Trafo 40 Mva.pdf

INSTRUCTION MANUAL

TRANSFORMER Type: TNER3E 40000/115PN

Serial no. Rated Power Rated Voltage Connection (vector group) Year of Manufacture

1133751 40/40/40 MVA 115 ± 9 x 1.778 % / 11 / 6.6 kV YNd11d11 2007

Internal order no. K.570.1.A002-11152 ABB Sp. z o.o. Branch Office in Łódź ul. Aleksandrowska 67 / 93 91-205 Łódź Poland

tel. + 48 42 29 93 000 fax + 48. 42 29 93 002 http://www.abb.com/powertransformers

Serial no. 1133751

LIST OF CONTENTS 1

Main Technical Data of Transformer

2

Drawings 2.1 Rating Plate

881.537.1A

2.2 Diagram Plate

883.632.1A

2.3 Dimension drawing

51.14.3-03-3601

2.4 Transport drawing

51.14.3-15-0841

2.5 Electrical diagram of cooling control and protection box

8.710.03-06-0700

2.6 Pictures 3

Shipping, off-loading, assembling, testing and commissioning of transformer. 3.1 -Shipping of Transformers- General Overview

1ZBA4601-200

3.2 -Off-loading and moving transformer

1ZBA4601-202

3.3 -Monitoring of dry gas filled transformer

1ZBA4601-203

3.4 - Receiving Inspection. Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled

1ZBA4601-206

3.5 -Storage on site before assembly

1ZBA4601-211

3.6 -Transformer assembly instruction

1ZBA4601-212

3.7 -Receiving and handling transformer oil on site. Quality control

1ZBA4601-213

3.8 - Final oil Filling on Site. Atmospheric Pressure

1ZBA4601-214

3.9 -Acceptance testing and energization

1ZBA4601-216

3.10 -Field test record

1ZBA4601-217

3.11 -Oil conservators with air cell

1ZBA4601-219

3.12 -Supervision on transformers and reactors

1ZBA4601-222

1/4

Serial no. 1133751 4

Accessories of transformer. List of manufacturers/suppliers

5

On-load tap changer UCGRN 650/300/C with motor drive BUL 5.1 On-load tap-changers, type UC. Technical guide

1ZSE 5492-105 en, Rev. 5

5.2 Motor-drive mechanism, type BUL. Technical guide

1ZSE 5483-105 en, Rev. 3

5.3 On-load tap-changers, types UCG and UCL with motor-drive mechanism, types BUE and BUL. Installation and commissioning guide

1ZSE5492-116 en, Rev. 8

5.4 On-load tap-changer, type UCG with motor-drive mechanisms, types BUE and BUL. Maintenance guide

1ZSE 5492-124 en, Rev. 5

5.5 On-load tap-changers, types UCG, UCL, UCC and UCD with motor-drive mechanisms, types BUE and BUL. Repair Guide

1ZSE 5492-129 en, Rev. 6

5.6 On-load tap-changers, types UCG, UCL, UCC and UCD with motor-drive mechanisms, types BUE and BUL. Spare Parts List

1ZSE 5492-133 en, Rev. 3

5.7 Tap-Changer UCGR UCGRN

54920104-8

5.8 Top Section, Accessories Tap-Changer UCG

54920103-2

5.9 External Shaft System

54920083-4

5.10 Connection Diagram

5492 0095-118

5.11 Circuit Diagram Relief Vent

5478 003-59

5.12 Circuit Diagram Motor-Drive Mechanism Type BUL

5483 538-66 5475 908-11 5475 913-26 5483 540-1 5483 540-30

2/4

Serial no. 1133751 6

Bushings 6.1 HV bushing type GOB 550-800

LF 123 191 K, L6=500

6.2 HV neutral bushing type GOB 550-800

LF 123 189 K, L6=100

6.3 Transformer bushings, type GOB. Installation and maintenance guide

2750 515-12 en, Rev. 9

6.4 MV bushing type 20f/3150 FIG B1, C1=440 6.5 MV bushing type 10f/4500 FIG C1, b1=380 6.6 SOLID BUSHING TYPE DIN 42533 – 42534 & EN 50180.PRODUCT INFORMATION & OPERATING INSTRUCTIONS 7

Cooling system 7.1 Cooler LK-S-190-50-1a-2x910-R13-100-h. Operating and maintenance manual 7.2 Pump

DB-TR-005 - GB

7.3 Liquid flow indicator 8

Transformer Protection 8.1 Buchholz Relay BF80/10. Operating instruction

01/02/04/02

8.2 Safety valve VS 150 9

OLTC protection 9.1 Monitoring relay for tap changers. Technical description

Catalogue 01 / 05

9.2 Pressure relay for on-load tap-changers. Technical information

1ZSE 5492-151 en, Rev. 5

10

Conservator air cell (separator) installation

11

Electronic Transformer Monitor for Liquid filled Transformers 509-100 11.1 Operations Manual

IST-072-1

11.2 Software Manual

IST-073-1

11.3 Resistance Bulb Platinum

103-023-01

3/4

Serial no. 1133751 12

Oil Temperature Indicator for Power Transformer type : MSRT 150

13

Winding Temperature Indicator for Power Transformers type : MSRT 150-W

14

Oil level indicators

15

16

14.1 Oil level indicator. Product information

1ZBA 569 002-4

14.2 Oil level indicator fore OLTC (LA22)

1ZBA 569001-C

14.3 Oil level indicator for main tank (LB22)

1ZBA 569 001-X

Air breathers 15.1 KC-Trockenperlen Orange

1ZBA676002-1

15.2 Model EM5DA

1ZBA 676001-C

15.3 Model EM2DA

1ZBA 676001-A

Valves 16.1 Throttle valves WKKI-1 16.2 Ball valves WK 2a

17

Transformer oil 17.1 Naphthenics Product Data Sheet. Nynas Transformer Oil - Nytro 10XN 17.2 Naphthenics Safety Data Sheet

18

Test Report

2007/0141/025

19

Certificates of transformer accessories

4/4

Serial no. 1133751

Main Technical Data of Transformer 1

Type

2

Serial no.

3

Manufacturer

4

Rated Power

TNER3E 40000/115 PN

4.1 4.2 4.3

HV MV LV

5.1 5.2 5.3

Insulation level HV MV LV

5

1133751 ABB Sp. z o.o. ul. Żegańska 1, 04-713 Warszawa Branch Office in Lodz ul. Aleksandrowska 67/93 91-205 Lodz, Poland 40 MVA MVA MVA

40 40 40

LI450 AC185 -I325 AC185 LI95 AC38 LI75 AC28

6

Phase number

7

Frequency

Hz

50

Rated voltage HV MV LV

kV kV kV

110 ± 9 x 1.778 % 11 6.6

8 8.1 8.2 8.3

3

9

Voltage regulation

On-load

10

Connection (vector group)

YNd11d11

11 11.1 11.2 11.3

Impedance voltage at nominal tap (guaranteed/measured) HV-MV @ 40 MVA % 11.0 / 10.69 HV-LV @ 40 MVA % 16.5 / 16.36 MV-LV @ 40 MVA % 30.0 / 30.05

1/2

Serial no. 1133751 12 12.1 12.2 12.3

Load losses at nominal tap and at rated power (guaranteed/measured) HV-MV @ 40 MVA kW 185.0 / 177.42 HV-LV @ 40 MVA kW 205.0 / 216.37 MV-LV @ 40 MVA kW 220.0 / 243.16

13

No-load losses (guaranteed/measured)

14

Standard

15 15.1 15.2

Ambient temperature maximum minimum

16

Cooling system

17

Noise level. Sound pressure at no-load and with operating cooling system (guaranteed/measured)

18

Total mass

kg

74,000

19

Mass of transformer oil

kg

18,500

20

Corrossion protection / Color

21

Grade of transformer oil used for first transformer filling / Manufacturer

KW

25.0 / 22.45

IEC 60076

°C °C

+ 40 - 35

OFAF

dB(A)

75.00 / 71.5

C3 / RAL 7032

2/2

Nytro 10XN Nynas Naphthenics AB

Serial no. 1133751

2

Drawings

2.1 Rating Plate

881.537.1A

2.2 Diagram Plate

883.632.1A

2.3 Dimension drawing

51.14.3-03-3601

2.4 Transport drawing

51.14.3-15-0841

2.5 Electrical diagram of cooling control and protection box

8.710.03-06-0700

2.6 Pictures

1/1

1133751

PICTURES

HV-side

LV-side

1/3

1133751

HV Leads

LV leads

2/3

1133751

Connection to OLTC

3/3

Serial no. 1133751

3

Shipping, off-loading, assembling, testing and commissioning of transformer.

3.1 -Shipping of Transformers- General Overview

1ZBA4601-200

3.2 -Off-loading and moving transformer

1ZBA4601-202

3.3 -Monitoring of dry gas filled transformer

1ZBA4601-203

3.4 - Receiving Inspection. Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled

1ZBA4601-206

3.5 -Storage on site before assembly

1ZBA4601-211

3.6 -Transformer assembly instruction

1ZBA4601-212

3.7 -Receiving and handling transformer oil on site. Quality control

1ZBA4601-213

3.8 - Final oil Filling on Site. Atmospheric Pressure

1ZBA4601-214

3.9 -Acceptance testing and energization

1ZBA4601-216

3.10 -Field test record

1ZBA4601-217

3.11 -Oil conservators with air cell

1ZBA4601-219

3.12 -Supervision on transformers and reactors

1ZBA4601-222

1/1

PowerIT Transformers and Reactors SHIPPING OF TRANSFORMERS - GENERAL OVERVIEW Table of contents Scope ............................................................................................................................................ 2 Shipping Information ....................................................................................................................... 2 2.1 Shipping Sketch........................................................................................................................ 2 2.2 Shipping Braces and Covers ....................................................................................................... 2 3 Transportation ................................................................................................................................ 2 3.1 Impact Recorder ....................................................................................................................... 2 4 Successful Shipment Verification ....................................................................................................... 3 4.1 General.................................................................................................................................... 3 4.2 Impact Recorder ....................................................................................................................... 3 4.3 Other Checks............................................................................................................................ 3 4.4 External inspection.................................................................................................................... 4 5 Arrival at Customer’s Mounting Pad ................................................................................................... 5 1 2

1

Scope Special instruction for Transport from ABB manufacturer to customer site They are intended to provide guidelines in the transport of transformers from ABB manufacturer to customer site to maintain their quality and reliability. The Instructions are intended for the guidance of personnel who have been trained for, or who have experience in transportation of heavy electrical power equipment, including the use of good safety practices. These instructions are intended to supplement, and not eliminate the necessity for such training

2

Shipping Information

2.1

Shipping Sketch In the shipping sketch details of weights and dimensions of the main tank is indicated. This sketch shows a three dimensional profile of the stripped down, as-shipped transformer tank. The centre of gravity in three dimensions along with distances to the tank extremities is indicated. Information is given whether the transformer is shipped in oil or in dry gas, (air or nitrogen) and the shipping weight with or without oil. The shipping sketch also details special lifting, handling or shipping bracing instructions

2.2

Shipping Braces and Covers Shipping covers, and sometimes special braces, are required for shipment. These braces and covers must be removed after arrival site during the re-assembly process. The covers and braces are identified in the shipping documentation and are painted a contrasting colour, such as yellow, for easy identification.

3

Transportation 3.1

Impact Recorder The use of a three-dimension impact recorder (also known as a bump recorder or accelerometer) to monitor the quality of the trip and to chronicle potential excessive shocks to the transformer is in many cases a standard and Customer specified requirement. An electronic or mechanical impact recorder may be used. The impact recorder is mounted on the transformer . Core form transformers are to be shipped upright, with the transformer mounted on the rail car or truck such that the long axis is in the same direction as the direction of travel.

<<<<<< Direction of Travel >>>>>> Rail Car or Truck Transformer Plan View of a Transformer Placed on a Rail Car or Truck The impact recorder is mounted on the transformer to ensure: • the Longitudinal Acceleration direction lines up with the direction of travel • the Lateral Acceleration direction lines up with the direction a right angles to the direction of travel • the Vertical Acceleration will detect the up and down movement. See separate information leaflet for handling of impact recorder. .

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-200

Rev. No:

D

Page No:

Page 2 of 6

Title: SHIPPING OF TRANSFORMERS - GENERAL OVERVIEW

4

Successful Shipment Verification 4.1

General After leaving the factory, whenever the transformer and components are transferred from one mode of transportation (rail car, truck, ship, etc.) to another, checks should be made to confirm that shipping damage has not been sustained. These checks should be made before the equipment is moved from the transport mode. Since transformers are shipped partially disassembled, electrical testing to confirm fitness cannot be performed at this stage. Care must be taken to properly and completely perform the limited amount of inspection that can be done at this time. In the event of apparent or suspected damage, claims must be made against the transport carrier, and the Factory and Customer are to be notified immediately.

4.2

Impact Recorder Refer to separate instruction leaflet for instructions on removing impact recorder at final destination. Acceptable impact levels for the Longitudinal, Lateral and Vertical Acceleration will be defined by the individual Factories. If the transformer and components are being inspected at an interim point, at a change of transportation mode, the impact recorder should be monitored. The impact recorder should not be removed from the transformer until the transformer has reached the final destination.

4.3

Other Checks If Shipping weight and dimension limits allow, smaller transformers are shipped with all or most of the oil required in the main tank. Some of these smaller units may also be shipped with dry nitrogen or air in the gas space on top of the oil, this gas will be at a positive pressure when the transformer leaves the factory. To reduce shipping weight, larger units are totally drained of oil and then filled with dry gas (nitrogen or air) to maintain winding and insulation dryness during transit. Of the gas filled units, some will be filled in the factory and then be equipped with temporary gas cylinders for adding gas to the tank during transit as needed. Other gas filled units will leave the factory with an initial filling only and no supplementary cylinders added. In all cases, the gas filled units will leave the factory with a positive pressure of dry gas. For transformers shipped in oil, check for oil leaks at valves, flanges, bushings and welded seams. If evidence of oil leaks are observed, contact ABB. For transformers shipped in oil with a gas layer on top of the oil, perform oil leak checks and draw oil from suspect units. In addition, theses transformers will be equipped with a vacuum/pressure gauge to monitor the gas layer pressure. This gauge must be checked and value of pressure/vacuum noted along with the oil temperature as read from the top oil temperature gauge. For transformers shipped dry gas filled, the monitoring of the vacuum/pressure gauge and the temperature gauge is critical and is often checked at various stages of the journey. A leak will compromise the winding and insulation integrity. The pressure and temperature gauge values must be recorded and compared to the readings obtained in the factory prior to shipment. The transformers are shipped with a positive pressure but a negative (vacuum) reading may occur if the ambient temperature is substantially lower than recorded in the factory. The worst case condition is a reading of zero pressure, which may be indicating a leak. In conditions of zero pressure or a pressure/temperature relationship that conflicts with the factory results, a dew point measurement may be taken. The dew point measurement will establish the moisture content of the gas, which can be compared to the measurement made in the factory prior to shipment. See 1ZBA 4601-203 and 1ZBA 4601-204 for further information on monitoring dry gas filled units during shipment. The following is a general listing of tests and checks that should be performed on shipped transformers. Not all checks are required for all shipping variations.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-200

Rev. No:

D

Page No:

Page 3 of 6

Title: SHIPPING OF TRANSFORMERS - GENERAL OVERVIEW

4.4

External inspection Any external evidence of damage or evidence indicating the possibility of hidden damage must be reported to the carrier’s representative and to an ABB representative before off-loading the transformer. Take pictures of external damage. The receiver must assume all responsibility for off-loading damaged transformers. The external inspection prior to off-loading the transformer should include the following. 1.

Measure the core insulation resistance to ground. o measured at 1000 V DC, corrected to 20 C.

The minimum acceptable value is 500 k ohms when

2.

Are all tie rods undamaged and nuts tight, all cables tight?

3.

Is all blocking tight and in good condition?

4.

Is there any evidence of load shifting in transit?

5.

Does the impact recorder indicate any impacts beyond the acceptance zones?

6.

Are there indications of external damage such as broken glass on gauges, broken welds on flanges?

7.

Is the paint finish damaged?

8.

Are all fittings, which were shipped attached, still in place and undamaged (see the outline drawings)?

9.

Is there any evidence of oil leakage around valves, fittings, flanges and tank seams?

10.

Is the pressure in the gas filled transformer tank acceptable according to Product Information 1ZBA 4601-203 or 1ZBA 4601-204?

11.

Inspect bushings that are assembled to the tank for signs of breakage, are they chipped or otherwise damaged?

12.

Check the Packing List to confirm delivery of all major components and accessory boxes.

13.

Do crates or boxes show evidence of damage or moisture entrance?

14.

Check the temporary shipping silica gel breather, moisture ingress will be indicated by the silica gel desiccant changing colour.

15.

Check that detached radiators, coolers and pumps have openings closed off with blind flanges and plugs.

If there is no evidence of shipping damage, proceed to off-load the transformer. If shipping damage is found, contact the nearest ABB Power Transformers representative for further instructions prior to off-loading the transformer. Written notations of apparent loss and damage must be made on the carrier’s delivery receipt. Concealed damage must be reported immediately to the delivering carrier with a request for an inspection. See Product Information for specific Receiving Inspection Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Complete Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled Transformer Designed with Oil Conservator, Shipped Dry-Gas Filled, Partially Disassembled Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Complete Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Partially Disassembled 1ZBA 4601-210 Transformer Designed with Sealed Tank, Gas Space, Shipped Dry-Gas Filled, Shipped Partially Disassembled 1ZBA 4601-205 1ZBA 4601-206 1ZBA 4601-207 1ZBA 4601-208 1ZBA 4601-209

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-200

Rev. No:

D

Page No:

Page 4 of 6

Title: SHIPPING OF TRANSFORMERS - GENERAL OVERVIEW

5

Arrival at Customer’s Mounting Pad The Following Product Information documents will provide guidance for the required operations once the transformer has arrived on site and been Inspected. Choose the applicable documents. 1ZBA 4601-202 Off-Loading and Moving a Transformer 1ZBA 4601-211 Storage on Site Before Assembly 1ZBA 4601-212 Transformer Assembly Instructions 1ZBA 4601-213 Receiving and Handling Transformer Oil on Site – Quality Control 1ZBA 4601-214 Final Oil Filling on Site – Atmospheric Pressure 1ZBA 4601-215 Vacuum Oil Filling on Site 1ZBA 4601-216 Acceptance Testing and Energization 1ZBA 4601-217 Filed Test Record 1ZBA 4601-218 Oil Conservators Without Air Cell 1ZBA 4601-219 Oil Conservators With Air Cell

Revision A: 2001-02 B: 2004-04-04 C: 2003-06-17 D: 2003-08-11

new Template iT Doc-no was 1ZBA4601-201 Rewritten & renamed

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-200

W. Klein PTPT/GD W. Klein PTPT/GD L Ostman PDC/LP

Rev. No:

D

Page No:

Page 5 of 6

Title: SHIPPING OF TRANSFORMERS - GENERAL OVERVIEW

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should comunicated to: ABB Power Transformers acording to contact list in Aspect Viewer

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form. Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-200

Rev. No:

D

Page No:

Page 6 of 6

Title: SHIPPING OF TRANSFORMERS - GENERAL OVERVIEW

PowerIT Transformers and Reactors OFF-LOADING AND MOVING A TRANSFORMER Table of contents 1

Inspection before off-loading

2

2

Off-loading the transformer

3

2.1 2.2 3

Off-load with overhead crane ..................................................................................................... 4 Off-loading when overhead crane is not available ...................................................................... 4 Revision 6

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY

6

1

Inspection before off-loading Before off-loading a transformer from any kind of vessel or carrier, an inspection of the transported goods shall be made in order to reveal any shipping losses or damage. Shipping papers, packing list with transport outline drawings, instruction leaflets and other pertinent documents furnished with the transformer must be available for use during the inspection. See Product Information for specific Receiving Inspection - Transformers Designed With: 1ZBA 4601-205 Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Complete 1ZBA 4601-206 Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled 1ZBA 4601-207 Transformer Designed with Oil Conservator, Shipped Dry-Gas Filled, Partially Disassembled 1ZBA 4601-208 Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Complete 1ZBA 4601-209 Transformer Designed with Sealed Tank, Gas Space, Shipped Oil Filled, Shipped Partially Disassembled 1ZBA 4601-210 Transformer Designed with Sealed Tank, Gas Space, Shipped Dry-Gas Filled, Shipped Partially Disassembled If there is no evidence of shipping damage, proceed to unload the transformer. If shipping damage is found, contact the nearest ABB Power Transformers representative for further instructions prior to off-loading the transformer. Written notations of apparent loss and damage must be made on the carrier’s delivery receipt. Concealed damage must be reported immediately to the delivering carrier with a request for an inspection.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-202

Rev. No:

C

Page No:

Page 2 of 6

Title:

OFF-LOADING AND MOVING A TRANSFORMER

2

Off-loading the transformer Most large power transformers arrive to their destination loaded on depressed centre cars for rail or road. The transformer must have the shipping braces and blocking removed from the car, and then be lifted or skidded from the car to the correct position at the installation site. Caution Failure to follow these instructions may result in equipment damage or personal injury. Locate the car on a straight and level section of track, set the brakes on both ends of the car, and place chock blocks under the wheels at both ends. This will prevent movement of the car during the off-loading operations. After the receiving inspection has been completed, remove the tie rods and the blocking from the car, Figure 1.

Figure 1 - Transformer shipment showing tie-rods and blocking When the blocking has been welded to the car, use an acetylene-cutting torch and burn the blocking from the car bed, Figure 2. Do not attempt to burn the blocking at the point where it fits to the transformer base because this will damage the transformer paint finish and may damage the tank wall and cause an oil leak.

Figure 2 - Blocking Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-202

Rev. No:

C

Page No:

Page 3 of 6

Title:

OFF-LOADING AND MOVING A TRANSFORMER

2.1

Off-load with overhead crane If an overhead crane with sufficient capacity is available to lift the transformer from the car; this is the most convenient method to unload the transformer. Use a spreader bar, or slings with sufficient length to achieve a lifting angle small enough to meet the requirements given in the transport or outline drawing. Attach the slings to the lifting hooks on the transformer. The lifting hooks will be shown on the outline drawing and are generally located at all four corners of the tank. Do not attempt to lift the transformer from any point other than the designated lifting hooks. Do not allow the slings to come in contact with any accessory items such as indicating instruments or bushings.

2.2

Off-loading when overhead crane is not available If a suitable overhead crane is not available, the transformer must be raised from the car bed with jacks, and then skidded or rolled into the desired position.

Figure 3 - Jacking Pad Place lifting jacks at the points near the base that are designated jacking pads - Figure 3. Operate the jacks at all four lifting points simultaneously so that the transformer base is kept level during the jacking. (Do not locate the jack base directly on the car bed.) Block the car frame before the transformer is jacked up to keep it stable during the off-loading and skidding operation. Warning Be certain the jacks are secured directly under the jack pads on the tank so they will not slip out of position during the lifting operation. Failure to do this may cause equipment damage and severe personal injury.

Figure 4 - Transformer raised. Cribbing placed under transformer. Jack the transformer approximately 20 to 25 cm (8 to 10 inches) above the car bed and slip successively heavy timbers or rails between the transformer and the car bed. The free clearance up to the transformer bottom during the jacking operation shall for safety reasons never exceed 5 cm (2 inches). The timbers should be located at the same point that Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-202

Rev. No:

C

Page No:

Page 4 of 6

Title:

OFF-LOADING AND MOVING A TRANSFORMER

planking was placed on the car bed when the unit was loaded. The timbers or rails should extend beyond the width of the transformer base to be certain the base is not damaged during the off-loading operation. Lower the transformer on to the timbers and remove the jacks. Construct cribbing along the side of the rail car up to the same height as the top of the timbers under the base. Skid the transformer from the rail car onto the cribbing. Be certain to use only the designated pulling eyes when you move the transformer. Do not allow the pulling cables to contact any piping or cooling equipment that may be installed on the transformer. Set up the lifting jacks at the jacking point on the transformer and raise if off the cribbing. Remove one layer of max. 5 cm (2 inches) of the cribbing from under the transformer. Lower the transformer to the next layer of cribbing, reposition the jacks, and lift the transformer off the cribbing and remove another layer of cribbing. Continue this procedure until the transformer can be placed on the rollers or skids and moved to the prepared pad. Figure 4 illustrated skidding on timbers and Figure 5, application of rollers. Keep the base level at all times.

Figure 5 - Transformer raised. Cribbing and rollers placed under transformer. Be certain to support the base of the transformer as shown on the outline drawing or the base drawing when you unload it from the car and move it to the foundation. Use the designated pulling eyes and move the transformer to the prepared pad on rollers or skids and lower the transformer onto the pad. Check to be certain the base is level and proceed with the assembly and oil filling process. If rollers are used, they should be located directly under the two walls parallel to the direction of movement. Rollers should be used on each side with a maximum centre to centre distance between rollers of one meter, or three feet. Failure to keep the rollers within the designated support area of the base may damage the tank bottom.

3

Revision A:

2001-02

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-202

Rev. No:

C

Page No:

Page 5 of 6

Title:

OFF-LOADING AND MOVING A TRANSFORMER

B: C:

2003-04-08 2003-08-11

new Format new contact address

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should comunicated to: ABB Power Transformers acording to contact list in Aspect Viewer

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-202

Rev. No:

C

Page No:

Page 6 of 6

Title:

OFF-LOADING AND MOVING A TRANSFORMER

PowerIT Transformers and Reactors MONITORING OF DRY-GAS FILLED TRANSFORMERS WITHOUT GAS CYLINDERS DURING SHIPMENT AND STORAGE

Table of contents SCOPE.................................................................................................................................................... 2 1

Pressure Gauge and Filling Valve ..................................................................................................... 2

2

Pressure Limits ................................................................................................................................. 2

3

Monitoring under storage................................................................................................................... 2

4

Revision ............................................................................................................................................ 2

SCOPE Note: Nitrogen gas is sometimes used instead of dry air. In these cases, a warning label is affixed to the tank. This Instruction is valid for both dry air and dry nitrogen. These transformers are shipped without oil and with accessories and fittings removed. The tank has been filled with dry gas to a slight over-pressure in the factory. It is important that the transformer remains perfectly sealed during shipment and storage. The gas pressure shall be monitored at regular intervals. Instructions and report forms are enclosed in the "Shipping Manual".

1

Pressure Gauge and Filling Valve A pressure gauge and filling valve are fitted under a protective cover on the side or the top of the tank. There is either a transparent cover, through which the pressure gauge may be read without opening it, or a marked steel cover. In the latter case, make sure that the cover is put back properly after every inspection. The pressure gauge has a range +- 60 kPa (+-10 psi). The filling valve will accept a plastic tube with an inner diameter of 5-8 mm (1/4 in).

2

Pressure Limits The gas pressure in the tank when the transformer leaves the factory is 20 kPa (3psi) at a temperature of about 20°C (65-70°F). This pressure will change with the ambient temperature, see Figure 1. Even at -25°C there should be a small positive over-pressure and in a warm climate the pressure still is about 30 kPa. 30

20 Pressure kPa 10

0 -20

-10

0

10

20

30

Temperature OC

Figure 1 Correct pressure at different ambient temperatures If, after inspection, the pressure is completely lost, there must be a leak somewhere. It is possible that there may even have been under-pressure at some time (due to a sudden temperature drop), and moisture may have entered the tank. Complete loss of gas-filling pressure must be reported immediately for further action. If the pressure read on the gauge is not completely lost, but has fallen below 5 kPa (1 psi), then the tank shall be filled up with dry gas to the original reading of about 20 kPa. The guaranteed dryness of the filling gas shall be such that the dew point is below -40°C (-40°F). Before filling, the plastic hose used shall be blown clean with gas from the bottle.

3

Monitoring under storage When the transformer is under storage for longer time than one month, the filling pressure shall be checked and recorded. See information in instruction 1ZBA4601-211 STORAGE ON SITE BEFORE ASSEMBLY. If the unit is opened and pressurized again the pressure must be rechecked again after 24 hours

4

Revision A: B: C:

2001-02 2003-04-09 2003-08-11

new Format change contact address. Paragraph 3

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-203

Rev. No:

C

Page No:

Page 2 of 3

Title:

MONITORING OF DRY-GAS FILLED TRANSFORMERS WITHOUT GAS CYLINDERS DURING SHIPMENT AND STORAGE

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should comunicated to: ABB Power Transformers acording to contact list in Aspect Viewer

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-203

Rev. No:

C

Page No:

Page 3 of 3

Title:

MONITORING OF DRY-GAS FILLED TRANSFORMERS WITHOUT GAS CYLINDERS DURING SHIPMENT AND STORAGE

PowerIT Transformers and Reactors RECEIVING INSPECTION Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled

Table of contents Scope ...................................................................................................................................................... 2 1

Visual inspection on arrival at site ..................................................................................................... 2

2

Revision ............................................................................................................................................ 2

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY ........................................................ 3

Scope These transformers are shipped with oil in the tank close to cover level. Certain fittings are removed for shipment because of shipping limitations or risk of damage. A silica gel breather may be temporarily fitted to the top of the transformer during shipment.

1

Visual inspection on arrival at site Upon arrival at site the transformer is carefully inspected. In order to maintain the warranty, the Receiving Inspection Checklist must be completed by the purchaser's representative or an ABB Representative, for each unit, and returned to ABB Power Transformers. 1.

Measure the core insulation resistance to ground. o measured at 1000 V DC, corrected to 20 C.

The minimum acceptable value is 500 kohms when

2.

Are all tie rods undamaged and nuts tight, all cables tight?

3.

Is all blocking tight and in good condition?

4.

Is there any evidence of load shifting in transit?

5.

Does the impact recorder indicate any impacts beyond the acceptance zones?

6.

Are there indications of external damage such as broken glass on gauges, broken welds on flanges?

7.

Is the paint finish damaged?

8.

Are all fittings, which were shipped attached, still in place and undamaged (see the outline drawings)?

9.

Is there any evidence of oil leakage around valves, fittings, flanges and tank seams?

10.

Inspect bushings that are assembled to the tank, or are in crates or boxes for signs of breakage, are they chipped or otherwise damaged?

11.

Is oil level in bushings normal?

12.

Check the Packing List to confirm delivery of all major components and accessory boxes.

13.

Do crates or boxes show evidence of damage or moisture entrance?

14.

Check the temporary shipping silica gel breather, moisture ingress will be indicated by desiccant changing colour.

15.

Check that detached radiators, coolers and pumps have openings closed of with blind flanges and plugs.

If there is no evidence of shipping damage, proceed to off-load the transformer. If shipping damage is found, contact the nearest ABB Power Transformers representative for further instructions prior to off-loading the transformer. In the event of apparent or suspected damage, claims must be made against the transport carrier, and the Factory and Customer are to be notified immediately. Note: Accessories and detail parts must be placed in a location, which will minimise exposure to weather and the possibility of damage or loss.

2

Revision A: B: C:

2001-02 2003-04-09 2003-08-11

new Format new contact address added

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-206

Rev. No:

C

Page No:

Page 2 of 3

Title:

RECEIVING INSPECTION Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein. ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should be FAXed to: ABB Power Transformers acording to contact list in Aspect Viewer

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-206

Rev. No:

C

Page No:

Page 3 of 3

Title:

RECEIVING INSPECTION Transformer Designed with Oil Conservator, Shipped Oil Filled, Shipped Partially Disassembled

PowerIT Transformers and Reactors STORAGE ON SITE BEFORE ASSEMBLY

Table of contents 1

General ................................................................................................................................................ 2

2

Separate Storage of UN-MOUNTED accessories ............................................................................... 2

3

Storage of main unit in oil (FOR UNITS SHIPPED IN OIL).................................................................. 3

4

Storage of main unit in dry gas (for units shipped in dry gas) .............................................................. 3

5

Revision ............................................................................................................................................... 3

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY.......................................................... 4

1

General This instruction deals with storage and supervision on the erection site, in particular if the shipment has arrived early, and the assembly will not take place immediately. The transformer may have been shipped with some accessories and fittings removed. The tank may have been filled with dry gas or oil during the shipment. The shipment consists of the “Main Unit” - the closed tank with core and coils, and crates and boxes having contents as indicated by the Packing List. The Main Unit shall preferably be placed on the mounting foundation, if it is ready, or on a suitable temporary pad. Be certain to support the base of the transformer as shown on the outline drawing or the base drawing to avoid deformation or damage of the tank bottom. Crates and boxes are to be kept protected from weather, indoors when required, but may also be stored outdoors, supported off the ground, and well covered with tarpaulins.

2

Separate Storage of UN-MOUNTED accessories When accessories are not mounted immediately after the transformer is received, they must be given care to protect them from damage or loss during storage. The following general instructions provide guidelines for storage and inspection. See also the instruction leaflets for the individual parts for storage instructions. Radiators and Coolers The radiators are shipped with the top and bottom openings sealed airtight and watertight. Radiators should be stored on blocks to keep them off the ground. Make visual inspection of vent and drain plugs to check for tightness. If they have been loosened, re-tighten before storage. Gaskets or Teflon sealing tape may be used for sealing plug threads. Bushings The bushings removed for shipment should remain in the shipping crates until they are required for the transformer assembly. Bushings are to be stored as described in the Bushing Leaflets. Load Tap-Changers The load tap-changer will generally be shipped attached to the transformer. The tap-changer may be shipped detached from the main unit. In either case, all oil compartments of the load tap-changer must be filled with oil to positive pressure during storage. The electrical space heaters in the control compartments are to be connected to a power circuit and energized to keep the control equipment dry. Fan Motors Fan motors are typically mounted on the radiators and will be stored as per the radiator requirements. Other Boxes Boxes that are marked for protected storage will be stored in a clean, dry place. Inertaire Equipment The Inertaire equipment is shipped on the transformer when shipping clearances allow. The pressure gauge, reducing valves, three-way valve, sump and plastic hoses are assembled and in the cabinet. Flexible tubing for connecting the nitrogen tank to the cabinet is shipped in the detail box. The nitrogen tank must be assembled on the transformer before the transformer is stored or any work is started. Paint Finish Inspect the paint finish on the main unit and all painted detail parts for damaged areas. Apply touch-up paint (primer and finish coat) to these areas as required.

Prepared By:

L.Ostmann

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-12-10

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-211

Rev. No:

E

Page No:

Page 2 of 4

Title:

STORAGE ON SITE BEFORE ASSEMBLY

3

Storage of main unit in oil (FOR UNITS SHIPPED IN OIL) With proper preparation and maintenance, transformers may be stored indefinitely if they are filled with oil. As soon as possible after receiving the transformer, locate it on its permanent foundation, or a solid temporary foundation, and perform the required inspection and tests. Report any damage or shortage before storage. As many accessories as possible should be installed, and the remaining parts stored properly. Transformers with sectionalised tanks or major components such as bushing turrets that have been removed for shipment must have permanent covers installed. If bushings are installed during storage they should be temporary connected (grounded) to the transformer tanks Test oil from a bottom sampling valve for chemical properties. If the transformer is being stored with a dry gas cushion on top of the oil, positive pressure must be maintained during storage. A record of temperature and gas pressure must be maintained. Record temperature and gas pressure daily for the first two weeks of storage, then weekly for the next month followed by monthly readings. If Inertaire equipment is being used, Nitrogen consumption should be recorded. If the transformer is shipped partly filled with oil and with Air Breather, the condition of the drying agent must be checked regularly according to detailed information in product leaflet. After six months and subsequently on the Customer normal maintenance schedule, check the oil from the main unit and other oil filled compartments for chemical properties.

4

Storage of main unit in dry gas (for units shipped in dry gas) If a transformer is to be stored for more than a few months prior to installation it is strongly recommended to oil fill prior to the storage period. When this is not practical, storage in dry gas is acceptable with following precautions. In all cases where gas storage is performed it is necessary that positive gas pressure be maintained in the transformer tank at all times. If the unit is equipped for Inertaire, this can be used for maintaining pressure. If the unit does not have Inertaire, a temporary installation of the apparatus or other gas pressure control system can be made. A record of temperature and gas pressure must be maintained. Record temperature and gas pressure daily for the first two weeks of storage, then weekly for the next month followed by monthly readings. If Inertaire equipment is being used, gas consumption should be recorded. In the event of loss of gas pressure, the dew point must be measured after restoration of pressure. Storage in dry gas beyond 6 months must be approved by the Supplying Factory.

5

Revision A: B: C: D: E:

2001-02 2003-04-09 2003-08-11 2003-11-20 2003-12-10

new Format new contact address Grounding of bushings included. Change to 4 Long time storage. Change to 4

Prepared By:

L.Ostmann

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-12-10

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-211

Rev. No:

E

Page No:

Page 3 of 4

Title:

STORAGE ON SITE BEFORE ASSEMBLY

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should comunicated to: ABB Power Transformers acording to contact list in Aspect Viewer

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form.

Prepared By:

L.Ostmann

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-12-10

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-211

Rev. No:

E

Page No:

Page 4 of 4

Title:

STORAGE ON SITE BEFORE ASSEMBLY

PowerIT Transformers and Reactors TRANSFORMER ASSEMBLY INSTRUCTIONS

Table of contents 1 2 3 4

Scope..................................................................................................................................................................................... 2 Safety designations................................................................................................................................................................ 2 General .................................................................................................................................................................................. 2 Preparation............................................................................................................................................................................. 2 4.1 The following equipment may be needed except hand tools mentioned in 12.1 ............................................................ 2 5 Checking for leaks and dryness after shipment...................................................................................................................... 2 6 Dew point measurement ........................................................................................................................................................ 3 7 Preparation for oil filling.......................................................................................................................................................... 3 8 Checking for leaks during assembly....................................................................................................................................... 3 9 External Assembly ................................................................................................................................................................. 4 9.1 Radiators, Coolers and Pumps....................................................................................................................................... 4 9.2 Mounting the COPS Oil Preservation System ................................................................................................................ 4 9.3 Mounting the Nitrogen Blanket Oil Preservation System................................................................................................ 4 9.4 Load Tap-Changers ....................................................................................................................................................... 4 9.5 Tap-Changers Mounted for Shipment ............................................................................................................................ 4 9.6 Tap-Changers Removed for Shipment........................................................................................................................... 4 10 Internal Assembly........................................................................................................................................................... 5 10.1 General ...................................................................................................................................................................... 5 10.2 Bushing Installation .................................................................................................................................................... 6 10.3 Tap-Changers Removed for Shipment....................................................................................................................... 6 10.4 De-energized Tap-Changer........................................................................................................................................ 6 11 Closing the Transformer................................................................................................................................................. 6 12 Revision ......................................................................................................................................................................... 7

1

Scope These instructions are intended to provide guidelines in the installation of transformers to maintain their quality and reliability. They are intended for the guidance of personnel who have been trained for, or who have experience in the installation, maintenance and servicing of high-voltage electrical power equipment, including the use of good safety practices. These instructions are intended to supplement, and not eliminate the necessity for such training. Oil filing are treated in instruction 1ZBA4601-215, Vacuum oil filling on site and 1ZBA 4601-214 Final oil filling at site atmospheric pressure.

2

Safety designations The following text highlights particular procedures and precautions that are specific to ABB procedures and are of critical importance. Safety notations are intended to alert personnel of possible personal injury, death, or property damage. They have been inserted in the instruction text prior to the step in which the condition is cited. The safety designations are headed by one of three hazard intensity levels, which are defined as follows: 1) Danger - immediate hazard that will result in severe personal injury, death, or property damage. 2) Warning - hazard or unsafe practice that could result in severe personal injury, death, or property damage. 3) Caution - hazard or unsafe practice that could result in minor personal injury, death, or property damage.

3

General Transformer internal components must be free of contamination and dry for effective and safe operation. These conditions, established during manufacture and sustained during transport must be maintained during assembly. The transformer tank shall be grounded prior to beginning any assembling operations.

4

Preparation The transformer shall be moved into position on the substation pad and the base should be levelled. Install shims under the base for levelling if necessary. The transformer base shall be supported on the foundation pad or piers as noted on the transformer base drawing detailed on the transformer outline drawing. The transformer foundation should be prepared so that the transformer shall have adequate air circulation necessary to cool the transformer. 4.1

The following equipment may be needed except hand tools mentioned in 12.1 ! ! !

5

An oxygen content meter to verify that the atmosphere inside the tank does not present personal risk of suffocation. Dew point meter for checking the dryness of the shipping gas and indirectly the insulation. A supply of dry air from bottles or from an air dryer for releasing vacuum. The dry air shall have a dew point of - 40 °C or lower.

Checking for leaks and dryness after shipment A large transformer is normally shipped with fittings and auxiliary equipment taken off, and the tank filled with dry gas to a slight over pressure. The gas pressure is checked in the course of extended shipment, and when the transformer arrives on site. See further Instruction 1ZBA4601-203 or 1ZBA4601-204. The transformers are shipped with a positive pressure but a negative (vacuum) reading may occur if the ambient temperature is substantially lower than recorded in the factory. The worst-case condition is a reading of zero pressure that may be indicating a leak. In conditions of zero pressure or a pressure/temperature relationship that conflicts with the factory results, a dew point measurement must be taken. The matter must be reported back to an ABB representative.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-212

Rev. No:

C

Page No:

Page 2 of 7

Title:

TRANSFORMER ASSEMBLY INSTRUCTIONS

6

Dew point measurement Excessive moisture in a transformer is a negative factor that will lead to dielectric breakdown and failure. When transformers are manufactured, the moisture content of the materials are controlled and prior to final assembly and testing, the transformer goes through a drying process that removes the bulk of the water from the insulation material. This dryness integrity must be maintained during shipment and final assembly at site. Larger transformers are shipped in dry-gas (air or nitrogen). The moisture in the insulation can be determined by monitoring the moisture in the gas. This measurement of the gas moisture content is called the dew point. After an equilibrium period of 12 - 24 hours of constant temperature, some of the moisture in the insulation will migrate into the gas. The moisture in the gas is proportional to the moisture in the insulation and can be used to determine the relative dryness of the transformer insulation. The level of moisture is also related to temperature. See Figure 1 for a graph showing the relationship between dew point, temperature and % moisture content on the surface of the insulation.

Surface moisture content % -20º

2

-10º

0º

10º 20º

1.5

Temperature inside transformer

1

30º

0.7 40º

0.5 0.4 0.3

Water vapor pressure inside

0.2 0.01

0.03

0.3

0.1

-60º

-50º

mm Hg -30º

-40º

-20º

Dew- point of air inside the transformer Figure 1 Surface moisture as function of dew point Figure 1 shows how the surface moisture content of the insulation can be read from the moisture content of the gas in the tank, expressed by its dew point temperature. A low moisture content correlates to a low dew point. The surface moisture shall be below 0.8 % for a new transformer.

7

Preparation for oil filling It is good practice to assemble the complete transformer and begin oil filling as soon as practical possible. Storage of partially assembled units in oil or in dry gas is acceptable providing the guidelines in Product Information 1ZBA 4601211 are followed.

8

Checking for leaks during assembly During the assembly on site, the transformer must be sealed off and pressurized with dry gas during work stoppages (over night or during inclement weather). When work resumes, the pressure, correlated with the temperature, must be checked . Suspected leaks may be located with leak detection instruments, with soapy water, or with plastic bags tightened around valves (being inflated by leaking air). In this way the assembled seals may be checked successively as the work continues.

9

External Assembly The items removed and shipped separately are listed on the outline drawing, the outside assembly drawing, or packing list. The items generally removed and shipped separately are the bushings, cooling equipment, forced oil pumps (if the

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-212

Rev. No:

C

Page No:

Page 3 of 7

Title:

TRANSFORMER ASSEMBLY INSTRUCTIONS

transformer has a forced cooling rating), surge arresters and arrester mounting brackets and the sudden pressure relay. The number of accessory items removed will vary depending on the physical size of the transformer. All air or gas fittings and all oil fitting joints that are pre-assembled at the factory must be checked for leaks and resealed. 9.1

Radiators, Coolers and Pumps Radiators, coolers, the associated oil pumps and piping shipped as detail items that are assembled at the final location must be inspected prior to installation to be certain that no water or foreign material is in the oil space The radiators or coolers should be installed on the transformer the same day they are opened. Do not permit the cooling apparatus to stand exposed after opening for inspection. The detailed illustrations for mounting and piping arrangements are shown on the outside assembly or the outline drawings. Use new gasket material when installing the radiators, coolers, or pumps.

9.2

Mounting the COPS Oil Preservation System If the transformer is equipped with a constant oil pressure (COPS) oil preservation system, mount the support structure for the COPS tank, mount the tank and install the valves on the main tank and the COPS tank. The valve to the COPS piping on the transformer cover should remain closed. The detailed illustrations for mounting and piping the COPS system are shown on the outline drawings. Do not install the connected piping between the main tank and the COPS system until the vacuum filling process of the main tank has been completed.

9.3

Mounting the Nitrogen Blanket Oil Preservation System If the transformer is equipped with a nitrogen blanket oil preservation system, the nitrogen system control cabinet generally remains on the transformer for shipment. If it was removed, install the cabinet and the nitrogen bottle. If the cabinet is already mounted, install the nitrogen bottle and connect the piping to the control. If the transformer was shipped with oil, the tubing connection from the cabinet to the gas space is not connected. This prevents oil from entering the line during shipment. Check the line to be certain it is clear of oil and connect the tubing at the cabinet. The nitrogen supply valve should remain closed in either case.

9.4

Load Tap-Changers The UVT, UTT and RMT-1 Tap-Changers are usually shipped mounted on the transformer. The UZE and UZF TapChangers are also shipped mounted on the transformer. The compartment for Tap-Changers such as the Reinhausen M, T, and G and the ABB type UCG, UCL may be removed for shipment. Temporary shipping braces are sometimes used in the removed Tap-Changer compartment. These braces will be shown on the internal assembly drawing. The braces must be removed before the Tap-Changer is placed in service. Gaskets used for Tap-Changer inspection doors can be reused. Gaskets used for Tap-Changer inspection doors can be reused. WARNING DO NOT OPEN ANY COVERS OR FITTINGS UNLESS THE INTERNAL PRESSURE IS AT ZERO GAUGE. FAILURE TO RELIEVE THE PRESSURE COULD CAUSE THE PART BEING REMOVED TO BE A HAZARDOUS FLYING OBJECT. ALWAYS RELIEVE INTERNAL PRESSURE SLOWLY THROUGH VALVES. Before placing Tap-Changers in service, read the appropriate Tap-Changer instruction leaflet. The leaflets are included in the transformer instruction book. Always follow the inspection and filling instructions given in the TapChanger instruction leaflet.

9.5

Tap-Changers Mounted for Shipment No internal assembly operations or taping are required but sometimes they have a shipping support that need to be taken away.

9.6

Tap-Changers Removed for Shipment See paragraph 10.3

10 Internal Assembly 10.1

General Entry into a transformer should only be considered if necessary to complete installation or for investigation of potential damage. In any case, only trained personnel under the guidance of ABB may enter the transformer.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-212

Rev. No:

C

Page No:

Page 4 of 7

Title:

TRANSFORMER ASSEMBLY INSTRUCTIONS

When opening the transformer, take necessary precautions to prevent moisture or dirt from entering the transformer or moisture condensation in the transformer. The transformer should not be opened during periods of inclement weather Necessary confined entry procedures must be followed in compliance with Company policy and local regulations. WARNING When transformer has been shipped with nitrogen, the gas must be replaced with dry air prior to making any entrance into the tank. Never use nitrogen or gases other than air for ventilation. The oxygen content must be at least 19.5% prior to entering the tank. To remove the nitrogen, it is advisable to pull vacuum to fully remove all nitrogen and break the vacuum with dry air. Caution Be certain the internal pressure in the transformer is at zero gauge before opening the manhole cover. Open the transformer at the manhole cover. It is preferred to have only one manhole open at a time. It is also recommended that the tank opening be covered with clear plastic or a tarp. Dry air must be used to ventilate the inside of the tank when it is opened for internal fitting. The air must have a dew point less than -40°C and sufficient airflow for the number of operators in the tank must be maintained. Purge the air hoses with dry air from the supply to remove any moisture and dirt in the hoses prior to use. Make the connections for the dry air supply in the tank space below the working level in the tank. WARNING DO NOT ENTER THE TRANSFORMER OR BREATHE THE INTERNAL ATMOSPHERE UNLESS THE OXYGEN CONTENT OF THE GAS INSIDE THE TRANSFORMER IS AT LEAST 19.5%. OXYGEN CONTENTS LESS THAN THIS CAN CAUSE DROWSINESS, INJURY OR DEATH. TRANSFORMERS SHIPPED IN GAS ARE NOT SAFE TO ENTER. ALWAYS CHECK THE OXYGEN CONTENT. Caution To prevent contamination of the transformer, only the manhole and the opening for the item being installed should be opened. Cover all other openings with dry pressboard or a clean plastic sheet. This will also minimize the flow of dry air from the unit. Start the airflow into the transformer. The volume must be sufficient to maintain continuous airflow outward through the tank openings. Never enter a transformer with dirty or wet clothing. Clean cloth overshoes over work boots or clean nitrile rubber boots should be worn. All tools, equipment and material entering the transformer shall be listed and checked to verify all material has been removed from the transformer. Tools used to perform work inside a transformer tank must have working surfaces hardened so that they will not peel or chip during normal use. Tool working surfaces must not be coated in any way such as painting or plating. Tools that are polished metal or have black oxide body finish are preferred. To prevent accidental disassembly during normal use, all tools with movable parts must use positively retained joints. Tools such as hammers and screwdrivers must have one-piece heads. Moulded-on plastic or fibreglass handles are preferred; if the handle is wood, it must be retained by a wood or plastic wedge. Nameplates or tags attached to tools should be removed. If a nameplate is necessary for tool identification, the plate must be non-metallic and be secured with non-conducting tape. While the transformer is open, do not permit anyone access to the transformer until they have emptied all pockets, checked for loose objects, and removed watches, rings, and other objects. Rubber gaskets should be changed during the assembly operations. If required, new gaskets are provided. Rev. No: Page No: W. Klein Date: 1998-04-30

Prepared By:

Approved By: Applicability:

Anders Lindroth TrafoStar

Rev. Date: 2003-08-11 Lang:

en

Document No.

1ZBA4601-212

C

Page 5 of 7

Title:

TRANSFORMER ASSEMBLY INSTRUCTIONS

10.2

Bushing Installation On large transformers, the bushings will be removed for shipment to meet shipping clearances and to avoid shipping damage to the bushings. The bushing leads may be supported by temporary shipping braces that are an integral part of the blind flange. The flange will be stencilled with a warning note if this method is used. The bushing leads must be disconnected from these temporary braces before the blind flange covers or shipping covers are removed. An alternate method of supporting the bushing leads is to tie the coiled lead to the highest point on the transformer cleats and leads assembly. Caution Failure to disconnect the leads from the temporary shipping braces before the blind flanges or shipping covers are lifted can cause damage to the leads, bridge structure and associated coils, and may necessitate return of the transformer to the factory for repair and re-testing. The bushings removed for shipment should remain in the shipping crates until they are required for the transformer assembly. Note the requirements in the bushing instruction leaflet for temporary storage. Clean the bushing before installing it in the transformer. Power factor and capacitance measurements may be performed as optional tests. Install the bushings in the transformer. When a draw-through-lead or draw-rod design is used, this will be noted on the outline drawing. The procedure for installing the bushing and connecting the leads is described in the bushing instruction leaflet. For bottom connected bushing designs, the connection details will be shown on the outline drawing or the internal assembly drawing. Ground the external bushing terminals after they are installed and connected. The inside assembly drawings or taping sketch furnished with the instruction book contain taping requirements and lead clearances. The internal assembly drawings identify all internal items requiring field taping. Non-metallic bolts, nuts, and studs are sometimes used on insulation structures. Nuts of this type should be tightened to a snug fit only since breakage or thread stripping may occur. Bolts and studs installed at the factory will either have the nuts cemented on or use a second nut as a jamb nut so that re-tightening should not be necessary.

10.3

Tap-Changers Removed for Shipment The leads will need to be connected and taping will be required. Work in the Tap-Changer compartment should be completed as quickly as possible. The leads are identified by tags or a number stamped in the end of the lug. The leads and corresponding terminal lugs are match marked. Start connecting leads in the center and work towards the outside. This allows a little more room for taping. The correct thickness must be applied; too little tape can result in an electrical failure and too much tape can cause overheating of the joint. Follow the taping drawings included in the instruction book for the transformer. Remove all items used during taping the leads before you close the Tap-Changer compartment. Before final oil filling and placing the Tap-Changer in service, check the operation of the Tap-Changer as noted in the instruction book

10.4

De-energized Tap-Changer Check the de-energized Tap-Changer to confirm that the contacts are on the correct positions. Check the external operators to confirm they are on the correct positions. Operate all de-energized Tap-Changers in both directions to each limit to verify the correct alignment of the TapChanger contacts. Perform a winding ratio check at each tap position and record the results. Refer to the TapChanger instruction leaflet for procedures to correct the contact alignment if the ratio checks are not satisfactory.

11 Closing the Transformer This procedure only applies if internal work was required to a transformer that was received without oil or had all oil removed. After the assembly has been completed, remove all the tools and working material from the transformer, seal the transformer and pressurize with dry air or nitrogen to 20 kPa; 3 PSI (0.2 bar). If the exposure time has been excessive or there are others factors that suggest the transformer may have been exposed to excessive moisture contamination, then a dew point measurement may be required.

12

Revision A: B: C:

2001-02 2003-04-09 2003-08-11

new Format

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-212

Rev. No:

C

Page No:

Page 6 of 7

Title:

TRANSFORMER ASSEMBLY INSTRUCTIONS

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should comunicated to: ABB Power Transformers acording to contact list in Aspect Viewer

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

Rev. No:

C

Page No:

Page 7 of 7

Title:

TRANSFORMER ASSEMBLY INSTRUCTIONS

1ZBA4601-212 IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form.

PowerIT Transformers and Reactors RECEIVING AND HANDLING TRANSFORMER OIL ON SITEQUALITY CONTROL Table of contents 1

General ............................................................................................................................................. 2

2

Different types of oil, CHARACTERIZED by origin and chemical composition................................... 2 2.1 Inhibited oils................................................................................................................................ 2

3

Supplier certificate............................................................................................................................. 2

4

Sampling on site................................................................................................................................ 3

5

Testing of samples. Oil characteristics. (f0r non-certified oil) ............................................................. 3

6

Treatment of the oil before filling the transformer............................................................................... 3

7

Revision ............................................................................................................................................ 3

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY ........................................................ 4

1

General This Instruction lists the main quality requirements that are to be fulfilled when transformer oil is delivered to an installation site for filling into the transformer. The oil shall fulfill the requirements in material specification 1ZBA117 001-1, 2, 3 or 4. The user of the transformer may have issued an oil specification of his own, or may have specified oil of a particular trademark from an internationally recognized supplier. This may add to, but does not relieve any of the requirements specified in this Instruction. They are necessary for long-term reliable operation of the transformer.

2

Different types of oil, CHARACTERIZED by origin and chemical composition Transformer oils are specially refined products made from crude oils of different types from different wells. Terms as naphtenic ,parafinic, aromatic and aliphatic refer to different types of hydrocarbons in the oil, which are balanced by the manufacturer to give a combination of high insulation withstand strength, low viscosity, low volatility/high flammability temperature, low sulfur content, and low aging (oxidation) tendency. At the present time there is no essential, documented difference in overall quality between materials from different crude origins, as long as the final products are manufactured by competent refineries and fulfill the requirements of the ABB material specification. A maximum of 10 % from a different oil base may be added to a primary oil supply. When transformers are shipped from the ABB Transformer factory filled with oil, or when oil for the first filling is part of the delivery from ABB, it is supplied against ABB’s own Material Specification 1ZBA117 001-1, 2, 3 or 4.

2.1

Inhibited oils An inhibitor is a particular substance, added to the oil in small quantities in order to neutralize certain intermediate "radicals" - agents in the process of oxidation of the oil. The result is a retardation of the aging, until the quantity of inhibitor has been consumed. From that time onwards, the aging will proceed and accelerate freely. The efficiency of the inhibitor depends on the degree of refining of the oil. Due to that, the best result is obtained if the oil was refined with the objective to be inhibited. Some users hold the view that inhibitors should not be used, because they may mask, for a while, the inherent aging properties of the oil and lull the operating staff into false security. After the inhibitor has been consumed, it may escape attention that the oil deteriorates more rapidly. ABB Transformers does not share this view, and recommends inhibited transformer oil. However, if a customer specification forbids inhibited oil, the filling will be made with un-inhibited oil fulfilling the ABB material specification. Note. The chemical short name for the usual inhibitor substance is DBPC (di-butyl-para-cresol). This must not be confused with the objectionable class of compositions, called PCBs (poly-chlorinated biphenyl’s "askarels"). DBPC is not environmentally noxious - as a matter of fact it has an alternative use as a stabilizer agent in foodstuffs.

3

Supplier certificate The supplier of transformer oil shall guarantee, and supply a certificate that the oil, delivered from the refinery, fulfills the list of requirements specified in the actual ABB material specification 1ZBA117 001-1, 2, 3 or 4. The quality of the oil at delivery condition shall be guaranteed through certificates of the oil characteristics from the oil in the transportation containers or through sample tests. This certificate or tests shall include Power factor/Dissipation Factor at 100°C or 90°C and the Interfacial Tension against water. These tests are to assure that no contamination of the oil has occurred during transportation and storage.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-213

Rev. No:

C

Page No:

Page 2 of 4

Title:

RECEIVING AND HANDLING TRANSFORMER OIL ON SITEQUALITY CONTROL

4

Sampling on site No specific sampling is required for certified oil. The following comments applied to non-certified oil. For transformers shipped in dry-gas, bulk deliveries of oil in tank trailers are normally scheduled to arrive just in time for the filling procedure. This oil will be tested after final filling and processing. For transformer shipped oil filled, the top up oil may be delivered in drums. Oil in drums will be kept in storage with unbroken seals up to the time when filling procedures are to be commenced. The drums shall be stored in horizontal position, with the openings horizontal (at same height). When the oil is delivered in drums and if it has to be tested, the extent of sampling shall be as follows: No of drums sampled No of drums delivered 2 5 2 6 20 3 21 50 4 51 100 7 101 200 10 201 400 15 Most of the properties of insulating oil are affected by impurities, particularly water. Care must be taken in order to avoid contamination of the oil samples. All equipment used in obtaining samples and the sample container shall be clean and dry. When the oil is delivered in tanker trailers: Take two samples from each separate tank compartment.

5

Testing of samples. Oil characteristics. (f0r non-certified oil) The requirement for breakdown strength of the oil at delivery condition is specified according to IEC Standard Publication 296 and ASTM D3487. The dielectric strength of the filtered oil that is filled into the transformer shall meet or exceed the following: 60 kV/2.5 mm 56 kV/0.08” 30 kV/0.1”

method IEC 156 (VDE electrodes). method ASTM D1816 method ASTM D877

The test procedure is according to IEC Publication 156 [using hemispherical electrodes (VDE electrodes) with 2.5 mm spacing]. The minimum breakdown strength for oil as delivered is 30-kV/2.5 mm. The test procedure in accordance with ASTM D877 is using cylindrical electrodes with 0.1 inch spacing. The minimum breakdown strength for oil in delivery condition is 30 kV/0.1 “. After heating with particle and vacuum filtration the breakdown strength shall rise to at least: 80 kV/2.5 mm 64 kV/0.08” 35 kV/0.1”

method IEC 156 method ASTM D1816 method ASTM D877

This method is only accepted for transformers with nominal voltage below 230 kV. Note that the above values refer to the oil coming out from the vacuum filter equipment and it does not refer to oil samples from the transformer. For new oil that never has been in contact with the equipment the Power factor/Dissipation Factor 0.005 at 100°C or 90°C and 50 or 60 Hz Interfacial Tension against water ≥ 40 Nm/m at 25 °C. Note: Oil with Power factor at 100°C or 90°C > 0.2 or Interfacial tension against water < 20 Nm/m shall be regenerated or substituted.

6

Treatment of the oil before filling the transformer The necessary quantity of oil shall be collected and prepared in one or more clean storage tanks. Before being used, the tanks are visually inspected inside for cleanliness. Any liquid residue from earlier use will be carefully removed, and the container flushed with a small quantity of new oil, which is then discarded. The oil, received in drums, is pumped through the vacuum filter plant into the storage tank. The drums or trailer tanks shall not be emptied to the last drop, a sump of an inch or so is left, to avoid possible solid dirt or water on the bottom.

7

Revision A: B: C:

2001-02 2003-04-10 2003-08-11

new Format new contact list added

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-213

Rev. No:

C

Page No:

Page 3 of 4

Title:

RECEIVING AND HANDLING TRANSFORMER OIL ON SITEQUALITY CONTROL

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein. ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should be FAXed to: ABB Power Transformers according to contact list in Aspect Viewer

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-213

Rev. No:

C

Page No:

Page 4 of 4

Title:

RECEIVING AND HANDLING TRANSFORMER OIL ON SITEQUALITY CONTROL

PowerIT Transformers and Reactors

FINAL OIL FILLING ON SITE - ATMOSPHERIC PRESSURE -

List of Contents General ---------------------------------------------------------------------------------------------------------------------- 2 1

SUPPLY OF OIL, QUALITY REQUIREMENTS, AND CLEANLINESS------------------------------- 2

2

TOPPING UP PROCEDURE. ------------------------------------------------------------------------------------ 2 2.1 2.2

2.3 3

Transformers with conservator design. -------------------------------------------------------------- 3 Transformers with sealed tank design. --------------------------------------------------------------- 3 FILLING COOLERS AND RADIATORS.------------------------------------------------------------------ 3

Revision --------------------------------------------------------------------------------------------------------------- 3

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY--------------------------------------- 4

General This Product Information applies to adding top up oil to transformers with a nominal voltage below 200 kV, shipped with oil nearly up to the cover. Filling to normal oil level can in these cases be done with a filter unit. The quantity of top up oil to be added in this manner should be less than 16 % of the total oil volume in the transformer.

1

SUPPLY OF OIL, QUALITY REQUIREMENTS, AND CLEANLINESS The necessary quantity of top up oil for the final filling may be shipped with the transformer, or may be procured locally. If the Customer provides the oil, prior approval for use must be obtained from ABB and the characteristics must meet the requirements of 1ZBA4601-213 Competent supervision and a responsible work force are necessary requirements. Industry standard cleanliness and personal safety precautions must be observed in accordance with common sense and local regulations. Transformer internal components must be free of contamination and dry for effective and safe operation. These conditions, established during manufacture and sustained during transport must be maintained during oil filling and assembly. The top up oil is typically supplied in drums but may be supplied in a tanker if the required quantity is large enough. The drums (or tanker), all hoses, pumping equipment, valves and filters must be for the exclusive use of the transformer oil or have been meticulously cleaned and rinsed. Failure to ensure pristine oil and equipment puts at risk the viability of the transformer operation. Oil in drums or tanks, as delivered, should never be dumped right into the transformer, but always pumped through a filter unit. It is important that clean and dry filters are used. A small sump quantity should be left unused in the drums or tank.

2

TOPPING UP PROCEDURE. When a transformer has been shipped more or less complete, and with oil nearly up to the cover, the following procedure is used to complete the oil volume. A filter unit must be used.

Figure 1. The oil, stored in drums or in a storage tank, is pumped through the filter

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2004-10-14

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-214

Rev. No:

D

Page No:

Page 2 of 4

Title:

FINAL OIL FILLING ON SITE - ATMOSPHERIC PRESSURE -

2.1

Transformers with conservator design. For transformers designed with a conservator, the top up oil should first be pumped into the conservator with the valve between the conservator and the main tank closed. When the conservator is 3/4 full, stop the pumping and open all the bleeder valves the valve between the conservator and the main tank, then slowly allow the oil into the transformer. The oil must be introduced slowly to limit turbulence and air bubbles from going into the windings. Repeat this procedure until the proper oil volume is attained. (See also para. 2.3 Filling coolers and radiators) When filling nears completion, all bushings, turrets and other devices that require bleeding must be bled to avoid trapped air pockets, then sealed.

2.2

Transformers with sealed tank design. Sealed tank designs are often shipped overfilled with the quantity of oil required to fill the cooling equipment. The data on the oil volume and whether additional oil needs to be added will be shown on the outline or shipping drawing. For sealed tank designs, the top up oil should be added through the top filter connection valve. The oil must be introduced slowly to limit turbulence and air bubbles from going into the windings. Obtain a test sample from the main tank and test for dielectric strength. Purge the gas space in the transformer and seal the tank at atmospheric pressure (zero gauge).

2.3

FILLING COOLERS AND RADIATORS. Fill the cooling equipment by opening the lower valve between the cooler or radiator and the main tank and bleed the air through the top vent plug from each cooler or radiator. Ensure that the oil level in the main tank is always is above the top of the core and all insulation material. After completing assembly, check that the oil is at the correct level, being careful to make the appropriate correction for the oil temperature if different from 25 °C. For transformers that shall be pressurized, verify that all accessories in contact with the oil or oil preservation system have been assembled before pressurizing the transformer. After the oil filling procedure has been completed, the transformer should be left at least twelve hour

3

Revision A: B: C: D:

2001-02 2003-05-30 2003-08-11 2004-10-14

new Format new contact address 2.3 was 3, 3 was 4

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2004-10-14

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-214

Rev. No:

D

Page No:

Page 3 of 4

Title:

FINAL OIL FILLING ON SITE - ATMOSPHERIC PRESSURE -

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein. ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should be FAXed to: ABB Power Transformers, Literature Coordinator: +1-314-679-4595 or E-mailed to: [email protected] For a reply, please include your name, company, phone, fax and/or E-mail address.

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form. Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2004-10-14

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-214

Rev. No:

D

Page No:

Page 4 of 4

Title:

FINAL OIL FILLING ON SITE - ATMOSPHERIC PRESSURE -

Power Transformers

ACCEPTANCE TESTING AND ENERGIZATION

Table of contents 1

TRANSFORMER TESTING ON SITE AFTER ASSEMBLY ...................................................................................................2 1.1 Ratio test.........................................................................................................................................................................2 1.2 Winding resistance test (this test is optional) ..................................................................................................................2 1.3 Check of vector group (this test is optional) ....................................................................................................................3 1.4 Insulation resistance test ................................................................................................................................................3 1.4.1. Transformer main windings.....................................................................................................................................3 1.4.2. Current transformers ...............................................................................................................................................3 1.4.3. Control circuit cabling and auxiliary power cabling..................................................................................................3 1.4.4. Core to tank/core clamp ..........................................................................................................................................3 1.5 Capacitance and power factor or dissipation factor measurements................................................................................3 1.6 Check of tank ground circuit continuity ...........................................................................................................................3 1.7 Polarity check of current transformers ............................................................................................................................3 1.8 Check of thermometers and thermostats ........................................................................................................................3 1.9 Oil tests...........................................................................................................................................................................4 1.9.1. Check of the oil level ...............................................................................................................................................4 1.9.2. Check of dielectric strength values .........................................................................................................................4 1.9.3. Power factor (Optional) ...........................................................................................................................................4 1.9.4. Interfacial tension (Optional) ...................................................................................................................................4 1.9.5. Sampling of oil for dissolved gas analysis by special request .................................................................................4 1.10 Operational test of supervisory equipment......................................................................................................................4 1.11 Operational test of other equipment................................................................................................................................5 1.11.1. Cooling equipment ..................................................................................................................................................5 1.11.2. De-energized tap-changer with driving mechanism ................................................................................................5 1.11.3. On-load tap-changer with motor-drive mechanism .................................................................................................5 1.12 Final air bleeding.............................................................................................................................................................5 2 ENERGIZATION .....................................................................................................................................................................5 2.1 Preparation for energization............................................................................................................................................6 2.2 Energization ....................................................................................................................................................................6 2.3 Shut down and re-energization of transformers with Inertaire or Sealedaire Oil Preservation System. ..........................6 2.4 Shut down and re-energization of transformers with COPS Oil Preservation System. ...................................................6 3 Appendix 1 Table of three-phase transformer connections....................................................................................................7 4 Revision ................................................................................................................................................................................10

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2005-01-05

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Document No.

1ZBA4601-216

Acceptance Testing and Energization

1

TRANSFORMER TESTING ON SITE AFTER ASSEMBLY After a transformer has been completely assembled on site, it must be tested to confirm successful shipment and correct assembly. All tests must be carried out with instruments that have traceable, valid calibration. These instructions are intended to provide guidelines in the test of transformers to maintain their quality and reliability. They are intended for the guidance of personnel who have been trained for, or who have experience in test of high-voltage electrical power equipment, including the use of good safety practices. These instructions are intended to supplement, and not eliminate the necessity for such training The test results are to be recorded on a Test Record, see Product Information 1ZBA 4601-217. The second sheet of this Test Record is a list of all possible tests, some of which may not be applicable. When the on-site project manager or the assembly supervision has marked all applicable tests, this sheet forms an order-bound directive for the tests to be carried out. After the assembly is completed, a Notice of Delivery is issued. The Notice of Delivery must be signed by both the assembly supervisor and by the Customer's representative. The Field Test Record and the Notice of Delivery are to be sent to the local ABB representative for further distribution. When the documentation is complete and the transformer/reactor has been completed to ABB’s satisfaction, the ABB Installation and/or Service department issues a Service Certificate. 1.1 Ratio test The ratio test is used to confirm that the winding turns ratio is consistent with the voltage ratio as shown on the Nameplate. This is done primarily to check for shipping damage and to confirm that any tap-changer leads installed in the field have been correctly connected. In addition to the ratio measurement, exciting current is also often measured. The ratio measurements is normally done with a ratio bridge. Table of three-phase transformer connections Appendix 1 1.2 Winding resistance test (this test is optional) Measure the resistance of each winding at the rated and extreme tap positions and compare the results to the original value in the Factory test report. If the Tap Changer connections have been made at site, measuring at all positions should be done. Resistance is dependent on the temperature of the winding. The mean temperature of the oil is representative of the winding temperature, and providing that the oil is at a uniform temperature, the top oil temperature gauge value can be used. Resistance comparison must always be made at a common temperature. The conversion formula for copper and aluminium windings is show below. The formula giving the relation between the resistance and the temperature is:

 K + T 2 RT 2 = RT 1 ×    K + T1  where

RT2 = Resistance of the winding at temperature T2 RT1 = Resistance of the winding at temperature T1 K = 234.5 for winding made of copper acc to IEEE, K = 235 for winding made of copper acc IEC K = 225.0 for winding made of aluminium

The time constant may be very long when low voltage and low current sources are used.

WARNING A high voltage surge occurs at interruption of DC current at end of measurements. A discharge circuit should be used. Eg. see IEEE Std 62 figure 2

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Acceptance Testing and Energization

1.3 Check of vector group (this test is optional) The purpose of this series of tests is to check the polarity and the phase relationship of the multiple windings in a transformer. The test is carried out simultaneously with the transformer turns ratio test when using a turns ratio test set. In order to define the connection of a three-phase transformer and to facilitate the parallel connection with other transformers, the international standards prescribe specific vector groups. Every country has its own designation for the vector groups. IEC and IEEE (in USA) have recommended a method that will result in standardized and fully defined designations. 1.4 Insulation resistance test Insulation resistance can give some information of the integrity of the insulation structure. As an insulation structure begins to deteriorate due to contamination and moisture, the insulation resistance will decrease. The test equipment used is a DC insulation tester (Megger). It is essential that it is of a type, which is suitable for measurement on transformers and transformer core insulation. Ensure that bushings are clean and dry. Insulation resistance is temperature dependence why it is important that the oil temperature is noted. After the test has been completed, all terminals shall be grounded time enough to allow any trapped charge to decay to negligible value 1.4.1. Transformer main windings When conducting an insulation resistance test on transformer windings, a 2.5 or a 5 kV megger can be used. Test every winding to ground and between each winding. Make sure that the bushing porcelains are cleaned since dirt deteriorates the insulation resistance. The transformer tank must be grounded during the test. If the insulation resistance is > 1 MΩ/kV system voltage for the winding, it is acceptable. If lower values are measured, this must be reported to an ABB representative. According to IEEE the following shall be measured. High voltage to low voltage and ground, low voltage to high voltage and ground. 1.4.2. Current transformers When insulation resistance testing a current transformer, a 500 or 1000 megger is used. Test every connection to the ground. The acceptable value is 10 MΩ. 1.4.3. Control circuit cabling and auxiliary power cabling When insulation resistance testing control circuit cables and supply cables, a 500 or 1000 V megger is used. The acceptable value is 10 MΩ. Test every connection to the ground. 1.4.4. Core to tank/core clamp When insulation-testing a transformer core a 1000 V megger is used. The testing time is 1 minute. Core to ground, core-clamp to ground and core to core-clamp shall be measured.

1.5

1.6

Capacitance and power factor or dissipation factor measurements This is optional test in accordance with IEC See Clause 10.10 of IEEE C57.12.90 – 1999 Check of tank ground circuit continuity

By means of a buzzer check the ground connection between the tank and turret(s), and between the tank and bushing flanges. 1.7 Polarity check of current transformers In order to make sure that the current transformer is in its correct position in relation to the bushing (conductor), a polarity check must be carried out. By checking the polarity in this manner we are also certain that the current transformer generates a secondary current. The ratio test and the magnetizing curve are not performed on site in conjunction with the transformer assembly. 1.8 Check of thermometers and thermostats Oil and temperature gauges must be tested with their associated control, alarm and trip circuitry. Register the test records and compare them with the set points on the circuit diagram. Perform functionality tests to confirm operation of the alarm/trip contacts. For analogue thermometers

Prepared By:

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Acceptance Testing and Energization

Open the both of the connections of the current transformer feeding the heating resistor of the winding temperature indicator, and measure the total heating resistance. Record the value in the test record and compare the result with the resistance in the Factory test report of the transformer. For digital thermometers: Check that the settings for winding temperature gradients and hot spot factor agrees with the values given in the factory test reports. 1.9

Oil tests

1.9.1. Check the oil level in:

Check of the oil level

- The transformer - The tap-changer - Any other separate compartments Check that all devices containing oil that must be completely filled have been purged of air. 1.9.2. Check of dielectric strength values The transformer's performance and longevity greatly depends on the quality of the oil that is used. Therefore the oil's dielectric strength is checked before the transformer is handed over. A sample is taken from the conservator and the transformer/reactor's bottom valve and in some cases even from separate coolers, etc. Since the value of the dielectric strength greatly depends on which type of electrodes being used, it is essential to record the information in the test report. The acceptable dielectric strength value is indicated in 1ZBA4601-213 1.9.3. Power factor (Optional) The power factor is a measure of the dielectric losses in the oil when used in an alternating electric field and of the energy dissipated as heat. A low power factor indicates low a-c dielectric losses. It can be useful as a means to see changes in quality resulting from contamination and deterioration in service or as a result of handling. The test should be made as per IEC 247 or ASTM D 924. For new oil that has never been in contact with the transformer, the power factor at 90°C or 100°C and 50 or 60 Hz shall not exceed 0.005. (0.5%) 1.9.4. Interfacial tension (Optional) This test has shown by practice to give a reliable indication of the presence of hydrophilic compounds. The test should be made as per ISO 6295 or ASTM D 971. For new oil that has never been in contact with the transformer the interfacial tension against water shall be ≥ 40 mN/m at 25 °C. 1.9.5. Sampling of oil for dissolved gas analysis by special request Sometimes customers require that an oil sample for a gas analyse shall be taken. There are special instructions regarding this test within the ABB group. If the analysis is conducted at another laboratory, other vessels and methods might be prescribed. 1.10 Operational test of supervisory equipment Transformers and reactors are provided with special equipment for supervision of operation, overloading, cooling and many other purposes. After installation has been completed and before the transformer or reactor is placed in service, all the accessory equipment is tested preferably in conjunction with the equipment with which it will be used in service. Individual testing is conducted using a buzzer that is connected to the appropriate terminals in the control cabinet. Prior to energizing, the Customer is obliged to perform complete commissioning tests, which include the functions of the entire system, to which the transformer is an integral part.

Prepared By:

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Date:

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Acceptance Testing and Energization

1.11

Operational test of other equipment

1.11.1. Cooling equipment Before the transformer is place in service, the rotation direction of the pumps and fans of the cooling equipment are checked. Furthermore, the tripping of the motor protection devices are checked as well as the signal that is activated for each tripped motor protection device. The rotation direction of the pump is checked according to the following: When the pump is filled with oil and has the correct rotation direction, only a slight purring sound is heard. If the pump wheel rotates in the wrong direction, a rattling sound will occur that is several times louder. If uncertainty prevails, shift the two phases on the motor so that it will run in the opposite direction. It will then be easy to determine which rotation direction is correct. Note that if the pump housing is only partially filled with oil, a rattling sound will also occur. The rotation direction of the fans is checked visually. The thermal over current protection relays of the fan motors are set according to the rated current that is stamped on the rating plate. The relays for the pump motors are set according to what is stated on the list of apparatus. The thermal over current protection relays of the motors are tripped by a 2-phase connection of each motor. The signal of the tripped motor protection device is checked by means of a buzzer to the appropriate terminals in the control cabinet. Verify that shipping plugs, if applicable, have been removed from the motors. 1.11.2.

De-energized tap-changer with driving mechanism

At the end of the assembly and before being put into service, the de-energized tap-changer and the drive mechanism are checked. Operate the tap-changer to its end positions. Then check the drive mechanism’s locking device. Check that the contacts on the drive mechanism and its interlocking device connect and disconnect before the lock in the locking device is completely released. 1.11.3. On-load tap-changer with motor-drive mechanism If the transformer is fitted with an on-load tap-changer, then the tap-changer and the motor drive mechanism are tested before the transformer is put into service. The following checks should be done: All the external shafts have been lubricated The local/remote control is functioning correctly The heater in the drive mechanism is working The pressure relay operates adequately to the pressure setting The motor protection is adjusted to the current that is stated on the motor’s rating plate. The drive mechanism indicates the same position as the tap-changer. The drive mechanism has been operated through all positions manually (with the hand crank) and electrically in ascending and descending positions. The mechanical stops at extreme positions are working properly The interlocking switch for the mounted hand crank is working properly For the details on how to perform the above tests, refer to the appropriate tap-changer product information in the instruction manual. 1.12 Final air bleeding After all the tests have been carried out, the transformer and every separate compartment, including radiator banks, etc., is purged of air through the appropriate bleeding valves.

2

ENERGIZATION Prior to energization, the transformer should be visually inspected and the following items checked:

Prepared By:

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Date:

Approved By:

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Acceptance Testing and Energization

2.1 Preparation for energization Prior to energizing verify the following: a) b) c) d) e) f) g)

The oil level in the oil filled compartments The drying agent and the oil level in the dehydrating breather Check that all valves are set at the right position Check that the transformer, the control cabinet and all accessories are cleaned and touch up painted if needed Check that the heating element in the control cabinet is connected and in operation Check that the gas-operated relay is purged of air Check possible leakage. If the transformer has been stored more than two months after the assembly, all sealing joints must be retightened h) Check that connections to lines, bus-bars and earth are properly made i) Check that the distances between phases and phase to earth are sufficient j) Check that the covers are installed on the test taps and/or potential taps (if no potential device is connected) of the bushings to assure proper grounding of the taps. k) All temporary protective grounds have been removed from conductors. l) All protective and alarm circuits are operational and placed into service before the transformer is energized. m) Get confirmation that all installation procedures have been completed successfully. n) Get confirmation that there are no current transformer secondary open circuits. o) Set the cooling controls for automatic operation. p) The control selector-switch for the on-load tap changer in the control cabinet is set on REMOTE position. The transformer is ready for service upon the successful conclusion of the tests and completion of the set time. 2.2 Energization If possible the transformer should be energized in such a way that the voltage is increased step by step up to the rated voltage. This may be done by connecting the transformer to a generator by which the voltage is slowly increased. The higher the rated voltage, the more important to energize the transformer as described. If it is not possible to use a generator, the transformer may be connected directly to a live transmission line at no load. After energizing, the transformer has to be kept under careful observation for the first 12 hours. Check and record the oil temperature, the winding temperature, its instrumentation, the tank pressure (if applicable) and ambient temperature. Watch particularly for any sudden changes. When the transformer is successively loaded, observe carefully the transformer for a few hours, especially the temperature gauges and the gas relay. The observation should continue on a daily schedule for seven days and then weekly for the first month of operation. An oil sample should be taken after the first and twelfth month of operation for Gas-In-Oil Analysis. The results of these two analyses should be sent to the ABB representative as soon as they are known. This analysis should then be repeated annually. When the transformer has been in service at normal working temperatures for some weeks, all sealing joints have to be retightened. 2.3 Shut down and re-energization of transformers with Inertaire or Sealedaire Oil Preservation System. When you de-energize the transformer and plan to have it out of service for any reason, no special start-up/shut-down provisions are needed unless the transformer is provided with oil pumps. For FOA transformers follow this procedure: De-energize the transformer. Run one half of the pumps until the unit reaches temperature equilibrium with the ambient. Do not run any of the cooling fans during this cool-down cycle. This procedure moves the oil past the interface with the gas blanket to speed up the release of nitrogen from the oil. Running just one half of the pumps will reduce the static charge build up and not running the fans prevents too rapid cooling. Starting up after Shut Down Run one half of the pumps for 15 minutes to one hour and then de-energize these pumps and run the other half of the pumps for 15 minutes to one hour. This will dislodge any pockets of nitrogen in the oil and move the gas past the oil to gas blanket interface. Do not run both sets of pumps at one time because this may cause static charge buildup. Within twelve hours after running the second set of pumps, energize the transformer and set the cooling controls for automatic operation. This will allow the cooling to be initiated as required by the increasing winding temperature. 2.4 Shut down and re-energization of transformers with COPS Oil Preservation System. Transformers equipped with COPS oil preservation systems do not require the special shut down and start up procedures because there is no gas blanket on the transformer.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2005-01-05

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Lang:

1998-04-30

Rev. No:

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Acceptance Testing and Energization

3

Appendix 1 Table of three-phase transformer connections Note.

This table was based on the manual for Tettex Turn Ratio Meter 2791 Vector Ratio Indication HV-side LV-side Diagram group on meter u–n v–n w–n

YN-yn-0

U–N V–N W-N

YN-y-0

U–N V–N W-N

Y-yn-0

U – (V-W) V – (W-U) W – (U-V)

Y-y-0

U – (V-W) V – (W-U) W – (U-V)

u – (v-w) v – (w-u) w – (u-v)

YN-yn-6

U–N V–N W-N

n-u n-v n-w

YN-y-6

U–N V–N W-N

(v-w) - u (w-u) - v (u-v) - w

Y-yn-6

U – (V-W) V – (W-U) W – (U-V)

n-u n-v n–w

Y-y-6

U – (V-W) V – (W-U) W – (U-V)

(v-w) - u (w-u) - v (u-v) - w

D–d-0

U–V V–W W-U

u–v v–w w-u

D–d-2

U–V V–W W-U

w–v u–w v-u

D–d-4

U–V V–W W-U

w–u u–v v-w

u

U

n

N W

w

V

u

U

u – (v-w) v – (w-u) w – (u-v)

RN

v

N W

u–n v–n w–n

w

V

v

u

RN/1.5

U N

w

W

v

u

V

1.5* RN

u

w

v

w

U

w

v N

W

n

V

U

RN

v

RN

u

v

w

N W

V

u

RN /1.5

u

w

v

w

n

v

1.5* RN

u

v

u w

w u

v

RN

uu

U

w w

W

vv

V

RN

w

U W

u

v

V

U

RN

W

W

V

V

U

RN

Table of three-phase transformer connections Page 1 of 3

Prepared By:

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Acceptance Testing and Energization

Vector group D–d-6

D–d-8

HV-side

LV-side

U–V V–W W-U

v–u w–v u-v

U–V V–W W-U

v–w w–u u-v

U–V V–W W-U

u–w v–u w-v

U–N V–N W-N

u–v v–w w-u

U – (V – W) V – (W – U) W – (U – V)

u–v v–w w-u

U–N V–N W-N

w–u u–v v-w

U – (V – W) V – (W – U) W – (U – V)

w–u u–v v-w

U–N V–N W-N

v–u w–v u-w

U – (V – W) V – (W – U) W – (U – V)

v–u w–v u-w

U–N V–N W-N

u–w v–u w-v

U – (V – W) V – (W – U) W – (U – V)

u–w v–u w-v

U–V V–W W-U

n–v n–w n-u

U–V V–W W-U

(w – u) – V (u – v) – w (v – w) - u

V

U W

W

V

RN

U

U W

V

U V

D – d - 10

W

V

V

W

RN

U

u w

N W

v

V

u

RN

u

w

YN – d - 5

RN

U

U W

YN – d - 1

Y–d-1

Ratio Indication on meter

Diagram

w

v

v

U

1.5 * RN

W N

W

V

RN

U

V

Y–d-5 u

W

w

V

v

1.5 * RN

U

YN – d - 7 V

U N W

Y–d-7

u w

W

RN

W

1.5 * RN

U

V

V v

U

YN – d - 11 U W

Y – d - 11

Prepared By:

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V

RN

W

V

u

U

w

D – yn - 1

D–y-1

U N

V

v

U

W

U n

W

W V

RN

V

U W V

Rev. No:

D

1.5 * RN

U

W

RN/1.5 V

Page No:

Page 8 of 10

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Acceptance Testing and Energization

Vector group

HV-side

LV-side

D – yn - 5

U–V V–W W-U

n–u n–v n-w

D–y-5

U–V V–W W-U

(v –w) – u (w – u) – v (u – v) - w

D – yn - 7

U–V V–W W-U

v–n w–n u-n

D–y-7

U–V V–W W-U

v – (w – u) w – (u – v) u – (v –w)

D – yn - 11

U–V V–W W-U

u–n v–n w-n

D – y - 11

U–V V–W W-U

u – (v - w) v - (w – u) w – (u – v)

Ratio Indication on meter

Diagram w

v

U

n

W V

RN

u

v

U

w

W V

u

U

v

W V

u

RN/1.5

n w

RN

w

RN/1.5

v

U W V

u

u

U W

n

V

w

U

v

u

W V

RN

w

v

RN/1.5

Legend: RN = nominal ratio per limb. For definition of Vector group see IEC 60076-1 and 60616, also VDE 0532 part 4.

Marking on the transformer terminal Comparison between IEC/VDE and ANSI/IEEE standards

High-Voltage side of test object IEC/VDE ANSI/IEEE u H1 v H2 w H3 N H0

Low-Voltage side of test object IEC/VDE ANSI/IEEE u X1 v X2 w X3 n X0

Prepared By:

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4

Revision A: B: C: D:

1998-04-30 2003-05-30 2003-08-11 2005-01-05

new Format changes in P 1 change of table in Appendix 1. Removal of insulation value in 1.4.4

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should be communicated to ABB Power Transformers

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PowerIT Transformers and Reactors Field Test Record Table of contents FIE LD TEST RECORD ......................................................................................................................................................... 2 Ratio test ................................................................................................................................................................................ 3 2.1 Ratio when Ratio Bridge is used. ................................................................................................................................... 3 2.2 OLTC when Voltmeter method is used........................................................................................................................... 4 2.2.1. DETC...................................................................................................................................................................... 5 3 Resistance ............................................................................................................................................................................. 5 4 Check of vector group if Voltmeter method is used................................................................................................................ 6 5 Insulation Resistance test ...................................................................................................................................................... 7 5.1 Windings......................................................................................................................................................................... 7 5.2 Current Transformers ..................................................................................................................................................... 7 5.3 Control-circuit cabling and auxiliary power cabling......................................................................................................... 8 5.4 Core ............................................................................................................................................................................... 8 6 Check of potential connection between tank and turret.......................................................................................................... 8 7 Polarity check of Current Transformers.................................................................................................................................. 8 8 Check of winding temperature circuits.................................................................................................................................... 8 9 Oil test .................................................................................................................................................................................... 9 10 Operational test of supervisory equipment ........................................................................................................................... 10 10 Operational Test of other equipment .................................................................................................................................... 13 10.1 Coolers ..................................................................................................................................................................... 13 10.2 De-energized tap changer with driving mechanism.................................................................................................. 13 10.3 On-load tap-changer with motor drive mechanism ................................................................................................... 13 1 2

1

FIE LD TEST RECORD

Order No Serial No

Transformer type Serial No

Tap-changer type Motor-drive mechanism type

Serial No

Test 1

Ratio test

1.1

OLTC

1.2

DETC

2

Yes

Resistance

3

Check of vector group

4

Insulation Resistance test

4.1

Windings

4.2

Current Transformers

4.3

Control-circuit cabling and auxiliary power cabling

4.4

Core

5

Check of potential connection between tank and turret

6

Polarity check of Current Transformers

7

Check of winding temperature circuits Dew point measurements

8

Oil test

9

Operational test of supervisory equipment

10

Operational Test of other equipment

10.1

Coolers

10.2

De-energized tap changer with driving mechanism

10.3

On-load tap-changer with motor drive mechanism

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 2 of 15

Title:

Field Test Record

No

2

Ratio test Ratio when Ratio Bridge is used.

2.1

Ratio measurements First Terminals: Second Terminals: Phase displacement:

Tap position st nd 1 2 Term. Term.

Serial no…………………… Nominal

Rated voltage [kV]

Confirmed

Measured ratio and excitation current / / / 1) MA Ratio mA Ratio mA Ratio

Calculated ratio with multiplier

Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By…………………. 1)

When aviable in used Instrument. Termial used shall be indicated

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 3 of 15

Title:

Field Test Record

Max. difference %

2.2

Tap changer Position

OLTC when Voltmeter method is used and 3 phase power supply Magnetizing on ___-kV side [V]

No load current [mA]

U-measured on ___kV side

a-b [V]

a-c [V]

Calculated voltage

b-c [V]

a- b-c [V]

U-measured on ___kV side

a-b [V]

a-c [V]

b-c [V]

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By………………….

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 4 of 15

Title:

Field Test Record

Calculated voltage

a-b-c (V)

Max. difference %

2.2.1. Tap changer position

Magnetizing on ___-kV side [V]

DETC No load current [A]

U-measured on ___kV side

a-b [V]

a-c [V]

Calculated voltage

b-c [V]

a- b-c [V]

U-measured on ___kV side

a-b [V]

a-c [V]

Calculat ed voltage a-b-c [V)

Max. difference %

b-c [V]

1 2 3 4 5 6 7 Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By………………….

3

Resistance

Tap changer position

Terminal to Terminal Resistance [mς /]

Terminal to Terminal Resistance [mς] /

Terminal to Terminal Resistance [mς] /

Average Single Phase Resistance [mς]

Oil temperature..............°C Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By………………….

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 5 of 15

Title:

Field Test Record

Average Single Phase Resistance [mς] corrected to …..°C

4

Check of vector group if Voltmeter method is used

Connect A with

a

Magnetized on

kV side _____________

Measured voltage U between Bb [V]

Cc [V]

Connect A with

AB [V]

Bc [V]

Cb [V]

Connection

Bc [V]

Cb [V]

Connection

a

Magnetized on

kV side _____________

Measured voltage U between Bb [V]

Cc [V]

Instrument used in test

AB [V]

Type

Range

The vector group corresponds with connection diagram No

Remarks

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 6 of 15

Title:

Field Test Record

Serial Number

5

Insulation Resistance test Windings

5.1

Megger st

1 Terminals……………

kV

Note Maximum 5kV megger 2

nd

1 Minute[MΩ Ω]

Terminals……………

10 Minutes [MΩ Ω]

Weather conditions:______________________________________________________ Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By………………….

Current Transformers

5.2

Megger___________ V Note Maximum 1kV megger

LOCATION

[MΩ Ω]

TERMINAL

TO EARTH [MΩ Ω]

Weather conditions: ______________________________________________________ Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By………………….

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 7 of 15

Title:

Field Test Record

Control-circuit cabling and auxiliary power cabling

5.3

Megger_______ V Note Maximum 1kV megger Type_______________ Serial no________________

Cables to earth (min value) ________________ [MΩ Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By………………….

Core

5.4

Megger_______ V Note Maximum 1kV megger Type_______________ Serial no________________

Core - earth Core Clamp -earth Core Clamps-Core

________________ [MΩ] ________________ [MΩ] ________________ [MΩ]

Weather conditions: ________________________________________________________ Measuring instrument type…………………………………………… Measuring instrument serial no. ……………………………………… Last calibration date……….month………year……….Next calibration date………month………….year…… Measurement performed Place……………….Date………………….By………………….

REMARKS:

________________________________________________________

_________________________________________________________________ 6

Check of potential connection between tank and turret The potential connection between tank and turret has been checked with buzzer

! ! 7

yes no

Polarity check of Current Transformers Check of Current Transformers according to diagram No _______________________________ Location/terminal Location/terminal

8

Location/terminal Location/terminal

Location/terminal Location/terminal

Check of winding temperature circuits Current transformer for Location

Location

Location

Measured resistance for: Current transformer

[Ω]

[Ω]

[Ω]

Instrument

[Ω]

[Ω

[Ω]

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 8 of 15

Title:

Field Test Record

9

Oil test The oil level checked in

Date

!

Transformer reactor

!

Tap-changer/diverter switch

_

!

Other separate compartments

_

!

The oil system has been de aired

_

Oil samples are taken from Oil conservator Transformer/reactor tank Cooling group No Cooling group No Cooling group No

Cooling group No Oil test equipment type

Breakdown voltage Breakdown voltage Breakdown voltage Breakdown voltage Breakdown voltage Breakdown voltage with

[kV] [kV] [kV] [kV] [kV] [kV] electrodes

mm

Electrode distance

Oil samples for dissolved gas analysis have been taken REMARKS

_ _____________________________________________________

_______________________________________________________________________

_______________________________________________________________________

__________________________

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

_____________

Rev. No:

C

Page No:

Page 9 of 15

Title:

Field Test Record

10 Operational test of supervisory equipment Alarm circuit tested to Control circuit Control room No/OK No/OK

Trip circuit tested to Control circuit Breaker No/OK No/OK

Gas detector relay transformer Gas detector relay tap changer Oil level indicator tap changer High Low Oil level indicator transformer High Low Pressure relief valve for transformer Pressure relay for transformer Pressure relay for tap changer Flow indicators for coolers Cooler group 1 min oil flow max. oil flow min water flow max. water flow Cooler group 2 min oil flow max. oil flow min water flow max. water flow Cooler group 3 min oil flow max. oil flow min water flow max. water flow Manometers for coolers Cooler group 1 min oil pressure max. oil pressure min water max. water Cooler group 2 min oil pressure max. oil pressure min water max. water Cooler group 3 min oil pressure max. oil pressure min water max. water

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 10 of 15

Title:

Field Test Record

Alarm circuit tested to Control circuit Control room Cabinet No/OK No/OK

Trip circuit tested to Control circuit Breaker Cabinet No/OK No/OK

Thermometer for top oil Set for alarm Deg C Set for trip Deg C Set for start of Cooler group 1 Deg C Cooler group 2 Deg C Cooler group 3 Deg C Cooler group 4 Deg C Cooler group 5 Deg C Cooler group 6 Deg C Thermometer for kV winding Set for alarm Deg C Set for trip Deg C Set for start of Cooler group 1 Deg C Cooler group 2 Deg C Cooler group 3 Deg C Cooler group 4 Deg C Cooler group 5 Deg C Cooler group 6 Deg C Thermometer for kV winding Set for alarm Deg C Set for trip Deg C Set for start of Cooler group 1 Deg C Cooler group 2 Deg C Cooler group 3 Deg C Cooler group 4 Deg C Cooler group 5 Deg C Cooler group 6 Deg C

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 11 of 15

Title:

Field Test Record

Alarm circuit tested to Control circuit Cabinet No/OK Thermometer for Set for alarm

kV winding Deg C

Set for trip

Deg C

Control room No/OK

Trip circuit tested to Control circuit Cabinet No/OK

Set for start of Cooler group 1

Deg C

Cooler group 2

Deg C

Cooler group 3

Deg C

Cooler group 4

Deg C

Cooler group 5

Deg C

Cooler group 6

Deg C

Thermometer for

kV winding

Set for alarm

Deg C

Set for trip

Deg C

Set for start of Cooler group 1

Deg C

Cooler group 2

Deg C

Cooler group 3

Deg C

Cooler group 4

Deg C

Cooler group 5

Deg C

Cooler group 6

Deg C

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 12 of 15

Title:

Field Test Record

Breaker No/OK

10

Operational Test of other equipment Coolers 1. Pump rotation direction checked _______

10.1

2. Fans rotation direction checked _______ 3. Over current protection tripped at 2-phase connection: _______ After (sec.)

Fan No

Current setting [A]

After (sec)

Pump No

Current setting [A]

1 2 3 4 5 7 8 9 10 11 12 Alarm obtained for tripped current protection at terminals

_____________in the control cabinet.

De-energized tap changer with driving mechanism Contact movement The Tap changer was operated from end to end positions ___________________

10.2

The interlocking device of the driving mechanism checked. Alarm obtained when the driving mechanism was operated 10.3

terminal No

in the control cabinet.

On-load tap-changer with motor drive mechanism

The position indicators in motor drive mechanism and tap changer indicate the same position Shaft coupling lubricated with grease Gear box filled with lubricant to correct level Motor drive mechanism checked and test run lubricated end position contacts local/remote control interlocking switch manually and with the crank assembled setting of motor protection tripping time for blocked motor pressure relay tested heating element connected and In operation

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 13 of 15

Title:

Field Test Record

Remarks:

Tested and witnessed by

----------------------------------------

----------------------------------------

ABB

Customer

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 14 of 15

Title:

Field Test Record

Revision A: B: C:

1998-04-30 2003-05-30 2003-08-11

new Format p2, Instrument info added

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should comunicated to: ABB Power Transformers acording to contact list in Aspect Viewer

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form. Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-217

Rev. No:

C

Page No:

Page 15 of 15

Title:

Field Test Record

PowerIT Transformers and Reactors OIL CONSERVATORS WITH AIR CELL

Table of contents 1

General ..................................................................................................................................................................2 1.1 1.2

Design ............................................................................................................................................................2 With tap-changer conservator ........................................................................................................................2

2

Leakage test of air cell...........................................................................................................................................2

3

Replacing an air cell ..............................................................................................................................................3

4

Oil filling .................................................................................................................................................................3 4.1

5

Vacuum oil filling of conservator ....................................................................................................................3

Revision .................................................................................................................................................................3

1

General This procedure is for transformers equipped with oil conservators (expansion tanks) with an air cell, which prevents contact between the oxygen in the air and the transformer oil. The conservator is a reservoir, which takes up the expanded volume of the oil of a transformer or reactor tank. The volume of the conservator depends on the tank volume and the total oil temperature range.

1.1

Design A nameplate Oil Level Indicator Plate is used to indicate the filling level depending on the ambient temperature. Some conservators are designed to withstand vacuum. This is indicated on the Oil Level Indicator Plate Those not designed to withstand vacuum will have a vacuum proof valve between the conservator and the main tank. . If the Oil Level Indication Plate is missing please look for te information in the drawings All conservators have a level indicator. The divisions on the indicator dial may be calibrated to correspond to each 10% of the conservator volume or may be calibrated in degrees C to provide a general guide for estimating volume. The connection between the float mechanism and the dial indicator is magnetic. The level indicator is mounted under the conservator at 45° and the float moves vertically along the length of the conservator. The air cell is like a balloon that fits the shape of the inside of the conservator and floats over the oil as the level rise. The air inside the cell is isolated from the conservator through a flange at the top center of both the conservator and the air cell. This flange is connected to a Breather to avoid humidity condensation inside the cell and the possible formation of ice in cold weather conditions. When the conservator is vacuum proof, an extra flange is added next to the air cell flange and a U shaped pipe is supplied for interconnecting them temporarily during oil filling. This is to ensure that during the filling operation the pressure will be the same inside and outside the air cell. There are two pipe connections at the bottom of the conservator. The center one goes to the main tank and extends 50mm inside the conservator to prevent any dirt from entering the main tank. The second pipe with a valve is used for draining.

1.2

With tap-changer conservator The tap-changer conservator is an extension to the main conservator but completely separated from it with an endplate. These conservators have three pipe connections. Generally the center one goes to the tank. This pipe extends 50 mm inside the conservator to prevent any dirt from entering. The second pipe with a valve is for draining. The third connects the conservator to the Breather. The latter pipe extends inside the conservator all the way to the top. The length of this conservator is function of the oil volume in the tap-changer. In order to ensure that the level of the oil will always be lower than the main conservator, the volume is calculated to be larger than the minimum required.

Filling level is indicated on the Oil Level Indicator Plate.

2

Leakage test of air cell The air cell is shipped from the Factory with a positive pressure. This pressure is confirmed at site.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-219

Rev. No:

D

Page No:

Page 2 of 4

Title:

Oil Conservators with Air Cell

3

Replacing an air cell For fitting of, or replacing an air cell the following procedure is followed: − − − −

4

A simple tool consisting of two threaded rods (M12 or 1/2” UNC) are needed. Insert the rods through the holes of the air cell flange welded on top of the conservator for a length of 300mm using two nuts as stoppers. Enter the conservator through the manhole and threads the rods into the air cell flange after putting the gasket in place. Go back on top of the conservator, pulls the threaded rods up and secures two of the flange bolts. The rods are then removed and the other two bolts are fixed. Two hangers on either side of the air cell flange need to be attached to brackets inside the conservator.

Oil filling Oil filling is described in 1ZBA 4601-214 for transformers with a System Voltage less than 200 kV, shipped with oil, for others see 1ZBA 4601-215. Observe the following. When during oil filling, the oil level reaches 100 mm below the transformer tank cover, close the oil valve, break the vacuum, disconnect the plastic hose and open the valve to the conservator. Put 10 kPa or 1.5 psi air pressure in the air cell and open the two air bleeder valves on top of the conservator. Open the oil valve and pump oil at reduced (max. 1800 l / hr or 500 gal./hr) until the oil starts coming out both bleeding valves. Close both bleeder valves and remove the pressure from the air cell simultaneously. Continue pumping until the proper level is reached as specified on the nameplate. Disconnect all equipment and connect the air cell to the Breather.

4.1

Vacuum oil filling of conservator Remove the pipe connecting the conservator to the Breather and replace temporarily with a valve (not included, recommended 1” ball -valve). Keep it closed. Remove the vacuum valve on the air cell flange and connect the two flanges on top of conservator using the U flanged pipe supplied. Follow oil filling instruction in 1ZBA 4601-215. After filling remove the U shaped pipe and install the valve and a low pressure regulator suitable for 10 kPa on the air cell flange. Close the second flange with a cover and gasket. Put 10 kPa or 1.5 psi air pressure in the air cell. Open the oil valve at reduced flow (max. 1800 l / hr or 500 gal./hr) and pump oil until the oil starts coming out from both bleeder valves. Close both bleeder valves and remove the pressure from the air cell simultaneously. Continue pumping until the proper level is reached as specified on the nameplate. Disconnect all equipment and connect the air cell to the Breather. It is important for any type of tap-changer, to pull vacuum in the tap-changer and the main tank simultaneously (selector switch for outside TP and diverter switch for inner TP). This is to prevent excessive stresses on the partitions separating the device and the tank.

5

Revision A: B: C: D:

2001-02 2003-05-30 2003-08-11 2003-10-10

new Format Oil Level Indicator plate Revision of text in 4.1

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-219

Rev. No:

D

Page No:

Page 3 of 4

Title:

Oil Conservators with Air Cell

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein.

ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should comunicated to: ABB Power Transformers acording to contact list in Aspect Viewer

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form. Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-08-11

Applicability:

TrafoStar

Lang:

1998-04-30 en

Document No.

1ZBA4601-219

Rev. No:

D

Page No:

Page 4 of 4

Title:

Oil Conservators with Air Cell

PowerIT Transformers and Reactors SUPERVISION OF TRANSFORMERS AND REACTORS

Table of contents General ....................................................................................................................................... 2 Safety definitions.......................................................................................................................... 2 GENERAL MAINTENANCE ............................................................................................................... 2 3.1 Dirt, dust .............................................................................................................................. 2 3.2 Possible oil leakage ................................................................................................................. 2 3.3 Rust damages, touch-up painting ............................................................................................ 2 3.4 Oil-level indicator for oil conservator ......................................................................................... 2 3.5 Gas-operated relay ................................................................................................................. 3 3.6 Venting ................................................................................................................................. 3 3.7 Sudden pressure relief valve .................................................................................................... 3 4 OIL............................................................................................................................................. 3 4.1 Gas in oil analysis ................................................................................................................... 3 4.2 Oil analysis ............................................................................................................................ 3 4.2.1. Moisture.......................................................................................................................... 3 4.2.2. Sludge, acid..................................................................................................................... 3 5 TEMPERATURE SUPERVISION ......................................................................................................... 4 5.1 Overload ............................................................................................................................... 4 5.2 Thermometer for measuring of top-oil temperature. .................................................................... 4 5.3 Winding temperature indicator.................................................................................................. 4 5.4 Remote temperature indication ................................................................................................. 4 6 COOLING EQUIPMENT ................................................................................................................... 4 6.1 Air-side (Radiators, oil-air coolers) ............................................................................................ 4 6.2 Oil-side (Radiators, coolers for oil-air, oil-water) ......................................................................... 4 6.3 Water side (Coolers for oil-water) ............................................................................................. 5 6.4 Fans ..................................................................................................................................... 5 6.5 Flow-indicators, pressure meters .............................................................................................. 5 7 CONTROL CABINET ....................................................................................................................... 5 8 BUSHINGS................................................................................................................................... 5 9 CONNECTIONS ............................................................................................................................. 5 10 DE-ENERGISED TAP-CHANGERS (DETC) ....................................................................................... 5 11 ON-LOAD TAP-CHANGERS (OLTC) ................................................................................................ 5 12 RE-TIGHTENING ........................................................................................................................ 6 12.1 Hexagon head bolt, M-thread. Property class 8.8. ...................................................................... 6 12.2 Stud, M-thread. Property class 5.8 ......................................................................................... 6 1 2 3

1

General

In order to avoid faults and disturbances, it is important that a careful and regular supervision and control of the transformer and its components is planned and carried out. The frequency and extent of such a supervision and control depend on climate, environment and service conditions etc. The directions for a certain transformer are therefore preferably based on experiences from comparable transformer installations. Spare transformers are supervised and maintained according to the same schedule as transformers in service.

2

Safety definitions

Safety notations are intended to alert personnel of possible personal injury, death, or property damage. They have been inserted in the instructional text prior to the step in which the condition is cited. The safety notations are headed by one of three hazard intensity levels, which are defined as follows: DANGER - immediate hazard that will result in severe personal injury, death, or property damage; WARNING - hazard or unsafe practice that could result in severe personal injury, death, or property damage; CAUTION - hazard or unsafe practice that could result in minor personal injury or property damage.

CAUTION All of the openings in the transformer tank and the tap changer compartment or other oil-filled compartments must be tightly closed and sealed before the transformer is placed into operation Failure to seal the opening will allow oil leaks and will allow air and moisture to enter the transformer. This will cause deterioration of the insulating oil and may cause an electrical failure.

3

GENERAL MAINTENANCE 3.1

Dirt, dust

The external transformer surfaces shall be inspected regularly; and when required cleaned from dust, insects, leaves and other airborne dirt.

3.2

Possible oil leakage

After energizing a certain setting may appear in sealing joints. They should therefore be retightened after the transformer has been in operation for about a month and thereupon when needed. This applies especially to sealing joints with plain gaskets that are not placed in grooves. It should be noted that gaskets of cork-rubber type are difficult to retighten once they have started to leak.

3.3 Rust damages, touch-up painting A regular inspection of the external surface treatment of the transformer should be carried out. Possible rust is removed and the surface treatment restored to original state by means of the primer and finish-paints that are dispatched with the transformer. If requested ABB can supply additional paint in original colour. It may happen that the drying agent gets a slight light brown colour at the top of the drier. It can either be caused by a leak in the connection tubes to the conservator or too high moisture content in the transformer. The joints in the connection tube should then be checked and an oil sample should be extracted for moisture check. 3.4

Oil-level indicator for oil conservator

The oil conservator is provided with an oil-level indicator. The correct oil-filling level is specified on an information plate. The indicator has alarm contacts for low and high. On alarm, the cause shall be established and measures made to reach a correct oil level.

Prepared By:

L Ostman

Date:

Approved By:

Thomas Fogelberg

Date:

Applicability:

TrafoStar

Lang:

2004-03-03

Rev. No:

en

Title:

-

Document No.

1ZBA 4601-222

Page No:

Page 2 of 7

Supervision of Transformers

3.5

Gas-operated relay

The use of a gas-operated relay as protection for oil-immersed transformers is based on the fact that faults as flashovers, short-circuits and local overheating normally result in gas-generation. The gas-bubbles gathering in the gas-operated relay affect a float-controlled contact, which gives an alarm signal. The gas relay installed in the main tube to the conservator is also equipped with a sensor for high oil speed in the tube. The signal from that sensor should be connected for immediate trip of the transformer. The cause of a high oil speed is often a serious problem in the transformer, e.g. a flashover. Contact ABB for rules for sampling and evaluation of the properties of the gas collected. Information about the gas relay functions are given in separate instructions.

3.6

Venting

Certain transformers are provided with air venting valves on components positioned high up in order to drain possibly trapped air in the oil system. Trapped air should be checked for after the installation of the transformer, or an inspection that implies opening of the oil system.

3.7

Sudden pressure relief valve

Some transformers are equipped with a sudden pressure relief valve, which opens for a given overpressure in the tank. For detail description, see specific product information

4

OIL 4.1

Gas in oil analysis

Regular gas in oil analysis is recommended. The interval between consecutive analysis may vary depending on type of transformer, its location in the network/industry, etc. As a guiding value gas in oil analysis once a year is recommended.

4.2

Oil analysis

In addition to gas in oil analysis, a more or less complete chemical analysis of the oil is recommended. Within ABB Transformers there is a distinction between large and small analysis. The small test covers: − Colour − Visual inspection − Moisture content − Dielectric breakdown withstand − Neutralisation number The large test covers four more tests in addition the above: − Inhibitor content established (GC-method) − Power factor, tan delta, depending on the situation − Interfacial tension − PCB Content These tests are in addition to the conventional gas in oil analysis. Such tests are recommended when gas in oil analysis has given indication of nonconformance of the transformer. ABB Transformers is prepared to give advice on investigations to be carried out. As a guiding value, oil analysis should be done about once every fifth year if not otherwise necessary depending on the outcome of other tests.

4.2.1.

Moisture

Some build-up of water content is inevitable, due to the aging processes. The oil may also have been subjected to moist air. The moisture content and the dielectric withstands of the oil shall be checked as part of the small and large test or whenever there is a suspicion that oil been exposed to humidity.

4.2.2.

Sludge, acid

Normally the transformers and reactors from ABB are filled with inhibited oil if customer has not specified differently. The inhibitor works as an antioxidant (a preserving agent). When the oil is aging, sludge and acid products develop. The inhibitor retards the ageing process and extends the utilisation time of the oil. When this occurs the oil shall be analysed and the neutralisation number and the remaining inhibitor content shall be determined. The oil should be replaced or regenerated, if the neutralisation number is larger than 0,1 to 0,15 mg potassium hydro oxide (KOH) per gram oil in inhibited oil, (alternatively larger than 0,2 mgKOH/g in non-inhibited Prepared By:

L Ostman

Date:

Approved By:

Thomas Fogelberg

Date:

Applicability:

TrafoStar

Lang:

2004-03-03

Rev. No:

en

Title:

-

Document No.

1ZBA 4601-222

Page No:

Page 3 of 7

Supervision of Transformers

oil) and/or an inhibitor content less than 0,1%. Larger values on neutralisation number or less inhibitor content than stated here will accelerate the ageing. The exchange of oil should be as complete as possible, because old oil will infect the new one and thus speed up the ageing process. The exchange should preferably be carried out when the oil is warm and the oil viscosity is low. In inhibited oil where only the inhibitor content has decreased the addition of new inhibitor is a possible option. Oil not too far oxidised may be regenerated. Before any measures are carried out, consultation with ABB is recommended.

5

TEMPERATURE SUPERVISION

The service life of a transformer depends to a great extent on the temperatures in the core and windings during operation. It is thus important to keep the oil and winding temperatures under continuous observation. The temperatures should be read regularly and the measured values registered. These values will give guidance for judging of the service life of the transformer, cooling system functions etc.

5.1

Overload

A transformer can normally be overloaded at low ambient temperatures. However, the permissible overload must not be judged only with regard to the oil temperature. The winding absolute temperature has to be considered together with permissible current loading of accessories like bushings and tap-changer. For determination of the overload capacity for modern transformers we refer to applicable IEC Standard. If the temperature in a transformer shows a tendency to rise without a corresponding increase of the load, there may be a reduction of the ability of the cooling equipment due to dirt and dust. However, the thermometers should be checked first.

5.2

Thermometer for measuring of top-oil temperature.

For the description of function and adjustment of the thermometer, see separate product information. The instruction gives also advice on adjustments of temperature levels for signals and control of cooling equipment. Applicable values for a specific transformer are stated in the transformer manual.

5.3

Winding temperature indicator

The thermometer system has a sensor, temperature signal transmission and display system similar to the oil thermometer. The measured oil temperature is "adjusted" by a temperature increase corresponding to the temperature difference between the oil and the winding conductor. This temperature increase is obtained by a heating element carrying a current proportional to the winding current. A separate current transformer in the winding circuit will provide the current. An adjustable shunt resistor in the current transformer heating element circuit facilitates the calibration of the thermometer to display a correct winding temperature. The calibration is normally based on the outcome of a heat run test. The heating element and the shunt element may be located in the display instrument or at the sensor body in the thermometer pocket. For further information and calibration see separate product information on the winding thermometer. It will also give information on signal settings from the thermometer and advice on cooler starts.

5.4

Remote temperature indication

. For information and calibration see user’s manual for the transformer.

6

COOLING EQUIPMENT 6.1

Air-side (Radiators, oil-air coolers)

The cooling surfaces shall he inspected regularly and when required cleaned from dust, insects, leaves or other airborne dirt. This is especially important in case of fan cooling. The cleaning is preferably carried out by means of water flushing at high pressure.

6.2

Oil-side (Radiators, coolers for oil-air, oil-water)

Normally, no measures are necessary for keeping the internal cooling surfaces clean as long as the oil is in good condition. If, however, sludge formation has set in, the sludge may deposit on horizontal surfaces in radiators and coolers. If such a case, the radiators and coolers should he flushed internally with clean oil in connection with oil exchange.

Prepared By:

L Ostman

Date:

Approved By:

Thomas Fogelberg

Date:

Applicability:

TrafoStar

Lang:

2004-03-03

Rev. No:

en

Title:

-

Document No.

1ZBA 4601-222

Page No:

Page 4 of 7

Supervision of Transformers

6.3

Water side (Coolers for oil-water)

The coolers should be inspected regularly. All coolers can be disassembled on the waterside to permit efficient cleaning of cooling surfaces. Depending on the condition of the cooling water, the time intervals between inspections may vary. Suitable intervals are determined by experience.

6.4

Fans

The fan-motors are provided with permanently lubricated bearings and double sealing rings. The motor bearings are axially clamped with spring washers. If the sound level of the fan increases, first of all mounting supports should be retightening.

6.5

Flow-indicators, pressure meters

For information about maintenance of the indicator and possible exchange of rubber diaphragm, see separate information.

7

CONTROL CABINET

The function of the control cabinet with its components is described in the circuit diagram of the transformer.

8

BUSHINGS

Bushings manufactured by ABB are in general maintenance free. Bushing porcelains shall be cleaned from dust and dirt regularly. In areas where the air contains impurities as salt, cement dust, smoke or chemical substances, shorter intervals are required. See also the directions in the special information documents about bushings included in the transformer instruction manuals at delivery.

9

CONNECTIONS

In order to avoid dangerous temperature rises in the electrical connections of the transformer, all bolted joints should be checked and retighten regularly. For transformers in service, a thermo vision camera may be used to check the contact temperature of external current carrying joints.

10 DE-ENERGISED TAP-CHANGERS (DETC) At overhaul of DETC, the movable parts of the operating gear shall be lubricated. When the transformer is disconnected and not in use, the DETC should be operated to all positions and then re-set. The operation will prevent a build up of an insulation layer on the contact surfaces, which may lead to critical temperatures in the DETC.

11 ON-LOAD TAP-CHANGERS (OLTC) A description of function, supervision and maintenance of OLTC and its driving mechanism is available for each type of OLTC. The information documents are included in the transformer instruction manual. It should be noted that the on load tap-changer requires regular maintenance. The maintenance program prescribed by the tapchanger manufacturer should be followed. Such a program is often based on the number of tap-changing operations and/or the total operational time.

Prepared By:

L Ostman

Date:

Approved By:

Thomas Fogelberg

Date:

Applicability:

TrafoStar

Lang:

2004-03-03

Rev. No:

en

Title:

-

Document No.

1ZBA 4601-222

Page No:

Page 5 of 7

Supervision of Transformers

12 RE-TIGHTENING The following tightening torque values are applicable for joints between details of steel. It shall also be applied for bolted current carrying joints.

12.1 Thread Dim.

Finish

Hexagon head bolt, M-thread. Property class 8.8.

M8 M10 M12

Zincplated

M16

No Lubrication

M20 M24 M30

Untreated

M36

12.2 Thread Dim. M10 M12 M16 M20 M24 M30 M36

Finish

Hot dip galv.

Tightening torque Tol. +/- 10 % Nm Kpm

Lubrication

24,5

2,5

49,0

5.0

84

8,6

205

21

430

44

745

76

1520

155

2650

270

Stud, M-thread. Property class 5.8 Lubrication

No Lubricatio

Tightening torque Tol. +/- 10 % Nm kpm 29.5 3.0 50.5 5,1 123 12.5 258 26.3 447 45.5 912 93 1590 132

Prepared By:

L Ostman

Date:

Approved By:

Thomas Fogelberg

Date:

Applicability:

TrafoStar

Lang:

2004-03-03

Rev. No:

en

Title:

-

Document No.

1ZBA 4601-222

Page No:

Page 6 of 7

Supervision of Transformers

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein. ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should be FAXed to: ABB Power Transformers acording to contact list in Aspect Viewer.

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form. Prepared By:

L Ostman

Date:

Approved By:

Thomas Fogelberg

Date:

Applicability:

TrafoStar

Lang:

2004-03-03

Rev. No:

en

Title:

-

Document No.

1ZBA 4601-222

Page No:

Page 7 of 7

Supervision of Transformers

Serial no. 1133751

ACCESSORIES OF TRANSFORMER TYPE TNER3E 40000/115 PN LIST OF MANUFACTURERS/SUBSUPPLIERS Name of accessory

Type

Manufacturer/Subsupplier

UCGRN 650/300/C BUL

ABB Power Technologies AB Components Lyvikvägen 10 SE-77180 Ludvika, Sweden

Voltage regulation -

OLTC OLTC motor drive

Bushings -

HV bushing

GOB 550-800, LF 123 191-K, L6=500 mm Inner terminal: LF 170 011-S Outer terminal: LF 170 001A

-

HV-neutral bushing

GOB 550-800, LF 123 189-K, L6=100 mm Inner terminal: LF 170 011-S Outer terminal: LF 170 001A

-

MV bushings

20f/3150, Fig. B1, b1=380

-

LV bushings

10f/4500, Fig. C1, C1=440

ABB Power Technologies AB Components Lyvikvägen 10 SE-77180 Ludvika, Sweden

Terman’90 Strumentazione Industriale S.r.I. Via Ghisalba 13-20/21 20021 Bollate Milano, Italy

Cooling system -

Coolers

LK-S-190-50-1a-2x910-R13-100-h

GEA Technika Cieplna Sp. z o.o. ul. Oświęcimska 121 45-643 Opole Poland

-

Pumps

50/150/100/N/D/2/2

GEA Renzmann & Grünewald GmbH Industriestraße 6 · D-55569 Monzingen Germany

-

Liquid flow indicator

WPC-100 G L/P 0,8 IP553

INSTYTUT ENERGETYKI ODDZIAŁ TRANSFORMATORÓW ul.Kopernika 56/60 90-553 Łódź Poland

1/3

Serial no. 1133751 Protection, control and monitoring equipment Inteligent Electronic Device

509-100 Art. no. IED509-00026748

Resistance Bulb Platinum

Art. no. 103-023-01

-

Detachable Connector Assembly

CON000-00009199

-

Control cubicle

-

Buchholz relay

BF 80/10 4NO (09-22-244)

-

Monitoring relay for tap changers

URF 25/10

-

Winding temperature indicator

MSRT 150-W, capillary 10 m

-

Oil temperature indicator

MSRT 150,

-

Oil level indicator

LA22, 1ZBA569001-C

-

Oil level indicator

LB22, 1ZBA569001-X

-

Pressure safety valve

VS 150, 2CO

-

Silicagel air breather – transformer tank

EM5DA ABB dwg no. 1ZBA 676001-C

-

Silicagel air breather – OLTC

EM2DA ABB dwg no. 1ZBA 676001-A

-

Current transformer

JR 0,5

-

-

Qualitrol AKM Flygfaltsgatan 6C 128 30 Skarpnack Sweden

Szymański s.c. ul. Wiskicka 22 93-623 Łódź, Poland Elektromotoren und Geratebau Barleben GmbH Bahnhofstraβe 27/28 39179 Barleben, Germany

capillary 10 m

Terman’90 Strumentazione Industriale S.r.I. Via Ghisalba 13-20/21 20021 Bollate Milano, Italy

COMEM Strada Statale 11 36054 Montebello Vic.(VI), Italy Terman’90 Strumentazione Industriale S.r.I. Via Ghisalba 13-20/21 20021 Bollate Milano, Italy

COMEM Strada Statale 11 36054 Montebello Vic.(VI), Italy

EPRO Gallspach GmbH A-4713 Gallspach Styriastrasse 2 Postfach 20, Austria

2/3

Serial no. 1133751 Others -

Transformer oil

Nytro 10XN

Nynas Naphthenics AB Lindetorpsvägen 7 P.O. Box 10701 121 29 Stockholm, Sweden

-

Rubber air cell for conserwator

A=2010 mm, B=3510 mm, C=1300 mm Flange type 15

PRONAL S.A. L'Ingeniere de I'Elastomere Z.I.Roubaix Est-BP 18 F-59115 Leers France

-

Ball type valves

WK 2a

-

Throttle valves

WKKI-1

-

Gaskets

NBR PB 80

Przedsiębiorstwo Handlowo-Produkcyjne “EFAR” s.c. ul. Św. Antoniego 53 61-359 Poznań, Poland

3/3

James Walker & Co Ltd Lion House Woking Surrey GU22 8AP United Kingdom

Serial no. 1133751

5

On-load tap changer UCGRN 650/300/C with motor drive BUE

5.1 On-load tap-changers, type UC. Technical guide

1ZSE 5492-105 en, Rev. 5

5.2 Motor-drive mechanism, type BUE 2. Technical guide

1ZSE 5483-104 en, Rev. 3

5.3 On-load tap-changers, types UCG and UCL with motordrive mechanism, types BUE and BUL. Installation and commissioning guide

1ZSE5492-116 en, Rev. 8

5.4 On-load tap-changer, type UCG with motor-drive mechanisms, types BUE and BUL. Maintenance guide

1ZSE 5492-124 en, Rev. 5

5.5 On-load tap-changers, types UCG, UCL, UCC and UCD with motor-drive mechanisms, types BUE and BUL. Repair Guide

1ZSE 5492-129 en, Rev. 6

5.6 On-load tap-changers, types UCG, UCL, UCC and UCD with motor-drive mechanisms, types BUE and BUL. Spare Parts List

1ZSE 5492-133 en, Rev. 3

5.7 Tap-Changer UCGR UCGRN

54920104-8

5.8 Top Section, Accessories Tap-Changer UCG

54920103-2

5.9 External Shaft System

54920083-4

5.10 Connection Diagram

5492 0095-118

5.11 Circuit Diagram Relief Vent

5478 003-59

5.12 Circuit Diagram Motor-Drive Mechanism Type BUL

5483 538-66 5475 908-11 5475 913-26 5483 540-1 5483 540-30

1/1

On-load tap-changers, type UC Technical guide

Manufacturer’s declaration The manufacturer

ABB Components AB SE-771 80 LUDVIKA Sweden

Hereby declares that The products

On-load tap-changers type UC with motor-drive mechanisms types BUE and BUL

comply with the following requirements: By design, the machine, considered as component on a mineral oil filled power transformer, complies with the requirements of •

Machinery Directive 89/392/EEC (amended 91/368/EEC and 93/44/EEC) and 93/68/EEC (marking) provided that the installation and the electrical connection be correctly realized by the manufacturer of the transformer (e.g. in compliance with our Installation Instructions) and

•

EMC Directive 89/336/EEC regarding the intrinsic characteristics to emission and immunity levels and

•

Low Voltage Directive 73/23/EEC (modified by Directive 93/68/EEC) concerning the built-in motor and apparatus in the control circuits.

Certificate of Incorporation: The machines above must not be put into service until the machinery into which they have been incorporated have been declared in conformity with the Machinery Directive. Date

1997-02-10

Signed by

......................................................................... Olof Heyman

Title

Manager of Division for tap-changers

This Technical Guide has been produced to allow transformer manufacturers, and their designers and engineers, access to all the technical information required to assist them in their selection of the appropriate on-load tap-changer and motor-drive mechanism. The guide should be used in conjunction with the Selection Guide and the Design Guides, to allow the optimum selection to be made. The technical information pertaining to on-load tap-changers and motor-drive mechanisms manufactured by ABB Components has been divided and is contained in separate documents, with one document for each type. The information provided in this document is intended to be general and does not cover all possible applications. Any specific application not covered should be referred directly to ABB Components AB, or its authorized representative. ABB Components AB makes no warranty or representation and assumes no liability for the accuracy of the information in this document or for the use of such information. All information in this document is subject to change without notice. ABB Components also manufactures the following products: Transformer bushings Wall bushings GIS bushings

Table of Contents General Information ____________

4

Design Principles ______________

6

On-Load Tap-Changer _____________________ Diverter Switch ________________________ Tap Selector __________________________ Diverter Switch Housing and Top Section ___ Operating Mechanism __________________ Transition Resistors ____________________ Motor-Drive Mechanism ____________________ Type BUL ____________________________ Type BUE ____________________________ Special Applications ____________________ Accessories __________________________

Principles of Operation _________ On-Load Tap-Changer _____________________ Switching Sequence ____________________ Linear Switching (Type L) _______________ Change-over Selector for Plus/Minus Switching (Type R) ___________ Change-over Selector for Coarse/Fine Switching (Type D) __________

Characteristics and Technical Data ____________ On-Load Tap-Changer _____________________ Type Designation ______________________ Diverter Switches ______________________ Tap Selectors _________________________ Diverter Switch – Tap Selector Combinations _________________________ Rated Phase Step Voltage _______________ Contact Life __________________________ Standards and Testing __________________ Rating Plate __________________________ Insulation Levels ______________________ Mechanical Life _______________________ Short-circuit Current Strength ____________ Highest Phase Service Voltage Across the Regulating Winding ___________ Rated Through Current _________________ Occasional Overloading _________________

6 6 7 8 8 8 9 9 9 9 9 10 10 10 11 11 11

12 12 12 12 12 12 13 14 15 15 15 18 19 19 19 19

Oil Temperature _______________________ 20 Tie-ln Resistor ________________________ 20

Design, Installation and Maintenance ______________ On-Load Tap-Changer _____________________ Design Differences over the UC Range of On-Load Tap-Changers _______________ Drying _______________________________ Painting _____________________________ Weights _____________________________ Oil Filling ____________________________ Installation ___________________________ Maintenance __________________________ Oil Filter Unit _________________________ Pressure Relay ________________________ General Description _________________ Operation _________________________ Testing ___________________________ Installation _________________________ Motor-Drive Mechanism ____________________ Design ______________________________ Installation ___________________________ Maintenance __________________________ Dimensions _____________________________ Type UCG/C __________________________ Type UCG/I __________________________ Type UCG/III _________________________ Type UCL ____________________________ Type UCD/III _________________________ Type UCC ___________________________

Appendices: Single-Phase Diagrams _________ Appendix 1: Single-Phase Diagrams for UCG/C ___________ Appendix 2: Single-Phase Diagrams for UCG/I ___________ Appendix 3: Single-Phase Diagrams for UCG/III UCL/III and UCD/III _______________________ Appendix 4: Single-Phase Diagrams for UCC _____________

21 21 21 21 21 22 23 23 23 23 23 23 23 23 23 24 24 24 24 25 25 26 27 28 30 32

34 34 37

41 45

General Information When the on-load tap-changer operates, arcing occurs in the diverter switch. To avoid contamination of the transformer oil, the diverter switch has its own housing separate from the rest of the transformer. The tap selector, which is mounted beneath the diverter switch housing, consists of the fine tap selector and usually also of a change-over selector. The operating principle for the UC range of on-load tap-changers is called the diverter switch principle.

The UC types of on-load tap-changers are usually mounted inside of the transformer tank, suspended from the transformer cover. Drive to operate the on-load tapchanger is supplied from the motor-drive mechanism, which is mounted on the outside of the transformer tank away from the on-load tap-changer. The drive is transmitted by means of shafts and bevel gears. The UC types of on-load tap-changers come in a wide range of models with a rating suitable for every application.

Oil conservator Shaft

Bevel gear Transformer cover Transformer tank

On-Load Tap-Changer Shaft

Motor-Drive Mechanism

Fig. 1. Main parts, on-load tap-changers type UC 4

Cover

Diverter switch housing

Oil valve Buffer springs Lifting eye Bevel gear with mechanical indicator Pressure relay with testing valve

Earthing terminal

Top section

Vent plug

Shielding-ring

Oil tube

Insulating shaft

Shielding-ring Diverter switch

Transition resistors Insulating cylinder Fixed and moving contacts Plug-in contacts

Connections from the tap selector Locating pins

Valve for use at processing

Driving disc for the diverter switch

Bottom section Intermediate gear Current terminal

Fig. 2. On-load tap-changer type UCL 5

Design Principles On-Load Tap-Changer The on-load tap-changer is built in two separate sections, the diverter switch, which has its own housing, and the tap selector. The tap selector is mounted below the diverter switch housing and the complete unit is suspended from the transformer cover.

The diverter switch is equipped with plug-in contacts that automatically connect the switch with the tap selector when the diverter switch is lowered into the housing. Mechanical coupling to the motor-drive mechanism is automatically established when the driving pin enters the slot in the driving disc.

Diverter Switch

The current-carrying contacts are made of copper or copper and silver, and the breaking contacts of copper-tungsten.

The diverter switch is of the high-speed, spring-operated type with resistors as transition impedance.

The design and dimensioning of the diverter switch offers high reliability and long life with a minimum of maintenance and easy inspection.

The diverter switch is designed as a system of moving and fixed contacts. Movement of the moving contact system is controlled by a self-locking polygon link system with a set of helical springs. The link system is robust and has been carefully tested. The fixed contacts are placed on the sides of the diverter switch, which are made of insulated board.

Fig. 3. Diverter switch (UCL)

Fig. 4. Diverter switch (UCC)

L37049

6

L37050

Tap Selector Although the tap selector for the UC range of on-load tap-changer is available in various sizes, all have similar functions with different ratings. The fixed contacts are mounted in a circle around the central shafts. The moving contacts are mounted on, and are operated by, the shafts in the center of the selector. The moving contacts are connected, via current collectors, to the diverter switch by means of paper insulated copper conductors. Depending on the load current, the moving contacts have either one, two, or more contact arms in parallel with one, two or four contact fingers each. The fingers make contact at one end with the fixed contact, and at the other with the current collector. The moving contacts slide on the fixed contacts and the current collector rings, giving a wiping action which makes the contacts self cleaning. This arrangement promotes good conductivity and negligible contact wear.

Fig. 5. Tap selector size C

L36698

Fig. 6. Tap selector size III 7

L36700

Operating Mechanism

Diverter Switch Housing and Top Section

The bevel gear, mounted on the top section flange transfers the drive from the motor-drive mechanism, via the vertical shaft, to the intermediate gear for the diverter switch and the tap selector.

The top section forms the flange that is used for mounting to the transformer cover, and for carrying the gear box for the operating shafts. The top housing includes a connection for the conservator pipe, draining and filtering connections, an earthing terminal, the pressure relay, and the cover with its gasket.

From the intermediate gear, a drive shaft transfers the drive to the diverter switch through an oil tight gland in the bottom of the diverter switch housing. When the diverter switch is lowered into the housing (after inspection), the drive is automatically re-connected by a system that ensures that the drive shaft and the locating pin of the diverter mechanism is correctly aligned.

The bottom section has locating holes for the diverter switch, bearings, brackets for the tap selector mounting and the current terminal for the diverter switch. There is also a draining valve in the bottom which should only be opened during the drying process of the transformer.

The intermediate gear also drives the geneva gear, of the tap selector, via a free wheel connection. The geneva gear provides alternate movement to the two vertical shafts of the tap selector.

The top and bottom section are fixed to a cylinder of glassfibre reinforced plastic. The bushings through the cylinder wall are sealed by O-ring gaskets with elastic pressure. Each ready-made unit is tested under vacuum and the outside is exposed to helium and checked for leaks with the use of a helium gas detector.

Transition Resistors The transition resistors are made of wire, wound on insulating bobbins, and are located above the diverter switch contacts. The resistors are robust and designed to withstand an unlimited number of operations.

8

Motor-Drive Mechanism The motor-drive mechanism provides the drive to allow the on-load tap-changer to operate. As the name implies, drive is provided from a motor through a series of gears and out through a drive shaft. Several features are incorporated within the mechanism to promote long service intervals and reliability.

For detailed operation description, see separate Technical Guides for Motor-Drive Mechanisms types BUL or BUE, respectively.

There are two sizes of motor-drive mechanisms that can be used:

Special Applications

If there are any doubts about which type to select, please consult ABB Components.

ABB Components should be consulted for all special application on-load tap-changers.

Type BUL

Accessories

The BUL is for on-load tap-changers types UCG and UCL at star point or single-phase applications. However, when extra space is required for optional accessories the type BUE might have to be selected due to limited space in the BUL.

For a list of accessories available for both the on-load tap-changers and the motor-drive mechanisms, see the Selection Guide or consult ABB Components.

Type BUE The BUE is for all on-load tap-changers types UCG, UCL, UCC and UCD.

Fig. 7a. Motor-drive mechanism type BUE

L37166

Fig. 7b. Motor-drive mechanism type BUL 9

L37167

Principles of Operation On-Load Tap-Changer Switching Sequence The switching sequence of the on-load tap-changer from position 6 to position 5, is shown in the figures below. The sequence is designated the symmetrical flag cycle. This means that the main switching contact of the diverter switch, breaks before the transition resistors are connected across the the regulating step. This ensures maximum reliability when the switch operates with overloads.

Fig. 8c The main contact x has opened. The load current passes through the resistor Ry and the resistor contact y.

At rated load the breaking takes place at the first current zero after contact separation, which means an average arcing time of approximately 6 milliseconds. The total time for a complete sequence is approximately 50 milliseconds. The tap change operation time of the motor-drive mechanism is approximately 5 seconds per step. (10 seconds for through-positions.)

Fig. 8d The resistor contact u has closed. The load current is shared between Ry and Ru. The circulating current is limited by the resistance of Ry plus Ru.

Fig 8a. Position 6 Selector contact V lies on tap 6 and selector contact H on tap 7. The main contact x carries the load current.

Fig. 8e The resistor contact y has opened. The load current passes through Ru and contact u.

Fig. 8b Selector contact H has moved in the no-current state from tap 7 to tap 5.

Fig. 8f. Position 5 The main contact v has closed, resistor Ru is bypassed and the load current passes through the main contact v. The on-load tap-changer is now in position 5.

10

Linear Switching (Type L) The regulating range is equal to the voltage of the tapped winding. No change-over selector is used.

Fig. 9. Linear switching (Type L)

Change-over Selector for Plus/Minus Switching (Type R)

Reversing Change-over selector

The change-over selector extends the regulating range to twice the voltage of the tapped winding, by connecting the main winding to different ends of the regulating winding.

Fig. 10. Plus/Minus switching (Type R)

Change-over Selector for Coarse/Fine, Switching (Type D)

Change-over selector, Coarse/Fine

In type D switching the change-over selector extends the regulating range to twice the voltage of the tapped winding, by connecting or disconnecting the coarse regulating winding.

Fig. 11. Coarse/Fine switching (Type D)

11

Characteristics and Technical Data On-Load Tap-Changer

Diverter Switches

Type Designation

Type

Max. rated through-current

Impulse withstand voltage to earth

UCG.N UCG.E,T

380, 650, 750, 1050 kV

UCG.B

300, 500, 600 A 300, 500, 600, 900, 1200, 1500 A 300, 500, 600 A

380, 650, 750, 1050 kV 380, 650, 750, 1050 kV

UCL.N UCL.E,T UCL.B

600, 900 A 600, 900, 1800, 2400 A 600, 900 A

380, 650, 1050 kV 380, 650, 1050 kV 380, 650, 1050 kV

UCC.N

800, 1200, 1600 A

380, 650, 1050 kV

UCC.E

3600, 4500 A

380, 650, 1050 kV

UCG UCL UCD UCC

.. .. .. ..

XXXX/YYYY/Z XXXX/YYYY/Z XXXX/YYYY/Z XXXX/YYYY

Example: UCGRE 650/700/C Type of switching L Linear R Plus/Minus D Coarse/Fine Type of connection N Three-phase star point (one unit) E Single-phase (one unit) T Three-phase fully insulated (three units) B Three-phase delta (two units; single-phase and two-phase)

Tap Selectors

Impulse withstand voltage to earth UCG: 380 kV, 650 kV, 750 kV, 1050 kV UCL: 380 kV, 650 kV, 1050 kV UCD, UCC: 380 kV, 650 kV, 1050 kV Maximum rated through-current UCG.N, UCG.B: 300 A, 400 A, 500 A, 600 A UCG.E, UCG.T: 300 A, 400 A, 500 A, 600 A, 700 A, 900 A, 1050 A, 1200 A, 1500 A UCL.N, UCL.B: UCL.E, UCL.T:

600 A, 900 A 600 A, 900 A, 1800 A, 2400 A

UCD.N: UCD.E:

1000 A, 1200 A 1000 A, 1200 A, 1800 A, 2000 A 2400 A, 3000 A, 3600 A 1)

UCC.N: UCC.E:

800 A, 1200 A, 1600 A 3600 A, 4500 A

Max. rated throughcurrent

C

N E, T B

400 A 400, 700, 1050 A 400 A

27 27 27

350 kV 350 kV 350 kV

I

N E, T B

600 A 600, 1200, 1500 A 600 A

35 35 35

300 kV 300 kV 300 kV

III

N E, T

1000 A 1000, 1800, 2400 30001) A 1000 A

35

550 kV

35 35

550 kV 550 kV

800, 1200, 1600 A 3600, 4500 A

35 35

500 kV 500 kV

UCC 2) N E

Max. no. of pos.

Max impulse test voltage across range

1)

with enforced current splitting

2)

UCC requires one motor-drive mechanism for each unit and is therefore not available in connection B and T.

with enforced current splitting

Diverter Switch – Tap Selector Combinations

Maximum number of positions Linear switching Plus/Minus switching Coarse/Fine switching 1)

Connection

B

Tap selector size C = UCG tap selector I = UCG tap selector III = UCG, UCL and UCD tap selector 1)

Type

UCG, UCL, UCD 211) positions 35 positions 35 positions

UCC 23 positions 35 positions 35 positions

Only tap selector III is available up to 21 positions with linear switching.

Diverter Switch

UCG

UCL

UCC

Tap selector

C, I, III

III

III, UCC

UCC diverter switch combined with tap selector III is called UCD. The unit (diverter switch or tap selectors) with the lowest rating in any combination as per above, determines the type designation of the on-load tap-changer.

12

Rated Phase Step Voltage The maximum permitted step voltage is limited by the electrical strength and the switching capacity of the diverter switch. The rated phase step voltage is a function of the rated through current as shown in the diagrams below.

UCG.N, B

Step voltage

UCG.E, T Short version UCG.N, E, T, B

Step voltage

UCL.N, B UCL.E, T

Fig. 12. Rated phase step voltage for type UCG

Rated through current, A

4500A

3600A

1600A

1200A

UCC.E

800A

3600A2)

3000A

2400A

1800A 2000A

With enforced current splitting

2400A

UCC.N Step voltage

UCD.E

1000A 1200A 2)

Rated through current, A

Fig. 13. Rated phase step voltage for type UCL

UCD.N Step voltage

1800A

600A

Rated through current, A

900A

1500A

1200A

900A 1050A

500A 600A 700A

300A

Short version UCG.E, T

Rated through current, A

Fig. 14. Rated phase step voltage for type UCD

Fig. 15. Rated phase step voltage for type UCC

13

Contact Life The predicted contact life of the fixed and moving contact of the diverter switch, is shown as a function of the rated through current in the diagrams below. It is based on the type test with 50000 switching operations, and a current corresponding to the maximum rated through current. The contact life is stated on the rating plate.

Contact life Number of operations

Contact life Number of operations

2)

Contact life Number of operations

2400A

UCC. N

Rated through current, A R1 3000 without current splitting. R1 3600 with enforced current splitting.

4500A

3600A

1600A

1200A

UCC. E

800A

3600A2)

3000A1)

2400A

UCD. E

1800A

Rated through current, A

Fig. 17. Contact life for type UCL

UCD. N

1000A 1200A 1)

1800A

600A

Rated through current, A

900A

1500A

1200A

UCL. E, T

Fig. 16. Contact life for type UCG

Contact life Number of operations

UCL. N, B

UCG. E, T

900A 1050A

500A 600A 700A

300A

UCG.N, B

Rated through current, A

Fig. 18. Contact life for type UCD

Fig. 19. Contact life for type UCC

14

Standards and Testing

Rating Plate

The on-load tap-changers made by ABB Components fulfil the requirements according to IEC standards, publication 214. The type tests include: Contact temperature rise test Switching tests Short-circuit current test Transition impedance test Mechanical tests Dielectric tests The routine tests include: Check of assembly Mechanical test Sequence test Auxiliary circuits insulation test Vacuum test Final inspection

Fig. 20. Example of Rating Plate

Insulation Levels The insulation levels are indicated as:

Insulation Levels to Earth

1.2/50 µs impulse withstand voltage (kV)–power frequency withstand voltage (kV).

For UCG

380–150 kV, 650–275 kV 750–325 kV and 1050–460 kV.

The tests were carried out according to IEC 214 clause 8.6. with a new on-load tap-changer and clean insulation oil class 2 according to IEC Publication 296. The withstand voltage value of the oil was higher than 160 kV/cm.

For UCL

380–150 kV, 650–275 kV and 1050–460 kV.

For UCC and UCD

380–150 kV 650–275 kV 1050–460 kV.

Linear

L

b1 and b2 are to the corresponding contacts in the next phase

Fig. 21. Linear switching: Contact designations in tables 1-3 1) See note 1 for UCC.

Reversing

R

b1 and b2 are to the corresponding contacts in the next phase

Fig. 22. Reversing switching: Contact designations in Tables 1-3

15

Coarse/Fine

D

b1, b2 and d1 are to the corresponding contacts in the next phase

Fig. 23. Coarse/Fine switching: Contact designations in tables 1-3

16

9 11 13 15

R, D

300-125

290-120 250- 95

– –

250- 95

350-140

–

300-125

290-120 250- 95

– – –

350-140

300-125

I

350-140

C

420-150 350-140

490-160

420-150 350-140

490-160

420-150 350-140

490-160

US

a2 between ends of (fine) regulating winding

III

480-160 400-150

550-180

480-160 400-150

550-180

480-160 400-150

550-180

S

– –

350-140

–

350-140

– – –

350-140

C

290-120 250- 95

300-125

250- 95

300-125

290-120 250- 95

300-125

I

350-140 300-125

400-150

350-140

400-150

350-140 300-125

400-150

US

III

a3 between any other electrically non-adjacent taps

350-140 300-125

400-150

400-150

350-140 300-125

400-150

S

– –

400-150

400-150

C

350-140

I

600-200

600-200

US, S

III

c1 across change-over selector

130-50

C, I and III

e1, b2 between open contacts in diverter switch

– –

400-150

–

400-150

– – –

400-150

C

300-125

I

500-160

500-160

500-160

500-160

500-160

500-160

US

b1 between open fixed contacts in tap selector

III

500-160

550-180

550-180

550-180

550-180

S

Between phases for the neutral point type

– –

400-150

–

400-150

C

350-140

I

600-200

600-200

US, S

III

d1 between open fixed contacts in coarse change-over selector

NOTE: a1 Between electrically adjacent taps. The insulation withstands 300–125 in tap selector III but may be limited by the moving selector arms and by the diverter switch to e1 and b2 value. The distance a1 is not relevant for tap selector I and C, see single-phase diagrams in appendicies.

US = Unshielded contacts, S = Shielded contacts

17-19 21-23 25-27 29-31 33-35

9 11 13 15 17 18

L

Selector size

Type of switching and number of positions

Within one phase

Table 1. Withstand Voltages within UCG Tap-Changers (For UCG Tap-Changers with selectors C, I and III)

UCG

17

9 11 13 15

R, D

550-180

480-160 400-150

420-150 350-140

480-160 400-150

490-160

420-150 350-140

550-180

480-160 400-150

420-150 350-140

490-160

550-180

S

490-160

US

III

a2 between ends of (fine) regulating winding

350-140 300-125

400-150

350-140

400-150

350-140 300-125

400-150

US

350-140 300-125

400-150

400-150

350-140 300-125

400-150

S

600-200

600-200

US

III

600-200

600-200

S

c1 across changeover selector

150-50

US, S

UCL III

200-80

US, S

UCD III

e1, b2 between open contacts in diverter switch

500-160

500-160

500-160

500-160

500-160

500-160

US

III

500-160

550-180

550-180

550-180

550-180

S

b1 between open fixed contacts in tap selector

Between phases for the neutral point

600-200

600-200

US

III

600-200

600-200

S

d1 between open fixed contacts in coarse change-over selector

NOTE: a1 Between electrically adjacent taps. The insulation withstands 300–125 kV but may be limited by the moving selector arms and by the diverter switch to e1 and b2 value.

III

a3 between any other electrically non-adjacent taps

US = Unshielded contacts, S = Shielded contacts

17-19 21-23 25-27 29-31 33-35

9 11 13 15 17 18

L

Selector size

Type of switching and number of positions

Within one phase

Table 2. Withstand Voltages within UCL and UCD Tap-Changers (For UCL and UCD Tap-Changers with selector III)

UCL, UCD

UCC

Table 3. Withstand Voltage within UCC on-load tap-changers Within one phase Type of switching and number of positions

a2 between ends of (fine) regulating winding US

L

S

Between phases for the neutral point type a3 between any other electrically non-adjacent taps US

S

300–1251)

9–23 300–125 9–15

500–170

9–35 300–125

500–170

c1 across change-over selector

e1, b2 between open contacts in diverter switch

b1 between open fixed contacts in tap selector

US

S

US and S

US

––

––

200–80

300–125

500–170

S

d1 between open fixed contacts in coarse change-over selector US

S

–

–

500–170

R, D 160–75

250–85

300–125

600–200

200–80

US = Unshielded contacts, S = Shielded contacts 1)

For 17–23 positions, the withstand voltage between contacts on adjacent ribs is 180–100 kV.

NOTE: a1 Between electrically adjacent taps. The insulation withstands 200–80 kV.

Mechanical Life The mechanical life is based on an endurance test which showed that the mechanical wear was negligible, and that the on-load tap-changers were still mechanically sound after one million operations.

18

300–125

500–170

350–150 600–200

Short-circuit Current Strength

Rated Through Current

The short circuit current strength is verified with three applications of 2 seconds duration, without moving the contacts between the three applications. Each application has an initial value of 2.5 times the rms value.

The rated through-current of the on-load tap-changer is the current which the on-load tap-changer is capable of transferring from one tapping to the other at the relevant rated step voltage, and which can be carried continuously whilst meeting the technical data in this document. The rated through current is normally the same as the highest tapping current.

Type

UCG

Three applications of 2 seconds duration 1), rms

300 A 400 A 500 A, 600 A 700 A 900 A 1050 A 1200 A, 1500 A

7.0 kA 7.0 kA 7.0 kA 7.0 kA 9.0 kA 10.5 kA 15.0 kA

UCL

600 A 900 A 1800 A 2400 A

9.0 kA 9.0 kA 26.0 kA 26.0 kA

UCD

1000 A 1200 A 1800 A 2000 A 2400 A 3000 A

13.0 kA 12.0 kA 26.0 kA 24.0 kA 32.0 kA 36.0 kA

800 A 1200 A 1600 A 3600 A 4500 A

13.4 kA 13.4 kA 16.6 kA 30.0 kA 36.0 kA

UCC

1)

Max rated through current, rms

Reinforced

The rated through-current is limited by the step voltage according to the curves in the diagrams, Fig. 12 to Fig. 15. The rated through-current determines the dimensioning of the transition resistors and the contact life. The rated through-current is stated on the rating plate, Fig. 20.

Occasional Overloading If the rated through-current of the tap-changer is not less than the highest value of tapping current of the tapped winding of the transformer, the tap-changer will not restrict the occasional overloading of the transformer, according to IEC 354 ”Loading guide for oil-immersed transformers” (1991), ANSI/IEEE C57.92 ”Guide for loading mineral-oil-immersed power transformers” and CAN/CSA-C88-M90.

21 kA 66 kA

With an initial peak current of 2.5 times the rms value and without moving the contacts between the three applications.

To meet these requirements, the UC models have been designed so that the contact temperature rise over the surrounding oil does not exceed 20 K when loaded with a current of 1.2 times the maximum rated through current of the tap-changer.

Table 4. Short-circuit current strength

The contact life stated on the rating plate is given with consideration to that currents of maximum 1.5 times the rated through current occur during a maximum of 3% of the tap-change operations. Overloading beyond these values, results in increased contact wear and shorter contact life.

Highest Phase Service Voltage Across the Regulating Winding The table below show the highest permissible phase service voltage, in kV, for the different types of connections.

Contact shieldings:

Across the regulating winding with without

Across the coarse and fine winding with without

Tap-changer, connection UCC.N UCD.N UCL.N UCG.N UCC.E UCD.E, UCL.T, E, B UCG.T, E, B UCG.N UCG.T, E, B

52

35

75

45

60

– 45

80

– 60

– –

– 35 35

– –

– 40 45

III III

III C, I C, I

Table 5. Highest permissible phase service voltage across the regulating winding 19

Oil Temperature

Tie-ln Resistor

The temperature of the oil surrounding the on-load tapchanger shall be between -25 and +105 oC for normal operation, as illustrated below. The range can be extended to -40 oC provided that the viscosity is between 2-800 mm2/s (=cst).

If the service voltages and the winding capacitances are such that the potential of the tapped winding exceeds the values in table 6, it should be limited to this value by means of a tie-in resistor connected between the diverter switch and the mid tap of the tap selector.

On-load tap-changer 1) 2)

UCG.. /C UCG.. /I UCG.. /III UCL.. /III UCD.. /III UCC..

1) No operations allowed 2) Emergency overloading. The on-load tap-changer will not restrict the occasional overloading of the transformer according to the standards above.

Voltage (kV) 35 25 35 35 35 35

Table 6.

3) 3) Normal operating range

In order to eliminate the losses in the tie-in resistor, a tiein resistor switch (S), which connects the resistor only when the change-over selector is moving, can be added to the bottom of the tap selector. The tie-in resistor switch is not available for tap-selector C. The tie-in resistor is normally mounted separate from the on-load tap-changer, but in some cases it can be mounted below the tap selector.

4) When operating within this range, no overload is allowed 5) Operation with de-energized transformer only 4) 5)

Fig. 24. On-load tap-changer oil temperature

Fig. 25. Tie-in resistor connection Design information on tie-in resistors is provided in a separate document, On-Load Tap-Changer Tie-in Resistors, 5492 0030E-28. 20

Design, Installation and Maintenance On-Load Tap-Changer Design Differences over the UC Range of On-Load Tap-Changers The most obvious difference between the models in the UC range of on-load tap-changers is the size (see Fig. 26). Other differences are less obvious but include the use of different materials in the manufacture of the top sections (welded steel in the UCG and UCC/D models, casted alloy in the UCL model). The cylinder is glued in the UCG range, and riveted in the rest of the models.

UCG.N/C UCG.N/I 650 kV

There are also differences in the design and operation of the tap selector. For tap selectors sizes C and I, the moving contacts are driven by two parallel ribs in one cage. For tap selectors size III, the moving contacts are driven by two concentric shafts. For UCC, the system consists of two cages with one driving shaft in each.

UCG.N/III UCL.N/III 650 kV 650 kV

UCD.N/III 650 kV

UCC.N 650 kV

Fig. 26. On-load tap-changers type UC, size comparison

Drying

Painting

The on-load tap-changer must be stored indoors and left in its plastic shipping cover until time for assembly. For further instructions refer to the Installation Guide.

The standard painting on the top section consists of a primer of two-component epoxy type of max. thickness 60 µm.The on-load tap-changer may be delivered in this state for finish coating by the customer, or it can be delivered with a grey/blue finishing coat outside. Special painting will be quoted for on request.

21

Weights The tables below shows all the weights of the UC range of on-load tap-changers. On-load tap-changer Type Designation

1)

On-load tap-changer Type designation

Approximately weight in kg Tap-changer Required Total without oil 1) oil

UCG.N

380-750/300-600 1050/300-600

425 435

150 185

575 620

UCG.T

380-750/300-900 380-750/1050-1500 1050/300-900 1050/1050-1500

1025 1190 1090 1225

3x150 3x150 3x185 3x185

1475 1640 1645 1780

UCG.B

380-750/300-600 1050/300-600

760 780

2x150 2x185

1060 1150

UCG.E

380-750/300-900 380-750/1050-1500 1050/300-900 1050/1050-1500

360 410 370 425

150 150 185 185

510 560 555 610

The weight of the diverter switch, approximately 90 kg, is included.

UCL.N

380/600, 900 650/600, 900 1050/600, 900

480 500 510

260 300 340

740 800 850

UCL.T

380/600, 900 380/1800 380/2400 650/600, 900 650/1800 650/2400 1050/600, 900 1050/1800 1050/2400

1230 1350 1440 1290 1410 1500 1320 1440 1530

3x260 3x260 3x260 3x300 3x300 3x300 3x340 3x340 3x340

2010 2130 2220 2190 2310 2400 2340 2460 2550

UCL.B

380/600, 900 650/600, 900 1050/600, 900

850 890 910

2x260 2x300 2x340

1370 1490 1590

UCL.E

380/600, 900 380/1800 380/2400 650/600, 900 650/1800 650/2400 1050/600, 900 1050/1800 1050/2400

410 450 480 430 470 500 440 480 510

260 260 260 300 300 300 340 340 340

670 710 740 730 770 800 780 820 850

Table 7. Weights for type UCG

1)

Approximately weight in kg Tap-changer Required Total without oil 1) oil

The weight of the diverter switch, approximately 120 kg, is included.

Table 8. Weights for type UCL

On-load tap-changer Type designation

1)

Approximately weight in kg Tap-changer Required Total without oil 1) oil

UCD.N

380/1000 650/1000 1050/1000

950 980 1010

710 790 910

1660 1770 1920

UCD.E

380/1000 380/1800 380/2400 650/1000 650/1800 650/2400 1050/1000 1050/1800 1050/2400

890 920 950 920 950 980 950 980 1010

710 710 710 790 790 790 910 910 910

1600 1630 1660 1710 1740 1770 1860 1890 1920

On-load tap-changer type designation

1)

The weight of the diverter switch, approximately 250 kg, is included.

Table 9. Weights for type UCD

Approximately weight in kg Tap-changer Required Total without oil 1) oil

UCC.N

380/800, 1200 380/1600 650/800, 1200 650/1600 1050/800, 1200 1050/1600

1130 1220 1160 1250 1190 1280

710 710 790 790 910 910

1840 1930 1950 2040 2100 2190

UCC.E

380/3600 380/4500 650/3600 650/4500 1050/3600 1050/4500

1130 1220 1160 1250 1190 1280

710 710 790 790 910 910

1840 1930 1950 2040 2100 2190

The weight of the diverter switch, approximately 250 kg, is included.

Table 10. Weights for type UCC

22

Oil Filling For details of oil filling, consult the appropriate Installation Guide.

The pressure relay is mounted on a three-way valve. On the other two outlets of the valve there is a connection flange on one side, and a connection for test equipment on the other.

Installation The on-load tap-changers can be delivered for covermounting method or yoke-mounting method onto the transformer.

The relay is made of copper-free aluminium alloy and is externally coated with an enamel. A stainless steel model can be provided on request.

For detailed installation instructions, consult the appropriate Installation Guide.

The pressure relay has been pre-set by the manufacturer. The pressure relay is sealed to avoid unauthorized entrance. The electrical connection shall be made to the terminal box mounted onto the pressure relay.

Maintenance The UC range of on-load tap-changers have been developed over many years to provide a maximum of reliability. The simple and rugged design gives a service life that equals the service life of the transformer. A minimum of maintenance is required for absolutely trouble-free operation. The only parts that require maintenance during the service life are the diverter switch contacts that may need to be replaced, and the motor-drive mechanism. The oil in the diverter switch housing has also to be cleaned with certain intervals.

Operation When the pressure acting on the face of the piston exceeds the spring load of the piston, the piston will move and activate the switching element. The operation time is less than 10 ms. The operation time is the time it takes from the pressure in the tapchanger tank exceeds the function pressure, until the pressure relay gives a stable signal for operation of the transformer main switch.

Maintenance is easy to carry out since the design provides for quick and easy access and inspection. For overhaul, the top cover is removed and, if necessary, the diverter switch can be lifted out without further dismantling.

The function pressure (trip pressure) is shown in table 11. H 1)

An annual inspection should be carried out to read the counting device. These readings are used to determine when overhaul is due. Overhaul shall normally be carried out every seven years, and consists of checking the dielectric strength, filtering the oil, and checking the contacts (and replace them if they are worn). The motordrive mechanism should also be checked and lubricated, and the pressure relay checked.

< 7m 7 – 20 m 1)

2)

Function pressure (trip pressure) 100 kPa (14.5 Psi) 100-230 kPa (14.5-33.5 Psi) 2)

The height (H) is the distance between the level of the pressure relay and the oil level in the oil conservator. Option when H is 7-20 m.

Table 11. Function pressure (trip pressure)

The appropriate Maintenance Guide should be consulted if you need further information.

Testing

Oil Filter Unit The on-load tap-changer can be equipped with an oil filter unit for continuous oil filtration. For further information, see manual 1ZSE 5492-152.

Before the commissioning of the transformer and for testing the pressure relay, reference should be made to the specific instructions regarding the pressure relay, or to the appropriate Installation Guide.

Pressure Relay

Installation

General Description

The pressure relay is to be mounted directly on to the onload tap-changer tank, using the flange and fittings provided. Caution should be used when handling the relay to avoid damage. The relay should be stored in its protective box until attaching to the on-load tap-changer.

Protection for the on-load tap-changer is provided by a pressure relay which is mounted on the on-load tapchanger top section. In the event of an over-pressure in the tank, the relay will, if correctly connected, trip the transformers main circuit breakers. After a pressure relay trip, the on-load tap-changer must be carefully investigated. Faults, if any are located, should be repaired before the transformer is energized.

Caution should also be applied when attaching the relay to the on-load tap-changer tank, and the appropriate Installation Guide should be consulted.

23

Switching contact 30

54

67

ABB Components

Cable gland Adjusting nut

~200

~35

Spring Piston ;; ;;

110

One single-pole switching contact

Connection for test equipment

~155

15

32

11

Two single-pole switching contacts

NO NC C NO NC C 64 66 65 61 63 62

Fig. 27. Pressure relay

Motor-Drive Mechanism Design For detailed design description, see separate Technical Guides for Motor Drive Mechanisms types BUL or BUE, respectively.

Installation The motor-drive mechanism is fitted to the outside of the transformer tank, and connected to the on-load tapchanger by drive shafts and bevel gears. For the correct installation procedure, consult the appropriate Installation Guide.

Maintenance The motor-drive mechanism should be inspected at regular intervals and at the same time as the on-load tap-changer is inspected. For the correct inspection and maintenance procedures, consult the appropriate Maintenance Guide.

Operating shafts Length

L1 mm

L2 mm

L3 and L4 Motor-drive mm mechanism

Min/max

500/3100 500/3100

525/3100 600/3100

900/2700 –

BUE BUL

The minimum and maximum lengths refer to mechanical design only. See Fig 28. L2 vertical shaft see following pages. Also other shaft arrangements on request.

Fig. 28. Positioning of motor-drive mechanism 24

NO NC C 61 63 62

Dimensions Type UCG/C Dimensions in mm. The design, technical data and dimensions are subject to alteration without notice. 405

L1

H32)

70

290

205 111

1)

D=600

1)

L2

H1

D=470 157 75 194

A (BUE1) 592 (BUE2) 818

A

H2 390

36

134

345 C/L Tap selector

D=740

C/L Diverter switch 30 Section A – A Plus/Minus and R210 Coarse/Fine switching

80 332

16O 145

230

570

(BUE1) 233 (BUE2) 353 (BUE1) 320 (BUE2) 440

D=420 615 R210

Fig. 29. Dimensions, type UCG

Section A – A Linear switching 570

Diverter switch housing For tap selector size

Impulse withstand voltage to earth kV

C

380, 650, 750 1050

H1

H1, short version mm mm 1192 1492

972 1272

H3

H3 short version mm mm 1400 1700

D=420 615

1200 1500

Tap selector For on-load tap-changer type

1)

UCG.N

Shielding-rings are used only for insulation level 650-275 kV and higher.

2)

Space required for lifting the diverter switch, excluding the lifting equipment.

3)

UCG.T consists of three single-phase units.

4)

UCG.B consists of one single-phase and one two-phase unit arranged as shown in the dimension drawing for UCL.B (page 29).

UCG.E, UCG.T

UCG.B

4)

3)

Max rated through current A

H2, size C

400

959

400 700 1 050

519 739 959

400

Single-phase unit 519

mm

Two-phase unit 739

25

Dimensions Type UCG/I Dimensions in mm. The design, technical data and dimensions are subject to alteration without notice.

405 H32) L1

185

70

290

1)

111 D=600 L2

1)

H1

D=470

157 A

A 75 194

H2

(BUE1) 592 (BUE2) 818 390

36

134

1)

30

4)

C/L Tap selector

C/L Diverter switch

D=740

30

80 4203)

610 O

230

16 145

530

332

(BUE1) 233 (BUE2) 353

195

(BUE1) 320 (BUE2) 440

Section A – A Plus/Minus and Coarse/Fine switching

6053) 665

1)

Shielding-rings are used only for insulation level 650-275 kV and higher.

2)

Space required for lifting the diverter switch, excluding the lifting equipment.

3)

Dimension without shielding-ring.

4)

For tie-in resistor switch add 360 mm.

3903)

4103)

500

500

Fig. 30. Dimensions, type UCG 26

Section A – A Linear switching

Type UCG/III Model for mounting on transformer’s active part

Model for cover mounting

78

H1

H1+106

B

B

H2

C/L Tap selector

C/L Diverter switch 30

385

Diverter switch housing 4903)

590

Section B - B Plus/Minus and Coarse/Fine switching

2553) 8403) 295

For tap selector size

Impulse withstand voltage to earth kV

I

380, 650, 750 1050

1317 1617

1097 1397

1400 1700

1200 1500

III

380, 650, 750 1050

1354 1654

1134 1434

1400 1700

1200 1500

For on-load tap-changer type

4903) Section B - B Linear switching 580

UCG.E, UCG.T

580

UCG.B 6)

Fig. 31. Dimensions, type UCG Operating shafts The minimum and maximum lengths refer to mechanical design only.

Min/max

500/3100 500/3100

H3

H3 short version mm mm

Max. rated through current A

H2 size I mm

H2 size III mm

300–600

1030

1160

300–600 900 1200 1500

530 – 760 1030

552 552 856 856

300–600

singlephase unit 532

singlephase unit 552

twophase unit 774

twophase unit 856

UCG.N 4903)

L1 mm

H1, short version mm mm

Tap selector 940

Length

H1

L2 L3 and L4 mm mm 525/3100 600/3100

900/2700 –

Motor-drive mechanism BUE BUL

L3 and L4 for UCG.T, see Fig. 28, page 24.

27

5)

5)

UCG.T consists of three single-phase units.

6)

UCG.B consists of one single-phase and one two-phase unit arranged as shown in the dimension drawing for UCL.B (page 29).

Dimensions Type UCL/III Dimensions in mm. The design, technical data and dimensions are subject to alteration without notice.

Type UCL.N (three-phase, star point) and type UCL.E (single-phase)

Section A – A Plus/Minus and Coarse/Fine switching

Section A – A Linear switching

Diverter switch housing Impulse withstand voltage to earth kV

H1

H3

mm

mm

380 650 1050

1415 1615 1815

1500 1700 1900

For mounting on active part

H1+85

H3+100

5)

Fig. 32. Dimensions, type UCL 28

Type UCL.B (three-phase, delta)

Design for premounting on the active part of the transformer

Tap selector For on-load tap-changer type UCL.N UCL.E, UCL.T

UCL.B 7)

6)

Max rated through current A

H2 size III mm

600–900

1160

600–900 1800 2400

552 856 1160

600–900

single-phase unit H22 = 552 two-phase unit H21 = 856

1)

Shielding-rings are used only for insulation level 650-275 kV and higher.

2)

Space required for lifting the diverter switch, excluding the lifting equipment.

3)

Dimension without shielding-ring.

Operating shafts The minimum and maximum lengths refer to mechanical design only.

4)

For-tie in resistor switch add 370 mm

Length

5)

Model for mounting on transformers active part.

6)

UCL.T consists of three single-phase units.

7)

UCL.B consists of one single-phase and one two-phase unit.

Min/max

L1 mm 500/3100 500/3100

L2 L3 and L4 mm mm 525/3100 600/3100

900/2700 –

L3 and L4 for UCL.T, see Fig. 28, page 24.

29

Motor-drive mechanism BUE BUL

Dimensions Type UCD/III Dimensions in mm. The design, technical data and dimensions are subject to alteration without notice.

Fig. 33. Dimensions, type UCD 30

Operating shafts The minimum and maximum lengths refer to mechanical design only.

Diverter switch housing Impulse withstand voltage to earth kV

H1

H3

mm

mm

380 650 1050

1594 1734 1934

1600 1750 1950

Length Min/max

Tap selector For on-load tap-changer type

Max rated through current A

H2 size III mm

UCD.N

1000

1160

UCD.E

1000 1800 2400

552 856 1160

31

L1 mm

L2 mm

500/3100

525/3100

1)

Shielding-rings are used only for insulation level 550-230 kV and higher.

2)

Space required for lifting the diverter switch, excluding the lifting equipment.

3)

Dimension without shielding-ring.

4)

For tie-in resistor switch, add 370 mm.

5)

When two or three units are fitted together (three-phase delta and three-phase fully isolated respectively) the distance between the units (c) must be at least 1340 mm from mechanical point of view. For final dimensioning, check the insulation distance required.

Dimensions Type UCC Dimensions in mm. The design, technical data and dimensions are subject to alteration without notice.

Fig. 34. Dimensions, type UCC 32

Diverter switch housing Impulse withstand voltage to earth kV

H1

H3

mm

mm

380 650 1050

1540 1680 1880

1600 1750 1950

Max rated through current A

H2 mm

800, 1200 1600

1290 1530

1)

3600 4500

1290 1530

Shielding-rings are used only for insulation level 550-230 kV and higher.

2)

Space required for lifting the diverter switch, excluding the lifting equipment.

3)

Dimension without shielding-ring.

4)

For tie-in resistor switch add 340 mm.

5)

When two or three units are fitted together (three-phase delta and three-phase fully isolated respectively) the distance between the units (c) must be at least 1340 mm from mechanical point of view. For final dimensioning, check the insulation distance required.

Tap selector For on-load tap-changer type UCC.N UCC.E

Operating shafts The minimum and maximum lengths refer to mechanical design only. Length Min/max

L1 mm

L2 mm

500/3100

525/3100

33

Appendices: Single-Phase Diagrams The basic connection diagrams illustrate the different types of switching and the appropriate connections to the transformer windings. The diagrams illustrate the connections with the maximum number of turns in the transformer winding, with the tap-changer in position 1.

The tap-changer can also be connected in such a way that position 1 gives a minimum effective number of turns in the transformer winding with the tap-changer in position 1. The connection diagrams can be downloaded from our website: www.abb.se/com/

Appendix 1: Single-Phase Diagrams for UCG/C Linear

Plus/Minus

8 Steps

10 Steps

34

Coarse/Fine

Linear

Plus/Minus

12 Steps

14 Steps

16 Steps

18 Steps

35

Coarse/Fine

Linear

Plus/Minus

20 Steps

22 Steps

24 Steps

26 Steps

36

Coarse/Fine

Appendix 2: Single-Phase Diagrams for UCG/I Linear

Plus/Minus

8 Steps

10 Steps

12 Steps

14 Steps

37

Coarse/Fine

Linear

Plus/Minus

16 Steps

18 Steps

20 Steps

22 Steps

38

Coarse/Fine

Linear

Plus/Minus

24 Steps

26 Steps

28 Steps

30 Steps

39

Coarse/Fine

Linear

Plus/Minus

32 Steps

34 Steps

40

Coarse/Fine

Appendix 3: Single-Phase Diagrams for UCG/III, UCL/III and UCD/III Linear

Plus/Minus

8 Steps

10 Steps

12 Steps

14 Steps

41

Coarse/Fine

Linear

Plus/Minus

Coarse/Fine

16 Steps

17 Steps

18 Steps

18 Steps

20 Steps

22 Steps

42

Linear

Plus/Minus

24 Steps

26 Steps

28 Steps

30 Steps

43

Coarse/Fine

Linear

Plus/Minus

32 Steps

34 Steps

44

Coarse/Fine

Appendix 4: Single-Phase Diagrams for UCC Linear

Plus/Minus

8 Steps

10 Steps

12 Steps

14 Steps

45

Coarse/Fine

Linear

Plus/Minus

16 Steps

18 Steps

20 Steps

22 Steps

46

Coarse/Fine

Linear

Plus/Minus

24 Steps

26 Steps

28 Steps

30 Steps

47

Coarse/Fine

Linear

Plus/Minus

32 Steps

34 Steps

48

Coarse/Fine

Notes:

_

_

Notes:

_

_

1ZSE 5492-105 en, Rev. 5, 2000-11-15

ABB Components AB Visiting address: Lyviksvägen 10 Postal address: SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00 Fax +46 240 121 57 E-mail: [email protected] www.abb.com/transmission

Printed in Sweden by Globe, Ludvika, 2000

Motor-drive mechanism, type BUL Technical guide

This Technical Guide has been produced to allow transformer manufacturers, and their designers and engineers, access to all the technical information required to assist them in their selection of the appropriate on-load tap-changer and motor-drive mechanism. The guide should be used in conjunction with the Selection Guide and the Design Guides, to allow the optimum selection to be made. The technical information pertaining to on-load tap-changers and motor-drive mechanisms manufactured by ABB has been divided and is contained in separate documents, with one document for each type. The information provided in this document is intended to be general and does not cover all possible applications. Any specific application not covered should be referred directly to ABB, or its authorized representative. ABB makes no warranty or representation and assumes no liability for the accuracy of the information in this document or for the use of such information. All information in this document is subject to change without notice.

Table of Contents General Information ____________

4

Applications __________________________ Design ______________________________ Cabinet ______________________________ Tropical Version _______________________ Type Tests ___________________________ Ambient Air Temperature ________________ Connection of Motor-Drive Mechanism to Tap-Changer _______________________ Rating Plate __________________________

4 4 4 4 4 6

Mechanical Arrangements _______

8

Driving Arrangement ____________________ Hand Crank __________________________ ”One-Turn” Shaft ______________________ Position Indicator ______________________ Mechanical End Stops __________________ Electrical End Stops ____________________ Brake _______________________________ Indicator Flag _________________________ Operation Counter _____________________ Maintaining, Interlocking and Auxiliary Contacts ______________________ Multi Position Switches __________________ Position Transmitter, Potentiometer _____

8 8 8 8 8 8 8 9 9

6 7

Continuation Contact _________________ 9 Auxiliary Contacts ___________________ 9 Driving Mechanism Equipment ____________ 10 Exploded Views and Photos ______________ 11

Principles of Operation __________

14

Raise-Operation with Local Control ________ Lower-Operation with Local Control ________ Through Positions ______________________ Remote Control _______________________

14 14 14 14

Circuit Diagram ______________________ 15

9 9 9

Contact Timing Diagram _________________ 16

Standard Version _______________

17

Control ______________________________ Protection ____________________________ Indication ____________________________ Wiring _______________________________ Maintenance __________________________ Design Options ________________________ Multi-Position Switches __________________ Technical Data ________________________ Dimensions ___________________________ Weight ______________________________

17 17 17 17 17 17 17 18 19 19

General Information Applications The BUL Motor-Drive Mechanism is designed for outdoor operation of the On-Load Tap-Changers and large Deenergized Tap-Changers listed below.

Tap-Changer

Type of Connection

UBB UCG UCL

For all connections Star point or single-phase Star point or single-phase

The Motor-Drive Mechanism is mounted to the transformer tank with four screws or studs, M12 or ½”, through the backside of the cabinet. Those are screwed from the inside of the cabinet and also going through the frame for the mechanism. The bottom has a flange opening for cable connection, size FL 21, see page 19. When delivered the opening is covered with a 5 mm thick lightalloy cover. The cabinet has two vents. Filters prevents insects and dust from entering. In order to prevent condensation inside the cabinet a 50 W heater is supplied which is permanently connected. With this heater the Motor-Drive Mechanism functions satisfactorily down to -40 oC (-40 oF). For temperatures below -40 oC or on customers request an additional 100 W heater controlled by a thermostat can be supplied. This extra heater can also on request be supplied with a switch for manual disconnection.

Design The Motor-Drive Mechanism is normally mounted on the side of the transformer tank and by means of drive shafts and bevel gears connected to the Tap-Changer. The shaft system is described in the Technical Guide for each type of Tap-Changer.

The tightness of the cabinet has been type tested for protection class IP 56 according to IEC 529 (protected against dust and powerful water jets).

The BUL contains all the necessary equipment for operation of the Tap-Changer. Special equipment can be supplied in order to fulfil customers requests. Paralleling and voltage regulation systems can also be supplied to supplement the Motor-Drive Mechanism and TapChanger.

The handlamp is automatically switched on when the door is opened. On request the inside of the cabinet can have a 3 mm thick layer of anti-condensation paint.

Cabinet

Tropical Version

The cabinet is manufactured of welded sheet steel and is in standard version hot dip galvanized. On request it can instead be painted with a white primer or a complete painting system, primer and top coat, suitable for outdoor use.

The Motor-Drive Mechanism can be equipped to meet the requirements for humid tropical climate and desert conditions. Anti-condensation painting inside the cabinet and screens to shade from direct sun radiation can be supplied.

The front door is formed as a cap in order to give better access to the internal parts. The door can be hinged on either the left or the right hand side. Provision is made for eventual padlocking. The door is sealed with rubber gasket and the window is glued to the door.

Type Tests The BUL Motor-Drive Mechanism fulfills the requirements of IEC Standard 214, 1989-07, and has been type tested according to clause 12.

4

The position numbers below refers to page 10.

135

130 133

134

131

Fig. 1. Motor-Drive Mechanism type BUL

L036702

Fig. 2. Motor-Drive Mechanism type BUL

L036703

5

Ambient Air Temperature The ambient air temperature requirements for the MotorDrive Mechanism are shown in fig. 3. The normal operating range is between –40 oC and +60 oC. The Motor-Drive Mechanism has been type tested at ambient air temperatures of –40 oC and +70 oC.

The Motor-Drive Mechanism must be shaded from sun radiation by screens. It must be specially equipped if the ambient temperature exceeds +70 oC.

Normal operating range. (50 W heater shall operate). The temperature inside the cabinet should not exceed +75 oC.

Extra 100 W heater is required. Extra 100 W heater and anti-condensation coverage are required. ABB should be consulted.

Fig. 3. Motor-Drive Mechanism ambient air temperature

Connection of Motor-Drive Mechanism to Tap-Changers The connection between the Tap-Changer and the Motor-Drive Mechanism is made by means of drive shafts and bevel gears. This external shaft system is described in the Technical Guide for each Tap-Changer. The Motor-Drive Mechanism has the outgoing shaft going through a water resistant bearing in top of the cabinet. The shaft is terminated by a multiple hole coupling half.

6

Rating Plate The rating plate shows data for both Tap-Changer and Motor-Drive Mechanism and is placed on the front door of the Motor-Drive Mechanism.

Fig. 4. Example of Rating Plate

7

Mechanical Arrangements

(See Fig. 5–8 and legend on page 10)

Driving Arrangement The drive mechanism motor M1 with its pulley 121 drives, with ratio 4.5:1, pulley 122 on the intermediate shaft 140 via a toothed belt 101. On the intermediate shaft is a pinion with helical teeth 141 which with ratio 5:1 drives the helical gear 142 on the outgoing shaft 103. The outgoing shaft is then via a multiple hole coupling 143 directly connected to the shaft system of the TapChanger. The outgoing shaft makes 5 revolutions per operation.

for indication of the maximum and minimum positions. Those drag-hands can be restored manually. The position indicator is visible through a window in the door.

Mechanical End Stops The upper Geneva wheel 125 is supported by the Geneva shaft and turns independent of the shaft controlled by the upper driving pin 108 on the ”one-turn” shaft. On the Geneva wheel two screws 136 are fitted which at the end positions operates the mechanical end stop 113 via an arm 147. Extra screws could be placed in between the screws 136 if a decreased tap-change range is desired.

The Mechanism is assembled on a support of casted aluminium, 144.

Hand Crank The mechanism can be manually operated by means of a hand crank 104. The hand crank is put on the crank shaft 105, which through the bevel pinion 123, with ratio 3:1, drives the bevel gear 124 on the outgoing shaft. Direction of operation is clockwise for a raise operation and 15 revolutions are needed per operation. This is also shown on a sign placed on the transparent protection screen.

After the end position has been reached the mechanical end stop is pressed out in the way for a knob 148 under the helical gear 142 which prevents the outgoing shaft from further movement in that direction. When the mechanism is returned to the end position by manual cranking, the mechanical end stop will be pressed back by springs, which also keeps it positioned in all normal tap change positions.

When the hand crank is put onto the crank shaft, the interlocking switch S5 breaks the operating circuit of the motor thus preventing electrical operation.

The breakpin 114 in the bevel pinion 123 on the crank shaft 105 prevents overloading of the end stops by hand cranking.

With manual operation the mechanism must be put into an exact position. If the mechanism is left between two positions or in a through position, when it is electrically supplied, the mechanism starts directly on removal of the hand crank.

Electrical End Stops On the lower end of the shaft for arm 147 a cam curve 149 is mounted. When the mechanism is in an end position this cam curve operates limit switches S6 and S7 which breaks the operating circuit of the motor and two phases of the motor supply. Electrical operation beyond the end positions is thus impossible.

”One-Turn” Shaft A helical pinion 106 on the outgoing shaft drives, with ratio 5:1, the helical gear 102 placed on the ”one-turn” shaft 107. This shaft drives two Geneva wheels 125 and 126 with the ratio 36:1. The driving pin 108 for the upper Geneva wheel 125 shall in the normal position be in the slot of the Geneva wheel whereas the lower Geneva wheel 126 is locked by the circumference of the ”oneturn” shaft.

In case of faulty limit switches the motor will be stopped by the mechanical end stop and is dis-connected when the thermal over-current protection trips the motor protective switch Q1 see circuit diagram on page 15.

Brake On the upper end of the ”one-turn” shaft 107 is a cam disc 128 which operates a brake 117 working on a brake disc 118 on top of the intermediate shaft 140. This brake makes sure that the Motor-Drive Mechanism stops in the correct position after each tap change. The brake can be adjusted by a screw 150 which is pressing on the spring 151 that closes the brake.

Position Indicator The lower Geneva wheel 126 is pinned to the Geneva shaft 145, which through a bevel gear 109, with ratio 1:1 operates the position indicator shaft 146, on which the position indicator pointer 110 is assembled. On the position indicator shaft is also assembled drag-hands

8

Indicator Flag

Multi-Position Switches

The indicator flag is placed in the end of the indicator arm 116 which is operated by the cam disc 128. The flag is visible through a slot in the front plate 119. When the mechanism is in position the white part of the flag is visible and during a tap-change the red part is shown.

The lower end of the Geneva shaft 145 is via a coupling 111 connected to the multi position switch shaft 112. The multi position switch therefore moves 1/36 of a turn, 10o, per tap change step. The multi position switch 127 is assembled of up to 5 different printed circuit cards 160. Each card has a contact arm 161. A slot in the multi position switch shaft 112 transferes the turning to a knob on the contact arm. The contacts 162 on the arm are solid silver rivets and the contact surfaces 163 on the circuit cards are gold plated. Before delivery all cards are insulation tested with 2 kV to earth.

The indicator flag is also visible through the window in the door.

Operation Counter A seven digit mechanical operation counter 120 is also operated by the indicator arm 116. The counter is not possible to reset and will register the total number of operations carried out by the Motor-Drive Mechanism. The counter is mounted on the front plate 119 and is also visible through the window in the door.

The contacts on each card are protected against dust by a transparent cover 164. Position Transmitter (S14), Potentiometer

Maintaining, Interlocking and Auxiliary Contacts

As standard the contact device is supplied with a potentiometer transmitter which has 10 ohm, 0.6 W, resistances between each position. Other resistances can be supplied on request.

At the lower end of the ”one-turn” shaft is another cam disc 115 which via a lever 129 operates two sets of contacts, S3 and S4. S3 is affected during raise operations and S4 during lower operations.

On request a suitable measuring amplifier for moving-coil instrument can be supplied. Also the instrument for remote position indication in the control room can be included on request.

The cam disc does not release the lever and the contacts before the tap-change operation is completed. Before the start impulse disappears the maintaining contact 33-34, see Fig. 9, closes another feeding to the contactor K2 or K3 and thus keep the motor running until the operation is completed. After a possible interruption of the supply voltage during an operation this contact will also make the operation completed when the supply voltage returns.

Continuation Contact (S15) In cases when the Tap-Changer has two or more positions with the same voltage a continuation contact is supplied. Only one of the positions is the service position, and the others are through positions which are passed automatically at an electric operation. See description of operation on page 14.

The interlocking contacts 41-42, see Fig. 9, opens the circuit to the contactor for operation in the opposite direction. Thus unintentional change of direction is prevented. This contact also prevents operation in case the motor rotation should be wrong due to incorrect phase sequence.

Auxiliary Contacts Auxiliary contacts, break before make or make before break as well as odd-even switches for parallel control can be supplied on request.

The contacts 13-14 and 21-22, see Fig. 9, are auxiliary contacts. They can be used for signal to the control room or remote interlocking during tap change operation.

9

Driving Mechanism Equipment See Fig. 1, 2 and 5–8.

E1 E3 K1 K2 K3 M1 Q1 S1 S2 S3 S4 S5 S6 S7 S9 S14 S15 X1-17 U1 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119

Anti-condensation heater Cabinet light Step-by-step relay Contactor, Raise Contactor, Lower Motor Motor protective switch Control selector switch, Local-0-Remote Control switch, Lower-0-Raise Maintaining, interlocking and auxiliary contact, Raise Maintaining, interlocking and auxiliary contact, Lower Interlocking switch, open when hand crank is fitted Limit switch, Upper tap position Limit switch, Lower tap position Door operated switch Position transmitter, potentiometer Continuation contact Terminals Measuring amplifier Toothed belt Helical gear Outgoing shaft Hand crank Crank shaft Helical pinion ”One-turn” shaft Geneva wheel driving pin Bevel gear Mechanical position indicator Coupling Multi position switch shaft Mechanical end stop Breakpin Cam disc for maintaining contact Indicator arm Brake Brake disc Front plate

10

120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 140 141 142 143 144 145 146 147 148 149 150 151 160 161 162 163 164

Operation counter Pulley Pulley Bevel pinion Bevel gear Geneva wheel, upper Geneva wheel, lower Multi position switches Cam disc Lever for maintaining contact Rating plate Hinges Motor-drive mechanism cabinet Door Hand knob Air vent Screw for end stop Intermediate shaft Helical pinion Helical gear Multiple hole coupling half Support Geneva shaft Position indicator shaft Arm for end stop Knob for mechanical end stop Cam curve Screw for adjustment of brake Spring for brake Printed circuit card Contact arm Silver rivet contact Gold plated contact surface Transparent cover

= Direction of rotation for a raise operation

Fig. 5. Motor-Drive Mechanism type BUL 11

Fig. 6.

Fig. 7. 12

K2

K3

Fig. 8. 13

Principles of Operation Circuit Diagram for AC Supply, see Fig. 9.

Through Positions

The supplies for motor, control circuits and heater are connected to their respective terminal blocks according to the instructions on the diagram.

A so called ”Through position”, is a position the TapChanger has to pass without changing the ratio of the transformer. These positions are passed automatically. The continuation contact S15 bridges the maintaining contacts S3:33-34 and S4:33-34 via auxiliary contacts on raise contactor K2 at through positions. In this way the contactor K2 raise, or K3 lower, is kept energized and the motor will automatically make another operation.

Raise-Operation with Local Control When switch S1 is set in position ”Local” the mechanism can be operated by control switch S2. For a raise operation the procedure is as follows:

The connection of S15 to auxiliary contacts on K2, means that the drive, in the event of a control supply failure in a through position, always moves to a lower normal service position, when the voltage returns.

Motor contactor K2 is energized, the contactor closes the motor phases, the motor starts and drives the mechanism in the raise-direction. After about 0.2 seconds the brake is released and after about 0.4 seconds the maintaining contact S3: 33-34 closes and take over the feeding of contactor K2 when control switch S2 is released.

Remote Control Control selector switch S1 is placed in the ”Remote” position. The control supply for the remote pushbuttons or regulating relay is then received from a terminal in the Motor-Drive Mechanism Cabinet. Incoming control circuits for raise and lower impulses should be connected to other terminals as shown in the diagram. Local operation is not possible when switch S1 is in the ”Remote” position and remote operation is not possible in the ”Local” position.

The switching in the On-Load Tap-Changer takes place after about 3 seconds. The driving mechanism keeps on rolling until the cycle is completed, which takes about 5 seconds. About 0.2 seconds before the cycle is completed, the maintaining contact S3 is released, contactor K2 falls and the feeding of the motor is interrupted. At the same time the brake is engaged and the mechanism will stop in the new position.

Step-by-Step-Operation

Lower-Operation with Local Control

Step-by-step relay (K1) connected so that only one tap change operation is obtained each time the raise/lower switch is operated.

A similar cycle is obtained, but in the lower direction, when the control switch S2 is switched to lower position and contactor K3 is engaged.

Protection against Running-Through A relay (K6) stopping the motor-drive mechanism in case of a failure of the step-by-step control circuit which would cause a running-through of the motor-drive mechanism. The relay energizes the trip coil in the protective motor switch (Q1).

Contact Timing The contact timing diagram, Fig. 10, shows the contact sequences for one change of tap position for raise and lower directions.

14

Circuit Diagram The diagram shows the mechanism in middle position.

Fig. 9. 15

Contact Timing Diagram

Fig. 10. S3 Maintaining, interlocking and auxiliary contact, Raise S4 Maintaining, interlocking and auxiliary contact, Lower S15 Continuation contact

S14 Position transmitter, potentiometer S6 Limit switch, Upper tap position S7 Limit switch, Lower tap position 16

Standard Version Control

Wiring

z Control selector switch, Local-0-Remote. z Control switch, Raise-0-Lower. z Hand crank for manual operation.

The wiring is of grey polyvinylchloride-insulated, stranded wire. Type and data see Technical data. Every wire is marked with figures corresponding to terminal numbers. All external connections are made of thermosetting resin. Type and data see Technical data.

Protection

Short circuit protection (fuses) for control and heater supplies, if required, should be installed in the control cabinet or other separate compartment. No fuses are required for the motor, as the motor protective switch has magnetic overcurrent release.

z Protective switch for the motor with thermal overload

release and magnetic overcurrent release. z Limit switches – in both control and motor circuits. z Mechanical end stops. z Interlocking contact in the control circuit to prevent electrical operation during manual operation. z Interlocking contacts in raise and lower control circuits to prevent operation in wrong direction of rotation (with wrong phase sequence). z Motor contactors are electrically interlocked. z Protection against running-through in case of a failure of the step-by step control circuit. z Emergency stop push button.

Maintenance All bearings in the Motor-Drive Mechanism type BUL have rubber seals and are permanently greased and some gears and moving details are made of selflubricating material. No greasing is necessary during the lifetime of the Motor-Drive Mechanism at normal working conditions.

Indication

The Motor-Drive Mechanism should be inspected once a year.

z z z z

Mechanical position indicator Drag-hands for max. and min. position indication. Red flag for indication of Tap Changer in progress. Operation counter. (The above four items are visible through the window in the cabinet door). z Position transmitter, potentiometer, for remote position indication.

For the correct inspection and maintenance procedures, consult the appropriate Maintenance Guide.

Design Options For already prepared design options, please see Selection Guide and Ordering data forms. If other options than those listed in the Selection Guide and Ordering data forms are required, please consult ABB.

Multi-Position Switches Maximum 5 contact rows can be accomodated, including one continuation contact when there are through positions. Position transmitter

Auxiliary contact Break before make

Auxiliary contact Make before break

Step switches for parallel control Type 1 Type 2

Number of contact rows

1

1

1

Note: Master switch for parallel control is a break-before-make auxiliary contact.

17

1

2

Technical Data Subject

Standard version

Alternative version

Special version at an additional price

Motor voltage, 3-phase

220-240/380-420 V, 50 Hz

208/360 V, 60 Hz 220-240/380-420 V, 60 Hz 250-280/440-480 V, 60 Hz

120 V, 1-phase, 60 Hz 240 V, 1-phase, 60 Hz Optional

Current Rated output Speed

1.4/0.8 A 0.18 kW 1370 r/min

Voltage for control circuit

220 V, 50 Hz

240 V, 50 Hz, 220 V, 60 Hz 110 V, 220 V D.C. 120 V, 208 V, 240 V, 60 Hz Optional

Voltage for heater

220-240 V

110, 120-127 V

Optional

Multi position switches

0.15 A, 230 V A.C. 0.15 A, 220 V D.C. L/R = 40 ms

Mechanical position indicator

lowest position marked 1

middle position marked N

Optional

Terminal blocks in BUL Number of terminals supplied

28-Phönix UK 5N 41 A, 800 V A.C. acc. to IEC cross sectional area: 0.5 - 4 sqmm

Number of terminals that can be accomodated (depending on selected options) Cabling Test voltage on control circuits

122 - Phönix UK 5N 116 - Weidmüller SAK 4/35 PA 92 - Phönix URTK/S Ben 92 - Phönix URTK/S 68 - Phönix OTTA 6 Type H07V2-K, 1.5 sq mm, 750 V, 90 oC Type H05V2-K, 0.75 sq mm, 500 V, 90 oC

Optional

2 kV (50 Hz, 1 min)

Anti-condensation heater Additional heater

50 W

Approx. operating time

5 sec

Starting impulse length

> 0.5 sec

Number of revolutions per operation of the outgoing driving shaft the hand crank

5 15

Max. torque on the outgoing shaft

30 Nm

Max. number of positions

35

Degree of protection of cabinet

IP 56 acc. to IEC 529

100 W controlled by thermostat or hygrostat

(Dust protected/Protected against powerful water jets)

18

Dimensions

813

554

308 39 29

158

Weight Motor-Drive Mechanism type BUL:

75 kg

19

1ZSE 5483-105 en, Rev. 3, 2003-08-31

ABB Power Technology Products AB Components Visiting address: Lyviksvägen 10 Postal address: SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00 Fax +46 240 121 57 E-mail: [email protected] www.abb.com

Produced by Globe, Ludvika, Sweden, 2003

1ZSE 5492-116 en, Rev. 8, 2004-03-15

On-load tap-changers, types UCG and UCL with motor-drive mechanisms, types BUE and BUL 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 equipment. NOTE: A NOTE provides additional information to assist in carrying out the work described.

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 carcinogenic. 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. To be continued on the next page. iii

Waste and cleaning up: Should be absorbed by an absorber. Treat it as hazardous to the environment. Upon fire: The fire should be extinguished by using powder, foam or carbon acid. WARNING Be aware of the risk for slipperiness caused by oil spillage for instance when working on the transformer cover. WARNING The motor-drive mechanism must not be installed in any explosive atmosphere. The electrical equipment creates sparks which can cause an explosion. 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. WARNING 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 unexpected start of the motor-drive mechanism. WARNING Before starting any work inside the motor-drive mechanism, the auxiliary power must be switched off. N.B. The motor, contactors and heating element may be energized from separate sources.

During Drying of the Transformer CAUTION The diverter switch should not be installed during drying, since the process removes grease needed for operation. CAUTION During drying with hot air and vacuum, the maximum permitted pressure difference for the diverter switch housing is 100 kPa at the maximum permitted temperature of 135 °C (275 °F).

iv

CAUTION During drying by the vapour phase process the cover of the diverter switch housing and the bottom valve should be left open. The valve is opened with the special bottom valve key, a long hexagonal rod. The maximum permitted temperature is 135 °C (275 °F).

CAUTION Use the special bottom valve key only (delivered with the on-load tap-changer) to operate the bottom valve through the oil draining tube. The use of a stiffer tool may damage the valve.

CAUTION 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 tightening torque and finally with the recommended tightening torque as described in section 1.8 Tightening Torque, in this guide.

During Oil Filling WARNING When oil that has been used in a diverter 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 diverter switch housing if the transformer tank is under vacuum and the diverter switch housing is not.

CAUTION Do not fill oil into the transformer tank if the diverter switch housing is under vacuum and the transformer tank is not.

CAUTION Leave a gas cushion on top of the oil in the diverter switch housing.

v

After Oil Filling CAUTION Do not energize the transformer earlier than three hours after oil filling in atmospheric pressure. 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 6.5.

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.

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

WARNING The hand crank must not be inserted during electrical operation.

WARNING If the on-load tap-changer is not in its exact position and the hand crank is pulled out, the motor-drive mechanism will start and go to the exact position if the power supply is on.

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

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.

vi

Contents 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Introduction ____________________________________________ Type Designation ________________________________________ Required Tools _________________________________________ Required Material _______________________________________ Oil ___________________________________________________ Oil Conservator _________________________________________ Oil Filter Unit for Continuous Oil Filtration ___________________ Weights _______________________________________________ Tightening Torque _______________________________________

9 10 13 13 14 15 15 15 17

2 2.1 2.2 2.3

Receiving ______________________________________________ Unpacking _____________________________________________ Inspection on Receipt ____________________________________ Temporary Storage before Assembly ________________________

17 17 17 17

3 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1

18 19 19 25 29 33

3.2.3 3.3 3.4 3.4.1 3.4.2

Installation in the Transformer _____________________________ Cover-Mounting ________________________________________ UCG with Tap Selector size I or C __________________________ UCG with Tap Selector size III _____________________________ UCL with Tap Selector size III _____________________________ Yoke-Mounting _________________________________________ Mounting when the Transformer Ratio Measurement is carried out before Drying ________________________________ Mounting when the Transformer Ratio Measurement is carried out after Drying _________________________________ Mounting on Transformer Cover ____________________________ Connection to Terminals __________________________________ Transformer Ratio Measurement ____________________________ Transformer Ratio Measurement before Drying ________________ Transformer Ratio Measurement after Drying _________________

4 4.1 4.2 4.3

Drying ________________________________________________ Observations before Processing ____________________________ Observations after Processing ______________________________ Installation of Diverter Switch _____________________________

46 46 46 47

5 5.1 5.2 5.2.1 5.2.2

Final Assembly _________________________________________ Mounting of the Motor-Drive Mechanism ____________________ Mounting of External Drive Shafts __________________________ Mounting of Vertical Drive Shaft ___________________________ Mounting of Horizontal Drive Shafts, types UCG.N/UCL.N and UCG.E/UCL.E ____________________ Mounting of Horizontal Drive Shafts, type UCG.B/UCL.B _______ Mounting of Horizontal Drive Shafts, types UCG.T/UCL.T and UCGYD/UCLYD __________________ Before Operation ________________________________________ Pressure Relay __________________________________________ General _______________________________________________ Installation _____________________________________________ Checking at Commissioning of the Transformer _______________ Assembly of Accessories __________________________________ Connection to the Oil Conservator __________________________

49 49 52 54

3.2.2

5.2.3 5.2.4 5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.4 5.5

34 37 38 42 44 45 45

56 59 64 64 65 65 65 66 67 67

7

6 6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.5 6.5.1

Oil Filling _____________________________________________ Filling Methods and Restrictions ___________________________ Before Filling ___________________________________________ Filling at Atmospheric Pressure ____________________________ Filling under Vacuum ____________________________________ Oil Conservator Filled Afterwards __________________________ Oil Conservator Filled under Vacuum _______________________ Restoring the Gas Cushion ________________________________ Procedure ______________________________________________

68 68 68 69 69 70 70 71 72

7 7.1 7.2

Electrical Connection and Testing __________________________ General _______________________________________________ Connecting and Testing the Motor-Drive Mechanism and the On-Load Tap-Changer ____________________________________ Electrical Tests on the Transformer _________________________ After Energizing ________________________________________

73 73

Transport ______________________________________________ Dismantling before Transport ______________________________ Dismantling Preparations _________________________________ External drive shafts for UCG.N/UCL.N, UCG.E/UCL.E (One Unit) External drive shafts for UCG.B/UCL.B (Two Units) ___________ External drive shafts for UCG.T/UCL.T and UCGYD/UCLYD (Three Units) ____________________________ Accessories ____________________________________________ Oil Level During Transport ________________________________ Transformer filled with Oil ________________________________ Conservator mounted _____________________________________ Conservator dismounted __________________________________ Transformer drained _____________________________________ Conservator mounted _____________________________________ Conservator dismounted __________________________________

75 75 75 75 76

7.3 7.4 8 8.1 8.1.1 8.1.2 8.1.3 8.1.4 8.1.5 8.2 8.2.1 8.2.1.1 8.2.1.2 8.2.2 8.2.2.1 8.2.2.2 9 9.1 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.3 9.4 9.5 9.6 9.6.1 9.6.2 9.6.3 9.6.4 9.6.5 9.6.6 9.7 8

Commissioning _____________________________ Connection to the Oil Conservator __________________________ Mounting the Motor-Drive Mechanism and the Drive Shafts ______ Mounting of the Motor-Drive Mechanism ____________________ Mounting of the External Drive Shafts _______________________ Mounting of the Vertical Drive Shaft ________________________ Mounting of Horizontal Drive Shaft types UCG.N/UCL.N and UCG.E/UCL.E ______________________________________ Mounting of Horizontal Drive Shafts type UCG.B/UCL.B _______ Mounting of Horizontal Drive Shaft types UCG.T/UCL.T and UCGYD/UCLYD ____________________________________ Before Operation ________________________________________ Pressure Relay __________________________________________ Accessories ____________________________________________ Oil Filling _____________________________________________ Electrical Connection and Testing __________________________ Motor Protection ________________________________________ Disc Brake _____________________________________________ Counter _______________________________________________ Position Transmitter and other Position Switches _______________ Light _________________________________________________ Heater ________________________________________________ Putting into Operation ____________________________________

73 74 74

76 77 77 78 78 78 78 78 78 79 80 80 80 81 81 83 85 89 89 90 90 90 90 90 90 91 91 91 91 91

1 Introduction

1 Introduction The arrangement of on-load tap-changers types UCG and UCL are shown in Figs. 1 and 2. The on-load tap-changer may consist of one, two or three units driven by the same motor-drive mechanism. To make transportation easy the on-load tap-changer is delivered in three main parts. These are diverter switch housing, tap selector and motor-drive mechanism. The on-load tap-changer is performed for cover-mounting or for yoke-mounting. Cover-mounting means that the diverter switch housing is lowered through the hole in the transformer tank and then bolted straight onto the transformer cover, and after that the tap selector is mounted. Yoke-mounting means that the on-load tap-changer is temporarily put on a fork located on the active part of the transformer. Yoke mounting allows the transformer manufacturer to connect the windings to the on-load tapchanger 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 yokemounting in chapter 3. At cover-mounting the diverter switch housing is installed on the transformer cover before joining with the tap selector except for the UCG/I and UCG/C. On the latter the tap-selector and the diverter switch housing are joined before the entire on-load tapchanger is lowered through the hole in the transformer cover. After the drying process of the transformer 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 arrangement of the on-load tap-changer systems is shown in Fig. 2. Position numbers in the Installation Guide, for example SA11 (see section 5) correspond with those in the packing list for the on-load tap-changer. All instructions are for one on-load tap-changer unit. In case of more than one unit on the transformer, carry out the same procedures for each unit.

9

1 Introduction

1.1 Type Designation UCG .. UCL ..

XXXX/YYYY/I, III, C XXXX/YYYY/III

Example: UCLRE 650/900/III Type of switching L Linear R Plus/Minus D Coarse/Fine Type of connection N Three-phase star point (one unit) E Single-phase (one unit) T Three-phase fully insulated (three units) B Three-phase delta (two units; single-phase and two-phase) Impulse withstand voltage to earth Maximum rated through-current Tap selector size

Serial No.

Diverter switch type UCG

Serial No. in the bottom of the diverter switch

Serial No.

Serial No.

Tap selector size C

Tap selector size I

Fig. 1.

10

Tap selector size III

1 Introduction

Serial No. Diverter switch type UCL

TC_00263

Serial No. in the bottom of the diverter switch

Tap selector, size III

Fig. 1a.

11

1 Introduction

Bevel gear

Horizontal drive shafts and protective tubes

;

Bevel gear

Pressure relay

Vertical drive shafts and protective tubes Shielding caps (only for insulation level above 380 kV)

Type of connection, N or E

Rating plate Shielding rings (only for insulation level above 380 kV)

Hand crank (inside the cover) Motor-drive mechanism

Not used for selector, size C

fm_00218

Unit -1

;

;

Type of connection, B

fm_00189

Unit -1

Unit -2

;

;

;

Type of connection, T

fm_00219

Unit -1

Unit -2

Unit -3

Fig. 2. Example of on-load tap-changer system 12

1 Introduction

1.2 Required Tools Required for work according to chapter/section Normal set of open end wrenches (up to 24 mm)

General

Normal set of sockets (up to 24 mm)

General

Normal set of screw drivers

General

Socket handle

General

Set of pliers, including cutting pliers

General

Dynamometric wrench 5-85 Nm

General

Sliding caliper

General

Allen key sockets 2–10 mm

General

Pipe wrench

3.2

Bottom valve key (delivered with the on-load tap-changer)

3.2.1, 4 and 6.2

Lifting equipment for UCL. Article No. LL 136 016-D (can be ordered from ABB)

3.2.2

Lifting equipment for UCG. Article No. LL 135 016-A

3.2.2

Special hand crank for operating the on-load tap-changer on the bevel gear (can be ordered from ABB)

3.4

Hack saw (only for installation)

5

File

5

Folding ruler

5

Air pump with hose, pressure gauge (0–250 kPa) and connection with internal thread R 1/8”

5.3

Container, 50 litres

6

Small oil pump with connection to the oil valve (For connection dimensioning see the dimension drawing for the on-load tap-changer).

6

1.3 Required Material Rags for cleaning

General

Single-phase diagram for the on-load tap-changer

General

Pressboard sheet (t =1, approx. 100x300 mm, 2 pieces) (for UCL only)

3.1

Gasket for transformer flange

3.1, 3.2.3

Insulating paper

3.1, 3.2

Insulating bushings

3.2

13

1 Introduction

Required for work according to chapter/section Wooden block as spacer

3.3

Grease (ball bearing grease) GULF-718 EP, Mobil-Grease 28, SHELL-Aero Shell Grease 22 or similar

3, 9.2.2

Oil, see section 1.4

6

Dimension drawing for the on-load tap-changer for connection dimensions of the oil valve

6

Flange for connection to the oil conservator flange when filling under vacuum, see Fig. 38

6.4

Oil valves for connection to flange with dimensions according to Fig. 42. Can be ordered from ABB

6.4.1

Equipment for oil filling

6, 9.5

Sealing tape

6, 9.5

Maintenance Guide for UCG/UCL

7.2

Circuit diagram for the motor-drive mechanism

7.2

Oil filter (in case of common conservator for both the transformer and the on-load tap-changer, can be ordered from ABB).

5.5

1.4 Oil The oil quality should be of Class II according to IEC publication 60296. Table 1. Weight of oil in kg. Type designation

Oil weight 1) (kg)

UCG.. 380/..., 650/... 750/... UCG.. 1050/...

150 185

UCL.. 380/.... UCL.. 650/.... UCL.. 1050/....

260 300 340

1)

The oil for the conservator is not included.

NOTE: An UCG.B/UCL.B requires twice and UCG.T/UCL.T three times the amount specified above since they have two and three diverter switch housings respectively. WARNING Do not energize the transformer until oil has been filled according to chapter 6, Oil Filling, in this guide.

14

1 Introduction

1.5 Oil Conservator The on-load tap-changer has to be connected to an oil conservator. ABB recommends to use a separate conservator for the on-load tap-changer with both oil and air side separated 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 on-load tap-changers consisting of more than one unit require only one conservator. A suitable dimension of the tube for connection to the conservator is an innerdiameter 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.

1.6 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 are found in the manual for the oil filter unit, ”Oil filter unit for On-Load Tap-Changers, Manual” delivered with the oil filter unit.

1.7 Weights Motor-drive mechanism type BUE 1:

approximately 130 kg

Motor-drive mechanism type BUE 2:

approximately 155 kg

Motor-drive mechanism type BUL:

approximately 75 kg

The weights of the motor-drive mechanism and drive-shaft system are not included in the weights given on the next page.

15

1 Introduction

Table 2. Weights for UCG on-load tap-changers. On-load tap-changer Type designation

Approx. weight in kg Tap-changer Required without oil 1) oil

Total

UCG.N

380-750/300-600 1050/300-600

325 335

150 185

475 520

UCG.T

380-750/300-900 380-750/1050-1500 1050/300-900 1050/1050-1500

725 890 790 925

3x150 3x150 3x185 3x185

1175 1340 1345 1480

UCG.B

380-750/300-600 1050/300-600

560 580

2x150 2x185

860 950

UCG.E

380-750/300-900 380-750/1050-1500 1050/300-900 1050/1050-1500

260 310 270 325

150 150 185 185

410 460 455 510

1)

The weight of the diverter switch, approximately 90 kg, is included.

Table 3. Weights for UCL on-load tap-changers. On-load tap-changer Type designation

Total

UCL.N

380/600, 900 650/600, 900 1050/600, 900

480 500 510

260 300 340

740 800 850

UCL.T

380/600, 900 380/1800 380/2400 650/600, 900 650/1800 650/2400 1050/600, 900 1050/1800 1050/2400

1230 1350 1440 1290 1410 1500 1320 1440 1530

3x260 3x260 3x260 3x300 3x300 3x300 3x340 3x340 3x340

2010 2130 2220 2190 2310 2400 2340 2460 2550

UCL.B

380/600, 900 650/600, 900 1050/600, 900

850 890 910

2x260 2x300 2x340

1370 1490 1590

UCL.E

380/600, 900 380/1800 380/2400 650/600, 900 650/1800 650/2400 1050/600, 900 1050/1800 1050/2400

410 450 480 430 470 500 440 480 510

260 260 260 300 300 300 340 340 340

670 710 740 730 770 800 780 820 850

1)

16

Approx. weight in kg Tap-changer Required without oil 1) oil

The weight of the diverter switch, approximately 120 kg, is included.

2 Receiving

1.8 Tightening Torque The following tightening torques are recommended: For metallic screw joints:

M6, M8, M10, M12,

10 Nm 24.5 Nm 49 Nm 84 Nm

For non-metallic screw joints:

M10, 9 Nm M12, 13 Nm M16, 22 Nm

±10 % ±10 % ±10 % ±10 % ±10 % ±10 % ±10 %

if not otherwise is stated in this guide.

2 Receiving 2.1 Unpacking Check that the packages are free from transport damage. Open the covers of the transport boxes, Remove the supporting block of wood. If any package is damaged a careful investigation must be carried out. Lift the on-load tap-changer parts in their lifting eyes according to Fig. 3.

2.2 Inspection on Receipt 1.

Check that the diverter switch housing, tap selector, 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 photographs are taken of the damaged details. Mark the photos with ABB’s reference number and the serial number of the onload tap-changer and send them to ABB for comments.

3.

Check that the parts delivered, type designations and the serial number agrees with the delivery documents, e.g. the packing list or ABB’s order acknowledgement. The serial numbers to be checked are those on the rating plate, on the diverter switch housing and on the tap selector. For locations, see Figs. 1 and 2. The serial number on the parts belonging to one on-load tap-changer unit should all be the same.

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. 17

3 Installation in the Transformer

3 Installation in the Transformer The cover-mounting method or yoke-mounting method is used. WARNING The intermediate gear and the insulating shaft of the diverter switch housing moves during operation. Keep away during operation to avoid injuries! The diverter switch housing and the tap selector are designed to be lifted in the lifting eyes, see Fig. 3. WARNING To put down the complete on-load tap-changer to stand on the floor without any support on the top of the on-load tap-changer means a risk for tilting with risk for injuries to people and damage to the equipment.

Max 90o

TC_00114

Diverter switch housing Max 90o Max 90o

TC_00188

Max 90o

TC_00184

Tap selector C

TC_00185

Tap selector I

Fig. 3. How to lift.

18

Tap selector III

3 Installation in the Transformer

3.1 Cover-Mounting (For Yoke-Mounting, see section 3.2). The diverter switch housing and the tap selector are delivered packed separately.

3.1.1 UCG with Tap Selector size I or C 1.

Unpack the diverter switch housing and the tap selector. Remove the drying agents in the tap selector and on the diverter switch housing.

2.

Fit the gasket into the on-load tap-changer flange on the transformer cover, see Fig. 9. (This gasket is not included in the delivery).

3.

Remove the transport locking device and the lifting eyes from the top section of the tap selector, see Fig. 4.

CAUTION Do not operate the tap selector until it is connected to the diverter switch housing.

Lifting eyes (to be removed)

Transport locking (to be removed)

Screws (4 pcs) (to be removed)

TC_00209

Tap selector size I

TC_00211

Tap selector size C

Fig. 4. 4.

Lift the diverter switch housing in the lifting eyes and remove the transport support. For tap selector size C, remove the three limbs, see Fig. 5.

19

3 Installation in the Transformer

Diverter switch housing, lower part

Limbs (3 pieces) Hexagon screws and nut (3 pieces) TC_00215

Transport supports

Fig. 5. 5.

Lift the diverter switch housing onto the tap selector, the driving pin of the tap selector shall fit in the large gear wheel slot, see Figs. 6 and 7, view A–A.

CAUTION The driving crank on the tap selector must not be moved more than slightly to engage the slot in the large gear wheel of the diverter switch housing. 6.

20

Insert the fastening screws, three socket-head cap screws M12x40 for UCG with tap selector I, six hexagon screws M8x35 for UCG with tap selector C, and washers. Tighten the screws.

3 Installation in the Transformer

Washer 14x30x2,5

Spring washer Locking nut M12

Socket-head cap screw M12 F Shielding rings

Diverter switch housing, UCG B

B

F B–B

Conductor TC_00274

Insulating shaft

F–F

Washer 13x28x3

Conductors

Spring washer E

A

Locking nut M12

A

17 Washer, steel T=3

Tap selector, size I

Socket-head cap screw

25

C–C

E 13 17 Large gear wheel

C

Socket screw M8x20 (x4) Washer Tap selector

C

Locking nut M8

Current collector

D–D D Shielding ring, TS 11 M12x40 D Washer 13x24x2

Insulating screw M16x140 Conductors

Diverter switch housing

Insulating nut M16 Cleats

Tap selector E–E

Slot in the large gear wheel of the diverter switch housing Driving pin of the tap selector A–A

TC_00271

Fig. 6. Tap selector I and diverter switch UCG 21

3 Installation in the Transformer

Washer 14x30x2,5 Socket-head cap screw M12 F Shielding rings

Diverter switch housing, UCG

Spring washer Locking nut M12 F B–B

Conductor

Insulating shaft

TC_00274

B

B

F–F

Conductors

Locking nut M10 Spring washer Washer 10.5x24x3 D A

A

Socket-head cap screw

Large gear wheel Conductor D

C–C

Tap selector, size C Diverter switch housing

Current collector

C

C Tap selector Washer 8.4x20x2 Spring washer Hexagon headed screw M8x35

Conductors D–D

Insulating bolt M16x110

Slot in the large gear wheel of the diverter switch housing

Insulating nut M16 Cleats

Driving pin of the tap selector

TC_00272

A–A

Fig. 7. Tap selector, size C and diverter switch UCG

22

3 Installation in the Transformer

7a. In case the on-load tap-changer is equipped with a tie-in resistor for mounting under the tap selector, the tie-in resistor is mounted after joining the tap selector to the diverter switch housing. After mounting the tie-in resistor, the on-load tapchanger must not be put down standing on the tie-in resistor. It must be hanging, for instance in a traverse. WARNING To put down the on-load tap-changer to stand on the floor with the tie-in resistor mounted means a great risk for tilting the on-load tap-changer with risk for injuries to people and damage of the equipment. 7b. In case the on-load tap-changer is equipped with a tie-in resistor switch, (tap selector size I only) the switch is mounted under the tap selector at delivery. A special support in the box makes it standing on the tap selector bottom. If this special support is taken out of the box, the tap selector can be standing on this during joining to the diverter switch housing. After joining, the complete on-load tapchanger is lifted and the special support is removed. The complete on-load tapchanger must not be put on the special support. It must be hanging, for instance in a traverse. WARNING To put down the on-load tap-changer to stand on the floor with the tie-in resistor switch mounted means a great risk for tilting the on-load tap-changer with risk for injuries to people and damage of the equipment. 8.

Lift the on-load tap-changer in the lifting eyes as shown i Fig. 3 and lower it carefully through the opening in the transformer top cover, see Fig. 8. Place the on-load tap-changer correctly in position for mounting the outer shaft system (see transformer drawing). The studs on the flange on the transformer cover shall fit into the holes in the flange of the diverter switch housing.

Diverter switch UCG Top section Stud M12

Selector size I or C

Nut M12 (24x) Washer (24x) Flange

Opening in the transformer cover

Gasket

fm_00220

Fig. 8.

Fig. 9.

Transformer top cover TC_00282

23

3 Installation in the Transformer

9.

Mount the 24 washers and M12 nuts, see Fig. 9. Tighten the nuts.

WARNING The diverter switch housing and the tap selector contains moving parts. Be cautious! 10. Connect the supplied conductors between the diverter switch housing and tap selector, see Figs. 6 and 7. The conductor ends and their connecting points have the same markings. Make sure the assymetrical steel washers on the tap selector I contacts are mounted as shown in Fig. 6, view C–C. Fasten the conductors with cleats, see Fig. 6, A–A. The number of conductors is varying depending on the type of connection. 11. If the impulse withstand voltage to earth exceeds 380 kV, insulate the connections on the tap selector by winding paper around them to a thickness of approximately 3 mm, see Fig. 10. The paper should be of the same quality as used for insulation of conductors within the active part of the transformer. 12. UCG with tap selector I: If the impulse withstand voltage to earth exceeds 380 kV, mount the supplied shielding ring (TS 11) at the bottom plate of the tap selector, see Fig. 6, D–D. CAUTION After mounting the shielding ring, the on-load tap-changer must not stand on the shielding ring.

~ 100 mm

~ 3 mm

13. Continue with section 3.3.

Insulating paper

Locking nut Spring washer Plain washers

TC_00169

Socket screw

Conductor

Connection point on the tap selector

Fig. 10.

24

3 Installation in the Transformer

3.1.2 UCG with Tap Selector size III 1.

Unpack the diverter switch housing and the tap selector. Remove the drying agents in the tap selector and on the diverter switch housing.

2.

Fit the gasket into the on-load tap-changer flange on the transformer cover, see Fig. 9. (This gasket is not included in the delivery.)

3.

Lift the diverter switch housing in the lifting eyes as shown in Fig. 3 and lower it carefully through the opening in the transformer top cover, see Fig. 11. Place the diverter switch housing correctly in position for mounting the outer shaft system (see transformer drawing). The studs on the flange on the transformer cover shall fit into the holes in the flange of the diverter switch housing.

4.

Mount twenty-four washers and M12 nuts, see Fig. 9. Tighten the nuts.

Diverter switch UCG

Opening in the transformer cover

Selector size III

fm_00222

Fig. 11. 5.

Put the tap selector in position for joining to the diverter switch housing. Lift in the lifting eyes as shown in Fig. 3.

6a. In case the on-load tap-changer is equipped with a tie-in resistor for mounting under the tap selector, the tie-in resistor is mounted after joining the tap selector to the diverter switch housing. After mounting the tie-in resistor, the on-load tapchanger must not be put down standing on the tie-in resistor. It must be hanging, for instance in a traverse. WARNING To put down the on-load tap-changer to stand on the floor with the tie-in resistor mounted means a great risk for tilting the on-load tap-changer with risk for injuries to people and damage of the equipment.

25

3 Installation in the Transformer

6b. In case the on-load tap-changer is equipped with a tie-in resistor switch, the switch is mounted under the tap selector at delivery. A special support in the box makes it standing on the tap selector bottom. If this special support is taken out of the box, the tap selector can be standing on this during joining, to the diverter switch housing. After joining, the complete on-load tap-changer is lifted and the special support is removed. The complete on-load tap-changer must not be put on the special support. It must be hanging, for instance in a traverse. WARNING To put down the on-load tap-changer to stand on the floor with the tie-in resistor switch mounted means a great risk for tilting the on-load tap-changer with risk for injuries to people and damage of the equipment. 7.

Remove the transport locking and the lifting eyes with fasteners from the top section of the tap selector, see Fig. 12.

CAUTION Do not operate the tap selector until it is connected to the diverter switch housing.

Lifting eyes with fasteners (to be removed)

Transport locking (to be removed) Screw (to be removed)

TC_00216

Fig. 12. 8.

Lift the diverter switch housing in position and fit the tap selector to the diverter switch housing, see Fig. 13. The tap selector driving pin shall fit into the large gear wheel slot, see Fig. 13, A-A.

CAUTION The driving crank on the tap selector must not be moved more than slightly to engage the slot in the large gear wheel of the diverter switch housing. 9.

Insert four M10x40 screws and washers, see Fig. 13, E-E, through the tap selector upper part to the four supports of the diverter switch housing. Tighten the screws.

WARNING The diverter switch housing and the tap selector contains moving parts. Be cautious!

26

3 Installation in the Transformer

10. Connect the supplied conductors between the diverter switch housing and tap selector, see Fig. 13. The conductor ends and their connecting points have the same markings. Fasten the conductors with cleats, see Fig. 13, A–A. The number of conductors is varying depending on the rated through current and the type of connection. 11. If the impulse withstand voltage to earth exceeds 380 kV, insulate the connections on the tap selector by winding paper around them to a thickness of approximately 3 mm, see Fig. 10. The paper should be of the same quality as used for insulation of conductors within the active part of the transformer. 12. If the impulse withstand voltage to earth exceeds 380 kV, mount the supplied shielding ring (TS 11) at the bottom plate of the tap selector, see Fig. 13, D–D. CAUTION After mounting the shielding ring, the on-load tap-changer must not stand on the shielding ring. 13. Continue with section 3.3.

27

3 Installation in the Transformer

Washer 14x30x2,5

Spring washer Locking nut M12

Socket-head cap screw M12 F

Diverter switch housing, UCG

F B–B

B

Conductor

B

TC_00274

Insulating shaft

Conductors

F–F Locking nut M12 Spring washer

E A

A

Socket-head cap screw Washer 14x30x2.5

E Conductor C–C

Socket-head cap screw M8x25 Spring washer

C

C Locking nut M8

Current collector D–D Tap selector, size III

D

Shielding ring, TS 11 Diverter switch support

D

Tap selector

Cleats Insulating nut M16

Washer 10.5x24x3 (x4) Spring washer

Insulating stud M16x120

E–E

Socket-head cap screw M10x40 (x4)

Slot in the large gear wheel of the diverter switch housing

Conductors A–A

Driving pin of the tap selector TC_00273

Fig. 13. Tap selector III and diverter switch UCG. 28

3 Installation in the Transformer

3.1.3 UCL with Tap Selector size III 1.

Unpack the diverter switch housing and the tap selector. Remove the drying agents in the tap selector and on the diverter switch housing.

2.

Fit the gasket into the on-load tap-changer flange on the transformer cover, see Fig. 15. (This gasket is not included in the delivery.) Top cover

Top section

Diverter switch UCL Nut M12 (x24) Washer (x24)

Opening in the transformer cover

Stud (x24)

Gasket Transformer top cover

Selector size III

TC_00222

Fig. 14. 3.

Fig. 15.

TC_00218

Lift the diverter switch housing in the lifting eyes as shown in Fig. 3 and lower it carefully through the opening in the transformer top cover, see Fig. 14. Place the diverter switch housing correctly in position for mounting the outer shaft system (see transformer drawing). The studs on the flange on the transformer cover shall fit into the holes in the flange of the diverter switch housing. Mount twenty-four washers and M12 nuts, see Fig. 15. Tighten the nuts.

NOTE: For impulse withstand voltages to earth exceeding 380 kV, the diverter switch housing is equipped with shielding rings. The play between the on-load tap-changer flange in the transformer cover and the middle shielding ring is very small especially for the 1050 kV impulse withstand voltage to earth where the shielding ring is paper insulated. To avoid damages on the shielding rings, lower the diverter switch housing very carefully and cover the flange in the transformer cover next to the insulating shaft of the diverter switch housing and diametrically opposed (where the diameter of the shielding ring is greatest) with a thin sheet of pressboard (or similar). 4.

Put the tap selector in position for joining to the diverter switch housing. Lift in the lifting eyes as shown in Fig. 3.

5a. In case the on-load tap-changer is equipped with a tie-in resistor for mounting under the tap selector, the tie-in resistor is mounted after joining the tap selector to the diverter switch housing. After mounting the tie-in resistor, the on-load tapchanger must not be put down standing on the tie-in resistor. It must be hanging, for instance in a traverse.

29

3 Installation in the Transformer

WARNING To put down the on-load tap-changer to stand on the floor with the tie-in resistor mounted means a great risk for tilting the on-load tap-changer with risk for injuries to people and damage of the equipment. 5b. In case the on-load tap-changer is equipped with a tie-in resistor switch, the switch is mounted under the tap selector at delivery. A special support in the box makes it standing on the tap selector bottom. If this special support is taken out of the box, the tap selector can be standing on this during joining, to the diverter switch housing. After joining the complete on-load tap-changer is lifted and the special support is removed. The complete on-load tap-changer must not be put on the special support. It must be hanging, for instance in a traverse. WARNING To put down the on-load tap-changer to stand on the floor with the tie-in resistor switch mounted means a great risk for tilting the on-load tap-changer with risk for injuries to people and damage of the equipment. 6.

Remove the transport locking and the lifting eyes with fasteners from the top section of the tap selector, see Fig. 12.

CAUTION Do not operate the tap selector until it is connected to the diverter switch housing. 7.

Lift the diverter switch housing in position and fit the tap selector to the diverter switch housing, see Fig. 16. The tap selector driving pin shall fit into the large gear wheel slot, see Fig. 16, A-A.

CAUTION The driving crank on the tap selector must not be moved more than slightly to engage the slot in the large gear wheel of the diverter switch housing. 8.

Insert four M10x40 screws and washers, see Fig. 16, through the tap selector upper part to the four supports of the diverter switch housing. Tighten the screws.

WARNING The diverter switch housing and the tap selector contains moving parts. Be cautious!

30

3 Installation in the Transformer

9.

Connect the supplied conductors between the diverter switch housing and tap selector, see Fig. 16. The conductor ends and their connecting points have the same markings. Fasten the conductors with cleats, see Fig. 16, A–A. The number of conductors is varying depending on the rated through current and the type of connection.

10. If the impulse withstand voltage to earth exceeds 380 kV, insulate the connections on the tap selector by winding paper around them to a thickness of approximately 3 mm, see Fig. 10. The paper should be of the same quality as used for insulation of conductors within the active part of the transformer. 11. If the impulse withstand voltage to earth exceeds 380 kV, mount the supplied shielding ring (TS 11) at the bottom plate of the tap selector, see Fig. 16, D–D. CAUTION After mounting the shielding ring, the on-load tap-changer must not stand on the shielding ring. 12. Continue with section 3.3.

31

3 Installation in the Transformer Socket head cap screw M12

Washer 14x30x2.5 Spring washer Locking nut M12

F

F Diverter switch housing, UCL

F–F

B–B

Shielding ring (if the impulse withstand voltage to earth exceeds 380 kV)

Shielding rings Insulating shaft

Washer 14x30x2.5

Spring washer B

Locking nut M12

B

Socket-head cap screw

Conductors

E

C–C, 2 // connectors

Spring washer Locking nut M12 A

A

Washers 14x30x2.5

Socket-head cap screw

E

C

C–C, single connector

Socket-head cap screw M8x25 (x4)

Shielding ring, TS 11

C

Spring washers

Current collector Locking nut M8 Tap selector, size III

D–D

D

D Driving pin of the tap selector

Cleats

Diverter switch housing Tap selector

Insulating nut M16 Insulating stud M16x120

Washer 10.5x24x3 (x4) E–E Spring washer

Conductors A–A

Slot in the large gear wheel of the diverter switch housing

Socket-head cap screw M10x40 (x4) TC_00217

Fig. 16. 32

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 diverter switch housing is designed to be divided into an upper and a lower flange, see Figs. 18, 19 and 22, to fit the yoke-mounting.

Bevel gear Transformer active part

On-load tap-changer Yoke fork

TC_00120

Fig. 17. Yoke mounting principle Before lifting and joining the diverter switch housing to the transformer cover, it is placed on a yoke fork (two beams) which is fastened on the upper transformer yoke, see Fig. 17. NOTE: The guiding pins used on the yoke fork should be insulated with bushings in order to prevent circulating current in the yoke fork when the transformer is in operation. The mounting of the on-load tap-changer on the yoke fork can be carried out by two alternative methods depending on when the transformer ratio measurement is carried out: –

Transformer ratio measurement is carried out before drying process, see section 3.2.1.

–

Transformer ratio measurement is carried out after drying process, see section 3.2.2.

For mounting on transformer cover after drying process, see section 3.2.3. CAUTION To avoid seizing, do not operate the on-load tap-changer, neither during the drying process nor afterwards, until the diverter switch housing is filled with oil and the tap selector is immersed in oil.

33

3 Installation in the Transformer

3.2.1 Mounting when the Transformer Ratio Measurement is carried out before Drying 1.

Assemble the diverter switch housing and the tap selector as follows: UCG with tap selector I or C, see section 3.1.1, steps 1, 3-7 and 10-12 UCG with tap selector III, see section 3.1.2, steps 1 and 5-12 UCL with tap selector III, see section 3.1.3, steps 1, and 4-12

2.

Lift the on-load tap-changer onto the yoke fork (use the lifting eyes at the top of the on-load tap-changer, see Fig. 3). Place the on-load tap-changer correctly in position for mounting the outer shaft system (see transformer drawings). Insert and tighten the supplied guiding pins DS 7 and insulating bushings (not included in the delivery) in the lower flange, see Fig. 18. The guiding pin shall be secured by centre punch marks in the pins, see Fig. 20.

Secure with centre punch marks Upper flange

Lower flange

(35 mm)

O-ring

Yoke fork

Insulating bushing (not included)

Diverter switch housing

Guiding pin DS 7 (outer dia = 12 mm)

TC_00283

Fig. 18.

Fig. 20.

34

TC_00121

3 Installation in the Transformer

3.

Mount the conductors between the regulating winding and the tap selector according to section 3.3.

4.

Carry out transformer ratio measurement according to section 3.4 in this guide.

Position indicator

”Red point” TC_00281

Fig. 21.UCG and UCL Cover O-ring Lifting eye for the diverter switch

Bevel gear

Upper flange O-ring O-ring

Lower flange

Guiding bar for diverter switch Plain washer Spring washer Screw

TC_00295

UCL

Fig. 22.

Locking device DS 4

TC_00280

UCG

Fig. 23. 35

3 Installation in the Transformer

Oil draining plug Socket handle Bottom valve key DS16, key-width 10 mm

Oil draining tube

TC_00297

Fig. 24. 5.

Dismantle the diverter switch housing cover, see Fig. 22, by removing the screws. Store the cover, fasteners and O-ring in a dust-free place.

6.

If vapour phase process is going to be used: Remove the plug in the T-coupling for the oil draining tube. To open the bottom valve, let the ”bottom valve key” (DS16), slide down through the oil draining tube and, when it has gripped the valve, rotate it in anti-clockwise direction until there is stop after approximately 6 turns, see Fig. 24. Remount the dismantled plug.

7.

Dismantle the diverter switch by carefully lifting it straight out of the diverter switch housing by its lifting eye, see Fig. 22. Store the diverter switch in a dry and dustfree place.

8.

Remove the oil draining tube by hand or by means of a pipe wrench, using a cloth between the tube and the pipe wrench to protect the tube. Store the tube in the diverter switch housing until it is remounted.

9.

Remove the four clamp screws, M10 x 35, and the washers which hold the bevel gear, see Fig. 22. Note the position of the bevel gear. Remove the gear housing carefully. Take care of all details. Store the bevel gear in a dust-free place.

CAUTION Do not remove the locking device of the bevel gear. 10. Mount the locking device DS 4 on the driving shaft of the on-load tap-changer, see Figs. 22 and 23. CAUTION The driving shaft must not be rotated.

36

3 Installation in the Transformer

11. The guide bar for positioning of the diverter switch type UCL in the housing is fixed in the upper flange with screw and washers, see Fig. 22. Remove the screws and washers. Store the guide bar in the diverter switch housing until it is remounted. Take care of screws and washers. 12. Remove the nuts and washers inside the upper flange and remove the flange by lifting in the lifting eyes. Store the upper flange, and the O-ring in a dust-free place. Take care of nuts and washers. 13. The on-load tap-changer is now ready for drying together with the transformer. Follow instructions in chapter 4.

3.2.2 Mounting when the Transformer Ratio Measurement is carried out after Drying 1.

Assemble the diverter switch housing and the tap selector as follows: UCG with tap selector I or C, section 3.1.1, steps 1, 3-7 and 10-12 UCG with tap selector III, section 3.1.2, steps 1 and 5-12 UCL with tap selector III, section 3.1.3, steps 1 and 4-12.

2.

UCG: Follow instructions according to section 3.2.1, steps 5-11. UCL: Follow instructions according to section 3.2.1, steps 5-13.

Max 90o

Lifting equipment

TC_00224

Fig. 25.

37

3 Installation in the Transformer

3.

Apply the lifting equipment LL 136 016-D for UCL and LL 135 016-A for UCG in position according to Fig. 25.

NOTE: The lifting equipment must be tilted when applying. Lift the on-load tap-changer onto the yoke fork (use the lifting equipment, see Fig. 25). Place the on-load tap-changer correctly in position for mounting the outer shaft system (see transformer drawing). Insert supplied guiding bolts DS 7, and insulating bushings (not included in delivery) in the lower flange, see Fig. 20. The guiding bolts shall fit into the holes in the yoke fork and be secured by punch marks in the pins. When the on-load tap-changer is in place, remove the lifting equipment. 4.

Mount the conductors between the transformer winding and the tap selector according to section 3.3.

5.

The on-load tap-changer is now ready for drying together with the transformer. Follow the instructions in chapter 4.

3.2.3 Mounting on Transformer Cover (After drying process.) 1.

After the transformer cover is mounted, place the gasket in the flange for the onload tap-changer. (This gasket is not included in the on-load tap-changer delivery).

NOTE: Do not insert the studs for the upper flange in the transformer cover flange. This is carried out in step 8. 2.

Remove the locking device DS 4 from the driving shaft, see Figs. 22 and 23.

CAUTION Be careful not to drop the locking device and the screw. CAUTION The driving shaft must not be rotated.

38

3.

Place the O-ring in its groove in the lower flange, see Fig. 18.

4.

Place the upper flange over the opening in the transformer cover. Turn the upper flange so the flange for the bevel gear is aligned with the driving shaft. The screws in the lower flange shall fit into the holes in the upper flange, see Fig. 26.

3 Installation in the Transformer

Locking nut M8 (20x)

Upper flange

Spring washer

Studs M12 (24x) Nuts M12

Plain washer 8.4x20x2

Washers

O-ring Lower flange Yoke fork

TC_00296

Fig. 26.

5.

Lift the on-load tap-changer slowly until it just touches the upper flange. The lift can take place by using the lifting equipment LL 136 016-D for UCL and LL 135 016-A for UCG, see Fig. 26. Apply the equipment in the lower flange sides. The lifting equipment has to be tilted when mounted and dismounted, see Fig. 25.

6.

When the flanges touch, mount twenty M8 locking nuts and washers. Tightening the nuts alternately until fully home. Retighten all nuts with 24.5 Nm. After tightening the nuts, remove the lifting equipment.

7.

Place the O-ring of the bevel gear in its groove in the upper flange, see Fig. 27. Remount the bevel gear unit in the position it had before dismantling, and make sure that the pin in the spherical shaft end fits into the driving shaft slot, without rotating the driving shaft. Fix the gear unit in the flange by its four clamps screws M10x35 and washers.

39

3 Installation in the Transformer

CAUTION The gear box must not be forced down! If the coupling does not engage, lift the gear box and adjust the setting of the driving pin.

Fixing clamps

Pin

O-ring Slot in the driving shaft TC_00127

Fig. 27.

8.

Insert twenty-four studs, see Fig. 26, through holes in the upper flange, down into threaded holes in the flange of the transformer cover. If the studs do not fit, the position of the on-load tap-changer must be adjusted, which may require lifting. Lift in the lifting eyes as shown i Fig. 3. After mounting the studs, remove the lifting equipment and tighten the nuts.

9.

Mount the oil draining tube, see Fig. 24. If a pipe wrench is used, there must be a cloth protection between the wrench and the tube.

10. Mount the guide bar for the diverter switch, see Fig. 22. Mount washers and screw and tighten.

40

3 Installation in the Transformer

11. Remove the plug at the end of the T-coupling, see Fig. 28, slide down the ”bottom valve key”, and close the valve by turning the key clockwise approximately 6 turns. Tighten with 40 Nm. Remount the plug. 12. Install the diverter switch according to section 4.3.

Plug 40 Nm

Oil draining tube TC_00230

Fig. 28.

41

3 Installation in the Transformer

3.3 Connection to Terminals Connection to the tap selector should follow the connection diagram supplied with the on-load tap-changer. In order to obtain maximum reliability of the tap selector contacts, the temperature rise of the conductors connected to the tap selector should be kept as low as possible and should in no case exceed 30K above the surrounding oil. CAUTION All terminals must have conductors or connections. If there are connections between parallel conductors from the diverter switch on the tap selector terminal, the parallel conductors from the active part of the transformer shall also be connected together on the tap selector terminals (in order to avoid circulation currents through the tap selector contacts, see Fig. 31). Conductors from the diverter switch

Tap selector

Conductors from the active part of the transformer

Connection

Connection TC_00130

Fig. 29. If the impulse withstand voltage to earth exceeds 380 kV, the conductor connections on the tap selector shall be insulated by winding paper around them to a thickness of 3 mm, see Fig. 10. The paper should be of the same quality as used for insulating conductors within the active part of the transformer. CAUTION All connections should be made carefully and in such a way that there is no risk that they can become disconnected. The conductors must not cause mechanical strain on the tap selector terminal. Each conductor should be curved to take up expansion. See Fig. 30.

42

3 Installation in the Transformer

Tap selector

Terminal

TC_00130

Expansion bend

Faulty

Correct Fig. 30.

NOTE: When yoke mounted, inserts (wooden blocks, or similar) are placed between the yoke fork and the lower flange of the diverter switch housing, see Fig. 31, making the conductors mounted at correct final height. The wooden blocks must be removed before mounting the on-load tap-changer on the transformer cover.

Lower flange

Yoke fork beam Inserts TC_00232

Fig. 31.

CAUTION It is recommended that the distance between the cylinders or the bars of the tap selector and any conductor is at least 50 mm. The transformer manufacturer is responsible for keeping sufficient large insulation distances.

43

3 Installation in the Transformer

3.4 Transformer Ratio Measurement The transformer ratio measurement may be carried out before or after the drying process. If it is carried out before drying, no drive system is mounted. The on-load tap-changer has thus to be operated directly on the shaft coupling of the bevel gear on the upper flange. A special hand crank can be ordered from ABB, see section 1.2 ”Required Tools” in this guide. If it is carried out after drying, it is recommended to be carried out when the drive system is mounted, after ”Final Assembly”, see chapter 5 in this guide, to simplify the operation of the on-load tap-changer. 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.

CAUTION Before process, the on-load tap-changer is allowed to be operated maximum three times through the regulating range unless it is not oil immersed. After process the onload tap-changer has to be immersed in oil before operating.

CAUTION 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.

CAUTION Watch the voltmeter during the on-load tap-changer operations. No fast voltage drops may occur during operation. If such drops occur, the diverter switch is installed incorrectly or the on-load tap-changer is not correctly connected to the winding.

44

3 Installation in the Transformer

3.4.1 Transformer Ratio Measurement before Drying 1.

Remove the locking device from the gear unit on the upper flange, see Fig. 32. Keep the locking device for remounting after transformer ratio measurement. Also remove the cover of the bevel gear to get access to the position indicator. Keep all fasteners and the gasket for remounting. Note the position of the on-load tap-changer. Locking device

TC_00275

TC_00276

UCG and UCL.N or E

UCG and UCL.T or B

Fig. 32. 2.

Operate the on-load tap-changer by applying the special hand crank mentioned above on the shaft coupling of the bevel gear. Adjust the length of the handle. Be careful not do damage the coupling.

NOTE: When operating through the middle position on an on-load tap-changer with change-over selector, the torque on the hand crank will be higher. 3.

After the measurement, the on-load tap-changer must be operated in the direction and to the position shown in the single-phase diagram as the delivery position. The right position designation should be shown in the ”window” in the position indicator in the bevel gear of the on-load tap-changer and the ”window” should face the red point in the bevel gear housing exactly, see Fig. 21. Then remount the locking device on the bevel gear and the cover of the bevel gear. Fit the gasket properly.

3.4.2 Transformer Ratio Measurement after Drying Carry out this measurement after the drive system is mounted. Operate the on-load tap-changer by means of the motor-drive mechanism. Operate the on-load tap-changer in the direction and to the position shown in the single-phase diagram as the delivery position after the measurement.

45

4 Drying

4 Drying The on-load tap-changer is dried together with the transformer using one of the following processes: alternating hot-air and vacuum or vapour-phase at a temperature of max. 135 °C (275 °F).

4.1 Observations before Processing 1.

If not earlier done, lift the diverter switch out from the housing, see section 3.2.1 steps 5 and 7. The pressure relay with its test vent and the oil filter, if any, should be dismantled and kept protected from dust e.g. in a plastic bag or in their original packing.

2.

Do not expose the diverter switch housing to any pressure difference between inside and outside during the vapour-phase process. During the hot air and vacuum process, the maximum permitted pressure differential is 100 kPa at a temperature of 135 °C (275 °F). During the vapour-phase process the bottom valve of the diverter switch housing should be open. To open the bottom valve, proceed as follows, see Fig. 24: a.

Remove the plug on top of the oil draining tube, see Fig. 24.

b.

Use the bottom valve key through the oil draining tube, see Fig. 24.

c.

Turn the valve anticlockwise to its stop, approximately 6 turns.

d.

Remount the plug.

e.

Remove the O-ring in the lower flange (for mounting on active part only) before process.

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 diverter switch housing when vapour-phase process has been carried out. When cover mounted, close the bottom valve, see section 3.2.3, step 10. When yoke-mounted, the valve is closed during reassembly of the top section.

CAUTION Make sure the bottom valve key is removed after the valve has been closed.

46

2.

The cleats, on the upper section of the tap selector, holding the conductors between the diverter switch housing and the tap selector should be retightened (tightening torque 15 Nm) and locked by method specified by the transformer manufacturer for similar screw joints.

3.

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 for similar screw joints.

4 Drying

4.3 Installation of Diverter Switch When yoke-mounted, carry out section 3.2.3 before installing the diverter switch. CAUTION Check the serial numbers to make sure that the diverter switch is mounted in the correct housing, see Fig. 1. CAUTION Make sure that the diverter switch housing is clean and dry and that no foreign objects (tools etc.) are left in the housing. CAUTION Lower the diverter switch into its housing carefully so that neither the diverter switch nor the housing are damaged. The diverter switch is provided with guiding slots that fit against the guide bar and the oil draining tube in the diverter switch housing, see Fig. 33. Rotate the diverter switch so the half-circle shaped guiding slot is aligned with the oil draining tube, see Fig. 33. When the diverter switch is lowered, check visually that its plug-in contacts are aligned with the contacts in the cylinder wall. In order to ensure that the diverter switch pin has engaged the coupling disc, carry out at least three tap change operations in one direction. A distinct sound is heard when the diverter switch operates which indicates that the driving pin of the diverter switch has been connected. If no sound is heard, the diverter switch might need to be pushed down while operating the motor drive. Carry out another three operations in the same direction while pushing the diverter switch down. NOTE: The UCL diverter switch: It may be necessary to push and pull the lifting device of the diverter switch a little to and fro while pushing it down. The top part of the diverter switch lifting device should be below the level of the machined surface for the cover when lowered to its final position. Only the springs of the lifting device should be above this level. Insert the O-ring for the cover in the upper flange. Mount the on-load tap-changer cover. Turn the cover so the guiding pin in the housing is facing the guiding hole in the cover. (The cover has to be pressed down in order to overcome the spring force of the springs that hold the diverter switch pressed in place). Insert screws and washers and tighten them.

47

4 Drying

Springs Lifting device

Shielding-ring (when the impulse withstand voltage to earth exceeds 380 kV) (not on UCG short version) Transition resistors (Layed down on UCG short type)

Serial number (on the opposite side of the diverter switch)

A

A

Plug-in contacts Guiding pin

Guiding pin

Tie rod fm_00223

Driving pin

Coupling disc Notch for the driving pin

Holes for guiding pins Slot for guiding bar

Guiding bar for the diverter switch

Guiding pins Slot for the oil draining tube Oil draining tube

A–A, UCL TC_00233

UCL Diverter switch housing, view from above Coupling disc Notch for the driving pin

Slot for guiding bar

Holes for guiding pins

Guiding pins

Guiding bar for the diverter switch

Slot for the oil draining tube

Oil draining tube

TC_00284

A–A, UCG

UCG Diverter switch housing, view from above

Fig. 33. 48

TC_00285

5 Final Assembly

5 Final Assembly 5.1 Mounting of the Motor-Drive Mechanism See Figs. 34 and 35. 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 SA 21 on the edge of the transformer cover, see Fig. 36.

3.

Check that the position indicator in the motor-drive mechanism shows the same position as the indicator inside the bevel gear of the on-load tap-changer. (The cover has to be dismantled).

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

49

5 Final Assembly

Exact position

TC_00258

Tolerances Transformer

The same indicated tap position

Position indicator TC_00141

Brake disc

Adjustment nuts

TC_00203

Red mark

Brake assembly

Fig. 34. Position alignment for UCG, UCL with motor-drive mechanism type BUE 50

5 Final Assembly

Exact position

TC_00258

Transformer Tolerances The same indicated tap position

Indicator flag

fm_00224

Position indicator

TC_00253

Roller on the brake arm in the notch of the cam disc

Brake arm

Cam disc

Contra nut fm_00225

Brake disc Adjusting screw

Fig. 35. Position alignment for UCG, UCL with motor-drive mechanism type BUL 51

5 Final Assembly

5.2 Mounting of External Drive Shafts The external drive shafts consists of square tubes and should 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 correct 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. NOTE: The multihole couplings should be greased. 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. 34. CAUTION Make sure that all locking devices (on the bevel gear, on the on-load tap-changer and in the motor-drive) are mounted and the on-load tap-changer and the motor-drive are in the same service position. Check that the motor-drive mechanism is in its exact position according to Fig. 34 or 35. (BUE: The red mark on the brake disc facing the red mark on the brake assembly. BUL: The roller in the middle of the notch in the cam disc). If not, loosen the locking device and adjust it to its exact position, see Fig. 40. Remount the locking device. NOTE: Let the parts of the shaft system that should be dismantled before transporting the transformer to site keep their identification numbers according to the packing list to simplify the remounting of the shaft system on site.

52

SA 10 SA 11 SA 12 SA 13 SA 14 SA 15 SA 16 SA 17 SA 18 SA 19 SA 20 SA 21 SA 22 SA 23 SA 24 SA 25 SA 30 SA 31 SA 32 SA 33 SA 34 SA 35 SA 36

SA33

SA25

SA34 SA35

SA10

SA36

SA33

Hose Clip Coupling halves Hexhead cap screw M6 Washer Vertical square shaft Vertical protective tube Vertical protective tube Clamp Hexhead bolt M10 Washer O-ring Bevel gear Horizontal square shaft to unit -1 Horizontal protective tube to unit -1 Horizontal protective tube to unit -1 Information plate Horizontal square shaft to unit -2 Horizontal protective tube to unit -2 Horizontal protective tube to unit -2 Cover Horizontal square shaft to unit -3 Horizontal protective tube to unit -3 Horizontal protective tube to unit -3

Unit –3

Unit –2

Unit SA10 – 2

SA32

SA10

SA32

SA10

TC_00168

SA25

SA31

SA25

SA31

SA25

SA30

SA30

SA24 SA22

SA10

Unit –1 SA10

SA23

TC_00237

Motor-drive mechanism

BUE

SA20

SA18 SA19 SA17

SA21

TC_00236

SA18 SA19 SA17

SA21

BUL

SA10

TC_00235

TC_00239

SA11 SA12, SA13 SA10

SA14

SA15

SA16

SA11

SA12, SA 13

SA10

SA23

SA23

SA25

SA22

SA25

SA25

SA24 SA22

SA10

Connection type N or E

Unit –1

Connection type B SA24

SA10

Connection type T

Unit SA10 – 1

NB! The slot in the protective tube SA10 facing downwards

5 Final Assembly

Fig. 36.

53

5 Final Assembly

5.2.1 Mounting of Vertical 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. 36.

2.

Determine the dimension K2 between the spherical shaft ends, see Fig. 37a.

3.

Cut the vertical square shaft, SA14, to dimension = K2 minus 6 mm. Remove the burrs.

4.

Cut the protective tubes SA15 and SA16 so both of them get the same length LB2 according 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

LB2 = K2+180 mm 2

LB2 = K2+220 mm 2

LB2 = K2+410 mm 2

Example: K2 measured to 350 mm. LB1 is then = 350+220 = 570 = 285 mm 2

2

5.

See Fig. 37c. 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, see Fig. 37h. Tighten the two screws A first, see Fig. 37k, and then the other. Put on the two protective tubes, SA15 and SA16, (the greater diameter upmost) and two hose clips SA10.

6.

See Fig. 37d. Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear. Mount two coupling halves SA11 to the other end of the square shaft and the shaft of the motor-drive mechanism. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 37h. Tighten the screws lightly and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 37f. Tighten the screws A first and thereafter the other.

7.

Fig. 37e. Mount the tube with the greater diameter, SA16, to the bevel gear with a hose clip and the other SA15 to the flange on the motor-drive mechanism with a hose clip. Leave about 3 mm play to the flange ring (see Fig. 37g) for water draining.

NOTE: The tube with greater diameter shall be mounted to the bevel gear. NOTE: Tighten always the screws A first and then the other, according to Fig. 37k.

54

5 Final Assembly

SA21

SA11

SA10

SA10

SA16

SA16 SA15

SA15

SA10

SA14

BUE

SA14

TC_00147

K2

SA26

Fig. 37e.

Fig. 37d.

Driving pin

SA27, SA28 SA29

SA15

Min. 3, max 5 mm

Fig. 37c.

Max 6 mm

Fig. 37a.

SA10

TC_00148

BUL

Fig. 37b.

TC_00149

Fig. 37g.

Fig. 37f.

Square shaft

Max 3 mm

A SA11

SA13

SA12 TC_00147 TC_00170

Fig. 37h.

Fig. 37k.

A

55

5 Final Assembly

5.2.2 Mounting of Horizontal Drive Shafts, types UCG.N/UCL.N and UCG.E/UCL.E The following applies to the fitting of drive shafts and protective tubes when the onload tap-changer consists of one unit, UCG.N/UCL.N or UCG.E/UCL.E. 1.

Determine the dimension K1 between the spherical shaft ends, see Fig. 38a.

TC_00286

UCG

K1

TC_00241

UCL

Fig. 38a. 2.

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

3.

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

NOTE: Protective tube SA23 has one slotted end. Table 4. Length dimension for LB1 K1 = 170 to 290 mm

K1 = 291 to 600 mm

K1 = greater than 600 mm

LB1 = K1+200 mm 2

LB1 = K1+250 mm 2

LB1 = K1+500 mm 2

Example: K1 measured to 400 mm. LB1 is then = 400+250 = 650 = 325 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 should be possible when one of the tubes is pushed into the other. 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, see Fig. 37h. Tighten the two screws A first and then the others, see Fig. 37k. Put on the two protective tubes, SA23 and SA24, the slotted end of SA23 in the non-overlapping end, and two hose clips SA10, see Fig. 38b. LB1 Slotted end

SA14

SA24

SA10

SA23

Fig. 38b. 56

SA11 TC_00148

5 Final Assembly

A

Spherical coupling part

SA12 SA13 TC_00242

SA24

SA10 SA23

Slot

SA21

SA11

Fig. 38c.

5.

Dismount the locking device on the bevel gear of the diverter switch housing by loosening the two set screws, see Fig. 38g.

6.

Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear SA21, see Fig. 38c. Mount two coupling halves SA11 to the other end of the square shaft and to the shaft of the bevel gear on the on-load tap-changer. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 37h. Tighten light the screws and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 37f. Tighten the two screws A first and thereafter the other, see Fig. 37k.

7.

The motor-drive mechanism and the on-load tap-changer should have the same indicated tap position and be in their exact positions. Remove the cover of the gear box on the on-load tap-changer to get access to the position indicator, see Figs. 34 and 35. The motor-drive mechanism and on-load tap-changer are in the same position when the position indicators in bot of them show the same position, see Figs. 34 and 35. The motor-drive mechanism is in the exact position since section 5.2 has been carried out. The on-load tap-changer is in exact position when the ”window” where the position is read in the bevel gear is facing the red point in the gear box housing exactly, see Fig. 34 or 35.

If the gear box is not in its exact position, see Fig. 34 or 35, loosen the two screws in the multihole coupling on the gearbox and find the position of the screws that positions the opening in the brass toothed wheel closest to the red point in the gear box housing. The maximum deviation from exact alignment is given in Figs. 34 and 35. Tighten the screws. Remount the cover and the gasket of the gearbox on the onload tap-changer, see Fig. 27. CAUTION Assembly with the on-load tap-changer and the motor-drive mechanism in different operating positions may cause a transformer break down.

WARNING The bevel gear contains moving gears. Be cautious!

57

5 Final Assembly

Disc M8 screw Driving pin TC_00150

Fig. 38d.

SA10 SA24 SA25 SA23 SA25

SA10 SA21

Slot facing downwards

TC_00243

SA23 TC_00148

Fig. 38e. 8.

Push the two protective tubes on to the bevel gears and clamp them with hose clips, SA10, see Fig. 38e.

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

Locking device

TC_00287

Fig. 38g.

58

5 Final Assembly

5.2.3 Mounting of Horizontal Drive Shafts, Type UCG.B/UCL.B The following applies to the fitting of drive shafts and their protective tubes when the on-load tap-changer consists of two units of type UCG.B/UCL.B. The on-load tapchanger phase, which is placed closest to the driving mechanism, is called unit -1, the second unit -2, see Fig. 36. 1.

Determine the dimension K1 between the spherical shaft ends, see Fig. 39a. K1

TC_00241

Fig. 39a. 2.

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

3.

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

NOTE: Protective tube SA23 has one slotted end. Table 4. Length dimension for LB1 K1 = 170 to 290 mm

K1 = 291 to 600 mm

K1 = greater than 600 mm

LB1 = K1+200 mm 2

LB1 = K1+250 mm 2

LB1 = K1+500 mm 2

Example: K1 measured to 400 mm. LB1 is then = 400+250 = 650 = 325 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 should be possible when one of the tubes is pushed into the other. 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, see Fig. 37h. Tighten the two screws A first and then the others, see Fig. 37k. Put on the two protective tubes, SA23 and SA24, the slotted end of SA23 in the non-overlapping end, and two hose clips SA10, see Fig. 39b. LB1 Slotted end

SA14

SA24

SA10

SA23

SA11 TC_00148

Fig. 39b.

59

5 Final Assembly

A

Spherical coupling part

SA12 SA13 TC_00242

SA24

SA10 SA23

Slot

SA21

SA11

Fig. 39c.

5.

Dismount the locking device on the bevel gear of the diverter switch housing by loosening the two set screws, see Fig. 39f.

6.

Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear SA21, see Fig. 39c. Mount two coupling halves SA11 to the other end of the square shaft and to the shaft of the bevel gear on the on-load tap-changer. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 37h. Tighten light the screws and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 37f. Tighten the two screws A first and thereafter the other, see Fig. 37k.

7.

The motor-drive mechanism and the on-load tap-changer should have the same indicated tap position and be in their exact positions. Remove the cover of the gear box on the on-load tap-changer to get access to the position indicator, see Figs. 34 and 35. The motor-drive mechanism and on-load tap-changer are in the same position when the position indicators in bot of them show the same position, see Figs. 34 and 35. The motor-drive mechanism is in the exact position since section 5.2 has been carried out. The on-load tap-changer is in exact position when the ”window” where the position is read in the bevel gear is facing the red point in the gear box housing exactly, see Fig. 34 or 35.

If the gear box is not in its exact position, see Fig. 34 or 35, loosen the two screws in the multihole coupling on the gearbox and find the position of the screws that positions the opening in the brass toothed wheel closest to the red point in the gear box housing. The maximum deviation from exact alignment is given in Figs. 34 and 35. Tighten the screws. Remount the cover and the gasket of the gearbox on the onload tap-changer, see Fig. 27a. Make sure the slot in the gasket and the cutout in the cover is positioned above the conical gear. CAUTION Assembly with the on-load tap-changer and the motor-drive mechanism in different operating positions may cause a transformer break down. WARNING The bevel gear contains moving gears. Be cautious!

60

5 Final Assembly

Disc M8 screw Driving pin TC_00150

Fig. 39d.

SA10 SA24 SA25 SA23 SA25

SA10 SA21

Slot facing downwards

TC_00243

SA23 TC_00148

Fig. 39e. 8.

Push the two protective tubes on to the bevel gears and clamp them with hose clips, SA10, see Fig. 39e.

NOTE: The slot of the protective tube SA23 should be facing downwards. Apply the self-adhesive information plates SA25 around the tubes on about the middle of the tube length. 9.

Mount the cover SA33 and tighten the two set screws (taken from the locking device).

Locking device Set screws

Cover SA 33

TC_00244

Fig. 39f.

61

5 Final Assembly

10. Determine the dimension K3 between the spherical shaft ends, see Fig. 39g. K3

TC_00247

Fig. 39g. 11. Cut the horizontal square shaft SA30 to dimension = K3 minus 6 mm. Remove the burrs. 12. Cut the protective tubes SA31 and SA32 in the unslotted end to the dimension LB3 = K3+500 mm, see Fig. 39h. 2 LB3 A

SA30

SA32

SA10

SA31

SA11 TC_00148

Fig. 39h. 13. 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, see Fig. 37h. Tighten the two screws A first and then the others, see Fig. 39h. Put on the two protective tubes, SA31 and SA32, the slotted end of SA31 in the non-overlapping end, and two hose clips SA10, see Fig. 39h. 14. Dismount the locking device on the bevel gear of the diverter switch housing by loosening the two set screws, see Fig. 39f.

62

5 Final Assembly

Disc Coupling A

SA10

SA12 SA11 SA32 SA13

SA10

SA30 SA31

TC_00245

Fig. 39k. 15. Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear closest to the motor drive, see Fig. 39k. Mount two coupling halves SA11 to the other end of the square shaft and to the shaft of the bevel gear on the on-load tap-changer. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 37h. Tighten light the screws and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 37f. Tighten the two screws A first and thereafter the other. The unit should be in the same service position as the adjacent unit and be in the exact position. Compare with the adjacent unit and adjust this unit as described in section 5.2.3, point 7 if necessary. WARNING The bevel gear contains moving gears. Be cautious!

Locking device Cover SA 33

Set screw

SA10

SA25

SA32

SA10

SA31 TC_00246

Fig. 39m.

16. Push the two protective tubes on the bevel gears and clamp them with the hose clips SA10, see Fig. 39m. Apply the self-adhesive information plates SA25 around the tubes on about the middle of the tube length. NOTE: The slot of the protective tubes should be facing downwards. 17. Mount the protection cover SA33. Tighten the two sets screws, (taken from the locking device), see Fig. 39m.

63

5 Final Assembly

5.2.4 Mounting of Horizontal Drive Shafts, Types UCG.T/UCL.T and UCGYD/UCLYD The following applies to the fitting of drive shafts and their protective tubes when the on-load tap-changer consists of three phases UCG.T/UCL.T or UCGYD/UCLYD. The on-load tap-changer unit, which is placed closest to the driving mechanism, is called unit -1, the next unit -2 and the last unit -3, see Fig. 36. 1.

Mount the drive shaft to the on-load tap-changer unit -1 according to section 5.2.3, steps 1–8 above.

2.

Mount the drive shaft between unit -1 and unit -2 according to section 5.2.3, steps 1–8 above.

3.

Mount the drive shaft between unit -2 and unit -3 according to section 5.2.3, steps 2–9 above.

NOTE: The shaft is here called SA34, the protective tube closest to unit -2 is called SA35 and the other protective tube is called SA36. 4.

In cases where a support bearing is used, follow appropriate parts of section 5.2.3, steps 2–8 above.

WARNING The bevel gear contains moving gears. Be cautious!

5.2.5 Before Operation 1.

Check again that the on-load tap-changer and the motor-drive mechanism are in the same position.

2.

Remove the locking device of the motor-drive mechanism, see Fig. 40.

NOTE: If transformer ratio measurement is to be done after drying, this is a suitable stage to carry it out, see section 3.4.2.

Locking device TC_00262

BUE

Fig. 40. Locking device of motor-drive mechanism 64

fm_00208

BUL

5 Final Assembly

5.3 Pressure Relay 5.3.1 General The diverter switch housing of the on-load tap-changer is supplied with a pressure relay. In the event of overpressure in the diverter switch housing, the relay, if correctly connected, 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 Repair Guide. CAUTION To take the transformer into service after a pressure relay trip without carrying out a careful investigation of the diverter switch by lifting it out of the diverter switch housing, and repairing faults, if any, may cause severe damages to the on-load tapchanger and the transformer. 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.

5.3.2 Installation Remove the cover from the flange 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 housing. If the gland has to be changed to another type, the seal against the housing must be secured by a gasket or sealing liquid (example Loctite 275). CAUTION Tighten the cable gland with care, torque max 5 Nm.

65

5 Final Assembly

5.3.3 Checking at Commissioning of the Transformer

Information plate Valve handle

Test tap (R 1/8”)

TC_00264

Fig. 41. Pressure relay

66

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.

5 Final Assembly

5.4 Assembly of Accessories All details which have been removed for the transport are specified on the packing list. The openings on the on-load tap-changer are sealed by a transport cover. 1.

Remove the transport covers.

2.

Check the O-rings. Make sure they are pressed into the bottom of the groove on the flanges.

3.

Assemble all remaining accessories. Tightening torque for the nuts according to section 1.8.

5.5 Connection to the Oil Conservator NOTE: If oil filling is carried out under vacuum without oil conservator, this section is carried out after the oil filling. Remove the transport cover on the flange for connection to the oil conservator. Make sure the O-ring is in place on the flange 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 tapchanger, an oil filter must be placed in the pipe between the on-load tap-changer and the conservator. Oil filter with housing can be ordered from ABB.

67

6 Oil Filling

6 Oil Filling 6.1 Filling Methods and Restrictions Oil filling can be carried out at atmospheric pressure or under vacuum. The wall between the diverter switch housing and the transformer tank is designed to withstand vacuum on one side and atmospheric pressure on the other side. It is not allowed to have vacuum on one side and the pressure of a high oil column on the other side. NOTE: Oil filling may be carried out in different ways depending on what the transformer manufacturer finds convenient as long as the rules above are fulfilled and the on-load tap-changer is filled with oil to the correct level with a gas cushion on the top. The methods below are recommended and if 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 diverter switch housing. 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. 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. The oil level in the oil conservator should be checked after a month in service and if the oil level is lower than after the oil filling, (corrected for temperature differencies), the gas cushion should be restored according to section 6.5 ”Restoring the Gas Cushion” in this guide.

6.2 Before Filling At commissioning: Open the cover and check that the diverter switch housing is dry and clean. Check that the bottom valve is closed. Follow step 11 in section 3.2.3. Tightening torque 40 Nm (see Fig. 28). Remount the cover as per section 4.3.

68

6 Oil Filling

6.3 Filling at Atmospheric Pressure 1.

Open the conservator valve, if any.

2.

Dismantle the breathing device on the conservator for the on-load tap-changer.

3.

Pump oil into the diverter switch housing via the oil valve (connection dimensions, see the dimension drawing for the on-load tap-changer). Continue until the conservator is filled to the correct level at the actual temperature. See even section 1.5.

NOTE: When filling more than one unit: Fill the first unit/units until the oil level indicator on the oil conservator starts to move. Fill up the oil conservator to the right level when filling the last unit. 4.

Shut the oil valve and disconnect the pump. Fill all units according to point 2-4.

5.

Remount the breathing device. Make sure the connection to the breathing device is properly sealed.

CAUTION Do not energize the transformer earlier than three hours after oil filling in atmospheric pressure. This waiting period is needed to allow air bubbles to disappear.

6.4 Filling under Vacuum Filling under vacuum is not necessary but may be carried out with some of the following procedures. After filling under vacuum, no standing time is needed. The methods below ensure that no permitted pressure differencies are exceeded. Pipe connection Vacuum

Oil

OLTC

Transformer

fm_00226

Ø 75 Stud M10

Oil

Fig. 43. Oil filling under vacuum

Ø 44.2

Ø 5.7

TC_00249

O-ring

Ø 20

Fig. 42.

69

6 Oil Filling

6.4.1 Oil Conservator Filled Afterwards 1.

If an oil filter is mounted on the flange for the oil conservator (only on transformers with a common oil conservator for both the transformer and the on-load tapchanger), it should be removed.

2.

Establish a connection between the transformer and the diverter switch housing, for instance by putting oil valves on the flange for the conservator and the flange for the gas operated relay (the horizontal flange) respectively and connect a tube between the valves, see Fig. 43. Close the oil valve. Evacuate all units at the same time.

3.

Open the valves mounted under point 2. Put the transformer under vacuum. (The on-load tap-changer is put under vacuum automatically).

4.

Let oil in through the oil valve of the on-load tap-changer (for connection dimensions, see the dimension drawing for the on-load tap-changer).

5.

Let an oil amount equal to or slightly less than what is given in section 1.4 enter into the diverter switch housing. When the on-load tap-changer is filled with oil, shut the oil valve.

6.

When atmospheric pressure is restored in the transformer, shut the connection between the transformer and the on-load tap-changer by closing both the valves in the connection.

7.

Remove the connection tube between the valves mounted under point 2.

8.

Restore the gas cushion in the diverter switch housing/housings according to section 6.5.1 ”Restoring the Gas Cushion, procedure”, point 2-6 in this guide.

9.

Remove the oil valve on the flange for the conservator and remount the oil filter, if any. Connect the tube to the conservator, see section 5.5. Make sure the O-ring is properly in place.

10. Open the valve in the tube to the conservator. 11. Fill oil to the correct level in the conservator according to section 1.5 in this guide. 12. Mount the breathing device on the oil conservator. Make sure the connection to the breathing device is properly sealed. NOTE: By using this method, the oil valve on the flange for the gas operated relay must be left there. The connection to the gas operated relay is made on the oil valve.

6.4.2 Oil Conservator Filled under Vacuum

70

1.

Establish a connection between the oil conservator for the transformer and the oil conservator for the on-load tap-changer.

2.

Open the valve between all on-load tap-changer units and the conservator and close the oil valve.

3.

Put the transformer under vacuum. (The on-load tap-changer is put under vacuum automatically).

6 Oil Filling

4.

Let oil in through the oil valve of the on-load tap-changer. (For connection dimensions, see the dimension drawing for the on-load tap-changer).

5.

When the needle of the oil level indicator in the oil conservator starts to move, shut the oil valves in all units. Open one at a time and close it when the needle in the oil level indicator start to move. Fill up the conservator to the right level before shutting the oil level of the last unit. (This is done to make sure that all units are filled up properly. Differencies in flow rates might otherwise cause that some of the units are not filled up).

6.

When atmospheric pressure is restored in the transformer, remove the connection between the two conservators and connect the breathing device to the oil conservator for the on-load tap-changer. Make sure the connection to the breathing device is properly sealed.

7.

Restore the gas cushion in the diverter switch housing according to section 6.5.1 ”Restoring the Gas Cushion, procedure”, points 1-6 and 9 in this guide.

6.5 Restoring the Gas Cushion Check the oil level in the oil conservator one month after oil filling. If the oil level is lower now than when the oil filling was finished (correct for temperature differencies!) and no leakages are observed, the gas cushion has been solved in the oil and has to be restored. The procedure that follows 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 instructions in ”Oil filter unit for on-load tap-changers, manual” for restoring the gas cushion. 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.

WARNING The oil in the diverter switch housing may be hot. Be cautious! WARNING There is always a cushion of explosive gases in the top of the diverter switch housing. No open fire, hot surfaces or sparks may be present during opening of the housing or draining from the valve. After the cover is removed let the gas vent away approximately 15 min before any work is started.

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6 Oil Filling

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.

6.5.1 Procedure 1.

Close the valve in the tube to the conservator.

2.

Connect the oil pump to the oil valve. (For connection dimensions, see the dimension drawing for the on-load tap-changer), see Fig. 44.

3.

Open the oil valve and the air release valve.

4.

Start the oil pump and drain approximately 15 litres of oil for UCG and 25 l for UCL into a clean and dry container.

5.

Close the air release valve.

6.

Close the oil valve and disconnect the pump.

7.

Connect the output side of the pump to the oil valve.

8.

Open the oil valve.

9.

Open the valve in the tube to the conservator!

10. Pump the earlier drained oil back into the diverter switch housing. 11. Close the oil valve and disconnect the pump. The level in the oil conservator and the gas cushion are now restored. 12. If more than one unit, proceed with the other, (from step 1). CAUTION Avoid to do the restoring in damp weather since moisture will get into the diverter switch housing. If the restoring has to be done in such weather, the incoming air has to be dehydrated and the drained oil protected from water.

TC_00251

Oil valve

Air release valve

Air release valve

Fig. 44. The figures shows UCL 72

TC_00250

7 Electrical Connection and Testing

7 Electrical Connection and Testing 7.1 General Before the transformer is energized, tests have to be carried out to make sure that all mechanical and electrical connections are correct, and to check the proper functioning of the motor-drive mechanism and the on-load tap-changer. 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 7.2.

7.2 Connecting and Testing the Motor-Drive Mechanism and the On-Load Tap-Changer 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 motordrive mechanism. Connect the motor supply and the control supply to the correct terminals in the motordrive mechanism as shown by the circuit diagram supplied with the on-load tapchanger. Operate the motor-drive mechanism by means of the hand crank to a position in the middle of the range but not in a through position ( = a position with a letter in). Turn the control selector switch to position LOCAL. Then give an impulse for RAISE-operation. If the phase sequence is wrong, (three-phase supply), the motordrive mechanism will start in LOWER-direction. The motor-drive mechanism will stop when it has made approximately half of the complete operation and it will operate back and forth without the on-load tap-changer changes position until the control selector-switch is turned to position 0. If the phase sequence is wrong, reverse two of the motor supply cables in order to get the correct sequence. WARNING Dangerous voltage! For BUE: Run the motor-drive mechanism and check again that the red mark on the brake disc stops within the tolerance of ±25 degrees from exact position, see Fig. 34. For adjustment, see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125, Maintenance Guide for UCL.

73

7 Electrical Connection and Testing

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. 35. For adjustment, see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125, Maintenance Guide for UCL. 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 (where the indicator flag is positioned in the middle for BUE and when the indicator flag is white for BUL). Operate the onload tap-changer electrically to the other end position and repeat the test procedure above. WARNING The transformer should in no case be energized with an end stop out of order.

7.3 Electrical Tests on the Transformer Acceptance tests on the transformer or commissioning can now be performed.

7.4 After Energizing WARNING Before any work is carried out on the on-load tap-changer: Make sure that the transformer is disconnected and the earthing is properly done. Obtain a signed certificate from the engineer in charge.

74

8 Transport

8 Transport 8.1 Dismantling before Transport The on-load tap-changer is usually transported without accessories (pressure relay, motor-drive mechanism, bevel gear and drive shafts) to prevent damage to them. To make sure that everything is set up properly on site with a minimum of work, it is important to put the on-load tap-changer in the position and operated from the position given in the single-phase diagram delivered with the unit and fit locking devices properly during dismantling in the transformer factory. Dismantling of motor-drive mechanism and drive shafts is done in the opposite order of assembly.

8.1.1 Dismantling Preparations NOTE: Before dismantling, mark the details to facilitate identification. Check the position of the motor-drive mechanism according to Fig. 34 (BUE) or Fig. 35 (BUL). Use the hand crank to adjust it to its exact position. Install the locking device on the motor-drive mechanism, see Fig. 40.

8.1.2 External drive shafts for UCG.N/UCL.N and UCG.E/UCL.E (One Unit) See Fig. 34. 1.

If the horizontal shaft should be dismantled: Lock the bevel gear by means of the locking device, and two set screws, see Fig. 38g. Loosen the hose clips holding the protection tubes to the bevel gears. Push one of the protective tubes into the other. Loosen the screws holding the coupling halves in one end of the shaft and detach them. Detach the horizontal shaft. Mark the details.

2.

If the vertical shaft should be dismantled: Loosen the hose clips holding the protective tubes to the bevel gear and motordrive mechanism. Push one of the protective tubes into the other. Detach the screws holding the bevel gear SA21. Detach the bevel gear by carefully lifting it off the shaft while holding the vertical drive shaft. Detach the vertical shaft including protective tubes by lifting it off the coupling of the motor-drive mechanism. Mark the details.

3.

Pack screws, clamps, protective tubes, shafts, hose clips, protection cover,coupling halves, bevel gear and seals for transportation to site.

75

8 Transport

8.1.3 External Drive Shafts for UCG.B/UCL.B (Two Units) 1.

If the horizontal shafts should be dismantled: Detach the protection-cover SA33 on the bevel gear of unit -2, and lock the bevel gear by means of the locking device marked -2, and two set screws, see Fig. 38f. Loosen the hose clips holding the protective tubes to the bevel gears of unit -1 and -2. Push one of the protective tubes into the other. Loosen the screws holding the coupling halves in one end of the shaft and detach them. Detach the horizontal shaft between unit -1 and -2. Lock the bevel gear of unit -1 by means of locking device marked -1, and two set screws, see Fig. 38f. Loosen the hose clips holding the protection tubes to the bevel gear SA21 and the bevel gear of on-load tap-changer unit -1. Push one of the protective tubes into the other. Loosen the screws holding the coupling halves in one end of the shaft and detach them. Detach the horizontal shaft between unit -1 and bevel gear SA21. Mark the details.

2.

If the vertical shaft should be dismantled: Loosen the hose clips holding the protective tubes to the bevel gear and motordrive mechanism. Push one of the protective tubes into the other. Detach the screws holding the bevel gear SA21. Detach the bevel gear by carefully lifting it off the shaft while holding the vertical drive shaft. Detach the vertical shaft including protective tubes by lifting it off the coupling of the motor-drive mechanism. Mark the details.

3. Pack screws, clamps, protective tubes, shafts, hose clips, protection cover, coupling halves, bevel gear and seals for transportation to site.

8.1.4 External Drive Shafts for UCG.T/UCL.T and UCGYD/UCLYD (Three Units) 1.

If the horizontal shaft should be dismantled: Detach the protection-cover SA33 on the bevel gear of unit -3, and lock the bevel gear by means of the locking device and set screws marked -3, see Fig. 38f. Loosen the hose clips holding the protection tubes to the bevel gears of unit -2 and unit -3. Push one of the protective tubes into the other. Loosen the screws holding the coupling halves in one end of the shaft and detach them. Detach the horizontal shaft between unit -2 and -3. Lock the bevel gear of unit -2 by means of locking device marked -2 and two set screws, see Fig 38f. Loosen the hose clips holding the protective tubes to the bevel gears of unit -1 and -2. Push one of the protective tubes into the other. Loosen the screws holding the coupling halves in one end of the shaft and detach them. Detach the horizontal shaft between unit -2 and -1.

76

8 Transport

Lock the bevel gear of unit -1 by means of locking device marked -1 and set screws, see Fig. 39f. Loosen the hose clips holding the protection tubes to the bevel gear SA21 and the bevel gear of on-load tap-changer unit -1. Push one of the protective tubes into the other. Loosen the screws holding the coupling halves in one end of the shaft and detach them. Detach the horizontal shaft between unit -1 and bevel gear SA21. Mark the details. 2.

If the vertical shaft should be dismantled: Loosen the hose clips holding the protective tubes to the bevel gear and motordrive mechanism. Push one of the protective tubes into the other. Detach the screws holding the bevel gear SA21. Detach the bevel gear by carefully lifting it off the shaft while holding the vertical drive shaft. Detach the vertical shaft including protective tubes by lifting it off the coupling of the motor-drive mechanism.

3. Pack screws, clamps, protective tubes, shafts, hose clips, protection cover, coupling halves, bevel gear and seals for transportation to site.

8.1.5 Accessories 1.

If the pressure relay should be dismantled, see Fig. 41. Remove the electrical connection to the pressure relay and loosen the nuts. Remove the pressure relay and put it back in the delivery package. Mount the O-ring and the cover. Tighten the nuts.

2.

If other accessories are to be dismantled of transport reasons, pack them back in the packages they were delivered in and put back the transport covers. Mount the O-rings and tighten the nuts.

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 packing of the pressure relay until you are about to install it on the on-load tap-changer.

8.2 Oil Level During Transport The following adjustments of the oil level should be carried out when the on-load tapchanger should be transported. 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 dehydration.

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8 Transport

8.2.1 Transformer filled with Oil The transformer is transported filled with oil. When the transformer is transported filled with oil the on-load tap-changer should also be transported filled with oil.

8.2.1.1

Conservator mounted The diverter switch housing should be filled to normal operating level and the valve to the conservator should be open.

8.2.1.2

Conservator dismounted The oil level of the diverter switch housing should be lowered to 150 mm below the upper edge of the housing. When the conservator is removed, take off the cover of the diverter switch housing and drain oil with a pump to 150 mm below the upper edge of the housing. Remount the cover. Turn the cover so the guiding pin in the housing is facing the guiding hole in the cover. Make sure the gasket is properly in place. Seal all flange connections by mounting gaskets and covers. Shut all valves.

8.2.2 Transformer drained The transformer is transported without oil. When the transformer is transported without oil the on-load tap-changer should also be transported without oil.

8.2.2.1

Conservator mounted Drain the oil from the diverter switch housing by means of a pump connected to the oil valve. Let the on-load tap-changer be in contact with the ambient air through the breathing device on the conservator.

8.2.2.2

Conservator dismounted Drain the oil from the diverter switch housing by means of a pump connected to the oil valve. Open the air release valve, see Fig. 44, if necessary. Seal the diverter switch housing against the ambient air by mounting covers with´gaskets and shut all valves.

78

9 Commissioning

9 Commissioning This chapter describes tasks to be carried out on the on-load tap-changer 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, put drying agent inside the motor-drive cabinet and seal the vents.

Oil valve

Pressure relay

Horizontal drive shaft and protective tubes Bevel gear

Vertical drive shaft and protective tubes

Motor-drive mechanism

TC_00256

Fig. 45. On-load tap-changer system (single-unit shown) Fig. 45 shows the arrangement of the on-load tap-changer, motor-drive mechanism and drive shafts. 79

9 Commissioning

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. 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.

9.1 Connection to the Oil Conservator Follow appropriate parts of the instructions in section 5.5. Connect the cables to the low level alarm contact on the oil level indicator.

9.2 Mounting the Motor-Drive Mechanism and the Drive Shafts The motor-drive mechanism and drive-shaft system should have been assembled and disassembled in the transformer factory according to the instructions in this guide. Locking devices should have been installed when it was disassembled. If all locking devices are in place according to the transport sections in this guide, there should be no need for adjustments. If necessary, sections 5.1 and 5.2 give complete information for fitting and adjusting of the shaft system. NOTE: Check all fittings and alignments, even if the shaft system has been set up in the transformer factory. NOTE: The identification numbers on critical parts from the packing list is given in the following instructions, see sections 5.1 and 5.2.

9.2.1 Mounting of the Motor-Drive Mechanism See Figs. 34 and 35. Proceed as follows: 1.

Mount the motor-drive mechanism onto the transformer. The mounting holes on the transformer should be levelled within 1 mm. If adjustment is needed, shims should be used.

2.

Install the bevel gear, SA21, on the edge of the transformer cover, see Fig. 36.

3.

Check that the position indicator in the motor-drive mechanism shows the same position as the indicator inside the bevel gear of the on-load tap-changer.

4.

Remove the drying agent inside the cabinet.

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

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9 Commissioning

9.2.2 Mounting of the External Drive Shafts The external drive shafts consists of square tubes and should be connected to the spherical shaft ends on bevel gears and motor-drive mechanism by means of two coupling halves. CAUTION Before mounting of shafts and couplings, everything must be cleaned and greased for correct 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. NOTE: The multihole coupling should be greased. NOTE: The tubes around shafts and couplings are for protection. The arrangement of the driving shaft system is shown in Fig. 36. CAUTION Make sure that all locking devices (on the bevel gear, on the on-load tap-changer and in the motor drive) are mounted and the on-load tap-changer and the motor-drive are in the same service position. Check that the motor-drive mechanism is in its exact position according to Figs. 34 or 35. (BUE: The red mark on the brake disc facing the red mark on the brake assembly, BUL: The roller in the middle of the notch in the cam disc). If not, loosen the locking device and adjust it to its exact position. Remount the locking device.

9.2.3 Mounting of the Vertical Drive Shaft 1.

Mount the bevel gear SA21 on the transformer with O-ring, SA20, clamps SA17 screws and washers, see Figs. 46a and 46d.

2.

Put the square shaft SA14 with protective tubes SA15 and SA16 and hose clips according to Fig. 46a. Connect the square shaft with the mounted coupling halves to the motor-drive. Mount two coupling halves SA11 to the other end of the square shaft and the shaft of the bevel gear, see Fig 46b. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 47d. Tighten the screws lightly and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 47e. Tighten the screws A first and thereafter the other, see Fig. 47c.

3.

Mount the protective tube with the greater diameter, SA16 to the bevel gear with a hose clip, and the other tube SA15 to the flange of the motor-drive mechanism, see Fig. 46c. Leave about 3 mm play to the flange ring, see Fig. 46e, for water draining.

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9 Commissioning

SA18, SA19 SA17 SA21 SA20

Driving pin

SA10

SA11 SA16

SA16 SA10 SA15 SA15

SA14

SA10

Motor-Drive Mechanism

SA14

Fig. 46b.

Fig. 46a.

Fig. 46c.

SA20

TC_00147

SA18, SA19 SA15 SA17 SA10

TC_00156

Fig. 46d.

82

Fixing flange of the bevel gear

Min. 3, max 5 mm

TC_00147

TC_00156

TC_00149

Fig. 46e.

9 Commissioning

9.2.4 Mounting of Horizontal Drive Shaft types UCG.N/UCL.N and UCG.E/UCL.E

SA22 SA24

SA10

SA23

SA11 TC_00148

Fig. 47a. 1.

Put the square shaft SA22, protective tubes SA23 and SA24 and hose clips according to Fig. 47a.

For UCG: Loosen the screws for the locking device of the bevel gear on the top of the on-load tap-changer, see Fig. 47k. Remove the locking device. SA11

A

SA21

SA11 SA13 A TC_00178

TC_00242

SA12

Fig. 47b. 2.

Fig. 47c.

Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear, see Fig. 47b. Mount two coupling halves SA11 to the other end of the square shaft and the shaft of the other bevel gear. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 47d. Tighten the screws lightly and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 47e. Tighten the screws A first and thereafter the other, see Fig. 47c. Max. 3 mm M8 screw Coupling

Driving pin TC_00170

Fig. 47d.

TC_00148

Max. 6 mm

Fig. 47e.

Driving pin TC_00150

Fig. 47f.

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9 Commissioning

3.

The motor-drive mechanism and the on-load tap-changer should have the same indicated tap position and be in their exact positions. The motor-drive mechanism and the on-load tap-changer are in the same position when the position indicators in both of them show the same position, see Figs. 34 and 35. The motor-drive mechanism is in the exact position since point 9.2.2 has been carried out. The on-load tap-changer is in exact position when the ”window” where the position is read in the bevel gear is facing the red point in the gear box housing exactly, see Fig. 34. If the gear box is not in its exact position carry out point 5 and loosen the two screws in the multihole coupling on the gearbox and find the position of the screws that positions the opening in the brass toothed wheel closest to the red point in the gear box housing. The maximum deviation from exact alignment is given in Fig. 34. Tighten the screws.

CAUTION Assembly with the on-load tap-changer and the motor-drive mechanism in different operating positions may cause a transformer break down.

SA10 SA24

SA25

SA23 SA10

Slot facing downwards

TC_00243

SA23

Fig. 47g. 4.

Push the two protective tubes on the bevel gears and clamp them with hose clips SA10, see Fig. 47g.

NOTE: The slot of the protective tube SA23 should be facing downwards. The self-adhesive information plates SA25 are on about the middle of the tube length. NOTE: Do not remove the locking device before one end of the shaft of the bevel gear is finally connected to the drive shaft.

84

9 Commissioning

Locking device

Locking device

Set screws

Cover SA 33 TC_00244

TC_00287

Fig. 47h. UCL, UCG.B, UCG.T

Fig. 47k. UCG and UCL

9.2.5 Mounting of Horizontal Drive Shafts, Type UCG.B/UCL.B The following applies to the fitting of drive shafts and their protective tubes when the on-load tap-changer consists of units UCG.B/UCL.B. The on-load tap-changer unit, which is placed closest to the driving mechanism, is called unit -1, the second unit -2, see Fig. 36.

SA22 SA24

SA10

SA11

SA23

TC_00148

Fig. 48a. 1.

Put the square shaft SA22, protective tubes SA23 and SA24 and hose clips according to Fig. 48a. Loosen the screws for the locking device of the bevel gear on the top of the onload tap-changer, see Fig. 47k. Remove the locking device.

SA11

A

SA21

SA11 SA13 A TC_00178

TC_00242

SA12

Fig. 48b.

Fig. 48c.

85

9 Commissioning

2.

Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear, see Fig. 48b. Mount two coupling halves SA11 to the other end of the square shaft and the shaft of the other bevel gear. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 48d. Tighten the screws lightly and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 48e. Tighten the screws A first and thereafter the other, see Fig. 48c.

Max. 3 mm M8 screw Coupling

Driving pin TC_00148

TC_00170

Fig. 48d.

3.

Max. 6 mm

Fig. 48e.

Driving pin TC_00150

Fig. 48f.

The motor-drive mechanism and the on-load tap-changer should have the same indicated tap position and be in their exact positions. The motor-drive mechanism and the on-load tap-changer are in the same position when the position indicators in both of them show the same position, see Figs. 34 and 35. The motor-drive mechanism is in the exact position since point 9.2.2 has been carried out. The on-load tap-changer is in exact position when the ”window” where the position is read in the bevel gear is facing the red point in the gear box housing exactly, see Fig. 34. If the gear box is not in its exact position carry out point 5 and loosen the two screws in the multihole coupling on the gearbox and find the position of the screws that positions the opening in the brass toothed wheel closest to the red point in the gear box housing. The maximum deviation from exact alignment is given in Fig. 34. Tighten the screws.

CAUTION Assembly with the on-load tap-changer and the motor-drive mechanism in different operating positions may cause a transformer break down.

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9 Commissioning

SA10 SA24

SA25

SA23 SA10

Slot facing downwards

TC_00243

SA23

Fig. 48g. 4.

Push the two protective tubes on the bevel gears and clamp them with hose clips SA10, see Fig. 48g.

NOTE: The slot of the protective tube SA23 should be facing downwards. The self-adhesive information plates SA25 are on about the middle of the tube length. NOTE: Do not remove the locking device before one end of the shaft of the bevel gear is finally connected to the drive shaft. 5.

Loosen the set screws for the locking device of the bevel gear on the top of the on-load tap-changer, see Fig. 47h. Remove the locking device.

6.

Mount the cover SA33 and tighten the set screws (from the locking device).

SA30 SA32

SA10

SA31

SA11 TC_00148

Fig. 48h. 7.

Put the square shaft SA30, protective tubes SA31 and SA32 and hose clips according to Fig. 50h. Disc

Coupling

A

SA30

SA31

Unit -2

Unit -1 SA11 SA12

SA11 SA10 SA32

SA10 TC_00245

Fig. 48k. 87

9 Commissioning

8.

Connect the square shaft with the mounted coupling halves to the shaft of the bevel gear, see Fig. 48k. Mount two coupling halves SA11 to the other end of the square shaft and the shaft of the other bevel gear. Push the shaft to the bottom of the fitting in the coupling halves, see Fig. 48d. Tighten the screws lightly and check that the shaft can be moved approximately 2 mm in axial direction (axial play). Check the dimension shown in Fig. 48e. Tighten the screws A first and thereafter the other, see Fig. 48c.

NOTE: If the exact position of the closest unit has been adjusted, the locking device might have to be removed (step 6) before step 3 can be carried out. 9.

The motor-drive mechanism and the on-load tap-changer should have the same indicated tap position and be in their exact positions. The motor-drive mechanism and the on-load tap-changer are in the same position when the position indicators in both of them show the same position, see Figs. 34 and 35. The motor-drive mechanism is in the exact position since point 9.2.2 has been carried out. The on-load tap-changer is in exact position when the ”window” where the position is read in the bevel gear is facing the red point in the gear box housing exactly, see Fig. 34. If the gearbox of this unit is not in its exact position carry out point 6 and loosen the two screws in the multihole coupling on the gearbox and find the position of the screws that positions the opening in the brass toothed wheel closest to the red point in the gear box housing. The maximum deviation from exact alignment is given in Fig. 34. Tighten the screws.

CAUTION Assembly with the on-load tap-changer and the motor-drive mechanism in different operating positions may cause a transformer break down. Locking device Cover SA33

Set screws

SA10

SA25

SA32

SA10

SA31

TC_00246

Fig. 48l. 10. Push the two protective tubes on the bevel gears and clamp them with hose clips SA10, see Fig. 48l. Apply the self-adhesive information plates SA25 around the tubes on about the middle of the tube length. 11. Loosen the two set screws, see Fig. 39f and remove the locking device. 12. Mount the cover SA33. Tighten the two set screws, see Fig. 48l. (taken from the locking device). 88

9 Commissioning

9.2.6 Mounting of Horizontal Drive Shafts, Types UCG.T/UCL.T and UCGYD/UCLYD The following applies to the fitting of drive shafts and their protective tubes when the on-load tap-changer consists of three insulated units UCG.T/UCL.T or UCGYD/ UCLYD. The on-load tap-changer unit, which is placed closest to the driving mechanism, is called unit -1, the second unit -2 and the last unit -3, see Fig. 36. 1.

Mount the drive shaft to the on-load tap-changer unit -1 according to section 9.2.5 steps 1–5 above. Remove the set screws according to Fig. 47h.

2.

Mount the drive shaft between unit -1 and unit -2 according to section 9.2.5, steps 1-6 above. Remove the set screws according to Fig. 47h.

3.

Mount the drive shaft between unit -2 and unit -3 according to section 9.2.5, steps 2-7 above.

NOTE: The shaft is here called SA34, the protective tube closest to unit -2 is called SA35 and the other protective tube is called SA36. NOTE: Do not remove the locking device before one end of the shaft of the bevel gear is finally connected to the drive shaft. In cases where support bearing is used, follow appropriate parts of section 9.2.5, steps 2-5.

9.2.7 Before Operation 1.

Check again that the on-load tap-changer and the motor-drive mechanism are in the same operating position, see section 5.1.

2.

Remove the locking device of the motor-drive mechanism, see Fig. 49.

NOTE: The door of the motor-drive mechanism can be locked with a padlock (not included in the delivery). NOTE: Do not remove the locking device before one end of the shaft of the bevel gear is finally connected to the drive shaft.

Locking device TC_00262

BUE

BUL

Fig. 49. Locking device of motor-drive mechanism 89

9 Commissioning

9.3 Pressure Relay Follow appropriate parts of section 5.3.

9.4 Accessories Remount all other accessories, if any, that have been dismounted for the transport. Follow appropriate parts of section 5.4.

9.5 Oil Filling Follow appropriate parts of chapter 6.

9.6 Electrical Connection and Testing Make all wiring work and make the appropriate tests according to chapter 7. Remove the drying agent inside the cabinet of the motor-drive mechanism.

9.6.1 Motor Protection The function of the protective motor switch is checked. For three-phase AC motors, one of the phase fuses is removed and the function time of the protective motor switch is checked by a RAISE or LOWER operation. The protective motor switch should release within 60 seconds 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.

9.6.2 Disc Brake For BUE: Run the motor-drive mechanism and check that the red mark on the brake disc stops within the tolerance of ±25 degrees from exact position, see Fig. 34. For adjustment, see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125, Maintenance Guide for UCL. 90

9 Commissioning

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. 35. For adjustment, see 1ZSE 5492-124, Maintenance Guide for UCG or 1ZSE 5492-125, Maintenance Guide for UCL.

9.6.3 Counter Check that the counter is functioning at RAISE and LOWER operations.

9.6.4 Position Transmitter and other Position Switches Check the function of the position transmitter and other position switches.

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

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

9.7 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.

91

1ZSE 5492-116 en, Rev. 8, 2004-03-15

ABB Power Technologies AB Components Visiting address: Lyviksvägen 10 Postal address: SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00 Fax +46 240 121 57 E-mail: [email protected] www.abb.com/electricalcomponents

1ZSE 5492-124 en, Rev. 5, 1999-11-30

On-load tap-changer, type UCG with motor-drive mechanisms, types BUE and BUL Maintenance guide

This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Recommended Practices ABB Components recommends careful consideration of the following factors for maintenance work on on-load tap-changers: Before you start any work, make sure that the personnel doing the job have read and fully understood the Maintenance documents provided with the unit. To avoid damaging the unit, never exceed the operating limits stated in delivery documents and on rating plates. Do not alter or modify a unit without first consulting ABB Components. 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 equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work described.

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

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.

iii

WARNING 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 unexpected start of the motor-drive mechanism.

WARNING Before starting any work inside the motor-drive mechanism, the auxiliary power must be switched off. N.B. The motor, contactors and heating element may be energized from separate sources.

WARNING In no case should any person go down into the diverter switch housing. The cleaning of the diverter switch housing should be carried out by using brushes and rags and by flushing with oil.

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

CAUTION ABB Components recommends that only maintenance engineers trained by ABB Components carry out contact replacement.

During Service WARNING Small amounts of explosive gases will always come out from the breathing devices (dehydrating breather or one-way breather). Make sure that no open fire, hot surfaces or sparks occurs in the immediate surroundings of the breathing devices.

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

WARNING The hand crank must not be inserted during electrical operation.

iv

WARNING If the on-load tap-changer is not in its exact position and the hand crank is pulled out, the motor-drive mechanism will start and go to the exact position if the power supply is on.

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

During Oil Handling WARNING Unused transformer oil is slightly harmful. Fumes from unused warm oil may irritate the respiratory organs and the eyes. After long and repeated contact with transformer oil skin becomes very dry. Used on-load tap-changer oil from diverter switch housings and selector switch housings contains harmful substances. Fumes are irritating to the respiratory organs and the eyes and are very easily set on fire. Used transformer oil may well be carcinogenic. Avoid contact with the oil as much as possible and use oiltight protective gloves when handling the oil. First aid: Skin contact: Wash the hands. Use skin cream to counteract drying. In the eyes: Rinse the eyes in clean water. Swallowing: Drink water or milk. Avoid vomiting. Call a doctor. Collect used oil in oil drums. Waste and cleaning up: Should be absorbed by an absorber. Treat it as hazardous to the environment. Upon fire: The fire should be extinguished by using powder, foam or carbon acid.

WARNING When oil that has been used in a selector switch compartment 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.

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

WARNING There is always a cushion of explosive gases in the top of the diverter switch housing. No open fire, hot surfaces or sparks may be present during opening of the housing or draining from the valve. After the cover is removed let the gas vent away approximately 15 min before any work is started. v

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

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 dehydration.

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.

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

CAUTION Leave a gas cushion on top of the oil in the diverter switch housing.

After Oil Filling CAUTION Do not energize the transformer earlier than three hours after oil filling in atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

Mounting of Gaskets CAUTION Sealing surfaces and gaskets must be clean and undamaged. Diametrically opposed bolts in sealing joints must be tightened alternately several times, beginning with a low tightening torque and finally with the recommended tightening torque as described in section 1.3 Tightening Torque, in this guide.

vi

Contents 1 1.1 1.2 1.2.1 1.2.2 1.2.3 1.3

Introduction __________________________________________ General ______________________________________________ Maintenance Schedule __________________________________ Inspection ____________________________________________ Overhaul _____________________________________________ Contact Replacement ___________________________________ Tightening Torque _____________________________________

9 9 10 12 12 12 13

2 2.1 2.2

Inspection ____________________________________________ Required Tools and Material _____________________________ Procedure ____________________________________________

14 14 14

3 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.4 3.5 3.5.1 3.6 3.6.1 3.6.2 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.14.1 3.14.2 3.15

Overhaul _____________________________________________ Required Tools and Materials ____________________________ Procedure ____________________________________________ Preparations __________________________________________ On-Load Tap-Changer Position ___________________________ Disconnection and Earthing of the Transformer ______________ Oil Volumes and Lifting Heights __________________________ Recommended Set of Spare Parts__________________________ Oil Testing and Oil Draining _____________________________ Lifting and Cleaning the Diverter Switch ___________________ Lifting Rig ___________________________________________ Checking the Diverter Switch ____________________________ Cleaning the Diverter Switch Housing ______________________ Cleaning the Oil Filter (if any) ____________________________ Oil Filtration __________________________________________ Checking of the Breathing Device _________________________ Checking the Contact Positions ___________________________ Checking the Contact Wear ______________________________ Checking the Transition Resistors _________________________ Checking before Closing ________________________________ Installation of the Diverter Switch _________________________ Checking of the Pressure Relay ___________________________ Functional Check of the Pressure Relay _____________________ Replacing the Pressure Relay _____________________________ Lubrication of the On-Load Tap-Changer and the Drive Shaft System ______________________________

18 18 19 20 20 20 21 21 21 23 23 24 24 25 25 26 26 28 28 29 29 31 31 31 32

7

8

3.16 3.16.1 3.16.2 3.16.3 3.16.4 3.16.5 3.16.6 3.16.7 3.16.8 3.16.9 3.16.10 3.16.11 3.16.12 3.16.13 3.17 3.18 3.18.1 3.18.2 3.18.3 3.18.4 3.18.5 3.18.5.1 3.18.6 3.19 3.20

Checking of the Motor-Drive Mechanisms types BUE and BUL _ Motor Protection ______________________________________ Earth Fault Protector (option) ____________________________ Counter ______________________________________________ Heater _______________________________________________ Toothed Belt __________________________________________ Motor Cable Connections ________________________________ Disc Brake, BUE ______________________________________ Brake for the Maintaining Contact, BUE ____________________ Disc Brake, BUL ______________________________________ Position Transmitter and other Position Switches, BUE ________ Position Transmitter and other Position Switches, BUL ________ Lubrication, BUE ______________________________________ Lubrication, BUL ______________________________________ Operation Test ________________________________________ Oil Filling ____________________________________________ Filling Methods and Restrictions __________________________ Before Filling _________________________________________ Filling at Atmospheric Pressure ___________________________ Oil Level _____________________________________________ Restoring the Gas Cushion _______________________________ Procedure ____________________________________________ Waiting Period ________________________________________ Check of Contact Timing ________________________________ Putting into Operation __________________________________

32 35 35 35 35 35 36 36 37 37 38 38 39 39 41 41 41 42 42 42 43 44 45 45 48

4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

Contact Replacement ___________________________________ Dismantling the Boards _________________________________ Dismantling the Moving Main Contacts ____________________ Dismantling the Moving Transisition Contacts _______________ Mounting the Moving Transistion Contacts __________________ Mounting the Moving Main Contacts ______________________ Replacing the Fixed Main Contacts ________________________ Replacing the Fixed Transition Contacts ____________________ Mounting the Boards with Transition Resistors and Fixed Contacts

49 51 52 54 54 56 57 57 57

5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

Specification of Materials _______________________________ General ______________________________________________ Diverter Switch Housing ________________________________ Diverter Switch ________________________________________ Tap Selectors _________________________________________ Conductors ___________________________________________ Gearing Mechanism ____________________________________ Drive Shaft Systems ____________________________________ Motor-Drive Mechanism ________________________________

59 59 59 59 60 60 60 61 61

1 Introduction

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

Horizontal drive-shaft and protection tube

Bevel gear

Pressure relay Bevel gear

Shielding-rings (when impulse withstand voltage to earth exceeds 380 kV)

Vertical drive-shaft and protection tube

Insulating shaft Diverter switch housing containing the diverter switch

Hood and screws

Conductors Hand crank

Motor-drive mechanism

On-load tap-changer

Shielding-ring (when impulse withstand voltage to earth exceeds 380 kV). (Not on tap selector size C)

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

9

1 Introduction

Fig. 2 shows the general arrangement of an on-load tap-changer type UC. The main components are the spring-operated diverter switch and the tap selector with sliding contacts. For maintenance the diverter switch is lifted. The contacts are then immediately accessible and can be inspected for wear. The drive-shafts should not be dismantled when lifting the diverter switch. Maintenance is normally not required on the parts operating in the oil of the transformer tank. However, when the on-load tap-changer has made one million operations a check of the tap selector is recommended. The diverter switch has its own housing separate from the transformer oil. This is to prevent contamination of the transformer oil since the diverter switch oil deteriorates due to the switching operations. The oil needs to be checked and filtered at regular intervals to maintain adequate dielectric strength as well as to prevent mechanical wear. It is necessary to inspect the contacts and clean the insulation parts of the diverter switch as well as to clean the housing inside at regular intervals. The main components of the diverter switch are: Fixed main contacts Moving main contacts Fixed transition contacts Moving transition contacts Transition resistors Spring-driven polygon link system. Besides the maintenance of the diverter switch and cleaning of the oil, the motor-drive mechanism should be checked and lubricated. The pressure relay, the device that protects the transformer from damages due to excessive pressure in the diverter switch housing, should also be checked. NOTE: One on-load tap-changer of UCG type may consist of one, two or three units driven by a common motor-drive mechanism. The instructions in this guide deals with one unit. If there is two or three units, all work decribed should be carried on all units unless otherwise is stated. If more than one diverter switch is lifted out at the same time, make sure the right diverter switch is lowered into the right housing (compare with the serial numbers, see Fig. 2).

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

10

1 Introduction

Diverter switch housing

Cover Oil valve

Pressure relay

Bevel gear Position indicator

Top-section Serial No. Shielding-ring

1)

Earthing terminal Draining tube

Connection flange for gas operated relay

Insulating cylinder

Insulating shaft Shielding-ring

1)

Shielding-ring

2)

Diverter switch

Plug-in contacts

Transition resistors Fixed and moving contacts

Bottom section

Serial No. Guide-pins

Current terminal

Driving disc for the diverter switch

Tap selector

Bottom valve for drying process Intermediate gear Geneva gear

1)

Only at impulse withstand voltage to earth of 650 kV and 1050 kV

Change-over selector

2)

Not on UCG of the short type

Moving fineselector contacts

Current collector

Fixed fine-selector contacts

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

11

1 Introduction

1.2.1 Inspection On the rating plate, ”inspection once a year” is recommended. This principally concerns the motor-drive mechanism and refers to a visual inspection inside the motor-drive cabinet to check that nothing is loose and the heater is functioning. In the motor-drive mechanism a counter registers every tap-changer operation. During inspection the counter is read. If possible, motor and counter are tested by operating one step and then back. If the on-load tap-changer has its own oil conservator, the breather and the oil level indicator are checked according to the instructions from the transformer manufacturer. The inspection is carried out while the transformer is in service. If the on-load tap-changer is equipped with an oil filter unit from ABB Components, it should be inspected once a year according to the ”Oil filter unit for on-load tapchangers, manual”.

1.2.2 Overhaul The contact life and the frequency of operations or the time in service determine the time interval between overhauls. The number of operations run by the on-load tap-changer is recorded by a counter, housed in the motor-drive mechanism cabinet. The registered number of operations should be noted at every inspection and overhaul. The on-load tap-changer should normally be overhauled regularly at intervals of 1/5 of the estimated contact life. The relevant information is stated on the rating plate. Hereby, the contact wear can be followed and necessary preparations can be made for replacing the contacts. If the tap-change operations occur infrequently and a very long time elapses until the number of operations amounts to 1/5 of the contact life, the interval between overhauls should be limited to the time stated on the rating plate (normally 7 years).

1.2.3 Contact Replacement On the rating plate of the on-load tap-changer the estimated contact life of the breaking contacts in the diverter switch at rated load is stated. The contacts will withstand a very large number of switching operations. For normal power transformers the number of operations of the diverter switch is approximately 20 per day, which means that replacement of the contacts is not normally necessary during the life of the transformer. (In case of on-load tap-changers on furnace transformers, the frequency of operations may be considerably higher). CAUTION The number of operations must in no case exceed 500 000, due to weakening spring tension of the contacts.

12

1 Introduction

1.3 Tightening Torque The following tightening torques are recommended for metallic screw joints:

for non-metallic screw joints:

M6, M8, M10, M12,

10 Nm 24.5 Nm 49 Nm 84 Nm

M10, 9 Nm M12, 13 Nm M16, 22 Nm

±10 % ±10 % ±10 % ±10 % ±10 % ±10 % ±10 %

if not otherwise is stated in this guide.

13

2 Inspection

2 Inspection The inspection mainly consists of a visual check of the motor-drive mechanism and the conservator once a year while the transformer is in service. In the motor-drive mechanism the following points are to be checked: Motor and counter Heater The counter’s value. On the conservator the following are to be checked: Oil level Breather

2.1 Required Tools and Material The following equipment is required for the inspection: Set of screw drivers Pen and note pad.

2.2 Procedure CAUTION Approval should be given for inspection as well as for operating the on-load tapchanger. WARNING This work must be carried out from ground level since the transformer is energized!

1. Check the breathers according to the instructions for the transformer. WARNING The breathers and the tube from the conservator contains explosive gases. No open fire, hot surfaces or sparks may be present when loosening the breather. 2. Check the oil level in the conservator for the on-load tap-changer. The oil level should be according to the transformer documentation. See Figs. 3 and 4.

14

2 Inspection

3.

Open the cabinet door of the motor-drive mechanism and turn the selector-switch to the LOCAL position. Then turn the control switch to the RAISE (LOWER) position.

4.

Check that the motor works properly, the position indicator increases (decreases) one step and the counter advances one step for each operation. Record the counter’s value. The counter shows the number of operations run by the on-load tap-changer (the overhaul-schedule can be determined with the help of this information).

5.

Turn the control switch to the LOWER (RAISE) position for 1-2 seconds. Check that the motor also works properly in that direction, the position indicator decreases (increases) one step and the counter advances one step more. Reset the draghands.

6.

Check the emergency stop. Give a RAISE or LOWER impulse and after about one second press the emergency stop. The operation should be interrupted. Reset the emergency stop by turning the knob clockwise and by switching on the protective motor switch. The started operation should now be completed. Operate back to service position.

7.

Check the earth fault protector (option). If the motor-drive mechanism is equipped with an outlet, the earth fault protector should be tested by pressing the test knob on the outlet on BUE and by pressing the test knob on the separate earth fault protector on BUL.

8.

Disconnect the incoming auxiliary power.

WARNING Before starting any work inside the motor-drive mechanism the auxiliary power must be switched off. N. B. The motor, contactors and heating element may be energized from separate sources. 9.

Open the control panel

10. Check by feeling with a finger on the protection plate that the heater has been functioning. 11. Close the control panel and reconnect the incoming auxiliary power. 12. Complete the inspection by turning the switch to the REMOTE position and closing the cabinet door.

15

2 Inspection

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

21

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

20

Locking device prepared for padlock Emergency stop (Option) Switch for extra heater Air vent LOCAL/REMOTE switch RAISE/LOWER switch Outgoing shaft Lamp (40 W socket E27) Lifting eye Counter Tap-change in progress indicator Position indicator with draghands for max. and min. position

19

18

13. 14. 15. 16. 17. 18.

Shaft for handcrank Heater 50 W + optional 100 W (behind the panel) (Option) Outlet with earth fault protector Terminal blocks (behind the panel) Protective motor switch (Option) Thermostat or hygrostat for extra heater 100 W 19. Door-operated switch for lamp 20. Handcrank 21. User’s manual and circuit diagram

Fig. 3. Motor-Drive Mechanism, type BUE.

16

17

2 Inspection

1

2

3

4

5

18

19

20

21

6

7 8 9 10

11

12

13

14 15 16

17

1.

Position indicator with draghands for max. and min. position 2. Tap-change in progress indicator (Red = in progress, White = in position) 3. Counter 4. Outgoing shaft with multiple hole coupling half 5. Shaft for handcrank 6. Lifting eye 7. Locking device prepared for padlock 8. (Option) Multi position switches 9. (Option) Measuring amplifier 10. (Option) Switch for extra heater 11. (Option) Outlet 12. (Option) Earth fault protector

22

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

23

24

Emergency stop RAISE/LOWER switch LOCAL/REMOTE switch Protective motor switch Air vent (Remote position for automatic operation) Door operated switch for lamp Terminal blocks Hand lamp Heater 50 W + optional 100 W (Option) Thermostat or hygrostat for extra heater 100 W User’s manual and circuit diagram Handcrank

Fig. 4. Motor-Drive Mechanism, type BUL.

17

3 Overhaul

3 Overhaul WARNING Before any work is carried out on the on-load tap-changer: Make sure that the transformer is disconnected and that earthing is properly carried out. Obtain a signed certificate from the engineer in charge.

3.1 Required Tools and Materials Necessary for the overhaul is the following equipment: Normal hand tools (keywidth up to 19 mm) Normal set of combination spanners Pipe wrench Thickness gauges (0.40; 0.50; 1.20 mm) Small hammer Sliding caliper Spring balance (10 N) Watch (with hand for seconds) Oil can Ohmmeter (1-30 Ohm) Air pump with pressure gauge (0-200 kPa) and connection to R 1/8” male thread Telpher (at least 150 kg lifting force) Empty and clean barrels for transformer oil (calculate with max. 225 l for each diverter switch housing) Oil draining and filtering equipment with connections Test equipment according to IEC 156 Two buckets (approximately 10 l) Rags (non-fuzzying) 50 l of new transformer oil (class II according to IEC 296) Grease (GULF-718 EP synthetic grease, Mobilgrease 28, Shell-Aero Shell grease 22 or similar Oil (for plain ball and roller bearings) Degreasing agent Protective glooves, oil proof

18

3 Overhaul

Dimension drawing for the on-load tap-changer Pen and note pad Set of spare contacts (see ”Spare parts list for UC”) Brass shims according to Fig. 9 (12 pcs) New O-ring for the cover (435x8). When restoring the gas cushion. (section 3.18.5): Small oil pump with connection to the oil valve Empty and clean barrel for transformer oil ( ~ 15 l) Box wrench, 6 mm. When measuring contact timing, add this equipment: See section 3.19. When replacing contacts (chapter 4), add this equipment: Universal pliers Pipe wrench 4 mm mandrel 5 mm brass mandrel, 320 mm long Steel ruler Round file Torque wrench (10 Nm) Piece of wood, 50 mm thick, 400 mm long.

3.2 Procedure The overhaul procedure includes the following points: Oil testing and oil draining Lifting and cleaning the diverter switch Cleaning the diverter switch housing and the oil filter (if any) Oil filtration Checking the breathers Checking the contact positions Checking the contact wear Checking the transition resistors

19

3 Overhaul

Checking before lowering the diverter switch Lowering the diverter switch Checking the pressure relay Lubrication Checking the motor-drive mechanism Oil filling Check of contact timing Putting into operation.

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

3.3.1 On-Load Tap-Changer Position Note the position of the on-load tap-changer to enable restart of the transformer in the right tap position.

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

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.

20

3 Overhaul

3.3.3 Oil Volumes and Lifting Heights The necessary number of empty drums for collecting and filtering of the oil in the diverter switch housing should be kept ready. The drums must be carefully cleaned and free from water. New oil needed should be of class II according to IEC 296. Quantity of oil in the diverter switch housing and lifting height for the diverter switch UCG.. UCG.. UCG..

380/... 650/... 1050/...

Approx. 170 litres (lifting height 1.4 m) Approx. 170 litres (lifting height 1.4 m) Approx. 205 litres (lifting height 1.7 m)

NOTE: The volume of the oil conservator is not included. Alternatively, the oil may be replaced by new oil and the used oil filtered at some later occasion. A certain quantity of new oil, at least 50 litres, should be kept ready to replace waste oil and for cleaning CAUTION Do not energize the transformer until oil has been filled as per section 3.18 ”Oil Filling” in this guide.

3.3.4 Recommended Set of Spare Parts It is recommended to have a set of contacts for the diverter switch available during the overhaul, see Spare Parts List for ordering.

3.4 Oil Testing and Oil Draining The diverter switch housing is equipped with an oil valve placed on the top section. For connection dimensions, see the dimension drawing for the on-load tap-changer. WARNING The oil in the diverter switch housing may be hot. Be cautious!

Take an oil-sample from the oil valve and carry out the dielectric strength test according to IEC 156 (between spherical calottes, distance 2.5 mm). This test is carried out for deciding whether the oil can be filtered or must be exchanged. The dielectric strength of the oil should not be allowed to be less than 120 kV/cm for an on-load tap-changer in service. NOTE: When taking the oil-sample, first drain some oil into a bucket to clean the valve. If the oil conservator of the on-load tap-changer is common with the oil conservator of the transformer tank, close the valve in the pipe connection to the oil conservator and open the oil valve. After a while, open the air release valve. See Fig. 22. 21

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NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil filtration from ABB Components and it is maintained and operated according to our instructions, oil draining and filtering is not needed, provided that the dielectric strength is at least 160kV/cm (IEC 156). NOTE: There is a hole in the upper part of the draining tube to prevent air from being trapped inside the tube when oil filling. The air sucked in through this hole when draining might disturb the function of some types of pumps. In such case, drain the oil using a hose instead. CAUTION Never block the hole in the draining tube! Use the filtering equipment or the pump to drain oil from the on-load tap-changer into carefully cleaned oil drums. Connect the pump to the oil valve and drain the oil from the diverter switch housing and the conservator. Draining can be effected quickly if filtering equipment is used and at the same time the whole oil quantity will be filtered once. Remove the cover of the diverter switch housing while draining. WARNING There is always a cushion of explosive gases in the top of the diverter switch housing. No open fire, hot surfaces or sparks may be present during opening of the housing or draining from the valve. After the cover is removed let the gas vent away approximately 15 min before any work is started. WARNING When oil that has been used in a diverter 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. Drain the remaining oil in the bottom of the housing by using a hose.

Buffer springs

Lifting eye Lifting device

Shielding ring (only for impulse withstand voltages to earth exceeding 380 kV). (Not on UCG short with the transition resistors lying down.) Tie-rod

Self-coupling plug-in contacts

Coupling with driving-pin

Guiding pins

Fig. 5. Diverter switch, general arrangement 22

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3.5 Lifting and Cleaning the Diverter Switch The weight of the diverter switch is approximately 90 kg. Lift the diverter switch partly so you can flush it with oil. After careful flushing, lift the diverter switch from the housing and wipe it with rags. Lift according to Fig. 7. NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil filtration from ABB Components and it is maintained and operated according to our instructions, the flushing and wiping of the diverter switch is not necessary. CAUTION When lifting the diverter switch, use a manually operated telpher to avoid damages on the diverter switch. Make sure that the end of the tie-rod or its coupling is kept clear of the inner edge of the flange.

3.5.1 Lifting Rig The diverter switch (mass approximately 90 kg) can be lifted out of the housing by means of a telpher. As a holder for the telpher, it is recommended to use a rig similar to the one shown in Fig. 6. Install the supports on the flange of the top-section after the cover is removed, see Fig. 7. Ø10 40

70

5 30

Beam Ø56/48

600 Ø15 (2x)

2500

>5

50

453

65

Ø30

Ø15 (2x)

90 125

10

Support (2x)

Fig. 6. Lifting rig 23

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WARNING Make sure the rig is properly fixed to the cover flange before the diverter switch is lifted.

Beam Manually operated telpher

Lifting eye

Support

Fig. 7. Lifting arrangement

3.6 Cleaning 3.6.1 Cleaning the Diverter Switch Housing Clean the inner walls of the housing by means of a nylon brush, then flush with oil. Drain the oil. Wipe the bottom and inner walls with rags. NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil filtration from ABB Components and it is maintained and operated according to our instructions, the cleaning of the diverter switch is not necessary. WARNING In no case should any person go down into the diverter switch housing. The cleaning of the diverter switch housing should be carried out by using brushes and rags and by flushing with oil.

Drain the housing completely by using a hose before oil filling is carried out.

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3.6.2 Cleaning the Oil Filter in the Conservator Pipe (if any) The diverter switch housing and the oil conservator are connected by a pipe. The diverter switch oil is contaminated due to the arcing that occurs when the contacts operate. In case of a common conservator with the transformer the impure oil in the diverter switch housing must be prevented from entering the oil conservator. An oil filter is therefore mounted in the pipe. The filter, which is mounted in a flange pipe on the top of the diverter switch housing, is screwed from the inside. It can easily be screwed out for inspection and cleaning. The oil filter does not need to be replaced nor cleaned in any other way than by washing with oil. Screws

Housing

Filter element

Fig. 8. Oil filter details

3.7 Oil Filtration The drained oil should be filtered until it is cleaned and has regained the high dielectric strength required. The break-down value for purified oil should be at least 160 kV/cm according to IEC 156. To check the result of the filtering, take test sample after the oil has been filled into the on-load tap-changer. NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil filtration from ABB Components and it is maintained and operated according to our instructions, no further oil filtration is necessary. Only take an sample and measure the dielectric strength of the oil, see section ”Oil Testing and Oil Draining” in this guide.

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3.8 Checking of the Breathing Device Check the breathing device according to the instructions from the transformer manufacturer. WARNING The breathers and the tube from the conservator contains explosive gases. No open fire, hot surfaces or sparks may be present when loosening the breather.

3.9 Checking the Contact Positions Those parts of the fixed contacts and the moving contacts which are exposed to arcing during an operation are tipped by copper-tungsten. In a tap position, the moving main switching contacts and the fixed main switching contacts should have a clearance of min. 0.5 mm as shown in Fig. 9. For checking the clearance on both sides of the diverter switch it has to be operated. Operate it by turning the coupling with a pipe wrench, see Fig. 5. Note the position of the diverter switch before operation. WARNING Take care to avoid finger injuries when operating the diverter switch. Oil splash occurs during operation, especially in the moving direction. If the clearance is too small you may adjust the clearance by installing a shim of brass between the board and the current bar. The shims are included in the spare parts set. The shim dimensions are also shown in Fig. 9. Operate the diverter switch to the opposite side when mounting the shims. Operate the diverter switch back to the first side and check the clearance again. If still too small, put in a shim more and test again. CAUTION Never mount more than three shims on each other. Make sure all washers and screws are put back and tighten. Proceed with the other side of the diverter switch. When finished, operate the diverter switch back to the position it had before the first operation. Fig. 9 shows the current carriers through the fixed main contact and the copper part of the moving contact. Fig. 10 shows the copper-tungsten tips of the transition contact touching each other in a tap position.

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0.5–2 mm Fixed main switching contact

Moving main switching contact

20 14

Copper part

Ø6.4 26 14

Thickness 1 mm Current bar Fixed main contact

Moving main contact

Board

Fig. 9. Fixed and moving contacts clearance

Fig. 10. Transition contacts Make sure that all flexible connections, operating springs, contact springs and all plug-in contacts are in good condition. Make sure that no bolts have worked loose 27

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3.10 Checking the Contact Wear The contact system consists of fixed and moving contacts. Check the degree of contact burning on the breaking contacts. For a new contact with tips of copper-tungsten (Fig. 11), the thickness at (A) and (B) is 5.5 mm in the upper end of the contact. In the lower end, the thickness is 3 mm. Estimate the degree of contact burning and record this to enable comparison with the condition at the next overhaul. Do not file or smooth the burned and pitted contact surfaces. A contact with a tip of copper-tungsten (Fig. 11) should be replaced when the thickness at (A) and (B) in the upper end of the contact is approximately 0.5 mm. (The thickness in the upper and the lower end of the tip will be approximately the same when close to the limit for replacement). Also replace contacts which are assumed to wear out before the next overhaul. The dimensions above are valid for both main contacts and transition contacts. For contact replacement, see chapter 4 ”Contact Replacement”. A

B

Fig. 11. Tolerance limits for contact erosion

3.11 Checking the Transition Resistors Measurement is carried out on the side with open contacts. Connect one cable from the ohmmeter to a fixed main contact and the other cable to a fixed transition contact. Measure the resistance. Measure the resistance of each resistor branch across the open switch. Operate the diverter switch to the other side as described in section 3.9 and measure the resistance with open contacts.

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Check that the resistors are undamaged and compare with the value on the rating plate. The values must not differ by more than 10 %. Check that nothing has worked loose. Operate the diverter switch back to its previous position.

3.12 Checking before Closing Before installing the diverter switch, make sure that no foreign objects, tools, wires, rags etc. are left in the diverter switch housing.

3.13 Installation of the Diverter Switch CAUTION Check the serial numbers to make sure that the diverter switch is mounted in the correct housing, see Fig. 2.

CAUTION Make sure that the diverter switch housing is clean and dry and that no foreign objects (tools etc.) are left in the housing.

CAUTION Lower the diverter switch into its housing carefully so that neither the diverter switch nor the housing are damaged.

The UCG diverter switch is provided with a guiding slot that fits against the oil draining tube in the diverter switch housing, see Figs. 12 and 13. Rotate the diverter switch so the half-circle shaped guiding slot is aligned with the oil draining tube, see Figs. 12 and 13. When the diverter switch is lowered, check visually that its plug-in contacts are aligned with the contacts in the cylinder wall. In order to ensure that the diverter switch pin has engaged the coupling disc, carry out at least three tap change operations in one direction. A distinct sound is heard when the diverter switch operates which indicates that the driving pin of the diverter switch has been connected. If no sound is heard, the diverter switch might need to be pushed down while operating the motor-drive. Carry out another three operations in the same direction while pushing the diverter switch down. The top part of the diverter switch lifting device should be below the level of the machined surface for the cover when lowered to its final position. Only the springs of the lifting device should be above this level. 29

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If a check of contact timing should be carried out, proceed with that according to section 3.19 before mounting the cover. Insert a new O-ring for the cover in the upper flange. Mount the on-load tap-changer cover. Turn the cover so the guiding pin in the housing is facing the guiding hole in the cover. (The cover has to be pressed down in order to overcome the spring force of the springs which hold the diverter switch pressed in place.) Insert screws and washers and tighten them.

Springs Lifting device Lifting eye

Shielding-ring (when the impulse withstand voltage to earth exceeds 380 kV) (not on UCG short version)

Serial number (on the opposite side of the diverter switch)

A

A

Plug-in contacts Guiding pin

Guiding pin

Tie rod fm_00223

Driving pin

Fig. 12. Diverter switch

Coupling disc

Notch for the guiding pin Oil draining tube

Holes for guiding pins

Guiding pins Slot for the oil draining tube

Slot for guiding bar

TC_00284

A–A, UCG

Fig. 13. UCG Diverter switch housing, view from above

30

TC_00285

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3.14 Checking the Pressure Relay 3.14.1 Functional Check of the Pressure Relay

Information plate Valve handle (in service position)

Quick coupling

Test tap (R 1/8”)

TC_00264

Fig. 14. Pressure relay 1. Set the valve handle to the test position as shown on the information plate. 2. Connect the air pump and the pressure gauge to the test tap on the pressure relay. (Thread R 1/8”). 3. Raise the pressure until the pressure relay trips the circuit breakers of the transformer. 4. Read the pressure on the manometer and check against the pressure stated on the information plate. Max. permitted deviation is ±10 %. If the deviation is greater, the pressure relay should be replaced. 5. Check that the signal disappears when the pressure is released. 6. After finishing the check, turn back the valve handle to service position.

3.14.2 Replacing the Pressure Relay If replacement of the pressure relay is necessary, it is carried out according to the instruction in 1ZSE 5492-129, Repair Guide for On-Load Tap-Changers types UCG, UCL, UCC, UCD.

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3.15 Lubrication of the On-Load TapChanger and the Drive Shaft System The bevel gears are greased at delivery and the same type of grease is used for the couplings of the outer shaft system. For access to the couplings, loosen the hose-clips and push the protective tubes together. For access to the bevel gears, dismount the covers. WARNING The bevel gear contains moving gears. Be cautious!

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

3.16 Checking of Motor-Drive Mechanisms types BUE and BUL The motor-drive mechanism should be checked and lubricated at the same time as the on-load tap-changer. The overhaul includes the following points: Before disconnecting the power supply: Motor protection function Earth fault protector (option) Counter function After disconnecting the power supply: Heater function Toothed belt Cable connections Disc brake function Position transmitter and other position switches Lubrication Reconnect the power supply and make operation tests according to section 3.17.

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Brake Brake disc Maintaining contact

Roll pin Supporting shaft Brake block Arm system Driving roller

Brake for maintaining contact

One turn shaft Cam disc

Toothed belt

Geneva wheel

Position transmitter Contact plate

fm_00137

Motor

Fig. 15. Motor-drive mechanism, type BUE 33

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Operation counter Roller

(Grease) Notch Cam disc

(Grease) Brake arm

Geneva wheel

Adjusting screw

Maintaining contact

Bracket Brake disc

Limit switch

Toothed belt

Multi-position switches (Grease)

fm_00231

Fig. 16. Motor-drive mechanism, type BUL 34

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3.16.1 Motor Protection The function of the protective motor switch is checked. For three-phase AC motors, one of the phase fuses is removed and the function time of the protective motor switch is checked by a RAISE or LOWER operation. The protective motor switch shall release within 60 seconds at a current setting equal to the rated current of the motor at actual voltage. WARNING The motor power voltage is dangerous. If the protective motor switch do not trip within 60 seconds, switch off the power and adjust the current setting. Repeat the test when the motor is cold. Protective motor switches for DC motors and for single-phase AC motors are not tested.

3.16.2 Earth Fault Protector (option) If the motor-drive mechanism is equipped with an outlet, the earth fault protector should be tested by pressing the test knob on the outlet. (On BUL, the earth fault protector is separated from the outlet and knob is on the relay).

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

3.16.4 Heater WARNING Before starting any work inside the motor-drive mechanism, the auxiliary power must be switched off. N.B. The motor, contactors and heating element may be energized from separate sources. Check by feeling with a finger that the heating element has been functioning.

3.16.5 Toothed Belt Check that the toothed belt is sufficiently tight. If tightening is required, adjust the motor support. The tightness of the belt can be checked by a spring balance attached to the belt halfway between the pulleys. At a 10 N load the belt should yield about 5 mm on BUE and at a 6 N load the belt should yield about 2 mm on BUL. 35

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3.16.6 Motor Cable Connections Check that all cable connections within reach are secure.

3.16.7 Disc Brake, BUE Wipe the brake disc free from grease. The kinetic energy in the motor and the toothed wheels should be absorbed by the brake, and the motor-drive mechanism should stop as shown in Fig. 17, with a tolerance of ± 25 degrees as measured on the brake disc (± 125 degrees measured on the hand crank), see Fig. 17. This can be adjusted by tightening both of the spring bolts on the brake. Using the hand crank, operate the motor-drive mechanism until the brake is fully open. At this point the length of the springs must not be less than 35 mm. If the brake still does not function with that spring length, oil or grease has entered the brake linings, which will then need cleaning. Clean as follows: Using a pair of tongs, remove the roll pins that hold the supporting shafts on the brake blocks, see Fig. 15. Then remove the shaft and the brake blocks. Clean the brake linings on the two brake blocks with degreasing agent. When refitting the brake, check that the brake disc is completely free from grease. Adjust the spring force of the brake until the motor-drive mechanism stops within the tolerances given above. CAUTION If the motor-drive still not stops when the brake is adjusted to a spring length of 35 mm when the brake is fully open, please contact ABB Components for advice.

Adjusting nuts

Brake disc

Red mark ±25o from mark on brake pad Red mark

fm_00232

Brake pads

Fig. 17. Brake adjustment, type BUE

36

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3.16.8 Brake for the Maintaining Contact, BUE Check that the brake for the maintaining contact prevents the arm system on the maintaining contact shaft from swinging beyond its normal position when the roller on the driving arm moves free from the cam disc, see Fig. 15. At the end of the operation, contacts for operation in the opposite direction shall not move when the arm system swings back towards its normal position. Unpermitted swinging should be prevented by raising the braking force, i. e. tightening the spring bolt. An adjusted increasing spring force on the brake makes the maintaining contact arm swing back with a different speed, and the brake for the maintaining contact must be adjusted.

3.16.9 Disc Brake, BUL Run the motor-drive mechanism and check that the centre of the notch in the cam disc stops within ±2 mm from the centre of the roller on the brake arm, see Fig. 18. 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.

Roller on the brake arm in centre of the notch in the cam disc

Brake arm

Cam disc Contra nut Adjusting screw

fm_00225

Brake disc Min 15

Fig. 18. Brake adjustment, type BUL

CAUTION If the motor-drive still not stops when the brake is adjusted to min. 15 mm according to Fig. 18 please contact ABB Components for advice.

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3.16.10 Position Transmitter and other Position Switches, BUE Clean the contact plates and arms (Fig. 18) from dust and dirt with a dry cloth. Check and adjust the resilience of the moving contacts in the multi-position switches. The moving contact shall, in all positions, have a clearance between the nut and the contact arm of 0.4–1.2 mm. Adjustment is made with the nuts on the contact (Fig. 19).

Contact arm

Moving contact

Contact arm 0,6 +0.6 mm -0.2

Geneva wheel

Contact plate Fixed contact

View A – A

Fig. 19. Contact arm play

3.16.11 Position Transmitter and other Position Switches, BUL Check the contact function in all positions at both RAISE and LOWER operations. No adjustment of the contacts should be made. For replacement of a Position Switch see 1ZSE 5492-129, Repair Guide, On-Load Tap-Changers, types UCG, UCL, UCC and UCD. If there is a lot of dust, it can be removed from the circuit cards and the transparent covers with a vacuum cleaner, without disassembling the multi-position switch.

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Transparent cover

Contact arm

Circuit card

fm_00233

Fig. 20. Position transmitter, checking

3.16.12 Lubrication, BUE See Fig. 21. The bearing points of the brake blocks and the links should be sparingly lubricated with oil. (Use oil for plain ball and roller bearings.) The spur gears, the geneva wheel with the limit stop, the cam discs and the cam bar are sparingly lubricated with the same type of grease as for the shaft system when necessary. Other bearing points do not need lubrication. NOTE: Protect the brake disc and the brake linings against lubricants. Wipe off excess lubricant. Reconnect the power supplies.

3.16.13 Lubrication, BUL Lubrication is not needed at normal working conditions. All ball bearings have rubber seals and are permanently greased. All cam discs and some gears are made of selflubricating material. If needed, the bevel gears for the hand crank, the geneva wheels and the bevel gears for the position indicator might be sparingly lubricated with the same grease as the shaft system. (GULF-718EP Synthetic Grease, Mobilgrease 28, Shell-Aero Shell Grease 22 or similar). See Fig. 16. Reconnect the power supplies.

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Grease Grease

Oil

Oil

Grease

Grease

NOTE: The small bevel gear for the position indicator shaft shall be greased.

Grease

Fig. 21. Lubrication points, BUE 40

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3.17 Operation Test Operate the motor-drive mechanism, first by manual operation and then electrically between the limit positions. Check the limit stops by operating the on-load tapchanger to one of the end positions. When trying to operate it electrically beyond the end position, the motor should not start. 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. Handcrank back to the end position (where the indicator flag is positioned in the middle for BUE, and when the indicator flag shows white colour for BUL). Operate the on-load tap-changer electrically to the other end position and carry out the same test procedure as above. Check the emergency stop by giving a RAISE or LOWER impulse and after about one second press the emergency stop. The operation should be interrupted. Reset the emergency stop by turning the knob clockwise and switch on the protective motor switch. The started operation should now be completed. Check the running-through protection with the step-by-step function disengaged. This is done by first removing the connection between terminals X4:1 and X4:2 and then keep the RAISE/LOWER switch engaged. The motor-drive mechanism should stop before the fourth operation is completed. This checking must be done at least five steps from the end position. After the test reset the time relay by putting the LOCAL/ REMOTE switch to 0 and then back. Reset the protective motor switch to ON. Remount the connection between X4:1 and X4:2. Check the step-by-step relay by keeping the RAISE/LOWER switch engaged in RAISE. The on-load tap-changer shall make only one step. Repeat the check in LOWER. Check the function of the position transmitter and other multi position switches in all positions.

3.18 Oil Filling If check of contact timing is to be carried out, see section 3.19, fill the diverter switch housing with oil up to the level of the fixed main breaking contacts by easiest possible method before checking. Oil fill completely according to the instructions below after check of contact timing.

3.18.1 Filling Methods and Restrictions Oil filling can be carried out at atmospheric pressure or under vacuum. The wall between the diverter switch housing and the transformer tank is designed to withstand vacuum on one side and atmospheric pressure on the other side. It is not allowed to have vacuum on one side and the pressure of an oil column on the other side. After maintenance oil is normally filled at atmospheric pressure. This procedure is described in section 3.18.3. If filling is to be carried out under vacuum, see 1ZSE 5492-116 Installation and Commissioning Guide for UCG and UCL.

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After oil filling, a gas cushion should remain on the top of the oil in the diverter switch housing. The connection to the oil conservator is designed to automatically give a gas cushion when filling at atmospheric pressure. NOTE: If new oil, especially degassed oil, is filled into the diverter switch housing and the number of operations is low, the gas cushion may be dissolved in the oil. The oil level in the oil conservator should then be checked after a month in service and if the oil level is lower than after the oil filling, (corrected for temperature differencies), the gas cushion should be restored according to section 3.18.5 ”Restoring the Gas Cushion” in this guide.

3.18.2 Before Filling NOTE: Oil filling may be carried out in different ways depending on what is convenient as long as the rules above are fulfilled and the on-load tap-changer is filled with oil to the correct level with a gas cushion on the top. The method below is recommended and if it is followed in detail no pressure limits are exceeded and oil levels and gas cushion will be correct. If the on-load tap-changer consists of more than one unit, fill one at a time.

3.18.3 Filling at Atmospheric Pressure See Fig. 22. 1. Close the air release valve 2. Open the conservator valve, if any. 3. Dismantle the breathing device on the conservator for the on-load tap-changer. 4. Pump oil into the diverter switch housing via the oil valve (connection dimensions, see the dimension drawing for the on-load tap-changer). Continue until the conservator is filled to the correct level at the actual temperature. See even section 3.18.4. If there is more than one unit connected to the same conservator, fill all of them until the oil level indicator starts to move and fill up to the right level when filling the last unit. 5. Shut the oil valve and disconnect the pump. 6. Remount the breathing device. Make sure the connection to the breathing device is properly sealed.

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

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3.18.5 Restoring the Gas Cushion Check the oil level in the oil conservator one month after oil filling. If the oil level is lower now than when the oil filling was finished (correct for temperature differencies!) and no leakages are observed, the gas cushion has been solved in the oil and has to be restored. The procedure below 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 Components, and it is installed according to our recommendations, follow the instructions in ”Oil filter unit for on-load tapchangers, manual” for restoring the gas cushion. In case the on-load tap-changer consists of more than one unit, do the restoring in one unit at a time. 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.

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

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.

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3.18.5.1

Procedure 1.

Close the valve in the tube to the conservator.

2.

Connect the oil pump to the oil valve. (For connection dimensions, see the dimension drawing for the on-load tap-changer), see Fig. 22.

3.

Open the oil valve and the air release valve.

4.

Start the oil pump and drain approximately 15 litres of oil into a clean and dry container.

5.

Close the air release valve.

6.

Close the oil valve and disconnect the pump.

7.

Connect the output side of the pump to the oil valve.

8.

Open the oil valve.

9.

Open the valve in the tube to the conservator!

10. Pump the earlier drained 15 litres of oil back into the diverter switch housing. 11. Close the oil valve and disconnect the pump. 12. The level in the oil conservator and the gas cushion are now restored. If the on-load tap-changer consists of more than one unit, proceed with the other one until the last one has been restored. CAUTION Avoid to do the restoring in damp weather since moisture will get into the diverter switch housing. If the restoring has to be done in such weather, the incoming air has to be dehydrated and the drained oil protected from water.

Oil valve

Open end wrench key width 6 mm

Air release valve

Open

TC_00251

Oil valve

TC_00250

Fig. 22. Air release valve (position may be on another vertical flange)

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3.18.6 Waiting Period CAUTION Do not energize the transformer earlier than three hours after oil filling in atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

3.19 Check of Contact Timing Checking the contact timing is a good check of the condition of the on-load tapchanger, but it is not necessary to check contact timing at every overhaul. It is recommended to be carried out after every 500 000 operations. The test requires: Two indicator lamps (glow discharge lamps for the minimum possible magnetisation of the transformer) Necessary leads Two stiff insulated leads or bars. WARNING Never force DC current through the transformer windings. The insulated leads (or bars) are used for connection to the moving contact arms of the tap selector via the plug-in contacts of the diverter switch (They can be made of an insulating tube with a lead inside.) Connect the lamps as shown in Fig. 23. The diverter switch contacts are designated as shown in Fig. 24. Determine if x or v contacts are closed, see Fig. 24. In the contact-timing diagram for the on-load tap-changer you can find out the corresponding position. See Figs. 25 and 26. The diverter switch housing shall be filled with transformer oil up to the fixed main contacts to secure the correct function of the dash pots during operation of the diverter switch, see section 3.18. At repeated operations in the same direction the selector arms V and H operate every second time. When the direction of operation is reversed, the contact arms will be at rest during the first operation. The operation is then performed by means of the diverter switch only. NOTE: When testing, the operation must be carried out in the same direction as the previous operation.

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y

u

Fig. 23. Indicator lamp connection during contact timing test

v-contacts

x-contacts

TC_00284

Fig. 24. The diverter switch outlet marking The test is to be made on all three-phases and is to be carried out as follows: Find the exact position of the on-load tap-changer by adjusting the disc brake as shown in Figs. 17 and 18. 1. Note the number of whole turns and parts of turns on the hand crank, during a slow manual operation. 2. Note when each tap-selector arm breaks and makes (the corresponding lamp goes out or lights). 3. Note when the diverter switch flicks over (a distinct sound is heard). 46

3 Overhaul

After this, compare the operations with the contact-timing diagram applicable to the on-load tap-changer in Figs. 25 and 26. One operation corresponds to 25 turns of the hand crank on the motor-drive mechanism, type BUE and 15 turns for BUL. Remove the equipment for contact-time measuring. Mount the cover of the diverter switch housing according to section 3.13. Complete the oil filling according to section 3.18. CAUTION If the result is beyond the limits given here, please contact ABB Components.

Position

Min. 3 turns

–—— Contact closed

Position

Min. 3 turns

Position

Turns of the hand crank of the mechanism

Fig. 25. Example of contact-timing diagram, BUE NOTE: The diverter switch must have switched over before the 20th turn is finished with the hand crank.

47

3 Overhaul

Position

Min. 2 turns

Position

Min. 2 turns

Position

V H x

u y V

–—— Contact

Turns of the hand crank of the mechanism

Fig. 26. Example of contact timing diagram, BUL NOTE: The diverter switch must have switched over before the 12:th turn is finished with the hand crank.

3.20 Putting into Operation Operate the on-load tap-changer to the position noted in section 3.3.1. 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 mechanism cabinet. Close the door. Make sure that nothing is left on the transformer cover. Sign the revision protocol and give it to the engineer in charge and inform that the onload tap-changer is ready for energizing.

48

4 Contact Replacement

4 Contact Replacement CAUTION ABB Components recommends that only authorized personnel from ABB Components carry out contact replacement.

Replace worn-out main switching contacts and transition contacts as required. (It is not necessary to replace both main switching contacts and transition contacts if, for instance, only the main switching contacts are worn out). CAUTION Fixed contacts and its corresponding moving contacts should always be replaced at the same time.

Also replace contacts which are assumed to wear out before the next overhaul. Replacement of contacts is described in the following sections.

49

4 Contact Replacement

Fixed main switching contact Conical springwasher

Plain washer

Fixed transition contact Locking washer 1)

Plain washer

Conical spring washer

Moving transition contact

Conical spring washer Plain washer

Guide pin Nut Connection for transition resistor

Fixed transition contact

Moving main switching contact

1)

Mounted vertically on some types

Fig. 27. Diverter switch, contact design

50

4 Contact Replacement

4.1 Dismantling the Boards

Board

Guide pin

Locking washer

Screw

Fig. 28. Contact replacement, dismantling the boards

Dismantle the boards from the frame by removing the six screws and the locking washers from each board (Fig. 28). Punch the guide pins with a 4 mm mandrel. Note that the guide pins are placed high on one board and low on the other board in order to make the boards non-reversible. When mounting, use new locking washers and guide pins. Lift away the boards in the lifting eye, see Fig. 7 with fixed contacts and transition resistors from the contact-mechanism (Fig. 29). The boards, which are made of insulating material, shall be wiped with rags.

51

4 Contact Replacement

Fig. 29. Contact replacement, boards lifted away

4.2 Dismantling the Moving Main Contacts Dismantle the moving main contacts according to Figs. 30 and 31. Take away split pins, washers and springs in both ends of shafts 1–3. There is one shaft for each pair of contacts. NOTE: Notice that the outer end of the outer phase have washers with a larger diameter, see Fig. 30. Do the same for the contacts on the opposite side. Pull out shaft 1. Take care of the silver washers. Do the same with shaft 3. Punch out the middle shaft 2 by means of a 5 mm mandrel of brass. Shaft 2 must then be passed through the holes for shafts 1 or 3 and remain there until new contacts are mounted. Repeat the procedure for the contacts on the opposite side.

52

4 Contact Replacement

Contact

Washer with larger diameter

Shaft 1

Shaft 2

Shaft 3

Fig. 30. Contact replacement, taking away split pins

Contact

Shaft 1

Fig. 31. Contact replacement, pulling out shaft

53

4 Contact Replacement

4.3 Dismantling the Moving Transition Contacts Dismantling of the moving transition contacts should be carried out according to Figs. 32 and 33. The transition contacts are held by a common shaft 4 going through all the contacts. The shaft 4 is locked with two split pins (Fig. 33). Remove the split pins and punch out the shaft with a 5 mm mandrel of brass and take care of the springs, washers and contacts when the mandrel is pulled out. The springs in Fig. 33, view A – A, are loosened in the following way: Punch out the locking pin in one end of the pin with a 2 mm mandrel. Thereafter the spring holder can be loosened and the contacts with springs can be removed. Take care of the pin. Repeat the above procedure on the other side of the diverter switch.

Shaft 4

Fig. 32. Contact replacement, moving transition contacts

4.4 Mounting the Moving Transition Contacts Mount the moving transition contacts according to Fig. 33. A replacement contact consists of a contact with mounted spring.

54

4 Contact Replacement

Split pins A

A

Shaft

Spring Washer (insulating)

Pin

Contact

Locking pin

Spring

View A - A

Fig. 33. Transition contact construction Punch the shaft through the first bearing hole and put a contact, spring, insulating washer and another contact on the shaft as it is continuously punched in. Then proceed with the next phase. Finally lock it with new split pins. Mount the springs by means of the pin and new locking pins. Proceed with the other side of the diverter switch. Put a ruler on the linings of the tran-sition contacts. No lining should lie more than 1 mm from the ruler. If any lining does, adjust these contacts closer to the board by filing off material on the surface of the contact that lies against the stop shaft. When all transition contacts on both sides are mounted, make sure that the contacts move easily in the bearings and that the springs are functioning.

55

4 Contact Replacement

4.5 Mounting the Moving Main Contacts Fig. 34 shows how to mount the moving main contacts. Washers and springs shall be placed as shown in Fig. 34. The contacts are equipped with copper-tungsten tips. Washers and springs shall be placed as shown in Fig. 34. CAUTION The outer end of the outmost phases should have the washers with larger diameter, (Ø=25 mm) see Fig. 34. Fig. 34, view A – A shows the replacement contact which consist of two contacts with a mounted spring, mounted on the current bridge. Begin with the middle phase. Put the contact and the silver washers on the shaft and punch the shaft in to the bearing hole with the 5 mm mandrel. Put the next silver washer and contact in position and punch in the shaft. Mount washers, springs and split pins according to Fig. 34. Proceed with the outer phases. Put the outermost silver washer and contact on the shaft and punch the shaft into the bearing hole. Put the next silver washer and contact into position and punch in the shaft. Mount washers, springs and split pins as shown in Fig. 34. Check with Fig. 34 that all containing details are correctly assembled. A

Washer with larger diameter

Contact

Contact Silver washers

Spring

A View A - A Split pin

TC_00270

Insulating washer Spring

Steel washer

Fig. 34. Moving main contacts with tips of copper-tungsten, washers and springs Put a ruler on the linings of the moving main contacts. No lining should lie more than 1 mm from the ruler. If any lining does, adjust these contacts closer to the board by filing off material on the surface of the contact that lies against the stop shaft. Carry out the same procedure on the other side of the diverter switch. 56

4 Contact Replacement

4.6 Replacing the Fixed Main Contacts Unscrew the fixed main contacts, see Fig. 27. Mount new contacts. Use new conical spring washers and locking nuts. Put the washers as shown in Fig 27. Press the contacts against their bracket when tightening the screws. Tightening torque approximately 10 Nm, (not critical). NOTE: The conical end of the nut should be turned upwards.

4.7 Replacing the Fixed Transition Contacts Unscrew the screw and nut holding the connection for the transition resistors. Unscrew the fixed transition contact. Mount new contacts. Put the washers as shown in Fig. 27. Use new locking washers. Tighten the screws, tightening torque approximately 10 Nm. Mount the connection for the transition resistors as shown in Fig. 27. Tightening torque approximately 10 Nm. Use new conical spring washers and locking nuts. NOTE: The conicial end of the nut should be turned upwards.

4.8 Mounting the Boards with Transition Resistors and Fixed Contacts To assemble the mechanism and the boards with transition resistors and fixed contacts, do as follows: When the boards are lowered, put one side of the mechanism on an approximately 50 mm high piece of wood to make the fixed and moving contacts free from each other (Fig. 35).

57

4 Contact Replacement

Fixed main contact

Moving main contact

Piece of wood

Fig. 35. Contact replacement, mounting the boards The boards should be fixed with new guide pins (4 x 30 mm, spring-type straight pin slotted). Guide by inserting a 6 mm mandrel into an adjacent screw hole. Put in and tighten all screws. Secure the screws with new locking washers (Fig. 28). The plain washers should be closest to the board. Check that the linings of the fixed main contacts are aligned with the linings of the moving main contacts. If not, loosen the nuts slightly and adjust the fixed main contacts. Tighten the nuts. Check (and adjust, if necessary) the alignment of the transition contacts as described for the main contacts. Tighten the screws and lock the locking washers. Proceed with the other side of the diverter switch by first operating it to the other side as described in section 3.9. WARNING Take care to avoid finger injuries when operating the diverter switch.

Check (and adjust, if necessary) the diverter switch according to section 3.9. Operate it and check that the contact movement is correct. Remount the diverter switch into the housing according to section 3.13.

58

5 Specification of Materials

5 Specification of Materials 5.1 General On disposal of this product, it is recommended that local environmental regulations in each country are met. For environmental reasons, materials used are specified.

5.2 Diverter Switch Housing Material

Approx. amount

Steel

15 kg

Aluminium

75 kg

Copper and alloys

5 kg

Epoxy resin

35 kg

Transformer oil

150–200 kg

5.3 Diverter Switch Material

Approx. amount

Steel

25 kg

Copper and alloys

10 kg

Silver

25 g

Tungsten

0–1 kg

Polyester resin

20 kg

Presspan

1 kg

Resistor wire (mainly copper and nickel alloys with small amounts of aluminium and manganese)

5-50 kg

59

5 Specification of Materials

5.4 Tap Selectors Tap selector I:

Tap selector C:

Material

Approx. amount

Material

Steel

50 kg

Steel

Copper and alloys

25 kg

Aluminium

15 kg

Silver

0–100 g

Copper and alloys

20 kg

Phenol resin laminate

20 kg

Silver

70 g

Polyester resin

5 kg

Polyester resin Epoxy resin

Tap selector III: Material

Approx. amount

Steel

10 kg

Aluminium

40 kg

Copper and alloys

50 kg

Silver

10 g

Polyester resin

10 kg

Epoxy resin

20 kg

5.5 Conductors Material

Approx. amount

Copper

5-10 kg

Cellulose

5.6 Gearing Mechanism

60

Material

Approx. amount

Steel

15 kg

Copper and alloys

5 kg

Approx. amount 5 kg

5 kg 15 kg

5 Specification of Materials

5.7 Drive Shaft Systems Material

Approx. amount

Steel

8 kg

Aluminium

2 kg

Brass

2 kg

Polyethylene

2 kg

5.8 Motor-Drive Mechanism BUE

BUL

Material

Approx. amount

Approx. amount

Steel

100–120 kg

55 kg

Copper and alloys

5–10 kg

5 kg

Aluminium and alloys

–

10 kg

Silver

10 g

10 g

Plastics: chlorsulphonated polyethylene polyamide with MoS2 phenol resin laminate polyester PVC carbonate plastic

x x x x x x

x x

Rubbers: nitrile rubber fluorine rubber

x x

x x

x x x

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

61

1ZSE 5492-124 en, Rev. 5, 1999-11-30

ABB Power Technology Products AB Components Visiting address: Lyviksvägen 10 Postal address: SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00 Fax +46 240 121 57 E-mail: [email protected] www.abb.com

1ZSE 5492-129 en, Rev. 6, 1999-11-30

On-load tap-changers, types UCG, UCL, UCC and UCD with motor-drive mechanisms, types BUE and BUL Repair 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 Components recommends careful consideration of the following factors for service and repair work on on-load tap-changers. Do not repair an on-load tap-changer or motor-drive mechanism with a serious mechanical or electrical fault without first consulting ABB Components. Before you start any work, make sure that the personnel doing the job have read and fully understood the Repair documents provided with the unit. To avoid damaging the unit, never exceed the operating limits stated in delivery documents and on rating plates. Do not alter or modify a unit without first consulting ABB Components. 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 equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work described.

Safety Precautions CAUTION ABB Components recommends that only service engineers with appropriate skills regarding on-load tap-changers carry out the repairs.

CAUTION ABB Components recommends that only maintenance engineers trained by ABB Components carry out contact replacement.

iii

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.

WARNING The relevant technical documents should be read and understood before any work is started, and the procedures in this document should be followed at all times.

WARNING 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 unexpected start of the motor-drive mechanism.

WARNING Before starting any work inside the motor-drive mechanism, the auxiliary power must be switched off. N.B. The motor, contactors and heating element may be energized from separate sources.

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

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.

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

iv

WARNING The hand crank must not be inserted during electrical operation.

WARNING If the on-load tap-changer is not in its exact position and the hand crank is pulled out, the motor-drive mechanism will start and go to the exact position if the power supply is on.

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

During Oil Handling WARNING Unused transformer oil is slightly harmful. Fumes from unused warm oil may irritate the respiratory organs and the eyes. After long and repeated contact with transformer oil skin becomes very dry. Used on-load tap-changer oil from diverter switch housings and selector switch housings contains harmful substances. Fumes are irritating to the respiratory organs and the eyes and are very easily set on fire. Used transformer oil may well be carcinogenic. Avoid contact with the oil as much as possible and use oiltight protective gloves when handling the oil. First aid: Skin contact: Wash the hands. Use skin cream to counteract drying. In the eyes: Rinse the eyes in clean water. Swallowing: Drink water or milk. Avoid vomiting. Call a doctor. Collect used oil in oil drums. Waste and cleaning up: Should be absorbed by an absorber. Treat it as hazardous to the environment. Upon fire: The fire should be extinguished by using powder, foam or carbon acid.

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.

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

v

CAUTION Leave a gas cushion on top of the oil in the diverter switch housing.

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 diverter switch housing, if the on-load tap-changer is not operated. Restore the gas cushion and the oil level according to section 3.3. WARNING When oil that has been used in a diverter switch compartment 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.

WARNING The oil in the diverter switch compartment may be hot. Be cautious!

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 dehydration.

WARNING There is always a cushion of explosive gases over the oil surface. This is sucked into the on-load tap-changer tank during draining of the oil. No open fire, hot surfaces or sparks may be present when the top cover is opened.

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 tightening torque and finally with the recommended tightening torque as described in section 1.6 Tightening Torque, in this guide.

After Oil Filling CAUTION Do not energize the transformer earlier than three hours after oil filling in atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

vi

Contents 1 1.1 1.2 1.3 1.4 1.5 1.6

Introduction ____________________________________________ General ________________________________________________ Repair Categories _______________________________________ Serial Number __________________________________________ Spare Parts List _________________________________________ Maintenance Guide ______________________________________ Tightening Torque _______________________________________

9 9 9 11 11 12 12

2 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3

Trouble-shooting ________________________________________ On-Load Tap-Changer ____________________________________ Pressure Relay __________________________________________ Motor-Drive Mechanism __________________________________ Control System _________________________________________ Power System __________________________________________ Miscellaneous __________________________________________

13 13 14 15 15 17 17

3 3.1

Repairs and Adjustments __________________________________ Replacement of Gear Box on the On-Load Tap-Changer or Replacement of O-rings for the Gear box _____________________ General ________________________________________________ Tools Required _________________________________________ Material and Spare Parts Required __________________________ Procedure ______________________________________________ Replacement of Diverter Switch Housing Cover Gasket _________ General ________________________________________________ Tools Required _________________________________________ Material and Spare Parts Required __________________________ Procedure ______________________________________________ Restoring the Gas Cushion ________________________________ General ________________________________________________ Equipment Required _____________________________________ Procedure ______________________________________________ Replacement or addition of a Multi-position Switch (BUL only) __ General ________________________________________________ Tools Required _________________________________________ Procedure ______________________________________________ Examination of the Diverter Switch after a Pressure Relay Trip ___ Tools and Material Required _______________________________ Procedure ______________________________________________ Tests of the Pressure Relay ________________________________ Replacement of Pressure Relay _____________________________ General ________________________________________________ Tools Required _________________________________________ Spare Parts Required _____________________________________ Procedure ______________________________________________

22

3.1.1 3.1.2 3.1.3 3.1.4 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.5.2 3.6 3.7 3.7.1 3.7.2 3.7.3 3.7.4

22 22 22 22 23 27 27 27 27 27 28 28 29 29 30 30 30 31 33 33 33 34 35 35 35 35 35

7

8

1 Introduction

1 Introduction 1.1 General The UC range of on-load tap-changers manufactured by ABB Components has been developed over many years to provide maximum of reliability. The simple and rugged design gives a service life equal to the service life of the transformer. Minimum maintenance is required for trouble-free operation. The only parts requiring maintenance are contacts that might need replacement during the service life, the insulating oil and the motor-drive mechanism. The design allows excellent access to all parts, making inspection and maintenance quick and simple. The on-load tap-changers, type UC, are housed in the transformer tank. The motordrive mechanisms, types BUE or BUL are attached to the transformer tank and connected to the on-load tap-changer by means of drive-shafts and a bevel gear, see Figs. 1 and 2.

1.2 Repair Categories Repairs on the UC range of on-load tap-changers fall into two categories: Repairs. Repairs are to replace worn or end-of-service-life parts. Modifications. Modifications are only issued by ABB Components to improve the already very high standard of reliability and to assist in prolonging the service life of the equipment. The modifications fall into two areas: – Immediate, where the modification should be completed at the earliest possible opportunity. – Routine, where the modification should be completed during a routine service interval.

9

1 Introduction

Diverter switch housing

Cover Oil valve

Pressure relay

Bevel gear Position indicator

Top-section Serial No. Shielding-ring

1)

Earthing terminal Draining tube

Connection flange for gas operated relay

Insulating cylinder

Insulating shaft Shielding-ring

1)

Shielding-ring

2)

Diverter switch

Plug-in contacts

Transition resistors Fixed and moving contacts

Bottom section

Serial No. Guide-pins

Current terminal

Driving disc for the diverter switch

Tap selector

Bottom valve for drying process Intermediate gear Geneva gear

1)

Only at impulse withstand voltage to earth of 650 kV and 1050 kV

Change-over selector

2)

Not on UCG of the short type

Moving fineselector contacts

Current collector

Fixed fine-selector contacts

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

10

1 Introduction

1.3 Serial Number Before consulting ABB Components for technical advice to assist with repairs or to order spare parts to complete the repairs, the on-load tap-changer serial number must be known. The serial number can be found on the following locations: Rating plate on the motor-drive mechanism (Fig. 2) Diverter switch housing (Fig. 1) Diverter switch (Fig. 1) Tap selector (Fig. 1). If the on-load tap-changer serial number cannot be obtained, the transformer serial number should be used (only if the transformer is manufactured by ABB Transformers in Ludvika, Sweden). NOTE: One of these serial numbers must be quoted in all correspondence and telefax messages, and during any telephone conversations with ABB Components. Failure to use the serial number may cause delays.

Serial No.

FM_00006

FM_00200

BUE

BUL

Fig. 2. Rating plate

1.4 Spare Parts List The Repair Guide does not contain information about spare parts and how to order them. For information about spare parts, please refer to the 1ZSE 5492-133 Spare Parts List for the UC range of On-Load Tap-Changers with Motor-Drive Mechanisms, types BUE and BUL. The Spare Parts List also contains several exploded views, which can be very handy when making repairs.

11

1 Introduction

1.5 Maintenance Guide Inspection and overhaul of the UC range of on-load tap-changers are carried out according to the instructions in the appropriate Maintenance Guide. You will need the Maintenance Guide since references are made to it.

1.6 Tightening Torque The following tightening torques are recommended for metallic screw joints:

for non-metallic screw joints:

if not otherwise is stated in this guide.

12

M6, M8, M10, M12,

10 Nm 24.5 Nm 49 Nm 84 Nm

M10, 9 Nm M12, 13 Nm M16, 22 Nm

±10 % ±10 % ±10 % ±10 % ±10 % ±10 % ±10 %

2 Trouble-shooting

2 Trouble-shooting This chapter mainly contains information used to locate a fault. Instructions for correcting the fault, replacement of parts etc. are contained in chapter 3 Repairs and Adjustments.

2.1 On-Load Tap-Changer Error condition

Fault finding procedure

High oil level alarm

A rising oil level in the on-load tap-changer conservator may indicate a leakage between the diverter switch housing and the transformer tank. Make sure that the cause for the alarm is not overfilling at commissioning or overhaul. This can be checked by adjusting the oil level according to the transformer documentation and then rechecking some time later.

Low oil level in the oil conservator

1. Check for leakages. 2. If no leakages are found, the gas cushion is solved in the oil and should be restored. Follow the instructions in section 3.3 in this guide.

Pressure relay trip

See section ”Pressure Relay” in this guide.

13

2 Trouble-shooting

2.2 Pressure Relay WARNING To take the transformer into service after a pressure relay trip without carrying out a careful investigation of the diverter switch by lifting it out of the diverter switch housing, and repairing faults, if any, may cause severe damages to the onload tap-changer and the transformer.

Error condition

Fault finding procedure

The pressure relay has tripped during normal operation.

1. Examine the diverter switch according to section 3.5 ”Examination of the diverter switch after a pressure relay trip” in this guide. Continue with steps 2 and 3 if no fault is found. 2. Carry out tests on the pressure relay according to section 3.7 ”Tests of the pressure relay” in this guide. 3. The on-load tap-changer is now ready for service.

Information plate

Valve handle Connection nut

Test tap (R 1/8’’)

TC_00264

Fig. 3. Pressure relay

14

2 Trouble-shooting

2.3 Motor-Drive Mechanism 2.3.1 Control System Error condition

Fault finding procedure

LOCAL operation or REMOTE operation is not possible.

1. LOCAL operation is not possible when the control selector switch is in position REMOTE or 0, and REMOTE operation is not possible in position LOCAL or 0. 2. Check the power supply both for control and motor. 3. Check if the protective motor switch has been released. 4. Check if the emergency stop has been pressed. Release by turning clockwise and reset the protective motor switch. 5. Check if the running-through protection has been released. Reset by setting the LOCAL/REMOTE switch to 0 and then back to previous position and after that reset the protective motor switch. 6. If the motor-drive has been handcranked against the mechanical endstop, handcrank back to endposition.

The on-load tap-changer performs more steps than ordered, or operates towards the end stop.

1. Check that the maintaining contact releases after operation. WARNING Dangerous voltage! 2. Check that the raise and lower contactors function properly (see circuit diagram, Fig. 4 respectively Fig. 6, and contact timing diagram, Fig. 5 respectively Fig. 7). BUE: 3. Check that the brake disc stops in its middle position with a tolerance of ±25 degrees. For information about how to adjust the brake, refer to the Maintenance Guide. 4. Check that the starting contact fuctions properly (see circuit diagram and contact timing diagram).

15

2 Trouble-shooting

Error condition

Fault finding procedure

BUL: 3. Check that the roller on the brake arm stops in the middle of the notch in the cam disc. For information about how to adjust the brake, see the Maintenance Guide. The remote position indicator shows wrong position or there is no signal.

1. If there is a measuring amplifier: Adjust the output signal from the measuring amplifier with its two adjustment screws. If the failure does not disappear, proceed as follows: WARNING Dangerous supply voltage! Measure the output signal from the measuring amplifier in all positions. The signal shall raise linear up to the highest position. If no signal, check the feeding to the measuring amplifier and to the position transmitter. Check that the signal reaches the position indicator. 2. Measure the resistance on the terminals of the position transmitter in all positions after both raise and lower operations. WARNING Before starting any work inside the motordrive mechanism, the auxiliary power must be switched off. N.B. The motor, contactors and heating element may be energized from separate sources.

BUE: 3. Check that the contact plate and arm on the multi-position switch are free from dust and oxide. Check the contact function with the moving contact arm in all positions.

16

2 Trouble-shooting

Check the resilience of the moving contacts in the multi-position switch. For information about how to adjust the resilience, see the Maintenance Guide. BUL: 3. If the resistances are wrong replace the position transmitter. See section 3.4 in this guide.

2.3.2 Power System Error condition

Fault finding procedure

The three-phase motor runs back and forth without the on-load tap-changer changes position.

Reverse two of the phases of the incoming supply. WARNING Dangerous voltage!

2.3.3 Miscellaneous Error condition

Fault finding procedure

Corrosion and/or condensation in motor-drive mechanism cabinet.

1. Check the function of the anti-condensation heater. Refer to heater in the Maintenance Guide. 2. Check that the air vents not have been blocked.

Water in motor-drive mechanism cabinet.

1. Adjust the hinges on the cabinet door, if necessary. 2. Replace the door gasket, on the cabinet.

17

1)

Continuation contact is only included when the on-load tap-changer has through positions. Closed when the on-load tap-changer is in through positions.

2 Trouble-shooting

fm_00236

Fig. 4. Standard circuit diagram BUE

For actual information use the circuit diagram delivered with your on-load tap-changer.

18

2 Trouble-shooting

fm_00237

Fig. 5. Contact timing diagram BUE

19

1)

Continuation contact is only included when the on-load tap-changer has through positions. Closed when the on-load tap-changer is in through positions.

2 Trouble-shooting

fm_00238

Fig. 6. Standard circuit diagram BUL

For actual information use the circuit diagram delivered with your on-load tap-changer.

20

2 Trouble-shooting

fm_00239

Fig. 7. Contact timing diagram BUL

21

3 Repairs and Adjustment

3 Repairs and Adjustments 3.1 Replacement of Gear Box on the On-Load Tap-Changer or Replacement of O-rings for the Gear box 3.1.1 General This instruction guides you on how to replace the gear box on the top section of the UCG, UCL and UCC, UCD on-load tap-changers. If the gasket only is to be replaced, follow appropriate parts of the instructions.

CAUTION When making this repair it is important that neither the on-load tap-changer nor the motor-drive mechanism is operated with the shafts disconnected.

WARNING The gearbox contains moving gears. Be cautious!

3.1.2 Tools Required Normal set of handtools Socket wrench with extension socket for 8 mm Allen screw Sliding caliper Graduated limb.

3.1.3 Material and Spare Parts Required Gear Box O-ring (84.1 x 5.7), for UCL O-ring (92.5 x 5.7), for UCG, UCC, UCD Loctite 601 (UCL) Low temperature grease (ball bearing grease) GULF-718EP, Mobil-Grease 28, SHELL-Aero Shell Grease 22 or similar Locking device for the motor-drive (delivered with the unit).

22

3 Repairs and Adjustment

3.1.4 Procedure 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.

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

Tap-Changer from above Red point

Position indicator

Position indicator Exact position

TC_00257

Tolerances Bolts and tightening washers

Fig. 8b. Gear box, UCG, UCC, UCD

Fig. 8a. Gear box, UCL

Position indicator

TC_00156

Clamps, washers and screws

Locking device TC_00151

Fig. 8c. 23

3 Repairs and Adjustment

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

1. Lower the oil level of the transformer to just below the cover. For information about oil draining, refer to the transformer documentation. 2. Operate the on-load tap-changer electrically one step and let it stop in service position. Note the service position of the on-load tap-changer. 3. Operate the motor-drive by hand cranking the few degrees needed to position it in its exact position as given in section ”disc brake” in the appropriate maintenance guide. 4. Lock the motor-drive mechanism with the locking device delivered with the unit. 5. Remove the cover of the gear box to be replaced. If the on-load tap-changer consists of more than one unit driven by the same motor-drive, remove the covers of all the gear boxes. CAUTION The gear boxes, and the transformer when the gear box is removed, must be protected from water. If there is the slightest risk for rain or snow, some kind of protection must be arranged. 6. Check that all units are in their exact position acc. to Fig. 8. The opening in the brass toothed wheel should face the red point in the gear box housing exactly in all units. Max permitted deviation is shown in Fig. 8. Also check that all units are in the same service position as the motor-drive. If something is out of range, please consult ABB Components for advisory. CAUTION To take an on-load tap-changer that is not aligned and/or out of position into service means a great risk for damaging both the on-load tap-changer and the transformer.

CAUTION It is very important that the following instructions are followed in detail to make sure that the on-load tap-changer will be properly lined up after the repair. If gear boxes on more than one unit on an on-load tap-changer with two or three units driven by the same motor-drive are to be replaced, replace one at the time as described below. Start with the one closest to the motor-drive. 7. Loosen the hose clamps on the protection tubes on the shaft/shafts to be removed. Push the tubes together to get access to the couplings. CAUTION Note in which direction the gear box is mounted to ensure correct mounting of the new one.

24

3 Repairs and Adjustment

8.

For UCL: Unscrew the four screws (M10, cylindrical head with hexagon socket 8 mm) holding the gear box, see Fig. 8. These screws are locked with locking fluid and need considerably high loosing torque. For UCG, UCC, UCD: Unscrew the four screws M10 for the four clamps that hold the gear box.

9.

If there are two shafts, loosen the screws of one of the brass couplings on the shaft closest to the motor-drive. Lift out the gear box and take care of the shaft/ shafts when it/they comes/come loose from the gear box. If there are two shafts, note which sides they belong to.

CAUTION Make sure that no loose parts fall into the transformer through the hole for the gear box.

CAUTION No driving shaft of the on-load tap-changer is allowed to be rotated.

10. Remove the cover of the new gear box. 11. Adjust the new gear box to the same position as the motor-drive and to its exact position by rotating the shafts. 12. The shafts of the gear box have spherical couplings with driving pins that fit in the grooves of the couplings in the shaft ends. Turn the driving pin of the vertical coupling so its flat sides are vertical, parallel to the shaft in the transformer tank. 13. Mount a new O-ring in the flange for the gear box. 14. Check the position of the groove in the coupling of the shaft in the transformer tank, visible in the hole in the flange for the gear box. The driving pin of the spherical coupling should be positioned as the groove. 15. Lower the gear box on to the flange, directed as the old one. The driving pin should enter the groove in the insulating shaft. CAUTION The gear box must not be forced down! If the coupling does not engage, lift the gear box and adjust the setting of the driving pin. 16. For UCL: Mount the four screws (lock the screws with locking fluid) and the sealing washers. For UCG, UCC, UCD: Mount the four clamps with screws and washers. 17. If there are two horizontal shafts on the gear box, start with the one closest to the motor-drive. Connect the end of the shaft with the fixed brass coupling to the gear box closest to the motor-drive. Put on the protection tubes and hose clamps.

25

3 Repairs and Adjustment

18. Fit the loosened coupling to the replaced gear box. Tighten the two screws closest to the gear box first leaving an axial play of 2 mm. Tighten the remaining screws. Check that the position indicator in the gear box is in its exact position, see Fig. 8. If not, loosen the two screws in the multihole coupling on the gear box and find the position of the screws that positions the opening in the brass toothed wheel closest to the red point in the gear box housing. The deviation from exact alignment must not be more than shown in Fig. 8! Tighten the screws. 19. Apply grease on the couplings. Fit the protection tubes to the gear boxes, turning the slots downwards. Fit and tighten the hose clamps. For a single unit on-load tap-changer or when a gear box of the last unit is replaced, continue with point 23. If the on-load tap-changer consists of more than one unit and the gear box of the unit next to the one with replaced gear box also should be replaced, start doing that by restart from point 7. If not, proceed with point 20. 20. If the replaced gear box has two horizontal shafts, mount the second shaft as follows: Loosen the screws holding one of the brass couplings on the shaft. Connect the end of the shaft with the fixed brass coupling to the gear box it was connected to before disassembly. Put on the protection tubes and hose clamps. Fit the loosened coupling to the replaced gear box. Tighten the two screws closest to the gear box first leaving an axial play of 2 mm. Tighten the remaining screws. 21. Check that the position indicator in the second gear box is in its exact position, see Fig. 8. If not, loosen the two screws in the multihole coupling on the second gearbox and find the position of the screws that positions the opening in the brass toothed wheel closest to the red point in the gear box housing. The deviation from exact alignment must not be more than shown in Fig. 8! Also check and, if necessary, adjust the multihole coupling on the gear box of the third unit, if any. 22. Apply grease on the couplings. Fit the protection tubes to the gear boxes, turning the slots downwards. Fit and tighten the hose clamps. 23. Check that all gear boxes are lubricated with grease. If not, apply grease on the gears. 24. Make a final check that all gear boxes are in their exact positions within the tolerance given in Fig. 8 and that all on-load tap-changer units are in the same service position as the motor-drive. 25. Mount the gaskets and covers of the gear boxes. On UCL there is a slot in the cover for a gear. Make sure the cover is turned so the slot is above the gear. 26. Refill the transformer with oil according to the transformer documentation. 27. Remove the locking device of the motor-drive. Operate the on-load tap-changer a few number of operations in both directions to make sure that everything works properly. Put the on-load tap-changer back in the position noted in point 2. 28. If everything was working properly, the on-load tap-changer is now ready for energizing.

26

3 Repairs and Adjustment

3.2 Replacement of Diverter Switch Housing Cover Gasket 3.2.1 General This instruction guides you how to attend to an oil leakage. The instruction can be used for all UC-types of on-load tap-changers.

3.2.2 Tools Required Box wrench (19 mm).

3.2.3 Material and Spare Parts Required O-ring (8 mm), for UCG 428 x 8, and for UCL 540 x 8 O-ring, for UCD and UCC, 806 x 10 Grease (as for ball-bearings), (see 3.1.3).

3.2.4 Procedure 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.

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

CAUTION Protect the on-load tap-changer from water.

27

3 Repairs and Adjustment

1. Retighten the nuts that hold the cover. If the oil leakage still remains, the O-ring has to be replaced. WARNING The oil in the diverter switch housing may be hot. Be cautious!

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

2. Shut the valve to the oil conservator. 3. Remove the cover. If the oil level is less than 50 mm below the cover, point 6 should be carried out before energizing. 4. Replace the O-ring with a new one. Clean the slot and the corresponding part of the cover. The O-ring is not to be glued. 5. Mount the cover. Turn the cover so the guiding pin in the housing is facing the guiding hole in the cover. (The cover has to be pressed down in order to overcome the spring force of the springs that hold the diverter switch in place). Tighten the nuts alternately. Tightening torque 42 Nm. 6. Restore the gas cushion, if necessary, according to section 3.3 in this guide. 7. Open the valve to the oil conservator.

3.3 Restoring the Gas Cushion 3.3.1 General Check the oil level in the oil conservator one month after oil filling. If the oil level is lower now than when the oil filling was finished (correct for temperature differencies!) and no leakages are observed, the gas cushion has been solved in the oil and has to be restored. The procedure below 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 Components, and it is installed according to our recommendations, follow the instructions in ”Oil filter unit for on-load tapchangers, manual” for restoring the gas cushion. 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.

28

3 Repairs and Adjustment

3.3.2 Equipment Required Normal set of handtools Pump with connection to the oil valve Dimension drawing of the on-load tap-changer for connection dimensions of the oil valve.

3.3.3 Procedure WARNING The oil in the diverter switch housing may be hot. Be cautious!

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

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.

1.

Close the valve in the tube to the conservator.

2.

Connect the oil pump to the oil valve. (For connection dimensions, see the dimension drawing for the on-load tap-changer). Open

TC_00171

Air release valve

Fig. 9. 3.

Open the oil valve and the air release valve, see Fig. 9.

4.

Start the oil pump and drain oil according to below, into a clean and dry container. UCC/UCD: 45 l UCL: 25 l UCG: 15 l

29

3 Repairs and Adjustment

5.

Close the air release valve.

6.

Close the oil valve and disconnect the pump.

7.

Connect the output side of the pump to the oil valve.

8.

Open the oil valve.

9.

Open the valve in the tube to the conservator!

10. Pump the earlier drained oil back into the diverter switch housing. 11. Close the oil valve and disconnect the pump. 12. The level in the oil conservator and the gas cushion are now restored.

CAUTION Avoid to do the restoring in damp weather since moisture will get into the diverter switch housing. If the restoring has to be done in such weather, the incoming air has to be dehydrated and the drained oil protected from water.

3.4 Replacement or addition of a Multiposition Switch (BUL only) 3.4.1 General Addition of a multi-position switch as described below is possible when you have 1, 2, or 4 multi-position switches. In other cases the shaft must also be exchanged and ABB Components should be contacted for further instructions.

3.4.2 Tools Required Small wrench (10 mm).

30

3 Repairs and Adjustments

3.4.3 Procedure WARNING Before starting any work inside the motor-drive mechanism, the auxiliary power must be switched off. N.B. The motor, contactors and heating element may be energized from separate sources.

1. Dismantle the bottom plate, see Fig. 10 on next page. For replacement also remove necessary distance screws and multi-position switches, and their conductors. 2. For addition exchange the lower distance screws to new ones, length 20 and 10 or 35 mm. 3. Turn the contact arm on the new multi-position switch to the same position as the existing multi-position switches. Place the transparent cover on the multi-position switch and push it all on the shaft. The nob in the hub of the multi-position switch must enter the groove in the shaft. 4. Reassemble washers and distance screws. Press up the shaft and make sure the notch on the couplings have entered the grooves in the torque disc. Press down the sliding bearing in the bottom plate and assemble the bottom plate. Check that there is no axial play in the shaft. If necessary washers may be removed or added. 5. Note the position of the on-load tap-changer. Operate the the motor-drive mechanism in all positions both in raise and lower directions and check with a buzzer that all multi-position switches function properly. 6. Connect the terminals. 7. Reconnect all power supplies to the motor-drive. 8. Operate it back to the position noted in point 5.

31

3 Repairs and Adjustments

Upper coupling half

Torque disc

Lower coupling half

Shaft

Transparent cover

Multi-position switch

Contact arm

Distance screw L = 20 mm

Distance screw L = 10 mm or 35 mm

Bottom place Sliding bearing

Fig. 10. Multi-position switch for BUL

32

3 Repairs and Adjustments

3.5 Examination of the Diverter Switch after a Pressure Relay Trip The pressure relay has tripped during normal operation.

3.5.1 Tools and Material Required Maintenance Guide for the on-load tap-changer in question Lifting device as proposed in Maintenance Guide Sliding caliper Rags (non-fuzzying).

3.5.2 Procedure 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.

Close the valve to the oil conservator. Take off the cover of the diverter switch housing. The oil level should be at least 50 mm below the upper edge of the housing. If the housing is completely filled with oil or close to, the reason for the pressure relay trip is likely to be due to this small or absent gas cushion. Even if the gas cushion is small or absent, the diverter switch should be lifted out of the housing and be carefully investigated in order to exclude other reasons for the pressure relay trip. Follow the procedure in section ”Lifting and Cleaning the Diverter Switch” in Maintenance Guide, when lifting the diverter switch. Look for flash marks, loose parts etc. Measure the transition resistors according to section ”Checking the Transition Resistors” in Maintenance guide. Finish with an even number of operations of the diverter switch according to section ”Checking the Contact Positions” in Maintenance Guide. Make sure the diverter switch operates fast and distinct and stops in the end positions. If no faults are found, install the diverter switch according to section ”Installation of the Diverter Switch” in Maintenance Guide.

CAUTION It is very important that the diverter switch is correctly installed. An incorrect installation will jeopardize both the on-load tap-changer and the transformer! If necessary according to above, restore the gas cushion according to section 3.3 ”Restoring the Gas Cushion” in this guide. Make sure the valve to the oil conservator is open! After a pressure relay trip, we also recommend to carry out an insulation test and a ratio test of the transformer. If both the on-load tap-changer and the transformer are functioning properly, continue with the next step. 33

3 Repairs and Adjustment

3.6 Tests of the Pressure Relay Tools required: Air pump with pressure gauge (0-250 kPa) and connection to R 1/8” male thread. Screwdriver Megger (500-2 000 V)

1. Insulation Test Remove the cover of the relay housing. Disconnect all incoming wires from the terminals. Connect terminal NO (identified 61) on the pressure relay block to earth. Terminal C (identified 62) should be electrified with the megger (500-2000 V for one minute). Connect the pressure relay housing to earth. Short-circuit the four terminals and apply test voltage 500-2000 V on them for one minute. Remove the short-circuit from the terminals and reconnect the incoming wires. If the pressure relay does not withstand the electrical stress, the pressure relay should be replaced, see section 3.9 ”Replacement of Pressure Relay”.

2. Function Test Set the valve handle to the test position as shown on the information plate. Connect the air pump and the pressure gauge to the test tap on the pressure relay. (Thread R 1/8”). Raise the pressure until the pressure relay trips the circuit breakers of the transformer. Read the pressure on the manometer and check against the pressure stated on the information plate. Max. permitted deviation is ±10 %. If the deviation is greater, the pressure relay should be replaced, see section 3.9 ”Replacement of Pressure Relay”. Check that the signal disappears when the pressure is released. After finishing the check, turn back the valve handle to service position. Return to section 2.2.

34

3 Repairs and Adjustments

3.7 Replacement of Pressure Relay 3.7.1 General If the pressure relay fails to pass the insulation test and/or the function test, the pressure relay has to be replaced. CAUTION It is not permissible to replace only the microswitch inside the pressure relay.

3.7.2 Tools Required Screwdriver Open-end wrench (30 mm)

3.7.3 Spare Parts Required Pressure relay O-ring (17.1 x 1.6 mm).

3.7.4 Procedure 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.

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

Replacement of pressure relay: 1. Set the three-way valve handle to the test position (see Fig. 11 and the information plate on the pressure relay).

WARNING Disconnect all power sources before any work is carried out. Check that the power is disconnected by using a Voltmeter. 2. Disconnect the cable.

35

3 Repairs and Adjustment

3. Loosen the quick coupling and remove the pressure relay. 4. Install a new O-ring (17.1x1.6 mm). 5. Lubricate the threads of the connection nut with grease. 6. Mount the new pressure relay. Tightening torque approximately 25 Nm. 7. Carry out the testing procedure according to section 3.6. ”Tests of the Pressure Relay”. 8. Connect the cable. The seal between the cable gland and the pressure relay housing includes an O-ring. If the cable gland has to be changed to another type, the seal against the housing must be secured by a gasket or by gluing. Tighten with care, max 5 Nm torque. 9. Set the three-way valve handle back to the service position.

Information plate Pressure relay

Valve handle Connection nut Quick coupling

Test tap (R 1/8’’)

TC_00264

Three way valve handle

Fig. 11. Pressure relay

36

1ZSE 5492-129 en, Rev. 6, 1999-11-30

ABB Power Technology Products AB Components Visiting address: Lyviksvägen 10 Postal address: SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00 Fax +46 240 121 57 E-mail: [email protected] www.abb.com

1ZSE 5492-133 en, Rev. 3, 2004-04-15

On-load tap-changers, types UCG, UCL, UCC and UCD with motor-drive mechanisms, types BUE and BUL Spare Parts List

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.

Before You Order Check the identification of the on-load tap-changer. The type and serial number are always required for identification. Check this data on the rating plate on the tapchanger if you are not sure. Do not try to order spares without this information. It is very important that you give a complete identification for each and every part you order to have trouble-free delivery. The lists in this documentation together with the identification as described above give you all information required for correct ordering.

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 equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work described.

Safety Precautions WARNING This documentation is intended for procurement of spare parts only. Only personnel familiar with repairs of transformers and accessories should carry out replacement of parts. Electrical and other safety regulations at the repair site must be strictly adhered to.

iii

Contents 1 1.1 1.2 1.3 1.4 1.5

Introduction ____________________________________________ Type Designation and Serial Number ________________________ Item Number ___________________________________________ Name of Item ___________________________________________ Quantity _______________________________________________ Remarks _______________________________________________

7 7 7 7 7 7

2 2.1 2.2

General Arrangement ____________________________________ Standard Spare Parts _____________________________________ Special Spare Parts ______________________________________

8 8 8

3 3.1 3.2 3.3

Spare Parts for On-Load Tap-Changer _______________________ Type UCG _____________________________________________ Type UCL _____________________________________________ Types UCC and UCD ____________________________________

10 10 12 14

4

Accessories for On-Load Tap-Changer _______________________

16

5 5.1 5.2

Spare Parts for Motor-Drive Mechanism type BUE _____________ Electrical Details ________________________________________ Mechanical Details ______________________________________

18 18 20

6 6.1 6.2 6.3

Spare Parts for Motor-Drive Mechanism type BUL _____________ Electrical Details ________________________________________ Multi Position Switches___________________________________ Mechanical Details ______________________________________

24 24 26 28

7

Recommended Set of Spare Parts for Motor-Drive Mechanisms ___

30

1 Introduction

1 Introduction This spare parts list has been compiled to help you with procurement of spares. To obtain trouble-free deliveries you should note a few things which are explained in the following text. The breakdown level and general contents of this list have been worked out to cover normal customer requests. Our spares sales people will be happy to assist if you require any specific item that is not included in the list.

1.1 Type Designation and Serial Number The rating plate on the on-load tap-changer (OLTC) shows the type and serial number of the device you are ordering spares for. It is important to have this information, because the manufacture of parts gradually changes as materials and manufacturing technology improves. ABB makes every effort to supply spares that should fit your requirements. Some parts of later manufacture than those you are replacing may need some adaptation to fit into your device. Our spare parts sales people need to know the type designation and serial number to supply exactly what you require.

1.2 Item Number Item numbers are shown on the drawings and lists. As you will observe, one item number is used for several items of the same general type. These items have a specific specification for each and every variant of OLTC, hence you need to specify type and serial number in addition to the item number to obtain the appropriate spare.

1.3 Name of item The name should be specified when ordering to make sure the right type of item is ordered.

1.4 Quantity The figures given represent the number of items that are fitted to one OLTC.

1.5 Remarks Information pertinent to different variants of the OLTC is given in this column. Your model should be one of those shown.

7

2 General Arrangement

2 General Arrangement The general arrangement of an UC type on-load tap-changer is shown in fig. 1.

2.1 Standard Spare Parts The rugged design of ABB OLTCs means that only the fixed and moving contacts of the diverter switch might require replacement during lifetime of the transformer. This spare parts list tells you the part number of the contacts when ordering for your replacement requirements.

2.2 Special Spare Parts If you need parts other than the contacts in the lists, our staff will be happy to assist you. Please use fig. 1 as a reference when discussing your requirements. As usual, the type designation and serial number are essential for ordering.

8

2 General Arrangement

Diverter switch housing

Cover Oil valve

Pressure relay

Bevel gear Position indicator

Top-section Serial No. Shielding-ring

1)

Earthing terminal Draining tube

Connection flange for gas operated relay

Insulating cylinder

Insulating shaft Shielding-ring

1)

Shielding-ring

2)

Diverter switch

Plug-in contacts

Transition resistors Fixed and moving contacts

Bottom section

Serial No. Guide-pins

Current terminal

Driving disc for the diverter switch

Tap selector

Bottom valve for drying process Intermediate gear Geneva gear

1)

Only at impulse withstand voltage to earth of 650 kV and 1050 kV

2)

Not on UCG of the short type

Change-over selector

Moving fineselector contacts

Current collector

Fixed fine-selector contacts

Fig. 1. General arrangement of on-load tap-changer, type UC.

9

3 Spare Parts for On-Load Tap-Changer

3 Spare Parts for On-Load Tap-Changer 3.1 Type UCG

10

Item No.

Name of item

Quantity

Remarks

1

Contact set

1 set

UCG.E .../300 UCG.E .../500

1

Contact set

3 sets

UCG.T .../300 UCG.T .../500

1

Contact set

3 sets

UCGYD .../300 UCGYD .../500

1

Contact set

1 set

UCG.E .../600

1

Contact set

3 sets

UCG.T .../600

1

Contact set

3 sets

UCGYD .../600

1

Contact set

1 set

UCG.N .../300

1

Contact set

1 set

UCG.N .../500

1

Contact set

1 set

UCG.E .../1200

1

Contact set

3 sets

UCG.T .../1200

1

Contact set

3 sets

UCGYD .../1200

1

Contact set

1 set

UCG.N .../600

1

Contact set

1 set

UCG.E .../1500

1

Contact set

3 sets

UCG.T .../1500

1

Contact set

3 sets

UCGYD .../1500

Complete diverter switch

1

Complete tap selector

1

3 Spare Parts for On-Load Tap-Changer

Fig. 2. Diverter switch for UCG with replacement contacts. NOTE: This picture shows a neutral point type. Single phase types have not always contacts in all the three poles of the diverter switch.

11

3 Spare Parts for On-Load Tap-Changer

3.2 Type UCL

12

Item No.

Name of item

Quantity

Remarks

1

Contact set

1 set 3 sets

UCL.E .../600, UCL.E .../900 When the step voltage is outside the envelope for the 900 A type

1

Contact set

3 sets

UCL.E .../1800, UCL.E .../2400

1

Contact set

3 sets

UCL.N .../600, UCL.N .../900

1

Contact set

3 sets 9 sets

UCL.T .../600, UCL.T .../900 When the step voltage is outside the envelope for the 900 A type

1

Contact set

9 sets

UCL.T .../1800, UCL.T .../2400

1

Contact set

3 sets

UCL.B .../600, UCL.B .../900

Complete diverter switch

1

Complete tap selector

1

3 Spare Parts for On-Load Tap-Changer

Fig. 3. Diverter switch for UCL with replacement contacts.

13

3 Spare Parts for On-Load Tap-Changer

3.3 Types UCC and UCD Item No.

Name of item

Quantity

Remarks

1

Contact set

1 set

UCC.N .../800 UCC.N .../1200 UCC.N .../1600 UCC.E .../3600 UCC.E .../4500 UCD.N .../1000 UCD.E .../2400

14

Complete diverter switch

1

Complete tap selector

1

3 Spare Parts for On-Load Tap-Changer

Fig. 4. Diverter switch for UCC and UCD with replacement contacts.

15

4 Accessories for On-Load Tap-Changer

4 Accessories for On-Load Tap-Changer

16

Item No.

Name of item

Quantity

1

Pressure relay

1

2

Pressure relay with test valve

1

3

Pressure relief valve

1

4

Oil valve

1

5

Vent

1

6

Cover for connection to oil conservator

1

7

Bottom valve key

1

Remarks

4 Accessories for On-Load Tap-Changer

3

fm_00283

Fig. 5. Accessories (The figure shows type UCG).

17

5 Spare Parts for Motor-Drive Mechanism type BUE

5 Spare Parts for Motor-Drive Mechanism type BUE Item No.

Name of item

Quantity

Complete motor-drive mechanism with cabinet

1

Remarks

5.1 Electrical Details

18

Item No.

Name of item

Quantity

1

Control selector switch

1

2

Control switch raise/lower

1

3

Motor contactor

1

Raise

4

Motor contactor

1

Lower

5

Starting contact

1

6

Maintaining contact

1

7

Motor

1

8

Limit switch

1

11

Interlocking switch

1

12

Heater 50 W

1

14

Position transmitter

1

15

Continuation contact

1

19

Motor-protective switch

1

21

Step-by-step contactor

1

26

Terminal blocks

1

27

Heater 100 W

28

Thermostat

1

29

Switch for heater

1

31

Tap-changer for current transformer

1

33

Tap-changer for voltage transformer

1

36

Lamp for cabinet light

1

37

Door-operated switch

1

83

Master switch

1

84

Follower switch

1

86

Odd-even switch

1

Remarks

5 Spare Parts for Motor-Drive Mechanism type BUE

fm_00136

Fig. 6. Electrical details.

19

5 Spare Parts for Motor-Drive Mechanism type BUE

5.2 Mechanical Details

20

Item No.

Name of item

Quantity

Remarks

101

Toothed belt

1

102

Conical toothed wheel

1

103

Outgoing shaft

1

104

Hand crank

1

105

Operating shaft

1

106

Gear

1

107

One turn shaft

1

108

Geneva drive with shaft

1

109

Conical toothed wheel

1

110

Hand for position indication

1

111

Coupling

1

+1 for each cont. plate

112

Geneva drive with shaft

1

For pot. transmitter

112

Geneva drive with shaft

1

For other cont. device

113

End stop, cam disc

1

114

Shear pin

1

115

Cam disc

1

116

Arm

1

117

Brake

1

118

Brake disc

1

119

Front plate

1

120

Operation counter

1

121

Pulley

1

122

Pulley

1

123

Conical toothed wheel

1

124

Cylindrical toothed wheel

1

125

Geneva wheel

1

126

Geneva wheel with arm

1

127

Contact guide device

1

128

Cam bar

1

129

Brake for maintaining contact (item No. 6)

1

130

Cam disc for starting contact (item No. 5)

1

131

Driving disc for item No. 130

1

136

Screw for end stop

1

For double contact

5 Spare Parts for Motor-Drive Mechanism type BUE

fm_00137

Fig. 7. Mechanical details.

21

5 Spare Parts for Motor-Drive Mechanism type BUE

22

Item No.

Name of item

Quantity

Remarks

132

Cabinet

1

For BUE 1

132

Cabinet

1

For BUE 2

133

Gasket for door

1

For BUE 1

133

Gasket for door

1

For BUE 2

134

Hand knob

1

135

Air vent

1

140

Cover

1

141

Gasket

1

142

Vibration damper

4

143

Coupling

1

145

Shaft for maintaining contact (item No. 6)

1

146

Shaft for starting contact (item No. 5)

1

147b

Lever

1

148

Drive

1

149

Shaft

1

150b

Toothed wheel

1

151

Drive

1

152

Shaft

1

153

Shaft

1

154

Panel

1

155

Brake disc

2

156

Spring

2

157

Brake disc

1

158

Spring

1

159b

Sleeve

1

160

Nave

1

161

Operating wire for operation counter (item No. 120)

1

180

Door with window

1

For BUE 1

180

Door with window

1

For BUE 2

For DAG motor-switch

5 Spare Parts for Motor-Drive Mechanism type BUE

135

143

132

134

133

180 142

146 151

161

141

154

156

140

155 159b 157 150b 158 160 148 149 147b

152

fm_00274

153

Fig. 8. Mechanical details (cont.).

23

6 Spare Parts for Motor-Drive Mechanism type BUL

6 Spare Parts for Motor-Drive Mechanism type BUL Item No.

Name of item

Quantity

Complete motor-drive mechanism with cabinet

1

Remarks

6.1 Electrical Details

1)

24

Item No.

Name of item

Quantity

Remarks

B1

Thermostat

1

1)

B2

Hygrostat

1

1)

E1

Anti-condensation heater

1

50 W

E2

Extra heater

1

100 W 1)

E3

Cabinet light, Hand lamp

1

1)

K1

Step-by-step relay

1

M1

Motor 1

1

Q1

Motor protective switch

1

Q2

Contactor, Raise

1

Q3

Contactor, Lower

1

S1

Control selector switch

1

Local-0-Remote

S2

Control switch

1

Lower-0-Raise

S3+S4

Maintaining, interlocking and auxiliary contacts

1

Raise and lower, assembled on a mounting plate

S5

Interlocking switch

1

For handcrank

S6

Limit switch, Upper tap position

1

Including mounting plate with arm and roller

S7

Limit switch, Lower tap position

1

Including mounting plate with arm and roller

S9

Door operated switch

1

1)

S10

Switch for extra heater

1

U1

Measuring amplifier

1

X1-17

Terminal blocks

X38

Outlet

1

When ordering, it must be stated for this optional item, if it was already installed in the motordrive mechanism. If it is not the case, other assembly details will be included in the order.

6 Spare Parts for Motor-Drive Mechanism type BUL

S6

S3 + S4 S7 B2 B1

S10

M1

X38

S5

K1

X1-17

U1

S2

Q3

S1

Q2 Q1

E2 E1

E3 S9 fm_00246

Fig. 9. Electrical details, type BUL.

25

6 Spare Parts for Motor-Drive Mechanism type BUL

6.2 Multi Position Switches

26

Item No.

Name of item

S14, S24

Position transmitter, potentiometer

S15

Continuation contact

S20-S23

Auxiliary contacts, break before make

S25-S28

Auxiliary contacts, make before break

S86, S87

Step switch for parallel control

111.1

Coupling half

111.2

Torque disc

112

Shaft

164

Transparent cover

165

Distance screw

L=10, L=20, L=35 or L=60

166

Terminal, plug part

4-pole, 8-pole

Quantity

Remarks

<3 circuit cards 4–5 circuit cards

6 Spare Parts for Motor-Drive Mechanism type BUL

111.1 111.2 111.1

112

164

165

S14 (S24) S15 S20 (S21, S22, S23) S25 (S26, S27, S28) S86 (S87)

166 fm_00247

Fig. 10. Multi Position Switches, type BUL.

27

6 Spare Parts for Motor-Drive Mechanism type BUL

6.3 Mechanical Details

28

Item No.

Name of item

Quantity

101

Toothed belt

1

104

Hand crank

1

110

Pointer with drag hands for position indicator

1

120

Operation counter

1

Arm included

121

Pulley for toothed belt

1

Key, screw, washer included

131

Hinges

2

Screws, washers, shims included

132

Cabinet

1

134

Handknob with fasteners

2

135

Air vent

2

167

Gasket for cabinet

1

168

Thread bushing with nuts

4+8

170

Blank, FL 21

1

171

Gasket, FL 21

1

180

Door with window

1

Remarks

Screws, washers, shims included

6 Spare Parts for Motor-Drive Mechanism type BUL

168

131

180

132

134 167

104

135 171 101 170

120

121

110 fm_00248

Fig. 11. Mechanical details, type BUL.

29

7 Recommended Set of Spare Parts

7 Recommended Set of Spare Parts for Motor-Drive Mechanisms One set consists of the following parts: For type BUE:

„ Item 3, pages 14 and 15 Item 4, pages 14 and 15

Motor contactor, raise Motor contactor, lower

„ Item 7, pages 14 and 15

Motor

„ Item 19, pages 14 and 15

Motor-protective switch

„ Item 101, pages 16 and 17

Toothed belt

For type BUL:

„ Item Q2, pages 19 and 20 Item Q3, pages 19 and 20

30

Motor contactor, raise Motor contactor, lower

„ Item M1, pages 19 and 20

Motor

„ Item Q1, pages 19 and 20

Motor-protective switch

„ Item 101, pages 25 and 26

Toothed belt

1ZSE 5492-133 en, Rev. 3, 2004-04-15

ABB Power Technologies AB Components Visiting address: Lyviksvägen 10 Postal address: SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00 Fax +46 240 121 57 E-mail: [email protected] www.abb.com/electricalcomponents

Serial no. 1133751

6

Bushings

6.1 HV bushing type GOB 550-800

LF 123 191 K, L6=500

6.2 HV neutral bushing type GOB 550-800

LF 123 189 K, L6=100

6.3 Transformer bushings, type GOB. Installation and maintenance guide

2750 515-12 en, Rev. 9

6.4 MV bushing type 20f/3150 FIG B1, C1=440 6.5 MV bushing type 10f/4500 FIG C1, b1=380 6.6 SOLID BUSHING TYPE DIN 42533 – 42534 & EN 50180.PRODUCT INFORMATION & OPERATING INSTRUCTIONS

1/1

2750 515-12 en, Rev. 9, 2006-10-15

Transformer bushings, type GOB Installation and maintenance guide

This document must not be copied without our written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Safety information Keep this instruction available to those responsible for the installation, maintenance, and operation of the bushing. The installation, operation, and maintenance of a bushing present numerous potential unsafe conditions, including, but not limited to, the following:

 High pressures  Lethal voltages  Moving machinery  Heavy components  Slip, stumble or fall Specialized procedures and instructions are required and must be adhered to when working on such apparatus. Failure to follow the instructions could result in severe personal injury, death, and/or product or property damage. Additionally, all applicable safety procedures such as regional or local safety rules and regulations, safe working practices, and good judgement must be used by the personnel when installing, operating, maintaining and/or disposing such equipment. Safety, as defined in this instruction, involves two conditions: 1.

Personal injury or death.

2.

Product or property damage (includes damage to the bushing or other property, and reduced bushing life).

Safety notations are intended to alert personnel of possible personal injury, death or property damage. They have been inserted in the instructional text prior to the step in which the condition is cited. The safety conditions are headed by one of the three hazard intensity levels which are defined as follows: DANGER Immediate hazard which will result in severe personal injury, death, or property damage. WARNING Hazard or unsafe practice which could result in severe personal injury, death, or property damage.

CAUTION: Hazard or unsafe practice which could result in minor personal injury, or property damage.

4

2750 515-12 en, Rev. 8

Contents 1 1.1.1 1.1.2 1.2 1.3 1.4

Description _____________________________________________ Design ________________________________________________ Design of horizontally mounted bushings ______________________ Operating conditions _____________________________________ Mechanical loading ______________________________________ Spare parts _____________________________________________

6 6 8 9 9 10

2 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.6 2.7 2.8 2.9 2.9.1 2.9.2 2.9.3 2.9.4

Installation _____________________________________________ Tools _________________________________________________ Consumables ___________________________________________ Transport and handling ____________________________________ Lifting from the box ______________________________________ Mounting ______________________________________________ Mounting of oil-end shield _________________________________ Inner terminal / Stranded cable _____________________________ Solid rod conductor ______________________________________ Horizontal mounting of bushing _____________________________ Mounting of outer terminal _________________________________ Flange earthing __________________________________________ Waiting time before energizing _____________________________ Recommended tests before energizing _______________________ Tightness test between transformer and bushing________________ Tightness test of bushing outer terminal ______________________ Measurement of capacitance and tan δ ______________________ Check of through resistance _______________________________

10 10 10 11 11 12 12 13 14 15 15 16 16 17 17 17 18 20

3 3.1 3.1.1 3.1.2 3.1.3

Maintenance ___________________________________________ Recommended maintenance and supervision __________________ Cleaning of insulator surface _______________________________ Measurment of capacitance and tan δ _______________________ Thermovision (infrared camera) check for local overheating on connectors ___________________________________________ Check for leakage _______________________________________ Checking and adjustment of the oil level ______________________ De-mounting of horizontally mounted bushing __________________ Disposal after end of service life ____________________________

21 21 21 21

3.1.4 3.1.5 3.1.6 3.2

2750 515-12 en, Rev. 8

21 21 22 23 23

5

1 Description

1 Description 1.1.1

Design The design and dimensions of bushings type GOB are given in the Technical Guide, 1ZSE 2750-102. The design principle is also shown in Figs. 1a–d. For bushings with a relatively small oil quantity the expansion space at the top of the insulator is sufficient. For bushings with larger oil quantity the expansion space has been increased with at top housing according to Fig. 1b. An alternative design, with an oil level glass of prisma type according to Fig. 1c is also available. All GOB bushings are equipped with a test tap, see Fig. 2, connected to the outer layer of the condenser body. The test tap can be used for checking of the bushing insulation by capacitance and dissipation factor measurements. The maximum test voltage for the test tap is 2 kV, one minute at 50 to 60 Hz. It serves as a test tap, and in connection with an external capacitance it can be used as a voltage tap. The operation voltage is limited to 600 V. An adapter is available for permanent connection to measuring circuits, see Fig. 3.

Fig. 1. Design principle 1) Outer terminal stud 2) Oil filling holes with sealing plug M8, 2522 731-A 3) Oil 4) Expansion space 5) Prism type glass a) GOB 250 - 650 2911 720-2 b) GOB 750 - 1050 2911 730-1 6) Gasket a) GOB 250 - 650 O-ring 49.5 x 3 2152 2012-416 b) GOB 750 - 1050 O-ring 34.2 x 3 2152 2011-410 7) Porcelain insulator, air side 8) Test tap 9) Mounting flange 10) Condenser body 11) Insulated shield (integrated or separate) 12) Flange extension 13) Porcelain insulator, oil side

Fig. 1b

gob_0001

Fig. 1a Fig. 1c 6

2750 515-12 en, Rev. 8

1 Description

gob_0018

Fig. 1d. Sealing plug, 2522 731-A 1) Bolt with flange DIN 6921, 2121 738-18 2) Gasket, 2152 899-132

Fig. 2. Test tap 2769 531-B (not self-earthing) 1) Bushing for test tap 2) Disc spring 3) Press nut 4) Cover 2749 528-B with O-ring 2152 484-2 5) Contact pin, 4 mm 6) O-ring 7) O-ring 8) Cable

Fig. 3. Adapter for permanent connection to measuring circuits 2769 531-D 1) Cover 2) Box 3) Cable gland Pr (screwed steel conduit) 22.5 (Pg 16 acc. to DIN 40430) 4) Protecting resistor, 10 kW, 5 W 5) Earthing connection (to be removed before connection of outer cable) 6) Nut 7) Belleville spring washer 8) Connector to test tap 9) O-ring

2750 515-12 en, Rev. 8

gob_0015

goh_0008

7

1 Description

1.1.2

Design of horizontally mounted bushings If a bushing shall be mounted in horizontal position this must be clearly stated in the order. The bushing flange is then supplied with an oil hole at the oil side of the flange for connection of the bushing oil system to the transformer oil. As horizontally mounted bushings must be completely oil filled this hole will provide the necessary oil expansion for the bushing. At delivery the hole is covered by a flat rubber gasket and a steel plate as shown in the figure below. This arrangement makes sure that the hole is opened before mounting of the bushing. It is important to check that the gasket on the transformer flange does not cover this hole in service. The hole is located between two mounting holes and at a distance B from the flange edge. Table 1. Type GOB

Dimension B

250/800

54

250/1250

78

325/800

54

380/800

54

380/1250

78

450/800

54

550/800

60

550/1250

65

650/1250

65

750/1250

60 gob_0013

Fig. 1g.

gob_0012

Fig. 1f. Design principle - horizontally mounted bushing.

8

2750 515-12 en, Rev. 8

1 Description

1.2 Operating conditions The table below show the standard technical specifications for the GOB Oil - Air bushings. For conditions exceeding the below values, please contact ABB. Common specifications: Application:

Transformers

Classification:

Oil impregnated paper, capacitance graded, outdoor-immersed bushing

Ambient temperature:

+40 to -40 °C, minimum value as per temperature class 2 of IEC 60137

Altitude of site:

< 1 000 m

Level of rain and humidity:

1-2 mm rain/min horizontally and vertically, as per IEC 60060-1

Pollution level:

According to specified creepage distance and IEC 60815 1

Type of immersion medium:

Transformer oil. Maximum daily mean oil temp. 90 °C. Maximum temporary oil temperature 115 °C

Oil level below bushing flange: Maximum 30 mm Max. pressure of medium:

100 kPa overpressure

Markings:

Conforming to IEC/ IEEE

1

IEC 60815 "Guide for the selection of insulators in respect of polluted conditions".

1.3 Mechanical loading The bushings are designed for the following cantilever loads applied to the midpoint of the top end terminal, perpendicularly to the bushing axis. The bushing mounting angle can be 0 – 45° from vertical or horizontal (if the bushing is ordered for horizontal mounting). In axial direction, the GOB bushings can be loaded with 10 kN continuously. The bushing can withstand 30 Nm torque on the outer terminals. Table 2. Mechanical loading

2750 515-12 en, Rev. 8

Bushing

Type test load 1 minute (N)

Max. service load (N)

GOB 250/800 GOB 250/1250 GOB 325/800 GOB 380/800 GOB 380/1250 GOB 450/800 GOB 550/800 GOB 550/1250 GOB 650/1250 GOB 750/1250 GOB 1050/1100

2340 4000 1950 1800 3750 1500 1700 3100 3380 3350 3200

1800 3000 1500 1400 2900 1150 1300 2400 2600 2600 1250 9

2 Installation

1.4 Spare parts In case of major damage to the bushing we recommend that it is sent back to ABB for possible repair and re-testing. Certain parts (Figs. 1, 2, 7, 8 and 9), which may be damaged or lost during transport or installation, can be ordered from ABB.

2 Installation 2.1 Tools  Soft slings  Lifting eye screw M12 (DIN 580) for mounting at an angle, 2183 2001-3  Pull-through cord with M8 swivel, 9760 669-A  Torque wrench key for hexagon head screws, head width 16 mm (M10) and adjustable up to 66 mm

 Key for hexagon socket head cap screw 6 mm (Only for previous design of test tap cover)

2.2 Consumables  Water free vaseline, Mobilgrease 28 or other lubricant not harmful to the transformer oil, to lubricate screws that come into contact with the transformer oil.

 Mobilgrease 28 or other suitable grease to lubricate and protect the earthing screw and the outer terminal o-ring gasket.

10

2750 515-12 en, Rev. 8

2 Installation

2.3 Transport and handling CAUTION: The bushing may be transported and stored horizontally up to 6 months. For storing over 6 months it is recommended to raise the bushing to vertical position with the top end upwards or inclined position with the top end upwards and at an angle of at least 7°. Keep the bushings dry and clean and protected against mechanical damage. Keep the bushings protected from penetrating water when stored outdoors. This means that the case must not be stored in areas where it can be foreseen that the ground will be wet and muddy during heavy rains. Shelter the case from rain and snow with a tarpaulin or roofing. Carefully inspect the bushing on receiving with regard to shipping damage. Please note that the bushing has been routine tested in oil and some oil may be left, especially in the narrow openings between porcelain and metal. Vaseline is used for lubrications of threads, and at some temperatures the vaseline may appear as oil The bushings are normally delivered from ABB in boxes with the bushing supported by blocks and fibre boards. The boxes are marked with "Top End". "Top End"

Min. 7°

Fig. 4. Long-term storage.

2.4 Lifting from the box WARNING For lifting the bushing from the box, apply two clean lifting slings as shown in the figure below. Support the bushing at the same points as in the box if placed on the ground or block it under the flange and the metal top piece. Light bushings may be handled manually. F

123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 Fig. 5. 123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 Lifting from the box.123456789012345678901234567890121234567890123456789012 123456789012345678901234567890121234567890123456789012 123 12 123 12 123 12 gob_0011

2750 515-12 en, Rev. 8

11

2 Installation

2.5 Mounting CAUTION: Bushings mounted horizontally must be specially ordered for that, and mounted according to section 2.5.4. If additional requirements are not fulfilled, the bushing can be damaged. WARNING Light bushings may be handled manually. Lift heavier bushings with the aid of a lifting tool, see section 2.1 Tools. Lift the bushing to vertical position and to an angle according to the figures below. Use a soft bedding under the bottom end of the bushing, e.g. a rubber mat. The mass of the bushing is stated on the marking plate. Carefully clean and inspect the oil end of the bushing and the inside of the centre hole before mounting on the transformer. F Lifting sling arrangement

Soft sling F gob_0010

Soft sling Lifting eye 2183 2001-3

Soft bedding

Soft bedding

gob_0011

gob_0011

Fig. 6. Mounting.

2.5.1

Mounting of oil end-shield CAUTION: If the bushing is lowered in transformer oil, the air cushion in the end-shield must be vented by a hose. The shield is packed in a plywood box with the fastening screws and the washers included. The end-shield is mounted on the bottom end of the bushing according to Fig. 7.

Fig. 7. Mounting of end-shield. 1) End-shield 2) Washer 6.4 x 12 x 1.5 3) Socket screw M6 x 16 gom_0006

12

2750 515-12 en, Rev. 8

2 Installation

2.5.2

Inner terminal / Stranded cable CAUTION: Mounting of the conductor must be performed according to the procedure below. The contact surfaces must be clean. The oxide on brazed terminals is to be removed by brushing. 1.

Stretch the stranded cable with the brazed or crimped inner terminal, normally fastened to the cover plate. Avoid making any loops.

2.

Drop the pull-through cord through the bushing centre hole.

3.

Lift the bushing above the opening.

4.

Fasten the M8 swivel to the inner terminal at the end of the stranded cable. Lower the bushing into the transformer while directing the stranded cable by keeping the pull-through cord taut.

5.

Fix the bushing to the cover. Torque M12 to 50 ±5 Nm, 1/2" UNC to 55 ±5 Nm. Ensure to tighten the bolts evenly crosswise in order to avoid damages to the flange.

6.

Lock the inner terminal with the locking pin according to Fig. 8.

7.

Gently release the pull-through cord so the conductor rests on the locking pin.

8.

Remove the pull-through cord.

9.

Proceed immediately to section 2.6 Mounting of outer terminal. 60-80 Nm

M8

Grease with vaseline or similar compound

Lubricate the o-ring

gob_0005

Fig. 8. Outer and inner terminal stud. 1) Outer terminal 2) Inner terminal 3) O-ring 800 A: 2152 2011-412; 39.2 x 3 1100/1250 A: 2152 2012-420; 59.2 x 3 4) Locking pin 800 A: 2111 764-A 1100/1250 A: 2111 764-B 5) Width across flats 800 A: 55 mm for wrench 1100/1250 A: 66 mm 2750 515-12 en, Rev. 8

13

2 Installation

2.5.3

Solid rod conductor CAUTION: Mounting of the conductor must be performed according to the procedure below. The contact surfaces must be clean. If turning of the conductor is needed to line up the holes for the locking pin in the conductor tube with the hole in the conductor, the conductor must definitely be turned clockwise. Turning in opposite direction may loosen the current carrying joint in 800 A conductors. The lower part of the solid conductor is normally fastened to the cover plate of the transformer. The top part is usually delivered to site with the bushing. 1.

Drop the pull-through cord through the bushing centre hole.

2.

Fasten the M8 swivel to the top part of the solid conductor.

N = 17 (for wrench with gap 17 mm) Tightening torque 35 - 40 Nm

Tightening torque 35 - 40 Nm

gob_0006

Fig. 9. Solid conductor 800 A 1) Upper conductor 2) Lower conductor 3) Locking pin, 2111 764-A 4) Locking pin, 2111 764-C 5) Screw, 2122 751-2

14

Fig. 10. Solid conductor 1100/1250 A 1) Upper conductor 2) Lower conductor 3) Locking pin, 2111 764-B 4) Hexagon head screw M10 x 20 Previous non-captive design, 2121 2033-490 New captive design, 2121 738-19 5) Belleville spring washer, 2154 717-5 2750 515-12 en, Rev. 8

2 Installation

3.

Partly pull the top part of the solid rod up into the bushing centre hole, leaving the part with the jointing hole(s) sticking out.

4.

Secure the pull-through cord so the solid rod conductor top part cannot fall out of the bushing.

5.

Lift the bushing with the solid rod attached above the opening.

6.

Lower the bushing until the two solid conductor parts meet.

7.

Lubricate 1 x M12 (800 A) or 3 x M10 (1100/1250 A) screws with water-free vaseline, Mobilgrease 28 or other lubricant not harmful to the transformer oil. Insert and tighten to 35-40 Nm.

8.

Lower the bushing into the transformer while directing the assembled solid rod conductor by keeping the pull-through cord taut.

9.

Fix the bushing to the cover. Torque M12 to 50 ±5 Nm, 1/2" UNC to 55 ±5 Nm. Ensure to tighten the bolts evenly crosswise in order to avoid damages to the flange.

10. Lock the solid rod with the locking pin according to Figs. 9 and 10. 11. Gently release the pull-through cord so the conductor rests on the locking pin. 12. Remove the pull-through cord. 13. Proceed immediately to section 2.6 Mounting of outer terminal.

2.5.4

Horizontal mounting of bushing A horizontal GOB bushing normally has the tap to the left, seen from the air side when the bushing is mounted according to the instructions below. Alternative 1. At vacuum filling of transformer. Open the oil hole in the flange. Mount the bushing with the hole upwards. The bushing will be completely oil filled at the filling of the transformer. Alternative 2. Filling of transformer without vacuum. Place the bushing vertically and open one of the filling plugs at the top. Add clean and dry transformer oil until the bushing is completely filled. Put back and tighten the plug and place the bushing horizontally with the opening in the flange upwards. Remove the covering plate or plug immediately and mount the bushing in the transformer without turning or tilting it.

2.6 Mounting of outer terminal CAUTION: Before connection of conductor clamps, the outer terminals of aluminium must be carefully wire brushed and greased with a contact compund or vaseline. In order to obtain the correct pressure and a low contact resistance, the following must be carried out: 1. Clean the contact and gasket surfaces carefully. 2. The inner terminal / solid rod thread is to be lubricated with vaseline or other lubricant not harmful to the transformer oil. 3. Lubricate the o-ring before putting it into the groove. 4. Screw on the outer terminal and tighten with 60-80 Nm according to Fig. 8. 2750 515-12 en, Rev. 8

15

2 Installation

2.7 Flange earthing WARNING Proper earthing is essential! The bushing flange is provided with a tapped hole M12. After tightening the bolts fixing the bushing to the transformer tank, the flange should be earthed. This prevents electrical discharges between bushing flange and transformer tank under normal service conditions. Alternative 1 Insert a heavily greased (Mobilgrease 28 recommended) pointed set screw M12 (stainless steel A4-80 preferrably). Tighten to 40 Nm, penetrating the paint of the transformer tank down to the metal underneath. This makes an electrical connection between the bushing and the transformer tank, keeping them at the same voltage. Alternative 2 Apply a flexible cable between the M12 earthing hole in the bushing flange and a corresponding connection point in the transformer. Grease the screw (Mobilgrease 28 recommended) and tighten the M12 in the bushing to 40 Nm. Connect the other end of the cable to the transformer.

2.8 Waiting time before energizing CAUTION: When a bushing has been stored horizontally, it must be raised with the top up for at least 12 hours before service voltage is applied and 24 hours before test voltage is applied. If, by mistake, the bushing has been stored horizontally more than one year, it must be placed in the vertical position for at least one week before energizing. Some waiting time may be necessary before energizing in order to avoid flashovers or partial discharges due to airbubbles at the bushing surface. Choose a suitable procedure below. Vacuum filled transformer No waiting time is necessary from the bushing point of view. De-gassed oil-filled transformer During mounting, use a clean and dry paintbrush to release surface bubbles. Wait 6 hours before energizing. Gas-saturated oil-filled transformer During mounting, use a clean and dry paintbrush to release surface bubbles. Wait 24 hours before energizing. De-gassed oil filled transformer with reduced oil-level After restoring the oil-level, wait 24 hours before energizing. For all alternatives except vacuum-filled transformer, the oil should be allowed to enter the centre tube to at least flange height by releasing the outer terminal sealing system and allowing air to escape this way.

16

2750 515-12 en, Rev. 8

2 Installation

2.9 Recommended tests before energizing The following tests may be performed to check the insulation, sealing and current path of the bushing. The tests should be made after mounting, but before connecting the outer terminal of the bushing to the rest of the switchyard power circuit.

2.9.1

1.

Tightness test between transformer and bushing flange.

2.

Tightness test of bushing outer terminal.

3.

Measurement of capacitance and tan δ.

4.

Check of through-resistance.

Tightness test between transformer and bushing flange Several different methods may be used and we thus refer to instructions given by the company responsible for the field erection. As a simple example, the tightness of the seal between transformer and bushing flange may be checked when the transformer is oil-filled by using chalk or, perhaps easier, with paper strips.

2.9.2

Tightness test of bushing outer terminal Since the top terminal is often situated above the oil level of the transformer expansion system, a leak at this point is extremely serious, because water could enter directly into the transformer insulation this way. It is thus recommended to make a tightness test after assembly, preferably both with vacuum and over-pressure. Several different methods may be used and we refer to instructions given by the firm responsible for the field erection. One possible method is the tracer gas method:

2750 515-12 en, Rev. 8

1.

Put a tracer gas into the centre tube before mounting the outer terminal. The oil level of the transformer must be above the bottom end of the bushing but below the bushing flange.

2.

Increase the pressure in the center tube by increasing the oil level as much as possible.

3.

Search with a gas detector (sniffer) for leaking gas at the gasket.

17

2 Installation

2.9.3

Measurement of capacitance and tan δ WARNING The test tap is not self-earthing. Since C2 usually is relatively small, the test tap must never be open-circuited when applying a voltage to the bushing. It shall always be earthed or connected to an external impedance. No connection may destroy the bushing. Recommended maximum voltage for C1 is 10 kV and for C2 500 V. CAUTION: When not measuring, always make sure that the cap nut is properly tightened with the gasket in place. This is to prevent dust and water from coming in to the test tap. After mounting, a capacitance measurement is recommended. Connect a measuring bridge between the outer terminal and the test tap by using a ø 4 mm lead coupler or ABB's test tap adapter 2749 510-U. This is possible without removing the bushing as the bushing has an insulated test tap, see Fig. 2. More details can be found in product information 2750 515-142, "Bushing diagnostics and conditioning". With the transformer de-energized and the bushing outer terminal disconnected, the test tap cover is removed. The measuring equipment is connected to the test tap and the measuring voltage source to the bushing terminal. The capacitances C1 between the centre tube and the tap, and the capacitance C2, between the test tap and earth are marked on the marking plate. The nominal capacitances C1 of the different bushing types are listed in Table 3. C2 is highly dependent on the surrounding parts inside the transformer and it is not possible to give a nominal value valid for all service conditions.

18

2750 515-12 en, Rev. 8

2 Installation

Table 3. Nominal capacitances in pF (Manufacturing tolerances for C1 ± 10%). Type

2750 515-12 en, Rev. 8

Catalogue No.

Nominal capacitance (pF)

LF 123

C1

C2

GOB 250

013, 014, 171, 172 015, 016, 173, 174 017, 167 019, 168 083, 084, 175, 176 085, 169

125 205 165 270 275 375

90 500 110 750 800 1200

GOB 325

025, 026, 177, 178 027, 028, 179, 180 089, 090, 181, 182

135 200 260

95 200 425

GOB 380

037, 038, 183, 184 039, 040, 185, 186 041, 101 043, 102 095, 096, 187, 188 097, 103

145 200 185 265 245 320

110 335 150 550 550 1150

GOB 450

049, 050, 145, 146 051, 052, 147, 148 053, 054, 149, 150

145 200 245

125 570 770

GOB 550

061, 189, 062 063, 190, 064 107, 191, 108 065, 142 067, 143 109, 144

150 170 210 170 195 240

156 400 750 150 320 575

GOB 650

073,192 075, 193 113, 194

205 235 280

200 340 550

GOB 750

077, 104 078, 105 079, 106

205 235 275

390 565 950

GOB 1050

281 280

310 367

450 700

19

2 Installation

The dissipation factor varies with the temperature of the bushing body, and the measured value should thus be multiplied with the correction factor (multiplier) given in Table 4. Table 4. Dissipation factor variations as a function of temperature. Bushing body temperature °C 0-2 3-7 8-12 13-17 18-22 23-27 28-32 33-37 38-42 43-47 48-52 53-57 58-62 63-67 68-72 73-77 78-82 83-87

2.9.4

Multiplier to 20 °C 0.80 0.85 0.90 0.95 1.00 1.05 1.10 1.15 1.20 1.25 1.30 1.34 1.35 1.35 1.30 1.25 1.20 1.10

Check of through resistance This method can be used to detect very large faults in the current path, such as disruptions, and is not a tool for diagnostic of the bushing. The through resistance measurement method depends on the design of the transformer. Generally, a current is applied from bushing to bushing. The voltage drop from outer terminal to outer terminal is measured. The resistance is calculated with Ohm’s law, U = R·I. (U: Measured voltage drop. I: Through current. R: Total circuit resistance.) The total through resistance is the sum of the transformer winding and lead resistance and the bushing conductor and contact resistance. The additional resistance from he bushing conductor should not be more than 150 mΩ. Since the through resistance of the HV winding of a typical power transformer is in the order of 0.1 ..1 Ω, this is a very rough method. Less-than-perfect contacts can only be detected by making a sensitive measurement across each connection point, or by measuring the temperature increase during operation with an infrared sensitive camera (thermovision).

20

2750 515-12 en, Rev. 8

3 Maintenance

3 Maintenance The GOB bushings are maintenance-free. For bushings with oil-level glass, it is recommended to note the oil level during normal routine inspections in the plant. DANGER No work at all can be performed on the bushing while it is energized or not earthed.

3.1 Recommended maintenance and supervision

3.1.1

1.

Cleaning of insulator surface

2.

Measurement of capacitance and tan δ

3.

Thermovision (infrared camera) check for local overheating on connectors

4.

Check for leakage

5.

Checking and adjustment of the oil level

Cleaning of insulator surface CAUTION: Avoid having solvent on the bushing gasket and porcelain joints. Under conditions of extreme pollution it may be necessary to clean the porcelain insulator surface. This should be done by water-jet or by wiping with a moist cloth. If necessary, ethyl-alcohol or ethyl-acetate may be used.

3.1.2

Measurement of capacitance and tan δ Please refer to Chapter 2 Installation.

3.1.3

Thermovision (infrared camera) check for local overheating on connectors At maximum rated current, the bushing outer terminal normally takes a temperature of about 35 to 45 °C above the ambient air. Significantly higher temperatures, especially at lower current loading, can be a sign of bad connections.

2750 515-12 en, Rev. 8

21

3 Maintenance

3.1.4

Check for leakage Make a visual inspection for oil leakage during normal station supervision.

3.1.5

Checking and adjustment of the oil level CAUTION: Oil sampling and dissolved gas in oil analysis. Normally we do not recommend taking oil samples or opening our bushings. The bushing is sealed and tightness tested at the time of manufacturing. An oil sampling means that the bushing has to be opened. Thus, there is also a risk of improper sealing after the sampling is finished. However, when a problem is known, for example high power factor over C1 or visible leakage, there might be a need for oil sampling and gas analysis or oil level check. In this case, ask for product information 2750 515-142 "Bushing diagnostics and conditioning". Bushings with one oil level glass should show the oil level in the middle of the glass at 20 °C. The oil level change is approximately 3 mm per 10 °C. GOB 750 and 1050 has two glasses and the oil level at 20 °C is to be at the oil level plug between the two glasses. The oil level change is approximately 6 mm per 10 °C. The oil level in bushings without oil level glass may be checked through one of the two oil filling holes at the top end. A dry and clean dipstick should be used. In one of these holes there is a rubber plug. This plug may be pressed down into the bushing so that checking of the oil level can be carried out. Correct oil level is shown in Table 5. For bushings mounted at an angle it may be necessary to check at both holes and calculate the average. If the oil level is too high, oil can be sucked out by means of a narrow hose. If the oil level is too low, clean and dry transformer oil must be added. Adjustment of oil level is allowed only when the temperature of the bushing is +5 °C to +35 °C. It is recommended to provide the sealing plug with a new gasket after the check. The sealing plug is to be tightened with 20 Nm. For further information on oil sampling, see product information 2750 515-142. For topping-up of the bushing, any clean and dry transformer oil available at site may be used. Table 5. Oil level for bushings without oil level gauge Type GOB

Oil level A mm at 20 ±10 °C Fig. 1a Fig. 1b

Oil level change mm/10 °C *)

250

110 ±8

165 ±10

4

325

110 ±8

165 ±10

5

380

110 ±8

165 ±10

5

450

110 ±8

165 ±10

6

550

170 ±10

270 ±15

7

650

175 ±10

275 ±15

9

750

275 ±15

330 ±15

11

*) The bushing in vertical position.

22

2750 515-12 en, Rev. 8

3 Maintenance

3.1.6

De-mounting of horizontally mounted bushings When the bushing is removed from the transformer it is completely filled with oil. Drain a small volume of oil and tighten the flange hole with the gasket and cover plate or plug. Place the bushing vertically and adjust the oil level according to 3.1.5.

3.2 Disposal after end of service life The bushing consists of the following material:

2750 515-12 en, Rev. 8

-

Conductor of copper or low-alloy aluminium.

-

Terminals of copper, brass or low-alloy aluminium may be plated with for instance silver, tin, gold or nickel in layer thickness up to 20 μm.

-

Transformer oil as per IEC 60296, class 2.

-

Transformer oil impregnated condenser body consists of paper and 1 % aluminium foils.

-

Centre tube, on which the condenser body is wound, consists of aluminium alloy.

-

Top washer, top housing, flange, top nut, flange extension and end-shield consist of aluminium alloys.

-

Press ring for oil level glass and previous design of test tap cap consist of plated brass. New design of test tap consists of stainless steel.

-

Prism glass consists of glass.

-

Insulators consist of quartz or alumino silicated based porcelain.

23

2750 515-12 en, Rev. 9, 2006-10-15

ABB Power Technologies AB Components Visiting address: Lyviksvägen 10 Postal address: SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00 Fax +46 240 121 57 E-mail: [email protected] www.abb.com/electricalcomponents



* "(&(&(&$"(((&(((&"( All this range of bushings is normally supplied in accordance to the customer's own specifications, specially for the oil side connection design; our fig. T1, B1 and A1 show the most common executions; without any contrary specification of the customer, the bushing is supplied as fig C1 (exactly according to DIN standards). For the air side connection, normally the bushing is fitted with flags EP/FP DIN 43675 (or UNEL 38137-67 for the italian market or UNE 20-176-89 for the spanish market). A/horns are supplied, only upon request, in two executions shown at page 3.7. COMPONENTS LIST FOR BUSHINGS 10-20-30-52/1000-2000-3150 10-20-30/4500 Pos. 1: Porcelain Pos. 2: Copper rod Pos. 3: Brass cap "E" Pos. 4: Brass top washer "F" Pos. 7: NBR ring gasket "J" Pos. 8: Gasket "O" Pos. 9: NBR gasket "M" Pos. 10: NBR flange gasket "N" Pos. 11D: Flag EP/FP DIN 43675 Pos. 12: Brass ring "P" Pos. 13: Copper ring "S" Pos. 14: Brass nut DIN 934 Pos. 16: Fiber gasket Pos. 17: Vent/screw "R" Pos. 18: Locking screw Pos. 23: Bronze contact ring "U" Pos. 24: Aluminium fixing ring "C-D" DIN 42538 Pos. 25: Aluminium clamping piece "F" DIN 42538 Pos. 26: Mild steel zinkplated chromium passivated M12 DIN 934 Pos. 27: Mild steel washer d. 13 Pos. 28: Fixing stud M12x70 (not supplied) Pos. 29: Brass nut DIN 934 Pos. 30: Brass locknut DIN 936 Pos 31D: Flag EP/FP DIN 43675 Pos 32: Center ring (supplied upon request)

1 of 3

12



b1=380 mm

$*+ ,-.// * &/0 3,23, */ . )

2 of 3

15

c1=440 mm

BUSHINGS type 10 - 20 - 30 / 4500 3 of 3

SOLID BUSHING TYPE DIN 42533 – 42534 & EN 50180

PRODUCT INFORMATION & OPERATING INSTRUCTIONS

Ter.man.’90 Strumentazione Industriale S.r.l.–Via Ghisalba, 13– 20021 Bollate ITALY Tel. ++39.02.38303048 fax ++ 39.02.3510262 38303049 38303719

terman’90 A- SCOPE This product information and operating instructions manual contains informations regarding solid bushing insulators for electrical transformers, their handling, transportation, storage, commissioning and maintenance .

B- GENERAL INFORMATION These bushings are manufactured according to DIN standards, have porcelain as main insulation and are suitable for outdoor installation. All the bushings listed in this information manual fulfil the electrical specification and are suitable to withstand the test voltages from IEC 137 standards. For details see attached tables . The lower part of the porcelain insulator is directly in contact with the transformer oil and the inside space shall be completely filled with oil.

C- SAFETY INFORMATION No toxic or dangerous material is used to manufacture the various components of a DIN standard bushing. Anyway, during handling or operation or maintenance unsafe conditions may occur as: lethal voltages, heavy components moving, cranes or forklift operations… It is, as a consequence, necessary to issue handling and operation procedures in order to clearly inform the personnel about the cares necessary in mounting, handling, commissioning, maintaining or de-mounting the bushings. In particular the procedures must clearly inform about the risks due to the weight of the bushing, to the heavy danger of injury or death connected to the high voltages and to the oil temperature.

D- INSTALLATION Normally the bushing is supplied completely assembled, excluding the fixing components, and ready to be installed on the transformer cover before putting the active part into the tank . For the installation : 1- Place the flat gasket and the fixing flange on the transformer cover 2- Put the complete bushing in the hole on the cover being sure that the gasket is well centred 3- Lift the flange to allow the fixing pieces to be put on the studs 4- Fix the flange with nuts and washers. Tighten the nuts alternatively and uniformly. After tightening the first nut , the next one to be tightened must be the one opposite to the first nut . It is important to prevent unequal clamping strain and possible damage to the porcelain or to the mounting clamp. The suggested torque value of 25 / 30 Nm. will provide adequate gasket compression for sealing . 5- The support of the arcing horns, if supplied, must be fixed to the studs at the same time as the flange, to avoid stresses to the flange. 6- Connect the internal connections 7- Verify the tightening of the brass nut item 30 on the copper rod by referring to the following table : Current (A) Rod dimensions 1000 M30x2 2000 M42x3 3150 M48x3 4500 M55x3

Torque (Nm) 70 110 180 250

Spanner (mm.) 46 65 75 80

then verify the tightening of the screws – items 13 -on the flags by referring to the following table : Screws dimension M 10 M 12 M 16

Torque (Nm) 25 40 90

Spanner (mm.) 17 19 24

8- After the oil filling of the transformer, vent the air from the bushing by means of the proper screw item 07 – located in the upper part of the bushing

E- DE-MOUNTING To de-mount the bushing, first lower the oil level up to a few centimetres below the transformer cover and disconnect the internal connections, then unscrew the fixing nuts, lift the flange and take away the fixing pieces. now the complete bushing can be removed.

F- REPLACEMENT OF THE PORCELAIN It is possible to replace the porcelain only and/or the gaskets without disconnect the internal connection and with oil lowered only at cover level. 1- Unscrew the flag item 12 and the nut item 11 being sure that the copper rod is supported to avoid damages to the internal connections 2- Remove the items : 10; 09; 08; 05; 04 3- Unscrew the fixing nuts then lift the flange and take away the fixing pieces 4- Remove the porcelain 5- Mount the new porcelain being sure that the gasket item 2 is properly located and the ring item 1 fits without problems the seats in the porcelain. Fix this last to the cover as detailed in para D. 6- Remount items 04 to 10 7- After the oil refilling, vent the air

G- MAINTENANCE It is only suggested to carefully clean by time the surface of the bushing porcelain when working under very dirty conditions. It is recommended to make inspection to detect eventual cracks in porcelains which can cause oil leakage especially when the bushing is side wall mounted. It is important to stress that it is necessary to vent the air every time the oil level is lowered below the upper part of the bushing .

Process Equipment Division

Renzmann & Grünewald GmbH

Transformeroil Oil Technologie

Description-, Operatingand Maintenance Manual

Order No.: 4500098675/111 Our Com. No.: 39745 Password: Romania 40MVA

Renzmann & Grünewald GmbH Process Equipment Division

I.

Contents

1.

Instruction..........................................................................................................3

1.1 1.1.1 1.1.2 1.2 1.3

Notes fort he Customer ..................................................................................................................3 General...........................................................................................................................................3 Protective Equipment .....................................................................................................................4 Target Groups ................................................................................................................................4 Technical Drawing and EU Declaration .........................................................................................4

2.

General...............................................................................................................5

2.1 2.2 2.3 2.4

Liability and Warranty.....................................................................................................................5 Keeping the Operating Manual Ready...........................................................................................6 Additional Copies of the Manual ....................................................................................................6 Copyright........................................................................................................................................6

3.

Safety .................................................................................................................7

3.1 3.2 3.3 3.4 3.5 3.6

Pictograms .....................................................................................................................................7 General Safety Requirements........................................................................................................8 Protective Equipment .....................................................................................................................9 Intended Use................................................................................................................................10 Inappropriate Use.........................................................................................................................10 Inadmissible Operating Modes ....................................................................................................10

4.

Description and Function ................................................................................ 11

4.1 4.2

General.........................................................................................................................................11 Type Code....................................................................................................................................11

5.

Transport and Storage .................................................................................... 11

5.1 5.2 5.3 5.4

General.........................................................................................................................................11 Handling/ Transport......................................................................................................................11 Unpacking ....................................................................................................................................12 Storage location, Storage period, Protective measures ..............................................................12

6.

Commissioning ................................................................................................ 13

6.1 6.2 6.3 6.3.1 6.4

General.........................................................................................................................................13 Arrangement of the Product .........................................................................................................13 Cleaning and Filling of the Product ..............................................................................................13 Remove Preservation Agents ......................................................................................................13 Mounting ......................................................................................................................................13

7.

Operation......................................................................................................... 14

8.

Malfunctions.................................................................................................... 14

1

Renzmann & Grünewald GmbH Process Equipment Division

9.

Maintenance .................................................................................................... 14

9.1 9.2 9.3 9.4 9.5

General.........................................................................................................................................14 Cleaning .......................................................................................................................................15 Maintenance Schedule.................................................................................................................15 Maintenance and Repair Work ....................................................................................................15 Emergency /After sales Service...................................................................................................15

10. Taking out of Service, Dismantling, Disposal ................................................ 15 10.1 General.........................................................................................................................................15 10.2 Disposal Instructions ....................................................................................................................16 10.3 Environmental Compatibility ........................................................................................................16

11. Technical Datasheet and Drawings................................................................ 16 12. Spare Parts ....................................................................................................... 16

13. Product- Related Operating and Maintenance instructions ....................... 17f

Process Equipment Division

Renzmann & Grünewald GmbH

Renzmann & Grünewald • Industriestr. 6 • D-55569 Monzingen • Phone.++49(0)6751/9303-0 • Fax.++49(0)6751/9303-100 • email: [email protected] Rombacher Hütte 12a • D-44795 Bochum • Phone ++49(0)234/94342-0 • Fax ++49(0) 234/94342-379 •email: [email protected] For further info visit our internet site: www.renzmann.com VBE102.603 2

Renzmann & Grünewald GmbH Process Equipment Division

1. Introduction 1.1 Notes for the Customer Being familiar with the basic safety rules given in the “Safety” chapter of this Manual is a prerequisite for safe and trouble-free operation. The present instructions, in particular the safety notes, are to be followed by all people involved. In addition, the accident prevention rules applicable at the customer’s location are to be respected.

1.1.1 General If you are in doubt as to how to proceed, contact Renzmann & Grünewald GmbH. Before operating the product or making any modification or performing any maintenance, be sure to carefully read and observe the appropriate chapters of this Manual. As regards the representations and information contained in this Manual we reserve the right to implement necessary technical changes for product improvement purposes. The Owner is held to supplement this Operating Manual by including any provisions required by existing national accident prevention and environmental protection rules and regulations. Aside from this Operating Manual and the applicable provisions for the prevention of accidents ruling in the country where the equipment is to be used, the Owner is also held to observe the generally accepted technical rules governing safe and skilled working practices. This Manual is to be read and followed by any person involved in work on the products, for example in the fields of operation, maintenance and repairs. As regards faults or omissions Renzmann & Grünewald GmbH will, to the exclusion of any further claims, be liable within the framework of its warranty obligations laid down in the contract for sale. Claims for further damages on whatever legal grounds are expressly excluded. Liability and warranty claims are excluded: - if the notes and instructions given in this Manual are not observed; - if the product including pertinent accessories are incorrectly operated or handled in a way contrary to the prescribed purpose; - if the product is used for a different than the intended application; - if protective guards are left unused or taken out of service in whole or part; - if equipment functions of whatever kind are changed without Renzmann & Grünewald GmbH’s written consent; - if applicable safety provisions are not observed; - if the products including pertinent accessories are maintained inexpertly (both time wise and with respect to expertise), and this also embraces the use of appropriate spares.

3

Renzmann & Grünewald GmbH Process Equipment Division

1.1.2 Protective Equipment The Owner has to provide the necessary personal protective equipment, such as safety goggles, safety gloves, etc. According to the applicable regulations, the Owner has to make sure that there are adequate escape routes for their personnel in an emergency. They have to take care to ensure that the escape routes are not blocked or restricted in any manner.

1.2 Target Groups This Manual should be carefully studied and all relevant chapters should be duly taken note of. Definitionen of Users: a) The Owner is the legal person responsible for the appropriate operation of the product and for the training and assignment of the authorized personnel. The Owner shall define the competence and authority levels of the authorized plant personnel. b) A qualified person is a person who, based on their technical training, qualification and experience as well as in consideration of their knowledge of the relevant regulations, is capable of assessing the nature of the work assigned to them, so that they can identify any potential danger involved. A qualified person can only be a specially trained, skilled worker or a worker who has been specifically selected by the operator based on their competence. c) An instructed person is a person who has been informed about the work assigned to them and the hazards that may result from inappropriate working methods and who has been trained, if necessary, and instructed about the necessary safety equipment and protective measures. d) A layman is any person who is neither a qualified person according to b) nor an instructed person according to c). Any work to be carried out on the product shall be performed by qualified personnel only.

1.3 Technical Drawing and EU Declaration Depending on the kind of product a technical drawing or a technical data sheet as well as the EU Declaration for the product are part of this manual. The drawing and technical data sheets provide information about technical characteristics and nameplate details. The EU declaration mentions the relevant directives and standards on which the product is based.

4

Renzmann & Grünewald GmbH Process Equipment Division

2. General This chapter provides general information about the operating instructions and describes some safety measures. Read this chapter carefully to ensure safe operation of the products.

2.1 Liability and Warranty All the information and instructions given for the operation and maintenance of the products are based on past experience and our best knowledge and belief. Wear parts are not covered by the warranty scope provided by Renzmann & Grünewald GmbH. In the event of replacements only those spares and wear parts must be used that have been approved by Renzmann & Grünewald. If this requirement is disregarded any liability and warranty claims will be become forfeited. The design of the products corresponds with what has been written in our order acknowledgement. If modifications or amendments arise in the course of contract execution these have to be mutually laid down in writing. Official provisions and operating instructions issued by the Owner have been observed in the framework of the contract unless product-related aspects required a different approach. We shall be liable for any legal claims only to the extent covered by the warranty stipulated in the main contract. The original version of this Manual was written in German and reviewed by us for technical correctness. The translation into the customer’s language / contract language was made by an acknowledged professional translation bureau. Renzmann & Grünewald GmbH shall not be liable in any way, if -

the product is used, handled and stored inappropriately or other than for the intended purpose; unauthorized modifications are made; cleaning is not carried out as prescribed or maintenance and inspection instructions are disregarded.

We shall demand and enforce the exclusion of legal responsibility where we can prove that malfunction is attributable to operation or application faults. In certain cases, modifications and/or adjustments may be made to the products. Such modifications/adjustments require Renzmann & Grünewald’s prior approval in writing. Our operating instructions are updated on a regular basis. Your suggestions for improvement may help make these instructions even more user-friendly. So if you have any suggestion for improvement, please let us know. We request you to inform us in writing of any error, inconsistency or ambiguity that you may find in these operating and maintenance instructions. It is recommended to check the entire consignment immediately upon receipt for completeness and damage that may have occurred in transit. For this purpose the attached delivery note and accompanying documents will be of help. 5

Renzmann & Grünewald GmbH Process Equipment Division

As a rule, complaints can only be processed if reported to the forwarder and/or Renzmann & Grünewald GmbH on the day the equipment is received. Moreover, it is the Owner’s responsibility to follow all applicable environmental protection regulations and disposal requirements (packaging, oil changes, cleaning agents etc.). Storage must be in a dry, well ventilated location. Solvents, oil and paint material must not be stored in the same room. We shall not be held liable for any damage arising as a result of inappropriate storage such as for example corrosion damage.

2.2 Keeping the Operating Manual Ready This Manual must be available to the operators during the entire service life of the product. Please keep one copy at a place close to the product!

2.3 Additional Copies of the Manual Additional copies of this Manual can be obtained at the address given below. Please note that we will have to invoice you for any additional copies ordered. Renzmann & Grünewald GmbH Industriestrasse 6 Phone: 55569 Monzingen Fax: Germany Internet:

+ 49 (0)6751-9303-222 + 49 (0)6751-9303-100 www.renzmann.de

2.4 Copyright All rights are explicitly reserved. This Manual may not be reproduced or made available to a third party in any form without our written consent.

6

Renzmann & Grünewald GmbH Process Equipment Division

3. Safety This chapter describes the safety measures and safety equipment. Read this section carefully before performing any work on and with the product to ensure safe working and operating conditions.

3.1 Pictograms The following danger signs and messages are used in this Manual:

This symbol draws your attention to the potential for damage to property or the environment. Attention

This symbol points out that there is risk of injury or danger to life. Attention

Warning of dangerous electrical voltage.

Warning of contusion dangers.

Warning of hot surfaces.

No unauthorized entry.

Non-observance of these signs may severely affect human health and even lead to critical injury!

Packaging and insulation is to be disposed of expertly and in an environmentally compatible manner. Any national rules and directive must be adhered to.

7

Renzmann & Grünewald GmbH Process Equipment Division

Information This symbol draws the reader’s attention to important facts.

3.2 General Safety Requirements

The products are in compliance with the general safety and health requirements of the EU. Nonetheless, dangerous situations may occur. Attension The product has been designed as per state-of-the-art technology and recognized safety rules and regulations. Nevertheless, danger to life and limb of operating staff or third parties, or impairments of the products or other property may occur when the equipment is utilized The products must only be used in technically perfect condition, for its intended use, and in a safety-conscious and circumspect manner! Any malfunctions or disturbances, particularly those affecting the safety of the product, must be rectified immediately. The products are exclusively intended for use in the framework of the technical data specified in this Operating Manual. Any use of the machine that deviates from what has been prescribed will violate the provisions governing intended use. Any damage resulting from such a non-intended use will be excluded from Renzmann & Grünewald GmbH's liability with the risk lying solely with the user. The scope of intended/contractual use also includes that the Operating Manual is observed and the inspection and maintenance work carried out as scheduled. The operating manual and instructions including supervision and reporting duties must be supplemented to give due consideration to specific plantsite needs, e.g. with respect to work flow organization, operational sequences, staff assigned etc. Such duties also include, for example, the handling of hazardous substances or the provision/wearing of personal protective equipment/clothing, or prescription of other measures. Carefully adhere to the safety and hazard notes (if any) provided at/on the product and make sure such notes and signs are kept complete and well legible! All components and protective systems must be cleaned regularly and checked for correct functioning. In the event of any changes in the products that touch on safety aspects or affect the product’s operational behavior the product must at once be taken out of service and this is to be reported to the relevant person in charge immediately. This applies also to the mounting and adjustment of safety equipment/systems as well as to carrying out welding work on load-bearing and pressurized components. Safety equipment must neither be removed nor made inoperative/rendered ineffective. The products must exclusively be operated with protective guards/systems being complete and correctly functioning (if applicable). 8

Renzmann & Grünewald GmbH Process Equipment Division

The prescribed intervals for testing/inspection to be routinely carried out or as indicated in the operating manual must be adhered to! A maintenance schedule has been attached to this Manual. The minimum requirements specified therein must be supplemented by the Owner, if applicable. To enable maintenance/repair measures to be carried out it is mandatory that expedient workshop outfit/tooling is available. Personnel entrusted with various work assignments must have read and understood the operating manual prior to start of work, in particular the chapter containing safety notes. It will be too late to do this when work has commenced. This is especially true for persons only occasionally carrying out work such as product set-up, maintenance and similar activities. Respiratory equipment must be used when performing activities that may involve the intake of harmful gases. Respiratory equipment must be ready for use and quickly available in sufficient number. Personnel working with the product must report any operational irregularities to their superiors without delay. To verify the correct functioning of the product a test run must always be carried out prior to commissioning

3.3 Protective Equipment Note -

Before the product is put into operation all existing protective systems must have been correctly mounted and functioning.

-

Protective equipment/systems may only be removed - the product is inoperative and - after precautionary measures have been taken to rule out inadvertent starting (e.g. by locking the main switch).

-

Do not bridge safety switches.

If our supply involves the delivery of parts to be integrated into overall the Owner is held to mount protective systems as necessary.

systems

Depending on the heat exchanger mounting position, hot surfaces may have to be provided with protective devices to prevent accidental contact. If necessary a pictogram warning about hot surfaces is to be attached near dangerous areas.

9

Renzmann & Grünewald GmbH Process Equipment Division

3.4 Intended Use The products shall be used exclusively for the specified application. For details see the chapter ”Description and Function“ as well as “Technical Data”. The products shall be used only for the specified application and when in perfect working order. Operators shall observe our operating instructions and be always aware of safety requirements and potential hazards! Malfunctions which may affect the required safety shall be remedied immediately. The intended use of the product also applies to - observing all instructions given in the Operating Manual and - performing inspection and maintenance work as scheduled

3.5 Inappropriate Use If used inappropriately or for any other than the specified use, the products may pose hazards.

3.6 Inadmissible Operating Modes Operational safety of the products supplied can be guaranteed only if they are used for the specified application and in accordance with our contract documentation. The limit values specified in our documentation must never be exceeded.

This note for use shall be strictly observed! In case of deviation, Renzmann & Grünewald GmbH’s liability and warranty shall be excluded! Attention Pollutants shall always be disposed of in a manner that will not pose hazards to human beings or the environment. Please note that leakage of dangerous substances may also damage the environment. Legal provisions have to be carefully observed. Serious human injury may occur if: - covers are removed without permission - items are inappropriately used Danger

- items are wrongly installed and controlled

10

Renzmann & Grünewald GmbH Process Equipment Division

4. Description and Function 4.1 General Each product is provided with a nameplate. The attached drawing contains the main dimensions as well as further information.

Additional detailed information can be found in the enclosed product-related operating and maintenance instructions.

4.2 Type Code The product types are designated using a specific type code. Based on the code number the product can be clearly identified. or or

Comm.- No. 22300 Comm.- No. 22300-10 Comm.- No. 22300-10-1

The relevant details are shown on the nameplate.

Additional detailed information can be found in the enclosed product-related operating and maintenance instructions.

5. Transportation and Storage 5.1 General As soon as the consignment has been received all items have to be checked for completeness and damage. For this purpose the attached delivery note and accompanying documents will be of help. Complaints can only be processed if reported to the forwarder or Renzmann & Grünewald GmbH on the day the equipment is received.

5.2 Handling/Transport The equipment can be transported with normal handling systems with the necessary safety measures being taken.

Attention

Only use handling means and tools suitable for the task to be performed. For example, load carrying ropes and slings used for lifting must be of adequate size and not be damaged. Make sure no persons pass or stay under the goods lifted up during handling.

11

Renzmann & Grünewald GmbH Process Equipment Division

Transporting and attaching loads must only be carried out by competent personnel capable of performing this work on the basis of own knowledge and experience gathered in the field of materials handling. Goods can be lifted as described hereunder: 1. Use the lifting lugs provided on the equipment. 2. Use the lifting bars in the side walls, making sure, however, to apply shackles. 3. Observe instructions given in the technical drawing.

In cases of doubt consult the responsible technical department ! Attention

5.3 Unpacking Packaging and insulation material should be used repeatedly or correctly disposed of observing environmental needs and regulations. Any national rules and directive must be adhered to. Condensate that may have formed must be eliminated. The correct delivery state of the equipment is to be checked.

5.4 Storage location, Storage period, Protective measures -

In case of a storage duration exceeding 14 days, overseas consignments etc. Renzmann & Grünewald GmbH has to be contacted first. In such a case the products have to be specially protected and packed (seaworthy packing).

-

The products must be protected so as to prevent water damage. Wrap in suitable foil and cover the equipment using a large tarpaulin.

-

Storage must be in a dry, well ventilated location.

When storing zinc coated products over a longer period make sure to protect the items against water that has no or only a minor amount of mineral constituents. If there is an insufficient supply of air / CO 2 white rust (wet storage stain) may form on the zinc surface.

12

Renzmann & Grünewald GmbH Process Equipment Division

6. Commissioning 6.1 General This section describes the procedures to be followed in installing and starting up the plant. The description tells you how to carry out the work and on what points you should focus particular attention. Only qualified expert personnel must perform work in connection with transportation, mounting and commissioning as well as maintenance and repairs. Qualified skilled personnel in the sense of these basic safety considerations are persons that are familiar with the set-up, erection, commissioning and operation of the product and have obtained the necessary qualifications.

6.2 Arrangement of the Product All connections are specified on the drawing. Only the specified connections with the appropriate nominal diameters shall be used. The drawing also defines the mounting position of the product. Should the installation situation change, please consult with Renzmann & Grünewald GmbH. The products must not be subjected to any external loads (eg duct or nozzle loads). If desired, the products can be designed to resist earthquake and nozzle loads. The Owner must provide facilities for venting and draining.

6.3 Cleaning and Filling of the Product 6.3.1 Remove Preservation Agents Anti-corrosion agents need only be removed if products have been kept in storage and provided with a seaworthy packing. When using/applying aggressive cleaning agents make sure to observe instructions given by the respectived supplier (eg wear safety goggles, gloves etc.)

Cleaning agents have to be properly disposed of in line with environmental protection legislation. Any national rules and directive must be adhered to.

6.4 Mounting Detailed information can be found in the enclosed product-related operating and maintenance instructions.

13

Renzmann & Grünewald GmbH Process Equipment Division

7. Operation Detailed information can be found in the enclosed product-related operating and maintenance instructions.

8. Malfunctions In order to solve malfunctions only skilled personnel shall be assigned.

Detailed information can be found in the enclosed product-related operating and maintenance instructions.

9. Maintenance Only skilled personnel must be assigned to perform troubleshooting work/eliminate faults.

9.1 General Cleaning should be carried out on a regular basis and not only when fouling in the products becomes evident due to poor performance. The product should be checked to this effect at regular intervals. When carrying out repairs make sure the product is in a safe state to rule out people entrusted with the repairs are in danger. The correct functioning of safety equipment must never be impaired due to repairs being performed. Work on the product is prohibited as long as the equipment is in operation. Cleaning work and replacement of construction modules or components must be carried out as per instructions given in the Manual. We shall not be held liable in any way if the performance of the equipment is impaired due to disregard of the prescribed safety measures. Irrespective of the instructions given above the relevant local regulations or national rules have to be carefully observed.

Avoid, if possible, any contact with chemicals. Should, for example, your hands have come into contact with chemicals; make sure to wash them immediately. Danger

14

Renzmann & Grünewald GmbH Process Equipment Division

9.2 Cleaning If you want to clean the products that you are using, we will be pleased to provide information. We can make available expert cleaning instructions for any type of product supplied by us. The contacts in charge of your facility are indicated on page 2.

Detailed information can be found in the enclosed product-related operating and maintenance instructions.

9.3 Maintenance Schedule Detailed information can be found in the enclosed product-related operating and maintenance instructions.

9.4 Maintenance and Repair Work When maintenance or repair work is necessary please get in touch with our Service Department under the address given in the following section.

9.5 Emergency/Aftersales Services When you contact our Service Department please have product designation and serial number ready. Renzmann & Grünewald GmbH Industriestrasse 6 Phone: 55569 Monzingen Fax: Germany Internet:

+ 49 (0)6751-9303-222 + 49 (0)6751-9303-100 www.renzmann.de

10. Taking out of Service, Dismantling, Disposal 10.1 General To dispose of the products, you should take the following action: - Remove and destroy the nameplate. - Completely disassemble the product and dispose of the various components or recycle them. Only skilled personnel qualified for this work may dismantle the individual product modules.

15

Renzmann & Grünewald GmbH Process Equipment Division

10.2 Disposal Instructions 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

All components must be pressure less prior to disassembly. Oil, grease and other fluids have to be disposed of separately in accordance with local regulations. Bright steel parts are to be treated as steel scrap. Depending on local disposal regulations, painted steel parts may have to be shotblasted before they can be disposed of as steel scrap. Shot blast shall be disposed of separately. Galvanized steel parts must be disposed of separately, according to local regulations. Stainless steel parts are to be disposed of as stainless steel scrap. Nameplates (if of stainless steel) fall into the stainless steel category when scrapped. Aluminum parts, such as manhole components, come under aluminum scrap. Sealing materials have to be separately disposed of. Parts that are under mechanical stress should be dissembled with utmost care to avoid the energy trapped in these parts from unleashing and causing injury.

10.3 Environmental Compatibility The materials used are specified in the technical documents to enable environmentally compatible disposal. The local disposal regulations applicable in the country where the equipment is mounted shall be observed.

11. Technical datasheet and Drawings Detailed information can be found in the enclosed product-related operating and maintenance instructions.

12. Spare Parts Detailed information can be found in the enclosed product-related operating and maintenance instructions.

16

Renzmann & Grünewald GmbH Process Equipment Devision

Operating instructions for oil circulating pumps Type 25/..., 50/..., 100/... 1.)

Use: The oil circulating pumps are used for circulating oil in transformers and for conveying similar insulating, lubricating and non-aggressive liquids which do not contain any substances causing wear. The maximum permissible temperature of the liquid handled is 115 °C. The delivery rate and delivery head can be seen from the rating plate.

Mechanical construction The oil circulating pump is made of 3 main parts: the pump casing with motor, coiled casing (axial) and the hollow shaft with impeller.

Conditional on the execution with hollow shaft the pump has low noise, overdimensioned and maintenance-free plain bearing. The oil flows through the hollow shaft axial to the impeller. Pressure build up ensues in the axial coiled casing. In case of this execution pump an motor are combined to a completely closed, towards the outside completely sealed and glandless aggregate. Radio interfference suppression If the degree of radio interference suppression is not indicated on the rating plate, the oil circulating pump has at least the degree N to VDE 0875.

Transport, storage The oil circulating pumps are delivered with the intake and discharge branches closed off by bolted-on covers. These should not be removed before installation is started. If a pump is not put into service immediately after arrival, store it in a dry, vibrationfree room.

2.)

Installation: Fitting in pipeline The pumps can be provided with intake and discharge branches to DIN 2501 for fitting in a pipeline. The pumps can be fitted horizontally or vertically (discharging upwards or downwards) in a pipeline in the same way as a pipe fitting with flange gaskets. The longitudinal arrows moulded on both sides of intake branch indicate the direction of

Rev.: 3.1

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www.renzmann.de

Renzmann & Grünewald GmbH Process Equipment Devision

flow of the liquid. Pumps arranged horizontally should always be fitted so that the vent plug is on top. They can also be fitted at a point in the pipe system outdoors without any trouble. If there are any compensators mounted or the span is to large it is necessary to support the pump. Therefore are 4 fixing cams M12 (only on special order) at the pump casing. Before pumps are fitted clean the pipe system. When connecting the pump in the pipeline, it may happen, that the holes in the connecting flange do not quite coincide with those in the mating flange, in which case the bolts fixing the intake and discharge branches to the stator frame should be slackened. Then the branches and the stator frame can be turned within the play of bolts. It is essential that force be avoided since this would subject the parts of the pump to undue strain.

Connection the supply cable Examine the rating plate data to see that they agree with the power circuit to which the pump is to be connected. Select the size of the supply cable as required for the particular current rating. The cable should not be overdimensioned. Connect the supply-cable conductors in accordance with the instructions shown in the terminal box. The terminal housing, and thus the cable entry, can be turned in steps of 90° to allow for the position in which the pumps are fitted. Care should be taken to see that the vent branch and cable entry are always at the bottom. All the sealing faces of the terminal box are machined and are lightly greased when assembled in the works. For maintaining the type of protection provided by the enclosure, make sure that all sealing surfaces are in order when mounting the terminal box.

Checking the insulation resistance If the pump was stored in very damp surroundings for a prolonged period, the insulation resistance of the windings to frame must be measured. If the insulation resistance has a value less than 30 M Ω at a winding temperature of 25°C measured at 500 V, or less than 1 M Ω at 75°C and 500 V, the windings must be dried, before the unit is filled with liquid.

Filling the unit with liquid Before putting in operation fill and vent the pipe system with liquid. To do this the sealing cap is first removed and the vent plug underneath is then screwed out just sufficiently to enbale the air to escape from the interior of the pump through the recess in the bottom part of the screw. When all the air has been forced out, sealing cap and vent plug should be tightened up firmly again. Ensure that the gaskets are inserted under the head of both screws.

Rev.: 3.1

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www.renzmann.de

Renzmann & Grünewald GmbH Process Equipment Devision

Starting When starting the pump, check the direction of rotation. This is possible by resort of a phase-sequence indicator, by measuring the current input or by checking the noise of the pump. A strong noise is to state when the direction of rotation is wrong, instead of a lightly singing noise for right direction. If this is not the case, two supply-phase connections must be interchanged.

3.)

Maintenance: Dismantling, cleaning, assembling Before starting any work on the pump, make sure that it has been disconnected from the supply and that a safeguard is provided to prevent unintentional starting. Except of a complete ventilation of the pump before putting into operation the oil circulating pump is maintenance-free. When assembling the pump renew the flange gaskets if necessary.

Spare parts When ordering spare parts, please state the type and serial number of the pump as shown on the data plate. 1 Bearing 2 Spider 3 Terminal box 4 Terminals 5 O-ring 6 Vent (depending on form) 7 Impeller 8 Bearing 9 Pressure gauge (by choice) 10 Intake connection 11 Casing 12 Inductor alternator 13 Clamping sleeve 14 Winding 15 Drain (by choice) 16 Coiled casing (axial) 17 Pressure connection The position of the terminal box can be shiffted by always 90°. Cable connection M25x1,5

Rev.: 3.1

page 3 of 3

www.renzmann.de

Technical data sheet:

Transformer Oil Pumps

Pos. 10: Type

50/150/100

Dimensions acc. to sketch

NK 4231/4, Rev.2, but special housing material, suitbale for ambient temperatures down to -35°C 2-component CHING (≥140µm); RAL 7032 Transformer oil, 70°C 835 kg/m³ 3~Y 400 V / 50 Hz / 1450 min^-1 73 kg 66,5 dB (A) 150 mm 60,2 m³/h 5,2 m Fl.C 1,4 kW 3,3 A 42 A 7,6 A

Surface treatment Medium Density Voltage / Frequency / RPM Weight Level of max. soun capacity Impeller diamter Capacity Delivery head Working input Working current Starting current Protective motor switch setting

Delivery Head [m. Fl.C]

8,0 7,0 6,0 5,0 4,0 3,0 2,0 1,0 0,0 0

10

20

30

40

50

60

70

80

90

60

70

80

90

Working Power [kW]

1,5 1,0 0,5 0,0 0

10

20

30

40

50

Working Current [A]

5,0 4,0 3,0 2,0 1,0 0,0

Tolerance +/- 5% 0

10

20

30

40

50

60

70

80

90

Oil flow capacity [m³/h] 39745: Technical data sheet - Transformer Oil Pumps

page 1 of 1

LIQUID FLOW INDICATOR WPC-80 WPC-100 WPC-125 Application: the WPC Indicator is designed for monitoring liquid flow in pipelines of 80 to 125 mm bore. It is provided with an optical indicator and electric contacts for remote flow control. The indicator is suitable for synthetic and mineral oils, water.

Specifications: Pipe dia D, mm 80 100 125 Flow

Nominal liquid flow 3 dcm /s 2.4 7.0 12.0

Operating temperature Permissible gauge pressure in pipeline Dimensions Electric contact rating Climate Maintenance Mass

Electrical connection

<0.4 nom >0.6 nom

1-2 closed, 2-3 opened 1-2 opened, 2-3 closed

From -30oC to+100o C 0,4 Mpa see drawing 0.8A 220V D.C No limitations No required 1.33 kg

Electrical connection

Design and operation: case 1 of the WPC indicator made of aluminium alloy, is provided with two separate chambers. One chamber houses a pivoted rod 2 with a magnet and flap 3, actuated by liquid flow in a pipeline. The other chamber houses a pivoted second magnet with an optical indicator 4. The magnets move in synchronism which allows to observe the liquid flow optical indicator through a suitable sightglass. The second magnet actuates contacts of two reed switches to enable remote observation of the flow or no-flow conditions. The WPC indicator construction precludes the flowing liquid from crossing the case partition three sizes to suit various pipe line diameters. The indicator is fitted to a flanged stub pipe , welded to the pipeline. Electric cable enters the indicator case through a P 13.5 gland on the case back and is connected to suitable terminal blocs, accessible after removing cover 5. Note: Orders must include your pipeline diameter DN and flow direction (right or left, right shown above on the drawing) INSTYTUT ENERGETYKI ODDZIA£ TRANSFORMATORÓW ul.Kopernika 56/60 90-553 £ódŸ

Telefon: +48(0-prefix-42) 637 14 66 Telefax: +48(0-prefix-42) 637 17 22 e-mail: [email protected] htpp://www.ienot.com.pl

Elektromotoren und Gerätebau Barleben GmbH

OPERATING INSTRUCTIONS

Transformer Protection Relay (Buchholz Principle)

Elektromotoren und Gerätebau Barleben GmbH CONTENT

Item No.

Heading

Page

1.

Installation

3

1.1.

Installation in piping

3

1.2.

Filling the Buchholz relay

4

1.3.

Draining the Buchholz relay

4

1.4.

Electrical connection

4

2.

Functional test

8

2.1.

Testing by means of test button

8

2.1.1.

Single-float Buchholz relay

8

2.1.2.

Double-float Buchholz relay

9

2.2.

Testing by means of test pump

9

3.

Changing the contact setting

10

4.

Changing the damper setting

11

4.1.

Single-float Buchholz relay

11

4.2.

Double-float Buchholz relay

11

5.

Maintenance

11

2

Elektromotoren und Gerätebau Barleben GmbH 1. Installation 1.1.Installation in piping (Figure 1) The Buchholz relay (2) is installed in the piping (4) connecting the tank (1) of the device to be protected (transformer, reactance coil) with the expansion tank (5).

0°...5°

0°...5°

5 R >

2

50

0°...5°

4 R>

50

1

3

2

4

1

Figure 1 Installation in piping

Make sure that -

the red arrow on the Buchholz relay points to the expansion tank

-

the slope of the piping to the expansion tank is neither below 0° nor above 5°

-

oblique position of the Buchholz relay transverse to the direction of flow does not exceed 5° related to the perpendicular

-

the piping has no elbows, and bends are formed preferably with an inside pipe radius of R>50mm

-

the free pipe length between the Buchholz relay and the nearest reference point does not exceed the following values:

Nominal pipe diameter Distance (m)

DN 25

DN 50

DN 80

0.5

0.7

1.0

Should the distance exceed the above values, a support has to be provided in the immediate vicinity of the Buchholz relay. During installation make sure that no dirt, moisture or foreign matter penetrates in the relay. 3

Elektromotoren und Gerätebau Barleben GmbH 1.2. Filling the Buchholz relay (Figure 2) •

Remove small cap nut (1) from test valve (2)

•

Open test valve and let the air escape from the Buchholz relay

•

Close test valve as soon as insulating liquid comes out

•

Screw small cap nut onto test valve and tighten

Figure 2 Filling the Buchholz relay

1.3. Draining the Buchholz relay (Figure 1) •

Close shut-off valve (3) on the expansion tank side (5) Open the Buchholz relay.

Remove the Buchholz relay.

Lower the insulating liquid level to the top inspection glass marking

Lower the insulating liquid level to the lower interior wall of the pipe

1.4. Electrical connection (Figure 3) The terminal box is safe to touch and protected against pollution. To connect the cables, proceed as follows: •

Remove screws (2)

•

Remove cover ((1)

•

Insert cable through cable gland (3)

•

Connect cable to the marked terminal stud (4) (wire range: max. 4 mm²)

•

Fit cover

•

Fit screws and tighten

Figure 3 Electrical connection

Note: Remove temporary lock (Figure 5, Page 9) ● ● ●

Remove large cap nut (1) Remove temporary lock (2) from the large cap nut Fit large cap nut without temporary lock

Terminal assignment is shown in the following diagrams.

4

Elektromotoren und Gerätebau Barleben GmbH Single-float Buchhholz relay Contact setting, switching system (disconnection): 1 normally-closed 1 normally-open contact (NC) contact (NO)

12

13

11

21

13

23

12

14

12

22

14

24

14

11

13

11

14

12

13

2 normally-open contacts (NO)

11

13

12

Contact setting, switching system (disconnection): 1 change-over contact 1 normally-open contact (NO) and 1 normally-closed contact (NC)

14

2 normally-closed contacts (NC)

11

12

1

4

2 2

1

4

5

11

21

22

14

13

23

24

Elektromotoren und Gerätebau Barleben GmbH Double-float Buchholz relay Contact setting, upper switching system (warning): 1 normally-closed contact 1 normally-closed contact (NC) (NC)

1 normally-open contact (NO)

11

11

13

13

12

12

14

14

Contact setting, lower switching system (disconnection): 1 normally-closed contact 1 normally-open contact 1 normally-open contact (NC) (NO) (NO)

12

1 normally-open contact (NO)

1 normally-closed contact (NC)

21

13

23

11

22

14

24

12

11

22

21

12

11

14

14

13

13

24

23

14

13

12

11

Contact setting, upper switching system (warning): 1 normally-closed contact 1 normally-closed contact 1 normally-closed contact 1 normally-closed contact (NC) (NC) (NC) (NC) and 1 normallyopen contact (NO) 11

11

11

11

13

12

12

12

12

14

Contact setting, lower switching system (disconnection): 2 normally-closed 2 normally-open contacts 1 normally-open contact contacts (NC) (NO) (NO) and 1 normallyclosed contact (NC)

12

1 normally-closed contact (NC) and 1 normally-open contact (NO)

21

31

13

23

13

21

21

23

12

32

14

24

14

22

22

24

11

22

21

32

31

12

11

14

13

24

23

12

6

11

14

13

11

12

21

22

22

21

13

14

23

24

Elektromotoren und Gerätebau Barleben GmbH Double-float Buchholz relay Contact setting, upper switching system (warning): 1 normally-open contact 1 normally-open contact (NO) (NO)

1 normally-open contact (NO)

13

13

13

13

23

14

14

14

14

24

Contact setting, lower switching system (disconnection): 2 normally-open 2 normally-closed 1 normally-open contact contacts (NO) contacts (NC) (NO) and 1 normallyclosed contact (NC)

14

2 normally-open contacts (NO)

23

33

11

21

23

11

33

43

24

34

12

22

24

12

34

44

13

24

23

34

33

14

13

12

11

22

21

14

Contact setting, upper switching system (warning): 1 change-over contact 1 normally-open contact (NO)

24

22

13

24

23

14

13

34

33

12

11

24

23

44

43

1 change-over contact

23

21

21

22

24

24

Contact setting, lower switching system (disconnection): 1 change-over contact 1 change-over contact 1 normally-open contact (NO) 11

12 22

2 normally-open contacts (NO)

21

11

14

12

24

14

12

11

24

13

14

14 22

14

23

12

11

21

24

14

7

13

Elektromotoren und Gerätebau Barleben GmbH Explanation of symbols: Example: Single-float Buchholz relay Graphical symbol with --- terminal marking and identification number

11

12 12

11

---

Terminal assignment in terminal box

Note: The switching systems are shown in their normal position, i.e. with the Buchholz relay filled completely with insulating liquid corresponding to trouble-free operation of the device to be monitored. A plate showing the connection diagram and the terminal assignment is arranged inside the cover. Connected load:

Voltage Current

AC DC AC DC

12 volts to 250 volts 12 volts to 250 volts 0.5 to 2 amps cos φ ≥ 0.4 0.05 to 2 amps τ = L/R ≤ 75 ms

2. Functional test 2.1. Testing by means of test button 2.1.1. Single-float Buchholz relay (Figure 4) •

Remove large cap nut (1)

•

Press test button (3) down to position 1 (stop position), keep depressed

•

Obtain verification of correct function from control room

• •

Release test button Fit large cap nut Figure 4 Operation/testing

8

Elektromotoren und Gerätebau Barleben GmbH 2.1.2. Double-float Buchholz relay (Figure 5) •

Remove large cap nut (1)

•

Press test button (3) down to position 1 and keep depressed (upper switching system check)

•

Obtain verification of correct function from control room

•

Press test button down to position 2 (stop position) and release button (lower switching system check)

•

Obtain verification of correct function from control room

•

Note: Unlock the damper of the Buchholz with the identification number 23 by turning the test button counterclockwise

•

Fit large cap nut

x = Actuator travel Figure 5 Operation/testing

2.2. Testing by means of test pump (Figure 6) •

Remove small cap nut (1) from test valve (2)

•

Fit adapter (4) of the hose (3) providing the connection to the test pump on the valve nozzle (5)

•

Open test valve

•

Pump air into the Buchholz relay until falling of the (upper) float causes the magnetic switch to respond

•

Obtain verification of correct function from control room

•

Close test valve

•

Remove adapter from valve nozzle

•

Open test valve and let the air escape

•

Close test valve as soon as insulating liquid comes out

•

Fit small cap nut on test valve and tighten

9

Figure 6 Testing by means of test pump

Elektromotoren und Gerätebau Barleben GmbH 3. Changing the contact setting (Figure 7) Setting of contacts of the switching system is in accordance with client’s requirements. The contact setting „NO contact“ can be changed subsequently to „NC contact“, and vice versa. Switching systems equipped with change-over contact magnetic switches are provided with a fixed setting which does not allow subsequent changes. Changing the contact setting To change the

1

setting, proceed as follows:

2 Ö

•

Drain the Buchholz relay

•

Remove M8 hexagon screws from cover

•

Remove cover with switch mechanism from housing

•

Loosen M3 fillister head screw (1)

•

Turn magnetic retainer (2) to position „Ö“ (NC contact) or „S“ (NO contact) as far as to stop position

•

Tighten M3 fillister head screw

•

Fit cover with switch mechanism in housing

•

Make sure that - the red arrow on the Buchholz relay points to the conservator, and - seal and sealing surfaces are free from insulating liquid

• •

Tighten M8 hexagon nuts evenly Fill Buchholz relay and perform functional test

S

S Ö S = normally-open; Ö = normallyclosed Figure 7

4. Changing the damper setting (Figure 8, Figure 9) Setting of the damper is in accordance with client’s requirements. Subsequent change of setting is possible only when the damper is set to 0.65 m/s, 1.0 m/s or 1.5 m/s, then it can be set to one of the other two values. Settings other than those can be made by the manufacturer. However, such settings cannot be changed subsequently. To change the setting, proceed as follows: •

Drain the Buchholz relay

•

Remove M8 hexagon screws from cover

•

Remove cover with switch mechanism from housing

10

Elektromotoren und Gerätebau Barleben GmbH 4.1. Single-float Buchholz relay (Figure 8)

3

•

Displace the damper top part (3) until the cams snap in the damper bottom part (1) when the desired operating value is reached

•

Tighten the setscrew

Ö

Loosen the setscrew (2)

S

•

0,6 1,0 5 0 1,5 0

1 2

Figure 8 Setting the damper

4.2. Double-float Buchholz relay (Figure 9) •

Loosen the setscrew (2)

•

Lift the magnetic retainer (1) out of the lock-in slot (3) from the intermediate plate (4) and displace until the desired operating value appears in the window (5)

•

Snap in the magnetic retainer

•

Tighten the setscrew 1

2

3

4

5

•

Fit cover with switching mechanism in the housing

•

Make sure that - the red arrow on the Buchholz relay points to the conservator, and - seal and sealing surfaces are free from insulating liquid

•

Tighten the M8 hexagon screws evenly

Figure 8 Setting the damper

5. Maintenance Buchholz relays are relatively insensitive to ambient conditions. Therefore, no special maintenance is required during operation. Buchholz relays should be inspected and tested as specified in the maintenance instructions of the plant operator. Make sure that the functional tests described are performed. Gas accumulations can be analysed by means of a gas analyser. An auxiliary device allows gas sampling at normal service height. 11

Elektromotoren und Gerätebau Barleben GmbH

ELEKTROMOTOREN UND GERÄTEBAU BARLEBEN GmbH Bahnhofstraße 27/28 39179 BARLEBEN/ GERMANY Phone: +49 39203 79-0 Fax: +49 39203 53 30 Fax: +49 39203 54 50 e-mail: [email protected] Website: http://www.emb-online.de

Buchholz relay – 01/02/04/02 - Englisch The parameters given in this technical information are subject to changes due to technical modifications.

12

      

       ! "!#$#$"$$ The transformer tank filled with cooling liquid is a container subject to internal pressure and then has to be provided with one or more safety valves suitably calibrated for the maximum allowed pressure, so that overpressure caused by internal faults else can be instantaneously relieved through the valves, thus avoiding greater damages such as the deformation or even the burst of the tank and the spraying of oil with subsequent fire risks. It is necessary to protect the transformer tank with a suitable equipment capable of almost instantaneously discharging overpressure already at the development, before the structure integrity is damaged and    has just this function

   The safety valves consist schematically of:  a    comprising the valve opening with its specially profiled gasket and a seat for an Oring gasket on the flanged end towards the transformers tank;  a    pressed against the profiled gasket by calibrated helical spring, thus making the valve completely tight up to the rated pressure;  a single or a double    (on request).  a     to avoid damages caused by hot oil sprinkles (on request);  %   &'IP 65  '2000V 50Hz between terminals and earth for a 60 secs. time

(&'PG 13,5  )  %(* &  ' 10A 250V AC 1A 125V DC

       The safety valves are built with different Mayor Diameters and rated pressure to satisfy the requirements of the various applications. TYPE

MAYOR DIAMETER

RATED PRESSURE

PREVAILING USE

T 200

200mm.

0,3  0,7 bar

big power transformers

T 125 - VS 150

125mm.

0,3  1

bar

big power transformers

VS 100

100mm.

0,3  1

bar

medium power transformers

T80 - VS 80

80mm.

0,3  1

bar

small power transformers

T 50

50mm.

0,3  1

bar

cable boxes - small tanks

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

1

              ' the advantage of safety valves serie VS consists in the total b j i i the transformers tank making the mounting point choose easier. absence off projecting parts in These valves can be mounted, with regards to their base plane, both horizontally on the cover and vertically on thetransformer walls at the points where their safety action is presumed to be more necessary.     'the advantage of safety valves series T is that, showing the same effectiveness and reliability of valves serie VS, their simplicity consent to obtain very competitive prices.

   + ,-.

2 Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

127.0



 

142.5 160.0

 



DN150

 

199.0

4

4 50.0

190.0

285.0 294.0

16.

              + ,-.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

3

100.0

88.0

100.0

112.0

100.0



 

DN100 18

 



158.0

4

4 102.5

102.5

15.0 25.0

170.0

       + ,..

4 Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

"$/#"$/""0 !  The data about the transformer point where a short circuit is most likely to occur, the preferential direction the resulting shock wave may have, the intensity this one can reach, all depend on the transformer power, its transformation ratio, its construction characteristic and the behaviour of the other installed protection equipment. Therefore, is not possible to give strict rules about safety valves application. It is the manufacturer who must decide each time and on his own experience the valve type and its position. It is important to take these general suggestions into due consideration for a correct choice:       

     When a single valve is mounted the barycentric position with regards to these points shall be chosen;        

                   ;                       . Therefore, before operating the transformer, it is important to let possibly accumulated air come out through the suitable breather screw and above all to mount the valve so that the possible gasbubbles developed during operation can not accumulate on the valve;        

      .

/""0"1"""# The safety valves mounting is carried out by means of the suitable fastening holes of the flange, after the splash diverter removal and after the insertion of the O-ring gasket supplied with the valve. After the transformer filling, the air developed under the valve must be breathen by unscrewing the suitable breathing screw. This breathing screw shall be tightened again as soon as the oil starts to come out. During operation the safety valves do need a particular maintenance. Nevertheless, it is convenient to regularly check the electric contact good operation and to verify if there is no gas accumulation.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

5

"$/#"$$1$"0 !  The exhaust rated diameter shall be connected with the transformer oil quantity and with the number of mounted valves. When a single valve is mounted the barycentric position, with regards to the points where a failure is most likely to occur, must be chosen. To help the Technical Department to state types and number of valves to be mounted on a transformer, is possible to study the following indicative table: VALVE TYPE

OIL QUANTITY

VS 50 -T 50 T 80 VS 80 VS 100 T 125 VS 150 T 200

up to 1.000 dm3 (900Kgs.) up to 4.000 dm3 (3.600Kgs.) up to 6.000 dm3 (5.400Kgs.) up to 20.000 dm3 (18.000Kgs.) p to 20.000 dm3 ((18.000Kgs.) g ) up up to 35.000 dm3 (31.500Kgs.) up to 40.000 dm3 (36.000Kgs.)

In case of tanks containing larger quantities of oil must be mounted 2 or more valves of suitable dimensions (i.e.: if oil quantity is 95.000dm3 must be mounted 3 valves type VS 150 or 2 valves T 200 + 1 valve T 125).

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

6

 % 2  

             the aluminium alloy case is mounted on the wall of a tank filled with oil at the temperature of 90and at the pressure of 300 kpa.After 8 hours no leakages must be observed. The same test is carried out for float.

           the safety valve is mounted on a testing pressure circuit at the atmosferic pressure value. The pressure, controlled by a microprocessor based monitoring unit and recorded by a special recording instrument, slowly increases up to the Operating Pressure value - 5 kpa. The valve remains at this pressure value for 6 hours. During this period the valve must be completely sealed. Following three different gradients the pressure increases again to the Operating Pressure value. Itverified that the effective pressure of opening of the valve is contained in the following interval : O.P. -5% < O.P. < O.P. +8%.

      this test is performed by means of visual indicators mounted on a panel board. Commutation tolerance, commutation differential and electrical circuits are verified.

            

 IP 65.     carried out by means of a microprocessor controlled testing unit.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

7

Elektromotoren und Gerätebau Barleben GmbH

Monitoring relay for tap changers 1

Elektromotoren und Gerätebau Barleben GmbH Firm’s history

Preface

Since its foundation the company has been passed through an eventful history with regard to ownership, affiliation and connected with this changes of firm names.

The Monitoring relay for tap changers, also named protection relay for tap changers or oil flow relay, is a monitoring relay for oil-insulated tap changers. It protects the tap changer and the transformer from damage. On response the monitoring relay will generate a signal disconnecting immediately the tap changer and the transformer from the source of supply.

1863

Foundation of the company as sugar factory

1943

Establishment of SIEMENS Magdeburg

1948

VEB1 Elektromotorenwerk Barleben; VEM (state-owned firm)

1951

VEB1 Starkstromanlagenbau Magdeburg (state-owned firm)

1951

Start of manufacturing Buchholz relays at site in Barleben

1965

Start of manufacturing Monitoring relays for tap changers at site in Barleben

1970

VEB1 Elektrotechnik und Gerätebau Magdeburg; EGEM (state-owned firm)

1980

VEB1 Kombinat Elektromaschinenbau Dresden VEB1 Elektromotorenwerk Barleben; VEM; ELMO (state-owned firm)

1990

VEM Antriebstechnik AG Dresden Elektromotorenwerk Barleben GmbH; VEM; ELMO (public limited company)

1993

Elektromotoren und Gerätebau Barleben GmbH; EMB (privately owned company)

1

The company has had for more than 40 years experience in producing Monitoring relays and other protection devices for liquid-cooled appliances. It ranks among the most distinguished manufacturers of this kind of equipment. Experiences collected and profound know-how are the sound basis for a high product quality. References from reputed transformer and tap changer manufacturers as well as further users are proof of the high level of the products. The company is DIN EN ISO 9001/2000 certified. The staff of highly qualified engineers and experienced skilled workers do their best to guarantee top quality high-precision products.. The mechanical working of the casings is done on modern CNC-controlled machine tools. The final tests, where all the functions of the Monitoring relays are checked, are done with each device by using special test equipment. Each device is delivered with a test certificate.

Monitoring relays may be used in open-air or also in indoor equipment.

VEB = nationally owned firm 2

1. Design features Casing (Figure 1) The casing is a weather-resistant casting of light alloy and is provided with a paint coat. To check the switching system for proper function, the casing is provided with inspection glasses arranged opposite each other, protected by hinged lids (1).

1

Figure 1 : casing

Cover (Figure 2)

5

The cover is a weather-resistant casting of light alloy and is provided with a paint coat. Terminal box, test and reset button (1), covered by a cap nut as well as a bleeder screw (2) are arranged above the cover. The terminal box has an earthing contact (3) and the electrical connectors (4). By means of a removable cap (5) the terminal box is safe to touch and protected against pollution. The cable is to be brought in the terminal box through the cable gland (6).

6 3 4 2

1

Figure 2 : cover with dismantled cap (The picture shows the identif.no. 25 of table 2.)

Switchgear (Figure 3) The switchgear has the following main components: Switching system Carrier, frame Mechanical testing device. The switching system consists of the following components: damper (1) switching magnet(s) (2) magnet contact tube(s) (3)

3 2

2 1

3 Figure 3 : switchgear (The picture shows the identif.no. 25 of table 2.)

The damper is retained in its normal and response positions by permanent magnets. Via a link the switching magnet is firmly connected with the damper and initiates the contact-making process of the magnet contact tube at a certain oil flow.

3

Elektromotoren und Gerätebau Barleben GmbH 2. Function The Monitoring relay has to be mounted into the pipe leading from the tap changer head to the oil conservator – located as near as possible to the tap changer head. Due to the working method of the tap changer there is gas inside the gas collecting dom of the device. In case of oil flow the Monitoring relay responds as follows: Fault : An incident generates an oil flow in the direction of the conservator. Response: The liquid flow reaches the damper arranged in the liquid flow. If the flow rate exceeds the operating threshold of the damper, the latter moves in flow direction. Due to this movement a switch contact is actuated. For that the tap changer and the transformer are disconnected. Figure :4 : principle of working method of the damper

3. Technical data Table 1 Parameter Nominal voltage Nominal current Contact voltage capacity Insulation voltage capacity Temperature range: - ambient temperature

Data

Notes

AC 230 V DC 230 V AC 2 A DC 2 A AC 1000 V AC 2000 V

12 V to 250 V 12 V to 250 V 0.05 A to 2 A 0.05 A to 2 A -Contact against casing

-45oC to +55o C -49o F to +131o F

Others on request

- working range * temperature of the insulation liquid -25oC to +115oC -13o F to +239o F 1 mm2/s to 1100 mm2/s * viscosity of the insulation liquid Switching system: - Switching contact magnet contact tube - damper Response time of damper Response values of the damper

Resistance to pressure Resistance to vacuum Cable gland Degree of protection Nominal installation position

hold by magnets < 0.1 s 0.9 m/s 2.0 m/s 1.0 m/s 2.5 m/s 1.2 m/s 3.0 m/s 1.5 m/s 4.0 m/s 0.25 MPa < 2.5 kPa M 20x1.5 IP 54 ≥ 2 o ascending towards expansion vessel

Others on request Others on request normally-open, normally-closed, change-over Others on request

--Others on request Others on request 2 ° to 4 o

4. Special designs Table 2 Explanation

Identif.no.

Climatic version (suited for tropical open-air climates) Climatic version (suited for extrem frigidal open-air climates below –45 °C) Special design approved by RWE, Germany (formerly ÜRF 25/10-3) Switching system equipped with two magnet contact tubes (formerly ÜRF 25/10-2) Customer request on the basis of conditions agreed with the manufacturer 4

22 34 24 25 29

5.Types and Dimensional sketches 5.1. Type 12 ÜRF 25/10

5.2. Type 15 ÜRF 25

6. Ordering data For placing orders, please, use the following key :

XX Type code no. (see para.5) Special design (see table 2)

Important remark: NO = normally-open NC = normally-closed

XX . . . XX .

X

Damper setting 1 = 0,9 m/s 2 = 1,0 m/s 3 = 1,2 m/s 4 = 1,5 m/s 5 = 2,0 m/s 6 = 2,5 m/s 7 = 3,0 m/s 8 = 4,0 m/s 9 = special agreement with the customer

Ordering example: Monitoring relay ÜRF 25/10 12-22.25.-56 Explanation: 12 = ÜRF 25/10

X

Contact setting of switching system 1 = one NO-contact 2 = one NC-contact 3 = one change-over contact 4 = two NO-contacts 5 = two NC-contacts 6 = one NO-contact and one NCcontact 7 = two change-over contacts 8 = one NO-contact and one changeover contact 9 = one NC-contact and one changeover contact

22 = climatic version 25 = switching system equipped with 2 magnet contact tubes 5 = damper setting of 2.0 m/s 6 = contact setting of the switching system – 1 NO-contact and 1 NC-contact

5

Elektromotoren und Gerätebau Barleben GmbH 7. Tests To each Monitoring relay a works-number is given mentioned in the test certificate. Furthermore the tests made with the Monitoring relay are documented in the test certificate:

-

Dielectric strength test (AC 2000 V against casing) Leakage test (25 min with 80o C warm transformer oil at 0.25 MPa) Functional test (damper setting) .

The Monitoring cardboards.

relays

are

delivered

in

transport

With each device we deliver -

operating instructions test certificate

in the desired language.

DIN EN ISO 9001:2000 certificate

Flow test

Functional and leakage test

6

8. Further products Elektromotoren und Gerätebau Barleben GmbH may supply also products for protection and supervision of liquid-insulated transformers and choke coils. Please, ask for our separate catalogues. Designation

Description

BR

Buchholz relays Transformer protection relays (Buchholz principle)

NEW

NM series – Buchholz relays with analog measurement of the gas volume

ZG 1.2.

Gas sampling device The device is mounted at the transformer and connected to the Buchholz relay by means of a pipe. It allows to sample the relay gas at normal operating level. The device can be delivered with a lockable box.

ZG 3.1.

Gas testing device The device serves to analyze the relay gas by means of two test fluids. It can be mounted directly on the Buchholz relay as well as on the Gas sampling device ZG 1.2.

ZG 4.1.

Reflux lock The device prevents that the insulation liquid gets into the Gas testing device. Test pump The device serves to check the upper switching system by means of air.

ZG 5.1. ZG 5.2.

- manual-actuated - foot-actuated

ZG 6.1.

Oil sampling device The device is connected to the Buchholz relay by means of a pipe and serves to take oil samples (can be used for Buchholz relays with oil drain plug).

BGS

Buchholz gas sampler The Buchholz gas sampler can be connected to the Buchholz relay or to the Gas sampling device. It serves to sample and to transport safe the gas.

BGT

Buchholz gas tester The Buchholz gas tester serves to analyze the Buchholz gas regarding the hydrogen concentration.

SG 25 SF 25

Oil flow indicator - with thread connection - with flange connection

7

Elektromotoren und Gerätebau Barleben GmbH

Bahnhofstraße 27/28 39179 Barleben / Germany Phone: Telefax: Telefax:

+49 39203 790 +49 39203 5330 +49 39203 5450

E-Mail: Internet:

[email protected] http://www.emb-online.de

Edition: Catalogue Monitoring relays 01 / 05 English

Due to technical improvement of our products, the information contained in this brochure may be subjected to change without notice.

8

Pressure relay for on-load tap-changers Technical information

30

54

67

Switching contact - micro switch

Cable diameter 6 - 13 mm

ABB Components

Pr 22.5 ~35

~200

Adjusting nut Spring Piston

;; ;;

110

Two single-pole switching contacts

One single-pole switching contact

Connection for test equipment ~155

15

32

11

NO NC C NO NC C 64 66 65 61 63 62

NO NC C 61 63 62

General description

Operation

Protection for the on-load tap-changer is provided by a pressure relay which is mounted on the tap-changer oil compartment. In the event of an overpressure in the tap-changer oil compartment, the pressure relay will trip the transformer main circuit breakers.

When the pressure acting on the face of the piston exceeds the spring load of the piston, the piston will move and activate the switching element. See fig.

Design The pressure relay is mounted on a three-way valve. On the other two outlets of the valve there is a connection flange on one side, and a connection for test equipment on the other, see fig. The relay is made of copper-free aluminium alloy and is externally coated with an enamel. A stainless steel model can be provided on request. Degree of protection IP66. The function pressure (set point) has been set by the manufacturer in accordance to the requirements for each application. The electrical connection shall be made to the terminal block mounted onto the pressure relay. The pressure relay is designed for one or two switching elements (micro-switches). The micro-switch is hermetically sealed and filled with nitrogen with over-pressure, and separated from the connection space with a sealed cap. The pressure relay should always be disconnected during voltage test. 2 kV test has already been carried out. Breaking capacity Resistive load

Inductive load

110 V DC

0.8 A

0.2 A

125 V DC

0.6 A

220 V DC

0.4 A

125 V AC

5A

L < 40 ms R 0.15 A L < 40 ms R 0.1 A L < 40 ms R 5 A cos ϕ ≈ 0.4

250 V AC

2.5 A

2.5 A cos ϕ ≈ 0.4

Function pressure The value of the adjusted function pressure (set point) depends on the distance (H) between the pressure relay and the oil level in the oil conservator. Further information in the Technical, Installation & Commissioning, Maintenance and Repair Guides for each type of on-load tap-changer.

Mounting details The following parts are supplied together with the pressure relay: studs M10x40 (4x), nuts M10 (4x), washers 10x22x2 (4x) and O-ring 44.2x55.6 (1x).

Withstand voltage between contacts and earth

Distance H in metres 2 kV, 50 Hz, 1 min

Table 1. Technical data - Micro-switch

ABB Power Technologies AB Components SE-771 80 Ludvika, SWEDEN Tel.+46 240 78 20 00, Fax +46 240 121 57 E-mail: [email protected] www.abb.com/electricalcomponents

Type of OLTC

Function pressure (set point)

H<4

UZ

50 kPa (7 psi)

4≤H<7

UZ

100 kPa (14 psi)

H<7

UB, UC

125 kPa (17.5 psi)

7 ≤ H < 14

UB, UC

200 kPa (28 psi)

Table 2. Function pressure

Manufacturer: BETA B.V., Rijswijk, The Netherlands

Printed in Sweden by Globe, Ludvika, 2005

1ZSE 5492-151 en, Rev. 5, 2005-03-15

Voltage

The function time is less than 15 ms in the temperature range of -40 °C to +80 °C, with a pressure increase of 20-40 MPa/sec. The function time is the time from the pressure in the on-load tapchanger oil compartment exceeds the adjusted set point of the pressure relay until the pressure relay gives a stable signal for operating the main circuit breakers.

1/2

2/2

Q Qualitrol GmbH Willstätterstr. 49 40549 Düsseldorf / Germany Fon +49-211-5288374 Fax +49-211-5288367

Electronic Transformer Monitor for Liquid-Filled Transformers

509-100

Operations Manual IST-072-1

QualiTROL Electronic Transformer Monitor for LiquidLiquid-Filled Transformers Operations Manual

TABLE OF CONTENTS Table of Contents _______________________________________________________ i Overview ______________________________________________________________1 QualiTROL Electronic Transformer Monitor......................................................................1 QualiTROL...............................................................................................................................2 About This Manual ..................................................................................................................2

Controls, Indicators, and Modules _________________________________________3 Front Panel ...............................................................................................................................3 Modules.....................................................................................................................................4 509-RTD Input Module.......................................................................................................4 509-CT Input Module..........................................................................................................4 509-Potentiometer Input Module ........................................................................................4 509-Voltage Input Module ..................................................................................................5 509-Current Input Module...................................................................................................5 509-Dry Contact Closure Module .......................................................................................5 509-Powered Contact Closure Module ...............................................................................5

Installation _____________________________________________________________6 Location and Mounting ...........................................................................................................6 Power Supply............................................................................................................................7 Heater Option...........................................................................................................................7 RTD Input Module ..................................................................................................................8 CT input Module......................................................................................................................8 Potentiometer Input Module...................................................................................................9 Voltage Input Module............................................................................................................10 Current Input Module...........................................................................................................10 Dry Contact Closure Input Module .....................................................................................11 Powered Contact Closure Input Module .............................................................................12 Output Contacts.....................................................................................................................12 Remote Output Signals..........................................................................................................13 Communications ....................................................................................................................14

ECN 22852

i

April 19, 2002

Operation _____________________________________________________________15 Automatic Operation .............................................................................................................15 Viewing Channels (Viewing Mode Scrolling) ...................................................................15 Menu Mode .......................................................................................................................15 Program Mode...................................................................................................................16 Testing the System .................................................................................................................17

Functional Specification _________________________________________________18 Appendix _____________________________________________________________19

ECN 22852

ii

April 19, 2002

QualiTROL Electronic Transformer Monitor for Liquid filled Transformers Operations Manual OVERVIEW QualiTROL Electronic Transformer Monitor The QualiTROL Electronic Transformer Monitor (ETM) for Liquid-Filled Transformers (Model #509-100 Series) is an Intelligent Electronic Device (IED). Combining microprocessor technology and advanced digital signal processing, to accurately assess the health, and performance of three phase or autotransformers. The 509 can be tailored to suit the application. The ETM can monitor up to eight total parameters. Requiring inputs from Resistance Temperature Detectors (RTD’s), Current Transformers, Current loops (0-1 or 4-20 ma DC), Voltage (0100 mv or 0-10V), or Switch Contact Closure, this complete transformer monitoring system can monitor parameters such as: Liquid Temperatures (Main Tank Top or Bottom, Load Tap Changer), Winding Temperatures, Ambient Temperatures, Winding Current, Cooling Bank Currents, and a variety of parameters from transducers such as Tank Pressure, or Dissolved Gas in Oil analysis. The 509 Transformer Monitor offers: n

Advanced thermal modeling of winding temperatures

n

Superior temperature control for higher loads

n

Integrated Load Tap Changer temperature monitoring

n

Stand alone or networked substation monitoring

n

Diagnostic tool for condition based maintenance

n

Eight (8) form C adjustable relays to operate cooling equipment, signal alarms, and provide trip functions, depending on transformer conditions

n

Up to four (4) 0-1 or 4-20 ma DC loops for use with SCADA systems

n

Digital communication ports RS-232, RS-485

The device is extremely easy to install and use. It is designed to be mounted outdoors (heater available inside enclosure), or in the transformer control cabinet and is powered by a universal power supply of 90-264 VAC 47-63 Hz single phase power or 40-290 VDC. It comes with user friendly computer aided setup software, and can be supplied with non-intrusive, easy to retrofit sensors. 1

Electronic Transformer Monitor

QualiTROL QualiTROL has been a leader in supplying pressure, liquid level, and temperature controls since 1945. An ISO 9001 system certified company, we are committed to providing you with quality and reliability, both in our products and in our service.

About This Manual This manual provides all the information you will need to configure, install, and operate your QualiTROL Electronic Transformer Monitor. It is organized into the following sections: Controls, Indicators, and Modules — Diagrams and brief descriptions to help you locate and understand basic functions of each of the controls, indicators, and modules that make up the QualiTROL ETM. Installation — Step-by-step, illustrated instructions to guide you through mounting, supplying power to, and wiring your Transformer Monitor. Operation — A description of automatic operation, as well as easy instructions on how to view parameters, and set points, reset memories, program the ETM using the Keypad, and test the system. Functional Specification — A detailed functional specification of the unit. Appendix — A functional wiring diagram for your reference, an example of the front panel menu diagram, a rear cover view and a Configuration Table in which to record settings and connections to the ETM.

2

Electronic Transformer Monitor

CONTROLS, INDICATORS,

AND

MODULES

Front Panel The functions of the display and the keypad on the Front Panel are described below. For operating instructions, refer to the “Operation” section. DISPLAY — Automatically scrolls through the channels and displays the channel name and the value of the parameter every 2 seconds. Also used to display the selected indications of the keypad control. Keypad — The ENTER key is used to change menu modes or accept changes to values, the TEST key displays the setpoint source and value on the DISPLAY, the MENU key is used to access the programming menu, The RESET key is used to reset the maximum and minimum values (while in the program menu) The ARROWS keys are used to move around in the various menus. For a full operation description, refer to the “Operation” section. Set Point Indicators — A red LED illuminates to indicate that the set point for the relay indicated on the overlay has been exceeded. RS-232 Port —When used with the QualiTROL software, this port allows for the setup of all of the parameters of the Transformer Monitor. See Software Manual for a full description of this set up procedure.

3

Electronic Transformer Monitor

Modules The modules comprising the QualiTROL ETM include: n

509-RTD Input Module

n

509-CT Input Module

n

509-Potentiometer Input Module

n

509-Voltage Input Module

n

509 Current Input Module

n

509-Dry Contact Closure Module

n

509-Powered Contact Closure Module

This section describes the function and key components of each of these modules.

509509-RTD Input Input Module RTD Input Modules are provided for monitoring Liquid, Ambient or if used in a heated well, winding temperatures. The input to the module is either a 10 ohm copper or a 100 ohm platinum RTD(factory configured). For measuring Liquid or Ambient temperatures the Module is scaled over the range of –40°C to 120°C. If it is used in a heated well then the scale is –40° to 200°C. This needs to be specified when ordering the 509 unit from the factory.

509509- CT Input Module The CT Input Module is provided for monitoring Winding Temperatures, Winding Currents, Motor Currents of LTC’s or fan currents. The inputs to the module is a clamp on CT provided by QualiTROL, that have an input range of 05A, 0-10A or 0-20A (other ranges available), and have an output of 00.333VAC(to be used as the input to the CT Input Module). If this Module is used for temperatures, the scaling is in the range of -40°C to 200°C; for anything other than temperature, the range is scalable to a maximum of 99999.9.

509509-Potentiometer Input Input Module The Potentiometer Input Module is provided for monitoring Liquid Level, Flow Gauges, or Gas Accumulation. The input to the module is a potentiometer (typically supplied by QualiTROL). The range of the potentiometer input is 5000 ohms. Typically, the 25°mark on a liquid level dial is set to the center of the potentiometer range, and the high and low readings are simply ratios of the angular deflections from the “normal”(QualiTROL gauges use a 340 angular degree potentiometer on a 2:1 gear ratio from the dial travel to the potentiometer travel). The Scaling of the ETM is 0 to 100 percent for this module.

4

Electronic Transformer Monitor

509509-Voltage Input Module The Voltage Input Module is provided for Monitoring Transducer outputs with an output signal in either the 0-100 mV DC or 0-10VDC volt range. The range is scalable to a Maximum of 99999.9 for this module.

509509- Current Input Module The Current Input Module is provided for Monitoring Transducer outputs with an output signal in either the 0-1 ma DC or 4-20 ma DC range. These could be devices such as pressure transducers for measuring main tank pressure, bushing pressure, or dissolved gas in oil transducers. The input module can be configured to operate with either two wire loop transducers (powered by the module), or three wire transducers, either powered by the module, or powered from the transducer. The range is scalable to a Maximum of 9999.99 for this module.

509509-Dry Contact Closure Module The Contact Closure Module is provided for Monitoring a contact and simply indicating on the display whether it is open or closed. This can be used to ensure or monitor pumps or fans for example. This Module can monitor a non-powered (dry) contact.

509509-Powered Contact Closure Module The Powered Contact Closure Module is provided for Monitoring a powered contact and simply indicating on the display whether it is open or closed. This can be used to monitor alarms or active fans for example. This Module can monitor a powered contact (>80V AC or DC).

5

Electronic Transformer Monitor

INSTALLATION Location and Mounting Mounting Enclosure Style The QualiTROL Electronic Transformer Monitor is designed to be back-mounted on any smooth surface within the transformer control cabinet. Four 0.31 diameter through-holes are provided for use of 1/4" diameter fasteners. The Transformer Monitor requires an approximate area of 13" wide by 16" high and is 8 1/2" deep. Additional area below the Temperature Monitor should be allotted for wiring harness. See Figure 1.for mounting centers and dimensions. Panel Mount Style The QualiTROL Electronic Transformer Monitor is designed to be flushmounted inside a transformer control cabinet on any smooth surface. Four 0.31 diameter through-holes are provided for use of 1/4" diameter fasteners. The Transformer Monitor requires an approximate area of 11" wide by 13" high and is 3" deep. Additional area below the Transformer Monitor should be allotted for wiring harness. See Figure 1.

Figure 1. Mounting

6

Electronic Transformer Monitor

Power Supply Supply power is applied to Terminal Block TB1 terminals 14 and 15. For DC inputs positive voltage is applied to terminal 14 and ground or negative voltage is applied to terminal 15. Chassis ground is applied to terminal number 16 as shown in Figure 2. This non-metallic enclosure does not automatically provide a common grounding lug. Grounding must be provided as part of the installation, and must be in accordance with the requirements of the National Electrical Code.

Figure 2. Power Supply Connection

The power supply has an internal removable fuse. If it becomes necessary to replace this fuse, it must be replaced with the same type and rating. Failure to do so may impact warranty issues.

Heater Option If the unit is supplied with Heater Option, the supply power (120 or 240 VAC as specified by option) is applied to Terminal Block TB1 terminals 1 and 17 as shown in Figure 3:

Figure 3. Heater option connection

It is recommended that the heater circuit be fused for safety and protection purposes. This fuse is the responsibility of the installer. The rating of the heater is 120 volts AC and 100 watts. A 240 volt AC heater uses 2 of these heaters in series (a total of 200 watts). Qualitrol recommends a slow blow fuse rated at 1.25 or 1.5 Amps (600V).

7

Electronic Transformer Monitor

RTD Input Input Module Each RTD input module is specifically built to function with only a 10 ohm copper RTD or only a 100 ohm Platinum RTD. For each RTD input module one standard 10Ω RTD or 100Ω RTD (as specified), with a three conductor shielded cable is required to measure liquid temperature, ambient temperature or if in a heated well, winding temperature. The three conductors and the shield drain lead are connected to the Transformer Monitor as shown in Figure 4. NOTE: RTD WIRING TO BE CONTINUOUS AND SHIELD DRAIN LEAD MUST BE GROUNDED ONLY AT INSTRUMENT.

The Transformer Monitor provides a compensation scheme for the RTD cable connection. The three-wire connection compensates for the resistance of the connecting wires.

Figure 4. RTD Input Wiring Connections

If you are retrofitting an existing Qualitrol device, or if the RTD you have installed is a four wire RTD, DO NOT connect the fourth wire in parallel with the third wire, this will adversely affect the compensation scheme. IF YOU HAVE A FOURTH WIRE ON THE RTD CONNECTION, CUT THE FOURTH WIRE FLUSH TO THE JACKET. NOTE: Due to dimensional and mounting variations, the RTD, well, and connector must be ordered separately.

CT input Module For each CT input module one standard Clamp on CT (input current range as specified), is required to measure Winding Temperature, or Currents. Pull the supplied CT Sensor apart and place the wire which carries the current to be sensed into the CT opening, and push the CT sensor back together, making sure it is fully engaged. Connect output wires of Clamp on CT to Terminal board as shown in Figure 5.

8

Electronic Transformer Monitor

Figure 5. CT Input Connections

Potentiometer Input Module For each Potentiometer input module one standard potentiometer in the range of 0 to 5000 ohms (as supplied by various QualiTROL case assemblies) is required to measure Liquid Level, Flow, or Gas Accumulation. The three conductors and the shield drain lead are connected to the Transformer Monitor as shown in Figure 6. NOTE: WIRING TO BE CONTINUOUS AND SHIELD DRAIN LEAD MUST BE GROUNDED ONLY AT INSTRUMENT.

Figure 6. Potentiometer Input Connections

9

Electronic Transformer Monitor

Voltage Input Module For each Voltage input module one voltage transducer (0-100mV DC or 0-10 VDC as specified), is required. Connect output wires of Transducer to Terminal Block as shown in Figure 7.

Figure 7. Voltage Input Wiring

Current Input Module The Current input Module is configurable to accept either a 0-1 ma DC or a 4-20 ma DC (SCADA type) signal. Either of these options can be a transducer that is: 1. 2 wire (self powered from the transducer) 2. 2 wire (powered from the input module) 3. 3 wire (powered from the input module) For each Current input module one current transducer (0-1ma DC or 4-20 ma DC), is required. Connect output wires of Transducer to Terminal Block as shown in Figure 8.

10

Electronic Transformer Monitor

Figure 8. Current Input Wiring

Dry Contact Contact Closure Input Module The Dry Contact (Switch) Closure Input Module is designed to detect the actuation or de-actuation of one dry (non-powered) switch contact. See Figure 9. Contact Closure Wiring for proper circuit wiring.

Figure 9. Contact Closure Wiring

11

Electronic Transformer Monitor

Powered Contact Closure Input Module The Powered Contact (Switch) Closure Input Module is designed to detect the actuation or de-actuation of a powered switch contact. A measured potential across the switch contact of 0 volts being closed and a potential greater than 80 volts AC/DC as being an open contact. See Figure 10. Powered Contact Wiring for proper circuit wiring.

Figure 10. Powered Contact Wiring

Output Contacts Nine isolated sets of normally open/normally closed output contacts (for Output Relays 1-8 and the System State Output Relay) are provided for controlling cooling equipment, sounding an alarm, or operating remote breaker coils. Each set is capable of switching 115/230 VAC, 30 VDC @ 10 Amps and are accessed on Terminal Block TB1 see Figure 11. Refer to the Meter Panel for configuration and identification of the output contacts for each relay. Note that each relay is shown in the non-powered state.

12

Electronic Transformer Monitor

Figure 11. Relay Wiring

Remote Output Signals The Transformer Monitor is configured to supply four ma current outputs for remote indication or use with SCADA devices. This output is proportional to full scale of the parameter selected in the configuration (Refer to “Functional Specification,” page 17, for maximum load.) The output signals are accessed on Terminal Block TB2 terminals 1 through 8 See Figure 12. NOTE: ALL REMOTE OUTPUT SIGNALS ARE INDEPENDENT, VARIABLE CURRENT LOOPS, DRIVEN BY SYSTEM POWER AND DESIGNED TO DRIVE A RESISTIVE LOAD (I.E., CURRENT METER). THEY CANNOT BE GROUNDED OR TIED TOGETHER.

13

Electronic Transformer Monitor

Figure 12. Remote Output Signal Terminals

Communications The transformer Monitor comes Equipped with digital communication capabilities. A four wire RS-485 connection is located on the back of the unit see Figure 13. If the operator is using a two wire RS-485 connection with the 509, short TB2-9 with TB2-11 and TB2-10 with TB2-12. Now connect the two wire RS-485 as an A/B system. There is also a fiber optic connection option. See Figure 14 for the connection to this option. The RS-485 connection may be used with the Qualitrol Remote Software Package. See 509-100 Software Manual for a complete description of this feature. For specific and/or special communications protocol options contact Qualitrol, or our authorized representative.

Figure 13. Four Wire RS-485 Connection

14

Electronic Transformer Monitor

Figure 14. Optional Fiber Optic Connection

OPERATION Automatic Automatic Operation Viewing Channels (Viewing (Viewing Mode Scrolling) Scrolling) Power up,<enter> The QualiTROL Electronic Transformer Monitor upon power being applied automatically begins to monitor the inputs and controls outputs based on the factory configuration specified by the customer. The display however, shows only time/date. It will remain in this state until the ENTER key is depressed, at which time the display will go into Viewing Mode scrolling and will Auto Scroll all of the parameters being monitored at a frequency of two seconds.

Menu Mode Viewing Channels (Viewing Mode) (See the appendix for an example of the Menu structure.) View Mode Scrolling, Menu Pressing the Menu button moves the display out of Auto Scroll and into Viewing Mode. The Up and Down Arrows (or Enter) will move you through each parameter being monitored individually. If no activity takes place for 60 seconds the ETM automatically reverts to Auto Scroll, or pressing the Menu button again reverts back to Viewing Mode scrolling.

15

Electronic Transformer Monitor

Viewing Max Readings Readings View Mode Scrolling, Menu, Right Arrow From Viewing Mode, press the Right Arrow key. The Up and Down Arrows (or Enter) will move you through the Maximum values, as well as the time and date of each parameter being monitored. Pressing the Reset key will reset all of the Maximum readings. If no activity takes place for 60 seconds the ETM automatically reverts to Auto Scroll, or pressing the Menu button again reverts back to Viewing Mode scrolling. Qualitrol recommends resetting the maximum values immediately after setting up the unit to avoid any erroneous readings caused by the installation.

Viewing Min Readings View Mode Scrolling, Menu, Right Arrow, Right Arrow From Viewing Mode, press the Right Arrow key twice. The Up and Down Arrows (or Enter) will move you through the Minimum values, as well as the time and date of each parameter being monitored. Pressing the Reset key will reset all of the Minimum readings. If no activity takes place for 60 seconds the ETM automatically reverts to Auto Scroll, or pressing the Menu button again reverts back to Viewing Mode scrolling. Qualitrol recommends resetting the minimum values immediately after setting up the unit to avoid any erroneous readings caused by the installation.

Viewing Set Points View Mode Scrolling, Menu, Right Arrow, Right Arrow, Right Arrow From Viewing Mode, press the Right Arrow key three times. The Up and Down Arrows (or Enter) will move you through the Set Point values, as well as the Relay number of each relay. If no activity takes place for 60 seconds the ETM automatically reverts to Auto Scroll, or pressing the Menu button again reverts back to Viewing Mode scrolling.

Viewing Cooling Monitor Readings View Mode Scrolling, Menu, Rt. Arrow, Rt. Arrow, Rt. Arrow, Rt. Arrow From Viewing Mode, press the Right Arrow key four times. The display will read Cooling Monitor Inactive. Depressing the Up or Down Arrows (or Enter) will have no effect since this model does not have this feature. If no activity takes place for 60 seconds the ETM automatically reverts to Auto Scroll, or pressing the Menu button again reverts the system back to Viewing Mode Scrolling.

Program Mode View Mode Scrolling, Menu, Rt. Arrow, Rt. Arrow, Rt. Arrow, Rt. Arrow, Rt. Arrow From Viewing Mode, press the Right Arrow key five times. Hitting the Enter Button will place you into Menu Mode. This is where you can change the 16

Electronic Transformer Monitor

settings of the ETM. This mode is protected. Before you are allowed to change any parameters, you must first enter a program user ID#. If you are not authorized to change these settings, press the Menu key to go back to Viewing Mode scrolling. The Up, and Down Arrows will allow you to change the value of the character highlighted by the display, while the Right, and left Arrows will move the highlighted character. Hitting the Enter key moves you to the next setting. At the end of the Program Mode menu, hitting Enter reboots the system. If no activity takes place for 60 seconds, the ETM automatically reverts to Auto Scroll and discards any changes that were made or Pressing the Menu button again reverts back to Viewing Mode scrolling.

Figure 15. Front Panel Control

Testing the System To perform a system confidence test, press and hold the TEST Button. Pressing the TEST key displays the setpoint source and value on the DISPLAY in one-second intervals.

17

Electronic Transformer Monitor

FUNCTIONAL SPECIFICATION Universal, 90-264 VAC, 47-63 Hz and 40-290 VDC; (< 18 watts)

Power Supply: Front Panel and Interface

Display:

Status Indicators: Controls: Front Panel Membrane: Input Parameters:

Accuracy: Temperature: Current: Current loop: Voltage: Switch Contact Closure (isolated dry): Switch Contact Closure (powered)

Type: 1 Easy to read 2-line, 16 character alphanumeric Liquid Crystal Display (LCD) Character size: 0.38” (9.66 mm) high x 0.19” (4.84 mm) wide per line Backlight: Optional 8, Light Emitting Diode (LED) 8 Large keys for programable settings and user interaction UV stabilized polyester +/-0.5% full scale input range 100 ohm platinum (Pt100) or 10 ohm copper (Cu10) RTD sensors;-40 to 200°C range Clamp on CT 0-5A, 0-10A, 0-20A and others available 0-1 or 4-20 ma DC 0-100 mV or 0-10 VDC Open/Closed

>80 Volts AC/DC open, 0 volts closed; optically isolated

Outputs

Control/Alarm Contacts: Diagnostics Alarm: Heater control: Contact Rating: Remote (SCADA) Output: Data Communication:

8 form C (changeover) relay contacts for cooling control, alarms, trip, etc. 1 relay for sensors, power and internal instrument circuitry diagnostics 1 relay 10A @ 115/230 VAC, 10A @ 30VDC 0-1 ma, 4-20 ma, (other options available) maximum allowable load resistance: 10,000 ohms for 0-1 ma, 450 ohms for 4-20 ma RS-232, RS-485 (optically isolated), optional fiber optic interface ST connector

Immunity

Dielectric Isolation (hi pot): Surge Withstand Capability: Conducted/Radiated Emissions: Conducted/Radiated Radio Frequency Immunity: Safety:

2500 VAC, 60 seconds to ground

Environment:

IEEE C37.90.1 IEC 61000-6-1 IEC 61000-6-2

IEC 61010-1

Temperature Range: Storage Temperature Humidity:

-40°C to +72°C -50°C to +80°C

Vibration:

60/120 Hz @ .004 inch displacement.

Shock: Weatherproof Enclosure: Weight Approx:

10 G’s half-sine, in three orthogonal planes NEMA #3R (vented), UV stabilized, Corrosion proof fiberglass

90% non-condensing

Panel mount version: 4.5 lb. (2 kg) Weatherproof enclosure version 11.5 lb. (5.2 kg)

18

M u l t i- P h a s e E l e c t r o n i c T e m p e r a t u r e M o n i t o r

APPENDIX

19

M u l t i- P h a s e E l e c t r o n i c T e m p e r a t u r e M o n i t o r A

left

MENU SWITCH

05/24/2001 08:28:15 up

right left

B

C

VIEW/RESET MAXIMUM MEMORY up

up

TOP OIL 84.5 C MAX1 1524 051701 up

up

down/enter

WIND 1 CHAN 2 CURRNT 1224.5 A up

up

down/enter

WIND 1 1300.3 A MAX2 1524 051701 up

up

up

WIND 2 CHAN 3 CURRNT 1210.1 A up

up

up

down/enter

WIND 3 CHAN 4 CURRNT 1188.7 A up

WIND 3 92.8 C MAX4 1524 051701 up

down/enter

WIND 3 1286.1 A MAX4 1524 051701

up

up

up

enter INVALID NUMBER ID: 111111 (invalid)

(valid)

enter

SET TIME/DATE 15:24 05/24/01 enter TOP OIL RELAY 1 SETPNT 0070.0 C

up enter

down/enter

AMBIENT 16.5 C MIN5 1524 051701

TOP OIL - BOT OIL SETPNT 0010.0 C

TOP OIL RELAY 2 SETPNT 0080.0 C

up down/enter

up

enter

down/enter

CONS TK 65.7 C MIN6 1524 051701

CONS TK RELAY 6 SETPNT 0080.0 C up

down/enter

LTC TNK 65.9 C MIN7 1524 051701

MAX VAL CH 4 5 6 SETPNT 0090.0 C enter

down/enter

LTC TNK RELAY 7 SETPNT 0080.0 C

TOP OIL - LTC TNK SETPNT 0005.0 C

up down/enter

enter

down/enter

BOT OIL 70.0 C MIN8 1524 051701

RELAY 8 IS NOT ACTIVE

TOP OIL - BOT OIL SETPNT 0010.0 C

up

down/enter

enter

CH1-CH7 -007.5 C MIN 0917 051701

down/enter D

CONS TK RELAY 6 SETPNT 0080.0 C

down/enter

down/enter LTC TNK 72.0 C MAX7 1524 051701

enter

CH1-CH8 1.5 C MIN 1524 051701

LTC TNK RELAY 7 SETPNT 0080.0 C

up

up

down/enter E

TOP OIL - LTC TNK SETPNT 0005.0 C

down/enter

up

down/enter

enter PROGRAM USER ID: 111111

down/enter

WIND 3 86.5 C MIN4 1524 051701

up

CONS TK 79.2 C MAX6 1524 051701

CHANGE SETTINGS right ID # REQUIRED

up

down/enter

up

LTC TNK CHAN 7 69.0 C

MAX VAL CH 4 5 6 SETPNT 0090.0 C

up

AMBIENT 22.1 C MAX5 1524 051701

down/enter

down/enter

down/enter

down/enter CONS TK CHAN 6 72.1 C

WIND 2 88.1 C MIN3 1524 051701

up

up

up

up

down/enter

down/enter

down/enter AMBIENT CHAN 5 21.3 C

up

TOP OIL RELAY 2 SETPNT 0080.0 C

up

down/enter WIND 3 CHAN 4 90.1 C

down/enter

WIND 1 87.1 C MIN2 1524 051701

down/enter WIND 2 1298.2 A MAX3 1524 051701

right left

up

up

down/enter

COOLING MONITOR INACTIVE

TOP OIL RELAY 1 SETPNT 0070.0 C

down/enter

down/enter WIND 2 94.1 C MAX3 1524 051701

right left

down/enter

TOP OIL 73.2 C MIN1 1524 051701 up

WIND 1 96.3 C MAX2 1524 051701

VIEW SETPOINTS

down/enter

down/enter

down/enter WIND 2 CHAN 3 91.4 C

right left

up

down/enter

down/enter WIND 1 CHAN 2 92.5 C

VIEW/RESET MINIMUM MEMORY up

down/enter TOP OIL CHAN 1 77.5 C

right left

D

down/enter F

down/enter

TRANSFORMER MONITOR MENU

G

20

enter H

M u l t i- P h a s e E l e c t r o n i c T e m p e r a t u r e M o n i t o r E up

F down/enter

BOT OIL CHAN 8 73.1 C up

down/enter

TOP OIL - LTC TNK 8.4 C up

down/enter

TOP OIL - BOT OIL 4.2 C up

down/enter

TOP OIL - CONS TK 5.9 C up

down/enter

LTC TNK - CONS TK -3.4 C up

up

down/enter

BOT OIL 79.8 C MAX8 1524 051701 up

down/enter

CH1-CH7 1.1 C MAX 1524 051701 up

up

up

enter

down/enter

enter

CH7-CH6 3.5 C MIN 1524 051701

COOLING MONITOR CM4 INACTIVE

down/enter

enter RS232 BAUD RATE 19200

C

down/enter

up

enter RS485 BAUD DATA 9600 8

down/enter

enter

CH7-CH6 8.9 C MAX 1524 051701

B

RS485 PARITY STP NONE 1 enter

down/enter

UNIT WILL REBOOT NOW

down/enter

enter TOP OIL CHAN 1 ON enter WIND 1 CHAN 2 ON enter WIND 2 CHAN 3 ON enter WIND 3 CHAN 4 ON enter AMBIENT CHAN 5 ON

CONS TK CHAN 6 ON

down/enter

enter

LIFE CONSUMPTION WIND 3 000298 H up

enter RELAY 8 IS NOT ACTIVE

enter

LIFE CONSUMPTION WIND 2 000305 H up

H

COOLING MONITOR CM3 INACTIVE

CH1-CH6 4.7 C MAX 1524 051701

down/enter

LIFE CONSUMPTION WIND 1 000321 H

down/enter

CH1-CH6 2.3 C MIN 1524 051701

down/enter

CH1-CH8 6.9 C MAX 1524 051701 up

TRANSFORMER MONITOR MENU

G up

LTC TNK CHAN 7 ON

down/enter

enter

OPERATING HOURS TOTAL 000765 H

BOT OIL CHAN 8 ON

down/enter

enter COOLING MONITOR CM1 INACTIVE

A

enter COOLING MONITOR CM2 INACTIVE

enter

21

M u l t i- P h a s e E l e c t r o n i c T e m p e r a t u r e M o n i t o r

14

13

12

11

10

9

8

7

6

5

4

3

2

1

TB1

31

30

29

28

27

26

25

24

23

22

21

20

19

10 A

RELAY 4

10 A

RELAY 3

10 A

RELAY 2

10 A

RELAY 1

18

17

TB1

VAC LINE HEATER

15 32

MODEL NO. SERIAL NO.

VACC NEUT HEATER

RELAY 5 10 A

RELAY 6 10 A

RELAY 7 10 A

RELAY 8 10 A

SYSTEM STATE RELAY

(-)

(+)

(-)

(+)

5

4

3

2

1

14

13

12

11

10

9

T/RXD-(A)

T/RXD+(B)

GND

RXD-(A)

RXD+(B)

TXD-(A)

TXD+(B)

10 A

(+)

6

15

GND

MFG. DATE

(-)

7

16

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3

INPUT MODULE 1

TB3

INPUT MODULE 2

TB4

INPUT MODULE 3

TB5

INPUT MODULE 4

TB6

INPUT MODULE 5

TB7

INPUT MODULE 6

TB8

INPUT MODULE 7

TB9

INPUT MODULE 8

TB10

22

16

VAC LINE INPUT (+) VACC NEUT INPUT (-) EARTH GROUND

INPUT POWER: (UNIVERSAL) 90-264 VAC, 47-63 Hz 40-290 VDC

(+)

8

TB2

(-)

TB2

RELAY CONTACTS: 10 A @ 115/230 VAC 10 A @ 30 VDC

CURRENT LOOP 1

CURRENT LOOP 2

CURRENT LOOP 3

CURRENT LOOP 4

RS-485

M u l t i- P h a s e E l e c t r o n i c T e m p e r a t u r e M o n i t o r

Configuration Records Parameter Name

Comments/Range

Parameter Name

Set Point

Input Module 1:____________________

____________________

Relay 1:____________________

__________

Input Module 2:____________________

____________________

Relay 2:____________________

__________

Input Module 3:____________________

____________________

Relay 3:____________________

__________

Input Module 4:____________________

____________________

Relay 4:____________________

__________

Input Module 5:____________________

____________________

Relay 5:____________________

__________

Input Module 6:____________________

____________________

Relay 6:____________________

__________

Input Module 7:____________________

____________________

Relay 7:____________________

__________

Input Module 8:____________________

____________________

Relay 8:____________________

__________

Differential 1: ____________________

____________________

Differential 2: ____________________

____________________

RS-232 Baud Rate: ____________________

Differential 3: ____________________

____________________

RS-485 Baud Rate: ____________________

Differential 4: ______________________

______________________

RS-485 Parity/stop Bit: ____________________

Thermostat:__________

RS-485 Active Protocol: ___________________

23

M u l t i- P h a s e E l e c t r o n i c T e m p e r a t u r e Monitor

Auxiliary Modem: For remote communications Qualitrol offers a 33.6K modem that interfaces directly with the auxiliary port of the 509. When used with the Qualitrol Remote Software package the user is capable of operating the 509 as if they were connected locally.

Wiring Specifications: Input Power:

Universal; 90 – 264 VAC; 47 – 63 Hz; or 40 – 290 VDC

TB1-1

Line or (+)

TB1-2

Neutral or (-)

TB1-3

Earth Ground

Telephone Line: J1

Use a normal modem cable (not a null) Modular Telephone Jack

Software Configuration:

See the 509 Software Manual; IST-073-X

Mechanical Dimensions:

Length: 7.33 in; Width: 3.71 in; Height: 1.21 in; Weight 12 oz.

Modem Features: V.90/56K maximum data speed V.17 FAX Class 2 V.17 FAX Class 1 V.42 error correction V.42bis data compression

24

Electronic Transformer Monitor for Liquid-Filled Transformers

509-100

Software Manual IST-073-1

Qualitrol Software Instruction Manual

Software for Configuration of and Communication with the Transformer Monitor 509509-100

TABLE OF CONTENTS Table of Contents _______________________________________________________ i Overview ______________________________________________________________3 Software for the Qualitrol 509-100 Transformer Monitor..................................................3 General ................................................................................................................................3 Installation...........................................................................................................................3 Framework ...............................................................................................................................3 Communication Link Failure Trouble Shoot ......................................................................5 Applications..............................................................................................................................6 Monitor................................................................................................................................6 Simulator .............................................................................................................................7 Calibrator.............................................................................................................................9 Configurators; Customer and Factory ................................................................................11 Device Configuration ........................................................................................................12 Display Configuration .......................................................................................................12 Time and Date Configuration............................................................................................13 Password Configuration ....................................................................................................14 Communications Configuration ........................................................................................15 Heater Configuration ............................................................................................................16 Input Module Configuration ................................................................................................17 Winding Temperature Calculations ....................................................................................19 Advanced CT Temperature Scaling Configuration #1......................................................20 Life Consumption Calculation ..........................................................................................23 Output Loops Configuration .............................................................................................24 Maximum Calculation Configuration ...............................................................................27 Output Relay Configuration.................................................................................................28 Seasonal Setpoint Block....................................................................................................31 Ambient Temperature Forecast Configuration .................................................................32 Relay Exerciser .................................................................................................................33 System Relay Configuration .............................................................................................33 Bank Switching Configuration..........................................................................................34

ECN 22852

i

April 19, 2002

Importing and Exporting Configuration Files ...................................................................34 Remote Communications Using the Modem.......................................................................36 Frequently Asked Questions About the 509........................................................................37

ECN 22852

ii

April 19, 2002

Multi-Phase Electronic Transformer Monitor

OVERVIEW Software for the Qualitrol 509509-100 Transformer Monitor General The Software is used on a PC which connects to the 509-100 with a RS232 or RS485 connection for monitoring, simulation, calibration and configuration. Initial configuration must be done through the RS232 connection on the front panel after which either the RS232 or the RS485 connection may be used. Using a RS232 male to female DB-9 extension (not a null) shielded cable is recommended for substation environments.

Installation The software runs on Windows NT, 95 and 98. Insert the 3.5” diskette into the floppy disc station. Then it is recommended to create a directory on the hard drive i.e. “509 files” where the software and the help files can be saved and run. The software can also run directly from the floppy disk. Start up by clicking on the 509 Remote Icon in the explorer. The Icon can be dragged to appear as a shortcut on the desktop

Framework The first window that will open is the Framework, see picture below. From here you enter to the different applications.

The Framework window is used to establish communications with the 509 and to select a specific 509 application.

3

Multi-Phase Electronic Transformer Monitor

The File pull down menu list allows several options for selection of a communications file. The default communications file extension is ".QCO". A default communications data file is loaded automatically when the Framework is started. The file is called default.qco and must be located in the same directory that contains the remote software.

Open

opens an existing communications file.

Save

saves the communications data under the current communications file name.

Save As...

saves the communications data under a new communications file name.

Close terminates all applications and communications with the 509 and closes the Framework. The Save Communication Setup window is presented if any communications parameters have been changed and not saved prior to the Close command.

Address This window specifies the 509 address. Each 509 has an assigned address to allow for multiple 509s to be used with a common communication link. The initial factory default configuration is an address of 00. Baud Rate This window defines the communications baud rate. The Baud Rate must be the same as on the 509 unit you intend to communicate with. The range is 1,200 to 38,400. The default is 19,200. COM1 - 4 These four radio buttons select the serial communications port on the computer. The default is COM1. Choose the communication port that the serial port is connected to on your computer.

4

Multi-Phase Electronic Transformer Monitor

Modem This radio button allows the user to connect remotely with a 509 installed with the Qualitrol modem. See the modem section of this manual for operation. Off Line The Software can be run off-line, with no 509 connected to it. By using an established configuration file, the user can modify some of the settings offline and save them as a file to be downloaded later. This would save time when configuring the 509 at installation time. There is also a ’demo’ feature that can be used off-line. After the user clicks on the off-line connection they may type in ’demo’ into the factory configuration to see what features are available with the 509 series and how to manipulate them. This feature is useful during training or to learn the product when there is no 509 available. Note, any changes made in the ’demo’ mode will not be permanent. These modifications can neither be saved nor downloaded into a device. Connect / Disconnect with a 509.

These buttons establish and terminate communications

Tx and Rx This status window indicates transmission activity. Note that short transmissions will occur too fast to be viewed by the operator. Close All This button closes all open 509 applications, terminates communications and closes the Framework. The Save Communication Setup window is presented if any communications parameters have been changed and not saved prior to the Close command.

Communication Link Failure Trouble Shoot This window is presented when there is a communications failure between the PC and the 509. To correct the communications failure, check the following:

· · · · ·

the cable is a straight thru cable ( not a null) and is securely connected to the PC and the 509 the 509 power is on the cable is connected to the same COM port as specified by the Framework Communications Block the 509 Device Address matches the selection in the Framework Communications Address Block. the Baud Rate selection matches the 509 Service Port Baud Rate Configuration. The default baud rate configuration is 19,200 baud. If the Service Port communications

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Multi-Phase Electronic Transformer Monitor

baud rate was re-configured to another baud rate, the Framework Communications Baud Rate must match this configuration. Retry Button This button will attempt to establish communications with the 509 again. Ignore Button This button ignores the communications error. However, for proper operation of the system, it is essential that communication to the 509 is established and functioning properly.

Applications There are five applications, which can be launched from the Framework:

Monitor

allows remote operation of the 509.

Simulator

allows simulation of field input signals.

Calibrator

allows calibration of 509 inputs and outputs.

Configurator - Customer

allows the customer to configure the 509.

Configurator - Factory

allows the factory to configure the 509.

Password Each application requires a password to enable access to it. The “Configurator Factory” can only be entered by Qualitrol Factory personnel. This section is reserved for the Factory except in the ’demo’ mode which was discussed earlier. Remember Me First enter a valid password. Now by checking this box, the password is stored in the communications file and does not have to be re-entered every time the application is started. Note: enabling this feature will disable any security protection allowing anyone to gain access to this software. Start

This button activates the selected application.

The 509 Passwords as shipped from the factory are: MONITOR

111111

SIMULATOR

111111

CALIBRATOR

if required, call Application Engineering at 585-586-1515

CONFIGURATOR-CUSTOMER

111111

Monitor The Monitor window provides remote monitoring and controlling of the 509. It opens with the start button and the correct password. The contents on the 509 LCD and relay LED´s are represented on the PC screen. The monitor requests an update from the 509 three times every second.

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Multi-Phase Electronic Transformer Monitor

There are 8 control buttons: Test, Reset, Menu, Enter, Up, Down, Left, and Right. These buttons are activated by clicking on them using the left mouse button. Activating a button in this manner will cause the same effect as depressing the same button on the actual unit. Refer to the 509 Hardware Manual for specific information on the control and operation of the 509. Close The Close button terminates the Monitor operation. Note that the actual 509 continues to operate when the Monitor application is closed.

Simulator The Simulator allows the user to simulate values regardless of the actual inputs that the sensors register. The 509 will respond to the input signal changes from the Simulator as if the signals originated in the field. This Mode is useful for testing relay connections etc.

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Start Simulation The field inputs are disconnected from the actual field signals and are connected to the simulated signals from the Simulator applications. The signals can now be changed as desired, remotely. The 509 will respond to the simulated signals as if they were the actual field signals. Note that the transfer from the field to the simulation is almost seamless because the initial simulation value is set to the last value of the actual field signal with the exception of CT temperature signals. Also note that while the simulation is active, the actual field signals are not being monitored. Important note! If you have Trip functions connected to the 509 they can be activated in Simulation mode. End Simulation The field signals are re-connected to the input of the 509. The 509 will immediately respond to these actual field signals.

The Simulation is automatically ended if the operator makes no changes to any of the input signals for over 3 minutes. Whenever any button is pressed, the 3-minute timer is reset.

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Calibrator In the Calibrator the user can calibrate most inputs. Note that all channels are calibrated in the factory and under normal operation they will not need to be calibrated again. Qualitrol recommends having a separate password for this application to prevent someone from accidentally putting the unit out of calibration.

Input Channel Calibration

Set Input Signal To This window provides the value of the external signal that must be applied to the module terminals. For the RTD modules, the input signal is expressed in terms of degrees C. Please contact factory if there are any doubts in the calibration procedure.

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Multi-Phase Electronic Transformer Monitor

Next Button Clicking the Next button signals that the input signal level has been set as instructed in the Set Input Signal To window. The second step is automatically started. The next button is only available at the first step of the calibration procedure. This button changes to Finish button on the second step. All channels require a two-step calibration procedure. By clicking the Back button, the calibration procedure returns to the first step. Finish Button When the input is set to the second value click the Finish button. The calibration of this particular channel is completed. Output Channel Calibration The analog outputs can be adjusted in a four point calibration. However, this should not be necessary since it was already done at the Factory. Saving calibrations in files It is possible to save calibration values in files using the pull down menu. Import A valid calibration is imported from a file stored in the PC. The default file extension is ".QCA". Export The current calibration is stored in the previously specified file for future use. The default file extension is ".QCA". Export As... The current calibration is stored in a newly specified file for future use. The default file extension is ".QCA".

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Multi-Phase Electronic Transformer Monitor

Configurators; Customer and Factory The Configurator window provides for configuration of all adjustable parameters of the 509. The Factory Configurator is used to set hardware configurations of the unit. The Customer Configurator limits access to some of the 509 parameters such as Serial no, manufacturing date, etc. Note that configurations can be saved as files and if need be used to restore settings or to pre-configure before connecting to the 509. See the section on Importing and Exporting configuration files.

Subsystem Configuration Selection Window This window provides for selection of the desired subsystem to be configured.

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Multi-Phase Electronic Transformer Monitor

Device Configuration This window is used to configure basic manufacturing data about the 509 and is only accessible for Qualitrol manufacturing purposes.

Display Configuration This window is used to configure the Display. If the 509 being configured has a back light display then the intensity may be adjusted. Back light Intensity Slider display.

Is used to adjust the intensity of the back light of the

Display Contrast Slider appropriate viewing level.

Use the slider to adjust the display contrast to an

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Multi-Phase Electronic Transformer Monitor

Time and Date Configuration This window is used to configure Time and Date stored in the 509. Note that the Time and date also can be changed with front panel operations. Current PC Time Shows the current time of the personal computer that is connected to the 509 at the instance when the Time and Date Configuration window is opened. This value is not continuously updated. The current time of this PC will be loaded into the 509 at the instance when the Load button is pressed. If the Current PC Time value is not correct, exit the Remote System, adjust the PC's clock to the correct time and then restart the Remote System and continue with the configuration procedure. Time Zone Difference This window allows adjustment for a difference in time zones between the location of configuration and the location where the 509 will be installed. If the two locations are the same, set the value to 0, otherwise select the appropriate number of hours to provide for a correct time at the installation location. For example, if the configuration is done in New York and the installation is in California, the Time Zone Difference should be set to -3 hours. 509 Time and Date

Shows the current values for the date, time, and zone in the 509.

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Multi-Phase Electronic Transformer Monitor

Password Configuration This window is used to configure the passwords, which provide access for different software applications. The passwords are stored in the 509. Note that the passwords are case sensitive. Also note that the customer configurator password is also the password used to enter the modification section of the menu mode from the front panel of the 509.

Password These 5 windows accept the password for the associated application. A password consists of 1 to 6 alphanumeric characters. The Factory Password can only be set at the factory. Verify These 5 windows are used to check the corresponding password. The password and the verification are compared when the passwords are loaded into the 509. If a given password and its verification do not match an error message is generated. When passwords are changed in the Configurator, the new password values must be used the next time the Start button for that specific application is pressed. Cancel button Clicking on the cancel button will remove the user from this window without saving any changes. Load button Striking the load button will cause the unit to accept verified passwords into the system.

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Communications Configuration This window is used to configure the 509 communications ports.

Service Port Baud Rate This window configures the baud rate used to communicate over the RS232 service port at the front panel. The default value is 19,200

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Multi-Phase Electronic Transformer Monitor

baud. The Framework application software automatically configures the PC's COM port with the correct parameters for communicating with the Remote Software. Main Port Type This information only window indicates the type of signaling hardware used for the Main Port. Main Port Select Type These two radio buttons select between having a wire RS-485 or fiber optical hardware connection for the Main Port communications channel. (Only if the fiber optical option has been installed). DNP Installed Check Box This check box indicates if the DNP V3.00 communications protocol has been installed. Only the factory can control this feature. Modbus Installed Check Box This check box indicates if the Modbus communications protocol has been installed. Only the factory can control this feature. QASCII Installed Check Box This check box indicates if the Qualitrol ASCII communications protocol has been installed. Only the factory can control this feature. Main Port Protocol This window selects between the available communications protocols to be used by the Main Port communications. Main Port Address specified protocol.

This is the communication address of the 509 used by the

Main Port Baud Rate This window selects the desired baud rate for the Main Port communications protocol. The default value is 19,200. Main Port Data Bits This window selects the desired number of data bits for the Main Port communications protocol. The default value is 8. Main Port Parity This window selects the desired type of parity for the Main Port communications protocol. The default is none. Main Port Stop Bits This window selects the desired number of stop bits for the Main Port communications protocol. The default value is 1. The Expansion port will be used for future application expansions. This unit does not support this feature at the present time. Expansion Port Type This information only window indicates the type of signaling hardware used for the Expansion Port. Expansion Port Installed Check Box This check box indicates if the Expansion Port is installed. Only the factory can control this feature. Default Button This button sets all communications parameters to their default values. The parameters still must be loaded into the 509 by pressing the Load button. Load Button This button loads all communications parameters from the PC into the 509. All new communications parameters take effect only after the 509 hardware has been reset.

Heater Configuration

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This window is used to configure the 509 Heater option. The heater is not a standard option but has to be ordered. It is used in extremely cold or moist environments. The Heater is controlled by the 509 internal temperature measurement.

Heater Setpoint This window controls when the Heater is turned on, if the Heater Option has been installed. The Heater is turned on if the internal temperature of the 509 drops below the Setpoint value. Heater Hysteresis This window controls when the Heater is turned off, if the Heater Option has been installed. The Heater is turned off if the internal temperature of the 509 rises above the sum of the Setpoint and the Hysteresis values.

Input Module Configuration The 509-100 has capability of up to eight input modules. The types of modules available are described in the Qualitrol Operation manual. This first window is used to select which of the eight input modules the user wishes to configure. By selecting the desired radio button and hitting the configure button the operator will be taken to the Input Module Configuration screen for the chosen input module.

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Multi-Phase Electronic Transformer Monitor

Input Module Number This information only window indicates the input module number that is being configured. Input Module Type This window indicates what module type was installed in this corresponding site of the 509. This was designated at the factory according to what input module was ordered and installed. If the module type indicates "undefined" then there is no physical module installed in that location. Input Module Function These two radio buttons enable and disable the module function. If the input module is disabled it will no longer be viewed on the LCD display located on the front panel nor will it control any relays. Input Signal Name This window identifies the Input Module Name. The name can be changed and be up to 7 alphanumeric characters long. This name will also appear on the 509 LCD display along with its input signal. Custom Scaling Block The configuration parameters in this block provide the ability to change the scaling of the process input signal. The Custom Scaling is not available if the Module Type is a "CT, Temperature", "Logic Switch" or "AC/DC Input". For the

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Multi-Phase Electronic Transformer Monitor

RTD input modules the Custom Scaling Block limits the user to toggling between displaying the temperature values in centigrade or Fahrenheit. Use Custom Scaling This check box indicates that custom scaling is defined for the input signal. If the box is checked, three additional parameters for the input must be specified: units label, low end value, and high end value. Custom Units Label This window holds the Custom Unit Label. If the Use Custom Scaling Check box is checked., this label will be used by the 509 instead of the default label as defined by the Module Type. The label can be up to 3 alphanumeric characters. Low End and High End Scaling Value These windows are used to provide the custom value corresponding to the indicated low end value for the selected module type. The 509 will translate the input signal into the alternate units using the low and high end values provided. An example is a Dissolved Gas Monitor with a 0-1mA representing 0 – 2000 PPM scale. Using a 0-1mA input module set the low end scale to 0mA = 0, set the high end scale to 1mA = 2000 and the custom units label to PPM. If the Input Module is of type "CT, Current" or ”CT, CT Current Scaling Block Temperature”, the CT Current Scaling function provides for linear scaling between the 509 output and the actual current being sensed by the Power Transformer CT. CT Clamp On Sensor Rating This window provides the maximum rating of the CT Clamp On Sensor used with this module. (I.E. 10 Amp, 30 Amp) This rating may be read off the Clamp On Sensor. CT Ratio These two windows provide the parameters needed for CT Current Scaling. The left window identifies the true current being sensed by the CT. The right window identifies the secondary or output of the CT of the corresponding true current. For example, if the Instrument CT being used on the transformer has a ratio of 1200 : 5 Amps, the two windows will be set to ”CT Ratio = 1200 : 5”. (The clamp on sensor would be on the 5 amp circuit and now knows to scale the current to the 1200 amp range.)

Winding Temperature Calculations CT Temperature Scaling Block This block provides for the configuration of the "CT, Temperature" input module type. The software provides for two different winding calculation methods at this point in time.

Simple Temperature Scaling Calculation This window configures the Simple CT Temperature Scaling parameters. The winding calculation method represented here would correspond to the process used on the Qualitrol 109 product line.

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Multi-Phase Electronic Transformer Monitor

Input Module Number This window indicates the CT, temperature module number for which the Simple Temperature Scaling parameters are being set. Input Signal Name This window indicates the name the user gave the module for which the Simple Temperature Scaling parameters are being set. Temperature Adder This window selects one of the available RTD input modules. The selected RTD input module will be the liquid temperature measurement that is added to the winding curve simulation. i.e. Top oil temperature. Temperature Rise Of These two windows specify the temperature rise at a given winding current. This is also often referred to as the Delta T. These two parameters are used to compute the temperature for the module being configured. These are derived during the transformer test runs and may be obtained from the manufacturer of the transformer. Time Constant This window specifies the time constant for the temperature rise of this winding. The time constant is defined as the time it takes the winding temperature to reach 63.2% of its final value for a given current input.

Advanced CT Temperature Scaling Configuration #1 This window configures the Advanced CT Temperature Scaling parameters. The formulas for calculating winding temperatures for this window were derived from the IEEE standard C57.91-1995.

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Multi-Phase Electronic Transformer Monitor

Winding Temperature and Cooling Importance Paper insulation used in transformers contains organic materials which deteriorate over time at elevated temperatures. Cooling which is activated too slowly or poorly modeled winding temperatures will degrade this insulation. While switching the cooling system on and off inappropriately will lead to reduced fan and/or oil pump life. The 509 implements advances in thermal modeling technology to increase both insulation and cooling system life: Different parameters can be set for each of the possible cooling modes, or stages (ONAN, ONAF, OFAF, ODAF designations for natural convection, forced, or directed air and oil cooling). Then, during operation, the 509 can dynamically alter the parameters to match the present cooling stage. Each winding can be individually programmed for accurate representation of the winding "rise" (gradient). The winding time constant, and the load current "exponent" can be programmed for each cooling stage. Input Module Number These three information only windows indicate the module numbers of up to three type "CT, Temperature" input modules for which the advanced scaling parameters are being configured. The inputs are identified as A, B, and C.

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Multi-Phase Electronic Transformer Monitor

Input Signal Name These three windows indicate the given signal names of the three "CT, Temperature" input modules i.e. Wind1, Wind2, Wind3. Cooling Relays These three windows select the output relays that activate the different cooling modes. i.e. Relay 2 controls fan bank 1, Relay 3 controls fan bank 2 & Relay 4 turns on the oil pump. Current Factors In these windows the secondary current i.e. 5A corresponding to nameplate rating at the specific cooling mode should be entered. An example: A 30/40/50 MVA Single Phase Transformer at 132 to 32kV with a CT 2000/5A at secondary side which is the winding to be configured. In ONAN mode

30MVA/32kV*5/2000=X

In first cooling mode

40MVA/32kV*5/2000=X

In second cooling mode 50MVA/32kV*5/2000=X

Note that the current would have to be divided by the square root of three in a three phase transformer application.

The 509 can be programmed for up to four cooling modes including natural convection. If there are less than four cooling modes the unused rows should match the last configured row. At no time should zeroes be entered as a value.

Temperature Gradients In these twelve windows the temperature gradients, or delta T, are entered for each winding at each cooling stage. This value is the winding temperature rise over the specified liquid temperature for that given current factor. The liquid temperature most commonly will be the top oil temperature measurement. Exponent These four windows specify the exponent parameter used in the temperature calculation for each of the four Cooling Modes. The exponent describes the “rise” curve of the winding temperature above the oil temperature. In the case of installing a 509 on older transformers this information might be difficult to get. In those cases we recommend: For ONAN

1.6

For ONAF

1.6

For OFAF

1.8

For ODAF

2.0

Time In these four windows the time constant for each of the four cooling modes should be entered. The time constant is defined as the time required to reach 63.2% of the final winding temperature rise for a specific load increase. Common Temperature Adder In this window, the RTD input module that is the selected liquid temperature measurement to be added to the winding rise should be entered. (i.e. Top oil).

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Multi-Phase Electronic Transformer Monitor

Preset Default Coefficients Button Qualitrol provides a Default setting that can be used as an example of how to set up the window. If appropriate values can not be obtained from the transformer manufacturer, Qualitrol recommends using the Simple Calculation Method. If using this window, it is important to verify what relays are actually connected to the cooling equipment. Advanced Calculation #2: Future option. Advanced Calculation #3: Future option.

Life Consumption Calculation

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The 509 calculates relative “life consumption” according to IEEE standards. These standards are based on the Ahrrenius formulas for deterioration of organic insulation material with time and temperature. Each 6-8 degree increase in temperature approximately doubles the rate of decay. Life Consumption metering helps to prioritize maintenance activities between transformers based on the cumulative exponential effects of temperature over time. It also helps to equalize load between transformers to maximize system life and minimize maintenance. The Consumption Counter Installed checkbox indicates if the 509 was equipped with the Life Consumption Calculation. Consumption and operating counters can be preloaded with starting values. The values will be configured using the Configure button.

Input Signals, Module Number and Name These three windows identify the three module numbers of up to three "CT, Temperature" modules in the system. Life Consumption Formula Variables The 509 uses the IEEE Std C57.91-1995 & CEI/IEC 354:1991 for calculating the transformer loss of life in it’s life consumption equations. Both of those manuals use the Montsinger rule of thermal degradation, which is a simplified version of the Arrhenius Law of General Chemical/Thermal Degradation. Depending on the application, the customer may select different unity hot spot temperatures by inputting the corresponding constants. See the table below for recommended values.

Per unit life = A EXP [B / Winding Temperature + 273] for a life of 20 years. A

B

-11.269 6328.8 -11.968 6328.8 -11.804 6328.8 -13.391 6972.15 -14.133 6972.15

UNITY HOT SPOT TEMPERATURE 110 RECOMMENDED FOR 65°C INSULATION 95 RECOMMENDED FOR 55°C INSULATION 98 IEC 354:1991 SPECIFICATION 101 87

Consumption Counter Preset Value These three windows can hold initial values for the corresponding Consumption counters. If there are no preset values to enter, Qualitrol recommends zeroing the values upon installation. Life Counter Preset Value This window can hold an initial value for the Life Counter. The Life Counter is controlled by the real time clock of the 509. Meaning that it is the operating hours of the transformer if the 509 and the transformer are powered simultaneously.

Output Loops Configuration The 509 comes equipped with four 0-1 mA or 4-20 mA (0-10mA on request) outputs to provide information to SCADA systems or remote indications. Each output can be configured to send data of any of the modules or a derived calculation such as: A winding temperature, a differential calculation or a maximum comparison of three values.

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Multi-Phase Electronic Transformer Monitor

This window is used to configure the four current loop output channels.

Loop Function These two radio buttons enable and disable the output loop operation. Loop Type These two radio buttons select between 0-1mA and 4-20mA current loop ranges. If requested when ordering, these radio buttons will select between 0-1mA and 010mA current loop ranges. Controlled By Block This block defines the control source signal for this current loop. The choices are: Single Input, Difference Calculation or Maximum Calculation.

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Multi-Phase Electronic Transformer Monitor

Single Input Configuration This window selects a specific module as the source to control the output current loop (or if in the Relay section of the configurator, to control an output relay).

Input This window selects one of the available input modules as the control signal for the output current loop (or output relay).

Difference Calculation Configuration This window is used to configure the difference calculations. The 509 can handle up to four difference calculations. Any of the difference calculations can be assigned to control an output current loop (or an output relay). Difference A, B, C, D Buttons These four radio buttons select which difference calculation is assigned to control the output current loop (or output relay) currently being configured. Input A - Input B The input signal B will be subtracted from signal A. The result will appear with a negative sign if B is greater than A. .

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Multi-Phase Electronic Transformer Monitor

Maximum Calculation Configuration The Maximum Calculation window is used to compare up to three values and send the highest on the analog output (or control a relay). A typical application is to use the hottest of three windings to control cooling.

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Multi-Phase Electronic Transformer Monitor

.

Input A, B, C These three windows select three input signals. The control value will be the largest of the three signals selected.

Output Relay Configuration There are eight output relays. Each relay can be controlled by either a single input, a differential calculation or a maximum calculation.

Relay Number This window indicates the number of the relay being configured. Relay Function These two radio buttons enable and disable the relay function. When the relay is disabled, it will remain in the non-energized state.

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Multi-Phase Electronic Transformer Monitor

Relay Operation These two radio buttons select Failsafe or Non-Failsafe operation. In Failsafe operation the contacts of the relay will change state upon supplying power to the unit (unless the set point condition have been met). Failsafe is therefore recommended for cooling equipment relays. Failsafe means the relay status will remain in a power supply failure. This is to ensure cooling on a Transformer that is not supervised. Non-Failsafe is therefore recommended for transformer trip circuits to avoid trip due to a disconnected 509 unit.

Test Lock Out These two radio buttons turn the Test Lock Out on and off. When the Test Lock Out is on, the relay will not change states when the Test button is pressed on the front face of the 509. Having the Test Lock Out on is therefore recommended for Trip circuits and other circuits that should not be activated when the test button is pressed

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Multi-Phase Electronic Transformer Monitor

on the 509 front panel. Relays that are not in Test lock out mode will also be activated when the system relay is activated. Actuation Direction These two radio buttons select the Actuation Direction. When Low to High is selected, the relay will actuate when the input signal becomes greater than the setpoint. When High to Low is selected, the relay will actuate when the input signal becomes less than the setpoint. Primary Setpoint This window specifies the primary setpoint. When the control signal crosses the specified setpoint temperature, the relay is activated. (See the Actuation Direction above). Hysteresis This window specifies the temperature switching differential required to de-activate the relay. If the relay is set low to high, then when the control signal becomes less than the primary setpoint minus the hysteresis, the relay is deactivated. If the relay is set on high to low, then when the signal becomes greater than the setpoint plus the hysteresis, the relay is de-activated. Delay (hours and minutes) These two windows specify by how many hours and minutes the activation of the relay is delayed after the control signal has continually exceeded the setpoint. Auxiliary Current Setpoint This window specifies a secondary setpoint in terms of current. This setpoint is used if the control input signal is derived from a "CT, Temperature" type module. In the event that the actual current exceeds the Auxiliary Current Setpoint value before the temperature value exceeds the Primary Setpoint, the relay is activated. This is used for early cooling on a high load. If the value is set to zero this function is deactivated. The current that is compared to this setpoint is the primary side of the instrumentation CT. For example, if we have a 1200 : 5 CT, and we have the clamp-on on the 5 amp circuit and we know we want the auxiliary current setpoint to be 3 amps on the secondary of the instrumentation CT, then we should enter (1200 / 5 * 3 = 720) 720 amps as our setpoint. It is recommended to connect this function to Fans only, unless the low temperature lockout feature is used with the cooling pumps for the reason that running pumps with too cool oil might cause static electrification which might lead to arcing and insulation damages. Low Temperature Lockout This window specifies the temperature setpoint of which the corresponding liquid temperature signal must be equal to or exceeded for the relay to actuate. This liquid temperature signal is the one selected in the ”CT, Temperature” module winding calculations as the RTD adder. This feature is used to prevent cooling pumps from coming on if the auxiliary current setpoint feature is being used and the temperature is below acceptable temperature limits. It is recommended to also use the Trip Lockout feature in conjunction with this one to prevent accidentally turning on cooling relays when the temperature is below the setpoint value. Controlled By This block defines the control source signal for this relay. A relay can be controlled by a Single Input, a Difference Calculation or a Maximum Calculation. These functions are explained in the previous chapter, Output Loops Configuration.

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Multi-Phase Electronic Transformer Monitor

Seasonal Setpoint Block This window configures the common Seasonal Setpoint function. The Setpoint may need to be adjusted with the changing weather. For example, if a cooling bank is set to actuate at 80 C normally, then during the summer months, with the anticipation of warmer weather, it may be desired to lower the Setpoint to 70 C.

Start Date (Month and Day) Setpoint goes into effect.

These two windows select the date when the Seasonal

End Date (Month and Day) Seasonal Setpoint has effect.

These two windows select the last date when the

Seasonal Setpoint This window specifies the temperature setpoint, which will control the relay during the time period between the Start Date and End Date, when the Seasonal Setpoint is active.

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Multi-Phase Electronic Transformer Monitor

Ambient Temperature Forecast Configuration This window controls the common (all eight relays uses this one set of values) Ambient Temperature Forecast function. This function measures the Ambient Temperature for a designated amount of time and allows the user to automatically adjust the setpoint during heat waves. If the Threshold Value is exceeded by the Ambient Temperature for more than the number of designated Exceeded Hours during the Measurement Period, then the Temperature Shift takes effect.

Controlled By This window specifies the temperature signal source to be used to forecast the temperature. This should be an Ambient temperature probe. Measurement Period This window specifies the Measurement Period in hours. Exceeded Hours This window specifies for how many hours the controlling signal must exceed the Threshold Value in the span of the Measurement Period for the Setpoint Temperature Shift to take effect.

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Threshold Value This window specifies the Threshold Value that takes place of the standard value. All other settings for the relay remain the same, for example hysteresis and time delay. Setpoint Temperature Shift This window specifies the number of degrees to be subtracted from the Setpoint when the Threshold Value has been exceeded for the designated number of hours. For example: If the ambient temperature is greater than 30 degrees C for at least 12 hours over the last 120 hours, then reduce the primary setpoint of the selected relay by 10 degrees C. Then put the values in as the example in the manual shows.

Relay Exerciser The relay exerciser is used to “exercise” the cooling equipment on a regular basis even if the threshold of the activating relay never is passed. This is used to circulate any lubricants and prevent bearings or fans from sitting in a single position and cause static wear. Exercise Time This window specifies the number of minutes the relay will be turned on. For example if the Cycle Time is set to 20 days and the Exercise Time is set to 10 minutes, the relay will activate for 10 minutes every twenty days. Do not enable the exerciser for any relay that controls a trip function.

System Relay Configuration This window configures the System Relay.

The system relay is activated by any abnormal condition in the sensors, internal circuitry or microprocessor failures. The system relay is also activated on power supply failure if set in fail-safe mode. Relays that are not in Test lock out mode will also be activated when the system relay is activated.

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Bank Switching Configuration This window configures the bank switching function. This feature is for evening out wear of cooling equipment in two different cooling groups. For example: If a cooling group is activated by relay 1 at 60 degrees and another cooling group is activated by relay 2 at 75 degrees, then this means that the first group would be used extensively more than the second group. By switching the relays functions the wear will be evened out. There are four blocks, each specifying two relays, labeled as Bank X and Y. The function of the two specified relays in each block is switched once per day.

Relay Pair 1,2,3,4

These four sections specify the pairs of relays that will be bank switched.

Bank A,B,C…..

These eight windows specify the two relays that will be switching functions.

Importing and Exporting Configuration Files Configurations can be saved as files. This is convenient if the same configuration is to be made on multiple 509´s. It could also be convenient to configure a 509 off-line and simply import this configuration at site. The following pull down menu commands are used:

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Multi-Phase Electronic Transformer Monitor

Import A given configuration is imported from a file stored in the PC. The default file extension is ".qcf".

Export The current configuration is stored in the previously specified file for future use. The default file extension is ".qcf".

Export As... The current configuration is stored in a newly specified file for future use. The default file extension is ".qcf".

Print

Will print the current configuration file on the attached printer.

Print Preview Displays the current configuration file on the monitor.

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Multi-Phase Electronic Transformer Monitor

Remote Communications Using the Modem For those applications where it is more convenient to be connected to the 509 remotely, Qualitrol offers a 33.6K modem to work in conjunction with the 509 and the Remote Software. The modem installed in the 509 should be connected to the phone service using a normal (not a null) modem/phone cable. In the Framework window of the Remote Software click on the Modem radio button and hit Connect. The following window will appear on your computer screen.

Phone Number If the 509 is connected to the phone system then enter the corresponding phone number here. Use commas for wait periods if required. TAPI Line

This selects which computer modem to use.

Abort window.

Clicking on the Abort button will remove the user from this

Dial Clicking on the Dial button will cause the computer modem to dial the entered number.

Should the computer modem fail to make a connection the following window will be displayed.

36

Multi-Phase Electronic Transformer Monitor

If the connection fails, check the cable connections, the phone number and make sure the 509 is powered. Once the connection is made the Remote Software will function as specified in the manual.

Frequently Asked Questions About the 509 Q:

While configuring the unit, the display on the 509 reads ’CALL FACTORY ERROR #060’. How do I correct this?

A:

If the user is configuring a unit with multiple CT, Temperature inputs and sets part of the inputs for the simple CT calculation and the rest as the advanced calculation then the unit will display this configuration error. This can be corrected by using the remote software and setting every CT, Temperature input modules as either the simple calculation or as the advanced calculation.

Q:

In the Simple CT Temperature Scaling Configuration, what is the Temperature Adder? And where do I get the values for the other three variables?

A:

The Simple CT Temperature Scaling Configuration calculates the winding temperature of the transformer by using the oil temperature of the transformer and the load or current running through the windings. The RTD input module that is measuring this oil temperature would be the Temperature Adder. As for the temperature rise at a certain current for a specific time constant, these can be deduced from the Transformer Test Report that came with the transformer. The temperature rise (or delta T) is the hot spot temperature of the winding over the oil temperature at a given load. The current is calculated by dividing the secondary KVA with the secondary voltage. Then divide by the instrumentation CT ratio that is being used to give you the load current for that delta T rise. For example: The transformer is a 14000 KVA with a winding of 34400 volts. The instrumentation CT is 1200 : 5. Divide 14000KVA by 34400 to give 407 amps. Divide 407 by 1200/5 which gives 1.69 amps. On the same report it says that the hot spot rise over fluid is 12.7 degrees. So we enter 12.7 degrees at 1.69 amps in the software window. If there is no time constant given on the heat run test report and the

37

Multi-Phase Electronic Transformer Monitor

manufacturer can not supply it then the IEEE Std C57.91 recommends using a number between 5 and 8 minutes.

Q:

What is a time constant?

A:

The time constant is the time that it takes for the winding temperature to reach 63.2% of its full value for a given current load. That means for a given load on a transformer it will take approximately 5 time constants for the winding temperature to reach its final value. So if the time constant is 6 minutes it will take the winding temperature 30 minutes to reach full temperature for a given load.

Q:

What do I do if there isn’t a transformer heat run test report?

A:

First try calling the transformer manufacturers to see if they have a copy of the test report. If not, then see if they have a test report for a similar transformer type or see if there are any specifications mounted directly on the transformer. If all else fails and this is a retrofit project it would be possible to read the mechanical winding gauge (subtract the oil measurement) and measure the current that is coming directly off the instrumentation CT. Then these two values could be plugged into the remote software. If choosing this last method, the closer to full load the transformer is running at the more accurate the values that you’ll be entering into the system will be.

Q:

What is the difference between failsafe and non-failsafe for a relay?

A:

In the 509, Qualitrol uses form C relays. That is a relay with three contacts: normally open, normally closed and a common. When the unit has no power applied to it then the common and normally closed contacts are shorted together while the common and normally open contacts are open. For a non-failsafe relay, when power is applied to the 509, the relay contacts are shorted on the common/normally closed side and open on the common/normally open side. (The same as if no power was supplied to the unit). When the controlling input signal reaches the set point the relay changes states so that the common/normally open side are now shorted (closed) and the common/normally closed side are open. A non-failsafe relay only changes states when the set point has been exceeded and this is why the ’trip’ function is normally assigned to a non-failsafe relay. When power is applied to the unit with a failsafe relay, the relay will immediately change states so that the common/normally open side are shorted together and the common/normally closed side are apart. If the controlling signal reaches the set point or if power is removed from the unit then the relay changes state back to having the common/normally closed being shorted and the common/normally open being apart. It is for this reason that most alarms and cooling systems are connected to a failsafe relay as they will actuate if the set point has been exceeded or if the unit loses power.

38

O OIILL TTEEM MPPEERRAATTUURREE IINNDDIICCAATTO ORR ttyyppee M MSSRRTT 115500 Introduction. Oil temperature indicators serie MSRT are the result of considerable research and experiment commitment which has led to internationally patented new concept instruments design and costruction. The component designs of our instruments are protected by : ITALIAN PATENT No. 208603 ITALIAN PATENT No. 89113 E.E.C. PATENT No. 0245212 U.S. PATENT No. 4,727,227. Effectiveness of these instruments must be stressed, both as regards measuring/commutation precision and extreme semplicity of operation. Special attention has been paid to design of each single part resulting in extreme high reliability of our instruments and ensuring long-lasting accurate operating. We have designed the setting system, the mounting devices and the dimensions of the cable boxes to consent the operator to easily install the indicator and to save time in setting and making cable layout. To grant the quality each instrument has to pass about 70 quality control steps regarding the dimensions, the surface treatments, the precision, the electrical performances, the insulation. Besides the exact constructional and severe quality control we adopt, the high performances of our instruments are further assured by the employ of the best products supplied by European technology’s more advanced names. In particular : 

the POINTER SHAFT is mounted on 2 micro ball bearings to reduce the frictions and to grant right working under vibrations;



the AWG 22 CABLES we adopt are silver plated and protected teflon according to MIL - W - 16878-4 Standard;



the TERMINAL BLOCKS (WEIDMULLER - Germany) grant very high performances and are certified in accordance with VDE and EN standards;



the POWDER PAINT (BAYER) grants total protection against corrosion and increases the insulation of the device;



the SENSING SPRING TUBE is manufactured with a special bronze alloy that avoid any plastic deformation and histeresis of the spring.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

Description and general specifications. TEMPERATURE SENSING SYSTEM: expansion type compensated for ambient temperature changes by means of a built-in compensating device. To avoid checkings after setting into works and periodical re-calibrations we adopt particular cares in testing the components are really useful. In particular the sensing system is subject to 3 different tests: 1. vacuum test: the sensing system is connected to a vacuum plant. The plant pressure is decreased to -3 2x10 mbar (hpa) to verify the quality of the weldings and the porosity of the material; 2. pressure test: the sensing system is put under pressure up to 280 bar to verify the weldings and that the spring is not subject to any deformation; 3. overheating test: after being completed, the sensing system bulbs are located in a heating plant controlled by a microprocessor based temperature monitoring system. The temperature is increased up to a value that is 20% more than the maximum range value of the sensing systems ( i.e. for an indicator 0/150°C the overheating test temperature is 180°C ). The temperature remains at that value for 24 hours in this way simulating 1 year life under normal working conditions ( i.e. for an indicator range = 0/150°C ---> 110°C ). In this way we train the spring and verify that the precision is stable. CAPILLARY TUBE PROTECTION: rilsan tubing / stainless steel armouring / steel + PVC armouring BULB: bronze alloy. CASING: aluminium alloy powder painted (RAL 7035) suitable to withstand to any climate and to heavy polluted atmosphere in as well tropical or artical climates (-40/+70°C). All components are made of corrosion resistant or surface treated materials. The case is provided with a breather device to avoid dew on the lens. To make cable layout quick and easy, the case is equipped with a large junction box that is completely separate from instrument’s sensing system. Cable glands PG 16 - M20 - 3/4"BSP MECHANICAL PROTECTION DEGREE: IP 65.

WORKING TEMPERATURE : -40/+70°C ( optional -50/+70°C ) LENS: glass or polycarbonate

LOCKING RING: NIckel plated brass. Transparent coated. STANDARD MEASURING RANGES: 0/+150°C;

0/+160°C.

MEASURING TOLERANCE: 1,5% of full scale value.

COMMUTATION TOLERANCE: 2% of full scale value.

COMMUTATION DIFFERENTIAL: 4% of full scale value. On customer’s request the differential can be increased.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

INSULATION: 2000V 50Hz between terminals and earth for a 60secs. time MICROSWITCHES MAKING AND BREAKING CAPACITY : VOLTAGE 125 VAC 250 VAC 30 VDC 50 VDC 75 VDC 125 VDC 250 VDC

STANDARD MICROSWITCHES RESISTIVE LOAD INDUCTIVE LOAD 5 A 5 A 5 A 5 A 5 A 3 A 1 A 1 A 0,75 A 0,25 A 0,5 A 0,1 A 0,25 A 0,1 A

HIGH-PERFORMANCE MICROSWITCHES RESISTIVE LOAD INDUCTIVE LOAD 10 A 10 A 10 A 10 A 10 A 10 A 3 A 2,5 A 1 A 0,5 A 0,5 A 0,1 A 0,25 A 0,1 A

Options. ELASTIC SUSPENSION (Drwg. No.1231): it’s a vibration damping system able to minimize the effects of the machine vibrations on the instrument. EARTHQUAKE PROOF VERSION: equipping the instrument with the elastic suspension and suitable internal components it is possible to have earthquake proof winding temperature indicators. PT 100 SENSOR: the winding temperature indicator can be equipped with a PT 100 sensor that converts the temperature values in resistance values and transmits them to a receiver or to a monitoring system. Up to 2 PT 100 sensors can be mounted on the WTI RECEIVER (Drwg. No.1479 or 1529): we can supply digital receivers (different power supply voltage options from standard 230VAC 50/60Hz to special values including DC) to display the temperature signal received from the sensor or from a transducer. TRANSDUCER 4…20mA (Drwg. No.1707): we can supply a wide range of transducer 4…20mA that converts the resistance values ( input Pt100 ) into current values ( output 0..20mA or 4..20mA ) or into voltage values ( 0..5V or 0..10 V). Are also available transducers with double output, with galvanically isolated terminals, for special purposes. This device must be mounted on a DIN rail inside of the transformer marshalling box.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

ELASTIC SUSPENSION

OIL TEMPERATURE INDICATOR MSRT 150

M 14

RIGID LOCKING SCREW 50

6

1

30

9

REAR FLANGE

90

60

150

PATENTED

NO.: B47952

OIL TEMPERATURE

11 4

P. 1 2 3 4 5 6 7 8 9

TERMAN

7,6

Ø 6,5

2

10

120

0

3

50

260

50

Total lenght 377

Ø 172

92

244

Total lenght 258

M 14

9 92

ITALY

12

5

CAPILLARY OUTPUT RIGID LOCKING SCREW / ELASTIC SUSPENSION 10 MAXIMUM INDICATING POINTER 11 DIAL 12 GLASS OR POLYCARBONATE WINDOW

A

PT 100

NO.04 HOLES Ø 6,5mm. at 45° on Ø 175 mm.

B b

115

DESCRIPTION CASE LOCKING GLASS RING MICROSWITCH SETTING POINTER MICROSWITCH SETTING DIAL JUNCTION BOX BREATHER

8

51

Maintenance No particular maintenance is required. Only periodical inspections ( typical interval 6 months ) to verify precision, functions and electrical connections. In case of working test effected with thermostatic bath, please note that WTI bulb MUST NOT be immersed in water. The WTI bulb is surrounded by the heating resistance and water may cause serious damages to the heating system. The calibration test must be done with oil or hot air only. When the instrument is equipped with polycarbonate lens, cleaning must be done with care in order to avoid scraps on the surface. Use water and soap only.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

Operating instructions . MOUNTING: mount the instrument on its machine or plant:  rigid locking screw M14 (Drwg. No.1242/B) located on the top of the thermometer;  elastic suspension (Drwg. 1231) that is mounted on the top of the thermometer with a screw M14 that consents to install the instrument to the plant,  rear flange (Drwg. No.1242/BFN) for wall mounting to the oil tank. REMOVE THE TERMINAL BOX COVER: by unscrewing the 4 stainless steel screws.

CABLE LAYOUT: the numerations 1-2-3-4 indicate the microswitches progression (red, blue, green, yellow pointer). Close to the terminals you will find the following abbreviations: • C = common • NO = normally open • NC = normally closed that allow the operator to choose the desired cable layout. Connect the microswitches terminals and the earth terminal. If the thermal image is equipped with the PT 100 probe you find also the PT 100 terminals with a clear label that indicates how you can connect the probe to the display or to a transducer. After having done all the connecting operations re-position the terminal box cover taking care to put the flat gasket in the right position and screwing the 4 stainless steel screw. SETTING: to set microswitches pls., follow exactly the instructions:  remove the locking ring;  remove the polycarbonate locking clear window (take care to the O-ring);   

stop the microswitches setting dial (small black dial) with two fingers and slide the frictioned microswitches setting pointers until they are located at the desired temperature. Note that to reduce errors you have to slide the pointers towards higher temperature value. Replace the polycarbonate locking clear window taking care that the max. temperature indicating pointer is located on the right side of the temperature indicating pointer and that the lens is correctly positioned over the sealing O-ring; Lock the lens screwing the locking ring.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

Finished Product Quality Control Tests. INSTRUMENT CALIBRATION: carried out through termostatic baths controlled by a computer system. The procedure varies according to instrument scale and number of microswitches. Example of procedure for a thermal image with range 0/150°C: the calibration is made using 5 different baths set at the following temperatures: bath 1 = 0°C bath 2 = 20°C bath 3 = 50°C bath 4 = 100°C bath 5 = 125°C CALIBRATION PROCEDURE: Step 1: a check is carried out to see wheter the temperature taken by the instrument under test differs from that taken through the sample sensor by more than the 70% of the maximum allowed instrument reading tolerance value. This test is performed by sequentially plunging the Winding Temperature bulb into successive temperature increasing thermostatic baths: 0°C/+20°C/+50°C/+100°C/+125°C Step 2: the instrument is heated until the instrument pointer exceeds by 20% the angular full scale value. Step 3: step 1 is repeated, but inversely. MICROSWITCHES ACTUATION TEST: performed through a computer controlled testing unit. The bulb is immersed in a thermostatic bath. The computer changes the temperature inside the bath and by means of suitable sensors verifies the commutation tolerance, the commutation differential, the electrical circuits of each microswitch. At the end of the test a test report is directly printed by the computer. CHECK OF INSTRUMENT MECHANICAL PROTECTION DEGREE: IP 65. This test is carried out by means a lance-sprinkled water jet on all sides of device ISOLATION TEST: carried out by means of a microprocessor controlled testing unit.

NOTE: all the collected data are immediately transferred, by means of the computer net, to the quality control and to the design departments to be supervised and evaluated. In our files, we keep all the above mentioned informations and, for each instrument, we can supply to the customer detailed reports regarding the performances of each instrument delivered.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

W WIINNDDIINNG G TTEEM MPPEERRAATTUURREE IINNDDIICCAATTO ORR ttyyppee M MSSRRTT 115500--W W Introduction. The winding is the component with the highest temperature within the transformer and, above all, the one subject to the fastest temperature increases as the load increases. Thus, to have total control of the temperature parameter within the transformer, the temperature of the winding must also be measured. An indirect system is used to measure this latter since it is dangerous to place a sensor close to the winding due to the high voltage. The indirect measuring is done by means of a Thermal Image. This instrument is designed to measure the temperature of the winding by means of a special bulb surrounded by a heating resistance through which passes a current proportional to the current passing through the transformer winding subject to a given load and immersed in insulating oil at temperature Toil. It’s possible to adjust the heating system by means of a potentiometer whose knob is located on the winding temperature indicator’s dial. In this way the value of the winding temperature indicated by the instrument will be equal to the ones planned by the trafo manufacturer for a given transformer load. The winding temperature indicators can be fitted with one, two, three or four change-over microswitches suitable to control cooling equipments and protection circuits (alarm and trip) of the transformer. This sector of our production is the result of considerable research and experiment commitment which has led to internationally patented new concept instruments design and costruction. The component designs of our instruments are protected by : ITALIAN PATENT No. 208603 ITALIAN PATENT No. 89113 E.E.C. PATENT No. 0245212 U.S. PATENT No. 4,727,227. Effectiveness of these instruments must be stressed, both as regards measuring/commutation precision and extreme semplicity of operation. Special attention has been paid to design of each single part resulting in extreme high reliability of our instruments and ensuring long-lasting accurate operating. We have designed the setting system, the mounting devices and the dimensions of the cable boxes to consent the operator to easily install the indicator and to save time in setting and making cable layout. Besides the exact constructional and severe quality control we adopt, the high performances of our instruments are further assured by the employ of the best products supplied by European technology’s more advanced names. In particular :     

the INDICATING SHAFT is mounted on 2 micro ball bearings to reduce the frictions and to grant right working under vibrations; the AWG 22 CABLES we adopt are silver plated and protected teflon according to MIL - W - 16878-4 Standard; the TERMINAL BLOCKS (WEIDMULLER - Germany) grant very high performances and are certified in accordance with VDE and EN standards; the POWDER PAINT (BAYER) grants total protection against corrosion and increases the insulation of the device; the SENSING SPRING TUBE is manufactured with a special bronze alloy that avoid any plastic deformation and histeresis of the spring.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

Description and general specifications. TEMPERATURE SENSING SYSTEM: expansion type compensated for ambient temperature changes by means of a built-in compensating device. To avoid checkings after setting into works and periodical re-calibrations we adopt particular cares in testing the components are really useful. In particular the sensing system is subject to 3 different tests: 1. vacuum test: the sensing system is connected to a vacuum plant. The plant pressure is decreased to -3 2x10 mbar (hpa) to verify the quality of the weldings and the porosity of the material; 2. pressure test: the sensing system is put under pressure up to 280 bar to verify the weldings and that the spring is not subject to any deformation; 3. overheating test: after being completed, the sensing system bulbs are located in a heating plant controlled by a microprocessor based temperature monitoring system. The temperature is increased up to a value that is 20% more than the maximum range value of the sensing systems ( i.e. for an indicator 0/150°C the overheating test temperature is 180°C ). The temperature remains at that value for 24 hours in this way simulating 1 year life under normal working conditions ( i.e. for an indicator range = 0/150°C ---> 110°C ). In this way we train the spring and verify that the precision is stable. CAPILLARY TUBE PROTECTION: rilsan tubing / stainless steel armouring / steel + PVC armouring BULB: bronze alloy. CASING: aluminium alloy powder painted (RAL 7035) suitable to withstand to any climate and to heavy polluted atmosphere in as well tropical or artical climates (-40/+70°C). All components are made of corrosion resistant or surface treated materials. The case is provided with a breather device to avoid dew on the lens. To make cable layout quick and easy, the case is equipped with a large junction box that is completely separate from instrument’s sensing system. Cable glands PG 16 - M20 - 3/4"BSP MECHANICAL PROTECTION DEGREE: IP 65.

WORKING TEMPERATURE : -40/+70°C ( optional -50/+70°C ) LENS: glass or polycarbonate

LOCKING RING: NIckel plated brass. Transparent coated. STANDARD MEASURING RANGES: 0/+150°C;

0/+160°C.

MEASURING TOLERANCE: 1,5% of full scale value.

COMMUTATION TOLERANCE: 2% of full scale value.

COMMUTATION DIFFERENTIAL: 4% of full scale value. On customer’s request the differential can be increased.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

INSULATION: 2000V 50Hz between terminals and earth for a 60secs. time MICROSWITCHES MAKING AND BREAKING CAPACITY : VOLTAGE 125 VAC 250 VAC 30 VDC 50 VDC 75 VDC 125 VDC 250 VDC

STANDARD MICROSWITCHES RESISTIVE LOAD INDUCTIVE LOAD 5 A 5 A 5 A 5 A 5 A 3 A 1 A 1 A 0,75 A 0,25 A 0,5 A 0,1 A 0,25 A 0,1 A

HIGH-PERFORMANCE MICROSWITCHES RESISTIVE LOAD INDUCTIVE LOAD 10 A 10 A 10 A 10 A 10 A 10 A 3 A 2,5 A 1 A 0,5 A 0,5 A 0,1 A 0,25 A 0,1 A

Options. ELASTIC SUSPENSION (Drwg. No.1231): it’s a vibration damping system able to minimize the effects of the machine vibrations on the instrument. EARTHQUAKE PROOF VERSION: equipping the instrument with the elastic suspension and suitable internal components it is possible to have earthquake proof winding temperature indicators. PT 100 SENSOR: the winding temperature indicator can be equipped with a PT 100 sensor that converts the temperature values in resistance values and transmits them to a receiver or to a monitoring system. Up to 2 PT 100 sensors can be mounted on the WTI RECEIVER (Drwg. No.1479 or 1529): we can supply digital receivers (different power supply voltage options from standard 230VAC 50/60Hz to special values including DC) to display the temperature signal received from the sensor or from a transducer. TRANSDUCER 4…20mA (Drwg. No.1707): we can supply a wide range of transducer 4…20mA that converts the resistance values ( input Pt100 ) into current values ( output 0..20mA or 4..20mA ) or into voltage values ( 0..5V or 0..10 V). Are also available transducers with double output, with galvanically isolated terminals, for special purposes. This device must be mounted on a DIN rail inside of the transformer marshalling box.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

92

50

3

7

5

NO.04 HOLES Ø 6,5mm. at 45° on Ø 175 mm.

Ø 6,5

REAR FLANGE

M 14

Total lenght 258

0

30

60

T

CURRENT 2A

12 0

ITALY

15 0

15 0W

TERMAN

90

M SR T

NO.: B47952

A RE IN SE RT JUM PER AFT ER ADJUSTEM ENT

RED

115

BLUE

GREEN

SWITCH N.1 SWITCH N.2 SWITCH N.3

nc c no nc c no

150

120

PATENTED

90

SWITCH N.4

YELLOW

WINDING TEMPERATURE

MAX POWER ABSORBED: 15 VA

30

0

60

HEATING RESISTANCE ADJUSTMENT

MAX CURRENT : 2 A

6

Ø 172

12

4

11

10

244

RIGID LOCKING SCREW

50

51

92

260

50

WINDING TEMPERATURE INDICATOR MSRT 150-W

7,6

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/ 12

10 11

9

8

7

P. 1 2 3 4 5 6

50

DESCRIPTION CASE LOCKING GLASS RING MICROSWITCH SETTING POINTER MICROSWITCH SETTING DIAL JUNCTION BOX AIR HOLE POTENTIOMETER FOR HEATING RESISTANCE ADJUSTMENT CAPILLARY OUTPUT RIGID LOCKING SCREW ELASTIC SUSPENSION MAXIMUM INDICATING POINTER DIAL GLASS OR POLYCARBONATE WINDOW

9

M 14

ELASTIC SUSPENSION

Total lenght 377

Operating instructions . MOUNTING: mount the instrument on its machine or plant:  rigid locking screw M14 (Drwg. No.1242/B) located on the top of the thermometer;  elastic suspension (Drwg. 1231) that is mounted on the top of the thermometer with a screw M14 that consents to install the instrument to the plant,  rear flange (Drwg. No.1242/BFN) for wall mounting to the oil tank. REMOVE THE TERMINAL BOX COVER: by unscrewing the 4 stainless steel screws.

CABLE LAYOUT: the numerations 1-2-3-4 indicate the microswitches progression (red, blue, green, yellow pointer). Close to the terminals you will find the following abbreviations: • C = common • NO = normally open • NC = normally closed that allow the operator to choose the desired cable layout. Connect the microswitches terminals and the earth terminal. If the thermal image is equipped with the PT 100 probe you find also the PT 100 terminals with a clear label that indicates how you can connect the probe to the display or to a transducer. After having done all the connecting operations re-position the terminal box cover taking care to put the flat gasket in the right position and screwing the 4 stainless steel screw. REGULATION OF THE VALUE OF T: within the instrument’s terminal board there are, as well as earth and microswitches connection terminals, the terminals T-T and the terminals A-A (see Drwg. No.1455). Procedure for regulating the instruments: 1. insert the ammeter probes in terminals A-A 2. remove jumper A-A 3. connect terminals T-T to the current transformer. AFTER having checked that the value of the power supply current printed on the dial (above the knob for regulating overheating) is, in fact, the same as that of TA 4. regulate the current on the basis of curve I - T attached 5. replace jumper A-A 6. remove the ammeter probes 7. wait a few minutes to allow Tw to stabilize 8. check the exactitude of Tw N.B.: the bulb of the thermometer for the thermal image must be filled with oil to accelerate the heat interchange occurrences. The bulb must be inserted in a well filled with transformer oil: the oil will rise through a suitable hole located in the bottom of the bulb itself until it covers the resistance. It’s very important to stress that the I - T curves are only valid if the bulb is immersed in oil. SETTING: to set microswitches pls., follow exactly the instructions:  remove the locking ring;  remove the polycarbonate locking clear window (take care to the O-ring);   

stop the microswitches setting dial (small black dial) with two fingers and slide the frictioned microswitches setting pointers until they are located at the desired temperature. Note that to reduce errors you have to slide the pointers towards higher temperature value. Replace the polycarbonate locking clear window taking care that the max. temperature indicating pointer is located on the right side of the temperature indicating pointer and that the lens is correctly positioned over the sealing O-ring; Lock the lens screwing the locking ring.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

Maintenance No particular maintenance is required. Only periodical inspections ( typical interval 6 months ) to verify precision, functions and electrical connections. In case of working test effected with thermostatic bath, please note that WTI bulb MUST NOT be immersed in water. The WTI bulb is surrounded by the heating resistance and water may cause serious damages to the heating system. The calibration test must be done with oil or hot air only. When the instrument is equipped with polycarbonate lens, cleaning must be done with care in order to avoid scraps on the surface. Use water and soap only.

Finished Product Quality Control Tests. INSTRUMENT CALIBRATION: carried out through termostatic baths controlled by a computer system. The procedure varies according to instrument scale and number of microswitches. Example of procedure for a thermal image with range 0/150°C: the calibration is made using 5 different baths set at the following temperatures: bath 1 = 0°C bath 2 = 20°C bath 3 = 50°C bath 4 = 100°C bath 5 = 125°C CALIBRATION PROCEDURE: Step 1: a check is carried out to see wheter the temperature taken by the instrument under test differs from that taken through the sample sensor by more than the 70% of the maximum allowed instrument reading tolerance value. This test is performed by sequentially plunging the Winding Temperature bulb into successive temperature increasing thermostatic baths: 0°C/+20°C/+50°C/+100°C/+125°C Step 2: the instrument is heated until the instrument pointer exceeds by 20% the angular full scale value. Step 3: step 1 is repeated, but inversely. MICROSWITCHES ACTUATION TEST: performed through a computer controlled testing unit. The bulb is immersed in a thermostatic bath. The computer changes the temperature inside the bath and by means of suitable sensors verifies the commutation tolerance, the commutation differential, the electrical circuits of each microswitch. At the end of the test a test report is directly printed by the computer. CHECK OF INSTRUMENT MECHANICAL PROTECTION DEGREE: IP 65. This test is carried out by means a lance-sprinkled water jet on all sides of device ISOLATION TEST: carried out by means of a microprocessor controlled testing unit.

NOTE: all the collected data are immediately transferred, by means of the computer net, to the quality control and to the design departments to be supervised and evaluated. In our files, we keep all the above mentioned informations and, for each instrument, we can supply to the customer detailed reports regarding the performances of each instrument delivered.

Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY Tel. +39 0238303048 Fax +39 02 38303719 E-mail : [email protected] website : http://www.terman.com/

terman’90 THERMAL IMAGE MICROSWITCHES-EQUIPPED WINDING TEMPERATURE INDICATOR “MSRT 150W” CURVE I - ∆T FOR TEMPERATURE RISING ADJUSTMENT RISE ∆T (°C)

CURRENT I2 (A) 0,5 0,7 0,85 1 1,1 1,2 1,35 1,45 1,5 1,6 1,7 1,8

POWER ABSORBED (VA) if I1=2A

5 10 15 20 25 30 35 40 45 50 55 60

4,4 6,2 7,9 9 9,9 10,8 12 13 13,5 14,4 15,3 15,7

TEMPERATURE RISE CURVE - I1=2A thermometer bulb oil filled

I2 (A) 2

Toil=50°C

1,8 1,6 1,4 1,2 1 0,8 0,6 0,4 0,2 0 0

10

20

30

40

50

60

NOTE: I - ∆T CURVE IS VALID ONLY IF THE BULB IS IMMERSED IN OIL

2A

70 ∆ T (°C)

BA Power Transformers Product Information Authorised by: Project Manager

1ZBA 569 002-4

Revision No. Replaces:

2001-10-15 Page: 1 of 4

Oil Level Indicator

TYPES LA14XOS LA22XOS LB14XOS LB22XOS

Revisions: No Date 2000-04-19 1 2001-10-15 A

Pages

First Edition: 2000-03-31 No. Date Pages B C

ABB TPT BA-Standard Revision No. A

Oil Level Indicator Page 2

1ZBA 569 002-4 2001-10-15

1 Scope This Product Information contains general information of the referring product itself as well as general procedure to be followed, regarding the installation assembling and operation. This instruction does not support to cover all possible contingencies, which may arise during installation, operation or maintenance. Once you require further information of your equipment, contact the ABB Power Transformer factory or ABB local representative company 2 General There are two types of Oil Level Indicator available: Radial; for application on oil conservator without polyurethane air cell. The float movement direction in this case is radial in respect of the axis of conservator. Two diameter gauge are available; Ø140 or Ø220 mm. Axial for application on conservator with polyurethane air cell. The float movement direction in this case is axial respect of the axis of conservator. Two diameter gauge are available; Ø140 or Ø220 mm. The standardised Oil Level Indicator is supplied with two micro-switches for minimum and maximum oil level indication and a float with a variable length float rod. 3 Design The Oil Level Indicator consists of a waterproof case (1), a float + float rod (2), a magnetic coupling, a gauge disk (4) and a bottom terminal box with cable gland (6) Pg 16 to DIN 46320, see figure 1. The case is made of aluminium alloy casting, painting with double coat of polyurethane. Finish colour RAL 7001. The float is made in nitrophy and it has no chamber in it, which prevents damage during vacuum proof or loose function when it is possible to have oil inside. The Oil Level Indicator contains two micro-switches for indication the minimum and maximum oil level. The micro-switches are set with an advance angle of 5º with respect to the indication of the minimum or maximum oil level in the conservator. The float rod is completely thread and the length must be specified when ordering an Oil Level Indicator.

ABB TPT BA-Standard Revision No. A

Oil Level Indicator Page 3

1ZBA 569 002-4 2001-10-15

The movement of the float rod and the gauge disk takes place by means of the magnetic coupling through an angle of 120º. In this way, for every variation in the level of the oil there is a correspondent rotation of the magnetic coupling with consequent variation of the indication on the dial of the gauge. The gauge disk is coloured white and black. The system is closed with a screenprinted polycarbonate disk with graduated scale reference marks corresponding to the levels that the oil should reach. FIGURE 1

2

3

1

4 5 6 2

1 - Case 2 - Float with arm 3 - Fixing screew 4 - Disk 5 - Name plate 6 - Junction box 7 - O-ring rim

4 Specification Application:

Oil-filled transformer

Ambient temperature:

-25 to 60 °C

Operation temperature:

-25 to 120 °C

Installation:

Indoors and out of doors, tropical

Protective class:

IP54 to DIN VDE 0470-1

Insulation test:

2,5 kV, 50/60 Hz, 1 minute.

Materials Casing: Screen-printed: Box cover , bolts, nuts and name plate Cable glands Gaskets:

Aluminium alloy painting with double polyurethane. Finish colour RAL 7001 Polycarbonate Stainless steel Brass, zinc plated Nitrile rubber

coat

of

ABB TPT BA-Standard Revision No. A

Oil Level Indicator Page 4

1ZBA 569 002-4 2001-10-15

Micro-switches Number:

2 changeover type

Power supply:

24 to 220 Vac/Vdc

Contact materials:

Silver-Cadmium-Oxide (AgCdO10)

Switching capacity (A):

Voltage

Resistive load

125/250Vac 125 Vdc 250 Vdc

3

Contact life:

Inductive load L/R = 40 ms 0 0,5 0,25

250.000 switching operations at a switching frequency of 0,5 Hz and ambient temperature of 25 ºC.

5 Mounting The micro-switches are set with an advance angle of 5º with respect to the indication of the minimum or maximum oil level in the conservator. After installation of the gauges it is possible to check the correct operation of the micro-switches and, in general, good operation of all the internal parts of the gauge by proceeding as follows. Remove the cap situated in the centre of the dial on the front of the level gauge, unscrewing it in an anticlockwise direction. Insert a screwdriver in the slot provided and turn the gauge disk until the electrical circuit connected to it switches on or off. Close the cap again, being particularly careful to position the O-ring correctly under the cap and to screw the cap on quite firmly. FIGURE 2 – WRING DIAGRAM

MA OIL

12 11 14 22 21

MI

WIRING

6 MAINTENANCE The Oil Level Indicator is maintenance free. It is, however, recommended to make a visual inspection for oil leakage during normal station, insulation test towards earth and micro-switches operations.

Rev. ind. Revision

A

Redrawn

B

Hole D=11.5 was D=7

C

O-ring Ø 161 was Ø 103

Appd.

Date

S. K.

2000-04-31

W. Klein

2001-03-05

G. Y.

2001-09-25

PURCHASE DRAWING Material: Casing: Bolts, nut and name plate: Float: Cable gland: Rod (arm) float: Screen-printed: Gaskets:

Aluminium alloy casting, painted with double coat of polyurethane. Finish colour grey RAL 7001 Stainless steel Nitrophil full vacuum and l kgf/cm2 Brass, zinc plated Brass Polycarbonate Nitrile rubber

Specification: Increment protection: Operating temperature: Insulation class:

IP 54 to DIN VDE 0470-1 -40 to 120ºC 2,5 kV, 50/60 Hz, 1 min.

We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without expressed authority is strictly forbidden.

Microswitch: Type: Switching capacity (A):

2, changeover for Minimum and Maximum level signalling Voltage Resistive load Inductive load L/R=40 ms 125/250 Vac 3 125 Vdc 0,5 250 Vdc 0,25

Supply condition: Type DN (Comem ref.)

 ABB Transform

LA22XOS •

Ø220

Float arm length

Remark

Mass kg

1000 (ABB will adjust for

2 O-ring (OR221) will be supplied

each transformer order)

with the Oil Level Indicator

2,95

Nameplate with “CE Marking” 90 8x Ø11.5

56,5 24

19º 12º 60º

60º

Name Plate

123 Based on

9º

325

Ø220

Ø 190

9º 9º 60º

11º 12º 19º

58

60º

11º 9º

R=1000

Ø 60

Ø161

Terminal Box Float

Ø58

Reg. No.

569 Prepared

Responsible department

S. Kamikata:

TPT/D

Approved

Take over department

R. Girgis: 1998-10-27

Pg 16, DIN 46320

Dial graduations (Do not show the angle on the dial)

OIL LEVEL INDICATOR For conservator without polyurethane cell

Revision

DN = 220, float rod = 1000

C Document No.

ABB Transformers

1ZBA 569001-C

Language

en Page

1 (1)

60°

24 Ø20

H min Ø 60

5 Rolling Float

Z

Ø 220 150

 ABB Power Technology Products Management

Ltd.

123

325

45°

L

2001

Indicator type: Number of contact/type Contact braking capacity Connection type Insulation class Reference temperature Float material withstand Float arm length Bolts, nuts, washers material Increment protection Painting Operating temperature Mass: Remark:

Model LB22X0S-magnetic type (COMEM designation) 2 contacts (Minimum level and Maximum level) Microswitch - Changeover-switch 3A , 125/250 Vac (resistive) 0.5A, 125 Vdc for inductive load L/R = 40 ms 0.25A, 250 Vdc for inductive load L/R = 40 ms Terminal box with outlet thread Pg16 2.5 kVac, 50/60 Hz, 1 min. “Min” ; “Max” Nitrophil, full vacuum and l kgf/cm2 The indicator should be tested at Comem Stainless steel IP 54 Double coat of polyurethane mono-component on aluminum part, finish color gray RAL 7001 -40o C to +120o C 3.3kg 2 Nitrile rubber gaskets (OR221, D=5.34, Inner Dia.=149.2 acc. to 1ZBA 115 001-6) will be supplied with the Oil Level Indicator

Nameplate with “CE Marking” Design engng. review

58

A

36

Production engng. review

We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without expressed authority is strictly forbidden.

PG 16

140

45°

Inspection engng. review

Z

Ø12

120°

Z

90

3.5 Ø11.5

L= 1531

Ø150

H max

Ø161

A

Ø 220

45°

Ø190

jig kjoijoijokjokjnlkjnf

The microswitches are set with an advance angle of 5° with respect to the indication of the minimum (Hmin) or maximum (Hmax) oil level

Based on

Reg. No.

Prepared

Responsible department

S. Kamikata

PTPT/ GD

Approved

Take over department

D

Float arm length was 1490, Float arm bent

W. Klein

2002-08-02

W. Klein 1998-10-27

C

Float arm length was 1680

W. Klein

2002-04-19

Revision

Total mass [kg]

B

Modify drawing

M .Cai

2001-07-26

D

3.3

A

Redrawn

Rev. ind. Revision

S. K.

2000-03-31

Appd.

Date

Title

569

BA Power Transformers

Scale

Oil Level Indicator LB 22 (Float arm length = 1531)

Language

en

Order

Page

Document No.

cont.

1

1ZBA 569 001-X

-

PowerIT Transformers and Reactors

KC-Trockenperlen Orange

Table of contents 1.0Scope ........................................................................................................................................ 3 2.0Design and mode of operation................................................................................................... 3 3.0Assembly and Inspection ........................................................................................................... 3 4.0Exchange of KC-Trockenperlen Orange .................................................................................... 3 5.0Reactivation of KC-Trockenperlen Orange ................................................................................ 3 6.0Hazards Identification and First Aid Measures........................................................................... 4 7.0Revision..................................................................................................................................... 4

Oil

TYPEN EM2DA EM4DA EM5DA EM6DA EM7DA EM8DA

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-05-05

Applicability:

TrafoStar

Lang:

1995-06-28 en

Document No.

1ZBA676002-1

Rev. No:

D

Page No:

Page 2 of 4

Title:

KC-Trockenperlen Orange

1.0

Scope The function of the breather is to keep free from moisture the air, which is sucked into the conservator by temperature changes in oil-filled transformers. The device is filled with a highly effective damp absorbing substance, KCTrockenperlen Orange. KC-Trockenperlen Orange in the active state is orange, but as it becomes saturated with moisture its colour changes to neutral. Saturated KC-Trockenperlen Orange can be re-used after reactivation.

2.0

Design and mode of operation The design of the breather is shown in Fig. 1. The breather is connected to the tube from the oil conservator by flange 1. The container for the KC-Trockenperlan Orange consists of a polycarbonate cylinder 2, cover 3 and end piece 4, the parts being held together by bolt 5. The air is sucked in through holes in the end piece and continues through the oil and up through the KC-Trockenperlen Orange as shown by the arrows in figure 1. Figure 1

1

8

. . . . .. .. .. .. .. .. .. . ....... .. ............

3 1 1- Flange Flange 2 Cylinder 2 - Cylinder 3 3- Cover Cover 4 End piece 4 5- Bolt End piece 5 6- Oil Stud fastener pocket 6 7- Transformer Oil pocket oil protector 7 8- Cylinder Transformer oil 8 - Cylinder protector

5 2 4 7 8

Oil

3.0

Assembly and Inspection When installing the breather, the tube from the conservator is connected to the flange of the breather. The breathers are supplied separately and their openings are plugged to prevent the KC-Trockenpleran Orange becoming affected by moisture. These plugs are removed before the breathers are installed. A correctly installed breather requires little attention. It is designed for an operating time of 12 months. The time is, however, dependent on the moisture content of the air sucked in and the size and frequency of the load variations, and it can therefore vary considerably. In very damp climates only half the normal operating time can be guaranteed. Moisture saturation of the KC-Trockenperlen Orange takes place gradually, beginning at the inlet end, and can be seen from the colour change. Check occasionally that gasket and pipe connections are in order and that the polycarbonate cylinder is whole. The moisture saturation of the KC-Trockenperlen Orange should also be checked in regular intervals.

4.0

Exchange of KC-Trockenperlen Orange When the KC-Trockenperlen Orange has become neutral in colour, it must be changed. This should be done when the transformer temperature is rising, and the air current going out. If dry KC-Trockenperlen Orange is available, it should be used to fill the cylinder. If this is not the case, the used KC-Trockenperlen Orange can be used again after it has been reactivated.

5.0

Reactivation of KC-Trockenperlen Orange For re-activation KC-Trockenperlen Orange, is spread out in a thin layer on a metal or glass plate, which is then placed in a ventilated oven. Drying is carried out at 130 – 160 °C (266 - 320 °F). When the colour of the KC-Trockenperlen Orange has changed from neutral to orange, it can be re-used. Temperature above 160 °C are not allowed.

Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-05-05

Applicability:

TrafoStar

Lang:

1995-06-28 en

Document No.

1ZBA676002-1

Rev. No:

D

Page No:

Page 3 of 4

Title:

KC-Trockenperlen Orange

6.0

Hazards Identification and First Aid Measures KC-Trockenperlen is not classified as dangerous in the meaning of transport regulations (ADR). The substance is not classified as a dangerous substance according to European directive on classification of hazardous preparations 93/112/EEC. Usual precautions in handling chemicals must be observed. First air measures General advice

No hazards which require special first aid measures

Inhalation

Do not breathe dust. Have a rest, move to fresh air, contact a physician

Skin contact

Wash hands and face before breaks and immediately after handling the product. If skin irritation persists, call a physician.

Eye contact

Rinse thoroughly with plenty of water, also under the eylids. If eye irritation persists, consult a specialist.

Ingestion Call a physician immediately The information above was provided by the manufacturer of the KC-Trockenperlen Orange.

7.0

Revision B C D

2000-03-31 2002-06-25 2003-05-05

Silica gel replaced by KC-Trockenperlen New Format

DISCLAIMER OF WARRANTIES AND LIMITAITON OF LIABILITY THERE ARE NO UNDERSTANDINGS, AGREEMENTS, REPRESENTATIONS, OR WARRANTIES, EXPRESS OF, OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THOSE SPECIFICALLY SET OUT BY AN EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF THE SELLER. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP. The information, recommendations, descriptions, and safety notations in this document are based on our experience and judgment with respect to transformers. THIS INFORMATION SHOULD NOT BE CONSIDERED TO BE INCLUSIVE OR TO COVER ALL CONTINGENCIES. If further information is required, ABB should be consulted. NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, DESCRIPTIONS, AND SAFETY NOTATIONS CONTAINED HEREIN. In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability, or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever including, but not limited to, damage to, or loss of use of, equipment, plant or power system, cost of capital, loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, or claims against the user by its customers resulting from the use of the information, recommendations, description, and safety notations contained herein. ABB continually strives to make its instructions accurate, up-to-date, and easy to understand. All comments and suggestions for improvement should be FAXed to: ABB Power Transformers, Literature Coordinator: +1-314-679-4595 or E-mailed to: [email protected] For a reply, please include your name, company, phone, fax and/or E-mail address.

IT

Industrial Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for lifecycle product support in consistent electronic form. Prepared By:

W. Klein

Date:

Approved By:

Anders Lindroth

Rev. Date: 2003-05-05

Applicability:

TrafoStar

Lang:

1995-06-28 en

Document No.

1ZBA676002-1

Rev. No:

D

Page No:

Page 4 of 4

Title:

KC-Trockenperlen Orange

Rev. ind. Revision

Appd.

Date

B

Redrawn

S. K.

00-03-31

C

Masses corrected

JMG

00-8-21

PURCHASE DRAWING Material: Silicagel: Flange and end piece: Cylinder and oil pocket: Protection of cylinder, bolts, nuts and name plate: Gaskets: Specification: Operating temperature:

Silicium - oxide (silicagel) with orange indicator Aluminium alloy, double coat with polyurethane Finish colour grey RAL 7001 Polycarbonate Stainless steel Nitrile rubber -40 ºC to +100 ºC

Ø14

675

15

We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without expressed authority is strictly forbidden.  ABB Transformer

Supply condition: Mass Type kg (Comem ref.) Total Silicagel EM5DA 16,7 10,5 Supplied with silicagel and sealed package

Ø110 Ø140

Ø220

Based on

Reg. No.

Prepared

Responsible department

S. Kamikata: 95-03-20 Approved

AIR BREATHER TPT/D

Take over department

Language

R. Girgis: 95-03-25

en

Revision

Page

C

EM5DA Document No.

ABB Transformers

1ZBA 676001-C

1 (1)

Rev. ind. Revision

Appd.

Date

B

Redrawn

S. K.

00-03-31

C

Masses, dimensions corrected

JMG

00-7-01

PURCHASE DRAWING Material: Silicagel: Flange and end piece:

Silicium - oxide (silicagel) with orange indicator Aluminium alloy, double coat with polyurethane. Finish colour grey RAL 7001 Polycarbonate

Cylinder and oil pocket: Protection of cylinder, bolts, nuts and nameplate: Gaskets:

Stainless steel Nitrile rubber

Specification: Operating temperature:

-40 ºC to +100 ºC

12

Ø12

265

 ABB Transformer

We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without expressed authority is strictly forbidden.

Supply condition: Type Mass (Comem ref.) kg Total Silicagel EM2DA 3 0,76 Supplied with silicagel and sealed package The breather has to contain a label with indication of “Dry and wet” silicagel and the nameplate “CE marking”

Ø75 Ø100

140 Ø135

Based on

Reg. No.

Prepared

Responsible department

S. Kamikata: 95-03-20 Approved

AIR BREATHER TPT/D

Take over department

Language

R. Girgis: 95-03-25

en

Revision

EM2DA

C Document No.

ABB Transformers

1ZBA 676001-A

Page

1 (1)

Naphthenics Product Data Sheet

2005-04-08

Nynas Transformer Oil - Nytro 10XN PROPERTY

UNIT

TEST METHOD

GUARANTEED DATA Min Max

TYPICAL DATA

kg/dm3 mm2/s mm2/s

IEC 60296 ISO 12185 ISO 3104 ISO 3104 ISO 3016

Clear, free from sediment 0.895 8.0 800 -45

% % Wt % mg/kg

IEC 62021 DIN 51353 ISO 14596 IEC 60590 IEC 60666 IEC 60814

0.01 non-corrosive 0,15

mN/m

IEC 60247 ISO 6295

40

<0.001 50

kV kV

IEC 60156 IEC 60296/60156

30 70

40-60 >70

1. Physical Appearance Density, 20°C Viscosity, 40°C Viscosity, -30°C Pour Point

°C

0.877 7.6 730 -63

2. Chemical Acidity Corrosive sulphur Sulphur content Aromatic content Antioxidant, phenols Water content

mg KOH/g

0,4 30

<0.01 <0,01 7 0.3 <20

3. Electrical Dielectric dissipation factor at 90°C Interfacial tension Breakdown voltage - Before treatment - After treatment

0.005

4. Oxidation Stability At 120°C, 500h Total acidity Sludge DDF/90 °C

IEC 61125 C mg KOH/g Wt %

0,30 0,05 0,05

0,04 <0,02 0.03

5. Health, safety and environment Flash Point, PM DMSO extractable compounds (PCA) PCB

°C

ISO 2719

140

146

Wt %

IP 346 IEC 61619

3 not detectable

<3

Nytro 10XN is an inhibited transformer oil with extremely good electrical and low temperature properties and very good oxidation stability. This product meets IEC 60296 (03), special applications and ASTM D3487 type II (excluding gassing tendency).

1/8

Naphthenics Safety Data Sheet

2005-04-05

SAFETY DATA SHEET

1.

Identification of the Substance/Preparation and the Company/Undertaking Product Name:

Nytro 10XN

Product Type:

Insulating Oil

Supplier:

Nynas Naphthenics AB P. O. Box 10701 S-121 29 STOCKHOLM Sweden

2.

Telephone No:

+46-8-602 1200

Fax: +46-8-81 62 02

Emergency Phone No:

Please contact your local Nynas sales office for specific information regarding your country.

Composition/Information of Ingredients Chemical Name:

CAS-No.:

Hydrotreated Light Naphthenic Distillate

64742-53-6 265-156-6 128-37-0

EC-No.:

204-881-4

Weight%

Symbols/Phrases

99,7 0,3

R 51/53, N

2,6-ditertiary Butyl-4-Methyl Phenol

Issuing date: 2005-04-05

Nytro 10XN

2/8

3.

Hazards identification Classification: Human Health:

Environment:

Physical and chemical hazard:

4.

No classification needed according to 67/548/EC and 1999/45/EC. Inhalation of vapours and/or mists might irritate respiratory tract. Prolonged skin contact will cause defatting and possible irritation. Eye contact might cause irritation. Slow biodegradation, the product will remain for long time in the environment. Risk for contamination of earth, soil and water. At elevated temperatures flammable vapours and decomposition products will be released. Risk for slippery floors if spilled out.

First Aid Measures General advice: Inhalation:

Skin contact: Eye contact: Ingestion:

5.

If inhalation of mists, fumes or vapours occur causing irritation, move to fresh air. If the symptoms persist, obtain medical advice. Remove immediately adhering matter and wash off with soap and plenty of water. Rinse with plenty of water. Clean mouth with water. Obtain medical advice if a large amount has been swallowed. Do not induce vomiting.

Fire-fighting Measures Suitable extinguishing media: Extinguishing media which must not be used for safety reasons:

Issuing date: 2005-04-05

Extinguish preferably with dry chemical, carbon dioxide (CO2), or foam. Waterspray / mist may be used. Water jet, unless used by authorised people.(Stain risk caused by combustion).

Nytro 10XN

3/8

6.

Accidental Release Measures Personal precautions:

Suitable protection equipment should be used. In case of large spillage, the cleaning procedure should be carried out using suitable protective clothing such as overall, gloves and boots. Remove contaminated clothes as soon as possible. Smaller spillage can be wiped up with paper cloths, using protective

Environmental precautions:

gloves. Prevent spills to enter and spread to drains, sewers, water courses, and soil. Contact local safety authorities.

Methods for cleaning up: Absorb leaking product with sand, earth or other suitable inert material and collect. Disposal according to section 13.

7.

Handling and Storage Handling:

Storage:

8.

Handle in accordance with good industrial hygiene and safety practices. If handled at elevated temperatures or with high speed mechanical equipment, vapours or mists might be released and require a well ventilated workplace. Store at ambient temperature or with lowest necessary heating as handling requires.

Exposure Controls/Personal Protection Control parameters:

Exposure via the air and normal handling.

Chemical name:

Mineral oil.

Short term value:

5 mg/m3. TLV-TWA 8 hours ACGIH (1998). Engineering measures to Mechanical ventilation and local exhaust will reduce exposure reduce exposure: via the air. Use oil resistant material in construction of handling equipment. Store under recommended conditions and if heated, temperature control equipment should be used to avoid overheating.

Issuing date: 2005-04-05

Nytro 10XN

4/8

Personal protection equipment: - Respiratory protection: If the product is heated under manual handling, use suitable mask with filter A1P2 or A2P2. Handling in automatic production lines, with exhaust or ventilation, will not require mask. - Hand protection: Wear oil-resistant protective gloves if there is a risk of repeated skin contact. Suitable gloves are neoprene, nitrile- or acrylnitrilebutadiene rubber, or PVC. Take notice of CEN 420:94, CEN 374:1-3:94 and CEN 388:94. - Eye protection: Wear safety goggles / safe shield if splashes may occur. - Skin and body protection:

Wear protective clothing if there is a risk of skin contact and change them frequently, or when contaminated.

Hygienic measures:

Act in accordance with good industrial hygiene and safety practice.

Issuing date: 2005-04-05

Nytro 10XN

5/8

9.

Physical and Chemical Properties Form:

Viscous liquid

Colour:

<0.5, pale light yellow

Odour:

Odourless / light petroleum

Melting point/pour point:

-60°C

Initial boiling point:

>250°C

Density 15°C:

879 kg/m3

Flash point, PM:

144°C

Auto ignition temp.:

>270°C

Solubility in water:

Non soluble

Solubility in organic solvents:

Soluble

Decomposition temp.:

>280°C

Vapour pressure at 100°C:

160 Pascal

DMSO extractible compounds according

< 3%

to IP346: Calculated partition coefficient

>6

n-octanol/water, log Pow: Viscosity at 40°C:

7,6 cSt

pH:

non relevant

10. Stability and Reactivity Stability: Avoid: Hazardous decomposition products:

Issuing date: 2005-04-05

Stable at normal conditions. Start to decompose at 280°C or higher. Excessive heating and highly oxidizing agents. Flammable gases which might also be noxious. With air present, there is a risk for auto ignition at temperatures >270°C.

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11. Toxicological Information Acute toxicity:

Studies available indicate oral and dermal LD50 s of >5 000 mg/kg which is considered as low acute toxicity.

Local effects: - Inhalation: - Oral: - Skin contact:

Prolonged and repeated inhalation of mist or vapour generated at elevated temperatures may irritate respiratory tract. May cause nausea and eventually vomiting and diarrhoea.

- Eye contact:

Prolonged or repeated exposure may lead to defatting of the skin and subsequent irritation. May cause redness and transient pain.

- Sensitisation:

Studies indicate no evidence of sensitisation.

12. Ecological Information Mobility:

Low, due to low water solubility.

Persistence/degradability: The baseoil is not readily biodegradable. Substances may not meet criteria for ready biodegradability. Studies indicate inherent, primary biodegradation in the range of 20-60 % based on carbondioxide Bio-accumulation:

Ecotoxicity:

Issuing date: 2005-04-05

evolution. Base oil has Log Pow in the range >3,9->6,0. Log Pow is used for estimating the bioacccumulation in fish. A value >3,0 indicates possible bioaccumulation. The size of the hydrocarbon molecules reduces the risk for bioaccumulation. Aquatic toxicity data on base oils indicate LC50 values of >1 000 mg/l, which is considered as low toxicity. Chronic toxicity studies shows no long-term hazard to the aquatic environment.

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13. Disposal Considerations Residues of unused product is not regarded as hazardous waste. Residues of products/packageing must not be disposed of in the environment, but taken care of in accordance with local regulations. Emptying instructions: Barrels and equals: Turn the barrel upside down and tilt it approximately 10° until nondripping. Nondripping is less than one drop / minute at 15 °C. The product viscosity depends on temperature, and it is important that the emptying not is done at to low temperature. It can be necessary to scrape out highviscous products. When the barrel is nondripping send it for recycling. If the residue volume is more than 1% send it for destruction of barrels. Empty barrels with < 1 % residue is not dangerous goods. Notify local regulations. Bags for one way use/multiple use: Follow instructions given by the bag manufacturer. The last residues in the bag can be removed by placing the hose over the remaining residues or by lifting the bag so the product can run towards the hose. Bottom residues; roll up the bag towards the hose to press out the oil One way bags of polyethylene can be recycled or disposed of by incineration. Notify local regulations.

14. Transport Information The product is not classified as hazardous goods for land, sea and air transport according to the respective regulations (ADR, IMDG, IATA-DGR).

15. Regulatory Information Classified according to European directives on classification of hazardous substances and preparations. Not classified as hazardous. No statutory label required. Listed in TSCA ( Toxic Substances Control Act) and EINECS.

Issuing date: 2005-04-05

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16. Other Information The information for labelling and ecotoxicity is according to Concawe Report No. 95/59, 98/54, 01/53 and 01/54. Classified according to the Dangerous Substance Directive, 67/548/EC up to the 28th ATP, the Dangerous Preparation Directive 1999/45/EC, and the Safety Data Sheet Directive 2001/58/EC. Classification of component with CAS no 128-37-0: Classified as dangerous for the environment, N, according to 67/548/EC and 1999/45/EC. R51/53: Toxic to aquatic organisms, may cause long term effects in the aquatic enviroment. Component CAS no 64742-53-6, has DMSO extractible compounds according to IP 346 <3%. Release date: 2005-04-05.

Nota L The classification as a carcinogen need not apply if it can be shown that the substance contains less than 3 w%w DMSO extract as measured by IP 346. This Nota applies only to certain complex oil-derived substances in Annex 1. Nota N The classification as a carcinogen need not apply if the full refining history is known and it can be shown that the substance from which it was produced is not a carcinogen. This Nota applies only to certain complex oilderived substances in Annex 1.

Issuing date: 2005-04-05

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