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MR VACUTAP VV-Ex Series Operating Instructions Manual

On-load tap-changer
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On-Load Tap-Changer
VACUTAP® VV-Ex
Operating Instructions
4983689/00 EN

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Summary of Contents for MR VACUTAP VV-Ex Series

  • Page 1 On-Load Tap-Changer VACUTAP® VV-Ex Operating Instructions 4983689/00 EN...
  • Page 2 © All rights reserved by Maschinenfabrik Reinhausen Dissemination and reproduction of this document and use and disclosure of its content are strictly prohibited unless expressly permitted. Infringements will result in liability for compensation. All rights reserved in the event of the granting of patents, utility models or designs.

  • Page 3: Table Of Contents

    Table of contents Table of contents Introduction......................... 6 Validity..............................6 Manufacturer............................6 Subject to change without notice......................7 Completeness............................7 Safekeeping............................7 Notation conventions........................... 7 1.6.1 Symbols................................. 8 1.6.2 Hazard communication system..........................9 1.6.3 Information system.............................. 10 Safety..........................11 General safety information........................ 11 Appropriate use..........................
  • Page 4 Table of contents 3.2.3 Name plate................................26 Drive shaft............................26 3.3.1 Function description............................26 3.3.2 Design/versions..............................28 3.3.3 Identification plate............................... 30 Protective relay..........................30 3.4.1 Function description............................30 3.4.2 Setup/versions..............................31 3.4.3 Name plate................................32 Commissioning the transformer at the operating site..........33 Checking motor-drive unit........................
  • Page 5 On-load tap-changer head with oil suction pipe (737060)..............55 Installation drawing (738902)......................56 Oil suction pipe (739172)........................57 Dimensions of oil suction pipe (not supplied by MR, 734342)............58 Tracing template for on-load tap-changer head (893787)..............59 Mounting drawing (898866)....................... 60 Mounting with bell-type tank installation (899110)................

  • Page 6: Introduction

    1 Introduction Introduction This technical file contains detailed descriptions for monitoring during opera- tion, troubleshooting, and maintenance. It also includes safety instructions and general information about the prod- uct. Information about installation can be found in the installation and commis- sioning instructions.

  • Page 7: Subject To Change Without Notice

    1 Introduction Falkensteinstraße 8 93059 Regensburg, Germany Tel.: (+49) 9 41/40 90-0 Fax: (+49) 9 41/40 90-7001 E-mail: sales@reinhausen.com Further information on the product and copies of this technical file are avail- able from this address if required. Subject to change without notice The information contained in this technical file comprises the technical speci- fications approved at the time of printing.

  • Page 8: Symbols

    1 Introduction 1.6.1 Symbols Symbol Meaning Wrench size Tightening torque Number and type of fastening material used Fill with oil Cut open, cut through Clean Visual inspection Use your hand Adapter ring Apply a coat of paint Use a file Grease Coupling bolt Use a ruler...

  • Page 9: Hazard Communication System

    1 Introduction Symbol Meaning Wire eyelet, safety wire Use a screwdriver Apply adhesive Lock tab Table 1: Symbols 1.6.2 Hazard communication system Warnings in this technical file are displayed as follows. 1.6.2.1 Warning relating to section Warnings relating to sections refer to entire chapters or sections, sub-sec- tions or several paragraphs within this technical file.

  • Page 10: Information System

    1 Introduction Signal Meaning word WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in injury. NOTICE Indicates measures to be taken to prevent damage to property.

  • Page 11: Safety

    2 Safety Safety General safety information This technical file contains detailed descriptions of the safe and proper oper- ation of the product and monitoring during operation. ▪ Read this technical file through carefully to familiarize yourself with the product. ▪ Particular attention should be paid to the information given in this chap- ter.

  • Page 12: Standards And Regulations

    2 Safety Unauthorized or inappropriate changes to the product may lead to personal injury, material damage, and operational faults. Only modify product follow- ing discussion with Maschinenfabrik Reinhausen GmbH. Standards and regulations The standards and regulations which apply to the explosion-protected prod- uct are described in the following chapters.
  • Page 13 2 Safety Equipment category / zone classification (number 3) Designa- Designa- Definition tion for tion for gases dusts Equipment in this category is intended for use in areas in which explosive atmospheres (20) caused by mixtures of air and gases, vapors or mists or by air/dust mixtures are present continuously, for long periods or frequently.

  • Page 14: Standards And Regulations

    2 Safety EN/IEC Gases, vapors (examples) Min. ignition energy (mJ) Ethylene, isoprene, town gas 0.06 Acetylene, carbon disulfide, hy- 0.02 drogen Table 8: Explosion groups Temperature classes (number 7) Tempera- Maximum equipment surface Ignition tempera- ture class temperature ture of the flamma- ble substances 450 °C >...

  • Page 15: Measures For Ensuring Compliance With Explosion Protection Requirements

    2 Safety Measures for ensuring compliance with explosion protection requirements 2.5.1 Measures taken by the manufacturer Maschinenfabrik Reinhausen has taken the following measures for ensuring compliance with explosion protection requirements. You do not need to take any special measures in this regard. 2.5.1.1 Quality of the insulating oil in the on-load tap-changer The quality of the insulating oil required by IEC 60296 and the quality of the...
  • Page 16 2 Safety 2.5.2.2 Setting up the on-load tap-changer oil system Operate the on-load tap-changer only with a suitable oil system. This divert- er switch oil system consists of the diverter switch oil compartment, protec- tive relay, and oil conservator of the on-load tap-changer. It ensures that enough insulating oil is present in the diverter switch oil compartment at all times.
  • Page 17 2 Safety 2.5.2.3.1 Dehydrating breather The oil conservator must be equipped with a dehydrating breather in accord- ance with VDE 0532-216-5. The dehydrating breather prevents water, impur- ities, insects etc. from entering the insulating oil. 2.5.2.3.2 Level indicator The oil conservator must have a level indicator from which the minimum oil quantity required and the maximum quantity permitted, as well as the current oil level, can be read.

  • Page 18: Personnel Qualification

    2 Safety 2.5.2.4 Corrosion protection measures Because further installation steps are required before operation of the on- load tap-changer, sufficient corrosion protection cannot be provided at cer- tain interfaces to the transformer when the device leaves the factory. Figure 2: On-load tap-changer head Sealing surface on piping con- Contact surface on on-load nection flange...

  • Page 19: Operator's Duty Of Care

    2 Safety Operator's duty of care To prevent accidents, disruptions and damage as well as unacceptable ad- verse effects on the environment, those responsible for transport, installa- tion, operation, maintenance and disposal of the product or parts of the prod- uct must ensure the following: ▪...

  • Page 20: Protective Devices

    2 Safety Always wear Protective clothing Close-fitting work clothing with a low breaking strength, with tight sleeves and with no protruding parts. It mainly serves to protect the wearer against being caught by moving machine parts. Do not wear any rings, necklaces or other jewelry.

  • Page 21: Protective Relay Rs 2001-Ex

    2 Safety 2.9.1 Protective relay RS 2001-Ex The protective relay RS 2001-Ex is an oil flow-controlled relay in accordance with IEC 60214-1. It is installed between the on-load tap-changer head and the oil conservator of the on-load tap-changer. It triggers when the specified oil flow between oil compartment of the on-load tap-changer and oil conservator is exceeded.

  • Page 22: Product Description

    3 Product description Product description This chapter contains an overview of the design and function of the product. Scope of delivery The product is packaged with protection against moisture and is usually de- livered as follows: ▪ Ex on-load tap-changer with and without change-over selector ▪...

  • Page 23: Setup/Models

    3 Product description A motor-drive unit which receives a control impulse (e.g. from a voltage reg- ulator) changes the operating position of the on-load tap-changer, as a result of which the transformer's transmission ratio is adapted to the prevailing op- erating requirements.
  • Page 24 3 Product description For the number of maximum operating positions of the on-load tap-changer, refer to the Technical data. Figure 4: VACUTAP® VV® Change-over selector Supporting flange On-load tap-changer head Connection contact 3.2.2.1 Pipe connections The on-load tap-changer head features 4 pipe connections for different pur- poses.
  • Page 25 3 Product description Depending on the order, some or all of these pipe connections are fitted with pipe bends ex factory. All pipe bends can be freely swiveled once the pres- sure ring is loosened. Figure 5: Pipe connections with pipe bends Pipe connection Q The pipe connection Q is closed with a blank cover.

  • Page 26: Name Plate

    3 Product description 3.2.3 Name plate The name plate is on the on-load tap-changer head cover. Figure 6: Position of name plate Drive shaft 3.3.1 Function description The drive shaft is the mechanical connection between drive and on-load tap- changer head. The bevel gear changes the direction from vertical to horizontal (see drawing 892916).
  • Page 27 3 Product description The explosion-proof drive shaft consists of a square tube with insulator and is coupled by two coupling brackets and one coupling bolt at both ends to the drive or driven shaft end of the device to be connected. Figure 7: Explosion-proof drive shaft with insulator Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN...

  • Page 28: Design/Versions

    3 Product description 3.3.2 Design/versions The design of the explosion-proof drive shaft is described in this section. Figure 8: Components of the explosion-proof drive shaft Bevel gear Hose clip Screws Telescopic protective tube Coupling bracket Insulator Double coupling bracket Square tube Adapter ring Protective cover Hose clip...
  • Page 29 3 Product description Configuration V 1 min Intermediate bearing [mm] for [mm] Distance between middle of V 1 > 2472 hand crank and middle of bevel gear, maximum permissible ax- ial offset 2° Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 30: Identification Plate

    3 Product description 3.3.3 Identification plate The identification plate is on the telescopic protective tube. Figure 9: Position of the identification plate Protective relay 3.4.1 Function description The protective relay is used to protect the on-load tap-changer and the transformer when a malfunction occurs in the diverter switch oil compartment or selector switch oil compartment.

  • Page 31: Setup/Versions

    3 Product description 3.4.2 Setup/versions Front view Figure 10: RS 2001-Ex Inspection window Gore membrane Rear view Figure 11: RS 2001-Ex Ground connection Name plate Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 32: Name Plate

    3 Product description View from above Figure 12: RS 2001-Ex Gasket Potential tie-in Terminal box cover OPERATION (reset) test but- Slotted head screw for poten- OFF (test tripping) test button tial tie-in Protective conductor connec- Protective cover with picto- tion gram for terminal assignment Cable bushing with dummy Connection terminal...

  • Page 33: Commissioning The Transformer At The Operating Site

    Proceed as follows: Checking motor-drive unit Before commissioning the transformer, repeat the function tests on the mo- tor-drive unit as described in MR operating instructions for motor-drive unit. Danger of death or severe injury! WARNING Danger of death or severe injury due to incorrect operation! ►...

  • Page 34: Checking Protective Relay

    4 Commissioning the transformer at the operating site NOTICE Damage to the on-load tap-changer and motor-drive unit! Damage to on-load tap-changer and motor-drive unit due to incorrect use of position transmitter equipment! ► Only circuits stated in the chapter Technical data for position transmitter equipment may be connected to the position transmitter module con- nections.

  • Page 35: Filling The Oil Compartment Of The On-Load Tap-Changer With Oil

    4 Commissioning the transformer at the operating site Filling the oil compartment of the on-load tap-changer with Danger of death or severe injury! WARNING Danger of death or severe injury from explosive gases under the on-load tap-changer head cover, in the pipework system, in the oil conservator or at the dehydrating breather opening! ►...

  • Page 36: Bleeding On-Load Tap-Changer Head And Suction Pipe

    4 Commissioning the transformer at the operating site Fill on-load tap-changer with new mineral insulating oil for transformers in accordance with IEC 60296 using one of the two free pipe connec- tions of the on-load tap-changer head. Figure 15: Pipe connection S and R Take oil sample from oil compartment.

  • Page 37: Bleeding Suction Pipe On Pipe Connection S

    4 Commissioning the transformer at the operating site Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on- load tap-changer head. Figure 17: Valve tappet Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). 4.4.2 Bleeding suction pipe on pipe connection S Remove screw cap from pipe connection S.

  • Page 38: Commissioning The Transformer

    Check, in both end positions, the function of the electrical and mechani- cal end stop (see MR operating instructions for motor-drive unit). Commissioning the transformer Loop the signaling contact for falling below the minimum oil level in the on-load tap-changer's oil conservator into the tripping circuit of the cir- cuit breaker.

  • Page 39: Operation

    5 Operation Operation The following sections describe the circumstances under which you are per- mitted to operate the motor-drive unit using the hand crank and how to moni- tor the on-load tap-changer and motor-drive unit. How to check the quality of the insulating oils is also explained.
  • Page 40 5 Operation Check the oil quality of the on-load tap-changer oil at regular intervals: ▪ 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 windings (class 2 in accordance with IEC 60214-1): every 2 years To do so, proceed as follows: Take oil sample from oil compartment.

  • Page 41: Fault Elimination

    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-Ex 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...
  • Page 42 Check that hose clips and protective covers are seated cor- rectly. Contact MR in the event of noise from the motor-drive unit. Red message on monitoring unit If possible read out database and send to MR along with error code.

  • Page 43: Tripping Of The Protective Relay And Re-Commissioning The Transformer

    Deviation from desired value during transformer ra- Contact manufacturer of transformer and, if neces- tio test sary, MR and provide measured values. Deviation from limit value for diverter switch oil val- Carry out oil change, check oil conservator breath- er of on-load tap-changer.

  • Page 44: Flap Valve In In Service Position

    6 Fault elimination 6.1.1 Flap valve in IN SERVICE position If the flap valve is in the IN SERVICE position, there may be a fault in the tripping circuit. Check the tripping circuit in this case. If you are not able to clarify why the protective relay tripped, be sure to contact Maschinenfabrik Reinhausen to check the on-load tap-changer.

  • Page 45: Inspection And Maintenance

    7 Inspection and maintenance Inspection and maintenance Risk of life-threatening injury due to electric shock! DANGER Electrical accidents have thermal and muscle-paralyzing effects which may be fatal. ► Work on the device and system peripherals may only be undertaken by qualified specialists, who are also familiar with the safety rules applica- ble in electrical operating facilities.

  • Page 46: Maintenance

    MR or are otherwise suitably qualified to carry out the work. In such cas- es, we would ask you to forward to us a report on the maintenance per- formed so we can update our maintenance files.
  • Page 47 7 Inspection and maintenance When using the TAPGUARD® 260 device, the maintenance intervals stated on the TAPGUARD® 260 device display apply. More information can be found in the operating instructions for the TAPGUARD® 260. Figure 19: Label showing maintenance intervals Interval Action after 150,000 switching operations...

  • Page 48: Oil Change

    7 Inspection and maintenance 7.2.2 Oil change Damage to the on-load tap-changer! NOTICE Damage to the on-load tap-changer resulting from switching the on-load tap-changer at impermissible oil temperatures! ► The on-load tap-changer can be operated in the temperature range of the surrounding transformer oil of between –25 °C and +105 °C and in accordance with IEC 60214-1 up to +115 °C (during emergency trans- former operation in accordance with IEC 60076-7).

  • Page 49: Technical Data

    8 Technical data Technical data An overview of all key technical data for the on-load tap-changer and motor- drive unit exists in the form of separate documents, which are available on request. Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 50: Limit Values For Dielectric Strength And Water Content Of On-Load Tap-Changer Oil

    8.1 Limit values for dielectric strength and water content of on-load tap-changer oil Limit values for dielectric strength and water content of on- load tap-changer oil The following table provides the limit values for dielectric strength (measured in accordance with IEC 60156) and water content (measured in accordance with IEC 60814) of the on-load tap-changer oil for VACUTAP®...

  • Page 51: 8.2 Technical Data For Protective Relay

    8.2 Technical data for protective relay Technical data for protective relay General technical data Housing Outdoor model Degree of protection IP 54 Relay actuation Flap valve with aperture Vibration immunity up to max. 3 g Weight approx. 3.5 kg Oil flow speed of available types 0.65 ±...

  • Page 52: Protective Relay With Several Dry-Reed Magnetic Switches

    8.2 Technical data for protective relay Maximum DC switching capacity 130 W Minimum switched current at 24 V 50 mA Minimum switched current at 250 V 4.8 mA Table 19: Connection to a non-inherently safe circuit Thermal data Ambient temperature Ta -25°...

  • Page 53: Drawings

    9 Drawings Drawings External view (737774) Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 54: On-Load Tap-Changer Head Without Oil Suction Pipe (898863)

    9 Drawings On-load tap-changer head without oil suction pipe (898863) VACUTAP® VV-Ex 4983689/00 EN Maschinenfabrik Reinhausen GmbH 2016...

  • Page 55: On-Load Tap-Changer Head With Oil Suction Pipe (737060)

    9 Drawings On-load tap-changer head with oil suction pipe (737060) Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 56: Installation Drawing (738902)

    9 Drawings Installation drawing (738902) VACUTAP® VV-Ex 4983689/00 EN Maschinenfabrik Reinhausen GmbH 2016...

  • Page 57: Oil Suction Pipe (739172)

    9 Drawings Oil suction pipe (739172) Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 58: Dimensions Of Oil Suction Pipe (Not Supplied By Mr, 734342)

    9 Drawings Dimensions of oil suction pipe (not supplied by MR, 734342) VACUTAP® VV-Ex 4983689/00 EN Maschinenfabrik Reinhausen GmbH 2016...

  • Page 59: Tracing Template For On-Load Tap-Changer Head (893787)

    9 Drawings Tracing template for on-load tap-changer head (893787) Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 60: Mounting Drawing (898866)

    9 Drawings Mounting drawing (898866) VACUTAP® VV-Ex 4983689/00 EN Maschinenfabrik Reinhausen GmbH 2016...

  • Page 61: Mounting With Bell-Type Tank Installation (899110)

    9 Drawings Mounting with bell-type tank installation (899110) Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 62: Position Of On-Load Tap-Changer (899409)

    9 Drawings 9.10 Position of on-load tap-changer (899409) VACUTAP® VV-Ex 4983689/00 EN Maschinenfabrik Reinhausen GmbH 2016...

  • Page 63: Position Of Connection Contacts (899051)

    9 Drawings 9.11 Position of connection contacts (899051) Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 64: Tap-Change Supervisory Control (733469)

    9 Drawings 9.12 Tap-change supervisory control (733469) VACUTAP® VV-Ex 4983689/00 EN Maschinenfabrik Reinhausen GmbH 2016...

  • Page 65: Bevel Gear Cd 6400, Dimensional Drawing (892916)

    9 Drawings 9.13 Bevel gear CD 6400, dimensional drawing (892916) Maschinenfabrik Reinhausen GmbH 2016 4983689/00 EN VACUTAP® VV-Ex...

  • Page 66: Glossary

    Glossary Glossary Dielectric strength Material-specific property of isolators [kV/2.5 mm]; maximum electrical field strength without a breakdown (arc) Dielectric strength Material-specific property of isolators [kV/2.5 mm]; maximum electrical field strength without a breakdown (arc) The International Electrotechnical Commission (IEC for short) is involved in the preparation and publication of international standards for electri- cal, electronic and related technologies.
  • Page 68 Phone: +60 3 2142 6481 E-Mail: sales@au.reinhausen.com Fax: +60 3 2142 6422 E-Mail: mr_rap@my.reinhausen.com Brazil P.R.C. (China) MR do Brasil Indústria Mecánica Ltda. MR China Ltd. (MRT) Av. Elias Yazbek, 465 CEP: 06803-000 开德贸易（上海）有限公司 Embu - São Paulo 中国上海浦东新区浦东南路 360 号...

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