Table of contents Table of contents Introduction......................... 6 Manufacturer............................ 6 Completeness............................. 6 Safekeeping............................ 6 Notation conventions .......................... 7 1.4.1 Hazard communication system .......................... 7 1.4.2 Information system.............................. 8 1.4.3 Instruction system .............................. 8 Safety.......................... 10 Appropriate use .......................... 10 Inappropriate use.......................... 11 Fundamental safety instructions ....................... 11 Personnel qualification........................
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Table of contents Operation........................... 38 Operating the motor-drive unit with the hand crank................ 38 Fault elimination ....................... 40 Tripping the protective relay and re-commissioning the transformer.......... 42 6.1.1 Flap valve in OPERATION position ........................ 43 6.1.2 Flap valve in OFF position .......................... 43 6.1.3 Re-commissioning the transformer ........................ 43 Tripping the pressure monitoring device and putting the transformer back into operation ....
1 Introduction 1 Introduction This technical file contains detailed descriptions for monitoring during opera- tion, fault elimination, and maintenance. It also includes safety instructions and general information about the prod- uct. Information about installation can be found in the installation and commis- sioning instructions.
1 Introduction 1.4 Notation conventions 1.4.1 Hazard communication system Warnings in this technical file are displayed as follows. 1.4.1.1 Warning relating to section Warnings relating to sections refer to entire chapters or sections, sub-sec- tions or several paragraphs within this technical file. Warnings relating to sections use the following format: Type of danger! WARNING...
1 Introduction Pictograms warn of dangers: Pictogram Definition Warning of a danger point Warning of dangerous electrical voltage Warning of combustible substances Warning of danger of tipping Warning of danger of crushing Table 2: Pictograms used in warning notices 1.4.2 Information system Information is designed to simplify and improve understanding of particular procedures.
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1 Introduction Aim of action ü Requirements (optional). ► Step 1 of 1. ð Result of step (optional). ð Result of action (optional). Multi-step instructions Instructions which consist of several process steps are structured as follows: Aim of action ü Requirements (optional). 1.
2 Safety 2 Safety ▪ Read this technical file through to familiarize yourself with the product. ▪ This technical file is a part of the product. ▪ Read and observe the safety instructions provided in this chapter. ▪ Read and observe the warnings in this technical file in order to avoid func- tion-related dangers.
2 Safety Exceeding the rated step voltage U for a short period by up to 10% is per- mitted if the rated through-current I is not exceeded. 2.2 Inappropriate use Use is considered inappropriate if the product is used in a way other than as described in the "Appropriate use"...
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2 Safety Work area Untidy and poorly lit work areas can lead to accidents. ▪ Keep the work area clean and tidy. ▪ Make sure that the work area is well lit. ▪ Observe the applicable laws for accident prevention in the relevant coun- try.
2 Safety ▪ Only use lubricants and auxiliary materials approved by the manufacturer. ▪ Contact the manufacturer. Modifications and conversions Unauthorized or inappropriate changes to the product may lead to personal injury, material damage and operational faults. ▪ Only modify the product after consultation with Maschinenfabrik Rein- hausen GmbH.
2 Safety Operator The operator uses and operates the product in line with this technical file. The operating company provides the operator with instruction and training on the specific tasks and the associated potential dangers arising from im- proper handling. Technical Service We strongly recommend having maintenance, repairs and retrofitting carried out by our Technical Service department.
3 Product description 3 Product description 3.1 On-load tap-changer 3.1.1 Function description On-load tap-changers are used to adjust the transmission ratio of transform- ers without interrupting the load flow. This makes it possible to compensate for aspects such as fluctuations in voltage occurring in the power transmis- sion grid.
3 Product description 4 Bevel gear 9 Oil conservator 5 Horizontal drive shaft 10 Active part of the transformer 3.1.2 Setup/models The following drawing shows the main components of the on-load tap- changer. You will find a detailed drawing of the on-load tap-changer in the "Drawings [►Section 9, Page 66]"...
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3 Product description Depending on the order, some or all of these pipe connections are fitted with pipe bends ex factory. All pipe bends without terminal box for the tap-change supervisory control can be freely swiveled once the pressure ring is loos- ened.
3 Product description tween the transformer tank and oil compartment of the on-load tap-changer, which is necessary for drying, filling with insulating fluid and transportation of the transformer. 3.1.3 Nameplate and serial number The nameplate with serial number is on the on-load tap-changer head cover. Figure 4: Nameplate The serial number can also be found on the selector.
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3 Product description 3.1.4.1 Protective relay 3.1.4.1.1 Function description The protective relay is looped into the circuit breaker tripping circuit, thus protecting the on-load tap-changer and transformer in the event of a fault within the on-load tap-changer oil compartment. It is tripped when the speci- fied speed of flow from the on-load tap-changer head to the oil conservator is exceeded due to a fault.
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3 Product description Rear view Figure 7: Protective relay RS 2001 1 Dummy plug 2 Nameplate The protective relay RS 2001/R has an extra inspection window on the rear. View from above Figure 8: Protective relay RS 2001 1 Gasket 2 Potential tie-in 3 Terminal box cover 4 Slotted head screw for potential tie-in...
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3 Product description 11 Connection terminal 12 Pressure equalization element 13 Cylinder head screw for protective conductor connection The protective relays RS 2003 and RS 2004 have a 1/2"-14NPT adapter in place of the cable gland. 3.1.4.1.3 Nameplate The nameplate is on the back of the protective relay. Figure 9: Nameplate 3.1.4.2 Pressure monitoring device DW 3.1.4.2.1 Function description...
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3 Product description 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. Additional use of a pressure monitoring device also requires installation of the provided protective relay.
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3 Product description The housing and the cover cap of the pressure monitoring device consist of lightweight, corrosion-resistant metal. Figure 10: Snap-action switch and pressure measuring element 1 Snap-action switch 2 Pressure measuring element ® ® Maschinenfabrik Reinhausen GmbH 2020 5993419/02 EN VACUTAP...
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3.1.4.4 Pressure relief device MPreC® On request, MR will supply a pre-fitted MPreC® pressure relief device in place of the rupture disk. This device responds to a defined overpressure in the oil compartment of the on-load tap-changer.
3 Product description 3.2 Drive shaft 3.2.1 Function description The drive shaft is the mechanical connection between the drive and the on- load tap-changer/de-energized tap-changer. The bevel gear changes the direction from vertical to horizontal. Accordingly, the vertical drive shaft has to be mounted between drive and bevel gear, and the horizontal drive shaft between bevel gear and on-load tap-changer or de-energized tap-changer.
3 Product description 3.2.2 Design/versions The drive shaft consists of a square tube and is coupled at each end by two coupling brackets and one coupling bolt to the driving or driven shaft end of the device to be connected. Figure 12: Components of the drive shaft 1 Bevel gear 2 Hose clip...
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3 Product description 3.2.2.1 Drive shaft without cardan joint and without insulator Figure 13: Drive shaft without cardan joint and without insulator (= standard version) Configuration V 1 min Intermediate bearing Middle of hand crank – middle of 536 mm When the maximum value bevel gear (maximum permissible of 2472 mm is exceeded, it axial offset 2°)
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3 Product description 3.2.2.2 Drive shaft without cardan joint and with insulator Figure 14: Drive shaft without cardan joint and with insulator (= special model) Configuration V 1 min Intermediate bearing Middle of hand crank – middle of 706 mm When the maximum value bevel gear (maximum permissible of 2472 mm is exceeded, it axial offset 2°)
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3 Product description 3.2.2.3 Drive shaft with cardan joint and without insulator Figure 15: Drive shaft with cardan joint and without insulator (= special model) Configuration V 1 min [mm] Intermediate bearing for [mm] Middle of hand crank – middle of V 1 >...
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3 Product description 3.2.2.4 Drive shaft with cardan joint and with insulator Figure 16: Drive shaft with cardan joint and with insulator (= special model) Configuration V 1 min [mm] Intermediate bearing for [mm] Middle of hand crank – middle of V 1 >...
4 Commissioning 4 Commissioning WARNING Danger of explosion! Explosive gases in the oil compartment of the on-load tap-changer, trans- former, pipework system, oil conservator and at the dehydrating breather opening can deflagrate or explode and result in severe injury or death! ►...
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4 Commissioning 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 17: Connecting lead between E2 and Q 3.
4 Commissioning 4.1.2 Bleeding on-load tap-changer head and suction pipe 4.1.2.1 Bleeding on-load tap-changer head 1. Open all forward valves and return valves in the pipe system. 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover.
4 Commissioning 4.1.2.2 Bleeding suction pipe on pipe connection S 1. Remove screw cap from pipe connection S. Figure 21: Screw cap NOTICE! An incompletely bled suction pipe significantly impairs the insu- lation capability of the on-load tap changer to ground. Open vent screw and bleed suction pipe completely.
Tests on the motor-drive unit 1. Perform function checks as described in relevant MR operating instruc- tions for motor-drive unit. NOTICE! An incorrectly coupled motor-drive unit will lead to damage to the on-load tap-changer.
4 Commissioning 4. Loosen the three screws on the terminal box cover and lift off the terminal box cover. 5. Remove the slotted head screw for potential tie-in and remove the termi- nal box cover with wire. 6. Press OFF test button. 7.
4 Commissioning 7. Ensure that the transformer's circuit breaker cannot be closed. ð Passive protection test 8. Activate the sensor on the snap-action switch. ð Sensor is in the OPERATION position. 9. Leave the transformer's danger zone. 10. Close the transformer's circuit breaker with isolating switches open and the transformer grounded on all sides.
5 Operation 5 Operation 5.1 Operating the motor-drive unit with the hand crank WARNING Danger of explosion! Unauthorized operation of the motor-drive unit with the hand crank may re- sult in death or serious injury. ► Never operate the motor-drive unit electrically or with the hand crank be- fore the transformer has been disconnected if you think there may be a fault in the transformer or on-load tap-changer / de-energized tap- changer.
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5 Operation 2. Switch off motor protective switch Q1 (position 0). 3. Insert the hand crank mounted in the motor-drive unit into the hand crank aperture in the upper cover plate. ð The built-in hand crank interlock switch interrupts the motor circuit at two poles.
In the event of faults on the on-load tap-changer and motor-drive unit which cannot be easily corrected on site, or if the protective relay or additional pro- tective devices have been tripped, please inform your authorized MR repre- sentative, the transformer manufacturer or contact MR directly.
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If the fill level has fallen below the limit values, also contact MR. On-load tap-changer not changing tap position (sluggish- Contact MR.
6 Fault elimination Fault description Action Red message on monitoring unit If possible read out database and send to MR along with error code. Warning or tripping of Buchholz relay on transformer Notify manufacturer of transformer. Deviation from desired value when measuring winding re-...
6 Fault elimination 4. Check the on-load tap-changer head cover. If insulating fluid is leaking, close the oil conservator stop valve immediately. 5. Check whether the flap valve of the protective relay is in the OFF or OP- ERATION position. 6.1.1 Flap valve in OPERATION position If the flap valve is in the OPERATION position, there may be a fault in the tripping circuit.
6 Fault elimination 6.2 Tripping the pressure monitoring device and putting the transformer back into operation WARNING Danger of death or severe injury! Danger of severe injury or death if on-load tap-changer and transformer are insufficiently tested. ► Be sure to contact Maschinenfabrik Reinhausen to check on-load tap- changer and transformer after the pressure monitoring device has been tripped.
6 Fault elimination 2. Contact and inform Maschinenfabrik Reinhausen of the following: ð What was the load of the transformer at the instant of tripping? ð Was there a tap-change operation on the on-load tap-changer immedi- ately before or during the tripping? ð...
7 Maintenance 7 Maintenance DANGER Electric shock! An energized transformer could cause death or serious injuries. ► Switch off transformer on high and low-voltage side. ► Lock transformer to prevent unintentional restart. ► Ensure that everything is de-energized. ► Visibly connect all transformer terminals to ground (grounding leads, grounding disconnectors) and short circuit them.
7 Maintenance 7.1 Inspection Monitoring the on-load tap-changer and motor-drive unit is limited to occa- sional visual checks of the on-load tap-changer head, protective relay and motor-drive unit, as well as monitoring the quality of the insulating fluid. For efficiency reasons these visual inspections can be combined with the usual checks on the transformer.
► Adherence to the following maintenance intervals is mandatory. If you are operating the on-load tap-changer without an MR monitoring sys- tem, the following maintenance intervals shall apply.
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MR monitoring system issues a maintenance warning. ► In the event of failure or shutdown of the MR monitoring system, observe the maintenance intervals as specified in the maintenance plan without the MR monitoring system.
7 Maintenance 7.3 Changing the insulation fluid NOTICE Damage to the on-load tap-changer! Small parts in the oil compartment may block the diverter switch insert, thereby damaging the on-load tap-changer. ► Ensure that parts do not fall into the oil compartment. ►...
7 Maintenance 2. Depending on version, loosen 4 or 6 screws on coupling brackets to upper gear unit and bevel gear. Figure 24: Loosening coupling brackets 3. Remove horizontal drive shaft. Be sure not to lose the coupling bolts. Figure 25: Removing drive shaft 7.3.3 Emptying the oil compartment and oil conservator 1.
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7 Maintenance 4. Once the gas has been discharged and insulating fluid is flowing out of the air-vent valve, close the air-vent valve. 5. Close the stop-cock between the oil conservator and on-load tap-changer. 6. Open air-vent valve E1 again and extract approximately 5–10 liters of in- sulating fluid via the pipe connection S until the area under the on-load tap-changer head cover is free of insulating fluid.
7 Maintenance 7.3.4 Filling the oil compartment and oil conservator with fresh insulating fluid NOTICE Damage to the on-load tap-changer! Unsuitable insulating fluids cause damage to the on-load tap-changer. ► Only use insulating fluids that meet the requirements in accordance with IEC 60296.
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7 Maintenance 5. Screw the on-load tap-changer head cover onto the on-load tap-changer head. Figure 30: On-load tap-changer head cover 6. Fill the oil conservator with fresh insulating fluid. 7. Vent the on-load tap-changer head via air-vent valve E1 on the on-load tap-changer head cover.
7 Maintenance 15. Flush the oil suction pipe and take an insulating fluid sample from the oil compartment via pipe connection S. 16. Record the temperature of the sample immediately after the sample is taken. 17. Determine dielectric strength and water content at a sample temperature of 20°C ±...
3. For special design types featuring cardan shafts, be sure to check the ex- pansion bellows and the lubricant reservoir of the cardan shafts. You will find a detailed description of how to fit the drive shaft in the MR op- erating instructions "Drive shaft".
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7 Maintenance Perform the DC resistance measurement in various on-load tap-changer op- erating positions. You need to distinguish here whether the measured cur- rent is interrupted when changing operating position or not. Status of oil compart- Without interruption in With interruption (mea- ment measured current sured current = 0 A be-...
8 Technical data 8 Technical data An overview of all key technical data for the on-load tap-changer and motor- drive unit exists in the form of separate documents, which are available on request. 8.1 Technical data for on-load tap-changer 8.1.1 On-load tap-changer properties Electrical data On-load tap-changer VMS III 400 Y...
8 Technical data Drying temperatures See installation and commissioning instructions, chapter "As- sembly" Compressive strength See technical data TD 61 – General Section Installation height of the oil conservator See technical data TD 61 – General Section Installation height above sea level See technical data TD 61 –...
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8 Technical data Switching capacity (switching load on an off) Maximum switched current DC (highest 0.9 A (at 250 V with L/R = 40 ms) voltage) Maximum switched current AC (highest 2 A (at 125 V with cos φ = 0.6) current) Maximum switched current AC (highest 1.6 A (at 250 V with cos φ...
8 Technical data Dielectric strength AC dielectric strength between all volt- 2,500 V, 50 Hz, test duration 1 minute age-carrying connections and the grounded parts AC dielectric strength between the 2,000 V, 50 Hz, test duration 1 minute opened contacts Table 17: Dielectric strength Ambient conditions Ambient temperature Ta...
8 Technical data Switching capacity (switching load on an off) Maximum switched current AC (highest 0.8 A (at 250 V with cos φ = 0.6) voltage) Switching operations 1,000 cycles Table 20: 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...
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8 Technical data 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) Utilization category IEC 60947-5-1: AC 15: 230 V/1 A DC 13: 60 V/0.5 A Maximum continuous current 10 A Rated insulation voltage AC: 2.5 kV/min...
8 Technical data 8.5 Limit values for dielectric strength and water content of insulating fluids The following table provides the limit values for dielectric strength (measured in accordance with IEC 60156) and water content (measured in accordance with IEC 60814) of insulating fluids. The values have been established based on IEC 60422.
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PROTECTIVE RELAY VM III 350 / 500 / 650 Y VM I 351 / 501 / 651 VMS III 400 / 650 Y - C VM I 802 / VM II 352 / 502 / 652 VM I 1203 / 1503 Sonderausführungen VM I 653 VM I 803...
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Ra 3,2 46, 47 REPRESENTATION OF REVERSING CHANGE- SCREENINGS SEE 730335 OVER SELECTOR 1: 2 REPRESENTATION WITHOUT CHANGE-OVER SELECTOR t = 8 1: 2 ADDITIONAL SCREENINGS / SELECTOR BASE PROVIDE SUFFICIENT SEE 893934, 893935, 725649 CLEARANCE (OPTIONAL) t = 8 1: 2 TRANSFORMER TANK BOTTOM 1: 2...
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THROUGH-HOLE VERTICAL THROUGH-HOLE HORIZONTAL M III 350 / 500 / 600Y M III 350 / 500 / 600Y M III 350 / 500 / 600Y VM III 350 / 500 / 650Y VM III 350 / 500 / 650Y VM III 350 / 500 / 650Y VMS III 400 / 650Y - C VMS III 400 / 650Y - C VMS III 400 / 650Y - C...
9 Drawings 9.3 On-load tap-changer head ® ® Maschinenfabrik Reinhausen GmbH 2020 5993419/02 EN VACUTAP...
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O-Ring 44,2-5,7 LIFTING GEAR SUCTION PIPE DRILL HOLE ROTATED IN SECTIONAL PLANE TRANSFORMER COVER O-RING LIFTING TRAVERSE SCREENING RING WITH Um=170/245/300kV ONLY SUPPORTING FLANGE LIFTING TRAVERSE Z = CENTERING BOLT = DRIVE SIDE OF SELECTOR SERIAL NUMBER DIMENSION ON-LOAD TAP-CHANGER ...
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GASKET WIDTH GROUND CONNECTION M12 37,5 1: 1 E1 = BLEEDING FACILITY FOR ON-LOAD TAP-CHANGER HEAD E2 = BLEEDING FACILITY FOR SPACE UNDER THE HEAD OUTSIDE THE TAP-CHANGER OIL COMPARTMENT (SAME PIPE CONNECTION AS R, S, Q OR BLEEDER SCREW CAN BE USED) Q = CONNECTION FOR OIL RETURN PIPE OR TAP-CHANGE SUPERVISORY CONTROL CONNECTIONS SWIVELING S = CONNECTION FOR SUCTION PIPE...
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BASIC CONNECTION DIAGRAMS 10010326 890 616 BASIC CONNECTION DIAGRAM 22 22 0 INSTALLATION DRAWINGS 893 978 M III 350 Y ... M I 1503 VM III 350 Y ... VM I 1503 746 230 ON-LOAD TAP-CHANGER HEAD M III 350 Y ... M I 1503 AND V M III 350 Y ...
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898 041 ARRANGEMENT OF CONTACTS AT THE SELECTOR BASIC CONNECTION DIAGRAMS 893 819 CONTACT ARRANGEMENT ON SELECTOR 891 114 ON-LOAD TAP-CHANGER HEAD 893 899 VARIANTS OF THE ON-LOAD TAP-CHANGER HEAD 720 026 SWIVEL RANGE OF THE GEAR UNIT 720 027 INSTALLATION DRAWING 893 900 VM 300...
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