Ormazabal CTC Instruction manual

CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
General Instructions
LIB
11.07.2007
Secondary Distribution
Switchgear
Primary Distribution
Switchgear
Protection and
Automation
Distribution
Transformers
IG-086-GB
version 02
Transformer
Substations

Legal Deposit: BI-2040/07
WARNING!
While any MV equipment is operating, some components are live, others may be moving, and some parts may become very
hot. Consequently, there may be electrical, mechanical and thermal hazards associated with its use.
In order to provide an acceptable level of protection for both persons and goods and taking into account the applicable
recommendations regarding the environment, Ormazabal develops and manufactures its products according to the principle of
integrated safety, based on the following criteria:
•Removing hazards whenever possible.
•When this is not technically or economically viable, by incorporating suitable safeguards in the equipment itself.
•Providing information on remaining risks, in order to assist in the design of operational procedures to prevent
such risks, training operational staff in their use, and using appropriate personal protection facilities.
•Using recyclable materials and establishing equipment and component processing procedures so that when
these have reached the end of their service life they are appropriately handled so as to respect, as far as possible,
the environmental criteria established by the proper organizations.
Consequently, the specifications given in section 11.2 of the future IEC 62271-1 standard will be taken into account when
working on or near the equipment specified in this manual, and, in accordance with the EN 50110-1 Standard concerning safety
in electrical installations and EN 50110-2 Standard applicable to all types of activity on, with or close to electrical installations,
only duly trained and supervised personnel may work on, with, or near it when they are completely familiar with the instructions
and warnings contained in this manual and any other general instructions that may apply according to current legislation.
This must be carefully taken into account, because the safe and proper operation of this equipment depends not only on its
design, but on circumstances which are generally outside the scope and responsibility of the manufacturer, especially:
•Proper transport and handling of the equipment, from the factory gate to the installation site.
•Any intermediate storage being in conditions that do not change or adversely affect the assembly’s properties or
its component parts.
•Service conditions being compatible with the specified properties of the equipment.
•Handling and operation being carried out strictly in accordance with the instruction manual, and with a clear
understanding of the relevant operational and safety principles.
•Provision of proper maintenance, given the actual service and environmental conditions at the place of
installation.
Consequently, the manufacturer will not be responsible for any significant indirect damage caused by any violation of the
guarantee under any jurisdiction, including the loss of profits, times of inactivity, reparation costs or replacement of materials.
Guarantee
The manufacturer guarantees that this product will be free from any defects regarding materials and operation for the duration of
the contract. If any defect is detected, the manufacturer may choose to repair or replace the equipment. Inappropriate handling
of the equipment and any repairs carried out by the user will be considered to be a violation of the guarantee.
Trademarks and Copyrights
All the registered trademarks mentioned herein are the property of their respective owners. The copyright of this manual
belongs to the manufacturer.
As a result of the continuous evolution of standards and new designs, the characteristics of elements included in this
specification are subject to change without prior notice.
These characteristics, as well as material availability, are only valid if confirmed by Ormazabal’s Technical and Commercial
Department.

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 3 of 20
INDEX
1. OVERVIEW AND MAIN CHARACTERISTICS................................................................ 4
1.1. PREFABRICATED ENCLOSURE ............................................................................. 5
1.2. TRANSFORMER....................................................................................................... 5
1.3. LOW VOLTAGE BOARD........................................................................................... 5
1.4. MECHANICAL CHARACTERISTICS ........................................................................ 6
2. TRANSPORT ................................................................................................................... 7
2.1. ACCESS.................................................................................................................... 7
2.2. ROAD TRANSPORT ................................................................................................. 7
2.3. SEA TRANSPORT .................................................................................................... 8
3. INSTALLATION ............................................................................................................... 9
3.1. LOCATION ................................................................................................................ 9
3.2. PLANNING ................................................................................................................ 9
3.3. HANDLING................................................................................................................ 9
3.4. DIMENSIONS OF THE EXCAVATION.................................................................... 10
3.5. LEVELLING PROCESS .......................................................................................... 11
3.6. PROTECTION AND EARTHING CIRCUIT.............................................................. 12
3.6.1. Protection Earth Connection ............................................................................ 12
3.6.2. Service Earth Connection ................................................................................ 12
3.7. POSITIONING OF THE TRANSFORMER .............................................................. 14
3.8. ACCESS TO MV AND LV CABLES......................................................................... 16
3.8.1. Connection of the MV Cables to the Transformer............................................ 16
3.8.2. Connection between the Transformer and the LVB ......................................... 17
3.8.3. Connection of the Cables to the LVB Outgoing ............................................... 17
3.9. ELECTRICAL EQUIPMENT REPLACEMENT ........................................................ 18
4. MAINTENANCE ............................................................................................................. 19
5. ADDITIONAL INFORMATION ....................................................................................... 19
5.1. ACCESSORIES INCLUDED IN THE SUPPLY........................................................ 19

Page 4 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
1: Prefabricated Outer Enclosure
1.1: Concrete Monoblock Construction
1.2: Removable Cover
1.3: Transformer’s Doors
1.4: LVB Access Door
2: Power Transformer
3: Low Voltage Board (LVB)
1. OVERVIEW AND MAIN CHARACTERISTICS
Ormazabal’s CTC is an Under Pole Compact Transformer Substation designed to be
installed on the surface, with outdoor operation, complying with the UNE-EN 61330 standard.
It can be used in electrical distribution public networks up to 36 kV and can house a
transformer up to 250 kVA.
The main elements of the CTC Transformer Substation are as follows:
Figure 1.1: Main Elements of the CTC TS
1
1.1
1.3
1.4
2
3
1.2

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 5 of 20
1.1. PREFABRICATED ENCLOSURE
It consists of:
•Concrete monoblock prefabricated construction with IP339 rating, complying with the
UNE 20 324 standard.
•Removable cover.
•One front access door to the Low Voltage Board (LVB) with dimensions of
975 x 970 mm. The one leaf access door is provided with a system that allows to fix it
at 90º and avoids accidental closing. There is a physical barrier from the LVB access
area to the transformer access area.
•Two side doors with dimensions of 982 x 1320 mm that allow access to the
transformer area. Both doors can be unlocked from the LVB compartment.
•Two side grilles over each of the transformer access doors, for air intake / exhaust,
allowing optimal ventilation. They are provided with a mosquito netting of 6 mm
maximum mesh.
•Two cable access areas, one for MV cable incoming, with dimensions of
400 x 190 mm, at the CTC TS back bottom and another one for LV cable outgoing,
with dimensions of 440 x 190 mm, at the front bottom.
•Dielectric liquid collecting pit with a capacity of 400 l.
•Electrical warning plate.
1.2. TRANSFORMER
•Transformer up to 250 kVA, 36 kV[1] series.
1.3. LOW VOLTAGE BOARD
The CTC Transformer Substation can be supplied with the Low Voltage Board (LVB)
installed at the factory.
The LVB consists of a metal frame that supports the protection functional unit, which is made
up of vertical fuse holder bases BTVC. The busbar functional unit, made up of horizontal
bars, is fixed on these bases. To identify the horizontal bars different colours are used.
[1] This functional unit is included in the CTC TS only upon request.

Page 6 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
1.4. MECHANICAL CHARACTERISTICS
The dimensions and weights of the CTC Transformer Substation are as follows:
Total 2080
Height [mm] View 1600
Length [mm] 1330
Depth [mm] 2170
Without
Transformer 2000
Enclosure With
Transformer * 4600
Weight
[kg]
Cover 500
* Maximum weight for a 250 kVA / 36 kV transformer
ORMAZABAL
1330
2170
2080
4801600
Figure 1.2: CTC Dimensions
Dimensions in millimeters
2170 1330
1600
2080
480

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 7 of 20
2. TRANSPORT
2.1. ACCESS
The site must be visited in advance to check if vehicles can have access and if there is
sufficient space for unloading.
2.2. ROAD TRANSPORT
The transport takes place in a truck, placing the CTC TS on the truck’s platform on one or
two pallets, so that the sitting surface of the transformer substation is stable. The height from
the truck’s platform to the CTC TS base must be at least 80 mm.
The enclosures are loaded in such way that the door on the short side faces the truck’s cab.
Once the CTC TS has been placed on the pallets, it will be fixed to the truck’s platform with
slings (never with cables).
The corners will be protected with carton or polyspan between the sling and the CTC TS, in
order to avoid any marks or cracks as a consequence of the pressure exerted by the slings
when tightened.
minimo 80 mm
CAMA DEL CAMION
PALET DE MADERA
ESLINGAS (NO CABLES)
CANTONERAS
EJE DEL CAMION
Protection Slings (no cables)
Wooden Pallet
Truck’s axle Truck’s platform
≥80 mm
Figure 2.1: CTC TS Loading

Page 8 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
For multiple transport of CTC Transformer Substations, these are placed at enough distance
to avoid damage during transport.
The maximum amount of CTC TSs that can be transported at a time on a three-axle low
loader is five units. The truck should be articulated and provided with features that allow to
load the enclosures in the position indicated:
2.3. SEA TRANSPORT
The sea transport will take place in open reinforced floor “flat-rack” containers.
The ventilation grilles on the two biggest sides of the enclosure will be protected with elastic
plastic tape wound around several times, in order to avoid water filtering in the enclosure
during transport.
Two boards of 2000 x 150 x 20 mm will be used to rest the CTC Transformer Substation in
the container.
Once positioned inside the container, a 100 mm long 100 x 100 x 10 mm bracket will be
placed on each corner of the enclosure, welded to the floor of the container in order to
prevent any movement during transportation.
Then two transversal slings will be placed over the enclosure (as shown in Figure 2.3).
The corners will be protected with carton or polyspan between the sling and the transformer
substation, in order to avoid any marks or cracks as a consequence of the pressure exerted
by the slings when tightened.
ORMAZABAL
ORMAZABAL
Figure 2.2: Direction of the enclosures loading
Figure 2.3: Sea Transport

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 9 of 20
3. INSTALLATION
3.1. LOCATION
The site shall be defined exactly indicating the alignment and the height of reference points.
3.2. PLANNING
The coordination of the transport and the crane or tow truck adequate to the weight of the
CTC[2] Transformer Substation needs to be planned.
3.3. HANDLING
For a correct handling, the CTC TS is provided with DEHA hooks that used with a lifting beam,
slings and adequate hooks ensure that the lifting operation is as balanced as possible.
For the transversal balancing, a lifting beam with reference ABF/3 is used that allows to lift a
maximum of 3000 kg.
[2] See chapter 1.4. Mechanical Characteristics
Figure 3.2: Positioning of the lifting beam to handle the CTC
Figure 3.1: Correct fitting of the DEHA hooks
ATTENTION!
Lifting the CTC TS with the specified lifting beam is prohibited when the transformer is
installed inside it. To lift the TS with the transformer, consult Ormazabal’s Technical –
Commercial de
p
artment.

Page 10 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
3.4. DIMENSIONS OF THE EXCAVATION
It is recommended to make an excavation for the installation, as shown in Figure 3.3.
The burying level marked on the CTC TS walls must not be exceeded. The maximum
burying height is 480 mm measured from the base of the Transformer Substation.
These levels will be adapted to the earth network solution taken for each case, according to
the earth connection guide plan[3].
[3] Necessary excavation for the recommended earthing ring: see Figure 3.9.
ORMAZABAL
LECHO DE ARENA COMPACTADA DE
1770
2550
480
100 mm compacted sand
Dimensions in millimeters
Figure 3.3: Dimensions of the excavation
2550
1770
480

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 11 of 20
3.5. LEVELLING PROCESS
Levelling the ground is important for the correct installation of the enclosure.
The following tools are necessary:
•1 Bubble lever
•1 Square shovel
•8 Levelling tools
It is necessary to cover the base of the pit with a 100 mm thick layer of compacted and
levelled sand to avoid an uneven base.
The installation operation involves positioning the CTC TS in the excavation made for this
purpose and connecting the LV and MV cables, as well as the external earthing circuit.
VERY IMPORTANT:
For installations on sloping ground, consult Ormazabal’s Technical – Commercial
department.
INSTALACION DE TIERRA
SEGUN LOS VALORES DE
TIERRA OBTENIDOS EN
EL PROYECTO
ARENA COMPACTADA
TIERRA COMPACTADA
RELLENO COMPACTADO
INCLINACION 2 %
Figure 3.4: Excavation elements
Earth circuit installation
using the earth values
obtained in the project
Com
p
acted sand
Com
p
acted soil

Page 12 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
3.6. PROTECTION AND EARTHING CIRCUIT
The CTC TS is provided with an internal earthing circuit to connect the different elements to
the external earthing circuit.
Inside the enclosure, there are two earth disconnection boxes corresponding to:
•Protection earthing circuit (metallic parts).
•Service earthing circuit (transformer zero-sequence earth).
3.6.1. Protection Earth Connection
The protection earthing circuit (metallic parts) provided with the CTC Compact Transformer
Substation is connected to the protection earthing disconnection box on the right-hand side
wall of the transformer area, looking from the LVB.
The metal enclosure is connected to the protection earthing circuit (metallic parts) which is
finally connected to the protection disconnection box.
3.6.2. Service Earth Connection
The service earthing circuit (zero-sequence earth) connects the LVB zero-sequence to its
disconnection box located in the LVB area, on the left-hand side wall, looking from the LVB.
It is recommended to make the connection with insulated copper wire.
Both earthing circuits are independent.
The Transformer Substation project must include the section regarding the execution of the
earth connection (check the Utility's standard project), as well as the justification of its sizing.
The Earthing Installations section of the Regulations regarding Power Plants, Substations
and Transformer Substations (MIE-RAT 13) describes the requirements this kind of facility
must comply with.
VERY IMPORTANT:
The LVB zero-sequence bar (service earth connection) is not connected to the
protection earth connection bar (metallic parts).

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 13 of 20
The copper connector cross-section, the contact surface of terminals and tightening torques
shall be suitable for a default current delimited by Network protections.
In the cases when it is not feasible to maintain the values of step and touch voltages within
the limits specified in Supplementary Technical Instruction MIE-RAT 13 of the Transformer
Substations Regulations (R.D. 3275/1982 and updates), the owner of the facilities shall
implement at least one of the additional safety measures provided in this instruction, in order
to reduce the risks to persons and assets.
The recommended tightening torque for the electrical connections of the earthing network is
described on the table below:
TIGHTENING TORQUE [Nm]
METRIC Steel 8.8 Stainless A2
M8 21
M10 38
M12 60
3530
1000 10001330
4370
1000
10002170
IMPORTANT
It is recommended to make a 50 mm2 bare
copper loop without interruption. Use a
conductor prolonged to the inside of the
transformer substation to connect to the
disconnection box of the protection earthing
circuit.
Dimensions in millimetres
Figure 3.5: Recommended Earthing Ring
437
0
100
0
217
0
100
0
100
0
133
0
353
0
100
0

Page 14 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
3.7. POSITIONING OF THE TRANSFORMER
To position the transformer, follow the steps below:
1) Remove the plugs from the
cover tips and place the four
eyebolts supplied with the
equipment on the cover,
screwing them all the way in.
2) Lift the cover with four chains
of the same length.
3) Place the cover on the floor
on two boards.
4) Put the transformer into the
CTC TS with the tow-truck.
5) Place the cover on the CTC TS
and connect the earth cable
that connects the cover with the
enclosure.
6) Remove the eyebolts and place
the plugs on the tips.
ORMAZABAL
Figure 3.6: Removing the cover
ORMAZABAL
Figure 3.7: Inserting the transformer
Note: The transformer rests on the concrete enclosure base. It may be fixed to the floor
by tightening a set of nuts on the four fixing points available on the enclosure.

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 15 of 20
To access the transformer, follow the steps below:
1) Open the door of the CBT TS
compartment and put it in its fixed
position.
2) Install signals on the working area.
3) Activate the locking of the door-grille of
the transformer compartment.
To unlock the door, pull the bar upwards, as indicated in Figure 3.9.
TIRAR
TI RA
R
Figure 3.8: Access to the transformer
Figure 3.9: Door locking
PULL
PULL

Page 16 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
3.8. ACCESS TO MV AND LV CABLES
The CTC TS is provided with one MV cable incoming hole, with dimensions of
400 x 190 mm, at the rear of the enclosure, on the opposite side of the access door to the
LVB.
It also has another LV cable outgoing hole, with dimensions of 440 x 190 mm, at the front of
the enclosure, under the access door to the LVB.
To open a hole, just hit it with a hammer.
3.8.1. Connection of the MV Cables to the Transformer
If the transformer is fitted with 24 kV plug-in bushings, it is recommended to use 24 kV /
250 A single connection plug-in connectors and single core cable.
If the transformer is fitted with 36 kV plug-in bushings, it is recommended to make the
connection with 36 kV / 400 A plug-in connectors and a single core cable.
245
625 440
175 735
400
Dimensions in millimetres
Figure 3.11: Location of the LV cable outgoing
Dimensions in millimetres
Figure 3.10: Location of the MV cable incoming

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 17 of 20
If the transformer is fitted with open porcelain bushings, as per the standard UNE-EN 50180,
it is recommended to make the connection to the M12 bolt of the bushing with the connecting
points.
3.8.2. Connection between the Transformer and the LVB
It is recommended to make the connection between the transformer and the LVB with
0.6/1 kV extraflexible copper wire of adequate cross-section with hexagonal connectors, as
per DIN 46.235.
The connection is made directly on the busbar with M10 screws[4].
3.8.3. Connection of the Cables to the LVB Outgoing
The LV cable outgoings are made with the LVB’s BTVC bases screws.
[4] To identify the phases, pay attention to the colour code on the cables and on the bars.
Canalizacion
cables de AT Canalizacion
cables de BT
600
1770
2550
345
727698
390
255
915600
Tuberia ligera de material
termoestable °15
para acceso cables MT y BT
0,80m.
MV
Cables
LV
Cables
Dimensions in millimetres
Figure 3.12: Dimensions of the excavation and MV and LV mains
Figure 3.13: MV and LV mains
Light pipe made of º15 heat-
resistant material for MV and
LV cable access
800
Dimensions in millimetres
2550
600390
255
345
698
600
1770
915
727

Page 18 of 20
GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Once the cable connections to the LVB and to the transformer MV bushings have been
made, the cables will be sealed in the holes in order to obtain an adequate watertightness
level.
3.9. ELECTRICAL EQUIPMENT REPLACEMENT
To replace the transformer, follow the steps below:
1) Cut the LV and MV voltage sources.
2) Lock the breaking switchgear.
3) Check voltage absence.
4) Remove the plugs from the cover tips and replace them with the lifting eyebolts of the
CTC TS, as indicated in chapter 3.7.
5) Disconnect the protection earth wire (metallic parts) which connects the cover to the
concrete enclosure.
6) Lift the cover with four chains of the same length (see figure 3.6).
7) Place the cover on the floor on two boards.
8) Open the LVB compartment door (see figure 3.8)
9) Earth the circuit.
10) Activate the locking of the door-grille of the transformer compartment.
11) Open the transformer compartment doors.
12) Disconnect all the MV and LV cables (see chapters 3.8.1, 3.8.2 and 3.8.3)
13) Remove the transformer by lifting it. (see figure 3.7)
14) Place the new transformer in the CTC TS with the tow-truck.
15) Connect all bridges (see chapters 3.8.1, 3.8.2 and 3.8.3).
16) Place the cover on the CTC TS and connect the earth cable that connects the cover
with the enclosure.
17) Remove the eyebolts and place the plugs on the tips.
18) Restore service to the circuit.
Acera Perimetral
Puesta a Tierra
de Servicio
Puesta a Tierra
de Proteccion
Transformador Cuadro de Baja TensionPuentes de Baja Tension
Puentes de Alta Tension
Low Voltage Bridges
Transformer Low Voltage Board
Medium Voltage Bridges
Perimeter Area
Service Earth
Connection
Protection Earth
Connection
Figure 3.14: Elements of the CTC Transformer Substation

GENERAL INSTRUCTIONS FOR CTC
UNDER POLE COMPACT
TRANSFORMER SUBSTATION
IG-086-GB
version 02
11.07.2007
Page 19 of 20
4. MAINTENANCE
The prefabricated enclosure does not require maintenance. Occasionally, it might be
advisable to check and grease the locks.
There should be no obstacles (signs, plants, etc.) on the ventilation grilles of the
prefabricated enclosure.
5. ADDITIONAL INFORMATION
5.1. ACCESSORIES INCLUDED IN THE SUPPLY
¾First aid sign.
¾Electrical warning plate.
¾Document holder with the information specific to the CTC TS.
¾Insulated key to operate the LVB disconnector.
¾Eyebolts to lifth the cover.

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