Monitoring system TAPGUARD 240. Operating Instructions 244/04

Transcription

1 Monitoring system TAPGUARD 240 Operating Instructions 244/04

2 All rights reserved by Maschinenfabrik Reinhausen Copying and distribution of this document and utilization and communication of its contents are strictly prohibited unless expressly authorized. 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. 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. Generally, the information provided and the arrangements agreed during processing of the relevant quotations and orders are binding. The original operating instructions were drawn up in German.

3 Table of Contents Table of Contents 1 Introduction Manufacturer Subject to change without notice Completeness Supporting documents Safekeeping Notation conventions Abbreviations used Hazard communication system Information system Safety General safety information Appropriate use Inappropriate use Personnel qualification Operator duty of care Product description Performance features Scope of delivery Maschinenfabrik Reinhausen /04 EN TAPGUARD 240 3

4 Table of Contents 3.3 Hardware description Internal design Communication Interfaces Operation and indicator elements Operating concept Description of the display Description of key functions Description of LEDs Mounting Unpacking Mounting Connection Cable recommendation for standard connections Cable recommendation for optional connections Electromagnetic compatibility Connecting the cables to the system periphery Supplying the monitoring system Wiring of the monitoring system Function check Commissioning Configuration Setting the language Activating/deactivating display dimming Setting the display contrast Setting system time Setting system date Tap position capture TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

5 Table of Contents Digital tap position capture with BCD signal Analog tap position capture (optional) Transformer data Setting the primary transformer current Setting the current transformer connection Setting the operating position of the on-load tap-changer Configure communications interfaces Setting the COM1 serial interface Functions and settings Calling up general information Displaying the info screen Carrying out LED test Resetting parameters Displaying real-time clock Displaying upcoming messages Displaying the LOG file Measured values Displaying measurement values Display measured value raw data Displaying measured value memory Displaying peak memory Maintenance Displaying the maintenance status Enter Service password Maintenance events Fault elimination Operating faults Man Machine Interface Maschinenfabrik Reinhausen /04 EN TAPGUARD 240 5

6 Table of Contents Digital inputs General fault No solution Technical Data Indicator elements Electrical data Inputs and outputs Dimensions and weight Voltage and current measurement Ambient conditions Tests Electrical safety EMC tests Environmental durability tests Menu overview MR worldwide TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

7 1 Introduction 1 Introduction This technical file contains detailed descriptions on the safe and proper mounting, connection, commissioning and monitoring of the product. It also includes safety instructions and general information about the product. This technical file is intended solely for specially trained and authorized personnel. 1.1 Manufacturer The product is manufactured by: Maschinenfabrik Reinhausen GmbH Falkensteinstraße Regensburg Tel.: (+49) 9 41/ Fax: (+49) 9 41/ sales@reinhausen.com Further information on the product and copies of this technical file are available from this address if required. 1.2 Subject to change without notice The information contained in this technical file comprise the technical specifications approved at the time of printing. Significant modifications will be included in a new edition of the technical file. The document and version numbers of this technical file are shown in the footer. Maschinenfabrik Reinhausen /04 EN TAPGUARD 240 7

8 1 Introduction 1.3 Completeness This technical file is incomplete without the supporting documentation. 1.4 Supporting documents The following documents apply to this product: Operating instructions Connection diagrams In addition, generally applicable legal and other binding regulations of European and national law and the regulations for accident prevention and environmental protection in force in the country of use must be complied with. 1.5 Safekeeping This technical file and all supporting documents must be kept ready to hand and accessible for future use at all times. 1.6 Notation conventions This section contains an overview of the abbreviations, symbols and textual emphasis used. 8 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

9 1 Introduction Abbreviations used Abbreviation Definition C Degrees Celcius A Ampere AC Alternating Current BCD Binary Coded Decimal ca. circa CAN Controller Area Network CIC Communication Interface Card CPU Central Processing Unit DC Direct Current DIN Deutsches Institut für Normung (German Institute for Standardization) DNP Distributed Network Protocol EMC Electromagnetic compatibility ESC Escape Hz Hertz I Current IEC International Electrotechnical Commission IED Intelligent electronic device IP Internet Protocol kbaud Kilobaud kg Kilogram kv Kilovolt LED Light Emitting Diode FO Fiber-optic cable max. Maximum MB Megabyte MR Maschinenfabrik Reinhausen MHz Megahertz min. Minimum mm Millimeter ms Millisecond N nm OLTC RTC s SCADA Neutral Nanometer On-load tap-changer Real-time clock Second Supervisory Control and Data Acquisition Maschinenfabrik Reinhausen /04 EN TAPGUARD 240 9

10 1 Introduction Abbreviation t TCP V V Act V Ref USB V Table 1 Definition Time Transmission Control Protocol Voltage Actual voltage Reference voltage Universal serial bus Volt Abbreviations used Hazard communication system Warnings in this technical file use the following format: DANGER! Danger Consequences Action Action The following signal words are used: Signal word Hazard level Consequence of failure to comply Danger Immediate threat of danger Death or serious injury could occur Warning Possible threat of danger Death or serious injury could occur Attention Possible dangerous situation Minor or moderate injury could occur Note Possible dangerous situation Damage to property could occur Table 2 Signal words in warning notices 10 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

11 1 Introduction Pictograms warn of dangers: Picto gram Meaning Danger Dangerous electrical voltage Fire hazard Danger of tipping Table 3 Symbols used in warning notices Information system Information is designed to simplify and improve understanding of particular procedures. In this technical file they are laid out as follows: Important information Maschinenfabrik Reinhausen /04 EN TAPGUARD

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13 2 Safety 2 Safety 2.1 General safety information This technical file contains detailed descriptions on the safe and proper mounting, connection, commissioning and monitoring of the product. Read this technical file through carefully to familiarize yourself with the product. Particular attention should be paid to the information given in this chapter. 2.2 Appropriate use The product and associated equipment and special tools supplied with it comply with the relevant legislation, regulations and standards, particularly health and safety requirements, applicable at the time of delivery. If used as intended and in compliance with the specified requirements and conditions in this technical file as well as the warning notices in this technical file and attached to the product, then the product does not present any hazards to people, property or the environment. This applies throughout the product's full life, from delivery through installation and operation to disassembly and disposal. The operational quality assurance system ensures a consistently high quality standard, particularly in regard to the observance of health and safety requirements. Use is considered to be appropriate if the product is operated in accordance with this technical file and the agreed delivery conditions and technical data, and the associated equipment and special tools supplied with it are used solely for the intended purpose and in accordance with the specifications of this technical file. the product is used only with the transformer specified in the order. Maschinenfabrik Reinhausen /04 EN TAPGUARD

14 2 Safety 2.3 Inappropriate use Use is considered to be inappropriate if the product is used other than as described in Appropriate use on page 13. Maschinenfabrik Reinhausen does not accept liability for damage resulting from unauthorized or inappropriate changes to the product. Inappropriate changes to the product without consultation with Maschinenfabrik Reinhausen can lead to personal injury, damage to property and operational disruption. 2.4 Personnel qualification The product is designed solely for use in electrical energy systems and facilities operated by appropriately trained staff. This staff comprises people who are familiar with the installation, assembly, commissioning and operation of such products. 14 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

15 2 Safety 2.5 Operator duty of care To prevent accidents, disruptions and damages as well as unacceptable adverse effects on the environment, those responsible for transport, installation, operation, maintenance and disposal of the product or parts of the product must ensure the following: All warning and hazard notices are complied with. Personnel are instructed regularly in all relevant aspects of operational safety, the operating instructions and particularly the safety instructions contained therein. Regulations and operating instructions for safe working as well as the relevant instructions for staff procedures in the case of accidents and fires are kept on hand at all times and are displayed in the workplace where applicable. The product is only used when in a sound operational condition and safety equipment in particular is checked regularly for operational reliability. Only replacement parts, lubricants and auxiliary materials which are authorized by the manufacturer are used. The specified operating conditions and requirements of the installation location are complied with. All necessary devices and personal protective equipment for each activity are made available. The prescribed maintenance intervals and the relevant regulations are complied with. Fitting, electrical connection and commissioning of the product may only be carried out by qualified and trained personnel in accordance with this technical file. The operator must ensure appropriate use of the product. Maschinenfabrik Reinhausen /04 EN TAPGUARD

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17 3 Product description 3 Product description The TAPGUARD 240 monitoring system monitors the on-load tap-changer and calculates all important maintenance criteria. To do so, it is equipped with measuring devices that record all relevant information. Using the recorded values, the monitoring system determines when the next maintenance is due. This prognosis is displayed transparently on the operating monitor. The basis for prognoses are data from over 50 years of service experience with our on-load tap-changers. The monitoring system is the ideal tool for condition-oriented maintenance. It increases operating safety and the maintenance intervals of the on-load tapchanger, thereby reducing operating costs. Maschinenfabrik Reinhausen /04 EN TAPGUARD

18 3 Product description Figure 1 Overview of on-load tap-changer monitoring 18 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

19 3 Product description 3.1 Performance features The monitoring system helps you with condition-oriented maintenance of the on-load tap-changer. To this end, the monitoring system monitors the following maintenance criteria: Replacement of the abrasion parts Oil change, cleaning and replacing the oil filter (only OILTAP ) Taking an oil sample Calculates the contact wear (only OILTAP ) Operator interval The monitoring system records all measured values and events. These data can be selected and prepared using the TAPCON -trol visualization software. 3.2 Scope of delivery The following items are included in the delivery: Scope of delivery TAPGUARD 240 Monitoring System CD with TAPCON -trol Software (optional) Interface cable with USB adapter and CD driver (optional) Technical files Table 4 Scope of delivery Please note the following: 1. Use dispatch documents to check that the delivery is complete. 2. Store the parts in a dry place until installation. The functional range of the product is dependent on the equipment ordered or the product version and not on the content of this technical file. Maschinenfabrik Reinhausen /04 EN TAPGUARD

20 3 Product description 3.3 Hardware description The individual assemblies are fitted in a standardized 19-inch plug-in housing. The front panels of the assemblies are secured to the plug-in housing at the top and bottom. An IEC plug connector provides the electrical connection. The assemblies are connected to one another via a data bus and separate direct current (DC) supply. This allows for an upgrade with additional plug-in units and extension cards at a later date. An LCD graphic display, LEDs and function keys are integrated in the front panel of the product. Figure 2 Front view of the monitoring system 1 19-inch plug-in housing (in accordance with DIN Part 5) 2 Operating panel with display and LEDs 3 Assembly for optional expansions 20 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

21 3 Product description Internal design The device is controlled by a microregulator and includes isolated optocoupler inputs and floating output relay contacts in addition to the voltage and current transformers CPU card The CPU card processes measured values and monitors and controls other components in the monitoring system. The CPU card contains a flash memory (measured value memory) as a nonvolatile data storage in which the operating data such as measured values, events, torques, contact wear are stored in databases. An EEPROM for storing parameters and an RTC (Real-time clock) for recording time are included on the CPU card. Figure 3 CPU card Maschinenfabrik Reinhausen /04 EN TAPGUARD

22 3 Product description Wide range power supply SU card The wide range power supply (SU card) supplies the device with power. Figure 4 The wide range power supply (SU card) in a standard design The device can be supplied in a standard design as follows: Input Voltage Terminal L1 / + DC VAC/DC* SU-X1: 01 N / -DC VAC/DC* SU-X1: 02 Table 5 Inputs for the SU card (standard) * permissible frequency range when supplying with AC current : Hz. Alternatively, the device can also be delivered with a power supply pack for the following voltage ranges. Input Voltage Terminal + DC V DC SU-X1: 01 -DC V DC SU-X1: 02 or + DC V DC SU-X1: 01 - DC V DC SU-X1: 02 Table 6 Inputs for the SU card come in VDC version or VDC version 22 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

23 3 Product description Load current measurement card MI card The transformer load current is measured using the load current measurement card. The following functions are implemented via load current measurement: Overcurrent blocking Contact wear and oil soot calculation Calculation of the hot spot temperature (only inside the "cooling system control" function module) The load current is measured using the 1 A- or 5 A-measurement input of the current transformer on the load current measurement card. Currents can be measured that total up to 210% of the current transformer rated current on the transformer. The measurement input of the voltage transformer is not switched. As an alternative, the load current measurement can also be transferred as a standardized signal ( ma ) to the monitoring system. The load current is then recorded via the optional analog input card AD 8. If the load current equals 0 A for longer than 10 minutes, then the nominal current of the on-load tap-changer is displayed on the main screen. In this case, the nominal current is also drawn on to calculate the wear and the soot content. Figure 5 Load current measurement card MI card Maschinenfabrik Reinhausen /04 EN TAPGUARD

24 3 Product description Input and output card IO card The IO card is used to wire the inputs and outputs of the monitoring system. Figure 6 Input and output card (IO card) The inputs and outputs are assigned as follows: Input Function Terminal E1 Hand crank connected IO-X1:11-15 E2 Motor protective switch Q1 triggered IO-X1:12-15 E3 Door open IO-X1:13-15 E4 Reserve IO-X1:14-15 E5 Tap-change supervisory control 1 IO-X1:16-27 E6 Tap-change supervisory control 2 IO-X1:17-27 E7 MD moves toward n + 1 IO-X1:28-30 E8 MD runs toward n - 1 IO-X1:29-30 E9 Monitoring deactivated IO-X1:31-32 E10 Overpressure oil filter unit IO-X1:33-34 Table 7 Inputs for the IO card 24 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

25 3 Product description Output Function Contact* Terminal A1 "YELLOW" Message no IO-X1:25-26 A2 Tripping of the motor protective no IO-X1:23-24 switch A3 "GREEN" message no IO-X1:23-22 A4 ON/OFF heating of the motordrive unit nc IO-X1:18-19 no IO-X1:18-20 A5 "RED" message no IO-X1:8-10 nc IO-X1:8-9 A6 For internal use nc IO-X1:6-7 A7 For internal use nc IO-X1:4-5 A8 Status message no IO-X1:1-3 nc IO-X1:1-2 Table 8 Outputs for the IO card * no = Normally open (N/O contact), nc = normally closed (N/C contact) Maschinenfabrik Reinhausen /04 EN TAPGUARD

26 3 Product description Analog input card AD card (optional) The analog input card AD has 1 input that can be used to record 1 analog signal. The AD card can be optionally equipped with an additional board (AD1) in order to record 1 additional analog signal. The analog input card AD can record the following signals: V ma ma Resistance measurement (50 Ω...2 kω) Figure 7 Analog input card (AD card) 26 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

27 3 Product description Analog output card AN card (optional) The analog output card consists of a motherboard (measuring transducer 1) and an optional add-on board (measuring transducer). Each of these two boards has two outputs through which the analog signals can be issued Figure 8 Analog output card (AN card) Output Function Signal Terminal A1 A2 A3 A4 Table 9 Optional Optional Optional Optional Outputs for the AN card mA AN-X1: mA AN-X1: mA AN-X1: mA AN-X1: mA AN-X1: mA AN-X1: mA AN-X1: mA AN-X1:8 Maschinenfabrik Reinhausen /04 EN TAPGUARD

28 3 Product description Auxiliary power supply AC card (optional) Using the AC card, independent control voltage of 60 VDC can be generated if no direct current voltage is available for control inputs in the device. Figure 9 Auxiliary power supply (AC card) Input Voltage Terminal L1 230 VAC AC-X1:01 N 230 VAC AC-X1:02 Table 10 Inputs for the AC card Output Voltage Terminal + DC 60 VDC AC-X2:01 - DC 60 VDC AC-X2:02 Table 11 Outputs for the AC card 28 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

29 3 Product description Communication Interfaces Serial interface The parameters for the product can be set using a PC. The COM 1 (RS232) serial interface on the front panel is provided for this purpose. TAPCON trol software is needed for parameterization. It can be obtained from the Download Center on the Maschinenfabrik Reinhausen website ( Figure 10 Connecting the monitoring system to a PC 1 PC with TAPCON -trol software 2 Connection cable with RS232 / USB port 3 Monitoring system Maschinenfabrik Reinhausen /04 EN TAPGUARD

30 3 Product description CIC card The device can be optionally equipped with up to 2 additional communications interfaces (CIC card). These communication interfaces can be used to connect to a control system protocol and for parameterization. The second communication card (CIC2) is intended only for communication with the TAPCON -trol visualization software. The interface card is shown below. Figure 11 CIC card 1 RS232 (9 pin female SUB-D connector) 2 RS485 3 Ethernet RJ45 (optional) 4 FH-ST or F-SMA fiber-optic cable in 850 nm or 660 nm (optional) 5 Reset key 6 TxD LED for transmit signal 7 RxD LED for receive signal 8 Clk LED for operating mode (flashes for 2 seconds) 9 Clip for connecting cable shield with functional ground The available interfaces correspond to the information in the order. In other words, not all interface cards have all the interfaces shown above. 30 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

31 3 Product description 3.4 Operation and indicator elements The front of the monitoring system is subdivided into different areas for operating the device and displaying information. Below you can see an overview of the individual elements. Figure 12 Operating field of the monitoring system 1 LEDs 2 Keys for parameterization and configuration 3 COM1 serial interface (RS232) 4 Keys for operation management (only in conjunction with TAPCON 240) 5 Labeling strip for LEDs 6 Setting options for display contrast Maschinenfabrik Reinhausen /04 EN TAPGUARD

32 3 Product description Operating concept The monitoring system is operated by keys for parameterizing and configuring on the front panel of the device. Alternatively, configuration is also possible via the TAPCON -trol visualization software. The monitoring system is equipped with a key lock to prevent unintentional operation. To activate or deactivate, press the ESC and F5 keys simultaneously Description of the display Figure 13 Main screen 1 Status line 2 Progress bar for the maintenance interval 32 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

33 3 Product description Description of key functions Key Symbol Function RAISE No function (only for TAPCON 240). LOWER No function (only for TAPCON 240). REMOTE No function (only for TAPCON 240). MANUAL No function (only for TAPCON 240). AUTO No function (only for TAPCON 240). Arrow keys NEXT / PREV By pressing the arrow keys, you can set the display on the main screen. They can also be used to switch between windows in the submenus. ENTER ESC MENU Confirms or saves a changed parameter in the parameter menu. Pressing the ESC key takes you to the menu level above, in other words, always back one menu level. Pressing this key displays the menu selection window. F1-F5 The function keys are menu selection keys. They are also used to scroll through the menu subgroups and input screens and to mark decimal points which can be set by the user. Maschinenfabrik Reinhausen /04 EN TAPGUARD

34 3 Product description Description of LEDs The monitoring system has 10 light diodes above the display that signalize the different operating modes or events. Figure 14 Description of LEDs 1 Green Operating display 2 Red No function 3 Red No function 4 Red No function 5 Green No function 6 Green No function 7 Yellow No function 8 Yellow No function 9 Yellow No function 10 Green/yellow/red Event display 34 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

35 4 Mounting 4 Mounting If you have ordered TAPGUARD 240 combined with a TAPCON 240 voltage regulator, please be sure to read the assembly instructions in the voltage regulator operating instructions. 4.1 Unpacking The goods are packaged in a sturdy cardboard box. This ensures that the shipment remains in the intended transport position and that none of its components touches the load surface during transport or the floor after it is unloaded. Inlays inside the box stabilize the goods, preventing impermissible changes of position, and protect them from vibration. Unpack the voltage regulator as follows: 1. Remove the lid from the lower part of the cardboard box. The upper inlay contains the accessories supplied, the separate box labeled "Documentation" contains the device documents. 2. Check scope of supply for accessories. 3. Take the box labeled "Documentation" out of the cardboard box. 4. Remove the upper inlay from the packaging. 5. The voltage regulator in the underlying inlay can now be freely accessed. 6. Remove voltage regulator from the packaging. The voltage regulator has been unpacked and can be mounted. For mounting, proceed as described in the Mounting section. Maschinenfabrik Reinhausen /04 EN TAPGUARD

36 4 Mounting 4.2 Mounting After unpacking, the voltage regulator can be mounted. The voltage regulator's standardized plug-in housing is intended for fitting in a 19-inch control cabinet. We would recommend a design with a pivoting frame to allow easy access to the connections on the rear of the voltage regulator. The voltage regulator can be mounted in 4 different ways: Flush panel mounting 19" housing Flush panel mounting for half 19" housing Wall mounting for half 19" housing Wall mounting with terminal strip for half 19" housing 36 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

37 4 Mounting 4.3 Connection Cable recommendation for standard connections When wiring the voltage regulator, comply with the following recommendations from Maschinenfabrik Reinhausen. Cable Card Terminal Cable type Wire diameter Max. length Power supply SU X1: 1/2 unshielded 1.5 mm² - Voltage measurement MI/MI1 1/2 shielded 1.5 mm² - Current measurement MI/MI1 5/6/9/10 unshielded 4 mm² - Relay* IO X1: unshielded 1.5 mm² - X1: Relay* UC X1: unshielded 1.5 mm² - Signal inputs IO X1: shielded 1.0 mm² - X1: Signal inputs UC X1: shielded 1.0 mm² - X1: CAN bus CPU shielded 1.0 mm² 2000 m * Observe notices (see below) Table 12 Recommendation for connection cable NOTE Output relay malfunction Excessive electrical power can prevent the relay contacts from breaking the contact current. The effect of the cable capacitance of long control lines in control circuits operated with alternating current on the function of the relay contacts must be taken into account. Maschinenfabrik Reinhausen /04 EN TAPGUARD

38 4 Mounting Cable recommendation for optional connections Cable Card Terminal Cable type Wire diameter Max. length AC SU X1/2:1/2 unshielded 1.5 mm² - Analog inputs AD/AD 1 X1:1...3 shielded 1.5 mm² 400 m (< 25 Ω/km) Analog outputs AN/AN X1 shielded 1mm² - 1 RS-232 CIC X8 shielded 0.25 mm² 25 m RS-485 CIC X9 shielded 0.75 mm² 1000 m (< 50 Ω/km) Ethernet SID CIC RJ45 X7 shielded, CAT 7 Media converter MC1 Optical fiber with MTRJ- ST duplex patch cable Table 13 Recommendation for connection cable m TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

39 4 Mounting Electromagnetic compatibility The product was developed in compliance with the relevant EMC standards. To ensure compliance with the EMC standards, please note the following points Wiring requirement of installation site Note the following when selecting the installation site: The system's overvoltage protection must be effective. The system's ground connection must comply with all technical regulations. Separate system parts must be joined by a potential equalization. The voltage regulator and its wiring must be at least 10 m away from circuit-breakers, load disconnectors and busbars. Maschinenfabrik Reinhausen /04 EN TAPGUARD

40 4 Mounting Wiring requirement of operating site Note the following when wiring the operating site: The connection cables must be laid in metallic cable ducts with a ground connection. Do not route lines which cause interference (e.g. power lines) and lines susceptible to interference (e.g. signal lines) in the same cable duct. Maintain a gap of at least 10 cm between lines causing interference and those susceptible to interference. Reserve lines must be grounded at both ends. The voltage regulator must never be connected using four-pin collective cables. Figure 15 Recommended wiring 1 Cable duct for lines causing interference 2 Interference-causing line (e.g. power line) 3 Cable duct for lines susceptible to interference 4 Line susceptible to interference (e.g. signal line) 40 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

41 4 Mounting Signal lines must be routed in shielded cables. The individual conductors in the cable core (outgoing/return conductors) must be twisted in pairs. The shield must be fully (360º) connected to the voltage regulator or a nearby ground rail. Figure 16 Recommended shielding connection, do not extend the shield to the grounding point with a wire (pigtail). NOTE Reduced effectiveness of the shielding. Using "pigtails" may considerably reduce the effectiveness of the shielding. Connect shield to cover all areas. Maschinenfabrik Reinhausen /04 EN TAPGUARD

42 4 Mounting Wiring requirement in control cabinet Note the following when wiring the control cabinet: The control cabinet for fitting the voltage regulator must be prepared in accordance with EMC requirements: functional division of control cabinet (physical separation) constant potential equalization (all metal parts are joined) line routing in accordance with EMC requirements (separation of lines which cause interference and those susceptible to interference) optimum shielding (metal housing) overvoltage protection (lightning protection) collective grounding (main grounding rail) cable bushings in accordance with EMC requirements any protective inductors present must be interconnected The voltage regulator's connection cables must be laid in contact with the grounded metal housing or in metallic cable ducts with a ground connection. Signal and power/switching lines should be laid in separate cable ducts. 42 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

43 4 Mounting The voltage regulator must be grounded at the screw provided using a ground strap (cross-section min. 8 mm²). The voltage regulator's ground connection is a functional ground and serves to dissipate interfering currents. Figure 17 Ground strap connection Maschinenfabrik Reinhausen /04 EN TAPGUARD

44 4 Mounting Connecting the cables to the system periphery Connect the lines, which should be wired to the monitoring system, to the system periphery as shown in the connection diagrams supplied. WARNING Electric shock Connection mistakes may endanger life Earth the monitoring system using the grounding screw attached to the housing. Pay attention to the phase difference of the secondary terminals for the current and voltage transformers. Connect the output relays correctly to the motor-drive unit. NOTE Damages to the monitoring system and system periphery An incorrectly connected monitoring system can lead to damages in the monitoring system and system periphery. Prior to commissioning, be sure to check the entire configuration and the measuring and operating voltage. To obtain a better overview when connecting cables, only use as many leads as necessary. Use only the specified cables for wiring. You will find a cable recommendation in the corresponding section (see "Cable recommendation for standard connections" on page 37). To do the wiring, proceed as described in the Wiring section. 44 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

45 4 Mounting Supplying the monitoring system The monitoring system comes in a standard design with power supplied by a multi-voltage mains unit. The permissible supply voltage is V AC, DC. The alternative is the monitoring system with a supply mains unit for the V DC or V DC range Wiring of the monitoring system Wire the monitoring system according to the connection diagram. WARNING Electric shock Connection mistakes may endanger life Earth the monitoring system using the grounding screw attached to the housing. Pay attention to the phase difference of the secondary terminals for the current and voltage transformers. Connect the output relays correctly to the motor-drive unit. NOTE Damages to the monitoring system and system periphery An incorrectly connected monitoring system can lead to damages in the monitoring system and system periphery. Prior to commissioning, be sure to check the entire configuration and the measuring and operating voltage. To obtain a better overview when connecting cables, only use as many leads as necessary. Maschinenfabrik Reinhausen /04 EN TAPGUARD

46 4 Mounting 4.4 Function check Perform a function check to make sure the monitoring system is correctly wired. Check the following: After turning the device on, the monitor displays the MR logo and then the maintenance status. The green LED "Operating display" top left on the monitoring system lights up. The monitoring system can now be configured. The actions required for this are described in the following chapter (see "Commissioning" on page 47). 46 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

47 5 Commissioning 5 Commissioning Several parameters need to be set and function tests performed before commissioning the device. These are described in the following chapter. 5.1 Configuration The relevant settings for commissioning are described in more detail in the following sections. When the TAPGUARD 240 monitoring system is combined with a TAP- CON 240 voltage regulator, additional menu points and parameters appear. To adjust additional parameters, please read the operating instructions for the TAPCON 240 voltage regulator. Maschinenfabrik Reinhausen /04 EN TAPGUARD

48 5 Commissioning Setting the language The display language can be set or changed as desired. The following languages are available: English German French Spanish Italian Portuguese 1. > Configuration > General. <00> Language. 2. Press or to select the required language. 3. Press. The language is set. 48 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

49 5 Commissioning Activating/deactivating display dimming If you activate this function, the display is automatically dimmed if no key is pressed within a period of 15 minutes. However, the display can still be read. Activating this function extends the lifespan of the display. The display returns to full brightness by pressing any key. 1. > Configuration > General > 10x. <10> Display off. 2. Press or to switch display on (ON) or off (OFF). 3. Press. Display is switched ON/OFF. Maschinenfabrik Reinhausen /04 EN TAPGUARD

50 5 Commissioning Setting the display contrast You can adjust the contrast in the display with the help of an adjustment screw on the front of the device. To adjust the contrast, proceed as follows: Use a screwdriver to turn the adjustment screw on the front until the contrast is adjusted to the desired setting. Figure 18 Setting the display contrast 50 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

51 5 Commissioning Setting system time You can set the system time in this display. The time format can be set using the 24-hour format: HH:MM:SS To set the system time, proceed as follows: 1. > Configuration > Continue > Continue > Memory > 6x. <06> Time. 2. Press or to select the number to be edited. The digit position you want is highlighted and can be changed. 3. Press or to edit the digit. 4. Press. The system time is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

52 5 Commissioning Setting system date You can set the system date in this display. The system date can be set from to and has the following format: DD:MM:YY To set the system date, proceed as follows: 1. > Configuration > Continue > Continue > Memory > 7x. <07> Date. 2. Press or to select the number to be edited. The digit position you want is highlighted and can be changed. 3. Press or to edit the digit. 4. Press. The system date is set. 52 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

53 5 Commissioning 5.2 Tap position capture The current tap position of the on-load- tap-changer is transferred from the motor-drive unit to the monitoring system. The tap position can be transferred via the following methods: Analog signal by means of the tap position transmitter (resolver) Digital signal via BCD Digital tap position capture with BCD signal The tap position is normally transferred as a digital signal from the motor-drive unit to the monitoring system. To do so, the tap position is converted into a BCD signal. For this purpose, the following components in the motor-drive unit are necessary: A tap position reporting device tap position 1...n A diode matrix installed downstream as code converter (tap position 1...n to BCD) The corresponding data lines between the motor-drive unit and the monitoring system Analog tap position capture (optional) As an option, tap position capture can occur as an analog signal. For this purpose, the device is equipped with an AD analog card. The device is configured at the factory according to the order. However, should modifications be necessary, please read the following sections. Maschinenfabrik Reinhausen /04 EN TAPGUARD

54 5 Commissioning Setting lower limit value (%) for input 1 To configure the analog input, the lower value of the input signal must be specified. With injected current as the transmitter signal, 0 % should be entered for 0 ma. 20 % should be entered for 4 ma. Example: Tap position Current Value Minimum tap position 1 Table 14 4 ma Example for configuring the analog input 20 % of analog input signal range If the signal transmitter for capturing the tap position is a resistor contact series, then 20 % should generally be set. Setting range Step size Factory setting 0 % % 0.1 % 0 % Table 15 Setting range of analog value - lower limit value as % 54 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

55 5 Commissioning To assign the analog value for the lower limit, proceed as follows: 1. > Configuration > Continue > Analog inputs. <00> Input 1, lower limit. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The analog value for the lower limit is assigned. Maschinenfabrik Reinhausen /04 EN TAPGUARD

56 5 Commissioning Setting upper limit value (%) for input 1 To configure the analog input, the upper value of the input signal must be specified. With impressed current as the transmitter signal, 20 % should be entered for 0 ma. Example: Tap position Current Value Maximum tap position 19 Table ma 100 % of analog input signal range Example for configuring the analog input (maximum) If the signal transmitter for capturing the tap position is a resistor contact series, then 100 % should generally be set. Setting range Step size Factory setting 0 % % 0.1 % 100 % Table 17 Setting range of analog value - upper limit value as % 56 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

57 5 Commissioning To assign the analog value for the upper limit, proceed as follows: 1. > Configuration > Continue > Analog inputs > 1x. <01> Input 1, upper limit. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The analog value for the upper limit is assigned. Maschinenfabrik Reinhausen /04 EN TAPGUARD

58 5 Commissioning Setting lower limit value (absolute) of input 1 To configure the analog input, an absolute value must be assigned to the lower value of the applied signal. Example: You can set "1" for the lowest tap position. Table 18 Setting range Step size Factory setting / Setting range for lower limit value (absolute value) 1. > Configuration > Continue > Analog inputs > 2x. <02> Input 1, lower value. 2. Press to increase the value or to reduce it. 3. Press. The lowest tap position is set. 58 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

59 5 Commissioning Setting upper limit value (absolute) for input 1 To configure the analog input, an absolute value must be assigned to the upper value of the applied signal. Example: You can set "25" for the highest tap position. Setting range Step size Factory setting / Table 19 Setting range for upper limit value (absolute value) To set the highest tap position, proceed as follows: 1. > Configuration > Continue > Analog inputs > 3x. <03> Input 1, upper value. 2. Press to increase the value or to reduce it. 3. Press. The highest tap position is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

60 5 Commissioning Setting lower limit value (%) for input 2 To configure the analog input, the lower value of the input signal must be specified. With injected current as the transmitter signal, 0 % should be entered for 0 ma. 20 % should be entered for 4 ma. Example: Tap position Current Value Minimum tap position 1 Table 20 4 ma Example for configuring the analog input 20 % of analog input signal range If the signal transmitter for capturing the tap position is a resistor contact series, then 20 % should generally be set. Setting range Step size Factory setting 0 % % 0.1 % 0 % Table 21 Setting range of analog value - lower limit value as % 60 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

61 5 Commissioning To assign the analog value for the lower limit, proceed as follows: 1. > Configuration > Continue > Analog inputs > 4x. <04> Input 2, lower limit. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The analog value for the lower limit is assigned. Maschinenfabrik Reinhausen /04 EN TAPGUARD

62 5 Commissioning Setting upper limit value (%) for input 2 To configure the analog input, the upper value of the input signal must be specified. With impressed current as the transmitter signal, 20 % should be entered for 0 ma. Example: Tap position Current Value Maximum tap position 19 Table ma 100 % of analog input signal range Example for configuring the analog input (maximum) If the signal transmitter for capturing the tap position is a resistor contact series, then 100 % should generally be set. Setting range Step size Factory setting 0 % % 0.1 % 100 % Table 23 Setting range of analog value - upper limit value as % 62 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

63 5 Commissioning To assign the analog value for the upper limit, proceed as follows: 1. > Configuration > Continue > Analog inputs > 5x. <05> Input 2, upper limit. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The analog value for the upper limit is assigned. Maschinenfabrik Reinhausen /04 EN TAPGUARD

64 5 Commissioning Setting lower limit value (absolute) of input 2 To configure the analog input, an absolute value must be assigned to the lower value of the applied signal. Example: You can set "1" for the lowest tap position. Table 24 Setting range Step size Factory setting / Setting range for lower limit value (absolute value) 1. > Configuration > Continue > Analog inputs > 6x. <06> Input 2, lower value. 2. Press to increase the value or to reduce it. 3. Press. The lowest tap position is set. 64 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

65 5 Commissioning Setting upper limit value (absolute) for input 2 To configure the analog input, an absolute value must be assigned to the upper value of the applied signal. Example: You can set "25" for the highest tap position. Setting range Step size Factory setting / Table 25 Setting range for upper limit value (absolute value) To set the highest tap position, proceed as follows: 1. > Configuration > Continue > Analog inputs > 7x. <07> Input 2, upper value. 2. Press to increase the value or to reduce it. 3. Press. The highest tap position is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

66 5 Commissioning 5.3 Transformer data This section describes how to set the transformer data. You have to set the following parameters for the device to function correctly: Primary transformer current Current transformer connection Setting the primary transformer current Primary current No parameterization No parameterization 50 A 50 A In general the voltage regulator displays the percentage current of the chosen measurement input. As soon as the primary rated current (e.g. 50 A) is set on the voltage regulator, the display in the Info menu switches over to "A" (amperes). The primary current is always displayed in "A" on the main screen or as "0" if no primary current is specified. Setting parameter Secondary current Current feed Electrical connection Display Info screen Primary / secondary current Main screen Unknown 1 A 100 % 0 A 1 A 1 A 1 A 0 A Unknown 1 A 100 % (of primary current) 1 A 1 A 1 A (of secondary current) 50 A (of primary current) 50 A (of primary current) Table 26 Example of unit displayed: % / A 66 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

67 5 Commissioning Setting range Step size Factory setting 100 A 10,000 A 1 A 200 A Table 27 Setting range for primary transformer current To set the primary transformer current, proceed as follows: 1. > Configuration > Transformer data > 2x. <02> Primary current. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press.. The primary transformer current is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

68 5 Commissioning Setting the current transformer connection The current transformer connection must be selected in order to obtain the correct display. If you set the current transformer connection to "Unknown" in the display, the percentage value is shown. However, if a connection is selected, the absolute value (in amps) is displayed. The following values can be set: 0.2 A 1 A 5 A To set the current transformer connection, proceed as follows: 1. > Configuration > Transformer data > 3x. <03> Current transformer connection. 2. Press or to select the required terminal. 3. Press. The current transformer connection has been set. 68 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

69 5 Commissioning 5.4 Setting the operating position of the on-load tap-changer Using the following parameters, you can define the top and the bottom operating position of the on-load tap-changer. The device is configured at the factory according to the order. However, should modifications be necessary, please read the following sections. Table 28 Setting range Step size Factory setting acc. to order Setting range for the top and bottom operating position of the on-load tap-changer To set the top and bottom operating position, proceed as follows: 1. > Configuration > Continue > Continue > OLTC > 2x/3x. <02/03> Top/bottom operating position. 2. Press to increase the value or to reduce it. 3. Press. The top/bottom operating position is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

70 5 Commissioning 5.5 Configure communications interfaces The monitoring system has the following communication interfaces: COM1 serial interface CIC card (optional) You can find an overview of the available interfaces in the Communication interfaces on page 29 section. When configuring the communication interfaces, you have 2 options to enter the network data: directly on the TAPGUARD 240 using TAPCON -trol software If you use the TAPCON -trol software, we recommend you enter the network data via your PC. Before initially configuring the network data using the TAPCON -trol software, you have to install this software on your computer. The TAPCON -trol software CD also contains relevant operating instructions. Follow the below steps: Please read the TAPCON -trol operating instructions thoroughly. Connect your computer using the serial cable included and, if applicable, the USB adapter, to the serial interface on the front panel of the TAP- GUARD 260. In the system settings of your PC, define the COM interface used for the serial connection. Install the software on your computer and follow the steps described in TAPCON -trol operating instructions. 70 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

71 5 Commissioning Setting the COM1 serial interface The COM1 serial interface is located on the front panel of the device. This interface establishes a connection to a computer by means of the TAPCON trol visualization software. The next section describes which parameters have to be set on the device to establish a connection to the PC Setting the regulator ID The regulator ID consists of a 4-digit sequence of digits and is used as additional identification for a voltage regulator. Identification is only used for the "TAPCON -trol - Software" visualization. If you do not want to set the regulator ID, the serial number and firmware version are the only features. The regulator ID can be used to ensure that the connection is established between the visualization software and a specific voltage regulator. During online communication, the software running on the PC queries this ID and compares it with the regulator data available. This enables accurate assignment of data or parameters. Maschinenfabrik Reinhausen /04 EN TAPGUARD

72 5 Commissioning To set the regulator ID, proceed as follows: 1. > Configuration > General > 1x. <01> Regulator ID. 2. Press to change the first digit. If you wish to enter a multi-digit sequence, proceed to step 3. If you do not wish to enter additional digits, proceed to step 7: 3. Press repeatedly (digit > 9) until another position appears. 4. If necessary press to highlight a digit position. The digit position you want is highlighted and can be changed. 5. Press or to change the digit. 6. Repeat steps 3 to 5 until all required digits have been entered. 7. Press. 8. The regulator ID is set. 72 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

73 5 Commissioning Setting the COM1 baud rate In this display, you can set the baud rate for the COM1 interface, for example to define the speed of transfer for communication with the TAPCON -trol software. The following values can be set: 9.6 kilobaud 19.2 kilobaud 38.4 kilobaud 57.6 kilobaud To set the baud rate, proceed as follows: 1. Press. The manual mode is active and the associated LED lights up. 2. > General > 2x. <02> COM1 setting. 3. Press or to set the option you want. 4. Press. The baud rate is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

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75 6 Functions and settings 6 Functions and settings This chapter describes the functions and setting options for the device. 6.1 Calling up general information The following section describes the screens that allow you to call up general information on the device Displaying the info screen Information on the device can be viewed here. Figure 19 Info screen 1 Type designation 2 Software version 3 Date of issue 4 Size of EEPROM / ID number of module 5 Flash memory 6 RAM memory Maschinenfabrik Reinhausen /04 EN TAPGUARD

76 6 Functions and settings To display the info screen, proceed as follows: > Info <00> Info Carrying out LED test An LED function test can be carried out based on the information displayed. This checks whether all the LEDs are functioning properly. This function only tests the functional reliability of the LEDs. The underlying function is not therefore tested. To carry out the LED test, proceed as follows: 1. > Info > 2x. <02> LED TEST. 2. To carry out the function test, press any F key for the LED you want to test. Key LED no LED 1... LED 5 LED 6... LED 9 All LEDs Table 29 Selecting the LEDs for tests 76 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

77 6 Functions and settings Resetting parameters With this display you can reset your settings to the factory settings. To reset the parameters, proceed as follows: If you reset the parameters to the factory settings, then your settings are permanently deleted. 1. > Info > 6x. <06> Parameter. 2. Press and at the same time. 3. Press. All parameters have been reset to the factory settings. Maschinenfabrik Reinhausen /04 EN TAPGUARD

78 6 Functions and settings Displaying real-time clock A counter is started when the voltage regulator is first switched on. This continues to run even if the device is switched off. To display the real-time clock, proceed as follows: > Info > 7x. <07> RTC Displaying upcoming messages This display shows upcoming messages, such as: Undervoltage Overvoltage Fault in parallel operation etc. To display the upcoming messages, proceed as follows: > Info > 13x. <16> UPCOMING MESSAGES. 78 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

79 6 Functions and settings Displaying the LOG file The LOG file documents confirmation of maintenance work undertaken. Once maintenance has been done and the corresponding reset then performed, the name and time are entered automatically. The LOG file can be displayed and prepared using the TAPCON -trol visualization software. For more information, please read the operating instructions for thetapcon -trol visualization software. To display the LOG file, proceed as follows: 1. > Info > 16x. <22> LOG file. 2. Press or to scroll slowly (line-byline), or to scroll quickly (page-bypage). Maschinenfabrik Reinhausen /04 EN TAPGUARD

80 6 Functions and settings 6.2 Measured values The current measured values of the on-load tap-changer are located in the Measured value display under the Info menu point. In addition, you can display the measured value raw data from the inputs and outputs Displaying measurement values To display the measured values, proceed as follows: Menu > Info > 1x. <01> Measured values. 80 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

81 6 Functions and settings Display measured value raw data In the Info menu, you can call up all measured raw data from the respective cards. You can display the raw data of the following cards: Input / Output Card UC1 card UC2 card All active messages or signals from all cards are displayed in the status displays. The displays have the following structure: Figure 20 Status display 1 Signalling status 2 Control inputs/output relays 3 Signalling status 4 Control inputs/output relays The following sections describe how you can display the respective status windows. Maschinenfabrik Reinhausen /04 EN TAPGUARD

82 6 Functions and settings Displaying input/output status The status of the respective optocoupler inputs is shown under "INPUT / OUTPUT-STATUS". As soon as a continuous signal is present at the input, it is shown in the display with a "1". "0" indicates no signal at the input. To query the status, proceed as follows: > Info > 3x <03> INPUT/OUTPUT STATUS Querying status of UC1 card The status of the respective optocoupler inputs is shown under "UC1 CARD STATUS". As soon as a continuous signal is present at the input, it is shown in the display with a "1". "0" indicates no signal at the input. To query the status, proceed as follows: > Info > 4x <04> UC1 CARD STATUS. 82 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

83 6 Functions and settings Querying status of UC2 card The status of the respective optocoupler inputs is shown under "UC2 CARD STATUS". As soon as a continuous signal is present at the input, it is shown in the display with a "1". "0" indicates no signal at the input. To query the status, proceed as follows: > Info > 5x <06> UC3 CARD STATUS Displaying measured value memory As an option, the voltage regulator can be equipped with a long-term memory module. You can display information about the memory in this window. To display the measured value memory, proceed as follows: > Info > 12x. <12> MEASURED VALUE MEMORY. Maschinenfabrik Reinhausen /04 EN TAPGUARD

84 6 Functions and settings Displaying peak memory The minimum and maximum voltage measured since the last reset and the minimum and maximum on-load tap-changer tap positions are shown here. All values recorded are stored with a time and date. The minimum and maximum values continue to be stored in an internal fixed value memory even in the event of power failure. Figure 21 Peak memory: Minimum (left) and maximum values (right) 1 Maximum measured voltage V1 2 Maximum on-load tap-changer tap position 3 Time (HH:MM:SS) and date (DD.MM.YY) of maximum measured voltage V1 4 Time (HH:MM:SS) and date (DD.MM.YY) of maximum recorded tap position 5 Time (HH:MM:SS) and date (DD.MM.YY) of minimum recorded tap position 6 Time (HH:MM:SS) and date (DD.MM.YY) of minimum measured voltage V1 7 Minimum on-load tap-changer tap position 8 Minimum measured voltage V1 84 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

85 6 Functions and settings To display the peak memory, proceed as follows: > Info > 13x. <13> Peak memory. 6.3 Maintenance The monitoring system monitors the state of the on-load tap-changer and determines when the next maintenance is due. The monitoring system administers the following maintenances: Abrasion parts Parts replacement Diverter switch insert replacement Tap selector inspection Tap selector replacement Oil change and cleaning Oil change and cleaning Oil filter change (only when operating an oil filter unit) Contact wear (only with OILTAP on-load tap-changer types) Replacement of the vacuum interrupters (only VACUTAP on-load tapchanger types) Oil sample On-site time interval and on-site operations interval Maschinenfabrik Reinhausen /04 EN TAPGUARD

86 6 Functions and settings Displaying the maintenance status You will find an overview of the current maintenance status in this screen. The different maintenance activities are combined into 5 groups and stored in a progress bar. The progress bar shows the progress in percent of the maintenance interval. The progress bar always refers to the most advanced maintenance. Depending on the type of on-load tap-changer, the following maintenance criteria are displayed: OILTAP Abrasion parts Oil change + cleaning Contact wear Oil sample Operator interval VACUTAP Abrasion parts Oil change + cleaning Vacuum interrupters Oil sample Operator interval Table 30 Maintenance criteria 86 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

87 6 Functions and settings To request additional information on the maintenance criteria, proceed as follows: 1. Press desired functional key (... ) and hold down. The information screen is displayed. 2. If necessary, in addition to the already pressed function key, press maintenances. to display further The forecast data indicate when the next maintenance is due. These data are determined depending on condition. For a correct forecast, at least 200 tap-change operations are required. If this number of tap-change operations is not achieved, the standard values are displayed. Maschinenfabrik Reinhausen /04 EN TAPGUARD

88 6 Functions and settings Enter Service password The Service password is used to protect the monitoring system from unauthorized access. The following activities cannot be performed until the correct password is entered: Setting contact wear Resetting maintenance To enter the Service password, proceed as follows: 1. > configuration > 3 x Continue > Service. <00> TAPGUARD password. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The Service password is set. 88 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

89 6 Functions and settings Maintenance events The monitoring system informs you of an impending maintenance in 2 steps: Message of an impending maintenance (e. g. at 90 % of the respective limit value) Impending maintenance (at 100 % of the respective limit value) The announcement of an impending maintenance is signaled by a blinking progress bar. In the case of an impending maintenance, a warning display additionally appears. The warning display can be temporarily hidden. To hide warning messages, proceed as follows: Press. The warning display is temporarily hidden. The warning display is shown again after each tap-change operation as long as the impending maintenance was not performed and confirmed. Maschinenfabrik Reinhausen /04 EN TAPGUARD

90 6 Functions and settings Setting the maintenance announcement The limit for announcing a maintenance is set using this parameter. If this limit value is achieved, the corresponding progress bar blinks in the maintenance status display. Table 31 Setting range Step size Factory setting 0.0 % % 0.1 % 90 % Setting range for the maintenance announcement To set the maintenance announcement, proceed as follows: 1. > Configuration > 1x Continue > Maintenance <00> Abrasion parts message. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The maintenance announcement is set. 90 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

91 6 Functions and settings You can determine these parameters for the following maintenances separately: Maintenance announcement Press Page number in the display Abrasion parts - <00> Diverter switch insert 1x <01> exchange Tap selector 2x <02> inspection Oil change and 3x <03> cleaning Contact wear 4x <04> Oil sample 5x <05> Table 32 Setting the maintenance announcement Confirm maintenance If maintenance was performed, this must be confirmed in the monitoring system. Only confirmed maintenances do not result in new maintenance events. As soon as a maintenance is confirmed, a corresponding note is written in the maintenance history database. The wear values of the on-load tap-changer contacts are measured during maintenance work on the abrasion parts and have to be entered in the corresponding Menu prior to confirming maintenance. Maschinenfabrik Reinhausen /04 EN TAPGUARD

92 6 Functions and settings To confirm maintenance, proceed as follows: 1. Enter Service password (Page 88). 2. > Configuration > 3x > Service > 1x. <00> TAPGUARD password. 3. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 4. Press to increase the value or to reduce it. 5. Press. The TAPGUARD password is set. 6. Press as often as it takes until the desired display appears. <01> Reset abrasion parts. 7. Press to select the Yes option. 8. Press. a security question appears. 9. Simultaneously press and to confirm maintenance. Maintenance is confirmed. 92 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

93 6 Functions and settings Each maintenance can be confirmed separately: Maintenance Press Page number in the display Abrasion parts 1x <01> Oil change and 2x <02> cleaning Diverter switch insert 3x <03> exchange Tap selector 4x <04> inspection Oil sample 5x <05> Operator number of 6x <06> tap-change operations Operator time 7x <07> Oil filter change 8x <08> Vacuum interrupter (only VACUTAP ) 9x <09> Table 33 Confirm maintenance Contact wear When monitoring the OILTAP type on-load tap-changers, the monitoring system calculates the following values after each operation: Switching contact wear Resistance contact wear Oil soot The monitoring system checks the calculated values with regard to the following limit values: Absolute value of the wear Difference in wear between main switching contact and resistance contact Difference in wear between two resistance contacts After maintenance work on the on-load tap-changer, the computed wear of the switch contacts and the resistance contacts have to be entered into the monitoring system. The monitoring system adapts its calculation model automatically using the computed wear. By doing so, future calculations of the wear will be even more precise. Maschinenfabrik Reinhausen /04 EN TAPGUARD

94 6 Functions and settings Determining contact wear The thickness of the wear to be entered is the sum of the wear of the movable and the fixed contact part. Figure 22 Determining the contact wear 1 Fixed contact 2 Movable contact x 1 Thickness of the contact coating when new (fixed contact) Thickness of the worn contact coating (fixed contact) y 1 x 2 y 2 Thickness of the contact coating when new (movable contact) Thickness of the worn contact coating (movable contact) The thickness of the wear to be entered is determined as follows: z = x 1 - y 1 + x 2 - y 2 If more than one on-load tap-changer is monitored by the monitoring system, the thickest layer of wear has to be entered. 94 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

95 6 Functions and settings Setting contact wear You have to enter the previously determined contact wear for each switching and resistance contact. Setting range Step size Factory setting mm mm mm 0.00 mm Table 34 Setting range for contact wear The monitoring system ignores contact wear entries that deviate heavily from the calculated value (z entry > 10 z calculated ) in order to avoid entry errors. Nevertheless, if you would like to enter a value that heavily deviates, the contact wear has to be set to 0.00 mm beforehand. To enter the computed wear, proceed as follows: 1. Enter Service password (Page 88). 2. > Configuration > 3 x > Service. <00> TAPGUARD password. 3. > Div. sw. insert > / / div. sw. insert 1 / 2 / 3 > Press as often as it takes until the desired display appears. <01> SKA. 4. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 5. Press to increase the value or to reduce it. 6. Press. The switch contact wear is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

96 6 Functions and settings You can also set the wear z for all further contacts as described above. To activate the corresponding parameter screen, pay attention to the following table: Contact Press Page number in the display SKA - <00> SKB 1x <01> WKA / WK1A 2x <02> WKB / WK1B 3x <03> WK2A* 4x <04> WK2B* 5x <05> Table 35 Setting contact wear * The resistance contacts WK2A and WK2B are not available for every onload tap-changer. If these contacts are not available, the value 0.00 mm has to be set. 96 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

97 6 Functions and settings Operator limit values You can use these parameters to determine your own limit values. These limit values are displayed in the bottom progress bar of the maintenance status. You can set the following limit values: Number of tap-change operations: Time interval Setting the operator tap-change operation interval This parameter defines a tap-change operation interval. This interval defines the maximum number of tap-change operations. Table 36 Setting range Step size Factory setting * Setting range for the operator tap-change operation interval * The set value has to be multiplied by 1000 to obtain the tap-change operation interval. Example: if the value is set to 300, the tap-change interval is 300,000. To set the tap-change operation interval, proceed as follows: 1. > Configuration > 4x Continue > Operator. <00> On-site operations interval. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The on-site operations interval is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

98 6 Functions and settings Setting the message for the on-site operations interval This parameter sets the limit for the message for the number of on-site operations intervals. If this limit value is achieved, the corresponding progress bar blinks in the maintenance status display. Table 37 Setting range Step size Factory setting 0.0 % % 0.1 % 90 % Setting range for the message for the number of on-site operations intervals. In order to set the message for the number of on-site operations intervals, proceed as follows: 1. > Configuration > 4x Continue > Operator > 1x. <01> on-site ops message 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The on-site operations interval message is set. 98 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

99 6 Functions and settings Setting the on-site time interval This parameter defines a time interval. Together with the "On-site date interval" parameter, the time interval calculates the status bar. Setting range Step size Factory setting 0.00 years years 0.01 years years Table 38 Setting range for on-site time interval To set the time interval, proceed as follows: 1. > Configuration > 4x Continue > Operator > 2x. <02> On-site time interval. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The time interval is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

100 6 Functions and settings Setting the date for the operator interval This parameter defines the final date for the operator interval. The date can be set from to and has the following format: DD:MM:YY The time format can be set using the 24-hour format: HH:MM:SS To set the on-site interval date, proceed as follows: 1. > Configuration > 4x Continue > Operator > 3x. <03> On-site interval date. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The date for the operator interval is set. 100 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

101 6 Functions and settings Setting the announcement of the operator interval The limit for announcing an operator interval is set using this parameter. If this limit value is achieved, the corresponding progress bar blinks in the maintenance status display. Table 39 Setting range Step size Factory setting 0.0 % % 0.1 % 90 % Setting range for the operator interval announcement. To set the announcement of for the operator interval, proceed as follows: 1. > Configuration > 4x Continue > Operator > 4x. <04> On-site time interval message. 2. Press to highlight a digit. The digit position you want is highlighted and the value can be changed. 3. Press to increase the value or to reduce it. 4. Press. The announcement for the operator interval is set. Maschinenfabrik Reinhausen /04 EN TAPGUARD

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103 7 Fault elimination 7 Fault elimination The following chapter describes how to eliminate simple operating faults and the meaning of possible event messages. 7.1 Operating faults If faults occur in the device during operation, these can usually be remedied by the user. The tables below are intended to provide assistance in recognizing and remedying faults Man Machine Interface Characteristics/detail Cause Remedy Contrast incorrectly set. Display No display. Voltage supply interrupted. Set contrast using resistor contact series in front panel. Check voltage supply. Display Different brightness if there are several monitoring systems. COM1 Cannot be connected to PC using TAPCONtrol Fuse faulty. Display dimming activated/deactivated. Different baud rates set. Replace fuse. Check "Display dimming" setting. Check "Baud rate" parameter (monitoring system and TAP- CON -trol). Correct if necessary. Table 40 Troubleshooting: Man Machine Interface Maschinenfabrik Reinhausen /04 EN TAPGUARD

104 7 Fault elimination Digital inputs Characteristics/detail Cause Remedy Signal discontinuous. Intermittent DC voltage. Check source of DC voltage. Check signal transmitter. Check wiring. Table 41 Troubleshooting: Digital inputs General fault Characteristics/detail Cause Remedy No function Fuse tripped. Check all fuses. Supply voltage. Replace if necessary. Relays chatter Supply voltage too low. Check supply voltage. Table 42 Troubleshooting: General faults No solution If you cannot resolve a problem, please contact Maschinenfabrik Reinhausen. Please have the following data to hand: Serial number This can be found: Outer right side when viewed from the front Info screen ( > Info) Please provide answers to the following questions: Has a firmware update been carried out? Has there previously been a problem with this device? Have you previously contacted Maschinenfabrik Reinhausen about this issue? If yes, then who was the contact? 104 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

105 8 Technical Data 8 Technical Data 8.1 Indicator elements Display LEDs Table 43 Indicator elements LCD, monochrome, graphics-capable 128 x 128 pixels 15 LEDs for operation display and messages 8.2 Electrical data Power supply Power consumption 110 (-20%) V DC V AC Optional: V DC or V DC 25 VA Table 44 Electrical data 8.3 Inputs and outputs Control voltage of inputs Contact loadability of outputs V DC With pulsating DC voltage, the voltage minimum must always exceed 40 V. min. 12 V / 100 ma max. AC 250 V / 5 A max. DC see diagram Table 45 Inputs and outputs Maschinenfabrik Reinhausen /04 EN TAPGUARD

106 8 Technical Data Figure 23 Maximum contact loadability of outputs with direct current 1 Ohmic load 8.4 Dimensions and weight Housing (W x H x D) Weight Table 46 Dimensions and weight 19-inch plug-in housing in accordance with DIN Part x 133 x 178 mm 5.0 kg 106 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

107 8 Technical Data 8.5 Voltage and current measurement Voltage transformer Current transformer Measuring error Measuring range: V Effective value: Hz Intrinsic consumption: < 1 VA 0.2 / 1 / 5 A Effective value: Hz Intrinsic consumption: < 1 VA Overload capacity: 2 x I N (continuously), 40 x I N / 1 s Voltage measuring: < 0.3 % ± 40 ppm/ C Current measuring: < 0.5 % ± 40 ppm/ C Table 47 Voltage and current measurement 8.6 Ambient conditions Operating temperature Storage temperature -25 C C -30 C C Table 48 Permissible ambient conditions 8.7 Tests Electrical safety EN Safety requirements for electrical measurement and control and regulation equipment and laboratory instruments IEC Dielectric test with operating frequency 2.5 kv / 1 min IEC Dielectric test with impulse voltage 5 kv, 1.2 / 50 μs IEC Level of contamination 2, overvoltage category III Table 49 Electrical safety Maschinenfabrik Reinhausen /04 EN TAPGUARD

108 8 Technical Data EMC tests IEC Electrostatic discharges (ESD) 6 kv /8 kv IEC Electromagnetic fields (HF) 10 V/m MHz IEC Fast transients (burst) 2 kv IEC Surge transient immunity 2 kv IEC HF interference immunity (lines) 10 V, 150 khz...80 MHz IEC Power frequency magnetic field immunity 30 A/m, 50 Hz, continuous IEC Voltage dips, short interruptions and voltage variations immunity tests IEC Voltage dips, short interruptions and voltage variations on d.c. input power port immunity tests IEC Immunity requirements for industrial environments IEC Emission standard for industrial environments Table 50 EMC tests Environmental durability tests DIN EN Degree of protection IP20 IEC Dry cold - 25 C / 20 hours IEC Dry heat + 70 C / 16 hours IEC Constant moist heat + 40 C / 93% / 2 days, no dew IEC Cyclic moist heat ( hours) + 55 C / 93 % / 6 cycles Table 51 Environmental durability tests 108 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

109 9 Menu overview 9 Menu overview The following sections give an overview of the relevant menus and submenus. Level 1 Level 2 Parameters Primary current (Page 66) Current transformer connection (Page 66) Language (Page 48) Regulator ID (Page 71) COM1 Setting (Page 71) Display dark (Page 49) Input 1 lower limit Input 1 upper limit Input 1 lower value Input 1 upper value (Optional) Time (Page 51) Date (Page 52) Maschinenfabrik Reinhausen /04 EN TAPGUARD

110 9 Menu overview Level 1 Level 2 Parameters Abrasion parts announcement (Page 90) Diverter switch insert exchange announcement Tap selector inspection announcement Oil change and cleaning announcement Contact wear announcement Oil sample announcement On-load tap-changer type* On-load tap-changer serial number* Lower operating position (Page 69) Top operating position (Page 69) Average step voltage* R1* R2* Factor "s" of current splitting* Parallel sectors* *) Parameter is pre-set and may only be changed by MR. SKA (Page 93) SKB WKA / WK1A WKB / WK1B WK2A WK2B 110 TAPGUARD /04 EN Maschinenfabrik Reinhausen 2011

111 9 Menu overview Level 1 Level 2 Parameters Operator tap-change operation interval Operator tap-change operation interval On-site time interval On-site date interval On-site time interval message TAPGUARD password (Page 88) Reset abrasion parts (Page 91) Reset oil change Reset DSI exchange Reset tap selector inspection Reset oil sample Reset number of operator tap-change operations Reset operator time Reset oil filter change Info (Page 75) Measured values (Page 80) LED test (Page 76) Input/output status (Page 82) UC1 card status (Page 82) Parameters (Page 77) RTC (Page 78) Parallel operation Data on CAN bus Measured value memory (Page 83) Peak memory (Page 84) Upcoming messages (Page 78) LOG file (Page 79) Maschinenfabrik Reinhausen /04 EN TAPGUARD