Voltage Regulators

Reference Data Effective December 2017 COOPER POWER

SERIES
Supersedes
TD225010EN February 2012 (R225-80-9)

Routine Production Testing of Voltage Regulators

Tests Performed in Accordance with a loss of pressure. Certification that this test
the IEEE Std C57.15™/ IEC 60076-21™ was performed and passed is indicated by
Standards the words "All regulators listed have received
and passed the following tests: ...Leak" in the
This document describes the routine production certified test report.
tests performed on Eaton's Cooper Power series
voltage regulators. These tests are performed as 4. Rated Voltage Operational Test
part of normal production activities and may be This test verifies the proper operation of the
witnessed by the customer. Two weeks notice tap changer and the position indicator limit
prior to the tests will be given if Eaton is informed switches using applied rated voltage. During
of the test witness requirement at time of order. the test, voltage is applied between the S and
These test are performed in accordance with the SL bushings. There are two parts to the test.
routine tests described in the IEEE Std C57.15™ / During the first part, the limit switches are
IEC 60076-21™ standards. place at 8 Raise and 8 Lower. The tap changer
is raised and lowered checking for proper
1. Ratio Tests on All Tap Connections operation of the tap changer, tap changer
The verification of proper ratios is performed indexing, mechanical position indicator
prior to placing the internal regulator assembly limit switches and percentage regulation of
into the tank. The values are recorded voltage. In the second part, the limit switches
and saved for a period of time but are not are moved to 16 Raise and 16 Lower and the
reported. Certification that this test was test is repeated.
performed and passed is indicated by the 5. Polarity Test
words "All regulators listed have received and The polarity test is used to confirm that the
passed the following tests: ...Ratio" in the current and voltage transformers are installed
certified test report. with the correct polarity. The test verifies the
2. External Voltage Run-in Test phase shift of the current in the CT in relation
This test verifies the proper operation of to the control voltage when 30% of rated
the tap changer and position indicator limit current is circulated in the series windings.
switches. The test is performed after the A phase shift of less than 90° is acceptable.
tank has been filled with oil under vacuum. Certification that this test was performed
The test consists of 1000 operations of the and passed is indicated by the wording "All
tap changer with the position indicator limit regulators listed have received and passed the
switches set at 12 Raise and 12 Lower. An following tests: ...Polarity and Phase Relation"
application of 120 volts is applied to the motor in the certified test report.
circuit via the control cable connection under 6. Resistance Measurements of All Windings
the junction box. Certification that this test The resistance of the shunt winding and
was performed and passed is indicated by series windings at taps 16 Raise, 15 Raise, 15
the words "Units have received and passed a Lower, and 16 Lower is measured during the
1,000 operations run-in test" in the certified load loss test. The results are compared to
test report. design values for consistency. The results are
3. Leak Test entered into the test data system and upon
A leak test is performed to confirm that the request, are listed in the certified test report.
regulator tank is free from leaks and that all 7. Insulation Power Factor Test
seals are performing as designed. After the The power factor is measured using a
voltage regulator is filled with fluid under capacitance dissipation bridge (30 VAC). In
vacuum, it is pressurized to 10 PSI or 7 PSI for this test, all three bushings are tied together
round or rectangular tanks, respectively. After and energized while the tank is grounded. This
a minimum of 1 hour has elapsed, the unit is value is reported in the certified test report.
inspected for signs of oil on tank surfaces and
Reference Data TD225010EN Routine Production Testing of Voltage Regulators
Effective December 2017

8. Insulation Resistance Test (Megger) 12. No Load (Excitation) Loss at Rated Voltage and Frequency
During the insulation resistance test, the bushing terminals are No load (core) loss is measured and recorded at taps Neutral
tied together while the tank is grounded. 5 kV DC is applied and 1 Raise for Type A and B regulators with rated voltage
between the bushing terminals and ground for one minute. The applied across the shunt (excitation) windings. A regulator with
final value is read and recorded in meg ohms (MΩ). This data is a series transformer is tested at Neutral, 15 Raise and 16 Raise.
shown in the certified test report. This data is shown in the certified test report.
9. Applied Potential Test (AC Hi-Pot) 13. Excitation Current at Rated Voltage and Frequency
The applied voltage test is performed with all three bushings This test is performed in conjunction with the No Load
tied together and energized at the level specified per IEEE Std (Excitation) Loss test. Exciting current (in amperes) is measured
C57.15™ standard while the tank is grounded. Certification that and recorded at taps Neutral and 1 Raise for Type A and
this test is performed and passed is indicated by the statement B regulators with rated voltage applied across the shunt
"All regulators listed have received and passed the following (excitation) winding. A regulator with a series transformer is
tests: ...Applied Voltage" in the certified test report. tested at Neutral, 15 Raise and 16 Raise. The percentage values
10. Routine Impulse Test for this test are calculated and printed on the report. This data is
During the routine impulse test, all bushing terminals are tested shown in the certified test report.
at rated BIL. The line terminals, S and L, are tied together 14. Impedance and Load Loss at Rated Current and Frequency
through a resistor of 450 Ω ±10% to limit induced voltage. A Load (winding) losses and impedance (in volts) are measured
Type A voltage regulator has the test applied to the source (S) and recorded at taps 16 Raise, 15 Raise, 15 Lower, and 16
terminal while set in the maximum buck position. A Type B Lower at rated current. Impedance percentage is calculated and
voltage regulator has the test applied to the load (L) terminal printed on the certified test report.
while set in the maximum boost position. In addition, voltage
regulators have impulse voltage applied to the SL line terminal.
Two shots are given per test, a reduced full wave shot at
50-70% of BIL impulse levels and a full wave shot at 100% of
BIL impulse levels. The wave shapes are displayed on a memory
oscilloscope and compared for similarities. The detection system
is such that a fault as small as a turn-to-turn short can be
detected. Certification that this test is performed and passed is
indicated by the statement "All regulators listed have received
and passed the following tests: ...Routine Impulse" in the
certified test report.
11. Induced Potential Test (Over Excitation)
This test is performed with 200% of rated voltage applied to
the windings. The duration of the test is 7200 cycles (400 Hz
for 18 seconds). Certification that this test was performed and
passed is indicated by the statement "All regulators listed have
received and passed the following tests: ...Induced Voltage" in
the certified test report.

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Eaton’s Power Systems Division

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United States
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All Rights Reserved For Eaton‘s Cooper Power series product
Printed in USA All other trademarks are property information, call 1-877-277-4636 or visit:
Publication No. TD225010EN of their respective owners. www.eaton.com/cooperpowerseries.