ABB UZE Installation And Commissioning Manual
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ABB UZE Installation And Commissioning Manual

On-load tap-changers with motor-drive mechanism, type buf 3
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1ZSE 5492-115 en, Rev. 5
On-load tap-changers, type UZE and UZF,
with motor-drive mechanism, type BUF 3
Installation and commissioning guide

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  • Page 1 1ZSE 5492-115 en, Rev. 5 On-load tap-changers, type UZE and UZF, with motor-drive mechanism, type BUF 3 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 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 After oil filling CAUTION Do not energize the transformer earlier than three hours after oil filling in atmospheric pres- sure. This waiting period is needed to allow airbubbles to disappear. During service WARNING Small amounts of explosive gases will always come out from the breathing devices (dehydrating breather or one-way breather).

  • Page 7: Table Of Contents

    Contents 1. Introduction _______________________________________________________9 1.1 Required tools _________________________________________________10 1.2 Required material _______________________________________________10 1.3 Oil ____________________________________________________________11 1.4 Oil conservator _________________________________________________11 1.5 Filter unit for continuous oil filtration ________________________________13 1.6 Weights _______________________________________________________13 1.7 Tightening torque _______________________________________________13 2. Receiving _________________________________________________________14 2.1 Unpacking _____________________________________________________14 2.2 Inspection upon receiving ________________________________________14 2.3 Temporary storage before assembly _______________________________14 3.
  • Page 8 9. Commissioning ____________________________________________________28 9.1 Reassembly ___________________________________________________28 9.2 Oil filling _______________________________________________________28 9.2.1 Dehydrating breather ________________________________________28 9.3 Electrical connection and testing __________________________________28 9.3.1 Motor protection ____________________________________________28 9.3.2 Counter ___________________________________________________28 9.3.3 Position transmitter and other multi-position switches ____________28 9.3.4 Light ______________________________________________________28 9.3.5 Heater ____________________________________________________29 9.3.6 Pressure relay ______________________________________________29 9.4 Putting into operation ___________________________________________29 APPENDIX A.

  • Page 9: Introduction

    1 Introduction 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.

  • Page 10: Required Tools

    1 Introduction UZE requires the transformer conductors to be accessed from the rear of the on-load 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.

  • Page 11: Oil

    The on-load tap-changer has to be connected to an oil conservator, except when it is an UZE with expansion volume in the tank. ABB recommends the use of a separate conserva- tor for the on-load tap-changer with both oil and air side separated from the main conserva- tor of the transformer.
  • Page 12 1 Introduction Min 3° fm_00089 Fig. 2. UZE with separate oil conservator. fm_00118 Fig. 3. UZE with oil expansion volume in the tank. tc_00182 Fig. 4. UZF with built-on oil conservator. 1ZSE 5492-115 en, Rev. 5...

  • Page 13: Filter Unit For Continuous Oil Filtration

    1 Introduction 1.5 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 14: Receiving

    It is also recommended that photographs be taken of the damaged details. Mark the photos with the serial number of the on-load tap-changer and send them to ABB for comments.

  • Page 15: Drying

    3 Drying 3. Drying Drying of the on-load tap-changer is normally not required, see section 2.2, step 6. The following temperatures and pressures between the on-load tap-changer tank and the transformer tank are allowed when drying: Pressure Standard on-load tap-changer On-load tap-changer with reinforced barrier Zero...

  • Page 16: Installation On The Transformer

    Ensure that the surfaces being in contact with the gaskets are clean and free from grease and oil. After cleaning, stick the gaskets to the transformer tank flange (Fig. 7) with ABB glue 1 3401-608, by brushing glue on both the gasket and the flange.
  • Page 17 The required amount of glue (ABB 1 3401-608) is 0.5 kg. Do not glue gaskets at temperatures below 0 °C (32 °F). NOTE: ABB glue 1 3401-608 is a contact adhesive of nitrile rubber base. Sealing gasket Supporting gasket...

  • Page 18: Assembly Of Accessories

    On UZE the winding has to be connected from the rear. On both UZE and UZF the cable lugs can be either crimped or brazed. The free distance between the cable lugs for adjacent contacts must be at least 7 mm. Tightening torque is 38 Nm.
  • Page 19 4 Installation on the transformer Neutral connection fm_000196 Fig. 8. Assembly of the neutral connection. 1ZSE 5492-115 en, Rev. 5...

  • Page 20: Connection To The Oil Conservator

    Where the conservator is common to 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. Filter with housing can be ordered from ABB, ordering No. LL 114 004-AP. 1ZSE 5492-115 en, Rev. 5...

  • Page 21: Pressure Relay

    5 Pressure relay 5. Pressure relay 5.1 General The tank of the on-load tap-changer is supplied with a pressure relay. In the event of over- pressure in the tank the relay, if correctly connected, will trip the transformer’s main circuit breakers.

  • Page 22: Checking When Commissioning The Transformer

    5 Pressure relay 5.3 Checking when commissioning the transformer Information plate Valve handle fm_00117 Test tap (R 1/8”) Fig. 10. 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 23: Oil Filling

    UZE can be delivered with an oil expansion volume in top of the tank. The design of UZF does not allow an oil expansion volume in the tank. Instead, UZF can be delivered with a built-on oil conservator.

  • Page 24: Filling Under Vacuum

    6 Oil filling 6.3 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 25: Electrical Connection And Testing

    Operate the on-load tap-changer electrically. Check that the flywheel in the motor-drive mechanism stops with the brake between the outer marks on the flywheel. For any adjust- ment needed, see 1ZSE 5492-123 Maintenance Guide for UZE/UZF. Operate the driving mechanism electrically between the end positions. Check the end stops.

  • Page 26: Electrical Tests On Transformer

    7 Electrical connection and testing 7.3 Electrical tests on 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 that earthing is properly carried out.

  • Page 27: Transport

    Drain about 20 % of the oil from the on-load tap-changer. Oil weights according to sec- tion 1.3. Close the opening to the conservator with a transport cover. UZE with oil expansion volume in the tank The on-load tap-changer should be filled with oil. 8.1.2 Transformer drained Conservator mounted Drain the oil from the on-load tap-changer.

  • Page 28: Commissioning

    9 Commissioning 9. 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 29: Heater

    9 Commissioning 9.3.5 Heater Switch off all power supplies and feel by hand that the heater has been warmed up during earlier tests. Switch on the power afterwards. Check that the air vents are open. Remove the drying agent used during transport. 9.3.6 Pressure relay Check the function as per section 5.3.

  • Page 30: Appendix A. Welding And Mounting Instruction

    Welding equipment ■ Lifting yoke Type designation Lifting yoke upright assembly Lifting yoke inclined assembly Article No. Article No. UZE..200/..., ..250/... LL 114 007-C LL 114 007-G UZE..380/... LL 114 007-D LL 114 007-H UZE..550/..., ..650/... LL 114 007-E LL 114 007-N ■...

  • Page 31: A2 Receiving

    Appendix A 2 Receiving – 3 Welding and mounting instruction A2 Receiving Do not break the plastic bag until the tap-changer shall be mounted! Check that the serial numbers of the on-load tap-changer and the motor-drive mechanism are the same. Serial numbers fm_00074 Fig.
  • Page 32 LL 322 006-4 D = 280 mm T = 16 mm LL 322 006-5 D = 305 mm Assembly kit for flange (2): LL 322 005-A Type designation Dimensions (mm) UZE.. 200/... 97±5 493±2 411±2 UZE.. 250/... 97±5 493±2 411±2 UZE..

  • Page 33: A3.2 Installing The On-Load Tap-Changer And The Motor-Drive Mechanism In The Tank

    Appendix A 3 Welding and mounting instruction A3.2 Installing the on-load tap-changer and the motor-drive mechanism in the tank First install the on-load tap-changer and then the motor-drive mechanism. CAUTION Leave the locking devices for transportation on until both the on-load tap-changer and motor-drive mechanism have been installed.
  • Page 34 Appendix A 3 Welding and mounting instruction CAUTION The link according to Fig. A4 must be attached before taking away the support. Lifting yoke Link fm_00077 Fig. A4. Lifting after raising. Install the on-load tap-changer in the tank and bolt it to the tank with the gasket between the tank and the on-load tap-changer.

  • Page 35: A3.2.2 Installation Of The Motor-Drive Mechanism

    Appendix A 3 Welding and mounting instruction A3.2.2 Installation of the motor-drive mechanism Fit the O-ring, included in mounting kit LL 322 005-A, to flange (LL 322 006-3, LL 322 006-4 or LL 322 006-5) in the cabinet. Lift the motor-drive mechanism in the hole Ø 40 mm on the frame by the lifting yoke, see Fig.
  • Page 36 Appendix A 3 Welding and mounting instruction Support for geneva gear LL 114 007-F Driving disc Driving pin Locking device fm_00080 Fig. A7. Positioning of driving pin. Locking device in drive mechanism (behind the control panel) fm_00081 Fig. A8. Location of locking device. 1ZSE 5492-115 en, Rev.

  • Page 37: A3.3 Mounting Of Fittings For Motor-Drive Mechanism Cabinet

    Appendix A 3 Welding and mounting instruction A3.3 Mounting of fittings for motor-drive mechanism cabinet Fig. A9 shows fittings and other details to be installed after the frame and door have been painted. Rating plate Filter Sealing Screw M6x12 Screw M3x5 plugs Spring washer Earth connection...

  • Page 38: A3.4 Welding Of The Flange And Mounting Of The Pressure Relay

    Appendix A 3 Welding and mounting instruction A3.4 Welding of the flange and mounting of the pressure relay Weld the flange and install the pressure relay on the tank. Pressure relay LL 114 009 Quickcoupling Flange Three way valve LL 114 006-9 Test tap Hole in wall Ø...

  • Page 39: A4 Welding Instruction For Inclined Assembly

    Appendix A 4 Welding instruction for inclined assembly A4 Welding instruction for inclined assembly Carry out fitting of the on-load tap-changer in a tank with 30 inclination as described in chapter A3, with the following exceptions. A4.1 Welding of flange and frame for motor-drive mechanism Weld the flange to the end plate of the on-load tap-changer with dimensions A, B, C and tolerances as shown in Fig.

  • Page 40: A4.2 Mounting Of The On-Load Tap-Changer

    Appendix A 4 Welding instruction for inclined assembly A4.2 Mounting of the on-load tap-changer When handling the on-load tap-changer, use lifting yokes (according to the table in section A1.1) which are mounted as shown in Fig. A13. Strap the on-load tap-changer to the lifting yoke.
  • Page 44 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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