ABB Integral Flange LV Bushings

LV Bushing
Oil to Air Dry Insulation

PTAB-SLV832
Technical Guide
600 V, 30 kV BIL, 600-2500 A
5/8" Integral Flange Bushing 1.0" Integral Flange Bushing
1.25" Bushing
General Description
The ABB low voltage bushings are designed for use on pad
or surface mounted distribution transformers. They serve to
terminate the transformer’s internal low voltage leads at the
tank wall and to provide a standard threaded connection for
600 A
the external low voltage circuit. The bushings consist of a
thermoset body which is molded around a copper conduc-
tor stud. The conductor stud is terminated with an internal 1200 A
connection spade and an external mounting thread.
Features and Advantages
Test Proven Quality and Reliability Integral Flange on 5/8" & 1.0" Conductors
The ABB low voltage bushings have passed a series of de- The mounting flange on the 5/8" and 1.0" conductor bush-
sign tests which were designed to verify ratings, suitability for ings is molded as an integral part of the bushing. This
use on pad mounted distribution transformers, and long term eliminates the need for a separate mounting flange, and in
reliability. the case of a metal mounting flange, the associated elec-
trical losses through induced current in the flange.
1. Seal Integrity Test
2. Full Wave Impulse Test Compression Limited Gasket Designs
3. Low Frequency Voltage Withstand Test The integral flange assembly of the 5/8" and 1.0" conduc-
4. Conductor Stud Torque Test tor bushing has a molded-in gasket seat to ensure proper
5. Flange compression Strength Test gasket location and compression during mounting. The
6. Cantilever Load Test 1.25" conductor bushing uses a compression ring to prop-
7. Flange Torque Test erly locate the gasket and limit gasket compression.
8. Thermal Cycle Test
9. Temperature Rise Test
Conductor Variety
Most ABB low voltage bushings are available in a stan-
In addition to the design testing, the following routine pro-
dard or extended length thread design.
duction tests are done on an audit basis:
1. Dimension Check
2. Visual Inspection Proven Thermoset Material
3. Leak test Because of the critical nature of the low voltage bushing
application, high strength, molded, thermoset materials
Interchangeable are used. These materials have proven their ability to with-
stand the stresses of the transformer environment through
The ABB low voltage bushings have been designed to be
their many years of field service and rigorous aging tests.
dimensionally interchangeable with the majority of low volt-
age bushings presently on the market. Included in these in-
terchangeable dimensions are: the bolt circle for the integral Certification of 5/8" and 1.0" Bushings
mounting flange; the tank wall hole size; the conductor stud To Certify the product ratings, production samples of the
diameter; and the external thread size. 5/8" and 1.0" diameter low voltage bushing rated through
600 volt were tested. The tests were conducted at the
ABB Engineering Laboratories in Alamo, TN and Raleigh,
NC. The tests were conducted in accordance with ANSI/
IEEE.
Design Tests
The design tests were divided into (3) three parts:
1. Dielectric Tests
• Impulse test
• Low Frequency 60 Hz Withstand test
2. Mechanical Strength Tests
• Leak test
• Stud Interface Strength test
• Stud Torque Strength test
• Cantilever test
• Flange Torque test
2 ABB
3. Environmental Tests are screwed onto the threaded portion of the bushing simu-
• Thermal Cycle test lating the attachment of a standard H-spade. The nut is
• Oil Compatibility test tightened until failure. The average torque value was 92
ft-lb for the 5/8" stud and 199 ft-lb for the 1" stud. In all
1. Dielectric Tests cases either the threads stripped or the stud broke.
• Impulse Test • Cantilever Test

The purpose of this test is to verify the impulse withstand This test demonstrates the ability of the bushing to with-
of the bushing. Sample bushings were subjected to two stand the stresses generated when attaching line leads to
positive and two negative full wave impulses. The voltage the conductor. With the bushings attached to simulate
impulse used was a standard 1.2 x 50 µs wave having the transformer mounting, an extension is threaded onto the
crest value of the specified voltage. The voltage level at- bushing stud and a load applied until failure. With a con-
tained was well above the BIL rating of 30 kV. Samples figuration of one hole down on the integral flange, the av-
successfully passed 36 kV impulse test levels. Samples erage failure occurred at 172 ft-lb for the 5/8" stud, and
successfully passed chopped wave tests well above the 421 ft-lb for the 1" stud bushing.
rating of 36 kV.
• Flange Torque Test
• Low Frequency 60 Hz Withstand Test The purpose of the flange torque test is to demonstrate
The purpose of the low frequency withstand test is to verify the ability of the integral flange to withstand the stresses
the integrity of the insulation structure of the bushing at generated while being mounted to a transformer tank. The
operating frequency. The samples were tested at 12 kV bushing is mounted to the test fixture with the mounting
for one minute and then allowed to rest for one minute. bolts tightened to the standard 90 in-lb. The bolts are
They were then retested for another minute. All samples sequentially tightened in increments of 25 in-lb until fail-
passed this test. ure. The pads crushed at an average torque of 516 in-lb.
2. Mechanical Strength Tests 3. Environmental Test
• Leak Test • Thermal Cycle Test

The purpose of the leak test is to ensure that, over the life The purpose of the thermal cycle test is to verify the integ-
of the bushing, no leak will occur between the copper rity of materials used in the bushing over the expected
stud and the polyester resin. The bushings were tested service life of the bushing. The sample bushings previ-
using two methods. For the first method, sample bush- ously leak tested were subjected to 20 thermal cycles in
ings were tested by mounting them in a tank pressurized air. One cycle consists of: a 2 hour transition to 135°C, 2
to 30 psi and submerging the tank in water for 1 minute. hours at 135°C, a 4 hour transition from 135°C to -40°C,
For the second method, the bushings were attached to a then 2 hours at -40°C. After the thermal cycle test, the
leak test fixture which mates the bushing to a Helium de- bushings were tested again with no bushing showing any
tector (Veeco Instruments). A vacuum is created around indication of leaking.
the internal surfaces of the bushing. Any leak will be de-
tected if Helium passes into the detector through the bush- • Oil Compatibility Test
ing. All bushings passed with no indication of leaking air The purpose of this test is to verify that the bushing will
when submerged in water or leaks faster than 1 x 10-9 not degrade the transformer's oil as it ages. Samples of
atm cc/sec using the Helium detector. bushings are aged under controlled conditions in a test
vessel containing tansformer oil. At the conclusion of the
• Stud Interface Strength Test test, the molding material is tested for degradation. The
The purpose of this test is to verify that no damage will material passed the standard oil compatibility test. In ad-
result when bushing terminals are connected or removed. dition, this bushing is molded from a thermoset polyester
With the bushings attached to simulate transformer mount- resin system which has essentially the same chemistry as
ing, a nut is threaded onto the threaded copper stud and that which has been used for insulators in other oil filled
torqued to 50 ft-lb twenty times. The bushings are then apparatus for over 30 years.
leak tested to verify that the seal between the copper stud
and the polyester resin remained intact.
• Stud Torque Strength Test

The purpose of this test is to verify the strength of the
copper stud. Two brass nuts separated by a steel washer
ABB 3
ABB Inc.
www.abb.com
Fax: 731-696-5362
1128 S. Cavalier Drive
Alamo, TN 38001, USA
Telephone: 731-696-5561
IZUA 2761-600en Replaces TPL 44-841 February 98. Printed in USA by Tennessee Industrial Printing Services, Inc.

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ABB Integral Flange LV Bushings

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LV Bushing

Oil to Air Dry Insulation

5/8" Integral Flange Bushing 1.0" Integral Flange Bushing

Features and Advantages

• Impulse Test • Cantilever Test

2. Mechanical Strength Tests 3. Environmental Test

• Leak Test • Thermal Cycle Test

• Stud Torque Strength Test

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