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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.
ABB makes no warranty or representation and assumes no liability for the
accuracy of the information in this document or for the use of such information. All
information in this document is subject to change without notice.
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.
Content
General information.................................................................................................. 5
Applications........................................................................................................ 5
Design................................................................................................................ 5
Cabinet............................................................................................................... 5
Type tests........................................................................................................... 5
Ambient air temperature...................................................................................... 7
Connection of motor-drive mechanism to tap-changers......................................... 7
Rating plate......................................................................................................... 7
Mechanical arrangements......................................................................................... 8
Drive arrangement............................................................................................... 8
Hand crank ........................................................................................................ 8
One-turn shaft. .................................................................................................... 8
Position indicator. ................................................................................................ 8
Mechanical end-stops......................................................................................... 8
Electrical end-stops............................................................................................. 8
Brake.. ................................................................................................................ 8
Indicator flag....................................................................................................... 9
Operation counter............................................................................................... 9
Holding, interlocking and auxiliary contacts........................................................... 9
Multi-position switches........................................................................................ 9
Position transmitter (S14), potentiometer ........................................................ 9
Continuation contact (S15).............................................................................. 9
Auxiliary contacts........................................................................................... 9
Drive mechanism equipment ............................................................................... 10
Principles of operation.............................................................................................. 14
Raise operation with local control......................................................................... 14
Lower operation with local control........................................................................ 14
Through-positions............................................................................................... 14
Remote control.................................................................................................... 14
Step-by-step-operation....................................................................................... 14
Protection against run-through............................................................................. 14
Contact timing..................................................................................................... 14
Circuit diagram. ................................................................................................... 14
Contact timing diagram........................................................................................ 16
Standard version...................................................................................................... 17
Control................................................................................................................ 17
Protection........................................................................................................... 17
Indication............................................................................................................ 17
Wiring................................................................................................................. 17
Maintenance....................................................................................................... 17
Design options.................................................................................................... 17
Multi-position switches........................................................................................ 17
Technical data..................................................................................................... 18
Dimensions......................................................................................................... 19
General information
Applications
The BUL2 motor-drive mechanism is designed for outdoor
operation of the on-load tap-changers listed below.
Tap-changer
Type of connection
UBB, VUBB
UCG, VUCG
UCL, VUCL
The cabinet has two vents. Filters prevent insects and dust
from entering the cabinet. To prevent condensation inside
the cabinet, a 50-W heater is supplied which is permanently
connected. There is also a 100-W heater, controlled by a
thermostat.
The tightness of the cabinet has been type tested for
protection class IP 66 according to IEC 60529 (protected
against dust and powerful water jets).
The lighting is automatically switched on when the door is
opened.
As standard, the inside of the cabinet has an anticondensation layer.
Type tests
The BUL2 motor-drive mechanism fulfills the requirements of
IEC 60214:2003 and IEEE C.57-131-2012.
E3
135
131
135
130
133
134
104
S8
S1
133
Q1
S2
S9
131
135
132
F2
F1
C
The motor-drive mechanism must be shaded
from solar radiation by screens.
ABB should be consulted.
+70
-40
ABB should be consulted.
Rating plate
The rating plate shows data for both the tap-changer and
motor-drive mechanism and is placed on the upper panel of
the motor-drive mechanism.
Mechanical arrangements
Mechanical end-stops
The upper Geneva wheel 125 is supported by the Geneva
shaft and turns independently of the shaft, controlled by the
upper drive pin 108 on the one-turn shaft. On the Geneva
wheel, two screws 136 are fitted which at the end-positions
operate the mechanical end-stop 113 via arm 147. Extra
screws could be placed between the screws 136 if a
decreased tap-change range is desired.
After the end-position has been reached, the mechanical endstop is pressed out to obstruct knob 148 under the helical
gear 142, which prevents further movement of the outgoing
shaft in that direction.
When the mechanism is returned to the end-position by
manual cranking, the mechanical end-stop will be pressed
back by springs, which also keeps it positioned in all normal
tap-change positions.
The breakpin 114 in the bevel pinion 123 on the crank shaft
105 prevents overloading of the end-stops by hand cranking.
Electrical end-stops
On the lower end of the shaft for arm 147, cam curve 149 is
mounted. When the mechanism is at an end-position, this
cam curve operates limit switches S6 and S7, which break
the operating circuit of the motor and two phases of the
motor supply. Electrical operation beyond the end-positions is
thus impossible.
In event of faulty limit switches, the motor is stopped by the
mechanical end-stop and disconnected when the thermal
overcurrent protection trips the motor protective switch Q1;
see the circuit diagram on page 15.
Brake
On the upper end of the one-turn shaft 107 is cam disc 128,
which controls brake 117 working against brake disc 118 on
top of the intermediate shaft 140. This brake makes sure that
the motor-drive mechanism stops at the correct position after
each tap-change. The brake can be adjusted by screw 150,
which presses against the spring 151 that closes the brake.
Indicator flag
The indicator flag is placed at the end of the indicator
arm116, which is operated by the cam disc 128. The flag
is visible through a slot in the front plate 119. When the
mechanism is in position, the white part of the flag is visible,
and during a tap change the red part is shown.
The indicator flag is also visible through the window in the
door.
Operation counter
A seven-digit mechanical operation counter 120 is also
operated by the indicator arm 116. The counter cannot be
reset and will register the total number of operations carried
out by the motor-drive mechanism. The counter is mounted
on the front plate 119 and is also visible through the window
in the door.
Holding, interlocking and auxiliary contacts
At the lower end of the one-turn shaft is another cam
disc,115, which via lever 129 operates two sets of contacts,
S3 and S4. S3 is affected during raise operations and S4
during lower operations.
The cam disc does not release the lever and the contacts
before the tap-change operation is completed. Before the
start impulse ends, the holding contact 33-34 (see Fig. 9)
closes another feed to the contactor K2 or K3 and thus
keeps the motor running until the operation is completed.
After possible interruption of the supply voltage during an
operation, this contact will also enable completion of the
operation when the supply voltage returns.
The interlocking contacts 41-42 (see Fig. 9) opens the circuit
to the contactor for operation in the opposite direction.
Unintentional change of direction is thus prevented. This
contact also prevents operation in case motor rotation should
be incorrect due to incorrect phase sequence.
The contacts 13-14 and 21-22 (see Fig. 9) are auxiliary
contacts. They can be used for signals to the control room or
remote interlocking during tap-change operation.
Multi-position switches
The lower end of the Geneva shaft 145 is via coupling 111
connected to the multi-position switch shaft 112. The multiposition switch thus moves 1/36 of a turn, 10, per tapchange step.
The multi-position switch 127 is made up of up to 8 different
printed circuit boards, 160. Each board has a contact arm,
161. A slot in the multi-position switch shaft 112 transfers
rotation to a knob on the contact arm. The contacts 162 on
the arm are solid silver rivets and the contact surfaces 163 on
the circuit boards are gold plated. Before delivery, all boards
are insulation tested at 2 kV to ground.
The contacts on each board are protected against dust by
transparent cover 164.
Position transmitter (S14), potentiometer
As standard, the contact device is supplied with a
potentiometer transmitter, which has 10 , 0.6 W resistors
between each position. Other resistors can be supplied upon
request.
Upon request, a suitable measuring amplifier for movingcoil instruments can be supplied. The instrument for remote
position indication in the control room can also be included
upon request.
Continuation contact (S15)
In cases when the tap-changer has two or more positions
with the same voltage, a continuation contact is supplied.
Only one of the positions is the service position; the others
are through-positions that are passed automatically during
an electrical operation. See the description of operation on
page14.
Auxiliary contacts
Auxiliary contacts, break-before-make or make-before-break,
as well as odd-even switches for parallel control, can be
supplied upon request.
Position
Item
Position
Item
B1
Thermostat
114
Breakpin
E1
Anti-condensation heater, 50 W
115
E2
Heater
116
Indicator arm
E3
Lamp
117
Brake
F1
118
Brake disc
F2
119
Front plate
K1
120
Operation counter
K2
Motor contactor
121
Pulley
K3
Motor contactor
122
Pulley
K601
123
Bevel pinion
K602
124
Bevel gear
M1
Motor
125
Q1
126
S1
127
Multi-position switches
S2
Control switch
128
Cam disc
S3/S4
129
130
Rating plate
131
Hinges
132
S5
133
Door
S6/S7
134
Hand knob
S8
135
Air vent
S9
Door-operated switch
136
S14
140
Intermediate shaft
S15
Continuation contact
141
Helical pinion
U5
142
Helical gear
143
101
Toothed belt
144
Support
102
Helical gear
145
Geneva shaft
103
Outgoing shaft
146
104
Hand crank
147
105
Crank shaft
148
106
Helical pinion
149
Cam curve
107
One-turn shaft
150
108
151
109
Bevel gear
160
110
161
Contact arm
111
Coupling
162
112
163
113
Mechanical end-stop
164
Transparent cover
109
146
143
116
119
120
128
108
110
125
136
106
126
102
115
107
129
117
S3
S4
145
111
118
148
150
113
151
136
147
141
S7
142
149
112
160
127
(S14, S15)
140
122
101
121
M1
104
105
123
114
124
103
161
164
162
160
163
112
120
119
110
144
136
106
103
125
142
150
117
Fig. 6. View of the drive mechanism from above.
116
107
128
109
105
S5
M1
104
B1
E1
E2 K601 K602 K1
K2
K3
U5
Fig. 7.
Principles of operation
Circuit diagram for AC supply, see Fig. 8. The feeds for the
motor, control circuits and heater are connected to their
respective terminal blocks according to the instructions on the
diagram.
Raise operation with local control
When switch S1 is set at position Local, the mechanism can
be operated by control switch S2. For a raise operation, the
procedure is as follows:
Motor contactor K2 is energized, the contactor closes the
motor phases, the motor starts and runs the mechanism
in the raise direction. After about 0.2 seconds, the brake is
released, and after about 0.4 seconds, the holding contact
S3: 33-34 closes and takes over feed of contactor K2 when
control switch S2 is released.
Switching in the tap-changer takes place after about
3seconds.
The drive mechanism continues until the cycle is completed,
which takes about 5 seconds. About 0.2 seconds before
the cycle is completed, the holding contact S3 is released,
contactor K2 falls and feed to the motor is disconnected.
At the same time, the brake is engaged and the mechanism
stops at the new position.
Lower operation with local control
A similar cycle is performed, but in the lower direction, when
the control switch S2 is switched to the lower position and
contactor K3 is activated.
Remote control
Control selector switch S1 is placed at the Remote position.
The control supply for the remote pushbuttons or regulating
relay is then received from a terminal in the motor-drive
mechanism cabinet. Incoming control circuits for raise and
lower impulses should be connected to other terminals as
shown in the diagram. Local operation is not possible when
switch S1 is at the Remote position and remote operation is
not possible at the Local position.
Step-by-step-operation
Step-by-step relay (K1) is connected so that only one tapchange operation is made each time the raise/lower switch is
operated.
Protection against running-through
A relay (K601) stops the motor-drive mechanism in case of a
failure of the step-by-step control circuit, which would cause
a running-through of the motor-drive mechanism. The relay
energizes the trip coil in the protective motor switch (Q1).
Contact timing
The contact timing diagram, Fig. 9, shows the contact
sequences for one change of tap position for the raise and
lower directions.
Circuit diagram
The diagram shows the mechanism at the middle position.
Towards motor-drive upper limit
Towards motor-drive lower limit
Through-positions
A through-position is a position the tap-changer must pass
without changing the ratio of the transformer. These positions
are passed automatically. The continuation contact S15
bridges the holding contacts S3:33-34 and S4:33-34 via
auxiliary contacts on raise contactor K2 at through-positions.
In this way, the contactor K2 raise, or K3 lower, is kept
energized and the motor will automatically conduct another
operation.
The connection of S15 to auxiliary contacts on K2 means that
the drive, in the event of a control supply failure in a throughposition, always moves to a lower normal service position
when the voltage returns.
LOCAL control
REMOTE control
n n+1
1 tap
n n-1
1 tap
Upper limit-position
Lower limit-position
PE
Protective ground
Crank
INITIATION
PREPARED FOR
PROTECTION RELAY
REMOTE
TRIPPING
HOLDING CIRCUIT
CIRCUIT BREAKER
OFF
UPPER LIMIT
LOWER LIMIT
CLOSED AT
UPPER LIMIT
CLOSED AT
LOWER LIMIT
STEP-BY-STEP
IN OPERATION
STEP-BY-STEP
DE-ENERGIZED
2) REMOVE CONNECTION X4:1-2 TO DISABLE STEPBY-STEP FUNCTION AND X3:11-12 TO DISABLE THE
RELAY K601 (RUN-THROUGH PROTECTION).
REMOTE
LOCAL
ITEM F2 OFF
TAP-CHANGE IN
PROGRESS
ITEM Q1 ON
ITEM Q1 OFF
TAP-CHANGE
INCOMPLETE
REMOTE
LOCAL
TURNS ON
HAND CRANK OF
MOTOR-DRIVE
MECHANISM
POS.
POS.
POS.
POS.
CONTACT
(MBB)
(S14)
(S15)
(BBM)
UPPER
LIMITPOS.
TAP-CHANGE OPERATION
LOWER
LIMITPOS.
Standard version
Control
Control selector switch, Local-0-Remote.
Control switch, Raise-0-Lower.
Hand crank for manual operation.
Wiring
The wiring is executed with grey polyvinylchlorideinsulated, stranded wire. Each wire is marked with numbers
corresponding to terminal numbers. All external connections
are made with thermosetting resin. For type and data, see
Technical data.
Protection
Circuit breaker in heater + control circuit
Protective switch for the motor with thermal overload
release and magnetic overcurrent release.
Limit switches in both control and motor circuits.
Mechanical end-stops.
Interlocking contact in the control circuit to prevent
electrical operation during manual operation.
Interlocking contacts in raise and lower control circuits to
prevent operation in incorrect direction of rotation (with
incorrect phase sequence).
Motor contactors are electrically interlocked.
Protection against run-through in case of a failure of the
step-by-step control circuit.
Emergency stop pushbutton.
Indication
Mechanical position indicator
Drag-hands for max. and min. position indication.
Red flag for indication of tap-changer in progress.
Operation counter.
Design options
For previously prepared design options, please see the
ordering data form. If other options are required, please
consult ABB.
(The four items above are visible through the window in the
cabinet door.)
Multi-position switches
Maximum of 8 contact rows can be accommodated, including
one continuation contact when there are through-positions.
Position transmitter
Auxiliary contact
Auxiliary contact
Break-before-make
Make-before-break
Type 1
Type 2
Technical data
Subject
Standard version
Motor voltage
220-240 V, 50 Hz
220 V, 1-phase, 50 Hz
380-420 V, 50 Hz
240 V, 1-phase, 60 Hz
208 V, 60 Hz
120 V, 1-phase, 60 Hz
220-240 V, 60 Hz
110-127 V DC
380-420 V, 60 Hz
220 V DC
440-480 V, 60 Hz
Voltage for control circuit
110 V, 50 Hz
230-240 V, 60 Hz
120 V, 50 Hz
250-260 V, 60 Hz
220-230 V, 50 Hz
24 V DC
240 V, 50 Hz
48 V DC
110-120 V, 60 Hz
110 V DC
127 V, 60 Hz
125-127 V DC
208 V, 60 Hz
220 V DC
220 V, 60 Hz
Voltage for heater
100-240 V AC
Multi-position switches
0.15 A, 230 V AC
0.15 A, 220 V DC
L/R = 40 ms
Optional
Phnix UK 5N
41 A, 800 V AC acc. to IEC
Cross-section area: 0.5 - 4 mm 2
210 - Phnix UK 5N
options)
Cabling
Optional
Heaters
50 W
Humidistat
5s
> 0.5 s
15
30 Nm
35
C4
C5MH
Dimensions
408
Weight: 95 kg
49
1274 1197
1212
37
A
560
45
21
79
626
475
384
75
202
33
A
146
34
80
45
213
Ground
connection M12
91.5 36.5
352.5
475
292
2 x FL 33
550
A
Max 120
36
6 x 12.5
30
M12
Anti-vibration pad
293
A-A
6
75
ABB AB
Components
SE-771 80 Ludvika, Sweden
Phone: +46 240 78 20 00
Fax:
+46 240 121 57
E-Mail: sales@se.abb.com
www.abb.com/electricalcomponents
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