MR VACUTAP VR User manual

On-Load Tap-Changer
VACUTAP® VR®
Operating Instructions
6028618/00 EN . High-temperature version

© 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 36028618/00 EN VACUTAP® VR®
Table of contents
1 Introduction......................................................................................................................... 5
1.1 Manufacturer....................................................................................................................................... 5
1.2 Completeness..................................................................................................................................... 5
1.3 Safekeeping........................................................................................................................................ 5
1.4 Notation conventions .......................................................................................................................... 5
1.4.1 Hazard communication system .............................................................................................................................6
1.4.2 Information system................................................................................................................................................7
1.4.3 Instruction system .................................................................................................................................................7
2 Safety................................................................................................................................... 9
2.1 Appropriate use .................................................................................................................................. 9
2.2 Inappropriate use.............................................................................................................................. 10
2.3 Fundamental safety instructions ....................................................................................................... 10
2.4 Personnel qualification...................................................................................................................... 12
2.5 Personal protective equipment ......................................................................................................... 13
3 Product description.......................................................................................................... 15
3.1 On-load tap-changer......................................................................................................................... 15
3.1.1 Function description ............................................................................................................................................15
3.1.2 Design/versions...................................................................................................................................................17
3.1.3 Nameplate and serial number .............................................................................................................................20
3.1.4 Protective devices ...............................................................................................................................................21
3.2 Drive shaft......................................................................................................................................... 25
3.2.1 Function description ............................................................................................................................................25
3.2.2 Design/versions...................................................................................................................................................26
3.2.3 Identification plate ...............................................................................................................................................31
4 Commissioning................................................................................................................. 32
4.1 Commissioning transformer at operating site ................................................................................... 32
4.1.1 Filling the oil compartment of the on-load tap-changer with insulating fluid........................................................32
4.1.2 Bleeding on-load tap-changer head and pipe system.........................................................................................34
4.1.3 Checking motor-drive unit ...................................................................................................................................35
4.1.4 Checking protective relay (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5, 2001/R, 2001/T, 2003) ........................36
4.1.5 Commissioning the transformer ..........................................................................................................................37

Table of contents
Maschinenfabrik Reinhausen GmbH 201846028618/00 ENVACUTAP® VR®
5 Fault elimination ............................................................................................................... 38
5.1 Tripping the protective relay and re-commissioning the transformer................................................ 41
5.1.1 Flap valve in OPERATION position ....................................................................................................................41
5.1.2 Flap valve in OFF position ..................................................................................................................................42
5.1.3 Re-commissioning the transformer .....................................................................................................................42
6 Maintenance...................................................................................................................... 43
6.1 Inspection ......................................................................................................................................... 44
6.2 Maintenance intervals....................................................................................................................... 44
6.3 Changing the insulation fluid............................................................................................................. 46
6.3.1 Moving on-load tap-changer to adjustment position ...........................................................................................46
6.3.2 Removing horizontal drive shaft..........................................................................................................................46
6.3.3 Emptying the oil compartment and oil conservator .............................................................................................48
6.3.4 Filling the oil compartment and oil conservator with fresh insulating fluid...........................................................49
6.3.5 Installing horizontal drive shaft............................................................................................................................52
6.3.6 Centering on-load tap-changer and motor-drive unit ..........................................................................................53
7 Technical data................................................................................................................... 54
7.1 Technical data for on-load tap-changer ............................................................................................ 54
7.1.1 On-load tap-changer properties ..........................................................................................................................54
7.1.2 Permissible ambient conditions...........................................................................................................................55
7.2 Technical data for protective relay.................................................................................................... 55
7.2.1 Protective relay with several dry-reed magnetic switches...................................................................................57
7.2.2 Tests ...................................................................................................................................................................58
7.3 Limit values for dielectric strength and water content of on-load tap-changer oil ............................. 59
8 Drawings ........................................................................................................................... 60
8.1 Dimensional drawings....................................................................................................................... 60
8.2 On-load tap-changer head................................................................................................................ 64
8.3 Adjustment plans .............................................................................................................................. 71
Glossary ............................................................................................................................ 82

1 Introduction
Maschinenfabrik Reinhausen GmbH 2018 56028618/00 EN VACUTAP® VR®
1 Introduction
This technical file contains detailed descriptions for monitoring during opera-
tion, fault elimination, and maintenance.
It also includes safety instructions and general information about the prod-
uct.
Information about installation can be found in the installation and commis-
sioning instructions.
This technical file is intended solely for specially trained and authorized per-
sonnel.
1.1 Manufacturer
The product is manufactured by:
Maschinenfabrik Reinhausen GmbH
Falkensteinstraße 8
93059 Regensburg, Germany
Tel.: [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.
1.2 Completeness
This technical file is incomplete without the supporting documents.
The following documents are considered supporting documents:
▪ Unpacking instructions
▪ Supplement
▪ Routine test report
▪ Connection diagrams
▪ Dimensional drawings
▪ Order confirmation
1.3 Safekeeping
Keep this technical file and all supporting documents ready at hand and ac-
cessible for future use at all times.
1.4 Notation conventions
This section contains an overview of the symbols and textual emphasis
used.

1 Introduction
Maschinenfabrik Reinhausen GmbH 201866028618/00 ENVACUTAP® VR®
1.4.1 Hazard communication system
Warnings in this technical file are displayed as follows.
1.4.1.1 Warning relating to section
Warnings relating to sections refer to entire chapters or sections, sub-sec-
tions or several paragraphs within this technical file. Warnings relating to
sections use the following format:
WARNING Type of danger!
Source of the danger and outcome.
► Action
► Action
1.4.1.2 Embedded warning information
Embedded warnings refer to a particular part within a section. These warn-
ings apply to smaller units of information than the warnings relating to sec-
tions. Embedded warnings use the following format:
DANGER! Instruction for avoiding a dangerous situation.
1.4.1.3 Signal words and pictograms
The following signal words are used:
Signal word Definition
DANGER Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE Indicates measures to be taken to prevent damage to property.
Table1: Signal words in warning notices

1 Introduction
Maschinenfabrik Reinhausen GmbH 2018 76028618/00 EN VACUTAP® VR®
Pictograms warn of dangers:
Pictogram Definition
Warning of a danger point
Warning of dangerous electrical voltage
Warning of combustible substances
Warning of danger of tipping
Warning of danger of crushing
Table2: Pictograms used in warning notices
1.4.2 Information system
Information is designed to simplify and improve understanding of particular
procedures. In this technical file it is laid out as follows:
Important information.
1.4.3 Instruction system
This technical file contains single-step and multi-step instructions.
Single-step instructions
Instructions which consist of only a single process step are structured as fol-
lows:

1 Introduction
Maschinenfabrik Reinhausen GmbH 201886028618/00 ENVACUTAP® VR®
Aim of action
üRequirements (optional).
► Step 1 of 1.
ðResult of step (optional).
ðResult of action (optional).
Multi-step instructions
Instructions which consist of several process steps are structured as follows:
Aim of action
üRequirements (optional).
1. Step 1.
ðResult of step (optional).
2. Step 2.
ðResult of step (optional).
ðResult of action (optional).

2 Safety
Maschinenfabrik Reinhausen GmbH 2018 96028618/00 EN VACUTAP® VR®
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 on-load tap-changer adjusts the transmission ratio of transformers with-
out interrupting the load flow. The on-load tap-changer is designed solely for
use in electrical energy systems and facilities in accordance with IEC
61936-1. 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 on-load tap-changer, then the on-load tap-
changer does not present any danger to people, property or the environ-
ment. This applies throughout service life of the product, from delivery to in-
stallation and operation through to disassembly and disposal.
The following is considered appropriate use:
▪ Use the on-load tap-changer only with the transformer specified in the or-
der.
▪ Only use remote switching of the on-load tap-changer if the transformer is
energized.
▪ Always operate the on-load tap-changer in conjunction with the oil cooling
unit and the temperature sensors.
▪ Ensure that there are no installed parts above the on-load tap-changer
head cover or the protective relay which either radiate heat themselves
onto the on-load tap-changer head cover or protective relay or which pre-
vent the dissipation of heat.
▪ 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 applicable to the on-load tap-changer and the
year of issue on the nameplate.
▪ Operate the on-load tap-changer in accordance with this technical file, the
agreed delivery conditions and technical data.
▪ Ensure that all necessary work is performed by qualified personnel only.

2 Safety
Maschinenfabrik Reinhausen GmbH 201810 6028618/00 ENVACUTAP® VR®
▪ 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:
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 Inappropriate use
Use is considered inappropriate if the product is used in a way other than as
described in the "Appropriate use" section. In addition, observe the following:
Prohibited electrical operating conditions
All operating conditions that do not comply with the design data in accor-
dance with the order confirmation are prohibited.
Prohibited operating conditions may arise due to short circuits as well as due
to inrush current impulses when energizing transformers or other electrical
machines. This applies to the affected transformer itself just as it does to
transformers electrically connected in parallel or serially or other electrical
machines.
Higher voltages may occur due to transformer overexcitation following load
shedding, for example.
Operations outside of the permitted operating conditions can lead to injury to
persons and damage to the product.
▪ Prevent any such operations outside of the permitted operating conditions
by taking suitable measures.
2.3 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:

2 Safety
Maschinenfabrik Reinhausen GmbH 2018 116028618/00 EN VACUTAP® VR®
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 2.5, Page
13].
▪ 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.
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.
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 ar-
eas where a risk of explosion is present.
Explosion protection
Impermissible on-load tap-change operations can lead to severe explosions
and fire. This poses a danger to life and limb.
▪ Never actuate the motor-drive unit with the hand crank if the transformer
is energized.
▪ Never actuate the motor-drive via the RAISE key / LOWER key on the
motor-drive unit if the transformer is energized.
▪ Never actuate the motor-drive unit manually via the voltage regulator in
the danger zone of the transformer if the transformer is energized.
▪ Ensure that no persons are in or enter the danger zone of the transformer
during an on-load tap-change operation.

2 Safety
Maschinenfabrik Reinhausen GmbH 201812 6028618/00 ENVACUTAP® VR®
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.
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.
▪ Use MIDEL 7131 as the insulating fluid. Other insulating fluids on request.
▪ It is imperative that you consult with Maschinenfabrik Reinhausen GmbH
because specific operating conditions apply to alternative insulating fluids.
▪ 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.
2.4 Personnel qualification
The person responsible for assembly, commissioning, operation, mainte-
nance and inspection must ensure that the personnel are sufficiently quali-
fied.

2 Safety
Maschinenfabrik Reinhausen GmbH 2018 136028618/00 EN VACUTAP® VR®
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.
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.
2.5 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 Safety
Maschinenfabrik Reinhausen GmbH 201814 6028618/00 ENVACUTAP® VR®
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.
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 2018 156028618/00 EN VACUTAP® VR®
3 Product description
This chapter contains an overview of the design and function of the product.
3.1 On-load tap-changer
3.1.1 Function description
On-load tap-changers are used to adjust the transmission ratio of transform-
ers without interrupting the load flow. Fluctuations in voltage occurring in the
power transmission grid, for example, can therefore be compensated for. For
this purpose, on-load tap-changers are fitted in transformers and connected
to the active part of the transformer.

3 Product description
Maschinenfabrik Reinhausen GmbH 201816 6028618/00 ENVACUTAP® VR®
A motor-drive unit which receives a control impulse (e.g. from a voltage reg-
ulator) changes the operating position of the on-load tap-changer, as a result
of which the transformer's transmission ratio is adapted to the prevailing op-
erating requirements.
Figure1: System overview of transformer on-load tap-changer
1 Oil conservator 2 On-load tap-changer
3 Active part of the transformer 4 Heat exchanger
5 Transformer tank 6 Fan
7 Oil cooling unit 8 Shielding housing
9 Motor-drive unit 10 Vertical drive shaft
11 Pipe (hot insulating fluid) 12 Pipe (cooled insulating fluid)

3 Product description
Maschinenfabrik Reinhausen GmbH 2018 176028618/00 EN VACUTAP® VR®
13 Bevel gear 14 Horizontal drive shaft
15 Upper gear unit 16 RS protective relay
3.1.2 Design/versions
The on-load tap-changer consists of the on-load tap-changer head, oil com-
partment with built-in diverter switch insert and the selector mounted below
(also available with change-over selector on request).
The design and designation of the most important on-load tap-changer com-
ponents are shown in the installation drawings in the appendix.

3 Product description
Maschinenfabrik Reinhausen GmbH 201818 6028618/00 ENVACUTAP® VR®
For the number of maximum operating positions of the on-load tap-changer,
refer to the technical data.
Figure2: Design of VACUTAP® VR
1 On-load tap-changer head 2 Temperature sensor
3 Pipe bend 4 Oil compartment
5 Tap selector 6 Change-over selector (optional)
7 On-load tap-changer head cover 8 Rupture disk
9 Upper gear unit

3 Product description
Maschinenfabrik Reinhausen GmbH 2018 196028618/00 EN VACUTAP® VR®
3.1.2.1 Pipe connections
There are 5 pipe connections on the on-load tap-changer head and on-load
tap-changer head cover for various purposes. Depending on the order, some
or all of these pipe connections are fitted with pipe bends ex factory.
All pipe bends without terminal box for the tap-change supervisory device
can be freely swiveled once the pressure ring is loosened.
Figure3: Pipe connections with pipe bends
Pipe connection Q
The connection cable of the tap-change supervisory device delivered as an
option is routed through pipe connection Q. Pipe connection Q is closed with
a blank cover on the on-load tap-changer version without tap-change super-
visory device.
The functions of the R and Q pipe connections can be interchanged. You
must, however, use the long pipe bend on the pipe connection through
which the tap-change supervisory control cable is to be threaded.
Pipe connection S
Pipe connection S is provided for returning the insulating fluid from the heat
exchanger. The pipe bend on pipe connection S is equipped with a vent
screw so that the pipe system can be bled.
Pipe connection R
Pipe connection R is provided for attaching the protective relay and connect-
ing the on-load tap-changer oil conservator.
The functions of the R and Q pipe connections can be interchanged. You
must, however, use the long pipe bend on the pipe connection through
which the tap-change supervisory control cable is to be threaded.

3 Product description
Maschinenfabrik Reinhausen GmbH 201820 6028618/00 ENVACUTAP® VR®
Pipe connection E2
Pipe connection E2 is sealed off with a blank cover. It leads into the oil tank
of the transformer, directly under the on-load tap-changer head and can be
connected to a collective pipe for the Buchholz relay, if necessary. This pipe
connection serves a further purpose, namely to equalize the pressure be-
tween the transformer tank and oil compartment of the on-load tap-changer,
which is necessary for drying, oil filling and transportation of the transformer.
Pipe connection A
Pipe connection A in the on-load tap-changer head cover is provided for
feeding the insulating fluid into the pump unit of the oil cooling unit.
3.1.3 Nameplate and serial number
The nameplate with the serial number is on the on-load tap-changer head
cover.
Figure4: Position of nameplate