Methods Assembly TR

CONTENT
CONTENT .............................................................................................................................1
1 General transformer assembly method ............................................................................2
2 Core Building .................................................................................................................7
3 Assembly of core clamping...........................................................................................29
4 Potential ring body manufacturing ................................................................................30
5 Pre- and final gluing of the pressboard cylinder ............................................................38
6 Disc windings with turn over technology on horizontal machine...................................46
7 Two direction wound disc windings on horizontal machine ..........................................66
8 Disc winding manufacturing on vertical machine..........................................................86
9 Winding assembly method ..........................................................................................108
10 Preparation of transformer core...............................................................................115
11 Matching of the inner winding on the core (traditional method) ..............................119
12 Inner winging matching to the core by TRANSPOLIM...........................................125
13 Pressing of the windings mounted on the core.........................................................134
14 Joining of the winding rectangular copper conductors by butt welding ....................140
15 Joining of the winding rectangular copper conductors by butt soldering ..................144
16 Joining of the winding rectangular copper conductors by overlapped soldering.......149
17 Preparation of internal connection by crimping .......................................................155
18 Drying and impregnation of transformers................................................................165
19 Relaxing time of oil impregnated transformers........................................................190
Page 1 of 192
1 General transformer assembly method
Subject: The paper gives the summary of the transformer assembly actions being
independent from the type of the transformer. If required by the
transformer design, the special assembly instructions shall be included in
special papers.
1.1 Core stacking
1.1.1 Making a bandage
• Spool a bandage from polyglass tape.
1.1.2 Core stacking
• Move the beams, flitch plates and bridges to the place of the
stacking. Clean the threads by rethreading, and polish the earthing
lugs to metal.
• Lay the turnable core-stacking device down; put the starting side
frame beams and flitch plates in the proper position.
• Place the starting side insulations, stepped and other wood supports
in their designed position.
• Move the core sheets to the place of the stacking and put them on
racks around the core-stacking device considering the layout of the
core.
• Make the stacking of the core sheets as given on the drawing (with
or without stacking the upper yoke as prescribed).
• Make the oil ducts at the given places.
1.1.3 Assembling the frame structure
• Put the stepped wood supports and the insulations of the frame and
the flitch plates on their place.
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• Put the flitch plates and the frame beams on the core. Assemble
them together with the bridges and the cushion plates. Make the
temporary limb fastening and yoke bandage.
• Erect the core.
• Varnish the surface of the core.
• Put the core lathes around the core limbs, and make the bandages.
• Test the core insulation.
• Prepare the wires and make the equipotential connections.
• Move the core in the test room, prepare for testing.
1.2 Preliminary assembly of the winding
• Turn the winding in vertical position, pull out and store the mandrel
(only in case of horizontal winding machine)
• Cut the leads to the needed length, and clean them. Mount up the
prescribed part of the end-blocks. Mount the winding into the press
device.
• Dry and prepress the winding.
• After drying, press the winding by the force prescribed on the
winding drawing. Check the length and determine the needed
height compensation.
1.3 Assembling the windings in a phase-block
• Mount the individually dried and pressed windings with the end-
blocks and the filling spacers into the block-pressing device.
• Press and dry the phase-block.
1.4 Electrical assembling
1.4.1 Preparing the core for assembly
• Put the core in the drying oven. Tighten its clamping components.
• Install the required turns for preliminary tests.
• Place the core into the assembly bay.
Page 3 of 192
• Test the insulation between packets. Remove the upper yoke
lamination (if the core is not open).
• Thread the textile bags if the windings supported to the core by
resin filling.
• Fit the core lathes to the inner diameter of the winding.
• Fit the base plates
1.4.2 Assembling the windings on the core
One after the other:

• Assemble the windings on the core
• Mount up the main insulations between windings
In phase-block:
• Assemble the lifting device on the phase-block
• Lift the phase-block on the limb
• Fill up the textile bags by resin (in case of resin support)
1.4.3 Mounting up the upper yoke
• Clamp the winding system on the core preliminary

• If the height of the windings exceeds the needed dimension,
prepare the active part for drying, lift it on the oven carriage. Dry
and press the winding system, check the height. After drying, place
the active part back in the assembly bay.
• Build up 20% of the upper yoke. Clean the leads. Test the voltage
ratio. Complete the upper yoke.
• Mount on the upper frame beams, assemble the upper clamping
components
1.4.4 Mounting up the connection walls, prepare for drying
• Make the earthing of the core.

• Mount up the connection supports and the connections.
• Fix the tank cover on the active part.
• Assemble the tap changer. Make the connections to the tap
changer.
Page 4 of 192
• Make the lead connections with bushings or models.
• Try the active part into the tank.
• Lift the active part on the oven carriage.
1.4.5 Revision of the active part, tanking, oil filling
• After drying the active part press the phase-blocks with the force
prescribed on the winding assembly drawing. Tighten the spring
clamping, make the wedging.
• Tighten and lock the screwed joints.
• Mount the magnetic shields and Faltenbalgs in the tank, if
applicable.
• Lift the active part in the tank. Prepare for oil filling. Close the tank
by the cover.
• (Fill up the tank with oil without delay.)
1.4.6 Preparing the transformer for testing
• Assemble the cable boxes. Try them on their final place.

• Mount the LV bushings, the connection and cable boxes, turrets,
etc. on.
• Install the accessories needed to the tests in the test bay
(conservators, relays, etc.)
• Assemble the HV connections.
• After cleaning, mount the radiators on the tank.
• Install the cooling fans.
• Make the wiring.
• Deaerate the transformer
1.4.7 Oil leakage test
• Prepare the transformer for oil leakage test and perform the test.
• Measure the deformations.
1.4.8 Preparing the transformer for transport
Page 5 of 192
• Drain the oil off. Dismount the accessories transported separately,
and close the openings.
• Install the filling device and fill up the transformer with nitrogen.
• Mount up the accessories required for transport (supports, etc.)
• Hand the separately transported accessories over to the Transport
Department.
• Lift the transformer on the transport vehicle.
1.5 Mechanical assembling
1.5.1 Preliminary assembly of the tank and the accessories
• Perform the preparing actions on the tank and the cover, and clean
them. Mount the blind flanges, consoles etc. on.
• Prepare the cable boxes.
• Clean the choke and the butterfly valves, and provide them with
stud bolts.
• After trying the active part in the tank, weld the positioning blocks
in, and fit the holes.
• Assemble the conservator together (end plates, rubber bag,
accessories, etc.)
1.5.2 Preparing for tests
• Assemble the oil-air heat exchangers on.

• Make the piping.
• Install the pumps and the oil flow indicators.
• Assemble the oil-water heat exchangers and the oil pump on.
• Fit, weld and finish the piping.
1.5.3 Preparing for transportation
• Disassemble the coolers

• Mount the support of the nitrogen-filling device on.
Page 6 of 192
2 Core Building
The temporary process specification applies to stacking and erecting of transformer

cores using the turnable device made as per drawing No. 556-280/I/A.
2.1 Tools and devices
2.1.1 The turnable devices for core building as per the assembly drawing No.
556-280/I/A with all the assigned accessories.
Maximum load of the device: 400 kN

The weight of the device: 60 kN
2.1.2 The rocking lever of 180 kN lifting capacity for lining the two 100 KN
cranes.
2.1.3 Joiner’s tools for trimming the components made of wood and
pressboard.
2.1.4 Fitter’s tools.
2.1.5 Soft copper plate or cloth-base bakelite plate for aligning the core
sheets. Do not use iron plate for this job.
2.1.6 Two-component epoxy resin for gluing the edges of the core sheets. The
type of resin: RL 810.
2.1.7 Vessel and flat brush for applying the resin.
Balance for measuring the components of resin.

Acetone is to be used as solvent.
2.1.8 Racks for supporting the adequate number of the core sheets out to size.
2.1.9 Master plate for stacking and other auxiliary devices.
2.1.10 nivelling plummet and water levels.
Page 7 of 192
2.1.11 Storage box for the fittings of the turnable device.
2.1.12 5 pc permanent magnets for checking the anti-magnetic feature of the

flitch plates.
2.1.13 Pair of crane cables of adequate capacity for turning and lifting the
completed core.
2.1.14 Dust exhauster
2.1.15 Insulation tester of 500 V and testing set of 2 kV.
2.1.16 Plastic foil to cover the core.
2.2 General
2.2.1 Do not dismount the supports of the sub base when starting the core
stacking in order to assure a firm support of the core on the device.
2.2.2 The core sheets shall be delivered to site arranged in accordance with
the layout of the core sheets. Check the weights of the sheets of the
same type. Should the height of each step be less than figure given in
the drawing the adequate number of core sheet shall be added. The
number of the sheets in addition to that specified in the drawing shall be
established by taking the size of the core steps and these sheets shall be
cut. The overmade number of core sheets shall be put in the middle, in
the widest core step.
2.2.3 Do not bend the sheets, do not keep hitting those with iron parts. In
general do not expose the sheets to high mechanical stresses. The
sheets shall be transferred from the racks to the core on a slip way.
2.2.4 Rusty, damaged sheets or sheets with burrs, peeling insulation must not
be fitted.
2.2.5 The tolerance applying the core building are given in Appendix 1
Page 8 of 192
2.2.6 The gluing of the core edges shall be made according to the instructions
of the Process Specification No. TTFO/30.
2.2.7 Check the flitch plates for burrs and correct size and shape before the
assembly.
2.2.8 All the insulation components shall be stored clean and dry. Should the
core building be stopped for longer period (e.g. the time between the
finish of the afternoon shift and the start of the morning shift of the
following day) the core shall be covered with plastic foil. In this way the
dust and/or contamination of various origin can be avoided.
2.2.9 The coat of the oil-proof paint on the frames shall be continuous and
free from any impurities.
2.2.10 Voltage withstand test of the insulating components of the core, if any.
a) The voltage withstand test of the insulating components of the core shall
be performed with the insulation tester in the course of the stacking and
when the core (transformer) is completed. The test voltage shall be 500
V. The fingers of the testing apparatus shall be put on the sheets next to
both sides of the insulation.
NOTE:
He space of the oil ducts in the core are made of insulating material.
These are to be tested as any other insulation layer of the core.
Check the position of these spacers. The spacers along the periphery
shall be aligned to the edges of the sheets otherwise the two sheets at
the sides of the oil duct can get in contact when the core is compressed.
b) 2 kV test voltage shall be applied for the voltage withstand test of other
insulation parts, viz. the insulation parts of the frame, flitch plate,
supports, bolts etc.
2.2.11 Take care of the packets of the core sheets cut the size during the
storage and transport. The packets shall be protected against humidity,
dust, contamination of various kind and high mechanical stresses. Only
Page 9 of 192
one packet is allowed to be put on the other during the storage. The
edges of the packets shall be aligned. Do not put packets on each other
during the transport.
2.2.12 If the core has no iron cushions ensuring the standing stability,
preliminary supports shall be provided under the bottom frame.
2.2.13 After erecting the core fit all the fixing elements of the connections not
fitted onto the frame to make easy the stacking. The defected areas of
painting shall be repaired.
2.2.14 Should enough lifting capacity be available the cores of maximum 400
kN total weight can be made on this turnable device.
NOTE:
If the weight of the complete core (+frame) is more than 250 kN check
whether the resultant median of the relevant core and the turning device
is not outside of the rolling path when the core is erected. The resultant
median shall be maintained inside the rolling path in order to avoid the
additional pull of the crane in the last phase of erection.
2.2.15 The core must be considered to be completed if all the fixing elements
of the connections, either those are welded or screwed, the holes, the
winding clamps are provided, the frame is painted, the screws and nuts
are locked, all the dimensions are checked, the voltage withstand tests
and the preliminary measurements of the no-load loss are performed.
Page 10 of 192
2.3 Core building
2.3.1.1 Set the position of the two I-beam supporting the top and bottom
frame beams on the turnable device to the frame beams so as these
shall be – as far as possible – in the middle line of the two windows
of the trhee-limb core. (See Figure 1)
2.3.1.2 Set the base plates of the screw-type lifting suporting the limbs in the
middle line of the limbs. Put the lifting legs preliminary on these. (See
Figure 2)
Page 11 of 192
Figure 1
2.3.2 Measure the width of the boom plate at the palces where the boom
plates of the top and bottom frame beams seat on the supporting I-
beams.
Make the selection of insert plates to be put on the I-beams for levelling
according to the dimensions measured. The web plates of the frame
beams seated on the insert plates shall be leveled co-planar and parallel to
the turnable device and to the boom plates of the I-beams seated on it
respectively. (See Figure 2)
2.3.3 Put the insert plates selected on the I-beams where the frame beams
will be seated. Tighten the fixing screws slightly.
Page 12 of 192
2.3.4 Put the top and bottom frame beam provided with holes for fixing the
master plates of stacking on the I-beam seated on the turnable device.
Take care of seating the bottom plates of the frame on the insert plates.
(See Figure 2)
Bore holes in the beams for fixing the master plates of stacking if those
are not made. The holes shall be made only in the top and bottom
beams at the side being more suitable for stacking.
Figure 2
2.3.5 Fit the master plates of stacking on the beam bridging the top and
bottom frame beams. Take care of keeping the master plates clear of the
screw-type lifting supports.
Page 13 of 192
2.3.6 Screw the bridging beams fitted with the master plates of stacking to the
frame beams. Put the spacers of U-beams on the bridging beam so as so
to make the fitting of the glass-fibre easy.
2.3.7 Insert home the claws of the flitch plates in the cutouts of the web
plates of the frames. The inner edges of the claws shall be in contact
with the edges of the cutouts. (See Figure 3) Measure the distance
between the top and bottom frame beams and check whether those are
parallel and co-planer. Should any deviations occur, correct them by
means of insert plates. Use water level for checking. The full surface of
the claws shall be in contact with the rim of the cutout.
2.3.8 Assemble the iron cushion to the bottom frame beam with the relevant
insulating sheets and stepped wood supports matched to the steps of
the bottom yoke. If the core steps project more from the bottom boom
plate of the frame than it is given by relevant drawing put additional
adjusting plates between the frame and the iron cushion. The number
and thickness of the plates shall be chosen according to the measured
projection. The diameter of the through hole shall be fitted to the size of
the screw. (See Figure 4)
Page 14 of 192
NOTE:
The total thickness of the adjusting plates fitted at each place shall not be
over 5 mm. Should be more total thickness of plates required, check the
dimensions of the steel structures. Compare the dimensions to the ones
given in the drawing. If no deviation can be stated considering also the
permissible tolerances a verification is required whether the transformer
construction enables the application of additional adjusting plates.
2.3.9 Set the position of the turnable device, when it is assembled but not
fixed by screws, the frame and the iron cushion so as to have 5 mm gap
between the iron cushions and the truning base. After setting check the
distance between the frame beams and the matching of the claws of the
flitch plates and all the important dimensions. Use water level for
checking whether the components are co-planar. Adjust the setting in
accordance with the stated deviations of dimension if necessary.
Page 15 of 192
2.3.10 After the final setting the following parts shall be firmly fixed:
2.3.10.1 2 pcs I-beams supporting the frame to the T-slots of the turnable
device. (see Figure 1.)
2.3.10.2 The bases of the 3 pcs screw-type lifting supports under the core
limbs to the T-slots of the turnable device.
2.3.10.3 The screw-type lifting supports to the base. The stiffening flat steel
of the bridging pieces of the master plate shall be supported by the
knurled heads of the screw-type lifting supports. (See Figure 5)
2.3.10.4 The iron cushions to the bottom frame beams. (See Figure 4) Use
nivelling plimmet for checking.
Page 16 of 192
2.3.10.5 Bridges of the master plate to the top and bottom web plates of the
frame. If the length of the bridge can be adjusted, tighten also the
screw fixing the length. (See Figure 6)
2.3.10.6 Bridges of the master plate to the top and bottom web plates of the
frame. If the lenght of the bridge can be adjusted, tighten also the
screws fixing the length. (See Figure 6)
2.3.11 Dismantle the turning base and put aside.
2.3.12 Fit the insulating plate of the frame and the flitch plate and the stepped
wood supports. Whenever the insulating plate of the flitch plate is butt
jointed or its width exceeds the width of the flitch plate with less than
5 mm put additional insulating pressboard of 1 mm which has
overlapped joint and width exceeding the flitch plate by 10 mm at each
side. Check always the dimensions of the insulating parts and be sure
that the adequate creepage path for 2 kV is avaiable. Protect the
insulating parts always against humidity because the wet insulating
material can not withstand the test voltage.
Page 17 of 192
Page 18 of 192
2.3.13 Arrange the racks around the turnable device corresponding to the
layout of the core sheets. Put the adequate number of the core building
and the positions of the workers during the stacking are shown in Figure
7. The core sheets of the 2-3 smallest bottom core steps shall be
distributed in two half and put on the rack side by side in order to avoid
the lability arising from the wider and wider steps on each other. (See
Figure 8/a. and 8/b.)
NOTE:
The core sheets shall be distributed in accordance with the layout and
arranged in due sequence. The adequate number of the core sheets shall
be delivered for stacking on the racks. If the step height of the sheets
cut as many is specified in the drawing, is less than required, additional
sheets shall be cut.
If the core thickness is less, put the additional sheets in the widest step
in the middle, then in the smaller steps. Keep always in mind that the
core steps shall not project over the core circle. If the core thickness is
more, remove the sheets from the smallest step, the proceed towards
the wider steps. The correction of each step is not recommended, not in
any case and form.
Page 19 of 192
The arrangement of the core sheets around the turnable device can be
made also in other chronological order, e.g. also during the assembly of
the turnable device. In any case the core sheets shall be easy to handle
and next to the core as close as possible.
2.3.14 Make the stacking of the core sheets as given in the drawing. After
making the first some steps check the dimensions, the matching and
right angles at the corners. If the core is divided put the distance pieces
of bakelite in the gap between the two sections after making the thrid-
fourth step. Put bakelite laths of 50-60 mm width also at the corners of
the divided core in order to make the core building more reliable and
easy. (See figure 9) during the stacking the core sheets shall be
contacted also to these. When the core is finished remove these laths.
Page 20 of 192
The gap between the edges of the joining sheets of the limb and the
yoke shall be minimum. In any case avoid the overlaping of the co-planar
sheets with careful stacking. After fitting the sheets of the core steps
contact them to the bakelite plates between the two halves of the core
section. For this tap the core sheets home with soft copper or cloth-base
bakelite plate. Never use iron plate. (See Figure 10.)
The deformed adjusting plates shall be renewed if necessary.
2.3.15 Put the insulating sheets, if any, in the places of the core section as
shown in the relevant drawing. After stacking 15 mm core lamination
check each insulating sheets by means of 500 V insulation tester. The
core limbs shall be preliminary insulated from the master plates of
stacking by means of 0,5 mm pressboard to enable the performance of
the voltage withstand test on the insulating sheets between the steps.
The soundness of this pressboard shall be maintained in order to make
possible the repetition of the voltage withstand test before removing the
master plates.
2.3.16 Put the spacers of the oil ducts in the core where it is specified in the
relevant drawing of the core. The operations of making the oil ducts shall
comply with the Process Specification No. TTFO/18.
2.3.17 When the core stacking is finished remove the preliminary distance
pieces from the gap of the divided core.
2.3.18 Put the wood supports fitting to the steps of the top and bottom yoke in
final position and slip home the insulating sheets of the frame and the
flitch plate respectively. Should the wood support misfit trim them
accordingly if necessary.
2.3.19 Put the flitch plates and the top and bottom frame beams on the core.
The bolt (or bridging support) clamping the yoke shall be fitted in the
frame on the turnable device prior to fitting the top frame. Attention!
After fitting the yoke bolt (or bridging support) its insulation can not be
Page 21 of 192
fitted any more. Take care of the proper contact between the claw of the
flitch plate and the rim of the cutout of the frame.
2.3.20 Assemble the top bridges onto the top beams of the frame and the iron
cushion onto the bottom beams. Fit the bolts connecting the top and
bottom beams and tighten the nuts.
2.3.21 For gluing the core edges put the U-beams on the flitch plates. Assemble
the preliminary calmping frames on the core-limbs and tighten their bolts
slightly just to fix them. The gluing of the core shall be performed
according to the Process Specification TTFO/30. (See Figure 11.) the
clamping forces shall produce 15 N/cm2 pressure on the surface of the
widest sheet.
2.3.22 Apply the glue at the places as follows:
a) Edges of the limb sheets on both side

b) Edges of the sheets of the bottom yoke on the side of the window and
on the side of the iron cushion where ready to hand.
Attention!
Do not apply glue on the limbs along a section of 100 mm under the top
yoke.
Do not apply glue on the top yoke in order to enable the removal of the
yoke sheets.
2.3.23 Leave the glued core rest to allow the glue setting in accordance with
the instruction for use of the glue. Put paper sheets on the base plate to
stop the draining glue entering the threaded holes of the base plate.
2.3.24 Dismantle the preliminary clamping frames, the pressing beams and the
master pieces from the glued core.
2.3.25 Put the core lathes around the core-limb. Take care of proper fitting.
Fasten the lathes preliminary to the core-limb along the periphery where
the fitting of the glas-fibre bandages are not in the way.
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2.3.26 Fit the glas-fibre bandages on the core. The screws shall be tightened
with the torque specified by the Transformer Design Department
according to the Process Specification TTFO/19/A. Use torque spanner.
Page 23 of 192
2.3.27 Assemble the beams fixing the finished core to avoid falling when the
device is erected. For fixing fit the attached T-bolt in the T-slot of the
frame.
2.3.28 Assemble the turning base onto the turnable device.
2.3.29 Remove all the tools and other parts not fixed from the turning device.
Keep in mind that the hard metal pieces (tools) can damage the core if
they fall. The damaged edges of the core sheet can cause short circuit in
the flux path and the core can be burned locally. Due to these the no-
load loss of the transformer increses. The same trouble is effected by the
high burrs of the sheets.
2.3.30 Turn the device with the fixed core. After the erection fix the angle type
supports of the device.
2.3.31 Hold the beams fixing the core against falling by means of the crane,
remove the nuts from the T-bolts, then the fixing beams.
2.3.32 Hold the core with the crane, the lift it from the device.
2.3.33 Dismantle the beams of the master pieces. Lock the screws excepting
those around the top yoke, because here the clamps will be
disconnected from removing the yoke lamination.
2.3.34 The finished core shall be checked by the Quality Control Department.
2.4 Labour safety
2.4.1 Use palm protecting glove during stacking.
2.4.2 The corner of sheet stacks shall be provided with protective fittings.
2.4.3 Proper lighting shall be ensured.
Page 24 of 192
2.4.4 During the preparation and the application of the glue the use of rubber
glove is obligatory.
2.4.5 The glue must be removed without delay from the skin by flow of
lukewarm, soapy water.
2.4.6 The voltage withstand tests shall be carried out in conformity with the
instructions below:
a) The core shall be ringed around for the time of testing and one person
shall stand over.
b) Warning plate shall be provided.
c) During testing only the persons performing the test shall remain at the
core ringed around.
This Specification refers the following Process specification.
TTFO/18/A Manufacture of oil duct

TTFO/19/A Fitting of glas-fibre bandages
TTFO/30 Gluing of cores
Page 25 of 192
APPENDIX 1.
2.5 Tolerances on core
a) Tolerances of core sheet dimensions

Ranges of Tolerances of sheet Tolerances of sheet
dimensions length widht
(mm) (mm) (mm)
50 - 120 ± 0,3 ± 0,4
120 - 315 ± 0,4 ± 0,7
135 - 800 ± 0,5 ± 1,0
800 - 1600 ± 1,0 ± 1,5
1600 - 3150 ± 1,5 -
3150 - 5000 ± 2,0 -
b) Tolerances of the cores when clamped

Core circle diameter Tolerances of
upto diameter thickness
(mm) (mm)
80 ± 1,5
100 ± 2,0
200 ± 2,5
300 ± 3,0
400 ± 3,5
500 ± 4,0
600 ± 4,5
700 ± 5,0
800 ± 5,5
900 ± 6,0
1000 ± 7,0
Above 1000 ± 8,0
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c) Tolerance of core weights: +4%
-0%
d) Permissible gap between the sheet edges:

Maximum 2 mm parallel gap is permissible. (See Figure 12.)
The maximum number of parallel gaps is 30% both in limb section and
yoke section.
Permissible gap due to angular deviation, measured at the outer edge is

maximum 3 mm. (See Figure 13.) The maximum number of gaps due to
angular deviation is 15% both in limb section and yoke section.
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Permissible gap due to the parallel and angular deviation, measure at the
outer edge is maximum 4 mm. (See Figure 14.) The maximum number of
gaps due to the parallel and angular deviation is 15% both is the limb and
yoke section.
The maximum number of gaps of all three types at the same time is 35% both
in limb and yoke section.
Page 28 of 192
3 Assembly of core clamping
Subject: The assembly of one and three phase transformers
Purpose: Pre matching of the core wooden slats in order to avoid the planning and
burnishing on the ready made core in the assembly hall.
Description of the operation:
After the checking of the dimensions of the stacked core, the temporary
pressing elements (300-350 mm distance from each other) are to be
mounted and the core is to be stood upright. Keeping the limbs in upright
position by crane, the edges of the core are to be lacquered. After this the
temporary pressing elements are to be tightened.
After the drying of the lacquer the slats are to be mounted on one of the
limbs and fix them on 2-3 places. The dimensions of each slat are to be
measured diagonally by compasses. The measured values are to be
compared to the dimensions indicated on the drawing. The measured
dimensions shall be less by 2 mm than the internal diameter of the winding
cylinder as indicated on the drawing.
The measured plus shall be indicated on each slats and passed to the
insulation material (carpentry) workshop for machining the indicated plus.
After this correction, the slats are to be mounted and the dimensions are
to be checked.
The bandages are to be mounted and the core shall be handed over to
assembly workshop.
Page 29 of 192
4 Potential ring body manufacturing
Subject: Base body manufacturing for potential ring with alu-crape paper
shielding
Purpose: Determine the technology and the sequence of operations
Tools
• hot air circulating drying oven
• circle-cutting shears
• belt saw
• lathe
• drilling machine
• drawing table
• pressing machine for gluing
• joiner hand-tools
• measuring tape, calliper, micrometer
• compasses, ruler
• vessel for adhesive and lacquer
• brush
4.1 Preparation of the parts of the body
The rings and segments shall be cut from hard pressboard sheet in that way
that the inner diameters are smaller by 30 mm and the outer ones are larger by
30 mm than it is given on the drawing.
The form of the segments shall be made with the use of a pressboard pattern.
The rings shall be cut with circle-cutting shear; the segments shall be cut by
belt saw. The burrs shall be removed after cutting by knife.
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4.1.1 At the construction of the ring form body, the followings shall be
considered.
• The top and bottom layer shall be made from closed rings with
equal thickness
• If possible the thicknesses of the segments shall be the same as the
outer layers. The deviation can be as small as possible.
• To allow the preparation on circle-cutting shear, the thickness of the
layers can be maximum 4 mm.
• The outmost layers must not less than 3 mm.
• Between the two closed outer ring, the number of the layers made
from segments can’t be more that 3. If the numbers of layers are
more than 5, an additional closed ring shall be built in.
• The construction always shall be symmetrical.
• If the thickness, v ≤ 7 mm, the body shall be constructed from one
layer.
• In case of 8 ≤ v ≤ 14 mm, two equal closed layers shall be used.
Example: v = 18 mm thick body construction
x = closed ring
4.1.2 Determination of the dimension of the segments.
Depending on the diameter of the ring, 60° or 90° segments shall be

manufactured.
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Dk ≤ 1000 mm α = 90° s = 1,41 x R
Dk > 1000 mm α = 60° s=R
Dk – the outer diameter of the potential ring

Db – the inner diameter of the potential ring
The dimensions of the segment or ring to be cut:

R = Dk / 2 + 15 mm
r = Db / 2 + 15 mm
H = R – r + r (1 – Cos(α/2))
In order to make economical the use of sheet material, the arrangement of
the segments on the sheet to be cut, shall result a material use for one
segment smaller than H.
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4.2 Gluing
The adhesives are to be used:

• Kazein (ARTISTAN NR. 120) FROM Weidmann
• Rubersol 204
The building shall be made in glue press. It shall be started with one of the
outer closed ring. The outer layer on one side, the inner layer on both
sides shall be spread by adhesive continuously and smoothly.
If more potential ring body is manufactured in the same time with the
same dimensions, paper handled with paraffin shall be mounted between
the different bodies as separator.
Special care shall be taken for the setting of the adhesive. Depending on
the potential ring dimension, the applying of the adhesive and the
assembling of the ring shall be performed by 2-3 workers, and then
immediately shall be pressed the glued, assembled stack.
The sliding of the layers shall be avoided, if necessary with the use of
temporary side supports.
The segments of the different layers shall be mounted overlapped.

The segments of the same layers shall be fit with butt-joint.
The shifting of the butt-joint in different layers:

a. 90° segments in case of 2 or 3 layers
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b. 60° segments in case of 2 or 3 layers
Example:
Arrangement of overlapping of the fits of a ring having 5 layers (2 closed

ring and 3 segmented)
The pressing sheets must be parallel.

The press shall be kept on the ring for 24 hours on room temperature.
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4.3 Drying
The rings shall be mounted on plane surface, between the rings spacers
shall be applied before starting the drying.
In case of drying in hot air circulating oven the parameters are the
followings:
T = 72 hours
t = 100 - 105 °C
If the drying is cancelled by opening of the oven for a short time, the
duration shall be extended for 96 hours.
4.4 Machinery
After finishing the drying, a ring can be taken out from the oven if the
immediate starting of processing is ensured. At the same time so many
rings can be taken out, than the machinery of all of them can be finished
18 hours.
The additions shall be removed; the final dimensions and radiuses shall be
set by lathe machining.
For the dried and ready formed ring, the acceptable tolerances of the
thickness (v) are the followings.
Thickness [mm] Tolerance [mm]
v≤7 ±4
+ 0,7
8 ≤ v ≤14
- 0,5
+ 1,0
15 ≤ v
- 0,6
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The thickness is over the tolerances the additions shall be machine off. If
the additional thickness to be removed is larger, in this case the machining
of shall be done on both side.
After finalizing the dimensions and radiuses, can be started the performing
the other forms (boring, channel …).
All the edges and burrs coming into being during machinery shall be
removed by emery cloth and file. The final form radiuses shall be smooth
and homogeneously transition.
4.5 Varnishing
The ready made, checked ring shall be put to hot air circulating oven for
48 hours on 100 – 105 °C temperature.
The dried ring cooled back to room temperature shall be coated by
synthetic, polyurethane lacquer (Synthine AC-41).
The setting time is 24 hours on room temperature.
For drying, between the rings mounted horizontally shall be applied
spacers covered by foil.
4.6 Storage
The rings are waiting for the further processing, must be stored in dry
condition, horizontally. They must not be stored hanging position or leaned
against the wall in order to avoid deformation.
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The rings having the same dimensions can be placed on each other
without spacers.
4.7 Quality Control
The following things shall be controlled.

• the drying accordance to the rules
• The inner and outer diameter of the ring after lathe machining and
drying before varnishing
• The smooth and homogeneously transition of radiuses
• Smooth and consistent lacquer
4.8 Safety rules and environmental protection
No special rules shall be taken into consideration beyond the general rules
valid for the workshops and machines.
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5 Pre- and final gluing of the pressboard cylinder
Subject: Pre- and final gluing of the dried pressboard cylinders during cylinder
manufacturing process
Purpose: Prescribe the sequences of the operations and the relevant technical
parameters of the process
5.1 Tools
• Hot-plate glue press (VERMONT Ltd.)
• Lower and upper pressing piece – Ø 350 – Ø 750
• Lower and upper pressing piece – Ø 750 – Ø 1500
• Lower and upper pressing piece – Ø 1500 – Ø
• Metallic measuring tape – 5 m
• Clamping tool – Attachment 1 / I
• Clamping tool – Attachment 1 / II
• Clamping tool – Attachment 1 / III
• Ball pen
• Red crayon
• Cylinder support screw frame
5.2 Schematic drawing of the pressing machine
Figure 1
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5.3 Control board of the pressing machine
Figure 2
Pos. 1 Temperature control with indicator

Pos. 2 Switch on button, black
Pos. 3 Switch on lamp, white
Pos. 4 Emergency stop button
Pos. 5 hydraulic motor switched on indicator lamp, green
Pos. 6 Hand operation indicator lamp, yellow
Pos. 7 Foot operation indicator lamp, blue
Pos. 8 Open stage of presser indicator lamp, red
Pos. 9 Close stage of presser indicator lamp, red
Pos. 10 Heating on indicator lamp, white
Pos. 11 Holding at a temperature indicator lamp, green
Pos. 12 Heating up indicator lamp, red
Pos. 13 Switch for starting the hydraulic motor
Pos. 14 Change-over switch between hand and foot operation
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Pos. 15 Change-over switch between batch and continuous moving os
the pressing piece
Pos. 16 Opening the presser button, black
Pos. 17 Closing the presser button, red
Pos. 18 Starting the heater switch
Pos. 19 Lowering the lower pressing piece starting button, black
Pos. 20 Rising the lower pressing piece starting button, red
5.4 Function between the cylinder length and the hydraulic pressure
It is shown on the figure 3. The pressure is shown by Pos. 21 voltage

indicator. The setting of the pressure is done by Pos. 22 wheel.
The pressure is given in [bar], the length in [m].
Figure 3
5.5 Cleaning
At every change of shifts, the lower and upper pressing pieces shall be
cleaned by denatured alcohol.
5.6 Setting the pressing machine
After the drying the pressing pieces, the pressing machine shall be
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switched on by Pos. 2.
Pos. 14 is to be set to hand operation.
Presser is to be closed by Pos. 17.
The hydraulic system is to be set to ready for operation by Pos. 13.
Pressure is to be set to 0 by the Pos. 22 wheel.
5.7 Continuous operation
Continuous operation is to be set by the Pos. 15

The lower moving pressing piece is to be raised up to the upper fix
pressing piece by Pos. 20. At the moment of contacting, the moving is
automatically stopped.
5.8 Setting the heating temperature (0 - 70 °C) on the temperature

control board (Figure 4).
Figure 4
For the pressing of the SET button, the actual temperature is shown. With
the temperature rising button 55°C shall be set, and then with the pressing
of SET button, it shall be fixed. After this the actual temperature is shown
on the indicator. If we press the SET button for 2 seconds, the set
temperature is shown for a short time, and stepping back to the actual.
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5.9 Heating up
Heating up is to be switched on by the Pos. 18.

The upper fix pressing piece is heated only; the lower part is getting heat
through conduction of heat. It takes around 2-2,5 hours.
The cycle of heating up shall be kept strictly, just after finishing the cycle
can be started gluing of the cylinders.
5.10 Pre-gluing
The dried, milled cylinder surface shall be smeared by casein according to

Figure 5.
Figure 5
After smearing, the cylinder shall be pressed according to the attachment

1, taking care on the fitting of the marking. After this a 15-20 minutes
holding period is coming.
5.11 Moving
The milled edges of the cylinders are made from two halves shall be
pressed and fixed by a clamping tool, in this way the cylinder can be
moved by crane (attachment 1).
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5.12 Lower pressing piece are to be moved down by Pos. 19. Presser is to be
opened by Pos16. If the diameter of the cylinder is more than Ø 800 mm,
than the cylinder support screw frame shall be assembled according to the
attachment 2.
5.13 The clamping is to be removed from the glued part.
5.14 The pressboard cylinder is to be place to the pressing machine, so the red
arrow on the fix piece is at the half length of the cylinder.
5.15 The presser is to be closed by the Pos. 17. The lower pressing piece is to
be moved up by Pos. 20, so the cylinder is pressed.
5.16 Final gluing
The hydraulic pressure is to be set based on the diagram of figure 3 by the

Pos. 22.
The time of the gluing process is ¾ - 1 hour.
5.17 During the gluing process, the next cylinder is to be prepared.
5.18 Being over the gluing period, the lower pressing piece is to be lowered, the
presser is to be opened, and cylinder is to be removed from the machine.
5.19 The bulges of the inner and outer cylinder surface are to be milled off.
5.20 Checking: The QC shall check the diameter, the length and the milling of
the cylinder.
5.21 Safety: The moving of the cylinders at the hot pressing machine shall be
done using glove. The cylinder is heavier that 50 kg, shall be moved by
crane.
5.22 Fire protection: The smoking and use of open flame are prohibited during
working with denatured spirit.
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Attachment 1
Clamping tools
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Attachment 2
1 Pressboard cylinder
2 Guiding sheet
3 Nut for moving
4 Spanning spindle
5 Fixing
6 Gluing press upper part
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6 Disc windings with turn over technology on
horizontal machine
Subject: Technological instructions of manufacturing the disc windings on

horizontal winding machine with turn over winding technology.
Purpose: Putting down the sequence of manufacturing and operations.
6.1 Assembling the core cylinder on the winding machine
6.1.1 Checking the core cylinder
Directly after drying, check the soundness of the pressboard core cylinder
visually.
Measure the circumference, length and wall thickness of the cylinder using
measuring tape.
6.1.2 Choosing the mandrel
Measure the circumference of the adjustable-diameter wooden-rib

mandrel. Ensure by choosing the proper mandrel that the distance
between two consecutive ribs can not exceed 100 mm when the mandrel
ribs are pressed to the inner surface of the core cylinder.
Check the technical condition of the mandrel.
6.1.3 Moving the mandrel and the core cylinder to the place of preparation
(See Figure 1)
Make free area for preparation works close to the winding machine. Cover
the floor by wrapping paper, call the crane and prepare the lifting hemp
ropes. Fasten the core cylinder to the crane. Lift it up, move it to the
preparation area and put it on the wrapping paper. Unfasten the crane.
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Move the crane to the mandrel store, fasten the chosen mandrel on and
change the mandrel position from vertical to horizontal. Modify the
fastening suitably and move the mandrel to the preparation area. During
lowering the mandrel on the floor, put a roller having a diameter of 100
mm under that at 1/3 length distance measured from the threaded end of
the shaft.
Figure 1
Core cylinder and mandrel
6.1.4 Assembling the core cylinder on the mandrel (See Figure 2)
Adjust the outer diameter of the mandrel up to 50 mm smaller than the

inner diameter of the pressboard core cylinder. The mandrel diameter shall
be adjusted by means of the central nut on the threaded shaft extension.
Fix the mandrel ribs by ratchet belt. Lift up the core cylinder by hand or by
crane if it is needed by the weight or the dimensions. (In case of using
crane, lifting hemp rope shall be put around and fixed at the end of the
cylinder.)
Pull the core cylinder on the mandrel as far as the roller. Lift up the
mandrel at the clutch disc end and slip it into the core cylinder carefully
until the threaded end of the mandrel shaft get out from the cylinder.
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Figure 2
Pulling the core cylinder on the mandrel
6.1.5 Lifting and fixing the mandrel in the winding machine (See Figure 3)
Fasten the crane to the two ends of the mandrel. Prop the ropes to the
ends of the mandrel ribs to avoid any damage caused on the core cylinder
by the rope.
Lift the mandrel with the core cylinder in the winding machine. Fit the
clutch disc end of the mandrel to the disc of the machine by pilot. Adjust
the threaded end of the mandrel to the tailstock and set the position of the
tailstock by the gear bar. After pressing it by the handwheel to the end of
the mandrel, fix the tailstock by screws. If rings are needed in the winding
(e.g. angle rings), the rings shall be pulled on the spindle of the tailstock
before lifting the mandrel in the winding machine.)
6.1.6 Expanding the mandrel to the inner surface of the core cylinder
Adjust the core cylinder on the mandrel. Loose the ratchet belts around
the mandrel ribs. Put an extension tube on a lug of the central nut at the
threaded shaft end. Prop the extension tube up. Start the turning of the
machine in the proper direction.
During expanding the mandrel ribs to the inner surface of the core
cylinder, align the ends of the ribs by beating.
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The inner surface of the core cylinder must seat on the outer surface of
the ribs perfectly.
Figure 3
Mandrel and core cylinder in the winding machine
6.1.7 Using relief tube (Relieving the core cylinder)
If it is required by the thickness of the core cylinder or the distance

between the mandrel ribs, relief tube shall be used between the cylinder
and the ribs. The relief tube is a pressboard split cylinder having 2-3 mm
smaller outer diameter than the inner diameter of the core cylinder and
about 100 mm extension over the core cylinder height.
Pull the relief tube in the core cylinder by hand, then assemble the core
cylinder on the mandrel according to 6.1.4.
6.1.8 Assembling the extension tube
If the height of the winding without pressing is larger than the length of
the core cylinder, lengthen the cylinder by added extension tube. The
extension tube shall have the same cross section as the core cylinder. The
sum of its and the core cylinder heights shall exceed the height of the
winding without pressing by about 50 mm.
The extension tube shall be pulled on the finishing end of the mandrel, and
tightly fitted to the core cylinder during assembling the core cylinder on
the mandrel. Further actions are in accordance with 6.1.6.
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PROPOSAL: To make easier the selection of the proper mandrel, use
identification marks on each mandrel and determine the dimension range
within which they can be applied.
NOTE: The operations written above are related to wooden mandrels.

In case of metal mandrels, fixing of the ribs by ratchet bell and aligning
the ends of the ribs is not needed, of course.
6.2 Assembling the strips and the temporary strips on the core
cylinder
6.2.1 Cleaning the core cylinder
Clean the outer surface of the tight core cylinder using sand cloth. Remove
the accidental impurities. Arrange the folds and deformations. Hoover the
dust from the cylinder, the winding machine and its environment.
Deburr the ends of the cylinder by knife.
6.2.2 Making the marker tape
Measure the circumference of the core cylinder by means of a craft paper

tape. Divide the measured length by the number of the pressboard strips.
The calculated pitch distance shall be marked on the paper tape by a
pencil free of graphite. Wedge shape pinches shall be made at the markers
on one edge of the tape.
6.2.3 Make pitch markers on the core cylinder
Draw an axial base line on the surface of the core cylinder. Location of the
base line shall be chosen so that the strips can seat over the mandrel ribs
as far as possible.
Put the marker tape around and glue one of it ends to the core cylinder.
The first pitch on the marker tape shall start from the base line on the
cylinder surface. Mark the pitches on the cylinder at both the bottom and
the upper end (see Figure 4). Rule parallel lines between the bottom and
the upper pitch marks.
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All marking and ruling shall be made by graphite free pencil.
Figure 4
Marking the pitches
6.2.4 Pulling the axial spacers on the strips
The total height of the axial spacers designed on the same strip shall be
measured and corrected in accordance with the Spacer filling instructions.
Trim one end of the strips to make easier pulling up the axial spacers.
After applying paraffin film on the surface of the strips, pull the axial
spacers on them in the order specified on the drawings.
6.2.5 Mounting the strips on the core cylinder
Fasten twill tapes around the core cylinder at three different places. Two
pieces near to the two ends of the cylinder and the third one at about 300
mm distance from the starting end.
Put the strips with the spacers on the surface of the cylinder under the two
twill tapes near to the ends. (The strips will move to the bottom part of the
cylinder because of the weight of the spacers.) Divide the spacers into two
parts. At 1/3 winding length distance from the starting end, after 1/3
portion of the spacers, put a ratchet belt around the cylinder. Another
ratchet belt shall be placed at about 200 mm from the finishing end. The
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belts shall be tightened so that the strips could not move due to their
weight, but they can be moved by hand.
Adjust the strips on the pitch lines, and tighten the belts. (See Figure 5)
6.2.6 Making and assembling temporary strips
Cut 25-40 mm wide and 400 mm long strips of a 1 mm thick pressboard by

arm shears. Put so many strips together that the total thickness be equal
to the thickness of the main strips. Use 0.5 mm thick pressboard to adjust
the correct thickness of the temporary strips if necessary.
After applying paraffin film on the surface of the temporary strips, put
them on the surface of the core cylinder under the twill tapes in
accordance with the arrangement shown on Figure 5.
Figure 5
Prepared core cylinder for winding
6.2.7 Angle ring substituting cylinders
If angle ring is designed between the strips and the winding, a temporary
pressboard cylinder shall substitute the angle ring during winding process.
The turns shall be wound on the substituting cylinder (see Figure 5).
Cut rectangles from 1.5-2 mm thick pressboard by arm shears. The width
shall exceed the length of the angle ring under the winding by about 20
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mm. The length shall be equal to the inner circumference of the winding.
Put so many rectangles together that the total thickness be equal to the
thickness of the angle ring. Wind twill tape around them rarely. Put the
substituting cylinder on the core surface of the strips and fasten it by twill
tape.
6.2.8 Assembling the wooden supports of the first disc
Fasten a twill tape around the mandrel at the starting end. Put wooden
support under the twill tape at each third mandrel rib. The supports shall
reach over the core cylinder as far as the first disc (about 25 mm from the
end of the cylinder).
Fix the disc supports by ratchet belt.
NOTE: The temporary strips can be used at more winding process.

Having standard dimensions, only the used up strips shall be replaced.
6.3 Adjusting the reel carriages and the stretcher
6.3.1 Adjusting the reel carriages
Locate reel carriage proportionally to the axis of the winding machine and
in line with the starting of the winding.
The distance between the reel carriage and the stretcher shall be minimum
2 meter.
If the winding has more than 8 parallel wires, use a row of reel carriages.
Up to 24 parallel wires apply carriages with 300-500 mm, 500-700 mm and
700-900 mm heights. Because of the steps in the height, these carriages
can be used together without any additional measure. Start the row form
the winding machine by the smallest carriage and close it by the highest
one.
Over 24 parallel wires, further carriages having 700-900 mm height shall
be added to the former row. The increasing height shall be ensured by
putting platforms under the added carriages. The platform dimensions
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shall be chosen considering the needed movement of the carriages parallel
to the machine axis.
6.3.2 Placing the reels on the carriage
Check both the bare and the insulated dimensions of the wires.
Measure the width of the reels and prepare the proper centring sleeves.
Lift up the reel by crane and pull the centring sleeves on the two ends of
the shaft. Place the reel on the shaft bearing considering the winding
direction. Check the unhindered turning of the reel by hand.
Remove the protective packing from the wire.
Figure 6
Location of the reel carriage and the stretcher
6.3.3 Adjusting the stretcher (See Figure 6)
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Arrange the stretcher in line with the starting of the winding.
Loosen the tightening plates of the stretcher. Draw the needed wires off
the reel carriage to the stretcher. Thread them through the tightening
plates in the proper order. Form storeys from the tightening plates if
necessary. Draw the wires to the core cylinder. Tighten the screws of the
stretcher properly.
6.4 Winding manufacturing with whole turn discs
6.4.1 Fixing the wires to the mandrel
Fasten together the parallel wires coming from the stretcher by twill tape.
Bend a loop on the end of the wires. Fix the loop by twill tape. Thread a
hemp rope through the loop and fasten the end of the rope to the mandrel
ribs. Drag the wires on the core cylinder by starting the machine in the
winding direction. Considering the needed length to make the lead, fasten
the wires on the mandrel by ratchet belt.
6.4.2 Winding a turn-over disc
Figure 7
Winding a disc
Wind the material of the disc on the cylinder guiding one turn above the
other. During winding, arrange and upset the disc by using plastic hammer
and beating plate. Check the insulation and repair it if necessary. If
turning-over of the disc could not be performed with the prescribed oil
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channel spacers (e.g. radial spacers or noppenband between the turns),
wind temporary oil channel spacer (strip) in the disc.
6.4.3 Making temporary oil channel spacers
Cut strips from 1 mm thick pressboard. The width of the strips shall be
equal to the width of the wires (height of the disc). Their length shall be
the same as the circumference of the oil channel. To make easier the
work, the strips can be made of several pieces.
Place the pressboard strips together until the taped thickness is equal to
the thickness of the oil channel and bandage them by batiste tape with ½
overlap.
6.4.4 Bending the inner transposition
Fix the turn-over disc by clamp or twill tape. Sign match mark on the
parallel wires, then the place of bending the inner transposition. Use
graphite free pencil. Place of the transpositions shall be between the
consecutive axial spacers in such position that they could not deform the
axial spacer (see Figure 9).
Bend the inner transposition on the parallel wires by special bending tool
(Figure 8) taking into account the height of the wire and the thickness of
the axial spacer.
Figure 8
Bending tools for transposition
Level the occasional deformations by using a plastic hammer and a

levelling block. Remove the damaged insulation by knife and reinsulate the
wire to the thickness of the original insulation by crape paper with ½
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overlap. Each paper layer shall be wound one by one. To wind more layers
simultaneously by putting papers together is prohibited.
Put Z-shape or trapezium spacer on the transposition. Shanks of the Z-

spacer shall be bandaged to the transposition by crape paper.
Thickness of the spacers:
• Z-spacer 1 mm
• Trapezium spacer 0.5 mm or two parallel 0.5 mm
Figure 9
Location of the transposition
6.4.5 Turning the disc over
Arrange the parallel wires together setting them to the match mark. Fasten
the wires together on a length of 100 mm in front of the inner
transposition using crape tape.
Remove the clamp or twill tape from the disc. Lift down and put the turns
on the core cylinder one after the other. Draw the turns apart and then
mount up the disc with the temporary oil channel spacers arranging the
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turns in reverse order. Push the turned-over disc to the axial spacers after
the previous disc (or to the wooden supports, in case of the first disc).
6.4.6 Tightening the wires, upsetting the disc
Tighten the stretcher. Place sliding pressboard sheets under the inner
transpositions. Tighten the disc by operating the winding machine step by
step in the winding direction. During the tightening process, the disc shall
be formed and upset by beating it with a plastic hammer and beating
plate. The disc shall be tightly pressed to the spacers of the previous disc
by axial beating.
6.4.7 Putting the oil channel spacers in the disc
Pick the temporary oil channel spacers out of and put the radial spacers or
the noppenband in the disc simultaneously. Adjust the spacers using fibre
wedge. Take care that the radial spacers be fitted to the axial ones
properly. The noppenband shall be glued to the wire at each 200 mm.
After putting in the oil channel spacers, tighten the disc again, and then
remove the sliding sheets.
6.4.8 Pulling the spacers to the disc, adjusting the temporary strips
Pull the axial spacers to the wound disc considering the prescribed number
and thickness. Arrange the winding material at the bottom transpositions,
and fit them to the spacers.
Adjust the temporary strips in such position that only 3-4 discs can cover
it.
6.4.9 Simply wound disc manufacturing
Adjust the tightness of the wires. Start the machine and wind the disc with
the wires led through at the inner transposition according to the turn
number prescribed on the winding drawing. Oil channel spacers shall be
put in the disc during the winding process. Radial spacers shall be fitted to
the axial ones; noppenband shall be glued to the wire at each 200 mm.
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During winding, form and upset the disc and fit it tightly to the previous
disc as written in 6.4.6.
6.4.10 Bending the outer transposition (See Figure 9)
Fix the simply wound disc. Bend the outer transpositions at the places and
in the direction prescribed by transposition arrangement drawing. Bending,
forming. levelling and insulation shall be made in accordance with 6.4.4.
Arrange the wires having transpositions, place them into the disc and put
Z-spacers under the transpositions. Thickness of the Z-spacer shall be
0.5 mm.
6.4.11 Pulling axial spacers to the disc
See in 6.4.8.
6.4.12 Repeat the actions from 6.4.2 to 6.4.10 until the prescribed number of
the discs is achieved.
6.4.13 Pressing the winding during manufacturing
Figure 10
Pressing the winding during manufacturing
After reaching the disc number determined in the documentation or where

the Quality Control Department requires that, the winding shall be pressed
during manufacturing. The pressing shall be made usually at each 4th-6th
spacer pitch, but minimum four places on the circumference. The pressing
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can be done on the top of the winding (position A) or at the side (position
B), but always in the plain of the winding machine axis (see Figure 10).
Position of the pressing tool shall be ensured by crane on the top or by

support at the side of the winding. Put arched wood spacers between the
winding and the jaws of the press tool. Tighten the jaws by ratchet
spanner. The discs with the axial spacers shall be tightly pressed together.
The winding shall be turned twice round, and pressing shall be applied at
each second pressing place per revolution.
Figure 11
Winding press tool
6.4.14 Finishing the winding process
Fasten the last wound disc at a point by twill tape. Cut the end of the wire
by bolt clipper considering the needed length of the lead. Tie the exterior
four discs together by twill tape at each 4th pitch on both ends of the
winding.
6.5 Winding manufacturing with discs having special half turn
Only the special actions are written here. Others can be found in 6.4.
Wind N+1 turns in the disc according to 6.4.2, where N is the number of
the whole turns.
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Lift the half of the parallel wires in the last wound turn out of the disc.
Draw them apart on the core cylinder. These parallel wires – forming ½
turn – will be mounted in the next disc. See 6.5.5.
Make the inner transpositions on the parallel wires both of the ½ turn
remaining in the disc and the ½ turn lifted out.
Fasten the parallel wires of the two ½ turn together separately on about
100 mm length under the transpositions. Use crape tape.
6.5.3 Turning the disc over
Follow the instruction in 6.4.5, but the ½ turn lifted out shall not be put in
the disc.
6.5.4 Tightening the wires, upsetting the disc
Follow the instructions in 6.4.6. In this case, the tightening is made only
with the half of the parallel wires. Increased care shall be taken that the
wires do not slide on the others; otherwise the wires of the ½ turn lifted
out can loosen.
6.5.5 Simply wound disc manufacturing
Lift the ½ turn from the core cylinder on the transposition coming from the
previous turned-over disc. Adjust the tightness of the wires. Wind N turns
in the disc according to 6.4.9.
6.6 Winding of interleaved discs
6.6.1 Making outer transposition and backward joints
Fix the wound disc.
Cut the backward wires at 3-4 pitch distance from the place of the outer
transposition.
Sign the place of the outer transpositions on the parallel wires.
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Bend transpositions towards the previous disc on the backward wires and
towards the next disc on the forward wires.
Arrange the backward wires in the disc, sign match marks on the wires to
be jointed together, and cut the ends at the marks. Make the joints by
welding or soldering. See paragraph 6.7.
Draw the cut wires back to the reel carriage. Thread them through the
stretcher mixing with the forward wires in the prescribed order. Fix the
bottom and the upper wires to the forward wire by tape under the
transposition.
Guide the forward wires of the wound disc together with the wires fixed to
them on the core cylinder. Put turn-over spacer under the guided wires.
Wind a turn, and then put another turn-over spacer on the other side of
the turn. Wind the needed turns each on the others next to the fist turn.
See 6.4.2.
Other actions are the same as in paragraph 6.4.
6.7 Joining of winding material
Cover the affected area of the winding by heatproof veil before welding
or soldering.
Joining of the rectangular conductors in the winding shall be made by

welding or soldering according to the relevant technological instructions.
Overlapped joint shall be preferred.
6.8 Turning out the leads and fixing the discs
6.8.1 Turning out the leads
Adjust the winding machine to turning out. Mark the place of the bending
on the wires using a graphite free pencil.
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Bend the parallel wires one after the other by the special bending tool (the
same as for transposition bending). Level the occasional deformations by
using a plastic hammer and a levelling block.
Remove the damaged insulation by knife and reinsulate the wire by crape
paper with ½ overlap to the thickness of the original insulation. Each
paper layer shall be wound one by one. To wind more layers
simultaneously by putting papers together is prohibited. The end of the
insulation paper shall be fixed by using the minimum amount of dextrin
glue.
Put and bandage the leads turned out together. Provide the fillers and
make the outer insulation in accordance with the design.
Bend the lead above the winding and fix it to the winding by twill tape.
6.8.2 Fixing the discs by bandage
On the base of the winding drawing or a special request from Quality

Control Department, hemp cord or terylene pipe bandage shall be taken on
the determined discs (usually on the exterior discs at each fourth spacer
pitch).
Put on the disc a pressboard banding having the thickness and number of
layers prescribed on the drawing. Spool terylene pipe side by side tightly
on the pressboard, providing a bandage having thickness of minimum 15
mm. Surface of the bandage shall be covered by glue.
In case of hemp cord bandage, pressboard banding is not used.
6.8.3 Handing the ready winding over
Call the representative of the Quality Control Department to check the

ready winding. Perform the repair actions if required.
Lift the winding out of the winding machine and hand it over to the
assembly workshop.
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6.9 QUALITY CONTROL
The Quality Control Department is obliged to check the followings during the
actions identified with the number of the paragraph related:
Paragraph Parameters should be checked

6.1 Soundness, circumference, length and wall thickness of the core
cylinder. Technical condition of the mandrel.
Location of the core cylinder on the mandrel and seating of the
cylinder on the ribs.
6.2 Cleanliness of the core cylinder. Accuracy of the pitch marks and
parallelism of the pitch lines.
Height and height correction of the spacer columns acc. to Spacer
filling instructions. Arrangement of the main and temporary strips
on the core cylinder.
6.3 Bare and insulated dimensions of the wires.
Location and adjustment of the reel carriages and the stretchers.
Unhindered going of the wires.
6.4, 6.5, 6.6, Distance of the first disc from the end of the core cylinder.
6.7 Compactness of the discs and their tightness to the others.
Dimension and location of the oil channels. Location of the Z-
spacers. Place, form and insulation of the joints.
Tensile strength of the joints tested on random samples.
Proper order of the wires at transpositions.
6.8 Number of the turned out wires. Location and shape of the leads.
Repair of the damaged insulations. Gluing of the prescribed
insulation components. Location, number and fixing of the needed
bandages.
Acceptance By test lamp: proper order of the wires, continuity
tests of the By test carriage: interturn insulation
ready winding Number of the discs, turns and interdisc spacers.
Apply of the prescribed insulation and protection components.
Soundness of the winding after lifting it out of the machine.
Storage.
Control tools:
• 5 m measuring tape
• Slide calliper
• Measuring tape
• Test lamp
• Test carriage
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6.10 SAFETY INSTRUCTIONS
In addition to the knowledge and keeping of the actual general safety

instructions, the worker shall take care of the following special conditions and
risks:
1. During lifting and fixing the lifted assembly, take care of the health of
workers. Loads can be lifted by the bridge cranes up to the load capacity of
the crane. Fixing of the load before lifting can be performed only by trained
and certified workers. The crane operator shall be directed by the worker who
fixes the load or an assigned lifting leader using unambiguous indications.
Take care on the proper loading to eliminate the risk of tumbling down.
Do not stay under the load during lifting, moving or transporting. It is
dangerous.
2. During operation the winding machine is rotating. Using it, keep all safety
instructions related to the rotating machines. Working at the machine in torn
or hanging clothes is prohibited.
Take care on not operating the machine by stepping on the pedal switch
accidentally. Before starting the rotation of the machine, make sure that any
tools or auxiliary (e.g. plastic hammer, beating plate, etc.) are not left on the
top of the winding and the assistant worker finished his action on the other
side.
The operator is obliged to let his production leader know about any failure of
the machine. The production leader is obliged to arrange for repairing. The
operator must not repair the faulty machine.
3. Joining of the winding materials is made by welding or soldering.
Before using the welding apparatus, check if the insulation of connection leads
and plugs is sound, and if the protective earthing is connected properly.
Before welding, care shall be taken to remove all the flammable material from
the affected area. Waste papers and other waste materials shall be removed
without delay.
During welding, use of face shield and other protective things in obligatory.
4. The fire-hazard class of the total workshop area is “C”. All relevant protection
instructions against fire shall be kept.
Smoking is prohibited!
Page 65 of 192
7 Two direction wound disc windings on horizontal
machine
Subject: If winding in “U”-trough is prescribed or the width of a disc is larger than

120 mm, it is practical to manufacture the disc winding by two direction
winding. These windings are usually interleaved having 2, 4, 6 or 8
parallel wires.
Two direction winding technology can be used only if stretchers and reel
carriages can be located on both sides of the winding machine.
7.1 Assembling the core cylinder on the winding machine
7.1.1 Checking the core cylinder
Directly after drying, check the soundness of the pressboard core cylinder
visually.
Measure the circumference, length and wall thickness of the cylinder using
measuring tape.
7.1.2 Choosing the mandrel
Measure the circumference of the adjustable-diameter wooden-rib

mandrel. Ensure by choosing the proper mandrel that the distance
between two consecutive ribs can not exceed 100 mm when the mandrel
ribs are pressed to the inner surface of the core cylinder.
Check the technical condition of the mandrel.
7.1.3 Moving the mandrel and the core cylinder to the place of preparation
(see Figure 1)
Make free area for preparation works close to the winding machine. Cover
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the floor by wrapping paper, call the crane and prepare the lifting hemp
ropes. Fasten the core cylinder to the crane. Lift it up, move it to the
preparation area and put it on the wrapping paper. Unfasten the crane.
Move the crane to the mandrel store, fasten the chosen mandrel on and
change the mandrel position from vertical to horizontal. Modify the
fastening suitably and move the mandrel to the preparation area. During
lowering the mandrel on the floor, put a roller having a diameter of 100
mm under that at 1/3 length distance measured from the threaded end of
the shaft.
Figure 1
Core cylinder and mandrel
7.1.4 Assembling the core cylinder on the mandrel (See Figure 2)

inner diameter of the pressboard core cylinder. The mandrel diameter shall
be adjusted by means of the central nut on the threaded shaft extension.
Fix the mandrel ribs by ratchet belt. Lift up the core cylinder by hand or by
crane if the weight or the dimensions need it. (In case of using crane,
lifting hemp rope shall be put around and fixed at the end of the cylinder.)
Pull the core cylinder on the mandrel as far as the roller. Lift up the
mandrel at the clutch disc end and slip it into the core cylinder carefully
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until the threaded end of the mandrel shaft get out from the cylinder.
Figure 2
Pulling the core cylinder on the mandrel
7.1.5 Lifting and fixing the mandrel in the winding machine (See Figure 3)
Fasten the crane to the two ends of the mandrel. Prop the ropes to the
ends of the mandrel ribs to avoid any damage caused on the core cylinder
by the rope.
Figure 3
Mandrel and core cylinder in the winding machine
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Lift the mandrel with the core cylinder in the winding machine. Fit the
clutch disc end of the mandrel to the disc of the machine by pilot. Adjust
the threaded end of the mandrel to the tailstock and set the position of the
tailstock by the gear bar. After pressing it by the handwheel to the end of
the mandrel, fix the tailstock by screws. If rings are needed in the winding
(e.g. angle rings), the rings shall be pulled on the spindle of the tailstock
before lifting the mandrel in the winding machine.)
7.1.6 Expanding the mandrel to the inner surface of the core cylinder
Adjust the core cylinder on the mandrel. Loose the ratchet belts around
the mandrel ribs. Put an extension tube on a lug of the central nut at the
threaded shaft end. Prop the extension tube up. Start the turning of the
machine in the proper direction.
During expanding the mandrel ribs to the inner surface of the core
cylinder, align the ends of the ribs by beating.
The inner surface of the core cylinder must seat on the outer surface of
the ribs perfectly.
7.1.7 Using relief tube (Relieving the core cylinder)
If it is required by the thickness of the core cylinder or the distance

between the mandrel ribs, relief tube shall be used between the cylinder
and the ribs. The relief tube is a pressboard split cylinder having 2-3 mm
smaller outer diameter than the inner diameter of the core cylinder and
about 100 mm extension over the core cylinder height.
Pull the relief tube in the core cylinder by hand, then assemble the core
cylinder on the mandrel according to 7.1.4.
7.1.8 Assembling the extension tube
sum of its and the core cylinder heights shall exceed the height of the
winding without pressing by about 50 mm.
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The extension tube shall be pulled on the finishing end of the mandrel and
tightly fitted to the core cylinder during assembling the core cylinder on
the mandrel. Further actions are in accordance with 7.1.6.
PROPOSAL: To make easier the selection of the proper mandrel, use

identification marks on each mandrel and determine the dimension range
within which they can be applied.
NOTE: The operations written above are related to wooden mandrels.

In case of metal mandrels, fixing of the ribs by ratchet bell and aligning
the ends of the ribs is not needed, of course.
7.2 Assembling the strips and the temporary strips on the core
cylinder
7.2.1 Cleaning the core cylinder
dust from the cylinder, the winding machine and its environment.
Deburr the ends of the cylinder by knife.
7.2.2 Making the marker tape

pencil free of graphite. Wedge shape pinches shall be made at the markers
on one edge of the tape.
7.2.3 Make pitch markers on the core cylinder
Draw an axial base line on the surface of the core cylinder. Location of the
base line shall be chosen so that the strips can seat over the mandrel ribs
as far as possible.
Put the marker tape around and glue one of it ends to the core cylinder.
The first pitch on the marker tape shall start from the base line on the
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cylinder surface. Mark the pitches on the cylinder both at the bottom and
the upper end (see Figure 4). Rule parallel lines between the bottom and
the upper pitch marks.
Figure 4
Marking the pitches
7.2.4 Pulling the axial spacers on the strips
Trim one end of the strips to make easier pulling up the axial spacers.
After applying paraffin film on the surface of the strips, pull the axial
spacers on them in the order specified on the drawings.
7.2.5 Mounting the strips on the core cylinder
Fasten twill tapes around the core cylinder at three different places. Two
pieces near to the two ends of the cylinder and the third one at about
300 mm distance from the starting end.
Put the strips with the spacers on the surface of the cylinder under the two
twill tapes near to the ends. (The strips will move to the bottom part of the
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cylinder because of the weight of the spacers.) Divide the spacers into two
parts. At 1/3 winding length distance from the starting end, after 1/3
portion of the spacers, put a ratchet belt around the cylinder. Another
ratchet belt shall be placed at about 200 mm from the finishing end. The
belts shall be tightened so that the strips could not move due to their
weight, but they can be moved by hand.
Adjust the strips on the pitch lines, tighten the belts. (See Figure 5)
7.2.6 Making and assembling temporary strips
Cut 25-40 mm wide and 400 mm long strips of a 1 mm thick pressboard by

arm shears. Put so many strips together that the total thickness be equal
to the thickness of the main strips. Use 0.5 mm thick pressboard to adjust
the correct thickness of the temporary strips if necessary.
After applying paraffin film on the surface of the temporary strips, put
them on the surface of the core cylinder under the twill tapes in
accordance with the arrangement shown on Figure 5.
Figure 5
Prepared core cylinder for winding
7.2.7 Angle ring substituting cylinders
If angle ring is designed between the strips and the winding, a temporary
pressboard cylinder shall substitute the angle ring during winding process.
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The turns shall be wound on the substituting cylinder (see Figure 5).
Cut rectangles from 1.5-2 mm thick pressboard by arm shears. The width
shall exceed the length of the angle ring under the winding by about 20
mm. The length shall be equal to the inner circumference of the winding.
Put so many rectangles together that the total thickness be equal to the
thickness of the angle ring. Wind twill tape around them rarely. Put the
substituting cylinder on the core surface of the strips and fasten it by twill
tape.
7.2.8 Assembling the wooden supports of the first disc
Fasten a twill tape around the mandrel at the starting end. Put wooden
support under the twill tape at each third mandrel rib. The supports shall
reach over the core cylinder as far as the first disc (about 25 mm from the
end of the cylinder).
Fix the disc supports by ratchet belt.
NOTE: The temporary strips can be used at more winding process.

Having standard dimensions, only the used up strips shall be replaced.
7.3 Adjusting the reel carriages and the stretchers
7.3.1 Adjusting the reel carriages
Locate reel carriages on both sides proportionally to the axis of the winding
machine and in line with the starting of the winding.
The distance between the reel carriage and the stretcher on the same side
shall be minimum 1.5 meter.
During winding, the reel carriage shall be moved parallel with the machine
axis to ensure that it be located in line with the disc being wound.
7.3.2 Placing the reels on the carriage
Check both the bare and the insulated dimensions of the wires.
Put reels being full of wire on the carriage located at the starting side of
the winding. The carriage on the other side shall be filled up with empty
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reels. The number of the reels shall be equal to the number of the parallel
wires.
Pass the shaft through the reel and pull the centring sleeves on the two
ends of it. Place the reel on the shaft bearing considering the winding
direction. Move the filled reels by crane and the empty ones by hand.
Check by hand the unhindered turning of the reels.
Figure 6
Location of the reel carriage and the stretcher
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7.3.3 Adjusting the stretcher
Arrange the stretchers in line with the starting of the winding on both
sides.
Loosen the tightening plates of the stretcher on the filled reel side. Draw
the needed wires off the reel carriage to the stretcher. Thread them
through the stretcher in the proper order (Figure 6).
7.4 Interleaved winding manufacturing
7.4.1 Temporary storing the winding material of the even disc on the core
cylinder
Draw the needed parallel wires from the stretcher to the core cylinder.
Bend a loop on the end of each wire and fix the ends to the mandrel by
hemp ropes.
Tighten the wires. Wind the material of the even disc on the cylinder
guiding one turn next to the other. Consider the distance between the
stretcher and the winding and the needed length of the lead.
Mark the location of the inner transpositions on the parallel wires using
graphite free pencil. Place of the transpositions shall be between the
consecutive axial spacers in such position that they could not deform the
spacers (see Figure 8).
Bend the inner transposition on the parallel wires by special bending tool
(Figure 7) taking into account the height of the wire and the thickness of
the axial spacer. Level the occasional deformations by using a plastic
hammer and a levelling block. Remove the damaged insulation by knife
and reinsulate the wire to the thickness of the original insulation by crape
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paper with ½ overlap. Each paper layer shall be wound one by one. To
wind more layers simultaneously by putting papers together is prohibited.
Put Z-shape or trapezium spacer on the transposition. Shanks of the Z-

spacer shall be bandaged to the transposition by crape paper.
Thickness of the spacers:
• Z-spacer 1 mm
• Trapezium spacer 0.5 mm or two parallel 0.5 mm
Figure 7
Bending tools for transposition
Figure 8
Location of the transposition
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7.4.3 Odd disc manufacturing (See Figure 9)
Adjust the tightening of the wires by the screws of the stretcher. Wind one
turn on the other in the disc until the required number of turns is reached.
Do not forget to wind the oil channel spacers between the parallel wires or
the turns as it is required by the design. The oil channel spacer can be
noppenband or radial spacer (Figure 10).
Figure 9
Odd disc manufacturing
Figure 10
Oil channel spacers
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Placing the noppenband in the disc:
After reaching the disc height prescribed draw the noppenband between
the wires and wind it in the disc together with them. During winding, glue
the noppenband to the wire under that at each 200 mm. Adjust the
position of the noppenband using fibre wedge.
Placing radial spacer in the disc:

After reaching the prescribed disc height, the radial spacers shall be fitted
on the axial ones between the wires one by one. Position them by fibre
wedge.
Fix the wound disc by twill tape or clamps. Cut the parallel wires
considering the needed length to the lead at the first disc and to the
backward joint at the others.
7.4.4 Making the backward joints (from odd to even disc)
Sign the place of the outer transposition on the proper half of the parallel
wires wound in the odd disc. (The other parallel wires shall be fixed on the
disc. The half of the wires in the next even disc will be connected back to
these wires.)
Bend transposition on the marked wires to the previously made even disc
by special bending tool. Level the occasional deformations by using a
plastic hammer and a levelling block. Repair the insulation if necessary.
Tape the transposition with 1 layer crape paper using ½ overlap.
Sign match marks on the transposed wire ends and the free wire ends of
the even disc putting them together. Cut the wires to the needed end and
make the joint by welding or soldering (see 7.7).
Firstly the innermost wire shall be jointed. The last is the outermost one.
Put the jointed wires into the disc, level the disc by plastic hammer and
beating plate. Put Z-spacers under the upper joints.
Page 78 of 192
Figure 11
Backward joints
7.4.5 Winding the material of the even discs on the empty reels
Loosen the fixing of the even disc material stored on the core cylinder
temporarily. Thread the parallel wires through the stretcher on the side
opposite to the starting of the winding. Operating the winding machine,
spool the wires on the empty reels.
7.4.6 Pulling the spacers to the odd disc, adjusting the temporary strips
Pull the axial spacers to the wound odd disc according to the prescribed
number and thickness. Arrange the winding material at the bottom
transpositions, fit them to the spacers.
Adjust the temporary strips in such position that it can be covered by

maximum three discs.
7.4.7 Even disc manufacturing
Reverse the turn direction of the winding machine. Adjust the tightness of
the wires. Wind the disc according to 7.4.3 and fix it.
7.4.8 Pulling spacers to the even disc
See the instructions in 7.4.6.
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7.4.9 Making the backward joints (from even to odd disc)
See the instructions in 7.4.4.
If special ½ turn is designed in the disc, wind the first turn in 7.4.1 and
the last turn in 7.4.7 with half of the parallel wires.
Repeat the actions from 7.4.1 to 7.4.9 until the designed number of the
discs is achieved.
7.5 Winding in “U”-trough with backward joints
If it is prescribed that a part of the winding shall be wound in “U”-trough,

do the followings:
cylinder
Fix the “U”-trough (usually two pieces) on the core cylinder by twill tape.
Wind the turns in accordance with 7.4.1. Guide the wires at the end of the
last turn into the “U”-trough. In such way the inner transpositions will be in
the “U”-trough.
See in 7.4.2.
7.5.3 Winding the odd disc in “U”-trough
In case of winding in a “U”-trough, “U”-spacers are used instead of the

standard axial spacers. Put “U”-spacers in the ”U”-trough during winding
the first turn. Align the “U”-spacers using fibre wedge and plastic hammer.
Wind the disc in the “U”-spacers in accordance with 7.4.3. Fix the disc,
remove the twill tape, adjust the spacers.
7.5.4 Making the backward joints (from odd to even disc)
Instructions can be found in 7.4.4.
7.5.5 Winding the material of the even discs on the empty reels
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Instructions can be found in 7.4.5.
7.5.6 Winding the even disc in “U”-trough
Put “U”-spacers in the “U”-trough. Wind the disc in the “U”-spacers as in

7.4.7.
7.5.7 Making the backward joints (from even to odd disc)
See in 7.4.4.
7.6 Pressing the winding during manufacturing
After reaching the disc number determined in the documentation or where

the Quality Control Department requires that, the winding shall be pressed
during manufacturing. The pressing shall be made usually at each 4th-6th
spacer pitch, but minimum four places on the circumference. The pressing
can be done on the top of the winding (position A) or at the side (position
B), but always in the plain of the winding machine axis (see Figure 12).
Figure 12
Pressing the winding during manufacturing
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Position of the pressing tool shall be ensured by crane on the top or by
support at the side of the winding. Put arched wood spacers between the
winding and the jaws of the press tool. Tighten the jaws by ratchet
spanner. The discs with the axial spacers shall be tightly pressed together.
The winding shall be turned twice round, and pressing shall be applied at
each second pressing place per revolution.
Figure 13
Winding press tool
or soldering.

7.8 Turning out the leads and fixing the discs
on the wires using a graphite free pencil.
using a plastic hammer and a levelling block.
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Remove the damaged insulation by knife and reinsulate the wire by crape
paper with ½ overlap to the thickness of the original insulation. Each
paper layer shall be wound one by one. To wind more layers
simultaneously by putting papers together is prohibited. The end of the
insulation paper shall be fixed by using the minimum amount of dextrin
glue.

pitch).
7.8.3 Handing the ready winding over

Lift the winding out of the winding machine and hand it over to the
assembly workshop.
7.9 QUALITY CONTROL
The Quality Control Department is obliged to check the followings during the
actions identified with the number of the paragraph related:
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Paragraph Parameters should be checked
7.1 Soundness, circumference, length and wall thickness of the core

cylinder. Technical condition of the mandrel.
Location of the core cylinder on the mandrel and seating of the
cylinder on the ribs.
7.2 Cleanliness of the core cylinder. Accuracy of the pitch marks and
parallelism of the pitch lines.
Height and height correction of the spacer columns acc. to Spacer
filling instructions. Arrangement of the main and temporary strips
on the core cylinder.
7.3 Bare and insulated dimensions of the wires.
Location and adjustment of the reel carriages and the stretchers.
Unhindered going of the wires.
7.4, 7.5, 7.6, Distance of the first disc from the end of the core cylinder.
7.7 Compactness of the discs and their tightness to the others.
Dimension and location of the oil channels. Location of the Z-
spacers. Place, form and insulation of the joints.
Tensile strength of the joints tested on random samples.
Proper order of the wires at transpositions.
7.8 Number of the turned out wires. Location and shape of the leads.
Repair of the damaged insulations. Gluing of the prescribed
insulation components. Location, number and fixing of the needed
bandages.
Acceptance By test lamp: proper order of the wires, continuity
tests of the By test carriage: interturn insulation
ready winding Number of the discs, turns and interdisc spacers.
Apply of the prescribed insulation and protection components.
Soundness of the winding after lifting it out of the machine.
Storage.
Control tools:
• 5 m measuring tape
• Slide calliper
• Measuring tape
• Test lamp
• Test carriage
Page 84 of 192

risks:
dangerous.
instructions related to the rotating machines. Working at the machine in torn
or hanging clothes is prohibited.
accidentally. Before starting the rotation of the machine, make sure that any
tools or auxiliary (e.g. plastic hammer, beating plate, etc.) are not left on the
top of the winding and the assistant worker finished his action on the other
side.
The operator is obliged to let his production leader know about any failure of
the machine. The production leader is obliged to arrange for repairing. The
operator must not repair the faulty machine.
Before using the welding apparatus, check if the insulation of connection leads
and plugs is sound, and if the protective earthing is connected properly.
without delay.
instructions against fire shall be kept.
Page 85 of 192
8 Disc winding manufacturing on vertical machine
Subject: Technological instructions of manufacturing the interleaved windings on

vertical winding machine with turn over or two direction winding
technologies.
8.1 Assembling the mandrel and the core cylinder on the winding
machine, filling up and adjusting the reel carriage
8.1.1 Assembling the mandrel on the winding machine
Make free area for preparation works close to the winding machine. Open
the adjustable opening on the work floor to a diameter 500 mm larger
than the outer diameter of the chosen mandrel. Lower the base plate of
the machine to the lowest position.
Move the mandrel by a crane over the work-floor opening of the winding
machine. Lower it on the base plate. Hollow shaft of the mandrel shall be
pulled on the main shaft of the base plate. When the mandrel is lowered
close to the base plate, the joining parts of the mandrel and the base plate
shall be fitted together. Position the mandrel as required. Lower the
mandrel with its total weight on the base plate.

inner diameter of the pressboard core cylinder of the winding. The mandrel
diameter shall be adjusted by means of the central nut, a special spanner
and proper turning of the mandrel:
• Lift the mandrel to the proper height level.
• Join the spanner on the central nut of the mandrel.
• Prop up the shank of the spanner and fix its end to a fixing point by
hemp rope.
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• Turn the mandrel in the proper direction until the required diameter
is achieved.
During the adjustment, the machine shall be operated by pedal switch at
the lowest turning speed. Care shall be taken to ensure that protruding
parts on the top of the mandrel do not get caught by the spanner of the
adjusting nut.
Assemble the winding supporting consoles on the mandrel ribs:

• Lift the base plate directly below the work floor. In case of a
machine having adjustable work-floor opening, care shall be taken
to avoid the lifting of the covering by the base plate. (In case of
machines with fix work-floor opening this problem can not occur
because of a limit switch.)
• Assemble winding supporting console on each fourth mandrel rib.
(e.g. in case of a mandrel with 32 ribs, console shall be mounted on
the 1st, 5th, 9th, 13th, 17th, 21st, 25th and 29th ribs.) The
consoles shall be fastened by screws in the threaded holes at the
bottom of the mandrel ribs. It is practical to use ratchet spanner for
screwing.
In case of machine with fix work-floor opening (where the base plate could
not be lifted over the work floor), mount wooden raising blocks on the
consoles to ensure that the start of the winding and the lowest position of
the stretcher being near on the same level. In such way, break of the
conductor coming out of the stretcher can be avoided and the action can
be performed much more easily.
In case of machine with adjustable work-floor opening, mounting of the

raising blocks is also practical. However it is not essential, because the
opening can be opened so large that the base plate can be lifted over the
work-floor.
8.1.2 Assembling the core cylinder on the mandrel
Directly after drying, the core cylinder standing in vertical position shall be
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fastened on the crane using clamp vices and moved to the preparation
area.
Check the soundness, the circumference, length and wall thickness of the
cylinder.
Put pressboard spacers on the winding supporting consoles (or on the

wooden raising blocks) and lower the mandrel below the work floor. Lift
the core cylinder above the mandrel and pulling on the mandrel lower it on
the consoles. During the action the clamp vices shall be directed between
the mandrel ribs.
Remove the clamp vices, send the crane away.
If it is required by the thickness of the core cylinder, put relief tube

between that and the mandrel ribs. The relief tube is a pressboard split
cylinder having 2-3 mm smaller outer diameter than the inner diameter of
the core cylinder and about 100 mm extension over the core cylinder
height.
sum of its and the core cylinder height shall exceed the height of the
winding without pressing by about 100 mm. The extension tube shall be
tightly fitted to the upper end of the core cylinder.
Expand the mandrel ribs to the inner surface of the core cylinder by
increasing the mandrel diameter in accordance with 8.1.1.
After finishing the action, put press caps on the adjusting nuts. Fix the
mandrel to the base plate by the special “barb nut” and a locking nut.
8.1.3 Cleaning the core cylinder and marking
dust due to polishing.
Page 88 of 192
Make the marker tape
pencil free of graphite. Wedge shape pinches shall be made at the
markers on one edge of the tape.
Make pitch markers on the core cylinder

Draw an axial base line on the surface of the core cylinder. (In case of
pressboard cylinder the base line shall be drawn at the joint of the
cylinder. In case of bakelized paper cylinder it can be located anywhere.)
Fit the marker tape to the base line. Mark the pitches on the cylinder both
at the bottom and the upper end. Rule parallel lines between the bottom
and the upper pitch marks.
Pull the bottom potential ring (or the substituting wooden or pressboard
ring) on the core cylinder and locate it on the winding supporting consoles.
If potential ring is not designed, the bottom disc of the end-block shall be
pulled on.
The Quality Control Department is obliged to check the followings:

• Circumference, length and wall thickness of the core cylinder
• Cleanness and soundness
• Location and accuracy of the pitch lines
Applied tools:
• Measuring tape
• Slide calliper
8.1.4 Assemble the strips and the temporary strips on the core cylinder
Trim one end of the strips to make easier pulling up of the axial spacers
Page 89 of 192
Put the strips on the surface of the cylinder under twill tapes. The trimmed
end of the strips shall be at the top. Adjust the strips on the pitch marks
and glue them to the cylinder by “Rubbersol” at each 300 mm. Take care
on not moving the strips from the pitch lines during gluing.
Remove the twill tape. After applying paraffin film on the outer surface of
the strips, pull the axial spacers on them in the order specified on the
drawings. It is practical to store the spacers on the upper section of the
strips and to draw only as many spacers to the winding area as they are
required to make 10-15 discs.
Fix a twill tape around the core cylinder at 300 mm height measured form
the bottom end. Put temporary strips under the twill tape between the
main strips. The temporary strips can be made of hardwood or composed
of 1 mm and 0.5 mm thick pressboard strips with changeable thickness.
The Quality Control Department is obliged to check the adjustment and

gluing of the strips.
Applied tool: Measuring tape
8.1.5 Filling up and adjusting the reel carriage
Adjust in line with the stretcher and the mandrel a reel carriage being
designed to hold eight vertical shaft wire reels.
Check the bare and insulated dimensions of the prepared wire.
Put the wire reels on wooden supports on their side (take care on the
winding direction). Bottom of the reel shall be hanged by a four-hook
lifting device. Lift up and move it to the reel carriage. Pulling on the
vertical shaft put the reel on the support disc. Remove the protective
packing and check by hand the unhindered turning of the reel. Repeat the
action until the needed number of the reels is on the carriage.
The Quality Control Department is obliged to check:

• Adjustment of the reel carriage
Page 90 of 192
• Bare and insulated dimensions of the wire
• Free turning of the reels
Applied tool: Micrometer
8.1.6 Make the winding adapters
Big winding adapter (see Figure 1)

Put together pressboard strips having the same width as the wire to
produce a winding adapter. The height at the highest point (h) shall be
equal to the radial width of the winding disc minus the thickness of a wire.
Then it should be reduced gradually by the wire thickness at the location
of each outer transposition.
The length of the adapter (l) shall be equal to the height of four discs plus
the distance which is required by the consecutive transpositions on the
circumference of the core cylinder. After cutting the pressboard strips on
the required size, put them together and tape around by a batiste ribbon
with ½ overlap.
Figure 1
Big winding adapter
Small winding adapter

The small winding adapter shall be made in similar way as the big one. Put
it together from the pressboard strips and tape around. The small adapter
shall have a height equal to the radial width of the fist turn, and a length
equal to two pitches on the core cylinder surface.
Page 91 of 192
8.2 Interleaved disc winding by turn over technology
8.2.1 Adjusting the start of the winding
Draw the needed wires off the reel carriage to the stretcher. Thread them
through the stretcher in the proper order and draw their ends to the core
cylinder.
Mark the length needed to make the lead turn-out on the proper wires (on
the half of the wires), and the position of bending the outer transpositions
on the wires passing into the second disc. Because of welding/soldering
the joints back form the second to the first disc (backward-joints), the
position of the transpositions shall be marked at about 300-500 mm from
the end of the wires.
Put together the parallel wires taking care on the needed length for lead
turn-outs and outer transpositions. Tightly fix them together by twill tape
bandage on a length of about 100 mm. The bandage is used to avoid the
movement of each wire from one another during winding process.
Bend a loop on each wire end and fix them by twill tape.
Fix the wire ends to the mandrel using hemp rope. Adjust the height of the
stretcher and the base plate. Pull down the bottom spacers on the strips to
the potential ring. Put “U”-shape turn-over forks on the potential ring at
each 5th-6th pitch.
8.2.2 Winding the turn-over disc in the “U”-shape forks (see Figure 2 and 3)
Guide the wires being arranged radially into the “U”-forks. Starting from
the outer transpositions, place the big winding adapter under the wires.
Adjust the tightness of the wires, start the winding machine in the proper
turning direction by the pedal switch. Wind the first turn of the disc.
Passing over the big adapter, by means of the small winding adapter
putted on the core cylinder guide the parallel wires down beside the first
Page 92 of 192
turn and go ahead with winding.
Figure 2
Winding the turn-over disc in the “U”-shape forks
Make axial oil channels at the designed disc height by winding noppenband
in the disc:
Figure 3
Winding the noppenband in a disc
Page 93 of 192
• Guide a noppenband tape between the parallel wires or between
the turns, and wind the turn together with it.
• Interrupt the winding process at each 100 mm of the circumference
and glue the noppenband tape to the wire under that radially. (see
Figure 3)
After reaching the designed oil cannel thickness, the noppenband shall be
torn. Winding of the disc shall be continued until the needed turn number
is provided.
8.2.3 Bending the inner transposition (See Figure 4)
Fix the turn-over disc lying in the “U”-forks by using tweezers and clamps.
Mark the location of the inner transpositions on the parallel wires. After
turning the disc over and tightening the wires, the ready transpositions
shall be found between the axial spacers in such position that they could
not deform the spacers.
Figure 4
Bending the inner transposition
Page 94 of 192
The exact location of the transposition bending shall be determined during
making the first turn-over disc. Then a marking tool shall be made. The
transposition marks of the next discs shall be signed by using the marking
tool.
Markings shall be made always with graphite free pencil.
Bend the inner transposition on the parallel wires by special bending tool.
Level the occasional deformations by using a plastic hammer and a
levelling block. Remove the damaged insulation and reinsulate the wire by
crape paper with ½ overlap to the thickness of the original insulation.
Apply paraffin film on the inner surface of the transpositions.
8.2.4 Turning over the disc, tightening the wires, upsetting
Remove the fixing tools from the disc. Loosen the turns by turning the
mandrel opposite to the winding direction. Put the turns on the top of the
“U” forks in reverse order to the winding in the forks (see Figure 5).
Figure 5
Turned over disc on the top of “U” forks
Tighten the stretcher, change the turning direction and slightly tighten the
wires in the disc. Remove the “U”-forks from under the disc. Lower the
Page 95 of 192
disc on the spacers. Place sliding pressboard under the inner
transpositions. Tighten the disc by operating the winding machine step by
step in the winding direction. During the tightening process, the disc shall
be upset by axial and radial beating using a plastic hammer and beating
plate.
Pull the next axial spacers on the turned over disc. (Number and thickness
of the needed spacers is prescribed on the drawings.) Arrange the spacers
at the inner transpositions.
Check the position of the inner transpositions, adjust it if necessary. Put

the prescribed pressboard fillers to the transpositions.
Figure 6
Putting the fillers to the inner transpositions
8.2.5 Simply wound disc manufacturing (see Figure 7)
Adjust the tightness of the wires. Wind the disc according to 8.2.2. It is not
required to fix the noppenband by gluing within the simply wound discs.
During the winding process, upset the disc by axial and radial beating.
Take care on the soundness of insulation and repair it if necessary. Pull the
next axial spacers on the ready disc.
Page 96 of 192
Figure 7
Simply wound disc manufacturing
8.2.6 Making the backward-joints and the outer transpositions
Fix the simply wound disc. Mark the place of the outer transposition on the
forward wires of the simply wound disc and the backward wires of the
turned over disc. (The wires to be jointed backwards and others to go
forwards are identified on the transposition arrangement drawing. The
drawing gives information about making the transpositions between which
spacers.)
Bend transposition on the backward wires of the turned over disc in

accordance with 8.2.3 and put them in the simply wound disc. Sign the
match marks on the wire ends to be welded/soldered (see Figure 8). Cut
the ends to the correct length. It shall be considered during marking, that
the welded/soldered joints shall be arranged in different spacer pitches at
3-4 pitch from the outer transpositions. (In case of twin conductor the two
welded/soldered joints should be in the same spacer pitch. Distance
between the two joint shall be 40-50 mm.)
Lift out from the disc the wires needed to the backward joint and joint
them together by welding or soldering in accordance with the relevant
technological instruction.
Page 97 of 192
Figure 8
Signing the match marks on the wire ends
Arrange the jointed wires in the disc by the proper special tool. Form the
joint by plastic hammer and beating plate. Put pressboard spacer under
the backward transpositions.
Bend the outer transposition on the forward wires and insulate them (see
in 8.2.3).
If the transpositions rise from the cylinder surface of the winding

excessively, the pressboard cubes of the noppenband shall be omitted or
their height should be reduced. To fit to the rated diameter of the disc,
winding pressboard strip in it is allowed.
8.2.7 Changing the order of the wires in the stretcher, fixing the cut wires to
the forward ones
Loosen the stretcher. Draw back to the reels the wires cut because of the
backward joints. Arranging them in the designed order thread those
through the stretcher (see Figure 9).
Page 98 of 192
Figure 9
Changing the order of the wires in the stretcher
Draw the wires through the stretcher to the winding by hand. Fix them to
the forward wires by twill tape before the outer transpositions. During
fitting the cut wires to the forward ones consider the wire length needed to
the next backward joint. (See Figure 10)
Figure 10
Fixing the cut wires to the forward ones
Page 99 of 192
Put “U”-shape fork into each 5th-6th spacer pitch and repeat the actions
periodically until the designed number of discs is achieved.
During winding procedure:

• Take care on the insulation of the wires continuously. Repeat it if
necessary.
• Check the diameter of the discs systematically.
• Beat the axial spacers in line vertically.
• Adjust the position of the temporary strips so, that it can be covered
by maximum 3-4 discs.
• Clean up the wastes without delay.
• The winding shall be lifted/lowered to the level, which makes the
work least fatiguing.
• Markings on the winding shall be done by graphite free pencil.
Quality Control Department is obliged to check:

• tightness of the discs
• radial dimension of the discs
• number of turns
• placing of the noppenband
• number and thickness of the axial spacers
• location of the transpositions and backward joints
• welding/soldering and insulation of the joints
on the wires.
using a plastic hammer and a levelling block. Remove the damaged
insulation by knife and reinsulate the wire by crape paper with ½ overlap
to the thickness of the original insulation.
Page 100 of 192

Above actions shall be performed both at the bottom and the upper end of
the winding.

pitch).
8.2.10 Acceptance tests on the ready winding

Quality Control Department is obliged to check:

• the order of the wires and the continuity by test lamp
• the interturn insulation with the test carriage
• number of the discs and the turns
• number of the axial spacers
• presence of the prescribed insulation and protection components
• the form of the winding, the leads and the bandages visually.
8.3 Interleaved disc winding by two direction technology
cylinder (see Figure 11)
Page 101 of 192

Draw the needed parallel wires from the reels to the core cylinder through
the stretcher. Bend a loop on the end of each wire and fix the ends to the
mandrel by hemp ropes.
Figure 11
Material of the even disc stored on the core cylinder
Tighten the wires. Wind the material of the even disc on the cylinder
guiding one turn under the other. Consider the distance between the
stretcher and the winding.
8.3.2 Making the inner transposition
See the instruction in 8.2.3.
Page 102 of 192

Figure 12
Bending the inner transposition
8.3.3 Odd disc manufacturing
Adjust the inner transpositions between the axial spacers.
Wind the disc in accordance with 8.2.5. Cut the wires, allowing the length
needed to the bottom lead turn-out and the backward joint. Fix the wire
ends on the top of the disc by using twill tape or clamp. The other side of
the cut wires shall be drawn back on the reels.
8.3.4 Even disc manufacturing
Loosen the stretcher. Change the turn direction of the winding machine.
Turning the mandrel slowly, spool back the material of the even disc -
stored on the core cylinder temporarily - on the reels through the stretcher
as it is shown on Figure 13.
Put the spacers on the inner transpositions and adjust them by a fibre
wedge.
Tighten the stretcher. Wind the disc with the required number of turns.
Page 103 of 192

Wind the oil channel spacers (noppenband) in the disc as it is required by
the winding drawing (see 8.2.2).
Figure 13
Spooling the winding material back on the reels
8.3.5 Making the backward-joints and the outer forward transpositions
Fix the even disc by using tweezers and clamps. Mark on each wire
determined by the design documentation (on the half of the wires) the
place of the bending required to the outer transposition of the backward
joints.
Make the backward joints and the outer transpositions according to 8.2.6.
On the forward wires transpositions shall be bended, length of the wires

shall be matched and wires shall be welded/soldered only after
manufacturing the next odd disc.
After putting the welded/soldered wires in the disc, place pressboard fillers
to the transpositions.
If it is prescribed that a part of the winding shall be wound in “U”-trough,

do the followings:
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• Put the “U”-trough on the top of the last disc finished. “U”-trough
consists of two half ring usually. They shall be fixed to the core
cylinder by twill tape.
• Wind the material of the even disc on the core cylinder for
temporary storing according to 8.3.1., but the last turn shall be
wound in the upper part of the “U”-trough. In this way the inner
transpositions will be in the “U”-trough and the odd disc can be
wound directly in the “U”-trough.
• Guide the wires in the “U”-trough by means of an increasing and a
decreasing radial height pressboard adapter made of pressboard
strips.
• Make the inner transposition in accordance with 8.3.2.
• During winding the first turn of the odd disc (the first disc in the
“U”-trough), put “U” spacers in place of the standard axial spacers
and wind the disc in these “U” spacers. When the disc is finished,
remove the twill tape.
• Material of the even disc (the second disc in the “U”-trough) shall be
spooled back to the reels according to 8.3.4. Then it shall be wound
in the “U” spacers within the “U”-trough with opposite turning
direction to the odd disc.
• Make of the backward joint and outer forward transpositions is the
same as in 8.3.5.
• Repeat the actions until achieving the required disc number.
• Turning out the lead and fixing by bandage shall be made according
to 8.2.8 and 8.2.9.
Instructions for quality control are given in 8.2.10.
or soldering.

Page 105 of 192

8.5 Lifting out the finished winding
Lift the winding to the height where changing of the mandrel diameter can
be done. Reduce the diameter of the mandrel by about 20 mm as it is
written in 8.1.1.
Lower the base plate to a height making possible to fix the winding on the
crane from the work floor.
Put on the lifting star four equal length and load capacity ropes assembled
with L-shape lifting hooks. The ropes shall be put on the lifting star in such
a way, that the tightened shanks of the ropes going near to the winding be
parallel to the outer surface of the winding practically.
Move the lifting star over the winding by the crane. Put the four lifting
hooks in the winding area designed for lifting. The lifting hooks shall be
distributed by 90° pitches in line with the relevant spacer columns. To
avoid the damage of the winding, place pressboard spacers between the
horizontal hook arms and the bottom of the winding, and cork between the
winding surface and the ropes or the vertical hook shank.
Fix the vertical hook shanks to the winding by ratchet belts at two height.
Keeping the winding on level by the crane, lower the base plate to the
lowest position. Lift the winding over the spindle of the mandrel and the
height level of the work floor opening. Move the winding to the store-
place. Put the winding on arched wood supports in vertical position.
Remove the belts, ropes and hooks. Move the lifting star to the store.

risks:
Page 106 of 192

workers. Loads can be lifted by the bridge cranes up to the load capacity
of the crane. Fixing of the load before lifting can be performed only by
trained and certified workers. The crane operator shall be directed by the
worker who fixes the load or an assigned lifting leader using unambiguous
indications.
dangerous.
instructions related to the rotating machines. Working at the machine in
torn or hanging clothes is prohibited.
accidentally. Before starting the rotation of the machine, make sure that
any tools or auxiliary (e.g. plastic hammer, beating plate, etc.) are not left
on the top of the winding and the assistant worker finished his action on
the other side.
The operator is obliged to let his production leader know about any failure
of the machine. The production leader is obliged to arrange for repairing.
The operator must not repair the faulty machine.
Before using the welding apparatus, check if the insulation of connection
leads and plugs is sound, and if the protective earthing is connected
properly. Before welding, care shall be taken to remove all the flammable
material from the affected area. Waste papers and other waste materials
shall be removed without delay.
4. If the machine is not used for winding, the base plate shall be lowered
under the work floor and the fix work floor opening shall be railed off.
5. The fire-hazard class of the total workshop area is “C”. All relevant
protection instructions against fire shall be kept.
Page 107 of 192

9 Winding assembly method
9.1 Pressing of individual windings
The winding of the transformer shall be mounted into the proper press device.
Knowing the construction and dimensions of the press device and the length
of the winding the needed pressure discs and wood supports shall be
determined.
During assembling the press device, the extension of the spindles over the
upper pressure disc shall be provided with suitable length distance pipe to
ensure that the length of the spindles over the nuts being about 40-60 mm.
If the pressing force prescribed by the drawing of the winding is less than 15
tons, the pressing force shall be provided by tightening the nuts of the press
device using a torque spanner.
In case of higher pressing forces hydraulic press shall be used as it is
described in paragraph 9.1.7 - 9.1.9.
9.1.1 Before mounting the winding into the press device:
• Build the end-blocks up to the pressing plains

• Adjust each spacers of the winding under the others vertically
• Make the turn out of the bottom lead (see in the relevant operation
instruction)
9.1.2 Install the bottom pressure disc horizontally
9.1.3 Fit the L-shape lifting hooks to the winding and fix them by using ratchet
belts around at the bottom and the top of the assembly.
Hang the winding upon the lifting star hanging on the crane by plastic
ropes.
Lift up the winding by the crane, move and centre it over the bottom
pressure disc.
9.1.4 Place the needed wood supports under the winding hanging centrally.
Page 108 of 192

Lower the winding on the wood supports.
Remove the lifting hooks.
9.1.5 Locate the wooden pressure pieces on top of the winding evenly.
Hang the upper pressure disc on the crane by steel rope and lift it up.
Lower the pressure disc above the pressure pieces centrally and keep it in
this position.
9.1.6 After fixing the crane, lift and locate the pressing spindles in the proper
position by hand.
Apply the needed distance tubes, washers and pressing nuts. Tighten the
nuts by a torque of 40-50 Nm.
9.1.7 Lift the winding mounted in the press device upon the press carriage
centrally.
Draw the assembly under the press equipment.

Press the winding by the force prescribed on the drawing.
9.1.8 Keeping the pressing force at constant value, the loose nuts on the
spindles shall be tightened around.
9.1.9 Remove the pressing force, draw out the press carriage and lift the
winding with the press device on the oven carriage.
The windings shall be located on the carriage in proper position ensuring

enough space to tighten the nuts of the press device by torque limited
spanner after drying.
9.1.10 Dry the winding at 95-100°C for 72 hours period in an air-circulating

oven.
The drying procedure shall be interrupted at each 24 hours:

• the carriage shall be drawn out of the oven,
• the pressing nuts shall be tightened by 40-50 Nm diagonally
• then the 9.1.7 - 9.1.9 paragraphs shall be repeated
Page 109 of 192

9.1.11 During pressing the winding after the 72 hours drying:
• measure the length of the winding

• determine and report the quantity of the needed filling up spacers
• test the insulation of the winding between parallel conductors by
500 V
• remove the pressing force
9.1.12 Put in the filling-up spacers at locations prescribed on the “winding

assembly” drawing.
In case of windings with end-blocks having angle rings, the following

procedure shall be used:
9.1.12.1 If the winding is assembled with angle rings having larger diameter
than the pressboard cylinder under the winding (i.e. the angle ring is
mounted in during the winding process), the bottom and top end-
blocks with the filling up spacers shall be mounted up from pre-dried
elements after pressing the individual winding.
9.1.12.2 Using only angle rings having smaller diameter than the pressboard
cylinder under the winding, the angle rings and that part of the end-
blocks which could not be assembled before locating the angle rings
shall be mounted up during assembling the winding in the block-
pressing device. If location of the filling-up spacers is designed in this
part of the end-block, the proper quantity of them determined during
pressing (see 9.1.11) shall be mounted in the winding also at this
time. Angle rings and all components of the end-blocks shall be used
in pre-dried condition.
9.1.13 The adjusted height windings shall be stored on 60°C in pressed

condition until assembling in the block-pressing device.
Page 110 of 192

9.2 Mounting the windings together in a block pressing device
The windings of a core limb shall be fit together in a suitable block-pressing

device. The process can be started only if each windings of the limb are ready
in pre-dried, height stabilized condition. Assembly shall be performed without
interruption within the shortest possible period. Before assembling the inner
winding in the device, it shall be tried on the proper limb of the opened core.
The bottom support discs of the winding column shall also be tried on the core
limb. Check if the support discs lie on the core and the support parts of the
bottom clamp beam properly, forming a proportional plain to the core limb.
Mounting in the block pressing device can be started only if the conditions
prescribed above are ensured.
9.2.1 Mount the centring components on the bottom pressure disc. Fit the
wooden fillers in horizontal position and fix them by pins.
9.2.2 Mounting of the windings in the block pressing device corresponds to the
mounting them on the core limb. If the construction makes it impossible
to perform the filling up of the winding directly after the individual
pressing (see 9.1.12), the filling spacers and the remaining section of
the end-blocks shall be mounted in during block assembly.
9.2.3 After turning out and insulating the upper leads of the windings, the
wooden pressure pieces shall be located and positioned on the top
according to the relevant drawing.
Hang the upper pressure disc on the crane by steel rope and lift it up.
Lower the pressure disc above the pressure pieces centrally.
9.2.4 Lift the pressing spindles by crane in their proper position.
Assemble on the spindles the distance tubes, washers and pressing nuts.
Tighten the nut by 40-50 Nm diagonally.
9.2.5 Lift the winding system mounted in the press device upon the press
carriage centrally.
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Draw the assembly under the press equipment.
Press the winding system by the force prescribed on the “winding
assembly” drawing. (This force is different from the sum of the press
forces of the individual windings assembled under the common pressure
ring!)
9.2.6 Keeping the pressing force at constant value, the loose nuts on the
spindles shall be tightened around.
Remove the pressing force, draw out the press carriage.

Lift the winding block with the press device on the oven carriage.
9.2.7 Dry the winding at 100°C for 24 hours period.
9.2.8 Draw out the oven carriage. Check the tightness of the pressing nuts.
Lift the winding block on the oven carriage. Draw the carriage into the
oven.
9.2.9 Press the winding system by the force mentioned in 9.2.5.
Check the height of the winding block. If the measured height makes it
possible to mounting up the upper yoke of the core safely, the drying
process can be finished.
If condition of safe mounting up the upper yoke is not provided, 24 hour
drying and pressing shall be repeated.
If condition of safe mounting up the upper yoke can not be achieved after
three drying and pressing cycles, the problem shall be consulted with
design and production engineering.
If a winding block is pressed down temporarily, it shall be considered to
determine the expected height that the winding pressed by the prescribed
force can be pressed back during lamination process only by the half of the
height increase after press release.
9.2.10 Dried winding blocks shall be mounted on the core limb within the
shortest period possible. However, mounting on the core can be started
Page 112 of 192

only after having all the three winding blocks in dried and height
stabilized condition.
Until mounting on the core, the dried and height stabilized winding blocks
shall be stored with the block-pressing device at minimum 60°C in an
oven.
9.3 Assembling the lifting device on the winding block
The dried winding blocks in the block-pressing device shall be lifted on the
core limb by a special lifting device. Mounting on the core can be started
only after having all winding blocks in dried and height stabilized condition.
Assembly shall be performed without interruption within the shortest
possible period. Then the yoke shall be laminated without delay.
9.3.1 Four vertical lifting beams shall be assembled together with the
horizontal lifting arms. If needed, lengthening components shall be used.
9.3.2 Lift up the assembled lifting beams by crane using lifting forks, eyebolts
or lugs. Fit them in the gap of the winding assembly designed for lifting.
9.3.3 Fix the pairs of the lifting beams together by interconnecting tools.
9.3.4 Loosen the pressing nuts of the block-pressing device. Nuts, washers
and distance tubes shall be removed. Pressing spindles shall be lifted out
by crane. The upper pressing plates shall be removed by lifting. Use
steel rope.
9.3.5 Lift up a horizontal lifting beam, and hang the vertical lifting beams on it
symmetrically using 4 steel ropes of the same length.
9.3.6 Lift up the winding block by the assembled lifting device. Move it and
centre above the core limb. Lower the winding block on the limb.
9.3.7 Remove the lifting beams by means of crane.
Page 113 of 192


risks:
dangerous.
2. On the carriage of the oven the load must be located evenly and
symmetrically.
3. Windings assembled in the pressing device can be lifted off the oven carriage
only after tightening the pressing nut in accordance with the instructions
above.
4. Before using the electrical test trolley, its connection leads, protective earthing
and validity of the contact protection certificate shall be checked. During
electrical test the area around the examined winding shall be closed to
passage. The area shall be attended by an assigned worker.
5. The hydraulic winding press can be operated only by trained worker keeping
the instructions of its manual. The operator is obliged to let his production
leader know about any failure of the apparatus. The production leader is
obliged to arrange for repairing. The operator must not repair the faulty
apparatus.
instruction against fire shall be kept.
without delay.
Page 114 of 192

10 Preparation of transformer core
Subject: One and three phase transformer cores
Purpose: Core preparation for winding assembly
Application: Cores with diameter not higher than 450 mm
The cores in subject usually does not have permanent bandage on the limbs. In
this case the inner winding cylinder is clamping the limbs. Before putting the
windings on the core, temporary clamping is used. These temporary clamping
elements (steel bandage, plastic bandage, steel bracket) are mounted on the
lying core. In this size range possible to have cores with permanent bandage or
bolted cores.
Description of operational process:
10.1 Test of the core insulation
On the assembly place the insulation shall be checked with a movable

teszter by 2 kV.
If there is insulation inside the core, between steps, 500 V shall be applied.
All the other insulation in the frame or insulation between the frame and
core shall be tested by 2 kV.
The core is assembled with the frame shall be checked by the QC.
10.2 Preparation for core loss measurement
If the Engineering is required, core loss measurement shall be performed.

In this case the test turns specified by the test room shall be mounted on
the limbs. The mounting of the cable turns shall be tight and well
distributed.
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After the test, the cables shall be dismounted and given back to the test
room.
During the measurement closed metallic loop can’t be present on the limb.
If the temporary clamping can make this effect, it shall be removed.
On the long and slim cores, in the middle height an fixing band shall be
apply to each limb.
10.3 Checking of the clamping
The proper mounting of the temporary U-brackets, the bends fixing the
core slats and bandages shall be checked. The necessary corrections shall
be performed.
The temporary clamping shall remain on the core till the winding assembly.
10.4 Pre-matching of the core slats
The temporary clamping shall be removed from one limb. This operation
can be done on only one limb in the same time. The slats are to be
mounted and fixed on the limb. The enveloping circle of the mounted slats
shall be designated by calliper. If necessary the slats shall be planed to the
proper dimension. The core diameter shall be checked by pattern. The
clamping shall be assembled back after finishing the pre-matching.
10.5 Place the core to the assembly bay
The lower pressing beam shall be set to the proper dimension in the
assembly place. The lifting ropes are to be fit to the upper lifting eyes of
the frame, lifting by crane, mounting on the pressing beams, and the
lifting ropes are to be removed. The assembly platforms shall be set.
10.6 Delamination of the upper yoke
The upper frame bridges (except the middle ones), the clamping, bolts,
nuts shall be removed. The pressing bolts and nuts are to be loosened, the
support blocks and insulations are to be removed. The lifting ropes are to
be fit to the both end of the frame, keeping it while the bridges are
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removing. The upper yoke frame is to be lifting and putting to the storage
area.
The storage sheets with proper dimensions for the delaminated magnetic
sheets shall be put on the platform.
Soiled sheets must not used.
The yoke insulation is to be removed. The magnetic sheets are to be

removed starting on both side. The direction of removing is outside to the
centre. The removed sheets are to be laid on the storage sheets. The place
of the different sheets is to be marked in order to help the lamination. The
insulation between steps in the core and the removed magnetic sheets
must not be damaged.
The removed sheets shall be packed with care, symmetrically, without the
danger of collapsing. If no insulation is in the centre, the last yoke sheet
and the connecting limb sheet shall be marked. The limbs and flitch plates
shall be pulled together after removing the upper yoke.
The storages sheets are to be lifted up and moved to the storage area.
The sheets are to be protected from the dust and pollutions by coverages.
10.7 Fitting of the base discs
Before assembling the base discs the lower yoke insulations shall be
mounted.
The parts of the base disc shall be put for test the matching to the frame,
the core and the yoke insulation. The upper parts shall be in one plane,
shall be rectangular to the limb centre line and one plane with the yoke
insulation. The setting shall be steady. The matching of the base discs
parts are important because in case of phase block assembling, this fitting
can’t make easily.
The mounting and matching shall be controlled by the QC.
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10.8 Preparation of earthing
The Cables and copper plates are to be prepared. The contacting surfaces are
to be cleaned, the insulation of core sheet is to be removed. In case of
earthing is internally connected to the frame, the necessary connecting holes
are to be prepared. In case of earthing is made out of the transformer, the
cables are to be fixed to the plates. At the putting of the earthing plates to the
core sheets can’t be damaged.
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11 Matching of the inner winding on the core
(traditional method)
Subject: Fitting of the transformer inner winding on the core.
Purpose: Determine the technology and the sequence of operations to give

enough information to make a perfect job.
11.1 Determination of the dimensions and shape of the internal

cylinder
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The internal circumference is to be measured on the superficies and the
diameter in four point having 45° angle to each other. These
measurements shall be performed in four different vertical positions, 100
mm from the top, 100 mm from the bottom and in the centreline. The
results are to be documented in a table.
In case of pressboard cylinder the measurements shall be performed in

dried condition.
In case of phenolic paper tube the bigger diameter, if any, shall be at the
lower end of the winding.
The constructive line of the straight-shaped or cone-shaped cylinder can

be only straight. I t can be checked by the three measured circumferences.
In case of doubt, the measurements shall be performed in additional
positions.
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The allowable deviations of measured diameters in one vertical position are
the following in the function of the diameter:
Nominal diameter [mm] Deviation of diameters [mm]
< 300 1
300 – 400 1,5
400 – 600 2
600 – 900 3
> 900 4
If the deviation is exceeding the (not in large measure) the limits given by
the above table, a correction shall be made as follows.
A screwed pressing rod shall be put in the small axis of ellipse, and the
cylinder shall be pressed outwards. A spacer fitting to the form of cylinder
shall be put between the cylinder and bar, in order to avoid any damage
on the cylinder.
The cylinder lower edge and the upper end of the slats on the core shall be
formed on a shape helping the start of sliding down the winding.
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11.2 The check of the position of the slats on the core
The equal placing around the circumference and the vertical position to the
base plane of cylinder shall be checked.
The evaluation of the received deviations is to be made based on the

check of drawing and with the trying to mount the winding to the core.
11.3 The determination of the necessary matching of the slats
11.3.1 The diameters of the cylinder shall be calculated from the measured
circumferences in different positions.
11.3.2 The real radial position of the slats shall be determined compared to the
constructive line of the cylinder placing on a symmetrical circle.
The diameters to be considered in different positions shall be calculated as

above mentioned. The thickness of the slats shall be modified accordingly.
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11.4 The measuring of the slats
The deviation between the slats and the straight-shaped or cone-shaped

cylinder shall be determined on different levels. The measured differences
are to be red on the slat with sign.
11.4.1 If the (+) deviation is large, it shall be investigated if the making thinner
is dangerous for the core bandage. If it is than the machining shall be
made on the surface facing to the core (internal surface).
11.4.2 If the thickness of the slat is not reaching the internal diameter of the
cylinder, pressboard strip shall be glued on the internal surface of the
core. After this, the bandages shall be tightened, and check again the
dimension.
11.5 Forming of the slats
The determined (+) dimensions shall be removed by hand plane. To avoid

the over planning a pressboard circle pattern are to be used.
11.6 After the forming the slats, the following checking shall be
performed
11.6.1 It shall be checked if the slats are straight
11.6.2 Measuring the distances between slats diagonally at the bottom, at the
top and between the bandages.
The final condition shall be documented by the Quality Control
11.7 Test mounting of winding
To help the sliding, the slats shall be greased by silicone than the inner
windings shall be put on the core for checking taking care also on the
position of the leads
The proper identification shall be applied to fix the leg and winding
relationship.
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After removing the winding, based on the marks of the stats on the
cylinder the matching shall be checked.
The block assembly can be done only with winding perfectly matched.
11.8 Checking
The on-line checking of the operation can be done by the worker, but the
final checking and the document shall be made by the QC.
11.9 Safety
Beyond the general safety regulations the specific dangers shall be

considered during the operation, for instance the use of plane or the
dropping of the marking tools.
Page 124 of 192

12 Inner winging matching to the core by
TRANSPOLIM
Subject: Matching by TRANSPOLIM
Purpose: Having a uniform, solid and massive radial support on the core
12.1 1. Materials:
• TRANSPOLIM “A” resin

Manufacturer: Kompositor Kft.
Structure: high viscosity, white colour, polyester resin liquid
Viscosity: 20000-30000 MPA s on 15-25 °C
Density: 1,8 g/cm3 on 20 °C
Fire protection: inflammable material
Storage: 6 months on room temperature in the original package,
protected from light
• TRANSPOLIM “B” catalyst

Structure: blue colour, organic, peroxide catalyst
Fire protection: strongly inflammable material
Storage: 72 h on room temperature in the original package
• Textile tube
Structure: sewn tube made from impregnated polyester
Storage: unlimited
• Acetone
Fire protection: strongly inflammable material
The whole used quantity is 1 dl per occasion
Page 125 of 192

• Band
• Plastic string (for instance Trevira Ø3mm)
• Powder
• Paper for cleaning
• Adhesive tape
12.2 Tools:
• Foil funnel
• Intermediate tube
• Hanging up ring
• Supporter for hanging up ring
• Hypodermic syringe with needle ( approx 20 ml)
• Pot protected against overturning
• Vessel for acetone (200 ml) with narrow opening
• Alcoholic pen
• Vessel with 5% sodium carbonate solution
• Refuse container for the waste contaminated by resin and acetone
• Rubber gloves
• Safety goggles
• Vessel for liquid washing eyes, not earlier by 1 month (the solution
is 5% Na-ascorbic or 2% NaHCO3)
12.3 Operations:
12.3.1 Preparation of the core
The surface of the core being in contact with the textile tube shall checked
carefully before threaded the tube.
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It can be happened that the surface is not smooth due to a not proper
gluing by enamel of the core. It can be made damages on the tube.
The not proper surface shall be scraped and burnished.
The position of the pressboard stripe under the bandage shall be carefully
checked, because if it is wrinkled it can cause a bottleneck on the tube
which could be critical.
If there are wrinkling it shell be removed by cutting.
Figure 1
12.3.2 Threading of the textile tube, fixing the guiding slats
The prepared core shall be checked by the Quality Control before

threading the tubes. Without the QC permission the work cannot be
continued.
Based on the drawings at the tube lower edge on the core a marking shall
be done by the pen.
The different diameter folded tubes shall be threaded under the bandage.
Special care shall be taken during the threading on the followings. The
Page 127 of 192

tube must not be got stuck or caught between the core edge and bandage,
turning or overlapping.
The cross section after threading:
Optimal folding for filling Cannot be filled properly

Figure 2
The worker who made the job must take the whole responsibility of the
job, because later the appropriation can’t be checked. The QC shall ensure
the documentation of the responsibility can be discovered any time.
A fiber rod with a carefully rounded and polished end shall be lead to every
tube to the closed end for opening any closings. The rod must not make
damage on the tube.
The upper end of the textile tube shall be fixed to the core by adhesive
tape to avoid any sweep away caused by the winding during lowering to
the core.
The laminated wood guiding slats shall be put on and press and fix to the
core temporarily by tapes.
The upper tape shall be mounted under the upper and of the guiding slats
by at least 150 mm
At the lower part a temporary support shall be used not to being sweep
away.
12.3.3 Mounting the winding on the core
Before starting this operation the QC shall check the position, dimension of
all of the tubes. The work can be continued only after having the QC
permission after proper documentation.
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The properly prepared phase block or individual winding shall be lowered
to the core carefully.
Special care shall be taken so as not to get jam the cylinder on the guiding
slats in order to avoid any damage on the cylinder. If getting jam is
realized, the winding shall be pulled back, the wooden element shall be
made thinner.
The tapes making the temporary fixing shall be removed in time during the
lowering the winding.
Adhesive tape can’t be remained in the transformer!
12.3.4 QC shall control the followings: position of the winding or phase block
soundness of the winding and its cylinder.
The upper part of the winding shall be covered by paper I order to get any
particles in the windings.
The core 300 mm over the winding shall be wound by pressboard in order
to avoid the damage of foil funnel caused by core edges.
4 ring supporters per column shall be put into free core steps.
1 ring per column shall be fixed on the supporter by plastic string.
Figure 3 Figure 4
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The intermediate tube shall be fixed to the lower outlet of the funnel and
the upper end of the textile tube by cable fixing bands. (Figure 3.) Metal
wire must not be used for fixing.
The foil funnel shall be mounted according to the Figure 4. Instead foil
funnel plastic bottle can be used. The foil is waste after use.
Temporary the funnel outlet shall be blocked by making a knot (Figure 4)
On funnel the quantity to be filled shall be indicated by pen.
12.3.5 Mixing of the resin and filling
Mixing table shall be moved to the stand.
Vessels for acetone and catalyst, syringe with needle, cleaning paper,
scissors, and vessel with eye washing liquid shall be collected to the stand
beside the table.
Vessel with sodium carbonate solution for the waste contaminated by the
catalyst, and a refuse container (paper) for the waste contaminated by
resin and acetone shall be put on the stand.
The resin package shall be prepared.
Pot protected against overturning shall be filled by catalyst.
SAFETY MASK AND RUBBER GLOVES MUST BE USED DURING

PORTIONING THE CATALYST AND MIXING WITH RESIN!
The dropped catalyst shall be wiped up and put to the sodium carbonate
solution.
ANY WASTE CONTAMINATED BY CATALYST MUST NOT BE PUT TO

NORMAL WASTE CONTAINER, MUST BE PUT INTO SODIUM CARBONATE
SOLUTION.
Vessel with narrow opening shall be filled by acetone.
One portion of resin in double package is to be put on the table.
Outer coverage shall be removed by scissors.
Page 130 of 192

Catalyst shall be sucked up by syringe, 1 ml more than it is necessary to
the resin.
The following table 1. is showing the necessary catalyst quantity versus

temperature.
Catalyst to be filled to 1 kg resin

Temperature [°C]
[ml]
10-15 8
18-20 7
20-22 6
22-25 5
25-28 4
The air shall be removed from the syringe, during this operation the needle
shall be covered by paper.
TAKE CARE OF THE EYES!
Needle is to be cleaned by paper.
The needle shall be stick into the resin package through the foil coverage.
The catalyst shall be injected into the resin.
The resin package shall be kneaded carefully approx. 4 minutes while the
blue catalyst makes the resin to grey-blue uniformly.
After this mixing the polymerisation of the resin is starting immediately,

but it is started to be gel condition in the textile tube mixed with the given
quantity of catalyst and on the adequate temperatures after 60 minutes.
The setting of the viscosity allows getting the proper filling within 30
minutes.
The end of the bag shall be cut and put into the funnel, the other end shall
be fixed to the ring taking care not to closing the funnel by the lower end.
The filled in resin quantity shall be documented.
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After the air jammed bellow the resin left the funnel the closing of the
funnel lower part shall be removed.
A small quantity of resin can be got through the sewing holes. Some resin
can be dropped, being at the yoke, the end insulation level. These cannot
take into consideration as a mistake.
Two main mistakes can be happened:

• The tube is being closed somewhere. The resin cannot be flowed
down properly. In this case large quantity of resin remains in the
funnel.
• The textile tube is damaged, torn somewhere the resin is flowing out
at the damaged place. The resin is disappearing from the funnel, a
resin puddle come into being somewhere. In that case the process
shall be stopped for 45 minutes, and repeat it.
In case of having problem with tubes next each other , it shall be

consulted by the Engineering. The QC shall check the quantities of the
resin spilled out and find the location of the failures.
The resin is setting in 1,5-2 hours. After setting the resin filled tube shall
be cut over the windings by chisel. The upper part of the filled tube
together with funnel shall be broken down. The location of the break on
the tube shall be covered by Rembrandint RL 810 lacquer to avoid further
development of fringes.
12.4 3. Safety regulation
During the work with TRANSPOLIM it shall be considered that the material
is dangerous for health and inflammable. The following consideration shall
be taken during the work.
• Both Transpolim “A” and Transpolim “B” contain dangerous materials
for skin, for this reason the wearing of rubber gloves and safety
goggles is a must.
• If it is get to the eyes, the liquid washing eyes shall be used
immediately (solution is 5% Na-aszkorbinát or 2% NaHCO3). If these
Page 132 of 192

solutions are not there the eyes shall be cleaned by water for 15
minutes. In any case a doctor shall be consulted.
• The TRANSPOLIM “A”, TRANSPOLIM “B” and the acetone is
inflammable material so close to operation with this materials must
not use flame and must not make work generating spark (for instance
welding).
• Close to the operation fire-extinguisher must be placed.
• At the end of the operation the special wastes shall be handled
properly.
Page 133 of 192

13 Pressing of the windings mounted on the core
Subject: Pressing of windings mounted on the core with a common pressure ring
Purpose: Putting down the sequence of operations needed:

• to press the phase-block (all windings on a limb) having common
pressure ring
• to fix the pressing force by spring clamping or yoke wedging
13.1 Tools and instruments
13.1.1 Electrohydraulic press device
• Electrohydraulic supply unit with a capacity of 70 MPa

• 12 pcs hydraulic press with a capacity of 300 kN
• Auxiliaries: distributors, connection pipes, plugs
13.1.2 Filler plates to be placed under the press cylinder; and spherical-seat
pressure plates to be used on the top of the pressure head.
13.1.3 Filling spacers between the pressure ring and the ribs of the clamping
beam.
13.1.4 Glue (Rubersol 204) to fix the filling spacers
13.2 Possible applications
• On the assembled active part before drying

• After drying
• After preliminary impregnation with oil
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13.3 General considerations for application
13.3.1 Each phase-block shall be pressed separately if possible. (e.g.:

Sometimes, in the old constructions common insulation components can
be found connecting the phase-blocks together in the end-block rigidly.)
13.3.2 The number and the place of the hydraulic presses above the phase-
block is determined by the followings:
• Pressing force prescribed on the winding assembly drawing

• Construction of the clamping structure
• Dimensions of the wooden load distributor blocks placed on the top
of the pressure ring
• Location of the electrical connections and their supports
• Location of the winding leads coming through the pressure ring
Advantageous location of the hydraulic presses can be made easier by

disassembling the obstructing lead fixing and connection support
components, etc. temporarily.
13.3.3 Effort shall be made to apply as many hydraulic presses as possible.

They shall be distributed evenly to reduce the bending stress in the
pressure ring.
Bending stresses can be reduced by using load distributor blocks (see

Figure 1).
The load distributor block is suitable only if it has enough bending

strength. It can be made of high density laminated wood or steel. In case
of steel, the edges being in contact with the pressure ring shall be rounded
off.
Filler plates and pressure plates are usually made from steel only for this
special purpose (see 13.3.4). If it is needed (e.g. not enough space), other
solution is also possible taking care on the followings:
• Plates can be made only from high density laminated wood or steel
• If the pressing surface is small, do not use laminated wood plates.
Page 135 of 192

• Do not press laminated wood plates directly by the pressing head.
They must not be applied on the pressing tubes of a spring
clamping.
• Diameter of the filler plates can be reduced only if it is absolutely
needed. In this case, increased care shall be taken to ensure that
the plate be under the press cylinder centrally.
Figure 1
Possible locations of the load distributor blocks
13.3.4 Application of steel filler and spherical-seat pressure plates
Application arrangement is shown on Figure 2
• The available filler plates have thickness of 5, 10, 20 and 30 mm. To

achieve the needed thickness they can be varied without any
limitation. Sliding a plate on the other or sliding down the hydraulic
press from a plate is avoided by the flanges of the plates.
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• After placing the spherical seat pressure plates on the press
cylinders, they shall be fitted to the outer flange of the cylinders.
Figure 2
13.4 Arrangement of the pressing device
The pressing device shall be assembled according to the prescribed number and
location of the hydraulic presses.
Figure 3
Example: Pressing device arrangement for maximum 2.4 MN pressing force, in
case of a phase-block mounted on the outer limb of a transformer
Page 137 of 192

The bottom point of the oil pipe connecting fitting is only some millimetre above
the bottom plain of the hydraulic press. Take care on its soundness during
assembling and pressing.
13.5 Pressing process
13.5.1 Preparation
• Clean the working area

• Prepare the needed filling spacers, wedges (in dried condition at
final pressing), filler plates with different thickness
• Assemble the pressing system
Only faultless tools can be used for pressing. Check the condition of the
high pressure pipes, fittings, electrical cables and plugs. The operator is
obliged to let his production leader know about any failure or damage
of the tools.
13.5.2 Determining the pressing force and the pressure
Pressing force prescribed on the

winding assembly drawing
Set force on the supply unit =
Number of the applied hydraulic
presses
The pressure can be determined by the data of the hydraulic press.
13.5.3 Pressing
ATTENTION: Pressing can be started only after the operator

being sure that the observers and assistants are
prepared for the action.
13.5.3.1 Apply a small preliminary pressure on the assembled pressing

system. Ensure enough time for checking the components.
13.5.3.2 Increase the pressing force step by step until the set value
determined in 13.5.2.
13.5.3.3 Keep the force for 10 minutes, and then reduce it to zero.
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13.5.3.4 Repeat the last two actions twice, but at the end of the third period
keep the pressure. Final supporting of the pressure ring to the
clamping structure shall be performed.
13.5.3.5 In case of final pressing of the phase-block the filling spacers shall
be fixed by gluing, and if it is prescribed on the drawing, the wedges
shall be put between the yoke and the pressure ring.
13.5.3.6 Pressing shall be performed on the other phase-blocks accordingly.
13.6 Checking
The Quality Control Department is obliged to check the followings:

• Value of the pressing force
• Keeping of the pressing schedule
• Supporting and wedging
• Soundness of the pressure rings
13.7 Safety instructions

instructions, the workers shall take care on special conditions and risks.
Performing the actions improperly, the different plates, filling spacers and
wedges can jump out and cause serious injury. The leader of the work is
obliged to check the installation of the hydraulic presses before starting the
pressing.
Sources of the danger:

• Improper installation of the hydraulic presses
• Application of faulty or frail pressure and filler plates
• Improperly fitted seatings
• Faulty connection elements or pipe in the high pressure system
Page 139 of 192

14 Joining of the winding rectangular copper
conductors by butt welding
Subject: Butt welding of copper rectangular conductor
Purpose: Determine the technology and the sequence of operations.
The welding can be performed by person having valid examination

and qualification for this kind of activity.
Tools and auxiliary materials:
• Welding transformer equipped with wire fixing

• Pin cutter
• Peeling knife
• tailor's scissors
• pliers
• file
• emery cloth
• fAg15P 0,127 mm – silfos plate
• Rubersol 204 adhesive
• Creep paper tape – 60/90 g/mm2
• Heatproof veil
14.1 Making bare the wire end, filing to plane
The flat wires to be welded shall be cut to the required length in

rectangular shape by the pin cutter.
The insulation shall be removed at the cut end in 80 mm length. The

insulation shall be prepared for cone-shaped (Figure 1.), in order to ensure
the proper insulation strength with the re-insulation.
Page 140 of 192

In order to avoid the loosening of the insulation, the ends of the tapes are
to be glued by Rubersol. The applied adhesive shall be as less as possible.
Figure 1
14.2 Butt welding of the conductor (Figure 2.)
Place the welding transformer to the welding position. If it is close to the

winding, the winding shall be covered by heatproof veil.
The end of the wires shall be made rectangular by file and fix in the fixing
tool of the welding transformer.
Figure 2
Page 141 of 192

The wires shall be pressed together matched perfectly. The matching of
the wires shall be checked visually, if necessary it shall be make better by
flat-nose pliers.
The welding transformer shall be switched on and off periodically, so the

wire ends are glowing, at the close to the fitting it is fusing.
The welding shall be investigated visually and glowing again, the non-
uniformity of the surface shall be filled by silfos. The filling shall made
using silfos as less as possible. The occasionally developed flows shall be
removed from the wire in melted condition if possible.
14.3 Re-insulation
The unnecessary material shall be removed; the welded part is to be

formed to the original wire form by file. The surface is to be burnished to
smooth by emery cloth.
The occasionally burned insulations shall be removed. The welded region

shall be re-insulated by using creep paper in ½ overlapping. The thickness
shall be equal to the original + one layer.
The ends of the tapes are to be fixed by using adhesive as less as possible.
14.4 Quality Control
Checking’s are to be performed during butt welding activity.
By visual inspection:
• after removing the insulation the cone-shaped preparation
• gas cavity
• porosity
• formation of any step
• increasing of the thickness
• the re-insulation with ½ overlapping
• use of adhesive
Page 142 of 192

By micrometer:
• the increasing of the thickness after re-insulation shall not exceed
20%
In the mechanical laboratory:
• tensile test of the soldering by random sampling (the welded part
can’t show deviation with the original one more than 20%)
14.5 Safety regulations:
Further the regulations are valid for the workshop, the followings must be
considered.
Before starting the operation with the welding machine, the insulation of
the wires, the plugs and the sockets shall be checked.
The flammable materials shall be removed from the region of the

operation (for instance the removed insulating papers).
Safety goggles shall be used during the soldering.
If more welding is made within a short time the clamping head may be
overloaded, that is why in this case the overheating shall be checked
carefully. If overheating is received, the welding shall be closing down up
to cooling down of the tool.
After finishing the job or pending it for longer time the cable of the welding
machine shall be removed from the socket.
The operation can be done with a machine having valid certification for
protection against electric shock.
Page 143 of 192

conductors by butt soldering
Subject: Butt soldering of copper rectangular conductor during winding

production.
The soldering can be performed by person having valid examination and

qualification for this kind of activity.
Tools and auxiliary materials:
• ISEA BC10, BC20 type soldering machine

• SB-1 type air cooled, soldering pincers with carbon jaws
• Pin cutter
• Peeling knife
• pliers
• wire fixing tool
• file
• emery cloth
• Fag 15P 0,127 mm – silfos plate
• Heatproof veil
15.1 The 0,2 mm thick silfos plate shall be cut by scissor to the
required dimension.
The required dimensions are the cross section of the flat wire to be
Page 144 of 192

soldered + 1,5 mm per side.
It is practical to make the cutting in advance for all the soldering to be
performed during winding production.
Determination of silfos dimension
15.2 The flat wires to be soldered shall be cut to the required length in
rectangular shape by the pin cutter.
15.3 The insulation shall be removed at the cut end in 80 mm length. The
insulation shall be prepared for cone-shaped (figure 1.), in order to ensure
Page 145 of 192

15.4 The end of the wires shall be made rectangular by file; the soldering head
shall be set to the proper position. The end of the wires shall be pressed
together and fix in the soldering head.
The wires shall be matched perfectly, backside is leading on the fixing tool,
the matching point is to be in line with the marker of the fixing tool.
The matching of the wires shall be checked visually, if necessary it shall be
make better by flat-nose pliers.
15.5 The matched wire ends are to be opened by the tool, placing the silfos
plate between them and closing again. The silfos plate shall fit to the wire
end surface and it shall hang out by 1,5mm on each side.
The wire ends with silfos
Page 146 of 192

15.6 The parameters of the soldering machine are to be set (current,
soldering time).
The machine shall be switched on with the foot operated switch, heating
the wires up to silfos becoming totally liquefied, and then switching off.
If the silfos is not becoming totally liquefied during the soldering time, the
soldered parts shall be investigated, if there is any material separation on
the surface. If it is not, the soldering shall be repeated.
If there is any material separation, from the preparation shall be repeated

the process.
If the hating process is not cancelled automatically by the machine, the

switch off shall be made by foot and the settings shall be modified.
15.7 Visual check of the soldering after removing from the fixing tool.
The soldering is not proper if:

• the wire ends lost the position, moved
• there is step at the edges
• the silfos is not perfectly liquefied
• the gap between the wires are not filled totally by the silfos
If the soldering failed, shall be tried to repeat by re-heating. If it is not
successful, the soldered part shall be removed by cutting and the whole
soldering operation shall be started from the beginning.
15.8 Forming after soldering
The rest of the silfos is to be removed from outside, the soldered part is to
be formed to the original wire form by fine file. The surface is to be
burnished to smooth by emery cloth.
The soldered region shall be re-insulated by using creep paper in ½

overlapping. The thickness shall be equal to the original + one layer.
Page 147 of 192

Checking’s are to be performed during soldering activity.

• formation of the wires, presence of gap
• if the silfos totally liquefied, the filling of the small gaps
• formation of steps
• use of adhesive
By micrometer:
20%
• tensile test of the soldering by random sampling (the soldered
part can’t show deviation with the original one more than 20%)
considered.
Before starting the operation with the soldering machine, the insulation of

After finishing the job or pending it for longer time the cable of the
soldering machine shall be removed from the socket.
Page 148 of 192

conductors by overlapped soldering
Subject: Overlapped soldering of copper rectangular conductor during winding

production.
The soldering can be performed by person having valid examination and

qualification for this kind of activity.
16.1 Tools and auxiliary materials:
• ISEA BC10, BC20 type soldering machine

• SB-1 type air cooled, soldering pincers with carbon jaws
• Pin cutter
• Steel hammer – 0,75 kg
• Steel platform for flattening
• scissors for sheet cutting
• pliers
• wire fixing tool – 538-449/A
• file
• emery cloth
• Fag 15P 0,127 mm – silfos plate
• Heatproof veil
16.2 The flat wire shall be cutting according to the required length.
16.3 The winding shall be covered by the heatproof veil at the region of
soldering.
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16.4 The insulation shall be removed at the cut end in 80 mm length. The
insulation shall be prepared for cone-shaped (Figure 1.), in order to ensure
Figure 1
16.5 The end of the flat wires shall be hammered to wedge shape for the
overlapping. The overlapped length shall be equal or longer than the width
of the flat wire (Figure 2).
Figure 2
Page 150 of 192

16.6 The wedge shaped wire ends shall be cut according to the wire length
(Figure 2.).
16.7 The silfos plate is to be cut to the proper dimension according to Figure 3.
A = flat wire width

B = Overlapped length + 1 mm
Figure 3
16.8 The wire ends to be soldered shall be fixed to the fixing tool. The ends
hammered to wedge shape shall be fit together by overlapping; the silfos
plate shall be mounted between them (Figure 4.).
At the setting carefully shall be checked that the overlapped wires and
silfos are in touch, no gaps are present which cannot be filled by the silfos.
It can happen if the surface is not properly formed (concave or convex
surface).
Figure 4
Page 151 of 192

16.9 The parameters of the soldering machine are to be set (current,
soldering time).
The overlapped wire ends shall be pressed by the soldering pincers

(Figure 5.).
The machine shall be switched on with the foot operated switch, heating
the wires up to silfos becoming totally liquefied, and then switching off.
The pincers can be loosened only after getting the silfos solidified.
Figure 5
16.10 Visual check of the soldering
The soldering is not proper if:

• the overlapped wire ends lost the position, moved
• there is step at the edges
• the silfos is not perfectly liquefied
• the gap between the wires are not filled totally by the silfos
If the soldering failed, shall be tried to repeat by re-heating. If it is not
successful, the soldered part shall be removed by cutting and the whole
soldering operation shall be started from the beginning.
Page 152 of 192

16.11 Forming after soldering
The deformations shall be formed by the hammer and platform for

flattering. The rest of the silfos is to be removed from outside, the
soldered part is to be formed to the original wire form by fine file. The
surface is to be burnished to smooth by emery cloth.
16.12 The soldered region shall be re-insulated by using creep paper in ½

overlapping. The thickness shall be equal to the original + one layer.
Checking’s are to be performed during soldering activity.

• the overlapping of the wires, formation of the wires, presence of
gap
• if the silfos totally liquefied, the filling of the small gaps
• formation of steps
• use of adhesive
By micrometer:
20%
• tensile test of the soldering by random sampling (the soldered
part can’t show deviation with the original one more than 20%)
considered.
Page 153 of 192

Before starting the operation with the soldering machine, the insulation of

After finishing the job or pending it for longer time the cable of the
soldering machine shall be removed from the socket.
Page 154 of 192

17 Preparation of internal connection by crimping
Tools:
a. Electro-hydraulic supply unit (CPE-0) with foot or hand operated

switch
b. PA 6 Power Team Pneu-Hydraulic supply unit
c. Hydraulic pressing head (RHU 130-C)
d. Cable cutting adapter
e. Round stamp set
17.1 Cutting for proper dimension, removing of insulation of leads to

be connected
Connecting leads (winding lead, taps, cables etc.) shall be cut according to
the dimension indicated on the relevant drawing and bended if necessary.
The cut shall be performed by hand tool (cable cutter, bolt clipper etc.) or
cable cutting adepter of the hydraulic tool, according to the dimensions of
the lead to be cut.
During the bending of leads to be extended, the distances to be kept by

voltage point of view and the distances necessary for the pressing head
shall be considered.
The leads to be extended the insulation shall be removed, the ends of the
paper tapes shall be fixed by adhesive tape.
The length is to be dismantled are the followings:
a. in case of connector - the length taken in the connector + 15 mm

b. in case of shoe - the length taken in the shoe + 0 mm
In case of stranded cable, special care shall be taken for the safety of the
outer individual strands.
Page 155 of 192

In case of joining winding conductor, every wire shall be burnished before
crimping. The reason is to remove the oxide layer.
The insulation shall be prepared for cone-shaped, in order to ensure the

proper insulation strength with the re-insulation. The dimensions shall be
considered according to the Figure 1.
Figure 1
17.2 Round forming of the not round form leads
The non-round form leads (flat wire, winding wires) shall be formed round
cross section before crimping the connector or shoe. The round formed
length, shall be over the length taken in the connector or shoe by 5 mm.
The round forming of the lead is done by round stamp equipped pressing
head. The round stamp shall be chosen based on the table 1.
If the lead own cross section is not enough to fill connector, then
additional wire pieces shall be add beside the lead. The additional wire
shall have the same quality as the original one.
Attention: The leads shall be cleaned to metal.
The sequence of round forming:
a. The additional wire cutting to proper length
Page 156 of 192

The additional wire length, shall be over the length taken in the
connector or shoe by 5 mm. The cross section shall be in
accordance with the internal section of the connector.
b. Fixing the additional wire to the lead

The additional wire is to be placed beside the lead, the ends shall be
fit. The fixing shall be made by adhesive tape, placing close to the
end (5 mm), in order the easy removing. The additional wire always
shall be added symmetrically to the lead (Figure 2).
Figure 2
c. Placing the stamp to the hydraulic pressing head

The equipment is to be de-energised; the proper stamp is to be
mounted.
d. Pressing to round form
The end of the lead is to be pushed into the pressing head; the
stamp is to be set for the lead section. The presser is to be started
by hand or foot operated switch. It is working up to the automatic
switch off.
Page 157 of 192

The pressing shall be repeated step by step until a continuous,
round formed lead is prepared (Figure 3).
Figure 3
17.3 Crimping the connector or shoe to the lead
a. Push the connector or shoe the lead end
The connector or shoe shall be pulled up to the lead up to stopping by

the buffer inside. In case of using additional wire, just 2-3 mm pulling
shall be done, after this the adhesive tape can be removed, and then
the pulling up shall be finished.
In case of stranded cable, It has to be sure that all the strands are
placed inside the connector or shoe. If not, removing is necessary and
after rearrangement of the strands, the pulling up shall be repeated.
b. Placing hexagon stamp to the pressing head
c. Crimping the connector or shoe to the lead end. Quality is to be

checked by visual inspection. The text engraved to the stamp shall be
clearly visible on the pressed connector. The connector shall be pressed
on the whole length. If the length of the connector and the dimension
of the stamps make possible, two pressing shall be made. If the and of
the connector is turning up, after repositioning of the stamp, the
Page 158 of 192

pressing shall be repeated. The possible burrs are to be removed by
hammering. It must not be filed.
The finished crimping must not pressed again.
Crimping can be made on standard parts or manufactured parts based on
the standard (table 1).
The crimping of winding conductor and stranded cable with additional wire
is shown on Figure 4 /a, b, c and d.
Figure 4
Page 159 of 192

Figure 4
17.4 Insulation around the connecting part
Creep paper tapes are to be cut for the necessary length.
The steps and gaps formed on the connection are to be filled by parts
formed from paper (Figure 5).
Page 160 of 192

Figure 5
Aluminium layered crape tape shall be folded half, so that the aluminium is
outside (Figure 6) or two alu-crape is to be fit as the aluminium is outside.
Figure 6
The connection shall be covered by the prepared alu-creep tape in one

layer and ½ overlapping. The alu-creep surfaces shall be continuously
contacted with the metallic surfaces of the leads, connectors or shoes.
Page 161 of 192

In order to ensure the continuous contact, at bending and not smooth
surfaces, the tapes shall be smooth by hand. The overlapping shall be
checked by visual inspection
At the end of the shielding, the alu-creep tape inner layer shall be cut
10 cm shorter than the outer one. Than the outer layer shall be bended
under the inner one (metallic surface facing to the lead) and fixed by
adhesive.
Figure 7
The connection shall be insulated by creep paper tape to the required

thickness by ½ overlapping. The end of the tapes are to be fixed by
adhesive as less as possible.
The insulation thickness is to be checked.
17.5 Removing of the crimped connectors or cable shoes
The insulation is to be removed from region of the connector. The

connector is to be opened by coldest or saw, and expanded by pincers.
17.6 Quality Control:
Cone-shape preparation of the removed insulation (Figure 1).

Round forming of the lead with additional wire, fitting to the connector.
Burnishing of winding conductor (removing the oxide layer).
Perfect removing the adhesive tape before crimping.
Quality of the crimping, visibility of the engraved text.
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Removing of the burrs.
Alu-crape tape continuous contact.
The insulation of the connection.
Appearance of the connection.
17.7 Safety:
Before removing the insulation the safety of the knife is to be checked.
Before using the hydraulic supply unit, all the wires and connectors are to
be checked.
Before using the foot pump, the soundness of the air pipe is to be
checked.
The crimping can be started only if the settings are finished and the hand
of the worker is far from the stamp. Up to the automatic switch of the
machine nobody’s hand can be close to the stamp.
The changing of the pressing head or stamp can be made only if the
machine is disconnected from the electric network and the pressure is
zero.
The general safety regulations of the workshop are to be considered.
Page 163 of 192

Page 164 of 192
18 Drying and impregnation of transformers
18.1 Drying of windings from paper insulated rectangular and twin

conductors
18.1.1 Competences
Task of winding workshop:

• preparation of the winding for drying in hot air circulation or
vacuum oven.
• checking of the proper condition of temperature indicator
• checking of the dying process and taking decision regarding the
oven opening time based on this regulation
• at the end of the process, measuring the winding height and
indicating on the quality page of the winding
18.1.2 General
• every winding shall be dryed between steel discs pressed condition.

• the pressing force applied before and after drying shall be according
to the prescription of the relating
• pressure measuring equipment shall be used during the pressing of
the winding
• after the drying the winding shall be removed form the pressing
device
18.1.3 Winding preparation for dying
Mounting the winding between steel discs. Spacers made from steel or
wood shall be put between the winding and steel disc. These spacers are
for ensuring that the winding is pressed over its spacers, furthermore the
right vertical position of the winding and its cylinder, adequate space for
winding leads, appropriate space for air circulation.
Page 165 of 192

As far as possible the end insulation shall be dried together the winding.
Before drying in cold condition 75 % of the prescribed pressure shall be
applied on the winding and fix this pressure by the pressing discs.
18.1.4 Drying
Winding drying can be performed both vacuum or hot air circulating oven
18.1.4.1 Drying in hot air circulating oven

• the temperature in the oven must not be higher than 120 °C , but
must be higher than 105 °C
• after reaching the above temperature, it should be kept as follows:
• 36 hours in case of a transformer rating lower than 40 MVA and
voltage lower than 150 kV
• 48 hours in case of a transformer rating higher than 40 MVA and
voltage higher than 150 kV
• In case of oven opening before finishing the process the time shall
be extended by the time have been taken between the opening and
reaching again the prescribed drying temperature
18.1.4.2 Drying in vacuum oven

• the temperature of the winding must not be higher than 110 °C, but
must be higher than 100 °C, the vacuum shall be lower than 1 mbar
• after reaching the above temperature, it should be kept as follows:
• 20 hours in case of a transformer rating lower than 40 MVA and
voltage lower than 150 kV
• 35 hours in case of a transformer rating higher than 40 MVA and
voltage higher than 150 kV
• temperature indicator position is according to attachment 2
18.1.5 Pressing in hot condition and compensation
Taking out of the winding from the oven immediately shall be pressed.
• the pressure shall be according to the drawing prescription and shall

be measured the value
• the height measurement shall be done as follows:
Page 166 of 192

• measuring between the outermost turns on 4 places on the
circumference
• the difference between the 4 measured points shall not higher than
3 mm
• in case of helical, layer, spiral windings the plus one turn shell be
considered
• in case of deviating height compensation shall be done, it can be
performed by spacers or pressboard stripe between the end ring
and last turn
• during the pressing after compensation the turn to turn insulation
shall be checked, Quality Control shall be involved
Page 167 of 192

18.2 Winding with CTC
18.2.1 Competences
Task of winding workshop:

• preparation of the winding for drying and curing
• putting in and removing the winding from the oven
• checking the condition of the temperature indicators
• checking of the dying process and taking decision regarding the
oven opening time based on this regulation
• pressing and its checking according to this regulation
• compensation according to this regulation
• ensuring that at the end of the process the winding height is within
the tolerances
18.2.2 General
• subject: this regulation is to apply for all kind of winding made form
epoxy bounded CTC
• task of the procedure: the windings shall have the proper
dimensions after the drying and pressing, the parallel conductors of
the CTC are to be glued together forming uniform block
• dimension tolerance: ± 5 mm or as it is defined on the drawing
18.2.3 Preparation for drying and curing
• removing the epoxy from the lead
In order to have a flexible lead after curing, the epoxi shall be

removed from the winding end, additionally the enamel shall be
removed before putting the cable shoes on it for connection
The transposed conductors should be separated. The must is the

removing the epoxi, but in the mean time the enamel can be removed
as well depending on the method.
Page 168 of 192

One possibility is the removing of epoxi by a 1:1 mixture of 95%
concentration alcohol and clean acetone. Be careful that only the lead
end is handling. In this method the enamel is removed by burning
and/or scratching after drying
Other method is the burning epoxy and enamel together before

drying, but in this case the cleaning of the conductors shall be
repeated after drying because of the oxidation.
• Mounting the winding between steel discs. Spacers made from steel or
wood shall be put between the winding and steel disc. These spacers
are for ensuring that the winding is pressed over its spacers,
furthermore the right vertical position of the winding and its cylinder,
adequate space for winding leads, appropriate space for air circulation.
• Pressing the winding by the 75% of the pressure prescribed on the

drawing
• Putting 3 sample from the CTC beside the winding, lower, middle and
upper position. It is for checking the proper curing, and giving the test
result to the engineering.
18.2.4 Drying, curing
Hot air circulating oven is proposed, vacuum oven can be used, but
without applied vacuum, on normal pressure and circulating air.
The temperature of the oven is 120 ±5 °C for at least 60 hours. The
difference of the hot and cold point of the oven must not higher that 9 °C.
Hot air shall be circulated.
18.2.5 Pressing, fixing, compensation
At the end of the curing time taking out the winding and starting the
pressing as quick as possible. The pressure continuously checked. The
nominal pressure prescribed on the drawing is reached in 3 steps and
repeated 3 times as follows.
• 1/3 nominal pressure for 3 minutes
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• 0 pressure 1/2 minutes
• 0 pressure 1/2 minutes
The above cycle shall be repeated 3 times.
If the winding height is out of tolerance internal compensation is used. In

case of disc or helical winding with spacers, spacers can be removed or
added. The compensation shall be done symmetrically for the winding
centreline. ±5 mm is the accepted deviation. In case of layer winding the
compensation can be done only between the end ring and the winding or
over the end ring.
NOTE: In case of critical compensation or any disturbance, the engineering

shall be involved.
Page 170 of 192

18.3 Drying of the phase block assembly
18.3.1 Task of the winding workshop
• preparation for drying, putting to the oven and taking out

• mounting of the temperature indicator (attachment 2)
• check of the phase block height and indicating on the QC document
18.3.2 General
• Phase block shall be dried in pressed condition between steel discs

and can be kept this pressing if it is assembled to the core within 48
hours. If this time limit is exceeded, the phase block shall be kept in
warm oven. If this is not possible, the pressing shall be cancelled
and the drying shall be repeated in time.
• The pressure applied after drying is 70% of the sum of the
individual winding pressures.
• The applied pressure shall be measured and controlled carefully.
18.3.3 Preparation for drying
• The phase block assembly shall be performed, from the base disc to
the clamping ring.
• The phase block shall be positioned on the middle of the pressing
disc, the height shall be set on a manner that avoid the contact
between winding ends and pressing disc
• Since the insulation under and over the windings receiving the
drying and pressing just this stage, its dimensions shall be checked
now and compensated in case of necessity.
• Mounting the upper pressing disc
• The prepressing is the 70% of the pressure prescribed for phase
block. If no prescription, the 50% of the sum of the individual
winding pressure shall be applied
18.3.4 Drying
Page 171 of 192

Vacuum or dry hot air circulating oven can be used
18.3.4.1 Dry hot air circulating oven

• heating the oven up to 120 °C (max.)
• ≤ 40 MVA and ≤ 220 kV transformer – 48 hours
> 40 MVA and > 220 kV transformer – 72 hours
keeping on the above temperature
18.3.4.2 Drying in the vacuum oven

• heating up to 118 °C (max.)
• after minimum 4 hours starting the vacuum pumps and operating as
follows:
≤ 40 MVA and ≤ 220 kV transformer – 30 hours
18.3.5 Pressing in hot condition and compensation
After taking out the block from the oven, the followings shall be done
immediately
• the phase block shall be pressed the specified pressure by the

design
• The winding height is measured in four points. The differences of

the 4 measured values cannot exceed the 5 mm.
• In case of the dimension of the phase block are within the +0 and –
9 mm tolerance, the drying is finished. The stiffness of the windings
and the proper dimensions of the horizontal cooling channels are to
be checked. In case of necessity with the removing of the clamping
ring, the correction of the vertical dimensions can be performed.
• The phase block shall be dried further according to the followings
≤ 40 MVA and ≤ 220 kV transformer – 12 hours

• If the phase block dimension is lower then –9mm of the nominal,

additional insulation materials shall be built in. If the necessary
Page 172 of 192

compensation is less than 10 mm, it can be done in the upper part,
if it is more than 10 mm, 50-50% shall be put to the lower and
upper end insulation.
Note: If the dimensions are still out of the tolerances after the
modification, the engineering shall be contacted
Page 173 of 192

18.4 Active part drying in traditional vacuum oven
18.4.1 Competences
Responsibility of the oven operator:

• Preparation of the devices and measuring equipment
• Drying according to this document
• Measuring the pressure, volume and temperature of the condensed
water, document the measured values
18.4.2 Works to perform
• Core temperature – to be check and document every hours, except

it is documented automatically
• Temperature of the insulation – in the first period of the dying the
temperature shall be checked in every hour. The temperature
indicators shall be placed to the upper end insulation and to the
core, except it is otherwise specified by the engineering
• Vacuum – The measuring equipments shall be mercury (Mac Leod,
Kammerer etc.) or electric type (Thermotron II etc.)
• Quantity of the water
o In the period of the heating up, large quantity of water is

leaving through the pipeline connected to the oven, which
cannot be measured. That is why the whole quantity of the
removed water cannot be measured. The specific quantity of
the removed water shall be measured at the end of fine
drying phase. It can be performed at the condense vessel of
the vacuumpump or by the equipment VZ402/Micafil.
o If the water is mixed with oil, the measurement can be

performed after minimum half an hour.
o The necessary cooling liquid quantity and the cleanness of

the cooling element are to be ensured in order to reach the
15 °C outgoing gas temperature.
Page 174 of 192

18.4.3 Preparation for drying
Putting the active part to the oven, installing the temperature indicator,
closing the oven, starting the drying.
18.4.4 Test of vacuum tightness (leakage test)
• Every 3 month the leakage value shall be tested. The same test shall be
done after any kind of event which can have effect on the tightness, for
instance changing of gaskets, repairing of equipment having direct contact
with the oven.
• The method of the test
o Approximately 0,5 mbar vacuum shall be set in the room temperature
oven
o After disconnecting the oven from the vacuum preparing system, the
change of the vacuum value in the oven shall be measured every 30
minutes in a 3,5 hours period.
o The leakage value are to be calculated as follows
SZ=(∆p x V) / t - (torr x liter) / sec
∆p – changing of the pressure in the examined period [torr]

V – volume of the oven [litre]
t – investigated peiod [second]
Notes:
- starting of the examined period is 30 minutes after disconnection
- conversion: 1 mbar = 0,75 torr = 1 hPa
- considered volume of the ovens
normal vacuum – 245.000,- litre + 5.000,- litre non-disconnectable
pipeline
vapour phase – 340.000,- litre
• Acceptable leakage values
Normal vacuum – 20 torr x litre / sec
Vapour phase - 10 torr x litre / sec
Page 175 of 192

The leakage shall be stopped, if it is exceeding the acceptable limits
18.4.5 The first drying
• Heating up
o Air vents opening inwards, starting extractor fans
o Wall heating switching on (max. 140 °C)
o Air heating and circulation switching on (max. 130 °C air temperature)
o The average heating up gradient of the active part can be maximum
10 °C/hours
o During the heating up, in order to remove the stagnating evaporation,
the vacuum can be reduced by approx. 100 mbar. Max. 3 times can be
repeated the action.
o The heating up can be stopped if the lower measured active part
temperature reached the 90 °C
• Continuous vacuum
Starting the continuous vacuum drying when the core temperature reached
the 90°C
• The allowable temperature limits

Hottest spot in the oven – 125°C
Max. core temperature – 110°C
Max. temperature of the insulation – 115°C
• The parameters of the finishing period of the drying

o Minimum core temperature – 90°C
o Minimum temperature of the insulation – 100°C
o Measured pressure values with mercury equipment less than 0,3 mbar,
with electric equipment less than 0,35 mbar
o The removed water from the insulation by the condensers in the last
24 hours is less than 20 gram/(tons x hour)
Note:
In case of a transformer handled by oil before drying, the following
pressure values shall be reached:
Page 176 of 192

Measuring Power of the transformer
equipment ≤ 100 MVA > 100 MVA
Mercury 0,85 mbar 1,1 mbar
Electric 1,0 mbar 1,3 mbar
18.4.6 Fixing of the active part
• The fixing of the active part shall be finished within 48 hours (dry room)
after getting contact with air.
• First step is the final pressing of the winding system, within 6 hours (dry
room)
• Every material sensitive for the moisture (for instance Weidmann faltenbalg
etc.) shall be impregnated by dry, degassed oil, if it has not been done by
the supplier.
• The following data shall be documented on the quality page:

o Time passed between the oven opening and finishing the winding
pressing
o The whole time of active part on the air
• If dry room (air-conditioned room, with a controlled very low moisture

content, and temperature) is not available, the fixing shall be done in the
workshop.
The above specified 48 hour staying in dry room is equivalent with
12 hours in the workshop
18.4.7 Second handling, drying
This kind of handling has 3 main types

A – on room temperature
B – on low temperature
C – on normal temperature
Page 177 of 192

18.4.7.1 “A” type handling in the own tank
• It can be performed on an active part BIL≤1050kV, staying in Dry Room

less than 48 hours or in the workshop less than 12 hours
• After the fixing, the active part is mounted in its own tank and
connecting the vacuuming system to the tank
• Setting the necessary vacuum value
• The handling is finished when the pressure in the tank is lower than
0,5 mbar for a 24 hours period
18.4.7.2 “B” type of handling in the oven
• It is applicable for an active part BIL≤1050kV and staying in the Dry

Room 48h≤t≤96h or in the workshop 12h≤t≤18h. Furthermore it is
applicable for transformer BIL>1050kV even if it has stayed in the Dry
Room less than 48 hours or in the workshop less than 12 hours.
• The active part is putting back to the oven and the above explained
FIRST DRYING process shall be repeated with the exception of the core
temperature, which can be 80°C
• The process can be finished if the removed water quantity reached the
20 gram/tons x hours in the last 24 hours period
18.4.7.3 “C” type handling in the oven
• Must be used for the following cases:
o transformer with BIL ≤ 1050 kV staying more than 96 hours in Dry

Room or more than 18 hours in the workshop
o transformer with BIL > 1050 kV staying more than 48 hours in Dry
Room or more than 12 hours in the workshop
• In this case the handling shall be identical with the first drying with the
same temperatures and same finishing criteria’s
Page 178 of 192

18.5 Oil filling
At the end of the fixing or second handling the oil filling shall be performed
to the level, which is 150 mm lower than the top cover.
The filling shall be performed from the bottom, under vacuum with treated
(filtered, degassed, low water content) oil.
Before filling the oil parameters are to be checked. The velocity of the
filling is maximum 300 mm/hours.
If the filling is performed out of oven, it shall be finished 150 mm lower to

vacuum pipe connection.
The pipeline and accessories between the transformer and oil storage shall
be vacuum proof.
After the filling it shall be checked if the oil is covering the pressing ring
and the paper insulated connections in highest position. At the connection
will be inside the HV bushing, the oil impregnation under vacuum is not a
need.
The oil parameters before filling shall be accordance with the E 6.1. More
strict requirements can be applied for HV transformers. It is to be specified
by the engineering.
Page 179 of 192

18.6 Active part drying in vapour phase drying oven
18.6.1 General
In case of vapour phase drying the vapour of mineral oil origin liquid is
used instead of dry air. In this way the drying is made in oxygen free
environment. During the condensation of the vapour, it releases large heat
which results an intensive and uniform heating up of the active part.
18.6.2 Competences
18.6.2.1 Operator responsibility

• preparation and maintenance of the equipment
• execution of the drying, handling according to this rules
• measurement of temperatures, pressure, removed water
• removed water measurement by the VZ402 PC MICAFIL
18.6.2.2 Quality control responsibility

• daily checking of the documentation of the running handlings,
dryings, its comparison with the prescriptions
• filling in the forms attached to the drying documentation
• Checking the proper operation and settings of the equipment,
regularly performing the certifying and document the results with
the softwer
• Justify the documentation with signature
18.6.2.3 Engineering responsibility

• The quantity of the insulation material, the quantity and quality of
the oil shall be prescribed in the design documentation of each
transformer
Page 180 of 192

Table for vapour phase processing
Operation BIL ≤ 950 950 < BIL ≤ 1425 BIL > 1425
First drying in vapour

x x x
H2O ≤ 20 gr / tons · hour , p < 0,3 mbar
Fixing in Dry Room

x x x
T=20+5 °C, Relative Humidity ≤ 25%
Second drying in vapour

x x
Second drying in vacuum oven

x
Oil filling in vacuum oven

x
p≤0,5 mbar, Oil temperature = 65 °C
Oil filling out of vacuum oven

x x
Final oil filling for test (after assembling
the accessories) x x x
18.6.3 Vapour phase drying method (first drying)
18.6.3.1 Preparation of active part

Connecting the temperature indicators on active part and putting into the
oven, closing the oven
18.6.3.2 General preparations

Air is to be removed from the whole vapour emitting system.
The leaking shall be checked regularly, must be lower than
1,5 mbar x litre / seconds.
The vapour emitting system shall be filled up by the proper quantity
kerosene, which is enough for the whole process without refilling.
18.6.3.3 Preparation for starting

The kerosene is heated up to 130 °C in the vapour emitting system. The
Page 181 of 192

vapour pipeline to the oven is to be closed.
In the mean time the air is removed from the oven by vacuum pumps,
reaching the 7 mbar pressure.
18.6.3.4 Heating up with intermediate pressure reducing
The valves shall be opened between the oven and vapour emitting system.
The vapour is expanding in the oven and condensing on the cold internal
surfaces in the first stage. The pumps are pressing back the condensed
kerosene to the emitting system after proper filtering. The active part
received the heat transferred by the condensed kerosene.
The temperature is increasing. The kerosene vapour pressure in the oven

is increasing. The steam pressure in the insulation is increasing. Since the
steam pressure in the insulation is much higher than the kerosene
pressure, consequently the moisture started to be removed from the
insulation on relatively low temperature. In the oven a mixture of the
gasses are formed (steam, kerosene and small air), it is come to the
condenser through the vapour pipeline.
The steam and the kerosene vapour is condensed in the condenser, the air
is pressed out by the vacuum pump. The mixture of the water and
kerosene is separated in the separator in consequence of the different
specific densities. Kerosene is return back to the emitter through the filter.
The pressures shall be decreased when the insulation temperature reached

the 80 °C.
The second pressure reduction is done when the average temperature

reached the 105 °C.
For these actions, the vapour inlet is stopped and the pressure in the oven
is reduced to 45 mbar. In that way the stagnating vapour is removed,
which could disturb the condensation.
In case of necessity, more pressure reducing is applied. When the finishing

temperatures are reached for a certain period the temperatures are to be
hold, for removing the moisture from small closed parts.
Page 182 of 192

18.6.3.5 Final pressure reduction
In this stage the vapour emission is stopped, the kerosene absorbed by the
insulation is become vapour again, than condensing and coming to the
emitter. The final pressure of this stage is 0,26 mbar.
18.6.3.6 Fine vacuum

This is the final part of the dying. The vacuum is generated on traditional
way by pumps to the level of pressure is lower than 0,3 mbar. This phase
is shorter because the temperature of the insulation is starting from a
higher value, the moisture content is starting from a lower value. The end
of this phase is determined by VZ 402 PC Micafil equipment, which is
connected to the computer. The limit is for the removed water lower than
20 gr / tons x hour.
18.6.3.7 Air opening

Air let in the oven through the filter, when the pressure is normal the
active part is taken out from the oven.
18.6.4 Fixing
The active part shall be put into the dry room after removing the
temperature indicators. The dry room parameters in working hours:
temperature 20+5°C, relative humidity less than 25%. Out of working
hours the parameters shall be decreased by 10 %.
Within 60-108 hours shall be finished the fixing after the oven opening.
Within this period all the problems shall be solved, all the necessary
changes, additions shall be decided.
First the windings shall be pressed and fixed within 6 hours (except oil
impregnated transformer).
All the parts sensitive for moisture shall be protected (for instance
Weidmann Faltenbalg etc.)
The following data shall be documented on the quality page:
• Time passed between the oven opening and finishing the winding
pressing
• The whole time of active part on the air
Page 183 of 192

Note:
If Dry Room (air-conditioned room, with a controlled very low moisture
content, and temperature) is not available, the fixing shall be done in the
workshop. The type of second drying to be performed is depanding of the
fixing time.
This prescription is presuming the use of Dry Room.
The equivalent fixing times are the followings:
Dry room [hours] Workshop [hours]
48 12 <=950kV
60 14
<=1050kV
84 16,5
96 18
108 19 <=1425kV
18.6.5 Second handling, drying
This kind of handling has 3 main types

A – on room temperature
B – in vapour phase oven
C – vacuum oven with own tank
18.6.5.1 “A” type handling in the own tank
• It can be performed on an active part BIL≤950kV, staying in Dry

Room less than 60 hours or in the workshop less than 14 hours.
• If it spent more than 60 hours in dry room, decision shall be taken

by the engineering.
o Active part shall be put into the tank. The tank is connected to
the vacuum pump in that manner that the oil level can reach the
150 mm from the tank cover.
Page 184 of 192

o The handling is finished if the pressure in the tank was under
0,3 mbar for 24 hours.
18.6.5.2 “B” type handling (by vapour in oven)
• This type of handling is used for transformers with 950 kV < BIL ≤
1452 kV, staying in Dry Room max. 84 hours (16,5 hours in
workshop).
• If the time is longer, it shall be discussed with the engineering.
• The drying shall be performed according to the prescription for

vapour phase drying.
• After finishing the drying, the active part is taking out from the
oven, putting into the tank and the tank is connected to the vacuum
pumps.
• Before starting the oil filling, the vacuum shall be less than 0,3 mbar
for a min. 8 hours period.
18.6.5.3 “C” type handling in vacuum oven in the own tank

Applicable for transformers with BIL > 1425kV, staying more than 108
hours out of oven.
• Heating up according to the specification for vacuum oven.
• Starting the continuous vacuum after reaching the 90 ° C core

temperature
• Temperature limits to be considered
o Hottest spot in the oven is 125 °C
o Core temperature is max. 105 °C
o Insulation temperature is max. 115 °C
• Condition of finishing the process
o Core temperature is to be over 95 °C on the last 3 days
o Insulation temperature is to be over 100 °C on the last 3 days
Page 185 of 192

o Vacuum is under 0,3 mbar in the last 48 hours
o Water removing is under 20 gr / tons x hours in the last 24

hours
If Weidmann Faltenbalg or similar insulation part is used without
impregnation, the drying shall be in accordance to the supplier
prescriptions. If that part are in oil impregnated and hermetically packed
condition, the transformer parameters shall be kept during drying.
18.6.6 Oil filling, impregnation
18.6.6.1 Filling
After finishing the A, B or C type of handling, the vacuum proof oil
pipelines are to be assembled while the active part is under vacuum. The
air shall be removed from the pipeline before filling.
The oil parameters shall be the followings:
• breakdown voltage – min 240 kV/mm
• moisture content – max. 20 ppm
• temperature – 50-65 °C
• dissolved gasses – max. 0,05 tf%
The filling shall be performed under vacuum, at 0,6-1 mbar. The filling
shall be interrupted, if the pressure during the filling exceeding 1 mbar. It
can be continued after reaching again 0,6 mbar. The oil inlet shall be at the
bottom. The oil filling can be performed with a max. 300 mm/hour velocity.
18.6.6.2 Impregnation
The following suck in times shall be considered:
• 8 hours BIL < 950 kV
• 10 hours BIL 950 – 1425 kV
• 12 hours BIL > 1425 kV
Page 186 of 192

18.6.6.3 Relaxing time (includes the suck in time)
• 48 hours BIL ≤ 350 kV
• 60 hours 350 kV < BIL ≤ 450 kV
• 72 hours 450 kV < BIL ≤ 550 kV
• 84 hours 550 kV < BIL ≤ 750 kV
• 96 hours 750 kV < BIL ≤ 950 kV
• 144 hours 950 kV < BIL ≤ 1425 kV

The regulation referring to the relaxing period is described in a separate
method.
Page 187 of 192

Appendix 1
Placement of temperature indicators
Hot air circulating drying oven
Temperature measuring points:
incoming air temperature

outgoing air temperature
Temperature inside the oven (sensors are fixed on the wall)
Page 188 of 192

Appendix 2
Temperature sensors on the winding
Disc winding
Spiral winding
In order to achieve the proper result, the sensors shall be pushed to the surface and
protected against the heat radiation. If windings are in the oven with different
weights, the sensors are to be mounted on the heaviest one in middle height. If
windings are in the oven with similar weights, the sensors are to be mounted on the
winding nearest to the opening of the oven.
Page 189 of 192

19 Relaxing time of oil impregnated transformers
Relaxing time: the time passed between the finishing the oil filling and
starting the high voltage tests of the transformer
Purpose of relaxing: to get the proper electric strength of the high voltage oil
insulation system
The relaxing times indicated in the table are valid for the oil around the
transformer active part with the following conditions:
• The filled in oil is degassed (dissolved gas content is less than 0,05%)
• The temperature of the filled in oil: t = 60 – 65 °C
• The vacuum at the filling process: p ≤ 0,05 mbar, measured with
equipment mounted on the top of the transformer or measured in the
oven
• The velocity of the filling is max. 300 mm/hour
≤ ≤ ≤ ≤ ≤ ≤
Voltage level Um [kV]
72,5 123 145 170 245 420
BIL [kV] 350 450 550 750 950 1425
Relaxing time T
48 60 72 84 96 144
[hours]
In case of a transformer having very low required PD level, the extension of the
relaxing time should be suitable. The common decision shall be taken by the
Engineering and the Test Room.
Remarks:
1. The relaxing period is beginning when the transformer is completely filled with
oil including the conservator (the normal or the temporary one), and not
Page 190 of 192

necessary to make additional oil manipulation till to the finishing of the high
voltage test of the transformer.
The compensation of the decreasing oil volume due to the cooling down of the
filled in oil is not modify the starting time of the relaxing period if it is done
through the conservator and the oil level is still in the conservator.
2. If oil manipulation is necessary during the relaxing period, it shall be

extended.
2.1. The half of the duration form the beginning to the manipulation shall be
subtracted from the whole relaxing time. The given time is to be utilized as
relaxing time starting from the finishing the oil manipulations.
Example: The relaxing time for the transformer is 48 hours and it was
cancelled at 16 hours. The necessary relaxing time after finishing
the oil manipulations to the starting the high voltage test is 48 –
16 / 2 = 40
2.2. If the cancellation of the relaxing is happened after taking the half of the
required relaxing time, the 75% of the required relaxing time shall be
applied after finishing the oil manipulation.
Example: The relaxing time for the transformer is 48 hours and it was
cancelled at 38 hours. The necessary relaxing time after finishing
the oil manipulations to the starting the high voltage test is 48 x
0,75 = 38
3. The 2.1. and 2.2. points can be applied only if the oil level is not lowered to
the level of high voltage insulation elements and the necessary manipulation
can be done quickly (during the manipulation the oil temperature is not
decreasing very much).
4. In case of a transformer having separated oil chambers form the active part
having in contact each others only in the conservator, the following process
shall be used.
4.1. If the separate oil chamber contains materials to be oil impregnated (thick
paper, pressboard, and laminated wood), than the relaxing time is the same
as the relaxing time of the active part.
Page 191 of 192

4.2. If. in the oil chamber there are not materials to be oil impregnated, or only
thin paper (max 1-2 mm) is there, the necessary relaxing time is 12 hours
after the last air realising without realised air.
5. The separate oil chambers are also to be filled under vacuum, even if it is a
reduced one. If the structure is not vacuum proof at all, the filling shall be
performed in the vacuum oven.
6. In case of fully insulated transformers, the relaxing times given by the table in
the function of the Um is to be increased by 24 hours.
Example: 120 kV fully insulated unit
Relaxing time is 60 + 24 = 84 hours
7. The time necessary for oil impregnation is drastically increasing with the
decreasing oil temperature that is why the filled in oil temperature shall be
kept on the required 60-65 °C.
8. Since it is possible that the oil pump can suck in air to the system because of
any tightening problem, the operation of the oil pumps connecting to the
transformer shall be avoided during relaxing period.
9. During the relaxing period, air releasing shall be done frequently. If there is
released air at the end of relaxing time, the transformer must not be issued
for testing.
10. If the transformer is failed the test and the repair can be done quickly, the
unit shall be put back to the tank without new drying, and performing the oil
filling with the keeping required rules.
In that case the time between lifting out of the active part and closing the
tank is maximum 12 hours. The relaxing time can by decreased by 25%.
Page 192 of 192

Methods Assembly TR

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CONTENT

1 General transformer assembly method ............................................................................2

2 Core Building .................................................................................................................7

3 Assembly of core clamping...........................................................................................29

4 Potential ring body manufacturing ................................................................................30

5 Pre- and final gluing of the pressboard cylinder ............................................................38

6 Disc windings with turn over technology on horizontal machine...................................46

7 Two direction wound disc windings on horizontal machine ..........................................66

8 Disc winding manufacturing on vertical machine..........................................................86

9 Winding assembly method ..........................................................................................108

10 Preparation of transformer core...............................................................................115

11 Matching of the inner winding on the core (traditional method) ..............................119

12 Inner winging matching to the core by TRANSPOLIM...........................................125

13 Pressing of the windings mounted on the core.........................................................134

14 Joining of the winding rectangular copper conductors by butt welding ....................140

15 Joining of the winding rectangular copper conductors by butt soldering ..................144

16 Joining of the winding rectangular copper conductors by overlapped soldering.......149

17 Preparation of internal connection by crimping .......................................................155

18 Drying and impregnation of transformers................................................................165

19 Relaxing time of oil impregnated transformers........................................................190

1.1 Core stacking

1.1.1 Making a bandage

• Spool a bandage from polyglass tape.

1.1.2 Core stacking

1.1.3 Assembling the frame structure

1.2 Preliminary assembly of the winding

1.3 Assembling the windings in a phase-block

1.4 Electrical assembling

1.4.1 Preparing the core for assembly

1.4.2 Assembling the windings on the core

One after the other:

1.4.3 Mounting up the upper yoke

• Clamp the winding system on the core preliminary

1.4.4 Mounting up the connection walls, prepare for drying

• Make the earthing of the core.

1.4.5 Revision of the active part, tanking, oil filling

1.4.6 Preparing the transformer for testing

• Assemble the cable boxes. Try them on their final place.

1.4.7 Oil leakage test

1.4.8 Preparing the transformer for transport

1.5 Mechanical assembling

1.5.1 Preliminary assembly of the tank and the accessories

1.5.2 Preparing for tests

• Assemble the oil-air heat exchangers on.

1.5.3 Preparing for transportation

• Disassemble the coolers

The temporary process specification applies to stacking and erecting of transformer

2.1 Tools and devices

Maximum load of the device: 400 kN

2.1.4 Fitter’s tools.

2.1.7 Vessel and flat brush for applying the resin.

Balance for measuring the components of resin.

2.1.9 Master plate for stacking and other auxiliary devices.

2.1.10 nivelling plummet and water levels.

2.1.12 5 pc permanent magnets for checking the anti-magnetic feature of the

2.1.14 Dust exhauster

2.1.15 Insulation tester of 500 V and testing set of 2 kV.

2.1.16 Plastic foil to cover the core.

2.3.11 Dismantle the turning base and put aside.

The deformed adjusting plates shall be renewed if necessary.

2.3.22 Apply the glue at the places as follows:

a) Edges of the limb sheets on both side