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

Table of contents

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

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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.: [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.

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 Safety

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 Safety

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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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 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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3 Product description

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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3 Product description

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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3 Product description

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 Product description

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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3 Product description

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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3 Product description

between the transformer tank and oil compartment of the on-load tap-chang­er, which is necessary for drying, oil filling and transportation of the trans­former.

3.2.3

3.3

3.3.1

Name plate

The name plate is on the on-load tap-changer head cover.

Figure 8: Position of name plate

Drive shaft

Function description

The drive shaft is the mechanical connection between drive and on-load tap­changer head.

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.

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3 Product description

The explosion-proof drive shaft consists of a square tube with insulator and
is coupled by two coupling brackets and one coupling bolt at both ends to
the drive or driven shaft end of the device to be connected.

Figure 9: Explosion-proof drive shaft with insulator

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3 Product description

3.3.2

Design/Model

The design of the explosion-proof drive shaft is described in this section.

Figure 10: Components of the explosion-proof drive shaft

1 Bevel gear 2 Hose clip

3 Screws 4 Telescopic protective tube

5 Coupling bracket 6 Insulator

7 Double coupling bracket 8 Square tube

9 Pin 10 Adapter ring

11 Protective cover 12 Hose clip

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3 Product description

Configuration V 1 min Intermediate bearing

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3 Product description

3.3.3

Distance between middle of
hand crank and middle of bevel
gear

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)

Identification plate

The identification plate is on the telescopic protective tube.

Figure 11: Position of the identification plate

Protective relay

3.4

3.4.1

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Function description

The protective relay is used to protect the on-load tap-changer and the
transformer when a malfunction occurs in the diverter switch oil compartment
or selector switch oil compartment. It is tripped when the specified speed of
oil flow from the on-load tap-changer head to the oil conservator is exceeded
due to a fault. The flowing oil actuates the flap valve which tips over into po­sition OFF. The contact in the dry-reed magnetic switch is thereby actuated,
the circuit breakers are tripped, and the transformer is de-energized.

3 Product description

The protective relay is part of an on-load tap-changer filled with insulating
liquid and its properties conform to the applicable valid version of IEC publi­cation 60214-1.

Diverter switch operations at rated switching capacity or at permissible over­load will not cause the protective relay to trip.

The protective relay responds to oil flow, not to gas accumulated in the pro­tective relay. It is not necessary to bleed the protective relay when filling the
transformer with oil. Gas accumulation in the protective relay is normal.

3.4.2

Setup/versions

Front view

Figure 12: RS 2001-Ex

1 Inspection window 2 Pressure equalization element

Rear view

Figure 13: RS 2001-Ex

1 Ground connection 2 Nameplate

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3 Product description

View from above

Figure 14: RS 2001-Ex

3.4.3

1 Gasket 2 Potential tie-in

3 Terminal box cover 4 OPERATION (reset) test but-

ton

5 Slotted head screw for poten-

6 OFF (test tripping) test button

tial tie-in

7 Protective conductor connec-

tion

8 Protective cover with picto-

gram for terminal assignment

9 Dummy plug 10 Connection terminal

Name plate

The name plate for the explosion-protected protective relay is on the rear of
the product.

Figure 15: Position of name plate

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4 Packaging, transport and storage

Packaging, transport and storage

4

Packaging

4.1

The products are sometimes supplied with a sealed packaging and some­times also dried depending on what is required.

A sealed packaging surrounds the packaged goods on all sides with plastic
foil. Products that have also been dried are identified by a yellow label on the
sealed packaging.

The information in the following sections should be applied as appropriate.

4.1.1

NOTICE

4.1.2

Suitability

Property damage due to incorrectly stacked crates!

Stacking the crates incorrectly can lead to damage to the packaged goods!

► Only stack up to 2 equally sized crates on top of one another.

► Do not stack crates above a height of 1.5 m.

The packaging is suitable for undamaged and fully functional means of
transportation in compliance with local transportation laws and regulations.

The packaged goods are packed in a stable crate. This crate ensures that
when in the intended transportation position the packaged goods are stabi­lized to prevent impermissible changes in position, and that none of the parts
touch the loading surface of the means of transport or touch the ground after
unloading.

A sealed packaging surrounds the packaged goods on all sides with plastic
foil. The packaged goods are protected from humidity using a desiccant. The
plastic foil is bonded after the drying agent is added.

Markings

The packaging bears a signature with instructions for safe transport and cor­rect storage. The following symbols apply to the shipment of non-hazardous
goods. Adherence to these symbols is mandatory.

Protect
against

moisture

Table 10: Shipping pictograms

Top Fragile Attach lifting

Center of

gear here

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mass

4 Packaging, transport and storage

Transportation, receipt and handling of shipments

4.2

WARNING

Danger of death and damage to property!

Danger of death and damage to property due to tipping or falling load.

► Transport crate when closed only.

► Do not remove the mounting material used in the crate during transport.

► Only trained and appointed persons may select the sling gear and se-

cure the load.

► Do not walk under the hanging load.

► Use means of transport and lifting gear with a sufficient carrying capaci-

ty in accordance with the weight stated on the delivery slip.

In addition to oscillation stress and shock stress, jolts must also be expected
during transportation. In order to prevent possible damage, avoid dropping,
tipping, knocking over and colliding with the product.

If a crate tips over, falls from a certain height (e.g. when slings tear) or expe­riences an unbroken fall, damage must be expected regardless of the
weight.

Every delivered shipment must be checked for the following by the recipient
before acceptance (acknowledgment of receipt):

▪ Completeness based on the delivery slip

▪ External damage of any type.

Visible damage

The checks must take place after unloading when the crate or transport con­tainer can be accessed from all sides.

If external transport damage is detected on receipt of the shipment, proceed
as follows:

▪ Immediately record the transport damage found in the shipping docu-

ments and have this countersigned by the carrier.

▪ In the event of severe damage, total loss or high damage costs, immedi-

ately notify the sales department at Maschinenfabrik Reinhausen and
the relevant insurance company.

▪ After identifying damage, do not modify the condition of the shipment

further and retain the packaging material until an inspection decision
has been made by the transport company or the insurance company.

▪ Record the details of the damage immediately onsite together with the

carrier involved. This is essential for any claim for damages!

▪ Photograph damage to packaging and packaged goods. This also ap-

plies to signs of corrosion on the packaged goods due to moisture inside
the packaging (rain, snow, condensation).

▪ NOTICE! Be absolutely sure to also check the sealed packaging. If the

sealed packaging is damaged, do not under any circumstances install or
commission the packaged goods. Either dry the dried packaged goods
again as per the operating instructions for the relevant on-load tap-

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4 Packaging, transport and storage

changer/de-energized tap-changer or contact Maschinenfabrik Reinhau­sen GmbH to agree on how to proceed with drying. If this is not done,
the packaged goods may be damaged.

▪ Name the damaged parts.

Hidden damage

4.3

When damages are not determined until unpacking after receipt of the ship­ment (hidden damage), proceed as follows:

▪ Make the party responsible for the damage liable as soon as possible by

telephone and in writing, and prepare a damage report.

▪ Observe the time periods applicable to such actions in the respective

country. Inquire about these in good time.

With hidden damage, it is very hard to make the transportation company (or
other responsible party) liable. Any insurance claims for such damages can
only be successful if relevant provisions are expressly included in the insur­ance terms and conditions.

Storage of shipments

Packaged goods dried by Maschinenfabrik Reinhausen

Upon receipt of the shipment, immediately remove the packaged goods
dried by Maschinenfabrik Reinhausen from the sealed packaging and store
air-tight in dry insulating oil until used if the packaged goods were not sup­plied in oil.

Non-dried packaged goods

Non-dried packaged goods but with a functional sealed packaging can be
stored outdoors when the following conditions are complied with.

When selecting and setting up the storage location, ensure the following:

▪ Protect stored goods against moisture (flooding, water from melting

snow and ice), dirt, pests such as rats, mice, termites and so on, and
against unauthorized access.

▪ Store the crates on timber beams and planks as a protection against ris-

ing damp and for better ventilation.

▪ Ensure sufficient carrying capacity of the ground.

▪ Keep entrance paths free.

▪ Check stored goods at regular intervals. Also take appropriate action af-

ter storms, heavy rain or snow and so on.

Protect the packaging foil from direct sunlight so that it does not disintegrate
under the influence of UV rays, which would cause the packaging to lose its
sealing function.

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4 Packaging, transport and storage

If the product is installed more than 6 months after delivery, suitable meas­ures must be taken without delay. The following measures can be used:

▪ Correctly regenerate the drying agent and restore the sealed packaging.

▪ Unpack the packed goods and store in suitable storage space (well ven-

Unpacking shipments and checking for transportation

4.4
damages

▪ NOTICE! Transport the packaged crate to the place where installation

▪ WARNING! When unpacking, check the condition of the packaged

▪ Check completeness of supplementary parts on the basis of the delivery

tilated, as dust-free as possible, humidity < 50 % where possible).

will take place. Do not open the sealed packaging until just before instal­lation. If this is not done, damage to the packaged goods may occur due
to ineffectively sealed packaging.

goods.Secure packaged goods in an upright crate from tipping out. If
this is not done, the packaged goods may be damaged and serious inju­ries may result.

slip.

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Mounting

5

5 Mounting

WARNING

Risk of crushing from moving parts!

When the on-load tap-changer undertakes a tap-change operation, compo­nents move on the selector, change-over selector, and potential connection
unit, some of which are freely accessible. Reaching into the selector,
change-over selector or potential connection unit during a tap-change oper­ation may result in serious injuries.

► Keep at a safe distance of at least 1 m during tap-change operations.

► Do not reach into the selector, change-over selector, or potential con-

nection unit during tap-change operations.

► Do not switch the on-load tap-changer when working on the selector,

change-over selector, or potential connection unit.

This chapter describes how to install the on-load tap-changer in a transform­er and how to dry it, and also how to mount the protective devices and drive
components.

Preparatory work

5.1

Perform the work stated below before installing the on-load tap-changer in
the transformer.

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5 Mounting

5.1.1

Fitting mounting flange on transformer cover

A mounting flange is required for fitting the on-load tap-changer head on the
transformer cover. This can be supplied as an option or can be produced by
the customer. Mounting flanges made by the customer must comply with the
installation drawings in the appendix.

► NOTICE! Fit mounting flange on transformer cover (pressure tight).En-

sure that the sealing face makes complete contact and is not damaged.

5.1.2

Figure 16: Mounting flange

Fitting stud bolts on mounting flange

To attach the stud bolts to the mounting flange, use a tracing template. This
can be provided upon request free of charge for the initial installation of the
on-load tap-changer.

1. Place tracing template on mounting flange and use the four markings to

align.

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2. Fit stud bolts on mounting flange.

5 Mounting

5.2

5.2.1

5.2.1.1

Figure 17: Tracing template, stud bolts

Installing the standard version on-load tap-changer in the transformer

Perform the work stated below in order to install the on-load tap-changer in
the transformer (standard version).

Fastening on-load tap-changer to transformer cover

This chapter describes how to fasten the on-load tap-changer to the trans­former cover.

Fastening oil compartment on transformer cover

1. CAUTION! Prior to installing the on-load tap-changer, remove the
red-colored packaging and transport material from the on-load tap­changer.

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5 Mounting

2. CAUTION! Place the oil compartment on a level surface and secure
it against tipping. An unstably positioned oil compartment may tip over,
resulting in serious injuries and damage.

3. Clean sealing surfaces on mounting flange and on-load tap-changer
head, place oil-resistant gasket on mounting flange.

Figure 18: Sealing surfaces, seal

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5 Mounting

4. Lift the oil compartment by hooking up the on-load tap-changer head
and carefully lower the oil compartment into the cover opening of the
transformer.

Figure 19: Oil compartment

5. Check that the on-load tap-changer head is mounted in the position
specified by the design.

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5 Mounting

6. Screw on-load tap-changer head to mounting flange.

Figure 20: On-load tap-changer head with mounting flange

7. Remove the blocking device from the coupling of the oil compartment
base.

Figure 21: VACUTAP® VRC/VRE, blocking strip

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5 Mounting

Figure 22: VACUTAP® VRD/VRF, blocking plate and shackle

Figure 23: VACUTAP® VRG, blocking plate and shackle

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5 Mounting

5.2.1.2

Securing tap selector on oil compartment of the on-load tap-changer VRC/VRE

1. WARNING! Place the selector on a level surface and secure it
against tipping CAUTION! . An unstably positioned selector may tip,

resulting in injuries and property damage.

2. Remove plastic bag with fastening materials from the selector and keep
them ready.

Figure 24: Plastic bag with fastening materials

3. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.

Figure 25: Blocking strip

4. Place the selector on the lifting device. The weight of the selector is a
maximum of 165 kg.

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5 Mounting

5. NOTICE! Carefully lift selector below the oil compartment, ensuring that
the tap-selector connecting leads are free when lifting the selector on
the oil compartment and do not touch the compartment. Failure to com­ply with this instruction may result in the tap-selector connecting leads
being damaged.

6. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans in the appendix.

7. Screw selector onto oil compartment.

5.2.1.3

Figure 26: Selector with oil compartment

Securing tap selector on oil compartment of the on-load tap-changer VRC/VRE

1. WARNING! Place the selector on a level surface and secure it
against tipping CAUTION! . An unstably positioned selector may tip,

resulting in injuries and property damage.

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5 Mounting

2. Remove plastic bag with fastening materials from the selector and keep
them ready.

Figure 27: Plastic bag with fastening materials

3. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.

Figure 28: Blocking strip

4. Place the selector on the lifting device. The weight of the selector is a
maximum of 270 kg.

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5 Mounting

5. Remove the ring nuts from the selector.

Figure 29: Ring nut

6. NOTICE! Carefully lift selector below the oil compartment, ensuring that
the tap-selector connecting leads are free when lifting the selector on
the oil compartment and do not touch the compartment. Failure to com­ply with this instruction may result in the tap-selector connecting leads
being damaged.

7. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans in the appendix.

8. Screw selector onto oil compartment.

Figure 30: Selector with oil compartment

9. Remove the wooden support on the underside of the change-over se­lector.

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5.2.1.4

Securing tap selector on oil compartment of the on-load tap-changer VRG

1. WARNING! Place the selector on a level surface and secure it
against tipping CAUTION! . An unstably positioned selector may tip,

resulting in injuries and property damage.

2. Remove plastic bag with fastening materials from the selector and keep
them ready.

Figure 31: Plastic bag with fastening materials

3. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.

Figure 32: Blocking strip

4. Place the selector on the lifting device. The weight of the selector is a
maximum of 465 kg.

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5. Remove the ring nuts from the selector.

Figure 33: Ring nut

5 Mounting

6. NOTICE! Carefully lift selector below the oil compartment, ensuring that
the tap-selector connecting leads are free when lifting the selector on
the oil compartment and do not touch the compartment. Failure to com­ply with this instruction may result in the tap-selector connecting leads
being damaged.

7. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans in the appendix.

8. Screw selector onto oil compartment.

Figure 34: Selector with oil compartment

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5.2.1.5

Connecting tap-selector connecting leads

Proceed as follows to connect the tap-selector connecting leads:

1. NOTICE! Carefully screw tap-selector connecting leads to connecting
piece or ring segment. Comply with specified tightening torque and se­cure screw connection. Failure to do so may result in damage to the on­load tap-changer and transformer.

2. Attach screening caps to screw connection.

Figure 35: Connecting piece

Figure 36: Ring segment

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5.2.2

Connecting the tap winding and on-load tap-changer take-off lead

NOTICE

5.2.2.1

Damage to the on-load tap-changer!

Connecting leads which place mechanical strain on the on-load tap-changer
will damage the on-load tap-changer!

► Establish connections carefully.

► Do not twist connection contacts.

► Connect connecting leads without warping or deforming.

► If necessary, use an expansion loop for connecting leads.

► Fit screening caps provided to screw connections.

The tap winding and on-load tap-changer take-off lead must be connected in
accordance with the connection diagram included with the delivery.

Tap selector connection contacts VRC/VRE

The selector connection contacts are indicated on the selector bars, have
crimped ends and a through-hole for M10 screws to allow the tap-selector
connecting leads to be connected with cable shoes.

The screening caps are supplied separately.

In this case a locking washer must be placed below each screening cap. The
M10 connection screws, the nuts, and locking washers are not included in
the scope of delivery.

The through-holes of the connection contacts are either horizontal or verti­cal, depending on the on-load tap-changer version.

Figure 37: Selector connection contacts

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Figure 38: Screening caps

NOTICE

5.2.2.2

Selector connection contacts for multiple coarse change-over selector

In the case of multiple coarse change-over selectors, take care when routing
the cables for connecting to the selector connection contacts and the multi­ple coarse change-over selector connection contacts. These cables should
be as far away as possible from neighboring connection contacts.

► The selector connection contacts that face both multiple coarse change-

over selector columns must have at least 3 mm of paper insulation to
ensure dielectric strength.

Damage to the on-load tap-changer!

Tap-winding connecting leads situated too closely to the change-over selec­tor's moving parts block the change-over selector and therefore result in on­load tap-changer damage!

► Tap-winding connecting leads in the area of the change-over selector

have to be routed such that they are at a sufficient distance from the
change-over selector's moving parts.

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In this regard, please also pay attention to the dimensional drawing on which
the order is based.

Figure 39: Paper insulation

1 Connection from MR already

p Connections to be insulated

has 3 mm of paper insulation

5.2.2.3

Change-over selector connection contacts for reversing change-over selector connection VRC/VRE

The (+) and (-) change-over selector connection contacts are designed as
connecting lugs with through-holes for M10 screws for reversing change­over selector connection.

Connection contact K is designed as an extended fine tap selector connec­tion contact (also with through-hole for M10 screws).

Figure 40: Change-over selector connection contacts for reversing change-over se­lector connection

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NOTICE

Damage to the on-load tap-changer!

Tap-winding connecting leads situated too closely to the change-over selec­tor's moving parts block the change-over selector and therefore result in on­load tap-changer damage!

► Tap-winding connecting leads in the area of the change-over selector

have to be routed such that they are at a sufficient distance from the
change-over selector's moving parts.

Figure 41: Change-over selector connection contacts for reversing change-over se­lector connection (top view)

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5.2.2.4

Change-over selector connection contacts for coarse tap selector connection VRC/VRE

With coarse tap selector connection, the (+) and (-) change-over selector
connection contacts are secured to the respective laminated paper bars of
the coarse change-over selector. Their external appearance is identical to
the fine tap selector contacts (through-hole for M10 screws, always in verti­cal position).

NOTICE

Figure 42: Change-over selector connection contacts for coarse tap selector connec­tion

Damage to the on-load tap-changer!

Tap-winding connecting leads situated too closely to the change-over selec­tor's moving parts block the change-over selector and therefore result in on­load tap-changer damage!

► Tap-winding connecting leads in the area of the change-over selector

have to be routed such that they are at a sufficient distance from the
change-over selector's moving parts.

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Figure 43: Change-over selector connection contacts for coarse tap selector connec­tion (top view)

5.2.2.5

Selector connection contacts VRD/VRF

The selector connection contacts have a through-hole for M12 screws. The
screening caps are supplied separately.

Figure 44: Selector connection contacts

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5.2.2.6

5.2.2.7

Change-over selector connection contacts for reversing change-over selector connection VRD/VRF

The (+) and (-) change-over selector connection contacts are designed like
fine tap selector connection contacts for reversing change-over selector con­nections. The change-over selector connection contacts (0) are produced as
terminal lugs of the crimped connecting lead (=0/K) with a through-hole for
M12 screws.

Figure 45: Change-over selector connection contacts for reversing change-over se­lector connection

Change-over selector connection contacts for coarse tap selector connection VRD/VRF

5.2.2.8

For coarse tap selector connection, the (0) and (–) change-over selector
connection contacts are designed like the fine tap selector connection con­tacts. The change-over selector connection contacts (+) are produced as ter­minal lugs of the crimped connecting lead (+/K) with a through-hole for M12
screws.

Figure 46: Change-over selector connection contacts for coarse tap selector connec­tion

Parallel bridges for VRF I 1601/1801

Bridges for connecting the connection contacts of the fine tap selector and
change-over selector in parallel in accordance with drawing 786919 will be
supplied.

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5.2.2.9

Fine-tap-selector and change-over-selector connection contacts VRG

The selector connection contacts are indicated on the selector bars. The
connection is made at the thread stud of the selector connection contact via
cable shoes and locknuts.

Every connection point must be covered by a screening cap. The screening
caps are designed for lateral connection with a straight cable shoe or for
front connection with an angled cable shoe.

Figure 47: Tap selector connection contacts and change-over selector connection
contacts

Each screening cap is attached with a steel angle piece and 2 screws. The
connection is secured by centre-punching at the perimeter of the screw
head. The distance between the screening caps and adjacent tap-selector
connecting leads must be at least 25 mm!

Figure 48: Screening caps

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5.2.2.10

5.2.2.11

Parallel bridges for VRG I 1601/1801

Bridges for connecting the connection contacts of the fine tap selector and
change-over selector in parallel in accordance with drawing 786920 will be
supplied.

Connecting on-load tap-changer take-off lead

There are through-holes 13 mm in diameter at several points in the take-off
ring of the oil compartment for connecting the on-load tap-changer take-off
lead.

Proceed as follows to connect the on-load tap-changer take-off lead:

1. Connect the on-load tap-changer take-off lead to any through-hole on
the take-off ring of the oil compartment.

2. Secure screw connection.

5.2.3

Figure 49: Take-off ring on oil compartment

Carrying out transformer ratio test before drying

To perform the transformer ratio test, proceed as follows:

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NOTICE

Damage to property!

Damage to on-load tap-changer due to transformer ratio test being incor­rectly performed!

► Do not perform more than 250 tap-change operations on the on-load

tap-changer. If more than 250 tap-change operations are performed,
completely fill oil compartment with insulating oil and lubricate sliding
surfaces of contacts on selector and selector gear with insulating oil.

► Only switch the on-load tap-changer from one operating position to the

next via the upper gear unit. You can use a short tube (diameter
25 mm) with screwed-in coupling bolt (diameter 12 mm) with a hand
wheel or crank for this. When using a drill, do not exceed a maximum
speed of 250 rpm.

► Always check the operating position reached through the inspection

window in the on-load tap-changer head cover. Never overshoot the
end positions, which are indicated in the connection diagram supplied
with the delivery.

► For multiple-column applications with a shared drive, link all on-load

tap-changer heads to one another with the horizontal drive shaft part.

1. Switch on-load tap-changer into the desired operating position. The
diverter switch operation can be heard distinctly.

When actuating the change-over selector a higher torque is required.

5.2.4

2. NOTICE! After operating the diverter switch, continue to crank 2.5 revo­lutions in the same direction on the drive shaft of the upper gear unit in
order to correctly end the tap-change operation. An incomplete tap­change operation may damage the on-load tap-changer!

3. Carry out the transformer ratio test.

4. Repeat the transformer ratio test in all operating positions.

5. Once the transformer ratio test is complete, return on-load tap-changer
to its adjustment position (see supplied connection diagram of the on­load tap-changer).

After the transformer ratio test, open the kerosene drain plug in the oil com­partment if the on-load tap-changer is to be dried with kerosene in the trans­former tank. After drying, the diverter switch insert must be removed, the
kerosene drain plug in the oil compartment closed and the diverter switch
insert refitted.

Measuring DC resistance on transformer

Note the measurement scenarios listed below and the associated maximum
measurement currents when measuring DC resistance on the transformer.

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The measurement DC current is normally restricted to 10 % of the rated cur­rent of the measured transformer winding in order to prevent the winding
from overheating.

5.2.5

NOTICE

Measure the DC resistance in the various on-load tap-changer operating po­sitions. You need to distinguish here whether the measurement current is in­terrupted when changing operating position or not.

Without interruption

in measurement cur­rent

Oil compartment emp-tyMaximum 10 A DC Maximum 50 A DC

Oil compartment filled
with insulating oil

Table 11: Maximum permitted measurement currents when measuring DC resistance
on transformer

Maximum 50 A DC Maximum 50 A DC

With interruption
(measurement cur­rent = 0 A before
change in operating
position)

Drying on-load tap-changer in autoclave

Property damage!

Damage to on-load tap-changer resulting from insufficient dielectric strength
of the mineral insulating oil caused by moisture in the oil compartment.

► Within 10 hours of drying, seal off oil compartment with on-load tap-

changer head cover.

5.2.5.1

Dry on-load tap-changer using the following instructions to ensure the dielec­tric values assured by MR on the on-load tap-changer.

If drying in an autoclave, the following methods are possible:

▪ Vacuum-drying

▪ Vapor-phase drying

Vacuum-drying in the autoclave

Before starting vacuum-drying in the autoclave, you must remove the on­load tap-changer head cover and on-load tap-changer accessories:

1. NOTICE! Remove the on-load tap-changer head cover (24 screws M10/
wrench size 17 with safety elements) and store it outside the autoclave.
If this is not done, the on-load tap-changer head cover may be dam­aged.

2. NOTICE! Remove on-load tap-changer accessories and store outside
autoclave: motor-drive unit, drive shaft, protective relay, bevel gear,
temperature sensor. If this is not done, the on-load tap-changer acces­sories may be damaged.

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Vacuum-drying in the autoclave

1. Heat up the on-load tap-changer in air at atmospheric pressure with a
temperature increase of about 10 °C/h to a final temperature of maxi­mum 110 °C.

2. Pre-dry the on-load tap-changer in circulating air at a max. temperature
of 110 °C for a period of 20 hours.

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

5.2.5.2

Vapor-phase drying in the autoclave

For vapor-phase drying in the autoclave, you must open the kerosene drain
plug in the oil compartment base before drying so that the kerosene conden­sate can drain from the oil compartment.

1. Unscrew kerosene drain plug in base of oil compartment counter-clock­wise. The kerosene drain plug cannot be unscrewed all the way.

Figure 50: Kerosene drain plug

2. NOTICE! Remove the on-load tap-changer head cover (24 screws M10/
wrench size 17 with locking washers) and store it outside the autoclave.
Otherwise, the on-load tap-changer head cover may be damaged.

3. NOTICE! Remove on-load tap-changer accessories and store outside
autoclave: motor-drive unit, drive shaft, protective relay, bevel gear,
temperature sensor. Otherwise, the on-load tap-changer accessories
may be damaged.

Vapor-phase drying in the autoclave

1. Supply kerosene vapor at a temperature of around 90 °C. Keep this
temperature constant for 3 to 4 hours.

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2. Increase the kerosene vapor temperature by approx. 10 °C/hour to the
desired final temperature of max. 125 °C at the on-load tap-changer.

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

► NOTICE! Close kerosene drain plug clockwise (tightening torque 20

Nm). An open kerosene drain plug leads to oil escaping from the oil
compartment and therefore to damage to the on-load tap-changer and
transformer.

5.2.6

NOTICE

5.2.6.1

Drying on-load tap-changer in transformer tank

Property damage!

Damage to on-load tap-changer resulting from insufficient dielectric strength
of the mineral insulating oil caused by moisture in the oil compartment.

► Within 10 hours of drying, seal off oil compartment with on-load tap-

changer head cover.

Dry on-load tap-changer using the following instructions to ensure the dielec­tric values assured by MR on the on-load tap-changer.

If you want to dry the on-load tap-changer in the transformer tank, first com­plete transformer assembly and then undertake drying.

If drying in the transformer tank, the following methods are possible:

▪ Vacuum-drying

▪ Vapor-phase drying

Vacuum-drying in the transformer tank

To vacuum dry the on-load tap-changer in the transformer tank, proceed as
follows.

The on-load tap-changer head cover remains closed during the entire drying
process.

1. Establish a connecting lead either between connections E2 and Q or
connections E2 and R on the on-load tap-changer head.

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2. Seal off unused pipe connections with a suitable blank cover.

Figure 51: Connecting lead

Vacuum-drying in the transformer tank

1. Heat up the on-load tap-changer in air at atmospheric pressure with a
temperature increase of about 10 °C/h to a final temperature of maxi­mum 110 °C.

2. Pre-dry the on-load tap-changer in circulating air at a max. temperature
of 110 °C for a period of 20 hours.

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following drying".

5.2.6.2

Vapor-phase drying in the transformer tank

If you have not opened the kerosene drain plug in advance (e.g. after the
transformer ratio test), you have to open the kerosene drain plug before dry­ing the kerosene in the transformer tank so that the kerosene condensate
can drain from the oil compartment.

The kerosene drain plug is located in the oil compartment base and is not
generally accessible from the outside. For this reason, you first have to re­move the diverter switch insert, open the kerosene drain plug, and then in­stall the diverter switch insert again. After the drying process, you have to re­move the diverter switch insert again to close the kerosene drain plug.

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NOTICE

5.2.6.2.1

5.2.6.2.1.1

Damage to the on-load tap-changer!

Damage to the on-load tap-changer and oil suction pipe due to incorrect or­der of installation.

► Strictly adhere to the order of installation. Make sure to always install

the diverter switch insert before inserting the oil suction pipe into the oil
compartment.

Removing diverter switch insert

Proceed as follows to remove the diverter switch insert.

Moving on-load tap-changer to adjustment position

► Switching the on-load tap-changer into the adjustment position (see

supplied connection diagram of the on-load tap-changer).

5.2.6.2.1.2

WARNING

Figure 52: Adjustment position

Removing on-load tap-changer head cover

Danger of explosion!

Danger of death from explosive gases under the on-load tap-changer 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 arise.

► De-energize all auxiliary circuits (for example tap-change supervisory

device) before removing the on-load tap-changer 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.

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NOTICE

Damage to the on-load tap-changer and transformer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer and transformer!

► Take care to avoid parts falling into the oil compartment.

► Check that you have the same number of small parts when disassem-

bling and reassembling.

1. Make sure that inspection window is sealed off with cover.

2. Loosen screws with locking elements on on-load tap-changer head cov­er.

Figure 53: On-load tap-changer head cover

3. NOTICE! Remove the on-load tap-changer head cover. Make sure that
sealing surfaces on the on-load tap-changer head cover and on-load
tap-changer head are in sound condition when removing and during all
other work and that the o-ring is also undamaged. Damaged sealing
surfaces lead to oil escaping and therefore to on-load tap-changer and
transformer damage.

Figure 54: On-load tap-changer head cover

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5.2.6.2.1.3

5.2.6.2.1.4

Removing tap position indicator (version without multiple coarse change-over selector)

► Pull the spring clip off the shaft end and remove the tap position indica-

tor disc.

Figure 55: Tap position indicator disk

Removing tap position indicator from multiple coarse change-over selector with more than 35 operating positions

1. Ensure that the red marks on the panel, tap position indicator disk and
cover disk produce a continuous red line.

2. Remove countersunk head screw.

Figure 56: Countersunk head screw

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3. Lever cover disk off underlying disk with flat screwdriver and pull out po­sition-indication disk from between panel and bracket.

Figure 57: Cover disk and position-indication disk

4. Remove hexagon screws and associated lock tab.

Figure 58: Lock tab

5. Pull panel and bracket up and off indicator drive shaft.

Figure 59: Panel

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5.2.6.2.1.5

NOTICE

Removing the tap-change supervisory device

Damage to the on-load tap-changer and transformer!

Removing the tap-change monitoring unit without due care may damage it,
thereby resulting in damage to the on-load tap-changer and transformer!

► Disconnect tap-change monitoring unit with care in order not to damage

or rip out the connecting leads.

1. Take the tap-change supervisory device plug connector out of the
mounting bracket and disconnect it.

Figure 60: Plug connector

2. Remove nuts and locking elements (3 or 4 depending on model) on the
mounting plate.

Figure 61: Mounting plate

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3. Remove tap-change supervisory device with mounting plate and drive
shaft.

Figure 62: Tap-change supervisory device with mounting plate and drive shaft

4. Swivel the lead of the tap-change supervisory device out of the on-load
tap-changer head in direction indicated by the arrow until the cable will
not be damaged when the on-load tap-changer insert is pulled out.

Swiveling out the lead of the tap-change supervisory device

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5.2.6.2.1.6

Removing the oil suction pipe

1. Remove cable ties from the oil suction pipe.

Figure 63: Cable tie

2. Pull oil suction pipe out of on-load tap-changer head.

5.2.6.2.1.7

Figure 64: Oil suction pipe

Lifting out diverter switch insert

1. By turning the coupling tube on the upper screening ring, align it in such
a manner that the triangular marks on the on-load tap-changer head and
those on the coupling tube match up.

Figure 65: Aligning the coupling tube

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2. Insert the lifting gear in the eyebolts of the coupling tube and position
vertically above the diverter switch insert.

3. Lift the diverter switch insert slowly and vertically out of oil compartment.

5.2.6.2.2

Figure 66: Diverter switch insert

4. CAUTION! Place the diverter switch insert on a level surface and se­cure it against tipping. An unstably positioned diverter switch insert may
tip, resulting in injuries and damage.

5. NOTICE! Neither operate the diverter switch insert while removed nor
change the position of the tap selector coupling.Otherwise, the diverter
switch insert may be damaged when being reinstalled.

Opening kerosene drain plug

► NOTICE! Unscrew kerosene drain plug with extended socket wrench

counter-clockwise until it starts to get hard to turn.Never unscrew the
kerosene drain plug all the way.

Figure 67: Kerosene drain plug

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5.2.6.2.3

5.2.6.2.3.1

Inserting diverter switch insert

Proceed as follows to insert the diverter switch insert.

Inserting diverter switch insert

1. Check that all six insulating shims are present in the energy accumula­tor carrier.

Figure 68: Insulating shim

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2. To fit the diverter switch insert, ensure that the tap selector coupling is in
the adjustment position.

Figure 69: Adjustment markings in oil compartment base VACUTAP® VRC/VRE

Figure 70: Adjustment markings in oil compartment base VACUTAP® VRD/VRF

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Figure 71: Adjustment markings in oil compartment base VACUTAP® VRG

3. Ensure that the diverter switch insert's energy accumulator is inter­locked (the energy accumulator's eccentric disk is at its highest point).

4. Attach lifting gear to diverter switch insert and position diverter switch in­sert over oil compartment.

5. Align diverter switch insert such that the red markings at the top of the
energy accumulator and on the on-load tap-changer head are opposite
one another.

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6. Slowly lower diverter switch insert until it meets the oil compartment
base.

Figure 72: Markings

7. Carefully press until energy accumulator carrier is in position. The shape
of the tap selector coupling ensures that coupling is only possible in the
correct position.

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8. Check the distance between the upper edge of the diverter switch insert
coupling tube and the on-load tap-changer head flange. The distance is
10 ± 2 mm (cover mounting and bell-type tank mounting).

Figure 73: Distance between the upper edge of the coupling tube and the on-load
tap-changer head flange

5.2.6.2.3.2

NOTICE

Inserting oil suction pipe

Damage to the on-load tap-changer!

Damage to the on-load tap-changer and oil suction pipe due to incorrect or­der of installation.

► Strictly adhere to the order of installation. Make sure to always install

the diverter switch insert before inserting the oil suction pipe into the oil
compartment.

1. Insert oil suction pipe into on-load tap-changer head.

Figure 74: Inserting oil suction pipe

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2. Fasten oil suction pipe on retaining bracket with cable tie.

Figure 75: Fastening the oil suction pipe

5.2.6.2.3.3

Inserting the tap-change supervisory device

1. Insert tap-change supervisory device with mounting plate and drive
shaft.

Figure 76: Mounting plate with drive shaft

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2. Check that drive shaft feather key is seated correctly in the groove.

Figure 77: Feather key and groove

3. Secure mounting plate (3 or 4 nuts and locking elements depending on
model).

Figure 78: Mounting plate

4. Connect plug connector outside its bracket.

Figure 79: Plug connector

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5. Insert plug connector into the bracket.

Figure 80: Plug connector in bracket

5.2.6.2.3.4

Inserting the tap position indicator without multiple coarse change­over selector

Due to the coupling pin, the tap position indicator disc can only be installed
when in the correct position.

► Place tap position indicator disk on indicator drive shaft, slide spring clip

on to shaft end.

Figure 81: Tap position indicator disk

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5.2.6.2.3.5

Inserting tap position indicator with multiple coarse change-over selector with more than 35 operating positions

1. Place panel with bracket on indicator drive shaft and fasten with hexa­gon screws and associated lock tab.

Figure 82: Fitting panel

2. Insert position-indication disk horizontally between panel and bracket
and fit cover disk. Align tap position indicator disc and cover disk to pro­duce a continuous red line.

Figure 83: Inserting position-indication disk

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3. Secure cover disk with countersunk head screw. The countersunk head
screw must be suitable for center-punching.

Figure 84: Fastening cover disk

4. Secure countersunk head screw by center-punching.

5.2.6.2.3.6

Securing on-load tap-changer head cover

1. NOTICE! Place on-load tap-changer head cover on on-load tap-chang­er head and take care not to damage the o-ring inserted in the on-load
tap-changer head cover. A damaged o-ring leads to oil escaping and
therefore to damage of the on-load tap-changer. Also ensure that the
red triangular marks on the on-load tap-changer head and the on-load
tap-changer head cover match up.

Figure 85: On-load tap-changer head cover with o-ring

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2. Screw on-load tap-changer head cover using screws and washers.

Figure 86: On-load tap-changer head cover

5.2.6.2.4

Drying the on-load tap-changer

1. Connect pipe connections R and Q of on-load tap-changer head to the
kerosene vapor lead using one shared lead.

2. Seal off unused pipe connections with a suitable blank cover.

Figure 87: Shared lead

Vapor-phase drying in the transformer tank

1. Supply kerosene vapor at a temperature of around 90 °C. Keep this
temperature constant for 3 to 4 hours.

2. Increase the kerosene vapor temperature by approx. 10 °C/hour to the
desired final temperature of max. 125 °C at the on-load tap-changer.

3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.

4. Residual pressure of no more than 10-3 bar.

5.2.6.2.5

Closing kerosene drain plug

1. Removing [► 70] the diverter switch insert.

2. Close kerosene drain plug with extended socket wrench by turning
clockwise (tightening torque 20 Nm).

3. Inserting [► 78] the diverter switch insert.

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If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following drying".

5.2.7

NOTICE

Carrying out transformer ratio test after drying

To perform the transformer ratio test, proceed as follows:

Damage to property!

Damage to on-load tap-changer due to transformer ratio test being incor­rectly performed!

► Make sure that the selector/de-energized tap changer is fully immersed

in transformer oil and that the oil compartment of the on-load tap­changer is completely filled with oil.

► The on-load tap-changer/de-energized tap-changer can be operated in

the following temperature range:

- when surrounded by transformer oil: –25 °C…+105 °C and up to
+115 °C as per IEC 60214-1 during emergency transformer operation
in accordance with IEC 60076-7

- with synthetic esters in accordance with IEC 61099: –15 °C…+105 °C
and up to +115 °C as per IEC 60214-1 during emergency transformer
operation in accordance with IEC 60076-7

► Only switch the on-load tap-changer from one operating position to the

next via the upper gear unit. You can use a short tube (diameter
25 mm) with screwed-in coupling bolt (diameter 12 mm) with a hand
wheel or crank for this. When using a drill, do not exceed a maximum
speed of 250 rpm.

► Always check the operating position reached through the inspection

window in the on-load tap-changer head cover. Never overshoot the
end positions, which are indicated in the connection diagram supplied
with the delivery.

► For multiple-column applications with a shared drive, link all on-load

tap-changer heads to one another using the horizontal drive shaft part.

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1. Switch on-load tap-changer into the desired operating position. The
diverter switch operation can be heard distinctly.

When actuating the change-over selector, a higher torque is required.

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2. NOTICE! After operating the diverter switch, continue to crank 2.5 revo­lutions in the same direction on the drive shaft of the upper gear unit in
order to correctly end the tap-change operation. An incomplete tap­change operation may damage the on-load tap-changer!

3. Carry out the transformer ratio test.

4. Repeat the transformer ratio test in all operating positions.

5. Once the transformer ratio test is complete, return on-load tap-changer
to its adjustment position (see supplied connection diagram of the on­load tap-changer).

Installing on-load tap-changer in transformer (bell-type

5.3
tank version)

The following chapters explain how to install the on-load tap-changer in the
transformer.

5.3.1

5.3.1.1

Inserting on-load tap-changer into supporting structure

Proceed as follows to insert the on-load tap-changer in the supporting struc­ture:

Securing tap selector on oil compartment of the on-load tap-changer VRC/VRE

1. CAUTION! Place the tap selector on a level surface and secure it

against tipping. An unstably positioned tap selector may tip, resulting in
serious injuries and damage.

2. Remove plastic bag with fastening materials from the tap selector and

lay out.

Figure 88: Plastic bag with fastening materials

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3. Remove the blocking strip from the tap selector coupling. Once the
blocking strip is removed, the tap selector coupling must no longer be
turned.

Figure 89: Blocking strip

4. CAUTION! Place the oil compartment on a level surface and secure
it against tipping. An unstably positioned oil compartment may tip over,
resulting in serious injuries and damage.

5. Remove the blocking device from the coupling of the oil compartment
base.

Figure 90: Blocking strip

6. Lift the oil compartment by hooking up the on-load tap-changer head
and carefully raise above tap selector.

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7. Align the position of both coupling parts and attachment points on the oil
compartment and the tap selector with one another. The correct position
of the two coupling parts is shown in the adjustment plans in the appen­dix.

8. Screw tap selector onto oil compartment.

5.3.1.2

Figure 91: Tap selector with oil compartment

Securing tap selector on oil compartment of the on-load tap-changer VRC/VRE

1. CAUTION! Place the tap selector on a level surface and secure it
against tipping. An unstably positioned tap selector may tip, resulting in
serious injuries and damage.

2. Remove plastic bag with fastening materials from the tap selector and
lay out.

Figure 92: Plastic bag with fastening materials

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3. Remove the ring nuts from the tap selector.

Figure 93: Ring nut

4. Remove the blocking strip from the tap selector coupling. Once the
blocking strip is removed, the tap selector coupling must no longer be
turned.

Figure 94: Blocking strip

5. CAUTION! Place the oil compartment on a level surface and secure
it against tipping. An unstably positioned oil compartment may tip over,
resulting in serious injuries and damage.

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6. Lift the oil compartment by hooking up the on-load tap-changer head
and remove the blocking device on the coupling of the oil compartment
base.

Figure 95: Blocking plate and shackle

7. Carefully raise oil compartment above tap selector.

8. Align the position of both coupling parts and attachment points on the oil
compartment and the tap selector with one another. The correct position
of the two coupling parts is shown in the adjustment plans in the appen­dix.

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9. Screw tap selector onto oil compartment.

5.3.1.3

Figure 96: Tap selector with oil compartment

Securing tap selector on oil compartment of the on-load tap-changer VRG

1. CAUTION! Place the tap selector on a level surface and secure it
against tipping. An unstably positioned tap selector may tip, resulting in
serious injuries and damage.

2. Remove plastic bag with fastening materials from the tap selector and
lay out.

Figure 97: Plastic bag with fastening materials

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3. Remove the ring nuts from the tap selector.

Figure 98: Ring nut

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4. Remove the blocking strip from the tap selector coupling. Once the
blocking strip is removed, the tap selector coupling must no longer be
turned.

Figure 99: Blocking strip

5. CAUTION! Place the oil compartment on a level surface and secure
it against tipping. An unstably positioned oil compartment may tip over,
resulting in serious injuries and damage.

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6. Lift the oil compartment by hooking up the on-load tap-changer head
and remove the blocking device on the coupling of the oil compartment
base.

Figure 100: Blocking plate and shackle

7. Carefully raise oil compartment above tap selector.

8. Align the position of both coupling parts and attachment points on the oil
compartment and the tap selector with one another. The correct position
of the two coupling parts is shown in the adjustment plans in the appen­dix.

9. Screw tap selector onto oil compartment.

Figure 101: Tap selector with oil compartment

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5.3.1.4

Connecting tap-selector connecting leads

Proceed as follows to connect the tap-selector connecting leads:

1. NOTICE! Carefully screw tap-selector connecting leads to connecting
piece or ring segment. Comply with specified tightening torque and se­cure screw connection. Failure to do so may result in damage to the on­load tap-changer and transformer.

2. Attach screening caps to screw connection.

Figure 102: Connecting piece

5.3.1.5

Figure 103: Ring segment

Inserting on-load tap-changer into supporting structure

1. NOTICE! Using spacers, insert on-load tap-changer vertically into sup­porting structure (maximum 1° deviation from the vertical) so that the
on-load tap-changer reaches its final installation height and only has to
be raised a maximum of 5 to 20 mm after fitting the bell-type tank. If this
is not done, once the tap winding and on-load tap-changer take-off lead

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are connected, tension may occur which will damage the on-load tap­changer and transformer. There is also a risk of malfunctions from se­lector contacts moving to the closing position incorrectly.

Figure 104: On-load tap-changer with spacers on supporting structure

2. Remove red supports on selector base (if present).

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3. Temporarily fasten on-load tap-changer to supporting structure. The
supporting flange has through holes for this purpose.

Figure 105: Fastening the on-load tap-changer

5.3.2

Connecting the tap winding and on-load tap-changer take-off lead

NOTICE

5.3.2.1

Damage to the on-load tap-changer!

Connecting leads which place mechanical strain on the on-load tap-changer
will damage the on-load tap-changer!

► Establish connections carefully.

► Do not twist connection contacts.

► Connect connecting leads without warping or deforming.

► If necessary, use an expansion loop for connecting leads.

► Fit screening caps provided to screw connections.

The tap winding and on-load tap-changer take-off lead must be connected in
accordance with the connection diagram included with the delivery.

Tap selector connection contacts VRC/VRE

The selector connection contacts are indicated on the selector bars, have
crimped ends and a through-hole for M10 screws to allow the tap-selector
connecting leads to be connected with cable shoes.

The screening caps are supplied separately.

In this case a locking washer must be placed below each screening cap. The
M10 connection screws, the nuts, and locking washers are not included in
the scope of delivery.

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