MR COMTAP ARS User manual

Advanced Retard Switch
COMTAP® ARS
Operating Instructions
4434052/01 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 2016 34434052/01 EN COMTAP® ARS
Table of contents
1Introduction......................................................................................................................... 5
1.1 Validity................................................................................................................................................. 5
1.2 Manufacturer....................................................................................................................................... 5
1.3 Completeness...................................................................................................................................... 5
1.4 Safekeeping......................................................................................................................................... 6
1.5 Notation conventions........................................................................................................................... 6
1.5.1 Symbols................................................................................................................................................................. 6
1.5.2 Hazard communication system............................................................................................................................. 7
1.5.3 Information system................................................................................................................................................ 9
2Safety................................................................................................................................. 10
2.1 Appropriate use................................................................................................................................. 10
2.2 Fundamental safety instructions........................................................................................................ 10
2.3 Personnel qualification...................................................................................................................... 12
2.4 Personal protective equipment.......................................................................................................... 13
3Product description.......................................................................................................... 15
3.1 Scope of delivery............................................................................................................................... 15
3.2 COMTAP® ARS................................................................................................................................ 15
3.2.1 Function description............................................................................................................................................ 15
3.2.2 Setup/models...................................................................................................................................................... 16
3.2.3 Name plate.......................................................................................................................................................... 17
3.2.4 Protective devices............................................................................................................................................... 17
3.3 Drive shaft......................................................................................................................................... 17
3.3.1 Function description............................................................................................................................................ 17
3.3.2 Design/versions................................................................................................................................................... 18
4Commissioning transformer at operating site............................................................... 22
4.1 Checking motor-drive unit.................................................................................................................. 22
4.2 Performing trial tap-change operations............................................................................................. 23
4.3 Commissioning transformer............................................................................................................... 23
5Operation........................................................................................................................... 24
5.1 Temperature range............................................................................................................................ 24
5.2 Switching COMTAP® ARS................................................................................................................ 24

Table of contents
Maschinenfabrik Reinhausen GmbH 20164 4434052/01 ENCOMTAP® ARS
5.3 Actuating motor-drive unit with hand crank....................................................................................... 25
5.4 Monitoring during operation............................................................................................................... 26
6Maintenance...................................................................................................................... 27
6.1 Safety precautions............................................................................................................................. 27
6.2 Maintenance...................................................................................................................................... 27
7Fault elimination................................................................................................................ 29
8Drawings............................................................................................................................ 31
8.1 COMTAP® ARS, installation drawing (732771)................................................................................ 31
8.2 COMTAP® ARS, installation drawing bell-type tank design (733023).............................................. 32
8.3 COMTAP® ARS, position of supporting structure (supporter, 735714)............................................ 33
8.4 COMTAP® ARS, tap-change supervisory control (726977).............................................................. 34
8.5 COMTAP® ARS, mounting flange (725857)..................................................................................... 35
8.6 COMTAP® ARS, mounting flange made by the customer (742013)................................................. 36
8.7 COMTAP® ARS, tracing template (726728)..................................................................................... 37
8.8 COMTAP® ARS, mounting of the COMTAP® ARS on the lower cage ring (user-specific, 732773_1)
........................................................................................................................................................... 38
8.9 COMTAP® ARS, mounting of the COMTAP® ARS on the lower cage ring (user-specific, 732773_2)
........................................................................................................................................................... 39
8.10 COMTAP® ARS, head with upper gear unit (725737)...................................................................... 40
8.11 COMTAP® ARS, connection contact (734095)................................................................................. 41
8.12 COMTAP® ARS, connecting leads (10015335)................................................................................ 42
8.13 COMTAP® ARS, horizontal drive shaft (limit dimensions, 778664_2).............................................. 43
8.14 COMTAP® ARS, swivel range of upper gear unit (732769_2).......................................................... 44
8.15 COMTAP® ARS, supplementary drawings (734087)........................................................................ 45
8.16 Bevel gear CD 6400, dimensional drawing (892916)........................................................................ 46
8.17 Lifting traverse (72673703)................................................................................................................ 47

1 Introduction
Maschinenfabrik Reinhausen GmbH 2016 54434052/01 EN COMTAP® ARS
Introduction
This technical file contains detailed descriptions for monitoring during opera-
tion, troubleshooting, 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.
Validity
The document supplied with the product is always the valid version. This
technical file is configured for the specific order and applies to the following
products, the serial numbers of which can be found on the delivery docu-
ments:
▪ Advanced Retard Switch COMTAP® ARS
▪ Drive shaft
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.
Completeness
This technical file is incomplete without the supporting documents.
The following documents apply:
▪ Unpacking instructions (included in the scope of delivery)
▪ Supplement (included in the scope of delivery)
▪ Routine test report (included in the scope of delivery)
▪ Connection diagrams (included in the scope of delivery)
▪ Dimensional drawings (included in the scope of delivery)
1
1.1
1.2
1.3

1 Introduction
Maschinenfabrik Reinhausen GmbH 20166 4434052/01 ENCOMTAP® ARS
▪ Technical data - General section (available on request)
▪ Technical data - Product-specific section (available on request)
Safekeeping
Keep this technical file and all supporting documents ready at hand and ac-
cessible for future use at all times.
Notation conventions
This section contains an overview of the symbols and textual emphasis
used.
Symbols
Symbol Meaning
Wrench size
Tightening torque
Number and type of fastening material used
Fill with oil
Cut open, cut through
Clean
Visual inspection
Use your hand
Adapter ring
Apply a coat of paint
Use a file
1.4
1.5
1.5.1

1 Introduction
Maschinenfabrik Reinhausen GmbH 2016 74434052/01 EN COMTAP® ARS
Symbol Meaning
Grease
Coupling bolt
Use a ruler
Use a saw
Hose clip
Wire eyelet, safety wire
Use a screwdriver
Apply adhesive
Lock tab
Table 1: Symbols
Hazard communication system
Warnings in this technical file are displayed as follows.
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 and source of danger
Consequences
► Action
► Action
1.5.2
1.5.2.1

1 Introduction
Maschinenfabrik Reinhausen GmbH 20168 4434052/01 ENCOMTAP® ARS
Embedded warning information
Embedded warnings refer to a particular part within a section. These warn-
ings apply to smaller units of information than the warnings relating to sec-
tions. Embedded warnings use the following format:
DANGER! Instruction for avoiding a dangerous situation.
Signal words and pictograms
The following signal words are used:
Signal
word
Meaning
DANGER Indicates a hazardous situation which, if not avoided, will
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 2: Signal words in warning notices
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 3: Pictograms used in warning notices
1.5.2.2
1.5.2.3

1 Introduction
Maschinenfabrik Reinhausen GmbH 2016 94434052/01 EN COMTAP® ARS
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

2 Safety
Maschinenfabrik Reinhausen GmbH 201610 4434052/01 ENCOMTAP® ARS
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 part of the product.
▪ Read and observe the safety instructions provided in this chapter in par-
ticular.
▪ 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.
Appropriate use
The product is an Advanced Retard Switch and is used to reverse the polari-
ty of a winding when the transformer is in operation. The product is designed
solely for use in electrical energy systems and facilities. If used as intended
and in compliance with the requirements and conditions specified in this
technical file as well as the warning notices in this technical file and attached
to the product, then the product does not present any danger to people,
property or the environment. This applies throughout the product's entire life,
from delivery to installation and operation through to disassembly and dis-
posal.
The following is considered appropriate use:
▪ Use the product only with the transformer specified in the order.
▪ The serial numbers of COMTAP® ARS and COMTAP® ARS accesso-
ries (motor-drive unit, drive shaft, bevel gear, protective relay etc.) must
match if COMTAP® ARS and COMTAP® ARS accessories are supplied
as a set for one order.
▪ You will find the applicable standard for the product and the year of is-
sue on the nameplate.
▪ Operate the product only in accordance with this technical file, the
agreed delivery conditions and technical data.
▪ Ensure that all necessary work is performed only by qualified personnel.
▪ Use the equipment and special tools supplied solely for the intended
purpose and in accordance with the specifications of this technical file.
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
2.1
2.2

2 Safety
Maschinenfabrik Reinhausen GmbH 2016 114434052/01 EN COMTAP® ARS
Personal protective equipment
Loosely worn or unsuitable clothing increases the danger of becoming trap-
ped or caught up in rotating parts and the danger of getting caught on pro-
truding parts. This increases the danger to life and limb.
▪ All necessary devices and personal protective equipment required for
the specific task, such as a hard hat, safety footwear, etc. must be worn.
Observe the section "Personal protective equipment" [► 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
country.
Working during operation
You must only operate the product when it is in a sound operational condi-
tion. Otherwise it poses a danger to life and limb.
▪ Regularly check the operational reliability of safety equipment.
▪ Comply with the maintenance work and maintenance intervals descri-
bed in this technical file.
Explosion protection
Highly flammable or explosive gases, vapors and dusts can cause serious
explosions and fire.
▪ Do not install or operate the product in areas where a risk of explosion is
present.
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.

2 Safety
Maschinenfabrik Reinhausen GmbH 201612 4434052/01 ENCOMTAP® ARS
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 Maschinenfabrik
Reinhausen GmbH could damage the product.
▪ Only use lubricants and auxiliary materials approved by the manufactur-
er.
▪ Contact Maschinenfabrik Reinhausen GmbH.
Modifications and conversions
Unauthorized or inappropriate changes to the product may lead to personal
injury, material damage and operational faults.
▪ Only modify product following consultation with Maschinenfabrik Rein-
hausen GmbH.
Spare parts
Spare parts not approved by Maschinenfabrik Reinhausen GmbH may
cause physical injury and damage the product.
▪ Only use spare parts approved by the manufacturer.
▪ 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

2 Safety
Maschinenfabrik Reinhausen GmbH 2016 134434052/01 EN COMTAP® ARS
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 will be
performed correctly. If maintenance is not carried out by our Technical Serv-
ice 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 protective equipment.
▪ Follow information about personal protective equipment provided in the
work area.
Always wear
Protective clothing
Close-fitting work clothing with a low tear-
ing strength, with tight sleeves and with no
protruding parts. It mainly serves to pro-
tect the wearer against being caught by
moving machine parts.
2.4

2 Safety
Maschinenfabrik Reinhausen GmbH 201614 4434052/01 ENCOMTAP® ARS
Always wear
Safety shoes
To protect against falling heavy objects
and slipping on slippery surfaces.
Table 4: Personal protective equipment to be worn at all times
Wear the following in spe-
cial environments
Special personal protective equipment
is needed in special environments.
The choice of equipment depends on
the circumstances.
Safety glasses
To protect the eyes from flying parts and
splashing liquids.
Visor
To protect the face from flying parts and
splashing liquids or other dangerous sub-
stances.
Hard hat
To protect from falling and flying parts and
materials.
Hearing protection
To protect from hearing damage.
Protective gloves
For protection from mechanical, thermal,
and electrical hazards.
Table 5: Personal protective equipment to be worn in special environments

3 Product description
Maschinenfabrik Reinhausen GmbH 2016 154434052/01 EN COMTAP® ARS
Product description
This chapter contains an overview of the design and function of the product.
Scope of delivery
The product is packaged with protection against moisture and is delivered as
follows:
▪ COMTAP® ARS
▪ TAPMOTION® ED motor-drive unit
▪ Drive shaft with coupling parts and bevel gear
▪ Technical files
Note the following information:
▪ 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 on-
ly be removed immediately before installation
You will find more information in the "Packaging, transport, and storage"
chapter.
COMTAP® ARS
Function description
The COMTAP® ARS C is used to reverse the polarity of a winding during
transformer operation. During this process, the through-current is commutat-
ed from one current path to another current path with the same potential.
The COMTAP® ARS always has 2 operating positions.
The COMTAP® ARS is changed over from one operating position to the
next by the TAPMOTION® ED motor-drive unit.
The COMTAP® ARS can be used for different applications in combination
with an on-load tap-changer. The COMTAP® ARS is primarily used to re-
verse the polarity of the regulating voltage in applications with large regulat-
ing ranges (e.g. phase shifter transformers).
In on-load tap-changer applications with reversing change-over selector
where the change-over selector capacity is outside the permitted range, a
combination of on-load tap-changer without reversing change-over selector
and COMTAP® ARS can be used.
3
3.1
3.2
3.2.1

3 Product description
Maschinenfabrik Reinhausen GmbH 201616 4434052/01 ENCOMTAP® ARS
Setup/models
The COMTAP® ARS is produced in a single-phase and three-phase design
with a maximum possible rated through-current of 2400 A.
The design of the COMTAP® ARS and the designation of its main parts are
shown in the installation drawings in the appendix (see page [► 31]).
Figure 1: COMTAP® ARS
1 Tap-change supervisory con-
trol with inspection window for
tap position indicator
2 COMTAP® ARS head
3 Upper gear unit 4 Connection contact
5 COMTAP® ARS cage 6 Set-down cylinder
3.2.2

3 Product description
Maschinenfabrik Reinhausen GmbH 2016 174434052/01 EN COMTAP® ARS
Name plate
The name plate is on the head of the COMTAP® ARS.
Figure 2: Position of name plate
Protective devices
Tap-change supervisory control
The COMTAP® ARS is equipped with a tap-change supervisory control,
which is fitted in a housing on the head of the COMTAP® ARS (see page
[► 34]).
Depending on the application, the tap-change supervisory control may have
different safety functions in conjunction with the motor-drive unit and the as-
sociated on-load tap-changer units.
These safety functions are specified individually in a binding manner for
each delivery depending on application and documented in an associated
functional description.
Electrical tripping contact/interlocking contact
When combining the COMTAP® ARS with on-load tap-changers, the
COMTAP® ARS may only be actuated in a certain on-load tap-changer posi-
tion. This means that it may only be actuated when all windings of the on-
load tap-changer tap winding are disconnected and the voltage at the rele-
vant winding is therefore zero.
For this reason, non-permitted switching operations are prevented by a mu-
tual electrical interlock of the on-load tap-changer and COMTAP® ARS.
Please refer to the order-specific technical documentation, safety instruc-
tions, and functional description.
Drive shaft
Function description
The drive shaft is the mechanical connection between motor-drive and on-
load tap-changer head / de-energized tap-changer head.
3.2.3
3.2.4
3.3
3.3.1

3 Product description
Maschinenfabrik Reinhausen GmbH 201618 4434052/01 ENCOMTAP® ARS
The bevel gear changes the direction from vertical to horizontal (see drawing
892916).
Accordingly, the vertical drive shaft has to be mounted between drive and
bevel gear and the horizontal drive shaft between bevel gear and on-load
tap-changer or de-energized tap-changer.
Design/versions
The drive shaft consists of a square tube and is coupled at each end by two
coupling brackets and one coupling bolt to the drive / driven shaft end of the
device to be connected.
Figure 3: Components of the drive shaft
1 Bevel gear 2 Hose clip
3 Telescopic protective tube 4 Coupling bracket
5 Square tube 6 Coupling bolt
7 Adapter ring 8 Protective cover
9 Hose clip
3.3.2

3 Product description
Maschinenfabrik Reinhausen GmbH 2016 194434052/01 EN COMTAP® ARS
Drive shaft without cardan joint and without insulator
Figure 4: Drive shaft without cardan joint and without insulator (= normal model)
Configuration V 1 min Intermediate bearing
Middle of hand crank – middle
of bevel gear (maximum per-
missible axial offset 2°)
536 mm When the maximum
value of 2472 mm is
exceeded, it is neces-
sary to use an inter-
mediate bearing.
V 1 ≤ 2472 mm (with-
out intermediate bear-
ing)
V 1 > 2472 mm (with
intermediate bearing)
3.3.2.1

3 Product description
Maschinenfabrik Reinhausen GmbH 201620 4434052/01 ENCOMTAP® ARS
Drive shaft without cardan joint and with insulator
Figure 5: Drive shaft without cardan joint and with insulator (= special model)
Configuration V 1 min Intermediate bearing
Middle of hand crank – middle
of bevel gear (maximum per-
missible axial offset 2°)
706 mm When the maximum
value of 2472 mm is
exceeded, it is neces-
sary to use an inter-
mediate bearing.
V 1 ≤ 2472 mm (with-
out intermediate bear-
ing)
V 1 > 2472 mm (with
intermediate bearing)
3.3.2.2