Maschinenfabrik Reinhausen VACUTAP VM-Ex User manual

On-load tap-changer
VACUTAP® VM-Ex
Operating Instructions
5293069/01 EN

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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
Maschinenfabrik Reinhausen GmbH 2020 35293069/01 EN VACUTAP® VM-Ex
Table of contents
1 Introduction......................................................................................................................... 6
1.1 Manufacturer....................................................................................................................................... 6
1.2 Completeness..................................................................................................................................... 6
1.3 Safekeeping........................................................................................................................................ 6
1.4 Notation conventions .......................................................................................................................... 7
1.4.1 Hazard communication system .............................................................................................................................7
1.4.2 Information system................................................................................................................................................8
1.4.3 Instruction system .................................................................................................................................................8
2 Safety................................................................................................................................. 10
2.1 Appropriate use ................................................................................................................................ 10
2.2 Inappropriate use.............................................................................................................................. 11
2.3 Fundamental safety instructions ....................................................................................................... 11
2.4 Standards and regulations................................................................................................................ 13
2.4.1 Application range of the on-load tap-changer .....................................................................................................13
2.4.2 Standards and regulations ..................................................................................................................................15
2.5 Measures for ensuring compliance with explosion protection requirements .................................... 16
2.5.1 Measures taken by the manufacturer..................................................................................................................16
2.5.2 Measures to be taken by the transformer manufacturer/operator.......................................................................16
2.6 Personnel qualification...................................................................................................................... 19
2.7 Personal protective equipment ......................................................................................................... 21
3 Product description.......................................................................................................... 22
3.1 Scope of delivery .............................................................................................................................. 22
3.2 On-load tap-changer......................................................................................................................... 22
3.2.1 Function description ............................................................................................................................................22
3.2.2 Setup/models ......................................................................................................................................................23
3.2.3 Nameplate and serial number .............................................................................................................................27
3.2.4 Protective devices ...............................................................................................................................................27
3.3 Drive shaft......................................................................................................................................... 30
3.3.1 Function description ............................................................................................................................................30
3.3.2 Design/Model ......................................................................................................................................................32
3.3.3 Identification plate ...............................................................................................................................................34

Table of contents
Maschinenfabrik Reinhausen GmbH 202045293069/01 ENVACUTAP® VM-Ex
4 Commissioning................................................................................................................. 35
4.1 Commissioning transformer at operating site ................................................................................... 35
4.1.1 Filling the oil compartment of the on-load tap-changer with insulating fluid........................................................35
4.1.2 Bleeding on-load tap-changer head and suction pipe.........................................................................................37
4.1.3 Checking motor-drive unit ...................................................................................................................................38
4.1.4 Checking protective relay....................................................................................................................................39
4.1.5 Commissioning the transformer ..........................................................................................................................40
5 Operation........................................................................................................................... 41
5.1 Actuating motor-drive unit with hand crank....................................................................................... 41
6 Fault elimination ............................................................................................................... 43
6.1 Tripping the protective relay and re-commissioning the transformer................................................ 45
6.1.1 Flap valve in OPERATION position ....................................................................................................................45
6.1.2 Flap valve in OFF position ..................................................................................................................................46
6.1.3 Re-commissioning the transformer .....................................................................................................................46
7 Maintenance...................................................................................................................... 47
7.1 Inspection ......................................................................................................................................... 48
7.2 Maintenance intervals....................................................................................................................... 49
7.3 Changing the insulation fluid............................................................................................................. 51
7.3.1 Moving on-load tap-changer to adjustment position ...........................................................................................51
7.3.2 Removing horizontal drive shaft..........................................................................................................................51
7.3.3 Emptying the oil compartment and oil conservator .............................................................................................53
7.3.4 Filling the oil compartment and oil conservator with fresh insulating fluid...........................................................55
7.3.5 Installing horizontal drive shaft............................................................................................................................57
7.3.6 Centering on-load tap-changer and motor-drive unit ..........................................................................................58
7.4 Performing DC resistance measurement on transformer ................................................................. 58
8 Technical data................................................................................................................... 60
8.1 Permissible ambient conditions ........................................................................................................ 60
8.2 Technical data for protective relay.................................................................................................... 60
8.2.1 Protective relay with several dry-reed magnetic switches...................................................................................62
8.3 Limit values for dielectric strength and water content of insulating fluids ......................................... 63
9 Drawings ........................................................................................................................... 64
9.1 VACUTAP® VM, installation drawing (746230)................................................................................ 64
9.2 VACUTAP® VM 300, installation drawing (765192)......................................................................... 66

Table of contents
Maschinenfabrik Reinhausen GmbH 2020 55293069/01 EN VACUTAP® VM-Ex
9.3 VACUTAP® VM, installation position of selector connection contacts (890477) ............................ 67
9.4 Special design for bell-type tank installation for Um up to 300kV (896762) .................................... 68
9.5 On-load tap-changer head (893899) ................................................................................................ 69
9.6 On-load tap-changer head with tap-change supervisory control (894109)....................................... 70
9.7 Pipe connection Q with tap-change supervisory control (766161) ................................................... 71
9.8 Tracing template for on-load tap-changer head (890183) ................................................................ 72
9.9 Socket wrench for kerosene drain plug (890182) ............................................................................. 73
9.10 Screw tools for installation and maintenance (890478) .................................................................... 74
9.11 Bevel gear CD 6400, dimensional drawing (892916) ....................................................................... 75
Glossary ............................................................................................................................ 76

1 Introduction
Maschinenfabrik Reinhausen GmbH 202065293069/01 ENVACUTAP® VM-Ex
1 Introduction
This technical file contains detailed descriptions for monitoring during opera-
tion, fault elimination, and maintenance.
It also includes safety instructions and general information about the prod-
uct.
Information about installation can be found in the installation and commis-
sioning instructions.
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.: [phone]
E-mail: [email protected]
Further information on the product and copies of this technical file are avail-
able from this address if required.
1.2 Completeness
This technical file is incomplete without the supporting documents.
The following documents are considered supporting documents:
▪ Unpacking instructions
▪ Supplement
▪ Routine test report
▪ Connection diagrams
▪ Dimensional drawings
▪ Order confirmation
1.3 Safekeeping
Keep this technical file and all supporting documents ready at hand and ac-
cessible for future use at all times.

1 Introduction
Maschinenfabrik Reinhausen GmbH 2020 75293069/01 EN VACUTAP® VM-Ex
1.4 Notation conventions
1.4.1 Hazard communication system
Warnings in this technical file are displayed as follows.
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

1 Introduction
Maschinenfabrik Reinhausen GmbH 202085293069/01 ENVACUTAP® VM-Ex
Pictograms warn of dangers:
Pictogram Definition
Warning of a danger point
Warning of dangerous electrical voltage
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:

1 Introduction
Maschinenfabrik Reinhausen GmbH 2020 95293069/01 EN VACUTAP® VM-Ex
Aim of action
üRequirements (optional).
► Step 1 of 1.
ðResult of step (optional).
ðResult of action (optional).
Multi-step instructions
Instructions which consist of several process steps are structured as follows:
Aim of action
üRequirements (optional).
1. Step 1.
ðResult of step (optional).
2. Step 2.
ðResult of step (optional).
ðResult of action (optional).

2 Safety
Maschinenfabrik Reinhausen GmbH 202010 5293069/01 ENVACUTAP® VM-Ex
2 Safety
▪ 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 product is an on-load tap-changer and adjusts the transmission ratio of
transformers without interrupting the load flow. The product is designed
solely for use in electrical energy systems and facilities. If used as intended
and in compliance with the requirements and conditions specified in this
technical file as well as the warning notices in this technical file and attached
to the product, then the product does not present any danger to people,
property or the environment. This applies throughout the service life of the
product, from delivery, installation and operation to removal and disposal.
The following is considered appropriate use:
▪ Use the product only with the transformer specified in the order.
▪ Only operate the product with the versions of the motor-drive unit, drive
shaft and protective relay that have been approved for use in explosive ar-
eas.
▪ The serial numbers of on-load tap-changer and on-load tap-changer ac-
cessories (drive, drive shaft, bevel gear, protective relay, etc.) must match
if the on-load tap-changer and on-load tap-changer accessories are sup-
plied as a set for one order.
▪ You will find the standard valid for the product and the year of issue on the
nameplate.
▪ Operate the product in accordance with this technical file, the agreed-
upon delivery conditions and the technical data.
▪ Ensure that all necessary work is performed by qualified personnel only.
▪ Only use the equipment and special tools included in the scope of delivery
for the intended purpose and in accordance with the specifications of this
technical file.
▪ The on-load tap-changer is not intended to be used with an oil filter unit.
▪ The measures described in this technical file must be taken in order to
comply with explosion protection requirements.
Permitted electrical operating conditions
In addition to the design data in accordance with the order confirmation, ob-
serve the following limits for the through-current and the step voltage: