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Warning

This guide intended for standard


range oil-immersed distribution
transformers as described in
France Transfo product
catalogues.
If in doubt, our After-Sales Service
remains wholly at your disposal.
Tl. (33) 03 87 70 57 72
fax: (33) 03 87 70 56 21

France Transfo

Taking delivery of equipment and preliminary checking


On receipt of equipment, ensure that it corresponds with your order by checking
machine characteristics indicated on the rating plate (capacity, voltages, etc.)
Distribution transformers are delivered "ready for installation", i.e. completely filled
with oil and with accessories either fitted or delivered separately.
When unloading, check that the transformer has not been damaged during
transport (broken insulators, damaged tank, etc.) and that all accessories ordered
have been delivered.
Also check that the tank lead seal, fixed to one of the cover screws (usually at a
tank corner) is intact, because its breakage causes the transformer guarantee to
lapse.
Should the unit have been damaged or if accessories ordered are found to be
missing:

enter a reservation on the final haulage contractor's delivery note and confirm
by recorded delivery letter within 3 days.

write a report and send it immediately to your supplier (France Transfo or a


dealer as the case may be).

France Transfo

Handling
Transformers are usually stabilised during transit by heavy timber bearers fixed to
the vehicle bed. It is therefore essential to remove these bearers before lifting the
transformer unit off the vehicle.

Transformer units incorporate specific handling devices.

Lifting by means of slings or a lifting beam (figure 1)

The unit must be handled using the 2 lifting rings located on the transformer cover.

Hauling (figure 2)

or

The transformer must only be hauled from its chassis. 30 mm diameter holes have
been drilled in the ends of chassis members for this purpose, except in the case
of low capacity units or those built to a special specification. Hauling must only
been undertaken in two directions: along and perpendicular to the chassis centreline.

Handling using a forklift truck (figure 2)

Forks must only lift the chassis from within the inverted channel sections, with idler
rollers removed.

France Transfo

2
hole for hauling

Handling

Positioning of idler rollers (figure 3)

either by lifting with slings or a lifting beam.

or by lifting with a forklift truck.


In this case, position the forks of the truck within the inverted channel sections.
Place heavy timber bearers, which are slightly higher than the idler rollers, crosswise beneath the ends of the chassis members and lower the unit onto these timbers.
Position jacks and remove timber bearers one by one.
At the same time, fix each idler roller in the required position (idlers swivel in
2 directions) using the locking screw.
Then, remove the jacks and allow the unit to rest on its idler rollers.
Ground clearance due to the idler rollers is essential for transformer cooling.

timber bearer

idler rollers

France Transfo

Installation
Ensure that machine characteristics shown on the rating plate correspond with
installation conditions: primary voltage(s), tapping links.
This plate may be moved and attached to any side of the tank so that it is visible
once the machine is in position.
In general, installation must comply with the requirements of IEC Standard
71-1, 2 and 3 in relation to insulation co-ordination.
E.g.: case of overhead-underground connection to be protected by lightning
arresters installed at both ends of the HV cable.

unit to be installed at a maximum altitude of 1000 m, unless otherwise specified


with order, because air rarefaction adversely affects cooling of the windings.

unless otherwise specified with order, transformers of standard design are


sized in accordance with IEC Standard 76 for the following ambient
temperatures:
maximum
average daily
average annual
minimum

: 40C
: 30C
: 20C
: 25C

When the transformer is live, the ambient temperature inside the plantroom must
comply with the above values, unless the transformer has been specially designed
on the basis of a particular specification.

France Transfo

Installation
Determining the height and cross-sectional areas of
ventilation wall openings (figure 4)

In the general case involving natural cooling (AN), the purpose of the plantroom
ventilation system is to disperse the heat, resulting from the total heat losses
generated by the operating transformer, by natural convection.

S
200 mm
mini

An efficient ventilation system comprises a fresh air inlet wall opening of crosssectional area S positioned low down in the room, and air outlet opening of crosssectional area S' positioned high up on the opposite wall of the room at a height
H above the air inlet opening.
It should be noted that restricted air circulation around the unit causes a reduction
in available power. For this reason, the transformer must be positioned at a
minimum distance of 200 mm from any solid wall.

H
Groupe Merlin Gerin Usine de Maizires-ls-Metz (Moselle) France

n 216540

Design calculation:
P = sum of losses under no load and losses due to load on transformer, expressed
in kW at 75C, plus losses generated by any other unit in the same room.
S = cross-sectional area of fresh air inlet wall opening (deduct possible area
obstructed by grill), expressed in m2.
S= cross-sectional area of air outlet wall opening (deduct possible area
obstructed by grill), expressed in m2.
H = difference in height between inlet and outlet wall opening centre-lines,
expressed in m.
, 18P- and S = 1, 10 S
S = 0
---------------H

This formula is valid for an average annual ambient temperature of 20C and at a
maximum altitude of 1000 metres.
France Transfo

Installation
Forced ventilation of plantroom (figure 5)

A ventilation system of this type is required for a cramped or poorly ventilated


plantroom, or for a room in which the ambient temperature is much higher than the
temperature outside, in view of the ambient temperatures used for designing the
transformer. Should the transformer be frequently overloaded, a forced ventilation
system can help to disperse the heat generated by the unit, although it will not
reduce the adverse effects of such overloading on the equipment's life.

S
200 mm
mini

An air extract fan discharging outside the plantroom may be fitted to the outlet
wall opening, located at high level, in order to increase natural convection in the
room; this fan can be thermostat-controlled.

H
Groupe Merlin Gerin Usine de Maizires-ls-Metz (Moselle) France

Recommended discharge rate (m3/s) at 20C = 0.10 P


P = total heat losses to be dispersed, expressed in kW, for all equipment installed.

France Transfo

n 216540

Installation
Setting the voltage
commutator
Adjustments to tapping point or
voltage commutators must be
undertaken with the transformer
off-load and de-energized.

Tapping links
Set the tapping point
commutator to the required
position:
Pos. 1: upper primary voltage
Pos. 2: rated primary voltage
Pos. 3: lower primary voltage
red locking knob

- unscrew fully the red locking knob,


- simultaneously pull and turn the
commutator rotating head until the
pointer indicates the right setting,
- push the rotating head back ensuring
that the pointer is engaged in the
notch for the setting required,
- rescrew fully the red locking knob

commutator rotating head

index

Double primary voltage


For units using 2 primary
voltages, select position as
required.

Commutator setting is carried out in the


following way:

Pos. 1: HV1
Pos. 2: HV2

France Transfo

Installation
Statutory restrictions for oil-immersed transformers
Each country issues its own regulations covering the installation of oil-immersed
transformers on its territory.
These regulations invariably respond to concerns for the protection of people,
property and the environment. Available protection systems depend on the
technology adopted for the transformer concerned.
When the unit is in service, the volume of the dielectric fluid used to cool its coils
(usually mineral oil complying with IEC Standard 296) varies continually, due to
temperature variations in the windings.
These volume changes must be "absorbed" by a suitable expansion system
which has given rise to two distinct technologies:

Hermetically sealed type transformer


The unit's tank, containing the active part, is hermetically sealed: variations in
volume are absorbed by expansion of the cooling fins positioned around the tank,
the dielectric fluid is not exposed to the surrounding air.
Maintenance of this type of unit is thus greatly reduced (see page 20).

10

France Transfo

Installation
Protection accessory: the protection relay (figure 6)

Fitted directly to the transformer cover, this relay ensures protection against
internal faults, prolonged overvoltages and fire risks associated with the use of
inflammable dielectric fluids.
The accessory continuously monitors:
- dielectric fluid level,
- tank internal pressure,
- dielectric fluid temperature at two different thresholds.

oil

To operate properly, the protection relay must be fully filled with fluid (level higher
than the float visible in the transparent section of the unit). If this is not the case,
check the instructions which appear inside each casing.

sensors

To ensure optimum protection, the following action and adjustments are


recommended:
Finding

Recommended
adjustment

Fault detected

Action to be taken

Gas emitted or drop in


level

Large float at the top

Serious fault

Pressure switch

0.20 bar

Serious fault

De-energize unit

Thermostat threshold 1

90C

Overvoltages

Activate alarm

Thermostat threshold 2

100C

Overvoltages

De-energize unit

De-energize unit

France Transfo

11

Installation
Faults detected on live transformer unit

Dielectric fluid level is detected as low


The protection relay is empty and the large float is at the bottom.
May be due to:
- air entering; there must be a dielectric fluid leak and thus oily stains should be
visible on the ground.
Accurately localise the fault, carry out repair, then recheck the level with the
body of fluid at a temperature of 20C, before switching the unit live again
(see oil grades, page 20),
- internal gas emission: gas should be sampled using a syringe and then analysed.
Whilst awaiting results, under no circumstances should the transformer be
switched live again because a risk of total destruction exists.
Should gas analysis reveal an inflammable gas, contact FRANCE TRANSFO
After-Sales Service (see page 23), or your SCHNEIDER correspondent.

Overheating is detected
This may be due to:
- improper cooling of the transformer (insufficient air flow around unit or plantroom ventilation),
- continuous overvoltage.

Excess pressure is detected


This may be due to:
- overheating: see above,
- internal gas emission: see above,
- topping up of dielectric fluid with the body of fluid below 20C; drain the overflow with the transformer de-energised and the dielectric fluid at 20C.

12

France Transfo

Installation
Breather type transformer with expansion tank (figure 7)
The transformer tank is connected by pipework to an expansion tank, mounted
above the unit, which ensures that the dielectric fluid level remains sufficiently high
in the transformer tank: variations in dielectric fluid volume are absorbed by the
expansion tank which remains at atmospheric pressure.

7
oil

This type of unit therefore requires maintenance which is both regular and suited
to the climatic conditions in the vicinity of the transformer (see page 21).
Protection accessory : the Buchholz relay
Fitted to the pipework linking the expansion tank to the transformer tank, this
accessory ensures protection against internal faults only, by monitoring dielectric
fluid levels and fluctuations.
To ensure proper operation, the Buchholz relay must be completely bled of air.
Faults detected on live transformer unit

Dielectric fluid level is detected as low.


The Buchholz relay is partially empty, the top level float is at the bottom.
Reasons for this low fluid level are the same as those given for the protection
relay (see page 11) but in the present case, the relay will activate automatically
the alarm.

Major discharge of oil towards the expansion tank is detected


A violent emission of gas, resulting in serious electrical faults within the
transformer tank, leads to a large discharge of oil to the expansion tank, which
causes the Buchholz relay bottom float to pivot; the transformer unit must be
de-energised immediately and permanently.
Contact FRANCE TRANSFO After-Sales Service (see page 23), or your
SCHNEIDER correspondent.
France Transfo

13

Installation
Dielectric fluid retention system
In an environmental protection context, the retention system used must be
capable of containing the total quantity of dielectric fluid, unless otherwise
specified by local regulations.
It may comprise:
- a raised door threshold if the plantroom floor is oil tight,
- a low oil tight wall around the transformer,
- a steel trough positioned beneath the transformer.
In the last two cases, ensure that the system does not adversely affect transformer
cooling by preventing air circulation around the tank cooling fins.

14

France Transfo

HV and LV connections
Bushing type
Transformers may be provided with the following connections.
LV connections to busbar bushings (only used above 250 kVA units)
100

1250A

14,5
11

1600A

310

250

31,5

14,5

135

35
50
50

250

31,5
11

50

50

3150A

2500A

locking ring

locking ring

18

18

45

52

31,5

52

155

14,5

11

31,5

20

25

12

50

52

12

12

221

31,5

31,5
31,5

12

106,5

31,5

97,5

63

120
50

120

31,5

31,5

31,5

45

63

HV connections to
plug-in bushings

with draw-out
angle connector

5000A

LV connections to porcelain bushings (mandatory for 100 and 160 kVA units) DIN 42530

HV connections to
porcelain bushings DIN 42531

150

20

with draw-out
straight connector

M 12

50

15
10
M 20
M 12

26

60

100

25
20
40

15

14

26
M 30

340

60

M 42

30

150

165

20
40

120

14

60
263

138

17

100

120

14
372

465

385

65

M 48

178

DT 250A DT 630A

DT 1000A

DT 3150A

DT 2000A

N.B.: under no circumstances should porcelain


HV bushings be used
with cover-protected HV
systems.

250A

5300A

Example of bushing choice for LV = 400 V.


100

160

250

315

400

500

630

800

1000

1250

1600

2000

2500

3150

LV busbar bushings

1250A

1250A

1250A

1250A

1250A

1250A

1600A

2500A

2500A

3150A

5000A

5000A

LV porcelain bushings

250A

250A

630A

630A

630A

1000A

1000A

1600A

1600A

2500A

2500A

3150A

4000A

5300A

kVA

France Transfo

15

HV and LV connections
Assembly and tightening torque
Bushings must not be subjected to stresses resulting from cable or busbar
connections; such loads can cause leaks at various joints.
Furthermore, the following connection details and tightening torque values shall
be complied with:
HV or LV connection to porcelain bushing
(U 52 kV - M12 stud)
nut tightening
torque: 25 Nm

LV connection to busbar bushing


M12 brass stud

steel bolt

locknut

load in accordance
with I.E.C. 137:
connecting terminal
inclined < 30, F = 50 daN
connecting terminal
inclined > 30, F = 30 daN

clearance:
approx. 5 mm

end lug

large diameter metric series


steel plain washers
tin-plated copper busbar bushing

reminder:
1 N.m = 0.102 mkg
1 mkg = 0.98 daN.m

16

France Transfo

N.B.: end lug, bolt and washers are not supplied.

HV and LV connections
Table of tightening torque values

Bolts

Class 6.8
anticorrosion
-treated steel

Class A2-70
and A4-70
stainless steel

Class A2-80
and A4-80
stainless steel

Brass

M8

15.2

15.5

17.7

M10

30

30

35

15.1

7.6

M12

52

53

60

25

M14

83

85

97

41

M16

130

133

152

55

Tightening torque given in N.m.


Tightening tolerance 20%.
The above torque values are for assemblies incorporating plain washers.
However, we recommend the incorporation of contact washers behind the plain
washers; the above torque values should be increased by 35% if this is done.
Steel and stainless steel bolts shall be greased prior to fitting.
If aluminium bolts are used, please refer to manufacturer's recommendations.

France Transfo

17

HV and LV connections
Protection
HV bushings

Draw-out connectors (straight or angle) may be kept plugged into the plug-in
bushings using a padlockable locking device (padlock / lock not supplied);
Release of this locking system may be made conditional on prior isolation of
the transformer from the HV supply (figure 8);

Porcelain bushings may be fitted with a sealable protective cover, whose


design will depend on the HV voltages, the configuration and number of cables.

LV bushings

Busbar or porcelain bushings may be protected by a sealable cover.

18

France Transfo

Transformer operation in parallel


Connection of several transformers in parallel leads to the following constraints:

If their power outputs are different, the total available combined power output
will be slightly less (< 10%) than the sum of the power outputs for each
transformer coupled separately.

The power output of the largest transformer should not be more than twice that
of the smallest unit.

Transformers must be supplied by the same network.

Connections must be of the same length and have similar characteristics


between the LV terminals of the different units and the coupling circuit-breaker
(figure 9).

Couplings must be identical.

Short-circuit voltages must be identical (10%).

Differences in secondary voltages between the different units must not exceed 0.4%.

The switch shall be positioned identically on each unit.

9
recommend

to advise

LV

France Transfo

19

Maintenance
Mineral oil and component materials
The transformer is filled with mineral oil complying with ICE Standard 296.
Transformer component materials are free of polychlorobiphenyls (PCB's),
polychloroterphenyls (PCT's) and polychlorobenzyltoluene (PCBT).
Moreover, the PCB content of this unit is guaranteed to be less than the detectable
threshold (2 ppm*) in strict compliance with standards currently in force.
Hermetically sealed type transformer
Under normal operating and environmental conditions, maintenance of this
transformer is reduced. It is in fact limited to regularly checking the tightness of
connections and visual inspection of transformer oil tightness.
Under conditions of extreme pollution (depositing of dust, salt, chemicals, etc.),
cleaning of porcelain or busbar bushings may be required.
As long as the dielectric fluid has not been exposed to the air for a particular
reason (tank opening, repairs, fitting of accessories, topping up of oil, etc.), one
dielectric withstand test, on a sample taken from the bottom of the tank (minimum
breakdown voltage 30 kV), every 10 years is sufficient.
The transformer is hermetically sealed and has no gas cushion. In other words,
filling and closure have been carried out in such a way that pressures are balanced
(internal and external atmospheric pressure) under conditions approaching
normal, i.e. temperature of 20C and pressure of 1013 mbar.

* parts per million.

20

France Transfo

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Maintenance
If necessary, this transformer may be opened in accordance with the following
recommendations:
Transformer is hot ( > 20C)
The unit's internal pressure is higher than atmospheric and opening it causes
leakage of some dielectric fluid which can only be reinjected in full, once its
temperature has returned to 20C.
Until this occurs, the unit can fulfil its functions. However, replacement of all the
dielectric fluid lost at the earliest opportunity is preferable.
Transformer is cold ( < 20C)
The unit's internal pressure is lower than atmospheric and opening it causes a
drop in oil level in the tank. After servicing and topping up dielectric fluid, if
required, put the unit back into operation and purge when hot.
To prevent excess pressure in the tank, the volume of dielectric fluid which may
have been added (during topping up) should be drained, once the unit's
operating temperature has risen to 20C.

France Transfo

21

Maintenance
Breather type transformer with expansion tank
Because the dielectric fluid is exposed permanently to the surrounding air, the
frequency of oil quality checks must be increased: once a year is an absolute
minimum, which should be further increased if a gradual deterioration of fluid
dielectric withstand is observed (reminder: minimum breakdown voltage: 30 kV).
If an air dehumidifier has been fitted to the expansion tank to filter the incoming air,
the colour of the silica gel it contains should be monitored:
- blue colour : silica gel is in a good condition for ensuring dehumidification,
- pink or white colour : silica gel has absorbed humidity and has become ineffective, it should therefore be replaced (supplied by our After-Sales Service,
see page 23).
Also check that the glass, located at the bottom of the dehumidifier, is filled with
oil to the required level, in order that dust carried by the surrounding air flow is
effectively retained.

22

France Transfo

After-Sales Service
When making enquiries or ordering spare parts, it is essential to quote the main
characteristics given on the rating plate and, in particular, the unit serial number.

TECHNICAL MEMO
(data to be copied from unit rating plate)

After-Sales Service
tel.: (33) 03 87 70 57 72
fax: (33) 03 87 70 56 21
www.francetransfo.com

No.

Year

Power output

kVA

Frequency

Hz

Cooling

Coupling

Rated high
voltage

kV

Low voltage

Mass of
dielectric

kg

Total mass

kg

France Transfo

23

Precommissioning checks
Operations prior to connecting transformer
check data given on rating plate in relation to needs (power output, voltage,
etc...)

ensure transformer plantroom is clean and cannot flood


ensure correct ventilation
- plantroom air vents are clear and of suitable area (pages 7 and 8)
- sufficient clearance between unit and solid walls in plantroom (page 7)
- sufficient clearance between unit and floor (unit resting on idler rollers page 5)

check general condition and cleanliness of transformer


measure values of insulation resistance using a 2,500 V insulation tester
Measuring points

Usual values for


mineral oil

Measured values

HV / earth

250 M

LV / earth

50 M

HV/LV

250 M

If the measured values are significantly less than the usual values, please call
your After-Sales Service (page 22).

check oil tightness of unit (welds, gaskets, valves, drains, plugs).


Checks carried out on: ......................................... by: .........................................

24

France Transfo

Precommissioning checks
Operations prior to switching transformer live
ensure there is no foreign body on the unit (metal filings, nuts and bolts, etc.)
if the transformer is an hermetically sealed type unit fitted with a protection
relay, check that the large float is at the top and that the drain is properly
closed (close by turning clockwise). Refer to instructions supplied with each
transformer in relation to testing.

if the transformer is a breather type unit with an expansion tank and Buchholz
relay, check that all air bubbles have been bled from the latter unit and carry
out relay testing using the devices provided for this (rod to be pushed or
pulled to activate alarm or trip).
Check condition of silica gel in the dehumidifier and the level of oil in the bottom glass vessel.

ensure that cables and busbars are properly supported; no loads should be
applied to the transformer connection lugs.

check wiring of protection or ventilation auxiliaries with respect to:


- insulation clearances and cable fixings,

operation.check tightness of connections (pages 16 and 17)


check earthing continuity - to ensure the safety of operating personnel, the
transformer earthing system must be grounded.

check that rotating switch head is correctly set to, and locked in, the required
position.

ensure that ventilation grills are clear.


- if unit is to operate in parallel, check short-circuit voltage, phase consistency
and voltage ratio (page 19)

France Transfo

25

notes

26

France Transfo

BP 10140
F-57281 Maizires-ls-Metz cedex
France
Tel: 33 (0)3 87 70 57 57
fax: 33 (0)3 87 51 10 16
http://www.francetransfo.com

GEa 220000 b

Since this manual was edited, a number of alterations may have


been incorporated in the equipment you have received. The sole
reason for this resides in our constant efforts to improve the
quality and performance of our equipment.

Edited by: France Transfo - 05/2008


Typesetting and illustrations: EDITECH.COM

SAS au capital de 1 709 622 euros Code APE : 2711 Z Siret : 357 801 109 000 20 N ident. TVA : FR 78 357801109 Imprim en France

Postal address:

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