ABB VUBB Installation And Commissioning Manual

1ZSC000562-AAK EN, REV. 2, 2019-07-03

Vacuum on-load tap-changers, type VUBB

Installation and commissioning guide

The information contained in this document may be subject to change without prior warning and should not be considered

as binding on ABB AB’s behalf. ABB AB accepts no liability for any errors that may appear in this document. ABB AB is

not liable for any damage resulting from the incorrect interpretation of this document. This document, or parts thereof, may

not be reproduced or copied without ABB AB’s consent. It may not be distributed to others, or used by unauthorized

parties. Any breaches to the above will be penalized with the support of applicable laws.

Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

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Contents

1 Safety 5

1.1 Levels of safety risks ................................................................................................................................................................... 5

1.2 Hazardous working situations ..................................................................................................................................................... 6

1.3 Safety precautions....................................................................................................................................................................... 6



2 Product description 7

2.1 Design ......................................................................................................................................................................................... 7



3 Delivery 9

3.1 Incoming inspection..................................................................................................................................................................... 9

3.2 Transportation ............................................................................................................................................................................. 9

3.3 Storage........................................................................................................................................................................................ 9

3.4 Lifting........................................................................................................................................................................................... 10

3.4.1 Lifting the transport box............................................................................................................................................. 10

3.4.2 Lifting the tap-changer out of the transport box......................................................................................................... 11



4 Installation in the transformer 15

4.1 Tools ............................................................................................................................................................................................ 15

4.2 Consumables .............................................................................................................................................................................. 16

4.3 Installation in the transformer ...................................................................................................................................................... 16

4.3.1 Installation in the cover.............................................................................................................................................. 16

4.3.2 Installation on the yoke ............................................................................................................................................. 19

4.4 Connection of conductors to the terminals .................................................................................................................................. 21

4.5 Installation of the top flange, yoke-mounting............................................................................................................................... 22

4.6 Transformer ratio measurement ..................................................................................................................................................25



5 Drying 29

5.1 Preparations ................................................................................................................................................................................ 29

5.2 Drying processes......................................................................................................................................................................... 30

5.2.1 Overview ................................................................................................................................................................... 30

5.2.2 Drying with the alternating hot air and vacuum process............................................................................................ 30

5.2.3 Drying with the vapor phase process ........................................................................................................................ 30

5.3 After drying .................................................................................................................................................................................. 31



6 Final assembly 33

6.1 Installation of the motor-drive mechanism................................................................................................................................... 33

6.2 Installation of the external drive shafts ........................................................................................................................................ 33

6.3 Synchronization of the motor-drive.............................................................................................................................................. 44

6.3.1 Synchronization of BUL2........................................................................................................................................... 44

6.3.2 Synchronization of BUE2 .......................................................................................................................................... 46

6.4 Installation of the oil conservator................................................................................................................................................. 47

6.5 Installation of the oil tap............................................................................................................................................................... 49

6.6 Installation of protection devices ................................................................................................................................................. 51

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Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03



7 Oil-filling 53

7.1 Preparations ................................................................................................................................................................................ 53

7.2 Oil-filling with the atmospheric process ....................................................................................................................................... 54

7.3 Oil-filling with the vacuum process .............................................................................................................................................. 57



8 Electrical connection and testing 61

8.1 Connection of the operational circuits ......................................................................................................................................... 61

8.2 Testing of the electrical connections............................................................................................................................................ 62

8.2.1 Testing of BUE2......................................................................................................................................................... 62

8.2.2 Testing of BUL2 ......................................................................................................................................................... 65

8.3 Testing of the protection devices ................................................................................................................................................. 67



9 Preparations for transportation to site 69

9.1 General........................................................................................................................................................................................ 69

9.2 Transportation with transformer oil in the transformer.................................................................................................................69

9.3 Transportation without transformer oil in the transformer............................................................................................................71



10 Commissioning at site 73

10.1 Installation of the removed parts ................................................................................................................................................. 73

10.2 Connection of the electrical connections..................................................................................................................................... 73

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11 Spare parts 75

11.1 Summary ..................................................................................................................................................................................... 75

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12 Disposal and enviromental information 77

12.1 Overview ..................................................................................................................................................................................... 77

12.2 Disposal and recycling ................................................................................................................................................................ 77



13 References 79

13.1 Summary ..................................................................................................................................................................................... 79

Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

5

1 Safety

1.1 Levels of safety risks

Throughout the manual, various types of safety risks are indicated. The most serious level on this scale

provides a warning about serious personal injury or possible death, or major damage to a product, if the

instructions are not observed.

Symbols and their meanings

The following describes the symbols that appear in the manual, along with their meaning.

DANGER!

The yellow, filled warning triangle warns that an accident will occur if the instructions are not

complied with and that it will result in serious personal injury or death and/or major damage to the

product.

It is used, for example, to warn of such dangers as: contact with high voltage, explosion or fire

risk, risk for toxic gases, risk of crushing, impacts, falls from high places, etc.

CAUTION!

The round warning symbol warns that an accident could occur if the instructions are not observed,

and that this could result in personal injury and/or damage to the product.

It is also used to warn of risks that entail burns, eye or skin injuries, impaired hearing, crushing or

slipping injuries, tripping, impacts, falls from high places, etc.

In addition, it is used to warn of functional requirements when assembling or removing equipment

where there is a risk of damage to the product or downtime.

NOTE!

The comment symbol identifies important information and conditions. Also used to indicate any

danger that could lead to property damage.

Torque

The torque symbol indicates tightening torque.

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Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

1.2 Hazardous working situations

Hazard Action

Working close to high voltage. Disconnect all plant power. Ground all objects at the workplace.

If work must be done close to live plant components, make sure that

the safety distance is in compliance with the applicable safety

regulations.

Working on ladders and platforms. Work must be done in accordance with the applicable safety

regulations.

Do not use ladders or platforms in poor weather conditions.

Working with heavy objects. Do not walk under lifted objects.

Make sure that heavy objects are stable before starting work.

1.3 Safety precautions

Precaution Action

Transformer oil Collect used transformer oil in drums.

Transformer oil is dangerous. Fumes from hot oil can cause irritation

to the respiratory organs and the eyes. Long and repeated contact

with transformer oil can cause damage to your skin.

Waste and cleaning up Clean up liquid waste with an adsorbent. Treat waste as hazardous

to the environment.

Fire Extinguish fires with powder, foam or carbon dioxide.

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2 Product description

2.1 Design

Overview

The VUBB on-load tap-changer features an in-tank design. The motor-drive mechanism is attached to the

side of the transformer tank, and connected to the tap-changer by drive shafts and a bevel gear.

G004252

1 Vertical driveshaft

2 Bevel gear

3 Horizontal driveshaft

4 Tap-changer

5 Transformer tank

6 Motor-drive mechanism

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Installation and commissioning guide

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Protection devices and accessories

The standard IEC 60214-1requires that at least one protection device is supplied with the tap-changer.

Protection devices must detect all faults related to the tap-changer as quickly as possible. Protection devices

operate when they detect high temperatures, high pressure pulses or high oil-flows caused by an internal

failure in the tap-changer.

The tap-changer is always supplied with a protection device, a pressure relay as standard and/or an oil-flow

relay. One of these protection devices are mandatory.

Two protection devices are available for redundancy. The tap-changer configuration is specified on the

packing list.

Protection device Standard Option Note

Pressure relay Yes Mandatory

Oil-flow relay* Yes For redundancy, or as

alternative to pressure

relay.

Temperature switch Yes For redundancy.

Pressure relief device Yes For redundancy.

* The oil-flow relay is installed on the oil-conservator pipe and not shown in the figure.

G004491

Position Flange Designated use

1 A Pressure relay, standard

2 B Temperature switch, option

3 C Empty, for oil conservator

4 D Drain valve, standard

5 Top Pressure relief device, option

Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

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3 Delivery

3.1 Incoming inspection

• Make sure that all items have been delivered, refer to the packing list.

• Carefully inspect the tap-changer for shipping damage.

If damage is found, submit the following to ABB:

• A damage report with photos of the damaged parts.

• ABB's order number.

• The tap-changer's serial number.

• The crate number.

3.2 Transportation

• The tap-changer must be transported in the transport box.

• Carefully inspect the tap-changer for damage after transportation.

3.3 Storage

Short and long term storage

• Store the tap-changer and motor-drive mechanism indoors, in a controlled temperature with low

humidity.

• Keep the units in their moisture-proof wrapping.

• Do not remove the drying agent before installation.

• Replace the drying agent, if it has been exposed to the atmosphere.

CAUTION!

Do not store the tap-changer or motor-drive mechanism in an environment with high humidity or

varying temperatures. Condensation can cause corrosion.

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Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

3.4 Lifting

3.4.1 Lifting the transport box

Overview

G004307

1 Center of gravity

2 Soft lifting slings

3 Forklift lifting points

Type Weights

Transport box Tap-changer Total weight

VUBB 30 kg 280 kg 310 kg

Procedure

1. Make sure that the crane is approved for lifting the total weight of the transport box and tap-changer.

Refer to the packing list.

2.

Attach soft lifting slings (2) to the correct locations.

3.

Carefully lift the transport box.

4.

Put down the transport box on a flat surface.

End of instruction

Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

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3.4.2 Lifting the tap-changer out of the transport box

Procedure

1. Make sure that the crane is approved for lifting the weight of the tap-changer. Refer to the net weight

on the packing list.

2.

Remove the cover (1) and the sides (2) of the

transport box.

G004258

3.

Remove all accessories from the transport box,

and then remove the straps (7).

G004525

4.

Put the soft lifting sling (4) around the cylinder,

and then attach the soft lifting sling to the lifting

eye (3).

CAUTION!

Make sure that the crane hook is

exactly above the center of gravity (4).

The contacts can break if the

tap-changer moves in the soft lifting

sling.

G004257

5.

Carefully lift the tap-changer.

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Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

6. Lower the bottom of the tap-changer down onto a

soft bedding (5).

G004477

7.

Remove one soft lifting sling (4).

G004478

8.

Lift the tap-changer to the vertical position.

G004479

Installation and commissioning guide

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9. Put supports under the tap-changer, or attach a

safety cable from the ceiling to a lifting eye (3).

DANGER!

If the tap-changer tips, it could cause

death or injury to personnel.

G004480

End of instruction

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Installation and commissioning guide

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4 Installation in the transformer

4.1 Tools

Tool Part number Note

Air pump with pressure gauge and

hose

- Pressure range 0-250 kPa, hose

connection with internal thread

R 1/8”.

Standard set of open-end

wrenches

- Up to 18 mm.

Standard set of socket wrenches - Up to 18 mm.

Socket wrench extender - -

Standard set of screwdrivers - -

Hex keys - 5 mm and 6 mm.

Hand crank LL 117 016-M Ordered separately.

Torque wrench - 5-85 Nm, tolerance ≤ 10 %.

Buzzer - For testing the pressure relay.

500 V DC power unit/insulation

tester

- For testing the pressure relay.

Bottom valve key LL 117 016-A Supplied with the tap-changer.

Tool for opening oil drum - -

Hacksaw - -

Bucket - 10 liters

Soft lifting slings - Rated for a weight higher than the

combined weight of the

tap-changer and transport box.

Lifting chains - Rated for a weight higher than the

combined weight of the

tap-changer and transport box.

Crane - Rated for a weight higher than the

combined weight of the

tap-changer and transport box.

Equipment for oil filling - -

Soft bedding - Particleboard, thick rubber-mat or

equivalent.

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Installation and commissioning guide

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4.2 Consumables

Use an approved grease or grease with equivalent properties.

Item Brand Part number Note

GULF-718 EP Gulf - For ball bearings.

Mobilgrease 28 Mobil 11714014-407 Lubricates and protects

metals against corrosion.

Protects rubber. Does not

react with transformer oil.

Aero Shell Grease 22 Shell - -

Rags for cleaning - - Lint-free

4.3 Installation in the transformer

4.3.1 Installation in the cover

Overview

The tap-changer is made for both cover-mounting and yoke-mounting. This procedure describes

cover-mounting.

Procedure

1. Make sure that the stud bolts (1) in the

transformer cover fit the holes (2) in the

tap-changer.

G004262

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2. Install the gasket in the groove (3) in the

transformer cover.

NOTE!

The gasket is not included in the

tap-changer delivery.

G004261

3.

Attach lifting chains (4) to the lifting eyes, and lift

the tap-changer.

CAUTION!

Make sure that the angle between the

lifting chains (4) is less than 90°.

A greater angle can cause deformation

of the lifting eyes.

G004254

4.

Carefully lower the tap-changer into the

transformer.

CAUTION!

Do not cause damage to the

terminals (5). The terminals (5) can

easily bend or break if they catch on

the transformer cover.

G004263

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Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

5. Turn the tap-changer as necessary to make

installation of drive shaft and pipes possible.

Please refer to the transformer manufacturer´s

documentation.

NOTE!

The bevel gear (1) must be within the

limits (9).

G004260

6.

Remove the lifting chains from the lifting eyes.

G004264

7.

Install the washers and nuts on the stud bolts (1),

and tighten the nuts.

G004265

Torque

M12 49 Nm

End of instruction

Installation and commissioning guide

1ZSC000562-AAK EN, REV. 2, 2019-07-03

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4.3.2 Installation on the yoke

Overview

The tap-changer is made for both cover-mounting and yoke-mounting. This procedure describes

yoke-mounting.

Procedure

1. Remove the bolts (1), and then remove the top

cover (2).

CAUTION!

Carefully lift the top cover straight up.

The shaft for the bevel gear can bend if

the top cover is not lifted straight up.

G004481

2.

Remove the bolts (3), and then remove the top

flange (4).

NOTE!

Keep the gasket and the parts, they will

be used again.

G004270

3.

Attach the lifting chains to the four lifting eyes (5).

G004271

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4. Install the gude pins (7) in the flange.

NOTE!

The guide pins are delivered with the

tap-changer.

G006833

5.

Make sure that the holes (6) in the yoke fits the

guide pins.

NOTE!

The guide pins are Ø 7 mm.

G004266

6.

Put the tap-changer on the yoke.

G004267

7.

Turn the tap-changer as necessary, to make installation of drive shaft and pipes possible. Please refer

to the transformer manufacturer's documentation.

End of instruction

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ABB VUBB Installation And Commissioning Manual

ABB VUBB Installation And Commissioning Manual

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