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Oil Transform. Company produces distribution transformers with power of 2500 kVA and voltage levels of 10, 20, 30 kV. Transformers are produced with conservator and with hermetically sealed tank. They can be installed on power-line poles or on the ground. Transformers are produced to comply with standard and special requirements. Slower process of insulation ageing and high stability of dielectric properties enable considerably extended life of transformer and minimal maintenance costs. technical characteristics 1 Frequency Rated frequency is 50 Hz. 2 Rated high voltage The rated high (primary) voltage is the voltage at which transformer is designed to operate. The rated primary voltage determines the basic insulated level (BIL) of transformer according to IEC 76. Transformers which are the subject of this manual are designed to operate at power network voltages up to 36kV (38*kV). 3 Voltage regulation and selection of primary voltage level warning Handling with the tap changer and the voltage selector must be done when transformer is out of voltage! Voltage regulation is performed at higher voltage side of the transformer and realized by means of turning the handle of the tap changer, which is placed on the transformer cover. Selection and change of primary voltage level of dual primary transformers is realized by means of turning the handle of the voltage selector, which is placed on the transformer cover. 4 Ambient conditions and temperature rise Transformers are designed for normal operation in the following ambient conditions: - the highest altitude for installation and operation of transformer is 1000m above sea level, - air ambient temperature may not exceed value given in technical characteristics of transformer. Under these conditions guaranteed temperature rise (maximal temperature rise of oil and average temperature rise of windings) above the ambient temperature will not exceed values given in technical characteristics of transformer. If the ambient temperature exceeds value given in technical characteristics of the transformer it will endanger the life time of the transformer even if the transformer operate with rated load (IEC 354). In that case allowable temperature rises need to be reduced to the some degree by means of reducing the transformer power. 5 Hermetically sealed transformers This type of transformer’s construction guarantees that the transformer oil will not come into contact with atmosphere. Transformers are C. After sealing, pressurefilled with oil at the ambient temperature of 20 inside the transformer is equal to normal atmospheric pressure. Variation of the oil volume due to its temperature variations caused by variation of the load during normal operation of the transformer causes either increase or decrease of the internal pressure. According to absorbing manner of internal pressure changes there are two design variants for these transformers: 1 – Hermetically sealed–completely filled with oil In this variant changes of internal pressure are absorbed with flexible corrugated walls of the transformer tank.Maximal overpressure inside the tank is 30kPa. 2 - Hermetically sealed–with air cushion In this variant the transformer tank is designed with rigid structure and changes of internal pressure are absorbed with air cushion placed underneath the transformer cover. Maximal overpressure inside the tank is 50kPa. The transformer tank cannot be deformed permanently if the transformer is loaded in accordance with guidelines of standard IEC 354 (Loading guide for oil-immersed power transformers). warning The oil level must not be below minimum mark for normal and safe transformer’s operation. It is necessary to keep air-tightness for this type of transformer’s construction. As a default, these transformers are equipped with oil level indicator. In the event that oil level falls below minimum mark on the scale of oil level indicator, the transformer must be immediately switched off, any leaks found, sealed and poured with the oil up to necessary level. Only when these actions are done it is allowed to start-up the transformer again. 6 Transformers with conservator Transformers of this type are equipped with the conservator mounted on the transformer cover. The conservator is connected with the transformer tank and its purpose is to compensate any volume variations of the transformer oil. The transformer oil is not into direct contact with the atmosphere. The contact is realized through silica-gel placed inside dehydrating breather (placed on the conservator) which absorbs all moisture from air and prevents it for entering the transformer tank. warning The oil level must not be below minimum mark for normal and safe transformer’s operation. As a default, the conservator is equipped with oil level indicator. In the event that oil level falls below minimum mark on the scale of oil level indicator, the transformer must be immediately switched off, any leaks found, sealed and poured with the oil up to necessary level. Only when these actions are done it is allowed to start-up the transformer again. 7 Loading of transformers Transformer should be loaded in accordance with guidelines of standard IEC 354 - Loading guide for oil-immersed power transformers. 8 Short-circuit withstand capacity Transformers are designed, manufactured and guaranteed to withstand without any damage all mechanical and thermal effects of short-circuit in accorance with requirements of standard IEC 76. 9 Withstand voltage Transformers are designed, manufactured and guaranteed to withstand without any damage all test voltages according to the customer requirements or according to requirementa of standards which are stated on the rating plate and in the routine test report of the transformer. transformer construction and design 1 Magnetic circuit The magnetic circuit is made of high quality, cold-rolled, grain-oriented silicon steel with low magnetic losses. The magnetic circuit is of the three-leg construction with circle cross-section. Low level of no-load losses, small magnetizing current and low level of the noise are achieved by modern cutting and composing technology as well as by optimized tightening of steel strips. 2 Windings Both the primary and secondary windings are made of electrolytic copper with the use of high quality insulating materials. Windings are placed concentrically around the magnetic circuit legs. High voltage windings are multi-layer type, wounded with round enameled wire or rectangular, paper insulated wire, for high power ratings. Low voltage windings are wounded with rectangular, paper insulated wire or copper foil insulated with diamond- dotted paper and presspan. Electrical, thermal and dynamic stability of the transformer is achieved by windings construction with adequate channels for oil circulation (cooling and hot-spot temperature limit), right selection of insulation and effective tightening of windings in axial and radial direction. 3 Tap changer Transformer is equipped with a three phase off-load tap changer (at HV side) which enabling voltage regulation only when transformer is de-energized. The voltage regulation is realized by means of turning the tap changer handle to the required position. warning Transformer must be de-energized while using the tap changer! The tap changer handle is placed on the transformer cover. Voltages and corresponding handle positions are stated on the rating plate. The tap changer mechanism operates synchronously on all three phases of the transformer. 4 Voltage selector Dual primary transformer is equipped with voltage selector besides tap changer. The voltage selector enables voltage selection only when transformer is deenergized! warning Transformer must be de-energized while using the voltage selector! The voltage selector handle is placed on the transformer cover. The operating voltage selection (for instance 20kV or 10kV in case of 20/10 kV/kV dual primary transformer) is realized by means of turning the voltage selector handle to the required position. 5 Tank The tank is made of high quality steel. Hermetically sealed and completely filled transformers have tank with corrugated walls. Transformers with conservator may have tank either with corrugated walls or with cooling radiators. High quality of the tank welding provides high mechanical strength and impermeability so tank withstands, without permanent deformation, all strains during transport and exploitation. In accordance with type of the transformer and its installation place the following facilities can be found on the tank: warning Do not use corrugated walls or radiators for lifting, displacement, installation or securing of the transformer. It may result in damage of the tank or oil leakage! oil drain valve or oil draining device, oil sampling device, hooks for pole mounting, transformer support (with or without bidirectional wheels), with holes for pulling of the transformer, reinforcements for lifting and pushing the rating plate (at LV side as a default), earthing terminal 6 Cover The following facilities can be found on the transformer cover: HV and LV bushings, the tap changer handle, the voltage selector handle (dual primary type), thermometer pocket (optional), oil filling orifice (hole), lifting lugs for lifting of transformer or its active part, earthing terminal (optional) and other facilities according to contract. 7 Conservator Conservator (expansive vessel) is located horizontally over the tank and mounted on conservator’s supports connected with the cover. Conservator is designed in such a way to accept all oil volume variations during temperature change between -25°C and 100°C. 8 Transformer oil Transformers are filled with mineral insulating oil. Filling of the transformer with oil must be done only after vacuuming if the transformer active part. Characteristics of the transformers oil are in compliance with requirements of standard IEC 296 and value of the oil breakdown voltage is above 50kV/2.5mm. 9 Anti-corrosive protection Variant 1 – Protection with organic coats In this case anti-corrosive protection consists of 4 coats (two primer coats and two final color coats) with total thickness between 100 and 120 μ m. Final coat color is dark gray (RAL 7033) as a default. Anti-corrosive protection system may be particularly adjusted to the requirements of any contract for instance: kind of the organic coat binder (alkyd, modificated alkyd, epoxy or polyurethane resin), thickness and color of the final coat. Varijant 2 – Hot-dip galvanizing This kind of anti-corrosive protection is effective and more economic (for neutral environmental conditions) than protection with organic coats. It is realized by hotdip galvanizing technology. Hot-dip galvanizing outlasts protection with organic coats. Quality of zinc film is in compliance with requirements of ISO 1461 standard. transformer accessories and equipment 1 Thermometer pocket Transformers are equipped with a thermometer pocket enabling installation of mercury or double contact thermometer. Before the installation of these devices thermometer pocket must be half-filled with the transformer oil. Unused thermometer pocket must be sealed to prevent water or air entering into the transformer. Water entering inside the pocket and ice expanding at very low ambient temperatures may result in pocket damage. 2 Double contact thermometer 2.1. Double contact thermometer - AKM 44612 type This instrument is designed for indication of the oil temperature inside transformer. It is fitted with two electric switches (contacts for alarm and tripping) and the indicating pointer of maximal temperature. The instrument is made for outdoor use under tropical as well as arctic conditions. Technical data: note Adjusted temperature for generation of tripping signal must not be above 105°C! case – protective class IP43 two micro switches rated for 5A, 250V AC or 0.2A,250V DC – normally open (NO) electrically separated switching circuits connection by swivel fitting BSP1” or BSP ¾” ambient temperature: min -40°C; max +70°C measurement range between 10 and 120°C measurement accuracy: ±2°C between 50-120°C. 2.2. Double contact thermometer - KTT001 type This instrument is designed for measuring of the oil temperature inside transformer with generation of alarm and tripping signals possibility. It is fitted with magnetic type switch. Contacts are normally open (NO). Technical data: note Adjusted temperature for generation of tripping signal must not be above 105°C! case – protective class IP43 power: 200W,2A working voltage: 220V, 50Hz breakdown voltage 2000V measurement range between 20°C and 120°C ambient temperature: min -30°C; max +60°C accuraccy class: 4,6 connection by swiwel fitting BSP1” or BSP ¾” 3 Oil level indicator 3.1. Magnetic oil level indicator - KSS F This instrument is mounted on transformers with conservator with purpose of showing current oil level into the transformer. The radial movement of the float is transmitted magnetically to the pointer. 3.2. Oil level indicator vertical – KSS-D This instrument is mounted on hermetically sealed transformers with purpose of showing current oil level into the transformer. 3.3. Oil level indicator vertical – Maier G1 1/2” This instrument is mounted on hermetically sealed transformers with purpose of showing current oil level into the transformer. The instrument is to be screwed into the filling pipe on the transformer cover. It offers possibility to monitor: - gas forming in the transformer, - accumulations of air pockets in the tank, - indication of leakage. Installation and adjustment The oil level indicator has to be screwed to the filling pipe. The indicator device must be adjusted in the following manner: - unscrew the ring nut (pos.2), - remove the viewing dome (pos.3) and sealing ring (pos.4), - lift out the indicator scale complete with the upper magnet (pos.6), - turn scale into the correct position by loosening the centre screw, - again complete the instrument. When the transformer is properly filled with oil only the white indicator should be visible in the indicating field. Red warning field appears when oil falls below necessary level for normal operation of the transformer. 4 Buchholz relay Buchholz relay is a protective instrument for oil-immersed transformers with conservator. It is placed directly into the pipe connecting the transformer tank and conservator. This instrument is designed for detecting of faults inside the transformer tank by monitoring of the oil level fluctuation. faults The buchholz relay detects following faults: Low oil level When the oil level in the Buchholz relay is low the upper contact closes by reacting of corresponding float gauge and activates signalization. In a case of serious faults gases appear in the transformer tank followed with intensive oil flow to conservator through the Buchholz relay. At that time the lower float closes the lower contact and transformer will be turned off. In that case contact sales department of Trafo a.d. or your supplier immediately. Buchholz relay operates when gases appear, loss of oil or flow rate increases what may happen in the following cases: - electrical breakdown between live parts, electrical breakdown between live parts and magnetic circuit or the tank, - shortcircuit between turns, - interruption of phase conductor, - oil leakage from the transformer tank, - entrance of air into the system. The upper contact (signalization) Closes by reacting of corresponding float gauge when gas appears in the relay or when the oil level changes in the upper part. The lower contact (turn-off) Closes by reacting of corresponding float gauge when the oil level falls to the bottom of the relay or when the oil flow speed is between 65 and 150cm3/s. The buchholz relay must be installed with the arrow pointing to the conservator! 5 Safety valve Safety valve is used as one of the protective devices for hermetically sealed transformers. Safety valve reaction enables releasing of oil from the transformer tank and thereby overpressure caused by various internal faults can be instantaneously relieved. This will prevent permanent deformation or even explosion of the transformer tank. Safety valve’s overpressure of reacting can be adjusted and its adjustment range is between 0.03MPa and 0.040Mpa. 6 Dehydrating breather Transformers with conservator are equipped with the dehydrating breather. The dehydrating breather collects all moisture from air and prevents it for entering the transformer tank. It contains silica-gel (SiO2 crystals) which absorbs the air moisture and changes its color during air convection. When silica-gel changes its color in the 2/3 of its volume it must be dried (drying temperature120°C to150°C) or it must be replaced. Oil valve of the dehydrating breather must be filled with the oil. Transport Displacement of the transformer can be done in the following manners: Lifting – by means of chains or the lifting beam Transformer can be lifted by means of the lifting lugs placed on the transformer cover (2 or 4 psc.) Pulling – by means of the pulling eyes Default construction of the transformer support has the pulling eyes (with holes diameter 12.5mm or 15mm) designed especially for this purpose. Pulling is possible into two directions: along longitudinal axis or along transversal axis of the transformer. Displacement by the forklift Displacement by the forklift is possible when forks of the forklift are leaned on the reinforcements of the transformer support. note Do not use corrugated walls, radiators, accessories or equipment, which is not especially designed for displacement, lifting, installation or securing of the transformer during transport! It may result in damage of the transformer tank or oil leakage! Sometimes hard conditions of the transportation caused by multiple reloading or low quality of the road can result in the considerable damage of the transformer. It may cause disturbance during transformer's normal operation or even totally disable operation of the transformer. Acting according to the following remarks will avoid specified problems: Handle carefully with the transformer during the transport. Do not use corrugated walls or radiator coolers for displacement of the transformer. Secure the transformer firmly during the transport to avoid its displacement. Protect conservator, bushings and radiator coolers from punches, cracking, breaking and damaging. Only professional and experienced person may manage the unloading of transformers. Visual inspection must be done before the unloading of the transformer to determine any possible damage. After determining of any damage, provide evidence and immediately inform carrier and deliverer. During transportation transformers are usually secured to the floor of the truck trailer by means of wooden girders. Before lifting of the transformer from the trailer it is necessary to remove wooden girders. Weels Placing and removing of the weels Place solid wooden beams a little higher than wheels underneath the transformer, positioned transversly to the transformer support. Put transformer on the beams and fix every wheel with corresponding screws. Lift the transformer, remove beams and carefully lean the transformer to its wheels. Removing of the wheels has to be done in reverse order of actions. Transformers can be also transported in wooden boxes designed and constructed according to regulations for the overseas transport. Transformer is fixed to the floor of the wooden box with screws, wheels are already disassembled and als fixed to the floor next to the transformer. Packing list with the routine test report and installation manual are packed inside the wooden box together with the transformer. Manipulation with the wooden box must be done according to signs placed on the box. Acceptance and survey Upon receipt of the transformer it is necessary to assure that transformer matches with requirements from your order. note Compare technical characteristics of the transformer from your order with data stated on the rating plate (rated power, rated voltages, vector group, etc.). Distribution transformers are delivered to the customer fully assembled, completely filled with insulated oil with corresponding equipment and ready for the operation. Visual inspection is recommended to determine any possible transport damages (broken or cracked bushings, dented wall of the tank, damaged accessories or equipment, etc.) and to compare ordered and delivered equipment. Very important is to assure that manufacturer’s securing seals are not damaged otherwise transformer’s guarantee is no more valid. Transformer installation At place of the installation, transformer’s weight must be distributed evenly across all supporting points and all indicators should be visible and easily accessible. Transformers can be installed: 1. indoor 2. outdoor (two ways): ground installation–on the flat and solid surface on the pole–using hooks or on the platform Ventilation system When transformer is going to be installed inside an electric room (the indoor installation), particular attention should be paid to the ventilation in the installation room (necessary for the cooling of the transformer) i.e. leading away of the heat generated because of the total losses during the transformer operation. We are recommending the following variants for the ventilation system of the transformer installation room: System without fan Effective ventilation system consist of two openings, one is for the input of air at ground level with cross-section area S(m2) and the other opening for the output of air at height H (m) above the input opening, with its cross-section area S’(m2). Necessary surfaces of the openings would be calculated as follows: S(m²)=0.18*P(kW)/√H(m) i S'(m²)=1.10*S(m²) Where P(kW) is sum of no-load losses, load losses and losses of other electrical equipment sharing the installation room. This formula is valid for the yearly average ambient temperature of 20°C, maximal altitude above sea level of 1000m and for maximal difference between the openings air temperatures of 15°C. It is also necessary that transformer must be placed at least 200mm from any solid barrier otherwise available transformer’s power will be lower than rated because of deteriorated cooling conditions and difficult air circulation around transformer. System with fan In the case of narrow and poorly ventilated rooms as well as when air temperature inside room is much above the outside air temperature it is necessary to embed ventilator into the output opening. The ventilator flow (m3/s) in this case should be 0.10*P, where P (kW) is the value of the total losses of the transformer and other electrical equipment sharing the installation room. connecting and preparing Before the transformer start-up it is necessary to: Secure the transformer to prevent any displacement. Connecting the earthing cables. At transformers with conservator check the value of breakdown voltage for a sample of the transformer oil taken from the transformer tank using a sampling valve. Measured value must not be less than 45kV/2.5mm. Take measurement of insulation level. Measured value must (with 2500V, DC) must not be less than: - 250MΩ for voltage levels >1.1kV and - 50MΩ for voltage levels <1.1kV Measure effective HV and LV resistances for each position of the tap changer. These values should be equal (with reasonable tolerances) in all three phases. Put the voltage selector handle into desirable position (dual primary transformers – 20/10 for instance – look in 1) Put the tap changer handle into desirable position (look in 2) Connect HV cables to correspond HV bushings. Connect LV cables to correspond LV bushings. Measure earthing resistance. Connect leads to the all applicable additional accessories and instruments (Remark: According to the connecting diagram!) Inspect the whole transformer to double check for any errors in the connections or faulty equipment. Measure insulation level of the transformer with all connections except connection to star point. 1 Selection of the primary voltage level (dual primary transformers) note Transformer must be de-energized while changing the voltage selector handle position! Selection of the primary voltage level (dual primary transformers) Selection of the primary voltage level must be done when transformer is deenergized and it is realized by means of turning the voltage selector handle to the required position. Procedure is similar to the using the tap changer handle (look in 2) 2 Voltage regulation using the tap changer note Transformer must be de-energized while changing the tap changer handle position! U postupku promene položaja regulatora napona potrebno je uraditi sledeće: disconnect all cables leading to HV and LV bushings, - earth both HV and LV windings, - put the tap changer into required position by turning the tap changer handle, placed on the transformer cover, - re-connect all cables, - start-up the transformer. Variant 1 :: Selection of the tap changer position should be done according to values of high voltage (stated on the rating plate) in the following manner: unblock the latch of the tap changer handle (pos.2), push the latch until it come out of the notch, turn the tap changer handle (pos.1) to required position, loosen the latch and spring (pos.3) will return it to the notch of required position, block the latch of the tap changer handle. Position marks (numbers) on the tap changer handle correspond to the available values of primary voltage. Connection between marks and the values of the voltage is stated on the transformer rating plate. Variant 2 :: Tap changer - KDR type In this variant, selection of the tap changer position should be done according to values of high voltage (stated on the rating plate) in the following manner: loosen the position fixing button (red color) of the tap changer handle, the latch is coming out from limiter by pulling up the tap changer handle and enabling turning of the tap changer handle to required position, push down the tap changer handle and fix it with the position fixing button. Position marks (numbers) on the tap changer handle correspond to the available values of primary voltage. Connection between marks and the values of the voltage is stated on the transformer rating plate. transformatora. Transformer operation 1 Transformer operation During normal transformer operation it should be treated according to the internal manuals of user. 2 Overloading In the case of need for overloading, act according to guidelines of standard IEC 354: Loading guide for oil-immersed power transformers. 3 Damages during transformer operation 1 Overheating Causes of the overheating can be: continuous overloading, unproper cooling of the transformer (insufficient air flow around transformer, inappropriate ventilation of the installation room, etc.) serious internal damages (in this case contact sales department of Minel Trafo a.d.) 2 Low oil level Caused by: oil leakage – oil spots and traces are clearly visible underneath the transformer. 3 Apperance of gases inside the transformer tank Apperance of gases inside the transformer tank is caused by: partial discharges, poorly sealing – underpressure. 4 Too high overpressure inside the transformer tank Caused by: overheating, apperance of gases inside the transformer tank. 4 Routine transformer inspections During the routine transformer inspections particular attention should be paid to: current oil level inside the transformer (shown by oil level indicator), temperature of the transformer oil indicated by the thermometer installed on the transformer cover, current value of load (Does it exceed rated power? Is the load symmetrical?), conditions of accessories and equipment, conditions of bushings and connections, conditions of protective devices and their connections, any abnormalities in the sound generated by the transformer, any spots and traces of oil underneath the transformer. untanking the transformer Untanking the transformer note If any irregularities are discovered during the inspection, it may become necessary to untank the transformer to determine the cause. If there is any suspicion that gases accumulated in the transformer tank, underneath the cover do not carry out any electrical measurements. This may result in a spark and cause an explosion of accumulated gases. Measurements should be only carried out when the active part is removed from the transformer tank! When untanking the transformer the following sequence must be done: disconnect all cables leading to HV and LV bushings, drain necessary oil quantity from the tank through the drain valve placed near the bottom of the tank - disconnect all cables leading to additional accessories, equipment and protective, unscrew nuts and bolts on the cover, lift the transformer active part from the tank by lugs on the cover, allow some time for percolation of the active part and then place the active part on the flat, dry and clean surface. Drained oil should be stored in a clean, tightly closed vessel. The active part of transformer must be re-immersed in oil within 8 hours. In a case of exceeding this period the active part must be dried again. After draying the active part should be impregnated with oil. Now the transformer start-up should be done according to instructions for connecting the transformer and preparing for start-up. transformer oil 1 Collecting oil samples for testing Transformer oil testing should be done: before the transformer start-up, during the routine transformer inspections, in any circumstances indicating possibility of damage of the transformer particularly when any protective device are triggered. To collect a sample use a sampling valve located near the bottom of the tank. It is important to place the collected oil sample to a clean vessel. Transformer oil is a hygroscopic substance and must be protected against contact with moisture. 2 Pouring of the transformer oil In a case of need, pouring of the transformer oil should be done, through oil filling hole placed on the cover, with new, filtered oil with the breakdown voltage value of 50kV/2.5mm and characteristics in accordance with standard IEC 296. Pouring of oil from the same manufacturer and the same type as the oil already inside the tank is the most preferable otherwise it is allowed to pour oil of the other manufacturers and types but in maximal quantity of 10% from oil weight stated on the transformer rating plate. new in technology The most modern equipment for steplep cutting and packing of magnetic sheets, produced by GEORG (Germany), enable manufacturing of transformers with very low level of losses. Computer aidded design and construction of transformers, with moderntechnology, which we are using in their manufacturing, enable us to produce wide range of standard and non-standard transformers. New in control 1 Impulse generator Type: SGS 300 kV, 15 kJ - impulse generator control Type: GC223 - high resolution impulse analysin system Type: HiAS 743 - impulse calibrator Type: RIC 422 - overshoot compensation Type: SGC - OC Manufacturer: HAEFELY - TRENCH 2 Reccurent surge generator Type: RSG 481 Manufacturer: HAEFELY - TRENCH 3 Device for measuring of tan(delta), C, cos(fi) Type: 2818/5283 - automatic 12 kV insulation test system (tan(delta), C, cos(fi)) in-site measurements Manufacturer: TETTEX INSTRUMENTS 4 Sound level meter Type: 2236 - precision integrating sound level meter Manufacturer: BRÜEL & KJAR 5 LCR meter Type: HP 4263B Manufacturer: HEWLETT PACKARD Guarantee This product is guaranteed by Trafo for a period specified in contract and in the product guarantee list. The guarantee covers defects due to faulty workmanship, materials and equipment. The guarantee applies provided the product is handled properly for its internal use, in accordance with its operation instruction and upon presentation of required documents. Trafo may not apply guarantee if :: documents have been altered or changed in any way or made illegible, type or product serial number altered, changed, deleted, removed or made illegible, repairs or product modifications and alternations have been executed by unauthorised services, service organisations or persons, damage is caused by accidents including but not limited to lightning, water or fire, misuse or neglect, etc.