MR BA - VV - Ex - en

www.reinhausen.
com
On-load tap-changer VACUTAP V V-EX

Operating Instructions BA 273/02
NOTE
Changes may have been made to a product after going to press with this documentation. We expressly reserve the right to make changes to a products technical data and design as well as changes to the scope of delivery. In all cases, the information submitted and agreements concluded during processing of the quotation and order in question shall be binding.
Contents
Contents
1 General ......................................................................................................................................................................................... 1.1 1.2 2 3 Safety Instructions ....................................................................................................................................................... Specified application ................................................................................................................................................... 5 5 5 6 7 7 8 8 8 8 8 9 9 10 10 10 10 10 10 10 11
Design / Types ............................................................................................................................................................................ Standards and regulations for explosion-proof on-load tap-changers ........................................................... 3.1 3.2 Basic principles .............................................................................................................................................................. Explosion protection types ........................................................................................................................................
Measures for ensuring compliance with explosion protection requirements ................................................ 4.1 4.2 4.3 Oil quality for explosion-proof on-load tap-changers ..................................................................................... Oil quality for the explosion-proof transformer ................................................................................................ Maximum surface temperature (DIN 60079-0 after 5.3) ................................................................................
Installation instructions ........................................................................................................................................................ 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 On-load tap-changer oil system ................................................................................................................................ On-load tap-changer oil system equipment .......................................................................................................... Insulating oil .................................................................................................................................................................... Level control .................................................................................................................................................................... Dehydrating breather .................................................................................................................................................... Oil conservator ................................................................................................................................................................ Level indicator ................................................................................................................................................................. Monitoring of the protective fluid level .................................................................................................................
6 7
Shipment .....................................................................................................................................................................................
Installing the on-load tap-changer for cover mounting .......................................................................................... 13 7.1 7.2 Mounting flange ............................................................................................................................................................. 13 Attaching the on-load tap-changer to the transformer tank .......................................................................... 13
Installing the on-load tap-changer in a transformer with bell-type cover ..................................................... 15 8.1 8.2 8.3 8.4 Installing the on-load tap-changer in the supporting structure .................................................................... Preparation ....................................................................................................................................................................... Separating the top part of the on-load tap-changer head from the bottom part ................................... Attaching the bell-type cover .................................................................................................................................... 15 16 16 17
Connecting the tap winding and the tap-changer take-off terminal ............................................................... 17
BA 273/02 - VACUTAP V V-Ex

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The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. 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. Maschinenfabrik Reinhausen GmbH 2007
Contents
10 11
Transformer ratio test .............................................................................................................................................................. 18 Drying process and oil filling ................................................................................................................................................ 18 11.1 Drying process ................................................................................................................................................................. 11.1.1 Vacuum-drying .................................................................................................................................................. 11.1.1.1 Vacuum-drying in the autoclave ................................................................................................ 11.1.1.2 Vacuum-drying in the transformer tank .................................................................................. 11.1.2 Vapour-phase drying ....................................................................................................................................... 11.1.2.1 Vapour-phase drying in the autoclave ...................................................................................... 11.1.2.2 Vapour-phase drying in the transformer tank ........................................................................ 11.1.3 Operating the on-load tap-changer ........................................................................................................... Oil filling ........................................................................................................................................................................... 18 18 18 19 19 19 19 20 20
11.2 12
Pipe connections ........................................................................................................................................................................ 20 12.1 12.2 12.3 Pipe connection R for protective relay RS 2001-Ex ............................................................................................ 20 Pipe connections S and R (connection Q specially designed) Connection to tap-changer interior ......................................................................................................................... 20 Connection E2 ................................................................................................................................................................. 21
13
Mounting the motor drive, bevel gear and drive shaft ............................................................................................. 21 13.1 13.2 13.3 Mounting the motor-drive unit (see appendix, drawing 898743) .................................................................. 21 Mounting the bevel gear ............................................................................................................................................. 21 Mounting the drive shaft (square tube) .................................................................................................................. 21
14
Commissioning the on-load tap-changer at the transformer manufacturer's site ...................................... 22 14.1 14.2 14.3 14.4 Operational tests ............................................................................................................................................................. Complete oil filling ........................................................................................................................................................ Ground connections ...................................................................................................................................................... Electrical tests on the transformer ............................................................................................................................ 22 23 23 23
15 16 17 18 19 20
Transport to the operating site ............................................................................................................................................ 24 Commissioning at the operating site ................................................................................................................................ 24 Monitoring during service ...................................................................................................................................................... 25 Failures ........................................................................................................................................................................................... 25 Maintenance ................................................................................................................................................................................ 26 Appendix ........................................................................................................................................................................................ 27
BA 273/02 - VACUTAP V V-Ex 4

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General
1
1.1
General
Safety Instructions 1.2 Specified application
All personnel involved in installing, commissioning, operating, maintenance or repair of the equipment must: be suitably qualified and strictly observe these Operating Instructions. Improper operation or misuse can lead to serious or fatal injury, damage to the equipment and property of the user and a reduction in the efficiency of the equipment. Safety instructions in this manual are presented in three different forms to emphasize important information.
CAUTION
The on-load tap-changer may only be used with the transformer specified in the order. Installation, electrical connection and commissioning of the on-load tap-changer must only be carried out by qualified, skilled personnel and only in accordance with these Operating Instructions. It is the responsibility of the user to ensure that the onload tap-changer is used for the specified application only. For safety reasons, any unauthorised work such as installation, alteration, electrical connection, commissioning or modification to the on-load tap-changer equipment is forbidden without first consulting MR! The trouble-free operation of the drive, on-load tapchanger and transformer may be put at risk. Operation of the VACUTAP VV-EX is always permitted within the entire temperature range covered by IEC 60214-1. The properties required by MR for the types of oil to be used must always be adhered to under all circumstances.
WARNING
This information indicates particular danger to life and health. Disregarding such a warning can lead to serious or fatal injury.
CAUTION
This information indicates particular danger to the equipment or other property of the user. Serious or fatal injury cannot be excluded.
WARNING
All relevant fire protection regulations must be strictly observed.
NOTE
Notes give important information on specific subjects.

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2 Design/Types
Design/Types
The on-load tap-changer VACUTAP V V-Ex (fig. 1) is constructed as an on-load tap-changer of tubular design. It combines the functions of a diverter switch unit and a tap selector. The on-load tap-changer is attached to the transformer cover by the tap-changer head. Where required, the on-load tap-changer is equipped with a change-over selector. The design and designation of the main components of the on-load tap-changer can be found in the installation drawings (see appendix, drawing 898864). The on-load tap-changer designs V V-Ex without a changeover selector are available with a maximum of 12 operating positions. Designs with a change-over selector have a max. of 23 operating positions. These Operating Instructions apply to the following on-load tap-changer designs (each with or without a change-over selector): Three-phase tap-changers: V V III 250 Y-Ex, V V III 400 Y-Ex, V V III 600 Y-Ex V V III 250 -Ex, V V III 400 -Ex, V V III 600 D-Ex

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Standards and regulations for explosion-proof on-load tap-changers
3
3.1
Standards and regulations for explosion-proof on-load tap-changers

Basic principles
All VV-Ex on-load tap-changers from the MR product range are certified for II 3G EEx nAC II T3.
II 3G EEx nAC II T3
!
Sign for explosion protection
Equipment category
Equipment groups
I II
Equipment group
Protection type Explosion-proof equipment
Equipment in this category is intended for use in underground parts of mines as well as those parts of surface installations of such mines endangered by firedamp and/or combustible dust. Equipment in this category is intended for use in other areas in which explosive atmospheres may be present.
Equipment category / zone classification

for powder for gases
Temperature class
Explosion group
Protection types
d e l m o p q n flameproof enclosure increased safety intrinsic safety (la, lb) encapsulation oil immersion pressurized apparatus powder filling protection type n (only zone 2) n A: non-sparking apparatus n C: sparking apparatus with special protection of contacts n R: restricted breathing enclosures n L: energy-limited equipment n P: equipment with simplified n-pressurization
Definition
1G (0)
1D (20)
Equipment in this category is intended for use in areas in which explosive atmospheres caused by mixtures of air and gases, vapors or mists or by air/dust mixtures are present continuously, for long periods or frequently. Equipment in this category is intended for use in areas in which explosive atmospheres caused by gases, vapors, mists or air/dust mixtures are likely to occur.
2G (1)
2D (21)
3G (2)
3D (22)
Equipment in this category is intended for use in areas in which explosive atmospheres caused by gases, vapors, mists, or air/dust mixtures are unlikely to occur or, if they do occur, are likely to do so only infrequently and for a short period only.
Explosion group
Gases, vapors (examples) - ammonia - acetone, methane, ether, petrol, benzene, diesel, petroleum, acetic acid, fuel oil, hexane, methane, propane - ethylene, isoprene, town gas - hydrogen, acetylene, carbon disulfide 0.06 0.02 IIB IIC Min. ignition energy (mJ) -EN/IEC
Temperature classes
Temperature class Max. equipment surface temperature Ignition temperature of the inflammable substances > 450 C > 300 C < 450 C > 200 C < 300 C > 135 C < 200 C > 100 C < 135 C > 85 C < 100 C
IIA
T1 T2 T3 T4 T5 T6
450 C 300 C 200 C 135 C 100 C 85 C

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3 4
Standards and regulations for explosion-proof on-load tap-changers Measures for ensuring compliance with explosion protection requirements
3.2
Explosion protection types
The following standards and regulations apply to explosionproof on-load tap-changers: Protection type "nAC" according to EN 60079-15 for sparking equipment with suitably protected contacts (except restricted breathing enclosures, energy-limited circuits or pressurized apparatus). Supplementary requirements apply to: vacuum interrupters - hermetically sealed equipment that generates arcs, sparks or hot surfaces the on-load tap-changer oil compartment - sealed or enclosed equipment that generates arcs, sparks or hot surfaces
CAUTION
The oil quality and the dielectric strength must be checked regularly. The service intervals (oil change) must be complied with. For certain on-load tap changer types (see Operating Instructions no. 18, oil filter plant) an MR oil filter plant is used. 4.3 Maximum surface temperature (DIN 60079-0 after 5.3)
Measures for ensuring compliance with explosion protection requirements
For certification of the on-load tap-changer for application in areas subject to explosion hazard, explosion protection class "nAC" according to the harmonized EN 60079-15 standard is used. 4.1 Oil quality for explosion-proof on-load tapchangers
During each switching operation additional heat is transferred to the oil. The heat originates from the transition resis-tors. The switch-off value of the temperature sensor is set such that the temperature of the warmest oil layers in tap-changer oil compartment does not exceed +130 C. Temperature monitoring in the on-load tap-changer cover prevents further switching operations of the on-load tap-changer, thus preventing an additional temperature rise of the insulating oil in the on-load tap-changer. This ensures that the surface temperature at the on-load tap-changer, the protective relay and the oil filter plant does not exceed 130C during operation. For each order, the set value of the temperature sensor is specified individually for all explosion-proof on-load tap changer types.
The quality of the insulating oil in the diverter switch oil compartment that is required according to IEC 60296 is ensured through compliance with the thermal application criteria specified in IEC 60214, and through application of vacuum cells in transition circuits. 4.2 Oil quality for the explosion-proof transformer
CAUTION
The set value of the temperature monitoring system is set in the factory. This value must not be changed.
During switching operations, sparks (low energy) may be generated at the tap selector of the on-load tap-changer in the transformer oil chamber. Sections 5.1.6 and 5.1.7 of the IEC 60214 on-load tapchanger standard must be followed.

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Installation instructions
5
5.1
On-load tap-changer oil system
The oil system of the on-load tap-changer consists of an oil conservator, a protective relay and an on-load tap-changer oil compartment.
The required oil level in the on-load tap-changer oil system is maintained through the measures described in sections 5.2 to 5.8.
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5.2
On-load tap-changer oil system equipment
5.5
Dehydrating breather
The explosion-proof on-load tap-changer must only be operated in conjunction with an explosion-proof protective relay.
A dehydrating breather [6] (see fig. 2) with oil barrier prevents water, impurities, insects etc. from entering the insulating oil. 5.6 Oil conservator
CAUTION
The explosion-proof on-load tap-changer must only be operated in conjunction with an explosion-proof protective relay (fig. 2; no. 2).
The oil conservator [5] (see fig. 2) ensures that all oil system piping of the on-load tap-changer is always filled with insulating oil during the operation (when temperature changes of the insulating oil occur). 5.7 Level indicator
5.3
Insulating oil
MR on-load tap-changers, protective relays and associated oil filter plants must only be operated with insulating oil according to IEC 60296 and IEC 60422. This requirement is currently specified in the Technical Data / General Part / Section 2.16 (and noted in the operating instructions for the explosionproof on-load tap-changer and the explosion-proof protective relay). 5.4 Level control
A level indicator [3] (see fig. 2) enables the level of the protective fluid to be monitored during operation. The maximum and minimum level of the protective fluid must be clearly identified. 5.8 Monitoring of the protective fluid level
The explosion-proof on-load tap-changer must only be operated in conjunction with an oil conservator with level controller. Using a suitable oil system, the oil conservator or the fittings and the pipes must ensure the oil level in the onload tap-changer oil conservator. The customer is responsible for the installation of the oil conservator and all associated piping. It is not part of MRs scope of delivery.
Monitoring of the protective fluid level [4] (see fig. 2) in the oil conservator ensures that during the specified operation the oil system piping of the on-load tap-changer is always filled with insulating oil. The minimum permissible protective fluid level is in the oil conservator. The protective fluid level must be monitored continuously at the oil conservator during operation via a limit value contact or limit value contacts (if prior warning is required).
CAUTION
If the oil level falls below the lowest permissible protective fluid level, the transformer must be turned off.
CAUTION
Any existing stop valves may not be allowed to affect level regulation.

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Shipment
Shipment
TAPMOTION ED-Ex 100 S-Ex (ca. 80 kg), or TAPMOTION ED-Ex 100 L-Ex (ca. 130 kg), fig. 4. Drive shafts with coupling parts and bevel gear (max. ca. 20 kg), fig. 5. Protective relay RS 2001-Ex (3.5 kg), fig. 6. The shipment should be checked against the consignment documents to ensure it is complete. The parts must be stored in a dry place until assembly. The on-load tap-changer must remain packed air-tight in the protective wrapping and should only be removed shortly before installation.
On-load tap-changer and motor-drive unit are shipped in the adjustment position. The on-load tap-changer equipment is shipped as follows: (insulating parts are protected against moisture): On-load tap-changer VACUTAP V V-Ex V V III 250/400/600/40 kV, with change-over selector, (ca. 240 kg), V V III 250/400/600//76 kV, with change-over selector, (ca. 255 kg), V V III 250/400/145 kV, with change-over selector, (ca. 280 kg), fig. 3
NOTE
In general, the drive shafts, the bevel gear and the protective relay are packed with the on-load tap-changer.
WARNING
When carrying out any work on the on-load tap-changer, motor-drive or components, ensure they are positioned securely. Otherwise there is a danger that individual devices may tip over accidentally. This can result in serious injury and, in some cases, fatalities.
3
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11
Shipment
898743
726140
MR
6
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Installing the on-load tap-changer for cover mounting
7
7.1

Mounting flange
A mounting flange is required for mounting the tap- changer head to the transformer cover. This mounting flange should be designed according to the sealing surface of the tapchanger head (see fig. 7 and fig. 8 and appendix, drawing 898866). We recommend using a template to position the studs (M12, max. length 45mm), see fig. 9 and appendix, drawing 893787. This template is supplied free of charge for the initial installation of an on-load tap-changer VACUTAP V V-Ex, if desired. 7.2 Attaching the on-load tap-changer to the transformer cover
CAUTION
When attaching the on-load tap-changer, ensure that the lifting device uses 4 cables of equal length, at least 1m (see appendix, drawing 898866), otherwise the equipment may be damaged. Proceed as follows to attach the on-load tap-changer: 1. Remove the tap-changer cover (fig. 10) Loosen the 24 bolts M10 x 35/w.s.17, remove the 24 locking washers. Remove the tap-changer head paying attention to the sealing (fig. 11). Loosen the fixing screws in the top part of the head (22 hexagonal screws M8/w.s.13, locking washers for securing, fig. 12).
2.
164M005
plan
CAUTION
Under all circumstances, avoid dropping parts into the oil compartment, as there is a risk that the on-load tapchanger will be blocked. This could damage the on-load tap-changer and the transformer. For this reason, check the quantities of small parts when disassembling and reassembling to ensure they are identical.
8
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13
3.
Separate the top part of the head from the bottom part Lift up the top part of the head. Take care not to damage the O-ring gasket on the bottom part of the head (fig. 13). Clean the sealing surface on the mounting flange and on the tap-changer head. Place an oil-resistant gasket on the mounting flange. Place upper part of the tap-changer head over the stud bolts of the mounting flange do not tighten! Check the position of the tap-changer head when it is installed. The on-load tap-changer can be turned towards the top part of the head in steps of 15 degrees. Slowly lift the on-load tap-changer from underneath towards the top part of the head using 4 cables of equal length (min. 1m), (see appendix, drawing 898866). Pay attention to the centering bolts. Screw the top and bottom part of the head together 22 hexagonal screws M8/w.s.13 (tightening torque 20 Nm). Attach upper part of the tap-changer head to the mounting flange. Fix the tap-changer cover 24 bolts M10 x 35/w.s.17 (max. torque 34 Nm), 24 locking washers.
4. 5. 6. 7.
8.
int014
9.
10. 11.
10
11
r
164M009 273/02/01/0
Installing the on-load tap-changer in a transformer with bell-type cover
Installing the on-load tap-changer in a transformer with bell-type cover

8.1 Installing the on-load tap-changer in the supporting structure
NOTE
Due to the supporting structure, the diverter switch with an external change-over selector is limited in its installation position. The supporting structure and the changeover selector including the activation lever must not collide (see appendix, drawing 899409).
Lift the on-load tap-changer into the supporting structure. Check the installation position of the tap-changer and fix it securely.
NOTE
The on-load tap-changer must be suspended exactly vertical in the supporting structure. The on-load tap changer must be installed, so it cannot be lifted by more than 5-20 mm after the bell-type cover is attached.
To install the on-load tap-changer in a transformer with a bell-type cover, the on-load tap-changer must be mounted onto a supporting structure. For this purpose, the bottom part of the tap-changer head is designed as a supporting flange (see appendix, drawing 899110). Firstly, lift the on-load tap-changer into the supporting structure and connect it to the tap winding. The on-load tapchanger must be attached to the supporting structure in such a way so it cannot be displaced. The supporting flange is provided with drill holes, so it can be fixed to the supporting structure easily. Placing spacer blocks between the supporting structure and the supporting flange temporarily may be of help. These are to be removed before attaching the bell-type cover. Once the bell-type cover is attached, lift the on-load tapchanger with the lifting device (see appendix, drawing 899110) and fix it to the bell-type cover together with the top part of the head. To attach the tap-changer head to the bell-type cover, we recommend using a mounting flange as described in section 7.1.
By using the temporary spacer blocks between the supporting structure and the supporting flange, the on-load tap-changer is at the correct final installation height after the bell-type cover is attached. This means the leads to be connected to the on-load tapchanger are correctly dimensioned in length. Connect the tap winding and the tap-changer lead according to section 9.
CAUTION
When attaching the on-load tap-changer, ensure that the lifting device uses 4 cables of equal length, at least 1m (see appendix, drawing 899110), otherwise the equipment may be damaged.
CAUTION
Make sure that the connected leads do not exert any force on the on-load tap-changer. In addition, there should be sufficient slack so that the onload tap-changer can be raised to its final installation position after the bell-type cover is attached. The transformer ratio test and drying process are to be carried out according to sections 10 and 11.

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8 Installing the on-load tap-changer in a transformer with bell-type cover
8.2
Preparation
8.3
Before attaching the bell-type cover, the top part of the head must be separated from the bottom part of the head (see 8.3). Make sure the on-load tap-changer is in the adjustment position. This position is given in the connection diagram supplied with the on-load tap-changer.
Separating the top part of the on-load tap-changer head from the bottom part
Proceed as follows to attach the on-load tap-changer: 1. Remove tap-changer cover (fig. 10) loosen the 24 bolts M10 x 35/w.s.17, remove the 24 locking washers. lift off the tap-changer cover. Take care not to damage the sealing (fig. 11). Loosen the fixing screws in the top part of the head (22 hexagonal screws M8/w.s.13, locking washers for securing, fig. 12). Keep the loose parts for reinstallation. Separate the top part of the head from the bottom part; Lift up the top part of the head from the bottom part. Take care not to damage the O-ring gasket on the bottom part of the head (fig. 13).
2.
3.
CAUTION
Under all circumstances, avoid dropping parts into the oil compartment, as there is a risk that the on-load tapchanger will block. This could damage the on-load tap-changer and the transformer. For this reason, check the quantities of small parts when disassembling and reassembling to ensure they are identical.
12
164M008
r
13
7280700
16
r
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8 9
Installing the on-load tap-changer in a transformer with bell-type cover Connecting the tap winding and the tap-changer take-off terminal
Connecting the tap winding and the tap-changer take-off terminal
8.4
Attaching the bell-type cover
1. Before attaching the bell-type cover, clean the sealing surface of the bottom part of the head. Remove the spacer blocks (see section 8.1). 2. Lift the bell-type cover over the active part of the transformer. 3. Before mounting the tap-changer head clean the sealing surfaces on the mounting flange of the transformer. Place an oil-resistant gasket on the mounting flange. Depending on the height adjustment, there must be a clearance of 5 - 20 mm between the top part of the head and the bottom part. The position of the fixing holes in the top part of the head must align with the position of the threaded holes in the bottom part of the head. The on-load tap-changer can be turned towards the top part of the tap-changer head in steps of 15 degrees. 4. Place upper part of the tap-changer head over the stud bolts of the mounting flange do not tighten! 5. Check the position of the tap-changer head when it is installed. The on-load tap-changer can be turned towards the top part of the head in steps of 15 degrees. 6. Using the lifting device, lift the on-load tap-changer to a position (see appendix, drawing 899110) so that the bottom part of the head is aligned with the top part of the head and the connection screws of the top part and bottom part of the head (22 hexagonal screws M8/w.s.13 and locking washers for safety) can be screwed in. Pay attention to the centering bolts. 7. Screw the top part of the head and the bottom part together: 22 hexagonal screws M8/w.s.13 (20 Nm tightening torque) 8. Attach upper part of the tap-changer head to the mounting flange. 9. Fix the tap-changer head 24 bolts M10 x 35/w.s.17 (max. torque 34 Nm) 24 locking washers
The tap winding and the tap-changer take-off terminal must be connected according to the connection diagram supplied with the tap-changer equipment.
CAUTION
Make sure that all connections are correctly and securely made. The connection leads must be connected without exerting force on the on-load tap-changer. If connection leads have to cross the open surface of the oil compartment, there must be a clearance of at least 50 mm between the lead and the surface. The designation of the tap-changer connecting terminals are shown in the connection diagram. They are provided with vertical drill holes, 11mm diameter for M10 bolts (see appendix, drawing 898864).
CAUTION
The connecting terminals must not be twisted as this will jeopardise the functioning of the on-load tap-changer.
CAUTION
Under no circumstances should the on-load tap- changer be lifted up with the fixing screws as this can damage the top part of the head.

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10 Transformer ratio test 11 Drying process and oil filling
10
Transformer ratio test
11
11.1
Drying process and oil filling

Drying process
It is recommended that a transformer ratio test be carried out before the transformer undergoes drying. To operate the drive shaft of the tap-changer head, a pipe (nominal width 25mm) with screwed-in coupling bolts (diameter 12mm) and a hand wheel or hand crank can be used. 16.5 drive shaft revolutions are required for one tap change operation. You should be able to hear the switching action of the on-load tap-changer clearly. When operating the change-over selector (adjustment position 1 tap position), noticeable by the increased expenditure of force, the tap-change operation already under way must always be completed without changing the rotation direction. Keep the number of tap-change operations without oil to a minimum. The end positions, which are given in the connection diagram supplied with the equipment (position designation), must never be overrun. To ensure this, always check the operating position reached through the inspection window on the tapchanger head (fig. 14). After the transformer ratio test, the on-load tap-changer must be operated back to the adjustment position (see connection diagram supplied with the on-load tap-changer).
A precondition of MR's guaranteed dielectric values of the on-load tap-changer is that a minimum drying process must be carried out according to the instructions below (either 11.1.1 or 11.1.2). 11.1.1 Vacuum-drying
11.1.1.1 Vacuum-drying in the autoclave
NOTE
Before drying the transformer in the autoclave, the on-load tap-changer cover must be removed and stored outside the autoclave. Heating: Heat the on-load tap-changer in air at atmospheric pressure, increasing the temperature by approx. 20 C/h up to a max. temperature of 110 C. Pre-drying: Pre-dry the on-load tap-changer in circulating air at a max. temperature of 110C for 10 hours.
bN
14
KHW1139-4
Drying: Vacuum-dry the on-load tap-changer at a max. temperature of 110 C. The duration of the drying process depends on that of the transformer.

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11 Drying process and oil filling
11.1.1.2 Vacuum-drying in the transformer tank
11.1.2.1 Vapour-phase drying in the autoclave
NOTE
If the transformer is to be dried in its own tank, the interior of the on-load tap-changer must be connected to the vacuum by a connecting pipe, as the tap-changer head cover remains closed for the entire drying process. The tap-changer head cover is vacuum-proof. To ensure the interior of the oil compartment and the built-in tap changer insert is sufficiently dried, a short connecting pipe with a nominal width of 25mm must be inserted between the transformer tank and a connecting flange on the tap-changer head which leads directly to the interior of the oil compartment. The connecting pipe should be fitted on the tap-changer head between the connections E2 and Q or E2 and R (for the position of the connections see fig. 16 and section 12). Details on the procedure, temperature and duration of the drying process are described in section 11.1.1.1. 11.1.2 Vapour-phase drying
NOTE
Before drying the transformer in the autoclave, the tapchanger cover must be removed and stored outside the autoclave. Heating: Supply kerosene vapour at a temperature of approx. 90C. Keep this temperature constant for approx. 3-4 hours. Drying: Increase the kerosene vapour temperature applied to the onload tap-changer by approx.10 C/h to the desired final temperature which should not exceed 125 C. The duration of the drying process depends on that of the transformer. Check that the kerosene drain plug screw is closed after the drying procedure.
CAUTION
Before the drying process, the kerosene drain plug screw in the oil compartment bottom must be opened to drain the condensate. The kerosene drain plug screw can be opened from outside (w.s.24) or from the inside (hexagonal recess screw w. s.8), (see fig. 15). The plug cannot be lost as it is attached. It must be closed again after the drying process (torque 39 Nm). Ensure the kerosene drain plug screw is securely closed after the drying process to avoid oil from the oil compartment getting into the oil chamber of the transformer tank. 11.1.2.2 Vapour-phase drying in the transformer tank For vapour-phase drying in the transformer tank, the tapchanger insert must be removed to unscrew the kerosene drain plug from inside the oil compartment (fig. 15). Please contact MR for specific instructions on removing and re-installing the tap-changer insert.
r
15
164M013

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19
11 Drying process and oil filling 12 Pipe connections
12
11.1.3 Operating the on-load tap-changer
Pipe connections
CAUTION
Do not operate the on-load tap-changer after drying without a complete oil filling of the oil compartment, as bearings and gaskets will be damaged. The external change-over selector must also be wetted with oil after the kerosene drying, when switching occurs.
There are 2 pipe connections provided on the tap-changer head for different purposes. All pipe connections can swivel freely by loosening the thrust collar (4 bolts M10/w.s.17), see fig.16 and appendix, drawing 898863. 12.1 Pipe connection R for the protective relay RS 2001-Ex
Install the protective relay RS 2001-Ex (see appendix, drawing 723653) according to our Operating Instructions no. 272 for protective relay RS 2001-Ex.
11.2
Oil filling
Close the tap-changer head by lowering the cover. Tighten all 24 bolts M10/ w.s.17 on the cover uniformly (torque 34 Nm).
NOTE
The stamped serial number must match the serial number of the on-load tap-changer. The protective relay must be installed directly on the tapchanger head in a horizontal position. The arrow on the installed protective relay must point to the oil conservator. The pipe leading to the oil conservator must have an inclination of at least 2 %. Ensure that the maximum space between the transformer cover and the top edge of the tap-changer oil conservator does not exceed 5 m. 12.2 Pipe connections S and R (Connection Q as special design) Connection to tap-changer interior
CAUTION
Under vacuum, fill the on-load tap-changer and transformer simultaneously with new transformer oil.
To fill with oil, use the connection S or R on the tap-changer head. To apply a vacuum to the transformer and oil compartment simultaneously, install a connection pipe between the connection E2 and R or S.
CAUTION
The oil compartment and its associated oil conservator must only be filled with new insulating oil for transformers according to IEC 60296 (Specification for unused mineral insulating oils for transformers and switchgear) and IEC 60422 (Supervision and maintenance guide for mineral insulating oils in electrical equipment). For dielectric strength limit values see section 19, table 1. The use of any other oils may put the trouble-free operation of the on-load tap-changer and the transformer at risk.
To lower the oil level during maintenance (approx. 7 l), a pipe connection should be fitted to one of the free connections R, S or Q which ends at the side of the transformer tank at operating height for a drainage tap.

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12 Pipe connections 13 Mounting the motor-drive unit, bevel gear and drive shaft
13
Mounting the motor-drive unit, bevel gear and drive shaft

Mounting the motor-drive unit (see appendix, drawing 898743)
12.3
Connection E2
13.1
This connection is closed by a dummy plug. It leads into the oil chamber of the transformer, directly under the tapchanger head. When necessary, it can be connected to a collective pipe for the Buchholz-relay.
Detailed mounting instructions can be found in our Operating Instructions no. 271 for the TAPMOTION ED-Ex.
NOTE
The serial number of the motor-drive unit must match that of the on-load tap-changer (name plate). The motor-drive unit must be in the same operating position as the on-load tap-changer when coupling. The adjustment position is given in the connection diagram supplied with the on-load tap-changer. The motor-drive unit must be mounted at the provided place on the transformer tank in a vertical position and protected against transformer vibrations. 13.2 Mounting the bevel gear
16
164M014
The bevel gear is attached to a support on the transformer cover with 2 screws (drill holes 18 mm, see appendix, drawing 892916).
NOTE
The stamped serial number must match that of the on-load tap-changer. The horizontal drive shaft must align with the shaft end of the tap-changer head. By loosening the thrust collar (6 screws M8/w.s. 13) the upper gear unit can swivel freely. After mounting, tighten the thrust collar, (torque 15 Nm). The bolts are to be secured. The above instructions also apply to bevel gears of special designs and to intermediate bearings of the vertical and horizontal drive shafts. 13.3 Mounting the drive shaft (square tube)
The drive shaft must be mounted according to our Operating Instructions no. Nr. 276 for drive shaft-Ex. The drive shaft is the mechanical connection between the motor-drive unit and the tap-changer head. The bevel gear is responsible for changing the direction from vertical to horizontal. BA 273/02 - VACUTAP V V-Ex
273/02/01/0
21
13 Mounting the motor-drive unit, bevel gear and drive shaft 14 Commissioning the OLTC at the transformer manufacturer's site
14
Commissioning the on-load tapchanger at the transformer manufacturer's site
Accordingly, the vertical drive shaft must be installed between the motor-drive unit and the bevel gear, and the horizontal drive shaft between the bevel gear and the tapchanger head. The drive shaft is designed as a square tube and is connected on both ends to the end of the drive shaft or driven shaft of the respective unit by two coupling brackets and one coupling bolt.
14.1 Operational tests Before voltage is applied to the transformer, test tap change operations must be performed to check the mechanical function of the on-load tap-changer and the motor-drive. These tap-change operations are to be performed over the entire operating range. Make sure that the position indicators of the motor-drive and the on-load tap-changer (inspection glass on the tap-changer head) have the same reading in every operating position.
NOTE
When installing the drive shaft, make sure that the shaft ends to be connected are exactly aligned and the coupling bolts are greased. Square tubes, coupling brackets, coupling bolts and screws are corrosion-resistant. The guard plate, which serves as a foot step protection for the horizontal drive shaft over the transformer cover, and the square tubes are supplied in oversized lengths (various standard lengths). These parts must be cut to the required size before mounting. Before coupling the upper gear unit of the tap-changer head, operate the on-load tap-changer to the exact adjustment position (including idling) as follows: Loosen the screws on the tap-changer head cover (24 bolts M10/w.s. 17, locking washers), raise the tap-changer cover at least 15 mm so that the upper gear unit disengages. Support the tap-changer cover using suitable pieces of wood or similar. Turn the upper gear unit of the tap-changer cover in the desired direction so the drive shaft can be properly coupled. Check the position of the driven shaft on the output side of the gear unit below the tap-changer cover and turn the drive shaft manually until the driven shaft engages into the coupling of the gear unit. Remove the supporting pieces of wood and fix the tap-changer cover again, 24 bolts M10/w.s. 17, max. torque 34 Nm, locking washers for securing. Finally, check the idling torque of the motor-drive unit against the diverter switch operation of the tap-changer according to our Operating Instructions no. 271 for the motor-drive unit ED-Ex.
CAUTION
If the position indicators on the on-load tap-changer and the motor-drive read different operating positions, there is a coupling fault. Operating the equipment with incorrect coupling will result in damage to the on-load tap-changer and to the transformer. The transformer may not be put into operation. Check that the automatic switch-off is working in both end positions and check the function of the electrical and mechanical end position limits (see Operating Instructions no. 271 for the motor-drive ED-Ex).

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14 Commissioning the OLTC at the transformer manufacturer's site
14.2
Complete oil filling
CAUTION
Vacuum filling is imperative after installation and maintenance.
In order to comply with the explosion protection requirements, the complete oil system of the on-load tap-changer has to be fully vented. Bleed as follows: bleed the oil chamber of the tap-changer head using the bleeder valve in the tap-changer head cover (E1): Open the screw cap M30/w. s. 36, torque 10 Nm (fig. 17), lift the valve tappet using a screwdriver. the elbow connection with bleeder screw: screw cap M16/w.s. 22, max. torque 9 Nm, bleeder screw M6 with slotted head, torque 2 Nm (fig. 18). 14.3 Ground Connections
17
KHW 1157
Connect the ground screw of the tap-changer head to the transformer cover (1 screw M12 with nut (w. s. 19), torque 60 Nm, fig. 19). Connect the ground screw of the motor-drive protective housing to the transformer tank. 14.4 Electrical tests on the transformer
The electrical tests required for the final inspection of the transformer can be performed after the afore-mentioned work has been completed.
18
19
273/02/01/0
r
KHW 1158
r
23
15 Transport to the operating site 16 Commissioning at the operating site
15
Transport to the operating site
16
Commissioning at the operating site
If the motor-drive unit has to be dismounted for the transport of the transformer to the operating site, operate it to the adjustment position and then uncouple it.
Before commissioning the transformer, a function test must be carried out on the on-load tap-changer and motor-drive unit according to section 14.1. The function of the protective relay should also be checked at this point.
CAUTION NOTE
Do not operate the motor-drive unit while it is not coupled to the on-load tap-changer. The protective relay must be inserted into the tripping circuit of the circuit breakers so the transformer is immediately shut down by the circuit breakers when the protective relay is triggered (see Operating Instructions no. 272 for the protective relay RS 2001-Ex). As a control test, trigger the connected circuit breaker by activating the test button "OFF" of the protective relay. Make sure that closing of the circuit breakers is only possible again after the protective relay has been brought to the "IN SERVICE" position by pressing the other test button.
Follow the instructions in section 13.1 and 13.3 in order to re-install the motor-drive unit.
NOTE
If the transformer is filled with oil, but is stored or transported without an oil conservator, a pipe must be connected between the interior of the tap-changer oil compartment and the transformer oil chamber to equalize the static pressure.
CAUTION
The relevant safety regulations must be observed here.
This pipe should be connected on the tap-changer head between the connections E2 and one of the free connections R, S or Q. It is sufficient to lower the oil level in the tap-changer head by approx. 7 litres for short standing periods, 2-4 weeks, without an oil conservator. If the transformer is completely emptied of oil, the tapchanger insulating oil must also be completely drained. The interior of the oil compartment is to be conserved in the same way as the transformer (e.g. by filling with nitrogen). For longer standing periods, the motor-drive unit heating must be connected and operated.
CAUTION
Check that all stop valves between the oil conservator and the on-load tap-changer are open. After energizing the transformer, tap change operations under load can be performed.

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17 Monitoring during service 18 Failures
17
Monitoring during service
18
Failures
Monitoring the on-load tap-changer and motor-drive unit is limited to regular visual inspections of the tap-changer head, protective relay and motor-drive unit. These can be carried out at the same time as the usual control inspections on the transformer. Pay particular attention to the following: sealing points of the tap-changer head, protective relay and connected pipes are to be oil-proof, sealings of the protective housing of the motor-drive unit, trouble-free functioning of the built-in electrical heating in the protective housing of the motor-drive unit, silicagel breather for the tap-changer oil conservator is to be in perfect condition function test of the protective relay according to Operating Instructions no. 272 for protective relay RS 2001-Ex. The insulating oils in the transformer should be monitored by the user according to the relevant regulations (also see section 19).
WARNING
If the protective relay is triggered, the on-load tapchanger and transformer must be thoroughly checked. This involves withdrawing the tap-changer insert and checking it according to the Maintenance Manual. For more details of the protective relay RS 2001-Ex, follow the Operating Instructions no. 272. This applies analogously when other protective device e. g. the pressure relief device trip in the on-load tapchanger. Only operate the equipment again when you are sure there is no damage to the on-load tap-changer or to the transformer. Operating the transformer without prior checking is not permitted as serious damage to the on-load tap-changer and the transformer can occur. For more serious problems with the on-load tap-changer or motor-drive unit, which cannot be rectified easily on site, or if the protective relay is triggered, please inform your authorised MR representative or the transformer manufacturer. Alternatively, contact us directly at Maschinenfabrik Reinhausen GmbH Technical Service Postfach 12 03 60 93025 Regensburg Germany Telephone: (+49) 9 41 40 90-0 Fax: (+49) 9 41 40 90-501 Email: service@reinhausen.com Internet: www.reinhausen.com

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25
19 Maintenance
19
Maintenance
In such a case, we would ask you to forward us a report on the maintenance performed, to complete our maintenance records. For inquires about spare parts we ask you to inform us about the serial number (see the name plate on the motordrive unit) and the number of switching operations. In addition to the maintenance intervals mentioned above the switching elements of the diverter switch unit must be replaced after 600,000 tap-change operations, the diverter switch insert and the gearing mechanism after 1,200,000 tap-change operations and the change-over selector of the on-load tapchanger after 2,100,000 tap-change operations (counter reading/motor drive). In addition, the limit values in Table I below should be considered when exchanging or treating the diverter switch oil.
Maintenance intervals: Maintenance has to be carried out on the VACUTAP VVEx after every 300,000 tap-change operations. The scope and type of maintenance are specified in the corresponding Maintenance Instructions from MR. If the appropriate preparations are made, a proper maintenance can be carried out within a day.
WARNING
Disregarding the maintenance intervals or an incomplete / improper maintenance can lead to severe damage on the on-load tap-changer and the transformer. The on-load tap-changer VACUTAP V V-Ex with VACUTAPvacuum switching technology has considerably longer maintenance intervals when compared to conventional tapchangers with oil switching technology, which dramatically lowers operating and maintenance costs. This means that properly conducted maintenance is even more important. For this reason we emphatically recommend that our Technical Service Department carry out each maintenance. As well as guaranteeing that all work is properly carried out, specific components are also retro-fitted to the latest standard of technology. If a maintenance is not carried out by our Technical Service department, please ensure that the personnel who carry out the maintenance are trained by MR or are otherwise suitably qualified to carry out the work.
CAUTION
The oil compartment and its associated oil conservator must only be filled with new insulating oil for transformers according to IEC 60296 (Specification for unused mineral insulating oils for transformers and switchgear) and IEC 60422 (Supervision and maintenance guide for mineral insulating oils in electrical equipment). For dielectric strength limit values see table 1. The use of any other oils may put the trouble-free operation of the on-load tapchanger and the transformer at risk.
Limit values for the exchange or treatment of the tap-changer oil: On-load tap-changer V V III 250 Y, V V III 400 Y, V V III 600 Y V V I 401 !, V V III 250 !, V V III 400 !" V V III 600 ! Table I *) measured according to IEC 60156 The temperature of the oil sample at the time of measuring the dielectric strength should be noted. The given values for dielectric strength are valid for oil temperatures of 20 5 C. Dielectric Strength*) 30 kV/2.5 mm (minimum) 40 kV/2.5 mm (minimum)

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20 Appendix
20
Appendix
Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36 Page 37 Page 38 Page 39 Page 40 Page 41
On-load tap-changer VACUTAP V V-Ex, tap-changer head .............................................................................................. 725210 On-load tap-changer VACUTAP V V, tap-changer head ................................................................................................... 898863 On-load tap-changer VACUTAP V V-Ex, installation drawing ......................................................................................... 898864 On-load tap-changer VACUTAP V V-Ex, drilling template for the tap-changer head ............................................... 893787 On-load tap-changer VACUTAP V V-Ex, assembly drawing .............................................................................................. 898866 On-load tap-changer VACUTAP V V-Ex, mounting of the bell-type cover ................................................................... 899110 On-load tap-changer VACUTAP V V-Ex, position of the on-load tap-changer ........................................................... 899409 On-load tap-changer VACUTAP V V-Ex, transport instructions ....................................................................................... 899063 On-load tap-changer VACUTAP V V-Ex, switching sequence .......................................................................................... 899083 On-load tap-changer VACUTAP V V-Ex, positioning of connection terminals ........................................................... 899051 Protective Relay RS 2001-Ex ...................................................................................................................................................... 723653 TAPMOTION ED-S-Ex, protective housing ............................................................................................................................. 898743 TAPMOTION ED-Ex, protective housing-Ex, damped against vibration ........................................................................ 734850 Bevel gear, dimension drawing ................................................................................................................................................. 892916


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27
72521001E
On-load tap-changer VACUTAP V V-Ex Tap-changer head

273/02/01/0
8988637E
On-load tap-changer VACUTAP V V-Ex Tap-changer head

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29
8988646E
On-load tap-changer VACUTAP V V-Ex Installation drawing

273/02/01/0
8937870E
On-load tap-changer VACUTAP V V-Ex Drilling template for the tap-changer head
3 mm thick
Marks pounded

273/02/01/0
31
8988667E
On-load tap-changer VACUTAP V V-Ex Assembly drawing

273/02/01/0
8991103E
On-load tap-changer VACUTAP V V-Ex Mounting of the bell-type cover

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33
8994092E
On-load tap-changer VACUTAP V V-Ex Position of the on-load tap-changer

273/02/01/0
8990632E
On-load tap-changer VACUTAP V V-Ex Transport instructions

273/02/01/0
35
8990831E
On-load tap-changer VACUTAP V V-Ex Switching sequence

273/02/01/0
8990515E
On-load tap-changer VACUTAP V V-Ex Positioning of connection terminals

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37
7236530E
Protective relay RS 2001-Ex Dimension drawing
Inspection window
Cable gland M25 x 1.5
Name plate
Gasket
Gasket
Test push buttons Earth terminal IN SERVICE (reset) OFF (test tripping)
Identification label
The arrow must always point towards the oil pipe leading to the oil conservator of the transformer.
Plan view of test push buttons (cover removed)
Key of versions
Contact positions Arrangement of terminals IN SERVICE OFF
Version
Relay designation1)
Reed switch
0.65 1.2 3.0 4.8 0.65 1.2 3.0 4.8 0.65 1.2 3.0 4.8
2NO / EX 2NO / EX 2NO / EX 2NO / EX 2NC / EX 2NC / EX 2NC / EX 2NC / EX NO + NC / EX NO + NC / EX NO + NC / EX NO + NC / EX
2A
2B
1 A und 1 B
1)
NO - normally open, NC - normally closed
The protective relay is to be connected in such a way that if it is energized, the power transformer is switched off immediately by the corresponding circuit breakers.

273/02/01/0
8987434E
TAPMOTION ED-S-Ex Protective housing

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39
7348500E
TAPMOTION ED-Ex Protective housing-Ex, damped against vibration

273/02/01/0
8929166E
Bevel gear Dimension drawing

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e2 = 215 for design with ball joint
e1 = 205 for standard design
41
www.reinhausen.com
Maschinenfabrik Reinhausen GmbH Falkensteinstrae Reinhausen GmbH Maschinenfabrik 8 93059 Regensburg 8 Falkensteinstrasse 93059 Regensburg, Germany
Telefon Telefax Phone E-Mail Fax E-mail
+49 941 40 90-0 +49 941 40 90-111 +49 941 40 90-0 sales@reinhausen.com +49 941 40 90-111 sales@reinhausen.com
BA 273/02 en 0208/20 273/02/01/0 F0144601 Printed in Germany

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On-load tap-changer VACUTAP V V-EX

BA 273/02 - VACUTAP V V-Ex

BA 273/02 - VACUTAP V V-Ex 4

BA 273/02 - VACUTAP V V-Ex

BA 273/02 - VACUTAP V V-Ex 6

Standards and regulations for explosion-proof on-load tap-changers

Standards and regulations for explosion-proof on-load tap-changers

Protection type Explosion-proof equipment

Equipment category / zone classification

450 C 300 C 200 C 135 C 100 C 85 C

BA 273/02 - VACUTAP V V-Ex

Explosion protection types

Measures for ensuring compliance with explosion protection requirements

BA 273/02 - VACUTAP V V-Ex 8

On-load tap-changer oil system

On-load tap-changer oil system equipment

BA 273/02 - VACUTAP V V-Ex 10

Installing the on-load tap-changer for cover mounting

Installing the on-load tap-changer for cover mounting

Installing the on-load tap-changer for cover mounting

Installing the on-load tap-changer in a transformer with bell-type cover

Installing the on-load tap-changer in a transformer with bell-type cover

BA 273/02 - VACUTAP V V-Ex

8 Installing the on-load tap-changer in a transformer with bell-type cover

Connecting the tap winding and the tap-changer take-off terminal

Attaching the bell-type cover

BA 273/02 - VACUTAP V V-Ex

10 Transformer ratio test 11 Drying process and oil filling

Transformer ratio test

Drying process and oil filling

11.1.1.1 Vacuum-drying in the autoclave

BA 273/02 - VACUTAP V V-Ex 18

11 Drying process and oil filling

11.1.1.2 Vacuum-drying in the transformer tank

11.1.2.1 Vapour-phase drying in the autoclave

BA 273/02 - VACUTAP V V-Ex

11 Drying process and oil filling 12 Pipe connections

BA 273/02 - VACUTAP V V-Ex 20

Mounting the motor-drive unit, bevel gear and drive shaft

Commissioning the on-load tapchanger at the transformer manufacturer's site

BA 273/02 - VACUTAP V V-Ex 22

14 Commissioning the OLTC at the transformer manufacturer's site

Complete oil filling

Vacuum filling is imperative after installation and maintenance.

15 Transport to the operating site 16 Commissioning at the operating site

Transport to the operating site

Commissioning at the operating site

BA 273/02 - VACUTAP V V-Ex 24

17 Monitoring during service 18 Failures

Monitoring during service

BA 273/02 - VACUTAP V V-Ex

BA 273/02 - VACUTAP V V-Ex 26

BA 273/02 - VACUTAP V V-Ex

On-load tap-changer VACUTAP V V-Ex Tap-changer head

BA 273/02 - VACUTAP V V-Ex 28

On-load tap-changer VACUTAP V V-Ex Tap-changer head

BA 273/02 - VACUTAP V V-Ex

On-load tap-changer VACUTAP V V-Ex Installation drawing

BA 273/02 - VACUTAP V V-Ex 30

BA 273/02 - VACUTAP V V-Ex

On-load tap-changer VACUTAP V V-Ex Assembly drawing