www.reinhausen.

com On-Load Tap-Changer Type R

Operating Instructions BA 119/06
2 119/06 EN
 Contents

Contents

1 General ......................................................................................................................................... 5
1.1 Safety instructions ............................................................................................................... 5
1.2 Specified application ........................................................................................................... 5

2 Design ....................................................................................................................................... 6

3 Shipment ................................................................................................................................... 6

4 Installation of the on-load tap-changer for cover attachment .............................................. 8

4.1 Mounting flange ................................................................................................................... 8
4.2 Attaching the on-load tap-changer head to the transformer cover .................................... 8
4.3 Mounting the tap selector and the diverter switch oil compartment .................................. 9

5 Installation of the on-load tap-changer into the bell-type tank ............................................. 11

5.1 Assembly of diverter switch oil compartment and tap selector,
connection of tap selector connecting leads ..................................................................... 11
5.2 Installation of the on-load tap-changer into the supporting structure ................................. 11
5.3 Preparations ..................................................................................................................... 12
5.4 Mounting the bell-type transformer cover ......................................................................... 13

6 Connection of tap winding and tap-changer take-off leads .................................................. 16

6.1 Tap selector ...................................................................................................................... 16
6.2 Parallel bridges for R I 2002 an R I 3000 .......................................................................... 17
6.3 Connecting the tap-changer take-off lead ......................................................................... 17

7 Transformer ratio test .............................................................................................................. 18

8 Drying procedure and filling with oil ...................................................................................... 18

8.1 Drying procedure .............................................................................................................. 18
8.1.1 Vacuum-drying process .......................................................................................... 18
8.1.1.1 Drying in the autoclave .............................................................................. 18
8.1.1.2 Drying in the transformer tank ................................................................... 18
8.1.2 Vapor-phase drying process ................................................................................... 19
8.1.2.1 Drying in the autoclave .............................................................................. 19
8.1.2.2 Drying in the transformer tank ................................................................... 19
8.1.3 Operating the OLTC ............................................................................................... 19
8.2 Filling with oil .................................................................................................................. 20

9 Pipe connections ...................................................................................................................... 20

9.1 Pipe connection R for protective relay RS 2001 ............................................................... 20
9.2 Pipe connection S for suction pipe ................................................................................... 20
9.3 Pipe connection Q ............................................................................................................ 20
9.4 Connection flange E2 ....................................................................................................... 20

NOTE

Data contained herein may differ in details from the tap-changing equipment delivered.
We reserve the right to make alterations without notice.

119/06 EN 3
 Contents

10 Mounting the motor drive unit, the bevel gear and the drive shaft ...................................... 21
10.1 Mounting the motor drive unit ........................................................................................... 21
10.2 Mounting the bevel gear ................................................................................................... 21
10.3 Mounting the drive shaft (square tube) ............................................................................. 21

11 Putting the on-load tap-changer into operation at the transformer factory ........................ 22
11.1 Operational tests .............................................................................................................. 22
11.2 Final oil filling .................................................................................................................. 22
11.3 Ground connections ......................................................................................................... 23
11.4 Electrical transformer tests ............................................................................................... 23

12 Transport to the operating site ................................................................................................ 24

13 Putting into service at the operating site ............................................................................... 24

14 Supervision during service, failures ....................................................................................... 25

15 Inspections ............................................................................................................................... 26

16 Appendix ................................................................................................................................... 28

4 119/06 EN
 1
General

1 General
1.1 Safety instructions 1.2 Specified application

All personnel involved in installation, commissioning,

operation, maintenance or repair of the equipment
must:
- be suitably qualified and
- strictly observe these Operating Instructions.
Improper operation or misuse can lead to
- a reduction in the efficiency of the equipment
- damage to the equipment and property of the
user
- serious or fatal injury.
Safety instructions in this manual are presented in three
different forms to emphasize important information.
WARNING
This information indicates particular danger to life and
health. Disregarding such a warning can lead to
serious or fatal injury.
CAUTION
Only use the on-load tap-changer with the transfor-
mer specified in the order. Installation, electrical
connection and commissioning of the on-load tap-
changer may only be carried out by qualified, skilled
personnel and only in accordance with these operat-
ing instructions.
It is the responsibility of the user to make sure that
the on-load tap-changer is used for the specified
application only.
For safety reasons, any unauthorized work, i.e. in-
stallation, modification, alteration of the tap-changing
equipment, electrical connection or commissioning of
the equipment is forbidden without first consulting MR!
The trouble-free operation of the drive, the on-load
tap-changer and the transformer may be put at risk.
CAUTION

All relevant fire protection regulations must be strictly

CAUTION
observed.

This information indicates particular danger to the

equipment or other property of the user. Serious or
fatal injury cannot be excluded.

NOTE

These notes give important information on a certain

subject.

119/06 EN 5
 2 Design
3 Shipment

2 Design 3 SHIPMENT

The on-load tap-changer (OLTC) consists of the diver- On-load tap-changer and motor drive are shipped in the
ter switch with the tap selector mounted below (fig. 1). adjustment position. The on-load tap-changer is packed
in two parts, diverter switch and tap selector, and is well
The diverter switch is installed in its own oil compart-
protected against moisture. Both the diverter switch and
ment.
the tap selector are blocked in the adjustment position.
The on-load tap-changer is attached to the transformer
The tap-changing equipment is shipped as follows:
cover by means of the tap-changer head.
Diverter switch oil compartment with tap-changer head
If required, the tap selector may be equipped with a
and diverter switch unit (max. weight approx. 210 kg),
change-over selector.
fig. 2.
The change-over selector of all type R OLTCs is
Tap selector (max. weight approx. 270 kg), fig. 3.
laterally attached to the fine tap selector.
Motor drive unit ED-S (approx. 80 kg) fig. 4.
OLTC models without change-over selector are avail-
able for max. 18, and with change-over selector for Drive shaft with coupling parts and bevel gear (max.
max. 35 operating positions. weight approx. 20 kg), fig. 5.
The design of the on-load tap-changer and the designa- Protective relay RS 2001(weight 3.5 kg), fig. 6.
tion of its main parts are shown in the installation draw- Check shipment against documents.
ing 896 705 in the appendix. Store all parts in a dry place until installation.
These Operating Instructions contain all information The tap-changer parts must be left wrapped in their
regarding installation and operation of the following airtight cover, unwrap just before installation.
OLTC standard models, which are available with and
without change-over selector.
Three-phase OLTC:
R III 1200 (see fig. 1)
Single-phase OLTC:
R I 2000/2002/2402, R I 3000/3600.
All single-phase OLTCs are also available as a group
3 x R I 2002/2402 or
3 x R I 3000/3600
with a common motor drive. A

V2 W1

3 1

U1
4 2

U21
3 1

V1
4 2

V2
3 1

W1
4 2

W2

1 KHW 1086-4

6 119/06 EN
 3
Shipment

NOTE

In general, drive shaft, bevel gear and protective

relay are packed with the on-load tap-changer.

4 KHW 915-4

MR
V2 W1

2 KHW 1087-4

5 KHW 766-4

MR

3 1

4 2

3 1

4 2

3 1

4 2

3 KHW 1097-4 6 KHW 848-4

119/06 EN 7
 4
Installation of the on-load tap-changer for cover attachment

4 Installation of the on-load tap-

changer for cover attachment (fig. 7)

4.1 Mounting flange

To mount the tap-changer head to the transformer cover M12
a mounting flange is necessary. This mounting flange

25
should meet the requirements of the tap-changer head

45
gasket surface (see fig. 7, and section 16, drawing

15
896 705).
To position the thread studs (M12, max. length = 45 mm)
we recommend the use of a drilling template (see
fig. 8 and section 16, dwg. 890 183). If requested, the
drilling template will be supplied without charge with the

15
0
first on-load tap-changer type R. 74
710

7,5
15
4.2 Attachment of the tap-changer

65
0
head to the transformer cover
The diverter switch oil compartment is lowered through
the cover aperture (= mounting flange) of the trans- 7 KHW 770-4
former. The tap-changer head is attached to the mount-
ing flange by means of bolts.
7,5
Then, the tap selector is fastened to the diverter switch
15
oil compartment (see section 4.3). 24
x1
5
=3
5
Proceed as follows: 60

1. Place the diverter switch oil compartment on a level

surface.

0
0
74
2. Clean sealing surfaces of mounting flange and tap- 71

changer head.
650
3. Put an oil-proof gasket on the mounting flange of
60
20

the transformer cover.

200 200
4. Lift the diverter switch oil compartment by hooking
up the tap-changer head. Lower the oil compartment
cautiously into the mounting flange.
Take care of screening rings (with Um 170 kV only).
5. Check position of tap changer head. 8 8 KHW 769-4

6. Attach the tap-changer head to the mounting flange

with bolts.

NOTE

Remove the blocking plate from the coupling (fig. 9)

of the oil compartment bottom.

8 119/06 EN
 4
Installation of the on-load tap-changer for cover attachment

4.3 Mounting the tap selector and the

diverter switch oil compartment

Raise the tap selector to the oil compartment and

attach. At the same time the mechanical coupling for
the tap selector drive has to be performed. Finally,
connect the tap selector connecting leads to the
diverter switch oil compartment.
Proceed as follows:
1. Put the tap selector down on a level surface. Get
ready 4 lock nuts M12 with washers.

NOTE

Remove the blocking strip from the tap selector

coupling (fig. 10).
The coupling must not be displaced afterwards.

2. Put the tap selector on an appropriate lifting device. 9 KHW 1111-4

rh-1111-4-0/1

Remove the ring nuts.

3. Raise the tap selector to the diverter switch oil
compartment. Be sure that tap selector connecting
leads clear the diverter switch oil compartment and
remain undamaged.
4. Position coupling parts and attachment points of
tap selector and oil compartment to match properly.
5. Raise the tap selector to its final height (fig. 11).
6. Bolt tap selector attachment points to the oil
compartment bottom:
4 lock nuts M 12/w.s.19, washers,
max. torque 65 Nm (fig. 12).
7. Remove the wooden support from the laterally
attached change-over selector.

10 KHW 1098-4
rh-1098-4-0/1

1500

11 KHW 1102-4

119/06 EN 9
 4
Installation of the on-load tap-changer for cover attachment

Connection of the tap selector connnecting leads to the

diverter switch oil compartment:

CAUTION

All connections must be carried out carefully. The

tightening torques indicated must be applied. Be
sure that bolts are tightened carefully and screened
by the screening caps supplied with the equipment
(fig. 13).

OLTCs R III 1200 and R I 3000/3600

6 connecting leads to oil compartment terminals
according to fig. 14.
Each one attached by 1 bolt M12 (w.s.19) lock nut and 13 KHW653-3
screening cap, torque 80 Nm.
OLTC R I 2002/2402
4 connecting leads to oil compartment terminals
according to fig. 15.
Each one attached by 1 bolt M12, lock nut and screen-
ing cap, torque 80 Nm. A

1V1 1V2

14 KHW 1088-4

3 4

12 KHW 1091-4 15 KHW 1093-4

10 119/06 EN

Installation of the on-load tap-changer into the bell-type tank
5 Installation of the on-load tap-
changer into the bell-type tank
To install the on-load tap-changer into a transformer
with bell-type tank the on-load tap-changer must be
mounted onto a supporting structure.
For this purpose, the OLTC is equipped with a sup-
porting flange at the diverter switch oil compartment
(= special design, section 16, dwg. 896 762).
Firstly, lift the on-load tap-changer into the supporting
structure and connect it to the tap winding. The OLTC
must be attached to the supporting structure in such a
way that it cannot be displaced. The supporting flange
is provided with through-holes which allow it to be fixed
to the supporting structure. It is advisable to put spacer
blocks temporarily between supporting structure and
supporting flange and to remove them before the bell-
type cover is set up.
Once the bell-type cover is attached, lift the on-load tap-
changer (with the diverter switch unit removed) by
means of the lifting traverse (see section 16, drawing
890 180) and fix it to the bell-type cover together with
the top part of the head.
To attach the tap-changer head to the bell-type cover,
we recommend using a mounting flange as described in
section 4.1.
5.1 Assembly of diverter switch oil com-
partment and tap selector, attachment
of tap selector connecting leads
The assembly of diverter switch oil compartment and
tap selector as well as the connection of tap selector
connecting leads has to be carried out according to
section 4.3.
119/06 EN
5
5.2 Installation of the on-load tap changer
into the supporting structure
Lift the assembled on-load tap-changer, according to
section 4.1, into the supporting structure. Make sure
that the on-load tap-changer is in proper mounting
position and fasten it there safely.
NOTE
In the supporting structure the on-load tap-changer
must be in an exactly vertical position. The on-load
tap-changer must be mounted to the supporting
structure ensuring that it need not be lifted by more
than 5 to 20 mm to reach its final position after the
bell-type cover is set up.
It is of advantage to install spacer blocks between
supporting structure and supporting flange in such a
way that the on-load tap-changer is in its final position
after the bell-type cover is set up. This measure helps
to cut the tap leads to their correct lengths. Remove the
spacer blocks after the leads have been connected.
To connect the tap winding and the tap-changer take-off
terminal follow the instructions according to section 6.
CAUTION
The connected leads must not exercise any force on
the on-load tap-changer. Moreover there must be
sufficient clearance so that it is possible to lift the on-
load tap-changer in its final installation position after
the bell-type tank has been mounted.
The drying procedure and the transformer ratio test are
to be performed in accordance with sections 7 and 8.
11
 5
Installation of the on-load tap-changer into the bell-type tank

5.3 Preparations

Prior to setting up the bell-type tank the tap-changer

head must be removed from the on-load tap-changer.
1. For this purpose, open the tap-changer head cover
(24 hexagonal head screws M10, w.s.17, with lock
washers).
2. Take care of the cover gasket
(round rubber gasket, fig. 16).
3. Remove the position indicator dial (remove the clip
from the shaft end, fig. 17).
4. Take note of the red-marked area not covered by
the supporting plate of the diverter switch unit
(fig. 18).
5. Remove the fixing nuts of the supporting plate (4
nuts M8, w.s.13, lock washers, fig. 19).
17 KHW 1101-4
rh-1101-4-0/1
6. Withdraw the diverter switch unit carefully from the
oil compartment (fig. 20). Keep the diverter switch
unit in a vertical position.
7. Remove the suction pipe. The pipe connection has
to be withdrawn from within the tap-changer head
(fig. 21). Take care of O-rings.
8. Unscrew the remaining nuts in the tap-changer head
(fig. 22), 17 nuts M8, w.s.13, lock washers.
Lift off the tap-changer head from the supporting
flange. Take care of the gasket.

18 KHW 1103-4
rh-1103-4-0/1

16 KHW 762-4
19 KHW 1105-4
rh-1105-4-0/1

12 119/06 EN
 5
Installation of the on-load tap-changer into the bell-type tank

5.4 Mounting the bell-type

transformer cover

1. Before mounting the bell-type transformer cover

clean the sealing surface of the oil compartment
supporting flange. Place the gasket onto the flange
(fig. 23). Withdraw the spacer blocks (see section
5.2).
2. Lift the bell-type cover over the transformer active
part and lower it to its final position.
3. Before mounting the tap-changer head clean the
sealing surfaces (bottom of tap-changer head,
mounting flange). Put an oil-resistant gasket on the
mounting flange.

21 KHW 1106-4

22 KHW 1110-4
rh-1110-4-0/1

20 KHWrh-1109-4-0/1
1109-4 23 KHW 1107-4
rh-1107-4-0/1

119/06 EN 13
 5
Installation of the on-load tap-changer into the bell-type tank

4. Place the tap-changer head on the mounting flange.

Check the mounting position of the tap-changer
head by means of 2 adjusting bolts (fig. 23) and the
marks of the supporting flange and tap-changer
head (fig. 24) which allow assembly in the correct
position only. Depending on the final height
adjustment leave a clearance of 5 to 20 mm
between tap-changer head and supporting flange
5. Lift the on-load tap-changer slightly by means of the
lifting traverse (see fig. 25 and section 16, drawing
890 180). Make sure that all supporting flange studs
easily slide through the fixing holes of the tap-
changer head.

CAUTION
24 KHW 1100-4

Take care not to drop any parts into the diverter

switch oil compartment. Otherwise the diverter
switch can block and cause severe damage to the
on-load tap-changer and transformer.
Therefore, make sure that the number of small
parts is complete when disassembling and
reinstalling. Count them to be sure.

25 KHW 1108-4

14 119/06 EN
 5
Installation of the on-load tap-changer into the bell-type tank

6. Attach the tap-changer head in the red marked area

not covered by the supporting plate of the diverter
switch (fig. 26, see also section 5.3). Use 17 nuts
M8 (wrench size 13, max. torque 14 Nm, lock
washers). Attach the tap-changer head to the
mounting flange.
7. Remount the suction pipe. Make sure that the O-
rings are placed properly. The O-rings should slightly
be greased before being mounted.
8. Remount the diverter switch unit. Make sure that the
diverter switch supporting plate is in its proper
position within the tap-changer head (the red marked
areas must be left free). Attach the supporting plate
by means of 5 nuts M8 (wrench size 13, max. torque
14 Nm, lock washers).
9. Attach the position indication dial: 26 KHW 1110-4
rh-1110-4-0/1
Put the clip onto the shaft end.
The dial can be mounted in correct position only by
means of its coupling pin (fig. 27).
10.Mount the cover on the tap-changer head. Make
sure that the rubber gasket (O-ring) in the cover is in
proper position.Fasten the 24 screws M10 (wrench
size 17) equally, max. torque 34 Nm (fig. 28).

27 KHW 1101-4
rh-1101-4-0/1

28 KHW 1104-4
rh-1104-4-0/1

119/06 EN 15
 6
Connection of tap winding and tap-changer take-off leads

6 Connection of tap winding and tap-

changer take-off leads

The tap winding has to be connected to the on-load tap-

changer according to the connection diagram supplied
with the particular tap-changer equipment.

CAUTION
3 1

All connections to the on-load tap-changer must be 4 2

made carefully and locked safely. The tap leads must

3 1

be assembled in such a way to allow for connecting

all leads to the on-load tap-changer without tension. 4 2

If necessary, lead ends must be shaped in form of

3 1

expansion loops.
4 2

Single-phase OLTCs R I 2002 and R I 3000 require the 29 KHW 1096-4

parallel connection of the tap selector terminals with
identical terminal numbers in order to avoid over-
voltages between parallel contacts.
If requested, bridges for the parallel connection of tap A10
selector terminals according to dwg. 896 706 (see ap-
pendix) can be supplied.
In case of OLTCs R I 2402 and R I 3600 the parallel
connection of tap selector terminals by means of
parallel bridges is not applicable as the enforced current B9
splitting of tap leads is provided by two or three isolated
winding branches on each tap selector terminal.

B10

6.1 Tap selector (fig. 29)

C9
Fine tap selector terminals
with through-hole for M12 screws(fig. 30). If reques- 30 KHW 1090-4
rh-1090-4-0/1

ted, screening caps (MR part number 078 957) will be

supplied with the delivery.
Change-over selector terminals
Reversing switch: terminals (+) and () like the fine
tap selector terminals, terminals (0) as terminal lug of
the connecting lead (0/K) with through-hole for M12
screws (see fig. 31).
Coarse tap selector: terminals (0) and () like the fine
tap selector terminals, terminals (+) as terminal lug of
the cranked connecting lead (+/K) with through-holes
for M12 screws (see fig. 31).

31 KHW 1089-4
rh-1089-4-0/1

16 119/06 EN
 6
Connection of tap winding and tap-changer take-off leads

6.2 Parallel bridges for R I 2002

and R I 3000 (fig. 32)

Parallel bridges for the fine tap selector and change-

over selector according to dwg. 896 706 (see appendix)
can be supplied on request.
Parallel bridges consist of two identical parts which are
joined by a single M12 bolt with lock nut (wrench size
19, max. torque 60 Nm). They are provided with two
through-holes to accommodate connection of tap leads.

6.3 Connecting the tap-changer

take-off lead
The tap-changer take-off lead is to be connected to 33 894 490 0M

the bus bar ring of the diverter switch oil compartment

(fig. 33). The screw connection must be locked safely
(Md = 60 Nm).
OLTC type R III 1200 (starpoint connection)
One throughhole each for M12 bolts is provided on
different points of the bus bar ring displaced by 120 A
(fig. 34).
OLTC type R I 2002/2402 and R I 3000/3600
Three or four throughholes each for M12 bolts are pro-
vided on different points of the bus bar ring displaced 1V1
by 120 (fig. 35).
1V2

34 KHW 1094-4
rh-1094-4-0/1

3 4

32 KHW 1099-4 35
rh-1099-4-0/1 KHW 1095-4

119/06 EN 17
 7 Transformer ratio test
8 Drying procedure and filling with oil
7 Transformer ratio test
We recommend to ratio-meter the transformer with a
low AC voltage before drying.
To operate the drive shaft in the tap-changer head a
short tube of nominal width 25 mm with an insert
coupling bolt of 12 mm dia. together with a hand wheel
or a hand crank may be used.
In case of OLTC set 3 x R I 2002 ... 3600 all three tap-
changer heads have to be coupled by the horizontal
drive shafts (see section 10).
When using an ED, 16.5 drive shaft revolutions of the
tap-changer drive shaft are required for one tap-change
operation. The diverter switch action can be heard
distinctly.
To operate the change-over selector a higher torque is
necessary.
The end positions shown on the connection diagram
supplied with the delivery must never be overrun. It is
therefore necessary to check the operating position
through the inspection glass in the tap-changer head
cover (fig. 36). Keep the number of tap-change opera-
tions to a minimum as long as the on-load tap-changer
has not been immersed in oil. After the transformer ratio
test the on-load tap-changer has to be set back to the
adjustment position in which it was delivered by MR.
The position is indicated in the connection diagram
delivered with the equipment.
NOTE
If the transformer is to be vapor-phase dried in its own
tank, open the kerosene drain plug (see section 8.1.2).
b
9
36 KHW 764-4
18
8 Drying procedure and filling with oil
8.1 Drying procedure
The dielectric properties of the on-load tap-changer can
only be guaranteed, if the on-load tap-changer is sub-
jected to a drying treatment according to the following
instructions (8.1.1 or 8.1.2).
8.1.1 Vacuum-drying process
8.1.1.1 Drying in the autoclave
NOTE
When drying the transformer in the autoclave remove
the tap-changer cover and store it outside the vacuum
autoclave.
Heating up
the on-load tap-changer in air of atmospheric
pressure with a temperature rise of approx. 10 C/
hour to a final temperature of at most 110 C.
Preparatory drying
in circulating air at 110 C max. applied to the on-
load tap-changer for a duration of 20 hours.
Vacuum drying
at a temperature of 110 C max. applied to the on-
load tap-changer and a residual pressure of at most
10-3 bar for a duration of at least 50 hours.
8.1.1.2 Drying in the transformer tank
NOTE
If the transformer is to be dried in its tank the interior
of the diverter switch oil compartment must be con-
nected to vacuum, as the tap-changer head cover
remains closed during the entire drying process.
The tap-changer head cover is vacuum-proof.
To ensure sufficient drying of the interior of the oil
compartment and the diverter switch insert, connect a
by-pass tube of 25 mm nominal width between the
transformer tank and the connecting flange which leads
into the oil compartment.
For ease of handling connect the bypass tube either
between flanges E2 and Q or flanges E2 and R of the
tap-changer head (for position of connecting flanges
see section 9 and dwg. 893 899 of appendix).
Procedure, temperature, pressure and duration of the
drying process are as described in section 8.1.1.1.
119/06 EN

8.1.2 Vapor-phase drying process
NOTE
Before starting the drying procedure, open the
kerosene drain plug (fig. 37) to drain the condensate
from the oil compartment.
The kerosene drain plug has an hexagonal recess
screw (w.s. 8) and is easily accessible between oil
compartment bottom and tap selector gear. It can be
unscrewed from the outside. The thread of the kerosene
drain plug has a plastic coat so that it can only be
turned with some force.
NOTE
Do not continue turning the kerosene drain plug
beyond the point where it starts moving tightly.
When drying the transformer in its own tank (see
section 8.1.2.2) the drain plug, in general, is not
accessible from outside and can only be opened
from inside the oil compartment.
In this case the diverter switch unit must be removed
and the kerosene drain plug must be unscrewed with a
socket wrench (see section 16, dwg. 890 182). Then
reinstall the diverter switch unit.
CAUTION
The kerosene drain plug must be closed again after
the drying process to ensure that no oil from the
diverter switch oil compartment can flow into the
transformer tank!
8 mm
8 mm
Coating
37 KHW 831-4
119/06 EN
8
Drying procedure and filling with oil
8.1.2.1Drying in the autoclave
NOTE
When drying in the autoclave remove the tap-changer
head cover first and store it outside the vacuum
autoclave.
Heating up
by admitting the kerosene vapor at a temperature of
about 90C. Keep this temperature constant for 3 to
4 hours.
Drying
by increasing the kerosene vapor temperature by
about 10C per hour to the desired final temperature
with not more than 125 C applied to the on-load tap-
changer. The duration of the drying procedure is
normally the same as that of the transformer.
8.1.2.2 Drying in the transformer tank
If the transformer is to be dried in its own tank, the tap-
changer head cover remains closed during the entire
drying process. The tap-changer head cover is vacuum-
proof. To ensure sufficient drying of the interior of the
diverter switch oil compartment and of the diverter
switch unit connect a common tube of at least 50 mm
width between the vapor lead and two connecting
flanges of the tap-changer head leading into the oil
compartment.
Use flanges Q and R for OLTCs type R. (For position of
connecting flanges see section 9 and 16, dwg. 893 899).
Procedure, temperature and duration of the drying
process are described in item 8.1.2.1.
8.1.3 Operating the OLTC
CAUTION
Do not operate the on-load tap-changer without oil
after drying otherwise bearings and gaskets will be
damaged.
The on-load tap-changer must not be operated before
the diverter switch oil compartment has been filled with
oil and the tap selector has been completely immersed
in the transformer oil.
19
 8 Drying procedure and filling with oil
9 Pipe connections
8.2 Filling with oil
CAUTION
The tap-changer oil compartment and the associated
oil conservator must only be filled with new mineral
insulating oil for transformers according to IEC 296.
The use of other oil affects the trouble-free operation
of on-load tap-changer and transformer.
Place the cover on the tap-changer head. Tighten all
24 cover bolts M10 (wrench size 17, max. torque 34 Nm).
On-load tap-changer and transformer are filled simul-
taneously with new oil under vacuum.
For this purpose use pipe connection S or R. To eva-
cuate, a by-pass tube between connections E2 and Q is
to be installed in order to apply vacuum to both diverter
switch oil compartment and transformer tank simultane-
ously.
R S Q (special design, required for
E2
38
KHW 805-4
20
9 Pipe connections
The tap-changer head is provided with 3 pipe connec-
tions for different purposes. After loosening the thrust
collar (4 bolts M10, w.s. 17) these pipe connections can
be swivelled (see fig. 38 and appendix, dwg. 893 899).
9.1 Pipe connection R for
protective relay RS 2001
The mounting of the protective relay RS 2001 (see
section 16, dimension drawing 892 608) is pursuant to
our Operating Instructions No. 59.
NOTE
The relay serial number must be the same as that of
the on-load tap-changer.
The relay must be mounted in horizontal position and
as near to the tap-changer head as possible.
The arrow on the relay should point towards the oil
conservator when mounted.
The pipe to the oil conservator must be installed with
an inclination of at least 2%.
9.2 Pipe connections S for suction pipe
This is the connection for the feeding pipe of a sta-
tionary oil filter. If there is no filter, the pipe connection
should be provided with a pipe with a drain cock easily
accessible on one side of the transformer tank.
9.3 Pipe connection Q
stationary oil filter only)
This is the pipe connection for the return pipe of a
stationary oil filter.
If no oil filter is provided, a dummy plug is mounted
instead of the pipe connection.
9.4 Connection flange E2
In general, this flange is covered by a dummy plug.
The flange hole is open to the transformer tank directly
beneath the tap-changer head.
If necessary, it may be connected to the gas accumulat-
ing tube for the Buchholz relay.
119/06 EN

Mounting the motor drive unit, the bevel gear and the drive shaft
10 Mounting the motor drive unit,
the bevel gear and the drive shaft
10.1 Mounting the motor drive unit (see
appendix, dwg. 898 801, 898 802)
You may find comprehensive mounting instructions in
our Operating Instructions No. 138 for motor drive ED.
NOTE
Serial number of motor drive unit and on-load tap-
changer must be identical (nameplate).
Motor drive unit and on-load tap-changer must be in
the same operating position. The adjustment position
is indicated in the connection diagram supplied with
the equipment.
The motor drive unit must be mounted at the provided
place on the transformer tank in a vertical position
and protected against excessive transformer
vibrations.
10.2 Mounting the bevel gear
The bevel gear is to be attached to a support on the
transformer cover by means of 2 bolts (through-holes
18 mm dia., see section 16, drawing 892 916).
NOTE
Make sure that bevel gear serial number and on-load
tap-changer serial number are identical.
The horizontal drive shaft must be in proper alignment
with the trunnion in the tap-changer head.
After loosening the thrust collar (6 bolts M8, w.s. 13)
the upper gear unit can be swivelled (fig. 39). After
adjusting the upper gear unit, the thrust collar must be
re-tightened (max. torque 15 Nm).
Tab-lock the screws.
In case of bevel gears in special design and
intermediate bearings of the vertical or horizontal
drive shaft above instructions apply analogously.
119/06 EN
10
10.3 Mounting the drive shaft
The drive shaft must be assembled according to our
Operating Instructions No. 42. The drive shaft is the
mechanical connection between the motor drive and the
tap changer head.
The bevel gear diverts the driving force from the vertical
to the horizontal direction.
Accordingly, the vertical part of the drive shaft is to be
mounted between motor drive unit and bevel gear,
whereas the horizontal part of the drive shaft is to be
mounted between bevel gear and tap-changer head.
The drive shaft itself consists of a square tube and is to
be connected on both ends to the respective equipment
by two coupling brackets and one coupling bolt.
NOTE
When mounting the drive shaft make sure that the
shaft ends to be connected are aligned properly.
Square shafts, coupling brackets, coupling bolts,
screws, nuts and lock tabs are made of corrosion-proof
steel. We recommend, however, to apply the same
outside coating here as to the transformer tank.
The square shafts and the guard plate for the footstep
protection for the horizontal drive shaft at the trans-
former cover are supplied in oversize (various standard
lengths).
These parts must be cut to the required size before
mounting.
Finally equalize the rotation lag between on-load tap-
changer and motor drive unit (according to Operating
Instructions No. 138 for ED).
39 KHW 767-4
21
 10 Mounting the motor drive unit, the bevel gear and the drive shaft
11 Putting the OLTC into operation in the transformer factory
OLTCs 3 x R I 2002 ... 3600
The following procedure is also recommended for
OLTC R III 1200.
Due to the special arrangement of the tap-changer
phases in three columns, the horizontal drive shaft must
be mounted between the three tap-changer heads
above the tank cover. Since a swivelling of the upper
gear unit will initiate a switching action, make sure that
the adjustment position of the diverter switch is re-
gained after the alignment of the gear units.
For this purpose proceed as follows:
1. Check that the operating positions of all columns
are identical (tap-changer head, inspection win
dow). Each one of the one-phase OLTCs must be
in the adjustment position.
2. Turn the upper gear unit of the tap-changer heads
into the desired installation position and fix them
there (tighten thrust collars and tab-lock the
screws).
Take note of the arrow on the drive shaft flange
below the punched serial number. The direction of
the arrow indicates the rotation sense when crank-
ing the motor drive clockwise and must be identical
on all gear units.
3. Operate the tap-changer poles separately by one
step by rotating the trunnions counter-clockwise
until the diverter switch operates once.
Check coincidence of operating positions of all
tap-changer heads.
4. Mount the horizontal drive shaft between the tap-
changer heads.
5. Return the OLTC set, that is all tap-changer
poles together, into the adjustment position.The
adjustment position is reached by turning the drive
shaft in clockwise direction.
Check simultaneous operation of all diverter
switches.
Check coincidence of position of all tap-
changer heads and the motor drive unit.
6. Mount the vertical drive shaft.
CAUTION
The supervisory control must be installed according
to the connection diagram of the relevant motor drive
unit. Incorrect installation will cause damage of both
on-load tap-changer and transformer in case of
malfunction.
22
11 Putting the OLTC into operation in
the transformer factory
11.1 Operational tests
Before applying voltage to the transformer check the
mechanical operation of on-load tap-changer and motor
drive.
For these test operations the on-load tap-changer has
to be run through the complete operating cycle.
Make sure that in each operating position the indi-
cators of motor drive and on-load tap-changer (tap-
changer head) read the same position.
CAUTION
Misalignment between on-load tap-changer and
motor drive unit exists, if on-load tap-changer and
motor drive unit show different operating positions.
Misalignment of coupling between on-load tap-
changer and motor drive unit leads to severe damage
of on-load tap-changer and transformer, if operation
is continued. The transformer must not be taken in
operation.
Make sure that in both end positions the electrical and
mechanical limit stops function automatically (see
Operating Instructions No. 138 for ED).
11.2 Final oil filling
Fill up the on-load tap-changer completely with trans-
former oil via the oil conservator and evacuate.
Bleed the tap-changer head via the bleeder valve in
the head cover (E1):
Remove screw cap M30/w.s. 36 (fig. 40), lift valve
tappet by means of a screw driver.
Bleed the suction pipe (S) via the bleeder screw of
the elbow: cap nut M16 (w.s. 22, max. torque 9 Nm),
slotted bleeder screw M6 (max. torque 2 Nm,
fig. 41).
CAUTION
Make sure that the suction pipe has been bled
completely. The insulation capability of the on-load
tap-changer to ground is otherwise significally
impaired.
119/06 EN
 11
Putting the OLTC into operation in the transformer factory

11.3 Ground connections

Connect the ground screws (2 screws M12 with nuts,

w.s. 19, max. torque 60 Nm, fig. 42) of the tap-changer
head to the transformer cover.
Connect the ground screw (M12, w.s. 19, max. torque
60 Nm) of the motor drive housing to the transformer
tank.

11.4 Electrical transformer tests

After the afore mentioned steps the necessary electrical

acceptance tests of the transformer can be performed.

40 KHW 773-4

41 KHW 811-4

42 KHW 811-4

119/06 EN 23
 12 Transport to the operating site
13 Putting into service at the operating site
12 Transport to the operating site
If the transformer is to be transported without the motor
drive unit, set the motor drive to the adjustment position
and uncouple.
CAUTION
Do not operate the motor drive unit while the on-load
tap-changer is uncoupled.
To remount the motor drive unit follow the instructions
according to section 10.1 and 10.3.
NOTE
If the transformer is filled with oil but stored or trans-
ported without oil conservator, a bypass tube must be
installed between the interior of the tap changer and
the transformer tank to compensate the static
pressure caused by expansion of oil.
Install this by-pass tube between pipe connections E2
and Q of the tap-changer head.
For short time conditions of 2 to 4 weeks without oil
conservator, lower the oil level by approx. 5 litres.
If the transformer is to be transported or stored without
oil filling, drain the oil of the on-load tap-changer com-
pletely.
The interior of the on-load tap-changer should be
conserved and protected in the same way as the
transformer itself (nitrogen-sealing).
If a prolonged stand-by period is expected, the heater of
the motor drive unit must be connected to the suitable
power supply.
24
13 Putting into service at the operating
site
Before putting the transformer into service, operational
tests of on-load tap-changer and motor drive have to be
performed according to section 11.1. At the same time
check the function of the protective relay. Loop in
signaling contact for undershooting the minimum oil
level in the on-load tap-changer oil conservator in the
on-load tap-changer tripping circuit.
NOTE
The protective relay has to be inserted into the trip-
ping circuit of the circuit breakers so that energiza-
tion of the protective relay switches off the trans-
former immediately (see Operating Instructions
No. 59 for protective relay RS 2001).
Make sure that the circuit breakers switching off the
transformer operate when the test push button OFF
is pressed. Be sure that they energize the transformer
only after push button IN SERVICE of the protective
relay has been pressed.
CAUTION
Check whether all stop valves between oil
conservator and tap-changer head are open.
After the transformer has been energized, tap-change
operations under load can be performed. Gas accumu-
lating under the cover of the tap-changer head will
cause minor oil displacement and/or escape via the oil
conservator.
119/06 EN
 Supervision during service, failures 14

14 Supervision during service, failures

Maschinenfabrik Reinhausen GmbH

NOTE Technical Service
Postfach 12 03 60
Damage to the on-load tap-changer due to not D-93025 Regensburg
enough oil in the oil conservator of the on-load tap- Phone: (+49) 9 41 / 40 90-0
changer! Telefax: (+49) 9 41 / 40 90-5 01
Actuation of the on-load tap-changer with too little oil Telex: 65881
in the on-load tap-changers oil conservator may
cause damage to the on-load tap-changer!
Make sure that the contact for signaling the falling
below the minimum oil level in the on-load tap-
changers oil conservator was looped through to the
tripping circuit of the circuit-breaker and that the
circuit-breaker will immediately de-energize the
transformer when the oil has fallen below this
minimum oil level in the oil conservator.
It is only necessary to inspect the tap-changer head, the
protective relay and the motor drive unit occasionally.
Pay special attention to:
oil tightness of sealings of the tap-changer head, the
protective relay and the pipe connections,
sealings at the motor drive housing,
proper function of the electrical space heater inside
the motor drive unit,
the condition of the control devices in the motor drive
unit.

WARNING

If the protective relay operates, do not reset until the

on-load tap-changer and the transformer have been
checked. For this purpose also withdraw the diverter
switch unit and check it according to our Inspection
Instructions. Proceed in detail according to our
Operating Instructions No. 59 for the protective relay
RS 2001.
Before returning to energized operation, make sure
that the cause of the trouble has been corrected and
that the on-load tap-changer and the transformer are
free of damage.
Never reconnect the transformer without prior
checking. Continued operation of the on-load tap
changer can result in severe damage of on-load tap-
changer and transformer.

In case of serious trouble with on-load tap-changer or

motor drive provided that the repair cannot easily be
done at site and in case of a tripping of the protective
relay please contact the authorized MR representative,
the transformer manufacturer or directly

119/06 EN 25
 15
Inspections

15 Inspections

NOTE

The tap-changing equipment must be inspected at

regular intervals to maintain a high level of operating
reliability.

In general, the inspection can be carried out by

qualified and MR-trained personnel within one day,
provided it is well prepared and organized.
We strongly recommend to have inspections performed
by our Technical Service. This guarantees a professio-
nal performance including all the latest updating
measures.
Inquire for spare parts when preparing an inspection
which will not be carried out by MR personnel (please
indicate OLTC number and number of operations).
The number of tap-change operations determining the
inspection intervals indicated in table II and table III are
figures based on experience with oil qualities normally
used.
The tap selector of the on-load tap-changer is generally
maintenance-free. In special cases, however, if OLTCs
are used in industrial transformers where high operating
numbers are to be expected, our technical service
department must be contacted after about 1,000,000
operations. The diverter switch insert of the OLTC is to
be replaced after 800,000 operations.
If the number of operations per year is 15,000 or higher,
the use of our oil filter plant type OF100 with paper filter
insert (see Operating Instructions No. 18) is recommen-
ded. The use of our oil filter plant type OF100 with
combination filter insert is obligatory for OLTC type R
with insulation to ground Um < 245 kV.
Filtering of switching oil allows to extend the inspection
intervals.
The user should regularly test the transformer insulating
oil according to the relevant standards.
If inspection has not been performed by MR-personnel,
please give us your report for data collecting purposes.

26 119/06 EN
 15
Inspections

CAUTION

Inspections of the tap-changer equipment are obliga-

tory. Disregarding the inspection intervals endangers
the trouble-free operation of on-load tap- changer and
transformer.

Standard values for oil testing according to CIGRE report 12-13 (1982) applying to transformer oil at service
temperature:

On-load tap-changer Water content*) Dielectric strengh**)

Neutral-end tap-changers < 40 ppm > 30 kV/2,5 mm

Single-pole tap-changers < 30 ppm > 40 kV/2,5 mm

*) measured according to Karl-Fischer method based on IEC Publication 814 (1985)

**) measured according to DIN 57370 Teil1/VDE 0370 Teil 1/12.78 Teil 1

Table I Guide values for monitoring the tap-changer oil

On-load tap-changer Transformer Number of tap-change operations

rated current without MR oil filter with oil filter

R III 1200 up to 600 A 80 000 100 000

up to 1200 A 60 000 100 000

R I 1201 up to 600 A 80 000 100 000

up to 1200 A 60 000 100 000

R I 2002 up to 2000 A 40 000 80 000

R I 2402 up to 2400 A 40 000 80 000

R I 3000 up to 3000 A 40 000 80 000

R I 3600 up to 3600A 40 000 80 000

Table II Inspection intervals for

OLTC type R in star-point connection (Y)
One-phase OLTC with Um < 245 kV used in autotransformers or for regulation at the line end of
winding of the transformer.

First inspection and further inspections: after 7 years or the number of operations indicated in Table II, depending on
what is reached first.

119/06 EN 27
 15 Inspections
16 Appendix

On-load tap-changer Transformer Number of tap-change operations

rarted current without MR oil filter with MR oil filter

R I 1201 up to 600 A 40 000 50 000

up to 1200 A 30 000 50 000

R I 2002 up to 2000 A 20 000 40 000

R I 2402 up to 2400 A 20 000 40 000

R I 3000 up to 3000 A 20 000 40 000

R I 3600 up to 3600 A 20 000 40 000

Table III Inspection intervals for one-phase OLTCs type R with Um 245 kV and used in autotransformers
or for the regulation at line end of winding of the transformer.

First inspection: after 2 years or 20,000 operations, depending on what is reached first.
Next inspections: without MR filter plant after every 4 years, with MR filter plant (combination filter) after
every 6 years or the number of operations indicated in table III whatever is reached first.

16 APPENDIX

Installation drawing _____________________________________________________________________ 896 705

OLTCs R I 2002 / R I 3000, bridges for parallel connection of tap selector terminals ___________________ 896 706
Tap-changer head ______________________________________________________________________ 893 899
Drilling template for tap-changer head ______________________________________________________ 890 183
Supporting flange for the installation into bell-type tank _________________________________________ 896 762
Lifting traverse _________________________________________________________________________ 890 180
Socket wrench for kerosene drain plug ______________________________________________________ 890 182
Protective relay RS 2001, dimension drawing _________________________________________________ 899 084
Motor drive unit ED-S, dimension drawing ___________________________________________________ 898 801
Motor drive unit ED-L, dimension drawing ____________________________________________________ 898 802
Bevel gear CD 6400, dimension drawing ____________________________________________________ 892 916

28 119/06 EN
 16
Appendix

Flat
surface

max. withdrawal height 1750 mm

Protective
relay

Take-off
terminal

11 Mounting flange on transformer cover

12 Fixing bolt M12
13 Gasket for tap-changer head
14 Position indicator
15 Inspection window
16 Drive shaft for position indicator
17 Through-hole 15 mm dia.
21 Tap-changer head
22 Bolt for tap-changer head cover
23 Gasket for tap-changer head cover
24 Tap changer head cover
25 Centric gear unit with drive shaft 25a
26 Pipe connection R for protective relay
27 Pipe connection S for suction pipe
28 Pipe connection Q for return pipe
(with oil filter only)
29a Bleeder valve of tap-changer head cover
29b Bleeding facility for transformer oil
29c Bleeder screw for suction pipe
31 Diverter switch oil compartment
32 Bottom of oil compartment
33 Grading ring (with Um = 170/245 kV)
34 Terminal of diverter switch oil compartment
35 Tap-changer take-off terminal (with R III 1200 neutral)
36 Suction pipe
41 Suspension of tap selector
42 Tap selector gear
43 Fine tap selector
44 Change-over selector
45 Tap selector terminals.
see corresponding dimension drawing
46 Change-over selector terminals.
see corresponding dimension drawing
48 Connecting lead for tap selector
48a Holding strip for 48
51 Diverter switch unit
52 Supporting cylinder
See also variants of tap selector 53 Gear plate
bottom 896 702 provide sufficient 54 Fixing bolt
55 Lifting Lug
clearance!
56 Transition resistors
Transformer tank bottom

Tap selector drive side

On-load tap-changer type R 896 705:5E

Installation drawing

119/06 EN 29
 16
Appendix

On-load tap-changer type R

Bridges for parallel connection of tap selector terminals 896 706:5E
for OLTCs R I 2002, R I 3000
(not applicable in case of enforced current splitting)

30 119/06 EN
 16
Appendix

width of
gasket

Detail at A

Connection flange
for Q, S, R
16
Thickness

Tap selector drive side

E1 = Bleeding facility for tap- changer head

E2 = Bleeding facility for space under the head outside the tap-changer oil compartment
(same pipe connection as R, S, Q or bleeder screw can be used)
Q = Connection for oil return pipe (only for oil filter)
S = Connection for suction pipe Connections orientable
O-Ring R = Connection for protective relay (exchangeble with connection Q) through 360
44.2 - 5.7
= Earth connection M12

On-load tap-changers type MS, M, T, R 893 899:9E

Tap-changer head

119/06 EN 31
 16
Appendix

3 thick

Marks to be pounded

On-load tap-changers type MS, M, T, R 890 183:6E

Drilling template

32 119/06 EN
 16
Appendix

Lifting device
O-Ring 44.2 - 5.7

Suction pipe

Drilling hole represented

in the sectional plane

Transformer cover
Gasket

Level traverse

Grading ring with

Um170/245/300 kV only

Supporting flange

Level traverse

Tap selector drive side

Z = Guiding pin

On-load tap-changer type R

896 762:6E
Special design for installation into bell-type tank

119/06 EN 33
 16
Appendix

Sheet steel
St 37-2 DIN 17 100

On-load tap-changer type R 890 180:3E

Lifting traverse

34 119/06 EN
 16
Appendix

Item-No. 014 820 Item-No. 017 660

Socket wrench L = 1350 mm L = 1860 mm

To be used Type M (except M ) M III 350/600

for OLTC Typ MS Type T, R, G

On-load tap-changer type MS, M, T, R

Socket wrench for kerosene draining screw 890 182:7E

119/06 EN 35
 16
Appendix

Cable gland
Inspection PG 16
window

Identification label

Gasket
Gasket

Test push buttons

IN SERVICE OFF
(reset) (test tripping)

Metal - dummy plug PG 16

The arrow must always point towards the oil pipe leading Plan view of test push buttons
to the oil conservator of the transformer. (cover removed)

Key of variants

Contact positions
Variant Relay designation1) Reed Arrangement of terminals Design
contact In service Off

0.65 - NO
Standard design
1 1.2 - NO A
3.0 - NO
4.8 - NO
0.65 - NC
2 1.2 - NC B
3.0 - NC
4.8 - NC
0.65 - CO
3 1.2 - CO C
3.0 - CO
Special design against surcharge

4.8 - CO
0.65 - 2NO
4 1.2 - 2NO 2A
3.0 - 2NO
4.8 - 2NO
0.65 - 2NC
5 1.2 - 2NC 2B
3.0 - 2NC
4.8 - 2NC
0.65 - NO + NC
6 1.2 - NO + NC 1A &1B
3.0 - NO + NC
4.8 - NO + NC

1)
NO - normally open, NC - normally closed, CO - change-over contact

The protective relay is to be connected in such a way that if it is energized, the power transformer is switched off immediately by the corresponding
circuit breakers.

Protective Relay RS 2001

899 084:0E
(STANDARD)

36 119/06 EN
 16
Appendix

Vertical guard
plate with
spacing ring Handcrank

* for design with

intermediate
bearing

3 dummy plates for packing glands

special design with OLTC
monitoring required
Wall of transformer tank
Shm
i

Attachment of
protective housing
The cover can be opened
to the left or to the right
depending on the arrange-
ment of the hinge pins.
ca. 690 if opened 130
ca. 864 if opened 180

Aperture of fixing holes on protective housing Aperture in protective housing for cables
(rear view) (underside view)

Motor Drive ED-S

898 801:2E
Protective Housing

119/06 EN 37
 16
Appendix

Vertical guard plate

with spacing ring Hand
crank

* for design with

intermediate
bearing

3 dummy plates for packing

glands
special design with OLTC
monitoring required

Wall of transformer tank Shm

i

Attachment of protective
housing

The cover can be opened

to the left or to the right
depending on the arrange-
ca. 690 if opened 130 ment of the hinge pins.
ca. 864 if opened 180

Aperture of fixing holes on protective housing Aperture in protective housing for cables
(rear view) (underside view)

Motor Drive ED-L

898 802:2E
Protective Housing

38 119/06 EN
 16
Appendix

e2 = 215 for design with ball joint

e1 = 205 for standard design

Bevel gear CD 6400

892 916:6E
Dimension drawing

119/06 EN 39
 Maschinenfabrik Reinhausen GmbH Telefon: (+49) 9 41 / 40 90-0
Postfach 12 03 60 Telefax: (+49) 9 41 / 40 90-111
www.reinhausen.com
D-93025 Regensburg Telex: 65881

BA 119/06 EN 02/11 F0002203 Printed in Germany