MR TAPMOTION ED Series User manual

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

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

Table of contents
Maschinenfabrik Reinhausen GmbH 2020 31800138/08 EN TAPMOTION® ED
Table of contents
1Introduction......................................................................................................................... 6
1.1 Manufacturer....................................................................................................................................... 6
1.2 Completeness...................................................................................................................................... 6
1.3 Safekeeping......................................................................................................................................... 6
1.4 Notation conventions........................................................................................................................... 6
1.4.1 Hazard communication system............................................................................................................................. 6
1.4.2 Information system................................................................................................................................................ 8
1.4.3 Instruction system................................................................................................................................................. 8
1.4.4 Typographic conventions...................................................................................................................................... 9
2Security.............................................................................................................................. 10
2.1 Appropriate use................................................................................................................................. 10
2.2 Fundamental safety instructions........................................................................................................ 11
2.3 Personnel qualification...................................................................................................................... 13
2.4 Personal protective equipment.......................................................................................................... 14
3Product description.......................................................................................................... 16
3.1 Scope of delivery............................................................................................................................... 16
3.2 Function description.......................................................................................................................... 16
3.3 Type designation............................................................................................................................... 16
3.4 Design............................................................................................................................................... 17
3.4.1 Indication field..................................................................................................................................................... 18
3.4.2 Anti-condensation heater.................................................................................................................................... 18
3.4.3 Swing frame/terminal rail..................................................................................................................................... 19
3.4.4 Position transmitter equipment............................................................................................................................ 20
3.4.5 Transmission gear cover plate............................................................................................................................ 20
3.5 Protective devices............................................................................................................................. 21
3.6 Safety markings................................................................................................................................. 22
4Packaging, transport and storage................................................................................... 23
4.1 Packaging.......................................................................................................................................... 23
4.1.1 Suitability............................................................................................................................................................. 23
4.1.2 Markings.............................................................................................................................................................. 24
4.2 Transportation, receipt and handling of shipments............................................................................ 24
4.3 Storage of shipments......................................................................................................................... 25

Table of contents
Maschinenfabrik Reinhausen GmbH 202041800138/08 ENTAPMOTION® ED
4.4 Unpacking shipments and checking for transportation damages...................................................... 26
5Mounting............................................................................................................................ 27
5.1 Fitting motor-drive unit on transformer.............................................................................................. 27
5.2 Mounting drive shafts and bevel gear................................................................................................ 29
5.3 Centering on-load tap-changer and motor-drive unit......................................................................... 29
5.4 Cable recommendation..................................................................................................................... 36
5.5 Installing electrics for motor-drive unit............................................................................................... 37
6Commissioning................................................................................................................. 39
6.1 Starting up motor-drive unit............................................................................................................... 39
6.2 Tests on motor-drive unit................................................................................................................... 40
6.2.1 Checking correct electric switch-off..................................................................................................................... 40
6.2.2 Checking mechanical and electric end stop of on-load tap-changer/off-circuit tap-changer and motor-drive unit
............................................................................................................................................................................ 40
6.2.3 Checking tripping of motor protective switch....................................................................................................... 41
6.3 Tests on the transformer................................................................................................................... 42
6.3.1 High-voltage tests on the transformer................................................................................................................. 42
6.3.2 Dielectric tests on transformer wiring.................................................................................................................. 42
6.4 Transporting transformer to the operating site.................................................................................. 43
6.5 Commissioning the transformer at the operating site........................................................................ 43
7Operation........................................................................................................................... 44
7.1 Operating the motor-drive unit remotely............................................................................................ 44
7.2 Operating motor-drive unit locally...................................................................................................... 44
7.3 Operating the motor-drive unit with the hand crank........................................................................... 45
8Fault elimination................................................................................................................ 47
8.1 Safety instructions............................................................................................................................. 47
8.2 General information........................................................................................................................... 48
8.3 Fault in the environment of the motor-drive unit................................................................................ 48
8.4 Fault in the motor-drive unit when the switching operation has not ended........................................ 48
8.5 Fault in the motor-drive unit after the switching operation is ended correctly.................................... 49
8.6 Hand crank operation in the event of faults....................................................................................... 49
9Inspection and maintenance............................................................................................ 51
9.1 Care................................................................................................................................................... 51
9.2 Inspection.......................................................................................................................................... 51

Table of contents
Maschinenfabrik Reinhausen GmbH 2020 51800138/08 EN TAPMOTION® ED
9.3 Maintenance...................................................................................................................................... 51
10 Disassembly...................................................................................................................... 53
11 Disposal............................................................................................................................. 55
12 Special motor-drive unit models..................................................................................... 56
13 Technical data................................................................................................................... 57
13.1 Technical data for TAPMOTION® ED............................................................................................... 57
13.2 Technical data for position transmitter equipment............................................................................. 57
13.3 Permissible ambient conditions......................................................................................................... 58
14 Appendix............................................................................................................................ 60
14.1 898802............................................................................................................................................... 61
14.2 898801............................................................................................................................................... 62

1 Introduction
Maschinenfabrik Reinhausen GmbH 202061800138/08 ENTAPMOTION® ED
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:
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 availa-
ble from this address if required.
Completeness
This technical file is incomplete without the supporting documents.
The following documents also apply in addition to this technical file:
▪ Connection diagrams
▪ Routine test report
▪ Supplement
Also observe generally valid legislation, standards, and guidelines as well as
specifications on accident prevention and environmental protection in the re-
spective country of use.
Safekeeping
Keep this technical file and all supporting documents ready at hand and ac-
cessible for future use at all times.
Notation conventions
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 2020 71800138/08 EN TAPMOTION® ED
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 Definition
DANGER Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE Indicates measures to be taken to prevent damage to property.
Table 1: Signal words in warning notices
Pictograms warn of dangers:
Pictogram Definition
Warning of a danger point
Warning of dangerous electrical voltage
1.4.1.1
1.4.1.2
1.4.1.3

1 Introduction
Maschinenfabrik Reinhausen GmbH 202081800138/08 ENTAPMOTION® ED
Pictogram Definition
Warning of combustible substances
Warning of danger of tipping
Warning of danger of crushing
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
Maschinenfabrik Reinhausen GmbH 2020 91800138/08 EN TAPMOTION® ED
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 messages,
signals
Function monitoring alarm triggered
[► Number of pages]. Cross reference [► 41].
Table 3: Typographic conventions
1.4.4

2 Security
Maschinenfabrik Reinhausen GmbH 202010 1800138/08 ENTAPMOTION® ED
Security
▪ Read this technical file through to familiarize yourself with the product.
▪ This technical file is a part of the product.
▪ Read and observe the safety instructions provided in this chapter.
▪ Read and observe the warnings in this technical file in order to avoid func-
tion-related dangers.
▪ The product is manufactured on the basis of state-of-the-art technology.
Nevertheless, risks to life and limb for the user or impairment of the prod-
uct and other material assets due to the function may arise in the event of
improper use.
Appropriate use
The motor-drive unit adjusts the operating position of on-load tap-changers
in regulating transformers to the individual operating requirements. The mo-
tor-drive unit is designed solely for use in electrical energy systems and fa-
cilities. If used as intended and in compliance with the requirements and
conditions specified in this technical file as well as the warning notices in this
technical file and attached to the product, then the motor-drive unit does not
present any danger to people, property or the environment. This applies
throughout the service life of the product, from delivery, installation and oper-
ation to removal and disposal.
The following is considered appropriate use:
▪ Only operate the product in accordance with this technical file and the
agreed delivery conditions and technical data.
▪ Use the equipment and special tools supplied solely for the intended pur-
pose and in accordance with the specifications of this technical file.
▪ Use the product only with the transformer/on-load tap-changer/de-ener-
gized tap-changer specified in the order.
▪ You will find the standard valid for the product and the year of issue on the
nameplate.
▪ The serial numbers of on-load tap-changer / de-energized tap-changer
and on-load tap-changer accessories / de-energized tap-changer acces-
sories (drive, drive shaft, bevel gear, protective relay, etc.) must match if
these products are supplied as a set for one order.
▪ Electrically operate the motor-drive unit remotely during normal operation.
▪ In special operating cases (such as during maintenance tasks), the motor-
drive unit can also be operated electrically on site via control switch S3.
▪ Never operate the motor-drive unit electrically or with the hand crank be-
fore the transformer has been disconnected if you think there may be a
fault in the transformer or on-load tap-changer/de-energized tap-changer.
For more information, refer to the "Troubleshooting" [►Section 8, Page
47] chapter.
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2.1

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Maschinenfabrik Reinhausen GmbH 2020 111800138/08 EN TAPMOTION® ED
▪ The provided hand crank is for activating the motor-drive unit during in-
stallation and tests in the transformer plant or during maintenance tasks if
the transformer has been disconnected.
▪ For details about using the hand crank in emergency operation when the
transformer is energized, refer to the "Operation" [►Section 7, Page 44]
chapter.
Fundamental safety instructions
To prevent accidents, malfunctions and damage as well as unacceptable ad-
verse effects on the environment, those responsible for transport, installa-
tion, operation, maintenance and disposal of the product or parts of the prod-
uct must ensure the following:
Personal protective equipment
Loosely worn or unsuitable clothing increases the danger of becoming trap-
ped or caught up in rotating parts and the danger of getting caught on pro-
truding parts. This poses a danger to life and limb.
▪ Wear appropriate personal protective equipment such as a helmet, work
gloves, etc. for the respective activity.
▪ Never wear damaged personal protective equipment.
▪ Never wear rings, necklaces, or other jewelry.
▪ If you have long hair, wear a hairnet.
Work area
Untidy and poorly lit work areas can lead to accidents.
▪ Keep the work area clean and tidy.
▪ Make sure that the work area is well lit.
▪ Observe the applicable laws for accident prevention in the relevant coun-
try.
Drying the transformer
Drying the motor-drive unit will cause damage to property as well as motor-
drive unit malfunctions.
▪ Never dry the motor-drive unit.
Working during operation
The product may only be operated in a sound, operational condition. Other-
wise it poses a danger to life and limb.
▪ Regularly check the operational reliability of safety equipment.
▪ Comply with the inspection work, maintenance work and maintenance in-
tervals described in this technical file.
2.2

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Maschinenfabrik Reinhausen GmbH 202012 1800138/08 ENTAPMOTION® ED
Hand crank aperture
Reaching into the hand crank aperture during a tap-change operation may
lead to injuries caused by a rotating drive shaft.
▪ Never reach into the hand crank aperture.
Securing the motor-drive unit
If you open the motor-drive unit during operation, there is a danger of electric
shock due to live components behind the swing frame.
▪ Secure the motor-drive unit against unauthorized opening during opera-
tion by using a padlock.
▪ The motor-drive unit may only be opened by an electrically skilled person.
Opening the swing frame
Opening the swing frame while the motor-drive unit is in operation may result
in electric shocks due to live components.
▪ The swing frame may only be opened by an electrically skilled person.
Explosion protection
Highly flammable or explosive gases, vapors and dusts can cause serious
explosions and fire. This increases the danger to life and limb.
▪ Do not install, operate or perform maintenance work on the product in
areas where a risk of explosion is present.
Safety markings
Warning signs and safety information plates are safety markings on the
product. They are an important aspect of the safety concept.
▪ Observe all safety markings on the product.
▪ Make sure all safety markings on the product remain intact and legible.
▪ Replace safety markings that are damaged or missing.
Ambient conditions
To ensure reliable and safe operation, the product must only be operated
under the ambient conditions specified in the technical data.
▪ Observe the specified operating conditions and requirements for the in-
stallation location.

2 Security
Maschinenfabrik Reinhausen GmbH 2020 131800138/08 EN TAPMOTION® ED
Auxiliary materials and operating materials
Auxiliary materials and operating materials not approved by the manufactur-
er can lead to personal injury, damage to property and malfunctions of the
product.
▪ Only use conductive and grounded hoses, pipes, and pump equipment
that are approved for flammable liquids.
▪ Only use lubricants and auxiliary materials approved by the manufacturer.
▪ Contact the manufacturer.
Modifications and conversions
Unauthorized or inappropriate changes to the product may lead to personal
injury, material damage and operational faults.
▪ Only modify the product after consultation with Maschinenfabrik Reinhau-
sen GmbH.
Spare parts
Spare parts not approved by Maschinenfabrik Reinhausen GmbH may lead
to physical injury, damage to the product and malfunctions.
▪ Only use spare parts that have been approved by Maschinenfabrik Rein-
hausen GmbH.
▪ Contact Maschinenfabrik Reinhausen GmbH.
Personnel qualification
The person responsible for assembly, commissioning, operation, mainte-
nance and inspection must ensure that the personnel are sufficiently quali-
fied.
Electrically skilled person
The electrically skilled person has a technical qualification and therefore has
the required knowledge and experience, and is also conversant with the ap-
plicable standards and regulations. The electrically skilled person is also pro-
ficient in the following:
▪ Can identify potential dangers independently and is able to avoid them.
▪ Is able to perform work on electrical systems.
▪ Is specially trained for the working environment in which (s)he works.
▪ Must satisfy the requirements of the applicable statutory regulations for
accident prevention.
2.3

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Maschinenfabrik Reinhausen GmbH 202014 1800138/08 ENTAPMOTION® ED
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.
Protective clothing Close-fitting work clothing with a low tearing strength,
with tight sleeves and with no protruding parts. It mainly
serves to protect the wearer against being caught by
moving machine parts.
Safety shoes To protect against falling heavy objects and slipping on
slippery surfaces.
Safety glasses To protect the eyes from flying parts and splashing liq-
uids.
Visor To protect the face from flying parts and splashing liq-
uids or other dangerous substances.
Hard hat To protect against falling and flying parts and materials.
2.4

2 Security
Maschinenfabrik Reinhausen GmbH 2020 151800138/08 EN TAPMOTION® ED
Hearing protection To protect against hearing damage.
Protective gloves To protect against mechanical, thermal, and electrical
hazards.
Table 4: Personal protective equipment

3 Product description
Maschinenfabrik Reinhausen GmbH 202016 1800138/08 ENTAPMOTION® ED
Product description
Scope of delivery
The motor-drive unit is packaged with protection against moisture and is de-
livered as follows:
▪ Motor-drive unit
▪ Product documentation
Please note the following:
1. Check the shipment for completeness on the basis of the shipping docu-
ments.
2. Store the parts in a dry place until installation.
3. The product must remain in its airtight, protective wrapping and may only
be removed immediately before installation.
Function description
The motor-drive unit adjusts the operating position of on-load tap-changers
in regulating transformers to the individual operating requirements.
The tap-change operation is activated by starting the motor-drive unit (a sin-
gle control impulse triggered, for example, by a voltage regulator of the
TAPCON®-series). This operation is always completed regardless of any
other control pulses emitted during the tap-change operation. In the standard
design, the next tap-change operation can only proceed once all control de-
vices have reached their resting positions.
Behavior in the event of a voltage interruption
Should the voltage be interrupted during an on-load tap-change operation,
once the voltage supply returns, the motor-drive unit completes the started
on-load tap-change operation.
Type designation
The various basic designs of the TAPMOTION® ED are clearly identified by
explicit product definitions.
Type designa-
tion
Description Variants
ED 100-ST Product designation Electric Drive
ED 100-ST Transmission gear design 100 or 200 (depending on the
torque required)
ED 100-ST Protective housing design S = small protective housing
L = large protective housing
3
3.1
3.2
3.3

3 Product description
Maschinenfabrik Reinhausen GmbH 2020 171800138/08 EN TAPMOTION® ED
Type designa-
tion
Description Variants
ED 100-STSpecial applications … = none
C = Plunger coil design
T = TAPCON® or TAPGUARD®
ED 100-S-ISM Special application ISM = "Integrated Smart Module"
for recording, aggregating and in-
terpreting data on the transform-
er
Table 5: Type designation
Design
This chapter contains an overview of the design of the motor-drive unit.
Components not described here in detail are described in the motor-drive
unit's technical data.
Figure 1: Motor-drive unit, open
1 Protective housing cover 9 S3 control switch
2 Viewing window for indication field 10 Swing frame/anti-condensation
heater
3.4

3 Product description
Maschinenfabrik Reinhausen GmbH 202018 1800138/08 ENTAPMOTION® ED
3 Fixing lug 11 Indication field
4 Ground connection 12 Nameplate
5 Output shaft 13 Motor protective switch Q1
6 Hand-crank aperture with hand-
crank interlock switch
14 Document pocket
7 Hand lamp 15 Transmission-gear cover plate
8 Hand crank
Indication field
A clear indication field is fitted in the motor-drive unit. Pointer and operations
counter are mechanically driven and indicate the tap-change operation se-
quence and operating position of the motor-drive unit. The reset wheel on
the operations counter is lead-sealed at the factory.
Figure 2: Indication field
1 Tap position indicator 3 Tap-change indicator: Shows the
current position of the control cam
(33 tap-change indicator sections
per operating position)
2 The two drag hands indicate the
regulating range currently used
4 The mechanical operations coun-
ter shows the overall number of
tap-change operations
Anti-condensation heater
The anti-condensation heater is designed as a panel heater which also acts
as the front cover of the swing frame.
The design of the motor-drive unit and panel heater ensures that air circu-
lates inside the motor-drive unit and therefore that there is a constant interior
temperature which is always higher than the outside temperature.
3.4.1
3.4.2

3 Product description
Maschinenfabrik Reinhausen GmbH 2020 191800138/08 EN TAPMOTION® ED
Swing frame/terminal rail
The swing frame protects all electrical and mechanical parts of the motor-
drive unit behind the swing frame against accidental contact.
The terminal rail behind the swing frame makes electrical connection of the
motor-drive unit a simple task. The wiring is easily connected using vertically
arranged cap rails with the corresponding installed terminal bars.
Figure 3: Terminal rail
1 Swing frame 4 Cable duct
2 Position transmitter module 5 Cap rail
3 Terminal bar X1 6 Opening for cable entry (sealed by
base plate)
3.4.3

3 Product description
Maschinenfabrik Reinhausen GmbH 202020 1800138/08 ENTAPMOTION® ED
Position transmitter equipment
NOTICE
Damage to the on-load tap-changer and motor-drive unit!
Damage to on-load tap-changer and motor-drive unit due to incorrect use of
position transmitter equipment.
► Only circuits stated in the chapter Technical data for position transmitter
equipment [►Section 13.2, Page 57] may be connected to the position
transmitter module connections.
► The switchover point of the position transmitter equipment in the motor-
drive unit is not the same as the switchover point of the diverter switch
operation. This depends on the type of diverter switch. This fact should
be noted when project planning the locking circuits between the motor-
drive unit and external equipment (e.g. transformer circuit breaker).
► Therefore, the "Tap changer in operation" position transit contact shown
in the connection diagram should be used for external monitoring, locking
and control purposes instead of the position transmitter equipment.
The position transmitter equipment is used to indicate the operating position
of the on-load tap-changer/off-circuit tap-changer when idle.
The remote display is available in various versions.
The position transmitter module for connection by the customer is located on
the terminal rail [►Section 3.4.3, Page 19].
For more information about the position transmitter equipment, see Techni-
cal data for position transmitter equipment [►Section 13.2, Page 57].
Transmission gear cover plate
WARNING Danger of death and severe injury from electrical voltage!
Danger of death and severe injury from electrical voltage if the transmission
gear cover plate is not fitted.
► Never start up motor-drive unit without transmission gear cover plate.
3.4.4
3.4.5