HM0.460.531
SY □ ZZ On-Load Tap Changer
Operating Instructions
HM 0.460.531
Shanghai Huaming Power Equipment Co.,Ltd.
Thank you for choosing our products and please read our
operating instruction thoroughly before use.
HM0.460.531
CONTENTS
1. General ………………………………………………………………………………………………… 2
2. Technical Data…………………………………………………………………………………………3
3. Structure and Operation Principles……………………………………………………………………5
4. Installation and Commissioning…………………………………………………………………………7
5. Operation and Maintenance……………………………………………………………………………10
6. Package and Shipment…………………………………………………………………………………11
7. Appendix…………………………………………………………………………………………………12
1
1. General
SY□ ZZ series is a compound resistance transition type on-load tap changer, it combines the
function of tap selector and diverter switch together, the motor drive mechanism is on the head of
the tap changer, and tap changer has its oil compartment separated from the transformer tank, it is
simple structure and convenient for installation and maintenance.
It is designed and produced according to IEC60214-1 Standard.
Fig.1
Designations of model codes are as follows:
S Y □ Z Z-□/□-□ □
Three phases
Loaded voltage regulation
X means neutral output terminal is
equipped (for SYXZZ type only)
J for middle-bridging regulation
Operating positions
X for linear regulation in neutral
Maximum rated through-current (A)
point connection
T for linear regulation
The highest voltage for equipment (kV)
Selector switch type
Resistance transition
For example, SYXZZ-40.5/200-7 means three phases, linear regulation in neutral point connection,
the highest voltage for equipment is 40.5kV, the maximum rated through current is 200A, resistance
transition and selector switch type on-load tap changer, 7 operating positions.
2
HM0.460.531
2. Technical Data
2.1 Table of main technical data
Item
Model
1
Maximum rated through-current (A)
200
2
Rated Frequency (Hz)
50 or 60
3
Phase
3
4
Connection
5
Short-circuit
withstand
current (kA)
6
Y
(neutral point)
Dynamic stability (peak value)
10
600
10
9
Rated voltage
35
Highest voltage for equipment
40.5
Rated separate source AC withstand voltage
(kV/50Hz, 1min)
95
Rated lightning impulse withstand voltage
(kV, 1.2/50μs)
250
95
95
Rated lightning impulse withstand
voltag (kV, 1.2/50μs)
75
250
250
Between
max.
and min. tap
35
Rated separate source AC withstand
voltage (kV/50Hz, 1min)
45
Rated lightning impulse withstand
voltag (kV, 1.2/50μs)
105
Rated separate source AC withstand
voltage (kV/50Hz, 1min)
10
Rated lightning impulse withstand
voltag (kV, 1.2/50μs)
30
9
Mechanical life
Not less than 500,000 operations
10
Electrical life
Not less than 50,000 operations
11
12
13
Sealing test
10
Rated separate source AC withstand
voltage (kV/50Hz, 1min)
Between
adjacent taps
Between
phases
To ground
Intenmal
SYTZZ-35/200
Y or D
Y or D
(middle-bridging) (Linear regulation)
4
Rated step voltage (V)
Insulation level (kV)
SYJZZ-35/200
Thermal stability (3s)
Maximum operating positions
8
SYXZZ-35/200
Working pressure
0.03MPa
Test pressure
0.08MPA for 24 hours no leakage
Protective relay
QJ-25 setting oil speed 1.0m/s ± 10%
Overpressure protection
Rupture disc breaks at 300kPa+-20% overpressure
Weight (excluding oil)(kg)
150
Drying
Max. 110℃ for vapor phase drying,
Max. 110℃ for vacuum drying
Affiliated AVR
HMK-35D
3
2.2 Contact resistance of tap changer contacts ≤ 500μΩ
2.3 Switching time is 35~50ms
2.4 Basic connection diagram (see Fig. 2a, 2b, 2c)
2.5 Oil temperature in any conduct parts of OLTC shall not exceed 20K.
2.6 Operation conditions
2.6.1 The storage ambient temperature of OLTC is from -25℃ to 40℃ . The storage humidity of the
OLTC should be no more than 85 percent.
The service temperature of standard designed OLTC is -25℃ to 40℃ If the temperature exceeds
the range of above (-25℃ to 40℃ ), please specify when ordering.
2.6.2 To meet the ordering requirements and comply with the operating environment, if the
requested service temperature is out of the range of -25℃ to 40℃ , the material and accessories of
the OLTC will be specially designed and selected.
2.6.3 The degree of inclination of tap changer should be less than 2° when it is installed in
transformer.
2.6.4 The place where OLTC is to be installed shall be prevented from any heavy dust, explosive
and/or corrosive gases.
(a) Type SYXZZ
(b) Type SYJZZ
Fig.2
4
(c) Type SYTZZ
HM0.460.531
3. Structure and operation principles
3.1 Tap changer structure
SY□ ZZ type on-load tap changer is installed in a single oil compartment separated from the oil in
transformer.(see supplement 1 for standard design and supplement 9 for optional design)
The tap changer consists of four sections:
3.1.1 Motor drive mechanism (includes motor, two-stage worm gear, arm plate, turning arm and
pulling spring, etc.)
3.1.2 The diverter switch assembly (includes rotation arm, Geneva wheel, main shaft, movable and
stationary contact system and transition resistor, etc.)
3.1.3 Oil compartment (includes top cover, oil conservator, insulation cylinder and cylinder bottom,
etc.)
3.1.4 Signal and safety devices (includes position sensor panel, protective relay , pressure
relief valve, mechanical limit device) (electrical position limit, sequence control are in HMK-35D
automatic voltage regulator)
3.2 Operation principles
After it is energized, motor drives two-stage worm & worm gear gearing down mechanism and
the arm plate, which drives turning arm during the rotation, consequently stretches the spring to
accumulate energy, once the turning arm overpasses the "dead point " position where it is lined
up with the stretched spring, the spring will release suddenly, making the turning arm quickly push
Geneva wheel via the dialing disc, meanwhile, the Geneva wheel drives the moving contacts
assembly through main shaft from one position to the next one, because the transition resistor
is added between main contacts and transition contacts, which operates one by one in certain
sequences, therefore the main contacts can move from one tap to the adjacent one without current
interruption.
5
3.3 The OLTC is applied with HMK-35D automatic voltage regulator.
Automatic voltage regulator diagram illustrates as follows(Figure 3):
1) Optional PT signal voltage 400V or 100V
Fig.3
6
HM0.460.531
3.4 OLTC operating sequence (see figure 4)
a. Single-resistor for linear regulation
b. Double-resistor for middle-bridging regulation
Fig.4
4. Installation and commissioning
4.1 Installation of tap changer in transformer with standard tank mounting flange.
It is recommended to weld an installation flange on the transformer cover,which will locate tap
changer correctly and protect its sealing. For the requirements of dimensions and surface finishes
of installation flange pleasesee overall dimensions drawings in supplements, we suggest using a jig
to proces the flange so that it could be easily located, fix the tap changer on the above installation
flange. Between tap changer and the installation flange is an 8 mm thick oil-proof gasket.
Note: Movable and stationary contacts have already adjusted to a fixed position (figure 6)
where user is to install OLTC.
Installation steps:
4.1.1. Clean up the sealing surface concerned and place a sealing gasket on the installation flange;
4.1.2. Lift the tap changer upward and insert it into opening of transformer cover slowly;
7
Note: All terminals and shield caps must not be damaged during this process.
4.1.3. Check the relative location of tap changer on the cover of transformer tank, finally fix it on the
flange
4.2 Drying process
4.2.1 Vacuum drying
The drying can be performed in an vacuum oven or transformer tank, in order to avoid damage
caused by pressure difference between the interior and exterior of the tap change oil compartment
during drying, the top cover of the tap changer should be removed, or a connection between
transformer oil tank and tap changer oil compartment should be established before drying.
Drying process:
Under standard atmospheric pressure, heat up the tap changer at an increasing rate of 10℃ per
hour gradually until 110℃ is reached, and then it is dried last out 15 hours by hot air, finally it is
kept under 110℃ and vacuum residual pressure 10-3 Bar for 80 hours.
11b
Ø610
Bolt (23×M12 ) evenly separating in 15
40
Flange to be
installed
Welding
35KV OLTC Setting Position
ransformer
tank cover
Ø520
7
15°
0
15°
7
Ø5
3
2
1
M16
Positioning Hole
23×M12
Size of Flange installed on transforme
Fig.5
8
4
5
2
6
1
8
7
Output
terminal
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
Selector Switch contact Position
Tap changer Indicator
Working Position
Voltage Regulation Figure
Setting position
Fig.6
8
7
4
HM0.460.531
4.2.2 Hot air circulation drying
Remove the top cover of tap changer before drying.
Drying process:
Under standard atmospheric pressure, heat up the tap changer at an increasing rate of 10℃ per
hour gradually until 110℃ is reached, and then it is dried last out 72 hours by hot air circulation.
Warning: Operation of the tap changer without oil is forbidden after drying.
4.3 Oil filling
Vent hole on tap changer (see supplement 1) should be loosened firstly, from which gases inside
the transformer tank could be expelled when oil is filled, and screw it tightly till oil overflowing.
Tap changer should be filled with superior transformer oil that has an insulation level over 40kV.
Connect the oil-inlet and oil-drain pipe with a long pipe that could reach a certain height over
the ground and to which a valve is attached for sampling oil periodically, facilitating filtering and
replacing oil when necessary.
4.4 Commissioning
Generally, tap changer is vertically fixed onto transformer cover.
Attention should be paid to the electrical insulation distances of leads linking transformer to tap
changer, the distances such as lead to wall, leads to other phase coils please refer to transformer
data.
Following tests and check-ups should be carried out before commissioning
4.4.1 Press down tripping-off probe on the top cover of protective relay,check whether the probe
and protection circuit of transformer operate normally.
4.4.2 Operate three cycles and check whether tap changer runs smoothly, the position indication
displays correct position, and mechanical & electrical limit switches actuates reliably.
4.4.3 Measure DC resistances of transformer winding together with tap changer and check
whether the values of resistances are normal by comparing them with data offerred by the OLTC
manufacturer.
4.4.4 Check whether the oil quality is in good condition.
9
5. Operation and maintenance
Sealing of tap changer head section, protective relay, wiring socket for control cable and pipes
connection must be checked before the transformer is put into operation. Record operation times of
the tap changer regularly and keep the save data.
The mechanism of this series tap changer is fully immerged in oil. During normal operation, check
the oil sample from tap changer bottom through oil suction tube every 3~6 months. When sampling,
the first 2kg of oil should be discharged before sampling in order to guarantee the reality of the
sample. If the dielectric test value is less than 30kV or the water content is more than 40ppm, the
oil should then be changed or filtered. The dielectric strength of the added fresh oil should be over
than 40kV and the water content should be less than 10ppm.
It is recommended that regular maintenance must be conducted in order to guarantee the reliable
operation of the tap changer.
During the first year of its operation, routine check up should be conducted every six months. After
that, a periodic check up should be carried out every 5,000~10,000 operations under operation
condition. During the inspection, method for taking out the inserter of the tap changer is as follows:
(1) Discharge oil from oil-drain pipe until the oil level of the tap changer reaching below the lower
flange of oil compartment;
(2) Remove top cover and its accessories;
(3) Disassemble leads of control circuit on outlet terminals within the head compartment;
(4) Remove nuts from the location screws of the inserter;
(5) Pull out the inserter. In order to avoid impacting and wearing out the spring contacts, it should
be done in two steps, first to pull the inserter upward about 60mm and then turn an angle about
10° to make non contact of the spring contacts and its matching stationary contacts on insulation
cylinder, then pull upward again to take out the inserter.
Its re-inserting process is just in a vice versa way.
Besides cleaning the inserter and internal of the tap changer oil compartment, following sections
should also be checked.
10
HM0.460.531
(1) Pull out pile for pulling spring, check if the tap changer can be turned flexibly, check if silde
between moving contact and stationary contact is reliable and their action is normal.
(2) Check the status of the fast moving mechanism to see if the pull spring is damaged, or if it is
burred on arc surfaces of the Geneva wheel and the dial disc, and to see if the worm wheel gear
still operate flexibly.
(3) Check the interface between the surfaces of the Geneva wheel and the dial disc to see if their
gaps on two sides are kept in equal distances.
(4) Check the burned status of the copper-tungsten alloy block of the tap changer contacts.
The burned worn-out could be polished by fine abrasive cloth slightly in order to reduce friction
resistance between the moving contacts and the stationary contacts (When polishing the main
contacts, please note that the contacts must be moved to their idle position). The contacts should
be changed if the worn out is over 2mm. Since the contact wear of each section differs quite a
bit, the contacts can be exchanged with each other in order to expand their service life. However,
during the adjustment, please pay close attentions on correcting the level position of the contact to
keep it within ±0.1mm
(5) Check the transition resistors to see if there is any over-heat, and measure DC resistances in
comparison with manufactory data to determine if they are normal.
Warnings:
1. During the maintenance of the tap changer, be sure to de-energize and properly ground
the tap changer and the transformer.
2. Exposure of the main tap changer body into dry air should not exceed necessary time
(maximum 10 hours).
3. During the check process, be careful not to drop down any parts into the main tap
changer body.
6. Package and shipment
Usually OLTC is sealed and wrapped with plastic bag in thickness of 0.1~0.15mm. Package
project includes main engine of OLTC, AVR, cables, an original copy of Operation Instruction and
Qualification Certificate(please be subject to packing list for details). All the above mentioned
facilities shall be packed in one wooden carton marked with relevant shipping signs.
11
7. Appendix
Appendix 1 SY□ZZ On-Load Tap Changer Structure…………………………………………………13
Appendix 2 Overall dimensions and installation size of Gas Relay…………………………………14
J
Appendix 3 Overall dimension of SY X ZZ-35/200 78 ………………………………………………………15
Appendix 4 Overall dimension of SY XJ ZZ-35/200109 ………………………………………………………16
7
Appendix 5 Overall dimension of SYXZZ-35/200 8 X with output terminal……………………………17
9
Appendix 6 Overall dimension of SYXZZ-35/20010 X with output terminal……………………………18
Appendix 7 Overall dimension of SYTZZ-35/200109 ……………………………………………………19
Appendix 8 Overall dimension of SYTZZ-35/200 78 ……………………………………………………20
7
Appendix 9 Overall dimension of SY XJ ZZ-35/400 8 ………………………………………………………21
Appendix 10 Overall dimension of SY XJ ZZ-35/400 78 for bell type………………………………………22
Appendix 11 Overall dimension of mounting flange……………………………………………………23
Appendix 12 Overall dimension of oil conservator………………………………………………………24
Appendix 13 The principle diagram of tap changer and controller……………………………………25
Appendix 14 General trouble-shooting…………………………………………………………………26
12
HM0.460.531
Appendix 1 SY□ ZZ On-Load Tap Changer Structure
1. Motor
2. Worm
3. Pulling spring
4. Worm gear
5. Top cover
6. Arm plate
7. Turning arm
8. Geneva wheel
9. Driving plate
10. Mounting flange
11. Moving contact
12. Stationary contact
13. Wiring terminal
14. Cylinder bottom
15. Transition resistor disk
16. Main shaft
17. Insulating cylinder
18. Position indication disk
19. Oil-drain pipe
20. Oil-inlet pipe
21. Cover
13
14
Type QJ6-25 Buchholz relay
Type QJ4G-25 Buchholz relay
Appendix 2 Overall dimensions and installation size of Gas Relay
Unit:mm
HM0.460.531
J
7
Appendix 3 Overall dimension of SY X ZZ-35/200 8
Unit:mm
15
J
9
Appendix 4 Overall dimension of SY X ZZ-35/200 10
Unit:mm
16
HM0.460.531
7
Appendix 5 Overall dimension of SYXZZ-35/200 8 X with output terminal
Unit:mm
17
9
Appendix 6 Overall dimension of SYXZZ-35/20010X with output terminal
Unit:mm
18
HM0.460.531
Appendix 7 Overall dimension of SYTZZ-35/200
9
10
Unit:mm
19
Appendix 8 Overall dimension of SYTZZ-35/200
7
8
Unit:mm
20
HM0.460.531
J
7
Appendix 9 Overall dimension of SY X ZZ-35/400 8
Unit:mm
21
J
7
Appendix 10 Overall dimension of SY X ZZ-35/400 8 for bell type
Unit:mm
22
HM0.460.531
Appendix 11 Overall dimension of mounting flange
locating screw
Unit:mm
23
Appendix 12 Overall dimension of oil conservator
Unit:mm
24
HM0.460.531
Appendix 13 The principle diagram of tap changer and controller
Notes:
1. The diagram is applied to tap changer with remote controller.
2. In drawing, 1, 2, 3, 4, 5, 6, 7, 8, 9 represent tap position indication; 10 represents common terminal of the tap
position; 11, 12, 13 represent motor leads D1, D2, D3.
3. When the terminals 11, 12 are connected to power supply, tap changer will run from 1 to N. When the
terminals 12, 13 are connected to the power supply, tap changer will run from N to 1.
25
Appendix 14 General trouble-shooting
Please have a check tap changer body, HMK-35D AVR and connection cable if there is any failure
occurs.
Malfunction
1. Indicators on AVR is
not on
Solutions
1. Whether power fuse is in good condition.
2. Whether 380V power supply is connected well.
2. Tap position displayed 1. Examine AVR, remove cable plug in the back and short-circuit the
'0" on AVR as power
common terminal "10" and any other position,it proves normal if shortsupply is connected
circuited position is identical to displayed position.
with it
2. Check cable, measure resistance between two ends of each wire in
cable one by one, if any pair of terminals are not conducted, it means
something wrong with the cable.
3. Confirm the present position of tap changer, take off cable plug and
measure resistance between common terminal "10" and another
operation position. If it is disconnected, take the core out and check
whether signal of position indication is normal.
3. Push "1-N" or "N-1"
button while signal
are normal, tap
changer does not run
26
1. Whether the fuse for motor is good.
2. Listen whether contactor in AVR is attracted together.
3. Whether there is malfunction in the motor.
HM0.460.531
Shanghai Huaming Power Equipment Co., Ltd.
Address:
Tel:
Fax: Web:
No 977 Tong Pu Road, Shanghai 200333, P.R.China
+86 21 5270 3965 (direct)
+86 21 5270 8966 Ext. 8688 / 8123 / 8698 / 8158 / 8110 / 8658
+86 21 5270 2715
www.huaming.com
E-mail:
export@huaming.com
Printing: December 2010