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ABB UCG Series, Installation And Commissioning Manual

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ABB UCG Series Installation And Commissioning Manual Download Page 9

1ZSC000562-AAZ en

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Installation and commissioning guide UCL/VUCL

   9

1. Introduction

The arrangement of on-load tap-changers types UCL and 

VUCL, and of the tap-changer system, are shown in Figs. 1 

and 2. The tap-changer may consist of one, two or three units 
driven by the same motor-drive mechanism. The tap-changer 
is delivered in three main parts: diverter switch housing, tap 
selector and motor-drive mechanism.

The tap-changer is available in designs 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, 
followed by mounting of the tap selector. Yoke-mounting 
means that the 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 tap-changer before drying and without having the 
transformer cover-mounted. The transformer cover is then 
lowered onto the tank, and the tap-changer is lifted and 
bolted to the cover. Use the appropriate instruction for cover-
mounting or yoke-mounting in Chapter 3.

After the transformer drying process, the motor-drive 
mechanism and bevel gear are fitted to the transformer tank 
and the drive shafts are fitted to complete the assembly of the 
motor-drive mechanism, bevel gear and tap-changer before 
oil filling and testing.

Position numbers in this guide, for example SA11 (see 

Chapter 5), correspond to those on the packing list for the 

tap-changer.

All instructions are for one tap-changer unit. When there is 
more than one unit on the transformer, carry out the same 
procedures for each unit.

Fig. 1. On-load tap-changer system (single-unit shown).

Horizontal drive shaft 
and protective tubes

Bevel gear

Vertical drive shaft 
and protective tubes

Motor-drive mechanism

Pressure relay

Oil valve

Summary of Contents for UCG Series

Page 1: ...On load tap changers type UCL and VUCL Installation and commissioning guide 1ZSC000562 AAZ en ...

Page 2: ...entative 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 C...

Page 3: ... 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 res...

Page 4: ... is 135 C 275 F CAUTION Use the special bottom valve key only delivered with the tap changer to operate the bottom valve through the oil draining tube The use of a stiffer tool may damage the valve CAUTION To avoid seizing do not operate the tap changer during the drying process or afterwards until it is filled with oil Mounting of gaskets CAUTION Sealing surfaces and gaskets must be clean and und...

Page 5: ...ed during electrical operation WARNING If the tap changer is not at 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 Trip or alarm from supervisory devices in the user s manual CAUTION The pressure relay is a calibrated monitoring...

Page 6: ... transformer cover after the drying process 23 3 3 Connection to terminals 25 3 4 Transformer ratio measurement 27 3 4 1 Transformer ratio measurement before drying 27 3 4 2 Transformer ratio measurement after drying 27 4 Drying 28 4 1 Precautions before processing 28 4 2 Precautions after processing 28 4 3 Installation of diverter switch 28 5 Final assembly 30 5 1 Mounting of motor drive mechanis...

Page 7: ...rt 46 8 2 1 Transformer filled with oil 46 8 2 1 1 Conservator mounted 46 8 2 1 2 Conservator unmounted 46 8 2 2 Transformer drained 46 8 2 2 1 Conservator mounted 46 8 2 2 2 Conservator unmounted 46 9 Commissioning 47 9 1 Connection to the oil conservator 47 9 2 Mounting the motor drive mechanism and the drive shafts 47 9 2 1 Mounting of the motor drive mechanism 47 9 2 2 Mounting of the external...

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Page 9: ...sformer manufacturer to connect the windings to the tap changer before drying and without having the transformer cover mounted The transformer cover is then lowered onto the tank and the tap changer is lifted and bolted to the cover Use the appropriate instruction for cover mounting or yoke mounting in Chapter 3 After the transformer drying process the motor drive mechanism and bevel gear are fitt...

Page 10: ...tective tubes Shielding caps only for insulation level above 380 kV Type of connection N or E Hand crank inside the cover Motor drive mechanism Bevel gear Shielding rings only for insulation level above 380 kV Not used for selector size C Unit 1 Fig 2 Example of on load tap changer systems Type of connection T Type of connection B Unit 1 Unit 2 Unit 1 Unit 2 Unit 3 ...

Page 11: ...s 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 ground Maximum rated through current Tap selector size Serial no Serial no Fig 3 Diverter switch housing UCL VUCL...

Page 12: ...tor for both the transformer and the tap changer this can be ordered from ABB 1 4 Oil The oil quality should be I 30 according to IEC 60296 2012 and comply with IEC 60422 2008 Upon commissioning the break down value should be at least 40 kV 2 5 mm according to IEC 60156 Type designation Oil weight kg The oil for the conservator is not included UCL VUCL 380 260 UCL VUCL 650 300 UCG VUCG 1050 340 Ta...

Page 13: ... 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 Table 2 Weights for type UCL 1 The weight of the diverter switch approximately 120 kg is included On load tap changer type des...

Page 14: ...ecommended that photographs be taken of the damaged parts Mark the photos with ABB s reference number and the serial number of the tap changer and send them to ABB 3 Check that the parts delivered type designations and the serial numbers agree with the delivery documents e g the packing list or ABB s order acknowledgement The serial numbers to be checked are those on the rating plate on the divert...

Page 15: ...ed WARNING The intermediate gear and the insulating shaft of the diverter switch housing moves during operation Maintain a safe distance during operation to avoid injuries The diverter switch housing and the tap selector are designed to be lifted by the lifting eyes see Fig 4 WARNING The angle between the lifting slings should be no more than 90 WARNING Lowering the complete tap changer to the flo...

Page 16: ...elding 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 area where the diameter of the shielding ring is greatest with a thin sheet of pressboard or similar material 4 Position the tap selector for joining to the diverter switch housing Lift by the lifting eyes ...

Page 17: ...ctors between the diverter switch housing and tap selector The conductor ends and their connecting points have the same markings Fasten the conductors with cleats The number of conductors varies depending on the rated through current and the type of connection WARNING The wires coming from the transformer s regulating winding may not pass through the spaces between the change over selector and the...

Page 18: ...rter switch housing Shielding rings Insulating shaft C C 2 conductors C C single conductor Locking nut M12 Spring washer Socket head cap screw Washer 14x30x2 5 Shielding ring if the impulse withstand voltage to ground exceeds 380 kV Washers 14x30x2 5 Socket head cap screw Spring washers Socket head cap screw M8x25 x4 Locking nut M8 Socket head cap screw M10x40 x4 Spring washer Washer 10 5x24x3 x4 ...

Page 19: ...ent in the yoke fork when the transformer is in operation Mounting of the 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 the drying process see Section 3 2 1 Transformer ratio measurement is carried out after the drying process see Section 3 2 2 For mou...

Page 20: ...ttom valve let the bottom valve key DS16 slide down through the oil drainage tube and when it has gripped the valve rotate it in a counter clockwise direction until it stops after approximately 6 turns see Fig 14 Refit the plug 7 Remove the diverter switch by carefully lifting it straight out of the diverter switch housing by its lifting eye see Fig 13 Store the diverter switch at a dry and dust f...

Page 21: ...N The drive shaft must not be rotated 11 The guide bar for positioning the diverter switch in the housing is secured in the upper flange with screws and washers Remove the screws and washers Store the guide bar in the diverter switch housing until it is remounted Save the screws and washers 12 Remove the nuts and washers inside the upper flange and remove the flange by lifting it by the lifting ey...

Page 22: ...ice must be tilted when attaching Lift the tap changer onto the yoke fork Place the tap changer in position for mounting the outer shaft system see transformer drawing Insert the supplied guide bolts DS 7 and insulating bushings not included in delivery in the lower flange see Fig 11 The guide bolts must fit into the holes in the yoke fork and be secured by punch marks in the pins When the tap cha...

Page 23: ...ned Retighten all nuts to 24 5 Nm After tightening the nuts remove the lifting device 7 Place the O ring for the bevel gear in its groove in the upper flange see Fig 17 Remount the bevel gear unit in the position it had before removal and make sure that the pin in the spherical shaft end fits into the drive shaft slot without rotating the drive shaft Secure the gear unit in the flange with its fou...

Page 24: ...CL 1ZSC000562 AAZ en Attachment clamps Fig 17 Slot in drive shaft O ring Pin Oil drainage tube Fig 18 Plug 40 Nm Spring washer Locking nut M8 20x Flat washer 8 4x20x2 Yoke fork Lower flange O ring Upper flange Studs M12 24x Nuts M12 Washers Fig 16 ...

Page 25: ...the tap selector shall be insulated by winding paper around them to a thickness of 3 mm see Fig 7 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 loosen The conductors must not cause mechanical strain on the tap selector terminal...

Page 26: ...issioning guide UCL VUCL 1ZSC000562 AAZ en Faulty Correct Tap selector Expansion bend Terminal Fig 20 Connection of conductors to the selector Yoke fork beam Inserts Lower flange Fig 21 Mounting of tap changer on the yoke fork ...

Page 27: ...verter switch is installed incorrectly or the tap changer is not correctly connected to the winding 3 4 1 Transformer ratio measurement before drying 1 Remove the locking device from the gear unit on the upper flange see Fig 22 Save the locking device for reuse after transformer ratio measurement Also remove the cover of the bevel gear to access the position indicator Save all fasteners and the ga...

Page 28: ...at the bottom valve key is removed after the valve has been closed 2 The cleats on the upper section of the tap selector that hold the conductors between the diverter switch housing and the tap selector should be retightened tightening torque 15 Nm and locked by a method specified by the transformer manufacturer for similar screw joints 3 If a tie in resistor from ABB is supplied its screw joints ...

Page 29: ...direction while pushing down the diverter switch For UCL it may be necessary to push and pull the lifting device for the diverter switch a little back and forth while pushing down The top part of the diverter switch lifting device should be below the level of the upper part of the housing for the cover when lowered to its final position Only the springs of the lifting device should be above this l...

Page 30: ...ormer should be level 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 26 3 Check that the position indicator on the motor drive mechanism shows the same position as the indicator inside the bevel gear of the tap changer The cover has to be removed WARNING Do not energize the transformer before the tap changer and ...

Page 31: ...issioning guide UCL VUCL 31 Fig 24 Position alignment for UCL VUCL with motor drive mechanism BUE Transformer Position indicator Adjustment nuts Brake disc Brake assembly The same indicated tap position Red mark Exact position Max deviation ...

Page 32: ...3 14 15 16 17 18 19 Fig 25 Position alignment for UCL VUCL with motor drive mechanism type BUL Exact position Max deviation Transformer Roller on the brake arm in the notch of the cam disc Contra nut Adjusting screw Brake arm Brake disc Cam disc Position indicator Indicator flag The same indicated tap position ...

Page 33: ...al protective tube SA 17 Clamp SA 18 Hex head bolt M10 SA 19 Washer SA 20 O ring SA 21 Bevel gear SA 22 Horizontal square shaft for unit 1 SA 23 Horizontal protective tube for unit 1 SA 24 Horizontal protective tube for unit 1 SA 25 Information label SA 30 Horizontal square shaft for unit 2 SA 31 Horizontal protective tube for unit 2 SA 32 Horizontal protective tube for unit 2 SA 33 Cover SA 34 Ho...

Page 34: ...he motor drive mechanism with a hose clip Leave about 3 mm of play to the flange ring for water drainage The tube with the larger diameter is mounted on the bevel gear Tighten the two screws A and then the other according to Fig 32 5 2 Mounting of external drive shafts The external drive shafts consist of square tubes and should be connected to the spherical shaft ends on the bevel gears and motor...

Page 35: ...issioning guide UCL VUCL 35 SA10 SA10 SA15 SA16 SA21 SA11 SA14 SA15 SA16 SA10 SA10 SA15 SA27 SA28 SA26 SA29 BUL A SA12 SA13 SA11 A BUE K2 SA14 Fig 28 Fig 29 Drive pin Fig 30 Fig 27 Square shaft Fig 32 Fig 31 Max 3 mm Max 6 mm Min 3 max 5 mm ...

Page 36: ...g halves see Fig 31 Lightly tighten the screws and check that the shaft can be moved approximately 2 mm in the axial direction axial play Check the dimension shown in Fig 30 Tighten the two screws A first and then the other see Fig 32 7 See Figs 24 and 25 The motor drive mechanism and the tap changer should have the same indicated tap position and be in their exact positions Remove the cover of th...

Page 37: ...34 Fig 35 Fig 36 Locking device single unit tap changer K1 SA14 SA24 SA10 SA23 SA11 LB1 Slotted end Drive pin M8 screw Disc Locking device Fig 37 Fig 38 A SA10 Slot SA24 SA23 SA21 Spherical coupling part SA12 SA13 SA11 SA10 SA24 SA25 SA23 SA25 SA10 SA21 SA23 Slot facing downwards ...

Page 38: ...ve cover SA33 Tighten the two set screws taken from the locking device see Fig 43 5 2 3 Mounting of horizontal drive shaft for two units The following applies to the fitting of drive shafts and their protective tubes when the tap changer consists of two phases UCL B VUCL B The tap changer unit which is placed closest to the drive mechanism is called unit 1 and the second unit 2 see Fig 26 Mount th...

Page 39: ...ng guide UCL VUCL 39 Fig 43 Locking device and cover multiple unit tap changer Cover SA 33 Locking device Set screws SA12 SA13 SA11 SA32 SA30 SA31 Coupling Disc A SA10 SA10 Fig 41 SA10 SA10 SA32 SA25 SA31 Locking device Cover SA 33 Set screw Fig 42 ...

Page 40: ...t the same position 2 Remove the locking device for the motor drive mechanism see Fig 44 Locking device BUE BUL Fig 44 Locking device for motor drive mechanism If transformer ratio measurement is to be conducted after drying this is a suitable stage to carry it out see Section 3 4 2 5 3 Supervisory equipment Accessories and safety devices are described in a separate document Accessories and protec...

Page 41: ...ground level Fig 47 Extra oil sampling valve The valve is removed and then refitted at the end of the sampling tube Fig 45 Oil valve Fig 46 Sample pipe dimensions Extra oil valve shall be removed and used as a sample valve Oil valve O ring Ø 44 2 x 5 7 4 x Ø 11 Ø 75 A A B B Ø 75 Ø 106 Ø 106 4 x M10 45 45 UCL top cover Transformer cover Tube The tube through which oil samples are taken must be conn...

Page 42: ...ntil the conservator is filled to its correct level Also see Section 1 5 7 Shut the oil valve and disconnect the pump 8 Refit the breathing device Make sure that the connection to the breathing device is properly sealed WARNING 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 6 4 Filli...

Page 43: ...562 AAZ en Installation and commissioning guide UCL VUCL 43 Ø 75 Ø 5 7 Ø 20 Ø 44 2 Vacuum Tap changer Oil Fig 49 Oil filling under vacuum Oil Transformer Fig 48 Assembly O ring Stud M10 O ring Pipe connection ...

Page 44: ...on The motor drive mechanism will stop when it has made approximately half of the complete operation and will operate back and forth without the tap changer changing position until the control selector switch is turned to position 0 If the phase sequence is wrong reverse two of the motor supply cables to attain the correct sequence WARNING Dangerous voltage For BUE Run the motor drive mechanism an...

Page 45: ... shafts for two units 1 Detach the protective cover SA33 on the bevel gear of unit 2 and lock the bevel gear with the locking device marked 2 and two set screws see Fig 36 2 Loosen the hose clips holding the protective tubes to the bevel gears for units 1 and 2 Push one of the protective tubes into the other Loosen the screws holding the coupling halves at one end of the shaft and detach them Deta...

Page 46: ...servator 8 2 2 2 Conservator unmounted Drain the oil as described in Section 8 2 2 1 Now remove the conservator connection Seal the diverter switch housing against ambient air by fitting covers with gaskets and closing all valves 8 1 6 Accessories If the pressure relay is to be removed see the assortment guide 1ZSC000562 AAD If other accessories are to be removed for transport reasons pack them in...

Page 47: ...uide there should be no need for adjustments If necessary Sections 5 1 and 5 2 provide complete information for fitting and adjusting of the shaft system The arrangement of the drive shaft system is shown in Fig 26 Check all fittings and alignments even if the shaft system has been set up in the transformer factory The identification numbers on critical parts from the packing list are specified in...

Page 48: ...t SA14 with protective tubes SA15 and SA16 and hose clips according to Fig 28 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 28 Push the shaft to the bottom of the fitting in the coupling halves see Fig 31 Tighten the screws lightly and check that the shaft can ...

Page 49: ...for both of them show the same position The motor drive mechanism is at the exact position since the steps in Section 9 2 2 have been carried out The tap changer is at the exact position when the window where the position is read on the bevel gear is exactly facing the red mark in the gear box housing SA21 SA11 Fig 52 If the gear box is not at its exact position carry out point 5 and loosen the tw...

Page 50: ...ut 5 See Figs 24 and 25 The motor drive mechanism and the tap changer should have the same indicated tap position and be at their exact positions The motor drive mechanism and the tap changer are at the same position when the position indicators for both of them show the same position The motor drive mechanism is at the exact position since the steps in Section 9 2 2 have been carried out The tap ...

Page 51: ...ap changer and the motor drive mechanism at different operating positions may cause transformer failure The door of the motor drive mechanism can be locked with a padlock not included in the delivery Do not remove the locking device before one end of the shaft of the bevel gear is connected to the drive shaft 9 3 Supervisory equipment Accessories and safety devices are described in Accessories and...

Page 52: ...0498 ABJ for VUCL 9 6 3 Counter Check that the counter is functioning for 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 sources and check with a f...

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Page 56: ...us Copyright 2013 ABB All rights reserved 1ZSC000562 AAZ en 2013 10 30 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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