ABB UZE Bedienungsanleitung

On-load tap-changers, type UZE and UZF

Installation and commissioning guide

1ZSE 5492-115 en, Rev. 6

Original instruction

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.

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.

Safety warnings

The following warnings and notes are used in the manual:

WARNING

WARNING indicates an imminently hazardous

situation, which if not avoided will result in death or

serious injury. This signal word is to be limited to the

most extreme situations.

WARNING also indicates a potentially hazardous

situation, which if not avoided could result in death or

serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation,

which if not avoided may result in minor or moderate

injury. It may also be used to alert of unsafe practices.

CAUTION may also indicate property-damage-only

hazards.

INFO provides additional information to assist in

carrying out the work described and to provide

trouble-free operation.

Safety precautions

WARNING

Unused transformer oil is 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 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 highly flammable. Used

transformer oil may well be carcinogenic.

Avoid contact with the oil and use oil-tight protective

gloves when handling the oil.

First aid:

Skin contact: Wash your hands. Use skin cream to

counteract drying.

In the eyes: Rinse your eyes in clean water.

Swallowing: Drink water or milk. Avoid vomiting. Call

a doctor.

Collect used oil in oil drums.

Waste and clean-up: Should be absorbed by an

absorber. Treat it as hazardous to the environment.

In the event of fire: Any fires should be extinguished

with powder, foam or carbonic acid extinguishing

agents.

WARNING

The motor-drive mechanism must not be installed in

an explosive atmosphere. The electrical equipment

creates sparks that can cause an explosion.

WARNING

Before any work is carried out on the tap-changer:

Make sure that the transformer is disconnected and

that grounding is properly conducted. Obtain a signed

certificate from the engineer in charge.

WARNING

Before carrying out work on the tap-changer, put

the LOCAL/REMOTE switch on the motor-drive

mechanism to position 0. It is also advisable to shut

the door of the motor-drive mechanism and pad lock

it when work is carried out on the tap-changer. The

key should be kept by the operator. This is done

to avoid an unexpected start of the motor-drive

mechanism.

WARNING

Before starting any work inside the motor-drive

mechanism, the auxiliary power must be switched off.

NOTE: The motor, contactors and heating element

may be energized from separate sources.

During drying of the transformer

CAUTION

The tap-changer must not be included in the

vapour phase drying process of the transformer. For

permissible pressure and temperature at the rear

during drying process, see chapter 3.

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.

During oil filling

WARNING

When oil that has been used in a diverter switch

housing is pumped out, grounded conducting

tubes and hoses should be used to avoid the risk of

explosion due to the gases produced by arcs during

service.

CAUTION

Do not fill the tap-changer with oil if the transformer

tank is under vacuum and the tap-changer is not.

CAUTION

Do not fill the transformer tank with oil if the tap-

changer is under vacuum and the transformer tank is

not.

CAUTION

The oil level in the oil conservator of the tap-

changer should never be above the oil level in the oil

conservator of the transformer.

After oil filling

CAUTION

Do not energize the transformer earlier than three

hours after oil filling at atmospheric pressure. This

waiting period is needed to allow air bubbles to

dissipate.

During service

WARNING

Small amounts of explosive gases might 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 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.

Content

1. Introduction ..........................................................................................................................9

1.1 Required tools ..............................................................................................................10

1.2 Required material..........................................................................................................10

1.3 Oil.................................................................................................................................10

1.4 Oil conservator..............................................................................................................11

1.5 Filter unit for continuous oil ltration...............................................................................12

1.6 Weights ........................................................................................................................12

1.7 Tightening torque..........................................................................................................12

1.8 Pressure relay and other protection devices..................................................................12

2. Receiving..............................................................................................................................13

2.1 Unpacking ....................................................................................................................13

2.2 Inspection upon receiving .............................................................................................13

2.3 Temporary storage before assembly..............................................................................13

3. Drying...................................................................................................................................14

4. Installation on the transformer...............................................................................................15

4.1 Attaching the tap-changer to the transformer ...............................................................15

4.1.1 Welding ..................................................................................................................15

4.1.2 Bolting....................................................................................................................15

4.1.3 Assembly of accessories ........................................................................................17

4.1.4 Retightening ...........................................................................................................17

4.2 Connection of the regulating winding of the transformer................................................17

4.3 Connection to the oil conservator..................................................................................18

5. Oil lling ................................................................................................................................19

5.1 Retightening .................................................................................................................19

5.2 Filling methods and restrictions .....................................................................................19

5.2.1 Filling at atmospheric pressure................................................................................19

5.2.2 Filling under vacuum...............................................................................................19

5.3 Correct oil level .............................................................................................................19

6. Electrical connection and testing ..........................................................................................20

6.1 General.........................................................................................................................20

6.2 Connecting and testing.................................................................................................20

6.3 Electrical tests on transformer.......................................................................................20

6.4 After energizing.............................................................................................................20

6.5 Resistance measurement..............................................................................................20

7. Transport ..............................................................................................................................21

7.1 Oil level during transport ...............................................................................................21

7.1.1 Transformer lled with oil.........................................................................................21

7.1.2 Transformer drained ...............................................................................................21

8. Commissioning.....................................................................................................................22

8.1 Reassembly ..................................................................................................................22

8.2 Oil lling ........................................................................................................................22

8.2.1 Dehydrating breather..............................................................................................22

8.3 Electrical connection and testing...................................................................................22

8.3.1 Motor protection.....................................................................................................22

8.3.2 Counter ..................................................................................................................22

8.3.3 Position transmitter and other multi-position switches ............................................22

8.3.4 Light.......................................................................................................................22

8.3.5 Heater ....................................................................................................................22

8.3.6 Pressure relay.........................................................................................................22

8.4 Putting into operation....................................................................................................22

1ZSE 5492-115 en, Rev. 6 | Installation and commissioning guide UZE/UZF 9

1. Introduction

The on-tank concept of on-load tap-changer, realized by ABB

in the UZ range, is unique. The design offers advantages in

installation and maintenance. The whole device is delivered

installed in a tank that is simply mounted onto the transformer

tank together with the motor-drive mechanism.

In the event of a tap-changer being delivered without a tank,

the transformer manufacturer will supply the tank. Appendix A

includes a welding and mounting instruction.

It is easy to access all parts of the tap-changer for

maintenance and repair. After draining the oil, you simply

unbolt and open the front cover to access any part you may

need to inspect or replace.

UZE requires the transformer conductors to be accessed from

the rear of the tap-changer.

UZF has an inclined rear wall and a top cover that is

removable to provide access to the transformer conductors.

WARNING

The cover for access to conductors on top of UZF

tank may be opened after draining the transformer

main tank.

UZE models are available for use without a separate oil

conservator, for example, when used on sealed tank

transformers.

Fig. 1. General arrangement of on-load tap-changer.

Lifting eye

Connection to oil conservator

Tap-changer tank

Oil valve

Pressure relay

Terminals for

conductors

Attachment ange to

transformer tank

Cover for access to terminals,

UZFonly

10 Installation and commissioning guide UZE/UZF | 1ZSE 5492-115 en, Rev 6

1.3 Oil

The oil quality should be IEC 60296-LCSET -30° (former

ClassII). The oil should have an electrical withstand of at least

40 kV, measured in a 2.5 mm gap, according to IEC 60156.

New oil should have a water content below 15 ppm and have

been handled and stored according to IEC 60422 point 10.

Table 1. Weight of oil in kg.

Type designation

UZE.N, UZE.T

Tap-changer with separate

conservator

(The oil for the conservator

is not included.)

Tap-changer with

expansion volume

in the tank

200/... 500 450

250/... 500 450

380/... 950 880

550/... 1250 1150

650/... 1250 1150

Type designation

UZF.N, UZF.T

Tap-changer with separate

conservator

(The oil for the conservator

is not included.)

Tap-changer with

expansion volume

in the tank

200/... 400 430

250/... 400 430

380/... 750 800

550/... 1050 1120

650/... 1050 1120

WARNING

Do not energize the transformer until oil has been

filled as per chapter 6, Oil filling, in this manual.

1.1 Required tools

– Standard set of screwdrivers

– Standard set of open-end wrenches

– Hexagonal wrench, 8 mm

– Dynamometric wrench (5-85 Nm)

– Air pump with pressure gauge and connection to male

thread R 1/8” (0-100 kPa)

– Flexible tube with connection, internal thread R 1/8”

– Tool for opening of oil drums

– Clamping blocks, (only for installation)

– Small brush (width 10 mm, only for installation)

1.2 Required material

– Equipment for oil filling for connection to the oil valve. For

dimensions see the dimension drawing.

– Equipment for connection between the tap-changer and

the transformer when filling under vacuum.

– Sealing tape

– Glue (ABB 1234 0016-608), 0.5 kg (contact adhesive on

nitrile rubber base, only for installation)

– Oil as per section 1.3

– Maintenance Guide, 1ZSE 5492-123

– Circuit diagram for the motor-drive mechanism

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