INSTRUCTION FOR OPERATION &

MAINTENANCE
 TRANSPORTATION, INSTALLATION, COMMISSIONING
AND MAINTENANCE OF
SGB CAST RESIN TRANSFORMER
TITt 12/2006
Site Training Hand out for cast resin transformer
Contents

1. General Information 5. Installation

2. Packaging 6. Commissioning
3. Transport 7. Operation
4. Storage 8. Maintenance

1. General Information

According to national regulations ( VDE 0532, part 6 ) and international resolutions ( IEC 726 ), cast
resin transformers are classified as dry-type transformers.

Characteristic technical values and constructive design conform generally to DIN 42523 and especially
to customer specification for each order.

Special characteristics of the cast resin transformer are their HV windings, cast completely in resin and
their LV windings, which are insulated in synthetic resin and come most often in the form of oil windings.
These features differentiate cast resin transformers from other dry-type transformers in that they enable
better partial discharge, short circuit and electric strength (especially switching impulse voltage and
lightning impulse voltage strength) and higher resistance to detrimental environmental conditions such
as humidity, dampness and dust.

All other technical details are either visible (since cast resin transformers do not have tanks) or can be
found the following sources :

- rating plate and connection diagram (on the transformer)

- dimension drawing and item list (upon request)
- measurement and test sheets
- information about transformer enclosures (where applicable)
- wiring diagram for temperature control

2. Packaging

Cast resin transformers are not sensitive to natural humidity. Domestic transportation over shot distances
on covered vehicles generally does not require packaging. For long distance or overseas transportation,
the transformer are wrapped in protective covering and placed in containers or wooden crates.
Packaging details are decided in each individual order either acc. to customer specification or by SGB,
based on the transport route.

3. Transportation

3.1. When lifting the transformer, all 4 lifting lugs must be used simultaneously. Lifting directly by the yoke
is not permissible !.

3.2. Lift crates and containers only where indicated.

3.3. Use only pneumatic suspension vehicles for street transportation.

3.4. For short distance transportation by truck, place the undercarriage of the transformer on squared timber
and secure these against sliding on the loading area. Use the 4 lugs in the upper clamping beams to
fasten the transformer with lashes. Adjust the tension with the lash control device at a minimum of 30
slack angle above the lash belts. Rates are given on the plate near the lugs levels for acceleration during
transport must not exceed 0.8g in driving direction and 0.5g in transverse direction.

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 3.5. In case of damage or visible shifts of the winding positions in the transformer, submit complaints
immediately to the forwarding agent; if necessary, contact SGB.

3.6. Transport with fork lifts, for example, should only be carried out with lifting gear when the 4 lifting lugs
are used (see 3.1).

4. Storage

Temporary storage during transportation or prior to installation must be done only in rainproof storage
areas. Plastic coverings should be fitted over the transformer in such a away that condensed water is
prevented from forming, for example by rear ventilation. The same applies to transformers already
installed in enclosures.

5. Installation

5.1. Remove packaging and transportation materials and clean the transformer. Special care should be given
to the cooling ducts and the spaces between the windings.
"DO NOT PUSH THE OUTER COIL DURING INSTALLATION WORK".

5.2. Position the transformers free from wobble in the station. Lock the wheels. When using anti-vibration
supports be sure to position them exactly in relation to the transformer.

5.3. Make sure there is a properly dimensioned ventilation system in the room where the
transformer is installed. (Take higher load losses into account under AF operation). For this set up,
guidelines in the work sheet J11 " Transformer Substations" can be used. This will be sent upon request.

5.4. Unpack and remove parts that have been packed separately for transportation, such as connecting
leads, control boxes, etc. and mount them (see 7.3).

5.5. The undercarriage must not be dismantled from the bottom yoke clamping beams !

5.6. If protection enclosures have been delivered, install it as per drawing enclosed. Roller must be roll above
flat surface like mild steel plate.

5.7. If there is to be a great deal of time between installation and commissioning of a transformer, and if
there is a danger of the transformer becoming dirty during this time, use plastic coverings (see 4).

5.8. Connection of the Temperature Control

PTC are used in the LV windings and for each control system connected in series. Each control
system (e.g. for alarm, tripping, fan control) has a separate PTCs row with different nominal
response temperatures (NRT) marked by the colour of the individual leads. When one thermistor
reaches his NRT, the tripping relay is operated. This way, single-phase overloads are also prevented.

The terminal strip which connects the thermistor rows with the tripping relays is generally located on
the upper clamping beam. The tripping relays are usually packed separately when delivered, have
screws and snaps for clamping and are for control panel installation.
See separate diagram for temperature control wiring.

5.9. Another sensor is PT100 which allow to monitor continuous temperature of transformer . The sensor
is located at phase 2V (center coil). All sensors are connected to 1 realy called, TS 02. The relay could
control the fan, provide dry contact for alarm and trip to up stream breaker.
Type of controller : Jopich or elbag
Input voltage : 24 to 230 AC or DC
Input sensor : 2 PTC sensor (Alarm and trip) , 1 PT100 (Fan control)
Fan operated: Fan will operate above set point (temperature) and 20 minute on hold when temperature
goes to below than set point.

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 Setting Instruction: Push and hold on set button for 3 second, display will blinking push up of down to set
new set point.
Mulfunction display; Refer to checklist for error message (Elbag)

6. Commissioning

Before starting, do the following :

6.1. Remove plastic coverings.

6.2. Connect earthings properly and check them.

6.3. Check transformer for dirt and foreign bodies; clean again if necessary.

6.4. Make sure the upper coil supports are tight. The 20 mm thick artificial rubber supports must be presses
a little bit. Tighten axial clamping bolts if necessary.

6.5. Connect temperature control systems and check them by interrupting the sensor circuit on the terminal
strip (see 7.2).

6.6. If fans are included, check that propellers turn in the proper direction and that the control device works
(see wiring diagram, temperature control).

6.7. Do phase connection according to connection diagram (see 6.9). If the tapping connection installed by
the manufacturer has to be changed to another tap position, complete according 7.3.

6.8. Check and tighten all screw/bolts in electrical connections! see last page for torque values.

6.9. Check clearances :

Places all connections and control leads, as well as support devices and fastenings with a
sufficient distance from the HV cast resin windings. We recommend clearance such as those
for bare conductors, as in VDE 0532 :

Um = 12 kV - 115 mm ]
Um = 24 kV - 215 mm ] installation height < 1000 m above sea level
Um = 36 kV - 300 mm ]

CAUTION !

The HV cast resin windings are insulated by a coat of cast resin, but they are not safe to touch
in the sense that the VDE regulations provide. This means that work on the transformer is
off-circuit and earthed.

7. Operation

The general regulations and conditions of operation in VDE 0532 / IEC 75 apply to cast resin
transformers, provided that customer specifications do not deviate from them.

Cast resin transformers differ from fluid filled transformer in their overload capacity. Since common
guidelines for loading are missing, the following guidelines should be abserved :

7.1. Overload Capacity

Compared to oil-filled distribution transformers, cast resin transformers have different thermal capacities,
temperature of the insulating system and the thermal time constants, which determine the overload

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 capacity depending on the pre-load, temperature of the coolant and time. Because of the various
contructions and models, general guidelines for loading cannot be applied. They must be calculated
individually and are available upon request.

7.2. Temperature Control

The thermistors (thermistor rows) are connected in series and built into the LV windings. They generally
consist of two level with a difference in nominal response temperature (NRT) ,The sensor is PTC or PT100
whereby the lower NRT is used as an alarm and the higher NRT to trip the transformer.
It is tripped by relay that installed inside the marshalling box. Basically convert from Sensor signal to dry contact
When the higher NRT for tripping is reached, the temperature limit of the insulation system is usually
exceeded and life expectancy of the transformer is thus reduced.

The lower NRT for alarm reacts at an ambient temperature of 20°C if the continuos rated load
temperature has been reached. In this case the load must be prevented from increasing.

Cause for overheating may be :

- Overload
- Ambient temperature higher than 40°C at rated load
- Insufficient cooling of the transformer (check ventilation)

Under no circumstances may the thermistors be replaced by thermistors with a higher rated
operation temperature !

7.3. Changing the tap links

Tap change only when the transformer is off-circuit !

Change the HV tap links individually, without changing the position of the delta connection :

- Loosen the connection between tap link and delta connection

- Remove fastening bolt from the terminal insert
- Slide tap link over the newly chosen terminal, insert and refasten tightly with bolt
- Reconnect the tap link to the delta connection

Tap Changer for Cast Resin :

Voltage : 11/0.433
Taping range : 2 * +/-2.5

Hint :
1. If the outgoing voltage is high , bring down the voltage
to normal voltage by changing the tap to higher tap
e.g. :
1.1If the output voltage is 260V (at tap 3 ,single phase voltage)
Action to be taken : Change the higher tap ( tap 1)
1.2 The voltage should come down to around 247V

2.1 If the voltage is too low , change the tap to lower tap (tap 4
Photo No 1 or tap 5)

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 Photo no 2 Photo No 3

Copper link

S1
S2

1. Un tighten the screw S1 and S2 3. Lead no 2 connect to no 7(refer to photo no3)

2. Swing the copper link to selected terminal number un tighten the S1 and S2 and connect the S2 to no 7
which indicate in the connection diagram (All phase has to change)

IMPORTANT:Change all phases (1U , 1V , 1W) .

DO NOT CHANGE 1 PHASE ,IT WILL CAUSE UNBALANCE
VOLTAGE .
Counter-moment must be applied to the HV tap links with an open ended spanner, size 20-21,
when loosening or tightening the connections (see sketch) !

See last page for torques.

8. Maintenance

Cast resin transformers are largely maintenance free.

8.1. Function of fans and fan control must be checked approx. every six months.

8.2. Check pollution of transformer surface within self selected intervals and clean them if dirty. After
installation in a new place with unknown pollution risk we recommend a first check latest six months
after. If pollution is unimportant check intervals can be lengthened without problems. If transformer
surface are especially dirty, cleaning should be more frequent according to the extent of the dirt, and
preventive measures should be taken to reduce the amount of dirt in the future.

When cleaning, special attention must be paid to the cooling ducts and to the spaces between the
windings. Cleaning is done with vacuums, dry compressed air, and cleaning cloths. If dirty is very
persistent, cleaning cloths can be impregnated with a special cleaning fluid (e.g. Rivolta S.L.X. - Top,
supplier Bremer & Leguil GmbH). In the case we recommend you to put the treated surface under
seal again (should be done with plunged into varnish type 3H, supplier Dr. Wiedeking or into shellac
varnish).

8.3. The function of the temperature control must be checked every 6 months by interrupting the thermistor
row on the terminal strip.

If the resistance of the thermistors is checked, the voltage used with the measurement device
must not exceed 2.5 V !

Torques for copper bar connections

Thread Size Torques *) * ) without lubricant

M 10 40 Nm
M 12 70 Nm
M 16 140 Nm

Torques for tap links and threaded inserts

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