Dry-Type

Trasfor S.A.
T ransformers
Molinazzo di Monteggio
Lugano
(AN/AF/WF +Heat Exchangers)
Switzerland
I NSTALLATION , O PERATION
INSTALLATION
OPERATION & M AINTENANCE M ANUAL
MAINTENANCE

Revision : XII 1 GENERAL

Date : February 2012 The instructions in this manual apply to transformers up to 36kV, single
or three phases, cast resin or dry type, power or distribution which can
be fitted with Air / Water heat exchangers. The manual contains the
CONTENTS basic instructions for installing, maintaining, and operating the
1 GENERAL transformer and its associated equipment.
1.1 EQUIPMENT DESCRIPTION
1.2 ACCESSORIES
The transformers described in this manual are delivered completely
assembled and ready for operation. The only connections to be made
2 DELIVERY / HANDLING are the HV & LV main power connections, the Safety earth, the over
2.1 LIFTING temperature protection system and the auxiliary components.
2.2 LATERAL MOVEMENT
3 STORAGE
Further detailed descriptions of commissioning, operation and
maintenance instructions of other components or devices such as Heat
4 INSTALLATION Exchangers or Temperature Protection Relays are supplied separately
4.1 SITE PREPARATION as appendices (See Section 8 for listing).
4.2 VENTILATION
4.3 CONNECTION PRIOR TO COMMENCING ANY OPERATION ON THE SUPPLIED EQUIPMENT,
4.4 START UP PLEASE READ THIS MANUAL CAREFULLY AND ADHERE STRICTLY TO THE
5 OPERATION INSTRUCTIONS WITHIN.
5.1 TAP CHANGING
5.2 THERMAL PROTECTION IN ADDITION TO THIS MANUAL, THE MANUFACTURER SHOULD BE
5.3 SWITCHING CONSULTED FOR RECOMMENDATIONS ON SPECIAL CONDITIONS.
6 MAINTENANCE THE INSTRUCTIONS AND ACTIONS COVERED IN THIS MANUAL SHOULD
7 TROUBLE SHOOTING ONLY BE CARRIED OUT BY SUITABLY QUALIFIED PERSONNEL OPERATING
7.1 OVER HEATING UNDER THE CURRENT RELEVANT LOCAL REGULATIONS.
7.2 SMOKE
7.3 VIBRATION AND NOISE TRASFOR CANNOT BE HELD RESPONSIBLE FOR ANY DAMAGE TO
7.4 SHORT CIRCUIT PERSONNEL OR GOODS, WHICH HAVE OCCURRED AS A RESULT OF THE
7.5 INSULATION FAILURE FAILURE TO COMPLY WITH THE INSTRUCTIONS IN THIS MANUAL.
7.6 CONTAMINATION
8 HEAT EXCHANGER Trasfor products are designed, constructed and tested in compliance
with the IEC Standards.

Office & Works:
CH-6995 Molinazzo
di Monteggio
Tel. +41 91/611 30 11
Fax. +41 91/608 24 60
E-mail: infotrasfor@trasfor.ch
http://www.trasfor.ch
All transformers are routine tested according to IEC 76 & 726
Standards. Type tests and / or Special tests will be conducted as
specified. Please see the relevant test certification.
Should further information on the following pages be required, please f
eel free to contact Trasfor on the numbers listed opposite.
Art:00900236

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1.1 EQUIPMENT DESCRIPTION

The complete equipment may consists of:

• Magnetic Core
• HV Winding & LV winding
• Core Clamping and Structural Support
• Client termination / Connection points
• IP23 to IP54 Enclosure
• Air to Water AFWF Heat Exchanger system
• Thermal Protection & Temperature Monitor
• Anti Condensation Heaters

Please refer to the General Arrangement drawing for details or any further fittings.

NOTES AND DRAWINGS CONTAINED HEREIN MAY DIFFER IN ASPECT FROM THE DESIGN DELIVERED.
They are for reference only and are subject to change without notice.

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1.2 ACCESSORIES

Protective enclosures are supplied pre-assembled and are mounted on the transformer core assembly.
Enclosure
The transformer-mounted enclosure permits the transformer and enclosure to be lifted and positioned
as a single composite unit. The enclosure is fitted with removable panels to allow access to the
transformer during installation and maintenance. These panels are marked to ensure correct fitting of
the appropriate panel in the required position. See General Arrangement drawing for location of base
fixing holes.
Cable Entry
Cable entry is achieved directly into the transformer enclosure via un-drilled gland plates or Multiple
Cable Transits (MCT). See the General Arrangement drawing for type and location. Client connection
points for both the HV and LV power circuits are provided internal to the enclosure and are mounted off
the transformer assembly.
Thermal Protection
The transformer, as standard, is provided with a thermal protection relay – See schematic drawing.
The thermal sensing elements for the thermal protection can be PT100 or PTC thermistors. These are
positioned in the LV winding of each phase and are removable in the event of damage / failure.
If PTC thermistors are used, two sets are usually provided: the first one to provide an Alarm signal
and the second one for the Trip signal. Each set is connected in series and wired to a terminal strip.
Temperatures of PTC thermistors are preset, and cannot be adjusted. The PTC thermistors can be
connected to a temperature relay to operate a circuit breaker or provide remote indication.
If PT100 sensors are installed, the same functions as by PTC thermistors are supplied; moreover the
PT100 can provide an effective local temperature indication that can be displayed through an
appropriate temperature control unit. If PT100 are installed, both Alarm and Trip temperatures can be
independently adjusted by the user through programming of the temperature control unit.
The PT100 sensors monitor the coil temperature on each phase and permit alarm and trip signals to be
provided via the thermal protection relay. The Alarm and Trip settings can be independently adjusted
by the user. For Alarm and Trip settings please see Section 5.2.
In addition to the alarm and trip contacts the relay has 2 further contacts.
a) Fan control contact: If the transformer is fitted with an Air/Water heat exchanger. The heat
exchanger is fitted with 2 off 3-phase motors which drive the AF cooling fans. These fans must be
operational for 100% of the time that the transformers remains energised. The fan are not intended to
be thermostatically controlled using the fan control relay on the thermal protection relay. The fan control
function is supplied as standard on this device but should NOT be utilised during the operation of this
transformer. The security of the power supply to the fan motor is the responsibility of the user.
b) Fault contact: This provides a signal in the event of a PT100 sensor failure OR in the event of loss
of power to the monitor. In both cases a fault signal is generated. This will not initiate a trip signal to the
protection circuit. The fault relay is supplied as standard on this device and must be utilised during the
operation of this transformer. The security of the power supply to the monitor is the responsibility of the
user.
Details of the operation of the temperature monitor device are located under section 5.2 Thermal
Protection.

IN ALL THE ABOVE CASES IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT THE THERMAL
PROTECTION IS CORRECTLY CONNECTED TO THE SUPPLY CIRCUIT BREAKER (VIA A SHUNT TRIP OR
SIMILAR DEVICE). THIS IS TO ENSURE THAT THE TRANSFORMER WILL BE DISCONNECTED FROM THE
SUPPLY IN THE EVENT OF A FAULT CONDITION.

Please refer to the Electrical Schematic supplied as part of the drawing package for details

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 Warning: It is responsibility of the user to set the control unit with the correct
temperature levels for Alarm and/or Trip before energizing the transformer.

Always refer to the Electrical drawings for details of the type of thermal protection or
fan cooling circuit provided. In case of uncertainty please contact the manufacturer.

Air / Water Heat Exchanger

The transformer enclosure is IP44/54 non-ventilated.

The removal of the dissipated losses is achieved via the Air / Water heat exchanger. The heat
exchanger provides a ‘closed –circuit’ air cooling system. The heat exchanger is a double-tube design
with the cooling fin material being 90/10 CuNi.

The forced air (AF) circulation is achieved via electrically operated fans. There are 2 fans mounted on
the heat exchanger(s) body. These are powered by 3 phase motors. These fans must both be
operational once the transformer is energised.

The forced water (WF) circuit for the heat exchanger is accessed via an inlet and outlet flange located
on the bottom of the heat exchanger body. The inlet and outlet connections are supplied with water
connections flanges to BS 4504 PN16.

The forced circulation of the coolant is provided by others. The flow rate should be maintained in line
with the data specified on the drawing.
The maximum working pressure is 6 bar and the test pressure 10 bar.

The water-cooling circuit is designed for CLOSED circuit operation using FRESH water. It is
permissible to use Nitrites within the coolant if the cooling system is designated as a CLOSED system
and is not therefore in direct contact with oxygen which could lead to the production of ammonia within
the coolant. Routine maintenance checks will not accelerate the production of ammonia but care should
be taken to ensure that the ammonia content within the coolant does not exceed 5ppm.

The heat exchanger must be operational once the transformer becomes energised and is not
dependant upon the kVA loading of the transformer.

The heat exchanger is fitted with a leak detector to detect loss of coolant. This is supplied with
changeover contacts. – See schematic drawing.

The air inlet and air outlet ports inside the transformer enclosure are fitted with PT100 sensors. The
PMS system should be set to detect these two temperatures. 1 x air inlet to Alarm at 40°C and 1 x air
outlet to Alarm at 50°C.

The heat exchanger is fitted with an air vent for use during filling and a drain plug.

Details of the operation of the heat exchanger are located under section 8 Heat Exchanger.

Anti-Condensation Heaters
The transformer is fitted with Anti-Condensation Heaters. Each heater is rated 150W. For supply
voltage details see the General Arrangement Drawing. If the transformer is de-energised for any period
of time longer than 24 hours then the anti-condensation heaters should be connected to the
appropriate supply and should remain active during the whole period of de-energisation. Please refer to
the General Arrangement drawing for details of anti-condensation heaters and their position. Care
should be taken to avoid contact with the ACHs during operation to avoid injury to personnel.

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2 DELIVERY / HANDLING

Following the delivery of the equipment the transformer or the protective packaging (protective
sheeting, packing crate etc) should be inspected for signs of transit damage and to ensure that the unit
has not been tampered with during transit. The equipment should also be checked to ensure that it has
been adequately protected from the weather and that no water has entered either the packaging or the
assembly.

ANY DAMAGE OR WATER INGRESS SHOULD BE RECORDED ON THE DELIVERY DOCUMENTATION &
IMMEDIATELY NOTIFIED TO TRASFOR.

Unless specifically requested in the contract Trasfor will not be responsible for the offloading, handling
and positioning of the equipment. The personnel responsible for this operation should adhere to the
following instructions to ensure that the transformer is handled correctly.
The total weight of the assembly is indicated on the General Arrangement drawing and also on the
rating plate attached to the enclosure.

Prior to any lifting operation please ensure that the crane, slings, chains and lifting tackle are
adequately rated and suitable for the specified weight.
For lifting purposes the Centre of Gravity can be considered as the geometrical centre of the unit.
At all times the transformer assembly should be stored indoors in dry conditions and be fully protected
from water, dust, direct sunlight and general contamination.

During the removal of the packing material care is to be taken not to damage the equipment. Ensure
that the transformer assembly is complete and undamaged and that any ancillary fittings or spare parts
listed have been correctly delivered. Any missing components should be reported to Trasfor
immediately.
If the equipment is not intended for immediate installation please refer to Storage chapter 3.

2.1 LIFTING

Personnel should not be positioned under the equipment at any time during lifting. All
local regulations relating to health and safety at work should be adhered to at all times.

1. Ensure that the lifting equipment is adequately rated for the specified weight (shown on the
rating plate) and fit for purpose.
2. Transformer mounted enclosures are designed to be lifted as a complete unit and the lifting
points will be rated accordingly.
3. The lifting points are located inboard of the enclosure and are accessed via the lid mounted
removable steel cover. Following the lifting operation this cover is to be replaced immediately to
prevent ingress of foreign bodies and / or contamination.
4. Use only lifting slings of sufficient length to obtain an angle of 45° between the transformer's top
clamping profiles and the slings. See lifting label located on enclosure.
5. Lift the transformer carefully, avoiding abrupt movements.
6. Avoid standing directly underneath the transformer, when lifted, unless absolutely necessary.
7. Lower the transformer slowly and place it gently on the ground.

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2.2 HORIZONTAL MOVEMENT

Do not use the transformer windings, terminals, connection bars or auxiliary terminal
boxes for pushing or towing purposes

BY ROLLERS
1. The transformer should be placed on adequate steel channels / plates suitable for this purpose.
2. Should this not be possible, ensure that the surface is level and flat and that it can support the
transformer's weight shown on the rating plate(s).
3. To drag the transformer, use only the holes provided in its lower profiles.

BY FORKLIFT (FOR TRANSFORMER WITHOUT ENCLOSURE ONLY)

1. Position the forks under the bottom clamping profile with the forks as far apart as practicable.
2. Lift only a small amount above the floor surface at all times during transit.

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3 STORAGE
 
Warning! If the transformer is de-energized for any period of time longer than 24 hours
then similar precautions to the above must be taken. Anti-condensation heaters (if
fitted) shall be connected to the appropriate supply and shall remain energized during
the whole period of de-energization of the transformer
Please refer to the General Arrangement drawing for details concerning the anti-
condensation heaters.

 
 
General

The packing of each transformer is designed for protecting it during transportation and short term
storage; if the transformer is not to be installed and put into service directly upon receipt on site it must
be adequately protected during the storage period as follows :

1) Wide temperature changes must be avoided; the minimum ambient temperature must never be
lower than -20°C.

2) Transformers stored indoor

The transformer shall be placed on pallets or in a case, stored indoor in a well ventilated storage area
and protected from the following agents:
¨ Water, water vapour, moisture
¨ Solar radiation
¨ Saline environnement
¨ Pollution
¨ Vermin.

3) Transformers stored outdoor

If the transformer is to be stored for longer than 24 hours without being energized, one of the
following conditions must be met:
• the original sealed packing can be maintained:
o before any storage operation check the integritiy of the heat-sealed polythene
liner bag foreseen for sea-freight transportation.
o Periodically check the level of humidity and if necessary replace the run-down
silica gel bags and re-seal the bag. In any case replace the silica-gel bags and
re-seal the bag every 12 months; please refer to shipping date for the first
replacement.
• the original sealed packing must be removed: energize the anti-condensation heaters
until the transformer remains not energized. If the transformer is not equipped with anti-
condensation heaters, these must be duly installed and energized (if necessary refer to
Trasfor for relevant information)
Before service a thorough inspection and electrical test must be performed by qualified personnel.

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4 INSTALLATION
Installation of this equipment must be done in full compliance with the "Health and
Safety at Work Act"’ relevant to the country of installation and all work must be carried
out by suitably qualified personnel.

During the installation of the transformer all previous instructions relating to the
handling and storage are applicable

4.1 SITE PREPARATION

The equipment is designed for indoor installation. It must only be operated in a clean, dust free
environment, protected from direct sunlight, rain, snow and contamination. The ambient temperature
must not fall below -20°C (see Storage chapter 3).
Ensure that the floor of the transformer room is capable of supporting the weight of the equipment.
Sufficient space should be left around the perimeter of the transformer to ensure:
♦ Ease of installation, cable connection and maintenance
♦ To maintain adequate circulation of cooling air and water coolant
♦ To maintain minimum electrical clearance in line with local safety standards.
Special consideration should be given to the installation of any transformer if noise is a factor in its
location and operation. Many locations can result in an amplification of the sound level.
4.1.1 SITE PREPARATION TRANSFORMERS FOR INDOOR INSTALLATIONS

If the equipment is designed for indoor installation, it must only be operated in a clean, dust free
environment, protected from direct sunlight, rain, snow and contamination. The ambient temperature
must not fall below -20°C (see Storage - chapter 3).
4.1.2 SITE PREPARATION TRANSFORMERS FOR OUTDOOR INSTALLATIONS

If the equipment is designed for outdoor installation, please refer to general drawings to ensure that the
transformers is placed into a correct environment; specific attention must be given to the presence of
corrosive atmospheres.
4.1.3 SECURING
Please refer to the drawings of the specific transformer and general layout drawings to see how the
transformer must be secured to the floor; following the customer’s requirements, two main securing
options are available: by welding or by bolting.
Welding: if securing of the transformer is foreseen by welding then be aware that proper welding are
performed and from qualified welding personnel.

Warning: ensure proper protection to all transformer’s parts in order to avoid damage
due to projection of weldings.
Tigthening: if securing of the transformer is foreseen by bolting, use the special holes provided in the
base supports; ensure that joints elements are properly dimensioned, of proper steel strength and
tightened with the correct torques. We suggest to use calibrated torque wrenches.

4.2 VENTILATION / COOLING

In order to make optimum use of the full transformer rating it is essential that the losses produced by
the core and the windings are effectively removed. Obstructions around the transformer or adjacent to
the enclosure ventilation openings which could restrict airflow must be avoided. As a general rule an
airflow rate of 5 m3 / minute for every kW of transformer loss produced can be used as a guide.
The design ambient temperature should never be exceeded.
For permissible overloads or increased ratings in lower ambient temperatures please refer to
IEC 60076-11 "Loading Guide for Dry-Type Power Transformers".
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Should the existing ventilation or air conditioning in the transformer room not allow the correct removal
of the losses, additional fans or ventilation must be provided.
If the transformer is provided with cooling fans for forced ventilation (AF or ANAF), the fans will be
controlled via the relevant panel supplied with the unit. The circuit diagram will be located in the panel.
Please refer to the Electrical Schematic drawing for details of the type of thermal protection or fan
cooling circuit provided.

4.3 CONNECTIONS
Always have a copy of the General Arrangement drawing and the Electrical Schematic drawings
available during installation.

The removal of the enclosure panels or doors will provide improved access during cabling and
installation. These must be replaced prior to commissioning and energisation.

To prevent injury to personnel and or damage to equipment the earth terminal of the
transformer must be connected to the main installation (or sub-station) earth before
any other supply cable connections.

Prior to the connection of any external cable or bus-bar the contact area of the jointing surfaces must
be cleaned of any dirt or grease using a wire brush or suitable abrasive. Any swarf or metallic dust
produced during this operation must be cleaned from the joint face. Care must be taken to ensure that
these particles do not come into contact with the windings. The joint face should be treated using a
suitable jointing compound paste. In areas where the atmosphere is particularly corrosive the joint
should be further protected using a suitable varnish or paint.

All mechanical and electrical connections shall be made using Class 8 (Cf. DIN 933 & 934) steel
components (nuts, bolts, washers, etc) treated against corrosion (plated, anodised etc). All nuts and
bolts shall be used with the addition of a Contact Ripped Spring Washer under the nut and directly
against the electrical termination point, and a plain washer under the head of the bolt.
If remaking of an already existing connection is needed, take care that the new connection is following
the same configuration of the existing one (type and position of the washers included).
The connections shall be tightened using a torque wrench inline with the appropriate torque settings
listed below (see Table 1). Following a period of one month after the initial installation all connections
should be checked and if necessary re-tightened to the original value.
The torque values are shown in the following table, valid for nuts and bolts in steel 8 / 8.

At the end of the guarantee period we suggest you to get in contact with our
Customer Service, in order to benefit from our skills, our professionalism and our
experience on transformers maintenance.

Tightening torques [Nm]

Bolt M 3 4 5 6 8 10 12 14 16 20 24 30
A Cl. 4.6 0.5 1.2 2.4 4 10 20 32 50 80 160 280 570
B Brass Nuts - - - 8 12 25 40 - 75 120* - -
Cl. 8.8 INOX
C Brass Inserts
1.4 3.3 6.5 11 25 50 90 140 220 450 760 1550
*For thin M20 brass nuts with 27mm hexagon : reduce torque at 80 Nm
**For connections with 0.5d counter-nut tighten with class 4.6 torque (row A)

Table 1 - Tightening torques (electrical and mechanical connections)

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Care must be taken to ensure that all cables have adequate slack and are not under any mechanical
strain. This includes both power cables and auxiliary supply cables. No cable should be connected that
will cause mechanical stress to the termination point. All cables should be adequately supported so that
their weight is never supported by the termination point. Cable support cleats are arranged on both HV
and LV sides if required. These are adjustable vertically in increments of 100mm. The correct
positioning of the cables and any necessary cable support is under the responsibility of the installation
personnel. When making electrical or mechanical connections between the transformer and the
incoming / outgoing power circuits, care should be taken to avoid the transmission of vibration.

Cables / bars being connected to the transformer should only be connected using the termination
points intended for this purpose. These termination points are clearly marked on both the transformer
and on the General Arrangement / Electrical Schematic drawings.

Modifications to the original transformer connection configuration (for purposes of phase rotation,
vector group etc) are not recommended without written confirmation from the manufacturer.

All connections for auxiliary supplies can be located in the terminal boxes Referenced JB1 & JB2

JB1 contains connections for all PT100 thermal sensors and the T154 temperature Relay.
JB2 contains connections for AF cooling motors, the motor starters, the Anti-Condensation Heaters, the
water leakage detector.

The installation personnel are also responsible for the correct installation of the thermal protection
device fitted to the transformer. If correctly installed and connected to the supply circuit breaker (via a
shunt trip or similar device) the thermal protection will enable the transformer to be disconnected from
the supply in the event of a fault condition and will help to prevent irreparable damage to the
transformer. Please refer to the Electrical Schematic drawing for details of the type of thermal
protection provided.

FAILURE TO CONNECT THE THERMAL PROTECTION IN LINE WITH THE MANUFACTURERS INSTRUCTIONS
WILL RENDER THE GUARANTEE NULL AND VOID.

4.4 START UP

All operations to the transformers must be carried out with the transformer de-
energised, all the terminals earthed and in full compliance with Health & Safety
regulations

Contact with the energised transformer coils or terminations must be avoided. The
resin insulation system will not provide sufficient protection from electric shock.

Ensure that General Arrangement Drawings / Electrical Schematics and Test Certificates are available
before commencing any operation. Prior to energising the transformer, the core and coil assembly
should be thoroughly cleaned (see Maintenance chapter 6).

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 PRELIMINARY CHECK LIST

1. Check the compatibility between the transformer rated values and the system(s) to which it will
be connected.
2. Check to ensure that minimum electrical clearance is in line with local safety standards.
3. Check the actual system voltage of the supply system and if provided adjust the supply voltage
tapping accordingly. These are off-circuit/off-voltage tapping links (see Tap changing chapter
5.1).
4. Check that the control wiring to the thermal sensors in the windings have not been damaged
during installation.
5. Check to ensure that the thermal sensors are connected to the thermal protection device and
that this is correctly connected to the supply circuit breaker (via a shunt trip or similar device).
6. Check that the main transformer earth is connected to the installation earth or sub-station earth.
7. Carry out a visual inspection of the complete equipment. Remove any tools and or left over
materials. Ensure that all ventilation grills are unobstructed and that the free air circulation is
adequate.
8. Check that all auxiliary equipment is correctly connected and functional.
9. Replace all protective enclosure panels.

IF THERE IS ANY DOUBT REGARDING ANY OF THE ABOVE CHECKS PLEASE CONTACT THE MANUFACTURER
IMMEDIATELY.

When the Commissioning Engineer is satisfied with the results of this test, and the
correct permits have been provided, the equipment may be energised.

All operations involving HV switching of the transformer, either in or out of circuit, must be performed
with the ambient temperature between -5°C and +50°C.
Energisation of any transformer will produce magnetic phenomena called magnetising inrush current.
These transient currents will be of considerable amplitude and will produce electro-dynamic stresses
within the winding. Opening the HV circuit breaker will also produce considerable voltage transients
causing dielectric stresses within the winding insulation. The transformer is designed to withstand such
stresses however it is recommended that repeated operation of the HV circuit breaker be kept to a
minimum. If repeated operations are to be made please contact the manufacturer for guidance.

It is advisable, in the first instance, to energise the transformer at no load (this allows
for a possible check of the no load current and of the noise level) and then to proceed,
if possible, with a gradual increase of the load.

When the transformer is operating close to its rated load and if it is fitted with a thermal protection
device, which permits a visual indication of the individual phase temperatures, it is recommended to
check the temperature levels.

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5 OPERATION
All operations to the transformers must be carried out with the transformer de-
energised, the terminals earthed and in full compliance with Health & Safety
regulations.

Contact with the energised transformer coils or terminations must be avoided. The
resin insulation system will not provide sufficient protection from electric shock.

5.1 TAP CHANGING

HV tapping links are provided to allow for supply voltage variation. These are of the
bolted link variety and must be manually adjusted only with the transformer in the de-
energised condition (off-circuit).

1. Isolate the transformer from the supply (primary and secondary side). Ensure that all safety
earthing facilities or interlocks are in place and that the appropriate permit to work has been
obtained.
2. Check open circuit on both HV and LV side.
3. Ensure that a safety earth is in place on the HV and LV terminals.
4. Remove the tapping link bar from the factory set position. Clean all contact surfaces.
5. Using the connection diagram and the Electrical Schematic drawing re-position the bar onto the
required voltage range. Ensure that tappings on each of the phases are set in the same
position. For transformers with Dual Primary windings ensure that the tappings are set the same
on all 6 coils.
6. Insert and re-tighten the bolts using the washers supplied. The bolt should be tightened using a
torque wrench to the relevant setting as illustrated in Maintenance chapter 4.
7. Disconnect the safety earth and apply start up procedure as illustrated in Start up section 4.4.

5.2 THERMAL PROTECTION

The thermal sensors are located in the LV winding of each phase and they are removable in the event
of damage / failure. Sensors can be supplied as either PTC thermistors or PT100 linear devices.
If PTC thermistors are used, two sets are usually provided: the first one to provide an Alarm signal
and the second one for the Trip signal. Each set is connected in series and wired to a terminal strip.
Temperatures of PTC thermistors are preset, and cannot be adjusted. The PTC thermistors can be
connected to a temperature relay to operate a circuit breaker or provide remote indication.
If PT100 sensors are installed, the same functions as by PTC thermistors are supplied; moreover the
PT100 can provide an effective local temperature indication that can be displayed through an
appropriate temperature control unit. If PT100 are installed, both Alarm and Trip temperatures can be
independently adjusted by the user through programming of the temperature control unit.

Warning: It is responsibility of the user to set the control unit with the correct
temperature levels for Alarm and/or Trip before energizing the transformer.

Always refer to the Electrical drawings for details of the type of thermal protection or
fan cooling circuit provided. In case of uncertainty please contact the manufacturer.

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Should the thermal protection be achieved via a dial type thermometer, this will be provided with two
contacts for alarm and trip (contacts NO in the standard configuration).
If the thermal relay is supplied separately for installation by others please follow the instructions
supplied with the relay. Connection of the thermal sensors (PTC or PT100) to the thermal relay will be
as illustrated in the Electrical Schematic drawing.
The recommended maximum settings are as follows: please refer to the electrical diagram to
check the correct temperature settings.

For AN transformers please refer to the following table:

AN (Natural Air Ventilation) setpoint values

Insulation Winding PT100
class Alarm Trip
F 150°C 160°C
H 170°C 180°C

For AN/AF transformers (transformers provided with fans for forced ventilation), the FAN control (if
required) will be achieved via the relevant control circuit supplied with the unit. The circuit diagram is
located in the panel. The relevant control settings for fans on / off are illustrated in the following table.
AN/AF (Natural Air Ventilation / Air Forced) setpoint values
Insulation Winding PT100
class Alarm Trip Fan ON Fan OFF
F 140°C 150°C 110°C 80°C
H 160°C 170°C 110°C 80°C

For AFWF transformers fans are continuously working and not controlled by any thermal probe.
AF/WF (Air Forced / Water Cooled)
Winding PT100 PT100 Cold Air PT100 Hot Air
Insulation class
Alarm Trip Alarm Trip Alarm Trip
F 140°C 150°C 60°C 65°C 80°C 85°C
H 160°C 170°C 60°C 65°C 80°C 85°C

In any case, for your facility and in case of special design, you can find the right setting proposal for
your transformer on the relevant test certification.

IN ALL THE ABOVE CASES IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT THE THERMAL
PROTECTION IS CORRECTLY CONNECTED TO THE SUPPLY CIRCUIT BREAKER (VIA A SHUNT TRIP OR
SIMILAR DEVICE). THIS IS TO ENSURE THAT THE TRANSFORMER WILL BE DISCONNECTED FROM THE
SUPPLY IN THE EVENT OF A FAULT CONDITION.

5.3 SWITCHING

Energisation of any transformer will produce a magnetic phenomena called magnetising inrush current.
These transient currents will be of considerable amplitude and will produce electro-dynamic stresses
within the winding. Opening the HV circuit breaker will also produce considerable voltage transients
causing dielectric stresses within the winding insulation. The transformer is designed to withstand such
stresses however it is recommended that repeated operation of the HV circuit breaker be kept to a
minimum. It is recommended that a period of 20 minutes be allowed between successive switching
operations. If repeated operations are to be made please contact the manufacturer for guidance.

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6 MAINTENANCE
Dry type transformers do not require an extensive maintenance program. By following some very basic
rules it will be possible to avoid potential problems and to increase the useful service life of the
transformer.

All operations to the transformers must be carried out with the transformer de-
energised, the terminals earthed and in full compliance with Health & Safety
regulations.

Contact with the energised transformer coils or terminations must be avoided. The
resin insulation system will not provide sufficient protection from electric shock.

The instructions and actions covered in this manual should only be carried out by
suitably qualified personnel operating under the current and relevant local regulations.

After a period of 1 month it is recommended to carry out an initial routine inspection.

This can be performed when checking the torque settings on the cable connections.
It will also permit an evaluation of the environment in which the transformer is operating.
Based upon this assessment a regular maintenance program can be established.
At the end of the guarantee period and then every year a routine inspection, including
checks of the electrical connections is strongly recommended.

The criteria for this assessment should be based upon:

♦ Excessive levels of dust
♦ Traces of electrical discharges (visual marks)
♦ Abnormal colour of the coils
♦ Traces of rust.
It is recommended that maintenance be carried out, as a minimum, every year. However this is
dependent upon the working environment.
The maintenance should include but not be limited to the following:

1. Thorough cleaning of all surfaces, especially the conducting parts, by means of dry cloth and an
industrial vacuum cleaner. It is not recommended to use a high-pressure air line to blow the
dust away. Do not use solvents or any kind of liquid (especially on the coils).
2. Clean all ventilation grills / opening.
3. Check and if necessary re-tighten all bolts on the magnetic core clamping assembly, on the HV
and LV connections, on the HV tapping or series / parallel links, and on all earth connections.
The appropriate tightening torque must be applied (see Insulation chapter 4).
4. Check the condition of all painted surfaces. This applies to the core, the enclosure and other
structural metallic parts. Remove traces of rust, if any, by means of wire brush. When
necessary, apply locally two coats of new paint. Only a temperature resistant (155 °C) and
insulating paint should be used.
5. Check the operating settings and correct function of the thermal protection device.
6. Check the operating setting and correct function of cooling fans (if fitted) for forced ventilation.
It is recommended to record the dates of all operations performed on the transformer assembly.

Before re-energisation, apply the Start up procedure (see Installation chapter 4).

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7 TROUBLE SHOOTING
During the commissioning stage or even during routine operation of the transformer the following
protective devices may register a "fault" condition or initiate the tripping of the main supply breaker.
This may be the result of spurious tripping or it may be a true fault or overload condition. All "fault"
conditions must be investigated, and if necessary corrected, before continued operation.
♦ Over-temperature protection
♦ Over-current protection
♦ Over-voltage protection
♦ Differential protection.

Ensure that General Arrangement Drawings / Electrical Schematics and Test Certificates are available
before commencing any operation.

If any of the above devices indicate a fault condition, the reason for that signal must be
checked and corrected.

All operations to the transformers must be carried out with the transformer de-
energised, the terminals earthed, and in full compliance with Health & Safety
regulations.

Contact with the energised transformer coils or terminations must be avoided. The coil
insulation system will not provide sufficient protection from electric shock.

Following a fault condition a complete visual inspection of the transformer should be carried out.
Particular attention should be paid to the following areas:
♦ Areas of electrical discharge
♦ Signs of surface tracking
♦ Signs of excessive overheating
♦ Signs of movement or damage to the coils or the termination points.
IF ANY OF THE ABOVE IS PRESENT IT MUST BE REPORTED TO THE MANUFACTURER IMMEDIATELY.
WE ALSO RECOMMEND THAT THE TIME AND DATE OF THE INCIDENT BE RECORDED.

If none of the above are evident then it will be possible to re-energise the transformer.
Below is a list of potential malfunctions together with the appropriate course of action.

7.1 OVER HEATING

This may be due to:
♦ Long term or repetitive overloads
♦ Ineffective or restricted AF ventilation circuit
♦ High water temperature
♦ Internal fault within the transformer.

In all the above cases the thermal protection relay (if correctly installed) will register an "Alarm" signal
followed by a "Trip" signal and will help to prevent irreparable damage to the transformer. Check the
operating condition at the time of the fault and adjust as necessary.
Should the problem continue, investigate the possibility of localised overheating spots, if any, and
contact the manufacturer.

7.2 SMOKE
If smoke is observed or detected at any time during the operation of the equipment the transformer
must be switched off immediately and the manufacturer contacted.
THIS IS AN INDICATION OF A SERIOUS FAULT AND REQUIRES THE ADVICE OF THE MANUFACTURER.
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7.3 VIBRATION AND NOISE
Depending on the operating conditions (voltage / frequency variation) vibration and noise may vary with
time. Ensure that the setting of the supply voltage tappings corresponds to the actual system voltage in
use.
If they reach abnormal values, switch the transformer off and check the tightening of all structural parts.
Should the problem continue, contact the manufacturer.

7.4 SHORT CIRCUIT

After a short circuit, the transformer must be switched off, in order to verify if any mechanical or thermal
damage has occurred. The breaker should not be re-closed until an investigation has taken place. The
fault details should be recorded along with the time and date of fault.
IF THERE IS EVIDENCE OF SMOKE, MOVEMENT OF COILS AND / OR COIL SUPPORTS, OR A CHANGE IN THE
ACTIVE PARTS, OR INSULATING PARTS OF THE TRANSFORMER, CONTACT THE MANUFACTURER.

7.5 INSULATION FAILURE

If following an inspection there is evidence of insulation damage (i.e. damage or cracking of the varnish
/ insulation) then the transformer must be switched off immediately.
THIS IS AN INDICATION OF A SERIOUS FAULT AND REQUIRES THE ADVICE OF THE MANUFACTURER.

7.6 CONTAMINATION
If the transformer has been exposed to excessive levels of humidity (particularly in the de-energised
state during storage or maintenance) or if the transformer has been exposed to dripping or flood water
then it will be necessary to dry out the insulation system before energising.
THE TRANSFORMER MUST BE DRIED BEFORE RE-ENERGISING. THIS WILL REQUIRE SPECIALIST ADVICE
FROM THE MANUFACTURER.

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8 HEAT EXCHANGER
The contents of this part of the manual apply to transformers equipped with Heat Exchangers.

8.1 GENERAL INFORMATION RELEVANT TO THE HEAT EXCHANGER

Pictograms used in this part of the manual
Dangerous situation with possibility of personal injury as well as damage to the equipment.

Reference to tips, comments and supplements with regard to using the equipment.

The general standards apply to symbols that are applied to the installation by the owner.
This manual supplies information and instructions for the correct and safe use of the device.

Many accidents are the result of incorrect use.

Instructions in this manual must therefore always be followed.

The safety instructions must also always be observed when work is done on the equipment.
The complete manual must be carefully read.
If, after reading this manual, questions still exist, you must contact the supplier / contractor for more
information.

The installation may NOT be put into operation before all unclear issues have been resolved.

8.2 PRODUCT INFORMATION

Product : Element with removable covers
Type : See Technical Specification Sheet or type plate

Elements with removable covers are primarily used in installations for exchanging heat between a liquid
and a gas, using a medium in the tubes from which internal fouling is expected.
The removable cover makes it possible to clean the heat exchanger mechanically.
These heat exchangers are often built into so-called air-water coolers in order to eliminate the excess
heat produced by the electromotor. The hot air flows past the finned tubes that give off the heat to the
cooling water running through the tubes.

INSTALLATION COMPOSITION

1. Medium supply (heating) / Medium return (cooling)

2. Medium supply (cooling) / Medium return (heating)
3. Element
4. Connecting flange
5. Valve
6. Compensator
7. Pipe
8. Vent and drain
9. Leak indicator
Fig. 1

8.4 PROHIBITIONS TO (PUTTING INTO) OPERATION

It is Prohibited to operate the Unit beyond Design Conditions

The equipment is designed according to the design parameters as stated in the enclosed
technical specification sheet. If these parameters are exceeded then it is PROHIBITED to put the
installation into operation without prior consultation with the manufacturer.
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Moreover all continued use in such a non-design situation is considered contrary to the
regulations. The manufacturer is not liable for any material damage or personal injury that
results from further use : this risk is solely the responsibility of the owner / user.

The supplier has advised in the choice of materials, the user remains responsible for the media used
with regard to corrosion. Some information on materials and mediums that Klima has collected during
many years of experience can be found in Chapter 8.14. This is purely informative. The user remains
responsible for the mediums and materials that he uses.

8.5 GUARANTEE

Any damage and/or decrease in capacity due to non-observance of this user manual are not covered
by the guarantee.
The guarantee expires if any adaptations or changes are made to the heat exchanger.
The equipment must always be inspected upon delivery for damage to the equipment during transport.
The manufacturer must immediately be notified of any damage during transport.

8.6 GENERAL SAFETY

Physical injuries
Physical injuries can be caused by:
• Burning, by touching the heat exchanger or other parts of the installation.
• The accidental release of a medium under pressure, which presents a risk for burns and other
injuries because of the high pressure.
• Contact with escaping chemicals.
• Contact with the fins or other sharp parts of the installation.

Damage to the equipment

Damage to the equipment can be caused by:
• External forces.
• Corrosion.
• Chemical corrosion.
• Erosion.
• Fatigue.
• Steam shock.
• Pressure / temperature too high.
• Impact load.
• Freezing.
• Transport

For transport See: Instructions for Transport and Hoisting

If handled incorrectly there is a risk for physical injury and/or damage to the equipment.
Even after switching off the installation the heat exchanger surface can still be hot.

The unit may only be fed with the mediums stated in the technical specification sheet.

No fatigue analysis has been taken into account and therefore the unit should only be used
for static load.
If a cold medium is present in the heat exchanger but is not flowing whilst a hot medium is
flowing through the heat exchanger, then the cold medium may start boiling and the heat
exchanger will be damaged.
Sudden changes in pressure and temperature must be avoided.

The values stated in the technical specification sheet must not be exceeded.

This manual describes other safety instructions than those safety instructions related to the
chapter in which they occur. The complete manual must therefore be read to be aware of all
safety provisions and measures to be taken when using this installation.

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 Danger of freezing. When an idle heat exchanger (filled with water or a water mixture not of
an anti-freeze type ) is exposed to temperatures below zero, the pipes can burst and the
cover can be deformed. In cases where a danger of freezing may exist all of the medium
must be drained from the heat exchanger.

8.7 INSTALLATION

The assembly and start-up must be carried out by a suitably qualified person appointed by
the buyer or by a qualified installer. The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.

8.7.1 SAFETY MEASURES AND FACILITIES ON THE HEAT EXCHANGER / INSTALLATION.

Installation must be carried out in such a manner that all likely risks are excluded.
To achieve this, the following points must at least be observed:
• The necessary fittings must be attached so that filling and emptying the equipment can take place safely.
• The installation must be fitted with adequate drainage and venting facilities.
• There must be sufficient valves in the supply and return pipes, close to the heat exchanger, so that the whole
system does not have to be drained if work needs to be carried out. .
• A pressure-limiting device must be fitted, adjusted to the maximum pressure allowed for in the design and
registered on the type plate.
• A temperature-limiting device must be placed in the circuit to protect against excessive temperatures.
• The fitting of inspection and checking facilities such as temperature and pressure gauges.
• For heat exchangers using steam as a medium one must ensure that they are fitted with a correctly functioning
system for condensate drainage.
• For the choice of a steam trap and other fittings it is advisable to seek advice from the suppliers.

8.7.2 PREPARATION FOR INSTALLATION

General:
• For a heat exchanger with removable covers there must be sufficient space available around the covers of the
heat exchanger to facilitate problem-free disassembly of these covers.
• For heat exchangers that have removable covers ensure that there is enough space so that the brushes used for
mechanical cleaning can be employed without problem. (see fig. 4, distance X).

Fig. 2
• Remove the plastic caps from the connecting holes.
• Before the heat exchanger can be connected, the tubes must be clean so that no pollutants can enter the unit.
• The gaskets used must be suitable for the medium, temperature and pressure to be applied.
• The bedplate, construction and mounting must be of sufficient strength.
• Pressure impulses, pulsations and mechanical vibrations in the heat exchanger should be avoided.

The design specifications, stated in the technical specification sheet must always be
respected. If the user deviates from these values, the responsibility is his.

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8.7.3 INSTALLATION
• The instructions for transport and hoisting must be observed when placing or moving the
equipment.
• During assembly of the piping all pipes / flanges must be mounted stress-free to the heat
exchanger.
• Pipes must be able to expand. If necessary compensators must be fitted to the pipes.
• Bolt-nut connections must be clean and lightly oiled.
• Gasket used: reinforced graphite gasket 1,5 mm.

8.7.4 TIGHTENING OF THE BOLTS

The bolts of the removable covers must be tightened with a torque wrench (for the torque and order of tightening see diagrams in Fig. 5).
Tightening of bolts must be done “diagonally” in at least four steps.

Bolt Torque Nm
diameter Step Step Step Step
Steel 1 2 3 4
M10 20 40 40 40
M12 40 60 60 60

Bolt Torque Nm
diameter Step Step Step Step
Stainless 1 2 3 4 Fig. 5
steel
M10 20 40 40 40
M12 40 60 60 60

The assembly and start-up must be carried by a suitably qualified person appointed by the
buyer or by a qualified installer.
The installation may only be operated, maintained and repaired by authorised, trained and
instructed personnel.

8.8 START-UP

8.8.1 INSPECTION BEFORE PUTTING THE UNIT INTO OPERATION

As a rule the safety devices in the system to guard against excesses in pressure and temperature must
be properly adjusted and tested before start-up. The entire circuit must also be inspected to check
whether all connections have been properly made.
All relevant safety regulations must be observed both before and during start-up.

The unit has been tested by Klima in accordance with the test pressure stated on the type
plate

8.8.2 FILLING AND VENTING.

8.8.2.1 FILLING A HEAT EXCHANGER COMPARTMENT WITH A LIQUID.

Proceed as follows:
• Open vent.
• Slowly feed the medium.

If a cold medium is present in the heat exchanger but is not flowing whilst a hot medium is
flowing through the heat exchanger, then the cold medium may start boiling and the heat
exchanger will be damaged.

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• Ensure that all air has been allowed to escape from the unit.
• Allow the circuit to pressurize and open the return valve so the medium can flow through.
• Check for leakages. In case of leakage see Chapter 7.

8.8.2.2 FILLING A HEAT EXCHANGER COMPARTMENT WITH A GAS.

Proceed as follows:
• Slowly feed the medium.
• Allow the circuit to pressurize and open the return valve so the medium can flow through.
• Check for leakages. In case of leakage see Chapter 7.

8.8.3 RE-TIGHTENING OF THE BOLTS.

The bolts on the connecting flanges must be re-tightened after the device has cooled down for the first time.
See Chapter 8.9.4

8.8.4 INSPECTION AFTER START-UP:

After heating the heat exchanger for a certain period of time, all connections must be inspected for
leakage. In case of leakage they must be repaired. See Chapter 7.
Check whether the settings of the measuring and control devices reflect the expected values.
8.8.5 SHUT DOWN OF THE INSTALLATION:
To shut down the heat exchanger the supply and return flows of the circuit must be closed.

First close the supply of hot medium and then, only when the heat exchanger has reached
the temperature of the cold medium, close the supply of the cold medium.
Danger of freezing. When an idle heat exchanger (filled with water or a water mixture not of
an anti-freeze type) is exposed to temperatures below zero, the pipes may burst and the
covers may be deformed. If there is a danger of freezing all the medium must be drained
from the heat exchanger.

8.9 MAINTENANCE AND INSPECTION

The assembly and start-up must be carried out by a suitably qualified person appointed by
the buyer or by a qualified contractor. The installation may only be operated, maintained and
repaired by authorised, trained and instructed personnel.

The owner must post warnings against environmental factors that can pose a threat.
Preferably using pictograms and/or text.

The owner must enforce the wearing of protective clothing and gloves by the personnel
wherever necessary.

Maintenance, cleaning etc. must only take place on a shut-down device.

Special measures apply for a shutdown device. See Chapter 8.10.5.

Depending upon operating conditions, maintenance should be carried out every 1000 hours of operation or minimally
1x per year. The heat exchanger is mounted via a bolted flange to the outside of the transformer enclosure. Removal
and re-fitting can be conducted without entry into the main transformer enclosure.

8.9.1 INSPECTION
To guarantee a high degree of operational reliability regular inspection of the equipment by the
maintenance and operating personnel is necessary for the following:
• Fin surfaces damaged, dirtied or blocked.
• Leakage.
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• Pressure and temperature within the permissible limits.
• Presence of air in a system where a liquid medium is being used.
• If applicable, the presence of adequate condensate drainage.
• Fouling of the heat exchanger (drop in capacity).
• Vibrations / strange noises.
• General condition of the installation.
• Corrosion.
• Functioning of the safety devices.
• Torque of the bolts.

8.9.2 CLEANING OF THE HEAT EXCHANGER.

8.9.2.1 DISASSEMBLY OF THE HEAT EXCHANGER.

(For Parts See Fig. 6.)

Proceed as follows:
• Close the supply and return flows of the circuit.
Firsts close the supply of hot medium and only when the heat exchanger has cooled to the
temperature of the cold medium close the supply of the cold medium.
• Wait until the heat exchanger has cooled down!
• Drain the medium (vent open).
• Where necessary mark the position of the parts to be disassembled.
• Remove the supply and return pipes and disassemble the cover.

Beware! The covers must be supported during disassembly due to the possible extreme
weight of the covers.

Beware!
When disconnecting or disassembling the heat exchanger it is possible that residual medium
may seep from the heat exchanger. To avoid damage to underlying parts or floor it is
necessary to catch the medium in, for example, a drip tray.

8.9.2.2 REMOVAL OF HEAT EXCHANGER FROM TRANSFORMER ENCLOSURE.

• Heat exchanger is mounted to enclosure body via a bolted flange.

• Heat exchanger body extends 200mm inside main transformer enclosure body. Removal
distances must take this into account.
• Remove inlet and outlet water connections.
• Isolate and make safe the power supply to the fan motors.
• Remove all electrical connections to the fan from the base of the fan motor body.
• Remove earth strap between heat exchanger body and main enclosure earth (Internal and
External to transformer enclosure).
• Remove auxiliary cables connected between the PMS and the heat exchanger leak detector
terminal chamber.
• Support mass of heat exchanger using heat exchanger lifting points at top (Marked ‘Lifting
Points for Heat Exchanger Only’).
• Remove fixing bolts around flange connection.
• Withdraw heat exchanger body allowing the components internal to the transformer enclosure
to be clear of the enclosure aperture.
• Lift and transport
• Refitting is the reverse of above.

8.9.2.3 REMOVAL OF THE HEAT EXCHANGER FAN MOTOR

• Fan motor is mounted to the heat exchanger rear face via a circular bolted flange. The fan
propeller is fixed to the shaft.

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 • Fan body extends 300mm inside heat exchanger body. Removal distances must take this into
account.
• Isolate and make safe the power supply to the fan motors.
• Remove all electrical connections to the fan from the base of the fan motor body.
• Remove earth strap between mounting flange and heat exchanger body.
• Support mass of fan motor (40kg)
• Remove fixing bolts around flange connection.
• Withdraw fan motor body allowing the internal impeller to be clear of the enclosure aperture.
• Refitting is the reverse of above.

1. Cover connecting side

2. Gasket connecting side
3. Tube bundle
4. Side wall
5. Fin package
6. Gasket return side
7. Cover return side
8. Bolt / nut
9. Leak indicator

Fig. 6

8.9.2.4 CLEANING THE HEAT EXCHANGER

CHEMICAL CLEANING
The heat exchanger can be cleaned by rinsing with a detergent or chemical solvent. When using chemicals we advise
you to contact a company that specialises in chemical cleaning. Klima can if necessary advise you on this. If
chemicals are used the equipment (material) can be affected. Be especially careful that the gaskets used are resistant
to the chemicals used.

Beware! De leak indication space on double tube elements may not be cleaned.

MECHANICAL CLEANING

Cleaning the Liquid Side of the Heat Exchanger.

Proceed as follows:

A heat exchanger with straight tubes can be cleaned internally with a special brush. To do so the covers must be
disassembled, See Point: “Disassembly of the Heat Exchanger”. After cleaning, the tubes must be thoroughly rinsed
with a clean medium as noted in the technical specification sheet!

Cleaning the Gas Side of the Heat Exchanger.

Proceed as follows:

Blow the fins clean using compressed air in the opposite direction to the normal airflow.
Take care that the fins do not deform.

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8.9.2.5 ASSEMBLY OF THE HEAT EXCHANGER.

• Make sure that all gasket faces are clean and undamaged.
• Always use new gaskets.
• Apply the gaskets.
• Assemble the cover (observe the marking!). See 4.4 for Torque Specifications. For Start-Up See Chapter 5: “Start-
up”.

8.9.2.6 (RE)PRESSURIZING OF THE HEAT EXCHANGER.

Proceed as follows:
• Close the supply and return flows of the circuit.

First close the supply of hot medium and then, only when the heat exchanger has cooled to
the temperature of the cold medium, close the supply of the cold medium.

• Drain the heat exchanger (vents open).

• Remove the supply and return pipes.
• Blind de cover flange with blind flanges.
• Fill the heat exchanger through a feeder with unheated, clean medium, using the medium as specified in the
technical specification sheet.
• Pressurize the system for 30 minutes (at room temperature) to the design pressure as specified on the type plate.
• Inspect for leakage. See Chapter 7.
• Slowly de-pressurize the heat exchanger to atmospheric pressure.
• For assembly, See: “Assembly of the Heat Exchanger”.

8.10 MALFUNCTION / TROUBLE-SHOOTING GUIDE FOR THE HEAT EXCHANGER

8.10.1 IDENTIFICATION AND CORRECTION OF MALFUNCTIONS

Malfunction Possible cause Correction of the malfunction

Heat There is air in the installation. Inspect the pipe work for possible air pockets.
exchanger has - Remove any air in the liquid.
insufficient - Then bleed the heat exchanger thoroughly and if
capacity. necessary fill up the medium.
The operating conditions deviate Adjust the operating conditions to the specified /
from those stated in the technical design conditions.
specification sheet.
The heat exchanger is fouled. Clean the heat exchanger (see Chapter: Cleaning
the Heat Exchanger).
The connections have been Correct the connections.
interchanged.
The fins are dirtied or damaged. Clean and / or re-align the fins.
Heat Gasket faces dirtied or damaged. Clean gasket faces. In case of damaged gasket
exchanger is faces, contact your supplier.
leaking. Defective gasket. Replace gasket.
Bolt tightened insufficiently. Check the connection and carefully re-tighten.
Defective tube. When a tube is defective it can be blocked as an
emergency measure using conical plugs on the inlet
and outlet sides. This may only be done after
consulting and obtaining permission from Klima!
External forces. Assemble the installation to be stress-free.
Defective tube – tube plate To replace a tube or to repair the heat exchanger:
connection. contact Klima’s service department

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8.10.2 SAFETY MEASURES / FACILITIES:

Facilities must be provided (ladders, steps, cat ways etc.) to be able to safely reach all places to make
adjustments and to perform maintenance and repair service:

8.11 CUSTOMER SERVICE

8.11.1 ORDERING SPARE PARTS

When ordering spare parts it is important to provide the correct data.

One should at least state:
• Project and order number.
• Complete description of product / type (See Technical Specification / type plate).
• Required part (for name see documentation).

8.12 GENERAL INFORMATION ABOUT MATERIAL AND MEDIUMS (HEAT EXCHANGER)

The data have been collected through years of experience and are merely indicative and for
information. The user is responsible for the mediums and materials used with regard to corrosion etc.

For your information

Materials: Medium velocity:

Minimum Maximum
Steel 1.0 m/s 3.0 m/s
Copper 1.0 m/s 1.5 m/s
Stainless Steel 316L 1.0 m/s 3.0 m/s
CuNi10 1.0 m/s 2.0 m/s
CuNi30 1.0 m/s 3.0 m/s

Flue gas:
Combustion gasses must be free of pollutants, for example a sulphur level of < 10 mg/m³ and a chloride level of < 1 mg/l.

Chemical value for neutral water (fresh water).

pH –value : 7< pH.< 11
Chloride level 10 - 50 mg/l at 80ºC < 250 mg/l at 40ºC
Ammonium level NH3 = 0
Hardness (calcium) maximum: 40 French degrees or 22 German degrees at 40ºC -Æ 400 ppm
1 French degree or 0.5 German degree at 80ºC (softened water) --Æ 10 ppm

Stainless Steel:
AISI 304(L), 316(L), DIN17440 14306,14404
Danger from: -Stress corrosion by chlorides at temp. > 70ºC (maximum 10-50 mg/l Chloride) and stress in the material.
-Biological corrosion from stagnant water.

Copper and copper alloys:

Sf-Cu, CuNi10, CuNi30, CuZn38SnAl
Danger from: - Ammonium compounds
- Low strength at high temperatures.
- Electroplated corrosion on carbon steel.

Steel: St.35.8, P265GH,

Danger from: -General corrosion
-Pitting corrosion by oxygen 02 and CO2
-Stress corrosion (lye pH < 8)

Maximum value
Steel Stainl.St.316L Copper alloys
Ammonium NH4 0.00 oz/l 10-50 mg/l 250 mg/1
Ammonium NH4 10 mg/l 0.00 oz/s
PH-value >8 6-8 6-8

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8.13 INSTRUCTION FOR USE OF AIR-WATER COOLERS WITH SEA WATER

- Material in contact with sea water : Use CuNi9010, CuNi7030, CuZn38 SnAl or steel with Rilsan.

- Filtration: 300 to 500 μm :Avoid introduction of foreign bodies inside the exchanger which can create
water overspeeds and/or create an abnormal erosion.

- Minimum speed of water: 1m/s Avoid the organic deposit of pollution which can damage the tubes
Give oxygen at the interior of the exchanger in order to create a layer of natural protection (Passivation)

- Maximum speed of water in tubes: 2m/s for CuNi 9010 and 3m/s for CuNi7030
Beyond this values a premature erosion of the tubes may occur.

- Water circulation through exchanger is obligatory:

During a specific stop and very short duration(1 day), it is necessary to drain the exchanger and,
if possible , to make a rinsing with treated clear water.

- New exchangers are delivered without specific treatment on the tubes:

Consequently a layer of natural protection of the tubes(passivation) must be done at time of startup of
installation (in the first days), with a sea water charged out of oxygen.

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 TRASFOR CUSTOMER SERVICE

Monday to Friday
24 h/day mail
07.30 am to 06.00 pm

service@trasfor.ch +41.91.6113011

www.trasfor.com

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