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MR VACUTAP VV-Ex Installation And Commissioning Instructions

On-load tap-changer
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On-load tap-changer
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VACUTAP
VV-Ex
Installation and commissioning instructions
4983703/01 EN

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  • Page 1 On-load tap-changer ® VACUTAP VV-Ex Installation and commissioning instructions 4983703/01 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.........................  7 Manufacturer............................ 7 Completeness.............................  7 Safekeeping............................ 7 Notation conventions ..........................  7 1.4.1 Hazard communication system .......................... 7 1.4.2 Information system.............................. 9 1.4.3 Instruction system .............................. 9 Safety.......................... 11 Appropriate use .......................... 11 Inappropriate use.......................... 12 Fundamental safety instructions .......................  12 Standards and regulations........................
  • Page 4 Table of contents Packaging, transport and storage ..................  35 Packaging ............................ 35 4.1.1 Suitability................................ 35 4.1.2 Markings................................ 36 Transportation, receipt and handling of shipments................ 36 Storage of shipments........................ 37 Unpacking shipments and checking for transportation damages .............  38 Mounting ...........................  39 Installation information........................ 39 Preparatory work ..........................
  • Page 5 Table of contents 5.5.3 Fitting motor-drive unit ............................ 87 5.5.4 Fitting drive shaft.............................. 87 5.5.5 Centering on-load tap-changer and motor-drive unit .................. 111 5.5.6 Making the electrical connections for the motor-drive unit ................ 111 Commissioning.......................  112 Commissioning the on-load tap-changer at the transformer manufacturer's site ...... 112 6.1.1 Bleeding on-load tap-changer head and suction pipe.................. 112 6.1.2...
  • Page 6 On-load tap-changer head with oil suction pipe (737060) ..............  137 Installation drawing (738902)...................... 138 Oil suction pipe (739172)........................  139 Dimensions of oil suction pipe (not supplied by MR, 734342) ............ 140 Tracing template for on-load tap-changer head (893787) ..............  141 Mounting drawing (898866) ...................... 142 Mounting with bell-type tank installation (899110)................

  • Page 7: Introduction

    1 Introduction 1 Introduction This technical file contains detailed descriptions of the safe and proper in- stallation, connection, and commissioning of the product. It also includes safety instructions and general information about the prod- uct. Information about operation can be found in the operating instructions. This technical file is intended solely for specially trained and authorized per- sonnel.
  • Page 8 1 Introduction 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 Source of the danger and outcome. ►...

  • Page 9: Information System

    1 Introduction Pictogram Definition 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. In this technical file it is laid out as follows: Important information.
  • Page 10 1 Introduction Aim of action ü Requirements (optional). 1. Step 1. ð Result of step (optional). 2. Step 2. ð Result of step (optional). ð Result of action (optional). ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 11: Safety

    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.

  • Page 12: Inappropriate Use

    2 Safety In the standard version, the on-load tap-changer is designed for sinusoidal 50/60 Hz alternating current with a curve form symmetrical to the zero axis and can switch 1.5 times the rated through-current I at its rated step voltage Exceeding the rated step voltage U for a short period by up to 10% is per- mitted if the rated through-current I...
  • Page 13 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.

  • Page 14: Standards And Regulations

    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. ▪...
  • Page 15 2 Safety Equipment groups (number 2) 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.

  • Page 16: Standards And Regulations

    2 Safety Explosion group (number 6) EN/IEC Gases, vapors (examples) Min. ignition energy (mJ) Ammonia Acetic acid, acetone, benzene, diesel, 0.18 ethane, ether, fuel oil, hexane, meth- ane, petrol, petroleum, propane Ethylene, isoprene, town gas 0.06 Acetylene, carbon disulfide, hydrogen 0.02 Table 7: Explosion groups Temperature classes (number 7)

  • Page 17: Measures For Ensuring Compliance With Explosion Protection Requirements

    2 Safety 2.5 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 synthetic esters required by IEC 61099 in the oil compartment of the on-load...
  • Page 18 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 di- verter switch oil system consists of the diverter switch oil compartment, pro- tective 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 19 2 Safety 2.5.2.3.1 Dehydrating breather The oil conservator must be equipped with a dehydrating breather in accor- dance with VDE 0532-216-5 with downward-leading outlet and a protection degree of at least IP66 in accordance with IEC 60529. 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 20: 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 1 Sealing surface on piping connec- 3 Contact surface on on-load tap- tion flange...
  • Page 21 2 Safety 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. The electrically skilled person is also pro- ficient in the following: ▪...

  • Page 22: Personal Protective Equipment

    2 Safety 2.7 Personal protective equipment Personal protective equipment must be worn during work to minimize risks to health. ▪ Always wear the personal protective equipment required for the job at hand. ▪ Never wear damaged personal protective equipment. ▪ Observe information about personal protective equipment provided in the work area.

  • Page 23: Product Description

    3 Product description 3 Product description 3.1 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 ▪ Ex motor-drive unit ▪ Ex drive shaft with coupling parts and bevel gear ▪...

  • Page 24: Setup/Models

    3 Product description Figure 3: System overview of on-load tap-changer, transformer 1 Transformer tank 6 Gear unit 2 Motor-drive unit 7 On-load tap-changer 3 Vertical drive shaft 8 Protective relay 4 Bevel gear 9 Oil conservator 5 Horizontal drive shaft 10 Active part 3.2.2 Setup/models The following drawing shows the main components of the on-load tap- changer.
  • Page 25 3 Product description You will find a detailed drawing of the on-load tap-changer in the "Drawings [►Section 9, Page 135]" section. Figure 4: On-load tap-changer 1 Upper gear unit 2 On-load tap-changer head 3 Supporting flange 4 Connection contact 5 Oil compartment 6 Change-over selector 7 Pipe bend 8 Rupture disk...
  • Page 26 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 27: Nameplate And Serial Number

    3 Product description 3.2.3 Nameplate and serial number The nameplate is on the on-load tap-changer head cover. Figure 6: Nameplate with serial number 3.2.4 Protective devices The on-load tap-changer is equipped with the following protective devices. 3.2.4.1 Protective relay 3.2.4.1.1 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.
  • Page 28 3 Product description 3.2.4.1.2 Setup/versions Front view Figure 7: RS 2001-Ex 1 Inspection window 2 Pressure equalization element Rear view Figure 8: RS 2001-Ex 1 Ground connection 2 Nameplate ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 29 3 Product description View from above Figure 9: RS 2001-Ex 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 Protective conductor connection 9 Protective cover 10 Dummy plug...

  • Page 30: Drive Shaft

    3 Product description 3.2.4.2 Rupture disk The rupture disk is a pressure relief device without signaling contact in ac- cordance with IEC 60214-1 and is located in the on-load tap-changer head cover. The rupture disk responds to a defined overpressure in the oil compartment of the on-load tap-changer.
  • Page 31 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 11: Explosion-proof drive shaft with insulator ®...

  • Page 32: Design/Model

    3 Product description 3.3.2 Design/Model The design of the explosion-proof drive shaft is described in this section. Figure 12: Components of the explosion-proof drive shaft 1 Bevel gear 2 Hose clip 3 Screws 4 Telescopic protective tube 5 Coupling bracket 6 Insulator 7 Double coupling bracket 8 Square tube 9 Pin...
  • Page 33 3 Product description Configuration V 1 min Intermediate bearing Middle of hand crank – middle of 706 mm If the maximum value of bevel gear (maximum permissible 2472 mm is exceeded, the axial offset 2°) use of an intermediate bearing is necessary. V 1 ≤ 2472 mm (without in- termediate bearing) V 1 >...

  • Page 34: Identification Plate

    3 Product description 3.3.3 Identification plate The identification plate is on the telescopic protective tube. Figure 13: Position of the identification plate ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 35: Packaging, Transport And Storage

    4 Packaging, transport and storage 4 Packaging, transport and storage 4.1 Packaging The products are sometimes supplied with sealed packaging and sometimes in a dry state, depending on requirements. Sealed packaging surrounds the packaged goods with plastic foil on all sides.

  • Page 36: Markings

    4 Packaging, transport and storage 4.1.2 Markings The packaging bears a signature with instructions for safe transport and cor- rect storage. The following symbols apply to the shipment of non-hazardous goods. Adherence to these symbols is mandatory. Protect against Fragile Attach lifting Center of mass moisture...

  • Page 37: Storage Of Shipments

    4 Packaging, transport and storage Visible damage If external transport damage is found upon receipt of the shipment, proceed as follows: ▪ Immediately record the identified transport damage in the shipping docu- ments and have this countersigned by the carrier. ▪...

  • Page 38: Unpacking Shipments And Checking For Transportation Damages

    4 Packaging, transport and storage When selecting and setting up the storage location, ensure the following: ▪ Protect stored goods against moisture (flooding, water from melting snow and ice), dirt, pests such as rats, mice, termites and so on, and against unauthorized access.

  • Page 39: Mounting

    5 Mounting 5 Mounting This chapter describes how to correctly install and connect the device. DANGER Danger of explosion! Death or serious injury may result from installing the on-load tap-changer in an environment at risk of explosion and from installation on an energized transformer! ►...

  • Page 40: Preparatory Work

    5 Mounting 9. Apply suitable corrosion protection to cut edges of the drive shaft's protec- tive cover. 10. Seal joins after installation, e.g. by painting over them. You will find more information about surface treatment and detailed informa- tion about repairing damage to the protective layer in the repair instructions. These are available from Maschinenfabrik Reinhausen GmbH's Technical Service department on request.

  • Page 41: Installing The On-Load Tap-Changer In The Transformer (Standard Version)

    5 Mounting 2. Fit stud bolts on mounting flange. Figure 15: Tracing template, stud bolts 5.3 Installing the on-load tap-changer in the transformer (standard version) 5.3.1 Fastening on-load tap-changer to transformer cover Note that only on-load tap-changers with an unscrewed supporting flange can be fitted in a transformer with the standard design.
  • Page 42 5 Mounting 5.3.1.1 Lifting top part of on-load tap-changer head off supporting flange (bottom part) 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. ►...
  • Page 43 5 Mounting 6. Remove on-load tap-changer head cover. Figure 17: On-load tap-changer head cover 7. For design with oil suction pipe, loosen screw connection of R3/4" oil suc- tion pipe. Check for leaks. Figure 18: Oil suction pipe ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...
  • Page 44 5 Mounting 8. Remove bolts and locking washers between top part of on-load tap- changer head and supporting flange. Figure 19: On-load tap-changer head 9. Lift top part of on-load tap-changer head off supporting flange. Figure 20: On-load tap-changer head ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 45 5 Mounting 5.3.1.2 Positioning the top part of the on-load tap-changer head on the transformer cover 1. Clean sealing surfaces on mounting flange and on-load tap-changer head, place oil-resistant gasket on mounting flange. Figure 21: Mounting flange and on-load tap-changer head 2.
  • Page 46 5 Mounting For design without oil suction pipe, the on-load tap-changer head can be turned towards the supporting flange in 15° steps. For design with oil suc- tion pipe, turning at 15° increments is not possible. When positioning the on-load tap-changer head, do however note that the tap-change supervisory control restricts the swivel range of the upper gear unit.
  • Page 47 5 Mounting NOTICE!  Incorrectly lifting the on-load tap-changer will damage it. Secure 4 ropes of equal length (at least 1 m in length) to the attachment points provided and slowly lift on-load tap-changer from below towards on-load tap-changer head. Under no circumstances should the on-load tap- changer be lifted up with the fixing bolts.
  • Page 48 5 Mounting 3. For design with oil suction pipe, connect oil suction pipe screw connec- tion. Check for leaks. Figure 25: Oil suction pipe 4. Screw the on-load tap-changer head to the mounting flange. The tighten- ing torque depends on the screw connection elements used. Figure 26: On-load tap-changer head ®...

  • Page 49: Connecting The Tap Winding And On-Load Tap-Changer Take-Off Lead

    5 Mounting 5. Place on-load tap-changer head cover on on-load tap-changer head and secure. Figure 27: On-load tap-changer head cover 5.3.2 Connecting the tap winding and on-load tap-changer take-off lead NOTICE Damage to the on-load tap-changer! Connecting leads which place mechanical strain on the on-load tap-changer will damage the on-load tap-changer! ►...

  • Page 50: Performing Transformer Ratio Test Before Drying

    5 Mounting 5.3.3 Performing transformer ratio test before drying NOTICE Damage to the on-load tap-changer! Damage to the on-load tap-changer due to transformer ratio test being in- correctly performed. ► Do not perform more than 250 tap-change operations on the on-load tap- changer.

  • Page 51: Performing Dc Resistance Measurement On Transformer

    ► Within 10 hours of drying, seal off oil compartment with on-load tap- changer head cover. Dry on-load tap-changer in accordance with the following instructions to en- sure the dielectric values assured by MR for the on-load tap-changer. If drying in an autoclave, the following methods are possible: ▪ Vacuum drying ▪...
  • Page 52 5 Mounting Vacuum-drying in the autoclave 1. Heat up the on-load tap-changer in air at atmospheric pressure with a temperature increase of approximately 10 °C/h to a final temperature of maximum 110 °C. 2. Pre-dry the on-load tap-changer in circulating air at a maximum tempera- ture of 110 °C for a period of at least 20 hours.

  • Page 53: Drying On-Load Tap-Changer In Transformer Tank

    5.3.6 Drying on-load tap-changer in transformer tank Dry on-load tap-changer in accordance with the following instructions to en- sure the dielectric values assured by MR on the on-load tap-changer. If you want to dry the on-load tap-changer in the transformer tank, fully as- semble the transformer first and then undertake drying.
  • Page 54 5 Mounting 2. Seal off unused pipe connections and pipe bends with a suitable blank cover. Figure 29: Connecting lead Vacuum-drying in the transformer tank 1. Heat up the on-load tap-changer in air at atmospheric pressure with a temperature increase of approximately 10 °C/h to a final temperature of maximum 110 °C.
  • Page 55 5 Mounting 2. Unscrew kerosene drain plug in base of oil compartment clockwise. The kerosene drain plug cannot be unscrewed all the way. Figure 30: Kerosene drain plug 3. Insert on-load tap-changer insert. Please request the documents for in- stallation from Maschinenfabrik Reinhausen GmbH. 4.

  • Page 56: Filling The Oil Compartment Of The On-Load Tap-Changer With Insulating Fluid

    5 Mounting NOTICE!  An open kerosene drain plug leads to oil escaping from the oil compartment and therefore to damage to the on-load tap-changer. Close kerosene drain plug counter-clockwise (tightening torque 39 Nm). 3. Insert on-load tap-changer insert. 5.3.7 Filling the oil compartment of the on-load tap-changer with insulating fluid NOTICE Damage to the on-load tap-changer!

  • Page 57: Performing Transformer Ratio Test After Drying

    5 Mounting 2. Fill on-load tap-changer with new insulating fluid using one of the two free pipe connections of the on-load tap-changer head. Figure 33: Pipe connections S and R 5.3.8 Performing transformer ratio test after drying NOTICE Damage to the on-load tap-changer! Damage to the on-load tap-changer due to transformer ratio test being in- correctly performed.

  • Page 58: Installing On-Load Tap-Changer In Transformer (Bell-Type Tank Version)

    5 Mounting When actuating the change-over selector, a higher torque is required. 1. Switch the on-load tap-changer into the desired operating position. The di- verter switch operation can be heard distinctly. NOTICE!  An incomplete tap-change operation may damage the on-load tap-changer.
  • Page 59 5 Mounting NOTICE!  Tensile forces can lead to damage and malfunctions on the on- load tap-changer. Using spacers, insert on-load tap-changer vertically into supporting structure (maximum 1° deviation from the vertical) so that the on-load tap-changer reaches its final installation height and only has to be raised a maximum of 5 to 20 mm after fitting the bell-type tank.

  • Page 60: Connecting The Tap Winding And On-Load Tap-Changer Take-Off Lead

    5 Mounting 5.4.2 Connecting the tap winding and on-load tap-changer take-off lead NOTICE Damage to the on-load tap-changer! Connecting leads which place mechanical strain on the on-load tap-changer will damage the on-load tap-changer! ► Establish and secure connections with care. ►...

  • Page 61: Performing Dc Resistance Measurement On Transformer

    5 Mounting When actuating the change-over selector, a higher torque is required. 1. Switch the on-load tap-changer into the desired operating position. The di- verter switch operation can be heard distinctly. NOTICE!  An incomplete tap-change operation may damage the on-load tap-changer.

  • Page 62: Drying On-Load Tap-Changer In Autoclave

    ► Within 10 hours of drying, seal off oil compartment with on-load tap- changer head cover. Dry on-load tap-changer in accordance with the following instructions to en- sure the dielectric values assured by MR for the on-load tap-changer. If drying in an autoclave, the following methods are possible: ▪ Vacuum drying ▪...
  • Page 63 5 Mounting 5.4.5.2 Vapor-phase drying in the autoclave For vapor-phase drying in the autoclave, you must open the kerosene drain plug in the oil compartment base before drying so that the kerosene conden- sate can drain from the oil compartment. 1.

  • Page 64: Lifting Top Part Of On-Load Tap-Changer Head Off Supporting Flange (Bottom Part)

    5 Mounting 5.4.6 Lifting top part of on-load tap-changer head off supporting flange (bottom part) WARNING Danger of explosion! Explosive gases under the on-load tap-changer head cover can deflagrate or explode and result in severe injury or death. ► Ensure that there are no ignition sources such as open flames, hot sur- faces or sparks (e.g.
  • Page 65 5 Mounting 4. Remove screws and locking washers on on-load tap-changer head cover. Figure 38: On-load tap-changer head cover 5. Remove on-load tap-changer head cover. Figure 39: On-load tap-changer head cover 6. For design with oil suction pipe, loosen screw connection of R3/4" oil suc- tion pipe.
  • Page 66 5 Mounting 7. Remove bolts and locking washers between top part of on-load tap- changer head and supporting flange. Figure 41: On-load tap-changer head 8. Lift top part of on-load tap-changer head off supporting flange. Figure 42: Top part of on-load tap-changer head ®...

  • Page 67: Attaching The Bell-Type Tank And Connecting The On-Load Tap-Changer To The Top Part Of The On-Load Tap-Changer Head

    5 Mounting 5.4.7 Attaching the bell-type tank and connecting the on-load tap- changer to the top part of the on-load tap-changer head 5.4.7.1 Attaching bell-type tank 1. Clean sealing surface of supporting flange, place o-ring on supporting flange. Figure 43: Supporting flange with o-ring 2.
  • Page 68 5 Mounting 5.4.7.2 Positioning top part of on-load tap-changer head on bell-type tank 1. Clean sealing surfaces on mounting flange and on-load tap-changer head, place oil-resistant gasket on mounting flange. Figure 45: Mounting flange and on-load tap-changer head 2. Position top part of on-load tap-changer head on mounting flange. Figure 46: On-load tap-changer head ®...
  • Page 69 5 Mounting For design without oil suction pipe, the on-load tap-changer head can be turned towards the supporting flange in 15° steps. For design with oil suc- tion pipe, turning at 15° increments is not possible. When positioning the on-load tap-changer head, do however note that the tap-change supervisory control restricts the swivel range of the upper gear unit.
  • Page 70 5 Mounting NOTICE!  Incorrectly lifting the on-load tap-changer will damage it. Secure 4 ropes of equal length (at least 1 m in length) to the attachment points provided and slowly lift on-load tap-changer from below towards on-load tap-changer head. Under no circumstances should the on-load tap- changer be lifted up with the fixing bolts.
  • Page 71 5 Mounting 3. For design with oil suction pipe, connect oil suction pipe screw connec- tion. Check for leaks. Figure 49: Oil suction pipe 4. Screw the on-load tap-changer head to the mounting flange. The tighten- ing torque depends on the screw connection elements used. Figure 50: On-load tap-changer head ®...

  • Page 72: Drying On-Load Tap-Changer In Transformer Tank

    5.4.8 Drying on-load tap-changer in transformer tank Dry on-load tap-changer in accordance with the following instructions to en- sure the dielectric values assured by MR on the on-load tap-changer. If you want to dry the on-load tap-changer in the transformer tank, fully as- semble the transformer first and then undertake drying.
  • Page 73 5 Mounting 2. Seal off unused pipe connections and pipe bends with a suitable blank cover. Figure 52: Connecting lead Vacuum-drying in the transformer tank 1. Heat up the on-load tap-changer in air at atmospheric pressure with a temperature increase of approximately 10 °C/h to a final temperature of maximum 110 °C.
  • Page 74 5 Mounting 2. Unscrew kerosene drain plug in base of oil compartment clockwise. The kerosene drain plug cannot be unscrewed all the way. Figure 53: Kerosene drain plug 3. Insert on-load tap-changer insert. Please request the documents for in- stallation from Maschinenfabrik Reinhausen GmbH. 4.

  • Page 75: Filling The Oil Compartment Of The On-Load Tap-Changer With Insulating Fluid

    5 Mounting NOTICE!  An open kerosene drain plug leads to oil escaping from the oil compartment and therefore to damage to the on-load tap-changer. Close kerosene drain plug counter-clockwise (tightening torque 39 Nm). 3. Insert on-load tap-changer insert. 5.4.9 Filling the oil compartment of the on-load tap-changer with insulating fluid NOTICE Damage to the on-load tap-changer!

  • Page 76: Performing Transformer Ratio Test After Drying

    5 Mounting 2. Fill on-load tap-changer with new insulating fluid using one of the two free pipe connections of the on-load tap-changer head. Figure 56: Pipe connections S and R 5.4.10 Performing transformer ratio test after drying NOTICE Damage to the on-load tap-changer! Damage to the on-load tap-changer due to transformer ratio test being in- correctly performed.

  • Page 77: Fitting Protective Devices And Drive Components

    5 Mounting When actuating the change-over selector, a higher torque is required. 1. Switch the on-load tap-changer into the desired operating position. The di- verter switch operation can be heard distinctly. NOTICE!  An incomplete tap-change operation may damage the on-load tap-changer.
  • Page 78 5 Mounting 5.5.2.1 Electrical protection NOTICE Damage to the connection cable! Damage to the connection cable due to incorrect connection. ► When routing the cable, observe the manufacturer specifications. ► Avoid impermissibly tight bending radii and kinking. You may only connect the protective relay to circuits with an external over- current protection device and an all-pole isolating device, enabling the equip- ment to be fully de-energized if required (service, maintenance etc.).
  • Page 79 5 Mounting 5.5.2.2 Checking function of protective relay Check the function of the protective relay before installing it in piping be- tween the on-load tap-changer head and the oil conservator. The associated contact positions for checking electrical continuity are shown in the dimen- sional drawing provided.
  • Page 80 5 Mounting 3. Press OFF test button. ð Flap valve is inclined. The red indicator is not visible. Figure 59: OFF position 4. Press OPERATION test button. ð Flap valve is vertical. The red indicator appears in the viewing window. Figure 60: OPERATION position ®...
  • Page 81 5 Mounting 5. Position the wire for the terminal box cover and affix using the slotted head screw. Figure 61: Terminal box cover 6. Attach the terminal box cover and secure with screws. Figure 62: Terminal box cover 5.5.2.3 Installing protective relay in piping Ensure the following for installation and proper function of the protective re- lay: 1.
  • Page 82 5 Mounting 6. The magnetic field strength (bushings, busbars etc.) must be < 20 kA/m. Higher field strengths have a negative effect on the function of the protec- tive relay. 7. The piping from the protective relay to the oil conservator must be routed with an inclination of at least 2% (1.2°) to ensure the switching gases can escape freely.
  • Page 83 5 Mounting 9. The reference arrow on the terminal box cover must point toward the on- load tap-changer's oil conservator. Figure 64: Reference arrow pointing towards the on-load tap-changer's oil conservator ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...
  • Page 84 5 Mounting 10. Install a stop-cock with a nominal width of at least 25 mm between the protective relay and oil conservator. Figure 65: Stop-cock 5.5.2.4 Installing electrics for protective relay The protective relay's dry-reed magnetic switch is supplied as either an NC or NO contact in the following variants: ▪...
  • Page 85 When making the electrical connection for the protective relay, proceed as follows. 1. Connect protective conductor with cable cross-section of 1…4 mm cylinder head screw. 2. Take off MR dummy plug. Figure 66: Dummy plug 3. Insert explosion-certified cable bushing into tapped hole on side of termi- nal box.
  • Page 86 5 Mounting 5. Take off the slotted head screw for potential tie-in and remove the termi- nal box cover with wire. Figure 68: Terminal box cover 6. Remove screw for the protective cover and take off the protective cover. Figure 69: Terminal box cover and protective cover 7.

  • Page 87: Fitting Motor-Drive Unit

    11. Attach the terminal box cover and secure with screws. Figure 71: Terminal box cover 5.5.3 Fitting motor-drive unit ► Fit motor-drive unit to transformer as described in relevant MR operating instructions for motor-drive unit. 5.5.4 Fitting drive shaft Observe the following during mounting: ®...
  • Page 88 5 Mounting NOTICE Damage to drive and on-load tap-changer or de-energized tap- changer! Trouble-free operation of the drive and the on-load tap-changer or de-ener- gized tap-changer cannot be guaranteed. ► The shaft ends to be connected must be exactly aligned. Permitted axial displacement Minor axial displacement can be tolerated as long as it does not exceed 35 mm per 1,000 mm square tube length (that corresponds to 2°).
  • Page 89 5 Mounting Figure 73: Permitted maximum axial displacement of horizontal drive shaft Resistance to corrosion of components Square tubes, coupling brackets, coupling bolts, screws, and locking wash- ers are corrosion-resistant. We therefore recommend not applying the same external coating to these parts as to the transformer tank. Cutting square tubes, telescopic protective tubes, and protective cover The square tubes, telescopic protective tubes, and protective cover are sup- plied in overlengths (graded standard lengths).
  • Page 90 5 Mounting 5.5.4.1 Fitting vertical drive shaft with insulator To fit the vertical drive shaft, proceed as follows.  CAUTION!  Switch off motor protective switch Q1 in the motor-drive unit (position O). If this is not done, the motor-drive unit may be started in- advertently and cause injuries.
  • Page 91 5 Mounting 3. Determine dimension A between shaft end of drive and shaft end of bevel gear. Shorten the square tube to length of A–179 mm, taking the insulator into account. Figure 75: Shortening square tube ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...
  • Page 92 5 Mounting 4. Deburr the cut surfaces on the square tube. Figure 76: Deburring cut surfaces 5. Screw down the double coupling bracket with the insulator supplied and the square tube. Mount the insulator on the side facing the drive. Figure 77: Screwing down the square tube and the insulator with double coupling part ®...
  • Page 93 5 Mounting 6. Slide the loosely screwed-together coupling part onto the insulator until the stop is reached. Figure 78: Sliding the coupling part onto the insulator 7. Insert the coupling bolt into the shaft end of the drive. Grease the coupling part, coupling bolt and shaft end (e.g.
  • Page 94 5 Mounting 8. Attach the square tube to the drive. Figure 80: Attaching the square tube to the drive 9. Pivot the square tube away from the axis. Figure 81: Pivoting the square tube away from the axis 10. When installing the telescopic protective tube, shorten the inner tube on the side without slots if necessary.
  • Page 95 5 Mounting The inner tube must not be deformed and must be deburred in order to slide easily in the outer tube. Figure 82: Deburring the inner tube Dimension A (= distance between Inner tube Outer tube the shaft end of the drive and the shaft end of bevel gear) 170 mm...190 mm Shorten to 200 mm...
  • Page 96 5 Mounting 11. For the separate grounding with 110 mm spacing (viewed from the slot- ted side), drill an 11 mm diameter hole in the inner tube. Figure 83: Producing grounding hole on the telescopic protective tube ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 97 5 Mounting 12. Slide the outer tube over the inner tube. When doing so, make sure that the non-slotted side of the inner tube is facing upwards. Slide the tele- scopic protective tube onto the square tube. Then slide the hose clips over the telescopic protective tube.
  • Page 98 5 Mounting 13. Place the adapter ring over the bearing collar of the bevel gear and slide upwards. Insert the coupling bolt into the shaft end of the bevel gear. Pivot the square tube back to the axis. Figure 85: Fitting the adapter ring and the coupling bolt ®...
  • Page 99 5 Mounting 14. Grease the coupling brackets, coupling bolt and shaft end (e.g. ISOFLEX TOPAS L32) and secure the square tube with the coupling brackets on the bevel gear. Set a unilateral axial clearance of 3 mm between the coupling bolt and the upper coupling piece. Figure 86: Mounting the coupling brackets ®...
  • Page 100 5 Mounting 15. Use a grounding cable and the supplied screw with contact washers to establish a connection between the bottom protective tube (inner tube) and the functional ground. Due to the risk of collision with the screw head, fit the fixing screw for the grounding cable from the inside. Figure 87: Screwing down the grounding cable on the telescopic protective tube ®...
  • Page 101 5 Mounting 16. Attach the bottom protective tube (inner tube) with a hose clip to the bearing collar of drive . Then slide the upper protective tube (outer tube) over the adapter on the bevel gear . Secure the upper protective tube to the second hose clip at top end Figure 88: Mounting the protective tube ®...
  • Page 102 5 Mounting 17. Drill two holes (4.5 mm in diameter) in the two tubes, roughly in the cen- ter and offset by 180°. Then, screw in the two tapping screws provided and lock the protective tubes against one another to produce a galvanic connection.
  • Page 103 5 Mounting 2. Loosen screws and turn pressure ring segments to one side. Figure 90: Pressure ring segments NOTICE!  Align gear unit such that the horizontal drive shaft is flush with the drive shaft of the gear unit. While aligning the gear unit, turn the unit's drive shaft such that its output shaft retains its original position.
  • Page 104 5 Mounting 4. Swivel pressure ring segments back towards gear unit and tighten screws. Ensure that the locking washer is between the screw head and pressure ring segment and that the pressure ring segments are firmly in contact with the gear unit housing. Figure 92: Securing pressure ring segments Fitting the horizontal drive shaft To mount the horizontal drive shaft, proceed as follows:...
  • Page 105 5 Mounting 2. Calculate inside width B between the housings of the upper gear unit and the bevel gear. Cut down the protective cover to B-2 mm and deburr the cut edges. Figure 94: Shortening and deburring the protective cover 3. For the separate grounding with 110 mm spacing from the bevel gear, drill an 11 mm diameter hole in the protective cover.
  • Page 106 5 Mounting 4. Screw down the double coupling bracket with the insulator supplied and the square tube. Mount the insulator on the side facing the bevel gear. Figure 96: Screwing down the square tube and the insulator with double coupling part 5.
  • Page 107 5 Mounting 6. Grease the coupling bolt, coupling part and shaft end of the bevel gear (e.g. ISOFLEX TOPAS L32) and insert the coupling bolt into shaft end. Thread the hose clip onto the square tube and slide the square tube with the coupling part onto the shaft end.
  • Page 108 5 Mounting 8. Grease the coupling bolt, the coupling brackets and the shaft end of the upper gear unit (e.g. ISOFLEX TOPAS L32) and insert the coupling bolt into the shaft end. Secure the square tube with the coupling brackets on the upper gear unit.
  • Page 109 5 Mounting 9. Attach the shortened protective cover to the housing lugs on the on-load tap-changer head and the bevel gear. Secure each end of the protective cover with a hose clip. Figure 101: Fitting the protective cover ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...
  • Page 110 5 Mounting 10. Use the grounding cable and the supplied screw with the contact wash- ers to establish a connection between the protective cover and the func- tional ground. Due to the risk of collision with the screw head, fit the fix- ing screw for the grounding cable from the inside.

  • Page 111: Centering On-Load Tap-Changer And Motor-Drive Unit

    MR operating instructions for motor-drive unit. 5.5.6 Making the electrical connections for the motor-drive unit ► Make electrical connections for the motor-drive unit as described in rele- vant MR operating instructions for the motor-drive unit. ® Maschinenfabrik Reinhausen GmbH 2020...

  • Page 112: Commissioning

    6 Commissioning 6 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! ►...
  • Page 113 6 Commissioning 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 103: Air-vent valve E1 3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load tap-changer head. Figure 104: Valve tappet 4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). ®...

  • Page 114: Grounding The On-Load Tap-Changer

    6 Commissioning 6.1.1.2 Bleeding suction pipe on pipe connection S 1. Remove screw cap from pipe connection S. Figure 105: Pipe connection S 2. Open vent screw and bleed piping. 3. Close vent screw. 4. Seal vent screw with screw cap. 6.1.2 Grounding the on-load tap-changer If necessary, reduce the stated tightening torque according to the grounding line used.

  • Page 115: Checking Motor-Drive Unit

    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.

  • Page 116: High-Voltage Tests On The Transformer

    6 Commissioning 6.1.4 High-voltage tests on the transformer Note the following points before performing high-voltage tests on the trans- former: ▪ Ensure that the oil compartment of the on-load tap-changer is completely filled with insulating fluid. ▪ Ensure that all protective devices for the on-load tap-changer are function- ing correctly and are ready for use.

  • Page 117: Transport With Full Transformer Tank And Without Oil Conservator

    4. Do not actuate an on-load tap-changer which is uncoupled and do not turn its drive shaft. 5. Transport the drive to the installation site in the MR delivery packaging. 6. Fit the drive [►Section 5.5.3, Page 87] and the drive shaft to the trans- former at the installation site.

  • Page 118: Transport With Empty Transformer Tank

    6 Commissioning 6.2.3 Transport with empty transformer tank NOTICE Damage to the on-load tap-changer! The on-load tap-changer may be subject to oscillating movements during transformer transportation if the transformer is transported without insulating fluid and the on-load tap-changer oil compartment is transported with insu- lating fluid.
  • Page 119 6 Commissioning 6.2.3.2 Emptying oil compartment without oil suction pipe WARNING Danger of explosion! Explosive gases under the on-load tap-changer head cover can deflagrate or explode and result in severe injury or death. ► Ensure that there are no ignition sources such as open flames, hot sur- faces or sparks (e.g.

  • Page 120: Commissioning Transformer At Operating Site

    6 Commissioning 6.3 Commissioning transformer at operating site Before energizing the transformer, check that the motor-drive unit and pro- tective devices are functioning correctly and fill the on-load tap-changer oil compartment with fresh insulating fluid. 6.3.1 Filling the oil compartment of the on-load tap-changer with insulating fluid Damage to the on-load tap-changer! NOTICE...

  • Page 121: Bleeding On-Load Tap-Changer Head And Suction Pipe

    6 Commissioning 2. Fill on-load tap-changer with new insulating fluid using one of the two free pipe connections of the on-load tap-changer head. Figure 110: Pipe connections S and R 3. Take an insulating fluid sample from the oil compartment. 4. Record the temperature of the sample immediately after the sample is taken.
  • Page 122 6 Commissioning 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 111: Air-vent valve E1 3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load tap-changer head. Figure 112: Valve tappet 4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). ®...

  • Page 123: Checking Motor-Drive Unit

    6 Commissioning 6.3.2.2 Bleeding suction pipe on pipe connection S 1. Remove screw cap from pipe connection S. Figure 113: Pipe connection S 2. Open vent screw and bleed piping. 3. Close vent screw. 4. Seal vent screw with screw cap. 6.3.3 Checking motor-drive unit Damage to the on-load tap-changer / de-energized tap-changer! NOTICE...

  • Page 124: Checking Protective Relay

    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.

  • Page 125: Commissioning The Transformer

    6 Commissioning 8. Press IN SERVICE test button. 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. 11. Press OFF test button. 12. Ensure that the transformer's circuit breaker is open. ð...

  • Page 126: 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 protective relay or additional pro- tective devices have been tripped, please inform your authorized MR repre- sentative, the transformer manufacturer or contact MR directly.
  • Page 127 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. Warning or tripping of Buchholz relay on transformer Notify manufacturer of transformer.

  • Page 128: Tripping The Protective Relay And Re-Commissioning The Transformer

    7 Fault elimination 7.1 Tripping the protective relay and re-commissioning the transformer WARNING Danger of explosion! Explosive gases in the protective relay can deflagrate or explode and result in severe injury or death. ► Wait 15 minutes after switching off the transformer before beginning fur- ther work on the protective relay so that the gases can dissipate.

  • Page 129: Flap Valve In Off Position

    7 Fault elimination 7.1.2 Flap valve in OFF position If the flap valve is in the OFF position, proceed as follows: 1. Ensure that the transformer is not started up under any circumstances. 2. Contact and inform Maschinenfabrik Reinhausen of the following: ð...

  • Page 130: Technical Data

    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 Permissible ambient conditions Air temperature during operation -25°C…+50°C Temperature of the insulating fluid in operation Insulating fluid in accordance with IEC 60296: -25°C…+105°C...
  • Page 131 8 Technical data Electrical data DC switching capacity 1.2 W…200 W AC switching capacity (50 Hz) 1.2 VA…400 VA Switching voltage AC/DC 24 V…250 V Switched current AC/DC 4.8 mA…2 A Table 17: Electrical data Switching capacity (switching load on an off) Minimum switched current AC/DC (low- 50 mA (at 24 V) est voltage)

  • Page 132: Protective Relay With Several Dry-Reed Magnetic Switches

    8 Technical data Switching capacity (switching load on an off) Maximum switched current DC (highest 2 A (at 125 V with L/R = 40 ms) current) Maximum switched current DC (highest 1 A (at 250 V with L/R = 40 ms) voltage) Maximum switched current AC (highest 2 A (at 125 V with cos φ...

  • Page 133: Tests

    8 Technical data 8.2.2 Tests Electrical safety IEC 61010-1 Safety requirements for electrical measurement and con- trol and regulation equipment and laboratory instruments ▪ Overvoltage category III ▪ Contamination level 2 Table 24: Electrical safety ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 134: Limit Values For Dielectric Strength And Water Content Of Insulating Fluids

    8 Technical data 8.3 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.

  • Page 135: Drawings

    9 Drawings 9 Drawings 9.1 External view (737774) ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 136: On-Load Tap-Changer Head Without Oil Suction Pipe (898863)

    9 Drawings 9.2 On-load tap-changer head without oil suction pipe (898863) ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 137: On-Load Tap-Changer Head With Oil Suction Pipe (737060)

    9 Drawings 9.3 On-load tap-changer head with oil suction pipe (737060) ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 138: Installation Drawing (738902)

    9 Drawings 9.4 Installation drawing (738902) ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 139: Oil Suction Pipe (739172)

    9 Drawings 9.5 Oil suction pipe (739172) ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 140: Dimensions Of Oil Suction Pipe (Not Supplied By Mr, 734342)

    9 Drawings 9.6 Dimensions of oil suction pipe (not supplied by MR, 734342) ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 141: Tracing Template For On-Load Tap-Changer Head (893787)

    9 Drawings 9.7 Tracing template for on-load tap-changer head (893787) ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 142: Mounting Drawing (898866)

    9 Drawings 9.8 Mounting drawing (898866) ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 143: Mounting With Bell-Type Tank Installation (899110)

    9 Drawings 9.9 Mounting with bell-type tank installation (899110) ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 144: Position Of On-Load Tap-Changer (899409)

    9 Drawings 9.10 Position of on-load tap-changer (899409) ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 145: Position Of Connection Contacts (899051)

    9 Drawings 9.11 Position of connection contacts (899051) ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 146: Tap-Change Supervisory Control (733469)

    9 Drawings 9.12 Tap-change supervisory control (733469) ® VACUTAP VV-Ex 4983703/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 147: Bevel Gear Cd 6400, Dimensional Drawing (892916)

    9 Drawings 9.13 Bevel gear CD 6400, dimensional drawing (892916) ® Maschinenfabrik Reinhausen GmbH 2020 4983703/01 EN VACUTAP VV-Ex...

  • Page 148: Glossary

    Glossary Glossary Direct current Ingress protection Dielectric strength Material-specific property of isolators [kV/2.5 Maschinenfabrik Reinhausen GmbH mm]; maximum electrical field strength without a breakdown (arc) Normally Closed contact The International Electrotechnical Commission (IEC for short) is involved in the preparation and Normally Open contact publication of international standards for electri- cal, electronic and related technologies.
  • Page 150 Maschinenfabrik Reinhausen GmbH Falkensteinstrasse 8 93059 Regensburg +49 (0)941 4090-0 sales@reinhausen.com www.reinhausen.com ® 4983703/01 EN - VACUTAP VV-Ex - - 08/20 - Maschinenfabrik Reinhausen GmbH 2020 THE POWER BEHIND POWER.

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