Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
Document 2.4.96, Revision 0
March, 2013
Instructions (HI-104)
Installation, Operation, and Maintenance of
Single-Phase Pad-Mounted Compartmental-Type
Distribution Transformers
Howard Industries
Distribution Transformer Division
1
Document 2.4.96, Revision 0
March, 2013
! READ THIS IMPORTANT SAFETY INFORMATION
▲
READ THIS ENTIRE INSTRUCTION MANUAL CAREFULLY AND BECOME FAMILIAR WITH THE EQUIPMENT AND ALL SAFETY-RELATED INFORMATION BEFORE PROCEEDING WITH INSTALLATION, OPERATION, OR MAINTENANCE ACTIVITIES.
Safe use of this equipment is dependent on proper installation, operation, and maintenance procedures. Follow all applicable local and national codes.
Do not attempt to service or perform maintenance activities on the equipment until it has been effectively de-energized, and all high-voltage and low-voltage bushing terminals have been properly
grounded.
Only qualied personnel should install, maintain, and operate this equipment. Qualied personnel
are those who are trained in the installation, maintenance, and operation of high-voltage equipment,
trained in the proper use of personal protective equipment (PPE) and trained in appropriate rst aid
procedures. Refer to NFPA 70E.
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
Do not rely solely on fuse removal or switch position as conclusive indication that a transformer is
de-energized. Be absolutely certain that a transformer is de-energized by checking for zero voltage
on all terminals.
Certain information in this manual is marked with the words DANGER, WARNING, or CAUTION, which
indicate hazards as listed below.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death
or serious personal injury, and could also result in damage to the equipment.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious personal injury, and could also result in damage to the equipment.
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor
or moderate personal injury, and could also result in damage to the equipment.
These instructions are intended as a general guide for the installation, operation and maintenance of
the equipment, when operated in “Usual Service Conditions” as dened in IEEE Standard C57.12.00.
Although every effort has been made to ensure accuracy and completeness, these instructions do
not address every conceivable application or circumstance that might be encountered. Howard Industries makes no representation or warranty with respect to, and assumes no responsibility for the
completeness, accuracy, sufciency, or usefulness of, these instructions. Features presented herein
may not be present in all equipment designs. Standard and optional features are subject to change
without notice.
Questions regarding installation, operation, and maintenance of the equipment, particularly when
encountering unusual or special circumstances which may not be sufciently covered by these instructions, should be directed to the Howard Industries Transformer Division.
2
Document 2.4.96, Revision 0
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
SECTION 2: RECEIVING, HANDLING, AND STORAGE ................................................................................................. 6
Drawings and Documents ....................................................................................................................................... 6
Lifting and Handling ................................................................................................................................................. 6
Lifting and Handling ................................................................................................................................................. 9
Jacking, Skidding and Rolling .................................................................................................................................. 9
Location and Mounting ............................................................................................................................................ 9
SECTION 4: INSPECTION AND TESTING BEFORE AND AFTER INITIAL ENERGIZATION ......................................12
Pre-Energization Inspection and Tests .................................................................................................................. 12
Ratio Test ................................................................................................................................................................. 12
Tap Changer Setting. ............................................................................................................................................... 12
Fluid Temperature ................................................................................................................................................... 13
Current Transformers. ............................................................................................................................................. 13
Tank Finish .............................................................................................................................................................. 13
Post-Energization Inspection and Tests ................................................................................................................. 13
Verifying Correct Voltage ......................................................................................................................................... 13
Checking for Leaks. ................................................................................................................................................. 14
Tap Changer ............................................................................................................................................................ 16
Other Switching and Fusing Devices ........................................................................................................................................ 23
SECTION 6: OPERATION OF TERMINAL COMPARTMENT, BUSHINGS, GAUGES AND ACCESSORY DEVICES ..................... 24
Fluid Level Gauge and Sight Plug .............................................................................................................................................24
Fluid Temperature Gauge .........................................................................................................................................................24
Drain Valve and Sampling Device .............................................................................................................................................24
Current Transformers ................................................................................................................................................................ 26
Other Accessory Devices ...........................................................................................................................................................27
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
SECTION 7: MAINTENANCE AND REPAIR .....................................................................................................................................28
Other Accessory Devices ...........................................................................................................................................................31
Sampling and Testing the Fluid ................................................................................................................................................31
Filtering the Fluid .......................................................................................................................................................................31
Removing or Lowering the Fluid ................................................................................................................................................31
Filling with Fluid .........................................................................................................................................................................31
Opening the Transformer Tank ................................................................................................................................................ 32
Repair Parts .............................................................................................................................................................................. 34
Table 4: Torque Guidelines for Accessories ........................................................................................................... 34
4
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
SECTION 1: INTRODUCTION
Document 2.4.96, Revision 0
March, 2013
This document is intended as a general guide for the
installation, operation and maintenance of Howard
Industries uid-lled, single-phase, pad-mounted
compartmental-type distribution transformers.
Although every effort has been made to ensure
accuracy and completeness, these instructions
do not address every conceivable application or
circumstance that might be encountered. Features
presented herein may not be present in all
transformer designs. Standard and optional features
are subject to change without notice.
These instructions are applicable to single-phase,
pad-mounted compartmental-type distribution
transformers (including IEEE Type 1, IEEE Type 2 and
other styles covered by IEEE Standards C57.12.25
and C57.12.38, and the Space-Saver™ style), which
are designed as a single-door style with a one-piece
ip-top hood, or the double-door style (sometimes
called a “wardrobe-style” transformer), which is
designed with two hinged access doors.
All transformer styles are designed for mounting
outdoors on a concrete pad or other suitable
surface. High-voltage and low-voltage cables enter
the transformer terminal compartment from below
ground through an opening in the mounting pad.
The instructions contained herein are applicable
to transformers operated in usual conditions as
specied in the “Usual Service Conditions” section
of IEEE Standard C57.12.00. Questions regarding
installation, operation, and maintenance (particularly
when encountering unusual or special circumstances
not sufciently covered by these instructions) should
be directed to the Howard Industries Transformer
Division.
IT IS IMPORTANT TO READ AND COMPLY WITH ALL
SAFETY INFORMATION AND WARNINGS DISPLAYED
THROUGHOUT THESE INSTRUCTIONS BEFORE
ATTEMPTING ANY INSTALLATION, OPERATION, OR
MAINTENANCE ACTIVITIES.
5
Document 2.4.96, Revision 0
March, 2013
SECTION 2: RECEIVING, HANDLING, AND STORAGE
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
Drawings and Documents
Locate all shipping papers, packing lists,
specications, and other pertinent information for
use during inspection. Verify that the transformer is
supplied with a nameplate, required warning labels,
and terminal designation markings. Verify that the
terminal designation markings are consistent with
those on the nameplate. The transformer nameplate
provides electrical characteristics, winding
connections, and weights. The transformer wiring
diagram provides details of any control, fan and
alarm wiring that may have been provided.
Lifting and Handling
Lifting lugs or bosses are provided to lift the
completely assembled transformer. All lifting lugs
or bosses must be used simultaneously to provide
a safe, balanced lift. The transformer must not be
lifted from any points other than the provided lifting
lugs or bosses. Do not use holes in the lifting hooks
for lifting. These holes are for tie-down purposes
only and are not suitable for lifting. Refer to the
transformer nameplate to determine the total weight
of the assembled transformer.
Lifting bosses, when provided, consist of 5/8”-11
threaded inserts. Lifting should be accomplished
with user-installed 5/8”-11 lifting bolts that have
been fully engaged into the threaded bosses and
hoist rings. Do not lift with lifting bolts alone. Lifting
bolts and hoist rings must be rated to safely support
the weight of the completely assembled transformer.
A spreader bar should be used to keep the lifting
cables or straps nearly vertical, enabling a safe lift
and reducing the likelihood of tank deformation or
damage to painted surfaces. Transformers should be
lifted in an upright position, allowing the transformer
to tilt no more than 15 degrees from vertical. Lifting
cables or straps should be no more than 20 degrees
from vertical.
Single-door style transformers may also be lifted with
a forklift truck of adequate lifting capacity to safely
handle the weight of the completely assembled
transformer. Forks should be of sufcient length to
extend completely through the shipping pallet or
runners. Transformers should be lifted with the tank
(core/coil and uid compartment) oriented toward
the forklift truck, so that the transformer center of
gravity is adequately supported. Lifting transformers
from the terminal compartment side is not safe, as
the transformer may tip and fall.
Lifting double-door style transformers with a forklift
truck is not recommended, since weight and balance
can be problematic, and radiator panels can be
easily damaged.
Transformers should be handled with special care
when the ambient temperature is below minus 20°C
(minus 4°F); otherwise, permanent damage to the
transformer may result.
!
▲
WARNING
FAILURE TO FOLLOW THE INSTRUCTIONS
BELOW COULD RESULT IN DEATH OR SERIOUS
PERSONAL INJURY, AND COULD ALSO RESULT
IN DAMAGE TO THE EQUIPMENT.
• Lifting equipment, including forklift trucks,
cranes, hoists, cables, straps, lifting bolts,
hoist rings and spreader bars, must be of
adequate capacity to safely lift the completely
assembled transformer.
• Keep unnecessary personnel clear while
unloading and moving the transformer.
Initial Inspection
Although all transformers, components, and
accessories are carefully inspected and tested prior
to shipment from the factory, a thorough receiving
inspection should be conducted to detect any
damage or loss that might have occurred during
shipment. The receiving inspection should be
completed upon receipt and before unloading from
the truck. Note any damage or discrepancies on the
bill of lading, le a claim with the carrier, and notify
the Howard Industries Transformer Division prior to
unloading the transformer and before attempting any
repair.
6
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
Document 2.4.96, Revision 0
March, 2013
Before unloading the transformer, the following
checks should be performed:
1. Read the serial number on the transformer
nameplate and make sure it matches
the serial number listed on the shipping
documents. Also, check the nameplate
for kVA rating, high-voltage rating, lowvoltage rating, impedance and other design
characteristics, and make sure they comply
with the specications.
2. Check shipping documents to make sure
the shipment is complete, including all listed
accessories and hardware. Be aware that
additional items may arrive on separate
pallets. Claims for shortages or errors
must be noted on the shipping documents
and reported immediately to the Howard
Industries Transformer Division. Failure
to make a timely claim will constitute
unqualied acceptance and a waiver of all
such claims by the purchaser.
3. The tank vacuum/pressure gauge, when
provided, may indicate a positive or negative
reading when the transformer is received,
depending on the relative temperatures of
the uid and ambient air. A rising or falling
reading that varies over time with ambient
temperature indicates that the transformer
tank is sealed effectively. If the vacuum/
pressure gauge shows a constant zero
reading, this indicates the possibility of a
tank leak. If this occurs, the tank should be
checked carefully for leaks as indicated in
the following step.
4. Check the tank for indication of uid leaks,
looking carefully at weld seams, bushings,
gauges, valves and all other tank ttings. If
suspicious indications are found, investigate
thoroughly to determine if a leak does
exist on the transformer. Indications of a
leak can sometimes be residual uid that
was not cleaned during the manufacturing
process and not an actual leak. In many
cases a small pinhole tank leak or leak
from a bushing, gauge, valve or other tting
can be easily repaired on site. Refer to
the “Maintenance and Repair” section for
information about the repair of uid leaks.
5. Check for external damage including dents
or scratches on the tank walls, radiators and
terminal compartment. Dents and scratches
can often be repaired on site using simple
touch-up procedures. If touch-up painting
is performed, do not remove or obscure
any warning labels, instructional labels or
nameplates.
6. Check for broken, cracked, or damaged
bushings, gauges, valves and other ttings
and accessories.
7. Check for missing or damaged component
parts and for packages that shipped
separately from the transformer.
Fluid Level
The transformer is shipped from the factory with
insulating uid lled to the proper level. Before
energizing the transformer, verify proper uid level
by observing the uid level gauge, if provided. The
uid level gauge pointer should be between the
“High” and “Low” marks. For transformers provided
with a uid sight plug, the uid level can be directly
observed if it is within acceptable range. If the
transformer does not have a uid level gauge or sight
plug, the uid level can be checked by removing
the liquid level plug located at the 25°C mark. Prior
to removing the ll plug, relieve tank pressure by
operating the PRV, being careful to avoid any hot
uid that might be expelled from the valve. Exercise
caution when checking the uid level using the
uid level plug, as the uid may spill out and may
be extremely hot. When reinstalling the ll plug,
apply a suitable sealing compound to the threads to
ensure a proper seal. When checking the uid level,
be aware that the level will vary as a function of uid
temperature.
A transformer found to have a low uid level should
be checked for potential leaks and lled to the
proper level with the same type of liquid as that
specied on the transformer nameplate. Refer to
“Filling with Fluid.”
7
Document 2.4.96, Revision 0
March, 2013
! WARNING
▲
FAILURE TO FOLLOW THE INSTRUCTIONS
BELOW COULD RESULT IN DEATH OR SERIOUS
PERSONAL INJURY, AND COULD ALSO RESULT
IN DAMAGE TO THE EQUIPMENT.
• Do not energize the transformer if the uid
level is low.
• Maintain proper uid level at all times while
the transformer is energized.
• Exercise caution when checking the uid level
with the uid level plug, as the uid may spill
and may be extremely hot.
Internal Inspection
An internal inspection of the transformer tank is
rarely necessary and is recommended only when
there are obvious indications that the transformer
has received severe impact damage during transit
or when necessary to perform recommended preenergization tests or inspections. Do not open
the transformer tank without authorization from
the Howard Industries Transformer Division. If the
transformer tank must be opened, refer to “Opening the Transformer Tank” for instructions.
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
Transformers should be stored on a rm level
surface. They may also be stored in racks designed
for that purpose. Transformers should not be stacked
directly on top of one another, as this may damage
the paint nish and cause cabinet misalignment.
It is recommended that the transformer be inspected
periodically while it is in extended storage. Ensure
that an effective pressure seal is maintained, and
check for leaks and corrosion. Any damage or
defects should be repaired immediately.
Fluid Sampling
Sampling and testing of the uid is not required
unless there is indication that moisture or other
contaminants have accidently entered the tank
during transit. If moisture or contaminants in the
uid is suspected, contact the Howard Industries
Transformer Division immediately for instructions.
If uid sampling is required, refer to “Sampling the Fluid” for instructions.
Transformer Storage
Transformers may be temporarily stored if properly
prepared. It is recommended that transformers
be stored completely assembled. Prior to storage,
transformers should be thoroughly inspected as
described above in the “Initial Inspection” section.
If the transformer is not completely assembled,
separate components and accessories should be
stored in a clean dry area in their original shipping
containers. Do not store the transformer in a
corrosive environment.
8
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
SECTION 3: INSTALLATION
Lifting and Handling
Lifting lugs or bosses are provided to lift the
completely assembled transformer. All lifting lugs
or bosses must be used simultaneously to provide
a safe, balanced lift. The transformer must not be
lifted from any points other than the provided lifting
lugs or bosses. Do not use holes in the lifting hooks
for lifting. These holes are for tie-down purposes
only and are not suitable for lifting. Refer to the
transformer nameplate to determine the total weight
of the assembled transformer.
Lifting bosses, when provided, consist of 5/8”-11
threaded inserts. Lifting should be accomplished
with user-installed 5/8”-11 lifting bolts that have
been fully engaged into the threaded bosses and
hoist rings. Do not lift with lifting bolts alone. Lifting
bolts and hoist rings must be rated to safely support
the weight of the completely assembled transformer.
A spreader bar should be used to keep the lifting
cables or straps nearly vertical, enabling a safe lift
and reducing the likelihood of tank deformation or
damage to painted surfaces. Transformers should be
lifted in an upright position, allowing the transformer
to tilt no more than 15 degrees from vertical. Lifting
cables or straps should be no more than 20 degrees
from vertical.
Single-door style transformers may also be lifted
with a forklift truck of adequate lifting capacity to
safely handle the weight of the completely assembled
transformer. Forks should be of sufcient length to
extend completely through the shipping pallet or
runners. Transformers should be lifted with the tank
(core/coil and uid compartment) oriented toward the
forklift truck, so that the transformer center of gravity
is adequately supported. Lifting transformers from
the terminal compartment side is not safe, as the
transformer may tip and fall.
Lifting double-door style transformers with a forklift
truck is not recommended, since weight and balance
can be problematic, and radiator panels can be easily
damaged.
Transformers should be handled with special care
when the ambient temperature is below minus 20°C
(minus 4°F); otherwise, permanent damage to the
transformer may result.
FAILURE TO FOLLOW THE INSTRUCTIONS BELOW
COULD RESULT IN DEATH OR SERIOUS PERSONAL INJURY AND COULD ALSO RESULT IN DAMAGE TO THE EQUIPMENT.
• Lifting equipment, including forklift trucks,
• Keep unnecessary personnel clear while
Jacking, Skidding and Rolling
Double-door style transformers are designed for
jacking, skidding and rolling. Do not use radiator ns,
bushings, valves, pipe ttings, gauges or sheet metal
surfaces for jacking. Jacking must be done using
the proper jacking provisions from two adjacent
corners simultaneously to prevent warping of the
tank bottom. When rolling, use an adequate number
of rollers to distribute the transformer weight evenly.
Refer to the transformer outline drawing for the total
weight of the assembled transformer.
Location and Mounting
Consult local and national codes to ensure that
the installation meets all applicable requirements.
Location of the transformer must permit it to operate
in conditions that meet the requirements specied
in the “Usual Service Conditions” section of IEEE
Standard C57.12.00 General Requirements for
Liquid-Immersed Distribution, Power and regulating
Transformers. Operation not meeting these service
condition requirements will compromise transformer
capacity and reliability, unless the transformer is
designed specically for operation in conditions
other than usual service conditions. Contact the
Howard Industries Transformer Division, if additional
information is needed about location and mounting
issues not covered by these instructions
The transformer should be mounted on a level
concrete foundation or other suitable surface, which
is rated to support the weight of the completely
Document 2.4.96, Revision 0
! WARNING
▲
cranes, cables, straps, lifting bolts, hoist
rings and spreader bars, must be of adequate capacity to safely lift the completely
assembled transformer.
unloading and moving the transformer.
March, 2013
9
Document 2.4.96, Revision 0
March, 2013
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
assembled transformer. The transformer should sit
ush with the mounting surface, so that there are no
gaps that might compromise tamper resistance of
the terminal compartment. The installed transformer
should not tilt in any direction more than three
degrees. Greater tilt may compromise insulating
uid coverage of live parts within the tank and may
prevent insulating uid from circulating properly
through the cooling radiators. Improper circulation of
insulating uid may cause overheating and reduced
transformer life.
The transformer should be located at least 24 inches
from any obstruction and have adequate clearance
to allow the terminal compartment hood or doors to
open fully. Avoid locating the transformer in corrosive
areas. Remove any shipping braces and packing
material that may have been installed at the factory.
Hold-down cleats or brackets should be used to
securely fasten the transformer to the mounting
surface.
Verifying Enclosure Integrity
Howard single-phase compartmental-type padmounted transformers are designed and constructed
to be tamper resistant according to the requirements
of IEEE Standard C57.12.28 Pad-Mounted
Equipment—Enclosure Security, or C57.12.29 Pad-
Mounted Equipment—Enclosure Security for Coastal
Environments, as applicable, and therefore need not
be installed in a restricted area. Do not modify the
tank or terminal compartment in such a way that it
will compromise tamper resistance. If for any reason
modications must be made to the tank or terminal
compartment that compromise tamper resistance,
the transformer must then be located in a restricted
area. Such modications of may void the warranty.
Consult with the Howard Industries Transformer
Division before making any modications to the
transformer.
! WARNING
▲
FAILURE TO FOLLOW THE INSTRUCTIONS
BELOW COULD RESULT IN DEATH OR SERIOUS
PERSONAL INJURY, AND COULD ALSO RESULT
IN DAMAGE TO THE EQUIPMENT.
Do not modify the transformer in any way that
might compromise its tamper-resistant construction.
Grounding
The transformer must be permanently grounded
according to applicable local and national codes.
Ground the transformer by using ground pads or
nuts located inside the terminal compartment at
the base of the front panel. Do not use hold-down
bolts, pipe connections or any other ttings for
ground connections. A proper low-resistance ground
connection is necessary for safe operation.
In addition to proper tank grounding as stated above,
transformers designed for use on a grounded-wye
system must also have all winding neutrals securely
and effectively grounded to the system neutral.
! WARNING
▲
FAILURE TO FOLLOW THE INSTRUCTIONS
BELOW COULD RESULT IN DEATH OR SERIOUS
PERSONAL INJURY, AND COULD ALSO RESULT
IN DAMAGE TO THE EQUIPMENT.
The transformer must be properly grounded at
all times.
High-Voltage and Low-Voltage Connections
Before making high-voltage and low-voltage line
connections, check to make sure that all mating
connector surfaces are clean and smooth.
Connections must be tightened appropriately to
prevent overheating and possible failure of the
connection. Refer to the nominal torque guidelines
contained in Table 3. Connections should be made
with care to avoid placing undue cantilever stress on
the bushings.
High-Voltage Terminals
Dead-front transformers are designed to use the
separable insulated high-voltage connector system
dened in IEEE Standard 386. These dead-front
transformers come equipped with universal bushing
wells only, one-piece (integral) bushings or universal
bushing wells with factory-installed bushing inserts.
Either loadbreak-rated or non-loadbreak-rated
bushings can be provided as specied by the user.
When transformers are provided with universal
bushing wells only, bushing inserts must be installed
in the eld by the user before cable connections can
be made. Bushing well inserts must be compatible
10
Single-Phase Pad-Mounted Compartmental-Type Distribution Transformers
with the universal bushing wells. Do not use
incompatible or improperly rated bushing inserts,
or equipment damage could occur. When installing
inserts, follow the manufacturer’s instructions
accompanying the inserts. Insulated dead-end caps
or plugs must be installed on all unused high-voltage
bushings before energizing. Shipping dust caps must
never be used in place of insulated dead-end caps or
plugs.
Live-front transformers are equipped with highvoltage bushings having tin-plated eye-bolt or spade
terminals that are suitable for connection with either
aluminum or copper conductors to the high-voltage
source.
Low-Voltage Terminals
Single-phase pad-mounted transformers are usually
provided with externally-clamped, molded, lowvoltage bushings, with or without NEMA standard
spade terminals. When threaded terminals are
installed, a backup nut should be installed and
tightened against the terminal to ensure an
adequate connection that will not loosen or overheat.
Secondary line leads should be securely attached to
the terminals to ensure a low-resistance connection.
Document 2.4.96, Revision 0
March, 2013
Space-Saver™ style transformers may be provided
with a block-mounted, wire-lead, low-voltage
termination instead of molded bushings. These wire
leads are designed to be crimp-connected to the
load leads.
11
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