MR TAPCON 250 User manual

Voltage Regulator
TAPCON® 250
Operating Instructions
297/07 EN

© All rights reserved by Maschinenfabrik Reinhausen
Dissemination and reproduction of this document and use and disclosure of its content are strictly prohibited
unless expressly permitted.
Infringements will result in liability for compensation. All rights reserved in the event of the granting of patents,
utility models or designs.
The product may have been altered since this document was published.
We reserve the right to change the technical data, design and scope of supply.
Generally the information provided and agreements made when processing the individual quotations and orders
are binding.
The original operating instructions were written in German.

Table of contents
Maschinenfabrik Reinhausen GmbH 2018 3297/07 EN TAPCON® 250
Table of contents
1Introduction......................................................................................................................... 8
1.1 Manufacturer....................................................................................................................................... 8
1.2 Completeness...................................................................................................................................... 8
1.3 Safekeeping......................................................................................................................................... 8
1.4 Notation conventions........................................................................................................................... 8
1.4.1 Hazard communication system............................................................................................................................. 8
1.4.2 Information system.............................................................................................................................................. 10
1.4.3 Instruction system............................................................................................................................................... 10
1.4.4 Typographic conventions.................................................................................................................................... 11
2Safety................................................................................................................................. 12
2.1 Appropriate use................................................................................................................................. 12
2.2 Fundamental Safety Instructions....................................................................................................... 12
2.3 Personnel qualification...................................................................................................................... 14
2.4 Personal protective equipment.......................................................................................................... 15
3Product description.......................................................................................................... 17
3.1 Scope of delivery............................................................................................................................... 17
3.2 Function description of the voltage regulation................................................................................... 17
3.3 Performance features........................................................................................................................ 17
3.4 Operating modes............................................................................................................................... 18
3.5 Hardware........................................................................................................................................... 20
3.5.1 Name plate.......................................................................................................................................................... 21
3.5.2 Operating controls............................................................................................................................................... 23
3.5.3 Display elements................................................................................................................................................. 25
3.5.4 Serial interface.................................................................................................................................................... 26
3.5.5 Assemblies.......................................................................................................................................................... 26
4Packaging, transport and storage................................................................................... 28
4.1 Packaging.......................................................................................................................................... 28
4.1.1 Purpose............................................................................................................................................................... 28
4.1.2 Suitability, structure and production ................................................................................................................... 28
4.1.3 Markings.............................................................................................................................................................. 28

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4.2 Transportation, receipt and handling of shipments............................................................................ 29
4.3 Storage of shipments......................................................................................................................... 30
5Mounting............................................................................................................................ 31
5.1 Mounting device................................................................................................................................ 31
5.2 Connecting device............................................................................................................................. 32
5.2.1 Cable recommendation....................................................................................................................................... 32
5.2.2 Electromagnetic compatibility.............................................................................................................................. 33
5.2.3 Information about laying fiber-optic cable............................................................................................................ 36
5.2.4 Connecting cables to the system periphery........................................................................................................ 37
5.2.5 Wiring device....................................................................................................................................................... 37
5.2.6 Checking functional reliability.............................................................................................................................. 44
6Commissioning................................................................................................................. 46
6.1 Function tests.................................................................................................................................... 46
6.1.1 Checking control functions.................................................................................................................................. 46
6.1.2 Checking additional functions.............................................................................................................................. 48
6.2 Setting parameters............................................................................................................................ 51
6.2.1 Setting the language........................................................................................................................................... 51
6.2.2 Setting date and time.......................................................................................................................................... 51
6.2.3 Setting further parameters................................................................................................................................... 52
7Operation........................................................................................................................... 55
7.1 General.............................................................................................................................................. 55
7.1.1 Setting device ID................................................................................................................................................. 55
7.1.2 Setting the baud rate........................................................................................................................................... 56
7.1.3 Setting the voltage display kV/V.......................................................................................................................... 56
7.1.4 Setting current display unit.................................................................................................................................. 57
7.1.5 Setting the switching pulse time.......................................................................................................................... 57
7.1.6 Setting the consumption interval......................................................................................................................... 60
7.1.7 Setting motor runtime monitoring........................................................................................................................ 60
7.1.8 Setting the behavior in the event of negative active power flow.......................................................................... 62
7.1.9 Defining the signal type....................................................................................................................................... 62
7.2 Key lock............................................................................................................................................. 63
7.3 NORMset........................................................................................................................................... 64
7.4 Control parameters............................................................................................................................ 66

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7.4.1 Setting desired value 1...4................................................................................................................................... 68
7.4.2 Analog setting of the desired value (optional)..................................................................................................... 69
7.4.3 Bandwidth............................................................................................................................................................ 72
7.4.4 Setting voltage balance....................................................................................................................................... 75
7.4.5 Setting delay time T1........................................................................................................................................... 75
7.4.6 Setting control response T1................................................................................................................................ 76
7.4.7 Setting delay time T2........................................................................................................................................... 77
7.5 Limit values........................................................................................................................................ 78
7.5.1 Setting undervoltage monitoring V<.................................................................................................................... 78
7.5.2 Setting overvoltage monitoring V>...................................................................................................................... 81
7.5.3 Activating/deactivating function monitoring......................................................................................................... 83
7.5.4 Setting hunting alarm limit................................................................................................................................... 83
7.6 Compensation................................................................................................................................... 84
7.6.1 R&X compensation.............................................................................................................................................. 84
7.6.2 Z compensation................................................................................................................................................... 87
7.7 Transformer data............................................................................................................................... 88
7.7.1 Setting the phase difference for the current transformer/voltage transformer..................................................... 89
7.7.2 Setting the primary transformer voltage.............................................................................................................. 93
7.7.3 Setting the secondary transformer voltage.......................................................................................................... 93
7.7.4 Setting primary transformer current..................................................................................................................... 94
7.8 Configurable inputs and outputs........................................................................................................ 94
7.8.1 Linking inputs with functions................................................................................................................................ 94
7.8.2 Setting user-defined collective message............................................................................................................. 96
7.9 Parallel operation............................................................................................................................... 96
7.9.1 Assigning CAN bus address................................................................................................................................ 97
7.9.2 Assigning a parallel operation group................................................................................................................... 98
7.9.3 Selecting parallel operation method.................................................................................................................... 98
7.9.4 Setting delay time for parallel operation error messages.................................................................................. 101
7.9.5 Setting the follower tapping direction................................................................................................................ 102
7.9.6 Activating/deactivating parallel operation.......................................................................................................... 103
7.9.7 Setting the behavior in the event of CAN bus error........................................................................................... 103
7.10 LED selection.................................................................................................................................. 104
7.11 Memory............................................................................................................................................ 104
7.11.1 Setting undervoltage threshold.......................................................................................................................... 105
7.11.2 Setting overvoltage threshold............................................................................................................................ 106

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7.11.3 Setting time difference of average value interval.............................................................................................. 107
7.11.4 Setting event memory size................................................................................................................................ 107
7.11.5 Time plotter....................................................................................................................................................... 110
7.12 Communication interface................................................................................................................. 116
7.12.1 Selecting the communication protocol............................................................................................................... 116
7.12.2 Selecting communication port........................................................................................................................... 117
7.12.3 Selecting communication baud rate.................................................................................................................. 117
7.12.4 Assigning network address............................................................................................................................... 118
7.12.5 Assigning TCP port........................................................................................................................................... 118
7.12.6 Setting fiber-optic cable transmission behavior................................................................................................. 119
7.12.7 Setting CI address............................................................................................................................................. 119
7.12.8 Setting SCADA master address........................................................................................................................ 120
7.12.9 Enabling unsolicited messages......................................................................................................................... 121
7.12.10 Setting number of attempts to transmit unsolicited messages.......................................................................... 121
7.12.11 Timeout for application confirm responses........................................................................................................ 122
7.12.12 Setting transmission delay time for RS485 interface......................................................................................... 122
7.13 Tap positions................................................................................................................................... 123
7.13.1 Analog tap position capture (optional)............................................................................................................... 123
7.13.2 Tap position output............................................................................................................................................ 125
7.13.3 Permitted tap positions...................................................................................................................................... 126
7.13.4 Tap-position indication...................................................................................................................................... 127
7.14 Displaying information about device................................................................................................ 128
7.14.1 Displaying the info screen................................................................................................................................. 128
7.14.2 Displaying measured values............................................................................................................................. 128
7.14.3 Carrying out LED test........................................................................................................................................ 129
7.14.4 Display of the IO status..................................................................................................................................... 130
7.14.5 Displaying status of the AI card......................................................................................................................... 130
7.14.6 Displaying status of the CI card......................................................................................................................... 130
7.14.7 Resetting parameters........................................................................................................................................ 131
7.14.8 Displaying real-time clock.................................................................................................................................. 131
7.14.9 Displaying parallel operation............................................................................................................................. 131
7.14.10 Displaying data on CAN bus............................................................................................................................. 132
7.14.11 Displaying measured value memory................................................................................................................. 133
7.14.12 Displaying peak memory................................................................................................................................... 133
7.14.13 Displaying the operations counters................................................................................................................... 134

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7.14.14 Displaying upcoming messages........................................................................................................................ 134
7.14.15 Display of the consumption............................................................................................................................... 135
8Fault elimination.............................................................................................................. 136
8.1 No regulation in AUTO mode.......................................................................................................... 136
8.2 Unexplained tap change.................................................................................................................. 137
8.3 Man-machine interface.................................................................................................................... 137
8.4 Incorrect measured values.............................................................................................................. 137
8.5 Parallel operation faults................................................................................................................... 138
8.6 Customized GPIs/GPOs.................................................................................................................. 139
8.7 General faults.................................................................................................................................. 139
8.8 Other faults...................................................................................................................................... 140
9Disposal........................................................................................................................... 141
10 Overview of parameters................................................................................................. 142
11 Technical data................................................................................................................. 147
11.1 Display elements............................................................................................................................. 147
11.2 Voltage supply................................................................................................................................. 147
11.3 Voltage measurement and current measurement........................................................................... 147
11.4 Digital inputs and outputs................................................................................................................ 148
11.5 Analog inputs and outputs (AI module)........................................................................................... 149
11.6 System networking (CI module)...................................................................................................... 150
11.7 Dimensions and weight................................................................................................................... 150
11.8 Ambient conditions.......................................................................................................................... 152
11.9 Electromagnetic compatibility.......................................................................................................... 152
11.10 Environmental durability tests.......................................................................................................... 152
11.11 Mechanical stability......................................................................................................................... 153
Glossary........................................................................................................................... 154
List of key words............................................................................................................. 155

1 Introduction
Maschinenfabrik Reinhausen GmbH 20188 297/07 ENTAPCON® 250
Introduction
This technical file contains detailed descriptions on the safe and proper in-
stallation, connection, commissioning and monitoring of the product.
It also includes safety instructions and general information about the prod-
uct.
This technical file is intended solely for specially trained and authorized per-
sonnel.
Manufacturer
The product is manufactured by:
Reinhausen Manufacturing Inc.
2549 North 9th Avenue
Humboldt, Tennessee 38343, USA
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Further information on the product and copies of this technical file are availa-
ble from the address listed above or at www.tapcon250.com.
Completeness
This technical file is incomplete without the further applicable documentation.
The following documents apply to this product:
▪ Operating instructions
▪ Connection diagrams
Safekeeping
Keep this technical file and all supporting documents ready at hand and ac-
cessible for future use at all times.
Notation conventions
This section contains an overview of the symbols and textual emphasis
used.
Hazard communication system
Warnings in this technical file are displayed as follows.
1
1.1
1.2
1.3
1.4
1.4.1

1 Introduction
Maschinenfabrik Reinhausen GmbH 2018 9297/07 EN TAPCON® 250
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
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.
Signal words and pictograms
The following signal words are used:
Signal word Meaning
DANGER Indicates a hazardous situation which, if not avoided, will re-
sult in death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could
result in injury.
NOTICE Indicates measures to be taken to prevent damage to prop-
erty.
Table 1: Signal words in warning notices
Pictograms warn of dangers:
Pictogram Meaning
Warning of a danger point
1.4.1.1
1.4.1.2
1.4.1.3

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Pictogram Meaning
Warning of dangerous electrical voltage
Warning of combustible substances
Warning of danger of tipping
Table 2: Pictograms used in warning notices
Information system
Information is designed to simplify and improve understanding of particular
procedures. In this technical file it is laid out as follows:
Important information.
Instruction system
This technical file contains single-step and multi-step instructions.
Single-step instructions
Instructions which consist of only a single process step are structured as fol-
lows:
Aim of action
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:
1.4.2
1.4.3

1 Introduction
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Aim of action
üRequirements (optional).
1. Step 1.
ðResult of step (optional).
2. Step 2.
ðResult of step (optional).
ðResult of action (optional).
Typographic conventions
The following typographic conventions are used in this technical file:
Typographic convention Purpose Example
UPPERCASE Operating controls, switches ON/OFF
[Brackets] PC keyboard [Ctrl] + [Alt]
Bold Software operating controls Press Continue button
…>…>… Menu paths Parameter > Control parameter
Italics System messages, error messag-
es, signals
Function monitoring alarm trig-
gered
[► Number of pages]. Cross reference [► 41].
Table 3: Typographic conventions
1.4.4

2 Safety
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Safety
Appropriate use
The TAPCON® keeps the output voltage of a transformer with an on-load
tap-changer constant. The product is designed solely for use in stationary
large-scale electrical energy systems and facilities.
If used as intended, in compliance with the requirements and conditions
specified in this technical file and observing the warning notices in this tech-
nical file and attached to the product, the product does not pose risk of injury
or damage to property or the environment. This applies across the entire
service life of the product, from delivery to installation and operation through
to disassembly and disposal.
The following is considered appropriate use:
▪ You will find the standard valid for the product and the year of issue on
the nameplate.
▪ Operate the product in accordance with this technical file, the agreed-
upon delivery conditions and the technical data.
▪ Ensure that all necessary work is performed by qualified personnel only.
▪ Only use the equipment and special tools included in delivery for the in-
tended purpose and in accordance with the specifications of this techni-
cal file.
▪ Only operate the product in industrial areas.
▪ Observe the notices in this technical file regarding electromagnetic com-
patibility and the technical data.
Fundamental Safety Instructions
To prevent accidents, disruptions and damage as well as unacceptable ad-
verse effects on the environment, those responsible for transport, installa-
tion, operation, maintenance and disposal of the product or parts of the prod-
uct must ensure the following:
Personal protective equipment
Loosely worn or unsuitable clothing increases the danger of becoming trap-
ped or caught up in rotating parts and the danger of getting caught on pro-
truding parts. This increases the danger to life and limb.
▪ All necessary devices and personal protective equipment required for
the specific task, such as a hard hat, safety footwear, etc. must be worn.
Observe the section "Personal protective equipment" [► 15].
▪ Never wear damaged personal protective equipment.
▪ Never wear rings, necklaces, or other jewelry.
▪ If you have long hair, wear a hairnet.
2
2.1
2.2

2 Safety
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Work area
Untidy and poorly lit work areas can lead to accidents.
▪ Keep the work area clean and tidy.
▪ Make sure that the work area is well lit.
▪ Observe the applicable laws for accident prevention in the relevant
country.
Working during operation
The product may be operated only in a sound, operational condition. Other-
wise it poses a danger to life and limb.
▪ Regularly check the operational reliability of safety equipment.
▪ Comply with the inspection work, maintenance work and maintenance
intervals described in this technical file.
Invisible laser radiation
Looking directly into the beam or the reflected beam can cause eye damage.
The beam is emitted at the optical connections or at the end of the fiber-optic
cables connected to them on the assemblies. Read the chapter "Technical
Data" [► 147] for further information.
▪ Never look directly into the beam or the reflected beam.
▪ Never look into the beam with the aid of optical instruments such as a
magnifying glass or a microscope.
▪ In the event that the laser beam strikes your eyes, close your eyes im-
mediately and move your head out of the path of the beam.
Working with current transformers
Dangerous high voltages may occur when a current transformer is operated
with an open secondary circuit. This can lead to injuries and property dam-
age.
▪ Never operate a current transformer with an open secondary circuit;
short-circuit the current transformer to prevent this.
▪ Observe the information in the current transformer operating instruc-
tions.
Explosion protection
Highly flammable or explosive gases, vapors and dusts can cause serious
explosions and fire.
▪ Do not install or operate the product in areas where a risk of explosion is
present.

2 Safety
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Safety markings
Warning signs and safety information plates are safety markings on the
product. They are an important aspect of the safety concept.
▪ Observe all safety markings on the product.
▪ Make sure all safety markings on the product remain intact and legible.
▪ Replace safety markings that are damaged or missing.
Ambient conditions
To ensure reliable and safe operation, the product must only be operated
under the ambient conditions specified in the technical data.
▪ Observe the specified operating conditions and requirements for the in-
stallation location.
Modifications and conversions
Unauthorized or inappropriate changes to the product may lead to personal
injury, material damage and operational faults.
▪ Only modify the product after consultation with the manufacturer.
Spare parts
Spare parts not approved by the manufacturer may lead to physical injury,
damage to the product and operational faults.
▪ Only use spare parts approved by the manufacturer.
▪ Contact the manufacturer.
Personnel qualification
The person responsible for assembly, commissioning, operation, mainte-
nance and inspection must ensure that the personnel are sufficiently quali-
fied.
Electrically skilled person
The electrically skilled person has a technical qualification and therefore has
the required knowledge and experience, and is also conversant with the ap-
plicable standards and regulations. The electrically skilled person is also pro-
ficient in the following:
▪ Can identify potential dangers independently and is able to avoid them.
▪ Is able to perform work on electrical systems.
2.3

2 Safety
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▪ Is specially trained for the working environment in which (s)he works.
▪ Must satisfy the requirements of the applicable statutory regulations for
accident prevention.
Electrically trained persons
An electrically trained person receives instruction and guidance from an
electrically skilled person in relation to the tasks undertaken and the poten-
tial dangers in the event of inappropriate handling as well as the protective
devices and safety measures. The electrically trained person works exclu-
sively under the guidance and supervision of an electrically skilled person.
Operator
The operator uses and operates the product in line with this technical file.
The operating company provides the operator with instruction and training
on the specific tasks and the associated potential dangers arising from im-
proper handling.
Technical Service
We strongly recommend having maintenance, repairs and retrofitting carried
out by our Technical Service department. This ensures that all work is per-
formed correctly. If maintenance is not carried out by our Technical Service
department, please ensure that the personnel who carry out the mainte-
nance are trained and authorized by Maschinenfabrik Reinhausen GmbH to
carry out the work.
Authorized personnel
Authorized personnel are trained by Maschinenfabrik Reinhausen GmbH to
carry out special maintenance.
Personal protective equipment
Personal protective equipment must be worn during work to minimize risks to
health.
▪ Always wear the personal protective equipment required for the job at
hand.
▪ Never wear damaged personal protective equipment.
▪ Observe information about personal protective equipment provided in
the work area.
2.4

2 Safety
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Personal protective equipment to be worn at all times
Protective clothing
Close-fitting work clothing with a low tearing
strength, with tight sleeves and with no pro-
truding parts. It mainly serves to protect the
wearer against being caught by moving ma-
chine parts.
Safety shoes
To protect against falling heavy objects and
slipping on slippery surfaces.
Special personal protective equipment for particular environments
Safety glasses
To protect the eyes from flying parts and
splashing liquids.
Visor
To protect the face from flying parts and
splashing liquids or other dangerous sub-
stances.
Hard hat
To protect from falling and flying parts and
materials.
Hearing protection
To protect from hearing damage.
Protective gloves
To protect from mechanical, thermal, and
electrical hazards.

3 Product description
Maschinenfabrik Reinhausen GmbH 2018 17297/07 EN TAPCON® 250
Product description
This chapter contains an overview of the design and function of the product.
Scope of delivery
The following items are included in the delivery:
▪ TAPCON® 250
▪ CD MR-Suite (contains the TAPCON®-trol program)
▪ Technical files
▪ Serial cable RS232
▪ USB adapter with installation CD (optional)
Please note the following:
▪ Check the shipment for completeness on the basis of the shipping docu-
ments.
▪ Store the parts in a dry place until installation.
Function description of the voltage regulation
The TAPCON® keeps the output voltage of a transformer with an on-load
tap-changer constant.
The TAPCON® compares the transformer's measured voltage (Uactual) with a
defined reference voltage (Udesired). The difference between Uactual and Udesired
is the control deviation dU.
The TAPCON® parameters can be optimally adjusted to the line voltage be-
havior to achieve a balanced control response with the on-load tap-changer
only making a small number of tap-change operations.
Performance features
The TAPCON® is responsible for controlling tapped transformers.
Apart from control tasks, the TAPCON® provides additional functions such
as:
▪ Integrated monitoring functions:
– Undervoltage blocking and overvoltage blocking
– Overvoltage detection with high-speed return
– Oscillation messaging
▪ 4 digital inputs and 1 digital output can be individually programmed on-
site by the customer
▪ Additional indicators using LEDs outside the display for freely selectable
functions
3
3.1
3.2
3.3

3 Product description
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▪ Display of all measured values such as voltage, current, active power,
apparent power or reactive power, power factor (cos φ)
▪ Selection of 4 different desired values
▪ Desired value setting by means of analog signals (optional)
▪ Tap position capture (optional):
– Using analog signal 4…20 mA, 0…1 mA, 0…20 mA
– Using analog signal via resistor contact series
▪ Tap position output by means of analog signals (optional)
▪ Parallel operation of up to 6 transformers in 2 groups using the following
methods:
– Master/follower
– Circulating reactive current minimization
▪ SCADA:
– DNP3
– Modbus ASCII
– Modbus RTU
Operating modes
The device can be operated in the following operating modes:
Auto mode (AUTO)
In auto mode, the voltage is automatically controlled in accordance with the
set parameters. You cannot change further device settings in auto mode.
There is no active management by a higher level control system in this oper-
ating mode.
Manual mode (MANUAL)
In manual mode, there is no automatic control. The motor-drive unit can be
controlled via the device's operating panel. You can change the device set-
tings.
Local mode (LOCAL)
There is no active management by a superordinate control system in this op-
erating mode.
Remote mode (REMOTE)
In remote mode, you can execute commands via an external control level. In
this case, manual operation of the , , and keys is disabled.
3.4

3 Product description
Maschinenfabrik Reinhausen GmbH 2018 19297/07 EN TAPCON® 250
+ LOCAL + RE-
MOTE
+ LOCAL + RE-
MOTE
Automatic regulation Yes Yes No No
Tap-change operation via operat-
ing controls
No No Yes No
Tap-change operation via inputs No No No Yes
Tap-change operation via SCADA No No No Yes
Value adjustment via SCADA* No Yes No Yes
Table 4: Overview of operating modes
*) Optional when connecting TAPCON® to a control system (SCADA)

3 Product description
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Hardware
The individual assemblies are mounted in optimized, EMC-protected hous-
ings. The front plate contains the operating controls, the display and the
LEDs.
Figure 1: Front view
3.5