SMS SHZV Operating Instructions Manual
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SMS SHZV Operating Instructions Manual

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SHZV
On-Load Tap-changer
Operating Instructions
HM 0.460.3901-03.09/2021
IMPORTANT:
Please read this manual carefully
before using the tap-changer and
save it for reference.

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  • Page 1 SHZV On-Load Tap-changer Operating Instructions HM 0.460.3901-03.09/2021 IMPORTANT: Please read this manual carefully before using the tap-changer and save it for reference.
  • Page 2 HM0.460.3901 Thank you for choosing Huaming products. Before using, please read this instruction carefully. The product may have been modified since this document was published. We reserve the right to change the technical data, design and scope of supply without warning in advance. Generally, information provided with individual quotations and orders is binding.

  • Page 3: Table Of Contents

    1.Foreword .............................4 2. General ..........................8 3. Technical data ........................11 3.1 Type SHZV On-Load Tap Changer Technical Data ............11 3.2 Operation conditions ....................... 12 4. Type designation ....................... 12 4.1 Type designation ......................12 4.2 Insulation level of tap selector ..................14 5.

  • Page 4: Foreword

    HM0.460.3901 1.Foreword This instruction manual is a comprehensive description of product transportation, installation, commissioning, test and maintenance. It is intended for trained and qualified staff related to transformer production, testing and quality assurance, and has reference value for transformer design and operation personnel.
  • Page 5 HM0.460.3901 1.4 Hazard communication system Warnings in this technical file use the following format: SIGNAL WORD! Consequences Action The following signal words are are used: Signal Hazard level Consequences of failure to comply words Danger Immediate threat of danger Death or serious injury certainly occur Warning Death or serious injury apparently occur Waring Prpbable threat of danger...
  • Page 6 HM0.460.3901 1.5 Information system Information is designed to simplify and improve understanding of particular procedures. In this technical file they are laid out as follows: NOTE! The blue note symbol indicates important information that must be noted. 1.6 Safety precautions Precaution Action Always unplug a device before inspection.
  • Page 7 HM0.460.3901 the product is used only with the transformer specified in the order. • the serial number of the manual drive matches that of the SHZV type non-excitation tap switch • 1.8 Inappropriate use Use is considered to be inappropriate if the product is used other than as described in Chapter 1.7.

  • Page 8: General

    OLTC reliable, even replacing the new OLTC within the service life of transformer, the cost for maintaining its normal operation is quite expensive. The type of oil-immersed and vacuum arc-extinguishing OLTC-SHZV, with arc contacts replaced by vacuum interrupter, has very prominent advantages˖...
  • Page 9 HM0.460.3901 General view Figure 2-1 Overview of tap-changer （ ） inside transformer Cylinder Tap Selector 1. Transformer tank 2. Motor drive unit 3. Vertical drive shaft 4. Bevel gear box 5. Horizontal drive shaft 6. Upper gear unit 7. Tap-changer 8.
  • Page 10 HM0.460.3901 Figure 2-2 Overview of tap-changer 1. Pipe bend 2. Rupture disk 3. Tap-changer head cover 4. Tap-changer head 5. Diverter switch 6. Change-over selector 7. Tap selector 8. Upper gear unit Table 2-2 List of tap-changer components...

  • Page 11: Technical Data

    SHM-D or CMA7 Note: SHZV with cylinder tap selector is applicable for the contact pitches of 10, 12 and 14 in linear, reversing and coarse and fine regulating. SHZV with cage tap selector is applicable for the contact pitches of 12,14,16 and 18 in linear, reversing and coarse and fine regulating.

  • Page 12: Operation Conditions

    4. Type designation 4.1 Type designation SHZV tap-changers have a variety of specifications due to different combinations of the number of phases, the maximum rated through current, the highest voltage of the equipment, the insulation class of the selector and the connection mode. Therefore, the above-mentioned performance parameters should be clearly reflected in the model of the tap-changer, and the detailed description of each code is shown in Figure 4-1.
  • Page 13 HM0.460.3901 4.1.1 Basic connection According to the transformer voltage regulation and winding connection mode, the tap selector has a variety of different specifications. It is composed of the number of tap selector pitch, the number of operating positions and the form of the changeover selector. The designation of the tap selector model is shown in Figure 4-2.

  • Page 14: Insulation Level Of Tap Selector

    HM0.460.3901 4.2 Insulation level of tap selector The tap selector has 4 different insulation classes, which are represented by B, C, D and DE respectively. The insulation class data is shown in here below. unit(kV) Table 4-1 Insulation level of Tap selector...
  • Page 15 HM0.460.3901 4.3 Tap selector wiring diagram The different transformer voltage winding tapping methods correspond to different specifications of tap selector’s basic wiring diagrams. Figure 4-3 shows the common basic wiring diagrams. Special designs can be made to meet customers’ requirements. Basic connection diagram of Tap Figure-4-3 selector...

  • Page 16: Packing, Transportation & Storage

    • Customer-required special accessories if any. Please refer to the corresponding packing list delivered with the tap-changer for exact supplied components. Figure 5-1 set of SHZV tap changer 5.2 Transportation & acceptance 5.2.1 Transportation • Packings is suitable for all common kinds of transportations. The boxes of tap selector and MDU are allowed to be appropriately stacked during storage, and the load-bearing capacity of the box’s top...
  • Page 17 HM0.460.3901 5.2.2 Goods receiving Each batch of delivered goods must be checked by the consignee before accepted (signing acceptance confirmation). Following items must be checked by the consignee carefully: • When receiving the goods, check the quantity of components received according to the packing list.

  • Page 18: Storage

    HM0.460.3901 5.3 Storage When the goods are stored continuously for more than 1 year, the equipment should be inspected thoroughly before installation. Specially packed goods with sealed packing can be stored outdoors if they meet the following conditions. • The storage environment temperature should not be ≥ -25℃ and ≤40℃. •...

  • Page 19: Mounting Of Tap-Changer On The Transformer

    HM0.460.3901 6. Mounting of tap-changer on the transformer 6.1 Transformer mounting flange for tap-changer installation A mounting flange is required to fix the tap-changer head on the transformer cover. The structure of the flange should be designed according to the shape of the tap-changer head’s sealing surface (Figure 6-1). Double- thread screw (M12, maximum length=45mm) should be accurately positioned.

  • Page 20: Mounting Of Shzv On Bell-Type Transformer

    Therefore, they must be put on a horizontally flat surface. 6.2.1 Disassembly of SHZV top cover and lifting of switch insert a. Make sure OLTC is at the setting position b. Unscrew the 24 pieces of M10 bolts on the OLTC head cover (with spring washer, 16mm box wrench) c.
  • Page 21 HM0.460.3901 d. Remove the fastening nuts (not the red area) on the flange (9 pieces of M8 nuts with spring washers, 13mm wrench). Pull out the oil suction pipe (See Figure-6-3). NOTE! Do not damage the O sealing ring on the pipe connection. Do not drop fasteners into the oil compartment and keep them in safe places.
  • Page 22 HM0.460.3901 Figure-6-6 6.2.3Assembly of tap selector and diverter switch’s oil compartment Lift the oil compartment to be above the tap selector and connect them two. The steps are as follows: a. Put the tap selector on a horizontally flat table b.
  • Page 23 HM0.460.3901 NOTE! It’s dangerous to connect wrongly. After removing the positioning plate, it’s forbidden to move the genevawheel driving piece Figure-6-9 f. Align the oil compartment’s mounting hole with the selector’s and use the mounting connector in the accessory box 1 of the tap selector to connect these two parts (see Figure-6-9). Torque is 50～60N.m. NOTE! Pay attention to the diverter switch and tap selector’s verticality (the deviation should be smaller than 2%)
  • Page 24 HM0.460.3901 g. Assemble the tap selector and the diverter switch’s odd & even cables Figure-6-10 Take out the cables inside the diverter switch’s packing box and use 25 pieces of M8 and 35 pieces of M10 bolts according to the serial number to connect the diverter switch’s and tap selector’s wiring heads serial number: The serial number is printed on the terminals of the tap selector of each type of switch and on the terminals of the diverter switch, here, for example, the three-phase switch has the words U1, V1 and W1 printed on its terminals, please use the wires with the corresponding words for connection.
  • Page 25 HM0.460.3901 6.2.4 Install tap changer into bell-type transformer tank First, place the tap changer on the temporary support frame inside the transformer. To realize this, the tap changer is equipped with a support flange on the oil compartment. The assembly steps are as follows: a.
  • Page 26 HM0.460.3901 c. Clean the sealing surface before installing the tap changer mounting flange. Place the sealing gasket on the transformer mounting flange, and fix the tap changer mounting flange on the transformer’s (24 pieces of M10 bolts, torque 100 to 110 N.m.). (see Figure-6-14) Figure 6-13 Figure 6-14 d.
  • Page 27 HM0.460.3901 6.2.6 Installation of switch insert. a. Make sure that the tap selector and the bottom connector are in the setting position when installing the switch insert, and roughly align with the small end position of the connector; (see Figure-6-16) Figure-6-16 b.
  • Page 28 HM0.460.3901 c. Install the oil suction pipe. Insert one end of the oil suction pipe into the switch insert’s oil suction pipe positioning hole, and the other end into the bell-type flange oil suction pipe hole. (See Figure-6-18) PROHIBITION! Do not damage the O-ring on the coupling connector. d.

  • Page 29: Installation Of Tap Changer On Standard Type Transformer

    (24 pieces of M10 bolts, torque of 100 to 110 N.m.) (see Figure-6-12). b. Lift the transformer box cover over the transformer body and assemble it. 6.3.5 Use lifting equipment to lift SHZV to the mounting surface of bell flange support flange for connection.
  • Page 30 HM0.460.3901 After tightening it by the M10 connecting nuts which provide with tap changer, the washer of shield cover should be turned up 90° in two sides. (Figure-6-19) Figure-6-19 This diagram only shows how to install, for example the SHZV1000 has two mounting holes, other models are also available in customised designs, please follow this diagram when installing according to the actual situation.

  • Page 31: Transformer Ratio Test And Transformer Dc Resistance Measurement

    HM0.460.3901 7. Transformer ratio test and transformer DC resistance measurement It is suggested that the ratio test and DC resistance measurement should be carried out before drying. CAUTION! Operation without oil will lead to damage of OLTC. • Without oil, tap-changer cannot be operated more than 10 cycles before drying. •...

  • Page 32: Transformer Dc Resistance Measurement

    HM0.460.3901 For two or three sets of linkage switch group, all tap changer heads should be connected with horizontal axis. A tap change, the sound of the diverter switch action can be heard clearly. After the sound of the diverter switch be heard, it must continue to rotate two and a half turns in the same direction to complete the first level tap change.

  • Page 33: Drying Process And Oil Filling

    HM0.460.3901 8. Drying process and oil filling 8.1 Drying process To ensure the insulation property of tap-changer, necessary drying must be taken as per below description (vacuum drying or vapor phase drying). 8.1.1 Vacuum drying CAUTION! OLTC top cover, transmission gear box and OLTC accessories are not allowed to be vacuum dried together with the transformer in the drying oven.
  • Page 34 HM0.460.3901 8.1.2 Vapor phase drying CAUTION! OLTC top cover, transmission gear box and OLTC accessories are not allowed to be vacuum dried together with the transformer in the drying oven. Otherwise, they will be damaged. 8.1.2.1 Vapor phase drying in the vacuum tank NOTE! Top cover, transmission gear box and accessories of the on-load tap-changer are not allowed to be dried in the vacuum tank together with the transformer,...
  • Page 35 HM0.460.3901 NOTE! 1. Make sure to prevent small parts from falling into the oil compartment. 2. When disassembling and reassembling, the quantity of some small parts must be complete, be sure to count clearly. 3. Avoid damaging the top cover of the on-load tap-changer and the sealing surface of the on- load tap-changer head during disassembly and other operations.

  • Page 36: Oil Filling

    HM0.460.3901 8.1.2.2.1 Pass kerosene vapor into on-load tap-changer The pipe joints R and Q on the tap-changer head (See Figure-8-3) for the position of the pipe joint on the tap-changer head) are connected to the connecting pipe, and the inner diameter is at least 50mm to connect to kerosene vapor.
  • Page 37 - According to IEC60214-1, for SHZV type tap-changer, switching operation is allowed for the diverter switch oil temperature range from -25°C to +105°C, and it can be +115°C when overloaded.

  • Page 38: Installation Of Tap-Changer Protection Device And Transmission Device Components

    HM0.460.3901 9. Installation of tap-changer protection device and transmission device components 9.1 Installation of gas relay Install according to the instruction manual provided when the gas relay is supplied. 9.2 Use of pressure relief device The red bar on the top of the pressure relief device must be removed before operation (Figure 9-1). Red protective plate Figure 9-1 Pressure relief device 9.3 Installation of motor drive unit...

  • Page 39: Installation Of Horizontal And Vertical Drive Shafts

    HM0.460.3901 When horizontal and vertical driving shafts are over two meters, an intermediate support gear box must be added. The installation of the specially designed bevel gear box, steering gear box and the intermediate support gear box of the vertical or horizontal driving shaft can be carried out according to the above instructions.
  • Page 40 HM0.460.3901 Figure-9-3 (See Figure-9-4) Intermediate gear box should be added if the vertical shaft length exceeds 2M. horizontal drive shaft Middle support Vertical Tap-changer drive shaft body Figure-9-4...

  • Page 41: Installation Of Driving Shaft Shield Cover

    HM0.460.3901 9.6 Installation of driving shaft shield cover Figure-9-5 9.6.1 Installation of horizontal shield cover The length of the horizontal shield is determined by the design of the transformer manufacturer. After installation of the driving shaft, put the clamps on both ends of the horizontal shield covers (provided in the accessories), then clamp them on the protruding platform of the gear box and the bevel gear box, and finally move the clamps to the protruding platform positions on both sides, tighten and firm.
  • Page 42 HM0.460.3901 9.6.2.3 Place the bushing HM8210.301.3 on the upper end of the motor drive unit, fix with 4 pieces of M6×10 set screws, and 4 arcs to avoid 4 bolts. (See Figure-9-8) 9.6.2.4 Put the two shield covers outside of the driving shaft with the gaps at both ends, and the thicker one (HM8170.301) on the top.

  • Page 43: Installation Of Three Single Phase Tap Changer

    HM0.460.3901 9.6.2.6 Pull up the protective cover HM817.301 to the lower end of the square gear box, and set it on the bushing HM8210.303.3, with the 3 notches facing directly,3 cylindrical pins, and then rotate the protective cover so that the cylindrical pins are just stuck in the horizontal groove (see Figure-9-11). (3 pins are only for temporary hang) 9.6.2.7 At this time, the two protective covers have been positioned, use two clamps on the thinner protective cover (HM8170.302) at the bottom.
  • Page 44 The connection verification between the SHZV tap changer and the SHM electric mechanism: from the 10 position (setting position) to the 11 position, m=5 circle, from the 11 position back to the 10 position (the original setting position) k=3 circle, the handle rotates a circle Number difference: mk=5-3=2 turns Adjust the number of turns (mk) 1/2=1/2(5-3)=1 turn.

  • Page 45: Tap-Changer Factory Test And Test Preparation

    HM0.460.3901 10. Tap-changer Factory test and test preparation 10.1 Test preparation 10.1.1 OLTC Fully gas release Before putting into operation for the first time, use the bleed plug of the suction pipe on the switch head to deflate the connection pipe. 10.1.1.1 Gas release a.

  • Page 46: Test In Transformer Factory

    HM0.460.3901 b. Connect the grounding bolt M12 (No. 19 wrench, torque 50～60N.m.) on the transmission mechanism protection box to the transformer oil tank. 10.2 Test in transformer factory 10.2.1 Operation test Pre- operation must be carried out to check the mechanical functions of the tap-changer and the motor- drive mechanism before the transformer is energized.

  • Page 47: Transformer Transportation And Put Into Operation On Site

    HM0.460.3901 11. Transformer transportation and put into operation on site 11.1 Remove the MDU for transportation 1) Place the MDU at the calibration position and then remove the coupling 2) Remove the MDU 3) Do not operate the MDU when the tap-changer is not connected well. The re-assembly of the MDU and drive shaft must be carried out according to Chapter 9.3 to 9.7 of this instruction manual.
  • Page 48 HM0.460.3901 NOTE! Please confirm: there is no open flame, heat source or electric spark (such as electric spark produced by static electricity) within its direct contact range, and there is no possibility of generating it. 2) To fully release gas in OLTC, please follow Chapter 10.1.1 3) For pre-operation procedure, please follow Chapter 10.2.1 4) Please make sure that the OLTC oil conservator’s lowest oil level signal contact is connected to the circuit breaker’s trip circuit.

  • Page 49: Tap-Changer Operation Monitoring And Maintenance

    HM0.460.3901 12. Tap-changer operation monitoring and maintenance CAUTION Inspection of OLTC head cover, protective relay and MDU should be carried out regularly. - Whether there is leakage at the connection between the protection relay and the pipeline； - The condition of the MDU sealing and all electric components； - If the protective relay alarms, a thorough inspection should be done to the transformer and OLTC.

  • Page 50: Maintenance

    HM0.460.3901 13. Maintenance Electric shock! An energized transformer may cause death or serious injury. ►Turn off the high voltage and low voltage ends of the transformer. ►Lock the transformer to prevent accidental restart. ►Ensure that all components are powered off. ►Clearly ground all transformer terminals (ground wire, ground isolation switch) and short-circuit them.

  • Page 51: Inspection

    HM0.460.3901 13.1 Inspection Please follow the inspection instruction below: Interval Instruction Check the door tightness, cable bushings, MDU protective cabinet and Once per year control panel’s ventilation device Check the tightness of tap-changer head cover, protective relay and Once per year all pipes’...

  • Page 52: Notice

    HM0.460.3901 Interval Instruction After 300,000 times OLTC After 300,000 times OLTC operation (based on the operation (based on the number number shown in MDU’s counter OLTC inspection shown in MDU’s counter OLTC and maintenance. Regarding this, please contact inspection and maintenance. Huaming’s after-sales department.

  • Page 53: Appendix

    14.APPENDIX Appendix 1. SHZV head flange,overall dimension ................54 Appendix 2. SHZV head flange with pressure relief valve overall dimension ........ 55 Appendix 3. SHZV supporting flange, overall dimension ..............56 Appendix 4. SHZV bell-type head flange,overall dimension, cage tap selector ......57 Appendix 5.

  • Page 54: Appendix 1. Shzv Head Flange,Overall Dimension

    HM0.460.3901 Appendix 1. SHZV head flange, overall dimension（cylinder tap selector）...

  • Page 55: Appendix 2. Shzv Head Flange With Pressure Relief Valve Overall Dimension

    HM0.460.3901 Appendix 2. SHZV head flange with pressure relief valve overall dimension（cylinder tap selector）...

  • Page 56: Appendix 3. Shzv Supporting Flange, Overall Dimension

    HM0.460.3901 Appendix 3. SHZV supporting flange, overall dimension （cylinder tap selector）...

  • Page 57: Appendix 4. Shzv Bell-Type Head Flange,Overall Dimension, Cage Tap Selector

    HM0.460.3901 Appendix 4. SHZV bell-type head flange,overall dimension, cage tap selector...

  • Page 58: Appendix 5. Shzv Bell-Type Supporting Flange Overall Dimension, Cage Tap Selector

    HM0.460.3901 Appendix 5. SHZV bell-type supporting flange overall dimension, cage tap selector...

  • Page 59: Appendix 6. The Overall Dimension Of Bevel Gearbox

    HM0.460.3901 Appendix 6. The overall dimension of bevel gearbox Appendix 7. The overall dimension of 4:1 bevel gearbox...

  • Page 60: Appendix 7. The Overall Dimension Of 4:1 Bevel Gearbox

    HM0.460.3901 Appendix 7. The overall dimension of 4:1 bevel gearbox...

  • Page 61: Appendix 8. Schematic Drawing For Connection Of Shzv And Shm-D

    HM0.460.3901 Appendix 8. Schematic drawing for connection of SHZV and SHM-D...

  • Page 62: Appendix 9. Schematic Drawing For Connection Of Shzv And Cma-7

    HM0.460.3901 Appendix 9. Schematic drawing for connection of SHZV and CMA-7 （cylinder tap selector） 6621...

  • Page 63: Appendix 10. By-Pass Pipe, Overall Dimension

    HM0.460.3901 Appendix 10. By-pass pipe, overall dimension...

  • Page 64: Appendix 11. Schematic Drawing For Connection Of Horizontal Shaft And Vertical Shaft

    HM0.460.3901 Appendix 11. Schematic drawing for connection of horizontal shaft and vertical shaft unit:mm...

  • Page 65: Appendix 12. Lifting Plate Dimension

    HM0.460.3901 Appendix 12. lifting plate dimension...

  • Page 66: Appendix 13. Shzv (10050) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 13. SHZV (10050) operating position table and connection diagram...

  • Page 67: Appendix 14. Shzv (10070) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 14. SHZV (10070) operating position table and connection diagram...

  • Page 68: Appendix 15. Shzv (10090) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 15. SHZV (10090) operating position table and connection diagram...

  • Page 69: Appendix 16. Shzv (10100) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 16. SHZV (10100) operating position table and connection diagram...

  • Page 70: Appendix 17 Shzv (14140) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 17 SHZV (14140) operating position table and connection diagram...

  • Page 71: Appendix 18 Shzv (10051W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 18 SHZV (10051W) operating position table and connection diagram...

  • Page 72: Appendix 19 Shzv (10071W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 19 SHZV (10071W) operating position table and connection diagram...

  • Page 73: Appendix 20 Shzv (10091W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 20 SHZV (10091W) operating position table and connection diagram...

  • Page 74: Appendix 21 Shzv (10191W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 21 SHZV (10191W) operating position table and connection diagram...

  • Page 75: Appendix 22 Shzv (10191G) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 22 SHZV (10191G) operating position table and connection diagram...

  • Page 76: Appendix 23 Shzv (10193W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 23 SHZV (10193W) operating position table and connection diagram...

  • Page 77: Appendix 24 Shzv (10193G) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 24 SHZV (10193G) operating position table and connection diagram...

  • Page 78: Appendix 25 Shzv (12111W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 25 SHZV (12111W) operating position table and connection diagram...

  • Page 79: Appendix 26 Shzv (12231W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 26 SHZV (12231W) operating position table and connection diagram...

  • Page 80: Appendix 27 Shzv (12231G) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 27 SHZV (12231G) operating position table and connection diagram...

  • Page 81: Appendix 28 Shzv (12233W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 28 SHZV (12233W) operating position table and connection diagram...

  • Page 82: Appendix 29 Shzv (14131W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 29 SHZV (14131W) operating position table and connection diagram...

  • Page 83: Appendix 30 Shzv (14271W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 30 SHZV (14271W) operating position table and connection diagram...

  • Page 84: Appendix 31 Shzv (14273W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 31 SHZV (14273W) operating position table and connection diagram...

  • Page 85: Appendix 32 Shzv (18351W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 32 SHZV (18351W) operating position table and connection diagram...

  • Page 86: Appendix 33 Shzv (18351G) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 33 SHZV (18351GW) operating position table and connection diagram...

  • Page 87: Appendix 34 Shzv (18353W) Operating Position Table And Connection Diagram

    HM0.460.3901 Appendix 34 SHZV (18353W) operating position table and connection diagram...

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