1ZSE 5492-127 en, Rev.

5, 2005-05-15

On-load tap-changers, type UBB with

motor-drive mechanisms, types BUE and BUL
Maintenace 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 for maintenance work
on on-load tap-changers:
Before you start any work, make sure that the personnel doing the job have read and
fully understood the Maintenance documents provided with the unit.
To avoid damaging the unit, never exceed the operating limits stated in delivery
documents and on rating plates.
Do not alter or modify a unit without first consulting ABB.
Follow local and international wiring regulations at all times.
Use only factory authorized replacement parts and procedures.

WARNING, CAUTION and NOTE

WARNING
A WARNING provides information which, if disregarded, could cause injury or
death.

CAUTION
A CAUTION provides information which, if disregarded, could cause damage to the
equipment.

NOTE: A NOTE provides additional information to assist in carrying out the work
described.

Safety Precautions
WARNING
The Maintenance Guide should be read and understood before any work is
started, and the procedures in this document should be followed at all times.

WARNING
Before 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.

iii
 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.

CAUTION
Approval should be given for inspection as well as for operating the on-load tap-
changer.

CAUTION
ABB recommends that only maintenance engineers trained by ABB carry out contact
replacement.

During Service
WARNING
Small amounts of explosive gases will always come out from the breathing
devices (dehydrating breather or one-way breather). Make sure that no open
fire, hot surfaces or sparks occurs in the immediate surroundings of the
breathing devices.

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

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

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.

iv
During Oil Handling
WARNING
Unused transformer oil is slightly harmful. Fumes from unused warm oil may
irritate the respiratory organs and the eyes. After long and repeated contact with
transformer oil skin becomes very dry.

Used on-load tap-changer oil from diverter switch housings and selector switch
housings contains harmful substances. Fumes are irritating to the respiratory
organs and the eyes and are very easily set on fire. Used transformer oil may well
be carcinogenic.

Avoid contact with the oil as much as possible and use oiltight protective gloves
when handling the oil.

First aid:
Skin contact: Wash the hands. Use skin cream to counteract drying.
In the eyes: Rinse the eyes in clean water.
Swallowing: Drink water or milk. Avoid vomiting. Call a doctor.

Collect used oil in oil drums.

Waste and cleaning up: Should be absorbed by an absorber. Treat it as

hazardous to the environment.

Upon fire: The fire should be extinguished by using powder, foam or carbon
acid.

WARNING
When oil that has been used in an on-load tap-changer 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.

WARNING
The oil in the on-load tap-changer may be hot. Be cautious!

WARNING
There is always a cushion of explosive gases in the top of the on-load tap-
changer. No open fire, hot surfaces or sparks may be present during opening of
the housing or draining from the valve. After the cover is removed let the gas
vent away approximately 15 min before any work is started.

WARNING
Be aware of the risk for slipperiness caused by oil spillage for instance when
working on the transformer cover.

v
 CAUTION
Do not fill oil into the on-load tap-changer if the transformer tank is under vacuum
and the on-load tap-changer is not.

CAUTION
Do not fill oil into the transformer tank if the on-load tap-changer is under vacuum
and the transformer tank is not.

CAUTION
Leave a gas cushion on top of the oil in the on-load tap-changer.

After Oil Filling

CAUTION
Do not energize the transformer earlier than three hours after oil filling in
atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

Mounting of Gaskets
CAUTION
Sealing surfaces and gaskets must be clean and undamaged. Diametrically opposed
bolts in sealing joints must be tightened alternately several times, beginning with a
low tightening torque and finally with the recommended tightening torque as
described in section 1.3 Tightening Torque, in this guide.

vi
Contents
1 Introduction ___________________________________________ 9
1.1 General ______________________________________________ 9
1.2 Maintenance Schedule ___________________________________ 10
1.2.1 Inspection ____________________________________________ 10
1.2.2 Overhaul _____________________________________________ 12
1.2.3 Contact Replacement ____________________________________ 12
1.3 Tightening Torque ______________________________________ 12
2 Inspection ____________________________________________ 13
2.1 Required Tools and Material ______________________________ 13
2.2 Procedure _____________________________________________ 13
2.2.1 Checking of the Breather _________________________________ 14
2.2.2 Checking of the Oil Level in the Conservator _________________ 14
2.2.3 Checking of the Motor and the Counter _____________________ 14
2.2.4 Checking of the Emergency Stop __________________________ 14
2.2.5 Checking of the Earth Fault Protector (Option) _______________ 14
2.2.6 Checking of the Heater __________________________________ 15
3 Overhaul _____________________________________________ 18
3.1 Required Tools and Material ______________________________ 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 __________________________ 20
3.3.4 Recommended Set of Standard Spare Parts __________________ 21
3.4 Oil Testing and Oil Draining ______________________________ 22
3.5 Lifting and Cleaning the Selector Switch Insert _______________ 23
3.5.1 Dismantling the Top Cover of the On-Load Tap-Changer _______ 23
3.5.2 Removal of the Mechanism and Fixed Contact Blades _________ 24
3.5.3 Adjustment of the Holding Tool for Removal of Fixed Contacts __ 26
3.5.4 Positioning of Selector Switch and Change-Over Selector
before Lifting __________________________________________ 27
3.5.5 Lifting _______________________________________________ 27
3.5.6 Cleaning ______________________________________________ 28
3.6 Oil Filtration __________________________________________ 29
3.7 Checking of the Breather _________________________________ 29
3.8 Checking Contacts ______________________________________ 30
3.8.1 Moving Contacts _______________________________________ 30
3.8.2 Fixed Contacts with Tips of Copper-Tungsten ________________ 31
3.8.3 Fixed Contacts made of Copper ___________________________ 32
3.9 Checking the Transition Resistors __________________________ 33
3.10 Lowering the Selector Switch Insert ________________________ 33
3.11 Mounting the Top Cover on the On-Load Tap-Changer _________ 34
3.12 Lubrication of the On-Load Tap-Changer and the
Drive Shaft System _____________________________________ 35

7
 3.13 Checking the Pressure Relay ______________________________ 36
3.13.1 Functional Check of the Pressure Relay _____________________ 36
3.13.2 Replacing the Pressure Relay _____________________________ 36
3.14 Checking of Motor-Drive Mechanisms types BUE and BUL _____ 37
3.14.1 Motor Protection _______________________________________ 40
3.14.2 Earth Fault Protector (option) _____________________________ 40
3.14.3 Counter ______________________________________________ 40
3.14.4 Heater _______________________________________________ 40
3.14.5 Toothed Belt __________________________________________ 40
3.14.6 Cable Connections ______________________________________ 41
3.14.7 Disc Brake, BUE _______________________________________ 41
3.14.8 Brake for the Maintaining Contact, BUE ____________________ 42
3.14.9 Disc Brake, BUL _______________________________________ 42
3.14.10 Position Transmitter and other Position Switches, BUE_________ 43
3.14.11 Position Transmitter and other Position Switches, BUL_________ 43
3.14.12 Starting Contact, BUE ___________________________________ 45
3.14.13 Lubrication, BUE ______________________________________ 45
3.14.14 Lubrication, BUL ______________________________________ 45
3.15 Operation Test _________________________________________ 47
3.16 Oil Filling ____________________________________________ 47
3.16.1 Filling Methods and Restrictions __________________________ 47
3.16.2 Before Filling _________________________________________ 48
3.16.3 Filling at Atmospheric Pressure ___________________________ 48
3.16.4 Oil Level _____________________________________________ 48
3.16.5 Restoring the Gas Cushion _______________________________ 49
3.16.6 Waiting Period _________________________________________ 50
3.17 Putting into Operation ___________________________________ 50
4 Contact Replacement ____________________________________ 51
4.1 Moving Contacts _______________________________________ 51
4.2 Fixed Contacts _________________________________________ 51
5 Tap-changer in the transformer ____________________________ 52
5.1 Resistance measurement _________________________________ 52
6 Specification of Materials ________________________________ 53
6.1 General ______________________________________________ 53
6.2 Selector Switch Housing _________________________________ 53
6.3 Selector Switch Insert ___________________________________ 53
6.4 Gearing Mechanism_____________________________________ 53
6.5 Drive Shaft Systems ____________________________________ 54
6.6 Motor-Drive Mechanism _________________________________ 54
Appendix, Tools_______________________________________________ 55

8
 1 Introduction

1 Introduction
1.1 General
The UB range of on-load tap-changers manufactured by ABB has been developed to
provide maximum reliability. The simple and rugged design gives a service life equal
to the service life of the transformer. A minimum of 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 UBB, 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 shaft with protection cover

Bevel gear Bevel gear

Vertical shaft
with protection cover

Rating plate

TC_00255

On-load tap-changer Motor-drive mechanism

Fig. 1. On-load tap-changer and motor-drive mechanism, type BUL

9
1 Introduction

Fig. 2 shows the general arrangement of a UB-type on-load tap-changer. The main
components are the selector switch (combined tap selector and diverter switch), the
change-over selector, the selector switch housing and the gearing mechanism. For
maintenance the top cover and the gear base plate (Fig. 4a) are removed before lifting
the selector switch insert. The contacts are then immediately accessible and can be
inspected for wear.
The selector switch housing has its own oil separated from the transformer oil. This is
to prevent contamination of the transformer oil since the oil of the on-load tap-changer
deteriorates due to the switching operations. The oil needs to be changed at regular
intervals to maintain adequate dielectric strength as well as to prevent mechanical
wear.
The selector switch comprises three phases, each consisting of:

Selector switch (with replaceable fixed and moving contacts)

Transition resistors.

It is necessary to inspect and clean the contacts and insulation parts of the selector
switch, as well as to clean the housing inside at regular intervals.
Besides the maintenance of the selector switch and changing of the oil, the motor-
drive mechanism should be checked and lubricated.
The pressure-relay, the device that protects the transformer from excessive pressure in
the selector switch housing, should also be checked.

1.2 Maintenance Schedule

Maintenance of the on-load tap-changer consists of three major steps:

Inspection
Overhaul
Contact replacement

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, the heater is functioning, etc.
In the motor-drive mechanism a counter registers every tap-change 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.

10
 1 Introduction

Top cover Air release valve to Connection to oil

on-load tap-changer conservator

Pressure relay

Bevel gear

Oil valve

Flange

Air release valve

to transformer tank
Cylinder

Indicator window
Change-over selector:
Moving contacts
Fixed contacts

Selector switch:
Fixed contacts Current collector
terminal

Moving contacts

Transition resistor

Selector switch shaft

Shielding rings

Bottom valve
drain screw

Bottom

fm_00235

Fig. 2. General arrangement of on-load tap-changer, type UB

11
1 Introduction

1.2.2 Overhaul
The contact life and the frequency of operations or the time in service determine the
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 5 years).
The overhaul will normally take at least 8 hours, including the 3 hours waiting period
after oil filling, even if it is made by trained personnel. We recommend that the
overhaul is carried out under supervision of a service engineer trained by ABB.

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 selector 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 selector 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 trans-
formers, 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.

1.3 Tightening Torque

The following tightening torques are recommended:
M6, 10 Nm ±10 % (7.4 lbf x ft)
M8, 24.5 Nm ±10 % (18 lbf x ft)
M10, 49 Nm ±10 % (36 lbf x ft)
M12, 84 Nm ±10 % (62 lbf x ft)
unless otherwise stated in this guide.

12
 2 Inspection

2 lnspection
The inspection 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

If the on-load tap-changer is equipped with an oil filter unit from ABB it should be
inspected once a year according to the ”Oil Filter Unit for On-Load Tap-Changer
manual”.

2.1 Required Tools

The following equipment is required for the inspection:

Set of screwdrivers
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.

13
2 Inspection

2.2.1 Checking of the Breather

Check the breather 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 removing the breather.

If more than half of the drying agent has changed colour, it must be dried or replaced.
The drying agent normally starts to change colour from the bottom of the breather. If it
changes colour at the top of the breather, there is a leakage in the connections to the
conservator. Locate the leakage and seal it.

2.2.2 Checking of the Oil Level in the Conservator

The oil level in the conservator should be according to the instructions in the trans-
former documentation.

2.2.3 Checking of the Motor and the Counter

Open the motor-drive cabinet door and turn the selector-switch to the LOCAL
position. Then turn the control switch to the RAISE (LOWER) position.
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).
Turn the control switch to the LOWER (RAISE) position. 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.

2.2.4 Checking of 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 set the protective motorswitch to ON. The started operation
should now be completed. Operate back to service position.

2.2.5 Checking of 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 or on the separate
earth fault protector on BUL.

14
 2 Inspection

2.2.6 Checking of the Heater

Disconnect the incoming auxiliary power.

WARNING
Before starting any work inside the motor-drive mechanism the auxiliary power
must be switched off.

N. B. The motor, contactors and heating element may be energized from separate
sources.

Open the control panel. (BUE only).

Check by feeling with a finger on the protection plate that the heater has been
functioning.
Close the control panel. (BUE only). Reconnect the incoming auxiliary power.
Complete the inspection by turning the selector-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

Layout of motor-drive mechanism, type BUE

1. Locking device prepared for padlock 13. Shaft for handcrank
2. Emergency stop 14. Heater 50 W + optional 100 W (behind the
3. (Option) Switch for extra heater panel)
4. Air vent 15. (Option) Outlet with earth fault protector
5. LOCAL/REMOTE switch 16. Terminal blocks (behind the panel)
6. RAISE/LOWER switch 17. Protective motor switch
7. Outgoing shaft 18. (Option) Thermostat or hygrostat for extra
heater 100 W
8. Lamp (40 W socket E27)
19. Door-operated switch for lamp
9. Lifting eye
20. Handcrank
10. Counter
21. Descriptions and circuit diagram
11. Tap-change in progress indicator
12. Position indicator with draghands for max. and
min. position

16
 2 Inspection

1 2 3 4 5 6

10

11

12

13

14

15

16

17 18 19 20 21 22 23 24

Layout of motor-drive mechanism, type BUL

1. Position indicator with draghands for max. and
min. position 13. Emergency stop
2. Tap-change in progress indicator 14. RAISE/LOWER switch
(Red = in progress, White = in position) 15. LOCAL/REMOTE switch
3. Counter 16. Protective motor switch
4. Outgoing shaft with multihole coupling half 17. Air vent
5. Shaft for handcrank 18. Door operated switch for lamp
6. Lifting eye 19. Terminal blocks
7. Locking device prepared for padlock 20. Hand lamp
8. (Option) Multi position switches 21. Heater 50 W + optional 100 W
9. (Option) Measuring amplifier 22. (Option) Thermostat or hygrostat for extra
10. (Option) Switch for extra heater heater 100 W
11. (Option) Outlet 23. Descriptions and circuit diagram
12. (Option) Earth fault protector (when outlet is 24. Handcrank
installed)

17
3 Overhaul

3 Overhaul
The overhaul mainly consists of lifting and cleaning of the selector switch insert,
checking of the selector switch and change-over selector (if any), checking of the
transition resistors, checking of contacts and the motor-drive mechanism.

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

3.1 Required Tools and Materials

Necessary for the overhaul, besides common hand tools, is the following equipment:

Normal set of open end wrenches (metric, up to 18 mm)

Normal set of sockets (metric, up to 18 mm)
Allen socket, 5 and 6 mm
Ratchet wrench handle with extension
Normal set of screwdrivers
Oil test equipment (for dielectric strength testing according to IEC 156),
New transformer oil, volume according to section 3.3.3. The oil quality should be
IEC 60296-LCSET -30° (former Class II). The oil should have an electrical with-
stand of at least 40 kV, measured in a 2.5 mm gap, according to IEC 60156.
Clean and empty drums (for approximately 200 l)
Bucket (10 l)
Rags (non-fuzzying)
Brush with extensible shaft (for cleaning of cylinder and selector switch shaft),
see Appendix, Fig. A1
Spring balance (10 N) for checking of belt tension
Megger (500 V)
Set of spare contacts
Guide for rollers, see Appendix, Fig. A6
Holding tool (for remounting of fixed contact blade and guiding when lowering
the insert), see Appendix, Fig. A2
Screwing tool (for remounting of fixed contact blade), see Appendix, Fig. A3
Lifting and operating tool, see Appendix, Fig. A4
Lifting rig, see Appendix, Fig. A5

18
 3 Overhaul

Lifting jack (about 40 kg, 1.6 m lifting height)

Protective gloves, oil-proof
Hand lamp
Ohmmeter (0.5-50 Ohm)
Slide calliper
Air pump with pressure gauge (0-200 kPa), connection to thread R1/8” male
Oil for bearings
Grease: GULF-718EP Synthetic grease, Mobilgrease 28, SHELL-Aero Shell
Grease 22 or similar
Watch, with hand for seconds
Pen and paper and revision protocol

3.2 Procedure
The overhaul procedure includes the following points:

Oil draining and filtering

Lifting and cleaning the selector switch housing and insert
Checking fixed and moving contacts of the selector switch and change-over
selector (if any)
Checking the transition resistors
Lowering the selector switch insert
Checking the pressure-relay
Lubrication of the drive shaft system
Checking the motor-drive mechanism
Oil filling
Putting into operation

19
3 Overhaul

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 outage time of the trans-
former, carry out all work on the on-load tap-changer and the oil filling before the
maintenance of the motor-drive mechanism is started.

3.3.1 On-Load Tap-Changer Position

Note the position of the on-load tap-changer to enable restart of the transformer in the
right tap position.

3.3.2 Disconnection and Earthing of the Transformer

WARNING
Before starting any work in the on-load tap-changer the protective motor switch
and the LOCAL/REMOTE switch must be set at 0.

WARNING
Before any work is carried out on the on-load tap-changer:
Make sure that the transformer is disconnected and that earthing is properly
carried out. Obtain a signed certificate from the engineer in charge.

Operate the on-load tap-changer by the hand crank until the Maintenance position is
reached.

NOTE: The Maintenance position is marked on the rating plate.

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 IEC 60296-LCSET -30° (former
Class II). The oil should have an electrical withstand of at least 40 kV, measured in a
2.5 mm gap, according to IEC 60156. The oil should have a water content below
15 ppm and have been handled and stored according to IEC 60422 point 10.

Quantity of oil in the on-load tap-changer and lifting height for insert

UBB.N 200/... Approx. 100 kg (lifting height 1.3 m)

UBB.N 350/...

UBB.T 200/... Approx. 125 kg (lifting height 1.6 m)

UBB.T 350/...

NOTE: The volume of the oil conservator is not included.

20
 3 Overhaul

Alternatively, the oil may be replaced by new oil and the used oil filtered at some later
occasion. A certain quantity of new oil, approximately 40 kg, 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 Standard Spare Parts

It is recommended to have a set of contacts for the selector switch available at the
overhaul. See Fig. 3.

Moving contacts
Fixed contact

Socket screw

Locking washer

fm_00227

Fig. 3.

21
3 Overhaul

3.4 Oil Testing and Oil Draining

The selector switch housing is equipped with an oil valve placed on the top section.
For connection dimensions, see the dimension drawing for the on-load tap-changer.

WARNING
The oil in the on-load tap-changer may be hot. Be cautious!

Take an oil-sample from the oil valve and carry out the dielectric strength test
according to IEC 60156 (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 30 kV in the
test above for an on-load tap-changer in service. For new oil or after filtering of the
old oil, the dielectric strength must be at least 40 kV to be allowed for filling the tap-
changer.

NOTE: When taking the oil-sample, first drain some oil into a bucket to clean the
valve.

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB 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
40 kV measured in a gap according to IEC 60156.

Use the filtering equipment or the pump to drain oil from the on-load tap-changer into
carefully cleaned oil drum. Connect the pump to the oil valve and drain the oil from
the selector switch housing and the conservator. (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 to the on-load tap-changer, see Fig. 2.) Pump until the
oil flow stops. The oil level will then be about 300 mm below the cover. Draining can
be effected quickly if filtering equipment is used and at the same time the whole oil
quantity will be filtered once.
WARNING
There is always a cushion of explosive gases in the top of the on-load tap-changer.
No open fire, hot surfaces or sparks may be present during opening of the
housing or draining from the valve. After the cover is removed let the gas vent
away approximately 15 min before any work is started.

WARNING
When oil that has been used in a on-load tap-changer 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.

Remove the top cover of the selector switch housing. See section 3.5.1. Put the hose
from the pump down to the bottom of the selector switch housing and pump out the
remaining oil.

22
 3 Overhaul

3.5 Lifting and Cleaning the Selector

Switch Insert
3.5.1 Dismantling the Top Cover of the On-Load Tap-
Changer
See Fig. 4.
1. Remove the connection to the oil conservator and pressure relay and other
connections made.
2. Loosen the hose clips for the protective tubes on the bevel gears and push the tube
from the bevel gear so that the coupling halves for the square shaft can be seen.
3. Loosen the bolts for the top cover.
4. Lift the cover carefully min 100 mm straight upwards before moving it in hori-
zontal direction. Hold the shaft so it not will fall when the cover is lifted. Take
away the shaft and store it temporary. Check that the driving disc on the lower
side of the cover and the tightening surface not become damaged when storing the
cover temporary.

Protective tube Hose clip Cover

Bevel gear

Top cover

Screw M6 A
Coupling half

Driving pin
Guiding pin

Driving disc

Indicator window

A A

Earthing symbol

fm_00012

Key in the bevel gear

Fig. 4.

23
3 Overhaul

3.5.2 Removal of the Mechanism and Fixed Contact

Blades
Loosen the four M8-screws in the corners of the base plate and remove the
mechanism, see Fig. 5.
If the base plate is hard fitted it can be loosened by means of two M10x50 (or longer)
screws. Mount the screws through the two clearance holes in the upper part of the
selector switch, see Fig. 5. Tighten the screws and the base plate will be pressed
upwards. Remove the screws immediately when the base plate with selector
mechanism is removed.

Base plate for selector mechanism The oblong hole of the position selector
Four M8 Allen screws

Position selector for the

change-over selector

Holes for M10x50 fm_00228

(or longer) screws

Fig. 5

24
 3 Overhaul

Removed fixed
contact blade

Current collector knob

Moving contact arm in

maintenance position fm_00242

Change-over contact in
position

Fig. 6. UBB in position before removal of the switch insert.

At 10-pitch, (the number of fixed contacts in one phase of the selector switch), remove
the contact blade next to the current collector in each phase, see Fig. 6, if 12- or 14-
pitch removing of two contact blades in each phase is recommended.
Proceed as follows:

1. Adjust the contact holder of the holding tool, for the actual contact (different
contacts for 10-, 12-, 14-pitches). See 3.5.3 and Fig. A2.
2. Attach the holding tool on the contact blade in the upper phase.
3. Loosen the two M6-screws completely in the contact blade by using the screwing
tool, see Fig. A3.
4. Lift both tools and the contact blade and the M6-screws. Store the blade and
screws temporarily.
5. For the blades in the lower phases, repeat the steps 2-4 above.

25
3 Overhaul

3.5.3 Adjustment of the Holding Tool for Removal of

Fixed Contacts
See Fig 7.
The plate spring must be adjusted to dimension B for the fixed contacts respectively
(see the table below). Turn the adjusting screw clockwise to reduce and anticlockwise
to increase the dimension B. If the adjusting according to above not is enough, bend
carefully the plate spring to the right dimension. Use a spare contact blade to check
the adjustment.

Fixed contact for Dimension B

10-pitches 41 +1/-0
12-pitches 36 +1/-0
14-pitches 31 +1/-0

Adjusting screw

Screw
Contact Washer
(B) fm_00021
Plate spring

Fig. 7.

26
 3 Overhaul

3.5.4 Positioning of Selector Switch and Change-Over

Selector before Lifting
See Fig. 6.
1. Attach the lifting and operating tool, see Fig. A4, to the two M8-holes on the up-
per end of the selector switch.
2. Twist the tool clockwise until the moving contacts of the selector switch shaft
have reached the position for the removed fixed contact blades and close to the
current collectors. See Fig. 6.
3. Place the slot in the outer arm of the tool over the roller on the change over
selector.
4. Twist the moving contacts of the change-over selector by means of the arm until
they are between two fixed long contacts.

3.5.5 Lifting
The selector switch insert (mass approximately 30 kg) can be lifted out of the cylinder
by means of a lifting jack. As a holder for the lifting jack it is recommended to use a
”rig” similar to the one shown in Appendix, Fig. A5.

1. Couple the hook of the lifting jack to the lifting and operating tool and lift the
insert carefully until the current collectors just leaved their knobs.
2. Twist the shaft so both the moving contacts and the current collectors are in the
position for the removed fixed contact blades, see Fig. 8.
3. Lift carefully until the selector switch insert is completely removed from the
selector switch cylinder.
4. The insert can be put down on two non-metallic (wood) supports.

CAUTION
Make sure that there always is clearance between the insert and the fixed contact
blades, so no parts will be deformed or damaged.

27
3 Overhaul

Moving contact arm

during lifting

Removed fixed
contact blade

Current collector
during lifting

Current collector knob

Change over contact

during lifting

fm_00243

Fig. 8. UBB in position for lifting of the switch insert.

3.5.6 Cleaning
Clean the selector switch insert as follows:
1. Remove all carbon deposits on the outside by brushing. Flush with clean oil.
2. Clean the inside of the selector switch shaft by putting in the brush from the bot-
tom and moving it up and down during turning. Flush the inside with clean oil.

Clean the selector switch cylinder:

1. Remove all carbon deposits with the brush moved up and down during turning.
Flush with clean oil.
2. Remove the remaining oil on the cylinder bottom by using a non-fuzzying rag.
Pick up rags from the bottom.

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB and it is maintained and operated according to our instructions,
the cleaning of the selector switch housing is very easy.

28
 3 Overhaul

3.6 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
40 kV measured in a 2.5 mm gap according to IEC 60156.
To check the result of the filtering, take test sample during the oil filtration and after
the oil has been filled into the on-load tap-changer.

NOTE: If the on-load tap-changer is equipped with an oil filter unit for continuous oil
filtration from ABB and it is maintained and operated according to our instructions,
no further oil filtration should be necessary. Only take a sample and measure the
dielectric strength of the oil, see section ”Oil Testing and Oil Draining” in this guide.

3.7 Checking of the Breather

Check the breather according to the instructions for the transformer.

WARNING
The breathers and the tube from the conservator contain explosive gases. No
open fire, hot surfaces or sparks may be present when removing the breather.

If more than half of the drying agent has changed colour, it must be dried or replaced.
The drying agent normally starts to change colour from the bottom of the breather. If it
changes colour at the top of the breather, there is a leakage in the connections to the
conservator. Locate the leakage and seal it.

29
3 Overhaul

3.8 Checking Contacts

3.8.1 Moving Contacts
NOTE: If the moving contacts are replaced, also replace any fixed contacts that are
considerably worn, in order to minimize the wear of the new moving contacts.
If the on-load tap-changer has only used a few positions during the period of opera-
ting, you may replace any worn contacts in these positions with unworn contacts from
positions not used.

Replace a moving contact when the diameter of its contact rollers is less than the
diameters given in the table 1. Measure the diameter of each roller halfway between
the roller ends.
Compare the measurements of the most worn roller with the diameters given in
table 1. See Fig. 9.

Measure the roller

diameter (d) here fm_00230

Fig. 9. Moving contact arm

NOTE: If a contact is replaced, the comparision at the next revision shall start again
with the value for Revision 1.

Table 1. Contact minimum dimensions.

Revision 1) Measure d (mm)
1 ≤ 18.5
2 ≤ 18
3 ≤ 17.5
4 ≤ 17
5 ≤ 17
1)
According to recommendations on the rating plate.

The base for the dimensions are, at the same service conditions in the future, the
contacts are not likely to be worn out before next overhaul.
CAUTION
If the on-load tap-changer has exceeded 500 000 operations, the contacts must be
replaced, due to weakening spring tension of the contacts.

30
 3 Overhaul

3.8.2 Fixed Contacts with Tips of Copper-Tungsten

Check the degree of contact burning and establish which side is most worn. Then
check, on the most worn side of the contact, which surface (upper or lower part) is
least worn. Measure the wear on this surface 6 mm up on the tip, according to Fig. 10.
The contact has to be loosened to make the measurement possible.
a
Measure the ”a” value at
Most worn side
this point

Least worn surface

a
6 mm
A A

View A-A Tip of Copper-Tungsten

b
fm_00022

Fig. 10. Measure the wear of the contacts

Replace the contact if worn beyond the limits stated in table 2.

NOTE: If a contact is replaced, the comparison at next revision shall start again with
the value for Revision 1.
Table 2. Contact minimum dimensions.
1)
Revision b=30 b=24.5 b=21.5
Measure a (mm) Measure a (mm) Measure a (mm)

1 ≤ 3.5 (3.0) ≤ 3.5 (3.0) ≤ 4.0 (3.5)

2 ≤ 3.5 (3.0) ≤ 3.5 (3.0) ≤ 4.0 (3.5)
3 ≤ 2.5 (2.5) ≤ 2.5 (2.5) ≤ 3.0 (3.0)
4 ≤ 2.0 (1.5) ≤ 2.0 (1.5) ≤ 2.5 (2.0)
5 ≤ 1.5 (1.5) ≤ 1.5 (1.5) ≤ 2.0 (2.0)
1)
According to recommendations on the rating plate.

The base for the dimensions are, at the same service conditions in the future, the
contacts are not likely to be worn out before next overhaul.
The values within brackets apply to situations of equal wear of the contact’s upper and
lower surfaces (within ± 0.5 mm).
As applicable, reinstall the old contacts or install new ones, according to instructions
in section 4.2 Fixed Contacts.

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3 Overhaul

3.8.3 Fixed Contacts made of Copper

Check the degree of contact burning and establish which side is most worn. Then
check, on the most worn side of the contact, which surface (upper or lower part) is
least worn. Measure the wear on this surface 18 mm up on the tip, according to
Fig. 11. The contact has to be loosened to make the measurement possible.
Replace the contact if worn beyond the limits stated in table 3.

NOTE: If a contact is replaced, the comparison at next revision shall start again with
the value for Revision 1.
Table 3. Contact minimum dimensions.
Revision 1) b=30.5 b=25 b=22
Measure a (mm) Measure a (mm) Measure a (mm)
1 ≥ 5.5 (6.0) ≥ 5.5 (6.0) ≥ 4.0 (4.5)
2 ≥ 6.0 (6.5) ≥ 6.0 (6.5) ≥ 4.5 (5.0)
3 ≥ 6.5 (7.0) ≥ 6.5 (7.0) ≥ 5.0 (5.5)
4 ≥ 7.0 (7.5) ≥ 7.0 (7.5) ≥ 5.5 (6.0)
5 ≥ 7.5 (8.0) ≥ 7.5 (8.0) ≥ 6.0 (6.5)
1)
According to recommendations on the rating plate

The base for the dimensions are, at the same service conditions in the future, the
contacts are not likely to be worn out before next overhaul.
The values within brackets apply to situations of equal wear of the contact’s upper and
lower surfaces (within ± 0.5 mm).
As applicable, reinstall the old contacts or install new ones, according to instructions
in section 4.2 Fixed Contacts.
Least worn surface

View A–A

Most worn side

A A

18

fm_00023

a
b
Fig. 11. Measure the wear of the contacts

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 3 Overhaul

3.9 Checking the Transition Resistors

Connect one of the cables from the ohmmeter to one transition contact and the other
cable to the moving main contact, in all phases as described above, then measure the
resistance.
Measure the resistance of each resistor and compare with values given on the rating
plate. Check that the resistors are undamaged. The values may not differ by more than
10 percent.
Check that the screw joints for contacts, resistors etc. have not worked loose.

3.10 Lowering the Selector Switch Insert

See Fig. 8.

1. Check that no foreign objects, tools, rags etc. are left in the selector switch
housing.
2. Put the guiding round-bar, see Fig. A2, carefully in the centre hole in the bottom
of the selector switch housing.

NOTE: The total length should be 1200 mm for UBB.N and 1500 mm for UBB.T. See
also Fig. A2.

3. Attach the lifting and operating tool, (if removed), to the two M8 holes on the up-
per end of the selector switch.
4. Attach the lifting rig, see Fig. A5, on the flange of the selector switch housing.
5. Couple the lifting jack hook to the lifting and operating tool.
6. Before lowering, the moving contacts and the current collectors shall be
positioned over the gap where the contact blades are removed and the moving
contacts of change-over selector between two long fixed contacts.
7. Lower the insert carefully until the current collectors are a little bit above the
current collector knobs.
8. Twist the insert carefully to the position with the current collectors exactly above
the current collector knobs respectively.
9. Lower the insert carefully and check that all the current collectors have entered
the knobs. If necessary push the current collectors with the screwing tool or
similar. Check that the bottom part of the insert enters the bearing, if not adjust by
lifting it.
10. Remove the lifting jack and lifting rig.
11. By means of the lifting and operating tool position the moving contacts of the
change-over selector to the contact blades respectively. See Fig. 6.

NOTE: The position of the roller.

12. Position, by means of the same tool, the moving contacts of the selector switch to
the contact blades representing the Maintenance position, see Fig. 6.

33
3 Overhaul

13. Remove the lifting and operating tool.

14. Remove the guiding round bar.
15. Remount the contact blades in each phase using the two tools according to
sections 3.5.2 and 3.5.3. Tightening torque 15 Nm.
16. Make sure that the sealing underneath and on top of the mechanism are in place,
see Fig. 12. Remount the mechanism and tighten the four M8-screws in the
corners of the base plate, see Fig. 5.

NOTE: The driving pins in the top of the selector switch shall enter in the
corresponding holes in the driving mechanism.

NOTE: If it is an on-load tap-changer with change-over device, make sure that the
roller on top of the change-over ring is engaged in the slot of the position selector
under the gear base plate.

Fig. 12. Sealings

34
 3 Overhaul

3.11 Mounting the Top Cover on the On-Load

Tap-Changer
See Fig. 4.
1. Check the O-ring in the groove in the flange. Grease the shaft ends of the bevel gears.
See section 3.12.
2. Before mounting the top cover check that the position of the driving disc on the lower
side of the cover is according to Fig. 4. Remove the cover of the bevel gear on the on-
load tap-changer top cover.
3. Lower the top cover straight down towards the flange. The guiding pin in the flange
shall clear the hole in the cover. The horizontal shaft with the protective tube shall be
remounted during the lowering.
Open the cover of the gear box on the top cover of the on-load tap-changer. Check
that the key on the vertical shaft in the bevel gear is facing the earthing symbol on the
flange of the on-load tap-changer. See Fig. 4.
CAUTION
The position of the driving disc must be according to Fig. 4 and the guiding pin must fit in the hole.
4. Check that the number, readable through the indicator window in the top cover, is the
same as maintenance position and that the motor-drive mechanism has the same
indicated position.
5. Mount the bolts for the top cover and tighten.
6. If drive shaft coupling has been dismantled:
Mount the coupling halves to the square shaft and the shaft of the bevel gear. Tighten
the screws light and check that the shaft not can be moved more than
2 mm in axial direction (axial play). Tighten the two screws A, (see Fig. 4) first and
then the others.
7. Reconnect the pipe-hooks on the top cover to the flanges of the pipe to the oil
conservator and the pressure relay.
8. Lubricate the bevel gear, see section 3.12 and reassemble the cover.
9. Reassemble the protective tubes with the hose clips.
CAUTION
The motor-drive mechanism and on-load tap-changer shall have the same indicated tap-
position. Check in the indicator window and the motor-drive mechanism.

3.12 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
The bevel gear contains moving gears. Be cautious!
WARNING
Rotating shafts. Be cautious!
Check and lubricate with grease if necessary. Recommended types of grease are GULF-718
EP Synthetic Grease, Mobilgrease 28, Shell-Aero Shell Grease 22 or similar.
Remount covers (make sure the gaskets are properly in place).
35
3 Overhaul

3.13 Checking the Pressure Relay

3.13.1 Functional Check of the Pressure Relay

Information
plate

Valve handle
(in service
position)

Quick coupling

Test tap (R 1/8”)

TC_00264

Fig. 13. Pressure relay

1. Set the valve handle to the test position as shown on the information plate.
2. Connect the air pump and the pressure gauge to the test tap on the pressure relay.
(Thread R 1/8”).
3. Raise the pressure until the pressure relay trips the circuit breakers of the
transformer.
4. Read the pressure on the manometer and check against the pressure stated on the
information plate. Max. permitted deviation is ±10 %. If the deviation is greater,
the pressure relay should be replaced.
5. Check that the signal disappears when the pressure is released.
6. After finishing the check, turn back the valve handle to service position.

3.13.2 Replacing the Pressure Relay

If replacement of the pressure relay is necessary, it is carried out according to the
instruction in 1ZSE 5492-130, Repair Guide for On-Load Tap-Changer, type UB.

36
 3 Overhaul

3.14 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 3.15.

37
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. 14. Motor-drive mechanism, type BUE

38
 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. 15. Motor-drive mechanism, type BUL

39
3 Overhaul

3.14.1 Motor Protection

Open the motor-drive cabinet door and turn the selector-switch to the LOCAL
position. 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.

3.14.2 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 the knob is on the protector).

3.14.3 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 counter’s value. The counter shows the number of
operations run by the on-load tap-changer.

3.14.4 Heater
WARNING
Before starting any work inside the motor-drive mechanism, the auxiliary power
must be switched off.

N.B. The motor, contactors and heating element may be energized from separate
sources.

Check by feeling with a finger that the heating element has been functioning.

3.14.5 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.

40
 3 Overhaul

3.14.6 Cable Connections

Check that all cable connections within reach are secure.

3.14.7 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. 16, with a
tolerance of ± 25 degrees measured on the brake disc (± 125 degrees measured on the
hand crank), see Fig. 16.
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. 14. 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 for advisory.

Adjusting nuts

Brake disc

Red mark ±25°

from mark on
brake pad

Red mark

Brake pads
fm_00232

Fig. 16. Brake adjustment, type BUE

41
3 Overhaul

3.14.8 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. 14. 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. tight-
ening the spring bolt.
An adjusted increasing spring force on the disc brake makes the maintaining contact
arm swing back with a different speed, and the brake for the maintaining contact must
be adjusted.

3.14.9 Disc Brake, BUL

Run the motor-drive mechanism and check that the centre of the notch in the cam disc
stops within ±2 mm from the centre of the roller on the brake arm, see Fig. 17. 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. 17. Brake adjustment, type BUL

CAUTION
If the motor-drive still not stops when the brake is adjusted to min. 15 mm according
to Fig. 17 please contact ABB for advisory.

42
 3 Overhaul

3.14.10 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 0.6–1.0 mm. Adjustment is made with the nuts on the contact.

Moving contact
Contact arm

Contact arm
0.8 ±0.2 mm

Geneva wheel

Contact plate
A A Fixed contact
View A – A
fm_00096

Fig. 18. Contact arm play

3.14.11 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 5492-130, Repair Guide, On-Load Tap-Changer, type UB.
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.

Transparent cover

Contact arm
Circuit card

fm_00233

Fig. 19. Position transmitter, checking

43
 3 Overhaul

Indicator window

999987
fm_00235

LOWER POSITION RAISE

9
8 9 10
7 11
6 12
5 13
4 14

– +

Position indicator

Adjustment nuts

Brake disc
Red mark
fm_00240

Brake pads

Fig. 20. Starting contact, BUE

44
 3 Overhaul

3.14.12 Starting contact, BUE

Check that the contact timing is correct. There must be a 100° (±20°) difference
between the maintaining contact and the starting contact.
Place the motor-drive in its exact position according to Fig. 20. Operate manually
24 turns. In the very first beginning of turn 25, the maintaining contact is released and
after 100° (±20°) more on the hand-crank the starting contact shall switch on again. If
this sequence is not correct, the drive disc of the starting contact needs adjustment.

3.14.13 Lubrication, BUE

See Fig. 21.
The bearing points of the brake blocks and the links should be sparingly lubricated
with oil. (Use oil for 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.

3.14.14 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. See Fig. 15.
Reconnect the power supplies.

45
 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.

46
 3 Overhaul

3.15 Operation Test

To check that the shafts have been correctly assembled, the motor-drive mechanism
should be placed in the exact position acc. to Fig. 16 or 17. Operate the tap-changer
with the hand crank, counting the number of turns from the exact position until the
tap-changer operates. The test is performed in both RAISE and LOWER directions.
With BUL, the tap-changer should operate after 11.5 ±1 turns of the hand crank. With
BUE, the tap-changer should operate after 19 ±1.5 turns of the hand crank. If not, one
of the shaft couplings is mounted incorrectly.
Operate the motor-drive mechanism, first one step manually using the hand crank, and
then electrically to the position next to the end-position. Then operate manually to the
end-position. Check the mechanical end-stop by trying to hand crank beyond the end-
position. After a couple of turns you should reach the mechanical end-stop. Hand
crank back to the end-position . When trying to operate electrically beyond the end-
position, the motor should not start. Operate the motor-drive mechanism electrically to
the position next to the other end-position and carry out the same 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 disabled. 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.

3.16 Oil Filling

3.16.1 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.
The oil quality should be IEC 60296-LCSET -30° (former Class II). The oil must have
an electrical withstand of at least 40 kV, measured in a 2.5 mm gap, according to
IEC 60156. New oil should have a water content below 15 ppm and have been hand-
led and stored according to IEC 60422 point 10.
After maintenance oil is normally filled at atmospheric pressure. This procedure is
described in section 3.16.3. If filling is to be carried out under vacuum, see
1ZSE 5492-118, Installation and Commissioning Guide for UB.

47
3 Overhaul

After oil filling, a gas cushion should remain on the top of the oil in the selector
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 selector switch housing
and the number of operations is low, the gas cushion may be dissolved in the oil. The
gas cushion should be restored according to section 3.16.5 ”Restoring the Gas
Cushion” in this guide.

3.16.2 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.

3.16.3 Filling at Atmospheric Pressure

See Fig. 2.
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 selector 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.
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.

3.16.4 Oil Level

For correct oil level in the oil conservator, see the transformer documentation.

48
 3 Overhaul

3.16.5 Restoring the Gas Cushion

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.

If the on-load tap-changer has been filled with degassed oil and has a very low
frequency of operation, the gas cushion may have been absorbed by the oil. To avoid
fault trip by the pressure relay, the gas cushion should be restored.
Proceed as follows:
1. Shut the conservator valve.
2. Connect a pump to the oil valve and start to suck out oil. Open the air vent to the
on-load tap-changer and let air in. Stop the pumping after about 2 litres of oil has
been sucked out from the on-load tap-changer.

WARNING
The oil in the selector switch housing may be hot. Be cautious!

3. Shut the air vent and the oil valve and disconnect the pump.
4. Open the conservator valve and an appropriate gas cushion will be formed.

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.

The procedure above 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
Avoid to do the restoring in damp weather since moisture will get into the selector
switch housing. If the restoring has to be done in such weather, the incoming air has
to be dehydrated.

49
3 Overhaul

3.16.6 Waiting Period

CAUTION
Do not energize the transformer earlier than three hours after oil filling in
atmospheric pressure. This waiting period is needed to allow airbubbles to disappear.

3.17 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.

50
 4 Contact Replacement

4 Contact Replacement
CAUTION
ABB recommends that only maintenance engineers with appropriate knowledge about
the UBB selector switch carry out contact replacement.

Check the wearing of the contacts as described in section 3.8. Replace worn out
contacts.
Replacing of contacts is described in the following sections.

B
D (10 Nm)
B (24.5 Nm)

Transition contact, unit 1

Main contact, unit 2

fm_00227

Transition contact, unit 3

C (10 Nm)

Fig. 22. Moving contact system design

4.1 Moving Contacts

The two transition contact units and the main contact unit are delivered as assembled
sets. When changing the moving contacts the whole units shall be replaced.
At first the transition resistors shall be loosened, but not removed, by loosening two
bolts (B), see Fig. 22.

51
5 Tap-changer in the transformer

Remove the complete transition contact unit 1 and 3 by unbolting the four bolts (C).
The moving main contact unit 2 is removed by unbolting the two bolts (D).
The new main contact unit and transition contact units are then remounted. Begin with
the main contact. The transition contact units will be correctly positioned when the
guide for the rollers according to Figs. 22 and A6 is used. All bolts should be tighte-
ned according to Fig. 22. It is not necessary to use a torque wrench. The torques (in
brackets) are only guide values.

fm_00024

Fig. 23. Guide for the rollers

4.2 Fixed Contacts

To remove the fixed contact blades you have to loosen the two socket screws. Use the
holding tool to hold the blade and screws and the screwing tool to loosen screws.
When mounting the new contact blades, the socket screws should be tightened with a
torque of 15 Nm.

5 Tap-changer in the transformer

5.1 Resistance measurement
If there are any problems with too high resistance during measurement of the trans-
former, the tap-changer should be operated 10 cycles over all positions to clean the
contacts.
Another cause for problems at resistance measurement may be too low measuring
current. We recommend a measuring current of at least 50 A.

52
 6 Specification of Materials

6 Specification of Materials
6.1 General
This chapter specifies the materials used in the on-load tap-changer.
On disposal of this product, it is recommended that local environmental regulations in
each country are met. For environmental reasons, materials used are specified.

6.2 Selector Switch Housing

Material Amount

Steel 5 kg
Aluminium 45 kg
Copper and alloys 5 kg
Epoxy resin 30 kg
Transformer oil 100-125 kg

6.3 Selector Switch Insert

Material Amount

Steel 5 kg
Aluminium 5 kg
Copper and alloys 10 kg
Silver 25-50 g
Tungsten 0-1.5 kg
Epoxy resin 12 kg
Polyphenylene sulfide resin 2 kg
Resistor wire (mainly copper 0.5-3 kg
and nickel alloys with lesser
amounts of aluminium and
manganese)

6.4 Gearing Mechanism

Material Amount

Steel 8 kg
Aluminium 2.5 kg
Copper and alloys 2 kg

53
6 Specification of Materials

6.5 Drive Shaft Systems

Material Amount

Steel 8 kg
Aluminium 2 kg
Brass 2 kg
Polyethylene 2 kg

6.6 Motor-Drive Mechanism

Material BUE BUL
Amount 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
phenol resin laminate x
polyester x x
PVC x 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.

54
 Appendix

Appendix. Tools

1350

Brush of bottle-cleaner type

Material: plastic

fm_00025

Catalogue no.: LL 117 016-L

Fig. A1. Brush

55
Appendix

Alternative 1 Alternative 2

Handle 1175 for UBB.N

1500 for UBB.T

1200 for UBB.N

1500 for UBB.T

Holding tool

fm_00026
For UBB delivered Guiding round-bars For UBB delivered
2001 and earlier 2002 and later

Catalogue no.: LL 117 016-D

Fig. A2. Holding tool and guiding round-bar

56
 Appendix

1400

fm_00027

Catalogue no.: LL 117 016-E

Fig. A3. Screwing tool

57
Appendix

220

264

fm_00020

Catalogue no.: LL 117 016-B

Fig. A4. Lifting and operating tool

58
 Appendix

460

2050

fm_00028

Catalogue no.: LL 117 016-C

Fig. A5. Lifting rig

59
Appendix

14

10-pitches
20
Catalogue no.: LL 117 016-F

12-pitches
20
Catalogue no.: LL 117 016-G

4.5

14-pitches
20
Catalogue no.: LL 117 016-H

fm_00029

Fig. A6. Guide for the rollers

60
61
 1ZSE 5492-127 en, Rev. 5, 2005-05-15

ABB Power Technologies AB

Components
Visiting address: Lyviksvägen 10
Postal address: SE-771 80 Ludvika, SWEDEN
Tel.+46 240 78 20 00
Fax +46 240 121 57
E-mail: sales@se.abb.com
www.abb.com/electricalcomponents