www.reinhausen.com Digital On-Load Tap Changer Voltage Controller Operating Instructions (short version) BA 289 Defined movement of the drive shaft REGULATING TRANSFORMER Changing the Transformer Ratio MOTOR-DRIVE Drive Shaft Actual voltage LOAD PROFILE Need of Power Changes Control pulse for changing the tap position Regulating circuit Power grid REFERENCE VOLTAGE LEVEL TAPCON Matching Actual and Reference Voltage
Contents 1 Safety... 3 2 Technical Data/Information... 6 3 General Information... 8 4 Connection... 8 5 User Interface... 9 6 Typical External Connections... 12 7 Parameters... 14 8 Accessories... 21 NOTE! The product may have been modified after this document went to press. We expressly reserve the right to make changes to the technical data, the design or the scope of delivery. In general, the information provided and the arrangements agreed during processing of the relevant offers and orders are binding. 2 Operating Instructions - short version
1 Safety 1.1 Safety labels The following safety labels relating to the operation of the are used in these operating instructions. These labels must be observed at all times! DANGER! Refers to an imminent danger that may result in death or severe injury. WARNING! Refers to a potentially hazardous situation that may result in death or severe injury. CAUTION! Refers to a potentially hazardous situation that may result in slight injury or material damage. NOTE! Contains important information and special notes. Special safety labels are used for certain hazards, such as electric shock. The following specific safety warnings are used in these operating instructions: DANGER! Fire hazard! DANGER! Risk of electric shock! Operating Instructions - short version
1.2 Safety instructions All warnings and safety instructions must be observed at all times! Danger of death and risk of injury! Not following the safety instructions may lead to accidents and severe personal injury. Please read these operating instructions before commissioning the equipment! Read the operating instructions before commissioning the. As operator, you are responsible for ensuring that users of the equipment have fully understood the operating and safety instructions. Always connect the to an electrical ground! To avoid shock hazard, the chassis must be connected to an electrical ground. When servicing the in a test area, the protective earth terminal must be attached to a seperate ground securely by use of a tool since it is not grounded by external connectors. Only suitably qualified personnel should work at the TAPCON 250! The contains high voltages which can cause serious injury or death! It is designed exclusively for application in electrical or energy systems and facilities operated by appropriately trained staff who are familiar with the installation, operation and maintenance of such products. Exercise due care when operating or servicing alone. Do not operate the in an explosive environment! Do not operate this equipment in the presence of flammable or explosive gases or fumes. To do so would risk a possible fire or explosion. Keep away from live circuits! Operating personnel must not remove the cover or expose the printed circuit board while power is applied. Dangerous voltages may exist even when power is disconnected. To avoid electrical shock, always disconnect 4 Operating Instructions - short version
power and discharge circuits before working on the unit. Do not modify the! Do not perform any unauthorized changes on the. Contact Reinhausen Manufacturing regarding any modification. If authorized modifications are to be attempted, be sure to follow replacement procedures carefully to assure that safety features are maintained. Avoid static charge! The contains MOS circuitry which can be damaged by improper test or rework procedures. Avoid static charge on work surfaces and service personnel. Use extreme caution during any diagnostic work! Any attempt to perform any diagnostic work or connection between points on the printed circuit board, unless services noted in the Operating Instructions is likely to cause damage or permanent failure to the. Operating Instructions - short version 5
2 Technical Data/Information 2.1 Environmental 2.1.1 Temperature Operation IEC 60068-2-1 IEC 60068-2-2 High voltage IEEE C37.90.1-2002 4,000 Vpk IEC 61000-4-2 1,500 VAC rms to ground for one minute with a leakage current not to exceed 15 ma (except communication ports, CAN bus terminals P1 and terminals P2.33...P2.37) Contact Discharge +/-8kV Air Discharge +/-15 kv Fast Transient Burst Electrostatic discharge test IEC 61000-4-3 10 V/m, 80...4,000 MHz Immunity against HF fields IEC 61000-4-4 4 kv @ 2.5 khz (1 min.) Fast transient disturbance test IEC 61000-4-5 4,000 Vpk Immunity against Surge IEC 61000-4-6 10 V, 150 khz... 80 MHz Immunity against HF on lines IEC 61000-4-8-13 F...+158 F (-25 C...+70 C)* * extended temperature range on demand 2.1.2 Applicable Standards Dry Cold -40 F/ -40 C for 96 hours Dry Heat +176 F/ +80 C for 96 hours IEC 60068-2-3 Damp Heat 104 F/ +40 C for 96 hours, rel. air humidity 93% IEC 60068-2-30 Damp Heat, cyclic (12 h +12 h), 131 F/ 55 C, stress duration: 6 cycles 2.1.3 Mold Resistance A conformal coating on the printed circuit is used to inhibit mold growth. 2.2 Transient Protection 1,000 A/m, 60 Hz, continuous Radiated electromagnetic withstand capability Immunity against magnetic fields All units are protected against electromagnetic radiated interference from portable communications transceivers. Operating Instructions - short version
2.3 Industrial Certifications TAPCON250 is a UL Listed (Industrial Control Equipment) device. 2.4 Technical Data Protective Housing Dimensions Weight Protective Housing 5.81 x 8.5 x 3.08 (W x H x D) (147.6 x 216 x 78.2 mm) approx. 6.2 lbs (2.8 kgs) 2.5 Warranty The is offered with an extended warranty. Operating Instructions - short version 7
3 General Information These operating instructions provide a quick overview of the main functions of the voltage controller, enabling you to put the device into operation very quickly. More comprehensive information about the configuration and operating principle of the voltage controller along with settings for special applications can be found in the following document: Operating instructions BA297 Digital On-Load Tap Changer Voltage Controller. 4 Connection The is powered by a measurement voltage from a potential source ranging from 85 to 140 VAC (45...65 Hz) on pin P2.1(Line) and pin P2.3(Neutral). The voltage controller alternatively accepts an external 12 VDC power supply on terminal P3, [P3.1(+) and P3.2(-)], for continuous operation during an AC power outage. Assembly instructions Familiarize yourself with the inputs and outputs at the bottom of the voltage controller. Ensure proper grounding of the voltage controller by means of the chassis ground screw attached to the housing. This connection maintains the EMC characteristics of the device. Connect the voltage controller according to the wiring diagram, the connection diagram (see fig. 3; for detailed description see operating instructions BA297) and according to the wiring diagram of the respective motor-drive. Refer to specific adapter panel information provided separately for wiring details. 8 Operating Instructions - short version
5 User Interface Raise/Lower command LEDs Remote Manual Automatic operating modes Contrast Serial interface COM2 (Parameter Software only) Function keys Status LED Scroll arrow keys show measured values and navigate menus Enter Escape Menu Fig. 1: Front panel 5.1 Description of the front panel (see fig. 1) LEDs The LEDs indicate overcurrent, under voltage, overvoltage, parallel active, NORMset active and (4) assignable functions or modes. Function keys F1 F5 These soft keys are used to navigate the menu sub-groups or adjust specific parameter settings in the input screens. Status LED If the status LED is illuminated, the device is working properly. MENU key This key, when pressed, displays the initial menu screen. Operating Instructions - short version 9
ESC key The ESC key, when pressed, displays the previous higher menu level or returns to the operating display. Enter key Once a value or setting is changed in a specific parameter menu, this key must be pressed to enter the new parameter into the operating memory. Arrow keys In Auto and Manual mode, the arrow keys can be used for changing the Measured value display (see display layout, Fig. 2) and for navigating between the parameter screens within a menu sub-group. Automatic mode Indication only; this mode can be controlled separately by a 120VAC input (see fig. 3). Manual mode Indication only; this mode can be controlled separately by a 120VAC input (see fig. 3). Remote mode Indication only; this mode can be controlled separately by a 120 VAC input (see fig. 3). Raise/Lower keys The on-load tap-changer can be operated via the Raise/Lower keys (changing the step voltage). During Auto mode, the raise/lower command has to be confirmed with Enter in the upcoming display before the signals a raise/lower command. Changing the measured value display By default, the system deviation rate du is displayed first when the device is switched on. Deviation - du - current (A) - apparent power (VA) - active power (W) - reactive load (VAr) - phase angle (deg.) - Cos can also be displayed by pressing the scroll arrow keys. Serial interface COM 2 The COM2 port used to connect the voltage controller with a PC only for parameter settings. The TAPCON-trol system parameter software and interface cable are included with each controller. 10 Operating Instructions - short version
5.2 Description of the display (see fig. 2) 1 2 7 6 3 4 5 1 Status line; displays menu items or error/alarm messages 2 Actual measured voltage level in V/kV 3 Reference or alternate voltage level in V/kV 4 Measured value display (voltage deviation and other values) 5 Tap changer operating position 6 Deviation from reference or alternate voltage level 7 Timing bar Fig. 2: LCD graphic display Operating Instructions - short version 11
6 External Connections 12 Operating Instructions - short version
Notes 1. Motor voltage may be 120 or 240 V to neutral, or 240 V phase-to-phase. 2. A ground connection has to be provided to the CT/VT s neutral connection, external to the control. WARNING! WARNING! When an adapter panel is not used, automatic shorting of CT inputs is not provided by the ; the customer must provide a method for shorting the CT s before the control is disconnected. When an adapter panel is not used, the has to be protected by an external fuse (0.375 A, slo-blo ) on pin P2.1. Fig. 3: Wiring scheme for definition of external connections Operating Instructions - short version 13
7 Parameters 7.1 NORMset Activating the NORMset function Menu => NORMset => NORMset Activation The term NORMset function stands for an automated control function which considerably simplifies the parameter setting of a voltage controller. The only requirement left to do for the operator when commissioning during the NORMset mode is to enter the reference voltage level and, if required, the CT/VT values and subsequently place the device into operation. All other parameters required for simple voltage regulation will be preassigned at the factory (e. g. bandwidth of 1 %). Should the actual value exceed the set bandwidth, an appropriate switching operation will be initiated at the on-load tap-changer. The voltage change ensuing from the switching operation corresponds to the transformer s tap voltage and is checked for plausibility by the controller, using the preset bandwidth. The bandwidth value is then corrected and optimized in accordance with the results determined by this function/mode. If the next system deviation occurs, the new bandwidth will be used as basis, which will be rechecked and readjusted, if necessary. Should the marginal conditions change, the controller will again optimize itself automatically. Specific settings such as LDC, parallel operation or position display among others are still applicable and can be changed in the standard mode. These settings will be taken into consideration during the NORMset mode of operation to optimize the voltage and the use of the tap changer. 14 Operating Instructions - short version
Setting the primary voltage NOTE! The parameters for undervoltage/ overvoltage and overcurrent are not set by the NORMset function. If required, these parameters have to be entered manually during commissioning/initiation. The NORMset function is deactivated during parallel operation. Menu => NORMset => Primary voltage Setting range: 0... 999.0 kv Setting the secondary voltage Menu => NORMset => Secondary voltage Setting range: 100.0... 135.0 V Operating Instructions - short version 15
Setting the reference voltage level 1 within NORMset Menu => NORMset => Reference voltage level 1 Setting range: 100.0...135.0 V The setting of the reference voltage level 1 refers either to the secondary or to the primary voltage side of the voltage transformer connected to the TAPCON 250. The secondary voltage is displayed in Volt (V), the primary voltage in kilovolt (kv). If NORMset function is off for operation, the reference voltage level 1 can be set in the PARAMETER menu subgroup. This display requires the correct input of the CT/VT data in the following two menu windows. 7.2 CT/VT data Menu => Configuration The transformer ratios and measuring values of the voltage and current transformers applied can be set in the corresponding menus within the CONFIGURATION subgroup and use of the soft function keys F1 thru F5. Setting the primary VT voltage Menu => Configuration => Data of meas. Trf. => Primary voltage Setting range: 0... 999.0 kv 16 Operating Instructions - short version
Setting the secondary VT voltage Menu => Configuration => Data of meas. Trf. => Secondary voltage Setting range: 100.0... 135.0 V Setting the primary CT current Menu => Configuration => Data of meas. Trf. => Primary current Setting range: 1... 10,000 A Setting the phase angle relationship of current/voltage transformers This setting of the conventional measuring circuits is in accordance with fig. 4. Menu => Configuration => Data of meas. Trf. => Instr. transformer circuit Operating Instructions - short version 17
Fig. 4: Measurement circuits 18 Operating Instructions - short version
Setting the time and date Menu => Configuration => Continue => Memory Press the Right Arrow key (screen 06) six times to view the input field for the system time. Press the F4 function key to select the digit(s) you want to edit and then press the F1 and F5 keys to set the display forward or backward in one-step increments. The time format in HH:MM:SS is available in a 24-hour format. Press the Right Arrow key (screen 07) seven times to view the input field for the system date. Press the F4 function key to select the digit(s) you want to edit and then press the F1 and F5 keys to set the display forward or backward in one-step increments. The date format in DD.MM.YY can be set to any date between 01/01/2001 and 29/12/2099. 7.3 Parallel operation settings (optional) Setting of parallel operation principle Menu => Configuration => Parallel operation => Parallel operation method Set the desired parallel operation principle by pressing the F1 and F5 function keys. Operating Instructions - short version 19
Setting options: Off = no parallel operation Circulating current = parallel operation following the current principle of minimum circulating reactive current Master = Master/Follower principle: the controller assumes Master function Follower = Master/Follower principle: the controller assumes Follower function Synchr.Auto = Master/Follower principle: with this setting, the controller with the lowest CAN address of all connected controllers is automatically selected as Master. XPA = Parallel operation with the TAPCON-XPA, external Paralleling Assistant, following the principle of minimum circulating reactive current with CT circuits connected between power transformers. Parallel control according to the Master/Follower principle requires no further settings other than the T1 and T2 delay times must be greater than 8 seconds. In each case, the voltage controllers engaged in parallel operation have to be connected either via the CAN bus interface (see fig. 4) or via the TAPCON- XPA (ANSI scheme). Note: Please remember that the CAN bus must be connected with a resistor of 120 Ω at both ends (at the first and last controller). The resistor is included in the scope of delivery. CAN Address To permit controller communication via CAN bus, each individual controller needs a separate identifier. Menu => Configuration => Parallel operation => CAN Address Assign a number as address to each controller by pressing the F1 or F5 function keys. The values assigned as CAN address may range between 1 and 127. 0 = no CAN bus communication 20 Operating Instructions - short version
7.4 Regulating parameters This specific sub-group contains all parameters required for the regulating functions. Menu => PARAMETER Example of Parameter Adjustment Setting the reference voltage level 1 Menu => Parameter => Regulation param. => Reference voltage level 1 Setting range: 100.0... 135.0 V Operating Instructions - short version 21
8 Accessories For further information on: Analog Input/Output extension Communication Interface Card with RS232, RS485, Modem/Ethernet and fiber optic connection Adapter Panels please contact Reinhausen Manufacturing or www.tapcon250.com. 22 Operating Instructions - short version
Fig. 5: Connection diagram Operating Instructions - short version 23
www.reinhausen.com/rm/en/ www.tapcon250.com Reinhausen Manufacturing Inc. Phone: (+1)731/784-7681 2549 North 9th Avenue Fax: (+1)731/784-7682 Humboldt, Tennessee 38343, USA E-Mail: reinhausen@bestltc.com BA en 0407/300 F0161200 Printed in USA