications 1

Fused Windings Use 2 fuses "set" per phase as shown

Each set has one BF and one CLF

Different voltages mean different Fuses calculated for 6930 volts

fuses. In some cases DV switches allow
to include fuses in the windings for Tap changer
Deck 1
both voltages avoiding to take Fuses calculated for 13860 volts
transformer out to make the fuses
change

2
For 500 kVA: VOLTS POS CONNECT
3
I6930v = 41.7 amps I13860v = 20.8 amps
In parallel connection the current 6930 1
1-3
through each branch is 41.7A/2 = 20.8A. 2-4

By placing the fuse for 13860v within one

of the parallel branches, it will see same
current, regardless the series or parallel Tap changer
VOLTS POS CONNECT
connection. Deck 2

In series connection (13200v), the 6930v

fuse will see only half its rated current,
so it will allow the 13200v fuse to 13860 2 2-3
operate.
4
Dual Voltage Switches
Selection Tips
3:1 Series – Recommended Part Numbers 1 deck

Complete Assembly !!
Dual Voltage Switches
Selection Tips
3:1 Series – Recommended Part Numbers 3 decks

Complete Assembly !!
Dual Voltage Switches
Selection Tips
3:1 Series Recommended handle
Dual Voltage Switches
Selection Tips
3:1 Series Indicator Plates – Drawing CM70324283
Dual Voltage Switches
Selection Tips
2:1 Series – Recommended Part Numbers Switch
Dual Voltage Switches
Selection Tips
2:1 Series – Recommended Part Numbers Handle
Dual Voltage Switches
Selection Tips
2:1 Series – Recommended Part Numbers Indicator Plates