MR VACUTAP VR I HD-Ex, VACUTAP VR I-Ex, VACUTAP VR II-Ex, VACUTAP VR III-Ex Installation And Commissioning Instructions
On-Load Tap-Changer
VACUTAP® VR I HD-Ex
Installation and Commissioning Instructions
5293014/00 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......................................................................................................................... 8
1.1 Manufacturer....................................................................................................................................... 8
1.2 Subject to change without notice......................................................................................................... 8
1.3 Completeness...................................................................................................................................... 8
1.4 Safekeeping......................................................................................................................................... 9
1.5 Notation conventions........................................................................................................................... 9
1.5.1 Symbols................................................................................................................................................................. 9
1.5.2 Hazard communication system........................................................................................................................... 10
1.5.3 Information system.............................................................................................................................................. 11
2 Safety................................................................................................................................. 13
2.1 Appropriate use................................................................................................................................. 13
2.2 Fundamental safety instructions........................................................................................................ 14
2.3 Standards and regulations................................................................................................................. 15
2.3.1 Application range of the on-load tap-changer..................................................................................................... 15
2.3.2 Standards and regulations.................................................................................................................................. 18
2.4 Measures for ensuring compliance with explosion protection requirements..................................... 18
2.4.1 Measures taken by the manufacturer.................................................................................................................. 18
2.4.2 Measures to be taken by the transformer manufacturer/operator....................................................................... 18
2.5 Personnel qualification...................................................................................................................... 22
2.6 Personal protective equipment.......................................................................................................... 23
3 Product description.......................................................................................................... 25
3.1 Scope of delivery............................................................................................................................... 25
3.2 On-load tap-changer.......................................................................................................................... 25
3.2.1 Function description............................................................................................................................................ 25
3.2.2 Setup/models...................................................................................................................................................... 26
3.2.3 Name plate.......................................................................................................................................................... 31
3.3 Drive shaft......................................................................................................................................... 31
3.3.1 Function description............................................................................................................................................ 31
3.3.2 Design/Model...................................................................................................................................................... 33
3.3.3 Identification plate............................................................................................................................................... 35
3.4 Protective relay.................................................................................................................................. 35
3.4.1 Function description............................................................................................................................................ 35
3.4.2 Setup/versions..................................................................................................................................................... 36
Maschinenfabrik Reinhausen GmbH 2017 35293014/00 EN VACUTAP® VR I HD-Ex
Table of contents
3.4.3 Name plate.......................................................................................................................................................... 37
4 Packaging, transport and storage................................................................................... 38
4.1 Packaging.......................................................................................................................................... 38
4.1.1 Suitability............................................................................................................................................................. 38
4.1.2 Markings.............................................................................................................................................................. 38
4.2 Transportation, receipt and handling of shipments............................................................................ 39
4.3 Storage of shipments......................................................................................................................... 40
4.4 Unpacking shipments and checking for transportation damages...................................................... 41
5 Mounting............................................................................................................................ 42
5.1 Preparatory work............................................................................................................................... 42
5.1.1 Fitting mounting flange on transformer cover...................................................................................................... 43
5.1.2 Fitting stud bolts on mounting flange................................................................................................................... 43
5.2 Installing the standard version on-load tap-changer in the transformer............................................ 44
5.2.1 Fastening on-load tap-changer to transformer cover.......................................................................................... 44
5.2.2 Connecting the tap winding and on-load tap-changer take-off lead.................................................................... 56
5.2.3 Carrying out transformer ratio test before drying................................................................................................. 64
5.2.4 Measuring DC resistance on transformer............................................................................................................ 65
5.2.5 Drying on-load tap-changer in autoclave............................................................................................................. 66
5.2.6 Drying on-load tap-changer in transformer tank.................................................................................................. 68
5.2.7 Carrying out transformer ratio test after drying.................................................................................................... 89
5.3 Installing on-load tap-changer in transformer (bell-type tank version)............................................... 90
5.3.1 Inserting on-load tap-changer into supporting structure...................................................................................... 90
5.3.2 Connecting the tap winding and on-load tap-changer take-off lead.................................................................. 100
5.3.3 Carrying out transformer ratio test before drying............................................................................................... 108
5.3.4 Measuring DC resistance on transformer.......................................................................................................... 109
5.3.5 Drying on-load tap-changer in autoclave........................................................................................................... 110
5.3.6 Lifting top part of on-load tap-changer head off supporting flange (bottom part).............................................. 112
5.3.7 Fit the bell-type tank and connect the on-load tap-changer to the top part of the on-load tap-changer head... 121
5.3.8 Drying on-load tap-changer in transformer tank................................................................................................ 134
5.3.9 Carrying out transformer ratio test after drying.................................................................................................. 156
5.4 Filling the oil compartment of the on-load tap-changer with oil....................................................... 157
5.5 Fitting protective devices and drive components............................................................................. 158
5.5.1 Connecting the tap-change supervisory device................................................................................................ 158
5.5.2 Installing protective relay in piping and connecting........................................................................................... 159
5.5.3 Fitting motor-drive unit....................................................................................................................................... 168
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Table of contents
5.5.4 Fitting drive shaft............................................................................................................................................... 168
5.5.5 Centering on-load tap-changer and motor-drive unit......................................................................................... 192
5.5.6 Installing electrics for motor-drive unit............................................................................................................... 192
6 Commissioning the on-load tap-changer at the transformer manufacturer's site... 193
6.1 Bleeding on-load tap-changer head and suction pipe..................................................................... 193
6.1.1 Bleeding on-load tap-changer head.................................................................................................................. 193
6.1.2 Bleeding suction pipe on pipe connection S...................................................................................................... 194
6.2 Grounding the on-load tap-changer................................................................................................. 194
6.3 Performing tests on motor-drive unit............................................................................................... 196
6.4 Performing trial tap-change operations........................................................................................... 196
6.5 High-voltage tests on the transformer............................................................................................. 197
7 Transporting transformer to the operating site........................................................... 199
7.1 Transport with removed drive.......................................................................................................... 199
7.2 Transport with oil fill and without oil conservator............................................................................. 199
7.3 Transport without oil fill.................................................................................................................... 200
7.3.1 Emptying oil compartment via pipe connection S.............................................................................................. 200
8 Commissioning the transformer at the operating site................................................ 202
8.1 Checking motor-drive unit................................................................................................................ 202
8.2 Checking protective relay................................................................................................................ 203
8.2.1 Checking protective relay (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5, 2001/R, 2003).................................... 203
8.2.2 Checking protective relay (RS 2004)................................................................................................................. 204
8.3 Filling the oil compartment of the on-load tap-changer with oil....................................................... 204
8.4 Bleeding on-load tap-changer head and suction pipe..................................................................... 206
8.4.1 Bleeding on-load tap-changer head.................................................................................................................. 206
8.4.2 Bleeding suction pipe on pipe connection S...................................................................................................... 207
8.5 Performing trial tap-change operations........................................................................................... 207
8.6 Commissioning the transformer....................................................................................................... 208
9 Fault elimination.............................................................................................................. 209
9.1 Tripping of the protective relay and re-commissioning the transformer........................................... 211
9.1.1 Flap valve in IN SERVICE position................................................................................................................... 212
9.1.2 Flap valve in OFF position................................................................................................................................. 212
9.1.3 Re-commissioning the transformer................................................................................................................... 212
10 Technical data................................................................................................................. 213
Maschinenfabrik Reinhausen GmbH 2017 55293014/00 EN VACUTAP® VR I HD-Ex
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10.1 Limit values for dielectric strength and water content of on-load tap-changer oil............................ 214
10.2 Technical data for protective relay................................................................................................... 215
10.2.1 Protective relay with several dry-reed magnetic switches................................................................................. 216
11 Drawings.......................................................................................................................... 217
11.1 VACUTAP® VRC/VRE-Ex, installation drawing (899992)............................................................... 217
11.2 VACUTAP® VRC/VRE-Ex, installation drawing (743600)............................................................... 218
11.3 VACUTAP® VRD/VRF-Ex, installation drawing (899898)............................................................... 219
11.4 VACUTAP® VRD/VRF-Ex, installation drawing (743601)............................................................... 220
11.5 VACUTAP® VRG-Ex, installation drawing (899945)....................................................................... 221
11.6 VACUTAP® VRG-Ex, installation drawing (743602)....................................................................... 222
11.7 VACUTAP® VRC/VRE-Ex, installation position of tap selector connection contacts (727042)...... 223
11.8 VACUTAP® VRC/VRE-Ex, installation position of tap selector connection contacts (743603)...... 224
11.9 VACUTAP® VRD/VRF/VRG-Ex, fine tap selector connection contact and change-over selector
connection contact (899941)........................................................................................................... 225
11.10 VACUTAP® VR-Ex, special design for bell-type tank installation (720781).................................... 226
11.11 VACUTAP® VR-Ex, lifting device for bell-type tank installation (720845)....................................... 227
11.12 VACUTAP® VR-Ex, on-load tap-changer head (720847)............................................................... 228
11.13 Pipe connection Q with tap-change supervisory control (766161).................................................. 229
11.14 VACUTAP® VR-Ex, adjustment positions (728557)....................................................................... 230
11.15 VACUTAP® VRC/VRE-Ex, adjustment plan without change-over selector (719853)..................... 231
11.16 VACUTAP® VRC/VRE-Ex, adjustment plan without change-over selector (742422)..................... 233
11.17 VACUTAP® VRD/VRF-Ex, adjustment plan without change-over selector (721089)..................... 235
11.18 VACUTAP® VRD/VRF-Ex, adjustment plan without change-over selector (742423)..................... 237
11.19 VACUTAP® VRC III/VRC II/VRE III-Ex, adjustment plan with reversing change-over selector
connection (719850)........................................................................................................................ 239
11.20 VACUTAP® VRC I/VRE I-Ex, adjustment plan with reversing change-over selector connection
(719851).......................................................................................................................................... 240
11.21 VACUTAP® VRD/VRF-Ex, adjustment plan with reversing change-over selector connection
(721092).......................................................................................................................................... 241
11.22 VACUTAP® VRD/VRF-Ex, adjustment plan with reversing change-over selector connection
(745024).......................................................................................................................................... 242
11.23 VACUTAP® VRG-Ex, adjustment plan with reversing change-over selector connection (727074).......
243
11.24 VACUTAP® VRG-Ex, adjustment plan with reversing change-over selector connection (742424).......
244
11.25 VACUTAP® VRC/VRE-Ex, adjustment plan with coarse tap selector connection (719852)........... 245
11.26 VACUTAP® VRC/VRE-Ex, adjustment plan with coarse tap selector connection (742425)........... 246
Maschinenfabrik Reinhausen GmbH 20176 5293014/00 ENVACUTAP® VR I HD-Ex
Table of contents
11.27 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 10, 2-5 coarse tap connections (731412)............................................................. 247
11.28 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 10, 2-5 coarse tap connections (745032)............................................................. 248
11.29 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 12, 2-5 coarse tap connections (731411)............................................................. 249
11.30 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 12, 2-5 coarse tap connections (745031)............................................................. 250
11.31 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 14, 2-5 coarse tap connections (731410)............................................................. 251
11.32 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 14, 2-5 coarse tap connections (745030)............................................................. 252
11.33 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 16, 2-5 coarse tap connections (731000)............................................................. 253
11.34 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 16, 2-5 coarse tap connections (745029)............................................................. 254
11.35 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 18, 2-5 coarse tap connections (730977)............................................................. 255
11.36 Adjustment plan VACUTAP® VRC-Ex with multiple coarse change-over selector for change-over
selector division 18, 2-5 coarse tap connections (745028)............................................................. 256
11.37 VACUTAP® VRD/VRF-Ex, adjustment plan with coarse tap selector connection (721091)........... 257
11.38 VACUTAP® VRD/VRF-Ex, adjustment plan with coarse tap selector connection (742426)........... 258
11.39 VACUTAP® VRG-Ex, adjustment plan with coarse tap selector connection (727075)................... 259
11.40 VACUTAP® VRG-Ex, adjustment plan with coarse tap selector connection (742427)................... 260
11.41 Tracing template for on-load tap-changer head (890183)............................................................... 261
11.42 Socket wrench for kerosene drain plug (723015)............................................................................ 262
11.43 Screw tools for installation and maintenance (723016)................................................................... 263
11.44 Bevel gear CD 6400, dimensional drawing (892916)...................................................................... 264
Maschinenfabrik Reinhausen GmbH 2017 75293014/00 EN VACUTAP® VR I HD-Ex
1 Introduction
Introduction
1
This technical file contains detailed descriptions of the safe and proper installation, connection, and commissioning of the product.
It also includes safety instructions and general information about the product.
Information about operation can be found in the operating instructions.
This technical file is intended solely for specially trained and authorized personnel.
Manufacturer
1.1
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 are available from this address if required.
Subject to change without notice
1.2
The information contained in this technical file comprises the technical specifications approved at the time of printing. Significant modifications will be included in a new edition of the technical file.
The document number and version number of this technical file are shown in
the footer.
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)
▪ Technical data - General section (available on request)
▪ Technical data - Product-specific section (available on request)
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1 Introduction
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
Grease
Maschinenfabrik Reinhausen GmbH 2017 95293014/00 EN VACUTAP® VR I HD-Ex
Symbol Meaning
Coupling bolt
Use a ruler
Use a saw
Hose clip
Wire eyelet, safety wire
Use a screwdriver
1 Introduction
WARNING
1.5.2
1.5.2.1
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
1.5.2.2
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:
Maschinenfabrik Reinhausen GmbH 201710 5293014/00 ENVACUTAP® VR I HD-Ex
1 Introduction
DANGER! Instruction for avoiding a dangerous situation.
1.5.2.3
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
1.5.3
Warning of combustible substances
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:
Maschinenfabrik Reinhausen GmbH 2017 115293014/00 EN VACUTAP® VR I HD-Ex
Important information.
1 Introduction
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2 Safety
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
The product is an on-load tap-changer and keeps the output voltage of a
transformer constant. 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 across the entire service life of the product, 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 on-load tap-changers and on-load tap-changer
accessories (drive, drive shaft, bevel gear, protective relay, etc.) must
match if the on-load tap-changers and on-load tap-changer accessories
are supplied as a set for one order.
▪ You will find the standard valid for the product and the year of issue on
the nameplate.
▪ Operate the product in accordance with this technical file, the agreed-
upon delivery conditions and the technical data.
▪ Ensure that all necessary work is performed by qualified personnel only.
▪ Only use the equipment and special tools included in delivery for the in-
tended purpose and in accordance with the specifications of this technical file.
▪ The on-load tap-changer is not intended to be used with an oil filter unit.
▪ The measures described in this technical file must be taken in order to
comply with explosion protection requirements.
Maschinenfabrik Reinhausen GmbH 2017 135293014/00 EN VACUTAP® VR I HD-Ex
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:
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" [► 23].
▪ Never wear damaged personal protective equipment.
▪ Never wear rings, necklaces, or other jewelry.
▪ If you have long hair, wear a hairnet.
2 Safety
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 the product in potentially explosive areas.
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.
2.3
2.3.1
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.
Standards and regulations
The standards and regulations which apply to the explosion-protected product are described in the following chapters.
Application range of the on-load tap-changer
The on-load tap-changer is certified for Ex II 3G Ex nAC IIC T3 Gc. Refer to
the following overview for the resulting application range.
1 2 3 4 5 6 7 8
II 3G Ex nAC IIC T3 Gc
Table 4: Example of the application range
Number Meaning
1 Sign for explosion protection
2 Equipment group
3 Equipment category
Maschinenfabrik Reinhausen GmbH 2017 155293014/00 EN VACUTAP® VR I HD-Ex
Number Meaning
4 Ex: Symbol for explosion-protected equipment
5 Ignition protection type
6 Explosion group
7 Temperature class
8 EPL (Equipment Protection Level)
Equipment groups (number 2)
I Equipment in this category is intended for use in under-
ground parts of mines as well as those parts of surface installations of such mines endangered by firedamp and/or
combustible dust.
II Equipment in this category is intended for use in other
areas in which explosive atmospheres may be present.
Table 5: Equipment groups
2 Safety
Equipment category / zone classification (number 3)
Designation for
gases
1G
(0)
Designation for
dusts
1D
(20)
Definition
Equipment in this category is intended for
use in areas in which explosive atmospheres
caused by mixtures of air and gases, vapors
or mists or by air/dust mixtures are present
continuously, for long periods or frequently.
2G
(1)
2D
(21)
Equipment in this category is intended for
use in areas in which explosive atmospheres
caused by gases, vapors, mists or air/dust
mixtures occur occasionally.
3G
(2)
3D
(22)
Equipment in this category is intended for
use in areas in which explosive atmospheres
caused by gases, vapors, mists, or air/dust
mixtures are unlikely to occur or, if they do
occur, are likely to do so only infrequently
and for a short period only.
Table 6: Equipment category / zone classification
Ignition protection types (number 5)
d Pressure-proof enclosure
e Increased safety
I Intrinsic safety (ia, ib)
m Encapsulation
o Oil immersion
p Pressurized apparatus
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2 Safety
q Powder filling
n Ignition protection type "n" (only zone 2)
n A: non-sparking equipment
n C: sparking equipment with special protection for contacts
n R: vapor-protected housing
Table 7: Ignition protection types
Explosion group (number 6)
EN/IEC Gases, vapors (examples) Min. ignition energy
(mJ)
IIA Ammonia -
IIA Acetic acid, acetone, benzene,
0.18
diesel, ethane, ether, fuel oil, hexane, methane, petrol, petroleum,
propane
IIB Ethylene, isoprene, town gas 0.06
IIC Acetylene, carbon disulfide, hy-
0.02
drogen
Table 8: Explosion groups
Temperature classes (number 7)
Temperature class
Maximum equipment surface
temperature
Ignition temperature of the flammable substances
T1 450 °C > 450 °C
T2 300 °C > 300 °C < 450 °C
T3 200 °C > 200 °C < 300 °C
T4 135 °C > 135 °C < 200 °C
T5 100 °C > 100 °C < 135 °C
T6 85 °C > 85 °C < 100 °C
Table 9: Temperature classes
Equipment protection level (EPL) (number 8)
The EPL indicates the level of protection defined for a device based on the
level of probability of ignition and taking account of the differences between
potentially explosive gas atmospheres, potentially explosive dust atmospheres, and potentially explosive atmospheres in mine workings affected by
firedamp.
Maschinenfabrik Reinhausen GmbH 2017 175293014/00 EN VACUTAP® VR I HD-Ex
2 Safety
2.3.2
2.4
2.4.1
2.4.1.1
Standards and regulations
The following standards and regulations apply to explosion-proof on-load
tap-changers:
▪ EN 60079-0: Equipment – General requirements
▪ EN 60079-15: Equipment protection by type of protection "n"
▪ Additional requirements apply to vacuum interrupters, as these are her-
metically sealed devices that generate arcs, sparks or hot surfaces.
▪ Additional requirements apply to the diverter switch oil compartment, as
this is a sealed or encapsulated device that generates arcs, sparks or
hot surfaces.
Measures for ensuring compliance with explosion protection requirements
Measures taken by the manufacturer
Maschinenfabrik Reinhausen has taken the following measures for ensuring
compliance with explosion protection requirements. You do not need to take
any special measures in this regard.
Quality of the insulating oil in the on-load tap-changer
2.4.1.2
2.4.2
The quality of the insulating oil required by IEC 60296 and the quality of the
synthetic esters required by IEC 61099 in the oil compartment of the on-load
tap-changer is ensured by using vacuum cells in transition resistors.
Monitoring the oil temperature in the diverter switch oil compartment
A temperature sensor is provided in the on-load tap-changer head cover for
monitoring the oil temperature in the diverter switch oil compartment. The
corresponding temperature monitoring relay is in the TAPMOTION® ED-Ex.
Temperature monitoring prevents further switching of the on-load tap-changer when the maximum permitted temperature is reached. This maximum permitted temperature is factory-configured for each specific order for all onload tap-changer types (maximum 130 °C) and secured against accidental
incorrect adjustment.
Measures to be taken by the transformer manufacturer/operator
The following measures for ensuring compliance with explosion protection
requirements must be taken by the transformer manufacturer/operator.
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2 Safety
2.4.2.1
Prescribed protective and drive components
Operate the on-load tap-changer only in conjunction with the following components:
▪ Ex protective relay
▪ Ex motor-drive unit
▪ Ex drive shaft
Maschinenfabrik Reinhausen GmbH 2017 195293014/00 EN VACUTAP® VR I HD-Ex
2 Safety
2.4.2.2
Setting up the on-load tap-changer oil system
Operate the on-load tap-changer only with a suitable oil system. This diverter switch oil system consists of the diverter switch oil compartment, protective relay, and oil conservator of the on-load tap-changer. It ensures that
enough insulating oil is present in the diverter switch oil compartment at all
times.
2.4.2.3
Figure 1: On-load tap-changer oil system
1 Diverter switch oil compart-
5 Signaling contacts
ment
2 Temperature sensor 6 Oil conservator
3 Protective relay 7 Dehydrating breather
4 Level indicator
Oil conservator to be used
The oil conservator of the on-load tap-changer ensures that sufficient insulating oil is present in the on-load tap-changer oil system at all times during
operation.
Therefore, operate the on-load tap-changer only with a oil conservator that
fulfills the following requirements:
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2.4.2.3.1
2.4.2.3.2
2.4.2.3.3
2.4.2.3.4
Dehydrating breather
The oil conservator must be equipped with a dehydrating breather in accordance with VDE 0532-216-5. The dehydrating breather prevents water, impurities, insects etc. from entering the insulating oil.
Level indicator
The oil conservator must have a level indicator from which the minimum oil
quantity required and the maximum quantity permitted, as well as the current
oil level, can be read.
Level monitoring
The oil level in the oil conservator must be monitored at all times during operation. Therefore, loop the signaling contact for falling below the minimum
oil level in the on-load tap-changer's oil conservator to the tripping circuit of
the circuit breaker so that the circuit breaker will immediately de-energize the
transformer when the oil level in the oil conservator falls below this minimum.
Insulating oil to be used
When filling the diverter switch oil compartment and its oil conservator, use
only new mineral insulating oil for transformers in accordance with IEC
60296 (Specification for unused mineral insulating oils for transformers and
switchgear) or synthetic ester in accordance with IEC 61099 (Specifications
for unused synthetic organic esters for electrical purposes).
2.4.2.3.5
Checking the quality of the insulating oil in the Ex transformer
During the tap changes, polarity sparks (low energy) may occur at the tap
selector of the on-load tap-changer in the transformer tank. In this regard,
observe Section 5.1.6 and 5.1.7 in the on-load tap-changer standard IEC
60214.
Therefore, check the quality and dielectric strength of the insulating oil in the
transformer tank on a regular basis and comply with the service intervals for
the oil change.
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2.4.2.4
Corrosion protection measures
Because further installation steps are required before operation of the onload tap-changer, sufficient corrosion protection cannot be provided at certain interfaces to the transformer when the device leaves the factory.
Figure 2: On-load tap-changer head
1 Sealing surface on piping con-
nection flange
2 Air-vent valve 4 Through-holes
3 Contact surface on on-load
tap-changer head
The sealing surfaces on the piping connection flange are zinc-plated ex factory. The through-holes are zinc-plated and partially painted.
The contact surface of the on-load tap-changer head is primed ex factory.
The through-holes are primed and partially painted.
The transformer manufacturer is responsible for the design of the mating
surfaces on the transformer and piping and that of the screw connections
needed for these attachments.
1. Provide suitable sealing to prevent electrolytes from entering sealing
surfaces and holes.
2. Design screws, washers, nuts etc. in A4 in accordance with ISO
3506-1/ISO 3506-2 standard.
3. If the painted surfaces are damaged, note repair instructions. These can
be requested from Maschinenfabrik Reinhausen GmbH's Technical
Service department.
Personnel qualification
2.5
The person responsible for assembly, commissioning, operation, maintenance and inspection must ensure that the personnel are sufficiently qualified.
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2 Safety
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.
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
2.6
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 personal protective equipment.
▪ Observe information about personal protective equipment provided in
the work area.
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2 Safety
Personal protective equipment to be worn at all times
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.
Safety shoes
To protect against falling heavy objects
and slipping on slippery surfaces.
Special personal protective equipment for particular environments
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
To protect from mechanical, thermal, and
electrical hazards.
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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 usually delivered as follows:
▪ Oil compartment with on-load tap-changer head and built-in diverter
switch insert
▪ Selector
▪ Ex motor-drive unit
▪ Ex drive shaft with coupling parts and bevel gear
▪ Ex protective relay
▪ Technical files
Please refer to the delivery slip for full details of scope of delivery.
Single-phase on-load tap-changers are also available as an on-load tapchanger set with a common motor-drive unit.
3.2.1
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
You will find more information in the "Packaging, transport, and storage"
[► 38] chapter.
On-load tap-changer
3.2
Function description
On-load tap-changers are used to adjust the transmission ratio of transformers without interrupting the load flow. Fluctuations in voltage occurring in the
power transmission grid, for example, can therefore be compensated for. For
this purpose, on-load tap-changers are fitted in transformers and connected
to the active part of the transformer.
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A motor-drive unit, which receives a control impulse (e.g. from a voltage regulator), changes the on-load tap-changer's operating position, which adapts
the transmission ratio of the transformer to the respective operating requirements.
3.2.2
Figure 3: System overview of on-load tap-changer Transformer
1 Transformer tank 6 Upper gear unit
2 Motor-drive unit 7 On-load tap-changer
3 Vertical drive shaft 8 RS protective relay
4 Bevel gear 9 Oil conservator
5 Horizontal drive shaft 10 Active part of the transformer
Setup/models
The on-load tap-changer consists of the on-load tap-changer head, oil compartment with built-in diverter switch insert and the tap selector mounted below (also available with change-over selector on request).
The design and designation of the most important on-load tap-changer components are shown in the installation drawings in the appendix.
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For the number of maximum operating positions of the on-load tap-changer,
refer to the Technical data.
Figure 4: VACUTAP® VRC/VRE
1 On-load tap-changer head 3 Tap selector
2 Oil compartment 4 Change-over selector
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Figure 5: VACUTAP® VRD/VRF
1 On-load tap-changer head 3 Tap selector
2 Oil compartment 4 Change-over selector
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3.2.2.1
Figure 6: VACUTAP® VRG
1 On-load tap-changer head 3 Tap selector
2 Oil compartment 4 Change-over selector
Pipe connections
The on-load tap-changer head features 4 pipe connections for different purposes.
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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 loosened.
Figure 7: Pipe connections with pipe bends
Pipe connection Q
Pipe connection Q is sealed off with a blank cover and, depending on the
on-load tap-changer type, is intended for the bushing of the tap-change supervisory device supplied as an option.
The functions of the R and Q pipe connections can be interchanged.
Pipe connection S
The pipe bend on pipe connection S features a vent screw and can be connected to a pipe that ends with a drain valve on the side of the transformer
tank at operating height. If the on-load tap-changer is fitted with an oil suction pipe, the on-load tap-changer can be completely emptied via pipe connection S.
Pipe connection R
Pipe connection R is provided for attachment of the protective relay and connection of the on-load tap-changer oil conservator and can be interchanged
with pipe connection Q.
Pipe connection E2
The pipe connection E2 is sealed off with a blank cover. It leads into the oil
tank of the transformer, directly under the on-load tap-changer head and can
be connected to a collective pipe for the Buchholz relay, if necessary. This
pipe connection serves a further purpose, namely to equalize the pressure
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