DRIVE SHAFTS & ADJUSTMENTS
July 2018
PT PLN (PERSERO) PT Reinhausen Indonesia (RID)
Drive Shafts
Drive Shafts
Warning:
Do not open the bevel gears for OLTC’s manufactured
after July 1999.
These bevel gears are filled with “liquid grease”
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Drive Shafts
Drive Shafts
Horizontal DS Upper
Bevel gear gear unit
Vertical DS
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Drive Shafts
Drive Shafts
Old design with 6 coupling bracket bolts
New design with 4 self locking screws
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Drive Shafts
Drive Shafts
-Grease the O-ring and coupling
bolt – the coupling bolt should be
free to move in the shaft
-Connect the shaft end and
square tube by two coupling
brackets
Note: there are 2 different types
of coupling brackets as shown
previously
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Drive Shafts
Drive Shafts
After drive shafts are serviced and refitted
make sure there is axial clearance as
shown.
Axial clearance of 3 mm
This allows for expansion and movement of
coupling due to minor misalignment (less
than 2 degrees).
This axial clearance must be in both vertical
and horizontal drive shafts
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Drive Shafts
Drive Shafts – Symmetrical
– Symmetrical Coupling
Coupling
sometimes also referred to as “the alignment” or “the symmetrical
alignment”.
is the mechanical connection of the OLTC and the motor drive unit with the
drive shafts so that both are in the same tap position and the correct
adjustment of the operation to make sure that:
the OLTC completes the tap change before the motor drive unit stops
the difference in the number of turns of the motor drive output shaft
between the tap change completing and the motor drive stopping is
approximately the same in both directions (i.e. the operation is
symmetrical in both directions).
The symmetrical coupling or alignment has to be checked and adjusted if
necessary, whenever the drive shafts connecting the OLTC to the motor drive
unit are removed and re-installed for any reason e.g. servicing of the drive
shafts and the diverter switch.
7
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Drive Shafts – Symmetrical Coupling
Drive Shafts – Symmetrical Coupling
(MA7 and ED)
PROCEDURE FOR THE ADJUSTMENT OF THE SYMMETRICAL COUPLING
(ALIGNMENT) FOR THE MA7 AND ED MOTOR DRIVES
(This is one of several methods that can be used and is shown for the ED motor drive)
The centre mark in the grey field of the tap change indicator will
be used as reference for following procedures.
One tap change operation is represented by one full rotation of
the pointer on the tap change indicator. This indicator is divided
into 33 sections where one section corresponds to one rotation
of the hand crank.
The number of sections from when the diverter switch operates
until the pointer reaches the center mark should be equal
(symmetrical) in both directions.
A slight asymmetry of maximum 1 section is permissible.
To obtain a symmetrical coupling, proceed as follows
WARNING
Before starting any coupling work make sure that the motor
protective switch is tripped to prevent any unintentional start of
the motor drive.
Carry out any adjustment work by manual operation only.
TAP CHANGE INDICATOR
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Drive Shafts – Symmetrical Coupling
Drive Shafts – Symmetrical Coupling
(MA7 and ED)
Step 1:
Make sure the tap changer and the motor drive are in
their adjustment positions before commencing any
adjustment work.
When adjusting, make sure that the position indicators
of the tap changer and the motor drive show the same
position.
Step 2:
couple the motor drive and vertical drive shaft by mounting
the coupling brackets
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Drive Shafts – Symmetrical Coupling
Drive Shafts – Symmetrical Coupling
(MA7 and ED)
Step 3:
Attach the manual handle in the motor drive to the shaft end located in the upper cover
plate. this activates the handle interlock switch and disconnects the supply to the motor.
NOTE: Turn the manual handle slowly to achieve the most accurate
adjustment.
WARNING:
Make sure motor protective device is tripped
Step 4:
Turn manual handle in one direction until the diverter switch operates and stop turning
the handle.
When operating the motor drive manually observe the tap change indicator. This
mechanically shows the progress of the tap-change operation.
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Drive Shafts – Symmetrical Coupling
Drive Shafts – Symmetrical Coupling
(MA7 and ED)
Step 5:
Now turn the manual handle in the same
direction while counting the number of sections
required for the pointer to reach the center mark
of the tap changer indicator.
Note the determined value A and the direction of
rotation. The tap changer operation is completed
Step 6:
Turn the manual handle in the opposite
direction, until the diverter switch
operates.
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Drive Shafts – Symmetrical Coupling
Drive Shafts – Symmetrical Coupling
(MA7 and ED)
Step 7:
Now turn the manual handle in the same
direction while counting the number of
sections required for the pointer to reach
the center mark of the tap changer
indicator.
Note the determined value B and the
direction on rotation. The tap change
operation is completed.
Step 8:
If the value obtained for both direction are identical, the tap
changer and the motor drive are correctly coupled. Carry out
several tap change operations in both directions to make
sure the symmetrical coupling is correct. A=B
Check that the tap changer and the motor drive are showing
the same tap position.
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Drive Shafts – Symmetrical Coupling
Drive Shafts – Symmetrical Coupling
(MA7 and ED)
Step 9:
If the values for A and B are not equal,
proceed as follows: C= A + B
2
Determined the correction value C by
dividing the difference between A and B by 2.
Step 10:
Operate the motor drive using the manual handle in the direction of the
higher value, either A or B until the diverter switch operates and then turn the
handle by the number of sections on the tap-change indicator that is equal to
C.
Uncouple the motor drive and the vertical drive shaft by removing the
coupling brackets. Turn the manual handle until the pointer of the tap change
indicator is in the centre position.
Re-couple motor drive and tap changer.
Check the symmetrical coupling after the adjustment work is correct by
carrying out a few tap change operations in both directions.
Make sure that the pointer of the tap change indicator is in centre position
within the grey field once the manual operation is finished.
Check that the tap changer and the motor drive are showing the same tap
position.
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Drive Shafts
Drive Shafts –– Symmetrical
Symmetrical Coupling (MA9)
Coupling
PROCEDURE FOR CHECKING AND ADJUSTING THE SYMMETRICAL
COUPLING (ALIGNMENT) FOR THE MA9 MOTOR DRIVE
The procedure for the MA9 is different to the procedure for the MA7 and ED.
• For one tap change operation of the MA9, 30 turns of the hand crank turns the
output shaft 1 OR 2 turns depending on when the MA9 was manufactured.
• One tap change operation is represented by one full rotation of the tap change
indicator dial.
• This indicator dial is divided into 30 sections where one section corresponds to
one rotation of the hand crank
• The number of output shaft turns MUST be checked BEFORE the symmetrical
coupling (alignment) can be accurately adjusted.
WARNING – Before commencing the symmetrical coupling (alignment) procedure.
* Make sure the OLTC and the motor drive are showing the same tap position.
* Make sure all the safety precautions detailed in the procedure for the MA7 and
ED are also followed for this procedure.
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Drive Shafts
Drive Shafts –– Symmetrical
Symmetrical Coupling (MA9)
Coupling
MA9 with 30 turns of the hand crank turning the output shaft 1 turn for each
operation of the OLTC i.e. ratio 30:1
The vertical drive shaft coupled to the MA9 is square (4 sides) so the closest the
symmetrical coupling (alignment) can be adjusted is ¼ of a turn of the output shaft.
For ratio 30:1
7.5 turns of the hand crank turns the output shaft ¼ of a turn (i.e. 30 divided by 4)
Starting with the centre mark (usually RED) of the tap change indicator dial in line
with the corresponding mark in the window in the cover plate:
• Slowly turn the hand crank in one direction until the diverter switch operates
and stop turning the hand crank.
• Now turning the hand crank in the same direction, count the number of sections
of the indicator dial until the centre mark lines up with the corresponding mark in
the window of the cover plate. Record this number of sections and the direction
of rotation as value A.
• Now turning the hand crank in the opposite direction, repeat the 2 steps above.
Record this number of sections and the direction of rotation as value B.
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Drive Shafts
Drive Shafts –– Symmetrical
Symmetrical Coupling (MA9)
Coupling
EXAMPLE: (MA9 with ratio 30:1, ¼ turn of the output shaft is 7.5 sections
of the indicator dial)
Value A Value B
Direction of rotation - clockwise Direction of rotation - anticlockwise
Number of sections - 14 Number of sections - 3
The difference in the number of sections between value A and value B is 11 so the
symmetrical coupling can be adjusted to be closer.
So taking 7.5 sections off A = 6.5 sections and adding 7.5 sections to B = 10.5
sections
Now the difference in the number of sections between value A and value B is 3. This
is the closest the symmetrical coupling (alignment) can be adjusted.
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Drive Shafts
Drive Shafts –– Symmetrical
Symmetrical Coupling (MA9)
Coupling
To correct the symmetrical coupling (alignment)
• Turn the hand crank in the direction for value A until the diverter switch operates
and stop.
• Turn the hand crank another 7.5 turns in the same direction and stop
• Uncouple the vertical drive shaft from the output shaft of the motor drive.
• Hold the vertical shaft to prevent it from turning and turn the hand crank in the
same direction until the centre mark lines up with the corresponding mark in the
window of the cover plate. The output shaft will have turned ¼ of a turn.
• Re-couple the vertical drive shaft to the output shaft of the motor drive.
• Check the symmetrical coupling (alignment) is correct by operating the tap
changer a few times in both directions.
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Drive Shafts
Drive Shafts –– Symmetrical
Symmetrical Coupling (MA9)
Coupling
MA9 with 30 turns of the hand crank turning the output shaft 2 turns for each
operation of the OLTC i.e. ratio 30:2
15 turns of the hand crank turns the output shaft 1 turn
The vertical drive shaft coupled to the MA9 is square (4 sides) so the closest the
symmetrical coupling (alignment) can be adjusted is ¼ of a turn of the output shaft.
For ratio 30:2 equal to 15:1
3.75 turns of the hand crank turns the output shaft ¼ of a turn (i.e. 15 divided by 4)
Starting with the centre mark (usually RED) of the tap change indicator dial in line
with the corresponding mark in the window in the cover plate:
• Slowly turn the hand crank in one direction until the diverter switch operates and
stop turning the hand crank.
• Now turning the hand crank in the same direction, count the number of sections of
the indicator dial until the centre mark lines up with the corresponding mark in the
window of the cover plate. Record this number of sections and the direction of
rotation as value A.
• Now turning the hand crank in the opposite direction, repeat the 2 steps above.
Record this number of sections and the direction of rotation as value B.
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Drive Shafts
Drive Shafts –– Symmetrical
Symmetrical Coupling (MA9)
Coupling
EXAMPLE: (MA9 with ratio 30:2 (equal to 15:1), ¼ turn of the output shaft
is 3.75 sections of the indicator dial)
Value A Value B
Direction of rotation - clockwise Direction of rotation - anticlockwise
Number of sections - 2 Number of sections - 15
The difference in the number of sections between value A and value B is 13 so the symmetrical
coupling can be adjusted to be closer.
adding 3.75 sections to A = 5.75 sections and taking 3.75 sections off B = 11.25 sections
Now the difference in the number of sections between value A and value B is 5.5.
The symmetrical coupling (alignment) can be adjusted closer.
adding 3.75 sections to A = 9.5 sections and taking 3.75 sections off B = 7.5 sections
Now the difference in the number of sections between value A and value B is 2. This is the
closest the symmetrical coupling (alignment) can be adjusted. 19
19
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Drive Shafts
Drive Shafts –– Symmetrical
Symmetrical Coupling (MA9)
Coupling
To correct the symmetrical coupling (alignment)
• Turn the hand crank in the direction for value B until the diverter switch operates
and stop.
• Turn the hand crank another 7.5 turns in the same direction and stop
• Uncouple the vertical drive shaft from the output shaft of the motor drive.
• Hold the vertical shaft to prevent it from turning and turn the hand crank in the
same direction until the centre mark lines up with the corresponding mark in the
window of the cover plate. The output shaft will have turned ½ of a turn.
• Re-couple the vertical drive shaft to the output shaft of the motor drive.
• Check the symmetrical coupling (alignment) is correct by operating the tap
changer a few times in both directions.
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Drive
Drive Shafts––Synchronising
Shafts the
Synchronising the operation
operation of of
multiple
multiplepoles
poles
To ensure that all the separate poles of a tap changer with one motor drive unit,
operate at the same time during each operation of the tap changer.
Typical multiple pole tap changers are as follows
MIII Delta – 2 poles
3 x MI – 3 poles
MIII K – 2 poles ( 1 x MII and 1 x MI)
Synchronising the operation of the multiple poles of the tap changer should
be carried out before the checking and adjusting of the symmetrical
coupling(alignment) of the motor drive unit and the tap changer
(The following procedure is one of several methods that can be used for
synchronising the separate poles of a multi-pole tap changer)
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Drive
Drive Shafts––Synchronising
Shafts the
Synchronising the operation
operation of of
multiple
multiplepoles
poles
WARNING FOR SAFETY REASONS
Before doing any work on the drive shaft system, the motor protective switch in the motor
drive unit should be tripped to prevent operation of the motor drive unit.
Only carry out the adjusting work by manual operation using the manual operating handle.
Step 1
Make sure all the poles and the motor drive unit are in the adjustment position and install all the shafts
loosely between the poles and the bevel gear and the motor drive.
Step 2
NOTE: An observer should be on top of the transformer to identify which tap changer pole operates first
and to note the direction of rotation of the horizontal drive shafts.
Using the manual operating handle slowly operate the tap changer until the diverter switch of the first
pole to operate is heard - STOP turning the handle when it is heard.
The observer identifies the pole that operated first and notes the direction of rotation of the drive shafts.
Step 3
• Remove the horizontal drive shaft (or shafts) from the pole that operated first so that it cannot be
moved anymore.
• Remove the drive shaft from the horizontal side of the bevel gear.
• Remove the other horizontal shafts between the remaining poles (or pole) so that other poles (or
pole) can be operated separately by turning the horizontal drive shaft still connected to it. in the
direction of rotation as noted by the observer in Step 2.
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Drive
Drive Shafts––Synchronising
Shafts the
Synchronising the operation
operation of of
multiple
multiplepoles
poles
Step 4
Manually turn the horizontal shaft for each remaining pole in the direction of rotation as noted by
the observer in Step 2 until the diverter switch operates - STOP turning the shaft as soon as each
switch operates.
Check to make sure all the poles and the motor drive unit are now on the same tap position.
Step 5
Install all the shafts that were removed to reconnect all the poles and the bevel gear to the motor
drive unit. The poles should all now be synchronised.
Step 6
• Using the manual operating handle, finish the operation of the tap changer started in step 2.
• Slowly make another operation of the tap changer and stop turning the handle when the
diverter switch or switches operate.
• Slowly turn the handle and count the number of sections of the tap change indicator until the
last pole operates.
• A maximum of 1 section difference is allowed between the operation of the first and last pole.
• If the synchronising procedure is done carefully enough, it is possible for all the poles to
operate together.
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Drive
Drive Shafts––Synchronising
Shafts the
Synchronising the operation
operation of of
multiple
multiplepoles
poles
Step 7
Check the synchronising of the poles for several operations in both directions.
Step 8
Check and adjust as necessary the symmetrical coupling of the motor drive unit and the tap
changer using the operation of the last pole as the point to count the number of sections on the
tap change indicator until the pointer is at the centre mark. Refer to the procedure for the
adjustment of the symmetrical coupling.
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