Tap Manager TM100 - Redirection · 189/01/01/0 5 All personnel involved in installation, commissioning, operation and maintenance of the device must - be suitably qualified and -

Tap Manager®

TM100Operating Instructions

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Contents

NOTE

Data contained herein may differ in small details from the unit delivered. We reserve the right to makealterations without notice.

1 General ..................................................................................................................................................... 5

1.1 Safety instructions ........................................................................................................................... 51.2 Application....................................................................................................................................... 5

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

2.1 Controls ........................................................................................................................................... 62.1.1 Scroll keys in display field ..................................................................................................... 62.1.2 Enter key ............................................................................................................................... 62.1.3 Local/Remote switch ............................................................................................................. 72.1.4 Raise/Lower keys .................................................................................................................. 7

2.2 Displays .......................................................................................................................................... 72.2.1 LCD display .......................................................................................................................... 72.2.2 LED displays ......................................................................................................................... 8

2.3 Diagnosis interface .......................................................................................................................... 8

2.4 Modules .......................................................................................................................................... 82.4.1 Network filter module ....................................................................................................................... 8

2.4.2 Power supply module ............................................................................................................ 82.4.3 Control module ...................................................................................................................... 82.4.4 Temperature measuring module ............................................................................................ 92.4.5 Position module ..................................................................................................................... 92.4.6 Power measuring module...................................................................................................... 92.4.7 CPU module .......................................................................................................................... 92.4.8 Front bus-board .................................................................................................................... 92.4.9 External connections of the standard device ......................................................................... 9

2.5 Technical data ................................................................................................................................ 92.6 Environmental conditions ............................................................................................................... 92.7 Housing, dimensions, weight ........................................................................................................... 92.8 Power supply ................................................................................................................................... 92.9 Measuring ranges ........................................................................................................................... 92.10 Relays (control of output contacts) .................................................................................................. 92.11 External digital inputs ..................................................................................................................... 9

3 Operation ................................................................................................................................................. 10

3.1 Drive control .................................................................................................................................... 103.1.1 Starting a tap-change operation ............................................................................................ 103.1.2 Blocking a tap-change operation ........................................................................................... 103.1.3 Local acknowledgement of alarms and warnings .................................................................. 10

3.2 Drive monitoring .............................................................................................................................. 113.2.1 Monitoring during the tap-change operation .......................................................................... 113.2.2 Monitoring during resting ....................................................................................................... 113.2.3 Wrong phase sequence ........................................................................................................ 11

3.3 Hand crank operation ...................................................................................................................... 11

Contents

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Contents

Contents

NOTE

Data contained herein may differ in small details from the unit delivered. We reserve the right to makealterations without notice.

3.4 Monitoring of limit values ................................................................................................................. 113.4.1 Torque monitoring ................................................................................................................. 113.4.2 Temperature monitoring ........................................................................................................ 113.4.3 Contact wear ......................................................................................................................... 123.4.4 Replacement of parts ............................................................................................................ 123.4.5 Oil change ............................................................................................................................. 12

3.5 Data storage.................................................................................................................................... 123.5.1 Storage principle ................................................................................................................... 123.5.2 Event memory ....................................................................................................................... 123.5.3 Raw torque data .................................................................................................................... 123.5.4 evaluated torque data............................................................................................................ 123.5.5 Wear data ............................................................................................................................. 133.5.6 Temperature data .................................................................................................................. 133.5.7 Current data .......................................................................................................................... 13

3.6 Maintenance display ........................................................................................................................ 13

3.7 General information on maintenance ............................................................................................... 13

4 Appendices .............................................................................................................................................. 13

5189/01/01/0

All personnel involved in installation, commissioning,operation and maintenance of the device must

- be suitably qualified and- strictly observe these Operating Instructions.

Improper operation or misuse can lead to

- serious or fatal injury,- damage to the device and other property of the

user, and- a reduction in the efficiency of the device.

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 toserious or fatal injury.

CAUTION

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

NOTE

These notes give important information on a certainsubject.

1 General1.1 Safety instructions 1.2 Application

CAUTION

The monitoring system and memory card may only beused with the on-load tap-changer specified in theorder. Installation, electrical connection and com-missioning must only be carried out by qualifiedpersonnel according to these Operating Instructions.It is the responsibility of the user to make sure that thedevice is used for the specified application only.For safety reasons, unauthorized work such asinstallation, modification, alteration, electricalconnection or commissioning of the equipment mustnot be carried out without first consulting MR !The trouble-free operation of the motor drive, the on-load tap-changer and the transformer may be put atrisk.

CAUTION

All relevant fire protection regulations must be strictlyobserved.

1General

The electronic on-load tap changer monitoring systemTM100 controls, monitors and records data from motordrive units and high voltage on-load tap-changers.The advantages of the TM100 include early detection offaults and the possibility for condition-dependent tap-changer maintenance. Activating the motor drive, whichoperates according to the step-by-step principle, resultsin a voltage change of one step on the transformer.

During the tap-change operation switching-relevantevents are recorded and and limit values such as thetorque are monitored. If any faults are detected or ifcritical limit values are exceeded the subsequent tap-change operation is blocked. During a tap-changeoperation the motor drive can be blocked by real-timemonitoring modules. The events are stored and amessage is sent.

The device is equipped with a 2-MB memory card forstoring parameters and data sets on the on-load tap-changer and motor drive operating values. The datarecorded can be read from a serial interface andprocessed by a visualisation program. The limit valueparameters can be changed using the diagnosis ormonitoring interface and can be stored in the non-volatile flash memory on the memory card.

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The device is delivered in a standardized 19“ rackaccording to DIN 41494 (fig. 1).

The design is modular, which means the individualfunctions are performed by individual modules.The front plate contains the controls and a two-lineLCD display. The RS232 diagnosis interface isconnected to a 9-pole sub-D socket.

All components on the front are soldered onto a bus-board which is also a connecting board for the indivi-dual electronic modules.

All electronic modules are plugged into the rear of thedevice and are mechanically locked in their positionsby EMC barriers (fig. 2).

2Design

2 Design

1

2.1 Controls2.1.1 Scroll keys in display field

Using the scroll keys (fig. 3) the important operatingdata can be displayed, e.g. number of tap-changeoperations, end positions, operating current of the on-load tap-changer, temperature, time and date.

2.1.2 Enter key

This key can be used to acknowledge an event or errormessage code (fig. 4). The acknowledged code is ex-plained in a reference list which is included with theconnection diagrams.

2

3

4KHW 1154

KHW 1146

SCROLL

KHW 1148

INPUT

KHW 1147

READY

TAP CHANGE

END POSITION REACHED

HAND CRANK OPERATION

ATTENTION CALL SERVICE!

WARNING! FAILURE

STATUS LINEMODE OF OPERATIONMANUAL CONTROL

DATA PORT

RS232

SCROLL INPUT

LOCAL REMOTE

REINHAUSENGERMANYRM

OLTC - MONITORING - SYSTEMTM100

MA

DE

IN G

ER

MA

NY

READY

TAP CHANGE



ATTENTION CALL SERVICE!

WARNING! FAILURE

STATUS LINEMODE OF OPERATIONMANUAL CONTROL

DATA PORT

RS232

SCROLL INPUT

LOCAL REMOTE

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2Design

2.2 Displays

With trouble-free operation and when the motor drive isin the resting range (grey field on the tap-changeindicator), the first line (fig. 7) shows that the on-loadtap-changer is ready for an operation. The second lineshows the tap position and number of sections on thetap-change indicator of the motor drive.

2.2.1 LCD displayThis slide switch is used to select the Local or Remotemode of operation.Tap-change operations can only be activated by thecontrol keys on the TM100 when Local mode isselected.

2.1.4 Raise/Lower keys (fig. 6)

These keys are used to initiate an on-load tap-changeoperation in manual mode in either the Raise or Lowerdirection.

2.1.3 Local/Remote switch (fig. 5)

5

6

7

When a message is generated by the monitoringsystem, it is displayed as an event code number.This also occurs with alarms and warnings (fig. 8).

8

KHW 1149

MODE OF OPERATION

LOCAL REMOTE

KHW 1150

MANUAL CONTROL

KHW 1151-S

KHW 1151-W

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2Design

• Ready (green)The device is switched on and the tap position inputis correct.

• Tap-change operation (yellow)A tap-change operation is in progress („running“indication)

• End position reached (yellow)The on-load tap-changer is in one of its two endpositions.

• Hand crank operation (yellow)The hand crank is fitted. The switching sequence isno longer monitored.

• Attention! Call Service! (yellow)Alarms are present. Tap-change operation is stillpossible.

• Warning! Failure (red blinking)A warning is present. Tap-change operation is notpossible until the warnings are acknowledged.

2.2.2 LED displays (fig. 9)

9

Using this RS232 interface, data can be read andsettings altered locally by means of the MR visualisationprogram.

2.3 Diagnosis interface (fig. 10)

10

STATUS LINE

READY

TAP-CHANGE



ATTENTION! CALL SERVICE!

WARNING! FAILURE

2.4 Modules

2.4.1 Network filter module

This module contains a network filter. In AC design itadditionally contains the voltage setting of 100 V AC upto 260 V AC, and in DC design a chopper unit.

2.4.2 Power supply module

AC design:

Rated voltages of 100 V, 110 V, 120 V, 130 V, 200 V,210 V, 220 V, 230 V, 240 V, 250 V and 260 V AC can beset via winding taps on the network filter module.

DC design:

Thanks to prewired winding taps, power supply unitswith 110 V, 125 V, 200 V, 220 V, 250 V are available.

2.4.3 Control module

This module contains 8 optocoupler inputs.The optocouplers are operated with a 30 V controlvoltage provided by the module.

There are 4 relays for controlling the switchgear, eachwith an N/O contact and one common terminal.

DATA PORT

RS232

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2Design

This module contains 4 measuring channels for the MRdigital temperature sensors. The temperature sensorsare interrogated via an interface with signal levelsaccording to RS 485. A sensor on the module measuresthe internal temperature of the unit.

2.4.5 Position moduleThis module reads the position of the on-load tap-changer and tap selector contacts. A rotary transmitterattached to the position transmitter shaft in the motordrive supplies an absolute-position signal.

2.4.6 Power measuring moduleThis module measures the motor current and motorvoltage and prepares the values correctly phased forthe analog/digital conversion. The CPU determines apower value from 200 real-time samples taken duringeach period which is then converted by a transmissionfunction into an on-load tap-changer torque value.

2.4.7 CPU moduleThis is the core of the system. It processes themeasured values, controls and monitors the othermodules and operates the motor drive control. The CPUmodule contains the memory card (see BA 188, section4.2) as non-volatile data memory and also may havetwo fibre-optic interfaces.Transmission range at 660 nm wavelength: < 100 mTransmission range at 850 nm wavelength: 1500 m

2.4.8. Front bus-boardThe front bus-board is located behind the front paneland connects the modules. The controls, displays andsignalling lights are mounted on and connected to it.

2.4.9 External connections of thestandard device

X22 Power supplyX24, X26 Control board 1X25, X27 Control board 2X38 Temperature measuring boardX40 Position input boardX34 Power measuring board

2.4.4 Temperature measuring module

Note: Only values indicating tolerances or limits can beconsidered guaranteed data. Values without tolerancedetails are for information only and are not guaranteed.

2.6 Environmental conditions

Temperature range -25 °C ... + 85 °CDegree of protection IP00

2.7 Housing, dimensions, weight

Housing according to DIN 41494 Teil 5Height 132,5 mmWidth 483 mmDepth 180 mmWeight ca. 12 kg (with max. equipment)

2.8 Power supply

230 V AC, -15 % bis +10 %, for settings see 2.4.2.

2.9 Measuring ranges

Temperature measuring board:Measuring range: -30 °C to 100 °C, accuracy ± 1.2 °C

-45 °C to 130 °C, accuracy ± 2 °C

Power measuring board:

AC: 260 V, 6 A 520 V, 6 ADC: 300 V, 7 A

2.10 Relays (control of output contacts)N/C contacts with common terminal (each board with4 relays)240 V AC, 8 A30 V DC, 5 A110 V DC, 0.4 A250 V DC 0.3 AExternal digital outputs are connected via couplingrelays and are wired as electrically-separate change-over contacts to the terminal strip X1 of the motor drivebut only if the TM100 wiring is carried out by MR.

2.11 External digital inputs

External digital inputs are electrically separated bycoupling relays.

Control voltage of coupling relays: 230 V AC.An auxiliary voltage (30 V DC) provided by the TM100 isswitched via potential-free contacts to TM100 inputs(see 2.4.3).

2.5 Technical data

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Local mode operation:

When the Local/Remote switch is in Local position(fig. 11) and when the display shows „OLTC ready“(fig. 12), a tap-change operation can be initiated, e.g.towards position 27 or towards position 1, using theRaise or Lower keys, respectively.

Remote mode of operation:

When the Local/Remote slide switch is in the Remoteposition and when the display shows „OLTC ready“, a tap-change operation can be initiated, e.g. towards position27 or towards position 1, by a control voltage pulse(ca. 0.5 s) applied to terminal X1.10 or X1.11 respectively.

12

3Operation

3 Operation 3.1 Drive control 3.1.1 Starting a tap-change operation

11

Exception:

Hand crank operation:

If the motor drive is operated by the hand crank past theresting range to the point that a step-by-step switch istriggered, the initiated tap-change operation is automa-tically completed.

3.1.2 Blocking a tap-change operation

An initiated tap change-operation is blocked under thefollowing circumstances:

• a warning is present which is indicated by theblinking red LED „Warning! Event!“,

• an end position is reached but the next tap-changeoperation intended is in the same direction,

• the hand crank is fitted,

• the factory-set maximum permissible tap-changercurrent is exceeded,

• the maximum permissible temperature range isexceeded.

3.1.3 Local acknowledgement of alarmsand warnings

In the Local mode of operation a warning or alarmdisplayed as the event number (fig. 13) can beacknowledged by pressing the Enter key.

If several warnings and alarms occur at the same time,the warnings are shown first and then the alarms.The sequence is determined by the code number.The message with the highest code number must beacknowledged first.

13

Schalter bereit

KHW 1151-W

MODE OF OPERATION

LOCAL REMOTEKHW 1149

KHW 1151-S

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3Operation

3.2 Drive monitoring

3.4.1 Torque monitoring

The on-load tap-changer torque is monitored in realtime during a tap-change operation. If the set maximumtorque is exceeded, the tap-change operation isimmediately stopped and the motor protective switch istripped.At the end of each tap-change operation the recordedtorque measurement points are evaluated. The maxi-mum torques in each section of the tap-change opera-tion are compared to the corresponding limit valuesand, if necessary, alarms and warnings are sent.If none of the limit values are exceeded, the on-loadtap-changer is ready for a new operation and the dis-play shows “OLTC ready”.

3.4.2 Temperature monitoring

When the TM100 is switched on, the followingtemperatures are measured:

• oil temperature in the on-load tap-changer oilcompartment

• transformer oil temperature and, in bolt-on tap-changers, the tap selector temperature

• external temperature• internal temperature in the TM100 electronics.

If the actual values exceed or fall below the limit values,corresponding alarm or error messages are sent.Deviations or below the temperature thresholds canblock the operation of the on-load tap-changer.

Yellow: Operation can continue (withoutacknowledgement of message)

Red: Operation can continue only afteracknowledgement of message.The motor drive control is blocked.

If the difference between the internal and externaltemperature exceeds 8 Kelvin and if the internal tem-perature is less than 10 °C, the heater is switched on.

3.4 Monitoring of limit values

During a tap-change operation the motor drive runningtime and the movement of the drive shaft in the motordrive are monitored (also see 3.4.1).

If the running time is exceeded, an error message issent and the motor protective switch is tripped.

3.2.2 Monitoring during resting

After completion of the tap-change operation the motordrive is monitored to ensure the motor does not con-tinue running after its slow-down period. If, due to asticking contactor, the motor continues running withoutcontrol the motor protective switch is tripped.

3.2.3 Wrong phase sequence

The TM100 monitors the direction of rotation of themotor drive and trips the motor protective switch if thedirection of rotation is wrong. In addition, it sends theerror message „Wrong direction of rotation“. After theerror is corrected and the message is acknowledgedthe motor drive completes the initiated tap-changeoperation.

3.3 Hand crank operation

If the hand crank safety switch signals that the handcrank is fitted, the TM100 changes to hand crankoperation.

The automatic drive control and monitoring are not inoperation when the hand crank is used. The on-loadtap-changer can be operated to any position within themechanical limits.

If the hand crank is withdrawn outside the neutral zoneor in a position to be passed, the initiated tap-changeoperation is automatically completed.

WARNING

If the maximum torque of the on-load tap-changer isexceeded during a tap-change operation and themotor drive is immediately stopped, MR’s TechnicalService should be informed.Serious damage may occur to the on-load tap-changer.Disregarding this warning can lead to serious damageto property or serious or fatal injury.

3.2.1 Monitoring during a tap-changeoperation

CAUTION

If the motor drive is operated when the red alarm isactivated, serious damage to the motor drive, on-loadtap-changer and transformer can occur.

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3Operation

The wear of the switching and resistor contacts of thediverter switch is determined from the on-load tap-changer current.

After each tap-change operation the contact wear iscalculated from the on-load tap-changer current usingan algorithm. If the permissible wear is exceeded, awarning is sent and the on-load tap-changer is blocked.

If the contact wear reaches 90 %, an alarm (yellow)appears. An imminent technical service should beplanned.

3.4.4 Replacement of parts

The precautionary replacement of parts depends on thenumber of switching operations. The correspondingdata is stored in the TM100. When 90 % of the numberof operations is reached, an attention signal (yellowsignal) appears to indicate that a parts replacementservice should be planned. In this case please contactthe MR Technical Service.

3.4.5 Oil change

The criteria are stored in the TM100. When 90 % of thecriteria is reached, an attention signal (yellow signal)appears. Together with the oil change it is necessary toclean and inspect the diverter switch oil compartmentand diverter switch insert. For details refer to the in-spection instruction manual for the respective on-loadtap-changer.

If the on-load tap-changer is operated with an MR oilfilter plant, the response pressure of the filter plant isthe criterion for the filter cartridge replacement. This isalso signalled by the TM100. For the criteria of thediverter switch oil change refer to the operating instruc-tion manual for the MR oil filter plant.

3.4.3 Contact wear

Data is stored on a PCMCIA memory card.There are two memory blocks for data which arerewritable. If both blocks are full, the block with the olderdata is deleted.

Essential operational data such as parameters, alarmsand error messages, wear data and faulty torquecharacteristics are stored in memory areas which arenon-rewritable.

3.5.2 Event memory

All events are stored with a time stamp in the rewritablememory area.

The memory capacity is 2 blocks with 16 000 eventseach which are alternately rewritable.In addition, attention and warning messages are storedin a non-rewritable space of the Memory Card.

3.5.3 Raw torque data

The torque measurement points from each tap-changeoperation together with essential operation data such astap position, tap-change operation type, temperature,motor voltage and on-load tap-changer current arestored in a rewritable memory area.

The memory capacity contains 2 blocks which are alter-nately rewritable.

If limit values are exceeded, the data set is additionallystored in a non-rewritable memory area.

3.5.4 Evaluated torque data

After completion of a tap-change operation the torquedata is evaluated according to the type of tap-changeoperation and the corresponding functional sequence inthe on-load tap-changer. The maximum torques duringeach tap change operation are used by the monitoringsystem to analyse the functional sequence in the on-load tap-changer mechanics and as a comparisonagainst specified limit values. The data set created isstored.

3.5 Data storage3.5.1 Storage principle

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Operation 3Appendices 4

4 Appendices

Front view with control .............................................................................................................................. TM_FRTEN

Rear view with plug designations .............................................................................................................. TM_BGTRU

Block diagram ........................................................................................................................................... TM100B1D



Circuit diagram ......................................................................................................................................... ZM0004S1




If the specified number of operations is reached, or if aservice is required, the monitoring system issues andsends corresponding messages.If operating conditions are such that continuing opera-tion jeopardises the equipment, the monitoring systemblocks the motor drive.

3.7 General information on maintenance

Maintenance measures can be carried out with mini-mum expense. They can be effectively combined withthe usual control checks on the transformer.

• Visually checking the motor drive

• Checking the protective function of the protective relay of the on-load tap-changer

• Checking the on-load tap-changer oil

• Checking the silicagel breather

Refer to the respective Operating Instructions of theindividual on-load tap-changers for details on limitvalues.

3.6 Maintenance display

From the specified transformer step voltages, the on-load tap-changer current at the moment of the tapchange and from known characteristics of the contactmaterial, the monitoring system calculates the wear ofthe switching and resistor contacts on the on-load tap-changer using a mathematical model.

The results are stored and used to evaluate wear diffe-rences between the individual contacts and the totalwear. In connection with the limit values of the diverterswitch to be monitored the system monitors the condi-tion of the contacts subject to wear.

3.5.6 Temperature data

As well as constantly monitoring the on-load tap-changer temperature, the measured temperatures areperiodically stored.

In addition, the minimum, maximum and averagetemperature values are stored at the end of eachcalendar day.

3.5.7 Load current data

The monitoring system can measure the on-load tap-changer current from different sources.This current value is required to calculate the contactwear. However, it is also stored in the same way as thetem-perature value so that minimum, maximum andaverage current values are available for evaluation.

3.5.5 Wear data

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Tap Manager® TM100TM_FRTEN.PIC

Front view with controls

4Appendices

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Tap Manager® TM100TM_BGTRU.PIC

Rear view with plug designations

Option:Modem, STE3, TX1, TX2,

RX1, RX2

4Appendices

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Tap Manager® TM100TM100B1E

Block diagram

4Appendices

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Block diagram

4Appendices

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Block diagram

4Appendices

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Motor Drive Unit ED Monitoring ZM0004

Circuit diagram Sheet 1

4Appendices

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4Appendices

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4Appendices

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Current Diagram Sheet 4

4Appendices

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© Maschinenfabrik Reinhausen GmbH 2001Postfach 12 03 6093025 RegensburgGermanyPhone: (+49) 9 41 / 40 90-0Fax: (+49) 9 41 / 40 90-111Internet: http://www.reinhausen.comEmail: [email protected]

BA 189/01 en - 0501/1000189/01/01/0F0067300Printed in Germany

Documents

Tap Manager TM100 - Redirection · 189/01/01/0 5 All personnel involved in installation, commissioning, operation and maintenance of the device must - be suitably qualified and -