USER MANUAL WITH

INSTRUCTIONS
FOR OPERATION, INSTALLATION
AND MAINTENANCE OF
CAST RESIN DISTRIBUTION
TRANSFORMERS
 TABLE OF CONTENTS

1. General information 2
1.1 Standards of reference 3
2. Transport, unloading and storage 4
2.1 Acceptance of delivery and unloading 4
2.2 Handling 4
2.3 Lifting 5
2.4 Storage 5
2.5 Altitude of installation 5
2.6 Ambient temperature 5
3. Installation 6
3.1 Transformer location inside the substation 7
3.2 Rules for installing the temperature monitor unit 8-9
and the sensors
4. Transformer protection 10
4.1 Over voltage protection 10
4.2 Over current protection 10
4.3 Electrical connections and clamps / Torque Settings 10
5. Transformer cooling 12
6. Commissioning 14
6.1 Transformer Earthing 14
6.2 Connection 14
6.3 Cleaning 15
6.4 Adjusting the input voltage 15
6.5 Energising 15
6.6 Parallel operation 16
7. Maintenance 17
8. Maintenance schedule 18
9. Malfunctions and initial correction work 19
10. Transformer installation checklist 20-21
 1. GENERAL INFORMATION
The purpose of this document is to recommed the procedures to be followed for safe installation and use 1.1 Standards of reference
in compliance with safety regulations of dry type transformers with cast resin windings, manufactured in
compliance with the applicable Standards and intended for use in industrial plants and commercial and IEC EN 60076-11 - IEC EN 60076-1
service facilities. Power transformers – Part 11 : Dry Type transformers
If properly used, the cast resin transformers have the following advantages:
• They are resistant to combustion and self-extinguishing in the event of fire whereby the And any other standard that is required by customer specifications.
cause of fire has ceased
• Reduced maintenance time and costs.
• Reduced overall dimensions.
• High resistance to dynamic short-circuit stress.

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 2. TRANSPORT, UNLOADING AND STORAGE
MAX 60˚
2.1 Acceptance of Delivery and Unloading 2.3 Lifting

The transformer is delivered completely assembled and ready for connection both on the MV (Medium The transformer shall be lifted by using the
Voltage) and on the LV (Low Voltage) side. At the time of receipt, it is recommended that a careful check is eyebolts located on the upper supports and cables
made in order to find out any transportation damages to be reported immediately on the transportation long enough to get max. 60° angle between them
document. To enable the manufacturer and the carrier to reply promptly, any non-conformity shall be (Fig. 3).
noted on the delivery note.
Fig. 3
Make sure that the features on the plate comply with the inspection report attached and the features noted
on the order. Moreover, make sure that the transformer is complete with all the requested accessories (e.g.
handling wheels, thermoresistance, temperature control equipment, etc.) 2.4 Storage

2.2 Handling The resin transformer is intended for indoor installation, therefore it must not be stored outdoors. If the
transformer is not installed immediately, it is advisable not to remove the original packaging; this will
During handling, never apply pressure to the coils or HV/LV connections (Fig.1) . If the transformer needs prevent it from accumulating dust.
to be handled manually for positioning of the wheels, a jack can be used ensuring that a suitable piece
of wood is placed between the jack and the metallic supports bearing the machine (Fig.2). Jacking the 2.5 Altitude of installation
transformer up by the HV/LV coils or by the magnetic core must be absolutely avoided.
Unless otherwise specified in the order, the maximum altitude of installation shall be the one envisaged in
the relevant standards, that is 1.000 m. above sea level.

2.6 Ambient temperature

The ambient temperatures shall meet the requirements specified in the ECI standard, in particular:
• Temperature of the air cooling the transformer max 40°C
• Max. daily average value 30°C
• Max. yearly average value 20°C
• Transportation and storage temperature up to -25°C.

Fig.1 Fig.2

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 3. INSTALLATION 3.1 Transformer installation inside the substation

The resin transformers are designed for indoor installation, if the provided degree of protection is IP00, they Each part of the resin transformer shall be considered as live; therefore it is absolutely forbidden to touch the
shall be located in a dry and isolated room, in which no risk of water leakage is present. transformer when it is energized. For this reason, the transformer shall always be in an isolated room (ref.
Table B). This room will be accessible exclusively through a door which is interlocked with the MV switch so
When installing the transformer, always refer to the following recommendations: that the switch opens, hence there is no voltage when accessing
• Earth all non-live metallic parts by means of the earth point, which is always provided and marked. the room. When positioning the transformer, observe the safety
• Earth the neutral point, if provided, according to the earth-fault protection system. distances indicated in the Table A-B between coils and walls and
• Make sure that the cables are properly connected and supported, and far enough from the surface of between earth and HV and LV cables. Furthermore, make sure that
the windings as per Table A. all metallic parts (ducting for auxiliary cables, supporting metallic
• Make sure that the transformer is properly fastened to the floor and avoid any metal parts in the bars, etc) are at the correct distance from the surface of the coils, H H

vicinity in order to prevent any vibration when the transformer is operating. from delta connection and from any other live part, in accordance
• In the case of transformers with dual primary or secondary voltage, check that the transformer is set with the insulation class. As already stated, the istance depends
on the correct value corresponding to the supply voltage or to the voltage output. on the max. insulation voltage (Um) of the transformer and on the
• Check that the adjustment tappings are set on the value corresponding to the mains voltage; type of enclosure/substation walls.
if the value needs to be modified, follow the indications on the transformer rating plate and refer to The surfaces of the coils shall be considered as “live parts” KEEP
paragraph “Commissioning” - Adjusting the input voltage (page 12). THE SAFETY DISTANCE.
• Connect the temperature monitoring system according to the supplied diagram.
• Check the absence of foreign objects (metallic items, screws, etc) near or on the transformer.
• Check that both HV and LV coils are perfectly concentric and that the rubber blocks are correctly Um
12 17,5 24 36
Table (kV)
centered and tightened.
A
120 220 220 220 320

Table B

Um A (mm) A (mm)
(kV) Full Part Part Griey
12 120 300

17,5 220 300

24 220 300

36 220 320

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3.2 Rules for installing the temperature monitor unit and the sensors

In order to ensure proper and reliable operation of the system to control the temperature of the transformer, 7. The terminals must be tightened to avoid contact that could cause false readings of temperatures.
you must follow the guidelines for installation of the temperature monitor unit and the sensors. 8. Any tips of the conductors must be properly crimped to avoid false contacts
9. The unit should not be installed close to equipment DC/AC or AC/DC.
Power Supply
For further information not contained in this paragraph please refer to the specific manual installation of
The temperature monitor unit must be powered with a correct voltage, as reported in the manual. When control units and sensors.
the unit is powered directly from the secondary of the transformer to be protected, it can be demaged by
high-intensity over voltages: in this case, we suggest the use of a surge arrester or an insulating transfomer.

PT100 Sensors connection

For a proper connection of the sensors, please take into consideration the following rules:

1. Each PTC/PT100 should be connected with a cable with three conductors with a minimum diameter
of 0,35 ² and a maxiumum of 1 mm ².
2. Extension cable must be shielded with 80% tinned copper braid covering.
3. Conductors must be twisted.
4. Cable shield must be grounded only on one end, preferably on the side of the unit.
5. Cable signal transfer PTC/PT100 should not be near power transmission cable, low voltage and high
voltage ones.
6. Cable signal transfer PTC/PT100 must be placed in a linear way, without entanglements.

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 4. TRANSFORMER PROTECTION
4.1 Over voltage protection
Electrical connections
In case of overvoltage on the transformer the use of surge arresters, which earth any possible peak on the
supply network, is suggested. Screw type Tightening torque [Nm]*
The arrester type shall be selected depending on the system requirements and arrester ratings M6 5
M8 11
4.2 Overcurrent protection
M 10 25
The transformer also requires protection devices against the thermal and dynamic effects of over current M 12 40
phenomena due to short circuits.
In the event of short circuits the transformer should be protected by an automatic switch with over current M 14 60
disconnection devices intervening in the prescribed times, but consideration should be given to possible M 16 85
overloads.

4.3 Electrical connections and clamps / Torque settings

The electric connections and the mechanical fasteners shall be tightened according to the following tables. Electrical connections
*Note: 1 Nm ~ 0,1 kgm
Screw type Torque value [Nm]*
M 12 85
M 14 135
M 16 210
M 18 290
M 20 410
M 22 560

M 24 710

Friction Coefficient 0,14

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 5. TRANSFORMER COOLING
To prevent incorrect cooling from damaging the transformer irreparably, the heat generated by no-load Air volume and input section
losses on the magnetic core and by the load losses produced by the windings during transformer operation
shall be completely dissipated. Given that:
Overheating occurs if the transformer is installed in a small room and/or where the air flow inlet is reduced Pt Total loss to be dissipated expressed in KW.
with respect to the effective requirements, or when it is positioned incorrectly. In these cases, the air ΔO Temperature gradient expressed in °C between input and output air.
change might be improved by using an forced air system through ventilators or aspirators in the upper part Q Air change expressed in m³/s
of the substation and by an inlet duct at the bottom. H Distance expressed in m between the central line of the transformer and the central line of the
For natural circulation, the inlet shall always be located in the lower part of the room, with maximum opening.
height no greater then the bottom of the HV winding, to produce the stack effect and allow the air flow S Usable surface of the lower opening in m² (grate excluded)
in the duct between the HV and LV coils. If the supporting wheels are removed, the transformer shall be The volume required for a correct cooling can be calculated as follows:
raised from the floor in order to achieve the required height and allow proper airflow.
As regards the openings to be provided for air input and output, the lower one shall be located under the Q = Pt / ( 1,15 * ΔO ) [m3 / s ]
transformer at floor level. The upper opening shall normally have a section higher than 10 - 15 % allowing
for the higher volume of the hot output air and avoid accumulation. The usable area of the lower opening area can be calculated as follows:

S = 10,752 * ( Pt / (√(H*ΔO3))[m2]

Event to be avoided:
• Cooling air temperature above the values foreseen in the standards or in the design.
Hot air exhaust
• Transformer installation in small rooms having walls exposed to sunlight.
• Transformer installation in environments equipped with heat-radiating systems.
• Installation in poorly ventilated environments, in which air change could be insufficient (sometimes,
H

this problem can be compensated for by installing forced-ventilation air-change systems see above).
• Installing the transformer peripherally to the normal airflow from input-to-output, which shall
always pass through the transformer from the bottom upwards, taking the transformer centre line
as a reference.

Fresh air inlet

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 6. COMMISSIONING
6.1 Transformer Earthing 6.3 Cleaning

Check that the transformer is earthed through the plates with proper earthing braids complying If the transformer has been stored in a dusty environment for a long time, clean it thoroughly. Remove dust
with the relevant standards. from the coils and clean dirt traces, if any, use low-pressure air jets and dry cloths.

6.2 Connection 6.4 Adjusting the input voltage

Check the coils for eventual damages or movements due to transport and handling; also check the fastening
blocks for proper positioning and tightness. This operation is to be carried out with the transformer off load. The variation of the supply voltage (within
Check the connections and tightening of the connection bolts of both high voltage and low voltage cables. range ± 5%) as guaranteed by the supply company, can be adjusted by means of the tappings in order to
With regards to the low-voltage cables, check that they are suitably supported by the appropriate plates. obtain the correct output ratio. Usually there are five taps, ± 2 x 2.5 %. If the
Check that no earth cable or connection runs close to live parts or the coils surfaces (for minimum distance, medium voltage value at the input is other than the nominal voltage value,
refer to the relevant TABLE A on page 7), and also that there is continuity between the connections of all it is recommended to follow the instructions supplied for the connections
the elements that must be earthed. on the plate in order to achieve a value that is as close as possible to the one
If the transformer is equipped with temperature control devices (thermometers, electronic control unit), delivered by the electricity company. It is recommended
check that they are set at the correct alarm and trip temperatures and that the unit is working properly. to place all regulations in the same position.
Check that the cooling ducts are not clogged.

INSULATION CLASS WORKING RANGE

6.5 Energising
B From -25°C to 120°C
F From -25°C to 140°C After checking the appliances and ensuring that no foreign bodies have accidentally entered the transformer
(between the HV and LV coils, between the LV coil and the core, between HV/LV connections), enable the
switch/circuit breaker from the HV side with transformer in no-load condition. Then enable load on the LV
side through the relevant switch/circuit breaker.
INSULATION CLASS ALARM TRIP

B 110°C 120°C
F 130°C 140°C

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 7. MAINTENANCE
6.6 Parallel operation A dry transformer with cast resin windings requires little maintenance. However, a series of checks will
be required, the frequency of which is dependent on general environmental and operating conditions. In
For correct parallel operation, the following conditions shall be observed: relatively clean and dry environments and in normal operating conditions, checks can be made at fairly
• The coil ratio in all tapping positions shall be the same for all the transformers in parallel long intervals. It is advisable however to carry out an inspection at least once a year. It is recommended to
• The vector group shall be the same. reduce the interval time for any installation that is located in a particularly dirty and / or dusty environment
• The short circuit voltage value shall be the same and shall fall within the tolerances allowed by the or that is subject to variable intensity loads or peaks. Dry cloths and compressed air should be used to dust
IEC standards. and clean the coil. A check should also be made to ensure that no dirt is blocking the cooling channels that
The standards suggest the parallel operation of the transformers with output ratio not higher than 1 / 2; are located between either the HV and LV coils or that are located between the LV coil and the core. The
take this fact into account when selecting the machine. Start by establishing the parallel connection. Then cables should be checked to ensure that they have been fitted to the connectors at the correct tensioning
before closing the connection, check that the HV and LV cables are connected in the same phase to each torque. Check that the voltage tapping links are also tightened to the correct torque. Finally check that
transformer and that the switching bars are all positioned at the same position on each one of the terminal the coil spacing blocks have been fitted into place correctly. Please note that all of the aforementioned
boxes. This will result in the same voltage being fixings can work themselves loose as a result of a momentary overload or due to vibrations within the core
supplied to each phase and to each transformer and that occur when the transformer is in operation. Sometimes, the transformer may absorb humidity for a
the same voltage ratio being evident at the output variety of different reasons. The transformer would then need to be put through a dehydration process and
(which will correspond to the foreseen voltage the insulation resistance value would need to be checked before the transformer is energized again. The
ratio). average value of insulation resistance should be measured using a megaohmeter. Checks should be made
Please note that to achieve this, a metal connecting between each LV phase and earth, between HV and LV coils and between HV coils and earth.
bridge must be fitted between the transformer’s
secondary coils to permit comparison of the
different phase voltages. It is advisable to create
the metal connection in presence of a neutral wire.
A voltmeter should be used to determine the value
of the potential difference that exists between wL3,
vL2, uL1. A recorded value that is consistently zero
signifies that all of the paralleling conditions have
been met and that the low voltage switches can be
closed.

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 8. MAINTENANCE SCHEDULE 9. MALFUNCTIONS AND INITIAL CORRECTION WORK

INSPECTION MAINTENANCE FAULTY PARTS /

RESULT MALFUNTION SOLUTIONS
REQUIRED INTERVAL PROBABLE CAUSES

Inspect the Annual inspection and following Electrical continuity Presence of dirt Clean using dry air,
thermo-resistances any non-routine work measured using a tester Dielectric humidity dry by ventilation
absorption
Low insulation
resistance
Check the ability of the safety In accordance with In accordance with the Dielectric fault caused by Contact the
equipment to deal with an planned schedule instructions ageing or dirt manufacturer
overload

Remove any dirt or dust as well Six-monthly inspection and Clean with compressed air and Insulation problem Contact the
as any foreign bodies from the inspection following a shutdown cloths with the HV coil manufacturer
windings

Torque tightening Change in voltage / the value Make sure that the position indicated
HV/LV terminal and delta / star Annual inspection and following (please refer to table 4.3)
Automatic cut-off of the voltage in the primary to the voltage change position is the
connection bolts any non-routine work using a torque wrench activated coil does not coincide with that same as
reported at the terminal box the line one

Bolts and nuts intended to Annual inspection and Electrical continuity Time and current intensity Review the timing and adjust the
secure the following any measured using a tester of protection relay are not intensity value
transformer to the floor non-routine work properly adjusted

HV to earth, min. 250 MΩ

Inspect the insulation between Whenever the transformer LV to earth, min. 50 MΩ Voltage in the primary is not
the windings and between the remains unused for a long period MT/LV, min. 250 MΩ equal to the nominal value. No Contact the electricity supply and
windings and earth of time Mega-ohmmeter (megger-type) voltage in the primary distribution company
with a voltage that exceeds 1000 V
min. and LV insulaton class Erroneous secondary
voltage value
Check the phase fixing block Annual inspection and Tightening torque values Incorrectly positioned voltage Correct position of
torque values following any min 10 Nm - max 15 Nm tappings tappings
non-routine work using a torque wrench

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 10. TRANSFORMER INSTALLATION CHECKLIST
NOTES:

Serial Number: Date:

Check: Result:
• Verify absence bodies (screws, washers, metal shavings etc..) Pass Fail (See Notes)
• Verify correct insulation distance between transformer live parts Pass Fail (See Notes)
and power cables/extraneous metalwork (Note: Cast Resin
windings are to be considered live parts)
• Verify support and fixing of supply cables and bus-ducts, in order to Pass Fail (See Notes)
ensure that no undue strain is placed on the transformers insulators
and conductors
• Verify correct installation and operation of all auxiliary circuits/ Pass Fail (See Notes)
protection systems / ventilation measures
• Verify all mechanical and electrical connections torque settings Pass Fail (See Notes)
• Verify correct earthing of transformer (and enclosure if provided) Pass Fail (See Notes)
• Verify correct ventilation measures are in place and operational Pass Fail (See Notes)
• Verify correct positioning of Input Voltage no-load tapping Pass Fail (See Notes)
connections
• For parallel operation, verify phase/voltage/vector group/short Pass Fail (See Notes)
circuit voltage value match.

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