Page 1 On-load tap-changer ® VACUTAP VM-Ex Installation and commissioning instructions 5293079/01 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 .................. 36 Packaging ............................ 36 4.1.1 Suitability................................ 36 4.1.2 Markings................................ 37 Transportation, receipt and handling of shipments................ 37 Storage of shipments........................ 38 Unpacking shipments and checking for transportation damages ............. 39 Mounting ........................... 40 Installation information........................ 40 Preparatory work ..........................
Page 5 Table of contents 5.5.2 Installing protective relay in piping and connecting................... 138 5.5.3 Fitting motor-drive unit ............................ 148 5.5.4 Fitting drive shaft............................... 148 5.5.5 Centering on-load tap-changer and motor-drive unit .................. 172 5.5.6 Making the electrical connections for the motor-drive unit ................ 172 Commissioning....................... 173 Commissioning the on-load tap-changer at the transformer manufacturer's site ......
Page 6 Table of contents VACUTAP® VM, installation position of selector connection contacts (890477) ...... 197 Special design for bell-type tank installation for Um up to 300 kV (896762) ........ 198 Lifting traverse for bell-type tank installation (890180) .............. 199 On-load tap-changer head (893899) .................... 200 On-load tap-changer head with tap-change supervisory control (894109)........
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 VM-Ex 5293079/01 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: ▪ Oil compartment with on-load tap-changer head and built-in diverter switch insert ▪ Selector ▪ Ex motor-drive unit ▪...
Page 24: Setup/Models
3 Product description Figure 3: System overview of on-load tap-changer, transformer 1 Transformer tank 6 Upper 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 of the transformer 3.2.2 Setup/models The on-load tap-changer consists of the on-load tap-changer head, oil com-...
Page 25 3 Product description For the number of maximum operating positions of the on-load tap-changer, refer to the technical data. Figure 4: VACUTAP® VM 1 On-load tap-changer head 3 Selector 2 Oil compartment 4 Change-over selector ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 26 3 Product description Figure 5: VACUTAP® VM 300 1 On-load tap-changer head 3 Change-over selector 2 Oil compartment 4 Selector 3.2.2.1 Pipe connections The on-load tap-changer head features 4 pipe connections for different pur- poses. ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 27 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 6: Pipe connections with pipe bends Pipe connection Q The pipe connection Q is closed with a blank cover.
Page 28: Nameplate And Serial Number
3 Product description 3.2.3 Nameplate and serial number The nameplate with serial number is on the on-load tap-changer head cover. Figure 7: Nameplate The serial number can also be found on the selector. Figure 8: Serial number 3.2.4 Protective devices The on-load tap-changer is equipped with the following protective devices. ®...
Page 29 3 Product description 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. 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.
Page 30 3 Product description Rear view Figure 10: RS 2001-Ex 1 Ground connection 2 Nameplate View from above Figure 11: 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...
Page 31: Drive Shaft
3 Product description 3.2.4.1.3 Name plate The name plate for the explosion-protected protective relay is on the rear of the product. Figure 12: Position of name plate 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.
Page 32 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 13: Explosion-proof drive shaft with insulator ®...
Page 33: Design/Model
3 Product description 3.3.2 Design/Model The design of the explosion-proof drive shaft is described in this section. Figure 14: 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 34 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 35: Identification Plate
3 Product description 3.3.3 Identification plate The identification plate is on the telescopic protective tube. Figure 15: Position of the identification plate ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42: Installing The On-Load Tap-Changer In The Transformer (Standard Version)
5 Mounting 2. Fit stud bolts on mounting flange. Figure 17: 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 5.3.1.1 Fastening oil compartment on transformer cover CAUTION! An unstably positioned oil compartment may tip over, re- sulting in injuries or property damage.
Page 43 5 Mounting NOTICE! Unsuitable gaskets may lead to oil escaping and therefore to damage to the on-load tap-changer. Place a gasket suitable for the in- sulating medium in use on the mounting flange . Clean the sealing sur- faces on the mounting flange and on-load tap-changer head. Figure 18: Sealing surfaces, gasket NOTICE! Lowering the oil compartment without due care can result in the...
Page 44 5 Mounting 6. Screw the on-load tap-changer head to the mounting flange. Figure 20: On-load tap-changer head with mounting flange 7. Remove the blocking strip from the coupling of the oil compartment base. Figure 21: Blocking strip 5.3.1.2 Fastening tap selector on oil compartment of diverter switch (not for VACUTAP® VM 300) CAUTION! Place the selector on a level surface and secure it against tipping.
Page 45 5 Mounting 2. Remove plastic bag with fastening materials from the selector and keep it ready. Figure 22: Plastic bag with fastening materials 3. Remove the blocking strip from the selector coupling. Once the blocking strip is removed, the selector coupling may no longer be turned. Figure 23: Selector coupling with blocking strip 4.
Page 46 5 Mounting 6. Carefully lower the oil compartment vertically and align the position of both coupling parts and attachment points of the oil compartment and se- lector with one another. The correct position of the two coupling parts is shown in the adjustment plans supplied. 7.
Page 47 5 Mounting 9. Fit screening caps to screw connections and fold up brackets on hexagon screws. The screening caps differ depending on insulation to ground. Figure 26: Screening caps on screw connection 10. Remove red supports on selector base (if present). ®...
Page 48 5 Mounting 5.3.1.3 Connecting tap-selector connecting leads (not applicable for VACUTAP® VM 300) Proceed as follows to connect the tap-selector connecting leads: 1. Screw tap-selector connecting leads to connecting piece with care. Comply with specified tightening torque and secure screw connection. Failure to do so may result in damage to the on-load tap-changer and transformer.
Page 49 5 Mounting 2. Fit screening caps to screw connections and fold up brackets on hexagon screws. The screening caps differ depending on insulation to ground. Figure 28: Screening caps on screw connection ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 50: Fastening Vacutap® Vm 300 To Transformer Cover
5 Mounting 5.3.2 Fastening VACUTAP® VM 300 to transformer cover CAUTION! Place on-load tap-changer on a level surface and secure it against tipping. An unstably positioned on-load tap-changer may tip, re- sulting in serious injuries or damage! CAUTION! Prior to installation, remove the red-colored packaging and transport material from the on-load tap-changer.
Page 51 5 Mounting 4. Remove the connecting leads on an on-load tap-changer with potential connection unit or on-load tap-changer with 3W/2W/3G change-over se- lector to enable the on-load tap-changer to fit through the transformer cover opening. Figure 30: Removing connecting leads ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP...
Page 52 5 Mounting CAUTION! Lift on-load tap-changer by hooking up on-load tap- changer head and carefully lower vertically into cover opening of trans- former. Otherwise the shielding rings on the oil compartment may be dam- aged (only if Vm ≥ 170 kV is present). Figure 31: Lowering on-load tap-changer into transformer 6.
Page 53: Connecting The Tap Winding And On-Load Tap-Changer Take-Off Lead
5 Mounting 7. Screw the on-load tap-changer head to the mounting flange. Figure 32: Screwing the on-load tap-changer head to the mounting flange 8. Reattach the connecting leads for an on-load tap-changer with potential connection unit or an on-load tap-changer with 3W/2W/3G change-over selector.
Page 54 5 Mounting The tap winding and on-load tap-changer take-off lead must be connected in accordance with the connection diagram included with the delivery. 5.3.3.1 Selector connection contacts for VACUTAP® VM and VM 300 The selector connection contacts are indicated on the selector bars, have crimped ends and a through-hole for M10 screws (M8 screws for VACUTAP® VM 300) to allow the tap-selector connecting leads to be con- nected with cable shoes.
Page 55 5 Mounting Screening caps are available on request. Figure 36: Selector connection contact with screening caps In this case a locking washer must be placed below each screening cap. The connection screws, nuts, and locking washers are not included in the scope of delivery.
Page 56 2. Please pay attention to the dimensional drawing on which the order is based. Figure 37: Paper insulation 1 Connection from MR already has 3 p Connections to be insulated mm of paper insulation 5.3.3.3 Change-over selector connection contacts for reversing change-over...
Page 57 5 Mounting 3. Close the screening caps and make sure they are seated correctly. The screw head and nut must be fully covered. Figure 38: Change-over selector connection contacts for reversing change-over selector con- nection Figure 39: Change-over selector connection contacts for reversing change-over selector con- nection (top view) 5.3.3.4 Change-over selector connection contacts for reversing change-over selector connection VACUTAP® VM 300...
Page 58 5 Mounting Connection contact K is designed as an extended fine tap selector connec- tion contact (also with through-hole for M8 screws). Figure 40: Change-over selector connection contacts for reversing change-over selector con- nection VACUTAP® VM 300 Damage to the on-load tap-changer! NOTICE Tap-winding connecting leads situated too closely to the change-over selec- tor's moving parts block the change-over selector and therefore result in damage to the on-load tap-changer.
Page 59 5 Mounting With coarse tap selector connection, the external appearance of the (+) and (-) change-over selector connection contacts is identical to the tap selector contacts (through-hole for M10 screws, always in vertical position). 1. Fasten the tap-winding connecting leads to the change-over selector in accordance with the connection diagram provided.
Page 60 5 Mounting Figure 42: Change-over selector connection contacts for coarse tap selector connection (top view) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 61 5 Mounting 5.3.3.6 Change-over selector connection contacts for coarse tap selector connection VACUTAP® VM 300 With coarse tap selector connection, the (+) and (-) change-over selector connection contacts are secured to the respective laminated paper bars of the coarse change-over selector. Their external appearance is identical to the fine tap selector contacts (through-hole for M8 screws, always in horizon- tal position).
Page 62 5 Mounting 2. Take suitable measures to ensure the screw connection cannot come loose or settle (e.g. by using clamping washers). Figure 44: Take-off lead connection on oil compartment 5.3.3.7.2 Take-off lead connection on take-off ring 1. Connect the on-load tap-changer take-off lead to 1 of the 3 through-holes on the take-off ring using a cable shoe and screw.
Page 63: Performing Transformer Ratio Test Before Drying
5 Mounting 5.3.4 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 64: 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 65 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 66: Drying On-Load Tap-Changer In Transformer Tank
5.3.7 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 67 5 Mounting 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. 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 68 5 Mounting 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. ► Check that all small parts are accounted for. 1.
Page 69 5 Mounting 5.3.7.2.1.3 Removing tap position indicator disk without multiple coarse change- over selector ► Pull spring clip off shaft end and remove tap position indicator disk. Figure 50: Tap position indicator disk 5.3.7.2.1.4 Removing tap position indicator disk with multiple coarse change-over selector with more than 35 operating positions 1.
Page 70 5 Mounting 3. Lever cover disk off underlying disk with flat screwdriver and pull out posi- tion-indication disk from between panel and bracket. Figure 52: Cover disk and position-indication disk 4. Remove hexagon screws and associated lock tab. Figure 53: Lock tab ®...
Page 71 5 Mounting 5. Pull panel and bracket up and off indicator drive shaft. Figure 54: Panel 5.3.7.2.1.5 Lifting out diverter switch insert 1. Remove attachment and locking elements on carrier plate of diverter switch insert. Figure 55: Carrier plate of diverter switch insert ®...
Page 72 5 Mounting 2. Insert lifting gear in the brackets on the diverter switch insert carrier plate and position vertically above the diverter switch insert. Figure 56: Brackets on carrier plate 3. Lift out diverter switch insert slowly and vertically. Figure 57: Lifting out diverter switch insert CAUTION! An unstably positioned diverter switch insert may tip, re- sulting in injuries and property damage.
Page 73 5 Mounting 5.3.7.2.2 Opening kerosene drain plug ► NOTICE! Never remove the kerosene drain plug completely. Unscrew kerosene drain plug with extended socket wrench counter-clockwise until it starts to become hard to open. Figure 58: Kerosene drain plug 5.3.7.2.3 Inserting diverter switch insert 5.3.7.2.3.1 Inserting diverter switch insert 1.
Page 74 5 Mounting 2. Insert lifting gear in the brackets provided on the diverter switch insert car- rier plate and position vertically above the diverter switch insert. Figure 60: Brackets on carrier plate 3. Ensure that diverter switch insert is in the final end position on the same side as when it was removed (side A or side B).
Page 75 5 Mounting 6. Align diverter switch insert such that the red triangles at the top of the en- ergy accumulator and on the on-load tap-changer head are opposite one another. Slowly lower diverter switch insert. Figure 62: Aligning diverter switch insert 7.
Page 76 5 Mounting 5.3.7.2.3.2 Inserting the tap position indicator without multiple coarse change- over selector Due to the coupling pin, the tap position indicator disc can only be installed when in the correct position. ► Place tap position indicator disk on indicator drive shaft, slide spring clip on to shaft end.
Page 77 5 Mounting 2. Insert position-indication disk horizontally between panel and bracket and fit cover disk. Align tap position indicator disc and cover disk to produce a continuous red line. Figure 67: Inserting position-indication disk 3. Secure cover disk with countersunk head screw. The countersunk head screw must be suitable for center-punching.
Page 78 5 Mounting 5.3.7.2.3.4 Securing on-load tap-changer head cover NOTICE! Place on-load tap-changer head cover on on-load tap-changer head and take care not to damage the o-ring inserted in the on-load tap- changer head cover. A damaged o-ring leads to oil escaping and there- fore to damage of the on-load tap-changer.
Page 79 5 Mounting 2. Seal off unused pipe connections with a suitable blank cover. Figure 71: Shared lead Vapor-phase drying in the transformer tank 1. Supply kerosene vapor at a temperature of around 90°C. Keep this tem- perature constant for 3 to 4 hours. 2.
Page 80: Filling The Oil Compartment Of The On-Load Tap-Changer With Insulating Fluid
5 Mounting 5.3.8 Filling the oil compartment of the on-load tap-changer with insulating fluid NOTICE Damage to the on-load tap-changer! Unsuitable insulating fluids cause damage to the on-load tap-changer. ► Use insulating fluids that meet the requirements in accordance with IEC 60296.
Page 81: 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 73: Pipe connections S and R 5.3.9 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 82: 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 83 5 Mounting 2. Remove plastic bag with fastening materials from the selector and keep it ready. Figure 74: Plastic bag with fastening materials 3. Remove the blocking strip from the selector coupling. Once the blocking strip is removed, the selector coupling may no longer be turned. Figure 75: Selector coupling with blocking strip CAUTION! Place the oil compartment on a level surface and secure it against tipping.
Page 84 5 Mounting 6. Remove the blocking strip from the coupling of the oil compartment base. Figure 76: Oil compartment base with blocking strip 7. Lift the oil compartment by hooking up the on-load tap-changer head and carefully move it over the selector. 8.
Page 85 5 Mounting 11. Screw tap-selector connecting leads to the connecting pieces. Figure 78: Screwing on the tap-selector connecting leads 1 Hexagon screw 4 Tap-selector connecting lead 2 Screening cap 5 Connecting piece 3 Washer ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 86 5 Mounting 12. Fit screening caps to screw connections and fold up brackets on hexagon screws. The screening caps differ depending on insulation to ground. Figure 79: Screening caps on screw connection ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 87 5 Mounting 5.4.1.2 Connecting tap-selector connecting leads (not applicable for VACUTAP® VM 300) Proceed as follows to connect the tap-selector connecting leads: NOTICE! Screw tap-selector connecting leads to connecting piece with care. Comply with specified tightening torque and secure screw connec- tion.
Page 88 5 Mounting 3. Fit screening caps to screw connections and fold up brackets on hexagon screws. The screening caps differ depending on insulation to ground. Figure 81: Screening caps on screw connection ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 89 5 Mounting 5.4.1.3 Inserting on-load tap-changer into supporting structure NOTICE! Tensile forces can lead to damage and malfunctions on the on- load tap-changer. Using spacers, insert the on-load tap-changer vertically into the 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...20 mm once the tap winding and the on-load tap-changer take-off lead have been connected and the bell-type...
Page 90: Connecting The Tap Winding And On-Load Tap-Changer Take-Off Lead
5 Mounting 3. Remove the red protective cap on the 0-bar of the change-over selector (if present). Figure 84: Protective cap 4. Secure selector with pitch of tap selector contact circle 36 to prevent it twisting as a result of being turned and slid. There are 3 holes, 20 mm in diameter, in the selector base for this purpose.
Page 91 5 Mounting The tap winding and on-load tap-changer take-off lead must be connected in accordance with the connection diagram included with the delivery. 5.4.2.1 Selector connection contacts for VACUTAP® VM and VM 300 The selector connection contacts are indicated on the selector bars, have crimped ends and a through-hole for M10 screws (M8 screws for VACUTAP® VM 300) to allow the tap-selector connecting leads to be con- nected with cable shoes.
Page 92 5 Mounting Screening caps are available on request. Figure 87: Selector connection contact with screening caps In this case a locking washer must be placed below each screening cap. The connection screws, nuts, and locking washers are not included in the scope of delivery.
Page 93 2. Please pay attention to the dimensional drawing on which the order is based. Figure 88: Paper insulation 1 Connection from MR already has 3 p Connections to be insulated mm of paper insulation 5.4.2.3 Change-over selector connection contacts for reversing change-over...
Page 94 5 Mounting 3. Close the screening caps and make sure they are seated correctly. The screw head and nut must be fully covered. Figure 89: Change-over selector connection contacts for reversing change-over selector con- nection Figure 90: Change-over selector connection contacts for reversing change-over selector con- nection (top view) 5.4.2.4 Change-over selector connection contacts for reversing change-over selector connection VACUTAP® VM 300...
Page 95 5 Mounting Connection contact K is designed as an extended fine tap selector connec- tion contact (also with through-hole for M8 screws). Figure 91: Change-over selector connection contacts for reversing change-over selector con- nection VACUTAP® VM 300 Damage to the on-load tap-changer! NOTICE Tap-winding connecting leads situated too closely to the change-over selec- tor's moving parts block the change-over selector and therefore result in damage to the on-load tap-changer.
Page 96 5 Mounting With coarse tap selector connection, the external appearance of the (+) and (-) change-over selector connection contacts is identical to the tap selector contacts (through-hole for M10 screws, always in vertical position). 1. Fasten the tap-winding connecting leads to the change-over selector in accordance with the connection diagram provided.
Page 97 5 Mounting Figure 93: Change-over selector connection contacts for coarse tap selector connection (top view) ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 98 5 Mounting 5.4.2.6 Change-over selector connection contacts for coarse tap selector connection VACUTAP® VM 300 With coarse tap selector connection, the (+) and (-) change-over selector connection contacts are secured to the respective laminated paper bars of the coarse change-over selector. Their external appearance is identical to the fine tap selector contacts (through-hole for M8 screws, always in horizon- tal position).
Page 99 5 Mounting 2. Take suitable measures to ensure the screw connection cannot come loose or settle (e.g. by using clamping washers). Figure 95: Take-off lead connection on oil compartment 5.4.2.7.2 Take-off lead connection on take-off ring 1. Connect the on-load tap-changer take-off lead to 1 of the 3 through-holes on the take-off ring using a cable shoe and screw.
Page 100: Performing Transformer Ratio Test Before Drying
5 Mounting 5.4.3 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 101: 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 102 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 103: Lifting Top Part Of On-Load Tap-Changer Head Off Supporting Flange (Bottom Part)
5 Mounting 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. Vacuum-dry on-load tap-changer at between 105°C and maximum 125°C for at least 50 hours. 4. Residual pressure of no more than 10 bar.
Page 104 5 Mounting 2. Remove temporary fastening and spacers and slowly lower on-load tap- changer. Figure 98: Removing fastening 3. Loosen screws with locking elements on on-load tap-changer head cover. Figure 99: On-load tap-changer head cover NOTICE! Remove the on-load tap-changer head cover. Make sure that sealing surfaces on the on-load tap-changer head cover and on-load tap- changer head are in sound condition when removing and during all other work and that the o-ring is also undamaged.
Page 105 5 Mounting 5.4.6.2 Removing tap position indicator disk without multiple coarse change- over selector ► Pull spring clip off shaft end and remove tap position indicator disk. Figure 101: Tap position indicator disk 5.4.6.3 Removing tap position indicator disk with multiple coarse change-over selector with more than 35 operating positions 1.
Page 106 5 Mounting 3. Lever cover disk off underlying disk with flat screwdriver and pull out posi- tion-indication disk from between panel and bracket. Figure 103: Cover disk and position-indication disk 4. Remove hexagon screws and associated lock tab. Figure 104: Lock tab ®...
Page 107 5 Mounting 5. Pull panel and bracket up and off indicator drive shaft. Figure 105: Panel 5.4.6.4 Lifting out diverter switch insert 1. Remove attachment and locking elements on carrier plate of diverter switch insert. Figure 106: Carrier plate of diverter switch insert ®...
Page 108 5 Mounting 2. Insert lifting gear in the brackets on the diverter switch insert carrier plate and position vertically above the diverter switch insert. Figure 107: Brackets on carrier plate 3. Lift out diverter switch insert slowly and vertically. Figure 108: Lifting out diverter switch insert CAUTION! An unstably positioned diverter switch insert may tip, re- sulting in injuries and property damage.
Page 109 5 Mounting 5.4.6.5 Removing the oil suction pipe ► Pull the connecting piece of the oil suction pipe in the on-load tap-changer head inwards and out. Pay attention to the O-ring. Figure 109: Oil suction pipe 5.4.6.6 Lifting on-load tap-changer head off supporting flange 1.
Page 110 5 Mounting 2. Lift off the on-load tap-changer head from the supporting flange. Figure 111: On-load tap-changer head ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 111: 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 112: Supporting flange with o-ring 2.
Page 112 5 Mounting 5.4.7.2 Positioning top part of on-load tap-changer head on bell-type tank NOTICE! Unsuitable gaskets may lead to oil escaping and therefore to damage to the on-load tap-changer. Place a gasket suitable for the in- sulating fluid used on the mounting flange .
Page 113 5 Mounting 2. Lower and position the top part of the on-load tap-changer head on mounting flange so that the triangular markings, pins and mounting holes on the top part and bottom part of the on-load tap-changer head are aligned. Figure 115: Markings and fitted bolt ®...
Page 114 5 Mounting 5.4.7.3 Connecting on-load tap-changer to top part of on-load tap-changer head NOTICE Incorrectly lifting the on-load tap-changer will damage it! If the connection screws of the supporting flange are used to lift the on-load tap-changer, the screws may be damaged, which makes it impossible to properly screw the on-load tap-changer and the on-load tap-changer head together! ►...
Page 115 5 Mounting NOTICE! Inaccurate alignment of on-load tap-changer head to supporting flange will damage the on-load tap-changer when it is lifted. Lift on-load tap-changer with lifting traverse and ensure that the triangular markings are aligned and that all supporting flange stud bolts go easily through the mounting holes of the on-load tap-changer head.
Page 116 5 Mounting 4. Remove lifting traverse. Figure 119: Removing lifting traverse 5. Screw the on-load tap-changer head to the mounting flange. Figure 120: Screwing the on-load tap-changer head to the mounting flange 5.4.7.4 Inserting oil suction pipe 1. Lightly grease the O-rings of the oil suction pipe. ®...
Page 117 5 Mounting 2. Insert the oil suction pipe into the on-load tap-changer head. Make sure the O-rings are correctly fitted. Figure 121: Oil suction pipe 5.4.7.5 Inserting diverter switch insert 1. To fit diverter switch insert, ensure that selector coupling and indicator gear are in the adjustment position.
Page 118 5 Mounting 2. Insert lifting gear in the brackets provided on the diverter switch insert car- rier plate and position vertically above the diverter switch insert. Figure 123: Brackets on carrier plate 3. Ensure that diverter switch insert is in the final end position on the same side as when it was removed (side A or side B).
Page 119 5 Mounting NOTICE! Mixing up the diverter switch inserts will lead to damage to the on-load tap-changer. Ensure the same number of triangles on the top of the energy accumulator and on-load tap-changer head. 6. Align diverter switch insert such that the red triangles at the top of the en- ergy accumulator and on the on-load tap-changer head are opposite one another.
Page 120 5 Mounting 5.4.7.6 Inserting the tap position indicator without multiple coarse change- over selector Due to the coupling pin, the tap position indicator disc can only be installed when in the correct position. ► Place tap position indicator disk on indicator drive shaft, slide spring clip on to shaft end.
Page 121 5 Mounting 2. Insert position-indication disk horizontally between panel and bracket and fit cover disk. Align tap position indicator disc and cover disk to produce a continuous red line. Figure 129: Inserting position-indication disk 3. Secure cover disk with countersunk head screw. The countersunk head screw must be suitable for center-punching.
Page 122: 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 123 5 Mounting 5.4.8.1 Vacuum-drying in the transformer tank The on-load tap-changer head cover remains closed during the entire drying process. 1. Establish a connecting lead between either connections E2 and Q or con- nections E2 and R on the on-load tap-changer head. 2.
Page 124 5 Mounting 5.4.8.2.1 Removing diverter switch insert 5.4.8.2.1.1 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. 5.4.8.2.1.2 Removing on-load tap-changer head cover WARNING Danger of explosion! Danger of death from explosive gases under the on-load tap-changer head...
Page 125 5 Mounting NOTICE! Remove the on-load tap-changer head cover. Make sure that sealing surfaces on the on-load tap-changer head cover and on-load tap- changer head are in sound condition when removing and during all other work and that the o-ring is also undamaged. Damaged sealing surfaces lead to oil escaping and therefore to on-load tap-changer and transformer damage.
Page 126 5 Mounting 2. Remove countersunk head screw. Figure 137: Countersunk head screw 3. Lever cover disk off underlying disk with flat screwdriver and pull out posi- tion-indication disk from between panel and bracket. Figure 138: Cover disk and position-indication disk ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 127 5 Mounting 4. Remove hexagon screws and associated lock tab. Figure 139: Lock tab 5. Pull panel and bracket up and off indicator drive shaft. Figure 140: Panel 5.4.8.2.1.5 Lifting out diverter switch insert NOTICE! Loosen nuts and locking elements on carrier plate of diverter switch insert.
Page 128 5 Mounting 2. Insert lifting gear in the brackets provided on the diverter switch insert car- rier plate and position vertically above the diverter switch insert. Figure 142: Brackets on carrier plate 3. Lift out diverter switch insert slowly and vertically. Figure 143: Lifting out diverter switch insert CAUTION! Place the diverter switch insert on a level surface and se- cure it against tipping.
Page 129 5 Mounting Figure 144: Kerosene drain plug 5.4.8.2.3 Inserting diverter switch insert 5.4.8.2.3.1 Inserting diverter switch insert 1. To fit diverter switch insert, ensure that selector coupling and indication gear are in the adjustment position. Figure 145: Adjustment position ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 130 5 Mounting 2. Insert lifting gear in the brackets provided on the diverter switch insert car- rier plate and position vertically above the diverter switch insert. Figure 146: Brackets on carrier plate 3. Ensure that diverter switch insert is in the final end position on the same side as when it was removed (side A or side B).
Page 131 5 Mounting 6. Align diverter switch insert such that the red triangles at the top of the en- ergy accumulator and on the on-load tap-changer head are opposite one another. Slowly lower diverter switch insert. Figure 148: Aligning diverter switch insert 7.
Page 132 5 Mounting 5.4.8.2.3.2 Inserting the tap position indicator without multiple coarse change- over selector Due to the coupling pin, the tap position indicator disc can only be installed when in the correct position. ► Place tap position indicator disk on indicator drive shaft, slide spring clip on to shaft end.
Page 133 5 Mounting 2. Insert position-indication disk horizontally between panel and bracket and fit cover disk. Align tap position indicator disc and cover disk to produce a continuous red line. Figure 153: Inserting position-indication disk 3. Secure cover disk with countersunk head screw. The countersunk head screw must be suitable for center-punching.
Page 134 5 Mounting 5.4.8.2.3.4 Securing on-load tap-changer head cover NOTICE! Place on-load tap-changer head cover on on-load tap-changer head and take care not to damage the o-ring inserted in the on-load tap- changer head cover. A damaged o-ring leads to oil escaping and there- fore to damage of the on-load tap-changer.
Page 135 5 Mounting 2. Seal off unused pipe connections with a suitable blank cover. Figure 157: Shared lead Vapor-phase drying in the transformer tank 1. Supply kerosene vapor at a temperature of around 90°C. Keep this tem- perature constant for 3 to 4 hours. 2.
Page 136: Filling The Oil Compartment Of The On-Load Tap-Changer With Insulating Fluid
5 Mounting 5.4.9 Filling the oil compartment of the on-load tap-changer with insulating fluid NOTICE Damage to the on-load tap-changer! Unsuitable insulating fluids cause damage to the on-load tap-changer. ► Use insulating fluids that meet the requirements in accordance with IEC 60296.
Page 137: 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 159: 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 138: 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 139 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 140 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 141 5 Mounting 3. Press OFF test button. ð Flap valve is inclined. The red indicator is not visible. Figure 162: OFF position 4. Press OPERATION test button. ð Flap valve is vertical. The red indicator appears in the viewing window. Figure 163: OPERATION position ®...
Page 142 5 Mounting 5. Position the wire for the terminal box cover and affix using the slotted head screw. Figure 164: Terminal box cover 6. Attach the terminal box cover and secure with screws. Figure 165: 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 143 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 144 5 Mounting 9. The reference arrow on the terminal box cover must point toward the on- load tap-changer's oil conservator. Figure 167: Reference arrow pointing towards the on-load tap-changer's oil conservator ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 145 5 Mounting 10. Install a stop-cock with a nominal width of at least 25 mm between the protective relay and oil conservator. Figure 168: 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 146 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 169: Dummy plug 3. Insert explosion-certified cable bushing into tapped hole on side of termi- nal box.
Page 147 5 Mounting 5. Take off the slotted head screw for potential tie-in and remove the termi- nal box cover with wire. Figure 171: Terminal box cover 6. Remove screw for the protective cover and take off the protective cover. Figure 172: Terminal box cover and protective cover 7.
Page 148: Fitting Motor-Drive Unit
11. Attach the terminal box cover and secure with screws. Figure 174: 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 149 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 150 5 Mounting Figure 176: 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 151 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 152 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 178: Shortening square tube ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 153 5 Mounting 4. Deburr the cut surfaces on the square tube. Figure 179: 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 180: Screwing down the square tube and the insulator with double coupling part ®...
Page 154 5 Mounting 6. Slide the loosely screwed-together coupling part onto the insulator until the stop is reached. Figure 181: 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 155 5 Mounting 8. Attach the square tube to the drive. Figure 183: Attaching the square tube to the drive 9. Pivot the square tube away from the axis. Figure 184: 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 156 5 Mounting The inner tube must not be deformed and must be deburred in order to slide easily in the outer tube. Figure 185: 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 157 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 186: Producing grounding hole on the telescopic protective tube ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 158 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 159 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 188: Fitting the adapter ring and the coupling bolt ®...
Page 160 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 189: Mounting the coupling brackets ®...
Page 161 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 190: Screwing down the grounding cable on the telescopic protective tube ®...
Page 162 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 191: Mounting the protective tube ®...
Page 163 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 164 5 Mounting 2. Loosen screws and turn pressure ring segments to one side. Figure 193: 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 165 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 195: Securing pressure ring segments Fitting the horizontal drive shaft To mount the horizontal drive shaft, proceed as follows:...
Page 166 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 197: 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 167 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 199: Screwing down the square tube and the insulator with double coupling part 5.
Page 168 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 169 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 170 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 204: Fitting the protective cover ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 171 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 172: Centering On-Load Tap-Changer And Motor-Drive Unit
► Center on-load tap-changer and motor-drive unit as described in relevant 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. ® VACUTAP VM-Ex...
Page 173: 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 174 6 Commissioning 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 206: Screw cap 3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load tap-changer head. Figure 207: Valve tappet 4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). ®...
Page 175: 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 208: 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.
Page 176: Checking Motor-Drive Unit
6 Commissioning 1. Ground the on-load tap-changer. To do this, only connect the grounding terminal on the on-load tap-changer head with the transformer cover. Figure 209: Grounding terminal on on-load tap-changer head 2. Ground the motor-drive unit. To do this, only connect the motor-drive unit's ground connection with protection against twisting to the trans- former's ground connection.
Page 177: High-Voltage Tests On The Transformer
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 178: 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 5.5.3, Page 148] and the drive shaft to the trans- former at the installation site.
Page 179: Transport With Empty Transformer Tank
6 Commissioning In the event of a short-term immobilization time (maximum of 4 weeks) with- out an oil conservator, it is also sufficient to remove approximately 5 liters of insulating fluid from the on-load tap-changer oil compartment. 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...
Page 180: 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 181: 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 213: 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 182 6 Commissioning 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 214: Screw cap 3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load tap-changer head. Figure 215: Valve tappet 4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). ®...
Page 183: 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 216: 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.
Page 184: 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 185: 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 186: 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 187 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 188: 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 189: 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 190: 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 191 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 192: 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 193: 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 194: Drawings
9 Drawings 9 Drawings 9.1 VACUTAP® VM, installation drawing (746230) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 195 9 Drawings VACUTAP® VM - installation drawing of centrical drive (746230) –2– ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 196: Vacutap® Vm 300, Installation Drawing (765192)
9 Drawings 9.2 VACUTAP® VM 300, installation drawing (765192) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 197: Vacutap® Vm, Installation Position Of Selector Connection Contacts (890477)
9 Drawings 9.3 VACUTAP® VM, installation position of selector connection contacts (890477) ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 198: Special Design For Bell-Type Tank Installation For Um Up To 300 Kv (896762)
9 Drawings 9.4 Special design for bell-type tank installation for Um up to 300 kV (896762) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 199: Lifting Traverse For Bell-Type Tank Installation (890180)
9 Drawings 9.5 Lifting traverse for bell-type tank installation (890180) ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 200: On-Load Tap-Changer Head (893899)
9 Drawings 9.6 On-load tap-changer head (893899) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 201: On-Load Tap-Changer Head With Tap-Change Supervisory Control (894109)
9 Drawings 9.7 On-load tap-changer head with tap-change supervisory control (894109) ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 202: Pipe Connection Q With Tap-Change Supervisory Control (766161)
9 Drawings 9.8 Pipe connection Q with tap-change supervisory control (766161) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 203: Tracing Template For On-Load Tap-Changer Head (890183)
9 Drawings 9.9 Tracing template for on-load tap-changer head (890183) ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 204: Socket Wrench For Kerosene Drain Plug (890182)
9 Drawings 9.10 Socket wrench for kerosene drain plug (890182) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 205: Screw Tools For Installation And Maintenance (890478)
9 Drawings 9.11 Screw tools for installation and maintenance (890478) ® Maschinenfabrik Reinhausen GmbH 2020 5293079/01 EN VACUTAP VM-Ex...
Page 206: Bevel Gear Cd 6400, Dimensional Drawing (892916)
9 Drawings 9.12 Bevel gear CD 6400, dimensional drawing (892916) ® VACUTAP VM-Ex 5293079/01 EN Maschinenfabrik Reinhausen GmbH 2020...
Page 207: 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 210 Maschinenfabrik Reinhausen GmbH Falkensteinstrasse 8 93059 Regensburg +49 (0)941 4090-0 sales@reinhausen.com www.reinhausen.com ® 5293079/01 EN - VACUTAP VM-Ex - - 08/20 - Maschinenfabrik Reinhausen GmbH 2020 THE POWER BEHIND POWER.

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