RUN-OLTC01 Transformer On-Load-Tap-Changer Tester

User Manual

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 Content
I. Overview: ...................................................................................................................................... 3
II. Feature: ......................................................................................................................................... 3
III. Technical Parameter:..................................................................................................................... 4
IV. Panel Introduction ......................................................................................................................... 5
V. Operation Instructions ................................................................................................................... 6

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I. Overview:

The on-load tap-changer is the only moving part connected to the transformer circuit, so the detection
of the on-load tap-changer has attracted more and more attention. In the "Power Equipment Handover and
Preventive Test Regulations", it is required to check the action sequence of the on-load tap-changer, measure
the switching time, etc. The instrument is mainly used to measure the transition waveform, transition time,
transition resistance value of each moment, and three-phase synchronicity of transformer on-load tap-
changer.

The instrument has a high degree of intelligence, all English menu prompts, and simple operation. The
instrument is small in size, light in weight, and has strong anti-interference ability, which greatly reduces the
labor intensity of on-site staff. It is an ideal instrument for power generation and power supply units and
transformer manufacturing industries to ensure safe production and improve product quality.

II. Feature:

1. Large Output Current, light weight

2. 7-inch high resolution LCD touchscreen, easy on-site operation. Good visibility even under strong light.

3. YN, Y, △ type transformer, display resistance value directly.

4. A complete protective circuit, good reliability.

5. The waveform display automatically adjusts the resistance, time value and amplitude according to the
sampling value.
6. Internal data storage up to 500 sets.
7. Bluetooth and USB Port for data storage and PC communication.
8. Built-in thermo-printer.

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III. Technical Parameter:

Item Parameter Inaccuracy

Output current 1.0A, 0.5A,0.2A

0.3Ω～20Ω(1.0A)

5Ω～40Ω(0.5A) ±(5% readings±0.1Ω)

Transition Resistance Range
20Ω～100Ω(0.2A)

Transition Period 0～320ms ±(0.1% reading±0.2ms)

Sampling Rate 20kHz

Open Circuit Voltage 24V

Display 7-inch color LCD touch screen

Data Storage 500 sets

Operating Temperature -10℃～50℃

Relative Humidity <85%RH，non-condensing

Power supply AC 220V±10%，50Hz±1 Hz

Dimension 360*290*170（mm）/360*290*170（mm）

Weight Instrument box：6.15 KG Accessories Box: 4.55 KG

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IV. Panel Introduction

1. Fan: exhaust port.

2. A, B, C, N correspond to A, B, C, N of the transformer respectively.

3. AC220V: The power input port of the whole machine is equipped with an AC socket, a safe and a switch.

4. Grounding post: It is used for grounding the shell of the whole machine.

5. Cooling holes.

6. 232 serial port

7. USB port: Data Transfer

8. Printer: High-speed printer, print test results.

9. Display: 7-inch high-brightness LCD display.

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V. Operation Instructions

Precautions during operation:

⚫ Before use, the ground terminal of the instrument must be connected to the ground wire.

⚫ During the test, it is not allowed to remove the test lead.

⚫ When testing with windings, the non-test end of the transformer should be short-circuited to ground in three
phases.

⚫ For the on-load switch that has not been moved for a long time, the switch should be switched several times
before the test to remove the oxide layer and impurities on the surface of the contact.

(1) Test method with winding

1. Remove the three-side leads of the transformer under test, and short-circuit the non-test terminals (usually the
medium-voltage side and the low-voltage side) to three-phase grounding. Clamp the yellow, green, red and black test
clamps to the A, B, C three-phase and neutral points of the voltage regulation side (usually the high voltage side)
bushing of the transformer under test in turn, and then connect the other end of the test wire to the yellow, The green,
red and black wires are connected to the A, B, C and N terminals of the instrument respectively. The following figure
shows the wiring methods of different types of transformers:

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2. Wiring as per above diagram, power on, the tester will do self-check, and then enter into Homepage

3. Click “TEST” to set parameter

Name: test product name

Direction: Upwards or Downwards

Phase: Single or Three phase

Connection Type: YN/Y/△

Current: 3 current selections: 0.2A/0.5A/1.0A

Range: 1.0A（1Ω～20Ω）

0.5A（5Ω～40Ω）

0.2A（20Ω～100Ω）

Grade: 00-95

Trigger Resistance: After the test current is selected, there will be a preset trigger resistance, which generally does not
need to be modified; (when a false trigger occurs, the trigger resistance needs to be increased to reduce the trigger
sensitivity; when the trigger cannot be triggered, the trigger resistance needs to be reduced. some, improve trigger
sensitivity)

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4. When parameter setting completed, Click “TEST”

The three curves will change based on the test data. Because the instrument has a charging process for the
windings and switches, the curve will change from small to large. After the three-phase curves are stable, press
"TEST". At this time, the mechanism can be manually or electrically operated (please Switch the switch within two
minutes. In order to protect the equipment, the duration of each measurement of the output current is 2 minutes. If
more than two minutes, the output will automatically stop and switch back to the parameter setting interface). After
the action is completed, the LCD screen will automatically display the action waveform. Press The buttons at the
bottom of the screen can adjust the magnification of the curve and move it to the left and right, which is convenient for
viewing the waveform.

Next Grade: Automatically switch to the next grade, press "TEST" to start a new test

Upward: Press "UPWARD" to switch to “DOWNWARD”, and vice versa; this way, you don't need to go back
to the parameter setting interface to make settings

SAVE: save the test data to the device

PRINT: Print test result

AUTO: When the automatic button displays "Auto", the instrument automatically determines the waveform data.
Generally, do not press this button first. When the automatically determined data cannot meet the requirements, press
this button to manually set the value to be printed. (Only when the data processed by the automatic discrimination
method is incorrect, it is recommended to use the manual processing method, and it is not recommended to use the
manual method under normal circumstances.)

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(2). No winding test method

Connect the test lead yellow, green and red test clamps to the voltage regulating switches X1 (A1), Y1 (B1), Z1 (C1)
respectively, and connect them to the corresponding X2 (A2), Y2 (B2), Z2 (C2) by short-circuit lead, the black test
clamp is connected to the neutral point, and the rest of the operation steps are the same as those of the winding test.
Compared with the test without winding, the action time of the former is long, about 3-7 ms.

Wiring diagram as below:

Note: A, B, C three-phase moving contacts are short-circuited and then connected to the neutral terminal of the
instrument

(3). Test method for transformers whose neutral point is not drawn out of the Y-connection of the
voltage-regulating side winding

The test product of this structure cannot lead out the neutral point without hanging the core, so it is necessary to
test every two phases, for example, two phases A and B. The wiring method is shown as below, and C is regarded as
the neutral point. The operation steps are the same as the test method with windings, except that only two sets of
waveforms and data are displayed on the LCD screen at a time. The analysis of the data is the same as the analysis
method of the transformer with the neutral point, but the transition resistance value needs to be converted: set the
measurement value as R', the actual value is R, then R=1/3R' for two-phase measurement (for example, R=1/2R' for
single-phase measurement). After the A and B phases are measured, the A can be used as the neutral point to measure
the B and C phases, or the B phase can be used as the neutral point and the A and C phases can be measured. The
wiring method and data analysis are the same.

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(4). Test method for transformers with delta-connected windings on the regulating side
The test wiring method is the same as below. The operation steps and data analysis are the same as other transformer
test methods, except that the transition resistance value needs to be converted: set the measured value to be R' and the
actual value to be R, then when two-phase measurement is performed, R=R', single-phase measurement. R=2/3 R' for
phase measurement.

(5). Data Query

Click ”WAVE” to check waveform data

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(6). System Setting

Filter setting: Set the filter level of the test waveform, 0-60, preset 30; the larger the number, the stronger the filtering
ability. When the waveform is not very good, it is recommended to increase the filter value.

Backlight setting: LCD backlight, 10-64;

(7). Time Setting

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(8). Switching action principle and waveform analysis

a. Switch Action

The tap changer operates in the order of a-g, and the normal operation generates a standard waveform as shown in the
following figure:

R0: Coil resistance and test lead resistance

R1: Transition resistance 1

R2: Transition resistor 2

T0: Three-phase synchronization, (based on the earliest detected switching phase)

T1: Transition resistance 1 running time

T2: Bridge time

T3: Transition resistor 2 runtime

T4: Transition time

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b. Waveform Analysis

1.

As can be seen from the above figure, the time before bridging is too long, reaching 50ms (three times of the normal
time), and it is not only one phase, but three phases. This is a typical fast mechanism energy storage spring aging and
slowing down.

2.

It can be seen from the above figure that phase A has a symmetrical zero-crossing segment from single to double (3-4)
and double to single (4-3), which is on the odd side, and the transition resistance value is much larger than 50Ω from
the instrument. (Over 50Ω can be regarded as an open circuit). This is a typical transition resistance defect. After
hanging inspection, it was found that the transition resistance on the singular side had been broken.

3.

The waveform in the above figure is due to the relatively high sensitivity selected at the beginning of the test, and the
3-2 direction (inductance increase) is easy to cause oscillation. Appropriately reduce the sensitivity by the 1-n
direction test results are normal.

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4.

It can be seen from the above figure that the waveform of phase A is chaotic, and the transition resistance value
printed is only 0.3-0.5Ω, and this is the case from 1-7. The hanging inspection found that the soft connection of the
lead wire of the A-phase switch was broken, which caused the A-phase transition resistance to be short-circuited (not
connected to death). After on-site processing, the waveform is normal.

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