Tap Manager TM100 Operating Instructions
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Contents Contents 1 General... 5 1.1 Safety instructions... 5 1.2 Application... 5 2 Design... 6 2.1 Controls... 6 2.1.1 Scroll keys in display field... 6 2.1.2 Enter key... 6 2.1.3 Local/Remote switch... 7 2.1.4 Raise/Lower keys... 7 2.2 Displays... 7 2.2.1 LCD display... 7 2.2.2 LED displays... 8 2.3 Diagnosis interface... 8 2.4 Modules... 8 2.4.1 Network filter module... 8 2.4.2 Power supply module... 8 2.4.3 Control module... 8 2.4.4 Temperature measuring module... 9 2.4.5 Position module... 9 2.4.6 Power measuring module... 9 2.4.7 CPU module... 9 2.4.8 Front bus-board... 9 2.4.9 External connections of the standard device... 9 2.5 Technical data... 9 2.6 Environmental conditions... 9 2.7 Housing, dimensions, weight... 9 2.8 Power supply... 9 2.9 Measuring ranges... 9 2.10 Relays (control of output contacts)... 9 2.11 External digital inputs... 9 3 Operation... 10 3.1 Drive control... 10 3.1.1 Starting a tap-change operation... 10 3.1.2 Blocking a tap-change operation... 10 3.1.3 Local acknowledgement of alarms and warnings... 10 3.2 Drive monitoring... 11 3.2.1 Monitoring during the tap-change operation... 11 3.2.2 Monitoring during resting... 11 3.2.3 Wrong phase sequence... 11 3.3 Hand crank operation... 11 NOTE Data contained herein may differ in small details from the unit delivered. We reserve the right to make alterations without notice. 3
Contents Contents 3.4 Monitoring of limit values... 11 3.4.1 Torque monitoring... 11 3.4.2 Temperature monitoring... 11 3.4.3 Contact wear... 12 3.4.4 Replacement of parts... 12 3.4.5 Oil change... 12 3.5 Data storage... 12 3.5.1 Storage principle... 12 3.5.2 Event memory... 12 3.5.3 Raw torque data... 12 3.5.4 evaluated torque data... 12 3.5.5 Wear data... 13 3.5.6 Temperature data... 13 3.5.7 Current data... 13 3.6 Maintenance display... 13 3.7 General information on maintenance... 13 4 Appendices... 13 NOTE Data contained herein may differ in small details from the unit delivered. We reserve the right to make alterations without notice. 4
1 General 1 General 1.1 Safety instructions 1.2 Application All personnel involved in installation, commissioning, operation and maintenance of the device must - be suitably qualified and - strictly observe these Operating Instructions. Improper operation or misuse can lead to - serious or fatal injury, - damage to the device and other property of the user, and - a reduction in the efficiency of the device. Safety instructions in this manual are presented in three different forms to emphasize important information. WARNING This information indicates particular danger to life and health. Disregarding such a warning can lead to serious or fatal injury. The electronic on-load tap changer monitoring system TM100 controls, monitors and records data from motor drive units and high voltage on-load tap-changers. The advantages of the TM100 include early detection of faults and the possibility for condition-dependent tapchanger maintenance. Activating the motor drive, which operates according to the step-by-step principle, results in a voltage change of one step on the transformer. During the tap-change operation switching-relevant events are recorded and and limit values such as the torque are monitored. If any faults are detected or if critical limit values are exceeded the subsequent tapchange operation is blocked. During a tap-change operation the motor drive can be blocked by real-time monitoring modules. The events are stored and a message is sent. The device is equipped with a 2-MB memory card for storing parameters and data sets on the on-load tapchanger and motor drive operating values. The data recorded can be read from a serial interface and processed by a visualisation program. The limit value parameters can be changed using the diagnosis or monitoring interface and can be stored in the nonvolatile flash memory on the memory card. CAUTION This information indicates particular danger to the device or other property of the user. Serious or fatal injury cannot be excluded. NOTE These notes give important information on a certain subject. CAUTION The monitoring system and memory card may only be used with the on-load tap-changer specified in the order. Installation, electrical connection and commissioning must only be carried out by qualified personnel according to these Operating Instructions. It is the responsibility of the user to make sure that the device is used for the specified application only. For safety reasons, unauthorized work such as installation, modification, alteration, electrical connection or commissioning of the equipment must not be carried out without first consulting MR! The trouble-free operation of the motor drive, the onload tap-changer and the transformer may be put at risk. CAUTION All relevant fire protection regulations must be strictly observed. 5
MANUAL CONTROL MODE OF OPERATION STATUS LINE READY TAP CHANGE END POSITION REACHED HAND CRANK OPERATION ATTENTION CALL SERVICE! WARNING! FAILURE 2 Design 2 Design The device is delivered in a standardized 19 rack according to DIN 41494 (fig. 1). 2.1 Controls 2.1.1 Scroll keys in display field Using the scroll keys (fig. 3) the important operating data can be displayed, e.g. number of tap-change operations, end positions, operating current of the onload tap-changer, temperature, time and date. TM100 OLTC - MONITORING - SYSTEM DATA PORT RS232 SCROLL INPUT SCROLL REINHAUSEN MRGERMANY LOCAL REMOTE MADE IN GERMANY DATA PORT SCROLL INPUT RS232 MANUAL CONTROL MODE OF OPERATION STATUS LINE READY TAP CHANGE LOCAL REMOTE END POSITION REACHED HAND CRANK OPERATION ATTENTION CALL SERVICE! WARNING! FAILURE 1 KHW 1146 3 KHW 1147 The design is modular, which means the individual functions are performed by individual modules. The front plate contains the controls and a two-line LCD display. The RS232 diagnosis interface is connected to a 9-pole sub-d socket. All components on the front are soldered onto a busboard which is also a connecting board for the individual electronic modules. All electronic modules are plugged into the rear of the device and are mechanically locked in their positions by EMC barriers (fig. 2). 2.1.2 Enter key This key can be used to acknowledge an event or error message code (fig. 4). The acknowledged code is explained in a reference list which is included with the connection diagrams. INPUT 2 KHW 1154 4 KHW 1148 6
2 Design 2.1.3 Local/Remote switch (fig. 5) This slide switch is used to select the Local or Remote mode of operation. Tap-change operations can only be activated by the control keys on the TM100 when Local mode is selected. 2.2 Displays 2.2.1 LCD display With trouble-free operation and when the motor drive is in the resting range (grey field on the tap-change indicator), the first line (fig. 7) shows that the on-load tap-changer is ready for an operation. The second line shows the tap position and number of sections on the tap-change indicator of the motor drive. MODE OF OPERATION LOCAL REMOTE 5 KHW 1149 7 KHW 1151-S 2.1.4 Raise/Lower keys (fig. 6) These keys are used to initiate an on-load tap-change operation in manual mode in either the Raise or Lower direction. When a message is generated by the monitoring system, it is displayed as an event code number. This also occurs with alarms and warnings (fig. 8). MANUAL CONTROL 6 KHW 1150 8 KHW 1151-W 7
2 Design 2.2.2 LED displays (fig. 9) Ready (green) The device is switched on and the tap position input is correct. Tap-change operation (yellow) A tap-change operation is in progress ( running indication) End position reached (yellow) The on-load tap-changer is in one of its two end positions. Hand crank operation (yellow) The hand crank is fitted. The switching sequence is no longer monitored. Attention! Call Service! (yellow) Alarms are present. Tap-change operation is still possible. Warning! Failure (red blinking) A warning is present. Tap-change operation is not possible until the warnings are acknowledged. 2.3 Diagnosis interface (fig. 10) Using this RS232 interface, data can be read and settings altered locally by means of the MR visualisation program. DATA PORT RS232 10 STATUS LINE READY 9 TAP-CHANGE END POSITION REACHED HAND CRANK OPERATION ATTENTION! CALL SERVICE! WARNING! FAILURE 2.4 Modules 2.4.1 Network filter module This module contains a network filter. In AC design it additionally contains the voltage setting of 100 V AC up to 260 V AC, and in DC design a chopper unit. 2.4.2 Power supply module AC design: Rated voltages of 100 V, 110 V, 120 V, 130 V, 200 V, 210 V, 220 V, 230 V, 240 V, 250 V and 260 V AC can be set via winding taps on the network filter module. DC design: Thanks to prewired winding taps, power supply units with 110 V, 125 V, 200 V, 220 V, 250 V are available. 2.4.3 Control module This module contains 8 optocoupler inputs. The optocouplers are operated with a 30 V control voltage provided by the module. There are 4 relays for controlling the switchgear, each with an N/O contact and one common terminal. 8
2 Design 2.4.4 Temperature measuring module This module contains 4 measuring channels for the MR digital temperature sensors. The temperature sensors are interrogated via an interface with signal levels according to RS 485. A sensor on the module measures the internal temperature of the unit. 2.4.5 Position module This module reads the position of the on-load tapchanger and tap selector contacts. A rotary transmitter attached to the position transmitter shaft in the motor drive supplies an absolute-position signal. 2.4.6 Power measuring module This module measures the motor current and motor voltage and prepares the values correctly phased for the analog/digital conversion. The CPU determines a power value from 200 real-time samples taken during each period which is then converted by a transmission function into an on-load tap-changer torque value. 2.4.7 CPU module This is the core of the system. It processes the measured values, controls and monitors the other modules and operates the motor drive control. The CPU module contains the memory card (see BA 188, section 4.2) as non-volatile data memory and also may have two fibre-optic interfaces. Transmission range at 660 nm wavelength: < 100 m Transmission range at 850 nm wavelength: 1500 m 2.4.8. Front bus-board The front bus-board is located behind the front panel and connects the modules. The controls, displays and signalling lights are mounted on and connected to it. 2.4.9 External connections of the standard device X22 Power supply X24, X26 Control board 1 X25, X27 Control board 2 X38 Temperature measuring board X40 Position input board X34 Power measuring board 2.5 Technical data Note: Only values indicating tolerances or limits can be considered guaranteed data. Values without tolerance details are for information only and are not guaranteed. 2.6 Environmental conditions Temperature range -25 C... + 85 C Degree of protection IP00 2.7 Housing, dimensions, weight Housing according to DIN 41494 Teil 5 Height 132,5 mm Width 483 mm Depth 180 mm Weight ca. 12 kg (with max. equipment) 2.8 Power supply 230 V AC, -15 % bis +10 %, for settings see 2.4.2. 2.9 Measuring ranges Temperature measuring board: Measuring range: -30 C to 100 C, accuracy ± 1.2 C -45 C to 130 C, accuracy ± 2 C Power measuring board: AC: 260 V, 6 A 520 V, 6 A DC: 300 V, 7 A 2.10 Relays (control of output contacts) N/C contacts with common terminal (each board with 4 relays) 240 V AC, 8 A 30 V DC, 5 A 110 V DC, 0.4 A 250 V DC 0.3 A External digital outputs are connected via coupling relays and are wired as electrically-separate changeover contacts to the terminal strip X1 of the motor drive but only if the TM100 wiring is carried out by MR. 2.11 External digital inputs External digital inputs are electrically separated by coupling relays. Control voltage of coupling relays: 230 V AC. An auxiliary voltage (30 V DC) provided by the TM100 is switched via potential-free contacts to TM100 inputs (see 2.4.3). 9
3 Operation 3 Operation 3.1 Drive control 3.1.1 Starting a tap-change operation Local mode operation: When the Local/Remote switch is in Local position (fig. 11) and when the display shows OLTC ready (fig. 12), a tap-change operation can be initiated, e.g. towards position 27 or towards position 1, using the Raise or Lower keys, respectively. Exception: Hand crank operation: If the motor drive is operated by the hand crank past the resting range to the point that a step-by-step switch is triggered, the initiated tap-change operation is automatically completed. 3.1.2 Blocking a tap-change operation 11 MODE OF OPERATION LOCAL REMOTE KHW 1149 Remote mode of operation: When the Local/Remote slide switch is in the Remote position and when the display shows OLTC ready, a tapchange operation can be initiated, e.g. towards position 27 or towards position 1, by a control voltage pulse (ca. 0.5 s) applied to terminal X1.10 or X1.11 respectively. An initiated tap change-operation is blocked under the following circumstances: a warning is present which is indicated by the blinking red LED Warning! Event!, an end position is reached but the next tap-change operation intended is in the same direction, the hand crank is fitted, the factory-set maximum permissible tap-changer current is exceeded, the maximum permissible temperature range is exceeded. 3.1.3 Local acknowledgement of alarms and warnings In the Local mode of operation a warning or alarm displayed as the event number (fig. 13) can be acknowledged by pressing the Enter key. Schalter bereit 13 KHW 1151-W 12 KHW 1151-S If several warnings and alarms occur at the same time, the warnings are shown first and then the alarms. The sequence is determined by the code number. The message with the highest code number must be acknowledged first. 10
3 Operation 3.2 Drive monitoring 3.2.1 Monitoring during a tap-change operation During a tap-change operation the motor drive running time and the movement of the drive shaft in the motor drive are monitored (also see 3.4.1). If the running time is exceeded, an error message is sent and the motor protective switch is tripped. WARNING If the maximum torque of the on-load tap-changer is exceeded during a tap-change operation and the motor drive is immediately stopped, MR s Technical Service should be informed. Serious damage may occur to the on-load tapchanger. Disregarding this warning can lead to serious damage to property or serious or fatal injury. 3.2.2 Monitoring during resting After completion of the tap-change operation the motor drive is monitored to ensure the motor does not continue running after its slow-down period. If, due to a sticking contactor, the motor continues running without control the motor protective switch is tripped. 3.2.3 Wrong phase sequence The TM100 monitors the direction of rotation of the motor drive and trips the motor protective switch if the direction of rotation is wrong. In addition, it sends the error message Wrong direction of rotation. After the error is corrected and the message is acknowledged the motor drive completes the initiated tap-change operation. 3.3 Hand crank operation If the hand crank safety switch signals that the hand crank is fitted, the TM100 changes to hand crank operation. The automatic drive control and monitoring are not in operation when the hand crank is used. The on-load tap-changer can be operated to any position within the mechanical limits. If the hand crank is withdrawn outside the neutral zone or in a position to be passed, the initiated tap-change operation is automatically completed. 3.4 Monitoring of limit values CAUTION If the motor drive is operated when the red alarm is activated, serious damage to the motor drive, on-load tap-changer and transformer can occur. 3.4.1 Torque monitoring The on-load tap-changer torque is monitored in real time during a tap-change operation. If the set maximum torque is exceeded, the tap-change operation is immediately stopped and the motor protective switch is tripped. At the end of each tap-change operation the recorded torque measurement points are evaluated. The maximum torques in each section of the tap-change operation are compared to the corresponding limit values and, if necessary, alarms and warnings are sent. If none of the limit values are exceeded, the on-load tap-changer is ready for a new operation and the display shows OLTC ready. 3.4.2 Temperature monitoring When the TM100 is switched on, the following temperatures are measured: oil temperature in the on-load tap-changer oil compartment transformer oil temperature and, in bolt-on tapchangers, the tap selector temperature external temperature internal temperature in the TM100 electronics. If the actual values exceed or fall below the limit values, corresponding alarm or error messages are sent. Deviations or below the temperature thresholds can block the operation of the on-load tap-changer. Yellow: Operation can continue (without acknowledgement of message) Red: Operation can continue only after acknowledgement of message. The motor drive control is blocked. If the difference between the internal and external temperature exceeds 8 Kelvin and if the internal temperature is less than 10 C, the heater is switched on. 11
3 Operation 3.4.3 Contact wear The wear of the switching and resistor contacts of the diverter switch is determined from the on-load tapchanger current. After each tap-change operation the contact wear is calculated from the on-load tap-changer current using an algorithm. If the permissible wear is exceeded, a warning is sent and the on-load tap-changer is blocked. If the contact wear reaches 90 %, an alarm (yellow) appears. An imminent technical service should be planned. 3.4.4 Replacement of parts The precautionary replacement of parts depends on the number of switching operations. The corresponding data is stored in the TM100. When 90 % of the number of operations is reached, an attention signal (yellow signal) appears to indicate that a parts replacement service should be planned. In this case please contact the MR Technical Service. 3.4.5 Oil change The criteria are stored in the TM100. When 90 % of the criteria is reached, an attention signal (yellow signal) appears. Together with the oil change it is necessary to clean and inspect the diverter switch oil compartment and diverter switch insert. For details refer to the inspection instruction manual for the respective on-load tap-changer. If the on-load tap-changer is operated with an MR oil filter plant, the response pressure of the filter plant is the criterion for the filter cartridge replacement. This is also signalled by the TM100. For the criteria of the diverter switch oil change refer to the operating instruction manual for the MR oil filter plant. 3.5 Data storage 3.5.1 Storage principle Data is stored on a PCMCIA memory card. There are two memory blocks for data which are rewritable. If both blocks are full, the block with the older data is deleted. Essential operational data such as parameters, alarms and error messages, wear data and faulty torque characteristics are stored in memory areas which are non-rewritable. 3.5.2 Event memory All events are stored with a time stamp in the rewritable memory area. The memory capacity is 2 blocks with 16 000 events each which are alternately rewritable. In addition, attention and warning messages are stored in a non-rewritable space of the Memory Card. 3.5.3 Raw torque data The torque measurement points from each tap-change operation together with essential operation data such as tap position, tap-change operation type, temperature, motor voltage and on-load tap-changer current are stored in a rewritable memory area. The memory capacity contains 2 blocks which are alternately rewritable. If limit values are exceeded, the data set is additionally stored in a non-rewritable memory area. 3.5.4 Evaluated torque data After completion of a tap-change operation the torque data is evaluated according to the type of tap-change operation and the corresponding functional sequence in the on-load tap-changer. The maximum torques during each tap change operation are used by the monitoring system to analyse the functional sequence in the onload tap-changer mechanics and as a comparison against specified limit values. The data set created is stored. 12
Operation 3 Appendices 4 3.5.5 Wear data 3.6 Maintenance display From the specified transformer step voltages, the onload tap-changer current at the moment of the tap change and from known characteristics of the contact material, the monitoring system calculates the wear of the switching and resistor contacts on the on-load tapchanger using a mathematical model. The results are stored and used to evaluate wear differences between the individual contacts and the total wear. In connection with the limit values of the diverter switch to be monitored the system monitors the condition of the contacts subject to wear. 3.5.6 Temperature data As well as constantly monitoring the on-load tapchanger temperature, the measured temperatures are periodically stored. In addition, the minimum, maximum and average temperature values are stored at the end of each calendar day. 3.5.7 Load current data If the specified number of operations is reached, or if a service is required, the monitoring system issues and sends corresponding messages. If operating conditions are such that continuing operation jeopardises the equipment, the monitoring system blocks the motor drive. 3.7 General information on maintenance Maintenance measures can be carried out with minimum expense. They can be effectively combined with the usual control checks on the transformer. Visually checking the motor drive Checking the protective function of the protective relay of the on-load tap-changer Checking the on-load tap-changer oil Checking the silicagel breather Refer to the respective Operating Instructions of the individual on-load tap-changers for details on limit values. The monitoring system can measure the on-load tapchanger current from different sources. This current value is required to calculate the contact wear. However, it is also stored in the same way as the tem-perature value so that minimum, maximum and average current values are available for evaluation. 4 Appendices Front view with control... TM_FRTEN Rear view with plug designations... TM_BGTRU Block diagram... TM100B1D Block diagram... TM100B2D Block diagram... TM100B3D Circuit diagram... ZM0004S1 Circuit diagram... ZM0004S2 Circuit diagram... ZM0004S3 Circuit diagram... ZM0004S4 13
4 Appendices Tap Manager TM100 Front view with controls TM_FRTEN.PIC 14
4 Appendices Option: Modem, STE3, TX1, TX2, RX1, RX2 Tap Manager TM100 Rear view with plug designations TM_BGTRU.PIC 15
4 Appendices Tap Manager TM100 Block diagram TM100B1E 16
4 Appendices Tap Manager TM100 Block diagram TM100B2E 17
4 Appendices Tap Manager TM100 Block diagram TM100B3E 18
4 Appendices Motor Drive Unit ED Monitoring ZM0004 Circuit diagram Sheet 1 19
4 Appendices Motor Drive Unit ED Monitoring ZM0004 Circuit diagram Sheet 2 20
4 Appendices Motor Drive Unit ED Monitoring ZM0004 Circuit diagram Sheet 3 21
4 Appendices Motor Drive Unit ED Monitoring ZM0004 Current Diagram Sheet 4 22
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Maschinenfabrik Reinhausen GmbH 2001 Postfach 12 03 60 93025 Regensburg Germany Phone: (+49) 9 41 / 40 90-0 Fax: (+49) 9 41 / 40 90-111 Internet: http://www.reinhausen.com Email: sales@reinhausen.com BA 189/01 en - 0501/1000 F0067300 Printed in Germany