TAPMOTION® ED-Ex

TAPMOTION® ED-ExOperating Instructions BA 271/04

www.reinhausen.com

2BA 271/04 - TAPMOTION® ED-Ex

The copying, distribution and utilization of this document as well as the communication of its contents to others withoutexpressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event

of the grant of a patent, utility model or ornamental design registration. ©Maschinenfabrik Reinhausen GmbH 2011

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Contents

Contents

NOTE

The data described in these Operating Instructions may vary in detail from the design delivered. We expressly reservethe right to make changes to the technical data, the design or the scope of delivery.In general, the information provided and the arrangements agreed during processing of the relevant offers and orders arebinding.

1 General .......................................................................................................................................................................................... 4

1.1 Safety instructions ........................................................................................................................................................ 41.2 Specified application ................................................................................................................................................... 51.3 Function ......................................................................................................................................................................... 51.4 Type designations ......................................................................................................................................................... 6

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

2.1 Mechanical equipment ............................................................................................................................................... 62.1.1 Protective housing ..................................................................................................................................... 62.1.2 Protective housing cover ......................................................................................................................... 72.1.3 Swing frame ................................................................................................................................................. 72.1.4 Hand crank ................................................................................................................................................... 72.1.5 Indication field ............................................................................................................................................ 92.1.6 Hand lamp .................................................................................................................................................... 92.1.7 Control elements ......................................................................................................................................... 92.1.8 Anti-condensation heater ........................................................................................................................ 9

2.2 Gearing ......................................................................................................................................................................... 102.2.1 Transmission gear ....................................................................................................................................... 102.2.2 Control gear ................................................................................................................................................. 102.2.3 Indicating equipment gear ...................................................................................................................... 102.2.4 Position transmitter equipment .............................................................................................................. 112.2.5 Transmission gear, control gear, motor unit wiring .......................................................................... 112.2.6 Covering for transmission gear, control gear, motor unit ............................................................... 11

2.3 Driving motor ................................................................................................................................................................ 11

2.4 Electrical equipment .................................................................................................................................................... 122.4.1 Swing frame ................................................................................................................................................. 122.4.2 Position transmitter equipment .............................................................................................................. 122.4.3 Terminal rails ................................................................................................................................................ 13

33271/04

BA 271/04 - TAPMOTION® ED-ExThe copying, distribution and utilization of this document as well as the communication of its contents to others without

expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the eventof the grant of a patent, utility model or ornamental design registration. ©Maschinenfabrik Reinhausen GmbH 2011

Contents

3 Standards and regulations ................................................................................................................................................... 14

3.1 Protection type overpressure encapsulation "p“ ................................................................................................ 14

4 Measures for compliance with the Ex protection requirements .......................................................................... 15

4.1 Measures for compliance with the "General regulations" ............................................................................... 15

4.2 Measures for compliance with the overpressure encapsulation "p" ............................................................ 15

4.3 Limit temperature, ambient temperature .............................................................................................................. 16

4.4 Temperature monitoring in the on-load tap-changer oil container by the temperaturemonitoring relay in the TAPMOTION® ED-Ex ........................................................................................................ 16

5 Montage ....................................................................................................................................................................................... 16

5.1 Installing the motor-drive unit onto the transformer tank ............................................................................... 16

5.2 Installing the drive shafts and the bevel gear ....................................................................................................... 17

5.3 Coupling on-load tap-changer and motor-drive ................................................................................................ 17

5.4 Electrical connection of the motor-drive .............................................................................................................. 20

6 Commissioning ............................................................................................................................................................................. 20

6.1 Function test .................................................................................................................................................................. 20

6.1.1 Preparations ................................................................................................................................................. 206.1.2 Checking the step-by-step operation ................................................................................................... 206.1.3 Checking the end position switches and the protective device against

passage of positions .................................................................................................................................. 21

6.1.4 Checking the leakage rate ....................................................................................................................... 21

6.1.5 Prerinse of motor-drive ........................................................................................................................... 21

6.2 Commissioning on site ................................................................................................................................................ 21

7 Transport ..................................................................................................................................................................................... 22

8 Maintenance ............................................................................................................................................................................... 22

9 Special designs ........................................................................................................................................................................... 23

9.1 Special designs based on on-load tap-changer features and operating conditions ................................ 23

10 Appendix ...................................................................................................................................................................................... 24

10.1 Technical data TAPMOTION® ED-Ex ......................................................................................................................... 24

10.2 Technical data, overpressure encapsulation "p" ............................................................................................... 24

10.3 Technical data position transmitter equipment ................................................................................................... 25

10.4 Dimension drawing/Functional sequence diagram ........................................................................................... 26




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WARNING

Do not open the motor-drive when it is switched on.

WARNING

After switch-off, wait 30 minutes before opening.

CAUTION

This housing may contain inert gases and lead to a risk ofsuffocation.

CAUTION

The motor-drive is designed as pressurized apparatus(ignition protection type = overpressure encapsulation)with leakage compensation. Overpressure and prerinsinghave to be monitored by an appropriate safety device.The minimum overpressure of 100 Pa may not beundershot at the inlet. In addition, the maximumoverpressure of 2000 Pa may not be exceeded.

1 General

1.1 Safety Instructions

All personnel involved in installation, commissioning,operation, maintenance or repair of the equipment must:- be suitably qualified and- strictly observe these Operating Instructions.

Improper operation or misuse can lead to- a reduction in the efficiency of the equipment- damage to the equipment and property of the user- serious or fatal injury.

Safety instructions in this manual are presented in threedifferent forms to emphasize important information.

WARNING

This information indicates particular danger to life andhealth. Disregarding such a warning can lead to serious orfatal injury.

CAUTION

This information indicates particular danger to theequipment or other property of the user. Serious or fatalinjury cannot be excluded.

NOTE

These notes give important information on a certain subject.

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1 General

CAUTION

All the safety equipment is designed for such anapplication.

CAUTION

The motor-drive unit may only be used to operate theon-load tap-changer/off-circuit tap-changer of the sameserial number. All safety devices have been adjusted to thisspecific application.

It is the responsibility of the user to make sure that theequipment is used for the specified application only.For safety reasons, unauthorized work, i. e. installation,modification, alteration, electrical connection or com-missioning of the equipment must not be carried out with-out first consulting MR !The trouble-free operation of the motor-drive, the on-loadtap-changer/off-circuit tap-changer and the transformermay be put at risk.

1.2 Specified application

The TAPMOTION® ED-Ex is to be used exclusively for operat-ing on-load tap-changers and off-circuit tap-changers inregulating transformers as well as for operating plunger-coreearth-fault neutralizers.

Lock the motor-drive unit using a padlock (not included) toprevent operation by unauthorized personnel.

1.3 Function

The modular-designed TAPMOTION® ED-Ex works by adjustingthe operating position of on-load tap-changers and off-circuittap-changers in regulating transformers to the individualoperating requirements (figs. 2, 3).

The tap-change operation is activated by starting the motor-drive (for example by a single control pulse triggered by aregulator of the TAPCON®-series). This operation is alwayscompleted regardless of any other control pulses emittedduring the operating time. The next tap-change operation canonly proceed once the control devices have been adjusted totheir rest positions.

Fig. 1 shows the sequence of a tap-change operation.

1

Motor-drive

Tapselector

Diverterswitchoperation

Diverterswitchcontactmovement

ca. 5,4 s

33 sections

Wicklung




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1 General2 Design

1.4 Type designation

The various basic designs of the TAPMOTION® ED-Ex are clearly identified by explicit product definitions.

2 Design

2.1 Mechanical equipment

2.1.1 Protective housing

TAPMOTION® ED-Ex is characterized by two main features: itsuniform construction for all motor-drive designs and itsmodular drive concept.

The TAPMOTION® ED-Ex can only be supplied in the ED 100/200 S-Ex housing variant, fig. 3.The protective housing consists of two parts, the housing andthe cover, both of which are made of non-corroding cast-aluminium. They are finished with a one-layer prime coat (RAL6019) and a one-layer finishing coat (RAL 7033).The spaces between the housing and the cover, as well as allapertures required for operation (driven shaft, inspectionwindow, aperture for hand crank in special arctic design, etc.),are thoroughly sealed. Thus protection against dust and jets ofwater is ensured (IP 66).

The Ex-protected variant does not possess the air vent of theprotective housing using two labyrinth apertures with metalfilters, in order to keep the leakage rate to a minimum.

The housing is closed with a dummy plate. Only Ex-certifiedcable entries may be attached to this, providing that they donot have a negative effect on the leakage rate of the motor-drive.

Type designation Description Types

ED Product definition Electric Drive

ED 100/200 Type of transmission gear 100 = small transmission gear (motor, 6.5 Nm)

200 = large transmission gear (motor, 13/18 Nm)

ED 100/200-S Type of protective housing S = small protective housing

ED 100/200-S-Ex Special designs = without

M = Monitoring

C = Plunger-core earth-fault neutralizer designT = Voltage regulator TAPCON® 240 (not possible for

Ex-protected version)

Ex= Overpressure encapsulation "p"

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2 Design

2.1.2 Protective housing cover

In the Ex-version, the protective housing cover is stiffenedusing four solid struts and is fixed to the housing with fourscrews on each side. In this way, it is possible to guarantee aneven pressure and thus a low leakage rate. To avoid anydamage to the window, and thus to avoid leaks, there is anadditional protective grate. The motor-drive is operated whenthe protective housing is closed. The cover can be opened inboth directions, by approximately 180°.On the inner side of the protective housing cover, there is apocket for documents for the storage of the connectiondiagrams.

WARNING

After switch-off, wait 30 minutes before opening.

32

All control elements are installed in a closed swing-framepanel located behind the protective housing cover. This panelprotects all electrical and mechanical parts of the motor- driveagainst accidental contact.The closing system of the swing frame is designed to preventthe frame from banging against the base or cover. The closedswing frame is attached to the protective housing by twospring-supported door bolts. The standard design of the swingframe always opens to the left.

CAUTION

When manually operating the motor-drive unit only usethe built-in hand crank. Otherwise, there is a risk of seriousor fatal injury.The safety switch in the hand crank disconnects the motor-drive circuit at two poles; however, it does not disconnectthe control circuit.

2.1.4 Hand crank

The hand crank is used to manually operate the motor-drivein emergencies or for adjustment purposes. It is attached tothe upper cover plate inside the protective housing.

WARNING

Before opening the swing frame the relevant safetyinstructions must be observed in order to avoidserious or fatal injury.

2.1.3 Swing frame




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2 Design

4

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2 Design

5

4

7

5

6

2.1.5 Indication field

A clearly arranged indication field (fig. 5) is installed in theupper part of the control panel cover (fig. 4).The data displayed and the displays are detailed as follows:

- The mechanical operation counter shows the overallnumber of operations performed by the motor-drive.

- The position indicator shows the position of the motor-drive and the on-load tap-changer (standard,max. 35 positions) / off-circuit tap-changer).

- The two drag hands indicate the regulating rangecurrently used.

- The tap change indicator shows the current position ofthe control cam (33 sections per tap-change operation)

Pointer and operations counter are mechanically driven andindicate the switching sequence of the motor-drive.The reset-wheel on the operations counter is lead-sealed atthe factory.

2.1.6 Hand lamp

For reasons of safety, the Ex-prepared TAPMOTION® ED is notequipped with a hand lamp.

2.1.7 Control elements

The standard design contains the following control elementsmounted in the upper part of the swing frame (see fig. 4):

– Motor protective switch

– Control switch “RAISE/LOWER“ to initiate a tap-changeoperation electrically.

2.1.8 Anti-condensation heater

CAUTION

Do not touch the panel heater as it becomes very hot duringoperation.

The anticondensation heater, fig. 4 (ED 100/200 S:50 W, ED 100/200 L: 60 W) is designed as a panel heaterwhich also acts as the front cover of the swing frame.

NOTE

This new heater design:

- is a complete anti-condensation heater suitablefor all climate regions except the arctic.

- saves the need for an anti-condensation coat ifit has a MR-standard inside coat.

- does not require a thermostat or a hygrometer.




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6

2.2.2 Control gear

The control gear (fig. 7) (step-by-step device with cam-operated contacts) is installed below the transmission gear.

8 KHW 929

9

7 KHW 935

2.2 Gearing

2.2.1 Transmission gear

Transmission gear, control gear and the gear for the indi-cating equipment are located in the upper part of the pro-tective housing. They are protected against accidental contactby a cover plate.

The entire gearing system (fig. 6) is located behind the uppercontrol panel in the upper part of the housing. The transmis-sion gear is a low-noise, single-stage belt-type gear which hasunchanging 16.5 revolutions (= 33 hand crank rotations) perswitching operation. The transmission is a wear-resistant belt.

NOTE

The transmission gear belt must not come into contactwith lubricants.

It contains cam discs which are used to mechanically triggerthe cam switches. The modular-designed position indicatorequipment and the additional cam-operated contacts aredriven by the control gear, the indicating equipment gear isdriven by a cam shaft (fig. 8).

Electrical limit switches prevent overrunning of the endpositions. In addition to this, mechanical and electricallimiting devices prevent tap-change operations beyond theregulating range.

2.2.3 Indicating equipment gear

The indicating equipment gear (fig. 9) mechanically reflectsthe tap position on the indicator panel.

2 Design

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2 Design

2.3 Driving motors

The TAPMOTION® ED-Ex is equipped with a three-phase motorwhich covers a wide voltage range as well as covering the 50/60 Hz frequencies. The motor unit is installed below thetransmission gear.

The on-load tap-changers and their corresponding motor-drive unit designs are listed in a separate selection table.

2.2.4 Position transmitter equipment

The position transmitter equipment comprises:

- the position transmitter,

- the position transmitter module and

- a plug-in connecting cable.

The position transmitter is installed below the control gear. Theposition transmitter module for the connection by thecustomer is located on the terminal rails (fig. 12).

2.2.5 Transmission gear, control gear, motor unitwiring

The transmission gear, control gear and motor unit are wiredusing black, flexible line material (1.5 mm2).

2.2.6 Covering for transmission gear, control gear,motor unit

The touch-protected covering of the transmission gear,control gear and motor unit is provided with an opening forthe hand crank used for manual operation (fig. 10).

The covering is equipped with fixing clamps and hooks tohold the hand crank.

10




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2 Design

2.4 Electrical equipment

2.4.1 Swing frame

The electrical equipment is mounted on the back of the swingframe (fig. 11). Mounting rails and clamping rails (some two-sided) allow for an easy installation of components.The individual devices are clearly marked with designations foreasier identification on the connection diagram kept in thepocket of the door.

In the standard design, the swing frame is equipped with thefollowing components:

- anti-condensation heating: designed as a panelheater (temperature increase in relation to ambienttemperature by ΔT ≈ 7 K)

- motor protection with trip coil

- control switch for RAISE/LOWER control

- contactors for RAISE/LOWER- auxiliary contactor for step-by-step operation

The cable connection bundle between the swing frame andthe terminal rails has a zip and a strain relief device on bothsides.

2.4.2 Position transmitter equipment

In the standard model, the following designs of the positiontransmitting equipment are available:

- resistor-type position transmitter device

- N/O contact position transmitter device• break before make-type• make before break-type

– position transmitter module, diode matrix

11

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2 Design

12KHW 1168

314

6 57 2

2.4.3 Terminal rails

The terminal board facilitates an easy electrical connection ofthe motor-drive unit (fig. 12).

The wiring is easily connected using vertically arrangedclamping rails and terminal bars.

1 - cable entries(closed by 3 bottom plates)

2 - terminal bar X13 - cable duct4 - clamping rail5 - position transmitter module

6 - connection bundleswing frame – terminal rails

7 - connection bundleterminal rails - transmission gear,control gear, motor unit




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3 Standards and regulations

The TAPMOTION® ED-Ex is certified for Ex II 2G EEx px II.Depending on the ambient conditions prevailing at the placeof use, it can belong to either temperature class T3 or T4.

3 Standards and regulations

Equipment in this category is intended for use in areas in which explosiveatmospheres caused by mixtures of air and gases, vapors or mists or by air/dustmixtures are present continuously, for long periods or frequently.

Equipment in this category is intended for use in areas in which explosiveatmospheres caused by gases, vapors, mists or air/dust mixtures are likely to occur.

Equipment in this category is intended for use in areas in which explosiveatmospheres caused by gases, vapors, mists, or air/dust mixtures are unlikely to occuror, if they do occur, are likely to do so only infrequently and for a short period only.

for

gase

s

for

pow

der

Definition

1G(0)

2G(1)

3G(2)

1D(20)

2D(21)

3D(22)

Equipment category / zone classification

Equipment in this category is intended for use in underground parts of mines as well as those parts of surface installations of suchmines endangered by firedamp and/or combustible dust.

Equipment in this category is intended for use in other areas in which explosive atmospheres may be present.

Equipment groups

I

II

Temperature class

Explosion group

Protection type

Explosion-proof equipmentEquipment category

Equipment group

Sign for explosionprotection

d flameproof enclosuree increased safetyl intrinsic safety (la, lb)m encapsulationo oil immersionp pressurized apparatusq powder filling

n protection type „n“ (only zone 2)

n A: non-sparking apparatusn C: sparking apparatus with special

protection of contactsn R: restricted breathing enclosuresn L: energy-limited equipmentn P: equipment with simplified

n-pressurization

Protection types

3.1 Protection type overpressure encapsulation "p“

Temperature Max. equipment Ignition temperatureclass surface temperature of the inflammable

substances

T1 450 °C > 450 °C

T2 300 °C > 300 °C < 450 °C

T3 200 °C > 200 °C < 300 °C

T4 135 °C > 135 °C < 200 °C

T5 100 °C > 100 °C < 135 °C

T6 85 °C > 85 °C < 100 °C

Gases, vapors Min. ignition EN/IEC(examples) energy

(mJ)

- ammonia -- IIA

- acetone, methane, ether, petrol, benzene,diesel, petroleum, acetic acid, fuel oil, hexane,methane, propane

- ethylene, isoprene, town gas 0.06 IIB

- hydrogen, acetylene, carbon disulfide 0.02 IIC

Explosion group Temperature classes

II 3G EEx px II T3/T4

Depending on the temperature class selected, theTAPMOTION® ED-Ex can be operated at an ambienttemperature of up to 40° C for temperature class T4 or 50° Cfor temperature class T3. The actual temperatures may behigher in the case of positioning in direct sunlight. In suchcases, the drive must be provided with additional shade (e. g.MR sunshade).

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4 Measures for compliance with the Ex protection requirements

4 Measures for compliance with theEx protection requirements

To guarantee the correct operation of the TAPMOTION® ED-Ex ,the operator must undertake the following measures tocomply with the Ex-protection requirements.

Basic standards:

- EN 60079-0 General requirements- EN 60079-2 Overpressure encapsulation p

4.1 Measures for compliance with the "Generalrequirements"

The requirements specified by EN 60079-0 „General require-ments“ (such as the selection of the material, IP protectiontype, tightness and pressure resistance of the equipment,earth, etc.) were taken into account during the construction ofthe motor-drive. No special measures need to be taken by thecustomer.

4.2 Measures for compliance with overpressureencapsulation "p"

• Cable entriesThe housing of the TAPMOTION® ED 100/200S-Ex motor-drive possesses IP66 protection. The housing is closed witha dummy plate. Only those Ex-certified cable entries maybe attached which do not have a negative influence on theleakage rate of the motor-drive.

• Maximum operating pressure:The maximum operating pressure of the TAPMOTION®ED100/ 200S-Ex motor-drive is 2 kPa.

• Safety equipment, protective gas supply:The safety equipment as well as the equipment for theprotective gas supply must be provided by the operator.

The safety equipment and the equipment for the pro-tective gas supply must be certified for explosion pro-tection in the same way as the TAPMOTION® ED-Ex,i. e. on the basis of the directive 94/9/EC.

The following points must be observed during the selectionand operation of the protective gas supply unit:

– N2 and air of a quality usually used for measurementequipment can be used as the protective gas.

– The temperature of the protective gas must not exceed40° C at the housing inlet.

– Minimum prerinse volume: 1700 dm³ (free housingvolume 170 dm³ x 10)Minimum rinse length: dependent on the line cross-sectionselected and the selected rinse pressure.

– Minimum overpressure at inlet: 100 Pa– Maximum overpressure at inlet: 2000 Pa– Leakage rate at Pmax: 0.3 dm³/h– Limit temperature of the protective gas:

Tmax. ≤ 50° C - for temperature class T3Tmax. ≤ 40°C - for temperature class T4

These values are valid both for the N2 protective gas and forair due to the low differences in density.

WARNING

Do not exceed the maximum pressure of 2000 Pa at theinlet valve.




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4 Measures for compliance with the Ex protection requirements5 Installation

5.1 Attachment of the motor-drive to thetransformer tank

There are four stud bolts (not in MR scope of supply) attachedto the transformer tank for fixing the motor-drive. The cor-responding installation boreholes - identical for all versions ofthe ED - are located on the exterior, on the fixing straps of theprotective housing.

For correct attachment of the 4 stud bolts onto the trans-former tank see the dimension diagram in paragraph 10.4.

CAUTION

The motor-drive’s protective housing must not be warped ordeformed in any way when fixing it to the transformer tank.Make sure the motor-drive is mounted vertically and that itsdriven shaft is correctly aligned with the vertical drive shaftof the bevel gear in order to prevent damage to the motor-drive, the on-load / off-circuit tap-changer and the trans-former.

5 Installation

WARNING

No installation and commissioning work may be carriedout in an area with a risk of explosion.

CAUTION

For the potential tie-in of the TAPMOTION® ED-Ex, use onlythe supplied torsion-protected earthing connection(fig. 13).The earthing is suited to the use of a cable cross-section of16 – 80 mm².Make sure that the earthing line is positioned correctly andfirmly. Tightening torque: 16 Nm (the tightening torque mayneed to be reduced, depending on the selected earthingline).

If the transformer causes extremely strong mechanical vibra-tions, the use of vibration absorbers is recommended.

4.3 Limit temperature, ambient temperature

The TAPMOTION® ED-Ex was certified for temperature class T3(unlimited operating modes) and T4 (limited operatingmodes).

– The certification for T3 is valid for motor-drives for un-limited operating modes in an ambient temperaturerange: –25° C ≤ Ta ≤ +50° C

– The certification for T4 is valid for motor-drives for limitedoperating modes in an ambient temperature range:–25° C ≤ Ta ≤ +40° C

Limitation of the operating mode:A maximum of 216 switching operations may becarried out in sequence using this motor-drive,followed by an operational break of at least ten hours.

NOTE

A warning notice is attached to the motor-drive, saying thatthe motor-drive may only be opened after 30 minutes haveelapsed since it was disconnected from the power supply:"Open at earliest 30 minutes after disconnection frompower supply".This instruction is valid for motor-drives of both temper-ature classes (T3 / T4).

4.4 Temperature monitoring in on-load tap-changeroil container using temperature monitoring relayin the TAPMOTION® ED-Ex

To monitor the oil temperature in the on-load tap-changer oilcontainer, there is a temperature sensor in the cover of the on-load tap-changer. The corresponding control unit (temper-ature monitoring relay) is integrated in the TAPMOTION® ED-Ex.

The temperature monitoring prevents additional switchingoperations being carried out by the on-load tap-changerwhen the limit temperature is reached.The setting value of the temperature monitoring is specifiedfor each order for all Ex-on-load tap-changer types andlocked against unintentional alteration.

CAUTION

The setting value of the temperature monitoring is specifiedat the factory. Do not change this setting value.

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5 Installation

CAUTION

Make sure that the on-load tap-changer completes the tap-change operation before the motor-drive stops by correctlycoupling the motor-drive to the on-load tap-changer andalso ensuring that the position indication of the on-loadtap-changer and the motor-drive are the same for eachoperating position. These measures can prevent damage tothe motor-drive, on-load tap-changer and the transformer.

of KHW 93414

5.2 Installing the drive shafts and the bevel gear

Further information on attaching these drive components canbe found in the Operating Instructions No. BA 276 for driveshaft-Ex.

13

5.3 Coupling on-load tap-changer and motor-drive

The above-mentioned requirements are met by setting thetime at which the operation of the on-load tap-changeroccurs 1.5 – 2 sections before the grey area of the tap changeindicator (fig. 14).

The centre mark in the grey field of the tap-change indicationwill be used as reference for the following procedures.

One tap-change operation is represented by one rotation ofthe pointer on the tap change indicator. This indicator isdivided into 33 sections where one section corresponds toone rotation of the hand crank.

The number of sections from the beginning of the diverterswitch action until the pointer reaches the centre mark of theresting range should be equal in both directions.

Resting range ofthe motor-drive

Centre mark




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A slight asymmetry of a max. of 1 section is permissible.To obtain a symmetrical coupling, proceed as follows: WARNING

Before starting any coupling work make sure that the motorprotective switch is tripped to prevent an unin-tentional start of the motor-drive.

Procedure Example

Zeitpunkt derLastumschaltung

5 Installation

Carry out any adjustment work by manual operation only.

Attach the hand crank in the motor-drive to the shaft end located in the upper coverplate. This activates a safety switch which disconnects the motor-drive at two poles.

Make sure the on-load tap-changer and the motor-drive are in their adjustmentpositions before commencing any adjustment work.When adjusting, make sure the position indicators on the on-load tap-changer andon the motor-drive are identical.

Couple the motor-drive and vertical drive shaft by mounting the coupling brackets.

Turn hand crank in one direction until the diverter switch operation begins.When operating the motor-drive manually, observe the tap changeindicator which mechanically reflects the progress of the tap-changeoperation.

Once the diverter switch operation begins, turn the hand crank in thesame direction while counting the sections required for the pointer toreach the centre mark of the tap-change indicator.Note the determined value A and the direction of rotation.The tap-change operation is completed.

A = 5 SSE Mittel-marke

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5 Installation

Procedure Example

B = 3 SSERuheposition(Mittelmarke)

Zeitpunkt der Lastumschaltung

C = A - B 2

A = B

Turn the hand crank in the opposite direction, until the diverter switchoperation occurs.

Count the remaining sections from the time the diverter switchoperation occurs until the pointer reaches the centre mark ofthe tap-change indicator.Note the determined value B and the direction of rotation.

If the values obtained for both directions are identical, the on-load tap-changer and themotor-drive are correctly coupled.

As a control measure, carry out several tap-change operations in both directions.

If the values for A and B are not equal, proceed as follows:

Determine the correction value C bydividing the difference between Aand B by 2.

Uncouple the motor-drive and the vertical drive shaft by removing the coupling brackets

Operate the motor-drive using the hand crank in direction of the higher value, either A or B by the number of sections on thetap-change indication which equals C.

Re-couple motor-drive and on-load tap-changer and check the coupling using the above procedure.

Make sure that the pointer of the tap-change indicator is in centre position within the greyfield once the manual operation is finished.

Check the coupling after adjustment work by carrying out a few tap-change operations in both directions.Check that the operating positions of the on-load tap-changer and the motor-drive are identical.




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5.4 Electrical connection of the motor-drive

Connect the motor-drive to the mains supply according to theconnection diagram in the pocket of the swing frame door.The standard terminal block illustrated in fig. 15 on the termi-nal barl X (fig. 12) is used for this purpose.

WARNING

Before connecting the motor-drive to the mains supply,the relevant safety instructions must be observed in order toprevent serious or fatal injury.

Terminal bar X1

15

WARNING

For power connections, use only Ex-certified cable glands,which do not have a negative impact on the leakage rate ofthe motor-drive.

5 Installation6 Commissioning

6.1 Function test

6.1.1 Preparations

Phase sequence testWhen checking the motor circuit voltage, make sure thatvoltage applied to the connecting terminals has a clockwisephase sequence.

6.1.2 Checking the step-by-step operation

- Initiate a tap-change operation by turning the controlswitch S3 (fig. 16) and keeping it turned while the motor-drive is in operation.

- Check that the motor-drive switches off automatically afterperforming one operation of the on-load/off-circuit tap-changer and that the pointer of the tap-change indicatorstops within the grey field.

- Carry out this test in both directions.

WARNING

The function test must be performed with the supplyvoltage connected. Make sure that the on-load/off-circuittap-changer completes the tap-change operation beforethe motor-drive stops by properly coupling the motor-driveto the on-load/off-circuit tap-changer. Also ensure that theposition indications of the on-load/off-circuit tap-changerand the motor-drive are the same for each operatingposition. These measures can prevent damage to the motor-drive, the on-load/off-circuit tap-changer and thetransformer.The relevant safety instructions must be strictly observed toprevent serious or fatal injury.

CAUTION

Electrical mains supplyMake sure that the mains supply fulfils all the connectionrequirements of the motor-drive unit.

6 Commissioning

16

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6 Commissioning

6.1.3 Checking the end position switches and theprotective device against passage of positions

- To check the end position switch, operate the motor-drive to the penultimate position by turning the controlswitch S3. Using the hand crank, manually operate themotor-drive to its end position.

- When the S3 switch is turned further in the same direc-tion, the motor-drive must not continue to operate. Checkto make sure.

- Using the same procedure, operate the motor-drive to theother end position and repeat the above check.

Check that the pointer of the tap-change indication is in thegrey field.To check the protective device against passage of positions,operate the motor-drive using the hand crank while the motorprotective switch is activated.Check that the motor protective switch trips after a max. of4 sections.

6.1.4 Testing the leakage rate

To ensure that the cable glands used do not have a negativeimpact on the leakage rate of the motor, check the tightnessof the motor-drive after the installation and electricalconnection of the drive:Close the closing screw on the top side of the motor-drivehousing (G1").Connect the feed line on the bottom side of the motor-drive,(G1/2") to a compressed air supply. At a maximum pressure of2000Pa, the leakage rate may not exceed 0.3dm³/h. Due tothe low difference in density, this value is valid both for theuse of air and also of N2 as a protective gas.

6.1.5 Prerinsing of the motor-drive

Before commissioning, always prerinse the TAPMOTION® ED-Exwith a volume of protective gas of 1700 dm³ (this value isvalid both for the use of air and also of N2 as a protective gas.This method ensures that there is no explosive gaseousatmosphere in the inside of the motor-drive. The minimumrinse length is dependent on the selected line cross-sectionand the selected rinse pressure.

6.2 Commissioning on site

The function tests as per 6.1 are to be repeated before thetransformer is commissioned.

WARNING

Under no circumstances is the transformer to be com-missioned, if the devices described in 6.1 do not pass thefunction test. Otherwise serious or fatal injury may result.

WARNING

Do not exceed the maximum pressure of 2000Pa at the inletvalve.

WARNING

The temperature of the protective gas at the inlet may notexceed the maximum ambient temperature of the drive(T4 =>40° C, T3=>50° C)




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The ED-Ex motor-drive unit does not require regular main-tenance. However, if used with industrial transformers, ourTechnical Service department must be contacted after the unitperforms 500.000 tap-change operations.

We recommend that the following control checks be carriedout on the motor-drive unit during routine transformerinspections:

- checking that the sealing of the protective housing iswater-proof,

- checking that the built-in electrical heater is functioningtrouble-free,

- checking the exterior condition of the equipmentinstalled in the motor-drive.

When inspecting the on-load tap-changer, also carry out afunctional test of the motor-drive according to 6.1.

7 Transport / 8 Maintenance

7 Transport

If it is neccessary to remove the motor-drive for transportingthe transformer, proceed according to section 5 of theseOperating Instructions when re-installing the unit.

NOTE

To prevent damage to the motor-drive unit during trans-portation use the packing material provided by the MRdelivery.If the motor-drive has to be removed for transporting thetransformer from the factory to the site of operation,operate the on-load/off-circuit tap-changer and the motor-drive to the adjustment position beforehand.Reinstall the motor-drive according to section 5 of theseOperating Instructions.

WARNING

The control checks must be performed with the supplyvoltage connected.

The relevant safety instructions must be strictly observed.Failure to do so can lead to serious or fatal injury.

8 Maintenance

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9 Special designs

The standard design of the TAPMOTION® ED-Ex can be modified to accommodate specific operating requirements.

9.1 Special designs based on on-load tap-changer features and operating conditions

Number of mid-positions of on-load tap-changer >1 Automatic passage of positionsDevice for automatic passage of positions throughone or more operational positions

On-load tap-changer with change-over selector for Monitoring of drive shafts, tap-change operation andstar-delta change-over operation star-delta change-over operation

Furnace and electrolysis operation Additional input terminals for "operation without step-bystep switch".Possibility to install position indication modules withN/O contact range, 10 A (make-before-break) for thecontrol of external current matching transformers.

Higher max. number of operating positions Control gear + position indicator for 71 operating positions

Control gear + position indicator for 107 operating positions

Design with vibration damping feature Special fixing: protective housing with vibrationabsorbers according to drawing 734850

Feature Special design TAPMOTION®

9 Special designs




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10.2 Technical data - Overpressure encapsulation "p"

Minimum overpressure (inlet) [Pa]: 100

Maximum overpressure (inlet) [Pa]: 2000

Minimum prerinse volume [dm³]: 1700

Protective gas: Air / N2

Leakage rate [dm³/h]: 0.3

10 Appendix

10 Appendix

10.1 Technical data: TAPMOTION® ED-Ex

The technical data is relevant to the standard design and may vary depending on the design delivered. It is subject to changewithout notice.

TAPMOTION® ED 100/200-S-Ex

Motor power 0.75 kW 2.0 kW 2.2 kW

Voltage 3 AC/N 230/400 V

Current 1.9 A 5.2 A 6.2 A

Frequency 50 Hz

Synchronous speed 1500 1/min

Rotations of the drive shaft per tap-change operation 16.5

Duration of the tap-change operation ca. 5.4 s

Rated torque of the drive shaft 45 Nm 90 Nm 125 Nm

Rotations of the hand crank per tap-change operation 33 54

Max. number of operating positions 35

Control and heater voltage AC 230 V

Power input of the control circuit 100 VA / 25 VA(control / operation)

Heating power 50 W for the ED 100/200 S-Ex

Temperature range (ambient temperature) -25° C to +40° C (T4)-25° C to +50° C (T3)

Test voltage to ground 2 kV / 60 s

Weight max. 100 kg

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10 Appendix

10.2 Technical data: position transmitter equipment

Resistance-type position transmitterStandard resistance: 10.0 Ω (0,6 W, +/-1 %) per stepThe maximum load on the module is determined by the number of resistors loaded and can be inferred from the capability curvebelow. The permissible supply voltage is calculated from these power ratings and the total resistance value. However, the supplyvoltage should not exceed DC 220 V.

load

on

the

mod

ule

[W]

Number of resistors loaded

N/O contact position transmitter (break-before-make contact)AC: 250 V, 0.5 A (ohmic load)DC: 220 V, 0.2 A (ohmic load)Minimum voltage level for signal and data processing: 24 V

N/O contact position transmitter (make-before-break contact)AC, DC: 250 V, 0.02 A (ohmic load)AC, DC: 24 V, 0.20 A (ohmic load)Minimum voltage level for signal and data processing: 24 V

N/O contact position transmitter, 10 A (make-before-break contact) for controlling current matching transformer inindustrial applications.AC, DC: 250 V, 10 A (ohmic load)

Position transmitter, diode matrixDC: 220 V, 0.2 A (ohmic load)Minimum voltage level for signal and data processing: 24 V

Load on the resistance-type position transmitterPermissible load in relation to the number of resistors

26

10 Appendix

10.4 Dimension drawing/Functional sequence diagram

TAPMOTION® ED-S-Ex, protective housing ........................................................................................................................................................ 898743

TAPMOTION® ED-Ex, protective housing-Ex, damped against vibration ................................................................................................... 734850

Functional sequence diagram............................................................................................................................................................ EN 60079-2:2004

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Motor-drive unit ED-S-ExProtective housing

8987434E




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TAPMOTION® ED-Ex

Protective housing-Ex, damped against vibration7348500E

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Functional sequence diagramEN 60079-2:2004

SO S1 S2 S3 MOP XOP PFLO PTIM

1 0 0 0 0 1 0 11 0 0 0 0 0 0 11 0 0 0 1 1 1 01 0 0 0 1 1 0 11 0 0 0 1 1 1 11 0 0 0 0 1 1 11 0 0 0 0 0 1 11 0 0 0 1 1 0 01 0 0 0 0 1 0 01 0 0 0 0 0 0 01 0 0 0 0 0 1 01 0 0 0 0 1 1 00 1 0 0 1 0 0 00 0 1 0 1 0 1 00 0 0 1 1 0 0 10 0 0 1 1 0 1 1

Table B.1 – Truth table of a prerinse controller with compensation for leakages

Fig. B.1 – Status diagram of a prerinse controller with compensation for leakages

All the states of the system are determined by the input variables of the monitoring units. The system is always inthis state. Transfers between the states are only permitted along the paths indicated by arrows and only in thedirection of the arrows. The logical conditions for the occupation of a state are defined clearly by Booleanexpressions. The truth table shows all the possible combinations of input conditions.

LOGIC DEFINITIONS FOR THE COMPENSATION OF LEAKAGES

Overpressure too high = [XOP]

Overpressure > 50 Pa (25 Pa for pz) = [MOP]

Prerinse gas flow > Minimum = [PFLO]

Prerinse time not elapsed = [PTIM]

Prerinse time elapsed = [PTIM]

Starting state = SO

[MOP] & [XOP] & [PFLO] & [PTIM] = S1 Precondition for starting prerinsing

[MOP] & [XOP] & [PFLO] & [PTIM] = S2 Prerinsing running

[MOP] & [XOP] & [PTIM] = S3 rerinsing complete, power supply switched on

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BA 271/04 EN • 02/11 • F0144303 • Printed in Germany

©Maschinenfabrik Reinhausen GmbH Phone +49 941 40 90-0Falkensteinstrasse 8 Fax +49 941 40 90-11193059 Regensburg, Germany E-mail [email protected]

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TAPMOTION® ED-Ex