OPERATION AND MAINTENANCE

PROCEDURES FOR
DRY TYPE TRANSFORMERS

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 CONTENTS
SL.NO DESCRIPTION Page No

1.0 GENERAL INFORMATION 3

1.1 STANDARDS OF REFERENCE 3

2.0 INSTALLATION 4
2.1 ELECTRICAL CONNECTIONS AND CLAMPS / TORQUE SETTINGS 5

3.0 COMMISSIONING
3.1 TRANSFORMER EARTHING 6
3.2 CONNECTION 6
3.3 ADJUSTING THE INPUT VOLTAGE 6
3.4 ENERGISING 6
3.5 PRECOMMISSIONING CHECKS 6

4.0 PRECAUTIONS FOR SAFE OPERATION 7

4.1 TRANSFORMER EARTHING 7

5.0 MAINTENANCE 8
5.1 MAINTENANCE PROCEDURES 8
5.2 CLEANING 8

6.0 PERIODIC INSPECTIONS 9

6.1 Checking for Dust Accumulation 9
6.2 While the Transformer is Energized 9
6.3 While the Transformer is De energized 9

7.0 STORAGE 10

8.0 MALFUNCTIONS AND INITIAL CORRECTION WORK 11

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 1. GENERAL INFORMATION
This manual is intended to provide the user with all necessary information regarding the
procedures to be followed for safe transport, storage, installation and maintenance of UII dry type
transformers and use in compliance with safety regulations of dry type transformers with cast resin
windings, manufactured in compliance with the applicable Standards and intended for use in industrial
plants and commercial and service facilities.

If properly used, the cast resin transformers have the following advantages:
• They are resistant to combustion and self-extinguishing in the event of fire whereby the cause of
fire has ceased.
• Reduced maintenance time and costs.
• Reduced overall dimensions.
• High resistance to dynamic short-circuit stress.

All UII dry type transformers are designed and built strictly according to the last editions of the IS
standards / IEC standards. Therefore, the information contained herein remains subject to changes
without previous notice.

1.1 Standards of reference:

For those who wish to obtain further information about the applicable standards, we recommend
the reading of the following standards: ·
IS 11171: Dry-type transformers
IEC 60076-11: Dry-type transformers. ·
IEC 60076-12: Loading guide for dry-type power transformers.

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 2. INSTALLATION
The installation site should be such there is ample clearance of at least 500mm all round for
proper ventilation and accessibility for inspection. No special foundation other than a level floor strong
enough to support the weight of the transformer and prevent accumulation of water is required. As far as
possible the location should be free from dust and water. Move the transformer to its final position and
bolt it to its foundation. Remove the covers of the primary and secondary cable boxes. Connect the cables
and replace the covers.

When installing the transformer, always refer to the following recommendations:

• Earth all non-live metallic parts by means of the earth point, which is always provided and
marked.
• Earth the neutral point, if provided, according to the earth-fault protection system.
• Make sure that the cables are properly connected and supported, and far enough from the surface
of the windings as per Table A.
• Make sure that the transformer is properly fastened to the floor and avoid any metal parts in the
vicinity in order to prevent any vibration when the transformer is operating.
• In the case of transformers with dual primary or secondary voltage, check that the transformer is
set on the correct value corresponding to the supply voltage or to the voltage output.
• Check that the adjustment tappings are set on the value corresponding to the mains voltage; if the
value needs to be modified, follow the indications on the transformer rating plate and refer to
paragraph “Commissioning” - Adjusting the input voltage (page 12).
• Connect the temperature monitoring system according to the supplied diagram.
• Check the absence of foreign objects (metallic items, screws, etc) near or on the transformer.
• Check that both HV and LV coils are perfectly concentric and that the rubber blocks are correctly
centered and tightened.

Table A
Voltage(kV) (Um) 12 17.5 24 36
Safety Distance (in mm) 120 220 220 320

Each part of the resin transformer shall be considered as live; therefore it is absolutely forbidden to
touch the transformer when it is energized. For this reason, the transformer shall always be in an
isolated room. This room will be accessible exclusively through a door which is interlocked with the MV
switch so that the switch opens, hence there is no voltage when accessing the room. When positioning
the transformer, observe the safety distances indicated in the Table A between coils and walls and
between earth and HV and LV cables. Furthermore, make sure that all metallic parts (ducting for
auxiliary cables, supporting metallic bars, etc) are at the correct distance from the surface of the coils,
from delta connection and from any other live part, in accordance with the insulation class. As already
stated, the distance depends on the max. insulation voltage (Um) of the transformer and on the type of
enclosure/substation walls. The surfaces of the coils shall be considered as “live parts”

RESPECT THE SAFETY DISTANCE.

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2.1 Electrical connections and clamps / Torque settings
Electrical connections

Screw type Tightening

torque [Nm]*
M6 5
M8 11
M 10 25
M 12 40
M 14 60
M 16 85

Mechanical connections

Screw type Torque value

[Nm]*
M 12 95
M 14 150
M 16 235
M 18 320
M 20 455
M 22 615
M 24 790

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 3. COMMISSIONING
3.1 Transformer Earthing
Check that the transformer is earthed through the plates with proper earthing braids complying
with the relevant standards.

3.2 Connection
Check the coils for eventual damages or movements due to transport and handling; also check the
fastening blocks for proper positioning and tightness. Check the connections and tightening of the
connection bolts of both high voltage and low voltage cables. With regards to the low-voltage cables,
check that they are suitably supported by the appropriate plates. Check that no earth cable or connection
runs close to live parts or the coils surfaces (for minimum distance, refer to the relevant TABLE A on
page 4), and also that there is continuity between the connections of all the elements that must be
earthed. If the transformer is equipped with temperature control devices (thermometers, electronic
control unit), check that they are set at the correct alarm and trip temperatures and that the unit is
working properly. Check that the cooling ducts are not clogged.

3.3 Adjusting the input voltage

This operation is to be carried out with the transformer off load. The variation of the supply volt-
age (within range ± 5%) as guaranteed by the supply company, can be adjusted by means of the tappings
in order to obtain the correct output ratio. Usually there are five taps, ± 2 x 2.5 %. If the medium voltage
value at the input is other than the nominal voltage value, it is recommended to follow the instructions
supplied for the connections on the plate in order to achieve a value that is as close as possible to the one
delivered by the electricity company. It is recommended to place all regulations in the same position.

3.4 Energising

After checking the appliances and ensuring that no foreign bodies have accidentally entered the
transformer (between the HV and LV coils, between the LV coil and the core, between HV/LV con-
nections), enable the switch/circuit breaker from the HV side with transformer in no-load condition.
Then enable load on the LV side through the relevant switch/circuit breaker.

3.5 Precommissioning checks

Following checks to be performed before energizing the transformer

•Cast resin transformers are suitable for direct connection to mains. But due conditions of transport and
storage, it is recommended to check the insulation resistance by using a Megger of the transformer.
Recommended values are mentioned in test report of transformer provided by us. Use 1000 V Megger for
LV-Earth & min 2500 V HV-Earth.
•If Insulation resistance values are lower than recommended, use heaters to remove the moisture •Check
the tightness of all electrical connections. Verify the recommended torque values.
•Check the tap connection and corresponding voltage
•After ensuring all conditions are ok, connect the Transformer to HV Mains
•It is recommended to keep the transformer in No load condition for atleast four hours and observe for
any abnormality.
•Afterwards, connect load to the transformer in progressive way until rated power is reached.
• Start maintaining the load data of the transformer for future reference.

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 4. PRECAUTIONS FOR SAFE OPERATION
A) Kindly check the cables for insulation value, earthing, phase sequence before making connection to the
transformer.
B) Ensure the weight of cable is taken by the compression gland provided on the cable box gland plate.
The cables should also be supported by proper cable trays / adjacent supports.
C) Switch off incoming supply before changing the tap links or removing the cable box, top side covers.
D) Ensure that the load rating does not exceed the specified value as on the rating plate.
E) Ensure that the transformer is properly earthed for better performance.
F) Paint the transformer once in a year.
G) Any trip switching devices in the input / output of the transformer should be selected to avoid
nuisance tripping during normal operation

4.1 INSPECTION ON RECEIPT

• Following points to be verified on receipt of transformer.

• Check the equipment for any transit damages. If found, Inform manufacturer.
• Check nameplate and test report.
• Check the paint work for damages, if equipped with Enclosure.
• Check the accessories.
• Identify the Lifting points for handling the transformer.
• Check if mechanical & electrical connections are loosened during transport.
• Check the identification mark on bolts.

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 5. MAINTENANCE
Being one of the greatest advantages of this type of transformer, the dry transformers require
very little maintenance. Nevertheless, it is necessary to establish a constant follow-up in order to prevent
any troubles caused by the accumulation of dirt (Which could cause a loss of cooling performance and a
consequent loss of power), inspect for any deformations of their structure, inspect all connections and
other procedures.

5.1 MAINTENANCE PROCEDURES:

1. Visual inspection of the place;

2. Cleaning as specified hereinafter in item 5.2, inspection of the air inlets and outlets;
3. Check all terminal connections for any occurred overheating;
4. Check the thermal protective assembly for proper operation;
5. The contacts of terminals and the changeover switch panel for a proper contact pressure.
6. Make sure the grounding is properly connected to the right terminals.
The transformer and its installation room should remain essentially clean all the time for a proper
operation. Therefore, cleansing should be part of the check-list upon every periodic maintenance
procedure.

5.2 CLEANING:

An important factor for a better operation of this type of transformer is to keep it clean as
constantly and effectively as possible in order to prevent any damage to its important features. For this
reason, we have listed different cleaning procedures for each type of impurities, as follows:
1) With the help of a vacuum cleaner or a duster and a dry cloth, remove all dust accumulated on the
transformer. Thereafter, use compressed air to remove any remaining dust and clean the ventilation
channels of the coils and between the coil and the core. The injection of compressed air into the
ventilation channels should be carried out from the bottom to the top. At the end, use a clean and dry
cloth to remove any residues left on the coils, particularly around the terminals and the isolators.
2) The last step should be carried out always using a clean and dry cloth in order to wipe the entire
surface, particularly in the region of the connection terminals.

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 6. PERIODIC INSPECTIONS
For an extended life and optimal performance of your dry type transformer, maintenance
activities are highly recommended on a periodic basis.

The list below covers important checkpoints for routine maintenance. The frequency of periodic
inspections will vary depending on the operating environment, as well as the type of load being applied.

6.1 Checking for Dust Accumulation

1. Visually inspect cover louvers, screens, and internal coil cooling ducts for dust build-up. If found,
wait until the transformer is deenergized to remove any panels
2. Once de energized, vacuum out as much of the dust as possible.
3. Clean the transformer with a brush or lint-free rag. Avoid detergents or cleaning products as they
may accumulate future dust and accelerate the deterioration of your transformer.
4. In inaccessible areas, blow dry air into the unit

Allowing dust and debris to accumulate over time can cause problems with your transformers that can
lead to an electrical short and overheating.

6.2 While the Transformer is Energized

1. Verify proper ventilation.
2. Monitor any changes in the characteristics of your transformer’s audible sound.

6.3 While the Transformer is De energized

1. Ensure all accessible hardware is tightened.
2. Clean cooling fans.
3. Inspect insulation surfaces for any discoloration or signs of heat damage.
4. Isolation dampeners should be monitored for signs of deterioration.

Regardless of how often you’re doing maintenance on your units, issues can arise at any time. Be sure to
be observant of your transformer’s appearance and operation. If you notice anything out of the ordinary,
it’s vital that you attend to the issue immediately to avoid damage.

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 7. STORAGE
• If the transformer is intended for Indoor operation, it should be stored indoors only.
• Storage location should be dry , free from dust & dirt
• Care to be taken to avoid condensation in that area
• If transformers with enclosure suitable for outdoor installation, they should be protected form
entrance of water, moisture and foreign materials
• Temperature of the storage area shall not be less than -5 °C.
• If the transformer is to be stored for long periods, care should be taken to avoid moisture entry &
dust accumulations etc.
• If stored for long periods, proper ventilation should be provided. Periodic inspections shall be
conducted to verify the stored transformer.

8. MALFUNCTIONS AND INITIAL CORRECTION WORK

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MALFUNTION FAULTY PARTS /
PROBABLE CAUSES
Low insulation resistance Presence of dirt Dielectric
humidity absorption
Dielectric fault caused by
ageing or dirt
Automatic cut-off Insulation problem with
activated the HV coil
Change in voltage / the
value of the voltage in the
primary coil does not
coincide with that
reported at the terminal
box
Time and current intensity
of protection relay are not
properly adjusted
Voltage in the primary is
Erroneous secondary not equal to the nominal
voltage value value. No voltage in the
primary
Incorrectly positioned
voltage tappings
SOLUTIONS
Clean using dry air, dry by
ventilation
Contact us
Contact us
Make sure that the
position indicated to the
voltage change position is
the same as the line one
Review the timing and
adjust the intensity value
Contact the electricity
supply and distribution
company
Correct position of tappings
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