www.reinhausen.com Advanced-Retard-Switch (ARS) Operating Instructions BA 274/01 Contents Contents 1 General ......................................................................................................................................................................................... 1.1 Safety instructions ....................................................................................................................................................... 1.2 Specified application ................................................................................................................................................... 3 3 3 2 Structure / Design .................................................................................................................................................................... 4 3 Shipment ..................................................................................................................................................................................... 6 4 Installation of the ARS for cover mounting ................................................................................................................... 8 5 Installation of the ARS into bell-type tank ................................................................................................................... 12 6 Connection of the transformer winding .......................................................................................................................... 14 7 Transformer ratio test .............................................................................................................................................................. 14 8 Drying procedure of the transformer and filling with oil ........................................................................................ 15 9 Final assembly ............................................................................................................................................................................. 16 9.1 9.2 9.3 9.4 9.5 9.6 9.7 Drive unit .......................................................................................................................................................................... Bevel gear ......................................................................................................................................................................... Drive shaft (square tube) .............................................................................................................................................. Coupling the ARS with the motor-drive unit ........................................................................................................ Functional test ................................................................................................................................................................ Complete oil filling ........................................................................................................................................................ Ground connection ........................................................................................................................................................ 16 16 16 16 19 19 19 10 Safety precautions ..................................................................................................................................................................... 20 11 Maintenance ................................................................................................................................................................................ 23 12 Appendix ........................................................................................................................................................................................ 24 NOTE Changes may have been made to a product after going to press with this documentation. We expressly reserve the right to make changes to a product’s technical data and design as well as changes to the scope of delivery. In all cases, the information submitted and agreements concluded during processing of the quotation and order in question shall be binding. 2 274/01/01/0 1 General 1 1.1 General 1.2 Specified application Safety instructions All personnel involved in installation, commissioning, operating, maintenance or repare of the equipment must: be suitably qualified and strictly observe these Operating Instructions. Improper operation or misuse can lead to serious or fatal injury, damage to the equipment and property of the user and a reduction in the efficiency of the equipment. Safety instructions in this manual are presented in three different forms to emphasize important information. WARNING This information indicates particular danger to life and health. Disregarding such a warning can lead to serious or fatal injury. CAUTION This information indicates particular danger to the equipment or other property of the user. Serious or fatal injury cannot be excluded. CAUTION The ARS may only be used with the transformer specified in the order. Installation, electrical connection and commissioning of the ARS must 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 ARS is used for the specified application only. The ARS can be operated at oil temperatures between –25° C and + 105° C. For safety reasons, any unauthorized work such as installation, alteration, electrical connection, commissioning or modification to the ARS equipment is forbidden without first consulting MR. The trouble-free operation of the drive unit, the ARS and transformer may be put at risk. WARNING All relevant fire protection regulations must be strictly observed. NOTE These notes give important information on a certain subject. 274/01/01/0 3 2 Structure / Design 2 Structure / Design An Advanced Retard Switch (abbreviated ARS) is used to switch a winding during transformer operation. The ARS always has two operating positions. During an ARS operation, the through-current is commutated from one current path to another current path of the same potential. The contact system is equipped for this with special contacts. The ARS is changed over from one operating position to the next by turning an insulating drive shaft. This insulating drive shaft is actuated by a 60° step-by-step gear which is driven by an ED motor-drive unit. The change in operating positions requires a 120° tap-change. This means that two motor-drive switching operations (double tap-change) are required for one ARS operation. The contact system of the ARS has a contact circle diameter of 841 mm and is designed for a maximum operating current of 800 A per contact plane. Operating currents of more than 800 A are distributed over parallel contact surfaces. CAUTION The ARS with the relevant drive unit is to be used only with the transformer specified in the order. Installation, electrical connection and commissioning of the ARS must only be carried out by qualified, skilled personnel and only in accordance with these Operating Instructions. Do not alter or modify the ARS equipment without first consulting MR. Any unauthorized works such as installation, electrical connection or commissioning of the ARS equipment endangers the trouble-free operation of the motor-drive unit, of the ARS and of the transformer. The ARS can be used for different applications in combination with an on-load tap-changer. The ARS is primarily used to reverse the poles of the regulating voltage (double reversing change-over selector) for applications with large regulating ranges (e. g., phase shifter transformers). WARNING With ARS on-load tap-changer combinations, the ARS may only be actuated in a certain position of the on-load tapchanger. This means that it may only be actuated when all windings of the on-load tap-changer regulating winding are disconnected. For this reason, non-permitted switching operations are prevented by a mutual electrical interlock of on-load tap-changer and ARS. Order-related technical documents, safety notes and the function description must be complied with. 4 274/01/01/0 3 Shipment 3 Shipment ARS and motor-drive unit are shipped in the adjustment position. The ARS equipment is shipped as follows: – ARS (fig. 1) – motor-drive unit ED (fig. 2) – drive shaft with coupling parts and bevel gear The shipment is to be fully checked against consignment documents to ensure it is complete. All parts must be stored in a dry place until assembly. The ARS must remain packed in the protective wrapping and should only be removed shortly before installation. 2 1 274/01/01/0 5 4 Installation of the ARS for cover mounting 4 Installation of the ARS for cover mounting A mounting flange is necessary for mounting the ARS head to the transformer cover (see fig. 3 and section 12, installation drawing 725762). This mounting flange has to match the gasketing area of the ARS head. To position the stud bolts (M12, max. length = 45 mm) we recommend the use of a drilling template (see fig. 4 and drawing. 896 135, section 12). If requested, the drilling template will be supplied with the first installation of a ARS free of charge. 3 4 6 274/01/01/0 4 Installation of the ARS for cover mounting The ARS head must be removed before mounting the ARS (figures 5, 6).The ARS head is then attached to the mounting flange of the transformer cover and the ARS mounted to the ARS head from below (see fig. 7 and section 12, dwg. 725762). NOTE The position of the gear unit installed on the head cannot be changed. It is fixed (i. e., cannot be turned) in the position specified in the order. Proceed as follows: 1. Place the ARS on a level surface. Remove 3 screws M12 (wrench size 19) on the underside of the upper cage ring. Pay special attention to washers and lock tabs. Take off the ARS head (ca. 25kg). 5 2. Clean the gasket surfaces (head underside, mounting flange). Place an oil-resistant gasket on the mounting flange. 3. Turn the Geneva crank of the step-by-step gear inwards by 90° (see fig. 8 and appendix, installation drawing 725762). Position the ARS head onto the mounting flange. 4. Check its installation position which determines the mounting position of the ARS when installed. Fasten the ARS head to the mounting flange. NOTE The position of the gear unit installed on the head cannot be changed. It is fixed (i. e., cannot be turned) in the position specified in the order. 5. Lift the ARS to the ARS head from below. A centering bolt allows attachment and coupling of ARS head and ARS in the correct position only. 6 6. Attach the ARS to the ARS head from below by 3 screws M12 (w. s. 19), with washers and lock tabs, max. torque 80 Nm. The screws must be safely locked! 7. Turn the Geneva crank of the step-by-step gear back into the original position by 90° (see installation drawing 725762). 274/01/01/0 7 4 Installation of the ARS for cover mounting 7 Geneva crank 8 8 274/01/01/0 5 Installation of the ARS into a bell-type tank 5 Installation of the ARS into a bell-type tank (see section 12, drawing 725770) The connection of the ARS requires the use of a supporting structure that allows the ARS to be provisionally attached to the supporting flange. The attachment of the ARS head, which is here equipped with an intermediate flange, requires a different mounting flange on the transformer tank, as described in section 4 (fig. 9). The respective drilling template (see fig. 10 and section 12, drawing 896136) will be supplied on request with the first ARS for bell-type tank installation, free of charge. The ARS is lifted onto the supporting structure, fixed in this provisional position and connected to the leads. CAUTION Make sure that the connected leads do not exert any force on the ARS. Moreover there must be sufficient clearance so that it is possible to raise the ARS to its final installation position after the bell-type tank has been mounted. NOTE The position of the gear unit installed on the head cannot be changed. It is fixed (i. e., cannot be turned) in the position specified in the order. Then the ARS head and intermediate flange are removed from the ARS . The intermediate flange is mounted to the mounting flange of the bell-type tank after the set-up of the bell-type tank. The ARS below is lifted to its final position and securely fastened to the intermediate flange (fig. 11). Finally, the ARS head is placed on the intermediate flange and fastened. Proceed in detail as follows: 1. Lift the ARS onto the supporting structure, check the installation position and fix it there. The installation position of the ARS must be aligned to the ARS head that will be mounted with the bell-type tank set up later on. 9 NOTE The position of the gear unit installed on the head cannot be changed. It is fixed (i. e., cannot be turned) in the position specified in the order. 2. The connection of the ARS to the transformer winding is described in section 6. 3. After installation of the ARS, a transformer ratio test is to be performed (see section 7). 4. Remove all 18 nuts M12/w. s. 19 from the ARS head. Take the ARS head off the intermediate flange (ca. 25 kg). 10 274/01/01/0 9 5 Installation of the ARS into a bell-type tank 5. Remove the 3 suspension screws (hexagon socket type M12/w. s. 8) which attach the intermediate flange to the ARS. Take care of the spring washers. Take the intermediate flange off the ARS. Take care of the O-ring gasket. Keep all loose parts for reinstallation. 6. Lift the bell-type tank over the active part of the transformer. Prior to mounting the intermediate flange, clean the gasket surfaces (underside of intermediate flange, top side of mounting flange). Place the 0-ring gasket in mounting flange. Place the intermediate flange on the mounting flange and fasten securely. Depending on the final height adjustment there must be a clearance of 5 to 20 mm between intermediate flange and top of the ARS. Check the installation position of intermediate flange and ARS head. 7. Lift the ARS by its lifting lugs positioned at its supporting flange. Attach the ARS to the intermediate flange (3 screws M12/ w. s. 8, max. torque 80 Nm, secure with spring washers). 8. Before mounting the ARS head clean the gasket surfaces and turn the Geneva crank inwards by 90° (fig. 8). Place the ARS head in position. A centering bolt in the ARS head allows the ARS head to be mounted in its correct position only. 9. Attach the ARS head to the intermediate flange (18 nuts M12/w. s. 19, with washers, max torque 40 Nm). ARS head Intermediate flange Monting flange Supporting flange 11 10 274/01/01/0 6 7 6 Connection of the transformer winding Transformer ratio test Connection of the transformer winding The connection of the ARS has to be carried out in accordance with the connection diagram which accompanies the delivery. The terminals are clearly indicated on the insulating bars. Use mounting screws with a 12-mm diameter for the connection (see fig. 12). These are not included in the delivery. CAUTION 7 Transformer ratio test Before drying it is recommended to carry out a ratio test. A short tube of 25 mm nominal width with a screwed-in coupling bolt of 12 mm diameter together with a hand wheel or a hand crank may be used to operate the ARS at the ARS head’s drive shaft. Operating the ARS from one operating position to the next requires 33 revolutions. Check each operating position (arrow and indication disc on top of the ARS head) against the connection diagram. After completion of the test the ARS has to be set back to the adjustment position. All connections must be made carefully and locked safely. The tap leads must be assembled in such a way as to allow all leads to be connected to the ARS without tension. If necessary, the connection ends of the tap leads must be shaped in form of expansion loops. 12 274/01/01/0 11 8 8 Drying procedure of the transformer and filling with oil Drying procedure of the transformer and filling with oil Before drying the following steps must be carried out: 1. Check of adjustment position The adjustment position must be checked on the basis of the connection diagram supplied with the delivery of the ARS. Make sure that the movable contacts close symmetrically on the stationary contacts. Exact setting of the adjustment position can be achieved by turning the drive shaft at the gear unit. 2. Removal of the supporting plate of the tap-change supervisory control at the ARS head. The tap-change supervisory control is located in a housing above the gear unit. Remove the cover of the housing (8 nuts M6/w. s. 10). Take off the gasket. Remove the supporting plate of the tap-change supervisory control (3 hexagon socket screws M6 X 20/ w. s. 5, marked yellow), see fig. 13. All parts must be safely stored until reinstallation (see section 9.4). CAUTION Before drying the transformer make sure that the supporting plate is removed, otherwise the installed micro-switches will be damaged during the drying procedure. Perform the drying procedure. As a precondition of MR’s guarantee of the dielectric properties of the equipment, a minimum drying treatment must be carried out according to the following instructions (alternatively vacuum drying or vapor phase drying): Vacuum-drying Heating up: In air of atmospheric pressure by increasing the temperature by about 10 °C/h to a final temperature of max. 110 °C. Pre-drying: In circulating air for 20 hours, maximum temperature 110 °C at the ARS. Drying: Maximum temperature 110 °C at the ARS , residual pressure about 10-3 bar. Drying time for ARS at least 50 hours. 12 13 Vapor-phase drying Heating up: Excessive increase in temperature of the insulation materials of the ARS may damage these materials. For this reason, do not expose the ARS to the kerosene vapor directly at vapor entry (if necessary, use guide plates). Drying: The temperature on the ARS must not exceed 125 °C. The duration of the drying process depends on that of the transformer. However, it should be at least 50 hours. CAUTION Do not operate the ARS after drying without oil wetting. Filling with oil Fill up the transformer with new transformer oil under vacuum. Please note that insulating oils used in transformers must comply with the relevant standards, especially with respect to dielectric strength and water content, e. g. IEC 60296. 274/01/01/0 9 Final assembly 9 Final assembly 9.1 Drive unit For detailed instructions on the installation, see Operating Instructions no. 138 for motor-drive units ED-S and ED-L (see also section 12, dimension drawings 898801 and 898802). Please note: • The serial number of drive unit and ARS have to be identical (rating plate). • Drive unit and ARS must be in the same operating position (adjustment position). The adjustment position is given in the connection diagram supplied with the ARS. • The drive unit must be attached to the place provided on the transformer in vertical position. 9.2 Bevel gear The bevel gear is to be attached to a support on the transformer cover by 2 bolts (see section 12, dimension drawing 892916). CAUTION The stamped on serial number must be the same as that of the ARS. The horizontal drive shaft must be in proper alignment with the drive shaft of the ARS head. 9.3 Drive shaft (square tube) The drive shaft must be mounted according to our Operating Instructions No. 42. The drive shaft is the mechanical connection between drive unit and ARS head. Diversion of the driving force from the vertical into the horizontal position is performed by the bevel gear. Accordingly, when mounting, the vertical drive shaft is to be attached between drive unit and bevel gear, whereas the horizontal drive shaft is to be attached between bevel gear and ARS head. The drive shaft itself consists of a square tube and is to be connected at both ends to the respective shaft end by two coupling brackets and one coupling bolt. When mounting the drive shaft make sure that the shaft ends to be connected are aligned exactly. Square tubes, coupling bolts, coupling brackets, screws and nuts are made of corrosion-resistant steel. We recommend, however, to apply the same outside coating to these parts as to the transformer tank. The square tubes and the guard plate which serves as a foot step protection for the horizontal drive shaft over the transformer cover, are supplied in oversize (various standard lengths) and have to be cut to the required length when they are mounted on the transformer. This also applies to the vertical protective plates if these have also been ordered. 9.4 Coupling the ARS with the motor-drive unit NOTE NOTE The position of the gear unit installed on the head cannot be changed. It is fixed (i. e., cannot be turned) in the position specified in the order. ARS and drive unit must be in their adjustment position. It is absolutely necessary that the ARS operation is accomplished before the drive unit stops. This is ensured by setting the time of ARS action at a distinct interval before the end of the drive unit action. In case of drive unit the hatched section of the tap-change indication is used as a reference when adjusting. 274/01/01/0 13 9 Final assembly An ARS operation requires two rotations on the tap-change indicator on the motor-drive unit. The tap-change indication is divided into sections each of which corresponds to one hand crank revolution. The number of hand crank revolutions from the ARS operation to the end of the drive unit action must be the same in both rotation directions. Symmetrical coupling is achieved as follows: – Adjustment must be carried out by manual operation only. – When adjusting, make sure the position indicators on the drive unit and ARS are identical. – Perform coupling of ARS and drive unit. – Turn the hand crank in one direction until the arrow (fig. 14) of the position indicator in the ARS head stops. – Count the number of sections until the center mark of the tap-change indication is in mid-position. – Repeat this procedure in the opposite direction. – If there is a difference in sections counted in both directions, the motor-drive unit must be readjusted in relation to the ARS by half the difference in sections as counted before. – Finally check the symmetrical coupling in both directions. – ARS and drive unit must be in their adjustment position when being coupled. 14 14 274/01/01/0 9 Final assembly In case of tap-change supervisory control at the ARS head. – Make sure that ARS and drive unit are in the adjustment position. – Check position of the Geneva crank in the tap-change supervisory control housing. The triangular marks must be exactly aligned (fig. 15). – If the position of the Geneva crank deviates, the hexagon socket screw M6 of the Geneva crank must be loosened and turned until the triangular marks are in exact alignment. Then fasten the screw by 9 Nm. – lnstall the supporting plate: this is done by arresting the lever of the lower microswitch (S90) in pressed condition by means of the retention pin (fig. 16). – Place the supporting plate and remove the retention pin. Fix the supporting plate with 3 hexagon socket screws M6 x 20 (marked yellow, w. s. 5, max. torque 9 Nm) and secure with locking washers. CAUTION Make sure to remove the retention pin after the supporting plate has been mounted; otherwise the function of the tap-change supervisory control will be blocked. – Connect the tap-change supervisory control to the drive unit (see section 10). – Replace the gasket and attach the housing cover (8 nuts M6/w. s. 10). 15 274/01/01/0 15 9 Final assembly 9.5 Functional test Operate the ARS from the adjustment position across the whole tapping range by using the motor-drive unit. If necessary, repeat the ratio test (see section 7). Check in every operating position that the tap position indicator of the drive unit and ARS show the same position. WARNING A coupling fault between ARS and drive unit exists, if ARS and drive unit show different operating positions. Misalignment of coupling between ARS and drive unit leads to severe damage of ARS and transformer, if operation is continued. Serious or fatal injury cannot be excluded. 16 CAUTION After coupling the ARS with the drive unit and after adjustment of the tap-change supervisory control, the ARS must not be uncoupled any more. Otherwise the whole adjustment procedure must be repeated according to section 9.4. 9.6 Complete oil filling Fill up the transformer with new transformer oil. While doing this vent the oil space in the ARS head (bleeder screw in the ARS head: locking screw M18 (w.s. 24), max. torque 10Nm, slotted head screw M6, max. torque 2Nm. 9.7 Ground connection Connect the ground screw of the ARS head (screw M12/w. s. 19, max. torque 60 Nm) to the transformer cover. Connect the ground screw of the motor-drive unit ED (screw M12/w. s. 19, max. torque 60 Nm) to the transformer tank. 16 274/01/01/0 10 Safety precautions 10 Safety precautions Each ARS is equipped with a tap-change supervisory control. This is installed in a housing over the gear unit of the ARS head (see section 12, appendix, dimension drawing 896948). Depending on the particular application, the tap-change supervisory control of the ARS offers various functions in connection with the motor-drive unit and related on-load tap-changer units. These required safety functions are always specified for each individual delivery as binding based on the particular application and documented in a function description which is included. WARNING The transformer must be energized only, when operating positions of ARS and corresponding drive unit are the same. The order-related safety measures must be strictly observed. Disregarding such a warning can lead to serious or fatal injury and to severe damage to the ARS and the transformer. WARNING CAUTION With ARS on-load tap-changer combinations, the ARS may only be actuated in a certain position of the on-load tapchanger. This means that it may only be actuated when all windings of the on-load tap-changer regulating winding are disconnected. For this reason, non-permitted switching operations are prevented by a mutual electrical interlock of on-load tap-changer and ARS. Order-related technical documents, safety notes and the function description must be complied with. Before commissioning and in any case of technical change check the safety measures for effectiveness. CAUTION The wiring between tap-change supervisory control and motor-drive unit varies with the binding connection diagram of the related motor-drive unit for the specific job. 274/01/01/0 17 11 Maintenance 11 Maintenance WARNING Prior to the performance of every maintenance job on the ARS, the transformer must be switched off on all sides and short-circuited on all connections and grounded. If not adhered to, there exists a danger of death. Maintenance has to be carried out on the ARS after every 100.000 tap-change operations on the ARS motor-drive unit (counter indicator). This means that the ARS has performed 50,000 switching operations since one ARS operation requires two motor-drive unit operations. We recommend that our Technical Service Department carry out each maintenance. As well as guaranteeing that all work is properly carried out, specific components are also retrofitted to the latest standard of technology. If a maintenance is not carried out by our Technical Service department, please ensure that the personnel who carry out the maintenance are trained by MR or are otherwise suitably qualified to carry out the work. In such a case, we would ask you to forward us a report on the maintenance performed, to complete our maintenance records. For inquires about spare parts we ask you to inform us about the serial number (see the name plate on the ARS and on the motor-drive unit) and the number of switching operations. NOTE After maintenance and any replacement measures, the points in section 9 of these Operating Instructions must be adhered to. A new transformer ratio test is recommended (see section 7). To fill with oil, adhere to section 8. WARNING The transformer must be energized only, when operating positions of ARS and corresponding drive unit are the same. The order-related safety measures must be strictly observed. Disregarding such a warning can lead to serious or fatal injury and to severe damage to the ARS and the transformer. CAUTION Before commissioning and in any case of technical change check the safety measures for effectiveness. WARNING Disregarding the maintenance intervals or an incomplete / improper maintenance can lead to severe damage on the ARS and the transformer. Danger of death may also exist. 18 274/01/01/0 12 Appendix 12 Appendix Installation drawing ARS ....................................................................................................................................................... 725762 Page 20 Fixing the ARS on the lower cage ring ............................................................................................................................. 725832 Page 21 Head, dimension drawing ..................................................................................................................................................... 896948 Page 22 Head for installation into bell-type tank ......................................................................................................................... 725770 Page 23 Cover mounting ........................................................................................................................................................................ 896135 Page 24 Bell-type tank mounting ....................................................................................................................................................... 896136 Page 25 Motor-drive unit ED-S, protective housing, dimension drawing .............................................................................. 898801 Page 26 Motor-drive unit ED-L, protective housing, dimension drawing .............................................................................. 898802 Page 27 Bevel gear CD 6400, dimension drawing ......................................................................................................................... 892916 Page 28 Drilling template for ARS head Drive units 274/01/01/0 19 7257620E 20 Advanced-Retard-Switch Installation drawing 274/01/01/0 7258320E 274/01/01/0 Advanced-Retard-Switch Fixing on the lower cage ring 21 8969487E 22 Advanced-Retard-Switch Head, dimension drawing 274/01/01/0 7257700E Advanced-Retard-Switch Head for installation into bell-type tank 274/01/01/0 23 8961350E Advanced-Retard-Switch Drilling template for ARS head, cover mounting 24 274/01/01/0 8961360E Advanced-Retard-Switch Drilling template for ARS head, bell-type tank mounting 274/01/01/0 25 8988012E Motor-drive unit ED-S Protective housing, dimension drawing 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 Shim Attachment of protective housing ca. 690 if opened 130° ca. 864 if opened 180° Aperture of fixing holes on protective housing (rear view) 26 The cover can be opened to the left or to the right depending on the arrangement of the hinge pins. Aperture in protective housing for cables (underside view) 274/01/01/0 8988022E Motor-drive unit ED-L Protective housing, dimension drawing 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 tansformer tank Shim Attachment of protective housing ca. 690 if opened 130° ca. 864 if opened 180° Aperture of fixing holes on protective housing (rear view) 274/01/01/0 The cover can be opened to the left or to the right depending on the arrangement of the hinge pins. Aperture in protective housing for cables (underside view) 27 28 e2 = 215 for design with ball joint e1 = 205 for standard design 8929166E Bevel gear CD 6400 Dimension drawing 274/01/01/0 www.reinhausen.com © Maschinenfabrik Reinhausen GmbH Falkensteinstrasse 8 93059 Regensburg, Germany Phone +49 941 40 90-0 Fax +49 941 40 90-111 E-mail sales@reinhausen.com BA 274/01 en • 1205/20 • 274/01/01/0 • F0141000 • Printed in Germany