4360601_03en_Type R

On-Load Tap-Changer
OILTAP® R
Installation and Commissioning Instructions
4360601/03 EN . Selector Sizes RC/RD/RDE/RE/RF

© All rights reserved by Maschinenfabrik Reinhausen
Dissemination and reproduction of this document and use and disclosure of its content are strictly prohibited
unless expressly permitted.
Infringements will result in liability for compensation. All rights reserved in the event of the granting of patents,
utility models or designs.
The product may have been altered since this document was published.
We reserve the right to change the technical data, design and scope of supply.
Generally the information provided and agreements made when processing the individual quotations and orders
are binding.
The original operating instructions were written in German.
Table of contents
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 Symbols................................................................................................................................................................. 8
1.4.2 Hazard communication system............................................................................................................................. 9
1.4.3 Information system.............................................................................................................................................. 10
2 Safety................................................................................................................................. 11
2.1 Appropriate use................................................................................................................................. 11
2.2 Fundamental safety instructions........................................................................................................ 11
2.3 Personnel qualification...................................................................................................................... 13
2.4 Personal protective equipment.......................................................................................................... 14
3 Product description.......................................................................................................... 16
3.1 Scope of delivery............................................................................................................................... 16
3.2 On-load tap-changer.......................................................................................................................... 16
3.2.1 Function description............................................................................................................................................ 16
3.2.2 Setup/versions..................................................................................................................................................... 17
3.2.3 Nameplate and serial number............................................................................................................................. 20
3.2.4 Protective devices............................................................................................................................................... 21
3.3 Drive shaft......................................................................................................................................... 29
3.3.1 Function description............................................................................................................................................ 29
3.3.2 Design/versions................................................................................................................................................... 30
3.4 OF 100 Oil Filter Unit......................................................................................................................... 33
4 Packaging, transport and storage................................................................................... 34

4.1 Packaging.......................................................................................................................................... 34
4.1.1 Suitability............................................................................................................................................................. 34
4.1.2 Markings.............................................................................................................................................................. 34
4.2 Transportation, receipt and handling of shipments............................................................................ 35
4.3 Storage of shipments......................................................................................................................... 36
4.4 Unpacking shipments and checking for transportation damages...................................................... 37
5 Mounting............................................................................................................................ 38
Maschinenfabrik Reinhausen GmbH 2017 4360601/03 EN OILTAP® R 3

Table of contents
5.1 Preparatory work............................................................................................................................... 38

5.1.1 Fitting mounting flange on transformer cover...................................................................................................... 39
5.1.2 Fitting stud bolts on mounting flange................................................................................................................... 39
5.2 Installing the standard version on-load tap-changer in the transformer............................................ 40
5.2.1 Fastening on-load tap-changer to transformer cover.......................................................................................... 40
5.2.2 Connecting the tap winding and on-load tap-changer take-off lead.................................................................... 53
5.2.3 Carrying out transformer ratio test before drying................................................................................................. 59
5.2.4 Measuring DC resistance on transformer............................................................................................................ 60
5.2.5 Drying on-load tap-changer in autoclave............................................................................................................. 61
5.2.6 Drying on-load tap-changer in transformer tank.................................................................................................. 68
5.2.7 Carrying out transformer ratio test after drying.................................................................................................... 82
5.3 Installing on-load tap-changer in transformer (bell-type tank version)............................................... 83
5.3.1 Inserting on-load tap-changer into supporting structure...................................................................................... 83
5.3.2 Connecting the tap winding and on-load tap-changer take-off lead.................................................................... 93
5.3.3 Carrying out transformer ratio test before drying............................................................................................... 100
5.3.4 Measuring DC resistance on transformer.......................................................................................................... 101
5.3.5 Drying on-load tap-changer in autoclave........................................................................................................... 102
5.3.6 Lifting top part of on-load tap-changer head off supporting flange (bottom part).............................................. 109
5.3.7 Fit the bell-type tank and connect the on-load tap-changer to the top part of the on-load tap-changer head... 116
5.3.8 Drying on-load tap-changer in transformer tank................................................................................................ 127
5.3.9 Carrying out transformer ratio test after drying.................................................................................................. 141
5.4 Filling the oil compartment of the on-load tap-changer with oil....................................................... 142
5.5 Fitting protective devices and drive components............................................................................. 143
5.5.1 Connecting the tap-change supervisory device................................................................................................ 143
5.5.2 Installing protective relay in piping and connecting........................................................................................... 144
5.5.3 Installing and connecting the pressure-operated relay...................................................................................... 162
5.5.4 Fitting motor-drive unit....................................................................................................................................... 164
5.5.5 Fitting drive shaft............................................................................................................................................... 164
5.5.6 Centering on-load tap-changer and motor-drive unit......................................................................................... 217
5.5.7 Installing electrics for motor-drive unit............................................................................................................... 217
6 Commissioning the on-load tap-changer at the transformer manufacturer's site... 218

6.1 Bleeding on-load tap-changer head and suction pipe..................................................................... 218
6.1.1 Bleeding on-load tap-changer head.................................................................................................................. 218
6.1.2 Bleeding suction pipe on pipe connection S...................................................................................................... 219
6.2 Grounding the on-load tap-changer................................................................................................. 220
6.3 Performing tests on motor-drive unit............................................................................................... 221
4 OILTAP® R 4360601/03 EN Maschinenfabrik Reinhausen GmbH 2017

Table of contents
6.4 Performing trial tap-change operations........................................................................................... 221

6.5 High-voltage tests on the transformer............................................................................................. 222
7 Transporting transformer to the operating site........................................................... 224

7.1 Transport with removed drive.......................................................................................................... 224
7.2 Transport with oil fill and without oil conservator............................................................................. 224
7.3 Transport without oil fill.................................................................................................................... 225
7.3.1 Emptying oil compartment via pipe connection S.............................................................................................. 225
8 Commissioning the transformer at the operating site................................................ 227

8.1 Checking motor-drive unit................................................................................................................ 227
8.2 Checking protective relay................................................................................................................ 228
8.2.1 Checking protective relay (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5, 2001/R, 2003).................................... 228
8.2.2 Checking protective relay (RS 2004)................................................................................................................. 229
8.3 Checking pressure monitoring device............................................................................................. 229
8.4 Filling the oil compartment of the on-load tap-changer with oil....................................................... 230
8.5 Bleeding on-load tap-changer head and suction pipe..................................................................... 231
8.5.1 Bleeding on-load tap-changer head.................................................................................................................. 231
8.5.2 Bleeding suction pipe on pipe connection S...................................................................................................... 233
8.6 Performing trial tap-change operations........................................................................................... 233
8.7 Commissioning the transformer....................................................................................................... 234
9 Fault elimination.............................................................................................................. 235

9.1 Tripping of the protective relay and re-commissioning the transformer........................................... 237
9.1.1 Flap valve in IN SERVICE position................................................................................................................... 238
9.1.2 Flap valve in OFF position................................................................................................................................. 238
9.1.3 Re-commissioning the transformer................................................................................................................... 238
9.2 Tripping the pressure-operated relay and putting the transformer back into operation................... 239
9.2.1 Sensor in the OPERATION position.................................................................................................................. 239
9.2.2 Sensor in the OFF position................................................................................................................................ 239
9.2.3 Re-commissioning the transformer................................................................................................................... 240
10 Technical data................................................................................................................. 241

10.1 Technical data for protective relay................................................................................................... 241
10.2 Special models of protective relay................................................................................................... 243
10.2.1 Protective relay with CO change-over contact as tripping switch ..................................................................... 243
10.2.2 Protective relay with several dry-reed magnetic switches................................................................................. 243
10.3 Technical data for pressure monitoring device................................................................................ 244

Table of contents
10.4 Limit values for dielectric strength and water content of on-load tap-changer oil............................ 245
11 Drawings.......................................................................................................................... 246
11.1 Dimensional drawings..................................................................................................................... 246
11.2 Selector contacts............................................................................................................................. 253
11.3 On-load tap-changer head............................................................................................................... 262
11.4 Supporting flange for bell-type tank installation............................................................................... 265
11.5 Adjustment plans............................................................................................................................. 268
11.6 Accessories..................................................................................................................................... 275
Glossary........................................................................................................................... 279

1 Introduction
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, Germany
Tel.: (+49) 9 41/40 90-0
Fax: (+49) 9 41/40 90-7001
E-mail: sales@reinhausen.com
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 apply:

▪ Unpacking instructions (included in the scope of delivery)
▪ Supplement (included in the scope of delivery)
▪ Routine test report (included in the scope of delivery)
▪ Connection diagrams (included in the scope of delivery)
▪ Dimensional drawings (included in the scope of delivery)
▪ Technical data - General section (available on request)
▪ Technical data - Product-specific section (available on request)
1.3 Safekeeping
Keep this technical file and all supporting documents ready at hand and ac-
cessible for future use at all times.
1.4 Notation conventions

This section contains an overview of the symbols and textual emphasis
used.

1 Introduction
1.4.1 Symbols
Symbol Meaning
Wrench size
Tightening torque
Number and type of fastening material used
Fill with oil
Cut open, cut through
Clean
Visual inspection
Use your hand
Adapter ring
Apply a coat of paint
Use a file
Grease
Coupling bolt
Use a ruler
Use a saw
Hose clip

1 Introduction
Symbol Meaning
Wire eyelet, safety wire
Use a screwdriver
Apply adhesive
Lock tab
Table 1: Symbols
1.4.2 Hazard communication system

Warnings in this technical file are displayed as follows.
1.4.2.1 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 and source of danger

Consequences
► Action
► Action
1.4.2.2 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.
1.4.2.3 Signal words and pictograms
The following signal words are used:
Signal Meaning
word
DANGER Indicates a hazardous situation which, if not avoided, will
result in death or serious injury.

1 Introduction
Signal Meaning
word
WARNING Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could
result in injury.
NOTICE Indicates measures to be taken to prevent damage to
property.
Table 2: Signal words in warning notices
Pictograms warn of dangers:
Pictogram Meaning
Warning of a danger point
Warning of dangerous electrical voltage
Warning of combustible substances
Warning of danger of tipping
Table 3: Pictograms used in warning notices
1.4.3 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.

2 Safety
2 Safety
This technical file contains detailed descriptions on the safe and proper in-
stallation, connection, commissioning and monitoring of the product.
▪ Read this technical file through carefully to familiarize yourself with the
product.
▪ This technical file is part of the product.
▪ Read and observe the safety instructions provided in this chapter in par-
ticular.
▪ Observe the warnings in this technical file in order to avoid function-re-
lated dangers.
▪ The product is manufactured on the basis of state-of-the-art technology.
Nevertheless, risks to life and limb of the user or impairment of the prod-
uct and other material assets may occur during use due to function-re-
lated dangers.
2.1 Appropriate use

The product is an on-load tap-changer and keeps the output voltage of a
transformer constant. The product is designed solely for use in electrical en-
ergy systems and facilities. If used as intended and in compliance with the
requirements and conditions specified in this technical file as well as the
warning notices in this technical file and attached to the product, then the
product does not present any danger to people, property or the environment.
This applies throughout the product's entire life, from delivery to installation
and operation through to disassembly and disposal.
The following is considered appropriate use:

▪ Use the product only with the transformer specified in the order.
▪ The serial numbers of on-load tap-changers and on-load tap-changer
accessories (drive, drive shaft, bevel gear, protective relay, etc.) must
match if the on-load tap-changers and on-load tap-changer accessories
are supplied as a set for one order.
▪ You will find the standard valid for the product and the year of issue on
the nameplate.
▪ Operate the product in accordance with this technical file, the agreed
delivery conditions and technical data.
▪ Ensure that all necessary work is performed only by qualified personnel.
▪ Use the equipment and special tools supplied only for the intended pur-
pose and in accordance with the specifications of this technical file.
2.2 Fundamental safety instructions

To prevent accidents, disruptions and damage as well as unacceptable ad-
verse effects on the environment, those responsible for transport, installa-
tion, operation, maintenance and disposal of the product or parts of the prod-
uct must ensure the following:

2 Safety
Personal protective equipment
Loosely worn or unsuitable clothing increases the danger of becoming trap-

ped or caught up in rotating parts and the danger of getting caught on pro-
truding parts. This increases the danger to life and limb.
▪ All necessary devices and personal protective equipment required for
the specific task, such as a hard hat, safety footwear, etc. must be worn.
Observe the section "Personal protective equipment" [► 14].
▪ Never wear damaged personal protective equipment.
▪ Never wear rings, necklaces or other jewelry.
▪ If you have long hair, wear a hairnet.
Work area
Untidy and poorly lit work areas can lead to accidents.

▪ Keep the work area clean and tidy.
▪ Make sure that the work area is well lit.
▪ Observe the applicable laws for accident prevention in the relevant
country.
Working during operation
You must only operate the product when it is in a sound operational condi-
tion. Otherwise it poses a danger to life and limb.
▪ Regularly check the operational reliability of safety equipment.
▪ Comply with the maintenance work and maintenance intervals descri-
bed in this technical file.
Explosion protection
Highly flammable or explosive gases, vapors and dusts can cause serious
explosions and fire.
▪ Do not install or operate the product in areas where a risk of explosion is
present.
Safety markings
Warning signs and safety information plates are safety markings on the
product. They are an important aspect of the safety concept.
▪ Observe all safety markings on the product.
▪ Make sure all safety markings on the product remain intact and legible.
▪ Replace safety markings that are damaged or missing.

2 Safety
Ambient conditions
To ensure reliable and safe operation, the product must only be operated
under the ambient conditions specified in the technical data.
▪ Observe the specified operating conditions and requirements for the in-
stallation location.
Auxiliary materials and operating materials
Auxiliary materials and operating materials not approved by Maschinenfabrik

Reinhausen GmbH could damage the product.
▪ Only use lubricants and auxiliary materials approved by the manufactur-
er.
▪ Contact Maschinenfabrik Reinhausen GmbH.
Modifications and conversions
Unauthorized or inappropriate changes to the product may lead to personal

injury, material damage and operational faults.
▪ Only modify product following consultation with Maschinenfabrik Rein-
hausen GmbH.
Spare parts
Spare parts not approved by Maschinenfabrik Reinhausen GmbH may

cause physical injury and damage the product.
▪ Only use spare parts approved by the manufacturer.
▪ Contact Maschinenfabrik Reinhausen GmbH.
2.3 Personnel qualification

The person responsible for assembly, commissioning, operation, mainte-
nance and inspection must ensure that the personnel are sufficiently quali-
fied.
Electrically skilled person
The electrically skilled person has a technical qualification and therefore has
the required knowledge and experience, and is also conversant with the ap-
plicable standards and regulations. The electrically skilled person is also pro-
ficient in the following:
▪ Can identify potential dangers independently and is able to avoid them.
▪ Is able to perform work on electrical systems.
▪ Is specially trained for the working environment in which (s)he works.
▪ Must satisfy the requirements of the applicable statutory regulations for
accident prevention.

2 Safety
Electrically trained persons
An electrically trained person receives instruction and guidance from an

electrically skilled person in relation to the tasks undertaken and the poten-
tial dangers in the event of inappropriate handling as well as the protective
devices and safety measures. The electrically trained person works exclu-
sively under the guidance and supervision of an electrically skilled person.
Operator
The operator uses and operates the product in line with this technical file.
The operating company provides the operator with instruction and training
on the specific tasks and the associated potential dangers arising from im-
proper handling.
Technical Service
We strongly recommend having maintenance, repairs and retrofitting carried

out by our Technical Service department. This ensures that all work will be
performed correctly. If maintenance is not carried out by our Technical Serv-
ice department, please ensure that the personnel who carry out the mainte-
nance are trained and authorized by Maschinenfabrik Reinhausen GmbH to
carry out the work.
Authorized personnel
Authorized personnel are trained by Maschinenfabrik Reinhausen GmbH to

carry out special maintenance.
2.4 Personal protective equipment

Personal protective equipment must be worn during work to minimize risks to
health.
▪ Always wear the personal protective equipment required for the job at
hand.
▪ Never wear damaged personal protective equipment.
▪ Observe information about personal protective equipment provided in
the work area.
Personal protective equipment to be worn at all times

Protective clothing
Close-fitting work clothing with a low tear-
ing strength, with tight sleeves and with no
protruding parts. It mainly serves to pro-
tect the wearer against being caught by
moving machine parts.

2 Safety
Safety shoes
To protect against falling heavy objects
and slipping on slippery surfaces.
Special personal protective equipment for particular environments

Safety glasses
To protect the eyes from flying parts and
splashing liquids.
Visor
To protect the face from flying parts and
splashing liquids or other dangerous sub-
stances.
Hard hat
To protect from falling and flying parts and
materials.
Hearing protection
To protect from hearing damage.
Protective gloves
To protect from mechanical, thermal, and
electrical hazards.

3 Product description
This chapter contains an overview of the design and function of the product.
3.1 Scope of delivery

The product is packaged with protection against moisture and is usually de-
livered as follows:
▪ Oil compartment with on-load tap-changer head and built-in diverter
switch insert
▪ Selector
▪ Motor-drive unit
▪ Drive shaft with coupling parts and bevel gear
▪ Protective device
▪ Technical files
Please refer to the delivery slip for full details of scope of delivery.
Single-phase on-load tap-changers are also available as an on-load tap-

changer set with a common motor-drive unit.
Note the following information:

▪ Check the shipment for completeness on the basis of the shipping docu-
ments.
▪ Store the parts in a dry place until installation
▪ The product must remain in its airtight, protective wrapping and may on-
ly be removed immediately before installation
You will find more information in the "Packaging, transport, and storage"
[► 34] chapter.
3.2 On-load tap-changer
3.2.1 Function description

On-load tap-changers are used to adjust the transmission ratio of transform-
ers without interrupting the load flow. Fluctuations in voltage occurring in the
power transmission grid, for example, can therefore be compensated for. For
this purpose, on-load tap-changers are fitted in transformers and connected
to the active part of the transformer.

A motor-drive unit, which receives a control impulse (e.g. from a voltage reg-
ulator), changes the on-load tap-changer's operating position, which adapts
the transmission ratio of the transformer to the respective operating require-
ments.
Figure 1: System overview of on-load tap-changer Transformer
1 Transformer tank 6 Upper gear unit

2 Motor-drive unit 7 On-load tap-changer
3 Vertical drive shaft 8 RS protective relay
4 Bevel gear 9 Oil conservator
5 Horizontal drive shaft 10 Active part of the transformer
3.2.2 Setup/versions
The on-load tap-changer consists of the on-load tap-changer head, oil com-
partment with built-in diverter switch insert and the selector mounted below
(also available with change-over selector on request).
The design and designation of the most important on-load tap-changer com-
ponents are shown in the installation drawings in the appendix.

For the number of maximum operating positions of the on-load tap-changer,

refer to the technical data.
Figure 2: OILTAP® R on-load tap-changer
1 On-load tap-changer head 5 Tap selector

2 Upper gear unit 6 Change-over selector (option-
al)

3 Pipe bend 7 On-load tap-changer head

cover
4 Oil compartment 8 Rupture disk
3.2.2.1 Pipe connections
The on-load tap-changer head features 4 pipe connections for different pur-
poses.
Depending on the order, some or all of these pipe connections are fitted with
pipe bends ex factory. All pipe bends without terminal box for the tap-change
supervisory control can be freely swiveled once the pressure ring is loos-
ened.
Figure 3: Pipe connections with pipe bends
Pipe connection Q
Pipe connection Q is sealed off with a blank cover and, depending on the
on-load tap-changer type, is intended for the bushing of the tap-change su-
pervisory device supplied as an option or for connecting the oil filter unit.
The functions of the R and Q pipe connections can be interchanged.
Pipe connection S
The pipe bend on pipe connection S features a vent screw and can be con-
nected to a pipe that ends with a drain valve on the side of the transformer
tank at operating height. If the on-load tap-changer is fitted with an oil suc-
tion pipe, the on-load tap-changer can be completely emptied via pipe con-
nection S.

Pipe connection R
Pipe connection R is provided for attachment of the protective relay and con-
nection of the on-load tap-changer oil conservator and can be interchanged
with pipe connection Q.
Pipe connection E2
The pipe connection E2 is sealed off with a blank cover. It leads into the oil
tank of the transformer, directly under the on-load tap-changer head and can
be connected to a collective pipe for the Buchholz relay, if necessary. This
pipe connection serves a further purpose, namely to equalize the pressure
between the transformer tank and oil compartment of the on-load tap-chang-
er, which is necessary for drying, oil filling and transportation of the trans-
former.
3.2.3 Nameplate and serial number

The nameplate with the serial number is on the on-load tap-changer head
cover.
Figure 4: Position of nameplate

The serial number can also be found on the selector.
Figure 5: Serial number
3.2.4 Protective devices

The following protective devices for the product are included as standard in
the scope of delivery or are available as options.
3.2.4.1 Protective relay
3.2.4.1.1 Function description
The protective relay is used to protect the on-load tap-changer and the
transformer when a malfunction occurs in the diverter switch oil compartment
or selector switch oil compartment. It is tripped when the specified speed of
oil flow from the on-load tap-changer head to the oil conservator is exceeded
due to a fault. The flowing oil actuates the flap valve which tips over into po-
sition OFF. The contact in the dry-reed magnetic switch is thereby actuated,
the circuit breakers are tripped, and the transformer is de-energized.
The protective relay is part of an on-load tap-changer filled with insulating

liquid and its properties conform to the applicable valid version of IEC publi-
cation 60214-1.

Diverter switch operations at rated switching capacity or at permissible over-

load will not cause the protective relay to trip.
The protective relay responds to oil flow, not to gas accumulated in the pro-
tective relay. It is not necessary to bleed the protective relay when filling the
transformer with oil. Gas accumulation in the protective relay is normal.
3.2.4.1.2 Design/versions
Front view
Figure 6: RS 2001
1 Inspection window

Rear view
Figure 7: RS 2001
1 Dummy plug 3 Ventilation for terminal box

2 Identification plate
The protective relay RS 2001/R has an extra inspection window on the rear.

View from above
Figure 8: RS 2001
1 Gasket 7 Cable connection

2 Grounding cable 8 Protective cover
3 Terminal box cover 9 Dummy plug
4 OPERATION (reset) test but- 10 Connection terminals
ton
5 Slotted head screw 11 Cylinder head screw for pro-
tective conductor connection
6 OFF (test tripping) test button
The protective relays RS 2003 and RS 2004 have a 1/2"-14NPT adapter in

place of the cable connection (position 7).

3.2.4.1.3 Nameplate
The nameplate is on the back of the protective relay.
Figure 9: Position of nameplate
3.2.4.2 Pressure monitoring device DW
3.2.4.2.1 Function description
The DW 2000 pressure-operated relay protects the on-load tap-changer

from unacceptable pressure increases, contributing to the safety of the
transformer. The pressure-operated relay is installed on the outside of the
on-load tap-changer and is tripped by unacceptable static and dynamic pres-
sures in the on-load tap-changer oil vessel.
The pressure-operated relay works on the same principle as a barometric

corrugated tube with a counter-pressure spring and a mechanically linked
snap-action switch. The sensor on the snap-action switch snaps to the other
position by itself after tripping and has to be reset into the initial position by
hand.
The pressure increase activates the sensor on the snap-action switch that
flips into the OFF position. This triggers the circuit breaker and de-energizes
the transformer.
Low-energy interference does not cause the pressure-operated relay to trip

since the required tripping pressure is not reached. The tripping pressure is
set at the factory and prevented from being changed.
The pressure-operated relay responds faster than the RS 2001 protective re-
lay in relation to large pressure increases. The RS 2001 protective relay is
part of the default MR protection system that comes standard.

Additional use of a pressure-operated relay also requires installation of the

provided RS 2001 protective relay.
The features and characteristics of the pressure-operated relay comply with

the respective applicable version of IEC publication 60214-1.
Diverter switch operations at the rated switching capacity or permitted over-

load do not cause the pressure-operated relay to trip.
The pressure-operated relay responds to a pressure change and not to gas

accumulation under the pressure-operated relay. Gas accumulation under
the pressure-operated relay is normal.
3.2.4.2.2 Design/versions
This chapter gives you an overview of the structure of the pressure monitor-
ing device.

The pressure monitoring device consists of a pressure measuring element

and an adjacent snap-action switch.
Figure 10: Snap-action switch and pressure measuring element
1 Snap-action switch 2 Pressure measuring element
The snap-action switch has a normally open switch and normally closed
switch with snap action.

During operation, the snap-action switch and pressure measuring element

are protected by a cover cap. Ventilation is provided on the top of the pres-
sure monitoring device.
Figure 11: Pressure monitoring device with cover cap and ventilation
1 Ventilation 2 Cover cap
There are two variants of the pressure monitoring device:

▪ DW 2000 for vertical installation
▪ DW 2000 for horizontal installation
The housing and cover cap of the pressure monitoring device consist of
lightweight, corrosion-resistant metal.
3.2.4.3 Rupture disk
The rupture disk is a pressure relief device without signaling contact in ac-
cordance with IEC 60214-1 and is located in the on-load tap-changer head
cover.
The rupture disk responds to a defined overpressure in the oil compartment

of the on-load tap-changer.

3.2.4.4 Pressure relief device MPreC®
On request, in place of the rupture disk MR will supply a pre-fitted pressure

relief device MPreC® that responds to a defined overpressure in the oil com-
partment of the on-load tap-changer.
The on-load tap-changer therefore meets the requirements of IEC 60214-1

regarding pressure relief devices.
3.2.4.5 Tap-change supervisory control
The tap-change supervisory control monitors both the drive shaft between
on-load tap-changer(s) and motor-drive unit and the correct switching of the
diverter switch.
3.2.4.6 Temperature monitoring
The temperature monitoring device monitors the oil temperature in the oil
compartment of the on-load tap-changer.
3.3 Drive shaft
3.3.1 Function description

The drive shaft is the mechanical connection between motor-drive and on-
load tap-changer head / de-energized tap-changer head.
The bevel gear changes the direction from vertical to horizontal (see drawing
892916).
Accordingly, the vertical drive shaft has to be mounted between drive and
bevel gear and the horizontal drive shaft between bevel gear and on-load
tap-changer or de-energized tap-changer.

3.3.2 Design/versions
The drive shaft consists of a square tube and is coupled at each end by two
coupling brackets and one coupling bolt to the drive / driven shaft end of the
device to be connected.
Figure 12: Components of the drive shaft
1 Bevel gear 2 Hose clip

3 Telescopic protective tube 4 Coupling bracket
5 Square tube 6 Coupling bolt
7 Adapter ring 8 Protective cover
9 Hose clip

3.3.2.1 Drive shaft without cardan shafts, without insulator (= normal model)
Figure 13: Drive shaft without cardan shaft, without insulator (= normal model)
Configuration V 1 min Intermediate bearing

[mm] for [mm]
Middle of hand crank – middle 536 V 1 > 2,472
of bevel gear (maximum per-
missible axial offset 2°)
3.3.2.2 Drive shaft without cardan shafts, with insulator (= special model)
Figure 14: Drive shaft without cardan shaft, with insulator (= special model)

[mm] for [mm]
Middle of hand crank – middle 706 V 1 > 2472
missible axial offset 2°)

3.3.2.3 Drive shaft with cardan shafts, without insulator (= special model)
Figure 15: Drive shaft with cardan shaft, without insulator (= special model)

[mm] for [mm]
missible axial offset alpha =
20°)
3.3.2.4 Drive shaft with cardan shafts, with insulator (= special model)
Figure 16: Drive shaft with cardan shaft, with insulator (= special model)

[mm] for [mm]
missible axial offset alpha =
20°)

3.4 OF 100 Oil Filter Unit

Along with the paper filter insert, the purpose of the OF 100 oil filter unit is to
clean the on-load tap-changer's insulating oil and, with the combined filter in-
sert, to clean and dry it.
If the number of tap-change operations per year is 15,000 or higher, we rec-

ommend the use of the OF 100 oil filter unit with paper filter insert. The main-
tenance intervals can therefore be extended.
For more information, consult the MR operating instructions "OF 100 oil filter
unit".
You must use the OF 100 oil filter unit with combined filter insert for
OILTAP® R on-load tap-changers with operating voltage Ub from 245 kV and
voltage for equipment Um from 300 kV.

4 Packaging, transport and storage
4.1 Packaging
The products are sometimes supplied with a sealed packaging and some-
times also dried depending on what is required.
A sealed packaging surrounds the packaged goods on all sides with plastic
foil. Products that have also been dried are identified by a yellow label on the
sealed packaging.
The information in the following sections should be applied as appropriate.
4.1.1 Suitability
NOTICE Property damage due to incorrectly stacked crates!

Stacking the crates incorrectly can lead to damage to the packaged goods!
► Only stack up to 2 equally sized crates on top of one another.
► Do not stack crates above a height of 1.5 m.
The packaging is suitable for undamaged and fully functional means of

transportation in compliance with local transportation laws and regulations.
The packaged goods are packed in a stable crate. This crate ensures that
when in the intended transportation position the packaged goods are stabi-
lized to prevent impermissible changes in position, and that none of the parts
touch the loading surface of the means of transport or touch the ground after
unloading.
A sealed packaging surrounds the packaged goods on all sides with plastic
foil. The packaged goods are protected from humidity using a desiccant. The
plastic foil is bonded after the drying agent is added.
4.1.2 Markings
The packaging bears a signature with instructions for safe transport and cor-
rect storage. The following symbols apply to the shipment of non-hazardous
goods. Adherence to these symbols is mandatory.
Protect Top Fragile Attach lifting Center of

against gear here mass
moisture
Table 4: Shipping pictograms

4.2 Transportation, receipt and handling of shipments
WARNING Danger of death and damage to property!

Danger of death and damage to property due to tipping or falling load!
► Transport crate only when closed.
► Do not remove the mounting material used in the crate during transport.
► Only trained and appointed persons may select the sling gear and se-
cure the load.
► Do not walk under the hanging load.
► Use means of transport and lifting gear with a sufficient carrying capaci-
ty in accordance with the weight stated on the delivery slip.
In addition to oscillation stress and shock stress, jolts must also be expected
during transportation. In order to prevent possible damage, avoid dropping,
tipping, knocking over and colliding with the product.
If a crate tips over, falls from a certain height (e.g. when slings tear) or expe-
riences an unbroken fall, damage must be expected regardless of the
weight.
Every delivered shipment must be checked for the following by the recipient
before acceptance (acknowledgment of receipt):
▪ Completeness based on the delivery slip
▪ External damage of any type.
The checks must take place after unloading when the crate or transport con-
tainer can be accessed from all sides.
Visible damage If external transport damage is detected on receipt of the shipment, proceed
as follows:
▪ Immediately record the transport damage found in the shipping docu-
ments and have this countersigned by the carrier.
▪ In the event of severe damage, total loss or high damage costs, immedi-
ately notify the sales department at Maschinenfabrik Reinhausen and
the relevant insurance company.
▪ After identifying damage, do not modify the condition of the shipment
further and retain the packaging material until an inspection decision
has been made by the transport company or the insurance company.
▪ Record the details of the damage immediately onsite together with the
carrier involved. This is essential for any claim for damages!
▪ Photograph damage to packaging and packaged goods. This also ap-
plies to signs of corrosion on the packaged goods due to moisture inside
the packaging (rain, snow, condensation).
▪ NOTICE! Be absolutely sure to also check the sealed packaging. If the
sealed packaging is damaged, do not under any circumstances install or
commission the packaged goods. Either dry the dried packaged goods
again as per the operating instructions for the relevant on-load tap-

changer/de-energized tap-changer or contact Maschinenfabrik Reinhau-

sen GmbH to agree on how to proceed with drying. If this is not done,
the packaged goods may be damaged.
▪ Name the damaged parts.
Hidden damage When damages are not determined until unpacking after receipt of the ship-
ment (hidden damage), proceed as follows:
▪ Make the party responsible for the damage liable as soon as possible by
telephone and in writing, and prepare a damage report.
▪ Observe the time periods applicable to such actions in the respective
country. Inquire about these in good time.
With hidden damage, it is very hard to make the transportation company (or
other responsible party) liable. Any insurance claims for such damages can
only be successful if relevant provisions are expressly included in the insur-
ance terms and conditions.
4.3 Storage of shipments
Packaged goods dried by Maschinenfabrik Reinhausen
Upon receipt of the shipment, immediately remove the packaged goods

dried by Maschinenfabrik Reinhausen from the sealed packaging and store
air-tight in dry insulating oil until used if the packaged goods were not sup-
plied in oil.
Non-dried packaged goods
Non-dried packaged goods but with a functional sealed packaging can be

stored outdoors when the following conditions are complied with.
When selecting and setting up the storage location, ensure the following:
▪ Protect stored goods against moisture (flooding, water from melting
snow and ice), dirt, pests such as rats, mice, termites and so on, and
against unauthorized access.
▪ Store the crates on timber beams and planks as a protection against ris-
ing damp and for better ventilation.
▪ Ensure sufficient carrying capacity of the ground.
▪ Keep entrance paths free.
▪ Check stored goods at regular intervals. Also take appropriate action af-
ter storms, heavy rain or snow and so on.
Protect the packaging foil from direct sunlight so that it does not disintegrate
under the influence of UV rays, which would cause the packaging to lose its
sealing function.

If the product is installed more than 6 months after delivery, suitable meas-
ures must be taken without delay. The following measures can be used:
▪ Correctly regenerate the drying agent and restore the sealed packaging.
▪ Unpack the packed goods and store in suitable storage space (well ven-
tilated, as dust-free as possible, humidity < 50 % where possible).
4.4 Unpacking shipments and checking for transportation

damages
▪ NOTICE! Transport the packaged crate to the place where installation
will take place. Do not open the sealed packaging until just before instal-
lation. If this is not done, damage to the packaged goods may occur due
to ineffectively sealed packaging.
▪ WARNING! When unpacking, check the condition of the packaged
goods.Secure packaged goods in an upright crate from tipping out. If
this is not done, the packaged goods may be damaged and serious inju-
ries may result.
▪ Check completeness of supplementary parts on the basis of the delivery
slip.

5 Mounting
5 Mounting
WARNING Risk of crushing from moving parts!
When the on-load tap-changer undertakes a tap-change operation, compo-
nents move on the selector, change-over selector, and potential connection
unit, some of which are freely accessible. Reaching into the selector,
change-over selector or potential connection unit during a tap-change oper-
ation may result in serious injuries.
► Keep at a safe distance of at least 1 m during tap-change operations.
► Do not reach into the selector, change-over selector, or potential con-
nection unit during tap-change operations.
► Do not switch the on-load tap-changer when working on the selector,
change-over selector, or potential connection unit.
This chapter describes how to install the on-load tap-changer in a transform-

er and how to dry it, and also how to mount the protective devices and drive
components.
5.1 Preparatory work

Perform the work stated below before installing the on-load tap-changer in
the transformer.

5 Mounting
5.1.1 Fitting mounting flange on transformer cover

A mounting flange is required for fitting the on-load tap-changer head on the
transformer cover. This can be supplied as an option or can be produced by
the customer. Mounting flanges made by the customer must comply with the
installation drawings in the appendix.
► NOTICE! Fit mounting flange on transformer cover (pressure tight).En-
sure that the sealing face makes complete contact and is not damaged.
Figure 17: Mounting flange
5.1.2 Fitting stud bolts on mounting flange

To attach the stud bolts to the mounting flange, use a tracing template. This
can be provided upon request free of charge for the initial installation of the
on-load tap-changer.
1. Place tracing template on mounting flange and use the four markings to
align.

5 Mounting
2. Fit stud bolts on mounting flange.
Figure 18: Tracing template, stud bolts
5.2 Installing the standard version on-load tap-changer in the

transformer
Perform the work stated below in order to install the on-load tap-changer in
the transformer (standard version).
5.2.1 Fastening on-load tap-changer to transformer cover

This chapter describes how to fasten the on-load tap-changer to the trans-
former cover.
5.2.1.1 Fastening oil compartment on transformer cover

1. CAUTION! Place the oil compartment on a level surface and secure
it against tipping. An unstably positioned oil compartment may tip over,
resulting in severe injuries or property damage!

5 Mounting
2. Remove red-colored packaging material and transport material from on-

load tap-changer.
3. Clean sealing surfaces on mounting flange and on-load tap-changer
head, place oil-resistant gasket on mounting flange.
Figure 19: Sealing surfaces, oil-resistant gasket

5 Mounting
4. NOTICE! Lift the oil compartment by hooking up the on-load tap-chang-

er head and carefully lower it vertically into the opening of the transform-
er cover. If this is not done, damage to the oil compartment or the
shielding rings (if installed) may result.
Figure 20: Lowering oil compartment
5. Check that the on-load tap-changer head is mounted in the position

specified by the design.

5 Mounting
6. Screw on-load tap-changer head to mounting flange.
Figure 21: On-load tap-changer head with mounting flange
7. Remove the blocking strip from the coupling of the oil compartment
base.
5.2.1.2 Securing selector on oil compartment

1. CAUTION! Place the selector with transport pallet on a level surface
and secure it against tipping. An unstably positioned selector may tip,
resulting in severe injuries and property damage!

5 Mounting
2. Remove plastic bag with fastening materials from the selector and keep
them ready.
Figure 22: Plastic bag with fastening materials

5 Mounting
3. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.
Figure 23: Selector coupling with blocking strip
4. Place the selector on the lifting device. The weight of the selector is a
maximum of 420 kg.
5. NOTICE! Carefully lift the selector below the oil compartment, ensuring
that the tap-selector connecting leads and potential connection unit (if
installed) are free when lifting the selector on the oil compartment and
do not touch the compartment. If this is not done, the tap-selector con-
necting leads, potential connection unit or oil compartment may be dam-
aged.
6. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans supplied.

5 Mounting
7. Screw selector bracket onto oil compartment.
Figure 24: Screwing selector onto oil compartment

5 Mounting
8. Remove red supports on selector base (if present).
Figure 25: Disassembly of supports
Connecting tap-selector connecting leads
Proceed as follows to connect the tap-selector connecting leads:

1. NOTICE! Screw tap-selector connecting leads to connecting lug with
care. Comply with specified tightening torque and secure screw connec-
tion. Failure to do so may result in damage to the on-load tap-changer
and transformer.

5 Mounting
2. Close the screening caps and make sure they are seated correctly. The
screw head must be completely covered.
Figure 26: Tap-selector connecting leads
1 Hexagon screw 5 Connecting lug

2 Screening cap 6 Washer
3 Washer 7 Nut
4 Tap-selector connecting leads
Fastening potential connection unit to selector
If the selector is intended to be used with a potential connection unit, the po-
tential connection unit will either be pre-mounted on the selector at the facto-
ry or supplied separately in a crate, depending on the type series and height
of the selector.
If the potential connection unit is already mounted on the selector, continue

with "Fastening the potential connection unit to the oil compartment".
Otherwise fasten the potential connection unit to the selector first then fasten
the potential connection unit to the oil compartment.

5 Mounting
Proceed as follows to fasten the potential connection unit to the selector:

1. Lift the potential connection unit by the pre-mounted lifting straps and lift
it above the change-over selector.
Figure 27: Lifting potential connection unit

5 Mounting
2. Slowly lower the potential connection unit onto the pre-mounted carrier
on the change-over selector so that the studs on the carriers engage
with the openings on the potential connection unit and the drilled holes
in the carriers and potential connection unit line up.
Figure 28: Lowering potential connection unit
3. Carefully drive in the locking pins provided from the outside until they
are centrally seated.
Figure 29: Fastening potential connection unit

5 Mounting
4. Remove the lifting straps from the potential connection unit.
Figure 30: Removing lifting straps
5. Only for version without tie-in switch: Screw 3 or 6 potential connection

leads to the change-over selector. Attach screening caps in the process.
The fixing materials and screening caps are included in the delivery
scope.
Figure 31: Potential connection leads

5 Mounting
Fastening potential connection unit to oil compartment
You only have to fasten the potential connection unit to the oil compartment
if the potential connection unit has a mounting bracket.
► Screw the potential connection unit to the take-off ring of the oil com-
partment.
1 Nut 5 Spring washer

2 Washer 6 Screening cap
3 Spacing sleeve 7 Screw
4 Mounting bracket

5 Mounting
5.2.2 Connecting the tap winding and on-load tap-changer take-off

lead
NOTICE Damage to the on-load tap-changer!

Connecting leads which place mechanical strain on the on-load tap-changer
will damage the on-load tap-changer!
► Establish connections carefully.
► Do not twist connection contacts.
► Connect connecting leads without warping or deforming.
► If necessary, use an expansion loop for connecting leads.
► Fit screening caps provided to screw connections.
The tap winding and on-load tap-changer take-off lead must be connected in
accordance with the connection diagram included with the delivery.
5.2.2.1 Selector connection contacts

1. Fasten tap-winding connecting leads with cable shoes and M12 screws
as specified in the connection diagram provided (cable shoes and fas-
tening materials are not included in the delivery scope). The through-
holes of the connection contacts are horizontal as standard.
Figure 33: Selector connection contacts
2. Make sure that the tap-winding connecting leads are not exerting any
mechanical loads on the selector.

5 Mounting
3. Take suitable measures to ensure that each screw connection cannot

come loose or settle (e.g. use clamping washers). Attach the screening
caps as shown in the illustration.
Figure 34: Selector connection contact with screening caps
screw head and nut must be fully covered.
5.2.2.2 Change-over selector connection contacts for reversing change-over

selector connection

Tap-winding connecting leads situated too closely to the change-over selec-
tor's moving parts block the change-over selector and therefore result in on-
load tap-changer damage!
► Tap-winding connecting leads in the area of the change-over selector
have to be routed such that they are at a sufficient distance from the
change-over selector's moving parts.

5 Mounting
Figure 35: Change-over selector connection contacts for reversing change-over se-
lector connection
Figure 36: Route tap-winding connecting leads so they are a sufficient distance apart

5 Mounting
5.2.2.3 Change-over selector connection contacts for coarse tap selector

connection

Figure 37: Change-over selector connection contacts for coarse tap selector connec-
tion

5 Mounting

5 Mounting
5.2.2.4 Connecting the potential connection unit

► Connect leads to the angle connectors on the potential connection unit
using cable shoes and M8 screws as specified in the connection dia-
gram provided (cable shoes and fastening materials are not included in
the scope of delivery). Make sure that the leads are not exerting any
mechanical loads on the potential connection unit.
Figure 39: Angle connector of potential connection unit
1 Angle connector for connection at customer's premises
5.2.2.5 Connecting on-load tap-changer take-off lead
There are through-holes 12.5 mm in diameter at several points in the take-

off ring of the oil compartment for connecting the on-load tap-changer take-
off lead.
Proceed as follows to connect the on-load tap-changer take-off lead:

1. Connect the on-load tap-changer take-off lead to any through-hole on
the take-off ring using the cable shoe and screw. The cable shoe and
fastening materials are not included in the scope of delivery.

5 Mounting
2. Take suitable measures to ensure the screw connection cannot come

loose and settle (e.g. use clamping washers).
Figure 40: Take-off ring on oil compartment
5.2.3 Carrying out transformer ratio test before drying

To perform the transformer ratio test, proceed as follows:

5 Mounting
NOTICE Damage to property!

Damage to on-load tap-changer due to transformer ratio test being incor-
rectly performed!
► Do not perform more than 250 tap-change operations on the on-load
tap-changer. If more than 250 tap-change operations are performed,
completely fill oil compartment with insulating oil and lubricate sliding
surfaces of contacts on selector and selector gear with insulating oil.
► Only switch the on-load tap-changer from one operating position to the
next via the upper gear unit. You can use a short tube (diameter
25 mm) with screwed-in coupling bolt (diameter 12 mm) with a hand
wheel or crank for this. When using a drill, do not exceed a maximum
speed of 250 rpm.
► Always check the operating position reached through the inspection
window in the on-load tap-changer head cover. Never overshoot the
end positions, which are indicated in the connection diagram supplied
with the delivery.
► For multiple-column applications with a shared drive, link all on-load
tap-changer heads to one another with the horizontal drive shaft part.
1. Switch on-load tap-changer into the desired operating position. The

diverter switch operation can be heard distinctly.
When actuating the change-over selector a higher torque is required.
2. NOTICE! After operating the diverter switch, continue to crank 2.5 revo-
lutions in the same direction on the drive shaft of the upper gear unit in
order to correctly end the tap-change operation. An incomplete tap-
change operation may damage the on-load tap-changer!
3. Carry out the transformer ratio test.
4. Repeat the transformer ratio test in all operating positions.
5. Once the transformer ratio test is complete, return on-load tap-changer
to its adjustment position (see supplied connection diagram of the on-
load tap-changer).
After the transformer ratio test, open the kerosene drain plug in the oil com-
partment if the on-load tap-changer is to be dried with kerosene in the trans-
former tank. After drying, the diverter switch insert must be removed, the
kerosene drain plug in the oil compartment closed and the diverter switch
insert refitted.
5.2.4 Measuring DC resistance on transformer

Note the measurement scenarios listed below and the associated maximum
measurement currents when measuring DC resistance on the transformer.

5 Mounting
The measurement DC current is normally restricted to 10 % of the rated cur-

rent of the measured transformer winding in order to prevent the winding
from overheating.
Measure the DC resistance in the various on-load tap-changer operating po-

sitions. You need to distinguish here whether the measurement current is in-
terrupted when changing operating position or not.
Without interruption With interruption

in measurement cur- (measurement cur-
rent rent = 0 A before
change in operating
position)
Oil compartment emp- Maximum 10 A DC Maximum 50 A DC
ty
Oil compartment filled Maximum 50 A DC Maximum 50 A DC
with insulating oil
Table 5: Maximum permitted measurement currents when measuring DC resistance
on transformer
5.2.5 Drying on-load tap-changer in autoclave
NOTICE Property damage!

Damage to on-load tap-changer resulting from insufficient dielectric strength
of the mineral insulating oil caused by moisture in the oil compartment.
► Within 10 hours of drying, seal off oil compartment with on-load tap-
changer head cover.
Dry on-load tap-changer using the following instructions to ensure the dielec-
tric values assured by MR on the on-load tap-changer.
If drying in an autoclave, the following methods are possible:

▪ Vacuum-drying
▪ Vapor-phase drying
5.2.5.1 Vacuum-drying in the autoclave
To vacuum dry the on-load tap-changer in the autoclave, proceed as follows.
If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following drying"
[► 82].

5 Mounting
5.2.5.1.1 Moving on-load tap-changer to adjustment position

► Switching the on-load tap-changer into the adjustment position (see
supplied connection diagram of the on-load tap-changer).
Figure 41: Adjustment position
5.2.5.1.2 Removing on-load tap-changer head cover
WARNING Danger of explosion!

Danger of death from explosive gases under the on-load tap-changer head
cover!
► Ensure that there are no open flames, hot surfaces or sparks (for exam-
ple caused by static charging) in the immediate surroundings and that
none arise.
► De-energize all auxiliary circuits (for example tap-change supervisory
devices, pressure relief devices, pressure monitoring devices) before
removing the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (for example risk
of sparks caused by impact wrench).
► Only use conductive and grounded hoses, pipes, and pump equipment
that are approved for flammable liquids.
NOTICE Damage to the on-load tap-changer and transformer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer and transformer!
► Take care to avoid parts falling into the oil compartment.
► Check that you have the same number of small parts when disassem-
bling and reassembling.
1. Make sure that inspection window is sealed off with cover.

5 Mounting
2. Loosen screws on the on-load tap-changer head cover.
Figure 42: On-load tap-changer head cover
3. NOTICE! Remove the on-load tap-changer head cover. Check that

sealing surfaces on on-load tap-changer head cover and on-load tap-
changer head are in sound condition when removing and during all oth-
er work. Ensure that o-ring is in sound condition too. Damaged sealing
surfaces lead to oil escaping and therefore to on-load tap-changer and
transformer damage.
5.2.5.1.3 Drying the on-load tap-changer

Damage to the accessories of the on-load tap-changer due to drying of ac-
cessories in the autoclave.
► Keep the following accessories outside the autoclave and never dry
them with the on-load tap-changer: motor-drive unit, drive shaft, protec-
tive relay, pressure monitoring device, pressure relief device, bevel
gear, temperature sensor, oil filter unit.
1. Heat up the on-load tap-changer in air at atmospheric pressure with a

temperature increase of about 10 °C/h to a final temperature of maxi-
mum 110 °C.

5 Mounting
2. Pre-dry the on-load tap-changer in circulating air at a max. temperature

of 110 °C for a period of 20 hours.
3. Vacuum dry on-load tap-changer at between 105 °C and maximum 125
°C for at least 50 hours.
4. Residual pressure of no more than 10-3 bar.
5.2.5.1.4 Securing on-load tap-changer head cover

1. NOTICE! Place on-load tap-changer head cover on on-load tap-chang-
er head and take care not to damage the o-ring inserted in the on-load
tap-changer head cover. A damaged o-ring leads to oil escaping and
therefore to damage of the on-load tap-changer. Also ensure that the
red triangular marks on the on-load tap-changer head and the on-load
tap-changer head cover match up.
Figure 44: On-load tap-changer head cover with o-ring
2. Screw on-load tap-changer head cover using screws and washers.
5.2.5.2 Vapor-phase drying in the autoclave
To dry the on-load tap-changer with kerosene in the autoclave, proceed as

follows.

5 Mounting
[► 82].


cover!
none arise.


5 Mounting

transformer damage.

5 Mounting
5.2.5.2.3 Opening kerosene drain plug

► NOTICE! Unscrew kerosene drain plug between oil compartment base
and selector gear clockwise until it starts to offer resistance to turning.
Never unscrew the kerosene drain plug all the way.
Kerosene drain plug

1. Supply kerosene vapor at a temperature of around 90 °C. Keep this

temperature constant for 3 to 4 hours.
2. Increase the kerosene vapor temperature by approx. 10 °C/hour to the
desired final temperature of max. 125 °C at the on-load tap-changer.
5.2.5.2.5 Closing kerosene drain plug

► NOTICE! Close kerosene drain plug (tightening torque 20 Nm). An
open kerosene drain plug leads to oil escaping from the oil compartment
and therefore to damage to the on-load tap-changer and transformer.

5 Mounting

5.2.6 Drying on-load tap-changer in transformer tank

changer head cover.

5 Mounting
If you want to dry the on-load tap-changer in the transformer tank, first com-
plete transformer assembly and then undertake drying.
If drying in the transformer tank, the following methods are possible:

▪ Vacuum-drying
5.2.6.1 Vacuum-drying in the transformer tank
To vacuum dry the on-load tap-changer in the transformer tank, proceed as

follows.
The on-load tap-changer head cover remains closed during the entire drying
process.
1. Establish a connecting lead either between connections E2 and Q or

connections E2 and R on the on-load tap-changer head.
2. Seal off unused pipe connections with a suitable blank cover.
Figure 51: Connecting lead
Vacuum-drying in the transformer tank

mum 110 °C.
[► 82].

5 Mounting
5.2.6.2 Vapor-phase drying in the transformer tank
If you have not opened the kerosene drain plug in advance (e.g. after the
transformer ratio test), you have to open the kerosene drain plug before dry-
ing the kerosene in the transformer tank so that the kerosene condensate
can drain from the oil compartment.
The kerosene drain plug is located in the oil compartment base and is not
generally accessible from the outside. For this reason, you first have to re-
move the diverter switch insert, open the kerosene drain plug, and then in-
stall the diverter switch insert again. After the drying process, you have to re-
move the diverter switch insert again to close the kerosene drain plug.
5.2.6.2.1 Removing diverter switch insert
Proceed as follows to remove the diverter switch insert.
5.2.6.2.1.1 Moving on-load tap-changer to adjustment position


5 Mounting
5.2.6.2.1.2 Removing on-load tap-changer head cover

cover!
none arise.




5 Mounting

transformer damage.
5.2.6.2.1.3 Removing tap position indicator disk

► Pull the spring clip off the shaft end and remove the tap position indica-
tor disk.
Figure 55: Tap position indicator disk
5.2.6.2.1.4 Disconnecting the plug connector of the tap-change supervisory

control
WARNING Danger of death or severe injury!

Danger of death or severe injury from explosive gases under the on-load
tap-changer head cover!
► Ensure that there is no supply voltage on the tap-change supervisory
control.

5 Mounting
NOTICE Damage to on-load tap-changer resulting from defective tap-

change supervisory control!
Disconnecting the tap-change supervisory control without due care may
damage it, thereby resulting in damage to the on-load tap-changer and
transformer!
► Disconnect tap-change supervisory control with care in order not to
damage or rip out the connecting leads.
1. Lift plug connector and leads out of bracket and retaining clamps.
Figure 56: Lifting out plug connector
2. Disconnect the plug connector.
Figure 57: Disconnecting plug connector
3. Put part B of plug connector back in bracket.
Figure 58: Placing part B of plug connector in bracket

5 Mounting
4. Swivel part A of plug connector out of on-load tap-changer head in di-

rection indicated by arrow until it is between the pipe connections and
the cable cannot be damaged when pulling out the diverter switch insert.
Figure 59: Swiveling out part A of plug connector
5.2.6.2.1.5 Lifting out diverter switch insert

1. Loosen bolts and safety elements on carrier plate of diverter switch in-
sert.
NOTICE! Make sure that parts do not fall into the oil compartment.
Parts in the oil compartment may block the diverter switch insert, there-
by damaging the on-load tap-changer and transformer. Check that you
have the same number of parts when disassembling and reassembling.
Figure 60: Carrier plate of diverter switch insert

5 Mounting
2. Insert the lifting gear in the brackets provided on the diverter switch in-
sert carrier plate and position vertically above the diverter switch insert.
Figure 61: Brackets on carrier plate
3. Lift out the diverter switch insert slowly and vertically.
Figure 62: Lifting out diverter switch insert
4. CAUTION! Place the diverter switch insert on a level surface and se-
cure it against tipping. An unstably positioned diverter switch insert may
tip, resulting in injuries and damage.

5 Mounting

► NOTICE! Unscrew kerosene drain plug with extended socket wrench
counter-clockwise until it starts to get hard to turn.Never unscrew the
kerosene drain plug all the way.
Figure 63: Kerosene drain plug
5.2.6.2.3 Inserting diverter switch insert
Proceed as follows to insert the diverter switch insert.
5.2.6.2.3.1 Inserting diverter switch insert

1. To fit the diverter switch insert, ensure that the selector coupling and in-
dicator gear are in the adjustment position.

5 Mounting
3. Ensure that the red triangles on the coupling and carrier plate match up.
Figure 66: Coupling

5 Mounting
4. Align diverter switch insert such that the red triangles at the top of the
energy accumulator and on the on-load tap-changer head are opposite
one another.
Figure 67: Aligning diverter switch insert
5. Slowly lower diverter switch insert.

6. Secure carrier plate of diverter switch insert with bolts and safety ele-
ments.
Carrier plate of diverter switch insert

5 Mounting
5.2.6.2.3.2 Connecting plug connector of the tap-change supervisory device

1. Lift part B of plug connector out of bracket.
Figure 68: Part B of plug connector
2. Connecting plug connector
Figure 69: Connecting plug connector
3. Place plug connector in bracket, secure leads on both sides of plug con-
nector in retaining clamps.
Figure 70: Placing plug connector in bracket
5.2.6.2.3.3 Inserting tap position indicator disk
Due to the coupling pin, the tap position indicator disk can only be installed
when in the correct position.

5 Mounting
► Place tap position indicator disk on indicator drive shaft, slide spring clip
on to shaft end.
5.2.6.2.3.4 Securing on-load tap-changer head cover


5 Mounting

1. Connect pipe connections R and Q of on-load tap-changer head to the
kerosene vapor lead using one shared lead.
Figure 74: Shared lead
Vapor-phase drying in the transformer tank


1. Removing [► 70] the diverter switch insert.
2. Close kerosene drain plug with extended socket wrench by turning
clockwise (tightening torque 20 Nm).
3. Inserting [► 76] the diverter switch insert.

5 Mounting
[► 82].
5.2.7 Carrying out transformer ratio test after drying

rectly performed!
► Make sure that the selector/de-energized tap changer is fully immersed
in transformer oil and that the oil compartment of the on-load tap-
changer is completely filled with oil.
► The on-load tap-changer/de-energized tap-changer can be operated in
the temperature range of the surrounding transformer oil of between –
25 °C and +105 °C and in accordance with IEC 60214-1 up to +115 °C
(during emergency transformer operation in accordance with IEC
60076-7).
speed of 250 rpm.
with the delivery.


5 Mounting

load tap-changer).
5.3 Installing on-load tap-changer in transformer (bell-type

tank version)
The following chapters explain how to install the on-load tap-changer in the
transformer.
5.3.1 Inserting on-load tap-changer into supporting structure

Proceed as follows to insert the on-load tap-changer in the supporting struc-
ture:
5.3.1.1 Securing selector on oil compartment

1. CAUTION! Place the selector with transport pallet on a level surface
and secure it against tipping. An unstably positioned selector may tip,
resulting in severe injuries and property damage!
2. Remove plastic bag with fastening materials from the selector and keep
them ready.
Figure 75: Plastic bag with fastening materials

5 Mounting
3. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling must no longer be turned.
Figure 76: Selector coupling with blocking strip
4. CAUTION! Place the oil compartment on a level surface and secure

it against tipping. An unstably positioned oil compartment may tip over,
resulting in severe injuries or property damage!
5. Prior to installation, remove the red-colored packaging and transport
material from the on-load tap-changer.
6. Remove the blocking strip from the coupling of the oil compartment
base.
7. Lift the oil compartment by hooking up the on-load tap-changer head
and carefully raise above selector. The weight of the oil compartment is
a maximum of 295 kg.
8. NOTICE! Carefully lower the oil compartment vertically, ensuring that
the tap-selector connecting leads and potential connection unit (if instal-
led) are free when lowering the oil compartment and do not touch the
compartment. If this is not done, the tap-selector connecting leads, po-
tential connection unit or oil compartment may be damaged.
9. Align the position of both coupling parts and attachment points on the oil
compartment and the selector with one another. The correct position of
the two coupling parts is shown in the adjustment plans supplied.

5 Mounting
10. Screw selector bracket onto oil compartment.
Figure 77: Screwing selector onto oil compartment

5 Mounting
Figure 78: Disassembly of supports
Connecting tap-selector connecting leads
Proceed as follows to connect the tap-selector connecting leads:

1. NOTICE! Screw tap-selector connecting leads to connecting lug with
care. Comply with specified tightening torque and secure screw connec-
tion. Failure to do so may result in damage to the on-load tap-changer
and transformer.

5 Mounting
screw head must be completely covered.
Figure 79: Tap-selector connecting leads
1 Hexagon screw 5 Connecting lug

2 Screening cap 6 Washer
3 Washer 7 Nut
4 Tap-selector connecting leads
Fastening potential connection unit to selector
If the selector is intended to be used with a potential connection unit, the po-
tential connection unit will either be pre-mounted on the selector at the facto-
ry or supplied separately in a crate, depending on the type series and height
of the selector.
If the potential connection unit is already mounted on the selector, continue

with "Fastening the potential connection unit to the oil compartment".
Otherwise fasten the potential connection unit to the selector first then fasten
the potential connection unit to the oil compartment.

5 Mounting
Proceed as follows to fasten the potential connection unit to the selector:

1. Lift the potential connection unit by the pre-mounted lifting straps and lift
it above the change-over selector.
Figure 80: Lifting potential connection unit

5 Mounting
2. Slowly lower the potential connection unit onto the pre-mounted carrier
on the change-over selector so that the studs on the carriers engage
with the openings on the potential connection unit and the drilled holes
in the carriers and potential connection unit line up.
Figure 81: Lowering potential connection unit
3. Carefully drive in the locking pins provided from the outside until they
are centrally seated.

5 Mounting
4. Remove the lifting straps from the potential connection unit.
Figure 83: Removing lifting straps
5. Only for version without tie-in switch: Screw 3 or 6 potential connection

leads to the change-over selector. Attach screening caps in the process.
The fixing materials and screening caps are included in the delivery
scope.
Figure 84: Potential connection leads

5 Mounting
Fastening potential connection unit to oil compartment
You only have to fasten the potential connection unit to the oil compartment
if the potential connection unit has a mounting bracket.
► Screw the potential connection unit to the take-off ring of the oil com-
partment.
1 Nut 5 Spring washer

2 Washer 6 Screening cap
3 Spacing sleeve 7 Screw
4 Mounting bracket
5.3.1.2 Inserting on-load tap-changer into supporting structure

1. NOTICE! Using spacers, insert on-load tap-changer vertically into sup-
porting structure (maximum 1° deviation from the vertical) so that the
on-load tap-changer reaches its final installation height and only has to
be raised a maximum of 5 to 20 mm after fitting the bell-type tank. If this
is not done, once the tap winding and on-load tap-changer take-off lead

5 Mounting
are connected tension may occur which will damage the on-load tap-
changer and transformer. There is also a risk of malfunctions from se-
lector contacts closing incorrectly.
Figure 86: On-load tap-changer with spacers on supporting structure

5 Mounting
3. Temporarily fasten on-load tap-changer to supporting structure. The

supporting flange has through holes for this purpose.
Figure 87: Fastening the on-load tap-changer
5.3.2 Connecting the tap winding and on-load tap-changer take-off

lead

Connecting leads which place mechanical strain on the on-load tap-changer
will damage the on-load tap-changer!
► Establish connections carefully.
► Do not twist connection contacts.
► Connect connecting leads without warping or deforming.
► If necessary, use an expansion loop for connecting leads.
► Fit screening caps provided to screw connections.
The tap winding and on-load tap-changer take-off lead must be connected in
accordance with the connection diagram included with the delivery.

5 Mounting
5.3.2.1 Selector connection contacts

1. Fasten tap-winding connecting leads with cable shoes and M12 screws
as specified in the connection diagram provided (cable shoes and fas-
tening materials are not included in the delivery scope). The through-
holes of the connection contacts are horizontal as standard.
Figure 88: Selector connection contacts
2. Make sure that the tap-winding connecting leads are not exerting any
mechanical loads on the selector.

5 Mounting
3. Take suitable measures to ensure that each screw connection cannot

come loose or settle (e.g. use clamping washers). Attach the screening
caps as shown in the illustration.
Figure 89: Selector connection contact with screening caps
screw head and nut must be fully covered.
5.3.2.2 Change-over selector connection contacts for reversing change-over

selector connection


5 Mounting
Figure 90: Change-over selector connection contacts for reversing change-over se-
lector connection

5 Mounting
5.3.2.3 Change-over selector connection contacts for coarse tap selector

connection

Figure 92: Change-over selector connection contacts for coarse tap selector connec-
tion

5 Mounting

5 Mounting
5.3.2.4 Connecting the potential connection unit

► Connect leads to the angle connectors on the potential connection unit
using cable shoes and M8 screws as specified in the connection dia-
gram provided (cable shoes and fastening materials are not included in
the scope of delivery). Make sure that the leads are not exerting any
mechanical loads on the potential connection unit.
Figure 94: Angle connector of potential connection unit
1 Angle connector for connection at customer's premises
5.3.2.5 Connecting on-load tap-changer take-off lead
There are through-holes 12.5 mm in diameter at several points in the take-

off ring of the oil compartment for connecting the on-load tap-changer take-
off lead.
Proceed as follows to connect the on-load tap-changer take-off lead:

1. Connect the on-load tap-changer take-off lead to any through-hole on
the take-off ring using the cable shoe and screw. The cable shoe and
fastening materials are not included in the scope of delivery.

5 Mounting
2. Take suitable measures to ensure the screw connection cannot come

loose and settle (e.g. use clamping washers).
Figure 95: Take-off ring on oil compartment
5.3.3 Carrying out transformer ratio test before drying


5 Mounting

rectly performed!
► Do not perform more than 250 tap-change operations on the on-load
tap-changer. If more than 250 tap-change operations are performed,
completely fill oil compartment with insulating oil and lubricate sliding
surfaces of contacts on selector and selector gear with insulating oil.
speed of 250 rpm.
with the delivery.

load tap-changer).
After the transformer ratio test, open the kerosene drain plug in the oil com-
partment if the on-load tap-changer is to be dried with kerosene in the trans-
former tank. After drying, the diverter switch insert must be removed, the
kerosene drain plug in the oil compartment closed and the diverter switch
insert refitted.
5.3.4 Measuring DC resistance on transformer

Note the measurement scenarios listed below and the associated maximum
measurement currents when measuring DC resistance on the transformer.

5 Mounting
The measurement DC current is normally restricted to 10 % of the rated cur-

rent of the measured transformer winding in order to prevent the winding
from overheating.
Measure the DC resistance in the various on-load tap-changer operating po-

sitions. You need to distinguish here whether the measurement current is in-
terrupted when changing operating position or not.
Without interruption With interruption

in measurement cur- (measurement cur-
rent rent = 0 A before
change in operating
position)
Oil compartment emp- Maximum 10 A DC Maximum 50 A DC
ty
Oil compartment filled Maximum 50 A DC Maximum 50 A DC
with insulating oil
Table 6: Maximum permitted measurement currents when measuring DC resistance
on transformer
5.3.5 Drying on-load tap-changer in autoclave

changer head cover.
If drying in an autoclave, the following methods are possible:

▪ Vacuum-drying
5.3.5.1 Vacuum-drying in the autoclave
To vacuum dry the on-load tap-changer in the autoclave, proceed as follows.
[► 141].

5 Mounting


cover!
none arise.


5 Mounting

transformer damage.


mum 110 °C.

5 Mounting


5.3.5.2 Vapor-phase drying in the autoclave
To dry the on-load tap-changer with kerosene in the autoclave, proceed as

follows.

5 Mounting
[► 141].


cover!
none arise.


5 Mounting

transformer damage.

5 Mounting

► NOTICE! Unscrew kerosene drain plug between oil compartment base
and selector gear clockwise until it starts to offer resistance to turning.
Never unscrew the kerosene drain plug all the way.
Kerosene drain plug



► NOTICE! Close kerosene drain plug (tightening torque 20 Nm). An
open kerosene drain plug leads to oil escaping from the oil compartment
and therefore to damage to the on-load tap-changer and transformer.

5 Mounting

5.3.6 Lifting top part of on-load tap-changer head off supporting

flange (bottom part)

5 Mounting
5.3.6.1 Removing on-load tap-changer head cover

cover!
none arise.


2. Remove temporary fastening and spacers and slowly lower on-load tap-
changer.
Figure 106: Removing fastening

5 Mounting

transformer damage.

5 Mounting
5.3.6.2 Removing tap position indicator disk

tor disk.
5.3.6.3 Disconnecting the plug connector of the tap-change supervisory

control

control.

transformer!

5 Mounting

5.3.6.4 Lifting out diverter switch insert

1. Loosen nuts and safety elements on carrier plate of diverter switch in-
sert.

5 Mounting
have the same number of parts when removing and installing.

5 Mounting
5.3.6.5 Removing the oil suction pipe

► Pull the connecting piece of the oil suction pipe in the on-load tap-
changer head inwards and out. Pay attention to the O-ring.
Figure 117: Oil suction pipe

5 Mounting
5.3.6.6 Lifting top part of on-load tap-changer head off supporting flange
1. Remove nuts and locking elements between top part of on-load tap-
changer head and supporting flange.
Figure 118: Top part of on-load tap-changer head with nuts
2. Lift top part of on-load tap-changer head off supporting flange.
Figure 119: Top part of on-load tap-changer head
5.3.7 Fit the bell-type tank and connect the on-load tap-changer to the
top part of the on-load tap-changer head
The following chapters explain how to connect the on-load tap-changer to
the upper part of the on-load tap-changer head once the bell-type tank has
been fitted.

5 Mounting
5.3.7.1 Mounting the bell-type tank

1. Clean sealing surface of supporting flange, place o-ring on supporting
flange.
Figure 120: Supporting flange with o-ring
2. Lift the bell-type tank over the active part of the transformer.
Figure 121: Bell-type tank

5 Mounting
5.3.7.2 Positioning top part of on-load tap-changer head on bell-type tank

1. Clean sealing surfaces on mounting flange and top part of on-load tap-
changer head, place oil-resistant gasket on mounting flange.
Figure 122: Mounting flange with gasket
1 Gasket 2 Mounting flange

5 Mounting
2. Position top part of on-load tap-changer head on mounting flange so

that the markings on the top part and bottom part of the on-load tap-
changer head match up. Pay attention to fitted bolt in bottom part.
Figure 123: Markings and fitted bolt

5 Mounting
5.3.7.3 Connecting on-load tap-changer to top part of on-load tap-changer

head
1. NOTICE! Always lift the on-load tap-changer using the specified lifting
traverse. If the connection screws from the supporting flange are used
to lift the on-load tap-changer, the screws may be damaged, which
makes it impossible to properly screw the on-load tap-changer and the
top part of the on-load tap-changer head together!
Figure 124: On-load tap-changer head
2. Screw top part of on-load tap-changer head to underlying supporting

flange in the area marked red using nuts and locking elements.
Figure 125: On-load tap-changer head
3. Remove lifting traverse.

5 Mounting
4. Screw on-load tap-changer head to mounting flange.
Figure 126: Screwing on-load tap-changer head to mounting flange
5.3.7.4 Inserting oil suction pipe

1. Lightly grease the O-rings of the oil suction pipe.
2. Insert the oil suction pipe into the on-load tap-changer head. Make sure
the O-rings are correctly fitted.
Figure 127: Oil suction pipe

5 Mounting
5.3.7.5 Inserting diverter switch insert


5 Mounting
Figure 130: Coupling

5 Mounting
one another.

6. Ensure correct position of carrier plate in on-load tap-changer head.
Area marked red must remain free.
7. Secure carrier plate of diverter switch insert with nuts and safety ele-
ments.

5 Mounting
5.3.7.6 Connecting plug connector of the tap-change supervisory device

5.3.7.7 Inserting tap position indicator disk

5 Mounting
on to shaft end.
5.3.7.8 Securing on-load tap-changer head cover


5 Mounting
5.3.8 Drying on-load tap-changer in transformer tank

changer head cover.
If you want to dry the on-load tap-changer in the transformer tank, first com-
plete transformer assembly and then undertake drying.
If drying in the transformer tank, the following methods are possible:

▪ Vacuum-drying
5.3.8.1 Vacuum-drying in the transformer tank
To vacuum dry the on-load tap-changer in the transformer tank, proceed as

follows.
The on-load tap-changer head cover remains closed during the entire drying
process.
1. Establish a connecting lead either between connections E2 and Q or

connections E2 and R on the on-load tap-changer head.

5 Mounting
Vacuum-drying in the transformer tank

mum 110 °C.
[► 141].
5.3.8.2 Vapor-phase drying in the transformer tank
If you have not opened the kerosene drain plug in advance (e.g. after the
transformer ratio test), you have to open the kerosene drain plug before dry-
ing the kerosene in the transformer tank so that the kerosene condensate
can drain from the oil compartment.
The kerosene drain plug is located in the oil compartment base and is not
generally accessible from the outside. For this reason, you first have to re-
move the diverter switch insert, open the kerosene drain plug, and then in-
stall the diverter switch insert again. After the drying process, you have to re-
move the diverter switch insert again to close the kerosene drain plug.
5.3.8.2.1 Removing diverter switch insert
Proceed as follows to remove the diverter switch insert.

5 Mounting
5.3.8.2.1.1 Moving on-load tap-changer to adjustment position

5.3.8.2.1.2 Removing on-load tap-changer head cover

cover!
none arise.


5 Mounting

transformer damage.

5 Mounting
5.3.8.2.1.3 Removing tap position indicator disk

tor disk.
5.3.8.2.1.4 Disconnecting the plug connector of the tap-change supervisory

control

control.

transformer!

5 Mounting

5.3.8.2.1.5 Lifting out diverter switch insert

1. Loosen nuts and safety elements on carrier plate of diverter switch in-
sert.

5 Mounting
have the same number of parts when removing and installing.

5 Mounting

► NOTICE! Unscrew kerosene drain plug with extended socket wrench
counter-clockwise until it starts to get hard to turn.Never unscrew the
kerosene drain plug all the way.
Figure 151: Kerosene drain plug
5.3.8.2.3 Inserting diverter switch insert
Proceed as follows to insert the diverter switch insert.

5 Mounting
5.3.8.2.3.1 Inserting diverter switch insert


5 Mounting
Figure 154: Coupling

5 Mounting
one another.

6. Ensure correct position of carrier plate in on-load tap-changer head.
Area marked red must remain free.
7. Secure carrier plate of diverter switch insert with nuts and safety ele-
ments.

5 Mounting
5.3.8.2.3.2 Connecting plug connector of the tap-change supervisory device

5.3.8.2.3.3 Inserting tap position indicator disk

5 Mounting
on to shaft end.
5.3.8.2.3.4 Securing on-load tap-changer head cover


5 Mounting

1. Connect pipe connections R and Q of on-load tap-changer head to the
kerosene vapor lead using one shared lead.
Figure 163: Shared lead
Vapor-phase drying in the transformer tank


1. Removing [► 128] the diverter switch insert.
2. Close kerosene drain plug with extended socket wrench by turning
clockwise (tightening torque 20 Nm).
3. Inserting [► 134] the diverter switch insert.

5 Mounting
[► 141].
5.3.9 Carrying out transformer ratio test after drying

rectly performed!
60076-7).
speed of 250 rpm.
with the delivery.


5 Mounting

load tap-changer).
5.4 Filling the oil compartment of the on-load tap-changer with

oil
After drying, completely fill the oil compartment (diverter switch insert fitted)
with oil again as soon as possible so that an impermissible amount of humid-
ity is not absorbed from the surroundings.
When filling the oil compartment and its oil conservator, use only new miner-
al insulating oil for transformers in accordance with IEC 60296 (Specification
for unused mineral insulating oils for transformers and switchgear).
1. Establish a connecting lead between the pipe connection E2 and one of
the pipe connections R, S or Q to ensure equal pressure during evacua-
tion in the oil compartment and transformer.
Figure 164: Connecting lead between E2 and Q.

5 Mounting
2. Fill on-load tap-changer with oil using one of the remaining pipe connec-
tions of the on-load tap-changer head.
Figure 165: Pipe connection S and R
5.5 Fitting protective devices and drive components
5.5.1 Connecting the tap-change supervisory device
DANGER Risk of fatal injury due to electrical voltage!

Danger of death due to electrical voltage when assembling and connecting
the device.
► De-energize the device and system peripherals and lock them to pre-
vent them from being switched back on.
► Connect monitoring contacts integrated into the on-load tap-changer

head (terminal box on pipe connection Q) to the motor-drive unit termi-
nals as specified in the connection diagram provided.

5 Mounting
5.5.2 Installing protective relay in piping and connecting

Danger of death or severe injury from explosive gases in the protective re-
lay, which accumulate during on-load tap-changer operation!
► Wait 15 minutes after switching off the transformer before you begin
further work on the protective relay so that the gases have a chance to
volatize.
► Ensure that there are no naked flames, hot surfaces or sparks (for ex-
ample caused by static charging) in the immediate surroundings and
that none occur.
► De-energize all auxiliary circuits before starting the work.
Always perform all transformer tests with the protective relay attached and
connected.

5 Mounting
5.5.2.1 Checking function of protective relay
Check the function of the protective relay before installing it in piping be-
tween on-load tap-changer head and oil conservator.
1. Open terminal box.
Figure 166: Protective relay with open terminal box

5 Mounting
NOTICE Damage to protective relay!

Damage to protective relay resulting from improper operation!
► Never press both test buttons at the same time.
2. Press OFF test button.

ð Flap valve is inclined. Line marker appears in the middle of the in-
spection window.
Figure 167: OFF position
3. Press OPERATION test button.

ð Flap valve is vertical.

5 Mounting
Figure 168: In service position

5 Mounting
4. Close terminal box.
Figure 169: Terminal box cover
The associated contact positions for checking electrical continuity are shown
in the dimensional drawing provided.

5 Mounting
5.5.2.2 Installing protective relay in piping
The following requirements must be satisfied in order to install the protective

relay in the piping:
▪ The pipes from the protective relay to the oil conservator must be routed
with an inclination of at least 2% to ensure the switching gases can es-
cape freely.
▪ The inner piping diameter must be at least 25 mm.
▪ The magnetic field strength (bushings, busbars etc.) must be < 20 kA/m.
▪ Install protective relay with good support and free from vibrations.
▪ The test buttons must be at the top.
▪ The reference arrow on the terminal box cover must point toward the
on-load tap-changer's oil conservator.
▪ Install protective relay such that it can be easily accessed for subse-
quent maintenance work.
Figure 170: Piping with inclination of at least 2 %

5 Mounting
Figure 171: Protective relay with test button at the top

5 Mounting
Figure 172: Reference arrow pointing towards the on-load tap-changer's oil conser-
vator
1. Install the protective relay horizontally in the pipe between on-load tap-
changer head and oil conservator as near as possible to the on-load
tap-changer head taking the above points into consideration.

5 Mounting
2. Provide a stop-cock (nominal width of at least 25 mm) between protec-

tive relay and oil conservator.
Figure 173: Stop-cock

5 Mounting
5.5.2.3 Installing electrics for protective relay
The protective relay's dry-reed magnetic switching tubes are supplied in the
standard version as either NC or NO contacts. Other contact equipment can
be supplied as special versions and is shown in the dimensional drawing
provided.
1. Insert cable connection (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5,
2001/R) or adapter (RS 2003 und RS 2004) in the tapped hole with the
most favorable position.
Figure 174: Cable bushing
2. Seal open tapped hole with MR dummy plug.
Figure 175: Dummy plug

5 Mounting
3. Open terminal box.
Figure 176: Terminal box

5 Mounting
4. Loosen screw, remove terminal box cover, and take off protective cover.
Figure 177: Terminal box cover and protective cover

5 Mounting
5. Guide cable through cable gland and into protective relay. Ensure that
the cable gland is well connected and sealed.
Figure 178: Cable bushing
WARNING Risk of death or severe injury!

Risk of death or severe injury due to improper electrical connection of pro-
tective relay.
► Connect the protective relay into the tripping circuit of the circuit break-
ers of the transformer to be protected so that the transformer is immedi-
ately de-energized by the circuit breakers when the protective relay is
tripped.
► Systems which only generate an alarm message are not permitted.

5 Mounting
6. Connect electric cables to connection terminals.
Figure 179: Electrical cables

5 Mounting
7. Connect protective conductor to cylinder head screw.
Figure 180: Protective conductor

5 Mounting
8. Insert protective cover.
Figure 181: Protective cover

5 Mounting
9. Secure terminal box cover.

5 Mounting
10. Close terminal box.

5 Mounting
5.5.3 Installing and connecting the pressure-operated relay
5.5.3.1 Checking the function of the pressure-operated relay
Check the function of the pressure-operated relay before you install it on a

pipe bend or the on-load tap-changer head.
1. Remove the cover cap.
2. Activate the snap-action switch.
ð Sensor is in the OFF position above the snap-action switch.
Figure 184: OFF position
1 Snap-action switch
2 Sensor in OFF position
3. Activate the snap-action switch again.
ð Sensor is in the OPERATION position below the snap-action
switch.

5 Mounting
Figure 185: OPERATION position
1 Snap-action switch
2 Sensor in the OPERATION position
4. Secure the cover cap.
Always check the position of the sensor!
5.5.3.2 Installing the pressure-operated relay
The pressure-operated relay can be installed in 2 variants.

▪ Fastening on the on-load tap-changer head (vertical installation)
▪ Fastening onto a pipe bend (horizontal installation)
It is installed using holes on the mounting ring. A mounting seal has to be

installed under the pressure-operated relay during installation.
During fastening, ensure that the ventilation is on top.
Ensure that there is sufficient space above the pressure-operated relay to

remove the cover cap.
5.5.3.3 Making the electrical connections for the pressure-operated relay

5 Mounting
DANGER Risk of fatal injury due to electrical voltage!

Danger of death due to electrical voltage when assembling and connecting
the device.
► De-energize the device and system peripherals and lock them to pre-
vent them from being switched back on.
WARNING Risk of severe injury or death!

Risk of severe injury or death from improperly making the electrical connec-
tions for the pressure-operated relay.
► Loop the pressure-operated relay into the trip circuit for the circuit
breaker of the transformer to be protected such that the circuit breaker
de-energizes the transformer immediately when the pressure-operated
relay is tripped.
► Circuits where only an alarm message is generated are not permitted.

2. Insert a M25x1.5 cable gland.
Use the tapped hole for routing lines for this.
3. Connect the lines to the terminals of the snap-action switch.
The snap-action switch is designed as a normally open and normally
closed switch; it flips after being triggered and can be reset.
4. Connect all of the electrical lines and the protective conductor.
Either 1 or 2 lines can be connected per terminal for the line connection
(Ø 0.75…2.5 mm²).
6. Ensure the fixing screw is positioned correctly, see Appendix.
5.5.4 Fitting motor-drive unit

► Fit motor-drive unit to transformer as described in relevant MR operating
instructions for motor-drive unit.
5.5.5 Fitting drive shaft

Observe the following during mounting:
NOTICE Damage to drive and on-load tap-changer or de-energized tap-

changer!
Trouble-free operation of the drive and the on-load tap-changer or de-ener-
gized tap-changer cannot be guaranteed.
► The shaft ends to be connected must be exactly aligned.

5 Mounting
Permitted axial displacement for the drive shaft without cardan joint
Minor axial displacement of the vertical and horizontal drive shafts is permit-
ted as long as it does not exceed 35 mm per 1000 mm square tube length
(that corresponds to 2°).
Figure 186: Permitted maximum axial displacement of vertical drive shaft

5 Mounting
Figure 187: Permitted maximum axial displacement of horizontal drive shaft
Resistance to corrosion of components
The square tubes, coupling brackets, coupling bolts, screws, and locking
washers are corrosion-resistant. We therefore recommend not applying the
same external coating to these parts as to the transformer tank.
Cutting square tubes, telescopic protective tubes, and protective cover
The square tubes, the telescopic protective tube and the protective cover are
supplied in overlengths (graded standard lengths). You must cut these parts
to the required size before mounting on the transformer. In rare cases, you
also have to cut the inner tube of the telescopic protective tube to the de-
sired length. The maximum permitted total drive shaft length of the drive -
last column = 15 m.
Standard lengths Motor-drive unit Manual drive

400 • •
600 • •
900 • •
1300 • •
1700 • •
2000 • •

5 Mounting
Standard lengths Motor-drive unit Manual drive

2500 Not permitted •1)
Table 7: Graded standard lengths of square tubes
1)
I>2000 only possible for vertical installation without shaft protection! Tele-
scopic protective tubes for manual drives with vertical dimensions V1> 2462
should be delivered vertically, similar to the motor-drive unit with intermedi-
ate bearing.
5.5.5.1 Fitting a vertical drive shaft without cardan joint
To fit the vertical drive shaft to the drive, proceed as follows:

1. CAUTION! Switch off motor protective switch Q1 in the motor-drive
unit (position O). If this is not done, the motor-drive unit may be started
by accident and thereby cause injuries.
2. Fasten the bevel gear to the transformer.
Figure 188: Bevel gear

5 Mounting
3. Determine dimension A between shaft end of drive and shaft end of

bevel gear. Shorten square tube to length of A – 9 mm.
Figure 189: Shortening square tube

5 Mounting
4. Deburr cut surfaces of square tube.
Figure 190: Deburring cut surfaces

5 Mounting
5. Slide the loosely screwed together coupling part onto square tube until
stop is reached.
Figure 191: Slide coupling part onto square tube

5 Mounting
6. Insert coupling bolt into shaft end of drive. Grease coupling part, cou-
pling bolt and shaft end (e.g. ISOFLEX TOPAS L32). Slide square tube
with coupling part onto shaft end.
Figure 192: Slide square tube with coupling part onto shaft end
7. Secure square tube onto drive.
Figure 193: Secure square tube onto drive

5 Mounting
8. Pivoting square tube.
Figure 194: Pivoting square tube
9. When installing inner tube of telescopic protective tube, if necessary

shorten on side without slits. The minimum dimension for overlapping
the two protective tubes is 100 mm.
Inner tube must not be deformed and must be deburred in order to slide
easily in the outer tube.

5 Mounting
Figure 195: Deburring inner tube
Dimension A (= distance be- Inner tube Outer tube

tween shaft end of drive and
shaft end of bevel gear)
170 mm...190 mm Shorten to 200 mm = 200 mm
191 mm...1130 mm Dimension A + 20 = 200 mm
mm
1131 mm...1598 mm = 700 mm = 1150 mm
1599 mm...2009 mm = 1150 mm = 1150 mm

5 Mounting
10. Slide outer tube over inner tube. When doing so, make sure that the un-
slotted side of the inner tube is facing upwards. Slide telescopic protec-
tive tube onto square tube Then slide hose clips over telescopic protec-
tive tube.
Figure 196: Sliding on telescopic protective tube

5 Mounting
11. Place adapter ring over bearing collar of bevel gear and slide upwards.
Insert coupling bolt into shaft end of bevel gear. Swing square tube in.
Figure 197: Fitting adapter ring and coupling bolt

5 Mounting
12. Grease coupling brackets, coupling bolt and shaft end (e.g. ISOFLEX
TOPAS L32) and secure square tube with coupling brackets on the bev-
el gear. Set a unilateral axial clearance of 3 mm between coupling bolt
and upper coupling piece.
Figure 198: Mounting coupling brackets

5 Mounting
13. Attach bottom protective tube (inner tube) with a hose clip to bearing
collar of drive . Then slide upper protective tube (outer tube) over
adapter ring on bevel gear . Secure upper protective tube to bottom
protective tube with hose clip both at top end and at the connection
point .
Figure 199: Mounting protective tube
5.5.5.2 Fitting a horizontal drive shaft without cardan joint
Aligning upper gear unit on the on-load tap-changer head
In order to correctly install the horizontal drive shaft, under certain circum-
stances you may have to first align the upper gear unit such that the horizon-
tal drive shaft is flush with the shaft end of the upper gear unit.

5 Mounting
Proceed as follows:
1. NOTICE! Make sure the oil compartment is filled completely with oil.
Aligning the gear unit after drying without filling the oil compartment
completely with oil will damage the on-load tap-changer.
2. Loosen screws and turn pressure ring segments to one side.
Figure 200: Pressure ring segments
3. NOTICE! Align gear unit such that the horizontal drive shaft is flush with
the drive shaft of the gear unit. While aligning the gear unit, turn the
unit's drive shaft such that its output shaft retains its original position.
Failure to do so may result in damage to the de-energized tap-changer
and transformer when starting up.
Figure 201: Aligning gear unit

5 Mounting
4. Swivel pressure ring segments back towards gear unit and tighten
screws. Ensure that the spring washer is between the screw head and
pressure ring segment and that the pressure ring segments are firmly in
contact with the gear unit housing.
Figure 202: Securing pressure ring segments
Fitting horizontal drive shaft
To fit the horizontal drive shaft, proceed as follows.

1. Calculate dimension A between shaft end of upper gear unit and shaft
end of bevel gear and shorten square tube to length A–9 mm.

5 Mounting
2. Calculate inside width B between housings of upper gear unit and bevel
gear. Cut down the protective cover to B-2 mm and deburr the cuts. Pro-
tect protective cover against corrosion with a coat of paint.
Figure 204: Shorten, deburr, and coat protective cover

5 Mounting
3. Slide loosely screwed together coupling part onto square tube until stop
is reached.
Figure 205: Slide coupling part onto square tube

5 Mounting
4. Grease coupling bolt, coupling part and shaft end of the bevel gear (e.g.
ISOFLEX TOPAS L32) and insert coupling bolt into shaft end. Thread
hose clip onto square tube and slide square tube with coupling part onto
shaft end.
5. Secure square tube on bevel gear.
Figure 207: Secure square tube on bevel gear

5 Mounting
6. Grease coupling bolt, coupling brackets and shaft end of the upper gear
unit (e.g. ISOFLEX TOPAS L32) and insert coupling bolt into shaft end.
Secure square tube with coupling brackets on upper gear unit.
Figure 208: Secure square tube on upper gear unit.

5 Mounting
7. Attach shortened protective cover to housing lugs on the on-load tap-

changer head and bevel gear. Secure each end of protective cover with
a hose clip.
Figure 209: Fitting protective cover

5 Mounting
8. If using a bearing block or angle gear, attach caps to the protective cov-
er.
Figure 210: Bearing block caps
Figure 211: Angle gear caps

5 Mounting
5.5.5.2.1 On-load tap-changer sets and combinations
For two-column and three-column on-load tap-changer models, you must

couple the on-load tap-changer heads above the transformer cover.
Proceed as follows:
1. Check that the operating positions of all on-load tap-changers are identi-
cal (inspection window in the on-load tap-changer head). Each on-load
tap-changer must be in the adjustment position.
2. Turn the pressure segments of upper gear units to one side by loosen-
ing the 6 M8 bolts/wrench size 13.
3. NOTICE! Move upper gear units into the required installation position
only by turning the drive shafts of the upper gear units with loosened
pressure segments. Otherwise, the on-load tap-changer may be dam-
aged when aligning the upper gear unit.
4. Swivel pressure segments back towards gear unit and tighten screws
(15 Nm tightening torque). Ensure that the spring washer is between the
screw head and pressure ring segment and that the pressure ring seg-
ments are firmly in contact with the gear unit housing.
5. Note arrow on drive shaft flange under the stamped serial number. The
direction of the arrow indicates the direction of rotation when turning the
hand crank of the motor-drive unit clockwise and must be identical for all
gear units.
6. Move each on-load tap-changer separately one step by rotating the
shaft ends counter-clockwise until the on-load tap-changer operates
once.
7. Check that the operating positions of all on-load tap-changer heads are
the same.
8. Fit horizontal drive shaft between the on-load tap-changer heads. Indi-
vidually couple each on-load tap-changer. Start with the on-load tap-
changer which is closest to the motor-drive unit.
9. NOTICE! After installing all drive shafts, continue cranking another 2.5
revolutions counter-clockwise on the drive shaft of the upper gear unit to
correctly complete the tap-change operation. An incomplete tap-change
operation may damage the on-load tap-changer!
10. Switch on-load tap-changer back into adjustment position by turning
drive shaft clockwise. Once the adjustment position has been reached
and the diverter switch has undergone the tap-change operation, contin-
ue cranking another 2.5 revolutions clockwise on the drive shaft of the
upper gear unit to correctly complete the tap-change operation.
11. Check operation of all on-load tap-changers. A slight time delay is per-
mitted.
12. Check that the operating positions of all on-load tap-changer heads are
the same.
13. Fit vertical drive shaft.

5 Mounting
5.5.5.3 Fitting drive shaft with cardan joints
Installation of the drive shaft with cardan joints is mainly designed as a verti-
cal drive shaft between motor-drive unit and bevel gear.
Technically, a horizontal design is also possible. However, if using a horizon-

tal design please note that the protective cover supplied must be adapted
accordingly and a cardan joint with an inner hub diameter of 25 mm must be
used if you want to use the cardan joint on the upper gear unit.
Permitted axial displacement
An axial displacement of 20° is permitted for the vertical and horizontal drive
shaft with cardan joints.
Figure 212: Permitted maximum axial displacement of vertical drive shaft with cardan
joints

5 Mounting
Figure 213: Permitted maximum axial displacement of horizontal drive shaft with car-
dan joints

Improper mounting of the cardan joint may result in damage or malfunc-
tions!
► Ensure that the folding cardan joint does not damage the expansion
bellows during mounting.
► Ensure that the angle of deflection α is no greater than 20°.
► Ensure that the angle of deflection α is the same on both cardan joints.

5 Mounting
Figure 214: Angle of deflection α

5 Mounting
To fit the drive shaft with cardan joints, proceed as follows:

1. Grease coupling bolts, coupling brackets, and shaft ends, e.g. ISOFLEX
TOPAS L 32.
Figure 215: Greasing coupling bolts, coupling brackets, and shaft ends

5 Mounting
2. Insert adapter rings into the collar of the rotating protective tube .
Place both parts of pivotable protective tube inside one another and
turn towards one another to set the corresponding angle.
Figure 216: Inserting adapter in pivotable protective tubes
3. When supplied, the cardan joints are fitted with coupling bolts . To
mount on the shaft end, the following steps must be taken: Remove
hose clip . Slide up expansion bellows . Remove coupling bolt .

5 Mounting
Slide cardan joint over device's output shaft . Push in coupling bolt
. Slide expansion bellows over this . Secure expansion bellows
with hose clip .
Figure 217: Mounting cardan joints
4. Connect shorter cardan joint supplied to shaft end of motor-drive unit

with coupling bolt.
Figure 218: Attach cardan joint on shaft end of motor-drive unit

5 Mounting
5. NOTICE! Attach second, longer cardan joint to the bevel gear such that
the position of both cardan joint lugs matches on the bevel gear and mo-
tor-drive unit. If this is not done, damage or malfunction may result.
Figure 219: Fit second cardan joint on bevel gear
6. Secure expansion bellows with hose clip.
Figure 220: Secure expansion bellows with hose clip

5 Mounting
7. Provisionally connect loose shaft ends of the joints to an angle bar and
align so that they are flush.
Figure 221: Connect shaft ends with angle bar

5 Mounting
8. Determine dimension A between the shaft ends. Cut square tube to

LR = A + 106 mm (LR = length of square tube). Deburr cut surfaces of
square tube.

5 Mounting
9. Before mounting, shorten both telescopic tubes to dimension A/

2 + 120 mm (A = dimension between both cardan joint ends) and de-
burr.
Figure 223: Shortening telescopic tubes

5 Mounting
10. Fit one adapter ring to bearing collar of motor-drive unit and fit other
adapter ring to bearing collar of bevel gear.
Figure 224: Fitting adapters
11. Slide previously shortened and deburred square tube over upper cardan
joint end until stop is reached.
Figure 225: Sliding square tube over upper cardan joint end

5 Mounting
12. Thread upper flexible protective tube with long outlet up onto square
tube from below.
Figure 226: Sliding flexible protective tube over square tube

5 Mounting
13. Slide inner tube into outer tube such that the slotted sides of the outer
and inner tube are both facing down. Thread the hose clips.
Figure 227: Sliding on telescopic tubes

5 Mounting
14. Slide everything up and secure with a screw clamp.
Figure 228: Secure everything with a screw clamp

5 Mounting
15. Slide bottom flexible protective tube (also with long outlet up) on to the
square tube and secure with screw clamp.
Figure 229: Sliding bottom flexible protective tube onto square tube

5 Mounting
16. Swing in square tube and slide all the way down.
Figure 230: Swinging square tube in

5 Mounting
17. Tighten bottom coupling brackets. Shaft end and coupling part must be
securely connected such that no axial clearance remains between the
coupling bolt and coupling bracket.
Figure 231: Tightening lower coupling brackets

5 Mounting
18. Fit upper coupling brackets with 3 mm axial clearance.
Figure 232: Fitting upper coupling brackets
19. Working from top to bottom, mount the individual parts of the shaft pro-
tection. Set angle position between both parts of pivotable protective
tube and fix with available hose clip. Secure both upper and lower pro-
tective tubes with a hose clip at both ends. Secure the two telescopic
protective tubes to one another using a hose clip.
The plastic adapters must be at the respective end of the pivotable protec-
tive tube. Only slide telescopic protective tube into upper and lower pivota-
ble protective tubes by the width of the adapter before tightening the hose
clips.

5 Mounting
Figure 233: Secure telescopic protective tube and flexible protective tubes with hose
clips
5.5.5.4 Fitting drive shaft with insulator
A model with insulator in the vertical drive shaft is available for insulating in-
stallation of the drive shaft.

5 Mounting
Minor axial displacement of the vertical drive shaft with insulator is permitted
as long as it does not exceed 35 mm per 1000 mm square tube length (that
corresponds to 2°).
Figure 234: Permitted maximum axial displacement of vertical drive shaft with insula-
tor
5.5.5.4.1 Fitting vertical drive shaft with insulator
To fit the vertical drive shaft, proceed as follows.

1. CAUTION! Switch off motor protective switch Q1 in the motor-drive
unit (position O). If this is not done, the motor-drive unit may be started
by accident and thereby cause injuries.

5 Mounting
2. Screw down the bevel gear for fastening on the transformer on both
sides with the contact washers provided to ensure permanent ground-
ing. Screws are not included in the scope of supply.
Figure 235: Bevel gear

5 Mounting
3. Determine dimension A between shaft end of drive and shaft end of

bevel gear. Shorten square tube to length of A–179 mm taking the insu-
lator into account.

5 Mounting
4. Deburr cut surfaces of square tube.
Figure 237: Deburring cut surfaces
5. Screw down double coupling part with insulator supplied and square
tube. Mount insulator on the side facing the drive.
Figure 238: Screwing down square tube and insulator with double coupling part

5 Mounting
6. Slide loosely screwed together coupling part onto insulator until stop is
reached.
Figure 239: Slide coupling part onto insulator
7. Place the supplied insulator ring on the bearing collar of the motor-drive
unit.
Figure 240: Insulating ring
8. Insert coupling bolt into shaft end of drive. Grease coupling part, cou-
pling bolt and shaft end (e.g. ISOFLEX TOPAS L32). Slide square tube
with coupling part onto shaft end.

5 Mounting
9. Secure square tube onto drive.
Figure 242: Secure square tube onto drive
10. Pivoting square tube.
Figure 243: Pivoting square tube
11. When installing inner tube of telescopic protective tube, if necessary

shorten on side without slits. The minimum dimension for overlapping
the two protective tubes is 100 mm.
Inner tube must not be deformed and must be deburred in order to slide
easily in the outer tube.

5 Mounting
Figure 244: Deburring inner tube
Dimension A (= distance be- Inner tube Outer tube

tween shaft end of drive and
shaft end of bevel gear)
170 mm...190 mm Shorten to 200 mm = 200 mm
191 mm...1130 mm Dimension A + 20 = 200 mm
mm
1131 mm...1598 mm = 700 mm = 1150 mm
1599 mm...2009 mm = 1150 mm = 1150 mm

5 Mounting
12. Slide outer tube over inner tube. When doing so, make sure that the un-
slotted side of the inner tube is facing up. Slide telescopic protective
tube onto square tube Then slide hose clips over telescopic protective
tube.
Figure 245: Sliding on telescopic protective tube

5 Mounting
13. Place adapter ring over bearing collar of bevel gear and slide upwards.
Insert coupling bolt into shaft end of bevel gear. Swing square tube in.
Figure 246: Fitting adapter ring and coupling bolt

5 Mounting
14. Grease coupling brackets, coupling bolt and shaft end (e.g. ISOFLEX
TOPAS L32) and secure square tube with coupling brackets on the bev-
el gear. Set a unilateral axial clearance of 3 mm between coupling bolt
and upper coupling piece.
Figure 247: Mounting coupling brackets

5 Mounting
15. Attach bottom protective tube (inner tube) with a hose clip to bearing
collar of drive . Then slide upper protective tube (outer tube) over
adapter on bevel gear . Secure upper protective tube to bottom pro-
tective tube with hose clip both at top end and at the connection point
.
Figure 248: Mounting protective tube
5.5.5.5 Fitting drive shaft with insulator and cardan joint
A model with insulator and cardan joint in the vertical drive shaft is also
available for insulating installation of the drive shaft.

5 Mounting
An axial displacement of 20° is permitted for a drive shaft with insulator and
cardan joint.
Figure 249: Permitted maximum axial displacement of vertical drive shaft with insula-
tor and cardan joint
5.5.6 Centering on-load tap-changer and motor-drive unit

Center on-load tap-changer and motor-drive unit as described in relevant
MR operating instructions for motor-drive unit.
5.5.7 Installing electrics for motor-drive unit

Install electrics for motor-drive unit as described in relevant MR operating in-
structions for motor-drive unit.

6 Commissioning the on-load tap-changer at the transformer manufacturer's site
6 Commissioning the on-load tap-changer at the

transformer manufacturer's site
WARNING Flying parts and spraying of hot oil resulting from on-load tap-
changer overload!
The on-load tap-changer can switch currents of up to two times the rated
through current. Higher currents occur when activating transformers (inrush
current impulse) or in the event of short-circuits, for example. Higher voltag-
es may occur from transformer overexcitation following load shedding, for
example.
Danger of death or severe injury from flying parts and spraying of hot oil!
► Ensure that the on-load tap-changer is not overloaded.
► Prevent on-load tap-change operations if higher currents arise.
► Ensure that the rated step voltage is not exceeded. The rated step volt-
age may be briefly exceeded by up to 10% as long as the rated through
current is not exceeded.
► Ensure that the temperature limit values stated in the technical data are
not exceeded.
Perform the following work and functional checks before commissioning the
transformer.
6.1 Bleeding on-load tap-changer head and suction pipe

Before first commissioning, the on-load tap-changer head and the suction
pipe on pipe connection S must be bled.
6.1.1 Bleeding on-load tap-changer head

1. Open all forward and return valves in the pipe system.
2. Remove screw cap on air-vent valve E1 on the on-load tap-changer
head cover.
Figure 250: Screw cap

3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-
load tap-changer head.
Figure 251: Valve tappet
4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm).
6.1.2 Bleeding suction pipe on pipe connection S

1. Remove screw cap from pipe connection S.
2. NOTICE! Open vent screw and bleed suction pipe. Make sure the suc-
tion pipe is fully vented. The insulation capability of the on-load tap-
changer to ground will otherwise be significantly impaired.
3. Close vent screw.
4. Seal vent screw with screw cap.

6.2 Grounding the on-load tap-changer

1. Connect the grounding screw on the on-load tap-changer head to the
transformer cover. It is essential that CUPAL washers are placed direct-
ly on the connecting lug on both sides. The aluminum side of the CU-
PAL washers must be facing the connecting lug.
Figure 253: Grounding screw head
2. Connect the grounding screw of the motor-drive protective housing to

the transformer tank. It is essential that a CUPAL washer is placed be-
tween the cable shoe and connecting lug. The aluminum side of the CU-
PAL washer must be facing the connecting lug.
Figure 254: Grounding screw on motor-drive unit
3. When using a temperature sensor, connect housing of temperature sen-

sor with grounding screw to on-load tap-changer head or another
grounding point on the transformer. It is essential that a CUPAL washer

is placed between the cable shoe and temperature sensor housing. The
aluminum side of the CUPAL washer must be facing the temperature
sensor housing.
Figure 255: Grounding temperature sensor
6.3 Performing tests on motor-drive unit
Function tests
► Perform function checks as described in relevant MR operating instruc-
tions for motor-drive unit.
Dielectric tests on transformer wiring

► Note information relating to dielectric tests on transformer wiring in rele-
vant MR operating instructions for motor-drive unit.
6.4 Performing trial tap-change operations

Before you energize the transformer, you must carry out trial tap-change op-
erations to check the mechanical function of on-load tap-changer and motor-
drive unit. Proceed as follows:
NOTICE Damage to the on-load tap-changer/de-energized tap-changer!

Damage to the on-load tap-changer/de-energized tap-changer by actuating
the on-load tap-changer/de-energized tap-changer without oil!
60076-7).

1. NOTICE! Undertake tap-change operation tests across entire range of

settings. Make sure that in each operating position the tap position indi-
cators of motor-drive unit and on-load tap-changer (inspection window in
the on-load tap-changer head) read the same position. An incorrectly
coupled motor-drive unit will damage the on-load tap-changer.
2. Check, in both end positions, the function of the electrical and mechani-
cal end stop (see MR operating instructions for motor-drive unit).
6.5 High-voltage tests on the transformer

tap-changer head cover, in the pipework system, in the oil conservator, at
the dehydrating breather opening, and from flying parts and hot oil splash-
ing!
that none occur.
► Ensure that the oil compartment of the on-load tap-changer is com-
pletely filled with oil.
► Ensure that all protective devices for the on-load tap-changer are ready
for use.
► Use suitable personal protective equipment/clothing.
► Keep away from the danger area during the transformer test.
► Observe applicable fire protection regulations.
► Make sure that only trained technicians perform work on the transform-
er.
It is essential that you ensure only trained, instructed expert personnel who
are familiar with and comply with the pertinent safety and technical regula-
tions, who are aware of the potential risks, and who consistently use the oc-
cupational safety equipment provided to prevent injury and property damage
are assigned to perform such a transformer test.
Note the following points before undertaking high voltage tests on the trans-
former:
▪ Ensure that the ground connections on the motor-drive protective hous-
ing and protective housing fastening are free of paint.
▪ Only perform high voltage test if motor-drive unit door is closed.
▪ Disconnect external connections to electronic components in the motor-
drive unit to prevent damage from overvoltage.
▪ When connecting the motor-drive unit's supply voltage, only use the ca-
ble bushings in the protective housing base intended for lead insertion.

▪ Guide all ground connecting leads to one central connection point (es-
tablishment of suitable reference earth).
▪ Disconnect all electronic components before the high voltage test. Be-
fore a wiring dielectric test, remove all devices with a withstand voltage
of < 1,000 V.
▪ Remove leads used for testing before the high voltage test as these
function as antennas.
▪ Wherever possible, route the measurement and data leads separately
from the energy cables.
Contact the manufacturer if you have any questions about possible sources
of danger.

7 Transporting transformer to the operating site

tap-changer head cover, in the pipework system, in the oil conservator or at
the dehydrating breather opening!
that none occur.
7.1 Transport with removed drive

If the drive must be removed in order to transport the transformer, proceed
as follows:
1. Ensure that the drive and the on-load tap-changer are in the adjustment
position.
2. Remove the drive.
3. Do not actuate the drive while the on-load tap-changer is uncoupled and
do not turn the output shaft.
4. Do not actuate an on-load tap-changer which is uncoupled and do not
turn its drive shaft.
5. Transport the drive to the installation site in the MR delivery packaging.
6. Fit drive [► 164] and drive shaft [► 164] to transformer at the installa-
tion site.
7.2 Transport with oil fill and without oil conservator

If the transformer is filled with oil but stored or transported without an oil con-
servator, a connecting lead for pressure compensation must be installed be-
tween the interior of the compartment and the transformer tank's oil cham-
ber.
To do so, proceed as follows:

► Establish the connecting lead on the on-load tap-changer head between
connections E2 and Q or E2 and R.

In case of a short-term immobilization time of maximum 4 weeks without an

oil conservator, dropping the oil level in the on-load tap-changer head by
about 5 liters is also sufficient.
7.3 Transport without oil fill

1. NOTICE! Completely empty the oil compartment of the on-load tap-
changer if the transformer is completely emptied of oil.If this is not done,
the oil compartment may be damaged.
2. Preserve the interior of the oil compartment in the same way as the
transformer (for example by filling with N2).
For longer immobilization periods, you must connect and operate the motor-
drive unit heating.
For downtimes prior to commissioning of more than 8 weeks and operation
interruptions more than 2 weeks, you must connect and operate the heating
to avoid condensation water in the interior of the protective housing.
7.3.1 Emptying oil compartment via pipe connection S

cover!
none arise.
1. De-energize all auxiliary circuits (for example tap-change supervisory

devices, pressure relief devices, pressure monitoring devices).
2. With stop-cock (slide valve) between oil conservator and oil compart-
ment open, open air-vent valve E1 on on-load tap-changer head.
3. Drain off the gas from under the on-load tap-changer cover. Ensure suf-
ficient fresh air (for example in transformer cells and work tents).
4. Once the gas has been drained off and the oil is flowing out of the air-
vent valve, close this valve and close the stop-cock between the oil con-
servator and oil compartment.
5. Open air-vent valve again and drain off around 5–10 liters of oil via the
pipe connection S until the area under the on-load tap-changer head
cover is free of oil.

6. Loosen 24 screws M10/wrench size 17 with locking elements on on-load

tap-changer head cover.
7. Remove on-load tap-changer head cover.
8. Extract oil via pipe connection S.
9. Open stop-cock between oil conservator and oil compartment.
ð The oil from the oil conservator flows into the oil compartment.
10. Extract oil via pipe connection S.
11. Place on-load tap-changer head cover on on-load tap-changer head.
12. Use 24 screws M10/wrench 17 and locking elements to screw down on-
load tap-changer head cover (tightening torque 34 Nm).

8 Commissioning the transformer at the operating site
8 Commissioning the transformer at the operating

site
WARNING Flying parts and spraying of hot oil resulting from on-load tap-
changer overload!
The on-load tap-changer can switch currents of up to two times the rated
through current. Higher currents occur when activating transformers (inrush
current impulse) or in the event of short-circuits, for example. Higher voltag-
es may occur from transformer overexcitation following load shedding, for
example.
Danger of death or severe injury from flying parts and spraying of hot oil!
► Ensure that the on-load tap-changer is not overloaded.
► Prevent on-load tap-change operations if higher currents arise.
► Ensure that the rated step voltage is not exceeded. The rated step volt-
age may be briefly exceeded by up to 10% as long as the rated through
current is not exceeded.
► Ensure that the temperature limit values stated in the technical data are
not exceeded.
Before energizing the transformer, check that the motor-drive unit and pro-
tective relay are functioning correctly and fill the on-load tap-changer oil
compartment with new mineral insulating oil. Proceed as follows:
8.1 Checking motor-drive unit

Before commissioning the transformer, repeat the function tests on the mo-
tor-drive unit as described in MR operating instructions for motor-drive unit.

Danger of death or severe injury due to incorrect operation!
► Under no circumstances is the transformer to be commissioned if the
functions specified in the section "Tests on motor-drive unit" are not
satisfied.
NOTICE Damage to the on-load tap-changer and motor-drive unit!

Damage to on-load tap-changer and motor-drive unit due to condensate in
protective housing of motor-drive unit!
► Always keep protective housing of the motor-drive unit tightly closed.
► In the event of downtimes prior to initial commissioning of more than 8
weeks or operation interruptions of more than 2 weeks, connect and
operate the anti-condensation heater in the motor-drive unit. If this is
not possible (e.g. during transportation), place a sufficient amount of
dehydrating agent in the protective housing.

NOTICE Damage to the on-load tap-changer and motor-drive unit!

Damage to on-load tap-changer and motor-drive unit due to incorrect use of
position transmitter equipment!
► Only circuits stated in the chapter Technical data for position transmitter
equipment may be connected to the position transmitter module con-
nections.
► The switchover point of the position transmitter equipment in the motor-
drive unit is not the same as the switchover point of the diverter switch
operation. This depends on the type of diverter switch. This fact should
be noted when project planning the locking circuits between the motor-
drive unit and external equipment (e.g. transformer circuit breaker).
► For external monitoring, locking, and control purposes, it is not there-
fore the position transmitter equipment but the "Tap changer in opera-
tion" position transit contact shown in the connection diagram that
should be used.
8.2 Checking protective relay
8.2.1 Checking protective relay (RS 2001, 2001/V, 2001/H, 2001/E,

2001/5, 2001/R, 2003)
ü Check that the protective relay is functioning correctly before commis-
sioning the transformer:
1. Ground the transformer on the high-voltage and low-voltage sides. En-
sure that the working ground connection on the transformer is not re-
moved during testing.
2. Ensure that transformer remains de-energized during testing.
3. Deactivate the automatic fire extinguishing device.
4. Open terminal box of protective relay.
6. Leave the transformer's danger zone.
7. Ensure that the transformer's circuit breaker cannot be closed.
ð Passive protection test
8. Press IN SERVICE test button.
10. Close the transformer's circuit breaker with isolating switches open and
the transformer grounded on all sides.
12. Ensure that the transformer's circuit breaker is open.
ð Active protection test.
13. Press IN SERVICE test button to reset the protective relay.

8.2.2 Checking protective relay (RS 2004)

ü Check that the protective relay is functioning correctly before commis-
sioning the transformer:
1. Ensure that the flap valve is in the IN SERVICE position.
ð Active protection test
8.3 Checking pressure monitoring device

ü Check that the pressure monitoring device is operating properly before
putting the transformer into operation:
1. Ground the transformer on the high-voltage and low-voltage sides. En-
sure that the working ground connection on the transformer is not re-
moved during testing.
2. Ensure that transformer remains de-energized during testing.
3. Deactivate the automatic fire extinguishing device.
5. Activate the sensor on the snap-action switch.
ð Sensor is in the OFF position.
7. Ensure that the transformer's circuit breaker cannot be closed.
ð Passive protection test
ð Sensor is in the OPERATION position
ð Sensor is in the OFF position.
ð Active protection test.
13. Activate the sensor on the snap-action switch to reset the pressure
monitoring device.
ð Sensor is in the OPERATION position

8.4 Filling the oil compartment of the on-load tap-changer with

oil

tap-changer head cover, in the pipework system, in the oil conservator or at
the dehydrating breather opening!
that none occur.

60076-7).
1. NOTICE! Check whether the on-load tap-changer head cover has a

flange for attaching a pressure relief device. If it does, operation without
a pressure relief device is not permitted and may result in damage to the
on-load tap-changer.
ð Fit a pressure relief device which is approved for this on-load tap
changer on the on-load tap-changer head.
2. Connect a lead between the pipe connection E2 and one of the pipe
connections R, S or Q to ensure equal pressure in the oil compartment
and transformer during evacuation.
Figure 257: Connecting lead between E2 and Q.

3. Fill on-load tap-changer with new mineral insulating oil for transformers
in accordance with IEC 60296 using one of the two free pipe connec-
tions of the on-load tap-changer head.
Figure 258: Pipe connection S and R
4. Take oil sample from oil compartment.

5. Record temperature of oil sample just after sample is taken.
6. Determine dielectric strength and water content at a diverter switch oil
temperature of 20 °C ± 5 °C. The dielectric strength and water content
must comply with the limit values specified in the technical data.
8.5 Bleeding on-load tap-changer head and suction pipe

Before first commissioning, the on-load tap-changer head and the suction
pipe on pipe connection S must be bled.
8.5.1 Bleeding on-load tap-changer head

1. Open all forward and return valves in the pipe system.

2. Remove screw cap on air-vent valve E1 on the on-load tap-changer

head cover.
3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-
load tap-changer head.
Figure 260: Valve tappet
4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm).

8.5.2 Bleeding suction pipe on pipe connection S

1. Remove screw cap from pipe connection S.
2. NOTICE! Open vent screw and bleed suction pipe. Make sure the suc-
tion pipe is fully vented. The insulation capability of the on-load tap-
changer to ground will otherwise be significantly impaired.
3. Close vent screw.
4. Seal vent screw with screw cap.
8.6 Performing trial tap-change operations

Before you energize the transformer, you must carry out trial tap-change op-
erations to check the mechanical function of on-load tap-changer and motor-
drive unit. Proceed as follows:

60076-7).

1. NOTICE! Undertake tap-change operation tests across entire range of

settings. Make sure that in each operating position the tap position indi-
cators of motor-drive unit and on-load tap-changer (inspection window in
the on-load tap-changer head) read the same position. An incorrectly
coupled motor-drive unit will damage the on-load tap-changer.
2. Check, in both end positions, the function of the electrical and mechani-
cal end stop (see MR operating instructions for motor-drive unit).
8.7 Commissioning the transformer

1. Loop the signaling contact for falling below the minimum oil level in the
on-load tap-changer's oil conservator into the tripping circuit of the cir-
cuit breaker.
2. Loop protective relay and additional protective devices into circuit break-
er's tripping circuit.
3. Ensure that all stop-cocks between on-load tap-changer and oil conser-
vator of the on-load tap-changer are open.
4. NOTICE! Switch on transformer. Once the transformer has been
switched on, ensure that the inrush current impulse has fully subsided
before undertaking an on-load tap-change operation. The inrush current
impulses are usually a multiple of the transformer rated current and can
overload the on-load tap-changer during the diverter switch operation.
ð After the transformer has been switched on and the inrush current im-
pulse has subsided, on-load tap-changer tap-change operations can be
performed both under no load and load conditions.
During all function checks and tests when commissioning, in addition to the
safety instructions in Chapter 2, also note the safety notice provided in the
chapter Electrical high voltage tests on the transformer [► 222].

9 Fault elimination
9 Fault elimination
cover!
none arise.

Tripping of the protective relay or other protective devices can indicate dam-
age on the on-load tap-changer and transformer! The transformer must not
be energized without first undertaking checks!
► Check on-load tap-changer and transformer when protective relay or
other protective devices have been tripped.
► Do not use the equipment again until you are sure there is no damage
to the on-load tap-changer or transformer.
The table below is intended to assist with detecting and, where possible,
remedying faults.
For more information, please consult the operating instructions for the RS
protective relay or the relevant protective device.
In the event of faults on the on-load tap-changer and motor-drive unit, which
cannot be easily corrected on site, or if the RS protective relay or additional
protective devices have been tripped, please inform your authorized MR rep-
resentative, the transformer manufacturer or contact us directly at:

Technical Service
Postfach 12 03 60
93025 Regensburg
Germany
Phone: +49 94140 90-0
Fax: +49 9 41 40 90-7001
E-mail: service@reinhausen.com
Internet: www.reinhausen.com

9 Fault elimination
Error pattern Action

Tripping of protective relay (for example RS) See [► 237]
Also contact MR.
Tripping of pressure relief device (for example On-load tap-changer and transformer must be
MPreC®) checked. Depending on the cause of tripping, take
measurements/carry out checks on the transform-
er.
Contact MR to check the on-load tap-changer.
Activation of pressure monitoring device (for exam- See [► 239]
ple DW 2000) Also contact MR.
Activation of tap-change supervisory device The motor-drive unit can no longer be electrically
actuated once the tap-change supervisory device
has been activated. Manual operation of the motor-
drive unit via the hand crank when the transformer
is switched on is prohibited.
On-load tap-changer and transformer must be
checked. Depending on the cause of tripping, take
er.
Activation of rupture disk in on-load tap-changer On-load tap-changer and transformer must be
head cover checked. Depending on the cause of tripping, take
er.
Tripping of motor protective switch in motor-drive See chapter "Fault elimination" in the operating in-
unit structions of the TAPMOTION® ED motor-drive
unit
Tripping of signaling contact that indicates that the Check pipework system (pipes etc.) and on-load
oil has fallen below the minimum oil level in the on- tap-changer head for leaks. Check oil level and oil
load tap-changer oil conservator quality of diverter switch oil in accordance with op-
erating instructions for on-load tap-changer. If the
oil falls below the limit values, also contact MR.
On-load tap-changer not changing tap position Contact MR.
(sluggishness, Raise keys/Lower keys not working,
no audible diverter switch action)
No change in voltage on transformer despite Contact MR.
change in position on motor-drive unit
Tap position indicator on motor-drive unit and on- Contact MR.
load tap-changer different
Noises on drive shaft or motor-drive unit when Ensure proper mounting of the drive shaft in ac-
changing tap position cordance with its operating instructions. Check that
hose clips and protective covers are seated cor-
rectly. Contact MR in the event of noise from the
motor-drive unit.

9 Fault elimination
Error pattern Action

Red message on monitoring unit If possible read out database and send to MR
along with error code.
Warning or tripping of Buchholz relay on transform- Notify manufacturer of transformer.
er
Deviation from desired value when measuring Contact manufacturer of transformer and, if neces-
winding resistance of transformer sary, MR and provide measured values.
Deviation from desired value during dissolved gas Contact manufacturer of transformer and, if neces-
analysis (transformer oil) sary, MR and provide measured values.
Deviation from desired value during transformer ra- Contact manufacturer of transformer and, if neces-
tio test sary, MR and provide measured values.
Deviation from limit value for diverter switch oil val- Carry out oil change, check oil conservator breath-
ues er of on-load tap-changer.
Table 8: Fault elimination
9.1 Tripping of the protective relay and re-commissioning the

transformer

Danger of death or severe injury from explosive gases in the protective re-
lay, which accumulate during on-load tap-changer operation!
► Wait 15 minutes after switching off the transformer before you begin
further work on the protective relay so that the gases have a chance to
volatize.
that none occur.
► De-energize all auxiliary circuits before starting the work.

Risk of severe injury or death if on-load tap-changer and transformer are in-
sufficiently tested!
► Be sure to contact Maschinenfabrik Reinhausen to check on-load tap-
changer and transformer after the protective relay has been tripped.
► Only use the equipment again when you are sure there is no damage to
the on-load tap-changer or transformer.
When the circuit breakers have been tripped by the protective relay, proceed
as follows:
1. Establish time of tripping.
2. Determine operating position of on-load tap-changer.

9 Fault elimination
3. As a precaution, block the motor-drive unit by tripping the motor protec-

tive switch to prevent the on-load tap-changer from being actuated by
remote control.
4. Check the on-load tap-changer head cover. If oil is leaking, shut the oil
conservator stop valve immediately.
5. Check whether the flap valve of the protective relay is in the OFF or IN
SERVICE position.
9.1.1 Flap valve in IN SERVICE position

If the flap valve is in the IN SERVICE position, there may be a fault in the
tripping circuit. Check the tripping circuit in this case. If you are not able to
clarify why the protective relay tripped, be sure to contact Maschinenfabrik
Reinhausen to check the on-load tap-changer.
9.1.2 Flap valve in OFF position

Note that protective relay RS 2004 features an automatic reset mechanism
which means that the flap valve does not remain in the OFF position after
tripping. If the protective relay RS 2004 has not tripped due to an error in
the tripping circuit, proceed as described below for RS 2004 too.
If the flap valve is in the OFF position, proceed as follows:

1. Ensure that the transformer is not started up under any circumstances.
2. Contact and inform Maschinenfabrik Reinhausen of the following:
ð Serial number of protective relay and on-load tap-changer
ð What was the load of the transformer at the instant of tripping?
ð Was the on-load tap-changer moved immediately before or during
tripping?
ð Did any other protective devices of the transformer respond at the
instant of tripping?
ð Were switching operations in the network being carried out at the
ð Were overvoltages registered at the instant of tripping?
3. Take further action in agreement with Maschinenfabrik Reinhausen.
9.1.3 Re-commissioning the transformer

Once the reason for the protective relay tripping has been established and
remedied, you can re-commission the transformer:
1. Ensure that the flap valve is in the IN SERVICE position.
2. Commission the transformer.

9 Fault elimination
9.2 Tripping the pressure-operated relay and putting the

transformer back into operation

Risk of severe injury or death if on-load tap-changer and transformer are in-
sufficiently tested!
► Be sure to contact Maschinenfabrik Reinhausen to check on-load tap-
changer and transformer after the pressure monitoring device has been
tripped.
► Only use the equipment again when you are sure there is no damage to
the on-load tap-changer or transformer.
If the circuit breaker is tripped by the pressure monitoring device, proceed as

follows:
1. Establish time of tripping.
2. Determine operating position of on-load tap-changer.
3. As a precaution, block the motor-drive unit by tripping the motor protec-
tive switch to prevent the on-load tap-changer from being actuated by
remote control.
4. Check the on-load tap-changer head cover. If oil is leaking, shut the oil
conservator stop valve immediately.
5. Check whether the pressure monitoring device sensor is in the OFF po-
sition or OPERATION position.
9.2.1 Sensor in the OPERATION position

If the sensor is in the OPERATION position, there may be an error in the trip-
ping circuit. Check the tripping circuit in this case. If you are not able to clari-
fy why the pressure monitoring device tripped, be sure to contact Maschi-
nenfabrik Reinhausen to check the on-load tap-changer.
9.2.2 Sensor in the OFF position

Proceed as follows if the sensor is in the OFF position.
1. Ensure that the transformer is not started up under any circumstances.

9 Fault elimination
2. Contact and inform Maschinenfabrik Reinhausen of the following:

ð What was the load of the transformer at the instant of tripping?
ð Was there a tap-change operation on the on-load tap-changer im-
mediately before or during the tripping?
ð Did any other protective devices of the transformer respond at the
ð Were switching operations in the network being carried out at the
ð Were overvoltages registered at the instant of tripping?
ð How high is the static pressure on the pressure relief device (height
difference between the oil level in the on-load tap-changer oil con-
servator and the pressure relief device)?
3. Take further action in agreement with Maschinenfabrik Reinhausen.
9.2.3 Re-commissioning the transformer

You can put the transformer back into operation after the cause for tripping
the pressure-operated relay has been determined and resolved:
1. Ensure that the sensor on the snap-action switch is in the OPERATION
position.
2. Commission the transformer.

10 Technical data
10 Technical data
An overview of all key technical data for the on-load tap-changer and motor-
drive unit exists in the form of separate documents, which are available on
request.
10.1 Technical data for protective relay
General technical data

Housing Outdoor model
Degree of protection IP 54
Relay actuation Flap valve with aperture
Weight About 3.5 kg
Oil flow speed of available types 0.65 m/s
when tripping (oil temperature 20 1.20 m/s
°C)
3.00 m/s
4.80 m/s
Table 9: General technical data
Tripping circuit
The protective relay can be supplied with either a normally open (NO) or a
normally closed (NC) dry-reed magnetic switch (see dimensional drawing
supplied).
Other contact combinations are available as special version.
Electrical data for normally open (NO) or normally closed (NC) dry-reed
magnetic switch
AC switching capacity 1.2 VA…400 VA
DC switching capacity 1.2 W…250 W
Maximum admissible voltage 250 V
AC/DC 24 V
Minimum admissible voltage
AC/DC
Maximum switched current AC/DC 2A
Minimum switched current AC/DC 4.8 mA at 250 V

10 Technical data
Power frequency withstand voltage Between all voltage-carrying con-

test nections and the grounded parts: at
least 2,500 V, 50 Hz, test duration
1 minute
Between open contacts: at least
2,000 V, 50 Hz, test duration 1 mi-
nute
Table 10: Electrical data for normally open (NO) or normally closed (NC) dry-reed
magnetic switch
Electrical data for connecting to an inherently safe circuit

Maximum input voltage Ui 60 V
Maximum input current Ii 2A
Minimum switched current at 24 V 50 mA
Maximum inner capacity Ci negligible
Maximum inner inductivity Li negligible
Table 11: Connection to an inherently safe circuit
Electrical data for connecting to a non-inherently safe circuit

Rated voltage UC 250 V
Rated current level 2A
Maximum AC switching capacity 200 VA
Maximum DC switching capacity 130 W
Minimum switched current at 24 V 50 mA
Minimum switched current at 250 V 4.8 mA
Table 12: Connection to a non-inherently safe circuit
Thermal data
Ambient temperature Ta -25° C…+50° C
Oil temperature < 130° C
Table 13: Thermal data

10 Technical data
10.2 Special models of protective relay
10.2.1 Protective relay with CO change-over contact as tripping switch

The protective relay can be supplied with a dry-reed magnetic switch, CO
change-over (variant 3) (see dimensional drawing supplied).
Electrical data for CO change-over dry-reed magnetic switch

AC switching capacity 1.2 VA…200 VA
DC switching capacity 1.2 W…130 W
Maximum admissible voltage 250 V
AC/DC 24 V
Minimum admissible voltage
AC/DC
Maximum switched current AC/DC 1A
Minimum switched current AC/DC 4.8 mA at 250 V
Power frequency withstand voltage Between all voltage-carrying con-
test nections and the grounded parts: at
least 2500 V, 50 Hz, test duration 1
minute
Between open contacts: at least
1150 V, 50 Hz, test duration 1 mi-
nute
Table 14: Electrical data for CO change-over dry-reed magnetic switch
10.2.2 Protective relay with several dry-reed magnetic switches

The protective relay can be supplied with several independent dry-reed mag-
netic switches. These can be designed as normally open (NO) or normally
closed (NC) contacts and are electrically isolated (see dimensional drawing
supplied).
Electrical data for normally open (NO) and normally closed (NC) dry-reed
magnetic switch

10 Technical data
10.3 Technical data for pressure monitoring device
General technical data

Setup Outdoor model
Ambient temperature -40 °C…+80 °C (mechanical)
Cable connection M25x1.5
Degree of protection IP 55 in accordance with IEC 60529 (enclosed
device)
Relay actuation Corrugated tubing with counter-pressure
spring
Oil temperature -40 °C – +100 °C
Weight About 1.2 kg
Equipment For standard insulating fluids (IEC60296 and
IEC60422) and alternative insulating fluids
Sealing material VITON
(oil – air)
Permitted pressure 1 bar…6 bar, vacuum not permitted
range
(absolute pressure)
Upper switching pres- 3.8 ±0.2 bar (trip pressure)
sure
Lower switching pres- 2.8 ± 0.2 bar
sure
Snap-action switch
Connection terminals Line connection: 1 or 2 lines per terminal
(Ø 0.75…2.5 mm²)
Contacts 1xNO (normally open), 1xNC (normally
closed)
Utilization category IEC 60947-5-1:
AC 15: 230 V/1 A
DC 13: 60 V/0.5 A
Maximum continuous 10 A
current
Rated insulation voltage AC: 2.5 kV/min
Table 15: General technical data

10.4 Limit values for dielectric strength and water content of on-load tap-changer oil
10.4 Limit values for dielectric strength and water content of on-
load tap-changer oil
The following tables provide the limit values for dielectric strength (measured
in accordance with IEC 60156) and water content (measured in accordance
with IEC 60814) of the on-load tap-changer oil for OILTAP® on-load tap-
changers. The values have been established on the basis of IEC 60422.
Ud H2O
When commissioning the trans- > 60 kV/2.5 mm < 12 ppm
former for the first time
During operation > 30 kV/2.5 mm < 40 ppm
After maintenance > 50 kV/2.5 mm < 15 ppm
Table 16: Limit values for on-load tap-changer oil in neutral point applications
Ud H2O
When commissioning the trans- > 60 kV/2.5 mm < 12 ppm
former for the first time
During operation > 40 kV/2.5 mm < 30 ppm
After maintenance > 50 kV/2.5 mm < 15 ppm
Table 17: Limit values for on-load tap-changer oil in non-neutral point applications

11 Drawings
11 Drawings
11.1 Dimensional drawings

11 Drawings

11.2 Selector contacts
11.2 Selector contacts

11.3 On-load tap-changer head
11.3 On-load tap-changer head

11.4 Supporting flange for bell-type tank installation
11.4 Supporting flange for bell-type tank installation

11.5 Adjustment plans
11.5 Adjustment plans

11.6 Accessories
11.6 Accessories

Glossary
Glossary
AC
Alternating current
CO
Change-Over contact
DC
Direct current
Dielectric strength
Material-specific property of isolators [kV/2.5
mm]; maximum electrical field strength without a
breakdown (arc)
IEC
The International Electrotechnical Commission
(IEC for short) is involved in the preparation and
publication of international standards for electri-
cal, electronic and related technologies.
IP
Ingress protection
MR
NC
Normally Closed contact
NO
Normally Open contact
NPT
National Pipe Thread (US thread standard)

MR worldwide
Australia Malaysia
Reinhausen Australia Pty. Ltd. Reinhausen Asia-Pacific Sdn. Bhd
17/20-22 St Albans Road Level 11 Chulan Tower
Kingsgrove NSW 2208 No. 3 Jalan Conlay
Phone: +61 2 9502 2202 50450 Kuala Lumpur
Fax: +61 2 9502 2224 Phone: +60 3 2142 6481
E-Mail: sales@au.reinhausen.com Fax: +60 3 2142 6422
E-Mail: mr_rap@my.reinhausen.com
Brazil
MR do Brasil Indústria Mecánica Ltda. P.R.C. (China)
Av. Elias Yazbek, 465 MR China Ltd. (MRT)
CEP: 06803-000 开德贸易（上海）有限公司
Embu - São Paulo 中国上海浦东新区浦东南路 360 号
Phone: +55 11 4785 2150 新上海国际大厦 4 楼 E 座
Fax: +55 11 4785 2185 邮编： 200120
E-Mail: vendas@reinhausen.com.br 电话：＋ 86 21 61634588
传真：＋ 86 21 61634582
Canada 邮箱：mr-sales@cn.reinhausen.com
Reinhausen Canada Inc. mr-service@cn.reinhausen.com
3755, rue Java, Suite 180
Brossard, Québec J4Y 0E4 Russian Federation
Phone: +1 514 370 5377 OOO MR
Fax: +1 450 659 3092 Naberezhnaya Akademika Tupoleva
E-Mail: m.foata@ca.reinhausen.com 15, Bld. 2 ("Tupolev Plaza")
105005 Moscow
India Phone: +7 495 980 89 67
Easun-MR Tap Changers Ltd. (Joint Venture) Fax: +7 495 980 89 67
612, CTH Road E-Mail: mrr@reinhausen.ru
Tiruninravur, Chennai 602 024
Phone: +91 44 26300883 South Africa
Fax: +91 44 26390881 Reinhausen South Africa (Pty) Ltd.
E-Mail: service@easunmr.com No. 15, Third Street, Booysens Reserve
Johannesburg
Indonesia Phone: +27 11 8352077
Pt. Reinhausen Indonesia Fax: +27 11 8353806
German Center, Suite 6310, E-Mail: support@za.reinhausen.com
Jl. Kapt. Subijanto Dj.
BSD City, Tangerang South Korea
Phone: +62 21 5315-3183 Reinhausen Korea Ltd.
Fax: +62 21 5315-3184 21st floor, Standard Chartered Bank Bldg.,
E-Mail: c.haering@id.reinhausen.com 47, Chongro, Chongro-gu,
Seoul 110-702
Iran Phone: +82 2 767 4909
Iran Transfo After Sales Services Co. Fax: +82 2 736 0049
(Joint Venture) E-Mail: you-mi.jang@kr.reinhausen.com
Zanjan, Industrial Township No. 1 (Aliabad)
Corner of Morad Str. U.S.A.
Postal Code 4533144551 Reinhausen Manufacturing Inc.
E-Mail: itass@iran-transfo.com 2549 North 9th Avenue
Humboldt, TN 38343
Italy Phone: +1 731 784 7681
Reinhausen Italia S.r.l. Fax: +1 731 784 7682
Via Alserio, 16 E-Mail: sales@reinhausen.com
20159 Milano
Phone: +39 02 6943471 United Arab Emirates
Fax: +39 02 69434766 Reinhausen Middle East FZE
E-Mail: sales@it.reinhausen.com Dubai Airport Freezone, Building Phase 6
3rd floor, Office No. 6EB, 341 Dubai
Japan Phone: +971 4 2368 451
MR Japan Corporation Fax: +971 4 2368 225
German Industry Park Email: service@ae.reinhausen.com
1-18-2 Hakusan, Midori-ku
Yokohama 226-0006
Phone: +81 45 929 5728
Fax: +81 45 929 5741
Luxembourg
Reinhausen Luxembourg S.A.
72, Rue de Prés
L-7333 Steinsel
Phone: +352 27 3347 1
Fax: +352 27 3347 99
E-Mail: sales@lu.reinhausen.com
Maschinenfabrik Reinhausen GmbH +49 (0)941 4090-0 www.reinhausen.com

Falkensteinstrasse 8 +49(0)941 4090-7001
93059 Regensburg sales@reinhausen.com
4360601/03 EN ▪ 01/17 ▪

4360601_03en_Type R

Uploaded by

Copyright:

Available Formats

4360601_03en_Type R

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4360601_03en_Type R

Uploaded by

Copyright:

Available Formats

On-Load Tap-Changer

4360601/03 EN . Selector Sizes RC/RD/RDE/RE/RF

4 Packaging, transport and storage................................................................................... 34

Maschinenfabrik Reinhausen GmbH 2017 4360601/03 EN OILTAP® R 3

5.1 Preparatory work............................................................................................................................... 38

6 Commissioning the on-load tap-changer at the transformer manufacturer's site... 218

4 OILTAP® R 4360601/03 EN Maschinenfabrik Reinhausen GmbH 2017

6.4 Performing trial tap-change operations........................................................................................... 221

7 Transporting transformer to the operating site........................................................... 224

8 Commissioning the transformer at the operating site................................................ 227

9 Fault elimination.............................................................................................................. 235

10 Technical data................................................................................................................. 241

Maschinenfabrik Reinhausen GmbH 2017 4360601/03 EN OILTAP® R 5

6 OILTAP® R 4360601/03 EN Maschinenfabrik Reinhausen GmbH 2017

Information about operation can be found in the operating instructions.

Maschinenfabrik Reinhausen GmbH

The following documents apply:

1.4 Notation conventions

Maschinenfabrik Reinhausen GmbH 2017 4360601/03 EN OILTAP® R 7

Number and type of fastening material used

Fill with oil

Cut open, cut through

Use your hand

Apply a coat of paint

8 OILTAP® R 4360601/03 EN Maschinenfabrik Reinhausen GmbH 2017

1.4.2 Hazard communication system

1.4.2.1 Warning relating to section

Warnings relating to sections refer to entire chapters or sections, sub-sec-

WARNING Type and source of danger

1.4.2.2 Embedded warning information

Embedded warnings refer to a particular part within a section. These warn-

DANGER! Instruction for avoiding a dangerous situation.

1.4.2.3 Signal words and pictograms

The following signal words are used:

Maschinenfabrik Reinhausen GmbH 2017 4360601/03 EN OILTAP® R 9

Pictograms warn of dangers:

Warning of dangerous electrical voltage

Warning of combustible substances

Warning of danger of tipping

Table 3: Pictograms used in warning notices

1.4.3 Information system

10 OILTAP® R 4360601/03 EN Maschinenfabrik Reinhausen GmbH 2017

2.1 Appropriate use

The following is considered appropriate use:

2.2 Fundamental safety instructions

Maschinenfabrik Reinhausen GmbH 2017 4360601/03 EN OILTAP® R 11

Personal protective equipment

Loosely worn or unsuitable clothing increases the danger of becoming trap-

Untidy and poorly lit work areas can lead to accidents.

Working during operation

12 OILTAP® R 4360601/03 EN Maschinenfabrik Reinhausen GmbH 2017

Auxiliary materials and operating materials

Auxiliary materials and operating materials not approved by Maschinenfabrik

Modifications and conversions

Unauthorized or inappropriate changes to the product may lead to personal

Spare parts not approved by Maschinenfabrik Reinhausen GmbH may

2.3 Personnel qualification

Electrically skilled person

Maschinenfabrik Reinhausen GmbH 2017 4360601/03 EN OILTAP® R 13

Electrically trained persons