On Load Tap Changer Type A General & Operating Manual

CONTENTS 1. Specification Detail 1.1 1.2 1.3 1.4 1.5 General......................................................................................................4 Functional principles................................................................................. 5 Basic connection of the tap winding..........................................................5 Designation of the tap changer model.......................................................6 Number of steps and basic connection diagram.......................................6 Table I Rated withstand voltages of insulating distances...........................8 Table II Rated step voltage and Relevant rated currents........................... 8 2. Principal parts of the on-load tap changer.......................................................... 8 2.1 2.2 2.3 3. 4. 5. Tap changer head...................................................................................... 8 Oil Compartment....................................................................................... 9 The tap changer insert............................................................................... 9

Installation of the tap changer............................................................................. 10 Connection of the tapped winding and take-off lead........................................... 10 Accessories ....................................................................................................... 10 5.1 5.2 Motor Drive.................................................................................................10 Protective Relay.........................................................................................11

APPENDIX A III 100 - D - 24kV - 09 - 0 A 111 100 - D - 24kV - 09 - W/G A 111100-D-36kV-09-0 A lit 100 - D - 36kV - 09 - W/G Coupling of OLTC and Drive Dimension Drawing ------------A0011 R2 Dimension Drawing ------------A0012 R2 Dimension Drawing ------------A0010R1 Dimension Drawing ------------A0002 R2 B25556

On Load Tap Changer Type A General & Operating Manual

On-Load Tap Changer Type A 1. Specification Details Layout Installed fully sunk in the transformer tank. (Can also be mounted in a separate tank) Selector switch operates in its own oil space (Oil Compartment) isolated from the transformer tank oil. On-load tap changer Alll 100, as star point tap changer for three phase star connected transformers. On-load tap changer Alll 100 D for application to delta connected transformer. or On-load tap changer A I 100 as single-phase tap changer for single phase transformer or for three phase transformers in any mode of connection Insulation: A.C test voltage (50Hz.;1.2/50Microsec.) Current rating Rated frequency Short-Circuit Withstand Step voltage Number of taps Insulation level voltages to earth 24, 36 & 52 kV According to IS,BS,IEC,VDE,ASA etc Internal selector insulation: Withstand voltages for all insulation distances on application 100 A when Star or Delta connected, single phase in any connection. 50 ~ 60 Hz Thermal: Over 20 times the rated current (rms), duration 3 seconds. Dynamic test; Over 50 times the rated current (peak value) Max 450 V. Tap selector with pre-selector (coarse tap selector or reversing switch): 8 steps with one mid-position (up to a maximum of 17 working positions differing in voltage) Tap selector without pre-selector 8 steps (up to a maximum of 9 working positions differing in voltage) Drive mechanism Motor drive MA9 as standard equipment, can be started and stopped by push-buttons from the cabinet and also from the control room. Remote position indication version for parallel operation and for connection to voltage regulators. Tap changer Type A is an in-tank, fully bi-directional, tapchanger which leads to a reduction in quantity of oil as compared to externally mounted tap changers. Can be adapted for transformers originally designed for externally mounted tap changers with minimum alterations to transformer tank design.

Application

On Load Tap Changer Type A General & Operating Manual

1.1 General On-load tap changer Number of poles Application Max.rated through-current (A) Short-circuit withstand capability (kA) thermic (three-second value) dynamic (peak value) Max. rated step voltage (V) Rated switching capacity (kVA) Rated frequency Operating positions Insulation Highest Voltage for Equipment Um (kV) Rated lightning impulse withstand voltage (kV, 1,2/50) Rated power-frequency withstand voltage (kV,50 Hz,1min) Withstand voltage of internal insulation Tap changer oil compartment On-load tap changer Weight (approx. in kg) Oil displacement volume (dm3) Without change over selector with change over selector without change over selector with change over selector ** 24 (26.4) ** 125 (150) 50 See table 1 Pressure-proof (complying with IEC 214) A III 100Y 50 Approx 16 Approx. 22 Approx 13 Approx. 18 A III 100D 60 20 27 24 ...40 16 22 19-32 AI 100 40 ca .12 ca.16 ca .10 ca.13 ** 36 (36.5) ** 170 (200) 70 52 250 95 A III 100Y 3 in the neutral 100 A III 100D AI 100

3 * at any location of the winding 100 100

2.0 5.0 450 37.5

2.0 5.0 450 37.5 50...60HZ

2.0 5.0 450 37.5

without change-over selector: with change-over selector:

max.9 max.17

Oil filling quantity Vs (dm3)

* **

Please contact Easun - MR Clause 8.6.4- IEC 214 applicable without restrictions upto Um = 26.4 kV or 36.5 kV and rated lightning impulse voltage of 150kV or 200 kV
4

On Load Tap Changer Type A General & Operating Manual

1.2 Functional principle The on-load tap changer type A is designed as a selector switch combining the function of a diverter and a tap selector in a single compartment. The load current transfer from one tap of the winding to the next is initially performed by 2 transition contacts and then by the main switching contact. a, b a1. b1 R main switching contacts transition contacts transition resistance

1.3 Basic connections of the tap winding The selector switch of the tap changer is equipped with 9 stationary contacts on each contact plane. The stationary contacts are arranged in a circle and can be connected successively to the tap changer take-off lead by means of the movable switching element. Without change-over selector Fig.2 (a) The linear voltage regulation may be achieved with a maximum of 8 steps (i.e., 9 operating positions at the most). With change-over selector Fig. 2 (b) & (c) Where required, the selector switch can be provided with a change-over selector which can be used either as reversing switch for the buck and boost connection or as coarse tap selector to connect the beginning or end of a coarse tap winding to the main winding. In either case the regulating range will be doubled to 8 steps (i.e. 17 operating positions).

On Load Tap Changer Type A General & Operating Manual

1.4 Designation of the tap changer model Every tap changer is available in different models varying according to the number of poles, maximum rated through-current, insulation according to highest voltage for equipment (U m) and basic connection diagram. The designation of a particular tap changer must, therefore, indicate these characteristics. (fig:3). This coding ensures unmistakable designation of every tap changer. Example: On-load tap changer type Number of pole pole appln.) Max. rated through-current Insulation voltage to earth Basic connection diagram : A, : III (for three : 100 Amps. : 24 kV : 09 17 1W

1.5 Number of steps and basic connection diagram The selector switch can be adapted to the tap winding with respect to the number of steps required. The connection diagram is referenced to the number of operating positions, number of midpositions and kind of change-over selector. The designation of the basic connection diagrams with their inherent number of steps is shown in fig. 4. Example: Pitch of the selector switch contact circle Number of mid positions Max. number of operating positions Type of switch :

9 1 17 Reversing

On Load Tap Changer Type A General & Operating Manual

Fig.5 Shows in schematic illustration the specific voltage stress applied to the transormer winding prior to the final choice of a particular tap changer. Be sure that the voltage stress of the transformer winding does not exceed the rated withstand voltages in table 1 even in the most unfavourable operating position of the tap changer.

a - across line tap winding of the same phase or between the end of the fine tap winding and the end of the coarse tap winding of the same phase. b- between any taps of the fine tap winding of different phases or between the ends of the coarse tap winding of different phases.

c1- between current carrying tap of the fine tap winding and the beginning of the coarse tap winding of the same phase. c2- between the movable contacts of the coarse tap selector of different phase. d- between the beginning and the end of the coarse tap winding of the same phase.
7

On Load Tap Changer Type A General & Operating Manual

Table 1 Rated withstand voltages of distance in kV on OLTC (Lightning impulse withstand voltage, power frequency withstand voltage) Insulating Distance a Shape and period of voltage kV 1.2/50 kV, 50Hz 1 min b kV 1.2/50 kV, 50Hz 1 min c1 kV 1.2/50 kV, 50Hz 1 min c2 kV 1.2/50 kV, 50Hz 1 min d kV 1.2/50 kV, 50HZ 1 min Table II Rated through-currents (lu ), relevant rated step voltage ( Ui ) and rated switching capacities PstN), highest and lowest step voltage On load tap changer Rated through current lu (A) Rated step voltage Ui (V) Rated switching capacity PstN (KVA) AIII 100 Y, AIII 100 D 75 450 37.5 100 280 28 1 75 450 37.5 2 A I 100 100 280 28 150 50 150 50 60 30 150 50 A lll 100 Y Onload tap changer Um = 24 kV Um = 36 kV 60 30 200 70 150 50 200 70 85 31 250 95 250 95 Um = 52 kV A I 100

2. Principal parts of the On-load Tap changer 2.1 Tap Changer Head The main parts of the tap changer type A are the tap changer head, the oil compartment, and the tap Changer insert. The tap changer itself will be fastened to the transformer tank cover by means of the tap Changer head. Mechanical connections for drive shaft and relay pipe are made from the tap Changer head.

4 3

1- Cover screw M12 (Wrench size 19) 2- Bleeding screw M8 (wrench size 17) of the tap Changer head cover 3- Pipe connection R1 (wrench size 30) protective relay 4- Earthing screw M12 (wrench size 19)

On Load Tap Changer Type A General & Operating Manual

The oil compantment is connected through the protective relay RS 2001 to the oil conservator by a pipe connection R. 2.2 Oil Compartment The oil compartment is a cylinder made of excellent electrical and mechanical properties with its upper end attached to the tap changer head and its lower end closed by the oil compartment bottom. The oil compartment of the tap changer is thus separated from the transformer tank oil. The oil compartment bottom moreover serves for bearing the lower end of the switching shaft. The fixed contacts of the change-over selector and selector switch are arranged in separate contact levels, mounted on the inside of the oil compartment cylinder and connected to the outside terminals. These feed-through contacts have been sealed by extensive measures to obtain oil tightness. 2.3 The Tap Changer Insert The tap changer insert comprises the entire movable contact system of the tap changer. It consists of the selector switch drive shaft and the switching elements . The selector switch drive shaft is connected at its

upper end to the gearing mechanism and with its lower end to a bearing centered in the oil compartment bottom. The changeover selector contact carrier is concentrically outside the oil vessel cylinder and independently movable. The switching elements are mounted to the drive shaft in the level of corresponding fixed contacts. There are three sets of contact rollers side by side per switching element, which function as main and auxiliary arcing contacts respectively during the tap changer operation. The contact material is of electrolytic copper. The contact rollers of the arcing contacts are connected to the transition resistor. Every contact roller is movable against spring pressure independently from the other. The transition resistors are wound upon grooved ceramic carrier from coiled wire of chrome nickel alloy particularly resistant to excessive temperature. The ambient oil is very effective in cooling so that the resistor materials cool down to oil temperature within shortest possible no-load periods. The entire tap changer insert can be withdrawn for Inspection after removal of the gearing mechanism. The distance between arcing contact rollers is such that they bridge properly two fixed adjacent contacts.

Fig . 7 Insert without Mounting rod

On Load Tap Changer Type A General & Operating Manual

3. Installation of the tap changer 3.1 Mounting flange For mounting the tap changer head on the transformer cover the use of a mounting flange welded to the cover is recommended. This mounting flange is to be made in accordance with the gasket surface of the tap changer head. For positioning the studs we recommend use of a drilling template which will be supplied with the first tapchanger on request free of charge. 3.2 Attachment of the tap changer to the transformer cover Proceed as follows: Clean the sealing surfaces (bottom of head & mounting flange). Put an oil-proof gasket on the mounting flange of the transformer cover. Lift the tap changer over the transformer cover and lower it carefully into the opening of the mounting flange. Take care not to damage the connecting contacts of the tap changer. Check the correct position of the tap changer head. Fasten the tap changer head to the mounting flange. 4. Connection of the Tapped Winding and Take-Off Lead The tap leads have to be connected to the tap changer according to the particular tap changer connection diagram which will be supplied together with equipment. Please note: All lead connections to tap changer must be carried out carefully and locked safely. The tap leads should be assembled in such a manner to allow for connecting all leads to the tap changer without using force If leads of different phases cross the oil compartment surface, be sure to retain an adequate clearance to surface and to live parts of the tap changer. All terminals are designated according to the connection diagram.

Fig. 8 Terminals of the change-over selector and take-off lead The terminals are designed as screw bolts. Connect the tap leads and lock the screws to a torque of 4Nm max. Change-over selector The terminals are designed as strips with throughhole for screws. Connect the leads and lock the screws firmly 5. Accessories Equipment 5.1. Motor Drive The on-load tap changer type A is operated by a motor drive unit MA9 mounted outside the transformer tank. All the components which constitute the motor drive are contained in a sheet metal housing designed for outdoor mounting and consisting of housing and door. The motor drive unit is fastened by four bolts to the transformer tank. The corresponding mounting holes are in the rear side of the housing and protected against excessive transformer vibrations. The position of these bolts should be adjusted to the axis of the hand crank of the drive shaft so that the correct measures of vertical length will be obtained. The motor drive unit is powered by a 415V 50 Hz. three phase motor and with a stepping mechanism for direct and remote operation.
10

On Load Tap Changer Type A General & Operating Manual

Over travel in either direction is prevented by Comprehensive mechanical and electrical safety Systems. The equipment also includes a six-figure Mechanical counter showing the number of tap Change operations performed and a dial indicating the present position of the on-load tap changer. Provision can be given for remote tap position Indication as well. The drive shaft is the mechanical connection between motor drive and tap changer head. The bevel gear translates the motion from the vertical to the horizontal direction. Accordingly, the vertical drive shaft has to be mounted between Motor drive and bevel gear and the horizontal drive Shaft between bevel gear and tap changer. The built-in electric heater prevents condensate Formation in the housing. For emergency operation and for setting up the motor drive unit when putting the on-load tap changer into service, a crank handle is provided. When pushed on to its shaft, this interrupts the motor circuit. 5.2 Protective Relay The protective relay is needed for disconnecting the transformer in which a fault condition has occurred in the OLTC. For connection of the protective relay a pipe connection with flange must be screwed in oil tight into the bore R of the tap changer head. Install the protective relay RS 2001 in accordance with our operating instruction manual for the same. Fig. 9 MA 9

Position in Service Fig. 10 Protective Relay

Attention !
Synchronise the OLTC and Drive Mechanism at Tap Position No.5 only

EMR/GEN OI/A/0100
11