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On-load tap-changer VACUTAP® VT
Operating Instructions BA 139/02
NOTE

Changes may have been made to a product after going to press with this documentation.
We expressly reserve the right to make changes to a product’s technical data and design as well as changes to
the scope of delivery.
In all cases, the information submitted and agreements concluded during processing of the quotation and order
in question shall be binding.
Contents

Contents

1 General ............................................................................................................................................................................................ 4
1.1 Safety instructions .......................................................................................................................................................... 4
1.2 Specified application ..................................................................................................................................................... 4

2 Structure/Design ......................................................................................................................................................................... 5

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

4 Installation of the on-load tap-changer ......................................................................................................................... 7

5 Installation of the motor-drive unit, bevel gear, and drive shafts ........................................................................ 7
5.1 Installation of the motor-drive unit (see appendix, dimension drawing 898801) ...................................... 7
5.2 Installation of the bevel gear ....................................................................................................................................... 7
5.3 Installation of the horizontal drive shaft (square-ended insulation shaft) .................................................... 8
5.4 Installation of the vertical drive shaft (square tube) ............................................................................................. 8

6 Connection of the tap winding and on-load tap-changer take-off lead .......................................................... 8

7 Commissioning of the on-load tap-changer at the transformer manufacturer´s site .................................. 9


7.1 Trial switching operation .............................................................................................................................................. 9
7.2 Ground connection ........................................................................................................................................................ 9
7.3 Electrical tests on the transformer ............................................................................................................................. 9

8 Transportation to the operating site ................................................................................................................................. 10

9 Commssioning at the operating site ................................................................................................................................... 10

10 Failures ............................................................................................................................................................................................ 10

11 Monitoring, cleaning and lubrication ................................................................................................................................ 10


11.1 Motor-drive unit ............................................................................................................................................................. 10
11.2 On-load tap-changer ..................................................................................................................................................... 10

12 Maintenance ................................................................................................................................................................................. 12

13 Appendix ........................................................................................................................................................................................ 13

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3
1 General

1 General

1.1 Safety instructions 1.2 Specified application


All personnel involved in installation, commissioning, opera-
tion, maintenance and repair of this equipment must:
- be suitably professionally qualified and CAUTION
- strictly observe these Operating Instructions.
Application of the on-load tap-changer shall be limited
Improper operation or misuse can lead to
solely and exclusively to the transformer indicated in the
- serious or fatal injury, underlying order.
- damage to the equipment and other property of the Installation, electrical connection and commissioning of the
user on-load tap-changer may only be carried out by qualified,
- a reduction in the efficiency of the equipment. skilled personnel and only in accordance with these
Safety instructions in this manual are presented in three Operating Instructions.
different forms to emphasize important information. It is the responsibility of the user to make sure that the on-
load tap-changer is used for the specific application only.
For safety reasons, any unauthorized and improperly exe-
WARNING cuted works, i.e. installation, modification, alteration of the
equipment, electrical connection, or commissioning of the
equipment, are forbidden without first consulting MR!
This information indicates particular danger to life and
health. Disregarding such a warning can lead to serious or The trouble-free operation of the drive unit, the on-load
tap-changer, and the transformer may be put at risk.
fatal injury.

CAUTION WARNING

This information indicates particular danger to the All relevant fire protection regulations must be strictly
equipment or other property of the user. Serious or fatal observed.
injury cannot be excluded.

NOTE

These notes give important information on a certain


subject.

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2 Structure/Design

2 Structure/Design

The air insulated on-load tap-changer VACUTAP® VT for in-


door installations serves for the uninterrupted adjustment of NOTE
the transformation ratio of the dry-type transformer under
load.
The minimum time distance of 1 min. between successive
switching operations as set in-house for the motor-drive
unit is absolutely compulsory.
WARNING The motor-drive unit appurtenant to the on-load tap-
changer group delivered is also set in-house in a manner
It is imperative to install the on-load tap-changer VACUTAP® ensuring compliance with this prerequisite. Do not to alter
VT in a manner which permits access to authorized personnel the settings of the corresponding monitoring time relays
only in order to protect it from misuse and prevent acci- incorporated in the motor-drive unit.
dental contact with freely accessible, live and movable
components.
To permit mechanical operation, the standard equipment of an
The user is responsible for implementing appropriate
on-load tap-changer includes a motor-drive unit which
measures for the reliable prevention of moisture conden-
operates in accordance with the well-known principle of step-
sation and icing on the on-load tap-changer.
by-step control. It contains all features required for local and
The on-load tap-changer has no protective housing. Indoor
remote control, for remote display of the operating position,
installation is mandatory according to environmental class
and an electrical as well as mechanical end position limiter.
E0 according to IEC 60076-11:2004.
Thanks to its protective housing the motor-drive unit can be
The max. installation height above sea level is 1000 m.
installed outdoors; for the encapsulated version of the dry-
type transformer the motor-drive unit can even be installed
The on-load tap-changer has been designed as a single-phase outside of the transformer housing.
module with direct assignment to one of the transformer limbs.
A motor-drive unit provides mechanical operation. A three-
pole 3 x VT I 500 system for star or delta connection can be
easily achieved by coupling several single-pole modules.
Given a linear voltage adjustment (by tap changing) for nine
service positions, the on-load tap-changer VACUTAP® VT
features a maximum rated through current of 500 A and a
maximum rated step voltage of 900 V. Its phase-to-earth
insulation corresponds to Um x 40,5 kV.
Each VACUTAP® VT module contains a compact-version tap
selector and diverter switch with high-speed resistor transition.
The movable tap selector contact system, the diverter switch
and the spring energy accumulator are combined in a single
switching element. This element is powered centrally by a
screw spindle. Vacuum interrupters serve as diverter switch
contact elements.

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3 Shipment

3 Shipment

Both the on-load tap-changer and motor-drive unit are shipped Motor-drive unit ED 100 S (approx. 80 kg), fig. 2.
in the adjustment position (see appendix, drawing 898613).
Vertical drive shaft (square tube) with coupling parts and
The on-load tap-changer equipment is shipped as follows: bevel gear (max. weight approx. 20 kg), fig. 3.
On-load tap-changerVACUTAP® VT Horizontal drive shafts (square-ended insulation shaft) with
1 x VT I 500 (approx 70 kg), coupling parts (approx. 15 kg max.), see appendix, drawing
3 x VT I 500 (approx 210 kg), 897975.
Fig. 1
The shipment is to be fully checked for completeness on the
basis of the shipping documents.
The on-load tap-changer and horizontal drive shafts must
remain packaged airtight in their protective wrapping and
must not be taken out except shortly prior to installation.

MR
NOTE

Drive shafts, bevel gear and coupling brackets are generally


packed with the on-load tap-changer.

WARNING

Be sure to provide safe storage and/or support for all items


of equipment while performing works to the on-load tap-
changer, motor-drive unit, or other components.
Otherwise there is a danger that individual items may tip
over accidentally.
1 KHW 920-4
This can result in serious , even lethal bodily injuries.

MR

2 KHW 914 3 KHW 1121-4

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4 Installation of the on-load tap-changer
5 Installation of the motor-drive unit, bevel gear, and drive shafts

4 Installation of the on-load tap- 5 Installation of the motor-drive


changer unit, bevel gear, and drive shafts
The on-load tap-changer modules shall be mounted to the 5.1 Installation of the motor-drive unit
transformer in the positions indicated (see appendix, drawing (see appendix, dimension drawing 898801)
898312). Installation of the on-load tap-changer housing
Detailed installation instructions can be found in our Opera-
shall be vertical, with the mounting bridge facing up. A mini-
ting Instructions no. 138 for the ED motor-drive unit.
mum distance of 100 mm shall be maintained between the tap
selector contacts and the transformer winding.
Also, sufficient safety clearance must be maintained between
the bottom bearing and the grounded parts of the transformer NOTE
and/or the bottom, respectively.
The serial number of the motor-drive unit must match the
serial number of the on-load tap-changer (nameplate).
CAUTION For coupling purposes, the motor-drive unit must be in the
same operating position as the on-load tap-changer.
The adjusted position of the on-load tap-changer is
The on-load tap-changer and bevel gear must be installed
indicated in the connection diagram included in the
in a manner ensuring perfect alignment of the horizontal
delivery.
shaft ends.
The motor-drive unit must be mounted at the intended
Misalignment of the shaft ends in excess of 15 mm per
position on the transformer tank in a vertical position and
meter may cause damage to the insulating shafts and
protected against transformer vibrations.
coupling parts.

5.2 Installation of the bevel gear


The bevel gear is to be attached to a support on the transfor-
mer by 2 bolts (through-holes 18 mm diameter, see appendix,
drawing 892916).

NOTE

The serial number of the bevel gear must match the serial
number of the on-load tap-changer.
The above notes shall apply analogously to special design
bevel gears and corner gears, as well as to intermediate
bearings of the vertical or horizontal drive shaft.

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5 Installation of the motor-drive unit, bevel gear, and drive shafts
6 Connection of the tap winding and on-load tap-changer take-off lead

5.3 Installation of the horizontal drive shaft 5.4 Installation of the vertical drive shaft
(square-ended insulation shaft) (square tube)
The horizontal drive shaft is the mechanical connection The vertical drive shaft must be installed according to our
between the bevel gear and the bevel gear of an on-load tap- Operating Instructions No. 42.
changer module, and between the bevel gears of different- The vertical drive shaft is the mechanical connection between
phase on-load tap-changer modules. the motor-drive unit and the bevel gear. The drive shaft was
The drive shaft was designed as a square-ended insulation designed as a as a square tube.
shaft.
Connection to the shaft ends is achieved by a coupling pin and
Connection to the shaft ends is achieved by a coupling pin and a coupler unit on either side of the square tube.
a coupler unit on either side of the insulating shaft. The square tube is delivered oversized and needs to be cut
The limits of size and layout of the horizontal drive shaft are down to the required length at the time of transformer
indicated in the appendix, drawing 897377. The square-ended installation.
insulation shaft is delivered oversized and needs to be cut The limits of size and layout of the vertical drive shaft are
down to the desired length at the time of mounting to the indicated in the appendix, drawing 898598.
transformer (see appendix, drawing 897975). The appropriate coupling of the on-load tap-changer and
The modules of the on-load tap-changer and motor-drive unit motor-drive unit shall be performed in accordance with our
must be in the adjustment position. The adjusted position of Operating Instructions No. 138 for the ED motor-drive unit.
the on-load tap-changer is indicated in the connection
diagram included in the delivery.
In detail, please proceed as follows: 6 Connection of the tap winding and
– Measure length C between the shaft ends, e.g. between the on-load tap-changer take-off lead
bevel gear and Module A, between Modules A and B, etc.
The connection of the tap winding and the on-load tap-
changer take-off lead has to be carried out according to the
CAUTION connection diagram included in the delivery.

The surfaces of the square-ended insulation shafts must be


unblemished to ensure disturbance-free operation. CAUTION
Damages to the square-ended insulation shafts must
therefore be avoided at all cost. Be sure to carefully prepare and secure all connections.
Take care to install all connecting leads in a manner ensuring
distortion-free connection to the on-load tap-changer.
– Cut the insulating shaft down to a length of L = C – 53 mm.
When cutting down the square-ended insulation shafts, The tap selector connecting leads shall be connected in the
please be sure to avoid surface damages at all cost. You manner indicated in drawing 898312. The tap selector con-
should therefore clamp the piece you intend to waste necting leads are not part of the scope of delivery.
before starting the cutting process. The cutting surfaces The terminal contacts of the on-load tap-changer have been
should be coated with varnish to keep moisture from identified in accordance with the connection diagram.
penetrating. They are to be equipped with vertical 13.5 mm diameter
– Lubricate the O-rings and coupling bolts at both shaft ends, boreholes (see appendix, drawing 897979).
insert the coupling bolt, and slide on the coupling sleeves.
– Slide two screening sleeves onto the insulating shaft.
Insert the insulating shaft into the two coupling sleeves.
CAUTION
Check for axial clearance (approx. 3mm). Slide the
Connection of the tap selector connecting leads shall be in
screening sleeves over the coupling sleeve as far as they
accordance with drawing 898312.
will go.
The connecting terminals must not be twisted.
– Secure each coupling sleeve with an M16 clamping piece, Otherwise, the functioning of the on-load tap-changer
w. s. 4, torque 9 Nm. will be jeopardized.

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7 Commissioning of the on-load tap-changer at the transformer
manufacturer’s site

7 Commissioning of the on-load


tap-changer at the transformer
manufacturer’s site

7.1 Trial switching operations 7.2 Ground connections


Before applying voltage to the transformer some trial switching Connect the ground screw of the mounting bridge to the
operations must be carried out to check the mechanical support bracket of the transformer (1 M10/ws 17 screw,
functions of on-load tap-changer and motor-drive unit. 30 Nm retaining torque, see drawing 898312).
These trial switching operations, which are carried out
manually, have to be performed for the entire setting range.
When performing trial switching sequences the operator is CAUTION
obliged to verify, on the basis of the connection diagram
included in the delivery, that the contact identification of the The grounding electrode conductor must not protrude into
on-load tap-changer and the position identification of the the grounding insulation distance!
motor-drive unit are in conformance for each single operating
position.
At the same time, the transmission ratio of the transformer has
to be measured. 7.3 Electrical tests on the transformer
Upon completion of the aforementioned works it is now time
to perform the electrical checks required by transformer
CAUTION acceptance.

Non-conformance of the position indication of the on-load


tap-changer and motor-drive unit indicates the presence of
a coupling error.
Operation in spite of incorrect coupling will cause damage to
the on-load tap-changer and transformer; refrain from
operating the equipment while it is in this condition.

Check and verify the automatic deactivation of the motor-drive


unit for both end positions (functionality of the electrical and
mechanical end position limiter, see Operating Instructions
No. 138 for the ED motor-drive unit).

NOTE

The minimum time distance of 1 min. between successive


switching operations as set in-house for the motor-drive
unit is absolutely compulsory. The motor-drive unit appur-
tenant to the on-load tap-changer delivered is also set in-
house in a manner ensuring compliance with this pre-
requisite.
Do not to alter the settings of the corresponding monitoring
time relays incorporated in the motor-drive unit.

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8 Transportation to the operating site 9 Commssioning at the operating site
10 Failures 11 Monitoring, cleaning and lubrication

8 Transportation to the operating 11 Monitoring, cleaning and


site lubrication
If the motor-drive unit has to be demounted for transport of 11.1 Motor-drive unit
the transformer to the operating site, the motor-drive unit has
to be put into the adjustment position (see appendix, drawing Monitoring of the motor-drive unit is actually limited to
898613) and then uncoupled. occasional visual inspections.
We recommend the use of the MR shipping box for any sub- These can be carried out at the same time as the usual control
sequent transportation. inspections on the transformer (see Operating Instructions
No. 138 for motor-drive unit ED).

CAUTION 11.2 On-load tap-changer


Every six (6) months, it is essential to clean the on-load tap-
Do not operate the motor-drive unit while the on-load tap- changer and square-ended insulation shaft, and to lubricate
changer is not coupled . the on-load tap-changer.

Reassembly is in accordance with sections 4, 5, 6 and 7.


CAUTION

Do make sure that the entire transformer unit is discon-


nected, short-circuited, grounded, and secured against
unintentional reactivation prior to cleaning and lubricating.
9 Commssioning at the operating
site Be sure to carefully follow the attached lubricating diagram
when carrying out these works.
Use a dry rag for cleaning the insulation material.
Before commissioning the transformer operational tests of on-
load tap-changer and motor-drive unit have to be performed Use only the lubricants indicated in the lubricating diagram
according to section 7.1. for lubrication. Remove the old lubricating grease.
Lubricate the new parts and perform operational tests twice
After energizing the transformer, tap-change operations under for the entire regulating range.
load can be performed.

Lubrication diagram (fig. 2, 3, 4, 5)


Lubricant: ISOFLEX TOPAS NCA 5051

10 Failures
Position no. Lubricating point

1 Threaded spindle
For more serious problems with the on-load tap-changer or
2 L guide rail
motor-drive unit, which cannot be rectified easily on site,
please inform your authorized MR representative or the 3 Take-off contact bar
transformer manufacturer, or get in touch directly with: 4 Terminal contac
Maschinenfabrik Reinhausen GmbH 5 Movable take-off contact
Technical Service 6 Movable shunt contact
Postfach 12 03 60 7 Movable resistor contact
93025 Regensburg
Germany 8 Auxiliary contact bar
Phone: (+49) 9 41 / 40 90-0
Fax: (+49) 9 41 / 40 90-501 MR are keeping one-kilogram cans of the lubricant ISOFLEX
Email: service@reinhausen.com TOPAS NCA 5051 (article no. 09947300) on stock. One can
Internet: www.reinhausen.com will last for 4 VT sets (12 modules).

10 139/02/01/0
11 Monitoring, cleaning and lubrication

Clean the entire

po surfaces
of both po
insulating plates
Clean
insulating
shafts on all
sides
o
o

MR
3 KHW 918

4 5 KHW 1160

2 6

3
5 8 KHW 1161
2 KHW 920-4

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11
12 Maintenance

12 Maintenance

The scope and type of the maintenance required are indicated


in the attached maintenance program.

WARNING

Disregarding the maintenance intervals or an incomplete /


improper maintenance can lead to severe damage on the
on-load tap-changer and the transformer.

We emphatically recommend that our Technical Service


Department or one of our subsidiaries carry out each
maintenance. That way, you can be sure that in addition to
getting the inspection works done in a professional manner,
our Technical Service will also retrofit specific components in
accordance with state-of-the-art manufacturing conditions.
If a maintenance is not carried out by our Technical Service
department, please ensure that the personnel who carry out
the maintenance are trained by MR or are otherwise suitably
qualified to carry out the work. In such a case, we would ask
you to forward us a report on the maintenance performed, to
complete our maintenance records. For inquires about spare
parts we ask you to inform us about the serial number (see the
nameplate on the motor-drive unit) and the number of
switching operations.

6 13901006

12 139/02/01/0
12 Maintenance
13 Appendix

Maintenance program

Interval Measure Action performed by

Cleaning, lubrication and visual Remove soiling with a dry rag, lubrication Transformer operator
inspection every six (6) months according to lubrication diagram and visual
control for damage.

First maintenance Examination for defects. We emphatically recommend to


after 2 years or after completion of Only after completion of 100,000 switching have maintenance works carried
100,000 switching operations, operations, in which case the weight counter- out by our Technical Service or by
whichever happens first. balance spring (1), two pawl-type blocks (2) an MR subsidiary.
and the shock absorber (4) have to be
replaced, see fig. 6.

Maintenance after completion of A replacement of the weight counterbalance We emphatically recommend to


every 100,000 switching spring (1), the two pawl-type locks (2) and the have maintenance works carried
operations: shock absorber, see fig. 6. out by our Technical Service or by
an MR subsidiary.

Additional works after completion Replacement of the vacuum interrupters (3) We emphatically recommend to
of 500,000 switching operations: and transition resistor (5), see fig. 6. have maintenance works carried
out by our Technical Service or by
an MR subsidiary.

After completion of 800,000 The on-load tap-changer needs to be


switching operations. replaced.

13 Appendix

On-load tap-changer VACUTAP® V T I 500, attachment drawing .......................................................................................................... 898312


On-load tap-changer VACUTAP® V T I 500, dimension drawing ............................................................................................................ 897979
On-load tap-changer VACUTAP® V T I 500, switching sequence ........................................................................................................... 899507
Motor-drive unit ED-S, protective housing .................................................................................................................................................. 898801
Bevel gear CD 6400, dimension drawing ..................................................................................................................................................... 892916
Motor-drive unit ED with CD 6400, limit dimensions of the vertical drive shaft .............................................................................. 898598
On-load tap-changer VACUTAP® V T I 500, arrangement of OLTC modules ....................................................................................... 897377
Laststufenschalter VACUTAP® V T I 500, adjustment plan ........................................................................................................................ 898613
Laststufenschalter VACUTAP® V T I 500, determination of insulation shaft length ........................................................................... 897975

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13
8983123E
On-load tap-changer VACUTAP® V T I 500
Attachment drawing

14 139/02/01/0
8979794E
On-load tap-changer VACUTAP® V T I 500
Dimension drawing

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15
8995070E On-load tap-changer VACUTAP® V T I 500
Switching sequence

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8988012E
Motor-drive unit ED-S
Protective housing

Vertical guard plate with


spacing ring
Hand crank

* for design with


intermediate bearing

3 dummy plates for packing glands


special design with OLTC monitoring required

Wall of transformer tank


Shim

Attachment of protective housing

The cover can be opened


to the left or to the right
depending on the arrange-
ment of the hinge pins.
ca. 690 if opened 130°
ca. 864 if opened 180°

Aperture of fixing holes on protective housing Aperture in protective housing for cables
(rear view) (underside view)

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17
18
8929166E
Dimension drawing
Bevel gear CD 6400

e1 = 205 for standard design

e2 = 215 for design with ball joint

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8985980E
Motor-drive unit ED mit CD 6400
Limit dimensions of the vertical drive shaft

1. Unit without cardan shaft, without insulator (a max. = 2°)


(= standard model)

Intermediate bearing
Configuration V1 min [mm] necessary if [mm]

Bevel gear 526 V1 > 2462

2. Unit without cardan shaft, with insulator (a max. = 2°)


(= special design)

Intermediate bearing
Configuration V1 min [mm] necessary if [mm]

Bevel gear 697 V1 > 2462

3. Unit with cardan shaft, without insulator (a max. = 20°)


(= special design)

Intermediate bearing
Configuration V1 min [mm] necessary if [mm]

Bevel gear 790 V1 > 2556

4. Unit with cardan shaft, with insulator (a max. = 20°)


(= special design)

Intermediate bearing
Configuration V1 min [mm] necessary if [mm]

Bevel gear 975 V1 > 2556

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19
8973775E
On-load tap-changer VACUTAP® V T I 500
Arrangement of OLTC modules

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8986132E
On-load tap-changer VACUTAP® V T I 500
Adjustment plan

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21
8979753E
On-load tap-changer VACUTAP® V T I 500
Determination of insulation shaft length

22 139/02/01/0
© Maschinenfabrik Reinhausen GmbH Phone +49 941 40 90-0
www.reinhausen.com
Falkensteinstrasse 8 Fax +49 941 40 90-111
93059 Regensburg, Germany E-Mail sales@reinhausen.com

BA 139/02 en • 0106/200 • 139/02/01/0 • F0089301 • Printed in Germany