MR COMTAP ARS Operating Instructions Manual

Advanced Retard Switch
COMTAP® ARS

Operating Instructions

4434052/01 EN

© All rights reserved by Maschinenfabrik Reinhausen

Dissemination and reproduction of this document and use and disclosure of its content are strictly prohibited
unless expressly permitted.

Infringements will result in liability 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 instructions were written in German.

Table of contents

Table of contents

1 Introduction......................................................................................................................... 5

1.1 Validity................................................................................................................................................. 5

1.2 Manufacturer....................................................................................................................................... 5

1.3 Completeness...................................................................................................................................... 5

1.4 Safekeeping......................................................................................................................................... 6

1.5 Notation conventions........................................................................................................................... 6

1.5.1 Symbols................................................................................................................................................................. 6

1.5.2 Hazard communication system............................................................................................................................. 7

1.5.3 Information system................................................................................................................................................ 9

2 Safety................................................................................................................................. 10

2.1 Appropriate use................................................................................................................................. 10

2.2 Fundamental safety instructions........................................................................................................ 10

2.3 Personnel qualification...................................................................................................................... 12

2.4 Personal protective equipment.......................................................................................................... 13

3 Product description.......................................................................................................... 15

3.1 Scope of delivery............................................................................................................................... 15

3.2 COMTAP® ARS................................................................................................................................ 15

3.2.1 Function description............................................................................................................................................ 15

3.2.2 Setup/models...................................................................................................................................................... 16

3.2.3 Name plate.......................................................................................................................................................... 17

3.2.4 Protective devices............................................................................................................................................... 17

3.3 Drive shaft......................................................................................................................................... 17

3.3.1 Function description............................................................................................................................................ 17

3.3.2 Design/versions................................................................................................................................................... 18

4 Commissioning transformer at operating site............................................................... 22

4.1 Checking motor-drive unit.................................................................................................................. 22

4.2 Performing trial tap-change operations............................................................................................. 23

4.3 Commissioning transformer............................................................................................................... 23

5 Operation........................................................................................................................... 24

5.1 Temperature range............................................................................................................................ 24

5.2 Switching COMTAP® ARS................................................................................................................ 24

Maschinenfabrik Reinhausen GmbH 2016 34434052/01 EN COMTAP® ARS

Table of contents

5.3 Actuating motor-drive unit with hand crank....................................................................................... 25

5.4 Monitoring during operation............................................................................................................... 26

6 Maintenance...................................................................................................................... 27

6.1 Safety precautions............................................................................................................................. 27

6.2 Maintenance...................................................................................................................................... 27

7 Fault elimination................................................................................................................ 29

8 Drawings............................................................................................................................ 31

8.1 COMTAP® ARS, installation drawing (732771)................................................................................ 31

8.2 COMTAP® ARS, installation drawing bell-type tank design (733023).............................................. 32

8.3 COMTAP® ARS, position of supporting structure (supporter, 735714)............................................ 33

8.4 COMTAP® ARS, tap-change supervisory control (726977).............................................................. 34

8.5 COMTAP® ARS, mounting flange (725857)..................................................................................... 35

8.6 COMTAP® ARS, mounting flange made by the customer (742013)................................................. 36

8.7 COMTAP® ARS, tracing template (726728)..................................................................................... 37

8.8 COMTAP® ARS, mounting of the COMTAP® ARS on the lower cage ring (user-specific, 732773_1)

........................................................................................................................................................... 38

8.9 COMTAP® ARS, mounting of the COMTAP® ARS on the lower cage ring (user-specific, 732773_2)

........................................................................................................................................................... 39

8.10 COMTAP® ARS, head with upper gear unit (725737)...................................................................... 40

8.11 COMTAP® ARS, connection contact (734095)................................................................................. 41

8.12 COMTAP® ARS, connecting leads (10015335)................................................................................ 42

8.13 COMTAP® ARS, horizontal drive shaft (limit dimensions, 778664_2).............................................. 43

8.14 COMTAP® ARS, swivel range of upper gear unit (732769_2).......................................................... 44

8.15 COMTAP® ARS, supplementary drawings (734087)........................................................................ 45

8.16 Bevel gear CD 6400, dimensional drawing (892916)........................................................................ 46

8.17 Lifting traverse (72673703)................................................................................................................ 47

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1 Introduction

Introduction

1

This technical file contains detailed descriptions for monitoring during opera­tion, troubleshooting, and maintenance.

It also includes safety instructions and general information about the prod­uct.

Information about installation can be found in the installation and commis­sioning instructions.

This technical file is intended solely for specially trained and authorized per­sonnel.

Validity

1.1

The document supplied with the product is always the valid version. This
technical file is configured for the specific order and applies to the following
products, the serial numbers of which can be found on the delivery docu­ments:

▪ Advanced Retard Switch COMTAP® ARS

▪ Drive shaft

Manufacturer

1.2

The product is manufactured by:

Maschinenfabrik Reinhausen GmbH

Falkensteinstraße 8
93059 Regensburg, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]

Further information on the product and copies of this technical file are avail­able from this address if required.

Completeness

1.3

This technical file is incomplete without the supporting documents.

The following documents apply:

▪ Unpacking instructions (included in the scope of delivery)

▪ Supplement (included in the scope of delivery)

▪ Routine test report (included in the scope of delivery)

▪ Connection diagrams (included in the scope of delivery)

▪ Dimensional drawings (included in the scope of delivery)

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1 Introduction

▪ Technical data - General section (available on request)

▪ Technical data - Product-specific section (available on request)

Safekeeping

1.4

Keep this technical file and all supporting documents ready at hand and ac­cessible for future use at all times.

Notation conventions

1.5

This section contains an overview of the symbols and textual emphasis
used.

1.5.1

Symbols

Symbol Meaning

Wrench size

Tightening torque

Number and type of fastening material used

Fill with oil

Cut open, cut through

Clean

Visual inspection

Use your hand

Adapter ring

Apply a coat of paint

Use a file

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1 Introduction

Symbol Meaning

Grease

Coupling bolt

Use a ruler

Use a saw

Hose clip

Wire eyelet, safety wire

WARNING

1.5.2

1.5.2.1

Use a screwdriver

Apply adhesive

Lock tab

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-sec­tions or several paragraphs within this technical file. Warnings relating to
sections use the following format:

Type and source of danger

Consequences

► Action

► Action

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1 Introduction

1.5.2.2

1.5.2.3

Embedded warning information

Embedded warnings refer to a particular part within a section. These warn­ings apply to smaller units of information than the warnings relating to sec­tions. Embedded warnings use the following format:

DANGER! Instruction for avoiding a dangerous situation.

Signal words and pictograms

The following signal words are used:

Signal

Meaning

word

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 to prevent damage to

property.

Table 2: Signal words in warning notices

Pictograms warn of dangers:

Pictogram Meaning

Warning of a danger point

Warning of dangerous electrical voltage

Warning of combustible substances

Warning of danger of tipping

Table 3: Pictograms used in warning notices

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1 Introduction

1.5.3

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.

Maschinenfabrik Reinhausen GmbH 2016 94434052/01 EN COMTAP® ARS

Safety

2

This technical file contains detailed descriptions on the safe and proper in­stallation, connection, commissioning and monitoring of the product.

▪ Read this technical file through carefully to familiarize yourself with the

product.

▪ This technical file is part of the product.

▪ Read and observe the safety instructions provided in this chapter in par-

ticular.

▪ Observe the warnings in this technical file in order to avoid function-re-

lated dangers.

▪ The product is manufactured on the basis of state-of-the-art technology.

Nevertheless, risks to life and limb of the user or impairment of the prod­uct and other material assets may occur during use due to function-re­lated dangers.

Appropriate use

2.1

2 Safety

The product is an Advanced Retard Switch and is used to reverse the polari­ty of a winding when the transformer is in operation. The product is designed
solely for use in electrical energy systems and facilities. If used as intended
and in compliance with the requirements and conditions specified in this
technical file as well as the warning notices in this technical file and attached
to the product, then the product does not present any danger to people,
property or the environment. This applies throughout the product's entire life,
from delivery to installation and operation through to disassembly and dis­posal.

The following is considered appropriate use:

▪ Use the product only with the transformer specified in the order.

▪ The serial numbers of COMTAP® ARS and COMTAP® ARS accesso-

ries (motor-drive unit, drive shaft, bevel gear, protective relay etc.) must
match if COMTAP® ARS and COMTAP® ARS accessories are supplied
as a set for one order.

▪ You will find the applicable standard for the product and the year of is-

sue on the nameplate.

▪ Operate the product only in accordance with this technical file, the

agreed delivery conditions and technical data.

▪ Ensure that all necessary work is performed only by qualified personnel.

▪ Use the equipment and special tools supplied solely for the intended

purpose and in accordance with the specifications of this technical file.

Fundamental safety instructions

2.2

To prevent accidents, disruptions and damage as well as unacceptable ad­verse effects on the environment, those responsible for transport, installa­tion, operation, maintenance and disposal of the product or parts of the prod­uct must ensure the following:

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2 Safety

Personal protective equipment

Loosely worn or unsuitable clothing increases the danger of becoming trap­ped or caught up in rotating parts and the danger of getting caught on pro­truding parts. This increases the danger to life and limb.

▪ All necessary devices and personal protective equipment required for

the specific task, such as a hard hat, safety footwear, etc. must be worn.
Observe the section "Personal protective equipment" [► 13].

▪ Never wear damaged personal protective equipment.

▪ Never wear rings, necklaces or other jewelry.

▪ If you have long hair, wear a hairnet.

Work area

Untidy and poorly lit work areas can lead to accidents.

▪ Keep the work area clean and tidy.

▪ Make sure that the work area is well lit.

▪ Observe the applicable laws for accident prevention in the relevant

country.

Working during operation

You must only operate the product when it is in a sound operational condi­tion. Otherwise it poses a danger to life and limb.

▪ Regularly check the operational reliability of safety equipment.

▪ Comply with the maintenance work and maintenance intervals descri-

bed in this technical file.

Explosion protection

Highly flammable or explosive gases, vapors and dusts can cause serious
explosions and fire.

▪ Do not install or operate the product in areas where a risk of explosion is

present.

Safety markings

Warning signs and safety information plates are safety markings on the
product. They are an important aspect of the safety concept.

▪ Observe all safety markings on the product.

▪ Make sure all safety markings on the product remain intact and legible.

▪ Replace safety markings that are damaged or missing.

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2 Safety

Ambient conditions

To ensure reliable and safe operation, the product must only be operated
under the ambient conditions specified in the technical data.

▪ Observe the specified operating conditions and requirements for the in-

stallation location.

Auxiliary materials and operating materials

Auxiliary materials and operating materials not approved by Maschinenfabrik
Reinhausen GmbH could damage the product.

▪ Only use lubricants and auxiliary materials approved by the manufactur-

er.

▪ Contact Maschinenfabrik Reinhausen GmbH.

Modifications and conversions

Unauthorized or inappropriate changes to the product may lead to personal
injury, material damage and operational faults.

▪ Only modify product following consultation with Maschinenfabrik Rein-

hausen GmbH.

Spare parts

Spare parts not approved by Maschinenfabrik Reinhausen GmbH may
cause physical injury and damage the product.

▪ Only use spare parts approved by the manufacturer.

▪ Contact Maschinenfabrik Reinhausen GmbH.

Personnel qualification

2.3

The person responsible for assembly, commissioning, operation, mainte­nance and inspection must ensure that the personnel are sufficiently quali­fied.

Electrically skilled person

The electrically skilled person has a technical qualification and therefore has
the required knowledge and experience, and is also conversant with the ap­plicable standards and regulations. The electrically skilled person is also pro­ficient in the following:

▪ Can identify potential dangers independently and is able to avoid them.

▪ Is able to perform work on electrical systems.

▪ Is specially trained for the working environment in which (s)he works.

▪ Must satisfy the requirements of the applicable statutory regulations for

accident prevention.

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2 Safety

Electrically trained persons

An electrically trained person receives instruction and guidance from an
electrically skilled person in relation to the tasks undertaken and the poten­tial dangers in the event of inappropriate handling as well as the protective
devices and safety measures. The electrically trained person works exclu­sively under the guidance and supervision of an electrically skilled person.

Operator

The operator uses and operates the product in line with this technical file.
The operating company provides the operator with instruction and training
on the specific tasks and the associated potential dangers arising from im­proper handling.

Technical Service

We strongly recommend having maintenance, repairs and retrofitting carried
out by our Technical Service department. This ensures that all work will be
performed correctly. If maintenance is not carried out by our Technical Serv­ice department, please ensure that the personnel who carry out the mainte­nance are trained and authorized by Maschinenfabrik Reinhausen GmbH to
carry out the work.

Authorized personnel

Authorized personnel are trained by Maschinenfabrik Reinhausen GmbH to
carry out special maintenance.

Personal protective equipment

2.4

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.

▪ Never wear damaged protective equipment.

▪ Follow information about personal protective equipment provided in the

work area.

Always wear

Protective clothing

Close-fitting work clothing with a low tear­ing strength, with tight sleeves and with no
protruding parts. It mainly serves to pro­tect the wearer against being caught by
moving machine parts.

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Always wear

Safety shoes

To protect against falling heavy objects
and slipping on slippery surfaces.

Table 4: Personal protective equipment to be worn at all times

2 Safety

Wear the following in spe­cial environments

Special personal protective equipment
is needed in special environments.

The choice of equipment depends on
the circumstances.

Safety glasses

To protect the eyes from flying parts and
splashing liquids.

Visor

To protect the face from flying parts and
splashing liquids or other dangerous sub­stances.

Hard hat

To protect from falling and flying parts and
materials.

Hearing protection

To protect from hearing damage.

Protective gloves

For protection from mechanical, thermal,
and electrical hazards.

Table 5: Personal protective equipment to be worn in special environments

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3 Product description

Product description

3

This chapter contains an overview of the design and function of the product.

Scope of delivery

3.1

The product is packaged with protection against moisture and is delivered as
follows:

▪ COMTAP® ARS

▪ TAPMOTION® ED motor-drive unit

▪ Drive shaft with coupling parts and bevel gear

▪ Technical files

Note the following information:

▪ Check the shipment for completeness 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

3.2

3.2.1

You will find more information in the "Packaging, transport, and storage"
chapter.

COMTAP® ARS

Function description

The COMTAP® ARS C is used to reverse the polarity of a winding during
transformer operation. During this process, the through-current is commutat­ed from one current path to another current path with the same potential.

The COMTAP® ARS always has 2 operating positions.

The COMTAP® ARS is changed over from one operating position to the
next by the TAPMOTION® ED motor-drive unit.

The COMTAP® ARS can be used for different applications in combination
with an on-load tap-changer. The COMTAP® ARS is primarily used to re­verse the polarity of the regulating voltage in applications with large regulat­ing ranges (e.g. phase shifter transformers).

In on-load tap-changer applications with reversing change-over selector
where the change-over selector capacity is outside the permitted range, a
combination of on-load tap-changer without reversing change-over selector
and COMTAP® ARS can be used.

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3 Product description

3.2.2

Setup/models

The COMTAP® ARS is produced in a single-phase and three-phase design
with a maximum possible rated through-current of 2400 A.

The design of the COMTAP® ARS and the designation of its main parts are
shown in the installation drawings in the appendix (see page [► 31]).

Figure 1: COMTAP® ARS

1 Tap-change supervisory con-

2 COMTAP® ARS head
trol with inspection window for
tap position indicator

3 Upper gear unit 4 Connection contact

5 COMTAP® ARS cage 6 Set-down cylinder

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3 Product description

3.2.3

3.2.4

Name plate

The name plate is on the head of the COMTAP® ARS.

Figure 2: Position of name plate

Protective devices

Tap-change supervisory control

The COMTAP® ARS is equipped with a tap-change supervisory control,
which is fitted in a housing on the head of the COMTAP® ARS (see page
[► 34]).

Depending on the application, the tap-change supervisory control may have
different safety functions in conjunction with the motor-drive unit and the as­sociated on-load tap-changer units.

3.3

3.3.1

These safety functions are specified individually in a binding manner for
each delivery depending on application and documented in an associated
functional description.

Electrical tripping contact/interlocking contact

When combining the COMTAP® ARS with on-load tap-changers, the
COMTAP® ARS may only be actuated in a certain on-load tap-changer posi­tion. This means that it may only be actuated when all windings of the on­load tap-changer tap winding are disconnected and the voltage at the rele­vant winding is therefore zero.

For this reason, non-permitted switching operations are prevented by a mu­tual electrical interlock of the on-load tap-changer and COMTAP® ARS.

Please refer to the order-specific technical documentation, safety instruc­tions, and functional description.

Drive shaft

Function description

The drive shaft is the mechanical connection between motor-drive and on­load tap-changer head / de-energized tap-changer head.

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3 Product description

The bevel 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 de-energized tap-changer.

3.3.2

Design/versions

The drive shaft consists of a square tube and is coupled at each end by two
coupling brackets and one coupling bolt to the drive / driven shaft end of the
device to be connected.

Figure 3: Components of the drive shaft

1 Bevel gear 2 Hose clip

3 Telescopic protective tube 4 Coupling bracket

5 Square tube 6 Coupling bolt

7 Adapter ring 8 Protective cover

9 Hose clip

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3 Product description

3.3.2.1

Drive shaft without cardan joint and without insulator

Figure 4: Drive shaft without cardan joint and without insulator (= normal model)

Configuration V 1 min Intermediate bearing

Middle of hand crank – middle
of bevel gear (maximum per­missible axial offset 2°)

536 mm When the maximum

value of 2472 mm is
exceeded, it is neces­sary to use an inter­mediate bearing.

V 1 ≤ 2472 mm (with­out intermediate bear­ing)

V 1 > 2472 mm (with
intermediate bearing)

Maschinenfabrik Reinhausen GmbH 2016 194434052/01 EN COMTAP® ARS

3 Product description

3.3.2.2

Drive shaft without cardan joint and with insulator

Figure 5: Drive shaft without cardan joint and with insulator (= special model)

Configuration V 1 min Intermediate bearing

Middle of hand crank – middle
of bevel gear (maximum per­missible axial offset 2°)

706 mm When the maximum

value of 2472 mm is
exceeded, it is neces­sary to use an inter­mediate bearing.

V 1 ≤ 2472 mm (with­out intermediate bear­ing)

V 1 > 2472 mm (with
intermediate bearing)

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3 Product description

3.3.2.3

3.3.2.4

Drive shaft with cardan joint and without insulator

Figure 6: Drive shaft with cardan joint and without insulator (= special model)

Configuration V 1 min

[mm]

Middle of hand crank – middle

798 V 1 > 2564

Intermediate bearing
for [mm]

of bevel gear (maximum per­missible axial offset alpha =
20°)

Drive shaft with cardan joint and with insulator

Figure 7: Drive shaft with cardan joint and with insulator (= special model)

Configuration V 1 min

[mm]

Middle of hand crank – middle

978 V 1 > 2772

Intermediate bearing
for [mm]

of bevel gear (maximum per­missible axial offset alpha =
20°)

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4 Commissioning transformer at operating site

Commissioning transformer at operating site

4

Checking motor-drive unit

4.1

Before commissioning the transformer, repeat the function tests on the mo­tor-drive unit as described in MR operating instructions for motor-drive unit.

WARNING

NOTICE

NOTICE

Danger of death or severe injury!

Danger of death or severe injury due to incorrect operation!

► Under no circumstances is the transformer to be commissioned if the

functions specified in the section "Tests on motor-drive unit" are not
satisfied.

Damage to the on-load tap-changer and motor-drive unit!

Damage to on-load tap-changer and motor-drive unit due to condensate in
protective housing of motor-drive unit!

► Always keep protective housing of the motor-drive unit tightly closed.

► In the event of downtimes prior to initial commissioning of more than 8

weeks or operation interruptions of more than 2 weeks, connect and
operate the anti-condensation heater in the motor-drive unit. If this is
not possible (e.g. during transportation), place a sufficient amount of
dehydrating agent in the protective housing.

Damage to the on-load tap-changer and motor-drive unit!

Damage to on-load tap-changer and motor-drive unit due to incorrect use of
position transmitter equipment!

► Only circuits stated in the chapter Technical data for position transmitter

equipment may be connected to the position transmitter module con­nections.

► The switchover point of the position transmitter equipment in the motor-

drive unit is not the same as the switchover point of the diverter switch
operation. This depends on the type of diverter switch. This fact should
be noted when project planning the locking circuits between the motor­drive unit and external equipment (e.g. transformer circuit breaker).

► For external monitoring, locking, and control purposes, it is not there-

fore the position transmitter equipment but the "Tap changer in opera­tion" position transit contact shown in the connection diagram that
should be used.

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4 Commissioning transformer at operating site

Performing trial tap-change operations

4.2

Before energizing the transformer, test change operations must be carried
out to check the mechanical function of the COMTAP® ARS.

1. DANGER! Switch off transformer on high and low-voltage side. Fail­ure to do so may result in severe injuries and property damage.

2. Lock transformer to prevent unintentional restart.

3. Starting from the adjustment position, undertake tap change operation
tests across the entire range of settings.

4. If necessary, repeat the transformer ratio test.

5. NOTICE! Make sure that in each operating position the tap position in­dicators of motor-drive unit and COMTAP® ARS read the same posi­tion. An incorrectly coupled motor-drive unit will damage the COMTAP®
ARS.

Commissioning transformer

4.3

Proceed as follows to commission the transformer:

1. DANGER! Ensure that the transformer is switched off on the high­voltage and low-voltage sides. Failure to do so may result in severe inju­ries and property damage.

2. Connect the drive to the tripping circuit of the transformer's circuit break­er.

3. DANGER! Ensure that COMTAP® ARS and motor-drive unit are in
the same operating position. Check that all safety measures are effec­tive. Failure to do so will result in danger of death and damage to prop­erty when commissioning the transformer.

4. Commission the transformer.

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Operation

5

The following sections describe how to operate the COMTAP® ARS and
monitor the COMTAP® ARS and motor-drive unit.

Temperature range

5.1

When using a vegetable oil as insulating fluid, the permissible temperature
range for operation of the DEETAP® DU/COMTAP® ARS is limited. Please
observe the relevant information in the specific order documents and on the
indicator plate on the drive.

5 Operation

You can operate the DEETAP® DU/COMTAP® ARS in the rated load range
at oil temperatures of -25 °C to +105 °C and in accordance with IEC 60214-1
up to +115 °C (during emergency transformer operation in accordance with
IEC 60076-7). Contact Maschinenfabrik Reinhausen GmbH if this tempera­ture range is not sufficient for the requirements of your application.

Switching COMTAP® ARS

5.2

Proceed as follows to switch the COMTAP® ARS:

1. DANGER! When also using an on-load tap-changer, ensure that the
mutual electrical interlocking of the on-load tap-changer and COMTAP®
ARS is working properly and preventing impermissible tap-change oper­ations. Ensure that all windings of the on-load tap-changer's tap winding
are disconnected and that the voltage at the winding whose polarity is to
be reversed is zero. Note technical files relating to order. Failure to do
so will result in the risk of explosion!

2. Switch COMTAP® ARS with the help of the motor-drive unit.

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5 Operation

Actuating motor-drive unit with hand crank

5.3

WARNING

Danger of explosion!

Unauthorized operation of the motor-drive unit with the hand crank may re­sult in death or serious injury.

► Never operate the motor-drive unit electrically or with the hand crank

before the transformer has been disconnected if you think there may be
a fault in the transformer or on-load tap-changer / de-energized tap­changer.

► Never use the hand crank to complete a tap-change operation that has

begun electrically, but has not been ended completely.

► If the hand crank is difficult to move, you must stop using it.

► When operating the motor-drive unit with the hand crank, never reverse

the direction of rotation.

► If there is any doubt about the on-load tap-changer / de-energized tap-

changer being in proper working condition or about the cause of a fault
in the motor-drive unit, contact the Technical Service department of Ma­schinenfabrik Reinhausen GmbH immediately.

► To operate the motor-drive unit manually, only use the hand crank

mounted in the motor-drive unit.

For information about fault rectification, refer to the "Troubleshooting" chap­ter.

Normal operation

During normal operation, there is no need to operate the unit with the hand
crank. The hand crank is mainly required during installation or for tests in the
transformer plant.

Use of the hand crank for operating the motor-drive unit is permitted if the
transformer is disconnected, e.g. for maintenance tasks, if there is no detect­able fault on the transformer or on-load tap-changer / de-energized tap­changer and the previous tap-change operation has been ended correctly.

Emergency operation exception

An operation is considered an emergency operation if a tap-change opera­tion is absolutely necessary when a transformer is energized, despite a fault
in the motor-drive unit. In this case, be sure to observe the warnings listed
above.

Operating motor-drive unit with hand crank

To carry out a tap-change operation with the hand crank, proceed as follows:

1. Open door of protective housing of motor-drive unit.

2. Switch off motor protective switch Q1 (position 0).

Maschinenfabrik Reinhausen GmbH 2016 254434052/01 EN COMTAP® ARS

3. Insert the hand crank mounted in the motor-drive unit into the hand
crank aperture in the upper cover plate.

ð The built-in hand crank interlock switch interrupts the motor circuit

at two poles. The control circuit will not be interrupted.

4. NOTICE! Turn in one direction with the hand crank until the pointer has
fully circled the tap-change indicator once and is again in the mid-posi­tion of the area marked in gray on the tap-change indicator. Otherwise
the tap-change operation is not completed correctly, which may result in
damage to the on-load tap-changer and transformer.

ð The tap-change operation is complete.

5. Take off hand crank and return to bracket.

6. Switch on motor protective switch Q1 (position I).

7. Close door of protective housing of motor-drive unit.

Monitoring during operation

5.4

Monitoring of the COMTAP® ARS and motor-drive unit is limited to occa­sional visual inspections on the COMTAP® ARS head and motor-drive unit.
For efficiency reasons these visual checks can be combined with the usual
checks on the transformer.

5 Operation

Pay particular attention to the following:

▪ No oil leaks at the COMTAP® ARS head sealing points

▪ Gaskets of protective housing of motor-drive unit

▪ Correct functioning of the installed electrical heater in the protective

housing of the motor-drive unit

The insulating oils in the transformer are to be monitored by the operator in
accordance with the appropriate rules and regulations.

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6 Maintenance

Maintenance

6

Safety precautions

6.1

WARNING

Danger of death and severe injury!

An energized transformer and energized COMTAP® ARS components
could cause death or serious injuries during maintenance work!

► Adherence to the following safety precautions is mandatory.

1. Switch off transformer on high and low-voltage side.

2. Lock transformer to prevent unintentional restart.

3. Make sure everything is de-energized.

4. Visibly connect all transformer terminals to ground (grounding leads,
grounding disconnectors) and short circuit them.

5. Cover or cordon off adjacent energized parts.

Maintenance

6.2

The COMTAP® ARS is basically maintenance-free. The COMTAP® ARS
has a mechanical service life of 100,000 tap-change operations. The contact
life depends on the specific application and may vary (verification by Maschi­nenfabrik Reinhausen GmbH at the order stage). The specific contact life is
shown on the label in the TAPMOTION® ED motor-drive unit.

We strongly recommend having maintenance carried out by our Technical
Service department. If this route is taken, in addition to the correct perform­ance of all work, certain components will be upgraded to the latest state of
technology and manufacturing status.

If maintenance is not carried out by our Technical Service department,
please ensure that the personnel who carry out the maintenance are trained
by Maschinenfabrik Reinhausen GmbH or are otherwise suitably qualified to
carry out the work. In such cases, we would ask you to forward to us a report
on the maintenance performed so we can update our maintenance files. For
inquiries about spare parts, please provide the serial number (see name
plate on COMTAP® ARS and motor-drive unit) and the number of tap­change operations.

Re-commissioning after maintenance

Proceed as follows to re-commission the transformer after maintenance:

1. Ensure that the COMTAP® ARS and motor-drive unit are correctly cen­tered (see page).

2. DANGER! Ensure that COMTAP® ARS and motor-drive unit are in
the same operating position. Check that all safety measures are effec­tive. Failure to do so will result in danger of death and damage to prop­erty when commissioning the transformer.

Maschinenfabrik Reinhausen GmbH 2016 274434052/01 EN COMTAP® ARS

6 Maintenance

3. Carry out a transformer ratio test (see page) and fill transformer with oil
(see page).

4. Commission the transformer.

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7 Fault elimination

Fault elimination

7

WARNING

NOTICE

Danger of death or severe injury!

Danger of death or severe injury from explosive gases under the
COMTAP® ARS head cover!

► Ensure that there are no open flames, hot surfaces or sparks (for exam-

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

► De-energize all auxiliary circuits (such as the tap-change supervisory

control) before removing the COMTAP® ARS head cover.

► Do not operate any electrical 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.

Damage to COMTAP® ARS and transformer!

Tripping of a protective device can indicate damage on the COMTAP® ARS
and transformer! The transformer must not be energized without being in­spected first!

► Check the COMTAP® ARS and transformer when a protective device

has been tripped.

► Do not use the equipment again until you are sure there is no damage

to the COMTAP® ARS and transformer.

Error pattern Action

Activation of tap-change supervisory device Contact MR.

Tripping of motor protective switch in motor-drive
unit

The table below is intended to assist with detecting and, where possible,
remedying faults.

In the event of faults on the COMTAP® ARS and motor-drive unit, which
cannot be easily corrected on site, or if a protective device has been tripped,
please inform your authorized MR representative, the transformer manufac­turer or contact us directly at:

Maschinenfabrik Reinhausen GmbH
Technical Service
Postfach 12 03 60
93025 Regensburg
Germany
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.reinhausen.com

See chapter "Fault elimination" in the operating in­structions of the TAPMOTION® ED motor-drive
unit

Maschinenfabrik Reinhausen GmbH 2016 294434052/01 EN COMTAP® ARS

Error pattern Action

COMTAP® ARS not changing tap position (slug-

Contact MR.

gishness, Raise keys/Lower keys not working)

No change in voltage on transformer despite

Contact MR.

change in position on motor-drive unit

Tap position indicator on motor-drive unit and

Contact MR.

COMTAP® ARS different

Noises on drive shaft or motor-drive unit when
changing tap position

Ensure proper mounting of the drive shaft in ac­cordance with its operating instructions. Check that
hose clips and protective covers are seated cor­rectly. Contact MR in the event of noise from the
motor-drive unit.

Warning or tripping of Buchholz relay on transform-erNotify manufacturer of transformer.

7 Fault elimination

Deviation from desired value when measuring
winding resistance of transformer

Deviation from desired value during dissolved gas
analysis (transformer oil)

Deviation from desired value during transformer ra­tio test

Table 6: Fault elimination

Contact manufacturer of transformer and, if neces­sary, MR and provide measured values.

Contact manufacturer of transformer and, if neces­sary, MR and provide measured values.

Contact manufacturer of transformer and, if neces­sary, MR and provide measured values.

Maschinenfabrik Reinhausen GmbH 201630 4434052/01 ENCOMTAP® ARS

8 Drawings

Drawings

8

COMTAP® ARS, installation drawing (732771)

8.1

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COMTAP® ARS, installation drawing bell-type tank design

8.2
(733023)

8 Drawings

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8 Drawings

COMTAP® ARS, position of supporting structure

8.3
(supporter, 735714)

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8 Drawings

COMTAP® ARS, tap-change supervisory control (726977)8.4

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8 Drawings

COMTAP® ARS, mounting flange (725857)8.5

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COMTAP® ARS, mounting flange made by the customer

8.6
(742013)

8 Drawings

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8 Drawings

COMTAP® ARS, tracing template (726728)8.7

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COMTAP® ARS, mounting of the COMTAP® ARS on the

8.8
lower cage ring (user-specific, 732773_1)

8 Drawings

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8 Drawings

COMTAP® ARS, mounting of the COMTAP® ARS on the

8.9
lower cage ring (user-specific, 732773_2)

Maschinenfabrik Reinhausen GmbH 2016 394434052/01 EN COMTAP® ARS

8 Drawings

COMTAP® ARS, head with upper gear unit (725737)8.10

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8 Drawings

COMTAP® ARS, connection contact (734095)8.11

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8 Drawings

COMTAP® ARS, connecting leads (10015335)8.12

Maschinenfabrik Reinhausen GmbH 201642 4434052/01 ENCOMTAP® ARS

8 Drawings

8.13

COMTAP® ARS, horizontal drive shaft (limit dimensions, 778664_2)

Maschinenfabrik Reinhausen GmbH 2016 434434052/01 EN COMTAP® ARS

8 Drawings

COMTAP® ARS, swivel range of upper gear unit (732769_2)8.14

Maschinenfabrik Reinhausen GmbH 201644 4434052/01 ENCOMTAP® ARS

8 Drawings

COMTAP® ARS, supplementary drawings (734087)8.15

Maschinenfabrik Reinhausen GmbH 2016 454434052/01 EN COMTAP® ARS

8 Drawings

8.16

Bevel gear CD 6400, dimensional drawing (892916)

Maschinenfabrik Reinhausen GmbH 201646 4434052/01 ENCOMTAP® ARS

8 Drawings

8.17

Lifting traverse (72673703)

Maschinenfabrik Reinhausen GmbH 2016 474434052/01 EN COMTAP® ARS

MR worldwide

Australia

Reinhausen Australia Pty. Ltd.
17/20-22 St Albans Road
Kingsgrove NSW 2208
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

Brazil

MR do Brasil Indústria Mecánica Ltda.
Av. Elias Yazbek, 465
CEP: 06803-000
Embu - São Paulo
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

Canada

Reinhausen Canada Inc.
3755, rue Java, Suite 180
Brossard, Québec J4Y 0E4
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

India

Easun-MR Tap Changers Ltd. (Joint Venture)
612, CTH Road
Tiruninravur, Chennai 602 024
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

Indonesia

Pt. Reinhausen Indonesia
German Center, Suite 6310,
Jl. Kapt. Subijanto Dj.
BSD City, Tangerang
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

Iran

Iran Transfo After Sales Services Co.
(Joint Venture)
Zanjan, Industrial Township No. 1 (Aliabad)
Corner of Morad Str.
Postal Code 4533144551
E-Mail: [e-mail]

Italy

Reinhausen Italia S.r.l.
Via Alserio, 16
20159 Milano
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

Japan

MR Japan Corporation
German Industry Park
1-18-2 Hakusan, Midori-ku
Yokohama 226-0006
Phone: [phone]
Fax: [phone]

Luxembourg

Reinhausen Luxembourg S.A.
72, Rue de Prés
L-7333 Steinsel
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

Malaysia

Reinhausen Asia-Pacific Sdn. Bhd
Level 11 Chulan Tower
No. 3 Jalan Conlay
50450 Kuala Lumpur
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

P.R.C. (China)

MR China Ltd. (MRT)

开德贸易（上海）有限公司
中国上海浦东新区浦东南路 360 号
新上海国际大厦 4 楼 E 座
邮编： 200120
电话：＋ 86 21 61634588
传真：＋ 86 21 61634582
邮箱：[e-mail]
[e-mail]

Russian Federation

OOO MR
Naberezhnaya Akademika Tupoleva
15, Bld. 2 ("Tupolev Plaza")
105005 Moscow
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

South Africa

Reinhausen South Africa (Pty) Ltd.
No. 15, Third Street, Booysens Reserve
Johannesburg
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

South Korea

Reinhausen Korea Ltd.
21st floor, Standard Chartered Bank Bldg.,
47, Chongro, Chongro-gu,
Seoul 110-702
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

U.S.A.

Reinhausen Manufacturing Inc.
2549 North 9th Avenue
Humboldt, TN 38343
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]

United Arab Emirates

Reinhausen Middle East FZE
Dubai Airport Freezone, Building Phase 6
3rd floor, Office No. 6EB, 341 Dubai
Phone: [phone]
Fax: [phone]
Email: [e-mail]

Maschinenfabrik Reinhausen GmbH
Falkensteinstrasse 8
93059 Regensburg

4434052/01 EN ▪ 11/16 ▪

[phone]
[phone]
[e-mail]

www.reinhausen.com