Professional Documents
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Recommended practices
ABB Components recommends careful personnel’s safety, including Protective clothing,
consideration of the following factors when safety shoes, safety glasses, hard hat, and
installing De-energized tap-changers. protective gloves.
Before you install a unit, make sure that the To avoid damaging the unit, never exceed the
personnel doing the job have read and fully operating limits stated in delivery documents and
understood the technical guide documents on rating plates.
provided with the unit.
Do not alter or modify a unit without first
Make sure that the personnel who carried out the consulting ABB.
installation, operate, maintenance and repair are
special trained and qualified. Personal protective Follow local and international wiring regulations at
equipment must be worn during work to ensure all times.
WARNING! WARNING!
A WARNING provides information which, if After the tap-changer is installed, operate
disregarded could cause injury or death. several cycles, must ensure that the
moving contact is in the center of the fix
CAUTION! contact in each position. Must follow the
A WARNING provides information which, if instructions as specified in section 6.3 to
disregarded could cause damage to the install the cover, and must follow the
equipment. instructions as specified in 6.5 to mount
the bevel gear and the hand-drive.
NOTE: A NOTE provides additional information to
assist in carrying out the work described.
When tap-changer is installed, operate
several cycles and do visual inspection on
Safety precautions the position indicator on the top cover.
During drying of the transformers Make sure that the position indication is
in the center of the glass window in each
CAUTION! position.
Do not operate the De-energized tap-
changer during the drying process or
The position shown on the hand-drive
afterwards until it is filled with oil to avoid must be same as the position shown on
seizing the top cover glass after installation.
Mounting of gaskets
Before operate the tap-changer, must
ensure that the transformer is de-
CAUTION! energized. The HV side and LV side must
Sealing surfaces and gaskets must be clean be switched off. Before energize the
and undamaged. Diametrically opposed transformer, must read the name plate of
bolts in sealing joints must be tightened the transformer carefully and check
alternately several times, beginning with a carefully on the position shown in the
low tightening torque and finally with the hand-drive to ensure that the new
recommended tightening torque as position is correct. The safety precautions
described in section 9 Tightening Torque, in must be executed properly, otherwise, it
this guide. will result in severe consequences,
including equipment damage or personnel
After oil filling injury or death.
CAUTION!
Do not energize the transformer earlier than
three hours after oil filling in atmospheric
pressure. This waiting period is needed to
allow air bubbles to disappear.
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 3
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Contents
1 Overview 4
2 Technical data 5
2.1 Type description 5
2.2 Scope 5
2.3 Working condition 5
2.4 Technical data 5
3 Tap-changer structure 6
4 Outline dimension 7
5 Scope of delivery 9
6 Installation 9
6.1 Mounting of the tap-changer when Transformer Ratio 9
Measurement is carried out before drying
6.2 Mounting of the tap-changer when Transformer Ratio 11
Measurement is carried out after drying
6.3 Mounting to the Transformer Cover from the yoke 12
6.4 Connection to Outside Terminals 14
6.5 Mounting the tap-changer to hand-drive mechanism 15
7 BUH Hand-Drive 20
7.1 BUH technical data 20
7.2 Safety precaution 20
7.3 Output signal 20
7.4 Hand-drive operation 20
8 Drying 21
9 Tightening torque 21
Appendix 23
Connection diagram 23
4 1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide
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1 Overview
— DPC Type De-energized tap-changer is specially DPC type De-energized tap-changer is installed in
Figure 1 DPC type De-
energized tap-changer developed by ABB for single phase, large power tank, and BUH hand-drive is installed on the
transformers. The technology and process used in external side of the tank. They will be connected by
this product is based on ABB current mature bevel gear and drive shaft.
design, which will provide maximum reliabilities
for end customers. Its simple and mature The regulating type is linear type, the max position
structure guarantee that it has the same operating is 5 positions. The drive type is manual.
life with the transformer.
—
Figure 1
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 5
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2 Technical data
Type DPCLE
Max. rated through current (A) 3200
Frequency (Hz) 50/60
Phase and regulation type Single phase, Linear
Highest equipment voltage (kV) 300
Short circuit withstand Thermal stability (3s r.m.s value) 32
capability (kA) Dynamic stability(peak value) 80
Positions 5
Power frequency withstand voltage (50Hz, 1min) 460
Insulation level
Lighting impulse withstand voltage (1.2/50 μS) 1050
(To earth) (kV)
Switching impulse withstand voltage 850
Internal insulation level (kV) Between first and last contacts 430/160
(Lighting impulse/Power frequency) Between adjacent contacts 430/160
Max weight (Kg) Approximate 220
6 1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide
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3 Tap-changer structure
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Figure 2 DPC De- Bevel gear
energized tap-changer Top flange
structure
Position indictor
Intermedia flange
Cylinder
Shielding ring
Moving contact
Fixed contact
Center shaft
Bottom support
—
Figure 2
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 7
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4 Outline dimension
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Figure 3 DPC
De-energized tap-
176.8
changer dimension
116
drawing
20
53.5
E E
Φ650
704.9
Φ480
2198
270
170
D D
170
170
270
50.8
120
Φ669
Φ14×16
Φ705
Grounding
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Figure 3
8 1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide
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4 Outline dimension
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Figure 3 DPC De-
energized tap-changer Φ14×8
dimension drawing
Φ660
Φ750
SECTION E-E
60°
4
Current
collector 15
terminal 8
40
3
1
Φ13
2
10°
SECTION D-D
Fixed contact
M12 SCREW
40
Cylinder
—
Figure 3
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 9
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5 Scope of delivery
1. DPCLE 1050/3200 De-energized tap-changer
4. Technical documents, Including test record, drawings, installation and operate guide
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6 Installation
The top section of the De-energized tap-changer is Mounting of the tap-changer to the “yoke-fork”
designed to be divided into an upper and a lower can be made according to two alternatives
flange, see Fig.4, to fit the yoke-mounting. depending on when the testing of the
transformation ratio shall be performed.
Before the tap-changer is lifted and attached to
the transformer cover it rests on a fork consisting Transformer ratio measurement before drying, see
of two beams protruding from the upper section 6.1
transformer yoke.
Transformer ratio measurement after drying, see
Note: If guiding pins are used on the fork, they section 6.2
should be insulated with bushings to prevent
circulation currents in the fork when the Mounting onto the transformer to the cover from
transformer is in operation. the yoke, see section 6.3
6.1 Mounting of the tap-changer when Transformer Ratio Measurement is carried out before drying
—
Figure 4
10 1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide
NOTE:Check that the de-energized tap-changer by using a Wrench to turning the square tube.
is positioned in the right way in rotational relation When tap-changer is moving from position 1 to
to the transformer cover before connection of position 5, the square tube shall be turned
conductors. anticlockwise (When facing the bevel gear), 2
circles for each tap-change.
2. Connect the conductors according to section When tap-changer is moving from position 5 to
6.4. position 1, the square tube shall be turned
clockwise (When facing the bevel gear), 2 circles
3. Transformer ratio measurement. for each tap-change.
—
Figure 5
4. Check the position indicator on the cover for 5. Loosen all the M12 bolts and washers in the top
each position. The numbers shown on the cover and lift the cover carefully min.100mm
indicator should be accordance with the position straight upwards before moving it in horizontal
of the moving contact. Unless otherwise stated, direction. The bevel gear may not be damaged
moving contact should be connected to fix contact when lifting. Keep the O-ring of the cover in a
“1” when in position 1.Moving contact should be dust- free place. See Fig. 4a
connected to fix contact “5” when in position 5.
There are markings on the fixed contact for easily 6. Remove the upper part of the top section by
recognition. loosening the M8-socket head cap screws inside it.
Keep the flange, the O-rings and store them
temporarily on a dust-free place. See Fig.4b
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 11
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Figure 4a
—
Figure 4b
—
Figure 4c
6.2 Mounting of the tap-changer when NOTE:Check that the de-energized tap-changer
Transformer Ratio Measurement is carried out is positioned in the right way in rotational relation
after drying to the transformer cover, before connection of
conductors.
Lift the tap-changer onto the “Yoke-fork” of the
transformer, See Fig.4d. 4. Remove the lifting eyes when the tap-changer is
in right position on the “Yoke-fork”.
1. Loosen all the M12 bolts and washers in the top
cover and lift the cover carefully min.100mm
straight upwards before moving it in horizontal
direction. The bevel gear may not be damaged
when lifting. Keep the O-ring of the cover in a
dust- free place. See Fig. 4a
—
Figure 4d
12 1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide
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Figure 4e. Mount onto the transformer cover from the “Yoke-Fork”
1. Place O-ring in the groove on the transformer 5. Lift the tap-changer until it touches the upper
flange (This O-ring is not included in the tap- flange. Mount a washer and screw in each of the
changer delivery) free holes.
2. Place the upper flange over the opening of the 6. Remove the lifting bar and mount a washer and
transformer cover. screw in each of the free holes.
NOTE:Check that the de-energized tap-changer 7. Mount the studs in the transformer cover
is positioned in the right way in rotational relation through the holes in the upper flange. Fit washers
to the transformer cover. and nuts.
3. Mount the lifting tool on the upper flange with 8. Place the O-ring in the groove in the upper
the four long bolts through the unthreaded holes flange.
in upper flange and in the tapped holes in the
lower flange. 9. Before mounting the cover, must check whether
the position of the drive stud on the mechanism is
4. Check when lifting that the guiding pin in the in the right position as shown in Fig.6 (The drive
lower flange clear the hole in the upper flange. stud has been put in the right position before
delivery, if found not in the right position, need to
CAUTION! adjust its position. But it is not allowed to touch
Lift very carefully to avoid damage to the the wheel gear during adjustment)
tap-changer.
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 13
WARNING!
This step must be implemented. Otherwise,
in some positions, the moving contact may
not touch the fixed contact after one tap-
change is completed.
90°
Drive Stud
—
Figure 6 Drive Stud positon before mounting the cover
WARNING!
After the cover mounting completed, the key
should point to the arrow symbol on the Key in the bevel gear should point to the arrow symbol
cover as shown in Fig. 7. When placing the on the cover.
The connection to terminals should follow the connection diagram. There are markings on the fixed
contacts. All terminals are using M12 bolts for connection.
Wrong
Right
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Figure 8 Leads connection
CAUTION!
All connections shall be made carefully and in
such a way that there is no risk for them to
come loose. Furthermore, the conductors
must not cause mechanical stresses on the
outside terminals. Make an expansion bend
on every conductor. See Fig. 8
6.5.1 DPC tap-changer mounting to BUH hand- In hand drive, it has the necessary mechanism for
drive mechanism operating the tap-changer, as well as necessary
BUH hand-drive mechanism is for operating the output terminal for the electrical inter-locking with
tap-changer, make the tap-changer switched from the transformer.
one tap location to another in order to realize the
voltage regulating purpose. Below picture shows the connection of the tap-
changer to the hand-drive mechanism.
2 Tap-changer
6 BUH Hand-drive
—
Figure 9
16 1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide
6.5.2 Mounting of External Drive Shafts 6.5.3 Mounting of Horizontal Drive shaft
The external drive shafts consists of square tubes 1. Mount the bevel gear SA21 on the transformer,
and shall be connected to the spherical shaft ends with O-ring SA20, four clamps SA17, hexagon head
on bevel gears and hand-drive mechanism by bolts M10, SA18 and washers SA19, see figure 10.
means of two coupling halves. The square shafts
and protective tubes must be cut before
mounting.
CAUTION!
1. Before mounting of shafts, everything
must be cleaned and greased for correct
function and to avoid corrosion
2. The hand-drive mechanism and tap-
changer shall have the same indicated tap
position.
—
Figure 10 External shaft system
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 17
2. Determine the dimension K1 between the 4. Cut the protective tubes SA23 and SA24 in the
spherical shaft ends, see Fig.10a. un-slotted end so that both of them get the same
length LB1 according to the table 1 below.
3. Cut the square shaft SA22 to dimension =K1
minus 6 mm.Remove the burrs. Note: Protective tubes with slotted ends shall be
used.
—
Figure 10a
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Table 1. Length dimension for LB1
—
Figure 10b
Earthing symbol
—
Figure 11
—
Figure 12
1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide 19
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Figure 13
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Table 2. Length dimensions for LB2 (mm)
CAUTION!
The hand-drive mechanism and the tap-
changer should have the same indicated
tap-position and the key in the bevel gear
onto the tap-changer shall be facing the
earthing symbol according to Fig.11
20 1ZKM013119 Rev A EN, DPC type De-energized tap-changer Installation and operate guide
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7 BUH Hand-Drive
7.1 BUH technical data In order to fulfill this safety requirements, a safety
design is provided in the hand-crank. When insert
BUH Hand-Drive technical data is shown in table 3. the hand crank to the operation port on the hand-
— drive, the Micro-cam switch in the operation port
Table 3 will close or break the transformer circuit breaker.
Item Parameter Value Need to connect this Micro-cam switch to the
1 Max positions 5 circuit of transformer’s breakers to realize this
2 Position output contact capacity DC110 V/0.5 A function.
3 Control contact output capacity NO AC220 V/2 A
NC AC220 V/2 A Micro cam switch terminal is in X1, see table 4
4 Output Shaft drive torque 50 Nm —
5 Output Shaft turns per switching 2 Table 4
and LV side must be switched off. Before CX1-5 Position signal “5”
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8 Drying
CAUTION!
After drying, tap-changer is not allowed to
operate without oil. The contact should
apply lubrication oil if have to operate the
tap-changer.
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9 Tightening torque
M6 10 Nm ±10%
M8 24.5 Nm±10%
M10 49 Nm±10%
M12 84 Nm±10%
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10 Disposal and environmental information
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Appendix
Connection diagram
Pos. Connection
Max effective number of turns in Pos.1.
1 1-15
2 2-15
Digram shows that the tap-changer is
in 3 position (Rating position). 3 3-15
4 4-15
5 5-15
2 15
3 5
1 4
2
3
4
5
Current collector
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Insulation & Component Division
ABB Hefei Transformer Co.Ltd.
Address: Lianhua Road 3318,
Hefei Eco. & Tech. Develop Zone
Post code: 230601
Tel: 0551-6227 3940
www.abb.com/transformercomponents
1ZKM013119 Rev A, EN, 2018-08-04 © Copyright 2018 ABB All rights reserved
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Disclaimer:
This document is for promotion purpose, so only for
reference. ABB Hefei make no guaranty for the accuracy of
the information or the use of the information. All
information is subject to change without notice.