www.reinhausen.com On-Load Tap-Changer Type ROperating Instructions BA 119/06

2 119/06 EN

3119/06 EN

Contents

Contents

1 General ......................................................................................................................................... 5

1.1 Safety instructions ............................................................................................................... 51.2 Specified application ........................................................................................................... 5

2 Design ....................................................................................................................................... 6

3 Shipment ................................................................................................................................... 6

4 Installation of the on-load tap-changer for cover attachment .............................................. 84.1 Mounting flange ................................................................................................................... 84.2 Attaching the on-load tap-changer head to the transformer cover .................................... 84.3 Mounting the tap selector and the diverter switch oil compartment .................................. 9

5 Installation of the on-load tap-changer into the bell-type tank ............................................. 11

5.1 Assembly of diverter switch oil compartment and tap selector,connection of tap selector connecting leads ..................................................................... 11

5.2 Installation of the on-load tap-changer into the supporting structure ................................. 115.3 Preparations ..................................................................................................................... 125.4 Mounting the bell-type transformer cover ......................................................................... 13

6 Connection of tap winding and tap-changer take-off leads .................................................. 16

6.1 Tap selector ...................................................................................................................... 166.2 Parallel bridges for R I 2002 an R I 3000 .......................................................................... 176.3 Connecting the tap-changer take-off lead ......................................................................... 17

7 Transformer ratio test .............................................................................................................. 18

8 Drying procedure and filling with oil ...................................................................................... 18

8.1 Drying procedure .............................................................................................................. 188.1.1 Vacuum-drying process .......................................................................................... 18

8.1.1.1 Drying in the autoclave.............................................................................. 188.1.1.2 Drying in the transformer tank ................................................................... 18

8.1.2 Vapor-phase drying process................................................................................... 198.1.2.1 Drying in the autoclave.............................................................................. 198.1.2.2 Drying in the transformer tank ................................................................... 19

8.1.3 Operating the OLTC ............................................................................................... 198.2 Filling with oil .................................................................................................................. 20

9 Pipe connections ...................................................................................................................... 20

9.1 Pipe connection R for protective relay RS 2001 ............................................................... 209.2 Pipe connection S for suction pipe ................................................................................... 209.3 Pipe connection Q ............................................................................................................ 209.4 Connection flange E2 ....................................................................................................... 20

NOTE

Data contained herein may differ in details from the tap-changing equipment delivered.We reserve the right to make alterations without notice.

4 119/06 EN

10 Mounting the motor drive unit, the bevel gear and the drive shaft ...................................... 2110.1 Mounting the motor drive unit ........................................................................................... 2110.2 Mounting the bevel gear ................................................................................................... 2110.3 Mounting the drive shaft (square tube) ............................................................................. 21

11 Putting the on-load tap-changer into operation at the transformer factory ........................ 2211.1 Operational tests .............................................................................................................. 2211.2 Final oil filling .................................................................................................................. 2211.3 Ground connections ......................................................................................................... 2311.4 Electrical transformer tests ............................................................................................... 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

Contents

5119/06 EN

1General

1 General1.1 Safety instructions

All personnel involved in installation, commissioning,operation, maintenance or repair of the equipmentmust:

- 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 threedifferent forms to emphasize important information.

1.2 Specified application

WARNING

This information indicates particular danger to life andhealth. Disregarding such a warning can lead toserious or fatal injury.

CAUTION

This information indicates particular danger to theequipment or other property of the user. Serious orfatal injury cannot be excluded.

NOTE

These notes give important information on a certainsubject.

CAUTION

All relevant fire protection regulations must be strictlyobserved.

CAUTION

Only use the on-load tap-changer with the transfor-mer specified in the order. Installation, electricalconnection and commissioning of the on-load tap-changer may only be carried out by qualified, skilledpersonnel and only in accordance with these operat-ing instructions.

It is the responsibility of the user to make sure thatthe on-load tap-changer is used for the specifiedapplication only.For safety reasons, any unauthorized work, i.e. in-stallation, modification, alteration of the tap-changingequipment, electrical connection or commissioning ofthe equipment is forbidden without first consulting MR!

The trouble-free operation of the drive, the on-loadtap-changer and the transformer may be put at risk.

6 119/06 EN

2 Design3 Shipment

2 Design

A

W 1

U1

U1U2

V1

V2

W2

W1

4 2

1

2

1

2

3

4

3

4

13

V2

KHW 1086-41

The on-load tap-changer (OLTC) consists of the diver-ter switch with the tap selector mounted below (fig. 1).

The diverter switch is installed in its own oil compart-ment.

The on-load tap-changer is attached to the transformercover by means of the tap-changer head.

If required, the tap selector may be equipped with achange-over selector.

The change-over selector of all type R OLTCs islaterally attached to the fine tap selector.

OLTC models without change-over selector are avail-able for max. 18, and with change-over selector formax. 35 operating positions.

The design of the on-load tap-changer and the designa-tion of its main parts are shown in the installation draw-ing 896 705 in the appendix.

These Operating Instructions contain all informationregarding installation and operation of the followingOLTC standard models, which are available with andwithout change-over selector.

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 group3 x R I 2002/2402 or3 x R I 3000/3600with a common motor drive.

On-load tap-changer and motor drive are shipped in theadjustment position. The on-load tap-changer is packedin two parts, diverter switch and tap selector, and is wellprotected against moisture. Both the diverter switch andthe tap selector are blocked in the adjustment position.

The tap-changing equipment is shipped as follows:

Diverter switch oil compartment with tap-changer headand diverter switch unit (max. weight approx. 210 kg),fig. 2.

Tap selector (max. weight approx. 270 kg), fig. 3.

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.

Protective relay RS 2001(weight 3.5 kg), fig. 6.

Check shipment against documents.Store all parts in a dry place until installation.

The tap-changer parts must be left wrapped in theirairtight cover, unwrap just before installation.

3 SHIPMENT

7119/06 EN

6 KHW 848-4

5 KHW 766-4

MR

MR

A

W 1V2

KHW 1087-42

3

4 2

1

2

1

2

3

4

3

4

3 1

KHW 1097-4

NOTE

In general, drive shaft, bevel gear and protectiverelay are packed with the on-load tap-changer.

3Shipment

4 KHW 915-4

8 119/06 EN

To mount the tap-changer head to the transformer covera mounting flange is necessary. This mounting flangeshould meet the requirements of the tap-changer headgasket surface (see fig. 7, and section 16, drawing896 705).

To position the thread studs (M12, max. length = 45 mm)we recommend the use of a drilling template (seefig. 8 and section 16, dwg. 890 183). If requested, thedrilling template will be supplied without charge with thefirst on-load tap-changer type R.

4.2 Attachment of the tap-changerhead to the transformer cover

The diverter switch oil compartment is lowered throughthe cover aperture (= mounting flange) of the trans-former. The tap-changer head is attached to the mount-ing flange by means of bolts.Then, the tap selector is fastened to the diverter switchoil compartment (see section 4.3).

Proceed as follows:

1. Place the diverter switch oil compartment on a levelsurface.

2. Clean sealing surfaces of mounting flange and tap-changer head.

3. Put an oil-proof gasket on the mounting flange ofthe transformer cover.

4. Lift the diverter switch oil compartment by hookingup the tap-changer head. Lower the oil compartmentcautiously into the mounting flange.

Take care of screening rings (with Um ≥ 170 kV only).

5. Check position of tap changer head.

6. Attach the tap-changer head to the mounting flangewith bolts.

4 Installation of the on-load tap-changer for cover attachment (fig. 7)

8

7

4Installation of the on-load tap-changer for cover attachment

4525

7,5°

15°

15°

740

650

710

15

M12

KHW 770-4

KHW 769-4

4.1 Mounting flange

NOTE

Remove the blocking plate from the coupling (fig. 9)of the oil compartment bottom.

20

200

60

7,5°

15°

740

710

200

8

650

5

24x15°=360°

9119/06 EN

4Installation of the on-load tap-changer for cover attachment

4.3 Mounting the tap selector and thediverter switch oil compartment

Raise the tap selector to the oil compartment andattach. At the same time the mechanical coupling forthe tap selector drive has to be performed. Finally,connect the tap selector connecting leads to thediverter switch oil compartment.

Proceed as follows:

1. Put the tap selector down on a level surface. Getready 4 lock nuts M12 with washers.

2. Put the tap selector on an appropriate lifting device.Remove the ring nuts.

3. Raise the tap selector to the diverter switch oilcompartment. Be sure that tap selector connectingleads clear the diverter switch oil compartment andremain undamaged.

4. Position coupling parts and attachment points oftap 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 oilcompartment bottom:4 lock nuts M 12/w.s.19, washers,max. torque 65 Nm (fig. 12).

7. Remove the wooden support from the laterallyattached change-over selector.

NOTE

Remove the blocking strip from the tap selectorcoupling (fig. 10).The coupling must not be displaced afterwards.

9

10

11

rh-1111-4-0/1KHW 1111-4

KHW 1102-4

rh-1098-4-0/1KHW 1098-4

1500

10 119/06 EN

4Installation of the on-load tap-changer for cover attachment

Connection of the tap selector connnecting leads to thediverter switch oil compartment:

OLTCs R III 1200 and R I 3000/3600

6 connecting leads to oil compartment terminalsaccording to fig. 14.Each one attached by 1 bolt M12 (w.s.19) lock nut andscreening cap, torque 80 Nm.

OLTC R I 2002/2402

4 connecting leads to oil compartment terminalsaccording to fig. 15.Each one attached by 1 bolt M12, lock nut and screen-ing cap, torque 80 Nm.

CAUTION

All connections must be carried out carefully. Thetightening torques indicated must be applied. Besure that bolts are tightened carefully and screenedby the screening caps supplied with the equipment(fig. 13).

12

13

14

15KHW 1091-4

A

1V1 1V2

KHW 1088-4

A

43

KHW 1093-4

KHW653-3

11119/06 EN

5 Installation of the on-load tap-changer into the bell-type tank

To install the on-load tap-changer into a transformerwith bell-type tank the on-load tap-changer must bemounted onto a supporting structure.For this purpose, the OLTC is equipped with a sup-porting flange at the diverter switch oil compartment(= special design, section 16, dwg. 896 762).

Firstly, lift the on-load tap-changer into the supportingstructure and connect it to the tap winding. The OLTCmust be attached to the supporting structure in such away that it cannot be displaced. The supporting flangeis provided with through-holes which allow it to be fixedto the supporting structure. It is advisable to put spacerblocks temporarily between supporting structure andsupporting flange and to remove them before the bell-type cover is set up.

Once the bell-type cover is attached, lift the on-load tap-changer (with the diverter switch unit removed) bymeans of the lifting traverse (see section 16, drawing890 180) and fix it to the bell-type cover together withthe top part of the head.To attach the tap-changer head to the bell-type cover,we recommend using a mounting flange as described insection 4.1.

5.1 Assembly of diverter switch oil com-partment and tap selector, attachmentof tap selector connecting leads

5Installation of the on-load tap-changer into the bell-type tank

The assembly of diverter switch oil compartment andtap selector as well as the connection of tap selectorconnecting leads has to be carried out according tosection 4.3.

5.2 Installation of the on-load tap changerinto the supporting structure

Lift the assembled on-load tap-changer, according tosection 4.1, into the supporting structure. Make surethat the on-load tap-changer is in proper mountingposition and fasten it there safely.

It is of advantage to install spacer blocks betweensupporting structure and supporting flange in such away that the on-load tap-changer is in its final positionafter the bell-type cover is set up. This measure helpsto cut the tap leads to their correct lengths. Remove thespacer blocks after the leads have been connected.

To connect the tap winding and the tap-changer take-offterminal follow the instructions according to section 6.

The drying procedure and the transformer ratio test areto be performed in accordance with sections 7 and 8.

CAUTION

The connected leads must not exercise any force onthe on-load tap-changer. Moreover there must besufficient clearance so that it is possible to lift the on-load tap-changer in its final installation position afterthe bell-type tank has been mounted.

NOTE

In the supporting structure the on-load tap-changermust be in an exactly vertical position. The on-loadtap-changer must be mounted to the supportingstructure ensuring that it need not be lifted by morethan 5 to 20 mm to reach its final position after thebell-type cover is set up.

12 119/06 EN

5.3 Preparations

5Installation of the on-load tap-changer into the bell-type tank

Prior to setting up the bell-type tank the tap-changerhead 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 lockwashers).

2. Take care of the cover gasket(round rubber gasket, fig. 16).

3. Remove the position indicator dial (remove the clipfrom the shaft end, fig. 17).

4. Take note of the red-marked area not covered bythe supporting plate of the diverter switch unit(fig. 18).

5. Remove the fixing nuts of the supporting plate (4nuts M8, w.s.13, lock washers, fig. 19).

6. Withdraw the diverter switch unit carefully from theoil compartment (fig. 20). Keep the diverter switchunit in a vertical position.

7. Remove the suction pipe. The pipe connection hasto 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 supportingflange. Take care of the gasket.

rh-1103-4-0/1

17

KHW 1103-4

19rh-1105-4-0/1

rh-1101-4-0/1KHW 1101-4

KHW 1105-4

18

16 KHW 762-4

13119/06 EN

5.4 Mounting the bell-typetransformer cover

5Installation of the on-load tap-changer into the bell-type tank

1. Before mounting the bell-type transformer coverclean the sealing surface of the oil compartmentsupporting flange. Place the gasket onto the flange(fig. 23). Withdraw the spacer blocks (see section5.2).

2. Lift the bell-type cover over the transformer activepart and lower it to its final position.

3. Before mounting the tap-changer head clean thesealing surfaces (bottom of tap-changer head,mounting flange). Put an oil-resistant gasket on themounting flange.

23

22

21 KHW 1106-4

20

rh-1110-4-0/1KHW 1110-4

rh-1107-4-0/1KHW 1107-4rh-1109-4-0/1KHW 1109-4

14 119/06 EN

4. Place the tap-changer head on the mounting flange.Check the mounting position of the tap-changerhead by means of 2 adjusting bolts (fig. 23) and themarks of the supporting flange and tap-changerhead (fig. 24) which allow assembly in the correctposition only. Depending on the final heightadjustment leave a clearance of 5 to 20 mmbetween tap-changer head and supporting flange

5. Lift the on-load tap-changer slightly by means of thelifting traverse (see fig. 25 and section 16, drawing890 180). Make sure that all supporting flange studseasily slide through the fixing holes of the tap-changer head.

CAUTION

Take care not to drop any parts into the diverterswitch oil compartment. Otherwise the diverterswitch can block and cause severe damage to theon-load tap-changer and transformer.Therefore, make sure that the number of smallparts is complete when disassembling andreinstalling. Count them to be sure.

24

25

KHW 1100-4

KHW 1108-4

5Installation of the on-load tap-changer into the bell-type tank

15119/06 EN

5Installation of the on-load tap-changer into the bell-type tank

6. Attach the tap-changer head in the red marked areanot covered by the supporting plate of the diverterswitch (fig. 26, see also section 5.3). Use 17 nutsM8 (wrench size 13, max. torque 14 Nm, lockwashers). Attach the tap-changer head to themounting flange.

7. Remount the suction pipe. Make sure that the O-rings are placed properly. The O-rings should slightlybe greased before being mounted.

8. Remount the diverter switch unit. Make sure that thediverter switch supporting plate is in its properposition within the tap-changer head (the red markedareas must be left free). Attach the supporting plateby means of 5 nuts M8 (wrench size 13, max. torque14 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 bymeans of its coupling pin (fig. 27).

10.Mount the cover on the tap-changer head. Makesure that the rubber gasket (O-ring) in the cover is inproper position.Fasten the 24 screws M10 (wrenchsize 17) equally, max. torque 34 Nm (fig. 28).

26

27

28

rh-1110-4-0/1KHW 1110-4

rh-1101-4-0/1KHW 1101-4

rh-1104-4-0/1KHW 1104-4

16 119/06 EN

6Connection of tap winding and tap-changer take-off leads

6 Connection of tap winding and tap-changer take-off leads

The tap winding has to be connected to the on-load tap-changer according to the connection diagram suppliedwith the particular tap-changer equipment.

Single-phase OLTCs R I 2002 and R I 3000 require theparallel connection of the tap selector terminals withidentical terminal numbers in order to avoid over-voltages between parallel contacts.

If requested, bridges for the parallel connection of tapselector terminals according to dwg. 896 706 (see ap-pendix) can be supplied.

In case of OLTCs R I 2402 and R I 3600 the parallelconnection of tap selector terminals by means ofparallel bridges is not applicable as the enforced currentsplitting of tap leads is provided by two or three isolatedwinding branches on each tap selector terminal.

6.1 Tap selector (fig. 29)

Fine tap selector terminalswith through-hole for M12 screws(fig. 30). If reques-ted, screening caps (MR part number 078 957) will besupplied with the delivery.

Change-over selector terminals

Reversing switch: terminals (+) and (–) like the finetap selector terminals, terminals (0) as terminal lug ofthe connecting lead (0/K) with through-hole for M12screws (see fig. 31).

Coarse tap selector: terminals (0) and (–) like the finetap selector terminals, terminals (+) as terminal lug ofthe cranked connecting lead (+/K) with through-holesfor M12 screws (see fig. 31).

29

30

31

4 2

1

2

1

2

3

4

3

4

13

KHW 1096-4

rh-1089-4-0/1KHW 1089-4

rh-1090-4-0/1

A10

B9

B10

C9

KHW 1090-4

CAUTION

All connections to the on-load tap-changer must bemade carefully and locked safely. The tap leads mustbe assembled in such a way to allow for connectingall leads to the on-load tap-changer without tension.If necessary, lead ends must be shaped in form ofexpansion loops.

17119/06 EN

Parallel bridges for the fine tap selector and change-over selector according to dwg. 896 706 (see appendix)can be supplied on request.

Parallel bridges consist of two identical parts which arejoined by a single M12 bolt with lock nut (wrench size19, max. torque 60 Nm). They are provided with twothrough-holes to accommodate connection of tap leads.

6.2 Parallel bridges for R I 2002and R I 3000 (fig. 32)

6.3 Connecting the tap-changertake-off lead

The tap-changer take-off lead is to be connected tothe bus bar ring of the diverter switch oil compartment(fig. 33). The screw connection must be locked safely(Md = 60 Nm).

OLTC type R III 1200 (starpoint connection)

One throughhole each for M12 bolts is provided ondifferent points of the bus bar ring displaced by 120°(fig. 34).

OLTC type R I 2002/2402 and R I 3000/3600

Three or four throughholes each for M12 bolts are pro-vided on different points of the bus bar ring displacedby 120° (fig. 35).

6Connection of tap winding and tap-changer take-off leads

32

33

rh-1099-4-0/1KHW 1099-4

A

3 4

KHW 1095-435

894 490 0M

34rh-1094-4-0/1

A

1V1 1V2

KHW 1094-4

18 119/06 EN

7 Transformer ratio test8 Drying procedure and filling with oil

36 KHW 764-4

7 Transformer ratio test

We recommend to ratio-meter the transformer with alow AC voltage before drying.

To operate the drive shaft in the tap-changer head ashort tube of nominal width 25 mm with an insertcoupling bolt of 12 mm dia. together with a hand wheelor a hand crank may be used.

In case of OLTC set 3 x RI2002 ... 3600 all three tap-changer heads have to be coupled by the horizontaldrive shafts (see section 10).

When using an ED, 16.5 drive shaft revolutions of thetap-changer drive shaft are required for one tap-changeoperation. The diverter switch action can be hearddistinctly.

To operate the change-over selector a higher torque isnecessary.

The end positions shown on the connection diagramsupplied with the delivery must never be overrun. It istherefore necessary to check the operating positionthrough the inspection glass in the tap-changer headcover (fig. 36). Keep the number of tap-change opera-tions to a minimum as long as the on-load tap-changerhas not been immersed in oil. After the transformer ratiotest the on-load tap-changer has to be set back to theadjustment position in which it was delivered by MR.The position is indicated in the connection diagramdelivered with the equipment.

9 b

NOTE

If the transformer is to be vapor-phase dried in its owntank, open the kerosene drain plug (see section 8.1.2).

8 Drying procedure and filling with oil8.1 Drying procedure

The dielectric properties of the on-load tap-changer canonly be guaranteed, if the on-load tap-changer is sub-jected to a drying treatment according to the followinginstructions (8.1.1 or 8.1.2).

8.1.1 Vacuum-drying process8.1.1.1 Drying in the autoclave

• Heating upthe on-load tap-changer in air of atmosphericpressure with a temperature rise of approx. 10 °C/hour to a final temperature of at most 110 °C.

• Preparatory dryingin circulating air at 110 °C max. applied to the on-load tap-changer for a duration of 20 hours.

• Vacuum dryingat a temperature of 110 °C max. applied to the on-load tap-changer and a residual pressure of at most10-3 bar for a duration of at least 50 hours.

8.1.1.2 Drying in the transformer tank

The tap-changer head cover is vacuum-proof.

To ensure sufficient drying of the interior of the oilcompartment and the diverter switch insert, connect aby-pass tube of 25 mm nominal width between thetransformer tank and the connecting flange which leadsinto the oil compartment.

For ease of handling connect the bypass tube eitherbetween flanges E2 and Q or flanges E2 and R of thetap-changer head (for position of connecting flangessee section 9 and dwg. 893 899 of appendix).

Procedure, temperature, pressure and duration of thedrying process are as described in section 8.1.1.1.

NOTE

When drying the transformer in the autoclave removethe tap-changer cover and store it outside the vacuumautoclave.

NOTE

If the transformer is to be dried in its tank the interiorof the diverter switch oil compartment must be con-nected to vacuum, as the tap-changer head coverremains closed during the entire drying process.

19119/06 EN

The kerosene drain plug has an hexagonal recessscrew (w.s. 8) and is easily accessible between oilcompartment bottom and tap selector gear. It can beunscrewed from the outside. The thread of the kerosenedrain plug has a plastic coat so that it can only beturned with some force.

When drying the transformer in its own tank (seesection 8.1.2.2) the drain plug, in general, is notaccessible from outside and can only be openedfrom inside the oil compartment.In this case the diverter switch unit must be removedand the kerosene drain plug must be unscrewed with asocket wrench (see section 16, dwg. 890 182). Thenreinstall the diverter switch unit.

8Drying procedure and filling with oil

8.1.2 Vapor-phase drying process

NOTE

Before starting the drying procedure, open thekerosene drain plug (fig. 37) to drain the condensatefrom the oil compartment.

CAUTION

The kerosene drain plug must be closed again afterthe drying process to ensure that no oil from thediverter switch oil compartment can flow into thetransformer tank!

37

8 mm

8 mm

CoatingKHW 831-4

8.1.2.1Drying in the autoclave

NOTE

When drying in the autoclave remove the tap-changerhead cover first and store it outside the vacuumautoclave.

• Heating upby admitting the kerosene vapor at a temperature ofabout 90°C. Keep this temperature constant for 3 to4 hours.

• Dryingby increasing the kerosene vapor temperature byabout 10°C per hour to the desired final temperaturewith not more than 125 °C applied to the on-load tap-changer. The duration of the drying procedure isnormally 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 tap-changer head cover remains closed during the entiredrying process. The tap-changer head cover is vacuum-proof. To ensure sufficient drying of the interior of thediverter switch oil compartment and of the diverterswitch unit connect a common tube of at least 50 mmwidth between the vapor lead and two connectingflanges of the tap-changer head leading into the oilcompartment.

Use flanges Q and R for OLTCs type R. (For position ofconnecting flanges see section 9 and 16, dwg. 893 899).

Procedure, temperature and duration of the dryingprocess are described in item 8.1.2.1.

8.1.3 Operating the OLTC

The on-load tap-changer must not be operated beforethe diverter switch oil compartment has been filled withoil and the tap selector has been completely immersedin the transformer oil.

CAUTION

Do not operate the on-load tap-changer without oilafter dryingotherwise bearings and gaskets will bedamaged.

NOTE

Do not continue turning the kerosene drain plugbeyond the point where it starts moving tightly.

20 119/06 EN

NOTE

The relay serial number must be the same as that ofthe on-load tap-changer.

The relay must be mounted in horizontal position andas near to the tap-changer head as possible.

The arrow on the relay should point towards the oilconservator when mounted.

The pipe to the oil conservator must be installed withan inclination of at least 2%.

8 Drying procedure and filling with oil9 Pipe connections

8.2 Filling with oil

CAUTION

The tap-changer oil compartment and the associatedoil conservator must only be filled with new mineralinsulating oil for transformers according to IEC 296.The use of other oil affects the trouble-free operationof on-load tap-changer and transformer.

Place the cover on the tap-changer head. Tighten all24 cover bolts M10 (wrench size 17, max. torque 34Nm).

On-load tap-changer and transformer are filled simul-taneously with new oil under vacuum.

For this purpose use pipe connection S or R. To eva-cuate, a by-pass tube between connections E2 and Q isto be installed in order to apply vacuum to both diverterswitch oil compartment and transformer tank simultane-ously.

9 Pipe connections

The tap-changer head is provided with 3 pipe connec-tions for different purposes. After loosening the thrustcollar (4 bolts M10, w.s. 17) these pipe connections canbe swivelled (see fig. 38 and appendix, dwg. 893 899).

9.1 Pipe connection R forprotective relay RS 2001

The mounting of the protective relay RS 2001 (seesection 16, dimension drawing 892 608) is pursuant toour Operating Instructions No. 59.

9.2 Pipe connections S for suction pipe

This is the connection for the feeding pipe of a sta-tionary oil filter. If there is no filter, the pipe connectionshould be provided with a pipe with a drain cock easilyaccessible on one side of the transformer tank.

9.3 Pipe connection Q(special design, required forstationary oil filter only)

This is the pipe connection for the return pipe of astationary oil filter.If no oil filter is provided, a dummy plug is mountedinstead 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 directlybeneath the tap-changer head.

If necessary, it may be connected to the gas accumulat-ing tube for the Buchholz relay.

SR

E2

Q

38 KHW 805-4

21119/06 EN

You may find comprehensive mounting instructions inour Operating Instructions No. 138 for motor drive ED.

10 Mounting the motor drive unit,the bevel gear and the drive shaft

10Mounting the motor drive unit, the bevel gear and the drive shaft

10.1 Mounting the motor drive unit (seeappendix, dwg. 898 801, 898 802)

NOTE

Serial number of motor drive unit and on-load tap-changer must be identical (nameplate).

Motor drive unit and on-load tap-changer must be inthe same operating position. The adjustment positionis indicated in the connection diagram supplied withthe equipment.

The motor drive unit must be mounted at the providedplace on the transformer tank in a vertical positionand protected against excessive transformervibrations.

NOTE

Make sure that bevel gear serial number and on-loadtap-changer serial number are identical.

The horizontal drive shaft must be in proper alignmentwith 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). Afteradjusting the upper gear unit, the thrust collar must bere-tightened (max. torque 15 Nm).Tab-lock the screws.

In case of bevel gears in special design andintermediate bearings of the vertical or horizontaldrive shaft above instructions apply analogously.

10.2 Mounting the bevel gear

The bevel gear is to be attached to a support on thetransformer cover by means of 2 bolts (through-holes18 mm dia., see section 16, drawing 892 916).

39 KHW 767-4

The drive shaft must be assembled according to ourOperating Instructions No. 42. The drive shaft is themechanical connection between the motor drive and thetap changer head.The bevel gear diverts the driving force from the verticalto the horizontal direction.

Accordingly, the vertical part of the drive shaft is to bemounted between motor drive unit and bevel gear,whereas the horizontal part of the drive shaft is to bemounted between bevel gear and tap-changer head.

The drive shaft itself consists of a square tube and is tobe connected on both ends to the respective equipmentby two coupling brackets and one coupling bolt.

Square shafts, coupling brackets, coupling bolts,screws, nuts and lock tabs are made of corrosion-proofsteel. We recommend, however, to apply the sameoutside coating here as to the transformer tank.

The square shafts and the guard plate for the footstepprotection for the horizontal drive shaft at the trans-former cover are supplied in oversize (various standardlengths).These parts must be cut to the required size beforemounting.

Finally equalize the rotation lag between on-load tap-changer and motor drive unit (according to OperatingInstructions No.138 for ED).

10.3 Mounting the drive shaft

NOTE

When mounting the drive shaft make sure that theshaft ends to be connected are aligned properly.

22 119/06 EN

10 Mounting the motor drive unit, the bevel gear and the drive shaft11 Putting the OLTC into operation in the transformer factory

OLTCs 3 x R I 2002 ... 3600

The following procedure is also recommended forOLTC R III 1200.

Due to the special arrangement of the tap-changerphases in three columns, the horizontal drive shaft mustbe mounted between the three tap-changer headsabove the tank cover. Since a swivelling of the uppergear unit will initiate a switching action, make sure thatthe adjustment position of the diverter switch is re-gained after the alignment of the gear units.

For this purpose proceed as follows:

1. Check that the operating positions of all columnsare identical (tap-changer head, inspection window). Each one of the one-phase OLTCs must bein the adjustment position.

2. Turn the upper gear unit of the tap-changer headsinto the desired installation position and fix them

there (tighten thrust collars and tab-lock thescrews).

Take note of the arrow on the drive shaft flangebelow the punched serial number. The direction ofthe arrow indicates the rotation sense when crank-ing the motor drive clockwise and must be identicalon all gear units.

3. Operate the tap-changer poles separately by onestep by rotating the trunnions counter-clockwiseuntil the diverter switch operates once.

Check coincidence of operating positions of alltap-changer heads.

4. Mount the horizontal drive shaft between the tap-changer heads.

5. Return the OLTC set, that is all tap-changerpoles together, into the adjustment position.Theadjustment position is reached by turning the driveshaft in clockwise direction.

Check simultaneous operation of all diverterswitches.

Check coincidence of position of all tap-changer heads and the motor drive unit.

6. Mount the vertical drive shaft.

CAUTION

The supervisory control must be installed accordingto the connection diagram of the relevant motor driveunit. Incorrect installation will cause damage of bothon-load tap-changer and transformer in case ofmalfunction.

11 Putting the OLTC into operation inthe transformer factory

11.1 Operational tests

Before applying voltage to the transformer check themechanical operation of on-load tap-changer and motordrive.

For these test operations the on-load tap-changer hasto be run through the complete operating cycle.

Make sure that in each operating position the indi-cators of motor drive and on-load tap-changer (tap-changer head) read the same position.

Make sure that in both end positions the electrical andmechanical limit stops function automatically (seeOperating Instructions No. 138 for ED).

CAUTION

Misalignment between on-load tap-changer andmotor drive unit exists, if on-load tap-changer andmotor drive unit show different operating positions.Misalignment of coupling between on-load tap-changer and motor drive unit leads to severe damageof on-load tap-changer and transformer, if operationis continued. The transformer must not be taken inoperation.

11.2 Final oil filling

Fill up the on-load tap-changer completely with trans-former oil via the oil conservator and evacuate.

• Bleed the tap-changer head via the bleeder valve inthe head cover (E1):Remove screw cap M30/w.s. 36 (fig. 40), lift valvetappet by means of a screw driver.

• Bleed the suction pipe (S) via the bleeder screw ofthe elbow: cap nut M16 (w.s. 22, max. torque 9 Nm),slotted bleeder screw M6 (max. torque 2 Nm,fig. 41).

CAUTION

Make sure that the suction pipe has been bledcompletely. The insulation capability of the on-loadtap-changer to ground is otherwise significallyimpaired.

23119/06 EN

11Putting the OLTC into operation in the transformer factory

40 KHW 773-4

41 KHW 811-4

Connect the ground screws (2 screws M12 with nuts,w.s. 19, max. torque 60 Nm, fig. 42) of the tap-changerhead to the transformer cover.

Connect the ground screw (M12, w.s. 19, max. torque60 Nm) of the motor drive housing to the transformertank.

11.4 Electrical transformer tests

After the afore mentioned steps the necessary electricalacceptance tests of the transformer can be performed.

42 KHW 811-4

11.3 Ground connections

24 119/06 EN

12 Transport to the operating site13 Putting into service at the operating site

12 Transport to the operating site

If the transformer is to be transported without the motordrive unit, set the motor drive to the adjustment positionand uncouple.

To remount the motor drive unit follow the instructionsaccording to section 10.1 and 10.3.

Install this by-pass tube between pipe connections E2and Q of the tap-changer head.For short time conditions of 2 to 4 weeks without oilconservator, lower the oil level by approx. 5 litres.

If the transformer is to be transported or stored withoutoil filling, drain the oil of the on-load tap-changer com-pletely.

The interior of the on-load tap-changer should beconserved and protected in the same way as thetransformer itself (nitrogen-sealing).

If a prolonged stand-by period is expected, the heater ofthe motor drive unit must be connected to the suitablepower supply.

13 Putting into service at the operatingsite

Before putting the transformer into service, operationaltests of on-load tap-changer and motor drive have to beperformed according to section 11.1. At the same timecheck the function of the protective relay. Loop insignaling contact for undershooting the minimum oillevel in the on-load tap-changer oil conservator in theon-load tap-changer tripping circuit.

Make sure that the circuit breakers switching off thetransformer operate when the test push button »OFF«is pressed. Be sure that they energize the transformeronly after push button »IN SERVICE« of the protectiverelay has been pressed.

After the transformer has been energized, tap-changeoperations under load can be performed. Gas accumu-lating under the cover of the tap-changer head willcause minor oil displacement and/or escape via the oilconservator.

CAUTION

Do not operate the motor drive unit while the on-loadtap-changer is uncoupled.

NOTE

If the transformer is filled with oil but stored or trans-ported without oil conservator, a bypass tube must beinstalled between the interior of the tap changer andthe transformer tank to compensate the staticpressure caused by expansion of oil.

NOTE

The protective relay has to be inserted into the trip-ping circuit of the circuit breakers so that energiza-tion of the protective relay switches off the trans-former immediately (see Operating InstructionsNo. 59 for protective relay RS 2001).

CAUTION

Check whether all stop valves between oilconservator and tap-changer head are open.

25119/06 EN

Supervision during service, failures 14

14 Supervision during service, failures

It is only necessary to inspect the tap-changer head, theprotective relay and the motor drive unit occasionally.

Pay special attention to:

• oil tightness of sealings of the tap-changer head, theprotective relay and the pipe connections,

• sealings at the motor drive housing,

• proper function of the electrical space heater insidethe motor drive unit,

• the condition of the control devices in the motor driveunit.

In case of serious trouble with on-load tap-changer ormotor drive – provided that the repair cannot easily bedone at site and in case of a tripping of the protectiverelay please contact the authorized MR representative,the transformer manufacturer or directly

NOTE

Damage to the on-load tap-changer due to notenough oil in the oil conservator of the on-load tap-changer!Actuation of the on-load tap-changer with too little oilin the on-load tap-changer’s oil conservator maycause damage to the on-load tap-changer!Make sure that the contact for signaling the fallingbelow the minimum oil level in the on-load tap-changer’s oil conservator was looped through to thetripping circuit of the circuit-breaker and that thecircuit-breaker will immediately de-energize thetransformer when the oil has fallen below thisminimum oil level in the oil conservator.

WARNING

If the protective relay operates, do not reset until theon-load tap-changer and the transformer have beenchecked. For this purpose also withdraw the diverterswitch unit and check it according to our InspectionInstructions. Proceed in detail according to ourOperating Instructions No. 59 for the protective relayRS 2001.

Before returning to energized operation, make surethat the cause of the trouble has been corrected andthat the on-load tap-changer and the transformer arefree of damage.

Never reconnect the transformer without priorchecking. Continued operation of the on-load tapchanger can result in severe damage of on-load tap-changer and transformer.

Maschinenfabrik Reinhausen GmbHTechnical ServicePostfach 12 03 60D-93025 RegensburgPhone: (+49) 9 41 / 40 90-0Telefax: (+49) 9 41 / 40 90-5 01Telex: 65881

26 119/06 EN

15 Inspections

In general, the inspection can be carried out byqualified and MR-trained personnel within one day,provided it is well prepared and organized.

We strongly recommend to have inspections performedby our Technical Service. This guarantees a professio-nal performance including all the latest updatingmeasures.

Inquire for spare parts when preparing an inspectionwhich will not be carried out by MR personnel (pleaseindicate OLTC number and number of operations).

The number of tap-change operations determining theinspection intervals indicated in table II and table III arefigures based on experience with oil qualities normallyused.

The tap selector of the on-load tap-changer is generallymaintenance-free. In special cases, however, if OLTCsare used in industrial transformers where high operatingnumbers are to be expected, our technical servicedepartment must be contacted after about 1,000,000operations. The diverter switch insert of the OLTC is tobe 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 filterinsert (see Operating Instructions No. 18) is recommen-ded. The use of our oil filter plant type OF100 withcombination filter insert is obligatory for OLTC type Rwith insulation to ground Um < 245 kV.

Filtering of switching oil allows to extend the inspectionintervals.

The user should regularly test the transformer insulatingoil according to the relevant standards.

If inspection has not been performed by MR-personnel,please give us your report for data collecting purposes.

NOTE

The tap-changing equipment must be inspected atregular intervals to maintain a high level of operatingreliability.

Inspections15

27119/06 EN

15Inspections

CAUTION

Inspections of the tap-changer equipment are obliga-tory. Disregarding the inspection intervals endangersthe trouble-free operation of on-load tap- changer andtransformer.

Standard values for oil testing according to CIGRE report 12-13 (1982) applying to transformer oil at servicetemperature:

*) 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 Number of tap-change operationsrated current without MR oil filter with oil filter

R III 1200 up to 600 A 80 000 100 000up to 1200 A 60 000 100 000

R I 1201 up to 600 A 80 000 100 000up to 1200 A 60 000 100 000

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 onwhat is reached first.

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

28 119/06 EN

15 Inspections16 Appendix

Table III Inspection intervals for one-phase OLTCs type R with Um ³ 245 kV and used in autotransformersor 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) afterevery 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

On-load tap-changer Transformer Number of tap-change operationsrarted current without MR oil filter with MR oil filter

R I 1201 up to 600 A 40 000 50 000up to 1200 A 30 000 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

29119/06 EN

16Appendix

896 705:5EOn-load tap-changer type RInstallation drawing

11 Mounting flange on transformer cover12 Fixing bolt M1213 Gasket for tap-changer head14 Position indicator15 Inspection window16 Drive shaft for position indicator17 Through-hole 15 mm dia.

21 Tap-changer head22 Bolt for tap-changer head cover23 Gasket for tap-changer head cover24 Tap changer head cover25 Centric gear unit with drive shaft 25a26 Pipe connection R for protective relay27 Pipe connection S for suction pipe28 Pipe connection Q for return pipe

(with oil filter only)29a Bleeder valve of tap-changer head cover29b Bleeding facility for transformer oil29c Bleeder screw for suction pipe

31 Diverter switch oil compartment32 Bottom of oil compartment33 Grading ring (with Um = 170/245 kV)34 Terminal of diverter switch oil compartment35 Tap-changer take-off terminal (with R III 1200 neutral)36 Suction pipe

41 Suspension of tap selector42 Tap selector gear43 Fine tap selector44 Change-over selector45 Tap selector terminals.

see corresponding dimension drawing46 Change-over selector terminals.

see corresponding dimension drawing48 Connecting lead for tap selector48a Holding strip for 48

51 Diverter switch unit52 Supporting cylinder53 Gear plate54 Fixing bolt55 Lifting Lug56 Transition resistors

Tap selector drive side

Flatsurface

Protectiverelay

Take-offterminal

See also variants of tap selectorbottom 896 702 provide sufficient

clearance!Transformer tank bottom

max

. w

ithdr

awal

hei

ght 1

750

mm

30 119/06 EN

16Appendix

896 706:5EOn-load tap-changer type R

Bridges for parallel connection of tap selector terminalsfor OLTCs R I 2002, R I 3000

(not applicable in case of enforced current splitting)

31119/06 EN

16Appendix

893 899:9EOn-load tap-changers type MS, M, T, RTap-changer head

16Thickness

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)

S = Connection for suction pipe Connections orientable

R = Connection for protective relay (exchangeble with connection Q) through 360°

= Earth connection M12

Connection flangefor Q, S, R

O-Ring44.2 - 5.7

Tap selector drive side

width ofgasket

Detail at A

32 119/06 EN

16Appendix

890 183:6EOn-load tap-changers type MS, M, T, RDrilling template

3 thick

Marks to be pounded

33119/06 EN

896 762:6EOn-load tap-changer type RSpecial design for installation into bell-type tank

Lifting device

Suction pipe

Drilling hole representedin the sectional plane

Supporting flange

Grading ring withUm170/245/300 kV only

Level traverse

Gasket

Z = Guiding pin

Level traverse

O-Ring 44.2 - 5.7

Transformer cover

Tap selector drive side

16Appendix

34 119/06 EN

16Appendix

890 180:3EOn-load tap-changer type RLifting traverse

Sheet steelSt 37-2 DIN 17 100

35119/06 EN

890 182:7EOn-load tap-changer type MS, M, T, R

Socket wrench for kerosene draining screw

Item-No. 014 820 Item-No. 017 660

Socket wrench L = 1350 mm L = 1860 mm

To be used Type M (except MΔ) M III 350/600Δfor OLTC Typ MS Type T, R, G

16Appendix

36 119/06 EN

16Appendix

Inspectionwindow

Identification label

Gasket

Gasket

Cable glandPG 16

Test push buttonsIN SERVICE OFF

(reset) (test tripping)

The arrow must always point towards the oil pipe leadingto the oil conservator of the transformer.

Plan view of test push buttons(cover removed)

1)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 correspondingcircuit breakers.

Sta

ndar

d de

sign

Spe

cial

des

ign

agai

nst s

urch

arge

0.65 - NO1 1.2 - NO A

3.0 - NO4.8 - NO

0.65 - NC2 1.2 - NC B

3.0 - NC4.8 - NC

0.65 - CO3 1.2 - CO C

3.0 - CO4.8 - CO

0.65 - 2NO4 1.2 - 2NO 2 A

3.0 - 2NO4.8 - 2NO

0.65 - 2NC5 1.2 - 2NC 2 B

3.0 - 2NC4.8 - 2NC

0.65 - NO + NC6 1.2 - NO + NC 1 A & 1 B

3.0 - NO + NC4.8 - NO + NC

Key of variants

Variant Arrangement of terminalsRelay designation1)

Contact positions

In service OffDesign

Protective Relay RS 2001899 084:0E

(STANDARD)

Metal - dummy plug PG 16

Reedcontact

37119/06 EN

Vertical guardplate with

spacing ring Hand crank

Wall of transformer tank

3 dummy plates for packing glandsspecial design with OLTCmonitoring required

Shim

Attachment ofprotective housing

ca. 690 if opened 130°ca. 864 if opened 180°

The cover can be openedto the left or to the rightdepending on the arrange-ment of the hinge pins.

Aperture of fixing holes on protective housing(rear view)

Aperture in protective housing for cables(underside view)

* for design withintermediate

bearing

Motor Drive ED-S898 801:2E

Protective Housing

16Appendix

38 119/06 EN

16Appendix

Motor Drive ED-L898 802:2E

Protective Housing

Vertical guard platewith spacing ring Hand

crank

Wall of transformer tank

3 dummy plates for packingglandsspecial design with OLTCmonitoring required

Shim

Attachment of protectivehousing

ca. 690 if opened 130°ca. 864 if opened 180°

The cover can be openedto the left or to the rightdepending on the arrange-ment of the hinge pins.

Aperture of fixing holes on protective housing(rear view)

Aperture in protective housing for cables(underside view)

* for design withintermediate

bearing

39119/06 EN

Bevel gear CD 6400892 916:6E

Dimension drawing

e 1 =

205

for

stan

dard

des

ign

e 2 =

215

for

desi

gn w

ith b

all j

oint

16Appendix

www.reinhausen.com

© Maschinenfabrik Reinhausen GmbHPostfach 12 03 60

D-93025 Regensburg

BA 119/06 EN • 02/11 • F0002203 • Printed in Germany

Telefon: (+49) 9 41 / 40 90-0Telefax: (+49) 9 41 / 40 90-111Telex: 65881