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
Top Related