SMS SHZV User manual

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

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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. Huaming has no liability for any damage due to incorrect interpretation of
this document.
The original document is written in Chinese.
Keep this manual at hand for future use and in case of any question, please contact Huaming.
©All rights reserved by Shanghai Huaming Power Equipment Co., Ltd. Unauthorized copying and
distribution of this document and the utilization and communication of its contents are strictly prohibited
unless expressly authorized.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model and ornamental design registration.
The product may have been modified after this document went to press. We expressly reserve the right to
make changes to the technical data, the design or the scope of delivery.
The information provided and the arrangements agreed during processing of the relevant quotations and
orders are strictly binding.
The original operating instructions were drawn up in Chinese.

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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. Packing, transportation & storage.....................................................................................16
5.1 Supplied components......................................................................................................16
5.2 Transportation & acceptance ..........................................................................................16
5.3 Storage............................................................................................................................18
6. Mounting of tap-changer on the transformer ....................................................................19
6.1 Transformer mounting flange for tap-changer installation..............................................19
6.2 Mounting of SHZV on bell-type transformer..................................................................20
6.3 Installation of tap changer on standard type transformer ................................................29
6.4 The installation of plate SHZV.......................................................................................29
6.5 Connection between tap of voltage regulating winding and terminal of tap changer......29
7. Transformer ratio test and transformer DC resistance measurement
................................. 31
7.1 Transformation ratio test ..............................................................................................31
7.2 Transformer DC resistance measurement .......................................................................32
8. Drying process and oil filling ...................................................................................................... 33
8.1Drying process.................................................................................................................33
8.2 Oil filling........................................................................................................................36
9. Installation of tap-changer protection device and transmission device components .......... 38
9.1 Installation of gas relay...................................................................................................38
9.2 Use of pressure relief device...........................................................................................38
9.3 Installation of motor drive unit .......................................................................................38
9.4 Installation of bevel gear box..........................................................................................38
9.5 Installation of horizontal and vertical drive shafts ..........................................................39
9.6 Installation of driving shaft shield cover.........................................................................41
9.7 Installation of three single phase Tap changer ................................................................43
9.8 Tap position calibration of tap-changer transmission system..........................................43
10. Tap-changer Factory test and test preparation ........................................................................ 45
10.1 Test preparation............................................................................................................45
10.2Test in transformer factory.............................................................................................46
11. Transformer transportation and put into operation on site .................................................... 47
11.1 Remove the MDU for transportation ............................................................................47
11.2 Oil filling and transportation without oil conservator ...................................................47
11.3 Transportation without oil.............................................................................................47
11.4 Putting transformer into operation on site.....................................................................47
12. Tap-changer operation monitoring and maintenance ............................................................ 49
13. Maintenance ................................................................................................................................. 50
13.1 Inspection .....................................................................................................................51
13.3 Notice ...........................................................................................................................52
14.Appendix ....................................................................................................................................... 53

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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.
1.1 Manufacturer
The product is manufactured by: Shanghai Huaming Power Equipment Co., Ltd. 977 Tongpu Road,
Shanghai, P.R.China 200333
Tel.:[phone] E-mail:[email protected]
Further information on the product and copies of this technical file are available from this address if
required.
1.2.Subject to change without notice
The information contained in this technical file comprise the technical specifications released at the
time of printing. Significant modifications will be included in a new edition of the technical file. The
document and version numbers for this technical file are shown in the footer
1.3 Safety
Safety instructions are explained in this manual. They must be observed and followed to avoid relevant
dangers.
Personal safety equipment must be worn during work to prevent potential risks.
Protective clothing for protecting personnel from hazards
in the work environment.
Safety shoes for protecting personnel from falling sharp
objects and slippery surfaces.
Goggles for protecting eyes and facial area from impact,
dust, liquid splash and high heat hazards.
Hard hat for protecting head from injury.
Hearing protection for protecting hearing from damage.
Protective gloves for protecting hands from mechanical,
chemical, and electrical hazards.
Table 1-1 Personal safety equipment list

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1.4 Hazard communication system
Warnings in this technical file use the following format:
The following signal words are are used:
Signal
words
Hazard level Consequences of failure to comply
Danger
Immediate threat of danger
Death or serious injury certainly occur Warning
Waring Prpbable threat of danger
Death or serious injury apparently occur
Warning
Prohibition
Probable dangerous
situation
Minor or moderate injury likely occur
Note
Possible dangerous
situation
Material damage may occur
Table 1-2 Signal words in safety instructions
Pictograms warn of dangers:
Pictogram Meaning
Danger
The yellow triangle warning sign means life and health may be at
risk if neglecting the instruction. Neglecting this warning can lead to
serious or fatal injuries.
Dangerous electrical voltage
Fire hazard
General prohibition sign!
The red symbol indicates some actions are prohibited.
Table 1-3 Symbols used in warning notices
SIGNAL WORD!
Consequences
Action

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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:
1.6 Safety precautions
Precaution
Action
Electric shock
Always unplug a device before inspection. Stay away from high-voltage
equipment and wear protective clothing.
Transformer oil
Collect used transformer oil in dedicated drums. Keep it away from
flames or sparks. Do not touch it which may cause damages to health.
Fire
In case of fire, extinguish it with powder, foam or carbon dioxide. Do
not use water.
Waste
Wastes are dangerous to the environment or human health. Clean them
up in time and use different methods according to the wastes’ categories.
Table 1-4 Safety precaution
1.7 Appropriate use
The product and associated equipment and special tools supplied with it comply with the relevant
legislation, regulations and standards, particularly health and safety requirements, applicable at the time
of delivery.
If used as intended in compliance with the specified requirements and conditions in this technical file as
well as the warning notices in this technical file and attached to the product, then the product does not
present any hazards for persons, property or the environment. This applies during the entire lifespan,
from delivery through installation and operation to disassembly and disposal.
The operational quality assurance system ensures a consistently high quality standard, particularly when
it comes to observance of the health and safety requirements.
Use is considered to be appropriate if
•the product is operated according to this technical file, the agreed delivery conditions and technical
data, and
•the associated equipment and special tools supplied with it are used solely for the intended purpose
and in accordance with the specifications of this technical file.
NOTE!
The blue note symbol indicates important information that must be noted.

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•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.
Shanghai Huaming Power Equipment Co., Ltd does not accept liability for damage from unauthorized or
inappropriate changes to the product. Unauthorized changes to the product without consultation with
Huaming can lead to personal injury, material damage and operational faults.
1.9 Personnel qualification
The product is designed solely for use in electrical or energy systems and facilities operated by
appropriately trained staff. This staff comprises people who are familiar with the installation, assembly,
commissioning and operation of such products.
1.10 Operator duty of care
To prevent accidents, faults and damage as well as unacceptable adverse effects on the environment,
those responsible for transport, installation, operation, maintenance and disposal of the product or parts
of the product must ensure the following:
•All warning and hazard notices are complied with.
•Personnel are instructed regularly inallrelevant aspects ofoperational safety, the Operating Instructions
and particularly the safety instructions contained therein.
•Regulations and operating instructions for safe working as well as the relevant instructions for staff
procedures inthe case of accidents andfires are kept on hand at all times and displayed in the workplace
where applicable.
•The product is only used in a sound operational condition and safety equipment in particular is checked
regularly for operational reliability.
•Use only replacement parts, lubricants and aids which are authorized by the manufacturer.
•Comply with the specified operating conditions and requirements of the installation location.
•All necessary devices and personal protective equipment for each activity are available.
•The prescribed maintenance intervals and the relevant regulations are complied with.
•Installation, electrical connection and commissioning of the product is only carried out by qualified and
trained personnel inaccordance with this technical file.
•The operator must ensure appropriate use of the product.

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2. General
Until now, the oil-immersed on-load tap-changer (hereinafter referred to as OLTC), being widely used in
worldwide substation, inside which the oil is an insulation medium for OLTC themselves and for extinguishing
arc occurred on the main switching contacts and transition contacts, as well as a medium for lubrication of
mechanical parts and for cooling of contacts and all other current carrying parts. Therefore, this type OLTC is also
called the OLTC of arc-extinguishing inside the oil. The carbonization of oil for this type of OLTC is inevitable
during the operating of tap-changer. With the switching times increasing, inside the OLTC oil chamber there will
be more and more carbonizations. Therefore, except from neutral point connection, in application for other
winding connections of transformer, or power transformer with voltage of 220kV or above, the auxiliary device
like online oil filter plant has to be assembled with the oil-immersed OLTC in order to guarantee the insulation
level of oil and to decrease the carbon granule. When this kind of OLTC is used in the rectification and furnace
transformer, it operates very frequently under the full-load or even over-load, which quickens the wearing-out of
arcing contacts, the carbonization of oil and also the wearing-out of mechanical parts. As a result, such works as
continual changing of new oil and replacement of arcing contacts, frequent inspection and maintenance have to be
done to make the 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˖
1. The current breaking in the vacuum interrupter, and the arc produced also extinguishing in the vacuum
interrupter, which solved the problem of oil carbonization. Therefore there is no need to equip with online filter
plant under any application condition.
2. Since the carbonization of oil in the oil compartment is eliminated, the carbon granule adhered to the surface of
insulation material does not exist any longer, the insulation level is guaranteed.
3. The task of carrying current for long time is undertaken by special mechanical main contacts while the vacuum
interrupter only taking the current instantly through, so the overload capacity of OLTC has been improved greatly.
4. All the vacuum interrupters are fixed firmly and mal-operation will not happen. The highest voltage of the
OLTC is 362 kV three-phase OLTC is application for neutral point winding connection of transformer with
voltage up to 765 kV,and single-phase OLTC can be used for any selectable winding connection, the max. rated
through current of tap-changer is 1300 Amp. in three-phase and 3000 Amp. in single-phase.
This instruction includes all necessary information for installing and using SHZV tap-changers.
NOTE!
Special design is available. Please contact Huaming for further information.

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General view
Figure 2-1 Overview of tap-changer （Cylinder Tap Selector）inside transformer
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. Protective relay
9. Oil conservator
10. Active part of the transformer
Table2-1 List of all parts

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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

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3. Technical data
SHZV tap-changer complies with IEC 60214-1: 2014 standard.
3.1 Type SHZV On-Load Tap Changer Technical Data
Item
Description
SHZVIII SHZVI
1
Max. rated through current (A) 400*
600
*
1000
1300
400 600
1000
1200
*
1500
*
1600
2400
3000
2
Rated frequency (Hz) 50 or 60
3
Connection
3-phase Y-connection
for neutral point only
Single-phase for any selectable
winding connection
4
Max. rated step voltage (V) 4000
5
Rated step capacity 1500 1600 3000
3300
1500
1600
3000
3000
4000
4400
5600
6000
6
Short-circuit
current test
(kA)
Thermal (3s)
6
8 12
15
6
8 12
24
24
24
24
30
Dynamic (peak)
15
20 30
37.5
15
20 30
60
60
60
60
75
7
Max. operating positions 18 without change-over selector; 35 with change-over selector
8
Insu
lation
to
ground
The highest voltage
for equipment (kV)
72.5 126 170
2
52 362
Rated separate source AC
withstand voltage
(kV/50Hz,1min)
140 230 350 260 550
Rated lightning impulse
withstand voltage
(kV,1.2/50μs
350 550 750 1050 1175
9
Tap
selector Categorized into B, C, D & DE four sizes
10
Mechanical life Not less than 1,500,000 operations
11
Electrical
life Not less than 600,000 operations
12
Oil compartment
of diverter switch
Service
pressure
0.03 MPa
Leakage test
No leakage under 0.08 MPa for 24 hours
Over
pressure
protection
Rupture disc bursts at 300 ± 20% KPa
Protective
relay
Set oil flow speed at 1.0m/s ± 10%
13
Motor drive unit SHM-D or CMA7
Note:
1) SHZV with cylinder tap selector is applicable for the contact pitches of 10, 12 and 14 in linear, reversing and
coarse and fine regulating.
2) 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.
3) Marked* indicate that these tap changer’s Max operating positions can be 35 without change-over selector 107
with change-over selector.
Table3-1 Type SHZV (Cylinder Tap Selector) Series of On-Load Tap Changer Technical Data
.

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3.2 Operation conditions
1). The operating temperature of the tap-changer inoil is ≥ -25℃ and ≤ +105℃ with overload up to
+115℃ according to IEC 60214-1.
2). The storage environment temperature of the tap-changer is ≥ -25℃and ≤ +40℃, and the humidity
should be not higher than 85%. Ifbeyond this standard, please mark your requirements before
ordering. The tap-changer material andaccessories will bespecially processed to meet the special
requirements of the environment.
3). After being mounted to the transformer, the non-perpendicular degree between the tap-changer and
the ground should be less than 2%。
4). No sever dust and other explosive or corrosive gases on the installation site.
P! Probihition!
Do not store the tap-changer or motor drive unit in a place with high humidity (≥85%). This
will cause condensation.
NOTE!
Special design is available to meet particular environment conditions. Please contact
Huaming for further information.
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.
SHZV III – 600 Y/ 126 C 12233W
Figure 4-1 SHZV model designation

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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.
Figure 4-2 Tap selector basic cone
For example:
1). Linear regulation: It is represented by 5 digits. For example, 14140 means that the contact position of
each phase is 14, the number of working positions is 14, and the number of intermediate positions is 0.
2). Reversing regulation: Add a letter W after 5 digits, such as 14131W, which means that the contact
position of each phase is 14, the number of working positions is 13. The number of intermediate
positions is reversing adjustment.
3). Coarse and fine regulation: 5 digits followed by a letter G, such as 14131G, indicating the contact
position of each phase 14, the number of working positions is 13. The number of intermediate positions
is coarse and fine adjustment.

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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 4-1Insulation level of Tap selector

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The different transformer voltage winding tapping methods correspond todifferent specifications
of tap selector’s basic wiring diagrams. Figure 4-3shows the common basic wiring diagrams.
Special designs can be made to meet customers’requirements.
Figure-4-3Basic connection diagram of Tap
selector 15

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5.Packing, transportation & storage
5.1 Supplied components
The complete set of tap-changer contains below parts
•Diverter switch
•Tap selector
•Motor drive unit (MDU), controller and connecting cables, transmission shafts, couplings, bevel
gear boxes and other transmission accessories
•Protection relay and accessories
•Special tools and accessories for tap-changer assembly
•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 tobe appropriately stacked during storage, and the load-bearing capacity ofthe box’s top
surface shall not exceed 500kg/m2.
•Boxes should beplaced reasonably according to the position of the gravity center. When lifting it
up, the markings on the box must be observed (Figure 5-1).
Figure 5-2 Example of markings on the box
DANGER!
When lifting and storing the boxes, people are not allowed to stand under or
near the boxes in case the boxes drop. All boxes must be stored properly and
safely.
CAUTION!
Choose appropriate forklift and crane according to the dimension and gross
weight of the boxes.
This side up
Fragile
Keep dry
Sling here

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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.
•Check whether the packing is intact. If it’s found to be damaged (if possible, take pictures of the
box and damaged goods) or the information of the goods does not match the packing list,
consignee should refuse to sign for acceptance, and immediately report the problem to the
shipping company and Huaming.
•The above steps are also applicable to corrosion of the goods due to moisture immersion (rain, snow,
condensed water). The components must be stored in a dry place before installation.
•The on-load tap-changer must be stored in a sealed packing box and opened before installation only.
5.2.3 Acceptance
Unpack the box and look for damage during transportation.
Transport the box to the installation site.
Check the equipment and its accessories according to the packing list.
NOTE!
When receiving the goods, please check carefully the packing and the supplied
components according to the packing list. In case anything is broken or missing,
please contact Huaming in time.
NOTE!
The transportation and lifting of the box must be operated by professionals.
The carrying capacity of transportation vehicles and cranes should be more than
1000kg.
CAUTION!
The packing box should be firmly fixed during transportation and lifting,
and be handled with care to avoid possible damage to the product due to
vibration, impact, falling, tipping, bumping, shaking, etc.
CAUTION!
If the box drops or is severely impacted, the possibility of damages must
be considered. Comprehensive inspection of the product should be
carried out, and if necessary, inspection(repair) shall be done by the
Huaming’s professional and technical personnel.
NOTE!
During unpacking and inspection, avoid damaging the original package.
NOTE!
If the received goods and its accessories do not match the list, contact Huaming in time.

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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℃.
•The tap-changer must not be stored in an environment with flammable, explosive and corrosive gases.
•It must be protected from moisture, dust, rodents and ants.
•Regularly check whether the stored equipment is abnormal
•If the tap-changer is stored for a long time, the desiccant must be replaced regularly, and re-packed
with sealed packing.
NOTE!
After long-term storage, the tap-changer and its accessories must be
carefully inspected before installation.

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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.
Figure 6-1 Transformer mounting flange

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6.2 Mounting of SHZV on bell-type transformer
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. Remove the OLTC head cover(See Figure-6-2)
During disassembly and other work, avoid damaging the OLTC’s head cover and sealing face (Oring, see
Figure-6-2)
Figure 6-2
DANGER!
If heavy components are not placed on a flat surface, they may tilt and
cause injuries! Therefore, they must be put on a horizontally flat
surface.
Remove
the head
cover
Head cover
connecting bolts
O ring
NOTE!
Carefully keep the head cover O ring in a safe place.