ABB VUBB, Installation And Commissioning Manual

Page 1: ...1ZSC000562 AAK EN REV 2 2019 07 03 Vacuum on load tap changers type VUBB Installation and commissioning guide ...

Page 2: ...or any errors that may appear in this document ABB AB is not liable for any damage resulting from the incorrect interpretation of this document This document or parts thereof may not be reproduced or copied without ABB AB s consent It may not be distributed to others or used by unauthorized parties Any breaches to the above will be penalized with the support of applicable laws ...

Page 3: ...the cover 16 4 3 2 Installation on the yoke 19 4 4 Connection of conductors to the terminals 21 4 5 Installation of the top flange yoke mounting 22 4 6 Transformer ratio measurement 25 5 Drying 29 5 1 Preparations 29 5 2 Drying processes 30 5 2 1 Overview 30 5 2 2 Drying with the alternating hot air and vacuum process 30 5 2 3 Drying with the vapor phase process 30 5 3 After drying 31 6 Final asse...

Page 4: ...ng of BUE2 62 8 2 2 Testing of BUL2 65 8 3 Testing of the protection devices 67 9 Preparations for transportation to site 69 9 1 General 69 9 2 Transportation with transformer oil in the transformer 69 9 3 Transportation without transformer oil in the transformer 71 10 Commissioning at site 73 10 1 Installation of the removed parts 73 10 2 Connection of the electrical connections 73 11 Spare parts...

Page 5: ...oduct It is used for example to warn of such dangers as contact with high voltage explosion or fire risk risk for toxic gases risk of crushing impacts falls from high places etc CAUTION The round warning symbol warns that an accident could occur if the instructions are not observed and that this could result in personal injury and or damage to the product It is also used to warn of risks that enta...

Page 6: ... safety regulations Do not use ladders or platforms in poor weather conditions Working with heavy objects Do not walk under lifted objects Make sure that heavy objects are stable before starting work 1 3 Safety precautions Precaution Action Transformer oil Collect used transformer oil in drums Transformer oil is dangerous Fumes from hot oil can cause irritation to the respiratory organs and the ey...

Page 7: ...he VUBB on load tap changer features an in tank design The motor drive mechanism is attached to the side of the transformer tank and connected to the tap changer by drive shafts and a bevel gear G004252 1 Vertical driveshaft 2 Bevel gear 3 Horizontal driveshaft 4 Tap changer 5 Transformer tank 6 Motor drive mechanism ...

Page 8: ...ice a pressure relay as standard and or an oil flow relay One of these protection devices are mandatory Two protection devices are available for redundancy The tap changer configuration is specified on the packing list Protection device Standard Option Note Pressure relay Yes Mandatory Oil flow relay Yes For redundancy or as alternative to pressure relay Temperature switch Yes For redundancy Press...

Page 9: ...2 Transportation The tap changer must be transported in the transport box Carefully inspect the tap changer for damage after transportation 3 3 Storage Short and long term storage Store the tap changer and motor drive mechanism indoors in a controlled temperature with low humidity Keep the units in their moisture proof wrapping Do not remove the drying agent before installation Replace the drying ...

Page 10: ... lifting points Type Weights Transport box Tap changer Total weight VUBB 30 kg 280 kg 310 kg Procedure 1 Make sure that the crane is approved for lifting the total weight of the transport box and tap changer Refer to the packing list 2 Attach soft lifting slings 2 to the correct locations 3 Carefully lift the transport box 4 Put down the transport box on a flat surface End of instruction ...

Page 11: ... list 2 Remove the cover 1 and the sides 2 of the transport box G004258 3 Remove all accessories from the transport box and then remove the straps 7 G004525 4 Put the soft lifting sling 4 around the cylinder and then attach the soft lifting sling to the lifting eye 3 CAUTION Make sure that the crane hook is exactly above the center of gravity 4 The contacts can break if the tap changer moves in th...

Page 12: ...mmissioning guide 1ZSC000562 AAK EN REV 2 2019 07 03 6 Lower the bottom of the tap changer down onto a soft bedding 5 G004477 7 Remove one soft lifting sling 4 G004478 8 Lift the tap changer to the vertical position G004479 ...

Page 13: ... 1ZSC000562 AAK EN REV 2 2019 07 03 13 9 Put supports under the tap changer or attach a safety cable from the ceiling to a lifting eye 3 DANGER If the tap changer tips it could cause death or injury to personnel G004480 End of instruction ...

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Page 15: ...arately Torque wrench 5 85 Nm tolerance 10 Buzzer For testing the pressure relay 500 V DC power unit insulation tester For testing the pressure relay Bottom valve key LL 117 016 A Supplied with the tap changer Tool for opening oil drum Hacksaw Bucket 10 liters Soft lifting slings Rated for a weight higher than the combined weight of the tap changer and transport box Lifting chains Rated for a weig...

Page 16: ...Lubricates and protects metals against corrosion Protects rubber Does not react with transformer oil Aero Shell Grease 22 Shell Rags for cleaning Lint free 4 3 Installation in the transformer 4 3 1 Installation in the cover Overview The tap changer is made for both cover mounting and yoke mounting This procedure describes cover mounting Procedure 1 Make sure that the stud bolts 1 in the transforme...

Page 17: ... 3 Attach lifting chains 4 to the lifting eyes and lift the tap changer CAUTION Make sure that the angle between the lifting chains 4 is less than 90 A greater angle can cause deformation of the lifting eyes G004254 4 Carefully lower the tap changer into the transformer CAUTION Do not cause damage to the terminals 5 The terminals 5 can easily bend or break if they catch on the transformer cover G0...

Page 18: ...ion of drive shaft and pipes possible Please refer to the transformer manufacturer s documentation NOTE The bevel gear 1 must be within the limits 9 G004260 6 Remove the lifting chains from the lifting eyes G004264 7 Install the washers and nuts on the stud bolts 1 and tighten the nuts G004265 Torque M12 49 Nm End of instruction ...

Page 19: ...ibes yoke mounting Procedure 1 Remove the bolts 1 and then remove the top cover 2 CAUTION Carefully lift the top cover straight up The shaft for the bevel gear can bend if the top cover is not lifted straight up G004481 2 Remove the bolts 3 and then remove the top flange 4 NOTE Keep the gasket and the parts they will be used again G004270 3 Attach the lifting chains to the four lifting eyes 5 G004...

Page 20: ...ered with the tap changer G006833 5 Make sure that the holes 6 in the yoke fits the guide pins NOTE The guide pins are Ø 7 mm G004266 6 Put the tap changer on the yoke G004267 7 Turn the tap changer as necessary to make installation of drive shaft and pipes possible Please refer to the transformer manufacturer s documentation End of instruction ...

Page 21: ... tension at installation they will cause the terminals on the tap changer to break when the transformer is in operation G004273 2 Make sure that there is a distance of more than 50 mm between the conductors 2 and the cylinder 1 G006840 3 Install the conductors with the shielding caps 1 Install the bolt washers and nut Put the large washer 4 under the small washer 3 2 Close the lid on the shielding...

Page 22: ...been installed in the transformer tank Procedure 1 Lower the active part into the transformer tank G006837 2 Put the transformer tank cover on the transformer tank 3 Install the O ring 10 NOTE This O ring was removed from the tap changer in Installation on the yoke page 19 G004309 4 Install the gasket in the groove 3 in the transformer cover NOTE The gasket is not included in the tap changer deliv...

Page 23: ...sioning guide 1ZSC000562 AAK EN REV 2 2019 07 03 23 5 Put the top flange 5 in position G004483 6 Attach the lifting chains to the four lifting eyes 6 G004482 7 Lift the tap changer 10 until it touches the top flange 5 G004268 ...

Page 24: ... Nm 9 Install the nuts 8 and plain washers G004265 Torque 84 Nm 10 10 Install the top cover 2 and then install the bolts 1 CAUTION Hold the top cover 10 cm above the tap changer and carefully lower it straight down The shaft for the bevel gear can bend if the top cover is not lowered straight down NOTE There is a guide pin 3 in the top flange that fits in a hole in the top cover G004269 Torque 47 ...

Page 25: ...sioning guide 1ZSC000562 AAK EN REV 2 2019 07 03 25 4 6 Transformer ratio measurement Procedure 1 Remove the cover 1 G004276 2 Record the position 2 of the tap changer G004277 3 Attach the hand crank to the bevel gear G004278 ...

Page 26: ...crank in the RAISE direction and do a check of the end position 2 Turn the hand crank in the LOWER direction and do a check of the end position CAUTION It is important that the end positions are correct If they are not catastrophic failure of the transformer can occur 6 Measure the voltage between two taps for all switching operations 1 Connect the voltmeter to the two taps to measure 2 Turn the h...

Page 27: ...Installation and commissioning guide 1ZSC000562 AAK EN REV 2 2019 07 03 27 8 Install the cover 1 G004276 End of instruction ...

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Page 29: ... straight up The shaft for the bevel gear can bend if the top cover is not lifted straight up CAUTION Do not drop bolts or other small parts into the tap changer Objects that fall into the tap changer can prevent the free movement of the mechanism or cause electrical short circuits G004481 2 Remove the O ring 3 G004284 3 Put the parts in storage in a dry and dust free area End of instruction ...

Page 30: ... 2 2 Drying with the alternating hot air and vacuum process Overview Make sure that both the pressure and temperature are less than the maximum permitted values during the drying process Maximum permitted Value Note Pressure difference 100 kPa Between the transformer tank and the tap changer Temperature 135 C Procedure 1 Do the drying process End of instruction 5 2 3 Drying with the vapor phase pr...

Page 31: ... Do not turn the bottom valve more than four turns NOTE The tap changer is tested in oil and small amounts of oil can flow out from the bottom valve G004305 2 Do the drying process End of instruction 5 3 After drying Procedure 1 Make sure that all liquid is drained from the tap changer 2 Make sure that the bottom valve on the tap changer is closed Top access tighten the bottom valve 1 with the bot...

Page 32: ...N Carefully lower the top cover straight down The shaft for the bevel gear can bend if the top cover is not lowered straight down CAUTION Do not drop bolts or other small parts into the tap changer Objects that fall into the tap changer can prevent the free movement of the mechanism or cause electrical short circuits G004269 Torque 25 5 Nm End of instruction ...

Page 33: ...sformer manufacturer Procedure 1 Install the consoles on the transformer tank refer to documentation from the transformer manufacturer 2 Install the motor drive on the consoles End of instruction 6 2 Installation of the external drive shafts Procedure for the horizontal drive shaft 1 Make sure that there is a horizontal difference of less than 4 between the spherical shaft ends NOTE 4 is equal to ...

Page 34: ...length K1 6 mm 4 Remove burrs and loose material from the drive shaft 5 Calculate the correct length LB1 for the protection tubes refer to the table Example if the length of K1 is 390 mm then LB1 is 390 210 2 600 2 300 mm For K1 mm Calculate LB1 mm 190 to 290 K1 160 2 291 to 600 K1 210 2 Greater than 600 K1 410 2 6 Cut the two protection tubes at the end 1 that is not slotted CAUTION Remove the tu...

Page 35: ...ed ends 5 outwards G004383 8 Put the hose clamps 6 on the protection tubes NOTE Do not tighten the hose clamps 6 9 Apply grease to the spherical shaft ends 7 and the unpainted surfaces on the bevel gears G004384 10 Install two coupling halves 3 on one side of the drive shaft Tighten the hex screws 2 with your fingers G004377 ...

Page 36: ...drive shaft 2 Install the coupling halves 3 to one bevel gear 3 Tighten the two outer hex screws 2 G004385 Torque 10 Nm 12 Tighten the four hex screws 2 G004381 Torque 10 Nm 13 Install two coupling halves 4 on the drive shaft turned 90 perpendicular to the first pair of coupling halves 3 Tighten the hex screws 2 with your fingers G004386 ...

Page 37: ...o outer hex screws 2 G004380 Torque 10 Nm 15 Tighten the four hex screws 2 G004382 Torque 10 Nm 16 Make sure that the axial play is less than 2 mm If the axial play is more than 2 mm 1 Loosen the hex screws 2 2 Move the coupling halves outwards 9 3 Tighten the hex screws 2 G004387 Torque 10 Nm ...

Page 38: ...er out of the protection tubes G004388 18 Put the adhesive caution plate around the protection tube CAUTION Do not step on the horizontal drive shaft It can bend G004389 End of instruction Procedure for the vertical drive shaft 1 Make sure that there is a vertical difference of less than 4 between the spherical shaft ends NOTE 4 is equal to 70 mm of rise or fall for every 1000 mm of drive shaft le...

Page 39: ...length K2 6 mm 4 Remove burrs and loose material from the drive shaft 5 Calculate the correct length LB2 for the protection tubes refer to the table Example if the length of K2 is 390 mm then LB2 is 390 210 2 600 2 300 mm For K2 mm Calculate LB2 mm 200 to 290 K2 180 2 291 to 600 K2 220 2 Greater than 600 K2 410 2 6 Cut the two protection tubes at the end 1 that is not slotted CAUTION Remove the tu...

Page 40: ...outward G004383 8 Put the hose clamps 6 on the protection tubes NOTE Do not tighten the hose clamps 6 9 Remove the two bolts in the multi hole coupling flange G004410 11 Multi hole coupling flange BUL2 12 Multi hole coupling flange BUE2 10 Apply grease to the spherical shaft ends 7 and the unpainted surfaces on the bevel gears G004393 ...

Page 41: ...04377 12 Install the drive shaft 1 Put the protection tube 8 on the drive shaft 2 Install the coupling halves 3 to one bevel gear 3 Tighten the two outer hex screws 2 CAUTION Put the protection tube with the larger diameter above the smaller protection tube This will keep rainwater out of the protection tubes G004394 Torque 10 Nm 13 Tighten the four hex screws 2 G004381 Torque 10 Nm ...

Page 42: ...4 Install two coupling halves 4 on the drive shaft turned 90 perpendicular to the first pair of coupling halves 3 Tighten the hex screws 2 with your fingers G004395 15 Tighten the two outer hex screws 2 G004380 Torque 10 Nm 16 Tighten the four hex screws 2 G004382 Torque 10 Nm ...

Page 43: ...ex screws 2 2 Move the coupling halves outwards 9 3 Tighten the hex screws 2 G004396 Torque 10 Nm 18 Move the protection tubes 8 apart and tighten the hose clamps 6 CAUTION Make sure that there is 3 to 5 mm of clearance between the lower protection tube and the horizontal surface of the motor drive This clearance is important for draining rainwater G004397 End of instruction ...

Page 44: ...3 1 Synchronization of BUL2 Procedure 1 Open the door 1 G004434 2 Open the inner panel 2 G006506 3 Inspect the brake assembly and make sure that the motor drive mechanism is in the correct position NOTE The brake assembly is at position 3 NOTE The correct position is when the roller is centered in the notch 4 G004433 ...

Page 45: ...the correct position 4 at the center of the notch NOTE One complete switching operation takes 11 5 1 turns on the hand crank 6 G004436 5 Make sure that the position indicators 7 and 8 show the same position CAUTION If the position indicators show different positions catastrophic failure of the transformer can occur G004437 6 Install the two bolts in the multi hole coupling flange 11 G004442 End of...

Page 46: ...mechanism is in the correct position NOTE The brake assembly is at position 3 NOTE The correct position is when the brake is centered on the red line 4 G004439 4 If the roller is not in the correct position 1 Put the hand crank 6 on the shaft end 5 2 Turn the hand crank 6 until the roller is in the correct position 4 centered on the red line NOTE One complete switching operation takes 19 1 5 turns...

Page 47: ... position CAUTION If the position indicators show different positions failure of the transformer can occur G004440 6 Install the two bolts in the multi hole coupling flange 11 G004443 End of instruction 6 4 Installation of the oil conservator Procedure 1 Remove the transport cover 1 from flange C NOTE Keep the nuts and the O ring G004446 ...

Page 48: ...e that the flange of the oil valve fits the tap changer NOTE Dimensions of the O ring 3 G004445 3 Install the oil valve 5 with the O ring 3 G004526 4 Install the pipe 2 on the oil valve 5 CAUTION Make sure that the O ring 3 is not damaged and is correctly installed G004447 Torque 49 Nm ...

Page 49: ...he angle of the pipe 2 is less than 3 air bubbles will not rise to the oil conservator G004448 End of instruction 6 5 Installation of the oil tap Overview An oil tap must be installed för sampling of transformer oil in the tap changer ABB does not supply the oil tap Procedure 1 Remove the transport cover 1 NOTE Keep the nuts and the O ring G004446 ...

Page 50: ...sions of the O ring 3 G004445 3 Install the pipe 2 to the oil tap with the O ring 3 CAUTION Make sure that the O ring 3 is not damaged and is correctly installed G004451 NOTE 24 Nm 4 Install the oil tap 4 at a convenient hight above the ground NOTE The oil tap 4 should be easily accessible for the regular taking of oil samples G004450 End of instruction ...

Page 51: ...019 07 03 51 6 6 Installation of protection devices Overview For the installtion of protection devices please refer to Accessories and protection devices for on load tap changers 1ZSC000562 AAD Refer to the packing list for the configuration of protection devices ...

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Page 53: ...ormer oil quality The oil volume of the tap changer is approximately 300 liter Requirement Standard The oil quality must be LC set 30 IEC 60296 2012 The oil must fully comply with this standard IEC 60422 2005 The correct oil level It is important that the oil levels of both oil conservators are the same CAUTION The oil level of the tap changer oil conservator must not be higher than the oil level ...

Page 54: ...temperature is under 20 C remove 10 of transformer oil on the scale for every 10 C 7 2 Oil filling with the atmospheric process Procedure 1 These three steps increases the speed of the oil filling process but are not required 1 Remove the inspection cover 1 2 Put the oil filling hose through the inspection hole 2 CAUTION Do not put a metal pipe into the tap changer use a soft hose A metal pipe can...

Page 55: ...SC000562 AAK EN REV 2 2019 07 03 55 2 Open the valve 2 between the tap changer and the oil conservator G004461 3 Remove the breathing device 4 from the tap changer s oil conservator G004463 4 Connect the oil pump 5 to the oil valve 3 G004527 ...

Page 56: ...or NOTE Refer to The correct oil level page 53 7 Close the oil valve 3 8 Disconnect the oil pump 9 Install the breathing device 4 G004463 10 Make sure that there are no leaks Use sealing tape on the threads Replace leaking O rings 11 Wait 3 hours before energizing the transformer CAUTION Air bubbles form during the oil filling process After 3 hours most air bubbles will have released from the tran...

Page 57: ...filling with the vacuum process Procedure 1 Make sure that the oil conservators are approved for vacuum 2 Connect both oil conservators with a pipe 1 G004459 3 Open the valve 2 between the tap changer and the oil conservator G004461 4 Connect the oil pump 5 to the oil valve 3 G004527 ...

Page 58: ... 7 Start the vacuum equipment NOTE The vacuum is drawn from the tap changer because it is connected to the transformer 8 When the vacuum is sufficient open the oil valve 3 on the tap changer G004462 9 Monitor the oil level and close the oil valve 3 on the tap changer at the correct oil level NOTE Refer to The correct oil level page 53 10 Release the vacuum ...

Page 59: ... 1ZSC000562 AAK EN REV 2 2019 07 03 59 11 Disconnect the pipe 1 between the oil conservators G004459 12 Install the breathing device 4 on the oil conservator on the tap changer Make sure that there are no leaks G004463 End of instruction ...

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Page 61: ...nding stud on the tap changer and a grounding point in the transformer G004464 2 Put a flexible cable 1 between the grounding stud on the motor drive and a grounding point in the transformer G004466 3 Connect the motor supply Refer to the circuit diagram that is supplied with the motor drive 4 Connect the control supply Refer to the circuit diagram that is supplied with the motor drive End of inst...

Page 62: ... show different positions catastrophic failure of the transformer can occur G004440 3 Operate the tap changer with the hand crank and count the number of turns from the exact position until the tap changer operates A full operation of the tap changer takes 19 1 5 turns of the hand crank NOTE The tap changer is in the exact position when the operation is completed and the contacts are centered NOTE...

Page 63: ...hanger in the raise direction NOTE If the phase sequence is incorrect from the three phase electrical supply then the motor drive mechanism will move in the lower direction The motor drive mechanism will oscillate around its service position until the control selector switch is turned to 0 7 If the phase sequence is incorrect reverse two of the motor supply cables to get the correct sequence DANGE...

Page 64: ... other end stop It should not be possible to electrically operate the tap changer against the mechanical end stop 11 Do a check of the mechanical end stops 1 Operate the tap changer manually to one end stop The tap changer should stop at the mechanical end stop 2 Operate the tap changer manually to the other end stop The tap changer should stop at the mechanical end stop NOTE After a couple of tur...

Page 65: ...ions catastrophic failure of the transformer can occur G004437 3 Operate the tap changer with the hand crank and count the number of turns from the exact position until the tap changer operates A full operation of the tap changer takes 11 5 1 turns of the hand crank NOTE The tap changer is in the exact position when the operation is completed and the contacts are centered NOTE If the tap changer d...

Page 66: ...hanger in the raise direction NOTE If the phase sequence is incorrect from the three phase electrical supply then the motor drive mechanism will move in the lower direction The motor drive mechanism will oscillate around its service position until the control selector switch is turned to 0 7 If the phase sequence is incorrect reverse two of the motor supply cables to get the correct sequence DANGE...

Page 67: ...a check of the mechanical end stops 1 Operate the tap changer manually to one end stop The tap changer should stop at the mechanical end stop 2 Operate the tap changer manually to the other end stop The tap changer should stop at the mechanical end stop NOTE After a couple of turns on the hand crank the tap changer should reach the mechanical end stop 12 Make sure that all tests have been complete...

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Page 69: ...ap changer NOTE It is important that all parts are correctly installed and in the same position as when they were removed 3 If parts are removed install transport covers over all openings 4 Keep the motor drive mechanism dry to prevent corrosion Put drying agent in the cabinet Seal the vents If electrical power is available connect the heater End of instruction 9 2 Transportation with transformer ...

Page 70: ...ounded equipment can cause explosive gases to ignite Explosive gases are generated during normal operation of the transformer G004471 2 Put a hose into the center hole 2 of the cover and connect it to an oil pump CAUTION Do not put a metal pipe into the tap changer use a soft hose A metal pipe can cause damage to the tap changer G004472 3 Remove oil with the pump until the oil level is 150 mm unde...

Page 71: ...transformer oil in the transformer Overview The tap changer must be drained from transformer oil if the transformer is drained Procedure 1 Drain the transformer oil from the tap changer CAUTION Do not transport the tap changer filled with transformer oil if the transformer oil has been drained from the transformer This will help to prevent damage to the tap changer End of instruction ...

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Page 73: ...t is important that all parts are correctly installed and in the same position as when they were removed 3 Remove the drying agent from the motor drive cabinet 4 If the transformer oil was removed for transportation then fill the tap changer and transformer with transformer oil Refer to Preparations page 53 End of instruction 10 2 Connection of the electrical connections Procedure 1 Connect the mo...

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Page 75: ...Installation and commissioning guide 1ZSC000562 AAK EN REV 2 2019 07 03 75 11 Spare parts 11 1 Summary Please contact ABB Components for spare parts and special tools ...

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Page 77: ...t should be sent to an approved recycling plant or sorted into different component materials for correct processing Metals Metals should be sorted according to type and surface coating and sent to an approved recycling plant After the removal of paint or other surface coatings clean metal can usually be melted down and used in new products Many metal components of iron steel and aluminum are large...

Page 78: ... oil waste can be separated into oil water and a range of contaminants In many cases the oil can then be reused As an alternative the energy content in oil can be recovered through combustion at a plant designed for the purpose Rubber Send rubber to an approved environmental waste treatment plant either for disposal or reuse for different purposes Rubber is used in seals and gaskets Other material...

Page 79: ...cal guide Motor drive mechanism type BUE 2 1ZSE 5483 104 Technical guide Motor drive mechanism type BUL 1ZSC000562 ABD Maintenance guide Motor drive mechanisms types BUE and BUL2 1ZSC000498 ABH Assortment guide Accessories and protection devices for on load tap changers 1ZSC000562 AAD Markings conforming to IEC 60214 1 Oil quality according to IEC 60296 2012 and IEC 60422 2005 ...

Page 80: ...ABB AB Components SE 771 80 Ludvika Sweden www abb com transformercomponents Copyright 2019 ABB All rights reserved Specifications subject to change without notice 1ZSC000562 AAK EN REV 2 2019 07 03 ...