1ZSE 5492-127 en, Rev.

On-load tap-changers, type UBB

Maintenance guide
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 for maintenance work on
on-load tap-changers:
Before you start any work, make sure that the personnel doing the job have read and fully
understood the Maintenance documents 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.

WARNING, CAUTION and NOTE

WARNING
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 equip-
ment.

NOTE: A NOTE provides additional information to assist in carrying out the work de-
scribed.

Safety precautions
WARNING
The Maintenance Guide should be read and understood before any work is started,
and the procedures in this document should be followed at all times.

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 unexpect-
ed start of the motor-drive mechanism.

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.

CAUTION
Approval should be given for inspection as well as for operating the on-load tap-changer.

ABB recommends that only maintenance engineers trained by ABB carry out contact re-
placement.
During service
WARNING
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 occurs in the immediate surroundings of the breathing devices.

If a failure in power supply occurs during operation, the operation will be completed
when the power returns.

The hand crank must not be inserted during electrical operation.

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 relay trip, follow the instructions in the chapter ”Pressure Relay” in the Re-
pair Guide.

During oil handling

WARNING
Unused transformer oil is slightly 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 on-load 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 very easily set on fire. Used transformer oil may well be carcino-
genic.

Avoid contact with the oil as much as possible and use oiltight protective gloves
when handling the oil.

First 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.

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.
 WARNING
When oil that has been used in an on-load tap-changer 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.

The oil in the on-load tap-changer may be hot. Be cautious!

There is always a cushion of explosive gases in the top of the on-load tap-changer.
No open fire, hot surfaces or sparks may be present during opening of the housing
or draining from the valve. After the cover is removed let the gas vent away approxi-
mately 15 min before any work is started.

Be aware of the risk for slipperiness caused by oil spillage for instance when working
on the transformer cover.

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.

Do not fill oil into the transformer tank if the on-load tap-changer is under vacuum and the
transformer tank is not.

Leave a gas cushion on top of the oil in the on-load tap-changer.

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.

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 tighten-
ing torque and finally with the recommended tightening torque as described in section 1.3
Tightening Torque, in this guide.
Contents
1. Introduction________________________________________________________9
1.1 General________________________________________________________9
1.2 Maintenance schedule____________________________________________10
1.2.1 Inspection__________________________________________________10
1.2.2 Overhaul_ __________________________________________________12
1.2.3 Contact replacement_________________________________________12
1.3 Tightening torque________________________________________________12
2. lnspection_________________________________________________________13
2.1 Required tools_ _________________________________________________13
2.2 Procedure______________________________________________________13
2.2.1 Checking of the breather______________________________________13
2.2.2 Checking of the oil level in the conservator_______________________13
2.2.3 Checking of the motor and the counter__________________________14
2.2.4 Checking of the emergency stop_______________________________14
2.2.5 Checking of the earth fault protector (option)_____________________14
2.2.6 Checking of the heater_ ______________________________________14
3. Overhaul___________________________________________________________17
3.1 Required tools and materials_ _____________________________________17
3.2 Procedure______________________________________________________18
3.3 Preparations____________________________________________________18
3.3.1 On-load tap-changer position__________________________________18
3.3.2 Disconnection and earthing of the transformer____________________18
3.3.3 Oil volumes and lifting heights_ ________________________________19
3.3.4 Recommended set of standard spare parts______________________19
3.4 Oil testing and oil draining_________________________________________20
3.5 Lifting and cleaning the selector switch insert_ _______________________21
3.5.1 Dismantling the top cover of the on-load tap-changer_ ____________21
3.5.2 Removal of the mechanism and fixed contact blades______________22
3.5.3 Adjustment of the holding tool for removal of fixed contacts_ _______24
3.5.4 Positioning of selector switch and change-over selector before lifting__25
3.5.5 Lifting______________________________________________________25
3.5.6 Cleaning_ __________________________________________________26
3.6 Oil filtration_ ____________________________________________________27
3.7 Checking of the breather__________________________________________27
3.8 Checking contacts_______________________________________________28
3.8.1 Moving contacts_____________________________________________28
3.8.2 Fixed contacts with tips of copper-tungsten______________________29
3.8.3 Fixed contacts made of copper________________________________30
3.9 Checking the transition resistors_ __________________________________31
3.10 Lowering the selector switch insert________________________________31
3.11 Mounting the top cover on the on-load tap-changer__________________33
3.12 Lubrication of the on-load tap-changer and the drive shaft system_ ____33
3.13 Checking the pressure relay______________________________________34
3.13.1 Functional check of the pressure relay_ ________________________34
3.13.2 Replacing the pressure relay__________________________________34
 3.14 Checking of motor-drive mechanisms types BUE and BUL____________35
3.14.1 Motor protection____________________________________________38
3.14.2 Earth fault protector (option)__________________________________38
3.14.3 Counter___________________________________________________38
3.14.4 Heater____________________________________________________38
3.14.5 Toothed belt_______________________________________________38
3.14.6 Cable connections__________________________________________38
3.14.7 Disc brake, BUE____________________________________________38
3.14.8 Brake for the maintaining contact, BUE_ _______________________39
3.14.9 Disc brake, BUL____________________________________________40
3.14.10 Position transmitter and other position switches, BUE___________40
3.14.11 Position transmitter and other position switches, BUL___________41
3.14.12 Starting contact, BUE______________________________________41
3.14.13 Lubrication, BUE__________________________________________41
3.14.14 Lubrication, BUL_ _________________________________________41
3.15 Operation test__________________________________________________44
3.16 Oil filling_______________________________________________________44
3.16.1 Filling methods and restrictions_______________________________44
3.16.2 Before filling_ ______________________________________________45
3.16.3 Filling at atmospheric pressure________________________________45
3.16.4 Oil level_ __________________________________________________45
3.16.5 Restoring the gas cushion_ __________________________________45
3.16.6 Waiting period______________________________________________46
3.17 Putting into operation_ __________________________________________46
4. Contact replacement________________________________________________47
4.1 Moving contacts_________________________________________________47
4.2 Fixed contacts_ _________________________________________________48
5. Tap-changer in the transformer________________________________________48
5.1 Resistance measurement_________________________________________48
6. Specification of materials_____________________________________________49
6.1 General________________________________________________________49
6.2 Selector switch housing_ _________________________________________49
6.3 Selector switch insert_____________________________________________49
6.4 Gearing mechanism______________________________________________49
6.5 Drive shaft systems______________________________________________49
6.6 Motor-drive mechanism___________________________________________50
Appendix. Tools_______________________________________________________51
 1 Introduction

1. Introduction

1.1 General
The UB range of on-load tap-changers manufactured by ABB has been developed to
provide maximum reliability. The simple and rugged design gives a service life equal to the
service life of the transformer. A minimum of maintenance is required for trouble-free opera-
tion. The only parts requiring maintenance are contacts that might need replacement during
the service life, the insulating oil and the motor-drive mechanism.
The design allows excellent access to all parts, making inspection and maintenance quick
and simple.
The on-load tap-changer, type UBB, is housed in the transformer tank. The motor-drive
mechanism is attached to the transformer tank and connected to the on-load tap-changer
by means of drive shafts and a bevel gear, see Fig. 1.

Horizontal shaft with protection cover

Bevel gear Bevel gear

Vertical shaft
with protection cover

Rating plate

TC_00255

On-load tap-changer Motor-drive mechanism

Fig. 1. On-load tap-changer and motor-drive mechanism, type BUL.

1ZSE 5492-127 en, Rev. 5 9

1 Introduction

Fig. 2 shows the general arrangement of a UB-type on-load tap-changer. The main compo-
nents are the selector switch (combined tap selector and diverter switch), the change-over
selector, the selector switch housing and the gearing mechanism. For maintenance the top
cover and the gear base plate (Fig. 4a) are removed before lifting the selector switch insert.
The contacts are then immediately accessible and can be inspected for wear.
The selector switch housing has its own oil separated from the transformer oil. This is to
prevent contamination of the transformer oil since the oil of the on-load tap-changer dete-
riorates due to the switching operations. The oil needs to be changed at regular intervals to
maintain adequate dielectric strength as well as to prevent mechanical wear.
The selector switch comprises three phases, each consisting of:
■■ Selector switch (with replaceable fixed and moving contacts)
■■ Transition resistors.
It is necessary to inspect and clean the contacts and insulation parts of the selector switch,
as well as to clean the housing inside at regular intervals.
Besides the maintenance of the selector switch and changing of the oil, the motor-drive
mechanism should be checked and lubricated.
The pressure-relay, the device that protects the transformer from excessive pressure in the
selector switch housing, should also be checked.

1.2 Maintenance schedule

Maintenance of the on-load tap-changer consists of three major steps:
■■ Inspection
■■ Overhaul
■■ Contact replacement

1.2.1 Inspection
On the rating plate, ”inspection once a year” is recommended. This principally concerns the
motor-drive mechanism and refers to a visual inspection inside the motor-drive cabinet, the
heater is functioning, etc.
In the motor-drive mechanism a counter registers every tap-change operation. During in-
spection the counter is read. If possible, motor and counter are tested by operating one step
and then back.
If the on-load tap-changer has its own oil conservator, the breather and the oil level indicator
are checked according to the instructions from the transformer manufacturer.
The inspection is carried out while the transformer is in service.

10 1ZSE 5492-127 en, Rev. 5

 1 Introduction

Top cover Air release valve to on- 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:
Fixed contacts Current collector
terminal

Moving contacts

Transition resistor

Selector switch shaft

Shielding rings

Bottom valve
drain screw

Bottom

fm_00235

Fig. 2. General arrangement of on-load tap-changer, type UBB.

1ZSE 5492-127 en, Rev. 5 11

1 Introduction

1.2.2 Overhaul
The contact life and the frequency of operations or the time in service determine the interval
between overhauls.
The number of operations run by the on-load tap-changer is recorded by a counter, housed
in the motor-drive mechanism cabinet. The registered number of operations should be noted
at every inspection and overhaul.
The on-load tap-changer should normally be overhauled regularly at intervals of 1/5 of the
estimated contact life. The relevant information is stated on the rating plate. Hereby, the
contact wear can be followed and necessary preparations can be made for replacing the
contacts.
If the tap-change operations occur infrequently and a very long time elapses until the num-
ber of operations amounts to 1/5 of the contact life, the interval between overhauls should
be limited to the time stated on the rating plate (normally 5 years).
The overhaul will normally take at least 8 hours, including the 3 hours waiting period after oil
filling, even if it is made by trained personnel. We recommend that the overhaul is carried out
under supervision of a service engineer trained by ABB.

1.2.3 Contact replacement

On the rating plate of the on-load tap-changer the estimated contact life of the breaking
contacts in the selector switch at rated load is stated.
The contacts will withstand a very large number of switching operations. For normal power
transformers the number of operations of the selector switch is approximately 20 per day,
which means that replacement of the contacts is not normally necessary during the life of
the transformer. (In case of on-load tap-changers on furnace transformers, the frequency of
operations may be considerably higher).

CAUTION
The number of operations must in no case exceed 500 000, due to weakening spring ten-
sion of the contacts.

1.3 Tightening torque

The following tightening torques are recommended:
M6, 10 Nm ±10 % (7.4 lbf x ft)
M8, 24.5 Nm ±10 % (18 lbf x ft)
M10, 49 Nm ±10 % (36 lbf x ft)
M12, 84 Nm ±10 % (62 lbf x ft)
unless otherwise stated in this guide.

12 1ZSE 5492-127 en, Rev. 5

 2 Inspection

2. lnspection
The inspection consists of a visual check of the motor-drive mechanism and the conservator
once a year while the transformer is in service.
In the motor-drive mechanism the following points are to be checked:
■■ Motor and counter
■■ Heater
■■ The counter’s value
On the conservator the following are to be checked:
■■ Oil level
■■ Breather
If the on-load tap-changer is equipped with an oil filter unit from ABB it should be inspected
once a year according to the ”Oil Filter Unit for On-Load Tap-Changer manual”.

2.1 Required tools

The following equipment is required for the inspection:
■■ Set of screwdrivers
■■ Pen and note pad

2.2 Procedure

CAUTION
Approval should be given for inspection as well as for operating the on-load tap-changer.

WARNING
This work must be carried out from ground level since the transformer is energized.

2.2.1 Checking of the breather

Check the breather according to the instructions for the transformer.

WARNING
The breathers and the tube from the conservator contains explosive gases. No open
fire, hot surfaces or sparks may be present when removing the breather.

If more than half of the drying agent has changed colour, it must be dried or replaced.
The drying agent normally starts to change colour from the bottom of the breather. If it
changes colour at the top of the breather, there is a leakage in the connections to the con-
servator. Locate the leakage and seal it.

2.2.2 Checking of the oil level in the conservator

The oil level in the conservator should be according to the instructions in the transformer
documentation.

1ZSE 5492-127 en, Rev. 5 13

2 Inspection

2.2.3 Checking of the motor and the counter

Open the motor-drive cabinet door and turn the selector-switch to the LOCAL
position. Then turn the control switch to the RAISE (LOWER) position.
Check that the motor works properly, the position indicator increases (decreases) one step,
and the counter advances one step for each operation. Record the counter’s value. The
counter shows the number of operations run by the on-load tap-changer (the overhaul-
schedule can be determined with the help of this information).
Turn the control switch to the LOWER (RAISE) position. Check that the motor also works
properly in that direction, the position indicator decreases (increases) one step and the
counter advances one step more.
Reset the draghands.

2.2.4 Checking of the emergency stop

Give a RAISE or LOWER impulse and after about one second press the emergency stop.
The operation should be interrupted. Reset the emergency stop by turning the knob clock-
wise and set the protective motorswitch to ON. The started operation should now be com-
pleted. Operate back to service position.

2.2.5 Checking of the earth fault protector (option)

If the motor-drive mechanism is equipped with an outlet, the earth fault protector should be
tested by pressing the test knob on the outlet on BUE or on the separate earth fault protec-
tor on BUL.

2.2.6 Checking of the heater

Disconnect the incoming auxiliary power.

WARNING
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.

Open the control panel. (BUE only).

Check by feeling with a finger on the protection plate that the heater has been functioning.
Close the control panel. (BUE only). Reconnect the incoming auxiliary power.
Complete the inspection by turning the selector-switch to the REMOTE position and closing
the cabinet door.

14 1ZSE 5492-127 en, Rev. 5

 2 Inspection

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

21 20 19 18 17

Layout of motor-drive mechanism, type BUE

1. Locking device prepared for padlock 13. Shaft for handcrank
2. Emergency stop 14. Heater 50 W + optional 100 W (behind the panel)
3. (Option) Switch for extra heater 15. (Option) Outlet with earth fault protector
4. Air vent 16. Terminal blocks (behind the panel)
5. LOCAL/REMOTE switch 17. Protective motor switch
6. RAISE/LOWER switch 18. (Option) Thermostat or hygrostat for extra heater
7. Outgoing shaft 100 W
8. Lamp (40 W socket E27) 19. Door-operated switch for lamp
9. Lifting eye 20. Handcrank
10. Counter 21. Descriptions and circuit diagram
11. Tap-change in progress indicator
12. Position indicator with draghands for max. and
min. position

1ZSE 5492-127 en, Rev. 5 15

2 Inspection

1 2 3 4 5 6

10

11

12

13

14

15

16

17 18 19 20 21 22 23 24

Layout of motor-drive mechanism, type BUL

1. Position indicator with draghands for max. and 13. Emergency stop
min. position 14. RAISE/LOWER switch
2. Tap-change in progress indicator 15. LOCAL/REMOTE switch
(Red = in progress, White = in position) 16. Protective motor switch
3. Counter 17. Air vent
4. Outgoing shaft with multihole coupling half 18. Door operated switch for lamp
5. Shaft for handcrank 19. Terminal blocks
6. Lifting eye 20. Hand lamp
7. Locking device prepared for padlock 21. Heater 50 W + optional 100 W
8. (Option) Multi position switches 22. (Option) Thermostat or hygrostat for extra heater
9. (Option) Measuring amplifier 100 W
10. (Option) Switch for extra heater 23. Descriptions and circuit diagram
11. (Option) Outlet 24. Handcrank
12. (Option) Earth fault protector (when outlet is
installed)

16 1ZSE 5492-127 en, Rev. 5

 2 Inspection

3. Overhaul
The overhaul mainly consists of lifting and cleaning of the selector switch insert, checking
of the selector switch and change-over selector (if any), checking of the transition resistors,
checking of contacts and the motor-drive mechanism.

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. Obtain a signed certificate from the engineer in charge.

3.1 Required tools and materials

Necessary for the overhaul, besides common hand tools, is the following equipment:
■■ Normal set of open end wrenches (metric, up to 18 mm)
■■ Normal set of sockets (metric, up to 18 mm)
■■ Allen socket, 5 and 6 mm
■■ Ratchet wrench handle with extension
■■ Normal set of screwdrivers
■■ Oil test equipment (for dielectric strength testing according to IEC 156),
■■ New transformer oil, volume according to section 3.3.3. 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.
■■ Clean and empty drums (for approximately 200 l)
■■ Bucket (10 l)
■■ Rags (non-fuzzying)
■■ Brush with extensible shaft (for cleaning of cylinder and selector switch shaft), see Ap-
pendix, Fig. A1
■■ Spring balance (10 N) for checking of belt tension
■■ Megger (500 V)
■■ Set of spare contacts
■■ Guide for rollers, see Appendix, Fig. A6
■■ Holding tool (for remounting of fixed contact blade and guiding when lowering the
insert), see Appendix, Fig. A2
■■ Screwing tool (for remounting of fixed contact blade), see Appendix, Fig. A3
■■ Lifting and operating tool, see Appendix, Fig. A4
■■ Lifting rig, see Appendix, Fig. A5
■■ Lifting jack (about 40 kg, 1.6 m lifting height)
■■ Protective gloves, oil-proof
■■ Hand lamp
■■ Ohmmeter (0.5-50 Ohm)
■■ Slide calliper
■■ Air pump with pressure gauge (0-200 kPa), connection to thread R1/8” male
■■ Oil for bearings
■■ Grease: GULF-718EP Synthetic grease, Mobilgrease 28, SHELL-Aero Shell Grease 22
or similar
■■ Watch, with hand for seconds
■■ Pen and paper and revision protocol

1ZSE 5492-127 en, Rev. 5 17

3 Overhaul

3.2 Procedure
The overhaul procedure includes the following points:
■■ Oil draining and filtering
■■ Lifting and cleaning the selector switch housing and insert
■■ Checking fixed and moving contacts of the selector switch and change-over selector (if
any)
■■ Checking the transition resistors
■■ Lowering the selector switch insert
■■ Checking the pressure-relay
■■ Lubrication of the drive shaft system
■■ Checking the motor-drive mechanism
■■ Oil filling
■■ Putting into operation

3.3 Preparations

NOTE: If the on-load tap-changer is oil filled under atmospheric pressure, a waiting
period of three hours is needed before energizing. To save outage time of the trans-
former, carry out all work on the on-load tap-changer and the oil filling before the
maintenance of the motor-drive mechanism is started.

3.3.1 On-load tap-changer position

Note the position of the on-load tap-changer to enable restart of the transformer in the right
tap position.

3.3.2 Disconnection and earthing of the transformer

WARNING
Before starting any work in the on-load tap-changer the protective motor switch and
the LOCAL/REMOTE switch must be set at 0.

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.

Operate the on-load tap-changer by the hand crank until the Maintenance position is
reached.

NOTE: The Maintenance position is marked on the rating plate.

18 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

3.3.3 Oil volumes and lifting heights

The necessary number of empty drums for collecting and filtering of the oil in the diverter
switch housing should be kept ready. The drums must be carefully cleaned and free from
water. New oil needed 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. The oil should have a water content below 15 ppm and have
been handled and stored according to IEC 60422 point 10.

Quantity of oil in the on-load tap-changer and lifting height for insert
UBB.N 200/... Approx. 100 kg (lifting height 1.3 m)
UBB.N 350/...
UBB.T 200/... Approx. 125 kg (lifting height 1.6 m)
UBB.T 350/...

NOTE: The volume of the oil conservator is not included.

Alternatively, the oil may be replaced by new oil and the used oil filtered at some later oc-
casion. A certain quantity of new oil, approximately 40 kg, should be kept ready to replace
waste oil and for cleaning.

CAUTION
Do not energize the transformer until oil has been filled as per section 3.18 ”Oil Filling” in this
guide.

3.3.4 Recommended set of standard spare parts

It is recommended to have a set of contacts for the selector switch available at the overhaul.
See Fig. 3.

Moving contacts
Fixed contact

Socket screw

Locking washer

Fig. 3. fm_00227

1ZSE 5492-127 en, Rev. 5 19

3 Overhaul

3.4 Oil testing and oil draining

The selector switch housing is equipped with an oil valve placed on the top section. For
connection dimensions, see the dimension drawing for the on-load tap-changer.

WARNING
The oil in the on-load tap-changer may be hot. Be cautious!

Take an oil-sample from the oil valve and carry out the dielectric strength test according to
IEC 60156 (between spherical calottes, distance 2.5 mm). This test is carried out for decid-
ing whether the oil can be filtered or must be exchanged.
The dielectric strength of the oil should not be allowed to be less than 30 kV in the test
above for an on-load tap-changer in service. For new oil or after filtering of the old oil, the
dielectric strength must be at least 40 kV to be allowed for filling the tap-changer.

NOTE: When taking the oil-sample, first drain some oil into a bucket to clean the
valve.

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB and it is maintained and operated according to our instructions, oil
draining and filtering is not needed, provided that the dielectric strength is at least 40
kV measured in a gap according to IEC 60156.
Use the filtering equipment or the pump to drain oil from the on-load tap-changer into care-
fully cleaned oil drum. Connect the pump to the oil valve and drain the oil from the selector
switch housing and the conservator. (If the oil conservator of the on-load tap-changer is
common with the oil conservator of the transformer tank, close the valve in the pipe con-
nection to the oil conservator and open the oil valve. After a while, open the air release valve
to the on-load tap-changer, see Fig. 2.) Pump until the oil flow stops. The oil level will then
be about 300 mm below the cover. Draining can be effected quickly if filtering equipment is
used and at the same time the whole oil quantity will be filtered once.

WARNING
There is always a cushion of explosive gases in the top of the on-load tap-changer.
No open fire, hot surfaces or sparks may be present during opening of the housing
or draining from the valve. After the cover is removed let the gas vent away approxi-
mately 15 min before any work is started.

When oil that has been used in a on-load tap-changer 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.

Remove the top cover of the selector switch housing. See section 3.5.1. Put the hose from
the pump down to the bottom of the selector switch housing and pump out the remaining
oil.

20 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

3.5 Lifting and cleaning the selector switch insert

3.5.1 Dismantling the top cover of the on-load tap-changer

See Fig. 4.
1. Remove the connection to the oil conservator and pressure relay and other connections
made.
2. Loosen the hose clips for the protective tubes on the bevel gears and push the tube
from the bevel gear so that the coupling halves for the square shaft can be seen.
3. Loosen the bolts for the top cover.
4. Lift the cover carefully min 100 mm straight upwards before moving it in horizontal di-
rection. Hold the shaft so it not will fall when the cover is lifted. Take away the shaft and
store it temporary. Check that the driving disc on the lower side of the cover and the
tightening surface not become damaged when storing the cover temporary.

Protective tube Hose clip Cover

Bevel gear

Top cover

Screw M6 A
Coupling half

Driving pin
Guiding pin

Driving disc

Indicator window

A A

Earthing symbol

Key in the bevel gear

fm_00012

Fig. 4.

1ZSE 5492-127 en, Rev. 5 21

3 Overhaul

3.5.2 Removal of the mechanism and fixed contact blades

Loosen the four M8-screws in the corners of the base plate and remove the mechanism,
see Fig. 5.
If the base plate is hard fitted it can be loosened by means of two M10x50 (or longer)
screws. Mount the screws through the two clearance holes in the upper part of the selector
switch, see Fig. 5. Tighten the screws and the base plate will be pressed upwards. Remove
the screws immediately when the base plate with selector mechanism is removed.

Base plate for selector mechanism The oblong hole of the position selector
Four M8 Allen screws

Position selector for the

change-over selector

Holes for M10x50 fm_00228

(or longer) screws

Fig. 5

22 1ZSE 5492-127 en, Rev. 5

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Removed fixed
contact blade

Current collector knob

Moving contact arm in

maintenance position fm_00242

Change-over contact in
position

Fig. 6. UBB in position before removal of the switch insert.

At 10-pitch, (the number of fixed contacts in one phase of the selector switch), remove
the contact blade next to the current collector in each phase, see Fig. 6, if 12- or 14-pitch
removing of two contact blades in each phase is recommended.
Proceed as follows:
1. Adjust the contact holder of the holding tool, for the actual contact (different contacts
for 10-, 12-, 14-pitches). See 3.5.3 and Fig. A2.
2. Attach the holding tool on the contact blade in the upper phase.
3. Loosen the two M6-screws completely in the contact blade by using the screwing tool,
see Fig. A3.
4. Lift both tools and the contact blade and the M6-screws. Store the blade and screws
temporarily.
5. For the blades in the lower phases, repeat the steps 2-4 above.

1ZSE 5492-127 en, Rev. 5 23

3 Overhaul

3.5.3 Adjustment of the holding tool for removal of fixed contacts

See Fig 7.
The plate spring must be adjusted to dimension B for the fixed contacts respectively (see
the table below). Turn the adjusting screw clockwise to reduce and anticlockwise to increase
the dimension B. If the adjusting according to above not is enough, bend carefully the plate
spring to the right dimension. Use a spare contact blade to check the adjustment.

Fixed contact for Dimension B

10-pitches 41 +1/-0
12-pitches 36 +1/-0
14-pitches 31 +1/-0

Adjusting screw

Screw
Contact Washer

Plate spring
(B) fm_00021

Fig. 7.

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3.5.4 Positioning of selector switch and change-over selector before lifting

See Fig. 6.
1. Attach the lifting and operating tool, see Fig. A4, to the two M8-holes on the upper end
of the selector switch.
2. Twist the tool clockwise until the moving contacts of the selector switch shaft have
reached the position for the removed fixed contact blades and close to the current col-
lectors. See Fig. 6.
3. Place the slot in the outer arm of the tool over the roller on the change over selector.
4. Twist the moving contacts of the change-over selector by means of the arm until they
are between two fixed long contacts.

3.5.5 Lifting
The selector switch insert (mass approximately 30 kg) can be lifted out of the cylinder by
means of a lifting jack. As a holder for the lifting jack it is recommended to use a ”rig” similar
to the one shown in Appendix, Fig. A5.
1. Couple the hook of the lifting jack to the lifting and operating tool and lift the insert care-
fully until the current collectors just leaved their knobs.
2. Twist the shaft so both the moving contacts and the current collectors are in the posi-
tion for the removed fixed contact blades, see Fig. 8.
3. Lift carefully until the selector switch insert is completely removed from the selector
switch cylinder.
4. The insert can be put down on two non-metallic (wood) supports.

CAUTION
Make sure that there always is clearance between the insert and the fixed contact blades,
so no parts will be deformed or damaged.

1ZSE 5492-127 en, Rev. 5 25

3 Overhaul

Moving contact arm

during lifting

Removed fixed
contact blade

Current collector
during lifting

Current collector knob

Change over contact

during lifting

fm_00243

Fig. 8. UBB in position for lifting of the switch insert.

3.5.6 Cleaning
Clean the selector switch insert as follows:
1. Remove all carbon deposits on the outside by brushing. Flush with clean oil.
2. Clean the inside of the selector switch shaft by putting in the brush from the bottom
and moving it up and down during turning. Flush the inside with clean oil.
Clean the selector switch cylinder:
1. Remove all carbon deposits with the brush moved up and down during turning. Flush
with clean oil.
2. Remove the remaining oil on the cylinder bottom by using a non-fuzzying rag. Pick up
rags from the bottom.

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB and it is maintained and operated according to our instructions,
the cleaning of the selector switch housing is very easy.

26 1ZSE 5492-127 en, Rev. 5

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3.6 Oil filtration

The drained oil should be filtered until it is cleaned and has regained the high dielectric
strength required. The break-down value for purified oil should be at least 40 kV measured in
a 2.5 mm gap according to IEC 60156.
To check the result of the filtering, take test sample during the oil filtration and after the oil
has been filled into the on-load tap-changer.

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB and it is maintained and operated according to our instructions, no
further oil filtration should be necessary. Only take a sample and measure the dielec-
tric strength of the oil, see section ”Oil Testing and Oil Draining” in this guide.

3.7 Checking of the breather

Check the breather according to the instructions for the transformer.

WARNING
The breathers and the tube from the conservator contain explosive gases. No open
fire, hot surfaces or sparks may be present when removing the breather.

If more than half of the drying agent has changed colour, it must be dried or replaced.
The drying agent normally starts to change colour from the bottom of the breather. If it
changes colour at the top of the breather, there is a leakage in the connections to the con-
servator. Locate the leakage and seal it.

1ZSE 5492-127 en, Rev. 5 27

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3.8 Checking contacts

3.8.1 Moving contacts

NOTE: If the moving contacts are replaced, also replace any fixed contacts that are
considerably worn, in order to minimize the wear of the new moving contacts.

If the on-load tap-changer has only used a few positions during the period of operat-
ing, you may replace any worn contacts in these positions with unworn contacts from
positions not used.
Replace a moving contact when the diameter of its contact rollers is less than the diameters
given in the table 1. Measure the diameter of each roller halfway between the roller ends.
Compare the measurements of the most worn roller with the diameters given in table 1. See
Fig. 9.

Measure the roller

diameter (d) here fm_00230

Fig. 9. Moving contact arm.

NOTE: If a contact is replaced, the comparision at the next revision shall start again
with the value for Revision 1.

Table 1. Contact minimum dimensions.

Revision (According to recommendations on Measure d (mm)

the rating plate)
1 ≤ 18.5
2 ≤ 18
3 ≤ 17.5
4 ≤ 17
5 ≤ 17

The base for the dimensions are, at the same service conditions in the future, the contacts
are not likely to be worn out before next overhaul.

CAUTION
If the on-load tap-changer has exceeded 500 000 operations, the contacts must be re-
placed, due to weakening spring tension of the contacts.

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3.8.2 Fixed contacts with tips of copper-tungsten

Check the degree of contact burning and establish which side is most worn. Then check, on
the most worn side of the contact, which surface (upper or lower part) is least worn. Mea-
sure the wear on this surface 6 mm up on the tip, according to Fig. 10. The contact has to
be loosened to make the measurement possible.

a
Measure the ”a” value at
Most worn side
this point

Least worn surface

a
6 mm
A A

View A-A Tip of Copper-Tungsten

b
fm_00022

Fig. 10. Measure the wear of the contacts.

Replace the contact if worn beyond the limits stated in table 2.

NOTE: If a contact is replaced, the comparison at next revision shall start again with
the value for Revision 1.

Table 2. Contact minimum dimensions.

Revision (According to b=30 b=24.5 b=21.5

recommendations on the Measure a (mm) Measure a (mm) Measure a (mm)
rating plate)
1 ≤ 3.5 (3.0) ≤ 3.5 (3.0) ≤ 4.0 (3.5)
2 ≤ 3.5 (3.0) ≤ 3.5 (3.0) ≤ 4.0 (3.5)
3 ≤ 2.5 (2.5) ≤ 2.5 (2.5) ≤ 3.0 (3.0)
4 ≤ 2.0 (1.5) ≤ 2.0 (1.5) ≤ 2.5 (2.0)
5 ≤ 1.5 (1.5) ≤ 1.5 (1.5) ≤ 2.0 (2.0)

The base for the dimensions are, at the same service conditions in the future, the contacts
are not likely to be worn out before next overhaul.
The values within brackets apply to situations of equal wear of the contact’s upper and lower
surfaces (within ± 0.5 mm).
As applicable, reinstall the old contacts or install new ones, according to instructions in sec-
tion 4.2 Fixed Contacts.

1ZSE 5492-127 en, Rev. 5 29

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3.8.3 Fixed contacts made of copper

Check the degree of contact burning and establish which side is most worn. Then check, on
the most worn side of the contact, which surface (upper or lower part) is least worn. Mea-
sure the wear on this surface 18 mm up on the tip, according to Fig. 11. The contact has to
be loosened to make the measurement possible.
Replace the contact if worn beyond the limits stated in table 3.

NOTE: If a contact is replaced, the comparison at next revision shall start again with
the value for Revision 1.

Table 3. Contact minimum dimensions.

Revision (According to b=30.5 b=25 b=22

recommendations on the Measure a (mm) Measure a (mm) Measure a (mm)
rating plate)
1 ≥ 5.5 (6.0) ≥ 5.5 (6.0) ≥ 4.0 (4.5)
2 ≥ 6.0 (6.5) ≥ 6.0 (6.5) ≥ 4.5 (5.0)
3 ≥ 6.5 (7.0) ≥ 6.5 (7.0) ≥ 5.0 (5.5)
4 ≥ 7.0 (7.5) ≥ 7.0 (7.5) ≥ 5.5 (6.0)
5 ≥ 7.5 (8.0) ≥ 7.5 (8.0) ≥ 6.0 (6.5)

The base for the dimensions are, at the same service conditions in the future, the contacts
are not likely to be worn out before next overhaul.
The values within brackets apply to situations of equal wear of the contact’s upper and lower
surfaces (within ± 0.5 mm).
As applicable, reinstall the old contacts or install new ones, according to instructions in sec-
tion 4.2 Fixed Contacts.
Least worn surface

View A–A

Most worn side

A A

18

fm_00023

a
b

Fig. 11. Measure the wear of the contacts.

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3.9 Checking the transition resistors

Connect one of the cables from the ohmmeter to one transition contact and the other cable
to the moving main contact, in all phases as described above, then measure the resistance.
Measure the resistance of each resistor and compare with values given on the rating plate.
Check that the resistors are undamaged. The values may not differ by more than 10 per-
cent.
Check that the screw joints for contacts, resistors etc. have not worked loose.

3.10 Lowering the selector switch insert

See Fig. 8.
1. Check that no foreign objects, tools, rags etc. are left in the selector switch housing.
2. Put the guiding round-bar, see Fig. A2, carefully in the centre hole in the bottom of the
selector switch housing.

NOTE: The total length should be 1200 mm for UBB.N and 1500 mm for UBB.T. See
also Fig. A2.
3. Attach the lifting and operating tool, (if removed), to the two M8 holes on the upper end
of the selector switch.
4. Attach the lifting rig, see Fig. A5, on the flange of the selector switch housing.
5. Couple the lifting jack hook to the lifting and operating tool.
6. Before lowering, the moving contacts and the current collectors shall be positioned over
the gap where the contact blades are removed and the moving contacts of change-
over selector between two long fixed contacts.
7. Lower the insert carefully until the current collectors are a little bit above the current col-
lector knobs.
8. Twist the insert carefully to the position with the current collectors exactly above the
current collector knobs respectively.
9. Lower the insert carefully and check that all the current collectors have entered the
knobs. If necessary push the current collectors with the screwing tool or similar. Check
that the bottom part of the insert enters the bearing, if not adjust by lifting it.
10. Remove the lifting jack and lifting rig.
11. By means of the lifting and operating tool position the moving contacts of the change-
over selector to the contact blades respectively. See Fig. 6.

NOTE: The position of the roller.

12. Position, by means of the same tool, the moving contacts of the selector switch to the
contact blades representing the Maintenance position, see Fig. 6.
13. Remove the lifting and operating tool.
14. Remove the guiding round bar.
15. Remount the contact blades in each phase using the two tools according to sections
3.5.2 and 3.5.3. Tightening torque 15 Nm.
16. Make sure that the sealing underneath and on top of the mechanism are in place, see
Fig. 12. Remount the mechanism and tighten the four M8-screws in the corners of the
base plate, see Fig. 5.

NOTE: The driving pins in the top of the selector switch shall enter in the correspond-
ing holes in the driving mechanism.

NOTE: If it is an on-load tap-changer with change-over device, make sure that the
roller on top of the change-over ring is engaged in the slot of the position selector
under the gear base plate.

1ZSE 5492-127 en, Rev. 5 31

3 Overhaul

Fig. 12. Sealings.

32 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

3.11 Mounting the top cover on the on-load tap-changer

See Fig. 4.
1. Check the O-ring in the groove in the flange. Grease the shaft ends of the bevel gears.
See section 3.12.
2. Before mounting the top cover check that the position of the driving disc on the lower
side of the cover is according to Fig. 4. Remove the cover of the bevel gear on the on-
load tap-changer top cover.
3. Lower the top cover straight down towards the flange. The guiding pin in the flange
shall clear the hole in the cover. The horizontal shaft with the protective tube shall be
remounted during the lowering.
Open the cover of the gear box on the top cover of the on-load tap-changer. Check
that the key on the vertical shaft in the bevel gear is facing the earthing symbol on the
flange of the on-load tap-changer. See Fig. 4.

CAUTION
The position of the driving disc must be according to Fig. 4 and the guiding pin must fit in
the hole.

4. Check that the number, readable through the indicator window in the top cover, is the
same as maintenance position and that the motor-drive mechanism has the same indi-
cated position.
5. Mount the bolts for the top cover and tighten.
6. If drive shaft coupling has been dismantled:
Mount the coupling halves to the square shaft and the shaft of the bevel gear. Tighten
the screws lightly and check that the shaft not can be moved more than 2 mm in axial
direction (axial play). Tighten the two screws A, (see Fig. 4) first and then the others.
7. Reconnect the pipe-hooks on the top cover to the flanges of the pipe to the oil conser-
vator and the pressure relay.
8. Lubricate the bevel gear, see section 3.12 and reassemble the cover.
9. Reassemble the protective tubes with the hose clips.

CAUTION
The motor-drive mechanism and on-load tap-changer shall have the same indicated tap-
position. Check in the indicator window and the motor-drive mechanism.

3.12 Lubrication of the on-load tap-changer and the drive shaft system
The bevel gears are greased at delivery and the same type of grease is used for the cou-
plings of the outer shaft system.
For access to the couplings, loosen the hose-clips and push the protective tubes together.
For access to the bevel gears, dismount the covers.

WARNING
The bevel gear contains moving gears. Be cautious!

Rotating shafts. Be cautious!

Check and lubricate with grease if necessary. Recommended types of grease are GULF-718
EP Synthetic Grease, Mobilgrease 28, Shell-Aero Shell Grease 22 or similar.
Remount covers (make sure the gaskets are properly in place).

1ZSE 5492-127 en, Rev. 5 33

3 Overhaul  

3.13 Checking the pressure relay

3.13.1 Functional check of the pressure relay

Information
plate

Valve handle
(in service
position)

Quick coupling

Test tap (R 1/8”)

TC_00264

Fig. 13. Pressure relay.

1. Set the valve handle to the test position as shown on the information plate.
2. Connect the air pump and the pressure gauge to the test tap on the pressure relay.
(Thread R 1/8”).
3. Raise the pressure until the pressure relay trips the circuit breakers of the
transformer.
4. Read the pressure on the manometer and check against the pressure stated on the
information plate. Max. permitted deviation is ±10 %. If the deviation is greater, the
pressure relay should be replaced.
5. Check that the signal disappears when the pressure is released.
6. After finishing the check, turn back the valve handle to service position.

3.13.2 Replacing the pressure relay

If replacement of the pressure relay is necessary, it is carried out according to the instruction
in 1ZSE 5492-130, Repair Guide for On-Load Tap-Changer, type UB.

34 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

3.14 Checking of motor-drive mechanisms types BUE and BUL

The motor-drive mechanism should be checked and lubricated at the same time as the on-
load tap-changer.
The overhaul includes the following points:
Before disconnecting the power supply:
■■ Motor protection function
■■ Earth fault protector (option)
■■ Counter function

After disconnecting the power supply:

■■ Heater function
■■ Toothed belt
■■ Cable connections
■■ Disc brake function
■■ Position transmitter and other position switches
■■ Lubrication
Reconnect the power supply and make operation tests according to section 3.15.

1ZSE 5492-127 en, Rev. 5 35

3 Overhaul

Brake
Brake disc
Maintaining contact

Roll pin

Supporting
shaft

Brake block
Arm system
Brake for maintaining contact Driving roller

One turn shaft

Cam disc

Toothed belt

Geneva wheel

Position
transmitter

Contact plate

fm_00137
Motor

Fig. 14. Motor-drive mechanism, type BUE.

36 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

Operation counter

Roller
(Grease)
Notch
Cam disc

(Grease)

Brake arm

Geneva
wheel Adjusting
screw

Maintaining
contact

Bracket

Brake disc
Limit switch

Toothed belt

Multi-position switches
(Grease)

fm_00231

Fig. 15. Motor-drive mechanism, type BUL.

1ZSE 5492-127 en, Rev. 5 37

3 Overhaul

3.14.1 Motor protection

Open the motor-drive cabinet door and turn the selector-switch to the LOCAL position. The
function of the protective motor switch is checked. For three-phase AC motors, one of the
phase fuses is removed and the function time of the protective motor switch is checked by a
RAISE or LOWER operation. The protective motor switch shall release within 60 seconds at
a current setting equal to the rated current of the motor at actual voltage.

WARNING
The motor power voltage is dangerous.

If the protective motor switch do not trip within 60 seconds, switch off the power and adjust
the current setting. Repeat the test when the motor is cold.
Protective motor switches for DC motors and for single-phase AC motors are not tested.

3.14.2 Earth fault protector (option)

If the motor-drive mechanism is equipped with an outlet, the earth fault protector should be
tested by pressing the test knob on the outlet. (On BUL, the earth fault protector is sepa-
rated from the outlet and the knob is on the protector).

3.14.3 Counter
Check that the counter is functioning at RAISE and LOWER operations. Check that the po-
sition indicator increases (decreases) one step and the counter advances one step for each
operation. Record the counter’s value. The counter shows the number of operations run by
the on-load tap-changer.

3.14.4 Heater

WARNING
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.

Check by feeling with a finger that the heating element has been functioning.

3.14.5 Toothed belt

Check that the toothed belt is sufficiently tight. If tightening is required, adjust the motor
support. The tightness of the belt can be checked by a spring balance attached to the belt
halfway between the pulleys. At a 10 N load the belt should yield about 5 mm on BUE and
at a 6 N load the belt should yield about 2 mm on BUL.

3.14.6 Cable connections

Check that all cable connections within reach are secure.

3.14.7 Disc brake, BUE

Wipe the brake disc free from grease.
The kinetic energy in the motor and the toothed wheels should be absorbed by the brake,
and the motor-drive mechanism should stop, as shown in Fig. 16, with a tolerance of
± 25 degrees measured on the brake disc (± 125 degrees measured on the hand crank),
see Fig. 16.

38 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

This can be adjusted by tightening both of the spring bolts on the brake. Using the hand
crank, operate the motor-drive mechanism until the brake is fully open. At this point the
length of the springs must not be less than 35 mm. If the brake still does not function with
that spring length, oil or grease has entered the brake linings, which will then need cleaning.
Clean as follows:
Using a pair of tongs, remove the roll pins that hold the supporting shafts on the brake
blocks, see Fig. 14. Then remove the shaft and the brake blocks. Clean the brake linings on
the two brake blocks with degreasing agent.
When refitting the brake, check that the brake disc is completely free from grease. Adjust
the spring force of the brake until the motor-drive mechanism stops within the tolerances
given above.

CAUTION
If the motor-drive still not stops when the brake is adjusted to a spring length of 35 mm
when the brake is fully open, please contact ABB for advisory.

Adjusting nuts

Brake disc

Red mark ±25°

from mark on
brake pad

Red mark

Brake pads
fm_00232

Fig. 16. Brake adjustment, type BUE.

3.14.8 Brake for the maintaining contact, BUE

Check that the brake for the maintaining contact prevents the arm system on the maintain-
ing contact shaft from swinging beyond its normal position when the roller on the driving arm
moves free from the cam disc, see Fig. 14. At the end of the operation, contacts for opera-
tion in the opposite direction shall not move when the arm system swings back towards its
normal position.
Unpermitted swinging should be prevented by raising the braking force, i. e. tightening the
spring bolt.
An adjusted increasing spring force on the disc brake makes the maintaining contact arm
swing back with a different speed, and the brake for the maintaining contact must be ad-
justed.

1ZSE 5492-127 en, Rev. 5 39

3 Overhaul

3.14.9 Disc brake, BUL

Run the motor-drive mechanism and check that the centre of the notch in the cam disc
stops within ±2 mm from the centre of the roller on the brake arm, see Fig. 17. If it does not
stop within the tolerances, adjust the breaking force with the adjusting screw in the lower
end of the brake arm. Loosen the contra nut. Tightening the screw (clockwise) makes the
stop earlier and loosening the screw (anticlockwise) makes the stop later. Tighten the contra
nut after the adjustment.

CAUTION
If the motor-drive still not stops when the brake is adjusted to min. 15 mm according to Fig.
17 please contact ABB for advisory.

Roller on the brake arm

in centre of the notch
in the cam disc Brake arm

Cam disc

Contra nut

Adjusting
screw
fm_00225 Brake disc

Min 15

Fig. 17. Brake adjustment, type BUL.

3.14.10 Position transmitter and other position switches, BUE

Clean the contact plates and arms (Fig. 18) from dust and dirt with a dry cloth.
Check and adjust the resilience of the moving contacts in the multi-position switches. The
moving contact shall, in all positions, have a clearance between the nut and the contact arm
of 0.6–1.0 mm. Adjustment is made with the nuts on the contact.

Moving contact
Contact arm

Contact arm
0.8 ±0.2 mm

Geneva wheel

Contact plate
A A Fixed contact
View A – A
fm_00096

Fig. 18. Contact arm play.

40 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

3.14.11 Position transmitter and other position switches, BUL

Check the contact function in all positions at both RAISE and LOWER operations. No
adjustment of the contacts should be made. For replacement of a Position Switch see
1ZSE 5492-130, Repair Guide, On-Load Tap-Changer, type UB.
If there is a lot of dust, it can be removed from the circuit cards and the transparent covers
with a vacuum cleaner, without disassembling the multi-position switch.

Transparent cover

Contact arm
Circuit card

fm_00233

Fig. 19. Position transmitter, checking.

3.14.12 Starting contact, BUE

Check that the contact timing is correct. There must be a 100° (±20°) difference between
the maintaining contact and the starting contact.
Place the motor-drive in its exact position according to Fig. 20. Operate manually 24
turns. In the very first beginning of turn 25, the maintaining contact is released and after
100° (±20°) more on the hand-crank the starting contact shall switch on again. If this se-
quence is not correct, the drive disc of the starting contact needs adjustment.

3.14.13 Lubrication, BUE

See Fig. 21.
The bearing points of the brake blocks and the links should be sparingly lubricated with oil.
(Use oil for bearings.)
The spur gears, the geneva wheel with the limit stop, the cam discs and the cam bar are
sparingly lubricated with the same type of grease as for the shaft system when necessary.
Other bearing points do not need lubrication.

NOTE: Protect the brake disc and the brake linings against lubricants. Wipe off ex-
cess lubricant.
Reconnect the power supplies.

3.14.14 Lubrication, BUL

Lubrication is not needed at normal working conditions. All ball bearings have rubber seals
and are permanently greased. All cam discs and some gears are made of selflubricating
material.
If needed, the bevel gears for the hand crank, the geneva wheels and the bevel gears for the
position indicator might be sparingly lubricated with the same grease as the shaft system.
See Fig. 15.
Reconnect the power supplies.

1ZSE 5492-127 en, Rev. 5 41

3 Overhaul

Indicator window

999987
fm_00235

LOWER POSITION RAISE

9
8 9 10
7 11
6 12
5 13
4 14

– +

Position indicator

Adjustment nuts

Brake disc
Red mark
fm_00240

Brake pads

Fig. 20. Starting contact, BUE.

42 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

Grease
Grease

Oil

Oil

Grease

Grease

NOTE: The small bevel gear

for the position indicator shaft
shall be greased.

Grease

Fig. 21. Lubrication points, BUE.

1ZSE 5492-127 en, Rev. 5 43

3 Overhaul

3.15 Operation test

To check that the shafts have been correctly assembled, the motor-drive mechanism should
be placed in the exact position acc. to Fig. 16 or 17. Operate the tap-changer with the hand
crank, counting the number of turns from the exact position until the tap-changer operates.
The test is performed in both RAISE and LOWER directions. With BUL, the tap-changer
should operate after 11.5 ±1 turns of the hand crank. With BUE, the tap-changer should
operate after 19 ±1.5 turns of the hand crank. If not, one of the shaft couplings is mounted
incorrectly.
Operate the motor-drive mechanism, first one step manually using the hand crank, and
then electrically to the position next to the end-position. Then operate manually to the end-
position. Check the mechanical end-stop by trying to hand crank beyond the end-position.
After a couple of turns you should reach the mechanical end-stop. Hand crank back to the
end-position . When trying to operate electrically beyond the end-position, the motor should
not start. Operate the motor-drive mechanism electrically to the position next to the other
end-position and carry out the same procedure as above.
Check the emergency stop by giving a RAISE or LOWER impulse and after about one sec-
ond press the emergency stop. The operation should be interrupted. Reset the emergency
stop by turning the knob clockwise and switch on the protective motor switch. The started
operation should now be completed.
Check the running-through protection with the step-by-step function disabled. This is done
by first removing the connection between terminals X4:1 and X4:2 and then keep the RAISE/
LOWER switch engaged. The motor-drive mechanism should stop before the fourth opera-
tion is completed. This checking must be done at least five steps from the end position.
After the test reset the time relay by putting the LOCAL/REMOTE switch to 0 and then back.
Reset the protective motor switch to ON. Remount the connection between X4:1 and X4:2.
Check the step-by-step relay by keeping the RAISE/LOWER switch engaged in RAISE. The
on-load tap-changer shall make only one step. Repeat the check in LOWER.
Check the function of the position transmitter and other multi position switches in all posi-
tions.

3.16 Oil filling

3.16.1 Filling methods and restrictions

Oil filling can be carried out at atmospheric pressure or under vacuum. The wall between the
diverter switch housing and the transformer tank is designed to withstand vacuum on one
side and atmospheric pressure on the other side. It is not allowed to have vacuum on one
side and the pressure of an oil column on the other side.
The oil quality should be IEC 60296-LCSET -30° (former Class II). The oil must have an elec-
trical 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 accord-
ing to IEC 60422 point 10.
After maintenance oil is normally filled at atmospheric pressure. This procedure is described
in section 3.16.3. If filling is to be carried out under vacuum, see 1ZSE 5492-118, Installation
and Commissioning Guide for UB.
After oil filling, a gas cushion should remain on the top of the oil in the selector switch hous-
ing.
The connection to the oil conservator is designed to automatically give a gas cushion when
filling at atmospheric pressure.

NOTE: If new oil, especially degassed oil, is filled into the selector switch housing and
the number of operations is low, the gas cushion may be dissolved in the oil. The gas
cushion should be restored according to section 3.16.5 ”Restoring the Gas Cushion”
in this guide.

44 1ZSE 5492-127 en, Rev. 5

 3 Overhaul

3.16.2 Before filling

NOTE: Oil filling may be carried out in different ways depending on what is convenient
as long as the rules above are fulfilled and the on-load tap-changer is filled with oil to
the correct level with a gas cushion on the top. The method below is recommended
and if it is followed in detail no pressure limits are exceeded and oil levels and gas
cushion will be correct.

3.16.3 Filling at atmospheric pressure

See Fig. 2.
1. Close the air release valve
2. Open the conservator valve, if any.
3. Dismantle the breathing device on the conservator for the on-load tap-changer.
4. Pump oil into the selector switch housing via the oil valve (connection dimensions, see
the dimension drawing for the on-load tap-changer). Continue until the conservator is
filled to the correct level at the actual temperature.
5. Shut the oil valve and disconnect the pump.
6. Remount the breathing device. Make sure the connection to the breathing device is
properly sealed.

3.16.4 Oil level

For correct oil level in the oil conservator, see the transformer documentation.

3.16.5 Restoring the gas cushion

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. Obtain a signed certificate from the engineer in charge.

If the on-load tap-changer has been filled with degassed oil and has a very low frequency
of operation, the gas cushion may have been absorbed by the oil. To avoid fault trip by the
pressure relay, the gas cushion should be restored.
Proceed as follows:
1. Shut the conservator valve.
2. Connect a pump to the oil valve and start to suck out oil. Open the air vent to the on-
load tap-changer and let air in. Stop the pumping after about 2 litres of oil has been
sucked out from the on-load tap-changer.

WARNING
The oil in the selector switch housing may be hot. Be cautious!

3. Shut the air vent and the oil valve and disconnect the pump.
4. Open the conservator valve and an appropriate gas cushion will be formed.

CAUTION
To operate the on-load tap-changer with a too small or no gas cushion means a risk for a
trip of the pressure relay.

1ZSE 5492-127 en, Rev. 5 45

3 Overhaul

The procedure above is used for on-load tap-changers without oil filter unit for continuous oil
filtration. 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.

CAUTION
Avoid to do the restoring in damp weather since moisture will get into the selector switch
housing. If the restoring has to be done in such weather, the incoming air has to be dehy-
drated.

3.16.6 Waiting period

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.

3.17 Putting into operation

Operate the on-load tap-changer to the position noted in section 3.3.1. Put the LOCAL/RE-
MOTE switch to REMOTE. Reset the drag hands. Make sure that no tools or foreign objects
are left in the motor-drive mechanism cabinet. Close the door. Make sure that nothing is left
on the transformer cover.
Sign the revision protocol and give it to the engineer in charge and inform that the on-load
tap-changer is ready for energizing.

46 1ZSE 5492-127 en, Rev. 5

 4 Contact replacement

4. Contact replacement
CAUTION
ABB recommends that only maintenance engineers with appropriate knowledge about the
UBB selector switch carry out contact replacement.

Check the wearing of the contacts as described in section 3.8. Replace worn out contacts.
Replacing of contacts is described in the following sections.

4.1 Moving contacts

The two transition contact units and the main contact unit are delivered as assembled sets.
When changing the moving contacts the whole units shall be replaced.
At first the transition resistors shall be loosened, but not removed, by loosening two
bolts (B), see Fig. 22.

B
D (10 Nm)
B (24.5 Nm)

Transition contact, unit 1

Main contact, unit 2

fm_00227
Transition contact, unit 3

C (10 Nm)

Fig. 22. Moving contact system design.

1ZSE 5492-127 en, Rev. 5 47

5 Tap-changer in the transformer

Remove the complete transition contact unit 1 and 3 by unbolting the four bolts (C). The
moving main contact unit 2 is removed by unbolting the two bolts (D).
The new main contact unit and transition contact units are then remounted. Begin with the
main contact. The transition contact units will be correctly positioned when the guide for
the rollers according to Figs. 22 and A6 is used. All bolts should be tightened according to
Fig. 22. It is not necessary to use a torque wrench. The torques (in brackets) are only guide
values.

fm_00024

Fig. 23. Guide for the rollers.

4.2 Fixed contacts

To remove the fixed contact blades you have to loosen the two socket screws. Use the
holding tool to hold the blade and screws and the screwing tool to loosen screws.
When mounting the new contact blades, the socket screws should be tightened with a
torque of 15 Nm.

5. Tap-changer in the transformer

5.1 Resistance measurement

If there are any problems with too high resistance during measurement of the transformer,
the tap-changer should be operated 10 cycles over all positions to clean the contacts.
Another cause for problems at resistance measurement may be too low measuring current.
We recommend a measuring current of at least 50 A.

48 1ZSE 5492-127 en, Rev. 5

 6 Specification of materials

6. Specification of materials

6.1 General
This chapter specifies the materials used in the on-load tap-changer. On disposal of this
product, it is recommended that local environmental regulations in each country are met. For
environmental reasons, materials used are specified.

6.2 Selector switch housing

Material Amount
Steel 5 kg
Aluminium 45 kg
Copper and alloys 5 kg
Epoxy resin 30 kg
Epoxy resin 100-125 kg

6.3 Selector switch insert

Material Amount
Steel 5 kg
Aluminium 5 kg
Copper and alloys 10 kg
Silver 25-50 g
Tungsten 0-1.5 kg
Epoxy resin 12 kg
Polyphenylene sulfide resin 2 kg
Resistor wire (mainly copper and 2 kg
nickel alloys with lesser amounts of
aluminium and manganese)

6.4 Gearing mechanism

Material Amount
Steel 8 kg
Aluminium 2.5 kg
Copper and alloys 2 kg

6.5 Drive shaft systems

Material Amount
Steel 8 kg
Aluminium 2 kg
Brass 2 kg
Polyethylene 2 kg

1ZSE 5492-127 en, Rev. 5 49

6 Specification of materials

6.6 Motor-drive mechanism

Material BUE BUL
Approx. amount Approx. amount
Steel 100–120 kg 55 kg
Aluminium and alloys – 10 kg
Copper and alloys 5–10 kg 5 kg
Silver 10 g 10 g
Plastics:
Chlorsulphonated polyethylene x x
polyamide with MoS2 x
phenol resin laminate x
polyester x x
PVC x x
carbonate plastic x x
Rubbers:
nitrile rubber x x
fluorine rubber x x

CAUTION
Materials listed in the table above without any specification of amount are included because
they may cause pollution problems during de-commissioning, even in the small quantities
used.

50 1ZSE 5492-127 en, Rev. 5

 Appendix

Appendix. Tools

1350

Brush of bottle-cleaner type

Material: plastic

fm_00025

Catalogue no.: LL 117 016-L

Fig. A1. Brush.

1ZSE 5492-127 en, Rev. 5 51

Appendix

Alternative 1 Alternative 2

Handle 1175 for UBB.N

1500 for UBB.T

1200 for UBB.N

1500 for UBB.T

Holding tool

fm_00026
For UBB delivered Guiding round-bars For UBB delivered
2001 and earlier 2002 and later

Catalogue no.: LL 117 016-D

Fig. A2. Holding tool and guiding round-bar.

52 1ZSE 5492-127 en, Rev. 5

 Appendix

1400

fm_00027

Catalogue no.: LL 117 016-E

Fig. A3. Screwing tool.

1ZSE 5492-127 en, Rev. 5 53

Appendix

220

264

fm_00020

Catalogue no.: LL 117 016-B

Fig. A4. Lifting and operating tool.

54 1ZSE 5492-127 en, Rev. 5

 Appendix

460

2050

fm_00028

Catalogue no.: LL 117 016-C

Fig. A5. Lifting rig.

1ZSE 5492-127 en, Rev. 5 55

Appendix

14

10-pitches
20
Catalogue no.: LL 117 016-F

12-pitches
20
Catalogue no.: LL 117 016-G

4.5

14-pitches
20
Catalogue no.: LL 117 016-H

fm_00029

Fig. A6. Guide for the rollers.

56 1ZSE 5492-127 en, Rev. 5

Contact us

ABB AB

© Copyright 2010 ABB, All rights reserved. 1ZSE 5492-127 en, Rev. 5, 2005-05-15
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