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1 Z S C0 0 0 5 6 2- A A R E N , R E V. 2

Oil filter unit, type OLU, for on-load

tap-changers
Manual
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Original instruction
The information provided in this document is intended to be general
and does not cover all possible applications. Any specific application
not covered should be referred directly to ABB, or its authorized
representative.

We reserve the right to make technical changes or modify the contents

of this document without prior notice. With regard to purchase orders,
the agreed particulars shall prevail. ABB does not accept any
responsibility whatsoever for potential errors or possible lack of
information in this document.

We reserve all rights in this document and in the subject matter and
illustrations contained therein. Any reproduction, disclosure to third
parties or utilization of its contents – in whole or in parts – is forbidden
without prior written consent of ABB.
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Table of contents

1. General information 5
1.1 Advantages with an oil filter unit 5
1.2 The oil filter unit 5
1.3 Electric equipment 18
1.4 Oil filter circuit 18
1.5 Continuous oil filtration 18
1.6 Filtration medium 19
1.7 Service temperature 20
1.8 Filter cartridge replacement interval 20
1.9 Leakage in the oil filter unit circuit 20
1.10 Oil level in the on-load tap-changer 20
1.11 Ordering data 20
1.12 Spare parts 20
1.13 Technical specifications 20
2. Installation 23
2.1 General 23
2.2 Tools 23
2.3 Material 23
2.4 Weight 23
2.5 Receiving 23
2.6 Mounting 23
3. Commissioning 25
4. Transportation 26
5. Maintenance 27
5.1 Tools 27
5.2 Material 27
5.3 Annual inspection 27
5.4 Maintenance 27
5.5 Filter cartridge replacement 28
6. Repair 33
6.1 Replacement of pump/motor unit 33
7. Spare parts list 35
7.1 Introduction 35
7.2 Oil filter unit serial number 35
7.3 Item number 35
7.4 Name of item 35
7.5 Quantity 35
7.6 Remarks 35
7.7 General arrangement 35
7.8 Standard spare parts 35
7.9 Special spare parts 35
7.10 Spare parts list for oil filter unit 35
8. Recycling 36
8.1 Introduction 36
8.2 Recycling of packaging material 36
8.3 Scrapping and destruction 36
8.4 Approximate material content 36
8.5 Hazardous waste 36
Recommended practices Safety precautions
ABB recommends careful consideration of the following
WARNING
factors when installing on-load tap-changers:

Almost all types of oil are potential threats to the

Before you install or commission a unit, make sure that the
environment and as such they should not be drained
personnel doing the job have read and fully understood the
into ordinary sewers and "dumped" in nature.
installation and commissioning guide provided with the
Always check that all oil carrying components are
unit.
sealed and tight before operating the oil filter unit.

To avoid damaging the unit, never exceed the operating WARNING

limits stated in delivery documents and on rating plates.
Be aware that oil spillage on the floor around the
Do not alter or modify a unit without first consulting ABB. filter unit is a safety risk!

Follow local and international wiring regulations at all times. WARNING

Used filter elements very often contain harmful

Use only factory authorized replacement parts and
substances separated from the oil. Always pack and
procedures.
seal used elements thoroughly until they can be
disposed of in accordance with local regulations.
Safety warnings
The following warnings and notes are used in the manual: WARNING
WARNING
Switch off the electrical power supply to the filter
unit when carrying out maintenance.
WARNING indicates an imminently hazardous
situation, which if not avoided will result in death or
WARNING
serious injury. This signal word is to be limited to
the most extreme situations. The oil filter unit may be hot. Be careful!

WARNING also indicates a potentially hazardous CAUTION

situation, which if not avoided could result in death
Do not expose the filter unit to ambient
or serious injury.
temperatures higher than 60 °C (140 °F) as this may
harm electrical wires, hoses and other rubber or
CAUTION
synthetic components!
CAUTION indicates a potentially hazardous
situation, which if not avoided may result in minor or CAUTION
moderate injury. It may also be used to alert of
The fluid temperature inside the filter unit must
unsafe practices.
never exceed 110 °C (230 °F). Higher fluid
CAUTION may also indicate property-damage-only
temperatures may cause damage to the seals and
hazards.
packings on and in the filter unit.

INFO provides additional information to assist in

carrying out the work described and to provide
trouble-free operation.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 5

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1. General information

This manual gives information for one oil filter unit. In case The motor/pump unit is a sealed unit and must not be
of two or more units on the same transformer, all disassembled. It is mounted on the filter house. The oil
procedures are the same for each one of the units. pump is a screw type pump.

1.1 Advantages with an oil filter unit The filter cartridge is delivered separately and it must be
All on-load tap-changers manufactured by ABB are designed mounted in the filter housing by the customer before
and tested for service in transformer oil without any kind of starting the oil filter unit.
filtration. Filtration of oil is necessary only when normal
maintenance is carried out. There is also a pressure gauge which measures the pressure
in the oil filter. At a certain pressure level, a filter cartridge
However, filtering gives the following advantages: replacement is necessary.
• Dielectric strength in the oil is maintained high, important
in line end applications. Each of the filter housings contains a lid with O-ring sealing.
• Eliminates risk for depositing “sludge” in electrically highly
stressed areas. The oil inlet connection is placed at the oil strainer. The oil
• Filtration reduces mechanical wear, which is beneficial in outlet connection is the port at the oil flow switch placed at
applications with high operation frequency. the bottom of the filter housing.
• It simplifies maintenance since no cleaning and no further
oil filtration is necessary. This is also important from a The tubes for connection between the oil filter unit and the
health point of view for the service staff and it also on-load tap-changer are not included in the delivery of the
shortens the transformer outage time. oil filter unit.

1.2 The oil filter unit 1.2.1 Y-strainer

See Fig. 1. See Fig. 1.

The oil filter unit and the filter cartridge are delivered by The oil pump in the filter unit will be damaged if big particles
ABB. The on-load tap-changer is also prepared for (such as welding sparks, dirt from grinding processes or
connection to the oil filter unit. The oil filter unit allows sealing agent) are allowed to enter the pump. To prevent
continuous service of the transformer during filtration. The that, a strainer (pos. 26) with a mesh width of 0.5 mm is
filter unit consists of a filter base, one or two filter housings, delivered with the oil filter unit. This strainer is mounted at
an electric motor, a pump, an electric connection box, a the inlet port of the oil pump.
sample valve and two threaded connections.
When the oil filter unit has been running for a while, e.g. two
There is also a pressure switch that could be used by the months, the strainer must be cleaned from particles. The
customer. The switch changes state when the pressure in cleaning should be repeated at every exchange of filter
the filter is such that a filter cartridge replacement is cartridge, or if, for some reason the oil pipes have been
necessary. This switch does not stop the motor, it only gives dismantled.
information about the filter status.

As an option, a flow switch can be mounted at the oil filter

unit outlet. The switch changes state when the oil flow
through the filter unit is approximately half of the nominal
oil flow. This switch does not stop the motor, it only tells if
there is an oil flow or not.
6 O I L F I LT E R U N I T T Y P E O L U M A N U A L

1. Auxiliary switch
2. Motor protective
switch
3. Pressure switch
4, 5. Pump/motor unit
6. Pressure gauge
7. Filtration element
9. Shunt release
20. Filter housing
21. Connection box
24. Drain plug
25. Lid
26. Y-strainer
27. Flow switch (option)
28. Air vent and oil
sample point, dirty oil
29. Wall bracket

Cable glands
2 pcs. M20 cable 8-13 mm
4 pcs. M16 cable 5-9 mm

Oil inlet G ¾” male acc. to ISO 228-1

Coupling part for flexible hose mounted.

Oil outlet G ¾” male acc. to ISO 228-1

Coupling part for flexible hose mounted.

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01 Oil filter unit OLU1C.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 7

Free space for exchange of filtration element

1) Flow switch is
an option.

N.B. 2 pcs of flexible PTFE-hose with flange for

O-ring sealing delivered with the oil filter and
must be mounted by the customer, according
to the included instructions.

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02 Oil filter unit OLU1C.
8 O I L F I LT E R U N I T T Y P E O L U M A N U A L

1. Auxiliary switch
2. Motor protective switch
3. Pressure switch
4, 5. Pump/motor unit
6. Pressure gauge
7. Filtration element
9. Shunt release
20. Filter housing
21. Connection box
24. Drain plug
25. Lid
26. Y-strainer
27. Flow switch (option)
28. Air vent and oil sample
point, dirty oil
29. Wall bracket

Cable glands
2 pcs. M20 cable 8-13 mm
4 pcs. M16 cable 5-9 mm

Oil inlet G ¾” male acc. to ISO 228-1

Coupling part for flexible hose mounted.

Oil outlet G ¾” male acc. to ISO 228-1

Coupling part for flexible hose mounted.

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03 Oil filter unit OLU1D.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 9

Free space for exchange of filtration element

1) Flow switch is
an option.

N.B. 2 pcs of flexible PTFE-hose with flange for

O-ring sealing delivered with the oil filter and
must be mounted by the customer, according
to the included instructions.

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04 Oil filter unit OLU1D.
10 O I L F I LT E R U N I T T Y P E O L U M A N U A L

1. Auxiliary switch
2. Motor protective
switch
3. Pressure switch
4, 5. Pump/motor unit
6. Pressure gauge
7. Filtration element
9. Shunt release
20. Filter housing
21. Connection box
24. Drain plug
25. Lid
26. Y-strainer
27. Flow switch (option)
28. Air vent and oil sample
point, dirty oil
29. Wall bracket

Cable glands
2 pcs. M20 cable 8-13 mm
4 pcs. M16 cable 5-9 mm

Oil inlet G ¾” male acc. to ISO 228-1

Coupling part for flexible hose mounted.

Oil outlet G ¾” male acc. to ISO 228-1

Coupling part for flexible hose mounted.

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05 Oil filter unit OLU2D.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 11

Free space for exchange of filtration element

1) Flow switch is
an option.

N.B. 2 pcs of flexible PTFE-hose with flange for

O-ring sealing delivered with the oil filter and
must be mounted by the customer, according
to the included instructions.

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06 Oil filter unit OLU2D.
12 O I L F I LT E R U N I T T Y P E O L U M A N U A L

Total length 335

Delivered unmounted

Min. bend radius 135 mm

Flexible hose of PTFE ½” with one braided

layer of stainless steel wire
Min. bend radius 135 mm
Temp. range: -50 °C to +150 °C

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07 Flexible PTFE hose with O-ring sealed flange.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 13

Option

Q> P>

1. Auxiliary switch
2. Protective motor switch
3. Pressure switch
5. Motor
9. Shunt release
27. Flow switch (option)

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08 Circuit diagram for oil filter unit with single phase motor.
14 O I L F I LT E R U N I T T Y P E O L U M A N U A L

Option

Q> P>

1. Auxiliary switch
2. Protective motor switch
3. Pressure switch
5. Motor
9. Shunt release
27. Flow switch (option)

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09 Circuit diagram for oil filter unit with 3-phase motor.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 15

Tube from oil filter outlet, min ½”

View show UCC/UCD

Valve
Flow switch as an option
Tube to oil filter inlet, min ½”

Valve

Oil filter outlet tube, min ½”

From filter To filter

View show UCG View show UCL

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10 On-load tap-changer type UC with oil filter unit.
16 O I L F I LT E R U N I T T Y P E O L U M A N U A L

Tube from oil filter outlet, min ½”

View show UCC/UCD

Valve

Tube to oil filter inlet, min ½”

Flow switch as an option
Valve

Oil filter outlet tube, min ½”

To filter
From filter

View show UCG View show UCL

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11 On-load tap-changer type UC with oil filter unit.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 17

Tube from oil filter outlet, min ½”

Flow switch
as an option Tube to oil filter inlet, min ½”

Valve

Valve

Oil filter outlet tube, min ½”

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12 On-load tap-changer type UZ with oil filter unit.

Tube from oil filter outlet, min ½”

Tube to oil filter inlet, min ½”

Flow
switch as
an option

Valve

Oil filter outlet tube, min ½”

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13 On-load tap-changer type UBB with oil filter unit.
18 O I L F I LT E R U N I T T Y P E O L U M A N U A L

1.3 Electric equipment 1.4 Oil filter circuit

See Figs. 8 and 9. See Figs. 10-13.

All motor control equipments are installed in a connection In the oil filter inlet port and outlet port respectively, there is
box. mounted one half of a swivelling fitting for the supplied
flexible PTFE hose. The PTFE hose must be used for
The oil filter unit needs an electric power supply to the connecting the oil filter unit to the pipe system. It is
motor. This power supply should be connected to the motor essential to do so to reduce noise and vibrations and also to
protective switch in the connection box. avoid excess forces from the pipe system. It is not allowed to
connect the pipe system directly to the oil filter ports,
The pressure switch has three electric connections. The without using the flexible PTFE hose.
signal from this switch is recommended to be used in a
control room as an indication for the need of filter cartridge The oil filter unit should be placed lower than the return
replacement. connection of the on-load tap-changer.

The flow switch (optional) has three electric connections. The oil filtering circuit is nearly the same for all different
The signal from this switch is recommended to be used in a types of ABB on-load tap-changers. The only difference is
control room as an indication that the motor/pump unit is the connection to the on-load tap-changers. The oil filter
pumping sufficient of oil in the right direction. unit inlet tube is connected to the UC and UZ types of on-
load tap-changers by flanges on the oil valves. On UB type of
It is recommended to connect the “low level contact” signal on-load tap-changers, the oil filter unit inlet tube is
from the oil level indicator on the conservator, so it trips the connected to a flange on a tube in the centre of the cover. No
motor protective switch by the trip coil in case of low oil valve is mounted.
level in the conservator due to leakage in the oil filter circuit
or some other cause. All flanges for the oil filter unit inlet tube have dimensions
according to Figs. 14 and 15.
The motor protective switch has a status indication contact
which shows if the motor circuit breaker is off or on. This The oil filter unit inlet tube shall have a valve near the oil
contact is recommended to be connected in a way that filter unit to make it possible to shut off the oil flow in case
makes a trip immediately visible in the control room. of filter cartridge replacement, repair work, etc.

Since the oil filter is working continuously, no other The oil filter unit outlet tube for the UB and UC types of on-
electrical components are necessary. load tap-changers shall be connected to the free flange on
the head of the on-load tap-changer. Dimensions are
according to Fig. 14. The position of this free flange may
vary, depending on where the pressure relay and the tube to
the conservator are connected.

WARNING

Make sure that the oil filter unit outlet tube is not
connected to the OLTC transformer main tank
flange.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 19

The oil filter unit outlet tube for the UZ type of on-load tap-
changers is connected to a flange on the top of the UZ-tank,
see Fig. 12. This flange has dimensions according to Fig. 15.
The exact position is shown on the dimension drawing for
M10
the on-load tap-changer.

The oil filter unit outlet tube shall have a valve near the oil
filter unit to make it possible to shut off the oil flow in case
of filter cartridge replacement, repair work, etc.

It is recommended to install a valve in a T-piece in the inlet

pipe close to the Y-strainer, see Fig. 10. This valve may be
used for draining or filling the conservator.

1.5 Continuous oil filtration a= 18-25 mm

The oil filter unit is working according to the continuous
55
operation principle. Thus the filtration runs continuously
with a low and smooth flow rate, giving the best filtration 75
result. This gives a number of advantages: 100
• Narrower pipes might be used.
• No change in flow rate eliminates release of already
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trapped particles. 14 Flange on on-load tap-changers type UBB and UC.
• Reduced risk of foam or gas bubbles.
• Moisture removal works even if the on-load tap-changer is
not operating.
• This method requires very little control equipment. The
necessary components are placed in the electric control
box.
• Maximum power needed is approximately 370 W per unit. M12
The average power consumption during a life cycle of the
oil filter unit is considerably lower.

1.6 Filtration medium

The oil filter unit should only be used for filtering
transformer oil according to IEC 60296. For other media,
please consult ABB.

52

75

100

130

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15 Flange on on-load tap-changers type UZ.
20 O I L F I LT E R U N I T T Y P E O L U M A N U A L

1.7 Service temperature 1.9 Leakage in the oil filter unit circuit
The ambient temperature may vary between -40˚ C to There is always a risk of leakage in an oil circuit, with a too
+60˚ C (-40˚ F to +140˚ F). low oil level in the on-load tap-changer housing as a result.
This risk can be reduced by using an oil level indicator, with
Normal operating range for the filtrated oil is from 0˚ C to alarm contacts for low level, on the conservator. The signal
+100˚ C (+32˚ F to 212˚ F). should be used to give an alarm in the control room, and to
trip the motor protective switch of the oil filter unit, by
An oil filter unit with a new filter cartridge can be started activating the shunt release coil. See the wiring diagrams in
with an oil temperature down to -25˚ C (-13˚ F) provided the Figs. 8 and 9.
viscosity is 1000 cSt or lower.
1.10 Oil level in the on-load tap-changer
If the filter cartridge has been in service for a while and a
When filling oil into an on-load tap-changer with an
pressure drop has been built up, the pressure switch may
oil filter unit, fill oil in excess into the conservator to
give alarm when starting at low oil temperatures. This can
avoid refilling afterwards!
be avoided by letting the transformer oil be warmed up to at
least 0˚ C (32˚ F) before the oil filter unit is switched on. The
• Approx. 20 liters for oil filter unit with 1 filter cartridge.
pressure switch will give signal until the warm oil from the
• Approx. 40 liters for oil filter unit with 2 filter cartridges.
on-load tap-changer has come into the oil filter unit.
• Approx. 80 liters for oil filter unit with 4 filter cartridges.

If the pressure switch is still giving signal after half an hour,

1.11 Ordering data
wait until the transformer oil has become even warmer and
When ordering an oil filter unit the following must be given:
then start again.
• The motor voltage
• The voltage for the trip coil of the motor circuit breaker.
If the transformer is subjected to many starts in very low
temperature (e.g. spare transformers), make sure that the
1.12 Spare parts
filter cartridge is changed frequently.
Avoid ordering spare filter cartridges until they are
If the service conditions are such that the ambient needed. They can not be stored for more than 24
temperature is very low (often and during long periods months without reduced water removing capacity.
below -10˚ C (-14˚ F), the oil temperature of the transformer See also chapter 7.
is low and the inlet tube is long (>3m), the oil filter unit inlet
tube should be heat insulated.

1.8 Filter cartridge replacement interval

See section 5.2 Maintenance.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 21

1.13 Technical specifications 1.13.2 Motor specification for oil filter unit with 1 cartridge
1.13.1 Technical specification for common parts of an oil type OLU1C50NV
filter unit Motor ABB article number for
Oil pump Settima screw pump a complete oil filter
Flow rate: 250-300 l/h (67-80 gph) unit with motor
Over-pressure valve: Opening pressure 5.0 bar Type: 1-phase, squirrel-cage 1ZSC027410-AAA
Filter cartridge: Type: 50 NVD Data: 110 V/0.37 kW, 50/60 Hz (without flow switch)
Material: Cellulose Speed: 1370-1660 rpm 1ZSC003676-AAA
Specially dried for water absorption Protection class: IP55 (flow switch included)
Filtering grade: 3 µm absolute Type: 1-phase, squirrel-cage 1ZSC027410-AAB
Typically pressure drop at 20 °C temperature and Data: 230 V/0.37 kW, 50/60 Hz (without flow switch)
new filter cartridge: <0.1 bar Speed: 1370-1660 rpm 1ZSC003676-AAB
Max. storage time: 24 months, with undamaged Protection class: IP55 (flow switch included)
package. Type: 3-phase, squirrel-cage 1ZSC027410-AAC
Pressure switch: GEMS PS41 Data: 500 V/0.37 kW, 50/60 Hz (without flow switch)
Adjusted value: 4 bar Speed: 1370-1660 rpm 1ZSC003676-AAC
Max. voltage: 230 V AC, 24 V DC Protection class: IP55 (flow switch included)
Contact rating: Max. current: Res. load 5 A Type: 3-phase, squirrel-cage 1ZSC027410-AAD
Ind. load 3 A at 28 V Data: 208-277 V/0.37 kW, 50/60 Hz (without flow switch)
Protection class: IP67 with 2 meter flying lead Speed: 1370-1660 rpm 1ZSC003676-AAD
Flow switch DKM-1 Protection class: IP55 (flow switch included)
(option): Adjusted value: Approximately 125 l/h (33 gph) Type: 3-phase, squirrel-cage 1ZSC027410-AAE
Contact rating Max. load 250 V, 1.5 A 50 VA (min. load 3 VA) Data: 360-480 V/0.37 kW, 50/60 Hz (without flow switch)
Reed contacts are very sensitive to overload and Speed: 1370-1660 rpm 1ZSC003676-AAE
must be protected against inductive, capacitive or Protection class: IP55 (flow switch included)
resistive overload.
A common way to protect is to use a RC-circuit.
Protection class: IP67 with 2 meter flying lead
Electric connection 2 cable glands M20, cable diameter 8-13 mm
box: 4 cable glands M16, cable diameter 5-9 mm
Max. 2 x 2.5 mm2 wire on each terminal.
Noise: <70 dB (A) acc. to ISO 4412
Connecting tubes: Min. ½“
Connections for oil: Male G ¾ “ acc. to ISO 228-1
Material: Stainless steel, painted carbon steel.
Colour: RAL 7032
22 O I L F I LT E R U N I T T Y P E O L U M A N U A L

1.13.3 Motor specification for oil filter unit with 2

cartridges type OLU1D50NV
Motor ABB article number for
a complete oil filter
unit with motor
Type: 1-phase, squirrel-cage 1ZSC027410-AAF
Data: 110 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAF
Protection class: IP55 (flow switch included)
Type: 1-phase, squirrel-cage 1ZSC027410-AAG
Data: 230 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAG
Protection class: IP55 (flow switch included)
Type: 3-phase, squirrel-cage 1ZSC027410-AAH
Data: 500 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAH
Protection class: IP55 (flow switch included)
Type: 3-phase, squirrel-cage 1ZSC027410-AAJ
Data: 208-277 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAJ
Protection class: IP55 (flow switch included)
Type: 3-phase, squirrel-cage 1ZSC027410-AAK
Data: 360-480 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAK
Protection class: IP55 (flow switch included)

1.13.4 Motor specification for oil filter unit with 4

cartridges type OLU2D50NV
Motor ABB article number for
a complete oil filter
unit with motor
Type: 1-phase, squirrel-cage 1ZSC027410-AAL
Data: 110 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAL
Protection class: IP55 (flow switch included)
Type: 1-phase, squirrel-cage 1ZSC027410-AAM
Data: 230 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAM
Protection class: IP55 (flow switch included)
Type: 3-phase, squirrel-cage 1ZSC027410-AAN
Data: 500 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAN
Protection class: IP55 (flow switch included)
Type: 3-phase, squirrel-cage 1ZSC027410-AAP
Data: 208-277 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAP
Protection class: IP55 (flow switch included)
Type: 3-phase, squirrel-cage 1ZSC027410-AAR
Data: 360-480 V/0.37 kW, 50/60 Hz (without flow switch)
Speed: 1370-1660 rpm 1ZSC003676-AAR
Protection class: IP55 (flow switch included)
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 23

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2. Installation

2.1 General 2.5.2 Inspection on receipt

The oil filter unit should be mounted at ground level to Check that the oil filter unit, the pressure gauge, the
enable maintenance and repair work without de-energizing pressure switch, the flow switch (optional) and the
the transformer and to avoid gas collection. Y-strainer are undamaged. If transport damage is found,
and it is judged that correct operation of the oil filter unit is
Figs. 10-13 shows the valves that are recommended to use in not possible, a damage report should be sent to the
the oil circuit. insurance company. It is also recommended that
photographs are taken of the damaged details. Mark the
A special bracket plate has to be placed on the transformer. photos with ABB’s reference number and the serial number
Dimensions for fixing screw joints, se Fig. 2. of the oil filter unit, and send them to ABB for comments.

For the UC-types of on-load tap-changers up to three units 2.5.3 Temporary storage before assembly
should be mounted one for each of on-load tap-changer. If the oil filter unit is not to be assembled immediately once
the delivery has been approved, keep the oil filter unit and
2.2 Tools the filter cartridge in the delivery package.
• Normal set of hand tools
• Small pipe wrench
CAUTION

2.3 Material
The package of the filter cartridge must not be
• A bucket, oil resistant
opened! The special package ensures maintained
• Cleaning paper
water absorption capacity of the filter cartridge.
• Lubrication for stainless steel connections

2.6 Mounting
2.4 Weight
Mounting may be carried out after mounting of the on-load
• Approximately 40 kg for oil filter unit with 1 filter cartridge
tap-changer in the transformer factory or at commissioning
(OLU1C)
on site.
• Approximately 80 kg for oil filter unit with 2 filter
cartridges (OLU1D)
A clearance of 500 mm is necessary above the filter housing
• Approximately 160 kg for oil filter unit with 4 filter
to enable exchange of filter cartridges. The filter unit should
cartridges (OLU2D)
be mounted on a vibration free surface. In case of vibrations,
vibration absorbing rubber feet should be used. The
2.5 Receiving
pressure gauge should be visible and easy to read. The
2.5.1 Unpacking
sample valves should be easily accessible.
Check that the package is undamaged.

Normally the filter units are delivered in boxes of wooden

material. Therefore only the assembly screws should be
removed.

Lifting of the box should be carried out with a lifting device.

Avoid manually heavy lifting.
24 O I L F I LT E R U N I T T Y P E O L U M A N U A L

2.6.1 Plumbing Try to keep the tubes short and with as few joints and bends
as possible. If the tubes are longer than 5 meters, increase
CAUTION
the tube diameter to 3/4 “.

Do not open the filter cartridge package at this

When the transformer will be operating on sites where the
stage
temperature frequently falls below -10˚ C (+14˚ F), it is
recommended to heat insulate the inlet tube.
Plumbing is recommended to be carried out after oil
filling of the on-load tap-changer.
When the oil filter unit has been running for a while, e.g. two
months, the Y-strainer must be cleaned from particles. The
Start by mounting the oil filter unit to a bracket plate on the
cleaning should be repeated at every exchange of filter
transformer. Manufacture an inlet tube and an outlet tube as
cartridge, or if, for some reason the oil pipes have been
recommended in Figs. 10-13, depending on which type of
dismantled.
on-load tap-changer the filter unit is to be connected to. For
dimensions of connecting flanges, see section 1.4 or the
2.6.2 Electrical connection
dimension drawing delivered with the on-load tap-changer.
WARNING

CAUTION
Make sure that the voltage is properly switched off
before starting wiring work!
Remove the plastic plugs from the inlet and outlet
connections before installation.
Only qualified personnel should attempt installation of
electrical equipment.
Make sure that the tubes are clean before connection to the
on-load tap-changer. Make sure that all O-rings are in place
Make sure that the available voltage and frequency is in
before connecting the flanges.
accordance with the rating of the electric motor.

WARNING Connect the motor supply to the electric connection box as

shown in the wiring diagram in Figs. 8 and 9 in this manual.
Do not mix up inlet and outlet ports on oil filter unit
or on the on-load tap-changer. The filtration will be The pressure switch and the flow switch (optional) should
poor, and in worst case, a flashover may occur in the be connected to give information to the control room if
on-load tap-changer. pressure is over its limit or if oil flow is below its limit.

The connection points are shown in Figs. 10-13. It is also recommended to use an oil level indicator with a
• UCG and UCL have vertical flanges instead of horizontal as contact for low oil level in the conservator, and to connect it
shown in Fig. 11 (UCC). Connect the inlet tube to the valve so a trip from that contact will switch off the motor
with flange. The outlet tube from the oil filter unit is protective switch to the oil filter unit, and to give an alarm in
connected to any one of the free flanges, except to the one the control room. See the wiring diagrams in Figs. 8 and 9.
connected to the transformer tank. Make sure that the motor has correct rotation direction by
• For UBB on-load tap-changers there is a flange connection comparing the rotation of the fan with the arrow on the
without a valve in the centre of the cover. motor.
• On UZ-type of on-load tap-changers there is a special
flange for oil filter unit outlet tube, se the dimension
WARNING
drawing delivered together with the on-load tap-changer
or Fig. 12 in this manual.
If the rotation direction is wrong, the cleaning of the
oil will be poor, and in worst case, a flashover may
occur in the on-load tap-changer.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 25

—
3. Commissioning

Make sure that all valves are closed. See Figs. 10-13.

Do not break the sealed package of the new filter

cartridges until immediately before installation.

1. Dismantle the filter housing lid (item 25) by loosening

the 6 nuts. (See Fig. 19.)
2. Dismantle the filter cartridge assembly bolt with seal,
spring and washers. (See Fig. 20.)
3. Inspect the O-ring at filter housing and replace it if
necessary. (See Fig. 23.)
4. Take the new filter element out of the plastic bag. Check
“use by date”. Throw the plastic bag, together with the
silica gel in a dedicated place. (See Fig. 24.)

Remove the package of silica gel from the new filter

cartridges before installation.

5. Check that an O-ring is fitted to the base of filter

cartridge. (See Fig. 25.)
6. Place the new filter cartridge on to the filter housing
center pipe and carefully lower the cartridge into the
filter housing (item 20). (See Fig. 26.)
7. Remount the filter cartridge assembly bolt with seal,
spring and washers, max. torque 15 Nm. (See Fig. 27.)
8. Remount the filter housing lid (item 25) and tighten the 6
nuts, max. torque 15 Nm. (See Figs. 29 and 30.)
9. For mounting of filter cartridges in the second filter
housing, repeat step 1 – 8.
10. Open the inlet and outlet valves.
11. Open the air vent valve, and the plug on the second filter
housing (item 28) and remove all air from the filter
housing, close valve and plug when no more air comes
out.
12. Fill up conservator with oil if necessary.
13. Start the filter unit.
14. Check that no leaks have occurred.
26 O I L F I LT E R U N I T T Y P E O L U M A N U A L

—
4. Transportation

The oil filter unit may be transported mounted on the 3. Mount the covers on the return flange of the on-load tap-
transformer, provided that it is properly fixed. If the unit changers.
should be dismounted before transportation, proceed as For UBB tap-changers: Mount a cover on the flange for
follows and prepare the on-load tap-changer as stated in the inlet tube.
the applicable guide. 4. Remove all wirings.

If the oil filter unit has been oil filled, drain as follows:
WARNING
1. Shut all valves. Drain all oil from the filter housing
(item 20). The bucket may be emptied several times
Make sure that the voltage is properly switched off
before the draining is completed.
before starting wiring work!
2. Dismount the tubes. Keep the O-rings, the screws, nuts
and the washers.
The oil filter unit is transported in its delivery package which
can be reused.
CAUTION
Remounting at site is done by using appropriate parts
Oil will pour out from the tubes when they are according to section 2.6.
loosened. Prepare for taking care of that oil!
Restart the oil filter unit by using appropriate parts
The sealing in the flange of the on-load tap-changer according to section 3.
work with “rubber excess” which makes the O-rings
looking somewhat damaged, but they can be reused
provided that they are left in their positions or
refitted in the same positions as they had earlier.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 27

—
5. Maintenance

The oil filter unit is maintained during the annual inspection 5.3 Annual inspection
of the on-load tap-changer and during the normal During the annual inspection of the on-load tap-changer,
maintenance of the on-load tap-changer. the pressure gauge is read. Note the reading so the change
from year to year can be seen.
The maintenance needed is replacement of the oil filter
cartridge when necessary and to clean the strainer. The If the pressure is close to 4 bar or more, the filter cartridge
cleaning should be repeated at every exchange of oil filter should be replaced.
cartridge, or if, for some reason the oil pipes have been
dismantled.
The pressure increase goes faster at the end of filter
cartridge lifetime.
When a new oil filter unit has been running for a while, e.g.
two months, the strainer must be cleaned from particles.
If moisture is suspected to have come into the on-load tap-
changer compartment, the filter cartridge should be
During the annual inspection of the on-load tap-changer,
replaced.
check for abnormal noise, heat or vibrations from the oil
filter motor/pump unit. If an oil flow switch is mounted, also
Also check for leakages. All leakages should be repaired.
check that it does not give an alarm signal.

5.4 Maintenance
The motor and pump is a sealed unit and must be replaced
The filter cartridge should be replaced every 2 years, even if
as one unit.
the pressure is lower than 4 bar.

5.1 Tools
For on-load tap-changers with a high switching frequency,
• Normal set of hand tools
e. g. furnace transformers, the filter cartridge is replaced
• Bucket (oil resistant)
when the pressure drop is 4 bar or more, or if moisture is
suspected to have come into the on-load tap-changer
5.2 Material
compartment.
Spare filter cartridge. For ordering, see chapter 7 Spare
parts list.
28 O I L F I LT E R U N I T T Y P E O L U M A N U A L

5.5 Filter cartridge replacement

A filter cartridge replacement could be performed without
turning off other systems.

The filter cartridge must be replaced when there is a

pressure drop of 4 bar over the filter cartridge. (At normal
service temperature)
—
16 Switch off the electric power to the motor.
Do not break the sealed package of the new filter
cartridge until immediately before installation.

1. Stop the motor of the oil filter unit by switching off the
power. (See Fig. 16.)
2. Close the valves in the inlet and outlet tubes.
3. Check that there is no pressure applied to the oil filter
unit when the work is started. The pressure gauge
pointer should be close to 0 bar. (See Fig. 17.)
4. Remove the draining plug (item 24) at the bottom of the
oil filter housing, use an 8 mm allen key or a 27 mm
spanner. (See Fig. 18.) —
17 Close the inlet and outlet valves and check that the pressure is off.
5. Open the air vent valve (item 28), wait till all oil is drained.
6. Dismantle the filter housing lid (item 25) by loosening
the 6 nuts. (See Fig. 19.)

—
18 Unscrew the drain plug and empty out the oil.

—
19 Unscrew the nuts and remove the lid.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 29

7. Dismantle the filter cartridge assembly bolt with seal,

spring and washers. (See Fig. 20.)
8. Pull the filter cartridge/s (item 7) out of the filter
housing (item 20). Use the handle on top of the filter
cartridge. Place them in a suitable vessel. (See Fig. 21)
9. Clean the Y-strainer (item 26) at the oil pump inlet port
10. Clean the inside of the filter housing and the lid if
necessary. (See Fig. 22)

—
20 Unscrew the cartridge screw.

—
21 Remove the filter cartridge with handles.

—
22 Clean the inside of the housing, if necessary.
30 O I L F I LT E R U N I T T Y P E O L U M A N U A L

11. Inspect the O-ring at filter housing and replace it if

necessary. (See Fig. 23)
12. Take the new filter element out of the plastic bag. Check
“use by date”. Throw the plastic bag, together with the
silica gel in a dedicated place. (See Fig. 24)

Remove the package of silica gel from the new filter

cartridges before installation.
13. Check that an O-ring is fitted to the base of filter
cartridge. (See Fig. 25)
14. Place the new filter cartridge on to the filter housing
center pipe and carefully lower the cartridge into the —
23 Inspect the O-ring and replace it if necessary.
filter housing (item 20). (See Fig. 26)

—
24 Take the new cartridge box and check “use by date“.

—
25 Check that the O-ring is fitted to the base of the cartridge.

—
26 Place the cartridge carefully in the housing by using the plastic handle.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 31

15. Remount the filter cartridge assembly bolt with seal,

spring and washers, max. torque is 15 Nm. (See Fig. 27)
16. When the new filter cartridge is in place, mount the
draining plug (item 24) back, use an 8 mm allen key or a
27 mm spanner. (See Fig. 28)
17. Remount the filter housing lid (item 25) and tighten the 6
nuts, max. torque is 15 Nm. (See Figs. 29 and 30)
18. For replacement of filter cartridges in the second filter
housing, repeat steps 6 – 17.
19. Open the inlet and outlet valves.
20. Open the air vent valve and the plug on the second filter
—
housing (item 28). Remove all air from the filter housing, 27 Fit the cartridge screw assembly with seal and washers.
close valve and plug when no more air comes out.
21. Fill up conservator with oil if necessary.
22. Start the filter unit.
23. Check that no leaks have occurred.

CAUTION

A used filter cartridge is a hazardous waste and has

—
to be handled according to local instructions. 28 Fit a new drain plug. A new sealing is included in the cartridge box.

—
29 Fit the lid to the filter housings.

—
30 Tighten the filter lid bolts.
32 O I L F I LT E R U N I T T Y P E O L U M A N U A L

—
6. Repair

Besides replacement of filter cartridge, no repair work is 6.1.4 Remounting

needed. However, after long time in service the ball bearings 1. Reconnect the Y-strainer to the motor/pump unit.
in the motor may be worn or the pumping capacity of the oil 2. Remount the draining plug, use a new sealing.
pump has become too low. 3. Put the motor/pump unit in place on the filter housing
clamp.
The motor/pump unit may also be damaged due to over- 4. Mount and tighten the four screws with washers.
voltage. The motor and pump is a sealed unit and must be 5. Remount the pipes to the motor/pump unit.
replaced as one unit.

6.1 Replacement of pump/motor unit WARNING

For ordering spare motor/pump unit, see chapter 7, Spare
parts list. Make sure that the voltage is properly switched off
before starting wiring work!
6.1.1 Tools
Normal set of hand tools. 6. Reconnect the electrical power supply to the motor.
7. Make a quick start and stop of the motor and check the
6.1.2 Material direction of rotation. The direction is shown with an
• Motor/pump unit arrow on the motor.
• Sealing ring for draining plug
• Bucket, oil resistant
CAUTION
6.1.3 Dismounting
1. Switch off the oil filter unit. If the rotation direction is wrong, the cleaning of the
2. Close the valves in the tubes on both sides of the oil filter oil will be poor, and in worst case, a flashover may
unit. occur in the on-load tap-changer.
3. Put a bucket under the draining plug (item 24) at the
bottom of the filter housing. Drain the filter housing 8. If necessary, change the rotation direction by changing
completely. place of two phases.
9. Open the valves in the tubes on both sides of the oil filter
unit.
WARNING
10. Fill up the filter housing with oil.
11. Open the air valve on top of the lid (item 28) until all air is
Make sure that the voltage is properly switched off
evacuated.
before starting wiring work!
12. Check that no leaks have occurred.
13. Make a final check of the rotation direction of the motor
4. Disconnect the electric power supply cable from the
by closing the valve on the outlet tube slowly. The
motor/pump unit.
pressure gauge should show increasing pressure.
5. Disconnect the pipe from the Y-strainer and the pipe
14. If not, change the rotation direction as described earlier
between pump and filter housing.
and check again.
6. Unscrew the four screws retaining the motor/pump unit
15. Open the valve fully afterwards.
to the filter housing clamp and lift off the motor/pump
unit. Take care of the screws and the washers.
7. Disconnect the Y-strainer from the motor/pump unit.
 O I L F I LT E R U N I T T Y P E O L U M A N U A L 33

6.1.5 Filling up small amount of oil in the oil conservator

When changing oil filter cartridges or motor/pump unit,
there will be a loss of oil in the conservator. Before the oil
level goes so low than an alarm from the oil level indicator
occurs it is necessary to fill up oil in the conservator. It can
be done with help of the oil filter pump.

1. Stop the oil filter unit by switching off the electric power.
2. Close the valves in the inlet and outlet tubes of the oil
filter unit.
3. Connect a clean oil resistant suction hose to the drain/
fill valve and put the free end in a drum with oil of proper
quality and amount, keep the hose as short as possible.
The drain/fill valve is the one mounted between the
Y-strainer and the shut off valve in the oil filter unit inlet
pipe, see Fig. 10.
4. Open the valve in the oil filter unit outlet pipe and open
the drain/fill valve.
5. Start the oil pump.
6. Fill up oil to the correct level in the conservator.
7. Open the valve in the inlet pipe and close the drain/fill
valve.
8. Remove the suction hose and remount the plug to the
drain/fill valve again.
9. If you have difficulties to make the pump suction oil from
the drum, it may help to shut off the oil pump and to
open the valve in the inlet pipe for a short while so a
small amount of oil from the on-load tap-changer can fill
up the suction hose.
10. Then start the oil pump and close the valve in the inlet
pipe. When doing so you must have strict control of the
oil level in the conservator and in the oil drum.
34 O I L F I LT E R U N I T T Y P E O L U M A N U A L

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7. Spare parts list

7.1 Introduction 7.7 General arrangement

This spare parts list has been compiled to help you with The general arrangement of an oil filter unit is shown in
procurement of spares. To obtain trouble-free deliveries you Fig. 1.
should note a few things which are explained in the
following text. 7.8 Standard spare parts
Standard spare parts for the oil filter unit are filter cartridge,
The breakdown level and general contents of this list have O-ring for the lid and motor/pump unit.
been worked out to cover normal customer requests. Our
spare part department will assist if you require any specific 7.9 Special spare parts
item that is not included in the list. If you need parts other than those in the list, our staff will be
happy to assist you. Please use Fig. 1 as a reference when
7.2 Oil filter unit serial number discussing your requirements. As usual, the serial number is
The rating plate on the oil filter unit shows the serial number essential for ordering.
of the device you are ordering spares for. It is important to
have this information, because the manufacture of parts 7.10 Spare parts list for oil filter unit
gradually changes as materials and manufacturing See Fig. 1.
technology improves.
Item Name of item Quantity Article number
ABB makes every effort to supply spares that should fit your Auxiliary switch,motor
requirements. Some parts of later manufacture than those 1 protector 1 1SAM201901R1001
you are replacing may need some adaptation to fit into your 2 Motor protective switch 1 Dependent of motor data
device. Our spare part department needs to know the serial 3 Pressure switch 1 1ZSC003676-ABX
number to supply exactly what you require. Motor/pump assembly
4/5 unit 1 Dependent of motor data
6 Pressure gauge 1 1ZSC003676-ABY
7.3 Item number
Item numbers are shown in Fig. 1 and in the list. 7 Filter element 1, 2 or 4 1ZSC003676-AAV
9 Shunt release 1 Dependent of motor data

7.4 Name of item 21 Connection box 1 1ZSC003676-ACB

The name should be specified when ordering to make sure 24 Drain plug 1 1ZSC003676-ACC
the right type of item is ordered. 26 Y-Strainer 1 1ZSC003676-ACD
27 Flow switch (option) 1 1ZSC003676-AAX
7.5 Quantity 28 Oil sampling valve 1 1ZSC003676-ACE
The figures given represent the number of items that are 29 Wall bracket 1 1ZSC003676-ABZ
fitted to one oil filter unit. Capacitor bracket 1 1ZSC003676-ACF
O-ring for filter
7.6 Remarks housing/lid 1 or 2 1ZSC003676-ACA

Information of the content and reference to Fig. 1.

 O I L F I LT E R U N I T T Y P E O L U M A N U A L 35

—
8. Recycling

8.1 Introduction
The following instructions should only be seen as
recommendations for environmentally sound disposal of
machines. It is the customer's responsibility to ensure that
local regulations are followed.

8.2 Recycling of packaging material

Once the oil filter unit has arrived on site, the packaging
material will need to be removed.
• Any wood packaging can be burned. For some countries,
the packaging used for shipping by sea is made of
impregnated wood that must be recycled according to
local regulations.
• Plastic wrappings can be recycled.

8.3 Scrapping and destruction

The end user has to, when the equipment has served its
time, take care to the current practice and local regulations
for scrapping and destruction.

8.4 Approximate material content

The material used in manufacturing of the oil filter unit is
mainly stainless steel and carbon steel. Also a minor part of,
among others, copper, plastics and rubber are included.

8.5 Hazardous waste

The oil from the filter unit is a hazardous waste and has to
be handled according to local instructions.
—
ABB AB, Components
SE-771 80 Ludvika
Sweden
E-mail: [email protected]

www.abb.com/transformercomponents

1ZSC000562-AAR en, Rev. 2, 2018-05-30

© Copyright 2018 ABB. All rights reserved.

Specifications subject to change without notice.