ABB VUBB User Manual
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ABB VUBB User Manual

ABB VUBB User Manual

Vacuum on-load tap-changers
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1ZSC000562-AAL EN, REV. B, 2020-03-18
Vacuum on-load tap-changers, type VUBB
User guide

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  • Page 1 1ZSC000562-AAL EN, REV. B, 2020-03-18 Vacuum on-load tap-changers, type VUBB User guide...
  • Page 2 The information contained in this document may be subject to change without prior warning and should not be considered as binding on ABB AB’s behalf. ABB AB accepts no liability for any errors that may appear in this document. ABB AB is not liable for any damage resulting from the incorrect interpretation of this document.

  • Page 3: Table Of Contents

    Levels of safety risks ................................... 5 Hazardous working situations ..............................6 Safety precautions..................................6   Introduction Overview of maintenance ................................7 Maintenance by ABB ................................... 7 Replacement at end of life................................8 Maintenance schedule ................................8 Design ......................................9   Preparations Planning ......................................
  • Page 4   Spare parts and special tools 10.1 Summary ..................................... 41   Disposal and environmental information 11.1 Overview ..................................... 43 11.2 Specification of materials ................................43 11.3 Disposal and recycling ................................44   References 12.1 Summary ..................................... 47 User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...

  • Page 5: Safety

    1 Safety 1.1 Levels of safety risks Throughout the manual, various types of safety risks are indicated. The most serious level on this scale provides a warning about serious personal injury or possible death, or major damage to a product, if the instructions are not observed.

  • Page 6: Hazardous Working Situations

    1.2 Hazardous working situations Hazard Action Working close to high voltage. Disconnect all plant power. Ground all objects at the workplace. If work must be done close to live plant components, make sure that the safety distance is in compliance with the applicable safety regulations.

  • Page 7: Introduction

    2 Introduction 2.1 Overview of maintenance General The ABB range of on-load tap-changers are developed for maximum reliability and a minimum of maintenance is required. The tap-changer is made for a service life equal to that of the transformer. The tap-changer oil is separated from the oil in the transformer oil, this prevents contamination of the the oil in the transformer.

  • Page 8: Replacement At End Of Life

    ABB. The estimated contact life of the vacuum interrupters in the selector switch at rated load is stated on the rating plate of the tap-changer. Refer to the table in Maintenance by ABB, page 7. 2.4 Maintenance schedule Maintenance schedule...

  • Page 9: Design

    2.5 Design Overview The VUBB on-load tap-changer is of the 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.   Vertical driveshaft Bevel gear...
  • Page 10 Exterior details of the tap-changer Pressure relay Bevel gear Position indicator window on inspection cover Valve Bottom flange with valve Selector switch Terminals Terminals User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...
  • Page 11 Details of the selector-switch Terminal Fixed contact Main auxillary contact Vacuum interrupter Transition resistor User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...
  • Page 12 User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...

  • Page 13: Preparations

    3 Preparations 3.1 Planning To shorten the down-time when doing maintenance, it is important to plan the work so that waiting time is minimized. Thus, when the tap-changer is oil-filled with the atmospheric process, work should be completed on the tap-changer before work is started on the motor-drive. So that the waiting time requirement is satisfied as soon as possible.
  • Page 14 About transformer oil Used transformer oil can be used again in the tap-changer, if the water content is ≤15 ppm, and it has been stored according to IEC 60422 point 10. A small volume of new transformer oil should be kept available to replace waste oil, and for cleaning. Approximately 40 liter is sufficient.

  • Page 15: Inspection

    4 Inspection 4.1 Inspection of the oil-level in the oil conservator Overview Maintenance interval End of life Yearly After 2,6,11,15 300000 600000 900000 1200000 and then every operations operations operations operations 3 year Maintenance schedule, page 8. Procedure Inspect the oil-level in the oil conservator, refer to the instructions form the supplier of the oil conservator.

  • Page 16: Inspection Of The Motor-Drive Mechanism

    Inspect the drying agent. If the top of the drying agent has changed color, inspect the breather and couplings for leakage. If there is a leakage, locate it and seal it. If more than half of the draying agent has changed color, then replace it. The drying agent can also be dried.
  • Page 17 Procedure Loosen the hose clamps (6), and move back the protective tubes (8). Make sure that the axial play is less than 2 mm. If the axial play is more than 2 mm: Loosen the hex screws (2). Move the coupling halves outwards (9). Tighten the hex screws (2).
  • Page 18 Move the protective tubes (8) apart, and tighten the hose clamps (6). Remove the four bolts (13), and remove the lid (14). Apply Aero Shell grease 22 to the gears. Install the lid (14). Torque 24 Nm End of instruction User guide 1ZSC000562-AAL EN, REV.

  • Page 19: Analysis

    5 Analysis 5.1 Oil filtration or replacement of oil Overview Maintenance interval End of life Yearly After 2,6,11,15 300000 600000 900000 1200000 and then every operations operations operations operations 3 years Maintenance schedule, page 8. Procedure Put the oil through the filtering equipment until the particle content is satisfactory. Refer to IEC 60422:2005.
  • Page 20 Procedure Connect the oil hose (5) to the oil valve (3). Refer to the dimension drawings of the tap-changer for the threads of the oil valve (3). DANGER! Make sure that hoses and equipment is correctly grounded. Unsatisfactorily grounded equipment can cause explosive gases to ignite.
  • Page 21 Close the oil valve (3) and disconnect the hose (5). Make sure that the oil valve (2) to the oil conservator is open. End of instruction User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...
  • Page 22 User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...

  • Page 23: Oil-Filling

    6 Oil-filling 6.1 Preparations Overview The transformer can be oil-filled with one of these two processes: • Atmospheric oil-filling process • Vacuum oil-filling process The tap-changer cylinder can withstand a vacuum on one side and atmospheric pressure on the other side. The oil volume of the tap-changer is approximately 300 liter.

  • Page 24: Oil-Filling With The Atmospheric Process

    Ambient temperature Oil-level in oil conservator If the ambient temperature is 20 °C, fill transformer oil to the center of the scale. If the ambient temperature is above 20 °C, add 10 % of transformer oil on the scale for every 10 °C. If the ambient temperature is below 20 °C, remove 10 % of transformer oil on the scale for every 10 °C.
  • Page 25 Open the oil valve (2) between the tap-changer and the oil conservator. Remove the breathing device (4) from the tap-changer's oil conservator. Connect the oil pump (5) to the oil valve (3). User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...
  • Page 26 Open the oil valve (3). Start the oil pump, and fill the tap-changer to the correct oil-level. Monitor the oil-level indicator on the oil conservator NOTE! Refer to The correct oil-level, page 23. Close the oil valve (3). Disconnect the oil pump. Install the breathing device (4).

  • Page 27: Oil-Filling With The Vacuum Process

    Wait 3 hours before energizing the transformer. CAUTION! Air bubbles form during the oil-filling process. After 3 hours most air bubbles will be dissipated in the oil. End of instruction 6.3 Oil-filling with the vacuum process Procedure Make sure that the oil conservators are approved for vacuum. If a gas/flow relay is connected between the diverter switch and oil conservator, make sure that plug is removed in the relay.
  • Page 28 Connect the oil pump (5) to the oil valve (3). Close the oil valve (3). Connect the vacuum equipment to the transformer. Start the vacuum equipment. NOTE! The vacuum is drawn from the tap-changer because it is connected to the transformer. When the vacuum is sufficient, open the oil valve (3) on the tap-changer.
  • Page 29 Release the vacuum. Disconnect the pipe (1) between the oil conservators. Install the breathing device (4) on the oil conservator on the tap-changer. NOTE! Make sure that there are no leaks. End of instruction User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...
  • Page 30 User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...

  • Page 31: Electrical Connection And Testing

    7 Electrical connection and testing 7.1 Testing of the electrical connections 7.1.1 Testing of motor-drive unit BUE2 Procedure Remove the cover (1). 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.
  • Page 32 Operate the tap-changer with the hand crank, and count the number of turns from the exact position until the tap-changer operates. NOTE! One complete switching operation takes 19 ± 1.5 turns on the hand crank. NOTE! The tap-changer is in the exact position when the operation is completed, and the contacts are centered.
  • Page 33 Turn the control switch S2 to operate the tap-changer. Make sure that the red mark (4) on the brake disc aligns with the red mark on the brake pad. If it does not stop with the red lines (4) aligned, then refer to the maintenance guide Motor-drive mechanisms, types BUE and BUL2 1ZSC000498-ABH.

  • Page 34: Testing Of Motor-Drive Unit Bul2

    7.1.2 Testing of motor-drive unit BUL2 Procedure Remove the cover (1). 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. Operate the tap-changer with the hand crank, and count the number of turns from the exact position until the tap-changer operates.
  • Page 35 Operate the motor-drive mechanism to the position (7) in the middle of the range. Turn the control selector switch S1 to position local. Turn the control switch S2 to operate the tap-changer 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.

  • Page 36: Testing Of The Protection Devices

    Make sure that the center of the notch (4) in the cam disc stops within ±2 mm of the center of the roller. If it does not stop at the center of the notch (4), then refer to the maintenance guide Motor-drive mechanisms, types BUE and BUL2 1ZSC000498-ABH.

  • Page 37: Troubleshooting

    Damaged O-ring at the top cover of the tap-changer. • Leakage between the bevel gear flange and the transformer cover. Refer to the Installation and commissioning guide, Vacuum on-load tap-changers, type VUBB 1ZSC000562-AAK. User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...
  • Page 38 Replacement of pressure relay If the pressure relay fails to pass the insulation test and/or the function test, it must be replaced. This is described in the assortment guide. CAUTION! It is not permitted to only replace the microswitch inside the pressure relay. User guide 1ZSC000562-AAL EN, REV.

  • Page 39: Electrical Diagrams

    Be sure to use the circuit diagram and the contact timing diagram delivered with your tap-changer. For more information regarding electrical circuit principles and contact sequences see technical guide for on-load tap-changers type VUBB, 1ZSC000562-AAJ. 9.2 Standard circuit diagram BUE User guide 1ZSC000562-AAL EN, REV.

  • Page 40: Standard Circuit Diagram Bul2

    9.3 Standard circuit diagram BUL2 User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...

  • Page 41: Spare Parts And Special Tools

    10 Spare parts and special tools 10.1 Summary Please contact ABB Components for spare parts and special tools. User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...
  • Page 42 User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...

  • Page 43: Disposal And Environmental Information

    11 Disposal and environmental information 11.1 Overview This chapter specifies the materials used in the Comply with local environmental regulations on disposal of this product, the materials used are specified for this purpose. 11.2 Specification of materials Overview This chapter specifies the materials that are used in the tap-changer. Refer to Disposal and recycling, page for general instructions about disposal.

  • Page 44: Disposal And Recycling

    10.1 11.3 Disposal and recycling ABB strives to minimize the product's impact on the environment throughout its entire life cycle. Technical and product development focuses on environmental aspects. The ecocycle approach is striven for, and consideration is taken to the materials' environmental impact and recycling alternatives. The manufacturing processes are selected to be as safe for the environment as possible.
  • Page 45 Many metal components of iron, steel and aluminum are large and easy to identify, e.g. support structures. ABB strives to reduce the use of precious metals and the release of environmentally hazardous metals.
  • Page 46 User guide 1ZSC000562-AAL EN, REV. B, 2020-03-18...

  • Page 47: References

    12 References 12.1 Summary • Technical guide Vacuum on-load tap-changers, type VUBB, 1ZSC000562-AAJ. • Technical 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.
  • Page 48 ABB AB, Components SE-771 80 Ludvika, Sweden www.abb.com/transformercomponents © Copyright 2020 ABB, All rights reserved. Specifications subject to change without notice.

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