TAPMOTION® ED Operating Instructions PDF

Motor-drive unit TAPMOTION® ED Operating Instructions 1800138/08 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 f...

Motor-drive unit TAPMOTION® ED Operating Instructions 1800138/08 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......................................................................................................................... 6 1.1 Manufacturer....................................................................................................................................... 6 1.2 Completeness...................................................................................................................................... 6 1.3 Safekeeping......................................................................................................................................... 6 1.4 Notation conventions........................................................................................................................... 6 1.4.1 Hazard communication system............................................................................................................................. 6 1.4.2 Information system................................................................................................................................................ 8 1.4.3 Instruction system................................................................................................................................................. 8 1.4.4 Typographic conventions...................................................................................................................................... 9 2 Security.............................................................................................................................. 10 2.1 Appropriate use................................................................................................................................. 10 2.2 Fundamental safety instructions........................................................................................................ 11 2.3 Personnel qualification...................................................................................................................... 13 2.4 Personal protective equipment.......................................................................................................... 14 3 Product description.......................................................................................................... 16 3.1 Scope of delivery............................................................................................................................... 16 3.2 Function description.......................................................................................................................... 16 3.3 Type designation............................................................................................................................... 16 3.4 Design............................................................................................................................................... 17 3.4.1 Indication field..................................................................................................................................................... 18 3.4.2 Anti-condensation heater.................................................................................................................................... 18 3.4.3 Swing frame/terminal rail..................................................................................................................................... 19 3.4.4 Position transmitter equipment............................................................................................................................ 20 3.4.5 Transmission gear cover plate............................................................................................................................ 20 3.5 Protective devices............................................................................................................................. 21 3.6 Safety markings................................................................................................................................. 22 4 Packaging, transport and storage................................................................................... 23 4.1 Packaging.......................................................................................................................................... 23 4.1.1 Suitability............................................................................................................................................................. 23 4.1.2 Markings.............................................................................................................................................................. 24 4.2 Transportation, receipt and handling of shipments............................................................................ 24 4.3 Storage of shipments......................................................................................................................... 25 Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 3  Table of contents 4.4 Unpacking shipments and checking for transportation damages...................................................... 26 5 Mounting............................................................................................................................ 27 5.1 Fitting motor-drive unit on transformer.............................................................................................. 27 5.2 Mounting drive shafts and bevel gear................................................................................................ 29 5.3 Centering on-load tap-changer and motor-drive unit......................................................................... 29 5.4 Cable recommendation..................................................................................................................... 36 5.5 Installing electrics for motor-drive unit............................................................................................... 37 6 Commissioning................................................................................................................. 39 6.1 Starting up motor-drive unit............................................................................................................... 39 6.2 Tests on motor-drive unit................................................................................................................... 40 6.2.1 Checking correct electric switch-off..................................................................................................................... 40 6.2.2 Checking mechanical and electric end stop of on-load tap-changer/off-circuit tap-changer and motor-drive unit............................................................................................................................................................................ 40 6.2.3 Checking tripping of motor protective switch....................................................................................................... 41 6.3 Tests on the transformer................................................................................................................... 42 6.3.1 High-voltage tests on the transformer................................................................................................................. 42 6.3.2 Dielectric tests on transformer wiring.................................................................................................................. 42 6.4 Transporting transformer to the operating site.................................................................................. 43 6.5 Commissioning the transformer at the operating site........................................................................ 43 7 Operation........................................................................................................................... 44 7.1 Operating the motor-drive unit remotely............................................................................................ 44 7.2 Operating motor-drive unit locally...................................................................................................... 44 7.3 Operating the motor-drive unit with the hand crank........................................................................... 45 8 Fault elimination................................................................................................................ 47 8.1 Safety instructions............................................................................................................................. 47 8.2 General information........................................................................................................................... 48 8.3 Fault in the environment of the motor-drive unit................................................................................ 48 8.4 Fault in the motor-drive unit when the switching operation has not ended........................................ 48 8.5 Fault in the motor-drive unit after the switching operation is ended correctly.................................... 49 8.6 Hand crank operation in the event of faults....................................................................................... 49 9 Inspection and maintenance............................................................................................ 51 9.1 Care................................................................................................................................................... 51 9.2 Inspection.......................................................................................................................................... 51 4 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 Table of contents 9.3 Maintenance...................................................................................................................................... 51 10 Disassembly...................................................................................................................... 53 11 Disposal............................................................................................................................. 55 12 Special motor-drive unit models..................................................................................... 56 13 Technical data................................................................................................................... 57 13.1 Technical data for TAPMOTION® ED............................................................................................... 57 13.2 Technical data for position transmitter equipment............................................................................. 57 13.3 Permissible ambient conditions......................................................................................................... 58 14 Appendix............................................................................................................................ 60 14.1 898802............................................................................................................................................... 61 14.2 898801............................................................................................................................................... 62 Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 5  1 Introduction 1 Introduction This technical file contains detailed descriptions on the safe and proper in- stallation, connection, commissioning and monitoring of the product. It also includes safety instructions and general information about the prod- uct. This technical file is intended solely for specially trained and authorized per- sonnel. 1.1 Manufacturer The product is manufactured by: Maschinenfabrik Reinhausen GmbH Falkensteinstraße 8 93059 Regensburg Tel.: (+49) 9 41/40 90-0 E-mail: [email protected] Further information on the product and copies of this technical file are availa- ble from this address if required. 1.2 Completeness This technical file is incomplete without the supporting documents. The following documents also apply in addition to this technical file: ▪ Connection diagrams ▪ Routine test report ▪ Supplement Also observe generally valid legislation, standards, and guidelines as well as specifications on accident prevention and environmental protection in the re- spective country of use. 1.3 Safekeeping Keep this technical file and all supporting documents ready at hand and ac- cessible for future use at all times. 1.4 Notation conventions 1.4.1 Hazard communication system Warnings in this technical file are displayed as follows. 6 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 1 Introduction 1.4.1.1 Warning relating to section Warnings relating to sections refer to entire chapters or sections, sub-sec- tions or several paragraphs within this technical file. Warnings relating to sections use the following format: WARNING Type of danger! Source of the danger and outcome. ► Action ► Action 1.4.1.2 Embedded warning information Embedded warnings refer to a particular part within a section. These warn- ings apply to smaller units of information than the warnings relating to sec- tions. Embedded warnings use the following format: DANGER! Instruction for avoiding a dangerous situation. 1.4.1.3 Signal words and pictograms The following signal words are used: Signal word Definition 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 minor or moderate injury. NOTICE Indicates measures to be taken to prevent damage to property. Table 1: Signal words in warning notices Pictograms warn of dangers: Pictogram Definition Warning of a danger point Warning of dangerous electrical voltage Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 7  1 Introduction Pictogram Definition Warning of combustible substances Warning of danger of tipping Warning of danger of crushing Table 2: Pictograms used in warning notices 1.4.2 Information system Information is designed to simplify and improve understanding of particular procedures. In this technical file it is laid out as follows: Important information. 1.4.3 Instruction system This technical file contains single-step and multi-step instructions. Single-step instructions Instructions which consist of only a single process step are structured as fol- lows: Aim of action ü Requirements (optional). ► Step 1 of 1. ð Result of step (optional). ð Result of action (optional). Multi-step instructions Instructions which consist of several process steps are structured as follows: 8 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 1 Introduction Aim of action ü Requirements (optional). 1. Step 1. ð Result of step (optional). 2. Step 2. ð Result of step (optional). ð Result of action (optional). 1.4.4 Typographic conventions The following typographic conventions are used in this technical file: Typographic convention Purpose Example UPPERCASE Operating controls, switches ON/OFF [Brackets] PC keyboard [Ctrl] + [Alt] Bold Software operating controls Press Continue button …>…>… Menu paths Parameter > Control parameter Italics System messages, error messages, Function monitoring alarm triggered signals [► Number of pages]. Cross reference [► 41]. Table 3: Typographic conventions Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 9  2 Security 2 Security ▪ Read this technical file through to familiarize yourself with the product. ▪ This technical file is a part of the product. ▪ Read and observe the safety instructions provided in this chapter. ▪ Read and observe the warnings in this technical file in order to avoid func- tion-related dangers. ▪ The product is manufactured on the basis of state-of-the-art technology. Nevertheless, risks to life and limb for the user or impairment of the prod- uct and other material assets due to the function may arise in the event of improper use. 2.1 Appropriate use The motor-drive unit adjusts the operating position of on-load tap-changers in regulating transformers to the individual operating requirements. The mo- tor-drive unit is designed solely for use in electrical energy systems and fa- cilities. 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 motor-drive unit does not present any danger to people, property or the environment. This applies throughout the service life of the product, from delivery, installation and oper- ation to removal and disposal. The following is considered appropriate use: ▪ Only operate the product in accordance with this technical file and the agreed delivery conditions and technical data. ▪ Use the equipment and special tools supplied solely for the intended pur- pose and in accordance with the specifications of this technical file. ▪ Use the product only with the transformer/on-load tap-changer/de-ener- gized tap-changer specified in the order. ▪ You will find the standard valid for the product and the year of issue on the nameplate. ▪ The serial numbers of on-load tap-changer / de-energized tap-changer and on-load tap-changer accessories / de-energized tap-changer acces- sories (drive, drive shaft, bevel gear, protective relay, etc.) must match if these products are supplied as a set for one order. ▪ Electrically operate the motor-drive unit remotely during normal operation. ▪ In special operating cases (such as during maintenance tasks), the motor- drive unit can also be operated electrically on site via control switch S3. ▪ Never operate the motor-drive unit electrically or with the hand crank be- fore the transformer has been disconnected if you think there may be a fault in the transformer or on-load tap-changer/de-energized tap-changer. For more information, refer to the "Troubleshooting" [►Section 8, Page 47] chapter. 10 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 2 Security ▪ The provided hand crank is for activating the motor-drive unit during in- stallation and tests in the transformer plant or during maintenance tasks if the transformer has been disconnected. ▪ For details about using the hand crank in emergency operation when the transformer is energized, refer to the "Operation" [►Section 7, Page 44] chapter. 2.2 Fundamental safety instructions To prevent accidents, malfunctions and damage as well as unacceptable ad- verse effects on the environment, those responsible for transport, installa- tion, operation, maintenance and disposal of the product or parts of the prod- uct must ensure the following: Personal protective equipment Loosely worn or unsuitable clothing increases the danger of becoming trap- ped or caught up in rotating parts and the danger of getting caught on pro- truding parts. This poses a danger to life and limb. ▪ Wear appropriate personal protective equipment such as a helmet, work gloves, etc. for the respective activity. ▪ Never wear damaged personal protective equipment. ▪ Never wear rings, necklaces, or other jewelry. ▪ If you have long hair, wear a hairnet. Work area Untidy and poorly lit work areas can lead to accidents. ▪ Keep the work area clean and tidy. ▪ Make sure that the work area is well lit. ▪ Observe the applicable laws for accident prevention in the relevant coun- try. Drying the transformer Drying the motor-drive unit will cause damage to property as well as motor- drive unit malfunctions. ▪ Never dry the motor-drive unit. Working during operation The product may only be operated in a sound, operational condition. Other- wise it poses a danger to life and limb. ▪ Regularly check the operational reliability of safety equipment. ▪ Comply with the inspection work, maintenance work and maintenance in- tervals described in this technical file. Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 11  2 Security Hand crank aperture Reaching into the hand crank aperture during a tap-change operation may lead to injuries caused by a rotating drive shaft. ▪ Never reach into the hand crank aperture. Securing the motor-drive unit If you open the motor-drive unit during operation, there is a danger of electric shock due to live components behind the swing frame. ▪ Secure the motor-drive unit against unauthorized opening during opera- tion by using a padlock. ▪ The motor-drive unit may only be opened by an electrically skilled person. Opening the swing frame Opening the swing frame while the motor-drive unit is in operation may result in electric shocks due to live components. ▪ The swing frame may only be opened by an electrically skilled person. Explosion protection Highly flammable or explosive gases, vapors and dusts can cause serious explosions and fire. This increases the danger to life and limb. ▪ Do not install, operate or perform maintenance work on the product in areas where a risk of explosion is present. Safety markings Warning signs and safety information plates are safety markings on the product. They are an important aspect of the safety concept. ▪ Observe all safety markings on the product. ▪ Make sure all safety markings on the product remain intact and legible. ▪ Replace safety markings that are damaged or missing. 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. 12 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 2 Security Auxiliary materials and operating materials Auxiliary materials and operating materials not approved by the manufactur- er can lead to personal injury, damage to property and malfunctions of the product. ▪ Only use conductive and grounded hoses, pipes, and pump equipment that are approved for flammable liquids. ▪ Only use lubricants and auxiliary materials approved by the manufacturer. ▪ Contact the manufacturer. Modifications and conversions Unauthorized or inappropriate changes to the product may lead to personal injury, material damage and operational faults. ▪ Only modify the product after consultation with Maschinenfabrik Reinhau- sen GmbH. Spare parts Spare parts not approved by Maschinenfabrik Reinhausen GmbH may lead to physical injury, damage to the product and malfunctions. ▪ Only use spare parts that have been approved by Maschinenfabrik Rein- hausen GmbH. ▪ Contact Maschinenfabrik Reinhausen GmbH. 2.3 Personnel qualification The person responsible for assembly, commissioning, operation, mainte- nance and inspection must ensure that the personnel are sufficiently quali- fied. 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 ap- plicable standards and regulations. The electrically skilled person is also pro- ficient 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. Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 13  2 Security Electrically trained persons An electrically trained person receives instruction and guidance from an electrically skilled person in relation to the tasks undertaken and the poten- tial dangers in the event of inappropriate handling as well as the protective devices and safety measures. The electrically trained person works exclu- sively 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 im- proper handling. Technical Service We strongly recommend having maintenance, repairs and retrofitting carried out by our Technical Service department. This ensures that all work is per- formed correctly. If maintenance is not carried out by our Technical Service department, please ensure that the personnel who carry out the mainte- nance 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. 2.4 Personal protective equipment Personal protective equipment must be worn during work to minimize risks to health. ▪ Always wear the personal protective equipment required for the job at hand. ▪ Never wear damaged personal protective equipment. ▪ Observe information about personal protective equipment provided in the work area. 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. Safety glasses To protect the eyes from flying parts and splashing liq- uids. Visor To protect the face from flying parts and splashing liq- uids or other dangerous substances. Hard hat To protect against falling and flying parts and materials. 14 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 2 Security Hearing protection To protect against hearing damage. Protective gloves To protect against mechanical, thermal, and electrical hazards. Table 4: Personal protective equipment Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 15  3 Product description 3 Product description 3.1 Scope of delivery The motor-drive unit is packaged with protection against moisture and is de- livered as follows: ▪ Motor-drive unit ▪ Product documentation Please note the following: 1. Check the shipment for completeness on the basis of the shipping docu- ments. 2. Store the parts in a dry place until installation. 3. The product must remain in its airtight, protective wrapping and may only be removed immediately before installation. 3.2 Function description The motor-drive unit adjusts the operating position of on-load tap-changers in regulating transformers to the individual operating requirements. The tap-change operation is activated by starting the motor-drive unit (a sin- gle control impulse triggered, for example, by a voltage regulator of the TAPCON®-series). This operation is always completed regardless of any other control pulses emitted during the tap-change operation. In the standard design, the next tap-change operation can only proceed once all control de- vices have reached their resting positions. Behavior in the event of a voltage interruption Should the voltage be interrupted during an on-load tap-change operation, once the voltage supply returns, the motor-drive unit completes the started on-load tap-change operation. 3.3 Type designation The various basic designs of the TAPMOTION® ED are clearly identified by explicit product definitions. Type designa- Description Variants tion ED 100-ST Product designation Electric Drive ED 100-ST Transmission gear design 100 or 200 (depending on the torque required) ED 100-ST Protective housing design S = small protective housing L = large protective housing 16 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 3 Product description Type designa- Description Variants tion ED 100-ST Special applications … = none C = Plunger coil design T = TAPCON® or TAPGUARD® ED 100-S-ISM Special application ISM = "Integrated Smart Module" for recording, aggregating and in- terpreting data on the transform- er Table 5: Type designation 3.4 Design This chapter contains an overview of the design of the motor-drive unit. Components not described here in detail are described in the motor-drive unit's technical data. Figure 1: Motor-drive unit, open 1 Protective housing cover 9 S3 control switch 2 Viewing window for indication field 10 Swing frame/anti-condensation heater Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 17  3 Product description 3 Fixing lug 11 Indication field 4 Ground connection 12 Nameplate 5 Output shaft 13 Motor protective switch Q1 6 Hand-crank aperture with hand- 14 Document pocket crank interlock switch 7 Hand lamp 15 Transmission-gear cover plate 8 Hand crank 3.4.1 Indication field A clear indication field is fitted in the motor-drive unit. Pointer and operations counter are mechanically driven and indicate the tap-change operation se- quence and operating position of the motor-drive unit. The reset wheel on the operations counter is lead-sealed at the factory. Figure 2: Indication field 1 Tap position indicator 3 Tap-change indicator: Shows the current position of the control cam (33 tap-change indicator sections per operating position) 2 The two drag hands indicate the 4 The mechanical operations coun- regulating range currently used ter shows the overall number of tap-change operations 3.4.2 Anti-condensation heater The anti-condensation heater is designed as a panel heater which also acts as the front cover of the swing frame. The design of the motor-drive unit and panel heater ensures that air circu- lates inside the motor-drive unit and therefore that there is a constant interior temperature which is always higher than the outside temperature. 18 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 3 Product description 3.4.3 Swing frame/terminal rail The swing frame protects all electrical and mechanical parts of the motor- drive unit behind the swing frame against accidental contact. The terminal rail behind the swing frame makes electrical connection of the motor-drive unit a simple task. The wiring is easily connected using vertically arranged cap rails with the corresponding installed terminal bars. Figure 3: Terminal rail 1 Swing frame 4 Cable duct 2 Position transmitter module 5 Cap rail 3 Terminal bar X1 6 Opening for cable entry (sealed by base plate) Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 19  3 Product description 3.4.4 Position transmitter equipment NOTICE Damage to the on-load tap-changer and motor-drive unit! Damage to on-load tap-changer and motor-drive unit due to incorrect use of position transmitter equipment. ► Only circuits stated in the chapter Technical data for position transmitter equipment [►Section 13.2, Page 57] may be connected to the position transmitter module connections. ► The switchover point of the position transmitter equipment in the motor- drive unit is not the same as the switchover point of the diverter switch operation. This depends on the type of diverter switch. This fact should be noted when project planning the locking circuits between the motor- drive unit and external equipment (e.g. transformer circuit breaker). ► Therefore, the "Tap changer in operation" position transit contact shown in the connection diagram should be used for external monitoring, locking and control purposes instead of the position transmitter equipment. The position transmitter equipment is used to indicate the operating position of the on-load tap-changer/off-circuit tap-changer when idle. The remote display is available in various versions. The position transmitter module for connection by the customer is located on the terminal rail [►Section 3.4.3, Page 19]. For more information about the position transmitter equipment, see Techni- cal data for position transmitter equipment [►Section 13.2, Page 57]. 3.4.5 Transmission gear cover plate WARNING Danger of death and severe injury from electrical voltage! Danger of death and severe injury from electrical voltage if the transmission gear cover plate is not fitted. ► Never start up motor-drive unit without transmission gear cover plate. 20 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 3 Product description The touch-protected transmission-gear cover plate features an opening for the hand crank used in manual mode. Transmission-gear cover plate 3.5 Protective devices The following protective devices are fitted in the motor-drive unit: ▪ End stop device (mechanical and electric) ▪ Device protecting against unintentional passage ▪ Motor protection device ▪ Protection against accidental contact Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 21  3 Product description 3.6 Safety markings The following safety markings are used on the product: Figure 4: Overview of safety markings 1 Warning of rotating parts 2 Warning of dangerous electrical voltage 3 Warning of hot surface 4 Read the documentation 22 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 4 Packaging, transport and storage 4 Packaging, transport and storage 4.1 Packaging The products are sometimes supplied with sealed packaging and sometimes in a dry state, depending on requirements. Sealed packaging surrounds the packaged goods with plastic foil on all sides. Products that have also been dried are identified by a yellow label on the sealed packaging. In the dry state, delivery is also possible in a transport container. The information in the following sections should be applied as appropriate. 4.1.1 Suitability NOTICE Property damage due to incorrectly stacked crates! Stacking the crates incorrectly can lead to damage to the packaged goods. ► The outer marking on the packaging states if, for example, the on-load tap-changer or selector has been packed upright. Never stack these crates. ► General rule: Do not stack crates above a height of 1.5 m. ► For other crates: Only stack up to 2 equally sized crates on top of one an- other. The packaging is suitable to ensure undamaged and fully functional means of transportation in compliance with local transportation laws and regula- tions. The packaged goods are packed in a sturdy crate. This crate ensures that, when in the intended transportation position, the packaged goods are stabi- lized to prevent impermissible changes in position, and that none of the parts touch the loading surface of the means of transport or touch the ground after unloading. Sealed packaging surrounds the packaged goods with plastic foil on all sides. The packaged goods are protected from humidity using a desiccant. The plastic foil was bonded after the desiccant is added. Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 23  4 Packaging, transport and storage 4.1.2 Markings The packaging bears a signature with instructions for safe transport and cor- rect storage. The following symbols apply to the shipment of non-hazardous goods. Adherence to these symbols is mandatory. Protect against Top Fragile Attach lifting Center of mass moisture gear here Table 6: Shipping pictograms 4.2 Transportation, receipt and handling of shipments WARNING Danger of death or severe injury! Danger of death or serious injuries due to tipping or falling load. ► Only transport the crate when closed. ► Do not remove the securing material used in the crate during transport. ► If the product is delivered on a pallet, secure it sufficiently. ► Only trained and authorized persons may select the sling gear and se- cure the load. ► Do not walk under the suspended load. ► Use means of transport and lifting gear with a sufficient carrying capacity in accordance with the weight stated on the delivery slip. In addition to oscillation stress, jolts must also be expected during transpor- tation. In order to prevent possible damage, avoid dropping, tipping, knock- ing over and colliding with the product. If a crate tips over, falls from a certain height (e.g. when slings tear) or is subject to 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 The checks must take place after unloading when the crate or transport con- tainer can be accessed from all sides. 24 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 4 Packaging, transport and storage Visible damage If external transport damage is found upon receipt of the shipment, proceed as follows: ▪ Immediately record the identified transport damage 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 manufacturer and the relevant insurance company. ▪ After identifying damage, do not modify the condition of the shipment fur- ther 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 on site together with the carrier involved. This is essential for any claim for damages. ▪ Photograph damage to packaging and packaged goods. This also applies to signs of corrosion on the packaged goods due to moisture inside the packaging (rain, snow, condensation). ▪ NOTICE! Damage to packaged goods due to damaged sealed packag- ing. If the product is delivered in sealed packaging, check the sealed packaging immediately. If the sealed packaging is damaged, do not under any circumstances install or commission the packaged goods. Either re- dry the dried packaged goods as per the operating instructions, or contact the manufacturer to agree on how to proceed. ▪ Identify the damaged parts. Hidden damage When damages are not determined until unpacking after receipt of the ship- ment (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 insur- ance terms and conditions. 4.3 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 fluid until used if the packaged goods were not sup- plied in insulating fluid. 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. Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 25  4 Packaging, transport and storage 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 after 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. If the product is installed more than 6 months after delivery, suitable meas- ures 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 a suitable storage space (well ven- tilated, as dust-free as possible, humidity < 50% where possible). 4.4 Unpacking shipments and checking for transportation damages ▪ NOTICE! Damage to packaged goods due to ineffectively sealed packag- ing. Transport the packaged crate to the place where the packaged goods are to be installed. Do not open the sealed packaging until just before in- stallation. ▪ WARNING! Serious injuries and damage to the packaged goods due to the packaged goods tipping out. Place the packaged goods in an up- right crate and protect it from tipping out. ▪ Unpack the packaged goods and check the condition. ▪ Check the completeness of the accessories kit using the delivery slip. 26 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 5 Mounting 5 Mounting This chapter describes how to correctly install and connect the device. WARNING Danger of death or severe injury! An energized transformer and energized on-load tap-changer components can cause death or serious injuries during installation of the drive! ► Ensure the de-energized state of the transformer and on-load tap-chang- er components during installation of the drive. 5.1 Fitting motor-drive unit on transformer 1. Attach four stud bolts (not supplied by MR) to the transformer tank. The arrangement and diameter of the fixing lugs can be found in the drawings in the Appendix [►Section 14, Page 60]. Figure 5: Stud bolts 2. For motor-drive unit with vibration damper: Attach the vibration damper to the motor-drive unit. 3. NOTICE! Damage to the drive due to mechanical tension. Make sure the drive is de-energized and fit it vertically to the transformer tank so that the output shaft of the drive is exactly aligned with the vertical shaft of the bevel gear. Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 27  5 Mounting The assembly holes for attaching the drive are located externally on the pro- tective housing's fixing lugs. Figure 6: Securing motor-drive unit 4. Connect grounding screw of motor-drive protective housing to transformer tank. It is essential that a CUPAL washer be placed between the cable shoe and connecting lug. The aluminum side of the CUPAL washer must be facing the connecting lug. Figure 7: Grounding screw 5. Connect the main protective conductor to the protective conductor termi- nal on terminal bar X1 (minimum connection cross-section 2.5 mm2). 28 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 5 Mounting Figure 8: Main protective conductor 5.2 Mounting drive shafts and bevel gear The process of mounting the drive shafts and bevel gear is described in the installation and commissioning instructions for the on-load tap-changer / de- energized tap-changer. 5.3 Centering on-load tap-changer and motor-drive unit WARNING Danger of death or severe injury! Danger of death or severe injury due to motor-drive unit starting up by acci- dent and due to electric voltage! ► Before starting any coupling work make sure that the motor protective switch is tripped. ► Carry out any adjustment work in manual mode only. ► When manually operating the motor-drive unit only use the hand crank provided for this purpose. ► Note that the hand crank safety switch causes a 2-pole disconnection of the motor circuit but that the control circuit is not interrupted. Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 29  5 Mounting NOTICE Damage to property! The on-load tap-changer will be damaged by incorrectly centering the mo- tor-drive unit. ► Do not perform more than 250 tap-change operations on the on-load tap- changer. If more than 250 tap-change operations are performed, com- pletely fill oil compartment with insulating oil and lubricate sliding surfaces of contacts on selector and selector gear with insulating oil. The following steps for centering the on-load tap-changer and motor-drive unit do not apply to the DEETAP® DU and COMTAP® ARS. The process for centering the motor-drive unit and DEETAP® DU or COMTAP® ARS is described in the relevant operating instructions. One on-load tap-change operation is represented by one rotation of the tap- change indicator. This indicator is divided into 33 tap-change indicator sec- tions, each of which corresponds to one hand crank revolution in the stand- ard motor-drive unit design. The time of the switchover depends on the on- load tap-changer/de-energized tap-changer type, but is always 2 tap-change indicator sections before the area marked in gray on the tap-change indica- tor at the latest. To center the on-load tap-changer and motor-drive unit, proceed as follows. 1. NOTICE! Move the on-load tap-changer/de-energized tap-changer and the motor-drive unit into the adjustment position before commencing any adjustment work. Ensure that the tap position indicators for the motor- drive unit and the on-load tap-changer/de-energized tap-changer match. Otherwise damage to the on-load tap-changer and transformer may re- sult. Figure 9: Adjustment position 30 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 5 Mounting 2. Attach the hand crank in the motor-drive unit to the shaft end located in the upper cover plate. This activates a hand crank interlock switch, which disconnects the motor circuit at 2 poles. Figure 10: Hand crank 3. Turn clockwise using the hand crank until the diverter switch operation be- gins. When turning the hand crank, observe the tap-change indicator, which mechanically reflects the progress of the tap-change operation. Figure 11: Turning the hand crank Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 31  5 Mounting 4. Once the diverter switch operation begins, continue to turn in the same di- rection while counting the tap-change indicator sections required for the pointer to reach the mid-position of the area marked in gray on the tap- change indicator. Note the number counted (value A) and the direction of rotation (example: A=2). Figure 12: Counting the tap changes needed to reach the mid-position 5. If value A is greater than 8 tap-change indicator sections, the tap-change operation has been completed correctly. If value A is less than 8 tap- change indicator sections, turn another 8-A tap-change indicator sections in the same direction (example: 8-2=6) to complete the tap-change opera- tion. Then turn in the opposite direction until the pointer is in the mid-posi- tion of the area marked in gray on the tap-change indicator. Figure 13: Completing the diverter switch operation 6. Turn the hand crank counter-clockwise until the diverter switch operation begins. 32 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 5 Mounting Figure 14: Turning the hand crank in the opposite direction 7. Once the diverter switch operation begins, continue to turn in the same di- rection while counting the tap-change indicator sections required for the pointer to reach the mid-position of the area marked in gray on the tap- change indicator. Note the number counted (value B) and the direction of rotation (example: B=5). Figure 15: Counting the tap-change indicator sections needed to reach the mid-position 8. If value B is greater than 8 tap-change indicator sections, the tap-change operation has been completed correctly. If value B is less than 8 tap- change indicator sections, turn another 8-B tap-change indicator sections in the same direction (example: 8-5=3) to complete the tap-change opera- tion. Then turn in the opposite direction until the pointer is in the mid-posi- tion of the area marked in gray on the tap-change indicator. Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 33  5 Mounting Figure 16: Completing the diverter switch operation 9. If the values obtained for A and B are identical, the on-load tap-changer and the motor-drive unit are correctly coupled (a slight imbalance of maxi- mum 1 tap-change indicator section is permitted). If the values obtained for A and B are different, establish correction value C by halving the differ- ence between A and B: C=|(A-B) x 0.5| Example: C=|(2-5) x 0.5|=|-1.5|=1.5 Also take numbers after the decimal point into account. 10. If the correction value |C| is less than 0.5 tap-change indicator sections, no further action is required. Refer to point 18 for how to proceed next. 11. Use the hand crank to crank in the direction in which the determined val- ue A or B was higher (example: counter-clockwise, because B > A) until the diverter switch operation begins. 12. Once the diverter switch operation begins, continue turning another 8 hand crank revolutions in the same direction to correctly complete the diverter switch operation. 13. Uncouple the motor-drive unit and vertical drive shaft by removing the coupling brackets. After uncoupling, do not turn the drive shaft any fur- ther. 34 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 5 Mounting Figure 17: Uncoupling the motor-drive unit and drive shaft 14. Operate the motor-drive unit using the hand crank in the same direction, continuing by C tap-change indicator sections on the tap-change indica- tor (example: 1.5 tap-change indicator sections). 15. Couple the motor-drive unit and on-load tap-changer by refitting the verti- cal drive shaft (tightening torque 9 Nm). Do not turn the drive shaft and output shaft of the bevel gear and motor-drive unit any further. 16. Continue to turn in the same direction while counting the tap-change in- dicator sections required for the pointer to reach the mid-position of the area marked in gray on the tap-change indicator. Note the number counted (value A) and the direction of rotation. If value A is greater than 8 tap-change indicator sections, the tap-change operation has been completed correctly. If value A is less than 8 tap-change indicator sec- tions, turn another 8-A tap-change indicator sections in the same direc- tion (example: 8-4=4) to complete the tap-change operation. Then turn in Maschinenfabrik Reinhausen GmbH 2020 1800138/08 EN TAPMOTION® ED 35  5 Mounting the opposite direction until the indicator is in the mid-position of the area marked in gray on the tap-change indicator. Check the coupling again as described previously. 17. The pointer of the tap-change indicator must be in the mid-position of the area marked in gray once the on-load tap-change operation with the hand crank is complete. Figure 18: Pointer in the mid-position 18. Once coupling is complete in both directions, check by undertaking sev- eral on-load tap-change operations and check that the on-load tap- changer and motor-drive unit are in the same tap position. 5.4 Cable recommendation Electromagnetic interference on signal lines, which can be expected due to the environment of the transformer, can disrupt the proper operation of the motor-drive unit. That is why Maschinenfabrik Reinhausen GmbH recommends using shield- ed signal lines when possible. NOTICE Damage to the device! Current flow through the shielding of signal lines can lead to the device get- ting damaged. ► For signal lines between the motor-drive unit and transformer, connect the shielding of the signal line to the motor-drive unit only. ► For all other signal lines, connect the shielding on both sides, as long as there is no potential difference between the two devices. If there is a po- tential difference, then connect the shielding only on one side for these signal lines, too. Circuit Function Cable type Motor circuit Power supply Unshielded, separate cable Control circuit Power supply Unshielded, separate cable Tap-change supervisory control Shielded Pulse circuit, raise/lower Shielded Trigger circuit Q1-Off Shielded 36 TAPMOTION® ED 1800138/08 EN Maschinenfabrik Reinhausen GmbH 2020 5 Mounting Circuit Function Cable type Monitoring circuit Temperature sensor Shielded Signaling circuits Signal transmission Shielded Cross wiring between motor-drive Power supply Unshielded, separate cable units Tap-change supervisory control Shielded Pulse circuit, raise/lower Shielded Trigger circuit Q1-Off Shielded Table 7: Recommendation for connection cable 5.5 Installing electrics for motor-drive unit WARNING Danger of death or severe injury! An energized transformer and energized on-load tap-changer components could cause death or serious injuries when installing the electrics! ► Adherence to the following safety precautions is mandatory. The drive may only be connected to circuits that are equipped with an exter- nal and all-pole isolating device as close to the drive as possible to ensure that the unit can be fully de-energized if required (service, maintenance etc.). Furthermore, a drive without its own overcurrent protective device for the control circuit and the heater circuit may only be connected to circuits that are equipped with an external overcurrent protective device. The protective device must ensure protection against indirect touching. The protection rec- ommended by Maschinenfabrik Reinhausen GmbH close to the drive is 1.6 A C (3.0 A C is to be used in a heater circuit with additional heating and sup- ply voltage