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INSTRUCTION MANUAL

TRANSFORMER
Type: TNER3E 40000/115PN

Serial no. 1133751


Rated Power 40/40/40 MVA
Rated Voltage 115 ± 9 x 1.778 % / 11 / 6.6 kV
Connection (vector group) YNd11d11
Year of Manufacture 2007

Internal order no. K.570.1.A002-11152

ABB Sp. z o.o.


Branch Office in Łódź
ul. Aleksandrowska 67 / 93 tel. + 48 42 29 93 000
91-205 Łódź fax + 48. 42 29 93 002
Poland http://www.abb.com/powertransformers
Serial no. 1133751

LIST OF CONTENTS

1 Main Technical Data of Transformer

2 Drawings

2.1 Rating Plate 881.537.1A

2.2 Diagram Plate 883.632.1A

2.3 Dimension drawing 51.14.3-03-3601

2.4 Transport drawing 51.14.3-15-0841

2.5 Electrical diagram of cooling control and 8.710.03-06-0700


protection box

2.6 Pictures

3 Shipping, off-loading, assembling, testing and commissioning of transformer.

3.1 -Shipping of Transformers- General Overview 1ZBA4601-200

3.2 -Off-loading and moving transformer 1ZBA4601-202

3.3 -Monitoring of dry gas filled transformer 1ZBA4601-203

3.4 - Receiving Inspection. 1ZBA4601-206


Transformer Designed with Oil Conservator,
Shipped Oil Filled, Shipped Partially
Disassembled

3.5 -Storage on site before assembly 1ZBA4601-211

3.6 -Transformer assembly instruction 1ZBA4601-212

3.7 -Receiving and handling transformer oil on site. 1ZBA4601-213


Quality control

3.8 - Final oil Filling on Site. Atmospheric Pressure 1ZBA4601-214

3.9 -Acceptance testing and energization 1ZBA4601-216

3.10 -Field test record 1ZBA4601-217

3.11 -Oil conservators with air cell 1ZBA4601-219

3.12 -Supervision on transformers and reactors 1ZBA4601-222

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Serial no. 1133751

4 Accessories of transformer. List of manufacturers/suppliers

5 On-load tap changer UCGRN 650/300/C with motor drive BUL

5.1 On-load tap-changers, type UC. Technical guide 1ZSE 5492-105 en, Rev. 5

5.2 Motor-drive mechanism, type BUL. Technical 1ZSE 5483-105 en, Rev. 3
guide

5.3 On-load tap-changers, types UCG and UCL with 1ZSE5492-116 en, Rev. 8
motor-drive mechanism, types BUE and BUL.
Installation and commissioning guide

5.4 On-load tap-changer, type UCG with motor-drive 1ZSE 5492-124 en, Rev. 5
mechanisms, types BUE and BUL. Maintenance
guide

5.5 On-load tap-changers, types UCG, UCL, UCC 1ZSE 5492-129 en, Rev. 6
and UCD with motor-drive mechanisms, types
BUE and BUL. Repair Guide

5.6 On-load tap-changers, types UCG, UCL, UCC 1ZSE 5492-133 en, Rev. 3
and UCD with motor-drive mechanisms, types
BUE and BUL. Spare Parts List

5.7 Tap-Changer UCGR UCGRN 54920104-8

5.8 Top Section, Accessories Tap-Changer UCG 54920103-2

5.9 External Shaft System 54920083-4

5.10 Connection Diagram 5492 0095-118

5.11 Circuit Diagram Relief Vent 5478 003-59

5.12 Circuit Diagram Motor-Drive Mechanism Type 5483 538-66


BUL 5475 908-11
5475 913-26
5483 540-1
5483 540-30

2/4
Serial no. 1133751

6 Bushings

6.1 HV bushing type GOB 550-800 LF 123 191 K, L6=500

6.2 HV neutral bushing type GOB 550-800 LF 123 189 K, L6=100

6.3 Transformer bushings, type GOB. 2750 515-12 en, Rev. 9


Installation and maintenance guide

6.4 MV bushing type 20f/3150 FIG B1, C1=440

6.5 MV bushing type 10f/4500 FIG C1, b1=380

6.6 SOLID BUSHING TYPE DIN 42533 – 42534 &


EN 50180.PRODUCT INFORMATION &
OPERATING INSTRUCTIONS

7 Cooling system

7.1 Cooler LK-S-190-50-1a-2x910-R13-100-h.


Operating and maintenance manual

7.2 Pump DB-TR-005 - GB

7.3 Liquid flow indicator

8 Transformer Protection

8.1 Buchholz Relay BF80/10. Operating instruction 01/02/04/02

8.2 Safety valve VS 150

9 OLTC protection

9.1 Monitoring relay for tap changers. Catalogue 01 / 05


Technical description

9.2 Pressure relay for on-load tap-changers. 1ZSE 5492-151 en, Rev. 5
Technical information

10 Conservator air cell (separator) installation

11 Electronic Transformer Monitor for Liquid filled


Transformers 509-100

11.1 Operations Manual IST-072-1

11.2 Software Manual IST-073-1

11.3 Resistance Bulb Platinum 103-023-01

3/4
Serial no. 1133751

12 Oil Temperature Indicator for Power


Transformer type : MSRT 150

13 Winding Temperature Indicator for Power


Transformers type : MSRT 150-W

14 Oil level indicators

14.1 Oil level indicator. Product information 1ZBA 569 002-4

14.2 Oil level indicator fore OLTC (LA22) 1ZBA 569001-C

14.3 Oil level indicator for main tank (LB22) 1ZBA 569 001-X

15 Air breathers

15.1 KC-Trockenperlen Orange 1ZBA676002-1

15.2 Model EM5DA 1ZBA 676001-C

15.3 Model EM2DA 1ZBA 676001-A

16 Valves

16.1 Throttle valves WKKI-1

16.2 Ball valves WK 2a

17 Transformer oil

17.1 Naphthenics Product Data Sheet.


Nynas Transformer Oil - Nytro 10XN

17.2 Naphthenics Safety Data Sheet

18 Test Report 2007/0141/025

19 Certificates of transformer accessories

4/4
Serial no. 1133751

Main Technical Data of Transformer


1 Type TNER3E 40000/115 PN

2 Serial no. 1133751

3 Manufacturer ABB Sp. z o.o.


ul. Żegańska 1, 04-713 Warszawa
Branch Office in Lodz
ul. Aleksandrowska 67/93
91-205 Lodz, Poland

4 Rated Power 40

4.1 HV MVA 40
4.2 MV MVA 40
4.3 LV MVA 40

5 Insulation level
5.1 HV LI450 AC185 -I325 AC185
5.2 MV LI95 AC38
5.3 LV LI75 AC28

6 Phase number 3

7 Frequency Hz 50

8 Rated voltage
8.1 HV kV 110 ± 9 x 1.778 %
8.2 MV kV 11
8.3 LV kV 6.6

9 Voltage regulation On-load

10 Connection (vector group) YNd11d11

11 Impedance voltage at nominal tap (guaranteed/measured)


11.1 HV-MV @ 40 MVA % 11.0 / 10.69
11.2 HV-LV @ 40 MVA % 16.5 / 16.36
11.3 MV-LV @ 40 MVA % 30.0 / 30.05

1/2
Serial no. 1133751

12 Load losses at nominal tap and at rated power (guaranteed/measured)


12.1 HV-MV @ 40 MVA kW 185.0 / 177.42
12.2 HV-LV @ 40 MVA kW 205.0 / 216.37
12.3 MV-LV @ 40 MVA kW 220.0 / 243.16

13 No-load losses (guaranteed/measured) KW 25.0 / 22.45

14 Standard IEC 60076

15 Ambient temperature
15.1 maximum °C + 40
15.2 minimum °C - 35

16 Cooling system OFAF

17 Noise level. Sound pressure at no-load and with dB(A) 75.00 / 71.5
operating cooling system (guaranteed/measured)

18 Total mass kg 74,000

19 Mass of transformer oil kg 18,500

20 Corrossion protection / Color C3 / RAL 7032

21 Grade of transformer oil used for first Nytro 10XN


transformer filling / Manufacturer Nynas Naphthenics AB

2/2
Serial no. 1133751

2 Drawings

2.1 Rating Plate 881.537.1A

2.2 Diagram Plate 883.632.1A

2.3 Dimension drawing 51.14.3-03-3601

2.4 Transport drawing 51.14.3-15-0841

2.5 Electrical diagram of cooling control and 8.710.03-06-0700


protection box

2.6 Pictures

1/1
1133751

PICTURES

HV-side

LV-side

1/3
1133751

HV Leads

LV leads

2/3
1133751

Connection to OLTC

3/3
Serial no. 1133751

3 Shipping, off-loading, assembling, testing and commissioning of transformer.

3.1 -Shipping of Transformers- General Overview 1ZBA4601-200

3.2 -Off-loading and moving transformer 1ZBA4601-202

3.3 -Monitoring of dry gas filled transformer 1ZBA4601-203

3.4 - Receiving Inspection. 1ZBA4601-206


Transformer Designed with Oil Conservator,
Shipped Oil Filled, Shipped Partially
Disassembled

3.5 -Storage on site before assembly 1ZBA4601-211

3.6 -Transformer assembly instruction 1ZBA4601-212

3.7 -Receiving and handling transformer oil on site. 1ZBA4601-213


Quality control

3.8 - Final oil Filling on Site. Atmospheric Pressure 1ZBA4601-214

3.9 -Acceptance testing and energization 1ZBA4601-216

3.10 -Field test record 1ZBA4601-217

3.11 -Oil conservators with air cell 1ZBA4601-219

3.12 -Supervision on transformers and reactors 1ZBA4601-222

1/1
PowerIT Transformers and Reactors

SHIPPING OF TRANSFORMERS - GENERAL OVERVIEW

Table of contents

1 Scope ............................................................................................................................................ 2
2 Shipping Information ....................................................................................................................... 2
2.1 Shipping Sketch........................................................................................................................ 2
2.2 Shipping Braces and Covers ....................................................................................................... 2
3 Transportation ................................................................................................................................ 2
3.1 Impact Recorder ....................................................................................................................... 2
4 Successful Shipment Verification ....................................................................................................... 3
4.1 General.................................................................................................................................... 3
4.2 Impact Recorder ....................................................................................................................... 3
4.3 Other Checks............................................................................................................................ 3
4.4 External inspection.................................................................................................................... 4
5 Arrival at Customer’s Mounting Pad ................................................................................................... 5
1 Scope
Special instruction for Transport from ABB manufacturer to customer site
They are intended to provide guidelines in the transport of transformers from ABB manufacturer to customer site to
maintain their quality and reliability.

The Instructions are intended for the guidance of personnel who have been trained for, or who have experience in
transportation of heavy electrical power equipment, including the use of good safety practices. These instructions are
intended to supplement, and not eliminate the necessity for such training

2 Shipping Information

2.1 Shipping Sketch

In the shipping sketch details of weights and dimensions of the main tank is indicated. This sketch shows a three
dimensional profile of the stripped down, as-shipped transformer tank. The centre of gravity in three dimensions along
with distances to the tank extremities is indicated. Information is given whether the transformer is shipped in oil or in dry
gas, (air or nitrogen) and the shipping weight with or without oil. The shipping sketch also details special lifting,
handling or shipping bracing instructions
2.2 Shipping Braces and Covers

Shipping covers, and sometimes special braces, are required for shipment. These braces and covers must be
removed after arrival site during the re-assembly process. The covers and braces are identified in the shipping
documentation and are painted a contrasting colour, such as yellow, for easy identification.

3 Transportation
3.1 Impact Recorder

The use of a three-dimension impact recorder (also known as a bump recorder or accelerometer) to monitor the quality
of the trip and to chronicle potential excessive shocks to the transformer is in many cases a standard and Customer
specified requirement. An electronic or mechanical impact recorder may be used.

The impact recorder is mounted on the transformer . Core form transformers are to be shipped upright, with the
transformer mounted on the rail car or truck such that the long axis is in the same direction as the direction of travel.

<<<<<< Direction of Travel >>>>>>

Rail Car
or Truck

Transformer

Plan View of a Transformer Placed on a Rail Car or Truck

The impact recorder is mounted on the transformer to ensure:


• the Longitudinal Acceleration direction lines up with the direction of travel
• the Lateral Acceleration direction lines up with the direction a right angles to the direction of travel
• the Vertical Acceleration will detect the up and down movement.

See separate information leaflet for handling of impact recorder.


.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 2 of 6


Applicability: TrafoStar Lang: en Title:
Document No. SHIPPING OF TRANSFORMERS - GENERAL
1ZBA4601-200 OVERVIEW
4 Successful Shipment Verification
4.1 General
After leaving the factory, whenever the transformer and components are transferred from one mode of transportation
(rail car, truck, ship, etc.) to another, checks should be made to confirm that shipping damage has not been sustained.
These checks should be made before the equipment is moved from the transport mode. Since transformers are
shipped partially disassembled, electrical testing to confirm fitness cannot be performed at this stage. Care must be
taken to properly and completely perform the limited amount of inspection that can be done at this time.
In the event of apparent or suspected damage, claims must be made against the transport carrier, and the
Factory and Customer are to be notified immediately.
4.2 Impact Recorder

Refer to separate instruction leaflet for instructions on removing impact recorder at final destination. Acceptable
impact levels for the Longitudinal, Lateral and Vertical Acceleration will be defined by the individual Factories.

If the transformer and components are being inspected at an interim point, at a change of transportation mode, the
impact recorder should be monitored. The impact recorder should not be removed from the transformer until the
transformer has reached the final destination.
4.3 Other Checks
If Shipping weight and dimension limits allow, smaller transformers are shipped with all or most of the oil required in the
main tank. Some of these smaller units may also be shipped with dry nitrogen or air in the gas space on top of the oil,
this gas will be at a positive pressure when the transformer leaves the factory.

To reduce shipping weight, larger units are totally drained of oil and then filled with dry gas (nitrogen or air) to maintain
winding and insulation dryness during transit. Of the gas filled units, some will be filled in the factory and then be
equipped with temporary gas cylinders for adding gas to the tank during transit as needed. Other gas filled units will
leave the factory with an initial filling only and no supplementary cylinders added. In all cases, the gas filled units will
leave the factory with a positive pressure of dry gas.

For transformers shipped in oil, check for oil leaks at valves, flanges, bushings and welded seams. If evidence of oil
leaks are observed, contact ABB.

For transformers shipped in oil with a gas layer on top of the oil, perform oil leak checks and draw oil from suspect
units. In addition, theses transformers will be equipped with a vacuum/pressure gauge to monitor the gas layer
pressure. This gauge must be checked and value of pressure/vacuum noted along with the oil temperature as read
from the top oil temperature gauge.

For transformers shipped dry gas filled, the monitoring of the vacuum/pressure gauge and the temperature gauge is
critical and is often checked at various stages of the journey.
A leak will compromise the winding and insulation integrity. The pressure and temperature gauge values must be
recorded and compared to the readings obtained in the factory prior to shipment. The transformers are shipped with a
positive pressure but a negative (vacuum) reading may occur if the ambient temperature is substantially lower than
recorded in the factory. The worst case condition is a reading of zero pressure, which may be indicating a leak. In
conditions of zero pressure or a pressure/temperature relationship that conflicts with the factory results, a dew point
measurement may be taken. The dew point measurement will establish the moisture content of the gas, which can be
compared to the measurement made in the factory prior to shipment.
See 1ZBA 4601-203 and 1ZBA 4601-204 for further information on monitoring dry gas filled units during shipment.

The following is a general listing of tests and checks that should be performed on shipped transformers. Not all checks
are required for all shipping variations.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 3 of 6


Applicability: TrafoStar Lang: en Title:
Document No. SHIPPING OF TRANSFORMERS - GENERAL
1ZBA4601-200 OVERVIEW
4.4 External inspection
Any external evidence of damage or evidence indicating the possibility of hidden damage must be reported to the
carrier’s representative and to an ABB representative before off-loading the transformer. Take pictures of external
damage. The receiver must assume all responsibility for off-loading damaged transformers. The external inspection
prior to off-loading the transformer should include the following.

1. Measure the core insulation resistance to ground. The minimum acceptable value is 500 k ohms when
o
measured at 1000 V DC, corrected to 20 C.

2. Are all tie rods undamaged and nuts tight, all cables tight?

3. Is all blocking tight and in good condition?

4. Is there any evidence of load shifting in transit?

5. Does the impact recorder indicate any impacts beyond the acceptance zones?

6. Are there indications of external damage such as broken glass on gauges, broken welds on flanges?

7. Is the paint finish damaged?

8. Are all fittings, which were shipped attached, still in place and undamaged (see the outline drawings)?

9. Is there any evidence of oil leakage around valves, fittings, flanges and tank seams?

10. Is the pressure in the gas filled transformer tank acceptable according to Product Information 1ZBA 4601-203 or
1ZBA 4601-204?

11. Inspect bushings that are assembled to the tank for signs of breakage, are they chipped or otherwise damaged?

12. Check the Packing List to confirm delivery of all major components and accessory boxes.

13. Do crates or boxes show evidence of damage or moisture entrance?

14. Check the temporary shipping silica gel breather, moisture ingress will be indicated by the silica gel desiccant
changing colour.

15. Check that detached radiators, coolers and pumps have openings closed off with blind flanges and plugs.

If there is no evidence of shipping damage, proceed to off-load the transformer. If shipping damage is found, contact
the nearest ABB Power Transformers representative for further instructions prior to off-loading the transformer.

Written notations of apparent loss and damage must be made on the carrier’s delivery receipt. Concealed damage
must be reported immediately to the delivering carrier with a request for an inspection.

See Product Information for specific Receiving Inspection -

1ZBA 4601-205 Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Complete
1ZBA 4601-206 Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled
1ZBA 4601-207 Transformer Designed with Oil Conservator, Shipped Dry-Gas Filled, Partially Disassembled
1ZBA 4601-208 Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Complete
1ZBA 4601-209 Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Partially
Disassembled
1ZBA 4601-210 Transformer Designed with Sealed Tank, Gas Space, Shipped Dry-Gas Filled, Shipped Partially
Disassembled

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 4 of 6


Applicability: TrafoStar Lang: en Title:
Document No. SHIPPING OF TRANSFORMERS - GENERAL
1ZBA4601-200 OVERVIEW
5 Arrival at Customer’s Mounting Pad

The Following Product Information documents will provide guidance for the required
operations once the transformer has arrived on site and been Inspected. Choose the
applicable documents.
1ZBA 4601-202 Off-Loading and Moving a Transformer

1ZBA 4601-211 Storage on Site Before Assembly

1ZBA 4601-212 Transformer Assembly Instructions

1ZBA 4601-213 Receiving and Handling Transformer Oil on Site – Quality Control

1ZBA 4601-214 Final Oil Filling on Site – Atmospheric Pressure

1ZBA 4601-215 Vacuum Oil Filling on Site

1ZBA 4601-216 Acceptance Testing and Energization

1ZBA 4601-217 Filed Test Record

1ZBA 4601-218 Oil Conservators Without Air Cell

1ZBA 4601-219 Oil Conservators With Air Cell

Revision
A: 2001-02
B: 2004-04-04 new Template iT W. Klein PTPT/GD
C: 2003-06-17 Doc-no was 1ZBA4601-201 W. Klein PTPT/GD
D: 2003-08-11 Rewritten & renamed L Ostman PDC/LP

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 5 of 6


Applicability: TrafoStar Lang: en Title:
Document No. SHIPPING OF TRANSFORMERS - GENERAL
1ZBA4601-200 OVERVIEW
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 6 of 6


Applicability: TrafoStar Lang: en Title:
Document No. SHIPPING OF TRANSFORMERS - GENERAL
1ZBA4601-200 OVERVIEW
PowerIT Transformers and Reactors

OFF-LOADING AND MOVING A TRANSFORMER

Table of contents

1 Inspection before off-loading 2

2 Off-loading the transformer 3

2.1 Off-load with overhead crane ..................................................................................................... 4


2.2 Off-loading when overhead crane is not available ...................................................................... 4

3 Revision 6

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY 6


1 Inspection before off-loading
Before off-loading a transformer from any kind of vessel or carrier, an inspection of the transported goods shall be
made in order to reveal any shipping losses or damage. Shipping papers, packing list with transport outline drawings,
instruction leaflets and other pertinent documents furnished with the transformer must be available for use during the
inspection.

See Product Information for specific Receiving Inspection - Transformers Designed With:
1ZBA 4601-205 Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Complete
1ZBA 4601-206 Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled
1ZBA 4601-207 Transformer Designed with Oil Conservator, Shipped Dry-Gas Filled, Partially Disassembled
1ZBA 4601-208 Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Complete
1ZBA 4601-209 Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Partially
Disassembled
1ZBA 4601-210 Transformer Designed with Sealed Tank, Gas Space, Shipped Dry-Gas Filled, Shipped Partially
Disassembled

If there is no evidence of shipping damage, proceed to unload the transformer. If shipping damage is found, contact the
nearest ABB Power Transformers representative for further instructions prior to off-loading the transformer.

Written notations of apparent loss and damage must be made on the carrier’s delivery receipt. Concealed damage
must be reported immediately to the delivering carrier with a request for an inspection.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 2 of 6


Applicability: TrafoStar Lang: en
Title:

Document No. OFF-LOADING AND MOVING A TRANSFORMER


1ZBA4601-202
2 Off-loading the transformer

Most large power transformers arrive to their destination loaded on depressed centre cars for rail or road. The
transformer must have the shipping braces and blocking removed from the car, and then be lifted or skidded from the
car to the correct position at the installation site.
Caution
Failure to follow these instructions may result in equipment damage or personal injury.

Locate the car on a straight and level section of track, set the brakes on both ends of the car, and place chock blocks
under the wheels at both ends. This will prevent movement of the car during the off-loading operations.

After the receiving inspection has been completed, remove the tie rods and the blocking from the car, Figure 1.

Figure 1 - Transformer shipment showing tie-rods and blocking

When the blocking has been welded to the car, use an acetylene-cutting torch and burn the blocking from the car bed,
Figure 2. Do not attempt to burn the blocking at the point where it fits to the transformer base because this will damage
the transformer paint finish and may damage the tank wall and cause an oil leak.

Figure 2 - Blocking

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 3 of 6


Applicability: TrafoStar Lang: en
Title:

Document No. OFF-LOADING AND MOVING A TRANSFORMER


1ZBA4601-202
2.1 Off-load with overhead crane
If an overhead crane with sufficient capacity is available to lift the transformer from the car; this is the most convenient
method to unload the transformer. Use a spreader bar, or slings with sufficient length to achieve a lifting angle small
enough to meet the requirements given in the transport or outline drawing. Attach the slings to the lifting hooks on the
transformer. The lifting hooks will be shown on the outline drawing and are generally located at all four corners of the
tank. Do not attempt to lift the transformer from any point other than the designated lifting hooks.
Do not allow the slings to come in contact with any accessory items such as indicating instruments or bushings.
2.2 Off-loading when overhead crane is not available
If a suitable overhead crane is not available, the transformer must be raised from the car bed with jacks, and then
skidded or rolled into the desired position.

Figure 3 - Jacking Pad

Place lifting jacks at the points near the base that are designated jacking pads - Figure 3.
Operate the jacks at all four lifting points simultaneously so that the transformer base is kept level during the jacking.
(Do not locate the jack base directly on the car bed.)
Block the car frame before the transformer is jacked up to keep it stable during the off-loading and skidding operation.
Warning
Be certain the jacks are secured directly under the jack pads on the tank so they will not slip out of position during the
lifting operation. Failure to do this may cause equipment damage and severe personal injury.

Figure 4 - Transformer raised. Cribbing placed under transformer.

Jack the transformer approximately 20 to 25 cm (8 to 10 inches) above the car bed and slip successively heavy timbers
or rails between the transformer and the car bed. The free clearance up to the transformer bottom during the jacking
operation shall for safety reasons never exceed 5 cm (2 inches). The timbers should be located at the same point that
Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 4 of 6


Applicability: TrafoStar Lang: en
Title:

Document No. OFF-LOADING AND MOVING A TRANSFORMER


1ZBA4601-202
planking was placed on the car bed when the unit was loaded. The timbers or rails should extend beyond the width of
the transformer base to be certain the base is not damaged during the off-loading operation.

Lower the transformer on to the timbers and remove the jacks. Construct cribbing along the side of the rail car up to the
same height as the top of the timbers under the base. Skid the transformer from the rail car onto the cribbing. Be
certain to use only the designated pulling eyes when you move the transformer.

Do not allow the pulling cables to contact any piping or cooling equipment that may be installed on the transformer.

Set up the lifting jacks at the jacking point on the transformer and raise if off the cribbing. Remove one layer of max. 5
cm (2 inches) of the cribbing from under the transformer. Lower the transformer to the next layer of cribbing, reposition
the jacks, and lift the transformer off the cribbing and remove another layer of cribbing. Continue this procedure until
the transformer can be placed on the rollers or skids and moved to the prepared pad.
Figure 4 illustrated skidding on timbers and Figure 5, application of rollers. Keep the base level at all times.

Figure 5 - Transformer raised. Cribbing and rollers placed under transformer.

Be certain to support the base of the transformer as shown on the outline drawing or the base drawing when you
unload it from the car and move it to the foundation.

Use the designated pulling eyes and move the transformer to the prepared pad on rollers or skids and lower the
transformer onto the pad. Check to be certain the base is level and proceed with the assembly and oil filling process.

If rollers are used, they should be located directly under the two walls parallel to the direction of movement. Rollers
should be used on each side with a maximum centre to centre distance between rollers of one meter, or three feet.
Failure to keep the rollers within the designated support area of the base may damage the tank bottom.

3 Revision
A: 2001-02

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 5 of 6


Applicability: TrafoStar Lang: en
Title:

Document No. OFF-LOADING AND MOVING A TRANSFORMER


1ZBA4601-202
B: 2003-04-08 new Format
C: 2003-08-11 new contact address

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 6 of 6


Applicability: TrafoStar Lang: en
Title:

Document No. OFF-LOADING AND MOVING A TRANSFORMER


1ZBA4601-202
PowerIT Transformers and Reactors

MONITORING OF DRY-GAS FILLED


TRANSFORMERS WITHOUT GAS CYLINDERS DURING
SHIPMENT AND STORAGE

Table of contents

SCOPE.................................................................................................................................................... 2

1 Pressure Gauge and Filling Valve ..................................................................................................... 2

2 Pressure Limits ................................................................................................................................. 2

3 Monitoring under storage................................................................................................................... 2

4 Revision ............................................................................................................................................ 2
SCOPE
Note: Nitrogen gas is sometimes used instead of dry air. In these cases, a warning label is affixed to the tank. This
Instruction is valid for both dry air and dry nitrogen.

These transformers are shipped without oil and with accessories and fittings removed. The tank has been filled with dry
gas to a slight over-pressure in the factory. It is important that the transformer remains perfectly sealed during shipment
and storage. The gas pressure shall be monitored at regular intervals. Instructions and report forms are enclosed in the
"Shipping Manual".
1 Pressure Gauge and Filling Valve
A pressure gauge and filling valve are fitted under a protective cover on the side or the top of the tank. There is either
a transparent cover, through which the pressure gauge may be read without opening it, or a marked steel cover. In the
latter case, make sure that the cover is put back properly after every inspection.

The pressure gauge has a range +- 60 kPa (+-10 psi). The filling valve will accept a plastic tube with an inner diameter
of 5-8 mm (1/4 in).
2 Pressure Limits
The gas pressure in the tank when the transformer leaves the factory is 20 kPa (3psi) at a temperature of about 20°C
(65-70°F). This pressure will change with the ambient temperature, see Figure 1. Even at -25°C there should be a
small positive over-pressure and in a warm climate the pressure still is about 30 kPa.

30

20
Pressure kPa

10

0
-20 -10 0 10 20 30

Temperature OC

Figure 1 Correct pressure at different ambient temperatures

If, after inspection, the pressure is completely lost, there must be a leak somewhere. It is possible that there may even
have been under-pressure at some time (due to a sudden temperature drop), and moisture may have entered the tank.
Complete loss of gas-filling pressure must be reported immediately for further action.

If the pressure read on the gauge is not completely lost, but has fallen below 5 kPa (1 psi), then the tank shall be filled
up with dry gas to the original reading of about 20 kPa.

The guaranteed dryness of the filling gas shall be such that the dew point is below -40°C (-40°F). Before filling, the
plastic hose used shall be blown clean with gas from the bottle.

3 Monitoring under storage


When the transformer is under storage for longer time than one month, the filling pressure shall be checked and
recorded. See information in instruction 1ZBA4601-211 STORAGE ON SITE BEFORE ASSEMBLY. If the unit is
opened and pressurized again the pressure must be rechecked again after 24 hours

4 Revision
A: 2001-02
B: 2003-04-09 new Format
C: 2003-08-11 change contact address. Paragraph 3

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 2 of 3


Applicability: TrafoStar Lang: en
Title:
MONITORING OF DRY-GAS FILLED
Document No.
TRANSFORMERS WITHOUT GAS CYLINDERS DURING
1ZBA4601-203 SHIPMENT AND STORAGE
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 3 of 3


Applicability: TrafoStar Lang: en
Title:
MONITORING OF DRY-GAS FILLED
Document No.
TRANSFORMERS WITHOUT GAS CYLINDERS DURING
1ZBA4601-203 SHIPMENT AND STORAGE
PowerIT Transformers and Reactors

RECEIVING INSPECTION
Transformer Designed with Oil Conservator,
Shipped Oil Filled, Shipped Partially Disassembled

Table of contents

Scope ...................................................................................................................................................... 2

1 Visual inspection on arrival at site ..................................................................................................... 2

2 Revision ............................................................................................................................................ 2

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY ........................................................ 3


Scope
These transformers are shipped with oil in the tank close to cover level. Certain fittings are removed for shipment
because of shipping limitations or risk of damage. A silica gel breather may be temporarily fitted to the top of the
transformer during shipment.

1 Visual inspection on arrival at site


Upon arrival at site the transformer is carefully inspected. In order to maintain the warranty, the Receiving Inspection
Checklist must be completed by the purchaser's representative or an ABB Representative, for each unit, and returned
to ABB Power Transformers.

1. Measure the core insulation resistance to ground. The minimum acceptable value is 500 kohms when
o
measured at 1000 V DC, corrected to 20 C.

2. Are all tie rods undamaged and nuts tight, all cables tight?

3. Is all blocking tight and in good condition?

4. Is there any evidence of load shifting in transit?

5. Does the impact recorder indicate any impacts beyond the acceptance zones?

6. Are there indications of external damage such as broken glass on gauges, broken welds on flanges?

7. Is the paint finish damaged?

8. Are all fittings, which were shipped attached, still in place and undamaged (see the outline drawings)?

9. Is there any evidence of oil leakage around valves, fittings, flanges and tank seams?

10. Inspect bushings that are assembled to the tank, or are in crates or boxes for signs of breakage, are they
chipped or otherwise damaged?

11. Is oil level in bushings normal?

12. Check the Packing List to confirm delivery of all major components and accessory boxes.

13. Do crates or boxes show evidence of damage or moisture entrance?

14. Check the temporary shipping silica gel breather, moisture ingress will be indicated by desiccant changing
colour.

15. Check that detached radiators, coolers and pumps have openings closed of with blind flanges and plugs.

If there is no evidence of shipping damage, proceed to off-load the transformer. If shipping damage is found, contact
the nearest ABB Power Transformers representative for further instructions prior to off-loading the transformer.

In the event of apparent or suspected damage, claims must be made against the transport carrier, and the Factory and
Customer are to be notified immediately.

Note: Accessories and detail parts must be placed in a location, which will minimise exposure to
weather and the possibility of damage or loss.

2 Revision
A: 2001-02
B: 2003-04-09 new Format
C: 2003-08-11 new contact address added

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 2 of 3


Applicability: TrafoStar Lang: en
Title:
RECEIVING INSPECTION
Document No.
Transformer Designed with Oil Conservator,
1ZBA4601-206 Shipped Oil Filled, Shipped Partially Disassembled
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should be FAXed to:
ABB Power Transformers acording to contact list in Aspect Viewer

IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 3 of 3


Applicability: TrafoStar Lang: en
Title:
RECEIVING INSPECTION
Document No.
Transformer Designed with Oil Conservator,
1ZBA4601-206 Shipped Oil Filled, Shipped Partially Disassembled
PowerIT Transformers and Reactors

STORAGE ON SITE BEFORE ASSEMBLY

Table of contents

1 General ................................................................................................................................................ 2

2 Separate Storage of UN-MOUNTED accessories ............................................................................... 2

3 Storage of main unit in oil (FOR UNITS SHIPPED IN OIL).................................................................. 3

4 Storage of main unit in dry gas (for units shipped in dry gas) .............................................................. 3

5 Revision ............................................................................................................................................... 3

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY.......................................................... 4


1 General
This instruction deals with storage and supervision on the erection site, in particular if the shipment has arrived early,
and the assembly will not take place immediately.
The transformer may have been shipped with some accessories and fittings removed. The tank may have been filled
with dry gas or oil during the shipment.
The shipment consists of the “Main Unit” - the closed tank with core and coils, and crates and boxes having contents as
indicated by the Packing List. The Main Unit shall preferably be placed on the mounting foundation, if it is ready, or on
a suitable temporary pad. Be certain to support the base of the transformer as shown on the outline drawing or the
base drawing to avoid deformation or damage of the tank bottom.
Crates and boxes are to be kept protected from weather, indoors when required, but may also be stored outdoors,
supported off the ground, and well covered with tarpaulins.

2 Separate Storage of UN-MOUNTED accessories


When accessories are not mounted immediately after the transformer is received, they must be given care to protect
them from damage or loss during storage. The following general instructions provide guidelines for storage and
inspection. See also the instruction leaflets for the individual parts for storage instructions.

Radiators and Coolers


The radiators are shipped with the top and bottom openings sealed airtight and watertight. Radiators should be stored
on blocks to keep them off the ground.
Make visual inspection of vent and drain plugs to check for tightness. If they have been loosened, re-tighten before
storage. Gaskets or Teflon sealing tape may be used for sealing plug threads.

Bushings
The bushings removed for shipment should remain in the shipping crates until they are required for the transformer
assembly. Bushings are to be stored as described in the Bushing Leaflets.

Load Tap-Changers
The load tap-changer will generally be shipped attached to the transformer. The tap-changer may be shipped
detached from the main unit. In either case, all oil compartments of the load tap-changer must be filled with oil to
positive pressure during storage. The electrical space heaters in the control compartments are to be connected to a
power circuit and energized to keep the control equipment dry.

Fan Motors
Fan motors are typically mounted on the radiators and will be stored as per the radiator requirements.

Other Boxes
Boxes that are marked for protected storage will be stored in a clean, dry place.

Inertaire Equipment
The Inertaire equipment is shipped on the transformer when shipping clearances allow. The pressure gauge, reducing
valves, three-way valve, sump and plastic hoses are assembled and in the cabinet. Flexible tubing for connecting the
nitrogen tank to the cabinet is shipped in the detail box. The nitrogen tank must be assembled on the transformer
before the transformer is stored or any work is started.

Paint Finish
Inspect the paint finish on the main unit and all painted detail parts for damaged areas. Apply touch-up paint (primer
and finish coat) to these areas as required.

Prepared By: L.Ostmann Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-12-10 E Page 2 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. STORAGE ON SITE BEFORE ASSEMBLY
1ZBA4601-211
3 Storage of main unit in oil (FOR UNITS SHIPPED IN OIL)
With proper preparation and maintenance, transformers may be stored indefinitely if they are filled with oil.
As soon as possible after receiving the transformer, locate it on its permanent foundation, or a solid temporary
foundation, and perform the required inspection and tests. Report any damage or shortage before storage. As many
accessories as possible should be installed, and the remaining parts stored properly.
Transformers with sectionalised tanks or major components such as bushing turrets that have been removed for
shipment must have permanent covers installed. If bushings are installed during storage they should be temporary
connected (grounded) to the transformer tanks
Test oil from a bottom sampling valve for chemical properties. If the transformer is being stored with a dry gas cushion
on top of the oil, positive pressure must be maintained during storage. A record of temperature and gas pressure must
be maintained. Record temperature and gas pressure daily for the first two weeks of storage, then weekly for the next
month followed by monthly readings. If Inertaire equipment is being used, Nitrogen consumption should be recorded.

If the transformer is shipped partly filled with oil and with Air Breather, the condition of the drying agent must be
checked regularly according to detailed information in product leaflet.
After six months and subsequently on the Customer normal maintenance schedule, check the oil from the main unit
and other oil filled compartments for chemical properties.

4 Storage of main unit in dry gas (for units shipped in dry gas)

If a transformer is to be stored for more than a few months prior to installation it is strongly recommended to oil fill prior
to the storage period. When this is not practical, storage in dry gas is acceptable with following precautions.

In all cases where gas storage is performed it is necessary that positive gas pressure be maintained in the transformer
tank at all times. If the unit is equipped for Inertaire, this can be used for maintaining pressure. If the unit does not
have Inertaire, a temporary installation of the apparatus or other gas pressure control system can be made.

A record of temperature and gas pressure must be maintained. Record temperature and gas pressure daily for the first
two weeks of storage, then weekly for the next month followed by monthly readings. If Inertaire equipment is being
used, gas consumption should be recorded. In the event of loss of gas pressure, the dew point must be measured
after restoration of pressure. Storage in dry gas beyond 6 months must be approved by the Supplying Factory.

5 Revision
A: 2001-02
B: 2003-04-09 new Format
C: 2003-08-11 new contact address
D: 2003-11-20 Grounding of bushings included. Change to 4
E: 2003-12-10 Long time storage. Change to 4

Prepared By: L.Ostmann Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-12-10 E Page 3 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. STORAGE ON SITE BEFORE ASSEMBLY
1ZBA4601-211
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: L.Ostmann Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-12-10 E Page 4 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. STORAGE ON SITE BEFORE ASSEMBLY
1ZBA4601-211
PowerIT Transformers and Reactors

TRANSFORMER ASSEMBLY INSTRUCTIONS

Table of contents
1 Scope..................................................................................................................................................................................... 2
2 Safety designations................................................................................................................................................................ 2
3 General .................................................................................................................................................................................. 2
4 Preparation............................................................................................................................................................................. 2
4.1 The following equipment may be needed except hand tools mentioned in 12.1 ............................................................ 2
5 Checking for leaks and dryness after shipment...................................................................................................................... 2
6 Dew point measurement ........................................................................................................................................................ 3
7 Preparation for oil filling.......................................................................................................................................................... 3
8 Checking for leaks during assembly....................................................................................................................................... 3
9 External Assembly ................................................................................................................................................................. 4
9.1 Radiators, Coolers and Pumps....................................................................................................................................... 4
9.2 Mounting the COPS Oil Preservation System ................................................................................................................ 4
9.3 Mounting the Nitrogen Blanket Oil Preservation System................................................................................................ 4
9.4 Load Tap-Changers ....................................................................................................................................................... 4
9.5 Tap-Changers Mounted for Shipment ............................................................................................................................ 4
9.6 Tap-Changers Removed for Shipment........................................................................................................................... 4
10 Internal Assembly........................................................................................................................................................... 5
10.1 General ...................................................................................................................................................................... 5
10.2 Bushing Installation .................................................................................................................................................... 6
10.3 Tap-Changers Removed for Shipment....................................................................................................................... 6
10.4 De-energized Tap-Changer........................................................................................................................................ 6
11 Closing the Transformer................................................................................................................................................. 6
12 Revision ......................................................................................................................................................................... 7
1 Scope
These instructions are intended to provide guidelines in the installation of transformers to maintain their quality and
reliability.

They are intended for the guidance of personnel who have been trained for, or who have experience in the installation,
maintenance and servicing of high-voltage electrical power equipment, including the use of good safety practices.
These instructions are intended to supplement, and not eliminate the necessity for such training.
Oil filing are treated in instruction 1ZBA4601-215, Vacuum oil filling on site and 1ZBA 4601-214 Final oil filling at site
atmospheric pressure.

2 Safety designations
The following text highlights particular procedures and precautions that are specific
to ABB procedures and are of critical importance.
Safety notations are intended to alert personnel of possible personal injury, death, or property damage. They have
been inserted in the instruction text prior to the step in which the condition is cited.

The safety designations are headed by one of three hazard intensity levels, which are defined as follows:

1) Danger - immediate hazard that will result in severe personal injury, death, or property damage.

2) Warning - hazard or unsafe practice that could result in severe personal injury, death, or property damage.

3) Caution - hazard or unsafe practice that could result in minor personal injury, death, or property damage.

3 General
Transformer internal components must be free of contamination and dry for effective and safe operation. These
conditions, established during manufacture and sustained during transport must be maintained during assembly.

The transformer tank shall be grounded prior to beginning any assembling operations.

4 Preparation
The transformer shall be moved into position on the substation pad and the base should be levelled. Install shims
under the base for levelling if necessary.

The transformer base shall be supported on the foundation pad or piers as noted on the transformer base drawing
detailed on the transformer outline drawing.

The transformer foundation should be prepared so that the transformer shall have adequate air circulation necessary to
cool the transformer.
4.1 The following equipment may be needed except hand tools mentioned in 12.1
! An oxygen content meter to verify that the atmosphere inside the tank does not present personal risk of
suffocation.
! Dew point meter for checking the dryness of the shipping gas and indirectly the insulation.
! A supply of dry air from bottles or from an air dryer for releasing vacuum. The dry air shall have a dew point of
- 40 °C or lower.

5 Checking for leaks and dryness after shipment


A large transformer is normally shipped with fittings and auxiliary equipment taken off, and the tank filled with dry gas to
a slight over pressure. The gas pressure is checked in the course of extended shipment, and when the transformer
arrives on site. See further Instruction 1ZBA4601-203 or 1ZBA4601-204.

The transformers are shipped with a positive pressure but a negative (vacuum) reading may occur if the ambient
temperature is substantially lower than recorded in the factory. The worst-case condition is a reading of zero pressure
that may be indicating a leak. In conditions of zero pressure or a pressure/temperature relationship that conflicts with
the factory results, a dew point measurement must be taken. The matter must be reported back to an ABB
representative.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 2 of 7


Applicability: TrafoStar Lang: en
Title:

Document No. TRANSFORMER ASSEMBLY INSTRUCTIONS


1ZBA4601-212
6 Dew point measurement
Excessive moisture in a transformer is a negative factor that will lead to dielectric breakdown and failure. When
transformers are manufactured, the moisture content of the materials are controlled and prior to final assembly and
testing, the transformer goes through a drying process that removes the bulk of the water from the insulation material.
This dryness integrity must be maintained during shipment and final assembly at site.

Larger transformers are shipped in dry-gas (air or nitrogen). The moisture in the insulation can be determined by
monitoring the moisture in the gas. This measurement of the gas moisture content is called the dew point. After an
equilibrium period of 12 - 24 hours of constant temperature, some of the moisture in the insulation will migrate into the
gas.

The moisture in the gas is proportional to the moisture in the insulation and can be used to determine the relative
dryness of the transformer insulation. The level of moisture is also related to temperature.
See Figure 1 for a graph showing the relationship between dew point, temperature and % moisture content on the
surface of the insulation.
Surface
moisture
content %
-20º
2 -10º 0º 10º

1.5 20º
Temperature inside transformer
1
30º
0.7

0.5 40º

0.4
0.3

0.2 Water vapor pressure inside

0.01 0.03 0.1 0.3 mm Hg

-60º -50º -40º -30º -20º

Dew- point of air inside the transformer

Figure 1 Surface moisture as function of dew point

Figure 1 shows how the surface moisture content of the insulation can be read from the moisture content of the gas in
the tank, expressed by its dew point temperature. A low moisture content correlates to a low dew point. The surface
moisture shall be below 0.8 % for a new transformer.
7 Preparation for oil filling
It is good practice to assemble the complete transformer and begin oil filling as soon as practical possible. Storage of
partially assembled units in oil or in dry gas is acceptable providing the guidelines in Product Information 1ZBA 4601-
211 are followed.

8 Checking for leaks during assembly


During the assembly on site, the transformer must be sealed off and pressurized with dry gas during work stoppages
(over night or during inclement weather). When work resumes, the pressure, correlated with the temperature, must be
checked . Suspected leaks may be located with leak detection instruments, with soapy water, or with plastic bags
tightened around valves (being inflated by leaking air). In this way the assembled seals may be checked successively
as the work continues.

9 External Assembly
The items removed and shipped separately are listed on the outline drawing, the outside assembly drawing, or packing
list. The items generally removed and shipped separately are the bushings, cooling equipment, forced oil pumps (if the
Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 3 of 7


Applicability: TrafoStar Lang: en
Title:

Document No. TRANSFORMER ASSEMBLY INSTRUCTIONS


1ZBA4601-212
transformer has a forced cooling rating), surge arresters and arrester mounting brackets and the sudden pressure
relay. The number of accessory items removed will vary depending on the physical size of the transformer.

All air or gas fittings and all oil fitting joints that are pre-assembled at the factory must be checked for leaks and
resealed.
9.1 Radiators, Coolers and Pumps
Radiators, coolers, the associated oil pumps and piping shipped as detail items that are assembled at the final location
must be inspected prior to installation to be certain that no water or foreign material is in the oil space

The radiators or coolers should be installed on the transformer the same day they are opened. Do not permit the
cooling apparatus to stand exposed after opening for inspection. The detailed illustrations for mounting and piping
arrangements are shown on the outside assembly or the outline drawings.

Use new gasket material when installing the radiators, coolers, or pumps.
9.2 Mounting the COPS Oil Preservation System
If the transformer is equipped with a constant oil pressure (COPS) oil preservation system, mount the support structure
for the COPS tank, mount the tank and install the valves on the main tank and the COPS tank. The valve to the COPS
piping on the transformer cover should remain closed. The detailed illustrations for mounting and piping the COPS
system are shown on the outline drawings.

Do not install the connected piping between the main tank and the COPS system until the vacuum filling process of the
main tank has been completed.
9.3 Mounting the Nitrogen Blanket Oil Preservation System
If the transformer is equipped with a nitrogen blanket oil preservation system, the nitrogen system control cabinet
generally remains on the transformer for shipment. If it was removed, install the cabinet and the nitrogen bottle. If the
cabinet is already mounted, install the nitrogen bottle and connect the piping to the control. If the transformer was
shipped with oil, the tubing connection from the cabinet to the gas space is not connected. This prevents oil from
entering the line during shipment. Check the line to be certain it is clear of oil and connect the tubing at the cabinet.
The nitrogen supply valve should remain closed in either case.
9.4 Load Tap-Changers
The UVT, UTT and RMT-1 Tap-Changers are usually shipped mounted on the transformer. The UZE and UZF Tap-
Changers are also shipped mounted on the transformer.
The compartment for Tap-Changers such as the Reinhausen M, T, and G and the ABB type UCG, UCL may be
removed for shipment. Temporary shipping braces are sometimes used in the removed Tap-Changer compartment.
These braces will be shown on the internal assembly drawing. The braces must be removed before the Tap-Changer
is placed in service.
Gaskets used for Tap-Changer inspection doors can be reused.
Gaskets used for Tap-Changer inspection doors can be reused.
WARNING

DO NOT OPEN ANY COVERS OR FITTINGS UNLESS THE INTERNAL PRESSURE IS AT ZERO GAUGE.
FAILURE TO RELIEVE THE PRESSURE COULD CAUSE THE PART BEING REMOVED TO BE A
HAZARDOUS FLYING OBJECT. ALWAYS RELIEVE INTERNAL PRESSURE SLOWLY THROUGH
VALVES.

Before placing Tap-Changers in service, read the appropriate Tap-Changer instruction leaflet. The leaflets are
included in the transformer instruction book. Always follow the inspection and filling instructions given in the Tap-
Changer instruction leaflet.
9.5 Tap-Changers Mounted for Shipment
No internal assembly operations or taping are required but sometimes they have a shipping support that need to be
taken away.
9.6 Tap-Changers Removed for Shipment
See paragraph 10.3

10 Internal Assembly
10.1 General
Entry into a transformer should only be considered if necessary to complete installation or for investigation of potential
damage. In any case, only trained personnel under the guidance of ABB may enter the transformer.
Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 4 of 7


Applicability: TrafoStar Lang: en
Title:

Document No. TRANSFORMER ASSEMBLY INSTRUCTIONS


1ZBA4601-212
When opening the transformer, take necessary precautions to prevent moisture or dirt from entering the transformer or
moisture condensation in the transformer.
The transformer should not be opened during periods of inclement weather
Necessary confined entry procedures must be followed in compliance with Company policy and local regulations.
WARNING

When transformer has been shipped with nitrogen, the gas must be replaced with dry air prior to making any
entrance into the tank. Never use nitrogen or gases other than air for ventilation. The oxygen content must be
at least 19.5% prior to entering the tank.

To remove the nitrogen, it is advisable to pull vacuum to fully remove all nitrogen and break the vacuum with dry air.

Caution

Be certain the internal pressure in the transformer is at zero gauge before opening the manhole cover.

Open the transformer at the manhole cover. It is preferred to have only one manhole open at a time. It is also
recommended that the tank opening be covered with clear plastic or a tarp.

Dry air must be used to ventilate the inside of the tank when it is opened for internal fitting. The air must have a dew
point less than -40°C and sufficient airflow for the number of operators in the tank must be maintained.
Purge the air hoses with dry air from the supply to remove any moisture and dirt in the hoses prior to use. Make the
connections for the dry air supply in the tank space below the working level in the tank.

WARNING

DO NOT ENTER THE TRANSFORMER OR BREATHE THE INTERNAL ATMOSPHERE UNLESS THE
OXYGEN CONTENT OF THE GAS INSIDE THE TRANSFORMER IS AT LEAST 19.5%. OXYGEN
CONTENTS LESS THAN THIS CAN CAUSE DROWSINESS, INJURY OR DEATH. TRANSFORMERS
SHIPPED IN GAS ARE NOT SAFE TO ENTER. ALWAYS CHECK THE OXYGEN CONTENT.

Caution

To prevent contamination of the transformer, only the manhole and the opening for the item being
installed should be opened. Cover all other openings with dry pressboard or a clean plastic sheet.

This will also minimize the flow of dry air from the unit.

Start the airflow into the transformer. The volume must be sufficient to maintain continuous airflow outward through the
tank openings.
Never enter a transformer with dirty or wet clothing. Clean cloth overshoes over work boots or clean nitrile rubber
boots should be worn.

All tools, equipment and material entering the transformer shall be listed and checked to verify all material has been
removed from the transformer.

Tools used to perform work inside a transformer tank must have working surfaces hardened so that they will not peel
or chip during normal use. Tool working surfaces must not be coated in any way such as painting or plating. Tools that
are polished metal or have black oxide body finish are preferred.

To prevent accidental disassembly during normal use, all tools with movable parts must use positively retained joints.

Tools such as hammers and screwdrivers must have one-piece heads. Moulded-on plastic or fibreglass handles are
preferred; if the handle is wood, it must be retained by a wood or plastic wedge.

Nameplates or tags attached to tools should be removed. If a nameplate is necessary for tool identification, the plate
must be non-metallic and be secured with non-conducting tape.

While the transformer is open, do not permit anyone access to the transformer until they have emptied all pockets,
checked for loose objects, and removed watches, rings, and other objects.

Rubber gaskets should be changed during the assembly operations. If required, new gaskets are provided.
Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 5 of 7


Applicability: TrafoStar Lang: en
Title:

Document No. TRANSFORMER ASSEMBLY INSTRUCTIONS


1ZBA4601-212
10.2 Bushing Installation
On large transformers, the bushings will be removed for shipment to meet shipping clearances and to avoid shipping
damage to the bushings. The bushing leads may be supported by temporary shipping braces that are an integral part
of the blind flange. The flange will be stencilled with a warning note if this method is used. The bushing leads must be
disconnected from these temporary braces before the blind flange covers or shipping covers are removed.
An alternate method of supporting the bushing leads is to tie the coiled lead to the highest point on the transformer
cleats and leads assembly.
Caution

Failure to disconnect the leads from the temporary shipping braces before the blind flanges or shipping
covers are lifted can cause damage to the leads, bridge structure and associated coils, and may necessitate
return of the transformer to the factory for repair and re-testing.

The bushings removed for shipment should remain in the shipping crates until they are required for the transformer
assembly. Note the requirements in the bushing instruction leaflet for temporary storage. Clean the bushing before
installing it in the transformer. Power factor and capacitance measurements may be performed as optional tests.

Install the bushings in the transformer. When a draw-through-lead or draw-rod design is used, this will be noted on the
outline drawing. The procedure for installing the bushing and connecting the leads is described in the bushing
instruction leaflet. For bottom connected bushing designs, the connection details will be shown on the outline drawing
or the internal assembly drawing. Ground the external bushing terminals after they are installed and connected.

The inside assembly drawings or taping sketch furnished with the instruction book contain taping requirements and
lead clearances. The internal assembly drawings identify all internal items requiring field taping.

Non-metallic bolts, nuts, and studs are sometimes used on insulation structures. Nuts of this type should be tightened
to a snug fit only since breakage or thread stripping may occur. Bolts and studs installed at the factory will either have
the nuts cemented on or use a second nut as a jamb nut so that re-tightening should not be necessary.
10.3 Tap-Changers Removed for Shipment
The leads will need to be connected and taping will be required. Work in the Tap-Changer compartment should be
completed as quickly as possible.
The leads are identified by tags or a number stamped in the end of the lug. The leads and corresponding terminal
lugs are match marked. Start connecting leads in the center and work towards the outside. This allows a little more
room for taping. The correct thickness must be applied; too little tape can result in an electrical failure and too much
tape can cause overheating of the joint.
Follow the taping drawings included in the instruction book for the transformer.
Remove all items used during taping the leads before you close the Tap-Changer compartment. Before final oil filling
and placing the Tap-Changer in service, check the operation of the Tap-Changer as noted in the instruction book
10.4 De-energized Tap-Changer
Check the de-energized Tap-Changer to confirm that the contacts are on the correct positions. Check the external
operators to confirm they are on the correct positions.

Operate all de-energized Tap-Changers in both directions to each limit to verify the correct alignment of the Tap-
Changer contacts. Perform a winding ratio check at each tap position and record the results. Refer to the Tap-
Changer instruction leaflet for procedures to correct the contact alignment if the ratio checks are not satisfactory.

11 Closing the Transformer


This procedure only applies if internal work was required to a transformer that was received without oil or had
all oil removed.
After the assembly has been completed, remove all the tools and working material from the transformer, seal the
transformer and pressurize with dry air or nitrogen to 20 kPa; 3 PSI (0.2 bar).

If the exposure time has been excessive or there are others factors that suggest the transformer may have been
exposed to excessive moisture contamination, then a dew point measurement may be required.

12 Revision
A: 2001-02
B: 2003-04-09 new Format
C: 2003-08-11

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 6 of 7


Applicability: TrafoStar Lang: en
Title:

Document No. TRANSFORMER ASSEMBLY INSTRUCTIONS


1ZBA4601-212
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 7 of 7


Applicability: TrafoStar Lang: en
Title:

Document No. TRANSFORMER ASSEMBLY INSTRUCTIONS


1ZBA4601-212
IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.
PowerIT Transformers and Reactors

RECEIVING AND HANDLING TRANSFORMER OIL ON SITE-


QUALITY CONTROL

Table of contents

1 General ............................................................................................................................................. 2

2 Different types of oil, CHARACTERIZED by origin and chemical composition................................... 2

2.1 Inhibited oils................................................................................................................................ 2

3 Supplier certificate............................................................................................................................. 2

4 Sampling on site................................................................................................................................ 3

5 Testing of samples. Oil characteristics. (f0r non-certified oil) ............................................................. 3

6 Treatment of the oil before filling the transformer............................................................................... 3

7 Revision ............................................................................................................................................ 3

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY ........................................................ 4


1 General
This Instruction lists the main quality requirements that are to be fulfilled when transformer oil is delivered to an
installation site for filling into the transformer.
The oil shall fulfill the requirements in material specification 1ZBA117 001-1, 2, 3 or 4.
The user of the transformer may have issued an oil specification of his own, or may have specified oil of a particular
trademark from an internationally recognized supplier. This may add to, but does not relieve any of the requirements
specified in this Instruction. They are necessary for long-term reliable operation of the transformer.

2 Different types of oil, CHARACTERIZED by origin and chemical composition


Transformer oils are specially refined products made from crude oils of different types from different wells. Terms as
naphtenic ,parafinic, aromatic and aliphatic refer to different types of hydrocarbons in the oil, which are balanced by the
manufacturer to give a combination of high insulation withstand strength, low viscosity, low volatility/high flammability
temperature, low sulfur content, and low aging (oxidation) tendency.

At the present time there is no essential, documented difference in overall quality between materials from different
crude origins, as long as the final products are manufactured by competent refineries and fulfill the requirements of the
ABB material specification. A maximum of 10 % from a different oil base may be added to a primary oil supply.

When transformers are shipped from the ABB Transformer factory filled with oil, or when oil for the first filling is part of
the delivery from ABB, it is supplied against ABB’s own Material Specification 1ZBA117 001-1, 2, 3 or 4.
2.1 Inhibited oils
An inhibitor is a particular substance, added to the oil in small quantities in order to neutralize certain intermediate
"radicals" - agents in the process of oxidation of the oil. The result is a retardation of the aging, until the quantity of
inhibitor has been consumed. From that time onwards, the aging will proceed and accelerate freely.
The efficiency of the inhibitor depends on the degree of refining of the oil. Due to that, the best result is obtained if the
oil was refined with the objective to be inhibited.

Some users hold the view that inhibitors should not be used, because they may mask, for a while, the inherent aging
properties of the oil and lull the operating staff into false security. After the inhibitor has been consumed, it may escape
attention that the oil deteriorates more rapidly.
ABB Transformers does not share this view, and recommends inhibited transformer oil. However, if a customer
specification forbids inhibited oil, the filling will be made with un-inhibited oil fulfilling the ABB material specification.

Note. The chemical short name for the usual inhibitor substance is DBPC (di-butyl-para-cresol). This must
not be confused with the objectionable class of compositions, called PCBs (poly-chlorinated biphenyl’s -
"askarels"). DBPC is not environmentally noxious - as a matter of fact it has an alternative use as a
stabilizer agent in foodstuffs.

3 Supplier certificate
The supplier of transformer oil shall guarantee, and supply a certificate that the oil, delivered from the refinery, fulfills
the list of requirements specified in the actual ABB material specification 1ZBA117 001-1, 2, 3 or 4.

The quality of the oil at delivery condition shall be guaranteed through certificates of the oil characteristics from the oil
in the transportation containers or through sample tests.
This certificate or tests shall include Power factor/Dissipation Factor at 100°C or 90°C and the Interfacial Tension
against water. These tests are to assure that no contamination of the oil has occurred during transportation and
storage.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 2 of 4


Applicability: TrafoStar Lang: en
Title:
RECEIVING AND HANDLING
Document No.
TRANSFORMER OIL ON SITE-
1ZBA4601-213 QUALITY CONTROL
4 Sampling on site
No specific sampling is required for certified oil. The following comments applied to non-certified oil.
For transformers shipped in dry-gas, bulk deliveries of oil in tank trailers are normally scheduled to arrive just in time for
the filling procedure. This oil will be tested after final filling and processing.

For transformer shipped oil filled, the top up oil may be delivered in drums. Oil in drums will be kept in storage with
unbroken seals up to the time when filling procedures are to be commenced. The drums shall be stored in horizontal
position, with the openings horizontal (at same height).
When the oil is delivered in drums and if it has to be tested, the extent of sampling shall be as follows:
No of drums delivered No of drums sampled
2 - 5 2
6 - 20 3
21 - 50 4
51 - 100 7
101 - 200 10
201 - 400 15
Most of the properties of insulating oil are affected by impurities, particularly water. Care must be taken in order to
avoid contamination of the oil samples. All equipment used in obtaining samples and the sample container shall be
clean and dry.
When the oil is delivered in tanker trailers: Take two samples from each separate tank compartment.

5 Testing of samples. Oil characteristics. (f0r non-certified oil)


The requirement for breakdown strength of the oil at delivery condition is specified according to IEC Standard
Publication 296 and ASTM D3487.
The dielectric strength of the filtered oil that is filled into the transformer shall meet or exceed the following:

60 kV/2.5 mm method IEC 156 (VDE electrodes).


56 kV/0.08” method ASTM D1816
30 kV/0.1” method ASTM D877

The test procedure is according to IEC Publication 156 [using hemispherical electrodes (VDE electrodes) with 2.5 mm
spacing]. The minimum breakdown strength for oil as delivered is 30-kV/2.5 mm.
The test procedure in accordance with ASTM D877 is using cylindrical electrodes with
0.1 inch spacing. The minimum breakdown strength for oil in delivery condition is
30 kV/0.1 “.

After heating with particle and vacuum filtration the breakdown strength shall rise to at least:

80 kV/2.5 mm method IEC 156


64 kV/0.08” method ASTM D1816
35 kV/0.1” method ASTM D877 This method is only accepted for transformers with nominal
voltage below 230 kV.
Note that the above values refer to the oil coming out from the vacuum filter equipment and it does not refer to oil
samples from the transformer.
For new oil that never has been in contact with the equipment the
Power factor/Dissipation Factor 0.005 at 100°C or 90°C and 50 or 60 Hz
Interfacial Tension against water ≥ 40 Nm/m at 25 °C.

Note: Oil with Power factor at 100°C or 90°C > 0.2 or Interfacial tension against water
< 20 Nm/m shall be regenerated or substituted.

6 Treatment of the oil before filling the transformer


The necessary quantity of oil shall be collected and prepared in one or more clean storage tanks. Before being used,
the tanks are visually inspected inside for cleanliness. Any liquid residue from earlier use will be carefully removed,
and the container flushed with a small quantity of new oil, which is then discarded.
The oil, received in drums, is pumped through the vacuum filter plant into the storage tank. The drums or trailer tanks
shall not be emptied to the last drop, a sump of an inch or so is left, to avoid possible solid dirt or water on the bottom.

7 Revision
A: 2001-02
B: 2003-04-10 new Format
C: 2003-08-11 new contact list added

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 3 of 4


Applicability: TrafoStar Lang: en
Title:
RECEIVING AND HANDLING
Document No.
TRANSFORMER OIL ON SITE-
1ZBA4601-213 QUALITY CONTROL
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should be FAXed to:
ABB Power Transformers according to contact list in Aspect Viewer

IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 4 of 4


Applicability: TrafoStar Lang: en
Title:
RECEIVING AND HANDLING
Document No.
TRANSFORMER OIL ON SITE-
1ZBA4601-213 QUALITY CONTROL
PowerIT Transformers and Reactors

FINAL OIL FILLING ON SITE


- ATMOSPHERIC PRESSURE -

List of Contents

General ---------------------------------------------------------------------------------------------------------------------- 2

1 SUPPLY OF OIL, QUALITY REQUIREMENTS, AND CLEANLINESS------------------------------- 2

2 TOPPING UP PROCEDURE. ------------------------------------------------------------------------------------ 2

2.1 Transformers with conservator design. -------------------------------------------------------------- 3


2.2 Transformers with sealed tank design. --------------------------------------------------------------- 3

2.3 FILLING COOLERS AND RADIATORS.------------------------------------------------------------------ 3

3 Revision --------------------------------------------------------------------------------------------------------------- 3

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY--------------------------------------- 4


General
This Product Information applies to adding top up oil to transformers with a nominal voltage below 200 kV,
shipped with oil nearly up to the cover.

Filling to normal oil level can in these cases be done with a filter unit. The quantity of top up oil to be added in
this manner should be less than 16 % of the total oil volume in the transformer.

1 SUPPLY OF OIL, QUALITY REQUIREMENTS, AND CLEANLINESS

The necessary quantity of top up oil for the final filling may be shipped with the transformer, or may be procured
locally. If the Customer provides the oil, prior approval for use must be obtained from ABB and the
characteristics must meet the requirements of 1ZBA4601-213

Competent supervision and a responsible work force are necessary requirements. Industry standard cleanliness
and personal safety precautions must be observed in accordance with common sense and local regulations.

Transformer internal components must be free of contamination and dry for effective and safe operation. These
conditions, established during manufacture and sustained during transport must be maintained during oil filling
and assembly.

The top up oil is typically supplied in drums but may be supplied in a tanker if the required quantity is large
enough.

The drums (or tanker), all hoses, pumping equipment, valves and filters must be for the exclusive use of the
transformer oil or have been meticulously cleaned and rinsed. Failure to ensure pristine oil and equipment puts
at risk the viability of the transformer operation.

Oil in drums or tanks, as delivered, should never be dumped right into the transformer, but always pumped
through a filter unit. It is important that clean and dry filters are used. A small sump quantity should be left
unused in the drums or tank.

2 TOPPING UP PROCEDURE.
When a transformer has been shipped more or less complete, and with oil nearly up to the cover, the following
procedure is used to complete the oil volume. A filter unit must be used.

Figure 1.

The oil, stored in drums or in a storage tank, is pumped through the filter

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2004-10-14 D Page 2 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. FINAL OIL FILLING ON SITE
1ZBA4601-214 - ATMOSPHERIC PRESSURE -
2.1 Transformers with conservator design.
For transformers designed with a conservator, the top up oil should first be pumped into the conservator with the
valve between the conservator and the main tank closed.

When the conservator is 3/4 full, stop the pumping and open all the bleeder valves the valve between the
conservator and the main tank, then slowly allow the oil into the transformer.

The oil must be introduced slowly to limit turbulence and air bubbles from going into the windings. Repeat this
procedure until the proper oil volume is attained. (See also para. 2.3 Filling coolers and radiators)

When filling nears completion, all bushings, turrets and other devices that require bleeding must be bled to
avoid trapped air pockets, then sealed.
2.2 Transformers with sealed tank design.
Sealed tank designs are often shipped overfilled with the quantity of oil required to fill the cooling equipment.

The data on the oil volume and whether additional oil needs to be added will be shown on the outline or
shipping drawing.

For sealed tank designs, the top up oil should be added through the top filter connection valve. The oil must be
introduced slowly to limit turbulence and air bubbles from going into the windings.

Obtain a test sample from the main tank and test for dielectric strength.
Purge the gas space in the transformer and seal the tank at atmospheric pressure (zero gauge).

2.3 FILLING COOLERS AND RADIATORS.


Fill the cooling equipment by opening the lower valve between the cooler or radiator and the main tank and
bleed the air through the top vent plug from each cooler or radiator.

Ensure that the oil level in the main tank is always is above the top of the core and all insulation
material.

After completing assembly, check that the oil is at the correct level, being careful to make the appropriate
correction for the oil temperature if different from 25 °C.

For transformers that shall be pressurized, verify that all accessories in contact with the oil or oil preservation
system have been assembled before pressurizing the transformer.

After the oil filling procedure has been completed, the transformer should be left at least twelve hour

3 Revision
A: 2001-02
B: 2003-05-30 new Format
C: 2003-08-11 new contact address
D: 2004-10-14 2.3 was 3, 3 was 4

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2004-10-14 D Page 3 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. FINAL OIL FILLING ON SITE
1ZBA4601-214 - ATMOSPHERIC PRESSURE -
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES,


EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT
BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER.
THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT,
COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on
our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE
CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is
required, ABB should be consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR
USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS,
DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible
to the user in contract, in tort (including negligence), strict liability, or otherwise for any special,
indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage
to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost
of replacement power, additional expenses in the use of existing power facilities, or claims against the
user by its customers resulting from the use of the information, recommendations, description, and
safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should be FAXed to:
ABB Power Transformers, Literature Coordinator: +1-314-679-4595

or E-mailed to: Transformer.Service@us.abb.com

For a reply, please include your name, company, phone, fax and/or E-mail address.

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2004-10-14 D Page 4 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. FINAL OIL FILLING ON SITE
1ZBA4601-214 - ATMOSPHERIC PRESSURE -
Power Transformers

ACCEPTANCE TESTING AND ENERGIZATION

Table of contents

1 TRANSFORMER TESTING ON SITE AFTER ASSEMBLY ...................................................................................................2


1.1 Ratio test.........................................................................................................................................................................2
1.2 Winding resistance test (this test is optional) ..................................................................................................................2
1.3 Check of vector group (this test is optional) ....................................................................................................................3
1.4 Insulation resistance test ................................................................................................................................................3
1.4.1. Transformer main windings.....................................................................................................................................3
1.4.2. Current transformers ...............................................................................................................................................3
1.4.3. Control circuit cabling and auxiliary power cabling..................................................................................................3
1.4.4. Core to tank/core clamp ..........................................................................................................................................3
1.5 Capacitance and power factor or dissipation factor measurements................................................................................3
1.6 Check of tank ground circuit continuity ...........................................................................................................................3
1.7 Polarity check of current transformers ............................................................................................................................3
1.8 Check of thermometers and thermostats ........................................................................................................................3
1.9 Oil tests...........................................................................................................................................................................4
1.9.1. Check of the oil level ...............................................................................................................................................4
1.9.2. Check of dielectric strength values .........................................................................................................................4
1.9.3. Power factor (Optional) ...........................................................................................................................................4
1.9.4. Interfacial tension (Optional) ...................................................................................................................................4
1.9.5. Sampling of oil for dissolved gas analysis by special request .................................................................................4
1.10 Operational test of supervisory equipment......................................................................................................................4
1.11 Operational test of other equipment................................................................................................................................5
1.11.1. Cooling equipment ..................................................................................................................................................5
1.11.2. De-energized tap-changer with driving mechanism ................................................................................................5
1.11.3. On-load tap-changer with motor-drive mechanism .................................................................................................5
1.12 Final air bleeding.............................................................................................................................................................5
2 ENERGIZATION .....................................................................................................................................................................5
2.1 Preparation for energization............................................................................................................................................6
2.2 Energization ....................................................................................................................................................................6
2.3 Shut down and re-energization of transformers with Inertaire or Sealedaire Oil Preservation System. ..........................6
2.4 Shut down and re-energization of transformers with COPS Oil Preservation System. ...................................................6
3 Appendix 1 Table of three-phase transformer connections....................................................................................................7
4 Revision ................................................................................................................................................................................10

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 1 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
1 TRANSFORMER TESTING ON SITE AFTER ASSEMBLY
After a transformer has been completely assembled on site, it must be tested to confirm successful shipment and correct
assembly. All tests must be carried out with instruments that have traceable, valid calibration.
These instructions are intended to provide guidelines in the test of transformers to maintain their quality and reliability.
They are intended for the guidance of personnel who have been trained for, or who have experience in test of high-voltage
electrical power equipment, including the use of good safety practices. These instructions are intended to supplement,
and not eliminate the necessity for such training
The test results are to be recorded on a Test Record, see Product Information 1ZBA 4601-217. The second sheet of this
Test Record is a list of all possible tests, some of which may not be applicable. When the on-site project manager or the
assembly supervision has marked all applicable tests, this sheet forms an order-bound directive for the tests to be carried
out. After the assembly is completed, a Notice of Delivery is issued. The Notice of Delivery must be signed by both the
assembly supervisor and by the Customer's representative.
The Field Test Record and the Notice of Delivery are to be sent to the local ABB representative for further distribution.
When the documentation is complete and the transformer/reactor has been completed to ABB’s satisfaction, the ABB
Installation and/or Service department issues a Service Certificate.

1.1 Ratio test


The ratio test is used to confirm that the winding turns ratio is consistent with the voltage ratio as shown on the Nameplate.
This is done primarily to check for shipping damage and to confirm that any tap-changer leads installed in the field have
been correctly connected. In addition to the ratio measurement, exciting current is also often measured. The ratio
measurements is normally done with a ratio bridge. Table of three-phase transformer connections Appendix 1

1.2 Winding resistance test (this test is optional)


Measure the resistance of each winding at the rated and extreme tap positions and compare the results to the original
value in the Factory test report. If the Tap Changer connections have been made at site, measuring at all positions should
be done.
Resistance is dependent on the temperature of the winding. The mean temperature of the oil is representative of the
winding temperature, and providing that the oil is at a uniform temperature, the top oil temperature gauge value can be
used. Resistance comparison must always be made at a common temperature. The conversion formula for copper and
aluminium windings is show below.
The formula giving the relation between the resistance and the temperature is:

 K + T 2
RT 2 = RT 1 ×  
 K + T1 

where RT2 = Resistance of the winding at temperature T2


RT1 = Resistance of the winding at temperature T1
K = 234.5 for winding made of copper acc to IEEE,
K = 235 for winding made of copper acc IEC
K = 225.0 for winding made of aluminium
The time constant may be very long when low voltage and low current sources are used.

WARNING

A high voltage surge occurs at interruption of DC current at end of measurements. A discharge circuit should be
used. Eg. see IEEE Std 62 figure 2

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 2 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
1.3 Check of vector group (this test is optional)
The purpose of this series of tests is to check the polarity and the phase relationship of the multiple windings in a
transformer. The test is carried out simultaneously with the transformer turns ratio test when using a turns ratio test set. In
order to define the connection of a three-phase transformer and to facilitate the parallel connection with other transformers,
the international standards prescribe specific vector groups. Every country has its own designation for the vector groups.
IEC and IEEE (in USA) have recommended a method that will result in standardized and fully defined designations.

1.4 Insulation resistance test


Insulation resistance can give some information of the integrity of the insulation structure. As an insulation structure
begins to deteriorate due to contamination and moisture, the insulation resistance will decrease. The test equipment used
is a DC insulation tester (Megger). It is essential that it is of a type, which is suitable for measurement on transformers
and transformer core insulation. Ensure that bushings are clean and dry. Insulation resistance is temperature dependence
why it is important that the oil temperature is noted.
After the test has been completed, all terminals shall be grounded time enough to allow any trapped charge to decay to
negligible value

1.4.1. Transformer main windings


When conducting an insulation resistance test on transformer windings, a 2.5 or a 5 kV megger can be used. Test every
winding to ground and between each winding. Make sure that the bushing porcelains are cleaned since dirt deteriorates
the insulation resistance. The transformer tank must be grounded during the test. If the insulation resistance is > 1 MΩ/kV
system voltage for the winding, it is acceptable. If lower values are measured, this must be reported to an ABB
representative.
According to IEEE the following shall be measured. High voltage to low voltage and ground, low voltage to high voltage
and ground.

1.4.2. Current transformers


When insulation resistance testing a current transformer, a 500 or 1000 megger is used. Test every connection to the
ground. The acceptable value is 10 MΩ.

1.4.3. Control circuit cabling and auxiliary power cabling


When insulation resistance testing control circuit cables and supply cables, a 500 or 1000 V megger is used. The
acceptable value is 10 MΩ. Test every connection to the ground.

1.4.4. Core to tank/core clamp


When insulation-testing a transformer core a 1000 V megger is used. The testing time
is 1 minute. Core to ground, core-clamp to ground and core to core-clamp shall be measured.

1.5 Capacitance and power factor or dissipation factor measurements


This is optional test in accordance with IEC
See Clause 10.10 of IEEE C57.12.90 – 1999
1.6 Check of tank ground circuit continuity
By means of a buzzer check the ground connection between the tank and turret(s), and between the tank and bushing
flanges.

1.7 Polarity check of current transformers


In order to make sure that the current transformer is in its correct position in relation to the bushing (conductor), a polarity
check must be carried out. By checking the polarity in this manner we are also certain that the current transformer
generates a secondary current. The ratio test and the magnetizing curve are not performed on site in conjunction with the
transformer assembly.

1.8 Check of thermometers and thermostats


Oil and temperature gauges must be tested with their associated control, alarm and trip circuitry. Register the test records
and compare them with the set points on the circuit diagram. Perform functionality tests to confirm operation of the
alarm/trip contacts.
For analogue thermometers

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 3 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
Open the both of the connections of the current transformer feeding the heating resistor of the winding temperature
indicator, and measure the total heating resistance. Record the value in the test record and compare the result with the
resistance in the Factory test report of the transformer.
For digital thermometers:
Check that the settings for winding temperature gradients and hot spot factor agrees with the values given in the factory
test reports.

1.9 Oil tests

1.9.1. Check of the oil level


Check the oil level in:
- The transformer
- The tap-changer
- Any other separate compartments
Check that all devices containing oil that must be completely filled have been purged of air.

1.9.2. Check of dielectric strength values


The transformer's performance and longevity greatly depends on the quality of the oil that is used. Therefore the oil's
dielectric strength is checked before the transformer is handed over.
A sample is taken from the conservator and the transformer/reactor's bottom valve and in some cases even from separate
coolers, etc.
Since the value of the dielectric strength greatly depends on which type of electrodes being used, it is essential to record
the information in the test report. The acceptable dielectric strength value is indicated in 1ZBA4601-213

1.9.3. Power factor (Optional)


The power factor is a measure of the dielectric losses in the oil when used in an alternating electric field and of the energy
dissipated as heat. A low power factor indicates low a-c dielectric losses. It can be useful as a means to see changes in
quality resulting from contamination and deterioration in service or as a result of handling.
The test should be made as per IEC 247 or ASTM D 924.
For new oil that has never been in contact with the transformer, the power factor at 90°C or 100°C and 50 or 60 Hz shall
not exceed 0.005. (0.5%)

1.9.4. Interfacial tension (Optional)


This test has shown by practice to give a reliable indication of the presence of hydrophilic compounds.
The test should be made as per ISO 6295 or ASTM D 971.
For new oil that has never been in contact with the transformer the interfacial tension against water shall be ≥ 40 mN/m at
25 °C.

1.9.5. Sampling of oil for dissolved gas analysis by special request


Sometimes customers require that an oil sample for a gas analyse shall be taken. There are special instructions regarding
this test within the ABB group. If the analysis is conducted at another laboratory, other vessels and methods might be
prescribed.

1.10 Operational test of supervisory equipment


Transformers and reactors are provided with special equipment for supervision of operation, overloading, cooling and
many other purposes. After installation has been completed and before the transformer or reactor is placed in service, all
the accessory equipment is tested preferably in conjunction with the equipment with which it will be used in service.
Individual testing is conducted using a buzzer that is connected to the appropriate terminals in the control cabinet. Prior to
energizing, the Customer is obliged to perform complete commissioning tests, which include the functions of the entire
system, to which the transformer is an integral part.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 4 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
1.11 Operational test of other equipment

1.11.1. Cooling equipment


Before the transformer is place in service, the rotation direction of the pumps and fans of the cooling equipment are
checked. Furthermore, the tripping of the motor protection devices are checked as well as the signal that is activated for
each tripped motor protection device.
The rotation direction of the pump is checked according to the following:
When the pump is filled with oil and has the correct rotation direction, only a slight purring sound is heard. If the pump
wheel rotates in the wrong direction, a rattling sound will occur that is several times louder. If uncertainty prevails, shift the
two phases on the motor so that it will run in the opposite direction. It will then be easy to determine which rotation
direction is correct. Note that if the pump housing is only partially filled with oil, a rattling sound will also occur.
The rotation direction of the fans is checked visually.
The thermal over current protection relays of the fan motors are set according to the rated current that is stamped on the
rating plate. The relays for the pump motors are set according to what is stated on the list of apparatus. The thermal over
current protection relays of the motors are tripped by a 2-phase connection of each motor.
The signal of the tripped motor protection device is checked by means of a buzzer to the appropriate terminals in the
control cabinet.
Verify that shipping plugs, if applicable, have been removed from the motors.

1.11.2. De-energized tap-changer with driving mechanism

At the end of the assembly and before being put into service, the de-energized tap-changer and the drive mechanism are
checked.
Operate the tap-changer to its end positions. Then check the drive mechanism’s locking device. Check that the contacts
on the drive mechanism and its interlocking device connect and disconnect before the lock in the locking device is
completely released.

1.11.3. On-load tap-changer with motor-drive mechanism


If the transformer is fitted with an on-load tap-changer, then the tap-changer and the motor drive mechanism are tested
before the transformer is put into service.
The following checks should be done:
All the external shafts have been lubricated
The local/remote control is functioning correctly
The heater in the drive mechanism is working
The pressure relay operates adequately to the pressure setting
The motor protection is adjusted to the current that is stated on the motor’s rating plate.
The drive mechanism indicates the same position as the tap-changer.
The drive mechanism has been operated through all positions manually (with the hand crank) and electrically in ascending
and descending positions.
The mechanical stops at extreme positions are working properly
The interlocking switch for the mounted hand crank is working properly
For the details on how to perform the above tests, refer to the appropriate tap-changer product information in the
instruction manual.

1.12 Final air bleeding


After all the tests have been carried out, the transformer and every separate compartment, including radiator banks, etc., is
purged of air through the appropriate bleeding valves.

2 ENERGIZATION
Prior to energization, the transformer should be visually inspected and the following items checked:

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 5 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
2.1 Preparation for energization
Prior to energizing verify the following:

a) The oil level in the oil filled compartments


b) The drying agent and the oil level in the dehydrating breather
c) Check that all valves are set at the right position
d) Check that the transformer, the control cabinet and all accessories are cleaned and touch up painted if needed
e) Check that the heating element in the control cabinet is connected and in operation
f) Check that the gas-operated relay is purged of air
g) Check possible leakage. If the transformer has been stored more than two months after the assembly, all sealing
joints must be retightened
h) Check that connections to lines, bus-bars and earth are properly made
i) Check that the distances between phases and phase to earth are sufficient
j) Check that the covers are installed on the test taps and/or potential taps (if no potential device is connected) of the
bushings to assure proper grounding of the taps.
k) All temporary protective grounds have been removed from conductors.
l) All protective and alarm circuits are operational and placed into service before the transformer is energized.
m) Get confirmation that all installation procedures have been completed successfully.
n) Get confirmation that there are no current transformer secondary open circuits.
o) Set the cooling controls for automatic operation.
p) The control selector-switch for the on-load tap changer in the control cabinet is set on REMOTE position.

The transformer is ready for service upon the successful conclusion of the tests and completion of the set time.

2.2 Energization
If possible the transformer should be energized in such a way that the voltage is increased step by step up to the rated
voltage. This may be done by connecting the transformer to a generator by which the voltage is slowly increased. The
higher the rated voltage, the more important to energize the transformer as described. If it is not possible to use a
generator, the transformer may be connected directly to a live transmission line at no load.
After energizing, the transformer has to be kept under careful observation for the first 12 hours. Check and record the oil
temperature, the winding temperature, its instrumentation, the tank pressure (if applicable) and ambient temperature.
Watch particularly for any sudden changes.
When the transformer is successively loaded, observe carefully the transformer for a few hours, especially the temperature
gauges and the gas relay.
The observation should continue on a daily schedule for seven days and then weekly for the first month of operation.
An oil sample should be taken after the first and twelfth month of operation for Gas-In-Oil Analysis. The results of these
two analyses should be sent to the ABB representative as soon as they are known. This analysis should then be repeated
annually.
When the transformer has been in service at normal working temperatures for some weeks, all sealing joints have to be
retightened.

2.3 Shut down and re-energization of transformers with Inertaire or Sealedaire Oil Preservation System.
When you de-energize the transformer and plan to have it out of service for any reason, no special start-up/shut-down
provisions are needed unless the transformer is provided with oil pumps. For FOA transformers follow this procedure:
De-energize the transformer. Run one half of the pumps until the unit reaches temperature equilibrium with the ambient.
Do not run any of the cooling fans during this cool-down cycle. This procedure moves the oil past the interface with the gas
blanket to speed up the release of nitrogen from the oil. Running just one half of the pumps will reduce the static charge
build up and not running the fans prevents too rapid cooling.
Starting up after Shut Down
Run one half of the pumps for 15 minutes to one hour and then de-energize these pumps and run the other half of the
pumps for 15 minutes to one hour. This will dislodge any pockets of nitrogen in the oil and move the gas past the oil to gas
blanket interface. Do not run both sets of pumps at one time because this may cause static charge buildup.
Within twelve hours after running the second set of pumps, energize the transformer and set the cooling controls for
automatic operation. This will allow the cooling to be initiated as required by the increasing winding temperature.

2.4 Shut down and re-energization of transformers with COPS Oil Preservation System.
Transformers equipped with COPS oil preservation systems do not require the special shut down and start up procedures
because there is no gas blanket on the transformer.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 6 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
3 Appendix 1 Table of three-phase transformer connections

Note. This table was based on the manual for Tettex Turn Ratio Meter 2791
Vector Ratio Indication
HV-side LV-side Diagram
group on meter

u–n u
U
U–N v–n
N n
YN-yn-0 V–N w–n W w
RN
V v
W-N

U u
U–N u – (v-w)
N
YN-y-0 V–N v – (w-u) W V w v
RN/1.5
W-N w – (u-v)

u–n u U
U – (V-W) v–n N
Y-yn-0 V – (W-U) w–n w v W V
1.5* RN
W – (U-V)

u u
U – (V-W) u – (v-w)
Y-y-0 V – (W-U) v – (w-u) w v w v
RN
W – (U-V) w – (u-v)

U v w
U–N n-u N n
YN-yn-6 V–N n-v W V RN
W-N n-w u

U
v w
U–N (v-w) - u N
YN-y-6 V–N (w-u) - v W V RN /1.5
u
W-N (u-v) - w

u v w
U – (V-W) n-u n
Y-yn-6 V – (W-U) n-v w v 1.5* RN
W – (U-V) n–w u

u v w
U – (V-W) (v-w) - u
Y-y-6 V – (W-U) (w-u) - v RN
w v u
W – (U-V) (u-v) - w

U uu
U–V u–v w
w
W
D–d-0 V–W v–w V vv
RN
W-U w-u

U–V w–v U w
D–d-2 V–W u–w W u RN
V v
W-U v-u

U W
U–V w–u W
D–d-4 V–W u–v V RN
V
U
W-U v-w

Table of three-phase transformer connections Page 1 of 3

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 7 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
Ratio
Vector
HV-side LV-side Diagram Indication
group
on meter
U V
D–d-6 U–V v–u W W
V–W w–v V U RN
W-U u-v
D–d-8 U
U–V v–w V
W U
V–W w–u V RN
W
W-U u-v

D – d - 10
U U
W V
U–V u–w
V W
V–W v–u RN
W-U w-v

YN – d - 1 U
u
U–N u–v N w
V–N v–w W V v RN
W-N w-u

Y–d-1 u
U – (V – W) u–v u
w
V – (W – U) v–w w v 1.5 * RN
v
W – (U – V) w-u

YN – d - 5
U W
U–N w–u
N V
V–N u–v W V U RN
W-N v-w

Y–d-5
U – (V – W) w–u u W
V – (W – U) u–v V 1.5 * RN
W – (U – V) v-w w v U

YN – d - 7
U V
U–N v–u
V–N w–v N W RN
W V U
W-N u-w

Y–d-7 u V
U – (V – W) v–u
V – (W – U) w–v W 1.5 * RN
w v
W – (U – V) u-w U

YN – d - 11
U U
U–N u–w
N V
V–N v–u W W
RN
V
W-N w-v

Y – d - 11
u U
U – (V – W) u–w
V – (W – U) v–u V 1.5 * RN
w v W
W – (U – V) w-v

D – yn - 1 U
W U
U–V n–v W
n
V
V–W n–w V
RN
W-U n-u

D–y-1 U U
U–V (w – u) – V W
W
V–W (u – v) – w RN/1.5
V
W-U (v – w) - u V

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 8 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
Ratio
Vector
HV-side LV-side Diagram Indication
group
on meter

v w
U–V n–u U
W n
D – yn - 5 V–W n–v RN
V
W-U n-w u

U v w
U–V (v –w) – u W
D–y-5 V–W (w – u) – v V RN/1.5
u
W-U (u – v) - w

U v
U–V v–n W n
D – yn - 7 V–W w–n V u w RN
W-U u-n

U v
U–V v – (w – u) W
D–y-7 V–W w – (u – v) V u w
RN/1.5
W-U u – (v –w)

U u
U–V u–n
W n
D – yn - 11 V–W v–n V w
RN
v
W-U w-n

U u
U–V u – (v - w) W
D – y - 11 V–W v - (w – u) V w v
RN/1.5
W-U w – (u – v)

Legend:

RN = nominal ratio per limb.

For definition of Vector group see


IEC 60076-1 and 60616, also VDE 0532 part 4.

Marking on the transformer terminal

Comparison between IEC/VDE and ANSI/IEEE standards

High-Voltage side of test object Low-Voltage side of test object


IEC/VDE ANSI/IEEE IEC/VDE ANSI/IEEE
u H1 u X1
v H2 v X2
w H3 w X3
N H0 n X0

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 9 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
4 Revision
A: 1998-04-30
B: 2003-05-30 new Format
C: 2003-08-11 changes in P 1
D: 2005-01-05 change of table in Appendix 1. Removal of insulation value in 1.4.4

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should be communicated to
ABB Power Transformers

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2005-01-05 D Page 10 of 10


Applicability: TrafoStar Lang: en
Title:
Document No.
1ZBA4601-216 Acceptance Testing and Energization
PowerIT Transformers and Reactors

Field Test Record

Table of contents
1 FIE LD TEST RECORD ......................................................................................................................................................... 2
2 Ratio test ................................................................................................................................................................................ 3
2.1 Ratio when Ratio Bridge is used. ................................................................................................................................... 3
2.2 OLTC when Voltmeter method is used........................................................................................................................... 4
2.2.1. DETC...................................................................................................................................................................... 5
3 Resistance ............................................................................................................................................................................. 5
4 Check of vector group if Voltmeter method is used................................................................................................................ 6
5 Insulation Resistance test ...................................................................................................................................................... 7
5.1 Windings......................................................................................................................................................................... 7
5.2 Current Transformers ..................................................................................................................................................... 7
5.3 Control-circuit cabling and auxiliary power cabling......................................................................................................... 8
5.4 Core ............................................................................................................................................................................... 8
6 Check of potential connection between tank and turret.......................................................................................................... 8
7 Polarity check of Current Transformers.................................................................................................................................. 8
8 Check of winding temperature circuits.................................................................................................................................... 8
9 Oil test .................................................................................................................................................................................... 9
10 Operational test of supervisory equipment ........................................................................................................................... 10
10 Operational Test of other equipment .................................................................................................................................... 13
10.1 Coolers ..................................................................................................................................................................... 13
10.2 De-energized tap changer with driving mechanism.................................................................................................. 13
10.3 On-load tap-changer with motor drive mechanism ................................................................................................... 13
1 FIE LD TEST RECORD

Order No
Serial No

Transformer type
Serial No
Tap-changer type

Motor-drive
Serial No
mechanism type

Test Yes No
1 Ratio test
1.1 OLTC
1.2 DETC
2 Resistance
3 Check of vector group
4 Insulation Resistance test
4.1 Windings
4.2 Current Transformers
4.3 Control-circuit cabling and auxiliary power cabling
4.4 Core
5 Check of potential connection between tank and turret
6 Polarity check of Current Transformers
7 Check of winding temperature circuits
Dew point measurements
8 Oil test
9 Operational test of supervisory equipment
10 Operational Test of other equipment
10.1 Coolers
10.2 De-energized tap changer with driving mechanism
10.3 On-load tap-changer with motor drive mechanism

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 2 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
2 Ratio test
2.1 Ratio when Ratio Bridge is used.
Ratio measurements Serial no……………………
First Terminals:
Second Terminals:
Phase displacement: Nominal Confirmed
Tap position Rated Measured ratio and excitation current Calculated Max.
st nd
1 2 voltage / / / ratio difference
1)
Term. Term. [kV] MA Ratio mA Ratio mA Ratio with %
multiplier

Measuring instrument type……………………………………………


Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

1)
When aviable in used Instrument. Termial used shall be indicated

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 3 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
2.2 OLTC when Voltmeter method is used and 3 phase power supply

U-measured on ___kV
Magnetizing U-measured on ___kV side Calculated Calculated
Tap No load side Max.
on ___-kV voltage voltage
changer current difference
side
Position [mA] %
[V]
a-b a-c b-c a- b-c a-b a-c b-c a-b-c
[V] [V] [V] [V] [V] [V] [V] (V)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Measuring instrument type……………………………………………
Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 4 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
2.2.1. DETC
Calculat
ed Max.
Magnetizing U-measured on ___kV side Calculated U-measured on ___kV side
Tap No load voltage difference
on ___-kV voltage
changer current a-b-c %
side [V)
position [A]
[V]
a-b a-c b-c a- b-c a-b a-c b-c
[V] [V] [V] [V] [V] [V] [V]

1
2
3
4
5
6
7
Measuring instrument type……………………………………………
Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

3 Resistance
Average Single
Terminal to Terminal Terminal to Terminal Terminal to Terminal
Average Single Phase Resistance
Tap changer Resistance Resistance Resistance
Phase Resistance [mς]
position [mς [mς] [mς]
[mς] corrected to …..°C
/] / /

Oil temperature..............°C
Measuring instrument type……………………………………………
Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 5 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
4 Check of vector group if Voltmeter method is used
Connect A with a
Magnetized on kV side
_____________

Measured voltage U between

Bb Cc AB Bc Cb
Connection
[V] [V] [V] [V] [V]

Connect A with a
Magnetized on kV side
_____________

Measured voltage U between

Bb Cc AB Bc Cb
Connection
[V] [V] [V] [V] [V]

Instrument used in test Type Range Serial Number

The vector group corresponds with connection


diagram No

Remarks

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 6 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
5 Insulation Resistance test
5.1 Windings
Megger kV Note Maximum 5kV megger

st nd
1 Terminals…………… 2 Terminals…………… Ω]
1 Minute[MΩ
Ω]
10 Minutes [MΩ

Weather conditions:______________________________________________________
Measuring instrument type……………………………………………
Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

5.2 Current Transformers


Megger___________ V Note Maximum 1kV megger

TO EARTH
LOCATION TERMINAL Ω]
[MΩ
Ω]
[MΩ

Weather conditions: ______________________________________________________


Measuring instrument type……………………………………………
Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 7 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
5.3 Control-circuit cabling and auxiliary power cabling
Megger_______ V Note Maximum 1kV megger Type_______________ Serial no________________

Cables to earth (min value) ________________ [MΩ


Measuring instrument type……………………………………………
Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

5.4 Core
Megger_______ V Note Maximum 1kV megger Type_______________ Serial no________________

Core - earth ________________ [MΩ]


Core Clamp -earth ________________ [MΩ]
Core Clamps-Core ________________ [MΩ]

Weather conditions: ________________________________________________________


Measuring instrument type……………………………………………
Measuring instrument serial no. ………………………………………
Last calibration date……….month………year……….Next calibration date………month………….year……
Measurement performed Place……………….Date………………….By………………….

REMARKS: ________________________________________________________

_________________________________________________________________

6 Check of potential connection between tank and turret


The potential connection between tank and turret has been checked with buzzer
! yes

! no

7 Polarity check of Current Transformers


Check of Current Transformers according to diagram No _______________________________

Location/terminal Location/terminal Location/terminal


Location/terminal Location/terminal Location/terminal

8 Check of winding temperature circuits


Current transformer for

Location Location Location

Measured resistance for:

Current transformer [Ω] [Ω] [Ω]

Instrument [Ω] [Ω [Ω]

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 8 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
9 Oil test
The oil level checked in Date

! Transformer reactor

! Tap-changer/diverter switch _

! Other separate compartments _

! The oil system has been de aired _

Oil samples are taken from


Oil conservator Breakdown voltage [kV]
Transformer/reactor tank Breakdown voltage [kV]
Cooling group No Breakdown voltage [kV]
Cooling group No Breakdown voltage [kV]
Cooling group No Breakdown voltage [kV]
Cooling group No Breakdown voltage [kV]

Oil test equipment type with electrodes

Electrode distance mm

Oil samples for dissolved gas analysis


have been taken

REMARKS _

_____________________________________________________

_______________________________________________________________________

_______________________________________________________________________

__________________________ _____________

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 9 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
10 Operational test of supervisory equipment
Alarm circuit tested to Trip circuit tested to
Control circuit Control room Control circuit Breaker
No/OK No/OK No/OK No/OK
Gas detector relay transformer
Gas detector relay tap changer
Oil level indicator tap changer High
Low
Oil level indicator transformer High
Low
Pressure relief valve for transformer
Pressure relay for transformer
Pressure relay for tap changer
Flow indicators for coolers
Cooler group 1 min oil flow
max. oil flow
min water flow
max. water flow
Cooler group 2 min oil flow
max. oil flow
min water flow
max. water flow
Cooler group 3 min oil flow
max. oil flow
min water flow
max. water flow
Manometers for coolers
Cooler group 1 min oil pressure
max. oil pressure
min water
max. water
Cooler group 2 min oil pressure
max. oil pressure
min water
max. water
Cooler group 3 min oil pressure
max. oil pressure
min water
max. water

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 10 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
Alarm circuit tested to Trip circuit tested to
Control circuit Control room Control circuit Breaker
Cabinet Cabinet
No/OK No/OK No/OK No/OK
Thermometer for top oil
Set for alarm Deg C
Set for trip Deg C
Set for start of
Cooler group 1 Deg C
Cooler group 2 Deg C
Cooler group 3 Deg C
Cooler group 4 Deg C
Cooler group 5 Deg C
Cooler group 6 Deg C
Thermometer for kV winding
Set for alarm Deg C
Set for trip Deg C
Set for start of
Cooler group 1 Deg C
Cooler group 2 Deg C
Cooler group 3 Deg C
Cooler group 4 Deg C
Cooler group 5 Deg C
Cooler group 6 Deg C
Thermometer for kV winding
Set for alarm Deg C
Set for trip Deg C
Set for start of
Cooler group 1 Deg C
Cooler group 2 Deg C
Cooler group 3 Deg C
Cooler group 4 Deg C
Cooler group 5 Deg C
Cooler group 6 Deg C

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 11 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
Alarm circuit tested to Trip circuit tested to
Control circuit Control circuit
Control room Breaker
Cabinet Cabinet
No/OK No/OK No/OK No/OK
Thermometer for kV winding
Set for alarm Deg C
Set for trip Deg C
Set for start of
Cooler group 1 Deg C
Cooler group 2 Deg C
Cooler group 3 Deg C
Cooler group 4 Deg C
Cooler group 5 Deg C
Cooler group 6 Deg C
Thermometer for kV winding
Set for alarm Deg C
Set for trip Deg C
Set for start of
Cooler group 1 Deg C
Cooler group 2 Deg C
Cooler group 3 Deg C
Cooler group 4 Deg C
Cooler group 5 Deg C
Cooler group 6 Deg C

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 12 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
10 Operational Test of other equipment
10.1 Coolers
1. Pump rotation direction checked _______

2. Fans rotation direction checked _______

3. Over current protection tripped


at 2-phase connection: _______
Current
After After Current setting
Fan No setting Pump No
(sec.) (sec) [A]
[A]
1
2
3
4
5
7
8
9
10
11
12
Alarm obtained for tripped current protection at
terminals _____________in the control cabinet.
10.2 De-energized tap changer with driving mechanism
Contact movement
The Tap changer was operated from end to end positions ___________________

The interlocking device of the driving mechanism checked. Alarm obtained when the

driving mechanism was operated terminal No in the control cabinet.


10.3 On-load tap-changer with motor drive mechanism
The position indicators in motor drive mechanism and tap changer indicate the
same position
Shaft coupling lubricated with grease
Gear box filled with lubricant to correct level
Motor drive mechanism checked and test run
lubricated
end position contacts
local/remote control
interlocking switch manually and with the crank assembled
setting of motor protection
tripping time for blocked motor
pressure relay tested
heating element connected and In operation

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 13 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
Remarks:

Tested and witnessed by

---------------------------------------- ----------------------------------------
ABB Customer

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 14 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
Revision
A: 1998-04-30
B: 2003-05-30 new Format
C: 2003-08-11 p2, Instrument info added

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

IT
Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 15 of 15


Applicability: TrafoStar Lang: en
Title:

Document No. Field Test Record


1ZBA4601-217
PowerIT Transformers and Reactors

OIL CONSERVATORS WITH AIR CELL

Table of contents

1 General ..................................................................................................................................................................2

1.1 Design ............................................................................................................................................................2


1.2 With tap-changer conservator ........................................................................................................................2

2 Leakage test of air cell...........................................................................................................................................2

3 Replacing an air cell ..............................................................................................................................................3

4 Oil filling .................................................................................................................................................................3

4.1 Vacuum oil filling of conservator ....................................................................................................................3

5 Revision .................................................................................................................................................................3
1 General
This procedure is for transformers equipped with oil conservators (expansion tanks) with an air cell, which prevents
contact between the oxygen in the air and the transformer oil.
The conservator is a reservoir, which takes up the expanded volume of the oil of a transformer or reactor tank. The
volume of the conservator depends on the tank volume and the total oil temperature range.
1.1 Design
A nameplate Oil Level Indicator Plate is used to indicate the filling level depending on the ambient temperature.
Some conservators are designed to withstand vacuum. This is indicated on the Oil Level Indicator Plate Those not
designed to withstand vacuum will have a vacuum proof valve between the conservator and the main tank. . If the Oil
Level Indication Plate is missing please look for te information in the drawings

All conservators have a level indicator. The divisions on the indicator dial may be calibrated to correspond to each 10%
of the conservator volume or may be calibrated in degrees C to provide a general guide for estimating volume.

The connection between the float mechanism and the dial indicator is magnetic.

The level indicator is mounted under the conservator at 45° and the float moves vertically along the length of the
conservator.

The air cell is like a balloon that fits the shape of the inside of the conservator and floats over the oil as the level rise.

The air inside the cell is isolated from the conservator through a flange at the top center of both the conservator and the
air cell. This flange is connected to a Breather to avoid humidity condensation inside the cell and the possible formation
of ice in cold weather conditions.

When the conservator is vacuum proof, an extra flange is added next to the air cell flange and a U shaped pipe is
supplied for interconnecting them temporarily during oil filling. This is to ensure that during the filling operation the
pressure will be the same inside and outside the air cell.

There are two pipe connections at the bottom of the conservator. The center one goes to the main tank and extends
50mm inside the conservator to prevent any dirt from entering the main tank. The second pipe with a valve is used for
draining.
1.2 With tap-changer conservator
The tap-changer conservator is an extension to the main conservator but completely separated from it with an
endplate. These conservators have three pipe connections.

Generally the center one goes to the tank. This pipe extends 50 mm inside the conservator to prevent any dirt from
entering. The second pipe with a valve is for draining.

The third connects the conservator to the Breather. The latter pipe extends inside the conservator all the way to the
top.

The length of this conservator is function of the oil volume in the tap-changer. In order to ensure that the level of the oil
will always be lower than the main conservator, the volume is calculated to be larger than the minimum required.
Filling level is indicated on the Oil Level Indicator Plate.
2 Leakage test of air cell
The air cell is shipped from the Factory with a positive pressure. This pressure is confirmed at site.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 2 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. Oil Conservators with Air Cell
1ZBA4601-219
3 Replacing an air cell
For fitting of, or replacing an air cell the following procedure is followed:

− A simple tool consisting of two threaded rods (M12 or 1/2” UNC) are needed.
− Insert the rods through the holes of the air cell flange welded on top of the conservator for a length of 300mm
using two nuts as stoppers.
− Enter the conservator through the manhole and threads the rods into the air cell flange after putting the gasket in
place.
− Go back on top of the conservator, pulls the threaded rods up and secures two of the flange bolts. The rods are
then removed and the other two bolts are fixed. Two hangers on either side of the air cell flange need to be
attached to brackets inside the conservator.

4 Oil filling
Oil filling is described in 1ZBA 4601-214 for transformers with a System Voltage less than 200 kV, shipped with oil, for
others see 1ZBA 4601-215.

Observe the following.


When during oil filling, the oil level reaches 100 mm below the transformer tank cover, close the oil valve, break the
vacuum, disconnect the plastic hose and open the valve to the conservator.

Put 10 kPa or 1.5 psi air pressure in the air cell and open the two air bleeder valves on top of the conservator.

Open the oil valve and pump oil at reduced (max. 1800 l / hr or 500 gal./hr) until the oil starts coming out both bleeding
valves. Close both bleeder valves and remove the pressure from the air cell simultaneously.

Continue pumping until the proper level is reached as specified on the nameplate.

Disconnect all equipment and connect the air cell to the Breather.

4.1 Vacuum oil filling of conservator


Remove the pipe connecting the conservator to the Breather and replace temporarily with a valve
(not included, recommended 1” ball -valve). Keep it closed.

Remove the vacuum valve on the air cell flange and connect the two flanges on top of conservator using the U flanged
pipe supplied.
Follow oil filling instruction in 1ZBA 4601-215.

After filling remove the U shaped pipe and install the valve and a low pressure regulator suitable for 10 kPa on the air
cell flange. Close the second flange with a cover and gasket.

Put 10 kPa or 1.5 psi air pressure in the air cell. Open the oil valve at reduced flow (max. 1800 l / hr or 500 gal./hr) and
pump oil until the oil starts coming out from both bleeder valves. Close both bleeder valves and remove the pressure
from the air cell simultaneously.

Continue pumping until the proper level is reached as specified on the nameplate.

Disconnect all equipment and connect the air cell to the Breather.

It is important for any type of tap-changer, to pull vacuum in the tap-changer and the main tank simultaneously
(selector switch for outside TP and diverter switch for inner TP). This is to prevent excessive stresses on the partitions
separating the device and the tank.

5 Revision
A: 2001-02
B: 2003-05-30 new Format
C: 2003-08-11 Oil Level Indicator plate
D: 2003-10-10 Revision of text in 4.1

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 3 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. Oil Conservators with Air Cell
1ZBA4601-219
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should comunicated to:
ABB Power Transformers acording to contact list in Aspect Viewer

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.

Prepared By: W. Klein Date: 1998-04-30 Rev. No: Page No:

Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 4 of 4


TrafoStar Title:
Applicability: Lang: en
Document No. Oil Conservators with Air Cell
1ZBA4601-219
PowerIT Transformers and Reactors

SUPERVISION OF TRANSFORMERS AND REACTORS

Table of contents
1 General ....................................................................................................................................... 2
2 Safety definitions.......................................................................................................................... 2
3 GENERAL MAINTENANCE ............................................................................................................... 2
3.1 Dirt, dust .............................................................................................................................. 2
3.2 Possible oil leakage ................................................................................................................. 2
3.3 Rust damages, touch-up painting ............................................................................................ 2
3.4 Oil-level indicator for oil conservator ......................................................................................... 2
3.5 Gas-operated relay ................................................................................................................. 3
3.6 Venting ................................................................................................................................. 3
3.7 Sudden pressure relief valve .................................................................................................... 3
4 OIL............................................................................................................................................. 3
4.1 Gas in oil analysis ................................................................................................................... 3
4.2 Oil analysis ............................................................................................................................ 3
4.2.1. Moisture.......................................................................................................................... 3
4.2.2. Sludge, acid..................................................................................................................... 3
5 TEMPERATURE SUPERVISION ......................................................................................................... 4
5.1 Overload ............................................................................................................................... 4
5.2 Thermometer for measuring of top-oil temperature. .................................................................... 4
5.3 Winding temperature indicator.................................................................................................. 4
5.4 Remote temperature indication ................................................................................................. 4
6 COOLING EQUIPMENT ................................................................................................................... 4
6.1 Air-side (Radiators, oil-air coolers) ............................................................................................ 4
6.2 Oil-side (Radiators, coolers for oil-air, oil-water) ......................................................................... 4
6.3 Water side (Coolers for oil-water) ............................................................................................. 5
6.4 Fans ..................................................................................................................................... 5
6.5 Flow-indicators, pressure meters .............................................................................................. 5
7 CONTROL CABINET ....................................................................................................................... 5
8 BUSHINGS................................................................................................................................... 5
9 CONNECTIONS ............................................................................................................................. 5
10 DE-ENERGISED TAP-CHANGERS (DETC) ....................................................................................... 5
11 ON-LOAD TAP-CHANGERS (OLTC) ................................................................................................ 5
12 RE-TIGHTENING ........................................................................................................................ 6
12.1 Hexagon head bolt, M-thread. Property class 8.8. ...................................................................... 6
12.2 Stud, M-thread. Property class 5.8 ......................................................................................... 6
1 General
In order to avoid faults and disturbances, it is important that a careful and regular supervision and control of the
transformer and its components is planned and carried out. The frequency and extent of such a supervision and control
depend on climate, environment and service conditions etc. The directions for a certain transformer are therefore
preferably based on experiences from comparable transformer installations. Spare transformers are supervised and
maintained according to the same schedule as transformers in service.

2 Safety definitions
Safety notations are intended to alert personnel of possible personal injury, death, or property damage. They have
been inserted in the instructional text prior to the step in which the condition is cited.
The safety notations are headed by one of three hazard intensity levels, which are defined as follows:
DANGER - immediate hazard that will result in severe personal injury, death, or property damage;
WARNING - hazard or unsafe practice that could result in severe personal injury, death, or property damage;
CAUTION - hazard or unsafe practice that could result in minor personal injury or property damage.

CAUTION
All of the openings in the transformer tank and the tap changer compartment or other oil-filled
compartments must be tightly closed and sealed before the transformer is placed into operation
Failure to seal the opening will allow oil leaks and will allow air and moisture to enter the transformer. This
will cause deterioration of the insulating oil and may cause an electrical failure.

3 GENERAL MAINTENANCE
3.1 Dirt, dust
The external transformer surfaces shall be inspected regularly; and when required cleaned from dust,
insects, leaves and other airborne dirt.

3.2 Possible oil leakage


After energizing a certain setting may appear in sealing joints. They should therefore be retightened after the
transformer has been in operation for about a month and thereupon when needed. This applies especially to
sealing joints with plain gaskets that are not placed in grooves. It should be noted that gaskets of cork-rubber type
are difficult to retighten once they have started to leak.
3.3 Rust damages, touch-up painting
A regular inspection of the external surface treatment of the transformer should be carried out. Possible rust is
removed and the surface treatment restored to original state by means of the primer and finish-paints that are
dispatched with the transformer. If requested ABB can supply additional paint in original colour.
It may happen that the drying agent gets a slight light brown colour at the top of the drier. It can either be caused
by a leak in the connection tubes to the conservator or too high moisture content in the transformer. The joints in
the connection tube should then be checked and an oil sample should be extracted for moisture check.
3.4 Oil-level indicator for oil conservator
The oil conservator is provided with an oil-level indicator. The correct oil-filling level is specified on an information
plate. The indicator has alarm contacts for low and high. On alarm, the cause shall be established and measures
made to reach a correct oil level.

Prepared By: L Ostman Date: 2004-03-03 Rev. No: Page No:

Approved By: Thomas Fogelberg Date: - Page 2 of 7


TrafoStar Title:
Applicability: Lang: en
Document No. Supervision of Transformers
1ZBA 4601-222
3.5 Gas-operated relay
The use of a gas-operated relay as protection for oil-immersed transformers is based on the fact that faults as
flashovers, short-circuits and local overheating normally result in gas-generation. The gas-bubbles gathering in the
gas-operated relay affect a float-controlled contact, which gives an alarm signal. The gas relay installed in the main
tube to the conservator is also equipped with a sensor for high oil speed in the tube. The signal from that sensor
should be connected for immediate trip of the transformer. The cause of a high oil speed is often a serious problem
in the transformer, e.g. a flashover. Contact ABB for rules for sampling and evaluation of the properties of the gas
collected. Information about the gas relay functions are given in separate instructions.
3.6 Venting
Certain transformers are provided with air venting valves on components positioned high up in order to drain
possibly trapped air in the oil system. Trapped air should be checked for after the installation of the transformer, or
an inspection that implies opening of the oil system.
3.7 Sudden pressure relief valve
Some transformers are equipped with a sudden pressure relief valve, which opens for a given overpressure in the
tank. For detail description, see specific product information
4 OIL
4.1 Gas in oil analysis
Regular gas in oil analysis is recommended. The interval between consecutive analysis may vary depending on
type of transformer, its location in the network/industry, etc. As a guiding value gas in oil analysis once a year is
recommended.
4.2 Oil analysis
In addition to gas in oil analysis, a more or less complete chemical analysis of the oil is recommended. Within ABB
Transformers there is a distinction between large and small analysis. The small test covers:
− Colour
− Visual inspection
− Moisture content
− Dielectric breakdown withstand
− Neutralisation number

The large test covers four more tests in addition the above:
− Inhibitor content established (GC-method)
− Power factor, tan delta, depending on the situation
− Interfacial tension
− PCB Content

These tests are in addition to the conventional gas in oil analysis. Such tests are recommended when gas in oil
analysis has given indication of nonconformance of the transformer. ABB Transformers is prepared to give advice
on investigations to be carried out. As a guiding value, oil analysis should be done about once every fifth year if not
otherwise necessary depending on the outcome of other tests.

4.2.1. Moisture
Some build-up of water content is inevitable, due to the aging processes. The oil may also have been subjected to
moist air. The moisture content and the dielectric withstands of the oil shall be checked as part of the small and
large test or whenever there is a suspicion that oil been exposed to humidity.

4.2.2. Sludge, acid


Normally the transformers and reactors from ABB are filled with inhibited oil if customer has not specified
differently. The inhibitor works as an antioxidant (a preserving agent). When the oil is aging, sludge and acid
products develop. The inhibitor retards the ageing process and extends the utilisation time of the oil. When this
occurs the oil shall be analysed and the neutralisation number and the remaining inhibitor content shall be
determined. The oil should be replaced or regenerated, if the neutralisation number is larger than 0,1 to 0,15 mg
potassium hydro oxide (KOH) per gram oil in inhibited oil, (alternatively larger than 0,2 mgKOH/g in non-inhibited
Prepared By: L Ostman Date: 2004-03-03 Rev. No: Page No:

Approved By: Thomas Fogelberg Date: - Page 3 of 7


TrafoStar Title:
Applicability: Lang: en
Document No. Supervision of Transformers
1ZBA 4601-222
oil) and/or an inhibitor content less than 0,1%. Larger values on neutralisation number or less inhibitor content than
stated here will accelerate the ageing.
The exchange of oil should be as complete as possible, because old oil will infect the new one and thus speed up
the ageing process. The exchange should preferably be carried out when the oil is warm and the oil viscosity is low.
In inhibited oil where only the inhibitor content has decreased the addition of new inhibitor is a possible option.
Oil not too far oxidised may be regenerated. Before any measures are carried out, consultation with ABB is
recommended.
5 TEMPERATURE SUPERVISION
The service life of a transformer depends to a great extent on the temperatures in the core and windings during
operation. It is thus important to keep the oil and winding temperatures under continuous observation. The
temperatures should be read regularly and the measured values registered. These values will give guidance for
judging of the service life of the transformer, cooling system functions etc.
5.1 Overload
A transformer can normally be overloaded at low ambient temperatures. However, the permissible overload must
not be judged only with regard to the oil temperature. The winding absolute temperature has to be considered
together with permissible current loading of accessories like bushings and tap-changer. For determination of the
overload capacity for modern transformers we refer to applicable IEC Standard. If the temperature in a transformer
shows a tendency to rise without a corresponding increase of the load, there may be a reduction of the ability of the
cooling equipment due to dirt and dust. However, the thermometers should be checked first.
5.2 Thermometer for measuring of top-oil temperature.
For the description of function and adjustment of the thermometer, see separate product information. The
instruction gives also advice on adjustments of temperature levels for signals and control of cooling equipment.
Applicable values for a specific transformer are stated in the transformer manual.
5.3 Winding temperature indicator
The thermometer system has a sensor, temperature signal transmission and display system similar to the oil
thermometer.
The measured oil temperature is "adjusted" by a temperature increase corresponding to the temperature difference
between the oil and the winding conductor. This temperature increase is obtained by a heating element carrying a
current proportional to the winding current. A separate current transformer in the winding circuit will provide the
current. An adjustable shunt resistor in the current transformer heating element circuit facilitates the calibration of
the thermometer to display a correct winding temperature. The calibration is normally based on the outcome of a
heat run test. The heating element and the shunt element may be located in the display instrument or at the sensor
body in the thermometer pocket. For further information and calibration see separate product information on the
winding thermometer. It will also give information on signal settings from the thermometer and advice on cooler
starts.
5.4 Remote temperature indication
.
For information and calibration see user’s manual for the transformer.
6 COOLING EQUIPMENT
6.1 Air-side (Radiators, oil-air coolers)
The cooling surfaces shall he inspected regularly and when required cleaned from dust, insects, leaves or other
airborne dirt. This is especially important in case of fan cooling. The cleaning is preferably carried out by means of
water flushing at high pressure.
6.2 Oil-side (Radiators, coolers for oil-air, oil-water)
Normally, no measures are necessary for keeping the internal cooling surfaces clean as long as the oil is in good
condition. If, however, sludge formation has set in, the sludge may deposit on horizontal surfaces in radiators and
coolers. If such a case, the radiators and coolers should he flushed internally with clean oil in connection with oil
exchange.

Prepared By: L Ostman Date: 2004-03-03 Rev. No: Page No:

Approved By: Thomas Fogelberg Date: - Page 4 of 7


TrafoStar Title:
Applicability: Lang: en
Document No. Supervision of Transformers
1ZBA 4601-222
6.3 Water side (Coolers for oil-water)
The coolers should be inspected regularly. All coolers can be disassembled on the waterside to permit efficient
cleaning of cooling surfaces.
Depending on the condition of the cooling water, the time intervals between inspections may vary. Suitable
intervals are determined by experience.
6.4 Fans
The fan-motors are provided with permanently lubricated bearings and double sealing rings. The motor bearings
are axially clamped with spring washers. If the sound level of the fan increases, first of all mounting supports should
be retightening.
6.5 Flow-indicators, pressure meters
For information about maintenance of the indicator and possible exchange of rubber diaphragm, see separate
information.
7 CONTROL CABINET
The function of the control cabinet with its components is described in the circuit diagram of the transformer.
8 BUSHINGS
Bushings manufactured by ABB are in general maintenance free. Bushing porcelains shall be cleaned from dust
and dirt regularly. In areas where the air contains impurities as salt, cement dust, smoke or chemical substances,
shorter intervals are required. See also the directions in the special information documents about bushings included
in the transformer instruction manuals at delivery.
9 CONNECTIONS
In order to avoid dangerous temperature rises in the electrical connections of the transformer, all bolted joints
should be checked and retighten regularly. For transformers in service, a thermo vision camera may be used to
check the contact temperature of external current carrying joints.
10 DE-ENERGISED TAP-CHANGERS (DETC)
At overhaul of DETC, the movable parts of the operating gear shall be lubricated. When the transformer is
disconnected and not in use, the DETC should be operated to all positions and then re-set. The operation will
prevent a build up of an insulation layer on the contact surfaces, which may lead to critical temperatures in the
DETC.
11 ON-LOAD TAP-CHANGERS (OLTC)
A description of function, supervision and maintenance of OLTC and its driving mechanism is available for each
type of OLTC. The information documents are included in the transformer instruction manual. It should be noted
that the on load tap-changer requires regular maintenance. The maintenance program prescribed by the tap-
changer manufacturer should be followed. Such a program is often based on the number of tap-changing
operations and/or the total operational time.

Prepared By: L Ostman Date: 2004-03-03 Rev. No: Page No:

Approved By: Thomas Fogelberg Date: - Page 5 of 7


TrafoStar Title:
Applicability: Lang: en
Document No. Supervision of Transformers
1ZBA 4601-222
12 RE-TIGHTENING
The following tightening torque values are applicable for joints between details of steel. It shall also be applied for
bolted current carrying joints.
12.1 Hexagon head bolt, M-thread. Property class 8.8.

Thread Finish Lubrication Tightening


Dim. torque
Tol. +/- 10 %
Nm Kpm
M8 24,5 2,5
M10 Zinc- 49,0 5.0
M12 plated 84 8,6
M16 No 205 21
M20 Lubrication 430 44
M24 Un- 745 76
M30 treated 1520 155
M36 2650 270

12.2 Stud, M-thread. Property class 5.8

Thread Finish Lubrication Tightening


Dim. torque
Tol. +/- 10 %
Nm kpm
M10 29.5 3.0
M12 50.5 5,1
M16 Hot dip 123 12.5
No
M20 galv. 258 26.3
Lubricatio
M24 447 45.5
M30 912 93
M36 1590 132

Prepared By: L Ostman Date: 2004-03-03 Rev. No: Page No:

Approved By: Thomas Fogelberg Date: - Page 6 of 7


TrafoStar Title:
Applicability: Lang: en
Document No. Supervision of Transformers
1ZBA 4601-222
DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF,


OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY
SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS
DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP.

The information, recommendations, descriptions, and safety notations in this document are based on our
experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED
TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be
consulted.

NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR


PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY
NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort
(including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential
damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or
power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in
the use of existing power facilities, or claims against the user by its customers resulting from the use of the
information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand.
All comments and suggestions for improvement should be FAXed to:
ABB Power Transformers acording to contact list in Aspect Viewer.

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for
lifecycle product support in consistent electronic form.
Prepared By: L Ostman Date: 2004-03-03 Rev. No: Page No:

Approved By: Thomas Fogelberg Date: - Page 7 of 7


TrafoStar Title:
Applicability: Lang: en
Document No. Supervision of Transformers
1ZBA 4601-222
Serial no. 1133751

ACCESSORIES OF TRANSFORMER TYPE


TNER3E 40000/115 PN
LIST OF MANUFACTURERS/SUBSUPPLIERS

Name of accessory Type Manufacturer/Subsupplier

Voltage regulation

- OLTC UCGRN 650/300/C ABB Power Technologies AB


- OLTC motor drive BUL Components
Lyvikvägen 10
SE-77180 Ludvika, Sweden

Bushings

- HV bushing GOB 550-800, LF 123 191-K, L6=500 mm


Inner terminal: LF 170 011-S ABB Power Technologies AB
Outer terminal: LF 170 001A Components
Lyvikvägen 10
- HV-neutral bushing GOB 550-800, LF 123 189-K, L6=100 mm SE-77180 Ludvika, Sweden
Inner terminal: LF 170 011-S
Outer terminal: LF 170 001A

- MV bushings 20f/3150, Fig. B1, b1=380 Terman’90


Strumentazione Industriale S.r.I.
- LV bushings 10f/4500, Fig. C1, C1=440 Via Ghisalba 13-20/21
20021 Bollate Milano, Italy

Cooling system

- Coolers LK-S-190-50-1a-2x910-R13-100-h GEA Technika Cieplna Sp. z o.o.


ul. Oświęcimska 121
45-643 Opole
Poland

- Pumps 50/150/100/N/D/2/2 GEA


Renzmann & Grünewald GmbH
Industriestraße 6 ·
D-55569 Monzingen
Germany

- Liquid flow WPC-100 G L/P 0,8 IP553 INSTYTUT ENERGETYKI ODDZIAŁ


indicator TRANSFORMATORÓW
ul.Kopernika 56/60
90-553 Łódź
Poland

1/3
Serial no. 1133751

Protection, control and monitoring equipment

- Inteligent Electronic 509-100 Qualitrol AKM


Device Art. no. IED509-00026748
Flygfaltsgatan 6C
- Resistance Bulb Art. no. 103-023-01 128 30 Skarpnack
Platinum
Sweden
- Detachable Connector CON000-00009199
Assembly

- Control cubicle Szymański s.c.


ul. Wiskicka 22
93-623 Łódź, Poland

- Buchholz relay BF 80/10 4NO Elektromotoren und Geratebau Barleben GmbH


(09-22-244) Bahnhofstraβe 27/28
39179 Barleben, Germany
- Monitoring relay for URF 25/10
tap changers

- Winding temperature MSRT 150-W, capillary 10 m Terman’90


indicator Strumentazione Industriale S.r.I.
Via Ghisalba 13-20/21
- Oil temperature MSRT 150, capillary 10 m 20021 Bollate Milano, Italy
indicator

- Oil level indicator LA22, 1ZBA569001-C COMEM


Strada Statale 11
- Oil level indicator LB22, 1ZBA569001-X 36054 Montebello Vic.(VI), Italy

- Pressure safety valve VS 150, 2CO Terman’90


Strumentazione Industriale S.r.I.
Via Ghisalba 13-20/21
20021 Bollate Milano, Italy

- Silicagel air breather – EM5DA


COMEM
transformer tank ABB dwg no. 1ZBA 676001-C
Strada Statale 11
- Silicagel air breather – EM2DA 36054 Montebello Vic.(VI), Italy
OLTC ABB dwg no. 1ZBA 676001-A

- Current transformer JR 0,5 EPRO Gallspach GmbH


A-4713 Gallspach
Styriastrasse 2
Postfach 20, Austria

2/3
Serial no. 1133751

Others

- Transformer oil Nytro 10XN Nynas Naphthenics AB


Lindetorpsvägen 7
P.O. Box 10701
121 29 Stockholm, Sweden

- Rubber air cell for A=2010 mm, B=3510 mm, PRONAL S.A.
conserwator C=1300 mm L'Ingeniere de I'Elastomere
Flange type 15 Z.I.Roubaix Est-BP 18
F-59115 Leers
France

- Ball type valves WK 2a Przedsiębiorstwo Handlowo-Produkcyjne


“EFAR” s.c.
- Throttle valves WKKI-1 ul. Św. Antoniego 53
61-359 Poznań, Poland

- Gaskets NBR PB 80 James Walker & Co Ltd


Lion House Woking
Surrey
GU22 8AP
United Kingdom

3/3
Serial no. 1133751

5 On-load tap changer UCGRN 650/300/C with motor drive BUE

5.1 On-load tap-changers, type UC. Technical guide 1ZSE 5492-105 en, Rev. 5

5.2 Motor-drive mechanism, type BUE 2. Technical guide 1ZSE 5483-104 en, Rev. 3

5.3 On-load tap-changers, types UCG and UCL with motor- 1ZSE5492-116 en, Rev. 8
drive mechanism, types BUE and BUL. Installation and
commissioning guide

5.4 On-load tap-changer, type UCG with motor-drive 1ZSE 5492-124 en, Rev. 5
mechanisms, types BUE and BUL. Maintenance guide

5.5 On-load tap-changers, types UCG, UCL, UCC and UCD 1ZSE 5492-129 en, Rev. 6
with motor-drive mechanisms, types BUE and BUL. Repair
Guide

5.6 On-load tap-changers, types UCG, UCL, UCC and UCD 1ZSE 5492-133 en, Rev. 3
with motor-drive mechanisms, types BUE and BUL. Spare
Parts List

5.7 Tap-Changer UCGR UCGRN 54920104-8

5.8 Top Section, Accessories Tap-Changer UCG 54920103-2

5.9 External Shaft System 54920083-4

5.10 Connection Diagram 5492 0095-118

5.11 Circuit Diagram Relief Vent 5478 003-59

5.12 Circuit Diagram Motor-Drive Mechanism Type BUL 5483 538-66


5475 908-11
5475 913-26
5483 540-1
5483 540-30

1/1
On-load tap-changers, type UC
Technical guide
Manufacturer’s declaration
The manufacturer ABB Components AB
SE-771 80 LUDVIKA
Sweden

Hereby declares that

The products On-load tap-changers


type UC
with motor-drive mechanisms
types BUE and BUL

comply with the following requirements:

By design, the machine, considered as component on a mineral oil filled power transformer, com-
plies with the requirements of

• Machinery Directive 89/392/EEC (amended 91/368/EEC and 93/44/EEC) and 93/68/EEC


(marking) provided that the installation and the electrical connection be correctly realized by the
manufacturer of the transformer (e.g. in compliance with our Installation Instructions) and
• EMC Directive 89/336/EEC regarding the intrinsic characteristics to emission and
immunity levels and

• Low Voltage Directive 73/23/EEC (modified by Directive 93/68/EEC) concerning the built-in
motor and apparatus in the control circuits.

Certificate of Incorporation:

The machines above must not be put into service until the machinery into which they have been
incorporated have been declared in conformity with the Machinery Directive.

Date 1997-02-10

Signed by .........................................................................
Olof Heyman

Title Manager of Division for tap-changers

This Technical Guide has been produced to allow transformer manufacturers, and their designers
and engineers, access to all the technical information required to assist them in their selection of
the appropriate on-load tap-changer and motor-drive mechanism. The guide should be used in
conjunction with the Selection Guide and the Design Guides, to allow the optimum selection to be
made.

The technical information pertaining to on-load tap-changers and motor-drive mechanisms


manufactured by ABB Components has been divided and is contained in separate documents,
with one document for each type.

The information provided in this document is intended to be general and does not cover all
possible applications. Any specific application not covered should be referred directly to
ABB Components AB, or its authorized representative.

ABB Components AB makes no warranty or representation and assumes no liability for the
accuracy of the information in this document or for the use of such information. All information in
this document is subject to change without notice.

ABB Components also manufactures the following products:

Transformer bushings
Wall bushings
GIS bushings
Table of Contents
General Information ____________ 4 Oil Temperature _______________________ 20
Tie-ln Resistor ________________________ 20
Design Principles ______________ 6
Design, Installation
On-Load Tap-Changer _____________________ 6
Diverter Switch ________________________ 6
and Maintenance ______________ 21
Tap Selector __________________________ 7 On-Load Tap-Changer _____________________ 21
Diverter Switch Housing and Top Section ___ 8 Design Differences over the UC Range
Operating Mechanism __________________ 8 of On-Load Tap-Changers _______________ 21
Transition Resistors ____________________ 8 Drying _______________________________ 21
Motor-Drive Mechanism ____________________ 9 Painting _____________________________ 21
Type BUL ____________________________ 9 Weights _____________________________ 22
Type BUE ____________________________ 9 Oil Filling ____________________________ 23
Special Applications ____________________ 9 Installation ___________________________ 23
Accessories __________________________ 9 Maintenance __________________________ 23
Oil Filter Unit _________________________ 23
Principles of Operation _________ 10 Pressure Relay ________________________ 23
General Description _________________ 23
On-Load Tap-Changer _____________________ 10 Operation _________________________ 23
Switching Sequence ____________________ 10 Testing ___________________________ 23
Linear Switching (Type L) _______________ 11 Installation _________________________ 23
Change-over Selector for Motor-Drive Mechanism ____________________ 24
Plus/Minus Switching (Type R) ___________ 11 Design ______________________________ 24
Change-over Selector for Installation ___________________________ 24
Coarse/Fine Switching (Type D) __________ 11 Maintenance __________________________ 24
Dimensions _____________________________ 25
Characteristics Type UCG/C __________________________ 25
Type UCG/I __________________________ 26
and Technical Data ____________ 12 Type UCG/III _________________________ 27
Type UCL ____________________________ 28
On-Load Tap-Changer _____________________ 12
Type UCD/III _________________________ 30
Type Designation ______________________ 12
Type UCC ___________________________ 32
Diverter Switches ______________________ 12
Tap Selectors _________________________ 12
Diverter Switch – Tap Selector Appendices:
Combinations _________________________ 12 Single-Phase Diagrams _________ 34
Rated Phase Step Voltage _______________ 13
Contact Life __________________________ 14 Appendix 1:
Standards and Testing __________________ 15 Single-Phase Diagrams for UCG/C ___________ 34
Rating Plate __________________________ 15 Appendix 2:
Insulation Levels ______________________ 15 Single-Phase Diagrams for UCG/I ___________ 37
Mechanical Life _______________________ 18 Appendix 3:
Short-circuit Current Strength ____________ 19 Single-Phase Diagrams for UCG/III
Highest Phase Service Voltage UCL/III and UCD/III _______________________ 41
Across the Regulating Winding ___________ 19 Appendix 4:
Rated Through Current _________________ 19 Single-Phase Diagrams for UCC _____________ 45
Occasional Overloading _________________ 19
General Information
When the on-load tap-changer operates, arcing occurs in The UC types of on-load tap-changers are usually
the diverter switch. To avoid contamination of the mounted inside of the transformer tank, suspended from
transformer oil, the diverter switch has its own housing the transformer cover. Drive to operate the on-load tap-
separate from the rest of the transformer. The tap changer is supplied from the motor-drive mechanism,
selector, which is mounted beneath the diverter switch which is mounted on the outside of the transformer tank
housing, consists of the fine tap selector and usually away from the on-load tap-changer. The drive is
also of a change-over selector. The operating principle transmitted by means of shafts and bevel gears.
for the UC range of on-load tap-changers is called the
diverter switch principle. The UC types of on-load tap-changers come in a wide
range of models with a rating suitable for every
application.

Oil conservator

Shaft

Bevel gear

Transformer cover

Transformer tank

On-Load Tap-Changer
Shaft

Motor-Drive Mechanism

Fig. 1. Main parts, on-load tap-changers type UC

4
Diverter switch housing Cover

Oil valve
Buffer springs
Lifting eye
Bevel gear with
mechanical indicator

Pressure relay with


Earthing terminal testing valve

Top section
Vent plug

Shielding-ring

Insulating shaft Oil tube

Shielding-ring
Diverter switch

Transition resistors
Insulating cylinder

Fixed and moving


contacts
Plug-in contacts

Connections from
the tap selector
Locating pins

Valve for use at


Driving disc for the processing
diverter switch

Bottom section

Intermediate gear
Current terminal

Fig. 2. On-load tap-changer type UCL

5
Design Principles
On-Load Tap-Changer
The on-load tap-changer is built in two separate The diverter switch is equipped with plug-in contacts that
sections, the diverter switch, which has its own housing, automatically connect the switch with the tap selector
and the tap selector. The tap selector is mounted below when the diverter switch is lowered into the housing.
the diverter switch housing and the complete unit is Mechanical coupling to the motor-drive mechanism is
suspended from the transformer cover. automatically established when the driving pin enters the
slot in the driving disc.
Diverter Switch The current-carrying contacts are made of copper or
copper and silver, and the breaking contacts of
The diverter switch is of the high-speed, spring-operated
copper-tungsten.
type with resistors as transition impedance.
The design and dimensioning of the diverter switch
The diverter switch is designed as a system of moving
offers high reliability and long life with a minimum of
and fixed contacts. Movement of the moving contact
maintenance and easy inspection.
system is controlled by a self-locking polygon link
system with a set of helical springs. The link system is
robust and has been carefully tested. The fixed contacts
are placed on the sides of the diverter switch, which are
made of insulated board.

Fig. 3. Diverter switch (UCL) L37049 Fig. 4. Diverter switch (UCC) L37050

6
Tap Selector
Although the tap selector for the UC range of on-load
tap-changer is available in various sizes, all have similar
functions with different ratings.
The fixed contacts are mounted in a circle around the
central shafts. The moving contacts are mounted on, and
are operated by, the shafts in the center of the selector.
The moving contacts are connected, via current
collectors, to the diverter switch by means of paper
insulated copper conductors.
Depending on the load current, the moving contacts
have either one, two, or more contact arms in parallel
with one, two or four contact fingers each. The fingers
make contact at one end with the fixed contact, and at
the other with the current collector. The moving contacts
slide on the fixed contacts and the current collector rings,
giving a wiping action which makes the contacts self
cleaning. This arrangement promotes good conductivity
and negligible contact wear.

Fig. 5. Tap selector size C L36698 Fig. 6. Tap selector size III L36700

7
Diverter Switch Housing and Operating Mechanism
Top Section The bevel gear, mounted on the top section flange
transfers the drive from the motor-drive mechanism, via
The top section forms the flange that is used for
the vertical shaft, to the intermediate gear for the diverter
mounting to the transformer cover, and for carrying the
switch and the tap selector.
gear box for the operating shafts. The top housing
includes a connection for the conservator pipe, draining From the intermediate gear, a drive shaft transfers the
and filtering connections, an earthing terminal, the drive to the diverter switch through an oil tight gland in
pressure relay, and the cover with its gasket. the bottom of the diverter switch housing. When the
diverter switch is lowered into the housing (after
The bottom section has locating holes for the diverter
inspection), the drive is automatically re-connected by a
switch, bearings, brackets for the tap selector mounting
system that ensures that the drive shaft and the locating
and the current terminal for the diverter switch. There is
pin of the diverter mechanism is correctly aligned.
also a draining valve in the bottom which should only be
opened during the drying process of the transformer. The intermediate gear also drives the geneva gear, of
the tap selector, via a free wheel connection. The
The top and bottom section are fixed to a cylinder of
geneva gear provides alternate movement to the two
glassfibre reinforced plastic. The bushings through the
vertical shafts of the tap selector.
cylinder wall are sealed by O-ring gaskets with elastic
pressure. Each ready-made unit is tested under vacuum
and the outside is exposed to helium and checked for Transition Resistors
leaks with the use of a helium gas detector.
The transition resistors are made of wire, wound on
insulating bobbins, and are located above the diverter
switch contacts. The resistors are robust and designed
to withstand an unlimited number of operations.

8
Motor-Drive Mechanism
The motor-drive mechanism provides the drive to allow For detailed operation description, see separate
the on-load tap-changer to operate. As the name implies, Technical Guides for Motor-Drive Mechanisms types
drive is provided from a motor through a series of gears BUL or BUE, respectively.
and out through a drive shaft. Several features are
If there are any doubts about which type to select,
incorporated within the mechanism to promote long
please consult ABB Components.
service intervals and reliability.
There are two sizes of motor-drive mechanisms that can Special Applications
be used:
ABB Components should be consulted for all special
Type BUL application on-load tap-changers.

The BUL is for on-load tap-changers types UCG and Accessories


UCL at star point or single-phase applications. However,
when extra space is required for optional accessories the For a list of accessories available for both the on-load
type BUE might have to be selected due to limited space tap-changers and the motor-drive mechanisms, see the
in the BUL. Selection Guide or consult ABB Components.

Type BUE
The BUE is for all on-load tap-changers types UCG,
UCL, UCC and UCD.

Fig. 7a. Motor-drive mechanism type BUE L37166 Fig. 7b. Motor-drive mechanism type BUL L37167

9
Principles of Operation
On-Load Tap-Changer
Switching Sequence
The switching sequence of the on-load tap-changer from
position 6 to position 5, is shown in the figures below.
The sequence is designated the symmetrical flag cycle.
This means that the main switching contact of the
diverter switch, breaks before the transition resistors are
connected across the the regulating step. This ensures
maximum reliability when the switch operates with
overloads. Fig. 8c

At rated load the breaking takes place at the first current The main contact x has opened. The load current pas-
zero after contact separation, which means an average ses through the resistor Ry and the resistor contact y.
arcing time of approximately 6 milliseconds. The total
time for a complete sequence is approximately 50
milliseconds. The tap change operation time of the
motor-drive mechanism is approximately 5 seconds per
step. (10 seconds for through-positions.)

Fig. 8d
The resistor contact u has closed. The load current is
shared between Ry and Ru. The circulating current is
limited by the resistance of Ry plus Ru.

Fig 8a. Position 6


Selector contact V lies on tap 6 and selector contact H
on tap 7. The main contact x carries the load current. Fig. 8e
The resistor contact y has opened. The load current
passes through Ru and contact u.

Fig. 8b
Selector contact H has moved in the no-current state
from tap 7 to tap 5. Fig. 8f. Position 5
The main contact v has closed, resistor Ru is bypassed
and the load current passes through the main contact v.
The on-load tap-changer is now in position 5.

10
Linear Switching (Type L)
The regulating range is equal to the voltage of the
tapped winding. No change-over selector is used.

Fig. 9. Linear switching (Type L)

Change-over Selector for Plus/Minus


Reversing
Switching (Type R) Change-over selector

The change-over selector extends the regulating range


to twice the voltage of the tapped winding, by connect-
ing the main winding to different ends of the regulating
winding.

Fig. 10. Plus/Minus switching (Type R)

Change-over Selector for Coarse/Fine,


Switching (Type D) Change-over selector,
Coarse/Fine
In type D switching the change-over selector extends the
regulating range to twice the voltage of the tapped
winding, by connecting or disconnecting the coarse
regulating winding.

Fig. 11. Coarse/Fine switching (Type D)

11
Characteristics and Technical Data
On-Load Tap-Changer Diverter Switches
Type Max. rated Impulse withstand
Type Designation through-current voltage to earth
UCG .. XXXX/YYYY/Z UCG.N 300, 500, 600 A 380, 650, 750, 1050 kV
UCL .. XXXX/YYYY/Z UCG.E,T 300, 500, 600,
UCD .. XXXX/YYYY/Z 900, 1200, 1500 A 380, 650, 750, 1050 kV
UCC .. XXXX/YYYY UCG.B 300, 500, 600 A 380, 650, 750, 1050 kV
Example: UCGRE 650/700/C
UCL.N 600, 900 A 380, 650, 1050 kV
Type of switching UCL.E,T 600, 900, 1800, 2400 A 380, 650, 1050 kV
L Linear UCL.B 600, 900 A 380, 650, 1050 kV
R Plus/Minus
D Coarse/Fine UCC.N 800, 1200, 1600 A 380, 650, 1050 kV

Type of connection UCC.E 3600, 4500 A 380, 650, 1050 kV


N Three-phase star point (one unit)
E Single-phase (one unit)
T Three-phase fully insulated (three units)
B Three-phase delta (two units; single-phase Tap Selectors
and two-phase)
Type Connection Max. rated Max. no. Max impulse
Impulse withstand voltage to earth through- of pos. test voltage
UCG: 380 kV, 650 kV, 750 kV, 1050 kV current across range
UCL: 380 kV, 650 kV, 1050 kV
UCD, UCC: 380 kV, 650 kV, 1050 kV C N 400 A 27 350 kV
E, T 400, 700, 1050 A 27 350 kV
Maximum rated through-current
B 400 A 27 350 kV
UCG.N, UCG.B: 300 A, 400 A, 500 A, 600 A
UCG.E, UCG.T: 300 A, 400 A, 500 A, 600 A, I N 600 A 35 300 kV
700 A, 900 A, 1050 A, 1200 A, 1500 A E, T 600, 1200, 1500 A 35 300 kV
B 600 A 35 300 kV
UCL.N, UCL.B: 600 A, 900 A
UCL.E, UCL.T: 600 A, 900 A, 1800 A, 2400 A III N 1000 A 35 550 kV
E, T 1000, 1800, 2400
UCD.N: 1000 A, 1200 A
30001) A 35 550 kV
UCD.E: 1000 A, 1200 A, 1800 A, 2000 A
B 1000 A 35 550 kV
2400 A, 3000 A, 3600 A 1)
UCC 2) N 800, 1200, 1600 A 35 500 kV
UCC.N: 800 A, 1200 A, 1600 A
E 3600, 4500 A 35 500 kV
UCC.E: 3600 A, 4500 A

Tap selector size 1)


with enforced current splitting
C = UCG tap selector
I = UCG tap selector 2)
UCC requires one motor-drive mechanism for each unit and is
III = UCG, UCL and UCD tap selector therefore not available in connection B and T.
1)
with enforced current splitting

Diverter Switch –
Maximum number of positions
Tap Selector Combinations
UCG, UCL, UCD UCC
Linear switching 211) positions 23 positions
Diverter Switch UCG UCL UCC
Plus/Minus switching 35 positions 35 positions
Coarse/Fine switching 35 positions 35 positions Tap selector C, I, III III III, UCC

1)
Only tap selector III is available up to 21 positions with
UCC diverter switch combined with tap selector III is
linear switching.
called UCD.
The unit (diverter switch or tap selectors) with the
lowest rating in any combination as per above,
determines the type designation of the on-load
tap-changer.

12
Rated Phase Step Voltage
The maximum permitted step voltage is limited by the
electrical strength and the switching capacity of the
diverter switch. The rated phase step voltage is a function
of the rated through current as shown in the diagrams
below.

Step voltage UCG.N, B


UCG.E, T

Short version Step voltage UCL.N, B


UCG.N, E, T, B UCL.E, T

Short version
UCG.E, T
1500A
1200A
1050A

1800A

2400A
300A

900A
600A
500A

700A

600A

Rated through 900A Rated through


current, A current, A

Fig. 12. Rated phase step voltage for type UCG Fig. 13. Rated phase step voltage for type UCL

UCD.N UCC.N
Step voltage UCC.E
Step voltage UCD.E
1200A

1600A
800A
3600A2)

3600A
1000A
1200A

1800A
2000A

2400A

3000A

4500A

Rated through
Rated through current, A
current, A
2)
With enforced current splitting

Fig. 14. Rated phase step voltage for type UCD Fig. 15. Rated phase step voltage for type UCC

13
Contact Life
The predicted contact life of the fixed and moving contact
of the diverter switch, is shown as a function of the rated
through current in the diagrams below. It is based on the
type test with 50000 switching operations, and a current
corresponding to the maximum rated through current. The
contact life is stated on the rating plate.

Contact life Contact life


Number of Number of
operations operations UCL. N, B
UCG.N, B
UCG. E, T UCL. E, T

1800A

2400A
1200A

1500A
1050A

600A
900A
700A
300A

500A
600A

900A

Rated through Rated through


current, A current, A

Fig. 16. Contact life for type UCG Fig. 17. Contact life for type UCL

Contact life Contact life


Number of Number of
UCD. N UCC. N
operations operations
UCD. E UCC. E
3600A2)
3000A1)
1000A
1200A

1800A

2400A

1200A

1600A

3600A
800A

4500A

Rated through current, A Rated through current, A


1)
R1 3000 without current splitting.
2)
R1 3600 with enforced current splitting.
Fig. 18. Contact life for type UCD Fig. 19. Contact life for type UCC

14
Standards and Testing Rating Plate
The on-load tap-changers made by ABB Components
fulfil the requirements according to IEC standards,
publication 214.
The type tests include:
Contact temperature rise test
Switching tests
Short-circuit current test
Transition impedance test
Mechanical tests
Dielectric tests

The routine tests include:


Check of assembly Fig. 20. Example of Rating Plate
Mechanical test
Sequence test
Auxiliary circuits insulation test
Vacuum test
Final inspection

Insulation Levels
The insulation levels are indicated as: Insulation Levels to Earth
1.2/50 µs impulse withstand voltage (kV)–power For UCG 380–150 kV, 650–275 kV
frequency withstand voltage (kV). 750–325 kV and 1050–460 kV.
The tests were carried out according to IEC 214 clause For UCL 380–150 kV, 650–275 kV
8.6. with a new on-load tap-changer and clean insula- and 1050–460 kV.
tion oil class 2 according to IEC Publication 296. The
withstand voltage value of the oil was higher than For UCC and UCD 380–150 kV
160 kV/cm. 650–275 kV
1050–460 kV.

Linear b1 and b2 are to the Reversing b1 and b2 are to the Coarse/Fine b1, b2 and d1 are to the
L corresponding contacts R corresponding contacts D corresponding contacts
in the next phase in the next phase in the next phase

Fig. 21. Linear switching: Fig. 22. Reversing switching: Fig. 23. Coarse/Fine switching:
Contact designations in tables 1-3 Contact designations in Tables 1-3 Contact designations in tables 1-3
1)
See note 1 for UCC.

15
UCG

Table 1. Withstand Voltages within UCG Tap-Changers (For UCG Tap-Changers with selectors C, I and III)

Within one phase Between phases for the neutral point type

Type of a2 a3 c1 e1, b2 b1 d1
switching between ends of between any other across change-over between between open fixed between open fixed
and (fine) regulating electrically selector open contacts in tap contacts in coarse
number winding non-adjacent taps contacts selector change-over selector
of in
positions diverter
switch

Selector C, I
size C I III C I III C I III and III C I III C I III

US S US S US, S US S US, S

L 9 350-140 300-125 490-160 550-180 350-140 300-125 400-150 400-150 130-50 400-150 300-125 500-160 550-180
11
13
15 – 290-120 420-150 480-160 – 290-120 350-140 350-140 – 500-160 550-180
17 – 250- 95 350-140 400-150 – 250- 95 300-125 300-125 –
18 – – –

R, D 9 350-140 300-125 490-160 550-180 350-140 300-125 400-150 400-150 400-150 350-140 600-200 400-150 500-160 550-180 400-150 350-140 600-200
11

16
13 420-150 480-160 500-160
15 – 250- 95 350-140 400-150 – 250- 95 350-140 – –

17-19 350-140 300-125 490-160 550-180 350-140 300-125 400-150 400-150 400-150 600-200 400-150 500-160 550-180 400-150 600-200
21-23
25-27
29-31 – 290-120 420-150 480-160 – 290-120 350-140 350-140 – – 500-160 500-160 –
33-35 – 250- 95 350-140 400-150 – 250- 95 300-125 300-125 – – –

US = Unshielded contacts, S = Shielded contacts

NOTE: a1 Between electrically adjacent taps. The insulation withstands 300–125 in tap selector III but may be limited by the moving selector arms and by the diverter switch to e1 and b2 value.
The distance a1 is not relevant for tap selector I and C, see single-phase diagrams in appendicies.
UCL, UCD

Table 2. Withstand Voltages within UCL and UCD Tap-Changers (For UCL and UCD Tap-Changers with selector III)

Within one phase Between phases for the neutral point

Type of a2 a3 c1 e1, b2 b1 d1
switching between ends of between any other across change- between between open fixed between open fixed
and num- (fine) regulating electrically over selector open contacts contacts in tap contacts in coarse
ber of winding non-adjacent taps in diverter selector change-over selector
positions switch

Selector UCL UCD


size III III III III III III III

US S US S US S US, S US, S US S US S

L 9 490-160 550-180 400-150 400-150 150-50 200-80 500-160 550-180


11
13
15 420-150 480-160 350-140 350-140 500-160 550-180
17 350-140 400-150 300-125 300-125
18

R, D 9 490-160 550-180 400-150 400-150 600-200 600-200 500-160 550-180 600-200 600-200
11
13 420-150 480-160 500-160

17
15 350-140 400-150 350-140

17-19 490-160 550-180 400-150 400-150 600-200 600-200 500-160 550-180 600-200 600-200
21-23
25-27
29-31 420-150 480-160 350-140 350-140 500-160 500-160
33-35 350-140 400-150 300-125 300-125

US = Unshielded contacts, S = Shielded contacts

NOTE: a1 Between electrically adjacent taps. The insulation withstands 300–125 kV but may be limited by the moving selector arms and by the diverter switch to e1 and b2 value.
UCC

Table 3. Withstand Voltage within UCC on-load tap-changers

Within one phase Between phases for the neutral point type

Type of a2 a3 c1 e1, b2 b1 d1
switching between ends of between any other across between open between open between open fixed
and (fine) regulating electrically change-over contacts in fixed contacts in contacts in coarse
number of winding non-adjacent taps selector diverter switch tap selector change-over
positions selector

US S US S US S US and S US S US S

L 9–23 300–125 300–1251) –– ––


200–80 300–125 – –
9–15 500–170 500–170 500–170

R, D
9–35 300–125 500–170 160–75 250–85 300–125 600–200 200–80 300–125 500–170 350–150 600–200

US = Unshielded contacts, S = Shielded contacts


1)
For 17–23 positions, the withstand voltage between contacts on adjacent ribs is 180–100 kV.

NOTE: a1 Between electrically adjacent taps. The insulation withstands 200–80 kV.

Mechanical Life
The mechanical life is based on an endurance test which
showed that the mechanical wear was negligible, and
that the on-load tap-changers were still mechanically
sound after one million operations.

18
Short-circuit Current Strength Rated Through Current
The short circuit current strength is verified with three The rated through-current of the on-load tap-changer is
applications of 2 seconds duration, without moving the the current which the on-load tap-changer is capable of
contacts between the three applications. Each appli- transferring from one tapping to the other at the relevant
cation has an initial value of 2.5 times the rms value. rated step voltage, and which can be carried
continuously whilst meeting the technical data in this
Type Max rated Three applications Reinforced document. The rated through current is normally the
through of 2 seconds same as the highest tapping current.
current, rms duration 1), rms
The rated through-current is limited by the step voltage
UCG 300 A 7.0 kA
400 A 7.0 kA according to the curves in the diagrams, Fig. 12 to
500 A, 600 A 7.0 kA Fig. 15.
700 A 7.0 kA
900 A 9.0 kA The rated through-current determines the dimensioning
1050 A 10.5 kA of the transition resistors and the contact life.
1200 A, 1500 A 15.0 kA
UCL 600 A 9.0 kA
The rated through-current is stated on the rating plate,
900 A 9.0 kA Fig. 20.
1800 A 26.0 kA
2400 A 26.0 kA
UCD 1000 A 13.0 kA Occasional Overloading
1200 A 12.0 kA
1800 A 26.0 kA If the rated through-current of the tap-changer is not less
2000 A 24.0 kA than the highest value of tapping current of the tapped
2400 A 32.0 kA
3000 A 36.0 kA
winding of the transformer, the tap-changer will not
restrict the occasional overloading of the transformer,
UCC 800 A 13.4 kA according to IEC 354 ”Loading guide for oil-immersed
1200 A 13.4 kA
1600 A 16.6 kA 21 kA
transformers” (1991), ANSI/IEEE C57.92 ”Guide for
3600 A 30.0 kA loading mineral-oil-immersed power transformers” and
4500 A 36.0 kA 66 kA CAN/CSA-C88-M90.
1)
With an initial peak current of 2.5 times the rms value and To meet these requirements, the UC models have been
without moving the contacts between the three applications. designed so that the contact temperature rise over the
surrounding oil does not exceed 20 K when loaded with
Table 4. Short-circuit current strength
a current of 1.2 times the maximum rated through cur-
rent of the tap-changer.
The contact life stated on the rating plate is given with
Highest Phase Service Voltage Across consideration to that currents of maximum 1.5 times the
the Regulating Winding rated through current occur during a maximum of 3% of
the tap-change operations. Overloading beyond these
The table below show the highest permissible phase values, results in increased contact wear and shorter
service voltage, in kV, for the different types of con- contact life.
nections.
Across the Across the
regulating coarse and fine
winding winding
Contact shieldings: with without with without

Tap-changer,
connection

UCC.N 52 35 75 45
UCD.N III
UCL.N
UCG.N III – –
UCC.E 60 45 80 60
UCD.E,
UCL.T, E, B
UCG.T, E, B III – –
UCG.N C, I – 35 – 40
UCG.T, E, B C, I – 35 – 45

Table 5. Highest permissible phase service voltage


across the regulating winding

19
Oil Temperature Tie-ln Resistor
The temperature of the oil surrounding the on-load tap- If the service voltages and the winding capacitances are
changer shall be between -25 and +105 oC for normal such that the potential of the tapped winding exceeds the
operation, as illustrated below. The range can be values in table 6, it should be limited to this value by
extended to -40 oC provided that the viscosity is between means of a tie-in resistor connected between the diverter
2-800 mm2/s (=cst). switch and the mid tap of the tap selector.

On-load tap-changer Voltage (kV)


1) UCG.. /C 35
2) 1) No operations allowed UCG.. /I 25
UCG.. /III 35
2) Emergency overloading. UCL.. /III 35
The on-load tap-changer will not UCD.. /III 35
restrict the occasional overloading
UCC.. 35
of the transformer according
to the standards above. Table 6.
3)
3) Normal operating range
In order to eliminate the losses in the tie-in resistor, a tie-
4) When operating within this range, in resistor switch (S), which connects the resistor only
no overload is allowed when the change-over selector is moving, can be added
to the bottom of the tap selector. The tie-in resistor
5) Operation with de-energized
transformer only switch is not available for tap-selector C. The tie-in
4) resistor is normally mounted separate from the on-load
tap-changer, but in some cases it can be mounted below
5) the tap selector.

Fig. 24. On-load tap-changer oil temperature

Fig. 25. Tie-in resistor connection

Design information on tie-in resistors is provided in a


separate document, On-Load Tap-Changer Tie-in
Resistors, 5492 0030E-28.

20
Design, Installation and Maintenance
On-Load Tap-Changer
Design Differences over the UC Range
of On-Load Tap-Changers
The most obvious difference between the models in the There are also differences in the design and operation of
UC range of on-load tap-changers is the size (see the tap selector. For tap selectors sizes C and I, the
Fig. 26). Other differences are less obvious but include moving contacts are driven by two parallel ribs in one
the use of different materials in the manufacture of the cage. For tap selectors size III, the moving contacts are
top sections (welded steel in the UCG and UCC/D driven by two concentric shafts. For UCC, the system
models, casted alloy in the UCL model). The cylinder is consists of two cages with one driving shaft in each.
glued in the UCG range, and riveted in the rest of the
models.

UCG.N/C
UCG.N/I UCG.N/III UCL.N/III UCD.N/III UCC.N
650 kV 650 kV 650 kV 650 kV 650 kV

Fig. 26. On-load tap-changers type UC, size comparison

Drying Painting
The on-load tap-changer must be stored indoors and left The standard painting on the top section consists of a
in its plastic shipping cover until time for assembly. For primer of two-component epoxy type of max. thickness
further instructions refer to the Installation Guide. 60 µm.The on-load tap-changer may be delivered in this
state for finish coating by the customer, or it can be
delivered with a grey/blue finishing coat outside. Special
painting will be quoted for on request.

21
Weights
The tables below shows all the weights of the UC range
of on-load tap-changers.

On-load tap-changer Approximately weight in kg On-load tap-changer Approximately weight in kg


Type Designation Tap-changer Required Total Type designation Tap-changer Required Total
without oil 1) oil without oil 1) oil

UCG.N 380-750/300-600 425 150 575 UCL.N 380/600, 900 480 260 740
1050/300-600 435 185 620 650/600, 900 500 300 800
1050/600, 900 510 340 850
UCG.T 380-750/300-900 1025 3x150 1475
380-750/1050-1500 1190 3x150 1640 UCL.T 380/600, 900 1230 3x260 2010
1050/300-900 1090 3x185 1645 380/1800 1350 3x260 2130
1050/1050-1500 1225 3x185 1780 380/2400 1440 3x260 2220
650/600, 900 1290 3x300 2190
UCG.B 380-750/300-600 760 2x150 1060 650/1800 1410 3x300 2310
1050/300-600 780 2x185 1150 650/2400 1500 3x300 2400
1050/600, 900 1320 3x340 2340
UCG.E 380-750/300-900 360 150 510 1050/1800 1440 3x340 2460
380-750/1050-1500 410 150 560 1050/2400 1530 3x340 2550
1050/300-900 370 185 555
1050/1050-1500 425 185 610 UCL.B 380/600, 900 850 2x260 1370
650/600, 900 890 2x300 1490
1)
The weight of the diverter switch, approximately 90 kg, is 1050/600, 900 910 2x340 1590
included. UCL.E 380/600, 900 410 260 670
380/1800 450 260 710
Table 7. Weights for type UCG 380/2400 480 260 740
650/600, 900 430 300 730
650/1800 470 300 770
650/2400 500 300 800
1050/600, 900 440 340 780
1050/1800 480 340 820
1050/2400 510 340 850
1)
The weight of the diverter switch, approximately 120 kg, is
included.

Table 8. Weights for type UCL

On-load tap-changer Approximately weight in kg On-load tap-changer Approximately weight in kg


Type designation Tap-changer Required Total type designation Tap-changer Required Total
without oil 1) oil without oil 1) oil

UCD.N 380/1000 950 710 1660 UCC.N 380/800, 1200 1130 710 1840
650/1000 980 790 1770 380/1600 1220 710 1930
1050/1000 1010 910 1920 650/800, 1200 1160 790 1950
650/1600 1250 790 2040
UCD.E 380/1000 890 710 1600 1050/800, 1200 1190 910 2100
380/1800 920 710 1630 1050/1600 1280 910 2190
380/2400 950 710 1660
650/1000 920 790 1710 UCC.E 380/3600 1130 710 1840
650/1800 950 790 1740 380/4500 1220 710 1930
650/2400 980 790 1770 650/3600 1160 790 1950
1050/1000 950 910 1860 650/4500 1250 790 2040
1050/1800 980 910 1890 1050/3600 1190 910 2100
1050/2400 1010 910 1920 1050/4500 1280 910 2190
1)
1)
The weight of the diverter switch, approximately 250 kg, is The weight of the diverter switch, approximately 250 kg, is
included. included.

Table 9. Weights for type UCD Table 10. Weights for type UCC

22
Oil Filling
For details of oil filling, consult the appropriate Installa- The pressure relay is mounted on a three-way valve. On
tion Guide. the other two outlets of the valve there is a connection
flange on one side, and a connection for test equipment
Installation on the other.

The on-load tap-changers can be delivered for cover- The relay is made of copper-free aluminium alloy and is
mounting method or yoke-mounting method onto the externally coated with an enamel. A stainless steel model
can be provided on request.
transformer.
For detailed installation instructions, consult the appro- The pressure relay has been pre-set by the manu-
priate Installation Guide. facturer. The pressure relay is sealed to avoid
unauthorized entrance. The electrical connection shall be
Maintenance made to the terminal box mounted onto the pressure
relay.
The UC range of on-load tap-changers have been
developed over many years to provide a maximum of Operation
reliability. The simple and rugged design gives a service
When the pressure acting on the face of the piston
life that equals the service life of the transformer. A
exceeds the spring load of the piston, the piston will
minimum of maintenance is required for absolutely
move and activate the switching element.
trouble-free operation. The only parts that require
maintenance during the service life are the diverter
The operation time is less than 10 ms. The operation
switch contacts that may need to be replaced, and the
time is the time it takes from the pressure in the tap-
motor-drive mechanism. The oil in the diverter switch
changer tank exceeds the function pressure, until the
housing has also to be cleaned with certain intervals.
pressure relay gives a stable signal for operation of the
Maintenance is easy to carry out since the design transformer main switch.
provides for quick and easy access and inspection. For
The function pressure (trip pressure) is shown in
overhaul, the top cover is removed and, if necessary, the
table 11.
diverter switch can be lifted out without further
dismantling.
H 1) Function pressure
An annual inspection should be carried out to read the (trip pressure)
counting device. These readings are used to determine
when overhaul is due. Overhaul shall normally be < 7m 100 kPa (14.5 Psi)
7 – 20 m 100-230 kPa (14.5-33.5 Psi) 2)
carried out every seven years, and consists of checking
the dielectric strength, filtering the oil, and checking the
1)
contacts (and replace them if they are worn). The motor- The height (H) is the distance between the level of the pressure
drive mechanism should also be checked and lubricated, relay and the oil level in the oil conservator.
2)
Option when H is 7-20 m.
and the pressure relay checked.
The appropriate Maintenance Guide should be consulted
Table 11. Function pressure (trip pressure)
if you need further information.
Testing
Oil Filter Unit
Before the commissioning of the transformer and for
The on-load tap-changer can be equipped with an oil testing the pressure relay, reference should be made to
filter unit for continuous oil filtration. For further the specific instructions regarding the pressure relay, or
information, see manual 1ZSE 5492-152. to the appropriate Installation Guide.

Pressure Relay Installation

General Description The pressure relay is to be mounted directly on to the on-


load tap-changer tank, using the flange and fittings
Protection for the on-load tap-changer is provided by a provided. Caution should be used when handling the
pressure relay which is mounted on the on-load tap- relay to avoid damage. The relay should be stored in its
changer top section. In the event of an over-pressure in protective box until attaching to the on-load tap-changer.
the tank, the relay will, if correctly connected, trip the
transformers main circuit breakers. After a pressure relay Caution should also be applied when attaching the relay
trip, the on-load tap-changer must be carefully to the on-load tap-changer tank, and the appropriate
investigated. Faults, if any are located, should be Installation Guide should be consulted.
repaired before the transformer is energized.

23
Switching contact

30 54 67

ABB Components

Cable gland
~35 ~200 Adjusting nut
Spring

Piston

;;
;;
110 Two single-pole One single-pole
switching contacts switching contact
Connection for
11 ~155 test equipment
32
15

NO NC C NO NC C NO NC C
64 66 65 61 63 62 61 63 62

Fig. 27. Pressure relay

Motor-Drive Mechanism
Design
For detailed design description, see separate Technical
Guides for Motor Drive Mechanisms types BUL or BUE,
respectively.

Installation
The motor-drive mechanism is fitted to the outside of the
transformer tank, and connected to the on-load tap-
changer by drive shafts and bevel gears.
For the correct installation procedure, consult the
appropriate Installation Guide.

Maintenance
The motor-drive mechanism should be inspected at
regular intervals and at the same time as the on-load
tap-changer is inspected.
For the correct inspection and maintenance procedures,
consult the appropriate Maintenance Guide.

Operating shafts
Length L1 L2 L3 and L4 Motor-drive
mm mm mm mechanism
Min/max 500/3100 525/3100 900/2700 BUE
500/3100 600/3100 – BUL

The minimum and maximum lengths refer to mechanical


design only. See Fig 28. L2 vertical shaft see following
pages. Also other shaft arrangements on request. Fig. 28. Positioning of motor-drive mechanism

24
Dimensions
Type UCG/C
Dimensions in mm. The design, technical data and
dimensions are subject to alteration without notice.

405
L1
H32)
70
290
205
111
1)

D=600
1)
L2
D=470 H1

157

75
194

A A
(BUE1) 592
(BUE2) 818
H2
390 36
134

345

C/L Tap selector C/L Diverter switch


D=740
30
Section A – A
Plus/Minus and
80 R210 Coarse/Fine
switching
16O 332
230 145 570
(BUE1) 233
(BUE2) 353
(BUE1) 320 D=420
(BUE2) 440 615

Fig. 29. Dimensions, type UCG R210


Section A – A
Linear switching
Diverter switch housing 570
For tap Impulse with- H1 H1, H3 H3
selector stand voltage short short
size to earth version version D=420
kV mm mm mm mm 615
C 380, 650, 750 1192 972 1400 1200
1050 1492 1272 1700 1500 Tap selector
For on-load Max rated H2, size C
tap-changer through current
type A mm
1)
Shielding-rings are used only for insulation level UCG.N 400 959
650-275 kV and higher. 3)
UCG.E, UCG.T 400 519
2)
Space required for lifting the diverter switch, excluding 700 739
the lifting equipment. 1 050 959
4)
3)
UCG.T consists of three single-phase units. UCG.B 400 Single-phase unit
519
4)
UCG.B consists of one single-phase and one two-phase
unit arranged as shown in the dimension drawing for Two-phase unit
UCL.B (page 29). 739

25
Dimensions
Type UCG/I
Dimensions in mm. The design, technical data and
dimensions are subject to alteration without notice.

405

H32)
L1

290
70 185
1)
111

D=600
1)

L2 D=470 H1

157
A A
75
194

(BUE1) 592 H2
(BUE2) 818
36
390

134
1)
30
4)

C/L Tap selector C/L Diverter switch


D=740 30

80
610 4203) 530
O
16 332
230 145
(BUE1) 233
(BUE2) 353 195 Section A – A
(BUE1) 320 Plus/Minus and
(BUE2) 440 6053) Coarse/Fine
switching

665
1)
Shielding-rings are used only for insulation level
650-275 kV and higher. 3903)
2)
Space required for lifting the diverter switch, excluding Section A – A
the lifting equipment. Linear switching
500 4103)
3)
Dimension without shielding-ring.
4)
For tie-in resistor switch add 360 mm.
500

Fig. 30. Dimensions, type UCG

26
Type UCG/III
Model for cover mounting Model for mounting on
transformer’s active part

78

H1 H1+106

B B

H2

C/L Tap selector C/L Diverter switch

30
385

Diverter switch housing


For tap Impulse with- H1 H1, H3 H3
4903) 590 selector stand voltage short short
size to earth version version
kV mm mm mm mm
Section B - B I 380, 650, 750 1317 1097 1400 1200
Plus/Minus and 2553)
1050 1617 1397 1700 1500
Coarse/Fine switching
III 380, 650, 750 1354 1134 1400 1200
8403)
1050 1654 1434 1700 1500

295
Tap selector

940 For on-load Max. rated H2 H2


tap-changer through current size I size III
4903) type A mm mm
Section B - B
UCG.N 300–600 1030 1160
Linear switching
4903) 580 UCG.E, UCG.T 5)
300–600 530 552
900 – 552
1200 760 856
1500 1030 856
580
UCG.B 6) 300–600 single- single-
Fig. 31. Dimensions, type UCG phase phase
unit unit
Operating shafts 532 552
The minimum and maximum lengths refer to mechanical two- two-
design only. phase phase
unit unit
Length L1 L2 L3 and L4 Motor-drive 774 856
mm mm mm mechanism
5)
UCG.T consists of three single-phase units.
Min/max 500/3100 525/3100 900/2700 BUE
6)
500/3100 600/3100 – BUL UCG.B consists of one single-phase and one two-phase
unit arranged as shown in the dimension drawing for
L3 and L4 for UCG.T, see Fig. 28, page 24. UCL.B (page 29).

27
Dimensions
Type UCL/III
Dimensions in mm. The design, technical data and
dimensions are subject to alteration without notice.

Type UCL.N (three-phase, star point) and


type UCL.E (single-phase)

Section A – A
Plus/Minus and
Coarse/Fine
switching

Section A – A
Diverter switch housing Linear switching
Impulse withstand H1 H3
voltage to earth
kV mm mm
380 1415 1500
650 1615 1700
1050 1815 1900
5)
For mounting on
active part H1+85 H3+100

Fig. 32. Dimensions, type UCL

28
Type UCL.B (three-phase, delta)

Design for premounting


on the active part of the
transformer

Tap selector
For on-load Max rated H2
tap-changer through current size III
type A mm

UCL.N 600–900 1160


6)
UCL.E, UCL.T 600–900 552
1800 856
2400 1160
UCL.B 7) 600–900 single-phase
unit
H22 = 552
two-phase
unit
H21 = 856

1)
Shielding-rings are used only for insulation level
650-275 kV and higher.
2)
Space required for lifting the diverter switch, excluding
the lifting equipment. Operating shafts
The minimum and maximum lengths refer to mechanical
3)
Dimension without shielding-ring. design only.
4) Length L1 L2 L3 and L4 Motor-drive
For-tie in resistor switch add 370 mm
5)
mm mm mm mechanism
Model for mounting on transformers active part.
6)
Min/max 500/3100 525/3100 900/2700 BUE
UCL.T consists of three single-phase units. 500/3100 600/3100 – BUL
7)
UCL.B consists of one single-phase and one two-phase
unit. L3 and L4 for UCL.T, see Fig. 28, page 24.

29
Dimensions
Type UCD/III
Dimensions in mm. The design, technical data and
dimensions are subject to alteration without notice.

Fig. 33. Dimensions, type UCD

30
Operating shafts
The minimum and maximum lengths refer to mechanical
Diverter switch housing design only.

Impulse withstand H1 H3 Length L1 L2


voltage to earth mm mm
kV mm mm
Min/max 500/3100 525/3100
380 1594 1600
650 1734 1750 1)
Shielding-rings are used only for insulation level
1050 1934 1950
550-230 kV and higher.
2)
Tap selector Space required for lifting the diverter switch, excluding
the lifting equipment.
For on-load Max rated H2 3)
tap-changer through current size III Dimension without shielding-ring.
type A mm 4)
For tie-in resistor switch, add 370 mm.
UCD.N 1000 1160 5)
When two or three units are fitted together (three-phase
delta and three-phase fully isolated respectively) the
UCD.E 1000 552
1800 856 distance between the units (c) must be at least 1340 mm
2400 1160 from mechanical point of view. For final dimensioning,
check the insulation distance required.

31
Dimensions
Type UCC
Dimensions in mm. The design, technical data and
dimensions are subject to alteration without notice.

Fig. 34. Dimensions, type UCC

32
Diverter switch housing
Impulse withstand H1 H3
voltage to earth
kV mm mm
380 1540 1600
650 1680 1750
1050 1880 1950

Tap selector
For on-load Max rated H2
tap-changer through current
type A mm
UCC.N 800, 1200 1290
1600 1530 1)
Shielding-rings are used only for insulation level
UCC.E 3600 1290 550-230 kV and higher.
4500 1530 2)
Space required for lifting the diverter switch, excluding
the lifting equipment.
Operating shafts 3)
Dimension without shielding-ring.
The minimum and maximum lengths refer to mechanical 4)
design only. For tie-in resistor switch add 340 mm.
5)
When two or three units are fitted together (three-phase
Length L1 L2
delta and three-phase fully isolated respectively) the
mm mm
distance between the units (c) must be at least 1340 mm
Min/max 500/3100 525/3100 from mechanical point of view. For final dimensioning,
check the insulation distance required.

33
Appendices: Single-Phase Diagrams
The basic connection diagrams illustrate the different The tap-changer can also be connected in such a way
types of switching and the appropriate connections to the that position 1 gives a minimum effective number of
transformer windings. The diagrams illustrate the turns in the transformer winding with the tap-changer in
connections with the maximum number of turns in the position 1.
transformer winding, with the tap-changer in position 1.
The connection diagrams can be downloaded from our
website: www.abb.se/com/

Appendix 1: Single-Phase Diagrams for UCG/C


Linear Plus/Minus Coarse/Fine

8 Steps

10 Steps

34
Linear Plus/Minus Coarse/Fine

12 Steps

14 Steps

16 Steps

18 Steps

35
Linear Plus/Minus Coarse/Fine

20 Steps

22 Steps

24 Steps

26 Steps

36
Appendix 2: Single-Phase Diagrams for UCG/I
Linear Plus/Minus Coarse/Fine

8 Steps

10 Steps

12 Steps

14 Steps

37
Linear Plus/Minus Coarse/Fine

16 Steps

18 Steps

20 Steps

22 Steps

38
Linear Plus/Minus Coarse/Fine

24 Steps

26 Steps

28 Steps

30 Steps

39
Linear Plus/Minus Coarse/Fine

32 Steps

34 Steps

40
Appendix 3: Single-Phase Diagrams for UCG/III, UCL/III and
UCD/III
Linear Plus/Minus Coarse/Fine

8 Steps

10 Steps

12 Steps

14 Steps

41
Linear Plus/Minus Coarse/Fine

16 Steps

17 Steps 18 Steps 18 Steps

20 Steps

22 Steps

42
Linear Plus/Minus Coarse/Fine

24 Steps

26 Steps

28 Steps

30 Steps

43
Linear Plus/Minus Coarse/Fine

32 Steps

34 Steps

44
Appendix 4: Single-Phase Diagrams for UCC
Linear Plus/Minus Coarse/Fine

8 Steps

10 Steps

12 Steps

14 Steps

45
Linear Plus/Minus Coarse/Fine

16 Steps

18 Steps

20 Steps

22 Steps

46
Linear Plus/Minus Coarse/Fine

24 Steps

26 Steps

28 Steps

30 Steps

47
Linear Plus/Minus Coarse/Fine

32 Steps

34 Steps

48
Notes:

_
Notes:

_
1ZSE 5492-105 en, Rev. 5, 2000-11-15

ABB Components AB
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com/transmission

Printed in Sweden by Globe, Ludvika, 2000


Motor-drive mechanism, type BUL
Technical guide
This Technical Guide has been produced to allow transformer manufacturers,
and their designers and engineers, access to all the technical information
required to assist them in their selection of the appropriate on-load tap-changer
and motor-drive mechanism. The guide should be used in conjunction with the
Selection Guide and the Design Guides, to allow the optimum selection to be
made.

The technical information pertaining to on-load tap-changers and motor-drive


mechanisms manufactured by ABB has been divided and is contained in
separate documents, with one document for each type.

The information provided in this document is intended to be general and does not
cover all possible applications. Any specific application not covered should be
referred directly to ABB, or its authorized representative.

ABB makes no warranty or representation and assumes no liability for the


accuracy of the information in this document or for the use of such information.
All information in this document is subject to change without notice.
Table of Contents
General Information ____________ 4 Continuation Contact _________________ 9
Auxiliary Contacts ___________________ 9
Applications __________________________ 4 Driving Mechanism Equipment ____________ 10
Design ______________________________ 4 Exploded Views and Photos ______________ 11
Cabinet ______________________________ 4
Tropical Version _______________________ 4
Type Tests ___________________________ 4 Principles of Operation __________ 14
Ambient Air Temperature ________________ 6
Connection of Motor-Drive Mechanism Raise-Operation with Local Control ________ 14
to Tap-Changer _______________________ 6 Lower-Operation with Local Control ________ 14
Rating Plate __________________________ 7 Through Positions ______________________ 14
Remote Control _______________________ 14
Circuit Diagram ______________________ 15
Mechanical Arrangements _______ 8 Contact Timing Diagram _________________ 16
Driving Arrangement ____________________ 8
Hand Crank __________________________ 8 Standard Version _______________ 17
”One-Turn” Shaft ______________________ 8
Position Indicator ______________________ 8 Control ______________________________ 17
Mechanical End Stops __________________ 8 Protection ____________________________ 17
Electrical End Stops ____________________ 8 Indication ____________________________ 17
Brake _______________________________ 8 Wiring _______________________________ 17
Indicator Flag _________________________ 9 Maintenance __________________________ 17
Operation Counter _____________________ 9 Design Options ________________________ 17
Maintaining, Interlocking and Multi-Position Switches __________________ 17
Auxiliary Contacts ______________________ 9 Technical Data ________________________ 18
Multi Position Switches __________________ 9 Dimensions ___________________________ 19
Position Transmitter, Potentiometer _____ 9 Weight ______________________________ 19
General Information
Applications
The BUL Motor-Drive Mechanism is designed for outdoor The Motor-Drive Mechanism is mounted to the transfor-
operation of the On-Load Tap-Changers and large De- mer tank with four screws or studs, M12 or ½”, through
energized Tap-Changers listed below. the backside of the cabinet. Those are screwed from the
inside of the cabinet and also going through the frame for
the mechanism. The bottom has a flange opening for
Tap-Changer Type of Connection cable connection, size FL 21, see page 19. When
delivered the opening is covered with a 5 mm thick light-
UBB For all connections alloy cover.
UCG Star point or single-phase
UCL Star point or single-phase The cabinet has two vents. Filters prevents insects and
dust from entering. In order to prevent condensation
inside the cabinet a 50 W heater is supplied which is
permanently connected. With this heater the Motor-Drive
Design Mechanism functions satisfactorily down to -40 oC
The Motor-Drive Mechanism is normally mounted on the (-40 oF). For temperatures below -40 oC or on customers
side of the transformer tank and by means of drive shafts request an additional 100 W heater controlled by a
and bevel gears connected to the Tap-Changer. The thermostat can be supplied. This extra heater can also
shaft system is described in the Technical Guide for each on request be supplied with a switch for manual
type of Tap-Changer. disconnection.

The BUL contains all the necessary equipment for The tightness of the cabinet has been type tested for
operation of the Tap-Changer. Special equipment can be protection class IP 56 according to IEC 529 (protected
supplied in order to fulfil customers requests. Paralleling against dust and powerful water jets).
and voltage regulation systems can also be supplied to The handlamp is automatically switched on when the
supplement the Motor-Drive Mechanism and Tap- door is opened.
Changer.
On request the inside of the cabinet can have a 3 mm
thick layer of anti-condensation paint.
Cabinet
The cabinet is manufactured of welded sheet steel and is Tropical Version
in standard version hot dip galvanized. On request it can
instead be painted with a white primer or a complete The Motor-Drive Mechanism can be equipped to meet
painting system, primer and top coat, suitable for outdoor the requirements for humid tropical climate and desert
use. conditions. Anti-condensation painting inside the cabinet
and screens to shade from direct sun radiation can be
The front door is formed as a cap in order to give better supplied.
access to the internal parts. The door can be hinged on
either the left or the right hand side. Provision is made
for eventual padlocking. The door is sealed with rubber
Type Tests
gasket and the window is glued to the door. The BUL Motor-Drive Mechanism fulfills the
requirements of IEC Standard 214, 1989-07, and has
been type tested according to clause 12.

4
The position numbers below refers to page 10.

135

130

133

134 131

Fig. 1. Motor-Drive Mechanism type BUL L036702

Fig. 2. Motor-Drive Mechanism type BUL L036703

5
Ambient Air Temperature
The ambient air temperature requirements for the Motor-
Drive Mechanism are shown in fig. 3. The normal
operating range is between –40 oC and +60 oC.

The Motor-Drive Mechanism has been type tested at


ambient air temperatures of –40 oC and +70 oC.

The Motor-Drive Mechanism must be


shaded from sun radiation by screens.
It must be specially equipped if the
ambient temperature exceeds +70 oC.

Normal operating range.


(50 W heater shall operate).
The temperature inside the cabinet
should not exceed +75 oC.

Extra 100 W heater is required.


Extra 100 W heater and anti-con-
densation coverage are required.
ABB should be consulted.

Fig. 3. Motor-Drive Mechanism ambient air temperature

Connection of Motor-Drive Mechanism


to Tap-Changers
The connection between the Tap-Changer and the
Motor-Drive Mechanism is made by means of drive shafts
and bevel gears. This external shaft system is described in
the Technical Guide for each Tap-Changer.
The Motor-Drive Mechanism has the outgoing shaft
going through a water resistant bearing in top of the
cabinet. The shaft is terminated by a multiple hole coupling
half.

6
Rating Plate
The rating plate shows data for both Tap-Changer and
Motor-Drive Mechanism and is placed on the front door
of the Motor-Drive Mechanism.

Fig. 4. Example of Rating Plate

7
Mechanical Arrangements
(See Fig. 5–8 and legend on page 10)

Driving Arrangement
The drive mechanism motor M1 with its pulley 121 for indication of the maximum and minimum positions.
drives, with ratio 4.5:1, pulley 122 on the intermediate Those drag-hands can be restored manually. The posi-
shaft 140 via a toothed belt 101. On the intermediate tion indicator is visible through a window in the door.
shaft is a pinion with helical teeth 141 which with ratio
5:1 drives the helical gear 142 on the outgoing shaft 103. Mechanical End Stops
The outgoing shaft is then via a multiple hole coupling
143 directly connected to the shaft system of the Tap- The upper Geneva wheel 125 is supported by the
Changer. The outgoing shaft makes 5 revolutions per Geneva shaft and turns independent of the shaft con-
operation. trolled by the upper driving pin 108 on the ”one-turn”
shaft. On the Geneva wheel two screws 136 are fitted
The Mechanism is assembled on a support of casted
which at the end positions operates the mechanical end
aluminium, 144.
stop 113 via an arm 147. Extra screws could be placed in
between the screws 136 if a decreased tap-change
Hand Crank range is desired.
The mechanism can be manually operated by means of After the end position has been reached the mechanical
a hand crank 104. The hand crank is put on the crank end stop is pressed out in the way for a knob 148 under
shaft 105, which through the bevel pinion 123, with ratio the helical gear 142 which prevents the outgoing shaft
3:1, drives the bevel gear 124 on the outgoing shaft. from further movement in that direction.
Direction of operation is clockwise for a raise operation
and 15 revolutions are needed per operation. This is also When the mechanism is returned to the end position by
shown on a sign placed on the transparent protection manual cranking, the mechanical end stop will be
screen. pressed back by springs, which also keeps it positioned
in all normal tap change positions.
When the hand crank is put onto the crank shaft, the
interlocking switch S5 breaks the operating circuit of the The breakpin 114 in the bevel pinion 123 on the crank
motor thus preventing electrical operation. shaft 105 prevents overloading of the end stops by hand
cranking.
With manual operation the mechanism must be put into
an exact position. If the mechanism is left between two Electrical End Stops
positions or in a through position, when it is electrically
supplied, the mechanism starts directly on removal of the On the lower end of the shaft for arm 147 a cam curve
hand crank. 149 is mounted. When the mechanism is in an end
position this cam curve operates limit switches S6 and
”One-Turn” Shaft S7 which breaks the operating circuit of the motor and
two phases of the motor supply. Electrical operation
A helical pinion 106 on the outgoing shaft drives, with beyond the end positions is thus impossible.
ratio 5:1, the helical gear 102 placed on the ”one-turn”
shaft 107. This shaft drives two Geneva wheels 125 and In case of faulty limit switches the motor will be stopped
126 with the ratio 36:1. The driving pin 108 for the upper by the mechanical end stop and is dis-connected when
Geneva wheel 125 shall in the normal position be in the the thermal over-current protection trips the motor
slot of the Geneva wheel whereas the lower Geneva protective switch Q1 see circuit diagram on page 15.
wheel 126 is locked by the circumference of the ”one-
turn” shaft. Brake
On the upper end of the ”one-turn” shaft 107 is a cam
Position Indicator disc 128 which operates a brake 117 working on a brake
The lower Geneva wheel 126 is pinned to the Geneva disc 118 on top of the intermediate shaft 140. This brake
shaft 145, which through a bevel gear 109, with ratio 1:1 makes sure that the Motor-Drive Mechanism stops in the
operates the position indicator shaft 146, on which the correct position after each tap change. The brake can be
position indicator pointer 110 is assembled. On the adjusted by a screw 150 which is pressing on the spring
position indicator shaft is also assembled drag-hands 151 that closes the brake.

8
Indicator Flag Multi-Position Switches
The indicator flag is placed in the end of the indicator The lower end of the Geneva shaft 145 is via a coupling
arm 116 which is operated by the cam disc 128. The flag 111 connected to the multi position switch shaft 112. The
is visible through a slot in the front plate 119. When the multi position switch therefore moves 1/36 of a turn, 10o,
mechanism is in position the white part of the flag is per tap change step.
visible and during a tap-change the red part is shown.
The multi position switch 127 is assembled of up to 5
The indicator flag is also visible through the window in different printed circuit cards 160. Each card has a
the door. contact arm 161. A slot in the multi position switch shaft
112 transferes the turning to a knob on the contact arm.
Operation Counter The contacts 162 on the arm are solid silver rivets and
the contact surfaces 163 on the circuit cards are gold
A seven digit mechanical operation counter 120 is also plated. Before delivery all cards are insulation tested with
operated by the indicator arm 116. The counter is not 2 kV to earth.
possible to reset and will register the total number of
The contacts on each card are protected against dust by
operations carried out by the Motor-Drive Mechanism.
a transparent cover 164.
The counter is mounted on the front plate 119 and is also
visible through the window in the door.
Position Transmitter (S14), Potentiometer

Maintaining, Interlocking and Auxiliary As standard the contact device is supplied with a
potentiometer transmitter which has 10 ohm, 0.6 W,
Contacts resistances between each position. Other resistances
At the lower end of the ”one-turn” shaft is another cam can be supplied on request.
disc 115 which via a lever 129 operates two sets of On request a suitable measuring amplifier for moving-coil
contacts, S3 and S4. S3 is affected during raise opera- instrument can be supplied. Also the instrument for
tions and S4 during lower operations. remote position indication in the control room can be
The cam disc does not release the lever and the contacts included on request.
before the tap-change operation is completed. Before the
start impulse disappears the maintaining contact 33-34, Continuation Contact (S15)
see Fig. 9, closes another feeding to the contactor K2 or In cases when the Tap-Changer has two or more posi-
K3 and thus keep the motor running until the operation is tions with the same voltage a continuation contact is
completed. After a possible interruption of the supply supplied. Only one of the positions is the service posi-
voltage during an operation this contact will also make tion, and the others are through positions which are
the operation completed when the supply voltage passed automatically at an electric operation. See
returns. description of operation on page 14.
The interlocking contacts 41-42, see Fig. 9, opens the
circuit to the contactor for operation in the opposite Auxiliary Contacts
direction. Thus unintentional change of direction is Auxiliary contacts, break before make or make before
prevented. This contact also prevents operation in case break as well as odd-even switches for parallel control
the motor rotation should be wrong due to incorrect can be supplied on request.
phase sequence.
The contacts 13-14 and 21-22, see Fig. 9, are auxiliary
contacts. They can be used for signal to the control room
or remote interlocking during tap change operation.

9
Driving Mechanism Equipment
See Fig. 1, 2 and 5–8.

E1 Anti-condensation heater 120 Operation counter


E3 Cabinet light 121 Pulley
K1 Step-by-step relay 122 Pulley
K2 Contactor, Raise 123 Bevel pinion
K3 Contactor, Lower 124 Bevel gear
M1 Motor 125 Geneva wheel, upper
Q1 Motor protective switch 126 Geneva wheel, lower
S1 Control selector switch, Local-0-Remote 127 Multi position switches
S2 Control switch, Lower-0-Raise 128 Cam disc
S3 Maintaining, interlocking and auxiliary contact, Raise 129 Lever for maintaining contact
S4 Maintaining, interlocking and auxiliary contact, Lower 130 Rating plate
S5 Interlocking switch, open when hand crank is fitted 131 Hinges
S6 Limit switch, Upper tap position 132 Motor-drive mechanism cabinet
S7 Limit switch, Lower tap position 133 Door
S9 Door operated switch 134 Hand knob
S14 Position transmitter, potentiometer 135 Air vent
S15 Continuation contact 136 Screw for end stop
X1-17 Terminals 140 Intermediate shaft
U1 Measuring amplifier 141 Helical pinion
101 Toothed belt 142 Helical gear
102 Helical gear 143 Multiple hole coupling half
103 Outgoing shaft 144 Support
104 Hand crank 145 Geneva shaft
105 Crank shaft 146 Position indicator shaft
106 Helical pinion 147 Arm for end stop
107 ”One-turn” shaft 148 Knob for mechanical end stop
108 Geneva wheel driving pin 149 Cam curve
109 Bevel gear 150 Screw for adjustment of brake
110 Mechanical position indicator 151 Spring for brake
111 Coupling 160 Printed circuit card
112 Multi position switch shaft 161 Contact arm
113 Mechanical end stop 162 Silver rivet contact
114 Breakpin 163 Gold plated contact surface
115 Cam disc for maintaining contact 164 Transparent cover
116 Indicator arm
117 Brake
118 Brake disc
119 Front plate

10
= Direction of rotation for a raise operation

Fig. 5. Motor-Drive Mechanism type BUL

11
Fig. 6.

Fig. 7.

12
K2

K3

Fig. 8.

13
Principles of Operation
Circuit Diagram for AC Supply, see Fig. 9. Through Positions
The supplies for motor, control circuits and heater are
A so called ”Through position”, is a position the Tap-
connected to their respective terminal blocks according
Changer has to pass without changing the ratio of the
to the instructions on the diagram.
transformer. These positions are passed automatically.
The continuation contact S15 bridges the maintaining
Raise-Operation with Local Control contacts S3:33-34 and S4:33-34 via auxiliary contacts on
raise contactor K2 at through positions. In this way the
When switch S1 is set in position ”Local” the mechanism contactor K2 raise, or K3 lower, is kept energized and
can be operated by control switch S2. For a raise opera- the motor will automatically make another operation.
tion the procedure is as follows:
The connection of S15 to auxiliary contacts on K2,
Motor contactor K2 is energized, the contactor closes the means that the drive, in the event of a control supply
motor phases, the motor starts and drives the failure in a through position, always moves to a lower
mechanism in the raise-direction. After about 0.2 se- normal service position, when the voltage returns.
conds the brake is released and after about 0.4 seconds
the maintaining contact S3: 33-34 closes and take over
the feeding of contactor K2 when control switch S2 is Remote Control
released.
Control selector switch S1 is placed in the ”Remote”
The switching in the On-Load Tap-Changer takes place position. The control supply for the remote pushbuttons
after about 3 seconds. or regulating relay is then received from a terminal in the
Motor-Drive Mechanism Cabinet. Incoming control
The driving mechanism keeps on rolling until the cycle is circuits for raise and lower impulses should be
completed, which takes about 5 seconds. About 0.2 connected to other terminals as shown in the diagram.
seconds before the cycle is completed, the maintaining Local operation is not possible when switch S1 is in the
contact S3 is released, contactor K2 falls and the feed- ”Remote” position and remote operation is not possible
ing of the motor is interrupted. At the same time the in the ”Local” position.
brake is engaged and the mechanism will stop in the
new position.
Step-by-Step-Operation
Lower-Operation with Local Control Step-by-step relay (K1) connected so that only one tap
change operation is obtained each time the raise/lower
A similar cycle is obtained, but in the lower direction, switch is operated.
when the control switch S2 is switched to lower position
and contactor K3 is engaged.
Protection against Running-Through
A relay (K6) stopping the motor-drive mechanism in case
of a failure of the step-by-step control circuit which would
cause a running-through of the motor-drive mechanism.
The relay energizes the trip coil in the protective motor
switch (Q1).

Contact Timing
The contact timing diagram, Fig. 10, shows the contact
sequences for one change of tap position for raise and
lower directions.

14
Circuit Diagram
The diagram shows the mechanism in middle position.

Fig. 9.

15
Contact Timing Diagram

Fig. 10.
S3 Maintaining, interlocking and auxiliary contact, Raise S14 Position transmitter, potentiometer
S4 Maintaining, interlocking and auxiliary contact, Lower S6 Limit switch, Upper tap position
S15 Continuation contact S7 Limit switch, Lower tap position

16
Standard Version
Control Wiring
z Control selector switch, Local-0-Remote. The wiring is of grey polyvinylchloride-insulated,
z Control switch, Raise-0-Lower. stranded wire. Type and data see Technical data.
z Hand crank for manual operation. Every wire is marked with figures corresponding to
terminal numbers. All external connections are made of
Protection thermosetting resin. Type and data see Technical data.

z Protective switch for the motor with thermal overload Short circuit protection (fuses) for control and heater
release and magnetic overcurrent release. supplies, if required, should be installed in the control
z Limit switches – in both control and motor circuits. cabinet or other separate compartment. No fuses are
z Mechanical end stops. required for the motor, as the motor protective switch has
z Interlocking contact in the control circuit to prevent magnetic overcurrent release.
electrical operation during manual operation.
z Interlocking contacts in raise and lower control Maintenance
circuits to prevent operation in wrong direction of
rotation (with wrong phase sequence). All bearings in the Motor-Drive Mechanism type BUL
z Motor contactors are electrically interlocked. have rubber seals and are permanently greased and
z Protection against running-through in case of a failure some gears and moving details are made of selflubri-
of the step-by step control circuit. cating material. No greasing is necessary during the
z Emergency stop push button. lifetime of the Motor-Drive Mechanism at normal working
conditions.
Indication The Motor-Drive Mechanism should be inspected once a
year.
z Mechanical position indicator
z Drag-hands for max. and min. position indication. For the correct inspection and maintenance procedures,
z Red flag for indication of Tap Changer in progress. consult the appropriate Maintenance Guide.
z Operation counter.
(The above four items are visible through the window
in the cabinet door).
Design Options
z Position transmitter, potentiometer, for remote For already prepared design options, please see
position indication. Selection Guide and Ordering data forms.
If other options than those listed in the Selection Guide
and Ordering data forms are required, please consult
ABB.

Multi-Position Switches
Maximum 5 contact rows can be accomodated, including
one continuation contact when there are through positions.

Position Auxiliary contact Auxiliary contact Step switches for parallel control
transmitter Break before make Make before break Type 1 Type 2

Number of contact rows


1 1 1 1 2

Note: Master switch for parallel control is a break-before-make auxiliary contact.

17
Technical Data

Special version
Subject Standard version Alternative version at an additional price

Motor voltage, 3-phase 220-240/380-420 V, 208/360 V, 60 Hz 120 V, 1-phase, 60 Hz


50 Hz 220-240/380-420 V, 60 Hz 240 V, 1-phase, 60 Hz
250-280/440-480 V, 60 Hz Optional

Current 1.4/0.8 A
Rated output 0.18 kW
Speed 1370 r/min

Voltage for control circuit 220 V, 50 Hz 240 V, 50 Hz, 220 V, 60 Hz 110 V, 220 V D.C.
120 V, 208 V, 240 V, 60 Hz Optional

Voltage for heater 220-240 V 110, 120-127 V Optional

Multi position switches 0.15 A, 230 V A.C.


0.15 A, 220 V D.C.
L/R = 40 ms

Mechanical position lowest position middle position Optional


indicator marked 1 marked N

Terminal blocks in BUL


Number of terminals
supplied 28-Phönix UK 5N
41 A, 800 V A.C. acc. to IEC
cross sectional area:
0.5 - 4 sqmm
Number of terminals that 122 - Phönix UK 5N
can be accomodated 116 - Weidmüller SAK 4/35 PA
(depending on selected 92 - Phönix URTK/S Ben
options) 92 - Phönix URTK/S
68 - Phönix OTTA 6

Cabling Type H07V2-K, 1.5 sq mm, 750 V, 90 oC Optional


Type H05V2-K, 0.75 sq mm, 500 V, 90 oC

Test voltage on
control circuits 2 kV (50 Hz, 1 min)

Anti-condensation heater 50 W
Additional heater 100 W controlled by
thermostat or hygrostat

Approx. operating time 5 sec

Starting impulse length > 0.5 sec

Number of revolutions per


operation of
the outgoing driving shaft 5
the hand crank 15

Max. torque on the


outgoing shaft 30 Nm

Max. number of positions 35

Degree of protection
of cabinet IP 56 acc. to IEC 529 (Dust protected/Protected against powerful water jets)

18
Dimensions

813

554
308

39

29

158

Weight
Motor-Drive Mechanism type BUL: 75 kg

19
1ZSE 5483-105 en, Rev. 3, 2003-08-31

ABB Power Technology Products AB


Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com

Produced by Globe, Ludvika, Sweden, 2003


1ZSE 5492-116 en, Rev. 8, 2004-03-15

On-load tap-changers, types UCG and UCL


with motor-drive mechanisms, types BUE and BUL
Installation and commissioning guide
This document must not be copied without our written permission, and the
contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Recommended Practices
ABB recommends careful consideration of the following factors when installing on-load
tap-changers:
Before you install or commission a unit, make sure that the personnel doing the job
have read and fully understood the Installation and Commissioning Guide provided
with the unit.
To avoid damaging the unit, never exceed the operating limits stated in delivery
documents and on rating plates.
Do not alter or modify a unit without first consulting ABB.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and procedures.

WARNING, CAUTION and NOTE


WARNING
A WARNING provides information which, if disregarded, could cause injury or
death.

CAUTION
A CAUTION provides information which, if disregarded, could cause damage to the
equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work
described.

Safety Precautions
WARNING
Unused transformer oil is slightly harmful. Fumes from unused warm oil may
irritate the respiratory organs and the eyes. After long and repeated contact with
transformer oil skin becomes very dry.

Used on-load tap-changer oil from diverter switch housings and selector switch
housings contains harmful substances. Fumes are irritating to the respiratory
organs and the eyes and are very easily set on fire. Used transformer oil may well
be carcinogenic.
Avoid contact with the oil as much as possible and use oiltight protective gloves
when handling the oil.

First aid:
Skin contact: Wash the hands. Use skin cream to counteract drying.
In the eyes: Rinse the eyes in clean water.
Swallowing: Drink water or milk. Avoid vomiting. Call a doctor.

Collect used oil in oil drums.


To be continued on the next page.

iii
Waste and cleaning up: Should be absorbed by an absorber. Treat it as
hazardous to the environment.

Upon fire: The fire should be extinguished by using powder, foam or carbon
acid.

WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.

WARNING
The motor-drive mechanism must not be installed in any explosive atmosphere.
The electrical equipment creates sparks which can cause an explosion.

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

WARNING
Before carrying out work on the on-load tap-changer, put the LOCAL/REMOTE
switch in the motor-drive mechanism to position 0. It is also recommended to
shut the door of the motor-drive mechanism and pad lock it when work is
carried out on the on-load tap-changer. The key should be kept by the operator.
This is done to avoid unexpected start of the motor-drive mechanism.

WARNING
Before starting any work inside the motor-drive mechanism, the auxiliary power
must be switched off.

N.B. The motor, contactors and heating element may be energized from separate
sources.

During Drying of the Transformer


CAUTION
The diverter switch should not be installed during drying, since the process removes
grease needed for operation.

CAUTION
During drying with hot air and vacuum, the maximum permitted pressure difference
for the diverter switch housing is 100 kPa at the maximum permitted temperature of
135 °C (275 °F).

iv
CAUTION
During drying by the vapour phase process the cover of the diverter switch housing and
the bottom valve should be left open. The valve is opened with the special bottom valve
key, a long hexagonal rod. The maximum permitted temperature is 135 °C (275 °F).

CAUTION
Use the special bottom valve key only (delivered with the on-load tap-changer) to
operate the bottom valve through the oil draining tube. The use of a stiffer tool may
damage the valve.

CAUTION
Do not operate the on-load tap-changer during the drying process or afterwards until
it is filled with oil, to avoid seizing.

Mounting of Gaskets
CAUTION
Sealing surfaces and gaskets must be clean and undamaged. Diametrically opposed
bolts in sealing joints must be tightened alternately several times, beginning with a
low tightening torque and finally with the recommended tightening torque as
described in section 1.8 Tightening Torque, in this guide.

During Oil Filling


WARNING
When oil that has been used in a diverter switch housing is pumped out, conduc-
ting tubes and hoses that are earthed should be used to avoid the risk of explo-
sion due to the gases produced by the arcs during service.

CAUTION
Do not fill oil into the diverter switch housing if the transformer tank is under vacuum
and the diverter switch housing is not.

CAUTION
Do not fill oil into the transformer tank if the diverter switch housing is under vacuum
and the transformer tank is not.

CAUTION
Leave a gas cushion on top of the oil in the diverter switch housing.

v
After Oil Filling
CAUTION
Do not energize the transformer earlier than three hours after oil filling in
atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

NOTE: Check the oil level one month after filling. It is usual for the oil level of the oil
conservator to fall due to gas absorption in the oil from the gas-cushion in the on-load
tap-changer, if the on-load tap-changer is not operated. Restore the gas-cushion and
the oil level according to section 6.5.

During Service
WARNING
Small amounts of explosive gases will always come out from the breathing
devices (dehydrating breather or one-way breather). Make sure that no open
fire, hot surfaces or sparks occur in the immediate surroundings of the breathing
devices.

WARNING
If a failure in power supply occurs during operation, the operation will be
completed when the power returns.

WARNING
The hand crank must not be inserted during electrical operation.

WARNING
If the on-load tap-changer is not in its exact position and the hand crank is pulled
out, the motor-drive mechanism will start and go to the exact position if the
power supply is on.

CAUTION
After a pressure relay trip, follow the instructions in the chapter ”Pressure Relay” in
the Repair Guide.

CAUTION
The pressure relay is a calibrated monitoring instrument. It must be handled with care
and protected against careless handling or any kind of mechanical damage. Do not
open the package of the pressure relay until you are about to install it on the on-load
tap-changer.

vi
Contents
1 Introduction ____________________________________________ 9
1.1 Type Designation ________________________________________ 10
1.2 Required Tools _________________________________________ 13
1.3 Required Material _______________________________________ 13
1.4 Oil ___________________________________________________ 14
1.5 Oil Conservator _________________________________________ 15
1.6 Oil Filter Unit for Continuous Oil Filtration ___________________ 15
1.7 Weights _______________________________________________ 15
1.8 Tightening Torque _______________________________________ 17
2 Receiving ______________________________________________ 17
2.1 Unpacking _____________________________________________ 17
2.2 Inspection on Receipt ____________________________________ 17
2.3 Temporary Storage before Assembly ________________________ 17
3 Installation in the Transformer _____________________________ 18
3.1 Cover-Mounting ________________________________________ 19
3.1.1 UCG with Tap Selector size I or C __________________________ 19
3.1.2 UCG with Tap Selector size III _____________________________ 25
3.1.3 UCL with Tap Selector size III _____________________________ 29
3.2 Yoke-Mounting _________________________________________ 33
3.2.1 Mounting when the Transformer Ratio Measurement
is carried out before Drying ________________________________ 34
3.2.2 Mounting when the Transformer Ratio Measurement
is carried out after Drying _________________________________ 37
3.2.3 Mounting on Transformer Cover ____________________________ 38
3.3 Connection to Terminals __________________________________ 42
3.4 Transformer Ratio Measurement ____________________________ 44
3.4.1 Transformer Ratio Measurement before Drying ________________ 45
3.4.2 Transformer Ratio Measurement after Drying _________________ 45
4 Drying ________________________________________________ 46
4.1 Observations before Processing ____________________________ 46
4.2 Observations after Processing ______________________________ 46
4.3 Installation of Diverter Switch _____________________________ 47
5 Final Assembly _________________________________________ 49
5.1 Mounting of the Motor-Drive Mechanism ____________________ 49
5.2 Mounting of External Drive Shafts __________________________ 52
5.2.1 Mounting of Vertical Drive Shaft ___________________________ 54
5.2.2 Mounting of Horizontal Drive Shafts,
types UCG.N/UCL.N and UCG.E/UCL.E ____________________ 56
5.2.3 Mounting of Horizontal Drive Shafts, type UCG.B/UCL.B _______ 59
5.2.4 Mounting of Horizontal Drive Shafts,
types UCG.T/UCL.T and UCGYD/UCLYD __________________ 64
5.2.5 Before Operation ________________________________________ 64
5.3 Pressure Relay __________________________________________ 65
5.3.1 General _______________________________________________ 65
5.3.2 Installation _____________________________________________ 65
5.3.3 Checking at Commissioning of the Transformer _______________ 66
5.4 Assembly of Accessories __________________________________ 67
5.5 Connection to the Oil Conservator __________________________ 67

7
6 Oil Filling _____________________________________________ 68
6.1 Filling Methods and Restrictions ___________________________ 68
6.2 Before Filling ___________________________________________ 68
6.3 Filling at Atmospheric Pressure ____________________________ 69
6.4 Filling under Vacuum ____________________________________ 69
6.4.1 Oil Conservator Filled Afterwards __________________________ 70
6.4.2 Oil Conservator Filled under Vacuum _______________________ 70
6.5 Restoring the Gas Cushion ________________________________ 71
6.5.1 Procedure ______________________________________________ 72
7 Electrical Connection and Testing __________________________ 73
7.1 General _______________________________________________ 73
7.2 Connecting and Testing the Motor-Drive Mechanism and the
On-Load Tap-Changer ____________________________________ 73
7.3 Electrical Tests on the Transformer _________________________ 74
7.4 After Energizing ________________________________________ 74
8 Transport ______________________________________________ 75
8.1 Dismantling before Transport ______________________________ 75
8.1.1 Dismantling Preparations _________________________________ 75
8.1.2 External drive shafts for UCG.N/UCL.N, UCG.E/UCL.E (One Unit) 75
8.1.3 External drive shafts for UCG.B/UCL.B (Two Units) ___________ 76
8.1.4 External drive shafts for UCG.T/UCL.T and
UCGYD/UCLYD (Three Units) ____________________________ 76
8.1.5 Accessories ____________________________________________ 77
8.2 Oil Level During Transport ________________________________ 77
8.2.1 Transformer filled with Oil ________________________________ 78
8.2.1.1 Conservator mounted _____________________________________ 78
8.2.1.2 Conservator dismounted __________________________________ 78
8.2.2 Transformer drained _____________________________________ 78
8.2.2.1 Conservator mounted _____________________________________ 78
8.2.2.2 Conservator dismounted __________________________________ 78

9 Commissioning _____________________________ 79
9.1 Connection to the Oil Conservator __________________________ 80
9.2 Mounting the Motor-Drive Mechanism and the Drive Shafts ______ 80
9.2.1 Mounting of the Motor-Drive Mechanism ____________________ 80
9.2.2 Mounting of the External Drive Shafts _______________________ 81
9.2.3 Mounting of the Vertical Drive Shaft ________________________ 81
9.2.4 Mounting of Horizontal Drive Shaft types UCG.N/UCL.N
and UCG.E/UCL.E ______________________________________ 83
9.2.5 Mounting of Horizontal Drive Shafts type UCG.B/UCL.B _______ 85
9.2.6 Mounting of Horizontal Drive Shaft types UCG.T/UCL.T
and UCGYD/UCLYD ____________________________________ 89
9.2.7 Before Operation ________________________________________ 89
9.3 Pressure Relay __________________________________________ 90
9.4 Accessories ____________________________________________ 90
9.5 Oil Filling _____________________________________________ 90
9.6 Electrical Connection and Testing __________________________ 90
9.6.1 Motor Protection ________________________________________ 90
9.6.2 Disc Brake _____________________________________________ 90
9.6.3 Counter _______________________________________________ 91
9.6.4 Position Transmitter and other Position Switches _______________ 91
9.6.5 Light _________________________________________________ 91
9.6.6 Heater ________________________________________________ 91
9.7 Putting into Operation ____________________________________ 91
8
1 Introduction

1 Introduction
The arrangement of on-load tap-changers types UCG and UCL are shown in Figs. 1
and 2.
The on-load tap-changer may consist of one, two or three units driven by the same
motor-drive mechanism.
To make transportation easy the on-load tap-changer is delivered in three main parts.
These are diverter switch housing, tap selector and motor-drive mechanism.
The on-load tap-changer is performed for cover-mounting or for yoke-mounting.
Cover-mounting means that the diverter switch housing is lowered through the hole in
the transformer tank and then bolted straight onto the transformer cover, and after that
the tap selector is mounted. Yoke-mounting means that the on-load tap-changer is
temporarily put on a fork located on the active part of the transformer. Yoke mounting
allows the transformer manufacturer to connect the windings to the on-load tap-
changer before drying and without having the transformer cover mounted. The trans-
former cover is then lowered onto the tank, and the on-load tap-changer is lifted and
bolted to the cover. Please use the appropriate instruction for cover-mounting or yoke-
mounting in chapter 3.
At cover-mounting the diverter switch housing is installed on the transformer cover
before joining with the tap selector except for the UCG/I and UCG/C. On the latter the
tap-selector and the diverter switch housing are joined before the entire on-load tap-
changer is lowered through the hole in the transformer cover.
After the drying process of the transformer the motor-drive mechanism and bevel gear
are fitted to the transformer tank and the drive shafts are fitted to complete the
assembly of motor-drive mechanism, bevel gear and on-load tap-changer before oil
filling and testing.
The arrangement of the on-load tap-changer systems is shown in Fig. 2.
Position numbers in the Installation Guide, for example SA11 (see section 5)
correspond with those in the packing list for the on-load tap-changer.
All instructions are for one on-load tap-changer unit. In case of more than one unit on
the transformer, carry out the same procedures for each unit.

9
1 Introduction

1.1 Type Designation

UCG .. XXXX/YYYY/I, III, C


UCL .. XXXX/YYYY/III
Example: UCLRE 650/900/III

Type of switching
L Linear
R Plus/Minus
D Coarse/Fine

Type of connection
N Three-phase star point (one unit)
E Single-phase (one unit)
T Three-phase fully insulated (three units)
B Three-phase delta (two units;
single-phase and two-phase)

Impulse withstand voltage to earth

Maximum rated through-current

Tap selector size

Serial No.

Diverter switch type UCG

Serial No. in the bottom


of the diverter switch

Serial No. Serial No.

Tap selector size C Tap selector size I Tap selector size III

Fig. 1.

10
1 Introduction

Serial No.

Diverter switch type UCL

TC_00263
Serial No. in the
bottom of the
diverter switch

Tap selector, size III

Fig. 1a.

11
1 Introduction

Horizontal drive shafts Bevel gear


and protective tubes
Bevel gear ;
Pressure relay
Vertical drive
shafts and
protective tubes
Shielding caps
(only for insulation Type of connection, N or E
level above 380 kV)
Rating plate

Shielding rings
Hand crank (only for insulation
(inside the cover) level above 380 kV)
Motor-drive
mechanism
fm_00218 Not used for selector, size C
Unit -1

; ;

Type of connection, B

fm_00189

Unit -1 Unit -2

; ; ;

Type of
connection, T

fm_00219

Unit -1 Unit -2 Unit -3

Fig. 2. Example of on-load tap-changer system

12
1 Introduction

1.2 Required Tools


Required for work
according to chapter/section
Normal set of open end wrenches (up to 24 mm) General
Normal set of sockets (up to 24 mm) General
Normal set of screw drivers General
Socket handle General
Set of pliers, including cutting pliers General
Dynamometric wrench 5-85 Nm General
Sliding caliper General
Allen key sockets 2–10 mm General
Pipe wrench 3.2
Bottom valve key (delivered with the on-load tap-changer) 3.2.1, 4 and 6.2
Lifting equipment for UCL. Article No. LL 136 016-D 3.2.2
(can be ordered from ABB)
Lifting equipment for UCG. Article No. LL 135 016-A 3.2.2
Special hand crank for operating the on-load tap-changer 3.4
on the bevel gear (can be ordered from ABB)
Hack saw (only for installation) 5
File 5
Folding ruler 5
Air pump with hose, pressure gauge (0–250 kPa) 5.3
and connection with internal thread R 1/8”
Container, 50 litres 6
Small oil pump with connection to the oil valve 6
(For connection dimensioning see the dimension drawing
for the on-load tap-changer).

1.3 Required Material


Rags for cleaning General
Single-phase diagram for the on-load tap-changer General
Pressboard sheet (t =1, approx. 100x300 mm, 2 pieces) 3.1
(for UCL only)
Gasket for transformer flange 3.1, 3.2.3
Insulating paper 3.1, 3.2
Insulating bushings 3.2

13
1 Introduction

Required for work


according to chapter/section
Wooden block as spacer 3.3
Grease (ball bearing grease) GULF-718 EP,
Mobil-Grease 28, SHELL-Aero Shell Grease 22 or similar 3, 9.2.2
Oil, see section 1.4 6
Dimension drawing for the on-load tap-changer for 6
connection dimensions of the oil valve
Flange for connection to the oil conservator flange 6.4
when filling under vacuum, see Fig. 38
Oil valves for connection to flange with dimensions 6.4.1
according to Fig. 42. Can be ordered from ABB
Equipment for oil filling 6, 9.5
Sealing tape 6, 9.5
Maintenance Guide for UCG/UCL 7.2
Circuit diagram for the motor-drive mechanism 7.2
Oil filter (in case of common conservator for both the 5.5
transformer and the on-load tap-changer, can be ordered
from ABB).

1.4 Oil
The oil quality should be of Class II according to IEC publication 60296.

Table 1. Weight of oil in kg.


Type designation Oil weight 1)
(kg)

UCG.. 380/..., 650/... 750/... 150


UCG.. 1050/... 185
UCL.. 380/.... 260
UCL.. 650/.... 300
UCL.. 1050/.... 340
1)
The oil for the conservator is not included.

NOTE: An UCG.B/UCL.B requires twice and UCG.T/UCL.T three times the amount
specified above since they have two and three diverter switch housings respectively.

WARNING
Do not energize the transformer until oil has been filled according to
chapter 6, Oil Filling, in this guide.

14
1 Introduction

1.5 Oil Conservator


The on-load tap-changer has to be connected to an oil conservator. ABB recommends
to use a separate conservator for the on-load tap-changer with both oil and air side
separated from the main conservator of the transformer.
The volume of the conservator should be such, that there is oil left in the conservator
even at the lowest oil temperature expected and such that no flooding can occur at the
highest oil temperature expected. Even on-load tap-changers consisting of more than
one unit require only one conservator.
A suitable dimension of the tube for connection to the conservator is an innerdiameter
of approximately 20 mm. The tube should be inclined at least 3 degrees to avoid gas
cushions in the tube. A valve in the connection to the conservator is recommended.
The conservator must be equipped with a breathing device that does not allow moist
air into the conservator and that allows the gas from the arcs to disappear.
The conservator should also be equipped with an oil level indicator and an alarm
contact for low oil level is recommended.

1.6 Oil Filter Unit for Continuous


Oil Filtration
If the on-load tap-changer should have an oil filter unit for continuous oil filtration
from ABB, installation and commissioning instructions are found in the manual for
the oil filter unit, ”Oil filter unit for On-Load Tap-Changers, Manual” delivered with
the oil filter unit.

1.7 Weights
Motor-drive mechanism type BUE 1: approximately 130 kg
Motor-drive mechanism type BUE 2: approximately 155 kg
Motor-drive mechanism type BUL: approximately 75 kg
The weights of the motor-drive mechanism and drive-shaft system are not included in
the weights given on the next page.

15
1 Introduction

Table 2. Weights for UCG on-load tap-changers.


On-load tap-changer Approx. weight in kg
Type designation Tap-changer Required Total
without oil 1) oil
UCG.N 380-750/300-600 325 150 475
1050/300-600 335 185 520
UCG.T 380-750/300-900 725 3x150 1175
380-750/1050-1500 890 3x150 1340
1050/300-900 790 3x185 1345
1050/1050-1500 925 3x185 1480
UCG.B 380-750/300-600 560 2x150 860
1050/300-600 580 2x185 950
UCG.E 380-750/300-900 260 150 410
380-750/1050-1500 310 150 460
1050/300-900 270 185 455
1050/1050-1500 325 185 510

1)
The weight of the diverter switch, approximately 90 kg, is included.

Table 3. Weights for UCL on-load tap-changers.


On-load tap-changer Approx. weight in kg
Type designation Tap-changer Required Total
without oil 1) oil
UCL.N 380/600, 900 480 260 740
650/600, 900 500 300 800
1050/600, 900 510 340 850
UCL.T 380/600, 900 1230 3x260 2010
380/1800 1350 3x260 2130
380/2400 1440 3x260 2220
650/600, 900 1290 3x300 2190
650/1800 1410 3x300 2310
650/2400 1500 3x300 2400
1050/600, 900 1320 3x340 2340
1050/1800 1440 3x340 2460
1050/2400 1530 3x340 2550
UCL.B 380/600, 900 850 2x260 1370
650/600, 900 890 2x300 1490
1050/600, 900 910 2x340 1590
UCL.E 380/600, 900 410 260 670
380/1800 450 260 710
380/2400 480 260 740
650/600, 900 430 300 730
650/1800 470 300 770
650/2400 500 300 800
1050/600, 900 440 340 780
1050/1800 480 340 820
1050/2400 510 340 850
1)
The weight of the diverter switch, approximately 120 kg, is included.

16
2 Receiving

1.8 Tightening Torque


The following tightening torques are recommended:
For metallic screw joints: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %
For non-metallic screw joints: M10, 9 Nm ±10 %
M12, 13 Nm ±10 %
M16, 22 Nm ±10 %
if not otherwise is stated in this guide.

2 Receiving
2.1 Unpacking
Check that the packages are free from transport damage. Open the covers of the
transport boxes, Remove the supporting block of wood. If any package is damaged a
careful investigation must be carried out.
Lift the on-load tap-changer parts in their lifting eyes according to Fig. 3.

2.2 Inspection on Receipt


1. Check that the diverter switch housing, tap selector, motor-drive mechanism and
accessories are undamaged.
2. If transport damage is found, and it is judged that correct operation of the on-load
tap-changer is not possible, a damage report should be sent to the insurance com-
pany. It is also recommended that photographs are taken of the damaged details.
Mark the photos with ABB’s reference number and the serial number of the on-
load tap-changer and send them to ABB for comments.
3. Check that the parts delivered, type designations and the serial number agrees
with the delivery documents, e.g. the packing list or ABB’s order acknowled-
gement. The serial numbers to be checked are those on the rating plate, on the
diverter switch housing and on the tap selector. For locations, see Figs. 1 and 2.
The serial number on the parts belonging to one on-load tap-changer unit should
all be the same.

2.3 Temporary Storage before Assembly


If the on-load tap-changer is not to be assembled immediately, once the delivery has
been approved the on-load tap-changer and the motor-drive mechanism must be kept
warm and dry indoors. Let the units be kept in their plastic enclosures and leave the
drying agent until assembly.
17
3 Installation in the Transformer

3 Installation in the Transformer


The cover-mounting method or yoke-mounting method is used.

WARNING
The intermediate gear and the insulating shaft of the diverter switch housing
moves during operation. Keep away during operation to avoid injuries!

The diverter switch housing and the tap selector are designed to be lifted in the lifting
eyes, see Fig. 3.

WARNING
To put down the complete on-load tap-changer to stand on the floor without any
support on the top of the on-load tap-changer means a risk for tilting with risk
for injuries to people and damage to the equipment.

Max 90o

TC_00114

Diverter switch housing

Max 90o

Max 90o Max 90o

TC_00188 TC_00184 TC_00185

Tap selector C Tap selector I Tap selector III

Fig. 3. How to lift.

18
3 Installation in the Transformer

3.1 Cover-Mounting
(For Yoke-Mounting, see section 3.2).
The diverter switch housing and the tap selector are delivered packed separately.

3.1.1 UCG with Tap Selector size I or C


1. Unpack the diverter switch housing and the tap selector. Remove the drying
agents in the tap selector and on the diverter switch housing.
2. Fit the gasket into the on-load tap-changer flange on the transformer cover, see
Fig. 9. (This gasket is not included in the delivery).
3. Remove the transport locking device and the lifting eyes from the top section of
the tap selector, see Fig. 4.
CAUTION
Do not operate the tap selector until it is connected to the diverter switch housing.

Lifting eyes Transport locking Screws (4 pcs)


(to be removed) (to be removed) (to be removed)

TC_00209 TC_00211
Tap selector size I Tap selector size C

Fig. 4.

4. Lift the diverter switch housing in the lifting eyes and remove the transport sup-
port. For tap selector size C, remove the three limbs, see Fig. 5.

19
3 Installation in the Transformer

Diverter switch
housing, lower part

Limbs (3 pieces)

Hexagon screws
and nut (3 pieces)
TC_00215

Transport supports

Fig. 5.

5. Lift the diverter switch housing onto the tap selector, the driving pin of the tap
selector shall fit in the large gear wheel slot, see Figs. 6 and 7, view A–A.

CAUTION
The driving crank on the tap selector must not be moved more than slightly to engage
the slot in the large gear wheel of the diverter switch housing.

6. Insert the fastening screws, three socket-head cap screws M12x40 for UCG with
tap selector I, six hexagon screws M8x35 for UCG with tap selector C, and
washers. Tighten the screws.

20
3 Installation in the Transformer

Washer
14x30x2,5 Spring washer

Socket-head Locking nut


cap screw M12 M12
F F
Diverter switch Shielding
housing, UCG rings B–B
Conductor
B B TC_00274
Insulating shaft F–F

Conductors Washer 13x28x3


Spring washer
E A Locking nut M12
A
17
Washer, Socket-head cap
steel T=3 screw

Tap selector, 25
E C–C
size I
13 17
Large gear Socket screw
wheel M8x20 (x4)
Washer

Tap selector
C C

Current Locking nut M8


collector D–D

D
Shielding ring, TS 11
M12x40
D
Washer 13x24x2
Insulating screw
M16x140
Conductors Diverter switch
Insulating housing
nut M16

Cleats Tap selector


E–E

Slot in the large gear wheel


of the diverter switch housing
Driving pin of the tap selector

A–A
TC_00271

Fig. 6. Tap selector I and diverter switch UCG

21
3 Installation in the Transformer

Washer
14x30x2,5 Spring washer

Socket-head Locking nut


cap screw M12 M12

Diverter switch F F
Shielding
housing, UCG rings
B–B
Conductor
Insulating shaft
TC_00274
B B F–F
Conductors

Locking nut M10


Spring washer
Washer 10.5x24x3
D
A A Socket-head cap
screw
Large gear wheel
Conductor
D C–C

Tap selector,
size C
Diverter switch
housing

C C
Current
collector
Tap selector
Washer 8.4x20x2

Spring washer

Hexagon headed
Conductors
screw M8x35

D–D
Insulating bolt
M16x110
Slot in the large gear wheel
Insulating
of the diverter switch housing
nut M16

Cleats

Driving pin of the tap selector

TC_00272

A–A

Fig. 7. Tap selector, size C and diverter switch UCG

22
3 Installation in the Transformer

7a. In case the on-load tap-changer is equipped with a tie-in resistor for mounting un-
der the tap selector, the tie-in resistor is mounted after joining the tap selector to
the diverter switch housing. After mounting the tie-in resistor, the on-load tap-
changer must not be put down standing on the tie-in resistor. It must be hanging,
for instance in a traverse.
WARNING
To put down the on-load tap-changer to stand on the floor with the tie-in resistor
mounted means a great risk for tilting the on-load tap-changer with risk for
injuries to people and damage of the equipment.

7b. In case the on-load tap-changer is equipped with a tie-in resistor switch, (tap
selector size I only) the switch is mounted under the tap selector at delivery. A
special support in the box makes it standing on the tap selector bottom. If this spe-
cial support is taken out of the box, the tap selector can be standing on this during
joining to the diverter switch housing. After joining, the complete on-load tap-
changer is lifted and the special support is removed. The complete on-load tap-
changer must not be put on the special support. It must be hanging, for instance in
a traverse.
WARNING
To put down the on-load tap-changer to stand on the floor with the tie-in resistor
switch mounted means a great risk for tilting the on-load tap-changer with risk
for injuries to people and damage of the equipment.

8. Lift the on-load tap-changer in the lifting eyes as shown i Fig. 3 and lower it
carefully through the opening in the transformer top cover, see Fig. 8. Place the
on-load tap-changer correctly in position for mounting the outer shaft system (see
transformer drawing). The studs on the flange on the transformer cover shall fit
into the holes in the flange of the diverter switch housing.

Diverter switch UCG


Top section

Selector size I or C Stud M12


Nut M12 (24x)
Washer (24x)

Opening in the Flange


transformer cover Gasket

fm_00220

Transformer
top cover
Fig. 8. Fig. 9.
TC_00282

23
3 Installation in the Transformer

9. Mount the 24 washers and M12 nuts, see Fig. 9. Tighten the nuts.

WARNING
The diverter switch housing and the tap selector contains moving parts. Be
cautious!

10. Connect the supplied conductors between the diverter switch housing and tap
selector, see Figs. 6 and 7. The conductor ends and their connecting points have
the same markings. Make sure the assymetrical steel washers on the tap
selector I contacts are mounted as shown in Fig. 6, view C–C. Fasten the
conductors with cleats, see Fig. 6, A–A. The number of conductors is varying
depending on the type of connection.
11. If the impulse withstand voltage to earth exceeds 380 kV, insulate the connections
on the tap selector by winding paper around them to a thickness of approximately
3 mm, see Fig. 10. The paper should be of the same quality as used for insulation
of conductors within the active part of the transformer.
12. UCG with tap selector I: If the impulse withstand voltage to earth exceeds
380 kV, mount the supplied shielding ring (TS 11) at the bottom plate of the tap
selector, see Fig. 6, D–D.

CAUTION
After mounting the shielding ring, the on-load tap-changer must not stand on the
shielding ring.

13. Continue with section 3.3.


~ 3 mm

~ 100 mm

Locking nut
Conductor
Spring washer
Insulating paper Plain washers

TC_00169
Socket screw
Connection point on
the tap selector

Fig. 10.

24
3 Installation in the Transformer

3.1.2 UCG with Tap Selector size III


1. Unpack the diverter switch housing and the tap selector. Remove the drying
agents in the tap selector and on the diverter switch housing.
2. Fit the gasket into the on-load tap-changer flange on the transformer cover, see
Fig. 9. (This gasket is not included in the delivery.)
3. Lift the diverter switch housing in the lifting eyes as shown in Fig. 3 and lower it
carefully through the opening in the transformer top cover, see Fig. 11. Place the
diverter switch housing correctly in position for mounting the outer shaft system
(see transformer drawing). The studs on the flange on the transformer cover shall
fit into the holes in the flange of the diverter switch housing.
4. Mount twenty-four washers and M12 nuts, see Fig. 9. Tighten the nuts.

Diverter switch UCG

Opening in the
transformer cover

Selector size III

fm_00222

Fig. 11.

5. Put the tap selector in position for joining to the diverter switch housing. Lift in
the lifting eyes as shown in Fig. 3.
6a. In case the on-load tap-changer is equipped with a tie-in resistor for mounting un-
der the tap selector, the tie-in resistor is mounted after joining the tap selector to
the diverter switch housing. After mounting the tie-in resistor, the on-load tap-
changer must not be put down standing on the tie-in resistor. It must be hanging,
for instance in a traverse.

WARNING
To put down the on-load tap-changer to stand on the floor with the tie-in resistor
mounted means a great risk for tilting the on-load tap-changer with risk for
injuries to people and damage of the equipment.

25
3 Installation in the Transformer

6b. In case the on-load tap-changer is equipped with a tie-in resistor switch, the
switch is mounted under the tap selector at delivery. A special support in the box
makes it standing on the tap selector bottom. If this special support is taken out of
the box, the tap selector can be standing on this during joining, to the diverter
switch housing. After joining, the complete on-load tap-changer is lifted and the
special support is removed. The complete on-load tap-changer must not be put on
the special support. It must be hanging, for instance in a traverse.

WARNING
To put down the on-load tap-changer to stand on the floor with the tie-in resistor
switch mounted means a great risk for tilting the on-load tap-changer with risk
for injuries to people and damage of the equipment.

7. Remove the transport locking and the lifting eyes with fasteners from the top
section of the tap selector, see Fig. 12.

CAUTION
Do not operate the tap selector until it is connected to the diverter switch housing.

Lifting eyes with


fasteners
(to be removed)
Transport locking
(to be removed)

Screw (to be removed)

TC_00216

Fig. 12.

8. Lift the diverter switch housing in position and fit the tap selector to the diverter
switch housing, see Fig. 13. The tap selector driving pin shall fit into the large
gear wheel slot, see Fig. 13, A-A.
CAUTION
The driving crank on the tap selector must not be moved more than slightly to engage
the slot in the large gear wheel of the diverter switch housing.

9. Insert four M10x40 screws and washers, see Fig. 13, E-E, through the tap selector
upper part to the four supports of the diverter switch housing. Tighten the screws.
WARNING
The diverter switch housing and the tap selector contains moving parts. Be
cautious!

26
3 Installation in the Transformer

10. Connect the supplied conductors between the diverter switch housing and tap
selector, see Fig. 13. The conductor ends and their connecting points have the
same markings. Fasten the conductors with cleats, see Fig. 13, A–A. The number
of conductors is varying depending on the rated through current and the type of
connection.
11. If the impulse withstand voltage to earth exceeds 380 kV, insulate the connections
on the tap selector by winding paper around them to a thickness of approximately
3 mm, see Fig. 10. The paper should be of the same quality as used for insulation
of conductors within the active part of the transformer.
12. If the impulse withstand voltage to earth exceeds 380 kV, mount the supplied
shielding ring (TS 11) at the bottom plate of the tap selector, see Fig. 13, D–D.

CAUTION
After mounting the shielding ring, the on-load tap-changer must not stand on the
shielding ring.

13. Continue with section 3.3.

27
3 Installation in the Transformer

Washer
14x30x2,5 Spring washer

Socket-head Locking nut


cap screw M12 M12
Diverter switch F F
housing, UCG
B–B
Conductor

B B TC_00274
F–F
Insulating
shaft Locking nut M12
Conductors
Spring washer
E

A A Socket-head
cap screw

Washer 14x30x2.5
E
Conductor
C–C
Socket-head cap
screw M8x25
Spring washer

C C
Locking nut M8
Current
collector
D–D

Tap selector,
size III D Shielding ring,
TS 11

Diverter switch
D support

Tap selector

Cleats

Insulating
nut M16 Washer 10.5x24x3 (x4)
Spring washer
Insulating E–E
stud Socket-head cap
M16x120 screw M10x40 (x4)
Slot in the large gear wheel
Conductors of the diverter switch housing

A–A Driving pin of the tap selector


TC_00273

Fig. 13. Tap selector III and diverter switch UCG.

28
3 Installation in the Transformer

3.1.3 UCL with Tap Selector size III


1. Unpack the diverter switch housing and the tap selector. Remove the drying
agents in the tap selector and on the diverter switch housing.
2. Fit the gasket into the on-load tap-changer flange on the transformer cover, see
Fig. 15. (This gasket is not included in the delivery.)

Top cover Top section

Diverter switch UCL


Nut M12 (x24)

Washer
Opening in the (x24)
transformer cover Stud (x24)

Gasket
Transformer
Selector size III top cover

TC_00222 TC_00218
Fig. 14. Fig. 15.
3. Lift the diverter switch housing in the lifting eyes as shown in Fig. 3 and lower it
carefully through the opening in the transformer top cover, see Fig. 14. Place the
diverter switch housing correctly in position for mounting the outer shaft system
(see transformer drawing). The studs on the flange on the transformer cover shall
fit into the holes in the flange of the diverter switch housing. Mount twenty-four
washers and M12 nuts, see Fig. 15. Tighten the nuts.

NOTE: For impulse withstand voltages to earth exceeding 380 kV, the diverter switch
housing is equipped with shielding rings. The play between the on-load tap-changer
flange in the transformer cover and the middle shielding ring is very small especially
for the 1050 kV impulse withstand voltage to earth where the shielding ring is paper
insulated. To avoid damages on the shielding rings, lower the diverter switch housing
very carefully and cover the flange in the transformer cover next to the insulating
shaft of the diverter switch housing and diametrically opposed (where the diameter of
the shielding ring is greatest) with a thin sheet of pressboard (or similar).

4. Put the tap selector in position for joining to the diverter switch housing. Lift in
the lifting eyes as shown in Fig. 3.
5a. In case the on-load tap-changer is equipped with a tie-in resistor for mounting un-
der the tap selector, the tie-in resistor is mounted after joining the tap selector to
the diverter switch housing. After mounting the tie-in resistor, the on-load tap-
changer must not be put down standing on the tie-in resistor. It must be hanging,
for instance in a traverse.

29
3 Installation in the Transformer

WARNING
To put down the on-load tap-changer to stand on the floor with the tie-in resistor
mounted means a great risk for tilting the on-load tap-changer with risk for
injuries to people and damage of the equipment.

5b. In case the on-load tap-changer is equipped with a tie-in resistor switch, the
switch is mounted under the tap selector at delivery. A special support in the box
makes it standing on the tap selector bottom. If this special support is taken out of
the box, the tap selector can be standing on this during joining, to the diverter
switch housing. After joining the complete on-load tap-changer is lifted and the
special support is removed. The complete on-load tap-changer must not be put on
the special support. It must be hanging, for instance in a traverse.

WARNING
To put down the on-load tap-changer to stand on the floor with the tie-in resistor
switch mounted means a great risk for tilting the on-load tap-changer with risk
for injuries to people and damage of the equipment.

6. Remove the transport locking and the lifting eyes with fasteners from the top
section of the tap selector, see Fig. 12.

CAUTION
Do not operate the tap selector until it is connected to the diverter switch housing.

7. Lift the diverter switch housing in position and fit the tap selector to the diverter
switch housing, see Fig. 16. The tap selector driving pin shall fit into the large
gear wheel slot, see Fig. 16, A-A.

CAUTION
The driving crank on the tap selector must not be moved more than slightly to engage
the slot in the large gear wheel of the diverter switch housing.

8. Insert four M10x40 screws and washers, see Fig. 16, through the tap selector up-
per part to the four supports of the diverter switch housing. Tighten the screws.

WARNING
The diverter switch housing and the tap selector contains moving parts. Be
cautious!

30
3 Installation in the Transformer

9. Connect the supplied conductors between the diverter switch housing and tap
selector, see Fig. 16. The conductor ends and their connecting points have the
same markings. Fasten the conductors with cleats, see Fig. 16, A–A. The number
of conductors is varying depending on the rated through current and the type of
connection.
10. If the impulse withstand voltage to earth exceeds 380 kV, insulate the connections
on the tap selector by winding paper around them to a thickness of approximately
3 mm, see Fig. 10. The paper should be of the same quality as used for insulation
of conductors within the active part of the transformer.
11. If the impulse withstand voltage to earth exceeds 380 kV, mount the supplied
shielding ring (TS 11) at the bottom plate of the tap selector, see Fig. 16, D–D.

CAUTION
After mounting the shielding ring, the on-load tap-changer must not stand on the
shielding ring.

12. Continue with section 3.3.

31
3 Installation in the Transformer

Socket head cap


screw M12 Washer 14x30x2.5
Spring washer
Locking nut M12

Shielding ring (if the


impulse withstand
F F voltage to earth
Diverter switch F–F B–B exceeds 380 kV)
housing, UCL
Shielding rings

Insulating shaft Washer 14x30x2.5


Spring washer

B B Locking nut M12


Socket-head
Conductors cap screw
C–C, 2 // connectors
Spring washer
E
Locking nut M12 Washers 14x30x2.5
A A

Socket-head cap screw

E C–C, single connector

Socket-head cap
screw M8x25 (x4)
Shielding ring,
C C TS 11 Spring washers
Current
collector
Locking nut M8

Tap selector,
D D–D
size III

D
Driving pin of
the tap selector Diverter switch housing
Cleats
Tap selector
Insulating
nut M16

Insulating
stud M16x120 Washer 10.5x24x3 (x4)
E–E
Spring washer
Conductors Slot in the large gear wheel Socket-head cap
of the diverter switch housing screw M10x40 (x4)
A–A
TC_00217

Fig. 16.

32
3 Installation in the Transformer

3.2 Yoke-Mounting
(Pre-mounting on active part of the transformer).
(For Cover-Mounting, see section 3.1).
The top section of the diverter switch housing is designed to be divided into an upper
and a lower flange, see Figs. 18, 19 and 22, to fit the yoke-mounting.

Bevel gear
Transformer active part

On-load
tap-changer
Yoke fork

TC_00120

Fig. 17. Yoke mounting principle

Before lifting and joining the diverter switch housing to the transformer cover, it is
placed on a yoke fork (two beams) which is fastened on the upper transformer yoke,
see Fig. 17.

NOTE: The guiding pins used on the yoke fork should be insulated with bushings in
order to prevent circulating current in the yoke fork when the transformer is in opera-
tion.

The mounting of the on-load tap-changer on the yoke fork can be carried out by two
alternative methods depending on when the transformer ratio measurement is carried
out:
– Transformer ratio measurement is carried out before drying process, see
section 3.2.1.
– Transformer ratio measurement is carried out after drying process, see
section 3.2.2.
For mounting on transformer cover after drying process, see section 3.2.3.

CAUTION
To avoid seizing, do not operate the on-load tap-changer, neither during the drying
process nor afterwards, until the diverter switch housing is filled with oil and the tap
selector is immersed in oil.

33
3 Installation in the Transformer

3.2.1 Mounting when the Transformer Ratio


Measurement is carried out before Drying
1. Assemble the diverter switch housing and the tap selector as follows:
UCG with tap selector I or C, see section 3.1.1, steps 1, 3-7 and 10-12
UCG with tap selector III, see section 3.1.2, steps 1 and 5-12
UCL with tap selector III, see section 3.1.3, steps 1, and 4-12
2. Lift the on-load tap-changer onto the yoke fork (use the lifting eyes at the top of
the on-load tap-changer, see Fig. 3). Place the on-load tap-changer correctly in
position for mounting the outer shaft system (see transformer drawings). Insert
and tighten the supplied guiding pins DS 7 and insulating bushings (not included
in the delivery) in the lower flange, see Fig. 18. The guiding pin shall be secured
by centre punch marks in the pins, see Fig. 20.

Secure with centre


punch marks
Upper flange
O-ring
(35 mm)

Lower flange

Insulating bushing
Yoke fork (not included)

TC_00283
Diverter switch Guiding pin DS 7
Fig. 18. housing (outer dia = 12 mm)

Fig. 20. TC_00121

34
3 Installation in the Transformer

3. Mount the conductors between the regulating winding and the tap selector
according to section 3.3.
4. Carry out transformer ratio measurement according to section 3.4 in this guide.

Position
indicator

”Red point”

TC_00281

Fig. 21.UCG and UCL

Cover

O-ring

Lifting eye for


the diverter
switch Bevel gear

Upper flange
O-ring
O-ring Guiding bar for
Lower flange diverter switch
Plain washer
Spring washer
Screw
TC_00295 UCL Fig. 22.

Locking device
DS 4

TC_00280 UCG

Fig. 23.

35
3 Installation in the Transformer

Oil draining plug

Socket handle

Bottom valve key


DS16, key-width
10 mm

Oil draining tube

TC_00297

Fig. 24.

5. Dismantle the diverter switch housing cover, see Fig. 22, by removing the screws.
Store the cover, fasteners and O-ring in a dust-free place.
6. If vapour phase process is going to be used: Remove the plug in the T-coupling
for the oil draining tube. To open the bottom valve, let the ”bottom valve key”
(DS16), slide down through the oil draining tube and, when it has gripped the
valve, rotate it in anti-clockwise direction until there is stop after approximately 6
turns, see Fig. 24. Remount the dismantled plug.
7. Dismantle the diverter switch by carefully lifting it straight out of the diverter
switch housing by its lifting eye, see Fig. 22. Store the diverter switch in a dry
and dustfree place.
8. Remove the oil draining tube by hand or by means of a pipe wrench, using a cloth
between the tube and the pipe wrench to protect the tube. Store the tube in the
diverter switch housing until it is remounted.
9. Remove the four clamp screws, M10 x 35, and the washers which hold the bevel
gear, see Fig. 22. Note the position of the bevel gear. Remove the gear housing
carefully. Take care of all details. Store the bevel gear in a dust-free place.
CAUTION
Do not remove the locking device of the bevel gear.

10. Mount the locking device DS 4 on the driving shaft of the on-load tap-changer,
see Figs. 22 and 23.
CAUTION
The driving shaft must not be rotated.

36
3 Installation in the Transformer

11. The guide bar for positioning of the diverter switch type UCL in the housing is
fixed in the upper flange with screw and washers, see Fig. 22. Remove the screws
and washers. Store the guide bar in the diverter switch housing until it is
remounted. Take care of screws and washers.
12. Remove the nuts and washers inside the upper flange and remove the flange by
lifting in the lifting eyes. Store the upper flange, and the O-ring in a dust-free
place. Take care of nuts and washers.
13. The on-load tap-changer is now ready for drying together with the transformer.
Follow instructions in chapter 4.

3.2.2 Mounting when the Transformer Ratio


Measurement is carried out after Drying
1. Assemble the diverter switch housing and the tap selector as follows:
UCG with tap selector I or C, section 3.1.1, steps 1, 3-7 and 10-12
UCG with tap selector III, section 3.1.2, steps 1 and 5-12
UCL with tap selector III, section 3.1.3, steps 1 and 4-12.
2. UCG: Follow instructions according to section 3.2.1, steps 5-11.
UCL: Follow instructions according to section 3.2.1, steps 5-13.

Max 90o

Lifting equipment

TC_00224

Fig. 25.

37
3 Installation in the Transformer

3. Apply the lifting equipment LL 136 016-D for UCL and LL 135 016-A for UCG
in position according to Fig. 25.

NOTE: The lifting equipment must be tilted when applying.

Lift the on-load tap-changer onto the yoke fork (use the lifting equipment, see
Fig. 25). Place the on-load tap-changer correctly in position for mounting the
outer shaft system (see transformer drawing). Insert supplied guiding bolts DS 7,
and insulating bushings (not included in delivery) in the lower flange, see Fig. 20.
The guiding bolts shall fit into the holes in the yoke fork and be secured by punch
marks in the pins. When the on-load tap-changer is in place, remove the lifting
equipment.
4. Mount the conductors between the transformer winding and the tap selector
according to section 3.3.
5. The on-load tap-changer is now ready for drying together with the transformer.
Follow the instructions in chapter 4.

3.2.3 Mounting on Transformer Cover


(After drying process.)

1. After the transformer cover is mounted, place the gasket in the flange for the on-
load tap-changer. (This gasket is not included in the on-load tap-changer deli-
very).

NOTE: Do not insert the studs for the upper flange in the transformer cover flange.
This is carried out in step 8.

2. Remove the locking device DS 4 from the driving shaft, see Figs. 22 and 23.

CAUTION
Be careful not to drop the locking device and the screw.

CAUTION
The driving shaft must not be rotated.

3. Place the O-ring in its groove in the lower flange, see Fig. 18.
4. Place the upper flange over the opening in the transformer cover. Turn the upper
flange so the flange for the bevel gear is aligned with the driving shaft. The
screws in the lower flange shall fit into the holes in the upper flange, see Fig. 26.

38
3 Installation in the Transformer

Locking nut
M8 (20x) Upper flange
Spring washer Studs M12 (24x)
Nuts M12
Plain washer
8.4x20x2 Washers

O-ring

Lower flange

Yoke fork

TC_00296

Fig. 26.

5. Lift the on-load tap-changer slowly until it just touches the upper flange.
The lift can take place by using the lifting equipment LL 136 016-D for UCL and
LL 135 016-A for UCG, see Fig. 26. Apply the equipment in the lower flange
sides. The lifting equipment has to be tilted when mounted and dismounted, see
Fig. 25.
6. When the flanges touch, mount twenty M8 locking nuts and washers. Tightening
the nuts alternately until fully home. Retighten all nuts with 24.5 Nm. After tight-
ening the nuts, remove the lifting equipment.
7. Place the O-ring of the bevel gear in its groove in the upper flange, see
Fig. 27. Remount the bevel gear unit in the position it had before dismantling, and
make sure that the pin in the spherical shaft end fits into the driving shaft slot,
without rotating the driving shaft. Fix the gear unit in the flange by its four
clamps screws M10x35 and washers.

39
3 Installation in the Transformer

CAUTION
The gear box must not be forced down! If the coupling does not engage, lift the gear
box and adjust the setting of the driving pin.

Fixing clamps

Pin

O-ring
Slot in the
driving shaft

TC_00127

Fig. 27.

8. Insert twenty-four studs, see Fig. 26, through holes in the upper flange, down into
threaded holes in the flange of the transformer cover. If the studs do not fit, the
position of the on-load tap-changer must be adjusted, which may require lifting.
Lift in the lifting eyes as shown i Fig. 3. After mounting the studs, remove the
lifting equipment and tighten the nuts.
9. Mount the oil draining tube, see Fig. 24. If a pipe wrench is used, there must be a
cloth protection between the wrench and the tube.
10. Mount the guide bar for the diverter switch, see Fig. 22. Mount washers and
screw and tighten.

40
3 Installation in the Transformer

11. Remove the plug at the end of the T-coupling, see Fig. 28, slide down the ”bottom
valve key”, and close the valve by turning the key clockwise approximately 6
turns. Tighten with 40 Nm. Remount the plug.
12. Install the diverter switch according to section 4.3.

Plug
40 Nm

Oil draining
tube
TC_00230

Fig. 28.

41
3 Installation in the Transformer

3.3 Connection to Terminals


Connection to the tap selector should follow the connection diagram supplied with the
on-load tap-changer.
In order to obtain maximum reliability of the tap selector contacts, the temperature
rise of the conductors connected to the tap selector should be kept as low as possible
and should in no case exceed 30K above the surrounding oil.
CAUTION
All terminals must have conductors or connections.

If there are connections between parallel conductors from the diverter switch on the
tap selector terminal, the parallel conductors from the active part of the transformer
shall also be connected together on the tap selector terminals (in order to avoid
circulation currents through the tap selector contacts, see Fig. 31).

Conductors from
the diverter switch
Tap selector

Conductors from the


active part of the
transformer

Connection Connection

TC_00130

Fig. 29.

If the impulse withstand voltage to earth exceeds 380 kV, the conductor connections
on the tap selector shall be insulated by winding paper around them to a thickness of
3 mm, see Fig. 10. The paper should be of the same quality as used for insulating
conductors within the active part of the transformer.

CAUTION
All connections should be made carefully and in such a way that there is no risk that
they can become disconnected. The conductors must not cause mechanical strain on
the tap selector terminal. Each conductor should be curved to take up expansion. See
Fig. 30.

42
3 Installation in the Transformer

Tap selector Terminal

TC_00130
Expansion bend
Faulty Correct

Fig. 30.

NOTE: When yoke mounted, inserts (wooden blocks, or similar) are placed between
the yoke fork and the lower flange of the diverter switch housing, see Fig. 31, making
the conductors mounted at correct final height. The wooden blocks must be removed
before mounting the on-load tap-changer on the transformer cover.

Lower flange

Yoke fork
beam

Inserts
TC_00232
Fig. 31.

CAUTION
It is recommended that the distance between the cylinders or the bars of the tap
selector and any conductor is at least 50 mm. The transformer manufacturer is
responsible for keeping sufficient large insulation distances.

43
3 Installation in the Transformer

3.4 Transformer Ratio Measurement


The transformer ratio measurement may be carried out before or after the drying
process.
If it is carried out before drying, no drive system is mounted. The on-load tap-changer
has thus to be operated directly on the shaft coupling of the bevel gear on the upper
flange. A special hand crank can be ordered from ABB, see section 1.2 ”Required
Tools” in this guide.
If it is carried out after drying, it is recommended to be carried out when the drive
system is mounted, after ”Final Assembly”, see chapter 5 in this guide, to simplify the
operation of the on-load tap-changer.

CAUTION
The on-load tap-changer should be operated through the whole operating range, both
in lower and raise direction, when carrying out ratio measurement.

CAUTION
Before process, the on-load tap-changer is allowed to be operated maximum three
times through the regulating range unless it is not oil immersed. After process the on-
load tap-changer has to be immersed in oil before operating.

CAUTION
The end positions must not be overrun during ratio measurement. When operating the
on-load tap-changer without drive system, check the designation of the end positions
on the single phase diagram and watch the position indicator in the bevel gear in
order to avoid overrunning of the end position.

CAUTION
Watch the voltmeter during the on-load tap-changer operations. No fast voltage drops
may occur during operation. If such drops occur, the diverter switch is installed
incorrectly or the on-load tap-changer is not correctly connected to the winding.

44
3 Installation in the Transformer

3.4.1 Transformer Ratio Measurement before Drying


1. Remove the locking device from the gear unit on the upper flange, see Fig. 32.
Keep the locking device for remounting after transformer ratio measurement.
Also remove the cover of the bevel gear to get access to the position indicator.
Keep all fasteners and the gasket for remounting. Note the position of the on-load
tap-changer.
Locking device

TC_00275 TC_00276

UCG and UCL.N or E UCG and UCL.T or B

Fig. 32.
2. Operate the on-load tap-changer by applying the special hand crank mentioned
above on the shaft coupling of the bevel gear. Adjust the length of the handle. Be
careful not do damage the coupling.

NOTE: When operating through the middle position on an on-load tap-changer with
change-over selector, the torque on the hand crank will be higher.

3. After the measurement, the on-load tap-changer must be operated in the direction
and to the position shown in the single-phase diagram as the delivery position.
The right position designation should be shown in the ”window” in the position
indicator in the bevel gear of the on-load tap-changer and the ”window” should
face the red point in the bevel gear housing exactly, see Fig. 21. Then remount the
locking device on the bevel gear and the cover of the bevel gear. Fit the gasket
properly.

3.4.2 Transformer Ratio Measurement after Drying


Carry out this measurement after the drive system is mounted.
Operate the on-load tap-changer by means of the motor-drive mechanism.
Operate the on-load tap-changer in the direction and to the position shown in the
single-phase diagram as the delivery position after the measurement.

45
4 Drying

4 Drying
The on-load tap-changer is dried together with the transformer using one of the
following processes: alternating hot-air and vacuum or vapour-phase at a temperature
of max. 135 °C (275 °F).

4.1 Observations before Processing


1. If not earlier done, lift the diverter switch out from the housing, see section 3.2.1
steps 5 and 7. The pressure relay with its test vent and the oil filter, if any, should
be dismantled and kept protected from dust e.g. in a plastic bag or in their original
packing.
2. Do not expose the diverter switch housing to any pressure difference between in-
side and outside during the vapour-phase process. During the hot air and vacuum
process, the maximum permitted pressure differential is 100 kPa at a temperature
of 135 °C (275 °F).
During the vapour-phase process the bottom valve of the diverter switch housing
should be open. To open the bottom valve, proceed as follows, see Fig. 24:
a. Remove the plug on top of the oil draining tube, see Fig. 24.
b. Use the bottom valve key through the oil draining tube, see Fig. 24.
c. Turn the valve anticlockwise to its stop, approximately 6 turns.
d. Remount the plug.
e. Remove the O-ring in the lower flange (for mounting on active part only)
before process.

4.2 Observations after Processing


CAUTION
To avoid seizing, do not operate the on-load tap-changer, neither during the drying
process nor afterwards, until it is filled with oil.

1. Make sure that all liquid has been drained from the diverter switch housing when
vapour-phase process has been carried out. When cover mounted, close the
bottom valve, see section 3.2.3, step 10. When yoke-mounted, the valve is closed
during reassembly of the top section.
CAUTION
Make sure the bottom valve key is removed after the valve has been closed.

2. The cleats, on the upper section of the tap selector, holding the conductors
between the diverter switch housing and the tap selector should be retightened
(tightening torque 15 Nm) and locked by method specified by the transformer
manufacturer for similar screw joints.
3. If a tie-in resistor from ABB is supplied, its screw joints are to be retightened
(tightening torque 15 Nm) and locked by the method specified by the transformer
manufacturer for similar screw joints.

46
4 Drying

4.3 Installation of Diverter Switch


When yoke-mounted, carry out section 3.2.3 before installing the diverter switch.

CAUTION
Check the serial numbers to make sure that the diverter switch is mounted in the
correct housing, see Fig. 1.

CAUTION
Make sure that the diverter switch housing is clean and dry and that no foreign
objects (tools etc.) are left in the housing.

CAUTION
Lower the diverter switch into its housing carefully so that neither the diverter switch
nor the housing are damaged.

The diverter switch is provided with guiding slots that fit against the guide bar and the
oil draining tube in the diverter switch housing, see Fig. 33.
Rotate the diverter switch so the half-circle shaped guiding slot is aligned with the oil
draining tube, see Fig. 33.
When the diverter switch is lowered, check visually that its plug-in contacts are
aligned with the contacts in the cylinder wall.
In order to ensure that the diverter switch pin has engaged the coupling disc, carry out
at least three tap change operations in one direction. A distinct sound is heard when
the diverter switch operates which indicates that the driving pin of the diverter switch
has been connected.
If no sound is heard, the diverter switch might need to be pushed down while opera-
ting the motor drive.
Carry out another three operations in the same direction while pushing the diverter
switch down.

NOTE: The UCL diverter switch: It may be necessary to push and pull the lifting
device of the diverter switch a little to and fro while pushing it down.

The top part of the diverter switch lifting device should be below the level of the
machined surface for the cover when lowered to its final position. Only the springs of
the lifting device should be above this level.
Insert the O-ring for the cover in the upper flange. Mount the on-load tap-changer
cover. Turn the cover so the guiding pin in the housing is facing the guiding hole in
the cover. (The cover has to be pressed down in order to overcome the spring force of
the springs that hold the diverter switch pressed in place). Insert screws and washers
and tighten them.

47
4 Drying

Springs
Lifting device

Shielding-ring (when the impulse withstand


voltage to earth exceeds 380 kV)
(not on UCG short version)

Transition resistors
(Layed down on UCG short type)

Serial number
(on the opposite
side of the Plug-in contacts
diverter switch) A A
Guiding pin
Guiding pin Tie rod
fm_00223
Driving pin
Coupling disc

Notch for the


Holes for guiding pins
driving pin Slot for guiding bar

Guiding bar
for the Guiding pins
diverter
switch Slot for the oil
draining tube

Oil draining A–A,


tube
UCL
TC_00233
UCL
Diverter switch housing,
view from above
Coupling disc
Notch for the
driving pin
Slot for guiding
Holes for bar
guiding pins
Guiding pins
Guiding bar
for the Slot for the oil
diverter draining tube
switch

Oil draining A–A,


TC_00284
tube TC_00285
UCG
UCG
Diverter switch housing,
view from above

Fig. 33.

48
5 Final Assembly

5 Final Assembly
5.1 Mounting of the Motor-Drive Mechanism
See Figs. 34 and 35.
Proceed as follows:
1. Mount the motor-drive mechanism onto the transformer. The mounting holes on
the transformer should be leveled within 1 mm. If adjustment is needed, shims
should be used.
2. Install the bevel gear SA 21 on the edge of the transformer cover, see Fig. 36.
3. Check that the position indicator in the motor-drive mechanism shows the same
position as the indicator inside the bevel gear of the on-load tap-changer. (The
cover has to be dismantled).

WARNING
Do not energize the transformer before the on-load tap-changer and the motor-
drive mechanism are correctly assembled.

49
5 Final Assembly

Exact position

TC_00258

Tolerances
Transformer

The same indicated


tap position

Position indicator
TC_00141

Brake disc TC_00203


Adjustment nuts

Red mark

Brake assembly

Fig. 34. Position alignment for UCG, UCL with motor-drive mechanism type BUE

50
5 Final Assembly

Exact position

TC_00258

Transformer

Tolerances

The same indicated


tap position

Indicator flag

Position indicator fm_00224

TC_00253

Roller on the brake


arm in the notch of
the cam disc Brake arm

Cam disc

Contra nut
fm_00225

Brake disc
Adjusting screw

Fig. 35. Position alignment for UCG, UCL with motor-drive mechanism type BUL

51
5 Final Assembly

5.2 Mounting of External Drive Shafts


The external drive shafts consists of square tubes and should be connected to the
spherical shaft ends on bevel gears and motor-drive mechanism by means of two
coupling halves. The square shafts and protective tubes must be cut before mounting.

CAUTION
Before mounting of shafts and couplings, everything must be cleaned and greased for
correct function and to avoid corrosion.

Apply a thin layer of grease, GULF-718EP Synthetic grease or Mobilgrease 28 or


SHELL-Aero Shell Grease 22 to all spherical shaft ends and unpainted surfaces of the
bevel gears.

NOTE: The multihole couplings should be greased.

The inclination of the shaft (the square tube) must not be more than 4o (=70mm for
every 1000 mm shaft length).

NOTE: The tubes around shafts and couplings are for protection.

The arrangement of the driving shaft system is shown in Fig. 34.

CAUTION
Make sure that all locking devices (on the bevel gear, on the on-load tap-changer and
in the motor-drive) are mounted and the on-load tap-changer and the motor-drive are
in the same service position.

Check that the motor-drive mechanism is in its exact position according to Fig. 34 or
35. (BUE: The red mark on the brake disc facing the red mark on the brake assembly.
BUL: The roller in the middle of the notch in the cam disc). If not, loosen the locking
device and adjust it to its exact position, see Fig. 40. Remount the locking device.

NOTE: Let the parts of the shaft system that should be dismantled before transporting
the transformer to site keep their identification numbers according to the packing list
to simplify the remounting of the shaft system on site.

52
NB! The slot in the
protective tube
Unit Unit Unit
SA33 –3 SA10 SA25 SA10 – 2 SA10 SA30 SA25 SA10 – 1 SA10 SA25 SA10 facing downwards

SA36 SA34 SA35 SA32 SA31 SA24 SA22 SA23


Connection type T TC_00235

Unit Unit
SA33 –2 SA10 SA25 SA10 –1 SA10 SA25 SA10 SA21

SA18
SA19

Fig. 36.
SA17
SA32 SA30 SA31 SA22 SA23
Connection type B SA24 TC_00236

SA 10 Hose Clip Unit


–1 SA10 SA25 SA21
SA 11 Coupling halves
SA 12 Hexhead cap screw M6 SA18
SA 13 Washer SA19
SA 14 Vertical square shaft SA17
SA 15 Vertical protective tube SA24 SA22 SA23
SA 16 Vertical protective tube SA10
SA20
SA 17 Clamp Connection type N or E SA12, SA 13
SA 18 Hexhead bolt M10
SA 19 Washer SA25 SA11
SA 20 O-ring
SA16
SA 21 Bevel gear
SA 22 Horizontal square shaft to unit -1
SA 23 Horizontal protective tube to unit -1
SA 24 Horizontal protective tube to unit -1 TC_00168
SA 25 Information plate SA15
SA 30 Horizontal square shaft to unit -2
SA14
SA 31 Horizontal protective tube to unit -2
SA 32 Horizontal protective tube to unit -2 SA11
SA 33 Cover SA12, SA13
SA 34 Horizontal square shaft to unit -3 SA10
SA 35 Horizontal protective tube to unit -3
SA 36 Horizontal protective tube to unit -3 BUL BUE
TC_00239 TC_00237
5 Final Assembly

53
Motor-drive mechanism
5 Final Assembly

5.2.1 Mounting of Vertical Drive Shaft


1. Mount the bevel gear SA21 on the transformer, with O-ring SA20, four clamps
SA17, hexagon head bolts M10, SA18 and washers SA19, see Fig. 36.
2. Determine the dimension K2 between the spherical shaft ends, see Fig. 37a.
3. Cut the vertical square shaft, SA14, to dimension = K2 minus 6 mm. Remove the
burrs.
4. Cut the protective tubes SA15 and SA16 so both of them get the same length LB2
according to the table 3 below.

Table 3. Length dimensions for LB2.


K2 = 200 to 290 mm K2 = 291 to 600 mm K2 = greater than 600 mm

LB2 = K2+180 mm LB2 = K2+220 mm LB2 = K2+410 mm


2 2 2

Example: K2 measured to 350 mm. LB1 is then = 350+220 = 570 = 285 mm


2 2

5. See Fig. 37c. Fit two coupling halves, SA11, on one end of the square shaft with
six screws SA12 and washers SA13. Push the shaft to the bottom of the fitting in
the coupling halves, see Fig. 37h. Tighten the two screws A first, see Fig. 37k,
and then the other. Put on the two protective tubes, SA15 and SA16, (the greater
diameter upmost) and two hose clips SA10.
6. See Fig. 37d. Connect the square shaft with the mounted coupling halves to the
shaft of the bevel gear. Mount two coupling halves SA11 to the other end of the
square shaft and the shaft of the motor-drive mechanism. Push the shaft to the
bottom of the fitting in the coupling halves, see Fig. 37h. Tighten the screws
lightly and check that the shaft can be moved approximately 2 mm in axial
direction (axial play). Check the dimension shown in Fig. 37f. Tighten the screws
A first and thereafter the other.
7. Fig. 37e. Mount the tube with the greater diameter, SA16, to the bevel gear with a
hose clip and the other SA15 to the flange on the motor-drive mechanism with a
hose clip. Leave about 3 mm play to the flange ring (see Fig. 37g) for water
draining.

NOTE: The tube with greater diameter shall be mounted to the bevel gear.
NOTE: Tighten always the screws A first and then the other, according to Fig. 37k.

54
5 Final Assembly

SA21

SA11 SA10

SA10 SA16

SA16

SA15
SA15
SA10
SA14
SA14

BUE
TC_00147

Fig. 37a. Fig. 37c. Fig. 37d. Fig. 37e.

Min. 3, max 5 mm
SA26
K2

Driving pin
Max 6 mm

SA27, SA28
SA15
SA29

SA10

TC_00148 TC_00149
BUL Fig. 37g.

Fig. 37b. Fig. 37f.

Square shaft

A
Max 3 mm

SA11

SA13

SA12
TC_00147
TC_00170

Fig. 37h. Fig. 37k. A

55
5 Final Assembly

5.2.2 Mounting of Horizontal Drive Shafts,


types UCG.N/UCL.N and UCG.E/UCL.E
The following applies to the fitting of drive shafts and protective tubes when the on-
load tap-changer consists of one unit, UCG.N/UCL.N or UCG.E/UCL.E.
1. Determine the dimension K1 between the spherical shaft ends, see Fig. 38a.

TC_00286

UCG K1

TC_00241
UCL
Fig. 38a.

2. Cut the horizontal square shaft SA22 to dimension = K1 minus 6 mm. Remove
the burrs.
3. Cut the protective tube SA23 and SA24 in the unslotted end so that both of them
get the same length LB1 according to the table 4 below.

NOTE: Protective tube SA23 has one slotted end.

Table 4. Length dimension for LB1


K1 = 170 to 290 mm K1 = 291 to 600 mm K1 = greater than 600 mm

LB1 = K1+200 mm LB1 = K1+250 mm LB1 = K1+500 mm


2 2 2

Example: K1 measured to 400 mm. LB1 is then = 400+250 = 650 = 325 mm


2 2

NOTE: If K1 is greater than 600 mm the mounted tubes shall overlap each other at
least 300 mm. Dismounting and inspection of the couplings should be possible when
one of the tubes is pushed into the other.
4. Fit two coupling halves, SA11, on one end of the square shaft with six screws
SA12 and washers SA13. Push the shaft to the bottom of the fitting in the
coupling halves, see Fig. 37h. Tighten the two screws A first and then the others,
see Fig. 37k. Put on the two protective tubes, SA23 and SA24, the slotted end of
SA23 in the non-overlapping end, and two hose clips SA10, see Fig. 38b.
LB1
Slotted end

SA14 SA24 SA10 SA23 SA11


TC_00148
Fig. 38b.

56
5 Final Assembly

Spherical coupling part A SA24 SA10 SA23 Slot SA21

SA12 SA11
SA13

TC_00242
Fig. 38c.

5. Dismount the locking device on the bevel gear of the diverter switch housing by
loosening the two set screws, see Fig. 38g.
6. Connect the square shaft with the mounted coupling halves to the shaft of the
bevel gear SA21, see Fig. 38c. Mount two coupling halves SA11 to the other end
of the square shaft and to the shaft of the bevel gear on the on-load tap-changer.
Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 37h.
Tighten light the screws and check that the shaft can be moved approximately
2 mm in axial direction (axial play). Check the dimension shown in Fig. 37f.
Tighten the two screws A first and thereafter the other, see Fig. 37k.
7. The motor-drive mechanism and the on-load tap-changer should have the same
indicated tap position and be in their exact positions. Remove the cover of the
gear box on the on-load tap-changer to get access to the position indicator, see
Figs. 34 and 35.
The motor-drive mechanism and on-load tap-changer are in the same position
when the position indicators in bot of them show the same position, see Figs. 34
and 35.
The motor-drive mechanism is in the exact position since section 5.2 has been
carried out.
The on-load tap-changer is in exact position when the ”window” where the posi-
tion is read in the bevel gear is facing the red point in the gear box housing
exactly, see Fig. 34 or 35.
If the gear box is not in its exact position, see Fig. 34 or 35, loosen the two screws in
the multihole coupling on the gearbox and find the position of the screws that
positions the opening in the brass toothed wheel closest to the red point in the gear
box housing. The maximum deviation from exact alignment is given in Figs. 34 and
35. Tighten the screws. Remount the cover and the gasket of the gearbox on the on-
load tap-changer, see Fig. 27.
CAUTION
Assembly with the on-load tap-changer and the motor-drive mechanism in different
operating positions may cause a transformer break down.

WARNING
The bevel gear contains moving gears. Be cautious!

57
5 Final Assembly

Disc

M8 screw

Driving pin

TC_00150

Fig. 38d.

SA10 SA24 SA25 SA23 SA25 SA10 SA21

Slot facing
downwards

TC_00243

SA23
TC_00148

Fig. 38e.

8. Push the two protective tubes on to the bevel gears and clamp them with hose
clips, SA10, see Fig. 38e.

NOTE: The slot of the protective tube SA23 should be facing downwards.

Apply the self-adhesive information plates SA25 around the tubes on about the
middle of the tube length.

Locking device

TC_00287

Fig. 38g.

58
5 Final Assembly

5.2.3 Mounting of Horizontal Drive Shafts,


Type UCG.B/UCL.B
The following applies to the fitting of drive shafts and their protective tubes when the
on-load tap-changer consists of two units of type UCG.B/UCL.B. The on-load tap-
changer phase, which is placed closest to the driving mechanism, is called unit -1, the
second unit -2, see Fig. 36.
1. Determine the dimension K1 between the spherical shaft ends, see Fig. 39a.
K1

TC_00241
Fig. 39a.

2. Cut the horizontal square shaft SA22 to dimension = K1 minus 6 mm. Remove
the burrs.
3. Cut the protective tube SA23 and SA24 in the unslotted end so that both of them
get the same length LB1 according to the table 4 below.

NOTE: Protective tube SA23 has one slotted end.

Table 4. Length dimension for LB1


K1 = 170 to 290 mm K1 = 291 to 600 mm K1 = greater than 600 mm

LB1 = K1+200 mm LB1 = K1+250 mm LB1 = K1+500 mm


2 2 2

Example: K1 measured to 400 mm. LB1 is then = 400+250 = 650 = 325 mm


2 2

NOTE: If K1 is greater than 600 mm the mounted tubes shall overlap each other at
least 300 mm. Dismounting and inspection of the couplings should be possible when
one of the tubes is pushed into the other.
4. Fit two coupling halves, SA11, on one end of the square shaft with six screws
SA12 and washers SA13. Push the shaft to the bottom of the fitting in the
coupling halves, see Fig. 37h. Tighten the two screws A first and then the others,
see Fig. 37k. Put on the two protective tubes, SA23 and SA24, the slotted end of
SA23 in the non-overlapping end, and two hose clips SA10, see Fig. 39b.
LB1
Slotted end

SA14 SA24 SA10 SA23 SA11


TC_00148

Fig. 39b.

59
5 Final Assembly

Spherical coupling part A SA24 SA10 SA23 Slot SA21

SA12 SA11
SA13
TC_00242
Fig. 39c.

5. Dismount the locking device on the bevel gear of the diverter switch housing by
loosening the two set screws, see Fig. 39f.
6. Connect the square shaft with the mounted coupling halves to the shaft of the
bevel gear SA21, see Fig. 39c. Mount two coupling halves SA11 to the other end
of the square shaft and to the shaft of the bevel gear on the on-load tap-changer.
Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 37h.
Tighten light the screws and check that the shaft can be moved approximately
2 mm in axial direction (axial play). Check the dimension shown in Fig. 37f.
Tighten the two screws A first and thereafter the other, see Fig. 37k.
7. The motor-drive mechanism and the on-load tap-changer should have the same
indicated tap position and be in their exact positions. Remove the cover of the
gear box on the on-load tap-changer to get access to the position indicator, see
Figs. 34 and 35.
The motor-drive mechanism and on-load tap-changer are in the same position
when the position indicators in bot of them show the same position, see Figs. 34
and 35.
The motor-drive mechanism is in the exact position since section 5.2 has been
carried out.
The on-load tap-changer is in exact position when the ”window” where the posi-
tion is read in the bevel gear is facing the red point in the gear box housing
exactly, see Fig. 34 or 35.
If the gear box is not in its exact position, see Fig. 34 or 35, loosen the two screws in
the multihole coupling on the gearbox and find the position of the screws that
positions the opening in the brass toothed wheel closest to the red point in the gear
box housing. The maximum deviation from exact alignment is given in Figs. 34 and
35. Tighten the screws. Remount the cover and the gasket of the gearbox on the on-
load tap-changer, see Fig. 27a. Make sure the slot in the gasket and the cutout in the
cover is positioned above the conical gear.
CAUTION
Assembly with the on-load tap-changer and the motor-drive mechanism in different
operating positions may cause a transformer break down.

WARNING
The bevel gear contains moving gears. Be cautious!

60
5 Final Assembly

Disc

M8 screw

Driving pin

TC_00150

Fig. 39d.

SA10 SA24 SA25 SA23 SA25 SA10 SA21

Slot facing
downwards

TC_00243

SA23
TC_00148

Fig. 39e.

8. Push the two protective tubes on to the bevel gears and clamp them with hose
clips, SA10, see Fig. 39e.

NOTE: The slot of the protective tube SA23 should be facing downwards.

Apply the self-adhesive information plates SA25 around the tubes on about the
middle of the tube length.
9. Mount the cover SA33 and tighten the two set screws (taken from the locking
device).

Locking device

Set screws

Cover SA 33

TC_00244

Fig. 39f.

61
5 Final Assembly

10. Determine the dimension K3 between the spherical shaft ends, see Fig. 39g.

K3

TC_00247

Fig. 39g.

11. Cut the horizontal square shaft SA30 to dimension = K3 minus 6 mm. Remove
the burrs.
12. Cut the protective tubes SA31 and SA32 in the unslotted end to the dimension
LB3 = K3+500 mm, see Fig. 39h.
2

LB3

SA30 SA32 SA10 SA31 SA11


TC_00148

Fig. 39h.

13. Fit two coupling halves, SA11, on one end of the square shaft with six screws
SA12 and washers SA13. Push the shaft to the bottom of the fitting in the
coupling halves, see Fig. 37h. Tighten the two screws A first and then the others,
see Fig. 39h. Put on the two protective tubes, SA31 and SA32, the slotted end of
SA31 in the non-overlapping end, and two hose clips SA10, see Fig. 39h.
14. Dismount the locking device on the bevel gear of the diverter switch housing by
loosening the two set screws, see Fig. 39f.

62
5 Final Assembly

Disc Coupling A SA10 SA10

SA12 SA11 SA32 SA30 SA31


TC_00245
SA13

Fig. 39k.

15. Connect the square shaft with the mounted coupling halves to the shaft of the
bevel gear closest to the motor drive, see Fig. 39k. Mount two coupling halves
SA11 to the other end of the square shaft and to the shaft of the bevel gear on the
on-load tap-changer. Push the shaft to the bottom of the fitting in the coupling
halves, see Fig. 37h. Tighten light the screws and check that the shaft can be
moved approximately 2 mm in axial direction (axial play). Check the dimension
shown in Fig. 37f. Tighten the two screws A first and thereafter the other.
The unit should be in the same service position as the adjacent unit and be in the
exact position. Compare with the adjacent unit and adjust this unit as described in
section 5.2.3, point 7 if necessary.

WARNING
The bevel gear contains moving gears. Be cautious!

Locking device

Cover SA 33 Set screw SA10 SA25 SA10

SA32 SA31
TC_00246

Fig. 39m.

16. Push the two protective tubes on the bevel gears and clamp them with the hose
clips SA10, see Fig. 39m. Apply the self-adhesive information plates SA25 aro-
und the tubes on about the middle of the tube length.

NOTE: The slot of the protective tubes should be facing downwards.

17. Mount the protection cover SA33. Tighten the two sets screws, (taken from the
locking device), see Fig. 39m.

63
5 Final Assembly

5.2.4 Mounting of Horizontal Drive Shafts,


Types UCG.T/UCL.T and UCGYD/UCLYD
The following applies to the fitting of drive shafts and their protective tubes when the
on-load tap-changer consists of three phases UCG.T/UCL.T or UCGYD/UCLYD.
The on-load tap-changer unit, which is placed closest to the driving mechanism, is
called unit -1, the next unit -2 and the last unit -3, see Fig. 36.

1. Mount the drive shaft to the on-load tap-changer unit -1 according to section
5.2.3, steps 1–8 above.
2. Mount the drive shaft between unit -1 and unit -2 according to section 5.2.3, steps
1–8 above.
3. Mount the drive shaft between unit -2 and unit -3 according to section 5.2.3, steps
2–9 above.

NOTE: The shaft is here called SA34, the protective tube closest to unit -2 is called
SA35 and the other protective tube is called SA36.

4. In cases where a support bearing is used, follow appropriate parts of section 5.2.3,
steps 2–8 above.
WARNING
The bevel gear contains moving gears. Be cautious!

5.2.5 Before Operation


1. Check again that the on-load tap-changer and the motor-drive mechanism are in
the same position.
2. Remove the locking device of the motor-drive mechanism, see Fig. 40.

NOTE: If transformer ratio measurement is to be done after drying, this is a suitable


stage to carry it out, see section 3.4.2.

Locking device

TC_00262 fm_00208

BUE BUL

Fig. 40. Locking device of motor-drive mechanism

64
5 Final Assembly

5.3 Pressure Relay


5.3.1 General
The diverter switch housing of the on-load tap-changer is supplied with a pressure
relay. In the event of overpressure in the diverter switch housing, the relay, if correctly
connected, trips the transformer main circuit breakers. It is also recommended to
connect the pressure relay in the trip circuit of the power supply during testing of the
transformer.
CAUTION
After a pressure relay trip, follow the instructions in the chapter ”Pressure Relay” in
the Repair Guide.

CAUTION
To take the transformer into service after a pressure relay trip without carrying out a
careful investigation of the diverter switch by lifting it out of the diverter switch
housing, and repairing faults, if any, may cause severe damages to the on-load tap-
changer and the transformer.

The pressure relay can easily be tested by applying air pressure by means of a pump to
the test tap on the valve and the handle can be pad-locked in the service position.

CAUTION
The pressure relay is a calibrated monitoring instrument. It must be handled with care
and protected against careless handling or any kind of mechanical damage. Do not
open the package of the pressure relay until you are about to install it on the on-load
tap-changer.

5.3.2 Installation
Remove the cover from the flange on the upper part of the on-load tap-changer and
install the pressure relay. Make sure that the gasket is correctly fitted.
Remove the cover from the pressure relay and connect the cables to the terminal
block.
The cable gland includes an O-ring sealing between the gland and the pressure relay
housing.
If the gland has to be changed to another type, the seal against the housing must be
secured by a gasket or sealing liquid (example Loctite 275).

CAUTION
Tighten the cable gland with care, torque max 5 Nm.

65
5 Final Assembly

5.3.3 Checking at Commissioning of the Transformer

Information
plate

Valve handle

Test tap (R 1/8”)


TC_00264

Fig. 41. Pressure relay

1. Set the valve handle in the test position as shown on the information plate.
2. Connect the air pump and the pressure gauge to the test tap on the pressure relay.
3. Raise the pressure until the pressure relay trips the circuit breakers for the trans-
former.
4. Read the pressure on the manometer and check against the pressure stated on the
information plate. Max. permitted deviation is ± 10 %.
5. Check that the alarm signal disappears when the pressure is lowered.
6. After finishing the check, turn back the valve handle to service position.

66
5 Final Assembly

5.4 Assembly of Accessories


All details which have been removed for the transport are specified on the packing
list. The openings on the on-load tap-changer are sealed by a transport cover.
1. Remove the transport covers.
2. Check the O-rings. Make sure they are pressed into the bottom of the groove on
the flanges.
3. Assemble all remaining accessories. Tightening torque for the nuts according to
section 1.8.

5.5 Connection to the Oil Conservator


NOTE: If oil filling is carried out under vacuum without oil conservator, this section
is carried out after the oil filling.

Remove the transport cover on the flange for connection to the oil conservator. Make
sure the O-ring is in place on the flange and connect the pipe to the oil conservator.
Tighten the nuts.
CAUTION
In case where the conservator is common for the transformer and the on-load tap-
changer, an oil filter must be placed in the pipe between the on-load tap-changer and
the conservator.

Oil filter with housing can be ordered from ABB.

67
6 Oil Filling

6 Oil Filling
6.1 Filling Methods and Restrictions
Oil filling can be carried out at atmospheric pressure or under vacuum. The wall
between the diverter switch housing and the transformer tank is designed to withstand
vacuum on one side and atmospheric pressure on the other side. It is not allowed to
have vacuum on one side and the pressure of a high oil column on the other side.

NOTE: Oil filling may be carried out in different ways depending on what the trans-
former manufacturer finds convenient as long as the rules above are fulfilled and the
on-load tap-changer is filled with oil to the correct level with a gas cushion on the
top.
The methods below are recommended and if they are followed in detail no pressure
limits are exceeded and oil levels and gas cushions will be correct.

After oil filling, a gas cushion should remain on the top of the oil in the diverter
switch housing.
The connection to the oil conservator is designed to automatically give a gas cushion
when filling at atmospheric pressure. When filling under vacuum a certain amount of
oil has to be drained in order to obtain the gas cushion.

NOTE: The oil dissolves gases, especially if degassed oil is used. If the number of
operations is low, the gas cushion may be dissolved in the oil. The oil level in the oil
conservator should be checked after a month in service and if the oil level is lower
than after the oil filling, (corrected for temperature differencies), the gas cushion
should be restored according to section 6.5 ”Restoring the Gas Cushion” in this
guide.

6.2 Before Filling


At commissioning: Open the cover and check that the diverter switch housing is dry
and clean. Check that the bottom valve is closed. Follow step 11 in section 3.2.3.
Tightening torque 40 Nm (see Fig. 28). Remount the cover as per section 4.3.

68
6 Oil Filling

6.3 Filling at Atmospheric Pressure


1. Open the conservator valve, if any.
2. Dismantle the breathing device on the conservator for the on-load tap-changer.
3. Pump oil into the diverter switch housing via the oil valve (connection
dimensions, see the dimension drawing for the on-load tap-changer). Continue
until the conservator is filled to the correct level at the actual temperature. See
even section 1.5.

NOTE: When filling more than one unit: Fill the first unit/units until the oil level
indicator on the oil conservator starts to move. Fill up the oil conservator to the right
level when filling the last unit.

4. Shut the oil valve and disconnect the pump. Fill all units according to point 2-4.
5. Remount the breathing device. Make sure the connection to the breathing device
is properly sealed.
CAUTION
Do not energize the transformer earlier than three hours after oil filling in
atmospheric pressure. This waiting period is needed to allow air bubbles to
disappear.

6.4 Filling under Vacuum


Filling under vacuum is not necessary but may be carried out with some of the
following procedures. After filling under vacuum, no standing time is needed. The
methods below ensure that no permitted pressure differencies are exceeded.
Pipe connection
Vacuum Oil

OLTC
Transformer

fm_00226
Oil

Ø 75
Fig. 43. Oil filling under vacuum
Stud M10

Ø 44.2

TC_00249 Ø 5.7 O-ring

Ø 20
Fig. 42.

69
6 Oil Filling

6.4.1 Oil Conservator Filled Afterwards


1. If an oil filter is mounted on the flange for the oil conservator (only on transform-
ers with a common oil conservator for both the transformer and the on-load tap-
changer), it should be removed.
2. Establish a connection between the transformer and the diverter switch housing,
for instance by putting oil valves on the flange for the conservator and the flange
for the gas operated relay (the horizontal flange) respectively and connect a tube
between the valves, see Fig. 43. Close the oil valve. Evacuate all units at the same
time.
3. Open the valves mounted under point 2. Put the transformer under vacuum. (The
on-load tap-changer is put under vacuum automatically).
4. Let oil in through the oil valve of the on-load tap-changer (for connection
dimensions, see the dimension drawing for the on-load tap-changer).
5. Let an oil amount equal to or slightly less than what is given in section 1.4 enter
into the diverter switch housing. When the on-load tap-changer is filled with oil,
shut the oil valve.
6. When atmospheric pressure is restored in the transformer, shut the connection
between the transformer and the on-load tap-changer by closing both the valves in
the connection.
7. Remove the connection tube between the valves mounted under point 2.
8. Restore the gas cushion in the diverter switch housing/housings according to
section 6.5.1 ”Restoring the Gas Cushion, procedure”, point 2-6 in this guide.
9. Remove the oil valve on the flange for the conservator and remount the oil filter,
if any. Connect the tube to the conservator, see section 5.5. Make sure the O-ring
is properly in place.
10. Open the valve in the tube to the conservator.
11. Fill oil to the correct level in the conservator according to section 1.5 in this
guide.
12. Mount the breathing device on the oil conservator. Make sure the connection to
the breathing device is properly sealed.

NOTE: By using this method, the oil valve on the flange for the gas operated relay
must be left there. The connection to the gas operated relay is made on the oil valve.

6.4.2 Oil Conservator Filled under Vacuum


1. Establish a connection between the oil conservator for the transformer and the oil
conservator for the on-load tap-changer.
2. Open the valve between all on-load tap-changer units and the conservator and
close the oil valve.
3. Put the transformer under vacuum. (The on-load tap-changer is put under vacuum
automatically).

70
6 Oil Filling

4. Let oil in through the oil valve of the on-load tap-changer. (For connection
dimensions, see the dimension drawing for the on-load tap-changer).
5. When the needle of the oil level indicator in the oil conservator starts to move,
shut the oil valves in all units. Open one at a time and close it when the needle in
the oil level indicator start to move. Fill up the conservator to the right level
before shutting the oil level of the last unit. (This is done to make sure that all
units are filled up properly. Differencies in flow rates might otherwise cause that
some of the units are not filled up).
6. When atmospheric pressure is restored in the transformer, remove the connection
between the two conservators and connect the breathing device to the oil
conservator for the on-load tap-changer. Make sure the connection to the
breathing device is properly sealed.
7. Restore the gas cushion in the diverter switch housing according to section 6.5.1
”Restoring the Gas Cushion, procedure”, points 1-6 and 9 in this guide.

6.5 Restoring the Gas Cushion


Check the oil level in the oil conservator one month after oil filling. If the oil level is
lower now than when the oil filling was finished (correct for temperature
differencies!) and no leakages are observed, the gas cushion has been solved in the oil
and has to be restored.
The procedure that follows is used for on-load tap-changers without oil filter unit for
continuous oil filtration. In case the on-load tap-changer is equipped with an oil filter
unit for continuous oil filtration from ABB, and it is installed according to our
recommendations, follow the instructions in ”Oil filter unit for on-load tap-changers,
manual” for restoring the gas cushion.

CAUTION
To operate the on-load tap-changer with a too small or no gas cushion means a risk
for a trip of the pressure relay.

WARNING
The oil in the diverter switch housing may be hot. Be cautious!

WARNING
There is always a cushion of explosive gases in the top of the diverter switch
housing. No open fire, hot surfaces or sparks may be present during opening of
the housing or draining from the valve. After the cover is removed let the gas
vent away approximately 15 min before any work is started.

71
6 Oil Filling

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

6.5.1 Procedure
1. Close the valve in the tube to the conservator.
2. Connect the oil pump to the oil valve. (For connection dimensions, see the dimen-
sion drawing for the on-load tap-changer), see Fig. 44.
3. Open the oil valve and the air release valve.
4. Start the oil pump and drain approximately 15 litres of oil for UCG and 25 l for
UCL into a clean and dry container.
5. Close the air release valve.
6. Close the oil valve and disconnect the pump.
7. Connect the output side of the pump to the oil valve.
8. Open the oil valve.
9. Open the valve in the tube to the conservator!
10. Pump the earlier drained oil back into the diverter switch housing.
11. Close the oil valve and disconnect the pump. The level in the oil conservator and
the gas cushion are now restored.
12. If more than one unit, proceed with the other, (from step 1).

CAUTION
Avoid to do the restoring in damp weather since moisture will get into the diverter
switch housing. If the restoring has to be done in such weather, the incoming air has
to be dehydrated and the drained oil protected from water.

TC_00251 Oil valve Air release valve Air release valve TC_00250

Fig. 44. The figures shows UCL

72
7 Electrical Connection and Testing

7 Electrical Connection and Testing


7.1 General
Before the transformer is energized, tests have to be carried out to make sure that all
mechanical and electrical connections are correct, and to check the proper functioning
of the motor-drive mechanism and the on-load tap-changer.
When testing the transformer, the on-load tap-changer can be operated either by the
hand crank or electrically. When operating electrically the motor-drive mechanism is
connected according to section 7.2.

7.2 Connecting and Testing the Motor-Drive


Mechanism and the On-Load Tap-Changer
Connect earth connection from the transformer to the earth terminal on the on-load
tap-changer flange.
Connect earth connection from the transformer to the earth terminal on the motor-
drive mechanism.
Connect the motor supply and the control supply to the correct terminals in the motor-
drive mechanism as shown by the circuit diagram supplied with the on-load tap-
changer.
Operate the motor-drive mechanism by means of the hand crank to a position in the
middle of the range but not in a through position ( = a position with a letter in).
Turn the control selector switch to position LOCAL. Then give an impulse for
RAISE-operation. If the phase sequence is wrong, (three-phase supply), the motor-
drive mechanism will start in LOWER-direction. The motor-drive mechanism will
stop when it has made approximately half of the complete operation and it will operate
back and forth without the on-load tap-changer changes position until the control
selector-switch is turned to position 0.
If the phase sequence is wrong, reverse two of the motor supply cables in order to get
the correct sequence.
WARNING
Dangerous voltage!

For BUE:
Run the motor-drive mechanism and check again that the red mark on the brake disc
stops within the tolerance of ±25 degrees from exact position, see Fig. 34. For
adjustment, see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125,
Maintenance Guide for UCL.

73
7 Electrical Connection and Testing

For BUL:
Run the motor-drive mechanism and check that the centre of the notch in the cam disc
stops within ±2 mm from the centre of the roller on the brake arm, see Fig. 35. For
adjustment, see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125,
Maintenance Guide for UCL.
Operate the driving mechanism electrically between the end positions. Check the end
stops. When trying to operate it electrically beyond the end position, the motor should
not get started. Check the mechanical end stop by trying to hand crank it beyond the
end position. After a couple of turns on the hand crank it should be mechanically
stopped. Hand crank back to the end position (where the indicator flag is positioned in
the middle for BUE and when the indicator flag is white for BUL). Operate the on-
load tap-changer electrically to the other end position and repeat the test procedure
above.
WARNING
The transformer should in no case be energized with an end stop out of order.

7.3 Electrical Tests on the Transformer


Acceptance tests on the transformer or commissioning can now be performed.

7.4 After Energizing


WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and the earthing is properly
done. Obtain a signed certificate from the engineer in charge.

74
8 Transport

8 Transport
8.1 Dismantling before Transport
The on-load tap-changer is usually transported without accessories (pressure relay,
motor-drive mechanism, bevel gear and drive shafts) to prevent damage to them. To
make sure that everything is set up properly on site with a minimum of work, it is
important to put the on-load tap-changer in the position and operated from the position
given in the single-phase diagram delivered with the unit and fit locking devices
properly during dismantling in the transformer factory. Dismantling of motor-drive
mechanism and drive shafts is done in the opposite order of assembly.

8.1.1 Dismantling Preparations


NOTE: Before dismantling, mark the details to facilitate identification.

Check the position of the motor-drive mechanism according to Fig. 34 (BUE) or


Fig. 35 (BUL). Use the hand crank to adjust it to its exact position. Install the locking
device on the motor-drive mechanism, see Fig. 40.

8.1.2 External drive shafts for UCG.N/UCL.N and


UCG.E/UCL.E (One Unit)
See Fig. 34.
1. If the horizontal shaft should be dismantled:
Lock the bevel gear by means of the locking device, and two set screws,
see Fig. 38g.
Loosen the hose clips holding the protection tubes to the bevel gears. Push one of
the protective tubes into the other. Loosen the screws holding the coupling halves
in one end of the shaft and detach them. Detach the horizontal shaft. Mark the
details.
2. If the vertical shaft should be dismantled:
Loosen the hose clips holding the protective tubes to the bevel gear and motor-
drive mechanism. Push one of the protective tubes into the other. Detach the
screws holding the bevel gear SA21. Detach the bevel gear by carefully lifting it
off the shaft while holding the vertical drive shaft. Detach the vertical shaft
including protective tubes by lifting it off the coupling of the motor-drive
mechanism. Mark the details.
3. Pack screws, clamps, protective tubes, shafts, hose clips, protection
cover,coupling halves, bevel gear and seals for transportation to site.

75
8 Transport

8.1.3 External Drive Shafts for UCG.B/UCL.B (Two Units)


1. If the horizontal shafts should be dismantled:
Detach the protection-cover SA33 on the bevel gear of unit -2, and lock the bevel
gear by means of the locking device marked -2, and two set screws, see Fig. 38f.
Loosen the hose clips holding the protective tubes to the bevel gears of unit -1
and -2. Push one of the protective tubes into the other. Loosen the screws holding
the coupling halves in one end of the shaft and detach them. Detach the horizontal
shaft between unit -1 and -2.
Lock the bevel gear of unit -1 by means of locking device marked -1, and two set
screws, see Fig. 38f.
Loosen the hose clips holding the protection tubes to the bevel gear SA21 and the
bevel gear of on-load tap-changer unit -1. Push one of the protective tubes into the
other. Loosen the screws holding the coupling halves in one end of the shaft and
detach them. Detach the horizontal shaft between unit -1 and bevel gear SA21.
Mark the details.
2. If the vertical shaft should be dismantled:
Loosen the hose clips holding the protective tubes to the bevel gear and motor-
drive mechanism. Push one of the protective tubes into the other. Detach the
screws holding the bevel gear SA21. Detach the bevel gear by carefully lifting it
off the shaft while holding the vertical drive shaft. Detach the vertical shaft
including protective tubes by lifting it off the coupling of the motor-drive
mechanism. Mark the details.
3. Pack screws, clamps, protective tubes, shafts, hose clips, protection cover,
coupling halves, bevel gear and seals for transportation to site.

8.1.4 External Drive Shafts for UCG.T/UCL.T and


UCGYD/UCLYD (Three Units)
1. If the horizontal shaft should be dismantled:
Detach the protection-cover SA33 on the bevel gear of unit -3, and lock the bevel
gear by means of the locking device and set screws marked -3, see Fig. 38f.
Loosen the hose clips holding the protection tubes to the bevel gears of unit -2
and unit -3. Push one of the protective tubes into the other. Loosen the screws
holding the coupling halves in one end of the shaft and detach them. Detach the
horizontal shaft between unit -2 and -3.
Lock the bevel gear of unit -2 by means of locking device marked -2 and two set
screws, see Fig 38f.
Loosen the hose clips holding the protective tubes to the bevel gears of unit -1
and -2. Push one of the protective tubes into the other. Loosen the screws holding
the coupling halves in one end of the shaft and detach them. Detach the horizontal
shaft between unit -2 and -1.

76
8 Transport

Lock the bevel gear of unit -1 by means of locking device marked -1 and set
screws, see Fig. 39f.
Loosen the hose clips holding the protection tubes to the bevel gear SA21 and the
bevel gear of on-load tap-changer unit -1. Push one of the protective tubes into the
other. Loosen the screws holding the coupling halves in one end of the shaft and
detach them. Detach the horizontal shaft between unit -1 and bevel gear SA21.
Mark the details.
2. If the vertical shaft should be dismantled:
Loosen the hose clips holding the protective tubes to the bevel gear and motor-
drive mechanism. Push one of the protective tubes into the other. Detach the
screws holding the bevel gear SA21. Detach the bevel gear by carefully lifting it
off the shaft while holding the vertical drive shaft. Detach the vertical shaft
including protective tubes by lifting it off the coupling of the motor-drive
mechanism.
3. Pack screws, clamps, protective tubes, shafts, hose clips, protection cover,
coupling halves, bevel gear and seals for transportation to site.

8.1.5 Accessories
1. If the pressure relay should be dismantled, see Fig. 41. Remove the electrical
connection to the pressure relay and loosen the nuts. Remove the pressure relay
and put it back in the delivery package. Mount the O-ring and the cover. Tighten
the nuts.
2. If other accessories are to be dismantled of transport reasons, pack them back in
the packages they were delivered in and put back the transport covers. Mount the
O-rings and tighten the nuts.
CAUTION
The pressure relay is a calibrated monitoring instrument. It must be handled with care
and protected against careless handling or any kind of mechanical damage. Do not
open the packing of the pressure relay until you are about to install it on the on-load
tap-changer.

8.2 Oil Level During Transport


The following adjustments of the oil level should be carried out when the on-load tap-
changer should be transported.

CAUTION
Take care to avoid ingestion of moist air when oil is drained. If the ambient air is
moist, let incoming air pass through a dehydrating breather with slow air flow to
obtain proper dehydration.

77
8 Transport

8.2.1 Transformer filled with Oil


The transformer is transported filled with oil. When the transformer is transported
filled with oil the on-load tap-changer should also be transported filled with oil.

8.2.1.1 Conservator mounted


The diverter switch housing should be filled to normal operating level and the valve to
the conservator should be open.

8.2.1.2 Conservator dismounted


The oil level of the diverter switch housing should be lowered to 150 mm below the
upper edge of the housing.
When the conservator is removed, take off the cover of the diverter switch housing
and drain oil with a pump to 150 mm below the upper edge of the housing. Remount
the cover. Turn the cover so the guiding pin in the housing is facing the guiding hole
in the cover. Make sure the gasket is properly in place. Seal all flange connections by
mounting gaskets and covers. Shut all valves.

8.2.2 Transformer drained


The transformer is transported without oil. When the transformer is transported
without oil the on-load tap-changer should also be transported without oil.

8.2.2.1 Conservator mounted


Drain the oil from the diverter switch housing by means of a pump connected to the
oil valve. Let the on-load tap-changer be in contact with the ambient air through the
breathing device on the conservator.

8.2.2.2 Conservator dismounted


Drain the oil from the diverter switch housing by means of a pump connected to the
oil valve. Open the air release valve, see Fig. 44, if necessary.

Seal the diverter switch housing against the ambient air by mounting covers
with´gaskets and shut all valves.

78
9 Commissioning

9 Commissioning
This chapter describes tasks to be carried out on the on-load tap-changer when the
transformer is being installed and tested on site.

CAUTION
The motor-drive mechanism must be protected against condensation.

Energize the heater when power is available. When not, put drying agent inside the
motor-drive cabinet and seal the vents.

Oil valve

Horizontal drive shaft Pressure relay


and protective tubes

Bevel gear

Vertical drive shaft


and protective tubes

Motor-drive
mechanism

TC_00256

Fig. 45. On-load tap-changer system (single-unit shown)

Fig. 45 shows the arrangement of the on-load tap-changer, motor-drive mechanism


and drive shafts.

79
9 Commissioning

The pressure relay is usually delivered in a separate package and installed at


commissioning. Depending on the transport requirements, the transformer may be
delivered with the motor-drive mechanism and drive shaft system mounted or not
mounted. The on-load tap-changer may be delivered filled with oil or without oil.
Please use the relevant parts of this manual to carry out commissioning.
For information about tools, materials and oil required, see relevant parts in chapter 1
of this guide.

9.1 Connection to the Oil Conservator


Follow appropriate parts of the instructions in section 5.5.
Connect the cables to the low level alarm contact on the oil level indicator.

9.2 Mounting the Motor-Drive Mechanism


and the Drive Shafts
The motor-drive mechanism and drive-shaft system should have been assembled and
disassembled in the transformer factory according to the instructions in this guide.
Locking devices should have been installed when it was disassembled. If all locking
devices are in place according to the transport sections in this guide, there should be
no need for adjustments.
If necessary, sections 5.1 and 5.2 give complete information for fitting and adjusting
of the shaft system.

NOTE: Check all fittings and alignments, even if the shaft system has been set up in
the transformer factory.

NOTE: The identification numbers on critical parts from the packing list is given in
the following instructions, see sections 5.1 and 5.2.

9.2.1 Mounting of the Motor-Drive Mechanism


See Figs. 34 and 35. Proceed as follows:
1. Mount the motor-drive mechanism onto the transformer. The mounting holes on
the transformer should be levelled within 1 mm. If adjustment is needed, shims
should be used.
2. Install the bevel gear, SA21, on the edge of the transformer cover, see Fig. 36.
3. Check that the position indicator in the motor-drive mechanism shows the same
position as the indicator inside the bevel gear of the on-load tap-changer.
4. Remove the drying agent inside the cabinet.
WARNING
Do not energize the transformer before the on-load tap-changer and the motor-
drive mechanism are correctly assembled.

80
9 Commissioning

9.2.2 Mounting of the External Drive Shafts


The external drive shafts consists of square tubes and should be connected to the
spherical shaft ends on bevel gears and motor-drive mechanism by means of two
coupling halves.
CAUTION
Before mounting of shafts and couplings, everything must be cleaned and greased for
correct function and to avoid corrosion.

Apply a thin layer of grease, GULF-718EP Synthetic grease or Mobilgrease 28 or


SHELL-Aero Shell Grease 22 to all spherical shaft ends and unpainted surfaces of the
bevel gears.

NOTE: The multihole coupling should be greased.

NOTE: The tubes around shafts and couplings are for protection.

The arrangement of the driving shaft system is shown in Fig. 36.

CAUTION
Make sure that all locking devices (on the bevel gear, on the on-load tap-changer and
in the motor drive) are mounted and the on-load tap-changer and the motor-drive are
in the same service position.

Check that the motor-drive mechanism is in its exact position according to Figs. 34 or
35. (BUE: The red mark on the brake disc facing the red mark on the brake assembly,
BUL: The roller in the middle of the notch in the cam disc). If not, loosen the locking
device and adjust it to its exact position. Remount the locking device.

9.2.3 Mounting of the Vertical Drive Shaft


1. Mount the bevel gear SA21 on the transformer with O-ring, SA20, clamps SA17
screws and washers, see Figs. 46a and 46d.
2. Put the square shaft SA14 with protective tubes SA15 and SA16 and hose clips
according to Fig. 46a. Connect the square shaft with the mounted coupling halves
to the motor-drive. Mount two coupling halves SA11 to the other end of the
square shaft and the shaft of the bevel gear, see Fig 46b. Push the shaft to the bot-
tom of the fitting in the coupling halves, see Fig. 47d. Tighten the screws lightly
and check that the shaft can be moved approximately 2 mm in axial direction
(axial play). Check the dimension shown in Fig. 47e. Tighten the screws A first
and thereafter the other, see Fig. 47c.
3. Mount the protective tube with the greater diameter, SA16 to the bevel gear with
a hose clip, and the other tube SA15 to the flange of the motor-drive mechanism,
see Fig. 46c. Leave about 3 mm play to the flange ring, see Fig. 46e, for water
draining.

81
9 Commissioning

SA18, SA19
SA17

SA21

Driving pin SA20

SA10
SA11
SA16
SA16
SA10

SA15
SA14 SA15
SA10
Motor-Drive
Mechanism SA14

Fig. 46a. Fig. 46b. Fig. 46c.


TC_00156 TC_00147 TC_00147

Min. 3, max 5 mm

SA20
SA18, SA19

SA15
SA17

SA10

TC_00156 TC_00149
Fixing flange
Fig. 46d. of the bevel gear Fig. 46e.

82
9 Commissioning

9.2.4 Mounting of Horizontal Drive Shaft


types UCG.N/UCL.N and UCG.E/UCL.E

SA22 SA24 SA10 SA23 SA11


TC_00148

Fig. 47a.

1. Put the square shaft SA22, protective tubes SA23 and SA24 and hose clips
according to Fig. 47a.
For UCG: Loosen the screws for the locking device of the bevel gear on the top of the
on-load tap-changer, see Fig. 47k. Remove the locking device.

SA11 SA21 A

SA11

SA13
A
TC_00242 TC_00178

SA12
Fig. 47b. Fig. 47c.

2. Connect the square shaft with the mounted coupling halves to the shaft of the
bevel gear, see Fig. 47b. Mount two coupling halves SA11 to the other end of the
square shaft and the shaft of the other bevel gear. Push the shaft to the bottom of
the fitting in the coupling halves, see Fig. 47d. Tighten the screws lightly and
check that the shaft can be moved approximately 2 mm in axial direction (axial
play).
Check the dimension shown in Fig. 47e. Tighten the screws A first and thereafter
the other, see Fig. 47c.
Max. 3 mm
M8 screw

Coupling

Driving pin
Driving pin
TC_00170 TC_00148 TC_00150
Max. 6 mm

Fig. 47d. Fig. 47e. Fig. 47f.

83
9 Commissioning

3. The motor-drive mechanism and the on-load tap-changer should have the same
indicated tap position and be in their exact positions.
The motor-drive mechanism and the on-load tap-changer are in the same position
when the position indicators in both of them show the same position, see Figs. 34
and 35.
The motor-drive mechanism is in the exact position since point 9.2.2 has been
carried out.
The on-load tap-changer is in exact position when the ”window” where the posi-
tion is read in the bevel gear is facing the red point in the gear box housing
exactly, see Fig. 34.
If the gear box is not in its exact position carry out point 5 and loosen the two
screws in the multihole coupling on the gearbox and find the position of the
screws that positions the opening in the brass toothed wheel closest to the red
point in the gear box housing. The maximum deviation from exact alignment is
given in Fig. 34. Tighten the screws.

CAUTION
Assembly with the on-load tap-changer and the motor-drive mechanism in different
operating positions may cause a transformer break down.

SA10 SA24 SA25 SA23 SA10

Slot facing
downwards

TC_00243
SA23

Fig. 47g.

4. Push the two protective tubes on the bevel gears and clamp them with hose clips
SA10, see Fig. 47g.
NOTE: The slot of the protective tube SA23 should be facing downwards.
The self-adhesive information plates SA25 are on about the middle of the tube
length.
NOTE: Do not remove the locking device before one end of the shaft of the bevel gear
is finally connected to the drive shaft.

84
9 Commissioning

Locking device Locking device

Set screws

Cover
SA 33

TC_00244

TC_00287
Fig. 47h. UCL, UCG.B, UCG.T Fig. 47k. UCG and UCL

9.2.5 Mounting of Horizontal Drive Shafts,


Type UCG.B/UCL.B
The following applies to the fitting of drive shafts and their protective tubes when the
on-load tap-changer consists of units UCG.B/UCL.B. The on-load tap-changer unit,
which is placed closest to the driving mechanism, is called unit -1, the second unit -2,
see Fig. 36.

SA22 SA24 SA10 SA23 SA11


TC_00148

Fig. 48a.

1. Put the square shaft SA22, protective tubes SA23 and SA24 and hose clips
according to Fig. 48a.
Loosen the screws for the locking device of the bevel gear on the top of the on-
load tap-changer, see Fig. 47k. Remove the locking device.

SA11 SA21 A

SA11

SA13
A
TC_00242 TC_00178

SA12
Fig. 48b. Fig. 48c.

85
9 Commissioning

2. Connect the square shaft with the mounted coupling halves to the shaft of the
bevel gear, see Fig. 48b. Mount two coupling halves SA11 to the other end of the
square shaft and the shaft of the other bevel gear. Push the shaft to the bottom of
the fitting in the coupling halves, see Fig. 48d. Tighten the screws lightly and
check that the shaft can be moved approximately 2 mm in axial direction (axial
play). Check the dimension shown in Fig. 48e. Tighten the screws A first and
thereafter the other, see Fig. 48c.

Max. 3 mm
M8 screw

Coupling

Driving pin
Driving pin
TC_00170 TC_00148 TC_00150
Max. 6 mm

Fig. 48d. Fig. 48e. Fig. 48f.

3. The motor-drive mechanism and the on-load tap-changer should have the same
indicated tap position and be in their exact positions.
The motor-drive mechanism and the on-load tap-changer are in the same position
when the position indicators in both of them show the same position, see Figs. 34
and 35.
The motor-drive mechanism is in the exact position since point 9.2.2 has been
carried out.
The on-load tap-changer is in exact position when the ”window” where the posi-
tion is read in the bevel gear is facing the red point in the gear box housing
exactly, see Fig. 34.
If the gear box is not in its exact position carry out point 5 and loosen the two
screws in the multihole coupling on the gearbox and find the position of the
screws that positions the opening in the brass toothed wheel closest to the red
point in the gear box housing. The maximum deviation from exact alignment is
given in Fig. 34. Tighten the screws.

CAUTION
Assembly with the on-load tap-changer and the motor-drive mechanism in different
operating positions may cause a transformer break down.

86
9 Commissioning

SA10 SA24 SA25 SA23 SA10

Slot facing
downwards

TC_00243
SA23
Fig. 48g.

4. Push the two protective tubes on the bevel gears and clamp them with hose clips
SA10, see Fig. 48g.

NOTE: The slot of the protective tube SA23 should be facing downwards.

The self-adhesive information plates SA25 are on about the middle of the tube
length.

NOTE: Do not remove the locking device before one end of the shaft of the bevel gear
is finally connected to the drive shaft.

5. Loosen the set screws for the locking device of the bevel gear on the top of the
on-load tap-changer, see Fig. 47h. Remove the locking device.
6. Mount the cover SA33 and tighten the set screws (from the locking device).

SA30 SA32 SA10 SA31 SA11


TC_00148

Fig. 48h.

7. Put the square shaft SA30, protective tubes SA31 and SA32 and hose clips
according to Fig. 50h.

Disc Coupling A SA30 SA31

Unit -2 Unit -1
SA11 SA11 SA10 SA32 SA10
SA12
TC_00245

Fig. 48k.

87
9 Commissioning

8. Connect the square shaft with the mounted coupling halves to the shaft of the
bevel gear, see Fig. 48k. Mount two coupling halves SA11 to the other end of the
square shaft and the shaft of the other bevel gear. Push the shaft to the bottom of
the fitting in the coupling halves, see Fig. 48d. Tighten the screws lightly and
check that the shaft can be moved approximately 2 mm in axial direction (axial
play). Check the dimension shown in Fig. 48e. Tighten the screws A first and
thereafter the other, see Fig. 48c.

NOTE: If the exact position of the closest unit has been adjusted, the locking device
might have to be removed (step 6) before step 3 can be carried out.

9. The motor-drive mechanism and the on-load tap-changer should have the same
indicated tap position and be in their exact positions.
The motor-drive mechanism and the on-load tap-changer are in the same position
when the position indicators in both of them show the same position, see Figs. 34
and 35.
The motor-drive mechanism is in the exact position since point 9.2.2 has been
carried out.
The on-load tap-changer is in exact position when the ”window” where the posi-
tion is read in the bevel gear is facing the red point in the gear box housing
exactly, see Fig. 34.
If the gearbox of this unit is not in its exact position carry out point 6 and loosen
the two screws in the multihole coupling on the gearbox and find the position of
the screws that positions the opening in the brass toothed wheel closest to the red
point in the gear box housing. The maximum deviation from exact alignment is
given in Fig. 34. Tighten the screws.
CAUTION
Assembly with the on-load tap-changer and the motor-drive mechanism in different
operating positions may cause a transformer break down.

Locking device
Cover
SA33 Set screws SA10 SA25 SA10

SA32 SA31 TC_00246

Fig. 48l.

10. Push the two protective tubes on the bevel gears and clamp them with hose clips
SA10, see Fig. 48l. Apply the self-adhesive information plates SA25 around the
tubes on about the middle of the tube length.
11. Loosen the two set screws, see Fig. 39f and remove the locking device.
12. Mount the cover SA33. Tighten the two set screws, see Fig. 48l. (taken from the
locking device).
88
9 Commissioning

9.2.6 Mounting of Horizontal Drive Shafts,


Types UCG.T/UCL.T and UCGYD/UCLYD
The following applies to the fitting of drive shafts and their protective tubes when the
on-load tap-changer consists of three insulated units UCG.T/UCL.T or UCGYD/
UCLYD. The on-load tap-changer unit, which is placed closest to the driving
mechanism, is called unit -1, the second unit -2 and the last unit -3, see Fig. 36.
1. Mount the drive shaft to the on-load tap-changer unit -1 according to section 9.2.5
steps 1–5 above. Remove the set screws according to Fig. 47h.
2. Mount the drive shaft between unit -1 and unit -2 according to section 9.2.5, steps
1-6 above. Remove the set screws according to Fig. 47h.
3. Mount the drive shaft between unit -2 and unit -3 according to section 9.2.5, steps
2-7 above.

NOTE: The shaft is here called SA34, the protective tube closest to unit -2 is called
SA35 and the other protective tube is called SA36.

NOTE: Do not remove the locking device before one end of the shaft of the bevel gear
is finally connected to the drive shaft.

In cases where support bearing is used, follow appropriate parts of section 9.2.5,
steps 2-5.

9.2.7 Before Operation


1. Check again that the on-load tap-changer and the motor-drive mechanism are in
the same operating position, see section 5.1.
2. Remove the locking device of the motor-drive mechanism, see Fig. 49.
NOTE: The door of the motor-drive mechanism can be locked with a padlock (not
included in the delivery).
NOTE: Do not remove the locking device before one end of the shaft of the bevel gear
is finally connected to the drive shaft.

Locking device
TC_00262

BUE BUL

Fig. 49. Locking device of motor-drive mechanism

89
9 Commissioning

9.3 Pressure Relay


Follow appropriate parts of section 5.3.

9.4 Accessories
Remount all other accessories, if any, that have been dismounted for the transport.
Follow appropriate parts of section 5.4.

9.5 Oil Filling


Follow appropriate parts of chapter 6.

9.6 Electrical Connection and Testing


Make all wiring work and make the appropriate tests according to chapter 7. Remove
the drying agent inside the cabinet of the motor-drive mechanism.

9.6.1 Motor Protection


The function of the protective motor switch is checked. For three-phase AC motors,
one of the phase fuses is removed and the function time of the protective motor switch
is checked by a RAISE or LOWER operation. The protective motor switch should
release within 60 seconds at a current setting equal to the rated current of the motor at
the actual voltage.
CAUTION
If the protective motor switch has not released within 60 seconds, disconnect the
power and check the settings with the rating plate of the motor. Adjust if necessary
and check again when the motor has cooled down.

WARNING
The motor power voltage is dangerous.

Protective motor switches for DC motors and for single-phase AC motors are not
tested.

9.6.2 Disc Brake


For BUE:
Run the motor-drive mechanism and check that the red mark on the brake disc stops
within the tolerance of ±25 degrees from exact position, see Fig. 34. For adjustment,
see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125, Maintenance
Guide for UCL.
90
9 Commissioning

For BUL:
Run the motor-drive mechanism and check that the centre of the notch in the cam disc
stops within ±2 mm from the centre of the roller on the brake arm, see Fig. 35. For
adjustment, see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125,
Maintenance Guide for UCL.

9.6.3 Counter
Check that the counter is functioning at RAISE and LOWER operations.

9.6.4 Position Transmitter and other Position Switches


Check the function of the position transmitter and other position switches.

9.6.5 Light
Check that the light is switched on when the door is opened and goes out when the
door is closed.

9.6.6 Heater
Switch off all power supplies and feel with a finger that the heater has been warmed
up during earlier tests. Switch on the power afterwards.

9.7 Putting into Operation


Put the LOCAL/REMOTE switch to REMOTE. Reset the drag hands. Make sure that
no tools or foreign objects are left in the motor-drive cabinet or on the transformer
cover. Close the door to the motor-drive.

91
1ZSE 5492-116 en, Rev. 8, 2004-03-15

ABB Power Technologies AB


Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com/electricalcomponents
1ZSE 5492-124 en, Rev. 5, 1999-11-30

On-load tap-changer, type UCG


with motor-drive mechanisms, types BUE and BUL
Maintenance guide
This document must not be copied without our written permission, and the
contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Recommended Practices
ABB Components recommends careful consideration of the following factors for
maintenance work on on-load tap-changers:
Before you start any work, make sure that the personnel doing the job have read and
fully understood the Maintenance documents provided with the unit.
To avoid damaging the unit, never exceed the operating limits stated in delivery
documents and on rating plates.
Do not alter or modify a unit without first consulting ABB Components.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and procedures.

WARNING, CAUTION and NOTE

WARNING
A WARNING provides information which, if disregarded, could cause injury or
death.

CAUTION
A CAUTION provides information which, if disregarded, could cause damage to the
equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work
described.

Safety Precautions
WARNING
The Maintenance Guide should be read and understood before any work is
started, and the procedures in this document should be followed at all times.

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

iii
WARNING
Before carrying out work on the on-load tap-changer, put the LOCAL/REMOTE
switch in the motor-drive mechanism to position 0. It is also recommended to
shut the door of the motor-drive mechanism and pad lock it when work is
carried out on the on-load tap-changer. The key should be kept by the operator.
This is done to avoid unexpected start of the motor-drive mechanism.

WARNING
Before starting any work inside the motor-drive mechanism, the auxiliary power
must be switched off.
N.B. The motor, contactors and heating element may be energized from separate
sources.

WARNING
In no case should any person go down into the diverter switch housing. The
cleaning of the diverter switch housing should be carried out by using brushes
and rags and by flushing with oil.

CAUTION
Approval should be given for inspection as well as for operating the on-load tap-
changer.

CAUTION
ABB Components recommends that only maintenance engineers trained by
ABB Components carry out contact replacement.

During Service
WARNING
Small amounts of explosive gases will always come out from the breathing
devices (dehydrating breather or one-way breather). Make sure that no open
fire, hot surfaces or sparks occurs in the immediate surroundings of the
breathing devices.

WARNING
If a failure in power supply occurs during operation, the operation will be
completed when the power returns.

WARNING
The hand crank must not be inserted during electrical operation.

iv
WARNING
If the on-load tap-changer is not in its exact position and the hand crank is pulled
out, the motor-drive mechanism will start and go to the exact position if the
power supply is on.

CAUTION
After a pressure relay trip, follow the instructions in the chapter ”Pressure Relay” in
the Repair Guide.

During Oil Handling


WARNING
Unused transformer oil is slightly harmful. Fumes from unused warm oil may
irritate the respiratory organs and the eyes. After long and repeated contact with
transformer oil skin becomes very dry.
Used on-load tap-changer oil from diverter switch housings and selector switch
housings contains harmful substances. Fumes are irritating to the respiratory
organs and the eyes and are very easily set on fire. Used transformer oil may well
be carcinogenic.
Avoid contact with the oil as much as possible and use oiltight protective gloves
when handling the oil.
First aid:
Skin contact: Wash the hands. Use skin cream to counteract drying.
In the eyes: Rinse the eyes in clean water.
Swallowing: Drink water or milk. Avoid vomiting. Call a doctor.
Collect used oil in oil drums.
Waste and cleaning up: Should be absorbed by an absorber. Treat it as
hazardous to the environment.
Upon fire: The fire should be extinguished by using powder, foam or carbon
acid.

WARNING
When oil that has been used in a selector switch compartment is pumped out,
conducting tubes and hoses that are earthed should be used to avoid the risk of
explosion due to the gases produced by the arcs during service.

WARNING
The oil in the selector switch compartment may be hot. Be cautious!

WARNING
There is always a cushion of explosive gases in the top of the diverter switch
housing. No open fire, hot surfaces or sparks may be present during opening of
the housing or draining from the valve. After the cover is removed let the gas
vent away approximately 15 min before any work is started.

v
WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.

CAUTION
Take care to avoid ingestion of moist air when oil is drained. If the ambient air is
moist, let incoming air pass through a dehydrating breather with slow air flow to
obtain proper dehydration.

CAUTION
Do not fill oil into the on-load tap-changer if the transformer tank is under vacuum
and the on-load tap-changer is not.

CAUTION
Do not fill oil into the transformer tank if the on-load tap-changer is under vacuum
and the transformer tank is not.

CAUTION
Leave a gas cushion on top of the oil in the diverter switch housing.

After Oil Filling


CAUTION
Do not energize the transformer earlier than three hours after oil filling in
atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

Mounting of Gaskets
CAUTION
Sealing surfaces and gaskets must be clean and undamaged. Diametrically opposed
bolts in sealing joints must be tightened alternately several times, beginning with a
low tightening torque and finally with the recommended tightening torque as
described in section 1.3 Tightening Torque, in this guide.

vi
Contents
1 Introduction __________________________________________ 9
1.1 General ______________________________________________ 9
1.2 Maintenance Schedule __________________________________ 10
1.2.1 Inspection ____________________________________________ 12
1.2.2 Overhaul _____________________________________________ 12
1.2.3 Contact Replacement ___________________________________ 12
1.3 Tightening Torque _____________________________________ 13
2 Inspection ____________________________________________ 14
2.1 Required Tools and Material _____________________________ 14
2.2 Procedure ____________________________________________ 14
3 Overhaul _____________________________________________ 18
3.1 Required Tools and Materials ____________________________ 18
3.2 Procedure ____________________________________________ 19
3.3 Preparations __________________________________________ 20
3.3.1 On-Load Tap-Changer Position ___________________________ 20
3.3.2 Disconnection and Earthing of the Transformer ______________ 20
3.3.3 Oil Volumes and Lifting Heights __________________________ 21
3.3.4 Recommended Set of Spare Parts__________________________ 21
3.4 Oil Testing and Oil Draining _____________________________ 21
3.5 Lifting and Cleaning the Diverter Switch ___________________ 23
3.5.1 Lifting Rig ___________________________________________ 23
3.6 Checking the Diverter Switch ____________________________ 24
3.6.1 Cleaning the Diverter Switch Housing ______________________ 24
3.6.2 Cleaning the Oil Filter (if any) ____________________________ 25
3.7 Oil Filtration __________________________________________ 25
3.8 Checking of the Breathing Device _________________________ 26
3.9 Checking the Contact Positions ___________________________ 26
3.10 Checking the Contact Wear ______________________________ 28
3.11 Checking the Transition Resistors _________________________ 28
3.12 Checking before Closing ________________________________ 29
3.13 Installation of the Diverter Switch _________________________ 29
3.14 Checking of the Pressure Relay ___________________________ 31
3.14.1 Functional Check of the Pressure Relay _____________________ 31
3.14.2 Replacing the Pressure Relay _____________________________ 31
3.15 Lubrication of the On-Load Tap-Changer
and the Drive Shaft System ______________________________ 32

7
3.16 Checking of the Motor-Drive Mechanisms types BUE and BUL _ 32
3.16.1 Motor Protection ______________________________________ 35
3.16.2 Earth Fault Protector (option) ____________________________ 35
3.16.3 Counter ______________________________________________ 35
3.16.4 Heater _______________________________________________ 35
3.16.5 Toothed Belt __________________________________________ 35
3.16.6 Motor Cable Connections ________________________________ 36
3.16.7 Disc Brake, BUE ______________________________________ 36
3.16.8 Brake for the Maintaining Contact, BUE ____________________ 37
3.16.9 Disc Brake, BUL ______________________________________ 37
3.16.10 Position Transmitter and other Position Switches, BUE ________ 38
3.16.11 Position Transmitter and other Position Switches, BUL ________ 38
3.16.12 Lubrication, BUE ______________________________________ 39
3.16.13 Lubrication, BUL ______________________________________ 39
3.17 Operation Test ________________________________________ 41
3.18 Oil Filling ____________________________________________ 41
3.18.1 Filling Methods and Restrictions __________________________ 41
3.18.2 Before Filling _________________________________________ 42
3.18.3 Filling at Atmospheric Pressure ___________________________ 42
3.18.4 Oil Level _____________________________________________ 42
3.18.5 Restoring the Gas Cushion _______________________________ 43
3.18.5.1 Procedure ____________________________________________ 44
3.18.6 Waiting Period ________________________________________ 45
3.19 Check of Contact Timing ________________________________ 45
3.20 Putting into Operation __________________________________ 48
4 Contact Replacement ___________________________________ 49
4.1 Dismantling the Boards _________________________________ 51
4.2 Dismantling the Moving Main Contacts ____________________ 52
4.3 Dismantling the Moving Transisition Contacts _______________ 54
4.4 Mounting the Moving Transistion Contacts __________________ 54
4.5 Mounting the Moving Main Contacts ______________________ 56
4.6 Replacing the Fixed Main Contacts ________________________ 57
4.7 Replacing the Fixed Transition Contacts ____________________ 57
4.8 Mounting the Boards with Transition Resistors and Fixed Contacts 57
5 Specification of Materials _______________________________ 59
5.1 General ______________________________________________ 59
5.2 Diverter Switch Housing ________________________________ 59
5.3 Diverter Switch ________________________________________ 59
5.4 Tap Selectors _________________________________________ 60
5.5 Conductors ___________________________________________ 60
5.6 Gearing Mechanism ____________________________________ 60
5.7 Drive Shaft Systems ____________________________________ 61
5.8 Motor-Drive Mechanism ________________________________ 61

8
1 Introduction

1 Introduction
1.1 General
The UC range of on-load tap-changers manufactured by ABB Components has been
developed over many years to provide maximum reliability. The simple and rugged
design gives a service life equal to the service life of the transformer. Minimum
maintenance is required for trouble-free operation. The only parts requiring
maintenance are contacts that might need replacement during the service life, the
insulating oil and the motor-drive mechanism.
The design allows excellent access to all parts, making inspection and maintenance
quick and simple.
The on-load tap-changer, type UCG, is housed in the transformer tank. The motor-
drive mechanism is attached to the transformer tank and connected to the on-load tap-
changer by means of drive-shafts and a bevel gear, see Fig. 1.

Horizontal drive-shaft
Bevel gear and protection tube Pressure relay

Bevel gear

Shielding-rings
(when impulse
withstand voltage to
Vertical drive-shaft earth exceeds
and protection tube 380 kV)

Insulating shaft

Diverter switch
housing containing
Hood and screws the diverter switch

Conductors
Hand crank

Motor-drive
Shielding-ring
mechanism
(when impulse
withstand voltage to
earth exceeds
On-load tap-changer
380 kV). (Not on
tap selector size C)

Fig. 1. On-load tap-changer and motor-drive mechanism

9
1 Introduction

Fig. 2 shows the general arrangement of an on-load tap-changer type UC. The main
components are the spring-operated diverter switch and the tap selector with sliding
contacts. For maintenance the diverter switch is lifted. The contacts are then
immediately accessible and can be inspected for wear. The drive-shafts should not be
dismantled when lifting the diverter switch.
Maintenance is normally not required on the parts operating in the oil of the
transformer tank. However, when the on-load tap-changer has made one million
operations a check of the tap selector is recommended.
The diverter switch has its own housing separate from the transformer oil. This is to
prevent contamination of the transformer oil since the diverter switch oil deteriorates
due to the switching operations. The oil needs to be checked and filtered at regular
intervals to maintain adequate dielectric strength as well as to prevent mechanical
wear.
It is necessary to inspect the contacts and clean the insulation parts of the diverter
switch as well as to clean the housing inside at regular intervals.
The main components of the diverter switch are:
Fixed main contacts
Moving main contacts
Fixed transition contacts
Moving transition contacts
Transition resistors
Spring-driven polygon link system.
Besides the maintenance of the diverter switch and cleaning of the oil, the motor-drive
mechanism should be checked and lubricated.
The pressure relay, the device that protects the transformer from damages due to
excessive pressure in the diverter switch housing, should also be checked.

NOTE: One on-load tap-changer of UCG type may consist of one, two or three units
driven by a common motor-drive mechanism. The instructions in this guide deals with
one unit. If there is two or three units, all work decribed should be carried on all units
unless otherwise is stated. If more than one diverter switch is lifted out at the same
time, make sure the right diverter switch is lowered into the right housing (compare
with the serial numbers, see Fig. 2).

1.2 Maintenance Schedule


Maintenance of the on-load tap-changer consists of three major steps:
Inspection
Overhaul
Contact replacement.

10
1 Introduction

Diverter switch housing Cover


Oil valve

Pressure relay
Bevel gear

Position indicator
Top-section
Serial No.
1)
Shielding-ring
Earthing terminal

Connection flange for Draining tube


gas operated relay
Insulating cylinder
Insulating shaft
Diverter switch
1)
Shielding-ring
2)
Shielding-ring
Transition resistors Plug-in contacts

Fixed and moving


contacts

Serial No. Bottom section

Guide-pins
Current terminal

Driving disc for the


diverter switch Tap selector

Bottom valve for


drying process

Intermediate gear
Geneva gear

1)
Only at impulse withstand Change-over
voltage to earth of 650 kV selector
and 1050 kV

2)
Not on UCG of the short type Moving fine-
selector contacts Current collector

Fixed fine-selector
contacts

Fig. 2. General arrangement of on-load tap-changer, type UC.

11
1 Introduction

1.2.1 Inspection
On the rating plate, ”inspection once a year” is recommended. This principally
concerns the motor-drive mechanism and refers to a visual inspection inside the
motor-drive cabinet to check that nothing is loose and the heater is functioning.
In the motor-drive mechanism a counter registers every tap-changer operation. During
inspection the counter is read. If possible, motor and counter are tested by operating
one step and then back.
If the on-load tap-changer has its own oil conservator, the breather and the oil level
indicator are checked according to the instructions from the transformer manufacturer.
The inspection is carried out while the transformer is in service.
If the on-load tap-changer is equipped with an oil filter unit from ABB Components, it
should be inspected once a year according to the ”Oil filter unit for on-load tap-
changers, manual”.

1.2.2 Overhaul
The contact life and the frequency of operations or the time in service determine the
time interval between overhauls.
The number of operations run by the on-load tap-changer is recorded by a counter,
housed in the motor-drive mechanism cabinet. The registered number of operations
should be noted at every inspection and overhaul.
The on-load tap-changer should normally be overhauled regularly at intervals of 1/5 of
the estimated contact life. The relevant information is stated on the rating plate.
Hereby, the contact wear can be followed and necessary preparations can be made for
replacing the contacts.
If the tap-change operations occur infrequently and a very long time elapses until the
number of operations amounts to 1/5 of the contact life, the interval between
overhauls should be limited to the time stated on the rating plate (normally 7 years).

1.2.3 Contact Replacement


On the rating plate of the on-load tap-changer the estimated contact life of the
breaking contacts in the diverter switch at rated load is stated.
The contacts will withstand a very large number of switching operations. For normal
power transformers the number of operations of the diverter switch is approximately
20 per day, which means that replacement of the contacts is not normally necessary
during the life of the transformer. (In case of on-load tap-changers on furnace
transformers, the frequency of operations may be considerably higher).

CAUTION
The number of operations must in no case exceed 500 000, due to weakening spring
tension of the contacts.

12
1 Introduction

1.3 Tightening Torque


The following tightening torques are recommended
for metallic screw joints: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %

for non-metallic screw joints: M10, 9 Nm ±10 %


M12, 13 Nm ±10 %
M16, 22 Nm ±10 %

if not otherwise is stated in this guide.

13
2 Inspection

2 Inspection
The inspection mainly consists of a visual check of the motor-drive mechanism and
the conservator once a year while the transformer is in service.
In the motor-drive mechanism the following points are to be checked:
Motor and counter
Heater
The counter’s value.
On the conservator the following are to be checked:
Oil level
Breather

2.1 Required Tools and Material


The following equipment is required for the inspection:
Set of screw drivers
Pen and note pad.

2.2 Procedure
CAUTION
Approval should be given for inspection as well as for operating the on-load tap-
changer.

WARNING
This work must be carried out from ground level since the transformer is
energized!

1. Check the breathers according to the instructions for the transformer.

WARNING
The breathers and the tube from the conservator contains explosive gases. No
open fire, hot surfaces or sparks may be present when loosening the breather.

2. Check the oil level in the conservator for the on-load tap-changer. The oil level
should be according to the transformer documentation.
See Figs. 3 and 4.

14
2 Inspection

3. Open the cabinet door of the motor-drive mechanism and turn the selector-switch
to the LOCAL position. Then turn the control switch to the RAISE (LOWER)
position.
4. Check that the motor works properly, the position indicator increases (decreases)
one step and the counter advances one step for each operation. Record the
counter’s value. The counter shows the number of operations run by the on-load
tap-changer (the overhaul-schedule can be determined with the help of this
information).
5. Turn the control switch to the LOWER (RAISE) position for 1-2 seconds. Check
that the motor also works properly in that direction, the position indicator
decreases (increases) one step and the counter advances one step more. Reset the
draghands.
6. Check the emergency stop.
Give a RAISE or LOWER impulse and after about one second press the
emergency stop. The operation should be interrupted. Reset the emergency stop
by turning the knob clockwise and by switching on the protective motor switch.
The started operation should now be completed. Operate back to service position.
7. Check the earth fault protector (option).
If the motor-drive mechanism is equipped with an outlet, the earth fault protector
should be tested by pressing the test knob on the outlet on BUE and by pressing
the test knob on the separate earth fault protector on BUL.
8. Disconnect the incoming auxiliary power.

WARNING
Before starting any work inside the motor-drive mechanism the auxiliary power
must be switched off.
N. B. The motor, contactors and heating element may be energized from separate
sources.

9. Open the control panel


10. Check by feeling with a finger on the protection plate that the heater has been
functioning.
11. Close the control panel and reconnect the incoming auxiliary power.
12. Complete the inspection by turning the switch to the REMOTE position and
closing the cabinet door.

15
2 Inspection

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

21 20 19 18 17

1. Locking device prepared for padlock 13. Shaft for handcrank


2. Emergency stop 14. Heater 50 W + optional 100 W (behind the panel)
3. (Option) Switch for extra heater 15. (Option) Outlet with earth fault protector
4. Air vent 16. Terminal blocks (behind the panel)
5. LOCAL/REMOTE switch 17. Protective motor switch
6. RAISE/LOWER switch 18. (Option) Thermostat or hygrostat for extra
7. Outgoing shaft heater 100 W
8. Lamp (40 W socket E27) 19. Door-operated switch for lamp
9. Lifting eye 20. Handcrank
10. Counter 21. User’s manual and circuit diagram
11. Tap-change in progress indicator
12. Position indicator with draghands for
max. and min. position

Fig. 3. Motor-Drive Mechanism, type BUE.

16
2 Inspection

1 2 3 4 5 6

10

11

12

13

14

15

16

17 18 19 20 21 22 23 24

1. Position indicator with draghands for 13. Emergency stop


max. and min. position 14. RAISE/LOWER switch
2. Tap-change in progress indicator 15. LOCAL/REMOTE switch
(Red = in progress, White = in position) 16. Protective motor switch
3. Counter 17. Air vent
4. Outgoing shaft with multiple hole (Remote position for automatic operation)
coupling half 18. Door operated switch for lamp
5. Shaft for handcrank 19. Terminal blocks
6. Lifting eye 20. Hand lamp
7. Locking device prepared for padlock 21. Heater 50 W + optional 100 W
8. (Option) Multi position switches 22. (Option) Thermostat or hygrostat for
9. (Option) Measuring amplifier extra heater 100 W
10. (Option) Switch for extra heater 23. User’s manual and circuit diagram
11. (Option) Outlet 24. Handcrank
12. (Option) Earth fault protector

Fig. 4. Motor-Drive Mechanism, type BUL.

17
3 Overhaul

3 Overhaul
WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

3.1 Required Tools and Materials


Necessary for the overhaul is the following equipment:
Normal hand tools (keywidth up to 19 mm)
Normal set of combination spanners
Pipe wrench
Thickness gauges (0.40; 0.50; 1.20 mm)
Small hammer
Sliding caliper
Spring balance (10 N)
Watch (with hand for seconds)
Oil can
Ohmmeter (1-30 Ohm)
Air pump with pressure gauge (0-200 kPa) and connection to R 1/8” male thread
Telpher (at least 150 kg lifting force)
Empty and clean barrels for transformer oil (calculate with max. 225 l for each
diverter switch housing)
Oil draining and filtering equipment with connections
Test equipment according to IEC 156
Two buckets (approximately 10 l)
Rags (non-fuzzying)
50 l of new transformer oil (class II according to IEC 296)
Grease (GULF-718 EP synthetic grease, Mobilgrease 28, Shell-Aero Shell grease
22 or similar
Oil (for plain ball and roller bearings)
Degreasing agent
Protective glooves, oil proof

18
3 Overhaul

Dimension drawing for the on-load tap-changer


Pen and note pad
Set of spare contacts (see ”Spare parts list for UC”)
Brass shims according to Fig. 9 (12 pcs)
New O-ring for the cover (435x8).

When restoring the gas cushion. (section 3.18.5):


Small oil pump with connection to the oil valve
Empty and clean barrel for transformer oil ( ~ 15 l)
Box wrench, 6 mm.

When measuring contact timing, add this equipment:


See section 3.19.

When replacing contacts (chapter 4), add this equipment:


Universal pliers
Pipe wrench
4 mm mandrel
5 mm brass mandrel, 320 mm long
Steel ruler
Round file
Torque wrench (10 Nm)
Piece of wood, 50 mm thick, 400 mm long.

3.2 Procedure
The overhaul procedure includes the following points:
Oil testing and oil draining
Lifting and cleaning the diverter switch
Cleaning the diverter switch housing and the oil filter (if any)
Oil filtration
Checking the breathers
Checking the contact positions
Checking the contact wear
Checking the transition resistors

19
3 Overhaul

Checking before lowering the diverter switch


Lowering the diverter switch
Checking the pressure relay
Lubrication
Checking the motor-drive mechanism
Oil filling
Check of contact timing
Putting into operation.

3.3 Preparations
NOTE: If the on-load tap-changer is oil filled under atmospheric pressure, a waiting
period of three hours is needed before energizing. To save out of service time of the
transformer, carry out all work on the on-load tap-changer and the oil filling before
the maintenance of the motor-drive mechanism is started.

3.3.1 On-Load Tap-Changer Position


Note the position of the on-load tap-changer to enable restart of the transformer in the
right tap position.

3.3.2 Disconnection and Earthing of the Transformer


WARNING
Before starting any work in the on-load tap-changer the protective motor switch
and the LOCAL/REMOTE switch must be set at 0.

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

20
3 Overhaul

3.3.3 Oil Volumes and Lifting Heights


The necessary number of empty drums for collecting and filtering of the oil in the
diverter switch housing should be kept ready. The drums must be carefully cleaned
and free from water. New oil needed should be of class II according to IEC 296.

Quantity of oil in the diverter switch housing and lifting height for the diverter switch

UCG.. 380/... Approx. 170 litres (lifting height 1.4 m)


UCG.. 650/... Approx. 170 litres (lifting height 1.4 m)
UCG.. 1050/... Approx. 205 litres (lifting height 1.7 m)

NOTE: The volume of the oil conservator is not included.


Alternatively, the oil may be replaced by new oil and the used oil filtered at some later
occasion. A certain quantity of new oil, at least 50 litres, should be kept ready to
replace waste oil and for cleaning

CAUTION
Do not energize the transformer until oil has been filled as per section 3.18 ”Oil
Filling” in this guide.

3.3.4 Recommended Set of Spare Parts


It is recommended to have a set of contacts for the diverter switch available during the
overhaul, see Spare Parts List for ordering.

3.4 Oil Testing and Oil Draining


The diverter switch housing is equipped with an oil valve placed on the top section.
For connection dimensions, see the dimension drawing for the on-load tap-changer.

WARNING
The oil in the diverter switch housing may be hot. Be cautious!

Take an oil-sample from the oil valve and carry out the dielectric strength test
according to IEC 156 (between spherical calottes, distance 2.5 mm). This test is
carried out for deciding whether the oil can be filtered or must be exchanged.
The dielectric strength of the oil should not be allowed to be less than 120 kV/cm for
an on-load tap-changer in service.
NOTE: When taking the oil-sample, first drain some oil into a bucket to clean the
valve.
If the oil conservator of the on-load tap-changer is common with the oil conservator of
the transformer tank, close the valve in the pipe connection to the oil conservator and
open the oil valve. After a while, open the air release valve. See Fig. 22.

21
3 Overhaul

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB Components and it is maintained and operated according to our
instructions, oil draining and filtering is not needed, provided that the dielectric
strength is at least 160kV/cm (IEC 156).
NOTE: There is a hole in the upper part of the draining tube to prevent air from
being trapped inside the tube when oil filling. The air sucked in through this hole
when draining might disturb the function of some types of pumps. In such case, drain
the oil using a hose instead.
CAUTION
Never block the hole in the draining tube!

Use the filtering equipment or the pump to drain oil from the on-load tap-changer into
carefully cleaned oil drums. Connect the pump to the oil valve and drain the oil from
the diverter switch housing and the conservator. Draining can be effected quickly if
filtering equipment is used and at the same time the whole oil quantity will be filtered
once. Remove the cover of the diverter switch housing while draining.
WARNING
There is always a cushion of explosive gases in the top of the diverter switch
housing. No open fire, hot surfaces or sparks may be present during opening of
the housing or draining from the valve. After the cover is removed let the gas
vent away approximately 15 min before any work is started.

WARNING
When oil that has been used in a diverter switch housing is pumped out,
conducting tubes and hoses that are earthed should be used to avoid the risk of
explosion due to the gases produced by the arcs during service.

Drain the remaining oil in the bottom of the housing by using a hose.

Lifting eye
Buffer springs

Lifting device

Shielding ring (only for impulse


withstand voltages to earth
exceeding 380 kV). (Not on
UCG short with the transition
resistors lying down.)

Tie-rod Self-coupling
plug-in contacts

Coupling with Guiding pins


driving-pin

Fig. 5. Diverter switch, general arrangement

22
3 Overhaul

3.5 Lifting and Cleaning the Diverter Switch


The weight of the diverter switch is approximately 90 kg.
Lift the diverter switch partly so you can flush it with oil. After careful flushing, lift
the diverter switch from the housing and wipe it with rags. Lift according to Fig. 7.
NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB Components and it is maintained and operated according to our
instructions, the flushing and wiping of the diverter switch is not necessary.

CAUTION
When lifting the diverter switch, use a manually operated telpher to avoid damages on
the diverter switch. Make sure that the end of the tie-rod or its coupling is kept clear
of the inner edge of the flange.

3.5.1 Lifting Rig


The diverter switch (mass approximately 90 kg) can be lifted out of the housing by
means of a telpher. As a holder for the telpher, it is recommended to use a rig similar
to the one shown in Fig. 6. Install the supports on the flange of the top-section after
the cover is removed, see Fig. 7.

Ø10
40
70
5 30
Beam

600
Ø56/48

Ø15 (2x)

2500

>5 453

50
65
Ø30
Ø15 (2x)

10
90
125

Support (2x)

Fig. 6. Lifting rig

23
3 Overhaul

WARNING
Make sure the rig is properly fixed to the cover flange before the diverter switch
is lifted.

Beam

Manually operated
telpher

Lifting eye

Support

Fig. 7. Lifting arrangement

3.6 Cleaning
3.6.1 Cleaning the Diverter Switch Housing
Clean the inner walls of the housing by means of a nylon brush, then flush with oil.
Drain the oil. Wipe the bottom and inner walls with rags.

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB Components and it is maintained and operated according to our
instructions, the cleaning of the diverter switch is not necessary.

WARNING
In no case should any person go down into the diverter switch housing. The
cleaning of the diverter switch housing should be carried out by using brushes
and rags and by flushing with oil.

Drain the housing completely by using a hose before oil filling is carried out.

24
3 Overhaul

3.6.2 Cleaning the Oil Filter in the Conservator Pipe


(if any)
The diverter switch housing and the oil conservator are connected by a pipe. The
diverter switch oil is contaminated due to the arcing that occurs when the contacts
operate. In case of a common conservator with the transformer the impure oil in the
diverter switch housing must be prevented from entering the oil conservator. An oil
filter is therefore mounted in the pipe.
The filter, which is mounted in a flange pipe on the top of the diverter switch housing,
is screwed from the inside. It can easily be screwed out for inspection and cleaning.
The oil filter does not need to be replaced nor cleaned in any other way than by
washing with oil.

Screws Housing Filter element

Fig. 8. Oil filter details

3.7 Oil Filtration


The drained oil should be filtered until it is cleaned and has regained the high
dielectric strength required. The break-down value for purified oil should be at least
160 kV/cm according to IEC 156.
To check the result of the filtering, take test sample after the oil has been filled into
the on-load tap-changer.
NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB Components and it is maintained and operated according to our
instructions, no further oil filtration is necessary. Only take an sample and measure
the dielectric strength of the oil, see section ”Oil Testing and Oil Draining” in this
guide.

25
3 Overhaul

3.8 Checking of the Breathing Device


Check the breathing device according to the instructions from the transformer
manufacturer.

WARNING
The breathers and the tube from the conservator contains explosive gases. No
open fire, hot surfaces or sparks may be present when loosening the breather.

3.9 Checking the Contact Positions


Those parts of the fixed contacts and the moving contacts which are exposed to arcing
during an operation are tipped by copper-tungsten.
In a tap position, the moving main switching contacts and the fixed main switching
contacts should have a clearance of min. 0.5 mm as shown in Fig. 9.
For checking the clearance on both sides of the diverter switch it has to be operated.
Operate it by turning the coupling with a pipe wrench, see Fig. 5. Note the position of
the diverter switch before operation.

WARNING
Take care to avoid finger injuries when operating the diverter switch. Oil splash
occurs during operation, especially in the moving direction.

If the clearance is too small you may adjust the clearance by installing a shim of brass
between the board and the current bar. The shims are included in the spare parts set.
The shim dimensions are also shown in Fig. 9. Operate the diverter switch to the
opposite side when mounting the shims.
Operate the diverter switch back to the first side and check the clearance again. If still
too small, put in a shim more and test again.

CAUTION
Never mount more than three shims on each other.

Make sure all washers and screws are put back and tighten. Proceed with the other
side of the diverter switch. When finished, operate the diverter switch back to the
position it had before the first operation.
Fig. 9 shows the current carriers through the fixed main contact and the copper part of
the moving contact.
Fig. 10 shows the copper-tungsten tips of the transition contact touching each other in
a tap position.

26
3 Overhaul

0.5–2 mm
Fixed main
switching contact

Moving main
switching contact

20

14

Ø6.4 Copper part


26
14

Thickness 1 mm
Current bar Moving main
Fixed main contact
contact
Board

Fig. 9. Fixed and moving contacts clearance

Fig. 10. Transition contacts

Make sure that all flexible connections, operating springs, contact springs and all
plug-in contacts are in good condition. Make sure that no bolts have worked loose

27
3 Overhaul

3.10 Checking the Contact Wear


The contact system consists of fixed and moving contacts.
Check the degree of contact burning on the breaking contacts.
For a new contact with tips of copper-tungsten (Fig. 11), the thickness at (A) and (B)
is 5.5 mm in the upper end of the contact. In the lower end, the thickness is 3 mm.
Estimate the degree of contact burning and record this to enable comparison with the
condition at the next overhaul. Do not file or smooth the burned and pitted contact
surfaces.
A contact with a tip of copper-tungsten (Fig. 11) should be replaced when the
thickness at (A) and (B) in the upper end of the contact is approximately 0.5 mm. (The
thickness in the upper and the lower end of the tip will be approximately the same
when close to the limit for replacement).
Also replace contacts which are assumed to wear out before the next overhaul.
The dimensions above are valid for both main contacts and transition contacts. For
contact replacement, see chapter 4 ”Contact Replacement”.

A B

Fig. 11. Tolerance limits for contact erosion

3.11 Checking the Transition Resistors


Measurement is carried out on the side with open contacts. Connect one cable from
the ohmmeter to a fixed main contact and the other cable to a fixed transition contact.
Measure the resistance.
Measure the resistance of each resistor branch across the open switch.
Operate the diverter switch to the other side as described in section 3.9 and measure
the resistance with open contacts.

28
3 Overhaul

Check that the resistors are undamaged and compare with the value on the rating plate.
The values must not differ by more than 10 %.
Check that nothing has worked loose. Operate the diverter switch back to its previous
position.

3.12 Checking before Closing


Before installing the diverter switch, make sure that no foreign objects, tools, wires,
rags etc. are left in the diverter switch housing.

3.13 Installation of the Diverter Switch


CAUTION
Check the serial numbers to make sure that the diverter switch is mounted in the
correct housing, see Fig. 2.

CAUTION
Make sure that the diverter switch housing is clean and dry and that no foreign
objects (tools etc.) are left in the housing.

CAUTION
Lower the diverter switch into its housing carefully so that neither the diverter switch
nor the housing are damaged.

The UCG diverter switch is provided with a guiding slot that fits against the oil
draining tube in the diverter switch housing, see Figs. 12 and 13.
Rotate the diverter switch so the half-circle shaped guiding slot is aligned with the oil
draining tube, see Figs. 12 and 13.
When the diverter switch is lowered, check visually that its plug-in contacts are
aligned with the contacts in the cylinder wall.
In order to ensure that the diverter switch pin has engaged the coupling disc, carry out
at least three tap change operations in one direction. A distinct sound is heard when
the diverter switch operates which indicates that the driving pin of the diverter switch
has been connected.
If no sound is heard, the diverter switch might need to be pushed down while
operating the motor-drive.
Carry out another three operations in the same direction while pushing the diverter
switch down.
The top part of the diverter switch lifting device should be below the level of the
machined surface for the cover when lowered to its final position. Only the springs of
the lifting device should be above this level.

29
3 Overhaul

If a check of contact timing should be carried out, proceed with that according to
section 3.19 before mounting the cover.
Insert a new O-ring for the cover in the upper flange. Mount the on-load tap-changer
cover. Turn the cover so the guiding pin in the housing is facing the guiding hole in
the cover. (The cover has to be pressed down in order to overcome the spring force of
the springs which hold the diverter switch pressed in place.) Insert screws and washers
and tighten them.

Springs
Lifting device
Lifting eye

Shielding-ring (when the impulse withstand


voltage to earth exceeds 380 kV) (not on
UCG short version)

Serial number
(on the opposite
side of the Plug-in contacts
diverter switch) A A
Guiding pin
Guiding pin Tie rod
fm_00223
Driving pin

Fig. 12. Diverter switch

Coupling disc Notch for the


guiding pin

Oil draining
tube
Holes for Guiding pins
guiding pins
Slot for the oil
Slot for draining tube
guiding bar

A–A,
TC_00284
UCG TC_00285

Fig. 13. UCG Diverter switch housing, view from above

30
3 Overhaul

3.14 Checking the Pressure Relay


3.14.1 Functional Check of the Pressure Relay

Information
plate

Valve handle
(in service
position)

Quick coupling

Test tap (R 1/8”)


TC_00264

Fig. 14. Pressure relay

1. Set the valve handle to the test position as shown on the information plate.
2. Connect the air pump and the pressure gauge to the test tap on the pressure relay.
(Thread R 1/8”).
3. Raise the pressure until the pressure relay trips the circuit breakers of the
transformer.
4. Read the pressure on the manometer and check against the pressure stated on the
information plate. Max. permitted deviation is ±10 %. If the deviation is greater,
the pressure relay should be replaced.
5. Check that the signal disappears when the pressure is released.
6. After finishing the check, turn back the valve handle to service position.

3.14.2 Replacing the Pressure Relay


If replacement of the pressure relay is necessary, it is carried out according to the
instruction in 1ZSE 5492-129, Repair Guide for On-Load Tap-Changers types UCG,
UCL, UCC, UCD.

31
3 Overhaul

3.15 Lubrication of the On-Load Tap-


Changer and the Drive Shaft System
The bevel gears are greased at delivery and the same type of grease is used for the
couplings of the outer shaft system.
For access to the couplings, loosen the hose-clips and push the protective tubes
together. For access to the bevel gears, dismount the covers.

WARNING
The bevel gear contains moving gears. Be cautious!

WARNING
Rotating shafts. Be cautious!

Check and lubricate with grease if necessary. Recommended types of grease are
GULF-718 EP Synthetic Grease, Mobilgrease 28, Shell-Aero Shell Grease 22 or
similar.
Remount covers (make sure the gaskets are properly in place).

3.16 Checking of Motor-Drive Mechanisms


types BUE and BUL
The motor-drive mechanism should be checked and lubricated at the same time as the
on-load tap-changer.
The overhaul includes the following points:
Before disconnecting the power supply:
Motor protection function
Earth fault protector (option)
Counter function
After disconnecting the power supply:
Heater function
Toothed belt
Cable connections
Disc brake function
Position transmitter and other position switches
Lubrication
Reconnect the power supply and make operation tests according to section 3.17.

32
3 Overhaul

Brake
Brake disc
Maintaining contact

Roll pin

Supporting
shaft

Brake block
Arm system
Brake for maintaining contact Driving roller

One turn shaft


Cam disc

Toothed belt

Geneva wheel

Position
transmitter

Contact plate

fm_00137
Motor

Fig. 15. Motor-drive mechanism, type BUE

33
3 Overhaul

Operation counter

Roller
(Grease)
Notch
Cam disc

(Grease)

Brake arm

Geneva
wheel Adjusting
screw

Maintaining
contact

Bracket

Brake disc
Limit switch

Toothed belt

Multi-position switches
(Grease)

fm_00231

Fig. 16. Motor-drive mechanism, type BUL

34
3 Overhaul

3.16.1 Motor Protection


The function of the protective motor switch is checked. For three-phase AC motors,
one of the phase fuses is removed and the function time of the protective motor switch
is checked by a RAISE or LOWER operation. The protective motor switch shall
release within 60 seconds at a current setting equal to the rated current of the motor at
actual voltage.

WARNING
The motor power voltage is dangerous.

If the protective motor switch do not trip within 60 seconds, switch off the power and
adjust the current setting. Repeat the test when the motor is cold.
Protective motor switches for DC motors and for single-phase AC motors are not
tested.

3.16.2 Earth Fault Protector (option)


If the motor-drive mechanism is equipped with an outlet, the earth fault protector
should be tested by pressing the test knob on the outlet. (On BUL, the earth fault
protector is separated from the outlet and knob is on the relay).

3.16.3 Counter
Check that the counter is functioning at RAISE and LOWER operations.
Check that the position indicator increases (decreases) one step and the counter
advances one step for each operation. Record the counters value. The counter shows
the number of operations run by the on-load tap-changer.

3.16.4 Heater
WARNING
Before starting any work inside the motor-drive mechanism, the auxiliary power
must be switched off.
N.B. The motor, contactors and heating element may be energized from separate
sources.

Check by feeling with a finger that the heating element has been functioning.

3.16.5 Toothed Belt


Check that the toothed belt is sufficiently tight. If tightening is required, adjust the
motor support. The tightness of the belt can be checked by a spring balance attached
to the belt halfway between the pulleys. At a 10 N load the belt should yield about
5 mm on BUE and at a 6 N load the belt should yield about 2 mm on BUL.

35
3 Overhaul

3.16.6 Motor Cable Connections


Check that all cable connections within reach are secure.

3.16.7 Disc Brake, BUE


Wipe the brake disc free from grease.
The kinetic energy in the motor and the toothed wheels should be absorbed by the
brake, and the motor-drive mechanism should stop as shown in Fig. 17, with a
tolerance of ± 25 degrees as measured on the brake disc (± 125 degrees measured on
the hand crank), see Fig. 17.
This can be adjusted by tightening both of the spring bolts on the brake. Using the
hand crank, operate the motor-drive mechanism until the brake is fully open. At this
point the length of the springs must not be less than 35 mm. If the brake still does not
function with that spring length, oil or grease has entered the brake linings, which will
then need cleaning.
Clean as follows:
Using a pair of tongs, remove the roll pins that hold the supporting shafts on the brake
blocks, see Fig. 15. Then remove the shaft and the brake blocks. Clean the brake
linings on the two brake blocks with degreasing agent.
When refitting the brake, check that the brake disc is completely free from grease.
Adjust the spring force of the brake until the motor-drive mechanism stops within the
tolerances given above.
CAUTION
If the motor-drive still not stops when the brake is adjusted to a spring length of
35 mm when the brake is fully open, please contact ABB Components for advice.

Adjusting nuts

Brake disc

Red mark ±25o


from mark on
brake pad

Red mark fm_00232

Brake pads

Fig. 17. Brake adjustment, type BUE

36
3 Overhaul

3.16.8 Brake for the Maintaining Contact, BUE


Check that the brake for the maintaining contact prevents the arm system on the
maintaining contact shaft from swinging beyond its normal position when the roller on
the driving arm moves free from the cam disc, see Fig. 15. At the end of the operation,
contacts for operation in the opposite direction shall not move when the arm system
swings back towards its normal position.
Unpermitted swinging should be prevented by raising the braking force, i. e.
tightening the spring bolt.
An adjusted increasing spring force on the brake makes the maintaining contact arm
swing back with a different speed, and the brake for the maintaining contact must be
adjusted.

3.16.9 Disc Brake, BUL


Run the motor-drive mechanism and check that the centre of the notch in the cam disc
stops within ±2 mm from the centre of the roller on the brake arm, see Fig. 18. If it
does not stop within the tolerances, adjust the breaking force with the adjusting screw
in the lower end of the brake arm. Loosen the contra nut. Tightening the screw
(clockwise) makes the stop earlier and loosening the screw (anticlockwise) makes the
stop later. Tighten the contra nut after the adjustment.

Roller on the brake arm


in centre of the notch
in the cam disc Brake arm

Cam disc

Contra nut

Adjusting screw

fm_00225 Brake disc

Min 15

Fig. 18. Brake adjustment, type BUL

CAUTION
If the motor-drive still not stops when the brake is adjusted to min. 15 mm according
to Fig. 18 please contact ABB Components for advice.

37
3 Overhaul

3.16.10 Position Transmitter and other Position Switches,


BUE
Clean the contact plates and arms (Fig. 18) from dust and dirt with a dry cloth.
Check and adjust the resilience of the moving contacts in the multi-position switches.
The moving contact shall, in all positions, have a clearance between the nut and the
contact arm of 0.4–1.2 mm. Adjustment is made with the nuts on the contact
(Fig. 19).

Moving contact
Contact arm

Contact arm
0,6 +0.6
-0.2
mm

Geneva wheel

Contact plate
Fixed contact
View A – A

Fig. 19. Contact arm play

3.16.11 Position Transmitter and other Position Switches,


BUL
Check the contact function in all positions at both RAISE and LOWER operations.
No adjustment of the contacts should be made. For replacement of a Position Switch
see 1ZSE 5492-129, Repair Guide, On-Load Tap-Changers, types UCG, UCL, UCC
and UCD.
If there is a lot of dust, it can be removed from the circuit cards and the transparent
covers with a vacuum cleaner, without disassembling the multi-position switch.

38
3 Overhaul

Transparent cover

Contact arm Circuit card

fm_00233

Fig. 20. Position transmitter, checking

3.16.12 Lubrication, BUE


See Fig. 21.
The bearing points of the brake blocks and the links should be sparingly lubricated
with oil. (Use oil for plain ball and roller bearings.)
The spur gears, the geneva wheel with the limit stop, the cam discs and the cam bar
are sparingly lubricated with the same type of grease as for the shaft system when
necessary.
Other bearing points do not need lubrication.
NOTE: Protect the brake disc and the brake linings against lubricants. Wipe off
excess lubricant.
Reconnect the power supplies.

3.16.13 Lubrication, BUL


Lubrication is not needed at normal working conditions. All ball bearings have rubber
seals and are permanently greased. All cam discs and some gears are made of
selflubricating material.
If needed, the bevel gears for the hand crank, the geneva wheels and the bevel gears
for the position indicator might be sparingly lubricated with the same grease as the
shaft system. (GULF-718EP Synthetic Grease, Mobilgrease 28, Shell-Aero Shell
Grease 22 or similar). See Fig. 16.
Reconnect the power supplies.

39
3 Overhaul

Grease
Grease

Oil

Oil

Grease

Grease

NOTE: The small bevel gear for


the position indicator shaft shall
be greased.

Grease

Fig. 21. Lubrication points, BUE

40
3 Overhaul

3.17 Operation Test


Operate the motor-drive mechanism, first by manual operation and then electrically
between the limit positions. Check the limit stops by operating the on-load tap-
changer to one of the end positions. When trying to operate it electrically beyond the
end position, the motor should not start. Check the mechanical end stop by trying to
hand crank it beyond the end position. After a couple of turns on the hand crank it
should be mechanically stopped. Handcrank back to the end position (where the
indicator flag is positioned in the middle for BUE, and when the indicator flag shows
white colour for BUL). Operate the on-load tap-changer electrically to the other end
position and carry out the same test procedure as above.
Check the emergency stop by giving a RAISE or LOWER impulse and after about one
second press the emergency stop. The operation should be interrupted. Reset the
emergency stop by turning the knob clockwise and switch on the protective motor
switch. The started operation should now be completed.
Check the running-through protection with the step-by-step function disengaged. This
is done by first removing the connection between terminals X4:1 and X4:2 and then
keep the RAISE/LOWER switch engaged. The motor-drive mechanism should stop
before the fourth operation is completed. This checking must be done at least five
steps from the end position. After the test reset the time relay by putting the LOCAL/
REMOTE switch to 0 and then back. Reset the protective motor switch to ON.
Remount the connection between X4:1 and X4:2.
Check the step-by-step relay by keeping the RAISE/LOWER switch engaged in
RAISE. The on-load tap-changer shall make only one step. Repeat the check in
LOWER.
Check the function of the position transmitter and other multi position switches in all
positions.

3.18 Oil Filling


If check of contact timing is to be carried out, see section 3.19, fill the diverter switch
housing with oil up to the level of the fixed main breaking contacts by easiest possible
method before checking. Oil fill completely according to the instructions below after
check of contact timing.

3.18.1 Filling Methods and Restrictions


Oil filling can be carried out at atmospheric pressure or under vacuum. The wall
between the diverter switch housing and the transformer tank is designed to withstand
vacuum on one side and atmospheric pressure on the other side. It is not allowed to
have vacuum on one side and the pressure of an oil column on the other side.
After maintenance oil is normally filled at atmospheric pressure. This procedure is
described in section 3.18.3. If filling is to be carried out under vacuum, see 1ZSE
5492-116 Installation and Commissioning Guide for UCG and UCL.

41
3 Overhaul

After oil filling, a gas cushion should remain on the top of the oil in the diverter
switch housing.
The connection to the oil conservator is designed to automatically give a gas cushion
when filling at atmospheric pressure.
NOTE: If new oil, especially degassed oil, is filled into the diverter switch housing
and the number of operations is low, the gas cushion may be dissolved in the oil. The
oil level in the oil conservator should then be checked after a month in service and if
the oil level is lower than after the oil filling, (corrected for temperature differencies),
the gas cushion should be restored according to section 3.18.5 ”Restoring the Gas
Cushion” in this guide.

3.18.2 Before Filling


NOTE: Oil filling may be carried out in different ways depending on what is
convenient as long as the rules above are fulfilled and the on-load tap-changer is
filled with oil to the correct level with a gas cushion on the top. The method below is
recommended and if it is followed in detail no pressure limits are exceeded and oil
levels and gas cushion will be correct. If the on-load tap-changer consists of more
than one unit, fill one at a time.

3.18.3 Filling at Atmospheric Pressure


See Fig. 22.
1. Close the air release valve
2. Open the conservator valve, if any.
3. Dismantle the breathing device on the conservator for the on-load tap-changer.
4. Pump oil into the diverter switch housing via the oil valve (connection dimensions,
see the dimension drawing for the on-load tap-changer). Continue until the
conservator is filled to the correct level at the actual temperature. See even
section 3.18.4. If there is more than one unit connected to the same conservator,
fill all of them until the oil level indicator starts to move and fill up to the right
level when filling the last unit.
5. Shut the oil valve and disconnect the pump.
6. Remount the breathing device. Make sure the connection to the breathing device is
properly sealed.

3.18.4 Oil Level


For correct oil level in the oil conservator, see the transformer documentation.

42
3 Overhaul

3.18.5 Restoring the Gas Cushion


Check the oil level in the oil conservator one month after oil filling. If the oil level is
lower now than when the oil filling was finished (correct for temperature
differencies!) and no leakages are observed, the gas cushion has been solved in the oil
and has to be restored.
The procedure below is used for on-load tap-changers without oil filter unit for
continuous oil filtration. In case the on-load tap-changer is equipped with an oil filter
unit for continuous oil filtration from ABB Components, and it is installed according
to our recommendations, follow the instructions in ”Oil filter unit for on-load tap-
changers, manual” for restoring the gas cushion.
In case the on-load tap-changer consists of more than one unit, do the restoring in one
unit at a time.

CAUTION
To operate the on-load tap-changer with a too small or no gas cushion means a risk
for a trip of the pressure relay.

WARNING
The oil in the diverter switch housing may be hot. Be cautious!

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

43
3 Overhaul

3.18.5.1 Procedure
1. Close the valve in the tube to the conservator.
2. Connect the oil pump to the oil valve. (For connection dimensions, see the
dimension drawing for the on-load tap-changer), see Fig. 22.
3. Open the oil valve and the air release valve.
4. Start the oil pump and drain approximately 15 litres of oil into a clean and dry
container.
5. Close the air release valve.
6. Close the oil valve and disconnect the pump.
7. Connect the output side of the pump to the oil valve.
8. Open the oil valve.
9. Open the valve in the tube to the conservator!
10. Pump the earlier drained 15 litres of oil back into the diverter switch housing.
11. Close the oil valve and disconnect the pump.
12. The level in the oil conservator and the gas cushion are now restored.
If the on-load tap-changer consists of more than one unit, proceed with the other one
until the last one has been restored.

CAUTION
Avoid to do the restoring in damp weather since moisture will get into the diverter
switch housing. If the restoring has to be done in such weather, the incoming air has
to be dehydrated and the drained oil protected from water.

Open end wrench


Oil valve Air release valve key width 6 mm

Open

TC_00251 Oil valve TC_00250

Fig. 22. Air release valve (position may be on another vertical flange)

44
3 Overhaul

3.18.6 Waiting Period


CAUTION
Do not energize the transformer earlier than three hours after oil filling in
atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

3.19 Check of Contact Timing


Checking the contact timing is a good check of the condition of the on-load tap-
changer, but it is not necessary to check contact timing at every overhaul.
It is recommended to be carried out after every 500 000 operations.
The test requires:
Two indicator lamps (glow discharge lamps for the minimum possible
magnetisation of the transformer)
Necessary leads
Two stiff insulated leads or bars.

WARNING
Never force DC current through the transformer windings.

The insulated leads (or bars) are used for connection to the moving contact arms of the
tap selector via the plug-in contacts of the diverter switch (They can be made of an
insulating tube with a lead inside.)
Connect the lamps as shown in Fig. 23.
The diverter switch contacts are designated as shown in Fig. 24.
Determine if x or v contacts are closed, see Fig. 24. In the contact-timing diagram for
the on-load tap-changer you can find out the corresponding position. See Figs. 25
and 26.
The diverter switch housing shall be filled with transformer oil up to the fixed main
contacts to secure the correct function of the dash pots during operation of the diverter
switch, see section 3.18.
At repeated operations in the same direction the selector arms V and H operate every
second time. When the direction of operation is reversed, the contact arms will be at
rest during the first operation. The operation is then performed by means of the
diverter switch only.
NOTE: When testing, the operation must be carried out in the same direction as the
previous operation.

45
3 Overhaul

y u

Fig. 23. Indicator lamp connection during contact timing test

v-contacts
x-contacts

TC_00284

Fig. 24. The diverter switch outlet marking

The test is to be made on all three-phases and is to be carried out as follows:


Find the exact position of the on-load tap-changer by adjusting the disc brake as
shown in Figs. 17 and 18.
1. Note the number of whole turns and parts of turns on the hand crank, during a
slow manual operation.
2. Note when each tap-selector arm breaks and makes (the corresponding lamp goes
out or lights).
3. Note when the diverter switch flicks over (a distinct sound is heard).

46
3 Overhaul

After this, compare the operations with the contact-timing diagram applicable to the
on-load tap-changer in Figs. 25 and 26.
One operation corresponds to 25 turns of the hand crank on the motor-drive
mechanism, type BUE and 15 turns for BUL.
Remove the equipment for contact-time measuring.
Mount the cover of the diverter switch housing according to section 3.13.
Complete the oil filling according to section 3.18.

CAUTION
If the result is beyond the limits given here, please contact ABB Components.

Position Min. 3 turns Position Min. 3 turns Position

–—— Contact closed Turns of the hand crank of the mechanism

Fig. 25. Example of contact-timing diagram, BUE

NOTE: The diverter switch must have switched over before the 20th turn is finished
with the hand crank.

47
3 Overhaul

Position Min. 2 turns Position Min. 2 turns Position

–—— Contact Turns of the hand crank of the mechanism

Fig. 26. Example of contact timing diagram, BUL

NOTE: The diverter switch must have switched over before the 12:th turn is finished
with the hand crank.

3.20 Putting into Operation


Operate the on-load tap-changer to the position noted in section 3.3.1. Put the
LOCAL/REMOTE switch to REMOTE. Reset the drag hands. Make sure that no tools
or foreign objects are left in the motor-drive mechanism cabinet. Close the door. Make
sure that nothing is left on the transformer cover.
Sign the revision protocol and give it to the engineer in charge and inform that the on-
load tap-changer is ready for energizing.

48
4 Contact Replacement

4 Contact Replacement
CAUTION
ABB Components recommends that only authorized personnel from ABB Components
carry out contact replacement.

Replace worn-out main switching contacts and transition contacts as required. (It is
not necessary to replace both main switching contacts and transition contacts if, for
instance, only the main switching contacts are worn out).

CAUTION
Fixed contacts and its corresponding moving contacts should always be replaced at
the same time.

Also replace contacts which are assumed to wear out before the next overhaul.
Replacement of contacts is described in the following sections.

49
4 Contact Replacement

Fixed main switching


contact

Conical
spring-
washer

Fixed transition Plain


contact washer

Locking
washer 1)
Plain
washer

Conical spring Guide pin


washer Conical spring
washer Nut

Plain washer Connection for


Moving transition
transition resistor
contact
Fixed transition
contact

Moving main
switching contact

1)
Mounted vertically
on some types
Fig. 27. Diverter switch, contact design

50
4 Contact Replacement

4.1 Dismantling the Boards

Board

Guide pin

Locking
washer
Screw

Fig. 28. Contact replacement, dismantling the boards

Dismantle the boards from the frame by removing the six screws and the locking
washers from each board (Fig. 28).
Punch the guide pins with a 4 mm mandrel. Note that the guide pins are placed high
on one board and low on the other board in order to make the boards non-reversible.
When mounting, use new locking washers and guide pins.
Lift away the boards in the lifting eye, see Fig. 7 with fixed contacts and transition
resistors from the contact-mechanism (Fig. 29). The boards, which are made of
insulating material, shall be wiped with rags.

51
4 Contact Replacement

Fig. 29. Contact replacement, boards lifted away

4.2 Dismantling the Moving Main Contacts


Dismantle the moving main contacts according to Figs. 30 and 31. Take away split
pins, washers and springs in both ends of shafts 1–3. There is one shaft for each pair
of contacts.
NOTE: Notice that the outer end of the outer phase have washers with a larger
diameter, see Fig. 30.
Do the same for the contacts on the opposite side.
Pull out shaft 1. Take care of the silver washers. Do the same with shaft 3. Punch out
the middle shaft 2 by means of a 5 mm mandrel of brass. Shaft 2 must then be passed
through the holes for shafts 1 or 3 and remain there until new contacts are mounted.
Repeat the procedure for the contacts on the opposite side.

52
4 Contact Replacement

Contact

Washer with
larger diameter

Shaft 1

Shaft 2 Shaft 3

Fig. 30. Contact replacement, taking away split pins

Contact

Shaft 1

Fig. 31. Contact replacement, pulling out shaft

53
4 Contact Replacement

4.3 Dismantling the Moving Transition


Contacts
Dismantling of the moving transition contacts should be carried out according to Figs.
32 and 33.
The transition contacts are held by a common shaft 4 going through all the contacts.
The shaft 4 is locked with two split pins (Fig. 33). Remove the split pins and punch
out the shaft with a 5 mm mandrel of brass and take care of the springs, washers and
contacts when the mandrel is pulled out.
The springs in Fig. 33, view A – A, are loosened in the following way:
Punch out the locking pin in one end of the pin with a 2 mm mandrel. Thereafter the
spring holder can be loosened and the contacts with springs can be removed. Take
care of the pin.
Repeat the above procedure on the other side of the diverter switch.

Shaft 4

Fig. 32. Contact replacement, moving transition contacts

4.4 Mounting the Moving Transition


Contacts
Mount the moving transition contacts according to Fig. 33.
A replacement contact consists of a contact with mounted spring.

54
4 Contact Replacement

Split pins

Shaft

Spring

Washer
(insulating)

Pin
Contact
Locking pin Spring

View A - A

Fig. 33. Transition contact construction

Punch the shaft through the first bearing hole and put a contact, spring, insulating
washer and another contact on the shaft as it is continuously punched in. Then proceed
with the next phase. Finally lock it with new split pins. Mount the springs by means of
the pin and new locking pins.
Proceed with the other side of the diverter switch. Put a ruler on the linings of the
tran-sition contacts. No lining should lie more than 1 mm from the ruler.
If any lining does, adjust these contacts closer to the board by filing off material on
the surface of the contact that lies against the stop shaft.
When all transition contacts on both sides are mounted, make sure that the contacts
move easily in the bearings and that the springs are functioning.

55
4 Contact Replacement

4.5 Mounting the Moving Main Contacts


Fig. 34 shows how to mount the moving main contacts.
Washers and springs shall be placed as shown in Fig. 34.
The contacts are equipped with copper-tungsten tips. Washers and springs shall be
placed as shown in Fig. 34.
CAUTION
The outer end of the outmost phases should have the washers with larger diameter,
(Ø=25 mm) see Fig. 34.

Fig. 34, view A – A shows the replacement contact which consist of two contacts with
a mounted spring, mounted on the current bridge.
Begin with the middle phase. Put the contact and the silver washers on the shaft and
punch the shaft in to the bearing hole with the 5 mm mandrel. Put the next silver
washer and contact in position and punch in the shaft. Mount washers, springs and
split pins according to Fig. 34.
Proceed with the outer phases. Put the outermost silver washer and contact on the
shaft and punch the shaft into the bearing hole. Put the next silver washer and contact
into position and punch in the shaft. Mount washers, springs and split pins as shown in
Fig. 34. Check with Fig. 34 that all containing details are correctly assembled.

Washer with
larger diameter Contact
Contact

Silver
washers Spring

A
View A - A

Split pin TC_00270

Insulating washer

Spring Steel washer

Fig. 34. Moving main contacts with tips of copper-tungsten, washers and springs
Put a ruler on the linings of the moving main contacts. No lining should lie more than
1 mm from the ruler.
If any lining does, adjust these contacts closer to the board by filing off material on
the surface of the contact that lies against the stop shaft.
Carry out the same procedure on the other side of the diverter switch.

56
4 Contact Replacement

4.6 Replacing the Fixed Main Contacts


Unscrew the fixed main contacts, see Fig. 27. Mount new contacts. Use new conical
spring washers and locking nuts.
Put the washers as shown in Fig 27. Press the contacts against their bracket when
tightening the screws. Tightening torque approximately 10 Nm, (not critical).
NOTE: The conical end of the nut should be turned upwards.

4.7 Replacing the Fixed Transition Contacts


Unscrew the screw and nut holding the connection for the transition resistors.
Unscrew the fixed transition contact. Mount new contacts.
Put the washers as shown in Fig. 27. Use new locking washers. Tighten the screws,
tightening torque approximately 10 Nm.
Mount the connection for the transition resistors as shown in Fig. 27. Tightening
torque approximately 10 Nm. Use new conical spring washers and locking nuts.
NOTE: The conicial end of the nut should be turned upwards.

4.8 Mounting the Boards with Transition


Resistors and Fixed Contacts
To assemble the mechanism and the boards with transition resistors and fixed
contacts, do as follows:
When the boards are lowered, put one side of the mechanism on an approximately
50 mm high piece of wood to make the fixed and moving contacts free from each
other (Fig. 35).

57
4 Contact Replacement

Fixed main
contact

Moving main
contact

Piece of
wood

Fig. 35. Contact replacement, mounting the boards

The boards should be fixed with new guide pins (4 x 30 mm, spring-type straight pin
slotted). Guide by inserting a 6 mm mandrel into an adjacent screw hole. Put in and
tighten all screws. Secure the screws with new locking washers (Fig. 28). The plain
washers should be closest to the board.
Check that the linings of the fixed main contacts are aligned with the linings of the
moving main contacts. If not, loosen the nuts slightly and adjust the fixed main
contacts. Tighten the nuts. Check (and adjust, if necessary) the alignment of the
transition contacts as described for the main contacts. Tighten the screws and lock the
locking washers.
Proceed with the other side of the diverter switch by first operating it to the other side
as described in section 3.9.

WARNING
Take care to avoid finger injuries when operating the diverter switch.

Check (and adjust, if necessary) the diverter switch according to section 3.9. Operate
it and check that the contact movement is correct. Remount the diverter switch into the
housing according to section 3.13.

58
5 Specification of Materials

5 Specification of Materials
5.1 General
On disposal of this product, it is recommended that local environmental regulations in
each country are met. For environmental reasons, materials used are specified.

5.2 Diverter Switch Housing


Material Approx. amount

Steel 15 kg

Aluminium 75 kg

Copper and alloys 5 kg

Epoxy resin 35 kg

Transformer oil 150–200 kg

5.3 Diverter Switch


Material Approx. amount

Steel 25 kg
Copper and alloys 10 kg

Silver 25 g

Tungsten 0–1 kg

Polyester resin 20 kg

Presspan 1 kg

Resistor wire (mainly copper and


nickel alloys with small amounts
of aluminium and manganese) 5-50 kg

59
5 Specification of Materials

5.4 Tap Selectors


Tap selector I: Tap selector C:

Material Approx. amount Material Approx. amount

Steel 50 kg Steel 5 kg

Copper and alloys 25 kg Aluminium 15 kg

Silver 0–100 g Copper and alloys 20 kg

Phenol resin laminate 20 kg Silver 70 g

Polyester resin 5 kg Polyester resin 5 kg

Epoxy resin 15 kg

Tap selector III:

Material Approx. amount

Steel 10 kg

Aluminium 40 kg

Copper and alloys 50 kg

Silver 10 g

Polyester resin 10 kg

Epoxy resin 20 kg

5.5 Conductors
Material Approx. amount

Copper 5-10 kg

Cellulose

5.6 Gearing Mechanism


Material Approx. amount

Steel 15 kg

Copper and alloys 5 kg

60
5 Specification of Materials

5.7 Drive Shaft Systems


Material Approx. amount

Steel 8 kg

Aluminium 2 kg

Brass 2 kg

Polyethylene 2 kg

5.8 Motor-Drive Mechanism


BUE BUL

Material Approx. amount Approx. amount

Steel 100–120 kg 55 kg

Copper and alloys 5–10 kg 5 kg

Aluminium and alloys – 10 kg

Silver 10 g 10 g

Plastics:
chlorsulphonated polyethylene x x
polyamide with MoS2 x x
phenol resin laminate x
polyester x x
PVC x x
carbonate plastic x x

Rubbers:
nitrile rubber x x
fluorine rubber x x

CAUTION
Materials listed in the table above without any specification of amount are included
because they may cause pollution problems during de-commissioning, even in the
small quantities used.

61
1ZSE 5492-124 en, Rev. 5, 1999-11-30

ABB Power Technology Products AB


Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com
1ZSE 5492-129 en, Rev. 6, 1999-11-30

On-load tap-changers, types UCG, UCL, UCC and UCD


with motor-drive mechanisms, types BUE and BUL

Repair Guide
This document must not be copied without our written permission, and the
contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Recommended Practices
ABB Components recommends careful consideration of the following factors for service
and repair work on on-load tap-changers.
Do not repair an on-load tap-changer or motor-drive mechanism with a serious
mechanical or electrical fault without first consulting ABB Components.
Before you start any work, make sure that the personnel doing the job have read and
fully understood the Repair documents provided with the unit.
To avoid damaging the unit, never exceed the operating limits stated in delivery
documents and on rating plates.
Do not alter or modify a unit without first consulting ABB Components.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and procedures.

WARNING, CAUTION and NOTE


WARNING
A WARNING provides information which, if disregarded, could cause injury or
death.

CAUTION
A CAUTION provides information which, if disregarded, could cause damage to the
equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work
described.

Safety Precautions
CAUTION
ABB Components recommends that only service engineers with appropriate skills
regarding on-load tap-changers carry out the repairs.

CAUTION
ABB Components recommends that only maintenance engineers trained by ABB
Components carry out contact replacement.

iii
WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

WARNING
The relevant technical documents should be read and understood before any
work is started, and the procedures in this document should be followed at all
times.

WARNING
Before carrying out work on the on-load tap-changer, put the LOCAL/
REMOTE switch in the motor-drive mechanism to position 0. It is also
recommended to shut the door of the motor-drive mechanism and pad lock it
when work is carried out on the on-load tap-changer. The key should be kept by
the operator. This is done to avoid unexpected start of the motor-drive
mechanism.

WARNING
Before starting any work inside the motor-drive mechanism, the auxiliary power
must be switched off.
N.B. The motor, contactors and heating element may be energized from separate
sources.

WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.

During Service
WARNING
Small amounts of explosive gases will always come out from the breathing
devices (dehydrating breather or one-way breather). Make sure that no open
fire, hot surfaces or sparks occur in the immediate surroundings of the breathing
devices.

WARNING
If a failure in power supply occurs during operation, the operation will be
completed when the power returns.

iv
WARNING
The hand crank must not be inserted during electrical operation.

WARNING
If the on-load tap-changer is not in its exact position and the hand crank is pulled
out, the motor-drive mechanism will start and go to the exact position if the
power supply is on.

CAUTION
After a pressure relay trip, follow the instructions in the chapter ”Pressure Relay” in
this Guide.

During Oil Handling


WARNING
Unused transformer oil is slightly harmful. Fumes from unused warm oil may
irritate the respiratory organs and the eyes. After long and repeated contact with
transformer oil skin becomes very dry.
Used on-load tap-changer oil from diverter switch housings and selector switch
housings contains harmful substances. Fumes are irritating to the respiratory
organs and the eyes and are very easily set on fire. Used transformer oil may well
be carcinogenic.
Avoid contact with the oil as much as possible and use oiltight protective gloves
when handling the oil.
First aid:
Skin contact: Wash the hands. Use skin cream to counteract drying.
In the eyes: Rinse the eyes in clean water.
Swallowing: Drink water or milk. Avoid vomiting. Call a doctor.
Collect used oil in oil drums.
Waste and cleaning up: Should be absorbed by an absorber. Treat it as
hazardous to the environment.
Upon fire: The fire should be extinguished by using powder, foam or carbon acid.

CAUTION
Do not fill oil into the on-load tap-changer if the transformer tank is under vacuum
and the on-load tap-changer is not.

CAUTION
Do not fill oil into the transformer tank if the on-load tap-changer is under vacuum
and the transformer tank is not.

v
CAUTION
Leave a gas cushion on top of the oil in the diverter switch housing.

NOTE: Check the oil level one month after filling. It is usual for the oil level of the oil
conservator to fall due to gas absorption in the oil from the gas cushion in the diverter
switch housing, if the on-load tap-changer is not operated. Restore the gas cushion
and the oil level according to section 3.3.

WARNING
When oil that has been used in a diverter switch compartment is pumped out,
conducting tubes and hoses that are earthed should be used to avoid the risk of
explosion due to the gases produced by the arcs during service.

WARNING
The oil in the diverter switch compartment may be hot. Be cautious!

CAUTION
Take care to avoid ingestion of moist air when oil is drained. If the ambient air is
moist, let incoming air pass through a dehydrating breather with slow air flow to
obtain proper dehydration.

WARNING
There is always a cushion of explosive gases over the oil surface. This is sucked
into the on-load tap-changer tank during draining of the oil. No open fire, hot
surfaces or sparks may be present when the top cover is opened.

Mounting of Gaskets
CAUTION
Sealing surfaces and gaskets must be clean and undamaged. Diametrically opposed
bolts in sealing joints must be tightened alternately several times, beginning with a
low tightening torque and finally with the recommended tightening torque as
described in section 1.6 Tightening Torque, in this guide.

After Oil Filling


CAUTION
Do not energize the transformer earlier than three hours after oil filling in
atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

vi
Contents
1 Introduction ____________________________________________ 9
1.1 General ________________________________________________ 9
1.2 Repair Categories _______________________________________ 9
1.3 Serial Number __________________________________________ 11
1.4 Spare Parts List _________________________________________ 11
1.5 Maintenance Guide ______________________________________ 12
1.6 Tightening Torque _______________________________________ 12
2 Trouble-shooting ________________________________________ 13
2.1 On-Load Tap-Changer ____________________________________ 13
2.2 Pressure Relay __________________________________________ 14
2.3 Motor-Drive Mechanism __________________________________ 15
2.3.1 Control System _________________________________________ 15
2.3.2 Power System __________________________________________ 17
2.3.3 Miscellaneous __________________________________________ 17
3 Repairs and Adjustments __________________________________ 22
3.1 Replacement of Gear Box on the On-Load Tap-Changer or
Replacement of O-rings for the Gear box _____________________ 22
3.1.1 General ________________________________________________ 22
3.1.2 Tools Required _________________________________________ 22
3.1.3 Material and Spare Parts Required __________________________ 22
3.1.4 Procedure ______________________________________________ 23
3.2 Replacement of Diverter Switch Housing Cover Gasket _________ 27
3.2.1 General ________________________________________________ 27
3.2.2 Tools Required _________________________________________ 27
3.2.3 Material and Spare Parts Required __________________________ 27
3.2.4 Procedure ______________________________________________ 27
3.3 Restoring the Gas Cushion ________________________________ 28
3.3.1 General ________________________________________________ 28
3.3.2 Equipment Required _____________________________________ 29
3.3.3 Procedure ______________________________________________ 29
3.4 Replacement or addition of a Multi-position Switch (BUL only) __ 30
3.4.1 General ________________________________________________ 30
3.4.2 Tools Required _________________________________________ 30
3.4.3 Procedure ______________________________________________ 31
3.5 Examination of the Diverter Switch after a Pressure Relay Trip ___ 33
3.5.1 Tools and Material Required _______________________________ 33
3.5.2 Procedure ______________________________________________ 33
3.6 Tests of the Pressure Relay ________________________________ 34
3.7 Replacement of Pressure Relay _____________________________ 35
3.7.1 General ________________________________________________ 35
3.7.2 Tools Required _________________________________________ 35
3.7.3 Spare Parts Required _____________________________________ 35
3.7.4 Procedure ______________________________________________ 35

7
8
1 Introduction

1 Introduction
1.1 General
The UC range of on-load tap-changers manufactured by ABB Components has been
developed over many years to provide maximum of reliability. The simple and rugged
design gives a service life equal to the service life of the transformer. Minimum
maintenance is required for trouble-free operation. The only parts requiring
maintenance are contacts that might need replacement during the service life, the
insulating oil and the motor-drive mechanism.
The design allows excellent access to all parts, making inspection and maintenance
quick and simple.
The on-load tap-changers, type UC, are housed in the transformer tank. The motor-
drive mechanisms, types BUE or BUL are attached to the transformer tank and
connected to the on-load tap-changer by means of drive-shafts and a bevel gear, see
Figs. 1 and 2.

1.2 Repair Categories


Repairs on the UC range of on-load tap-changers fall into two categories:
Repairs. Repairs are to replace worn or end-of-service-life parts.
Modifications. Modifications are only issued by ABB Components to improve the
already very high standard of reliability and to assist in prolonging the service life
of the equipment.
The modifications fall into two areas:
– Immediate, where the modification should be completed at the earliest possible
opportunity.
– Routine, where the modification should be completed during a routine service
interval.

9
1 Introduction

Diverter switch housing Cover


Oil valve

Pressure relay
Bevel gear

Position indicator
Top-section
Serial No.
1)
Shielding-ring
Earthing terminal

Connection flange for Draining tube


gas operated relay
Insulating cylinder
Insulating shaft
Diverter switch
1)
Shielding-ring
2)
Shielding-ring
Transition resistors Plug-in contacts

Fixed and moving


contacts

Serial No. Bottom section

Guide-pins
Current terminal

Driving disc for the


diverter switch Tap selector

Bottom valve for


drying process

Intermediate gear
Geneva gear

1)
Only at impulse withstand Change-over
voltage to earth of 650 kV selector
and 1050 kV

2)
Not on UCG of the short type Moving fine-
selector contacts Current collector

Fixed fine-selector
contacts

Fig. 2. General arrangement of on-load tap-changer, type UC.

10
1 Introduction

1.3 Serial Number


Before consulting ABB Components for technical advice to assist with repairs or to
order spare parts to complete the repairs, the on-load tap-changer serial number must
be known. The serial number can be found on the following locations:
Rating plate on the motor-drive mechanism (Fig. 2)
Diverter switch housing (Fig. 1)
Diverter switch (Fig. 1)
Tap selector (Fig. 1).
If the on-load tap-changer serial number cannot be obtained, the transformer serial
number should be used (only if the transformer is manufactured by ABB Transform-
ers in Ludvika, Sweden).
NOTE: One of these serial numbers must be quoted in all correspondence and telefax
messages, and during any telephone conversations with ABB Components. Failure to
use the serial number may cause delays.

Serial No.

FM_00200 FM_00006

BUL BUE

Fig. 2. Rating plate

1.4 Spare Parts List


The Repair Guide does not contain information about spare parts and how to order
them. For information about spare parts, please refer to the 1ZSE 5492-133 Spare
Parts List for the UC range of On-Load Tap-Changers with Motor-Drive
Mechanisms, types BUE and BUL.
The Spare Parts List also contains several exploded views, which can be very handy
when making repairs.

11
1 Introduction

1.5 Maintenance Guide


Inspection and overhaul of the UC range of on-load tap-changers are carried out
according to the instructions in the appropriate Maintenance Guide. You will need the
Maintenance Guide since references are made to it.

1.6 Tightening Torque


The following tightening torques are recommended
for metallic screw joints: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %

for non-metallic screw joints: M10, 9 Nm ±10 %


M12, 13 Nm ±10 %
M16, 22 Nm ±10 %

if not otherwise is stated in this guide.

12
2 Trouble-shooting

2 Trouble-shooting
This chapter mainly contains information used to locate a fault. Instructions for
correcting the fault, replacement of parts etc. are contained in chapter 3 Repairs and
Adjustments.

2.1 On-Load Tap-Changer


Error condition Fault finding procedure

High oil level alarm A rising oil level in the on-load tap-changer
conservator may indicate a leakage between the
diverter switch housing and the transformer tank.
Make sure that the cause for the alarm is not over-
filling at commissioning or overhaul. This can be
checked by adjusting the oil level according to the
transformer documentation and then rechecking some
time later.
Low oil level in the 1. Check for leakages.
oil conservator
2. If no leakages are found, the gas cushion is solved in
the oil and should be restored. Follow the instructions
in section 3.3 in this guide.
Pressure relay trip See section ”Pressure Relay” in this guide.

13
2 Trouble-shooting

2.2 Pressure Relay


WARNING
To take the transformer into service after a pressure relay trip without carrying
out a careful investigation of the diverter switch by lifting it out of the diverter
switch housing, and repairing faults, if any, may cause severe damages to the on-
load tap-changer and the transformer.

Error condition Fault finding procedure

The pressure relay has 1. Examine the diverter switch according to section
tripped during normal 3.5 ”Examination of the diverter switch after a
operation. pressure relay trip” in this guide. Continue with
steps 2 and 3 if no fault is found.
2. Carry out tests on the pressure relay according to
section 3.7 ”Tests of the pressure relay” in this
guide.
3. The on-load tap-changer is now ready for service.

Information plate

Valve handle

Connection nut

Test tap (R 1/8’’)

TC_00264

Fig. 3. Pressure relay

14
2 Trouble-shooting

2.3 Motor-Drive Mechanism


2.3.1 Control System
Error condition Fault finding procedure

LOCAL operation or 1. LOCAL operation is not possible when the control


REMOTE operation is selector switch is in position REMOTE or 0, and
not possible. REMOTE operation is not possible in position
LOCAL or 0.
2. Check the power supply both for control and
motor.
3. Check if the protective motor switch has been
released.
4. Check if the emergency stop has been pressed.
Release by turning clockwise and reset the
protective motor switch.
5. Check if the running-through protection has been
released. Reset by setting the LOCAL/REMOTE
switch to 0 and then back to previous position and
after that reset the protective motor switch.
6. If the motor-drive has been handcranked against
the mechanical endstop, handcrank back to end-
position.

The on-load tap-changer 1. Check that the maintaining contact releases after
performs more steps than operation.
ordered, or operates
towards the end stop. WARNING
Dangerous voltage!

2. Check that the raise and lower contactors function


properly (see circuit diagram, Fig. 4 respectively
Fig. 6, and contact timing diagram, Fig. 5
respectively Fig. 7).

BUE:
3. Check that the brake disc stops in its middle
position with a tolerance of ±25 degrees. For
information about how to adjust the brake, refer to
the Maintenance Guide.
4. Check that the starting contact fuctions properly
(see circuit diagram and contact timing diagram).

15
2 Trouble-shooting

Error condition Fault finding procedure

BUL:
3. Check that the roller on the brake arm stops in the
middle of the notch in the cam disc.
For information about how to adjust the brake, see
the Maintenance Guide.

The remote position 1. If there is a measuring amplifier:


indicator shows wrong Adjust the output signal from the measuring
position or there is no amplifier with its two adjustment screws. If the
signal. failure does not disappear, proceed as follows:

WARNING
Dangerous supply voltage!

Measure the output signal from the measuring


amplifier in all positions. The signal shall raise
linear up to the highest position.
If no signal, check the feeding to the measuring
amplifier and to the position transmitter.
Check that the signal reaches the position
indicator.
2. Measure the resistance on the terminals of the
position transmitter in all positions after both raise
and lower operations.

WARNING
Before starting any work inside the motor-
drive mechanism, the auxiliary power must be
switched off.
N.B. The motor, contactors and heating element
may be energized from separate sources.

BUE:
3. Check that the contact plate and arm on the
multi-position switch are free from dust and oxide.
Check the contact function with the moving
contact arm in all positions.

16
2 Trouble-shooting

Check the resilience of the moving contacts in the


multi-position switch.
For information about how to adjust the resilience,
see the Maintenance Guide.

BUL:
3. If the resistances are wrong replace the position
transmitter. See section 3.4 in this guide.

2.3.2 Power System


Error condition Fault finding procedure

The three-phase motor runs Reverse two of the phases of the incoming supply.
back and forth without the
on-load tap-changer WARNING
changes position. Dangerous voltage!

2.3.3 Miscellaneous
Error condition Fault finding procedure

Corrosion and/or conden- 1. Check the function of the anti-condensation heater.


sation in motor-drive Refer to heater in the Maintenance Guide.
mechanism cabinet.
2. Check that the air vents not have been blocked.

Water in motor-drive 1. Adjust the hinges on the cabinet door, if necessary.


mechanism cabinet.
2. Replace the door gasket, on the cabinet.

17
18
fm_00236
2 Trouble-shooting

tap-changer.
Fig. 4. Standard circuit diagram BUE

For actual information use the circuit diagram delivered with your on-load
1)
Continuation contact is only included when the on-load tap-changer has through positions.
Closed when the on-load tap-changer is in through positions.
2 Trouble-shooting

fm_00237

Fig. 5. Contact timing diagram BUE

19
20
fm_00238
2 Trouble-shooting

tap-changer.
Fig. 6. Standard circuit diagram BUL

For actual information use the circuit diagram delivered with your on-load
1)
Continuation contact is only included when the on-load tap-changer has through positions.
Closed when the on-load tap-changer is in through positions.
2 Trouble-shooting

fm_00239

Fig. 7. Contact timing diagram BUL

21
3 Repairs and Adjustment

3 Repairs and Adjustments


3.1 Replacement of Gear Box on the
On-Load Tap-Changer or Replacement
of O-rings for the Gear box
3.1.1 General
This instruction guides you on how to replace the gear box on the top section of the
UCG, UCL and UCC, UCD on-load tap-changers.
If the gasket only is to be replaced, follow appropriate parts of the instructions.

CAUTION
When making this repair it is important that neither the on-load tap-changer nor the
motor-drive mechanism is operated with the shafts disconnected.

WARNING
The gearbox contains moving gears. Be cautious!

3.1.2 Tools Required


Normal set of handtools
Socket wrench with extension socket for 8 mm Allen screw
Sliding caliper
Graduated limb.

3.1.3 Material and Spare Parts Required


Gear Box
O-ring (84.1 x 5.7), for UCL
O-ring (92.5 x 5.7), for UCG, UCC, UCD
Loctite 601 (UCL)
Low temperature grease (ball bearing grease) GULF-718EP, Mobil-Grease 28,
SHELL-Aero Shell Grease 22 or similar
Locking device for the motor-drive (delivered with the unit).

22
3 Repairs and Adjustment

3.1.4 Procedure
WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

WARNING
The oil in the diverter switch housing may be hot. Be cautious!

Tap-Changer from above

Red point

Position indicator Position indicator

Exact position

TC_00257
Tolerances
Bolts and tightening washers

Fig. 8b. Gear box, Fig. 8a. Gear box, UCL


UCG, UCC, UCD

Position indicator

TC_00156

Clamps, washers and screws

Locking device
TC_00151

Fig. 8c.

23
3 Repairs and Adjustment

WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.

1. Lower the oil level of the transformer to just below the cover. For information
about oil draining, refer to the transformer documentation.
2. Operate the on-load tap-changer electrically one step and let it stop in service
position. Note the service position of the on-load tap-changer.
3. Operate the motor-drive by hand cranking the few degrees needed to position it in
its exact position as given in section ”disc brake” in the appropriate maintenance
guide.
4. Lock the motor-drive mechanism with the locking device delivered with the unit.
5. Remove the cover of the gear box to be replaced. If the on-load tap-changer
consists of more than one unit driven by the same motor-drive, remove the covers
of all the gear boxes.
CAUTION
The gear boxes, and the transformer when the gear box is removed, must be protected
from water. If there is the slightest risk for rain or snow, some kind of protection must
be arranged.

6. Check that all units are in their exact position acc. to Fig. 8. The opening in the
brass toothed wheel should face the red point in the gear box housing exactly in all
units. Max permitted deviation is shown in Fig. 8.
Also check that all units are in the same service position as the motor-drive.
If something is out of range, please consult ABB Components for advisory.

CAUTION
To take an on-load tap-changer that is not aligned and/or out of position into service
means a great risk for damaging both the on-load tap-changer and the transformer.

CAUTION
It is very important that the following instructions are followed in detail to make sure
that the on-load tap-changer will be properly lined up after the repair.

If gear boxes on more than one unit on an on-load tap-changer with two or three
units driven by the same motor-drive are to be replaced, replace one at the time as
described below. Start with the one closest to the motor-drive.
7. Loosen the hose clamps on the protection tubes on the shaft/shafts to be removed.
Push the tubes together to get access to the couplings.

CAUTION
Note in which direction the gear box is mounted to ensure correct mounting of the
new one.

24
3 Repairs and Adjustment

8. For UCL: Unscrew the four screws (M10, cylindrical head with
hexagon socket 8 mm) holding the gear box, see Fig. 8. These screws are locked
with locking fluid and need considerably high loosing torque.
For UCG, UCC, UCD: Unscrew the four screws M10 for the four clamps that
hold the gear box.
9. If there are two shafts, loosen the screws of one of the brass couplings on the
shaft closest to the motor-drive. Lift out the gear box and take care of the shaft/
shafts when it/they comes/come loose from the gear box. If there are two shafts,
note which sides they belong to.

CAUTION
Make sure that no loose parts fall into the transformer through the hole for the gear
box.

CAUTION
No driving shaft of the on-load tap-changer is allowed to be rotated.

10. Remove the cover of the new gear box.


11. Adjust the new gear box to the same position as the motor-drive and to its exact
position by rotating the shafts.
12. The shafts of the gear box have spherical couplings with driving pins that fit in
the grooves of the couplings in the shaft ends. Turn the driving pin of the vertical
coupling so its flat sides are vertical, parallel to the shaft in the transformer tank.
13. Mount a new O-ring in the flange for the gear box.
14. Check the position of the groove in the coupling of the shaft in the transformer
tank, visible in the hole in the flange for the gear box. The driving pin of the
spherical coupling should be positioned as the groove.
15. Lower the gear box on to the flange, directed as the old one. The driving pin
should enter the groove in the insulating shaft.

CAUTION
The gear box must not be forced down! If the coupling does not engage, lift the gear
box and adjust the setting of the driving pin.

16. For UCL: Mount the four screws (lock the screws with locking fluid) and
the sealing washers.
For UCG, UCC, UCD: Mount the four clamps with screws and washers.
17. If there are two horizontal shafts on the gear box, start with the one closest to the
motor-drive. Connect the end of the shaft with the fixed brass coupling to the gear
box closest to the motor-drive. Put on the protection tubes and hose clamps.

25
3 Repairs and Adjustment

18. Fit the loosened coupling to the replaced gear box. Tighten the two screws closest
to the gear box first leaving an axial play of 2 mm. Tighten the remaining screws.
Check that the position indicator in the gear box is in its exact position, see
Fig. 8. If not, loosen the two screws in the multihole coupling on the gear box
and find the position of the screws that positions the opening in the brass toothed
wheel closest to the red point in the gear box housing. The deviation from exact
alignment must not be more than shown in Fig. 8! Tighten the screws.
19. Apply grease on the couplings. Fit the protection tubes to the gear boxes, turning
the slots downwards. Fit and tighten the hose clamps.
For a single unit on-load tap-changer or when a gear box of the last unit is
replaced, continue with point 23.
If the on-load tap-changer consists of more than one unit and the gear box of
the unit next to the one with replaced gear box also should be replaced, start
doing that by restart from point 7. If not, proceed with point 20.
20. If the replaced gear box has two horizontal shafts, mount the second shaft as
follows:
Loosen the screws holding one of the brass couplings on the shaft. Connect the
end of the shaft with the fixed brass coupling to the gear box it was connected to
before disassembly. Put on the protection tubes and hose clamps. Fit the loosened
coupling to the replaced gear box. Tighten the two screws closest to the gear box
first leaving an axial play of 2 mm. Tighten the remaining screws.
21. Check that the position indicator in the second gear box is in its exact position,
see Fig. 8. If not, loosen the two screws in the multihole coupling on the second
gearbox and find the position of the screws that positions the opening in the brass
toothed wheel closest to the red point in the gear box housing. The deviation from
exact alignment must not be more than shown in Fig. 8! Also check and, if
necessary, adjust the multihole coupling on the gear box of the third unit, if any.
22. Apply grease on the couplings. Fit the protection tubes to the gear boxes, turning
the slots downwards. Fit and tighten the hose clamps.
23. Check that all gear boxes are lubricated with grease. If not, apply grease on the
gears.
24. Make a final check that all gear boxes are in their exact positions within the
tolerance given in Fig. 8 and that all on-load tap-changer units are in the same
service position as the motor-drive.
25. Mount the gaskets and covers of the gear boxes. On UCL there is a slot in the
cover for a gear. Make sure the cover is turned so the slot is above the gear.
26. Refill the transformer with oil according to the transformer documentation.
27. Remove the locking device of the motor-drive. Operate the on-load tap-changer a
few number of operations in both directions to make sure that everything works
properly. Put the on-load tap-changer back in the position noted in point 2.
28. If everything was working properly, the on-load tap-changer is now ready for
energizing.

26
3 Repairs and Adjustment

3.2 Replacement of Diverter Switch


Housing Cover Gasket
3.2.1 General
This instruction guides you how to attend to an oil leakage. The instruction can be
used for all UC-types of on-load tap-changers.

3.2.2 Tools Required


Box wrench (19 mm).

3.2.3 Material and Spare Parts Required


O-ring (8 mm), for UCG 428 x 8, and for UCL 540 x 8
O-ring, for UCD and UCC, 806 x 10
Grease (as for ball-bearings), (see 3.1.3).

3.2.4 Procedure
WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.

CAUTION
Protect the on-load tap-changer from water.

27
3 Repairs and Adjustment

1. Retighten the nuts that hold the cover.


If the oil leakage still remains, the O-ring has to be replaced.

WARNING
The oil in the diverter switch housing may be hot. Be cautious!

WARNING
There is always a cushion of explosive gases in the top of the diverter switch
housing. No open fire, hot surfaces or sparks may be present during opening of
the housing or draining from the valve. After the cover is removed let the gas
vent away approximately 15 min before any work is started.

2. Shut the valve to the oil conservator.


3. Remove the cover. If the oil level is less than 50 mm below the cover, point 6
should be carried out before energizing.
4. Replace the O-ring with a new one. Clean the slot and the corresponding part of
the cover. The O-ring is not to be glued.
5. Mount the cover. Turn the cover so the guiding pin in the housing is facing the
guiding hole in the cover. (The cover has to be pressed down in order to overcome
the spring force of the springs that hold the diverter switch in place). Tighten the
nuts alternately. Tightening torque 42 Nm.
6. Restore the gas cushion, if necessary, according to section 3.3 in this guide.
7. Open the valve to the oil conservator.

3.3 Restoring the Gas Cushion


3.3.1 General
Check the oil level in the oil conservator one month after oil filling. If the oil level is
lower now than when the oil filling was finished (correct for temperature
differencies!) and no leakages are observed, the gas cushion has been solved in the oil
and has to be restored.
The procedure below is used for on-load tap-changers without oil filter unit for
continuous oil filtration. In case the on-load tap-changer is equipped with an oil filter
unit for continuous oil filtration from ABB Components, and it is installed according
to our recommendations, follow the instructions in ”Oil filter unit for on-load tap-
changers, manual” for restoring the gas cushion.

CAUTION
To operate the on-load tap-changer with a too small or no gas cushion means a risk
for a trip of the pressure relay.

28
3 Repairs and Adjustment

3.3.2 Equipment Required


Normal set of handtools
Pump with connection to the oil valve
Dimension drawing of the on-load tap-changer for connection dimensions of the
oil valve.

3.3.3 Procedure
WARNING
The oil in the diverter switch housing may be hot. Be cautious!

WARNING
There is always a cushion of explosive gases in the top of the diverter switch
housing. No open fire, hot surfaces or sparks may be present during opening of
the housing or draining from the valve. After the cover is removed let the gas
vent away approximately 15 min before any work is started.

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

1. Close the valve in the tube to the conservator.


2. Connect the oil pump to the oil valve. (For connection dimensions, see the
dimension drawing for the on-load tap-changer).
Open

TC_00171
Air release valve

Fig. 9.

3. Open the oil valve and the air release valve, see Fig. 9.
4. Start the oil pump and drain oil according to below, into a clean and dry
container.
UCC/UCD: 45 l
UCL: 25 l
UCG: 15 l

29
3 Repairs and Adjustment

5. Close the air release valve.


6. Close the oil valve and disconnect the pump.
7. Connect the output side of the pump to the oil valve.
8. Open the oil valve.
9. Open the valve in the tube to the conservator!
10. Pump the earlier drained oil back into the diverter switch housing.
11. Close the oil valve and disconnect the pump.
12. The level in the oil conservator and the gas cushion are now restored.

CAUTION
Avoid to do the restoring in damp weather since moisture will get into the diverter
switch housing. If the restoring has to be done in such weather, the incoming air has
to be dehydrated and the drained oil protected from water.

3.4 Replacement or addition of a Multi-


position Switch (BUL only)
3.4.1 General
Addition of a multi-position switch as described below is possible when you have
1, 2, or 4 multi-position switches. In other cases the shaft must also be exchanged and
ABB Components should be contacted for further instructions.

3.4.2 Tools Required


Small wrench (10 mm).

30
3 Repairs and Adjustments

3.4.3 Procedure
WARNING
Before starting any work inside the motor-drive mechanism, the auxiliary power
must be switched off.
N.B. The motor, contactors and heating element may be energized from separate
sources.

1. Dismantle the bottom plate, see Fig. 10 on next page.


For replacement also remove necessary distance screws and multi-position
switches, and their conductors.
2. For addition exchange the lower distance screws to new ones, length 20 and 10 or
35 mm.
3. Turn the contact arm on the new multi-position switch to the same position as the
existing multi-position switches. Place the transparent cover on the multi-position
switch and push it all on the shaft. The nob in the hub of the multi-position switch
must enter the groove in the shaft.
4. Reassemble washers and distance screws. Press up the shaft and make sure the
notch on the couplings have entered the grooves in the torque disc. Press down the
sliding bearing in the bottom plate and assemble the bottom plate. Check that there
is no axial play in the shaft. If necessary washers may be removed or added.
5. Note the position of the on-load tap-changer. Operate the the motor-drive
mechanism in all positions both in raise and lower directions and check with a
buzzer that all multi-position switches function properly.
6. Connect the terminals.
7. Reconnect all power supplies to the motor-drive.
8. Operate it back to the position noted in point 5.

31
3 Repairs and Adjustments

Upper coupling half


Torque disc

Lower coupling half

Shaft

Transparent cover

Contact arm Multi-position switch

Distance screw
L = 20 mm

Distance screw
L = 10 mm or 35 mm

Bottom place

Sliding bearing

Fig. 10. Multi-position switch for BUL

32
3 Repairs and Adjustments

3.5 Examination of the Diverter Switch after


a Pressure Relay Trip
The pressure relay has tripped during normal operation.

3.5.1 Tools and Material Required


Maintenance Guide for the on-load tap-changer in question
Lifting device as proposed in Maintenance Guide
Sliding caliper
Rags (non-fuzzying).

3.5.2 Procedure
WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

Close the valve to the oil conservator. Take off the cover of the diverter switch
housing. The oil level should be at least 50 mm below the upper edge of the housing.
If the housing is completely filled with oil or close to, the reason for the pressure relay
trip is likely to be due to this small or absent gas cushion.
Even if the gas cushion is small or absent, the diverter switch should be lifted out of
the housing and be carefully investigated in order to exclude other reasons for the
pressure relay trip. Follow the procedure in section ”Lifting and Cleaning the Diverter
Switch” in Maintenance Guide, when lifting the diverter switch.
Look for flash marks, loose parts etc. Measure the transition resistors according to
section ”Checking the Transition Resistors” in Maintenance guide. Finish with an
even number of operations of the diverter switch according to section ”Checking the
Contact Positions” in Maintenance Guide. Make sure the diverter switch operates fast
and distinct and stops in the end positions.
If no faults are found, install the diverter switch according to section ”Installation of
the Diverter Switch” in Maintenance Guide.
CAUTION
It is very important that the diverter switch is correctly installed. An incorrect instal-
lation will jeopardize both the on-load tap-changer and the transformer!

If necessary according to above, restore the gas cushion according to section 3.3
”Restoring the Gas Cushion” in this guide. Make sure the valve to the oil
conservator is open! After a pressure relay trip, we also recommend to carry out an
insulation test and a ratio test of the transformer.
If both the on-load tap-changer and the transformer are functioning properly, continue
with the next step.

33
3 Repairs and Adjustment

3.6 Tests of the Pressure Relay


Tools required:
Air pump with pressure gauge (0-250 kPa) and connection to R 1/8” male thread.
Screwdriver
Megger (500-2 000 V)

1. Insulation Test
Remove the cover of the relay housing. Disconnect all incoming wires from the
terminals.
Connect terminal NO (identified 61) on the pressure relay block to earth. Terminal C
(identified 62) should be electrified with the megger (500-2000 V for one minute).
Connect the pressure relay housing to earth. Short-circuit the four terminals and apply
test voltage 500-2000 V on them for one minute. Remove the short-circuit from the
terminals and reconnect the incoming wires.
If the pressure relay does not withstand the electrical stress, the pressure relay should
be replaced, see section 3.9 ”Replacement of Pressure Relay”.

2. Function Test
Set the valve handle to the test position as shown on the information plate.
Connect the air pump and the pressure gauge to the test tap on the pressure relay.
(Thread R 1/8”).
Raise the pressure until the pressure relay trips the circuit breakers of the transformer.
Read the pressure on the manometer and check against the pressure stated on the
information plate. Max. permitted deviation is ±10 %. If the deviation is greater, the
pressure relay should be replaced, see section 3.9 ”Replacement of Pressure Relay”.
Check that the signal disappears when the pressure is released.
After finishing the check, turn back the valve handle to service position.
Return to section 2.2.

34
3 Repairs and Adjustments

3.7 Replacement of Pressure Relay


3.7.1 General
If the pressure relay fails to pass the insulation test and/or the function test,
the pressure relay has to be replaced.

CAUTION
It is not permissible to replace only the microswitch inside the pressure relay.

3.7.2 Tools Required


Screwdriver
Open-end wrench (30 mm)

3.7.3 Spare Parts Required


Pressure relay
O-ring (17.1 x 1.6 mm).

3.7.4 Procedure
WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.

Replacement of pressure relay:


1. Set the three-way valve handle to the test position (see Fig. 11 and the information
plate on the pressure relay).
WARNING
Disconnect all power sources before any work is carried out. Check that the
power is disconnected by using a Voltmeter.

2. Disconnect the cable.

35
3 Repairs and Adjustment

3. Loosen the quick coupling and remove the pressure relay.


4. Install a new O-ring (17.1x1.6 mm).
5. Lubricate the threads of the connection nut with grease.
6. Mount the new pressure relay. Tightening torque approximately 25 Nm.
7. Carry out the testing procedure according to section 3.6. ”Tests of the Pressure
Relay”.
8. Connect the cable. The seal between the cable gland and the pressure relay housing
includes an O-ring. If the cable gland has to be changed to another type, the seal
against the housing must be secured by a gasket or by gluing. Tighten with care,
max 5 Nm torque.
9. Set the three-way valve handle back to the service position.

Information plate

Pressure relay

Valve handle

Connection nut
Quick coupling

Test tap (R 1/8’’)

TC_00264

Three way
valve handle

Fig. 11. Pressure relay

36
1ZSE 5492-129 en, Rev. 6, 1999-11-30

ABB Power Technology Products AB


Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com
1ZSE 5492-133 en, Rev. 3, 2004-04-15

On-load tap-changers, types UCG, UCL, UCC and UCD


with motor-drive mechanisms, types BUE and BUL

Spare Parts List


This document must not be copied without our written permission, and the
contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Before You Order
Check the identification of the on-load tap-changer. The type and serial number are
always required for identification. Check this data on the rating plate on the tap-
changer if you are not sure. Do not try to order spares without this information.
It is very important that you give a complete identification for each and every part you
order to have trouble-free delivery. The lists in this documentation together with the
identification as described above give you all information required for correct ordering.

WARNING, CAUTION and NOTE


WARNING
A WARNING provides information which, if disregarded, could cause injury or
death.

CAUTION
A CAUTION provides information which, if disregarded, could cause damage to the
equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work
described.

Safety Precautions
WARNING
This documentation is intended for procurement of spare parts only.

Only personnel familiar with repairs of transformers and accessories should


carry out replacement of parts. Electrical and other safety regulations at the
repair site must be strictly adhered to.

iii
Contents
1 Introduction ____________________________________________ 7
1.1 Type Designation and Serial Number ________________________ 7
1.2 Item Number ___________________________________________ 7
1.3 Name of Item ___________________________________________ 7
1.4 Quantity _______________________________________________ 7
1.5 Remarks _______________________________________________ 7
2 General Arrangement ____________________________________ 8
2.1 Standard Spare Parts _____________________________________ 8
2.2 Special Spare Parts ______________________________________ 8
3 Spare Parts for On-Load Tap-Changer _______________________ 10
3.1 Type UCG _____________________________________________ 10
3.2 Type UCL _____________________________________________ 12
3.3 Types UCC and UCD ____________________________________ 14
4 Accessories for On-Load Tap-Changer _______________________ 16
5 Spare Parts for Motor-Drive Mechanism type BUE _____________ 18
5.1 Electrical Details ________________________________________ 18
5.2 Mechanical Details ______________________________________ 20
6 Spare Parts for Motor-Drive Mechanism type BUL _____________ 24
6.1 Electrical Details ________________________________________ 24
6.2 Multi Position Switches___________________________________ 26
6.3 Mechanical Details ______________________________________ 28
7 Recommended Set of Spare Parts for Motor-Drive Mechanisms ___ 30
1 Introduction

1 Introduction
This spare parts list has been compiled to help you with procurement of spares. To
obtain trouble-free deliveries you should note a few things which are explained in the
following text.
The breakdown level and general contents of this list have been worked out to cover
normal customer requests. Our spares sales people will be happy to assist if you
require any specific item that is not included in the list.

1.1 Type Designation and Serial Number


The rating plate on the on-load tap-changer (OLTC) shows the type and serial number
of the device you are ordering spares for. It is important to have this information,
because the manufacture of parts gradually changes as materials and manufacturing
technology improves. ABB makes every effort to supply spares that should fit your
requirements. Some parts of later manufacture than those you are replacing may need
some adaptation to fit into your device. Our spare parts sales people need to know the
type designation and serial number to supply exactly what you require.

1.2 Item Number


Item numbers are shown on the drawings and lists. As you will observe, one item
number is used for several items of the same general type. These items have a specific
specification for each and every variant of OLTC, hence you need to specify type and
serial number in addition to the item number to obtain the appropriate spare.

1.3 Name of item


The name should be specified when ordering to make sure the right type of item is
ordered.

1.4 Quantity
The figures given represent the number of items that are fitted to one OLTC.

1.5 Remarks
Information pertinent to different variants of the OLTC is given in this column. Your
model should be one of those shown.

7
2 General Arrangement

2 General Arrangement
The general arrangement of an UC type on-load tap-changer is shown in fig. 1.

2.1 Standard Spare Parts


The rugged design of ABB OLTCs means that only the fixed and moving contacts of
the diverter switch might require replacement during lifetime of the transformer. This
spare parts list tells you the part number of the contacts when ordering for your
replacement requirements.

2.2 Special Spare Parts


If you need parts other than the contacts in the lists, our staff will be happy to assist
you. Please use fig. 1 as a reference when discussing your requirements. As usual, the
type designation and serial number are essential for ordering.

8
2 General Arrangement

Diverter switch housing Cover


Oil valve

Pressure relay
Bevel gear

Position indicator
Top-section
Serial No.
1)
Shielding-ring
Earthing terminal

Connection flange for Draining tube


gas operated relay
Insulating cylinder
Insulating shaft
Diverter switch
1)
Shielding-ring
2)
Shielding-ring
Transition resistors Plug-in contacts

Fixed and moving


contacts

Serial No. Bottom section

Guide-pins
Current terminal

Driving disc for the


diverter switch Tap selector

Bottom valve for


drying process

Intermediate gear
Geneva gear

1)
Change-over
Only at impulse withstand
selector
voltage to earth of 650 kV
and 1050 kV

2)
Not on UCG of the short type Moving fine-
selector contacts Current collector

Fixed fine-selector
contacts

Fig. 1. General arrangement of on-load tap-changer, type UC.

9
3 Spare Parts for On-Load Tap-Changer

3 Spare Parts for On-Load


Tap-Changer
3.1 Type UCG

Item No. Name of item Quantity Remarks

1 Contact set 1 set UCG.E .../300


UCG.E .../500
1 Contact set 3 sets UCG.T .../300
UCG.T .../500
1 Contact set 3 sets UCGYD .../300
UCGYD .../500
1 Contact set 1 set UCG.E .../600
1 Contact set 3 sets UCG.T .../600
1 Contact set 3 sets UCGYD .../600
1 Contact set 1 set UCG.N .../300
1 Contact set 1 set UCG.N .../500
1 Contact set 1 set UCG.E .../1200
1 Contact set 3 sets UCG.T .../1200
1 Contact set 3 sets UCGYD .../1200
1 Contact set 1 set UCG.N .../600
1 Contact set 1 set UCG.E .../1500
1 Contact set 3 sets UCG.T .../1500
1 Contact set 3 sets UCGYD .../1500
Complete diverter switch 1
Complete tap selector 1

10
3 Spare Parts for On-Load Tap-Changer

Fig. 2. Diverter switch for UCG with replacement contacts.

NOTE: This picture shows a neutral point type. Single phase types have not always
contacts in all the three poles of the diverter switch.

11
3 Spare Parts for On-Load Tap-Changer

3.2 Type UCL


Item No. Name of item Quantity Remarks

1 Contact set 1 set UCL.E .../600, UCL.E .../900


3 sets When the step voltage is outside
the envelope for the 900 A type
1 Contact set 3 sets UCL.E .../1800, UCL.E .../2400
1 Contact set 3 sets UCL.N .../600, UCL.N .../900
1 Contact set 3 sets UCL.T .../600, UCL.T .../900
9 sets When the step voltage is outside
the envelope for the 900 A type
1 Contact set 9 sets UCL.T .../1800, UCL.T .../2400
1 Contact set 3 sets UCL.B .../600, UCL.B .../900
Complete diverter switch 1
Complete tap selector 1

12
3 Spare Parts for On-Load Tap-Changer

Fig. 3. Diverter switch for UCL with replacement contacts.

13
3 Spare Parts for On-Load Tap-Changer

3.3 Types UCC and UCD

Item No. Name of item Quantity Remarks

1 Contact set 1 set UCC.N .../800


UCC.N .../1200
UCC.N .../1600
UCC.E .../3600
UCC.E .../4500

UCD.N .../1000
UCD.E .../2400
Complete diverter switch 1
Complete tap selector 1

14
3 Spare Parts for On-Load Tap-Changer

Fig. 4. Diverter switch for UCC and UCD with replacement contacts.

15
4 Accessories for On-Load Tap-Changer

4 Accessories for On-Load


Tap-Changer
Item No. Name of item Quantity Remarks

1 Pressure relay 1
2 Pressure relay with 1
test valve
3 Pressure relief valve 1
4 Oil valve 1
5 Vent 1
6 Cover for connection 1
to oil conservator
7 Bottom valve key 1

16
4 Accessories for On-Load Tap-Changer

fm_00283

Fig. 5. Accessories (The figure shows type UCG).

17
5 Spare Parts for Motor-Drive Mechanism type BUE

5 Spare Parts for Motor-Drive


Mechanism type BUE
Item No. Name of item Quantity Remarks

Complete motor-drive mechanism 1


with cabinet

5.1 Electrical Details


Item No. Name of item Quantity Remarks

1 Control selector switch 1


2 Control switch raise/lower 1
3 Motor contactor 1 Raise
4 Motor contactor 1 Lower
5 Starting contact 1
6 Maintaining contact 1
7 Motor 1
8 Limit switch 1
11 Interlocking switch 1
12 Heater 50 W 1
14 Position transmitter 1
15 Continuation contact 1
19 Motor-protective switch 1
21 Step-by-step contactor 1
26 Terminal blocks 1
27 Heater 100 W
28 Thermostat 1
29 Switch for heater 1
31 Tap-changer for current transformer 1
33 Tap-changer for voltage transformer 1
36 Lamp for cabinet light 1
37 Door-operated switch 1
83 Master switch 1
84 Follower switch 1
86 Odd-even switch 1

18
5 Spare Parts for Motor-Drive Mechanism type BUE

fm_00136

Fig. 6. Electrical details.

19
5 Spare Parts for Motor-Drive Mechanism type BUE

5.2 Mechanical Details


Item No. Name of item Quantity Remarks

101 Toothed belt 1


102 Conical toothed wheel 1
103 Outgoing shaft 1
104 Hand crank 1
105 Operating shaft 1
106 Gear 1
107 One turn shaft 1
108 Geneva drive with shaft 1
109 Conical toothed wheel 1
110 Hand for position indication 1
111 Coupling 1 +1 for each cont. plate
112 Geneva drive with shaft 1 For pot. transmitter
112 Geneva drive with shaft 1 For other cont. device
113 End stop, cam disc 1
114 Shear pin 1
115 Cam disc 1
116 Arm 1
117 Brake 1
118 Brake disc 1
119 Front plate 1
120 Operation counter 1
121 Pulley 1
122 Pulley 1
123 Conical toothed wheel 1
124 Cylindrical toothed wheel 1
125 Geneva wheel 1
126 Geneva wheel with arm 1 For double contact
127 Contact guide device 1
128 Cam bar 1
129 Brake for maintaining contact 1
(item No. 6)
130 Cam disc for starting contact 1
(item No. 5)
131 Driving disc for item No. 130 1
136 Screw for end stop 1

20
5 Spare Parts for Motor-Drive Mechanism type BUE

fm_00137

Fig. 7. Mechanical details.

21
5 Spare Parts for Motor-Drive Mechanism type BUE

Item No. Name of item Quantity Remarks

132 Cabinet 1 For BUE 1


132 Cabinet 1 For BUE 2
133 Gasket for door 1 For BUE 1
133 Gasket for door 1 For BUE 2
134 Hand knob 1
135 Air vent 1
140 Cover 1
141 Gasket 1
142 Vibration damper 4
143 Coupling 1
145 Shaft for maintaining contact 1
(item No. 6)
146 Shaft for starting contact 1
(item No. 5)
147b Lever 1
148 Drive 1
149 Shaft 1
150b Toothed wheel 1
151 Drive 1
152 Shaft 1
153 Shaft 1
154 Panel 1 For DAG motor-switch
155 Brake disc 2
156 Spring 2
157 Brake disc 1
158 Spring 1
159b Sleeve 1
160 Nave 1
161 Operating wire for operation counter 1
(item No. 120)
180 Door with window 1 For BUE 1
180 Door with window 1 For BUE 2

22
5 Spare Parts for Motor-Drive Mechanism type BUE

135 143 132

134

133

180

142

146

151

161

141
154
156

140

155

159b
157
150b

158
160

148

149

147b
152
fm_00274

153 Fig. 8. Mechanical details (cont.).

23
6 Spare Parts for Motor-Drive Mechanism type BUL

6 Spare Parts for Motor-Drive


Mechanism type BUL
Item No. Name of item Quantity Remarks

Complete motor-drive mechanism 1


with cabinet

6.1 Electrical Details


Item No. Name of item Quantity Remarks
1)
B1 Thermostat 1
1)
B2 Hygrostat 1
E1 Anti-condensation heater 1 50 W
E2 Extra heater 1 100 W 1)
1)
E3 Cabinet light, Hand lamp 1
K1 Step-by-step relay 1
M1 Motor 1 1
Q1 Motor protective switch 1
Q2 Contactor, Raise 1
Q3 Contactor, Lower 1
S1 Control selector switch 1 Local-0-Remote
S2 Control switch 1 Lower-0-Raise
S3+S4 Maintaining, interlocking and 1 Raise and lower,
auxiliary contacts assembled on a mounting
plate
S5 Interlocking switch 1 For handcrank
S6 Limit switch, Upper tap position 1 Including mounting plate
with arm and roller
S7 Limit switch, Lower tap position 1 Including mounting plate
with arm and roller
1)
S9 Door operated switch 1
S10 Switch for extra heater 1
U1 Measuring amplifier 1
X1-17 Terminal blocks
X38 Outlet 1

1)
When ordering, it must be stated for this optional item, if it was already installed in the motor-
drive mechanism. If it is not the case, other assembly details will be included in the order.

24
6 Spare Parts for Motor-Drive Mechanism type BUL

S6

S3 + S4
S7
B2

B1

S10
M1

X38 S5

K1

X1-17 U1

S2 Q3

S1
Q2

Q1
E2

E1

E3

S9
fm_00246

Fig. 9. Electrical details, type BUL.

25
6 Spare Parts for Motor-Drive Mechanism type BUL

6.2 Multi Position Switches


Item No. Name of item Quantity Remarks

S14, S24 Position transmitter,


potentiometer
S15 Continuation contact
S20-S23 Auxiliary contacts,
break before make
S25-S28 Auxiliary contacts,
make before break
S86, S87 Step switch for parallel control

111.1 Coupling half


111.2 Torque disc
112 Shaft <3 circuit cards
4–5 circuit cards
164 Transparent cover
165 Distance screw L=10, L=20, L=35 or L=60
166 Terminal, plug part 4-pole, 8-pole

26
6 Spare Parts for Motor-Drive Mechanism type BUL

111.1

111.2

111.1

112

164

S14 (S24)
165 S15
S20 (S21, S22, S23)
S25 (S26, S27, S28)
S86 (S87)

166
fm_00247

Fig. 10. Multi Position Switches, type BUL.

27
6 Spare Parts for Motor-Drive Mechanism type BUL

6.3 Mechanical Details


Item No. Name of item Quantity Remarks

101 Toothed belt 1


104 Hand crank 1
110 Pointer with drag hands for 1
position indicator
120 Operation counter 1 Arm included
121 Pulley for toothed belt 1 Key, screw, washer included
131 Hinges 2 Screws, washers, shims
included
132 Cabinet 1
134 Handknob with fasteners 2 Screws, washers, shims
included
135 Air vent 2
167 Gasket for cabinet 1
168 Thread bushing with nuts 4+8
170 Blank, FL 21 1
171 Gasket, FL 21 1
180 Door with window 1

28
6 Spare Parts for Motor-Drive Mechanism type BUL

168 131 180

132

134

167

104

135

171
101
170

120 121

110

fm_00248

Fig. 11. Mechanical details, type BUL.

29
7 Recommended Set of Spare Parts

7 Recommended Set of Spare Parts


for Motor-Drive Mechanisms
One set consists of the following parts:

For type BUE:


„ Item 3, pages 14 and 15 Motor contactor, raise
Item 4, pages 14 and 15 Motor contactor, lower
„ Item 7, pages 14 and 15 Motor
„ Item 19, pages 14 and 15 Motor-protective switch
„ Item 101, pages 16 and 17 Toothed belt

For type BUL:


„ Item Q2, pages 19 and 20 Motor contactor, raise
Item Q3, pages 19 and 20 Motor contactor, lower
„ Item M1, pages 19 and 20 Motor
„ Item Q1, pages 19 and 20 Motor-protective switch
„ Item 101, pages 25 and 26 Toothed belt

30
1ZSE 5492-133 en, Rev. 3, 2004-04-15

ABB Power Technologies AB


Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com/electricalcomponents
Serial no. 1133751

6 Bushings

6.1 HV bushing type GOB 550-800 LF 123 191 K, L6=500

6.2 HV neutral bushing type GOB 550-800 LF 123 189 K, L6=100

6.3 Transformer bushings, type GOB. 2750 515-12 en, Rev. 9


Installation and maintenance guide

6.4 MV bushing type 20f/3150 FIG B1, C1=440

6.5 MV bushing type 10f/4500 FIG C1, b1=380

6.6 SOLID BUSHING TYPE DIN 42533 – 42534 & EN


50180.PRODUCT INFORMATION & OPERATING
INSTRUCTIONS

1/1
2750 515-12 en, Rev. 9, 2006-10-15

Transformer bushings, type GOB


Installation and maintenance guide
This document must not be copied without our written permission, and the
contents thereof must not be imparted to a third party nor be used for any
unauthorized purpose. Contravention will be prosecuted.
Safety information
Keep this instruction available to those responsible for