LOAD TAP CHANGER

TYPE RMV-II
1500 A / 2000 A / 2500 A
VACUTAP®

INSTRUCTION MANUAL
TL 7002.07
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INSTRUCTION MANUAL TL 7002.07

TABLE OF CONTENTS PAGE

1. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Application Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Equipment Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2. SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 Tap Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.4 Change-over, Selector (reversing or coarse/fine) . . . . . . . . . . . . . . . . . . . . . .9
3.5 Vacuum Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.6 By-Pass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.7 Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.8 Drive Mechanism / Cam Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .11

4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.1 Receiving, Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.2 Mechanical Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.4 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.5 Oil Filling/Transformer Vacuum Processing . . . . . . . . . . . . . . . . . . . . . . . . .15

5. MAINTENANCE-FREE SCHEDULES AND SERVICE . . . . . . . . . . . . . . . . . . . .15

5.1 Maintenance-Free Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.2 Taking the LTC out of Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.3 Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.4 Internal Examinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.5 Preparing the LTC for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

NOTE 6. REPLACEMENT OF THE VACUUM INTERRUPTER . . . . . . . . . . . . . . . . . . . . .20

6.1 Removing the Old Vacuum Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
The instructions contained in this
6.2 Installing the New Vacuum Interrupter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
manual apply for tap changers with
standard position designation
16L...N...16R only. For LTC’s with a 7. DEHYDRATING BREATHER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
different position designation please 7.1 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
refer to the LTC sequence chart 7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
supplied for each order. 7.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
7.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

8. VACUUM INTERRUPTER MONITORING (VIM) SYSTEM . . . . . . . . . . . . . . . . .28

8.1 VIM System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.2 Evolution of Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
NOTE 8.3 Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.4 In-Service Monitoring System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Drawings and illustrations contained in
8.5 In-Service Monitoring System Trip (Lockout/86RL) . . . . . . . . . . . . . . . . . . . .29
this instruction manual are subject to
8.6 Replacement, Spare or Upgrade Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
change without notice and are for
8.7 Monitoring System Vintage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . .29
reference only. For specific details refer
to drawings submitted with each
9. SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
individual customer order.
10. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
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1. TECHNICAL DATA

The RMV-II load tap changer fulfills all requirements in IEC 60214-1 and ANSI/IEEE C57.131-1995.
The Motordrive Mechanism complies to IEEE C57.131-1995.

1.1 General Data

Design 3 phase, preventive autotransformer (reactor) switching principle (to break load
current by vacuum interrupters)
Tank Will withstand full vacuum (± 15 psi)
Size (LxWxH) Tank: 66 x 32 x 50 in. for 69 kV design, 66 x 29 x 43 in. for 15 and 25 kV design
Air compartment: 34 x 17 x 23.5 in. (250 lbs)
Total weight (incl. oil) 5,500 lbs. for 69 kV design, 4,440 lbs. for 15 and 25 kV design
Oil filling quantity 345 gals./2,590 lbs. for 69 kV design, 270 gals./2,025 lbs. for 15 and 25 kV design
Time per operation Approx. 2 seconds

1.2 Application Limits

NOTE
The maximum allowable recovery voltage across the
reversing switch during its operation is 20 kV.
Tie-in resistors are necessary in case 20 kV are exceeded.

Tap changer type RMV-II-1500-15 RMV-II-1500-25 RMV-II-1500 RMV-II-2000-15 RMV-II-2000-25 RMV-II-2000 RMV-II-2500

Operating voltage
phase-to-phase and to
ground 15 kV 26.4 kV 72.5 kV 15 kV 26.4 kV 72.5 kV 72.5 kV

Three phase kVA

of regulation 36,000 kVA 36,000 kVA 72,000 kVA 48,000 kVA 48,000 kVA 96,000 kVA 120,000 kVA

LTC through-current 1,500 Amp 1,500 Amp 1,500 Amp 2,000 Amp 2,000 Amp 2,000 Amp 2,500 Amp

Tap-to-tap voltage 1,000 V 1,000 V 2,000 V 1,000 V 1,000 V 2,000 V 2,000 V

Impulse withstand voltage

(full wave) phase-to-phase
and to ground 125 kV 150 kV 400 kV 125 kV 150 kV 400 kV 400 kV

Power-frequency test
voltage phase-to-phase
and to ground 40 kV r.m.s. 50 kV r.m.s. 140 kV r.m.s. 40 kV r.m.s. 50 kV r.m.s. 140 kV r.m.s. 140 kV r.m.s.

Impulse withstand voltage

(full wave) across tap range 75 kV 75 kV 250 kV 75 kV 75 kV 250 kV 250 kV

Power-frequency test
voltage across tap range 26 kV r.m.s. 26 kV r.m.s. 70 kV r.m.s. 26 kV r.m.s. 26 kV r.m.s. 70 kV r.m.s. 70 kV r.m.s.

Impulse withstand voltage

(full wave) tap-to-tap 45 kV 45 kV 125 kV 45 kV 45 kV 125 kV 125 kV

Power-frequency test voltage

tap-to-tap 15 kV r.m.s. 15 kV r.m.s. 50 kV r.m.s. 15 kV r.m.s. 15 kV r.m.s. 50 kV r.m.s. 50 kV r.m.s.

Number of positions (standard) 33 33 33 33 33 33 33

Regulating winding sections 9 (8 effective) 9 (8 effective) 9 (8 effective) 9 (8 effective) 9 (8 effective) 9 (8 effective) 9 (8 effective)
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1.3 Equipment Standard Features - Cam switch control: tap changer pilot shaft 10 cams,
tap changer limit shaft 4 cams
- Finish: light gray epoxy solid resin - Position indicator: 16L-N-16R, 33 positions/32 steps
- Oil gauge with low level SPDT contacts - Wiring: 12 pt. terminal blocks, PVC-insulated wire,
- Provision for pressure relief device preinsulated terminals
- Drain valve, 1 in. globe with sampler - Air compartment heater with thermostat
- Guide pins for access door - Stainless steel access door studs
- Non-corrosive hardware - Vacuum interrupters with monitoring system
- Dehydrating breather - Drive motor: single-phase, 208 - 240 V, 60 Hz, 1,725 r.p.m.
- Handcrank with interlocking switch (standard, other available on request)

2. SAFETY INSTRUCTIONS Improper operation or misuse can lead to

• a reduction in the efficiency of the equipment
All personnel involved in installation, commissioning, • damage to the equipment
operation, maintenance or repair of the equipment must: • serious or fatal injury to personnel.
• be suitably qualified
• strictly observe these Operating Instructions. Safety instructions in this manual are presented in three
different forms to emphasize important information.

NOTE WARNING CAUTION

These notes give important information on a certain This information indicates particular danger to life and This information indicates particular danger to the
subject. health. Disregarding such a warning can lead to serious or equipment or other property of the user. Serious or fatal
fatal injury. injury cannot be excluded.

Fig. 1. Three-phase RMV-II load tap changer

3. DESCRIPTION

The RMV-II Load Tap Changer (fig. 1) is used in interrupters to accomplish the tap change. Vacuum
conjunction with oil-immersed power transformers, interrupters are used to interrupt the circuit within a half
regulators and phase shifting transformers to change taps cycle. The interruption takes place in a vacuum of
under load thereby controlling voltage magnitude or phase approximately 10-6 torr instead of the usual arcing under
angle. The tap changer works on the preventive oil. Thus, oil contamination is eliminated.
autotransformer (reactor) switching principle with vacuum
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Fig. 2. Tap changer oil compartment

3.1 Design

The RMV-II load tap changer is a three-phase design

(fig. 2) with full insulation between phases and to ground.
It consists of an oil compartment containing tap and
change-over selectors (reversing or coarse/fine), vacuum
interrupters and by-pass switches, a separately housed
drive mechanism/cam switch assembly and other
accessories as required by customer specifications. Each
phase consists of a tap and change-over selectors
positioned on an epoxy molded terminal board and a
vacuum interrupter and by-pass switch on a separate
vertical insulating panel mounted rigidly from the top of
the tap changer oil compartment. All switching elements Fig. 3. Vacuum interrupter, schematic layout
involved in the tap change operation, selector and
change-over selectors, vacuum interrupters and by-pass
switches of all phases, are driven by one main shaft from The vacuum interrupter consists of a stationary and a
the drive mechanism. moving contact enclosed in a vacuum-tight ceramic
insulating envelope (fig. 3). The moving contact is sealed
The vacuum interrupter drive assembly is a cam action through a flexible metal bellows protected from the arc by
spring driven mechanism which impacts an operating rod, a shield. A metal shield surrounds the contacts forming an
when opening and closing. The operating rod is arc chamber and condensing surface to collect vaporized
connected to the vacuum interrupter moving contact. contact material which arises during arcing.
 7
The entire tap changer mechanism except the motor drive The motor drive/cam switch assembly is normally housed
is housed in an oil-tight, flat finished steel tank which is in a separate air compartment and is accessible through a
designed to be welded onto the transformer main tank weather-proof hinged door. Optionally, the compartment
(see 4.2.1). This tap changer oil compartment has a can be mounted at a lower level.
gasketed, hinged access/service door.

Fig. 4. Typical
RMV-II winding layout
(LTC on position 16 L)

Fig. 5. Tap
change from
position
16 L to 15 L

3.2 Operation (fig. 4 & 5)

The tap changer operation is divided into three major - Selection of the next tap position by the tap selector
functions: assemblies in proper sequence with the operation of the
vacuum interrupters and by-pass switches.
- Arc interruption and reclosing by use of the vacuum
interrupters in conjunction with the associated by-pass - Operation of reversing or coarse/fine selector in order to
switches. double the number of tap positions.
8
The tap changer is operated by a motor drive mechanism stays closed, routing the current through the vacuum
which drives the main insulating drive shaft through a interrupter just prior to its operation. The vacuum
reduction gear. A bevel gear assembly drives the interrupter opens by a spring-operated mechanism before
horizontal insulating drive shafts between selector the tap selector moving contact selects the next tap. The
switches. vacuum interrupter then closes under spring force and
locks in place followed by the by-pass switch reclosing to
The tap selector geneva gears, vacuum interrupter and shunt the vacuum interrupter, thus completing the tap
by-pass switch assemblies of each phase are driven change operation.
through crossed helical gears to assure a precise
operational sequence of the switching components. The tap selector connects the preventive autotransformer
alternately into a bridging or a non- bridging position. The
When moving from one tap position to the next, one set of change-over selector operates only when changing from
by-pass switch contacts opens, while the second set position 1 L to N or N to 1 L.

Fig. 6. Tap selector and change-over selector, 3-phase assembly, 72.5 kV design

3.3 Tap Selector (fig. 6)

The tap selector consists of two contact arms operated Each moving contact assembly consists of parallel
alternately by geneva gears. The geneva gears also lock contact fingers. The number of contact fingers used
the movable contacts on position between operations. depends on the through-current ratings of the LTC. The
stationary contacts and the inner collecting ring are
The stationary contact bus bars are cast into the epoxy silverplated. The moving contact assemblies are spring-
molded terminal board. They provide support for the loaded to provide safe contact force for both the normal
double-deck stationary contacts. load current and the excessive current during short-circuit
conditions.
 9

3.4 Change-over Selector (Reversing or Coarse/Fine)

The silverplated stationary contact assemblies of the

change-over selector are mounted on bus bars cast into
the epoxy terminal board adjacent to the tap selector
assembly. The moving contact arm is operated by an
insulating shaft and linked through a double-lever
mechanism to the geneva gear assembly.

The change-over selector moving contact assembly is of

the same design as the tap selector contacts but uses an
increased number of parallel contact fingers.

3.5 Vacuum Interrupter (fig. 7)

The vacuum interrupter assembly is mounted vertically on

the front of the insulating panel. Vacuum filling is,
therefore, not required when oil is replaced in the field.
Cam action drives the vacuum interrupter through a spring
mechanism which latches in at its end positions. The
mechanism provides a direct drive by its operating rod to
the vacuum interrupter contact, both moving in the same
action line. The interrupter is locked in the open position
while the selector switch changes taps. Upon completion
of the tap selection the interrupter mechanism unlocks
and the moving contact recloses under positive spring
force. Opening and closing speeds of the vacuum
interrupter are dashpot controlled.

Fig. 7. Vacuum interrupter, single-phase assembly

3.6 By-pass Switch (fig. 8)

The by-pass switch is located on the opposite (back) side

of the insulating panel from the vacuum interrupter
mechanism and is operated from the same drive shaft. It
consists of two contact assemblies with parallel spring-
loaded contact fingers that close on a silver-plated
contact rod.

The moving contacts are cam operated to open and

reclose. The by-pass switch normally bridges between the
legs of the preventive autotransformer, thus by-passing
the vacuum interrupter. During a switching operation the
by-pass switch opens one set of contacts allowing current
to be directed by the remaining closed set of contacts
through the vacuum interrupter before it operates.

Fig. 8. By-pass switch, single-phase assembly

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Fig. 9. Monitoring system

schematic diagram

3.7 Monitoring System (fig. 9)

CAUTION
A unique monitoring system is utilized to protect the LTC
The monitoring system is functional only when the
in the unlikely event that a vacuum interrupter fails to
RMV-II load tap changer is operated by control
interrupt and transfer the load current during a tap change
power (either by manual control switch raise/ lower
operation.
or automatically). It does not function if the unit is
operated by hand cranking. Therefore, never hand
crank the unit if the transformer is energized as
WARNING damage to the transformer and/or personal injury
may result if any of the vacuum interrupters fails to
Do not operate the LTC without this monitoring interrupt.
system properly connected and functional if the An optional mechanical interlock is available to
transformer is energized. Follow the test prevent hand cranking if a vacuum interrupter
procedures outlined in section 4.4.3. failure occurs or upon loss of control power. As with
any safety device, the mechanical interlock should
During operation, if the monitoring system trips, do not be intentionally defeated or tampered with.
not reset until the LTC has been inspected and the
cause of the trouble corrected. The monitoring system’s control and indicating
components are located inside the door of the drive
Failure to adhere to these requirements can lead to mechanism cabinet. It contains the electronic circuitry,
property damage and/or personal injury. power supply, 86 L, 86 C and 86 R trip relays, SP
supervision power relay, 3 red and 3 yellow LEDs and a
Please contact Reinhausen Manufacturing for green LED, a TEST push-button (green) and a RESET
assistance and refer to Chapter 8 for further details. push-button (red).

Three saturating current transformers in the stationary The red LEDs indicate energizing of the associated trip
contact leads of the vacuum interrupters are provided. relays. The yellow LED’s indicate energizing of the SP
The electrical signal from the current transformer is relay denoting loss of CT signal for the associated phase.
transmitted by fibre optic cable to the monitoring circuit The green LED indicates operability of the system. The
board. These cables must be handled with reasonable green TEST push-button is used to test the internal
care. DO NOT BEND OR COIL these cables to a radius circuitry of the monitoring system.
smaller than 100 mm (3.94”). Overbending will damage
the cable and destroy its ability to carry a light pulse. Pressing the TEST push-button simulates a failure
condition of all three phases, energizes the trip relays and
The system monitors the current in all three phases at a lights the three red and three yellow LEDs. After testing
threshold of less than 15 amperes after the interrupters the monitoring system must be reactivated by pressing
are open but prior to the movement of the tap selector the red RESET push-button.
contacts. The logic circuit evaluates these signals and
protects the LTC in case of vacuum interrupter failure by The system should be tested at installation and scheduled
operating a bistable output relay. This relay operation examination intervals. The physical layout of the
returns the LTC to the original position before the tap monitoring system circuit board is shown in fig. 11,
selector opens the circuit and prevents further operations. section 4.4.3.
 11

Fig. 10. drive mechanism cam switch assembly, hinged door open showing monitoring system and handcrank
3.8 Drive Mechanism/Cam Switch Assembly (fig. 10) A handcrank coupling with interlocking switch is provided
at the main gear unit and can be used with the air
The drive mechanism and cam switch control assembly compartment door open.
are housed in a separate air compartment attached to the
bottom of the tap changer oil compartment. The entire A modified version of the drive mechanism/cam switch
assembly, together with the position indicator, motor assembly with weather-proof drive shaft seal on top of the
capacitors and terminal blocks, is mounted to a housing allows for separate attachment of the air
detachable mounting plate affixed to the rear wall of the compartment to the transformer main tank at a lower
motor drive housing. level, if required. In this case, a single drive shaft couples
tap changer and drive mechanism. Its length may be
The drive mechanism is powered by a single-phase, 208 - varied according to customer specifications (max. shaft
240 volt, 60 Hertz, permanent split capacitor motor which length 2,500 mm (98.4 in.).
is flange-mounted to a self-contained reduction gear unit.
This gear unit is grease filled and sealed at the factory to The drive mechanism requires a separate customer
eliminate the need for subsequent lubrication. Its output supplied control cabinet with appropriately sized motor
shaft couples directly to the tap changer main shaft which control relays and protective circuit breaker. On request
extends through the tap changer oil compartment bottom. this control cabinet can be supplied by Reinhausen.
An auxiliary reduction gear driven from this gear unit Please consult wiring diagram supplied with each order
operates the factory preset cams and the position for specification guidelines concerning motor control
indicator. relays and protective circuit breaker.

The air compartment is accessible through a front Option

mounted, weather-proof, hinged door. The LTC tap
position indicator is visible through a viewing port in the The drive mechanism assembled on the mounting plate
door. including cam switch assembly, monitoring system circuit
The position indicator has two red drag hands indicating board, position indicator, drive shaft and required fittings
the maximum and minimum positions (raise and lower) of is also available to be mounted into the transformer
the actual operating range. control cabinet by the customer.
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4. INSTALLATION

4.1 Receiving, Handling and Storage

CAUTION
Welding adjacent to the epoxy terminal board may
Before mounting on the transformer the tap changer oil distort its mounting surface and cause damage to
compartment and the drive mechanism air compartment the terminal board or its oil seal.
should be opened and inspected for damage which may
have occurred in shipment due to rough handling. If
shipping damage is evident, file a claim with the 4.2.2 Mounting the drive mechanism air compartment
transporting company. The sales office of Reinhausen
Manufacturing should be notified promptly of damage The LTC and motor drive are shipped on separate pallets
occurring during shipment from its plant. in the neutral position. The LTC and motor drive serial
numbers should be checked prior to assembly to ensure
No special handling of the tap changer is required other they match.
than that accorded the transformer in general.

The tap changer is shipped from Reinhausen WARNING

Manufacturing filled with dry nitrogen under positive
Do not turn the LTC input shaft nor the drive
pressure. If the tap changer is opened and the nitrogen fill
mechanism output shaft until they are coupled with
is lost the tap changer oil compartment must be purged
each other.
and filled with dry nitrogen at a pressure not exceeding 4
psi, when stored again indoors.
Prior to shipment the LTC is locked in the neutral position
by a cotter pin which is inserted through the boss and the
The LTC and drive mechanism are not prepared for
drive shaft extension on the bottom of the tank. This
storage in an unheated building or outdoors. Such
cotter pin should not be removed until the motor drive is
conditions require:
ready for assembly to the LTC.
- filling the LTC tank with clean, dry oil and the gas
The motor drive unit is also shipped in the neutral
space with dry nitrogen,
position. Confirm this by checking that:
- weather protecting of the exterior of the tank and
1. the position indicator is on neutral
terminal board,
2. the cam switch timing wheel is at zero degrees
-heating the drive mechanism air compartment by
Standard Mounting
connecting the built-in space heater to power.
(Attachment to the LTC oil compartment)
4.2 Mechanical Set-up
The LTC and motor drive must be coupled in the neutral
position per drawing 4D32012 (see appendix).
4.2.1 Attaching the oil compartment
Detached (Ground Level) Mounting
Check the size of the opening in the transformer main (Attachment to the transformer main tank)
tank. For minimum tank opening dimensions see
customer dimensional arrangement drawing. Weld the LTC This version requires, provided by the transformer
compartment to the transformer main tank taking care manufacturer, a mounting support on the transformer main
that the weld is oil-tight, pressure and vacuum resistant. tank. The support is fastened to the rear of the drive
mechanism housing.

The LTC and motor drive must be coupled in the neutral

position per drawing 4D32009 (see appendix).
NOTE
The transformer manufacturer is responsible for
mounting the LTC on a transformer tank wall that is
designed to withstand normal test and operating
pressures (15 psi maximum). A 0.25-in. oil tight weld
is required around the outside perimeter of the LTC
mounting flange. Welding on the transformer side of
the LTC is not required.
 13

4.3 Electrical Connections

4.3.1 Connecting the tap leads to the LTC NOTE

Observe the engagement of tap selector moving
Connect tap leads to the proper LTC terminal on the contacts for smooth, non-binding operation.
epoxy terminal board. For terminal location and Observe closure of by-pass switch.
designation see dimensional arrangement drawing.
Hand crank in the lower direction (counter-clockwise)
4.3.2 Connecting the monitoring system and the drive back to neutral (position N). The same events should take
mechanism place in the same order as above except that the
movement is from 4 to M.
The drive mechanism is to be wired according to the
wiring diagram which is supplied with each order. To Withdraw the handcrank and place it in the storage holder
connect the monitoring system, insert the cable plug from provided.
the motordrive cabinet into the receptacle on the bottom
of the LTC tank per drawing 4D32012 (see appendix). 4.4.2 Motorized Test Operations
4.4 Test Procedures Operate the tap changer with the drive mechanism
connected to electrical power. Do not run more than 120
4.4.1 Manual Test Procedures consecutive operations or damage to the motor may
occur.
Open the LTC compartment and the drive mechanism.
Insert the handcrank into the guide lever and engage the
motor drive. Sequence check the LTC operation by hand
cranking one step in the lower direction, position N to 1L NOTE
(see sequence chart in drawing 897 151 of appendix). This Extended operation of the LTC without oil in air is not
movement requires 7.5 handcrank revolutions. recommended. However, the LTC may be run once
to both limits and back to neutral position for test
While hand cranking from N to 1L (counter-clockwise) purposes. When running the LTC electrically it
observe that the by-pass switch P2 opens, then the typically stops between 8° to 18° after the 0° mark on
vacuum interrupter trips open and the tap selector moving the timing wheel. This is a normal condition.
contact P1 (nearest to the terminal board) moves from M
to 11. At the same time as the tap selector, the change-
Make sure that both the monitoring system and the drive
over selector will move from B to A. Continue cranking
mechanism are connected to power. Make sure that the
and the vacuum interrupter will reclose and finally the by-
motor control breaker is closed and the handcrank is in its
pass switch P2 closes, positioning the tap changer in “on
storage holder. Place the monitoring system into
position”.
“Maintenance Mode” as per section 8.1 of this manual.
Operate the LTC by closing the raise/ lower switch one
step from neutral position toward the lower limit. Check
the movement of the position indicator to confirm that the
NOTE motor is connected properly. The drive mechanism should
operate and stop “on position”.
Observe the engagement of selector switch and
reversing switch moving contacts for smooth, Operate the LTC one step of at a time from position 1L
non-binding operation. Observe closure of by- toward the lower limit.
pass switch.
Open the handcrank interlock switch by lifting the
Hand crank in the raise direction (clockwise) back to handcrank guide lever while operating the LTC. The tap
neutral (position N). The same events should take place in changer should not operate. Continue with the operation
the same order as above except that the movement is toward the lower limit. Stop on the lowest limit position
from 11 to M and from A to B. (position 16L). With one hand on the motor control
breaker, close the raise/lower switch in the lower
Then check the LTC operation by hand cranking from direction. The drive mechanism should not run. If it does,
position N to 1R. While hand cranking in the raise turn off the circuit breaker at once because either the limit
direction (clockwise) observe that the by-pass switch P3 switch timing or connections are wrong.
opens, then the vacuum interrupter trips open, followed
by the tap selector moving contact P4 (furthest from the Remove the handcrank from its storage holder and insert.
terminal board) moving from M to 4. Continue hand Try to hand crank the tap changer in lower direction. The
cranking and the vacuum interrupter will reclose, then the mechanical stop should operate in approximately 2.5
by-pass switch P3 will reclose, positioning the LTC in “on handcrank revolutions. This can be felt readily on the
position”. handcrank. Do not force the handcrank.
14

Run the tap changer one step at a time in the raise Operational tripping test
direction and repeat the checks as above in the raise limit
(position 16R). 0.5 handcrank revolutions in the raise Connect a variable CT to busbar P2 and the stationary
direction should engage the mechanical stop. contact A of one of the vacuum interrupter assemblies
(Fig. 20), for example left phase. The CT should be able to
Upon completion of the checks return the tap changer to drive a current of at least 20 Amperes.
the assembly position (position N), return the handcrank
to its storage holder. Close the drive mechanism air A monitoring system trip test set is available; reference
compartment. spare parts list in section 9 of this manual.

Place monitoring system into “Maintenance Mode” so that

4.4.3 Monitoring System Tests all three yellow LED’s are flashing slowly (ref section 8.1).
Raise the CT input voltage to drive a primary current of
approximately 15 - 20 A. Start the drive mechanism in one
CAUTION direction. The 86 L relay should trip, the associated red
LED should light, the drive mechanism should stop and
The monitoring system is functional only when the return to its previous position. The moving selector
RMV-II load tap changer is operated by control contact must not disconnect from the stationary during
power (either by manual control switch raise/ lower the process. The drive mechanism must not be operable
or automatically). It does not function if the unit is in either direction, until the monitoring system is reset.
operated by hand cranking. Therefore, never hand
crank the unit if the transformer is energized as Perform same test procedure with the vacuum interrupter
damage to the transformer and/or injury to the assemblies of center and right phase. Observe tripping of
operator may result if any of the vacuum interrupters 86 C and 86 R relays. Be sure to reset the monitoring
fails to interrupt. system so that all 86 relays are untripped and all red lights
out. Close the LTC compartment access door.
Open the drive mechanism door for access to the
monitoring system. There is a green LED which indicates
operability of the system. Two push-buttons are provided, NOTE
one red to reset and one green to test. Figure 11 shows
the layout of these items. Do not overtighten the LTC access door nuts. These
nuts should be tightened to a maximum torque of 15
Check the green LED to ensure that the monitoring Nm (11.1 ft. lbs.), which corresponds to a
system is operative. compression of the gasket to 5/16” thickness.

Power-off test at the transformer control

cabinet 3 red and 3 yellow LED’s
GREEN Push button=TEST RIGHT
RED Push button=RESET CENTER
Open the transformer control cabinet. The green lamp 86
LEFT
GL in the control cabinet should be on indicating that the
monitoring system is energized.

Drop control power. Remove cover from monitoring

system circuit board. Interrupt the power supply to the
circuit board by removing the 1⁄4 A fuse. Reinstate control
power. The 86 GL lamp should then be off and the red
lamp 86 RL, on. Try to operate the LTC drive mechanism.
It should not start. Reinstall the monitoring system fuse
and it’s cover. Close the transformer control cabinet.

GREEN LED

Fig. 11. Monitoring system, cover removed

 15

4.5 Oil Filling/Transformer Vacuum Processing 5. MAINTENANCE-FREE SCHEDULES AND SERVICE

Prior to initial energization of the transformer, perform

tests and examinations per section 4.4.3 and 5.4.1.
NOTE
During transformer vacuum processing (drying) the Because of its basic design, the RMV-II Load Tap Changer
LTC should be considered part of the transformer. will require a minimum of maintenance. However, as with
Therefore, the tap changer and transformer gas any mechanical device, it should receive periodic
spaces should be connected together through the examination.
vent plug. The differential pressure across the
5.1 Maintenance-Free Intervals
terminal board and its gasket system will then be
zero during the entire processing cycle. Auxiliary
The RMV-II is a Maintenance-Free Load Tap Changer
devices, e.g. dehydrating breather, sudden pressure through 500,000 operation count intervals or through 7
relay, etc., must be removed or disconnected during year time spans, whichever occurs first.
processing or filling to prevent damage due to oil
“flooding”. The sudden pressure relay can also be The Maintenance-Free interval can become strictly
damaged by rapid pressure changes (consult the operation count based regardless of time span by use of
instruction leaflet). The vacuum should always be the Model 'B' monitoring system. Refer to section 8 for
broken with dry, inert gas to prevent moisture detailed information.
contamination.
1. The Maintenance-Free intervals, whether time-based or
In preparation for factory testing of the transformer at the operations count-based, will only need complementing by
maximum tap changer voltage rating (15 kV, 25 kV or 69 checks (annually) as follows:
kV), vacuum fill the LTC tank with oil to the proper level
prior to initiating any transformer tests. Oil Sampling - Check for dielectric, combustible gases
and water content - See section 4.5 "Oil Filling".
1 . Make the oil input and vacuum connections to the
compartment. Remove and plug the 1/4-in. coupling VIM System Test - Check circuit board ‘test & reset’
to the dehydrating breather system. function; simulated monitoring runback & ‘power off’
test - See sections 8.4 "In-Service Monitoring Verification"
2. Hold a vacuum of 1 torr, or better, on the tap changer and 4.4.3 "Power-Off" monitoring system test.
compartment for 2 hours prior to filling. Continue to
Motor drive condition - Check heater & accessory
hold this vacuum during filling. Degassed oil will
operation; general mechanical condition – See section
facilitate this process.
4.4.2 "Motorized Test Operations".
3. Break the vacuum with dry, inert gas. 2. Routine site visits should include as good
practice the following:
4. Take three oil samples from the LTC oil compartment
and test for breakdown voltage. All three samples Dehydrating Breather check - Check for oil level and
should have a minimum breakdown voltage of 30 kV desiccant material color – See sections 7.3 and 7.4
by ASTM D 877 or 28 kV by ASTM D 1816. "Operation and Maintenance".
Moisture content should not exceed 20 ppm by
ASTM D1533. Check for oil leaks - All areas with seals or gaskets that
retain oil should be examined.
5. Run the tap changer with motor power through the
complete range limit-to-limit, 16 L to 16 R. 5.2 Taking the LTC Out of Service

6. Reclose the compartment openings. De-energize the transformer and ground all external
bushings.

Open the drive mechanism motor control breaker.

NOTE
The RMV-II tank is designed to withstand a full Record the number of operations shown on the tap
vacuum. The terminal board is designed to changer operations counter.
withstand a maximum differential pressure of 18 psi.
This allows for full vacuum in the LTC tank with a
maximum positive pressure of 3.3 psi from the
transformer side of the terminal board.
16
5.4.1 Vacuum Interrupter Examination
5.3 Draining the Oil
Check the condition of the flexible connector for broken
Take a tap changer oil sample. Test and record the strands.
breakdown voltage.

Remove the vent plug on top of the LTC compartment

and drain oil.

CAUTION
Transformer oil should always be handled as a
flammable liquid. LTC tanks may, under some
conditions, accumulate explosive gasses. Filtering
and handling the oil may generate static electricity.
A damaging explosion could result if any electrical
discharge takes place in an explosive gas mixture.
Safety precautions should include purging the gas
space with dry nitrogen before filtering and
grounding the transformer, its bushings, and all oil
handling equipment.

If the drained oil is to be reused it should be pumped Fig.12. Mechanical test procedure for good vacuum
through a filter press to remove the small amount of
Mechanical test
carbon and metallic particles produced by the switching
duty of the by-pass switch and the normal wear of the
With the tap changer in “on position” lift the connector on
mechanism. Oil should be stored in clean, dry containers
the moving contact by means of a large screwdriver and
if reused.
pull the contact open about 6 mm (fig. 12).
Let it snap close. A good vacuum interrupter will require
Open the LTC access door. Check the door gasket for an opening force of approx. 35 to 40 pounds. The moving
signs of deterioration. Replace with a new gasket if contact should close freely and impact with a short
necessary. metallic ring.

5.4 Internal Examination If an interrupter were completely full of oil, due to bellows
failure, it would not flash over on the hi-pot test but the
pull to separate the contacts would not be more than 5 to
10 pounds or the contact would not snap close quickly.
CAUTION
Contact Erosion Indicator
CAUTION: The monitoring system uses FIBRE
OPTIC CABLES inside the LTC to transmit signals to
A contact erosion indicator consisting of a stationary
the electronic control box. These cables must be
pointer and movable scale is provided. This indicator is
handled with reasonable care. DO NOT BEND OR
located behind a viewing port of the drive mechanism
COIL these cables to a radius smaller than 100 mm
cover plate (see fig. 13). A scale showing the start (S) and
(3.94-in.). Overbending will damage the cable and
the finish (F) points is engraved. This scale is a visual
destroy its ability to carry a light pulse.
indication which gives a rough estimate of contact wear.
The anvil gap (see fig. 32 & 32A) is the governing factor
Check the LTC compartment floor and horizontal surfaces for worn vacuum interrupter replacement. Recording the
for debris that might indicate abnormal wear or trouble anvil gap at receipt and subsequent maintenance intervals
developing. Check all sliding surfaces for signs of will provide the best estimate of remaining contact life.
excessive wear.
At installation the indicator should be checked to confirm
Make a general examination of the tightness of bolts and that the pointer is on the S (start) line.
nuts on those parts which are subject to mechanical
shock and vibrations during tap change operation. When the load tap changer is opened for the first time and
at subsequent examinations (see 5.1) the indicator should
be checked so that contact wear can be evaluated. By
observing the position of the pointer on the scale and the
number of actual tap changer operations, a rough
estimate of the remaining life can be made.
 17

Hi-Pot Test

NOTE

Due to the high reliability we have experienced with

our products over many years in service, we
recommend the Hi-Pot Test only as a means of
troubleshooting in the unlikely event of a specific
suspicion that a vacuum interrupter might be
defective.

With the tap changer “off position” (180˚ on the cam

switch timing wheel) test each vacuum interrupter by
applying a hi-pot test of 25 kilovolts AC or 30 kilovolts DC
for one minute as follows:

Ground all transformer windings. Ground bus bars P2 and

Fig.13. Vacuum interrupter contact erosion indicator P3 (see fig. 14 & 16). Temporarily remove the solid bus
bar connector (see fig. 14) to the vacuum interrupter
stationary contact (bottom side). This will also require
disconnecting the fibre optic cable from the saturating
current transformer.

P3 P2

Fig. 14. Location of P2 & P3, solid bus bar

connector removed
Note the insulating panel between vacuum
interrupter and support

NOTE
The vacuum interrupter is rated for one million
Fig. 15. Test circuits to be used for the Hi-Pot Test
operations at full load. (Overload conditions may
reduce the operational life of the vacuum
(A) Test transformer without center tap
interrupter). However, when the erosion indicator is
near the F (finish) line of the index, turn the
(B) Test transformer with grounded
handcrank slightly until the upper pawl can latch in.
center tap and with max. test
The vacuum interrupter has to be replaced when
voltage of 50 kV or higher
the gap between the operating rod bolt and drive
dog of the drift-off plate is smaller than 0.5 mm (fig.
(C) Test transformer with grounded
32 & 32A show a gap of 5.3 mm when the vacuum
center tap, max. tests voltage lower
interrupter is in the new condition).
than 50 kV
18
Be sure to note the color code and location of the leads
for reinstallation (the green lead is closest to the CT, the
blue lead is in the center, and the orange lead is farthest
from the CT). Attach the fiber optic cable to the panel
support at the top of the tank prior to performing the hi-
pot test.

Locate an insulating panel 6.25 in. x 6.25 in. x 0.125 in.

between vacuum interrupter and support (see fig. 14).

A) Testing with an asymmetrical test

transformer (fig. 15A)
(A test set with one hot lead and one ground lead)

Connect the ground test lead to the vacuum interrupter

moving contact (top) and the hot test lead to the
stationary contact (bottom). Perform the hi-pot test. P3 P2
B) Testing with a symmetrical center-
tapped test transformer (fig. 15B)
(A test set with two hot leads and with max. test
voltage of 50 kV or higher)
Fig. 16. Location of P2 & P3 busbars, solid and flexible
Connect the ground test lead to the vacuum interrupter bus bar connectors removed
moving contact (top) and the hot test lead to the Note the insulating panel between vacuum
stationary contact (bottom). Perform the hi-pot test. interrupter and support

C) Testing with a symmetrical center-

tapped test transformer (fig. 15C)
(A test set with two hot leads and with max. test
5.4.2 By-pass switch (fig. 17)
voltage lower than 50 kV)
Check the condition of the by-pass switch contacts P2
Special method if the maximum voltage of the test
and P3. These contacts see light arcing as they switch the
transformer is less than 50 kV.
tap changer current through the vacuum interrupter during
a tap change operation. Therefore arcing tips are provided
which separate shortly after the moving finger contact
CAUTION assembly opens. Normally, the life of these contacts will
by far exceed the vacuum interrupter life.
Before performing this hi-pot test (C) the flexible
connector assy. 094807 must be disconnected. Push
With the moving contact finger assembly closed measure
back the screws on the vacuum interrupter moving
the total thickness of both arcing tips (see fig. 18). The
contact.
thickness should not be less than 10.5 mm when eroded.
Connect the ground test lead to P2 and P3 (see fig.
16). Connect one hot test lead to the vacuum
interrupter moving contact (top) and the other hot NOTE
test lead to the stationary contact (bottom).
A replacement of the stationary arcing contact tip
Perform the hi-pot test. becomes necessary when the total thickness of
both arcing tips is 10.5 mm or less.
Hi-Pot Test Spare Parts Kit
RM Part No. 095792
5.5 Preparing the LTC for Service
Reattach the bus bar shunt connector(s). Use new lock
nuts M6 (see Spare Parts Kits, section 9), max. torque 9.5 Perform vacuum interrupter examination as per section
Nm (71 in. lbs.). Remove the insulating panel. Attach the 5.4.1.
fibre optic cable. Operate the tap changer to “on
position”. Remove the grounds. Wipe the LTC compartment down to remove all dirty oil,
carbon deposits, metallic fall-out and moisture that may
A vacuum Interupter Hi-Pot Test Set is available; reference have condensed, during the open time, on the walls and
spare parts list in section 9 of this manual. insulating surfaces.
 19

P2 P3

Fig. 17. By-pass switch, single-phase assembly, location Fig. 18. Measuring the by-pass switch arcing tip thickness
of P2 & P3 bus bars
Take three oil samples and test for break-down voltage.
Check that drive mechanism and monitoring system are All three should have a minimum breakdown voltage of
operating properly. Perform test operations of the drive 30 kV by ASTM D877 or 28 kV by ASTM D1816. Moisture
mechanism and a monitoring system test according to content should not exceed 20 ppm by ASTM D1533.
section 4.4.
Close the LTC compartment. The dehydrating breather should be checked to confirm
that the desiccant is dry and the oil level in the clear
plastic oil collection cell is between the two fill level lines
NOTE on the cell (see fig. 19).

Do not overtighten the LTC access door nuts. These Remove grounds from external bushings.
nuts should be tightened to a maximum torque of 15
Nm (11. 1 ft. lbs), which corresponds to a Flare nut 3/8"
compression of the gasket to 5⁄16" thickness. Bracket
Pad
(on transformer
Make the oil input connections to the LTC drain valve. wall)
Remove and plug the 1/4-in. coupling to the dehydrating
breather system.

Fill the LTC compartment with clean, dry oil through a filter
press to the proper level. Vacuum filling is not required
during field service.
Protective grate
After oil filling reclose the LTC compartment openings and
reconnect the dehydrating breather system.

Run the Tap Changer with motor power from the neutral
(or assembly position) to position 16L (or the lowest
position) for approximately 100 operations without
pausing. Return to the neutral position.
Oil Collection
Let the tap changer sit de-energized for one hour to allow Cell
gas bubbles to dissipate from the oil.
Fig. 19. Dehydrating breather
20

6. REPLACEMENT OF THE VACUUM INTERRUPTER

6.1 Removing the Old Vacuum Interrupter (fig. 20)

When removing the old vacuum interrupter carefully P2

observe the configuration of the parts and hardware
during disassembly so that reinstallation can be made P3
easily and correctly. To remove the old vacuum interrupter
proceed as indicated below.

NOTE
If removal of the vacuum interrupter is for any
reason other than replacement, the anvil gap
measurement (see par. 6.2.4/5) must be taken for
reinstallation and proper setting of the vacuum
interrupter erosion indicator. A
Fig. 20. Vacuum interrupter assembly

CAUTION
The Fibre Optic Cables must be handled with
reasonable care. DO NOT BEND OR COIL these
cables to a radius smaller than 100mm (3.94-in.).
Overbending will damage the cable and destroy its
ability to carry a light pulse.

1. Disconnect the fiber optic cable connecting to the CT

located to the right hand side of the vacuum interrupter
being replaced. Be sure to note the color code and
location of the leads for reinstallation (the green lead is
closest to the CT, the blue lead is in the center and the
orange lead is farthest from the CT).

Remove the CT using a 10mm socket and wrench for the

M6 mounting hardware (fig. 21).

Fig. 21. Removing the CT from the interrupter assembly

 21

2. Loosen the hex jam nut M12 on the operating rod-bolt

using a 19mm wrench to turn the nut and a 28mm
wrench to hold the vacuum interrupter moving contact
stem (fig. 22).

CAUTION
If the vacuum interrupter is being removed for
reasons other than replacement DO NOT TWIST the
moving contact.
This may damage the bellows and cause the
vacuum interrupter to fail.

Fig. 22. Loosen the lock hex nut on the operating rod
bolt while holding the moving contact stem

3. Remove the M12 hex bolt from the stationary contact

stem using a 19mm wrench to turn the bolt and a
24mm wrench to hold the vacuum interrupter contact
stem (fig. 23).

Fig. 23. Use a 19mm wrench to turn the bolt and a

24mm wrench to hold the vacuum interrupter
contact stem
22

4. Unscrew the clamp on top of the vacuum interrupter,

which holds the interrupter to the bracket. Using a
7mm socket remove the clamp completely (fig. 24).

5. Remove brass support L-bracket by bending back

locking tabs. Loosen the four M8 nuts using a
13mm wrench (fig. 25). While holding the bracket,
slide the four M8 bolts out to drop the bracket down
(fig. 26). Note: Replace locking tabs with new ones
during reassembly.

Fig. 24. Unscrew the clamp on top of the vacuum

interrupter

Fig. 25. Remove the clamp completely Fig. 26. Drop bracket down
 23

6. Unscrew the vacuum interrupter completely by turning

it off from the operating rod (fig. 27). Make sure to
retain the Belleville washer under the hex jam nut
in place for reinstallation. Do not change the position
of the cam disk by hand cranking the LTC.

Fig. 27. Unscrew the vacuum interrupter completely

24

Fig. 28. Screw by hand until the lock nut is reached Fig. 29. Bolt heads and nuts are aligned to bend locking
tabs
6.2 Installing the New Vacuum Interrupter hand on to the operating rod bolt until the hex jam nut
M12 is reached (fig. 28). Do not tighten yet.
Note: Lock tabs and lock nuts should not be used twice 2. Reinstall brass support L-bracket with the four M8
for reasons of reliability. Always use new lock tabs and bolts and nuts using new locking tabs. Be sure to
lock nuts when reassembling the unit. Sufficient spare orientate the hardware properly (flat ends of the bolt
tabs and nuts are contained in our Spare Parts Kits (see heads and nuts) to allow bending of the locking tabs
section 9). on to the hardware (fig. 29). Attach the vacuum
interrupter stationary contact stem (bottom end) to the
To install the new vacuum interrupter follow the steps solid bus bar connector using the M12 hex bolt and a
previously described but in reverse order. M12 lock washer. Note: If a lock tab was originally
used, replace it with the 19mm lock washer supplied
1. Locate the operating rod bolt and slip on the Belleville with the vacuum interrupter kit (refer to page 40 of this
washer (concave side down) and the bus bar manual). Tighten slightly but do not lock yet.
connector with flexible shunts under the hex jam nut.
Thread the vacuum interrupter moving contact stem by 3. Reinstall the clamp on top of the vacuum interrupter.
Do not tighten firmly yet (fig. 30).

Fig. 30. Reinstall clamp but do not tighten firmly yet

 25

5.3mm

Fig. 31. Viewing the sight hole in the upper right hand
corner

Fig. 32. Location for feeler gauge measurement between

operating rod bolt (window) and drive dog of drift-
off plate (anvil gap)

4. Turn the handcrank slightly until the upper pawl 5. Insert a feeler gauge from the left side into the oval
(latch-rod) can latch onto the by-pass drive opening formed by the operating rod bolt (window)
mechanism. You can identify this action by and the drive dog of the drift-off plate (fig. 32, fig. 32A).
viewing the sight hole in the upper right corner The feeler gauge is to be set to 5.3mm thickness.
of the by-pass cover plate (fig. 31).

NOTE
If reinstalling a used vacuum interrupter, use the
previously measured value to adjust the
interrupter.

Fig. 32A. Anvil gap measurement, schematic

representation
26

Turn the vacuum interrupter and thread it until the

feeler gauge measures firmly. Check the position of the
feeler gauge through the viewing port while turning
(fig. 33).

6. Tighten the clamp to a torque of 2.5Nm (22 in. lbs.).

Hold the moving contact stem with a 24mm
wrench and tighten the hex head bolt M12 using a
19mm wrench to a maximum torque of 30Nm
( 22.1 ft. lbs.). Tighten the vacuum interrupter stationary
contact stem with a 19mm wrench, maximum torque
of 45Nm (33 ft. lbs.).

CAUTION

Although a guide with parallel flats is provided for

the moving contact stem, we recommend to avoid
excessive twisting of the bellows which is attached
to it. Excessive twisting will reduce the mechanical
life of the bellows or will fracture the bellows, which
destroys the vacuum making the vacuum
interrupter inoperative. Fig. 33. Adjustment of vacuum interrupter to the operating
rod-bolt during feeler gauge measurement.
7. Perform several test operations between two tap
positions to ensure the correct stroke of the vacuum
interrupter moving contact. Perform the operations by
hand cranking and observe the vacuum interrupter
opening and closing. Finally set the load tap changer to
"on position".

8. Check to ensure all locking tabs are bent in place and

all hardware is tight and properly torqued.

NOTE
Refer to sections 4.4 and 5.5 for testing
requirements prior to placing the LTC back in
service.
 27
7. DEHYDRATING BREATHER ASSEMBLY to trap any particles in the air during in-breathing.

The dehydrating breather is designed to remove moisture The cylindrical body is filled with dehydrating material
from the air breathed into the load tap changer. It consists which is orange in color when in the dry state. When it
of a cylindrical glass body, top connecting flange, bottom becomes saturated with moisture, its color changes to
breather/trap and an exterior protective grate with three green or colorless. The color change can be observed
observation ports. through the observation ports in the protective grate. The
dehydrating material should be replaced when 75% of the
material has changed from orange to green or colorless.
7.1 Receiving
The breather is shipped detail with the dehydrating
material placed in separate containers.
7.4 Maintenance
7.2 Installation
(For dimensional and general installation details see
drawing DD10008 in the appendix).
NOTE
To mount the disassembled breather:
Two dehydrating materials (desiccant) are
1. Fill the breather chamber with dry dehydrating available:
material (approx. 2.2 lbs.) through the opening in the 1. Silica gel (6 to 16 mesh) which is orange in color
flange on the breather top. when in dry state. It turns green when saturated.
2. Sorbead® ORANGE (4 to 8 mesh) which is
2. Place the flange gasket on top of the flange followed orange in color when in dry state. It turns colorless
by the mounting bracket, aligning the threaded when saturated.
hole with the flange opening. Secure with two M10 x
35 hex head bolts, washers and locking nuts.
The time between subsequent changes of the dehydrating
Mount the dehydrating chamber to the pad (provided by material depends upon the load cycle of the transformer
the user) on the transformer tank wall. See sketch "A" on and the ambient conditions. It is advisable to check the
drawing DD10008 for recommended mounting pad color of the material frequently at first, to determine the
dimensions. Secure with two M10 x 35 hex bolts, washers approximate time interval for replacement of the desiccant
and locking nuts. for the particular application.

Connect the tubing between the top of the breather and A recommended method is to have a second charge of
one of the 0.25" half couplings provided on the LTC side dry dehydrating material on hand in a sealed container.
walls. This allows a quick renewal of the dehydrating breather
filling. The removed saturated desiccant can later be dried
out and stored for the next change.
NOTE
To replace the desiccant, carefully remove and empty the
All connections must be air tight. Use of a high oil collection cell and remove the dehydrating breather
temperature grease on the screw joints helps from its holder by loosening the two M10 x 35 hex bolts.
prevent rust and permits the parts to be removed Empty the saturated material through the hole in the top
easily when necessary. flange into a pan. Refill the breather with a fresh charge
and fill the oil collection cell with clean transformer oil to
3. Remove the clear plastic oil collection cell by the level indicated on the cell. Reinstall the breather on its
squeezing the retaining bracket. Fill it with clean holder, making sure the flange gasket is in place. Finally,
transformer oil until the oil level is between the two fill place the oil collection cell in its bracket.
level lines on the cell. Carefully place the filled oil
collection cell back onto the breather housing bottom. The saturated desiccant can be placed in an open pan
and dried at a temperature of 130˚C to 160˚C for about 2-
3 hours. When dry, the material regains its orange color.
7.3 Operation Since the particles dry from the outside towards the
center, the outer surface will change its color first. This
The breather permits in- and out-breathing when there is a initial change in color should not be considered as a
difference in pressure between the LTC gas space and the complete reactivation of the desiccant. It should be
atmosphere exceeding the head of oil in the breather/trap. allowed to dry as specified above.
The dehydrating material is protected from the ambient
humidity by the oil in the collection cell which also serves
28

8.0 VACUUM INTERRUPTER MONITORING recognize the fault condition. The appropriate phase
(VIM) SYSTEM LED (Yellow) would be illuminated, and the (SP) trip
relay would be latched causing the 86RL pilot light to
illuminate and locking out the LTC.
NOTE
If the LTC is to be operated while being “out-of-service”,
Refer to section 3.7 for safety instructions. the Monitoring System is able to ignore the CT-Light
Conductor condition allowing tap change without a CT
8.1 Vacuum Interrupter Monitoring signal. Temporary bypass of the CT-Light Conductor
System Description integrity check (Maintenance Mode) can be initiated
with the TEST (Green) and RESET (Red) push-buttons
The RMV LTC utilizes a unique monitoring system to using the following sequence:
abort the tap change operation in case a vacuum
interrupter has failed to interrupt the current just prior to 1) Press and hold the RESET button for 5-6 seconds to
the opening of the tap selector contacts or in the event disable the verification system for 30 seconds (three
of monitoring system supply power loss. The system is yellow LEDs flash rapidly). At the end of the 30 seconds,
the only one of its kind on a load tap changer. the LED's go out and the unit returns to normal function.

Utilizing bias resistant fiber optic signals, which move 2) If while the Yellow LEDs are flashing, (indicating a 30
through the LTC tank for a portion of each tap change, second Maintenance Mode), the TEST button is pressed
the RMV provides self-examination of each and every once the verification system will be disabled for 10
operation. Special DC logic within the monitoring minutes (one yellow LED flashing slowly).
system electronics interprets current sensing optical
signals as trigger input is received from a precisely 3) Pressing the TEST button a second time, two yellow
timed cam-operated microswitch (186). Should current LEDs will light and strobe slowly indicating 20 minutes of
be flowing through the vacuum interrupter circuit when it Maintenance Mode. Push a third time for three slowly
normally would be open, the LTC is immediately strobing LEDs and 30 minutes of Maintenance Mode.
stopped and returned to the position from whence it Push a fourth time to manually exit Maintenance Mode
came. Latching alarm relays prevent further operation and return to normal function again, as opposed to
until the system has been reset. System verification waiting for the time to expire.
must always take place prior to resetting and placing In all cases the unit will return to normal function
the LTC back in operation. automatically when the applicable time limit expires.

Specific components utilized in the monitoring scheme The monitoring system electronics are protected from
are as follows: over-voltage and transient conditions on the power
SP supervisory power indication relay located on the supply by varistor technology and against inadvertent
printed circuit board; 86L, 86C, 86R latching alarm improper power supply by a traditional in-line
relays located on the printed circuit board; 86X, 86XL & replaceable fuse. The monitoring system is completely
86XR control relays located within customer’s control functional between 90 & 140 Vac supply voltage.
cabinet; 86GL (green/power on) & 86RL (red/alarm)
status pilot lights located within customer’s control 8.2 Evolution of Design
cabinet.
The original RMV-I vacuum interrupter monitoring
Any alarm condition, whether vacuum interrupter failure, system is triggered by a reed switch “RSW” with input to
abnormal CT signal, or loss of monitoring supply power, its circuit board at terminal points 19 & 24. This system
will cause the 86RL pilot light <alarm condition> to remained in production until superseded by the “186”
illuminate. Additionally, any single or combination of the microswitch design in August 1995. The “186”
latching relays will energize the 86X relay blocking the microswitch input to the circuit board was then changed
function of the raise/lower switch while bringing the LTC to terminal points 6 & 7. The circuit board at that time
back to the position from whence it came via the 86XL was changed to service either construction (universal) by
or 86XR relays, depending on which direction the LTC making terminal points 6 common to 19 and 7 common
was moving. to 24.

Additionally the function of the CT-Light Conductor A dedicated input circuit board with microprocessor
circuit within the LTC is continuously verified. Utilizing based logic (Model ‘A’) was introduced in September
the input from the AIW (‘All is Well’) microswitch, the 2002, to supersede the universal input circuit board. It
circuit checks for signals between the time that the has the “186” microswitch input only at terminal points 6
Bypass opens until the Vacuum Interrupter opens. In & 7.
this situation, CT signals should be present to indicate
that the devices (CTs, Light Conductors) and wiring are In addition an optional Model ‘B’ circuit board with a
functional and all is normal. If any component is not secondary microswitch “AIW” input at terminal points 8
working properly, the associated input terminal would & 9 was also introduced in September 2002, to base the
not have signals present, and the system would Maintenance-Free schedule strictly on operation count
 29

intervals regardless of time in service. The model ‘B’ 8.6 Replacement, Spare or Upgrade Parts
circuit board was made standard in July 2005 for all
RMV’s. • Original Reed Switch “RSW” Triggered System

8.3 Installation and Wiring Fuse for circuit board (1/8A 250V) . . . . . . . . . .58632700
Reed Switch “RSW” . . . . . . . . . . . . . . . . . . . . . . .094391
Due to the close proximity of the terminal points on the 186 Upgrade for RSW units . . . . . . . . . . . . . . . .1A68859
circuit board, care must be taken to insure that no loose Model ‘A’ Printed Circuit Board . . . . . . . . .8993C70H01*
strands of adjacent circuit wires contact one another. Model ‘B’ Upgrade (AIW) . . . . . . . . . . . . . . . . .1A68858*
Using wire ferrules or twisting and soldering strands
together will help insure that no loose strands contact • “186” Microswitch Triggered System
other conductors. Conductor capacity for the terminal (Time-Based Maintenance-Free Interval)
blocks is as follows: Single stranded conductor - 26 to
14 AWG; double stranded conductor (jumpers; sharing) Fuse for circuit board (1/4A 250V) . . . . . . . .8991C00H33
- 26 to 16 AWG. “186” Microswitch . . . . . . . . . . . . . . . . . . . .1A67580H02
Model ‘A’ Printed Circuit Board . . . . . . . . . .8993C70H01
If larger conductors must be used with the ends Model ‘B’ Upgrade (AIW) . . . . . . . . . . . . . . . . . .1A68858
reduced by cutting away strands, care must be taken to
insulate the cut back strands so they do not short to • “186” plus “AIW” Microswitch Triggered System
adjacent conductors! (heat shrink tubing is (Operation Count-Based Maintenance-Free Interval)
recommended).
“186” or “AIW” Microswitch . . . . . . . . . . . . .1A67580H02
8.4 In-Service Monitoring System Verification Model ‘B’ Printed Circuit Board . . . . . . . . . .8993C71H01

Verification of the monitoring and runback systems can It is recommended that the printed circuit board be
be accomplished while the transformer is energized, replaced every 15 years, regardless of the vintage or
model type.
with or without load. With the transformer energized,
bring the LTC to any bridging position. On a standard
*Note: If reed switch trigger is retained, the circuit board
position indicator 16L-N-16R, this would be any odd
will require jumpers from 6 to 19 and 7 to 24.
numbered position. In this position there will be enough
circulating current to generate a signal through the CT-
8.7 Monitoring System Vintage Identification
Light Conductor circuit. By simply simulating the closure
of the “RSW” or “186” switch while the LTC is on the
• Original Reed Switch “RSW” Triggered (Dedicated)
bridging position, a three phase vacuum interrupter Circuit
alarm can be generated. This test confirms the LTC
internal components are functional. For reed switch The circuit board for this version of the system has an
“RSW” triggered units momentarily jump terminals 19 & enclosed signal transformer which is blue in color and
24 and for “186” microswitch triggered units jump has relay covers that are transparent. This circuit board
terminals 6 & 7 while the LTC is on a bridging position to has one green and three red LEDs.
perform the test. All three red LEDs must come on and
the RESET (red) pushbutton on the circuit board must • “186” Microswitch or Reed Switch “RSW” Triggered
clear or turn the three red LEDs back off. (Universal) Circuit

The runback circuit may then be checked by initiating a The circuit board for this version of the system has an
tap change and pushing the TEST (green) button during open signal transformer which is yellow in color and has
the movement of the LTC. This test usually requires two relay covers that are transparent. This circuit board has
people; one at the control cabinet and one at the one green and three red LEDs.
monitoring circuit board. This should be performed in
both the raise and lower direction to verify the runback • “186” Microswitch Triggered (Dedicated) Circuit -
system. The RESET (red) pushbutton will need to be Model ‘A’
pushed to clear the alarm condition prior to testing in
the opposite direction. The circuit board for this version of the system has an
open signal transformer which is black in color and has
8.5 In-Service Monitoring System Trip relay covers that are also black. This circuit board has
(Lockout / 86RL) one green and three red LEDs.

If an in-service installation experiences a vacuum • “186” plus “AIW” Microswitch Triggered (Dedicated)
interrupter alarm on its own (one, two or three phases), Circuit - Model ‘B’
call Reinhausen Manufacturing for support and
instruction at 731-784-7681. The circuit board for this version of the system has an
open signal transformer which is black in color and has
relay covers that are also black. This circuit board has
one green, three red, and three yellow LEDs.
30

9. SPARE PARTS LIST (See section 8.6 for monitoring system parts)

No. Quantity Designation of Parts/Kits RM-Item No.

9.1 1 Set of “Hi-Pot Test” Spare Parts (miscellaneous hardware including 095 792
one Hi-Pot Test insulating panel 6.25 x 6.25 x 0.125 in.)

9.2 3 Vacuum Interrupter Kit, 1500 A / 2000 A / 2500 A 095 740

9.3 3 Flexible Connector Assembly, 1500 A / 2000 A / 2500 A 095 741

9.4 3 By-Pass Switch Kit 1500 A / 2000 A / 2500 A 095 744

9.5 1 Access door gasket (single door), 69 kV design 075 879

1 Access door gasket (flanged single door), 69 kV design 1A67701H01
1 Access door gasket (single door), 15 kV/25 kV design 8992C01H01
1 Access door gasket (flanged single door), 15 kV/25 kV design 1A67701H02

9.6 1 LTC Drive Shaft Flange Assembly 1A67799G01

1 Gear Box Drive Shaft Seal (large) 400 310
1 Endplug (large) 401 828
3 Gear Box Drive Shaft Seal (Small) 401 676
1 Endplug (Small) 401 827

9.7 1 Motor 208-240V, 60Hz, single phase 50115400

Motor with Thermo Switch (special design) 208-240V, 60Hz, single phase 8990C54H01
Motor 120V, 60Hz single phase 8990C01H01

9.8 1 Motor Capacitor (Cylindrical) 585 546

9.9 1 Brake Capacitor Set 094 608

9.10 1 Brake Relay (4 Pole) 8207C39H21

1 Brake Relay (3 Pole) 1A68742H01

9.11 1 Brake Relay Dust Cover (4 Pole) 8207C39H22

1 Brake Relay Base (3 Pole) 1A68742H02

9.12 1 Test Set: Monitoring System Tripping Device 4D36273

9.13 1 Test Set: Vacuum Interupter Hi-Pot Device 4D36277

 31

10. APPENDIX PAGE

Drive mechanism, standard mounting . . . . . . . . . . . . . . . . . . . . . . . .4D32012 . . . . . . . . . . . . . . . . . . . . . .33

Drive mechanism, ground level mounting . . . . . . . . . . . . . . . . . . . . .4D32009 . . . . . . . . . . . . . . . . . . . . . .35
RMV-II load tap changer, operational sequence schematic . . . . . . . .897 151 . . . . . . . . . . . . . . . . . . . . . .36
Dehydrating breather, dimensional and installation details . . . . . . . .DD10008 . . . . . . . . . . . . . . . . . . . . . .37
RMV-II load tap changer, vacuum interrupter assembly . . . . . . . . . . .897 152 . . . . . . . . . . . . . . . . . . . . . .39
RMV-II load tap changer, by-pass switch assembly . . . . . . . . . . . . . .897 153 . . . . . . . . . . . . . . . . . . . . . .41
RMV-II load tap changer, cam switch assembly . . . . . . . . . . . . . . . .4D32299 . . . . . . . . . . . . . . . . . . . . . .43
32
33
34
35
36

RMV-II LOAD TAP CHANGER 897 151 : 2E

Operational Sequence Schematic
 37

RMV LOAD TAP CHANGER DD10008:00

Dehydrating Breather Assembly
38

Part-No. Designation Part-No. Designation

022 313 Shim washer 094 805 Pawl

025 982 Shim washer 094 807 Flexible connector
025 994 Shim washer 401 021 Belleville washer
032 649 Shim washer 401 619 Circlip
032 759 Locktab 401 683 Circlip
040 098 Shim washer 401 726 O-ring
051 940 Coupling bolt 450 063 Hex. head screw M6 x 30
053 899 Shim washer 450 090 Hex. head screw M8 x 35
056 701 Locktab 450 351 Hex. head screw M6 x 10
063 109 Corona shield cap 451 237 Hex. nut M5
077 451 Cam disk 451 239 Hex. nut M8
077 482 Insulating panel 451 241 Hex. nut M12
077 498 Spring support 451 325 Washer
077 499 Operating rod bolt 451 328 Washer
077 500 Dash-pot cylinder 452 011 Ball bearing
077 501 Dash-pot bottom 452 216 Circlip
077 502 Jet disk 452 651 Lock washer
077 503 Piston 453 977 Lock hex. nut M6
077 504 Spring support 453 978 Lock hex. nut M8
077 506 Spacer 453 980 Lock hex. nut M12
077 507 Cover plate 455 035 Hex. head screw M12 x 35
077 509 Connector 500 756 Compression spring
077 512 Pressure plate 501 181 Compression spring
077 513 Support 501 183 Bus bar shunt connection
077 826 Connector 550 150 Compression spring
078 790 Locktab 585 591 Vacuum interrupter
093 701 Drive shaft 900 521 Clamp
094 802 Base assembly
094 803 Parallelogram drive
mechanism assy.

RMV-II LOAD TAP CHANGER Parts designation

Vacuum Interrupter Assembly for dwg 897 152 : 1E
 39

078790 replaced
by 452651

078790

RMV-II LOAD TAP CHANGER 897 152 : 1E

Vacuum Interrupter Assembly
40

Part-No. Designation Part-No. Designation

020 088 Washer 093 700 Lever assembly

023 372 U-sheet 094 807 Flexible connector
040 291 U-sheet 095 049 Tension spring assembly
046 417 U-sheet 095 262 Stationary arcing tip
051 331 Washer 200 841 Bush
057 108 Corona shield 200 886 Spring pad
057 612 Washer 200 915 Spring pad
063 235 Corona shield 200 926 Drive bar
072 867 Washer 400 042 Hex. head screw M6 x 70
075 258 Tubular spacer 400 978 Cyl. pin
075 260 Bearing bush 401 351 Hex. nut M20 x 1.5
075 261 Contact housing 401 621 Ring nut M28 x 1.5
075 262 Bolt 450 063 Hex. head screw M6 x 30
075 263 Moving contact 450 064 Hex. head screw M6 x 35
075 268 Stationary contact 450 067 Hex. head screw M6 x 50
075 270 Bolt 450 094 Hex. head screw M8 x 50
075 271 Connecting bridge 450 156 Hex. head screw M12 x 50
075 294 Corona shield 451 325 Washer
075 353 Cover plate 451 326 Washer
075 354 Washer 451 328 Washer
075 394 Solid connector P3 452 203 Circlip
075 395 Solid connector P2 452 206 Circlip
076 219 U-sheet 452 352 Belleville washer
076 243 Solid connector P 452 871 Circlip
077 065 U-sheet 453 977 Lock hex. nut M6
077 482 Insulating panel 453 978 Lock hex. nut M8
077 512 Guide plate 453 980 Lock hex. nut M12
093 589 Movable contact 460 100 Hex. nut M10 (plastic)
assembly with 501 235 Insul. thread bolt M10
arcing tip, left hand 501 236 Insul. distance sleeve
093 654 Movable contact assembly 550 397 Washer
with arcing tip, right hand

RMV-II LOAD TAP CHANGER Parts designation

By-Pass Switch Assembly for dwg 897 153 : 2E
 41

RMV-II LOAD TAP CHANGER 897 153 : 2E

By-Pass Switch Assembly
42

Part No. Designation Part No. Designation

011 618 CAM DISC 094 075 HNDCRNK LOCKOUT MTG PLATE
025 919 WASHER 094 076 HNDCRNK PIPE SLEEVE
043 126 MOUNTING PAD 094 083 TIMING WHEEL
049 010 WASHER 1A67533H03 SPRING
052 633 INSULATION 1A67580H01 MICROSWITCH
052 758 MOUNTING BOW 1A67580H02 MICROSWITCH 186 AND AIW ONLY
056 907 HOLDING SHEET 1A67582H01 INSULATION TUBING
074 284 MOUNTING BRACKET 200 887 SLIDING PAD
074 285 MOUNTING BRACKET 400 195 PIN SPNG DIN1481-4 x 24
074 286 MOUNTING BRACKET 400 441 SCR CHD DIN84-M 3 x 25-4.8
074 287 MOUNTING BRACKET 401 534 PIN SPNG DIN1481- 3 x 18
074 293 PLATE 401 641 KEY DIN6885-A 4x 4 x 18
076 156 DRIVE SHAFT 401 642 SCR SET DIN914-M 5 x 6
076 157 LIMIT SHAFT 401 643 SCR SET DIN914-M 4 x 6
076 158 PARALLEL SHAFT 401 670 PIN SPNG DIN1481- 3 x 12
076 159 PILOT SHAFT 401 815 SCR SET DIN914-M 3 x 5
076 160 TIE ROD 450 488 SCR HX DIN933-M 5 x 12-8.8
076 161 TIE ROD 450 494 SCR HX DIN933-M 6 x 12-8.8
076 163 SPUR GEAR 450 498 SCR HX DIN933-M 6 x 18-8.8
076 165 SPUR GEAR 451 251 NUT HX DIN934-M 5-8
076 169 MOUNTING BRACKET 451 334 WSHR FL DIN125-B 6.4
076 179 POS. IND. MOUNTING 451 385 WSHR LK DIN7980- 5
BRACKET 452 203 RING RTNG DIN471- 8 x 0.8
077 356 SPACER 453 256 SCR HX DIN933-M 5 x 16-8.8
077 403 POS. IND. SUPPORT 453 266 SCR HX DIN933-M 8 x 16-8.8
078 876 REDUCER BUSHING 453 373 WSHR GL *-VSKD 6
094 068 PLATE ASSEMBLY 453 973 NUT LK DIN980-V M 6-8
094 069 PLATE ASSEMBLY 455 284 WSHR GL *-VSKD 8
094 070 SPUR GEAR ASSY 584 836 POSITION INDICATOR
094 071 SPUR GEAR ASSY R0003700 RS3104-C M 3 x 8
094 072 SPUR GEAR ASSY R0003800 RS3104-C M 3 x 12
094 073 SPUR GEAR ASSY R0003900 RS3302-B 3.2MM
094 074 SPUR GEAR ASSY R0014200 RS3100-C .190-32 x .75
094 074 SPUR GEAR ASSY

RMV-II LOAD TAP CHANGER Parts designation

Cam Switch Assembly for dwg 4D32299
 43

RMV-II CAM SWITCH ASSEMBLY

4D32299
 REINHAUSEN MANUFACTURING INC.

2549 N. 9TH AVENUE

HUMBOLDT, TENNESSEE 38343

PHONE (731) 784-7681

FAX (731) 784-7682
Printed in U.S.A. www.reinhausen.com