On-load tap-changer

OILTAP® M
Installation and commissioning instructions

4427232/01 EN
© All rights reserved by Maschinenfabrik Reinhausen
Dissemination and reproduction of this document and use and disclosure of its content are strictly prohibited
unless expressly permitted.
Infringements will result in liability for compensation. All rights reserved in the event of the granting of patents,
utility models or designs.
The product may have been altered since this document was published.
We reserve the right to change the technical data, design and scope of supply.
Generally the information provided and agreements made when processing the individual quotations and orders
are binding.
The original operating instructions were written in German.
Table of contents

Table of contents

1 Introduction......................................................................................................................... 7
1.1 Manufacturer....................................................................................................................................... 7
1.2 Completeness..................................................................................................................................... 7
1.3 Safekeeping........................................................................................................................................ 7
1.4 Notation conventions .......................................................................................................................... 7
1.4.1 Hazard communication system ............................................................................................................................. 7
1.4.2 Information system................................................................................................................................................ 9
1.4.3 Instruction system ................................................................................................................................................. 9

2 Safety................................................................................................................................. 11
2.1 Appropriate use ................................................................................................................................ 11
2.2 Inappropriate use.............................................................................................................................. 12
2.3 Fundamental safety instructions ....................................................................................................... 12
2.4 Personnel qualification...................................................................................................................... 14
2.5 Personal protective equipment ......................................................................................................... 15

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/models ...................................................................................................................................................... 17
3.2.3 Nameplate and serial number ............................................................................................................................. 20
3.2.4 Protective devices ............................................................................................................................................... 20
3.3 Drive shaft......................................................................................................................................... 28
3.3.1 Function description ............................................................................................................................................ 28
3.3.2 Design/versions................................................................................................................................................... 29
3.4 OF 100 Oil Filter Unit ........................................................................................................................ 34

4 Packaging, transport and storage .................................................................................. 35

4.1 Packaging ......................................................................................................................................... 35
4.1.1 Suitability............................................................................................................................................................. 35
4.1.2 Markings.............................................................................................................................................................. 36
4.2 Transportation, receipt and handling of shipments........................................................................... 37
4.3 Storage of shipments........................................................................................................................ 38
4.4 Unpacking shipments and checking for transportation damages ..................................................... 39

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5 Mounting ........................................................................................................................... 40
5.1 Preparatory work .............................................................................................................................. 40
5.1.1 Fitting mounting flange on transformer cover...................................................................................................... 40
5.1.2 Fitting stud bolts on mounting flange .................................................................................................................. 41
5.2 Installing the on-load tap-changer in the transformer (standard version) ......................................... 42
5.2.1 Fastening on-load tap-changer to transformer cover .......................................................................................... 42
5.2.2 Connecting the tap winding and on-load tap-changer take-off lead.................................................................... 47
5.2.3 Performing transformer ratio test before drying .................................................................................................. 55
5.2.4 Performing DC resistance measurement on transformer.................................................................................... 56
5.2.5 Drying on-load tap-changer in autoclave ............................................................................................................ 56
5.2.6 Drying on-load tap-changer in transformer tank.................................................................................................. 64
5.2.7 Filling the oil compartment of the on-load tap-changer with insulating fluid........................................................ 81
5.2.8 Performing transformer ratio test after drying ..................................................................................................... 82
5.3 Installing on-load tap-changer in transformer (bell-type tank version).............................................. 84
5.3.1 Inserting on-load tap-changer into supporting structure...................................................................................... 84
5.3.2 Connecting the tap winding and on-load tap-changer take-off lead.................................................................... 88
5.3.3 Performing transformer ratio test before drying .................................................................................................. 97
5.3.4 Performing DC resistance measurement on transformer.................................................................................... 98
5.3.5 Drying on-load tap-changer in autoclave ............................................................................................................ 98
5.3.6 Lifting top part of on-load tap-changer head off supporting flange (bottom part) .............................................. 107
5.3.7 Attaching the bell-type tank and connecting 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................................................................................................ 129
5.3.9 Filling the oil compartment of the on-load tap-changer with insulating fluid...................................................... 146
5.3.10 Performing transformer ratio test after drying ................................................................................................... 147
5.4 Fitting protective devices and drive components............................................................................ 149
5.4.1 Connecting the tap-change supervisory device ................................................................................................ 149
5.4.2 Installing protective relay in piping and connecting........................................................................................... 149
5.4.3 Installing and connecting the pressure monitoring device ................................................................................ 161
5.4.4 Fitting motor-drive unit ...................................................................................................................................... 163
5.4.5 Fitting drive shaft............................................................................................................................................... 163
5.4.6 Centering on-load tap-changer and motor-drive unit ........................................................................................ 222
5.4.7 Making the electrical connections for the motor-drive unit ................................................................................ 222

6 Commissioning............................................................................................................... 223
6.1 Commissioning the on-load tap-changer at the transformer manufacturer's site ........................... 223
6.1.1 Bleeding on-load tap-changer head and suction pipe....................................................................................... 224

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6.1.2 Grounding the on-load tap-changer .................................................................................................................. 225

6.1.3 Checking motor-drive unit ................................................................................................................................. 227
6.1.4 High-voltage tests on the transformer ............................................................................................................... 227
6.2 Transporting transformer to the operating site................................................................................ 229
6.2.1 Transport with drive removed............................................................................................................................ 229
6.2.2 Transport with full transformer tank and without oil conservator....................................................................... 229
6.2.3 Transport with empty transformer tank ............................................................................................................. 230
6.3 Commissioning transformer at operating site ................................................................................. 231
6.3.1 Filling the oil compartment of the on-load tap-changer with insulating fluid...................................................... 231
6.3.2 Bleeding on-load tap-changer head and suction pipe....................................................................................... 233
6.3.3 Checking motor-drive unit ................................................................................................................................. 234
6.3.4 Checking protective relay.................................................................................................................................. 235
6.3.5 Checking pressure monitoring device ............................................................................................................... 236
6.3.6 Commissioning the transformer ........................................................................................................................ 237

7 Fault elimination ............................................................................................................. 238

7.1 Tripping the protective relay and re-commissioning the transformer.............................................. 240
7.1.1 Flap valve in OPERATION position .................................................................................................................. 241
7.1.2 Flap valve in OFF position ................................................................................................................................ 241
7.1.3 Re-commissioning the transformer ................................................................................................................... 241
7.2 Tripping the pressure monitoring device and putting the transformer back into operation ............. 242
7.2.1 Sensor in the OPERATION position ................................................................................................................. 242
7.2.2 Sensor in the OFF position ............................................................................................................................... 243
7.2.3 Re-commissioning the transformer ................................................................................................................... 243

8 Technical data................................................................................................................. 244

8.1 Permissible ambient conditions ...................................................................................................... 244
8.2 Technical data for protective relay.................................................................................................. 244
8.3 Special models of protective relay .................................................................................................. 247
8.3.1 Protective relay with CO change-over contact as tripping switch ..................................................................... 247
8.3.2 Protective relay with several dry-reed magnetic switches................................................................................. 248
8.4 Technical data for pressure monitoring device ............................................................................... 249
8.5 Limit values for dielectric strength and water content of insulating fluids ....................................... 250

9 Drawings ......................................................................................................................... 251

9.1 OILTAP® M, installation drawing of centrical drive (893978) ......................................................... 251
9.2 OILTAP® M, installation position of selector connection contacts (890477) .................................. 253
9.3 OILTAP® M, MS, R, RM, centrical drive (893899) ......................................................................... 254

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9.4 OILTAP® M, MS, R, RM, pipe connection with tap-change supervisory control (899648) ............ 255
9.5 Tracing template for on-load tap-changer head (890183) .............................................................. 256
9.6 OILTAP® M, MS, R, supporting flange, special version for bell-type tank installation for Um up to
300 kV (896762) ............................................................................................................................. 257
9.7 Lifting traverse for bell-type tank installation (890180) ................................................................... 258
9.8 Socket wrench for kerosene drain plug (890182) ........................................................................... 259
9.9 Screw tools for installation and maintenance (890478) .................................................................. 260
9.10 Bevel gear CD 6400, dimensional drawing (892916) ..................................................................... 261

Glossary .......................................................................................................................... 262

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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
Tel.: (+49) 9 41/40 90-0
E-mail: [email protected]

Further information on the product and copies of this technical file are avail-
able from this address if required.

1.2 Completeness
This technical file is incomplete without the supporting documents.

The following documents are considered supporting documents:

▪ Unpacking instructions
▪ Supplement
▪ Routine test report
▪ Connection diagrams
▪ Dimensional drawings
▪ Order confirmation

1.3 Safekeeping
Keep this technical file and all supporting documents ready at hand and ac-
cessible for future use at all times.

1.4 Notation conventions

1.4.1 Hazard communication system

Warnings in this technical file are displayed as follows.

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 1 Introduction

1.4.1.1 Warning relating to section

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

tions or several paragraphs within this technical file. Warnings relating to
sections use the following format:

WARNING Type of danger!

Source of the danger and outcome.
► Action
► Action

1.4.1.2 Embedded warning information

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

ings apply to smaller units of information than the warnings relating to sec-
tions. Embedded warnings use the following format:

DANGER! Instruction for avoiding a dangerous situation.

1.4.1.3 Signal words and pictograms

The following signal words are used:

Signal word Definition
DANGER Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE Indicates measures to be taken to prevent damage to property.
Table 1: Signal words in warning notices

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1 Introduction

Pictograms warn of dangers:

Pictogram Definition
Warning of a danger point

Warning of dangerous electrical voltage

Warning of combustible substances

Warning of danger of tipping

Warning of danger of crushing

Table 2: Pictograms used in warning notices

1.4.2 Information system

Information is designed to simplify and improve understanding of particular
procedures. In this technical file it is laid out as follows:

Important information.

1.4.3 Instruction system

This technical file contains single-step and multi-step instructions.

Single-step instructions

Instructions which consist of only a single process step are structured as fol-
lows:

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 1 Introduction

Aim of action
ü Requirements (optional).
► Step 1 of 1.
ð Result of step (optional).
ð Result of action (optional).

Multi-step instructions

Instructions which consist of several process steps are structured as follows:

Aim of action
ü Requirements (optional).
1. Step 1.
ð Result of step (optional).
2. Step 2.
ð Result of step (optional).
ð Result of action (optional).

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2 Safety

2 Safety
▪ Read this technical file through to familiarize yourself with the product.
▪ This technical file is a part of the product.
▪ Read and observe the safety instructions provided in this chapter.
▪ Read and observe the warnings in this technical file in order to avoid func-
tion-related dangers.
▪ The product is manufactured on the basis of state-of-the-art technology.
Nevertheless, risks to life and limb for the user or impairment of the prod-
uct and other material assets due to the function may arise in the event of
improper use.

2.1 Appropriate use

The product is an on-load tap-changer and adjusts the transmission ratio of
transformers without interrupting the load flow. The product is designed
solely for use in electrical energy systems and facilities. If used as intended
and in compliance with the requirements and conditions specified in this
technical file as well as the warning notices in this technical file and attached
to the product, then the product does not present any danger to people,
property or the environment. This applies throughout the service life of the
product, from delivery, installation and operation to removal and disposal.

The following is considered intended use:

▪ Use the product only with the transformer/motor-drive unit specified in the
order.
▪ The serial numbers of on-load tap-changer and on-load tap-changer ac-
cessories (drive, drive shaft, bevel gear, protective relay, etc.) must match
if the on-load tap-changer and on-load tap-changer accessories are sup-
plied 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 provided technical file, the
agreed delivery conditions and technical data.
▪ Ensure that all necessary work is performed by qualified personnel only.
▪ Only use the equipment and special tools included in the scope of delivery
for the intended purpose and in accordance with the specifications of this
technical document.

Permitted electrical operating conditions

In addition to the design data in accordance with the order confirmation, ob-
serve the following limits for the through-current and the step voltage:

In the standard version, the on-load tap-changer is designed for sinusoidal

50/60 Hz alternating current with a curve form symmetrical to the zero axis
and can switch 2 times the rated through-current Ir at its rated step voltage
Uir.

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 2 Safety

Exceeding the rated step voltage Uir by up to 10% for a short period is per-
mitted as long as the rated step capacity PStN permissible for this step volt-
age is not exceeded.

2.2 Inappropriate use

Use is considered inappropriate if the product is used in a way other than as
described in the "Appropriate use" section. In addition, observe the following:

Prohibited electrical operating conditions

All operating conditions that do not comply with the design data in accor-
dance with the order confirmation are prohibited.

Prohibited operating conditions may arise due to short circuits as well as due
to inrush current impulses when energizing transformers or other electrical
machines. This applies to the affected transformer itself just as it does to
transformers electrically connected in parallel or serially or other electrical
machines.

Higher voltages may occur due to transformer overexcitation following load

shedding, for example.

Operations outside of the permitted operating conditions can lead to injury to

persons and damage to the product.
▪ Prevent any such operations outside of the permitted operating conditions
by taking suitable measures.

2.3 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:

Personal protective equipment

Loosely worn or unsuitable clothing increases the danger of becoming

trapped or caught up in rotating parts and the danger of getting caught on
protruding parts. This poses a danger to life and limb.
▪ Wear appropriate personal protective equipment such as a helmet, work
gloves, etc. for the respective activity.
▪ Never wear damaged personal protective equipment.
▪ Never wear rings, necklaces, or other jewelry.
▪ If you have long hair, wear a hairnet.

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2 Safety

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 coun-
try.

Working during operation

The product may only be operated in a sound, operational condition. Other-

wise it poses a danger to life and limb.
▪ Regularly check the operational reliability of safety equipment.
▪ Comply with the inspection work, maintenance work and maintenance in-
tervals described in this technical file.

Explosion protection

Highly flammable or explosive gases, vapors and dusts can cause serious
explosions and fire. This increases the danger to life and limb.
▪ Do not install, operate or perform maintenance work on the product in ar-
eas 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.

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 the manufac-

turer can lead to personal injury, damage to property and malfunctions of the
product.
▪ Only use insulating fluids [►Section 8.1, Page 244] approved by the man-
ufacturer.
▪ Only use conductive and grounded hoses, pipes and pump equipment
that are approved for flammable liquids.

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 2 Safety

▪ Only use lubricants and auxiliary materials approved by the manufacturer.

▪ Contact the manufacturer.

Modifications and conversions

Unauthorized or inappropriate changes to the product may lead to personal

injury, material damage and operational faults.
▪ Only modify the product after consultation with Maschinenfabrik Rein-
hausen GmbH.

Spare parts

Spare parts not approved by Maschinenfabrik Reinhausen GmbH may lead

to physical injury, damage to the product and malfunctions.
▪ Only use spare parts that have been approved by Maschinenfabrik Rein-
hausen GmbH.
▪ Contact Maschinenfabrik Reinhausen GmbH.

2.4 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.

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.

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2 Safety

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 is per-
formed correctly. If maintenance is not carried out by our Technical Service
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.

2.5 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.
Protective clothing Close-fitting work clothing with a low tearing strength,
with tight sleeves and with no protruding parts. It mainly
serves to protect the wearer against being caught by
moving machine parts.
Safety shoes To protect against falling heavy objects and slipping on
slippery surfaces.
Safety glasses To protect the eyes from flying parts and splashing liq-
uids.
Visor To protect the face from flying parts and splashing liq-
uids or other dangerous substances.
Hard hat To protect against falling and flying parts and materials.
Hearing protection To protect against hearing damage.
Protective gloves To protect against mechanical, thermal, and electrical
hazards.
Table 3: Personal protective equipment

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 3 Product description

3 Product description

3.1 Scope of delivery

The product is packaged with protection against moisture and is usually de-
livered as follows:
▪ Diverter switch (oil compartment with diverter switch insert)
▪ Selector
▪ Motor-drive unit
▪ Drive shaft with coupling parts and bevel gear
▪ Protective devices
▪ Technical files

Please refer to the delivery slip for full details of the scope of delivery.

On-load tap-changers can also be provided 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 only
be removed immediately before installation

You will find more information in the "Packaging, transport, and stor-
age" [►Section 4, Page 35] 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. This makes it possible to compensate
for aspects such as fluctuations in voltage occurring in the power transmis-
sion grid. 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 operating position of the on-load tap-changer, as a result
of which the transformer's transmission ratio is adapted to the prevailing op-
erating requirements.

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3 Product description

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 Protective relay
4 Bevel gear 9 Oil conservator
5 Horizontal drive shaft 10 Active part of the transformer

3.2.2 Setup/models
The following drawing shows the main components of the on-load tap-
changer.

You will find a detailed drawing of the on-load tap-changer in the "Drawings
[►Section 9, Page 251]" section.

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 3 Product description

Figure 2: On-load tap-changer

1 Rupture disk 2 On-load tap-changer head cover

3 On-load tap-changer head 4 Oil compartment
5 Selector 6 Change-over selector
7 Pipe bend 8 Upper gear unit

3.2.2.1 Pipe connections

The on-load tap-changer head features 4 pipe connections for different pur-
poses.

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3 Product description

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

The pipe connection Q is closed with a blank cover. Depending on the on-
load tap-changer type, either the connection cables of the tap-change super-
visory device delivered as an option are routed through the pipe connection,
or the oil filter unit is connected to the pipe connection.

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 intended 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

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 be-

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 3 Product description

tween the transformer tank and oil compartment of the on-load tap-changer,
which is necessary for drying, filling with insulating fluid and transportation of
the transformer.

3.2.3 Nameplate and serial number

The nameplate with serial number is on the on-load tap-changer head cover.

Figure 4: Nameplate

The serial number can also be found on the selector.

Figure 5: Serial number

3.2.4 Protective devices

The on-load tap-changer is equipped with the following protective devices.

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3 Product description

3.2.4.1 Protective relay

3.2.4.1.1 Function description

The protective relay is looped into the circuit breaker tripping circuit. It is
tripped when the specified speed of flow from the on-load tap-changer head
to the oil conservator is exceeded due to a fault. The flowing insulating fluid
actuates the flap valve which tips over into position 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 a component of an on-load tap-changer filled with in-

sulating fluid and its properties conform to the respective applicable version
of IEC publication 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 flow, not to gas accumulated in the protec-
tive relay. It is not necessary to bleed the protective relay when filling the
transformer with insulating fluid. Gas accumulation in the protective relay is
normal.

3.2.4.1.2 Design/versions
Front view

Figure 6: Protective relay RS 2001

1 Inspection window 2 Pressure equalization element

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 3 Product description

Rear view

Figure 7: Protective relay RS 2001

1 Dummy plug 2 Nameplate

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

View from above

Figure 8: Protective relay RS 2001

1 Gasket 2 Potential tie-in

3 Terminal box cover 4 Slotted head screw for potential
tie-in
5 OPERATION (reset) test button 6 Slotted head screw for protective
cover
7 OFF (test tripping) test button 8 Cable gland
9 Protective cover 10 Dummy plug

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3 Product description

11 Connection terminal 12 Pressure equalization element

13 Cylinder head screw for protective
conductor connection

The protective relays RS 2003 and RS 2004 have a 1/2"-14NPT adapter in

place of the cable gland.

3.2.4.1.3 Nameplate

The nameplate is on the back of the protective relay.

Figure 9: Nameplate

3.2.4.2 Pressure monitoring device DW

3.2.4.2.1 Function description

The DW 2000 pressure monitoring device protects the on-load tap-changer

from impermissible pressure increases, contributing to the safety of the
transformer. The pressure monitoring device is installed on the outside of the
on-load tap-changer and is tripped by impermissible static and dynamic
pressures in the on-load tap-changer oil compartment.

The pressure monitoring device uses a concept where a corrugated tube

acts as a barometer together with a spring providing counter force. This as-
sembly is mechanically linked to the sensor on the snap-action switch.

The pressure increase activates the sensor on the snap-action switch, which
flips into the OFF position. This triggers the circuit breaker and de-energizes
the transformer. The sensor on the snap-action switch has to be reset to the
initial position by hand after tripping.

Low-energy interference does not cause the pressure monitoring device to

trip since the required tripping pressure is not reached. The tripping pressure
is set at the factory and prevented from being changed.

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 3 Product description

The pressure monitoring device responds to large pressure increases faster

than the protective relay. The protective relay is part of the standard MR pro-
tection system and comes as standard.

Additional use of a pressure monitoring device also requires installation of

the provided protective relay.

The features and characteristics of the pressure monitoring device 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

There are two variants of the pressure monitoring device:

▪ DW 2000 for vertical installation
▪ DW 2000 for horizontal installation

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3 Product description

The housing and the cover cap of the pressure monitoring device consist of
lightweight, corrosion-resistant metal.

Figure 10: Snap-action switch and pressure measuring element

1 Snap-action switch 2 Pressure measuring element

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 3 Product description

Figure 11: Pressure monitoring device with cover cap and ventilation

1 Ventilation 2 Cover cap

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, MR will supply a pre-fitted MPreC® pressure relief device in

place of the rupture disk. This device responds to a defined overpressure in
the oil compartment 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 device

The tap-change supervisory device monitors both the drive shaft between
on-load tap-changer(s) and motor-drive unit and the correct switching of the
diverter switch.

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3 Product description

3.2.4.6 Temperature monitoring

The temperature monitoring system monitors the temperature of the insulat-

ing fluid in the oil compartment of the on-load tap-changer.

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 3 Product description

3.3 Drive shaft

3.3.1 Function description

The drive shaft is the mechanical connection between the drive and the on-
load tap-changer/de-energized tap-changer.

The bevel gear changes the direction from vertical to horizontal.

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.

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3 Product description

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 driving or 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

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 3 Product description

3.3.2.1 Drive shaft without cardan joint and without insulator

Figure 13: Drive shaft without cardan joint and without insulator (= standard version)

Configuration V 1 min Intermediate bearing

Middle of hand crank – middle of 536 mm When the maximum value
bevel gear (maximum permissible of 2472 mm is exceeded, it
axial offset 2°) is necessary to use an in-
termediate bearing.
V 1 ≤ 2472 mm (without in-
termediate bearing)
V 1 > 2472 mm (with inter-
mediate bearing)

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3 Product description

3.3.2.2 Drive shaft without cardan joint and with insulator

Figure 14: Drive shaft without cardan joint and with insulator (= special model)

Configuration V 1 min Intermediate bearing

Middle of hand crank – middle of 706 mm When the maximum value
bevel gear (maximum permissible of 2472 mm is exceeded, it
axial offset 2°) is necessary to use an in-
termediate bearing.
V 1 ≤ 2472 mm (without in-
termediate bearing)
V 1 > 2472 mm (with inter-
mediate bearing)

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 3 Product description

3.3.2.3 Drive shaft with cardan joints, without insulator

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

Configuration V 1 min [mm] Intermediate bearing for

[mm]
Middle of hand crank – middle of 798 V 1 > 2564
bevel gear (maximum permissible
axial offset 20°)

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3 Product description

3.3.2.4 Drive shaft with cardan joints, with insulator

Figure 16: Drive shaft with cardan joints, with insulator (= special model)

Configuration V 1 min [mm] Intermediate bearing for

[mm]
Middle of hand crank – middle of 978 V 1 > 2772
bevel gear (maximum permissible
axial offset 20°)

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 3 Product description

3.4 OF 100 Oil Filter Unit

The purpose of the OF 100 oil filter unit is to clean the on-load tap-changer's
insulating fluid with the paper filter insert and to clean and dry the fluid with
the combined filter insert.

For on-load tap-changers where the number of tap-change operations per

year is higher than 15,000, we recommend the use of the OF 100 oil filter
unit with paper filter insert. This can extend the intervals between mainte-
nance.

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® M on-load tap-changers where Um=300 kV (insulated to ground)
and a linked operating voltage at the on-load tap-changer of 245…260 kV.

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4 Packaging, transport and storage

4 Packaging, transport and storage

4.1 Packaging
The products are sometimes supplied with sealed packaging and sometimes
in a dry state, depending on requirements.

Sealed packaging surrounds the packaged goods with plastic foil on all
sides.

Products that have also been dried are identified by a yellow label on the
sealed packaging. In the dry state, delivery is also possible in a transport
container.

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.
► The outer marking on the packaging states if, for example, the on-load
tap-changer or selector has been packed upright. Never stack these
crates.
► General rule: Do not stack crates above a height of 1.5 m.
► For other crates: Only stack up to 2 equally sized crates on top of one an-
other.

The packaging is suitable to ensure undamaged and fully functional means

of transportation in compliance with local transportation laws and regula-
tions.

The packaged goods are packed in a sturdy 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.

Sealed packaging surrounds the packaged goods with plastic foil on all
sides. The packaged goods are protected from humidity using a desiccant.
The plastic foil was bonded after the desiccant is added.

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 4 Packaging, transport and storage

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 against Top Fragile Attach lifting Center of mass

moisture gear here
Table 4: Shipping pictograms

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4 Packaging, transport and storage

4.2 Transportation, receipt and handling of shipments

WARNING Danger of death or severe injury!
Danger of death or serious injuries due to tipping or falling load.
► Only transport the crate when closed.
► Do not remove the securing material used in the crate during transport.
► If the product is delivered on a pallet, secure it sufficiently.
► Only trained and authorized persons may select the sling gear and se-
cure the load.
► Do not walk under the suspended load.
► Use means of transport and lifting gear with a sufficient carrying capacity
in accordance with the weight stated on the delivery slip.

In addition to oscillation stress, jolts must also be expected during trans-

portation. 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 is
subject to 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 found upon receipt of the shipment, proceed
as follows:
▪ Immediately record the identified transport damage 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 manufacturer and the relevant insurance company.
▪ After identifying damage, do not modify the condition of the shipment fur-
ther 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 on site together with the
carrier involved. This is essential for any claim for damages.
▪ Photograph damage to packaging and packaged goods. This also applies
to signs of corrosion on the packaged goods due to moisture inside the
packaging (rain, snow, condensation).
▪ NOTICE! Damage to packaged goods due to damaged sealed packag-
ing. If the product is delivered in sealed packaging, check the sealed
packaging immediately. If the sealed packaging is damaged, do not under

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 4 Packaging, transport and storage

any circumstances install or commission the packaged goods. Either re-

dry the dried packaged goods as per the operating instructions, or contact
the manufacturer to agree on how to proceed.
▪ Identify 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 fluid until used if the packaged goods were not sup-
plied in insulating fluid.

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 after
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.

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4 Packaging, transport and storage

If the product is installed more than 6 months after delivery, suitable mea-
sures 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 a 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! Damage to packaged goods due to ineffectively sealed packag-
ing. Transport the packaged crate to the place where the packaged goods
are to be installed. Do not open the sealed packaging until just before in-
stallation.
▪ WARNING! Serious injuries and damage to the packaged goods due
to the packaged goods tipping out. Place the packaged goods in an up-
right crate and protect it from tipping out.
▪ Unpack the packaged goods and check the condition.
▪ Check the completeness of the accessories kit using the delivery slip.

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 5 Mounting

5 Mounting
WARNING Risk of crushing!
When the on-load tap-changer undertakes a tap-change operation, compo-
nents – some of which are freely accessible – move on the selector,
change-over selector, and potential connection unit. Reaching into the se-
lector, change-over selector, or potential connection unit during a tap-
change operation 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 connec-
tion unit during tap-change operations.
► Do not switch the on-load tap-changer during work on the selector,
change-over selector, or potential connection unit.

5.1 Preparatory work

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

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

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5 Mounting

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.
2. Fit stud bolts on mounting flange.

Figure 18: Tracing template, stud bolts

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 5 Mounting

5.2 Installing the on-load tap-changer in the transformer

(standard version)

5.2.1 Fastening on-load tap-changer to transformer cover

5.2.1.1 Fastening oil compartment on transformer cover

1. CAUTION! An unstably positioned oil compartment may tip over, re-
sulting in injuries or property damage. Place the oil compartment on a
level surface and secure it against tipping.
2. Remove red-colored packaging material and transport material from the
oil compartment.
3. NOTICE! Unsuitable gaskets may lead to oil escaping and therefore to
damage to the on-load tap-changer. Place a gasket suitable for the in-
sulating medium in use on the mounting flange . Clean the sealing sur-
faces on the mounting flange and on-load tap-changer head.

Figure 19: Sealing surfaces, gasket

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5 Mounting

4. NOTICE! Lowering the oil compartment without due care can result in the
oil compartment colliding with the transformer cover and becoming dam-
aged. Lift the oil compartment by hooking up the on-load tap-changer
head and carefully lower it vertically into the opening of the transformer
cover.

Figure 20: Lowering oil compartment

5. Check that the on-load tap-changer head is mounted in the position speci-
fied by the design.
6. Screw the on-load tap-changer head to the mounting flange.

Figure 21: On-load tap-changer head with mounting flange

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 5 Mounting

7. Remove the blocking strip from the coupling of the oil compartment base.

Figure 22: Blocking strip

5.2.1.2 Securing selector on oil compartment

1. CAUTION! An unstably positioned selector may tip, resulting in in-
juries or property damage. Place the selector on a level surface and se-
cure it against tipping.
2. Remove red-colored packaging material and transport material from the
selector. Only remove the red protective cap on the 0-bar of the change-
over selector after fixing the selector to the oil compartment.
3. Remove plastic bag with fastening materials from the selector and keep it
ready.

Figure 23: Plastic bag with fastening materials

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5 Mounting

4. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling may no longer be turned.

Figure 24: Selector coupling with blocking strip

5. Place the selector on the lifting device. The weight of the selector is a
maximum of 165 kg.
6. NOTICE! Lifting the selector without due care can result in the selector
and oil compartment colliding and becoming damaged. Carefully lift the
selector below the oil compartment, ensuring that the tap-selector con-
necting leads and potential connection unit (if installed) are free when lift-
ing the selector onto the oil compartment, and that they do not touch the
compartment.
7. 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.
8. Screw selector onto oil compartment.

Figure 25: Selector with oil compartment

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 5 Mounting

9. NOTICE! Incorrect tightening torques and unsecured screw connections

can lead to damage to the on-load tap-changer. Screw the tap-selector
connecting leads to connecting piece with care. Comply with the specified
tightening torque, secure screw connections and snap the screening caps
in place over the screw heads.

Figure 26: Tap-selector connecting leads

10. Remove the red protective cap on the 0-bar of the change-over selector.

Figure 27: Protective cap

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5 Mounting

11. Secure selector with pitch of tap selector contact circle 36 to prevent it
twisting as a result of being turned and slid. There are 3 holes, 20 mm in
diameter, in the selector base for this purpose. Ensure that it can still be
slid in an axial direction.

The selector's pitch of tap selector contact circle is stated in the on-load tap-
changer's type designation after the selector size.
Example: M I 501-123/B-36340 (B = selector size, 36 = pitch of tap selector
contact circle)

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 that 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 Tap selector connection contacts

The tap selector connection contacts are provided with a through-hole for
M10 screws. The through-holes are either horizontal or vertical, depending
on the on-load tap-changer model.
1. Fasten the tap-winding connecting leads to the tap selector in accordance
with the connection diagram provided. The cable shoes and fastening ma-
terials are not included in the scope of delivery.
2. Take suitable measures to ensure that each screw connection cannot
come loose or settle (e.g. by using clamping washers). Be sure to attach
the screening caps as shown in the illustration if these are included in the
delivery scope.

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 5 Mounting

3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 28: Tap selector connection contacts

5.2.2.2 Tap selector connection contacts for multiple coarse tapping

arrangement

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

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5 Mounting

In the case of multiple coarse change-over selectors, take care when routing
the cables for connecting to the tap selector connection contacts and the
multiple coarse change-over selector connection contacts. These cables
should be as far away as possible from neighboring connection contacts.
1. The tap selector connection contacts that face both multiple coarse
change-over selector columns must have at least 3 mm of paper insula-
tion to ensure dielectric strength.
2. Please pay attention to the dimensional drawing on which the order is
based.

Figure 29: Paper insulation

1 Connection from MR already has 3 p Connections to be insulated

mm of paper insulation

5.2.2.3 Change-over selector connection contacts for reversing change-over

selector connection

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

The (+) and (-) change-over selector connection contacts are designed as
connecting lugs with through-holes for M10 screws for reversing change-
over selector connection.

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 5 Mounting

The connection contact K is designed as an extended tap selector connec-

tion contact with through-hole for M10 screws.
1. Fasten the tap-winding connecting leads to the change-over selector in
accordance with the connection diagram provided. The cable shoes and
fastening materials are not included in the scope of delivery.
2. Take suitable measures to ensure that each fitting cannot come loose or
settle (e.g. by using clamping washers). Be sure to attach the screening
caps if these are included in the delivery scope.
3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 30: Change-over selector connection contacts for reversing change-over selector con-
nection

Figure 31: Change-over selector connection contacts for reversing change-over selector con-
nection (top view)

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5 Mounting

5.2.2.4 Change-over selector connection contacts for coarse tap selector

connection

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

With coarse tap selector connection, the external appearance of the (+) and
(-) change-over selector connection contacts is identical to the tap selector
contacts (through-hole for M10 screws, always in vertical position).
1. Fasten the tap-winding connecting leads to the change-over selector in
accordance with the connection diagram provided. The cable shoes and
fastening materials are not included in the scope of delivery.
2. Take suitable measures to ensure that each fitting cannot come loose or
settle (e.g. by using clamping washers). Be sure to attach the screening
caps if these are included in the delivery scope.
3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 32: Change-over selector connection contacts for coarse tap selector connection

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 5 Mounting

Figure 33: Change-over selector connection contacts for coarse tap selector connection (top
view)

5.2.2.5 Change-over selector connection contacts for multiple coarse tapping

arrangement

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

With a multiple coarse tapping arrangement, the external appearance of the

change-over selector connection contacts is identical to the tap selector con-
tacts (through-hole for M10 screws, always in vertical position).
1. Fasten the tap-winding connecting leads to the change-over selector in
accordance with the connection diagram provided. The cable shoes and
fastening materials are not included in the scope of delivery.
2. Take suitable measures to ensure that each fitting cannot come loose or
settle (e.g. by using clamping washers). Be sure to attach the screening
caps if these are included in the delivery scope.

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5 Mounting

3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 34: Change-over selector connection contacts for multiple coarse tapping arrangement

Figure 35: Change-over selector connection contacts for multiple coarse tapping arrangement
with bridges on the connection contacts

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 5 Mounting

5.2.2.6 Connecting on-load tap-changer take-off lead

5.2.2.6.1 Take-off lead connection directly on oil compartment

1. Connect the on-load tap-changer take-off lead to the take-off lead connec-
tion using the cable shoe and screw. The cable shoe and fastening mate-
rials are not included in the scope of delivery.
2. Take suitable measures to ensure the screw connection cannot come
loose or settle (e.g. by using clamping washers).

Figure 36: Take-off lead connection on oil compartment

5.2.2.6.2 Take-off lead connection on take-off ring

1. Connect the on-load tap-changer take-off lead to 1 of the 3 through-holes
on the take-off ring using a cable shoe and screw. The cable shoe and
fastening materials are not included in the scope of delivery.
2. Pay attention to the screw length. A minimum distance of 2 mm must be
maintained between screw and oil compartment.

Figure 37: Connecting ring of oil compartment

3. Take suitable measures to ensure the screw connection cannot come

loose or settle (e.g. by using clamping washers).

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5 Mounting

5.2.3 Performing transformer ratio test before drying

NOTICE Damage to the on-load tap-changer!

Damage to the on-load tap-changer due to transformer ratio test being in-
correctly performed.
► Do not perform more than 250 tap-change operations on the on-load tap-
changer. If more than 250 tap-change operations are to be performed,
completely fill the oil compartment with insulating fluid and lubricate slid-
ing surfaces of contacts on the selector and selector gear with insulating
fluid.
► 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, for example. When using a drill, do not exceed a maximum
speed of 250 rpm.
► Always check the operating position reached through the inspection win-
dow in the on-load tap-changer head cover. Never overshoot the end po-
sitions, 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 using the horizontal drive shaft parts.

When actuating the change-over selector, a higher torque is required.

1. Switch the on-load tap-changer into the desired operating position. The di-
verter switch operation can be heard distinctly.
2. NOTICE! An incomplete tap-change operation may damage the on-load
tap-changer. After operating the diverter switch, continue to crank the
drive shaft of the upper gear unit for 2.5 revolutions in the same direction
in order to correctly complete the tap-change operation.
3. Perform the transformer ratio test.
4. Repeat the transformer ratio test in all operating positions.
5. Switch the on-load tap-changer into adjustment position (see the accom-
panying connection diagram for 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.

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5.2.4 Performing DC resistance measurement on transformer

The measured DC current is normally restricted to 10% of the rated current
of the measured transformer winding in order to prevent the winding from
overheating.

Perform the DC resistance measurement in various on-load tap-changer op-

erating positions. You need to distinguish here whether the measured cur-
rent is interrupted when changing operating position or not.
Status of oil compart- Without interruption in With interruption (mea-
ment measured current sured current = 0 A be-
fore change of operating
position)
Oil compartment empty Maximum 10 A DC Maximum 50 A DC
Oil compartment filled with Maximum 50 A DC Maximum 50 A DC
insulating fluid
Table 5: Maximum permitted measured currents when performing DC resistance measurement
on transformer

5.2.5 Drying on-load tap-changer in autoclave

NOTICE Damage to the on-load tap-changer!

Moisture in the oil compartment reduces the dielectric strength of the insu-
lating fluid and thus leads to damage to the on-load tap-changer.
► Within 10 hours of drying, seal off oil compartment with on-load tap-
changer head cover.

Dry on-load tap-changer in accordance with the following instructions to en-

sure the dielectric values assured by MR for the on-load tap-changer.

If drying in an autoclave, the following methods are possible:

▪ Vacuum drying
▪ Vapor-phase drying

As an alternative to drying the on-load tap-changer in an autoclave, it can

also be dried in the transformer tank.

5.2.5.1 Vacuum-drying in the autoclave

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.2.8, Page 82].

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5.2.5.1.1 Moving on-load tap-changer to adjustment position

► Move the on-load tap-changer to the adjustment position. The adjustment
position is indicated in the on-load tap-changer connection diagram in-
cluded in delivery.

5.2.5.1.2 Removing on-load tap-changer head cover

WARNING Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.
► Ensure that parts do not fall into the oil compartment.
► Check that all small parts are accounted for.

1. Ensure that the inspection window is sealed off with the cover.
2. Remove the screws and washers from the on-load tap-changer head
cover.

Figure 38: On-load tap-changer head cover

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3. Remove on-load tap-changer head cover.

Figure 39: On-load tap-changer head cover

5.2.5.1.3 Drying the on-load tap-changer

NOTICE Damage to the on-load tap-changer head cover and on-load tap-
changer accessories.
Both the on-load tap-changer head cover and the on-load tap-changer ac-
cessories will become damaged if they are dried.
► Never dry the on-load tap-changer head cover or the following acces-
sories: motor-drive unit, drive shaft, protective 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 approximately 10 °C/h to a final temperature of
maximum 110 °C.
2. Pre-dry the on-load tap-changer in circulating air at a maximum tempera-
ture of 110 °C for a period of at least 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

NOTICE Damage to the on-load tap-changer!

A missing or damaged o-ring as well as unclean sealing surfaces lead to in-
sulating fluid escaping and therefore to damage to the on-load tap-changer.
► Ensure that the o-ring is positioned untwisted in the on-load tap-changer
head cover.
► Ensure that the o-ring does not become damaged when mounting the
cover.
► Ensure that the sealing surfaces on the on-load tap-changer head cover
and on-load tap-changer head are clean.

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1. Check that the feather key is securely positioned in the adapter shaft.
Where necessary, use Vaseline to secure the feather key against falling
out.

Figure 40: Feather key

2. Position the on-load tap-changer head cover on the on-load tap-changer

head in such a way that the red triangular markings on the on-load tap-
changer head and the on-load tap-changer head cover are aligned.

Figure 41: Triangular markings and o-ring

3. Screw the on-load tap-changer head cover onto the on-load tap-changer
head.

Figure 42: On-load tap-changer head cover

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5.2.5.2 Vapor-phase drying in the autoclave

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.2.8, Page 82].

5.2.5.2.1 Moving on-load tap-changer to adjustment position

► Move the on-load tap-changer to the adjustment position. The adjustment
position is indicated in the on-load tap-changer connection diagram in-
cluded in delivery.

5.2.5.2.2 Removing on-load tap-changer head cover

WARNING Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.
► Ensure that parts do not fall into the oil compartment.
► Check that all small parts are accounted for.

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1. Ensure that the inspection window is sealed off with the cover.
2. Remove the screws and washers from the on-load tap-changer head
cover.

Figure 43: On-load tap-changer head cover

3. Remove on-load tap-changer head cover.

Figure 44: On-load tap-changer head cover

5.2.5.2.3 Opening kerosene drain plug

► NOTICE! Never remove the kerosene drain plug completely. Only un-
screw the kerosene drain plug between the oil compartment base and se-
lector gear clockwise until it starts to become hard to open.

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Figure 45: Kerosene drain plug

5.2.5.2.4 Drying the on-load tap-changer

NOTICE Damage to the on-load tap-changer head cover and on-load tap-
changer accessories.
Both the on-load tap-changer head cover and the on-load tap-changer ac-
cessories will become damaged if they are dried.
► Never dry the on-load tap-changer head cover or the following acces-
sories: motor-drive unit, drive shaft, protective relay, pressure monitoring
device, pressure relief device, bevel gear, temperature sensor, oil filter
unit.

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

perature constant for 3 to 4 hours.
2. Increase the kerosene vapor temperature by approx. 10°C/hour to the de-
sired final temperature of max. 125°C at the on-load tap-changer.
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.

5.2.5.2.5 Closing kerosene drain plug

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

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5.2.5.2.6 Securing on-load tap-changer head cover

NOTICE Damage to the on-load tap-changer!

A missing or damaged o-ring as well as unclean sealing surfaces lead to in-
sulating fluid escaping and therefore to damage to the on-load tap-changer.
► Ensure that the o-ring is positioned untwisted in the on-load tap-changer
head cover.
► Ensure that the o-ring does not become damaged when mounting the
cover.
► Ensure that the sealing surfaces on the on-load tap-changer head cover
and on-load tap-changer head are clean.

1. Check that the feather key is securely positioned in the adapter shaft.
Where necessary, use Vaseline to secure the feather key against falling
out.

Figure 46: Feather key

2. Position the on-load tap-changer head cover on the on-load tap-changer

head in such a way that the red triangular markings on the on-load tap-
changer head and the on-load tap-changer head cover are aligned.

Figure 47: Triangular markings and o-ring

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3. Screw the on-load tap-changer head cover onto the on-load tap-changer
head.

Figure 48: On-load tap-changer head cover

5.2.6 Drying on-load tap-changer in transformer tank

Dry on-load tap-changer in accordance with the following instructions to en-
sure the dielectric values assured by MR on the on-load tap-changer.

If you want to dry the on-load tap-changer in the transformer tank, fully as-
semble the transformer first and then undertake drying.

If drying in the transformer tank, the following methods are possible:

▪ Vacuum-drying
▪ Vapor-phase drying

As an alternative to drying the on-load tap-changer in the transformer tank, it

can also be dried in an autoclave.

5.2.6.1 Vacuum-drying in the transformer tank

The on-load tap-changer head cover remains closed during the entire drying
process.

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1. Establish a connecting lead between either connections E2 and Q or con-

nections E2 and R on the on-load tap-changer head.
2. Seal off unused pipe connections with a suitable blank cover.

Figure 49: Connecting lead

Vacuum-drying in the transformer tank

1. Heat up the on-load tap-changer in air at atmospheric pressure with a
temperature increase of approximately 10 °C/h to a final temperature of
maximum 110 °C.
2. Pre-dry the on-load tap-changer in circulating air at a maximum tempera-
ture of 110 °C for a period of at least 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.

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.2.8, Page 82].

5.2.6.2 Vapor-phase drying in the transformer tank

If you have opened the kerosene drain plug already (e.g. after the trans-
former ratio test), you can begin the drying [►Section 5.2.6.2.4, Page 80]
right away.

Otherwise, you first have to open the kerosene drain plug before you can be-
gin the drying.

5.2.6.2.1 Removing diverter switch insert

5.2.6.2.1.1 Moving on-load tap-changer to adjustment position

► Move the on-load tap-changer to the adjustment position. The adjustment
position is indicated in the on-load tap-changer connection diagram in-
cluded in delivery.

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5.2.6.2.1.2 Removing on-load tap-changer head cover

WARNING Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.
► Ensure that parts do not fall into the oil compartment.
► Check that all small parts are accounted for.

1. Ensure that the inspection window is sealed off with the cover.
2. Remove the screws and washers from the on-load tap-changer head
cover.

Figure 50: On-load tap-changer head cover

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3. Remove on-load tap-changer head cover.

Figure 51: On-load tap-changer head cover

5.2.6.2.1.3 Removing tap position indicator disk without multiple coarse change-
over selector
► Pull spring clip off shaft end and remove tap position indicator disk.

Figure 52: Tap position indicator disk

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5.2.6.2.1.4 Removing tap position indicator disk with multiple coarse change-over
selector with more than 35 operating positions
1. Ensure that the red marks on the panel, tap position indicator disk and
cover disk produce a continuous red line.
2. Remove countersunk head screw.

Figure 53: Countersunk head screw

3. Lever cover disk off underlying disk with flat screwdriver and pull out posi-
tion-indication disk from between panel and bracket.

Figure 54: Cover disk and position-indication disk

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4. Remove hexagon screws and associated lock tab.

Figure 55: Lock tab

5. Pull panel and bracket up and off indicator drive shaft.

Figure 56: Panel

5.2.6.2.1.5 Disconnecting the plug connector of the tap-change supervisory

control

DANGER Electric shock!

If supply voltage is applied to the tap-change supervisory device, this can
result in electric shock.
► Disconnect the tap-change supervisory device from the supply voltage
and secure it to prevent it from being switched back on again.

NOTICE Damage to the tap-change supervisory device!

Disconnecting the tap-change supervisory device without due care may
damage it, thereby resulting in damage to the on-load tap-changer.
► Disconnect the tap-change supervisory device with care in order not to
damage or rip out the connecting leads.

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1. Lift plug connector and leads out of bracket and retaining clamps.

Figure 57: Lifting out plug connector

2. Disconnect the plug connector.

Figure 58: Disconnecting plug connector

3. Put part B of plug connector back in bracket.

Figure 59: Placing part B of plug connector in bracket

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

tion indicated by arrow until it is between the pipe connections and the ca-
ble cannot be damaged when pulling out the diverter switch insert.

Figure 60: Swiveling out part A of plug connector

5.2.6.2.1.6 Lifting out diverter switch insert

1. Remove bolts and locking elements on carrier plate of diverter switch in-
sert.

Figure 61: Carrier plate of diverter switch insert

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2. Insert lifting gear in the brackets provided on the diverter switch insert car-
rier plate and position vertically above the diverter switch insert.

Figure 62: Brackets on carrier plate

3. Lift out diverter switch insert slowly and vertically.

Figure 63: Lifting out diverter switch insert

4. CAUTION! An unstably positioned diverter switch insert may tip, re-

sulting in injuries and property damage. Place the diverter switch insert on
a level surface and secure it against tipping.

5.2.6.2.2 Opening kerosene drain plug

► NOTICE! Never remove the kerosene drain plug completely. Unscrew
kerosene drain plug with extended socket wrench counter-clockwise until
it starts to become hard to open.

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Figure 64: Kerosene drain plug

5.2.6.2.3 Inserting diverter switch insert

5.2.6.2.3.1 Inserting diverter switch insert

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

Figure 65: Adjustment position

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2. Insert lifting gear in the brackets provided on the diverter switch insert car-
rier plate and position vertically above the diverter switch insert.

Figure 66: Brackets on carrier plate

3. Align diverter switch insert such that the red triangles at the top of the en-
ergy accumulator and on the on-load tap-changer head are opposite one
another.

Figure 67: Aligning diverter switch insert

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4. By turning the coupling tube, align it in such a manner that the red trian-
gles on the coupling tube and carrier plate match up.

Figure 68: Coupling tube

5. Slowly lower diverter switch insert.

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

Figure 69: Carrier plate of diverter switch insert

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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 70: Part B of plug connector

2. Connecting plug connector

Figure 71: Connecting plug connector

3. Place plug connector in bracket, secure leads on both sides of plug con-
nector in retaining clamps.

Figure 72: Placing plug connector in bracket

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5.2.6.2.3.3 Inserting the tap position indicator without multiple coarse change-
over selector

Due to the coupling pin, the tap position indicator disc can only be installed
when in the correct position.

► Place tap position indicator disk on indicator drive shaft, slide spring clip
on to shaft end.

Figure 73: Tap position indicator disk

5.2.6.2.3.4 Inserting tap position indicator with multiple coarse change-over

selector with more than 35 operating positions
1. Place panel with bracket on indicator drive shaft and fasten with hexagon
screws and associated lock tab.

Figure 74: Fitting panel

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2. Insert position-indication disk horizontally between panel and bracket and

fit cover disk. Align tap position indicator disc and cover disk to produce a
continuous red line.

Figure 75: Inserting position-indication disk

3. Secure cover disk with countersunk head screw. The countersunk head
screw must be suitable for center-punching.

Figure 76: Fastening cover disk

4. Secure countersunk head screw by center-punching.

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5.2.6.2.3.5 Securing on-load tap-changer head cover

NOTICE Damage to the on-load tap-changer!

A missing or damaged o-ring as well as unclean sealing surfaces lead to in-
sulating fluid escaping and therefore to damage to the on-load tap-changer.
► Ensure that the o-ring is positioned untwisted in the on-load tap-changer
head cover.
► Ensure that the o-ring does not become damaged when mounting the
cover.
► Ensure that the sealing surfaces on the on-load tap-changer head cover
and on-load tap-changer head are clean.

1. Check that the feather key is securely positioned in the adapter shaft.
Where necessary, use Vaseline to secure the feather key against falling
out.

Figure 77: Feather key

2. Position the on-load tap-changer head cover on the on-load tap-changer

head in such a way that the red triangular markings on the on-load tap-
changer head and the on-load tap-changer head cover are aligned.

Figure 78: Triangular markings and o-ring

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3. Screw the on-load tap-changer head cover onto the on-load tap-changer
head.

Figure 79: On-load tap-changer head cover

5.2.6.2.4 Drying the on-load tap-changer

1. Connect pipe connections R and Q of on-load tap-changer head to the
kerosene vapor lead using one shared lead.
2. Seal off unused pipe connections with a suitable blank cover.

Figure 80: Shared lead

Vapor-phase drying in the transformer tank

1. Supply kerosene vapor at a temperature of around 90°C. Keep this tem-
perature constant for 3 to 4 hours.
2. Increase the kerosene vapor temperature by approx. 10°C/hour to the de-
sired final temperature of max. 125°C at the on-load tap-changer.
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.

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5.2.6.2.5 Closing kerosene drain plug

NOTICE Damage to the on-load tap-changer!

Moisture in the oil compartment reduces the dielectric strength of the insu-
lating fluid and thus leads to damage to the on-load tap-changer.
► Within 10 hours of drying, seal off oil compartment with on-load tap-
changer head cover.

1. Remove [►Section 5.2.6.2.1, Page 65] the diverter switch insert.

2. NOTICE! An open kerosene drain plug leads to insulating fluid escaping
from the oil compartment and therefore to damage to the on-load tap-
changer. Close kerosene drain plug by turning clockwise with extended
socket wrench (tightening torque 20 Nm).
3. Insert [►Section 5.2.6.2.3, Page 73] the diverter switch insert.

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.2.8, Page 82].

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

insulating fluid

NOTICE Damage to the on-load tap-changer!

Unsuitable insulating fluids cause damage to the on-load tap-changer.
► Only use insulating fluids [►Section 8.1, Page 244] approved by the
manufacturer.

After drying, completely fill the oil compartment (diverter switch insert fitted)
with insulating fluid again as soon as possible so that an impermissible
amount of humidity is not absorbed from the surroundings.
1. Establish a connecting lead between pipe connection E2 and one of the
pipe connections R, S or Q to ensure equal pressure in the oil compart-
ment and transformer during evacuation.

Figure 81: Connecting lead between E2 and Q

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2. Fill on-load tap-changer with new insulating fluid using one of the two free
pipe connections of the on-load tap-changer head.

Figure 82: Pipe connections S and R

5.2.8 Performing transformer ratio test after drying

NOTICE Damage to the on-load tap-changer!

Damage to the on-load tap-changer due to transformer ratio test being in-
correctly performed.
► Ensure that the selector / de-energized tap changer is fully immersed in
the insulating fluid and that the oil compartment of the on-load tap-
changer is completely filled with insulating fluid.
► 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, for example. When using a drill, do not exceed a maximum
speed of 250 rpm.
► Always check the operating position reached through the inspection win-
dow in the on-load tap-changer head cover. Never overshoot the end po-
sitions, 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 using the horizontal drive shaft part.

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When actuating the change-over selector, a higher torque is required.

1. Switch the on-load tap-changer into the desired operating position. The di-
verter switch operation can be heard distinctly.
2. NOTICE! An incomplete tap-change operation may damage the on-load
tap-changer. After operating the diverter switch, continue to crank the
drive shaft of the upper gear unit for 2.5 revolutions in the same direction
in order to correctly complete the tap-change operation.
3. Perform the transformer ratio test.
4. Repeat the transformer ratio test in all operating positions.
5. Switch the on-load tap-changer into adjustment position (see the accom-
panying connection diagram for the on-load tap-changer).

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

tank version)

5.3.1 Inserting on-load tap-changer into supporting structure

5.3.1.1 Securing selector on oil compartment

1. CAUTION! An unstably positioned selector may tip, resulting in in-
juries or property damage. Place the selector on a level surface and se-
cure it against tipping.
2. Remove red-colored packaging material and transport material from the
selector. Only remove the red protective cap on the 0-bar of the change-
over selector after inserting the on-load tap-changer into the supporting
structure.
3. Remove plastic bag with fastening materials from the selector and keep it
ready.

Figure 83: Plastic bag with fastening materials

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4. Remove the blocking strip from the selector coupling. Once the blocking
strip is removed, the selector coupling may no longer be turned.

Figure 84: Selector coupling with blocking strip

5. CAUTION! An unstably positioned oil compartment may tip over, re-

sulting in injuries or property damage. Place the oil compartment on a
level surface and secure it against tipping.
6. Remove the blocking strip from the coupling of the oil compartment base.

Figure 85: Oil compartment base with blocking strip

7. Lift the oil compartment by hooking up the on-load tap-changer head and
carefully move it over the selector. The weight of the oil compartment is a
maximum of 320 kg.
8. NOTICE! Lowering the oil compartment without due care can result in the
oil compartment and selector colliding and becoming damaged. Carefully
lower the oil compartment, ensuring that the tap-selector connecting leads
and potential connection unit (if installed) are free when lifting the selector
onto the oil compartment, and that they do not touch the compartment.

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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.
10. Screw selector onto oil compartment.

Figure 86: Selector with oil compartment

11. NOTICE! Incorrect tightening torques and unsecured screw connections

can lead to damage to the on-load tap-changer. Screw the tap-selector
connecting leads to connecting piece with care. Comply with the speci-
fied tightening torque, secure screw connections and snap the screening
caps in place over the screw heads.

Figure 87: Tap-selector connecting leads

5.3.1.2 Inserting on-load tap-changer into supporting structure

1. NOTICE! Tensile forces can lead to damage and malfunctions on the on-
load tap-changer. Using spacers, insert the on-load tap-changer vertically
into the supporting structure (maximum 1° deviation from the vertical) so

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that the on-load tap-changer reaches its final installation height and only
has to be raised a maximum of 5...20 mm once the tap winding and the
on-load tap-changer take-off lead have been connected and the bell-type
tank fitted.

Figure 88: On-load tap-changer with spacers on supporting structure

2. Temporarily fasten on-load tap-changer to supporting structure. The sup-

porting flange has through holes for this purpose.

Figure 89: Fastening the on-load tap-changer

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3. Remove the red protective cap on the 0-bar of the change-over selector (if
present).

Figure 90: Protective cap

4. Secure selector with pitch of tap selector contact circle 36 to prevent it

twisting as a result of being turned and slid. There are 3 holes, 20 mm in
diameter, in the selector base for this purpose. Ensure that it can still be
slid in an axial direction.

The selector's pitch of tap selector contact circle is stated in the on-load tap-
changer's type designation after the selector size.
Example: M I 501-123/B-36340 (B = selector size, 36 = pitch of tap selector
contact circle)

5.3.2 Connecting the tap winding and on-load tap-changer take-off

lead

NOTICE Damage to the on-load tap-changer!

Connecting leads that 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.

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The tap winding and on-load tap-changer take-off lead must be connected in
accordance with the connection diagram included with the delivery.

5.3.2.1 Tap selector connection contacts

The tap selector connection contacts are provided with a through-hole for
M10 screws. The through-holes are either horizontal or vertical, depending
on the on-load tap-changer model.
1. Fasten the tap-winding connecting leads to the tap selector in accordance
with the connection diagram provided. The cable shoes and fastening ma-
terials are not included in the scope of delivery.
2. Take suitable measures to ensure that each screw connection cannot
come loose or settle (e.g. by using clamping washers). Be sure to attach
the screening caps as shown in the illustration if these are included in the
delivery scope.
3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 91: Tap selector connection contacts

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5.3.2.2 Tap selector connection contacts for multiple coarse tapping

arrangement

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

In the case of multiple coarse change-over selectors, take care when routing
the cables for connecting to the tap selector connection contacts and the
multiple coarse change-over selector connection contacts. These cables
should be as far away as possible from neighboring connection contacts.
1. The tap selector connection contacts that face both multiple coarse
change-over selector columns must have at least 3 mm of paper insula-
tion to ensure dielectric strength.
2. Please pay attention to the dimensional drawing on which the order is
based.

Figure 92: Paper insulation

1 Connection from MR already has 3 p Connections to be insulated

mm of paper insulation

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5.3.2.3 Change-over selector connection contacts for reversing change-over

selector connection

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

The (+) and (-) change-over selector connection contacts are designed as
connecting lugs with through-holes for M10 screws for reversing change-
over selector connection.

The connection contact K is designed as an extended tap selector connec-

tion contact with through-hole for M10 screws.
1. Fasten the tap-winding connecting leads to the change-over selector in
accordance with the connection diagram provided. The cable shoes and
fastening materials are not included in the scope of delivery.
2. Take suitable measures to ensure that each fitting cannot come loose or
settle (e.g. by using clamping washers). Be sure to attach the screening
caps if these are included in the delivery scope.
3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 93: Change-over selector connection contacts for reversing change-over selector con-
nection

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Figure 94: Change-over selector connection contacts for reversing change-over selector con-
nection (top view)

5.3.2.4 Change-over selector connection contacts for coarse tap selector

connection

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

With coarse tap selector connection, the external appearance of the (+) and
(-) change-over selector connection contacts is identical to the tap selector
contacts (through-hole for M10 screws, always in vertical position).
1. Fasten the tap-winding connecting leads to the change-over selector in
accordance with the connection diagram provided. The cable shoes and
fastening materials are not included in the scope of delivery.
2. Take suitable measures to ensure that each fitting cannot come loose or
settle (e.g. by using clamping washers). Be sure to attach the screening
caps if these are included in the delivery scope.

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3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 95: Change-over selector connection contacts for coarse tap selector connection

Figure 96: Change-over selector connection contacts for coarse tap selector connection (top
view)

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5.3.2.5 Change-over selector connection contacts for multiple coarse tapping

arrangement

NOTICE Damage to the on-load tap-changer!

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
damage to the on-load tap-changer.
► 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.

With a multiple coarse tapping arrangement, the external appearance of the

change-over selector connection contacts is identical to the tap selector con-
tacts (through-hole for M10 screws, always in vertical position).
1. Fasten the tap-winding connecting leads to the change-over selector in
accordance with the connection diagram provided. The cable shoes and
fastening materials are not included in the scope of delivery.
2. Take suitable measures to ensure that each fitting cannot come loose or
settle (e.g. by using clamping washers). Be sure to attach the screening
caps if these are included in the delivery scope.
3. Close the screening caps and make sure they are seated correctly. The
screw head and nut must be fully covered.

Figure 97: Change-over selector connection contacts for multiple coarse tapping arrangement

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Figure 98: Change-over selector connection contacts for multiple coarse tapping arrangement
with bridges on the connection contacts

5.3.2.6 Connecting on-load tap-changer take-off lead

5.3.2.6.1 Take-off lead connection directly on oil compartment

Applies to the following on-load tap-changers:

OILTAP® M III 350 Y, OILTAP® M III 500 Y, OILTAP® M III 600 Y,

OILTAP® M I 351, OILTAP® M I 501, OILTAP® M I 601

To connect the on-load tap-changer take-off lead, proceed as follows:

1. Connect on-load tap-changer take-off lead with take-off lead connection
on oil compartment.

Figure 99: Take-off lead connection on oil compartment

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Figure 100: Take-off lead connection on oil compartment

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

loose or settle (e.g. by using clamping washers).

5.3.2.6.2 Take-off lead connection on take-off ring

Applies to the following on-load tap-changers:

OILTAP® M I 802, OILTAP® M I 1203, OILTAP® M I 1503, OILTAP® M II

352, OILTAP® M II 502, OILTAP® M II 602

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.

To connect the on-load tap-changer take-off lead, proceed as follows:

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 fasten-
ing materials are not included in the scope of delivery.
2. Pay attention to the screw length. A minimum distance of 2 mm must be
maintained between screw and oil compartment.

Figure 101: Take-off ring on oil compartment

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Figure 102: Take-off ring on oil compartment

3. Take suitable measures to ensure the screw connection cannot come

loose or settle (e.g. by using clamping washers).

5.3.3 Performing transformer ratio test before drying

NOTICE Damage to the on-load tap-changer!

Damage to the on-load tap-changer due to transformer ratio test being in-
correctly performed.
► Do not perform more than 250 tap-change operations on the on-load tap-
changer. If more than 250 tap-change operations are to be performed,
completely fill the oil compartment with insulating fluid and lubricate slid-
ing surfaces of contacts on the selector and selector gear with insulating
fluid.
► 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, for example. When using a drill, do not exceed a maximum
speed of 250 rpm.
► Always check the operating position reached through the inspection win-
dow in the on-load tap-changer head cover. Never overshoot the end po-
sitions, 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 using the horizontal drive shaft parts.

When actuating the change-over selector, a higher torque is required.

1. Switch the on-load tap-changer into the desired operating position. The di-
verter switch operation can be heard distinctly.
2. NOTICE! An incomplete tap-change operation may damage the on-load
tap-changer. After operating the diverter switch, continue to crank the
drive shaft of the upper gear unit for 2.5 revolutions in the same direction
in order to correctly complete the tap-change operation.
3. Perform the transformer ratio test.

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4. Repeat the transformer ratio test in all operating positions.

5. Switch the on-load tap-changer into adjustment position (see the accom-
panying connection diagram for 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.

5.3.4 Performing DC resistance measurement on transformer

The measured DC current is normally restricted to 10% of the rated current
of the measured transformer winding in order to prevent the winding from
overheating.

Perform the DC resistance measurement in various on-load tap-changer op-

erating positions. You need to distinguish here whether the measured cur-
rent is interrupted when changing operating position or not.
Status of oil compart- Without interruption in With interruption (mea-
ment measured current sured current = 0 A be-
fore change of operating
position)
Oil compartment empty Maximum 10 A DC Maximum 50 A DC
Oil compartment filled with Maximum 50 A DC Maximum 50 A DC
insulating fluid
Table 6: Maximum permitted measured currents when performing DC resistance measurement
on transformer

5.3.5 Drying on-load tap-changer in autoclave

NOTICE Damage to the on-load tap-changer!

Moisture in the oil compartment reduces the dielectric strength of the insu-
lating fluid and thus leads to damage to the on-load tap-changer.
► Within 10 hours of drying, seal off oil compartment with on-load tap-
changer head cover.

Dry on-load tap-changer in accordance with the following instructions to en-

sure the dielectric values assured by MR for the on-load tap-changer.

If drying in an autoclave, the following methods are possible:

▪ Vacuum drying
▪ Vapor-phase drying

As an alternative to drying the on-load tap-changer in an autoclave, it can

also be dried in the transformer tank.

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5.3.5.1 Vacuum-drying in the autoclave

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.3.10, Page 147].

5.3.5.1.1 Moving on-load tap-changer to adjustment position

► Move the on-load tap-changer to the adjustment position. The adjustment
position is indicated in the on-load tap-changer connection diagram in-
cluded in delivery.

5.3.5.1.2 Removing on-load tap-changer head cover

WARNING Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.
► Ensure that parts do not fall into the oil compartment.
► Check that all small parts are accounted for.

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1. Ensure that the inspection window is sealed off with the cover.
2. Remove the screws and washers from the on-load tap-changer head
cover.

Figure 103: On-load tap-changer head cover

3. Remove on-load tap-changer head cover.

Figure 104: On-load tap-changer head cover

5.3.5.1.3 Drying the on-load tap-changer

NOTICE Damage to the on-load tap-changer head cover and on-load tap-
changer accessories.
Both the on-load tap-changer head cover and the on-load tap-changer ac-
cessories will become damaged if they are dried.
► Never dry the on-load tap-changer head cover or the following acces-
sories: motor-drive unit, drive shaft, protective 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 approximately 10 °C/h to a final temperature of
maximum 110 °C.
2. Pre-dry the on-load tap-changer in circulating air at a maximum tempera-
ture of 110 °C for a period of at least 20 hours.

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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.

5.3.5.1.4 Securing on-load tap-changer head cover

NOTICE Damage to the on-load tap-changer!

A missing or damaged o-ring as well as unclean sealing surfaces lead to in-
sulating fluid escaping and therefore to damage to the on-load tap-changer.
► Ensure that the o-ring is positioned untwisted in the on-load tap-changer
head cover.
► Ensure that the o-ring does not become damaged when mounting the
cover.
► Ensure that the sealing surfaces on the on-load tap-changer head cover
and on-load tap-changer head are clean.

1. Check that the feather key is securely positioned in the adapter shaft.
Where necessary, use Vaseline to secure the feather key against falling
out.

Figure 105: Feather key

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2. Position the on-load tap-changer head cover on the on-load tap-changer

head in such a way that the red triangular markings on the on-load tap-
changer head and the on-load tap-changer head cover are aligned.

Figure 106: Triangular markings and o-ring

3. Screw the on-load tap-changer head cover onto the on-load tap-changer
head.

Figure 107: On-load tap-changer head cover

5.3.5.2 Vapor-phase drying in the autoclave

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.3.10, Page 147].

5.3.5.2.1 Moving on-load tap-changer to adjustment position

► Move the on-load tap-changer to the adjustment position. The adjustment
position is indicated in the on-load tap-changer connection diagram in-
cluded in delivery.

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5.3.5.2.2 Removing on-load tap-changer head cover

WARNING Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.
► Ensure that parts do not fall into the oil compartment.
► Check that all small parts are accounted for.

1. Ensure that the inspection window is sealed off with the cover.
2. Remove the screws and washers from the on-load tap-changer head
cover.

Figure 108: On-load tap-changer head cover

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3. Remove on-load tap-changer head cover.

Figure 109: On-load tap-changer head cover

5.3.5.2.3 Opening kerosene drain plug

► NOTICE! Never remove the kerosene drain plug completely. Only un-
screw the kerosene drain plug between the oil compartment base and se-
lector gear clockwise until it starts to become hard to open.

Figure 110: Kerosene drain plug

5.3.5.2.4 Drying the on-load tap-changer

NOTICE Damage to the on-load tap-changer head cover and on-load tap-
changer accessories.
Both the on-load tap-changer head cover and the on-load tap-changer ac-
cessories will become damaged if they are dried.
► Never dry the on-load tap-changer head cover or the following acces-
sories: motor-drive unit, drive shaft, protective relay, pressure monitoring
device, pressure relief device, bevel gear, temperature sensor, oil filter
unit.

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

perature constant for 3 to 4 hours.
2. Increase the kerosene vapor temperature by approx. 10°C/hour to the de-
sired final temperature of max. 125°C at the on-load tap-changer.
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.

5.3.5.2.5 Closing kerosene drain plug

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

5.3.5.2.6 Securing on-load tap-changer head cover

NOTICE Damage to the on-load tap-changer!

A missing or damaged o-ring as well as unclean sealing surfaces lead to in-
sulating fluid escaping and therefore to damage to the on-load tap-changer.
► Ensure that the o-ring is positioned untwisted in the on-load tap-changer
head cover.
► Ensure that the o-ring does not become damaged when mounting the
cover.
► Ensure that the sealing surfaces on the on-load tap-changer head cover
and on-load tap-changer head are clean.

1. Check that the feather key is securely positioned in the adapter shaft.
Where necessary, use Vaseline to secure the feather key against falling
out.

Figure 111: Feather key

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2. Position the on-load tap-changer head cover on the on-load tap-changer

head in such a way that the red triangular markings on the on-load tap-
changer head and the on-load tap-changer head cover are aligned.

Figure 112: Triangular markings and o-ring

3. Screw the on-load tap-changer head cover onto the on-load tap-changer
head.

Figure 113: On-load tap-changer head cover

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

flange (bottom part)

5.3.6.1 Removing on-load tap-changer head cover

WARNING Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.
► Ensure that parts do not fall into the oil compartment.
► Check that all small parts are accounted for.

1. Ensure that the inspection window is sealed off with the cover.
2. Remove temporary fastening and spacers and slowly lower the on-load
tap-changer.

Figure 114: Temporary fasteners and spacers

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3. Remove the screws and washers from the on-load tap-changer head
cover.

Figure 115: On-load tap-changer head cover

4. Remove on-load tap-changer head cover.

Figure 116: On-load tap-changer head cover

5.3.6.2 Removing tap position indicator disk without multiple coarse change-
over selector
► Pull spring clip off shaft end and remove tap position indicator disk.

Figure 117: Tap position indicator disk

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5.3.6.3 Removing tap position indicator disk with multiple coarse change-over
selector with more than 35 operating positions
1. Ensure that the red marks on the panel, tap position indicator disk and
cover disk produce a continuous red line.
2. Remove countersunk head screw.

Figure 118: Countersunk head screw

3. Lever cover disk off underlying disk with flat screwdriver and pull out posi-
tion-indication disk from between panel and bracket.

Figure 119: Cover disk and position-indication disk

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4. Remove hexagon screws and associated lock tab.

Figure 120: Lock tab

5. Pull panel and bracket up and off indicator drive shaft.

Figure 121: Panel

5.3.6.4 Disconnecting the plug connector of the tap-change supervisory

control

DANGER Electric shock!

If supply voltage is applied to the tap-change supervisory device, this can
result in electric shock.
► Disconnect the tap-change supervisory device from the supply voltage
and secure it to prevent it from being switched back on again.

NOTICE Damage to the tap-change supervisory device!

Disconnecting the tap-change supervisory device without due care may
damage it, thereby resulting in damage to the on-load tap-changer.
► Disconnect the tap-change supervisory device with care in order not to
damage or rip out the connecting leads.

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1. Lift plug connector and leads out of bracket and retaining clamps.

Figure 122: Lifting out plug connector

2. Disconnect the plug connector.

Figure 123: Disconnecting plug connector

3. Put part B of plug connector back in bracket.

Figure 124: Placing part B of plug connector in bracket

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

tion indicated by arrow until it is between the pipe connections and the ca-
ble cannot be damaged when pulling out the diverter switch insert.

Figure 125: Swiveling out part A of plug connector

5.3.6.5 Lifting out diverter switch insert

1. Loosen nuts and locking elements on carrier plate of diverter switch insert.
NOTICE! Make sure that parts do not fall into the oil compartment. Parts
in the oil compartment may block the diverter switch insert, thereby dam-
aging the on-load tap-changer and transformer. Check that you have the
same number of parts when removing and installing.

Figure 126: Carrier plate of diverter switch insert

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2. Insert lifting gear in the brackets provided on the diverter switch insert car-
rier plate and position vertically above the diverter switch insert.

Figure 127: Brackets on carrier plate

3. Lift out diverter switch insert slowly and vertically.

Figure 128: Lifting out diverter switch insert

4. CAUTION! An unstably positioned diverter switch insert may tip, re-

sulting in injuries and property damage. Place the diverter switch insert on
a level surface and secure it against tipping.

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5.3.6.6 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 129: Oil suction pipe

5.3.6.7 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 130: Top part of on-load tap-changer head with nuts

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2. Lift top part of on-load tap-changer head off supporting flange.

Figure 131: Top part of on-load tap-changer head

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5.3.7 Attaching the bell-type tank and connecting the on-load tap-
changer to the top part of the on-load tap-changer head

5.3.7.1 Attaching bell-type tank

1. Clean sealing surface of supporting flange, place o-ring on supporting
flange.

Figure 132: Supporting flange with o-ring

2. Lift the bell-type tank over the active part of the transformer.

Figure 133: Bell-type tank

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

1. NOTICE! Unsuitable gaskets may lead to oil escaping and therefore to
damage to the on-load tap-changer. Place a gasket suitable for the in-
sulating fluid used on the mounting flange . Clean the sealing surfaces
on the mounting flange and on-load tap-changer head.

Figure 134: Mounting flange with gasket

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2. Lower and position the top part of the on-load tap-changer head on
mounting flange so that the triangular markings, pins and mounting holes
on the top part and bottom part of the on-load tap-changer head are
aligned.

Figure 135: Markings and fitted bolt

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

head

NOTICE Incorrectly lifting the on-load tap-changer will damage it!

If the connection screws of 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 on-load tap-changer head
together!
► Always lift the on-load tap-changer with the specified lifting traverse, and
never with the connection screws of the supporting flange.

1. Insert lifting traverse in on-load tap-changer head.

Figure 136: Lifting traverse

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2. NOTICE! Inaccurate alignment of on-load tap-changer head to supporting

flange will damage the on-load tap-changer when it is lifted. Lift on-load
tap-changer with lifting traverse and ensure that the triangular markings
are aligned and that all supporting flange stud bolts go easily through the
mounting holes of the on-load tap-changer head.

Figure 137: Lifting on-load tap-changer

3. Screw the top part and bottom part of the on-load tap-changer head to-
gether in the area marked in red.

Figure 138: Screwing the on-load tap-changer head onto the supporting flange

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4. Remove lifting traverse.

Figure 139: Removing lifting traverse

5. Screw the on-load tap-changer head to the mounting flange.

Figure 140: Screwing the on-load tap-changer head to the mounting flange

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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 141: Oil suction pipe

5.3.7.5 Inserting diverter switch insert

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

Figure 142: Adjustment position

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2. Insert lifting gear in the brackets provided on the diverter switch insert car-
rier plate and position vertically above the diverter switch insert.

Figure 143: Brackets on carrier plate

3. Align diverter switch insert such that the red triangles at the top of the en-
ergy accumulator and on the on-load tap-changer head are opposite one
another.

Figure 144: Aligning diverter switch insert

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4. By turning the coupling tube, align it in such a manner that the red trian-
gles on the coupling tube and carrier plate match up.

Figure 145: Coupling tube

5. Slowly lower diverter switch insert.

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 locking ele-
ments.

Figure 146: Carrier plate of diverter switch insert

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5.3.7.6 Connecting plug connector of the tap-change supervisory device

1. Lift part B of plug connector out of bracket.

Figure 147: Part B of plug connector

2. Connecting plug connector

Figure 148: Connecting plug connector

3. Place plug connector in bracket, secure leads on both sides of plug con-
nector in retaining clamps.

Figure 149: Placing plug connector in bracket

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5.3.7.7 Inserting the tap position indicator without multiple coarse change-
over selector

Due to the coupling pin, the tap position indicator disc can only be installed
when in the correct position.

► Place tap position indicator disk on indicator drive shaft, slide spring clip
on to shaft end.

Figure 150: Tap position indicator disk

5.3.7.8 Inserting tap position indicator with multiple coarse change-over

selector with more than 35 operating positions
1. Place panel with bracket on indicator drive shaft and fasten with hexagon
screws and associated lock tab.

Figure 151: Fitting panel

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2. Insert position-indication disk horizontally between panel and bracket and

fit cover disk. Align tap position indicator disc and cover disk to produce a
continuous red line.

Figure 152: Inserting position-indication disk

3. Secure cover disk with countersunk head screw. The countersunk head
screw must be suitable for center-punching.

Figure 153: Fastening cover disk

4. Secure countersunk head screw by center-punching.

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5.3.7.9 Securing on-load tap-changer head cover

NOTICE Damage to the on-load tap-changer!

A missing or damaged o-ring as well as unclean sealing surfaces lead to in-
sulating fluid escaping and therefore to damage to the on-load tap-changer.
► Ensure that the o-ring is positioned untwisted in the on-load tap-changer
head cover.
► Ensure that the o-ring does not become damaged when mounting the
cover.
► Ensure that the sealing surfaces on the on-load tap-changer head cover
and on-load tap-changer head are clean.

1. Check that the feather key is securely positioned in the adapter shaft.
Where necessary, use Vaseline to secure the feather key against falling
out.

Figure 154: Feather key

2. Position the on-load tap-changer head cover on the on-load tap-changer

head in such a way that the red triangular markings on the on-load tap-
changer head and the on-load tap-changer head cover are aligned.

Figure 155: Triangular markings and o-ring

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3. Screw the on-load tap-changer head cover onto the on-load tap-changer
head.

Figure 156: On-load tap-changer head cover

5.3.8 Drying on-load tap-changer in transformer tank

Dry on-load tap-changer in accordance with the following instructions to en-
sure the dielectric values assured by MR on the on-load tap-changer.

If you want to dry the on-load tap-changer in the transformer tank, fully as-
semble the transformer first and then undertake drying.

If drying in the transformer tank, the following methods are possible:

▪ Vacuum-drying
▪ Vapor-phase drying

As an alternative to drying the on-load tap-changer in the transformer tank, it

can also be dried in an autoclave.

5.3.8.1 Vacuum-drying in the transformer tank

The on-load tap-changer head cover remains closed during the entire drying
process.

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1. Establish a connecting lead between either connections E2 and Q or con-

nections E2 and R on the on-load tap-changer head.
2. Seal off unused pipe connections with a suitable blank cover.

Figure 157: Connecting lead

Vacuum-drying in the transformer tank

1. Heat up the on-load tap-changer in air at atmospheric pressure with a
temperature increase of approximately 10 °C/h to a final temperature of
maximum 110 °C.
2. Pre-dry the on-load tap-changer in circulating air at a maximum tempera-
ture of 110 °C for a period of at least 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.

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.3.10, Page 147].

5.3.8.2 Vapor-phase drying in the transformer tank

If you have opened the kerosene drain plug already (e.g. after the trans-
former ratio test), you can begin the drying [►Section 5.3.8.2.4, Page 145]
right away.

Otherwise, you first have to open the kerosene drain plug before you can be-
gin the drying.

5.3.8.2.1 Removing diverter switch insert

5.3.8.2.1.1 Moving on-load tap-changer to adjustment position

► Move the on-load tap-changer to the adjustment position. The adjustment
position is indicated in the on-load tap-changer connection diagram in-
cluded in delivery.

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5.3.8.2.1.2 Removing on-load tap-changer head cover

WARNING Danger of explosion!

Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer!

Small parts in the oil compartment may block the diverter switch insert,
thereby damaging the on-load tap-changer.
► Ensure that parts do not fall into the oil compartment.
► Check that all small parts are accounted for.

1. Ensure that the inspection window is sealed off with the cover.
2. Remove the screws and washers from the on-load tap-changer head
cover.

Figure 158: On-load tap-changer head cover

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3. Remove on-load tap-changer head cover.

Figure 159: On-load tap-changer head cover

5.3.8.2.1.3 Removing tap position indicator disk without multiple coarse change-
over selector
► Pull spring clip off shaft end and remove tap position indicator disk.

Figure 160: Tap position indicator disk

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5.3.8.2.1.4 Removing tap position indicator disk with multiple coarse change-over
selector with more than 35 operating positions
1. Ensure that the red marks on the panel, tap position indicator disk and
cover disk produce a continuous red line.
2. Remove countersunk head screw.

Figure 161: Countersunk head screw

3. Lever cover disk off underlying disk with flat screwdriver and pull out posi-
tion-indication disk from between panel and bracket.

Figure 162: Cover disk and position-indication disk

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4. Remove hexagon screws and associated lock tab.

Figure 163: Lock tab

5. Pull panel and bracket up and off indicator drive shaft.

Figure 164: Panel

5.3.8.2.1.5 Disconnecting the plug connector of the tap-change supervisory

control

DANGER Electric shock!

If supply voltage is applied to the tap-change supervisory device, this can
result in electric shock.
► Disconnect the tap-change supervisory device from the supply voltage
and secure it to prevent it from being switched back on again.

NOTICE Damage to the tap-change supervisory device!

Disconnecting the tap-change supervisory device without due care may
damage it, thereby resulting in damage to the on-load tap-changer.
► Disconnect the tap-change supervisory device with care in order not to
damage or rip out the connecting leads.

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1. Lift plug connector and leads out of bracket and retaining clamps.

Figure 165: Lifting out plug connector

2. Disconnect the plug connector.

Figure 166: Disconnecting plug connector

3. Put part B of plug connector back in bracket.

Figure 167: Placing part B of plug connector in bracket

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

tion indicated by arrow until it is between the pipe connections and the ca-
ble cannot be damaged when pulling out the diverter switch insert.

Figure 168: Swiveling out part A of plug connector

5.3.8.2.1.6 Lifting out diverter switch insert

1. Loosen nuts and locking elements on carrier plate of diverter switch insert.
NOTICE! Make sure that parts do not fall into the oil compartment. Parts
in the oil compartment may block the diverter switch insert, thereby dam-
aging the on-load tap-changer and transformer. Check that you have the
same number of parts when removing and installing.

Figure 169: Carrier plate of diverter switch insert

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2. Insert lifting gear in the brackets provided on the diverter switch insert car-
rier plate and position vertically above the diverter switch insert.

Figure 170: Brackets on carrier plate

3. Lift out diverter switch insert slowly and vertically.

Figure 171: Lifting out diverter switch insert

4. CAUTION! An unstably positioned diverter switch insert may tip, re-

sulting in injuries and property damage. Place the diverter switch insert on
a level surface and secure it against tipping.

5.3.8.2.2 Opening kerosene drain plug

► NOTICE! Never remove the kerosene drain plug completely. Unscrew
kerosene drain plug with extended socket wrench counter-clockwise until
it starts to become hard to open.

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Figure 172: Kerosene drain plug

5.3.8.2.3 Inserting diverter switch insert

5.3.8.2.3.1 Inserting diverter switch insert

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

Figure 173: Adjustment position

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2. Insert lifting gear in the brackets provided on the diverter switch insert car-
rier plate and position vertically above the diverter switch insert.

Figure 174: Brackets on carrier plate

3. Align diverter switch insert such that the red triangles at the top of the en-
ergy accumulator and on the on-load tap-changer head are opposite one
another.

Figure 175: Aligning diverter switch insert

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4. By turning the coupling tube, align it in such a manner that the red trian-
gles on the coupling tube and carrier plate match up.

Figure 176: Coupling tube

5. Slowly lower diverter switch insert.

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 locking ele-
ments.

Figure 177: Carrier plate of diverter switch insert

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5.3.8.2.3.2 Connecting plug connector of the tap-change supervisory device

1. Lift part B of plug connector out of bracket.

Figure 178: Part B of plug connector

2. Connecting plug connector

Figure 179: Connecting plug connector

3. Place plug connector in bracket, secure leads on both sides of plug con-
nector in retaining clamps.

Figure 180: Placing plug connector in bracket

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5.3.8.2.3.3 Inserting the tap position indicator without multiple coarse change-
over selector

Due to the coupling pin, the tap position indicator disc can only be installed
when in the correct position.

► Place tap position indicator disk on indicator drive shaft, slide spring clip
on to shaft end.

Figure 181: Tap position indicator disk

5.3.8.2.3.4 Inserting tap position indicator with multiple coarse change-over

selector with more than 35 operating positions
1. Place panel with bracket on indicator drive shaft and fasten with hexagon
screws and associated lock tab.

Figure 182: Fitting panel

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2. Insert position-indication disk horizontally between panel and bracket and

fit cover disk. Align tap position indicator disc and cover disk to produce a
continuous red line.

Figure 183: Inserting position-indication disk

3. Secure cover disk with countersunk head screw. The countersunk head
screw must be suitable for center-punching.

Figure 184: Fastening cover disk

4. Secure countersunk head screw by center-punching.

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5.3.8.2.3.5 Securing on-load tap-changer head cover

NOTICE Damage to the on-load tap-changer!

A missing or damaged o-ring as well as unclean sealing surfaces lead to in-
sulating fluid escaping and therefore to damage to the on-load tap-changer.
► Ensure that the o-ring is positioned untwisted in the on-load tap-changer
head cover.
► Ensure that the o-ring does not become damaged when mounting the
cover.
► Ensure that the sealing surfaces on the on-load tap-changer head cover
and on-load tap-changer head are clean.

1. Check that the feather key is securely positioned in the adapter shaft.
Where necessary, use Vaseline to secure the feather key against falling
out.

Figure 185: Feather key

2. Position the on-load tap-changer head cover on the on-load tap-changer

head in such a way that the red triangular markings on the on-load tap-
changer head and the on-load tap-changer head cover are aligned.

Figure 186: Triangular markings and o-ring

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3. Screw the on-load tap-changer head cover onto the on-load tap-changer
head.

Figure 187: On-load tap-changer head cover

5.3.8.2.4 Drying the on-load tap-changer

1. Connect pipe connections R and Q of on-load tap-changer head to the
kerosene vapor lead using one shared lead.
2. Seal off unused pipe connections with a suitable blank cover.

Figure 188: Shared lead

Vapor-phase drying in the transformer tank

1. Supply kerosene vapor at a temperature of around 90°C. Keep this tem-
perature constant for 3 to 4 hours.
2. Increase the kerosene vapor temperature by approx. 10°C/hour to the de-
sired final temperature of max. 125°C at the on-load tap-changer.
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.

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5.3.8.2.5 Closing kerosene drain plug

NOTICE Damage to the on-load tap-changer!

Moisture in the oil compartment reduces the dielectric strength of the insu-
lating fluid and thus leads to damage to the on-load tap-changer.
► Within 10 hours of drying, seal off oil compartment with on-load tap-
changer head cover.

1. Remove [►Section 5.3.8.2.1, Page 130] the diverter switch insert.

2. NOTICE! An open kerosene drain plug leads to insulating fluid escaping
from the oil compartment and therefore to damage to the on-load tap-
changer. Close kerosene drain plug by turning clockwise with extended
socket wrench (tightening torque 20 Nm).
3. Insert [►Section 5.3.8.2.3, Page 138] the diverter switch insert.

If you wish to perform another transformer ratio test after drying, proceed as
described in the section "Performing transformer ratio test following dry-
ing" [►Section 5.3.10, Page 147].

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

insulating fluid

NOTICE Damage to the on-load tap-changer!

Unsuitable insulating fluids cause damage to the on-load tap-changer.
► Only use insulating fluids [►Section 8.1, Page 244] approved by the
manufacturer.

After drying, completely fill the oil compartment (diverter switch insert fitted)
with insulating fluid again as soon as possible so that an impermissible
amount of humidity is not absorbed from the surroundings.
1. Establish a connecting lead between pipe connection E2 and one of the
pipe connections R, S or Q to ensure equal pressure in the oil compart-
ment and transformer during evacuation.

Figure 189: Connecting lead between E2 and Q

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2. Fill on-load tap-changer with new insulating fluid using one of the two free
pipe connections of the on-load tap-changer head.

Figure 190: Pipe connections S and R

5.3.10 Performing transformer ratio test after drying

NOTICE Damage to the on-load tap-changer!

Damage to the on-load tap-changer due to transformer ratio test being in-
correctly performed.
► Ensure that the selector / de-energized tap changer is fully immersed in
the insulating fluid and that the oil compartment of the on-load tap-
changer is completely filled with insulating fluid.
► 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, for example. When using a drill, do not exceed a maximum
speed of 250 rpm.
► Always check the operating position reached through the inspection win-
dow in the on-load tap-changer head cover. Never overshoot the end po-
sitions, 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 using the horizontal drive shaft part.

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When actuating the change-over selector, a higher torque is required.

1. Switch the on-load tap-changer into the desired operating position. The di-
verter switch operation can be heard distinctly.
2. NOTICE! An incomplete tap-change operation may damage the on-load
tap-changer. After operating the diverter switch, continue to crank the
drive shaft of the upper gear unit for 2.5 revolutions in the same direction
in order to correctly complete the tap-change operation.
3. Perform the transformer ratio test.
4. Repeat the transformer ratio test in all operating positions.
5. Switch the on-load tap-changer into adjustment position (see the accom-
panying connection diagram for the on-load tap-changer).

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5.4 Fitting protective devices and drive components

5.4.1 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 prevent
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 terminals using
a connecting lead as specified in the connection diagram provided.

5.4.2 Installing protective relay in piping and connecting

WARNING Danger of explosion!

Explosive gases in the protective relay can deflagrate or explode and result
in severe injury or death.
► Wait 15 minutes after switching off the transformer before beginning fur-
ther work on the protective relay so that the gases can dissipate.
► Ensure that there are no ignition sources such as naked flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits before beginning work.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

Always perform all transformer tests with the protective relay attached and
connected.

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5.4.2.1 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. The associated contact
positions for checking electrical continuity are shown in the dimensional
drawing provided.
1. Loosen the three screws on the terminal box cover and lift off the terminal
box cover.

Figure 191: Terminal box cover

2. Remove the slotted head screw for potential tie-in and remove the termi-
nal box cover with wire.

Figure 192: Terminal box cover

NOTICE Damage to protective relay!

Damage to protective relay resulting from improper operation.
► Never press both test buttons at the same time.

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3. Press OFF test button.

ð Flap valve is inclined. Line marker appears in the middle of the inspec-
tion window.

Figure 193: OFF position

4. Press OPERATION test button.

ð Flap valve is vertical.

Figure 194: OPERATION position

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5. Position the wire for the terminal box cover and affix using the slotted
head screw.

Figure 195: Terminal box cover

6. Attach the terminal box cover and secure with screws.

Figure 196: Terminal box cover

5.4.2.2 Installing protective relay in piping

Ensure the following for installation and proper function of the protective re-
lay:
1. Ensure that there are no foreign bodies in the piping or in the oil conserva-
tor.
2. Install protective relay such that it can be easily accessed for subsequent
maintenance work.
3. Install protective relay with good support and free from vibrations.
4. The test buttons must be at the top.
5. The interior diameter of the piping must be at least 25 mm.

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6. The magnetic field strength (bushings, busbars etc.) must be < 20 kA/m.
Higher field strengths have a negative effect on the function of the protec-
tive relay.
7. The piping from the protective relay to the oil conservator must be routed
with an inclination of at least 2% (1.2°) to ensure the switching gases can
escape freely.
8. The protective relay is intended for a horizontal operating position in close
proximity to the on-load tap-changer head. A positive inclination of up to
5° from horizontal is permitted in the direction to the conservator. An incli-
nation of up to 5° from vertical to either side is permitted.

Figure 197: Protective relay installation

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9. The reference arrow on the terminal box cover must point toward the on-
load tap-changer's oil conservator.

Figure 198: Reference arrow pointing towards the on-load tap-changer's oil conservator

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10. Install a stop-cock with a nominal width of at least 25 mm between the

protective relay and oil conservator.

Figure 199: Stop-cock

5.4.2.3 Making the electrical connections for the 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 combinations
can be supplied as special versions and are shown in the dimensional draw-
ing provided.

WARNING Risk of death or severe injury!

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

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1. Insert cable gland (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5, 2001/R) or
adapter (RS 2003 and RS 2004) in the tapped hole with the most favor-
able position.

Figure 200: Tapped hole

2. Seal open tapped hole with dummy plug.

Figure 201: Sealed with dummy plug

3. Loosen the three screws on the terminal box cover and lift off the terminal
box cover.

Figure 202: Terminal box cover

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4. Take off the slotted head screw for potential tie-in and remove the termi-
nal box cover with wire.

Figure 203: Terminal box cover

5. Remove screw for the protective cover and take off the protective cover.

Figure 204: Protective cover

6. Guide cable through cable gland and into protective relay. Ensure that the
cable gland is well connected and sealed.

Figure 205: Cable bushing

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7. Connect the electric cables to the connection terminals in accordance with

the connection diagram on the dimensional drawing.

Figure 206: Electrical cables

8. Connect protective conductor to cylinder head screw.

Figure 207: Protective conductor

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9. Insert the protective cover and secure using the screw.

Figure 208: Protective cover

10. Position the wire for the terminal box cover and affix using the slotted
head screw.

Figure 209: Terminal box cover

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11. Attach the terminal box cover and secure with screws.

Figure 210: Terminal box cover

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5.4.3 Installing and connecting the pressure monitoring device

5.4.3.1 Checking the function of the pressure monitoring device

Check the function of the pressure monitoring device before you install it on
the 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 211: OFF position

1 Snap-action switch
2 Sensor in the OFF position

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3. Activate the snap-action switch again.

ð Sensor is in the OPERATION position below the snap-action switch.

Figure 212: OPERATION position

1 Snap-action switch
2 Sensor in the OPERATION position

4. Secure the cover cap.

Always check the position of the sensor!

5.4.3.2 Installing the pressure monitoring device

The pressure monitoring device can be installed in 2 variants.

▪ Fastening on the on-load tap-changer head (vertical installation)
▪ Fastening onto the pipe bend (horizontal installation)

It is installed via the holes on the mounting ring. A mounting seal has to be
installed under the pressure monitoring device during installation.

During fastening, ensure that the ventilation is on top.

Ensure that there is sufficient space above the pressure monitoring device to
remove the cover cap.

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5.4.3.3 Making the electrical connections for the pressure monitoring 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 prevent
them from being switched back on.

WARNING Danger of death or severe injury!

Risk of severe injury or death due to improper electrical connection of the
pressure monitoring device.
► Loop the pressure monitoring device into the tripping circuit of the circuit
breakers of the transformer to be protected so that the transformer is im-
mediately de-energized by the circuit breakers when the pressure moni-
toring device is tripped.
► Circuits which only generate an alarm message are not permitted.

1. Remove the cover cap.

2. Insert Use the tapped hole for routing leads for this.
3. Connect the leads 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 leads and the protective conductor.
Either 1 or 2 leads can be connected per terminal for the lead connection
(Ø 0.75…2.5 mm²).
5. Secure the cover cap.
6. Ensure the fixing screw is positioned correctly, see also dimensional
drawing supplied.

5.4.4 Fitting motor-drive unit

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

5.4.5 Fitting drive shaft

Observe the following during mounting:

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.

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Cutting square tubes, telescopic protective tubes, and protective cover

The square tubes, the telescopic protective tube and the protective cover are
supplied over-length (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 desired
length. The maximum permitted total drive shaft length of the drive - last col-
umn = 15 m.
Standard lengths Motor-drive unit Manual drive
400 • •
600 • •
900 • •
1300 • •
1700 • •
2000 • •
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
are to be supplied with vertical intermediate bearing, as with the motor-drive
unit.

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5.4.5.1 Fitting a vertical drive shaft without cardan joint

Permitted axial displacement

Minor axial displacements of the vertical drive shaft are permitted as long as
they do not exceed 35 mm per 1000 mm of square tube length (this corre-
sponds to 2°).

Figure 213: Permitted maximum axial displacement of vertical drive shaft without cardan joint

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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 in-
advertently and cause injuries.
2. Fasten the bevel gear to the transformer.

Figure 214: Bevel gear

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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 215: Shortening square tube

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4. Deburr cut surfaces of square tube.

Figure 216: Deburring cut surfaces

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5. Slide the loosely screwed-together coupling part onto square tube until
stop is reached.

Figure 217: Slide coupling part onto square tube

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6. Insert coupling bolt into shaft end of drive. Grease coupling part, coupling
bolt and shaft end (e.g. ISOFLEX TOPAS L32). Slide square tube with
coupling part onto shaft end.

Figure 218: Sliding square tube with coupling part onto shaft end

7. Attach square tube to drive.

Figure 219: Attaching square tube to drive

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8. Pivot square tube away from axis.

Figure 220: Pivoting square tube away from axis

9. When installing inner tube of telescopic protective tube, shorten on the

side without slots if necessary. The minimum dimension for overlapping
the two protective tubes is 100 mm.

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Inner tube must not be deformed and must be deburred in order to slide
easily in the outer tube.

Figure 221: Deburring inner tube

Dimension A (= distance between Inner tube Outer tube

shaft end of drive and shaft end of
bevel gear)
170 mm...190 mm Shorten to 200 mm = 200 mm
191 mm...1,130 mm Dimension A + 20 mm = 200 mm
1,131 mm...1,598 mm = 700 mm = 1,150 mm
1,599 mm...2,009 mm = 1,150 mm = 1,150 mm

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10. Slide outer tube over inner tube. When doing so, make sure that the non-
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 222: Sliding on telescopic protective tube

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11. Place adapter ring over bearing collar of bevel gear and slide upwards.
Insert coupling bolt into shaft end of bevel gear. Pivot square tube back
to axis.

Figure 223: Fitting adapter ring and coupling bolt

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12. Grease coupling brackets, coupling bolt and shaft end (e.g. ISOFLEX
TOPAS L32) and secure square tube with coupling brackets on the bevel
gear. Set a unilateral axial clearance of 3 mm between the coupling bolt
and upper coupling piece.

Figure 224: Mounting coupling brackets

13. Attach bottom protective tube (inner tube) with a hose clip to bearing col-
lar 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 .

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Figure 225: Mounting protective tube

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5.4.5.2 Fitting a horizontal drive shaft without cardan joints

Permitted axial displacement

Minor axial displacements of the horizontal drive shaft are permitted as long
as they do not exceed 35 mm per 1000 mm of square tube length (this cor-
responds to 2°).

Figure 226: Permitted maximum axial displacement of 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 so that the upper
gear unit is flush with the bevel gear. With a multi-column on-load tap-
changer model, it may also be necessary to align the upper gear units in the
individual on-load tap-changer columns with each other in order to couple
the on-load tap-changer columns together.

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To do so, proceed as follows:

1. NOTICE! Damage to the on-load tap-changer due to alignment of the
gear unit when the oil compartment is not completely full.Ensure that the
oil compartment is filled completely with insulating fluid.
2. Loosen screws and turn pressure ring segments to one side.

Figure 227: Pressure ring segments

3. NOTICE! Damage to the on-load tap-changer due to incorrect alignment

of the upper gear unit. Align the gear unit so 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 so that its output shaft retains its original posi-
tion.

Figure 228: Aligning the gear unit

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4. Swivel pressure ring segments back towards the gear unit and tighten the
screws. Ensure that the locking washer is between the screw head and
the pressure ring segment and that the pressure ring segments are firmly
in contact with the gear unit housing.

Figure 229: Securing the pressure ring segments

Fitting horizontal drive shaft

You can turn the temperature sensor if this is necessary for fitting the drive
shaft.

To fit the horizontal drive shaft, proceed as follows.

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

Figure 230: Shortening square tube

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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 cut edges.
Protect protective cover against corrosion with a coat of paint.

Figure 231: Shortening, deburring, and coating protective cover

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3. Slide loosely screwed-together coupling part onto square tube until stop is
reached.

Figure 232: Sliding coupling part onto square tube

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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.

Figure 233: Sliding square tube with coupling part onto shaft end

5. Secure square tube on bevel gear.

Figure 234: Securing square tube on bevel gear

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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 235: Secure square tube on upper gear unit.

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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 236: Fitting protective cover

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8. If using a bearing block or angle gear, attach caps to the protective cover.
Drill two holes each with Ø 3.5 mm on the sides of the protective cover us-
ing a hand drill with drill bit prior to attaching the caps.

Figure 237: Bearing block caps

Figure 238: Angle gear caps

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5.4.5.2.1 On-load tap-changer sets and combinations

For two-column and three-column on-load tap-changer models, the individ-

ual on-load tap-changer columns can be driven by a common motor-drive
unit or several motor-drive units.

Regardless of the number of on-load tap-changer columns and motor-drive

units, all on-load tap-changer columns and motor-drive units must be in the
same operating position and must switch simultaneously (does not apply for
ABC switching sequence).

To make sure that the on-load tap-changer columns that are driven by a
common motor-drive unit switch simultaneously, you must couple these on-
load tap-changer columns with horizontal drive shafts via the transformer
cover. The offset between these on-load tap-changer columns during switch-
ing may be a maximum of 1 tap-change indicator section.

To couple the on-load tap-changer columns, proceed as follows:

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 so that the upper
gear unit is flush with the bevel gear. With a multi-column on-load tap-
changer model, it may also be necessary to align the upper gear units in the
individual on-load tap-changer columns with each other in order to couple
the on-load tap-changer columns together.

To do so, proceed as follows:

1. NOTICE! Damage to the on-load tap-changer due to alignment of the
gear unit when the oil compartment is not completely full.Ensure that the
oil compartment is filled completely with insulating fluid.
2. Loosen screws and turn pressure ring segments to one side.

Figure 239: Pressure ring segments

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3. NOTICE! Damage to the on-load tap-changer due to incorrect alignment

of the upper gear unit. Align the gear unit so 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 so that its output shaft retains its original posi-
tion.

Figure 240: Aligning the gear unit

4. Swivel pressure ring segments back towards the gear unit and tighten the
screws. Ensure that the locking washer is between the screw head and
the pressure ring segment and that the pressure ring segments are firmly
in contact with the gear unit housing.

Figure 241: Securing the pressure ring segments

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Coupling the on-load tap-changer columns together

1. Ensure that all arrows on the drive shaft flange under the stamped serial
number point in the same direction. The direction of the arrow indicates
the direction of rotation when turning the hand crank of the motor-drive
unit clockwise.
2. Switch the on-load tap-changer columns one after another to the next op-
erating position. To do so, turn the shaft end on each gear unit counter-
clockwise one after another until the on-load tap-changer column switches
position.

Figure 242: Manually switching the on-load tap-changer columns

3. Check that all on-load tap-changer columns are in the same position.

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4. Couple the on-load tap-changer columns together via horizontal drive

shafts. When doing so, begin with the on-load tap-changer column that is
closest to the motor-drive unit.

Figure 243: Coupling the on-load tap-changer columns

5. NOTICE! Damage to the on-load tap-changer columns due to incomplete

tap-change operation. After installing all drive shafts, crank the drive shaft
of the gear unit through a further 2.5 revolutions counter-clockwise to
complete the tap-change operation fully.
6. Switch the on-load tap-changer columns to the adjustment position by
turning the drive shaft on the gear unit clockwise. Once the adjustment
position has been reached and the on-load tap-changer columns have

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been switched, crank the drive shaft of the upper gear unit through an-
other 2.5 revolutions clockwise to correctly complete the tap-change oper-
ation.

Figure 244: Switching the on-load tap-changer columns to the adjustment position

7. Ensure that all on-load tap-changer columns switch simultaneously. Here,

a minimal offset of max. 0.25 revolutions on the drive shaft of the gear unit
is permitted.
8. Check that all on-load tap-changer columns are in the same position.

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9. Install the drive shaft between the bevel gear and the gear unit.

Figure 245: Installing the drive shaft between the bevel gear and the gear unit

5.4.5.3 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.

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Permitted axial displacements

An axial displacement of 20° is permitted for the vertical and horizontal drive
shaft with cardan joints.

Figure 246: Permitted maximum axial displacement of vertical drive shaft with cardan joints

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Figure 247: Permitted maximum axial displacement of horizontal drive shaft with cardan joints

NOTICE Damage to property!

Improper mounting of the cardan joint may result in damage or malfunc-
tions.
► Ensure that the folding cardan joint does not damage the expansion bel-
lows 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.

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Figure 248: Angle of deflection α

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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 249: Greasing coupling bolts, coupling brackets, and shaft ends

Position Name Quantity

1 below on the ED Adapter ring Ø 82×102 1
2 Adapter ring Ø 87×102.5 1

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3 Adapter ring Ø 94.5×102.5 1

4 above on the Adapter ring Ø 71×102.5 1
CD6400

2. Insert adapter rings into the collar of the rotating protective tube . Fit the
two parts of pivotable protective tube together and turn them towards
one another to set the corresponding angle.

Figure 250: 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 . Slide

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cardan joint over device's output shaft . Push in coupling bolt . Slide
expansion bellows over this . Secure expansion bellows with hose clip
.

Figure 251: Mounting cardan joints

4. Connect shorter cardan joint supplied to shaft end of motor-drive unit with
coupling bolt.

Figure 252: Attaching cardan joint on shaft end of motor-drive unit

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5. NOTICE! Attach second, longer cardan joint to the bevel gear such that
the position of both cardan joint lugs is the same on the bevel gear and
motor-drive unit. If this is not done, damage or malfunctions may result.

Figure 253: Fitting second cardan joint on bevel gear

6. Secure expansion bellows with hose clip.

Figure 254: Securing expansion bellows with hose clip

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7. Provisionally connect loose shaft ends of the joints to an angle bar and
align so that they are in line.

Figure 255: Connecting shaft ends with angle bar

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

LR = A + 100 mm (LR = length of square tube). Deburr cut surfaces of
square tube.

Figure 256: Shortening square tube

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9. Before beginning installation, shorten both telescopic tubes to the corre-

sponding dimension A (A = dimension between both cardan joint ends)
and deburr.

Figure 257: Shortening telescopic tubes

Dimension A (= distance be- Inner tube Outer tube

tween shaft ends of the drive
and the bevel gear)
260 mm Shorten to 200 mm 200 mm
261 mm...760 mm Shorten to A-60 mm 200 mm
761 mm...1,090 mm 700 mm Shorten to A-60 mm
1,091 mm...1,700 mm 700 mm 1,150 mm
1,701 mm...1,900 mm 1,150 mm 1,150 mm

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10. Fit one adapter ring to bearing collar of motor-drive unit and fit other
adapter ring to bearing collar of bevel gear.

Figure 258: Fitting adapters

11. Slide previously shortened and deburred square tube over upper cardan
joint end until stop is reached.

Figure 259: Sliding square tube over upper cardan joint end

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12. Thread upper pivotable protective tube with long outlet up onto square
tube from below.

Figure 260: Sliding pivotable protective tube over square tube

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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 261: Sliding on telescopic tubes

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14. Slide everything up and secure with a screw clamp.

Figure 262: Secure everything with a screw clamp

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15. Slide bottom pivotable protective tube (also with long outlet up) on to the
square tube and secure with screw clamp.

Figure 263: Sliding bottom pivotable protective tube over square tube

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16. Swing in square tube and slide all the way down.

Figure 264: Pivoting square tube back to axis

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17. Push the lower coupling bolt in and grease. Tighten lower 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 265: Tightening lower coupling brackets

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18. Fit upper coupling brackets with 3 mm axial clearance.

Figure 266: 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 piv-
otable protective tubes by the width of the adapter before tightening the
hose clips.

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Figure 267: Securing telescopic protective tube and pivotable protective tubes with hose clips

5.4.5.4 Fitting drive shaft with insulator

A model with insulator in the vertical drive shaft is available for insulating in-
stallation of the drive shaft.

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Permitted axial displacement

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 268: Permitted maximum axial displacement of vertical drive shaft with insulator

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5.4.5.4.1 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 in-
advertently and cause injuries.
2. Screw the bevel gear for mounting on the transformer. Screws are not in-
cluded in the scope of supply.

Figure 269: Bevel gear

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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 insulator into
account.

Figure 270: Shortening square tube

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4. Deburr cut surfaces of square tube.

Figure 271: Deburring cut surfaces

5. Screw down double coupling part with insulator supplied and square tube.
Mount insulator on the side facing the drive.

Figure 272: Screwing down square tube and insulator with double coupling part

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6. Slide loosely screwed-together coupling part onto insulator until stop is

reached.

Figure 273: Sliding coupling part onto insulator

7. Place the supplied insulator ring on the bearing collar of the motor-drive
unit.

Figure 274: Insulating ring

8. Insert coupling bolt into shaft end of drive. Grease coupling part, coupling
bolt and shaft end (e.g. ISOFLEX TOPAS L32). Slide square tube with
coupling part onto shaft end.

Figure 275: Sliding square tube with coupling part onto shaft end

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9. Attach square tube to drive.

Figure 276: Attaching square tube to drive

10. Pivot square tube away from axis.

Figure 277: Pivoting square tube away from axis

11. When installing inner tube of telescopic protective tube, shorten on the
side without slots if necessary. The minimum dimension for overlapping
the two protective tubes is 100 mm.

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Inner tube must not be deformed and must be deburred in order to slide
easily in the outer tube.

Figure 278: Deburring inner tube

Dimension A (= distance between Inner tube Outer tube

shaft end of drive and shaft end of
bevel gear)
170 mm...190 mm Shorten to 200 mm = 200 mm
191 mm...1,130 mm Dimension A + 20 mm = 200 mm
1,131 mm...1,598 mm = 700 mm = 1,150 mm
1,599 mm...2,009 mm = 1,150 mm = 1,150 mm

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12. Slide outer tube over inner tube. When doing so, make sure that the non-
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 279: Sliding on telescopic protective tube

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13. Place adapter ring over bearing collar of bevel gear and slide upwards.
Insert coupling bolt into shaft end of bevel gear. Pivot square tube back
to axis.

Figure 280: Fitting adapter ring and coupling bolt

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14. Grease coupling brackets, coupling bolt and shaft end (e.g. ISOFLEX
TOPAS L32) and secure square tube with coupling brackets on the bevel
gear. Set a unilateral axial clearance of 3 mm between the coupling bolt
and upper coupling piece.

Figure 281: Mounting coupling brackets

15. Attach bottom protective tube (inner tube) with a hose clip to bearing col-
lar of drive . Then slide upper protective tube (outer tube) over adapter
on bevel gear . Secure upper protective tube to bottom protective tube
with hose clip both at top end and at the connection point .

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Figure 282: Mounting protective tube

5.4.5.5 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.

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Permitted axial displacement

An axial displacement of 20° is permitted for a drive shaft with insulator and
cardan joint.

Figure 283: Permitted maximum axial displacement of vertical drive shaft with insulator and car-
dan joint

5.4.6 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.

5.4.7 Making the electrical connections for the motor-drive unit

► Make electrical connections for the motor-drive unit as described in rele-
vant MR operating instructions for the motor-drive unit.

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6 Commissioning
WARNING Danger of explosion!
Explosive gases in the oil compartment of the on-load tap-changer, trans-
former, pipework system, oil conservator and at the dehydrating breather
opening can deflagrate or explode and result in severe injury or death!
► Ensure that there are no ignition sources such as naked flame, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the trans-
former's immediate surroundings during commissioning and that none oc-
cur.
► Do not operate any electrical devices (e.g. risk of sparks from impact
wrench).
► Only use conductive and grounded hoses, pipes, and pump equipment
that are approved for flammable liquids.

WARNING Danger of explosion!

Overloading the on-load tap-changer can lead to explosion. Spraying hot in-
sulating fluid and flying parts can lead to death and serious injuries. Prop-
erty damage is highly probable.
► Ensure that the on-load tap-changer is not overloaded.
► Ensure use of the on-load tap-changer in accordance with section "Ap-
propriate use".
► Prevent operations outside of the permitted operating conditions by tak-
ing suitable measures.

6.1 Commissioning the on-load tap-changer at the transformer

manufacturer's site

Perform the following work and functional checks before commissioning the
transformer.

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6.1.1 Bleeding on-load tap-changer head and suction pipe

6.1.1.1 Bleeding on-load tap-changer head

1. Open all forward valves 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 284: Screw cap

3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load
tap-changer head.

Figure 285: Valve tappet

4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm).

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6.1.1.2 Bleeding suction pipe on pipe connection S

1. Remove screw cap from pipe connection S.

Figure 286: Screw cap

2. NOTICE! An incompletely bled suction pipe significantly impairs the insu-

lation capability of the on-load tap changer to ground. Open vent screw
and bleed suction pipe completely.
3. Close vent screw.
4. Seal vent screw with screw cap.

6.1.2 Grounding the on-load tap-changer

1. Connect grounding screw on the on-load tap-changer head to transformer
cover. It is essential that CUPAL washers are placed directly on the con-
necting lug on both sides. The aluminum side of the CUPAL washers
must be facing the connecting lug.

Figure 287: Grounding screw head

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2. Connect grounding screw of motor-drive protective housing to transformer

tank. It is essential that a CUPAL washer is placed between the cable
shoe and connecting lug. The aluminum side of the CUPAL washer must
be facing the connecting lug.

Figure 288: Grounding screw on motor-drive unit

3. When using a temperature sensor, connect housing of temperature sen-

sor with grounding screw on the 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 alu-
minum side of the CUPAL washer must be facing the temperature sensor
housing.

Figure 289: Grounding temperature sensor

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6.1.3 Checking motor-drive unit

NOTICE Damage to the on-load tap-changer / de-energized tap-changer!

Damage to the on-load tap-changer / de-energized tap-changer due to actu-
ation of the on-load tap-changer / de-energized tap-changer without insulat-
ing fluid.
► Ensure that the selector / de-energized tap changer is fully immersed in
insulating fluid and that the oil compartment of the on-load tap-changer is
completely filled with insulating fluid.

Prior to commissioning the transformer, check whether the motor-drive unit

and on-load tap-changer are correctly coupled and that the motor-drive unit
functions correctly.

Tests on the motor-drive unit

1. Perform function checks as described in relevant MR operating instruc-
tions for motor-drive unit.
2. NOTICE! An incorrectly coupled motor-drive unit will lead to damage to
the on-load tap-changer. Undertake trial tap-change operations across the
entire range of settings. Ensure that in each operating position, the tap po-
sition indicators of motor-drive unit and on-load tap-changer (inspection
window in the on-load tap-changer head) match.

Dielectric tests on transformer wiring

► Note information relating to dielectric tests on transformer wiring in rele-
vant MR operating instructions for motor-drive unit.

6.1.4 High-voltage tests on the transformer

Note the following points before performing high-voltage tests on the trans-
former:
▪ Ensure that the oil compartment of the on-load tap-changer is completely
filled with insulating fluid.
▪ Ensure that all protective devices for the on-load tap-changer are function-
ing correctly and are ready for use.
▪ Ensure that the ground connections on the motor-drive protective housing
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 cable
bushings in the protective housing base intended for lead insertion.
▪ Guide all ground connecting leads to one central connection point (estab-
lishment of suitable reference earth).
▪ Disconnect all electronic components before the high voltage test. Before
a dielectric test of the wiring, remove all devices with a withstand voltage
of < 1000 V.

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▪ Remove leads used for testing before the high voltage test as these func-
tion as antennas.
▪ Wherever possible, route the measurement leads and data leads sepa-
rately to the energy cables.

Contact the manufacturer if you have any questions about possible sources
of danger.

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6.2 Transporting transformer to the operating site

NOTICE Damage to motor-drive unit!
Damage to the 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 downtime lasting more than 8 weeks prior to initial com-
missioning, connect and operate the anti-condensation heater in the mo-
tor-drive unit. If this is not possible, place a sufficient amount of desiccant
in the protective housing.

6.2.1 Transport with drive removed

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 the drive [►Section 5.4.4, Page 163] and the drive shaft [►Section
5.4.5, Page 163] to the transformer at the installation site.

6.2.2 Transport with full transformer tank and without oil conservator
Attach a connecting lead between the on-load tap-changer's oil compartment
and the transformer tank if the transformer has been transported with a full
tank and without an oil conservator.
► Establish a connecting lead on the on-load tap-changer head between
connections E2 and Q or E2 and R.

Figure 290: Connecting lead

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In the event of a short-term immobilization time (maximum of 4 weeks) with-

out an oil conservator, it is also sufficient to remove approximately 5 liters of
insulating fluid from the on-load tap-changer oil compartment.

6.2.3 Transport with empty transformer tank

NOTICE Damage to the on-load tap-changer!

The on-load tap-changer may be subject to oscillating movements during
transformer transportation if the transformer is transported without insulating
fluid and the on-load tap-changer oil compartment is transported with insu-
lating fluid. These oscillating movements can lead to damage to the on-load
tap-changer.
► Completely empty the oil compartment if the transformer is to be trans-
ported without insulating fluid.
► Preserve the oil compartment in the same way as the transformer (for ex-
ample by filling with N2).

6.2.3.1 Emptying oil compartment via pipe connection S

1. De-energize all auxiliary circuits (e.g tap-change supervisory device, pres-
sure relief device, pressure monitoring device).
2. With the stop-cock (slide valve) between oil conservator and oil compart-
ment open, open air-vent valve E1 on the on-load tap-changer head.
3. Discharge the gas from under the on-load tap-changer cover. Ensure suf-
ficient fresh air (e.g. in transformer cells and work tents) when doing so.
4. Once the gas has been discharged and the insulating fluid is flowing out
of the air-vent valve, close the air-vent valve and close the stop-cock be-
tween the oil conservator and oil compartment.
5. Open air-vent valve again and drain off approximately 5–10 liters of insu-
lating fluid via the pipe connection S until the area under the on-load tap-
changer head cover is free of insulating fluid.
6. Loosen 24 screws M10 / wrench size 17 with locking elements on the on-
load tap-changer head cover.
7. Remove on-load tap-changer head cover.
8. Extract insulating fluid via pipe connection S.
9. Open stop-cock between oil conservator and oil compartment.
ð Insulating fluid flows out of the oil conservator into the oil compartment.
10. Extract insulating fluid via pipe connection S.
11. Place on-load tap-changer head cover on the on-load tap-changer head.
12. Screw down on-load tap-changer head cover using 24 screws M10 /
wrench size 17 and locking elements (tightening torque 34 Nm).

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6.3 Commissioning transformer at operating site

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

insulating fluid

NOTICE Damage to the on-load tap-changer!

Unsuitable insulating fluids cause damage to the on-load tap-changer.
► Only use insulating fluids [►Section 8.1, Page 244] approved by the
manufacturer.

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. Establish a connecting lead between pipe connection E2 and one of the
pipe connections R, S or Q to ensure equal pressure in the oil compart-
ment and transformer during evacuation.

Figure 291: Connecting lead between E2 and Q

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3. Fill on-load tap-changer with new insulating fluid using one of the two free
pipe connections of the on-load tap-changer head.

Figure 292: Pipe connections S and R

4. Take an insulating fluid sample from the oil compartment.

5. Record the temperature of the sample immediately after the sample is
taken.
6. Determine the dielectric strength and water content at a sample tempera-
ture of 20 °C ± 5 °C. The dielectric strength and water content must com-
ply with the limit values specified in the technical data.

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6.3.2 Bleeding on-load tap-changer head and suction pipe

6.3.2.1 Bleeding on-load tap-changer head

1. Open all forward valves 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 293: Screw cap

3. Use screwdriver to lift valve tappet on air-vent valve E1 and bleed on-load
tap-changer head.

Figure 294: Valve tappet

4. Seal air-vent valve E1 with screw cap (tightening torque 10 Nm).

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6.3.2.2 Bleeding suction pipe on pipe connection S

1. Remove screw cap from pipe connection S.

Figure 295: Screw cap

2. NOTICE! An incompletely bled suction pipe significantly impairs the insu-

lation capability of the on-load tap changer to ground. Open vent screw
and bleed suction pipe completely.
3. Close vent screw.
4. Seal vent screw with screw cap.

6.3.3 Checking motor-drive unit

NOTICE Damage to the on-load tap-changer / de-energized tap-changer!

Damage to the on-load tap-changer / de-energized tap-changer due to actu-
ation of the on-load tap-changer / de-energized tap-changer without insulat-
ing fluid.
► Ensure that the selector / de-energized tap changer is fully immersed in
insulating fluid and that the oil compartment of the on-load tap-changer is
completely filled with insulating fluid.

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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 connec-
tions.
► 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).
► Therefore, the "Tap changer in operation" position transit contact shown
in the connection diagram should be used for external monitoring, locking
and control purposes instead of the position transmitter equipment.

Prior to commissioning the transformer, check whether the motor-drive unit

and on-load tap-changer are correctly coupled and that the motor-drive unit
functions correctly.

Tests on the motor-drive unit

1. Perform function checks as described in relevant MR operating instruc-
tions for motor-drive unit.
2. NOTICE! An incorrectly coupled motor-drive unit will lead to damage to
the on-load tap-changer. Undertake trial tap-change operations across the
entire range of settings. Ensure that in each operating position, the tap po-
sition indicators of motor-drive unit and on-load tap-changer (inspection
window in the on-load tap-changer head) match.

Dielectric tests on transformer wiring

► Note information relating to dielectric tests on transformer wiring in rele-
vant MR operating instructions for motor-drive unit.

6.3.4 Checking protective relay

6.3.4.1 Checking protective relay (RS 2001, 2001/V, 2001/H, 2001/E, 2001/5,
2001/R, 2001/T, 2003)
ü Check that the protective relay is functioning correctly before commission-
ing the transformer:
1. Ground the transformer on the high-voltage side and low-voltage side. En-
sure that the grounding for work connection on the transformer is not re-
moved during testing.
2. Ensure that the transformer remains de-energized during testing.
3. Deactivate the automatic fire extinguishing device.

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4. Loosen the three screws on the terminal box cover and lift off the terminal
box cover.
5. Remove the slotted head screw for potential tie-in and remove the termi-
nal box cover with wire.
6. Press OFF test button.
7. Leave the transformer's danger zone.
8. Ensure that the transformer's circuit breaker cannot be closed.
ð Passive protection test
9. Press OPERATION test button.
10. Leave the transformer's danger zone.
11. Close the transformer's circuit breaker with isolating switches open and
the transformer grounded on all sides.
12. Press OFF test button.
13. Ensure that the transformer's circuit breaker is open.
ð Active protection test.
14. Press OPERATION test button to reset the protective relay.
15. Position the wire for the terminal box cover and affix using the slotted
head screw.
16. Attach the terminal box cover and secure with screws.

6.3.4.2 Checking protective relay (RS 2004)

ü Check that the protective relay is functioning correctly before commission-
ing the transformer:
1. Ensure that the flap valve is in the OPERATION position.
2. Leave the transformer's danger zone.
3. Close the transformer's circuit breaker with isolating switches open and
the transformer grounded on all sides.
4. Press OFF test button.
5. Ensure that the transformer's circuit breaker is open.
ð Active protection test

6.3.5 Checking pressure monitoring device

1. Ground the transformer on the high-voltage side and low-voltage side. En-
sure that the grounding for work connection on the transformer is not re-
moved during testing.
2. Ensure that the transformer remains de-energized during testing.
3. Deactivate the automatic fire extinguishing device.
4. Remove the cover cap.
5. Activate the sensor on the snap-action switch.
ð Sensor is in the OFF position.
6. Leave the transformer's danger zone.

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7. Ensure that the transformer's circuit breaker cannot be closed.

ð Passive protection test
8. Activate the sensor on the snap-action switch.
ð Sensor is in the OPERATION position.
9. Leave the transformer's danger zone.
10. Close the transformer's circuit breaker with isolating switches open and
the transformer grounded on all sides.
11. Activate the sensor on the snap-action switch.
ð Sensor is in the OFF position.
12. Ensure that the transformer's circuit breaker is open.
ð Active protection test.
13. Activate the sensor on the snap-action switch to reset the pressure moni-
toring device.
ð Sensor is in the OPERATION position.
14. Secure the cover cap.

6.3.6 Commissioning the transformer

ü The signaling contact for falling below the minimum insulating fluid fill level
in the on-load tap-changer's oil conservator is looped into the tripping cir-
cuit of the circuit breaker.
ü The protective relay and additional protective devices are looped into the
circuit breaker's tripping circuit.
ü The motor-drive unit and all protective devices are functioning correctly
and are ready for use.
ü The oil compartment of the on-load tap-changer is completely filled with
insulation fluid.
ü All stop-cocks between on-load tap-changer and oil conservator of the on-
load tap-changer are open.
1. Switch on transformer.
2. NOTICE! Inrush current impulses can be significantly greater than the
transformer rated current and may lead to current paths with asymmetrical
or non-sinusoidal curve shapes and, as a result, overload the on-load tap-
changer during the diverter switch operation. Only perform tap-change op-
erations - whether under no load or under load conditions - once the in-
rush current impulse has subsided.

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7 Fault elimination
WARNING Danger of explosion!
Explosive gases under the on-load tap-changer head cover can deflagrate
or explode and result in severe injury or death.
► Ensure that there are no ignition sources such as open flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits (for example tap-change supervisory de-
vice, pressure relief device, pressure monitoring device) before removing
the on-load tap-changer head cover.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

NOTICE Damage to the on-load tap-changer and transformer!

If the protective relay or other protective devices trip, this can indicate dam-
age to the on-load tap-changer and transformer. The transformer must not
be energized without being inspected first.
► 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.

NOTICE Damage to motor-drive unit!

Damage to the 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 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 desiccant
in the protective housing.

The table below is intended to assist with detecting and, where possible,
remedying faults.

For more information, please consult the operating instructions for the pro-
tective 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 protective relay or additional pro-
tective devices have been tripped, please inform your authorized MR repre-
sentative, the transformer manufacturer or contact MR directly.

Maschinenfabrik Reinhausen GmbH

Technical Service
Postfach 12 03 60
93025 Regensburg

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7 Fault elimination

Germany
Phone: +49 94140 90-0
Fax: +49 9 41 40 90-7001
E-mail: [email protected]
Internet: www.reinhausen.com
Fault description Action
Tripping of protective relay See "Tripping the protective relay and re-commissioning
the transformer"
Also contact MR.
Tripping of pressure relief device (e.g. MPreC®) On-load tap-changer and transformer must be checked.
Depending on the cause of tripping, take measurements /
carry out checks on the transformer.
Contact MR to check the on-load tap-changer.
Tripping of pressure monitoring device (e.g. DW 2000) See "Tripping the pressure monitoring device and putting
the transformer back into operation"
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 acti-
vated. Manual operation of the motor-drive unit via the
hand crank when the transformer is switched on is prohib-
ited.
On-load tap-changer and transformer must be checked.
Depending on the cause of tripping, take measurements /
carry out checks on the transformer.
Contact MR to check the on-load tap-changer.
Activation of rupture disk in on-load tap-changer head On-load tap-changer and transformer must be checked.
cover Depending on the cause of tripping, take measurements /
carry out checks on the transformer.
Contact MR to check the on-load tap-changer.
Tripping of motor protective switch in motor-drive unit See chapter "Fault elimination" in the operating instruc-
tions of the TAPMOTION® ED motor-drive unit
Tripping of signaling contact that indicates that the fill level Check pipe system (pipes etc.) and on-load tap-changer
of the insulating fluid has fallen below the minimum in the head for leaks. Check the fill level and the quality of the in-
on-load tap-changer oil conservator sulating fluid in the oil compartment in accordance with the
operating instructions for the on-load tap-changer. If the fill
level has fallen below the limit values, also contact MR.
On-load tap-changer not changing tap position (sluggish- Contact MR.
ness, Raise keys / Lower keys not working, no audible di-
verter switch action)
No change in voltage on transformer despite change in po- Contact MR.
sition on motor-drive unit
Tap position indicator on motor-drive unit and on-load tap- Contact MR.
changer different
Noises on drive shaft or motor-drive unit when changing Ensure proper mounting of the drive shaft in accordance
tap position with its operating instructions. Check that hose clips and
protective covers are seated correctly. Contact MR in the
event of noise from the motor-drive unit.

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Fault description 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 transformer Notify manufacturer of transformer.
Deviation from desired value when measuring winding re- Contact manufacturer of transformer and, if necessary,
sistance of transformer MR, and provide measured values.
Deviation from desired value during dissolved gas analysis Contact manufacturer of transformer and, if necessary,
(transformer oil) MR, and provide measured values.
Deviation from desired value during transformer ratio test Contact manufacturer of transformer and, if necessary,
MR, and provide measured values.
Deviation from limit value for insulating fluids Carry out insulating fluid change, check oil conservator
breather of on-load tap-changer.
Table 8: Fault elimination

7.1 Tripping the protective relay and re-commissioning the

transformer
WARNING Danger of explosion!
Explosive gases in the protective relay can deflagrate or explode and result
in severe injury or death.
► Wait 15 minutes after switching off the transformer before beginning fur-
ther work on the protective relay so that the gases can dissipate.
► Ensure that there are no ignition sources such as naked flames, hot sur-
faces or sparks (e.g. caused by the build-up of static charge) in the imme-
diate surroundings and that none occur.
► De-energize all auxiliary circuits before beginning work.
► Do not operate any electrical devices during the work (e.g. risk of sparks
from impact wrench).

WARNING Danger of death or severe injury!

Danger of severe injury or death if on-load tap-changer and transformer are
insufficiently tested.
► Be sure to contact Maschinenfabrik Reinhausen to check on-load tap-
changer and transformer if the protective relay has 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.
3. As a precaution, block the motor-drive unit by tripping the motor protective
switch to prevent the on-load tap-changer from being actuated by remote
control.

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7 Fault elimination

4. Check the on-load tap-changer head cover. If insulating fluid is leaking,

close the oil conservator stop valve immediately.
5. Check whether the flap valve of the protective relay is in the OFF or OP-
ERATION position.

7.1.1 Flap valve in OPERATION position

If the flap valve is in the OPERATION 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.

7.1.2 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, also proceed as described below for RS 2004.

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 trip-
ping?
ð Did any other protective devices of the transformer respond at the in-
stant of tripping?
ð Were switching operations in the network being carried out at the in-
stant of tripping?
ð Were overvoltages registered at the instant of tripping?
3. Take further action in agreement with Maschinenfabrik Reinhausen.

7.1.3 Re-commissioning the transformer

Once the reason for the protective relay tripping has been established and
remedied, you can re-commission the transformer:
1. Check the protective relay [►Section 6.3.4.1, Page 235].
2. Commission the transformer.

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 7 Fault elimination

7.2 Tripping the pressure monitoring device and putting the

transformer back into operation
WARNING Danger of death or severe injury!
Danger of severe injury or death if on-load tap-changer and transformer are
insufficiently 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 protective
switch to prevent the on-load tap-changer from being actuated by remote
control.
4. Check the on-load tap-changer head cover. If insulating fluid is leaking,
close the oil conservator stop valve immediately.
5. Check whether the pressure monitoring device sensor is in the OFF posi-
tion or OPERATION position.

7.2.1 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 clar-
ify why the pressure monitoring device tripped, be sure to contact Maschi-
nenfabrik Reinhausen to check the on-load tap-changer.

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7 Fault elimination

7.2.2 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.
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 immedi-
ately before or during the tripping?
ð Did any other protective devices of the transformer respond at the in-
stant of tripping?
ð Were switching operations in the network being carried out at the in-
stant of tripping?
ð Were overvoltages registered at the instant of tripping?
ð How high is the static pressure on the pressure relief device (height dif-
ference between the oil level in the on-load tap-changer oil conservator
and the pressure relief device)?
3. Take further action in agreement with Maschinenfabrik Reinhausen.

7.2.3 Re-commissioning the transformer

You can re-commission the transformer once the cause for tripping the pres-
sure monitoring device has been determined and resolved:
1. Ensure that the sensor on the snap-action switch is in the OPERATION
position.
2. Commission the transformer.

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 8 Technical data

8 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.

8.1 Permissible ambient conditions

Air temperature during operation -25°C…+50°C
Temperature of the insulating fluid in operation -25°C…+105°C (up to +115°C when the transformer is in emer-
gency operation)
Transport temperature, storage temperature -40°C…+50°C
Drying temperatures See installation and commissioning instructions, "Mounting"
chapter
Compressive strength See technical data TD 61 – General section
Insulating fluid ▪ Unused insulating oils derived from petroleum products1) in
accordance with IEC60296 and ASTM D3487 (equivalent
standards on request)
▪ Unused insulating oils derived from other virgin hydrocarbons
in accordance with IEC60296, or blends of these oils with pe-
troleum products1) in accordance with IEC60296, ASTM
D3487 or equivalent standards on request
▪ Alternative insulating fluids, such as natural and synthetic es-
ters or silicone oils, on request.
1)
Gas-to-liquid oils (GTL oils) are understood in this context as
petroleum products
Installation height of the oil conservator See technical data TD 61 – General section
Installation height above sea level See technical data TD 61 – General section
Table 9: Permissible ambient conditions

8.2 Technical data for protective relay

The technical data for the protective relay RS 2001 is listed in the following.
In accordance with DIN EN 60255-1, operational accuracy = base accuracy
Housing Outdoor model
Degree of protection IP66
Relay actuation Flap valve with aperture
Weight approx. 3.5 kg
Oil flow speed of available types when 0.65 ± 0.15 m/s
tripping (oil temperature 20 °C) 1.20 ± 0.20 m/s
3.00 ± 0.40 m/s
4.80 ± 0.60 m/s
Table 10: General technical data

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8 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 a special version.

Electrical data for normally closed (NC) dry-reed magnetic switch

Electrical data
DC switching capacity 1.2 W…200 W
AC switching capacity (50 Hz) 1.2 VA…400 VA
Switching voltage AC/DC 24 V…250 V
Switched current AC/DC 4.8 mA…2 A
Table 11: Electrical data

Switching capacity (switching load on an off)

Minimum switched current AC/DC (low- 50 mA (at 24 V)
est voltage)
Minimum switched current AC/DC (high- 4.8 mA (at 250 V)
est voltage)
Maximum switched current DC (highest 1.6 A (at 125 V with L/R = 40 ms)
current)
Maximum switched current DC (highest 0.9 A (at 250 V with L/R = 40 ms)
voltage)
Maximum switched current AC (highest 2 A (at 125 V with cos φ = 0.6)
current)
Maximum switched current AC (highest 1.6 A (at 250 V with cos φ = 0.6)
voltage)
Switching operations 1,000 cycles
Table 12: Switching capacity (switching load on an off)

Dielectric strength
AC dielectric strength between all volt- 2,500 V, 50 Hz, test duration 1 minute
age-carrying connections and the
grounded parts
AC dielectric strength between the 2,000 V, 50 Hz, test duration 1 minute
opened contacts
Table 13: Dielectric strength

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 8 Technical data

Electrical data for normally open (NO) dry-reed magnetic switch

Electrical data
DC switching capacity 1.2 W…250 W
AC switching capacity (50 Hz) 1.2 VA…400 VA
Switching voltage AC/DC 24 V…250 V
Switched current AC/DC 4.8 mA…2 A
Table 14: Electrical data

Switching capacity (switching load on an off)

Minimum switched current AC/DC (low- 50 mA (at 24 V)
est voltage)
Minimum switched current AC/DC (high- 4.8 mA (at 250 V)
est voltage)
Maximum switched current DC (highest 2 A (at 125 V with L/R = 40 ms)
current)
Maximum switched current DC (highest 1 A (at 250 V with L/R = 40 ms)
voltage)
Maximum switched current AC (highest 2 A (at 125 V with cos φ = 0.6)
current)
Maximum switched current AC (highest 1.6 A (at 250 V with cos φ = 0.6)
voltage)
Switching operations 1,000 cycles
Table 15: Switching capacity (switching load on an off)

Dielectric strength
AC dielectric strength between all volt- 2,500 V, 50 Hz, test duration 1 minute
age-carrying connections and the
grounded parts
AC dielectric strength between the 2,000 V, 50 Hz, test duration 1 minute
opened contacts
Table 16: Dielectric strength

Ambient conditions
Ambient temperature Ta -40°C…+50°C
Oil temperature <130 °C
Air pressure Corresponds to 0 m…4,000 m above
sea level
Table 17: Ambient conditions

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8 Technical data

8.3 Special models of protective relay

8.3.1 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

Electrical data
DC switching capacity 1.2 W…150 W
AC switching capacity (50 Hz) 1.2 VA…200 VA
Switching voltage AC/DC 24 V…250 V
Switched current AC/DC 4.8 mA…1 A
Table 18: Electrical data

Switching capacity (switching load on an off)

Minimum switched current AC/DC (low- 50 mA (at 24 V)
est voltage)
Minimum switched current AC/DC (high- 4.8 mA (at 250 V)
est voltage)
Maximum switched current DC (highest 1.0 A (at 150 V with L/R = 40 ms)
current)
Maximum switched current DC (highest 0.6 A (at 250 V with L/R = 40 ms)
voltage)
Maximum switched current AC (highest 1 A (at 200 V with cos φ = 0.6)
current)
Maximum switched current AC (highest 0.8 A (at 250 V with cos φ = 0.6)
voltage)
Switching operations 1,000 cycles
Table 19: Switching capacity (switching load on an off)

Dielectric strength
AC dielectric strength between all volt- 2,500 V, 50 Hz, test duration 1 minute
age-carrying connections and the
grounded parts
AC dielectric strength between the 1,150 V, 50 Hz, test duration 1 minute
opened contacts
Table 20: Dielectric strength

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 8 Technical data

8.3.2 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

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8 Technical data

8.4 Technical data for pressure monitoring device

General technical data

Setup Outdoor model
Ambient temperature -40 °C…+80 °C (mechanical)
Cable gland M25x1.5
Degree of protection IP55 in accordance with IEC 60529 (enclosed de-
vice)
Relay actuation Corrugated tubing with counter-pressure spring
Oil temperature -40 °C…+100 °C
Weight approx. 1.2 kg
Equipment For standard insulating fluids (IEC60296 and
IEC60422)
Sealing material VITON
(oil – air)
Permitted pressure range 1 bar…6 bar, vacuum not permitted
(absolute pressure)
Upper switching pressure 3.8 ± 0.2 bar (trip pressure)
Lower switching pressure 2,8 ± 0,2 bar
Snap-action switch
Connection terminals Lead connection: 1 or 2 leads 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 current 10 A
Rated insulation voltage AC: 2.5 kV/min
Table 21: General technical data

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 8 Technical data

8.5 Limit values for dielectric strength and water content of

insulating fluids
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 insulating fluids for OILTAP® on-load tap-changers. The
values have been established on the basis of IEC 60422.
In operation Ud H 2O
When commissioning the transformer for > 60 kV/2.5 mm < 12 ppm
the first time
During operation > 30 kV/2.5 mm < 40 ppm
After maintenance > 50 kV/2.5 mm < 15 ppm
Table 22: Limit values for insulating fluids for neutral point applications

In operation Ud H 2O
When commissioning the transformer for > 60 kV/2.5 mm < 12 ppm
the first time
During operation > 40 kV/2.5 mm < 30 ppm
After maintenance > 50 kV/2.5 mm < 15 ppm
Table 23: Limit values for insulating fluids for non-neutral point applications

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9 Drawings

9 Drawings

9.1 OILTAP® M, installation drawing of centrical drive (893978)

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 9 Drawings

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9 Drawings

9.2 OILTAP® M, installation position of selector connection

contacts (890477)

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 9 Drawings

9.3 OILTAP® M, MS, R, RM, centrical drive (893899)

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9 Drawings

9.4 OILTAP® M, MS, R, RM, pipe connection with tap-change

supervisory control (899648)

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 9 Drawings

9.5 Tracing template for on-load tap-changer head (890183)

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9 Drawings

9.6 OILTAP® M, MS, R, supporting flange, special version for

bell-type tank installation for Um up to 300 kV (896762)

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 9 Drawings

9.7 Lifting traverse for bell-type tank installation (890180)

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9 Drawings

9.8 Socket wrench for kerosene drain plug (890182)

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 9 Drawings

9.9 Screw tools for installation and maintenance (890478)

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9 Drawings

9.10 Bevel gear CD 6400, dimensional drawing (892916)

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 Glossary

Glossary
CO IP
Change-Over contact Ingress protection

DC MR
Direct current Maschinenfabrik Reinhausen GmbH

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

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Maschinenfabrik Reinhausen GmbH
Falkensteinstrasse 8
93059 Regensburg

+49 (0)941 4090-0

[email protected]

www.reinhausen.com

4427232/01 EN - OILTAP® M -
F0333801 - 10/21 - Maschinenfabrik Reinhausen GmbH 2021

THE POWER BEHIND POWER.