1ZSE 5492-118 en, Rev.

On-load tap-changers, type UBB

Installation and commissioning 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 when installing on-load tap-
changers:
Before you install or commission a unit, make sure that the personnel doing the job have
read and fully understood the Installation and Commissioning Guide provided with the unit.
To avoid damaging the unit, never exceed the operating limits stated in delivery documents
and on rating plates.
Do not alter or modify a unit without first consulting ABB.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and procedures.

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
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.

At fire: The fire is extinguished by using powder, foam or carbon acid.

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

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. Obtain a signed certificate from the engineer in charge.

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.

During drying of the transformer

CAUTION
During drying with hot air and vacuum, the maximum permitted pressure difference for the
on-load tap-changer is 100 kPa at a maximum permitted temperature of 135 °C (275 °F).

During drying by the vapour phase process the cover of the selector switch housing and the
bottom valve should be left open. The maximum permitted temperature is 135 oC (275 oF).

Use the special bottom key only (delivered with the on-load tap-changer) to operate the bot-
tom valve. The use of a stiffer tool may damage the valve.

Do not operate the on-load tap-changer during the drying process or afterwards until it is
filled with oil, to avoid seizing.

Mounting of gaskets
CAUTION
Sealing surfaces and gaskets must be clean and undamaged. 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 1.7
Tightening Torque, in this guide.
During oil filling
WARNING
When oil that has been used in a selector switch housing is pumped out, conducting
tubes and hoses that are earthed should be used to avoid the risk of explosion due to
the gases produced by the arcs during service.

CAUTION
Do not fill oil into the 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.

NOTE: Check the oil level one month after filling. It is usual for the oil level of the oil
conservator to fall due to gas absorption in the oil from the gas cushion in the on-load
tap-changer, if the on-load tap-changer is not operated. Restore the gas cushion and
the oil level according to section 7.5.

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 occur 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
The pressure relay is a calibrated monitoring instrument. It must be handled with care and
protected against careless handling or any kind of mechanical damage. Do not open the
package of the pressure relay until you are about to install it on the on-load tap-changer.
Contents
1. Introduction________________________________________________________9
1.1 Required tools_ _________________________________________________11
1.2 Required material________________________________________________11
1.3 Oil_____________________________________________________________11
1.4 Oil conservator__________________________________________________11
1.5 Oil filter unit for continuous oil filtration_________________________________ 12
1.6 Weights________________________________________________________12
1.7 Tightening torque________________________________________________12
2. Receiving__________________________________________________________13
2.1 Unpacking______________________________________________________13
2.2 Inspection upon receiving_________________________________________13
2.3 Temporary storage before assembly________________________________13
3. Installation in the transformer__________________________________________14
3.1 Cover-mounting_________________________________________________14
3.1.1 Connection to outside terminals________________________________15
3.2 Yoke-mounting _ ________________________________________________16
3.2.1 Mounting of the on-load tap-changer when transformer ratio
measurement is carried out before drying_____________________________17
3.2.2 Mounting of the on-load tap-changer when transformer ratio
measurement is carried out after drying_ _____________________________19
3.2.3 Mounting to the transformer cover from the yoke_ ________________21
4. Drying_____________________________________________________________24
4.1 Observations before processing____________________________________24
4.2 Observations after processing_____________________________________24
5. Final assembly______________________________________________________25
5.1 Mounting of the motor-drive mechanism_ ___________________________25
5.2 Mounting of accessories__________________________________________28
5.3 Mounting of external drive shafts___________________________________29
5.3.1 Mounting of horizontal drive shaft_ _____________________________31
5.3.2 Mounting of vertical drive shaft_________________________________33
5.4 Connection to the oil conservator_ _________________________________36
5.5 Before operation_________________________________________________36
5.5.1 Transformer ratio measurement after drying______________________37
6. Pressure relay______________________________________________________38
6.1 General________________________________________________________38
6.2 Installation______________________________________________________38
6.3 Checking at commissioning of the transformer_______________________39
7. Oil filling_ __________________________________________________________40
7.1 Filling methods and restrictions_ ___________________________________40
7.2 Filling at atmospheric pressure_____________________________________40
7.3 Filling under vacuum_ ____________________________________________41
7.4 Correct oil level__________________________________________________41
7.5 Restoring the gas cushion_ _______________________________________42
8. Electrical connection and testing_ _____________________________________43
8.1 General________________________________________________________43
8.2 Connecting and testing___________________________________________43
8.3 Electrical tests on transformer_ ____________________________________44
8.4 After energizing__________________________________________________44
9. Transport__________________________________________________________45
9.1 General________________________________________________________45
9.2 Transport preparations_ __________________________________________45
9.2.1 Transport with complete transformer____________________________45
9.2.2 Transport with dismounted conservator_ ________________________45
9.2.3 Protection of motor-drive______________________________________45
10. Commissioning____________________________________________________46
10.1 Reassembly_ __________________________________________________46
10.2 Oil filling_______________________________________________________46
10.3 Electrical connection and testing__________________________________46
10.3.1 Motor protection____________________________________________46
10.3.2 Disc brake_________________________________________________47
10.3.3 Counter___________________________________________________47
10.3.4 Position transmitter and other multi-position switches____________47
10.3.5 Light______________________________________________________47
10.3.6 Heater____________________________________________________47
10.3.7 Pressure relay______________________________________________47
10.4 Putting into operation_ __________________________________________47
 1 Introduction

1. Introduction
The delivery consists of on-load tap-changer, motor-drive mechanism and drive shaft sys-
tem.
The on-load tap-changer may be specified for cover-mounting or for yoke-mounting.
Cover-mounting means that the on-load tap-changer is lowered through a hole in the trans-
former cover and then bolted straight onto the transformer cover.
Yoke-mounting means that the on-load tap-changer is temporarily put onto a fork located
on the active part of the transformer. Yoke-mounting allows the transformer manufacturer
to connect the windings to the on-load tap-changer before drying and without having the
transformer cover mounted. The transformer cover is then lowered onto the tank, and the
on-load tap-changer is lifted and bolted to the cover. Please use the appropriate instruction
for cover-mounting or yoke-mounting!
The motor-drive mechanism and bevel gear are fitted to the transformer tank and the drive
shafts are fitted to complete the assembly of motor-drive mechanism, bevel gear and on-
load tap-changer before oil filling and testing.
The general arrangement of an on-load tap-changer system is shown in Fig. 1.
The general arrangement of an on-load tap-changer type UBB is shown in Fig. 2.

Horizontal drive shaft and

protection covers (SA)
Bevel gear
(SA21)
Bevel gear

On-load
tap-changer
(SS)

Vertical drive shaft

and protection covers
(SA)

Hand crank

fm_00001

Motor-drive
mechanism

Fig. 1. On-load tap-changer system.

1ZSE 5492-118 en, Rev. 4 9

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 UB.

10 1ZSE 5492-118 en, Rev. 4

 1 Introduction

1.1 Required tools

■■ Air pump with hose, pressure gauge (0-250 kPa) and connection with internal thread
R 1/8”
■■ Normal set of open end wrenches (up to 19 mm)
■■ Normal set of sockets (up to 19 mm)
■■ Socket handle
■■ Socket extender
■■ Normal set of screw drivers
■■ Allen key sockets 5 and 6 mm
■■ Lifting bar LL 117 016-K (yoke-mounting only)
■■ Dynamometric wrenches, 5-85 Nm
■■ Bottom valve key (delivered with the on-load tap-changer)
■■ Tool for opening of oil drum
■■ Hack saw
■■ Bucket, 10 litres
■■ Lifting jack

1.2 Required material

■■ Grease, (Ball bearing grease) GULF-718 EP, Mobil-Grease 28, SHELL-Aero Shell
Grease 22 or similar
■■ Equipment for oil filling
■■ Sealing tape
■■ Rags (non-fuzzying) for cleaning

1.3 Oil
The oil quality should be of Class II according to IEC publication 60296. The oil weight ac-
cording to table 1 in section 1.6.

WARNING
Do not energize the transformer until oil has been filled according to chapter 7, Oil
Filling in this guide.

1.4 Oil conservator

The on-load tap-changer has to be connected to an oil conservator. ABB recommends the
use of a separate conservator for the on-load tap-changer with both oil and air side sepa-
rated from the main conservator of the transformer.
The volume of the conservator should be such that there is oil left in the conservator even
at the lowest oil temperature expected and such that no flooding can occur at the highest
oil temperature expected. Even transformers with more than one on-load tap-changer unit
require only one conservator.
A suitable dimension of the tube for connection to the conservator is an inner diameter of
approximately 20 mm. The tube should be inclined at least 3 degrees to avoid gas cushions
in the tube. A valve in the connection to the conservator is recommended.
The conservator must be equipped with a breathing device that does not allow moist air into
the conservator and that allows the gas from the arcs to disappear.
The conservator should also be equipped with an oil level indicator, and an alarm contact for
low oil level is recommended.

1ZSE 5492-118 en, Rev. 4 11

1 Introduction

1.5 Oil 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” delivered with the oil filter unit.

1.6 Weights
Motor-drive mechanism BUE, weight: 130 kg
Motor-drive mechanism BUL, weight: 75 kg
Drive shaft system weight: about 10 kg
The weights of the motor-drive mechanism and drive shaft system are not included in the
weights given in table 1.

Table 1. Weights of on-load tap-changer, type UBB.

On-load tap-changer Approx. weight in kg
Type designation Tap-changer without oil Required oil Total weight
UBBLN XXX/YYY 140 100 240
UBBRN XXX/YYY
UBBDN XXX/YYY
UBBLT XXX/YYY 155 125 280
UBBRT XXX/YYY
UBBDT XXX/YYY

1.7 Tightening torque

The following tightening torques are recommended: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %
unless otherwise stated in this guide.

12 1ZSE 5492-118 en, Rev. 4

 2 Receiving

2. Receiving

2.1 Unpacking
Check that the packages are free from transport damage. Open the covers of the transport
boxes. Remove the supporting blocks of wood. If the package is damaged a careful investi-
gation must be carried out.
Lift the on-load tap-changer, using the lifting eyes on the top.

2.2 Inspection upon receiving

1. Check that the on-load tap-changer, drive shaft system, motor-drive mechanism and
accessories are undamaged.
2. If transport damage is found, and it is judged that correct operation of the on-load tap-
changer is not possible, a damage report should be sent to the insurance company. It is
also recommended that photos are taken of the damaged details. Mark the photos with
ABB’s reference number and the serial number of the on-load tap-changer and send
them to ABB for comments.
3. Check that the parts delivered, type designations and the serial number agree with the
delivery documents, e.g. the packing list or ABB’s ordering acknowledgement. The se-
rial number is stamped on the rating plate and on the on-load tap-changer flange, see
Fig. 3. The serial number on the parts belonging to one on-load tap-changer unit should
all be the same.

Serial No.
Serial No.

fm_00235

fm_00200 fm_00006

BUL BUE

Fig. 3. Locations of serial number.

2.3 Temporary storage before assembly

If the on-load tap-changer is not to be assembled immediately, once the delivery has been
approved the on-load tap-changer and the motor-drive mechanism must be kept warm and
dry indoors. Let the units be kept in their plastic enclosures and leave the drying agent until
assembly.

1ZSE 5492-118 en, Rev. 4 13

3 Installation in the transformer

3. Installation in the transformer

The cover-mounting method or yoke-mounting method is used.
When lifting an UBB model it is recommended to use the lifting eyes on the on-load tap-
changer top section.

WARNING
To put down the on-load tap-changer to stand on the floor without any support means
a risk for tilting with risk for injuries to people and damage to the equipment.

3.1 Cover-mounting
(For yoke-mounting, see section 3.2).

Max 90o
Lift
Top cover
O-ring

Gasket
Stud bolt
Nut
Washer
"a"

Transformer cover

fm_00201

Tightening of the suction pipe

”a”
Fig. 4. Cover-mounting details.

Proceed as follows:
1. Place the gasket (O-ring or plane gasket is usable) around the opening in the transform-
er cover. (This gasket is not included in the on-load tap-changer delivery).
2. Check that the on-load tap-changer flange is positioned in the right way in rotational
relation to the transformer cover.
3. Lower carefully without damaging the terminals the whole on-load tap-changer through
the hole in the transformer cover. If the on-load tap-changer is equipped with tie-in
resistors mounted on the outside terminals, they have to be removed during lowering
the on-load tap-changer through hole in the transformer cover. The studs on the trans-
former cover shall fit into the holes in the flange of the on-load tap-changer. Fit washers
and nuts. Tighten.

14 1ZSE 5492-118 en, Rev. 4

 3 Installation in the transformer

3.1.1 Connection to outside terminals

The connection to terminals for change-over selector, selector switch and current collec-
tor shall follow the connection diagram delivered with the on-load tap-changer. Connection
holes for bolts M10 are Ø11 mm for all terminals.

CAUTION
All connections shall be made carefully and in such a way that there is no risk for them to
come loose. Furthermore, the conductors must not cause mechanical stresses on the out-
side terminals. Make an expansion bend on every conductor. See Fig. 5.

Wrong
Terminal

Right
fm_00013

Fig. 5. Connection to outside terminals.

CAUTION
It is recommended that the distance between the cylinder and any conductor is at least
50 mm.

The transformer designer is responsible for providing sufficient insulating distances in the oil.

NOTE: There is no need of outer neutral connection leads at UBB.N-types, because

there is already a built-in connection in the on-load tap-changer insert.

1ZSE 5492-118 en, Rev. 4 15

3 Installation in the transformer

3.2 Yoke-mounting
(Pre-mounting on active part of the transformer).
(For cover-mounting, see section 3.1).
The top section of the on-load tap-changer is designed to be divided into an upper and a
lower flange, see Fig. 6, to fit the yoke-mounting.
Before the on-load tap-changer is lifted and attached to the transformer cover it rests on a
fork consisting of two beams protruding from the upper transformer yoke.

NOTE: If guiding pins are used on the fork, they should be insulated with bushings to
prevent circulation currents in the fork when the transformer is in operation.
Mounting of the on-load tap-changer to the ”yoke-fork” can be made according to two alter-
natives depending on when the testing of the transformation ratio shall be performed:
Transformer ratio measurement before drying, see section 3.2.1.
Transformer ratio measurement after drying, see section 3.2.2.
Mounting onto the transformer cover from the yoke, see section 3.2.3.

Max 90o

Top cover
O-ring

Stud

Upper Nut
part
Washer

Lower
part O-ring

Transformer cover

”Yoke-fork”

fm_00202

Sealing for the the suction pipe

”a"
Fig. 6.

16 1ZSE 5492-118 en, Rev. 4

 3 Installation in the transformer

3.2.1 Mounting of the on-load tap-changer when transformer ratio measurement is carried out
before drying
Mounting to the ”yoke-fork” of the transformer, see Fig. 6.
1. Mount the on-load tap-changer on the transformer’s ”yoke-fork”, the lifting lugs on the
upper part can be used, see Fig. 6. Handle with care without damaging the terminals
and tie-in resistors (if any).

NOTE: Check that the on-load tap-changer is positioned in the right way in rotational
relation to the transformer cover, before connection of conductors.
2. Connect the conductors according to section 3.1.1.
3. Transformer ratio measurement.
4. The on-load tap-changer can be operated by turning the shaft of the bevel gear. Use a
special hand crank, LL 117 016-M.
5. Two turns in clockwise direction (seen against the shaft end) for RAISE or two turns
anticlockwise for LOWER operation, will be equal to one switching between two taps.
Check the order documents if otherwise is stated according to the direction of rotation.

CAUTION
The on-load tap-changer should be operated through the whole operating range, both in
lower and raise direction, when carrying out ratio measurement.

The end positions must not be overrun during ratio measurement. When operating the on-
load tap-changer without drive system, check the designation of the end positions on the
single-phase diagram and watch the position indicator in the bevel gear in order to avoid
overrunning of the end position.

Watch the voltmeter during the on-load tap-changer operations. No fast voltage drops may
occur during operation. If such drops occur, the on-load tap-changer is not correctly con-
nected to the winding.

6. After the measurement, the position of the on-load tap-changer must be replaced to
the same position as the motor-drive mechanism indicates, check in the indicator win-
dow on the top cover.
7. Loosen all the twelve bolts and washers in the top cover and lift the cover carefully min.
10 cm straight upwards before moving it in horizontal direction. The bevel gear and the
pipe may not be damaged when lifting. If a crane is used arrange the straps according
to Fig. 8a.
8. Remove the upper part of the top-section by loosening the twelve M8-socket head cap
screws inside it. Keep the flange, the cover, the O-rings and the sealing for the suction
pipe, see Figs. 6 and 8 and store them temporarily on a dustfree place.
9. The on-load tap-changer and the transformer is now ready for drying. Follow the in-
structions in chapter 5.

NOTE: The gear mechanism on the gear base plate needs not and shall not be re-
moved, because it is fixed in the lower part.

NOTE: Spacers (for example of wood) can be placed between the ”yoke-fork” and
the lower flange. The connectors can hereby be mounted on the right final height.
The spacers must be removed before mounting of the on-load tap-changer onto the
transformer cover. See Fig. 7.

1ZSE 5492-118 en, Rev. 4 17

3 Installation in the transformer

O-ring for upper flange

Approx. 15 mm

fm_00209
Fig. 7.

max 90o

Fig. 8a.

max 90o

O-ring for top cover

Fig. 8b.

Sealing for suction pipe

O-ring for upper flange

FM_00203 Fig. 8c.

18 1ZSE 5492-118 en, Rev. 4

 3 Installation in the transformer

3.2.2 Mounting of the on-load tap-changer when transformer ratio measurement is carried out
after drying
Mounting to the ”yoke-fork” of the transformer. See Fig. 9.
1. Loosen all the twelve bolts and washers in the top cover and lift the cover carefully min.
100 mm straight upwards before moving it in horizontal direction. The bevel gear and
the pipe may not be damaged when lifting. If a crane is used arrange the straps accord-
ing to Fig. 8a.
2. Remove the upper part of the top section by loosening the twelve M8-socket head cap
screws inside it. Keep the flange, the cover, the O-rings and the sealing for the suction
pipe, see Fig. 8 and store them temporarily on a dustfree place.

NOTE: The gear mechanism on the gear base plate needs not and shall not be re-
moved, because it is fixed in the lower part.

max 90o

fm_00204

Fig. 9.

3. When lifting the on-load tap-changer onto the ”yoke-fork” it is recommended that
lifting eyes M12 are mounted in the lower flange.

NOTE: Check that the on-load tap-changer is positioned in the right way in rotational
relation to the transformer cover, before connection of conductors according to sec-
tion 4.3.

NOTE: Spacers (for example of wood) can be placed between the ”yoke-fork” and
the lower flange. The connectors can hereby be mounted on the right final height.
The spacers must be removed before mounting of the on-load tap-changer onto the
transformer cover. See Fig. 10.

1ZSE 5492-118 en, Rev. 4 19

3 Installation in the transformer

Approx. 15 mm

fm_00209

Fig. 10.

4. Remove the lifting eyes when the on-load tap-changer is in right position on the ”yoke-
fork”.
5. The on-load tap-changer and the transformer is now ready for drying. Follow the in-
structions in chapter 4.

20 1ZSE 5492-118 en, Rev. 4

 3 Installation in the transformer

3.2.3 Mounting to the transformer cover from the yoke

(After drying process).

Lift
Max 90 o

Screw M8 (12x)
Washer
Lifting bar LL 117 016-K
Nut M12 (16x) Upper flange
Washer
Stud M12 (16x) Gasket
(Not included
Transformer cover
in the delivery)
13
+10
15 – 5

”Yoke fork”
Lower flange
Guiding pin
O-ring
Cylinder

(Lifting bar)

Gear mechanism

fm_00205

Fig. 11. Mounting onto the transformer cover.

1. Place the O-ring in its groove in the lower flange.

2. Place the gasket around the opening of the transformer cover. (This gasket is not in-
cluded in the on-load tap-changer delivery).

1ZSE 5492-118 en, Rev. 4 21

3 Installation in the transformer

NOTE: Do not mount the studs for the upper flange now, they will be mounted ac-
cording to point 10.
3. Place the upper flange over the opening of the transformer cover.

NOTE: Check that the flange is positioned in the right way in rotational relation to the
lower flange.
4. Mount the lifting bar on the upper flange with the four long bolts through the clearens
holes in the upper flange and in the tapped holes in the lower flange, see Fig. 11.

NOTE: The on-load tap-changer is provided with a suction pipe, see Fig. 6, the seal-
ing may not be damaged when mounting the lifting bar.
5. Couple a lifting block or crane to the lifting bar.
6. Check when lifting that the guiding pin in the lower flange clear the hole in the upper
flange.

CAUTION
Lift very carefully to avoid damages onto the on-load tap-changer.

7. Lift the on-load tap-changer until it touches the upper flange. Mount a washer and a
screw in each of the free holes.
8. If the holes in the upper flange do not match the holes in the transformer cover, the po-
sition of the on-load tap-changer must be adjusted, which may require a careful lifting.
Mount two studs (diametrical positions) in the transformer cover.
9. Remove the lifting bar and mount a washer and a screw in each of the free holes.
10. (An alternative method, if the lifting bar is not available, is to use 4 studbolts M8x70 for
lifting the cylinder: Place the studs at opposite directions through the clearance holes
in the upper flange and threaded into the lower flange. Mount washers and nuts on the
studs. Then lift the cylinder by tightening of the nuts. Check when lifting that the guiding
pin in the lower flange enters the hole in the upper flange. Mount screws and washers in
each of the 8 free holes in the upper flange. Remove the lifting studs and mount screws
and washers also in those holes.)
11. Mount the studs in the transformer cover through the holes in the upper flange. Fit
washer and nuts.
12. Mount the O-ring in the groove in the upper flange and mount the sealing for the suc-
tion pipe, see Fig. 6.
13. Before mounting of the top cover check that the position of the driving disc, on the
lower side of the cover, is according to Fig. 12.

CAUTION
Before mounting of the top cover make sure that no foreign objects are in the on-load tap-
changer.

14. Lower the top cover straight down against the upper flange, the guiding pin in the
flange shall clear the hole in the lower side of the cover.

CAUTION
The position of the driving disc must be according to that in Fig. 12 and the guiding pin must
clear the hole at mounting of the top cover.

15. Mount the washer and M12-bolts for the top cover.

22 1ZSE 5492-118 en, Rev. 4

 3 Installation in the transformer

Protective tube Hose clip Cover

Bevel gear

Top cover

Screw M6
A
Coupling half

Driving pin
Guiding pin View A - A
Driving disc

A A

Key

fm_00012

Fig. 12.

1ZSE 5492-118 en, Rev. 4 23

4 Drying

4. Drying
A drying agent is placed inside the package to keep the on-load tap-changer dry during
transport. It is not necessary to dry the tap-changer if the package not have been destroyed.
The on-load tap-changer can be dried together with the transformer according to one of the
following processes: alternating hot-air and vacuum or vapour-phase at a temperature of
max. 135 °C (275 °F) and a maximum pressure difference of 100 kPa between tap-changer
and transformer.

4.1 Observations before processing

1. When drying with the vapour-phase process the bottom valve of the on-load tap-
changer shall be open and the cover of the on-load tap-changer, the O-ring and the
sealing of the suction pipe shall be removed. See section 3.2.2, point 1. To open the
bottom valve, proceed as follows:
2. Use the delivered bottom valve key to engage the internal hexagon hole of the bottom
valve. Open the valve by turning anticlockwise max. 4 turns.
3. When drying in a vacuum pan with the hot-air process, the top cover of the on-load
tap-changer, the O-ring and sealing of the suction pipe shall be removed. See section
3.2.2, point 1.

4.2 Observations after processing

CAUTION
To avoid seizing, do not operate the on-load tap-changer, neither during the drying process
nor afterwards, until it is filled with oil.

1. Make sure that all liquid has been drained from the selector switch housing. Close the
bottom valve. Tightening torque is approximately 15 Nm.
2. If a tie-in resistor from ABB is supplied, its screw joints are to be retightened (tightening
torque 15 Nm) and locked by the method specified by the transformer manufacturer.

24 1ZSE 5492-118 en, Rev. 4

 5 Final assembly

5. Final assembly

5.1 Mounting of the motor-drive mechanism

See figs. 1, 13 and 14.
Proceed as follows:
1. Mount the motor-drive mechanism onto the transformer.
The mounting holes on the transformer should be leveled within 1 mm. If adjustment is
needed, shims should be used.
2. Install the bevel gear on the edge of the transformer cover.
3. Check that the position indicator in the motor-drive mechanism shows the same posi-
tion as the indicator inside the top cover of the on-load tap-changer.

WARNING
Do not energize the transformer before the on-load tap-changer and motor-drive
mechanism are correctly assembled.

1ZSE 5492-118 en, Rev. 4 25

5 Final assembly

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. 13. Position alignment for type BUE.

26 1ZSE 5492-118 en, Rev. 4

 5 Final assembly

Indicator window

White indicator flag

fm_00235
10 11 12
8 9
7 13
6 14
5 15
9 4 16
3 17
2 18
1 19

Position indication

Roller on brake arm

in the notch of the
cam disc
Brake arm Contra nut
Cam disc

Brake disc
fm_00241

Adjusting screw

Fig. 14. Position alignment for type BUL.

1ZSE 5492-118 en, Rev. 4 27

5 Final assembly

5.2 Mounting of accessories

The accessories on the tap-changer top cover can be rearranged to suite the individual
transformer.
The bevel gear is turnable in order to have the horizontal shaft to the motor-drive mechanism
in right direction. The limit for the turning depends on the arrangement of the accessories
but is max. 140o respective 125o as in Fig. 15. The tube bends are turnable to suite for ex-
ample the location of the conservator and the oil filter unit (if any). The flanges ”A” are equal
and their accessories can be changed between them.
We recommend that the air release valve to the transformer, see Fig. 2, is replaced by a pipe
to the gas operated relay in order to get a signal from the relay as quick as possible in case
of gas production in the transformer.

CAUTION
The pressure relay is a calibrated monitoring instrument. It must be handled with care and
protected against careless handling or any kind of mechanical damage. Do not open the
package of the pressure relay until you are about to install it on the on-load tap-changer.

fm_00217
A

Fig. 15.

28 1ZSE 5492-118 en, Rev. 4

 5 Final assembly

5.3 Mounting of external drive shafts

The external drive shafts consists of square tubes and shall be connected to the spherical
shaft ends on bevel gears and motor-drive mechanism by means of two coupling halves.
The square shafts and protective tubes must be cut before mounting.

CAUTION
Before mounting of shafts and couplings, everything must be cleaned and greased for cor-
rect function and to avoid corrosion.

Apply a thin layer of grease, GULF-718EP Synthetic grease or Mobilgrease 28 or SHELL-

Aero Shell Grease 22 to all spherical shaft ends and unpainted surfaces of the bevel gears.

CAUTION
The motor-drive mechanism and on-load tap-changer shall have the same indicated tap
position. See section 5.1.

The inclination of the shaft (the square tube) must not be more than 4o (=70mm for every
1000 mm shaft length).

NOTE: The tubes around shafts and couplings are for protection.
The arrangement of the driving shaft system is shown in Fig. 16.

1ZSE 5492-118 en, Rev. 4 29

5 Final assembly

Bevel gear on the top cover SA10 SA11 SA25 SA22 SA24 SA23 SA25 SA11 SA10 SA21 SA20
SA12 SA12
SA13 SA13

SA17
SA18
SA19

Horizontal drive shaft

SA10

SA11
SA12
SA13
SA10 Hose clip
SA11 Couplinghalves Vertical drive shaft
SA12 Hexhead cap screw M6
SA16
SA13 Washer
SA14 Vertical square shaft SA14
SA15 Vertical protective tube
SA16 Vertical protective tube
SA15
SA17 Clamp
SA18 Hexhead bolt M10 SA11
SA19 Washer SA12
SA20 O-ring SA25 SA13
SA21 Bevel gear
SA10
SA22 Horizontal square shaft
SA23 Horizontal protective tube
SA24 Horizontal protective tube
SA25 Information plate TC_00168
SA26 Multiple hole coupling
SA27 Hexhead bolt M8 1)
SA28 Washer 1)
SA29 Locknut M8 1)

1)
Included in SA 26 Multiple hole
coupling

Motor-drive
mechanism

BUE

TC_00248

SA26
SA27, SA28
SA29

TC_00239 BUL

Fig. 16. External shaft system

30 1ZSE 5492-118 en, Rev. 4

 5 Final assembly

5.3.1 Mounting of horizontal drive shaft

1. Mount the bevel gear SA21 on the transformer, with O-ring SA20, four clamps SA17,
hexagon head bolts M10, SA18 and washers SA19, see Fig. 16.
2. Determine the dimension K1 between the spherical shaft ends, see Fig. 17.

K1
SA 21

TC_00238

Fig. 17.

3. Cut the square shaft SA22 to dimension = K1 minus 6 mm. Remove the burrs.

LB1

SA14 SA24 SA10 SA23 SA11

TC_00238
Fig. 18.

4. Cut the protective tubes SA23 and SA24 in the unslotted end so that both of them get
the same length LB1 according to the table 2 below.

NOTE: Protective tubes with slotted ends shall be used.

Table 2. Length dimension for LB1.

K1 = 190 to 290 mm K1 = 291 to 600 mm K1 = greater than 600 mm

K1+180 mm K1+210 mm K1+410 mm
LB1 = LB1 = LB1 =
2 2 2

390+210 600
Example: K1 measured to 390 mm. LB1 is then = = = 300 mm
2 2

NOTE: If K1 is greater than 600 mm the mounted tubes shall overlap each other at
least 300 mm. Dismounting and inspection of the couplings shall be possible when
one of the tubes is pushed into the other.

5. Fit two coupling halves, SA11, on one end of the square shaft with six screws SA12
and washers, SA13. Push the shaft to the bottom of the fitting in the coupling halves.
Tighten the two screws A first and then the others, see Fig. 19. Put on the two protec-
tive tubes, SA23 and SA24, the slotted ends outwards, and two hose clips SA10, see
Fig. 18.

1ZSE 5492-118 en, Rev. 4 31

5 Final assembly

Square shaft SA11 SA12 SA13 A Driving pin Square shaft SA11

Max. 3 mm
Max. 6 mm
A TC_00147 TC_00148 TC_00170

Fig. 19. Fig. 20. Fig. 21.

SA11 SA21

TC_00238

Fig. 22.

6. Connect the square shaft with the mounted coupling halves to the shaft of the bevel
gear SA21, see Fig. 22. Mount two coupling halves SA11 to the square shaft perpen-
dicular to the coupling in the other end and to the shaft of the bevel gear on the on-load
tap-changer. Tighten light the screws and check that the shaft not can be moved more
than 2 mm in axial direction (axial play). Tighten the two screws A first and thereafter the
other, see Figs. 19 and 20. If necessary the axial play may be adjusted by moving the
couplings on the shaft end according to Fig. 21.

SA10 SA24 SA25 SA23 SA10

Slot facing
downwards

TC_0238

SA23
Fig. 23.

7. Push the two protective tubes on to the bevel gears and clamp them with hose clips,
SA10, see Fig. 23.

NOTE: The slot of the protective tubes SA23 and SA24 shall be facing downwards.
Apply the self-adhesive information plates SA25 around the tubes on about the middle
of the tube length.

32 1ZSE 5492-118 en, Rev. 4

 5 Final assembly

5.3.2 Mounting of vertical drive shaft

1. Determine the dimension K2 between the spherical shaft ends, see Fig. 24.
2. Cut the vertical square shaft, SA14, to dimension = K2 minus 6 mm. Remove the burrs.
3. Cut the protective tubes SA15 and SA16 so both of them get the same length LB2 ac-
cording to the table 3 below.

Table 3. Length dimensions for LB2.

K2 = 200 to 290 mm K2 = 291 to 600 mm K2 = greater than 600 mm

K2+180 mm K2+220 mm K2+410 mm
LB2 = LB2 = LB2 =
2 2 2

4. Fit two coupling halves, SA11, on one end of the square shaft with six screws SA12
and washers SA13. Push the shaft to the bottom of the fitting in the coupling halves.
Tighten the two screws A first and then the other. See Fig. 19. Put on the two protective
tubes, SA15 and SA16, and two hose clips SA10. See Fig. 25.

SA21 Multiple hole

coupling

SA11

SA10
LB2
K2

Fig. 26.
SA16

SA15
SA14 Multiple hole
coupling

Fig. 24. Fig. 25. Fig. 27.

5. For BUE motor-drive mechanism loosen the two screws in the multiple hole coupling
inside the motor-drive mechanism. See Fig. 26.
For BUL motor-drive mechanism place the multiple hole coupling half (SA 26) on the
coupling half on the outgoing shaft. See Fig. 27.

1ZSE 5492-118 en, Rev. 4 33

5 Final assembly

6. Connect the square shaft with the mounted coupling halves to the shaft of the bevel
gear. Mount two coupling halves SA14 to the square shaft perpendicular to the cou-
pling in the other end, and the shaft of the motor-drive mechanism. Tighten the screws
lightly and check that the shaft not can be moved more than 2 mm in axial direction
(axial play). Tighten the screws A first and thereafter the other. See Fig. 28 and Fig. 19.
7. Mount the tube with the greater diameter, SA16, to the bevel gear with a hose clip
SA10. See Fig. 29.

SA10

SA16

SA14 SA14

TC_00265 TC_00265

Fig. 28. Fig. 29.

8. Check that the motor-drive mechanism is in the EXACT position and that the position
indicator in the motor-drive mechanism shows the same position as the indicator inside
the top-cover of the on-load tap-changer.
EXACT position for the BUE is when the red indicator flag is in POSITION and the red
mark on the brake disc is aligned with the red mark on the brake pad. See Fig. 13.
EXACT position for the BUL is when the roller on the brake arm is in the notch of the
cam disc. See Fig. 14.
If out of position hand crank the motor drive mechanism to EXACT position according
to above.
9. 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. 30. If not, the multiple hole coupling must
be adjusted. Turn the vertical shaft until the key is facing the earthing symbol. Mount the
two screws and the locking nuts in the two holes of the coupling halves which are clos-
est to each other and tighten.

CAUTION
If the key is not in position as described above, the tap-changer operation will be too early in
one direction and too late in the opposite direction.

The motor-drive mechanism and the on-load tap-changer shall have the same indicated
tap position and the key in the bevel gear onto the on-load tap-changer shall be facing the
earthing symbol according to Fig. 30.

WARNING
The bevel gear contains moving gears. Be cautious!

34 1ZSE 5492-118 en, Rev. 4

 5 Final assembly

140o

Earthing symbol

Key in the bevel gear 125o fm_00002

Fig. 30. Adjustment of bevel gear.

10. Pull down the protective tube SA15 and mount the hose clip SA10. See Fig. 31. Note
the clearance for draining. (Min 3 mm, max 5 mm).
11. Remount the cover of the gear box on the top of the on-load tap-changer.

SA10

SA16

SA15 Min. 3, max 5 mm

SA15
SA10
SA10

TC_00149

Fig. 31.

1ZSE 5492-118 en, Rev. 4 35

5 Final assembly

5.4 Connection to the oil conservator

NOTE: If oil filling is done under vaccum without oil conservator, this section is carried
out after oil filling. See Fig. 32.

Ø 14 (4x)

85
Ø
Ø 11 (4x)

Turnable flange

Ø 75 O-ring 44.2x5.7

Ø 110 fm_00210

Fig. 32.

Remove the transport cover on the tube bend. Make sure the O-ring is in place and connect
the pipe to the oil conservator. Tighten the nuts.

CAUTION
In case where the conservator is common for 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 conserva-
tor.

Oil filter with housing can be ordered from ABB on the ”Ordering data” sheet.

5.5 Before operation

1. Check that the on-load tap-changer and the motor-drive mechanism have the same
indicated position and that the key position of the on-load tap-changer bevel gear is in
accordance to Fig. 30.
2. Remove the locking device of the motor-drive mechanism (if not already done). See
Fig. 33.

Locking device

TC_00262 BUL fm_00208

BUE

Fig. 33. Locking device of motor-drive mechanism.

36 1ZSE 5492-118 en, Rev. 4

 5 Final assembly

5.5.1 Transformer ratio measurement after drying

If transformer ratio measurement is to be done after drying this is a suitable stage to carry it
out.

CAUTION
To avoid seizing, do not operate the on-load tap-changer until it is filled with oil.

Carry out this measurement after the drive system is mounted.

Operate the on-load tap-changer by means of the motor-drive mechanism.

CAUTION
The on-load tap-changer should be operated through the whole operating range, both in
lower and raise direction, when carrying out ratio measurement.

The end positions must not be overrun during ratio measurement. When operating the on-
load tap-changer without drive system, check the designation of the end positions on the
single-phase diagram and watch the position indicator in the bevel gear in order to avoid
overrunning of the end position.

Watch the voltmeter during the on-load tap-changer operations. No fast voltage drops may
occur during operation. If such drops occur, the on-load tap-changer is not correctly con-
nected to the winding.

1ZSE 5492-118 en, Rev. 4 37

6 Pressure relay

6. Pressure relay

6.1 General
The selector switch housing of the on-load tap-changer is supplied with a pressure relay.
In the event of overpressure in the selector switch housing and, if correctly connected, the
relay trips the transformer main circuit breakers. It is also recommended to connect the
pressure relay in the trip circuit of the power supply during testing of the transformer.

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

To take the transformer into service after a pressure relay trip without carrying out a careful
investigation of the selector switch by lifting it out of the selector switch housing, and repair-
ing faults, if any, may cause severe damages to the on-load tap-changer and the transform-
er.

The pressure relay can easily be tested by applying air pressure by means of a pump to the
test tap on the valve and the handle can be pad-locked in the service position.

CAUTION
The pressure relay is a calibrated monitoring instrument. It must be handled with care and
protected against careless handling or any kind of mechanical damage. Do not open the
package of the pressure relay until you are about to install it on the on-load tap-changer.

6.2 Installation
Remove the cover from the flange on one of the tube bends on the upper part of the on-
load tap-changer and install the pressure relay. Make sure that the gasket is correctly fitted.
Remove the cover from the pressure relay and connect the cables to the terminal block.
The cable gland includes an O-ring sealing between the gland and the pressure relay hous-
ing.
If the gland has to be changed to another type, the seal against the housing must be se-
cured by a gasket or sealing liquid (example Loctite 275).

CAUTION
Tighten the cable gland with care, torque max 5 Nm.

38 1ZSE 5492-118 en, Rev. 4

 6 Pressure relay

6.3 Checking at commissioning of the transformer

Information
plate

Valve handle

Test tap (R 1/8”)

TC_00264

Fig. 34. Pressure relay.

1. Set the valve handle in 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.
3. Raise the pressure until the pressure relay trips the circuit breakers for the transformer.
4. Read the pressure on the manometer and check against the pressure stated on the
information plate. Max. permitted deviation is ± 10 %.
5. Check that the alarm signal disappears when the pressure is lowered.
6. After finishing the check, turn back the valve handle to service position.

1ZSE 5492-118 en, Rev. 4 39

7 Oil filling

7. Oil filling

7.1 Filling methods and restrictions

Oil filling can be carried out at atmospheric pressure or under vacuum. The wall between the
on-load tap-changer 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.
Oil filling may be carried out in different ways depending on what the transformer manufac-
turer finds convenient as long as the rules above are fulfilled and the on-load tap-changer is
filled with oil to the correct level.
The methods below are recommended and it they are followed in detail no pressure limits
are exceeded and oil levels and gas cushions will be correct.
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. When filling under vacuum a certain amount of oil has to be
drained in order to obtain the gas cushion. See section 7.5.

NOTE: The oil dissolves gases, especially if degassed oil is used. If the number of
operations is low, the gas cushion may be dissolved in the oil.

NOTE: If the transformer is filled at atmospheric pressure the air release valve on the
flange should be opened and the trapped air let out. Even better is to replace the air
release valve with a pipe to the gas operated relay.

7.2 Filling at atmospheric pressure

1. Open the conservator valve, if any.
2. Dismantle the pipe to the breather. Or, if simpler, take away the dehydrating breather.
3. Connect the pump to the oil valve on the on-load tap-changer cover. Open the valve
and pump in oil to the correct level shown on the oil level indicator. For correct oil level,
see section 7.4.
4. Shut the oil valve and disconnect the pump.
5. Reassemble the pipe or the breather. The connections must be airtight, use sealing
tape on the threads and O-rings in the flanges.
When the transformer and the on-load tap-changer have a common oil conservator, a filter
in the connection between the on-load tap-changer and the conservator is needed.

1. The conservator valve should be shut.

2. Open the air release valve on the oil filter housing.
3. Connect the pump to the oil valve on the on-load tap-changer cover. Open the valve
and pump in oil. Stop the pump when oil reaches the air release valve.
4. Shut the oil valve and the air release valve and disconnect the pump.
5. Open the conservator valve.

NOTE: An appropriate gas cushion automatically remains under the top cover by
those methods.

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.

40 1ZSE 5492-118 en, Rev. 4

 7 Oil filling

7.3 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.
1. Open the conservator valve, if any.
2. Dismantle the pipe to the breather, or, if simpler, remove the dehydrating breather.
3. Connect the transformer to the breather connection on the conservator for the on-load
tap-changer.
4. Apply vacuum.
5. Connect the oil filling equipment to the oil valve on the on-load tap-changer. Open the
valve and let oil into the on-load tap-changer until the correct level is shown on the oil
level indicator. For correct oil level see section 7.4.
6. Shut the oil valve and disconnect the filling equipment.
7. When filling of the transformer is completed disconnect the vacuum pump and let air
into the conservator.
8. Reassemble the pipe or the breather. The connections must be airtight; therefore use
sealing tape on the threads and O-rings in the flanges.

7.4 Correct oil level

For installations where the on-load tap-changer and the transformer tank have a common oil
conservator, the instructions for the transformer should be used.
If possible, the oil levels of the oil conservators of the transformer tank and the on-load tap-
changer should be the same. The oil level of the oil conservator of the on-load tap-changer
should in no case be higher than the oil level of the transformer oil conservator.
At +20 °C (68 °F), oil is filled to the level where the pointer of the oil level indicator points
half-way between MIN and MAX.
For other temperatures than +20 °C (68 °F), proceed as follows:
-- For every 10 °C (18 °F) increase of temperature, adjust the oil level upwards a tenth of
the scale range of the oil level indicator.
-- For every 10 °C (18 °F) decrease of temperature, adjust the oil level downwards a tenth
of the scale range of the oil level indicator.

1ZSE 5492-118 en, Rev. 4 41

7 Oil filling

7.5 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.

After oil filling under vaccum a gas cushion has to be formed.

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.
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 as above.

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.

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.

42 1ZSE 5492-118 en, Rev. 4

 8 Electrical connection and testing

8. Electrical connection and testing

8.1 General
Before the transformer is energized tests have to be made to make sure that all mechanical
and electrical connections are correct, and to check the proper functioning of the on-load
tap-changer and the motor-drive mechanism.
When testing the transformer, the on-load tap-changer can be operated either by the hand
crank or electrically. When operating electrically the Motor-Drive Mechanism is connected
according to section 8.2.

8.2 Connecting and testing

Connect earth connection from the transformer to the earth terminal on the on-load tap-
changer flange.
Connect earth connection from the transformer to the earth terminal on the motor-drive
mechanism.
To check that the shafts have been correctly assembled, the motor-drive mechanism should
be placed in the exact position according to Figs. 13 or 14. Operate the tap-changer with
the hand crank counting the number of turns from the exact position until the tap-changer
operates.
With BUL the tap-changer should operate after 11,5 ± 1 turn 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 of the gears are incorrect mounted.
Hand crank the motor-drive mechanism to a position in the middle of the range.
Connect the motor supply and the control supply to the correct terminals in the motor-drive
mechanism as shown by the circuit diagram supplied with the on-load tap-changer.
Turn the control selector switch to position LOCAL. Give an impulse for RAISE-operation.
If the phase sequence is wrong, (three-phase supply) the motor-drive mechanism starts in
the LOWER-direction. The motor-drive mechanism moves back and forth around its service
position until the control selector-switch is turned to 0.
If the phase sequence is wrong, reverse two of the motor supply cables in order to get the
correct sequence.

WARNING
Dangerous voltage!

1ZSE 5492-118 en, Rev. 4 43

8 Electrical connection and testing

For BUE:
Run the motor-drive mechanism and check again that the red mark on the brake disc stops
within the tolerance limits, see Fig. 13.
If it is out of tolerance, charge the springs more or less by tightening or loosening the two
adjustment nuts on the brake assembly. Tightening makes the brake disc stop earlier, loos-
ening makes it stop later. The nuts should be adjusted equally.

For 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. 14. 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.
Check that the position indicators in both the motor-drive mechanism and the on-load tap-
changer show the same position. Operate one step and check that the on-load tap-changer
follows the motor-drive mechanism.
Operate the driving mechanism electrically between the end positions. Check the end stops.
When trying to operate it electrically beyond the end position, the motor should not get
started. Check the mechanical end stop by trying to hand crank it beyond the end position.
After a couple of turns on the hand crank it should be mechanically stopped. Hand crank
back to the end position. Operate the on-load tap-changer electrically to the other end posi-
tion and repeat the test procedure above.

WARNING
The transformer should in no case be energized with an end stop out of order.

8.3 Electrical tests on transformer

Acceptance tests on the transformer or commissioning can now be performed.

8.4 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. Obtain a signed certificate from the engineer in charge.

44 1ZSE 5492-118 en, Rev. 4

 9 Transport

9. Transport

9.1 General
If the transport dimensions allow, the transformer may be transported without dismantle any
parts of the on-load tap-changer.
If the motor-drive mechanism or any parts of the shaft system has to be dismantled for the
transport, the parts must be marked to ensure they can be set up properly on site and with
a minimum of work.
If any of the accessories on the on-load tap-changer has to be dismantled, the openings on
the on-load tap-changer should be protected with transport covers.

9.2 Transport preparations

Transport of the on-load tap-changer mounted in the transformer should be prepared as
described below.

9.2.1 Transport with complete transformer

In this case the oil conservator is connected to the on-load tap-changer during transporta-
tion. The on-load tap-changer should be filled with oil to normal operating level.

9.2.2 Transport with dismounted conservator

If the conservator is to be dismounted during transport the oil level in the on-load tap-chang-
er has to be lowered.
1. Connect a pump to the oil valve and suck out oil until the oil flow stops. The oil level will
then be 300-400 mm below the top cover.
2. Disconnect the conservator and the pump.
3. Protect the openings with covers.

CAUTION
Take care to avoid ingestion of moist air when oil is drained. If the ambient air is moist, let
incoming air pass through a dehydrating breather with slow air flow to obtain proper dehy-
dration.

9.2.3 Protection of motor-drive

The motor-drive mechanism must be protected against condensation. Energize the heater
when power is available. When not, put drying agent inside the motor drive cabinet and seal
the vents.

1ZSE 5492-118 en, Rev. 4 45

10 Commissioning

10. 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.

10.1 Reassembly
Reassemble the conservator and all other accessories which may have been dismantled for
the transport. Remember the O-rings in the flanges.
The pressure relay is usually delivered in a separate package and installed at commissioning.
Depending on the transport requirements, the transformer may be delivered with the motor-
drive mechanism and drive-shaft system mounted or not mounted. If any shafts have been
dismantled, see section 5.3 for assembly. Note especially section 5.3.2 points 8 and 9 for
syncronizing. The on-load tap-changer may be delivered filled with oil or without oil. Please
use the relevant parts of this manual to carry out commissioning.
For information about tools, materials and oil required, see relevant parts in chapter 1 of this
guide.

10.2 Oil filling

See chapter 7.

10.3 Electrical connection and testing

Do all wiring work and perform the appropriate tests as described in chapter 8.
Remove the drying agent inside the cabinet of the motor-drive mechanism. Check that the
air vents are open.

10.3.1 Motor protection

The function of the protective motor switch should be checked. For three-phase AC motors,
remove one of the phase fuses and check the function time of the protective motor switch
by a RAISE or LOWER operation. The protective motor switch should release within 60 sec-
onds at a current setting equal to the rated current of the motor at the actual voltage.

CAUTION
If the protective motor switch has not released within 60 seconds, disconnect the power
and check the settings with the rating plate of the motor. Adjust if necessary and check
again when the motor has cooled down.

WARNING
The motor power voltage is dangerous.

Protective motor switches for DC motors and for single-phase AC motors are not tested.

46 1ZSE 5492-118 en, Rev. 4

 10 Commissioning

10.3.2 Disc brake

For BUE:
Run the motor-drive mechanism and check again that the red mark on the brake disc stops
within the tolerance limits, see Fig. 13.
If it is out of tolerance, charge the springs more or less by tightening or loosening the two
adjustment nuts on the brake assembly. Tightening makes the brake disc stop earlier, loos-
ening makes it stop later. The nuts should be adjusted equally.

For 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. 14. 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.

10.3.3 Counter
Check that the counter functions upon RAISE and LOWER operations.

10.3.4 Position transmitter and other multi-position switches

Check the function of the position transmitter and other multi-position switches.

10.3.5 Light
Check that the light is switched on when the door is opened and goes out when the door is
closed.

10.3.6 Heater
Switch off all power supplies and feel with a finger on the protection plate that the heater has
been warmed up during earlier tests. Switch on the power afterwards.

10.3.7 Pressure relay

Check the function as per section 6.3.

10.4 Putting into operation

Put the LOCAL/REMOTE switch to REMOTE. Reset the drag hands. Make sure that no
tools or foreign objects are left in the motor-drive cabinet or on the transformer cover. Close
the door to the motor-drive.

1ZSE 5492-118 en, Rev. 4 47

Contact us

ABB AB

© Copyright 2010 ABB, All rights reserved. 1ZSE 5492-118 en, Rev. 4, 2003-03-30
Components
SE-771 80 Ludvika, Sweden
Phone: +46 240 78 20 00
Fax: +46 240 121 57
E-Mail: sales@se.abb.com

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