PO Box 370 Phone: Swansea NSW 2281 Fax: AUSTRALIA Mobile: Web:

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1 EZI-DRY Pty Limited ABN: PO Box 370 Phone: Swansea NSW 2281 Fax: AUSTRALIA Mobile: Web: INSTRUCTION MANUAL Silica Gel Breathers Part #: TMS-10, TMS-15, TMS-20, TMS-25 6

2 WARNING The EZI-DRY Silica Gel breathers are designed to be installed on electrical transformers. This work environment is hazardous and correct safety procedures should be in place and adhered to before attempting to install or remove these breathers. These instructions should be read in conjunction with any local safety regulations and work procedures. These instructions are only to be used for the correct installation, dismantling and assembly of the EZI-DRY breather. The silica gel in these breathers requires specific personal protective equipment to be used when dismantling and handling the contents. Consult the appropriate MSDS before dismantling. EZI-DRY Pty Ltd can recoend a suitable breather size for the required oil content but the purchaser should make their own determination for correct sizing. The use of these breathers outside these instruction guidelines may cause injury to personnel and/or damage to the equipment it is attached too. Please consult EZI-DRY Pty Ltd if these breathers are to be used in a manner outside these guidelines. 1

3 TABLE OF CONTENTS WARNING... 1 INSTALLING and REMOVAL INSTRUCTIONS... 3 Installing... 3 Removal... 3 DISMANTLING and ASSEMBLY... 4 Dismantling... 4 Assembly... 6 SPECIFICATIONS... 7 Table 1. Large Breather Specifications... 7 Table 2. Adaptor... 8 DESIGN INFORMATION... 8 Table 3. Air Flow Pressure Tests... 8 SIZING

4 INSTALLING AND REMOVAL INSTRUCTIONS CAUTION. These units are designed to mount onto electrical transformers. Dangerous voltages May be present in the vicinity of the mounting point. Ensure all local safety procedures and statutory regulations are carried out, prior to mounting and/or removal of breather and parts. These instructions are suitable for all of these models, TMS-10, TMS-15, TMS-20 and TMS-25. All models are similar in design, the length and number of separation discs is the only variance from unit to unit. (See Table 1) The breathers have been designed to mount into the adaptor (quick connect fitting Picture 1 & 2) which is supplied with each unit. The adaptor may be manufactured from acetyl plastic (standard on all units) or stainless steel depending on requirements. These fittings are manufactured to fit a ¾ BSP breather pipe. (1 BSP are available) The adaptor should be fitted onto the correct breather pipe on the transformer. Thread tape or sealer may be required to ensure no leakage occurs. Tighten adaptor until it is seated (approx 16 onto thread) Do not over tighten as this may damage the adaptor. Picture 1 Acetyl Adaptor Picture 2 Stainless Steel Adaptor Installing The breather unit is now ready to mount. The adaptor has a seating washer inside for correct sealing. Screw the breather into the adaptor and rotate anti-clockwise approx 1 ¼ turns until you can feel the breather male fitting meet the sealing washer. The breather is now installed. No further installation procedures are required. Removal The removal of the breather only requires the clockwise rotation of the breather in the adaptor. When removing, be sure to hold the weight of the breather by placing a hand under the base when rotating clockwise to ensure the secure removal without dropping. 3

5 DISMANTLING AND ASSEMBLY Dismantling The dismantling will require an area that is clean and tidy, preferably on a work bench at the correct working height. Use some form of blocking (approx 40 in height) so that the breather can be placed upside down onto the blocking and the male screw fitting is clear of the bench top and provides a flat stable area for the breather to sit on. Ensure that the work is carried out over a large containment vessel in case the silica gel is accidentally spilled. At this stage it would be a good idea to measure the distance between the separation discs so as to have an idea of placement when re-filling. Full dismantling should now be done in conjunction with Picture Remove stainless steel circlip from base (item P). 2. Remove black disc by placing a wire in one of the holes to remove (item O). 3. Remove filter pad and replace if contaminated (item N). 4. Remove valve system by using pliers to clamp one of the wings to pull out. Check O-ring on the valve and replace in required (items L & M). 5. Remove the base by placing both hands on either side of the Plexiglas tube and push up with your thumbs (item H) ensuring you maintain firm pressure on the Plexiglas with both your hands. It may require a tap with a rubber mallet on the lip if this does not work. Ensure the breather Plexiglas is held firmly in some manner when doing this. 6. Remove the fine white filter material and check for contamination. Replace if required. (item G) 7. The silica gel can now be emptied into a container. Ensure you have a large enough container to work over as the Plexiglas tube can now come out of the head and spill silica gel everywhere. The separation discs should come out with the weight of the silica gel. 8. Remove the Plexiglas tube and clean as required. The Plexiglas tube can be cleaned with Methylated spirits or Turpentine. Use a non abrasive cloth. Do not use thinners or petroleum products as they could damage the Plexiglas. (Always test cleaner on a small section of Plexiglas prior to use) 9. Check O-ring in the head piece and clean or replace if necessary. All O-rings should be cleaned and re-coated with a suitable silicon grease or lubricant before assembly. 4

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7 DISMANTLING AND ASSEMBLY Assembly 1. The head piece (item A) should be placed on the stable blocking material and the O-ring placed into position. 2. Place cleaned Plexiglas tube (item B) into head piece. The Plexiglas tube is only sitting loosely in the head while filling. Always hold down Plexiglas when filling with the silica gel. 3. Fill the first section with silica gel. Use measurements obtained prior to dismantling or refer to Table Insert the disc which has the vent holes in the outer edge (item E) in place. 5. Fill the second section. Insert the inner hole disc and continue to follow this sequence and using the correct number of discs (Table1) alternating from outer hole disc to inner hole disc until the silica gel is approximately 15 from the top of the Plexiglas. This allows room to tighten down base to required position. Temporarily place base (item H) in place without O-ring ( item I) to test for required gap. Remove base and replace O-ring. 6. Place fine white filter on shaft and then place base into position. Gently tap down the base so that the Plexiglas is in position and over the sealing O-ring. (item I) The base should now be hard up against the Plexiglas tube. 7. Tighten down base with the stainless steel spring washer in place and the 10 nut (item K, J). Do not over tighten. Nut should be close to flush with top of 10 shaft (item D) 8. Install valve system with o-ring in place (item L, M) 9. Install filter pad. Replace if contaminated (item M) 10. Place black disc with holes in centre into position (item O) 11. Place stainless steel circlip in place (item P) The breather is now ready for mounting. 6

8 Table 1. Large Breather Specifications Part # Silica Gel Content kg Dimension A SPECIFICATIONS Dimension B Dimension C Separators D # Separator Spacing TMS TMS TMS TMS

9 SPECIFICATIONS Table 2. Adaptor Part # Dimension A Dimension B TMS ¾ Thread Size C inch DESIGN INFORMATION These re-chargeable breathers have been designed with a reed valve system in place of the typical oil bath system. The reeds are designed to operate under normal air flow conditions generated by the expansion and contraction of the transformer oil within the transformer. Typical operation of the reed valve is <2 kpa. Each breather is pressurised to 10 kpa and tested for leakage prior to dispatch. (See Table 1 for typical airflow and pressure) TABLE 3. AIR FLOW PRESSURE TESTS Product Flow Rate Pressure ID L/min kpa TMS-10 TMS-15 TMS-20 TMS <1 50 <3 20 < <3 20 <2 50 <4 20 <2 50 <5 These test results may not be indicative of the breather that is purchased as settling of the silica gel in transport can cause further compaction which may alter these results. This testing was carried out in a workshop environment with a Key Instruments Flow meter & pressure gauge at 21 C. 8

10 SIZING There is no standard for the selection of silica gel quantity to oil quantity. Most manufacturers use approximately 1kg /3000 litres of oil. The design of the EZI-DRY breathers and in field testing combined with evidence has shown that the size of the EZI-DRY breather (silica gel quantity) can be reduced by up to 50% when compared to the standard oil bath breather with the same silica gel quantity. There are many factors which can affect the size selection for a transformer, some being: Maintenance inspection intervals. Local environmental conditions.(temperature range, rainfall, humidity) Transformer loading characteristics (oil temperature range/duration). Oil content (in relation to expansion and contraction quantities with temperature changes). When selecting the Silica gel breather size for your transformer, all of these factors should be considered and combined with any other relevant site conditions. EZI-DRY Pty Ltd can suggest a particular size breather, but the purchaser and installer must take the responsibility for correctly sizing the breather. 9