Trafo 40 Mva PDF

INSTRUCTION MANUAL
TRANSFORMER
Type: TNER3E 40000/115PN
Serial no. 1133751

Rated Power 40/40/40 MVA
Rated Voltage 115 ± 9 x 1.778 % / 11 / 6.6 kV
Connection (vector group) YNd11d11
Year of Manufacture 2007
Internal order no. K.570.1.A002-11152
ABB Sp. z o.o.

Branch Office in Łódź
ul. Aleksandrowska 67 / 93 tel. + 48 42 29 93 000
91-205 Łódź fax + 48. 42 29 93 002
Poland 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 8.710.03-06-0700

protection box
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. 1ZBA4601-206

Transformer Designed with Oil Conservator,
Shipped Oil Filled, Shipped Partially
Disassembled
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. 1ZBA4601-213

Quality control
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 1ZSE 5483-105 en, Rev. 3
guide
5.3 On-load tap-changers, types UCG and UCL with 1ZSE5492-116 en, Rev. 8
motor-drive mechanism, types BUE and BUL.
Installation and commissioning guide
5.4 On-load tap-changer, type UCG with motor-drive 1ZSE 5492-124 en, Rev. 5
mechanisms, types BUE and BUL. Maintenance
guide
5.5 On-load tap-changers, types UCG, UCL, UCC 1ZSE 5492-129 en, Rev. 6
and UCD with motor-drive mechanisms, types
BUE and BUL. Repair Guide
5.6 On-load tap-changers, types UCG, UCL, UCC 1ZSE 5492-133 en, Rev. 3
and UCD with motor-drive mechanisms, types
BUE and BUL. Spare Parts List
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 5483 538-66

BUL 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. 2750 515-12 en, Rev. 9

Installation and maintenance guide
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. Catalogue 01 / 05

Technical description
9.2 Pressure relay for on-load tap-changers. 1ZSE 5492-151 en, Rev. 5
Technical information
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
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
15 Air breathers
15.1 KC-Trockenperlen Orange 1ZBA676002-1
15.2 Model EM5DA 1ZBA 676001-C
15.3 Model EM2DA 1ZBA 676001-A
16 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 TNER3E 40000/115 PN
2 Serial no. 1133751
3 Manufacturer ABB Sp. z o.o.

ul. Żegańska 1, 04-713 Warszawa
Branch Office in Lodz
ul. Aleksandrowska 67/93
91-205 Lodz, Poland
4 Rated Power 40
4.1 HV MVA 40
4.2 MV MVA 40
4.3 LV MVA 40
5 Insulation level
5.1 HV LI450 AC185 -I325 AC185
5.2 MV LI95 AC38
5.3 LV LI75 AC28
6 Phase number 3
7 Frequency Hz 50
8 Rated voltage
8.1 HV kV 110 ± 9 x 1.778 %
8.2 MV kV 11
8.3 LV kV 6.6
9 Voltage regulation On-load
10 Connection (vector group) YNd11d11
11 Impedance voltage at nominal tap (guaranteed/measured)

11.1 HV-MV @ 40 MVA % 11.0 / 10.69
11.2 HV-LV @ 40 MVA % 16.5 / 16.36
11.3 MV-LV @ 40 MVA % 30.0 / 30.05
1/2
Serial no. 1133751
12 Load losses at nominal tap and at rated power (guaranteed/measured)

12.1 HV-MV @ 40 MVA kW 185.0 / 177.42
12.2 HV-LV @ 40 MVA kW 205.0 / 216.37
12.3 MV-LV @ 40 MVA kW 220.0 / 243.16
13 No-load losses (guaranteed/measured) KW 25.0 / 22.45
14 Standard IEC 60076
15 Ambient temperature
15.1 maximum °C + 40
15.2 minimum °C - 35
16 Cooling system OFAF
17 Noise level. Sound pressure at no-load and with dB(A) 75.00 / 71.5
operating cooling system (guaranteed/measured)
18 Total mass kg 74,000
19 Mass of transformer oil kg 18,500
20 Corrossion protection / Color C3 / RAL 7032
21 Grade of transformer oil used for first Nytro 10XN

transformer filling / Manufacturer Nynas Naphthenics AB
2/2
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 8.710.03-06-0700

protection box
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. 1ZBA4601-206

Shipped Oil Filled, Shipped Partially
Disassembled
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. 1ZBA4601-213

Quality control
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
1 Scope ............................................................................................................................................ 2
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 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: 1998-04-30 Rev. No: Page No:
Approved By: Anders Lindroth Rev. Date: 2003-08-11 D Page 2 of 6

Applicability: TrafoStar Lang: en Title:
Document No. SHIPPING OF TRANSFORMERS - GENERAL
1ZBA4601-200 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.

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. The minimum acceptable value is 500 k ohms when
o
measured at 1000 V DC, corrected to 20 C.
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 -
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

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 new Template iT W. Klein PTPT/GD
C: 2003-06-17 Doc-no was 1ZBA4601-201 W. Klein PTPT/GD
D: 2003-08-11 Rewritten & renamed L Ostman PDC/LP

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.

OFF-LOADING AND MOVING A TRANSFORMER
Table of contents
1 Inspection before off-loading 2
2 Off-loading the transformer 3
2.1 Off-load with overhead crane ..................................................................................................... 4

2.2 Off-loading when overhead crane is not available ...................................................................... 4
3 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.
Approved By: Anders Lindroth Rev. Date: 2003-08-11 C Page 2 of 6

Applicability: TrafoStar Lang: en
Title:
Document No. OFF-LOADING AND MOVING A TRANSFORMER

1ZBA4601-202
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

Title:

1ZBA4601-202
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

Title:

1ZBA4601-202
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

Title:

1ZBA4601-202
B: 2003-04-08 new Format
C: 2003-08-11 new contact address

consulted.

IT

Title:

1ZBA4601-202
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: 2001-02
C: 2003-08-11 change contact address. Paragraph 3

Title:
Document No.
1ZBA4601-203 SHIPMENT AND STORAGE

consulted.

IT

Title:
Document No.
1ZBA4601-203 SHIPMENT AND STORAGE
RECEIVING INSPECTION
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. The minimum acceptable value is 500 kohms when
o
measured at 1000 V DC, corrected to 20 C.
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: 2001-02
C: 2003-08-11 new contact address added

Title:
Document No.
1ZBA4601-206 Shipped Oil Filled, Shipped Partially Disassembled

consulted.

All comments and suggestions for improvement should be FAXed to:
IT

Title:
Document No.
1ZBA4601-206 Shipped Oil Filled, Shipped Partially Disassembled
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: 1998-04-30 Rev. No: Page No:
Approved By: Anders Lindroth Rev. Date: 2003-12-10 E Page 2 of 4

TrafoStar Title:
Applicability: Lang: en
Document No. STORAGE ON SITE BEFORE ASSEMBLY
1ZBA4601-211
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: 2001-02
D: 2003-11-20 Grounding of bushings included. Change to 4
E: 2003-12-10 Long time storage. Change to 4

TrafoStar Title:
1ZBA4601-211

consulted.

IndustrialIT Enabled products from ABB are building blocks for greater productivity featuring all the tools necessary for

TrafoStar Title:
1ZBA4601-211
TRANSFORMER ASSEMBLY INSTRUCTIONS
Table of contents
1 Scope..................................................................................................................................................................................... 2
2 Safety designations................................................................................................................................................................ 2
3 General .................................................................................................................................................................................. 2
4 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
! 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.
5 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.

Title:
Document No. TRANSFORMER ASSEMBLY INSTRUCTIONS

1ZBA4601-212
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
1.5 20º
Temperature inside transformer
1
30º
0.7
0.5 40º
0.4
0.3
0.2 Water vapor pressure inside
0.01 0.03 0.1 0.3 mm Hg
-60º -50º -40º -30º -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 4601-
211 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

Title:

1ZBA4601-212
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 Tap-
Changers 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 Tap-
Changer 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.

Title:

1ZBA4601-212
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.

Title:

1ZBA4601-212
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 Tap-
Changer contacts. Perform a winding ratio check at each tap position and record the results. Refer to the Tap-
Changer 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: 2001-02
C: 2003-08-11

Title:

1ZBA4601-212

consulted.

IT

Title:

1ZBA4601-212
IT
RECEIVING AND HANDLING TRANSFORMER OIL ON SITE-

QUALITY 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.

Title:
RECEIVING AND HANDLING
Document No.
TRANSFORMER OIL ON SITE-
1ZBA4601-213 QUALITY 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 delivered No of drums sampled
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 method IEC 156 (VDE electrodes).

56 kV/0.08” method ASTM D1816
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 method IEC 156

35 kV/0.1” 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: 2001-02
C: 2003-08-11 new contact list added

Title:
Document No.

consulted.

ABB Power Transformers according to contact list in Aspect Viewer
IT

Title:
Document No.
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 Transformers with conservator design. -------------------------------------------------------------- 3

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

TrafoStar Title:
Document No. FINAL OIL FILLING ON SITE
1ZBA4601-214 - 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: 2001-02
D: 2004-10-14 2.3 was 3, 3 was 4

TrafoStar Title:
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.

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 Power Transformers, Literature Coordinator: +1-314-679-4595
or E-mailed to: Transformer.Service@us.abb.com
For a reply, please include your name, company, phone, fax and/or E-mail address.

TrafoStar Title:
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

Title:
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

Title:
Document No.
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 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
1.6 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

Title:
Document No.
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 of the oil level

Check the oil level in:
- 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.

Title:
Document No.
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:

Title:
Document No.
2.1 Preparation for energization
Prior to energizing verify the following:
a) The oil level in the oil filled compartments

b) The drying agent and the oil level in the dehydrating breather
c) Check that all valves are set at the right position
d) Check that the transformer, the control cabinet and all accessories are cleaned and touch up painted if needed
e) Check that the heating element in the control cabinet is connected and in operation
f) Check that the gas-operated relay is purged of air
g) 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.

Title:
Document No.
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 u
U
U–N v–n
N n
YN-yn-0 V–N w–n W w
RN
V v
W-N
U u
U–N u – (v-w)
N
YN-y-0 V–N v – (w-u) W V w v
RN/1.5
W-N w – (u-v)
u–n u U
U – (V-W) v–n N
Y-yn-0 V – (W-U) w–n w v W V
1.5* RN
W – (U-V)
u u
U – (V-W) u – (v-w)
Y-y-0 V – (W-U) v – (w-u) w v w v
RN
W – (U-V) w – (u-v)
U v w
U–N n-u N n
YN-yn-6 V–N n-v W V RN
W-N n-w u
U
v w
U–N (v-w) - u N
YN-y-6 V–N (w-u) - v W V RN /1.5
u
W-N (u-v) - w
u v w
U – (V-W) n-u n
Y-yn-6 V – (W-U) n-v w v 1.5* RN
W – (U-V) n–w u
u v w
U – (V-W) (v-w) - u
Y-y-6 V – (W-U) (w-u) - v RN
w v u
W – (U-V) (u-v) - w
U uu
U–V u–v w
w
W
D–d-0 V–W v–w V vv
RN
W-U w-u
U–V w–v U w
D–d-2 V–W u–w W u RN
V v
W-U v-u
U W
U–V w–u W
D–d-4 V–W u–v V RN
V
U
W-U v-w
Table of three-phase transformer connections Page 1 of 3

Title:
Document No.
Ratio
Vector
HV-side LV-side Diagram Indication
group
on meter
U V
D–d-6 U–V v–u W W
V–W w–v V U RN
W-U u-v
D–d-8 U
U–V v–w V
W U
V–W w–u V RN
W
W-U u-v
D – d - 10
U U
W V
U–V u–w
V W
V–W v–u RN
W-U w-v
YN – d - 1 U
u
U–N u–v N w
V–N v–w W V v RN
W-N w-u
Y–d-1 u
U – (V – W) u–v u
w
V – (W – U) v–w w v 1.5 * RN
v
W – (U – V) w-u
YN – d - 5
U W
U–N w–u
N V
V–N u–v W V U RN
W-N v-w
Y–d-5
U – (V – W) w–u u W
V – (W – U) u–v V 1.5 * RN
W – (U – V) v-w w v U
YN – d - 7
U V
U–N v–u
V–N w–v N W RN
W V U
W-N u-w
Y–d-7 u V
U – (V – W) v–u
V – (W – U) w–v W 1.5 * RN
w v
W – (U – V) u-w U
YN – d - 11
U U
U–N u–w
N V
V–N v–u W W
RN
V
W-N w-v
Y – d - 11
u U
U – (V – W) u–w
V – (W – U) v–u V 1.5 * RN
w v W
W – (U – V) w-v
D – yn - 1 U
W U
U–V n–v W
n
V
V–W n–w V
RN
W-U n-u
D–y-1 U U
U–V (w – u) – V W
W
V–W (u – v) – w RN/1.5
V
W-U (v – w) - u V

Title:
Document No.
Ratio
Vector
HV-side LV-side Diagram Indication
group
on meter
v w
U–V n–u U
W n
D – yn - 5 V–W n–v RN
V
W-U n-w u
U v w
U–V (v –w) – u W
D–y-5 V–W (w – u) – v V RN/1.5
u
W-U (u – v) - w
U v
U–V v–n W n
D – yn - 7 V–W w–n V u w RN
W-U u-n
U v
U–V v – (w – u) W
D–y-7 V–W w – (u – v) V u w
RN/1.5
W-U u – (v –w)
U u
U–V u–n
W n
D – yn - 11 V–W v–n V w
RN
v
W-U w-n
U u
U–V u – (v - w) W
D – y - 11 V–W v - (w – u) V w v
RN/1.5
W-U w – (u – v)
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 Low-Voltage side of test object

IEC/VDE ANSI/IEEE IEC/VDE ANSI/IEEE
u H1 u X1
v H2 v X2
w H3 w X3
N H0 n X0

Title:
Document No.
4 Revision
A: 1998-04-30
C: 2003-08-11 changes in P 1
D: 2005-01-05 change of table in Appendix 1. Removal of insulation value in 1.4.4

consulted.

All comments and suggestions for improvement should be communicated to
ABB Power Transformers

Title:
Document No.
Field Test Record
Table of contents
1 FIE LD TEST RECORD ......................................................................................................................................................... 2
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 FIE LD TEST RECORD
Order No
Serial No
Transformer type
Serial No
Tap-changer type
Motor-drive
Serial No
mechanism type
Test Yes No
1 Ratio test
1.1 OLTC
1.2 DETC
2 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

Title:
Document No. Field Test Record

1ZBA4601-217
2 Ratio test
2.1 Ratio when Ratio Bridge is used.
Ratio measurements Serial no……………………
First Terminals:
Second Terminals:
Phase displacement: Nominal Confirmed
Tap position Rated Measured ratio and excitation current Calculated Max.
st nd
1 2 voltage / / / ratio difference
1)
Term. Term. [kV] MA Ratio mA Ratio mA 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

Title:

1ZBA4601-217
2.2 OLTC when Voltmeter method is used and 3 phase power supply
U-measured on ___kV
Magnetizing U-measured on ___kV side Calculated Calculated
Tap No load side Max.
on ___-kV voltage voltage
changer current difference
side
Position [mA] %
[V]
a-b a-c b-c a- b-c a-b a-c b-c a-b-c
[V] [V] [V] [V] [V] [V] [V] (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

Title:

1ZBA4601-217
2.2.1. DETC
Calculat
ed Max.
Magnetizing U-measured on ___kV side Calculated U-measured on ___kV side
Tap No load voltage difference
on ___-kV voltage
changer current a-b-c %
side [V)
position [A]
[V]
a-b a-c b-c a- b-c a-b a-c b-c
[V] [V] [V] [V] [V] [V] [V]
1
2
3
4
5
6
7
3 Resistance
Average Single
Terminal to Terminal Terminal to Terminal Terminal to Terminal
Average Single Phase Resistance
Tap changer Resistance Resistance Resistance
Phase Resistance [mς]
position [mς [mς] [mς]
[mς] corrected to …..°C
/] / /
Oil temperature..............°C

Title:

1ZBA4601-217
4 Check of vector group if Voltmeter method is used
Connect A with a
Magnetized on kV side
_____________
Measured voltage U between
Bb Cc AB Bc Cb
Connection
[V] [V] [V] [V] [V]
Connect A with a
Magnetized on kV side
_____________
Measured voltage U between
Bb Cc AB Bc Cb
Connection
[V] [V] [V] [V] [V]
Instrument used in test Type Range Serial Number
The vector group corresponds with connection

diagram No
Remarks

Title:

1ZBA4601-217
5 Insulation Resistance test
5.1 Windings
Megger kV Note Maximum 5kV megger
st nd
1 Terminals…………… 2 Terminals…………… Ω]
1 Minute[MΩ
Ω]
10 Minutes [MΩ
Weather conditions:______________________________________________________
5.2 Current Transformers

Megger___________ V Note Maximum 1kV megger
TO EARTH
LOCATION TERMINAL Ω]
[MΩ
Ω]
[MΩ
Weather conditions: ______________________________________________________


Title:

1ZBA4601-217
5.3 Control-circuit cabling and auxiliary power cabling
Megger_______ V Note Maximum 1kV megger Type_______________ Serial no________________
Cables to earth (min value) ________________ [MΩ

5.4 Core
Megger_______ V Note Maximum 1kV megger Type_______________ Serial no________________
Core - earth ________________ [MΩ]

Core Clamp -earth ________________ [MΩ]
Core Clamps-Core ________________ [MΩ]
Weather conditions: ________________________________________________________

REMARKS: ________________________________________________________
_________________________________________________________________
6 Check of potential connection between tank and turret

The potential connection between tank and turret has been checked with buzzer
! yes
! no
7 Polarity check of Current Transformers

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

Location/terminal Location/terminal Location/terminal
8 Check of winding temperature circuits

Current transformer for
Location Location Location
Measured resistance for:
Current transformer [Ω] [Ω] [Ω]
Instrument [Ω] [Ω [Ω]

Title:

1ZBA4601-217
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 Breakdown voltage [kV]
Transformer/reactor tank Breakdown voltage [kV]
Cooling group No Breakdown voltage [kV]
Oil test equipment type with electrodes
Electrode distance mm
Oil samples for dissolved gas analysis

have been taken
REMARKS _
_____________________________________________________
_______________________________________________________________________
_______________________________________________________________________
__________________________ _____________

Title:

1ZBA4601-217
10 Operational test of supervisory equipment
Alarm circuit tested to Trip circuit tested to
Control circuit Control room Control circuit Breaker
No/OK No/OK 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
max. oil flow
min water flow
max. water 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
max. oil pressure
min water
max. water
max. oil pressure
min water
max. water

Title:

1ZBA4601-217
Control circuit Control room Control circuit Breaker
Cabinet Cabinet
Thermometer for top oil
Set for alarm Deg C
Set for trip Deg C
Set for start of
Cooler group 1 Deg C
Thermometer for kV winding
Set for alarm Deg C
Set for trip Deg C
Set for start of
Set for alarm Deg C
Set for trip Deg C
Set for start of

Title:

1ZBA4601-217
Control circuit Control circuit
Control room Breaker
Cabinet Cabinet
Set for alarm Deg C
Set for trip Deg C
Set for start of
Set for alarm Deg C
Set for trip Deg C
Set for start of

Title:

1ZBA4601-217
10 Operational Test of other equipment
10.1 Coolers
1. Pump rotation direction checked _______
2. Fans rotation direction checked _______
3. Over current protection tripped

at 2-phase connection: _______
Current
After After Current setting
Fan No setting Pump No
(sec.) (sec) [A]
[A]
1
2
3
4
5
7
8
9
10
11
12
Alarm obtained for tripped current protection at
terminals _____________in the control cabinet.
10.2 De-energized tap changer with driving mechanism
Contact movement
The Tap changer was operated from end to end positions ___________________
The interlocking device of the driving mechanism checked. Alarm obtained when the
driving mechanism was operated terminal No in the control cabinet.

10.3 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

Title:

1ZBA4601-217
Remarks:
Tested and witnessed by
---------------------------------------- ----------------------------------------
ABB Customer

Title:

1ZBA4601-217
Revision
A: 1998-04-30
C: 2003-08-11 p2, Instrument info added

consulted.

IT

Title:

1ZBA4601-217
OIL CONSERVATORS WITH AIR CELL
Table of contents
1 General ..................................................................................................................................................................2
1.1 Design ............................................................................................................................................................2

1.2 With tap-changer conservator ........................................................................................................................2
2 Leakage test of air cell...........................................................................................................................................2
3 Replacing an air cell ..............................................................................................................................................3
4 Oil filling .................................................................................................................................................................3
4.1 Vacuum oil filling of conservator ....................................................................................................................3
5 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.

TrafoStar Title:
Document No. Oil Conservators with Air Cell
1ZBA4601-219
3 Replacing an air cell
For fitting of, or replacing an air cell the following procedure is followed:
− 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.
4 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: 2001-02
C: 2003-08-11 Oil Level Indicator plate
D: 2003-10-10 Revision of text in 4.1

TrafoStar Title:
1ZBA4601-219

consulted.


TrafoStar Title:
1ZBA4601-219
SUPERVISION OF TRANSFORMERS AND REACTORS
Table of contents
1 General ....................................................................................................................................... 2
2 Safety definitions.......................................................................................................................... 2
3 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 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: 2004-03-03 Rev. No: Page No:
Approved By: Thomas Fogelberg Date: - Page 2 of 7

TrafoStar Title:
Document No. Supervision of Transformers
1ZBA 4601-222
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

TrafoStar Title:
1ZBA 4601-222
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.

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1ZBA 4601-222
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 tap-
changer manufacturer should be followed. Such a program is often based on the number of tap-changing
operations and/or the total operational time.

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1ZBA 4601-222
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 Hexagon head bolt, M-thread. Property class 8.8.
Thread Finish Lubrication Tightening

Dim. torque
Tol. +/- 10 %
Nm Kpm
M8 24,5 2,5
M10 Zinc- 49,0 5.0
M12 plated 84 8,6
M16 No 205 21
M20 Lubrication 430 44
M24 Un- 745 76
M30 treated 1520 155
M36 2650 270
12.2 Stud, M-thread. Property class 5.8
Thread Finish Lubrication Tightening

Dim. torque
Tol. +/- 10 %
Nm kpm
M10 29.5 3.0
M12 50.5 5,1
M16 Hot dip 123 12.5
No
M20 galv. 258 26.3
Lubricatio
M24 447 45.5
M30 912 93
M36 1590 132

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1ZBA 4601-222

consulted.

ABB Power Transformers acording to contact list in Aspect Viewer.

TrafoStar Title:
1ZBA 4601-222
Serial no. 1133751
ACCESSORIES OF TRANSFORMER TYPE

TNER3E 40000/115 PN
LIST OF MANUFACTURERS/SUBSUPPLIERS
Name of accessory Type Manufacturer/Subsupplier
Voltage regulation
- OLTC UCGRN 650/300/C ABB Power Technologies AB

- OLTC motor drive BUL Components
Lyvikvägen 10
SE-77180 Ludvika, Sweden
Bushings
- HV bushing GOB 550-800, LF 123 191-K, L6=500 mm

Inner terminal: LF 170 011-S ABB Power Technologies AB
Outer terminal: LF 170 001A Components
Lyvikvägen 10
- HV-neutral bushing GOB 550-800, LF 123 189-K, L6=100 mm SE-77180 Ludvika, Sweden
Inner terminal: LF 170 011-S
Outer terminal: LF 170 001A
- MV bushings 20f/3150, Fig. B1, b1=380 Terman’90

Strumentazione Industriale S.r.I.
- LV bushings 10f/4500, Fig. C1, C1=440 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 WPC-100 G L/P 0,8 IP553 INSTYTUT ENERGETYKI ODDZIAŁ

indicator TRANSFORMATORÓW
ul.Kopernika 56/60
90-553 Łódź
Poland
1/3
Serial no. 1133751
Protection, control and monitoring equipment
- Inteligent Electronic 509-100 Qualitrol AKM

Device Art. no. IED509-00026748
Flygfaltsgatan 6C
- Resistance Bulb Art. no. 103-023-01 128 30 Skarpnack
Platinum
Sweden
- Detachable Connector CON000-00009199
Assembly
- Control cubicle Szymański s.c.

ul. Wiskicka 22
93-623 Łódź, Poland
- Buchholz relay BF 80/10 4NO Elektromotoren und Geratebau Barleben GmbH

(09-22-244) Bahnhofstraβe 27/28
39179 Barleben, Germany
- Monitoring relay for URF 25/10
tap changers
- Winding temperature MSRT 150-W, capillary 10 m Terman’90

indicator Strumentazione Industriale S.r.I.
Via Ghisalba 13-20/21
- Oil temperature MSRT 150, capillary 10 m 20021 Bollate Milano, Italy
indicator
- Oil level indicator LA22, 1ZBA569001-C COMEM

Strada Statale 11
- Oil level indicator LB22, 1ZBA569001-X 36054 Montebello Vic.(VI), Italy
- Pressure safety valve VS 150, 2CO Terman’90

Strumentazione Industriale S.r.I.
Via Ghisalba 13-20/21
20021 Bollate Milano, Italy
- Silicagel air breather – EM5DA

COMEM
transformer tank ABB dwg no. 1ZBA 676001-C
Strada Statale 11
- Silicagel air breather – EM2DA 36054 Montebello Vic.(VI), Italy
OLTC ABB dwg no. 1ZBA 676001-A
- Current transformer JR 0,5 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 A=2010 mm, B=3510 mm, PRONAL S.A.
conserwator C=1300 mm L'Ingeniere de I'Elastomere
Flange type 15 Z.I.Roubaix Est-BP 18
F-59115 Leers
France
- Ball type valves WK 2a Przedsiębiorstwo Handlowo-Produkcyjne

“EFAR” s.c.
- Throttle valves WKKI-1 ul. Św. Antoniego 53
61-359 Poznań, Poland
- Gaskets NBR PB 80 James Walker & Co Ltd

Lion House Woking
Surrey
GU22 8AP
United Kingdom
3/3
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 motor- 1ZSE5492-116 en, Rev. 8
drive mechanism, types BUE and BUL. Installation and
commissioning guide
5.4 On-load tap-changer, type UCG with motor-drive 1ZSE 5492-124 en, Rev. 5
mechanisms, types BUE and BUL. Maintenance guide
5.5 On-load tap-changers, types UCG, UCL, UCC and UCD 1ZSE 5492-129 en, Rev. 6
with motor-drive mechanisms, types BUE and BUL. Repair
Guide
5.6 On-load tap-changers, types UCG, UCL, UCC and UCD 1ZSE 5492-133 en, Rev. 3
with motor-drive mechanisms, types BUE and BUL. Spare
Parts List
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, com-
plies 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 Oil Temperature _______________________ 20
Tie-ln Resistor ________________________ 20
Design Principles ______________ 6
Design, Installation
On-Load Tap-Changer _____________________ 6
Diverter Switch ________________________ 6
and Maintenance ______________ 21
Tap Selector __________________________ 7 On-Load Tap-Changer _____________________ 21
Diverter Switch Housing and Top Section ___ 8 Design Differences over the UC Range
Operating Mechanism __________________ 8 of On-Load Tap-Changers _______________ 21
Transition Resistors ____________________ 8 Drying _______________________________ 21
Motor-Drive Mechanism ____________________ 9 Painting _____________________________ 21
Type BUL ____________________________ 9 Weights _____________________________ 22
Type BUE ____________________________ 9 Oil Filling ____________________________ 23
Special Applications ____________________ 9 Installation ___________________________ 23
Accessories __________________________ 9 Maintenance __________________________ 23
Oil Filter Unit _________________________ 23
Principles of Operation _________ 10 Pressure Relay ________________________ 23
General Description _________________ 23
On-Load Tap-Changer _____________________ 10 Operation _________________________ 23
Switching Sequence ____________________ 10 Testing ___________________________ 23
Linear Switching (Type L) _______________ 11 Installation _________________________ 23
Change-over Selector for Motor-Drive Mechanism ____________________ 24
Plus/Minus Switching (Type R) ___________ 11 Design ______________________________ 24
Change-over Selector for Installation ___________________________ 24
Coarse/Fine Switching (Type D) __________ 11 Maintenance __________________________ 24
Dimensions _____________________________ 25
Characteristics Type UCG/C __________________________ 25
Type UCG/I __________________________ 26
and Technical Data ____________ 12 Type UCG/III _________________________ 27
Type UCL ____________________________ 28
On-Load Tap-Changer _____________________ 12
Type UCD/III _________________________ 30
Type Designation ______________________ 12
Type UCC ___________________________ 32
Diverter Switches ______________________ 12
Tap Selectors _________________________ 12
Diverter Switch – Tap Selector Appendices:
Combinations _________________________ 12 Single-Phase Diagrams _________ 34
Rated Phase Step Voltage _______________ 13
Contact Life __________________________ 14 Appendix 1:
Standards and Testing __________________ 15 Single-Phase Diagrams for UCG/C ___________ 34
Rating Plate __________________________ 15 Appendix 2:
Insulation Levels ______________________ 15 Single-Phase Diagrams for UCG/I ___________ 37
Mechanical Life _______________________ 18 Appendix 3:
Short-circuit Current Strength ____________ 19 Single-Phase Diagrams for UCG/III
Highest Phase Service Voltage UCL/III and UCD/III _______________________ 41
Across the Regulating Winding ___________ 19 Appendix 4:
Rated Through Current _________________ 19 Single-Phase Diagrams for UCC _____________ 45
Occasional Overloading _________________ 19
General Information
When the on-load tap-changer operates, arcing occurs in The UC types of on-load tap-changers are usually
the diverter switch. To avoid contamination of the mounted inside of the transformer tank, suspended from
transformer oil, the diverter switch has its own housing the transformer cover. Drive to operate the on-load tap-
separate from the rest of the transformer. The tap changer is supplied from the motor-drive mechanism,
selector, which is mounted beneath the diverter switch which is mounted on the outside of the transformer tank
housing, consists of the fine tap selector and usually away from the on-load tap-changer. The drive is
also of a change-over selector. The operating principle transmitted by means of shafts and bevel gears.
for the UC range of on-load tap-changers is called the
diverter switch principle. 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
Diverter switch housing Cover
Oil valve
Buffer springs
Lifting eye
Bevel gear with
mechanical indicator
Pressure relay with

Earthing terminal testing valve
Top section
Vent plug
Shielding-ring
Insulating shaft Oil tube
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

Driving disc for the processing
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 The diverter switch is equipped with plug-in contacts that
sections, the diverter switch, which has its own housing, automatically connect the switch with the tap selector
and the tap selector. The tap selector is mounted below when the diverter switch is lowered into the housing.
the diverter switch housing and the complete unit is Mechanical coupling to the motor-drive mechanism is
suspended from the transformer cover. 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
The diverter switch is of the high-speed, spring-operated
copper-tungsten.
type with resistors as transition impedance.
The design and dimensioning of the diverter switch
The diverter switch is designed as a system of moving
offers high reliability and long life with a minimum of
and fixed contacts. Movement of the moving contact
maintenance and easy inspection.
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) L37049 Fig. 4. Diverter switch (UCC) L37050
6
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 L36700
7
Diverter Switch Housing and Operating Mechanism
Top Section The bevel gear, mounted on the top section flange
transfers the drive from the motor-drive mechanism, via
The top section forms the flange that is used for
the vertical shaft, to the intermediate gear for the diverter
mounting to the transformer cover, and for carrying the
switch and the tap selector.
gear box for the operating shafts. The top housing
includes a connection for the conservator pipe, draining From the intermediate gear, a drive shaft transfers the
and filtering connections, an earthing terminal, the drive to the diverter switch through an oil tight gland in
pressure relay, and the cover with its gasket. the bottom of the diverter switch housing. When the
diverter switch is lowered into the housing (after
The bottom section has locating holes for the diverter
inspection), the drive is automatically re-connected by a
switch, bearings, brackets for the tap selector mounting
system that ensures that the drive shaft and the locating
and the current terminal for the diverter switch. There is
pin of the diverter mechanism is correctly aligned.
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
The top and bottom section are fixed to a cylinder of
geneva gear provides alternate movement to the two
glassfibre reinforced plastic. The bushings through the
vertical shafts of the tap selector.
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 Transition Resistors
leaks with the use of a helium gas detector.
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
The motor-drive mechanism provides the drive to allow For detailed operation description, see separate
the on-load tap-changer to operate. As the name implies, Technical Guides for Motor-Drive Mechanisms types
drive is provided from a motor through a series of gears BUL or BUE, respectively.
and out through a drive shaft. Several features are
If there are any doubts about which type to select,
incorporated within the mechanism to promote long
please consult ABB Components.
service intervals and reliability.
There are two sizes of motor-drive mechanisms that can Special Applications
be used:
ABB Components should be consulted for all special
Type BUL application on-load tap-changers.
The BUL is for on-load tap-changers types UCG and Accessories

UCL at star point or single-phase applications. However,
when extra space is required for optional accessories the For a list of accessories available for both the on-load
type BUE might have to be selected due to limited space tap-changers and the motor-drive mechanisms, see the
in the BUL. 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 L37167
9
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
At rated load the breaking takes place at the first current The main contact x has opened. The load current pas-
zero after contact separation, which means an average ses through the resistor Ry and the resistor contact y.
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

Reversing
Switching (Type R) Change-over selector
The change-over selector extends the regulating range

to twice the voltage of the tapped winding, by connect-
ing 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 Max. rated Impulse withstand
Type Designation through-current voltage to earth
UCG .. XXXX/YYYY/Z UCG.N 300, 500, 600 A 380, 650, 750, 1050 kV
UCL .. XXXX/YYYY/Z UCG.E,T 300, 500, 600,
UCD .. XXXX/YYYY/Z 900, 1200, 1500 A 380, 650, 750, 1050 kV
UCC .. XXXX/YYYY UCG.B 300, 500, 600 A 380, 650, 750, 1050 kV
Example: UCGRE 650/700/C
UCL.N 600, 900 A 380, 650, 1050 kV
Type of switching UCL.E,T 600, 900, 1800, 2400 A 380, 650, 1050 kV
L Linear UCL.B 600, 900 A 380, 650, 1050 kV
R Plus/Minus
D Coarse/Fine UCC.N 800, 1200, 1600 A 380, 650, 1050 kV
Type of connection UCC.E 3600, 4500 A 380, 650, 1050 kV

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 Tap Selectors
and two-phase)
Type Connection Max. rated Max. no. Max impulse
Impulse withstand voltage to earth through- of pos. test voltage
UCG: 380 kV, 650 kV, 750 kV, 1050 kV current across range
UCL: 380 kV, 650 kV, 1050 kV
UCD, UCC: 380 kV, 650 kV, 1050 kV C N 400 A 27 350 kV
E, T 400, 700, 1050 A 27 350 kV
Maximum rated through-current
B 400 A 27 350 kV
UCG.N, UCG.B: 300 A, 400 A, 500 A, 600 A
UCG.E, UCG.T: 300 A, 400 A, 500 A, 600 A, I N 600 A 35 300 kV
700 A, 900 A, 1050 A, 1200 A, 1500 A E, T 600, 1200, 1500 A 35 300 kV
B 600 A 35 300 kV
UCL.N, UCL.B: 600 A, 900 A
UCL.E, UCL.T: 600 A, 900 A, 1800 A, 2400 A III N 1000 A 35 550 kV
E, T 1000, 1800, 2400
UCD.N: 1000 A, 1200 A
30001) A 35 550 kV
UCD.E: 1000 A, 1200 A, 1800 A, 2000 A
B 1000 A 35 550 kV
2400 A, 3000 A, 3600 A 1)
UCC 2) N 800, 1200, 1600 A 35 500 kV
UCC.N: 800 A, 1200 A, 1600 A
E 3600, 4500 A 35 500 kV
UCC.E: 3600 A, 4500 A
Tap selector size 1)

with enforced current splitting
C = UCG tap selector
I = UCG tap selector 2)
UCC requires one motor-drive mechanism for each unit and is
III = UCG, UCL and UCD tap selector therefore not available in connection B and T.
1)
with enforced current splitting
Diverter Switch –
Maximum number of positions
Tap Selector Combinations
UCG, UCL, UCD UCC
Linear switching 211) positions 23 positions
Diverter Switch UCG UCL UCC
Plus/Minus switching 35 positions 35 positions
Coarse/Fine switching 35 positions 35 positions Tap selector C, I, III III III, UCC
1)
Only tap selector III is available up to 21 positions with
UCC diverter switch combined with tap selector III is
linear switching.
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.
Step voltage UCG.N, B

UCG.E, T
Short version Step voltage UCL.N, B

UCG.N, E, T, B UCL.E, T
Short version
UCG.E, T
1500A
1200A
1050A
1800A
2400A
300A
900A
600A
500A
700A
600A
Rated through 900A Rated through

current, A current, A
Fig. 12. Rated phase step voltage for type UCG Fig. 13. Rated phase step voltage for type UCL
UCD.N UCC.N
Step voltage UCC.E
Step voltage UCD.E
1200A
1600A
800A
3600A2)
3600A
1000A
1200A
1800A
2000A
2400A
3000A
4500A
Rated through
Rated through current, A
current, A
2)
With enforced current splitting
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 Contact life

Number of Number of
operations operations UCL. N, B
UCG.N, B
UCG. E, T UCL. E, T
1800A
2400A
1200A
1500A
1050A
600A
900A
700A
300A
500A
600A
900A
Rated through Rated through

current, A current, A
Fig. 16. Contact life for type UCG Fig. 17. Contact life for type UCL
Contact life Contact life

Number of Number of
UCD. N UCC. N
operations operations
UCD. E UCC. E
3600A2)
3000A1)
1000A
1200A
1800A
2400A
1200A
1600A
3600A
800A
4500A
Rated through current, A Rated through current, A

1)
R1 3000 without current splitting.
2)
R1 3600 with enforced current splitting.
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 Fig. 20. Example of Rating Plate
Mechanical test
Sequence test
Auxiliary circuits insulation test
Vacuum test
Final inspection
Insulation Levels
The insulation levels are indicated as: Insulation Levels to Earth
1.2/50 µs impulse withstand voltage (kV)–power For UCG 380–150 kV, 650–275 kV
frequency withstand voltage (kV). 750–325 kV and 1050–460 kV.
The tests were carried out according to IEC 214 clause For UCL 380–150 kV, 650–275 kV
8.6. with a new on-load tap-changer and clean insula- and 1050–460 kV.
tion oil class 2 according to IEC Publication 296. The
withstand voltage value of the oil was higher than For UCC and UCD 380–150 kV
160 kV/cm. 650–275 kV
1050–460 kV.
Linear b1 and b2 are to the Reversing b1 and b2 are to the Coarse/Fine b1, b2 and d1 are to the
L corresponding contacts R corresponding contacts D corresponding contacts
in the next phase in the next phase in the next phase
Fig. 21. Linear switching: Fig. 22. Reversing switching: Fig. 23. Coarse/Fine switching:
Contact designations in tables 1-3 Contact designations in Tables 1-3 Contact designations in tables 1-3
1)
See note 1 for UCC.
15
UCG
Table 1. Withstand Voltages within UCG Tap-Changers (For UCG Tap-Changers with selectors C, I and III)
Within one phase Between phases for the neutral point type
Type of a2 a3 c1 e1, b2 b1 d1
switching between ends of between any other across change-over between between open fixed between open fixed
and (fine) regulating electrically selector open contacts in tap contacts in coarse
number winding non-adjacent taps contacts selector change-over selector
of in
positions diverter
switch
Selector C, I
size C I III C I III C I III and III C I III C I III
US S US S US, S US S US, S
L 9 350-140 300-125 490-160 550-180 350-140 300-125 400-150 400-150 130-50 400-150 300-125 500-160 550-180
11
13
15 – 290-120 420-150 480-160 – 290-120 350-140 350-140 – 500-160 550-180
17 – 250- 95 350-140 400-150 – 250- 95 300-125 300-125 –
18 – – –
R, D 9 350-140 300-125 490-160 550-180 350-140 300-125 400-150 400-150 400-150 350-140 600-200 400-150 500-160 550-180 400-150 350-140 600-200
11
16
13 420-150 480-160 500-160
15 – 250- 95 350-140 400-150 – 250- 95 350-140 – –
17-19 350-140 300-125 490-160 550-180 350-140 300-125 400-150 400-150 400-150 600-200 400-150 500-160 550-180 400-150 600-200
21-23
25-27
29-31 – 290-120 420-150 480-160 – 290-120 350-140 350-140 – – 500-160 500-160 –
33-35 – 250- 95 350-140 400-150 – 250- 95 300-125 300-125 – – –
US = Unshielded contacts, S = Shielded contacts
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.
UCL, UCD
Table 2. Withstand Voltages within UCL and UCD Tap-Changers (For UCL and UCD Tap-Changers with selector III)
Within one phase Between phases for the neutral point
switching between ends of between any other across change- between between open fixed between open fixed
and num- (fine) regulating electrically over selector open contacts contacts in tap contacts in coarse
ber of winding non-adjacent taps in diverter selector change-over selector
positions switch
Selector UCL UCD

size III III III III III III III
US S US S US S US, S US, S US S US S
L 9 490-160 550-180 400-150 400-150 150-50 200-80 500-160 550-180

11
13
15 420-150 480-160 350-140 350-140 500-160 550-180
17 350-140 400-150 300-125 300-125
18
R, D 9 490-160 550-180 400-150 400-150 600-200 600-200 500-160 550-180 600-200 600-200
11
13 420-150 480-160 500-160
17
15 350-140 400-150 350-140
17-19 490-160 550-180 400-150 400-150 600-200 600-200 500-160 550-180 600-200 600-200
21-23
25-27
29-31 420-150 480-160 350-140 350-140 500-160 500-160
33-35 350-140 400-150 300-125 300-125
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.
UCC
Table 3. Withstand Voltage within UCC on-load tap-changers
Within one phase Between phases for the neutral point type
switching between ends of between any other across between open between open between open fixed
and (fine) regulating electrically change-over contacts in fixed contacts in contacts in coarse
number of winding non-adjacent taps selector diverter switch tap selector change-over
positions selector
US S US S US S US and S US S US S
L 9–23 300–125 300–1251) –– ––

200–80 300–125 – –
9–15 500–170 500–170 500–170
R, D
9–35 300–125 500–170 160–75 250–85 300–125 600–200 200–80 300–125 500–170 350–150 600–200

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
Short-circuit Current Strength Rated Through Current
The short circuit current strength is verified with three The rated through-current of the on-load tap-changer is
applications of 2 seconds duration, without moving the the current which the on-load tap-changer is capable of
contacts between the three applications. Each appli- transferring from one tapping to the other at the relevant
cation has an initial value of 2.5 times the rms value. rated step voltage, and which can be carried
continuously whilst meeting the technical data in this
Type Max rated Three applications Reinforced document. The rated through current is normally the
through of 2 seconds same as the highest tapping current.
current, rms duration 1), rms
The rated through-current is limited by the step voltage
UCG 300 A 7.0 kA
400 A 7.0 kA according to the curves in the diagrams, Fig. 12 to
500 A, 600 A 7.0 kA Fig. 15.
700 A 7.0 kA
900 A 9.0 kA The rated through-current determines the dimensioning
1050 A 10.5 kA of the transition resistors and the contact life.
1200 A, 1500 A 15.0 kA
UCL 600 A 9.0 kA
The rated through-current is stated on the rating plate,
900 A 9.0 kA Fig. 20.
1800 A 26.0 kA
2400 A 26.0 kA
UCD 1000 A 13.0 kA Occasional Overloading
1200 A 12.0 kA
1800 A 26.0 kA If the rated through-current of the tap-changer is not less
2000 A 24.0 kA than the highest value of tapping current of the tapped
2400 A 32.0 kA
3000 A 36.0 kA
winding of the transformer, the tap-changer will not
restrict the occasional overloading of the transformer,
UCC 800 A 13.4 kA according to IEC 354 ”Loading guide for oil-immersed
1200 A 13.4 kA
1600 A 16.6 kA 21 kA
transformers” (1991), ANSI/IEEE C57.92 ”Guide for
3600 A 30.0 kA loading mineral-oil-immersed power transformers” and
4500 A 36.0 kA 66 kA CAN/CSA-C88-M90.
1)
With an initial peak current of 2.5 times the rms value and To meet these requirements, the UC models have been
without moving the contacts between the three applications. designed so that the contact temperature rise over the
surrounding oil does not exceed 20 K when loaded with
Table 4. Short-circuit current strength
a current of 1.2 times the maximum rated through cur-
rent of the tap-changer.
The contact life stated on the rating plate is given with
Highest Phase Service Voltage Across consideration to that currents of maximum 1.5 times the
the Regulating Winding rated through current occur during a maximum of 3% of
the tap-change operations. Overloading beyond these
The table below show the highest permissible phase values, results in increased contact wear and shorter
service voltage, in kV, for the different types of con- contact life.
nections.
Across the Across the
regulating coarse and fine
winding winding
Contact shieldings: with without with without
Tap-changer,
connection
UCC.N 52 35 75 45
UCD.N III
UCL.N
UCG.N III – –
UCC.E 60 45 80 60
UCD.E,
UCL.T, E, B
UCG.T, E, B III – –
UCG.N C, I – 35 – 40
UCG.T, E, B C, I – 35 – 45
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 tap- If the service voltages and the winding capacitances are
changer shall be between -25 and +105 oC for normal such that the potential of the tapped winding exceeds the
operation, as illustrated below. The range can be values in table 6, it should be limited to this value by
extended to -40 oC provided that the viscosity is between means of a tie-in resistor connected between the diverter
2-800 mm2/s (=cst). switch and the mid tap of the tap selector.
On-load tap-changer Voltage (kV)

1) UCG.. /C 35
2) 1) No operations allowed UCG.. /I 25
UCG.. /III 35
2) Emergency overloading. UCL.. /III 35
The on-load tap-changer will not UCD.. /III 35
restrict the occasional overloading
UCC.. 35
of the transformer according
to the standards above. Table 6.
3)
3) Normal operating range
In order to eliminate the losses in the tie-in resistor, a tie-
4) When operating within this range, in resistor switch (S), which connects the resistor only
no overload is allowed when the change-over selector is moving, can be added
to the bottom of the tap selector. The tie-in resistor
5) Operation with de-energized
transformer only switch is not available for tap-selector C. The tie-in
4) resistor is normally mounted separate from the on-load
tap-changer, but in some cases it can be mounted below
5) the tap selector.
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 There are also differences in the design and operation of
UC range of on-load tap-changers is the size (see the tap selector. For tap selectors sizes C and I, the
Fig. 26). Other differences are less obvious but include moving contacts are driven by two parallel ribs in one
the use of different materials in the manufacture of the cage. For tap selectors size III, the moving contacts are
top sections (welded steel in the UCG and UCC/D driven by two concentric shafts. For UCC, the system
models, casted alloy in the UCL model). The cylinder is consists of two cages with one driving shaft in each.
glued in the UCG range, and riveted in the rest of the
models.
UCG.N/C
UCG.N/I UCG.N/III UCL.N/III UCD.N/III UCC.N
650 kV 650 kV 650 kV 650 kV 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 The standard painting on the top section consists of a
in its plastic shipping cover until time for assembly. For primer of two-component epoxy type of max. thickness
further instructions refer to the Installation Guide. 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 Approximately weight in kg On-load tap-changer Approximately weight in kg

Type Designation Tap-changer Required Total Type designation Tap-changer Required Total
without oil 1) oil without oil 1) oil
UCG.N 380-750/300-600 425 150 575 UCL.N 380/600, 900 480 260 740
1050/300-600 435 185 620 650/600, 900 500 300 800
1050/600, 900 510 340 850
UCG.T 380-750/300-900 1025 3x150 1475
380-750/1050-1500 1190 3x150 1640 UCL.T 380/600, 900 1230 3x260 2010
1050/300-900 1090 3x185 1645 380/1800 1350 3x260 2130
1050/1050-1500 1225 3x185 1780 380/2400 1440 3x260 2220
650/600, 900 1290 3x300 2190
UCG.B 380-750/300-600 760 2x150 1060 650/1800 1410 3x300 2310
1050/300-600 780 2x185 1150 650/2400 1500 3x300 2400
1050/600, 900 1320 3x340 2340
UCG.E 380-750/300-900 360 150 510 1050/1800 1440 3x340 2460
380-750/1050-1500 410 150 560 1050/2400 1530 3x340 2550
1050/300-900 370 185 555
1050/1050-1500 425 185 610 UCL.B 380/600, 900 850 2x260 1370
650/600, 900 890 2x300 1490
1)
The weight of the diverter switch, approximately 90 kg, is 1050/600, 900 910 2x340 1590
included. UCL.E 380/600, 900 410 260 670
380/1800 450 260 710
Table 7. Weights for type UCG 380/2400 480 260 740
650/600, 900 430 300 730
650/1800 470 300 770
650/2400 500 300 800
1050/600, 900 440 340 780
1050/1800 480 340 820
1050/2400 510 340 850
1)
The weight of the diverter switch, approximately 120 kg, is
included.
Table 8. Weights for type UCL
On-load tap-changer Approximately weight in kg On-load tap-changer Approximately weight in kg

Type designation Tap-changer Required Total type designation Tap-changer Required Total
without oil 1) oil without oil 1) oil
UCD.N 380/1000 950 710 1660 UCC.N 380/800, 1200 1130 710 1840
650/1000 980 790 1770 380/1600 1220 710 1930
1050/1000 1010 910 1920 650/800, 1200 1160 790 1950
650/1600 1250 790 2040
UCD.E 380/1000 890 710 1600 1050/800, 1200 1190 910 2100
380/1800 920 710 1630 1050/1600 1280 910 2190
380/2400 950 710 1660
650/1000 920 790 1710 UCC.E 380/3600 1130 710 1840
650/1800 950 790 1740 380/4500 1220 710 1930
650/2400 980 790 1770 650/3600 1160 790 1950
1050/1000 950 910 1860 650/4500 1250 790 2040
1050/1800 980 910 1890 1050/3600 1190 910 2100
1050/2400 1010 910 1920 1050/4500 1280 910 2190
1)
1)
The weight of the diverter switch, approximately 250 kg, is The weight of the diverter switch, approximately 250 kg, is
included. included.
Table 9. Weights for type UCD Table 10. Weights for type UCC
22
Oil Filling
For details of oil filling, consult the appropriate Installa- The pressure relay is mounted on a three-way valve. On
tion Guide. the other two outlets of the valve there is a connection
flange on one side, and a connection for test equipment
Installation on the other.
The on-load tap-changers can be delivered for cover- The relay is made of copper-free aluminium alloy and is
mounting method or yoke-mounting method onto the externally coated with an enamel. A stainless steel model
can be provided on request.
transformer.
For detailed installation instructions, consult the appro- The pressure relay has been pre-set by the manu-
priate Installation Guide. facturer. The pressure relay is sealed to avoid
unauthorized entrance. The electrical connection shall be
Maintenance made to the terminal box mounted onto the pressure
relay.
The UC range of on-load tap-changers have been
developed over many years to provide a maximum of Operation
reliability. The simple and rugged design gives a service
When the pressure acting on the face of the piston
life that equals the service life of the transformer. A
exceeds the spring load of the piston, the piston will
minimum of maintenance is required for absolutely
move and activate the switching element.
trouble-free operation. The only parts that require
maintenance during the service life are the diverter
The operation time is less than 10 ms. The operation
switch contacts that may need to be replaced, and the
time is the time it takes from the pressure in the tap-
motor-drive mechanism. The oil in the diverter switch
changer tank exceeds the function pressure, until the
housing has also to be cleaned with certain intervals.
pressure relay gives a stable signal for operation of the
Maintenance is easy to carry out since the design transformer main switch.
provides for quick and easy access and inspection. For
The function pressure (trip pressure) is shown in
overhaul, the top cover is removed and, if necessary, the
table 11.
diverter switch can be lifted out without further
dismantling.
H 1) Function pressure
An annual inspection should be carried out to read the (trip pressure)
counting device. These readings are used to determine
when overhaul is due. Overhaul shall normally be < 7m 100 kPa (14.5 Psi)
7 – 20 m 100-230 kPa (14.5-33.5 Psi) 2)
carried out every seven years, and consists of checking
the dielectric strength, filtering the oil, and checking the
1)
contacts (and replace them if they are worn). The motor- The height (H) is the distance between the level of the pressure
drive mechanism should also be checked and lubricated, relay and the oil level in the oil conservator.
2)
Option when H is 7-20 m.
and the pressure relay checked.
The appropriate Maintenance Guide should be consulted
Table 11. Function pressure (trip pressure)
if you need further information.
Testing
Oil Filter Unit
Before the commissioning of the transformer and for
The on-load tap-changer can be equipped with an oil testing the pressure relay, reference should be made to
filter unit for continuous oil filtration. For further the specific instructions regarding the pressure relay, or
information, see manual 1ZSE 5492-152. to the appropriate Installation Guide.
Pressure Relay Installation
General Description The pressure relay is to be mounted directly on to the on-

load tap-changer tank, using the flange and fittings
Protection for the on-load tap-changer is provided by a provided. Caution should be used when handling the
pressure relay which is mounted on the on-load tap- relay to avoid damage. The relay should be stored in its
changer top section. In the event of an over-pressure in protective box until attaching to the on-load tap-changer.
the tank, the relay will, if correctly connected, trip the
transformers main circuit breakers. After a pressure relay Caution should also be applied when attaching the relay
trip, the on-load tap-changer must be carefully to the on-load tap-changer tank, and the appropriate
investigated. Faults, if any are located, should be Installation Guide should be consulted.
repaired before the transformer is energized.
23
Switching contact
30 54 67
ABB Components
Cable gland
~35 ~200 Adjusting nut
Spring
Piston
;;
;;
110 Two single-pole One single-pole
switching contacts switching contact
Connection for
11 ~155 test equipment
32
15
NO NC C NO NC C NO NC C
64 66 65 61 63 62 61 63 62
Fig. 27. Pressure relay
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 tap-
changer 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 L2 L3 and L4 Motor-drive
mm mm mm mechanism
Min/max 500/3100 525/3100 900/2700 BUE
500/3100 600/3100 – 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
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
D=470 H1
157
75
194
A A
(BUE1) 592
(BUE2) 818
H2
390 36
134
345
C/L Tap selector C/L Diverter switch

D=740
30
Section A – A
Plus/Minus and
80 R210 Coarse/Fine
switching
16O 332
230 145 570
(BUE1) 233
(BUE2) 353
(BUE1) 320 D=420
(BUE2) 440 615
Fig. 29. Dimensions, type UCG R210

Section A – A
Linear switching
Diverter switch housing 570
For tap Impulse with- H1 H1, H3 H3
selector stand voltage short short
size to earth version version D=420
kV mm mm mm mm 615
C 380, 650, 750 1192 972 1400 1200
1050 1492 1272 1700 1500 Tap selector
For on-load Max rated H2, size C
tap-changer through current
type A mm
1)
Shielding-rings are used only for insulation level UCG.N 400 959
650-275 kV and higher. 3)
UCG.E, UCG.T 400 519
2)
Space required for lifting the diverter switch, excluding 700 739
the lifting equipment. 1 050 959
4)
3)
UCG.T consists of three single-phase units. UCG.B 400 Single-phase unit
519
4)
UCG.B consists of one single-phase and one two-phase
unit arranged as shown in the dimension drawing for Two-phase unit
UCL.B (page 29). 739
25
Dimensions
Type UCG/I
405
H32)
L1
290
70 185
1)
111
D=600
1)
L2 D=470 H1
157
A A
75
194
(BUE1) 592 H2
(BUE2) 818
36
390
134
1)
30
4)

D=740 30
80
610 4203) 530
O
16 332
230 145
(BUE1) 233
(BUE2) 353 195 Section A – A
(BUE1) 320 Plus/Minus and
(BUE2) 440 6053) Coarse/Fine
switching
665
1)
Shielding-rings are used only for insulation level
650-275 kV and higher. 3903)
2)
Space required for lifting the diverter switch, excluding Section A – A
the lifting equipment. Linear switching
500 4103)
3)
Dimension without shielding-ring.
4)
For tie-in resistor switch add 360 mm.
500
Fig. 30. Dimensions, type UCG
26
Type UCG/III
Model for cover mounting Model for mounting on
transformer’s active part
78
H1 H1+106
B B
H2
30
385
Diverter switch housing

For tap Impulse with- H1 H1, H3 H3
4903) 590 selector stand voltage short short
size to earth version version
kV mm mm mm mm
Section B - B I 380, 650, 750 1317 1097 1400 1200
Plus/Minus and 2553)
1050 1617 1397 1700 1500
Coarse/Fine switching
III 380, 650, 750 1354 1134 1400 1200
8403)
1050 1654 1434 1700 1500
295
Tap selector
940 For on-load Max. rated H2 H2

tap-changer through current size I size III
4903) type A mm mm
Section B - B
UCG.N 300–600 1030 1160
Linear switching
4903) 580 UCG.E, UCG.T 5)
300–600 530 552
900 – 552
1200 760 856
1500 1030 856
580
UCG.B 6) 300–600 single- single-
Fig. 31. Dimensions, type UCG phase phase
unit unit
Operating shafts 532 552
The minimum and maximum lengths refer to mechanical two- two-
design only. phase phase
unit unit
Length L1 L2 L3 and L4 Motor-drive 774 856
mm mm mm mechanism
5)
UCG.T consists of three single-phase units.
Min/max 500/3100 525/3100 900/2700 BUE
6)
500/3100 600/3100 – BUL UCG.B consists of one single-phase and one two-phase
unit arranged as shown in the dimension drawing for
L3 and L4 for UCG.T, see Fig. 28, page 24. UCL.B (page 29).
27
Dimensions
Type UCL/III
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
Diverter switch housing Linear switching
Impulse withstand H1 H3
voltage to earth
kV mm mm
380 1415 1500
650 1615 1700
1050 1815 1900
5)
For mounting on
active part H1+85 H3+100
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 Max rated H2
tap-changer through current size III
type A mm
UCL.N 600–900 1160

6)
UCL.E, UCL.T 600–900 552
1800 856
2400 1160
UCL.B 7) 600–900 single-phase
unit
H22 = 552
two-phase
unit
H21 = 856
1)
650-275 kV and higher.
2)
Space required for lifting the diverter switch, excluding
the lifting equipment. Operating shafts
3)
Dimension without shielding-ring. design only.
4) Length L1 L2 L3 and L4 Motor-drive
For-tie in resistor switch add 370 mm
5)
mm mm mm mechanism
Model for mounting on transformers active part.
6)
Min/max 500/3100 525/3100 900/2700 BUE
UCL.T consists of three single-phase units. 500/3100 600/3100 – BUL
7)
UCL.B consists of one single-phase and one two-phase
unit. L3 and L4 for UCL.T, see Fig. 28, page 24.
29
Dimensions
Type UCD/III
Fig. 33. Dimensions, type UCD
30
Operating shafts
Diverter switch housing design only.
Impulse withstand H1 H3 Length L1 L2

voltage to earth mm mm
kV mm mm
Min/max 500/3100 525/3100
380 1594 1600
650 1734 1750 1)
1050 1934 1950
550-230 kV and higher.
2)
Tap selector Space required for lifting the diverter switch, excluding
the lifting equipment.
For on-load Max rated H2 3)
tap-changer through current size III Dimension without shielding-ring.
type A mm 4)
For tie-in resistor switch, add 370 mm.
UCD.N 1000 1160 5)
When two or three units are fitted together (three-phase
delta and three-phase fully isolated respectively) the
UCD.E 1000 552
1800 856 distance between the units (c) must be at least 1340 mm
2400 1160 from mechanical point of view. For final dimensioning,
check the insulation distance required.
31
Dimensions
Type UCC
Fig. 34. Dimensions, type UCC
32
Impulse withstand H1 H3
voltage to earth
kV mm mm
380 1540 1600
650 1680 1750
1050 1880 1950
Tap selector
For on-load Max rated H2
tap-changer through current
type A mm
UCC.N 800, 1200 1290
1600 1530 1)
UCC.E 3600 1290 550-230 kV and higher.
4500 1530 2)
Space required for lifting the diverter switch, excluding
the lifting equipment.
Operating shafts 3)
Dimension without shielding-ring.
The minimum and maximum lengths refer to mechanical 4)
design only. For tie-in resistor switch add 340 mm.
5)
When two or three units are fitted together (three-phase
Length L1 L2
delta and three-phase fully isolated respectively) the
mm mm
distance between the units (c) must be at least 1340 mm
Min/max 500/3100 525/3100 from mechanical point of view. For final dimensioning,
check the insulation distance required.
33
Appendices: Single-Phase Diagrams
The basic connection diagrams illustrate the different The tap-changer can also be connected in such a way
types of switching and the appropriate connections to the that position 1 gives a minimum effective number of
transformer windings. The diagrams illustrate the turns in the transformer winding with the tap-changer in
connections with the maximum number of turns in the position 1.
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 Coarse/Fine
8 Steps
10 Steps
34
12 Steps
14 Steps
16 Steps
18 Steps
35
20 Steps
22 Steps
24 Steps
26 Steps
36
Appendix 2: Single-Phase Diagrams for UCG/I
8 Steps
10 Steps
12 Steps
14 Steps
37
16 Steps
18 Steps
20 Steps
22 Steps
38
24 Steps
26 Steps
28 Steps
30 Steps
39
32 Steps
34 Steps
40
Appendix 3: Single-Phase Diagrams for UCG/III, UCL/III and
UCD/III
8 Steps
10 Steps
12 Steps
14 Steps
41
16 Steps
17 Steps 18 Steps 18 Steps
20 Steps
22 Steps
42
24 Steps
26 Steps
28 Steps
30 Steps
43
32 Steps
34 Steps
44
Appendix 4: Single-Phase Diagrams for UCC
8 Steps
10 Steps
12 Steps
14 Steps
45
16 Steps
18 Steps
20 Steps
22 Steps
46
24 Steps
26 Steps
28 Steps
30 Steps
47
32 Steps
34 Steps
48
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: sales@se.abb.com
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 Continuation Contact _________________ 9
Auxiliary Contacts ___________________ 9
Applications __________________________ 4 Driving Mechanism Equipment ____________ 10
Design ______________________________ 4 Exploded Views and Photos ______________ 11
Cabinet ______________________________ 4
Tropical Version _______________________ 4
Type Tests ___________________________ 4 Principles of Operation __________ 14
Ambient Air Temperature ________________ 6
Connection of Motor-Drive Mechanism Raise-Operation with Local Control ________ 14
to Tap-Changer _______________________ 6 Lower-Operation with Local Control ________ 14
Rating Plate __________________________ 7 Through Positions ______________________ 14
Remote Control _______________________ 14
Circuit Diagram ______________________ 15
Mechanical Arrangements _______ 8 Contact Timing Diagram _________________ 16
Driving Arrangement ____________________ 8
Hand Crank __________________________ 8 Standard Version _______________ 17
”One-Turn” Shaft ______________________ 8
Position Indicator ______________________ 8 Control ______________________________ 17
Mechanical End Stops __________________ 8 Protection ____________________________ 17
Electrical End Stops ____________________ 8 Indication ____________________________ 17
Brake _______________________________ 8 Wiring _______________________________ 17
Indicator Flag _________________________ 9 Maintenance __________________________ 17
Operation Counter _____________________ 9 Design Options ________________________ 17
Maintaining, Interlocking and Multi-Position Switches __________________ 17
Auxiliary Contacts ______________________ 9 Technical Data ________________________ 18
Multi Position Switches __________________ 9 Dimensions ___________________________ 19
Position Transmitter, Potentiometer _____ 9 Weight ______________________________ 19
General Information
Applications
The BUL Motor-Drive Mechanism is designed for outdoor The Motor-Drive Mechanism is mounted to the transfor-
operation of the On-Load Tap-Changers and large De- mer tank with four screws or studs, M12 or ½”, through
energized Tap-Changers listed below. 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
Tap-Changer Type of Connection cable connection, size FL 21, see page 19. When
delivered the opening is covered with a 5 mm thick light-
UBB For all connections alloy cover.
UCG Star point or single-phase
UCL Star point or single-phase 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
Design Mechanism functions satisfactorily down to -40 oC
The Motor-Drive Mechanism is normally mounted on the (-40 oF). For temperatures below -40 oC or on customers
side of the transformer tank and by means of drive shafts request an additional 100 W heater controlled by a
and bevel gears connected to the Tap-Changer. The thermostat can be supplied. This extra heater can also
shaft system is described in the Technical Guide for each on request be supplied with a switch for manual
type of Tap-Changer. disconnection.
The BUL contains all the necessary equipment for The tightness of the cabinet has been type tested for
operation of the Tap-Changer. Special equipment can be protection class IP 56 according to IEC 529 (protected
supplied in order to fulfil customers requests. Paralleling against dust and powerful water jets).
and voltage regulation systems can also be supplied to The handlamp is automatically switched on when the
supplement the Motor-Drive Mechanism and Tap- door is opened.
Changer.
On request the inside of the cabinet can have a 3 mm
thick layer of anti-condensation paint.
Cabinet
The cabinet is manufactured of welded sheet steel and is Tropical Version
in standard version hot dip galvanized. On request it can
instead be painted with a white primer or a complete The Motor-Drive Mechanism can be equipped to meet
painting system, primer and top coat, suitable for outdoor the requirements for humid tropical climate and desert
use. conditions. Anti-condensation painting inside the cabinet
and screens to shade from direct sun radiation can be
The front door is formed as a cap in order to give better supplied.
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
Type Tests
gasket and the window is glued to the door. 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 Motor-
Drive 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-con-
densation 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 for indication of the maximum and minimum positions.
drives, with ratio 4.5:1, pulley 122 on the intermediate Those drag-hands can be restored manually. The posi-
shaft 140 via a toothed belt 101. On the intermediate tion indicator is visible through a window in the door.
shaft is a pinion with helical teeth 141 which with ratio
5:1 drives the helical gear 142 on the outgoing shaft 103. Mechanical End Stops
The outgoing shaft is then via a multiple hole coupling
143 directly connected to the shaft system of the Tap- The upper Geneva wheel 125 is supported by the
Changer. The outgoing shaft makes 5 revolutions per Geneva shaft and turns independent of the shaft con-
operation. trolled by the upper driving pin 108 on the ”one-turn”
shaft. On the Geneva wheel two screws 136 are fitted
The Mechanism is assembled on a support of casted
which at the end positions operates the mechanical end
aluminium, 144.
stop 113 via an arm 147. Extra screws could be placed in
between the screws 136 if a decreased tap-change
Hand Crank range is desired.
The mechanism can be manually operated by means of After the end position has been reached the mechanical
a hand crank 104. The hand crank is put on the crank end stop is pressed out in the way for a knob 148 under
shaft 105, which through the bevel pinion 123, with ratio the helical gear 142 which prevents the outgoing shaft
3:1, drives the bevel gear 124 on the outgoing shaft. from further movement in that direction.
Direction of operation is clockwise for a raise operation
and 15 revolutions are needed per operation. This is also When the mechanism is returned to the end position by
shown on a sign placed on the transparent protection manual cranking, the mechanical end stop will be
screen. 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 The breakpin 114 in the bevel pinion 123 on the crank
motor thus preventing electrical operation. 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 Electrical End Stops
positions or in a through position, when it is electrically
supplied, the mechanism starts directly on removal of the On the lower end of the shaft for arm 147 a cam curve
hand crank. 149 is mounted. When the mechanism is in an end
position this cam curve operates limit switches S6 and
”One-Turn” Shaft S7 which breaks the operating circuit of the motor and
two phases of the motor supply. Electrical operation
A helical pinion 106 on the outgoing shaft drives, with beyond the end positions is thus impossible.
ratio 5:1, the helical gear 102 placed on the ”one-turn”
shaft 107. This shaft drives two Geneva wheels 125 and In case of faulty limit switches the motor will be stopped
126 with the ratio 36:1. The driving pin 108 for the upper by the mechanical end stop and is dis-connected when
Geneva wheel 125 shall in the normal position be in the the thermal over-current protection trips the motor
slot of the Geneva wheel whereas the lower Geneva protective switch Q1 see circuit diagram on page 15.
wheel 126 is locked by the circumference of the ”one-
turn” shaft. Brake
On the upper end of the ”one-turn” shaft 107 is a cam
Position Indicator disc 128 which operates a brake 117 working on a brake
The lower Geneva wheel 126 is pinned to the Geneva disc 118 on top of the intermediate shaft 140. This brake
shaft 145, which through a bevel gear 109, with ratio 1:1 makes sure that the Motor-Drive Mechanism stops in the
operates the position indicator shaft 146, on which the correct position after each tap change. The brake can be
position indicator pointer 110 is assembled. On the adjusted by a screw 150 which is pressing on the spring
position indicator shaft is also assembled drag-hands 151 that closes the brake.
8
Indicator Flag Multi-Position Switches
The indicator flag is placed in the end of the indicator The lower end of the Geneva shaft 145 is via a coupling
arm 116 which is operated by the cam disc 128. The flag 111 connected to the multi position switch shaft 112. The
is visible through a slot in the front plate 119. When the multi position switch therefore moves 1/36 of a turn, 10o,
mechanism is in position the white part of the flag is per tap change step.
visible and during a tap-change the red part is shown.
The multi position switch 127 is assembled of up to 5
The indicator flag is also visible through the window in different printed circuit cards 160. Each card has a
the door. contact arm 161. A slot in the multi position switch shaft
112 transferes the turning to a knob on the contact arm.
Operation Counter The contacts 162 on the arm are solid silver rivets and
the contact surfaces 163 on the circuit cards are gold
A seven digit mechanical operation counter 120 is also plated. Before delivery all cards are insulation tested with
operated by the indicator arm 116. The counter is not 2 kV to earth.
possible to reset and will register the total number of
The contacts on each card are protected against dust by
operations carried out by the Motor-Drive Mechanism.
a transparent cover 164.
The counter is mounted on the front plate 119 and is also
visible through the window in the door.
Position Transmitter (S14), Potentiometer
Maintaining, Interlocking and Auxiliary As standard the contact device is supplied with a
potentiometer transmitter which has 10 ohm, 0.6 W,
Contacts resistances between each position. Other resistances
At the lower end of the ”one-turn” shaft is another cam can be supplied on request.
disc 115 which via a lever 129 operates two sets of On request a suitable measuring amplifier for moving-coil
contacts, S3 and S4. S3 is affected during raise opera- instrument can be supplied. Also the instrument for
tions and S4 during lower operations. remote position indication in the control room can be
The cam disc does not release the lever and the contacts included on request.
before the tap-change operation is completed. Before the
start impulse disappears the maintaining contact 33-34, Continuation Contact (S15)
see Fig. 9, closes another feeding to the contactor K2 or In cases when the Tap-Changer has two or more posi-
K3 and thus keep the motor running until the operation is tions with the same voltage a continuation contact is
completed. After a possible interruption of the supply supplied. Only one of the positions is the service posi-
voltage during an operation this contact will also make tion, and the others are through positions which are
the operation completed when the supply voltage passed automatically at an electric operation. See
returns. 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 Auxiliary Contacts
direction. Thus unintentional change of direction is Auxiliary contacts, break before make or make before
prevented. This contact also prevents operation in case break as well as odd-even switches for parallel control
the motor rotation should be wrong due to incorrect can be supplied on request.
phase sequence.
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 Anti-condensation heater 120 Operation counter

E3 Cabinet light 121 Pulley
K1 Step-by-step relay 122 Pulley
K2 Contactor, Raise 123 Bevel pinion
K3 Contactor, Lower 124 Bevel gear
M1 Motor 125 Geneva wheel, upper
Q1 Motor protective switch 126 Geneva wheel, lower
S1 Control selector switch, Local-0-Remote 127 Multi position switches
S2 Control switch, Lower-0-Raise 128 Cam disc
S3 Maintaining, interlocking and auxiliary contact, Raise 129 Lever for maintaining contact
S4 Maintaining, interlocking and auxiliary contact, Lower 130 Rating plate
S5 Interlocking switch, open when hand crank is fitted 131 Hinges
S6 Limit switch, Upper tap position 132 Motor-drive mechanism cabinet
S7 Limit switch, Lower tap position 133 Door
S9 Door operated switch 134 Hand knob
S14 Position transmitter, potentiometer 135 Air vent
S15 Continuation contact 136 Screw for end stop
X1-17 Terminals 140 Intermediate shaft
U1 Measuring amplifier 141 Helical pinion
101 Toothed belt 142 Helical gear
102 Helical gear 143 Multiple hole coupling half
103 Outgoing shaft 144 Support
104 Hand crank 145 Geneva shaft
105 Crank shaft 146 Position indicator shaft
106 Helical pinion 147 Arm for end stop
107 ”One-turn” shaft 148 Knob for mechanical end stop
108 Geneva wheel driving pin 149 Cam curve
109 Bevel gear 150 Screw for adjustment of brake
110 Mechanical position indicator 151 Spring for brake
111 Coupling 160 Printed circuit card
112 Multi position switch shaft 161 Contact arm
113 Mechanical end stop 162 Silver rivet contact
114 Breakpin 163 Gold plated contact surface
115 Cam disc for maintaining contact 164 Transparent cover
116 Indicator arm
117 Brake
118 Brake disc
119 Front plate
10
= 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
A so called ”Through position”, is a position the Tap-
connected to their respective terminal blocks according
Changer has to pass without changing the ratio of the
to the instructions on the diagram.
transformer. These positions are passed automatically.
The continuation contact S15 bridges the maintaining
Raise-Operation with Local Control contacts S3:33-34 and S4:33-34 via auxiliary contacts on
raise contactor K2 at through positions. In this way the
When switch S1 is set in position ”Local” the mechanism contactor K2 raise, or K3 lower, is kept energized and
can be operated by control switch S2. For a raise opera- the motor will automatically make another operation.
tion the procedure is as follows:
The connection of S15 to auxiliary contacts on K2,
Motor contactor K2 is energized, the contactor closes the means that the drive, in the event of a control supply
motor phases, the motor starts and drives the failure in a through position, always moves to a lower
mechanism in the raise-direction. After about 0.2 se- normal service position, when the voltage returns.
conds 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 Remote Control
released.
Control selector switch S1 is placed in the ”Remote”
The switching in the On-Load Tap-Changer takes place position. The control supply for the remote pushbuttons
after about 3 seconds. or regulating relay is then received from a terminal in the
Motor-Drive Mechanism Cabinet. Incoming control
The driving mechanism keeps on rolling until the cycle is circuits for raise and lower impulses should be
completed, which takes about 5 seconds. About 0.2 connected to other terminals as shown in the diagram.
seconds before the cycle is completed, the maintaining Local operation is not possible when switch S1 is in the
contact S3 is released, contactor K2 falls and the feed- ”Remote” position and remote operation is not possible
ing of the motor is interrupted. At the same time the in the ”Local” position.
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
A similar cycle is obtained, but in the lower direction, switch is operated.
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 S14 Position transmitter, potentiometer
S4 Maintaining, interlocking and auxiliary contact, Lower S6 Limit switch, Upper tap position
S15 Continuation contact S7 Limit switch, Lower tap position
16
Standard Version
Control Wiring
z Control selector switch, Local-0-Remote. The wiring is of grey polyvinylchloride-insulated,
z Control switch, Raise-0-Lower. stranded wire. Type and data see Technical data.
z Hand crank for manual operation. Every wire is marked with figures corresponding to
terminal numbers. All external connections are made of
Protection thermosetting resin. Type and data see Technical data.
z Protective switch for the motor with thermal overload Short circuit protection (fuses) for control and heater
release and magnetic overcurrent release. supplies, if required, should be installed in the control
z Limit switches – in both control and motor circuits. cabinet or other separate compartment. No fuses are
z Mechanical end stops. required for the motor, as the motor protective switch has
z Interlocking contact in the control circuit to prevent magnetic overcurrent release.
electrical operation during manual operation.
z Interlocking contacts in raise and lower control Maintenance
circuits to prevent operation in wrong direction of
rotation (with wrong phase sequence). All bearings in the Motor-Drive Mechanism type BUL
z Motor contactors are electrically interlocked. have rubber seals and are permanently greased and
z Protection against running-through in case of a failure some gears and moving details are made of selflubri-
of the step-by step control circuit. cating material. No greasing is necessary during the
z Emergency stop push button. lifetime of the Motor-Drive Mechanism at normal working
conditions.
Indication The Motor-Drive Mechanism should be inspected once a
year.
z Mechanical position indicator
z Drag-hands for max. and min. position indication. For the correct inspection and maintenance procedures,
z Red flag for indication of Tap Changer in progress. consult the appropriate Maintenance Guide.
z Operation counter.
(The above four items are visible through the window
in the cabinet door).
Design Options
z Position transmitter, potentiometer, for remote For already prepared design options, please see
position indication. 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 Auxiliary contact Auxiliary contact Step switches for parallel control
transmitter Break before make Make before break Type 1 Type 2
Number of contact rows

1 1 1 1 2
Note: Master switch for parallel control is a break-before-make auxiliary contact.
17
Technical Data
Special version
Subject Standard version Alternative version at an additional price
Motor voltage, 3-phase 220-240/380-420 V, 208/360 V, 60 Hz 120 V, 1-phase, 60 Hz

50 Hz 220-240/380-420 V, 60 Hz 240 V, 1-phase, 60 Hz
250-280/440-480 V, 60 Hz Optional
Current 1.4/0.8 A
Rated output 0.18 kW
Speed 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 lowest position middle position Optional

indicator marked 1 marked N
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 122 - Phönix UK 5N
can be accomodated 116 - Weidmüller SAK 4/35 PA
(depending on selected 92 - Phönix URTK/S Ben
options) 92 - Phönix URTK/S
68 - Phönix OTTA 6
Cabling Type H07V2-K, 1.5 sq mm, 750 V, 90 oC Optional

Type H05V2-K, 0.75 sq mm, 500 V, 90 oC
Test voltage on
control circuits 2 kV (50 Hz, 1 min)
Anti-condensation heater 50 W
Additional heater 100 W controlled by
thermostat or hygrostat
Approx. operating time 5 sec
Starting impulse length > 0.5 sec
Number of revolutions per

operation of
the outgoing driving shaft 5
the hand crank 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 (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
Tel.+46 240 78 20 00
Fax +46 240 121 57
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, conduc-
ting tubes and hoses that are earthed should be used to avoid the risk of explo-
sion 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 Introduction ____________________________________________ 9
1.1 Type Designation ________________________________________ 10
1.2 Required Tools _________________________________________ 13
1.3 Required Material _______________________________________ 13
1.4 Oil ___________________________________________________ 14
1.5 Oil Conservator _________________________________________ 15
1.6 Oil Filter Unit for Continuous Oil Filtration ___________________ 15
1.7 Weights _______________________________________________ 15
1.8 Tightening Torque _______________________________________ 17
2 Receiving ______________________________________________ 17
2.1 Unpacking _____________________________________________ 17
2.2 Inspection on Receipt ____________________________________ 17
2.3 Temporary Storage before Assembly ________________________ 17
3 Installation in the Transformer _____________________________ 18
3.1 Cover-Mounting ________________________________________ 19
3.1.1 UCG with Tap Selector size I or C __________________________ 19
3.1.2 UCG with Tap Selector size III _____________________________ 25
3.1.3 UCL with Tap Selector size III _____________________________ 29
3.2 Yoke-Mounting _________________________________________ 33
3.2.1 Mounting when the Transformer Ratio Measurement
is carried out before Drying ________________________________ 34
3.2.2 Mounting when the Transformer Ratio Measurement
is carried out after Drying _________________________________ 37
3.2.3 Mounting on Transformer Cover ____________________________ 38
3.3 Connection to Terminals __________________________________ 42
3.4 Transformer Ratio Measurement ____________________________ 44
3.4.1 Transformer Ratio Measurement before Drying ________________ 45
3.4.2 Transformer Ratio Measurement after Drying _________________ 45
4 Drying ________________________________________________ 46
4.1 Observations before Processing ____________________________ 46
4.2 Observations after Processing ______________________________ 46
4.3 Installation of Diverter Switch _____________________________ 47
5 Final Assembly _________________________________________ 49
5.1 Mounting of the Motor-Drive Mechanism ____________________ 49
5.2 Mounting of External Drive Shafts __________________________ 52
5.2.1 Mounting of Vertical Drive Shaft ___________________________ 54
5.2.2 Mounting of Horizontal Drive Shafts,
types UCG.N/UCL.N and UCG.E/UCL.E ____________________ 56
5.2.3 Mounting of Horizontal Drive Shafts, type UCG.B/UCL.B _______ 59
types UCG.T/UCL.T and UCGYD/UCLYD __________________ 64
5.2.5 Before Operation ________________________________________ 64
5.3 Pressure Relay __________________________________________ 65
5.3.1 General _______________________________________________ 65
5.3.2 Installation _____________________________________________ 65
5.3.3 Checking at Commissioning of the Transformer _______________ 66
5.4 Assembly of Accessories __________________________________ 67
5.5 Connection to the Oil Conservator __________________________ 67
7
6 Oil Filling _____________________________________________ 68
6.1 Filling Methods and Restrictions ___________________________ 68
6.2 Before Filling ___________________________________________ 68
6.3 Filling at Atmospheric Pressure ____________________________ 69
6.4 Filling under Vacuum ____________________________________ 69
6.4.1 Oil Conservator Filled Afterwards __________________________ 70
6.4.2 Oil Conservator Filled under Vacuum _______________________ 70
6.5 Restoring the Gas Cushion ________________________________ 71
6.5.1 Procedure ______________________________________________ 72
7 Electrical Connection and Testing __________________________ 73
7.1 General _______________________________________________ 73
7.2 Connecting and Testing the Motor-Drive Mechanism and the
On-Load Tap-Changer ____________________________________ 73
7.3 Electrical Tests on the Transformer _________________________ 74
7.4 After Energizing ________________________________________ 74
8 Transport ______________________________________________ 75
8.1 Dismantling before Transport ______________________________ 75
8.1.1 Dismantling Preparations _________________________________ 75
8.1.2 External drive shafts for UCG.N/UCL.N, UCG.E/UCL.E (One Unit) 75
8.1.3 External drive shafts for UCG.B/UCL.B (Two Units) ___________ 76
8.1.4 External drive shafts for UCG.T/UCL.T and
UCGYD/UCLYD (Three Units) ____________________________ 76
8.1.5 Accessories ____________________________________________ 77
8.2 Oil Level During Transport ________________________________ 77
8.2.1 Transformer filled with Oil ________________________________ 78
8.2.1.1 Conservator mounted _____________________________________ 78
8.2.1.2 Conservator dismounted __________________________________ 78
8.2.2 Transformer drained _____________________________________ 78
8.2.2.1 Conservator mounted _____________________________________ 78
8.2.2.2 Conservator dismounted __________________________________ 78
9 Commissioning _____________________________ 79
9.1 Connection to the Oil Conservator __________________________ 80
9.2 Mounting the Motor-Drive Mechanism and the Drive Shafts ______ 80
9.2.1 Mounting of the Motor-Drive Mechanism ____________________ 80
9.2.2 Mounting of the External Drive Shafts _______________________ 81
9.2.3 Mounting of the Vertical Drive Shaft ________________________ 81
9.2.4 Mounting of Horizontal Drive Shaft types UCG.N/UCL.N
and UCG.E/UCL.E ______________________________________ 83
9.2.5 Mounting of Horizontal Drive Shafts type UCG.B/UCL.B _______ 85
9.2.6 Mounting of Horizontal Drive Shaft types UCG.T/UCL.T
and UCGYD/UCLYD ____________________________________ 89
9.2.7 Before Operation ________________________________________ 89
9.3 Pressure Relay __________________________________________ 90
9.4 Accessories ____________________________________________ 90
9.5 Oil Filling _____________________________________________ 90
9.6 Electrical Connection and Testing __________________________ 90
9.6.1 Motor Protection ________________________________________ 90
9.6.2 Disc Brake _____________________________________________ 90
9.6.3 Counter _______________________________________________ 91
9.6.4 Position Transmitter and other Position Switches _______________ 91
9.6.5 Light _________________________________________________ 91
9.6.6 Heater ________________________________________________ 91
9.7 Putting into Operation ____________________________________ 91
8
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 tap-
changer before drying and without having the transformer cover mounted. The trans-
former cover is then lowered onto the tank, and the on-load tap-changer is lifted and
bolted to the cover. Please use the appropriate instruction for cover-mounting or yoke-
mounting 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 tap-
changer 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 .. XXXX/YYYY/I, III, C

UCL .. 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 Tap selector size III
Fig. 1.
10
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
Horizontal drive shafts Bevel gear

and protective tubes
Bevel gear ;
Pressure relay
Vertical drive
shafts and
protective tubes
Shielding caps
(only for insulation Type of connection, N or E
level above 380 kV)
Rating plate
Shielding rings
Hand crank (only for insulation
(inside the cover) level above 380 kV)
Motor-drive
mechanism
fm_00218 Not used for selector, size C
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 3.2.2
(can be ordered from ABB)
Lifting equipment for UCG. Article No. LL 135 016-A 3.2.2
Special hand crank for operating the on-load tap-changer 3.4
on the bevel gear (can be ordered from ABB)
Hack saw (only for installation) 5
File 5
Folding ruler 5
Air pump with hose, pressure gauge (0–250 kPa) 5.3
and connection with internal thread R 1/8”
Container, 50 litres 6
Small oil pump with connection to the oil valve 6
(For connection dimensioning see the dimension drawing
for the on-load tap-changer).
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) 3.1
(for UCL only)
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 6
connection dimensions of the oil valve
Flange for connection to the oil conservator flange 6.4
when filling under vacuum, see Fig. 38
Oil valves for connection to flange with dimensions 6.4.1
according to Fig. 42. Can be ordered from ABB
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 5.5
transformer and the on-load tap-changer, can be ordered
from ABB).
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/... 150

UCG.. 1050/... 185
UCL.. 380/.... 260
UCL.. 650/.... 300
UCL.. 1050/.... 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 Approx. weight in kg
Type designation Tap-changer Required Total
without oil 1) oil
UCG.N 380-750/300-600 325 150 475
1050/300-600 335 185 520
UCG.T 380-750/300-900 725 3x150 1175
380-750/1050-1500 890 3x150 1340
1050/300-900 790 3x185 1345
1050/1050-1500 925 3x185 1480
UCG.B 380-750/300-600 560 2x150 860
1050/300-600 580 2x185 950
UCG.E 380-750/300-900 260 150 410
380-750/1050-1500 310 150 460
1050/300-900 270 185 455
1050/1050-1500 325 185 510
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 Approx. weight in kg
Type designation Tap-changer Required Total
without oil 1) oil
UCL.N 380/600, 900 480 260 740
650/600, 900 500 300 800
1050/600, 900 510 340 850
UCL.T 380/600, 900 1230 3x260 2010
380/1800 1350 3x260 2130
380/2400 1440 3x260 2220
650/600, 900 1290 3x300 2190
650/1800 1410 3x300 2310
650/2400 1500 3x300 2400
1050/600, 900 1320 3x340 2340
1050/1800 1440 3x340 2460
1050/2400 1530 3x340 2550
UCL.B 380/600, 900 850 2x260 1370
650/600, 900 890 2x300 1490
1050/600, 900 910 2x340 1590
UCL.E 380/600, 900 410 260 670
380/1800 450 260 710
380/2400 480 260 740
650/600, 900 430 300 730
650/1800 470 300 770
650/2400 500 300 800
1050/600, 900 440 340 780
1050/1800 480 340 820
1050/2400 510 340 850
1)
The weight of the diverter switch, approximately 120 kg, is included.
16
2 Receiving
1.8 Tightening Torque

The following tightening torques are recommended:
For metallic screw joints: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %
For non-metallic screw joints: M10, 9 Nm ±10 %
M12, 13 Nm ±10 %
M16, 22 Nm ±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 com-
pany. 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 on-
load 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 acknowled-
gement. 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

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
Max 90o
Max 90o Max 90o
TC_00188 TC_00184 TC_00185
Tap selector C Tap selector I Tap selector III
Fig. 3. How to lift.
18
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 Transport locking Screws (4 pcs)

(to be removed) (to be removed) (to be removed)
TC_00209 TC_00211
Tap selector size I Tap selector size C
Fig. 4.
4. Lift the diverter switch housing in the lifting eyes and remove the transport sup-
port. For tap selector size C, remove the three limbs, see Fig. 5.
19
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. 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.
20
Washer
14x30x2,5 Spring washer
Socket-head Locking nut

cap screw M12 M12
F F
Diverter switch Shielding
housing, UCG rings B–B
Conductor
B B TC_00274
Insulating shaft F–F
Conductors Washer 13x28x3

Spring washer
E A Locking nut M12
A
17
Washer, Socket-head cap
steel T=3 screw
Tap selector, 25
E C–C
size I
13 17
Large gear Socket screw
wheel M8x20 (x4)
Washer
Tap selector
C C
Current Locking nut M8

collector D–D
D
Shielding ring, TS 11
M12x40
D
Washer 13x24x2
Insulating screw
M16x140
Conductors Diverter switch
Insulating housing
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
Washer

cap screw M12 M12
Diverter switch F F
Shielding
housing, UCG rings
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
C C
Current
collector
Tap selector
Washer 8.4x20x2
Spring washer
Hexagon headed
Conductors
screw M8x35
D–D
Insulating bolt
M16x110
Insulating
of the diverter switch housing
nut M16
Cleats
Driving pin of the tap selector
TC_00272
A–A
Fig. 7. Tap selector, size C and diverter switch UCG
22
7a. In case the on-load tap-changer is equipped with a tie-in resistor for mounting un-
der 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 tap-
changer 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 spe-
cial 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
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
Selector size I or C Stud M12

Nut M12 (24x)
Washer (24x)
Opening in the Flange

transformer cover Gasket
fm_00220
Transformer
top cover
Fig. 8. Fig. 9.
TC_00282
23
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.
13. Continue with section 3.3.

~ 3 mm
~ 100 mm
Locking nut
Conductor
Spring washer
Insulating paper Plain washers
TC_00169
Socket screw
Connection point on
the tap selector
Fig. 10.
24
3.1.2 UCG with Tap Selector size III

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
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.
WARNING
25
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
7. Remove the transport locking and the lifting eyes with fasteners from the top
section of the tap selector, see Fig. 12.
CAUTION
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
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
cautious!
26
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.
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
shielding ring.
27
Washer

cap screw M12 M12
Diverter switch F F
housing, UCG
B–B
Conductor
B B TC_00274
F–F
Insulating
shaft Locking nut M12
Conductors
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
D support
Tap selector
Cleats
Insulating
nut M16 Washer 10.5x24x3 (x4)
Spring washer
Insulating E–E
stud Socket-head cap
M16x120 screw M10x40 (x4)
Conductors of the diverter switch housing
A–A Driving pin of the tap selector

TC_00273
Fig. 13. Tap selector III and diverter switch UCG.
28
3.1.3 UCL with Tap Selector size III

Fig. 15. (This gasket is not included in the delivery.)
Top cover Top section
Diverter switch UCL

Nut M12 (x24)
Washer
Opening in the (x24)
transformer cover Stud (x24)
Gasket
Transformer
Selector size III top cover
TC_00222 TC_00218
Fig. 14. Fig. 15.
3. Lift the diverter switch housing in the lifting eyes as shown in Fig. 3 and lower it
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.
29
WARNING
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
6. Remove the transport locking and the lifting eyes with fasteners from the top
section of the tap selector, see Fig. 12.
CAUTION
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
8. Insert four M10x40 screws and washers, see Fig. 16, through the tap selector up-
per part to the four supports of the diverter switch housing. Tighten the screws.
WARNING
cautious!
30
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.
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
shielding ring.
31
Socket head cap

screw M12 Washer 14x30x2.5
Spring washer
Locking nut M12
Shielding ring (if the

impulse withstand
F F voltage to earth
Diverter switch F–F B–B exceeds 380 kV)
housing, UCL
Shielding rings
Insulating shaft Washer 14x30x2.5

Spring washer
B B Locking nut M12

Socket-head
Conductors cap screw
C–C, 2 // connectors
Spring washer
E
Locking nut M12 Washers 14x30x2.5
A A
Socket-head cap screw
E C–C, single connector
Socket-head cap
screw M8x25 (x4)
Shielding ring,
C C TS 11 Spring washers
Current
collector
Locking nut M8
Tap selector,
D D–D
size III
D
Driving pin of
the tap selector Diverter switch housing
Cleats
Tap selector
Insulating
nut M16
Insulating
stud M16x120 Washer 10.5x24x3 (x4)
E–E
Spring washer
Conductors Slot in the large gear wheel Socket-head cap
of the diverter switch housing screw M10x40 (x4)
A–A
TC_00217
Fig. 16.
32
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 opera-
tion.
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
3.2.1 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
O-ring
(35 mm)
Lower flange
Insulating bushing
Yoke fork (not included)
TC_00283
Diverter switch Guiding pin DS 7
Fig. 18. housing (outer dia = 12 mm)
Fig. 20. TC_00121
34
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 Guiding bar for
Lower flange diverter switch
Plain washer
Spring washer
Screw
TC_00295 UCL Fig. 22.
Locking device
DS 4
TC_00280 UCG
Fig. 23.
35
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
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. 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 on-
load tap-changer. (This gasket is not included in the on-load tap-changer deli-
very).
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.
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.
38
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 tight-
ening 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
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
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
3.3 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
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
3.4 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 on-
load 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
3.4.1 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 in-
side 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.
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.
46
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 opera-
ting 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)
(Layed down on UCG short type)
Serial number
(on the opposite
side of the Plug-in contacts
diverter switch) A A
Guiding pin
Guiding pin Tie rod
fm_00223
Driving pin
Coupling disc
Notch for the

Holes for guiding pins
driving pin Slot for guiding bar
Guiding bar
for the Guiding pins
diverter
switch Slot for the oil
draining tube
Oil draining A–A,

tube
UCL
TC_00233
UCL
Diverter switch housing,
view from above
Coupling disc
Notch for the
driving pin
Slot for guiding
Holes for bar
guiding pins
Guiding pins
Guiding bar
for the Slot for the oil
diverter draining tube
switch
Oil draining A–A,

TC_00284
tube TC_00285
UCG
UCG
Diverter switch housing,
view from above
Fig. 33.
48
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 motor-
drive 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 TC_00203

Adjustment nuts
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
Position indicator fm_00224
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
NB! The slot in the
protective tube
Unit Unit Unit
SA33 –3 SA10 SA25 SA10 – 2 SA10 SA30 SA25 SA10 – 1 SA10 SA25 SA10 facing downwards
SA36 SA34 SA35 SA32 SA31 SA24 SA22 SA23

Connection type T TC_00235
Unit Unit
SA33 –2 SA10 SA25 SA10 –1 SA10 SA25 SA10 SA21
SA18
SA19
Fig. 36.
SA17
SA32 SA30 SA31 SA22 SA23
Connection type B SA24 TC_00236
SA 10 Hose Clip Unit

–1 SA10 SA25 SA21
SA 11 Coupling halves
SA 12 Hexhead cap screw M6 SA18
SA 13 Washer SA19
SA 14 Vertical square shaft SA17
SA 15 Vertical protective tube SA24 SA22 SA23
SA 16 Vertical protective tube SA10
SA20
SA 17 Clamp Connection type N or E SA12, SA 13
SA 18 Hexhead bolt M10
SA 19 Washer SA25 SA11
SA 20 O-ring
SA16
SA 21 Bevel gear
SA 22 Horizontal square shaft to unit -1
SA 23 Horizontal protective tube to unit -1
SA 24 Horizontal protective tube to unit -1 TC_00168
SA 25 Information plate SA15
SA 30 Horizontal square shaft to unit -2
SA14
SA 32 Horizontal protective tube to unit -2 SA11
SA 33 Cover SA12, SA13
SA 34 Horizontal square shaft to unit -3 SA10
SA 36 Horizontal protective tube to unit -3 BUL BUE
TC_00239 TC_00237
5 Final Assembly
53
Motor-drive mechanism
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 LB2 = K2+220 mm LB2 = K2+410 mm

2 2 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
SA14
BUE
TC_00147
Fig. 37a. Fig. 37c. Fig. 37d. Fig. 37e.
Min. 3, max 5 mm
SA26
K2
Driving pin
Max 6 mm
SA27, SA28
SA15
SA29
SA10
TC_00148 TC_00149
BUL Fig. 37g.
Fig. 37b. Fig. 37f.
Square shaft
A
Max 3 mm
SA11
SA13
SA12
TC_00147
TC_00170
Fig. 37h. Fig. 37k. A
55
5 Final Assembly

types UCG.N/UCL.N and UCG.E/UCL.E
The following applies to the fitting of drive shafts and protective tubes when the on-
load tap-changer consists of one unit, UCG.N/UCL.N or UCG.E/UCL.E.
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


2 2 2

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

TC_00148
Fig. 38b.
56
5 Final Assembly
Spherical coupling part A SA24 SA10 SA23 Slot SA21
SA12 SA11
SA13
TC_00242
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 posi-
tion 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 on-
load 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

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 tap-
changer phase, which is placed closest to the driving mechanism, is called unit -1, the
second unit -2, see Fig. 36.
K1
TC_00241
Fig. 39a.
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


2 2 2

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.
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

TC_00148
Fig. 39b.
59
5 Final Assembly
Spherical coupling part A SA24 SA10 SA23 Slot SA21
SA12 SA11
SA13
TC_00242
Fig. 39c.
loosening the two set screws, see Fig. 39f.
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.
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.
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 on-
load 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
WARNING
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.
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.
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

TC_00148
Fig. 39h.
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.
loosening the two set screws, see Fig. 39f.
62
5 Final Assembly
Disc Coupling A SA10 SA10

TC_00245
SA13
Fig. 39k.
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
Locking device
Cover SA 33 Set screw SA10 SA25 SA10
SA32 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 aro-
und 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

Types UCG.T/UCL.T and UCGYD/UCLYD
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.
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
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 fm_00208
BUE BUL
Fig. 40. Locking device of motor-drive mechanism
64
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
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 tap-
changer 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
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
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 trans-
former.
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.
66
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 tap-
changer, 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 trans-
former 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
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
Oil
Ø 75
Fig. 43. Oil filling under vacuum
Stud M10
Ø 44.2
TC_00249 Ø 5.7 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 transform-
ers with a common oil conservator for both the transformer and the on-load tap-
changer), 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

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).
70
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.
71
6 Oil Filling
WARNING
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 dimen-
sion 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 TC_00250
Fig. 44. The figures shows UCL
72
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 motor-
drive mechanism.
Connect the motor supply and the control supply to the correct terminals in the motor-
drive mechanism as shown by the circuit diagram supplied with the on-load tap-
changer.
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 motor-
drive 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
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
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 on-
load 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
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 motor-
drive 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.
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.
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
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 tap-
changer 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.
77
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
Horizontal drive shaft Pressure relay

Bevel gear
Vertical drive shaft

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 motor-
drive mechanism are correctly assembled.
80
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 bot-
tom 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.
81
9 Commissioning
SA18, SA19
SA17
SA21
Driving pin SA20
SA10
SA11
SA16
SA16
SA10
SA15
SA14 SA15
SA10
Motor-Drive
Mechanism SA14
Fig. 46a. Fig. 46b. Fig. 46c.

TC_00156 TC_00147 TC_00147
Min. 3, max 5 mm
SA20
SA18, SA19
SA15
SA17
SA10
TC_00156 TC_00149
Fixing flange
Fig. 46d. of the bevel gear Fig. 46e.
82
9 Commissioning
9.2.4 Mounting of Horizontal Drive Shaft

types UCG.N/UCL.N and UCG.E/UCL.E

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 SA21 A
SA11
SA13
A
TC_00242 TC_00178
SA12
Fig. 47b. Fig. 47c.
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
Driving pin
TC_00170 TC_00148 TC_00150
Max. 6 mm
Fig. 47d. Fig. 47e. Fig. 47f.
83
9 Commissioning
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.
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
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.
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

Type UCG.B/UCL.B
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.

TC_00148
Fig. 48a.
according to Fig. 48a.
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 SA21 A
SA11
SA13
A
TC_00242 TC_00178
SA12
Fig. 48b. Fig. 48c.
85
9 Commissioning
bevel gear, see Fig. 48b. Mount two coupling halves SA11 to the other end of the
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
Driving pin
TC_00170 TC_00148 TC_00150
Max. 6 mm
Fig. 48d. Fig. 48e. Fig. 48f.
and 35.
carried out.
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
CAUTION
86
9 Commissioning
Slot facing
downwards
TC_00243
SA23
Fig. 48g.
SA10, see Fig. 48g.
The self-adhesive information plates SA25 are on about the middle of the tube
length.
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).

TC_00148
Fig. 48h.
according to Fig. 50h.
Disc Coupling A SA30 SA31
Unit -2 Unit -1
SA12
TC_00245
Fig. 48k.
87
9 Commissioning
bevel gear, see Fig. 48k. Mount two coupling halves SA11 to the other end of the
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.
and 35.
carried out.
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
CAUTION
Locking device
Cover
SA33 Set screws SA10 SA25 SA10
SA32 SA31 TC_00246
Fig. 48l.
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

Types UCG.T/UCL.T and UCGYD/UCLYD
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.
1-6 above. Remove the set screws according to Fig. 47h.
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.
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).
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:
stops within ±2 mm from the centre of the roller on the brake arm, see Fig. 35. For
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
Tel.+46 240 78 20 00
Fax +46 240 121 57
www.abb.com/electricalcomponents
1ZSE 5492-124 en, Rev. 5, 1999-11-30
On-load tap-changer, type UCG

Maintenance guide
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.
Do not alter or modify a unit without first consulting ABB Components.
WARNING
death.
CAUTION
equipment.
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
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
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 tap-
changer.
CAUTION
ABB Components recommends that only maintenance engineers trained by
ABB Components carry out contact replacement.
During Service
WARNING
fire, hot surfaces or sparks occurs in the immediate surroundings of the
breathing devices.
WARNING
WARNING
iv
WARNING
power supply is on.
CAUTION
the Repair Guide.
During Oil Handling

WARNING
be carcinogenic.
First aid:
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
v
WARNING
CAUTION
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
CAUTION
After Oil Filling

CAUTION
Mounting of Gaskets
CAUTION
vi
Contents
1 Introduction __________________________________________ 9
1.1 General ______________________________________________ 9
1.2 Maintenance Schedule __________________________________ 10
1.2.1 Inspection ____________________________________________ 12
1.2.2 Overhaul _____________________________________________ 12
1.2.3 Contact Replacement ___________________________________ 12
1.3 Tightening Torque _____________________________________ 13
2 Inspection ____________________________________________ 14
2.1 Required Tools and Material _____________________________ 14
2.2 Procedure ____________________________________________ 14
3 Overhaul _____________________________________________ 18
3.1 Required Tools and Materials ____________________________ 18
3.2 Procedure ____________________________________________ 19
3.3 Preparations __________________________________________ 20
3.3.1 On-Load Tap-Changer Position ___________________________ 20
3.3.2 Disconnection and Earthing of the Transformer ______________ 20
3.3.3 Oil Volumes and Lifting Heights __________________________ 21
3.3.4 Recommended Set of Spare Parts__________________________ 21
3.4 Oil Testing and Oil Draining _____________________________ 21
3.5 Lifting and Cleaning the Diverter Switch ___________________ 23
3.5.1 Lifting Rig ___________________________________________ 23
3.6 Checking the Diverter Switch ____________________________ 24
3.6.1 Cleaning the Diverter Switch Housing ______________________ 24
3.6.2 Cleaning the Oil Filter (if any) ____________________________ 25
3.7 Oil Filtration __________________________________________ 25
3.8 Checking of the Breathing Device _________________________ 26
3.9 Checking the Contact Positions ___________________________ 26
3.10 Checking the Contact Wear ______________________________ 28
3.11 Checking the Transition Resistors _________________________ 28
3.12 Checking before Closing ________________________________ 29
3.13 Installation of the Diverter Switch _________________________ 29
3.14 Checking of the Pressure Relay ___________________________ 31
3.14.1 Functional Check of the Pressure Relay _____________________ 31
3.14.2 Replacing the Pressure Relay _____________________________ 31
3.15 Lubrication of the On-Load Tap-Changer
and the Drive Shaft System ______________________________ 32
7
3.16 Checking of the Motor-Drive Mechanisms types BUE and BUL _ 32
3.16.1 Motor Protection ______________________________________ 35
3.16.2 Earth Fault Protector (option) ____________________________ 35
3.16.3 Counter ______________________________________________ 35
3.16.4 Heater _______________________________________________ 35
3.16.5 Toothed Belt __________________________________________ 35
3.16.6 Motor Cable Connections ________________________________ 36
3.16.7 Disc Brake, BUE ______________________________________ 36
3.16.8 Brake for the Maintaining Contact, BUE ____________________ 37
3.16.9 Disc Brake, BUL ______________________________________ 37
3.16.10 Position Transmitter and other Position Switches, BUE ________ 38
3.16.11 Position Transmitter and other Position Switches, BUL ________ 38
3.16.12 Lubrication, BUE ______________________________________ 39
3.16.13 Lubrication, BUL ______________________________________ 39
3.17 Operation Test ________________________________________ 41
3.18 Oil Filling ____________________________________________ 41
3.18.1 Filling Methods and Restrictions __________________________ 41
3.18.2 Before Filling _________________________________________ 42
3.18.3 Filling at Atmospheric Pressure ___________________________ 42
3.18.4 Oil Level _____________________________________________ 42
3.18.5 Restoring the Gas Cushion _______________________________ 43
3.18.5.1 Procedure ____________________________________________ 44
3.18.6 Waiting Period ________________________________________ 45
3.19 Check of Contact Timing ________________________________ 45
3.20 Putting into Operation __________________________________ 48
4 Contact Replacement ___________________________________ 49
4.1 Dismantling the Boards _________________________________ 51
4.2 Dismantling the Moving Main Contacts ____________________ 52
4.3 Dismantling the Moving Transisition Contacts _______________ 54
4.4 Mounting the Moving Transistion Contacts __________________ 54
4.5 Mounting the Moving Main Contacts ______________________ 56
4.6 Replacing the Fixed Main Contacts ________________________ 57
4.7 Replacing the Fixed Transition Contacts ____________________ 57
4.8 Mounting the Boards with Transition Resistors and Fixed Contacts 57
5 Specification of Materials _______________________________ 59
5.1 General ______________________________________________ 59
5.2 Diverter Switch Housing ________________________________ 59
5.3 Diverter Switch ________________________________________ 59
5.4 Tap Selectors _________________________________________ 60
5.5 Conductors ___________________________________________ 60
5.6 Gearing Mechanism ____________________________________ 60
5.7 Drive Shaft Systems ____________________________________ 61
5.8 Motor-Drive Mechanism ________________________________ 61
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 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 motor-
drive mechanism is attached to the transformer tank and connected to the on-load tap-
changer by means of drive-shafts and a bevel gear, see Fig. 1.
Horizontal drive-shaft
Bevel gear and protection tube Pressure relay
Bevel gear
Shielding-rings
(when impulse
withstand voltage to
Vertical drive-shaft earth exceeds
and protection tube 380 kV)
Insulating shaft
Diverter switch
housing containing
Hood and screws the diverter switch
Conductors
Hand crank
Motor-drive
Shielding-ring
mechanism
(when impulse
withstand voltage to
earth exceeds
On-load tap-changer
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
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

Oil valve
Pressure relay
Bevel gear
Position indicator
Top-section
Serial No.
1)
Shielding-ring
Earthing terminal
Connection flange for Draining tube

gas operated relay
Insulating cylinder
Insulating shaft
Diverter switch
1)
Shielding-ring
2)
Shielding-ring
Transition resistors Plug-in contacts
Fixed and moving

contacts
Serial No. Bottom section
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 Change-over
voltage to earth of 650 kV selector
and 1050 kV
2)
Not on UCG of the short type Moving fine-
selector 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 tap-
changers, 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

The following tightening torques are recommended
for metallic screw joints: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %
for non-metallic screw joints: M10, 9 Nm ±10 %

M12, 13 Nm ±10 %
M16, 22 Nm ±10 %
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 tap-
changer.
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
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 20 19 18 17
1. Locking device prepared for padlock 13. Shaft for handcrank

2. Emergency stop 14. Heater 50 W + optional 100 W (behind the panel)
3. (Option) Switch for extra heater 15. (Option) Outlet with earth fault protector
4. Air vent 16. Terminal blocks (behind the panel)
5. LOCAL/REMOTE switch 17. Protective motor switch
6. RAISE/LOWER switch 18. (Option) Thermostat or hygrostat for extra
7. Outgoing shaft heater 100 W
8. Lamp (40 W socket E27) 19. Door-operated switch for lamp
9. Lifting eye 20. Handcrank
10. Counter 21. User’s manual and circuit diagram
11. Tap-change in progress indicator
12. Position indicator with draghands for
max. and min. position
Fig. 3. Motor-Drive Mechanism, type BUE.
16
2 Inspection
1 2 3 4 5 6
10
11
12
13
14
15
16
17 18 19 20 21 22 23 24
1. Position indicator with draghands for 13. Emergency stop

max. and min. position 14. RAISE/LOWER switch
2. Tap-change in progress indicator 15. LOCAL/REMOTE switch
(Red = in progress, White = in position) 16. Protective motor switch
3. Counter 17. Air vent
4. Outgoing shaft with multiple hole (Remote position for automatic operation)
coupling half 18. Door operated switch for lamp
5. Shaft for handcrank 19. Terminal blocks
6. Lifting eye 20. Hand lamp
7. Locking device prepared for padlock 21. Heater 50 W + optional 100 W
8. (Option) Multi position switches 22. (Option) Thermostat or hygrostat for
9. (Option) Measuring amplifier extra heater 100 W
10. (Option) Switch for extra heater 23. User’s manual and circuit diagram
11. (Option) Outlet 24. Handcrank
12. (Option) Earth fault protector
Fig. 4. Motor-Drive Mechanism, type BUL.
17
3 Overhaul
3 Overhaul
WARNING
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
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.. 380/... Approx. 170 litres (lifting height 1.4 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
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
3 Overhaul
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
WARNING
When oil that has been used in a diverter switch housing is pumped out,
Drain the remaining oil in the bottom of the housing by using a hose.
Lifting eye
Buffer springs
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 Guiding pins

driving-pin
Fig. 5. Diverter switch, general arrangement
22
3 Overhaul
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.
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
600
Ø56/48
Ø15 (2x)
2500
>5 453
50
65
Ø30
Ø15 (2x)
10
90
125
Support (2x)
Fig. 6. Lifting rig
23
3 Overhaul
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.
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.
24
3 Overhaul
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.
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.
25
3 Overhaul
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.
26
3 Overhaul
0.5–2 mm
Fixed main
switching contact
Moving main
switching contact
20
14
Ø6.4 Copper part

26
14
Thickness 1 mm
Current bar Moving main
Fixed main contact
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
3 Overhaul
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.
28
3 Overhaul
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
3 Overhaul
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 Plug-in contacts
diverter switch) A A
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
Slot for draining tube
guiding bar
A–A,
TC_00284
UCG TC_00285
Fig. 13. UCG Diverter switch housing, view from above
30
3 Overhaul
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
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.
31
3 Overhaul
3.15 Lubrication of the On-Load Tap-

Changer and the Drive Shaft System
The bevel gears are greased at delivery and the same type of grease is used for the
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
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.
32
3 Overhaul
Brake
Brake disc
Maintaining contact
Roll pin
Supporting
shaft
Brake block
Arm system
Brake for maintaining contact Driving roller
One turn shaft

Cam disc
Toothed belt
Geneva wheel
Position
transmitter
Contact plate
fm_00137
Motor
Fig. 15. Motor-drive mechanism, type BUE
33
3 Overhaul
Operation counter
Roller
(Grease)
Notch
Cam disc
(Grease)
Brake arm
Geneva
wheel Adjusting
screw
Maintaining
contact
Bracket
Brake disc
Limit switch
Toothed belt
Multi-position switches
(Grease)
fm_00231
Fig. 16. Motor-drive mechanism, type BUL
34
3 Overhaul
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
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
3 Overhaul
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
3 Overhaul
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

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.
37
3 Overhaul
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).
Moving contact
Contact arm
Contact arm
0,6 +0.6
-0.2
mm
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.
38
3 Overhaul
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.
39
3 Overhaul
Grease
Grease
Oil
Oil
Grease
Grease
NOTE: The small bevel gear for

the position indicator shaft shall
be greased.
Grease
Fig. 21. Lubrication points, BUE
40
3 Overhaul
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 tap-
changer 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.
41
3 Overhaul
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.
42
3 Overhaul
3.18.5 Restoring the Gas Cushion

The procedure below is used for on-load tap-changers without oil filter unit for
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 tap-
changers, 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
WARNING
WARNING
43
3 Overhaul
3.18.5.1 Procedure
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.
10. Pump the earlier drained 15 litres of oil back into the diverter switch housing.
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
Open end wrench

Oil valve Air release valve key width 6 mm
Open
TC_00251 Oil valve TC_00250
Fig. 22. Air release valve (position may be on another vertical flange)
44
3 Overhaul
3.18.6 Waiting Period

CAUTION
3.19 Check of Contact Timing

Checking the contact timing is a good check of the condition of the on-load tap-
changer, 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.
45
3 Overhaul
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 Position Min. 3 turns Position
–—— Contact closed 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
–—— 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 on-
load tap-changer is ready for energizing.
48
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
Fixed main switching

contact
Conical
spring-
washer
Fixed transition Plain

contact washer
Locking
washer 1)
Plain
washer
Conical spring Guide pin

washer Conical spring
washer Nut
Plain washer Connection for

Moving transition
transition resistor
contact
Fixed transition
contact
Moving main
switching contact
1)
Mounted vertically
on some types
Fig. 27. Diverter switch, contact design
50
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
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
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
4.3 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
Split pins
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
4.5 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.
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
4.6 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
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
5.1 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

Steel 25 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
5.4 Tap Selectors

Tap selector I: Tap selector C:
Material Approx. amount Material Approx. amount
Steel 50 kg Steel 5 kg
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 5 kg
Epoxy resin 15 kg
Tap selector III:
Steel 10 kg
Aluminium 40 kg
Silver 10 g
Polyester resin 10 kg
Epoxy resin 20 kg
5.5 Conductors
Copper 5-10 kg
Cellulose
5.6 Gearing Mechanism

Steel 15 kg
60
5.7 Drive Shaft Systems

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 x x
polyamide with MoS2 x x
phenol resin laminate x
polyester x x
PVC x x
carbonate plastic x x
Rubbers:
nitrile rubber x x
fluorine rubber x x
CAUTION
Materials listed in the table above without any specification of amount are included
because they may cause pollution problems during de-commissioning, even in the
small quantities used.
61
1ZSE 5492-124 en, Rev. 5, 1999-11-30

Components
Tel.+46 240 78 20 00
Fax +46 240 121 57
www.abb.com
1ZSE 5492-129 en, Rev. 6, 1999-11-30
On-load tap-changers, types UCG, UCL, UCC and UCD

Repair Guide
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.
Do not alter or modify a unit without first consulting ABB Components.

WARNING
death.
CAUTION
equipment.
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
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
sources.
WARNING
During Service
WARNING
fire, hot surfaces or sparks occur in the immediate surroundings of the breathing
devices.
WARNING
iv
WARNING
WARNING
power supply is on.
CAUTION
this Guide.
During Oil Handling

WARNING
be carcinogenic.
First aid:
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
v
CAUTION
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,
WARNING
The oil in the diverter switch compartment may be hot. Be cautious!
CAUTION
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
After Oil Filling

CAUTION
vi
Contents
1 Introduction ____________________________________________ 9
1.1 General ________________________________________________ 9
1.2 Repair Categories _______________________________________ 9
1.3 Serial Number __________________________________________ 11
1.4 Spare Parts List _________________________________________ 11
1.5 Maintenance Guide ______________________________________ 12
1.6 Tightening Torque _______________________________________ 12
2 Trouble-shooting ________________________________________ 13
2.1 On-Load Tap-Changer ____________________________________ 13
2.2 Pressure Relay __________________________________________ 14
2.3 Motor-Drive Mechanism __________________________________ 15
2.3.1 Control System _________________________________________ 15
2.3.2 Power System __________________________________________ 17
2.3.3 Miscellaneous __________________________________________ 17
3 Repairs and Adjustments __________________________________ 22
3.1 Replacement of Gear Box on the On-Load Tap-Changer or
Replacement of O-rings for the Gear box _____________________ 22
3.1.1 General ________________________________________________ 22
3.1.2 Tools Required _________________________________________ 22
3.1.3 Material and Spare Parts Required __________________________ 22
3.1.4 Procedure ______________________________________________ 23
3.2 Replacement of Diverter Switch Housing Cover Gasket _________ 27
3.2.1 General ________________________________________________ 27
3.2.2 Tools Required _________________________________________ 27
3.2.3 Material and Spare Parts Required __________________________ 27
3.2.4 Procedure ______________________________________________ 27
3.3 Restoring the Gas Cushion ________________________________ 28
3.3.1 General ________________________________________________ 28
3.3.2 Equipment Required _____________________________________ 29
3.3.3 Procedure ______________________________________________ 29
3.4 Replacement or addition of a Multi-position Switch (BUL only) __ 30
3.4.1 General ________________________________________________ 30
3.4.2 Tools Required _________________________________________ 30
3.4.3 Procedure ______________________________________________ 31
3.5 Examination of the Diverter Switch after a Pressure Relay Trip ___ 33
3.5.1 Tools and Material Required _______________________________ 33
3.5.2 Procedure ______________________________________________ 33
3.6 Tests of the Pressure Relay ________________________________ 34
3.7 Replacement of Pressure Relay _____________________________ 35
3.7.1 General ________________________________________________ 35
3.7.2 Tools Required _________________________________________ 35
3.7.3 Spare Parts Required _____________________________________ 35
3.7.4 Procedure ______________________________________________ 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 motor-
drive 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

Oil valve
Pressure relay
Bevel gear
Position indicator
Top-section
Serial No.
1)
Shielding-ring
Earthing terminal

gas operated relay
Insulating cylinder
Insulating shaft
Diverter switch
1)
Shielding-ring
2)
Shielding-ring
Fixed and moving

contacts
Guide-pins
Current terminal

Bottom valve for

drying process
Intermediate gear
Geneva gear
1)
Only at impulse withstand Change-over
voltage to earth of 650 kV selector
and 1050 kV
2)
Fixed fine-selector
contacts
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 Transform-
ers 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_00200 FM_00006
BUL BUE
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.

The following tightening torques are recommended
for metallic screw joints: M6, 10 Nm ±10 %
M8, 24.5 Nm ±10 %
M10, 49 Nm ±10 %
M12, 84 Nm ±10 %
for non-metallic screw joints: M10, 9 Nm ±10 %

M12, 13 Nm ±10 %
M16, 22 Nm ±10 %
12
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 over-
filling 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 1. Check for leakages.
oil conservator
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 on-
load tap-changer and the transformer.
The pressure relay has 1. Examine the diverter switch according to section
tripped during normal 3.5 ”Examination of the diverter switch after a
operation. 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
14
2 Trouble-shooting
2.3 Motor-Drive Mechanism

2.3.1 Control System
LOCAL operation or 1. LOCAL operation is not possible when the control

REMOTE operation is selector switch is in position REMOTE or 0, and
not possible. 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 end-
position.
The on-load tap-changer 1. Check that the maintaining contact releases after
performs more steps than operation.
ordered, or operates
towards the end stop. 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
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 1. If there is a measuring amplifier:

indicator shows wrong Adjust the output signal from the measuring
position or there is no amplifier with its two adjustment screws. If the
signal. 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 motor-
drive 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

The three-phase motor runs Reverse two of the phases of the incoming supply.
back and forth without the
on-load tap-changer WARNING
changes position. Dangerous voltage!
2.3.3 Miscellaneous
Corrosion and/or conden- 1. Check the function of the anti-condensation heater.

sation in motor-drive Refer to heater in the Maintenance Guide.
mechanism cabinet.
2. Check that the air vents not have been blocked.
Water in motor-drive 1. Adjust the hinges on the cabinet door, if necessary.

mechanism cabinet.
2. Replace the door gasket, on the cabinet.
17
18
fm_00236
2 Trouble-shooting
tap-changer.
Fig. 4. Standard circuit diagram BUE
For actual information use the circuit diagram delivered with your on-load
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_00237
Fig. 5. Contact timing diagram BUE
19
20
fm_00238
2 Trouble-shooting
tap-changer.
Fig. 6. Standard circuit diagram BUL
For actual information use the circuit diagram delivered with your on-load
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_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
3.1.4 Procedure
WARNING
WARNING
Tap-Changer from above
Red point
Position indicator Position indicator
Exact position
TC_00257
Tolerances
Bolts and tightening washers
Fig. 8b. Gear box, Fig. 8a. Gear box, UCL

UCG, UCC, UCD
Position indicator
TC_00156
Clamps, washers and screws
Locking device
TC_00151
Fig. 8c.
23
WARNING
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
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
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
3.2 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.

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
WARNING
CAUTION
Protect the on-load tap-changer from water.
27
1. Retighten the nuts that hold the cover.

If the oil leakage still remains, the O-ring has to be replaced.
WARNING
WARNING
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
The procedure below is used for on-load tap-changers without oil filter unit for
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 tap-
changers, manual” for restoring the gas cushion.
CAUTION
28
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
WARNING
WARNING

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

10. Pump the earlier drained oil back into the diverter switch housing.
12. The level in the oil conservator and the gas cushion are now restored.
CAUTION
3.4 Replacement or addition of a Multi-

position 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.

Small wrench (10 mm).
30
3.4.3 Procedure
WARNING
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
Upper coupling half

Torque disc
Lower coupling half
Shaft
Transparent cover
Contact arm Multi-position switch
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
3.5 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
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 instal-
lation 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
3.6 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
3.7 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.

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
WARNING
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. 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
36
1ZSE 5492-129 en, Rev. 6, 1999-11-30

Components
Tel.+46 240 78 20 00
Fax +46 240 121 57
www.abb.com
1ZSE 5492-133 en, Rev. 3, 2004-04-15
On-load tap-changers, types UCG, UCL, UCC and UCD

Spare Parts List

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 tap-
changer 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
death.
CAUTION
equipment.
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 Introduction ____________________________________________ 7
1.1 Type Designation and Serial Number ________________________ 7
1.2 Item Number ___________________________________________ 7
1.3 Name of Item ___________________________________________ 7
1.4 Quantity _______________________________________________ 7
1.5 Remarks _______________________________________________ 7
2 General Arrangement ____________________________________ 8
2.1 Standard Spare Parts _____________________________________ 8
2.2 Special Spare Parts ______________________________________ 8
3 Spare Parts for On-Load Tap-Changer _______________________ 10
3.1 Type UCG _____________________________________________ 10
3.2 Type UCL _____________________________________________ 12
3.3 Types UCC and UCD ____________________________________ 14
4 Accessories for On-Load Tap-Changer _______________________ 16
5 Spare Parts for Motor-Drive Mechanism type BUE _____________ 18
5.1 Electrical Details ________________________________________ 18
5.2 Mechanical Details ______________________________________ 20
6 Spare Parts for Motor-Drive Mechanism type BUL _____________ 24
6.1 Electrical Details ________________________________________ 24
6.2 Multi Position Switches___________________________________ 26
6.3 Mechanical Details ______________________________________ 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
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

Oil valve
Pressure relay
Bevel gear
Position indicator
Top-section
Serial No.
1)
Shielding-ring
Earthing terminal

gas operated relay
Insulating cylinder
Insulating shaft
Diverter switch
1)
Shielding-ring
2)
Shielding-ring
Fixed and moving

contacts
Guide-pins
Current terminal

Bottom valve for

drying process
Intermediate gear
Geneva gear
1)
Change-over
Only at impulse withstand
selector
voltage to earth of 650 kV
and 1050 kV
2)
Fixed fine-selector
contacts
9
3 Spare Parts for On-Load Tap-Changer
3 Spare Parts for On-Load

Tap-Changer
3.1 Type UCG
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.N .../300
Complete diverter switch 1
Complete tap selector 1
10
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
3.2 Type UCL

1 Contact set 1 set UCL.E .../600, UCL.E .../900

3 sets 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 UCL.T .../600, UCL.T .../900
9 sets 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
12
Fig. 3. Diverter switch for UCL with replacement contacts.
13
3.3 Types UCC and UCD
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
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
1 Pressure relay 1
2 Pressure relay with 1
test valve
3 Pressure relief valve 1
4 Oil valve 1
5 Vent 1
6 Cover for connection 1
to oil conservator
7 Bottom valve key 1
16
4 Accessories for On-Load Tap-Changer
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
Complete motor-drive mechanism 1

with cabinet
5.1 Electrical Details

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
18
fm_00136
Fig. 6. Electrical details.
19
5.2 Mechanical Details

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
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
124 Cylindrical toothed wheel 1
125 Geneva wheel 1
126 Geneva wheel with arm 1 For double contact
127 Contact guide device 1
128 Cam bar 1
129 Brake for maintaining contact 1
(item No. 6)
130 Cam disc for starting contact 1
(item No. 5)
131 Driving disc for item No. 130 1
136 Screw for end stop 1
20
fm_00137
Fig. 7. Mechanical details.
21
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 1
(item No. 6)
146 Shaft for starting contact 1
(item No. 5)
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 For DAG motor-switch
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 1
(item No. 120)
180 Door with window 1 For BUE 1
180 Door with window 1 For BUE 2
22
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
Complete motor-drive mechanism 1

with cabinet
6.1 Electrical Details

1)
B1 Thermostat 1
1)
B2 Hygrostat 1
E1 Anti-condensation heater 1 50 W
E2 Extra heater 1 100 W 1)
1)
E3 Cabinet light, Hand lamp 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 1 Raise and lower,
auxiliary contacts 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
1)
S9 Door operated switch 1
S10 Switch for extra heater 1
U1 Measuring amplifier 1
X1-17 Terminal blocks
X38 Outlet 1
1)
When ordering, it must be stated for this optional item, if it was already installed in the motor-
drive mechanism. If it is not the case, other assembly details will be included in the order.
24
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
6.2 Multi Position Switches

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 <3 circuit cards
4–5 circuit cards
164 Transparent cover
165 Distance screw L=10, L=20, L=35 or L=60
166 Terminal, plug part 4-pole, 8-pole
26
111.1
111.2
111.1
112
164
S14 (S24)
165 S15
S20 (S21, S22, S23)
S25 (S26, S27, S28)
S86 (S87)
166
fm_00247
Fig. 10. Multi Position Switches, type BUL.
27
6.3 Mechanical Details

101 Toothed belt 1

104 Hand crank 1
110 Pointer with drag hands for 1
position indicator
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 Screws, washers, shims
included
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
28
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 Motor contactor, raise
Item 4, pages 14 and 15 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 Motor contactor, raise
Item Q3, pages 19 and 20 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
30
1ZSE 5492-133 en, Rev. 3, 2004-04-15

Components
Tel.+46 240 78 20 00
Fax +46 240 121 57
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. 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

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 Description _____________________________________________ 6
1.1.1 Design ________________________________________________ 6
1.1.2 Design of horizontally mounted bushings ______________________ 8
1.2 Operating conditions _____________________________________ 9
1.3 Mechanical loading ______________________________________ 9
1.4 Spare parts _____________________________________________ 10
2 Installation _____________________________________________ 10
2.1 Tools _________________________________________________ 10
2.2 Consumables ___________________________________________ 10
2.3 Transport and handling ____________________________________ 11
2.4 Lifting from the box ______________________________________ 11
2.5 Mounting ______________________________________________ 12
2.5.1 Mounting of oil-end shield _________________________________ 12
2.5.2 Inner terminal / Stranded cable _____________________________ 13
2.5.3 Solid rod conductor ______________________________________ 14
2.5.4 Horizontal mounting of bushing _____________________________ 15
2.6 Mounting of outer terminal _________________________________ 15
2.7 Flange earthing __________________________________________ 16
2.8 Waiting time before energizing _____________________________ 16
2.9 Recommended tests before energizing _______________________ 17
2.9.1 Tightness test between transformer and bushing________________ 17
2.9.2 Tightness test of bushing outer terminal ______________________ 17
2.9.3 Measurement of capacitance and tan δ ______________________ 18
2.9.4 Check of through resistance _______________________________ 20
3 Maintenance ___________________________________________ 21
3.1 Recommended maintenance and supervision __________________ 21
3.1.1 Cleaning of insulator surface _______________________________ 21
3.1.2 Measurment of capacitance and tan δ _______________________ 21
3.1.3 Thermovision (infrared camera) check for local overheating
on connectors ___________________________________________ 21
3.1.4 Check for leakage _______________________________________ 21
3.1.5 Checking and adjustment of the oil level ______________________ 22
3.1.6 De-mounting of horizontally mounted bushing __________________ 23
3.2 Disposal after end of service life ____________________________ 23
2750 515-12 en, Rev. 8 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 Fig. 1b
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
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 gob_0015
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 goh_0008
connection of outer cable)

6) Nut
7) Belleville spring washer
8) Connector to test tap
9) O-ring
2750 515-12 en, Rev. 8 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

Bushing Type test load 1 minute (N) Max. service load (N)
GOB 250/800 2340 1800
GOB 250/1250 4000 3000
GOB 325/800 1950 1500
GOB 380/800 1800 1400
GOB 380/1250 3750 2900
GOB 450/800 1500 1150
GOB 550/800 1700 1300
GOB 550/1250 3100 2400
GOB 650/1250 3380 2600
GOB 750/1250 3350 2600
GOB 1050/1100 3200 1250
2750 515-12 en, Rev. 8 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 trans-
former 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.
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
Fig. 5. 123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
Lifting from the box.123456789012345678901234567890121234567890123456789012
123456789012345678901234567890121234567890123456789012
123 12
123
123 12
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 trans-
former.
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 Fig. 10. Solid conductor 1100/1250 A

1) Upper conductor 1) Upper conductor
2) Lower conductor 2) Lower conductor
3) Locking pin, 2111 764-A 3) Locking pin, 2111 764-B
4) Locking pin, 2111 764-C 4) Hexagon head screw M10 x 20
5) Screw, 2122 751-2 Previous non-captive design, 2121 2033-490
New captive design, 2121 738-19
5) Belleville spring washer, 2154 717-5
14 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.
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.
2.9.1 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:
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.
2750 515-12 en, Rev. 8 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 Catalogue No. Nominal capacitance (pF)
LF 123 C1 C2
GOB 250 013, 014, 171, 172 125 90
015, 016, 173, 174 205 500
017, 167 165 110
019, 168 270 750
083, 084, 175, 176 275 800
085, 169 375 1200
GOB 325 025, 026, 177, 178 135 95
027, 028, 179, 180 200 200
089, 090, 181, 182 260 425
GOB 380 037, 038, 183, 184 145 110
039, 040, 185, 186 200 335
041, 101 185 150
043, 102 265 550
095, 096, 187, 188 245 550
097, 103 320 1150
GOB 450 049, 050, 145, 146 145 125
051, 052, 147, 148 200 570
053, 054, 149, 150 245 770
GOB 550 061, 189, 062 150 156
063, 190, 064 170 400
107, 191, 108 210 750
065, 142 170 150
067, 143 195 320
109, 144 240 575
GOB 650 073,192 205 200
075, 193 235 340
113, 194 280 550
GOB 750 077, 104 205 390
078, 105 235 565
079, 106 275 950
GOB 1050 281 310 450
280 367 700
2750 515-12 en, Rev. 8 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 Multiplier to 20 °C
0-2 0.80
3-7 0.85
8-12 0.90
13-17 0.95
18-22 1.00
23-27 1.05
28-32 1.10
33-37 1.15
38-42 1.20
43-47 1.25
48-52 1.30
53-57 1.34
58-62 1.35
63-67 1.35
68-72 1.30
73-77 1.25
78-82 1.20
83-87 1.10
2.9.4 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 trans-
former. 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 opera-
tion 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

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
3.1.1 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 samp-
ling 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 Oil level A mm at 20 ±10 °C Oil level change
GOB Fig. 1a Fig. 1b 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:
- 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.
2750 515-12 en, Rev. 8 23

2750 515-12 en, Rev. 9, 2006-10-15

Components
Tel.+46 240 78 20 00
Fax +46 240 121 57

*"(&(&(&$"(((&(((&"(
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 stan-
dards).
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)
12
1 of 3

b1=380 mm
$*+ ,-.//
* &/0
3,23, 15
*/
.) 2 of 3
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 Torque (Nm) Spanner (mm.)

1000 M30x2 70 46
2000 M42x3 110 65
3150 M48x3 180 75
4500 M55x3 250 80
then verify the tightening of the screws – items 13 -on the flags by referring to
the following table :
Screws dimension Torque (Nm) Spanner (mm.)

M 10 25 17
M 12 40 19
M 16 90 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 .
Renzmann &
Grünewald GmbH
Process Equipment Transformeroil Oil Technologie
Division
Description-, Operating-
and 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 Notes fort he Customer ..................................................................................................................3
1.1.1 General...........................................................................................................................................3
1.1.2 Protective Equipment .....................................................................................................................4
1.2 Target Groups ................................................................................................................................4
1.3 Technical Drawing and EU Declaration .........................................................................................4
2. General...............................................................................................................5
2.1 Liability and Warranty.....................................................................................................................5
2.2 Keeping the Operating Manual Ready...........................................................................................6
2.3 Additional Copies of the Manual ....................................................................................................6
2.4 Copyright........................................................................................................................................6
3. Safety .................................................................................................................7
3.1 Pictograms .....................................................................................................................................7
3.2 General Safety Requirements........................................................................................................8
3.3 Protective Equipment .....................................................................................................................9
3.4 Intended Use................................................................................................................................10
3.5 Inappropriate Use.........................................................................................................................10
3.6 Inadmissible Operating Modes ....................................................................................................10
4. Description and Function ................................................................................ 11
4.1 General.........................................................................................................................................11
4.2 Type Code....................................................................................................................................11
5. Transport and Storage .................................................................................... 11
5.1 General.........................................................................................................................................11
5.2 Handling/ Transport......................................................................................................................11
5.3 Unpacking ....................................................................................................................................12
5.4 Storage location, Storage period, Protective measures ..............................................................12
6. Commissioning ................................................................................................ 13
6.1 General.........................................................................................................................................13
6.2 Arrangement of the Product .........................................................................................................13
6.3 Cleaning and Filling of the Product ..............................................................................................13
6.3.1 Remove Preservation Agents ......................................................................................................13
6.4 Mounting ......................................................................................................................................13
7. Operation......................................................................................................... 14
8. Malfunctions.................................................................................................... 14
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9. Maintenance .................................................................................................... 14
9.1 General.........................................................................................................................................14
9.2 Cleaning .......................................................................................................................................15
9.3 Maintenance Schedule.................................................................................................................15
9.4 Maintenance and Repair Work ....................................................................................................15
9.5 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 Renzmann &

Division Grünewald GmbH
Renzmann & Grünewald • Industriestr. 6 • D-55569 Monzingen • Phone.++49(0)6751/9303-0 •

Fax.++49(0)6751/9303-100 • email: shurtleff@renzmann.de
Rombacher Hütte 12a • D-44795 Bochum • Phone ++49(0)234/94342-0 •
Fax ++49(0) 234/94342-379 •email: fajferic@renzmann.de
For further info visit our internet site: www.renzmann.com
VBE102.603
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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 pre-
requisite 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 re-
spected.
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 gener-
ally 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 ex-
ample in the fields of operation, maintenance and repairs.
As regards faults or omissions Renzmann & Grünewald GmbH will, to the exclusion of any fur-
ther 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.
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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 compe-
tence and authority levels of the authorized plant personnel.
b) A qualified person is a person who, based on their technical training, qualification and ex-
perience 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 dan-
ger involved.
A qualified person can only be a specially trained, skilled worker or a worker who has been spe-
cifically 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 meas-
ures.
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.
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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 war-
ranty claims will be become forfeited.
The design of the products corresponds with what has been written in our order acknowledge-
ment. 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 pur-
pose;
- unauthorized modifications are made;
- cleaning is not carried out as prescribed or maintenance and inspection instructions are dis-
regarded.
We shall demand and enforce the exclusion of legal responsibility where we can prove that mal-
function is attributable to operation or application faults.
In certain cases, modifications and/or adjustments may be made to the products. Such modifica-
tions/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.
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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 regu-
lations 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.

Industriestrasse 6 Phone: + 49 (0)6751-9303-222
55569 Monzingen Fax: + 49 (0)6751-9303-100
Germany Internet: 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.
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3. Safety
This chapter describes the safety measures and safety equipment. Read this section carefully be-
fore performing any work on and with the product to ensure safe working and operating condi-
tions.
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.
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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 sup-
plemented 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 provi-
sion/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 cor-
rectly functioning (if applicable).
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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 work-

shop outfit/tooling is available.
Personnel entrusted with various work assignments must have read and understood the opera-
ting 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 occasion-
ally 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 systems
the Owner is held to mount protective systems as necessary.
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.
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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 speci-
fied 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 sub-
stances 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
- items are wrongly installed and controlled
Danger
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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 oper-

ating 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.
Comm.- No. 22300

or Comm.- No. 22300-10
or Comm.- No. 22300-10-1
The relevant details are shown on the nameplate.
Additional detailed information can be found in the enclosed product-related oper-

ating 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.
Only use handling means and tools suitable for the task to be performed. For exam-
ple, 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.
Attention
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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 equip-
ment 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 sup-
ply of air / CO 2 white rust (wet storage stain) may form on the zinc surface.
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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 particu-
lar attention. Only qualified expert personnel must perform work in connection with transporta-
tion, mounting and commissioning as well as maintenance and repairs. Qualified skilled person-
nel 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 qualifi-
cations.
6.2 Arrangement of the Product
All connections are specified on the drawing. Only the specified connections with the appropri-
ate 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 protec-

tion 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.
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7. Operation

8. Malfunctions
In order to solve malfunctions only skilled personnel shall be assigned.

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
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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.

9.3 Maintenance Schedule

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.

Industriestrasse 6 Phone: + 49 (0)6751-9303-222
55569 Monzingen Fax: + 49 (0)6751-9303-100
Germany Internet: 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.
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10.2 Disposal Instructions
1. All components must be pressure less prior to disassembly.

2. Oil, grease and other fluids have to be disposed of separately in accordance with local
regulations.
3. Bright steel parts are to be treated as steel scrap.
4. 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.
5. Galvanized steel parts must be disposed of separately, according to local regulations.
6. Stainless steel parts are to be disposed of as stainless steel scrap.
7. Nameplates (if of stainless steel) fall into the stainless steel category when scrapped.
8. Aluminum parts, such as manhole components, come under aluminum scrap.
9. Sealing materials have to be separately disposed of.
10. 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 compati-
ble disposal. The local disposal regulations applicable in the country where the equipment is
mounted shall be observed.
11. Technical datasheet and Drawings

12. Spare Parts

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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, vibration-
free 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
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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.

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

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
Surface treatment 2-component CHING (≥140µm); RAL 7032
Medium Transformer oil, 70°C
Density 835 kg/m³
Voltage / Frequency / RPM 3~Y 400 V / 50 Hz / 1450 min^-1
Weight 73 kg
Level of max. soun capacity 66,5 dB (A)
Impeller diamter 150 mm
Capacity 60,2 m³/h
Delivery head 5,2 m Fl.C
Working input 1,4 kW
Working current 3,3 A
Starting current 42 A
Protective motor switch setting 7,6 A
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
Working Power [kW]

1,5
1,0
0,5
0,0
0 10 20 30 40 50 60 70 80 90
Working Current [A]

5,0
4,0
3,0
2,0
1,0 Tolerance +/- 5%
0,0
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 Nominal liquid flow Operating temperature From -30oC to+100o C
3
D, mm dcm /s Permissible gauge pressure
80 2.4 in pipeline 0,4 Mpa
100 7.0
125 12.0 Dimensions see drawing
Electric contact
rating 0.8A 220V D.C
Flow Electrical connection
<0.4 nom 1-2 closed, 2-3 opened
Climate No limitations
>0.6 nom 1-2 opened, 2-3 closed Maintenance No required
Mass 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 sight-
glass. 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 Telefon: +48(0-prefix-42) 637 14 66

ODDZIA£ TRANSFORMATORÓW Telefax: +48(0-prefix-42) 637 17 22
ul.Kopernika 56/60 e-mail: kontakt@ienot.com.pl
90-553 £ódŸ htpp://www.ienot.com.pl
Elektromotoren und
Gerätebau Barleben GmbH
OPERATING INSTRUCTIONS
Transformer Protection Relay

(Buchholz Principle)
Elektromotoren und
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
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°
R 5
2
>
50
0°...5°
4
R>
50
1 2 3 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 DN 25 DN 50 DN 80
Distance (m) 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
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
1.3. Draining the Buchholz relay (Figure 1) Filling the Buchholz relay
• Close shut-off valve (3) on the expansion tank side (5)

Open the Buchholz relay. Remove the Buchholz relay.
Lower the insulating liquid level Lower the insulating liquid level
to the top inspection glass marking 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
Note: Electrical connection
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
Single-float Buchhholz relay
Contact setting, switching system (disconnection):

1 normally-closed 1 normally-open 2 normally-closed 2 normally-open
contact (NC) contact (NO) contacts (NC) contacts (NO)
11 13 11 21 13 23
12 14 12 22 14 24
12 11 14 13 12 11 21 22 14 13 23 24
Contact setting, switching system (disconnection):

1 normally-open 1 change-over contact
contact (NO) and
1 normally-closed
contact (NC)
13 11 1
14 12 2 4
14 13 11 12 2 1 4
5
Elektromotoren und
Double-float Buchholz relay
Contact setting, upper switching system (warning):

1 normally-closed contact 1 normally-closed contact 1 normally-open contact 1 normally-open contact
(NC) (NC) (NO) (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 1 normally-closed contact
(NC) (NO) (NO) (NC)
21 13 23 11
22 14 24 12
12 11 22 21 12 11 14 13 14 13 24 23 14 13 12 11

1 normally-closed contact 1 normally-closed contact 1 normally-closed contact 1 normally-closed contact
(NC) (NC) (NC) (NC) and 1 normally-
open contact (NO)
11 11 11 11 13
12 12 12 12 14

2 normally-closed 2 normally-open contacts 1 normally-open contact 1 normally-closed contact
contacts (NC) (NO) (NO) and 1 normally- (NC) and 1 normally-open
closed contact (NC) contact (NO)
21 31 13 23 13 21 21 23
12 32 14 24 14 22 22 24
12 11 22 21 12 11 14 13 12 11 14 13 11 12 21 22
32 31 24 23 22 21 13 14 23 24
6
Elektromotoren und
Double-float Buchholz relay

1 normally-open contact 1 normally-open contact 1 normally-open contact 2 normally-open
(NO) (NO) (NO) contacts (NO)
13 13 13 13 23
14 14 14 14 24

2 normally-open 2 normally-closed 1 normally-open contact 2 normally-open
contacts (NO) contacts (NC) (NO) and 1 normally- contacts (NO)
closed contact (NC)
23 33 11 21 23 11 33 43
24 34 12 22 24 12 34 44
14 13 24 23 14 13 12 11 14 13 24 23 14 13 34 33
34 33 22 21 12 11 24 23 44 43

1 change-over contact 1 normally-open contact 1 change-over contact
(NO)
21 23 21
22 24 24 22 24

1 change-over contact 1 change-over contact 1 normally-open contact
(NO)
11 11 13
12 14 12 14 14
22 21 24 14 24 23 14 22 21 24
12 11 12 11 14 13
7
Elektromotoren und
Explanation of symbols:
Example: Single-float Buchholz relay
11 Graphical symbol with

--- terminal marking and
identification number
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 AC 12 volts to 250 volts

DC 12 volts to 250 volts
Current AC 0.5 to 2 amps cos φ ≥ 0.4
DC 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
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)
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
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 Figure 6 Testing by means of test pump
out
• Fit small cap nut on test valve and tighten
9
Elektromotoren und
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 2
setting, proceed as
follows: Ö
• Drain the Buchholz relay S
• Remove M8 hexagon screws from cover

• Remove cover with switch mechanism from housing
S
• Loosen M3 fillister head screw (1)
Ö
• Turn magnetic retainer (2) to position „Ö“ (NC contact) or
„S“ (NO contact) as far as to stop position
S = normally-open; Ö = normally-
• Tighten M3 fillister head screw closed
• Fit cover with switch mechanism in housing
Figure 7
• 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
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
4.1. Single-float Buchholz relay (Figure 8) 1 2 3
• Loosen the setscrew (2)
• Displace the damper top part (3) until the cams snap in
the damper bottom part (1) when the desired operating
1,0 5
0,6
0
0
1,5
Ö
value is reached
S
• Tighten the setscrew
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
• Fit cover with switching mechanism in the housing Figure 8 Setting the damper
• 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
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
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: info@emb-online.de
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 O-
ring 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
1
Terman'90 Strumentazione Industriale Srl Via Ghisalba, 13 - 20021 Bollate (MI) - ITALY
Tel. +39 0238303048 Fax +39 02 38303719 E-mail : terman@terman.com website : http://www.terman.com/

' the advantage of safety valves serie VS consists in the total
b
absence off projecting
j i i the transformers tank making the mounting point choose easier.
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
127.0
199.0
DN150

142.5
160.0

285.0
4 294.0
50.0 190.0 16.

+
,-.
3
88.0 100.0 100.0
158.0
DN100

100.0
112.0

18
4
102.5 102.5
15.0
25.0 170.0

+
,..
4
"$/#"$/""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 gas-
bubbles 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.
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 up to 1.000 dm3 (900Kgs.)
T 80 up to 4.000 dm3 (3.600Kgs.)
VS 80 up to 6.000 dm3 (5.400Kgs.)
VS 100 up to 20.000 dm3 (18.000Kgs.)
T 125 p to 20.000 dm3 ((18.000Kgs.)
up g )
VS 150 up to 35.000 dm3 (31.500Kgs.)
T 200 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 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.
7
Elektromotoren und
Monitoring relay
for tap changers
1
Elektromotoren und
Firm’s history Preface
Since its foundation the company has been The Monitoring relay for tap changers, also named
passed through an eventful history with regard protection relay for tap changers or oil flow relay, is a
to ownership, affiliation and connected with this monitoring relay for oil-insulated tap changers. It protects
changes of firm names. the tap changer and the transformer from damage. On
response the monitoring relay will generate a signal
disconnecting immediately the tap changer and the
1863 Foundation of the company transformer from the source of supply.
as sugar factory
1943 Establishment of SIEMENS The company has had for more than 40 years experience
Magdeburg in producing Monitoring relays and other protection
devices for liquid-cooled appliances. It ranks among the
1948 VEB1 Elektromotorenwerk most distinguished manufacturers of this kind of
Barleben; VEM equipment.
(state-owned firm) Experiences collected and profound know-how are the
sound basis for a high product quality. References from
1951 VEB1 Starkstromanlagenbau reputed transformer and tap changer manufacturers as
Magdeburg well as further users are proof of the high level of the
(state-owned firm) products.
The company is DIN EN ISO 9001/2000 certified.
1951 Start of manufacturing
Buchholz relays at site
in Barleben The staff of highly qualified engineers and experienced
skilled workers do their best to guarantee top quality
1965 Start of manufacturing high-precision products..
Monitoring relays for The mechanical working of the casings is done on
tap changers at site modern CNC-controlled machine tools. The final tests,
in Barleben where all the functions of the Monitoring relays are
checked, are done with each device by using special test
1970 VEB1 Elektrotechnik und equipment.
Gerätebau Magdeburg; Each device is delivered with a test certificate.
EGEM
(state-owned firm)
1980 VEB1 Kombinat Monitoring relays may be used in open-air or also in

Elektromaschinenbau Dresden indoor equipment.
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
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).
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
6 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
3
is safe to touch and protected against pollution.
The cable is to be brought in the terminal box
4 through the cable gland (6).
1
2
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 3
Mechanical testing device.
2
The switching system consists of the 2
following components:
damper (1)
switching magnet(s) (2) 1
3
magnet contact tube(s) (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
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 Data Notes
Nominal voltage AC 230 V 12 V to 250 V

DC 230 V 12 V to 250 V
Nominal current AC 2 A 0.05 A to 2 A
DC 2 A 0.05 A to 2 A
Contact voltage capacity AC 1000 V --
Insulation voltage capacity AC 2000 V Contact against casing
Temperature range:
- ambient temperature -45oC to +55o C Others on request
-49o F to +131o F
- working range
* temperature of the insulation liquid -25oC to +115oC Others on request
-13o F to +239o F
* viscosity of the insulation liquid 1 mm2/s to 1100 mm2/s Others on request
Switching system:
- Switching contact magnet contact tube normally-open, normally-closed,
change-over
- damper hold by magnets
Response time of damper < 0.1 s
Response values of the damper 0.9 m/s 2.0 m/s Others on request
1.0 m/s 2.5 m/s
1.2 m/s 3.0 m/s
1.5 m/s 4.0 m/s
Resistance to pressure 0.25 MPa --
Resistance to vacuum < 2.5 kPa --
Cable gland M 20x1.5 Others on request
Degree of protection IP 54 Others on request
Nominal installation position ≥ 2 o ascending towards 2 ° to 4 o
expansion vessel
4. Special designs
Table 2
Explanation Identif.no.
Climatic version (suited for tropical open-air climates) 22

Climatic version (suited for extrem frigidal open-air climates below –45 °C) 34
Special design approved by RWE, Germany (formerly ÜRF 25/10-3) 24
Switching system equipped with two magnet contact tubes (formerly ÜRF 25/10-2) 25
Customer request on the basis of conditions agreed with the manufacturer 29
4
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 XX . . . XX . X X Contact setting of
switching system
Type code no.
Damper setting 1 = one NO-contact
(see para.5)
2 = one NC-contact
1 = 0,9 m/s 3 = one change-over contact
Special design 2 = 1,0 m/s 4 = two NO-contacts
(see table 2) 3 = 1,2 m/s 5 = two NC-contacts
4 = 1,5 m/s 6 = one NO-contact and one NC-
5 = 2,0 m/s contact
6 = 2,5 m/s 7 = two change-over contacts
7 = 3,0 m/s 8 = one NO-contact and one change-
8 = 4,0 m/s over contact
9 = special agreement 9 = one NC-contact and one change-
Important remark: with the customer over contact
NO = normally-open
NC = normally-closed
Ordering example:
Monitoring relay ÜRF 25/10 12-22.25.-56
Explanation: 12 = ÜRF 25/10 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
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 relays are delivered in transport

cardboards.
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. - manual-actuated
ZG 5.2. - foot-actuated
Oil sampling device

The device is connected to the Buchholz relay by means of a pipe and serves to
ZG 6.1. 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.
Oil flow indicator

SG 25 - with thread connection
SF 25 - with flange connection
7
Elektromotoren und
Bahnhofstraße 27/28
39179 Barleben / Germany
Phone: +49 39203 790

Telefax: +49 39203 5330
Telefax: +49 39203 5450
E-Mail: info@emb-online.de
Internet: 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 ABB Components
6 - 13 mm
Pr 22.5
~35
~200 Adjusting nut
Spring
Piston
110 ;;
;; Two single-pole One single-pole
switching contacts switching contact
Connection for
test equipment
11 ~155
32
15
NO NC C NO NC C NO NC C
64 66 65 61 63 62 61 63 62
General description Operation

Protection for the on-load tap-changer is provided by a pressure When the pressure acting on the face of the piston exceeds the
relay which is mounted on the tap-changer oil compartment. In the spring load of the piston, the piston will move and activate the
event of an overpressure in the tap-changer oil compartment, the switching element. See fig.
pressure relay will trip the transformer main circuit breakers. 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
Design function time is the time from the pressure in the on-load tap-
The pressure relay is mounted on a three-way valve. On the other changer oil compartment exceeds the adjusted set point of the
two outlets of the valve there is a connection flange on one side, pressure relay until the pressure relay gives a stable signal for
and a connection for test equipment on the other, see fig. operating the main circuit breakers.
The relay is made of copper-free aluminium alloy and is externally
coated with an enamel. A stainless steel model can be provided
Function pressure
on request. Degree of protection IP66. The value of the adjusted function pressure (set point) depends
The function pressure (set point) has been set by the manufacturer on the distance (H) between the pressure relay and the oil level
in accordance to the requirements for each application. in the oil conservator.
The electrical connection shall be made to the terminal block Further information in the Technical, Installation &
mounted onto the pressure relay. Commissioning, Maintenance and Repair Guides for each type
of on-load tap-changer.
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 Mounting details
connection space with a sealed cap. The pressure relay should The following parts are supplied together with the pressure
always be disconnected during voltage test. 2 kV test has already relay: studs M10x40 (4x), nuts M10 (4x), washers 10x22x2 (4x)
been carried out. and O-ring 44.2x55.6 (1x).
Voltage Breaking capacity Withstand voltage
Resistive Inductive between contacts
load load and earth
110 V DC 0.8 A 0.2 A L < 40 ms

R
Distance H Type of OLTC Function pressure
125 V DC 0.6 A 0.15 A L < 40 ms in metres (set point)
R
220 V DC 0.4 A 0.1 A L < 40 ms 2 kV, 50 Hz, 1 min H<4 UZ 50 kPa (7 psi)
R
4≤H<7 UZ 100 kPa (14 psi)
125 V AC 5A 5 A cos ϕ ≈ 0.4
H<7 UB, UC 125 kPa (17.5 psi)
250 V AC 2.5 A 2.5 A cos ϕ ≈ 0.4 7 ≤ H < 14 UB, UC 200 kPa (28 psi)
Table 1. Technical data - Micro-switch Table 2. Function pressure
1ZSE 5492-151 en, Rev. 5, 2005-03-15

Components Manufacturer:
SE-771 80 Ludvika, SWEDEN BETA B.V., Rijswijk, The Netherlands
Tel.+46 240 78 20 00, Fax +46 240 121 57
Printed in Sweden by Globe, Ludvika, 2005
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
Liquid-
Liquid-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 (0-
100 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
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
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
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.
509-
509-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.
509-
509- 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 0-
5A, 0-10A or 0-20A (other ranges available), and have an output of 0-
0.333VAC(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.
509-
509-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
509-
509-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.
509-
509- 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.
509-
509-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.
509-
509-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
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 flush-
mounted 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
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
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
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
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
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
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
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
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
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
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
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
FUNCTIONAL SPECIFICATION
Power Supply: Universal, 90-264 VAC, 47-63 Hz and 40-290 VDC; (< 18 watts)
Front Panel Display: Type: 1 Easy to read 2-line, 16 character alphanumeric Liquid Crystal
and Interface Display (LCD)
Character size: 0.38” (9.66 mm) high x 0.19” (4.84 mm) wide per line
Backlight: Optional
Status Indicators: 8, Light Emitting Diode (LED)
Controls: 8 Large keys for programable settings and user interaction
Front Panel UV stabilized polyester
Membrane:
Input Accuracy: +/-0.5% full scale input range
Parameters: Temperature: 100 ohm platinum (Pt100) or 10 ohm copper (Cu10) RTD sensors;-40
to 200°C range
Current: Clamp on CT 0-5A, 0-10A, 0-20A and others available
Current loop: 0-1 or 4-20 ma DC
Voltage: 0-100 mV or 0-10 VDC
Switch Contact Open/Closed
Closure (isolated
dry):
Switch Contact >80 Volts AC/DC open, 0 volts closed; optically isolated
Closure (powered)
Outputs Control/Alarm 8 form C (changeover) relay contacts for cooling control, alarms, trip,
Contacts: etc.
Diagnostics Alarm: 1 relay for sensors, power and internal instrument circuitry diagnostics
Heater control: 1 relay
Contact Rating: 10A @ 115/230 VAC, 10A @ 30VDC
Remote (SCADA) 0-1 ma, 4-20 ma, (other options available) maximum allowable load
Output: resistance: 10,000 ohms for 0-1 ma, 450 ohms for 4-20 ma
Data RS-232, RS-485 (optically isolated), optional fiber optic interface
Communication: ST connector
Immunity Dielectric Isolation 2500 VAC, 60 seconds to ground
(hi pot):
Surge Withstand IEEE C37.90.1
Capability:
Conducted/Radiated IEC 61000-6-1
Emissions:
Conducted/Radiated IEC 61000-6-2
Radio Frequency
Immunity:
Safety: IEC 61010-1
Environment: Temperature Range: -40°C to +72°C
Storage -50°C to +80°C
Temperature
Humidity: 90% non-condensing
Vibration: 60/120 Hz @ .004 inch displacement.
Shock: 10 G’s half-sine, in three orthogonal planes
Weatherproof NEMA #3R (vented), UV stabilized, Corrosion proof fiberglass
Enclosure:
Weight Approx: 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
A MENU SWITCH B C D
05/24/2001 right VIEW/RESET right VIEW/RESET right VIEW SETPOINTS right COOLING MONITOR right CHANGE SETTINGS right
left 08:28:15 left MAXIMUM MEMORY left MINIMUM MEMORY left left INACTIVE left ID # REQUIRED
up up up up
down/enter down/enter down/enter down/enter enter
TOP OIL CHAN 1 TOP OIL 84.5 C TOP OIL 73.2 C TOP OIL RELAY 1 PROGRAM USER
77.5 C MAX1 1524 051701 MIN1 1524 051701 SETPNT 0070.0 C ID: 111111
up up up up
WIND 1 CHAN 2 WIND 1 96.3 C WIND 1 87.1 C TOP OIL RELAY 2 INVALID NUMBER
92.5 C MAX2 1524 051701 MIN2 1524 051701 SETPNT 0080.0 C ID: 111111
up up up up (valid)
down/enter down/enter down/enter down/enter (invalid) enter
WIND 1 CHAN 2 WIND 1 1300.3 A WIND 2 88.1 C MAX VAL CH 4 5 6 SET TIME/DATE
CURRNT 1224.5 A MAX2 1524 051701 MIN3 1524 051701 SETPNT 0090.0 C 15:24 05/24/01
up up up up
WIND 2 CHAN 3 WIND 2 94.1 C WIND 3 86.5 C TOP OIL - LTC TNK TOP OIL RELAY 1
91.4 C MAX3 1524 051701 MIN4 1524 051701 SETPNT 0005.0 C SETPNT 0070.0 C
up up up up
WIND 2 CHAN 3 WIND 2 1298.2 A AMBIENT 16.5 C TOP OIL - BOT OIL TOP OIL RELAY 2
CURRNT 1210.1 A MAX3 1524 051701 MIN5 1524 051701 SETPNT 0010.0 C SETPNT 0080.0 C
up up up up
WIND 3 CHAN 4 WIND 3 92.8 C CONS TK 65.7 C CONS TK RELAY 6 MAX VAL CH 4 5 6
90.1 C MAX4 1524 051701 MIN6 1524 051701 SETPNT 0080.0 C SETPNT 0090.0 C
up up up up
WIND 3 CHAN 4 WIND 3 1286.1 A LTC TNK 65.9 C LTC TNK RELAY 7 TOP OIL - LTC TNK
CURRNT 1188.7 A MAX4 1524 051701 MIN7 1524 051701 SETPNT 0080.0 C SETPNT 0005.0 C
up up up up
AMBIENT CHAN 5 AMBIENT 22.1 C BOT OIL 70.0 C RELAY 8 TOP OIL - BOT OIL
21.3 C MAX5 1524 051701 MIN8 1524 051701 IS NOT ACTIVE SETPNT 0010.0 C
up up up up
down/enter down/enter down/enter enter
CONS TK CHAN 6 CONS TK 79.2 C CH1-CH7 -007.5 C CONS TK RELAY 6
down/enter
72.1 C MAX6 1524 051701 MIN 0917 051701 SETPNT 0080.0 C
D
up up up
down/enter down/enter down/enter enter
LTC TNK CHAN 7 LTC TNK 72.0 C CH1-CH8 1.5 C LTC TNK RELAY 7
69.0 C MAX7 1524 051701 MIN 1524 051701 SETPNT 0080.0 C
up up up
down/enter down/enter down/enter TRANSFORMER MONITOR enter

E F G MENU H
20
E F G TRANSFORMER MONITOR H
up up up MENU
down/enter down/enter down/enter enter enter
BOT OIL CHAN 8 BOT OIL 79.8 C CH1-CH6 2.3 C COOLING MONITOR RELAY 8
73.1 C MAX8 1524 051701 MIN 1524 051701 CM3 INACTIVE IS NOT ACTIVE
up up up
TOP OIL - LTC TNK CH1-CH7 1.1 C CH7-CH6 3.5 C COOLING MONITOR TOP OIL CHAN 1
8.4 C MAX 1524 051701 MIN 1524 051701 CM4 INACTIVE ON
up up
TOP OIL - BOT OIL CH1-CH8 6.9 C C RS232 BAUD RATE WIND 1 CHAN 2
4.2 C MAX 1524 051701 19200 ON
up up
down/enter down/enter enter enter
TOP OIL - CONS TK CH1-CH6 4.7 C RS485 BAUD DATA WIND 2 CHAN 3
5.9 C MAX 1524 051701 9600 8 ON
up up
down/enter down/enter enter enter
LTC TNK - CONS TK CH7-CH6 8.9 C RS485 PARITY STP WIND 3 CHAN 4
-3.4 C MAX 1524 051701 NONE 1 ON
up
enter
down/enter enter
down/enter
UNIT WILL REBOOT NOW
LIFE CONSUMPTION B AMBIENT CHAN 5
WIND 1 000321 H ON
up
down/enter enter
LIFE CONSUMPTION CONS TK CHAN 6
WIND 2 000305 H ON
up
down/enter enter
LIFE CONSUMPTION LTC TNK CHAN 7
WIND 3 000298 H ON
up
down/enter enter
OPERATING HOURS BOT OIL CHAN 8
TOTAL 000765 H ON
down/enter enter
A COOLING MONITOR
CM1 INACTIVE
enter
COOLING MONITOR
CM2 INACTIVE
enter
21
TB1 TB1
VAC LINE VACC NEUT
HEATER 1 17 HEATER
2 18 TB3
RELAY 1
3 19
RELAY 5 1 INPUT MODULE 1
10 A 10 A
4 20 2
5 21 3
RELAY 2 RELAY 6
10 A
6 22 10 A TB4
1 INPUT MODULE 2
7 23
2
8 24
RELAY 3 RELAY 7 3
10 A
9 25 10 A
10 26 TB5
1 INPUT MODULE 3
11 27
RELAY 4 RELAY 8 2
10 A
12 28 10 A
3
13 29
VAC LINE TB6
INPUT (+) 14 30 SYSTEM
VACC NEUT STATE
1 INPUT MODULE 4
INPUT (-) 15 31 RELAY
EARTH
2
10 A
GROUND 16 32
3
22
TB7
INPUT POWER: (UNIVERSAL)
1 INPUT MODULE 5
90-264 VAC, 47-63 Hz
MODEL NO. 2
40-290 VDC
SERIAL NO.
MFG. DATE
3
RELAY CONTACTS: 10 A @ 115/230 VAC
10 A @ 30 VDC
TB8
1 INPUT MODULE 6
TB2 TB2 2
(+) 1 9 TXD+(B) 3
CURRENT
LOOP 1
(-) 2 10 TXD-(A)
TB9
RS-485
(+) 3 11 RXD+(B) 1 INPUT MODULE 7
CURRENT
LOOP 2
(-) 4 12 RXD-(A) 2
(+) 5 13 GND 3
CURRENT
LOOP 3
(-) 6 14 T/RXD+(B)
TB10
1 INPUT MODULE 8
CURRENT
(+) 7 15 T/RXD-(A)
LOOP 4 2
(-) 8 16 GND
3
Configuration Records
Parameter Name Comments/Range Parameter Name Set Point
Input Module 1:____________________ ____________________ Relay 1:____________________ __________
Differential 1: ____________________ ____________________ Thermostat:__________
Differential 2: ____________________ ____________________ RS-232 Baud Rate: ____________________
Differential 3: ____________________ ____________________ RS-485 Baud Rate: ____________________
Differential 4: ______________________ ______________________ RS-485 Parity/stop Bit: ____________________
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: Use a normal modem cable (not a null)
J1 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 509-

509-100
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 509-

509-100 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
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
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 off-
line 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 These buttons establish and terminate communications
with a 509.
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
5
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.
6
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.
7
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.
8
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.
9
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".
10
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.
11
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 Is used to adjust the intensity of the back light of the
display.
Display Contrast Slider Use the slider to adjust the display contrast to an
appropriate viewing level.
12
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.
13
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.
14
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
15
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 This is the communication address of the 509 used by the
specified protocol.
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
16
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.
17
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
18
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.
CT Current Scaling Block If the Input Module is of type "CT, Current" or ”CT,
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.
19
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.
20
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.
21
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).
22
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
23
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 UNITY HOT SPOT
TEMPERATURE
-11.269 6328.8 110 RECOMMENDED FOR 65°C INSULATION
-11.968 6328.8 95 RECOMMENDED FOR 55°C INSULATION
-11.804 6328.8 98 IEC 354:1991 SPECIFICATION
-13.391 6972.15 101
-14.133 6972.15 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.
24
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 0-
10mA 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.
25
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.
.
26
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.
27
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.
28
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
29
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 de-
activated. 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.
30
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) These two windows select the date when the Seasonal
Setpoint goes into effect.
End Date (Month and Day) These two windows select the last date when the
Seasonal Setpoint has effect.
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.
31
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.
32
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.
33
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:
34
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.
35
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 Clicking on the Abort button will remove the user from this
window.
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
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
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

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.
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.
INSULATION: 2000V 50Hz between terminals and earth for a 60secs. time
MICROSWITCHES MAKING AND BREAKING CAPACITY :

STANDARD MICROSWITCHES HIGH-PERFORMANCE MICROSWITCHES
VOLTAGE RESISTIVE LOAD INDUCTIVE LOAD RESISTIVE LOAD INDUCTIVE LOAD
125 VAC 5 A 5 A 10 A 10 A
250 VAC 5 A 5 A 10 A 10 A
30 VDC 5 A 3 A 10 A 10 A
50 VDC 1 A 1 A 3 A 2,5 A
75 VDC 0,75 A 0,25 A 1 A 0,5 A
125 VDC 0,5 A 0,1 A 0,5 A 0,1 A
250 VDC 0,25 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.
ELASTIC SUSPENSION
OIL TEMPERATURE INDICATOR MSRT 150 M 14
RIGID LOCKING SCREW 9
92 Ø 172 92
M 14
Total lenght 377

50 50 50
6
1
Total lenght 258
60 90
10 2
9 30 120
0 150
REAR FLANGE 3 PATENTED NO.: B47952
11
4
244
260
OIL TEMPERATURE
P. DESCRIPTION
TERMAN
1 CASE
7,6
ITALY
2 LOCKING GLASS RING
12
3 MICROSWITCH SETTING POINTER
Ø 6,5
4 MICROSWITCH SETTING DIAL
5
5 JUNCTION BOX
6 BREATHER
7
8 CAPILLARY OUTPUT
RIGID LOCKING SCREW /
9
ELASTIC SUSPENSION
NO.04 HOLES Ø 6,5mm. at 45°
10 MAXIMUM INDICATING POINTER
PT 100
A
on Ø 175 mm.
11 DIAL
B
12 GLASS OR POLYCARBONATE
b
WINDOW
115 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.
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.
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.
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
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.
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.
INSULATION: 2000V 50Hz between terminals and earth for a 60secs. time
MICROSWITCHES MAKING AND BREAKING CAPACITY :

STANDARD MICROSWITCHES HIGH-PERFORMANCE MICROSWITCHES
VOLTAGE RESISTIVE LOAD INDUCTIVE LOAD RESISTIVE LOAD INDUCTIVE LOAD
125 VAC 5 A 5 A 10 A 10 A
250 VAC 5 A 5 A 10 A 10 A
30 VDC 5 A 3 A 10 A 10 A
50 VDC 1 A 1 A 3 A 2,5 A
75 VDC 0,75 A 0,25 A 1 A 0,5 A
125 VDC 0,5 A 0,1 A 0,5 A 0,1 A
250 VDC 0,25 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.
ELASTIC SUSPENSION
WINDING TEMPERATURE INDICATOR MSRT 150-W M 14
RIGID LOCKING SCREW 9
92 Ø 172 92
M 14
50 50 50
6
Total lenght 377
60 90
10
30 M
120
SR
T
15
0 0-
Total lenght 258

W
30 150
0 15
MAX CURRENT : 2 A 0
60 NO.: B47952
12
90 0
11
3 TERMAN
HEATING RESISTANCE PATENTED
ADJUSTMENT ITALY
244
4
260
MAX POWER ABSORBED: 15 VA
7 WINDING TEMPERATURE
REAR FLANGE
12 P. DESCRIPTION
5 1 CASE
T A nc c no nc c no
2 LOCKING GLASS RING
RE IN SE RT
SWITCH N.1 SWITCH N.2 SWITCH N.3 SWITCH N.4
CURRENT
JUM PER AFT ER
ADJUSTEM ENT
2A
RED BLUE GREEN YELLOW
3 MICROSWITCH SETTING POINTER
4 MICROSWITCH SETTING DIAL
50
7,6
5 JUNCTION BOX
6 AIR HOLE
Ø 6,5 POTENTIOMETER FOR HEATING
7
RESISTANCE ADJUSTMENT
8 CAPILLARY OUTPUT
115 51 RIGID LOCKING SCREW
9
NO.04 HOLES Ø 6,5mm. at 45° ELASTIC SUSPENSION
on Ø 175 mm. 10 MAXIMUM INDICATING POINTER
11 DIAL
GLASS OR POLYCARBONATE
12
WINDOW
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.
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
THERMAL IMAGE
MICROSWITCHES-EQUIPPED WINDING TEMPERATURE INDICATOR “MSRT 150-
W”
CURVE I - ∆T FOR TEMPERATURE RISING ADJUSTMENT
CURRENT I2 (A) RISE ∆T (°C) POWER ABSORBED (VA) if I1=2A

0,5 5 4,4
0,7 10 6,2
0,85 15 7,9
1 20 9
1,1 25 9,9
1,2 30 10,8
1,35 35 12
1,45 40 13
1,5 45 13,5
1,6 50 14,4
1,7 55 15,3
1,8 60 15,7
I2 (A) TEMPERATURE RISE CURVE - I1=2A Toil=50°C

thermometer bulb oil filled
2
1,8
1,6
1,4
1,2
0,8
0,6
0,4
0,2
0
0 10 20 30 40 50 60 70
∆ T (°C)
NOTE: I - ∆T CURVE IS VALID ONLY IF THE BULB IS IMMERSED IN OIL
2A
BA Power Transformers
Product Information
Authorised by: Project Manager 1ZBA 569 002-4
Revision No. 2001-10-15 Page: 1 of 4
Replaces:
Oil Level Indicator
TYPES
LA14XOS
LA22XOS
LB14XOS
LB22XOS
Revisions: First Edition: 2000-03-31

No Date Pages No. Date Pages
1 2000-04-19 B
A 2001-10-15 C
ABB TPT BA-Standard Oil Level Indicator 1ZBA 569 002-4
Revision No. A Page 2 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.
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 screen-
printed polycarbonate disk with graduated scale reference marks corresponding to the levels that the
oil should reach.
FIGURE 1
1
2
3
1 - Case
4 2 - Float with arm
3 - Fixing screew
5 4 - Disk
5 - Name plate
6 6 - Junction box
7 - O-ring rim
2
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: Aluminium alloy painting with double coat of
polyurethane. Finish colour RAL 7001
Screen-printed: Polycarbonate
Box cover , bolts, nuts and name plate Stainless steel
Cable glands Brass, zinc plated
Gaskets: Nitrile rubber
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 Inductive load
L/R = 40 ms
125/250Vac 3 0
125 Vdc 0,5
250 Vdc 0,25
Contact life: 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 Appd. Date
A Redrawn S. K. 2000-04-31
B Hole D=11.5 was D=7 W. Klein 2001-03-05
C O-ring Ø 161 was Ø 103 G. Y. 2001-09-25
PURCHASE DRAWING
Material:
Casing: Aluminium alloy casting, painted with double coat of
polyurethane. Finish colour grey RAL 7001
Bolts, nut and name plate: Stainless steel
Float: Nitrophil full vacuum and l kgf/cm2
Cable gland: Brass, zinc plated
Rod (arm) float: Brass
Screen-printed: Polycarbonate
Specification:
Increment protection: IP 54 to DIN VDE 0470-1
Operating temperature: -40 to 120ºC
Insulation class: 2,5 kV, 50/60 Hz, 1 min.
Microswitch:
Type: 2, changeover for Minimum and Maximum level signalling
Switching capacity (A): Voltage Resistive load Inductive load L/R=40 ms
125/250 Vac 3
contained therein. Reproduction, use or disclosure to third
We reserve all rights in this document and the information
125 Vdc 0,5

parties without expressed authority is strictly forbidden.
250 Vdc 0,25

Supply condition:
Type DN Float arm length Remark Mass
(Comem ref.) kg
1000 (ABB will adjust for 2 O-ring (OR221) will be supplied
LA22XOS Ø220 2,95
each transformer order) with the Oil Level Indicator
 ABB Transform
• Nameplate with “CE Marking”
90 56,5
24
8x Ø11.5 19º
12º
60º
60º 11º
Ø161
9º
Ø 190
9º
Ø220
Ø 60
9º
325
9º
60º 11º
R=1000
60º
12º
Name 19º
Plate
58
Terminal
Box
Dial graduations
123 Float Ø58 (Do not show the
Pg 16, DIN 46320 angle on the dial)
Based on Reg. No.
569
OIL LEVEL INDICATOR
Prepared Responsible department
S. Kamikata: TPT/D For conservator without
Approved Take over department Language
R. Girgis: 1998-10-27 polyurethane cell en
Revision Page
DN = 220, float rod = 1000
C 1 (1)
Document No.
ABB Transformers 1ZBA 569001-C

jig kjoijoijokjokjnlkjnf
45°
Ø 220
Ø190
A
Ø161
H max 3.5
Ø150
L= 1531
90 Z
Z
60°
Ø11.5
24
120°
H min
Ø20
45°
Ø 60 5
Rolling Float
Z Ø 220
140
Ø12
PG 16
150
123
58
Ltd.
325 A
 ABB Power Technology Products Management
36 45° L
2001
Indicator type: Model LB22X0S-magnetic type (COMEM designation)

Number of contact/type 2 contacts (Minimum level and Maximum level)
Microswitch - Changeover-switch
Contact braking capacity 3A , 125/250 Vac (resistive)
0.5A, 125 Vdc for inductive load L/R = 40 ms The microswitches are set with
0.25A, 250 Vdc for inductive load L/R = 40 ms an advance angle of 5° with
Connection type Terminal box with outlet thread Pg16 respect to the indication of the
Insulation class 2.5 kVac, 50/60 Hz, 1 min. minimum (Hmin) or maximum
Reference temperature “Min” ; “Max” (Hmax) oil level
Float material withstand Nitrophil, full vacuum and l kgf/cm2
Float arm length The indicator should be tested at Comem
Bolts, nuts, washers material Stainless steel
Production engng. review
Increment protection IP 54
Painting Double coat of polyurethane mono-component on
aluminum part, finish color gray RAL 7001
Operating temperature -40o C to +120o C
Mass: 3.3kg
Remark: 2 Nitrile rubber gaskets (OR221, D=5.34, Inner Dia.=149.2 acc. to
Based on Reg. No. Title Scale
1ZBA 115 001-6) will be supplied with the Oil Level Indicator 569 -
Nameplate with “CE Marking” Prepared Responsible department Oil Level Indicator
S. Kamikata PTPT/ GD LB 22
(Float arm length = 1531)
Inspection engng. review

D Float arm length was 1490, Float arm bent W. Klein 2002-08-02
Design engng. review
W. Klein 1998-10-27 en
C Float arm length was 1680 W. Klein 2002-04-19 Revision Total mass [kg] Order Page
B Modify drawing M .Cai 2001-07-26 D 3.3 1

A Redrawn S. K. 2000-03-31 Document No. cont.
Rev. ind. Revision Appd. Date BA Power Transformers 1ZBA 569 001-X -
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

TrafoStar Title:
Document No. KC-Trockenperlen Orange
1ZBA676002-1
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, KC-
Trockenperlen 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
3
1 1- Flange
Flange
2 Cylinder
2 - Cylinder
8 3 3- Cover
Cover
4 End piece
. . . . .. .. .. .. .. .. .. .
.......
.. ............
5 4 5- Bolt
End piece
5 6- Oil
Stud fastener
pocket
6 7- Transformer
Oil pocket oil
2
7 8- Cylinder protector
Transformer oil
4 8 - Cylinder protector
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.

TrafoStar Title:
1ZBA676002-1
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 2000-03-31
C 2002-06-25 Silica gel replaced by KC-Trockenperlen
D 2003-05-05 New Format

consulted.

ABB Power Transformers, Literature Coordinator: +1-314-679-4595
or E-mailed to: Transformer.Service@us.abb.com
For a reply, please include your name, company, phone, fax and/or E-mail address.
IT

TrafoStar Title:
1ZBA676002-1
B Redrawn S. K. 00-03-31
C Masses corrected JMG 00-8-21
PURCHASE DRAWING
Material:
Silicagel: Silicium - oxide (silicagel) with orange indicator
Flange and end piece: Aluminium alloy, double coat with polyurethane Finish colour
grey RAL 7001
Cylinder and oil pocket: Polycarbonate
Protection of cylinder, bolts,
nuts and name plate: Stainless steel
Specification:
Operating temperature: -40 ºC to +100 ºC
Supply condition:
Type Mass
(Comem ref.) kg
Total Silicagel
EM5DA 16,7 10,5
Supplied with silicagel and sealed package
15
 ABB Transformer
675
Ø14
Ø110
Ø140
Ø220
Based on Reg. No.

AIR BREATHER
S. Kamikata: 95-03-20 TPT/D
R. Girgis: 95-03-25 en
Revision Page
C EM5DA 1 (1)
Document No.
ABB Transformers 1ZBA 676001-C

B Redrawn S. K. 00-03-31
C Masses, dimensions corrected JMG 00-7-01
PURCHASE DRAWING
Material:
Silicagel: Silicium - oxide (silicagel) with orange indicator
Flange and end piece: Aluminium alloy, double coat with polyurethane. Finish
colour grey RAL 7001
Cylinder and oil pocket: Polycarbonate
Protection of cylinder, bolts,
nuts and nameplate: Stainless steel
Specification:
Operating temperature: -40 ºC to +100 ºC
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”
12
 ABB Transformer
265
Ø12
Ø75
Ø100
140
Ø135
Based on Reg. No.

AIR BREATHER
S. Kamikata: 95-03-20 TPT/D
R. Girgis: 95-03-25 en
Revision Page
C EM2DA 1 (1)
Document No.
ABB Transformers 1ZBA 676001-A

Naphthenics Product Data Sheet 2005-04-08
Nynas Transformer Oil - Nytro 10XN
PROPERTY UNIT TEST METHOD GUARANTEED TYPICAL
DATA DATA
Min Max
1. Physical
Appearance IEC 60296 Clear, free from sediment
Density, 20°C kg/dm3 ISO 12185 0.895 0.877
Viscosity, 40°C mm2/s ISO 3104 8.0 7.6
Viscosity, -30°C mm2/s ISO 3104 800 730
Pour Point °C ISO 3016 -45 -63
2. Chemical
Acidity mg KOH/g IEC 62021 0.01 <0.01
Corrosive sulphur DIN 51353 non-corrosive
Sulphur content % ISO 14596 0,15 <0,01
Aromatic content % IEC 60590 7
Antioxidant, phenols Wt % IEC 60666 0,4 0.3
Water content mg/kg IEC 60814 30 <20
3. Electrical
Dielectric dissipation
factor at 90°C IEC 60247 0.005 <0.001
Interfacial tension mN/m ISO 6295 40 50
Breakdown voltage
- Before treatment kV IEC 60156 30 40-60
- After treatment kV IEC 60296/60156 70 >70
4. Oxidation Stability
At 120°C, 500h IEC 61125 C
Total acidity mg KOH/g 0,30 0,04
Sludge Wt % 0,05 <0,02
DDF/90 °C 0,05 0.03
5. Health, safety and environment
Flash Point, PM °C ISO 2719 140 146

DMSO extractable
compounds (PCA) Wt % IP 346 3 <3
PCB IEC 61619 not detectable
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
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.
2. Composition/Information of Ingredients
Chemical Name: CAS-No.: EC-No.: Weight- Symbols/Phrases

%
Hydrotreated Light Naphthenic 64742-53-6 265-156-6 99,7
Distillate
128-37-0 204-881-4 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: No classification needed according to 67/548/EC and

1999/45/EC.
Human Health: Inhalation of vapours and/or mists might irritate respiratory
tract.
Prolonged skin contact will cause defatting and possible
irritation. Eye contact might cause irritation.
Environment: Slow biodegradation, the product will remain for long time in
the environment. Risk for contamination of earth, soil and
water.
Physical and chemical At elevated temperatures flammable vapours and
hazard: decomposition products will be released. Risk for slippery
floors if spilled out.
4. First Aid Measures
General advice:
Inhalation: If inhalation of mists, fumes or vapours occur causing irritation,
move to fresh air. If the symptoms persist, obtain medical
advice.
Skin contact: Remove immediately adhering matter and wash off with soap
and plenty of water.
Eye contact: Rinse with plenty of water.
Ingestion: Clean mouth with water. Obtain medical advice if a large
amount has been swallowed. Do not induce vomiting.
5. Fire-fighting Measures
Suitable extinguishing Extinguish preferably with dry chemical, carbon dioxide (CO2),
media: or foam. Waterspray / mist may be used.
Extinguishing media Water jet, unless used by authorised people.(Stain risk caused
which must not be used by combustion).
for safety reasons:

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
gloves.
Environmental Prevent spills to enter and spread to drains, sewers, water
precautions: 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: 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.
Storage: Store at ambient temperature or with lowest necessary heating
as handling requires.
8. 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.

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 Wear protective clothing if there is a risk of skin contact and
protection: change them frequently, or when contaminated.
Hygienic measures: Act in accordance with good industrial hygiene and safety
practice.

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 < 3%
according
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: Stable at normal conditions. Start to decompose at 280°C or

higher.
Avoid: Excessive heating and highly oxidizing agents.
Hazardous Flammable gases which might also be noxious. With air
decomposition products: present, there is a risk for auto ignition at temperatures
>270°C.

6/8
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: Prolonged and repeated inhalation of mist or vapour generated
at elevated temperatures may irritate respiratory tract.
- Oral: May cause nausea and eventually vomiting and diarrhoea.
- Skin contact: Prolonged or repeated exposure may lead to defatting of the
skin and subsequent irritation.
- Eye contact: 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
evolution.
Bio-accumulation: 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.
Ecotoxicity: 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.

7/8
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.

8/8
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 oil-
derived substances in Annex 1.

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INSTRUCTION MANUAL

Serial no. 1133751

Internal order no. K.570.1.A002-11152

ABB Sp. z o.o.

1 Main Technical Data of Transformer

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 8.710.03-06-0700

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. 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. 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

4 Accessories of transformer. List of manufacturers/suppliers

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

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 5483 538-66

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. 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 &

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

7.2 Pump DB-TR-005 - GB

7.3 Liquid flow indicator

8.1 Buchholz Relay BF80/10. Operating instruction 01/02/04/02

8.2 Safety valve VS 150

9.1 Monitoring relay for tap changers. Catalogue 01 / 05

10 Conservator air cell (separator) installation

11 Electronic Transformer Monitor for Liquid filled

11.1 Operations Manual IST-072-1

11.2 Software Manual IST-073-1

11.3 Resistance Bulb Platinum 103-023-01

12 Oil Temperature Indicator for Power

13 Winding Temperature Indicator for Power

14 Oil level indicators

14.1 Oil level indicator. Product information 1ZBA 569 002-4

14.2 Oil level indicator fore OLTC (LA22) 1ZBA 569001-C

15.1 KC-Trockenperlen Orange 1ZBA676002-1

15.2 Model EM5DA 1ZBA 676001-C

15.3 Model EM2DA 1ZBA 676001-A

16.1 Throttle valves WKKI-1

16.2 Ball valves WK 2a

17.1 Naphthenics Product Data Sheet.

17.2 Naphthenics Safety Data Sheet

18 Test Report 2007/0141/025

19 Certificates of transformer accessories

Main Technical Data of Transformer