Ministry of Defence

Defence Standard 02-535

Issue 2 Publication Date 15 May 2003

Requirements for Transformers

for Power Services

Category 2
 AMENDMENTS ISSUED SINCE PUBLICATION

AMD NO DATE OF TEXT AFFECTED SIGNATURE &

ISSUE DATE

Revision Note

This Issue of this Standard has been prepared to incorporate changes to text and presentation.
The technical content has been updated in line with current practice.

Historical Record

Def Stan 07-229 Issue 1 1 April 2000

Def Stan 02-535 Issue 1 1 April 2000
NES 537 Issue 4(IN PART)
NES 535 Issue 3 August 1990
NES 535 Issue 2
NES 535 Issue 1
 DEFENCE STANDARD 02-535

REQUIREMENTS FOR TRANSFORMERS FOR POWER

SERVICES

ISSUE 2

This Defence Standard is

authorized for use in MOD contracts
by the Defence Procurement Agency and
the Defence Logistics Organization

Published by:

Defence Procurement Agency

An Executive Agency of The Ministry of Defence
UK Defence Standardization
Kentigern House
65 Brown Street
Glasgow G2 8EX

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 DEF STAN 02-535 / ISSUE 2

SCOPE
1. This Defence Standard (DEF STAN) and related documents apply to particular requirements for
the design, performance, construction, marking and testing of drytype doublewound, naturally
air cooled power transformers for HM Surface Ships and Submarines.

2. The term `transformer' is used in this DEF STAN to refer to inductors and induction regulators,
as relevant, where these equipments are not directly mentioned. The System Requirement
Document (SRD) is to specify the type of equipment required.

3. A number of transformers designed in accordance with this DEF STAN are already in service.
Before designing a new transformer, advice is to be sought from Marine Electrical Systems (MLS)
2 on the suitability of an existing design.

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 DEF STAN 02-535 / ISSUE 2

FOREWORD
Sponsorship
1. This Defence Standard (DEF STAN) is sponsored by the Warship Support Agency (WSA),
Ministry of Defence (MOD).
2. Any user of this Standard either within MOD or in industry may propose an amendment to it.
Proposals for amendments that are not directly applicable to a particular contract shall be made
to the publishing authority identified on Page 1, and those directly applicable to a particular
contract shall be dealt with using existing departmental procedures.
3. If it is found to be unsuitable for any particular requirement, MOD shall be informed in writing
of the circumstances.
4. No alteration shall be made to this Standard except by the issue of an authorized amendment.
5. Unless otherwise stated, reference in this Standard to approval, approved, authorized and similar
terms means by the MOD in writing.
6. Any significant amendments that may be made to this Standard at a later date will be indicated by
a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line interval.
7. Extracts from British Standards quoted within this Standard have been included with the
permission of the British Standards Institution.
8. This Standard has been raised as a new Defence Standard.
Conditions of Release
General
9. This Standard has been devised solely for the use of the MOD, and its contractors in the execution
of contracts for the MOD. To the extent permitted by law, the MOD hereby excludes all liability
whatsoever and howsoever arising (including but without limitation, liability resulting from
negligence) for any loss or damage however caused when the Standard is used for any other
purpose.
10. This document is Crown Copyright and the information herein may be subject to Crown or third
party rights. It is not to be released, reproduced or published without written permission of the
MOD.
11. The Crown reserves the right to amend or modify the contents of this Standard without consulting
or informing any holder.
MOD Tender or Contract Process
12. This Standard is the property of the Crown. Unless otherwise authorized in writing by the MOD
it must be returned on completion of the contract, or submission of the tender, in connection with
which it is issued.
13. When this Standard is used in connection with a MOD tender or contract, the user shall ensure that
he is in possession of the appropriate version of each document, including related documents,
relevant to each particular tender or contract. Enquiries in this connection may be made to the
authority named in the tender or contract.
14. When Defence Standards are incorporated into MOD contracts, users are responsible for their
correct application and for complying with contractual and any other statutory requirements.
Compliance with a Defence Standard does not of itself confer immunity from legal obligations.

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DEF STAN 02-535 / ISSUE 2

Categories of Standard
15. The Category of this Standard has been determined using the following criteria:
a. Category 1. If not applied may have a Critical affect on the following:
Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
b. Category 2. If not applied may have a Significant affect on the following:
Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
Through life costs and support.
c. Category 3. If not applied may have a Minor affect on the following:
MOD best practice and fleet commonality.
Corporate Experience and Knowledge.
Current support practice.
Related Documents
16. In the tender and procurement processes the related documents listed in each section and Annex
A can be obtained as follows:
a. British Standards British Standards Institution,
389 Chiswick High Road,
London, W4 4AL.
b. Defence Standards Defence Procurement Agency,
An Executive Agency of The Ministry of Defence,
UK Defence Standardization,
Kentigern House,
65 Brown Street,
Glasgow, G2 8EX.
c. Other documents Tender or Contract Sponsor to advise.
17. All applications to Ministry Establishments for related documents shall quote the relevant MOD
Invitation to Tender or Contract number and date, together with the sponsoring Directorate and
the Tender or Contract Sponsor.
18. Prime Contractors are responsible for supplying their subcontractors with relevant documentation,
including specifications, standards and drawings.
Health and Safety
Warning
19. This Standard may call for the use of processes, substances and/or procedures that may be injurious
to health if adequate precautions are not taken. It refers only to technical suitability and in no way
absolves either the supplier or the user from statutory obligations relating to health and safety at
any stage of manufacture or use. Where attention is drawn to hazards, those quoted may not
necessarily be exhaustive.
20. This Standard has been written, and shall be used, taking into account the policy stipulated in
JSP430 MOD Ship Safety Management System Handbook.
Additional Information
(There is no relevant information included)

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 DEF STAN 02-535 / ISSUE 2

CONTENTS
Page No

TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Categories of Defence Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 1. PERFORMANCE SPECIFICATION . . . . . . . . . . . 7

1.1 Overall Performance . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.1 Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.2 Permissible Temperature Rises . . . . . . . . . . . . . . . . . 7
1.1.3 Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.4 Value and Calculation of Saturated Reactance . . . . 8
1.1.5 Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.6 Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . 8
1.1.7 Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 2. NATIONAL/INTERNATIONAL REGULATIONS 9

SECTION 3. MILITARY STANDARDS/REQUIREMENTS . . . 9

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.1 Tender Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2.2 Manufacturing Drawings . . . . . . . . . . . . . . . . . . . . . 10
3.2.3 Delegated Approval . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Special Purpose Transformers . . . . . . . . . . . . . . . . . 11
3.3.1 Portable Apparatus (Earthed) Transformers . . . . . 11
3.3.2 2 kVA Portable, Single Phase, Transformers . . . . . 11
Figure 1 Cable Hook End Terminal NSN 5940995259141,
SDN 007 502 095, Dimensions in mm. . . . . . . . . . . . 13
Figure 2 Cable Hook End Terminal NSN 5940995259142,
SDN 007 502 096, Dimensions in mm. . . . . . . . . . . . 14
3.3.3 Flameproof Enclosures . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.1 Classification of Tests . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4.2 Type Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4.3 Routine Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.4 Testing of 2 kVA Portable Transformers . . . . . . . . 17

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DEF STAN 02-535 / ISSUE 2

Page No
3.4.5 Tests At Other Than Rated Voltages and
Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.6 Shock and Vibration Tests . . . . . . . . . . . . . . . . . . . . 18
3.4.7 SelfInduced Airborne Noise and Vibration . . . . . . 18
3.4.8 Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.9 Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.1 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.2 Tieon Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Marker Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6.1 Identification Marker Plate . . . . . . . . . . . . . . . . . . . . 20
3.6.2 Earth Marker Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6.3 EarthScreening Marker Plate . . . . . . . . . . . . . . . . . 20
3.6.4 Marker Plates for 2 kVA Portable Single Phase
Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 4. DESIGN REQUIREMENTS/GUIDANCE . . . . . . . 21

4.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.1 Laminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.2 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.3 Electrostatic Screening . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.4 Impregnation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1.5 Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1.6 Terminals and Cables . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1.7 Terminal Arrangements . . . . . . . . . . . . . . . . . . . . . . 22
4.1.8 Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.9 Connections Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.10 Transformer InRush . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 5. NATIONAL/INTERNATIONAL REGULATIONS 23

ANNEX A RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . . 24

ANNEX B ABBREVIATIONS AND DEFINITIONS . . . . . . . . 25

ANNEX C PROCUREMENT CHECK LIST . . . . . . . . . . . . . . . 26

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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 DEF STAN 02-535 / ISSUE 2

1. PERFORMANCE SPECIFICATION
Related Documents: BS 171; BS 3399; DEF STAN 615 Part 4; see also Annex A.
1.1 Overall Performance
a. The equipment shall be capable of giving its full rated output continuously or at any
other specified loading cycle, within the normal ambient air temperature and steady
state tolerance electrical supply conditions, without exceeding the maximum
permissible temperature rises of Clause 1.1.2a and the regulations requirement of
Clause 1.1.3. Any allowable deterioration in regulation or reduction in output due
to abnormal ambient conditions shall be quoted in the System Requirement
Document (SRD). This relaxation in specification shall contain the maximum
permissible temperature rise within the requirements of Clause 1.1.2a.
b. The tolerances on electrical performance shall comply with BS 3399 unless
otherwise stated in the SRD.
1.1.1 Windings

a. Unless otherwise specified in the SRD, the windings shall conform to the vector
symbols (as defined in BS 171):
440 volts and below normal power supplies Yd 1
Welding Dy 11
Portable Apparatus (Earthed) See Clause 3.3

1.1.2 Permissible Temperature Rises

a. The maximum permissible temperature rises when operating in a normal

maximum ambient air temperature of 55°C shall be:
(1) Windings
Class of Insulation B F H C
Temperature Rise (measured by 80°C 100°C 125°C 150°C
resistance)

(2) Cores
(a) The temperature rise is in no case to reach such a value that there is risk
of damage to any insulation material on adjacent parts.
b. Where a normal ambient air temperature above 55°C is specified in the SRD, the
permissible temperature rises in Clause 1.1.2a. shall be reduced by the
corresponding amount. No increase in temperature rises is permitted when a
maximum ambient temperature lower than 55°C is quoted.
1.1.3 Regulation

a. Unless otherwise stated in the SRD the normal regulation at 0.8 power factor shall
not exceed 3.3%. Reference temperature and specific calculations are stated in BS
3399.

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DEF STAN 02-535 / ISSUE 2

1.1.4 Value and Calculation of Saturated Reactance

a. Saturated reactance of the transformer primary winding must exceed an order of

magnitude particular to the winding configuration. The value of saturated
reactance may be determined using the method given in Clause 1.1.4b.
b. The value of saturated reactance of the primary winding must be
4.2Fp
greater than: ohms/phase.
k

Where : Fp = Primary winding factor;

= 1 for star connection and;
= 3 for delta connection.
k = The total kVA rating of the transformer as specified in the
SRD.

The saturated reactance shall be calculated as follows :

Xt
80fN A x10 -10

2
ohms/phase
L

Where:N = Number of primary turns;

A = Mean crosssectional area of the coil formed by the primary
winding (mm2);
L = Axial length of winding (mm);
f = Supply frequency (Hz).
1.1.5 Voltage Control

a. The voltage control to meet the tolerances allowable on nominal electrical supplies
(see DEF STAN 615 Part 4) and the requirements of Clause 1.1.3 shall be obtained
by the inherent regulation of the transformer.
b. Tapped transformers may be specified. The tappings required shall be specified in
the SRD as is the provision of tapping links, offcircuit or onload tap changers.
c. The method of voltage control to meet any special requirements for regulation
which cannot be met by Clause 1.1.5a. shall be submitted at the time of tendering
for consideration by the Design Sponsor (MLS 2).
1.1.6 Short Circuit Protection

a. The transformer shall be capable of withstanding a short circuit at the output

terminals when being supplied at the upper steady state limit of input voltage, in
accordance with the requirements of BS 171. Additional information is given in BS
3399.
1.1.7 Parallel Operation

a. If the transformer is required to operate in parallel with other units this duty shall be
specified in the SRD and full details of the characteristics of the other units shall be
provided.
b. Transformers required to operate in parallel shall be arranged so that, although the
total load need not necessarily be shared in the same ratio at all values of load, any

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 DEF STAN 02-535 / ISSUE 2

two transformers of the same design, shall share a load equal to 90% of the sum of
their continuous ratings in such a manner that neither transformer will be
overloaded.

2. NATIONAL/INTERNATIONAL REGULATIONS
(No relevant information included)

3. MILITARY STANDARDS/REQUIREMENTS
Related Documents: BS 171; BS 3399; BS 4683; DEF STAN 02512 Part 10;
DEF STAN 02514; DEF STAN 02722; DEF STAN 02723; DEF STAN 02784;
DEF STAN 07226; DEF STAN 07256; DEF STAN 08107; DEF STAN 08120;
DEF STAN 08123; SDN 007 502 095; SDN 007 502 096; see also Annex A.
3.1 General

a. General requirements for the design of electrotechnical equipment can be found in

DEF STAN 08107.
3.2 Drawings

3.2.1 Tender Drawings

a. Tender drawings shall comprise three clear prints of the outline of the transformer,
showing approximate overall dimensions and proposed fixing arrangements. The
estimated total weight shall also be given. For tender purposes these drawings may
be submitted in the Contractor's own style and format.
b. The following information shall also be supplied:
(1) Voltage ratio at noload;
(2) Noload current;
(3) Fullload losses (fixed, copper and total);
(4) Efficiency (at full load Unity Power Factor (UPF) and half fullload UPF);
(5) Regulation (at UPF and 0.8PF lagging);
(6) Method of voltage control to meet any special requirements for regulation
which cannot be obtained by the inherent regulation of the transformer;
(7) Maximum allowable temperature in °C;
(8) Output at abnormal ambient temperature, if applicable;
(9) Main details of insulation.
c. A brief specification of the equipment offered shall be submitted, together with
confirmation that the transformer will conform in all respects to the SRD and

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DEF STAN 02-535 / ISSUE 2

relevant specifications or details of all proposed departures from the requirements

of these documents.
d. The Contractor shall confirm that all necessary tests, specified by this Standard, can
be performed AT THE RATED VOLTAGES AND FREQUENCIES at his Works.
If this is not possible the Contractor shall state any alternative proposals suitable to
meet the test requirements of the equipment.
3.2.2 Manufacturing Drawings

a. When called for in the Contract, a complete set of manufacturing drawings shall be
prepared, in accordance with DEF STAN 02722, and submitted to the Design
Sponsor (MLS 2).
b. The information provided shall include:
(1) Winding table giving:
(a) Number of turns per winding;
(b) Sizes of all winding wires, type and thick Standards of insulation and
NATO stock number where applicable;
(c) Resistance of each winding at 15°C and at the appropriate reference
temperature;
(d) Weight of each winding (copper and insulation only);
(e) Insulation details including type of material and thickness.
(2) Impregnation details including temperature and duration of vacuum, drying,
dipping, draining, stoving, and cooling cycles; identity of the impregnant and
finishing varnish;
(3) Efficiency at full load and half load, both at UPF;
(4) Output  at normal rating;
 at abnormal ambient temperature (see Clause 1.1a).
(5) Regulation at UPF and at 0.8PF lagging;
(6) Noload and fullload losses;
(7) Percentage impedance voltage;
(8) Maximum allowable temperature rise at full load;
(9) Reference to parallel operation, where specified;
(10) Vector Group reference symbol;
(11) Total weight of transformer complete;
(12) Weight of transformer without case;
(13) Position of centre of gravity;
(14) Size, number and disposition of fixing holes and details of shock mountings,
if fitted;
(15) Shock Grade.

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 DEF STAN 02-535 / ISSUE 2

3.2.3 Delegated Approval

a. Where a Main Contractor has design responsibility for transformers supplied by a

subcontractor, the Main Contractor will receive from the subcontractor the
drawings and information detailed in Clause 3.2.2b.
b. The Main Contractor will examine and comment on these drawings as appropriate.
When satisfied that the proposed design will meet the requirements, the Main
Contractor will approve the drawings.
3.3 Special Purpose Transformers

3.3.1 Portable Apparatus (Earthed) Transformers

a. This type of transformer is required to supply power to portable apparatus. It shall

conform to the following:
(1) Primary voltage: 440 volts, 3phase;
(2) Rating:In the range of 5 to 20kVA;
(3) Primary winding: Delta connected;
(4) Electrostatic screen: Between primary and secondaries
(see Clause 4.1.3a.);
(5) Secondary windings: Three separate windings. Two terminals
for each winding. Midpoint of each
winding earthed. Insulated phase barrier
between each pair of phase terminals;
(6) Secondary voltages: 118 volts at noload per winding.
3.3.2 2 kVA Portable, Single Phase, Transformers
a. This type of transformer is required to provide emergency power supplies. It shall
comply with the following:
(1) Rated output in kVA: 2;
(2) Nominal input: 440 volts, 60 Hz, single phase;
(3) Rated output voltage 120 volts at NOLOAD;
(4) Regulation: Not exceeding 3.3% at UPF;
(5) Insulation Class B;
classification:
(6) Winding: Double wound with earth screen;
(7) Weight: Total weight not to exceed 20 kg (excluding input
and output cables and fixture for bulkhead);
(8) Mounting: Four rubber foot mounts;
(9) Portability: A rigid handle mounted on top of transformer;
(10) Enclosure: Dripproof;
(11) Glands, Terminals and Stowage for Cables.

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DEF STAN 02-535 / ISSUE 2

Primary Side

Gland: One gland, to the specification indicated in the appropriate

part of DEF STAN 02514, to suit cable of diameter
10.5 mm.

Terminals: Three terminals to the specification indicated in

DEF STAN 02512 Part 10, size M6 to be clearly marked
A1, A2, Earth. The earth terminal shall be connected
permanently to the transformer frame.

Cable Stowage: Brackets and leather strap to be provided for stowage of

approximately 3 m of flexible cable, diameter 10.5 mm, on
one side of the transformer case.
Secondary Side

Glands: Not required.

Terminals: The secondary connections shall be brought out

from the transformer on the side opposite the primary gland
by means of two size M6 terminal studs; these shall pass
through insulated bushes to the exterior of the case and be
provided with captive wing nuts. The external terminals shall
be protected from inadvertent contact by a vertical barrier
between the studs and also by a hinged cover. There shall be
ample clearance around the studs to enable hook end
terminals, to the specification shown in Figure 1, to be
speedily fitted and secured to the studs IN THE DARK. A
third terminal stud, threaded M10, earthed to the
transformer frame and provided with a captive wing nut is to
be sited well below the other two and OUTSIDE the
dropdown enclosure. This earth stud shall accept cable hook
end terminal to the specification shown in Figure 2.

Cable Stowage: Not required.

(12) Earth Screen: For this particular type of transformer the screen
shall be connected to the earth terminal adjacent
to the primary terminals.

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 DEF STAN 02-535 / ISSUE 2

– Figure 1 -Cable Hook End Terminal NSN 5940995259141,

SDN 007 502 095, Dimensions in mm.

13
DEF STAN 02-535 / ISSUE 2

– Figure 2 - Cable Hook End Terminal NSN 5940995259142,

SDN 007 502 096, Dimensions in mm.

14
 DEF STAN 02-535 / ISSUE 2

3.3.3 Flameproof Enclosures

a. Normally, transformers shall not be mounted in magazines or other restricted areas,

but where it is absolutely necessary to do so, the cable entry through a flameproof
enclosure, shall be designed in accordance with BS 4683.
3.4 Testing

a. The requirements for comprehensive testing may be removed if the viability of

commercially available equipment produces an economical procurement.

b. It is the responsibility of the procurement authority to ensure that transformers

procured for Royal Navy service are fit for purpose. Manufacturers shall
demonstrate that commercially available units provide the degree of operation
required for a particular application.
c. It is the Design Sponsors responsibility to ensure that the procurement
documentation only includes tests essential for satisfactory operation and to avoid
unnecessary groups of tests. Tests shall be specified in the SRD.
d. Where testing is required, the tests shall be carried out in accordance with the
relevant Clause of BS 3399 or the applicable DEF STAN. Classifications of tests
are identified in Clause 3.4.1.
e. In certain cases, test figures are required to be quoted in handbooks as a guide
during maintenance and repair. For measurements taken during testing,
appropriately rated instruments complying with the requirements of
DEF STAN 07226 shall be used.

3.4.1 Classification of Tests

a. Each transformer shall be subjected to one of the following tests:

(1) Type Tests. The first transformer of a new design shall be subjected to Type
Tests unless otherwise specified in the SRD. These tests are listed in Clause
3.4.2.
(2) Routine Tests. All transformers which are not required to be Type Tested
shall be subjected to the Routine Tests listed in Clause 3.4.3. The tests to be
carried out on transformers embodying minor changes to a design which has
already been Type Tested will be given in the SRD.

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DEF STAN 02-535 / ISSUE 2

3.4.2 Type Testing

a. The following tests shall be carried out on transformers that are required to be Type
Tested:
To be Tested In
Type of Test
Accordance With
Measurement of winding resistance DEF STAN 07226
Ratio, polarity and phase relationship BS 3399
Impedance voltage BS 3399
Noload losses and noload current BS 3399
Temperature rise DEF STAN 07226
Regulation at UPF and 0.8 power factor BS 3399
Load losses BS 3399
Airborne noise and vibration Clause 3.4.7
Short circuit at full voltage BS 3399
Shock tests DEF STAN 08120 see
also Clause 3.4.6
Vibration tests DEF STAN 07256 see
also Clause 3.4.6
Tilt test DEF STAN 08123
Induced overvoltage withstand BS 3399
Separatesource voltage withstand BS 3399
Insulation resistance DEF STAN 07226
Effectiveness of enclosure DEF STAN 08123
Parallel operation (where this is a specified Clause 3.4.8
requirement)
Earth bonding test DEF STAN 07226

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 DEF STAN 02-535 / ISSUE 2

3.4.3 Routine Testing

a. The following tests shall be carried out on transformers that are required to be
Routine Tested:
To be Tested In
Type of Test
Accordance With
Measurement of winding resistance DEF STAN 07226
Ratio, polarity and phase relationship BS 3399
Impedance voltage BS 3399
Noload losses and noload current BS 3399
Load losses BS 3399
Selfinduced airborne noise and vibration (may be Clause 3.4.7
waived at the discretion of the Design
Authority)
Induced overvoltage withstand BS 3399
Separatesource voltage withstand DEF STAN 07226
Insulation resistance DEF STAN 07226
Parallel operation (where this is a specified Clause 3.4.8
requirement)
Earth bonding test DEF STAN 07226

3.4.4 Testing of 2 kVA Portable Transformers

a. The following Type Tests are not required to be carried out on 2 kVA portable,
single phase transformers:
(1) Shock tests;
(2) Vibration tests;
(3) Tilt test;
(4) Parallel operation.
b. The following Routine Test is not required to be carried out on 2 kVA portable,
single phase transformers:
(1) Parallel operation.

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DEF STAN 02-535 / ISSUE 2

3.4.5 Tests At Other Than Rated Voltages and Frequencies

a. For transformers rated at 100 kVA or less, tests shall not be accepted if carried out at
reduced voltages or at any frequency other than the rated frequency unless prior
agreement has been reached with MLS 2. Where agreement has been reached,
reference shall be made to this fact on each test sheet and the actual measured
quantities calculated from them shall be recorded on the test sheet.

b. Where equipment of higher rated capacity than the above cannot be tested at rated
voltage and frequency, the manufacturer shall submit proposals for carrying out
tests to demonstrate that the requirements of the SRD and this Standard will be met.

3.4.6 Shock and Vibration Tests

a. Before the shock and vibration tests are applied the transformer shall be allowed to
reach its normal operating temperature. During these tests, the primary winding
shall be energised at its normal voltage, the other windings being opencircuited.
After the shock and vibration tests, the following electrical tests, detailed in Clause
3.4.3a, shall be carried out:

(1) Induced overvoltage withstand test;

(2) Separatesource voltage withstand test;

(3) Insulation resistance.

3.4.7 SelfInduced Airborne Noise and Vibration

a. The selfinduced airborne noise level is not to exceed 60 dbA using the `A'
weighted scale. Measurements of selfinduced airborne noise are to be made on the
equipment under various load conditions in accordance with DEF STAN 07-256.
The selfinduced vibration is not to exceed 60 dBA using a refence datum of
10-5m/sec2. Measurements of selfinduced vibration are to be made on the
equipment under various load conditions in accordance with DEF STAN 07-256.
These target levels may change dependent on the application, the required levels
will be stated in the SRD which would take precedence.

3.4.8 Parallel Operation

a. Where parallel operation of transformers of the same design is required, the first
two transformers of a production batch shall be run in parallel. Before the test the
transformers shall be adjusted by the builtin trimmer controls, tapping switches,
etc, where fitted, so that their noload voltages are identical, or as close as possible.
The transformers shall be connected to the same supply.

b. Upon the gradual application of load equal to 90 percent of the total load of the two
transformers combined, the load sharing shall be such that neither equipment is
overloaded.

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 DEF STAN 02-535 / ISSUE 2

3.4.9 Test Results

a. The results of the Type Tests shall be compiled into a report by the Electrical
Contractor or Main Contractor as appropriate. The report shall include any
oscillographic records taken during the tests and two copies of the report shall be
forwarded to MLS 2.

b. If any equipment fails to meet the specified requirement in any way it may be
rejected, or, at the discretion of MLS 2, the faults may be rectified and the
equipment retested. MLS 2 may call for the repetition of any test(s) to ensure that
they represent the normal performance of the equipment.

3.5 Marking

a. Identification marking shall be in accordance with the requirements of DEF STAN

02723 and Safety marking in accordance with DEF STAN 02784.

b. Marker plates shall be sited:

(1) One on each long side of deck mounted transformers;

(2) One on the outside of the access plate for bulkhead mounted transformers.

c. The number and siting of voltage warning signs per transformer shall be the same as
for marker plates.

3.5.1 Terminals

a. Terminals shall be identified in accordance with BS 171 and suitable permanent

markings shall be made on the terminal board adjacent to the terminals. The input
and output voltages shall be marked adjacent to the respective terminals.

3.5.2 Tieon Labels

a. A manilla tieon label, bearing a printed or typed instruction to the installer of the
transformer, shall be attached to the terminal board, and where the transformer is
fitted in its own case, another similar label shall be tied to the external earthing stud.
The instruction on the label shall be.

INSTRUCTION TO INSTALLER

This transformer is fitted with an Electrostatic Screen. Ensure that

a. Earthing Terminal is efficiently bonded to earth.

b. Input and Output cables enter the transformer at OPPOSITE
ends and do not pass each other across the terminal board.

b. Exception, tieon labels, as above, are NOT required to be attached to 2 kVA

singlephase portable transformers.

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DEF STAN 02-535 / ISSUE 2

3.6 Marker Plates

3.6.1 Identification Marker Plate

a. The equipment Marker Plate for transformers shall bear the following additional
information:
(1) Nominal input voltage;
(2) Rated noload output voltage;
(3) Primary and secondary currents at rated output;
(4) Rated kVA, frequency, phases;
(5) Class of insulation;
(6) Maximum temperature rise allowable by resistance in °C.

3.6.2 Earth Marker Plate

a. Where the space exists, a marker plate carrying the legend `EARTH' shall be fitted
adjacent to the transformer earthing stud. Where there is insufficient space for a
marker plate, an `earth' symbol shall be indelibly marked in lieu.

3.6.3 EarthScreening Marker Plate

a. All doublewound transformers, with the exception of 2 kVA single phase portable
transformers, which are selfcontained in their own enclosure, shall be fitted with
earthscreening marker plates situated just below each identification marker plate
and marked:

SCREENED TRANSFORMER

It is essential to bond
Transformer to Earth
by EARTH terminal.

3.6.4 Marker Plates for 2 kVA Portable Single Phase Transformers

a. One of each of the following marker plates shall be fitted:

Type Location
440V Warning Adjacent primary gland
120V Front of dropdown cover
Earth Adjacent earth stud
Identification On outside of top cover
Diagram of connections On inside of top cover.

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 DEF STAN 02-535 / ISSUE 2

4. DESIGN REQUIREMENTS/GUIDANCE

Related Documents: BS EN 604641; BS 171, BS 2757, BS 3399, BS 5629; DEF STAN

08109; see also Annex A.

4.1 Construction

4.1.1 Laminations

a. Laminations shall be of cold rolled grainorientated steel, the grade being selected
to give minimum losses, size and weight. Transformers rated at 2 kVA and less can
have nongrainorientated steel laminations.
b. The laminations shall be tightly clamped to reduce noise emission and all bolts
passing through the magnetic circuit shall be effectively insulated.

4.1.2 Insulation

a. Unless otherwise specified in the SRD the insulation classification shall be to

BS 2757 Class H.
b. Where other classes of material are used for support or protection of insulation,
they shall be carefully selected for their thermal and mechanical properties with
respect to their function. The use of such materials shall be kept to a minimum.
Where hygroscopic materials are employed they must be preimpregnated with a
suitable varnish selected from BS EN 604641. BS 5629 may provide supportive
information.
c. The insulating material of windings shall include a minimum thickness of
0.50 mm of mica or micanite or other approved insulation appropriate to the
insulation class between one winding and any of the following parts:
(1) Core;
(2) Another winding;
(3) Earthed screen.

4.1.3 Electrostatic Screening

a. All doublewound transformers shall be fitted with an electrostatic screen between

each highervoltage winding and lowervoltage winding. It shall comprise a single
turn of copper or aluminium foil. The single turn must not form a closed loop but
the ends shall overlap and be insulated from each other. A connection shall be
brought out from the mid point of this screen and connected to the earth stud within
the transformer case (see Clause 4.1.5b.). For transformers required to operate in
Tempest designated areas reference shall be made to MLS 2.

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DEF STAN 02-535 / ISSUE 2

4.1.4 Impregnation

a. All windings shall be impregnated with a thermosetting varnish by either of the

following:
(1) Vacuum/pressure impregnation and bake, plus one dip and bake;
(2) Hot dip and bakethree times.
b. A smooth even finish of the windings is essential and an airdrying finishing
varnish may be applied after the impregnation process to achieve this if necessary,
provided that:
(1) The varnish is solventless;
(2) Airways are kept clean;
(3) It is properly cured.
c. The varnishes used shall meet the requirements of BS EN 604641. Additional
information is given in BS 5629.
4.1.5 Earthing

a. All transformers shall be fitted with a doubleended threaded M10 earth stud. It
shall be fitted through the casing of the transformer, adjacent to the cableentry
plate for the secondary winding. Where the transformer is a component of a main
equipment an earth screw will be acceptable.
b. The earth stud within the transformer case shall provide for earthing the following
items, as applicable:
(1) Electrostatic screen;
(2) Earthed windings;
(3) Screening/armouring of cables, if fitted.
c. The earth stud shall be identified as described in Clause 3.6.2a.

4.1.6 Terminals and Cables

a. The terminals and cables for a particular transformer will be given in the SRD.
4.1.7 Terminal Arrangements

a. Deck mounted transformers shall have their terminals sited above the core and
accessible by removal of the top cover (or front access where fitted). The terminals
of bulkhead mounted transformers shall be sited below the core and have adequate
access by removal of a detachable front plate.
b. The higher and lower voltage terminals shall be disposed so that neither the supply
and outgoing cables, nor the internal connections to the higher and lower voltage
windings, cross each other or form inductive loops.

22
 DEF STAN 02-535 / ISSUE 2

c. The terminal arrangements must be capable of withstanding the throughfault

current referred to in Clause 1.1.6a.
4.1.8 Cable Entries

a. The transformer casing shall be fitted with detachable cableentry plates to

accommodate glands or grommets as may be specified in the SRD.
b. Normally, one plate shall be fitted for the supply cable(s) and a second plate for the
output cables, the two plates being positioned on either side of the casing and sited
to suit the terminal positions as stated in Clause 4.1.7a.

c. Where the transformer shall become a component of a main equipment the external
casing and glands will not normally be required and this shall be indicated in the
SRD.

4.1.9 Connections Diagrams

a. The connection diagram shall conform with BS 171 and is also to indicate the
existence of the electrostatic screening. Additional information regarding
connection diagrams is given in BS 3399.

4.1.10 Transformer InRush

a. Inrush current depends upon the saturated reactance of the transformer primary
winding. The transformer input fuses must have the capability of withstanding the
inrush current. Related information on transformer in rush can be found in DEF
STAN 08109.

5. NATIONAL/INTERNATIONAL REGULATIONS
(No relevant information included)

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DEF STAN 02-535 / ISSUE 2

ANNEX A.
A.
RELATED DOCUMENTS
A1. The following documents and publications are referred to in this Standard:
BS EN 604641 Varnishes Used for Electrical Insulation. Definitions and General
Requirements.
BS 171 Specification for Power Transformers.
BS 2757 Method for determining the Thermal Classification of Electrical
Insulation.
BS 3399 Specification for Transformers for use in Ships.
BS 4683 Electrical Apparatus for Explosive Atmospheres.
BS 5629 Insulating Varnish containing Solvent.
JSP 430 Ship Safety Management System Handbook:
Volume 1: Policy and Guidance on MOD Ship and Equipment
Safety Management.
DEF STAN 02512 Guide to Cables, Electrical and Associated Items.
(NES 512) Part 10: Terminations and Connectors
DEF STAN 02514 Guide to Cable Entry, Termination and Junction Components for
(NES 514) Equipment.
DEF STAN 02722 Requirements for the Preparation, Identification and Marking of
(NES 722) Drawings.
DEF STAN 02723 Requirements for Marker Plates.
(NES 723)
DEF STAN 02784 Requirements for Safety Signs and Colours.
(NES 784)
DEF STAN 07226 Requirements for Electrical Testing of Equipment.
(NES 511)
DEF STAN 07256 Requirements for Structure Borne Vibration and Airborne Noise
(NES 813) Testing of Warship Equipment.
DEF STAN 08107 General Requirements for the Design of Electrotechnical and Naval
(NES 501) Weapon Equipment.
DEF STAN 08109 Guide to the Design of Electrical Supply and Distribution Systems
(NES 532) in Surface Ships and Nuclear Submarines.
DEF STAN 08120 Requirements for Determining the Shock Strength of Equipment.
(NES 814)
DEF STAN 08123 Requirements for Design and Testing of Equipments to Meet
(NES 1004) Environmental Conditions.
DEF STAN 615 Electrical Power Supply Systems below 650 volts:
Part 4: Power Supplies in HM Ships.
SDN 007 502 095 Cable Hook End Terminal (50 A M6 Stud).
SDN 007 502 096 Cable Hook End Terminal (250 A M10 Stud).

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 DEF STAN 02-535 / ISSUE 2

ANNEX B.
B.

ABBREVIATIONS AND DEFINITIONS

B1. For the purpose of this Standard the following abbreviations apply.

BR Book of Reference
BS British Standard
BS EN British Standard European
DPA Defence Procurement Agency
DEF STAN Defence Standard
DLO Defence Logistics Organisation
JSP Joint Service Publication
MLS Marine Electrical Systems
MOD Ministry of Defence
NATO North Atlantic Treaty Organisation
NES Naval Engineering Standard
NSN NATO Stock Number
PF Power Factor
SDN Service Drawing Number
SRD System Requirement Document
UPF Unity Power Factor

B2. For the purpose of this Standard the following definitions apply.

Design Authority The agency responsible for undertaking the actual design task and for
producing the Configuration Definition of the equipment. For the
purposes of this Standard the Design Authority will normally be a
Contractor entrusted with the Development Contract supported by a
SRD. The Design Authority may subcontract some of the detailed
design or drawing work, but nevertheless retains the ultimate technical
design responsibility . The Design Authority `certifies' the
manufacturing drawings, and in so doing accepts responsibility for the
correctness of the design.
NOTE It is emphasized that formal approval of the manufacturing
drawings, etc., by the Design Sponsor, subsequent to their
certification by the Design Authority, does NOT constitute
a `design audit' and does not relieve the Design Authority of
any part of their responsibility for the technical adequacy of
the design. Design Sponsor approval signifies that they are
satisfied that the Prototype has passed all relevant tests, and
that the manufacturing drawings and Production Test
Documentation constitute an adequate Configuration
Definition for MOD purposes.

25
DEF STAN 02-535 / ISSUE 2

ANNEX C.
C.
PROCUREMENT CHECK LIST
Notes:
C.1 This Check List is to ensure that certain aspects of this Defence Standard
are consulted when preparing a procurement specification for a particular
application.
application
C.2 Clauses where a preference for an option is to be used or where specific data is
to be added are included in the Check List.
C.3 Each item is to be marked either:

= included
NA = not applicable
CHECK
CHECK CLAUSE No
or NA
No
1 SRD to be prepared in accordance with
DEF STAN 028.
2 Type of equipment required. SCOPE
3 kVA rating if affected by abnormal ambient 1.1a.
conditions.
4 Tolerances if different. 1.1b.
5 Vector relationship if different. 1.1.1a.
6 Ambient air temperature if different. 1.1.2b.
7 Regulation if different. 1.1.3a.
8 Whether tapped transformer is required. 1.1.5b.
9 If transformer is required to operate in parallel. 1.1.7a.
10 Selfinduced airborne noise and vibration levels if 3.4.7a.
different.
11 Insulation classification if different. 4.1.2a.
12 Terminals and cables requirement. 4.1.6a.
13 Cable glands or grommets to be fitted. 4.1.8a.
14 Whether external casing and glands are required. 4.1.8c.
15 Total kVA rating. 1.1.4b.
16 Type tests if different. 3.4.1a.(1)
17 Routine tests requirement. 3.4.1a.(2)

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 DEF STAN 02-535 / ISSUE 2

ALPHABETICAL INDEX
(Note: Page numbers are given)

C identification , 20
Cable entries, detachable plates, 23 Marking , 19
Cables , flameproof enclosures , 22
N
D Noise and vibration, static conversion
equipment, 18
Diagram of connection , 23
Drawings
delegated approval , 11
P
manufacturing , 10 Parallel operation , 8
tender , 9 Power testing , 15

E R
Regulation , 7
Earthing, method of , 22

I S
Saturated reactance, calculation , 8
Identification , 19
Screening, electrostatic , 21
Insulation
Short circuit protection , 8
classification , 21
minimum thickness , 21
T
protection of , 21
Tapped transformers , 8
Temperature rise permissible , 7
L
cores , 7
Labels tie-on , 19
windings , 7
Laminations , 21 Tender
drawings , 9
M equipment specification , 9
Marker Plates information to be supplied , 9
2 kVA portable transformers , 20 Terminal arrangements , 23
earth , 20 marking , 19
earth screening , 20 Terminals , 22
Test facilities at contractors , 10
Tie-on labels , 19

27
DEF STAN 02-535 / ISSUE 2

V W
Varnishes, selection of , 22 Windings
Voltage control , 8 impregnation , 22
special requirements , 8 vector symbols , 7

28
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