Pole Top Equipment Voltage Regulators PDF

T&D PowerSkills Lineman Training Edition II
Page 1

Pole Top Equipment & Replacement
- Voltage Regulators

Edition II

Copyright MMVII

T&D PowerSkills, LLC
5501-A John Eskew Blvd.
Alexandria, LA 71303
866-880-1380

All rights reserved. This book or any part thereof
must not be reproduced in any form without the
written permission of T&D PowerSkills, LLC.

Printed in the United States of America

Page 2

T&D PowerSkills
General Guidelines for Students

This training unit is composed of a DVD and associated Student Manual. The DVD contains one
Course. The course is divided into Lessons, where each Lesson consists of a number of Topics.
The number of Lessons and Topics will vary with each course.

Recommended Sequence of Instruction

1. After the instructors introductory remarks, read the segment objectives found in the block at
the beginning of the first segment.
2. Briefly discuss the segment objectives with the instructor and other class members.
3. View the first segment of the DVD.
4. Read the text segment that corresponds to the first segment of the DVD.
5. Answer the questions at the end of the text segment. Check your answers with the correct
answers provided by the instructor.
6. Participate in a class discussion of the material just covered. Ask any questions you might
have concerning the material in the DVD and the text, and note any additional information
given by the instructor.
7. Before proceeding, be sure you understand the concepts presented in this segment.
8. Work through all segments in this manner.
9. A Course Test covering all the material will be administered by the instructor upon
completion of the unit.
10. Additional instruction and testing may be provided, at the instructors discretion.

OSHA Regulations Snap-Shot

OSHA Regulations, primarily in 1926.955, 1910.269 and 1910.268 will be used in conjunction
with this training unit. Where applicable, regulations will be highlighted and placed in a box like
this. Instructors and students are expected to review the current OSHA Regulations to
familiarize the student with the safety requirements expected by USDOL OSHA, specifically as
they relate to the topic being discussed. This information is an important part of this training
unit.

This T&D PowerSkills workbook is designed to be used in conjunction with
the associated training DVD/video.

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Field Performance Field Performance Field Performance Field Performance Requirements Requirements Requirements Requirements (FPR)

NAME: _____________________________ #___________

Complete

Incomplete
SECTION: Overhead Distribution De-energized

UNIT(S): Pole Top Equipment & Replacement

Voltage Regulators

VG = Very Good
ACC = Acceptable
NI = Needs Improvement
NA = Not Able to Complete
on this Crew

REQUIREMENTS SUPERVISOR SIGN-OFF

VG ACC NI NA
SEGMENT 1 POLE TOP VOLTAGE REGULATORS

1.1 Can describe the construction and operation of:
a. Induction Voltage Regulators ....

b. Step Voltage Regulators ....

SEGMENT 2 TROUBLESHOOTING POLE TOP VOLTAGE
REGULATORS

2.1 Can describe the basic parts of a step voltage regulator installed on
an overhead feeder....

2.2 Can demonstrate approved procedures for troubleshooting a mal-
functioning step voltage regulator .

SEGMENT 3 REPLACING POLE TOP VOLTAGE REGULATORS

3.1 Can demonstrate approved procedures and safe work practices for
replacing a pole top:

a. Voltage Regulator ...

__________________________ ______________________________
Employees Signature Supervisors Signature

_______________ Date

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PERFORMACE OTES: _____________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
1910.269(a)(2)(vii) as of July, 2006:

The employer shall certify that each employee has received the training required by paragraph
(a)(2) of this section. This certification shall be made when the employee demonstrates
proficiency in the work practices involved and shall be maintained for the duration of the
employees employment.

Note: Employment records that indicate that an employee has received the required training are
an acceptable means of meeting this requirement.
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TABLE OF COTETS

Section Title Page
1. Pole Top Voltage Regulators 8

1.1 Induction Regulators 9

1.2 Step Regulators 15

1.3 Voltage Control Circuitry 23

2. Troubleshooting Pole Top Voltage Regulators 30

2.1 Regulator Construction 30

2.2 Troubleshooting a Voltage Regulator 36

3. Pole Top Voltage Regulator Replacement 38

3.1 Preparations and Regulator Removal 38

3.2 Regulator Replacement 44

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LIST OF ILLUSTRATIOS

Figure Title Page
1-1. Parts of an Induction Regulator 9

1-2. Primary and Secondary Winding Voltages 10

1-3. Load Side Voltage Reduced by 10% 11

1-4. Load Side Voltage Reduced by 5% 12

1-5. Neutral Position 13

1-6. Load Side Voltage Increased by 10% 14

1-7. Parts of a Step Regulator 15

1-8. Taps, Contacts, and Bridging Reactor 16

1-9. Bridging Reactor Between Taps (In "Boost" Position) 17

1-10. Reversing Switch 18

1-11. Step Regulator at Neutral Position 19

1-12. Step Regulator at Step 1 20

1-13. Step Regulator at "Raise" Step 2 21

1-14. "Full Boost" Position 22

1-15. "Full Buck" Position 23

1-16. Voltage Control Circuit 34

1-17. Control Circuit Voltage Within Bandwidth 25

1-18. Control Circuit in "Lower" Position 26

1-19. Control Circuit in "Raise" Position 27

2-1. Single-Phase Step Voltage Regulator 28

2-2. Single-Phase Step Voltage Regulator Bushings 29

2-3. Position Indicator 32
Page 7

Figure Title Page
2-4. Oil Level Gauge 33

2-5. Solid-State Voltage Regulator Control Mechanism 34

2-6. Switches 35

3-1. Zeroing a Voltage Regulator 39

3-2. Removing Jumpers 41

3-3. Securing Control Mechanism to Tank 42

3-4. Regulator Rigged for Removal from Pole 43


1910.269 (c) (as of ovember, 2006)
Job Briefing.

The employer shall ensure that the employee in charge conducts a job briefing with employees involved before
they start each job. The briefing shall cover at least the following subjects: hazards associated with the job, work
procedures involved, special precautions, energy source controls, and personal protective equipment
requirements.
1. umber of briefings. If the work or operations to be performed during the work day or shift are repetitive
and similar, at least one job briefing shall be conducted before the start of the first job of each day or
shift. Additional job briefings shall be held if significant changes, which might affect the safety of the
employees, occur during the course of the work.
2. Extent of briefing. A brief discussion is satisfactory if the work involved is routine and if the employee,
by virtue of training and experience, can reasonably be expected to recognize and avoid the hazards
involved in the job. A more extensive discussion shall be conducted:
(i) if the work is complicated or particularly hazardous, or
(ii) if the employee cannot be expected to recognize and avoid the hazards involved in the job.

Page 8

POLE TOP EQUIPMET AD REPLACEMET - Voltage Regulators

1. Pole Top Voltage Regulators

Voltage tends to decrease along a distribution feeder. It can also fluctuate above and below
acceptable levels due to changing load conditions on the system. To maintain service to
customers in a useful range, voltage regulators are often installed on the system.

OBJECTIVES:

Describe the construction and operation of induction voltage regulators and step
voltage regulators.
Explain the operation of a voltage regulator control circuit.

Voltage regulators are a type of variable ratio voltage transformer. They are designed to respond
automatically to a voltage that is above or below a predetermined level by changing the
relationship between the transformer windings inside the regulator. This change adjusts the
voltage on the load side of the regulator so that it remains within acceptable limits.

Two commonly used types of pole top voltage regulators are induction regulators and step
regulators. Both types are capable of either raising or lowering voltage. In general, the
maximum amount that voltage is raised or lowered is 10%.

Page 9

1. Pole Top Voltage Regulators (continued)

1.1 Induction Regulators

Induction regulators adjust voltage in a continuous fashion. Figure 1-1 is a simplified illustration
of an induction regulator. The illustration shows a distribution feeder with a break in the line, so
that there is a line side and a load side of the feeder. The primary, or moving, winding of the
induction regulator is connected to the line side of the feeder at one end, and to a ground on the
other end. The secondary, or stationary, winding is connected in series with the feeder.

Figure 1-1. Parts of an Induction Regulator

Page 10


During normal operation, there is a voltage on both the primary and secondary windings. This
voltage is indicated by white arrows in Figure 1-2. The current on the primary winding forms a
magnetic field, which can cut across and magnetically couple with the secondary winding. This
magnetic field induces a voltage in the secondary winding that is opposite in direction to the
voltage on the primary winding. The induced voltage is indicated by the gray arrow in
Figure 1-2.

Figure 1-2. Primary and Secondary Winding Voltages

NOTES: ______________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
Page 11


For the purpose of comparison, the examples that follow show a constant voltage level on the
line side of the regulator and the effect of the regulator windings on the load side. In reality, the
voltage on the line side of the regulator varies, and the objective is to maintain a constant voltage
level on the load side.

When the direction of the voltage induced in the secondary winding is opposite to the existing
voltage in the secondary winding, the existing voltage is decreased, or "bucked." In Figure 1-3,
the two windings are lined up so that the magnetic coupling between them induces the maximum
voltage in the secondary winding. Since the direction of the induced voltage is opposite to the
direction of the voltage already in the secondary winding, the voltage on the load side of the
regulator is reduced by a full 10 percent. For example, if the line voltage is 2400 volts, the
primary winding in the "full buck" position causes the voltage on the secondary winding to
decrease by 240 volts. The voltage on the load side of the regulator is then 2160 volts.

Figure 1-3. Load Side Voltage Reduced by 10%

Page 12


When the primary winding is rotated to a 45-degree position in relation to the secondary winding
(Figure 1-4), the effect of the magnetic coupling is reduced to 5%, or 120 volts. The load side
voltage then becomes 2280 volts.

Figure 1-4. Load Side Voltage Reduced by 5%

Page 13


When the primary winding is rotated to a 90-degree position in relation to the secondary winding
(Figure 1-5), there is no magnetic coupling between the two windings. The voltage is the same
on both the line side and the load side. This position is usually referred to as the neutral position.

Figure 1-5. eutral Position

As the primary winding continues to rotate, the direction of the voltage induced in the secondary
winding changes. The induced voltage then increases, or "boosts," the voltage on the secondary
winding.

Page 14


When the primary winding is at its "full boost" position, the voltage on the load side of the
regulator is increased by full 10 percent. In Figure 1-6, the voltage is increased by 240 volts to
2640 volts.

Figure 1-6. Load Side Voltage Increased by 10%

The movement of the primary winding in an induction voltage regulator is continuous. As a
result, the change in the voltage is also continuous.
Page 15


1.2 Step Regulators

A step voltage regulator has a number of taps. It responds to voltage changes by moving from
one tap to another in specific steps. Figure 1-7 is a simplified illustration of a step regulator.
The regulator has two windings: a shunt winding and a series winding. Neither winding moves.
The shunt winding is connected on one end to the load side of the phase. The other end is
connected to a ground.

Figure 1-7. Parts of a Step Regulator

Page 16


The feeder is interrupted at the regulator so that there is a line side and a load side of the feeder.
The series winding is connected in series between the two sides of the feeder. Figure 1-8 shows
a section of the step regulator. The step regulator has eight taps connected at different places on
the series winding. Each tap ends in a contact. In Figure 1-8, the contacts are numbered 1
through 8. A ninth contact, which is not connected to the series winding, provides the regulator
with a neutral position. A bridging reactor is used to connect the taps to the line side of the
feeder.

Figure 1-8. Taps, Contacts, and Bridging Reactor

Page 17


When the reactor is moved from tap to tap, it changes the number of turns on the series winding
that are part of the circuit. (In this example, for clarity, the whole bridging reactor is moved. In
reality, only the contacts at the end of the bridging reactor move.) The bridging reactor can only
move one step at a time when it changes position. It prevents the circuit from breaking between
taps by maintaining contact with at least one tap at all times. When the reactor makes contact
with two adjacent taps (Figure 1-9), it provides an intermediate position and compensates for the
difference in voltage between the two taps. In this way, the number of steps between neutral and
"full buck" or "full boost" is increased from 8 to 16.

Figure 1-9. Bridging Reactor Between Taps
(In "Boost" Position)

Page 18


For the step regulator in this example, the maximum increase or decrease in the voltage is 10
percent. Each of the 16 steps above and below the neutral position represents a voltage change of
5/8 of one percent. On a 2400-volt primary line, each step changes the voltage by approximately
15 volts.

The ends of the series winding are connected through a reversing switch (Figure 1-10) to the
shunt winding on the load side. The reversing switch allows the direction of the voltage to be
changed in the series winding so that the same eight taps can be used for both increasing and
decreasing the voltage on the shunt winding. When the switch is in the "R" position, the voltage
is raised. When the switch is in the "L" position, the voltage is lowered.

Figure 1-10. Reversing Switch

Page 19


Figures 1-11 through 1-15 illustrate step voltage regulator operation. To begin (Figure 1-11),
line voltage on the circuit is 2400 volts. The bridging reactor is in the neutral position, so the
load side voltage is also 2400 volts. The current flow through the circuit is shown as a white
line.

Figure 1-11. Step Regulator at eutral Position

NOTES: ______________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
Page 20


In Figure 1-12, the reversing switch is in the "R" position, and the bridging reactor has moved
counterclockwise so that contacts are between the neutral position and the first tap contact.
Under these conditions, the voltage is raised by 5/8 of 1%, or 15 volts, to 2415 volts.

Figure 1-12. Step Regulator at Step 1

Page 21


Moving the contact arm one more step counterclockwise so that it is fully on the first contact
(Figure 1-13) is step 2. The line voltage is increased by another 5/8 of 1% for a total of 1 %, or
2430 volts.

Figure 1-13. Step Regulator at "Raise" Step 2

Page 22


This process can continue until the bridging reactor is fully on the last contact, which is the "full
boost" position (Figure 1-14). At this point, the voltage is 2640 volts.

Figure 1-14. "Full Boost" Position

NOTES: ______________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
Page 23


From the neutral position, changing the reversing switch to the "L" position causes the load side
voltage to be lowered. The bridging reactor moves clockwise one step at a time. Voltage is
lowered in 16 steps of 5/8 of 1% until the "full buck" position is reached (Figure 1-15). The
voltage on the load side of the regulator is a full 10% lower than the line side, or 2160 volts.

Figure 1-15. "Full Buck" Position

1.3 Voltage Control Circuitry

Both induction regulators and step regulators use a control circuit to sense voltage fluctuations
and keep the voltage within preset limits. Several kinds of electromechanical and solid-state
control units are available, but they all operate on similar principles.

Page 24


Figure 1-16 is a simplified illustration of an electromechanical control circuit. The circuit is
powered through a step-down transformer, which is connected at the load side of the regulator so
that the voltage on the circuit is in the secondary range. The circuit has a motor, which is
connected through two motor control relays. The motor is used to move the windings or to
change the taps, depending on the type of regulator used. One relay operates the motor in the
direction that raises the primary voltage, and the other relay operates the motor to lower the
primary voltage.

Figure 1-16. Voltage Control Circuit

A beam positioned on a pivot between two contacts has a voltage in the 120-volt range. This
voltage is used to operate the motor control relays. The beam is moved by a solenoid, and its
movement is balanced by a spring, which pulls the beam away from the solenoid. The secondary
voltage that energizes the solenoid is always proportional to the primary voltage on the load side
of the regulator. In a 2400-volt system, this proportion is 20 to 1.
Page 25


The control circuit represented in Figure 1-17 is adjusted to a range of from 120.5 to 123.5 volts,
or a total range of 3 volts. This range is called the bandwidth. The bandwidth prevents the
mechanism of the regulator from having to respond to minor voltage fluctuations, and thus
prevents excess wear and tear on the regulator. As long as the voltage on the control circuit
remains between 120.5 and 123.5 volts, the control circuit will not cause a voltage adjustment.
The control circuit can be set so that the beam is zeroed between the two contacts at a specific
voltage, in this case, 122 volts. The current path in the control circuit in Figure 1-17 is shown as
a white line.

Figure 1-17. Control Circuit Voltage Within Bandwidth

Page 26


If the load voltage increases so that the stepped-down voltage on the solenoid is above 122 volts,
the beam moves toward the lower contact. At 123.5 volts, the beam touches the lower contact
(Figure 1-18), closing the circuit to the lowering motor control relay. The motor then adjusts the
windings of the regulator to decrease the load voltage. Decreasing the load voltage causes the
solenoid to move the beam back to a position between the two contacts.

Figure 1-18. Control Circuit in "Lower" Position

Page 27


If the load voltage decreases so that the stepped-down voltage on the solenoid is below 122 volts,
the beam moves toward the upper contact. At 120.5 volts, the beam touches the upper contact
(Figure 1-19), and the motor adjusts the windings of the regulator to increase the load voltage.
Increasing the voltage causes the solenoid to move the beam back to its center position.

Figure 1-19. Control Circuit in "Raise" Position

Page 28


Questions

1-1. A _______________________ is a type of variable ratio voltage transformer that
is designed to respond to voltage changes above or below a predetermined level.

1-2. A voltage regulator adjusts voltage on the _____________ side of the
(line, load)
regulator so that it remains within acceptable limits.

1-3. A(n) (a) ___________________ regulator adjusts voltage in a continuous fashion,
while a(n) (b) __________________ regulator adjusts voltage in a number of
defined stages.

1-4. True or False. When the direction of the voltage induced in the secondary
winding of a regulator is opposite to the direction of the existing voltage in the
secondary winding, the existing voltage is decreased, or "bucked."

1-5. When the primary winding of an induction regulator is rotated to a 90-degree
position in relation to the secondary winding, the voltages on the line side and the
load side of the regulator are _____________________.
(the same, different)

1-6. Circle the correct answer.

A step regulator has which of the following types of windings?
a. Series
b. Step
c. Shunt
d. All of the above
e. Only a and c

1-7. A __________________________ reactor prevents a circuit from breaking
between the taps of a step regulator by maintaining contact with at least one tap at
all times.

Continued:
Page 29


1-8. True or False. A reversing switch in a step regulator allows the same eight taps to
be used for both increasing and decreasing voltage.

1-9. Voltage regulators use a _____________________ circuit to sense voltage
fluctuations and keep voltage within preset limits.

1-10. If the bandwidth of a voltage regulator is set at 120.5 volts to 123.5 volts, at 123.5
volts, the control circuit will cause the voltage regulator to ______________
(raise, lower)
the voltage on the load side of the regulator.

NOTES: ______________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Page 30

POLE TOP EQUIPMET AD REPLACEMET - Voltage Regulators (continued)

2. Troubleshooting Pole Top Voltage Regulators

OBJECTIVES:

Describe the basic parts of a step voltage regulator installed on an overhead
feeder.
Describe or demonstrate how to troubleshoot a malfunctioning step voltage
regulator.

2.1 Regulator Construction

Single-phase step voltage regulators are commonly installed on overhead feeders.
The tank of the regulator shown in Figure 2-1 has three bushings on its top.

Figure 2-1. Single-Phase Step Voltage Regulator

Page 31

2. Troubleshooting Pole Top Voltage Regulators (continued)
As shown in Figure 2-2, one bushing is for the connection to the line, one is for the connection to
the load, and one is for the connection to the pole ground. Surge arresters are connected to the
line and load bushings. On delta systems, there is no connection to ground. The third bushing is
connected to another phase.

Figure 2-2. Single-Phase Step Voltage Regulator Bushings

OSHA Regulations Snap-Shots
1910.269p (a) (2) Training (as of ovember, 2006):

(i) Employees shall be trained in and familiar with the safety-related work practices, safety
procedures, and other safety requirements in this section that pertain to their respective job
assignments. Employees shall also be trained in and familiar with any other safety practices,
including applicable emergency procedures (such as pole top and manhole rescue), that are
not specifically addressed by this section but that are related to their work and are necessary
for their safety. (ii) Qualified employees shall also be trained and competent in: (A) The
skills and techniques necessary to distinguish exposed live parts from other parts of electric
equipment, (B) The skills and techniques necessary to determine the nominal voltage of
exposed live parts, (C) The minimum approach distances specified in this section
corresponding to the voltages to which the qualified employee will be exposed, and (D) The
proper use of special precautionary techniques, personal protective equipment, insulating and
shielding materials, and insulated tools for working on or near exposed energized parts of
electric equipment. ote: For the purposes of this section, a person must have this training in
order to be considered a qualified person.
Ground Bushing
Surge Arresters
Line Bushing
Load Bushing
Page 32


A dial called a position indicator (Figure 2-3) is mounted on the regulator tank so that it can be
viewed from below. The dials scale has a zero, or neutral, position in its center, and 32 marks to
indicate the 16 steps above and below the 0 mark. A pointer indicates the regulator's present tap
position. Two drag hands indicate the regulator's highest and lowest tap positions since the
hands were last reset.

Figure 2-3. Position Indicator Dial

NOTES: ______________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Pointer
Drag Hands
Page 33


The regulator in this example uses oil as an arc extinguishing medium and insulation. An oil
level gauge (Figure 2-4) is located on the tank to allow the oil level to be checked. Always check
oil level prior to operating regulator

Figure 2-4. Oil Level Gauge

Oil Level
Page 34


This voltage regulator has a solid-state control mechanism, which is mounted in a metal box
located lower on the utility pole (Figure 2-5). The box is permanently attached to the regulator by
a control cable. When the regulator is changed out, the control mechanism and cable are usually
changed, as well. The control mechanism enables the voltage regulator to respond automatically
to changes in line voltage, and it can also be used to operate the regulator manually. The
mechanism is powered by a fused 120-volt source.

Figure 2-5. Solid-State Voltage Regulator Control Mechanism

1910.269 (w) (7) (as of ovember, 2006)
Backfeed.

If there is a possibility of voltage backfeed from sources of cogeneration or from the secondary system
(for example, backfeed from more than one energized phase feeding a common load), the requirements
of paragraph (l) of this section apply if the lines or equipment are to be worked as energized, and the
requirements of paragraphs (m) and (n) of this section apply if the lines or equipment are to be worked
as deenergized.
Page 35


In this example, the voltage regulators for each phase are mounted on separate poles. The phase
is broken by in-line insulators at the pole, and the regulator is connected to each side of the phase
through a pair of permanently mounted disconnect switches and a bypass switch (Figure 2-6).
The switches in this example are mounted on a common base, although other methods of
connection may be used.

Figure 2-6. Switches

Under normal conditions, the disconnect switches are closed and the bypass switch is open.
Power from the line side is fed down through the voltage regulator and then out to the load side.
When the regulator is in the neutral, or zero, position, it can be taken off line by closing the
bypass switch and opening both disconnect switches. (Before this is done, it is important to make
sure that the regulator is in the neutral position and off.) If the regulator is not in the neutral
position, a short circuit could result. There is also a danger of arcing, due to the difference
between the line and load voltages. This could cause personal injury and equipment damage.)

Load Disconnect
Switch (Open)
Load Disconnect
Switch (Closed)
By-Pass
Switch
(Closed)
Page 36


2.2 Troubleshooting a Voltage Regulator

When a problem occurs with a voltage regulator, a visual inspection is usually made to narrow
down the possible causes of the problem. For example, the jumpers and switches are checked for
any signs of heat damage or corrosion. The regulator's tank and bushings are checked for any
signs of damage that could affect the unit's performance, such as broken bushings or obvious oil
leaks. The oil level gauge is also checked. A low oil level may indicate a small leak over a
period of time. In addition, a low oil level could cause heat damage to the internal mechanism of
the regulator.

The regulator used as an example in this part of the program has limiting tabs on the "raise" and
"lower" sides of the position indicator. These tabs prevent movement beyond the eighth step, so
that the regulator can only vary the line voltage by a maximum of 5%. During a visual
inspection, the positions of the needle and the drag hands on the position indicator should be
noted. These positions can be compared with those of other regulators to see if one unit is
obviously malfunctioning.

The control cable, the control mechanism, and the control cable's connections to the regulator
tank should be checked for signs of damage. The control mechanism is checked to make sure
that it is still intact, and a voltage reading is taken to make sure that the mechanism is still
energized. After the visual inspection of the first voltage regulator is complete, the other two
regulators are inspected.

In the video presentation, when the third regulator was inspected, the crew noticed that the
regulator was in the "full boost" position, as shown by the needle on the position indicator. This
was a much higher position than the other two regulators. Further testing indicated that the
regulator was locked in that tap position and could not be changed manually. The crew reported
the malfunctioning unit to the proper authorities.

ote: Arc Flash Hazard

OSHA evaluates compliance with its electrical safety regulations, OSHA 1910 Subpart S and
OSHA 1926 Subpart K, using the comprehensive information in FPA 70E . While OSHA tells
you what to do to avoid electrical dangers, this vital Standard tells you how. Please refer to the
National Fire Protection Standard: NFPA 70E for Arc Flash protection compliance.
Page 37


Questions

2-1. A dial called a ________________________ shows the present tap position of a
typical step voltage regulator.

2-2. True or False. Drag hands indicate the highest and lowest voltages on a feeder.

2-3. Why must a voltage regulator be in its neutral, or zero, position before it is
bypassed?
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

2-4. True or False. The tap position of each regulator on a three-phase feeder is noted
and compared to the others to determine an obvious malfunction.

Which of the following checks are typically made during the visual inspection of a
voltage regulator?
a. Jumpers and switches checked for heat damage and corrosion
b. Tank and bushings checked for breakage or obvious oil leaks
c. Oil level gauge checked for proper oil level
d. Control mechanism and related connections checked for damage
e. All of the above

Notes:________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Page 38

POLE TOP EQUIPMET AD REPLACEMET - Voltage Regulators (continued)

3. Pole Top Voltage Regulator Replacement

OBJECTIVES:

Describe one method of safely zeroing and isolating a voltage regulator before
changeout.
Describe or demonstrate how to safely remove a step voltage regulator from an
overhead feeder and install a replacement unit.

The video presentation for this part of the program demonstrates one method of safely changing
out a pole top single-phase step voltage regulator. The demonstration is intended to illustrate the
basic tasks associated with the job. The actual steps performed during a changeout will depend
on the design and installation of the voltage regulator involved and on specific company
procedures.

The basic tasks involved in a voltage regulator changeout are similar to those involved in
changing out other types of equipment. They generally include holding a tailgate session,
electrically and physically isolating the regulator, rigging and replacing the regulator, and
connecting and energizing the new regulator.

3.1 Preparations and Regulator Removal

When the crew arrives at the job site, the trucks are parked, and the work area is safely marked
off. Then a tailgate session is held to discuss the steps involved in the job and specific safety
considerations. Crewmember job assignments are made so that each person is aware of his
responsibilities during the changeout, as well as those of the other crewmembers.

The replacement voltage regulator and control unit should be visually inspected to verify that
they are the proper size and type for the job. They should also be checked for any damage that
might have occurred during shipping and handling. If the control box and cable to the regulator
are permanently attached to the old unit, they are replaced along with the regulator. The new
control cable and control box should be inspected for any defects or damage.
Page 39

3. Pole Top Voltage Regulator Replacement (continued)

After the tailgate session, company procedures should be followed for notifying the proper
authorities that the voltage regulators must be bypassed to replace the defective regulator.
Bypassing all three voltage regulators will keep the voltage balanced on the feeder.

In this example, each of the three voltage regulators is located on a separate utility pole. (In this
example, all three voltage regulators are bypassed, but that may not always be necessary.
Company regulations specify the proper procedures for changing out voltage regulators in
specific systems.) Before each regulator is bypassed, it must be manually zeroed (Figure 3-1) so
that there is no potential difference between the two sides of the phase. In the video example, the
control switch in the control box was used to move the regulator mechanism to the neutral
position, one step at a time. When the neutral position was reached, the bypass switch for the
regulator could be closed, and the two disconnect switches could be opened.

Figure 3-1. Zeroing a Voltage Regulator

Page 40


In the video demonstration, when the crew tried to move the third regulator to the neutral
position, the controls did not respond. This regulator was stuck in its "full boost" position.
Under these conditions, there is a potential difference between the two sides of the regulator, and
it would be dangerous to attempt to close the regulator's bypass switch. One way that the
regulator could be bypassed was to have the load dropped on the feeder, bypass the regulator
while the line is de-energized, and then re-energize the feeder.

In the video demonstration, the load dispatcher was contacted, and arrangements were made to
have the feeder dropped. When the dispatcher confirmed that the load on the feeder had been
dropped, a statiscope was used to verify that the feeder was de-energized. When a statiscope is
used, it is first tested on a known voltage source to ensure that it is operating properly. Then the
phase is tested to verify that the line is dead. Finally, the statiscope is rechecked to make sure
that it is still working properly.

While the line is de-energized, the bypass switch can be closed. The two disconnect switches are
then opened to ensure that the regulator will remain de-energized and electrically isolated. The
load dispatcher is then contacted again, and the feeder is re-energized.

OSHA Regulations Snap-shot
1910.269(p)(as of ovember 2006)
(4) Operations near energized lines or equipment.
(i) Mechanical equipment shall be operated so that the minimum approach distances of Table R-6
through Table R-10 are maintained from exposed energized lines and equipment. However, the
insulated portion of an aerial lift operated by a qualified employee in the lift is exempt from this
requirement.
(ii) A designated employee other than the equipment operator shall observe the approach distance to exposed lines
and equipment and give timely warnings before the minimum approach distance required by paragraph (p)(4)(i) is
reached, unless the employer can demonstrate that the operator can accurately determine that the minimum approach
distance is being maintained.
(iii) If, during operation of the mechanical equipment, the equipment could become energized, the operation shall
also comply with at least one of paragraphs (p)(4)(iii)(A) through (p)(4)(iii)(C) of this section.
(A) The energized lines exposed to contact shall be covered with insulating protective material
that will withstand the type of contact that might be made during the operation.
(B) The equipment shall be insulated for the voltage involved. The equipment shall be positioned
so that its uninsulated portions cannot approach the lines or equipment any closer than the minimum
approach distances specified in Table R-6 through Table R-10.
(C) Each employee shall be protected from hazards that might arise from equipment contact with the energized
lines. The measures used shall ensure that employees will not be exposed to hazardous differences in potential. Unless the
employer can demonstrate that the methods in use protect each employee from the hazards that might arise if the
equipment contacts the energized line, the measures used shall include all of the following techniques
(1) Using the best available ground to minimize the time the lines remain energized,
(2) Bonding equipment together to minimize potential differences,
(3) Providing ground mats to extend areas of equipotential, and
(4) Employing insulating protective equipment or barricades to guard against any remaining
hazardous potential differences.
Page 41


To physically isolate the regulator so that it can be rigged for removal, the three jumpers are
disconnected (Figure 3-2). Before this is done, however, each jumper should be marked to
indicate load or line. After all three jumpers are disconnected, the other primary equipment
should be covered to make the work area safe.

Figure 3-2. Removing Jumpers

NOTES: ______________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Jumper
Page 42


The case ground is then disconnected, and the control box is disconnected from the pole. The
control box and cable were sent up and secured to the tank of the regulator (Figure 3-3).

Figure 3-3. Securing Control Mechanism to Tank

1926.251 (as of January 2007)
Rigging equipment for material handling
(a) General.
(1) Rigging equipment for material handling shall be inspected prior to use on each shift and as necessary during
its use to ensure that it is safe. Defective rigging equipment shall be removed from service.
(2) Rigging equipment shall not be loaded in excess of its recommended safe working load, as prescribed in Tables
H-1 through H-20 in this subpart, following 1926.252(e) for the specific equipment.
(3) Rigging equipment, when not in use, shall be removed from the immediate work area so as not to present a
hazard to employees.

Page 43

POLE TOP EQUIPMET AD REPLACEMET Voltage Regulators

To rig the regulator unit for removal, the boom of a derrick was maneuvered into position, and a
line was attached to the regulator's lifting lugs with a sling (Figure 3-4). A tag line was attached
to the regulator tank and run down to a crewmember on the ground. A test strain was then taken
to test the rigging.

Figure 3-4. Regulator Rigged for Removal from Pole

After the rigging is checked, the bolts holding the regulator to the pole are loosened, and the unit
is lifted free of the pole. As the regulator is lowered to the ground, the tag line can be used to
stabilize the regulator and guide it around obstacles.

Page 44


3.2 Regulator Replacement

When the old regulator reached the ground, the rigging was removed and attached to the
replacement unit. The replacement regulator was then lifted into position on the pole and bolted
into place. The regulator can then be physically connected to the system. After the control cable
is unwound, the control box and cable are lowered to their position on the pole, and then secured
to the pole.

The end of the wire attached to the pole ground is then cleaned, and the connection is made to the
regulator tank (or case ground). The end of each jumper is cleaned and attached to its proper
bushing on the regulator. Finally, the rubber gear is removed from the rest of the primary
equipment and sent down to the ground.

Before the regulator can be put into service, it must be energized and tested. The regulator used
as an example in the video demonstration had a built-in transformer to provide secondary control
power. (Other regulators may be powered from an outside source and may be tested differently.)
In this example, the disconnect switch on the line side of the regulator was closed first. Closing
this switch energizes the regulator and provides power to the step-down transformer inside the
tank, which allows the controls to be operated. The bypass switch remains closed, however,
keeping the regulator bypassed.

If the regulator is not in the neutral position, the control switch in the control box is operated
until the regulator mechanism moves into the neutral position. The regulator used as an example
in the video was preset to raise or lower the voltage 5% instead of a full 10%. To test the
mechanism, the crew moved the control switch to the "lower" position and made sure that the
regulator moved 8 steps to its maximum "lower" position.

Next, the reversing switch in the control box was moved to the "raise" position, and the regulator
was moved to its maximum "raise" position. The steps were visually confirmed with the pointer
position on the dial. The mechanism was then moved back to the neutral position. The drag
hands were reset, and the bandwidth was set. Any additional testing required by the company or
manufacturer may also be done at this time.

Page 45


Before the regulator is put back on line, it is important to verify that the control mechanism is in
the neutral position, that the control switch is in the "off" position, and that the main switch in
the control box is turned off. This prevents the voltage regulator from operating while the unit is
put back on line. If the regulator is in any position other than neutral, it may cause a short circuit,
equipment damage, and personal injury.

The disconnect switch on the load side of the regulator is closed, and the bypass switch is
opened, so that the regulator is carrying the full load. When the crew is satisfied with the
regulator unit's operation, the control box can be re-energized, and the control switch can be
turned to the automatic position, placing the unit back on line. The other two regulators are then
reset and returned to service, and the proper authorities are notified that the job is complete.

Questions


Which of the following are basic tasks associated with the changeout of a pole top
step voltage regulator?
a. Tailgate session
b. Physically and electrically isolating the old unit
c. Replacing the old unit
d. Connecting the replacement unit
e. Energizing the replacement unit
f. All of the above

3-2. True or False. Before a changeout is begun, the replacement unit and associated
equipment should be visually inspected for damage that might have occurred
during shipping and handling.

3-3. _______________________ and bypassing each regulator during a changeout
(Resetting, Zeroing)
ensures that there is no potential difference between the two sides of the phase.

Page 46


3-4. True or False. If a voltage regulator cannot be zeroed, the bushings on the unit
should be grounded so that the unit can be replaced.

3-5. When a voltage regulator's control mechanism is tested during a changeout, the
unit's bypass switch remains _______________.
(open, closed)

NOTES: ______________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Page 47

POLE TOP EQUIPMET AD REPLACEMET VOLTAGE REGULATORS

GLOSSARY

This glossary contains terms pertinent to the study of pole top equipment and maintenance. The
meanings of the terms are given in that context.

Bandwidth - The range of voltages that a voltage regulator
control circuit is set to tolerate before causing the
regulator to change the load side voltage.

Bleeder resistor - A resistor that is designed to drain any charge
remaining on a capacitor unit to 50 volts or less in
five minutes.

Bridging reactor - A device used to connect the taps to the series
winding of a step voltage regulator to the line side of
a feeder circuit; designed to prevent the circuit from
breaking between taps by maintaining contact with
at least one tap at all times.

Capacitive power - The power in a circuit that is needed to store a
charge.

Capacitor - A device that can be connected to a circuit to accept
and store a charge.

Dielectric constant - The measure of the insulating ability of a material;
commonly expressed as "K."

Drag hands - Pointers on a step voltage regulator's position
indicator that identify the highest and lowest tap
positions to which the regulator moved since the
hands were reset.

Fixed bank - A capacitor bank that is permanently attached to a
line.

Induction regulator - A voltage regulator that adjusts voltage in a
continuous fashion within a given range.

Page 48

POLE TOP EQUIPMET AD REPLACEMET VOLTAGE REGULATORS
Glossary (continued)

Inductive power - The power in a circuit that is needed to magnetize
motors, transformers, and similar equipment before
any work can be done.

Non-working power - Reactive power in a circuit; can be either inductive
or capacitive.

Position indicator - A dial mounted on the tank of a step voltage
regulator that indicates the regulator's tap position.

Power factor - The ratio of working power to the total power
supplied to a circuit.

Reactive power - Non-working power in a circuit; can be either
inductive or capacitive.

Reversing switch - A switch used to change the direction of tap
movement in a step voltage regulator.

Step regulator - A voltage regulator designed to respond to a voltage
change by moving from one tap to another in
specific steps, or stages.

Switched banks - Capacitor banks designed to be switched on and off
line to meet changing power demands.

Total power - The algebraic or vector combination of the working
and non-working power in a circuit.

Voltage regulator - A type of variable ratio voltage transformer
designed to respond automatically to a voltage that
is above or below a predetermined setting.

Working power - The power available in a circuit to perform work.

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