Cooper McGraw-Edison VR-32 Installation and operating instructions

Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Receiving, Installation and Maintenance . . . . . . . 1-1
Control Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Function Codes . . . . . . . . . . . . . . . . . . . . . 3-1
Control Advanced Features . . . . . . . . . . . . . . . . . . 4-1
Tap Changer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . 6-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
General
McGraw-Edison®VR-32 voltage regulators are
regulating auto-transformers. They regulate rated
voltage from 10% raise (boost) to 10% lower (buck) in 32
approximately 5/8percent steps.
McGraw-Edison regulators are supplied with the
following standard features:
• Dual-rated 55/65°C rise
• ADD-AMP™ capability
• Unit construction
• Sealed-tank construction
• Pressure relief device
• 17” minimum creep bushings with clamp-type
connectors
• MOV-type external series arrester
• Shunt arrester mounting bosses
• Two laser-etched nameplates
• Oil sight gauge
• Upper filter press connection
• Drain valve and oil-sampling device
• CE mark compliant control
• Control cable quick disconnect
The 65°C rise insulation system and the sealed-tank
construction allow for a bonus capacity 12% above the
55°C nominal rating without loss of normal insulation
life. The bonus capacity is stated on the nameplate
(such as 167/187 kVA for a nominal 167 kVA regulator).
All McGraw-Edison regulators are manufactured and
tested to ANSI standard C57.15.
Unit construction, which suspends the internal assembly
from the cover, allows for ease of inspection and
maintenance.
There are three types of step-voltage regulators: source-
side series winding (Type B), load-side series winding
(Type A), and series transformer. McGraw-Edison
regulators are usually equipped with an equalizer
winding. The nameplates located on the tank and control
box define the power circuit.
Voltage Regulators
McGraw-Edison®VR-32 Regulator and CL-5 Series
Control Installation, Operation and Maintenance
Instructions and Parts Replacement Information S225-10-10
October 2001 • Supersedes 12/00 • © 2001 Cooper Power Systems, Inc.
Printed in U.S.A.
These instructions do not claim to cover all details or variations in the equipment, procedure, or process described, nor to provide directions for
meeting every possible contingency during installation, operation or maintenance. When additional information is desired to satisfy a problem not
covered sufficiently for the user’s purpose, please contact your Cooper Power Systems representative.
Figure 1.
VR-32 Voltage Regulator with CL-5 Series Control
Service Information

McGraw-Edison VR-32 Regulator and CL-5 Series Control
2
The instructions in this manual are not intended as a
substitute for proper training or adequate experience in
the safe operation of the equipment described. Only
competent technicians who are familiar with this
equipment should install, operate, and service it.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions.
• Is trained in industry-accepted high-and low-voltage
safe operating practices and procedures.
• Is trained and authorized to energize, de-energize,
clear, and ground power distribution equipment.
• Is trained in the care and use of protective
equipment such as flash clothing, safety glasses,
face shield, hard hat, rubber gloves, hotstick, etc.
Following is important safety information. For safe
installation and operation of this equipment, be sure to
read and understand all cautions and warnings.
Safety Instructions
Following are general caution and warning statements
that apply to this equipment. Additional statements,
related to specific tasks and procedures, are located
throughout the manual.
Hazard Statement Definitions
This manual may contain these four types of hazard
statements:
DANGER: Indicates an imminently haz-
ardous situation which, if not avoided, will
result in death or serious injury.
WARNING: Indicates a potentially haz-
ardous situation which, if not avoided, could
result in death or serious injury.
CAUTION: Indicates a potentially hazard-
ous situation which, if not avoided, may
result in minor or moderate injury.
CAUTION: Indicates a potentially hazardous situ-
ation which, if not avoided, may result in equip-
ment damage only.
SAFETY FOR LIFE
Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We
actively promote safe practices in the use and maintenance of our products through our service literature, instructional
training programs, and the continuous efforts of all Cooper Power Systems employees involved in product design,
manufacture, marketing, and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working
around high voltage lines and equipment and support our “Safety For Life” mission.
SAFETY INFORMATION
WARNING: Before installing, operating,
maintaining, or testing this equipment, carefully
read and understand the contents of this manual.
Improper operation, handling or maintenance can
result in death, severe personal injury, and equipment
damage.
WARNING: This equipment is not intended to
protect human life. Follow all locally approved
procedures and safety practices when installing or
operating this equipment. Failure to comply may
result in death, severe personal injury and equipment
damage.
DANGER: Hazardous voltage. Contact with
hazardous voltage will cause death or severe
personal injury. Follow all locally approved safety
procedures when working around high voltage lines
and equipment.
WARNING: Power distribution equipment
must be selected for the intended application. It
must be installed and serviced by competent
personnel who have been trained and understand
proper safety procedures. These instructions are
written for such personnel and are not a substitute for
adequate training and experience in safety pro-
cedures. Failure to properly select, install or maintain
this equipment can result in death, severe personal
injury, and equipment damage.

S225-10-10
3
Figure 2.
External Features of the VR-32 Voltage Regulator
MOV-TYPE SERIES
ARRESTER
UPPER FILTER PRESS
CONNECTION
SHUNT ARRESTER
MOUNTING BOSSES
(3 PER BUSHING)
REGULATOR LIFTING LUGS
LASER-ETCHED
NAMEPLATES (2)
(SECOND ON CONTROL
ENCLOSURE DOOR)
BALL-TYPE OIL
SIGHT GAUGE
PANEL-TYPE RADIATORS
CONDUCTOR
STABILIZING BOSS
HANDHOLE COVER
COVER
AUTOMATIC
PRESSURE RELIEF
DEVICE
CONTROL CABLE WITH
DISCONNECT PLUG
LOCKABLE CONTROL
ENCLOSURE
CONTROL
POSITION INDICATOR
JUNCTION BOX
GROUND BOSSES (2)
DRAIN VALVE & OIL
SAMPLING DEVICE
BOLT-DOWN PROVISIONS (4)
CLAMP-TYPE CONNECTORS
THREADED-STUD
BUSHING TERMINALS
BUSHINGS
INTERNAL ASSEMBLY
LIFTING EYES
POLE MOUNTING
BRACKETS

1-1
Cooper Power Systems
Receiving
Inspection
Prior to shipment, the regulator is thoroughly tested
and inspected at the factory. Immediately upon receipt of
the regulator shipment, before unloading, a thorough
inspection should be made for damage, evidence of
rough handling or shortages. The position indicator,
junction box, arrester, radiators and bushings should
all be inspected for evidence of damage. Should this
initial inspection reveal evidence of rough handling,
damage, or shortages, it should be noted on the bill
of lading and a claim should immediately be made
with the carrier. Also, notify Cooper Power Systems,
2300 Badger Drive, Waukesha, Wisconsin 53188,
attention Service Manager.
Unloading
When an overhead crane is used for unloading, the
regulator must be lifted by means of a sling and
spreader bar utilizing the tank-mounted lifting lugs
which are shown in Figure 2. Do not lift the entire
unit with the lifting eyes on the cover. The lifting
eyes are only to be used to untank the internal assembly
which is attached to the cover.
Storing
If the regulator is not to be placed into immediate
use, it can be stored with minimal precautions. Store
the unit where the possibility of mechanical damage
is minimized.
Installation
Pre-Installation Inspection
Before connecting the regulator to the line, make the
following inspection:
1. Check oil sight gauge. Look for visible signs
of oil leakage.
2. Examine series arrester for damage. If damaged,
install a new arrester of same voltage rating.
3. Inspect porcelain bushings for damage or leaking
seals. If there is a suspicion that moisture has
entered unit, remove handhole cover and inspect
for evidence of moisture such as rust or water
tracks in oil. If moisture has entered that tank, dry
regulator and filter oil before putting unit in service.
See Table 1-5, page 1-12, for values that oil should
meet. Be sure to properly replace handhole cover.
4. Check position indicator for damage. When
cleaning the faceplate, do NOT use solvent or fuel.
5. If regulator has been stored for some time,
test dielectric strength of oil according to
Table 1-5, page 1-12.
6. Regulator may be energized at rated voltage (with
caution) and an operational check (see page 1-10)
can be performed. (This procedure is optional.)
7. A high-potential test may be done to ensure
adequate electrical clearances to ground. (This
procedure is optional.)
Receiving, Installation
and Maintenance
WARNING: The cover may fracture if the
cover-mounted lifting eyes are used to lift the
entire unit. Lift the entire unit only with tank-mounted
lifting lugs.
Figure 1-1.
Regulating a single-phase circuit
SHUNT
ARRESTERS
SERIES
ARRESTER
DISCONNECTS
BYPASS SWITCH
Ø
N
SL
LOAD
SOURCE
S
L
Figure 1-2.
Regulating one phase of a three-phase, four-wire circuit
SHUNT
ARRESTERS
SERIES
ARRESTER
DISCONNECTS
BYPASS SWITCH
A
B
C
N
SL
LOAD
SOURCE
S
L
McGraw-Edison VR-32 Regulator and CL-5 Series Control
CAUTION: Do not subject tap changer to
temperatures above 150°F (66°C). To do so
may cause damage to the contact panels, resulting in
misalignment of the contacts.

1-2
Systems Connections
A regulator can regulate a single-phase circuit, or
one phase of a three-phase wye (star) or delta circuit.
Two regulators connected phase-to-phase in open-delta,
or three regulators connected phase-to-phase in closed-
delta, can regulate a three-phase, three-wire circuit.
When connected in wye, three regulators can regulate a
three-phase, four-wire multi-grounded wye circuit. Three
regulators should not be connected directly in wye on
three-phase, three-wire circuits because of the
probability of neutral shift, unless the neutral is
connected to the neutral of a wye-connected bank of
distribution transformers or to the substation transformer
secondary neutral. Typical connection diagrams are
illustrated in Figures 1-1 through 1-5.
WARNING: Connect the “S” bushing to the
source, the “L” bushing to the load, and the
“SL” bushing to neutral. To do otherwise may cause
excessively high or low voltage on the load side of the
regulator or cause severe damage to the regulator.
Figure 1-3.
Regulating a three-phase, three-wire circuit with
two regulators
SHUNT
ARRESTER
SERIES
ARRESTER
DISCONNECTS
BYPASS SWITCH
A
B
C
S
L
12
SL SL
LOAD
SOURCE
S
L
Figure 1-4.
Regulating a three-phase, four-wire, multi-grounded wye (star) circuit with three regulators
SERIES
ARRESTER
SHUNT
ARRESTER
DISCONNECTS
BYPASS SWITCH
BYPASS SWITCH
BYPASS SWITCH
A
B
C
N
123
SL SL SL
LOAD
SOURCE
S
L
S
L
S
L
Figure 1-5.
Regulating a three-phase, three-wire circuit with three regulators
NOTE: Individual switches are shown for the bypass and disconnect functions. However, a regulator-bypass-disconnect switch can be used in
each phase to perform the bypassing and disconnecting operations in sequence. Each of these switches replaces one bypass and two disconnect
switches shown in the diagrams.
SHUNT
ARRESTER
DISCONNECTS
BYPASS SWITCH
BYPASS SWITCH
BYPASS SWITCH
A
B
C
123
SL
LOAD
SOURCE
SL SL
S
L
S
L
S
L
SERIES
ARRESTER
S225-10-10

McGraw-Edison VR-32 Regulator and CL-5 Series Control
1-3
Mounting
A regulator can be mounted on a pole, crossarm
platform or elevating structure. Regulators are normally
provided with either pole mounting brackets or a
substation base according to the rating. An elevating
structure can be provided to simplify substation
installation of regulators requiring a specific live part-to-
ground clearance.
The regulator control can be mounted on the regulator
tank, or at a point remote from the unit. Rubber-covered
cable is available in 5 foot (1.52 m) incremental lengths
from 15 feet (4.57 m) to 45 feet (13.7 m) for intercon-
nection between the control and the regulator.
Placing a Regulator in Service
Regulators can be placed in service without interrupting
load continuity once bypass and disconnect switches are
installed.
Procedure A should be followed when one bypass
switch and two disconnect switches are used. Procedure
B should be followed when a regulator bypass-dis-
connect switch is used.
A ground pad tapped for 1/2 inch 13 NC thread is
provided on the side of the control cabinet.
When energizing the control from an external source,
use only a 120 V ac source, unless the control is set up
for 240 volts, indicated by a decal adjacent to the
terminals.
Figure 1-6.
Back panel
KNIFE
SWITCHES RCT
WARNING:Closing the bypass switch with
the tap changer in any position other than
neutral will short-circuit part of the series winding.
Before closing the bypass switch, the regulator must
be in neutral, the control switch set to OFF and the
motor circuit fuse removed.
WARNING: For the protection of personnel
from surges while operating the control, the
following control enclosure grounding procedures
should be followed:
If the enclosure is attached to the regulator tank or
is remote from the tank but only accessible with a
ladder, then the enclosure should be connected to
the regulator-to-ground rod conductor.
If the enclosure is accessible by personnel standing
on the ground, then the enclosure should be directly
connected to a ground mat and ground rod.
CAUTION: Only an ac power supply is
to be used to energize the control externally;
direct current (dc) to alternating current (ac) inverters
are not to be used due to excessive harmonics that
can be generated, resulting in damage to the front
panel.
CAUTION: Be mindful of polarity when using an
external source. Polarity reversal may result in
control damage.

S225-10-10
1-4
Procedure A: One Bypass Switch and
Two Disconnect Switches
1. Verify from regulator nameplate that control circuit
is connected for proper regulated system voltage.
2. Set power switch to OFF and control switch to OFF.
3. Knife switches on back panel should be set with V1
(potential switch) (and V6if present) closed (pushed
in), and C (CT shorting switch) open (pulled out).
See Figure 1-6.
4. Close source-load (SL) disconnect switch if
available.
5. Close source (S) disconnect switch.
6. Set power switch to INTERNAL and control switch
to MANUAL.
7. Lift raise-lower switch to operate tap changer two
or three steps, then depress raise-lower switch
to return tap changer to the neutral position.
(These steps verify that the mechanism is
functional.) When on neutral, neutral light will
glow continuously and position indicator will
point to zero.
8. With regulator in neutral position, set control switch
to OFF, set power switch to OFF, open V1knife
switch (and V6if present), and remove 6 A motor
fuse.
9. Close load (L) disconnect switch.
10. Open bypass switch. The regulator is now
energized.
11. Replace 6 A motor fuse, close V1knife switch and
set power switch to INTERNAL.
12. Go to Setting the Control for Service, following.
Procedure B: Regulator Bypass-
Disconnect Switch
1. Verify from regulator nameplate that control circuit
is connected for proper regulated system voltage.
2. Set control switch to MANUAL and power switch to
EXTERNAL.
3. Knife switches on back panel should be set with V1
(potential switch) (and V6if present) open (pulled
out), and C (CT shorting switch) closed (pushed in).
See Figure 1-6.
4. Apply 120 V (or other voltage as indicated by the
decal) to external source terminals, if available. If
not, proceed to Step 7, below.
5. Lift raise-lower switch to operate tap changer two or
three steps, then depress raise-lower switch to
return tap changer to neutral position. (These steps
verify that the mechanism is functional.) When on
neutral, neutral light will glow continuously and
position indicator will point to zero.
6. Remove the voltage from external source terminals.
7. With regulator in the neutral position, set control
switch to OFF, set power switch to OFF, and
remove 6 A motor fuse.
8. Close source-load (SL) disconnect switch. (Delta
applications only.)
9. Close regulator bypass-disconnect switch. The
regulator is now energized.
10. Replace 6 A motor fuse, close V1knife switch (and
V6if present), open C knife switch, and set power
switch to INTERNAL.
11. Go to Setting the Control for Service, following.
Setting the Control for Service
There are more than 50 parameters on the control which
are user-selectable. Many of these values pertain to the
operation of the advanced features that are not needed
for normal regulator operations. A full detailed
description of each of the features is given in the Control
Advanced Features section, along with set-up
instructions.
The control must be energized to perform the
programming. This can be accomplished by applying
120 V (or other voltage as indicated by the decal) to the
external source terminals and placing the power switch
in the external position. Alternately, the regulator may be
energized at line potential, and the power switch placed
in the internal position. When power is applied to the
control, all segments of the display will light, followed by
a PASS indication. If the FAIL message is encountered,
see Diagnostics, on page 2-5.
Accessing the Control
Before gaining access to change the control settings, the
proper security level must be activated. This is
accomplished by entering a security code at the
Function Code 99 location. Depress the following
keys on the keypad:
FUNCTION, 99, ENTER
12121, ENTER
The proper level of security to change operational
settings has now been activated.
All programming of the control is done through the
keypad or communication ports.
For quick set-up of Cooper Power Systems regulators,
see Table 1-1, page 1-5. For complete set-up, see
Table1-2, page 1-6 for a detailed checklist for control
programming. The only two parameters this checklist
does not address are voltage and current calibration,
Function Codes 47 and 48.

McGraw-Edison VR-32 Regulator and CL-5 Series Control
1-5
TABLE 1-1
Setting the Controls for Basic Operation
Security System
Keys to Depress F.C Display Description
FUNCTION, 99, ENTER 99 _ _ _ _ _
12121, ENTER Func _ _ The security system is now activated for changing operational settings
Set Voltage
Range: 100.0 - 135.0 (Factory Setting: 120.0)
Keys to Depress F.C Display Description
1 01 120.0 This is the set voltage as shipped from the factory
Change 01 _ _ _._c Enter the desired value. Example: 122.0
1220, ENTER 01 122.0 The set voltage is now 122.0 volts.
Bandwith
Range: 1.0 - 6.0 (Factory Setting: 2.0)
Keys to Depress F.C. Display Description
2 02 2.0 This is the bandwith as shipped from the factory
Change 02 _._c Enter the desired value. Example: 3.0
30, ENTER 02 3.0 The bandwidth is now 3.0 volts
Time Delay
Range: 5 - 180 (Factory Setting: 30)
Keys to Depress F.C. Display Description
3 03 30 This is the time delay as shipped from the factory
Change 03 _ _ _c Enter the desired value. Example: 45
45, ENTER 03 45 The time delay is now 45 seconds
Line Drop Compensation, Resistance
Range: -96.0 - +96.0 (Factory Setting: 0.0)
Keys to Depress F.C. Display Description
4 04 0.0 This is the resistive compensation as shipped from the factory
Change 04 _ _._c Enter the desired value. Example: 5.0
50, ENTER 04 5.0 The resistive compensation is now 5.0 volts
Line Drop Compensation, Reactance
Range: -96.0 - +96.0 (Factory Setting: 0.0)
Keys to Depress F.C. Display Description
5 05 0.0 This is the reactive compensation as shipped from the factory
Change 05 _ _._c Enter the desired value. Example: 3.0
30, ENTER 05 3.0 The reactive compensation is now 3.0 volts
Regulator Configuration
Range: 0 - 2 (Factory Setting: 0 [Wye or Star])
Keys to Depress F.C. Display Description
FUNCTION, 41, ENTER 41 0 This is the regulator configuration as shipped from the factory
Change 41 _c Enter the desired value. Example: 1
1, ENTER 41 1 The regulator configuration is now Delta Lag
Control Operating Modes
Range: 0 - 2 (Factory Setting: 0 [Sequential])
Keys to Depress F.C. Display Description
FUNCTION, 42, ENTER 42 0 This is the control operating mode as shipped from the factory
Change 42 _c Enter the desired value. Example: 1
1, ENTER 42 1 The control operating mode is now Time Integrating
System Line Voltage
Range: 1200 - 36000 (Factory Setting: Regulator Rated Voltage)
Keys to Depress F.C. Display Description
FUNCTION, 43, ENTER 43 7620 This is the system line voltage for a 7620 volt regulator as shipped from the factory
Change 43 _ _ _ _ _c Enter the desired value. Example: 7200
7200, ENTER 43 1 The system line voltage is now 7200 volts
Overall Potential Transformer Ratio
Range: 10 - 300 (Factory Setting: PT ratio for Regulator Rated Voltage)
Keys to Depress F.C. Display Description
FUNCTION, 44, ENTER 44 63.5 This is the overall PT ratio for a 7620 volt regulator as shipped from the factory
Change 44 _ _ _._c Enter the desired value. Example: 60.0
600, ENTER 44 60.0 The system line voltage is now 7200 volts
Calendar Clock
Range: 10 - 300 (Factory Default Setting XX)
Keys to Depress F.C. Display Description
FUNCTION, 50, ENTER 50 1.01 This is the default value for the date.
Scroll up 50 x.xx This is the present time (hour/minute).
Scroll up 50 1d 90 This is the default value for the year, 1990.
Change 50 1 _ _c Enter the desired value for Year. Example: 2000
00, ENTER 50 1 0 The Year is now 2000.
Scroll up 50 2 1 This is the default value for the month, January.
Change 50 2 _ _c Enter the desired value for Month. Example: October
10, ENTER 50 2 10 The month is now October.
Scroll up 50 3 1 This is the default value for the Day 1.
Change 50 3 _ _c Enter the desired value for the Day. Example 24.
24, ENTER 50 3 24 The Day is now 24.
Scroll up 50 4 xx This is the present value for the Hour, xx.
Change 50 4 _ _c Enter the desired value for Hour. Example: 2:00 P.M.
14, ENTER 50 4 14 The Hour is now 14. Military Time.
Scroll up 50 5 xx This is the present value for the Minutes. Example: xx.
Change 50 5 _ _c Enter the desired value for Minutes. Example: 30.
30, ENTER 50 5 30 The Minutes is now 30.
Scroll up 50 6 xx This is the present value for the Seconds, xx.
Change 50 6 _ _c Enter the desired value for Seconds. Example 45.
45, ENTER 50 6 45 The Seconds is now 45.

S225-10-10
1-6
TABLE 1-2
CL-5 Series Control Programming Checklist
Step Activity/Question Function Factory Owner Check Next
Code Set Set Step
A Power up control or run Self Test (FC 91). Pass = B; Fail = Refer to page 2-5
B Access Security Level 3. 99 32123 C
Set Voltage 1 120
Bandwidth 2 2
C Set the Forward Power Flow Control Settings -- Time Delay 3 30
LDC Resistance 4 0
LDC Reactance 5 0 D
D Verify position indicator is in sync with tap changer by stepping
through the neutral position. E
E Is the Control Tap Position in sync with the position indicator? 12P No = F; Yes = G
F Set the Control Tap Position. 12P G
G Is Source Side Voltage Calculation required? 39 0 No = J; Yes = H
H Activate Source Side Calculation. 39 1 I
I Set Type of Regulator. (A and Series Transformer =1; B=2) 39-1 Nameplate value J
J Change Control I.D.? 40 Control Serial No. No = L; Yes = K
K Set Control I.D. 40 L
L Is regulator bank configuration closed or open delta? No = O; Yes = M
M Refer to Determination of Leading or Lagging, page 1-7. N
N Set Regulator Configuration. 41 0 O
O Change Operating Mode? (Factory set for sequential) 42 0 No = Q; Yes = P
P Set Operating Mode. 42 Q
Q Set System Line Voltage. 43 Rated Voltage R
R Set Overall P.T. Ratio. (from Nameplate) 44 Rated P.T.Ratio S
S Verify C.T. Primary Rating. (from Nameplate) 45 Rated C.T. Primary T
T Change Demand Time Interval? 46 15 No = V; Yes = U
USet Demand Time Interval. 46 V
V Change Tap Changer selection? 49 Nameplate value No = X; Yes = W
W Set Tap Changer selection. 49 Nameplate value X
X Are date and time correct? 50 No = Y; Yes = Z
Year 50-1
Month 50-2
Y Set the required date and time by way of subfunctions- Day 50-3
Hour 50-4
Minute 50-5
Second 50-6 Z
Z Should control be set up to react to a reverse power flow condition? No = AA; Yes = BA (Table 1-3)
AA Verify Reverse Sensing Mode is set on Locked Forward (0). 56 0 AB
AB Verify the baud rate of Local Channel #1 (Data Reader) is set for 4800. 60 4 AC
AC Set up Remote Communications Channel #2? No = AE; Yes = AD
64
65
AD Set Remote Communications Function Codes as desired. 66
67
68-1
68-2 AE
AE Verify the Blocking Status is normal. 69 0 AF
AF Is Voltage Reduction required? 70 0 No = AH; Yes = AG
70
72
AG Set Voltage Reduction Function Codes as desired. 73
74
75
76
77 AH
AH Is Soft Add-Amp required? 79* 0 No = AJ; Yes = AI
AI Activate Soft Add-Amp. 79* 1
Set Add-Amp Raise Limit. 79-1*
Set Add-Amp Lower Limit. 79-2* AJ
AJ Is Voltage Limiter required? 80 0 No = AL; Yes = AK
80
AK Set Voltage Limiter Function Codes as desired. 81
82 AL
85*
85-1
AL Set Profile Recorder Parameters. 85-2
85-3
85-4
85-5* AM
AM Is Security Override required? 92 0 No = AO; Yes = AN
AN Set Security Override. 92 1 AO
AO Change Security Codes? No = AQ; Yes = AP
96 1234
AP Set Security Codes as desired. 97 12121
98 32123 AQ
AQ Reset Metering & Tap Position. 38 AR
AR Take Data Reader reading (optional). AS
AS Press DISPLAY OFF key to return to Base Security Level. AT
AT CONTROL IS NOW FULLY PROGRAMMED.

Delta-connected (Line-to-line)
Regulators
Determination of Leading or Lagging
For a regulator to operate properly when connected
phase to phase, it is necessary for the control to be
programmed with the correct regulator configuration in
Function Code 41. It must be determined whether it is
connected “leading” or “lagging”. The control aids the
operator in making this determination.
1. Regulator must be installed.
2. Power switch must be set to Internal.
3. V1knife switch (and V6, if present) must be closed.
4. Knife switch C must be open. Current must be
flowing.
5. Control (Auto/Remote-Off-Manual) switch may be in
any position.
6. For regulator #1, set Function Code 41 to 1 (Delta
Lag) and record the Power Factor, Function
Code 13.
7. For the same regulator set Function Code 41 to 2
(Delta Lead) and record the Power Factor.
8. Repeat steps 6 and 7 for each regulator in the
bank.
For each regulator, one of the two power factor values
will be reasonable and the other will be unreasonable.
Set the Regulator Configuration (FC 41) to the value
which produced the reasonable power factor.
For one regulator: Set Function Code 41 to the value
which produced the reasonable power factor.
For two regulators in open delta: See the example in
Table 1-4. In an open delta connection one of the
regulators will always be leading and the other lagging.
The reasonable power factor for each regulator should
be very close to the typical power factor of the system. In
this example, regulator #1 is the lagging unit and
regulator #2 is the leading unit.
For three regulators in closed delta: In closed delta,
all three regulators are either leading or lagging,
depending on how they are connected relative to
generator phase rotation.
Step Activity/Question Function Factory Owner Check Next
Code Set Set Step
BA Is voltage regulation required on the source and load side of regulator? No = BC; Yes = BB
BB Is dispersed generation available on load side of regulator? No = BH; Yes = BI
BC Is voltage regulation required on the source side of regulator during a No = BD; Yes = BJ
reversal of power flow?
BD Is the load side of regulator dedicated to a Co-generation facility? No = BE; Yes = BK
BE Is Tap to Neutral required for excursions below a reverse power No = BF; Yes = BL
threshold?
BF Set Reverse Sensing Mode to Reverse Idle. 56 2 BG
BG Is source side metering required during a reversal of power flow? No = BQ; Yes = BN
BH Set Reverse Sensing Mode to Bi-directional. 56 3 BM, BN & BO
BI Set Reverse Sensing Mode to Reactive Bi-directional 56 6 BM, BN & BO
BJ Set Reverse Sensing Mode to Lock Reverse. 56 1 BM & BO
BK Set Reverse Sensing Mode to Co-Generation. 56 5 BM, BN & BO
BL Set Reverse Sensing Mode to Neutral Idle. 56 4 BM & BO
Set Voltage 51 120
Bandwidth 52 2
BM Set the Reverse Power Flow Control Settings - Time Delay 53 30
LDC Resistance 54 0
LDC Reactance 55 0 BR
BN Set Reverse Power Threshold (%) 57 2 BR
BO Does regulator have an internal or external source side sensing voltage? No = BP; Yes = BR
BP Activate Source Side Calculation. 39 1 BQ
BQ Set Type of Regulator. (A and Series Transformer =1; B=2) 39-1
Nameplate value BR
BR REQUIRED REVERSE MODE IS PROGRAMMED. See Table 1.2 - AB
TABLE 1-3
CL-5 Series Control Programming Checklist for Reverse Power Flow Detection and Operation
McGraw-Edison VR-32 Regulator and CL-5 Series Control
1-7
TABLE 1-4
Sample Power Factor Values for Regulators Connected in
Open Delta Configuration
Configuration Recorded Power Factor (FC 13)
(FC 41)
Set to This Reg. #1 Reg. #2
Value
1
(Delta Lag) 0.94* -0.77
2
(Delta Lead) 0.17 0.93*
*Reasonable power factor values.

S225-10-10
1-8
Figure 1-7.
Nameplate of a 60 hertz regulator with an internal series winding P.T.

McGraw-Edison VR-32 Regulator and CL-5 Series Control
1-9
Figure 1-8.
Nameplate of a 50 hertz regulator indicating metric weights and volumes
Cooper Power Systems

1-10
S225-10-10
Operational Check
Pre-Installation Operational Check
The CL-5 Series Control has the facilities for either
manual or automatic operation of the tap changer, using
either the internal source of power (the regulator), or an
external source. To perform an operational check of the
control before installing the regulator, follow these steps:
1. Open V1(and V6, if present) knife switch(es)
located on control backpanel.
2. Place POWER switch in OFF position, and
CONTROL switch in OFF position.
3. Connect a variable 120-volt 50/60 Hz source to
EXTERNAL SOURCE terminals. Grounded side of
external source must connect to ground (white)
terminal on control.
4. Place POWER switch in EXTERNAL position.
5. Move CONTROL switch to MANUAL, and depress
and hold RAISE-LOWER momentary toggle
switch. Allow tap changer to operate to 8L, the 5%
buck position.
6. Hold up on RAISE-LOWER momentary toggle
switch. Allow tap changer to operate to 8R, the 5%
boost position.
7. Now place Control switch in the AUTO/REMOTE
position.
8. Increase variable voltage source so applied
voltage is out of band. Note that “HIGH” band
annunciator in display will come on. After time
delay period, control will issue “LOWER” tap
change signals. Check to ensure that operations
counter is registering tap changes by pressing “0”
key on keypad.
9. Decrease variable voltage source so applied
voltage is out of band. Note that “LOW” band
annunciator in display will come on. After time
delay period, control will issue “RAISE” tap change
signals. Check to ensure that operations counter is
registering tap changes.
10. Place CONTROL switch in MANUAL position and
manually return tap changer to NEUTRAL. When
on NEUTRAL, NEUTRAL LAMP will light contin-
uously and position indicator will point to zero.
11. Place CONTROL switch in OFF position.
12. Press down on momentary toggle switch labeled
DRAG HAND RESET, and position indicator drag
hands will reset around indicating hand.
13. Turn POWER switch to OFF and disconnect power
supply from EXTERNAL SOURCE terminals.
In-Service Operational Check
With the control now set for basic operation, an
operational check of manual and automatic operation
should be performed as follows:
1. Depress “8” key to display compensated voltage.
2. Place control switch in MANUAL position.
3. Lift up on Raise/Lower switch to activate a raise
operation.
4. Allow tap changer to operate for enough steps to
take voltage out of band.
5. Place control switch in the AUTO position. After
time delay period, the control should cause
the regulator to step down to the top band edge.
(EXAMPLE: 120 V and a 2 V B.W. = 121 V top
band edge.) This should be shown in the display.
6. After voltage is brought in-band and tap changing
has stopped, move control switch to the MANUAL
position.
7. Press down on Raise/Lower switch to activate a
lower operation.
8. Allow tap changer to operate for enough steps to
take voltage out of band.
9. Place control switch in the AUTO position. After
time delay period, the control should cause the
regulator to step up to the lower band edge.
(EXAMPLE: 120 V and a 2 V B.W. = 119 V lower
band edge.) This should be shown in the display.
Field Calibration Check
If the operator also desires to check the calibration of
the control, perform the steps listed below.
NOTE: Field calibration checks are only an indication
of calibration, and are not nearly as precise as the
laboratory procedure described in the Troubleshooting
Guide section of this manual.
1. Connect an accurate true-RMS responding
voltmeter to the voltmeter terminals.
2. The easiest and most direct way to perform a
calibration check is to compare the voltage that the
control “sees” to the voltage measured at the test
terminals. This is accomplished by accessing the
keypad and keying:
FUNCTION, 47, ENTER.
3. Under ideal conditions, the displayed voltage of
the control will match the voltage of the voltmeter.
Realistically, the voltages may be slightly different
because:

McGraw-Edison VR-32 Regulator and CL-5 Series Control
1-11
a. The metering and operation is based upon the
RMS value of the fundamental power line
frequency. Thus, the metered values exclude the
influences of harmonic voltages which are
probably present on the line. A true-RMS meter
however, will include these harmonic voltages in
its calculations of the RMS voltage. This does
not present a problem with either metering
device, since each device uses a different
approach to metering.
b. The calibration of the voltmeter being used for
measurement is probably not exact. Even a
very good meter with a basic accuracy of 0.5%
could be in error by as much as 0.6 V (out of
120 V), and still be considered to be “in-
calibration.” The control is calibrated using a
conditioned power supply and reference
voltmeters which are periodically calibration-
checked, traceable to the National Bureau
of Standards.
NOTE: The control is designed to perform ratio correc-
tion in software. Through the use of the ratio correcting
transformer (RCT) located on the back panel, the
voltage brought to the front panel is usually already
corrected to the 120 V base voltage. However, there are
some ratings in which this voltage is not fully corrected
by the RCT. Column 6 in Table 1-10 or 1-11, page 1-21
gives a general indication of these voltages, however,
always refer to the nameplate which provides the
specific information for the particular regulator.
Whatever voltage results from dividing the nominal
system voltage, FC43, by the overall P.T. ratio, FC44, is
considered by the control to be the nominal voltage.
Therefore, when that voltage appears at the input of the
control, 120 volts will be reported as the output voltage,
FC6 (whether the nominal is actually 120 or not).
Likewise, the compensated voltage, FC8, and input
voltage, FC7, will be scaled accordingly. If the regulator
is equipped and programmed for reverse power
operation, the voltage displayed at Function Code 8 will
be correct even during reverse power conditions.
The load voltage, FC10, source voltage, FC11, and
calculated parameters such as the kVA, kW and kvar are
not scaled similar to FCs 6 and 8. Instead, they reflect
the true value of line voltage.
NOTE: The voltage measured at the test terminals
during reverse power flow is the new source voltage at
the L bushing of the regulator.
Removal From Service
Determining Neutral Position
Return the regulator to neutral. The regulator can be
safely removed from service without interrupting load
continuity only in the neutral position. It is recommended
to use more than one method to determine whether a
regulator is on neutral.
To Return the Regulator to Neutral
1. Use Raise/Lower switch to bring regulator to neutral
position.
2. When in neutral, neutral light will light continuously
and position indicator will point to zero.
WARNING: In order to prevent possible
damage to equipment and injury to personnel,
prior to bypass switching being attempted, the
following must be accomplished: 1) The regulator
must be placed in the neutral position; 2) action must
be taken to prevent tap changer operation while the
bypassing is being performed.
If the regulator is in any position other than
neutral, part of the series winding will be shorted
if bypass switch is closed. This results in high
circulating current which can severely damage
the regulator. If catastrophic failure occurs, it
could pose a threat of injury or death to operating
personnel.
WARNING: A regulator should be bypassed
with the line energized only if both the position
indicator and the neutral light indicate neutral. If both do
not indicate neutral, the line should be de-energized to
avoid shorting part of the series winding.
WARNING: Always use the control switch
(labeled AUTO/REMOTE-OFF-MANUAL) to
operate the regulator, not the power switch. Failure to
do so may result in the tap changer stepping off
of neutral immediately upon being energized.
WARNING: To stop the regulator on the
neutral position, the control switch should be
turned to OFF during the switching operation from
positions “1” or “-1” to position zero. Switching to
OFF prior to reaching the neutral position prevents
overshoot.

1-12
S225-10-10
3. To increase safety, we recommend verifying
that the regulator is in the neutral position using
the following three methods:
a. Verify that the neutral indicator light on the
control is indicating the neutral position. Neutral
is indicated only when the light is continuously
illuminated.
b. Verify that position indicator is in the neutral
position.
c. Using an acceptable method, verify that there
is no voltage difference between the source
and load bushings.
4. When the regulator has been placed in the neutral
position, and prior to bypassing, additional safety
action must be taken to ensure that the tap changer
will not inadvertently switch to an off-neutral
position. This can be accomplished by doing
the following:
a. Place the control (Auto/Remote-Off-Manual)
switch in OFF position.
b. Remove motor fuse.
c. Place control power switch in OFF position.
d. Open V1knife switch (and V6if present) located
on control back panel.
If the precautions listed above are taken, the
likelihood of damaging a regulator or injuring
personnel is eliminated.
De-energizing the Regulator
Once it has been established that the regulator is on
neutral, immediately proceed with the following steps:
1. Place control (Auto/Remote-Off-Manual) switch in
OFF position.
2. Place power switch in OFF position.
3. Open V1knife switch (and V6if present) on back
panel (see Figure 1-7, page 1-8).
4. Remove the 6 A motor fuse.
5. Close bypass switch.
6. Open load (L) disconnect switch.
7. Open source (S) disconnect switch.
8. Open source-load (SL) disconnect switch, if
available.
NOTE: If a regulator bypass disconnect is used in place
of three separate switches, steps 5, 6 and 7 are carried
out in one operation.
Maintenance Program
Periodic Inspections
Step-type voltage regulators are designed to provide
many years of trouble-free operation. Proper operation of
the regulator can be checked without removing the unit
from service. Using the manual mode of operation, run
the regulator several steps in the raise direction, and then
switch the control back to auto. After the time delay, FC3,
expires, the regulator should return to band edge. When
this has been completed, use the manual mode of
operation to run the regulator several steps in the lower
direction, and then switch the control back to auto. After
the time delay, the regulator should return to band edge.
If the regulator will not operate properly, a substitute
control can be tried before removing the unit from
service. Refer to the following sections for proper
procedures on removing and replacing the control.
Since the usable life of a regulator is affected by its
application, it may be desirable to periodically remove
the regulator from service and untank the unit to verify
contact wear, oil dielectric, etc. The time for this will vary,
depending on a specific user’s past experience.
The oil should be checked (a) prior to energization, if the
regulator has not been energized for a long time period,
or (b) at normal maintenance intervals. Table 1-5 shows
the characteristics that the oil should meet.
*Per C57.106.
TABLE 1-5
Oil Characteristics*
New Used
Dielectric Strength
(kV minimum)
ASTM D1816-84
0.08 inch gap 40 34
ASTM D877-87 30 26
Interfacial Tension
ASTM D971-91
(mN/m) 35 24
Water
ASTM D1533-88
(ppm maximum) 25 35

Removal of Control Front Panel
The front panel may be removed from the regulator with
the regulator energized.
To open the front panel, unscrew the captive knurled
knobs on the left side of the panel. This allows the
control to swing open on its hinges. With the control
open, the back panel is readily accessible. The design of
the control enclosure, back panel and front panel enable
easy replacement of the front panel, leaving the back
panel, control enclosure, and cable intact. To remove the
front panel, proceed as follows:
1. Push closed the current shorting switch, C. This
shorts out the secondary of the regulator CT.
NOTE: Regulators shipped with a quick disconnect
cable contain a solid-state CT shorting board in the
junction box. This device automatically places a burden
on the CT anytime the CT circuit is opened. For
consistency, it is recommended that the CT shorting
switch be used whenever it is present on the back panel.
2. Pull open disconnect switch, V1, (and V6if present).
This de-energizes terminal board TB2.
3. Loosen screws on terminal board TB2at the bottom
of back panel.
4. Pull fanning strip (a series of terminals, wired to
front panel) free from terminal strip.
5. Disconnect front panel ground lead from back
panel.
The front panel can now be lifted off its hinges. Care
should be taken to prevent damage to a control front
panel while in transit and/or storage.
Replacement of Control Front Panel
To replace a front panel in the control enclosure, follow
the procedure outlined below:
1. Engage the front panel on enclosure hinges.
2. Connect front panel ground lead to back panel.
3. Insert fanning strip from front panel wiring harness
under TB2terminal board screws.
4. Tighten screws on interconnecting terminal board.
5. Push closed the disconnect switch, V1, (and V6
if present).
6. Pull open the current shorting switch, C.
7. Close panel and tighten panel locking screws.
Untanking the Regulator
1. Manually run tap changer to neutral, if possible. If
not, record position indicator reading before
proceeding to untank.
2. Disconnect control cable from bottom of junction
box (Figure 1-9).
3. Remove series arrester. Release internal
pressure using pressure relief device on side of
regulator.
4. Free cover by removing clamping ring or cover
bolts.
5. Attach sling or hooks with spreader bar (Figure
1-10) to lifting eyes and raise the cover, with the
attached core-and-coil assembly, until the top
of the coil is approximately one inch under oil.
As a safety precaution, blocking between the cover
and tank lip should be used until inspection of the
tap changer or other maintenance is complete. A
service cable assembly is available for operating an
untanked regulator from the mounted control
cabinet, if connection cable is not long enough.
Contact customer service for availability.
1-13
CAUTION: Before untanking a regulator that
contains a thermometer, (1) lower the oil level
below the thermometer, then (2) remove the
thermometer well. Failure to do so will result in
damage to the thermometer well and/or spillage of
oil when the internal assembly is lifted.
CAUTION: Do not suspend the control box
using the control cable.
McGraw-Edison VR-32 Regulator and CL-5 Series Control
WARNING: Push the C shorting switch
closed before attempting to remove the
fanning strip. Failure to do so may open the regulator
CT circuit, producing a flashover in the control.
WARNING: Do not pull open the current
shorting switch, C, until the screws have been
tightened on the interconnecting terminal block.
Failure to do so could open the regulator CT
secondary causing a flashover in the control.
WARNING: When the internal assembly is
lifted for inspection or maintenance, blocking
should be placed between the cover and the top of
the tank to keep the assembly from falling should the
lifting apparatus fail.

1-14
S225-10-10
Retanking the Regulator
Retank the regulator as follows:
1. Be sure position indicator shows present
position of the tap changer. If not, remove
indicator cable in junction box from position
indicator shaft after loosening set screw. Rotate
indicator shaft until proper position is reached, then
tighten set screw. Verify coordination of position
indicator with tap changer in the neutral position
(control neutral light on). Refer to page 6-3 for
position indicator replacement.
2. Check gasket seat surfaces on cover and
tank and wipe clean. Wipe gasket and position
it on tank lip. Loosen horizontal side channel
bolts to ensure proper seating of regulator in tank
and proper cover seal.
3. Raise cover assembly and attached components
over tank. Make certain of proper orientation.
4. Lower unit, rotating channels counter-clockwise into
tank guides.
5. Seat unit in tank. Tighten cover clamps or bolts.
NOTE: Tap cover with a rubber hammer around edge to
properly seal gasket while tightening cover band.
6. Check and retighten horizontal side channel bolts
through handhole, if required.
7. Properly reseal handhole cover, being careful not
to damage cover or insulation on the handhole
cover bolt.
8. Connect control cable to connector at bottom of
junction box.
Maintenance
The following is the recommended maintenance
program for a regulator that has been untanked:
1. Check all connections for tightness.
2. Check all contacts for wear (refer to S225-10-2).
3. Avoid removing main core-and-coil assembly
from oil, except when a winding failure occurs.
Blocking between cover and tank lip should
be used to suspend core-and-coil assembly
within oil until inspection of tap changer or other
maintenance is complete.
If it is necessary to remove main core-and-coil
assembly from oil, the following steps should
be followed.
a. Tap changer must not be subjected to
temperatures above 150°F (66°C). It must
be removed if the unit is baked at higher
temperatures.
Figure 1-10.
Untanking
SPREADER
BAR
BLOCKING
MEMBERS
Figure 1-9.
Quick Disconnect Cable

b. If unit is out of oil more than four hours, it
must be rebaked for a minimum of 24 hours
at 100°C (212°F). The maximum number of
times a unit should be rebaked is twice over
its life.
c. Within four hours after bake, the unit should be
retanked and filled with oil.
d. It is recommended that a vacuum be pulled on
the unit for at least one hour (2 mm of vacuum
or better) after the unit is completely refilled with
oil. If vacuum processing is not available, allow
entire internal assembly to soak in oil for at least
five days before energizing.
Construction
Surge Protection
Series Arrester
All VR-32 Regulators are equipped with a bypass
arrester connected across the series winding between
the source (S) and load (L) bushings. This arrester limits
the voltage developed across the series winding during
lightning strikes, switching surges and line faults. The
series surge arrester can be seen in Figure 2, page 3. A
heavy-duty MOV-type series surge arrester of 3 kV
offers series winding protection on all regulators except
those rated 22,000 V and greater, which have a 6 kV
MOV-type series surge arrester.
Shunt Arresters
A shunt arrester is a recommended accessory on the
VR-32 regulator for protection of the shunt winding. The
shunt arrester is a direct-connected arrester mounted on
the tank and connected between the bushing and
ground (earth). It is recommended that arresters be
applied to all non-grounded bushings.
For best results, locate these arresters on the mounting
pads provided on the tank near the bushing. Connect the
arrester and the regulator tank to the same ground
connection using the shortest cable possible. Shunt
arrester application data is listed in Table 1-6.
Position Indicator & ADD-AMP
Capability
The position indicator (Figure 1-11) is mounted on a
junction box on the cover of the regulator and is directly
connected to the tap changer by a flexible drive shaft
passing through the junction box and terminal board
via a sealing gland.
The indicator face is graduated in steps. Drag hands
indicate the maximum and minimum positions attained
during raise and lower operations. The drag hands are
automatically reset around to the main hand position by
operating the drag hand reset switch on the control front
panel.
During forward power flow the main hand of the position
indicator will be to the right of the neutral position when
the regulator is boosting. During reverse power flow
the main hand will be to the left of the neutral
position when the regulator is boosting.
The ADD-AMP feature of VR-32 regulators allows
increased current capacity by reducing the regulation
range. This is accomplished by either setting limit
switches in the position indicator or enabling function
code 79 (soft ADD-AMP) to prevent the tap changer
from traveling beyond a set position in either raise or
lower directions.
The limit switches have scales graduated in percent
regulation, and are adjustable to specific values of 5,
61⁄4, 71⁄2, 83⁄4, and 10% regulation to alter the regulation
range. These percentages translate to tap position
limitations of 8, 10, 12, 14, or 16 raise or lower. The five
possible load current ratings associated with the reduced
regulation ranges are summarized in Tables 1-7 and 1-8.
Higher regulation ranges are realized in closed delta
application. When using the limit switches, a detent stop
at each setting provides positive adjustment. Settings
other than those stops are not recommended. The raise
and lower limits need not be the same value unless
reverse power is possible. The regulator will stay within
the ADD-AMP limits set forth by the control or the
position indicator, whichever limit is of a lower regulation
percentage.
NOTE: If the ADD-AMP limits have been programmed
into the control (soft ADD-AMP) and the limit switches
have not been set, it is possible to manually step the tap
changer beyond the ADD-AMP limit. If the unit is
switched back to automatic mode, the control will step
the regulator back to within the ADD-AMP limits set in
the control.
See also page 6-3 for position indicator replacement
and calibration.
1-15
McGraw-Edison VR-32 Regulator and CL-5 Series Control
TABLE 1-6
Shunt Arrester Application Data
Recommended Recommended
MOV Shunt MOV Shunt
Regulator Arrester Regulator Arrester
Voltage Ratings Voltage Ratings
Rating (kV) Rating (kV)
2500 3 14400 18
5000 6 15000 21
6600 9 19920 27
7620 10 22000 27
8660 12 33000 36
11000 15 34500 36
13800 18

1-16
Setting the Manual (Hard) Limit
Switches
Before setting the manual limit switches, be sure the
new settings will not conflict with the present tap changer
position. Do not set the switches below the indicated tap
changer position. For example, if the main hand is at
step 12 and the change to be made is from plus or
minus 10% (step 16) to plus or minus 5% (step 8), run
the tap changer back to step 7 or less, manually. Then
set the limit switches for plus or minus 5% regulation.
Limit switches should be set in anticipation of the
maximum deviation of primary voltage. For example, on
a circuit where 7200 V is to be maintained, plus or minus
10% will permit voltages between 6480 V and 7920 V to
be regulated effectively. For voltages outside this range,
the regulator will not be able to return the voltage to the
preselected level (7200 V). Five percent regulation
would accommodate circuit voltages between 6840 and
7560 V, maintaining 7200 V for all voltages in this range.
To set the limit switches, follow this two-step procedure:
1. Loosen the captive bezel securing screws and
swing the bezel open.
2. Lift the limit switch adjustment lever free of the
detent and slide it to the new setting allowing the
lever to snap into the detent stop.
Internal Construction & Wiring
Diagrams
The main core-and-coil assemblies are of the shell-form
configuration. The series winding on the input (source)
side of the regulator (Figure 1-12) allows all windings
(control, shunt and series) to be located in one coil
assembly. The load voltage is monitored by the control
winding.
Regulators that have the series winding on the
output (load) side (Figure 1-13) have a separate
potential transformer installed on the load side in lieu of
a control winding.
The control winding or separate potential transformer
supplies a voltage for the tap changer motor and the
control sensing circuit. Additional taps are available on
them for line voltages lower than rated voltage.
Most regulators, depending upon the rating, have an
equalizer winding. This winding improves contact life for
high-current applications.
Figure 1-14 shows a typical regulator power circuit with a
series transformer. This design is utilized when the load
current rating exceeds the tap changer rating. In this
type of design, the series transformer winding losses are
a function of the load alone and are independent of the
tap position. Because of this, limiting the range of
voltage regulation does not reduce losses and therefore,
the ADD-AMP feature is not applicable.
The bridging reactor is a core-form design, consisting of
a coil on each leg of one core. The inside half of one coil
is connected to the outside half of the other coil and vice
versa, providing equal current in each half of the reactor
winding. This interlacing of the two coils reduces the
interwinding leakage reactance to a very low value. The
reactor is completely isolated from ground by stand-off
insulators since the reactor coil is at line voltage above
ground. The reactor core, core clamps and other
associated parts approach this level.
The current transformer is a toroid, through which the
load current passes. It furnishes a current proportional to
load current for the line-drop compensator and metering
features.
The tap changer enables the regulator to provide
regulation in smooth, accurately proportioned steps at
a controlled speed that minimizes arcing and extends
contact life. Figures 6-3 and 6-4 in the Troubleshooting
section illustrate typical internal wiring schemes of the
various types of regulator constructions. Most of the
wiring is on the tap changer itself. Application,
troubleshooting and operation of the tap changer and
related components are covered extensively in Service
Manual S225-10-2.
The terminal board inside the junction box on the cover
connects the internal tank wiring to the position indicator
and control. The junction box wiring is shown in Figure
6-1, page 6-5.
S225-10-10
Figure 1-11.
Position Indicator
MAIN HAND BEZEL
COVER
LIMIT SWITCH TABS
DRAG HANDS

McGraw-Edison VR-32 Regulator and CL-5 Series Control
1-17
TABLE 1-7
ADD-AMP Capabilities of 60 Hz Ratings
†Load Current Ratings (amperes)
Regulation Range (Wye and Open Delta)
Rated Rated
Volts kVA ±10% ±8.75% ±7.5% ±6.25% ±5%
Regulation Range (Closed Delta)
±15% ±13.1% ±11.3% ±9.4% ±7.5%
25 100 110 120 135 160
50 200 220 240 270 320
75 300 330 360 405 480
100 400 440 480 540 640
2500 125 500 550 600 668 668
167 668 668 668 668 668
250 1000 1000 1000 1000 1000
333 1332 1332 1332 1332 1332
416.3 1665 1665 1665 1665 1665
25 50 55 60 68 80
50 100 110 120 135 160
100 200 220 240 270 320
125 250 275 300 338 400
5000 167 334 367 401 451 534
250 500 550 600 668 668
333 668 668 668 668 668
416.3 833 833 833 833 833
38.1 50 55 60 68 80
57.2 75 83 90 101 120
76.2 100 110 120 135 160
114.3 150 165 180 203 240
167* 219/232 241/255 263/278 296/313 350/370
7620 250* 328/347 361/382 394/417 443/469 525/556
333* 438/464 482/510 526/557 591/625 668
416.3* 548/580 603/638 658/668 668 668
500* 656/668 668 668 668 668
667* 875/926 875/926 875/926 875/926 875/926
833* 1093/1157 1093/1157 1093/1157 1093/1157 1093/1157
69 50 55 60 68 80
138 100 110 120 135 160
207 150 165 180 203 240
276 200 220 240 270 320
13800 414 300 330 360 405 480
500 362 398 434 489 579
552 400 440 480 540 640
667 483 531 580 652 668
833 604 664 668 668 668
72 50 55 60 68 80
144 100 110 120 135 160
288 200 220 240 270 320
333 231 254 277 312 370
416 289 318 347 390 462
14400 432 300 330 360 405 480
500 347 382 416 468 555
576 400 440 480 540 640
667 463 509 556 625 668
720 500 550 600 668 668
833 578 636 668 668 668
50 25.1 28 30 34 40
100 50.2 55 60 68 80
200 100.4 110 120 135 160
19920 333 167 184 200 225 267
400 200.8 220 240 270 320
500 250 275 300 338 400
667 335 369 402 452 536
833 418 460 502 564 668
1000 502 552 602 668 668
TABLE 1-8
ADD-AMP Capabilities of 50 Hz Ratings
†Load Current Ratings (amperes)
Regulation Range (Wye and Open Delta)
Rated Rated
Volts kVA ±10% ±8.75% ±7.5% ±6.25% ±5%
Regulation Range (Closed Delta)
±15% ±13.1% ±11.3% ±9.4% ±7.5%
33 50 55 60 68 80
66 100 110 120 135 160
99 150 165 180 203 240
132 200 220 240 270 320
6600 198 300 330 360 405 480
264 400 440 480 540 640
330 500 550 600 668 668
396 600 660 668 668 668
55 50 55 60 68 80
110 100 110 120 135 160
165 150 165 180 203 240
220 200 220 240 270 320
11000 330 300 330 360 405 480
440 400 440 480 540 640
550 500 550 600 668 668
660 600 660 668 668 668
75 50 55 60 68 80
150 100 110 120 135 160
225 150 165 180 203 240
15000 300 200 220 240 270 320
450 300 330 360 405 480
600 400 440 480 540 640
750 500 550 600 668 668
110 50 55 60 68 80
220 100 110 120 135 160
22000 330 150 165 180 203 240
440 200 220 240 270 320
660 300 330 360 405 480
165 50 55 60 68 80
33000 330 100 110 120 135 160
495 150 165 180 203 240
660 200 220 240 270 320
TABLE 1-9
Current Transformer Applications (50 & 60 Hz)
Regulator Current C.T.
Ratings Primary Current
25 25
50 50
75 75
100 100
150 150
167, 200 200
219, 231, 250 250
289, 300 300
328, 334, 347, 400 400
418, 438, 463, 500 500
548, 578, 656, 668 600
833, 875, 1000, 1093 1000
1332, 1665 1600
† 55/65°C rise rating on VR-32 regulators gives an additional 12%
increase in capacity if the tap changer’s maximum current rating
has not been exceeded. For loading in excess of the above values
please refer to customer service.
† 55/65°C rise rating on VR-32 regulators gives an additional 12%
increase in capacity if the tap changer’s maximum current rating
has not been exceeded. For loading in excess of the above values
please refer to customer service.
* Regulators are capable of carrying current corresponding to rated
kVA when operated at 7200 Volts.