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MR VACUTAP VV Installation And Commissioning Instructions

On-load tap-changer
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On-load tap-changer
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VACUTAP
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Installation and commissioning instructions
4349322/01 EN

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  • Page 1 On-load tap-changer ® ® VACUTAP Installation and commissioning instructions 4349322/01 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 Personal protective equipment ......................
  • Page 4 Table of contents Mounting ...........................  36 Preparatory work .......................... 36 5.1.1 Fitting mounting flange on transformer cover...................... 36 5.1.2 Fitting stud bolts on mounting flange ........................ 37 Installing the on-load tap-changer in the transformer (standard version) .........  37 5.2.1 Fastening on-load tap-changer to transformer cover .................. 37 5.2.2 Connecting the tap winding and on-load tap-changer take-off lead.............. 45 5.2.3...
  • Page 5 Table of contents Commissioning.......................  154 Commissioning the on-load tap-changer at the transformer manufacturer's site ...... 154 6.1.1 Bleeding on-load tap-changer head and suction pipe.................. 154 6.1.2 Grounding the on-load tap-changer ........................ 156 6.1.3 Checking motor-drive unit .......................... 158 6.1.4 High-voltage tests on the transformer ....................... 158 Transporting transformer to the operating site................
  • Page 6 Table of contents Limit values for dielectric strength and water content of insulating fluids ........ 181 Drawings .........................  182 737774............................ 183 898863............................ 184 737060............................ 185 738902............................ 186 739172............................ 187 890183............................ 188 898866............................ 189 899110............................ 190 899409............................ 191 9.10 899083............................ 192 9.11 899051............................

  • 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 4349322/01 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 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"...
  • 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: Personal Protective Equipment

    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: Personnel Qualification

    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.

  • Page 16: 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: ▪ On-load tap-changer ▪ Motor-drive unit ▪ Drive shaft with coupling parts and bevel gear ▪...

  • Page 17: 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 18 3 Product description You will find a detailed drawing of the on-load tap-changer in the "Drawings [►Section 9, Page 182]" section. Figure 2: 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 19 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.

  • Page 20: 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 4: 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 21 3 Product description 3.2.4.1.2 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. ®...
  • Page 22 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...
  • Page 23 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.
  • Page 24 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.
  • Page 25 3.2.4.4 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.

  • Page 26: Drive Shaft

    3 Product description 3.2.4.6 Temperature monitoring The temperature monitoring system monitors the temperature of the insulat- ing fluid in the oil compartment of the on-load tap-changer. 3.3 Drive shaft 3.3.1 Function description The drive shaft is the mechanical connection between the drive and the on- load tap-changer/de-energized tap-changer.

  • Page 27: Design/Versions

    3 Product description 3.3.2 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...
  • Page 28 3 Product description 3.3.2.1 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°)
  • Page 29 3 Product description 3.3.2.2 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°)
  • Page 30 3 Product description 3.3.2.3 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 >...
  • Page 31 3 Product description 3.3.2.4 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 >...

  • Page 32: 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 33: 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 34: 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 35: 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 36: Mounting

    5 Mounting 5 Mounting WARNING Risk of crushing! When the on-load tap-changer undertakes a tap-change operation, compo- nents – some of which are freely accessible – move on the selector, change-over selector, and potential connection unit. Reaching into the se- lector, change-over selector, or potential connection unit during a tap- change operation may result in serious injuries.

  • Page 37: Fitting Stud Bolts On Mounting Flange

    5 Mounting 5.1.2 Fitting stud bolts on mounting flange To attach the stud bolts to the mounting flange, use a tracing template. This can be provided upon request free of charge for the initial installation of the on-load tap-changer. 1. Place tracing template on mounting flange and use the four markings to align.
  • Page 38 5 Mounting 5.2.1.1 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 39 5 Mounting 6. Remove on-load tap-changer head cover. Figure 19: 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 20: Oil suction pipe ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 40 5 Mounting 8. Remove bolts and locking washers between top part of on-load tap- changer head and supporting flange. Figure 21: On-load tap-changer head 9. Lift top part of on-load tap-changer head off supporting flange. Figure 22: On-load tap-changer head ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 41 5 Mounting 5.2.1.2 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 23: Mounting flange and on-load tap-changer head 2.
  • Page 42 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 43 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 44 5 Mounting 3. For design with oil suction pipe, connect oil suction pipe screw connec- tion. Check for leaks. Figure 27: 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 28: On-load tap-changer head ®...

  • Page 45: 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 29: On-load tap-changer head cover 5.2.2 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 46: Performing Transformer Ratio Test Before Drying

    5 Mounting 5.2.3 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 47: 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 48 5 Mounting 5.2.5.1.1 Moving on-load tap-changer to adjustment position ► Move the on-load tap-changer to the adjustment position. The adjustment position is indicated in the on-load tap-changer connection diagram in- cluded in delivery. 5.2.5.1.2 Removing on-load tap-changer head cover Danger of explosion! WARNING Explosive gases under the on-load tap-changer head cover can deflagrate or explode and result in severe injury or death.
  • Page 49 5 Mounting 3. Remove on-load tap-changer head cover. Figure 31: On-load tap-changer head cover 5.2.5.1.3 Drying the on-load tap-changer Damage to the on-load tap-changer head cover and on-load tap- NOTICE changer accessories. Both the on-load tap-changer head cover and the on-load tap-changer ac- cessories will become damaged if they are dried.
  • Page 50 5 Mounting 5.2.5.1.4 Securing on-load tap-changer head cover NOTICE Damage to the on-load tap-changer! A missing or damaged o-ring as well as unclean sealing surfaces lead to in- sulating fluid escaping and therefore to damage to the on-load tap-changer. ► Ensure that the o-ring is positioned untwisted in the on-load tap-changer head cover.
  • Page 51 5 Mounting 5.2.5.2.1 Moving on-load tap-changer to adjustment position ► Move the on-load tap-changer to the adjustment position. The adjustment position is indicated in the on-load tap-changer connection diagram in- cluded in delivery. 5.2.5.2.2 Removing on-load tap-changer head cover Danger of explosion! WARNING Explosive gases under the on-load tap-changer head cover can deflagrate or explode and result in severe injury or death.
  • Page 52 5 Mounting 3. Remove on-load tap-changer head cover. Figure 34: On-load tap-changer head cover 5.2.5.2.3 Opening kerosene drain plug ► NOTICE!  Never remove the kerosene drain plug completely. Open kerosene drain plug in base of oil compartment counter-clockwise. Figure 35: Kerosene drain plug 5.2.5.2.4 Drying the on-load tap-changer Damage to the on-load tap-changer head cover and on-load tap- NOTICE...
  • Page 53 5 Mounting 1. Supply kerosene vapor at a temperature of around 90°C. Keep this tem- perature constant for 3 to 4 hours. 2. Increase the kerosene vapor temperature by approx. 10°C/hour to the de- sired final temperature of max. 125°C at the on-load tap-changer. 3.

  • Page 54: Drying On-Load Tap-Changer In Transformer Tank

    5.2.6 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 55 5 Mounting 2. Seal off unused pipe connections and pipe bends with a suitable blank cover. Figure 37: 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 56 5 Mounting 2. Unscrew kerosene drain plug in base of oil compartment clockwise. The kerosene drain plug cannot be unscrewed all the way. Figure 38: Kerosene drain plug 3. Insert on-load tap-changer insert. Please request the documents for in- stallation from Maschinenfabrik Reinhausen GmbH. 4.

  • Page 57: 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. 5.2.7 Filling the oil compartment of the on-load tap-changer with insulating fluid NOTICE Damage to the on-load tap-changer!

  • Page 58: 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 41: Pipe connections S and R 5.2.8 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 59: Installing On-Load Tap-Changer In Transformer (Bell-Type Tank Version)

    5 Mounting NOTICE!  An incomplete tap-change operation may damage the on-load tap-changer. After operating the diverter switch, continue to crank the drive shaft of the upper gear unit for 2.5 revolutions in the same direction in order to correctly complete the tap-change operation. 3.

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

    5 Mounting 3. Temporarily fasten on-load tap-changer to supporting structure. The sup- porting flange has through holes for this purpose. Figure 43: Temporary fastening 5.3.2 Connecting the tap winding and on-load tap-changer take-off lead Damage to the on-load tap-changer! NOTICE Connecting leads which place mechanical strain on the on-load tap-changer will damage the on-load tap-changer! ►...

  • Page 61: 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 62: 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 63 5 Mounting 5.3.5.1.1 Moving on-load tap-changer to adjustment position ► Move the on-load tap-changer to the adjustment position. The adjustment position is indicated in the on-load tap-changer connection diagram in- cluded in delivery. 5.3.5.1.2 Removing on-load tap-changer head cover Danger of explosion! WARNING Explosive gases under the on-load tap-changer head cover can deflagrate or explode and result in severe injury or death.
  • Page 64 5 Mounting 3. Remove on-load tap-changer head cover. Figure 45: On-load tap-changer head cover 5.3.5.1.3 Drying the on-load tap-changer Damage to the on-load tap-changer head cover and on-load tap- NOTICE changer accessories. Both the on-load tap-changer head cover and the on-load tap-changer ac- cessories will become damaged if they are dried.
  • Page 65 5 Mounting 5.3.5.1.4 Securing on-load tap-changer head cover NOTICE Damage to the on-load tap-changer! A missing or damaged o-ring as well as unclean sealing surfaces lead to in- sulating fluid escaping and therefore to damage to the on-load tap-changer. ► Ensure that the o-ring is positioned untwisted in the on-load tap-changer head cover.
  • Page 66 5 Mounting 5.3.5.2.1 Moving on-load tap-changer to adjustment position ► Move the on-load tap-changer to the adjustment position. The adjustment position is indicated in the on-load tap-changer connection diagram in- cluded in delivery. 5.3.5.2.2 Removing on-load tap-changer head cover Danger of explosion! WARNING Explosive gases under the on-load tap-changer head cover can deflagrate or explode and result in severe injury or death.
  • Page 67 5 Mounting 3. Remove on-load tap-changer head cover. Figure 48: On-load tap-changer head cover 5.3.5.2.3 Opening kerosene drain plug ► NOTICE!  Never remove the kerosene drain plug completely. Open kerosene drain plug in base of oil compartment counter-clockwise. Figure 49: Kerosene drain plug 5.3.5.2.4 Drying the on-load tap-changer Damage to the on-load tap-changer head cover and on-load tap- NOTICE...
  • Page 68 5 Mounting 1. Supply kerosene vapor at a temperature of around 90°C. Keep this tem- perature constant for 3 to 4 hours. 2. Increase the kerosene vapor temperature by approx. 10°C/hour to the de- sired final temperature of max. 125°C at the on-load tap-changer. 3.

  • Page 69: Lifting Top Part Of On-Load Tap-Changer Head Off Supporting Flange (Bottom Part)

    5 Mounting ► Place on-load tap-changer head cover on on-load tap-changer head and secure. Figure 50: On-load tap-changer head cover 5.3.6 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.
  • Page 70 5 Mounting 1. Ensure that the on-load tap-changer is in the adjustment position. The ad- justment position is indicated in the on-load tap-changer connection dia- gram included in delivery. 2. Ensure that the inspection window is sealed off with the cover. 3.
  • Page 71 5 Mounting 5. Remove on-load tap-changer head cover. Figure 53: On-load tap-changer head cover 6. For design with oil suction pipe, loosen screw connection of R3/4" oil suc- tion pipe. Check for leaks. Figure 54: Oil suction pipe ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 72 5 Mounting 7. Remove bolts and locking washers between top part of on-load tap- changer head and supporting flange. Figure 55: On-load tap-changer head 8. Lift top part of on-load tap-changer head off supporting flange. Figure 56: Top part of on-load tap-changer head ®...

  • Page 73: 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 5.3.7 Attaching the bell-type tank and connecting the on-load tap- changer to the top part of the on-load tap-changer head 5.3.7.1 Attaching bell-type tank 1. Clean sealing surface of supporting flange, place o-ring on supporting flange. Figure 57: Supporting flange with o-ring 2.
  • Page 74 5 Mounting 5.3.7.2 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 59: Mounting flange and on-load tap-changer head 2. Position top part of on-load tap-changer head on mounting flange. Figure 60: On-load tap-changer head ®...
  • Page 75 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 76 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 77 5 Mounting 3. For design with oil suction pipe, connect oil suction pipe screw connec- tion. Check for leaks. Figure 63: 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 64: On-load tap-changer head ®...

  • Page 78: Drying On-Load Tap-Changer In Transformer Tank

    5.3.8 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 79 5 Mounting 2. Seal off unused pipe connections and pipe bends with a suitable blank cover. Figure 66: 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 80 5 Mounting 2. Unscrew kerosene drain plug in base of oil compartment clockwise. The kerosene drain plug cannot be unscrewed all the way. Figure 67: Kerosene drain plug 3. Insert on-load tap-changer insert. Please request the documents for in- stallation from Maschinenfabrik Reinhausen GmbH. 4.

  • Page 81: 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. 5.3.9 Filling the oil compartment of the on-load tap-changer with insulating fluid NOTICE Damage to the on-load tap-changer!

  • Page 82: 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 70: Pipe connections S and R 5.3.10 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 83: Fitting Protective Devices And Drive Components

    5 Mounting NOTICE!  An incomplete tap-change operation may damage the on-load tap-changer. After operating the diverter switch, continue to crank the drive shaft of the upper gear unit for 2.5 revolutions in the same direction in order to correctly complete the tap-change operation. 3.
  • Page 84 5 Mounting 2. Loosen the hexagonal socket screws on the terminal box cover of the tap- change supervisory control and remove the terminal box cover. Figure 72: Tap-change supervisory control cover 3. Connect monitoring contacts to corresponding motor-drive unit terminals using connecting lead in accordance with connection diagram of relevant motor-drive unit.

  • Page 85: Installing Protective Relay In Piping And Connecting

    5 Mounting Figure 74: Tap-change supervisory control cover 5.4.3 Installing protective relay in piping and connecting Danger of explosion! WARNING 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 86 5 Mounting 5.4.3.1 Checking function of protective relay Check the function of the protective relay before installing it in piping be- tween on-load tap-changer head and oil conservator. The associated contact positions for checking electrical continuity are shown in the dimensional drawing provided.
  • Page 87 5 Mounting 3. Press OFF test button. ð Flap valve is inclined. Line marker appears in the middle of the inspec- tion window. Figure 77: OFF position 4. Press OPERATION test button. ð Flap valve is vertical. Figure 78: OPERATION position ® ®...
  • Page 88 5 Mounting 5. Position the wire for the terminal box cover and affix using the slotted head screw. Figure 79: Terminal box cover 6. Attach the terminal box cover and secure with screws. Figure 80: Terminal box cover 5.4.3.2 Installing protective relay in piping Ensure the following for installation and proper function of the protective re- lay: 1.
  • Page 89 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 90 5 Mounting 9. The reference arrow on the terminal box cover must point toward the on- load tap-changer's oil conservator. Figure 82: Reference arrow pointing towards the on-load tap-changer's oil conservator ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 91 5 Mounting 10. Install a stop-cock with a nominal width of at least 25 mm between the protective relay and oil conservator. Figure 83: Stop-cock 5.4.3.3 Making the electrical connections for the protective relay The protective relay's dry-reed magnetic switching tubes are supplied in the standard version as either NC or NO contacts.
  • Page 92 5 Mounting 1. Insert cable gland (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5, 2001/R) or adapter (RS 2003 and RS 2004) in the tapped hole with the most favor- able position. Figure 84: Tapped hole 2. Seal open tapped hole with dummy plug. Figure 85: Sealed with dummy plug ®...
  • Page 93 5 Mounting 3. Loosen the three screws on the terminal box cover and lift off the terminal box cover. Figure 86: Terminal box cover 4. Take off the slotted head screw for potential tie-in and remove the termi- nal box cover with wire. Figure 87: Terminal box cover 5.
  • Page 94 5 Mounting 6. Guide cable through cable gland and into protective relay. Ensure that the cable gland is well connected and sealed. Figure 89: Cable bushing 7. Connect the electric cables to the connection terminals in accordance with the connection diagram on the dimensional drawing. Figure 90: Electrical cables ®...
  • Page 95 5 Mounting 8. Connect protective conductor to cylinder head screw. Figure 91: Protective conductor 9. Insert the protective cover and secure using the screw. Figure 92: Protective cover ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...

  • Page 96: Installing And Connecting The Pressure Monitoring Device

    5 Mounting 10. Position the wire for the terminal box cover and affix using the slotted head screw. Figure 93: Terminal box cover 11. Attach the terminal box cover and secure with screws. Figure 94: Terminal box cover 5.4.4 Installing and connecting the pressure monitoring device 5.4.4.1 Checking the function of the pressure monitoring device Check the function of the pressure monitoring device before you install it on the pipe bend or the on-load tap-changer head.
  • Page 97 5 Mounting 2. Activate the snap-action switch. ð Sensor is in the OFF position above the snap-action switch. Figure 95: OFF position 1 Snap-action switch 2 Sensor in the OFF position ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 98 5 Mounting 3. Activate the snap-action switch again. ð Sensor is in the OPERATION position below the snap-action switch. Figure 96: OPERATION position 1 Snap-action switch 2 Sensor in the OPERATION position 4. Secure the cover cap. Always check the position of the sensor! 5.4.4.2 Installing the pressure monitoring device The pressure monitoring device can be installed in 2 variants.

  • Page 99: Fitting Motor-Drive Unit

    6. Ensure the fixing screw is positioned correctly, see also dimensional drawing supplied. 5.4.5 Fitting motor-drive unit ► Fit motor-drive unit to transformer as described in relevant MR operating instructions for motor-drive unit. 5.4.6 Fitting drive shaft Observe the following during mounting:...
  • Page 100 5 Mounting Cutting square tubes, telescopic protective tubes, and protective cover The square tubes, the telescopic protective tube and the protective cover are supplied over-length (graded standard lengths). You must cut these parts to the required size before mounting on the transformer. In rare cases, you also have to cut the inner tube of the telescopic protective tube to the desired length.
  • Page 101 5 Mounting 5.4.6.1 Fitting a vertical drive shaft without cardan joint Permitted axial displacement Minor axial displacements of the vertical drive shaft are permitted as long as they do not exceed 35 mm per 1000 mm of square tube length (this corre- sponds to 2°).
  • Page 102 5 Mounting 2. Fasten the bevel gear to the transformer. Figure 98: Bevel gear ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 103 5 Mounting 3. Determine dimension A between shaft end of drive and shaft end of bevel gear. Shorten square tube to length of A–9 mm. Figure 99: Shortening square tube ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 104 5 Mounting 4. Deburr cut surfaces of square tube. Figure 100: Deburring cut surfaces ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 105 5 Mounting 5. Slide the loosely screwed-together coupling part onto square tube until stop is reached. Figure 101: Slide coupling part onto square tube ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 106 5 Mounting 6. Insert coupling bolt into shaft end of drive. Grease coupling part, coupling bolt and shaft end (e.g. ISOFLEX TOPAS L32). Slide square tube with coupling part onto shaft end. Figure 102: Sliding square tube with coupling part onto shaft end 7.
  • Page 107 5 Mounting 8. Pivot square tube away from axis. Figure 104: Pivoting square tube away from axis 9. When installing inner tube of telescopic protective tube, shorten on the side without slots if necessary. The minimum dimension for overlapping the two protective tubes is 100 mm. ®...
  • Page 108 5 Mounting Inner tube must not be deformed and must be deburred in order to slide easily in the outer tube. Figure 105: Deburring inner tube Dimension A (= distance between Inner tube Outer tube shaft end of drive and shaft end of bevel gear) 170 mm...190 mm Shorten to 200 mm...
  • Page 109 5 Mounting 10. Slide outer tube over inner tube. When doing so, make sure that the non- slotted side of the inner tube is facing upwards. Slide telescopic protec- tive tube onto square tube. Then slide hose clips over telescopic protec- tive tube.
  • Page 110 5 Mounting 11. Place adapter ring over bearing collar of bevel gear and slide upwards. Insert coupling bolt into shaft end of bevel gear. Pivot square tube back to axis. Figure 107: Fitting adapter ring and coupling bolt ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 111 5 Mounting 12. Grease coupling brackets, coupling bolt and shaft end (e.g. ISOFLEX TOPAS L32) and secure square tube with coupling brackets on the bevel gear. Set a unilateral axial clearance of 3 mm between the coupling bolt and upper coupling piece. Figure 108: Mounting coupling brackets 13.
  • Page 112 5 Mounting Figure 109: Mounting protective tube ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 113 5 Mounting 5.4.6.2 Fitting a horizontal drive shaft without cardan joints Permitted axial displacement Minor axial displacements of the horizontal drive shaft are permitted as long as they do not exceed 35 mm per 1000 mm of square tube length (this cor- responds to 2°).
  • Page 114 5 Mounting 2. Loosen screws and turn pressure ring segments to one side. Figure 111: 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 115 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 113: Securing pressure ring segments Fitting horizontal drive shaft You can turn the temperature sensor if this is necessary for fitting the drive...
  • Page 116 5 Mounting 2. Calculate inside width B between housings of upper gear unit and bevel gear. Cut down the protective cover to B-2 mm and deburr the cut edges. Protect protective cover against corrosion with a coat of paint. Figure 115: Shortening, deburring, and coating protective cover ®...
  • Page 117 5 Mounting 3. Slide loosely screwed-together coupling part onto square tube until stop is reached. Figure 116: Sliding coupling part onto square tube ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 118 5 Mounting 4. Grease coupling bolt, coupling part and shaft end of the bevel gear (e.g. ISOFLEX TOPAS L32) and insert coupling bolt into shaft end. Thread hose clip onto square tube and slide square tube with coupling part onto shaft end.
  • Page 119 5 Mounting 6. Grease coupling bolt, coupling brackets and shaft end of the upper gear unit (e.g. ISOFLEX TOPAS L32) and insert coupling bolt into shaft end. Secure square tube with coupling brackets on upper gear unit. Figure 119: Secure square tube on upper gear unit. ®...
  • Page 120 5 Mounting 7. Attach shortened protective cover to housing lugs on the on-load tap- changer head and bevel gear. Secure each end of protective cover with a hose clip. Figure 120: Fitting protective cover ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 121 5 Mounting 8. If using a bearing block or angle gear, attach caps to the protective cover. Drill two holes each with Ø 3.5 mm on the sides of the protective cover us- ing a hand drill with drill bit prior to attaching the caps. Figure 121: Bearing block caps Figure 122: Angle gear caps ®...
  • Page 122 5 Mounting 5.4.6.2.1 On-load tap-changer sets and combinations For two-column and three-column on-load tap-changer models, the individ- ual on-load tap-changer columns are driven by a common motor-drive unit. You must couple the on-load tap-changer heads above the transformer cover together and ensure synchronous switching of the on-load tap- changer columns.
  • Page 123 5 Mounting 5.4.6.3 Fitting drive shaft with cardan joints Installation of the drive shaft with cardan joints is mainly designed as a verti- cal drive shaft between motor-drive unit and bevel gear. Technically, a horizontal design is also possible. However, if using a horizon- tal design, please note that the protective cover supplied must be adapted accordingly and a cardan joint with an inner hub diameter of 25 mm must be used if you want to use the cardan joint on the upper gear unit.
  • Page 124 5 Mounting Figure 124: Permitted maximum axial displacement of horizontal drive shaft with cardan joints NOTICE Damage to property! Improper mounting of the cardan joint may result in damage or malfunc- tions. ► Ensure that the folding cardan joint does not damage the expansion bel- lows during mounting.
  • Page 125 5 Mounting Figure 125: Angle of deflection α ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 126 5 Mounting To fit the drive shaft with cardan joints, proceed as follows: 1. Grease coupling bolts, coupling brackets, and shaft ends, e.g. ISOFLEX TOPAS L 32. Figure 126: Greasing coupling bolts, coupling brackets, and shaft ends Position Name Quantity 1 below on the ED Adapter ring Ø 82×102 Adapter ring Ø 87×102.5 ®...
  • Page 127 5 Mounting Adapter ring Ø 94.5×102.5 4 above on the Adapter ring Ø 71×102.5 CD6400 2. Insert adapter rings into the collar of the rotating protective tube . Fit the two parts of pivotable protective tube together and turn them towards one another to set the corresponding angle.
  • Page 128 5 Mounting 3. When supplied, the cardan joints are fitted with coupling bolts . To mount on the shaft end, the following steps must be taken: Remove hose clip . Slide up expansion bellows . Remove coupling bolt . Slide cardan joint over device's output shaft .
  • Page 129 5 Mounting NOTICE!  Attach second, longer cardan joint to the bevel gear such that the position of both cardan joint lugs is the same on the bevel gear and motor-drive unit. If this is not done, damage or malfunctions may result. Figure 130: Fitting second cardan joint on bevel gear 6.
  • Page 130 5 Mounting 7. Provisionally connect loose shaft ends of the joints to an angle bar and align so that they are in line. Figure 132: Connecting shaft ends with angle bar ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 131 5 Mounting 8. Determine dimension A between the shaft ends. Cut square tube to LR = A + 100 mm (LR = length of square tube). Deburr cut surfaces of square tube. Figure 133: Shortening square tube ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 132 5 Mounting 9. Before beginning installation, shorten both telescopic tubes to the corre- sponding dimension A (A = dimension between both cardan joint ends) and deburr. Figure 134: Shortening telescopic tubes Dimension A (= distance be- Inner tube Outer tube tween shaft ends of the drive and the bevel gear) 260 mm Shorten to 200 mm...
  • Page 133 5 Mounting 10. Fit one adapter ring to bearing collar of motor-drive unit and fit other adapter ring to bearing collar of bevel gear. Figure 135: Fitting adapters 11. Slide previously shortened and deburred square tube over upper cardan joint end until stop is reached. Figure 136: Sliding square tube over upper cardan joint end ®...
  • Page 134 5 Mounting 12. Thread upper pivotable protective tube with long outlet up onto square tube from below. Figure 137: Sliding pivotable protective tube over square tube ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 135 5 Mounting 13. Slide inner tube into outer tube such that the slotted sides of the outer and inner tube are both facing down. Thread the hose clips. Figure 138: Sliding on telescopic tubes ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 136 5 Mounting 14. Slide everything up and secure with a screw clamp. Figure 139: Secure everything with a screw clamp ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 137 5 Mounting 15. Slide bottom pivotable protective tube (also with long outlet up) on to the square tube and secure with screw clamp. Figure 140: Sliding bottom pivotable protective tube over square tube ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 138 5 Mounting 16. Swing in square tube and slide all the way down. Figure 141: Pivoting square tube back to axis ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 139 5 Mounting 17. Push the lower coupling bolt in and grease. Tighten lower coupling brackets. Shaft end and coupling part must be securely connected such that no axial clearance remains between the coupling bolt and coupling bracket. Figure 142: Tightening lower coupling brackets ®...
  • Page 140 5 Mounting 18. Fit upper coupling brackets with 3 mm axial clearance. Figure 143: Fitting upper coupling brackets 19. Working from top to bottom, mount the individual parts of the shaft pro- tection. Set angle position between both parts of pivotable protective tube and fix with available hose clip.
  • Page 141 5 Mounting Figure 144: Securing telescopic protective tube and pivotable protective tubes with hose clips 5.4.6.4 Fitting drive shaft with insulator A model with insulator in the vertical drive shaft is available for insulating in- stallation of the drive shaft. ® ®...
  • Page 142 5 Mounting Permitted axial displacement Minor axial displacement of the vertical drive shaft with insulator is permitted as long as it does not exceed 35 mm per 1000 mm square tube length (that corresponds to 2°). Figure 145: Permitted maximum axial displacement of vertical drive shaft with insulator 5.4.6.4.1 Fitting vertical drive shaft with insulator To fit the vertical drive shaft, proceed as follows.
  • Page 143 5 Mounting 2. Screw the bevel gear for mounting on the transformer. Screws are not in- cluded in the scope of supply. Figure 146: Bevel gear ® ® Maschinenfabrik Reinhausen GmbH 2020 4349322/01 EN VACUTAP...
  • Page 144 5 Mounting 3. Determine dimension A between shaft end of drive and shaft end of bevel gear. Shorten square tube to length of A–179 mm, taking the insulator into account. Figure 147: Shortening square tube ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 145 5 Mounting 4. Deburr cut surfaces of square tube. Figure 148: Deburring cut surfaces 5. Screw down double coupling part with insulator supplied and square tube. Mount insulator on the side facing the drive. Figure 149: Screwing down square tube and insulator with double coupling part ®...
  • Page 146 5 Mounting 6. Slide loosely screwed-together coupling part onto insulator until stop is reached. Figure 150: Sliding coupling part onto insulator 7. Place the supplied insulator ring on the bearing collar of the motor-drive unit. Figure 151: Insulating ring 8. Insert coupling bolt into shaft end of drive. Grease coupling part, coupling bolt and shaft end (e.g.
  • Page 147 5 Mounting 9. Attach square tube to drive. Figure 153: Attaching square tube to drive 10. Pivot square tube away from axis. Figure 154: Pivoting square tube away from axis 11. When installing inner tube of telescopic protective tube, shorten on the side without slots if necessary.
  • Page 148 5 Mounting Inner tube must not be deformed and must be deburred in order to slide easily in the outer tube. Figure 155: Deburring inner tube Dimension A (= distance between Inner tube Outer tube shaft end of drive and shaft end of bevel gear) 170 mm...190 mm Shorten to 200 mm...
  • Page 149 5 Mounting 12. Slide outer tube over inner tube. When doing so, make sure that the non- slotted side of the inner tube is facing upwards. Slide telescopic protec- tive tube onto square tube. Then slide hose clips over telescopic protec- tive tube.
  • Page 150 5 Mounting 13. Place adapter ring over bearing collar of bevel gear and slide upwards. Insert coupling bolt into shaft end of bevel gear. Pivot square tube back to axis. Figure 157: Fitting adapter ring and coupling bolt ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 151 5 Mounting 14. Grease coupling brackets, coupling bolt and shaft end (e.g. ISOFLEX TOPAS L32) and secure square tube with coupling brackets on the bevel gear. Set a unilateral axial clearance of 3 mm between the coupling bolt and upper coupling piece. Figure 158: Mounting coupling brackets 15.
  • Page 152 5 Mounting Figure 159: Mounting protective tube 5.4.6.5 Fitting drive shaft with insulator and cardan joint A model with insulator and cardan joint in the vertical drive shaft is also available for insulating installation of the drive shaft. ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...

  • Page 153: Centering On-Load Tap-Changer And Motor-Drive Unit

    MR operating instructions for motor-drive unit. 5.4.8 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 154: 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 155 6 Commissioning 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 161: Air-vent valve E1 3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load tap-changer head. Figure 162: Valve tappet 4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). ®...

  • Page 156: 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 163: 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 1.
  • Page 157 6 Commissioning 2. Connect grounding screw of motor-drive protective housing to transformer tank. It is essential that a CUPAL washer be placed between the cable shoe and connecting lug. The aluminum side of the CUPAL washer must be facing the connecting lug. Figure 165: Grounding screw on motor-drive unit 3.

  • Page 158: 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 159: Transporting Transformer To The Operating Site

    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 5.4.5, Page 99] and the drive shaft [►Section 5.4.6, Page 99] to the transformer at the installation site.

  • Page 160: Transport With Full Transformer Tank And Without Oil Conservator

    6 Commissioning 6.2.2 Transport with full transformer tank and without oil conservator Attach a connecting lead between the on-load tap-changer's oil compartment and the transformer tank if the transformer has been transported with a full tank and without an oil conservator. ►...
  • Page 161 6 Commissioning 3. Discharge the gas from under the on-load tap-changer cover. Ensure suf- ficient fresh air (e.g. in transformer cells and work tents) when doing so. 4. Once the gas has been discharged and the insulating fluid is flowing out of the air-vent valve, close the air-vent valve and close the stop-cock be- tween the oil conservator and oil compartment.

  • Page 162: Commissioning Transformer At Operating Site

    6 Commissioning 5. Open air-vent valve again and drain off around 5–10 liters of oil via the drain pipe until the area under the on-load tap-changer head cover is free of oil. 6. Loosen 24 screws M10/wrench size 17 with locking washers on on-load tap-changer head cover.

  • Page 163: Bleeding On-Load Tap-Changer Head And Suction Pipe

    6 Commissioning 2. Establish a connecting lead between pipe connection E2 and one of the pipe connections R, S or Q to ensure equal pressure in the oil compart- ment and transformer during evacuation. Figure 168: Connecting lead 3. Fill on-load tap-changer with new insulating fluid using one of the two free pipe connections of the on-load tap-changer head.
  • Page 164 6 Commissioning 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 170: Air-vent valve E1 3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load tap-changer head. Figure 171: Valve tappet 4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). ®...

  • Page 165: 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 172: 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 166: 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 167: Checking Pressure Monitoring Device

    6 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.

  • Page 168: Commissioning The Transformer

    6 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.

  • Page 169: 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 170 If the fill level has fallen below the limit values, also contact MR. On-load tap-changer not changing tap position (sluggish- Contact MR.

  • Page 171: Tripping The Protective Relay And Re-Commissioning The Transformer

    7 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-...

  • Page 172: Flap Valve In Operation Position

    7 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. 7.1.1 Flap valve in OPERATION position If the flap valve is in the OPERATION position, there may be a fault in the tripping circuit.

  • Page 173: Tripping The Pressure Monitoring Device And Putting The Transformer Back Into Operation

    7 Fault elimination 7.2 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.

  • Page 174: Re-Commissioning The Transformer

    7 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...

  • Page 175: 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 Technical data for on-load tap-changer 8.1.1 On-load tap-changer properties Electrical data for VACUTAP® VV®...

  • Page 176: Technical Data For Protective Relay

    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 –...
  • Page 177 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)

  • Page 178: Special Models Of Protective Relay

    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 17: 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...

  • Page 179: Protective Relay With Several Dry-Reed Magnetic Switches

    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...
  • Page 180 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)
  • Page 181 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.
  • Page 182 9 Drawings 9 Drawings ® ® VACUTAP 4349322/01 EN Maschinenfabrik Reinhausen GmbH 2020...
  • Page 183 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...
  • Page 184 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.
  • Page 185 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 ®...
  • Page 186 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...
  • Page 187 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.
  • Page 189 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...
  • Page 190 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...
  • Page 191 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...
  • Page 192 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...
  • Page 193 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 ®...
  • Page 194 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®...
  • Page 196 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.
  • Page 198 Maschinenfabrik Reinhausen GmbH Falkensteinstrasse 8 93059 Regensburg +49 (0)941 4090-0 sales@reinhausen.com www.reinhausen.com ® ® 4349322/01 EN - VACUTAP - 04/20 - Maschinenfabrik Reinhausen GmbH 2020 THE POWER BEHIND POWER.

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