MR VACUTAP RMV-II User manual

ON-LOAD TAP-CHANGER
VACUTAP® RMV-II
OPERATING INSTRUCTIONS
2159612/03 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 2019 32159612/03 EN VACUTAP® RMV-II
Table of contents
1 Introduction......................................................................................................................... 6
1.1 Validity ................................................................................................................................................ 6
1.2 Manufacturer....................................................................................................................................... 6
1.3 Completeness..................................................................................................................................... 6
1.4 Safekeeping........................................................................................................................................ 6
1.5 Notation conventions .......................................................................................................................... 7
1.5.1 Hazard communication system .............................................................................................................................7
1.5.2 Information system................................................................................................................................................8
1.5.3 Instruction system .................................................................................................................................................8
2 Safety................................................................................................................................. 10
2.1 Appropriate use ................................................................................................................................ 10
2.2 Fundamental safety instructions ....................................................................................................... 11
2.3 Personnel qualification...................................................................................................................... 13
2.4 Personal protective equipment ......................................................................................................... 14
3 Product description.......................................................................................................... 16
3.1 Scope of delivery .............................................................................................................................. 16
3.2 On-load tap-changer......................................................................................................................... 16
3.2.1 Function description for on-load tap-changer......................................................................................................16
3.2.2 On-load tap-changer design................................................................................................................................19
3.2.3 Protective devices ...............................................................................................................................................22
3.3 Motor-drive unit................................................................................................................................. 23
3.3.1 Function description ............................................................................................................................................23
3.3.2 Motor-drive unit design........................................................................................................................................23
3.3.3 Protective devices in the motor-drive unit ...........................................................................................................24
3.4 Monitoring system (VIM)................................................................................................................... 25
3.4.1 Function description of monitoring system..........................................................................................................25
3.4.2 Monitoring system displays and controls ............................................................................................................26
3.5 Dehydrating breather ....................................................................................................................... 26
4 Packaging, transport and storage .................................................................................. 28
4.1 Packaging ......................................................................................................................................... 28
4.1.1 Suitability.............................................................................................................................................................28
4.1.2 Markings..............................................................................................................................................................28

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4.2 Transportation, receipt and handling of shipments........................................................................... 29
4.3 Unpacking shipments and checking for transportation damages ..................................................... 30
4.4 Things to note when putting back into storage ................................................................................. 30
5 Fitting on-load tap-changer on transformer .................................................................. 31
5.1 Preparatory work .............................................................................................................................. 31
5.2 Fitting the on-load tap-changer......................................................................................................... 31
5.3 Connecting the tap winding and on-load tap-changer take-off lead ................................................. 32
6 Fitting motor-drive unit .................................................................................................... 33
6.1 Preparatory work .............................................................................................................................. 33
6.2 Fitting motor-drive unit to on-load tap-changer................................................................................. 36
7 Checks after assembly..................................................................................................... 37
7.1 Manual check.................................................................................................................................... 37
7.2 Checking motor-drive unit and monitoring system............................................................................ 38
7.3 Transformer ratio test and DC resistance measurement.................................................................. 38
7.3.1 Carrying out the transformer ratio test ................................................................................................................39
7.3.2 Measuring DC resistance on transformer ...........................................................................................................39
8 Drying the on-load tap-changer ...................................................................................... 40
9 Filling on-load tap-changer with oil ................................................................................ 41
10 Fitting accessories ........................................................................................................... 42
10.1 Fitting dehydrating breather ............................................................................................................. 42
10.2 Pressure relief device MPreC® ........................................................................................................ 44
11 Commissioning at the transformer manufacturer's site............................................... 45
11.1 Checks before commissioning.......................................................................................................... 45
11.2 Performing trial tap-change operations............................................................................................. 46
11.3 High-voltage tests on the transformer............................................................................................... 46
12 Transporting transformer to installation site................................................................. 48
12.1 Transport with removed drive ........................................................................................................... 48
13 Commissioning the transformer at the operating site.................................................. 49
13.1 Safety current circuits ....................................................................................................................... 50
13.2 Performing trial tap-change operations............................................................................................. 50
13.3 Switching on transformer .................................................................................................................. 51

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14 Actuating motor-drive unit with hand crank .................................................................. 52
15 Monitoring during operation ........................................................................................... 53
15.1 Annual checks .................................................................................................................................. 53
15.1.1 Checking oil quality .............................................................................................................................................53
15.1.2 Checking motor-drive unit ...................................................................................................................................54
15.1.3 Checking return to starting position.....................................................................................................................54
15.2 Occasional visual checks.................................................................................................................. 54
16 Fault elimination ............................................................................................................... 55
16.1 General information .......................................................................................................................... 55
16.2 Fault elimination overview ................................................................................................................ 56
16.3 Monitoring system displays and controls .......................................................................................... 57
16.4 Overview of monitoring system operating statuses .......................................................................... 58
17 Maintenance...................................................................................................................... 59
17.1 Maintenance intervals....................................................................................................................... 59
17.2 Taking on-load tap-changer out of service ....................................................................................... 60
17.3 Draining oil and testing oil quality ..................................................................................................... 60
17.4 Investigating vacuum interrupters..................................................................................................... 60
17.4.1 External integrity check .......................................................................................................................................60
17.4.2 Checking contact erosion indicator .....................................................................................................................61
17.4.3 Replacing vacuum interrupter .............................................................................................................................62
17.5 Checking by-pass switch .................................................................................................................. 62
17.6 Maintaining motor-drive unit ............................................................................................................. 63
17.7 Maintaining monitoring system ......................................................................................................... 63
17.8 Maintaining dehydrating breather ..................................................................................................... 64
17.9 Preparing the on-load tap-changer for service ................................................................................. 65
18 Technical data................................................................................................................... 66
18.1 General data ..................................................................................................................................... 69
18.2 Temperature range ........................................................................................................................... 69
19 Appendix ........................................................................................................................... 70
19.1 Limit values for dielectric strength and water content of on-load tap-changer oil ............................. 70

1 Introduction
Maschinenfabrik Reinhausen GmbH 201962159612/03 ENVACUTAP® RMV-II
1 Introduction
This technical file contains detailed descriptions on the safe and proper in-
stallation, connection, commissioning and monitoring of the product.
In addition, this file contains technical data for selecting the appropriate
product for a respective application.
It also includes safety instructions and general information about the prod-
uct.
This technical document is intended solely for specially trained and autho-
rized personnel.
1.1 Validity
This technical file applies to the VACUTAP® RMV-II on-load tap-changer
with the standard position designations 16L...N...16R.
Drawings and illustrations in this technical file are provided for reference
only. For specific details please refer to drawings submitted with each indi-
vidual customer order.
1.2 Manufacturer
This product is manufactured by:
Reinhausen Manufacturing Inc.
2549 North 9th Avenue, 38343 Humboldt, Tennessee, USA
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Further information on the product and copies of this technical file are avail-
able from this address if required.
1.3 Completeness
This technical file is incomplete without the supporting documents:
▪ Technical data and drawings which are provided upon order confirmation
and with the delivery.
1.4 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 2019 72159612/03 EN VACUTAP® RMV-II
1.5 Notation conventions
This section contains an overview of the symbols and textual emphasis
used.
1.5.1 Hazard communication system
Warnings in this technical file are displayed as follows.
1.5.1.1 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
1.5.1.2 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.
1.5.1.3 Signal words and pictograms
The following signal words are used:
Signal word Meaning
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 injury.
NOTICE Indicates measures to be taken to prevent damage to property.
Table1: Signal words in warning notices

1 Introduction
Maschinenfabrik Reinhausen GmbH 201982159612/03 ENVACUTAP® RMV-II
Pictograms warn of dangers:
Pictogram Meaning
Warning of a danger point
Warning of dangerous electrical voltage
Warning of combustible substances
Warning of danger of tipping
Table2: Pictograms used in warning notices
1.5.2 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.
1.5.3 Instruction system
This technical file contains single-step and multi-step instructions.
Single-step instructions
Instructions which consist of only a single process step are structured as fol-
lows:
Aim of action
üRequirements (optional).
► Step 1 of 1.
ðResult of step (optional).
ðResult of action (optional).

1 Introduction
Maschinenfabrik Reinhausen GmbH 2019 92159612/03 EN VACUTAP® RMV-II
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 201910 2159612/03 ENVACUTAP® RMV-II
2 Safety
This technical file contains detailed descriptions on the safe and proper in-
stallation, connection, commissioning and monitoring of the product.
▪ Read this technical file through carefully 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 in partic-
ular.
▪ Observe the warnings in this technical file in order to avoid function-re-
lated dangers.
▪ The product is manufactured on the basis of state-of-the-art technology.
Nevertheless, risks to life and limb of the user or impairment of the prod-
uct and other material assets may occur during use due to function-re-
lated dangers.
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 service life of the prod-
uct, from delivery to installation and operation through to disassembly and
disposal.
The following is considered appropriate use:
▪ Use the product only with the transformer specified in the order.
▪ 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 provided technical file, the
agreed delivery conditions and 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 technical
file.
▪ The on-load tap-changer is not intended to be used with an oil filter unit.
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:

2 Safety
Maschinenfabrik Reinhausen GmbH 2019 112159612/03 EN VACUTAP® RMV-II
In the standard version, the on-load tap-changer is designed for sinusoidal
50/60 Hz AC current with a curve form symmetrical to the zero axis and can
switch twice the rated through-current Ir at its rated step voltage Uir.
Exceeding the rated step voltage Uir for a short period by up to 10% is per-
mitted if the rated through-current Ir is not exceeded.
2.2 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
trapped or caught up in rotating parts and the danger of getting caught on
protruding 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. Ob-
serve the section "Personal protective equipment" [►Section 2.4, Page
14].
▪ 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.

2 Safety
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Limit step capacity and limit switching capacity
Tap change operations with currents of more than twice the rated through-
current Ir can lead to personal injuries and damage to property. The limit step
capacity is the largest step capacity that can be switched safely. The on-load
tap-changer can switch twice the rated through-current Ir at the rated step
voltage Uir for which the on-load tap-changer was configured.
▪ Take appropriate measures to prevent tap change operations with cur-
rents of more than twice the rated through-current Ir. Examples for such
operating states are the inrush current impulse when transformers are
switched on or a short circuit, for example.
▪ The rated step voltage may be briefly exceeded by up to 10% as long as
the rated through-current is not exceeded. Such an operating condition
can occur due to overexcitation of the transformer after load shedding, for
example.
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 in-
tervals described in this technical file.
Explosion protection
Highly flammable or explosive gases, vapors and dusts can cause serious
explosions and fire.
▪ Do not install, operate or perform maintenance work on the product in ar-
eas 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 Safety
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Auxiliary materials and operating materials
Auxiliary materials and operating materials not approved by the manufac-
turer 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 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.
2.3 Personnel qualification
The person responsible for assembly, commissioning, operation, mainte-
nance and inspection must ensure that the personnel are sufficiently quali-
fied.
Electrically skilled person
The electrically skilled person has a technical qualification and therefore has
the required knowledge and experience, and is also conversant with the ap-
plicable standards and regulations. The electrically skilled person is also pro-
ficient in the following:
▪ Can identify potential dangers independently and is able to avoid them.
▪ Is able to perform work on electrical systems.
▪ Is specially trained for the working environment in which (s)he works.
▪ Must satisfy the requirements of the applicable statutory regulations for
accident prevention.
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.

2 Safety
Maschinenfabrik Reinhausen GmbH 201914 2159612/03 ENVACUTAP® RMV-II
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 or
Reinhausen Manufacturing to carry out the work.
Authorized personnel
Authorized personnel are trained by Maschinenfabrik Reinhausen GmbH or
Reinhausen Manufacturing to carry out special maintenance.
2.4 Personal protective equipment
Personal protective equipment must be worn during work to minimize risks to
health.
▪ Always wear the personal protective equipment required for the job at
hand.
▪ Never wear damaged personal protective equipment.
▪ Observe information about personal protective equipment provided in the
work area.
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 protrud-
ing parts. It mainly serves to protect the wearer
against being caught by moving machine parts.
Safety shoes
To protect against falling heavy objects and slip-
ping on slippery surfaces.

2 Safety
Maschinenfabrik Reinhausen GmbH 2019 152159612/03 EN VACUTAP® RMV-II
Special personal protective equipment for particular environments
Safety glasses
To protect the eyes from flying parts and splash-
ing liquids.
Visor
To protect the face from flying parts and splash-
ing liquids or other dangerous substances.
Hard hat
To protect from falling and flying parts and mate-
rials.
Hearing protection
To protect from hearing damage.
Protective gloves
To protect from mechanical, thermal, and electri-
cal hazards.

3 Product description
Maschinenfabrik Reinhausen GmbH 201916 2159612/03 ENVACUTAP® RMV-II
3 Product description
This chapter contains an overview of the design and function of the product.
3.1 Scope of delivery
The product is packaged with protection against moisture and is delivered as
follows:
▪ Oil compartment with in-built on-load tap-changer, tap selector and
change-over selector
▪ The oil compartment is equipped with:
– Oil drain valve with 2" thread for customer connection and fixture for
taking oil samples
– Vacuum connection: 2" half-coupling
– Filler: 1" half-coupling
– Terminal board with connecting lugs, each prepared with two 0.625"
bores (without thread) for the customer's connection
▪ Pressure relief device MPrec
▪ Technical files
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.
▪ The product must remain in its airtight, protective wrapping and may only
be removed immediately before installation.
3.2 On-load tap-changer
3.2.1 Function description for on-load tap-changer
RMV-II on-load tap-changers are used in conjunction with oil-immersed
power transformers, regulating transformers and phase shifter transformers
to change taps under load thereby controlling voltage magnitude or phase
angle.
The RMV-II on-load tap-changer follows the switching concept of a preven-
tive auto transformer (reactor). Vacuum interrupters are used to interrupt the
circuit within a half cycle. The interrupt occurs in the vacuum, so there is no
shutdown arc in the oil and therefore no contamination of the oil.

3 Product description
Maschinenfabrik Reinhausen GmbH 2019 172159612/03 EN VACUTAP® RMV-II
The diagram below shows a typical winding arrangement with the on-load
tap-changer in operating position 16L:
Figure1: Typical winding arrangement of on-load tap-changer (example: operating position 16L)
A, B Main switching contacts of change-over selector (example: revers-
ing change-over selector)
M Central position contact
3, 4, … 12 Stationary change-over selector contacts (interface to the tap leads
of the tapped winding)
P1, P4Mobile change-over selector contacts
VI Vacuum interrupter
P2, P3Main switching contacts for by-pass switch
P Take-off terminal
The tap changer operation is divided into three major functions:
1. Arc interruption and reclosing using the vacuum interrupters in conjunction
with the associated by-pass switches P2 and P3
2. Selection of the next tap position by the tap selector assemblies in the
correct order with actuation of the vacuum interrupters and by-pass
switches
3. Operation of change-over selector (reversing change-over selector con-
nection or coarse/fine selector) in order to double the number of tap posi-
tions

3 Product description
Maschinenfabrik Reinhausen GmbH 201918 2159612/03 ENVACUTAP® RMV-II
The example below shows the process when changing the operating posi-
tion from 16L to 15L:
Figure2: Tap changes from position 16L to position 15L
The tap changer is operated using a motor-drive unit.
When moving from one tap position to the next, firstly a by-pass switch (in
the example P3) opens, while the second (P2) stays closed, routing the cur-
rent through the vacuum interrupter just prior to its operation.
The vacuum interrupter opens by a spring-operated mechanism before the
mobile fine tap selector contact (in the example P4) selects the next tap.
The vacuum interrupter then closes due to spring force and locks. The by-
pass switch closes again, completing the tap-change operation.
The tap selector connects the preventive auto transformer alternately into a
bridging or a non-bridging position. The change-over selector operates only
when changing from position 1 L to N or N to 1 L.
For more details on the operating positions, please refer to the order-specific
technical files that you received with the order confirmation.

3 Product description
Maschinenfabrik Reinhausen GmbH 2019 192159612/03 EN VACUTAP® RMV-II
3.2.2 On-load tap-changer design
The RMV-II on-load tap changer is a three-phase on-load tap-changer with
full insulation between phases and to ground. The on-load tap-changer com-
prises:
▪ Tank with tap selector and change-over selector (reversing change-over
selector connection or coarse/fine selector connection)
▪ By-pass switch
▪ Vacuum interrupters with monitoring system
▪ Motor-drive unit
▪ Dehydrating breather
All switching elements involved in the tap-change operation, selectors and
change-over selectors, vacuum interrupters and by-pass switches of all
phases, are driven by one main shaft from the drive mechanism.
Figure3: On-load tap-changer oil compartment

3 Product description
Maschinenfabrik Reinhausen GmbH 201920 2159612/03 ENVACUTAP® RMV-II
One vertical insulating plate per phase is permanently mounted on the top of
the on-load tap-changer oil compartment. The vacuum interrupter is
mounted vertically on the front of the insulating plate.
Figure4: Vacuum interrupter
The by-pass switch is located on the opposite (rear) side of the insulating
plate from the vacuum interrupter and is driven by the same drive shaft. The
by-pass switch consists of two contact assemblies with parallel spring-
loaded contact fingers.
Figure5: By-pass switch