ABB UCC Series User manual
On-load tap-changers, types UCC and UCD
with motor-drive mechanism, type BUE
Installation and Commissioning Guide
1ZSE 5492-117 en, Rev. 5, 2003-03-30
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 cons derat on of the follow ng factors when nstall ng on-load
tap-changers:
Before you nstall or comm ss on a un t, make sure that the personnel do ng the job
have read and fully understood the Installat on and Comm ss on ng Gu de prov ded
w th the un t.
To avo d damag ng the un t, never exceed the operat ng l m ts stated n del very
documents and on rat ng plates.
Do not alter or mod fy a un t w thout f rst consult ng ABB.
Follow local and nternat onal w r ng regulat ons at all t mes.
Use only factory author zed replacement parts and procedures.
WARNING, CAUTION and NOTE
WARNIN
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 carr ing out the work
described.
Safety Precautions
WARNIN
Unused transformer oil is slightly harmful. umes 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. umes 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.
irst 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.
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.
WARNIN
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.
WARNIN
The motor-drive mechanism must not be installed in any explosive atmosphere.
The electrical equipment creates sparks which can cause an
explosion.
WARNIN
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.
WARNIN
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.
WARNIN
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 dr ing, since the process removes
grease needed for operation.
CAUTION
During dr ing 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 oC (275 oF).
v
CAUTION
During dr ing b 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 ke , a long hexagonal rod. The maximum permitted temperature is 135 oC
(275 oF).
CAUTION
Use the special bottom valve ke onl (delivered with the on-load tap-changer) to
operate the bottom valve through the oil draining tube. The use of a stiffer tool ma
damage the valve.
CAUTION
Do not operate the on-load tap-changer during the dr ing 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. Diametricall
opposed bolts in sealing joints must be tightened alternatel several times, beginning
with a low tightening torque and finall with the recommended tightening torque as
described in section 1.8 Tightening Torque, in this guide.
During Oi Fi ing
WARNIN
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.
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 Oi Fi ing
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
WARNIN
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.
WARNIN
If a failure in power supply occurs during operation, the operation will be
completed when the power returns.
WARNIN
The hand crank must not be inserted during electrical operation.
WARNIN
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 rela trip, follow the instructions in the chapter Pressure Rela in
the Repair Guide.
CAUTION
The pressure rela is a calibrated monitoring instrument. It must be handled with
care and protected against careless handling or an kind of mechanical damage. Do
not open the package of the pressure rela until ou are about to install it on the on-
load tap-changer.
v
7
Contents
1 Introduction ____________________________________________ 9
1.1 Type Designation ________________________________________ 10
1.2 Required Tools __________________________________________ 13
1.3 Required Material _______________________________________ 13
1.4 Oil ___________________________________________________ 14
1. Oil Conservator _________________________________________ 14
1.6 Oil Filter Unit for Continuous Oil Filtration ___________________ 1
1.7 Weights _______________________________________________ 1
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 UCCwith Tap Selector size IV _____________________________ 19
3.1.2 UCDwith Tap Selector size III _____________________________ 23
3.1.3 UCDwith Tap Selector size G _____________________________ 26
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 _________________________________ 36
3.2.3 Mounting on Transformer Cover ____________________________ 37
3.3 Connection to Terminals __________________________________ 40
3.4 Transformer Ratio Measurement ____________________________ 42
3.4.1 Transformer Ratio Measurement before Drying ________________ 43
3.4.2 Transformer Ratio Measurement after Drying __________________ 43
4 Drying ________________________________________________ 44
4.1 Observations before Processing _____________________________ 44
4.2 Observations after Processing ______________________________ 44
4.3 Installation of Diverter Switch ______________________________ 4
Final Assembly _________________________________________ 49
.1 Mounting of the Motor-Drive Mechanism _____________________ 49
.2 Mounting of External Drive Shafts __________________________ 1
.2.1 Mounting of Vertical Drive Shaft ___________________________ 3
.2.2 Mounting of Horizontal Drive Shaft _________________________
.2.3 Before Operation ________________________________________ 7
.3 Pressure Relay __________________________________________ 8
.3.1 General ________________________________________________ 8
.3.2 Installation _____________________________________________ 8
.3.3 Checking at Commissioning of the Transformer ________________ 9
.4 Assembly of Accessories __________________________________ 9
. Connection to the Oil Conservator ___________________________ 60
8
6 Oil Filling ______________________________________________ 61
6.1 Filling Methods and Restrictions ____________________________ 61
6.2 Before Filling ___________________________________________ 61
6.3 Filling at Atmospheric Pressure _____________________________ 62
6.4 Filling under Vacuum ____________________________________ 62
6.4.1 Oil Conservator Filled Afterwards ___________________________ 63
6.4.2 Oil Conservator Filled under Vacuum ________________________ 63
6. Restoring the Gas Cushion _________________________________ 64
6. .1 Procedure ______________________________________________ 6
7 Electrical Connection and Testing ___________________________ 66
7.1 General ________________________________________________ 66
7.2 Connecting and Testing the Motor-Drive Mechanism and the
On-Load Tap-Changer ____________________________________ 66
7.3 Electrical Tests on Transformer _____________________________ 67
7.4 After Energizing _________________________________________ 67
8 Transport ______________________________________________ 68
8.1 Dismantling before Transport ______________________________ 68
8.1.1 Dismantling Preparations __________________________________ 68
8.2 Oil Level During Transport ________________________________ 69
8.2.1 Transformer filled with Oil ________________________________ 69
8.2.1.1 Conservator mounted _____________________________________ 69
8.2.1.2 Conservator dismounted ___________________________________ 69
8.2.2 Transformer drained _____________________________________ 69
8.2.2.1 Conservator mounted _____________________________________ 70
8.2.2.2 Conservator dismounted ___________________________________ 70
9Commissioning _____________________________ 70
9.1 Connection to the Oil Conservator ___________________________ 72
9.2 Mounting the Motor-Drive Mechanism and Drive Shafts _________ 72
9.2.1 Mounting of the Motor-Drive Mechanism _____________________ 72
9.2.2 Disc-Brake _____________________________________________ 72
9.2.3 Mounting of the External Drive Shafts _______________________ 73
9.2.4 Mounting of the Vertical Drive Shaft ________________________ 73
9.2. Mounting of the Horizontal Drive Shaft ______________________ 7
9.2.6 Before Operation ________________________________________ 77
9.3 Pressure Relay __________________________________________ 77
9.4 Accessories ____________________________________________ 77
9. Oil Filling ______________________________________________ 77
9.6 Electrical Connection and Testing ___________________________ 78
9.6.1 Motor Protection ________________________________________ 78
9.6.2 Disc Brake _____________________________________________ 78
9.6.3 Counter _______________________________________________ 78
9.6.4 Position Transmitter and other Position Switches _______________ 79
9.6. Light __________________________________________________ 79
9.6.6 Heater _________________________________________________ 79
9.7 Putting into Operation ____________________________________ 79
1 Introduction
1 Introduction
The arrangement of on-load tap-changers types UCC and UCD are shown in
Figs. 1 and 2.
A UCC on-load tap-changer has always tap selector IV. A UCD on-load tap-
changer has tap selector III or G.
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 and 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
transformer 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.
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 Figs. 2-2b.
Position numbers in the Installation Guide, for example SA11 (see chapter )
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
1.1 Type Designation
U C C . . XXXX/YYYY/IV
U C D . . XXXX/YYYY/III
Example: UCDRE 650/1000/III
Type of switching
L Linear
R Plus/Minus
D Coarse/Fine
Type of connection
N T ree-p ase star point (one unit)
E Single-p ase (one unit)
Impulse withstand voltage to earth
Maximum rated through-current
Tap selector size
1 Introduction
10
This manual suits for next models
1
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