Table of contents Table of contents Introduction......................... 6 Manufacturer............................ 6 Completeness............................. 6 Safekeeping............................ 6 Notation conventions .......................... 7 1.4.1 Hazard communication system .......................... 7 1.4.2 Information system.............................. 8 1.4.3 Instruction system .............................. 8 Safety.......................... 10 Appropriate use .......................... 10 Inappropriate use.......................... 11 Fundamental safety instructions ....................... 11 Personal protective equipment ......................
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Table of contents Operation........................... 37 Operating the motor-drive unit with the hand crank................ 37 Fault elimination ....................... 39 Tripping the protective relay and re-commissioning the transformer.......... 41 6.1.1 Flap valve in OPERATION position ........................ 42 6.1.2 Flap valve in OFF position .......................... 42 6.1.3 Re-commissioning the transformer ........................ 42 Tripping the pressure monitoring device and putting the transformer back into operation ....
1 Introduction 1 Introduction This technical file contains detailed descriptions for monitoring during opera- tion, fault elimination, 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.
1 Introduction 1.4 Notation conventions 1.4.1 Hazard communication system Warnings in this technical file are displayed as follows. 1.4.1.1 Warning relating to section Warnings relating to sections refer to entire chapters or sections, sub-sec- tions or several paragraphs within this technical file. Warnings relating to sections use the following format: Type of danger! WARNING...
1 Introduction Pictograms warn of dangers: Pictogram Definition Warning of a danger point Warning of dangerous electrical voltage Warning of combustible substances Warning of danger of tipping Warning of danger of crushing Table 2: Pictograms used in warning notices 1.4.2 Information system Information is designed to simplify and improve understanding of particular procedures.
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1 Introduction Aim of action ü Requirements (optional). ► Step 1 of 1. ð Result of step (optional). ð Result of action (optional). Multi-step instructions Instructions which consist of several process steps are structured as follows: Aim of action ü Requirements (optional). 1.
2 Safety 2 Safety ▪ Read this technical file through to familiarize yourself with the product. ▪ This technical file is a part of the product. ▪ Read and observe the safety instructions provided in this chapter. ▪ Read and observe the warnings in this technical file in order to avoid func- tion-related dangers.
2 Safety Exceeding the rated step voltage U for a short period by up to 10% is per- mitted if the rated through-current I is not exceeded. 2.2 Inappropriate use Use is considered inappropriate if the product is used in a way other than as described in the "Appropriate use"...
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2 Safety Work area Untidy and poorly lit work areas can lead to accidents. ▪ Keep the work area clean and tidy. ▪ Make sure that the work area is well lit. ▪ Observe the applicable laws for accident prevention in the relevant coun- try.
2 Safety ▪ It is imperative that you consult with Maschinenfabrik Reinhausen GmbH because specific operating conditions apply to alternative insulating fluids. ▪ Only use conductive and grounded hoses, pipes, and pump equipment that are approved for flammable liquids. ▪ Only use lubricants and auxiliary materials approved by the manufacturer. ▪...
2 Safety 2.5 Personnel qualification The person responsible for assembly, commissioning, operation, mainte- nance and inspection must ensure that the personnel are sufficiently quali- fied. Electrically skilled person The electrically skilled person has a technical qualification and therefore has the required knowledge and experience, and is also conversant with the ap- plicable standards and regulations.
3 Product description 3 Product description 3.1 On-load tap-changer 3.1.1 Function description On-load tap-changers are used to adjust the transmission ratio of transform- ers without interrupting the load flow. Fluctuations in voltage occurring in the power transmission grid, for example, can therefore be compensated for. For this purpose, on-load tap-changers are fitted in transformers and connected to the active part of the transformer.
3 Product description 4 Bevel gear 9 Oil conservator 5 Horizontal drive shaft 10 Active part 3.1.2 Setup/models The following drawing shows the main components of the on-load tap- changer. You will find a detailed drawing of the on-load tap-changer in the "Drawings [►Section 9, Page 65]"...
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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 3: Pipe connections with pipe bends Pipe connection Q The pipe connection Q is closed with a blank cover.
3 Product description 3.1.3 Nameplate and serial number The nameplate is on the on-load tap-changer head cover. Figure 4: Nameplate with serial number 3.1.4 Protective devices The on-load tap-changer is equipped with the following protective devices. 3.1.4.1 Protective relay 3.1.4.1.1 Function description The protective relay is looped into the circuit breaker tripping circuit, thus protecting the on-load tap-changer and transformer in the event of a fault within the on-load tap-changer oil compartment.
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3 Product description 3.1.4.1.2 Design/versions Front view Figure 5: Protective relay RS 2001 1 Inspection window 2 Pressure equalization element Rear view Figure 6: Protective relay RS 2001 1 Dummy plug 2 Nameplate The protective relay RS 2001/R has an extra inspection window on the rear. ®...
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3 Product description View from above Figure 7: Protective relay RS 2001 1 Gasket 2 Potential tie-in 3 Terminal box cover 4 Slotted head screw for potential tie-in 5 OPERATION (reset) test button 6 Slotted head screw for protective cover 7 OFF (test tripping) test button 8 Cable gland 9 Protective cover 10 Dummy plug...
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The pressure monitoring device responds to large pressure increases faster than the protective relay. The protective relay is part of the standard MR pro- tection system and comes as standard.
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3 Product description Diverter switch operations at the rated switching capacity or permitted over- load do not cause the pressure-operated relay to trip. The pressure-operated relay responds to a pressure change and not to gas accumulation under the pressure-operated relay. Gas accumulation under the pressure-operated relay is normal.
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3.1.4.4 Pressure relief device MPreC® On request, MR will supply a pre-fitted MPreC® pressure relief device in place of the rupture disk. This device responds to a defined overpressure in the oil compartment of the on-load tap-changer.
3 Product description 3.1.4.6 Temperature monitoring The temperature monitoring system monitors the temperature of the insulat- ing fluid in the oil compartment of the on-load tap-changer. 3.2 Drive shaft 3.2.1 Function description The drive shaft is the mechanical connection between the drive and the on- load tap-changer/de-energized tap-changer.
3 Product description 3.2.2 Design/versions The drive shaft consists of a square tube and is coupled at each end by two coupling brackets and one coupling bolt to the driving or driven shaft end of the device to be connected. Figure 11: Components of the drive shaft 1 Bevel gear 2 Hose clip...
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3 Product description 3.2.2.1 Drive shaft without cardan joint and without insulator Figure 12: Drive shaft without cardan joint and without insulator (= standard version) Configuration V 1 min Intermediate bearing Middle of hand crank – middle of 536 mm When the maximum value bevel gear (maximum permissible of 2472 mm is exceeded, it axial offset 2°)
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3 Product description 3.2.2.2 Drive shaft without cardan joint and with insulator Figure 13: Drive shaft without cardan joint and with insulator (= special model) Configuration V 1 min Intermediate bearing Middle of hand crank – middle of 706 mm When the maximum value bevel gear (maximum permissible of 2472 mm is exceeded, it axial offset 2°)
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3 Product description 3.2.2.3 Drive shaft with cardan joint and without insulator Figure 14: Drive shaft with cardan joint and without insulator (= special model) Configuration V 1 min [mm] Intermediate bearing for [mm] Middle of hand crank – middle of V 1 >...
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3 Product description 3.2.2.4 Drive shaft with cardan joint and with insulator Figure 15: Drive shaft with cardan joint and with insulator (= special model) Configuration V 1 min [mm] Intermediate bearing for [mm] Middle of hand crank – middle of V 1 >...
4 Commissioning 4 Commissioning WARNING Danger of explosion! Explosive gases in the oil compartment of the on-load tap-changer, trans- former, pipework system, oil conservator and at the dehydrating breather opening can deflagrate or explode and result in severe injury or death! ►...
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4 Commissioning NOTICE! Check whether the on-load tap-changer head cover has a flange for attaching a pressure relief device. If it does, operation without a pressure relief device is not permitted and may result in damage to the on-load tap-changer. ð...
4 Commissioning 4.1.2 Bleeding on-load tap-changer head and suction pipe 4.1.2.1 Bleeding on-load tap-changer head 1. Open all forward and return valves in the pipe system. 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 18: Air-vent valve E1 3.
4 Commissioning 4.1.2.2 Bleeding suction pipe on pipe connection S 1. Remove screw cap from pipe connection S. Figure 20: Pipe connection S 2. Open vent screw and bleed piping. 3. Close vent screw. 4. Seal vent screw with screw cap. 4.1.3 Checking motor-drive unit Damage to the on-load tap-changer / de-energized tap-changer! NOTICE...
Tests on the motor-drive unit 1. Perform function checks as described in relevant MR operating instruc- tions for motor-drive unit. NOTICE! An incorrectly coupled motor-drive unit will lead to damage to the on-load tap-changer.
4 Commissioning 4. Loosen the three screws on the terminal box cover and lift off the terminal box cover. 5. Remove the slotted head screw for potential tie-in and remove the termi- nal box cover with wire. 6. Press OFF test button. 7.
4 Commissioning 7. Ensure that the transformer's circuit breaker cannot be closed. ð Passive protection test 8. Activate the sensor on the snap-action switch. ð Sensor is in the OPERATION position. 9. Leave the transformer's danger zone. 10. Close the transformer's circuit breaker with isolating switches open and the transformer grounded on all sides.
5 Operation 5 Operation 5.1 Operating the motor-drive unit with the hand crank WARNING Danger of explosion! Unauthorized operation of the motor-drive unit with the hand crank may re- sult in death or serious injury. ► Never operate the motor-drive unit electrically or with the hand crank be- fore the transformer has been disconnected if you think there may be a fault in the transformer or on-load tap-changer / de-energized tap- changer.
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5 Operation 2. Switch off motor protective switch Q1 (position 0). 3. Insert the hand crank mounted in the motor-drive unit into the hand crank aperture in the upper cover plate. ð The built-in hand crank interlock switch interrupts the motor circuit at two poles.
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 protective relay or additional pro- tective devices have been tripped, please inform your authorized MR repre- sentative, the transformer manufacturer or contact MR directly.
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If the fill level has fallen below the limit values, also contact MR. On-load tap-changer not changing tap position (sluggish- Contact MR.
6 Fault elimination Fault description Action Red message on monitoring unit If possible read out database and send to MR along with error code. Warning or tripping of Buchholz relay on transformer Notify manufacturer of transformer. Deviation from desired value when measuring winding re-...
6 Fault elimination 4. Check the on-load tap-changer head cover. If insulating fluid is leaking, close the oil conservator stop valve immediately. 5. Check whether the flap valve of the protective relay is in the OFF or OP- ERATION position. 6.1.1 Flap valve in OPERATION position If the flap valve is in the OPERATION position, there may be a fault in the tripping circuit.
6 Fault elimination 6.2 Tripping the pressure monitoring device and putting the transformer back into operation WARNING Danger of death or severe injury! Danger of severe injury or death if on-load tap-changer and transformer are insufficiently tested. ► Be sure to contact Maschinenfabrik Reinhausen to check on-load tap- changer and transformer after the pressure monitoring device has been tripped.
6 Fault elimination 2. Contact and inform Maschinenfabrik Reinhausen of the following: ð What was the load of the transformer at the instant of tripping? ð Was there a tap-change operation on the on-load tap-changer immedi- ately before or during the tripping? ð...
7 Maintenance 7 Maintenance DANGER Electric shock! An energized transformer could cause death or serious injuries. ► Switch off transformer on high and low-voltage side. ► Lock transformer to prevent unintentional restart. ► Ensure that everything is de-energized. ► Visibly connect all transformer terminals to ground (grounding leads, grounding disconnectors) and short circuit them.
7 Maintenance 7.1 Inspection Monitoring the on-load tap-changer and motor-drive unit is limited to occa- sional visual checks of the on-load tap-changer head, protective relay and motor-drive unit, as well as monitoring the quality of the insulating fluid. For efficiency reasons these visual inspections can be combined with the usual checks on the transformer.
► Adherence to the following maintenance intervals is mandatory. If you are operating the on-load tap-changer without an MR monitoring sys- tem, the following maintenance intervals shall apply.
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MR monitoring system issues a maintenance warning. ► In the event of failure or shutdown of the MR monitoring system, observe the maintenance intervals as specified in the maintenance plan without the MR monitoring system.
7 Maintenance 7.3 Changing the insulation fluid NOTICE Damage to the on-load tap-changer! Small parts in the oil compartment may block the diverter switch insert, thereby damaging the on-load tap-changer. ► Ensure that parts do not fall into the oil compartment. ►...
7 Maintenance 2. Depending on version, loosen 4 or 6 screws on coupling brackets to upper gear unit and bevel gear. Figure 23: Loosening coupling brackets 3. Remove horizontal drive shaft. Be sure not to lose the coupling bolts. Figure 24: Removing drive shaft 7.3.3 Emptying the oil compartment and oil conservator 1.
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7 Maintenance 4. Once the gas has been discharged and insulating fluid is flowing out of the air-vent valve, close the air-vent valve. 5. Close the stop-cock between the oil conservator and on-load tap-changer. 6. Open air-vent valve E1 again and extract approximately 5–10 liters of in- sulating fluid via the pipe connection S until the area under the on-load tap-changer head cover is free of insulating fluid.
7 Maintenance 7.3.4 Filling the oil compartment and oil conservator with fresh insulating fluid NOTICE Damage to the on-load tap-changer! Unsuitable insulating fluids cause damage to the on-load tap-changer. ► Use insulating fluids that meet the requirements in accordance with IEC 60296.
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7 Maintenance 6. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). 7. Remove screw cap from pipe connection S. Figure 28: Pipe connection S 8. Open vent screw and bleed piping. 9. Close vent screw. 10. Seal vent screw with screw cap. 11.
7 Maintenance 7.3.5 Installing horizontal drive shaft 1. Secure horizontal drive shaft between upper gear unit and bevel gear with coupling brackets and 4 or 6 screws. Refer to the drive shaft operating in- structions for details. Figure 29: Securing drive shaft ®...
3. For special design types featuring cardan shafts, be sure to check the ex- pansion bellows and the lubricant reservoir of the cardan shafts. You will find a detailed description of how to fit the drive shaft in the MR op- erating instructions "Drive shaft".
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7 Maintenance Perform the DC resistance measurement in various on-load tap-changer op- erating positions. You need to distinguish here whether the measured cur- rent is interrupted when changing operating position or not. Status of oil compart- Without interruption in With interruption (mea- ment measured current sured current = 0 A be-...
8 Technical data 8 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. 8.1 Technical data for on-load tap-changer 8.1.1 On-load tap-changer properties Electrical data for VACUTAP® VV®...
8 Technical data Transport temperature, storage temperature - 40 °C…+ 50 °C Drying temperatures See installation and commissioning instructions, chapter "As- sembly" Compressive strength See technical data TD 61 – general section Alternative insulating liquids Natural ester liquid (IEC 62770) on request Synthetic ester liquid (IEC 61099) on request Installation height of the oil conservator See technical data TD 61 –...
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8 Technical data Switching capacity (switching load on an off) Minimum switched current AC/DC (low- 50 mA (at 24 V) est voltage) Minimum switched current AC/DC (high- 4.8 mA (at 250 V) est voltage) Maximum switched current DC (highest 1.6 A (at 125 V with L/R = 40 ms) current) Maximum switched current DC (highest 0.9 A (at 250 V with L/R = 40 ms)
8 Technical data Switching capacity (switching load on an off) Maximum switched current AC (highest 1.6 A (at 250 V with cos φ = 0.6) voltage) Switching operations 1,000 cycles Table 16: Switching capacity (switching load on an off) Dielectric strength AC dielectric strength between all volt- 2,500 V, 50 Hz, test duration 1 minute age-carrying connections and the...
8 Technical data Switching capacity (switching load on an off) Maximum switched current DC (highest 0.6 A (at 250 V with L/R = 40 ms) voltage) Maximum switched current AC (highest 1 A (at 200 V with cos φ = 0.6) current) Maximum switched current AC (highest 0.8 A (at 250 V with cos φ...
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8 Technical data Sealing material VITON (oil – air) Permitted pressure range 1 bar…6 bar, vacuum not permitted (absolute pressure) Upper switching pressure 3.8 ± 0.2 bar (trip pressure) Lower switching pressure 2,8 ± 0,2 bar Snap-action switch Connection terminals Lead connection: 1 or 2 leads per terminal (Ø 0.75…2.5 mm²) Contacts 1xNO (normally open), 1xNC (normally closed)
8 Technical data 8.5 Limit values for dielectric strength and water content of insulating fluids The following tables specify the limit values for dielectric strength (measured in accordance with IEC 60156) and water content (measured in accordance ® with IEC 60814) of insulating fluids for the VACUTAP on-load tap-changer.
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11 = Change-over selector pipe 12 = Change-over selector terminal "+" 13 = Change-over selector terminal "0" 14 = Change-over selector terminal "-" 21 = Take-off terminal 22 = Fine tap selector terminal 23 = Oil compartment bottom with kerosene drain plug 23a 24 = Tap changer oil compartment 30 = Tap changer head complete with 31 und 32 , refer to 898 863 : and 737 060 : 31 = Tap changer head - bottom part...
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O 660 O 509 O 489 only with 145 kV 15° Bleeding facility for Tap-Changer Tap-Changer head - bottom part Tap-Changer head - top part , can be turned towards the bottom part 31 of the head in steps of 15° The Tap-Changer head cover cannot be turned.
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POSITION OF THE UPPER PART OF THE OLTC HEAD IN THE MODEL WITH OIL SUCTION PIPE ALL OTHER DIMENSIONS OF THE OLTC HEAD SEE DRAWING 898 863 : = DRIVE SIDE THE UPPER PART OF THE OLTC HEAD 32 CANNOT BE TURNED IN THE MODEL WITH OIL SUCTION PIPE ON-LOAD TAP-CHANGER VACUTAP ®...
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Mounting flange on transformer cover Transformer cover On-Load Tap-Changer Withdrawal height V V I - 76 kV 920 mm V V I - 145 kV 1070 mm V V III - 40 kV 1910 mm V V III - 76 kV V V III - 145 kV 2310 mm The withdrawal height corresponds to the clearance between the cover flange and the lifting device of...
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Pipe connection "S" Oil suction pipe Drive side The upper part of the OLTC head 32 CANNOT be turned in the model with oil suction pipe , see drawing 737 060 : On-Load Tap-Changer VACUTAP ® V V 739172 0E Oil suction pipe (optional) dftr.
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Lifting device optional 712645: Width of gasket Transformer cover O 489 only with 145 kV O 535,5 Attention! Make sure that hooks and gear parts do not collide! O 18 Centering bolts 3x O - ring On-Load Tap-Changer VACUTAP V V assembly drawing cover mounting 8988668E Str 22.11.02...
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Lifting device optional 712645: Width of gasket Transformer cover O 489 only with 145 kV Support on the transformer Supporting flange Attention! O 535,5 Make sure that hooks and gear parts do not collide! O 18 O - ring Centering bolts 3x On-Load Tap-Changer VACUTAP V V assembly drawing bell-type mounting 8991104E...
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Support on transformer Swivelling range Support on transformer Swivelling range Support on Ensure free movement transformer of change-over selector lever only with 145 kV On-Load Tap-Changer VACUTAP V V 8994093E Positioning of OLTC for bell-type mounting DC 22.11.02 gez. gepr. Albrecht DIN A3...
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ca. 150 ms Tap selector contacts, main path Main switching contacts (vacuum interrupter), main path Tap selector contacts, transition path Transition contacts (vacuum interrupter), transition path Sliding take-off contacts Transition resistor Circulating current Switching sequence, 10 pitch On-Load Tap-Changer VACUTAP V V Switching operation 8990831E DC 07.02.02...
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22 Fine tap selector terminal If necessary compensate with washers These terminals are to be fitted with screening caps (included in MR's delivery) by the transformer manufacturer. M = Drive side The connecting diagram is binding for the designation of the terminals and phases On-Load Tap-Changer VACUTAP ®...
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Terminal block Position indicator with 8 x M6 triangle for adjustment position 36,5 M20 x 1,5 Clamping area ø7 - ø13 mm Note: Take care when when installing the electrical lines so that they do not obstruct the OLTC cover when it is opened for maintenance. On-Load Tap-Changer VACUTAP®...
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Glossary Glossary Change-Over contact Ingress protection Direct current Maschinenfabrik Reinhausen GmbH Dielectric strength Material-specific property of isolators [kV/2.5 Normally Closed contact mm]; maximum electrical field strength without a breakdown (arc) Normally Open contact The International Electrotechnical Commission (IEC for short) is involved in the preparation and National Pipe Thread (US thread standard) publication of international standards for electri- cal, electronic and related technologies.
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