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A) installation

1.0 INTRODUCTIO~
1. I Parts identification
2.0 TRANSPORT
3.0 ACCEPTANCE
4.0 HANDLING
4.1 Lifting
4.2 Translation
5.0 STORAGE
B) operation
6.0 TECHNICAL BASIC DATA
6.1 Name plate
6.2 Minimum insulation distance
6.3 Ambient temperature- operating temperature
6.4 Dissipation of heat produced kom transformer
6.5 Overvoltages
6.6 Connections
7.0 PUTTING INTO SERVICE
7.1 Preliminary controls
7.2 Temperature control
7.3 Overloads
7.4 Feeding

C) maintenance
8.0 CONTROLS-FREQUENCY
9.0 ASSISTANCE

NOTE :data contained herein may differ in small details from t h e t r a n s f o r m e r delivered.
W e reserve the right to m a k e alterations without notice.
A) INSTALLATION
1.0 INTRODUCTION

This manual defines h e conditions for utilisalion ,puning into service, maintenance and safety rules
compliance for cast resin mnsionners according to IEC 726 standards, in order to avoid wrong manoeuvres
and misuse.

1.1 P a r t s identification

No Description
1 LV terminals
2 HV terminals
3 Plates for tapping
4 Name plate
5 Auxiliary box
6 Bidireclional whccls
Pulling hales
Earthing terminal
Lirting lugs I
' 10 I Coil supports I
II I Connecting bar I
I.ower clamps 1
2.0 TRANSPORT
1

In order to avoid damages during transportation, the transformers i,lust be accurately fixed with ropes or
belts, utilising- the hooks located on the transformer.

The transformer MUST NOT BE transported with the wheels assembled.

! 3.0 ACCEPTANCE

t At the receiving, before unloading the transformer, it must be made an accurate check in order to verifL
possible damzges occurred during the transportation..
l If the inspection points out damages or faulty handling, it is necessary to do as follow^:

a) notice on the transport documents that the shipping has been received damaged or incomplete, specifying date
and signing
b) if the transformer has moved on the transportation, issue a short relation on the fixing conditions
C) ask for a verification on site from carrier's insurance surveyor
d) fill a formal reservation and damage covering request to thecarrier
e) communicate by letter anticipating by fax to our company the damage occurred.

4.1 Lifting
Lifting must be made utilising the four lifting hooks on the upper clamp(fig 2) remembering to use ropes
adequate to the mass to be lifted(see the mass on the nameplate) and enough long so that the mzximum angle
shot of the ropes do not exceed 60".

n NEVER use fork lift for lifting from the bollom (fig3) because the magnetic core, which s t i c k out frulll
the lower clamps, makes unstable the transformer, causing it to fall down. Furthermore, even if the
transformer will not fall down, the magnetic core [is& to be delinitively dan~aged.

Fig. 2 fi. 3
4.2 Translation

The translation of the transforn~ermust be made by using ropes apt for the mass to be moved; the ropes must
be hooked to the holes in the bottom channels (fig4); translation can also be done manually utilising a lever
as shown in fig. 5

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Fix. 5 i!

DO NOT make manual or mechanical tr@ations pushing directly the resin coils.
(fig. 6 e 7)
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For this reason, the installation must always be inside a barricr or a box, where the access is allowed only by
means of ~nterlockeddoors opening only when the ~ ? s f o r m e isr not connected to the net..
The transformer inside the box must be located in ordcr to resvect the minimum permissible insulation
distances against the walls.
These distances depend upon the maximum voltage Um of the tmnsfomer and are listed in fig 8 .

6.3 Ambient temperature and operating temperature


Ambient temperature must not exceed maximum 40°C and minimum -5°C.
':. .IEC standards indicate that the temperature must not exceed the average daily value of 30iC and the yearly
average value of 20°C.
The working tenlperature of the transformer varies in relation to the insulation classes as indicated in the
follo\ving table.

I i
1i Insulation class Temperature range I

i iI B - 5°C i +12OCC
F - j D C t +140°C
kl -j°C + ;-16j'C
I,
1.

I
6.4 1)issipation o r 11c;it produced from transformer

(. 6.4.1 Natural Cooling


In order to pre\cnt overheaiiil!!, which ma?, cause \\orking problem, it is necessar): that the thermal elleiz!,
I produced fro111 t!le transforiiirr is adequately dissipated. .Illis proble~iiis pariicularly important \\hen the
transfanners arc. installed in places or boxes of reduced dirae~lsio~l.
i..
In these cases it must be providid an adequate air flow, with grated louvers at thc boltoin for intaking ires11 air
.and at the top for exhausting warm air (fig. 9).

The formula used to calculate the exhaust of the heat generated froin the transformer losses P (kW), takes into
consideration the total area of the openings Af and the distance H from the openings.(for conversion ,lKW=
0,86 Kcalories)

Afe= P x 0 , 1 8 8 / d ~
Afu= I,lOxAfc
Afu= Area of upper louver in m2 (excluded the grate surface);
Afe= Area of lower louver in m2 (excluded the grate surface )
P= Transformer total loss in KW;
H = Central line distance of the upper and lower louver in mt.
6.4.2Forced ventilation-..
N'llen the room dimensions of the room do not allow an adequate exhaust of the heat, or in case of frequent
over~oadsor average temperature higher than 20°C, it is necessary to provide a forced ventilation by means
of a fan. This can be operated by an ambient thermostat.
I n this case the flow suggested in m3/s at 20°C is equal to 0,05 P (P= total losses in k\\.).

6.5 Overvoltages
T\\o Q'pes of overvoltages can occurr in the transforming rooms:

8) atii~osphcrical:
these are originated in the distributioi~net from direct lightins or from sra~i--I iarges: they are frequc~lt
during storms: the effect are as much bigger as t l ~ eaerial net is longer.
Panicular production clever devices guarantee tlie correct working of tlie transformer, independently from the
repeated Presence of ovulensions in the net: provided that these do not exceed the \:slues loreseen froin the
coordinalion of the insulation related to the net itself. .
b) iiianoeuvre:
these are caused by the openings and closing of the primary net switch: by suddeil s\\,itch-off of big load and
Or b?- capacitors batteries, either for serx~icereasoni aird for tripping of the relevant protection.
These overvoltages can have dimensions similar to the atmospherical ,but lasting some hundreds ps.
Ail?- hfV cable has a considerable capacirflmeter, and as a corisequeoce w11ei1a cable of a cenain length feeds
a transformer off load, the small primary current involved produces an increasc of the voltage at tbc
extreniilies.
PL~TTK~~~ECCC.LVICACOLOMUO
P.% B P ~ , Y D ~ C O P P . O , , ~
llll,,,!t,1,11,,1,11111li

Furtliermore, if the cable feeding is perturbed from an overvoltage, (his is drastically amplilied along the
cable, so to the transformer can be reached by a voltage n~uchhigher than the maximum allo\vable As n
consequence, it is necessary to protect the cable terminations against overvoltages .

6.6 Connections
In figures 10 and I I are illustrated some examples of connection of cables or bars MV and LV with
incoming line from upside and downside .
In all the cases, the cables-bars must be rigidly fixed in order to avoid dangerous mechanical solicitations to
the insulators-terminals.

LV cables must no be laid upon resin coils. It is advisable to keep the minimum insulation distance (see
point 6.1) also f o r cabtes.

7.0 PUTTLNG INTO SERVICE

7.1 Preliminary controls


Before feeding the transformer, make the follo\ving checks :

a) Cle:~niog:
After having detached tlie protecting plastic \\,rap, take awa)' dust depots which could have been ori$inaled
fro111the long stocking period, with low pressure compressed air.
Control that cooling channels behveen MV arid L\r are not closed, and eventually clear \vitli compressed air
Do not introduce any object behveen MV and LV .
b) Earl11 connection
Make sure that the transformer eariliing plate (located in the internal side of the lower chaonel) is con~ieclt.?
\\'ith a conductor apt to sustain default currents in case v:disciiarge against the magnetic core, -ccordinsl~
IEC noriiis.

c) Conuections:
Make sure that the windings have not been moved .
Verify the tightening of the bolts MV and L\l.
When temperature control devices are installed (thermometer, temperature monitoring units, fan convo\ ullirs
etc.. ) veriiy that tlie intervention level of the alarms are settled (see point 7.3) and make sure that these unirs
are perfectly working.
ELbm<Oh(ECCCANICA COLOYIIO i'rs 9 Edlvvnc OP??".~
d) Tightening control:
Check liglltenings, either electrical and mechanical, zs per value icdicated in the table.

e) Tap chaoger:

n Do not make regulations when the transformer is energised.

The voltage supplied form the net can fluctuate; these fluctuations can be balanced by means of the tap
changer, using the tapping plates in order to have constant the voltage to LV terminzls .
<\'hen MV voltage decreases, for instance from 15000 dotvn to 14625 V (- 2,5%), LV voltage decreases in
the same percentage, changing from 400 to 390 V (off load voltages).
TO bring LV voltage to des~redlevel (400V) it is necessav 10 set the tapping plates on position "-" (terminals
2 - 3 fiz.
- 12),
Irthe vollage increases, the balance is made moving the tapping plates to positions "+" or "-"

A The tapping used must be the same for all the M\' coils, in order to avoid circulating current which
can damage irreparablx the transformer.

w h e n the transformer is having two tapping boards fur each phase (fig. 13), it is m m p u k o ~that te
lapping plates be on the same position on all six boards in order to avoid circulating currents.

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f) Transformers with two MV tensions :


For the transformers having two primary voltages (ex. 15000 - 20000 V): the voltage tzpping varies
according to the required voltages; as a consequence it is necessary to refer to the connecting scheme reponed
in the test report and annexed.

g) Parallel connected transformers:


I
If the transformer must \vork parallel with others transformers, the following conditions must be respected
- same vector group
- same short circuit voltage (in %);
- same turn ratio in all tapping positions
! < - ratio between rating power of the transformers must not be higher than Y: (one transformer cannot e
rating power higher tlian hvo times the other).
I

11) Lr~sulationleuel:
! Control insulation level between the \vindings and against mass \\'it11 a megaohmeter i ;\,legger :pi-) Ila\'i~lg
Lollage 5000 V.
The values to be found are the rollo\ving:
- MV -+ mass = 250 MC2;
.f
- LV --t mass = 50 MR;
j - h,lV --t LV = 200 MR.

7.2 Tc.niperaiure control


Resin lransforri~ersare supplied as standard \\,it11 3 ther~nislors PT100, one per cach LV \\.indi~:galld upL7n
I requesl one also for thc magnetic core.
111order to control the temperature, is necessary to connect the themiistors to the monitoring unit.
'The connection to the monitoring unit are made in the auxiliar) box, according to the reponed schemes ifi9
I 4 f o r N o 3 PTIOOandfig.15TorN"4 PT100).
I'
The connection o f the terminals from the auxiliary box to the monitoring unit must be done utilising cables
with screen, size 3x1,s mm' (one for each thermistor).

According to the insulation class of the transformer, the temperature monitoring unit must he settled as
reported in the following table.

Tcmpaxaurc s a g
Insulat~onclass
FM insman M m T ~ P
Class D -90°C +IIO-c 1205c
Clasr F +11O0C + 130'C - 110'C
Class H + 130°C + 150°C - 165°C

i 7.3 Overloads
Our transforlners are designed and built in order to work at nominal power \\,it11 a normal ambient
i
LeVerature as defined in IEC standards (see point 6.2).
The \"orking life of the transfomier depends from the lasting of i& insulation; the speed of dclerioration of
tlie insulatioll increases at the increase of thc u~orkingtemperalure,whicli in its turn deperldi . pon the load
!
cycle to which the transformer undergoes.
Noc\b'itllstaodin~ that ,some overlaods are pernmitted willlout compromising the espeuctl life of the
! transfon~ler,at the conditions that tliey are compensated with tlomlal losd lower than the noniini!! power.
The O\crload current anyhow cannot be higher than 1,s times t l ~ evalue ol.tlle notninal currcllc,

The \'due and the duratioil of the overload are delcrnlincd by the initial load condiiiot~s.I-!, the a~ltbieilt
:. 'emPera[Ure and b:' t h e t i r ~ econstant ofthe transformer.

In the f ~ l f ~ \ ~ tables
i l l g are listed some typical overloads; Tor different sitilatiolls and claiificrtions please
contact our Techllical Dept.
i
Overloads permitted without exceeding temperatures allowed from standards IEC, ambient temp. 40°C

Former load at running Permined overload (in minutes) as a percentage of nominal


conditions as a percentage of power I
nominal power
10% 20% 30% 40% 50% !

Overloads permitted related to ambient temperature

Former load at running Ambient Continuous overload Power reduction as /


conditions as a percentage Temp. admitted as a percentageof percentage of nominal
of nominal uower nominal oower ~ower I
0.'
/ 0
"C % % i
100 0 30
100 10 25 !

100 20 26 i
!
100 30 6 !
100 35 4 i
100 40 0 0 -
100 45 6
inn zn 1i

7.1 Feeding
Afier making all the preliminay controls as indicated in the previous chapters, it is possihie tfi ~ i \ , \,31lzSe
s to
th? transformer, feeding it off load. This insertion causes an inrush current \vhich vat-ii-5 irfim S lo 12 times
the notiiinal current.
This transient period has a duration of few seconds; the intervention time of the circili! prareitior~011primaty
side must be delayed in order to avoid unuseful tripping during these current peaks.
Aker positive off load connecting, the load can be applied to the transfornier on L\' sidc.

A It is to avoid repeating of starting-closing manoeuvres.


C) MAINTENANCE

8.0 CONTROLS-FREQUENCY
t

t Resin transformers need a reduced maintenance

t It is necessary to carry out periodically some checks, which frequency depends on ambient and working
conditions :in clean spaces, dry and with regular and uniform working cycles, time intervals are reported in
! the table; in dusty, humid ambient. or when high and frequent load variations happen, as well as temperature,
the checks must be done with a frequency reduced to the half of the one indicated below.

Intervention frequency I
Evev 12
Conno1 3 months after starting months
Thermistor efficiency X X
Cleanine of dust. dim. moist X
Tightening of bolts and nuts MVILV X X
Tightening clamps of auxiliq boa X X
Check of temoerature monitorino unit X X
Control of coil supports x X I
Tightening of bolts of coil supports X X

In case o f atmospherical discharzes. accidental short circuits on LV side and anyhow nhenever working
anomalies are occurring, check ~nsulationlevel (see point 7.1 /e).
!

9.0 ASSISTANCE

ELETTROMECC.~NICA COLOS.IB0 provides a continuos post sale assistance lo his custolners for
\\rhatever problem concerning the runnlng and the utilisatlon of his transformers.
For an)' need please contact our Comlnerclal Dept i n d ~ c a t i nthe
~ serial number and the data of the transformer
reported on the name plate.
f LETTROMECCANICA COLOMBO
di Mainini GianAngelo & C. S.a.5.
Via Kennedy sn. - 20010 Mesero (MI) Italy
Tel. ++39 029787070 Fax ++39 029789198
E-~iiail:~~~aSo~~eleltrocolon~bo.co~i~
Intemet:\\.\v\~.ele~rocoloi~~bo.con~

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