OLTC Technical Data-1

ON-LOAD TAP-CHANGERS
OF HHI-B
MAIN CHARACTERISTICS AND TECHNICAL DATA
EA-740 ENG
Sofia Bulgaria
2008
EA-740/08 ENG
Contents
Main characteristics and technical data. General .................................................................................4
1. Application and operating principle

1.1 Electrical diagrams and operating sequence .....................................................................5
1.2 On-load tap-changer basic units and transformer tank building-in method .....................7
1.3 Basic regulation schemes .................................................................................................8
2. Technical characteristics of the on-load tap-changers ...............................................................9
3. Insulation system of the on-load tap-changers

3.1 Design characteristics .....................................................................................................10
3.2 Insulation system requirements ......................................................................................10
4. Current-carrying system of the on-load tap-changers

4.1 Design characteristics and general requirements ............................................................11
4.2 Temperature rise of contacts ...........................................................................................12
4.3 Short-circuit current test .................................................................................................12
4.4 Use of parallel current carrying paths .............................................................................13
4.5 OLTC overloading ..........................................................................................................13
5. Switching system of the on-load tap-changers

5.1 Admissible switching duties ...........................................................................................13
5.2 Special switching duty ....................................................................................................14
5.2.1 Switching with contact sets, connected in parallel .........................................................14
5.2.2 Switching at winding with coarse tap .............................................................................15
5.3 Switching problems at changing-over of tapped or coarse winding ...............................16
5.4 Transition resistors .........................................................................................................17
6. Mechanical system of the on-load tap-changes

6.1 Basic mechanisms in the tap-changer .............................................................................18
6.2 Motor-drive units and accessories ..................................................................................18
2
7. Operating conditions and protection of on-load tap-changers
7.1 The most important about the operation .........................................................................20
7.2 Protective devices ..........................................................................................................21
8. Mounting of the on-load tap-changers and motor-drive units to the transformer

8.1 Basic mounting diagrams ...............................................................................................21
8.2 Connection of the on-load tap-changer to the motor-drive unit .....................................22
9. Type and routine tests of the on-load tap-changers

9.1 Type tests ........................................................................................................................23
9.2 Routine tests ...................................................................................................................23
9.3 Quality control ................................................................................................................23
10. Selecting the on-load tap-changer ............................................................................................24
11. Appendix ....................................................................................................................................26
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GENERAL
Operating principle of the manufactured by Hyundai Heavy Industries-Bulgaria on-load tap-changers
(OLTC’s), technical parameters and data, that refer to all them and application methods are given in
this general specification. The specific data for each type of OLTC’s are represent in the particular type
specifications.
Transformer manufacturer could select the necessary OLTC from the general specification and the
particular type specifications.
For proper OLTC selection, the transformer manufacturer should fill up an order specification, which
should be confirmed by Hyundai Heavy Industries-Bulgaria (HHI-B). After transformer manufacturer
has already done the order according to agreed specification, he is responsible for the correct OLTC
selection. HHI-B keeps their rights to make changes in the general and particular type specifications for
the manufactured by HHI-B OLTC.
The data in the general specification are referred to OLTC types: RS5, RS6, RS7, RS9, RS12, RS16
and RS18, which operate by the classical resistor type of tap-changer diagram of switching and for
RS21, RS22, RSV5, RSV9 and, RSV20 which are provided with vacuum diverter switches.
Note:
Drawings, diagrams and technical data in this brochure are subject to changes without prior notice.
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The operating sequence of the OLTC con- →
tact elements from Fig. 1 can be represented

by cyclogram or circle diagram as shown on α
1
Fig. 3.
α
α
The circle diagrams are used when the cycle
α
2
of one tap-change operation is counted within α − Ν1
5
4
α
5
one revolution. To follow up the operation 3 α α
α +p
of the change-over selector on Fig. 3a a tap
change operation from 10-th to 11-th position is α
represented. The corresponding angles are: α1 + Ν1
– N1 starts moving; α2 – N1 opens; α3 – N1

-p
Fig. 3a Fig. 3b
closes; α4 – N1 stops moving; α5 – diverter
switching start; αc – operating angle of divert-
er switch (represented enlarged); αp – angle of N1
operation of the change-over selector. N2
When reversing (Fig. 3b), only switching K1

C
of diverter switch (αc) is carried out. This is K1'
+
accomplished by a connector with death zone P
-
of action for angle α0 in the kinematic chain n
between diverter switch and tap selector.

Fig. 3c
The HHIB motor-drive unit (MDU) makes
33 revolutions of the driving shaft for a tap- Fig. 3a – operating sequence shown by circle diagram
change operation from one tap to adjacent Fig. 3b – circle diagram at reversing
one. In this case the opening and closing of Fig. 3c – linear showing of operation by cyclogram
the contact elements, read as rotation number
n, can be represented by the cyclogram on Fig. 3c. The cyclogram is taken for every manufactured OLTC
and the results are recorded in the routine test certificate.
The HHIB diverter switches are high-speed resistor type with arc-quenching in transformer oil. They oper-
ate according to the ”flag” cycle diagram. Operating sequence of the contact elements represented by switch-
ing cyclogram and phasor diagram is shown on Fig. 4.
Fig. 4
Operating sequence of resistor type diverter switch
6
Switching duration for different types of diverter switches is within the range of 28÷45 ms. Switching
oscillograms in both directions are given in routine test certificates. The phasor diagram is represented
for given power factor (cos φ) and reflects the cases of tap-change operation at raising and lowering,
where Uc – step voltage, Ip – through current; Ic – circulating current.
Uc
Ic =
2R
HHIB produces also OLTCs with diverter switches using vacuum interrupters (VIs). The basic scheme
is with three VIs, one resistor R and a switching unit S (Fig. 5).
Fig. 5
Basic scheme of diverter switch with VIs
Main VIs (V1 and V2) interrupt the through current and transition VI (V3) interrupts the circulating
current which is limited by the resistor R to be smaller than the through current. Thereby the electrical
wear resistance of the diverter switch is increased. Diagrams with special design of S and such with two
VIs are applied. They are represented in the technical materials of on-load tap-changers for which they
are related to.
1.2. On-load tap-changer basic units and

transformer tank building-in method
The HHIB OLTCs are designed for trans-

former tank installation (Fig. 6). The OLTC
is immersed in the transformer tank (10) oil
(11), close to transformer active part (16) so
that the leads between tap winding and tap se-
lector are as short as possible.
Fig. 6 OLTC built in the transformer tank
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The basic units of the OLTC are: diverter switch oil vessel 1, diverter switch 3, tap selector 5, change-
over selector 6 and MDU 7. The MDU is side mounted to the tank 10 wall. The MDU motion is trans-
ferred by means of cardan coupler 8, vertical shaft 9, bevel gear 12 and horizontal shaft 13 to the worm
gear 14 on the tap-changer carrying flange. Further the motion is transferred to the vertical insulation
shaft 2 and the mechanism 4, which coordinates the operation of the diverter switch, tap selector and
change-over selector.
The diverter switch has three main components: transition resistors 3.1, contact system 3.2 and spring
energy accumulator 3.3.
The diverter switch oil vessel 1 is protected by oil-flow protective relay 15, connected by a pipeline
17 with the conservator. For draining the contaminated oil out of the diverter switch oil vessel a suction
pipe (siphon) is used (not shown).
The MDU consists of electric motor 7.1, reduction gear 7.2 with hand drive 7.3, electrical control 7.4
and electrical panel 7.5. All these elements are located in the protective cubicle 7.6.
As a high voltage electrical apparatus the tap-changer has five specific systems:
• Insulation system - ensures the insulation to earth and between the elements with different
potential;
• Current-carrying system – contact systems of tap selector, change-over selector
• Switching contact system – diverter switch contacts;
• Mechanical system – MDU, transmission elements and some special mechanisms;
• System for protection and maintenance.
1.3. Basic regulation schemes
The basic regulation diagrams and tap winding connections are shown on Fig. 7. Details for modifica-
tions of these connection schemes are given in the particular OLTC type catalogue.
a – linear regulation
b – reverse regulation at the neu-
tral point
c – regulation at delta connected
windings with coarse taps
d – regulation at delta connected
windings with asymmetrical
tapping windings with two-
phase and a single-phase tap-
changers.
e and f – specific schemes for au-
totransformers regulation.
g – regulation with booster trans-
former.
Fig. 7
Basic regulation diagrams
8
2. Technical characteristics of on-load tap-changers
The OLTCs have the following basic technical characteristics:

• Highest voltage for equipment – the highest phase-to-phase or phase-to-earth voltage r.m.s. for which
the OLTCs insulation is designed. The required by the standard test values of impulse and separate
source AC voltages to earth and where applicable between phases (poles) are determined based on
these voltages. The HHIB OLTCs have the following highest voltages: (41.5; 72.5; 123; 145; 170;
245 and 300) kV. On request special design can be provided.
• Rated frequency – power frequency for which the OLTC is designed. The standard design is for 50
Hz and 60 Hz.
• Rated through current – the r.m.s. value
of the current, which the OLTC is able
to carry continuously and divert without
failure and is in accordance with stan-
dard requirements. The HHIB OLTCs
have the following rated through cur-
rents: 200; 400; 630 (700); 1000; 1200
(1250) A for three-phase (poles) design
and additionally: 1600 A and 2000 A
– in a single-phase (pole) design. The
rated through current is related with:
maximum rated through-current (more
often 20% higher) and short-circuit
withstand current (r.m.s. and peak val-
ues).
• Number of phases (further – phase(s)
will mean pole(s)) – the HHIB OLTCs
have single-phase, two-phase and three-
phase execution.
• Rated level of internal insulation – it
is determined by the values of with-
stand impulse voltages and separate
source AC voltages between two ad-
jacent taps, across the tapping range
and across a part of tapping range.
The following sizes of tap selector
and change-over selector in ascending
withstand voltage values are offered:
K, L, M, N, P.
• Number of operating positions – the
largest number of operating positions Fig. 8 OLTC type Designation
for which the OLTC is designed. Most
often they are up to 35, but at special design they can be increased up to 107. The relation between
number of operating positions and change-over selector type is given in the basic connection dia-
gram.
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The OLTC type designation reflects the above technical characteristics. As an example this is shown
on Fig. 8 for OLTC type RS9.3.
Other important characteristics of the OLTC are rated step voltage and maximum rated step voltage.
These voltages are related with the values of the relevant rated through currents and are considered fur-
ther in relation with the OLTC switching system.
3. Insulation system of the on-load tap-changers

3.1. Design characteristics
HHIB OLTCs have the following design features:

OLTCs from the series RS9, RSV9, RS6, RS7 (single and three phase execution) and RS18 and RSV20
(three phase execution) are with separate oil vessel for the diverter switch. The tap selector and change-
over selector are located below the oil vessel in the pure oil (transformer tank oil) – Fig. 6.
The diverter switch is mounted to the contact elements on the bottom of oil vessel or on oil vessel in-
sulation cylinder. Thus the oil and insulation material of oil vessel secure the diverter switch insulation
to the earth. The OLTC driving shaft is also in pure oil. These design features provide higher reliability
of insulation system.
The OLTCs from series RS5 have the same design but the diverter switch is with three isolated phases.
The diverter switch is unified with those of RS9 but has three sets of contacts separated by radial gaps
providing oil insulation of diverter switch phases.
The OLTC RS21 (single phase execution) and RS22 (three phase execution) operating in SF6 gas en-
vironment have the same design principles.
The OLTCs RS12 and RS16 are with three phase diverter switches. The diverter switch phases are
vertically placed in column one under another and can be star connected or separated. The tap selector
contacts are placed around the diverter switch column. The change-over selector of all those types is in
pure oil.
3.2. Requirements to the insulation system
The main insulation of OLTCs (insulation to earth and between insulation phases) withstands the be-
low test voltages:
Highest voltage for equipment, kV r.m.s. 41.5 72.5 123 145 170 245 (300)
Separate source AC withstand voltage, kV r.m.s. 110 140 230 275 325 460
Impulse withstand voltage ( 1.2/50 μs ), kV peak 250 350 550 650 750 1050
Switching impulse withstand voltage ( 250/2500 μs), kV peak - - - - - 850
On request other values can be negotiated.
All declared withstand voltages are proven by type tests according to item 5.2.6 of IEC 60214-
1;2003.
The exact values of withstand voltages are given in the catalogues for each particular type OLTC (Fig. 9).
The withstand step voltages in the diverter switch with VI are comparatively lower than those of the
corresponding oil diverter switch. Special design measures have to be introduced when higher withstand
voltages are required such as: selection of proper switching diagram, disconnectors connected in series,
non-linear resistors etc.
10
WITHOUT WITH REVERSE WITH COARSE
CHANGE-OVER CHANGE-OVER CHANGE-OVER
SELECTOR SELECTOR SELECTOR
Fig. 9
Main insulation distances
a0 – insulation distance between parts of two adjacent taps (step)

b1 – insulation distance between parts, connected with the ends of the tapped winding (tapping range)
b2 – insulation distance between parts of two adjacent tap selector phases
d – insulation distance between parts, connected with coarse tap ends
c1 – insulation distance between the beginning of coarse winding tap and neutral (outgoing terminal
for delta connected windings)
c2 – insulation distance between parts, connected with coarse tap beginnings of two different phases
For OLTCs with highest voltages for equipment Um=121 kV and above, with regulation other than at
neutral point a partial discharge test is carried out. This is done according to item 5.2.6.9 of IEC 60214-
1;2003.
4. Current carrying system of the on-load tap-changers
4.1. Design characteristics and general requirements
The tap-changer current carrying system consists of current carrying elements connected in series,
fixed and movable contacts of change-over selector, tap selector and diverter switch (Fig. 1). All cur-
rent carrying path elements are designed for maximum rated through current and the guaranteed by the
manufacturer short-circuit currents. Special attention is paid to the movable contact connections. The
contact elements are made of copper or electrotechnical brass (with increased content of copper). In the
HHIB tap-changers all contact elements are coated with silver composition with increased mechanical
endurance regardless of the rated current.
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During manufacturing the following characteristics of the tap-changers are measured carefully and
filled in a routine test certificate:
• Contact pressure of the movable contact systems. It shall be within the limits, prescribed by
HHIB.
• Ohmic resistance of separate units and of the whole tap-changer current carrying path. The limits,
prescribed by HHIB should not be exceeded.
Current carrying path type tests of tap-changers are carried out according to IEC 60214–1:2003.
They are:
• Temperature rise of contacts.
• Short-circuit current test.
4.2. Temperature rise of contacts
The temperature rise test is carried out at current equal to 1.2 times the maximum rated current. The
established contacts temperature rise in respect to ambient temperature has to be reached in accordance
to the criteria described in the standard. The temperature rise of each contact of current carrying path
for oil immersed tap-changers should not exceed 20ºC. For the manufactured in HHIB tap-changers the
temperature rise most often is not more than 15ºC.
For tap-changers operating in SF6 gas such as RS 21 and RS 22 the temperature rise do not exceed
35ºC regardless that for the silver coated contacts the admissible temperature rise is 65ºC.
4.3. Short-circuit current test
According to IEC 60214-1:2003, item.5.2.3 the short circuit current test value is determined from the
curve of Fig. 10 as a multiple of the maximum rated through current.
Fig.10
Short circuit test value
The short circuit current is applied three times with duration of 2 seconds. The initial peak of the test
current shall have a value, equal to 2.5 times (±5%) the r.m.s. value of the rated test short-circuit cur-
rent.
The HHIB tap-changers withstand higher short-circuit currents than the standard requires. For some of
the types this reserve is double. The specified short-circuit values are given in the separate types techni-
cal specifications.
At request for short-circuit current different from the specified, additional test can be carried out and if
necessary design modifications can be utilized.
12
4.4. Use of parallel current carrying paths
In single-phase tap-changers for higher rated through-currents, the design of tap selector and change-
over selector provides two parallel contact sets. This is effective when the transformer tapped winding is
doubled, i.e. exact division of the common current in the two parallel branches is guaranteed (enforced
current split). In this case the HHIB OLTCs RS9.3-I-1600 A and RS6-I-2000 A have to be utilized. In
RS9.3-I-1600 A only the tap selector and the change-over selector have two parallel branches while in
RS6-I-2000 A not only the tap selector and the change-over selector, but also the diverter switch has two
parallel branches. Diverter switches for high currents have three phases (poles) connected in parallel.
The contact systems carrying the current continuously are silver coated.
If transformer tapped winding is not doubled, the current carrying path of the tap selector and change-
over selector is reinforced (RS9.3-I-1200 A).
In some transformers three single-phase tap-changers are mounted. It is recommended to drive them
with one motor-drive mechanism only. An adjustment is done in such a way, that the three diverter
switches operate within 300 ms in the process of switching.
In case of apprehension of short time high circulating currents, the transformer manufacturer should
consult HHIB.
4.5. OLTC ov erloading
According IEC 60214-1;2003 the tap-changers must be able to operate continuously overloaded with
20 % above their maximum rated through current. The OLTC should not restrict the overloading ability
of the transformer according to IEC 60354, IEC 60542 and ANSI C57.91. The HHIB OLTCs meet the
overload requirements, because the temperature rise of all current carrying path contacts is below 20ºC
when tested with current, equal to 1.2 times the maximum rated one. Moreover, the temperature rise of
the transition resistor is below 350ºC during the test with current 1.5 times the maximum rated one for a
half of complete cycle of operation, performed uninterrupted with its driving mechanism.
5. Switching system of the on-load tap-changers
5.1. Admissible switching duties
As it was shown on Fig. 4 the diverter switch main contacts set, operating by “flag” diagram, break the
transformer load current Ip. The arc is extinguished after current passing through the zero and the volt-
age between the opened contact elements starts recovering to a value, determined by the voltage drop,
caused by the current across the transition resistor (Ip.R). The transition contacts break the circulating
current (more often defined by the equation Ic=Uc/2R) added or subtracted with the half of the through-
current, depending on the regulation (tapping) direction. Therefore the tripping current values and recov-
ering voltages of the main and transition contacts depend on the selected values of the transition (current
limiting) resistors. These values are chosen in a way to achieve:
• The guaranteed breaking capacity for each type of tap-changer.
• The guaranteed electrical life of the diverter switch contacts for each type of tap-changer.
The breaking capacity of a particular type of diverter switch is presented as a diagram Uc=f(Ip), shown
on Fig. 11.
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The rated through-current of the tap-changer is I2 with a guaran-

teed relevant step voltage value U2. The tap-changer can be used in
transformers with lower than I2 through-currents at which the step
voltage can be higher than U2. Maximum step voltage U1 is deter-
mined at guaranteed through-current I1. The breaking capacity is
proved by test with double rated through-current (2I1, respectively
2I2) and relevant step voltages U2, respectively U1 according to
item 5.2.2 of IEC 60214-1;2003.
The electrical wear of the diverter switch contacts is considered
in a similar way. Most often the transition resistor value (R) is Fig. 11
determined so that the electrical wear of the main and transition
Diverter switch breaking capacity
contact elements to be approximately equal. In this way certain
number of switching operations at rated through-current is guaran-
teed (Fig.12). Lower electrical wear is ensured at lower through-
currents.
The minimum required number of switching operations at rat-
ed through-current is determined in compliance with IEC 60241-
1;2003, item 5.2.2.1 “Service duty test”. These are 50 000 switch-
ing operations at test with rated step voltage or the same switching
operations with exactly defined extra switching operations, if the
test is carried out with reduced step voltage. The electrical life at
rated through-current of HHIB OLTCs is proved at considerably
larger number of switching operations – from 200 000 to 500 000
depending on the rated through-current and diverter switch type.
Fig. 12
The HHIB OLTCs are tightness tested according to the require-
ments of IEC 60214-1;2003, item 5.2.5.4. This test is combined Switching operations at rated-through
current
with service duty test (electrical wear ability) according to item
5.2.2.1.
In some cases the higher values of step voltage could be achieved by special transition resistor dimension-
ing, but on the account of some decrease of the electrical life of the contacts.
All contentions made so far are valid for diverter switches with VI as well (Fig. 5). In a special design of the
switching contact unit S, the main VI break the through-current at 25 % of the switching operations and at the
remained 25 % - the difference between the through-current and circulating current (for example RSV 5).
5.2. Special switching duty
In some transformers the tap-changers can be subjected to more special switching duties. There are such
cases at single-phase tap-changers for high currents and utilized one or more coarse taps.
5.2.1. Switching with contact sets, connected in parallel
In single-phase diverter switches with rated through-current up to 700 A one phase of a three-phase
diverter switch is used only. For single-phase tap-changer for higher rated through-currents a three-phase
14
diverter switch with two or three phases (poles), con-
nected in parallel is applied (Fig. 13).
In case of a transformer taping winding split in two
branches (pos. a), the two phases of a tap selector and
two phases of diverter switch are used. Such a vari-
ant is applied for RS9.3-I-800/1200 A. Similar ap-
proach is implemented in RS6-I-2000 A, where two
three-phase diverter switches of RS9 type are located
one under another with insulation between them. The
three phases are connected in parallel for each divert-
er switch (pos. b). Three phases, connected in parallel
are used in RS9.3-I-1200 A and RS9.3-I-1600 A with
the purpose to increase the electrical life of the divert-
er switch contacts. Despite of the preliminary adjust-
ment providing opening time of the three main contact
sets within 1÷2 ms, the switching ability is defined by
one main contact set only. The properly dimensioned
transition resistors ensure the current division and arc
existing on the three connected in parallel transition
contact sets. The switching ability and electrical life
of the diverter switch contacts are proved in compli- b
ance with the requirements of IEC 60214-1; 2003. Fig. 13
Parallel connections of contact sets at two
5.2.2. Switching at a winding with coarse tap and three phase diverter switches
The recovery voltage of opened main contact set

grows according to sinusoid with rated frequency af-
ter current passing through zero value. This improves
considerably the arc quenching conditions, for exam-
ple in comparison with diverter switches using reac-
tors. The same refers to the transition contact sets dur-
ing a switching between the adjacent taps (Fig. 14a).
In this case the leakage inductance of one step is in-
significant by value in comparison with the transition
resistors value.
The more complicated case is during the switch-
ing operation from tap K to tap I (Fig. 14b). The fine
tapped winding and the coarse tap are connected in
series to the transition resistors and the inductance
(x1+x2) commensurate with the resistors value (2R).
The current is shifted towards the voltage, and the
recovery voltage becomes considerably steep. Arc
quenching conditions become worse and the guaran-
teed switching ability for tap-changer with reversing
change-over selector is decreased especially if the val- Switching at winding with coarse tap
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EA-740/08 ENG
ues of x1 and x2 are too big. HHIB has the experience and necessary data for different inductance (x1+x2)
and 2R at which secure switching operation is guaranteed. The client has to fill-in the values of x1 and x2
in the Order Specification Sheet when regulation diagram is with coarse tap. If required, additional tests
can be carried out in HHIB test laboratory.
When the values of inductances x1 and x2 are too big, it is recommended a 3G diagram to be used in-
stead of 1G diagram.
5.3. Switching problems at changing-over of a tapped or coarse winding
During the switching of the reverse change-over selector movable contact (Fig. 15a) the tapped wind-
ing remains with free potential for a short time (galvanically isolated from main winding). As a result
potential difference appears between the fixed contact elements connected to the tapped winding and the
movable contact element connected to the main winding, determined by the capacitance Cw between the
main and tapped windings and the capacitance Ce between the tapped winding and transformer.
This potential difference is called recovery voltage Uw. When the change-over selector contacts open
the capacitive current Is caused by above capacitances is interrupted. The recovery voltage and capaci-
tive current may cause electrical discharges. At high values of Is the switching over is attended by typical
discharge noise.
HHIB has an instruction for calculation of Uw and Is in all cases of application. The admissible values
of Uw and Is for HHIB tap-changers are shown on Fig. 15b. In case the calculations show the higher
values it is necessary tie-in resistors (connected according to Fig. 15c) to be used. The role of tie-in resis-
tors is to limit the potential of tapped winding during the switching operation. The tie-in resistors values
are calculated using the formulas, given in the instruction. The values of Cw and Ce have to be stated in
the Order Specification Sheet.
Regulation with reverse winding
Usually the tie-in resistors used in HHIB tap-changers are mounted in the following ways:
• Under the tap selector (Fig. 16a), which is applied most often for RS 9 and RS 6.
• Laterally (Fig. 16b), which is applied for example for RS 12.
On request other ways for mounting of tie-in resistors can be utilized as well.
16
1
5
2
3
7
a) b)
1 – OLTC carrying flange 5 – OLTC carrying flange
2 – diverter switch oil vessel 6 – Insulating cylinder
3 – tap selector 7 - change-over selector
4 – Tie-in resistors 8 – Tie-in resistors
Fig. 16
Disposition of tie-in resistors
5.4. Transition resistors
The transition resistors of HHIB tap-changers are usually executed in two variants:
From punched special steel sheets formed as a band with transverse slots. The band is winded together
with a band from insulation material as a spiral. So formed cylindrical packages are mounted vertically,
to ensure good vertical oil flow around the metal band. The resistor packages are unified for step voltages
up to 1600V and through-currents up to 630 A: up to100 A – 8 Ω; from 100 A to 200 A – 4 Ω; from 200
A to 400 A – 2 Ω and from 400 A to 630 A – 1.3 Ω. For special cases other values are used too.
From resistant wire (constantan). The wire is winded spirally, additionally insulated with packthread
and rolled with insulation band as packages, similar to these from item Fig. 16a above. This variants is
usably for over 1600V and throng currents over 630 A.
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The resistor packages are located in the diverter switch according to the respective design: over the
contact set in RS 9, RS 5 and others, around the contact set – RS 6, over and under the contact set – RS
12 and RS 16.
The transition resistors of all HHIB tap-changers are tested in compliance with IEC 60214-1;2003,
item 5.2.4 at uninterrupted number of subsequent operations, equal to a half of operating cycle with its
driving mechanism at a normal speed and current 1.5 times the maximum rated through-current at the
relevant rated step voltage. The temperature rise of all HHIB OLTCs has considerable reserve compared
with the admissible 350ºC.
The resistors quality is proved also during the breaking capacity tests.
6. Mechanical system of the on-load tap-changers
The mechanical system of the tap-changers consists of (Fig. 6):

• Mechanisms in the tap-changer.
• Mechanisms in the motor-drive unit.
• Mechanisms in the transmission.
6.1. Basic mechanisms in the tap-changer
The mechanisms are of extreme importance for the reliable operation of OLTC. The basic mechanisms
are:
• Contact system mechanism.
• Spring-energy accumulator.
• Mechanism for transformation from rotary to the reciprocating motion for charging the spring-
energy accumulator.
• Mechanisms with intermittent action like Geneva gear type.
• Connector with death zone providing the connection between the diverter switch and the tap selec-
tor.
• Mechanism for change-over selector operation.
Details for the designs of these mechanisms are given in the instructions for mounting and operation
of the respective tap-changers.
6.2. Motor-drive units (MDUs) and accessories
Three basic types of MDUs manufactured in HHIB are:

a) MDU MZ 4.1 with overall and assembly dimensions are shown on drawing MZ4.1/07.3.
b) MDU MZ 4.4 which is in protective cubicle with larger dimensions, front tap position indicator
according to ANSI requirements and protective panels at door opened. Overall and assembly
dimensions are shown on drawing MZ4.4/07.
c) MDU MZ 8 with overall and assembly dimensions according to drawing MZ 8/07. It is used
for driving light types tap-changers (for example RS 18, RS 20) and off-circuit tap-changers
(OffCTC) with motor-drive mechanism.
18
The basic technical characteristics of these types of MDUs are given in the table below:
MDU type MZ4.1 / MZ4.4 MZ8

Rated power of el. motor kW 0.75/1.1 0.37
Rated frequency Hz 50/60 50
Supply voltage V 3AC 400/230 3AC 400/230
Synchronous speed min-1 1500 1500
Handle revolutions per one tap-change operation rev. 33 33
Torque of outgoing shaft N.m 17/24 8
Tapping duration s 4.5 5
Maximum number of operating positions 35 27
Voltage of the control circuit V AC 230 AC 230
Insulation level kV 2 2
Heating power W 250 250
Degree of protection IP54 IP54
Weight kg 80/104 60
The MDUs can have also special design according to the client requirements.
For example:
• Degree of protection IP 65
• Revolutions of driving shaft per one tap-change operation: 0.5; 1; 6; 16.5; 66.
• Number of operating positions – up to 107
The MDUs manufactured in HHIB comply with all requirements of IEC 60214-1;2003, sub-clause 6.
HHIB MDUs have the following features:

• Possibility for automatic control of the MDU with AVR (automatic voltage regulator).
• Parallel operation of two or more MDUs.
• Signal for remote tap position indicator in BCD or binary code, current output of 4-20 mA and
others.
• Possibility for connection of monitoring system for observation and control of the tap-changers.
• Different voltages of the control circuit.
The basic electrical scheme for control of the MDU is shown on drawing №CV5.AP1C.00 sheet 1-3.
At request special schemes can be utilized for particular orders.
The MDU components are shown on the drawings bellow.
• Bevel gear – drawings №157 and №202
• Cardan coupler with or without protective rubber casing – drawings №442.3 and №442.3.1 respec-
tively.
• Remote tap position indicators – drawing №349.2
• Push buttons for remote control
The drawing №236.3 of worm gear with tap position indicator and end mechanical blocking device
is represented here because of its wide application in the HHIB tap-changers.
19
EA-740/08 ENG
The MDUs assembled with tap-changers and transmission elements have mechanical endurance mini-
mum 500 000 tap changing operations according to the requirements of IEC 60214-1;2003, sub-clause
5.2.5.1. The mechanical endurance is proved for 1 000 000 tap-changing operations.
7. Operating conditions and protection of on-load tap-changers
7.1. The most important about the operation
Most of the tap-changers manufactured in HHIB operate built-in the transformer tank in transformer
oil environment. According to IEC 60214-1;2003 the operating temperature range is from –25ºC up to
+100ºC. The upper limit is based on a rated load and maximum ambient temperature of +40ºC. At trans-
former emergency overload, the oil temperature can achieve 115ºC (IEC 60354).
A hole for mounting of a thermal sensor is provided in the tap changer head, which can block the MDU
operation at temperature below –25ºC. In case the thermal sensor is required it has to be explicitly speci-
fied by the client.
HHIB has to be consulted in case special insulation oils or different temperature ranges have to be ap-
plied.
Some special tap-changers, such as RS 21 and RS 22 operate in SF6 gas insulation environment. For
such applications the specific technical requirements have to be clarified with transformer manufac-
turer.
The MDUs and transmission elements most often are mounted in open air and are exposed to direct
atmospheric influences. The MDUs standard design is for temperature range –25ºC to +40ºC.
The MDUs for specific operating conditions are offered as well:
• Humid tropical climate with increased temperature up to +50ºC;
• Arctic climate – temperature down to –60ºC.
The protective cubicles of HHIB MDUs ensure internal microclimate so that reliable operation is guar-
anteed in all climate conditions.
The HHIB MDUs are offered with degree of protection IP54 in accordance with IEC 60259. The spe-
cial design is offered as well for degree of protection IP65.
The diverter switches of all HHIB tap-changers can be easily dismantled and taken out from OLTC
oil vessel for revision and eventual repair by means of hoist (drawing №206), which is always part of
delivery.
For the diverter switches of OLTCs types RS 12 and RS 16 which are with bigger height, the hoist is
with different design, shown in particular catalogues.
The diverter switches of tap-changers (except types RS 12 and RS 16) are fastened to the contact ele-
ments, mounted in the oil vessel by means of bolts screwed and unscrewed with special wrench (drawing
№205), which is always part of delivery.
This mounting way ensures insulation advantages. The insulation driving shaft is located laterally in
pure oil (Fig. 6) and the kinematic chain is not interrupted at opening the diverter switch oil vessel cover.
Thus during the revision, without taking out the diverter switch the following can be inspected:
• The operation cyclogram of the tap-changer, using three metal rods and a diagram similar to the
one from drawing №RS9-10
• The operation sequence of diverter switch set of contacts by means of portable oscilloscope and
exemplary diagram from drawing №RS9-09
The diverter switch oil vessels of the tap-changers usually have up four pipe outlets with flanges, lo-
20
cated on the tap-changer carrying flange:
• R – for connection to the protective oil flow relay.
• S – for oil suction pipe with the purpose of periodical changing of the contaminated oil with pure
one. It is recommended the outlet to be connected with cock pipe with valve at the level of the
transformer foundation for safe oil draining.
• Q – for second outlet if an oil filter is used.
As per standard execution the three outlets are located at intervals of 90ºC. At request their placement
on the carrying flange can be changed in two couples on the left and on the right side.
The standard execution of the worm gear (pos. 14 from Fig. 6) is with outgoing shaft, located tangen-
tially.
At request mounting at intervals of 90ºC can be performed in HHIB.
Eventual mounting deviations of the bevel gears and the shafts (pos. 12 and 13 on Fig. 6) is compen-
sated by the cardan couplers, which admit maximum deviation of 25ºC.
7.2. Protective de vices
The following protective devices proven in operation are used in the HHIB tap-changers:
• Protective oil flow relay. Most often used type is URF25/10-1 – Germany (drawing №203.1) but
other types can be utilized as well.
• Protective membrane, which is used together with the protective relay. At eventual failure in the oil
vessel accompanied with sudden increase of the pressure, the protective relay gives the impulse for
tripping to the circuit breaker, which protects the transformer. The circuit breaker has its own time
for tripping (about 60÷80ms). For this period of time the pressure may increases to values dangerous
for the diverter switch oil vessel. In such case membrane tears off releasing the pressure. For drain-
ing hot gas and oil to a safe place it is recommended a pipeline to be mounted over the membrane.
• According to drawing №174Q pressure relief device can be used instead of the protective mem-
brane
• Other pressure relays also can be used on client request.
8. Mounting of the on-load tap-changers and motor-drive units to the transformer
8.1. Basic mounting diagrams
All HHIB OLTCs are built-in the transformer tank. They are fixed to the transformer cover through
their carrying flange.
Assembly into a separate oil or SF6 gas vessels is performed occasionally.
The lighter types of tap-changers can be assembled to transformer tank cover without dismantling of
main components.
The heavier types are usually assembled after separation of the oil vessel with diverter switch and tap
selector with change-over selector. The oil vessel with diverter switch is mounted to the transformer tank
cover after that the tap selector with the change-over selector are assembled.
For transformers with bell type tank a special design of the carrying flange is utilized as shown on
drawing №RS9.3-07.3.
Other HHIB types OLTCs have similar design of the carrying flange for assembly to the bell type
transformer tanks. More details are given in the respective instructions for mounting and operation.
21
EA-740/08 ENG
The transmission connection between the tap-changer(s) and the MDU can be usually executed for
one, two or three tap-changers assembled in the transformer tank. The configuration and designations
of the transmission (driving shafts arrangement) diagrams are shown on drawing №209.3. The drawing
refers to №RS 9.3, but the diagrams for other types tap-changers are the same.
8.2. Connection of the on-load tap-changer to the motor-drive unit
The tap-changer and MDU have to be assembled at one and the same operating tap position (Fig. 17).
During the factory tests the proper assembly is checked by operating the MDU from one to the other
end of the regulation range. After the tests the disassembled tap-changer and MDU are provided with
mechanical locks on their shafts in order to avoid wrong assembly to the transformer at site.
The compliance between the positions of the tap selector and change-over selector set of contacts and
the MDU positions can be seen from the table enclosed to the drawing.
Position 19 18 17 16 15 14 13 12 11 1 09 8 7 6 5 4 3 2 1
Tap selector contact 9 8 7 6 5 4 3 2 1 K 9 8 7 6 5 4 3 2 1
Currently working
- - +
change over selector - - - - - - - - + + + + + + + +
- + +
contact
Switching direction Lower
Raise
Handle direction Counter-Clockwise
Clockwise
Moving contact direc- Clockwise
tion Counter-Clockwise
Motor drive unit con- From contactor K1 in MDU
trol From contactor K2 in MDU
Fig. 17
Designation of the operating positions and the contacts in the tap selector
22
According to HHIB practice, after carrying out the routine tests in the factory, the tap-changer and the
MDU are led to mid position and disassembled. The outgoing shaft A of the MDU and incoming shaft B
of the tap-changer are mechanically locked by special iron plate. Then they are packed and dispatched to
the client with the locks. The locking plates have to be removed after assembly of tap-changer and MDU
to the transformer and before coupling of the transmission elements.
Usually the vertical and horizontal shafts are delivered longer. The useless extra length is cut out to the
actually needed dimensions.
9. Type and routine tests of the on-load tap-changers
9.1. Type t ests
The type tests on a set of OLTC – MDU of all types are carried out in compliance with the requirements
of IEC 60214-1;2003.
The type tests as well as research and development tests are carried out in the HHIB specialized labo-
ratories.
A big part of the switching tests (item 5.2.2 of IEC 60214-1;2003) and short-circuit current test (item
5.2.3) have been carried out in the internationally recognized laboratories such as “KEMA” – the Neth-
erlands (at 50 and 60 Hz), “ZKU” – Czech Republic and “KERI” – Republic of Korea.
9.2. Routine t ests
The following routine tests are carried out in HHIB factory for each manufactured set of tap-changer
and MDU. The complete check on components compliance and conformity with the technical documen-
tation is performed as well.
1. Measurement of the contact pressure of all movable contacts for compliance with the design docu-
mentation.
2. Measurement of the current-carrying path ohmic resistances for compliance with the factory
norms.
3. Test of operating sequence of the contact sets (sequence of operation).
4. Oscillograms of diverter switch operation in both directions.
5. Mechanical test on the set OLTC-MDU by performing 500÷2000 tap-change operations within the
whole cycle of operation range.
6. Oil tightness test on diverter switch oil vessel at overpressure from inside to outside and from out-
side to inside.
7. Test of the tap-changer insulation to earth, on a tapping range and between two adjacent contacts
(step).
8. Test of the MDU insulation by 2 kV for 1 minute.
The results from the routine tests are written in routine test certificate, which is dispatched to the client
together with the set.
9.3. Quality c ontrol
The quality control system in accordance with ISO9001:1994 was implemented since 1998 and con-
23
EA-740/08 ENG
trolled by TUF Rheinland, TUV-CERT. In a certification audit in compliance with ISO9001:2000 was
held and the company was certified.
The utilized working procedures and documents required by the quality assurance system and their
strict observation guarantee no compromise with HHIB policy regarding OLTCs quality.
10. Selecting the on-load tap-changer
The proper selection of an OLTC is determined by the optimum technical and economical parameters
obtained in order to meet the requirements of transformer tests and transformer reliable operation.
Usually the transformer designer has to select the needed type of OLTC with respective individual
technical parameters.
For this purpose the Order Specification Sheets provided by HHIB have to be filled in and confirmed
by HHIB along with Order Acknowledgment.
The following examples illustrate the proper selection of OLTC in some particular type of transform-
ers:
Example 1
An OLTC for a transformer 20/25MVA with delta connected high voltage winding and regulation
range 66±8x1.25% kV have to be selected.
All necessary information about transformer, OLTC and MDU is presented in the filled in the Order
Specification Sheet (Example 1).
The selected OLTC is result of consideration on the following technical parameters: OLTC type, num-
ber of phases, max. rated through current, highest voltage for equipment Um , tap selector size and basic
connection diagram.
From the technical specification for the series RS 12 OLTC RS12-Δ-200-72.5.10.19.3W is chosen.
Using given values of the capacitances Cw and Ce the recovery voltage and capacitance current can
be calculated:
From the Fig. 15c could be estimated that tie-in resistors should be used. Their values are calculated
in accordance with the HHIB instructions and it is specified that two tie-in resistors of 120 kΩ have to
be used for each phase.
The fitting will be done in conformity with client requirements, according to the Fig. 16b.
Motor drive unit MZ4 is with supply voltage AC 400/230V and there is a connection to electronic volt-
age regulator 4÷20 mA.
24
Example 2
An OLTC shall be selected for three-phase transformer 50.4 MVA with regulation in high voltage star
connected winding 161±15 % kV (±13 taps) with coarse change-over selector at neutral point. The filled
in Order Specification Sheet is shown as (Example 2). The data is verified by HHIB and the selection of
OLTC R9.3-III-400-170/L-14.27.1G is confirmed. The calculation of tie-in resistors shows:
As it is shown on Fig. 15 for the selected OLTC there is no need to use tie-in resistors.
The switching of the winding with coarse change-over selector (according to 5.2.2) is more special.
The fine tapped winding and the coarse tap are connected in series and the inductance value is X1+X2=4.5
Ω The leakage inductance 14.3 mH is relatively high and it may cause longer arcing time of the auxiliary
contacts during the process of switching. According to HHIB experience and accumulated data from dif-
ferent tests it is necessary increased value of the current limiting resistors 2 pcs x 6 Ω to be selected.
On request pressure relief valve Qialitrol is mounted on the OLTC head. It’s installed at the place of
protective membrane (7.2).
The motor drive unit is equipped with terminals for OLTC digital remote position indicator – BCD-
code. There are also terminals for 4÷20 mA signal to the automatic voltage regulator (AVR).
Example 3
An OLTC for single-phase transformer with capacity of 166.7 MVA and a voltage of 345/√3±8x1.25
% kV has to be selected.
From the filled in Order Specification Sheet (Example 3) an OLTC R9.3-I-1200-245/P-10.19.3W is
selected. With given values for Cw and Ce the recovery voltage and inductance current are calculated:
In accordance with the Fig. 15, for the cases when Uw is lower then 35 kV there is no need of using
the tie-in resistors. The motor drive unit MZ 4.1 is selected according to a special electrical diagram for
60 Hz with motor supply 3AC and operating voltage 110 AC.
Terminals for 4÷20 mA signal are provided for automatic voltage regulator. The MDU is equipped
with terminals for OLTC digital remote position indicator - BCD-code with voltage DC 220 V on the
diode matrix.
25
EA-740/08 ENG
11. Appendix
1 Motor-drive unit MZ-4.1 – mounting and dimensions №MZ-4.1 / 07.3
2 Motor-drive unit MZ-4.4 – overall and fixing dimensions №MZ-4.4 / 07
3 Motor-drive unit MZ-8 – mounting and dimensions №MZ-8 / 07
4 Motor-drive unit MZ-4.1 – electrical diagram №CV5.AP1C.00 sh.1
7 Bevel gear №157
8 Bevel gear №202
9 Cardan coupler №442.3
10 Cardan coupler №442.3.1
11 Remote tap position indicator – µSI 02 №349.2
12 Push buttons for remote control №436
13 Worm gear with a tap position indicator №236.3
14 Hoist №206.1
15 Special wrench S14 №205
16 Sequence of operation diagram taking №RS9 – 10
17 Diagram for diverter switch oscillograph recording №RS9 – 09
18 Protective relay №203.2
19 Pressure relief device №174.Q
20 Mounting of OLTC RS 9.3 in the bell type transformer tank №RS9.3 – 07.3
21 RS 9.3 – driving shafts arrangement №209.3 sh.1
22 RS 9.3 – driving shafts arrangement №209.3 sh.2
23 Order Specification Sheets Example 1 ÷ 3
26
C
164
A
140 O 158
Lx Lx
112 5 6
134
95.5
75
75
O
Ø56
75
8 M10 8
Ø100
4
Ø56
95.5
140 Ø63.5
4
100
B
L
C
85
LB
B
2 Ø55
510
Ø25
2 VARIANT I
340 107
268
5
Ø2 137
VARIANT II
70
200
856
350
570
4xØ21
B
288
83
560(660)
164
OPTIONAL 520 (620) A
EARTING
260 SCREW M12
350 32.5 A
10
47.5
50 50 50 43
360
148
106
122
40
335
50
15
120 110 120

4xØ36 3xØ22
520
548
145
535
Lx=A-300 mm /RS-12,RS-16/
Lx=A-315 mm /RS-5,RS-9/
LB
430 OPENED BY 90° LB=B-515 mm ; L B = ; max = 25°
cos
800 OPENED BY 180° =1° - acceptable vertical deviation
O-O is OLTC - AXIS
WEIGHT - 86 kg.
MOTOR-DRIVE MECHANISM MZ-4.1 N° MZ-4.1/07.3

MOUNTING AND DIMENSIONS 2008
C A
164 O
Lx 140 158
Lx
112 5 6
134
95.5
75
75
O
8 Ø100 M10 Ø56
75
8
Ø56 4
95.5
140
Ø63.5
4
~100
C B
L
85
L 3
B
B
2 400 Ø55
50
Ø25 1
VARIANT I
2
288
226
9 9 20 0 4
13 14 15 16
140
12 17
11 18
10
9
19
20
8
21
7
22 23
56
24 25 26
33 =1
4
70
VARIANT II
2
27
1
HHIB
350
625
350
920
D
HHIB
B
EARTING
SCREW M12 560 (660)
(620)
10
520 B
4xØ21
120
140
170
145
272
320
50
370
400
570
610
602
Lx=A-300 mm /RS-12,RS-16/
Lx=A-315 mm /RS-5,RS-9/
LB
LB=B-525 mm ; L B = ; max = 25°
cos
=1° - acceptable vertical deviation
O-O is OLTC - AXIS

348 OPENED BY 90°
WEIGHT -104 kg.
905 OPENED BY 180°
MOTOR-DRIVE MECHANISM MZ-4.4 N° MZ-4.4/07

MOUNTING AND DIMENSIONS 2008
LB
L B=B-445 mm ; L B = ; max = 25°
cos
1 2 3 4 5 6 7 8
X1:7 230V X1:4
QFS
1SKF 1
A 3x400V,50Hz A
R I> 2
S KA1 1 KA2 1
/1.E3 2
T 2 2
N
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X3:7
X3:8
X3:9
X3:1
X3:2
X3:3
X1:1 5 6 8 PE
QFM 44 X3:5
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X3:10 22
/1.E6 S"L-R" S"L-R" /1.E6 14
QFM 2 4 6 23 13
X3:11
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B /1.E8 I> I> I> B
X3:4
K6 K6
1 3 5 S15 a 11 21
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K4 K4 K4 K3
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K5
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S11 1 SQ1 :c SQ2 :c S12 3 S13 c2
K1 K2 S11 5 S12 7
/1.E4 2 /1.E3 :d /1.E5 :d /1.E5 4 /1.E8 d2
K5
7 7 /1.E4 6 /1.E5 8 14 12
/1.E3 /1.E4
2 4 R4 R2 8 8 34
K5 /1.E6
-K3 /1.E6
1 3 R3 R1 61 61 31
/1.E2 K2 K1 11
D /1.E4 62 /1.E3 62
D
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/1.E2 :A1 :A1 /1.E5 :A1 :A2 :C1
:A2 K1 K2 :A2 K5 K6 QFM
:R :S :T /1.E3 /1.E4 /1.E6 /1.E7 /1.E8
:A2 :A2 :A2 :A1 :C2
M X1:7 X1:8 X1:8
3
~
PE S15
K3 QFS K1 K2 -K4 K5 K6 QFM S13
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I>
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/1.B6 12 /1.B1 3 4 /2.C3 :c1 :d1
1 1 31
I>
/1.D1 :R3 :R4 /2.B4 14 11 /1.C2 2 /1.B1 2 /1.C4 32 12

/1.B7 21 24 /1.B1 5 6 /2.B5 :a1 :b1
61 3 3 13
I>
/1.C8 62 12 /1.C2 4 /1.B1 4 /1.C7 14 /1.D8 21 24

E /1.D1 1 2 /1.C2 5 6 /1.B1 5 6 /1.C8 43 44 22 22 E
31 34 31 32
/1.D1 3 4 /1.D2 7 8 /1.C1 7 8 /1.C4 81 82 /1.D6 31 34
32 /1.B3 43 44
/1.C8 53 54 /1.C3 53 54 /1.C5 53 54 /1.C3 71 72 32
41 44 /2.B5 21 22
73 74 71 72 61 62 /2.C5 41 44
S3 42 /2.B4 13 14
83 84 83 84 SQ2 51 52 42
/1.C6 /1.C4 S12
S11 SQ1 /1.B6 21 22 C1 C2
Q3 /1.C5 :c :d /1.D6 8 7 13 14 /1.D8 S14
:c :d /1.B7
/1.B2 a1 c1 /1.D5 6 5 /1.D3 /2.C5 :a :b /1.D5 3 4
:a :b
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d1 /1.D3 1 2 /2.C5 :c :d
/2.C4 33 34 SQ3 /1.B8 :a :b
:c :d
/1.B8 :a :b
F F
CV5.AP1C.00
MOTOR DRIVE MZ 4.4
CIRCUIT DIAGRAMA 12 .2008 1/ 3
1 2 3 6 7 8
F
E
B
A
X1
PES
PE
XPE
M:PE
S13:c,d
S13:c,d
S12:3,4
S14:a,b
S14:a,b
PE
S11:1,2
EK:PE
QFM:2
R
1
30
1
1
2
QFE:1
3
31
QFS:1
X1:9
4
QFM:4
32
5
/1.C2
-EK
QFE
QFM:6
-SK1
X3:12
S T
230VX1:3
6
X1:10
I>
2
1
2
1
33
K1:A2
7
2
2
QFM:c2
8 X3:14
N
XS:N
9
/1.E2
X3:37
X3:36
EL
X3:37
QE
EK:N
:BK
X1
X2
:BW
10
PE
X3
X3:13
S"L-R":24
:B
XS :A
1
K6:11
S"L-R":14
3
2
K6:21
S3:14
3
3
3
SQ3:a
4
QFS:2
SQ3:b
5
QFM:C1
S13:b2
KA1:2 6
K4:13
S3:13 X3:23 -S3 X3:22
SKF:1 7
41
42
/1.E6
S3:22 -S3
KA2:2 8 X3:25 X3:24
33
34
/1.E6
S"L-R":13
KA2:1 9
/1.E3
4
QFS
QFM:43 X3:20
10
12
X3:19 X3:31
K3:83
11
14
11
S12:7
QFE:2 X3:16 QFM X3:15
12
13
14
QE:BK /1.E8
XS:A QFM
13 X3:18 X3:17
21
22
/1.E8
SK1:2
14 SQ1
EK:A X3:27 X3:26
:a
:b
QFM:13 /1.E3
15
X3:29 SQ2 X3:28
5
:a
QFM:14
:b
16 /1.E4
/1.E8
S13
QFM:21 X3:33 X3:32

17
:c1
:d1
/1.E8
QFM:22
S13
18 X3:31 X3:30
:a1
:b1
QFS:11
19 K3
X3:35 X3:34
73
74
QFS:12 /1.E2
20
QFS:14
21
S3:41
22
6
6
S3:42
23
S3:33
24
S3:34
25
S15 a c
b d
SQ1:a
26
SQ1:b
27
SQ2:a
28
7
7
SQ2:b
29
S13:a1
30
CIRCUIT DIAGRAMA
MOTOR DRIVE MZ 4.4
S13:b1
31
S13:c1
32
S13:d1
33
K3:73
34
8
8
K3:74
35
12 .2008
QE:BW
EL:1 36
X1:9
2/3
EL:2 37
CV5.AP1C.00
F
E
B
A
D
1 2 3 4 5 6 7 8
P K
A A
DESIGN DESCRIPTION
EL Lighter
EK Heater 250 W
:0 K1/K2 "LOWER RAISE" motor contactor
:n :1
:0 K3 "STOP" contactor
:2 K4 "Step control"
:1 :n K5,K6 Auxiliary relays
M Driving motor
PC Cycle counter
B Em Em QFM Motor circuit protection B
Q3 Hand-operated protecting device
QE Door actuated switch
QFE Auxiliary circuit protection
QFS Contr.and heat.circuit protect.
S3 "LOCAL REMOTE" selector switch
S"L-R" "LOWER RAISE" door control whit built
HQ1 into Control circuit supply indicator
S13 Auxiliary step-cicle switches
S11/S12 Step-cicle control swithes
C SB Emergency STOP button with buil C
HLA info breaking light indicator
SK1 Heating thermostat NC
SQ1 1 level LOWER UPPER
Em:k-1a
Em:k-1
Em:k-1b
1 Em:1
1 Em:0
2 Em:0
3 Em:n
2 Em:1
SQ2 limit switches
XE3
XE5
n+1 Em:n
SQ3 2 level Cut-Off limit switches
XS Outlet 220VAC/10A
X1 Input terminal block
X3 Remote control terminals
D PTM:resistor type PTM:N/O contact XE3-XE5 Positions terminal blocks D

External elements
18 SKF oil temperature in diverter switch
____ x _____ 6 W "break-before-make" ___ 1
KA1 current overload
(max.number - 2)
KA2 local control the transformer
____ x _____ W "make-before-break" ___
(max.number - 2)
E P Potentiometric contact rang E

K Contact rang for position
F F
CV5.AP1C.00
MOTOR DRIVE MZ 4.4
CIRCUIT DIAGRAMA 12 .2008 3/3
1 2 3 6 7 8
Mounting dimentions for
step indicator unit µ SI-02
72
µ SI-02
67
72
72
ELECTRUM
72
83
67
STEP INDICATOR
TYPE µSI-02
68
220V AC
67
POWER SUPPLY 220V AC 68

INPUT 27 steps
INPUT 26 x 6 W
140
140
1 23 4 5 6 7 8
X1 13 X1 23 3 X1
87
64
X2 14 X2 24 4 X2
4xM4
87
140
64
140
150
STOP LOWER RAISE AUTOM.

MANUAL
100
78
HYUNDAI
HEAVY INDUSTRIES CO.
BULGARIA
128
PUSH BUTTONS N° 436

FOR REMOTE CONTROL 2008
9 10 11 12 13
211
4
95.5
2
1
10
4
0.5
16
Ø56
Ø105
Marks for
1. BASE
"Normal Position"
2. GASKET
3. BOX
4. SHAFT WITH A SLЕЕVE
3
5. WORM WHEEL
6. LOCKING SECTOR
7. UPPER SUPPORT
8. COVER
9. TAP POSITION WINDOW
10. COVER
11. GENEVA WHEEL WITH POSITION INDICATOR
12. WORM
13. LOCKING ROD
WORM GEAR BOX WITH A N° 236.3

TAP POSITION INDICATOR 2008
46.5 150
975
240 40
166
2xØ25
52
111
122
N° 206.1
2008
5
125
4
3 3 9 2
A A
:
5-20
1
max 2 4xØ14 ~Ø50
A-A
8 7
6
294
8 10
4xØ14
280
158
130
280
7
280 345
294 359
MOUNTING OF OLTC RS9.3 N° RS9.3-07.3

FORK VERSION 2008
Example 1
“HHI Co.Bulgaria” Serial № Customer:
Filled in by
HHI Co Customer order N:
Factory order №
Bulgaria
Man-sheet pos. № Delivery date:
20/25 Tap winding connection

Rated power: MVA Overload – according to IEC 60354/91
Constant Decreasing from position №

Transformer data
66 50
Related voltage kV Rated frequency Hz
8x1.25 17
Tapping range   in taps
Operation : Generator Network Furnace Electrolysis
Value of leakage impedance (Only in case of coarse tap winding!)
- coarse tap winding x = j ohms- fine tap winding x= j ohms Change – over selector
4050 coarse reversing
Value of the - between main and tap winding CW = pF
capacitance
- between tap winding and transformer tank Ce =
1116
pF without
Mounting of the OLTC to transformer
Mounting on the active part / fork / Other kind of mounting / on the transformer cover /
Operating and test voltages Max operating voltage kV Test voltage , kV
Operating and test voltages
Impulse 1.2/50 s Power frequency

Transformer line terminal 350 140
OLTC to earth 350 140
Voltage stress in kV during H.V. transformer tests
Between tap in device and preselected tap ao 120 30
Across fine tap winding b1 180 50
Between ends of the tap windings of different phases b2 350 140
Across coarse and fine tap winding c1 -
Between beginning in the coarse tap winding of different phases c2 -
Between the beginning and the end of the coarse tap winding d1 180 50
825 In case of variable Ust :
Step voltage in the phase Ust = V
On-load tap-changer data
Ust max = V Ust min = V

140 Phase designation
Max through tapping current Imax = A
A, B, C Other
Drain pipe arrangement view from the preselector side Left Right
X, Y, Z …………………………
Climatic execution Moderate Arctic Tropical U, V, W …………………………
300 P2 I
Location of driving shafts drw. N 209 ; 209.3 ; or arrangement variant
Designation of Max number of one way effective turns Designation of mid “RAISE” means control of OLTC
operating 1 9a,9,9b 1
positions corresponds to positionN: positions N: towards position N:
Dimension of OLTC: Legends Documentation : language x
1596 240 English English x3
h= mm drw № (language) files
Protective relay - contacts - N.O. N.C. C.O.

x Pressure relief device yes no
Type of OLTC ( see standard designation in Example RS9 III 400 110/M 10.19.1 G
corresponding catalogue) RS12 Δ 200 72.5 10.19.3 W
For chosen type of OLTC
Notes: Please fill in the values or mark in the square.
1. The tie-in resistors to be mounted on the level of phases.
HYUNDAI HEAVY INDUSTRIES Co. Bulgaria Order specifications for Customer sign. / Date
№ OD 01-00-04 OLTC
Example 1
“HHI Co.Bulgaria” serial № Customer:
Filled in by
“HHI Co-Bulg Factory order № Customer order №
Man-sheet pos.№ Delivery date:

MOTOR DRIVE MECHANISM DATA
Designation of operating positions
Max. number of eff. turns Mid-positions: Automatic passage through “RAISE” means control
1 9a, 9b 1
Position: 9a, 9, 9b positions(s) towards pos.:
Motor circuit: Standard: 400V 50Hz 3 AC/N
Others: V Hz 3 AC/N 3 AC
Control circuit: Standard: 230 V 50 Hz AC (Ph-N)

Other V Hz AC 2 AC DC
Heating circuit: Standard supply voltage (230 V 50 Hz AC)
Add. heater with hygrostat Control switch on/off

Lighting: Standard movable lamp and door operated switch Hand operated switch
Position transmitter for remote position indication and/or parallel control:
Resistor contact range(P) 18 step resistors x 6 
Resistor contact range(P) step resistors x 
Contact range(K) 1 break before make, 1 make before break
Decadic contact range(D) Contact range - BCD – output(BCD) 1
Climatic execution: Moderate Arctic Tropical

Cabinet door drive hinge: Left Right
Legends (language): English
Documents-language x folds: English x3
LX= mm a1= mm c= mm Arrangement

P2
According
Driving LB= mm a2= mm d= 2200 mm Draw.№ 300
shafts Variant I
LB= mm b = 800 mm =  According
Draw.№ 300
Remote position indication: Standard - Digital for resistor contact range
Pointer instrument Aux.transformer: Prim.Voltage V; Sec.voltage VDC
Digital (for BCD-code) Measuring converter output mA, supply voltage 220 V AC
Electronic voltage regulation/parallel control: Isn’t standard delivery
Please specify:
*Please fill in the values or mark in the square !
Notes:
HYUNDAI HEAVY INDUSTRIES Co. Order specifications for motor-drive Customer sign. / Date
Bulgaria
mechanism and accessories
№ ОD 01-00-04
Example 2
Filled in by
Factory order №
Bulgaria
50.4 Tap winding connection


Transformer data
161 50
13x1.15 27
2.25 2.25
capacitance
500
pF without

Transformer line terminal 379.5/v3 kV 750 325
OLTC to earth 195.5/v3 kV 750 325
Between ends of the tap windings of different phases b2 250 60
Across coarse and fine tap winding c1 300 100
Between beginning in the coarse tap winding of different phases c2 300 100
Between the beginning and the end of the coarse tap winding d1 250 60
1073 In case of variable Ust :

A, B, C Other
X, Y, Z …………………………
209.3 P1 I
operating 1 14 1
1926 310.3 English English x3
corresponding catalogue) RS9.3- III - 400 -170/L 14.27.1 G
№ OD 01-00-04 OLTC
Example 2
Filled in by

1 1
Position: 14 positions(s) towards pos.:
Others: V Hz 3 AC/N 3 AC


Resistor contact range(P) step resistors x 
Contact range(K) break before make, make before break

LX= mm a1= mm c= mm Arrangement

P1
According
Driving LB= mm a2= mm d= 2000 mm Draw.№ 209.3
shafts Variant I
LB= mm b = 1500 mm =  According
Draw.№ 209.3
Digital (for BCD-code) Measuring converter output 4...20 mA, supply voltage 220 V AC
Please specify:
Notes:
Bulgaria
№ ОD 01-00-04
Example 3
Filled in by
Factory order №
Bulgaria
OLTC DATA
1ph. 166.7 Tap winding connection

Transformer data
345/v3 60
8x1.25 17
capacitance
1200
pF without

Transformer line terminal 379.5/v3 kV 1050 460
OLTC to earth 195.5/v3 kV 1050 460
Between ends of the tap windings of different phases b2
Across coarse and fine tap winding c1
Between beginning in the coarse tap winding of different phases c2
Between the beginning and the end of the coarse tap winding d1
4312.5/v3 In case of variable Ust :


A, B, C Other
X, Y, Z …………………………
209.3 P2 II
operating 1 9a,9b,9c 1
2224 491.3 English English x3

corresponding catalogue) RS9.3 I 1200 245/P 10.19.3 W
№ OD 01-00-04 OLTC
Example 3
Filled in by

1 9a, 9c 1
Position: 9a, 9b, 9c positions(s) towards pos.:
Others: 400 V 60 Hz 3 AC/N 3 AC

Other V110 V 60 Hz AC 2 AC DC
Other 230 V 60 Hz AC 2 AC DC

Contact range(K) 1 break before make, make before break

LX= 1000 mm a1= mm c= mm Arrangement

P2
According
Driving LB= 2000 mm a2= mm d= mm Draw.№ 209.3
shafts Variant II
LB= mm b= mm = 15  According
Draw.№ 209.3
Digital (for BCD-code) Measuring converter output 4...20 mA, supply voltage 220 V AC
Please specify:
Notes:
Voltage of diode matrix 220 V DC.
Bulgaria
№ ОD 01-00-04

OLTC Technical Data-1

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ON-LOAD TAP-CHANGERS

MAIN CHARACTERISTICS AND TECHNICAL DATA

Main characteristics and technical data. General .................................................................................4

1. Application and operating principle

2. Technical characteristics of the on-load tap-changers ...............................................................9

3. Insulation system of the on-load tap-changers

4. Current-carrying system of the on-load tap-changers

5. Switching system of the on-load tap-changers

6. Mechanical system of the on-load tap-changes

8. Mounting of the on-load tap-changers and motor-drive units to the transformer

9. Type and routine tests of the on-load tap-changers

10. Selecting the on-load tap-changer ............................................................................................24

11. Appendix ....................................................................................................................................26

The operating sequence of the OLTC con- →

tact elements from Fig. 1 can be represented

– N1 starts moving; α2 – N1 opens; α3 – N1

operation of the change-over selector. N2

When reversing (Fig. 3b), only switching K1

of diverter switch (αc) is carried out. This is K1'

between diverter switch and tap selector.

1.2. On-load tap-changer basic units and

The HHIB OLTCs are designed for trans-

Fig. 6 OLTC built in the transformer tank

1.3. Basic regulation schemes

The OLTCs have the following basic technical characteristics:

3. Insulation system of the on-load tap-changers

HHIB OLTCs have the following design features:

3.2. Requirements to the insulation system

a0 – insulation distance between parts of two adjacent taps (step)

4. Current carrying system of the on-load tap-changers

4.1. Design characteristics and general requirements

4.2. Temperature rise of contacts

4.3. Short-circuit current test

4.5. OLTC ov erloading

5. Switching system of the on-load tap-changers

5.1. Admissible switching duties

The rated through-current of the tap-changer is I2 with a guaran-

5.2. Special switching duty

5.2.1. Switching with contact sets, connected in parallel

The recovery voltage of opened main contact set

5.3. Switching problems at changing-over of a tapped or coarse winding

Regulation with reverse winding

5.4. Transition resistors

6. Mechanical system of the on-load tap-changers

The mechanical system of the tap-changers consists of (Fig. 6):

6.1. Basic mechanisms in the tap-changer

6.2. Motor-drive units (MDUs) and accessories

Three basic types of MDUs manufactured in HHIB are:

MDU type MZ4.1 / MZ4.4 MZ8

HHIB MDUs have the following features:

7. Operating conditions and protection of on-load tap-changers

7.1. The most important about the operation

7.2. Protective de vices

8. Mounting of the on-load tap-changers and motor-drive units to the transformer

8.1. Basic mounting diagrams

8.2. Connection of the on-load tap-changer to the motor-drive unit

9. Type and routine tests of the on-load tap-changers

9.1. Type t ests

9.2. Routine t ests

9.3. Quality c ontrol

10. Selecting the on-load tap-changer

1 Motor-drive unit MZ-4.1 – mounting and dimensions №MZ-4.1 / 07.3

2 Motor-drive unit MZ-4.4 – overall and fixing dimensions №MZ-4.4 / 07

3 Motor-drive unit MZ-8 – mounting and dimensions №MZ-8 / 07