OILTAP® M, MS/VACUTAP® VM® Replacement Instructions PDF

OILTAP® M, MS/VACUTAP® VM® Replacement instructions for diverter switch insert 2888956/00 © All rights reserved by Maschinenfabrik Reinhausen Copying and distribution of this document and the utilization and communication of its contents are strictly prohi- bited unless expressly authorized. Offenders will be held liable for the payment of damages. All rights reserved in the event of the granting of a pa- tent, utility model or ornamental design registration. The product may have been modified after this document went to press. We expressly reserve the right to make changes to the technical data, the design or the scope of delivery. Generally, the information provided and the arrangements agreed during processing of the relevant quotations and orders are binding. The original operating instructions were drawn up in German. Table of contents Table of contents 1 Introduction.................................................................................. 7 1.1 Manufacturer............................................................................................. 7 1.2 Subject to change without notice.............................................................. 7 1.3 Safekeeping.............................................................................................. 7 1.4 Notation conventions................................................................................ 8 1.4.1 Hazard communication system............................................................................. 8 1.4.2 Information system................................................................................................ 9 1.4.3 Symbols used..................................................................................................... 10 2 Safety.......................................................................................... 10 2.1 General safety information...................................................................... 10 2.2 Appropriate use....................................................................................... 11 2.2.1 Required minimum height of the oil conservator................................................ 13 2.2.2 Maximum height of the oil conservator............................................................... 14 2.3 Inappropriate use.................................................................................... 14 2.4 Personnel qualification............................................................................ 14 2.5 Operator's duty of care............................................................................ 14 2.6 Personal protective equipment............................................................... 15 3 Product description................................................................... 17 3.1 Performance features............................................................................. 17 3.2 Scope of delivery.................................................................................... 17 3.3 Setup/models.......................................................................................... 17 4 Packaging, transport and storage............................................ 18 4.1 Packaging............................................................................................... 18 4.1.1 Purpose............................................................................................................... 18 4.1.2 Suitability............................................................................................................. 18 4.1.3 Markings.............................................................................................................. 19 © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 3 Table of contents 4.2 Transportation, receipt and handling of shipments................................. 19 4.3 Storage of shipments.............................................................................. 21 5 Preparatory work........................................................................ 23 5.1 Safety precautions.................................................................................. 23 5.2 Providing auxiliary equipment................................................................. 23 5.3 Moving on-load tap-changer to adjustment position............................... 24 5.4 Removing horizontal drive shaft............................................................. 25 6 Removing OILTAP® M diverter switch insert.......................... 27 6.1 Lowering oil level in diverter switch oil compartment.............................. 27 6.1.1 Lowering oil level without oil filter unit................................................................ 28 6.1.2 Lowering oil level with oil filter unit..................................................................... 29 6.2 Switching off supply voltage to tap-change supervisory control (if present).................................................................................................. 31 6.3 Removing on-load tap-changer head cover........................................... 32 6.4 Emptying diverter switch oil compartment.............................................. 33 6.5 Removing the tap position indicator....................................................... 34 6.5.1 Removing tap position indicator (version with multiple coarse change-over selector, long panel)........................................................................................... 34 6.5.2 Removing tap position indicator (version with multiple coarse change-over selector, short panel).......................................................................................... 36 6.5.3 Removing tap position indicator (design without multiple coarse change- over selector)...................................................................................................... 38 6.6 Disconnecting tap-change supervisory control lead............................... 39 6.6.1 Tap-change supervisory control with terminal.................................................... 39 6.6.2 Tap-change supervisory control with plug connector......................................... 40 6.7 Removing diverter switch insert.............................................................. 42 6.8 Removing cover plate above indicator gear........................................... 44 6.9 Cleaning oil conservator, protective relay RS 2001, diverter switch oil compartment and suction pipe........................................................... 45 4 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 Table of contents 6.10 Taking oil filter unit out of operation........................................................ 46 7 Installing VACUTAP® VM® diverter switch insert................... 47 7.1 Drying diverter switch insert.................................................................... 47 7.1.1 Vacuum-drying in the autoclave......................................................................... 47 7.1.2 Vapor-phase drying in the autoclave.................................................................. 47 7.2 Inserting diverter switch insert................................................................. 48 7.3 Connecting tap-change supervisory control lead.................................... 51 7.3.1 Tap-change supervisory control with terminal.................................................... 51 7.3.2 Tap-change supervisory control with plug connector......................................... 52 7.4 Installing tap position indicator................................................................ 53 7.4.1 Installing tap position indicator (version with multiple coarse change-over selector, long panel)............................................................................................ 53 7.4.2 Installing tap position indicator (version with multiple coarse change-over selector, short panel).......................................................................................... 55 7.4.3 Installing tap position indicator (design without multiple coarse change- over selector)...................................................................................................... 56 7.5 Replacing temperature sensor................................................................ 57 7.6 Replacing manual air-vent valve............................................................. 57 7.7 Filling diverter switch oil compartment with oil........................................ 58 7.8 Securing on-load tap-changer head cover.............................................. 59 7.9 Bleeding on-load tap-changer head and suction pipe............................. 61 7.9.1 Bleeding on-load tap-changer head.................................................................... 61 7.9.2 Bleeding suction pipe on pipe connection S....................................................... 62 7.10 Installing horizontal drive shaft................................................................ 63 8 Commissioning the transformer............................................... 65 8.1 Preparatory work/tests............................................................................ 65 8.1.1 Checking motor-drive unit's reversal value......................................................... 65 8.1.2 Replacing protective relay................................................................................... 65 8.1.3 Monitoring system............................................................................................... 65 8.1.4 TAPMOTION® TD.............................................................................................. 66 © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 5 Table of contents 8.1.5 Centering motor-drive unit.................................................................................. 66 8.1.6 Energizing tap-change supervisory control........................................................ 66 8.1.7 Performing trial tap-change operations.............................................................. 66 8.1.8 Looping in signaling contact that indicates that the oil has fallen below the minimum oil level................................................................................................ 67 8.1.9 Checking function of protective relay.................................................................. 67 8.2 Commissioning the transformer.............................................................. 67 9 Monitoring during operation..................................................... 69 10 Troubleshooting......................................................................... 71 11 Maintenance................................................................................ 75 11.1 Scope and execution.............................................................................. 75 11.2 Maintenance intervals............................................................................. 75 11.3 Oil change.............................................................................................. 77 11.3.1 Oil to use............................................................................................................. 77 11.3.2 Performing oil change......................................................................................... 77 12 MR worldwide............................................................................. 78 6 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 1 Introduction 1 Introduction This technical file contains detailed descriptions on the safe and proper instal- lation, connection and commissioning of the product. It also includes safety instructions and general information about the product. 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 Germany Tel.: (+49) 9 41/40 90-0 Fax: (+49) 9 41/40 90-7001 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 Subject to change without notice The information contained in this technical file comprises the technical specifi- cations approved at the time of printing. Significant modifications will be in- cluded in a new edition of the technical file. The document and version numbers of this technical file are shown in the foo- ter. 1.3 Safekeeping This technical file and all supporting documents must be kept ready at hand and accessible for future use at all times. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 7 1 Introduction 1.4 Notation conventions This section contains an overview of the abbreviations, symbols and textual emphasis used. 1.4.1 Hazard communication system Warnings in this technical file use the following format: DANGER! Danger Consequences ► Action ► Action The following signal words are used: Signal word Hazard level Consequence of failure to comply Danger Immediate threat of danger Death or serious injury could occur Warning Possible threat of danger Death or serious injury could occur Possible dangerous situation Minor or moderate injury could oc- Caution cur Notice Possible dangerous situation Damage to property could occur Table 1 Signal words in warning notices 8 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 1 Introduction Pictograms warn of dangers: Picto- Definition gram Danger Dangerous electrical voltage Fire hazard Danger of tipping 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 © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 9 2 Safety 1.4.3 Symbols used Symbol Definition Wrench size Tightening torque Number and type of fastening materials used Fill with oil Cut open, cut through Clean Visual inspection Table 3 Symbols used 2 Safety 2.1 General safety information This technical file contains detailed descriptions on the safe and proper instal- lation, connection and commissioning of the product. Read this technical file through carefully to familiarize yourself with the prod- uct. Particular attention should be paid to the information given in this chapter. 10 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 2 Safety 2.2 Appropriate use The product and associated equipment and special tools supplied with it comply with the relevant legislation, regulations and standards, particularly health and safety requirements, applicable at the time of delivery. If used as intended and in compliance with the specified requirements and conditions 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 ha- zards to people, property or the environment. This applies throughout the product's entire life, from delivery through installation and operation to disas- sembly and disposal. The operational quality assurance system ensures a consistently high quality standard, particularly in regard to the observance of health and safety re- quirements. Use is considered to be appropriate if  the product is operated in accordance with this technical file and the agreed delivery conditions and technical data, and  the associated equipment and special tools supplied with it are used sole- ly for the intended purpose and in accordance with the specifications of this technical file.  the product is used only with the on-load tap-changer specified in the or- der. The on-load tap-changer is not intended to be used with an oil filter unit. DANGER! Danger of death or severe injury! Danger of death or severe injury due to electrical voltage, falling and/or tipping parts as well as dangerous cramped conditions resulting from moving parts. ► Adherence to the following prerequisites and conditions is mandatory. ► Adhere to warning notices. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 11 2 Safety NOTICE Damage to property and the environment! Damage to property and the environment due to electrical voltage, fall- ing and/or tipping parts and leaking oil. ► Adherence to the following prerequisites and conditions is mandatory. ► Adhere to warning notices. Since the diverter switch insert was dimensioned as per IEC 60214-1, it can switch currents of up to twice the value of the rated through current. No tap-change operations may be performed in operating states with higher currents.  Examples of such operating states:  Inrush current impulses when transformers are switching on  Short circuit The rated step voltage may be briefly exceeded by up to 10 % as long as the rated through current is not exceeded. Such an operating state can occur due to overexcitation of the transformer after load shedding, for example. The on-load tap-changer can be operated in the temperature range of the sur- rounding transformer oil of between -25 ° and +105 °C and with overload up to +115 °C in accordance with IEC 60214-1. 12 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 2 Safety 2.2.1 Required minimum height of the oil conservator The height (H) of the oil conservator for the on-load tap-changer is calculated from the upper edge of the on-load tap-changer cover to the oil level in the oil conservator. Oil-filled on-load tap-changer with open oil conservator oil conservator (m) Height (H) of the Installation height (m) above sea level Figure 1 Required minimum height of the oil conservator Figure 2 Transformer with on-load tap-changer, schematic presentation © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 13 2 Safety 2.2.2 Maximum height of the oil conservator In addition to the minimum height specified in the previous chapter, the maxi- mum height of the oil conservator must also be observed. The maximum height of the oil conservator for the on-load tap-changer is "minimum height + 5 m". The installation height of the oil conservator must be taken into account when designing pressure relief devices. If the oil conservators for the on-load tap-changer and transformer are at dif- ferent heights, the difference in height between them must be no more than 3 m. Other applications must be reviewed on a case-by-case basis. 2.3 Inappropriate use Use is considered to be inappropriate if the product is used other than as de- scribed in Appropriate use. Maschinenfabrik Reinhausen does not accept liability for damage resulting from unauthorized or inappropriate changes to the product. Inappropriate changes to the product without consultation with Maschinenfabrik Reinhausen can lead to personal injury, damage to property and operational disruption. 2.4 Personnel qualification The product is designed solely for use in electrical energy systems and facili- ties operated by appropriately trained staff. This staff comprises people who are familiar with the installation, assembly, commissioning and operation of such products. 2.5 Operator's duty of care To prevent accidents, disruptions and damage as well as unacceptable ad- verse 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:  All warning and hazard notices are complied with.  Personnel are instructed regularly in all relevant aspects of operational safety, the operating instructions and particularly the safety instructions contained therein. 14 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 2 Safety  Regulations and operating instructions for safe working as well as the re- levant instructions for staff procedures in the case of accidents and fires are kept on hand at all times and are displayed in the workplace where applicable.  The product is only used when in a sound operational condition and safe- ty equipment in particular is checked regularly for operational reliability.  Only replacement parts, lubricants and auxiliary materials which are au- thorized by the manufacturer are used.  The specified operating conditions and requirements of the installation lo- cation are complied with.  All necessary devices and personal protective equipment for the specific activity are made available.  The prescribed maintenance intervals and the relevant regulations are complied with.  Installation, electrical connection and commissioning of the product may only be carried out by qualified and trained personnel in accordance with this technical file.  The operator must ensure appropriate use of the product. 2.6 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.  Follow information about personal protective equipment provided in the work area. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 15 2 Safety Always wear Protective clothing Close-fitting work clothing with a low breaking strength, with tight sleeves and with no pro- truding parts. It mainly serves to protect the wearer against being caught by moving ma- chine parts. Do not wear any rings, necklaces or other je- welry. Safety shoes To protect against falling heavy objects and slipping on slippery surfaces. Table 4 Personal protective equipment to be worn at all times Special personal protective equipment is Wear the following in needed in special environments. special environments The choice of equipment depends on the cir- cumstances. Safety glasses To protect the eyes from flying parts and splashing liquids. Hard hat To protect from falling and flying parts and ma- terials. Hearing protection To protect from hearing damage. Table 5 Personal protective equipment to be worn in special environments 16 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 3 Product description 3 Product description 3.1 Performance features The product is particularly characterized by the following properties:  maintenance-free up to 300,000 tap-change operations  significantly reduced operating costs  no arcing in the insulating oil  extended lifespan of the insulating oil 3.2 Scope of delivery The product is packaged with protection against moisture and is delivered as follows:  Diverter switch insert  Replacement instructions 3.3 Setup/models Figure 3 VACUTAP® VM® diverter switch insert © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 17 4 Packaging, transport and storage 4 Packaging, transport and storage 4.1 Packaging 4.1.1 Purpose The packaging is designed to protect the packaged goods during transport, loading and unloading as well as periods of storage in such a way that no (de- trimental) changes occur. The packaging must protect the goods against per- mitted transport stresses such as vibration, knocks and moisture (rain, snow, condensation). The packaging also prevents the packaged goods from moving impermissibly within the packaging. The packaged goods must be prepared for shipment be- fore actually being packed so that the goods can be transported safely, eco- nomically and in accordance with regulations. 4.1.2 Suitability The packaging is suitable for:  all common types of transportation  stackability - 1000 kg/m2 top surface The packaged goods are packed in a stable wooden crate. This crate ensures that the shipment is secure when in the intended transportation position and that none of its parts touch the loading surface of the means of transport or touch the ground after unloading. The packaged goods are stabilized inside the crate to prevent impermissible changes in position. The sealed packaging surrounds the packaged goods on all sides with a PE foil. The product is protected using desiccant. The PE foil is bonded after the drying agent is added and any remaining air is extracted. This can be seen on the form-fit of the PE foil. 18 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 4 Packaging, transport and storage 4.1.3 Markings The packaging bears a signature with symbols 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 Top Fragile Figure 4 Shipping symbols 4.2 Transportation, receipt and handling of shipments WARNING! Danger of death or severe injury! Danger due to tipping or falling load. ► Only trained and appointed persons may select the sling gear and secure the load. ► Do not walk under the hanging load. ► Use means of transport and lifting gear with a carrying capacity of > 500 kg. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 19 4 Packaging, transport and storage NOTICE Damage to packaged goods due to falling and tipping over! Danger of damage due to falling and tipping over! ► Only trained and appointed persons may select the sling gear and secure the load. ► Do not walk under the hanging load. ► Use means of transport and lifting gear with a carrying capacity of > 500 kg. In addition to oscillation 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 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. The checks must take place after unloading when the crate or transport con- tainer 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, imme- diately notify the sales department at Maschinenfabrik Reinhausen 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 together with the carrier involved. This is essential for any claim for damages!  If possible, 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).  Be absolutely sure to also check the sealed packaging. 20 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 4 Packaging, transport and storage NOTICE Damage to property! Damage due to damaged sealed packaging! ► If the sealed packaging is damaged, do not under any circumstances in- stall or commission the packaged goods. ► Either dry the packaged goods as per these operating instructions or send them to Maschinenfabrik Reinhausen for drying.  Name the damaged parts. When damages are hidden, i.e. damages which are not determined until un- packing after receipt of the shipment, 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 1. Upon receipt of the shipment, immediately remove the dried packaged goods sent by MR from the sealed packaging. 2. Store the packaged goods in dry insulating oil until used. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 21 5 Preparatory work 5 Preparatory work Perform the following work before starting diverter switch insert replacement. 5.1 Safety precautions WARNING! Danger of death and severe injury! An energized transformer and energized on-load tap-changer compo- nents could cause death or serious injuries! ► Adherence to the following safety precautions is mandatory. 1. Switch off transformer. 2. Lock transformer to prevent unintentional restart. 3. Make sure transformer is de-energized. 4. Visibly connect all transformer terminals to ground (grounding leads, grounding disconnectors) and short circuit them. 5. Cover or cordon off adjacent energized parts. 6. Ensure that there is no supply voltage during all work on the tap-change supervisory control (if present). 5.2 Providing auxiliary equipment Provide the following auxiliary equipment for replacing the diverter switch in- sert:  Oil pump for performing an oil change  Working table  Oil sump © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 23 5 Preparatory work  Clean empty barrels and transformer oil for cleaning and oil change in accordance with table below (the oil quantity depends on the on-load tap- changer type and its rated voltage Vm) Highest voltage for equip- 36 72.5 123 170 245 300 ment Vm (kV) Approx. oil quantity (l) 125 130 150 170 190 210 Table 6 Oil quantity for oil change  Crane or MR lifting device (weight of diverter switch insert max. 80 kg, lift- ing force approx. 1300 N), see table below Rated voltage (kV) 36 72.5 123 170 245 300 Withdrawal height (mm) 830 870 1000 1130 1230 1380 Table 7 Withdrawal height 5.3 Moving on-load tap-changer to adjustment position ► Move on-load tap-changer to adjustment position. Figure 5 Adjustment position For motor-drive units, MA 7, MA 7/8 and MA 9, the adjustment position is marked in the motor-drive unit's tap position indicator by an arrow or a V. 24 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 5 Preparatory work 5.4 Removing horizontal drive shaft 1. Loosen hose ties on guard plate of horizontal drive shaft, remove guard plate. Figure 6 Loosening hose ties © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 25 5 Preparatory work 2. Depending on version, loosen 4 or 6 screws on coupling pieces to upper gear unit and bevel gear. Figure 7 Loosening screws on coupling pieces 3. Remove horizontal drive shaft. Figure 8 Removing drive shaft 26 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 6 Removing OILTAP® M diverter switch insert 6.1 Lowering oil level in diverter switch oil compartment Before removing the on-load tap-changer head cover, the oil level in the diver- ter switch oil compartment must be lowered. After removing the on-load tap- changer head cover, the remaining oil must be drained from the diverter switch oil compartment. WARNING! Danger of death or severe injury! Danger of death or severe injury from explosive gases under the on-load tap-changer cover, in the pipework system, in the oil conservator or at the dehydrating breather opening! ► Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused by static charging) in the immediate surroundings and that none occur. ► Observe applicable fire protection regulations. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 27 6 Removing OILTAP® M diverter switch insert 6.1.1 Lowering oil level without oil filter unit 1. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 9 Screw cap on air-vent valve E1 2. Use screwdriver to lift valve tappet on air-vent valve E1 until oil starts to come out. Figure 10 Valve tappet on air-vent valve E1 3. Close stop-cock between oil conservator and on-load tap-changer. 4. Place a bucket (10 l) under the drain valve of the on-load tap-changer to collect the drained oil. 5. Open drain valve. 28 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 6. Use screwdriver to lift valve tappet on air-vent valve E1. The oil level falls automatically. Figure 11 Valve tappet on air-vent valve E1 7. Once approx. 10 l of oil has been drained, close drain valve and seal air- vent valve E1 with screw cap. 8. Drain the remaining oil after removing the on-load tap-changer head cover (see "Removing on-load tap-changer head cover" on page 32). 9. Open stop-cock between oil conservator and on-load tap-changer and drain the oil flowing from the oil conservator. 6.1.2 Lowering oil level with oil filter unit 1. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 12 Screw cap M30/SW36 on air-vent valve E1 © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 29 6 Removing OILTAP® M diverter switch insert 2. Use screwdriver to lift valve tappet on air-vent valve E1 until oil starts to come out. Figure 13 Valve tappet on air-vent valve E1 3. Close stop-cock between oil conservator and on-load tap-changer. 4. Place a bucket (10 l) either under the drain valve or test valve in the supply pipe to collect the drained oil. 5. Open drain valve or test valve. 6. Use screwdriver to lift valve tappet on air-vent valve E1. The oil level falls automatically. 7. Once approx. 10 l of oil has been drained, close drain valve or test valve and seal air-vent valve E1 with screw cap. 8. Drain the remaining oil after removing the on-load tap-changer head cov- er (see "Removing on-load tap-changer head cover" on page 32). 9. Open stop-cock between oil conservator and on-load tap-changer and drain the oil flowing from the oil conservator. 30 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 6.2 Switching off supply voltage to tap-change supervisory con- trol (if present) If the on-load tap-changer is fitted with a tap-change supervisory control (you can tell this from the bushing on the pipe connection), the tap-change super- visory control must be de-energized before the on-load tap-changer head cover is removed. Figure 14 On-load tap-changer head with pipe connection with tap-change su- pervisory control bushing with oil filter unit Figure 15 On-load tap-changer head with pipe connection with tap-change su- pervisory control bushing without oil filter unit 1. De-energize tap-change supervisory control. 2. Make sure control is de-energized. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 31 6 Removing OILTAP® M diverter switch insert 6.3 Removing on-load tap-changer head cover WARNING! Danger of death or severe injury! Danger of death or severe injury from explosive gases under the on-load tap-changer cover! ► Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused by static charging) in the immediate surroundings and that none occur. ► De-energize all auxiliary circuits (e.g. tap-change supervisory control, pressure relief device, pressure-operated relays) before removing the on- load tap-changer cover. ► Do not operate any electrical equipment during the work (e.g. impact wrench  sparking). ► Only use conductive and grounded hoses, pipes and pump equipment that are approved for flammable liquids. NOTICE Damage to on-load tap-changer and transformer from blocking of diverter switch! Small parts in the diverter switch oil compartment may block the diver- ter switch insert, thereby damaging the on-load tap-changer and trans- former! ► Ensure that parts do not fall into the diverter switch oil compartment. ► Check that you have the same number of small parts when disassembling and reassembling. NOTICE Damage to the on-load tap-changer and transformer! Damage to on-load tap-changer and transformer from insufficient dielec- tric strength of the diverter switch oil! ► Do not expose the open diverter switch oil compartment to ambient hu- midity for longer than 10 hours. 32 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 1. Loosen screws with locking washers on the on-load tap-changer head cover. Figure 16 On-load tap-changer head cover 2. Remove the on-load tap-changer head cover. Check that the sealing sur- faces 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. Ensure that o-ring is in sound condition also. Figure 17 On-load tap-changer head cover with o-ring 6.4 Emptying diverter switch oil compartment ► Remove remaining oil from diverter switch oil compartment. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 33 6 Removing OILTAP® M diverter switch insert 6.5 Removing the tap position indicator 6.5.1 Removing tap position indicator (version with multiple coarse change-over selector, long panel) 1. Remove both countersunk head screws. Figure 18 Tap position indicator 2. Pull tap position indicator disc with cover disk out horizontally from be- tween panel and bracket. Figure 19 Tap position indicator disc with cover disk and panel 34 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 3. Remove both hexagon screws and associated lock tab. Figure 20 Lock tab with hexagon screws 4. Pull panel and bracket up and off indicator drive shaft. Figure 21 Panel with bracket © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 35 6 Removing OILTAP® M diverter switch insert 6.5.2 Removing tap position indicator (version with multiple coarse change-over selector, short panel) 1. Remove countersunk head screw. Figure 22 Tap position indicator 2. Lever cover disk off underlying tap position indicator disc with flat screw- driver. Figure 23 Cover disk 36 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 3. Pull tap position indicator disc out horizontally from between panel and bracket. Figure 24 Tap position indicator disc 4. Remove both hexagon screws and associated lock tab. Figure 25 Lock tab with hexagon screws © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 37 6 Removing OILTAP® M diverter switch insert 5. Pull panel and bracket up and off indicator drive shaft. Figure 26 Panel with bracket 6.5.3 Removing tap position indicator (design without multiple coarse change-over selector) ► Pull the spring clip off the shaft end and remove the tap position indicator disc. Figure 27 Tap position indicator disc with spring clip 38 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 6.6 Disconnecting tap-change supervisory control lead WARNING! Danger of death or severe injury! Danger of death or severe injury from explosive gases under the on-load tap-changer cover! ► Ensure that there is no supply voltage on the tap-change supervisory con- trol. 6.6.1 Tap-change supervisory control with terminal 1. Disconnect connecting lead and terminal. Place connecting lead between 2 pipe connections so that the cable cannot be damaged when pulling out the diverter switch insert. Figure 28 Tap-change supervisory control with terminal The tap-change supervisory control's terminal connection must not be used in an OILTAP® M with VACUTAP® VM® diverter switch insert. Instead the terminal connection must be replaced by a plug connector once the VACU- TAP® VM® diverter switch insert has been installed. Please contact Maschi- nenfabrik Reinhausen Technical Service for assistance. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 39 6 Removing OILTAP® M diverter switch insert 6.6.2 Tap-change supervisory control with plug connector 1. Lift plug connector and leads out of bracket and retaining clamps. Figure 29 Lifting plug connector out of bracket 2. Disconnect the plug connector. Figure 30 Disconnecting plug connector 40 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 3. Put part B of plug connector back in bracket. Figure 31 Putting part B of plug connector back in bracket 4. Place part A of plug connector between 2 pipe connections so that the cable cannot be damaged when pulling out the diverter switch insert. Figure 32 Placing part A of plug connector © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 41 6 Removing OILTAP® M diverter switch insert 6.7 Removing diverter switch insert NOTICE Damage to on-load tap-changer and transformer from blocking of diverter switch! Small parts in the diverter switch oil compartment may block the diver- ter switch insert, thereby damaging the on-load tap-changer and trans- former! ► Ensure that parts do not fall into the diverter switch oil compartment. ► Check that you have the same number of small parts when disassembling and reassembling. ► 1. Loosen 4 screws, including spring washers, for standard transformer de- sign or 5 nuts for bell-type tank transformer design on diverter switch in- sert carrier plate in area not marked red. Figure 33 Carrier plate screws (standard design) Figure 34 Carrier plate nuts (bell-type tank) 42 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 2. Insert the lifting gear in the eyebolts and position lifting gear vertically above the diverter switch insert. Figure 35 Eyebolts on diverter switch insert 3. Lift the diverter switch insert slowly and vertically. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 43 6 Removing OILTAP® M diverter switch insert CAUTION! Risk of injury due to unstable position of heavy parts! An unstably positioned diverter switch insert may tip, resulting in se- rious injuries. ► Place the diverter switch insert on a level surface. ► Secure the diverter switch insert against tipping. NOTICE Damage to property due to unstable position of heavy parts! An unstably positioned diverter switch insert may tip, resulting in dam- age to the insert or other parts! ► Place the diverter switch insert on a level surface. ► Secure the diverter switch insert against tipping. 4. Place the diverter switch insert on a level surface. NOTICE Damage to the on-load tap-changer and transformer! Damage to on-load tap-changer and transformer from insufficient dielec- tric strength of the diverter switch oil! ► Do not expose the open diverter switch oil compartment and removed di- verter switch insert to ambient humidity for longer than 10 hours. 6.8 Removing cover plate above indicator gear If your OILTAP® M on-load tap-changer was supplied before 1981, you will need to remove the cover plate above the indicator gear in the base of the di- verter switch oil compartment. Proceed as follows: 44 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 6 Removing OILTAP® M diverter switch insert 1. Remove countersunk head screws and nuts. Figure 36 Removing cover plate 2. Remove cover plate and spacing sleeves. Figure 37 Removing cover plate 6.9 Cleaning oil conservator, protective relay RS 2001, diverter switch oil compartment and suction pipe ► Clean oil conservator, protective relay, diverter switch oil compartment and suction pipe with new mineral insulating oil and absorbent, non-fluffy cleaning cloth. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 45 6 Removing OILTAP® M diverter switch insert 6.10 Taking oil filter unit out of operation Take the oil filter unit (if present) out of operation as follows: ► Switch off motor protective switch of the oil filter unit and provide a safe- guard to prevent unintentional restart ► Disconnect supply voltage for oil filter unit in unit's control cabinet or in motor-drive unit and isolate ends of leads. ► Remove filter cartridge and clean oil filter unit including pipe system. ► Open supply and return valves and leave open for operation. 46 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 7 Installing VACUTAP® VM® diverter switch insert 7.1 Drying diverter switch insert The diverter switch insert is usually dry when supplied. Should the diverter switch insert have to be dried despite this, minimum drying must be undertaken as specified below. 7.1.1 Vacuum-drying in the autoclave 1. Heat up the diverter switch insert 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 diverter switch insert in circulating air at a max. temperature of 110 °C for a period of 20 hours. 3. Vacuum dry diverter switch insert at between 105 °C and max. 125 °C for at least 50 hours. Residual pressure of no more than 10-3 bar. 7.1.2 Vapor-phase drying in the autoclave 1. Supply kerosene vapor at a temperature of around 90 °C. Keep this tem- perature constant for about 3 to 4 hours. 2. Raise the kerosene vapor temperature by about 10 °C/h to the desired end temperature (max. 125 °C on the diverter switch insert). 3. Vacuum dry diverter switch insert at between 105 °C and max. 125 °C. Residual pressure of no more than 10-3 bar. The drying period depends on the drying period of the transformer but should be at least 50 hours. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 47 7 Installing VACUTAP® VM® diverter switch insert 7.2 Inserting diverter switch insert 1. To fit the diverter switch insert, ensure that the tap selector coupling is in the adjustment position. Figure 38 Adjustment position 2. Ensure that the adapter shaft is seated correctly on the insulating tube. Figure 39 Adapter shaft 48 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 3. Remove supplied protective sleeve from diverter switch insert. Figure 40 Protective sleeve 4. Place protective sleeve on indicator drive shaft. Figure 41 Protective sleeve on indicator drive shaft 5. Insert the lifting gear in the lugs of the diverter switch insert carrier plate provided for this purpose and position diverter switch insert above diver- ter switch oil compartment. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 49 7 Installing VACUTAP® VM® diverter switch insert 6. Align diverter switch insert such that the red markings on the diverter switch insert and on on-load tap-changer head are opposite one another. Figure 42 Aligning diverter switch insert 7. Slowly lower diverter switch insert. 50 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 8. Secure carrier plate of diverter switch insert. Figure 43 Carrier plate of diverter switch insert for standard transformer design Figure 44 Carrier plate of diverter switch insert for bell-type tank transformer design 7.3 Connecting tap-change supervisory control lead 7.3.1 Tap-change supervisory control with terminal The tap-change supervisory control's terminal connection must not be used in an OILTAP® M with VACUTAP® VM® diverter switch insert. Instead the terminal connection must be replaced by a plug connector once the VACU- TAP® VM® diverter switch insert has been installed. Please contact Maschi- nenfabrik Reinhausen Technical Service for assistance. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 51 7 Installing VACUTAP® VM® diverter switch insert 7.3.2 Tap-change supervisory control with plug connector 1. Lift part B of plug connector out of bracket. Figure 45 Plug connector 2. Connect the plug connector. Figure 46 Connecting the plug connector 52 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 3. Place plug connector in bracket, secure leads on both sides of plug con- nector in retaining clamps. Figure 47 Putting plug connector back in bracket 7.4 Installing tap position indicator 7.4.1 Installing tap position indicator (version with multiple coarse change-over selector, long panel) 1. Place panel with bracket on indicator drive shaft and secure with two M5x12/SW8 hexagon screws and associated lock tab. Figure 48 Panel with bracket © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 53 7 Installing VACUTAP® VM® diverter switch insert 2. Insert tap position indicator disc with cover disk horizontally between panel and bracket. Figure 49 Tap position indicator disc with cover disk 3. Secure tap position indicator disc with countersunk head screws. Figure 50 Securing tap position indicator disc 4. Secure countersunk head screws by center-punching. 54 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 7.4.2 Installing tap position indicator (version with multiple coarse change-over selector, short panel) 1. Place panel with bracket on indicator drive shaft and secure with 2 hex- agon screws and associated lock tab. Figure 51 Panel with bracket 2. Insert tap position indicator disc horizontally between panel and bracket and fit cover disk. Align tap position indicator disc and cover disk to pro- duce a continuous red line. Figure 52 Tap position indicator disc © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 55 7 Installing VACUTAP® VM® diverter switch insert 3. Secure cover disk with countersunk head screw. Figure 53 Securing cover disk 4. Secure countersunk head screw by center-punching. 7.4.3 Installing tap position indicator (design without multiple coarse change-over selector) Due to the coupling pin, the tap position indicator disc can only be installed when in the correct position. ► Place tap position indicator disc on indicator drive shaft, slide spring clip on to shaft end. Figure 54 Tap position indicator 56 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 7.5 Replacing temperature sensor The temperature sensor must be replaced when its length (L) exceeds 80 mm. ► Determine length (L) of temperature sensor. Figure 55 Temperature sensor in on-load tap-changer head cover Length L of temper- Action required ature sensor L  80 mm Temperature sensor does not need replacing If your on-load tap-changer was supplied before the end of 1983, the on-load tap-changer head cover, including temperature sensor, must be replaced. L > 80 mm Please contact Maschinenfabrik Reinhausen Techni- cal Service for assistance. If your on-load tap-changer was supplied in or after 1984, only the temperature sensor must be replaced. Please contact Maschinenfabrik Reinhausen Techni- cal Service for assistance. 7.6 Replacing manual air-vent valve If the on-load tap-changer head cover is equipped with a manual air-vent valve, it must be replaced with an automatic version. Please contact Maschinenfabrik Reinhausen Technical Service for assis- tance. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 57 7 Installing VACUTAP® VM® diverter switch insert 7.7 Filling diverter switch oil compartment with oil 1. Fill oil conservator and diverter switch oil compartment up to the height of the carrier plate with new mineral insulating oil for transformers as per EC 60296 (Specification for unused mineral insulating oils for transformers and switch gear). NOTICE Damage to on-load tap-changer resulting from insufficient oil or no oil in the diverter switch oil compartment! Actuating the on-load tap-changer without oil will damage it! ► Before actuating the on-load tap-changer, the diverter switch oil compart- ment must be completely filled with oil. ► The on-load tap-changer can be operated in the temperature range of the surrounding transformer oil of between -25 ° and +105 °C and with over- load up to +115 °C in accordance with IEC 60214-1. 2. Determining dielectric strength and water content of the diverter switch oil after filling the diverter switch oil compartment: ► Record temperature of oil sample. ► Determine dielectric strength at a diverter switch oil temperature of 20 °C ± 5 °C. The dielectric strength and water content must comply with the limit values stated below. Ud [kV/2.5 mm] H2O (ppm) When putting transformer back into 50 (minimum) 15 (maximum) service Table 8 Limit values for on-load tap-changer oil (dielectric strength Ud meas- ured in accordance with IEC 60156) 58 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 7.8 Securing on-load tap-changer head cover 1. Insert new o-ring in on-load tap-changer head cover. NOTICE Damage to on-load tap-changer resulting from damaged o-ring! A damaged o-ring in the on-load tap-changer head cover will cause oil to escape from the diverter switch oil compartment, resulting in on-load tap-changer damage. ► Take care not to damage the o-ring inserted in the on-load tap-changer head cover. 2. Place the on-load tap-changer head cover on the on-load tap-changer head. Ensure that the red triangular marks on the on-load tap-changer head and the on-load tap-changer head cover match up. Figure 56 On-load tap-changer head cover with o-ring © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 59 7 Installing VACUTAP® VM® diverter switch insert 3. Screw down on-load tap-changer head cover with screws and locking washers. Figure 57 On-load tap-changer head cover 4. Replace current name plate on on-load tap-changer head cover with new one (VACUTAP® VM® diverter switch insert). 5. Replace name plate and label indicating maintenance interval in motor- drive unit with new name plate (VACUTAP® VM® diverter switch insert). 60 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 7.9 Bleeding on-load tap-changer head and suction pipe Before first commissioning, the on-load tap-changer head and the suction pipe on pipe connection S must be bled. 7.9.1 Bleeding on-load tap-changer head 1. Open all forward and return valves in the pipe system. 2. Remove screw cap on air-vent valve E1 on the on-load tap-changer head cover. Figure 58 Screw cap 3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on- load tap-changer head. Figure 59 Valve tappet 4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm). © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 61 7 Installing VACUTAP® VM® diverter switch insert 7.9.2 Bleeding suction pipe on pipe connection S 1. Remove screw cap from pipe connection S. Figure 60 Pipe connection S 2. Open vent screw and bleed piping. 3. Close vent screw (tightening torque 2 Nm). 4. Seal vent screw with screw cap (tightening torque 9 Nm). 62 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 7 Installing VACUTAP® VM® diverter switch insert 7.10 Installing horizontal drive shaft 1. Secure horizontal drive shaft between upper gear unit and bevel gear with coupling pieces and 4 or 6 screws. Refer to the drive shaft operating instructions for details. Figure 61 Horizontal drive shaft © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 63 7 Installing VACUTAP® VM® diverter switch insert 2. Use hose ties to secure guard plate to horizontal drive shaft. Figure 62 Guard plate 64 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 8 Commissioning the transformer 8 Commissioning the transformer 8.1 Preparatory work/tests Check the following before taking the transformer back into operation: 8.1.1 Checking motor-drive unit's reversal value If the on-load tap-changer is operated with a monitoring system, please con- tact Maschinenfabrik Reinhausen Technical Service with regard to the rever- sal value. If the on-load tap-changer is operated without a monitoring system, the motor- drive unit's reversal point must match that in the following table. Operating time Reversal value Normal (33 hand crank revolutions 7-7.5 hand crank revolutions correspond to 1 complete diverter switch operation) Half (16.5 hand crank revolutions cor- 3.5-3.75 hand crank revolutions respond to 1 complete diverter switch operation) Table 9 Reversal values for VACUTAP® VM® on-load tap-changer If the motor-drive unit's reversal value does not match that specified, please contact Maschinenfabrik Reinhausen Technical Service for assistance. 8.1.2 Replacing protective relay The protective relay must be replaced if the tripping value is not 1.2 m/s. 1. Establish tripping value on name plate of protective relay used. 2. If the tripping value is not 1.2 m/s, replace current protective relay with an RS 2001 relay with a tripping value of 1.2 m/s. 8.1.3 Monitoring system If a TM100 or TAPGUARD® 260 monitoring system is used, it will require changes for continued operation with a VACUTAP® VM® diverter switch in- sert. Please contact Maschinenfabrik Reinhausen Technical Service for assis- tance. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 65 8 Commissioning the transformer 8.1.4 TAPMOTION® TD If you are using TAPMOTION® TD for the transformer ratio test, please con- tact Maschinenfabrik Reinhausen Technical Service for assistance. 8.1.5 Centering motor-drive unit ► Ensure that the motor-drive unit is correctly centered (see operating in- structions for appropriate motor-drive unit). 8.1.6 Energizing tap-change supervisory control ► Energize the tap-change supervisory control. 8.1.7 Performing trial tap-change operations Before energizing the transformer, test tap change operations must be carried out to check the mechanical functions of on-load tap-changer and motor-drive unit. NOTICE Damage to on-load tap-changer resulting from insufficient oil or no oil in the diverter switch oil compartment! Actuating the on-load tap-changer without oil will damage it! ► Before actuating the on-load tap-changer, the diverter switch oil compart- ment must be completely filled with oil. ► The on-load tap-changer can be operated in the temperature range of the surrounding transformer oil of between -25 ° and +105 °C and with over- load up to +115 °C in accordance with IEC 60214-1. 1. Undertake tap change operation tests across entire range of settings. NOTICE Damage to on-load tap-changer resulting from coupling error! An incorrectly coupled motor-drive unit will damage the on-load tap- changer! ► Ensure that tap position indicators for the motor-drive unit and on-load tap- changer match. 66 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 8 Commissioning the transformer 2. Make sure that in each operating position the tap position indicators of motor-drive unit and on-load tap-changer (inspection window in the on- load tap-changer head) read the same position. 3. Check, in both end positions, the function of the electrical and mechanical end stop (see operating instructions for corresponding motor-drive unit). 8.1.8 Looping in signaling contact that indicates that the oil has fallen below the minimum oil level ► Loop in signaling contact that indicates that the oil has fallen below the minimum oil level in the on-load tap-changer's oil conservator in the trip- ping circuit of the transformer's circuit breaker. 8.1.9 Checking function of protective relay ► Check function of protective relay as described in operating instructions "RS 2001 Protective relay". 8.2 Commissioning the transformer NOTICE Damage to the on-load tap-changer and transformer! Closed stop-cocks between the oil conservator and on-load tap-changer may result in damage to the on-load tap-changer and transformer! ► Ensure that all stop-cocks between oil conservator and on-load tap- changer are open. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 67 8 Commissioning the transformer NOTICE Damage to on-load tap-changer and transformer from inrush current impulse! An inrush current impulse which has not fully subsided can damage the on-load tap-changer and transformer in the event of an on-load tap changing operation! ► Once the transformer has been switched on, ensure that the inrush current impulse has fully subsided before undertaking an on-load tap changing operation. The inrush current impulses are usually a multiple of the trans- former rated current and can overload the on-load tap-changer during the diverter switch operation. ► After the transformer has been turned on and the inrush current impulse has subsided, on-load tap-changer tap-change operations can be performed both under no load and load conditions. 68 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 9 Monitoring during operation 9 Monitoring during operation WARNING! Danger of death or severe injury! Danger of death or severe injury from explosive gases under the on-load tap-changer cover, in the pipework system, in the oil conservator or at the dehydrating breather opening! ► Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused by static charging) in the immediate surroundings and that none occur. NOTICE Damage to the on-load tap-changer due to insufficient oil in the oil conserva- tor of the on-load tap-changer! Actuation of the on-load tap-changer with insufficient oil in the on-load tap-changer's oil conservator may cause damage to the on-load tap- changer! ► Make sure that the contact that indicates that the oil has fallen below the minimum oil level in the on-load tap-changer's oil conservator was looped through to the tripping circuit of the circuit breaker and that the circuit breaker will immediately de-energize the transformer when the oil falls be- low this minimum oil level in the oil conservator. Monitoring the on-load tap-changer and motor-drive unit is limited to occa- sional visual checks of on-load tap-changer head, protective relay and motor- drive unit. For efficiency reasons these visual checks can be combined with the usual checks on the transformer. Pay particular attention to the following:  oil impermeability at the sealing points of the on-load tap-changer head, protective relay and connected pipes  gaskets of the protective housing of the motor-drive unit  correct functioning of the installed electrical heater in the protective hous- ing of the motor-drive unit  protective relay function test in accordance with respective operating in- structions © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 69 9 Monitoring during operation  perfect condition of the silica gel breather for the on-load tap-changer oil conservator The insulating oils in the transformer, including the on-load tap-changer, are to be monitored by the operator following the appropriate rules and regula- tions. The oil quality of the on-load tap-changer oil should be checked at regular in- tervals:  For on-load tap-changers used on the neutral point of windings (class 1 in accordance with IEC 60214-1): every 7 years  For on-load tap-changers used at points other than the neutral point of windings (class 2 in accordance with IEC 60214-1): every 2 years To do so, proceed as follows: 1. Take oil sample from diverter switch oil compartment. 2. Record temperature of oil sample just after sample is taken. 3. Determine dielectric strength at a diverter switch oil temperature of 20 °C ± 5 °C. The dielectric strength and water content must comply with the limit values stated below. Ud (kV/2.5 mm) H2O (ppm) During operation 30 (minimum) 30 (maximum) Table 10 Limit values for diverter switch oil (dielectric strength Ud measured in accordance with IEC 60156) 70 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 10 Troubleshooting 10 Troubleshooting WARNING! Danger of death or severe injury! Danger of death or severe injury from explosive gases under the on-load tap-changer cover, in the pipework system, in the oil conservator or at the dehydrating breather opening! ► Ensure that there are no naked flames, hot surfaces or sparks (e.g. caused by static charging) in the immediate surroundings and that none occur. ► Only use conductive and grounded hoses, pipes and pump equipment that are approved for flammable liquids. ► De-energize all auxiliary circuits (e.g. tap-change supervisory control, pressure relief device, pressure-operated relays) before removing the on- load tap-changer cover. ► Do not operate any electrical equipment during the work (e.g. impact wrench  sparking). NOTICE Damage to on-load tap-changer and transformer when protective relay or other protective devices have been tripped! Tripping of the protective relay or other protective devices can indicate damage on the on-load tap-changer and transformer! The transformer must not be energized without first undertaking checks! ► Check on-load tap-changer and transformer when protective relay or other protective devices have been tripped. ► Do not use the equipment again until you are sure there is no damage to the on-load tap-changer or transformer. The table below should offer you help in detecting and if necessary remedying faults. Do not use the equipment again until you are sure there is no damage to the on-load tap-changer or transformer. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 71 10 Troubleshooting For more information, please consult the operating instructions for the RS 2001 protective relay or the relevant protective device. In the event of faults on the on-load tap-changer and motor-drive unit, which cannot be easily corrected on site, or if the RS 2001 protective relay or addi- tional protective devices have been tripped, please inform your authorized MR representative, the transformer manufacturer or contact us directly at: Maschinenfabrik Reinhausen GmbH Technischer Service Postfach 12 03 60 93025 Regensburg Germany Tel.: +49 94140 90-0 Tel: +49 9 41 40 90-7001 E-mail: [email protected] Internet: www.reinhausen.com Error pattern Action Tripping of protective relay (e g Remove diverter switch insert following maintenance RS 2001) instructions for the present on-load tap-changer. De- pending on the reason for the tripping, take mea- surements/carry out checks on the transformer. Tripping of pressure relief device Remove diverter switch insert following maintenance (e.g. MPreC®) instructions for the present on-load tap-changer. De- pending on the reason for the tripping, take mea- surements/carry out checks on the transformer. Tripping of pressure-operated relay Remove diverter switch insert following maintenance (e.g. DW 2000) instructions for the present on-load tap-changer. De- pending on the reason for the tripping, take mea- surements/carry out checks on the transformer. Activation of tap-change supervisory Remove diverter switch insert following maintenance control instructions for the present on-load tap-changer. De- pending on the reason for the tripping, take mea- surements/carry out checks on the transformer. Activation of rupture disk in on-load Remove diverter switch insert following maintenance tap-changer head cover instructions for the present on-load tap-changer. De- pending on the reason for the tripping, take mea- surements/carry out checks on the transformer. Tripping of motor protective switch in Request "Information sheet on motor protective motor-drive unit switch tripping" from MR, complete and return to MR. Tripping of signaling contact that Check pipework system (pipes etc.) and on-load tap- indicates that the oil has fallen below changer head for leaks. Check oil level and oil quality the minimum oil level in the on-load of diverter switch oil in accordance with operating tap-changer oil conservator instructions for on-load tap-changer. If the oil falls below the limit values, also contact MR. 72 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 10 Troubleshooting On-load tap-changer not changing Contact MR. tap position (sluggishness, Raise/Lower keys not working, diver- ter switch action not audible) No change in voltage on transformer Contact MR. despite change in position on motor- drive unit Tap position indicator on motor-drive Contact MR. unit and on-load tap-changer differ- ent Noises on drive shaft or motor-drive Check that hose clips and guard plates are seated unit when changing tap position correctly. Contact MR in the event of noise from the motor-drive unit. Red message on monitoring unit If possible read out database and send to MR along with error code. Warning or tripping of Buchholz re- Notify manufacturer of transformer. lay on transformer Deviation from desired value when Contact manufacturer of transformer and if necessary measuring winding resistance of MR and provide measured values. transformer Deviation from desired value during Contact manufacturer of transformer and if necessary gas-in-oil-analysis (transformer oil) MR and provide measured values. Deviation from desired value during Contact manufacturer of transformer and if necessary transformer ratio test MR and provide measured values. Deviation from limit value for diverter Carry out oil change, check oil conservator breather switch oil values of on-load tap-changer. Table 11 Troubleshooting © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 73 11 Maintenance 11 Maintenance 11.1 Scope and execution The scope and execution of maintenance are determined by the maintenance instructions for the corresponding on-load tap-changer (available on request). If the appropriate preparations are made, proper maintenance can be carried out within one day per on-load tap-changer pole. We strongly recommend having maintenance carried out by our Technical Service department. If this route is taken, in addition to the correct perfor- mance of all work, certain components will be upgraded to the latest state of technology or manufacturing status. If maintenance is not carried out by our Technical Service department, please ensure that the personnel who carry out the maintenance are trained by MR or are otherwise suitably qualified to carry out the work. In such cases, we would ask you to forward to us a report on the maintenance performed so we can update our maintenance files. For inquiries about spare parts, please provide the serial number (see name plate on on-load tap- changer head and motor-drive unit) and the number of tap-change operations. 11.2 Maintenance intervals NOTICE Damage to property! Damage to on-load tap-changer and transformer from non-observance of maintenance intervals and improper maintenance! ► Observe maintenance intervals. ► Ensure complete and proper maintenance. © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 75 11 Maintenance Maintenance should be performed on the on-load tap-changer after 300,000 tap-change operations. A label on the inside of the door of the ED motor-drive unit clearly specifies the relevant maintenance interval. Figure 63 Label showing maintenance intervals 1 Door 2 Label The diverter switch insert must be replaced after 1,200,000 tap change opera- tions. After 1,200,000 tap-change operations (motor-drive unit counter reading), the tap selector requires maintenance work. 76 OILTAP® M, MS/VACUTAP® VM® 2888956/00 EN © Maschinenfabrik Reinhausen 2012 11 Maintenance 11.3 Oil change 11.3.1 Oil to use NOTICE Damage to on-load tap-changer resulting from switching at impermissible oil temperatures! Switching the on-load tap-changer at impermissible oil temperatures will damage it! ► The on-load tap-changer can be operated in the temperature range of the surrounding transformer oil of between -25 ° and +105 °C and with over- load up to +115 °C in accordance with IEC 60214-1. 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 switch- gear). The dielectric strength and water content of the diverter switch oil must be de- termined after filling with oil: 1. Record temperature of oil sample. 2. Determine dielectric strength at a diverter switch oil temperature of 20 °C ± 5 °C. The dielectric strength and water content must comply with the limit values stated below. Ud (kV/2.5 mm) H2O (pp) After maintenance 50 (minimum) 15 (maximum) Table 12 Limit values for on-load tap-changer oil (dielectric strength Ud meas- ured in accordance with IEC 60156) 11.3.2 Performing oil change Carry out the oil change according to the maintenance instructions for the cor- responding on-load tap-changer (available on request). © Maschinenfabrik Reinhausen 2012 2888956/00 EN OILTAP® M, MS/VACUTAP® VM® 77 12 MR worldwide 12 MR worldwide Australia Iran Russian Federation Reinhausen Australia Pty. Ltd. Iran Transfo After Sales Services Co. OOO MR Ground Floor Zanjan, Industrial Township No. 1 (Alia- Naberezhnaya Akademika Tupoleva 6-10 Geeves Avenue bad) 15, Bld. 2 ("Tupolev Plaza") Rockdale N. S. W. 2216 Corner of Morad Str. 105005 Moscow Phone: +61 2 9556 2133 Postal Code 4533144551 Phone: +7 495 980 89 67 Fax: +61 2 9597 1339 E-mail: [email protected] Fax: +7 495 980 89 67 E-mail: [email protected] E-mail: [email protected] Italy Brazil Reinhausen Italia S.r.l. South Africa MR do Brasil Indústria Mecánica Ltda. Via Alserio, 16 Reinhausen South Africa (Pty) Ltd. Av. Elias Yazbek, 465 20159 Milan No. 15, Third Street, Booysens Reserve CEP: 06803-000 Phone: +39 02 6943471 Johannesburg Embu - São Paulo Fax: +39 02 69434766 Phone: +27 11 8352077 Phone: +55 11 4785 2150 E-mail: [email protected] Fax: +27 11 8353806 Fax: +55 11 4785 2185 E-mail: [email protected] E-mail: [email protected] Japan MR Japan Corporation South Korea Canada German Industry Park Reinhausen Korea Ltd. Reinhausen Canada Inc. 1-18-2 Hakusan, Midori-ku Baek Sang Bldg. Room No. 1500 3755, rue Java, Suite 180 Yokohama 226-0006 197-28, Kwanhun-Dong, Chongro-Ku Brossard, Québec J4Y 0E4, Canada Phone: +81 45 929 5728 Seoul 110-718, Korea Phone: +1 514 370 5377 Fax: +81 45 929 5741 Phone: +82 2 767 4909 Fax: +1 450 659 3092 Fax: +82 2 736 0049 E-mail: [email protected] Luxembourg E-mail: [email protected] Reinhausen Luxembourg S.A. Germany 72, Rue de Prés U.S.A. Maschinenfabrik Reinhausen GmbH L-7333 Stei

OILTAP® M, MS/VACUTAP® VM® Replacement Instructions PDF

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