www.reinhausen.com
On-Load Tap-Changer Type R
Operating Instructions BA 119/06
2
119/06 EN
Contents
Contents
1
General .........................................................................................................................................
1.1 Safety instructions ...............................................................................................................
1.2 Specified application ...........................................................................................................
5
5
5
2
Design .......................................................................................................................................
6
3
Shipment ...................................................................................................................................
6
4
Installation of the on-load tap-changer for cover attachment ..............................................
4.1 Mounting flange ...................................................................................................................
4.2 Attaching the on-load tap-changer head to the transformer cover ....................................
4.3 Mounting the tap selector and the diverter switch oil compartment ..................................
8
8
8
9
5
Installation of the on-load tap-changer into the bell-type tank .............................................
5.1 Assembly of diverter switch oil compartment and tap selector,
connection of tap selector connecting leads .....................................................................
5.2 Installation of the on-load tap-changer into the supporting structure .................................
5.3 Preparations .....................................................................................................................
5.4 Mounting the bell-type transformer cover .........................................................................
11
11
11
12
13
6
Connection of tap winding and tap-changer take-off leads ..................................................
6.1 Tap selector ......................................................................................................................
6.2 Parallel bridges for R I 2002 an R I 3000 ..........................................................................
6.3 Connecting the tap-changer take-off lead .........................................................................
16
16
17
17
7
Transformer ratio test ..............................................................................................................
18
8
Drying procedure and filling with oil ......................................................................................
8.1 Drying procedure ..............................................................................................................
8.1.1 Vacuum-drying process ..........................................................................................
8.1.1.1 Drying in the autoclave ..............................................................................
8.1.1.2 Drying in the transformer tank ...................................................................
8.1.2 Vapor-phase drying process ...................................................................................
8.1.2.1 Drying in the autoclave ..............................................................................
8.1.2.2 Drying in the transformer tank ...................................................................
8.1.3 Operating the OLTC ...............................................................................................
8.2 Filling with oil ..................................................................................................................
18
18
18
18
18
19
19
19
19
20
9
Pipe connections ......................................................................................................................
9.1 Pipe connection R for protective relay RS 2001 ...............................................................
9.2 Pipe connection S for suction pipe ...................................................................................
9.3 Pipe connection Q ............................................................................................................
9.4 Connection flange E2 .......................................................................................................
20
20
20
20
20
NOTE
Data contained herein may differ in details from the tap-changing equipment delivered.
We reserve the right to make alterations without notice.
119/06 EN
3
Contents
10
Mounting the motor drive unit, the bevel gear and the drive shaft ......................................
10.1 Mounting the motor drive unit ...........................................................................................
10.2 Mounting the bevel gear ...................................................................................................
10.3 Mounting the drive shaft (square tube) .............................................................................
21
21
21
21
11
Putting the on-load tap-changer into operation at the transformer factory ........................
11.1 Operational tests ..............................................................................................................
11.2 Final oil filling ..................................................................................................................
11.3 Ground connections .........................................................................................................
11.4 Electrical transformer tests ...............................................................................................
22
22
22
23
23
12
Transport to the operating site ................................................................................................
24
13
Putting into service at the operating site ...............................................................................
24
14
Supervision during service, failures .......................................................................................
25
15
Inspections ...............................................................................................................................
26
16
Appendix ...................................................................................................................................
28
4
119/06 EN
1
General
1
1.1
General
Safety instructions
All personnel involved in installation, commissioning,
operation, maintenance or repair of the equipment
must:
be suitably qualified and
strictly observe these Operating Instructions.
Improper operation or misuse can lead to
a reduction in the efficiency of the equipment
damage to the equipment and property of the
user
serious or fatal injury.
Safety instructions in this manual are presented in three
different forms to emphasize important information.
WARNING
1.2
Specified application
CAUTION
Only use the on-load tap-changer with the transformer specified in the order. Installation, electrical
connection and commissioning of the on-load tapchanger may only be carried out by qualified, skilled
personnel and only in accordance with these operating instructions.
It is the responsibility of the user to make sure that
the on-load tap-changer is used for the specified
application only.
For safety reasons, any unauthorized work, i.e. installation, modification, alteration of the tap-changing
equipment, electrical connection or commissioning of
the equipment is forbidden without first consulting MR!
The trouble-free operation of the drive, the on-load
tap-changer and the transformer may be put at risk.
This information indicates particular danger to life and
health. Disregarding such a warning can lead to
serious or fatal injury.
CAUTION
CAUTION
All relevant fire protection regulations must be strictly
observed.
This information indicates particular danger to the
equipment or other property of the user. Serious or
fatal injury cannot be excluded.
NOTE
These notes give important information on a certain
subject.
119/06 EN
5
2
3
2
Design
Shipment
Design
The on-load tap-changer (OLTC) consists of the diverter switch with the tap selector mounted below (fig. 1).
The diverter switch is installed in its own oil compartment.
3
SHIPMENT
On-load tap-changer and motor drive are shipped in the
adjustment position. The on-load tap-changer is packed
in two parts, diverter switch and tap selector, and is well
protected against moisture. Both the diverter switch and
the tap selector are blocked in the adjustment position.
The on-load tap-changer is attached to the transformer
cover by means of the tap-changer head.
The tap-changing equipment is shipped as follows:
If required, the tap selector may be equipped with a
change-over selector.
Diverter switch oil compartment with tap-changer head
and diverter switch unit (max. weight approx. 210 kg),
fig. 2.
The change-over selector of all type R OLTCs is
laterally attached to the fine tap selector.
Tap selector (max. weight approx. 270 kg), fig. 3.
OLTC models without change-over selector are available for max. 18, and with change-over selector for
max. 35 operating positions.
Motor drive unit ED-S (approx. 80 kg) fig. 4.
Drive shaft with coupling parts and bevel gear (max.
weight approx. 20 kg), fig. 5.
The design of the on-load tap-changer and the designation of its main parts are shown in the installation drawing 896 705 in the appendix.
Protective relay RS 2001(weight 3.5 kg), fig. 6.
These Operating Instructions contain all information
regarding installation and operation of the following
OLTC standard models, which are available with and
without change-over selector.
The tap-changer parts must be left wrapped in their
airtight cover, unwrap just before installation.
Check shipment against documents.
Store all parts in a dry place until installation.
Three-phase OLTC:
R III 1200 (see fig. 1)
Single-phase OLTC:
R I 2000/2002/2402, R I 3000/3600.
All single-phase OLTCs are also available as a group
3 x R I 2002/2402 or
3 x R I 3000/3600
with a common motor drive.
A
V2
U1
W1
3
1
4
2
3
1
4
2
3
1
4
2
U21
V1
V2
W1
W2
1
6
KHW 1086-4
119/06 EN
3
Shipment
NOTE
In general, drive shaft, bevel gear and protective
relay are packed with the on-load tap-changer.
4
KHW 915-4
A
MR
V2
W1
2
KHW 1087-4
5
KHW 766-4
MR
3
119/06 EN
3
1
4
2
3
1
4
2
3
1
4
2
KHW 1097-4
6
KHW 848-4
7
4
Installation of the on-load tap-changer for cover attachment
4.1
Mounting flange
To mount the tap-changer head to the transformer cover
a mounting flange is necessary. This mounting flange
should meet the requirements of the tap-changer head
gasket surface (see fig. 7, and section 16, drawing
896 705).
25
M12
15
15°
To position the thread studs (M12, max. length = 45 mm)
we recommend the use of a drilling template (see
fig. 8 and section 16, dwg. 890 183). If requested, the
drilling template will be supplied without charge with the
first on-load tap-changer type R.
15°
0
74
710
Attachment of the tap-changer
head to the transformer cover
0
The diverter switch oil compartment is lowered through
the cover aperture (= mounting flange) of the transformer. The tap-changer head is attached to the mounting flange by means of bolts.
Then, the tap selector is fastened to the diverter switch
oil compartment (see section 4.3).
65
4.2
45
Installation of the on-load tapchanger for cover attachment (fig. 7)
7,5°
4
7
KHW 770-4
7,5°
15°
24
x1
5°
=3
5
Proceed as follows:
60
°
74
0
1. Place the diverter switch oil compartment on a level
surface.
2. Clean sealing surfaces of mounting flange and tapchanger head.
0
71
20
60
650
3. Put an oil-proof gasket on the mounting flange of
the transformer cover.
200
200
4. Lift the diverter switch oil compartment by hooking
up the tap-changer head. Lower the oil compartment
cautiously into the mounting flange.
Take care of screening rings (with Um ≥ 170 kV only).
5. Check position of tap changer head.
8 8
KHW 769-4
6. Attach the tap-changer head to the mounting flange
with bolts.
NOTE
Remove the blocking plate from the coupling (fig. 9)
of the oil compartment bottom.
8
119/06 EN
4
Installation of the on-load tap-changer for cover attachment
4.3
Mounting the tap selector and the
diverter switch oil compartment
Raise the tap selector to the oil compartment and
attach. At the same time the mechanical coupling for
the tap selector drive has to be performed. Finally,
connect the tap selector connecting leads to the
diverter switch oil compartment.
Proceed as follows:
1. Put the tap selector down on a level surface. Get
ready 4 lock nuts M12 with washers.
NOTE
Remove the blocking strip from the tap selector
coupling (fig. 10).
The coupling must not be displaced afterwards.
2. Put the tap selector on an appropriate lifting device.
Remove the ring nuts.
9
KHW
1111-4
rh-1111-4-0/1
3. Raise the tap selector to the diverter switch oil
compartment. Be sure that tap selector connecting
leads clear the diverter switch oil compartment and
remain undamaged.
4. Position coupling parts and attachment points of
tap selector and oil compartment to match properly.
5. Raise the tap selector to its final height (fig. 11).
6. Bolt tap selector attachment points to the oil
compartment bottom:
4 lock nuts M 12/w.s.19, washers,
max. torque 65 Nm (fig. 12).
7. Remove the wooden support from the laterally
attached change-over selector.
10
KHW
1098-4
rh-1098-4-0/1
1500
11
119/06 EN
KHW 1102-4
9
4
Installation of the on-load tap-changer for cover attachment
Connection of the tap selector connnecting leads to the
diverter switch oil compartment:
CAUTION
All connections must be carried out carefully. The
tightening torques indicated must be applied. Be
sure that bolts are tightened carefully and screened
by the screening caps supplied with the equipment
(fig. 13).
OLTCs R III 1200 and R I 3000/3600
6 connecting leads to oil compartment terminals
according to fig. 14.
Each one attached by 1 bolt M12 (w.s.19) lock nut and
screening cap, torque 80 Nm.
13
KHW653-3
OLTC R I 2002/2402
4 connecting leads to oil compartment terminals
according to fig. 15.
Each one attached by 1 bolt M12, lock nut and screening cap, torque 80 Nm.
A
1V1
1V2
14
KHW 1088-4
A
3
12
10
KHW 1091-4
15
4
KHW 1093-4
119/06 EN
5
Installation of the on-load tap-changer into the bell-type tank
5
Installation of the on-load tapchanger into the bell-type tank
To install the on-load tap-changer into a transformer
with bell-type tank the on-load tap-changer must be
mounted onto a supporting structure.
For this purpose, the OLTC is equipped with a supporting flange at the diverter switch oil compartment
(= special design, section 16, dwg. 896 762).
Firstly, lift the on-load tap-changer into the supporting
structure and connect it to the tap winding. The OLTC
must be attached to the supporting structure in such a
way that it cannot be displaced. The supporting flange
is provided with through-holes which allow it to be fixed
to the supporting structure. It is advisable to put spacer
blocks temporarily between supporting structure and
supporting flange and to remove them before the belltype cover is set up.
Once the bell-type cover is attached, lift the on-load tapchanger (with the diverter switch unit removed) by
means of the lifting traverse (see section 16, drawing
890 180) and fix it to the bell-type cover together with
the top part of the head.
To attach the tap-changer head to the bell-type cover,
we recommend using a mounting flange as described in
section 4.1.
5.1
Assembly of diverter switch oil compartment and tap selector, attachment
of tap selector connecting leads
The assembly of diverter switch oil compartment and
tap selector as well as the connection of tap selector
connecting leads has to be carried out according to
section 4.3.
119/06 EN
5.2
Installation of the on-load tap changer
into the supporting structure
Lift the assembled on-load tap-changer, according to
section 4.1, into the supporting structure. Make sure
that the on-load tap-changer is in proper mounting
position and fasten it there safely.
NOTE
In the supporting structure the on-load tap-changer
must be in an exactly vertical position. The on-load
tap-changer must be mounted to the supporting
structure ensuring that it need not be lifted by more
than 5 to 20 mm to reach its final position after the
bell-type cover is set up.
It is of advantage to install spacer blocks between
supporting structure and supporting flange in such a
way that the on-load tap-changer is in its final position
after the bell-type cover is set up. This measure helps
to cut the tap leads to their correct lengths. Remove the
spacer blocks after the leads have been connected.
To connect the tap winding and the tap-changer take-off
terminal follow the instructions according to section 6.
CAUTION
The connected leads must not exercise any force on
the on-load tap-changer. Moreover there must be
sufficient clearance so that it is possible to lift the onload tap-changer in its final installation position after
the bell-type tank has been mounted.
The drying procedure and the transformer ratio test are
to be performed in accordance with sections 7 and 8.
11
5
Installation of the on-load tap-changer into the bell-type tank
5.3
Preparations
Prior to setting up the bell-type tank the tap-changer
head must be removed from the on-load tap-changer.
1. For this purpose, open the tap-changer head cover
(24 hexagonal head screws M10, w.s.17, with lock
washers).
2. Take care of the cover gasket
(round rubber gasket, fig. 16).
3. Remove the position indicator dial (remove the clip
from the shaft end, fig. 17).
4. Take note of the red-marked area not covered by
the supporting plate of the diverter switch unit
(fig. 18).
5. Remove the fixing nuts of the supporting plate (4
nuts M8, w.s.13, lock washers, fig. 19).
6. Withdraw the diverter switch unit carefully from the
oil compartment (fig. 20). Keep the diverter switch
unit in a vertical position.
17
KHW 1101-4
rh-1101-4-0/1
7. Remove the suction pipe. The pipe connection has
to be withdrawn from within the tap-changer head
(fig. 21). Take care of O-rings.
8. Unscrew the remaining nuts in the tap-changer head
(fig. 22), 17 nuts M8, w.s.13, lock washers.
Lift off the tap-changer head from the supporting
flange. Take care of the gasket.
18
16
12
KHW 762-4
19
KHW
1103-4
rh-1103-4-0/1
KHW
1105-4
rh-1105-4-0/1
119/06 EN
5
Installation of the on-load tap-changer into the bell-type tank
5.4
Mounting the bell-type
transformer cover
1. Before mounting the bell-type transformer cover
clean the sealing surface of the oil compartment
supporting flange. Place the gasket onto the flange
(fig. 23). Withdraw the spacer blocks (see section
5.2).
2. Lift the bell-type cover over the transformer active
part and lower it to its final position.
3. Before mounting the tap-changer head clean the
sealing surfaces (bottom of tap-changer head,
mounting flange). Put an oil-resistant gasket on the
mounting flange.
21
20
119/06 EN
KHWrh-1109-4-0/1
1109-4
KHW 1106-4
22
rh-1110-4-0/1
KHW
1110-4
23
KHW
1107-4
rh-1107-4-0/1
13
5
Installation of the on-load tap-changer into the bell-type tank
4. Place the tap-changer head on the mounting flange.
Check the mounting position of the tap-changer
head by means of 2 adjusting bolts (fig. 23) and the
marks of the supporting flange and tap-changer
head (fig. 24) which allow assembly in the correct
position only. Depending on the final height
adjustment leave a clearance of 5 to 20 mm
between tap-changer head and supporting flange
5. Lift the on-load tap-changer slightly by means of the
lifting traverse (see fig. 25 and section 16, drawing
890 180). Make sure that all supporting flange studs
easily slide through the fixing holes of the tapchanger head.
CAUTION
24
KHW 1100-4
25
KHW 1108-4
Take care not to drop any parts into the diverter
switch oil compartment. Otherwise the diverter
switch can block and cause severe damage to the
on-load tap-changer and transformer.
Therefore, make sure that the number of small
parts is complete when disassembling and
reinstalling. Count them to be sure.
14
119/06 EN
5
Installation of the on-load tap-changer into the bell-type tank
6. Attach the tap-changer head in the red marked area
not covered by the supporting plate of the diverter
switch (fig. 26, see also section 5.3). Use 17 nuts
M8 (wrench size 13, max. torque 14 Nm, lock
washers). Attach the tap-changer head to the
mounting flange.
7. Remount the suction pipe. Make sure that the Orings are placed properly. The O-rings should slightly
be greased before being mounted.
8. Remount the diverter switch unit. Make sure that the
diverter switch supporting plate is in its proper
position within the tap-changer head (the red marked
areas must be left free). Attach the supporting plate
by means of 5 nuts M8 (wrench size 13, max. torque
14 Nm, lock washers).
9. Attach the position indication dial:
Put the clip onto the shaft end.
The dial can be mounted in correct position only by
means of its coupling pin (fig. 27).
26
KHW
1110-4
rh-1110-4-0/1
27
KHW
1101-4
rh-1101-4-0/1
28
KHW
1104-4
rh-1104-4-0/1
10.Mount the cover on the tap-changer head. Make
sure that the rubber gasket (O-ring) in the cover is in
proper position.Fasten the 24 screws M10 (wrench
size 17) equally, max. torque 34 Nm (fig. 28).
119/06 EN
15
6
Connection of tap winding and tap-changer take-off leads
6
Connection of tap winding and tapchanger take-off leads
The tap winding has to be connected to the on-load tapchanger according to the connection diagram supplied
with the particular tap-changer equipment.
CAUTION
All connections to the on-load tap-changer must be
made carefully and locked safely. The tap leads must
be assembled in such a way to allow for connecting
all leads to the on-load tap-changer without tension.
If necessary, lead ends must be shaped in form of
expansion loops.
Single-phase OLTCs R I 2002 and R I 3000 require the
parallel connection of the tap selector terminals with
identical terminal numbers in order to avoid overvoltages between parallel contacts.
3
1
4
2
3
1
4
2
3
1
4
2
29
If requested, bridges for the parallel connection of tap
selector terminals according to dwg. 896 706 (see appendix) can be supplied.
KHW 1096-4
A10
In case of OLTCs R I 2402 and R I 3600 the parallel
connection of tap selector terminals by means of
parallel bridges is not applicable as the enforced current
splitting of tap leads is provided by two or three isolated
winding branches on each tap selector terminal.
B9
B10
6.1 Tap selector (fig. 29)
Fine tap selector terminals
with through-hole for M12 screws(fig. 30). If requested, screening caps (MR part number 078 957) will be
supplied with the delivery.
C9
30
KHW
1090-4
rh-1090-4-0/1
31
KHW
1089-4
rh-1089-4-0/1
Change-over selector terminals
Reversing switch: terminals (+) and (–) like the fine
tap selector terminals, terminals (0) as terminal lug of
the connecting lead (0/K) with through-hole for M12
screws (see fig. 31).
Coarse tap selector: terminals (0) and (–) like the fine
tap selector terminals, terminals (+) as terminal lug of
the cranked connecting lead (+/K) with through-holes
for M12 screws (see fig. 31).
16
119/06 EN
6
Connection of tap winding and tap-changer take-off leads
6.2
Parallel bridges for R I 2002
and R I 3000 (fig. 32)
Parallel bridges for the fine tap selector and changeover selector according to dwg. 896 706 (see appendix)
can be supplied on request.
Parallel bridges consist of two identical parts which are
joined by a single M12 bolt with lock nut (wrench size
19, max. torque 60 Nm). They are provided with two
through-holes to accommodate connection of tap leads.
6.3
Connecting the tap-changer
take-off lead
The tap-changer take-off lead is to be connected to
the bus bar ring of the diverter switch oil compartment
(fig. 33). The screw connection must be locked safely
(Md = 60 Nm).
33
894 490 0M
OLTC type R III 1200 (starpoint connection)
One throughhole each for M12 bolts is provided on
different points of the bus bar ring displaced by 120°
(fig. 34).
A
OLTC type R I 2002/2402 and R I 3000/3600
Three or four throughholes each for M12 bolts are provided on different points of the bus bar ring displaced
by 120° (fig. 35).
1V1
1V2
34
KHW 1094-4
rh-1094-4-0/1
A
3
32
119/06 EN
KHW 1099-4
rh-1099-4-0/1
35
4
KHW 1095-4
17
7
8
7
Transformer ratio test
Drying procedure and filling with oil
Transformer ratio test
8
8.1
We recommend to ratio-meter the transformer with a
low AC voltage before drying.
To operate the drive shaft in the tap-changer head a
short tube of nominal width 25 mm with an insert
coupling bolt of 12 mm dia. together with a hand wheel
or a hand crank may be used.
In case of OLTC set 3 x R I 2002 ... 3600 all three tapchanger heads have to be coupled by the horizontal
drive shafts (see section 10).
The dielectric properties of the on-load tap-changer can
only be guaranteed, if the on-load tap-changer is subjected to a drying treatment according to the following
instructions (8.1.1 or 8.1.2).
8.1.1 Vacuum-drying process
8.1.1.1 Drying in the autoclave
NOTE
When using an ED, 16.5 drive shaft revolutions of the
tap-changer drive shaft are required for one tap-change
operation. The diverter switch action can be heard
distinctly.
To operate the change-over selector a higher torque is
necessary.
The end positions shown on the connection diagram
supplied with the delivery must never be overrun. It is
therefore necessary to check the operating position
through the inspection glass in the tap-changer head
cover (fig. 36). Keep the number of tap-change operations to a minimum as long as the on-load tap-changer
has not been immersed in oil. After the transformer ratio
test the on-load tap-changer has to be set back to the
adjustment position in which it was delivered by MR.
The position is indicated in the connection diagram
delivered with the equipment.
Drying procedure and filling with oil
Drying procedure
When drying the transformer in the autoclave remove
the tap-changer cover and store it outside the vacuum
autoclave.
•
Heating up
the on-load tap-changer in air of atmospheric
pressure with a temperature rise of approx. 10 °C/
hour to a final temperature of at most 110 °C.
•
Preparatory drying
in circulating air at 110 °C max. applied to the onload tap-changer for a duration of 20 hours.
•
Vacuum drying
at a temperature of 110 °C max. applied to the onload tap-changer and a residual pressure of at most
10-3 bar for a duration of at least 50 hours.
8.1.1.2 Drying in the transformer tank
NOTE
If the transformer is to be vapor-phase dried in its own
tank, open the kerosene drain plug (see section 8.1.2).
NOTE
If the transformer is to be dried in its tank the interior
of the diverter switch oil compartment must be connected to vacuum, as the tap-changer head cover
remains closed during the entire drying process.
The tap-changer head cover is vacuum-proof.
To ensure sufficient drying of the interior of the oil
compartment and the diverter switch insert, connect a
by-pass tube of 25 mm nominal width between the
transformer tank and the connecting flange which leads
into the oil compartment.
b
For ease of handling connect the bypass tube either
between flanges E2 and Q or flanges E2 and R of the
tap-changer head (for position of connecting flanges
see section 9 and dwg. 893 899 of appendix).
9
36
18
KHW 764-4
Procedure, temperature, pressure and duration of the
drying process are as described in section 8.1.1.1.
119/06 EN
8
Drying procedure and filling with oil
8.1.2 Vapor-phase drying process
8.1.2.1Drying in the autoclave
NOTE
NOTE
Before starting the drying procedure, open the
kerosene drain plug (fig. 37) to drain the condensate
from the oil compartment.
The kerosene drain plug has an hexagonal recess
screw (w.s. 8) and is easily accessible between oil
compartment bottom and tap selector gear. It can be
unscrewed from the outside. The thread of the kerosene
drain plug has a plastic coat so that it can only be
turned with some force.
NOTE
Do not continue turning the kerosene drain plug
beyond the point where it starts moving tightly.
When drying the transformer in its own tank (see
section 8.1.2.2) the drain plug, in general, is not
accessible from outside and can only be opened
from inside the oil compartment.
In this case the diverter switch unit must be removed
and the kerosene drain plug must be unscrewed with a
socket wrench (see section 16, dwg. 890 182). Then
reinstall the diverter switch unit.
CAUTION
The kerosene drain plug must be closed again after
the drying process to ensure that no oil from the
diverter switch oil compartment can flow into the
transformer tank!
8 mm
When drying in the autoclave remove the tap-changer
head cover first and store it outside the vacuum
autoclave.
•
Heating up
by admitting the kerosene vapor at a temperature of
about 90°C. Keep this temperature constant for 3 to
4 hours.
•
Drying
by increasing the kerosene vapor temperature by
about 10°C per hour to the desired final temperature
with not more than 125 °C applied to the on-load tapchanger. The duration of the drying procedure is
normally the same as that of the transformer.
8.1.2.2 Drying in the transformer tank
If the transformer is to be dried in its own tank, the tapchanger head cover remains closed during the entire
drying process. The tap-changer head cover is vacuumproof. To ensure sufficient drying of the interior of the
diverter switch oil compartment and of the diverter
switch unit connect a common tube of at least 50 mm
width between the vapor lead and two connecting
flanges of the tap-changer head leading into the oil
compartment.
Use flanges Q and R for OLTCs type R. (For position of
connecting flanges see section 9 and 16, dwg. 893 899).
Procedure, temperature and duration of the drying
process are described in item 8.1.2.1.
8.1.3 Operating the OLTC
CAUTION
Do not operate the on-load tap-changer without oil
after drying otherwise bearings and gaskets will be
damaged.
8 mm
Coating
37
119/06 EN
KHW 831-4
The on-load tap-changer must not be operated before
the diverter switch oil compartment has been filled with
oil and the tap selector has been completely immersed
in the transformer oil.
19
8
9
Drying procedure and filling with oil
Pipe connections
9
8.2
Pipe connections
Filling with oil
CAUTION
The tap-changer oil compartment and the associated
oil conservator must only be filled with new mineral
insulating oil for transformers according to IEC 296.
The use of other oil affects the trouble-free operation
of on-load tap-changer and transformer.
Place the cover on the tap-changer head. Tighten all
24 cover bolts M10 (wrench size 17, max. torque 34 Nm).
The tap-changer head is provided with 3 pipe connections for different purposes. After loosening the thrust
collar (4 bolts M10, w.s. 17) these pipe connections can
be swivelled (see fig. 38 and appendix, dwg. 893 899).
9.1
Pipe connection R for
protective relay RS 2001
The mounting of the protective relay RS 2001 (see
section 16, dimension drawing 892 608) is pursuant to
our Operating Instructions No. 59.
On-load tap-changer and transformer are filled simultaneously with new oil under vacuum.
For this purpose use pipe connection S or R. To evacuate, a by-pass tube between connections E2 and Q is
to be installed in order to apply vacuum to both diverter
switch oil compartment and transformer tank simultaneously.
NOTE
The relay serial number must be the same as that of
the on-load tap-changer.
The relay must be mounted in horizontal position and
as near to the tap-changer head as possible.
The arrow on the relay should point towards the oil
conservator when mounted.
The pipe to the oil conservator must be installed with
an inclination of at least 2%.
9.2
Pipe connections S for suction pipe
This is the connection for the feeding pipe of a stationary oil filter. If there is no filter, the pipe connection
should be provided with a pipe with a drain cock easily
accessible on one side of the transformer tank.
R
S
9.3
Q
E2
Pipe connection Q
(special design, required for
stationary oil filter only)
This is the pipe connection for the return pipe of a
stationary oil filter.
If no oil filter is provided, a dummy plug is mounted
instead of the pipe connection.
9.4
Connection flange E2
In general, this flange is covered by a dummy plug.
The flange hole is open to the transformer tank directly
beneath the tap-changer head.
38
20
KHW 805-4
If necessary, it may be connected to the gas accumulating tube for the Buchholz relay.
119/06 EN
10
Mounting the motor drive unit, the bevel gear and the drive shaft
10
10.1
Mounting the motor drive unit,
the bevel gear and the drive shaft
Mounting the motor drive unit (see
10.3
Mounting the drive shaft
appendix, dwg. 898 801, 898 802)
You may find comprehensive mounting instructions in
our Operating Instructions No. 138 for motor drive ED.
NOTE
Serial number of motor drive unit and on-load tapchanger must be identical (nameplate).
Motor drive unit and on-load tap-changer must be in
the same operating position. The adjustment position
is indicated in the connection diagram supplied with
the equipment.
The motor drive unit must be mounted at the provided
place on the transformer tank in a vertical position
and protected against excessive transformer
vibrations.
The drive shaft must be assembled according to our
Operating Instructions No. 42. The drive shaft is the
mechanical connection between the motor drive and the
tap changer head.
The bevel gear diverts the driving force from the vertical
to the horizontal direction.
Accordingly, the vertical part of the drive shaft is to be
mounted between motor drive unit and bevel gear,
whereas the horizontal part of the drive shaft is to be
mounted between bevel gear and tap-changer head.
The drive shaft itself consists of a square tube and is to
be connected on both ends to the respective equipment
by two coupling brackets and one coupling bolt.
NOTE
When mounting the drive shaft make sure that the
shaft ends to be connected are aligned properly.
10.2
Mounting the bevel gear
The bevel gear is to be attached to a support on the
transformer cover by means of 2 bolts (through-holes
18 mm dia., see section 16, drawing 892 916).
NOTE
Make sure that bevel gear serial number and on-load
tap-changer serial number are identical.
The horizontal drive shaft must be in proper alignment
with the trunnion in the tap-changer head.
After loosening the thrust collar (6 bolts M8, w.s. 13)
the upper gear unit can be swivelled (fig. 39). After
adjusting the upper gear unit, the thrust collar must be
re-tightened (max. torque 15 Nm).
Tab-lock the screws.
Square shafts, coupling brackets, coupling bolts,
screws, nuts and lock tabs are made of corrosion-proof
steel. We recommend, however, to apply the same
outside coating here as to the transformer tank.
The square shafts and the guard plate for the footstep
protection for the horizontal drive shaft at the transformer cover are supplied in oversize (various standard
lengths).
These parts must be cut to the required size before
mounting.
Finally equalize the rotation lag between on-load tapchanger and motor drive unit (according to Operating
Instructions No. 138 for ED).
In case of bevel gears in special design and
intermediate bearings of the vertical or horizontal
drive shaft above instructions apply analogously.
39
119/06 EN
KHW 767-4
21
10
11
Mounting the motor drive unit, the bevel gear and the drive shaft
Putting the OLTC into operation in the transformer factory
11
11.1
OLTCs 3 x R I 2002 ... 3600
The following procedure is also recommended for
OLTC R III 1200.
Due to the special arrangement of the tap-changer
phases in three columns, the horizontal drive shaft must
be mounted between the three tap-changer heads
above the tank cover. Since a swivelling of the upper
gear unit will initiate a switching action, make sure that
the adjustment position of the diverter switch is regained after the alignment of the gear units.
Before applying voltage to the transformer check the
mechanical operation of on-load tap-changer and motor
drive.
For these test operations the on-load tap-changer has
to be run through the complete operating cycle.
Make sure that in each operating position the indicators of motor drive and on-load tap-changer (tapchanger head) read the same position.
CAUTION
For this purpose proceed as follows:
1.
Check that the operating positions of all columns
are identical (tap-changer head, inspection win
dow). Each one of the one-phase OLTCs must be
in the adjustment position.
2.
Turn the upper gear unit of the tap-changer heads
into the desired installation position and fix them
there (tighten thrust collars and tab-lock the
screws).
Take note of the arrow on the drive shaft flange
below the punched serial number. The direction of
the arrow indicates the rotation sense when cranking the motor drive clockwise and must be identical
on all gear units.
3.
Operate the tap-changer poles separately by one
step by rotating the trunnions counter-clockwise
until the diverter switch operates once.
Check coincidence of operating positions of all
tap-changer heads.
4.
Mount the horizontal drive shaft between the tapchanger heads.
5.
Return the OLTC set, that is all tap-changer
poles together, into the adjustment position.The
adjustment position is reached by turning the drive
shaft in clockwise direction.
Check simultaneous operation of all diverter
switches.
Check coincidence of position of all tapchanger heads and the motor drive unit.
6.
Misalignment between on-load tap-changer and
motor drive unit exists, if on-load tap-changer and
motor drive unit show different operating positions.
Misalignment of coupling between on-load tapchanger and motor drive unit leads to severe damage
of on-load tap-changer and transformer, if operation
is continued. The transformer must not be taken in
operation.
Make sure that in both end positions the electrical and
mechanical limit stops function automatically (see
Operating Instructions No. 138 for ED).
11.2
Final oil filling
Fill up the on-load tap-changer completely with transformer oil via the oil conservator and evacuate.
•
Bleed the tap-changer head via the bleeder valve in
the head cover (E1):
Remove screw cap M30/w.s. 36 (fig. 40), lift valve
tappet by means of a screw driver.
•
Bleed the suction pipe (S) via the bleeder screw of
the elbow: cap nut M16 (w.s. 22, max. torque 9 Nm),
slotted bleeder screw M6 (max. torque 2 Nm,
fig. 41).
Mount the vertical drive shaft.
CAUTION
The supervisory control must be installed according
to the connection diagram of the relevant motor drive
unit. Incorrect installation will cause damage of both
on-load tap-changer and transformer in case of
malfunction.
22
Putting the OLTC into operation in
the transformer factory
Operational tests
CAUTION
Make sure that the suction pipe has been bled
completely. The insulation capability of the on-load
tap-changer to ground is otherwise significally
impaired.
119/06 EN
11
Putting the OLTC into operation in the transformer factory
11.3
Ground connections
Connect the ground screws (2 screws M12 with nuts,
w.s. 19, max. torque 60 Nm, fig. 42) of the tap-changer
head to the transformer cover.
Connect the ground screw (M12, w.s. 19, max. torque
60 Nm) of the motor drive housing to the transformer
tank.
11.4
Electrical transformer tests
After the afore mentioned steps the necessary electrical
acceptance tests of the transformer can be performed.
40
KHW 773-4
41
KHW 811-4
42
119/06 EN
KHW 811-4
23
12
13
12
Transport to the operating site
Putting into service at the operating site
Transport to the operating site
If the transformer is to be transported without the motor
drive unit, set the motor drive to the adjustment position
and uncouple.
CAUTION
13
Putting into service at the operating
site
Before putting the transformer into service, operational
tests of on-load tap-changer and motor drive have to be
performed according to section 11.1. At the same time
check the function of the protective relay. Loop in
signaling contact for undershooting the minimum oil
level in the on-load tap-changer oil conservator in the
on-load tap-changer tripping circuit.
Do not operate the motor drive unit while the on-load
tap-changer is uncoupled.
NOTE
To remount the motor drive unit follow the instructions
according to section 10.1 and 10.3.
NOTE
If the transformer is filled with oil but stored or transported without oil conservator, a bypass tube must be
installed between the interior of the tap changer and
the transformer tank to compensate the static
pressure caused by expansion of oil.
Install this by-pass tube between pipe connections E2
and Q of the tap-changer head.
For short time conditions of 2 to 4 weeks without oil
conservator, lower the oil level by approx. 5 litres.
If the transformer is to be transported or stored without
oil filling, drain the oil of the on-load tap-changer completely.
The interior of the on-load tap-changer should be
conserved and protected in the same way as the
transformer itself (nitrogen-sealing).
If a prolonged stand-by period is expected, the heater of
the motor drive unit must be connected to the suitable
power supply.
24
The protective relay has to be inserted into the tripping circuit of the circuit breakers so that energization of the protective relay switches off the transformer immediately (see Operating Instructions
No. 59 for protective relay RS 2001).
Make sure that the circuit breakers switching off the
transformer operate when the test push button »OFF«
is pressed. Be sure that they energize the transformer
only after push button »IN SERVICE« of the protective
relay has been pressed.
CAUTION
Check whether all stop valves between oil
conservator and tap-changer head are open.
After the transformer has been energized, tap-change
operations under load can be performed. Gas accumulating under the cover of the tap-changer head will
cause minor oil displacement and/or escape via the oil
conservator.
119/06 EN
Supervision during service, failures
14
14
Supervision during service, failures
NOTE
Damage to the on-load tap-changer due to not
enough oil in the oil conservator of the on-load tapchanger!
Actuation of the on-load tap-changer with too little oil
in the on-load tap-changer’s oil conservator may
cause damage to the on-load tap-changer!
Make sure that the contact for signaling the falling
below the minimum oil level in the on-load tapchanger’s oil conservator was looped through to the
tripping circuit of the circuit-breaker and that the
circuit-breaker will immediately de-energize the
transformer when the oil has fallen below this
minimum oil level in the oil conservator.
Maschinenfabrik Reinhausen GmbH
Technical Service
Postfach 12 03 60
D-93025 Regensburg
Phone: (+49) 9 41 / 40 90-0
Telefax: (+49) 9 41 / 40 90-5 01
Telex: 65881
It is only necessary to inspect the tap-changer head, the
protective relay and the motor drive unit occasionally.
Pay special attention to:
• oil tightness of sealings of the tap-changer head, the
protective relay and the pipe connections,
• sealings at the motor drive housing,
• proper function of the electrical space heater inside
the motor drive unit,
• the condition of the control devices in the motor drive
unit.
WARNING
If the protective relay operates, do not reset until the
on-load tap-changer and the transformer have been
checked. For this purpose also withdraw the diverter
switch unit and check it according to our Inspection
Instructions. Proceed in detail according to our
Operating Instructions No. 59 for the protective relay
RS 2001.
Before returning to energized operation, make sure
that the cause of the trouble has been corrected and
that the on-load tap-changer and the transformer are
free of damage.
Never reconnect the transformer without prior
checking. Continued operation of the on-load tap
changer can result in severe damage of on-load tapchanger and transformer.
In case of serious trouble with on-load tap-changer or
motor drive – provided that the repair cannot easily be
done at site and in case of a tripping of the protective
relay please contact the authorized MR representative,
the transformer manufacturer or directly
119/06 EN
25
15
Inspections
15
Inspections
NOTE
The tap-changing equipment must be inspected at
regular intervals to maintain a high level of operating
reliability.
In general, the inspection can be carried out by
qualified and MR-trained personnel within one day,
provided it is well prepared and organized.
We strongly recommend to have inspections performed
by our Technical Service. This guarantees a professional performance including all the latest updating
measures.
Inquire for spare parts when preparing an inspection
which will not be carried out by MR personnel (please
indicate OLTC number and number of operations).
The number of tap-change operations determining the
inspection intervals indicated in table II and table III are
figures based on experience with oil qualities normally
used.
The tap selector of the on-load tap-changer is generally
maintenance-free. In special cases, however, if OLTCs
are used in industrial transformers where high operating
numbers are to be expected, our technical service
department must be contacted after about 1,000,000
operations. The diverter switch insert of the OLTC is to
be replaced after 800,000 operations.
If the number of operations per year is 15,000 or higher,
the use of our oil filter plant type OF100 with paper filter
insert (see Operating Instructions No. 18) is recommended. The use of our oil filter plant type OF100 with
combination filter insert is obligatory for OLTC type R
with insulation to ground Um < 245 kV.
Filtering of switching oil allows to extend the inspection
intervals.
The user should regularly test the transformer insulating
oil according to the relevant standards.
If inspection has not been performed by MR-personnel,
please give us your report for data collecting purposes.
26
119/06 EN
15
Inspections
CAUTION
Inspections of the tap-changer equipment are obligatory. Disregarding the inspection intervals endangers
the trouble-free operation of on-load tap- changer and
transformer.
Standard values for oil testing according to CIGRE report 12-13 (1982) applying to transformer oil at service
temperature:
On-load tap-changer
Water content*)
Dielectric strengh**)
Neutral-end tap-changers
< 40 ppm
> 30 kV/2,5 mm
Single-pole tap-changers
< 30 ppm
> 40 kV/2,5 mm
*) measured according to Karl-Fischer method based on IEC Publication 814 (1985)
**) measured according to DIN 57370 Teil1/VDE 0370 Teil 1/12.78 Teil 1
Table I
Guide values for monitoring the tap-changer oil
On-load tap-changer
Transformer
rated current
Number of tap-change operations
without MR oil filter
with oil filter
R III 1200
up to 600 A
up to 1200 A
80 000
60 000
100 000
100 000
R I 1201
up to 600 A
up to 1200 A
80 000
60 000
100 000
100 000
R I 2002
up to 2000 A
40 000
80 000
R I 2402
up to 2400 A
40 000
80 000
R I 3000
up to 3000 A
40 000
80 000
R I 3600
up to 3600A
40 000
80 000
Table II
Inspection intervals for
– OLTC type R in star-point connection (Y)
– One-phase OLTC with Um < 245 kV used in autotransformers or for regulation at the line end of
winding of the transformer.
First inspection and further inspections: after 7 years or the number of operations indicated in Table II, depending on
what is reached first.
119/06 EN
27
15 Inspections
16 Appendix
On-load tap-changer
Transformer
rarted current
Number of tap-change operations
without MR oil filter
with MR oil filter
R I 1201
up to 600 A
up to 1200 A
40 000
30 000
50 000
50 000
R I 2002
up to 2000 A
20 000
40 000
R I 2402
up to 2400 A
20 000
40 000
R I 3000
up to 3000 A
20 000
40 000
R I 3600
up to 3600 A
20 000
40 000
Table III
Inspection intervals for one-phase OLTCs type R with Um ³ 245 kV and used in autotransformers
or for the regulation at line end of winding of the transformer.
First inspection:
after 2 years or 20,000 operations, depending on what is reached first.
Next inspections: without MR filter plant after every 4 years, with MR filter plant (combination filter) after
every 6 years or the number of operations indicated in table III – whatever is reached first.
16
APPENDIX
Installation drawing _____________________________________________________________________ 896 705
OLTCs R I 2002 / R I 3000, bridges for parallel connection of tap selector terminals ___________________ 896 706
Tap-changer head ______________________________________________________________________ 893 899
Drilling template for tap-changer head ______________________________________________________ 890 183
Supporting flange for the installation into bell-type tank _________________________________________ 896 762
Lifting traverse _________________________________________________________________________ 890 180
Socket wrench for kerosene drain plug ______________________________________________________ 890 182
Protective relay RS 2001, dimension drawing _________________________________________________ 899 084
Motor drive unit ED-S, dimension drawing ___________________________________________________ 898 801
Motor drive unit ED-L, dimension drawing ____________________________________________________ 898 802
Bevel gear CD 6400, dimension drawing ____________________________________________________ 892 916
28
119/06 EN
16
Appendix
max. withdrawal height 1750 mm
Flat
surface
Protective
relay
Take-off
terminal
11
12
13
14
15
16
17
Mounting flange on transformer cover
Fixing bolt M12
Gasket for tap-changer head
Position indicator
Inspection window
Drive shaft for position indicator
Through-hole 15 mm dia.
21
22
23
24
25
26
27
28
29a
29b
29c
Tap-changer head
Bolt for tap-changer head cover
Gasket for tap-changer head cover
Tap changer head cover
Centric gear unit with drive shaft 25a
Pipe connection R for protective relay
Pipe connection S for suction pipe
Pipe connection Q for return pipe
(with oil filter only)
Bleeder valve of tap-changer head cover
Bleeding facility for transformer oil
Bleeder screw for suction pipe
31
32
33
34
35
36
Diverter switch oil compartment
Bottom of oil compartment
Grading ring (with Um = 170/245 kV)
Terminal of diverter switch oil compartment
Tap-changer take-off terminal (with R III 1200 neutral)
Suction pipe
41
42
43
44
45
48
48a
Suspension of tap selector
Tap selector gear
Fine tap selector
Change-over selector
Tap selector terminals.
see corresponding dimension drawing
Change-over selector terminals.
see corresponding dimension drawing
Connecting lead for tap selector
Holding strip for 48
51
52
53
54
55
56
Diverter switch unit
Supporting cylinder
Gear plate
Fixing bolt
Lifting Lug
Transition resistors
46
See also variants of tap selector
bottom 896 702
provide sufficient
clearance!
Transformer tank bottom
Tap selector drive side
On-load tap-changer type R
Installation drawing
119/06 EN
896 705:5E
29
16
Appendix
On-load tap-changer type R
Bridges for parallel connection of tap selector terminals
for OLTCs R I 2002, R I 3000
(not applicable in case of enforced current splitting)
30
896 706:5E
119/06 EN
16
Appendix
width of
gasket
Detail at A
Connection flange
for Q, S, R
16
Thickness
Tap selector drive side
E1 = Bleeding facility for 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 (only for oil filter)
O-Ring
44.2 - 5.7
S
= Connection for suction pipe
Connections orientable
R
= Connection for protective relay (exchangeble with connection Q)
through 360°
= Earth connection M12
On-load tap-changers type MS, M, T, R
Tap-changer head
119/06 EN
893 899:9E
31
16
Appendix
3 thick
Marks to be pounded
On-load tap-changers type MS, M, T, R
Drilling template
32
890 183:6E
119/06 EN
16
Appendix
Lifting device
O-Ring 44.2 - 5.7
Suction pipe
Drilling hole represented
in the sectional plane
Transformer cover
Gasket
Level traverse
Grading ring with
Um170/245/300 kV only
Supporting flange
Level traverse
Tap selector drive side
Z = Guiding pin
On-load tap-changer type R
Special design for installation into bell-type tank
119/06 EN
896 762:6E
33
16
Appendix
Sheet steel
St 37-2 DIN 17 100
On-load tap-changer type R
Lifting traverse
34
890 180:3E
119/06 EN
16
Appendix
Socket wrench
Item-No. 014 820
L = 1350 mm
Item-No. 017 660
L = 1860 mm
To be used
for OLTC
Type M (except M Δ)
Typ MS
M III 350/600 Δ
Type T, R, G
On-load tap-changer type MS, M, T, R
Socket wrench for kerosene draining screw
119/06 EN
890 182:7E
35
16
Appendix
Cable gland
PG 16
Inspection
window
Identification label
Gasket
Gasket
Test push buttons
IN SERVICE
OFF
(reset)
(test tripping)
Metal - dummy plug PG 16
The arrow must always point towards the oil pipe leading
to the oil conservator of the transformer.
Plan view of test push buttons
(cover removed)
Key of variants
Contact positions
1)
Reed
contact
1
0.65
1.2
3.0
4.8
- NO
- NO
- NO
- NO
A
2
0.65
1.2
3.0
4.8
- NC
- NC
- NC
- NC
B
3
0.65
1.2
3.0
4.8
- CO
- CO
- CO
- CO
C
4
0.65
1.2
3.0
4.8
- 2NO
- 2NO
- 2NO
- 2NO
2A
5
0.65
1.2
3.0
4.8
- 2NC
- 2NC
- 2NC
- 2NC
2B
6
0.65
1.2
3.0
4.8
- NO + NC
- NO + NC
- NO + NC
- NO + NC
Arrangement of terminals
In service
Design
Off
Standard design
Relay designation1)
Special design against surcharge
Variant
1A &1B
NO - normally open, NC - normally closed, CO - change-over contact
The protective relay is to be connected in such a way that if it is energized, the power transformer is switched off immediately by the corresponding
circuit breakers.
Protective Relay RS 2001
(STANDARD)
36
899 084:0E
119/06 EN
16
Appendix
Vertical guard
plate with
spacing ring
Handcrank
* for design with
intermediate
bearing
3 dummy plates for packing glands
special design with OLTC
monitoring required
Wall of transformer tank
Shm
i
Attachment of
protective housing
ca. 690 if opened 130°
ca. 864 if opened 180°
Aperture of fixing holes on protective housing
(rear view)
Aperture in protective housing for cables
(underside view)
Motor Drive ED-S
Protective Housing
119/06 EN
The cover can be opened
to the left or to the right
depending on the arrangement of the hinge pins.
898 801:2E
37
16
Appendix
Vertical guard plate
with spacing ring
Hand
crank
* for design with
intermediate
bearing
3 dummy plates for packing
glands
special design with OLTC
monitoring required
Wall of transformer tank
Shm
i
Attachment of protective
housing
The cover can be opened
to the left or to the right
depending on the arrangeca. 690 if opened 130° ment of the hinge pins.
ca. 864 if opened 180°
Aperture of fixing holes on protective housing
(rear view)
Aperture in protective housing for cables
(underside view)
Motor Drive ED-L
Protective Housing
38
898 802:2E
119/06 EN
Bevel gear CD 6400
Dimension drawing
119/06 EN
e2 = 215 for design with ball joint
e1 = 205 for standard design
16
Appendix
892 916:6E
39
www.reinhausen.com
© Maschinenfabrik Reinhausen GmbH
Postfach 12 03 60
D-93025 Regensburg
Telefon: (+49) 9 41 / 40 90-0
Telefax: (+49) 9 41 / 40 90-111
Telex: 65881
BA 119/06 EN • 02/11 • F0002203 • Printed in Germany