MR VACUTAP VV-Ex Installation and operation manual

On-load tap-changer
VACUTAP® VV-Ex
Installation and commissioning instructions
4983703/01 EN

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Dissemination and reproduction of this document and use and disclosure of its content are strictly prohibited
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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 34983703/01 EN VACUTAP® VV-Ex
Table of contents
1 Introduction......................................................................................................................... 7
1.1 Manufacturer....................................................................................................................................... 7
1.2 Completeness..................................................................................................................................... 7
1.3 Safekeeping........................................................................................................................................ 7
1.4 Notation conventions .......................................................................................................................... 7
1.4.1 Hazard communication system .............................................................................................................................7
1.4.2 Information system................................................................................................................................................9
1.4.3 Instruction system .................................................................................................................................................9
2 Safety................................................................................................................................. 11
2.1 Appropriate use ................................................................................................................................ 11
2.2 Inappropriate use.............................................................................................................................. 12
2.3 Fundamental safety instructions ....................................................................................................... 12
2.4 Standards and regulations................................................................................................................ 14
2.4.1 Application range of the on-load tap-changer .....................................................................................................14
2.4.2 Standards and regulations ..................................................................................................................................16
2.5 Measures for ensuring compliance with explosion protection requirements .................................... 17
2.5.1 Measures taken by the manufacturer..................................................................................................................17
2.5.2 Measures to be taken by the transformer manufacturer/operator.......................................................................17
2.6 Personnel qualification...................................................................................................................... 20
2.7 Personal protective equipment ......................................................................................................... 22
3 Product description.......................................................................................................... 23
3.1 Scope of delivery .............................................................................................................................. 23
3.2 On-load tap-changer......................................................................................................................... 23
3.2.1 Function description ............................................................................................................................................23
3.2.2 Setup/models ......................................................................................................................................................24
3.2.3 Nameplate and serial number .............................................................................................................................27
3.2.4 Protective devices ...............................................................................................................................................27
3.3 Drive shaft......................................................................................................................................... 30
3.3.1 Function description ............................................................................................................................................30
3.3.2 Design/Model ......................................................................................................................................................32
3.3.3 Identification plate ...............................................................................................................................................34

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Maschinenfabrik Reinhausen GmbH 202044983703/01 ENVACUTAP® VV-Ex
4 Packaging, transport and storage .................................................................................. 35
4.1 Packaging ......................................................................................................................................... 35
4.1.1 Suitability.............................................................................................................................................................35
4.1.2 Markings..............................................................................................................................................................36
4.2 Transportation, receipt and handling of shipments........................................................................... 36
4.3 Storage of shipments........................................................................................................................ 37
4.4 Unpacking shipments and checking for transportation damages ..................................................... 38
5 Mounting ........................................................................................................................... 39
5.1 Installation information...................................................................................................................... 39
5.2 Preparatory work .............................................................................................................................. 40
5.2.1 Fitting mounting flange on transformer cover......................................................................................................40
5.2.2 Fitting stud bolts on mounting flange ..................................................................................................................40
5.3 Installing the on-load tap-changer in the transformer (standard version) ......................................... 41
5.3.1 Fastening on-load tap-changer to transformer cover ..........................................................................................41
5.3.2 Connecting the tap winding and on-load tap-changer take-off lead....................................................................49
5.3.3 Performing transformer ratio test before drying ..................................................................................................50
5.3.4 Performing DC resistance measurement on transformer....................................................................................51
5.3.5 Drying on-load tap-changer in autoclave ............................................................................................................51
5.3.6 Drying on-load tap-changer in transformer tank..................................................................................................53
5.3.7 Filling the oil compartment of the on-load tap-changer with insulating fluid........................................................56
5.3.8 Performing transformer ratio test after drying .....................................................................................................57
5.4 Installing on-load tap-changer in transformer (bell-type tank version).............................................. 58
5.4.1 Inserting on-load tap-changer into supporting structure......................................................................................58
5.4.2 Connecting the tap winding and on-load tap-changer take-off lead....................................................................60
5.4.3 Performing transformer ratio test before drying ..................................................................................................60
5.4.4 Performing DC resistance measurement on transformer....................................................................................61
5.4.5 Drying on-load tap-changer in autoclave ............................................................................................................62
5.4.6 Lifting top part of on-load tap-changer head off supporting flange (bottom part) ................................................64
5.4.7 Attaching the bell-type tank and connecting the on-load tap-changer to the top part of the on-load tap-changer
head ....................................................................................................................................................................67
5.4.8 Drying on-load tap-changer in transformer tank..................................................................................................72
5.4.9 Filling the oil compartment of the on-load tap-changer with insulating fluid........................................................75
5.4.10 Performing transformer ratio test after drying .....................................................................................................76
5.5 Fitting protective devices and drive components.............................................................................. 77
5.5.1 Electrically connecting the temperature sensor ..................................................................................................77
5.5.2 Installing protective relay in piping and connecting.............................................................................................77

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Maschinenfabrik Reinhausen GmbH 2020 54983703/01 EN VACUTAP® VV-Ex
5.5.3 Fitting motor-drive unit ........................................................................................................................................87
5.5.4 Fitting drive shaft.................................................................................................................................................87
5.5.5 Centering on-load tap-changer and motor-drive unit ........................................................................................111
5.5.6 Making the electrical connections for the motor-drive unit ................................................................................111
6 Commissioning............................................................................................................... 112
6.1 Commissioning the on-load tap-changer at the transformer manufacturer's site ........................... 112
6.1.1 Bleeding on-load tap-changer head and suction pipe.......................................................................................112
6.1.2 Grounding the on-load tap-changer ..................................................................................................................114
6.1.3 Checking motor-drive unit .................................................................................................................................115
6.1.4 High-voltage tests on the transformer ...............................................................................................................116
6.2 Transporting transformer to the operating site................................................................................ 116
6.2.1 Transport with drive removed............................................................................................................................116
6.2.2 Transport with full transformer tank and without oil conservator.......................................................................117
6.2.3 Transport with empty transformer tank .............................................................................................................118
6.3 Commissioning transformer at operating site ................................................................................. 120
6.3.1 Filling the oil compartment of the on-load tap-changer with insulating fluid......................................................120
6.3.2 Bleeding on-load tap-changer head and suction pipe.......................................................................................121
6.3.3 Checking motor-drive unit .................................................................................................................................123
6.3.4 Checking protective relay..................................................................................................................................124
6.3.5 Commissioning the transformer ........................................................................................................................125
7 Fault elimination ............................................................................................................. 126
7.1 Tripping the protective relay and re-commissioning the transformer.............................................. 128
7.1.1 Flap valve in OPERATION position ..................................................................................................................128
7.1.2 Flap valve in OFF position ................................................................................................................................129
7.1.3 Re-commissioning the transformer ...................................................................................................................129
8 Technical data................................................................................................................. 130
8.1 Permissible ambient conditions ...................................................................................................... 130
8.2 Technical data for protective relay.................................................................................................. 130
8.2.1 Protective relay with several dry-reed magnetic switches.................................................................................132
8.2.2 Tests .................................................................................................................................................................133
8.3 Limit values for dielectric strength and water content of insulating fluids ....................................... 134
9 Drawings ......................................................................................................................... 135
9.1 External view (737774) ................................................................................................................... 135
9.2 On-load tap-changer head without oil suction pipe (898863) ......................................................... 136

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Maschinenfabrik Reinhausen GmbH 202064983703/01 ENVACUTAP® VV-Ex
9.3 On-load tap-changer head with oil suction pipe (737060) .............................................................. 137
9.4 Installation drawing (738902).......................................................................................................... 138
9.5 Oil suction pipe (739172)................................................................................................................ 139
9.6 Dimensions of oil suction pipe (not supplied by MR, 734342) ........................................................ 140
9.7 Tracing template for on-load tap-changer head (893787) .............................................................. 141
9.8 Mounting drawing (898866) ............................................................................................................ 142
9.9 Mounting with bell-type tank installation (899110).......................................................................... 143
9.10 Position of on-load tap-changer (899409) ...................................................................................... 144
9.11 Position of connection contacts (899051)....................................................................................... 145
9.12 Tap-change supervisory control (733469) ...................................................................................... 146
9.13 Bevel gear CD 6400, dimensional drawing (892916) ..................................................................... 147
Glossary .......................................................................................................................... 148

1 Introduction
Maschinenfabrik Reinhausen GmbH 2020 74983703/01 EN VACUTAP® VV-Ex
1 Introduction
This technical file contains detailed descriptions of the safe and proper in-
stallation, connection, and commissioning of the product.
It also includes safety instructions and general information about the prod-
uct.
Information about operation can be found in the operating 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
Tel.: [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
1.4.1 Hazard communication system
Warnings in this technical file are displayed as follows.

1 Introduction
Maschinenfabrik Reinhausen GmbH 202084983703/01 ENVACUTAP® VV-Ex
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
Pictograms warn of dangers:
Pictogram Definition
Warning of a danger point
Warning of dangerous electrical voltage

1 Introduction
Maschinenfabrik Reinhausen GmbH 2020 94983703/01 EN VACUTAP® VV-Ex
Pictogram Definition
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:
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 Introduction
Maschinenfabrik Reinhausen GmbH 202010 4983703/01 ENVACUTAP® VV-Ex
Aim of action
üRequirements (optional).
1. Step 1.
ðResult of step (optional).
2. Step 2.
ðResult of step (optional).
ðResult of action (optional).