TAPCON® XPA-I – External Paralleling Assistant

www.reinhausen.comTAPCON® XPA-I – External Paralleling AssistantOperating Instructions BA 282/02

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Contents

Contents

1 General ............................................................................................................................................................................................................... 4

1.1 External Paralleling Assistant .......................................................................................................................................................... 4

2 Safety ................................................................................................................................................................................................................ 6

3 Introduction .................................................................................................................................................................................................. 7

3.1 Paralleling ............................................................................................................................................................................................ 73.1.1 Paralleling with MR-Tap-changer Controls TAPCON 230 ......................................................................................... 73.1.2 Paralleling with a Mixture of Controls ........................................................................................................................... 7

4 Theory of Operation ..................................................................................................................................................................................... 8

5 Application .................................................................................................................................................................................................. 9

5.1 Terminal Connections ....................................................................................................................................................................... 10Figure 1 Simplified Schematic of Current Circuit for ParallelingTwo Transformers using the Circulating Current Method ...................................................................................................... 10Figure 2 Paralleling Scheme for Two Transformers using the Circulating Current Method .......................................... 11Figure 3 Paralleling Scheme for Two Transformers for mixed controls usingthe Circulating Current Method ..................................................................................................................................................... 12Figure 4 Schematic for mixed controlsThree Transformers using the Circulating Current Method .................................................................................................... 13Figure 5 Interconnection TAPCON® XPA-I – TAPCON® 230 .................................................................................................. 14

6 Test Procedures .............................................................................................................................................................................................. 15

6.1 Two Transformer Parallel Verification Test Procedure ............................................................................................................. 15

6.2 Three Transformer Parallel Verification Test Guide ................................................................................................................... 17

7 Effect of the TAPCON® XPA-I on Control Sensitivity ..................................................................................................................... 19

Table 1 Sensitivity Settings .......................................................................................................................................................................... 19Figure 6 Vector Diagram .............................................................................................................................................................................. 20Figure 7 TAPCON® XPA-I Outline and Mounting Dimension .............................................................................................................. 21Figure 8 TAPCON® XPA-I Outline and Mounting Dimension .............................................................................................................. 22Figure 9 TAPCON® XPA-I Block diagram .................................................................................................................................................. 23

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1 General

1.1 External Paralleling Assistant

The mode of operation of TAPCON® XPA-I complies with themethod set forth in ANSI C57.12.10-1998, Paragraph 10.2.

TAPCON® XPA-I offers all the required components to place anadditional power transformer and on-load tap-changerelectrically in parallel with an existing transformer(s) using theminimum circulating reactive current method. It provides theparallel-independent control switch (43P), settable trip currentlevel to interrupt the motor operation and sensitivity adjust-ment to balance tap-changer operations. The characteristics ofthe present circulating reactive current is transferred via theCAN-Bus to the TAPCON® AVR family (90 Relay) for properregulation and control.

By using a special current transformer switching system,TAPCON® XPA-I registers the circulating reactive currentbetween parallel connected power transformers.

Since the sensitivity for the circulating reactive current can bebalanced directly at the TAPCON® XPA-I, problems such ashunting of tap position between two voltage steps of thetransformer (sensitivity too high) or the passing over of severalvoltage steps (sensitivity too low) can be effectively avoided.

Additionally, the motor-drive unit of the on-load tap-changercan be stopped by a relay contact in case the circulatingreactive current exceeds an adjustable threshold value.

Your advantages:

• Three-in-one: Paralleling module, AC-current relay andadaptable to replace existing equipment or install inexisting parallel provisions

• Prevents damage to LTC transformer’s switching mechanismunder excessive loads

• 50 % cost savings in wiring compared withnon-Reinhausen parallel regulated transformer

• Reduced electrical interference levels

• Compatible with all parallel working voltage controllers ofthe Reinhausen TAPCON® series

• Flush panel mounting or DIN rail

• Robust aluminium housing

• Usable with numerous non-Reinhausen paralleling voltagecontroller devices

• Easy one to one replaceable design

1 General

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1 General

Current InputsRated at 0.2 A, 10 VA, 50/60 Hz.

Current RatingsEither winding K1, K2 from terminal 1 to 5 is rated for 0.2 Acontinuous.

All windings will withstand the following: 0.4 A continuous,2.9 A for 5 sec; 3.3 A for 4 sec; 4.0 A for 3 sec; 5.0 A for 2 sec.Cores are unsaturated at 10 VA burden.

Sensitivity ControlSensitivity adjustment prevents LTC transformers from huntingor being several steps apart.Sensitivity is adjustable from two times normal to 0.5 timesnormal in nine steps.

Circulating Overcurrent-RelayIts range permits the maximum circulating current to be setfrom 5 % to 50 % of the rated full load current.

Parallel/Independent SwitchMode of LTC control is switch selectable.

Transient ProtectionInput and output circuits are protected against systemtransients. The –XPA-I will exhibit no component failure orfalse commands when subjected to the requirements of ANSI/IEEE C37.90.1-1989, which defines oscillatory and fasttransient surge withstand capability. All inputs and outputswill withstand 1500 V ac to chassis or instrument ground forone minute. Voltage inputs are electrically isolated from eachother, from other circuits, and from ground.

MountingPanel mounted using 8-1/2" x 6-1/8" cutout (21.59 cm x15.56 cm). May be surface mounted using the M-0124Surface Mounting Adapter.

EnvironmentalTemperature Range:Stated accuracies are maintained from –40 ° to +80 °C.

Humidity: Stated accuracies are maintained at up to 95 %relative humidity (non-condensing).

PhysicalSize: 10" high x 6-3/8" wide x 4-15/32" deep (25.40 cm x16.19 cm x 11.35 cm). When using the M-0124 SurfaceMounting Adapter, maximum depth is 4-9/16" (11.59 cm).

Approximate Weight: 5 lb (2.3 kg)

Approximate Shipping Weight: ……..

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2 Safety

2 Safety

WARNING

DANGEROUS VOLTAGES, capable of causing death or seriousinjury, are present on the external terminals and inside theequipment. Use extreme caution and follow all safety ruleswhen handling, testing or adjusting the equipment.However, these internal voltage levels are no greater thanthe voltages applied to the external terminals.

DANGER! HIGH VOLTAGE!

This sign warns that the area is connected to a dangeroushigh voltage, and you must never touch it.

PERSONNEL SAFETY PRECAUTIONS

The following general rules and other specific warningsthroughout the manual must be followed during appli-cation, test or repair of this equipment. Failure to do so willviolate standards for safety in the design, manufacture, andintended use of the product. Qualified personnel should bethe only ones who operate and maintain this equipment.Beckwith Electric Co., Inc. assumes no liability for thecustomer’s failure to comply with these requirements.

CAUTION

This sign means that you should refer to the correspondingsection of the operation manual for important informationbefore proceeding.

Always Ground the Equipment

To avoid possible shock hazard, the chassis must be con-nected to an electrical ground. When servicing equipmentin a test area, the Protective Earth Terminal must be attachedto a separate ground securely by use of a tool, since it is notgrounded by external connectors.

CAUTION

Do NOT operate in an explosive environmentDo not operate this equipment in the presence of flammableor explosive gases or fumes. To do so would risk a possiblefire or explosion.

Keep away from live circuitsOperating personnel must not remove the cover or exposethe printed circuit board while power is applied. In no casemay components be replaced with power applied. In someinstances, dangerous voltages may exist even when power isdisconnected. To avoid electrical shock, always disconnectpower and discharge circuits before working on the unit.

Exercise care during installation, operation, andmaintenance proceduresThe equipment described in this manual contains voltageshigh enough to cause serious injury or death. Only qualifiedpersonnel should install, operate, test, and maintain thisequipment. Be sure that all personnel safety procedures arecarefully followed. Exercise due care when operating orservicing alone.

Do not modify equipmentDo not perform any unauthorized modifications on thisinstrument. Return of the unit to a MR Electric repair facilityis preferred. If authorized modifications are to be attempted,be sure to follow replacement procedures carefully to assurethat safety features are maintained.

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3 Introduction

3 Introduction

BackgroundWhen LTC transformers are connected in parallel, a controlscheme is necessary to assure that the tap positions of allparalleled transformers remain at or near the same tap posi-tion. If tap positions are not maintained at or near the samepositions, reactive current will circulate between the transfor-mers, wasting energy and overheating the transformers,possibly causing damage. The circulating current control isthe most common method for control of LTC transformers inparallel, being covered by ANSI C57.12.10-1998 paragraph10.2, and has the following advantages:

• Any transformer can be automatically or manuallyswitched-out for maintenance; the remaining units willoperate properly (in parallel, if more than two are beingused).

• Proper line drop compensator (LDC) action for each unit isprovided at all times.

• Transformers from different manufacturers or vintages canbe easily paralleled if they meet certain performancecriteria, even if they were not originally equipped forparalleling.

3.1 Paralleling

The TAPCON® XPA-I Parallel Balancing Module includes all thecompo-nents that must be added to LTC transformers topermit them to operate in parallel, using the circulatingcurrent method. The transformer controls must have a 0.2 Ainput for load and circulating current.

3.1.1 Paralleling with MR On-Load Tap-ChangerControls TAPCON® 230

Excellent results are obtained using the MR On-Load Tap-Changer Controls TAPCON® 230. The fast response to voltagechanges, the excellent phase accuracy of the line drop com-pensator and the temperature stability of the MR On-LoadTap-Changer Controls assures that the parallel combinationwill maintain the same tap settings with changes in temper-ature and load, even when using low bandwidth settings.

3.1.2 Paralleling with a Mixture of Controls

A mixture of following Balancing-modules and controls ispossible!

TAPCON® XPA-I – SkB20 with Mk, Mk30 (MR)TAPCON® XPA-I – M-0115A with M-0067E

M-2001B, M-2001C (Beckwith)

MR cannot assure maximum performance where a mixture ofequipment from various manufacturers exists.

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4 Theory of Operation

4 Theory of Operation

The general paralleling schemes for two and three transformerparalleling using the circulating current method are shown inFigure 1 through.

Figure 1 shows the schematic of the current circuit only;redrawn from the Paralleling Scheme figures to allow easiertracing of the load current (IL) and circulating current (IP)paths.

A current, proportional to the transformer secondary current,is fed to the TAPCON® XPA-I unit. Because of the secondaryparallel connection, however, this is actually the vector sum ofthe desired load current and any undesired circulating current.The TAPCON® XPA-I separates these currents, and sends themto the circulating current transformer K3 and to the properload (LDC) inputs of the associated control.

Two current loops are formed. One involves the K3 auxiliarytransformers in each of the TAPCON® XPA-I units. This loopforms a measure of the transformer bank circulating current,subtracted from the LDC control input and forced to flow intothe secondary winding of K3.

The second loop involves the K1 and K2 auxiliary transformers.They force the load current to divide properly between thevarious controls so that each senses its proper portion of thetotal bank load. Thus, the LDC setting for each control mayproperly be the same, regardless of whether or not theassociated transformer is being used in parallel.

The first current path shown (Circulating Current) has a currentanalogous in angle and magnitude to the reactive currentcirculating through the paralleled transformers (The current ismeasured by amount and phase position. The difference iscalculated from this and transferred via CAN bus to the voltageregulator). It also includes the overcurrent relay function,which is used to detect excessive circulating current and blockthe on-load tap-changer movement, if this occurs. Also, a LEDwill alert the operator when excessive circulating current isdetected.

The second path shown (Balance Current), connecting the K1auxiliary C.T. of the TAPCON® XPA-I modules together, has abalance current which forces the two load currents of trans-formers #1 and #2 to be identical. This means that anydifference in currents must flow in the circulating currentpath.

The third and fourth path shown (Half Current and LDC Cur-rent), connecting the K2 auxiliary C.T. of the TAPCON® XPA-Imodules together, ensures proper operation of the Load DropCompensator circuit if one of the transformers is taken out ofservice by opening its breaker. For instance, if transformer #2is taken out of service by opening breaker 52-2, then half oftransformer #1’s load current is forced to flow through thehalf current loop. In this way, transformer #1’s voltageregulating control sees the same load current as it did before,and the proper amount of line drop compensation in thetransformer #1 control is maintained. This circuit configura-tion and grounding points must be maintained, if transformersare to be successfully paralleled.

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The ..XP-I Parallel Balancing Module can be ordered with newequipment from most transformer manufacturers or added toexisting transformers. If the Module is added to existingequipment, the following factors should be considered:

• If the old control uses a 5 A input for the line dropcompensator, a new control must be installed to providethe required 0.2 A load and circulating current inputs.

A MR On-Load Tap-Changer Control is recommended forthis application.

• If an existing 5/0.2 A auxiliary current transformer is notavailable to provide the measure of secondary loadcurrent, one must be added.

An Auxiliary Current Transformer is recommended for thisapplication (8,66 or 5/0,2 A).

• If phase-to-phase voltage is used, Figure 6 shows theapplication of two current transformers to derive a currentin phase with the voltage. Connection must be made toTerminal of the 8,66A-range.

• If circuit breakers (52) exist, then the auxiliary breakercontacts shown in the Paralleling Scheme figures arerequired to automatically change from parallel toindependent operation should the breakers operateautomatically or by remote control.

If these breakers do not exist and, for example, only onecommon load breaker is used, the circuit should be wiredto make a circuit where the normally closed contacts areshown. No circuit should be made where the normallyopen contacts are shown.

5 Application

5 Application

CAUTION

Do not place the TAPCON® XPA-I PARALLEL/INDEPENDENT switch in the INDEPENDENT position ifthe transformers are in parallel and under automatic control.

c. The TAPCON® XP-I PARALLEL/INDEPENDENT (P/I)switchshould be placed in the INDEPENDENT positionbefore the load switches are operated.

• If paralleling and hand-operated load switches are used:

a. AUTO/MANUAL switches on the TAPCON® 230 shouldbe placed in the MANUAL position.

b. Other controls should be placed in the MANUALposition.

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5 Application

5.1 Terminal connections

1

Fig. 1 Simplified Schematic of Current Circuit for Paralleling – Two Transformers using the Circulating Current Method

Notes:52 and 24 contacts are shown in the breaker colsed positon; 43 P in the parallel position

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5 Application

2

Fig. 2 Paralleling Scheme for Two Transformers using the Circulating Current Method

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5 Application

3

Fig. 3 Paralleling Scheme for Two Transformers for mixed controls using the Circulating Current Method

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5 Application

4

Fig. 4 Schematic for mixed controls – Three Transformers using the Circulating Current Method

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5 Application

5

Fig. 5 Interconnection TAPCON® XPA-I-TAPCON® 230

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6 Test Procedures

Test procedures are provided for two and three transformerapplications.

6.1 Two Transformer Parallel Verification TestProcedure

6 Test Procedures

NOTE

There must be a load on the transformer to perform thistest.

1. Place all transformer controls (adapter panels) in MANUALand parallel balancing modules (..XP-I) in the INDEPEN-DENT switch position.Set the sensitivity to N.Set the "TRIP CIRCULATING CURRENT" to maximum(100 mA)

2. Set all the transformer controls to the same tap positionand the same bandwidth setting.Neither control should be calling for a raise or lower.

3. Close all transformer breakers and tie breakers.

4. Verify that the load current has the correct polarity.

5. On the control the CT/VT phasing must be set 0 degrees.

6. Set Transformer #1 R Line Drop Compensation to 24.The control should call for a Raise. (If the control calls for aLower, then the polarity of the line current coming into thecontrol is reversed, and must be corrected beforecontinuing the test.)

7. Set Transformer #1 R Line Drop Compensation to 0.


The control should call for a Raise. (If the control calls for aLower, then the polarity of the line current coming into thecontrol is reversed, and must be corrected beforecontinuing the test.)

9. Place the Transformer #1 ..XP-I Parallel/Independentswitch in the Parallel position.

10. Place the Transformer #2 ..XP-I Parallel/Independentswitch in the Parallel position.

CAUTION

If the loads are not evenly balanced between the two trans-formers then the voltage on the transformer with the largerload may drop and the control may call for a raise and thetransformer with the smaller load may rise and the controlmay call for a lower.

11. Verify Transformer #1 voltage is within the band.

12. Manually raise Transformer #1 one to two taps (it couldtake three of four to obtain a response).

13. Manually lower Transformer #2 one to two taps (could takethree or four to obtain a response).

14. Verify that Transformer #2 calls for a Raise and Transformer#1 calls for a Lower.

15. Manually return Transformer #1 and Transformer #2 to thesame tap.Neither control should call for a Raise or Lower.

16. Manually raise Transformer #2 one or two taps (may take 3or 4 to obtain a response).

17. Manually lower Transformer #1 one or two taps (may take 3or 4 to obtain a response).

18. Verify that Transformer #1 calls for a raise and Transformer#2 calls for a lower.

19. Manually return Transformer #1 and Transformer #2 backto the same tap.Neither control should call for a Raise or Lower.

20. Open the tie breaker between Transformer #1 andTransformer #2 (24).

21. Verify that the controls do not call for a Raise or Lower.

22. Manually raise Transformer #1 two or three taps (may take4 or 5 to obtain a response).

23. Verify that Transformer #1 calls for a Lower, the circulatingcurrent is zero on both controls and Transformer #2 is notaffected.

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6 Test Procedures

41. Verify Transformer #2 is not affected.


43. Verify that Transformer #2 calls for a Lower andTransformer #1 is not affected.

44. Manually return Transformer #2 to the same tap.

45. Close the Transformer #1 /52-1).Test complete. Place the desired settings on the controlsand set all controls to AUTOMATIC.

46. Set circulating reactive current monitoring (TRIP-CIRCULATING CURRENT). Circulating reactive currentmonitoring is also set empirically. Prerequisite is thatautomatically-controlled parallel operation is workingcorrectly.

47. Proceed as shown below:Disconnect a voltage regulator from the motor-drive unitby changing the mode switch to MANUAL.Manually raise this motor-drive unit by the maximumpermissible difference of the operating positions betweenparallel-operating units (e. g., 2 to 3 taps).

48. Starting with the scaling value 100, turn the „TRIP CIRCU-LATING CURRENT“ rotary button slowly to the left until theLED shows „RELAY TRIPPED.“ The tripping value ofcirculating reactive current monitoring has been reachedwhen the lamp indicator lights up. It indicates the outputrelay of circulating reactive current monitoring and breaksthe contact between terminals 15, 16. The voltage regu-lator then blocks.

CAUTION

Transformer #1 is now supplying all the load, its voltage maydrop.



26. Verify that Transformer #2 calls for a Lower, the circulatingcurrent is zero. Transformer #1 is not affected.


28. Close the tie breaker between Transformer #1 andTransformer #2 (24).


30. Verify that Transformer #1 calls for a Lower andTransformer #2 calls for a Raise.

31. Place both controls in AUTOMATIC at the same time.

The controls should cause the on-load tap-changers toreturn to the same tap or within 1-2 taps of each other.

32. Return both controls to MANUAL.

33. Manually place Transformer #1 and Transformer #2 on thesame tap and in the bandwidth.

34. Open the transformer breaker on Transformer #2 (52-2).

35. Verify that Transformer #1 is not affected.


37. Verify that Transformer #1 calls for a Lower and thatTransformer #2 is not affected.


39. Close the Transformer #2 breaker (52-2).

40. Open Transformer #1 breaker (52-1).

CAUTION

Transformer #2 is now supplying all the load, its voltage maydrop.

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6 Test Procedures

NOTE

There must be a load on the transformer to perform thistest.

6.2 Three Transformer Parallel Verification Test Guide

1. Set all transformer controls as follows:a. Adapter Panels to MANUAL

b. Parallel Balancing modules ..XP-I set to INDEPENDENT.Set the sensitivity to N.

c. Set the block level to maximum (100 mA).

2. Set all transformer controls to the same tap position andthe same bandwidth setting.

Neither control should be calling for a raise or lower.

3. Close all transformer breakers and tie breakers.

4. Verify that the load current has the correct polarity.

5. On the control the CT/VT phasing must be 0 degrees.

6. Verify that the voltage and CT transformers are connectedto the same phase.


The control should call for a Raise. If the control calls for aLower, then the polarity of the line current coming into thecontrol is reversed, and must be corrected beforecontinuing the test.








13. Set Transformer #1, #2 and #3 Parallel Balancing ModulesTAPCON® XPA-I to the PARALLEL position.

14. Manually Raise Transformer #1 two or three taps (may take4 or 5 to obtain a response).

15. Verify that Transformer #2 and Transformer #3 call for aRaise and Transformer #1 calls for a Lower.

16. Return Transformer #1 back to the same tap. All controlsshould return to a state where no lower or raise is calledfor.

17. Manually Raise Transformer #2 two or three taps (may take4 or 5 to obtain a response).


19. Return Transformer #2 back to the same tap.

20. Manually Raise Transformer #3 two or three taps up (maytake 4 or 5 to obtain a response).



CAUTION

If the loads are not evenly balanced between the transfor-mers then the voltage on the transformer with the largerload may decrease and the control may call for a Raise andthe transformer with the smaller load may increase and thecontrol may call for a Lower.

23. Open the tie breaker between Transformer #1 andTransformer #2 (24-1), then verify that the controls are notaffected.

24. Manually Raise Transformer #1 two or three taps, thenverify that Transformer #2 and #3 are not affected.Transformer #1 should call for a Lower and have zerocirculating current on it’s control.


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6 Test Procedures

CAUTION

If the loads are not evenly balanced between the transfor-mers then the voltage on the transformer with the largerload may decrease and the control may call for a Raise andthe transformer with the smaller load may increase and thecontrol may call for a Lower.

37. Open Transformer #1 breaker 52-1, then verify thatTransformer #2 and #3 are not affected.

38. Manually Raise Transformer #2 two or three taps, thenverify that Transformer #2 calls for a Lower and Transformer#3 calls for a Raise.


40. Close Transformer #1 breaker 52-1.

41. Open Transformer #2 breaker 52-2, then verify Transformer#1 and #3 are not affected.


43. Manually return Transformer #1 back to the same tap.


Note: Since Transformer #1 and #2 will be supplying all theload, their voltage may decrease.

45. Open Transformer #3 breaker 52-3, then verify thatTransformer #1 and #2 are not affected.




Test complete. Place the desired settings on the controls andset all controls to automatic.

NOTE

Since Transformer #2 and #3 will be supplying all the load,their voltage may decrease.

26. Manually Raise Transformer #2 two or three taps, thenverify the following:

a. Transformer #2 calls for a Lower.

b. Transformer #3 calls for a Raise.

c. Transformer #1 is not affected.

27. Place Transformer #2 and Transformer #3 Controls to AUTOat the same time. Observe where the on-load tap-changerpositions settle, and adjust the sensitivity of the TAPCON®XP-I needed.


29. Close tie breaker 24-1 and open tie breaker 24-2 (betweenTransformer #2 and Transformer #3)

30. Verify that the controls are not affected.

31. Manually Raise Transformer #3 two or three taps, and thenverify that Transformer #1 and Transformer #2 are notaffected. Transformer #3 should call for a Lower.


33. Manually Raise Transformer #1 two or three taps, thenverify the following:

a. Transformer #1 calls for a Lower.

b. Transformer #2 calls for a Raise.

c. Transformer #3 is not affected.

34. Place Transformer #1 and Transformer #2 Controls to AUTOat the same time. Observe where the on-load tap-changerpositions settle, and adjust the sensitivity of the TAPCON®XPA-I if needed.


36. Close tie breaker 241 and 24-2.

NOTE

Since Transformer #1 and #3 will be supplying all the load,their voltage may decrease.

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7 Effect of the TAPCON® XPA-I on Control Sensitivity

7 Effect of the TAPCON® XPA-I onControl Sensitivity

The sensitivity of the circulating current to the TAPCON® 230.On-load tap-changer control is fixed at nominal 24 V at fullload current of 0.2 A.

The sensitivity of the on-load tap-changer controls is thenchanged by the TAPCON® XP-I as shown in Table 1.

Tap Nominal Full-Scale Sensitivity forTAPCON® 230

More 4 48 Vac

Sensitive 3 41 Vac

2 32 Vac

1 29 Vac

N 24 Vac

1 20 Vac

2 17 Vac

Less 3 14 Vac

Sensitive 4 12 Vac

Table 1 Sensitivity Settings

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6

NOTE: Only needed if Phase-to Phase voltage is used.

Fig. 6 Vector Diagram

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7

Fig. 7 TAPCON® XPA-I Outline and Mounting Dimension

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8

Fig. 8 TAPCON® XPA-I Outline and Mounting Dimension


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9

Fig. 9 TAPCON® XPA-I Block Diagram


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©Maschinenfabrik Reinhausen GmbH Phone +49 (0)941 4090 0Falkensteinstrasse 8 Fax +49 (0)941 4090-700193059 Regensburg, Germany E-Mail [email protected]

BA 282/02 en • 0909 • F0149701• Printed in Germany

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TAPCON® XPA-I – External Paralleling Assistant