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ABB UBB Series Installation And Commissioning Manual
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ABB UBB Series Installation And Commissioning Manual

On-load tap-changers
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1ZSE 5492-118 en, Rev. 4
On-load tap-changers, type UBB
Installation and commissioning guide

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  • Page 1 1ZSE 5492-118 en, Rev. 4 On-load tap-changers, type UBB Installation and commissioning guide...
  • Page 2 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.
  • Page 3 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.
  • Page 4 WARNING Be aware of the risk for slipperiness caused by oil spillage for instance when working on the transformer cover. The motor-drive mechanism must not be installed in any explosive atmosphere. The electrical equipment creates sparks which can cause an explosion. 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.
  • Page 5 During oil filling WARNING When oil that has been used in a selector 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. 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.

  • Page 7: Table Of Contents

    Contents 1. Introduction _______________________________________________________9 1.1 Required tools _________________________________________________11 1.2 Required material _______________________________________________11 1.3 Oil ____________________________________________________________11 1.4 Oil conservator _________________________________________________11 1.5 Oil filter unit for continuous oil filtration ________________________________ 12 1.6 Weights _______________________________________________________12 1.7 Tightening torque _______________________________________________12 2. Receiving _________________________________________________________13 2.1 Unpacking _____________________________________________________13 2.2 Inspection upon receiving ________________________________________13 2.3 Temporary storage before assembly _______________________________13 3.
  • Page 8 9. Transport _________________________________________________________45 9.1 General _______________________________________________________45 9.2 Transport preparations __________________________________________45 9.2.1 Transport with complete transformer ___________________________45 9.2.2 Transport with dismounted conservator ________________________45 9.2.3 Protection of motor-drive _____________________________________45 10. Commissioning ___________________________________________________46 10.1 Reassembly __________________________________________________46 10.2 Oil filling ______________________________________________________46 10.3 Electrical connection and testing _________________________________46 10.3.1 Motor protection ___________________________________________46 10.3.2 Disc brake ________________________________________________47 10.3.3 Counter __________________________________________________47...

  • Page 9: Introduction

    1 Introduction 1. Introduction The delivery consists of on-load tap-changer, motor-drive mechanism and drive shaft sys- tem. The on-load tap-changer may be specified for cover-mounting or for yoke-mounting. Cover-mounting means that the on-load tap-changer is lowered through a hole in the trans- former cover and then bolted straight onto the transformer cover.
  • Page 10 1 Introduction Air release valve to on- Top cover Connection to oil load tap-changer conservator Pressure relay Bevel gear Oil valve Flange Air release valve to transformer tank Cylinder Indicator window Change-over selector: Moving contacts Fixed contacts Selector switch: Current collector Fixed contacts terminal Moving contacts...

  • Page 11: Required Tools

    Filling in this guide. 1.4 Oil conservator The on-load tap-changer has to be connected to an oil conservator. ABB recommends the use of a separate conservator for the on-load tap-changer with both oil and air side sepa- rated from the main conservator of the transformer.

  • Page 12: Oil Filter Unit For Continuous Oil Filtration

    1 Introduction 1.5 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 can be found in the manual for the oil filter unit, ”Oil Filter Unit for On-Load Tap-Changers, Manual”...

  • Page 13: Receiving

    It is also recommended that photos 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.

  • Page 14: Installation In The Transformer

    3 Installation in the transformer 3. Installation in the transformer The cover-mounting method or yoke-mounting method is used. When lifting an UBB model it is recommended to use the lifting eyes on the on-load tap- changer top section. WARNING To put down the on-load tap-changer to stand on the floor without any support means a risk for tilting with risk for injuries to people and damage to the equipment.

  • Page 15: Connection To Outside Terminals

    3 Installation in the transformer 3.1.1 Connection to outside terminals The connection to terminals for change-over selector, selector switch and current collec- tor shall follow the connection diagram delivered with the on-load tap-changer. Connection holes for bolts M10 are Ø11 mm for all terminals. CAUTION All connections shall be made carefully and in such a way that there is no risk for them to come loose.

  • Page 16: Yoke-Mounting

    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 on-load tap-changer is designed to be divided into an upper and a lower flange, see Fig. 6, to fit the yoke-mounting. Before the on-load tap-changer is lifted and attached to the transformer cover it rests on a fork consisting of two beams protruding from the upper transformer yoke.

  • Page 17: Mounting Of The On-Load Tap-Changer When Transformer Ratio Measurement Is Carried Out Before Drying

    3 Installation in the transformer 3.2.1 Mounting of the on-load tap-changer when transformer ratio measurement is carried out before drying Mounting to the ”yoke-fork” of the transformer, see Fig. 6. Mount the on-load tap-changer on the transformer’s ”yoke-fork”, the lifting lugs on the upper part can be used, see Fig.
  • Page 18 3 Installation in the transformer O-ring for upper flange Approx. 15 mm Fig. 7. fm_00209 max 90 Fig. 8a. max 90 O-ring for top cover Fig. 8b. Sealing for suction pipe O-ring for upper flange Fig. 8c. FM_00203 1ZSE 5492-118 en, Rev. 4...

  • Page 19: Mounting Of The On-Load Tap-Changer When Transformer Ratio Measurement Is Carried Out After Drying

    3 Installation in the transformer 3.2.2 Mounting of the on-load tap-changer when transformer ratio measurement is carried out after drying Mounting to the ”yoke-fork” of the transformer. See Fig. 9. Loosen all the twelve bolts and washers in the top cover and lift the cover carefully min. 100 mm straight upwards before moving it in horizontal direction.
  • Page 20 3 Installation in the transformer Approx. 15 mm fm_00209 Fig. 10. Remove the lifting eyes when the on-load tap-changer is in right position on the ”yoke- fork”. The on-load tap-changer and the transformer is now ready for drying. Follow the in- structions in chapter 4.

  • Page 21: Mounting To The Transformer Cover From The Yoke

    3 Installation in the transformer 3.2.3 Mounting to the transformer cover from the yoke (After drying process). Lift Max 90 Screw M8 (12x) Washer Lifting bar LL 117 016-K Nut M12 (16x) Upper flange Washer Gasket Stud M12 (16x) (Not included Transformer cover in the delivery) ”Yoke fork”...
  • Page 22 3 Installation in the transformer NOTE: Do not mount the studs for the upper flange now, they will be mounted ac- cording to point 10. Place the upper flange over the opening of the transformer cover. NOTE: Check that the flange is positioned in the right way in rotational relation to the lower flange.
  • Page 23 3 Installation in the transformer Protective tube Hose clip Cover Bevel gear Top cover Screw M6 Coupling half Driving pin Guiding pin View A - A Driving disc fm_00012 Fig. 12. 1ZSE 5492-118 en, Rev. 4...

  • Page 24: Drying

    Make sure that all liquid has been drained from the selector switch housing. Close the bottom valve. Tightening torque is approximately 15 Nm. 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.

  • Page 25: Final Assembly

    5 Final assembly 5. Final assembly 5.1 Mounting of the motor-drive mechanism See figs. 1, 13 and 14. Proceed as follows: 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.
  • Page 26 5 Final assembly Indicator window 9 9 9 9 8 7 fm_00235 L O W E R P O S I T I O N R A I S E 1 0 1 1 – Position indicator Adjustment nuts Brake disc Red mark fm_00240 Brake pads...
  • Page 27 5 Final assembly Indicator window White indicator flag fm_00235 10 11 12 Position indication Roller on brake arm in the notch of the cam disc Brake arm Contra nut Cam disc Brake disc fm_00241 Adjusting screw Fig. 14. Position alignment for type BUL. 1ZSE 5492-118 en, Rev.

  • Page 28: Mounting Of Accessories

    5 Final assembly 5.2 Mounting of accessories The accessories on the tap-changer top cover can be rearranged to suite the individual transformer. The bevel gear is turnable in order to have the horizontal shaft to the motor-drive mechanism in right direction. The limit for the turning depends on the arrangement of the accessories but is max.

  • Page 29: Mounting Of External Drive Shafts

    5 Final assembly 5.3 Mounting of external drive shafts The external drive shafts consists of square tubes and shall 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 cor- rect function and to avoid corrosion.
  • Page 30 5 Final assembly SA11 Bevel gear on the top cover SA10 SA11 SA25 SA22 SA24 SA23 SA25 SA10 SA21 SA20 SA12 SA12 SA13 SA13 SA17 SA18 SA19 Horizontal drive shaft SA10 SA11 SA12 SA13 SA10 Hose clip SA11 Couplinghalves Vertical drive shaft SA12 Hexhead cap screw M6 SA16...

  • Page 31: Mounting Of Horizontal Drive Shaft

    5 Final assembly 5.3.1 Mounting of horizontal drive shaft 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. 16. Determine the dimension K1 between the spherical shaft ends, see Fig. 17. SA 21 TC_00238 Fig.
  • Page 32 5 Final assembly Square shaft Square shaft SA11 SA12 SA13 Driving pin SA11 Max. 3 mm Max. 6 mm TC_00147 TC_00148 TC_00170 Fig. 19. Fig. 20. Fig. 21. SA11 SA21 TC_00238 Fig. 22. Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear SA21, see Fig.

  • Page 33: Mounting Of Vertical Drive Shaft

    5 Final assembly 5.3.2 Mounting of vertical drive shaft Determine the dimension K2 between the spherical shaft ends, see Fig. 24. Cut the vertical square shaft, SA14, to dimension = K2 minus 6 mm. Remove the burrs. Cut the protective tubes SA15 and SA16 so both of them get the same length LB2 ac- cording to the table 3 below.
  • Page 34 5 Final assembly Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear. Mount two coupling halves SA14 to the square shaft perpendicular to the cou- pling in the other end, and the shaft of the motor-drive mechanism. Tighten the screws lightly and check that the shaft not can be moved more than 2 mm in axial direction (axial play).
  • Page 35 5 Final assembly Earthing symbol Key in the bevel gear fm_00002 Fig. 30. Adjustment of bevel gear. 10. Pull down the protective tube SA15 and mount the hose clip SA10. See Fig. 31. Note the clearance for draining. (Min 3 mm, max 5 mm). 11.

  • Page 36: Connection To The Oil Conservator

    Oil filter with housing can be ordered from ABB on the ”Ordering data” sheet. 5.5 Before operation Check that the on-load tap-changer and the motor-drive mechanism have the same indicated position and that the key position of the on-load tap-changer bevel gear is in accordance to Fig.

  • Page 37: Transformer Ratio Measurement After Drying

    5 Final assembly 5.5.1 Transformer ratio measurement after drying If transformer ratio measurement is to be done after drying this is a suitable stage to carry it out. CAUTION To avoid seizing, do not operate the on-load tap-changer until it is filled with oil. Carry out this measurement after the drive system is mounted.

  • Page 38: Pressure Relay

    6 Pressure relay 6. Pressure relay 6.1 General The selector switch housing of the on-load tap-changer is supplied with a pressure relay. In the event of overpressure in the selector switch housing and, if correctly connected, the relay 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.

  • Page 39: Checking At Commissioning Of The Transformer

    6 Pressure relay 6.3 Checking at commissioning of the transformer Information plate Valve handle Test tap (R 1/8”) TC_00264 Fig. 34. Pressure relay. Set the valve handle in 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. Raise the pressure until the pressure relay trips the circuit breakers for the transformer.

  • Page 40: Oil Filling

    7 Oil filling 7. Oil filling 7.1 Filling methods and restrictions Oil filling can be carried out at atmospheric pressure or under vacuum. The wall between the on-load tap-changer and the transformer tank is designed to withstand vacuum on one side and atmospheric pressure on the other side.

  • Page 41: Filling Under Vacuum

    7 Oil filling 7.3 Filling under vacuum Oil filling under vacuum is not necessary. If it is to be carried out, the on-load tap-changer and the transformer tank should be put under vacuum simultaneously. It is assumed that a vacuum-proof conservator is in use. Open the conservator valve, if any.

  • Page 42: Restoring The Gas Cushion

    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 instruc- tions in ”Oil filter unit for on-load tap-changers, manual” for restoring the gas cushion.

  • Page 43: Electrical Connection And Testing

    8 Electrical connection and testing 8. Electrical connection and testing 8.1 General Before the transformer is energized tests have to be made to make sure that all mechanical and electrical connections are correct, and to check the proper functioning of the on-load tap-changer and the motor-drive mechanism.

  • Page 44: Electrical Tests On Transformer

    8 Electrical connection and testing For BUE: Run the motor-drive mechanism and check again that the red mark on the brake disc stops within the tolerance limits, see Fig. 13. If it is out of tolerance, charge the springs more or less by tightening or loosening the two adjustment nuts on the brake assembly.
  • Page 45 9 Transport 9. Transport 9.1 General If the transport dimensions allow, the transformer may be transported without dismantle any parts of the on-load tap-changer. If the motor-drive mechanism or any parts of the shaft system has to be dismantled for the transport, the parts must be marked to ensure they can be set up properly on site and with a minimum of work.
  • Page 46 10 Commissioning 10. Commissioning This section describes tasks to be carried out 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 available, put drying agent inside the motor-drive cabinet and seal the vents.
  • Page 47 10 Commissioning 10.3.2 Disc brake For BUE: Run the motor-drive mechanism and check again that the red mark on the brake disc stops within the tolerance limits, see Fig. 13. If it is out of tolerance, charge the springs more or less by tightening or loosening the two adjustment nuts on the brake assembly.
  • Page 48 Contact us ABB AB Components SE-771 80 Ludvika, Sweden Phone: +46 240 78 20 00 Fax: +46 240 121 57 E-Mail: sales@se.abb.com www.abb.com/electricalcomponents...

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