RESIBLOC®
Cast Resin Transformers
250 kVA to 40.000 kVA
Installation and Operating Manual
Please read the installation and operating manual carefully before you install the transformer
or put it into operation.
Please contact ABB AG, Transformer Division, Brilon with any questions regarding installation, use and service.
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RESIBLOC®
Cast Resin Transformers
250 kVA to 40.000 kVA
These instructions for use must be given to the new owner when the transformer is passed on.
This text is a translation of the German original. The German text shall apply in case of doubt.
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Installation and Operating Manual RESIBLOC® Transformers
List of contents:
1
Basic information
1.1
Significance of this manual
1.2
General safety information
1.3
Regulations and conditions to be adhered to
1.4
Intended use
1.5
Improper use
1.6
Guarantee and liability
1.7.
Explanation of the danger symbols
2
Technical data
2.1
CE labelling
3
Assembly and function of the transformer
3.1
Product description
4
Acceptance, transport and storage
4.1
Acceptance
4.2
Transport
4.2.1
Transport using a fork lift truck or lift truck
4.2.2
Transport using a crane
4.3
Storage
5
Operation of the transformer
5.1
Installation location conditions
5.2
Preparation for placing into operation
5.3
Placing into operation
5.4
Operation
5.5
Breakdowns and troubleshooting, fault clearance
6
Taking the transformer out of service
7
Maintenance, repair and spare parts
8
Accessories
8.1
Pt 100 sensor, arrangement of the measuring sensors
9
Attachment
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Installation and Operating Manual RESIBLOC® Transformers
1. Basic information
1.1 Significance of this manual
This manual is directed towards the persons in charge of the transport and the assembly
of the transformer, his/her employees and the operating company. Inform all persons involved in good time. Among other things, the information that is provided is to be taken
into account in order to prepare the installation location and surrounding environment in
such a way that the opportunity is given to assemble, connect and operate the transformer immediately upon delivery.
For organisational reasons it may be necessary to store the transformer at the installation
location or other places before placing into operation. In this case please pay particular
attention to the chapter on “storage”.
It is assumed that the local building regulations, the electrical equipment requirements, all
pertinent safety regulations and relevant environment protection specifications were and
will be adhered to during all preliminary planning and measures.
We will not undertake any guarantee for damages caused by the non-observation of the
existing manual or any other form of negligence.
Should you have any questions that are not dealt with here, please contact ABB AG,
Transformer Division, Brilon quoting the order number.
The document to hand is an integral part of the documentation on the RESIBLOC® casting resin transformer.
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Installation and Operating Manual RESIBLOC® Transformers
1.2 General safety information
The following terms are used in the instructions for use in order to draw your attention to special safety information:
DANGER: refers to a hazardous situation that
can be fatal or lead to serious injuries if not
avoided.
Qualified staff must be used for all preliminary activities and when handling the transformer. On site
every employee must observe the respective valid
national accident prevention regulations and safety
regulations.
Five safety rules when working on active parts
Work must only be carried out on electric systems and equipment if the following safety rules
are observed:
-
Disconnect
Safeguard against re-start
Determine parts are free of voltage
Earth and short-circuit
Cover or shield any adjacent live parts
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Installation and Operating Manual RESIBLOC® Transformers
The RESIBLOC® windings are insulated on the outer surface by means of an epoxy resin
layer. This insulation does not, however, make them touch-proof in terms of the valid
standards. Work on the transformer is thus only permitted in voltage-free and earthed
condition.
Experienced specialised companies must be contracted to carry out transport and assembly of the transformer.
All further work on and with the transformer must only be carried out by electricians or instructed persons under the supervision of an electrician. Such persons must have read
this manual prior to commencing work.
We exclude all responsibility and liability for those cases in which direct or indirect damages are caused by the transformer not being assembled, connected and operated in accordance with the instructions. This also applies to the non-observation of the general national safety regulations applicable in each case even if these are not mentioned in full in
the documentation.
Please have the appropriate suitable tools and devices at the ready.
The transformer has been designed in accordance with the requirements described by the
client. It must only be operated in the operating conditions stated on the circuit diagram or
in the confirmation of order or delivery note respectively. In the event that the operating
conditions should change or if amendments to the transformer are necessary, it is imperative that this is approved by ABB AG, Transformer Division, Brilon.
Every transformer radiates a magnetic field when in operation. This field is also not significantly reduced by a housing. For this reason, any persons with a cardiac pacemaker or
metal implants should avoid the area within a radius of 3 metres.
Housing or housing parts must not be disassembled during operation.
Please pay attention to the necessary safety and protective equipment.
Hazards due to electric energy
On account of the materials used, the RESIBLOC transformer is of low flammability. In
case of a fire only approved fire-extinguishing systems and extinguishing agents must be
used. Please obtain advice from the specialised trade or your competent fire brigade.
We recommend that extinguishing is undertaken with a CO2 extinguishing agent.
If a different extinguishing agent is used, the transformer may subsequently be unusable
and operation must not be continued.
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Installation and Operating Manual RESIBLOC® Transformers
Warning notices, mandatory signs and prohibition signs to be affixed
DIN 8444 Part 1 “Safety Labelling“: The means of safety labelling described in this standard
or appropriate local regulation should be used wherever safety hazards for humans exist in
spite of applying suitable protective measures. The appropriate warning sign in accordance
with the DIN standard is already attached to the steel parts (press beam) of the transformer
or to the housing (if available), warning against dangerous electric voltage.
Warning must be given on site against unauthorised entry into the service room. Furthermore, suitable signs should be kept ready that are necessary when placing into operation
and later during maintenance and repair work.
Attention is drawn to the fact that it has not been possible to itemise all possible sources
of danger exhaustively in this manual, but that these are, however, to be considered.
1.3 Regulations and conditions to be adhered to
The following regulations are to be adhered during planning, preparation and operation of
an electric operating site:
DIN 57 100/VDE 0100: Construction of heavy current systems with nominal voltages up to
1000 V.
DIN 57 101/VDE 0101: Construction of heavy current systems with nominal voltages of
more than 1 kV.
DIN 57 105/VDE 0105: VDE provision for the operation of heavy current systems.
DIN VDE 0132: Firefighting in electric systems and nearby.
VDE 0108: construction and operation of heavy current systems in structural works for
human gatherings as well as for safety lighting in places of work.
DIN 57 141/VDE 0141: VDE provision for earthing in alternating current systems for nominal voltages of more than 1 kV.
DIN 57 532/VDE 0532: Transformers and inductors.
VDI 2078: Calculation of the cooling load of air-conditioned rooms.
Technical instructions on noise: technical instructions on protection against noise.
DIN 42 523: Casting resin transformers, natural cooling (AN), for 50 Hz three-phase current, 100 to 2500 kVA, up to Um = 24 kV (equivalent R 24).
AGI J 12: Worksheet issued by the Arbeitsgemeinschaft Industriebau e.V. (Industrial Construction Working Group, registered association)
ELT Bau VO: Electric service room regulation
Arb.Stätt. VO: Place of work regulation
Regulations issued by local authorities
In the event that the respective national provisions include broader regulations, these shall
take priority.
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Installation and Operating Manual RESIBLOC® Transformers
1.4 Intended use
The transformer has been built in line with the best available technology and the
recognised safety-related rules. It transforms electric energy. It is to be operated in
accordance with the fundamental standards and regulations within the framework of
the electric data itemised in the rating plate. Any other use or use over and above
this shall not be regarded as complying with the requirements and can lead to personal injuries, property damage and financial losses. Any improper use shall lead to
the exclusion of warranty and liability.
Intended use encompasses:
•
observance of all information in the operating instructions
•
observance of inspection and maintenance work
•
if attached, the function of the fan must be guaranteed
•
voltage separation must be observed
•
cooling intervals must be observed
•
ambient temperatures must be observed
•
warranty shall expire if mechanical processing is carried out on parts of the transformer
•
installation of an IP00 transformer in protective housing only with power reduction
and following consultation with the manufacturer
•
use in chemical-containing atmosphere only following consultation with the manufacturer
•
operation with rectifiers only following consultation with the manufacturer
•
these instructions are not able to describe all possible configuration variants. Certain configurations are, therefore, only described in “optional accessories“.
•
according to the valid national standard or IEC / VDE respectively, the transformer
must not be connected without earthing.
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Installation and Operating Manual RESIBLOC® Transformers
1.5 Improper use
While maintaining the guidelines in respect of intended use according to item 1.4 of this
manual, a few examples are listed below that constitute improper use.
•
Monitoring equipment must not be overridden and/or manipulated (changing the
set temperature values)
•
Attachment parts must not be altered and the function must be guaranteed (e.g.
fan, cooling systems etc.)
•
Alterations must not be made to the coils (e.g. by attaching adhesive labels to the
coil surface area; removal of information and warning signs)
•
Do not switch connections that are not provided for in the circuit diagram
•
Voltage applied to the respective tapping must not be greater than stated on the
power rating plate
•
The extracted power must not be greater than stated on the power rating plate
•
The frequency of the supply voltage must comply with the frequency stated on the
power rating plate
•
Primary voltage support points and terminal lugs must not be burdened mechanically
•
The transformer must not be operated without the existing housing or housing
parts
Attention is drawn to the fact that not all possible facts that constitute improper use can be
itemised exhaustively in this manual.
1.6 Guarantee and liability
As a matter of principle, our “general sales terms and delivery conditions“ shall apply. These
are available to the operating company upon conclusion of contract at the latest. Guarantee
and liability claims by the client in the event of personal injuries, damages to property and financial losses shall be excluded if they are to be attributed to one or more of the following
causes:
•
Improper use of the transformer
•
Improper installation, placing into operation, operation and maintenance of the
transformer
•
Operation of the transformer with faulty safety devices or improperly attached or
inoperable safety and protective devices
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Installation and Operating Manual RESIBLOC® Transformers
•
Non-observation of the information in the operating instructions with regard to
transport, storage, installation, placing into operation, operation and maintenance
of the transformer
•
Unauthorised structural alterations on the transformer
•
Inadequate monitoring of attached parts that are subject to wear
•
Improper execution of repair work
•
Catastrophes due to the influence of foreign substances and force majeure
•
Other causes not itemised here explicitly and that let one conclude that nonconventional use is involved
1.7 Explanation of the danger and information symbols
Danger symbols are to be found on the transformer and their meaning is elucidated as follows:
Warning sign
Danger of hazardous electric
voltage
Warning sign
Danger – High voltage
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Prohibition sign
Do not touch, surface area is
live
Information sign
Protect from rain and
keep dry
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Installation and Operating Manual RESIBLOC® Transformers
2. Technical data
See confirmation of order, delivery note, power rating plate, circuit diagram and test log
2.1 CE labelling
Transformers do not come under CE labelling. Further information can be requested from
Fachverband ZVEI (ZVEI trade association).
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Installation and Operating Manual RESIBLOC® Transformers
3. Assembly and function of the transformer
3.1 Product description
The described transformer is a RESIBLOC cast resin transformer produced by ABB AG,
Transformer Division in Brilon.
The RESIBLOC cast resin transformer transmits alternating voltage and alternating current of the same frequency between two or more windings on generally different voltage
and current values.
The products as described here have been tested in accordance with the valid international standard in order to achieve highest possible quality and service life.
The RESIBLOC® meets the greatest demands in respect of the climatic classes, environment classes and fire classes, namely
E2 (environment class),
C2 (climatic class) and
F1 (fire class) in accordance with IEC 60076-11.
The standard model excluding housing (protection category IP 00) is only intended for installation in locked electric operating sites. Housing-enclosed models are suitable for indoor installation according to the protection category stated on the power rating plate.
Installation outdoors or storage in the open is only permissible with special protective
housings.
Depending on the requirements the transformer can be fitted with a multitude of optional
attached parts, e.g. radial-flow fan or vibration absorber.
Unless ordered otherwise, the transformer is equipped with four travelling rollers that simplify transport at the installation location. They must all be fitted in the same desired running direction before installation.
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Installation and Operating Manual RESIBLOC® Transformers
Examples of various designs
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Installation and Operating Manual RESIBLOC® Transformers
4. Acceptance, transport and storage
4.1 Acceptance
A crane should be used in either case for unloading the transformer. Make plans in good
time for hoisting devices to be available that are designed for the weight of the transformer.
Delivery to building sites: View the on-site conditions a few days before delivery. Inform all
persons involved in good time with regard to the requirements of this manual. Ensure that
the transformer can be unloaded and installed without complications. If the transformer is
to be installed in a locked working area there must be a suitable surface, appropriate for
the protection category and the weight, in front of the room where the transformer can be
set down, in order to then be rolled into the room.
A comprehensive check of the transformer, including its attached parts, must be carried
out before and after unloading. All supplied documents (shipping documents, packing
lists, dimensioned drawings, this manual etc.) must be available for this check.
Check whether the details are identical to those on the power rating plate on the transformer. If this is not the case, please contact ABB AG, Transformer Division, Brilon immediately.
If damages are visible, please make a note of this on the consignment note and send this
to ABB AG, Transformer Division and a notification of claim to the transport company.
A transformer showing visible signs of damage must not be placed into operation without
consulting the manufacturer.
The following checklist provides certain test criteria that indicate transport damage:
Is the fastening and/or packaging (if available) damaged or imbrued?
Are the transformer fasteners damaged?
Are there any signs that the load was trans-shipped during transport or that it
shifted?
Is there any visible exterior damage?
Are the tap-connections or the insulated casting resin supports bent or twisted?
Is any damage recognisable to the coils?
Has the paintwork been damaged? Touch up damage to the paintwork immediately
in order to prevent corrosion. Please use temperature-resistant paint (up to 155 °C).
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Installation and Operating Manual RESIBLOC® Transformers
Additional devices
Are all the parts available that are shown on the delivery note?
Is the packaging undamaged?
Does the packaging show signs of damage due to damp?
Are all loose parts in perfect condition?
If parts are missing, please contact the carrier. If the details on the packaging do not coincide with those on the delivery note, please contact ABB AG, Transformer Division in
Brilon immediately quoting the order number.
The travelling rollers are attached to the outside or inside of the press beam for transport
purposes.
Travelling roller fitted to the press beam
Prior to the installation of the transformer the travelling rollers need to be installed in the
openings in the bogie beam all in the same direction, or they need to be removed in case
they should not be used.
4.2 Transport
Before transport, please check which means of conveyance is most suitable. A changeover should be avoided for reasons of damage. Transporting transformers without appropriate protection while rain or snow is falling is not permissible.
RESIBLOC® transformers can be exposed to temperatures of up to minus 40°C during
transport.
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Installation and Operating Manual RESIBLOC® Transformers
As a matter of principle, it is to be observed during all transport procedures that
the transformer is kept in an upright position at all times during transport.
the transformer is not moved onto the coils or their attached parts by applying an external force.
transformer parts and its attached parts are not damaged by ropes, chains or other
fasteners or means of conveyance; particular attention is to be paid to :
primary voltage and secondary voltage main leads and fans.
the fact that strong vibrations and oscillation during transport can cause mechanical
damage on the transformer.
the observance of all pertinent regulations on working with transport vehicles. Please see the delivery note or the power rating plate on the transformer for the weight
of the transformer.
the fact that the transformer is secured against shifting during transport so that the
transport procedure complies with the road traffic regulations and requirements. This
applies in particular to special transport procedures.
4.2.1 Transport using a fork lift truck or lift truck
As a matter of principle, it is not permitted to lift the transformer using a fork lift truck. An
exception is made for goods that have already been palletised by ABB AG, Transformer
Division.
The fork lift truck can be used to pull the transformer at the chassis support or at the lower
press beam.
Lashing point of the travelling roller support
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Installation and Operating Manual RESIBLOC® Transformers
4.2.2 Transport using a crane
Fasten the hoist ropes to all four hoist eyelets on the upper press beam. The rope sling
angle must be ≤60°.
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Installation and Operating Manual RESIBLOC® Transformers
4.3
Storage
In the event that the transformer is to be stored temporarily before assembly or at a later
point in time, the following provisions must be complied with:
Storage must only be in closed-in rooms that offer protection against dampness, dust and
other contamination.
Use foil to cover the transformer in order to protect it against deposits. Hazardous dust in
particular is to be kept away from the transformer as this forms a conductive film in dry or
damp condition, e.g. cement dust, salt deposits, coal dust etc.
In the event that the transformer is to be stored for a longer period of time, a suitable drying agent must be placed in the packaging in order to avoid the formation of condensation
water. This is to be checked on a regular basis so that it is able to maintain its moistureabsorbing properties. Should these properties dwindle, it is to be replaced immediately.
Accessories must be stored in a dry room on pallets or similar and not directly on the floor.
RESIBLOC® transformers can be exposed to temperatures of up to minus 60°C during
storage (and in operation). Any attached parts are to be considered separately.
Please observe item 5.1 before placing into operation.
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Installation and Operating Manual RESIBLOC® Transformers
5. Operation of the transformer
5.1 Installation location conditions
If it is necessary to still carry out work in the vicinity of the transformer before placing it
into operation, the transformer must be protected against contamination by means of a
tarpaulin. Dust, metal cuttings, screws, bolts, pins and other small parts that are caught up
in the windings lead to transformer damage.
In order to ensure troublefree operation and long service life of the transformer, the following ambient conditions must be adhered to. All details refer to the normal design.
In the event that demands are made that deviate from the ambient conditions quoted below, it is imperative that these are already stated when placing the order. Furthermore,
special provisions such as housing installation by the client, tropical climate, increased
mechanical load as found, among other things, during usage on ships or in areas endangered by earthquakes are to be taken into account.
Location
The location must not be higher than 1000 metres.
It must, at the least, comply with the requirements of
type of protection IP 23.
Direct solar irradiation must be avoided.
Subsurface
The even, dry subsurface must be in a condition to withstand the weight of the transformer and all accessory
equipment. The local building regulations must be complied with.
Ambient temperature
Unless stated differently, the transformer is designed for
the following temperatures: exceeding these values
leads to increased use of life:
Average annual temperature
20°C
Average monthly temperature
30°C
Maximum temperature
40°C
Minimum temperature
-40°C for transport
-60°C for operation
and storage
The accessory equipment (temperature monitoring,
thermometer, fan) is only designed for up to -20°C. If
lower temperatures are expected, please contact ABB
AG, Transformer Division, Brilon.
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Ventilation info.
The heat that arises during operation must be dissipated. For this purpose a ventilating flow should be conducted diagonally through the installation room as
shown in the following illustrations (please observe the
pertinent technical literature on the detailed layout of the
transformer cell).
Preferred variant
The necessary air cooling amounts to more than
4m3/min per kW total power dissipation of the transformer. Please see the test logs for exact details. In this
connection the maximum arising losses are to be taken
into account (e.g. in the case of forced cooling).
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The temperature of the cooling air must not exceed the
aforementioned ambient temperatures.
The air inlet and outlet cross sections must be dimensioned in such a way that the flow speed of the cooling
air inside the transformer cell does not exceed 1.5 m/s.
To prevent the chimney effect (natural flow of cooling
air) from being impeded, a forced ventilation of the
transformer cell should be dispensed with.
In case the supply air contains harmful substances (i. e.
substances that form a conductive film in dry or damp
condition, e.g. cement dust, salt deposits, coal dust etc.)
filtration must be used for cleaning. The filter elements
are to be cleaned or replaced at suitable intervals. The
reduced air flow due to the filter material must be allowed for by means of an enlarged cross section of the
vent holes.
Transformer with protective housing: In order to guarantee adequate air circulation the housing must be assembled at a sufficient distance to the floor. This distance
must be at least as great as the height of the travelling
rollers. At any rate, please verify this in the current drawings. In the case of transformers including a housing the
distance of the housing base to the roller or lower edge
of the base is to be maintained as a matter of principle.
Once this is removed, the client is to provide assemblies
that ensure that this distance is not fallen short of.
Transformers that are ventilated from underneath are an
exception to this ruling.
The distance to the ground is not necessary if there are
vent holes with an adequate cross section in the ground
directly underneath the transformer.
Air gratings or flaps in the air inlet and outlet holes must
be designed in such a way that they do not interfere with
the air flow. Furthermore, sufficient wall distance must
be maintained at air outlet hole height. In the case of
IP23 two thirds of the air grating height shall be maintained as a norm. (Example: grating height 540 mm
wall distance 360 mm)
In order to guarantee unimpeded air circulation we recommend a minimum distance to the wall of 0.3 metres
on all sides of the transformer. In addition to this, the
space required for the installation or maintenance activities must be included in the planning.
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Installation and Operating Manual RESIBLOC® Transformers
For heat dissipation the distance between two transformers should be more than 0.5 metres. Furthermore,
the minimum electric distances are to be maintained
(see table 1 on next page).
Dampness
The transformer and all accessories must not be exposed to splash water or dripping water (condensation
water). The location must be safeguarded against
flooding and furnished in such a way that there cannot
be a build-up of water logging underneath the transformer.
Minimum distances/
required space
Please see the enclosed dimensional drawing for the
dimensions of the transformer.
The transformer must be assembled in such a way
that all gauges are visible and available for direct
reading from a safe distance. Please plan the assembly in a transformer cell so that the type plate and
temperature monitor can be seen without having to
enter the cell.
The minimum distances as stated in the following table 1 must be adhered to between the live parts or between the live part and earth respectively.
Please take into account that concrete walls can be
steel-reinforced and thus the minimum distances must
also to be adhered to.
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Minimum distances to be adhered to:
Highest voltage
for operating
resources
Rated power
Rated power
Minimum
frequency
frequency / lightdistance
withstand voltage ning surge voltage
Um [kV]
AC [kV]
1.1
3
3.6
10
20
60
3.6
10
40
60
7.2
20
40
60
7.2
20
60
90
12.0
28
60
90
12.0
28
75
125
17.5
38
75
125
17.5
38
95
170
24.0
50
95
170
24.0
50
125
225
36.0
70
145
225
36.0
70
170
315
36.0
70
200
315
LI [kV]
[mm]
25
Table no. 1
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Installation and Operating Manual RESIBLOC® Transformers
Protection against
contact
Type of protection IP 00 transformers must only be installed in locked working areas. It must be ensured that
the transformer cannot be touched as long as it is live.
The casting resin surface of the transformer winding is
not touch-proof. Protection against accidental contact
can be achieved, for example, by means of a protective
plate or by means of a protective fence.
Noise emission
Depending on the position of the installation location, it
could be necessary to take noise-absorbing measures.
For example, this could be impact sound-insulated assembly. Fans can also cause additional noise.
Earth connections
The joint resistance of the protective earthing must be
dimensioned in such a way that protective systems (e.g.
fuses, overload switch) are in operation at all times and
trigger as the case may be. The cross section of the
earthing connections must comply with the regulations
and on-site conditions.
5.2 Preparation for placing into operation
Check whether the details on the delivery note are identical to those on the transformer
power rating plate. If this is not the case, please contact ABB AG, Transformer Division,
Brilon immediately.
In the event of queries or if you have service requirements, please be sure to quote the
serial number of the transformer.
Placing into operation must be carried out in compliance with the valid legal, national
guidelines. ABB AG, Transformer Division, Brilon factory is not responsible for correct
placing into operation.
If the transformer has become contaminated in the meantime, it must be cleaned before
being placed into operation (see chapter 7).
Warning notices, mandatory signs and prohibition signs to be attached
DIN 8444 part 1 “Safety Labelling“ or appropriate local regulations:
The safety labelling instruments described in this standard should be applied wherever
there are safety hazards for humans in spite of applying suitable protective measures. The
warning notice in accordance with the DIN standard cautioning against dangerous electric
voltage has already been attached to the steel parts of the transformer or on the exterior
of the housing respectively (if available).
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An on-site warning must be available cautioning against unauthorised entry into the service room. Moreover, suitable signs are to be kept at the ready that are necessary during
placing into operation and later during maintenance and repair work.
5.3 Placing into operation
All activities described at this point are only permissible if the transformer is in a voltage
free and earthed condition (see general safety information).
The following points are to be taken into account when placing into operation:
Any transportation locks, packaging and protective covers are to be removed before
placing into operation.
The travelling rollers shall be removed from the transport location at the lower press
beam and need to be fixed within the holes in the bogie beam. In case they should
not be used, because the transformer is e. g. brought to the final location with a
crane, the rollers can be stored in a different location. In no case the rollers shall
stay in the transport location during operation.
Check whether all connections are firmly fitted on the primary voltage side and that
they are not contaminated.
Check whether the earthing connections are firmly fitted and that the earthing has
been carried out correctly.
Check whether the flashover distance (see table 1) has been adhered to:
between live parts
between live and earthed parts
between the cables and the primary voltage windings
between the cables and the primary voltage circuit
Check the temperature monitoring. Where PTC thermistors are involved: interrupt
the sensor electric circuit. The temperature monitoring device must display a fault. In
the case of Pt 100: measure the resistance at the ambient temperature and compare this value with those in the literature. All connections must be tight.
Check the installation of the control circuit. Look out for damaged insulations and
loose connections.
Check the conformity of the connections with the pattern on the circuit diagram on
the transformer.
Especially in the case of reversible windings, check that the nominal voltage to be
applied coincides with the switched position of the windings.
Check whether all spacers are fitted firmly.
Check whether the ventilation is adequately effective.
Transformer with fans: check the connection of the fans to the power supply, their
faultless performance and the correct direction of rotation.
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Installation and Operating Manual RESIBLOC® Transformers
Ensure that all tools and aids that were used for the preparatory work have been
removed from the transformer.
In case it is necessary to check individual cables, these must first be disconnected
from the transformer.
Touch up all damage to the paintwork (corrosion protection).
Check whether the transformer is clean and free from foreign particles. Look out for
small parts in the air ducts of the windings. If necessary, clean the transformer using
a vacuum cleaner and/or dry, oil-free compressed air (max. 3 bars).
After being moved to the installation location the transformer must be given sufficient time to adopt the prevailing ambient temperature there and thus prevent the
formation of condensation water.
Check all screw connections using a torque wrench (also see further down this
page).
In the case of parallel operation please observe additionally:
Ensure that the pre-requisites for parallel connection are met.
Information on these pre-requisites can be obtained from ABB AG, Transformer Division
in Brilon.
Electrical and mechanical connections
Be sure without fail to adhere to the sequence of activities stated here when connecting
the transformer.
Before making the connections it must be ensured that:
all designated lines and the earthing system have been prepared in accordance with
the requirements,
the electrical data of the transformer (see power rating plate and circuit diagram) coincide with the electrical data of the primary voltage and secondary voltage network.
The minimum distance (according to table no. 1) between live parts as well as between
live parts and earthed parts must not be fallen short of. This relates to the distances between cables and high voltage windings in particular.
All retaining elements of the screw connections are to be checked and replaced as the
case may be before re-connecting.
All connections must fit tightly and be mechanically secure. The bolts for the electrical
connections are to be tightened using a torque wrench. Please see table 2 for the recommended tightening torques (excluding the use of lubricants).
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Installation and Operating Manual RESIBLOC® Transformers
Screw size
M8
M10 M12 M16 M20 M24
Tightening torque
[Nm]
15
30
60
120 240 480
Table no. 2
Shut down the transformer and re-tighten the bolts after one month using the same tightening values (see also chapter 7).
Change-over
Change-over is carried out by reconnecting the primary voltage connections to all windings whilst the transformer is in an zero-potential and earthed condition. In doing so
please observe that all windings are set to the same tapping. The allocation of the tappings is stated on the circuit diagram on the transformer.
Connect the cables using the corresponding connectors.
Secure the cable lug on the tappings using screw, nut and spring lock ring. To protect
against damage, please use two spanners for tightening. All retaining elements of the
screw connections are to be checked before re-connection and replaced as the case may
be.
Making connections
The following applies to transformers where the neutral point is led through on the secondary voltage: Connection must only be made to the primary voltage side when a compensator has been placed between the neutral conductor on the secondary voltage side and
the neutral conductor of the mains. It is thus prevented that excessive voltage is transferred to the secondary voltage side due to capacitive couplings in the event of an earth
fault in the mains.
Make the connections in accordance with VDE 0101 or your national standard. Please be
sure to observe the prescribed sequence.
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Installation and Operating Manual RESIBLOC® Transformers
A. Safeguard the transformer against disarrangement at the installation location.
B. Earth the transformer (earth screws on chassis).
C. For reversible transformers: Check the transmission ratio (comp. circuit diagram on
transformer). You must set the necessary circuit if necessary (see above).
D. Check the insulating resistances: floating windings against each other and every
winding against earth. Please use an insulation tester for this purpose. In each case
the resistances must amount to at least 1000 Ohm per volt operating voltage. In the
event that a dry transformer should become damp due to extraordinary circumstances, the normal insulating resistance decreases. In this case the transformer
must be dried. The Transformer Division of the ABB AG office closest to you will provide you with information on suitable drying methods.
E. Please check the voltage and phasing of the available mains.
F. Clean all connection points on the insulated supports and terminal lugs, making them
metallic bright.
G. For connecting aluminium with copper parts: Please insert copper-clad aluminium
sheets (CUPAL-sheets) in such a way that the same materials come into contact with
each other.
H. Please apply corrosion protection to all bright points (Vaseline, contact grease or
similar). In the case of aluminium connections please also apply corrosion protection
between the aluminium and the copper-clad aluminium sheets.
I.
Connect the monitoring device(s) and check its/their function(s).
J. Lay the cables. Please ensure that there is no major buckling or mechanical stress
and that the cables are not twisted together. In the case of currents of 1000 amps and
more, please use flexible connectors between the bus bars and the feeder clamps of
the transformer.
K. Fit a strain relief to the cables. You must ensure that the necessary contact pressure
is maintained.
L. Make the electric connections. You will find the allocation of the primary voltage connections on the circuit diagram on the transformer.
M. Apply corrosion protection to all screwed connections.
N. For transformers with housing: close off cable entry points that are not in use.
O. Do not be careless and leave any packaging material lying around. Plastic foils could
turn into a dangerous toy for children.
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Installation and Operating Manual RESIBLOC® Transformers
5.4 Operation
Operating temperatures
The insulating material class F transformer must be fitted with a temperature monitoring
device that ensures that it is shut down upon reaching a hot spot of 155°C. In as far as
this monitoring device is included in the scope of delivery, you will find information on this
in the “optional accessories” section.
Normal operation
(dependent on the ambient temperature)
The ambient temperatures and regulations stated in IEC 60076-11 and VDE 0532 were
used as a basis when designing the transformer.
Short-term overload
The transformer can be operated over and above its power rating for a limited period of
time without this leading to the average winding temperatures according to IEC 60076-11
and VDE 0532 being exceeded. This can be necessary if greater quantities of electricity
are required for a short period of time (e.g. when starting up motors).
Overload operation is only possible if the transformer was not operated at full load directly
prior to this, i.e. if it has still not been heated up to a high degree. As soon as it reaches a
temperature of 155°C, overload operation must be shut down automatically. In this connection please observe that operating the transformer above the warning limit of 140°C
leads to an increased use of life.
The permissible duration of overload operation depends on the ambient temperature and
the previous load (consistent loading before and after the peak load). The permissible
overload sizes are directly dependent on the rise in temperature during the nominal load
and the thermal delay times of the windings. These sizes can vary greatly on the various
transformer models and can differ for primary voltage windings and secondary voltage
windings of a transformer.
Overload sizes cannot be itemised in the general description for the stated reasons. In
case overload operation is necessary, please contact the Transformer Division at ABB AG
in Brilon. Please quote the ambient temperature, the required overload cycle and the serial number of the transformer. We can then calculate the permissible overload sizes for
the special transformer for you and inform you accordingly.
Rectifier operation
Transformers that are subsequently used for rectifier operation cannot be operated at full
load. Under certain circumstances this can lead to an inadmissible rise in the temperature
of the windings caused by the harmonic oscillation of the mains. In case it is necessary to
connect a rectifier, please contact the Transformer Division at ABB AG in Brilon.
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Installation and Operating Manual RESIBLOC® Transformers
Overvoltages
The insulation values for which the transformer has been designed are to be found on the
circuit diagram and in the test log. It must be ensured that the primary voltage connections
are protected against erratic increases in voltage if these are above the designated values. Suitable surge arresters must be installed if this should become necessary.
Improved air cooling
Inasfar as quoted when placing the order the transformer is equipped with radial-flow fans
in order to achieve the nominal load stated in the circuit diagram and test logs.
Subsequent installation of radial-flow fans may be possible. Please contact the Transformer Division at ABB AG, Brilon. The fans must be installed and their function checked
before the transformer is placed into operation. They are controlled by sensors so that
they are only activated as required.
The average service life of the fan motors amounts to 30,000 hours. This means that they
cannot be used for continual overloads during the entire service life of the transformer.
Changeover
Changeover is carried out by reconnecting the primary voltage connections on all windings when the transformer is in an zero-potential and earthed condition. In doing so please
observe that all windings are set to the same tapping. The allocation of the tappings is
stated on the circuit diagram on the transformer.
Connect the cables to the allocated connectors.
Secure the cable lug on the tappings using screw, nut and spring lock ring. To protect
against damage, please use two spanners for tightening.
Final shutdown
If it is to be assumed that non-hazardous operation is no longer possible, the transformer
is to be shut down and safeguarded against unintentional operation.
It is to be assumed that non-hazardous operation is no longer possible:
•
•
•
•
if the transformer shows visible damage
if the transformer has been disconnected from the mains by a safety device
following a longer period of storage in unfavourable conditions
following major transportation stress
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Installation and Operating Manual RESIBLOC® Transformers
5.5 Breakdowns and troubleshooting, (cause and remedy), fault
clearance
Fault
Possible reason
Corrective measures
Loud noises on transformer when switching on
An increased noise level
can arise after switching
on, especially on transformers with low no-load
losses. In time, however,
this level reduces to a
lower value. This is attributable to transient effects
after switching on.
Please wait for a few hours before assessment of the final
noise level.
Temperature sensors on
standard transformers already indicate values of
approx. 100°C to 120°C in
no-load condition
This is not a fault. The
temperature sensors are
positioned between the
core and secondary voltage
winding on the interior of
the winding. They are influenced by the heated core
when in no-load condition.
The current winding temperature is not displayed
until the winding temperature exceeds the temperature indicated in no-load
condition.
None
Temperature monitor gives a “warning“
One or more of the fitted
temperature sensors (PTC
or PT100) faulty
Replace temperature sensor(s)
Temperature monitoring
device is faulty
Replace temperature monitoring device
The actuation of optional
fans is incorrectly adjusted
or faulty
Set correct temperature values
on the temperature monitoring
device
Replace temperature monitoring device
Fans fitted as an option are
faulty
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Replace fans
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Installation and Operating Manual RESIBLOC® Transformers
Fault
Temperature monitoring
leads to transformer shut
down
Possible reason
Corrective measures
Transformer loaded 100 %
and the ambient temperature is 5 Kelvin higher than
the average annual ambient temperature. Permanent further operation of
the transformer leads to a
considerable reduction in
service life.
Reduce the load
The transformer is operated with rectifiers at a load
of < 100 %, but is not designed for operation with
rectifiers.
Consult ABB AG, Transformer
Division, Brilon.
One or more of the fitted
temperature sensors (PTC
or PT100) faulty
Replace temperature sensor(s)
Temperature monitoring
device is faulty
Replace temperature monitoring device
The actuation of optional
fans is incorrectly adjusted
or faulty
Set correct temperature values
on the temperature monitoring
device
Lower the ambient temperature
(e.g. by improving cooling of
the installation location)
Improve the ventilation of the
installation location
If possible, install radial-flow
fan on transformer
Replace temperature monitoring device
Fans fitted as an option are
faulty
Replace fans
Transformer loaded 100 %
and the maximum permissible ambient temperature
has been reached. Permanent further operation of
the transformer would lead
to premature breakdown of
the transformer. The transformer must, therefore, be
shut down immediately.
Reduce the load
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Lower the ambient temperature
(e.g. by improving cooling of
the installation location)
Improve the ventilation of the
installation location
If possible, install radial-flow
fan on transformer
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Installation and Operating Manual RESIBLOC® Transformers
Fault
Transformer is shut down
by the safety devices
Possible reason
Corrective measures
The transformer is operated with rectifiers at a load
of < 100 %, but is not designed for operation with
rectifiers.
Consult ABB AG, Transformer
Division, Brilon.
Fault on the safety devices
Check/replace the safety devices
Damage to one or more
windings, (not necessarily
visible from outside)
Do not put transformer back
into operation. Send to ABB
AG, Transformer Division, Brilon, for examination/repair.
Examples:
Voltage distances are fallen
short of due to twisted main
leads, short-circuits due to
small animals, metal parts
or forgotten tools
Corona discharges at
earthed metal parts of the
transformer during switching operations
Accumulation of dust in
certain areas of the coil
surface, e.g. in the centre
of the coil
Loose connections on
metal parts of the transformer
Check the connections and
tighten according to chapter
5.3.
Pre-ignition or backfiring in
the switch during switching
operation
Controlled activation of the
transformer
The coil surface can be
subjected to electrostatic
charging on account of the
electric field. This can lead
to an accumulation of dust
in certain areas of the coil
Regular cleaning of the transformer according to chapter 7
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Transformer RC protective circuit and/or use of overvoltage
conductors
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Installation and Operating Manual RESIBLOC® Transformers
Fault
Possible reason
Corrective measures
Development of white coatings in certain strictly
limited areas of the coil
surface, e.g. in the centre
of the coil
In certain unfavourable
conditions and in connection with contamination, corona discharges can develop on the surface of the
coil and whilst they are not
conductive in a dry condition, they become conductible when damp
Regular cleaning of the transformer according to chapter 7
Formation of condensation water in housings of
air to water cooled transformers.
This is not a fault. Conden- See maintenance
sation water can form if the
dew point at the heat exchanger of the cooler is
fallen short of.
Document no.: 1LDE000005 Rev. 04 01/2007
Following consultation with
ABB AG, Transformer Division, Brilon, a material can
possibly be applied to the surface of the coil to make this
water-repellent
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Installation and Operating Manual RESIBLOC® Transformers
6. Taking the transformer out of service
Disposal of a faulty or no longer required RESIBLOC transformer can be carried out by
ABB AG, Transformer Division, Brilon factory. All components are detached in accordance
with the environmental regulations. Materials are supplied for recycling in as far as possible. Contact us for advice.
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Installation and Operating Manual RESIBLOC® Transformers
7. Maintenance, repair and spare parts
As a basic principle RESIBLOC transformers are maintenance-free. We recommend
regular cleaning in case of use in factories with a high degree of dust exposure, for example steelworks and rolling mills, quarries, on building sites or similar.
Work must only be carried out on electric systems and equipment if the following safety
rules are observed:
- Disconnect
- Safeguard against re-start
- Determine parts are free of voltage
- Earth and short-circuit
- Cover or shield any adjacent live parts
Depending on the final location of the transformer the insulation surfaces can become
very contaminated. This can lead to the cooling being impeded.
The operating company must carry out an assessment of the necessary cleaning intervals. The first examination of the transformer should be carried out no later than one
month after being placed into operation and at practical intervals from then on. In doing so
the cleaning interval should be adapted to the degree of contamination. All maintenance
work is to be documented in writing.
7.1 Maintenance work to be performed
Visual examination
The coils, all cables and lines and the temperature monitoring device and other accessories are to be subjected to a visual examination. All damage must be documented in the
maintenance records and forwarded to the responsible persons.
Fans (if available) are cleaned in the same way as transformers. Subsequently check
function and operating characteristics.
Clean the protective housing (if available) in the same way as a control cabinet. Clean the
air inlets and outlets using a vacuum cleaner. The same applies to the transformer cell.
The air filters (if available) must be checked on a regular basis and replaced if necessary.
Cleaning
1.
First of all, remove the dust accumulations with a vacuum cleaner to remove any contamination, before it is transported into inaccessible areas with the subsequent processing using compressed air.
2.
Hard to reach areas (such as the cooling channels) should be blown through with dry,
oil-free compressed air.
3.
Remove the materials dislodged doing this using the vacuum cleaner again.
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Installation and Operating Manual RESIBLOC® Transformers
4.
Wipe off all electrically active surfaces (e.g. coil surface, surface of insulators) with a
dry, clean cloth.
5.
Any further contamination can be removed using methylated spirits.
6.
Any contamination that cannot be removed in this way can be removed with the help
of special electrical high-performance cleaners (e.g. Rivolta S.L.X. Top).
The transformer must be completely dry before being restarted.
Mechanical check
All screw connections should be checked using a torque spanner (see table 2) and the
functions of all warning devices reviewed. Inadequate fastenings can cause dangerous
and excessive temperatures at the connections.
Electrical check
Check the insulating resistances: floating windings against each other and every winding
against earth. Please use an insulation tester for this purpose. In each case the resistances must amount to at least 1000 Ohm per volt operating voltage. These values are to
be recorded in the maintenance records.
Check that the temperature monitoring functions correctly.
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Installation and Operating Manual RESIBLOC® Transformers
8. Accessories
All accessories that are an integral part of the order are described in the attachment. In
the event that no form of protective equipment is scheduled in the order, the transformer
will be fitted with Pt 100 resistors for shutdown as minimum protection.
8.1 Pt 100 sensor, arrangement of the measuring sensors
In case you replace the measuring sensors by other kinds, please be sure to observe that
they are insulated. Non-insulated measuring sensors in the cooling channels can cause a
short-circuit.
Fasten the new measuring sensor in the same position. As a precaution, please obtain information in any case from ABB AG, Transformer Division, Brilon, if you wish to use other
measuring sensors.
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Installation and Operating Manual RESIBLOC® Transformers
9. Attachments (upon delivery of the transformer):
Copy of the power rating plate
Dimensional drawing
Test report
Description of the accessories
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Power Engineering Division
Transformer Division
Gewerbegebiet Bremecketal
An der Bremecke 1
59929 Brilon
Germany
Tel: +49 (0) 29 61 / 7 97-0
Fax:+49 (0) 29 61 / 7 97-290
Document number: 1LDE000005 Rev. 04 01/2007
ABB AG