Comtap® Ars: Technical Data TD 1889046/03

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COMTAP ARS
Technical Data TD 1889046/03
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 of delivery. In general, the information provided and the arrangements agreed during processing of the relevant offers and orders are binding.
Table of Contents
Table of Contents
1 General ..........................................................................................................................................................
1.1 1.2 1.3 1.4 1.5 1.6 Safety labels .................................................................................................................................................. Safety instructions ....................................................................................................................................... Switching principle....................................................................................................................................... Commutation ................................................................................................................................................ COMTAP ARS type designation ................................................................................................................ COMTAP ARS mounting on the transformer.......................................................................................... 1.6.1 Cover mounting...................................................................................................................................................... 1.6.2 Bell-type tank installation................................................................................................................................... Summary of technical data......................................................................................................................... Contact life.................................................................................................................................................... TAPMOTION ED motor-drive unit ............................................................................................................
5
5 5 6 7 10 10 10 11
Technical data ..............................................................................................................................................

2.1 2.2
13
13 14
3 4 5 6
Drive unit ......................................................................................................................................................

3.1
15
15
Safety devices............................................................................................................................................... Installation.................................................................................................................................................... Appendix .......................................................................................................................................................

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 COMTAP ARS I 1000 - 123-170 kV (7340074E) ................................................................................. COMTAP ARS I 1822 - 123-170 kV (7340084E) ................................................................................. COMTAP ARS, ARS I 2433 - 123-170 kV (7340094E) ........................................................................ COMTAP ARS, ARS III 1000 - 123-170 kV (7340104E)...................................................................... COMTAP ARS, ARS III 1822 - 123-170 kV (7340114E)...................................................................... COMTAP ARS, adjustment plan for ARS (7341022E)........................................................................... COMTAP ARS, installation drawing (7327712E)................................................................................... COMTAP ARS, mounting of the off-circuit tap-changer at the lower cage ring (application-specific, 7327732E) .............................................................................................................. COMTAP ARS, head with gear unit (7257372E) ................................................................................... COMTAP ARS, installation for bell-type tank mounting, (7330231E)............................................... COMTAP ARS, lifting traverse (72673703)............................................................................................ COMTAP ARS, terminal contacts 1000 A (7340950E)......................................................................... COMTAP ARS, horizontal drive shaft (limit dimensions, 7327691E).................................................. COMTAP ARS, additional drawings (7340871E) ...................................................................................
16 17 18
18 19 20 21 22 23 24 25 27 28 29 30 31 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), which contains 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 by our Application Engineering Division.
Technical Data TD 1889046/03 EN COMTAP ARS

The 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 2010 1889046/03 EN 3
General
1
1.1
General
Safety labels 1.2 Safety instructions All warnings and safety instructions must be observed at all times! Failure to follow the safety instructions may lead to accidents and severe personal injury for you or your colleagues. Please read these operating instructions before commissioning the equipment! Please read these instructions before switching on the COMTAP ARS. As the operator, you are responsible for ensuring that users of the device have fully understood the operating and safety instructions. Train your staff! Before asking staff to work with the COMTAP ARS, provide training regarding general and special safety instructions and accident prevention regulations. Only suitably qualified personnel should work with the COMTAP ARS. The COMTAP ARS is designed exclusively for application in electrical or energy systems and facilities operated by appropriately trained staff, i.e. staff who are familiar with the installation, assembly, commissioning and operation of such products.
The following safety labels relating to the operation of the COMTAP ARS are used in this technical documentation. These instructions must always be followed!
WARNING!
Refers to a potentially dangerous situation that may result in death or severe injury if not avoided.
ATTENTION!
Refers to a potentially harmful situation that may result in damage of the product itself or of adjacent objects if not avoided.
NOTE!
Contains important information and special notes.

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 position to the next by rotating an insulating drive shaft. This insulating drive shaft is operated via a 60 control gear that is driven via a TAPMOTION ED motor-drive unit. Changing an operating position requires a 120 turn of the insulating drive shaft. One COMTAP ARS operation requires two motor drive switching operations (double tap change). The COMTAP ARS contact system has a contact circle diameter of 850 mm. During a COMTAP ARS operation the throughcurrent is commutated from one current path to another current path with the same potential. The contact system is equipped with special contacts for this purpose. The COMTAP ARS can be used for different applications in combination with an on-load tap-changer. The COMTAP ARS is primarily used to reverse the polarity of the regulating voltage in applications with large regulating ranges (e.g., phase shifter transformers, see Figure 1).
WARNING!
When combining the COMTAP ARS with on-load tap-changers, the ARS may only be actuated in a certain onload tap-changer position. This means that it may only be actuated when all on-load tap-changer regulating windings are disconnected and the voltage at the relevant winding is therefore zero. For this reason, nonpermitted switching operations are prevented by a mutual electrical interlock of the on-load tap-changer and COMTAP ARS. Please refer to the order-specific technical documentation, safety instructions, and functional description.
Figure 1
COMTAP ARS for reversing the polarity of a winding

General
In on-load tap-changer applications with reversing changeover selector where the change-over selector load is outside the permitted range, a combination of on-load tap-changer
without reversing change-over selector and COMTAP ARS can be used (see Figure 2).
a) COMTAP ARS in position 1 OLTC switches, COMTAP ARS blocked
b) COMTAP ARS during tap changing operation, OLTC blocked
c) COMTAP ARS in position 2 OLTC switches, COMTAP ARS blocked
Figure 2 1.4
COMTAP ARS as replacement for reversing change-over selector Commutation The intermediate position that is reached first during a tapchange operation is shown in Fig. 3b, where current I flows unchanged via the commutation loop. The next position is shown in Fig. 3c, where the current I1 in the commutation loop is reduced to 0 A. Current I mainly flows via the now parallel COMTAP ARS contacts. In the next step one of these contacts is opened (Fig. 3d), so that almost the whole current I has to be commutated onto the commutation loop via the COMTAP ARS contact that opens last (Fig. 3e). The current I1 has changed its direction in the commutation loop. Via the position shown in Fig. 3f the COMTAP ARS now reaches the other operating position (Fig. 3g).
During a COMTAP ARS tap-change operation the current I must be commutated against an impedance Z, consisting of R and X. The contact erosion caused by the commutation depends on the current I that flows through the COMTAP ARS contacts during the commutation and the impedance Z against which the current I has to be commutated. This impedance is formed by the cable route from the COMTAP ARS to the on-load tap-changer and back (commutation loop). Figure 3 shows the switchover sequence from one operating position to another. Fig. 3a shows one of the two COMTAP ARS operating positions.

General
Figure 3
COMTAP ARS tap-change sequence

General
The COMTAP ARS is dimensioned for a through-current of 1 000 A per contact plane. For through-currents > 1 000 A contact planes are connected in parallel. For applications with parallel current paths additional current division assessment during the COMTAP ARS tap-change operation is required. Please note that due to geometrical deviations the parallel COMTAP ARS current paths will not commutate the current simultaneously. The current division should be considered under the aspect that one current path has already commutated (Fig. 4: contact plane II) while the other current path is about to reach the commutation phase (Figure 4: contact plane I).
If the current division is not perfectly symmetric during the tap-change operation, the effect is the same as that of a current increase, resulting in a reduced number of permitted operations. The commutation current I (Figure 4) therefore has to be taken into account for determining the permitted number of operations during the tap-change operation. Consideration of steady-state current splitting (COMTAP ARS in end position) is therefore not sufficient. For parallel current paths no contact bridges may be used in the COMTAP ARS, because they would cancel the required current splitting.
series transfrer exciter transfomr
contact plane I
contact plane I
Figure 4
ARS application example (single-phase diagram). COMTAP ARS with parallel contact planes I and II during commutation.

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.
A R S Product Number of phases Max. rated through-current ARS I III 1 000 1 822 2 433 123 145 170 18 02 0 DW
X X X X
XXX
18
02
DW
Basic connection diagram 1 phase 3 phases 1 000 A 1 800 A 2 400 A 123 kV 145 kV 170 kV Contact circle diameter 850 mm 2 operating positions 0 mid-positions Double reverser connection
Highest voltage for equipment Um [kV] Contact circle pitch Operating positions Mid-positions Typ of connection
For COMTAP ARS versions for currents in excess of 1 000 A current splitting into parallel paths is required. The current splitting must 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 explains 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
2 parallel planes per phase dual current splitting
1.6 1.6.1
COMTAP ARS mounting on the transformer Cover mounting Separation of head and cage Separation of head and cage - mounting with mounting flange
Mounting flange
Standard
Mounting flange on request
NOTE!
The installation procedure is described in MR Operating Instructions BA 307 (section 4).

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 section 6, drawing 7330231E). The COMTAP ARS is lifted into the supporting structure without drive head, fixed in this temporary mounting position and connected to the tap winding.
ATTENTION!
Damage to the COMTAP ARS! Always use the lifting traverse in order 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 flange
Bell-type tank version on request Please note the following during installation: Please note the mounting position! Before connecting the COMTAP ARS move it into the designated mounting position it should have after it is screwed to the bell-type tank. Connect the COMTAP ARS in this mounting position (see Figure 5).
Figure 5 Lead assembly with minimum mechanical stress Ensure stress-free installation of the COMTAP ARS (Figure 6).
Figure 6

General
Position the COMTAP ARS on the mounting flange after the bell-type tank has been set down (see Figure 7). Lifting traverse Bell-type tank Mounting flange
Figure 7 Use a lifting traverse Lift the COMTAP ARS cage with the lifting traverse (section 6, drawing 72673703) until an air gap of approx. 5 mm is visible (see Figure 8). Before fastening
Figure 8 Fasten the COMTAP ARS head and cage in this position (see Figure 9).
After fastening
Figure 9

Technical data
2
2.1
Technical data
Summary of technical data
ARS I 1000 no 1 1 000 10 3 25 max. 1 104 max. 135 ARS I 1822 yes 1 1 800 18 3 45 max. 1 299 max. 160 ARS I 2433 yes 1 2 400 24 3 60 max. 1 494 max. 185 50 ... 60 ARS III 1000 no 3 1 000 10 3 25 max. 2 124 max. 235 ARS III 1822 yes 3 1 800 18 3 45 max. 2 709 max. 315
COMTAP ARS I / ARS III Current splitting required Number of phases Max. rated through-current Ium [A] Rated short-time current [kA] Rated short-circuit duration [s] Rated short-circuit current [kA] Installation length [mm] Weight [kg] Rated frequency [Hz] Rated insulation level Highest equipment voltage Um1) [kV] at insulation distances f and b 2) 3) Rated lightning impulse voltage (1.2/50) [kV] at insulation distances f and b 2) 3) Rated power-frequency withstand voltage (50 Hz, 1 min.) [kV] at insulation distances f and b 2) 3) Max. operating voltage [kV] at insulation distance a 3) Rated lightning impulse voltage (1.2/50) [kV] at insulation distance a 3) Rated power-frequency withstand voltage (50 Hz, 1 min.) [kV] at insulation distance a 3) Rated lightning impulse voltage between parallel planes of a phase (1.2/50) [kV]
123 550 230 123 550 230
145 650 275 145 650 275 400
170 750 325 145 650 290
Table 1
1)
Technical data
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. b-distance only for three-phase COMTAP ARS see Figure 10 a = between beginning and end of winding b = between the contacts for different phases f = between the contacts for phase U (top contact plane) and ground
2) 3)
Figure 10
Insulation distances

Technical data
The dielectric strength of the COMTAP ARS insulation distances is determined by the rated withstand voltages (Table 1) that correspond to the grades required in practice. Stress on the inner COMTAP ARS insulation distances mainly occurs during the impulse 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 and the transformer manufacturer to estimate the effect of the commutation current I and the impedance Z on the permitted wear for 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.
Commutation current I per current path 700 A 1 000 A (rated current) 1 300 A (overload)
Table 2
1)
(5 + j4) m 1) 330 000 1) 130 000 65 000
Impedance Z (9 + j4) m 280 000 1) 100 000 40 000
(11 + j6) m 150 000 1) 50 000 20 000
Theoretical number of COMTAP ARS operations from a contact wear perspective
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 contact life can also be determined from Table 2. For example, with an impedance of Z = (9+j4) m it is possible to reach 70 000 tapchange operations at a commutation current of I = 700 A (70 000/280 000 tap-change operations = 1/4 of contact life used) and 30 000 tap-change operations at a commutation current of I = 1 300 A (30 000/40 000 tap-change operations = 3/4 of contact life used. This option is shown in the following diagram, among others.
mechanical contact life limit 100000 I = 700 A I = 1300 A 80000
Number of operations
I = 1000 A 60000
40000 I = 1300 A
20000
0 0% 25% 50% Contact wear 75% 100%
Figure 11
Contact life examples for COMTAP ARS (Z = (9 + j4) mOhm)

Drive unit
Drive unit
3.1 TAPMOTION ED motor-drive unit The COMTAP ARS may only be used in conjunction with a motor-drive unit. Safety equipment for automatic tripping of the transformer circuit breakers and for monitoring coincidence of the operating positions of the COMTAP ARS and the motor drive are must be installed (see Section 4).
The drive unit is used to set the COMTAP ARS to the required operating position.
WARNING!
When combining the COMTAP ARS with on-load tap-changers, the ARS may only be actuated in a certain onload tap-changer position. This means that it may only be actuated when all on-load tap-changer regulating windings are disconnected and the voltage at the relevant winding is therefore zero. For this reason, non-permitted switching operations are prevented by a mutual electrical interlock of the onload tap-changer and COMTAP ARS. Please refer to the order-specific technical documentation, safety instructions, and functional description
WARNING!
The transformer must be energized only, if the COMTAP ARS and the associated drive unit are in the same operating positions. The order-specific safety precautions must be followed meticulously. Failure to do so can lead to serious or fatal injury or destruction of the COMTAP ARS and transformer.

Safety devices
Safety devices WARNING!

When combining the COMTAP ARS with on-load tap-changers, the ARS may only be actuated in a certain onload tap-changer position. This means that it may only be actuated when all on-load tap-changer regulating windings are disconnected and the voltage at the relevant winding is therefore zero. For this reason, non-permitted switching operations are prevented by a mutual electrical interlock of the onload tap-changer and COMTAP ARS. Please refer to the order-specific technical documentation, safety instructions, and functional description To prevent the equipment from being actuated unintentionally or by unauthorized persons, the motor-drive unit are provided with the following safety devices: a) Mechanical locking A mechanical locking device such as a padlock can be used or a lock can be installed. b) The tap-change supervisory control is installed in a housing at the COMTAP ARS head (dimension drawing 7327741E). In conjunction with the motor-drive unit it has several functions: Automatically trips the connected transformer circuit breakers if the COMTAP ARS is operated while not all windings of the on-load tap-changer regulating winding are disconnected. Interlocks the reclosure of the transformer circuit breakers, if the COMTAP ARS or motor-drive unit are not in a defined operating position. Monitors the drive shaft between COMTAP ARS and motor-drive unit.
ATTENTION!
Before commissioning and after any technical modification the effectiveness of the safety procedures must be verified.

Installation
Installation ATTENTION!
Impairment of the functional safety! Incorrectly installed leads can exert mechanical tension on the connecting contacts and thus cause changes in position of the connecting contacts and impairment of correct contacting. Install and secure the leads so that the application of force on the COMTAP ARS is minimal during all operational, testing and malfunction conditions (e.g. short circuit). All connections must be carried out carefully and secured. Connect the leads so that the COMTAP ARS can be lifted even after placement of the bell-type tank up to the final installation position and also cannot exert tension on the connections in its final position. If necessary, use expansion loops for the ends of the connections.
The COMTAP ARS must be installed according to Operating Instructions BA 307. In particular, the following instructions must be followed during installation of the COMTAP ARS: The COMTAP ARS is to be used only with the transformer specified in the order. The COMTAP ARS must be installed vertically (max. deviation 1), connected (according to the order-specific wiring diagram included in the delivery) and commissioned by qualified, skilled personnel. For certain COMTAP ARS types, due to the large installation length an insulating attachment between the lower cage ring and the transformer must be provided (drawing 7327732E sheet 1 and 2). This attachment must be done by the transformer manufacturer. The attachment must center the COMTAP ARS and ensure torsional protection. Thermal deformation in length L = +6/-6 mm must be taken into account. Please contact Maschinenfabrik Reinhausen GmbH if the height difference between COMTAP ARS head and the oil level in the oil conservator is more than 5 m to discuss the arising static over-pressure.

Appendix
6
6.1
Appendix
COMTAP ARS I 1000 - 123-170 kV (7340074E)

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

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

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

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

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

Appendix
6.7
COMTAP ARS, installation drawing (7327712E)

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

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

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

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

Appendix
6.11
COMTAP ARS, lifting traverse (72673703)

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

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

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

Appendix
6.14
COMTAP ARS, additional drawings (7340871E)

www.reinhausen.com
Maschinenfabrik Reinhausen GmbH Falkensteinstrasse 8 93059 Regensburg, Germany
Phone: Fax: E-mail:
+49 (0)941 4090 0 +49 (0)941 4090 7001 sales@reinhausen.com
TD 1889046/03 EN 08/10 F0182602 Printed in Germany

Comtap® Ars: Technical Data TD 1889046/03

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Technical data ..............................................................................................................................................

Drive unit ......................................................................................................................................................

Technical Data TD 1889046/03 EN COMTAP ARS

Technical Data TD 1889046/03 EN COMTAP ARS

COMTAP ARS for reversing the polarity of a winding

Technical Data TD 1889046/03 EN COMTAP ARS

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

b) COMTAP ARS during tap changing operation, OLTC blocked

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

Technical Data TD 1889046/03 EN COMTAP ARS

COMTAP ARS tap-change sequence

Technical Data TD 1889046/03 EN COMTAP ARS

series transfrer exciter transfomr

Technical Data TD 1889046/03 EN COMTAP ARS

Mounting flange on request

Technical Data TD 1889046/03 EN COMTAP ARS

Bell-type tank installation

Technical Data TD 1889046/03 EN COMTAP ARS

Technical Data TD 1889046/03 EN COMTAP ARS

123 550 230 123 550 230

145 650 275 145 650 275 400

170 750 325 145 650 290

Technical Data TD 1889046/03 EN COMTAP ARS

(5 + j4) m 1) 330 000 1) 130 000 65 000

Impedance Z (9 + j4) m 280 000 1) 100 000 40 000

(11 + j6) m 150 000 1) 50 000 20 000

Theoretical number of COMTAP ARS operations from a contact wear perspective

mechanical contact life limit 100000 I = 700 A I = 1300 A 80000

0 0% 25% 50% Contact wear 75% 100%

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

Technical Data TD 1889046/03 EN COMTAP ARS

Technical Data TD 1889046/03 EN COMTAP ARS

Safety devices WARNING!

Technical Data TD 1889046/03 EN COMTAP ARS

Technical Data TD 1889046/03 EN COMTAP ARS

Technical Data TD 1889046/03 EN COMTAP ARS

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

Technical Data TD 1889046/03 EN COMTAP ARS

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

Technical Data TD 1889046/03 EN COMTAP ARS

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

Technical Data TD 1889046/03 EN COMTAP ARS

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

Technical Data TD 1889046/03 EN COMTAP ARS

COMTAP ARS, adjustment plan for ARS (7341022E)

Technical Data TD 1889046/03 EN COMTAP ARS

COMTAP ARS, installation drawing (7327712E)

Technical Data TD 1889046/03 EN COMTAP ARS

Technical Data TD 1889046/03 EN COMTAP ARS

Technical Data TD 1889046/03 EN COMTAP ARS

COMTAP ARS, head with gear unit (7257372E)

Technical Data TD 1889046/03 EN COMTAP ARS

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

Technical Data TD 1889046/03 EN COMTAP ARS

COMTAP ARS, lifting traverse (72673703)

Technical Data TD 1889046/03 EN COMTAP ARS

COMTAP ARS, terminal contacts 1000 A (7340950E)

Technical Data TD 1889046/03 EN COMTAP ARS

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

Technical Data TD 1889046/03 EN COMTAP ARS

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