Type M Tap Changer
Type M Tap Changer
Type M Tap Changer
1. General 1.1 Operational principal of the on-load changer (fig.1) A tap-change operation begins with the tap selector preselecting the desired tap on the transformer winding.
The diverter switch transfers the current from the tap in service to the preselected tap. During this quick change-over, ohmic resistors are inserted in the circuit to ensure no-break transfer of the current.
1.2 Designation of an-load tap changer models (fig.2) Every type of tap changer is available in a number of different models. These design vary according to: number at poles, max rated through current, insulation to ground, tap sector size, and basic circuit diagram. The designation incorporates all these characteristics and permits easy identification of the tap changer. The basic circuit diagram code in the model designation identifies: number of operating positions, number of mid-positions, and type of changeover selector. Example in Fig.2: On-load tap changer type M single-pole, max rated throughcurrent 500A, insulation to ground according to Um = 123 kV, tap selector size B, basic circuit diagram code 10 19 1 W meaning: 10 contacts, 19 operating positions, with one midposition, change-over selector used as reversing switch 1.3 Principal parts of the onload tap changer (fig. 3) The principal parts of the unload tap changer are - the tap changer nead - the diverter switch compartment and - the tap selector Diverter switch unit & Top drive unit on tap head are subject to inspection
Fig.2 Designation of Tap Changer model and basic circuit diagram 10 12 14 16 18 without 10 12 14 16 18 09 11 13 15 17
Type Number of Poles Max. rated through. current in amperes and additonal indication of model Highes voltage for equipment Um Insulation go ground
Mid-positions 1 0 1 3
Change-over selector
Reversing switch
oil
Standard values for tap changer oil testing according to CIGRE report 12-13 (1982) apply to Transformer oil at servIce temperature:
Use of Tap Changer For use at the neutral point of windings For use at a position other than the neutral point of winding Water content) Dielectric strength) <40 ppm <30 ppm > 30 kV/2,5 mm > 40 kV/2,5 mm
*) measured accorclng to IS 13567/1992 **) measured according to 156792/I 972 On-load tap changer M III 350 M Ill 500 MIII 600 M1 351 M1 501 M1 601 M1 802 M1 1200 M1 1500 M1 1800 Transformer rated current 350 A 350 A 500 A 350 A 600 A 350 A 500 A 600 A 500 A 800 A 800 A 1200 A 1200 A 1500 A 1500 A 1800 A Number of tap change operations 100 000 100 000 80 000 100 000 80 000 100 000 100 000 100 000 100 000 80 000 80 000 70 000 70 000 60 000 60 000 50 000
Table I Inspection Intervals Note: 1. If Um >245 kV at the tapchanger the indicated numbers of tapchange operation must be halved & 2. regardless of the number of tap change operations listed in Table 1, inspection must becained out after 6 to 7 years 3. Regulation at the line end of the transformer with Um > 245 the first inspection must becanied out after 20,000 operations or after 2 years of seniice respectively, which ever comes first
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CAUTION: Do not operate the motor drive unit while the tap changer is uncoupled, either manually or electrically. To prevent electrical operation by remote control, it is good safety practice to isolate the motor drive unit by trIpping the motor protective switch. 3. Withdrawal of the Diverter Switch Unit (FIg.4)
Lowering the oil level: Shut the stop valve between oil conservator and tap changer head.
Lower the oil level in the tap changer head. To do this, open the bleeder valve in the head cover (remove screw cap M30/wrench size 36, lift valve tappet by means of a screwdriver) and the drain valve. WARNING: The switching oil ol the tap changer should always be handled as a I lam-mable liquid. Moreover, explosive gases can accumulate under the tap changer head cover, in the switching oil or in the oil com-partment. Therefore, strictly avoid open fire. Use a pump-ing equipment suitable for flammable liquids.
In case of an oil filter plant: open the return pipe sample valve and operate the filter unit, drain about 10 litres of oil from the tap changer head so that the support plate is out of the oil (check through the in-spection glass in the head cover). Uncoupling the drive shaft of the upper gear unit: Unscrew 6 screws M6 (w.s.1 0) from the coupling. Take care not to lose coupling baits, nuts and lock tabs. Normally the drive shaft can be moved to one side for clearance. It not, remove the other coupling on the bevel gear from the square tube (screws, nuts and lock labs as above) until the horizontal drive shaft can be removed. Take off the tap changer head cover (fig. 5) Unscrew the cover bolts Ml 0. Take care not to lose spring washers. Remove the cover, take care not to damage the Oring gasket of the head cover.
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Fig . 4 Tap Changer head 1. Drive shaft ( square tube ) 2. Coupling brackets and bolt 3. Upper gear unit (centric arrangement) 4. Tap Changer head cover 5. Bleeder Screw of head cover 6. Pipe connection R for protective relay 7. Pipe connection S with bleeder screw for suction pipe
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Dimantle In the following order Remove the position indicator disc (fig.6). Remove the clip from the shaft end. The coupling pin allows assembly in the correct position only.
Take note of the marks on the tap changer head and the support plate In the adjustment position the key in the diverter switch drive shaft
matches with the triangle mark on the support plate. Undo the screws fixing the support plate. Standard design: 4 screws MB x
and transition contacts above and below. For this purpose set the diverter switch to the opposite position by means of the operating
key Then measure again (Fig. 11). Compare the measured values against the indications on the nameplate. A 10 percent difference is pefmissibie. Detach the support cylinder. Undo 8 screws M8.20 (w.s.1 3) each with a self-locking nut, at the 4 fish-plates of the spring energy accumulator. When removing the screws take not to drop the parts into the diverter switch. Take off the support cylinder. Take off the in outling drive shaft clean the support cylinder inside and outside with a brush and
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5.7
5.5
Cleaning the diverter switch unit The contact shell with transition resistors and stationary contact system must be cleaned thoroughly with transformer oil. Special care should be taken when cleaning insulating parts. Flush all parts with clean oil. Since the contact shells and transi-tion resistors are to be disassembled and reassembled one sector before the next perform cleaning of the diverter switch between these procedures.
5.6
Cleaning the diverter switch Insulating drive shaft: To remove the insulating drive shaft, the support cylinder with support plate have to be detached from the energy accumulator case. CAUTION : Take care not to drop any parts Into the diverter switch. Otherwise the diverter switch can block and cause severe damage to the tap changer and transformer. There-fore, make sure that the number its is complete when disassembling and reassem-bling) count them to be sure.
Contact wear of main switching contacts and transition contact The admissible contact wear of the diverter switch contacts is determined by: a. The contact volume (see tig.22). The max. admissible contact wear of the individual contact is 4 mm. Contacts should be replaced if this value is reached or expected to be reached before the next inspection. b. the mechanical tap change operation sequence (see section 1.1), shunt contact (A, B), main switching contacts (a, b), transition contacts (al, bl). If the difference between main switching and transition contacts could become greater than certain given limits, the correct mechanical switching sequence of the diverter switch is no longer ensured. Unfavourable operating conditions can cause increased contact wear on transition contacts.
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switching and transition contacts by vernier gauge. Determine the contact wear by comparing the difference between new contact and measured value. 6. Replacement of the Diverter Arcing Contacts and Contact Braids 6.1 Diverter switch arcing contacts Each diverter switch sector is fitted with two main switching contacts (a, b) and two transition contacts (a1, b1). Each of these contacts exists as stationary and a movable contact. Each stationary and movable contact consists of two contact tips. Replacement of the contact tips of the stationary and movable contact system is simple (attachment : 1 screw M6 for each element). Note the following details: Stationary contact (see tig.23, 24) Each contact tip is fixed by one hexagon socket screw M6 x 16 (w.s. 4 or 5), max. torque 9 Nm, locked by centre punching the groove of the screw head. Movable contacts (see fig. 25, 26, 27) Each contact element is fixed by one hex head screw M6 x 16 (w.s. 10), 2 dished washers, max. torque 9 Nm, locked by lock tab. WARNING: Continued operation of the diverter switch with greatly differing contact layer thickness on arcing contacts can lead to severe damage of tap changer and transformer. The max. permissible difference of contact layer thickness between main switching and transition contact is 2.5 ... 2.6 mm. If this dif-ference has been reached or is expected to be reached before the next inspection, the contacts shall be replaced or matched to the other contacts by interchanging or milling. Determination of contact wear Measure and note the thickness ot the contact layers on the stationary and movable main 5.8 OLTC M III 350 M I 351: Before undoing contact tips remove the contact braids on top and bottom (see section 6.2). Note: In case of through-current exceeding 200 A contacts of tungsten
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contact system to the slide contact (= output terminal) of the diverter switch sector. These braids are fixed by a screw, washer and self-locking nut (fig. 28, 29). As a precaution, the contact braids should be replaced after 250,000 operations regardless of replacement of diverter switch contacts. Please note: OLTC 111350, M 1351 (see fig. 30) There are 8 sets of contact braids, two sets each on top and bottom as well as two sets of two in the middle of a sector. The contact braids of the main switching contacts and transition contacts are joined together at the output terminal. 2 sets ot contact braids (on top and bottom) Each fixed to the output terminal by one bolt M6 x 28 (w.s.10) with self-locking nut and washer, max. torque 9 Nm. Attachment to the main switching contact (double braid) by one bolt M6 x 18L, attachment to the transi-tion contact (single braid) by one bolt M6 x 16. copper are used tor tne transition contacts (a1, b1). OLTC M III 500, M III 600, M I 501, M l 601, M I 802, M I 1200, M I 1500, M I 1800. Before undoing the contact tips remove the contact braids on top (see section 6.2). 6.2 Contact braids All bolts with self-locking nut and washer, max. torque 9 Nm. 4 sets of double contact braids (in the middle) Attachment to the output terminal: each by one bolt M5 x 22 (w.s.8) with self-locking nut and washer, max. torque 5 Nm. Each fixed to the main switching contact by one bolt M6 x 1 BL (w.s.1 0) with selt-locking nut and washer, max. torque 9 Nm.
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The contact braids connect the main switching contacts and transition contact of the movable
Attachment to the main switching contact and transition contact: each by one bolt M6 x 16 (w.s. 10) with self-looking nut and washer. max. torque 9 Nm. Always use new self-locking nuts. 7. Reattachment of the contact shells Reattach the contact shell in reverse order to removal. The diverter switch is in the midposi-tion. Insert a chucking wedge between epoxy segment and contact carder to hold back the movable contact system of the diverter switch. This counters the pressure of the movable contact system (fig. 32. 33) and makes attachment of the contact shell easier. Refit the arc chutes and make sure that they are properly seated. Attachment of each contact shell by 8 screws M6 x 20 (w.s. 10), max. torque 5 Nm, with look tabs (fig.34). Use new self-locking screws and lock tabs. After tightening the screws, remove the chucking wedge in upward direction (fig.35). When all contact shells have been reinstalled, the spring energy accumulator must be set from the mid-position into a switched position of the diverter switch and locked-in. OLTC M III 500, M III 600, M I 501, M I 601, M I 802, M I 1200, M I 1500 M I 1800 (sec fig. 31) There are two sets of contact braids on top only, connected to main switching and transition contacts. The contact braid of the main switching contacts and transition contacts are joined together at the output terminal. Attachment to the output terminal by one bolt M6 x 28 (w.s. 10) with self-locking nut and washer, max. torque 9 Nm. Insert a screwdriver between wind-up sledge and cooking sledge of the energy accumulator (fig. 36).
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Actuate the eccentric by means of the operating key until the pawl locks-in (see fig. 37, 38). Operate the diverter switch several times to check its mechanical function. Finally check again the transition resistors as described in section 5.2. Set the diverter switch to its withdrawal position (see section 5.1). The diverter switch unit is now ready to be reinstalled.
8. Reattach the support cylinder with support plate: 8 bolts M8 x 20 (w.s.13), each with 2 washers, max. torque 22 Nm. En-sure alignment of triangle marks on bottom at the spring energy accumulator housing and on top at the support plate (fig. 39, 40). Operate the diverter switch several times to check its mechanical function (fig. 41). Final ly check again the transition resistors as described in section 5.2.
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Fill up the oil conservator with new oil to its original level. CAUTION: The transformer should be energised not earlier than 1 hour after the oil filling. 11. Motor Drive The on-load tap changer type M is operated by motor drive unit MA2 mounted outside the transformer tank, with maximum operating posi. tion of 35. Set the dlverter switch to Its withdrawal position (see section 5.1) The diverter switch unit is now ready to be reinstalled. 10. Oil Filling CAUTION: The tap changer oil compartment arid the associate oil conservator must only be filled with new mineral insuIating oil for transformers as per IEC 296 (1982). The use of other oil can affect the trouble-free operation of tap changer and transformer. Fill new oil into the diverter switch oil compartment up to the level of the support plate. Put the cover on the tap changer head making sure that the gasket fits property; if necessary replace the O-ring. The head cover is attached by 24 bolts M10 (w.s. 17), max. torque 34 Nm, secured by spring washers. Open the stop valve between protective relay and oil conser-vator. Vent the tap changer head through the bleeder valve in the tap changer head cover (remove screw cap M30 I w.s. 36 and lift valve tappet by means of a screwdriver). Vent the suction pipe (screw cap M161w.s 22. bleeder screw M6 with chees head, max. torque 2 Nm). see fig. 42. Units with stationary oil filter unit: operate the oil fitter unit and bleed. The drive shaft is the mechanical connection between motor drive and tap changer head. The bevel gear connects the vertical and horizontal parts of the drive shaft. The vertical part has to be mounted between motor drive unit and bevel gear, and the horizontal part be-tween bevel gear and tap changer head.The drive shaft couplings are the same for both parts. Both ends of the square shaft are connected to the respective implement by two coupling brackets and one coupling pin. Square shaft have to be trimmed to the required lengths when they are mounted on the transformer. 11.1 Coupling instructions When mounting observe the following instructions: 1. Check the shaft length between the two shaft ends. 2. Attach the coupling brackets to the shaft by 6 screws M6 (wrench size 10) add flat washer (m6) and lock washer (m6). Slide the coupling brackets on the square shaft as far as possible, tighten the M6 nuts. (maximum torque 9Nm). 3. Lubricate O ring and coupling pin.
9. Reinstallatlon ol the diverter switch unit Remove the tap changer head cover. Lift the diverter switch unit over the open tap changer head. Lower it down into the oil compartment slowly and carefully. When remounting the diverter switch unit turn, if necessary, the insulating shaft slightly until the coupling engages. Ensure alignment of marks on the support plate of diverter switch unit and in the tap changer head. Fix the diverter switch unit by the screws of the support plate. Standard design: 4 screws MB x 20 (w.s. 13). Special design for bell-type tank installation: 5 nuts M8 (w.s. 13). Both types secured by spring washers, max. torque 22 Nm. Reinstall the position indicating disc (put on clip to shaft end).
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4. Place the coupling pin into the trunion and slide the square shaft together with the coupling. 5. Provide the opposite trunion with coupling bracket and coupling pin. Fit in the square shaft. Place second coupling bracket and tighten the 6 bolts (M6) with flat washer, lock washer and (M6) nuts. 6. Make sure that there is an axial clearance of 2mm between coupling pin and coupling brackets. 7. Finally tighten the coupling brackets (max. torque 9Nm) placed on both side of the bevel gear and next to the tap changer head. Note: The screws of coupling brackets next to motor drive unit must be tightened and locked when the rotation lag of motor drive has been equalized. 11.2 RotatIonal lag adjustment of the tap changer and motor drive For the following procedure the tap changer and motor drive must be the same tap position. The motor drive has to be set to the same position as found in the tap changer. Motor drive and tap changer cans however, finally be coupled only when the rotation lag (if there is
any) has been balanced. For this purpose proceed as follows: 11.2.1Turn the hand crank clock-wise towards Lower until the energy accumulator of the tap changer is released. 11.2.2Continue cranking and count the revolutions necessary br releasing the spring unit of the motor drive, till a click which can be distinctly heard (about 3 to 5 revolutions). 11.2.3Turn the hand crank counter clockwise towards Raise until the energy accumulator of the lap changer is released. 11.2.4Continue cranking and count the revolutions, as in 11.2.1. 11.2.5Balancing the rotation lag is necessary if the number of clock-wise revolutions does not equal that of the counter clockwise revolu-tions. In this case the vertical part of the driving shaft is uncoupled. The hand crank is then turned in the rotation sense which required more revolutions to be effected. The number of the balancing revolutions amounts to half the difference between the clockwise and counter clockwise revolutions. Example (see Fig.43) Turn the crank clockwise (e.g. from position 6 to 5) rotation lag deter mined 3 revolutions (Fig.43). Turn the crank counter clockwise (e.g. from position 5 to 6) rotation rag determined: 5 revolutions. Uncouple. Equalize by truning the crank for half the difference: 1/2 (5-3) = 1 revolution counter clockwise. Recouple. Checking the result: Cranking clockwise (e.g. towards position 5) and then counter clock-wise (e.g. towards position 6) results in both oases in the same number of revolutions constituting the rotation lag (Ref. Fig.43).
EMR/OI/M/0010
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