• Demands on heavy goods vehicles (HGV’s):
  The vehicles must be in a technically immaculate condition and comply with the Highway Code. Furthermore all general statutory instructions must be adhered to. The loading area must be furnished with a weatherproof tarpaulin. Transporting cast resin transformers without a cover is not permitted. HGV’s must be equipped with appropriate load-securing loops or there will be no transport ex works Regensburg. At least 4 ratchet straps are to be provided per transformer with the HGV. The transformer must not be reloaded. The loading instruction applies to the loading of SGB Cast Resin Transformers on HGV’s. Road transport is to be strictly carried out with compressed air spring-mounted vehicles only. If there are differing modes of transport or conditions please consult with SGB Regensburg.

• Loading transformers with an indoor crane:

• HGV goes into the loading area.

• HGV driver opens and moves the HGV tarpaulin for loading and also removes the mounted poles.

• To lift the transformer the 4 lifting loops provided must be used simultaneously. Any lifting over the yoke is forbidden.

• With crates and containers only use the indicated lifting points.

• Transformer will be in the HGV loading area from behind with the indoor crane.

• Put the transformer down on the HGV loading area, if possible, alongside and concentrically (chassis on the HGV floor).

• The transformer can also be loaded transversely to the direction of travel if sufficient room is given to a correct and proper lashing down.

• Attaching the transformers on the HGV:
  Transformer is attached with 4 ratchet straps (Forwarder’s or HGV’s equipment) to 4 vertex loops on the upper clamping bar with a tension bracket of approx. 30 degrees downwards to the available lashing loops of the HGV.

• Loading transformer on a palette with a fork lift truck up to 4 to*:

• Transformer is bolted together on a suitable transport palette

• Load palette positively with the transformer on the HGV loading bridge

• Nail up the palette on the HGV floor

• Then as described in point 2 below attach the transformer with ratchet straps

• A fork lift truck without palette is not permitted and leads to damage of the cast resin transformer

• Function of the load-securing device:
  The load must be positioned and any inertia forces occuring during transport must be made safe. During transport strains occur on the load which have an effect lengthways (forces from start-up and braking procedures), crossways (forces when going around bends) or even vertical (forces when going over bumps) to the direction of travel.

Cast Resin Transformers are not sensitive to natural air moisture. Shorter domestic transport on vehicles with canopies mostly requires no packing. For longer interstate or overseas transport, foil coverings are fixed and wooden crates or containers are used. The prevailing customer specification or SGB decides on this in detail on the basis of the transport route.

The foil coverings are fixed in such a way that in the lifting points area, the foil is cut out and then fixed with adhesive tape so that any movement of the foil during transport can be prevented. You can then ensure that no additional holes are necessary with the arrival at the site or with further reloading!

The cast resin transformers should be operated as quickly as possible and at the very least no-load. In the case of a longer storage in a offline operation please consult the manufacturer.

General hints, recommendations:

• Lifting and putting the cast resin transformer down can only be done by trained staff. To start load bearing capacity as evenly as possible at the lifting points, lift the cast resin transformer slowly and not suddenly. The cast resin transformer should be put down gently (slowest crane speed). Putting it down suddenly can lead to transformer damage. Please bear in mind that the cast resin transformer is very heavy. There is risk of injury with the upper yoke, the top of the core as well as the clamping bars.

• With all work the relevant national and international safety instructions are to be obtained and heeded at all times. This applies to all transit as well as mechanical and electrical installation work.

• When rolling the cast resin transformer, it is imperative that attention is paid to the set direction of the castors. The cast resin transformer must only be moved in the direction of the castors and going round bends is not permitted. With this in mind the cast resin transformer is to be placed with a crane into the new direction of travel and the direction of the wheels changed accordingly.

Temporary storage during transport and before installation must only be carried out in rain-safe chambers. With foil coverings, short-term transport is possible, for example, from the HGV to the storage location outdoors in the rain.

The transformer foil covering must be fixed as described below in the
instructions on packing. Rear ventilation is to be provided so that any formation of condensation is prevented. The same applies to transformers already incorporated in the enclosure. If sufficient ventilation is not possible, silica gel should be used. This is to be scaled in accordance with the physical conditions and after that checked regularly so that the moisture absorbing effect remains.

The storage of cast resin transformers outdoors over several days is not permitted in order to avoid any moisture getting in with rain and any contamination through dust and carbon black particles from the ambient air. If any other conditions arise for the storage of cast resin transformers, as described above, please consult the manufacturer.

Hints on transport or storage:

• During transport of the cast resin transformer to the site, weather conditions, for example, high humidity, can bring about lower values for insulation resistance, lower than those indicated on the SGB check sheets. The transformer can nevertheless be switched on safely. If in doubt please get in touch with SGB.

1. Remove existing packaging and transport safeguards on the transformer.
    

2. Ensure a steady position at the installation site. Fix castors (e.g. with wedges or other fixing equipment). When using storage elements for insulating mechanical vibration, be mindful of exact positioning to the transformer.
     

3. Check transformer for impurities and foreign bodies and clean if necessary. At the same time classification can be made according to the degree of contamination of the high voltage coils:

• Slight contamination:

1. Wipe the high voltage coils dry with a cloth (on the outside, inside and in the cooling channels)

2. Rub a silicone-free penetrating oil into the high voltage coils (Rivolta T.R.S.plus, H-762880)
    

• Medium contamination (carbon black deposit build-up):

1. Wipe the high voltage coils dry with a cloth (on the outside, inside and in the cooling channels)

2. Wipe the surfaces (on the outside, inside, cooling channels) with alcohol for technical purposes (spirit, H-236109) and leave to dry for 1 hour

3. Rub a silicone-free penetrating oil into the high voltage coils (Rivolta T.R.S.plus, H-762880)
     

• With a considerable deposit build-up of dirt or traces of a leakage or powder, in any event, it is necessary to consult the relative persons responsible (SGB).

You can also use the following checklist to simplify any commissioning

• Checklist.pdf

All operations and inspections are to be carried out as per the installation instructions before commissioning. The following tasks are then to be executed:

1. Make sure there is correctly scaled ventilation and aeration in the installation area. (Take into consideration increased power loss with the AF-operation). For your own dimensioning, guidelines from the worksheet J11 transformer stations can be used and sent on request.

2. For dismantled parts for transport such as connection lugs, remove and assemble control boxes etc. from the packaging.

3. The chassis supports must not be disassembled from the lower clamping bar!

4. If protective enclosures are supplied, assemble them in accordance with the schemes enclosed.

5. If there is a big time gap between installation and commissioning and there is a risk of contamination e.g. from dust by the construction site, then please follow the directions in Cleaning the transformer.

6. Check that the upper support blocks sit firmly. The rubber bases must then be compressed a little. If necessary, retighten the pressure screws. As a guideline it is important that the rubber is thereby pressed 2 to 3 mm into the coil. For a more accurate value please consult SGB

7. Connect and check the earthing and potential equalisation on the transformer correctly. In a standard case the connections are on the chassis. Please bear in mind here the torque of the fixing screws and the minimum cross-sections of the potential equalisation conductors. The cross-section of the potential equalisation conductor must be at least half as big as the largest protective earthing conductor cross-section of the installation, but at least 6 mm² of copper for mechanical reasons. For potential equalisation conductors, 25mm² copper is mentioned for non-electrical installations as a satisfactory upper limt. Other than that the whole protective earthing conductor of 50 mm² is to be chosen as a cross-section for the potential equalisation conductor.
   Assignment of the minimum cross-sections of protective earthing conductors and neutral conductors to the cross-section of the outer cable in accordance with the Association for Electrical, Electronic & Information Technologies 0100, part 540:

¹) PEN-conductor >= 10 mm² Cu or >= 16 mm² Al, in accordance with article 8.2.1 of the Association for Electrical, Electronic & Information Technologies 0100, part 540
²) Unprotected movement of Al conductors is not permitted.
³) Use bare conductors chiefly from a cross-section of the outer cable of >= 95 mm² .

8. Connect temperature monitoring systems and check for functioning by means of an interruption of the sensor circuit on the marshalling panel.

9. If fans are available, check the correct direction of rotation of the fans and the functioning of the control system (see circuit diagram temperature monitoring).

10. Carry out phase connections in accordance with circuit plate. In doing so, be mindful also of the correct position of the converter bridges.

11. Check and retighten all screwed electrical connections.
    
    Torques CU rail connections:

Torques high voltage circuit lugs und sprue bushes:

Torques for fixing screws with cable lugs. Following the German Institute for Standardisation and the Association of Electrical, Electronic & Information Technologies 0220 part 2 the following torques are to be adhered to for screws of strength category 8.8:

Torques are effective without lubricant!

12. Check all connection cables for strain relief. No mechanical strain to be conducted on the transformer connections.

13. Check voltage intervals:
    Keep all lead wires and control wires, as well as attachments and auxiliary parts at a satisfactory interval to the high voltage cast resin coil. We recommend you keep to intervals as with bare, live conductors in accordance with the Association of Electrical, Electronic & Information Technologies 0532:

• with Um* = 12 kV - 115 mm

• with Um* = 24 kV - 215 mm installation altitude < 1000 m above sea level

• with Um* = 36 kV - 300 mm

Attention! The high voltage cast resin coils are indeed insulated with a cast resin layer, however they are not scoop-proof in the terms of the regulations of the Association of Electrical, Electronic & Information Technologies, i.e. when working with the transformer or in the immediate vicinity of which it is only permitted in a dead and earthed state.

14. Insulation measurements
    With 2,5 kV DC the insulation resistances are measured with the high voltage insulation meter Metriso 5000 (see picture).
    
    The following measurements are to be carried out:

• High voltage to low voltage

• High voltage to earth

• Low voltage to earth

• PTC to low voltage

• PTC to earth
  
  
  
  
   The values measured are to be compared with data on the check sheet. (Guideline: 1 MOhm per 1 kV, e.g.: 0,4 MOhm with 400V)
  Important: Before measuring PTC, remove high voltage and low voltage connection cables!
  Attention: in humid weather conditions the insulation resistance falls!
  
  Measure PTC ohmic resistances and PT100 and compare with values on the check sheet:
  
  
  
  
  Example: terminal connections plate standard
  
  PT100 are measured twice (always to the combined white conductor): here from terminal 1 to 2 and from terminal 1 to 3. The PT100 resistance is 20°C ambient temperature ca. 110 Ohms.
  
  With PTCs not every single resistance is measured but the entire series connection of the PTCs: here between terminal 5 and 6 and 7 and 8, and 9 and 10, and 11 and 12. The total resistance of the 3 switched thermistors in a row (PTCs) is 20°C ambient temperature between 60 and 750 Ohms.
  
  Attention: when checking the cold conductor resistance of the thermistors, the voltage to be measured from the meter should not be above 2.5V!
  
  Example: Data on check sheet
  
  
  
  Summary of the PTC’s used by SGB

15. List of implements for putting cast resin transformers into operation

• 2 open-ended spanners (SW 24) for screws M16

• 1 insulation resistance meter (Gossen Metriso 5000)

• 1 Ohmmeter for PT100 and PTC’s

• 1 Voltmeter

• 1 torque wrench with the appropriate bits (M10, M12, M16)

• 1 tape measure

• Scotch tape and possible shrinkable bandage

• Material for cleaning the transformer:

• Cleaning rag

• Alcohol for technical reasons ?641, H-236109

• Rivolta-T.R.S. plus, H-762880

• Flat brushes (Nylon), BA-No. 62307

• Round brushes (Nylon), BA-No. 62307

16. Necessary documents for commissioning:

• Transformer dimensioned drawing (also possibly enclosure with circuit diagram)

• Transformer check sheet

• Test log of high voltage coils (if the entire transformer was not measured TE)

• User guide for temperature monitoring instrument

• Possible production parts list for transformer

• Checklist for transformer commissioning

• Submission: Commissioning report / Commissioning log

• Fault maintenance

• Transport, installation, commissioning and maintenance of SGB Cast Resin Transformers (yellow brochure?)

Hints on transport or storage:

During transport of the cast resin transformer to the site, weather conditions, for example, high humidity, can bring about lower values for insulation resistance, lower than those indicated on the SGB check sheets. The transformer can nevertheless be switched on safely. If in doubt please get in touch with SGB

Check transformer for impurities and foreign bodies and clean if necessary. Classification can be made according to the degree of contamination of the high voltage coils:

• Slight contamination:

1. Wipe the high voltage coils dry with a cloth (on the outside, inside and in the cooling channels)

2. Rub a silicone-free penetrating oil into the high voltage coils (Rivolta T.R.S.plus, H-762880)
    

• Medium contamination (carbon black deposit build-up):

1. Wipe the high voltage coils dry with a cloth (on the outside, inside and in the cooling channels)

2. Wipe the surfaces (on the outside, inside, cooling channels) with alcohol for technical purposes (spirit, H-236109) and leave to dry for 1 hour

3. Rub a silicone-free penetrating oil into the high voltage coils (Rivolta T.R.S.plus, H-762880)
    

• With a considerable deposit build-up of dirt or traces of a leakage or powder, in any event, it is necessary to consult SGB.