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MR OILTAP R, Installation And Commissioning Instructions

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MR OILTAP R Installation And Commissioning Instructions Download Page 173

8 Commissioning the transformer at the operating site

Maschinenfabrik Reinhausen GmbH 2015

173

4427410/00 EN

OILTAP® R

1.

Ground the transformer on the high-voltage and low-voltage sides. En-
sure that the working ground connection on the transformer is not re-
moved during testing.

2.

Ensure that transformer remains de-energized during testing.

3.

Deactivate the automatic fire extinguishing device.

4.

Remove the cover cap.

5.

Activate the sensor on the snap-action switch.

ð

Sensor is in the OFF position.

6.

Leave the transformer's danger zone.

7.

Ensure that the transformer's circuit breaker cannot be closed.

ð

Passive protection test

8.

Activate the sensor on the snap-action switch.

ð

Sensor is in the OPERATION position

9.

Leave the transformer's danger zone.

10. Close the transformer's circuit breaker with isolating switches open and

the transformer grounded on all sides.

11. Activate the sensor on the snap-action switch.

ð

Sensor is in the OFF position.

12. Ensure that the transformer's circuit breaker is open.

ð

Active protection test.

13. Activate the sensor on the snap-action switch to reset the pressure

monitoring device.

ð

Sensor is in the OPERATION position

14. Secure the cover cap.

 

Filling the oil compartment of the on-load tap-changer with
oil

 WARNING

Danger of death or severe injury!

Danger of death or severe injury from explosive gases under the on-load
tap-changer head cover, in the pipework system, in the oil conservator or at
the dehydrating breather opening!
► Ensure that there are no naked flames, hot surfaces or sparks (for ex-

ample caused by static charging) in the immediate surroundings and
that none occur.

8.4

Summary of Contents for OILTAP R

Page 1: ...On Load Tap Changer OILTAP R Installation and Commissioning Instructions 4427410 00 EN ...

Page 2: ... for compensation All rights reserved in the event of the granting of patents utility models or designs The product may have been altered since this document was published We reserve the right to change the technical data design and scope of supply Generally the information provided and agreements made when processing the individual quotations and orders are binding The original operating instruct...

Page 3: ...te use 12 2 3 Inappropriate use 13 2 4 Personnel qualification 13 2 5 Operator s duty of care 13 2 6 Personal protective equipment 14 2 7 Protective devices 15 2 7 1 Protective relay RS 15 2 7 2 Pressure monitoring device 15 2 7 3 Rupture disk 16 2 7 4 Pressure relief device MPreC 16 2 7 5 Tap change supervisory control 16 2 7 6 Temperature monitoring 16 3 Product description 17 3 1 Scope of deliv...

Page 4: ...transformer 36 5 2 1 Fastening on load tap changer to transformer cover 36 5 2 2 Connecting tap winding and on load tap changer take off lead 44 5 2 3 Carrying out the transformer ratio test 48 5 2 4 Measuring DC resistance on transformer 51 5 2 5 Drying on load tap changer in autoclave 51 5 2 6 Drying on load tap changer in transformer tank 54 5 3 Installing the on load tap changer in the transfo...

Page 5: ...tap changer 164 6 3 Performing tests on motor drive unit 165 6 4 Performing trial tap change operations 165 6 5 High voltage tests on the transformer 166 7 Transporting transformer to the operating site 168 7 1 Transport with removed drive 168 7 2 Transport with oil fill and without oil conservator 168 7 3 Transport without oil fill 169 7 3 1 Emptying oil compartment via pipe connection S 169 8 Co...

Page 6: ...ectric strength and water content of on load tap changer oil 189 11 2 OILTAP R installation drawing for selector size C D 896705 190 11 3 OILTAP R installation drawing for selector size E 897873 191 11 4 OILTAP R R I 2002 2003 C D R I 3003 C D bridges for parallel connection of selector plane 896706 192 11 5 OILTAP R R I 2002 2003 E R I 3003 E bridges for parallel connection of selector plane 8987...

Page 7: ...nd on the delivery docu ments OILTAP R type on load tap changer RS protective relay Pressure monitoring device DW 2000 optional Drive shaft Manufacturer The product is manufactured by Maschinenfabrik Reinhausen GmbH Falkensteinstraße 8 93059 Regensburg Germany Tel 49 9 41 40 90 0 Fax 49 9 41 40 90 7001 E mail sales reinhausen com Further information on the product and copies of this technical file...

Page 8: ...ical data Product specific section available on request Also observe generally valid legislation standards and guidelines as well as specifications on accident prevention and environmental protection in the re spective country of use Safekeeping This technical file and all supporting documents must be kept ready at hand and accessible for future use at all times Notation conventions This section c...

Page 9: ...se a saw Hose clip Wire eyelet safety wire Use a screwdriver Table 1 Symbols Hazard communication system Warnings in this technical file are displayed as follows Warning relating to section Warnings relating to sections refer to entire chapters or sections sub sec tions or several paragraphs within this technical file Warnings relating to sections use the following format 1 6 2 1 6 2 1 ...

Page 10: ...words and pictograms The following signal words are used Signal word Meaning DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in injury NOTICE Indicates measures to be taken t...

Page 11: ...P R Pictogram Meaning Warning of danger of tipping Table 3 Pictograms used in warning notices Information system Information is designed to simplify and improve understanding of particular procedures In this technical file it is laid out as follows Important information 1 6 3 ...

Page 12: ...ered appropriate use Only operate the product in accordance with this technical file and the agreed delivery conditions and technical data Use the equipment and special tools supplied solely for the intended purpose and in accordance with the specifications of this technical file Use the product only with the transformer specified in the order You will find the standard valid for the product and t...

Page 13: ... Unauthorized or inappropriate changes to the product may lead to per sonal injury material damage and operational faults Only modify prod uct following discussion with Maschinenfabrik Reinhausen GmbH Personnel qualification The product is designed solely for use in electrical energy systems and facili ties operated by appropriately trained staff This staff comprises people who are familiar with t...

Page 14: ...ng of the product may only be carried out by qualified and trained personnel in accordance with this technical file The operator must ensure appropriate use of the product Personal protective equipment Personal protective equipment must be worn during work to minimize risks to health Always wear the personal protective equipment required for the job at hand Follow information about personal protec...

Page 15: ...ble as options Protective relay RS The protective relay RS is an oil flow controlled relay in accordance with IEC 60214 1 It is installed between the on load tap changer head and the oil conservator of the on load tap changer It triggers when the specified oil flow between oil compartment of the on load tap changer and oil conservator is exceeded Pressure monitoring device The pressure monitoring ...

Page 16: ...k MR will supply a pre fitted pressure relief device MPreC that responds to a defined overpressure in the oil com partment of the on load tap changer The on load tap changer therefore meets the requirements of IEC 60214 1 regarding pressure relief devices Tap change supervisory control The tap change supervisory control monitors both the drive shaft between on load tap changer s and motor drive un...

Page 17: ...eness on the basis of the shipping docu ments Store the parts in a dry place until installation The product must remain in its airtight protective wrapping and may on ly be removed immediately before installation You will find more information in the Packaging transport and storage 30 chapter On load tap changer Function description On load tap changers are used to adjust the transmission ratio of...

Page 18: ...zontal drive shaft 10 Active part Setup versions The on load tap changer consists of the on load tap changer head oil com partment with built in diverter switch insert and the tap selector mounted be low also available with change over selector on request The design and designation of the most important on load tap changer com ponents are shown in the installation drawings in the appendix For the ...

Page 19: ...compartment 4 Change over selector Pipe connections The on load tap changer head features 4 pipe connections for different pur poses Depending on the order some or all of these pipe connections are fitted with pipe bends ex factory All pipe bends without terminal box for the tap change supervisory control can be freely swiveled once the pressure ring is loos ened 3 2 2 1 ...

Page 20: ...ger is fitted with an oil suc tion pipe the on load tap changer can be completely emptied via pipe con nection S Pipe connection R Pipe connection R is provided for the attachment of the protective relay and the connection of the on load tap changer oil conservator and can be inter changed with pipe connection Q Pipe connection E2 The pipe connection E2 is closed with a blank cover It leads into t...

Page 21: ...el gear changes the direction from vertical to horizontal see drawing 892916 Accordingly the vertical drive shaft has to be mounted between drive and bevel gear and the horizontal drive shaft between bevel gear and on load tap changer or off circuit tap changer Setup models of drive shaft The drive shaft consists of a square tube and is coupled by two coupling brackets and one coupling bolt at bot...

Page 22: ...ration V 1 min mm Intermediate bearing for mm Middle of hand crank middle of bevel gear maximum per missible axial offset 2 536 V 1 2 472 Drive shaft without cardan shaft with insulator special model Figure 6 Drive shaft without cardan shaft with insulator special model Configuration V 1 min mm Intermediate bearing for mm Middle of hand crank middle of bevel gear maximum per missible axial offset ...

Page 23: ... V 1 min mm Intermediate bearing for mm Middle of hand crank middle of bevel gear maximum per missible axial offset alpha 20 798 V 1 2 564 Drive shaft with cardan shaft with insulator special model Figure 8 Drive shaft with cardan shaft with insulator special model Configuration V 1 min mm Intermediate bearing for mm Middle of hand crank middle of bevel gear maximum per missible axial offset alpha...

Page 24: ...ic switch is thereby actuated the circuit breakers are tripped and the transformer is de energized The protective relay is part of an oil insulated on load tap changer and its properties conform to the applicable valid version of IEC publication 60214 1 Therefore it is part of the scope of our delivery Diverter switch operations at rated switching capacity or at permissible over load will not caus...

Page 25: ...hinenfabrik Reinhausen GmbH 2015 25 4427410 00 EN OILTAP R Figure 10 RS 2001 1 Dummy plug 3 Ventilation for terminal box 2 Identification plate The protective relay RS 2001 R has an extra inspection window on the rear Rear view ...

Page 26: ...test tripping test button The protective relay RS 2003 and RS 2004 has a 1 2 14NPT adapter in place of the cable connection position 7 Pressure monitoring device DW Function description The DW 2000 pressure operated relay protects the on load tap changer from unacceptable pressure increases contributing to the safety of the transformer The pressure operated relay is installed on the outside of the...

Page 27: ...lay responds faster than the RS 2001 protective re lay in relation to large pressure increases The RS 2001 protective relay is part of the default MR protection system that comes standard Additional use of a pressure operated relay also requires installation of the provided RS 2001 protective relay The features and characteristics of the pressure operated relay comply with the respective applicabl...

Page 28: ...measuring element 1 Snap action switch 2 Pressure measuring element The snap action switch has a normally open switch and normally closed switch with snap action During operation the snap action switch and pressure measuring element are protected by a cover cap Ventilation is provided on the top of the pres sure operated relay ...

Page 29: ...metal OF 100 Oil Filter Unit Along with the paper filter insert the purpose of the OF 100 oil filter unit is to clean the on load tap changer s insulating oil and with the combined filter in sert to clean and dry it If the number of tap change operations per year is 15 000 or higher we rec ommend the use of the OF 100 oil filter unit with paper filter insert The main tenance intervals can therefor...

Page 30: ...nd fully functional means of transportation in compliance with local transportation laws and regulations The packaged goods are packed in a stable crate This crate ensures that when in the intended transportation position the packaged goods are stabi lized to prevent impermissible changes in position and that none of the parts touch the loading surface of the means of transport or touch the ground...

Page 31: ...elivery slip External damage of any type The checks must take place after unloading when the crate or transport con tainer can be accessed from all sides If external transport damage is detected on receipt of the shipment proceed as follows Immediately record the transport damage found in the shipping docu ments and have this countersigned by the carrier In the event of severe damage total loss or...

Page 32: ...ged goods dried by Maschinenfabrik Reinhausen from the sealed packaging and store air tight in dry insulating oil until used Non dried packaged goods Non dried packaged goods but with a functional sealed packaging can be stored outdoors when the following conditions are complied with When selecting and setting up the storage location ensure the following Protect stored goods against moisture flood...

Page 33: ...kaged crate to the place where installation will take place Do not open the sealed packaging until just before instal lation If this is not done damage to the packaged goods may occur due to ineffectively sealed packaging WARNING When unpacking check the condition of the packaged goods Secure packaged goods in an upright crate from tipping out If this is not done the packaged goods may be damaged ...

Page 34: ...p change operations Do not reach into the selector or change over selector during tap change operations Do not switch the on load tap changer when working on the selector and change over selector This chapter describes how to install the on load tap changer in a transform er and how to dry it Installation in both a standard version transformer and a bell type tank transformer is described Regardle...

Page 35: ...must comply with the installation drawings in the appendix NOTICE Fit mounting flange on transformer cover pressure tight En sure that the sealing face makes complete contact and is not damaged Figure 14 Mounting flange Fitting stud bolts on mounting flange To attach the stud bolts to the mounting flange use a tracing template This can be provided upon request free of charge for the initial instal...

Page 36: ...der to install the on load tap changer in the transformer standard version Fastening on load tap changer to transformer cover This chapter describes how to fasten the on load tap changer to the trans former cover Fastening oil compartment on transformer cover 1 CAUTION Place the oil compartment on a level surface and secure it against tipping An unstably positioned oil compartment may tip over res...

Page 37: ...27410 00 EN OILTAP R 2 Remove red colored packaging material and transport material from oil compartment 3 Clean sealing surfaces on mounting flange and on load tap changer head place oil resistant gasket on mounting flange Figure 16 Sealing surfaces seal ...

Page 38: ... up the on load tap chang er head and carefully lower the oil compartment into the cover opening of the transformer When lowering take care not to damage the screen ing rings only present if Um 170 kV Figure 17 Oil compartment 5 Check that the on load tap changer head is mounted in the position specified by the design ...

Page 39: ...ead with mounting flange 7 Remove the blocking device from the coupling of the oil compartment base Figure 19 Blocking plate and shackle Securing selector on oil compartment selector size C D 1 CAUTION Place the selector on a level surface and secure it against tipping An unstably positioned selector may tip resulting in seri ous injuries and damage 5 2 1 2 ...

Page 40: ... bag with fastening materials from the selector and keep them ready Figure 20 Plastic bag with fastening materials 4 Remove the blocking strip from the selector coupling Once the blocking strip is removed the selector coupling must no longer be turned Figure 21 Blocking strip 5 Place the selector on the lifting device The weight of the selector is a maximum of 270 kg ...

Page 41: ...the oil compartment and do not touch the compartment If this is not done the selector take off leads may be damaged 8 Align the position of both coupling parts and attachment points on the oil compartment and the selector with one another The correct position of the two coupling parts is shown in the adjustment plans in the appendix 9 Screw selector onto oil compartment Figure 23 Selector with oil...

Page 42: ...d damage 2 Remove red colored packaging material and transport material from se lector 3 Remove plastic bag with fastening materials from the selector and keep them ready Figure 24 Plastic bag with fastening materials 4 Remove the blocking strip from the selector coupling Once the blocking strip is removed the selector coupling must no longer be turned Figure 25 Blocking strip 5 Place the selector...

Page 43: ...e when lifting the selector on the oil compartment and do not touch the compartment If this is not done the selector take off leads may be damaged 8 Align the position of both coupling parts and attachment points on the oil compartment and the selector with one another The correct position of the two coupling parts is shown in the adjustment plans in the appendix 9 Screw selector onto oil compartm...

Page 44: ...ger take off lead NOTICE Damage to the on load tap changer Connecting leads which place mechanical strain on the on load tap changer will damage the on load tap changer Produce connections with care Do not twist connection contacts Connect connecting leads without warping or deforming If necessary use an expansion loop for connecting leads Fit screening caps provided to screw connections Connect t...

Page 45: ...change over selector connection contacts are designed like tap selector connection contacts for reversing change over selector connec tions The change over selector connection contacts 0 are produced as ter minal lugs of the crimped connecting lead 0 K with a through hole for M12 screws The screening caps are supplied separately Figure 30 Change over selector connection contacts for reversing chan...

Page 46: ...screws The screening caps are supplied separately Figure 31 Change over selector connection contacts for coarse change over selec tor connection Tap selector connection contacts and change over selector connection contacts for selector size E The tap selector connection contacts and change over selector connection contacts are labeled on the selector bars The connection is made at the thread stud ...

Page 47: ...ads must be at least 25 mm Figure 33 Screening caps Bridges for parallel connection of selector planes If bridges for the parallel connection of selector planes are needed for tech nical reasons or have been ordered the selector is supplied with the bridges and screening caps already fitted Detailed information about the bridges is available in the appendix Also refer to 2 OILTAP R R I 2002 2003 E...

Page 48: ...nnect the on load tap changer take off lead 1 Connect the on load tap changer take off lead to any through hole on the take off ring of the oil compartment 2 Secure screw connection Figure 34 Take off ring on oil compartment Carrying out the transformer ratio test We recommend carrying out a transformer ratio test before the transformer is dried The following types of transformer ratio test are po...

Page 49: ... insert must be removed the kerosene drain plug in the oil compartment closed and the diverter switch insert refitted In order to run the transformer ratio test we recommend using the TAPMOTION TD test drive The precise process is described in the test drive operating instructions Carrying out the transformer ratio test manually NOTICE Damage to the on load tap changer Performing too many operatio...

Page 50: ...ation can be heard distinctly 2 NOTICE After operating the diverter switch continue to crank 2 5 revo lutions in the same direction on the drive shaft of the upper gear unit in order to correctly end the tap change operation An incomplete tap change operation may damage the on load tap changer When actuating the change over selector a higher torque is required 3 NOTICE Carry out the transformer ra...

Page 51: ...sured transformer winding in order to prevent the winding from overheating Measure the DC resistance in the various on load tap changer operating po sitions You need to distinguish here whether the measured current is inter rupted when changing operating position or not Without interruption in measured current With interruption measured current 0 A before change in operating position Oil compartme...

Page 52: ...ccessories and store outside autoclave motor drive unit drive shaft protective relay pressure moni toring device pressure relief device bevel gear temperature sensor oil filter unit If this is not done the on load tap changer accessories may be damaged Vacuum drying in the autoclave 1 Heat up the on load tap changer in air at atmospheric pressure with a temperature increase of about 10 C h to a fi...

Page 53: ...aged 3 NOTICE Remove on load tap changer accessories motor drive unit drive shaft protective relay pressure monitoring device pressure relief device bevel gear temperature sensor oil filter unit and store outside autoclave If this is not done the on load tap changer accessories may be damaged Vapor phase drying in the autoclave 1 Supply kerosene vapor at a temperature of around 90 C Keep this temp...

Page 54: ...ponding pipe connections and seal off the pipe connections not being used with blank covers The on load tap changer head cover remains closed during the entire drying process 1 Establish a connecting lead either between connections E2 and Q or connections E2 and R on the on load tap changer head 2 Seal off unused pipe connections with a suitable blank cover Figure 38 Connecting lead Vacuum drying ...

Page 55: ...r switch insert open the kerosene drain plug and then in stall the diverter switch insert again After the drying process you have to re move the diverter switch insert again to close the kerosene drain plug If you have already opened the kerosene drain plug in the transformer for vapor phase drying in the transformer tank when installing the on load tap changer you can start the drying operation d...

Page 56: ...arks caused by impact wrench Only use conductive and grounded hoses pipes and pump equipment that are approved for flammable liquids NOTICE Damage to the on load tap changer and transformer Small parts in the oil compartment may block the diverter switch insert thereby damaging the on load tap changer and transformer Take care to avoid parts falling into the oil compartment Check that you have the...

Page 57: ...re 41 On load tap changer head cover 4 NOTICE Do not expose the open oil compartment to ambient humidity for more than 10 hours If you do this may result in damage to the on load tap changer and transformer due to insufficient dielectric strength of the diverter switch oil Removing the tap position indicator Pull the spring clip off the shaft end and remove the tap position indica tor disk Figure ...

Page 58: ...ry control NOTICE Damage to on load tap changer resulting from defective tap change supervisory control Disconnecting the tap change supervisory control without due care may damage it thereby resulting in damage to the on load tap changer and transformer Disconnect tap change supervisory control with care in order not to damage or rip out the connecting leads 1 Lift plug connector and leads out of...

Page 59: ...aged when pulling out the diverter switch insert Figure 46 Swiveling out part A of plug connector Lifting out diverter switch insert 1 Loosen bolts and safety elements on carrier plate of diverter switch in sert NOTICE Make sure that parts do not fall into the oil compartment Parts in the oil compartment may block the diverter switch insert there by damaging the on load tap changer and transformer...

Page 60: ... position vertically above the diverter switch insert Figure 48 Brackets on carrier plate 3 Lift out the diverter switch insert slowly and vertically Figure 49 Lifting out diverter switch insert 4 CAUTION Place the diverter switch insert on a level surface and se cure it against tipping An unstably positioned diverter switch insert may tip resulting in injuries and damage ...

Page 61: ... get hard to turn Never unscrew the kerosene drain plug all the way Figure 50 Kerosene drain plug Inserting diverter switch insert Proceed as follows to insert the diverter switch insert Inserting diverter switch insert 1 To fit the diverter switch insert ensure that the selector coupling and in dicator gear are in the adjustment position Figure 51 Adjustment position 5 2 6 2 2 5 2 6 2 3 5 2 6 2 3...

Page 62: ...nsert the lifting gear in the brackets provided on the diverter switch in sert carrier plate and position vertically above the diverter switch insert Figure 52 Brackets on carrier plate 3 Ensure that the red triangles on the coupling and carrier plate match up Figure 53 Coupling ...

Page 63: ...the red triangles at the top of the energy accumulator and on the on load tap changer head are opposite one another Figure 54 Aligning diverter switch insert 5 Slowly lower diverter switch insert 6 Secure carrier plate of diverter switch insert with bolts and safety ele ments Carrier plate of diverter switch insert ...

Page 64: ...B of plug connector 2 Connecting plug connector Figure 56 Connecting plug connector 3 Place plug connector in bracket secure leads on both sides of plug con nector in retaining clamps Figure 57 Placing plug connector in bracket Inserting the tap position indicator Due to the coupling pin the tap position indicator disk can only be installed when in the correct position 5 2 6 2 3 2 5 2 6 2 3 3 ...

Page 65: ...he on load tap changer head cover on the on load tap changer head and take care not to damage the o ring inserted in the on load tap changer head cover A damaged o ring will cause oil to escape from the diverter switch oil compartment resulting in on load tap chang er damage Also ensure that the red triangular marks on the on load tap changer head and the on load tap changer head cover match up Fi...

Page 66: ...red lead Vapor phase drying in the transformer tank 1 Supply kerosene vapor at a temperature of around 90 C Keep this temperature constant for 3 to 4 hours 2 Increase the kerosene vapor temperature by approx 10 C hour to the desired final temperature 125 C maximum on the on load tap chang er 3 Vacuum dry on load tap changer at between 105 C and maximum 125 C for at least 50 hours 4 Residual pressu...

Page 67: ...ting structure Proceed as follows to insert the on load tap changer in the supporting struc ture Securing selector on oil compartment selector size C D 1 CAUTION Place the selector on a level surface and secure it against tipping An unstably positioned selector may tip resulting in seri ous injuries and damage 2 Remove red colored packaging material and transport material from se lector 3 Remove p...

Page 68: ...Remove the blocking strip from the selector coupling Once the blocking strip is removed the selector coupling must no longer be turned Figure 64 Blocking strip 6 CAUTION Place the oil compartment on a level surface and secure it against tipping An unstably positioned oil compartment may tip over resulting in serious injuries and damage ...

Page 69: ...ocking device on the coupling of the oil compartment base Figure 65 Blocking plate and shackle 8 Carefully raise oil compartment above selector 9 Align the position of both coupling parts and attachment points on the oil compartment and the selector with one another The correct position of the two coupling parts is shown in the adjustment plans in the appendix ...

Page 70: ...selector size E 1 CAUTION Place the selector on a level surface and secure it against tipping An unstably positioned selector may tip resulting in seri ous injuries and damage 2 Remove red colored packaging material and transport material from se lector 3 Remove plastic bag with fastening materials from the selector and keep them ready Figure 67 Plastic bag with fastening materials 5 3 1 2 ...

Page 71: ...Remove the blocking strip from the selector coupling Once the blocking strip is removed the selector coupling must no longer be turned Figure 69 Blocking strip 6 NOTICE Place the oil compartment on a level surface and secure it against tipping An unstably positioned oil compartment may tip over re sulting in serious injuries and damage ...

Page 72: ...l compartment base Figure 70 Blocking plate and shackle 8 Carefully raise oil compartment above selector 9 Align the position of both coupling parts and attachment points on the oil compartment and the selector with one another The correct position of the two coupling parts is shown in the adjustment plans in the appendix 10 Screw selector onto oil compartment Figure 71 Selector with oil compartme...

Page 73: ... to the on load tap changer and transformer 2 Attach screening caps to screw connection Figure 72 Tap selector take off lead Inserting on load tap changer into supporting structure 1 NOTICE Using spacers insert on load tap changer vertically into sup porting structure maximum 1 deviation from the vertical so that the on load tap changer reaches its final installation height and only has to be rais...

Page 74: ... There is also a risk of malfunctions from se lector contacts closing incorrectly Figure 73 On load tap changer with spacers on supporting structure 2 Remove red supports on selector base if present 3 Temporarily fasten on load tap changer to supporting structure The supporting flange has through holes for this purpose Figure 74 Fastening the on load tap changer ...

Page 75: ...d in accordance with the connection diagram included with the delivery Tap selector connection contacts for selector size C D The tap selector connection contacts are provided with a through hole for M12 screws The screening caps are supplied separately Figure 75 Tap selector connection contacts Change over selector connection contacts for reversing change over selector connection for selector siz...

Page 76: ...ed connecting lead K with a through hole for M12 screws The screening caps are supplied separately Figure 77 Change over selector connection contacts for coarse change over selec tor connection Tap selector connection contacts and change over selector connection contacts for selector size E The tap selector connection contacts and change over selector connection contacts are labeled on the selecto...

Page 77: ...ads must be at least 25 mm Figure 79 Screening caps Bridges for parallel connection of selector planes If bridges for the parallel connection of selector planes are needed for tech nical reasons or have been ordered the selector is supplied with the bridges and screening caps already fitted Detailed information about the bridges is available in the appendix Also refer to 2 OILTAP R R I 2002 2003 E...

Page 78: ...nnect the on load tap changer take off lead 1 Connect the on load tap changer take off lead to any through hole on the take off ring of the oil compartment 2 Secure screw connection Figure 80 Take off ring on oil compartment Carrying out the transformer ratio test We recommend carrying out a transformer ratio test before the transformer is dried The following types of transformer ratio test are po...

Page 79: ... insert must be removed the kerosene drain plug in the oil compartment closed and the diverter switch insert refitted In order to run the transformer ratio test we recommend using the TAPMOTION TD test drive The precise process is described in the test drive operating instructions Carrying out the transformer ratio test manually NOTICE Damage to the on load tap changer Performing too many operatio...

Page 80: ...ation can be heard distinctly 2 NOTICE After operating the diverter switch continue to crank 2 5 revo lutions in the same direction on the drive shaft of the upper gear unit in order to correctly end the tap change operation An incomplete tap change operation may damage the on load tap changer When actuating the change over selector a higher torque is required 3 NOTICE Carry out the transformer ra...

Page 81: ...sured transformer winding in order to prevent the winding from overheating Measure the DC resistance in the various on load tap changer operating po sitions You need to distinguish here whether the measured current is inter rupted when changing operating position or not Without interruption in measured current With interruption measured current 0 A before change in operating position Oil compartme...

Page 82: ...ccessories and store outside autoclave motor drive unit drive shaft protective relay pressure moni toring device pressure relief device bevel gear temperature sensor oil filter unit If this is not done the on load tap changer accessories may be damaged Vacuum drying in the autoclave 1 Heat up the on load tap changer in air at atmospheric pressure with a temperature increase of about 10 C h to a fi...

Page 83: ...aged 3 NOTICE Remove on load tap changer accessories motor drive unit drive shaft protective relay pressure monitoring device pressure relief device bevel gear temperature sensor oil filter unit and store outside autoclave If this is not done the on load tap changer accessories may be damaged Vapor phase drying in the autoclave 1 Supply kerosene vapor at a temperature of around 90 C Keep this temp...

Page 84: ... remov ing the on load tap changer head cover Do not operate any electric devices during the work for example risk of sparks caused by impact wrench Only use conductive and grounded hoses pipes and pump equipment that are approved for flammable liquids NOTICE Damage to the on load tap changer and transformer Small parts in the oil compartment may block the diverter switch insert thereby damaging t...

Page 85: ... load tap changer head are in sound condition when removing and during all other work Ensure that o ring is in sound condition too Damaged seal ing surfaces lead to oil escaping and therefore to on load tap changer and transformer damage Figure 86 On load tap changer head cover 5 NOTICE Do not expose the open oil compartment to ambient humidity for more than 10 hours If you do this may result in d...

Page 86: ...ases under the on load tap changer head cover Ensure that there is no supply voltage on the tap change supervisory control NOTICE Damage to on load tap changer resulting from defective tap change supervisory control Disconnecting the tap change supervisory control without due care may damage it thereby resulting in damage to the on load tap changer and transformer Disconnect tap change supervisory...

Page 87: ... Swivel part A of plug connector out of on load tap changer head in di rection indicated by arrow until it is between the pipe connections and the cable cannot be damaged when pulling out the diverter switch insert Figure 91 Swiveling out part A of plug connector Lifting out diverter switch insert 1 Loosen nuts and safety elements on carrier plate of diverter switch in sert NOTICE Make sure that p...

Page 88: ...ing the on load tap changer and transformer Check that you have the same number of parts when removing and installing Figure 92 Carrier plate of diverter switch insert 2 Insert the lifting gear in the brackets provided on the diverter switch in sert carrier plate and position vertically above the diverter switch insert Figure 93 Brackets on carrier plate ...

Page 89: ...sert 4 CAUTION Place the diverter switch insert on a level surface and se cure it against tipping An unstably positioned diverter switch insert may tip resulting in injuries and damage Removing the oil suction pipe Pull the connecting piece of the oil suction pipe in the on load tap changer head inwards and out Pay attention to the O ring Figure 95 Oil suction pipe 5 3 6 5 ...

Page 90: ...r head and supporting flange Figure 96 On load tap changer head 2 Lift on load tap changer head off supporting flange Figure 97 On load tap changer head Attaching bell type tank and connecting on load tap changer head with on load tap changer The following chapters explain how to attach the bell type tank and connect the on load tap changer head with the on load tap changer 5 3 6 6 5 3 7 ...

Page 91: ...00 EN OILTAP R Mounting the bell type tank 1 Clean sealing surface of supporting flange place o ring on supporting flange Figure 98 Supporting flange with o ring 2 Lift the bell type tank over the active part of the transformer Figure 99 Bell type tank 5 3 7 1 ...

Page 92: ... 00 EN OILTAP R Mounting on load tap changer head on bell type tank 1 Clean sealing surfaces on mounting flange and on load tap changer head place oil resistant gasket on mounting flange Figure 100 Mounting flange with gasket 1 Gasket 2 Mounting flange 5 3 7 2 ...

Page 93: ...2015 93 4427410 00 EN OILTAP R 2 Position on load tap changer head on mounting flange such that the markings on the supporting flange and on load tap changer head match up Note fitted bolt on supporting flange Figure 101 Markings and fitted bolt ...

Page 94: ...crews from the supporting flange are used to lift the on load tap changer the screws may be damaged which makes it impossible to properly screw the on load tap changer and the on load tap changer head together Figure 102 On load tap changer head 2 Screw on load tap changer head to underlying supporting flange in the area marked red using nuts and securing elements Figure 103 On load tap changer he...

Page 95: ...to mounting flange Figure 104 Screwing on load tap changer head to the mounting flange Inserting oil suction pipe 1 Lightly grease the O rings of the oil suction pipe 2 Insert the oil suction pipe into the on load tap changer head Make sure the O rings are correctly fitted Figure 105 Oil suction pipe 5 3 7 4 ...

Page 96: ...r switch insert ensure that the selector coupling and in dicator gear are in the adjustment position Figure 106 Adjustment position 2 Insert the lifting gear in the brackets provided on the diverter switch in sert carrier plate and position vertically above the diverter switch insert Figure 107 Brackets on carrier plate 5 3 7 5 ...

Page 97: ...5 Mounting Maschinenfabrik Reinhausen GmbH 2015 97 4427410 00 EN OILTAP R 3 Ensure that the red triangles on the coupling and carrier plate match up Figure 108 Coupling ...

Page 98: ...d on the on load tap changer head are opposite one another Figure 109 Aligning diverter switch insert 5 Slowly lower diverter switch insert 6 Ensure correct position of carrier plate in on load tap changer head Area marked red must remain free 7 Secure carrier plate of diverter switch insert with nuts and safety ele ments Figure 110 Carrier plate of diverter switch insert ...

Page 99: ...rt B of plug connector 2 Connecting plug connector Figure 112 Connecting plug connector 3 Place plug connector in bracket secure leads on both sides of plug con nector in retaining clamps Figure 113 Placing plug connector in bracket Inserting the tap position indicator Due to the coupling pin the tap position indicator disk can only be installed when in the correct position 5 3 7 6 5 3 7 7 ...

Page 100: ...e the on load tap changer head cover on the on load tap changer head and take care not to damage the o ring inserted in the on load tap changer head cover A damaged o ring will cause oil to escape from the diverter switch oil compartment resulting in on load tap chang er damage Also ensure that the red triangular marks on the on load tap changer head and the on load tap changer head cover match up...

Page 101: ...mer tank first com plete transformer assembly and then undertake drying If drying in the transformer tank the following methods are possible Vacuum drying Vapor phase drying Vacuum drying in the transformer tank Before you start vacuum drying in the transformer tank you must place a connecting lead between the corresponding pipe connections and seal off the pipe connections not being used with bla...

Page 102: ...vapor phase drying in the transformer tank you have to open the kero sene drain plug before drying so that the kerosene condensate can drain from the oil compartment The kerosene drain plug is located in the oil compartment base and is not generally accessible from the outside For this reason you first have to re move the diverter switch insert open the kerosene drain plug and then in stall the di...

Page 103: ...nergize all auxiliary circuits for example tap change supervisory control pressure relief device pressure operated relays before remov ing the on load tap changer head cover Do not operate any electric devices during the work for example risk of sparks caused by impact wrench Only use conductive and grounded hoses pipes and pump equipment that are approved for flammable liquids NOTICE Damage to th...

Page 104: ...ad tap changer head cover and on load tap changer head are in sound condition when removing and during all other work Ensure that o ring is in sound condition too Damaged seal ing surfaces lead to oil escaping and therefore to on load tap changer and transformer damage Figure 120 On load tap changer head cover 4 NOTICE Do not expose the open oil compartment to ambient humidity for more than 10 hou...

Page 105: ... under the on load tap changer head cover Ensure that there is no supply voltage on the tap change supervisory control NOTICE Damage to on load tap changer resulting from defective tap change supervisory control Disconnecting the tap change supervisory control without due care may damage it thereby resulting in damage to the on load tap changer and transformer Disconnect tap change supervisory con...

Page 106: ...Swivel part A of plug connector out of on load tap changer head in di rection indicated by arrow until it is between the pipe connections and the cable cannot be damaged when pulling out the diverter switch insert Figure 125 Swiveling out part A of plug connector Lifting out diverter switch insert 1 Loosen nuts and safety elements on carrier plate of diverter switch in sert NOTICE Make sure that p...

Page 107: ...ng the on load tap changer and transformer Check that you have the same number of parts when removing and installing Figure 126 Carrier plate of diverter switch insert 2 Insert the lifting gear in the brackets provided on the diverter switch in sert carrier plate and position vertically above the diverter switch insert Figure 127 Brackets on carrier plate ...

Page 108: ...se cure it against tipping An unstably positioned diverter switch insert may tip resulting in injuries and damage Opening kerosene drain plug NOTICE Unscrew kerosene drain plug with extended socket wrench counter clockwise until it starts to get hard to turn Never unscrew the kerosene drain plug all the way Figure 129 Kerosene drain plug Inserting diverter switch insert Proceed as follows to inser...

Page 109: ...switch insert ensure that the selector coupling and in dicator gear are in the adjustment position Figure 130 Adjustment position 2 Insert the lifting gear in the brackets provided on the diverter switch in sert carrier plate and position vertically above the diverter switch insert Figure 131 Brackets on carrier plate 5 3 8 2 3 1 ...

Page 110: ...5 Mounting Maschinenfabrik Reinhausen GmbH 2015 110 4427410 00 EN OILTAP R 3 Ensure that the red triangles on the coupling and carrier plate match up Figure 132 Coupling ...

Page 111: ...d on the on load tap changer head are opposite one another Figure 133 Aligning diverter switch insert 5 Slowly lower diverter switch insert 6 Ensure correct position of carrier plate in on load tap changer head Area marked red must remain free 7 Secure carrier plate of diverter switch insert with nuts and safety ele ments Figure 134 Carrier plate of diverter switch insert ...

Page 112: ...B of plug connector 2 Connecting plug connector Figure 136 Connecting plug connector 3 Place plug connector in bracket secure leads on both sides of plug con nector in retaining clamps Figure 137 Placing plug connector in bracket Inserting the tap position indicator Due to the coupling pin the tap position indicator disk can only be installed when in the correct position 5 3 8 2 3 2 5 3 8 2 3 3 ...

Page 113: ...the on load tap changer head cover on the on load tap changer head and take care not to damage the o ring inserted in the on load tap changer head cover A damaged o ring will cause oil to escape from the diverter switch oil compartment resulting in on load tap chang er damage Also ensure that the red triangular marks on the on load tap changer head and the on load tap changer head cover match up F...

Page 114: ...hared lead Vapor phase drying in the transformer tank 1 Supply kerosene vapor at a temperature of around 90 C Keep this temperature constant for 3 to 4 hours 2 Increase the kerosene vapor temperature by approx 10 C hour to the desired final temperature 125 C maximum on the on load tap chang er 3 Vacuum dry on load tap changer at between 105 C and maximum 125 C for at least 50 hours 4 Residual pres...

Page 115: ...amount of humid ity is not absorbed from the surroundings When filling the oil compartment and its oil conservator use only new miner al insulating oil for transformers in accordance with IEC 60296 Specification for unused mineral insulating oils for transformers and switchgear 1 Establish a connecting lead between the pipe connection E2 and one of the pipe connections R S or Q to ensure equal pre...

Page 116: ... tap change supervisory control if installed DANGER Risk of fatal injury due to electrical voltage Danger of death due to electrical voltage when assembling and connecting the device De energize the device and system peripherals and lock them to pre vent them from being switched back on Connect monitoring contacts integrated into the on load tap changer head terminal box on pipe connection Q to th...

Page 117: ...and connected Checking function of protective relay Check the function of the protective relay before installing in piping between on load tap changer head and oil conservator 1 Open terminal box Figure 144 Protective relay with open terminal box NOTICE Damage to protective relay Damage to protective relay resulting from improper operation Never press both test buttons at the same time 5 5 2 5 5 2...

Page 118: ...5 118 4427410 00 EN OILTAP R 2 Press OFF test button ð Flap valve is inclined Line marker appears in the middle of the in spection window Figure 145 OFF position 3 Press IN SERVICE test button ð Flap valve is vertical Figure 146 In service position ...

Page 119: ...r to install the protective relay in the piping The pipes from the protective relay to the oil conservator must be routed with an inclination of at least 2 to ensure the switching gases can es cape freely The inner piping diameter must be at least 25 mm The magnetic field strength bushings busbars etc must be 20 kA m Install protective relay with good support and free from vibrations The test butt...

Page 120: ...n GmbH 2015 120 4427410 00 EN OILTAP R Install protective relay such that it can be easily accessed for subse quent maintenance work Figure 148 Piping with inclination of at least 2 Figure 149 Protective relay with test button at the top ...

Page 121: ... s oil conser vator 1 Install the protective relay horizontally in the pipe between on load tap changer head and oil conservator as near as possible to the on load tap changer head taking the above points into consideration 2 Provide a stop cock nominal width of at least 25 mm between protec tive relay and oil conservator Figure 151 Stop cock ...

Page 122: ...s either an NC or NO contact Other contact equipment can be sup plied as special versions and is shown in the dimensional drawing provided 1 Insert cable connection RS 2001 2001 V 2001 H 2001 E 2001 5 2001 R or adapter RS 2003 und RS 2004 in the tapped hole which seems to be in the most favorable position Figure 152 Cable bushing 2 Seal open tapped hole with MR dummy plug Figure 153 Dummy plug 5 5...

Page 123: ...5 Mounting Maschinenfabrik Reinhausen GmbH 2015 123 4427410 00 EN OILTAP R 3 Open terminal box Figure 154 Terminal box ...

Page 124: ...5 Mounting Maschinenfabrik Reinhausen GmbH 2015 124 4427410 00 EN OILTAP R 4 Loosen screw remove terminal box cover and take off protective cover Figure 155 Terminal box cover and protective cover ...

Page 125: ...ger of death and severe injury due to unprofessional electrical connec tion of protective relay Connect the protective relay into the tripping circuit of the circuit break ers of the transformer to be protected so that the transformer is immedi ately disconnected by the circuit breakers when the protective relay is tripped Systems which only generate an alarm message are not permitted 6 Connect el...

Page 126: ...ting Maschinenfabrik Reinhausen GmbH 2015 126 4427410 00 EN OILTAP R 7 Connect protective conductor to cylinder head screw Figure 158 Protective conductor 8 Insert protective cover Figure 159 Protective cover ...

Page 127: ...5 Mounting Maschinenfabrik Reinhausen GmbH 2015 127 4427410 00 EN OILTAP R 9 Secure terminal box cover Figure 160 Terminal box cover ...

Page 128: ... connecting the pressure operated relay Checking the function of the pressure operated relay Check the function of the pressure operated relay before you install it on a pipe bend or the on load tap changer head 1 Remove the cover cap 2 Activate the snap action switch ð Sensor is in the OFF position above the snap action switch 5 5 3 5 5 3 1 ...

Page 129: ...k Reinhausen GmbH 2015 129 4427410 00 EN OILTAP R Figure 162 OFF position 1 Snap action switch 2 Sensor in OFF position 3 Activate the snap action switch again ð Sensor is in the OPERATION position below the snap action switch ...

Page 130: ...lled in 2 variants Fastening on the on load tap changer head vertical installation Fastening onto a pipe bend horizontal installation It is installed using holes on the mounting ring A mounting seal has to be installed under the pressure operated relay during installation During fastening ensure that the ventilation is on top Ensure that there is sufficient space above the pressure operated relay ...

Page 131: ...ove the cover cap 2 Insert a M25x1 5 cable gland Use the tapped hole for routing lines for this 3 Connect the lines to the terminals of the snap action switch The snap action switch is designed as a normally open and normally closed switch it flips after being triggered and can be reset 4 Connect all of the electrical lines and the protective conductor Either 1 or 2 lines can be connected per term...

Page 132: ... of the surrounding transformer oil of between 25 and 105 C and with overload up to 115 C in accordance with IEC 60214 1 Observe the following during mounting NOTICE Damage to drive and on load tap changer or off circuit tap changer Trouble free operation of the motor drive and the on load tap changer or off circuit tap changer cannot be guaranteed The shaft ends to be connected must be exactly al...

Page 133: ...tor drive unit with intermedi ate bearing Fitting horizontal drive shaft Aligning upper gear unit on the on load tap changer head In order to correctly install the horizontal drive shaft under certain circum stances you may have to first align the upper gear unit such that the horizon tal drive shaft is flush with the shaft end of the upper gear unit Proceed as follows 1 NOTICE Make sure the oil c...

Page 134: ... gear unit drive shaft Never turn upper gear unit directly around its own axis to align it Figure 165 Aligning gear unit 4 Swivel pressure ring segments back towards gear unit and tighten screws Ensure that the spring washer is between the screw head and pressure ring segment and that the pressure ring segments are firmly in contact with the gear unit housing Figure 166 Securing pressure ring segm...

Page 135: ...gear unit and shaft end of bevel gear and shorten square tube to length A 9 mm Figure 167 Shortening square tube 2 Calculate inside width B between housings of upper gear unit and bevel gear Cut protective cover LSB length of protective cover accordingly and deburr the cutting surface Protect protective cover against corro sion with a coat of paint Figure 168 Shortening deburring and coating prote...

Page 136: ... loosely screwed together coupling part onto square tube until stop is reached Figure 169 Sliding coupling part onto square tube 4 Grease coupling bolt Fit coupling bolt onto bevel gear and slide square tube with coupling part over it Figure 170 Attaching coupling part to bevel gear ...

Page 137: ...R 5 Mount horizontal drive shaft on bevel gear Figure 171 Mounting horizontal drive shaft on bevel gear 6 Grease coupling bolts and coupling brackets for upper gear unit Mount coupling brackets on upper gear unit Figure 172 Mounting horizontal drive shaft on upper gear unit ...

Page 138: ...h shortened protective cover to housing lugs on the on load tap changer head and bevel gear Secure each end of protective cover with a hose clip Figure 173 Fitting protective cover 8 If using a bearing block or angle gear attach caps to the protective cov er Figure 174 Bearing block caps ...

Page 139: ... tap changer may be damaged when aligning the upper gear unit 4 Swivel pressure segments back towards gear unit and tighten screws 15 Nm tightening torque Ensure that the spring washer is between the screw head and pressure ring segment and that the pressure ring seg ments are firmly in contact with the gear unit housing 5 Note arrow on drive shaft flange under the stamped serial number The direct...

Page 140: ...tion continue cranking another 2 5 revolutions clockwise on the drive shaft of the up per gear unit to correctly complete the tap change operation 11 Check operation of all on load tap changers A slight time delay is per mitted 12 Check that the operating positions of all on load tap changer heads are the same 13 Fit vertical drive shaft Fitting vertical drive shaft Couple drive shaft with motor d...

Page 141: ...5 141 4427410 00 EN OILTAP R To fit the vertical drive shaft to the drive proceed as follows 1 Grease the coupling bolts coupling brackets and ball heads e g ISO FLEX TOPAS L 32 Figure 176 Grease the coupling bolts coupling brackets and ball heads ...

Page 142: ...410 00 EN OILTAP R 2 Determine dimension A between the shaft end of the drive and the shaft end of the bevel gear Shorten square tube to length of A 9 mm Figure 177 Shortening square tube 3 Deburr cut surface of square tube Figure 178 Deburring cut surfaces ...

Page 143: ...pling part onto square tube until stop is reached Figure 179 Sliding coupling part onto square tube 5 Insert coupling bolt into lower shaft end Grease coupling parts and cou pling bolts Slide square tube with coupling part on to coupling bolt Figure 180 Sliding square tube with coupling part on to coupling bolt ...

Page 144: ...ft on drive 7 Pivot square tube with coupling part Figure 182 Pivoting square tube 8 When installing inner tube of telescopic protective tube if necessary shorten on side without slits The minimum dimension for overlapping the two protective tubes is 100 mm Inner tube must not be deformed and must be deburred in order to slide easily in the outer tube ...

Page 145: ... 183 Deburring inner tube Dimension A distance be tween the shaft end of the drive and the shaft end of the bevel gear Inner tube Outer tube 170 mm 190 mm Shorten to 200 mm 200 mm 191 mm 1130 mm Dimension A 20 mm 200 mm 1131 mm 1598 mm 700 mm 1150 mm 1599 mm 2009 mm 1150 mm 1150 mm ...

Page 146: ...ttom Slide telescopic protective tubes onto square tube Then slide hose clips over telescopic protective tubes Figure 184 Sliding on telescopic protective tube 10 Place adapter ring over bearing collar of bevel gear and slide upwards Push in coupling bolt Swing square tube in Figure 185 Fitting adapter ring and coupling bolt ...

Page 147: ... on bevel gear Set a unilateral ax ial clearance of 3 mm between the coupling bolt and upper coupling piece To prepare for alignment tighten screws to approx 6 Nm After aligning on load tap changer to drive see MR operating instructions for TAPMOTION ED tighten screws to 9 Nm Figure 186 Mounting coupling brackets ...

Page 148: ...tive tube Figure 187 Mounting protective tube Fitting drive shaft with cardan joints NOTICE Damage to drive shaft Damage to expansion bellows from bending cardan joint Ensure a matching position of the opposing cardan joint straps Installation of the drive shaft with cardan joints is mainly designed as a verti cal drive shaft between motor drive unit and bevel gear Technically a hori zontal design...

Page 149: ...5 Mounting Maschinenfabrik Reinhausen GmbH 2015 149 4427410 00 EN OILTAP R Figure 188 Drive shaft with cardan joint ...

Page 150: ...015 150 4427410 00 EN OILTAP R To fit the drive shaft with cardan joints proceed as follows 1 Grease the coupling bolts coupling brackets and ball heads e g ISO FLEX TOPAS L 32 Figure 189 Grease the coupling bolts coupling brackets and ball heads ...

Page 151: ...esponding angle Figure 190 Inserting adapter in pivotable protective tubes 3 When supplied the cardan joints are fitted with coupling bolts To mount on the shaft end the following steps must be taken Remove hose clip Slide up expansion bellows Remove coupling bolt Slide cardan joint over device s output shaft Push in coupling bolt Slide expansion bellows over this Secure expansion bellows with hos...

Page 152: ... Fitting cardan joint to ball shaped head of motor drive unit 5 Fit second longer cardan joint to bevel gear If a cardan joint is attached to the upper gear unit then use a cardan joint with an inner hub diameter of 25 mm Figure 193 Fitting second cardan joint on bevel gear 6 Secure cardan shaft bolt to expansion bellows with hose clip Figure 194 Securing cardan shaft bolt with hose clip ...

Page 153: ... Mounting Maschinenfabrik Reinhausen GmbH 2015 153 4427410 00 EN OILTAP R 7 Provisionally connect loose shaft ends of the joints to an angle bar and align Figure 195 Connecting shaft ends with angle bar ...

Page 154: ...brik Reinhausen GmbH 2015 154 4427410 00 EN OILTAP R 8 Determine dimension A between the shaft ends Cut square tube to LR A 106 mm LR length of square tube Deburr cut surface of square tube Figure 196 Shortening square tube ...

Page 155: ...ing shorten both telescopic tubes to dimension A 2 120 mm A dimension between both cardan joint ends and de burr Figure 197 Shortening telescopic tubes 10 Fit one adapter to bearing collar of motor drive unit and fit other adapter to bearing collar of bevel gear Figure 198 Fitting adapters ...

Page 156: ...y shortened and deburred square tube over upper cardan joint end until stop is reached Figure 199 Sliding square tube over upper cardan joint end 12 Thread upper flexible protective tube with long outlet up onto square tube from below Figure 200 Sliding flexible protective tube over square tube ...

Page 157: ...EN OILTAP R 13 Thread on outer and inner tubes such that the slotted sides of the outer and inner tube are both facing down Figure 201 Sliding on telescopic tubes 14 Slide everything up and secure with a screw clamp Figure 202 Securing everything with a screw clamp ...

Page 158: ...einhausen GmbH 2015 158 4427410 00 EN OILTAP R 15 Slide bottom flexible protective tube also with long outlet up on to the square tube and secure with screw clamp Figure 203 Sliding bottom flexible protective tube onto square tube ...

Page 159: ...e tube in 17 Tighten bottom coupling brackets Shaft end and coupling part must be securely connected such that no axial clearance remains between the coupling bolt and coupling bracket To prepare for alignment tighten screws to approx 6 Nm After aligning on load tap changer to drive see MR operating instructions for TAPMOTION ED tighten screws to 9 Nm ...

Page 160: ...e Figure 206 Fitting upper coupling brackets 19 Working from top to bottom mount the individual parts of the shaft pro tection Set angle position between both parts of pivotable protective tube and fix with available hose clip Secure both upper and lower pro tective tubes with a hose clip at both ends Secure the two telescopic protective tubes to one another using a hose clip ...

Page 161: ... by the width of the adapter before tightening the hose clips Figure 207 Securing telescopic pipes and flexible protective tubes with hose clips Fitting drive shaft with insulator A model with insulator in the vertical drive shaft is available for insulating in stallation of the drive shaft Figure 208 Model with insulator maximum permissible offset 2 The insulator can also be used in connection wi...

Page 162: ...ffset 20 Centering on load tap changer and motor drive unit Center on load tap changer and motor drive unit as described in relevant MR operating instructions TAPMOTION ED Installing electrics for motor drive unit Install electrics for motor drive unit as described in relevant MR operating in structions TAPMOTION ED 5 5 7 5 5 8 ...

Page 163: ...p changer head and suction pipe Before first commissioning the on load tap changer head and the suction pipe on pipe connection S must be bled Bleeding on load tap changer head 1 Open all forward and return valves in the pipe system 2 Remove screw cap on air vent valve E1 on the on load tap changer head cover Figure 210 Screw cap 3 Use screwdriver to lift valve tappet on air vent valve E1 and blee...

Page 164: ...igure 212 Screw cap 2 NOTICE Open vent screw and bleed suction pipe Make sure the suc tion pipe is fully vented The insulation capability of the on load tap changer to ground will otherwise be significantly impaired 3 Close vent screw 4 Seal vent screw with screw cap Grounding the on load tap changer 1 Connect the grounding screw on the on load tap changer head to the transformer cover Figure 213 ...

Page 165: ...n relating to dielectric tests on transformer wiring in the associated MR operating instructions TAPMOTION ED Performing trial tap change operations Before energizing the transformer test tap change operations must be car ried out to check the mechanical functions of on load tap changer and mo tor drive unit NOTICE Damage to the on load tap changer Damage to the on load tap changer by actuating th...

Page 166: ...oil Only use conductive and grounded hoses pipes and pump equipment that are approved for flammable liquids Ensure that all the on load tap changer s safety equipment is ready for use Use suitable personal protective equipment clothing Keep away from the danger area during the transformer test Observe applicable fire protection regulations Make sure that only trained technicians perform work on th...

Page 167: ...eference earth Disconnect all electronic components before the high voltage test Be fore a wiring dielectric test remove all devices with a withstand voltage of 1 000 V Leads used for testing must be removed before the high voltage test as these function as antennas Wherever possible route the measurement and data leads separately from the energy cables Contact the manufacturer if you have any que...

Page 168: ... the on load tap changer are in the adjustment position 2 Remove the drive 3 Do not actuate drive while on load tap changer is not coupled and do not turn output shaft 4 Do not actuate an on load tap changer which is not coupled and do not turn its drive shaft 5 Transport drive to installation site in the MR delivery packaging 6 Fit drive and drive shaft to transformer at the operating site see pa...

Page 169: ...th or severe injury from explosive gases under the on load tap changer head cover Ensure that there are no naked flames hot surfaces or sparks for ex ample caused by static charging in the immediate surroundings and that none occur De energize all auxiliary circuits for example tap change supervisory control pressure relief device pressure operated relays before remov ing the on load tap changer h...

Page 170: ...nch size 17 with safety elements on on load tap changer head cover 7 Remove the on load tap changer head cover 8 Extract oil via pipe connection S 9 Open stop cock between oil conservator and oil compartment ð The oil from the oil conservator flows into the oil compartment 10 Extract oil via pipe connection S 11 Place the on load tap changer head cover on the on load tap changer head 12 Use 24 scr...

Page 171: ...missioning exceeds 8 weeks or opera tion is interrupted for longer than 2 weeks the heater must be connect ed and turned on to prevent the condensation of moisture inside the protective housing If this is not possible e g during transportation place a sufficient amount of dehydrating agent in the protective hous ing NOTICE Damage to the on load tap changer and motor drive unit Damage to on load ta...

Page 172: ...tion test 8 Press IN SERVICE test button 9 Leave the transformer s danger zone 10 Close the transformer s circuit breaker with isolating switches open and the transformer grounded on all sides 11 Press OFF test button 12 Ensure that the transformer s circuit breaker is open ð Active protection test 13 Press IN SERVICE test button to reset the protective relay Checking protective relay RS 2004 ü Ch...

Page 173: ...ion 9 Leave the transformer s danger zone 10 Close the transformer s circuit breaker with isolating switches open and the transformer grounded on all sides 11 Activate the sensor on the snap action switch ð Sensor is in the OFF position 12 Ensure that the transformer s circuit breaker is open ð Active protection test 13 Activate the sensor on the snap action switch to reset the pressure monitoring...

Page 174: ...nd the oil com partment completely filled with oil The on load tap changer can be operated in the temperature range of the surrounding transformer oil of between 25 and 105 C and with overload up to 115 C in accordance with IEC 60214 1 1 NOTICE Check whether the on load tap changer head cover has a flange for attaching a pressure relief device If it does operation without a pressure relief device ...

Page 175: ...inhausen GmbH 2015 175 4427410 00 EN OILTAP R 2 Establish a connecting lead between the pipe connection E2 and one of the pipe connections R S or Q to ensure equal pressure during evacua tion in the oil compartment and transformer Figure 216 Connecting lead between E2 and Q ...

Page 176: ...mple from oil compartment 5 Record temperature of oil sample just after sample is taken 6 Determine dielectric strength and water content at a diverter switch oil temperature of 20 C 5 C The dielectric strength and water content must comply with the limit values provided in the appendix Bleeding on load tap changer head and suction pipe Before first commissioning the on load tap changer head and t...

Page 177: ...410 00 EN OILTAP R 2 Remove screw cap on air vent valve E1 on the on load tap changer head cover Figure 218 Screw cap 3 Use screwdriver to lift valve tappet on air vent valve E1 and bleed on load tap changer head Figure 219 Valve tappet 4 Seal air vent valve E1 with screw cap tightening torque 10 Nm ...

Page 178: ...nctions of on load tap changer and mo tor drive unit NOTICE Damage to the on load tap changer Damage to the on load tap changer by actuating the on load tap changer without oil Before actuating the on load tap changer for the first time the tap se lector must be completely immersed in transformer oil and the oil com partment completely filled with oil The on load tap changer can be operated in the...

Page 179: ...d tap changer and oil conser vator of the on load tap changer are open 4 NOTICE Switch on transformer Once the transformer has been switched on ensure that the inrush current impulse has fully subsided before undertaking an on load tap change operation The inrush current impulses are usually a multiple of the transformer rated current and can overload the on load tap changer during the diverter sw...

Page 180: ...ctive devices can indicate dam age on the on load tap changer and transformer The transformer must not be energized without first undertaking checks Check on load tap changer and transformer when protective relay or other protective devices have been tripped Do not use the equipment again until you are sure there is no damage to the on load tap changer or transformer The table below is intended to...

Page 181: ...nce manual for the relevant on load tap changer Depending on the cause of tripping take measure ments carry out checks on the transformer Also contact MR Tripping of motor protective switch in motor drive unit Request Information sheet on motor protective switch tripping from MR complete and return to MR Tripping of signaling contact that indicates that the oil has fallen below the minimum oil lev...

Page 182: ...on load tap changer Table 10 Fault elimination Tripping of the protective relay and re commissioning the transformer WARNING Danger of death or severe injury Danger of death or severe injury if on load tap changer and transformer are insufficiently tested Be sure to check on load tap changer and transformer after the protec tive relay has been tripped The diverter switch insert or selector switch ...

Page 183: ...lve is in the OFF position proceed as follows 1 Ensure that the transformer is not started up under any circumstances 2 Remove and inspect diverter switch insert in accordance with corre sponding on load tap changer operating instructions 3 Contact Maschinenfabrik Reinhausen and inform them of the following Serial number of protective relay and on load tap changer What was the load of the transfor...

Page 184: ...f oil is leaking shut the oil conservator stop valve immediately 5 Check whether the pressure operated relay sensor is in the OFF posi tion or OPERATION position Sensor in the OPERATION position If the sensor is in the OPERATION position there may be an error in the trip ping circuit Check the tripping circuit in this case If the cause for the pres sure operated relay tripping cannot be ascertaine...

Page 185: ...tatic pressure on the pressure relief device height dif ference between the oil level in the on load tap changer oil conservator and the pressure relief device Re commissioning the transformer You can put the transformer back into operation after the cause for tripping the pressure operated relay has been determined and resolved 1 Ensure that the sensor on the snap action switch is in the OPERATIO...

Page 186: ...ypes when tripping oil temperature 20 C 0 65 m s 1 20 m s 3 00 m s 4 80 m s Table 11 General technical data Tripping circuit The protective relay can be supplied with either a normally open NO or a normally closed NC dry reed magnetic switch see dimensional drawing supplied Other contact combinations are available as special version Electrical data for normally open NO or normally closed NC dry re...

Page 187: ... magnetic switch AC switching capacity DC switching capacity 1 2 VA 200 VA 1 2 W 130 W Maximum admissible voltage AC DC Minimum admissible voltage AC DC 250 V 24 V Maximum switched current AC DC Minimum switched current AC DC 1 A 4 8 mA at 250 V Power frequency withstand voltage test Between all voltage carrying con nections and the grounded parts at least 2500 V 50 Hz test duration 1 minute Betwe...

Page 188: ...kg Equipment For standard insulating fluids IEC60296 and IEC60422 and alternative insulating fluids Sealing material oil air VITON Permitted pressure range absolute pressure 1 bar 6 bar vacuum not permitted Upper switching pres sure 3 8 0 2 bar trip pressure Lower switching pres sure 2 8 0 2 bar Snap action switch Connection terminals Line connection 1 or 2 lines per terminal Ø 0 75 2 5 mm Contact...

Page 189: ... OILTAP on load tap changers The values have been established on the basis of IEC 60422 Ud H2O When commissioning the trans former for the first time 60 kV 2 5 mm 12 ppm During operation 30 kV 2 5 mm 40 ppm After maintenance 50 kV 2 5 mm 15 ppm Table 15 Limit values for on load tap changer oil in neutral point applications Ud H2O When commissioning the trans former for the first time 60 kV 2 5 mm ...

Page 190: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 190 4427410 00 EN OILTAP R OILTAP R installation drawing for selector size C D 896705 11 2 ...

Page 191: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 191 4427410 00 EN OILTAP R OILTAP R installation drawing for selector size E 897873 11 3 ...

Page 192: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 192 4427410 00 EN OILTAP R OILTAP R R I 2002 2003 C D R I 3003 C D bridges for parallel connection of selector plane 896706 11 4 ...

Page 193: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 193 4427410 00 EN OILTAP R OILTAP R R I 2002 2003 E R I 3003 E bridges for parallel connection of selector plane 898713 11 5 ...

Page 194: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 194 4427410 00 EN OILTAP R OILTAP R on load tap changer head 893899 11 6 ...

Page 195: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 195 4427410 00 EN OILTAP R OILTAP R flange for pressure relief device 895168 11 7 ...

Page 196: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 196 4427410 00 EN OILTAP R Tracing template for on load tap changer head 890183 11 8 ...

Page 197: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 197 4427410 00 EN OILTAP R OILTAP R supporting flange for bell type tank installation up to Um 300 kV 896762 11 9 ...

Page 198: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 198 4427410 00 EN OILTAP R OILTAP R supporting flange for bell type tank installation up to Um 362 kV 725912 11 10 ...

Page 199: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 199 4427410 00 EN OILTAP R OILTAP R tap selector connection contacts and change over selector connection contacts for selector size E 897868 11 11 ...

Page 200: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 200 4427410 00 EN OILTAP R Lifting traverse for bell type tank installation 890180 11 12 ...

Page 201: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 201 4427410 00 EN OILTAP R Socket wrench for kerosene drain plug 890182 11 13 ...

Page 202: ...11 Appendix Maschinenfabrik Reinhausen GmbH 2015 202 4427410 00 EN OILTAP R Bevel gear CD 6400 dimensional drawing 892916 11 14 ...

Page 203: ...ct current Dielectric strength Material specific property of isolators kV 2 5 mm maximum electrical field strength without a breakdown arc IEC International Electrotechnical Commission IP Ingress protection MR Maschinenfabrik Reinhausen GmbH NC Normally Closed contact NO Normally Open contact NPT National Pipe Thread US thread standard ...

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