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COMTAP ARSTechnical Data TD 1889046/03

www.reinhausen.com

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NOTE!

The product may have been modified after this document went to press.We expressly reserve the right to make changes to the technical data, the design or the scope ofdelivery.In general, the information provided and the arrangements agreed during processing of therelevant offers and orders are binding.

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Table of Contents

Technical Data TD 1889046/03 EN COMTAP ARSThe 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 event of the grant of a patent, utility model or ornamental design registration.

Maschinenfabrik Reinhausen GmbH 20101889046/03 EN 3

Table of Contents

1 General .......................................................................................................................................................... 51.1 Safety labels.................................................................................................................................................. 51.2 Safety instructions ....................................................................................................................................... 51.3 Switching principle....................................................................................................................................... 61.4 Commutation ................................................................................................................................................ 71.5 COMTAP ARS type designation ................................................................................................................ 101.6 COMTAP ARS mounting on the transformer.......................................................................................... 10

1.6.1 Cover mounting...................................................................................................................................................... 101.6.2 Bell-type tank installation................................................................................................................................... 11

2 Technical data .............................................................................................................................................. 132.1 Summary of technical data......................................................................................................................... 132.2 Contact life.................................................................................................................................................... 14

3 Drive unit ...................................................................................................................................................... 153.1 TAPMOTION ED motor-drive unit............................................................................................................ 15

4 Safety devices............................................................................................................................................... 16

5 Installation.................................................................................................................................................... 17

6 Appendix ....................................................................................................................................................... 186.1 COMTAP ARS I 1000 - 123-170 kV (7340074E) ................................................................................. 186.2 COMTAP ARS I 1822 - 123-170 kV (7340084E) ................................................................................. 196.3 COMTAP ARS, ARS I 2433 - 123-170 kV (7340094E) ........................................................................ 206.4 COMTAP ARS, ARS III 1000 - 123-170 kV (7340104E)...................................................................... 216.5 COMTAP ARS, ARS III 1822 - 123-170 kV (7340114E)...................................................................... 22

6.6 COMTAP ARS, adjustment plan for ARS (7341022E)........................................................................... 236.7 COMTAP ARS, installation drawing (7327712E)................................................................................... 246.8 COMTAP ARS, mounting of the off-circuit tap-changer at the lower cage ring

(application-specific, 7327732E) .............................................................................................................. 256.9 COMTAP ARS, head with gear unit (7257372E) ................................................................................... 276.10 COMTAP ARS, installation for bell-type tank mounting, (7330231E)............................................... 286.11 COMTAP ARS, lifting traverse (72673703)............................................................................................ 296.12 COMTAP ARS, terminal contacts 1000 A (7340950E)......................................................................... 306.13 COMTAP ARS, horizontal drive shaft (limit dimensions, 7327691E).................................................. 316.14 COMTAP ARS, additional drawings (7340871E) ................................................................................... 33

NOTE!

This Technical Data document is intended for transformer designers.These type-specific data should always be read in conjunction with the general part (TD61), whichcontains important information on topics such as current splitting.We reserve the right to revise dimension drawings and connection diagrams without notice.The drawings submitted in conjunction with offers and orders are binding.COMTAP ARS is regarded as a special project. During the offer stage it is subject to clarification byour Application Engineering Division.
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1 General



Maschinenfabrik Reinhausen GmbH 2010 51889046/03 EN

1 General

1.1 Safety labels

The following safety labels relating to the operation of theCOMTAP ARS are used in this technical documentation.

These instructions must always be followed!

1.2 Safety instructions

All warnings and safety instructions must be observedat all times!

Failure to follow the safety instructions may lead toaccidents and severe personal injury for you or yourcolleagues.

Please read these operating instructions beforecommissioning the equipment!

Please read these instructions before switching on theCOMTAP ARS. As the operator, you are responsible forensuring that users of the device have fully understoodthe operating and safety instructions.

Train your staff!

Before asking staff to work with the COMTAP ARS, pro-vide training regarding general and special safety instruc-tions and accident prevention regulations.

Only suitably qualified personnel should work with theCOMTAP ARS.

The COMTAP ARS is designed exclusively for applicationin electrical or energy systems and facilities operated byappropriately trained staff, i.e. staff who are familiar withthe installation, assembly, commissioning and operation ofsuch products.

WARNING!

Refers to a potentially dangeroussituation that may result in death orsevere injury if not avoided.

ATTENTION!

Refers to a potentially harmful situa-tion that may result in damage of theproduct itself or of adjacent objects ifnot avoided.

NOTE!

Contains important information andspecial notes.

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6

1 General




1.3 Switching principle

The COMTAP ARS is used to reverse the polarity of a winding

during transformer operation.

The COMTAP ARS always has two operating positions.

The COMTAP ARS is changed over from one operating posi-tion to the next by rotating an insulating drive shaft. This in-sulating drive shaft is operated via a 60 control gear that isdriven via a TAPMOTION ED motor-drive unit. Changing anoperating position requires a 120 turn of the insulating driveshaft.One COMTAP ARS operation requires two motor drive swit-ching operations (double tap change).

The COMTAP ARS contact system has a contact circle diame-ter of 850 mm. During a COMTAP ARS operation the through-

current is commutated from one current path to another cur-rent path with the same potential. The contact system is equip-ped with special contacts for this purpose.

The COMTAP ARS can be used for different applications incombination with an on-load tap-changer. The COMTAP ARSis primarily used to reverse the polarity of the regulatingvoltage in applications with large regulating ranges (e.g., pha-se shifter transformers, see Figure 1).

Figure 1 COMTAP ARS for reversing the polarity of a winding

WARNING!When combining the COMTAP ARSwith on-load tap-changers, the ARSmay only be actuated in a certain on-load tap-changer position. This meansthat it may only be actuated when allon-load tap-changer regulatingwindings are disconnected and thevoltage at the relevant winding istherefore zero. For this reason, non-permitted switching operations areprevented by a mutual electrical

interlock of the on-load tap-changerand COMTAP ARS.Please refer to the order-specifictechnical documentation, safetyinstructions, and functional descrip-tion.

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1 General




In on-load tap-changer applications with reversing change-over selector where the change-over selector load is outsidethe permitted range, a combination of on-load tap-changer

without reversing change-over selector and COMTAP ARS canbe used (see Figure 2).

Figure 2 COMTAP ARS as replacement for reversing change-over selector

1.4 Commutation

During a COMTAP ARS tap-change operation the current Imust be commutated against an impedance Z, consisting of Rand X. The contact erosion caused by the commutation de-pends on the current I that flows through the COMTAP ARScontacts during the commutation and the impedance Zagainst which the current I has to be commutated. This im-pedance is formed by the cable route from the COMTAP ARSto the on-load tap-changer and back (commutation loop).Figure 3 shows the switchover sequence from one operatingposition to another. Fig. 3a shows one of the twoCOMTAP ARS operating positions.

The intermediate position that is reached first during a tap-change operation is shown in Fig. 3b, where current I flowsunchanged via the commutation loop. The next position isshown in Fig. 3c, where the current I1 in the commutationloop is reduced to 0 A. Current I mainly flows via the nowparallel COMTAP ARS contacts. In the next step one of thesecontacts is opened (Fig. 3d), so that almost the whole currentI has to be commutated onto the commutation loop via theCOMTAP ARS contact that opens last (Fig. 3e). The current I1has changed its direction in the commutation loop. Via the po-sition shown in Fig. 3fthe COMTAP ARS now reaches theother operating position (Fig. 3g).

a) COMTAP ARS in position 1OLTC switches, COMTAP ARS blocked

b) COMTAP ARS during tap changing operation,OLTC blocked

c) COMTAP ARS in position 2OLTC switches, COMTAP ARS blocked

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1 General




Figure 3 COMTAP ARS tap-change sequence

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1 General




The COMTAP ARS is dimensioned for a through-current of1 000 A per contact plane. For through-currents > 1 000 Acontact planes are connected in parallel. For applications withparallel current paths additional current division assessmentduring the COMTAP ARS tap-change operation is required.Please note that due to geometrical deviations the parallelCOMTAP ARS current paths will not commutate the currentsimultaneously. The current division should be consideredunder the aspect that one current path has alreadycommutated (Fig. 4: contact plane II) while the other currentpath is about to reach the commutation phase (Figure 4:contact plane I).

If the current division is not perfectly symmetric during thetap-change operation, the effect is the same as that of a cur-rent increase, resulting in a reduced number of permitted ope-rations.The commutation current I (Figure 4) therefore has to be ta-ken into account for determining the permitted number ofoperations during the tap-change operation. Consideration ofsteady-state current splitting (COMTAP ARS in end position)is therefore not sufficient.

For parallel current paths no contact bridges may be used inthe COMTAP ARS, because they would cancel the requiredcurrent splitting.

Figure 4 ARS application example (single-phase diagram). COMTAP ARS with parallel contact planes I and II duringcommutation.

series

transfrer

exciter

transfomr

contact

plane I

contact

plane I

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1 General




1.5 COMTAP ARS type designation

The COMTAP ARS type designation is the same as the off-circuit tap-changer type designation as explained below.

For COMTAP ARS versions for currents in excess of 1 000 A current splitting into parallel paths is required. The current splittingmust be enforced, e.g. through the transformer winding. Please specify how current splitting is ensured in the order.

The type designation indicates the number of required current divisions and the ARS switching levels. The following example ex-plains the make-up of the type identifier of a three-phase ARS for a max. rated through-current of 1 800 A with winding division.

ARS I I I 1 8 2 2

1.6 COMTAP ARS mounting on the transformer

1.6.1 Cover mounting

Separation of head and cage Separation of head and cage - mounting with mountingflange

Standard Mounting flange on request

NOTE!

The installation procedure is describedin MR Operating Instructions BA 307(section 4).

A R S X X X X - -

Product ARS

Number of phases I 1 phase

III 3 phases

Max. rated through-current 1 000 1 000 A

1 822 1 800 A

2 433 2 400 A

Highest voltage for 123 123 kV

equipment Um [kV] 145 145 kV

170 170 kV

Contact circle pitch 18 Contact circle diameter 850 mm

Operating positions 02 2 operating positions

Mid-positions 0 0 mid-positions

Typ of connection DW Double reverser connection

Basic connection diagram

X X X X 18 02 0 DW

Mounting flange

2 parallel planes per phasedual current splitting

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1 General




1.6.2 Bell-type tank installation

The installation of the COMTAP ARS into a transformer with bell-type tank requires the use of a supporting structure (supporter)

that allows the COMTAP ARS to be provisionally attached to the bell-type tank flange.The bell-type tank flange is provided with drill-holes, so that it can, without further measures, be fixed to the support (see section6, drawing 7330231E).

The COMTAP ARS is lifted into the supporting structure without drive head, fixed in this temporary mounting position and con-nected to the tap winding.

Please note the following during installation:

ATTENTION!

Damage to the COMTAP ARS!Always use the lifting traverse inorder to avoid damage to the

COMTAP ARS.

Bell-type tank installation

Separation of head and cage -mounting with bell-type tank flange

Bell-type tank version on request

Bell-type tank

flange

Please note the mounting position!Before connecting the COMTAP ARS move it into thedesignated mounting position it should have after it isscrewed to the bell-type tank.Connect the COMTAP ARS in this mounting position (seeFigure 5).

Figure 5

Lead assembly with minimum mechanical stress

Ensure stress-free installation of the COMTAP ARS(Figure 6).

Figure 6

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1 General




Position the COMTAP ARS on the mounting flange afterthe bell-type tank has been set down (see Figure 7).

Figure 7

Use a lifting traverse

Lift the COMTAP ARS cage with the lifting traverse (sec-tion 6, drawing 72673703) until an air gap of approx.5 mm is visible (see Figure 8).

Figure 8

Fasten the COMTAP ARS head and cage in this position(see Figure 9).

Figure 9

Lifting traverseBell-type tank

Mounting flange

Before fastening

After fastening

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2 Technical data




2 Technical data

2.1 Summary of technical data

Table 1 Technical data1) According to IEC 1-60214, section 3.57: RMS value of the phase-to-phase voltage for which an equipment is dimensioned in

terms of its insulation.2) b-distance only for three-phase COMTAP ARS3) see Figure 10

Figure 10 Insulation distances

COMTAP ARS I / ARS III

Current splitting required no yes yes no yes

Number of phases 1 1 1 3 3

Max. rated through-current

Ium [A]1 000 1 800 2 400 1 000 1 800

Rated short-time current [kA] 10 18 24 10 18

Rated short-circuit duration [s] 3 3 3 3 3

Rated short-circuit current [kA] 25 45 60 25 45

Installation length [mm]

Weight [kg]Rated frequency [Hz]

Rated insulation level

Highest equipment voltage Um1) [kV]

at insulation distances f and b 2) 3)145

Rated lightning impulse voltage (1.2/50) [kV]

at insulation distances f and b 2) 3)650

Rated power-frequency withstand voltage (50 Hz, 1 min.)

[kV] at insulation distances f and b 2) 3)275

Max. operating voltage [kV] at insulation distance a 3) 145

Rated lightning impulse voltage (1.2/50) [kV]

at insulation distance a3) 650

Rated power-frequency withstand voltage (50 Hz, 1 min.)

[kV] at insulation distance a 3)275

Rated lightning impulse voltage between parallel

planes of a phase (1.2/50) [kV]400

ARS III 1822ARS I 1000 ARS I 1822 ARS I 2433 ARS III 1000

max. 1 104 max. 1 299 max. 1 494 max. 2 124 max. 2 709

max. 135 max. 160 max. 185 max. 235 max. 31550 ... 60

123

550

230

650

290

123

170

750

325

145

230

550

a = between beginning andend of windingb = between the contacts for

different phasesf = between the contacts for

phase U (top contactplane) and ground

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2 Technical data




The dielectric strength of the COMTAP ARS insulation distances is determined by the rated withstand voltages (Table 1) that cor-respond to the grades required in practice. Stress on the inner COMTAP ARS insulation distances mainly occurs during the impul-se voltage test and during the induced voltage test of the transformer.

2.2 Contact life

Table 2 shows the theoretical number of operations for the COMTAP ARS from a contact life perspective. It enables the user andthe transformer manufacturer to estimate the effect of the commutation current I and the impedance Z on the permitted wearfor different load conditions. For example, with a commutation loop impedance of Z = (9 + j4) m and a commutation current I= 1 000 A the contact life is reached after 100 000 tap-change operations.

Table 2 Theoretical number of COMTAP ARS operations from a contact wear perspective1) For mechanical reasons the permitted number of COMTAP ARS operations is limited to 100 000.

In practice the transformer load is variable, which means the commutation current is also variable. The resulting effect on contactlife can also be determined from Table 2. For example, with an impedance of Z = (9+j4) m it is possible to reach 70 000 tap-change operations at a commutation current of I = 700 A (70 000/280 000 tap-change operations = 1/4 of contact life used) and30 000 tap-change operations at a commutation current of I = 1 300 A (30 000/40 000 tap-change operations = 3/4 of contactlife used. This option is shown in the following diagram, among others.

Figure 11 Contact life examples for COMTAP ARS (Z = (9 + j4) mOhm)

(5 + j4) m (9 + j4) m (11 + j6) m

700 A 330 0001)

280 0001)

150 0001)

1 000 A (rated current) 130 0001) 100 000 50 000

1 300 A (overload) 65 000 40 000 20 000

Impedance ZCommutation current I per current path

0

20000

40000

60000

80000

100000

0% 25% 50% 75% 100%

Numberofoperations

Contact wear

mechanical contact life limit

I = 700 A

I = 1300 A

I = 1300 A

I = 1000 A

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3 Drive unit




3 Drive unit

The drive unit is used to set the COMTAP ARS to the required

operating position.

3.1 TAPMOTION ED motor-drive unit

The COMTAP ARS may only be used in conjunction with a mo-tor-drive unit. Safety equipment for automatic tripping of thetransformer circuit breakers and for monitoring coincidence ofthe operating positions of the COMTAP ARS and the motordrive are must be installed (see Section 4).

WARNING!

When combining the COMTAP ARSwith on-load tap-changers, the ARSmay only be actuated in a certain on-load tap-changer position. This meansthat it may only be actuated when allon-load tap-changer regulatingwindings are disconnected and thevoltage at the relevant winding istherefore zero.For this reason, non-permitted swit-ching operations are prevented by amutual electrical interlock of the on-load tap-changer and COMTAP ARS.Please refer to the order-specifictechnical documentation, safetyinstructions, and functional descrip-tion

WARNING!

The transformer must be energizedonly, if the COMTAP ARS and theassociated drive unit are in the sameoperating positions.The order-specific safety precautionsmust be followed meticulously.Failure to do so can lead to serious orfatal injury or destruction of theCOMTAP ARS and transformer.

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4 Safety devices




4 Safety devices

To prevent the equipment from being actuated unintentionallyor by unauthorized persons, the motor-drive unit are providedwith the following safety devices:

a) Mechanical lockingA mechanical locking device such as a padlock can be usedor a lock can be installed.

b) The tap-change supervisory control is installed in a housingat the COMTAP ARS head (dimension drawing 7327741E).In conjunction with the motor-drive unit it has severalfunctions:

Automatically trips the connected transformer circuitbreakers if the COMTAP ARS is operated while not all

windings of the on-load tap-changer regulating windingare disconnected.

Interlocks the reclosure of the transformer circuit breakers,if the COMTAP ARS or motor-drive unit are not in adefined operating position.

Monitors the drive shaft between COMTAP ARS and mo-tor-drive unit.

WARNING!

When combining the COMTAP ARSwith on-load tap-changers, the ARSmay only be actuated in a certain on-load tap-changer position. This meansthat it may only be actuated when allon-load tap-changer regulatingwindings are disconnected and thevoltage at the relevant winding istherefore zero.

For this reason, non-permitted swit-ching operations are prevented by amutual electrical interlock of the on-load tap-changer and COMTAP ARS.Please refer to the order-specifictechnical documentation, safety in-structions, and functional description

ATTENTION!

Before commissioning and after anytechnical modification the effective-ness of the safety procedures must beverified.

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5 Installation




5 Installation

The COMTAP ARS must be installed according to Operating

Instructions BA 307.

In particular, the following instructions must be followed du-ring installation of the COMTAP ARS:

The COMTAP ARS is to be used only with the transformerspecified in the order.

The COMTAP ARS must be installed vertically (max. devia-tion 1), connected (according to the order-specific wiringdiagram included in the delivery) and commissioned byqualified, skilled personnel.

For certain COMTAP ARS types, due to the large installa-tion length an insulating attachment between the lower

cage ring and the transformer must be provided (drawing7327732E sheet 1 and 2). This attachment must be done bythe transformer manufacturer. The attachment must cen-ter the COMTAP ARS and ensure torsional protection.Thermal deformation in length L = +6/-6 mm must be ta-ken into account.

Please contact Maschinenfabrik Reinhausen GmbH if theheight difference between COMTAP ARS head and the oillevel in the oil conservator is more than 5 m to discuss thearising static over-pressure.

ATTENTION!Impairment of the functionalsafety!Incorrectly installed leads can exertmechanical tension on the connec-ting contacts and thus causechanges in position of the connec-ting contacts and impairment ofcorrect contacting.

Install and secure the leads so thatthe application of force on the

COMTAP ARS is minimal duringall operational, testing andmalfunction conditions (e.g. shortcircuit).

All connections must be carriedout carefully and secured.

Connect the leads so that theCOMTAP ARS can be lifted evenafter placement of the bell-typetank up to the final installationposition and also cannot exerttension on the connections in its

final position. If necessary, use expansion loops

for the ends of the connections.

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6 Appendix




6 Appendix

6.1 COMTAP ARS I 1000 - 123-170 kV (7340074E)

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6.2 COMTAP ARS I 1822 - 123-170 kV (7340084E)

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6.3 COMTAP ARS, ARS I 2433 - 123-170 kV (7340094E)

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6.4 COMTAP ARS, ARS III 1000 - 123-170 kV (7340104E)

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6.5 COMTAP ARS, ARS III 1822 - 123-170 kV (7340114E)

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6.6 COMTAP ARS, adjustment plan for ARS (7341022E)

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6.7 COMTAP ARS, installation drawing (7327712E)

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6.8 COMTAP ARS, mounting of the off-circuit tap-changer at the lower cage ring (application-specific,7327732E)

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COMTAP ARS, mounting of the off-circuit tap-changer at the lower cage ring (application-specific, 7327732E)

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6.9 COMTAP ARS, head with gear unit (7257372E)

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6.10 COMTAP ARS, installation for bell-type tank mounting, (7330231E)

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6.11 COMTAP ARS, lifting traverse (72673703)

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6.12 COMTAP ARS, terminal contacts 1000 A (7340950E)

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6.13 COMTAP ARS, horizontal drive shaft (limit dimensions, 7327691E)

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COMTAP ARS, horizontal drive shaft (limit dimensions, 7327691E)

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6.14 COMTAP ARS, additional drawings (7340871E)

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Maschinenfabrik Reinhausen GmbH Phone: +49 (0)941 4090 0Falkensteinstrasse 8 Fax: +49 (0)941 4090 700193059 Regensburg, Germany E-mail: [email protected]

www.reinhausen.com

1889046_03en

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