02en
02en
02en
VM®I HD
Operating Instructions 2332893/02
© All rights reserved by Maschinenfabrik Reinhausen
Copying and distribution of this document and the utilization and communication of its contents are strictly prohibited
unless expressly authorized.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent,
utility model or ornamental design registration.
The product may have been modified after this document went to press.
We expressly reserve the right to make changes to the technical data, the design or the scope of delivery.
Generally, the information provided and the arrangements agreed during processing of the relevant quotations and
orders are binding.
The original operating instructions were drawn up in German.
Table of contents
Table of contents
1 Introduction................................................................................... 9
1.1 Manufacturer............................................................................................. 9
2 Safety ........................................................................................... 13
3 Product description.................................................................... 21
3.4 Setup/design........................................................................................... 24
4.1 Packaging............................................................................................... 29
4.1.1 Purpose .............................................................................................................. 29
4.1.2 Suitability ............................................................................................................ 29
4.1.3 Markings............................................................................................................. 30
5.3.1 Securing tap selector on diverter switch oil compartment (not required for
VACUTAP® VM 300).......................................................................................... 59
5.3.2 Connecting tap selector take-off leads (not needed for VACUTAP® VM 300) ... 63
5.3.3 Inserting on-load tap-changer into supporting structure (required for all
VACUTAP® VM®) ............................................................................................. 65
5.3.4 Removing on-load tap-changer head ................................................................. 69
5.3.5 Mounting the bell-type tank ................................................................................ 80
5.3.6 Mounting on-load tap-changer head on bell-type tank ....................................... 81
5.3.7 Connecting on-load tap-changer head and on-load tap-changer ...................... 83
5.3.8 Inserting diverter switch insert ............................................................................ 86
5.3.9 Inserting tap-change supervisory control (if present) ......................................... 89
5.3.10 Inserting tap position indicator............................................................................ 90
5.3.11 Securing on-load tap-changer head cover ......................................................... 93
7.1 Transformer ratio test with TAPMOTION® TD test drive ...................... 107
10.3 Fitting motor-drive unit (see Chapter 17.13, 17.14) ................................ 144
12.2 Transport with oil fill and without oil conservator .................................. 156
15 Troubleshooting........................................................................ 163
17.5 Lifting traverse for bell-type tank installation (890180) ......................... 176
17.9 Tracing template for on-load tap-changer head (890183) .................... 180
18 MR worldwide............................................................................ 187
1 Introduction
This technical file applies to all on-load tap-changer versions which are listed in
the technical data available to you.
This technical file contains detailed descriptions on the safe and proper mount-
ing, connection, commissioning and monitoring of the product.
It also includes safety instructions and general information about the product.
This technical file is intended solely for specially trained and authorized person-
nel.
1.1 Manufacturer
The information contained in this technical file comprise the technical specifica-
tions approved at the time of printing. Significant modifications will be included
in a new edition of the technical file.
The document and version numbers of this technical file are shown in the footer.
1.3 Completeness
The technical data (product-specific technical data and technical data – general
section), unpacking instructions, accompanying connection diagrams and the
operating instructions for the following devices also apply in addition to this
technical file.
• Protective relay RS 2001
• TAPMOTION® ED motor-drive unit
• Drive shaft
All documents form part of the scope of delivery.
Generally applicable legal and other binding regulations of European and
national law and the regulations for accident prevention and environmental pro-
tection in force in the country of use must also be complied with.
1.5 Safekeeping
This technical file and all supporting documents must be kept ready to hand and
accessible for future use at all times.
SIGNAL WORD!
Danger
Consequences
Action
Action
Pictogram Meaning
Danger
Fire hazard
Danger of tipping
Important information
2 Safety
This technical file contains detailed descriptions on the safe and proper mount-
ing, connection, commissioning and monitoring of the product.
• Read this technical file through carefully to familiarize yourself with the
product.
• Particular attention should be paid to the information given in this chapter.
The product and associated equipment and special tools supplied with it comply
with the relevant legislation, regulations and standards, particularly health and
safety requirements, applicable at the time of delivery.
If used as intended and in compliance with the specified requirements and con-
ditions in this technical file as well as the warning notices in this technical file
and attached to the product, then the product does not present any hazards to
people, property or the environment. This applies throughout the product's full
life, from delivery through installation and operation to disassembly and dis-
posal.
The operational quality assurance system ensures a consistently high quality
standard, particularly in regard to the observance of health and safety require-
ments.
The on-load tap-changer is not intended to be used with an oil filter unit.
DANGER!
Danger of death and severe injury!
Danger of death and severe injury due to electrical voltage, falling and/
or tipping parts as well as dangerous cramped conditions resulting from
moving parts.
NOTE
Damage to property and the environment!
Since the on-load tap-changer was dimensioned as per IEC 60214-1, it can
switch currents of up to twice the value of the rated through current.
No tap-change operations may be performed in operating states with higher
currents.
The height of the oil conservator is calculated for the on-load tap-changer from
the upper edge of the on-load tap-changer cover to the oil level in the oil con-
servator (Figure 1, Figure 2).
1 On-load tap-changer
2 Motor-drive unit
3 Protective relay
4 Oil conservator
The product is designed solely for use in electrical energy systems and facilities
operated by appropriately trained staff. This staff comprises people who are
familiar with the installation, assembly, commissioning and operation of such
products.
• The product is only used when in a sound operational condition and safety
equipment in particular is checked regularly for operational reliability.
• Only replacement parts, lubricants and auxiliary materials which are autho-
rized by the manufacturer are used.
• The specified operating conditions and requirements of the installation loca-
tion are complied with.
• All necessary devices and personal protective equipment for each activity
are made available.
• The prescribed maintenance intervals and the relevant regulations are com-
plied with.
• Installation, electrical connection and commissioning of the product is only
carried out by personnel qualified and trained in accordance with this tech-
nical file.
• The operator must ensure appropriate use of the product.
Always wear
Protective clothing
Close-fitting work clothing with a low breaking strength, with
tight sleeves and with no protruding parts. This clothing mainly
serves to protect the wearer against being caught by moving
machine parts.
Do not wear any rings, necklaces or other jewelry.
Safety shoes
To protect against falling heavy objects and slipping on slippery
surfaces.
Safety glasses
To protect the eyes from flying parts and splashing liquids.
Hard hat
To protect from falling and flying parts and materials.
Hearing protection
To protect from hearing damage.
The following protective devices for the on-load tap-changer are included as
standard in the scope of delivery or are available as options.
The rupture disk is a pressure relief device without signaling contact in accor-
dance with IEC 60214-1 and is located in the on-load tap-changer head cover.
The rupture disk responds to a defined overpressure in the diverter switch oil
compartment.
The tap-change supervisory control monitors both the drive shaft between
on-load tap-changer(s) and motor-drive unit and the correct switching of the
diverter switch.
The temperature monitoring device monitors the oil temperature in the diverter
switch oil compartment.
3 Product description
On-load tap-changers are used to adjust the desired tap of a tap winding under
load.
During the tap-change operation the fine tap selector first selects the desired
tap of the tap winding. The diverter switch then switches from the current-carry-
ing tap to the preselected tap. During this tap-change operation one tapping
step of the tap winding is briefly bridged with an ohmic resistor so that the
diverter switch operation can be carried out without current interruptions.
1 On-load tap-changer
2 Motor-drive unit
With VACUTAP® VM 300, the tap selector is already secured to the oil com-
partment.
Please note:
1. Check the delivery for completeness against the dispatch documents.
2. Store the parts in a dry place until installation.
3. Keep the on-load tap-changer in its airtight, protective packaging and only
remove just prior to installation.
3.4 Setup/design
The on-load tap-changer head is provided with 4 pipe connections for different
purposes (Figure 6 and Chapter 17.6).
After the pressure ring (4 M10/wrench 17 screws) has been loosened, 2 pipe
connections (R and S) can be freely swiveled.
Pipe connection S features a vent screw and should be connected to a pipe that
ends with a drain valve on the side of the transformer tank at operating height.
Pipe connection Q is closed with a blank cover and is intended for connecting
the motor-drive unit to the optional tap-change supervisory control. (Chapter
17.7).
The pipe connection E2 is closed with a blank cover. It leads into the oil tank of
the transformer, directly below the on-load tap-changer head and can be con-
nected to a collection pipe for the Buchholz relay, if necessary.
4.1 Packaging
4.1.1 Purpose
The purpose of the packaging is to protect the packaged goods both during
transportation and loading/unloading as well as during storage so that they can-
not be changed in any way (to their detriment). The packaging must protect the
packaged goods from permissible transportation stresses such as jarring, jolt-
ing, moisture (rain, snow, condensation). The packaging also prevents unde-
sired position changes within the packaging. The packaged goods must be pre-
pared for shipment before actually being packed so that the goods can be
transported safely, economically and in accordance with regulations.
4.1.2 Suitability
4.1.3 Markings
The packaging bears a signature with symbols with instructions for safe trans-
port and correct storage. The following pictograms apply to shipment (of non-
hazardous goods) (Figure 7). It is essential that these pictograms are adhered
to.
WARNING!
Danger of death and severe injury!
Only trained and appointed persons may select the sling gear and secure
the load.
Do not walk under the hanging load.
Use means of transport and hoists with a carrying capacity of > 500 kg.
NOTE
Damage to property!
Only trained and appointed persons may select the sling gear and secure
the load.
Do not walk under the hanging load.
Use means of transport and hoists with a carrying capacity of > 500 kg.
In addition to oscillation and shock stress, jolts must also be expected during
transportation. In order to prevent possible damage, avoid dropping, tipping,
knocking over and colliding with the product.
If a crate falls from a particular height (e.g. when slings tear) or experiences an
unbroken fall, damage must be expected regardless of the weight.
Every delivered shipment must be checked for the following by the recipient
before acceptance (acknowledgment of receipt):
• Completeness based on the delivery slip
• External damage of any type.
The checks must take place after unloading when the crate can be accessed
from all sides.
NOTE
Damage to property!
When damages are hidden, i.e. damages which are not determined until
unpacking after the receipt of the shipment, proceed as follows:
• Immediately make liable the party which may have caused the damage (by
phone and in writing) and prepare a damage report.
• Observe, in this regard, the time periods applicable to such actions in the
respective country. Inquire about these in good time.
With hidden damage, it is very hard to make the transportation company (or
other responsible party) liable. Any insurance claims for such damages can only
be successful if relevant provisions are expressly included in the insurance
terms and conditions.
The following requirements should be met when selecting and setting up the
storage location.
• Stored goods are protected against moisture (flooding, water from melting
snow and ice), dirt, pests such as rats, mice, termites and so on, and against
unauthorized access.
• Crates are placed on wooden blocks and boards as a protection against
ground moisture and for improved ventilation.
• Carrying capacity of the ground under the goods is sufficient.
• Entrance and exit paths are kept free.
Check stored goods at regular intervals. Also take appropriate action after
storms, heavy rain or snow and so on.
Protect the packaging foil from direct sunlight so that it does not disintegrate
under the influence of UV rays and the packaging loses its sealing function.
If installation is delayed beyond the expected life span of the sealed packaging,
suitable measures must be taken before the sealing effect is lost. The following
measures can be used:
• Correctly regenerate the drying agent and restore the sealed packaging.
• Unpack the packed goods and store in suitable storage space (well
ventilated, as dust-free as possible, humidity < 50 %).
NOTE
Damage to property!
• Wherever possible transport the packaged crate to the place where installa-
tion will take place.
• When unpacking, check the condition of the packaged goods.
• Check the mounting materials kit against the delivery slip for completeness.
A mounting flange is required for fitting the on-load tap-changer head on the
transformer cover. This can be supplied as an option or can be produced by the
customer. Mounting flanges made by the customer must comply with Figure 10
and Chapter 17.2.
Fit mounting flange on transformer cover (Figure 10).
To fit the stud bolts on the mounting flange, use a tracing template (Figure 11
and Chapter 17.9). On request, this can be supplied free-of-charge the first
time the on-load tap-changer is fitted.
Marking
Figure 11 Tracing template
1. Place tracing template on mounting flange and use the four markings to align
(Figure 11).
2. Fit stud bolt (M12, maximum 45 mm long) on mounting flange (Figure 12).
Sealing surface
Before installing the on-load tap-changer, remove the red colored packaging
and transport material from the on-load tap-changer.
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
NOTE
Damage to property when lowering the diverter switch oil compartment!
If the diverter switch oil compartment is not lowered vertically into the
cover opening, the screening rings on the diverter switch oil
compartment may be damaged (only if Um ≥ 170 kV).
3. Lift the on-load tap-changer and carefully lower into the cover opening of the
transformer (Figure 23).
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
Figure 16 Tap selector with hexagonal recess head screws, spring washers
and nuts
3. Remove the cable tie from the tap selector coupling (Figure 17). Once the
cable is removed, the tap selector coupling may no longer be turned.
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
6. Lift the diverter switch oil compartment by hooking up the on-load tap-
changer head and carefully raise above tap selector.
7. Match the position of the two coupling parts and the attachment points of
diverter switch oil compartment and tap selector. The correct position of the
two coupling parts is shown in the adjustment plan supplied.
8. Use 6 hexagonal recess head screws M12/wrench 8 (screw head and spring
washer on outside, nut on inside) to screw tap selector suspension on to
diverter switch oil compartment (tightening torque 60 Nm, Figure 19).
Figure 19 Diverter switch oil compartment and tap selector screwed down
NOTE
Incorrectly connecting the tap selector take-off leads will result in damage to
property!
3
5
4
1 2
1 Hexagon screw
2 Screening cap
3 Washer
4 Tap selector take-off lead
5 Connecting piece
2. Fit screening caps to screw connections and fold up lugs on hexagon screw.
The screening caps differ depending on insulation to ground (Figure 21).
NOTE
Damage to property when lowering the diverter switch oil compartment!
If the diverter switch oil compartment is not lowered vertically into the
cover opening, the screening rings on the diverter switch oil
compartment may be damaged (only if Um ≥ 170 kV).
2. Lift the on-load tap-changer and carefully lower into the cover opening of the
transformer (Figure 23).
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
NOTE
Damage to property when lowering the diverter switch oil compartment!
If the diverter switch oil compartment is not lowered vertically into the
cover opening, the screening rings on the diverter switch oil
compartment may be damaged (only if Um ≥ 170 kV).
4. Lift the diverter switch oil compartment by hooking up the on-load tap-
changer head and carefully lower the oil compartment into the cover opening
of the transformer (Figure 27).
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
Figure 29 Tap selector with hexagonal recess head screws, spring washers
and nuts
3. Remove the cable tie from the tap selector coupling (Figure 30). Once the
cable tie is removed, the tap selector coupling may no longer be turned.
4. Place the tap selector on a lifting device (max. tap selector weight 165 kg).
NOTE
Damage to property when lifting tap selector!
The tap selector take-off leads may be damaged when lifting the tap
selector!
Carefully lift tap selector ensuring that the tap selector take-off leads are free
when lifting the tap selector on the diverter switch oil compartment and do
not touch the compartment.
5. Raise the tap selector below the diverter switch oil compartment.
6. Match the position of the two coupling parts and the attachment points of
diverter switch oil compartment and tap selector. The correct position of the
two coupling parts is shown in the adjustment plan supplied.
7. Use 6 hexagonal recess head screws M12/wrench 8 (screw head and spring
washer on outside, nut on inside) to screw tap selector suspension on to
diverter switch oil compartment (tightening torque 60 Nm, Figure 31).
Figure 31 Diverter switch oil compartment and tap selector screwed down
NOTE
Incorrectly connecting the tap selector take-off leads will result in damage to
property!
3
5
4
1 2
1 Hexagon screw
2 Screening cap
3 Washer
4 Tap selector take-off lead
5 Connecting piece
2. Fit screening caps to screw connections and fold up lugs on hexagon screw.
The screening caps differ depending on insulation to ground (Figure 33).
Before installing the on-load tap-changer, remove the red colored packaging
and transport material from the on-load tap-changer.
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
Figure 34 Tap selector with hexagonal recess head screws, spring washers
and nuts
3. Remove the cable tie from the tap selector coupling (Figure 35). Once the
cable tie is removed, the tap selector coupling may no longer be turned.
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
6. Lift the diverter switch oil compartment by hooking up the on-load tap-
changer head and carefully raise above tap selector.
7. Match the position of the two coupling parts and the attachment points of
diverter switch oil compartment and tap selector. The correct position of the
two coupling parts is shown in the adjustment plan supplied.
8. Use 6 hexagonal recess head screws M12/wrench 8 (screw head and spring
washer on outside, nut on inside) to screw tap selector suspension on to
diverter switch oil compartment (tightening torque 60 Nm, Figure 37).
Figure 37 Diverter switch oil compartment and tap selector screwed down
5.3.2 Connecting tap selector take-off leads (not needed for VACUTAP®
VM 300)
NOTE
Incorrectly connecting the tap selector take-off leads will result in damage to
property!
3
5
4
1 2
1 Hexagon screw
2 Screening cap
3 Washer
4 Tap selector take-off lead
5 Connecting piece
2. Fit screening caps to screw connections and fold up lugs on hexagon screw.
The screening caps differ depending on insulation to ground (Figure 39).
NOTE
Damage to on-load tap-changer and risk of malfunction resulting from tension!
NOTE
Damage to on-load tap-changer resulting from tension!
If the on-load tap-changer does not reach its final installation height
when the tap winding and on-load tap-changer take-off lead are
connected, once these have been connected tension may occur which
will damage the on-load tap-changer and transformer!
1
2
1 Supporting flange
2 Spacer
3 Supporting structure
1 Supporting flange
2 Spacer
3 Supporting structure
2. Remove the wooden support on the bottom of the change-over selector (if
present).
NOTE
Damage to on-load tap-changer and transformer from blocking of diverter
switch!
Small parts in the diverter switch oil compartment may block the
diverter switch, thereby damaging the on-load tap-changer and
transformer!
Ensure that parts do not fall into the diverter switch oil compartment.
Check you have the same number of small parts when disassembling and
reassembling.
2. Remove the on-load tap-changer head cover. Check that the sealing
surfaces on the on-load tap-changer head cover and on-load tap-changer
head are in sound condition when removing and during all other work.
Ensure that o-ring is in sound condition too (Figure 45).
1 O-ring
Figure 46 Tap position indicator disc for on-load tap-changer without multiple
coarse change-over selector
5.3.4.2.2 Design with multiple coarse change-over selector with more than 35
operating positions (version with short panel)
1. Move on-load tap-changer to adjustment position (see detailed connection
diagram).
2. Remove countersunk head screw M5x12/wrench 3 (Figure 47).
3. Lever cover disk off underlying washer with flat screwdriver (Figure 48).
4. Pull number disc out horizontally from between panel and bracket
(Figure 48).
5. Remove both hexagon screws M5x12/wrench 8 and associated lock tab
(Figure 49).
6. Pull panel and bracket up and off indicator drive shaft (Figure 50).
NOTE
Damage to on-load tap-changer resulting from defective tap-change
supervisory control!
1. Lift plug connector and leads out of bracket and retaining clamps (Fig-
ure 51).
2. Insert the lifting gear in the lugs provided on the diverter switch insert carrier
plate and position vertically above the diverter switch insert.
3. Lift the diverter switch insert slowly and vertically out of diverter switch oil
compartment (Figure 57).
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
Once the diverter switch insert has been removed, the position of the tap
selector coupling must not be changed during assembly work.
2. Lift off the on-load tap-changer head from the supporting flange (Figure 60).
2. Lift the bell-type tank over the active part of the transformer. Ensure
concentricity between bell-type tank duct and on-load tap-changer
(Figure 62).
Figure 63 Gasket
1 Gasket
2 Mounting flange
Figure 64 Markings
NOTE
Incorrectly lifting the on-load tap-changer will damage it!
If the supporting flange's connection screws are used to lift the on-load
tap-changer, these screws may be damaged which means that the on-
load tap-changer and on-load tap-changer head cannot be correctly
screwed down.
Always lift the on-load tap-changer with the specified lifting traverse, and
never with the connection screws of the supporting flange.
NOTE
Inaccurate positioning of the on-load tap-changer head will damage the on-
load tap-changer!
Make sure that all supporting flange stud bolts go easily through the
mounting holes of the on-load tap-changer head when lifting the on-load
tap-changer.
5-20 mm
1. To fit the diverter switch insert, ensure that the tap selector coupling is in the
adjustment position (Figure 70).
2. Insert the lifting gear in the lugs provided on the diverter switch insert carrier
plate and position vertically above the diverter switch insert.
3. Align diverter switch insert such that the red markings at the top of the
energy accumulator (Figure 72 and Chapter 17.6) and on the on-load tap-
changer head are opposite one another.
Figure 73 Carrier plate of diverter switch insert for standard transformer design
The tap position indicator disc can only be installed using the coupling pin when
in the correct position.
1. Place tap position indicator disc on indicator drive shaft, slide spring clip on
to shaft end (Figure 77).
Figure 77 Tap position indicator disc for on-load tap-changer without multiple
coarse change-over selector
5.3.10.2 Design with multiple coarse change-over selector with more than
35 operating positions (version with short panel)
1. Place panel with bracket on indicator drive shaft and secure with 2 hexagon
screws M5x12/wrench 8 and associated lock tab (Figure 78).
2. Insert number disc horizontally between panel and bracket and fit cover disk
(Figure 79).
NOTE
Damage to on-load tap-changer resulting from damaged o-ring!
A damaged o-ring in the on-load tap-changer head cover will cause oil
to escape from the diverter switch oil compartment, resulting in on-load
tap-changer damage.
Take care not to damage the o-ring inserted in the on-load tap-changer head
cover.
NOTE
Mechanical loads will damage the on-load tap-changer!
The tap winding and on-load tap-changer take-off lead must be connected in
accordance with the connection diagram included with the delivery.
The tap selector connection contacts are indicated on the tap selector bars. The
crimped ends of the contacts are provided with a through-hole for M10 screws
(M8 screws for VACUTAP® VM 300) to allow the tap selector take-off leads to
be connected by means of cable sockets (Figure 83, Figure 84).
In this case a locking washer must be placed below each screening cap. The
M10 connection screws, the nuts and locking washers are not included in the
scope of delivery.
The through-holes of the connection contacts are vertical in the VACUTAP® VM
300. In all other VACUTAP® VM®, the through-holes are either horizontal or ver-
tical, depending on the on-load tap-changer version (see Chapter 17.3).
6 Connecting the tap winding and on-load tap-changer take-off lead
6.1.1 Tap selector connection contacts for design with multiple coarse
change-over selector
With multiple coarse change-over selectors, care must be taken when laying
the cables for connection to the tap selector connection contacts and multiple
coarse change-over selector connection contacts. These cables should be
spaced as far away as possible from neighboring connection contacts.
The tap selector connection contacts which face the two multiple coarse
change-over selector columns must be insulated with at least 3 mm of paper to
ensure dielectric strength (Figure 86).
Also observe the information provided on the dimensional drawing on which the
order is based.
The (+) and (-) change-over selector connection contacts are designed as con-
necting lugs with through-holes for M10 screws for reversing change-over tap
selection.
Connection contact K is designed as an extended fine tap selector connection
contact (also with through-hole for M10 screws, Figure 87).
NOTE
Damage to on-load tap-changer due to blocking of change-over selector!
Figure 88 Tap selector for reversing change-over selection (view from above)
1 Connection contact
2 Movable parts
The (+) and (-) change-over selector connection contacts are designed as con-
necting lugs with through-holes for M10 screws for reversing change-over tap
selection.
Connection contact K is designed as an extended fine tap selector connection
contact (also with through-hole for M10 screws, Figure 89).
With coarse tap selection, the (+) and (-) change-over selector connection con-
tacts are secured to the respective laminated paper bars of the coarse change-
over selector. Their external appearance is identical to the fine tap selector con-
tacts (through-hole for M10 screws, always in vertical position Figure 90).
NOTE
Damage to on-load tap-changer due to blocking of change-over selector!
Figure 91 Tap selector for coarse tap selection (view from above)
1 Connection contact
2 Movable parts
With coarse tap selection, the (+) and (-) change-over selector connection con-
tacts are secured to the respective laminated paper bars of the coarse change-
over selector. Their external appearance is identical to the fine tap selector con-
tacts (through-hole for M10 screws, always in vertical position Figure 92).
NOTE
Damage to on-load tap-changer resulting from switching without oil!
Performing too many operations without oil will damage the on-load tap-
changer!
Do not perform more than 250 tap-change operations on the on-load tap-
changer without oil before drying.
Before the first actuation of the on-load tap-changer after drying of the
transformer, the tap selector must be completely immersed in transformer
oil and the diverter switch oil compartment must be completely filled with
oil.
We would recommend carrying out a transformer ratio test before the trans-
former is dried.
In order to run the transformer ratio test, we recommend using the TAPMO-
TION® TD test drive. The precise process is described in the test drive operating
instructions.
To actuate the drive shaft of the upper gear unit (Figure 95) of the on-load tap-
changer head, a short tube (25 mm nominal width) with a screwed-in coupling
bolt (12 mm diameter) may be used together with a hand wheel or a crank.
Always check the operating position reached through the inspection window in
the on-load tap-changer head cover (Figure 96). The end positions, which are
indicated in the connection diagram supplied with the delivery, must never be
overrun.
3. Once the transformer ratio test is complete, return on-load tap-changer to its
adjustment position (see supplied connection diagram of the on-load tap-
changer).
Open the kerosene drain plug in the diverter switch oil compartment if the
on-load tap-changer is to be dried with kerosene in the transformer tank. After
drying, the diverter switch insert must be removed, the kerosene drain plug in
the diverter switch oil compartment closed and the diverter switch insert refitted
(Chapter 9.1.2.2).
Note the measurement scenarios listed below and the associated maximum
measuring currents when measuring DC resistance on the transformer.
9.1.1 Vacuum-drying
NOTE
Damage to on-load tap-changer head cover and on-load tap-changer
accessories when vacuum-drying in the autoclave!
On-load tap-changer head cover, including upper gear unit and on-load
tap-changer accessories, must not be dried as well.
Remove the following parts before drying and keep outside autoclave:
• On-load tap-changer head cover including upper gear unit
• Motor-drive unit
• Protective relay
• Pressure-operated relay
• Pressure relief valve
• Bevel gear
• Temperature sensor
The on-load tap-changer head cover remains closed during the entire drying
process!
NOTE
Damage to on-load tap-changer head cover and on-load tap-changer
accessories when vacuum-drying in the autoclave!
On-load tap-changer head cover, including upper gear unit and on-load
tap-changer accessories, must not be dried as well.
Remove the following parts before drying and keep outside autoclave:
• On-load tap-changer head cover including upper gear unit
• Motor-drive unit
• Protective relay
• Pressure-operated relay
• Pressure relief valve
• Bevel gear
• Temperature sensor
During vapor-phase drying, the kerosene drain plug in the diverter switch oil
compartment base must be opened before drying so that the kerosene conden-
sate can drain from the diverter switch oil compartment.
Never unscrew the kerosene drain plug all the way but just until it starts to get
hard to turn.
3. Remove the on-load tap-changer head cover and store it outside the
vacuum autoclave.
4. Remove on-load tap-changer accessories (motor-drive unit, protective relay,
pressure-operated relay, pressure relief valve, bevel gear, temperature
sensor, oil filter unit) and store outside autoclave.
5. Supply kerosene vapor at temperature of around 90 °C. Keep this
temperature constant for about 3 to 4 hours.
6. Increase the kerosene vapor temperature by approx.10 °C/hour to the
desired final temperature (125 °C maximum on the on-load tap-changer).
7. Vacuum dry on-load tap-changer at between 105 °C and maximum 125 °C.
Residual pressure of no more than 10-3 bar. The drying period depends on
the drying period of the transformer but should be at least 50 hours.
NOTE
Damage to on-load tap-changer and transformer from oil escaping!
An open kerosene drain plug means that oil will escape from the diverter
switch oil compartment and therefore cause damage to the on-load tap-
changer and transformer.
NOTE
Damage to on-load tap-changer and transformer from blocking of diverter
switch!
Small parts in the diverter switch oil compartment may block the
diverter switch, thereby damaging the on-load tap-changer and
transformer!
Ensure that parts do not fall into the diverter switch oil compartment.
Check you have the same number of small parts when disassembling and
reassembling.
NOTE
Damage to on-load tap-changer and transformer from damaged sealing
surfaces!
Check that the sealing surfaces on the on-load tap-changer head cover and
on-load tap-changer head are not damaged during removal and during all
other work.
3. Remove the on-load tap-changer head cover. Check that the sealing
surfaces on the on-load tap-changer head cover and on-load tap-changer
head are in sound condition during removal and during all other work and
ensure that o-ring is also in sound condition (Figure 99).
Figure 100 Tap position indicator disc for on-load tap-changer without multiple
coarse change-over selector
Design with multiple coarse change-over selector with more than 35 oper-
ating positions (version with short panel)
1. Move on-load tap-changer to adjustment position (see detailed connection
diagram).
2. Remove countersunk head screw M5x12/wrench 3 (Figure 101).
3. Lever cover disk off underlying washer with flat screwdriver (Figure 102).
4. Pull number disc out horizontally from between panel and bracket
(Figure 102).
5. Remove both hexagon screws M5x12/wrench 8 and associated lock tab
(Figure 103).
6. Pull panel and bracket up and off indicator drive shaft (Figure 104).
NOTE
Damage to on-load tap-changer resulting from defective tap-change
supervisory control!
1. Lift plug connector and leads out of bracket and retaining clamps (Fig-
ure 105).
Figure 108 Swiveling part A of plug connector out of on-load tap-changer head
Figure 109 Carrier plate of diverter switch insert for standard transformer design
Figure 110 Carrier plate of diverter switch insert for bell-type tank transformer
design
2. Insert the lifting gear in the lugs provided on the diverter switch insert carrier
plate and position vertically above the diverter switch insert.
3. Lift out the diverter switch insert slowly and vertically (Figure 112).
CAUTION!
Risk of injury due to instable position of heavy parts!
NOTE
Damage to property due to unstable position of heavy parts!
Once the diverter switch insert has been removed, the position of the tap
selector coupling must not be changed during assembly work.
Never unscrew the kerosene drain plug all the way but just until it starts to get
hard to turn.
Unscrew kerosene drain plug with extended socket wrench (Chapter 17.10)
counter-clockwise until it starts to get hard to turn (Figure 114).
Figure 114 Kerosene drain plug in diverter switch oil compartment base
2. Insert the lifting gear in the lugs of the diverter switch insert carrier plate
provided for this purpose and position diverter switch insert above diverter
switch oil compartment.
3. Align diverter switch insert such that the red markings at the top of the
energy accumulator (Figure 116 and Chapter 17.6) and on the on-load tap-
changer head are opposite one another.
6. Secure carrier plate of diverter switch insert with 4 screws M8/wrench 13 for
standard transformer design (Figure 117) or 5 nuts M8/wrench 13 for bell-
type tank transformer design (Figure 118) and locking washers (maximum
tightening torque 20 Nm).
Figure 117 Carrier plate of diverter switch insert for standard transformer design
Figure 118 Carrier plate of diverter switch insert for bell-type tank transformer
design
The tap position indicator disc can only be installed using the coupling pin when
in the correct position.
1. Place tap position indicator disc on indicator drive shaft, slide spring clip on
to shaft end (Figure 122).
Figure 122 Tap position indicator disc for on-load tap-changer without multiple
coarse change-over selector
Design with multiple coarse change-over selector with more than 35 oper-
ating positions (version with short panel)
1. Place panel with bracket on indicator drive shaft and secure with 2 hexagon
screws M5x12/wrench 8 and associated lock tab (Figure 78).
2. Insert number disc horizontally between panel and bracket and fit cover disk
(Figure 124).
NOTE
Damage to on-load tap-changer resulting from damaged o-ring!
A damaged o-ring in the on-load tap-changer head cover will cause oil
to escape from the diverter switch oil compartment, resulting in on-load
tap-changer damage.
Take care not to damage the o-ring inserted in the on-load tap-changer
head cover.
9.1.2.2.11 Drying
1. Supply kerosene vapor at temperature of around 90 °C. Keep this
temperature constant for about 3 to 4 hours.
2. Increase the kerosene vapor temperature by approx.10 °C/hour to the
desired final temperature (125 °C maximum on the on-load tap-changer).
3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125 °C.
Residual pressure of no more than 10-3 bar. The drying period depends on
the drying period of the transformer but should be at least 50 hours.
9.1.2.2.13 Refitting diverter switch insert after closing kerosene drain plug
Insert diverter switch insert in accordance with Chapter 9.1.2.2.6, Chapter
9.1.2.2.7, Chapter 9.1.2.2.8.
After drying, the diverter switch oil compartment (diverter switch insert fitted)
must be filled with oil again as soon as possible so that an impermissible
amount of humidity isn't absorbed from the surroundings.
When filling the diverter switch oil compartment and the related oil conservator
with oil, only use new mineral insulating oil for transformers as per IEC 60296
(Specification of unused mineral insulating oils for transformers and switch-
gear).
For oil quality limit values, see Chapter 13 Table 6.
Diverter switch oil compartment and transformer are simultaneously filled with
new transformer oil under vacuum.
1. For evacuating purposes, install a connecting lead between connections E2
and Q in order to subject the diverter switch oil compartment and transformer
to a vacuum at the same time (Figure 128).
2. Fill diverter switch oil compartment with oil using either pipe connection S or
R of the on-load tap-changer head (Figure 6).
NOTE
Damage to on-load tap-changer resulting from insufficient oil or lack of oil in
the diverter switch oil compartment!
Actuating the on-load tap-changer without oil after drying will damage
it!
Before the first actuation of the on-load tap-changer after drying of the
transformer, the tap selector must be completely immersed in transformer
oil and the diverter switch oil compartment must be completely filled with
oil.
The on-load tap-changer may perform switching operations when the
surrounding transformer oil temperature is between –25 °C and +105 °C
and, during overload, up to +115 °C as per IEC 60214-1.
The stamped serial number of the bevel gear must match the serial number of
the on-load tap-changer.
The horizontal drive shaft must align with the shaft end of the upper gear unit
on the on-load tap-changer head.
Attach bevel gear to support on the transformer cover with 2 bolts (through-
holes 18 mm diameter, see Chapter 17.15).
NOTE
Property may be damaged from incorrectly aligning the upper gear unit!
Incorrectly aligning the upper gear unit will damage the on-load tap-
changer!
2
3
Figure 131 Upper gear unit
1 Drive shaft
2 Pressure segment
3 M8/wrench 13 bolt
Due to the special arrangement of three or two column constructions, the on-
load tap-changer heads must be coupled together above the transformer cover.
NOTE
Property may be damaged from incorrectly aligning the upper gear unit!
Incorrectly aligning the upper gear unit will damage the on-load tap-
changer!
Only align upper gear unit if pressure segments are loosened (Figure 131).
Never turn upper gear unit around its own axis to align it.
Only align upper gear unit by turning drive shaft of upper gear unit
(Figure 131).
2. Loosen pressure segments of upper gear units by loosening the 6 bolts M8/
wrench 13 (Figure 131).
3. Move upper gear units into the installation position desired by turning drive
shafts of upper gear units (Figure 131).
4. Lock and secure pressure segments (tightening torque 15 Nm, Figure 131).
5. Note arrow on drive shaft flange under the stamped serial number. The
direction of the arrow indicates the direction of rotation when turning the
hand crank of the motor-drive unit clockwise and must be identical for all
gear units.
6. Move each on-load tap-changer separately one step by rotating the shaft
ends counter-clockwise until the diverter switch operates once.
7. Check that the operating positions of all on-load tap-changer heads are the
same.
8. Fit horizontal drive shaft between the on-load tap-changer heads.
Individually couple each on-load tap-changer. Start with the on-load tap-
changer located closest to the motor-drive unit.
9. After installing all drive shafts, continue cranking another 2.5 revolutions
counter-clockwise on the drive shaft of the upper gear unit to correctly
complete the tap-change operation.
10.Move on-load tap-changer back into adjustment position by turning drive
shaft clockwise. Once the adjustment position has been reached and the
diverter switch has undergone the tap-change operation, continue cranking
another 2.5 revolutions clockwise on the drive shaft of the upper gear unit
to correctly complete the tap-change operation.
11. Check simultaneous operation of all on-load tap-changers.
12.Check that the operating positions of all on-load tap-changer heads are the
same.
13.Fit vertical drive shaft.
Before first commissioning, the on-load tap-changer head and the suction pipe
on pipe connection S must be bled.
2. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load
tap-changer head (Figure 132).
1. Remove screw cap (M16/wrench 22) from pipe connection S (Figure 134).
2. Open vent screw (M6 with slotted head) and bleed piping.
3. Close vent screw (tightening torque 2 Nm).
4. Seal vent screw with screw cap (tightening torque 9 Nm).
NOTE
Damage to on-load tap-changer resulting from insufficient oil or lack of oil in
the diverter switch oil compartment!
Before first actuating the on-load tap-changer after drying the transformer,
the tap selector must be completely immersed in transformer oil and the
diverter switch oil compartment must be completely filled with oil.
1. Fully immerse tap selector in oil-filled transformer and completely fill diverter
switch oil compartment with oil.
2. Undertake tap change operation tests across entire range of settings.
NOTE
Damage to on-load tap-changer resulting from coupling error!
Ensure that tap position indicators for the motor-drive unit and on-load tap-
changer match.
3. Make sure that in each operating position the tap position indicators of
motor-drive unit and on-load tap-changer (inspection window in the on-load
tap-changer head) read the same position.
4. Check, in both end positions, the function of the electrical and mechanical
end position limitation (see operating instructions for the motor-drive unit
TAPMOTION® ED).
WARNING!
Danger of death and severe injury!
Danger of death and severe injury from explosive gases under the on-
load tap-changer cover, in the pipework system, in the oil conservator,
at the dehydrating breather opening and from flying parts and hot oil
spluttering!
Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused
by static charging) in the immediate surroundings and that none occur.
Only use conductive and grounded hoses, pipes and pump equipment that
are approved for flammable liquids.
Use suitable personal protective equipment/clothing.
Keep away from the danger area during the transformer test.
Observe conventional fire protection regulations.
Ensure that only specialists trained as defined in Chapter 2.4 undertake
work on the transformer and on-load tap-changer.
Every on-load tap-changer has been specially designed by the manufacturer for
the transformer in the respective purchase order and is subjected to strict tests
and quality controls at the manufacturer’s factory.
However, joint operation of transformer and on-load tap-changer cannot be sim-
ulated by the manufacturer and cannot be tested alone on the on-load tap-
changer.
WARNING!
Danger of death and severe injury!
Danger of death and severe injury from explosive gases under the on-
load tap-changer cover, in the pipework system, in the oil conservator or
at the dehydrating breather opening!
Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused
by static charging) in the immediate surroundings and that none occur.
If the transformer is filled with oil but stored or transported without an oil conser-
vator, a connecting lead for pressure compensation must be installed between
the interior of the diverter switch oil compartment and the transformer tank.
Proceed as follows:
Install the connecting lead at the on-load tap-changer head between
connections E2 and Q.
For short immobilization periods of no more than 4 weeks without oil conserva-
tor, it is also sufficient to lower the oil level in the on-load tap-changer head by
approx. 5 liters.
If the transformer is completely emptied of oil, the diverter switch oil compart-
ment must also be completely emptied. The interior of the diverter switch oil
compartment should be conserved in the same way as the transformer (e.g. by
filling with nitrogen).
For longer immobilization periods, the motor-drive unit heating must be con-
nected and operated.
WARNING!
Danger of death and severe injury!
Danger of death and severe injury from explosive gases under the on-
load tap-changer cover!
WARNING!
Danger of death and severe injury!
Danger of death and severe injury from explosive gases under the on-
load tap-changer cover, in the pipework system, in the oil conservator or
at the dehydrating breather opening!
Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused
by static charging) in the immediate surroundings and that none occur.
NOTE
Damage to on-load tap-changer resulting from insufficient oil or lack of oil in
the diverter switch oil compartment!
1. In accordance with Chapter 9.2 completely fill on-load tap-changer with new
mineral insulating oil for transformers in accordance with IEC 60296 (Spec-
ification for unused mineral insulating oils for transformers and switchgear).
2. Determine the dielectric strength and water content of the diverter switch oil
after filling with oil:
Record oil sample temperature.
Determine dielectric strength at a diverter switch oil temperature of 20 °C
± 5 °C. The dielectric strength and water content must satisfy the limit
values stated in Table 6.
Ud [kV/2.5 mm]
When commissioning the transformer for the first time 60 (minimum)
Table 6 Limit values for on-load tap-changer oil (dielectric strength Ud measured in
accordance with IEC 60156)
NOTE
Damage to on-load tap-changer and transformer from inrush current impulse!
An inrush current impulse which has not fully subsided can damage the
on-load tap-changer and transformer in the event of an on-load tap
changing operation!
Once the transformer has been switched on, ensure that the inrush current
impulse has fully subsided before undertaking an on-load tap changing
operation. The inrush current impulses are usually a multiple of the
transformer rated current and can overload the on-load tap-changer during
the diverter switch operation.
During all function checks and tests when commissioning, in addition to the
safety instructions in Chapter 2 also note the safety notice provided in Chap-
ter 11.3.1.
After the transformer has been turned on and the inrush current impulse has
subsided, on-load tap-changer switching operations can be performed both
under no load and load conditions.
WARNING!
Danger of death and severe injury!
Danger of death and severe injury from explosive gases under the on-
load tap-changer cover, in the pipework system, in the oil conservator or
at the dehydrating breather opening!
Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused
by static charging) in the immediate surroundings and that none occur.
NOTE
Damage to the on-load tap-changer due to insufficient oil in the oil conservator
of the on-load tap-changer!
Make sure that the contact for signaling that the minimum oil level in the on-
load tap-changer's oil conservator has not been reached was looped
through to the tripping circuit of the circuit breaker and that the circuit
breaker will immediately de-energize the transformer when the oil falls
below this minimum oil level in the oil conservator.
The oil quality of the on-load tap-changer oil should be checked at regular inter-
vals:
• For on-load tap-changers used on the neutral point of windings (class 1 in
accordance with IEC 60214-1): every 7 years
• For on-load tap-changers used at points other than the neutral point of wind-
ings (class 2 in accordance with IEC 60214-1): every 2 years
To do so, proceed as follows:
1. Take oil sample from diverter switch oil compartment.
2. Record temperature of oil sample as soon as sample is taken.
3. Determine dielectric strength at a diverter switch oil temperature of 20 °C ±
5 °C. The dielectric strength and water content must satisfy the limit values
stated in Table 7.
15 Troubleshooting
WARNING!
Danger of death and severe injury!
Danger of death and severe injury from explosive gases under the on-
load tap-changer cover, in the pipework system, in the oil conservator or
at the dehydrating breather opening!
Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused
by static charging) in the immediate surroundings and that none occur.
Only use conductive and grounded hoses, pipes and pump equipment that
are approved for flammable liquids.
De-energize all auxiliary circuits (e.g. tap-change supervisory control,
pressure relief valve, pressure-operated relays) before removing the on-load
tap-changer cover.
Do not operate any electric devices (e.g. impact wrench risk of sparks)
during the work.
NOTE
Damage to on-load tap-changer and transformer when RS 2001 protective
relay or other protective devices have been tripped!
The table below should offer you help in detecting and if necessary remedying
faults.
Do not use the equipment again until you are sure there is no damage to the
on-load tap-changer or transformer.
For more information, please consult the operating instructions for the RS 2001
protective relay or the relevant protective device.
In the event of faults on the on-load tap-changer and motor-drive unit, which
cannot be easily corrected on site, or if the RS 2001 protective relay or addi-
tional protective devices have been tripped, please inform your authorized MR
representative, the transformer manufacturer or contact us directly at:
Maschinenfabrik Reinhausen GmbH
Technischer Service
Postfach 12 03 60
93025 Regensburg
Germany
Tel.: +49 94140 90-0
Tel: +49 9 41 40 90-7001
E-mail: [email protected]
Internet: www.reinhausen.com
16 Maintenance
NOTE
Damage to property!
Figure 136 Door of motor-drive unit with label showing maintenance intervals
1 Door
2 Label
The diverter switch insert must be replaced after 1.2 million switching opera-
tions.
After 1.2 million switching operations (motor-drive unit counter reading), the tap
selector requires maintenance work.
NOTE
Damage to on-load tap-changer resulting from switching at impermissible oil
temperatures!
To fill the diverter switch oil compartment and its oil conservator, us only new or
treated mineral insulating oil for transformers in accordance with IEC 60296
(Specification for unused mineral insulating oils for transformers and switch-
gear).
The dielectric strength and water content of the diverter switch oil must be
determined after filling with oil:
1. Record oil sample temperature.
2. Determine dielectric strength at a diverter switch oil temperature of 20 °C ±
5 °C. The dielectric strength and water content must satisfy the limit values
stated in Table 9.
Change the oil as detailed in the maintenance instructions for the corresponding
on-load tap-changer (available on request).
17 Appendix
17.4 VACUTAP® VM®, supporting flange, special design for bell-type tank installa-
tion for Um up to 300 kV (896762)
3 mm thick
Marks stamped
Screw connection
M25 x 1.5
Inspection window
Identification plate
Gasket Gasket
Test button
OPERATION OFF
(reset) (test tripping)
18 MR worldwide