IS : 8468-1977

Indian Standard
SPECIFICATION FOR
ON-LOAD TAP-CHANGERS
0. FOREWORD
0.1 This Indian Standard was adopted by the Indian Standards Institution
on 26 May 1977, after the draft finalized by the Transformers Sectional
Committee had been approved by the Electrotechnical Division Council.
0.2 This standard is based on lEG Doc: 14B (Central Office) 10, revision
of Publication 214 (1966) ‘On-load tap-changers’, issued by the Inter-
national Electrotechnical Commission.
0.3 For selecting an on-load tap-changer for a particular application re-
ference should be made to IS: 8478~l977*.
0.4 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, expressing
the result of a test shall be t~oundedoff in accordance with IS: 2-1960t.
The dumber of significant places retained in the rounded off value should
be the same as that of the specified value in this standard.

SECTION I GENERAL
1. SCOPE
1.1 This standard covers on-load tap-changers for power transformers,
and their motor-drive mechanisms. It relates mainly to oil-immersed tap-
changers.
1.2 Tap-changers for transformers for railway rolling stock are not covered
by this standard.
NOTE I — As this standard deals only with on-load tap-changers the expression is
shortened to ‘tap-changer’ in the remainder of this standard.
NOTE 2 — For the purpose of this standard a synthetic insulating liquid, for example,
askarel is regarded as an oil.

2. DEFINITIONS
2.0 For the purpose of this standard, the following definitions shall apply.
*Application guide for on-load tap-changers.
~Rules for rounding off numerical values (revised). -~ -

3
IS : 8468 - 1977

2.1 Definitions Relating to On-Load Tap-Changers (Excluding

Motor-Drive Mechanisms)
2.1.1 On-Load Taft-Changer—A device for changing the tapping con-
nections of a winding, suitable for operation whilst the transformer is ener-
gised and is on-load. Generally, it consists ofa diverter switch (2.1.3) with
a transition impedance (2.1.6) and a tap selector (2.1.2) which can be with
or without a change-over selector (2.1.5), the whole being operated by the
driving mechanism (2.1.7). In some forms of tap-changers, the functions
of the diverter switch and the tap selector are combined in a selector switch.
2.1.2 Tap Selector —A device designed to carry, but not to make or break
current, used in conjunction with a diverter switch to select tapping
connections.
2.1.3 Diverter Switch A switching device used in conjunction with a
tap selector to carry, make and break currents in circuits which have already
been selected.
NOTE Diverter switches of spring-operated type include an independent means of
storing energy for their operation.
2.1.4 Selector Switch A switching device capable of making, carrying
—

and breaking current, combining the duties of a tap selector and a diverter
switch.
2.1.5 Change-Over Selector A device designed to carry, but not to make
—

or break current, used in conjunction with a tap selector or selector switch

to enable its contacts and the connected tappings, to be used more than once
when moving from one extreme position to the other.
2.1.6 Transition Impedance A resistor or reactor consisting of one or
more units bridging the tapping in use and the tapping next to be used, for
the purpose of transferring load from one tapping to the other without
interruption or appreciable change in the load current, at the same time
limiting the circulating current for the period that both tappings are used.
2.1.7 Driving Mechanism —The means by which the drive to the tap-
changer is actuated.
Nom — The mechanism may include an independent means of storing energy to
control the operation.
2.1.8 Set of Contacts — A pair, or combination of pairs, of individual
fixed and moving contacts, operating substantially simultaneously.
2.1.9 Main Contacts and Main Switching Contacts of Diverter Switch or Selector
Switch
2.1.9.1 Main contacts Any set of through-current carrying contacts
—

which has no transition impedance between the transformer winding and

the contacts and which does not switch any current.
2.1.9.2 Main switching contacts Any set of contacts which has no
—

transition impedance between the transformer winding and the contacts

and which breaks the current.
4
 IS 8468-1977
2.1.10 Transition Contacts Any set of contacts where a transition im-
—

pedance is in series between the transformer winding and the contacts.

Nom — In the case of reactor transition tap-changers this set of contacts is used, in
many instances, to carry the through-current in the full tap-position.
2.1.11 Circulating Current That part of the current which flows through
—

the transition impedance at the time when two tappings are bridged during
a tap-change operation and which is due to the vkltage difference between
the tappings.
2.1.12 Switched Current The prospective current to be broken during
—

switching operation by each set of main switching or transition contacts

incorporated in the diverter switch or selector switch.
2.1.13 Recovery Voltage The power frequency voltage which appears
—

across each set of main switching or transition contacts of the diverter

switch or selector switch after these contacts have broken the switched
current.
2.1.14 Tap-Change Operation A complete sequence of events from the
—

initiation to the completion of one tap-change.

2.1.15 Cycle of Operation The movement of the tap-changer from one
—

end of its range to the other and the return to its original position.
2.1.16 Insulation Level The withstand values of the impulse and power
—

frequency test voltages to earth, and where appropriate between the phases
and between those parts where insulation is required.
2.1.17 Rated Through-Current (ia) The current flowing through the
—

tap-changer towards the external circuit, which the apparatus is capable of

transferring from one tapping to the other at the relevant rated step voltage
and which can be carried continuously while meeting the requirements of
this standard.
NOTE — As to the relationship between a rated through-current and relevant step
voltage, sec 5.2.
2.1.18 Maximum Rated Through-Current (‘um) — The rated through-
current for which both the temperature rise of the contacts (8.5) and the
service duty test (8.6.1) apply.
2.1.19 Rated Step Voltage (Ui) For each value of rated through-current,
—

the hi’ghest permissible voltage between terminals which are intended to be

connected to successive tappings of a transformer.
NOTE — If a rated step voltage is given in connection with a rated through-current, it is
called ‘relevant rated step voltage’.
2.1.20 Maximum Rated Step Voltage ((Jim) — The highest value ofthe rated
step voltage for which the tap-changer is designed.
2.1.21 Rated Frequency The frequency of the .~tlternatingcurrent for
—

which the tap-changer is designed.

2.1.22 Number of Tap Positions of the Tap-Changer
2.1.22.1 Number of inherent tap positions The highest number of tap
—

5
IS 8468 - 1977

positions for half a cycle of operation for which a tap-changer can be used
according to its design.
2.1.22.2 Number of service positions The number of tap positions for
—.

half a cycle of operation for which a tap-changer is used in a transformer.

NOTE — Terms defIned in 2.1.22.1 and 2.1.22.2 are generally ‘iven as the ~ values of
the relevant numbers, for example, ±11 positions; they are principally valid also for the
motor-drive mechanism.
When using the term ‘Number of tap positions’ in connection with a transformer, this
always refers to the number ofservice tap positions of the tap-changer.
2.1.22.3 Run-through tap The taps of the tap-changer connected to
—

the tap winding of the transformer, but the tap-changer when electrically
operated through these taps continues to run to the next tap without stop-
ping at these particular taps.
2.1.23 Type Test A test made on a tap-changer or the components of a
—

tap-changer, or a range of tap-changers or components all based on the

same design, to prove compliance with the standard.
NOTE — A range of tap-changers is a number of tap-changers based on the same design
and having the same characteristics, with the exception of the insulation levels to earth
and possibly between phases, the number of steps and the value of the transition
impedance.
2.1.24 Routine Test A test made on each finished tap-changer, the
—

design of which has been verified by type tests, to establish that the tap-
changer is without manufacturing defects.
2.2 Definitions Relating to Motor-Drive Mechanisms
2.2.1 Motor-Drive Mechanism A driving mechanisms (see 2.1.7), which
—

incorporates an electrical motor and control circuit.

2.2.2 Step-by-Step Control Electrical and mechanical devices stopping
—

the motor-drive mechanism after completion of one tap-change indepen-

dently of the operating sequence of the control switch.
2.2.3 Tap Position Indicator Electrical and/or mechanical devices for
—

indicating the tap position of the tap-changer.

2.2.4 Tap-Change in Progress Indication A device indicating that the
—

motor-drive mechanism is running.

2.2.5 Limiting Devices
2.2.5.1 Limit switches Electro-mechanical devices preventing opera-
—

tion of the tap-changer beyond either end position but allowing operation
towards the opposite direction.
2.2.5.2 Mechanical end stop A device which physically prevents
—

operation of the tap-changer beyond either end position but allows operation
towards the opposite direction.
2.2.6 Parallel Control Devices Electrical control devices to move, in the
—

case of parallel operation of several transformers with tappings, all tap-

6
 IS 8468 1977
-

changers to the required position and to avoid divergence of the respective

motor-drive mechanisms.
No’rs — Such devices would be necessary also in the case of single-phase transformers
forming a three-phase bank when each single-phase tap-changer is fitted with its own
motor-drive mechanism.
2.2.7 Emergency Tripping Device An electrical and/or mechanical device
—

for stopping the motor-drive mechanism at any time in such a way that a
special action should be performed before the next tap-change operation
can be started.
2.2.8 Overcurrent Blocking Device An electrical device preventing or
—

interrupting operation of the motor-drive mechanism for the period in

which an overcurrent exceeding a preset value is flowing in the transformer
winding. The blocking device may be in the form of a contactor in the
motor-drive mechanism.
2.2.9 Operation Counter Mechanism A device indicating the number of
—

tap-changes accomplished.
2.2.10 Manual Operation of Tap-Changer Operation of the tap-changer
—

manually by a mechanical device, blocking at the same time operation by

the electrical motor.
2.2.11 Motor-Drive Cubicle A cubicle housing the motor-drive
—

mechanism,
3. SERVICE CONDITIONS
3.1 Temperature of Tap-Changer Environment Unless more —

onerous conditions are specified by the purchaser, on-load tap-changers

shall be regarded as suitable for operation over a temperature range of
—5 to 100°Cwhen the cooling medium is oil.
NOTE — The value of 100°Cquoted above is based on a maximum ambient tempera-
ture of 50°Cas specified in IS: 2026(Part I).1977*.
3.2 Temperature of Motor-Drive Mechanism Environment Un- —

less more onerous conditions are specified by the purchaser, motor-drive

mechanisms are regarded as being suitable for operation in any ambient
temperature between —5°Cand 50°C.
3.3 Overload Conditions Tap-changers subjected to overload condi-
—

tions in accordance with IS: 6600-1972t shallgenerally be restricted to the

occasional overload conditions stated in IS: 2026 (Part 1)-I977* if not
specifically ordered for other overload conditions by the transformer
manufacturer (see IS : 8478 l977~).
-

NOTE — Tap-changers, like other switching devices, usually have ashorter thermal time
constant than electromagnetic devices of the same current ratings.
*Specification for power transformers: Part I General (first revision).
tGuide for loading of oil-immersed transformers.
~Application guide for on-load tap-changers.

7
IS 8468-1977

4. iNFORMATION REQUIRED WITH TENDER AND ORDER

4.1 The technical information that the purchaser is required to supply with
the tenders and orders is given in IS: 8478 - 1977*.

SECTION 2 ON-LOAD TAP-CHANGERS

(EXCLUDiNG REQUIREMENTS FOR MOTOR-DRIVE
MECHAN ISMS)
5. RATING
5.1 Rated Characteristics The characteristics of a tap-changer that
—

shall be used to determine the rating are as given in 5.2 to 5.6.

5.2 Rated Through-Current The rated through-current is inter-
—

related with a relevant rated step voltage. Therefore a tap-changer may

have different combinations of rated through-current and relevant rated
step voltage.
5.3 Maximum Rated Through-Current Preferred values ofmaximum
—

rated through-current, shall be:

100, 200, 400, 800, 1 250, 1 600, 2 000, 2 500 and 3 150 A.
Adoption ofother values does not invalidate compliance with this standard.
5.4 Rated Step Voltage This shall be stipulated by the purchaser.
—

5.5 Rated Frequency — The rated frequency shall be 50 Hz.

5.6 Rated Insulation Level — This shall be stipulated by the purchaser.

6. DESIGN AND CONSTRUCTION

6.1 Limiting Devices for the Protection of Tap-Changers Against
Transient Voltages — For tap-changers which incorporate limiting
devices for transient voltages, the manufacturer of the tap-changer shallgive
full details of the protective characteristics, together with any limitations
which shall be imposed during tests on the completed transformer.
When spark gaps are used, care has to be taken to ensure that after
spark-over, the discharge is quenched automatically.
6.2 Oil Level Gauges If diverter or selector switches are located in
—

separate oil containers breathing freely to the atmosphere, oil level gauges
shall be provided.
6.3 Suitable protective devices may be provided in the tap-changer.
*Application guide for on-load tap-changers.

B
 IS : 8468 - 1977

7. MARKING
7.1 Each tap-changer shall be provided with a name-plate of weather-proof
material fitted in a visible position showing at least the items indicated
below. The entries shall be indelibly marked (for example by etching,
engraving or stamping).
a) Number of this standard, Ref: IS: 8468,
b) Manufacturer’s name,
c) Manufacturer’s serial number,
d) Manufacturer’s type designation,
e) Year of manufacture,
f) Rated through-current,
g) Rated step voltage, and
h) Rated insulation level.
7.1.1 The tap-changers may also be marked with the 1ST Certification
Mark.
NOTE — The use of the 1St Certification Mark is governed by the provisions of the
Indian Standards institution (Certification Marks) Act and the Rules and Regulations
made thereunder. The 1St Mark on products covered by an Indian Standard conveys
the assurance that they have been produced to comply with the requirements of that
standard under a well-defined system of inspection, testing and quality control which is
devised and supervised by ISI and operated by the producer. ISI marked products
are also continuously checked by 1St for conformity to that standard as a further safe-
guard. Details of conditions under which a licence for the use of the ISI Certification
Mark may be granted to manufacturers or processors, may be obtained from the Indian
Standards Institution.

8. TESTS
8.1 Type Tests The type tests shall be performed on the samples of the
—

relevant tap-changer or components after their final development. The

following shall constitute the type tests:
a) Mechanical test (8.3),
b) Auxiliary circuits insulation tests (8.4),
c) Test for temperature-rise of contacts (8.5),
d) Switching tests (8.6),
e) Short circuit current test (8.7),
f) Transition impedance test (8.8),
g) Mechanical life test (8.9), and
h) Dielectric test (8.10).

8.2 Routine Tests The following shall constitute the routine tests:
—

a) Mechanical test (8.3),

b) Auxiliary circuits insulation tests (8.4), and
c) Dielectric tests [8.10.3(a) and 8.10.3(d) only.]
NoTE Attention is drawn to the tests to be carried out on tap-changers after assembly
—

on transformers specified in IS: 2026(Part I)~l977*.

•Spccification for power transformers: Part I General (first revision).

9
IS : 8468 - 1977
8.3 Mechanical Test With the tap-changer fully assembled, but
—

without the contacts energized, ten complete cycles of operation shall be

performed without failure.
8.4 Auxiliary Circuits Insulation Test The tap-changer auxiliary
—

circuits shall withstand without failure a power-frequency test voltage of

2 kV applied for one minute between all line terminals and the frame.
8.5 Test for Temperature-Rise of Contacts — Tests shall be per-
formed to verify that the temperature rise above the medium surrounding
each type of contact which carries current continuously in service does not
exceed the values given in Table 1, when the contacts have reached a steady
temperature after carrying the maximum rated through-current.

TABLE 1 CONTACT TEMPERATTJRE RISE-LIMITS

CONTACT MATERIAL IN On.

(1) (2)

OC

Plain copper 20
Silver-faced copper 20
Other materials 20

The temperatures shall be measured by thermocouples or other suitable

means positioned on the surface of the contacts as near the point of contact
as is practicable.
The temperature is considered to be steady when the difference of the
temperature between the contact and the surrounding medium does not
change by more than 1°Cover the last quarter of the test period.
The temperature of the surrounding medium shall be measured at not
less than 25 mm below the contacts.
Nora — The cross-section of the conductor carrying the current into the tap-changer or
components under test shall be stated.
8.6 Switching Tests Switching tests, which include service duty tests
—

and breaking capacity tests, shall simulate the most onerous conditions for
which the tap-changer is rated. Where reactor switching is concerned, the
most onerous condition shall be subject to agreement between the manu-
facturer and the purchaser. Unless otherwise agreed, it is assumed that
no reversal of power flow occurs in service.
Attention is drawn to Appendix A where the most onerous conditions for
resistor transition switching are indicated for the majority of contact
arrangements.
10
 IS 8468 - 1977

The switching tests may be limited to the diverter switch or selector switch
after proving that the contact operating conditions are not affected by such
limitation.
If the diverter switch or selector switch has several sets of contacts which
operate in a definite sequence, it is not permitted to test each set of contact
separately from the other unless it can be proved that the operating condi-
tions of any one set ofcontacts are not affected by the operation of the other
sets of contacts.
Where resistors are used as transition impedances these may be placed
outside the apparatus if necessitated by the construction of the tap-changer
or the test circuit, and they may have a higher thermal capacity than those
which are employed in service unless otherwise specified.
The value and type of the transition impedance shall be stated.
Contacts, and transformer oil in the case of oil-immersed tap-changers,
shall not be renewed during each of the tests.
In the case of three-phase switches, it is normally sufficient to test the
contacts of one phase.
If a particular tap-changer has more than one combination of rated
through-current and rated step voltage at least two braking capacity tests
shall be performed, one at maximum rated through-current ‘m and its
relevant step voltage U1 and one at the maximum rated step voltage Urn and
its relevant rated through-current I,~.
Interpolation may be facilitated by obtaining the mid-current point of
the curve between the extremes by calculating this mid-point X as:
(Isn+Iu) (Ux)~/UtImX Urn jn

The arrangement for testing shall be such that, except where otherwise
specified, neither the switched current, nor the recovery voltage, nor the
product of these shall, in any case, vary more than —5 percent to + 10
percent of the calculated values appropriate to the switching cycle (see
Table 5) at the appropriate through-current and relevant rated step voltage.
8.6.1 Service Duty Test — This test shall be performed in accordance with
8.6.1.1, 8.6.1.2 or 8.6.1.3.
After the tests, inspection of contact wear shall be done, the results of this
test shall leave no doubts as to the suitability of the tap-changer for service.
NOTE — The results of this test may be used by the manufacturer to demonstrate that
the contacts used for making and breaking current are capable of performing, without
replacement of the contacts, the number of tap-change operations declared by the manu-
facturer at the rated through-current and at the relevant step voltage.
8.6.1.1 Service duty test at rated step voltage — The contacts on diverter
switches and selector switches shall be subjected to a number of operations
corresponding to 20 000 tap-change operations in normal service when
carrying a current corresponding to not less than the maximum rated
through-current and the relevant rated step voltage.

11
IS : 8468 - 1977
In order to approximate to service conditions, selector switches shall have
the test performed over not more than eight tap-change positions (excluding
dead positions), these being centrally disposed about the change-over
selector if such is incorporated in the tap-changer design.
Comparison of oscillograms taken at regular intervals during the test
shall show that there is no significant alteration in the characteristics of the
tap-changer in such a way as to endanger the operation of the apparatus.
Twenty osdilograms shall be taken at the start of the test, and 20 after each
succeeding 5 000 operations, making a total of 100 oscillograms.
NOTE — Generally it is sufficient to compare the series of oscillograms taken at the
beginning and at the end of the test.
8.6.1.2 Service duty test at reduced step voltage Provided that the manu-
—

facturer supplies reasonable proof that the rate of wear is not affected,
a test at reduced step voltage may be performed under the following
conditions:
a) A service duty test of 20 000 operations shall be performed at a
current corresponding to not less than the maximum rated through-
current and a reduced step voltage. This voltage level shall be
such that the switched current is not less than that occurring during
operations at the relevant rated step voltage; furthermore, current
chopping shall not occur. In order to obtain the specified test
conditions, the value of the transition impedance shall be suitably
modified.
b) Using the same contacts and oil, 100 operations at the maximum
rated through-current and the relevant rated step voltage shall be
performed, each operation being oscillographically recorded.
Provided the oscillograms taken during these operations indicate
that the arcing time does not exceed -~ second (where f is the
rated frequency) this service duty test with the calculated switched
current and reduced step voltage will enable the mnufacturer to
demonstrate directly the number of operations likely to be achieved
without replacement of contacts.
c) When the oscillograms indicate that arcing times in excess of
seconds are occurring then further operations shall be performed at
the maximum rated through-current and the reduced step voltage.
The number of such additional operations shall be:

~0x20 000

where S=total number of half-cycles of arcing current, in the 100

operations from (b) above, which occur after the first current zero
following contact separation.
12
 IS 8468 - 1977
d) Comparison of the oscillograms taken under (b) above with those
taken under similar conditions with new contacts and clean trans-
former oil shall show whether there has been any significant
alteration in the characteristics of the tap-changer such as might
endanger the operation ofthe apparatus.
The test sequence specified above is designed to give substantially
the same contact erosion as would occur during 20 000 operations at
maximum rated through-current and the relevant rated step voltage.
8.6.1.3 Service duty testfor selector switches
— The tests may be performed
asin 8.6.1.1 or 8.6.1.2.
When selector switches are designed for asymmetrical pennant cycle
switching, owing to the load and circulating currents together with their
associated recovery voltages being vectorially subtractive, the most onerous
switching duties for the main contact occur at full-load and at no-load
(see Table 5).
In service the majority of transformers do not normally operate at full-
load and, in consequence, there is always arc-erosion in the subtractive
condition. Therefore in order to approximate more nearly to service
conditions the test shall be performed with 10 000 operations at full-load
parameters and 10 000 operations at no-load parameters.
8.6.2 Breaking Capacity Test— Forty operations shall be performed at a
current corresponding to twice the maximum rated through-current and
at the relevant rated step voltage.
The oscillograms taken for each operation shall indicate that in no case
is the arcing time such as to endanger the operation of the apparatus.
The breaking capacity test shall be performed, if possible, with a transi-
tion impedance ofthe same thermal and ohmic design as that to be employed
in service. If this is not possible the impedance as used in service shall be
tested separately in accordance with 8.8.1 but with twice maximum rated
through-current for one operation only.
8.6.3 Simulated Test Circuits The tests under 8.6.1.1, 8.6.1.2 and
—

8.6.1.3 may be performed with simulated circuits providing it is proved

that the test conditions are substantially equivalent. Two simulated test
circuits which are possible for use are described in Appendix B.
8.7 Short-Circuit Current Test — All contacts of different design carry-
ing current continuously shall be subjected to short-circuit currents, each of
two seconds (± 10 percent) duration. In the case of oil-immersed tap-
changers the test shall be performed in transformer oil.
In the case of three-phase tap-changers it is sufficient to test the contacts
of one phase only unless otherwise specified.
Three applications shall be made with an initial peak current of 2~5
(±5percent) times the symmetrical rms value of the short-circuit test
current.
13
IS : 8468-1977

When there are no facilities for point-on-wave switching and it is not

possible to obtain three short-circuit applications with an initial peak
current of 2~5times the rms value, the following test may be used:
The symmetrical value of the short-circuit test current may be
increased so that the peak current is obtained for the three applications
and the test duration reduced. When using this method the product
of the square of the increased rms current and the shorter test duration
shall not be less than the product of the square of the rated short-
circuit rms current and the 2 seconds duration.
The values of the short-circuit test current to be applied shall be as
specified in Table 2.
NOTE— If the short-circuit requirements of the transformer exceed that given in Table 2
for the maximum rated through-current of the tap-changer, unless otherwise a~reed
between the manufacturer and the purchaser, a tap-changer of the appropriate higher
maximum rated through-current shall be adopted.

TABLE 2 SHORT-CIRCUiT TEST CURRENT

MAXIMUM RATED
Tas~rCuaar~rr
THROUGH CURUNT RMS VALUR
(1) (2)
A kA

100 2
200 3
400 4

800 8

1 250 125
1 600 16
2 000 20
2 500 25
3 150 315

For intermediate values of maximum rated through-current up to 400 A,

the test current may be interpolated from the above table. For values
above 400 A, the test current shall be 10 times the maximum rated through-
current.
The open-circuit voltage for the test shall be at least 50 V.

14
 IS : 8468 - 1977
At the conclusion of the test, the contacts shall not have welded together
and shall not show abnormal signs of current marking or burning.
Current-carrying parts shall not show signs of permanent mechanical
distortion.
8.8 Transition Impedance Test
8.8.1 Transition Resistors The test shall be performed at the maximum
—

rated through-current and at the relevant rated step voltage.

The resistor shall be mounted as in service or separately under equivalent
thermal conditions.
The resistor shall be subjected to a number of power-impulses equivalent
to one-half of one cycle of uninterrupted operation (see 2.1.15) with the
driving mechanism operating at its normal speed. The final temperature
of the resistor shall be determined and recorded.
The temperature rise above the surrounding medium shall not exceed
200°Cfor oil-immersed tap-changers.
If it is not practicable to determine the temperature of the transition
resistor according to the above then the method given in Appendix C may
be employed.
NoTE — In cases where the rated through-current or the relevant rated step voltage is
different from the maximum rated through-current and the relevant rated step voltage,
it is permissible to calculate the thermal rating of the resistor from the results of the type
test.

8.8.2 Transition Reactors Transition reactors are normally tested

—

in accordance with the specification for the transformer with which the
tap-changer is intended for use.
Nom Precautions should be taken in the design of the transition reactors to avoid
—

high inrush currents during switching.

8.9 Mechanical Life Tests

8.9.1 Mechanical Endurance Test If the tap-changer is of oil-immersed
—

design it shall be assembled and filled with clean transformer oil, or immersed
in a test tank filled with clean transformer oil, and operated as for normal
service conditions. The contacts shall not be energized and the full range
of tappings shall be utilized until 200 000 tap-change operations have been
performed.
During the test there shall he no failure or undue wear of the mechanical
parts.
Normal servicing according to the manufacturer’s handbook shall be
permitted during the test.
It shall be permitted to perform this mechanical endurance test sepa-
rately on diverter switches, selector switches, tap selectors or other com-
ponents, provided that in each case the operation duplicates mechanically
its normal service operation.

15
IS 8468 - 1977

8.9.2 Sequence Test With tap-changer assembled as in service, and if of

—

oil-immersed design in clean transformer oil, it shall be operated over one

complete cycle of operations. With the contacts energized at the voltage
of the recording equipment the exact time sequence of operation of the tap
selector, change-over selector, diverter switch or selector switch, as appro-
priate, shall be recorded.
8.9.3 Pressure and Vacuum Tests If required, tests shall be performed to
—

establish the pressure and vacuum withstand values on the compartments

and bushings of the tap-changer. The manufacturer shall declare these
values.

8.10 Dielectric Tests

8.10.1 General The dielectric requirements of a tap-changer depend on
—

the transformer winding to which it is to be connected.

The transformer manufacturer shall be responsible not only for selecting
a tap-changer of the appropriate insultation level but also for the insulation
level of the connecting leads between the tap-changer and the windings of
the transformer.
Apparatus of oil-immersed design shall be filled with clean transformer oil
or immersed in a test tank filled with clean transformer oil before the tests
are performed.
8.10.2 Classification To permit selection of appropriate voltage test tap-
—

changers shall be classified according to Table 3.

TABLE 3 CLASSES OF TAP-CHANGERS

CLASS APPLICATION

I For use at the neutral point of windings

II For use at a position other than the neutral point of windings

8.10.3 J~/atureof Tests The insulation level of the tap-changer shall be

—

proved by the following power-frequency and/or impulse voltage withstand

tests:
a) To earth;
b) Between phases;
c) Between the first and last contacts of the tap selector or selector
switch and, where fitted, of the change-over selector;
d) Between any two adjacent contacts of the tap-changer or selector
switch or any other contacts relevant to the tap-changer contact
configuration; and

16
 IS I 8468-1977

e) Between diverter switch contacts in their final open position.

NOTE 1 Regarding item (a) above, for Class I tap-changers, impulse voltage tests
—

may not always be necessary. Their requirement shall be subject to agreement between
the manufacturer and the purchaser.
Nom 2 Item (b) above does not apply to single-phase tap-changers.
—

NOTE 3 — Partial discharge measurements and switching impulse test are specified in
IS: 2026(Part III)~l977* for transformers greater than 145 kV class. Consideration
should be given to the application of the appropriate tests to earth and where applicable
between phases of the tap-changer.

8.10.4 Test Voltages

8.10.4.1 Class I—For test 8.10.3 (a), the test voltage shall preferably
comply with an appropriate value values
from Table
shall 4.be For the tests
by 8.10.3(b) to
3(e), appropriate withstand declared the manu-
B.lO.
facturer of the tap-changer.
8.10.4.2 Class II For tests 8.lO.3(a) and 8.10.3(b) test voltages shall
—

preferably comply with the appropriate values from Table 4. For tests
8.lO.3(c) to 8.10.3(e), appropriate withstand values shall be declared by
the manufacturer of the tap-changer.

TABLE 4 TEST VOLTAGE

(Clauses 8.10.4.1 and 8.10.4.2)
POWER-FREQ~JXIeCY LIGHTNING IMPULSE
TEST VOLTAGE TEST VOLTAGE
(1) (2)
kV rms kV peak

10 40
20 60
28 75
38 95
50 125
70 170
95 250
149 325
185 450
230 550
275 650
325 750
360 850
395 950
460 1 050

8.10.5 Ajplication of Test Voltages For the voltage tests, the tap-changer
—

shall be assembled and dried out. It is not, however, necessary to include

*Specification for power transformers: Part III Insulation levels and dielectric test (first
revision).

17
IS 8468-1977

leads for connecting the tap-changer to the windings of a transformer.

Tests may be performed on separate components provided it can be shown
that same dielectric conditions apply.
For test 8.10.3(a) and test 8.10.3(b) in the case of Class II tap-changers
the live parts of each phase shall be short-circuited and connected either
to the voltage source or to earth as appropriate.
Where the tap-changer incorporates external insulation to earth, this
external insulation shall be proved in accordance with the relevant test
specified in IS: 2099_1973*.
8.10.6 Power-Frequency Voltage Test —The test shall be performed with
a single-phase alternating voltage in accordance with IS: 207 l(Part I)-
1974t and IS: 2071(Part II)-l974~at the required value. The duration
of each test application shall be 60 seconds.
8.10.7 Lighting Impulse Voltage Test —The wave for the test shall be the
standard impulse of 1 ~2(±30percent) 500 (+20 percent) microseconds as
defined in IS: 207l(Part I)-l974t and IS: 2071(Part III)-l974~. Each test
shall comprise three voltage applications of positive polarity and three of
negative polarity, at the required value.
8.10.8 Measurement of Partial Discharges Under consideration (see
—

8.10.3, Note 3).

8.10.9 Switching Impulse Test —Under consideration (see 8.10.3, Note 3).
8.11 Type-Test Certificate The certificate shall include the following:
a) Full details of the test arrangements adopted (for example, as-
sembly arrangement and drying out) with explanatory sketches as
necessary.
b) Full details of all tests applied in accordance with 8.3 to 8.10.
c) Full details of limiting devices for transient voltages, where appro-
priate (see 6.1).

SECTION 3 MOTOR-DRIVE MECHANISMS

FOR ON-LOAD TAP-CHANGERS

9. DESIGN AND CONSTRUCTION

9.1 Unless otherwise specifIed, component parts of motor-drive mechanisms
shall comply with relevant Indian Standards.
9.2 Permissible Variation to Auxiliary Supply The driving motor
—

and the electrical control of the motor-drive mechanism shall be designed to

*Speciflcation for bushings for a]tcrnating voltages above 1 000 V (first revision).
tMethods of high voltage testing: Part I General definitions and test requirements (first
revision).
~Methods of high voltage testing: Part II Test procedures (first revision).
§Methods of high voltage testing: Part III Measuring devices.

18
 IS : 8468-1977
operate satisfactorily within the limits of 85 to 110 percent of rated voltage
for an ac voltage and between 80 and 110 percent for a dc voltage.
9.3 Step-by-Step Control — The step-by-step circuit shall be designed in
such a way as to operate the tap-changer by one complete voltage step only
in the case of signals which may be continuous or immediately repetitive as
well as simultaneous from separate sources within one tap-change operation.
9.4 Tap Position Indicator
9.4.1 The position of the tap-changer shall be indicated on the motor-
drive by means of a mechanically operated device. This tap position shall
be visible through an inspection window while the motor-drive cubicle is
closed.
9.4.2 If required, an electrical remote position transmitter may be pro-
vided for indicating the tap-changer position in the control room.
9.5 Tap-Change in Progress Indication — If required, a suitable device
may be fitted to operate a means of indicating at a remote point that the
motor-drive mechanism is performing a tap-change operation.
9.6 Limiting Devices All motor-drive mechanisms shall be provided
—

with both electrical and mechanical limiting devices. The contacts of the
electrical limiting device shall be connected into the control or motor
circuits.
9.7 Parallel Control Devices — Provision of the necessary devices is to
be agreed, the purchaser being responsible for ensuring that the correct
requirements are specified.
9.8 Direction of Rotation Protection — If required, a device for pre-
vention of incorrect rotation of three-phase motors may be fitted by agree-
ment between the manufacturer and the purchaser.
9.9 Overcurrent Blocking Device — If required by the operational
condition of the transformer, this device may be fitted by agreement be-
tween the manufacturer and the purchaser.
9.10 Operation Counter — An operation counter shall be provided.

9.11 Manual Operation of the Motor-Drive Mechanism — A re-

movable crank shall be provided for manual operation of the tap-changer,
with blocking of the motor-drive taking place before actual engagement of
the crank with the manual operating shaft.
The direction of rotation shall be provided adjacent to the hand crank
engagement point and the number of crank rotations required for one tap-
change operation shall be given.
NOTE — The design of the mechanism should permit manual operation by one man
without undue effort. It can be assumed that this condition is satisfied if the maximum
torque which has to be applied to crank handle does not exceed 50 Nm.

19
IS : 8468 - 1977

9.12 Motor-Drive Cubicle — The motor-drive cubicle shall meet with

the protection requirements of IP 44 according to IS: 2147_1962* and shall
be protected against condensation by suitable means.
If required, other degrees of protection specified in IS: 2l47~l962* may
be agreed between the manufacturer and the purchaser.
10. MARKING
10.1 Each motor-drive mechanism shall be provided with a name-plate of
weather-proof material, fitted in a visible position showing the appropriate
items indicated below. The entries shall be indelibly marked (for example
by etching, engraving or stamping).
a) Number of this Indian Standard, Ref: IS: 8468;
b) Manufacturer’s name;
c) Manufacturer’s serial number and type;
d) Year of manufacture;
e) Rated voltage and rated frequency for the electrical motor (see
Note);
f) Rated voltage and rated frequency for the control equipment (see
Note);
g) Number of service tapping positions; and
Is) Direction of flow of power.
NOTE — In the case of direct current supply, the symbol ‘—‘should be used in place of
the indication of the rated frequency.

11. TESTS
11.1 Type Tests — The following shall constitute the type tests:

a) Mechanical test (11.3),

b) Auxiliary circuits insulation test (11.4),
c) Mechanical load test (11.5),
d) Overrun test (11.6), and
e) Protection of motor-drive cubicle (11.7).
11.2 Routine Tests The following shall constitute the routine tests:
—

a) Mechanical tests (11.3), and

b) Auxiliary circuits insulation tests (11.4).
11.3 Mechanical Tests
11.3.1 The motor-drive mechanism in the service condition or with an
equivalent simulated load shall be operated electrically for ten cycles of
operation without failure. During this test correct functioning to any
requirements of 9, where relevant, shall be checked.
* Degrees of protection provided by enclosures for low voltage switchgear and controlgear.

20
 IS 8468 - 1977

11.3.2 Following the test under 11.3.1, two further cycles of operation
shall be performed, one at the minimum and one at the maximum level of
the rated voltage of the auxiliary supply, also without failure.
NOTE — The mechanical tests may be performed on the motor-drive mechanism
separately or as under 8.9.
11.4 Auxiliary Circuits Insulation Test Auxiliary circuits, except the
—

motor and such elements which are to be tested with lower test voltages ac-
cording to the appropriate Indian Standards shall withstand a power-
frequency test of 2 kV applied for one minute between all live terminals and
the frame.
11.5 Mechanical Load Test — The motor-drive mech:inism output shaft
shall be loaded by the largest tap-changer for which it is designed or by an
equivalent simulated load, based on service conditions. At such a load
200 000 operations shall be performed across the whole tapping range.
NoTE — Additional cooling of the motor-drive is permissible during this test.
During this test 5 000 operations shall be performed at the minimum
voltage and 5 000 operations at the maximum voltage as specified in 9.2.
The correct functioning to the requirements of 9.4.1, 9.6, 9.10 and 9.11
shall be verified during this test.
The test shall be completed without failure of the mechanical parts.
Normal servicing according to the manufacutrer’s handbook shall be
permitted during the test.
11.6 Overrun Test—It shall be demonstrated that in the event ofa failure
of the electrical limit switches, the mechanical end stops prevent operation
beyond the end positions when a motorized tap-change is performed and the
motor-drive mechanism shall not suffer either electrical or mechanical
damage.
11.7 Protection of Motor-Drive Cubicle — When applicable, the motor-
drive cubicle shall be tested in accordance with IS: 2l47~J962*.

*Degrees of protection provided by enclosures for low voltage switchgear and controlgear.

21
IS : 8468.1977

APPENDIX A
(Clause 8.6)
SUPPLEMENTARY INFORMATION ON SWITCHING DUTY
RELATING TO TAP-CHANGERS WITH RESISTOR
TRANSITION ONLY

A-I. ADDITIONAL DEFINITIONS

A-1.1 Flag~Cyc1e* A method of performing a tap-change operation in
—

which the through-current is diverted from the main contacts before the
circulating current starts to flow.
NOTE — This cycle requires that the through-current connection is at the mid-point

of the transttson smpedance when this is carrying the circulating current.

Ut ‘U
1 Lii
2 1 RI
E
/p,~f
2 E

{E-RI) U
2

-~E*

~l

Fm. I FIAC CYCLE Fso. 2 SYMMETRICAL Fin. 3 ASYMMETRICAL

PENNANT CYCLE PENNANT CYCLE

‘The derivation of the designations ‘flag cycle’ and ‘pennant cele’ arises from the appear-
ance of the vector diagrams showing the change in output voltage of the transformer in
moving from one tapping to the adjacent one. In the ‘flag cycle’ the change of voltage
comprises four steps, while in the ‘pennant cycle’ only two steps occur (see Fig I to 3).

22
 IS : 8468 - 1977

A-i .2 Symmetrical Pennant Cycle* A method of performing a tap-

change operation in which the circulating current starts to flow before the
through-current is diverted from the main contacts.
NOTE — This cycle requires that the through-current connection is at the mid-point
of the transition impedance when this is carrying the circulating current.
A-i.3 Asymmetrical Pennant Cycle* — A method of performing a tap-
change operation in which, in one direction of movement of the switch, the
circulating current starts to flow before the through-current is diverted fl’om
the main contacts, while in the other direction of movement the through-
current is diverted before the circulating current starts to flow.
NOTE I — This cycle requires that the through-current connection is at one end of the
transition impedance when this is carrying circulating current.
NoTE 2 — Tap-changers employing the asymmetrical pennant cycle are normally
used with load flow in one direction only.

A-2. DUTY ON MAIN AND TRANSITION CONTACTS

A-2.1 Table 5 shows typical contact arrangements used for flag and pennant
cycles on diverter switches and selector switches. Only one pair of con-
tacts is shown for each function although, in practice, this may represent a
set of contacts.
A—2.2 Table 5 also shows the number of circuit-transfer operations per-
formed, together with the duty performed, by each pair of contacts for each
combination of switched current and recovery voltage during a number of
cycles of operation corresponding to N tap-change operations.
A-2.3 In the expressions for current and voltage in Table 5, the ‘~-‘ and
signs indicate vectorial addition and subtraction, not algebraic. The duty
on the contacts is consequently affected by the power-factor of’ the load on
the transformer which controls the phase angle between the through-current
I, and the step-voltage E. The effect of the load power-factor on the duty
of the various contacts is shown in Table 6.
A—2.4 If the transition impedance is divided into two units, these are
assumed to be of equal value, each equal to R.
A—2.5 The arrangements shown arc by no means exhaustive; other possible
arrangements exist and are used, such as the multiple resistor cycle which
may be an extension of either the flag cycle or pennant cycle principle.

*The derivation of the designations ‘flag cycle’ and ‘pennant cycle’ arises from the appear-
a nec of the vector diagrams showing the change iii output voltage ofthe transformerin moving
from one tapping to the adjacent one. In the ‘flag cycle’ the change of voltage comprise,
four steps, while in the ‘pennant cycle’ only two steps occur (see Fig. 1 to 3).

23
 TABLE 5 DUTY ON MAIN AND TRANSITION CONTACTS
(Clauses 8.6, 8.6.1.3, A-il. A-2.2 and A-2.31

MAIN CONTACT Dt,T’r TRANSITION CONTACT DUTY

coNTAcT
OPERATING Con- Switched Recovery No. of con- Switched Recovery No. of
Oanrs tact Current Voltage Opera- tact Current Voltage Opera-
tions tisnS

Diverter
switch

Selector
‘switch

NoTE 1 — Reversed load direction only affects contact T where the through.current and circulating current shall then add.
Nom 2 — Other circuits involving multiple resistors are not included, as they are extensions ofthe above basic circuits.
No’rs 3—For purpose ofclarity, the diagram of connections and contact operating order are given forone direction of movement ofthe switch, The expressions so
for contact duty and number of operations, however, take into account the movement of the switch in both directions. -.1
 IS : 8468-1977

TABLE 6 EFFECT OF LOAD POWER FACTOR ON CIRCUIT-BREAKING DUTY

(Clause A-2.3)

NoTe — Tap-changers employing the asymmetrical pennant cycle are normally used
withload euti’rcnt flow in one direction only,

APPENDIX B
(C/a?,se 8.6.3)
SiMULATED CIRCUITS FOR TESTS

B~1.Two proven simulated test circuits are shown in Fig. 4 and 5, Fig. 4
being a transformer method and Fig. 5 a resistance method.
These figures are given for information only and the use ofdiffercnt circutits
is not excluded.
IS: 8468 - 1977

AUTOTRANSFORMER
(OR TRANSFORMER) WITH
STEP-ADjUSTABLE VOLTAGES

DIVERTER SWITCH

1, 4 = Mains contacts
Transit ion contacts
2, 3
— Transition resistor
R
Adjttstablc reactor
Xa

U~—Three-phase supply voltage

(JSB

Test current, to be adjusted by means of U~ and Xa

It
Step-voltage relevant to It
L~J

NOTE — In order to meet the requirements under 8.6J and 8.6.2 and to take into ac-
count the reactances of the circuit and supply, the current and voltage values occurring
on the four contacts shall be controlled and when necessary suitably adjusted, for example
by means of variations of the (~
5,,X5and R values and!or of the mutual phase of the
voltage vectors.

Ftc. 4 TRANSFORMER METHOD

28
 IS 8468. 1977

POWER DIVIDER

1, 4 = main contacts
2, 3 = transition contacts
U
5 = single pitase supply
voltage
/? , = ohmic resistors
forming the
power divider

DIVERTER SWITCH

NOTE ‘11w calculated current and voltage values occurring in the whole tap-change
opcratuon on the four contacts shall he used to calculale the power divider. In the case
under consideration (flag cycle on a 4-contacts diverter switch) the formulae for the most
ortcrous conditions, are:

R •—
— U, U,)
I4(U5_L4) +L781,’
, R L1 (U. —
J~J~(U~U~)

— 14(U5
U, (Li,U4) +U,)u,I,
—
— R U,
T —
U8 (U5
1~(U3
_—
—
U,)
(14)
-

_____ U,, 1,, (U, — (1,1 , R I

~ u~3 14(U,—U4)+ L’ ~ am
U, U,,—U4 R _U, ~
4 s_ 5 3 s__ 3

R U, U,
~i u5—u4’
where -

I~,1, = switched current rnss values of contacts I and 2

U,, U~= recovery voltage rms values of contacts I and 2
U3, U1 applied voltage ross valstes of contacts 3 and 4
I~,14 making Current rms values of contacts 3 and 4
In order to meet the requirements under 8.6.1 and 8.6.2 and to take into account due
impedance of the s,tpply, the cutrrent and voltage values occstrring on the four contacts
shall be controlled anti when necessary adjusted by means of small variations of the R1
ohmic value.
Ftc. 5 RESISTANCE METHOD

29
IS 8468. 1977

APPENDIX C
(Clause 8.8)
METHOD OF DETERMINING THE EQUIVALENT TEM-
PERATURE OF THE TRANSITION RESISTOR USING
POWER PULSE CURRENTS

C-I. Set up the resistor in a tap-changer or in a thermally equivalent situa-

tion, suitable arrangements being made to measure the temperature of the
resistance material. The thermocouples or thermometers for measuring
the temperature of the cooling medium should be positioned not less than
25 mm below the lowest point of the resistance material.
C-2. Measure and record the temperatures of the resistance material and
of the cooling medium at the start of the test.
C-3. The test shall be performed with rms current
1p~the value of which
is obtained from:

I
:~
E(I 1~t
5 1)

= ~i e1 t~

where
= the cut-rent values;
= the time dewing which the current I~is flowing, botis quantities
taken as the mean valise from the 100 oscillograms recorded
at the service duty test according to 8.6.1.1 or if relevant to
8.6J.2(b); arid
k = a coefficient chosen to suit the testing requirements of the re-
sistor, the value adopted to be between 5 and 10 bearing in
mind that the heating phenomenon shall remain adiabatic.
The resistor shall be subjected to the above current for a number of times
corresponding to one half of one cycle of operations. The current appli-
cation time shall be determined from:

ip =k. j~l

C—4. The rest period, during which cssrt’ent cioe~not flow through the re-
sistor shall be equal to the minimum time interval that can occur between
two consecittive operations of’ the tap-changer.
C-5. To determine the peak temperature, extrapolation of recorded valties
may be necessary.

30 ~,

-j