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S225-10-4C - Cooper Industries

1. The user can select the appropriate method for control to SCADA message interaction handshake mode The available modes are 0 No handshaking The request to send RTS input line is ignored and the clear to send CTS output line is off 1 Handshaking The RTS input and CTS output line are both active 2 Transmit control handshaking The RTS input line is ignored and the CTS output line acts as a transmit enable This is the normal mode for the presently supported fiber optic loop system i e Function Code 66 2 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 67 Communications Resynch Time Chars 2 NA invalid 0 10 Messages are sent to the CL 4C control in a serial asynchronous manner from the SCADA RTU The control must determine when one message ends and the next begins This distinction is made based upon a period of idle time between received characters If a new character is not received within an expected as entered at this function code the control resynchs on the next charater as a new message This parameter is based upon the communications port baud rate Function Code 65 and is expressed as a number of characters This normally will be set to 1 for the DATA 2200 protocol FUNCTION UNIT SECURITY LEVEL KEY
2. 1 9 SECTION 7 7 1 PERIODIC INSPECTIONS 1 9 REMOVAL OF CL 4C FRONT PANEL 1 9 List of Tables Ee rr 7 1 REPLACEMENT OF CL 4C FRONT PANEL ne 1 9 List of Schematic Diagrams BSERRRRRERRRARRAERRRRRRARSARRRRRRAR 7 1 UNTANKING THE REGULATOR 1 9 Security Codes Pri 7 1 RETANKING THE REGULATOR 1 10 Function Codes sees 7 2 MAINTENANCE 1 10 Key Entry Error Codes 7 2 Construction 1 10 SURGE PROTECTION 1 10 POSITION One EU M 1 11 This manual pertains to these SERIAL NUMBERS INTERNAL CONSTRUCTION amp WIRING DIAGRAMS eene 1 13 CONTROL Refer to page 1 2 of these instructions for the definitions of warning and caution alerts These instructions do not claim to cover all details or varia tions in the equipment procedure or process described nor to provide direction for meeting every possible contingency during installation opera tion 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 September 1991 Supersedes 9 90 1991 9Cooper Power Syst
3. FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 41 Regulator Configuration 0 2 invalid 0 2 The CL 4C Control is designed to operate on wye connected and delta connected three phase systems Regulators connected line to ground wye develop potentials and currents suitable for direct implementation in the CL 4C Control Regulators connected line to line delta develop a potential to current phase shift which is dependent upon whether the regulator is defined as leading or lagging This phase shift must be known by the CL 4C Control to permit accurate calculations for correct operation This is accomplished by entering the proper code 0 Wye 1 Delta Lagging or 2 Delta Leading See Reference Bulletin R225 10 1 for a discussion of delta connections FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 42 Control Operating Mode 0 2 N A 0 0 2 The manner in which the control responds to out of band conditions is selectable by the user The available modes are Sequential standard Time Integrating and Voltage Averaging The appropriate mode is selected by entering the correspond ing code 0 Sequential 1 Time Integrating 2
4. FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 74 Remote Reduction Setting 2 96 0 2 0 0 0 0 0 0 Three levels of remotely activated voltage reduction are available with the CL 4C Control The percentage of voltage reduction to be performed at Remote Level 2 is programmed at Function Code 74 Remote activation is then accomplished by applying a signal to the appropriate input terminal when Function Code 70 2 or 3 See Voltage Reduction page 2 30 2 20 VR 32 Regulator and CL 4C Control FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 75 Remote Reduction Setting 3 0 2 0 0 0 0 10 0 Three levels of remotely activated voltage reduction are available with the CL 4C Control The percentage of voltage reduction to be performed at Remote Level 3 is programmed at Function Code 75 Remote activa tion is then accomplished by applying a signal simultaneously to both voltage reduction input terminals when Function Code 70 20 3 See Voltage Reduction 2 30 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS R
5. BUSHIN LOAD J8B C2 9 QUBB Ci 1 13 VR 32 Regulator and CL 4C Control POLARITY SOURCE BUSHING REVERSING SWITCH MARKER CURRENT TRANSFORMER LOAD BUSHING 4 N 3 EQUALIZER WINDING SHUNT WINDING LOAD POTENTIAL TRANSFORMER SQURCE LOAD BUSHING Figure 1 10 Power circuit series winding located on the load side Figure 1 12 Series transformer design 50 BUSHING SHUNT TRANSFORMER i POLARITY SERIES MARKER TRANSFORMER _ SOURCE LOAD a BUSHING Figure 1 11 Power circuit series transformer LOAD BUSHING CURRENT TRANSFORMER POTENTIAL TRANSFORMER 1 14 5225 10 4 JUNCTION BOX TERMINAL BOARD JBB TCB E JBB C 1 CURRENT TRANSFORMER C TO CONTROL TERMINAL BOARD AND JBB C TCB E POSITION INDICATOR 2 TCB G sw TCH NL RAISE LOWER 123 6 1 469 NEUTRAL LIGHT of TCB G MC 2 MC 1 4 TCB 5 2 3 MOTOR CAPACITOR MC HS 1 BLACK M 1 WHITE TCB 1 HS BLACK HS 2 BLUE M 2 BLUE TCB 1 NL ORANGE HS 3 RED M 3 RED TCB 4 BLUE JBB C1 WHITE MC 1 BLUE TCB 5 RED JBB C2 BLACK MC 2 RED TCB 6 WHITE JBB G WHITE NL C WHITE TCB 7 GREEN JBB HS ORANGE NL NC GREEN TCB E4 W
6. s with primary ratings other than the full load rating of the regulator In these instances this ratio must be considered for accurately establishing the turn on current Example 1 Desiring a turn on threshold at 75 of the full load rating on a 418 amp regulator which uses a 500 amp C T calculate the percentage as follows 418 500 x 75 63 Enter 63 at Function Code 78 or Function Code 79 Example 2 200 amp regulator is programmed with these settings Function Code 76 5 0 Function Code 77 2 5 Function Code 78 75 Function Code 79 100 then the control function will be as follows At 150 amp load current 5 0 of voltage reduction will occur this would be 6V on a 120V set ting The V RED annunciator turns on and Function Code 71 will display A 5 0 If the load current continues to increase to 200 amps the full load rating an additional 2 5 of voltage reduction will occur giving a total reduction of 7 5 9V ona 120V setting Function Code 71 will now display A 7 5 As the current flow is reduced to 180 amps 10 below level 2 current threshold voltage reduction goes to 5 0 When the load current falls below 135 amps 10 below level 1 current threshold auto matic voltage reduction is turned off 2 30 VR 32 Regulator and CL 4C Control Voltage Limiting The voltage limiting accessory is used to place both a high and low limit on the output voltage of the regulator When enabled
7. Rating Voltage Tap Ratio Tap t 1 2 3 4 5 6 7 2500 2500 20 1 120 125 20 1 2400 120 120 20 1 5000 5000 E1 P1 40 1 120 125 40 1 4800 E1 P1 120 120 40 1 4160 E1 P1 104 120 34 71 2400 E2 P2 20 1 120 120 20 1 7970 E1 P1 60 1 133 120 66 5 1 7620 7620 1 1 127 120 63 511 7200 E1 P1 120 120 60 1 4800 E2 P2 40 1 120 120 40 1 4160 E2 P2 104 120 34 74 2400 20 1 120 120 20 1 13800 13800 1 1 115 1 120 120 115 1 13200 1 1 115 120 110 2 1 12000 1 1 104 120 99 7 1 7970 2 2 57 5 1 133 125 63 771 7620 E2 P2 133 120 63 771 7200 E2 P2 120 125 57 51 6930 E2 P2 120 120 5 57 51 14400 14400 1 1 120 1 120 120 120 1 13800 E1 P1 115 120 115 1 13200 E1 P1 110 120 110 1 12000 E1 P1 104 115 104 1 7970 E2 P2 60 1 133 120 66 5 1 7620 E2 P2 127 120 63 5 1 7200 E2 P2 120 120 60 1 6930 E2 P2 115 120 5 57 5 1 19920 19920 166 1 120 120 166 1 17200 166 1 104 120 143 91 P taps are used with E taps only on regulators where an internal poten tial transformer is used in conjunction with the control winding to provide voltage supplies to the control See nameplate for verification of this type of control supply Test Terminal voltage and overall potential ratio may vary slightly from one regulator to another See the regulator nameplate for determining the exact values To calculate the appropriate voltage setting for system voltages other than that shown the following formula can be used along
8. VALUE LOW HIGH 03 Time Delay Forward sec 0 2 30 5 180 The time delay is the period of time in seconds that the control waits from when the voltage first goes out of band to when the relay closure occurs during forward power flow FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 04 Line Compensation Resistance Forward v 0 2 0 0 24 0 24 0 The resistive line drop compensation value is used to model the resistive line losses between the regulator and the theo retical load center The CL 4C Control uses this paramenter in conjunction with the load current flow to calculate the compensated voltage displayed at Function Code 8 during forward power flow FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 05 Line Compensation Reactance Forward v 0 2 0 0 24 0 24 0 The reactive line drop compensation value is used to model the reactive line losses between the regulator and the theo retical load center The CL 4C Control uses this paramenter in conjunction with the load current flow to calculate the compensated voltage displayed at Function Code 8 during forward
9. 4VA 40 C to 859 ANSI C57 15 Class VR 32 Regulator and CL 4C Control Adjust the variable voltage source so the applied voltage is at least 5 volts below the control voltage setting Note that the LOW band annunciator in the display will come on After the time delay period the control will issue RAISE tap change signals Check to ensure that the operations counter is registering tap changes J Place the CONTROL switch in the MANUAL position and manually return the tap changer to NEUTRAL When on NEUTRAL the NEUTRAL LAMP will light and the position indicator will point to zero K Place the CONTROL switch in the OFF position L Press down on the momentary toggle switch labeled DRAGHAND RESET and the position indicator drag hands will reset to neutral M Turn the POWER switch to OFF and disconnect the power power supply from the EXTERNAL SOURCE terminals Remove the shorting connection from the high voltage bushings and disconnect the ground 2 IN SERVICE OPERATIONAL CHECK The operation and calibration of the CL 4C Control can be checked while the regulator is in service However the user must understand that field calibration checks are only an indi cation of calibration and are not nearly as precise as the pro cedure described in the CONTROL TROUBLE SHOOTING SECTION page 4 1 which is a laboratory process The CL 4C Control is also communications capable Two additional boards are neede
10. Amp kVA Catalog Number Changer 2 5 100 25 RSAA025025AA 928D 200 50 RSAA025050AA 928D 60 300 75 RSAA025075AA 770B kV 400 100 RSAA025100AA 770B BIL 500 125 RSAA025125AA 660C 668 167 RSAA025167AA 660C 1000 2508 RSAA025250AA 770B 1332 333 5 RSAA025333AA 770B 1665 416 35 RSAA025416AA 770B 5 0 50 25 RSAA050025AA 928D 100 50 RSAA050050AA 928D 75 200 100 RSAA050100AA 928D kV 250 125 RSAA050125AA 770B BIL 334 167 RSAA050167AA 770B 500 2508 RSAA050250AA 660C 668 333 5 RSAA050333AA 660C 833 416 35 RSAA050416AA 660C 7 62 50 38 1 RSAA076038AA 928D 75 57 2 RSAA076057AA 928D 95 100 76 2 RSAA076076AA 928D kV 150 114 3 RSAA076114AA 928D BIL 219 167 RSAA076167AA 928D 328 2508 RSAA076250AA 770B 438 3338 RSAA076333AA 660C 548 416 3 RSAA076416AA 660C 656 500 S RSAA076500AA 660C 875 6675 RSAA076667AA 660C 1093 833 5 RSAA076833AA 660C 13 8 50 69 RSAA138069AA 170C 100 138 RSAA138138AA 170C 150 207 RSAA138207AA 170C 95 200 2765 RSAA138276AA 170C kV 300 4145 RSAA138414AA 770B BIL 362 500 5 RSAA138500AA 660C 400 5525 RSAA138552AA 660C 483 6675 RSAA138667AA 660C 604 833 S RSAA138833AA 660C 14 4 5 72 RSAA144072AA 170C 100 144 RSAA144144AA 170C 200 288 5 RSAA144288AA 170C 231 333 S RSM144333AA 770B 150 289 4165 RSAA144416AA 770B kV 300 4328 RSM144432AA 770B BIL 347 5005 RSAA144500AA 660C 400 5765 RSAA144576M 660C 463 6675 RSAA144667AA 660C 500 7205 RSAA144720AA 660C 578 833 5 RSAA144833AA 660C 19 92 25 1 50 RSM199050AA 170C 50 2 100 RSAA199100AA 170
11. ENTER 05 3 5 The reactive compensation is now 3 5 volts C PARAMETER RANGE FACTORY SETTING 41 REGULATOR CONFIGURATION 0 2 0 The CL 4C Control is designed to operate on wye connected and delta connected 3 phase systems Regulators connected line to ground wye develop potentials and currents suitable for direct implementation in the CL 4C Control Regulators connected line to line delta develop a potential to current phase shift which is dependent upon whether the regulator is defined as leading or lagging This phase shift must be known by the CL 4C Control to permit accurate calculations for correct operation This is accomplished by entering the proper code 0 Wye 1 Delta Lagging 2 Delta Leading See reference document R225 10 1 for an explanation of how to determine whether the regulator is leading or lagging Perform the following steps to program the regulator configuration into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 41 ENTER 41 0 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 lagging PARAMETER RANGE FACTORY SETTING 42 CONTROL OPERATING MODES 0 2 0 Cooper Power Systems is the only manufacturer that offers a selection of three modes in which the control responds to out of band conditions This permits the user to select the mode that best fits the applicati
12. KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 43 ENTER 43 7200 This is the system voltage for 7200V regulator CHANGE 43 Enter the desired value example 4160 4160 ENTER 43 4160 The system line voltage is now 4160 volts F C PARAMETER RANGE FACTORY SETTING 44 P T RATIO 20 0 300 0 RATIO FOR REGULATOR RATING Since the CL 4C Control performs ratio correction in software the P T ratio for the voltage sensing supply must be entered for the control to perform this calculation The ratio to be programmed in the CL 4C Control is the OVERALL POT RATIO as shown on the regulator nameplate for every applicable system voltage for the particular regulator This value includes the correction performed by the ratio correcting transformer RCT on the control back panel The voltage from the RCT is normally corrected to 120 volts However in the instance in which this voltage is other than 120 volts the CL 4C Control will dqfine the particular input voltage as the 120V base voltage and 120V will be displayed at Function Code 6 The voltage test terminals will continue to show the voltage as applied to the control from the RCT Perform the following steps to program the P T ratio into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 44 ENTER 44 60 0 This is the P T ratio for a 7620 volt regulator set at 7200V CHANGE 44 Enter the desired value example 34 7 347 ENTER 44 34 7 The P T ratio is now 34 7 1 PAR
13. The following instructions apply only to the junction box mounted position indicator construction that was initiated in April 1980 To replace a defective position indicator requires removing the unit from service as outlined in REMOVAL FROM SER VICE on page 1 8 1 A defect in the position indicator may have caused loss of synchronization between the tap changer and the indi cator hand Verify that the tap changer is in neutral via the neutral light of the control and visual inspection of the tap changer If the position indicator does not also show CAUTION It must be verified that BOTH the neu tral light AND the position indicator hand indicate NEUTRAL when the tap changer is physically in the neu tral position Lack of the synchronization will cause an indefinite indication of NEUTRAL Without both indications of neutral bypassing of the regulaotr or at a later time will not be possible and the line must be de energized to avoid shorting part of the series winding CONTROL CALIBRATION neutral refer to instructions in S225 10 2 Spring and Direct Drive Tap Changers All controls are factory calibrated and should not need to be recalibrated by the user However calibration can be performed for both the voltage and current circuits by performing the 2 Remove the junction box cover 3 Note the location of the indicating hand for future align ment and disengage the flexible shaft from the position indicator
14. the fixed 1 forward metering threshold The demand values acquired during reverse power flow are stored as reverse metered data but the values are not scaled to reflect the other side of the regulator since the operating direction of the regula tor never truly reverses FORWARD REVERSE NORMAL FORWARD METERING FORWARD METERING WITH REVERSE LDC 1 0 1 CURRENT FLOW Figure 2 12 Co generation metering OPERATION The control operates in the forward direction whenever the real component of the current is above the opera tor defined forward threshold Function Code 57 When the current exceeds the operator defined reverse threshold Function Code 57 the control continues to operate in the for ward direction using the forward settings for set voltage band width and time delay but uses the reverse settings for line drop compensation resistance and reactance When the current is in region between the two thresholds the control idles on the last tap position held before the threshold was crossed and the band edge indicators turn off The operational timer time delay is reset on any excursion below either threshold REVERSE FORWARD 7 CHANGING Z7 2 NORMAL_ FORWARD OPERATIONS 1 FORWARD OPERATIONS WITH REVERSE LOC P d 2 1 5 F C 57 1 5 F C 57 0 CURRENT LEVEL 2 INHIBITED YN Figure 2 13 Co generation mode op
15. 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 30 H L P Load Voltage Demand Reverse v 0 1 Reset This is secondary output voltage of the regulator during reverse flow a demand value according to the demand time interval at Function Code 46 H maximum value since last reset minimum value since last reset and P present value Scroll to L and P values An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 31 H L P Compensated Voltage Demand Reverse v 0 1 Reset This is calculated secondary voltage at the load center during reverse flow as demand value according to the demand time interval at Function Code 46 The line compensation settings for resistance and reactance Function Codes 54 and 55 are used in this calculation maximum value since last reset minimum value since last reset and P present value Scroll to the L and P values An optiona
16. 3 4 and 10 regulation to alter the regulation range The five possible load current ratings associated with the reduced regula tion ranges are summarized in Table 1 2 At each setting a detent stop provides positive adjustment Settings other than those with stops are not recommended The raise and lower limits need not be the same value SETTING THE LIMIT SWITCHES Before setting the 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 indicator 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 devi ation of primary voltage For example on a circuit where 7200 volts is to be maintained plus or minus 10 will permit voltages between 6480 and 7920 to be regulated effectively For voltages outside of this range the regulator will not be able to return the voltage to the preselected level in this case 7200 volts The tap changer will have stepped to the maximum tap position and will be unable to regulate further Five regulation would accommodate circuit voltages between 6840 and 7560 maintaining 7200 volts for all voltages in this range To set the limit switches follow this tw
17. 38 Voltage Harmonics SYSTEM CODES 39 Current Harmonics 0 All Systems Good 3 Frequency Detection Failure CONFIGURATION 5 A D Converter Failure 40 Control Operating Mode 2 6 nvalid Critical Parameters 0 Sequential 7 nput Voltage Channel Failure 1 Time Integrating 2 Voltage Averaging 8 Output Voltage Channel Failure 41 C T Ratio 2 9 nput amp Output Voltage Channel Failure 42 P T Ratio 2 43 System Line Voltage 2 ERROR CODES 44 Regulator Configuration 2 1 Input Value Too Low 0 Wye 1 Delta Lag 2 Delta Lead 2 nput Value Too High 45 Load Voltage Calibration 3 3 Improper Security to Change 46 Source Voltage Calibration 3 4 Invalid Security Code 47 Current mA 3 5 nvalid Option Level 48 Demand Time Interval 2 5225 10 4 VR 32 REGULATOR TAP CHANGER Section 3 TAP CHANGER OPERATION Spring and Direct drive Tap Changers Regulators for low current applications employ stored energy spring drive tap changers Commonly they are used on ratings 219 amps and below The tap changer for a specific rating is shown on the rating plate Figures 3 1 95 BIL and 3 2 150 BIL illustrate typical spring drive mechanisms On regulators manu factured January 1976 and later the model number is stamped on the drive frame Common models are either 859 or 928 Figure 3 1 and 170 Figure 3 2 followed by a suffix letter Voltage regulators used in medium and high current applica tions employ direct motor driven tap changers Th
18. Automatic Mode with an A Example If the display reads 71 A2 5 then 2 5 of voltage reduction is in effect and it has been activated by the Automatic Mode See Voltage Reduction page 2 30 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 72 Local Voltage Reduction 96 0 2 0 0 0 The percentage of local immediate voltage reduction to be performed is entered here Example If the regulator is for 125v voltage setting and 3 6 voltage reduction is required 3 6 is entered here first set Function Code 70 1 and the regu lator will tap down 4 5 volts 3 696 of 125v immediately following the time delay period See Voltage Reduction page 2 30 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 73 Remote Reduction Setting 1 96 0 2 0 0 0 0 0 0 Three levels of remotely activated voltage reduction are available with CL 4C Control The percentage of voltage reduction to be performed at Remote Level 1 is programmed at Function Code 73 Remote activation is then accomplished by applying a signal to the appropriate input terminal when Function Code 70 2 or 3 See Voltage Reduction page 2 30
19. ENTRY FUNCTION LIMIT CODE CODE PARAMETER oF TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 68 Communications Transmit Enable Delay msec 2 NA invalid 0 100 When the control is set for transmit control handshaking Function Code 66 2 the user may require a delay to occur between the time when the CTS line is enabled to when data is transmitted As an example if the CTS line were used as a keying device for a transmitter or modem a warm up period may be necessary before data can be transmitted The delay period can be entered at this function code and is normally set to 0 for the presently supported communications system FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 69 Regulation Blocking Status 0 2 0 0 1 The CL 4C Control with communications options allows the user to completely control the regulator through the SCADA system The SCADA system may place the regulator in a BLOCKED state thus inhibiting any further tap changer operation A practical example might be to perform a certain amount of voltage reduction and then disable the tap changer inhibit additional opera tions for an indefinite time period When the control is blocked automatic operation inhibited Function Code 69 will
20. ORME LIMITED TO x RATED SST LOAD AMPS 18 POLARITY MARKER 625404 REV 0 CAUTION WET LON 00 NOT BYPASS UNLESS ON NEUTRAL POSITION CONTROL SWITCH IS OFF READ INSTALLATION AND FILLED WITH MINERAL OIL THAT CONTAINEO LESS OPERATING INSTRUCTIONS S225 10 4 OR S225 10 5 THAN PPM PCB AT TIME OF MANUFACTURE Figure 2 18 Nameplate with Differntial P T installed 2 36 VR 32 Regulator and CL 4C Control CONTROL SYSTEM DESIGN AND OPERATION This section describes the CL 4C Control design and opera tion The overall control system schematic is shown in Figure 2 19 This is described in segments to aid in the understanding of the VR 32 regulator with the CL 4C Control DF DIFFERENTIAL VOLTAGE FUSE DHR DRAG HAND RESET EST EXTERNAL SOURCE TERMINALS HSL HOLDING SWITCH LOWER HSR HOLDING SWITCH RAISE IRS INDICATOR RESET SOLENOID POSITION INDICATOR JBB JUNCTION BOX TERMINAL BOARD ON THE COVER LLS LOWER LIMIT SWITCH POSITION INDICATOR MC MOTOR CAPACITOR MF MOTOR FUSE MOV METAL OXIDE VARISTOR NL NEUTRAL LIGHT NEUTRAL LIGHT CAPACITOR NLS NEUTRAL LIGHT SWITCH PD POTENTIAL OPENING DEVICE PF PANEL FUSE PS POWER SWITCH RCT RATIO CORRECTION TRANSFORMER RS RAISE LIMIT SWITCH POSITION INDICATOR SD CURRENT SHORTING DEVICE TB CONTROL TERMINAL BOARD TCB TAP CHANGER TERMINAL BOARD VDIFF DIFFERENTIAL
21. UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 91 Self Test N A N A N A N A N A N A The CL 4C Control will execute a self diagnostic routine by entry af Function Code 91 This causes the system to re boot or initialize itself and in so doing it checks the various components for failures This test initiates by lighting all segments in the display for 3 seconds and then displays PASS or FAIL depending upon the test results Performing the SELF TEST will appear as a power interruption to the CL 4C Control demand task and accordingly it will cause the present demands to go invalid dashes and the Max Min demands to cease tracking for one demand interval FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 93 Number Of EEPROM Corrections 3 3 0 This is a counter for the number of times the CL 4C Control has detected an incorrect value in its non volatile memory ROM nad has changed it to the correct value This is for information only FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 94 Number Of Resets 3
22. VOLTAGE VM MOTOR VOLTAGE VS SENSING VOLTAGE VIT VOLTAGE TEST TERMINALS NOTES 1 PORTIONS oF SCHEMATIC SHOWN IN DOTTED ENCLOSURE ARE LOCATED IN REGULATOR TANK Figure 2 19 VR 32 regulator and CL 4C control wiring diagram SOURCE BUSHING SERIES WINDING 1 1 1 1 1 1 l I 1 j I 1 1 1 1 1 1 l 1 I CHANI TERMINAL BOARD UNDER CURRENT TRANSFORMER TOROIDAL COIL SUURKLE LOAD BUSHING REMUVABLE _GRUUNU IDE OF 0 LOAD BUSHING sBB c2 1 1 4 amp REMOVABLE GROUND I LOCATED ON BACK PANEL PLATE INSIDE CONTROL BOX TB1 C2 1 1 1 1 TB2 CI 14 REMOVABLE JUMPERS FOR ACCESSORIES T82 C3 no iens CONTROL WINDING 2 37 5225 10 4 VR 32 Regulator and CL 4C Control NOTES DIFFERENTIAL VOLTAGE FUSE DRAG HAND RESET EXTERNAL SOURCE TERMINALS HOLDING SWITCH LOWER HOLDING SWITCH RAISE INDICATOR RESET SOLENOID POSITION INDICATOR JUNCTION BOX TERMINAL BOARD ON THE COVER LOWER LIMIT SWITCH POSITION INDICATOR MOTOR CAPACITOR MOTOR FUSE METAL OXIDE VARISTOR NEUTRAL LIGHT NEUTRAL LIGHT CAPACITOR NEUTRAL LIGHT SWITCH POTENTIAL OPENING DEVICE PANEL FUSE POWER SWITCH RATIO CORRECTION TRANSFORMER RAISE LIMIT SWITCH POSITION INDICATOR CURRENT SHORTING DEVICE CONTROL TERMINAL BOARD TAP CHANGER TERMINAL BOARD
23. Voltage Averaging See Control Operating Modes page 2 34 FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 43 System Line Voltage v 0 2 invalid 2400 36000 The CL 4C Control is designed to operate on primary system voltages from 2400v to 36000v Ratio correction is performed by the software and consequently the primary voltage must be entered for this calculation Example A regulator installed on a 7200 volt system line to neutral would have 7200 entered at Function Code 43 2 14 VR 32 Regulator and CL 4C Control FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER oF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 44 Potential Transformer Ratio 0 2 NA invalid 20 0 300 0 The CL 4C Control is designed to operate on primary system voltages from 2400v to 36000v Ratio correction is performed by the software and consequently the potential transformer ratio must be entered for this cal culation The P T ratio is available on the regulator nameplate and is summarized in Table 2 1 on page 2 4 for all regulator ratings Example a 13800 volt regualtor installed on a 7970 volt system would have 7970 entered at Function Code 43 and 63 8 ent
24. and P values An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 35 H L P kW Load Demand Reverse kW 0 1 Reset This is the load kVA during reverse flow as a demand value according to the demand time interval at Function Code 46 H maximum value since last reset minimum value since last reset and P present value Scroll to the L and P values An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 36 H L P kVAR Load Demand Reverse kVAR 0 1 Reset This is the load kVAR during reverse flow as demand value according to the demand time interval Function Code 46 H maximum value since last reset L minimum value since last reset and P present value Scroll to the L and P values An optional differential o
25. can regulate a three phase four wire multi grounded wye circuit Three regulators cannot be connected in wye on three phase three wire circuits because of the probability of neutral shift Typical connection dia grams are illustrated in Figure 1 3 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 exces sively high or low voltage on the load side of the regulator or cause severe damage to the regulator VR 32 Regulator and CL 4C Control p BYPASS STON E 1 2 4 2 2 rS EA a IT i t _ y 1 3 Eu jee 447 4 4 M INSCONNECTS SURE ARESTE S 4 4 4 4 4 m i i 1 if x na T 1 P d RA O O rm for QA OFS lt aL m 5 UR T HUNGE SERES 2 SURGE 22 SUMGE E 7 aRRESTERS 707 77 REGULATING SINGLE PHASE CIRCUIT BYPASS SWITCH 7 7 BYPASS SWITCH a BYPASS SWC LL i I e e 4 75 f SERIES SUHGE ARRESTERT lt 727 2 REGULATING THREE PHASE FOUR WIRE MULTI GROUNDED WYE CIRCUIT WITH THREE REGULATORS Figure 1 3 Typical connections diagram
26. complete the computed number of tap changes are performed without any delay between them up to a maximum of five 5 consecutive tap changes to avoid an accumula tive error The timer is not reset on voltage excursions in band unless the voltage stays in band for at least 10 continuous sec onds An error averaging characteristic is inherent with the voltage averaging mode NOTE To permit sufficient time for the microprocessor to average the voltage the time delay period must be 30 seconds or longer If the time delay is set for less than 30 seconds the control ignores the setting and uses 30 seconds Perform the following steps to program the control operating mode into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 42 ENTER 42 0 This is the control operating moed as shipped from the factory CHANGE 42 c Enter the desired value example 2 2 ENTER 42 2 The control operating mode is now Voltage Averaging 2 34 VR 32 Regulator and CL 4C Control C PARAMETER RANGE FACTORY SETTING 43 SYSTEM LINE VOLTAGE 2400 36000 REGULATOR RATED VOLTAGE The CL 4C Control performs ratio correction in software and consequently the primary voltage must be entered for the control to perform this calculation This value is simply the single phase voltage supplied across the S and SL terminals Regulators shipped from the factory are usually set for the rated voltage and this value is programmed into the control
27. connections Use of this type of voltage reduction module will cause meter ing errors in the CL 4C by the amount of voltage reduction being activated The Cooper Power Systems voltage reduction capabilities are described on page 2 30 GRN BLK REMOTE VOLIAGE REDUCTION MODULE PROVIDED BY OTHERS LI REMOVE JUMPER REAR PANEL NOTE CONECT M TO HS FOR DIRECT DRIVE AND TO HS FOR TAPCHANGERS Figure 2 23 SCADA connections to CL 4C control FOR REMOTE VOLTAGE REDUCTION REMOTE Tar CHANGER CON IROL PROVIDED BY OTHERS REMOVE JUMPER FOR AUTO INHIBIT CONNECT TO TB g 2 43 5225 10 4 CONTROL SWITCHES CURRENT RELAY CONTACTS REMOTE RAISE MOTOR CAPACITOR TO MOTOR CURRENT SENSING HOLDING SWITCH PROVIDED BY OTHERS Figure 2 24 SCADA connections basic scheme P CUSTOMER CONTACTS a 7 RELAY TAGE i BOTH FOR STAGE 3 COMMON INI Figure 2 25 Typical User Provided Voltage Reduction Module Figure 2 26 Voltage reduction customer contact points 2 44 VR 32 Regulator and CL 4C Control FIELD TRIAL CL 4 CONTROLS Users who participated in the field trial program of the CL 4 Control have devices serialized as 10 87 These devices contain all the same capabilities of the production CL 4 Controls serialized as 100200 and higher Field trial CL 4 C
28. display 1 Similarly when Function Code 69 displays 0 normal automatic operations will occur The operator may change the state of this code by entering the level 2 security level at the CL 4C Control and pressing the CHANGE RESET key If SCADA has the control blocked the operator may overide the SCADA system by changing Function Code 69 from 1 to 0 or if the operator chooses to block automatic operation Function Code 69 can be changed from 0 to 1 2 19 9225 10 4C FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 70 Voltage Reduction Mode 0 2 0 0 3 The CL 4C Control has three voltage reduction modes available for user selection The appropriate mode is activated by entering the corresponding code 0 Off 1 Locale 2 Remote 3 Automatic with Overide See Voltage Reduction page 2 30 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 71 Percent Voltage Reduction In Effect 96 0 This is actual percentage of voltage reduction presently active f automatic voltage reduction is in effect the display will also indicate that it is being activated by the
29. drive tap changer occurs as the main movable contacts enter or leave the neutral position A pin in the contact drive sprocket assembly engages a slot in the reversing segment when the main switch is in the neu tral position The first tap step in either direction rotates the seg ment and the reversing switch engages the appropriate reversing stationary The drive sprocket pin and reversing segment provide a mechanical stop located approximately 320 degrees on either side of neutral When the pin engages the end of the segment the spring drive mechanism will be loaded and the segment is locked to prevent any further motion in that direction The reversing switch motion on the direct drive tap changers occurs as the main movable contact moves from neutral to the first raise position On the Model 770B tap changer a roller on the back side of the rear roller plate engages a slot in the revers ing segment on the reversing insulating arm On Model 660C tap changer a pinion mounted on the same shaft as the rear roller plate engages a slot in the reversing segment on the reversing insulating arm As the rear roller plate rotates the reversing mov able contacts are driven from the VL reversing stationary contact to the VR contact Table 3 1 Tap Changer Model Application Chart Rated Load Volts Current Rated Tap kV
30. 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 This shorts out the secondary of the regulator CT WARNING Push the C shorting switch closed before attempting to remove the fanning strip Failure to do so will open the regulator CT circuit and may produce a flashover on the control 2 Pull open the disconnect switch V4 and Vg if present This de energizes the CL 4C front panel 3 Loosen the screws on the interconnecting terminal strip TB2 at the bottom of the back panel 4 Pull the fanning strip free from the terminal strip 5 Disconnect the front panel ground lead from the back panel The CL 4C can now be lifted off its hinges Care should be taken to prevent damage to a CL 4C front panel while in transit and or storage Replacement of CL 4C Front Panel To replace a CL 4C front panel in the control enclosure follow the procedure outlined below 1 Engage the front panel on the enclosure hinges 2 Connect the front panel ground lead to the back panel 3 Insert the fanning strip from the front panel wiring harness under the TB2 terminal block screws 4 Tighten the screws on the interconnecting terminal block 5 Push closed the disconnect switch V1 and Vg if present 6 Pull open the current shorting switch C WARNING Do not pull open the current s
31. has boosted the input voltage since last reset Each tap corresponds to approximately 0 625 of regulation change This value functions like the drag hand in the position indicator As the regulator increases the tap setting the drag hand is pushed higher Example The position indicator drag hand is on 8R the regulation drag hand Function Code 27 will display 5 0 An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 2 11 9225 10 4C FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 28 Maximum Buck Minimum Boost 96 0 1 Reset This is the highest percentage the regulator has reduced the input voltage since last reset Each tap corresponds to approximately 0 625 of regulation change This value functions like the drag hand in the position indicator As the regulator decreases the tap setting the drag hand is pushed lower Example the position indicator drag hand is on 4L the regulation drag hand Function Code 28 will display 2 5 optional differential source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2
32. insulators since the reactor coil is at line volt age above ground The reactor core core clamps and other asso ciated parts approach this level The current transformer is a toroid through which the load cur rent passes It furnishes a current proportional to load current to the line drop compensator circuit in the control and to optional metering packages The tap changer enables the regulator to provide regula ion in smooth accurately proportioned steps at a controlled speed that minimizes arcing and extends contact life Four different tap chang ers are used throughout the line of regulator ratings Figures 1 13 through 1 16 illustrate typical internal wiring schemes of the vari ous types of regulator constructions Most of the wiring is on the tap changer itself Application troubleshooting and operation of the spring and direct drive tap changers and related components are covered extensively in Service Manual 9225 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 4 1 page 4 2 SOURCE R 1 BUSHING REVERSING SWITCH REACTOR EQUALIZER WINDING SOURCF SHUNT WINDING SOURCE LOAD BUSHING N Figure 1 9 Power circuit series winding located on the source side POLARITY MARKER LOAD j v CURRENT TRANSFORMER
33. is lower than the input voltage that is the regulator is bucking the sign is An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this para meter displaying dashed Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 13 Power Factor 0 This is the power factor of the primary circuit as represented by the difference between the line current and voltage Leading current or capacitive loads are designed by a sign and lagging current or inductive loads are designated by implied sign REVERSE POWER FORWARD POWER LAGGING LEADING sd D UNITY SS ee UNITY 1 LEADING LAGGING e Figure 2 2 Figure 2 3 Reverse power vector diagram Forward power vector diagram 2 8 VR 32 Regulator and CL 4C Control FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 14 kVA Load kVA 0 N A N A N A N A N A This is the total kilovolt amperes drawn by the load as calculated by the product of the primary kV Function Code 10 times the primary l
34. levels 1 2 and 3 respectively Each level is completely independent of the others The customer inputs for the remote voltage reduction are located on the control back panel Fig 1 17 on page 1 19 on TB2 and are identified as 1 2 and J common Figure 2 15 illustrates the connection of customer contacts J is normally connected to signal ground but could be operated above ground The voltage source to activate the remote inputs can be derived from TB2 V9 if desired This terminal is at the nomi nal 127V motor potential when the control switch is set for AUTOMATIC It is off for other positions of the control switch CUSTUMER CUNIACIS STAGE 1 BOTH FOR TAGE STAGE 3 Figure 2 15 Voltage reduction customer contact points Example If Function Code 73 2 0 Function Code 74 5 0 and Function Code 75 7 5 then as input terminal 1 is activated the regulator steps down 2 0 from the set voltage level of the control The V RED annunciator turns on and Function Code 71 will display 2 0 if interronated If only input 2 is activated the regulator steps down 5 0 as entered at Function Code 74 and Function Code 71 will display 5 0 If both inputs are held active the regulator steps down an additional 2 5 for a total of 7 5 as programmed at Function Code 75 and Function Code 71 will display 7 5 AUTOMATIC WITH REMOTE OVERRIDE Func Code 70 3 A new feature to the industry is automatically activated
35. made when entering or changing a parameter a message such as 99 Enter Security Code ERROR 1 will be displayed The Following is a complete list of the error codes Input Value too Low Input Value too High NOTES Improper Security to Change Invalid Security Code BRON Adifferential P T or Source side P T is required for these functions to be active H L P For demand values the Highest maximum value since last reset the Lowest minimum value since last reset and the are stored Scroll to L and P values Present value COOPER Cooper Power Systems Quality from Cooper Industries Cooper Power Systems Inc is a registered trademark of Cooper Industries Inc P O Box 2850 Pittsburgh PA 15230 Quality from Cooper Indusiries
36. of accuracy in ist measurements 5225 10 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 18 3 5 7 9 11 Voltage Harmonics 0 N A N A N A N A This is the harmonic content of the voltage waveform at the 3rd 5th 7th 9th and 11th harmonic frequencies This is displayed as percentage of the fundamental RMS voltage Example 120 0v of 60 Hz fundamental power line frequen Cy with a reading of 0 5 at the 7th harmonic 420Hz is 06v RMS FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 19 3 5 7 9 11 Current Harmonics 96 0 N A N A N A N A N A This is the harmonic content of the current waveform at the 3rd 5th 7th 9th and 11th harmonic frequencies This is displayed as a percentage of the fundamental RMS current Example 200A fo 60 Hz fundamental power line frequen Cy with a reading of 1 9 at the 5th harmonic 300 Hz is 3 8A RMS FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 20 H L P Load Voltage Demand Forward v 0 N A N A Reset N A N A Thi
37. page 2 30 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 78 Percent Current For Automatic 1 0 2 0 0 20 150 When activated automatic voltage reduction occurs a result of the load currnet exceeding preset threshold value The turn on current for Automatic Level 1 is entered here as a percentage of full load C T secondary current Example Desiring a turn on threshold at 50 of the full load rating on a 328 amp regulator which uses a 400 amp C T calculate the threshold as follows 328 400 x 50 41 Enter 41 at Function Code 78 See Voltage Reduction page 2 30 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 79 Percent Current For Automatic 2 0 2 0 0 20 150 When activated automatic voltage reduction occurs as a result of the load currnet exceeding preset threshold The turn on current for Automatic Level 2 is entered here as a percentage of full load C T secondary current Example Desiring a turn on threshold at 100 of the full load rating on a 328 amp regulator which uses a 400 amp C T calculate the threshold as follows 328 400 x 100 82 Enter 82 at Function Code 78 See Voltage Redu
38. protection concept has proven very effective in the surge tests conducted by Cooper Power Systems Measures have also been taken in the software design to further enhance the CL 4C Control operation under adverse conditions orderly operation is ensured by MERTOS4 an operating system developed by Cooper Power Systems for microprocessor based systems There are four error detection soflware activities overseen by MERTOS4 which are an inher ent part of the normal operation 1 The microprocessor architecture includes a COP Computer operating Properly watchdog system to help protect against software failures A watchdog reset sequence is executed on a periodic basis so that the watchdog timer is never allowed to time out Should the software malfunction the reset sequence will not be generated and the COP will time out causing the system to enter a diagnostic routine 2 MERTOS4 continually polls the various software tasks to ensure that they are still operational If an abnormality is encountered MERTOS4 will cause the system to enter a diagnostic routine 3 Throughout the unused memory space commands are embedded which generate a system reset if executed Should an event occur which causes the processor to run errantly into unused memory space the system will immediately be direct ed to a diagnostic routine 4 The settings programmed into the CL 4C Control non volatile memory are stored in triplicate This permits a voting scheme
39. setting the power direction The metering will be forward until the current exceeds the 1 threshold in the reverse direction At this time the various parameters assume new values as previously described and the REV PWR annunciator turns on The con trol continues metering in reverse until the current exceeds the 1 threshold in the forward direction and then the parameter scaling reverts back to normal and the REV PWR annunciator turns off OPERATION The control operates in the forward direction whenever the real component of the current is above the oper ator defined forward threshold Function Code 57 The control operates in the reverse direction using the reverse settings at Function Codes 51 52 53 54 and 55 whenever the current is above the operator defined reverse threshold Function Code 57 When the current is in the region between the two thresh olds the control idles on the last tap position held before the current fell below the threshold The operational timer time delay is reset on any excursion below the threshold in either direction and the band edge indicators turn off JERSE du NORMAL REVERSE INHIBITED OPERATIONS OPE RATI IONS j 22 1 1 5 F c 57 4 F C 57 LEVEL Figure 2 9 Bi directional mode operation NEUTRAL IDLE MODE Function Code 56 4 Source is Required METERING A threshold level of 1 002A of the full load C T secondary current 20
40. the addition of two communications boards SCADA RELAY AND TERMINAL BLOCK For SCADA operation remote tap changer control per Figure 2 23 page 2 43 a SCADA relay and terminal block assembly Figure 5 4 is required Ir A Mibi Ed 1 Figure 5 4 SCADA relay and terminal block REMOTE MOUNTING CONTROL CABLE For remote mounting of the control cabinet various length cables are available See the Spare Parts section FAN COOLING ACCESSORY Voltage regulators 250 kVA and larger can be equipped with fan cooling Figure 5 5 Fan cooling increases the load capacity of the regulator by 25 Special requirements are necessary on regulators using fan cooling therefore the regulator must be ordered with fan cooling or with provisions for adding fan cooling Mounting cooling fans flush to the plate type radiator is accom plished by using T bolts that secure the cooling fan to the bank of radiators The automatic operation of the fan is controlled by a ther mometor having a thermal switch that will cycle the fan on or off when the top oil temperature reaches predetermined tempera ture limits The thermal switch has an upper limit adjustable from 80 C to 110 C The differential from make to break is 69 to 1 0 C The thermal switch when temperature activated or deacti vated signals a relay which turns the fan on or off For full details refer to 5225 10 1 Supplement 8 Figure 5 5 Fan cooling acc
41. the memory must be purged The list of parameters copied to the DATA READER is shown in Table 2 2 page 2 5 and includes all five values for both voltage and current harmonics and the H L and P val ues for all demand parameters Data Reader and Software Kit The Data Reader and Soflware Kit includes the Data Reader the Data Reader to control cable the Data Reader to PC cable and the Data Reader software The non copy protected software operates on an IBM type personal computer with DOS 2 0 or higher operating system The software allows the operator to perform the following functions 1 Upload the data from the Data Reader to the software data base Erase the Data Reader memory Scan the data on the CRT Print reports Transfer data to another data base Data Reader Assembly The Data Reader Assembly consists of the Data Reader and the Data Reader to control cable McGRAW EDISON DATA READER mm comma aem wren cream Figure 5 3 Data Reader Assembly 5 1 9225 10 4C DIGITAL COMMUNICATIONS This feature includes full remote metering and realtime opera tion capability Using this feature all metering and changing of parameters including all of the options can be controlled remotely Additional remote capabilities include the ability to tap up or down a specified number of taps and the ability to deter mine the status of local activity Digital communications requires
42. then applied to the sensing circuit of the control The control winding is wound on the core to obtain a sup ply voltage for the tap changer motor and the control sens ing circuits Taps are available on this winding for large step voltage ratio correction The shunt winding is wound over top of the control wind ing with the series winding wound over top of the shunt winding Most regulators depending upon the rating have an equalizer winding If applicable the equalizer winding is wound on the outside of the coil over the series winding Figure 1 11 shows a regulator power circuit with a series transformer This design is utilized when the load current rat ing exceeds the tap changer rating Figure 1 12 shows the internal construction of this regulator 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 re duce losses and therefore the ADD AMP feature is not applicable The preventive auto or bridging reactor is a core form design consisting of a coil on each leg of the 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 reac tance to a very low value The reactor is completely isolated from ground by stand off
43. voltage reduction dependent upon load current The CL 4C introduces this concept with two separately activated levels of reduction As the load current exceeds the current percentage programmed into Function Code 78 voltage reduction of the percentage entered at Function Code 76 is performed A second stage of voltage reduction is activated when the current percentage pro grammed into Function Code 79 is exceeded When this sec ond and presumably higher current value is exceeded the voltage reduction is the sum of the two levels at Function Codes 76 and 77 Since the addition of the two levels could potentially add up to 20 the control internally will limit the total to 10 Once a reduction setting is activated it remains active until the current falls below the turn on threshold by 10 As with the other modes of voltage reduction when active the V RED annunciator turns on and Function Code 71 will display the percentage of reduction in effect Additionally at Function Code 71 the display will indicate an A to distinguish the auto matic mode from the remote mode of activation When any of the remote reduction inputs are turned on the automatic mode will be overridden and remote reduction then takes place according to the programmed percentage for the particular input s The two current thresholds Function Codes 78 and 79 are entered as a percentage of the full load C T secondary cur rent Some regulators utilize C T
44. with an internal differential potential transformer an external source side potential transformer may be connected to the control See Reverse Power oper ation below ACCESSORY OPERATION Demand Task Operation The CL 4C Control provides demand values for six parame ters 1 load voltage 2 compensated voltage 3 load current 4 kVA load 5 kW load and 6 kVAR load Additionally the powerfactor at the maximum kVA demand and minimum kVA demand are also recorded These demand parameters work like drag hands as new peaks occur the high H value gets pushed higher and as new minimums occur the low L val ues get pushed lower The present P value indicates the demand at the present time The demand metering function is based upon a sliding win dow concept or moving integral The algorithm implemented simulates the response of a thermal demand meter which will reach 90 of its final value after one demand interval in response to a step function input This has the exponential response characteristic shown in Figure 2 5 100 90 T eT 3T 4T ST eT DEMAND TIME INTERVAL Figure 2 5 Demand time interval response The task itself works like this 1 For 3 minutes after a power outage OR power reversal no demands are calculated This allows the utility system to stabilize from the event which created the outage or power reversal 2 At 3 minutes the present deman
45. 0A is used in setting the power direction The metering will be forward until the current exceeds the 1 threshold in the reverse direction At this time the various param eters assume new values as previously described and the REV PWR annunciator turns on The control continues metering in reverse until the current exceeds the 1 threshold in the forward direction and then the parameter scaling reverts back to normal and the REV PWR annunciator turns off OPERATION The control operates in the forward direction when ever the real component of the current is above the operation defined forward threshold Function Code 57 When the current exceeds the operator defined reverse threshold Function Code 57 and is held for 10 continuous seconds the control will tap to neutral Neutral position is determined as when the percent buck boost is within 3 of 0 When the current is in the region between the two thresholds the control idles on the last tap posi tion held before the forward threshold was crossed While tapping to the neutral position if the current falls below the reverse threshold the control continues to tap until neutral position is reached The operational timer time delay is reset on any excur sion below the forward threshold YW joo 2 CHANGING 77 26 NEUTRAL 2 m NOPERATIONS D 1 5 F C 57 1 5 F C 57 DUBRENT LEVEL Figure 2 10 Neutral idle mode operation 2 27 5225 10 4 CO GENERATION MODE
46. 25 10 4C The three voltage circuits are routed from the power switch to the respective 6A motor fuse 2A panel fuses and 2A differ ential voltage fuse From the fuse the motor potential provides power to the auto manual selector switch the drag hand reset solenoid the neutral light and the holding switch alternate motor source circuits The sensing voltage and differential voltage are connected directly to their respective circuit board input terminals Current Circuit All VR 32 regulators are designed with an internal current transformer to provide a current source for the line drop com pensation calculations and for metering functions Table 2 5 provides the application information for the various C T s used on the Cooper Power System regulators These C T s provide 200 mA rated secondary output for the full load C T primary current The current developed by the C T is brought to the junction box terminal board through the control cable into the enclo sure and terminates at the knife switch labeled C Closing the knife switch provides a visible means of shorting the C T thus allowing the operator to work safely on the current circuitry For additional safety measures the V1 and V6 knife switch should also be opened At this knife switch one side of the C T is connected to the equipment ground and is also routed to the front panel for ter mination on the circuit board The high side of the current cir
47. 3 0 This is a counter for the number of times the CL 4C Control has experienced a transient condition such as a lightning stroke which causes it to rest The CL 4C Control will recover after a transient condition and will resume normal operations FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 95 System Status Code 3 The CL 4C Control is continually checking itself and the results of this self diagnosis are displayed at Function Code 95 via a System Code Number as Follows System Codes 0 All Systems Good 1 EEPROM Write Failure 2 EEPROM Erase Failure 3 Frequency Detection Failure 4 No Sampling Interrupt 5 Analog to Digital Converter Failure 6 Invalid Critical Parameters 7 No Source Voltage Detected 8 No Output Voltage Detected 9 No Source and Output Voltage Detected See System Protection Diagnostics page 2 31 2 23 5225 10 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 96 Level 1 Security Code 3 3 1234 1 9999 The number to be used as Level 1 security code is entered here The Level 1 code assigned at the factor
48. 400 448 440 480 540 64 667 483 541 531 580 652 668 833 604 668 664 668 668 668 72 50 56 55 60 68 80 144 100 112 110 120 135 16 288 200 224 220 240 270 320 333 231 259 254 277 312 37 416 289 324 318 347 390 462 14400 432 300 336 330 360 405 480 500 347 389 382 416 468 555 576 400 448 440 480 540 64 667 463 519 509 556 625 668 720 500 560 550 600 668 668 833 578 647 636 668 668 668 50 25 1 28 28 30 34 40 100 50 2 56 55 60 68 80 200 100 4 112 110 120 135 16 19920 333 167 187 184 200 225 267 400 200 8 224 220 240 270 32 500 250 280 275 300 338 400 667 335 375 369 402 452 536 833 418 468 460 502 564 668 55 65 C rise rating 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 the factory 1 12 9225 10 4C INTERNAL CONSTRUCTION amp 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 9 allows all windings control shunt and series to be located in one coil The load voltage is read directly by the control winding Regulators that have the series winding on the output load side Figure 1 10 possess an identical coil configura tion but have a separate potential transformer in lieu of a control winding installed on the output side This voltage is
49. 43 System Line Voltage and Function Code 44 PT Ratio 5225 10 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 11 Source Voltage Primary kV kV 0 This is the fundamental RMS voltage referred to the primary which appears at the input source terminals of the regulator Since ratio correction is performed by the software this parameter is scaled according to the inputs at Function Code 43 System Line Voltage and Function Code 44 PT Ratio An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this para meter displaying dashed Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 12 Percent Regulation 0 This is the actual percentage that the regulator is actively boosting or bucking the input Source voltage This is calculated as follows Percent Regulation OUTPUT INPUT 1 x 100 When the regulator output voltage is greater is greater than the input voltage that is the regulator is boosting the sign is implied When the regulator output voltage
50. 4C Control is designed to perform ratio correction in software Through the use of the ratio cor recting transformer RCT located on the back panel the voltage brought to the front panel is usually already cor rected to the 120 volt base voltage However there are some ratings in which this voltage is not fully corrected by the RCT Column 6 in Table 2 1 gives a general indication of these ratings but always refer to the nameplate which provides the specific information for the particular regula tor The voltage displayed at Function Code 8 compensated voltage is the voltage which the control is regulating This value takes into consideration the software ratio correction and any line drop compensation being used Additionally if the regulator is equipped for reverse power operation the voltage displayed at Function Code 8 will be correct even during reverse power conditions The voltage measured at the test terminals however will reflect the input SOURCE volt age instead of the output LOAD voltage Manually operate the regulator three or four steps above the in band voltage level while monitoring the voltage at Function Code 8 Place the CONTROL switch on AUTO After the time delay period the regulator should step down to within the top band edge Example 120v and 2v band width 121v top band edge Manually operate the regulator three or four steps below the in band voltage level again while monitoring the voltage at F
51. 4C controls to listen and change as commanded with no return response Similarly the FORM 4C recloser control is device type 3 its group address is 255 3 252 Any message sent to address 252 causes all connected FORM 4C recloser controls to listen and change as commanded with no return response This capabili ty allows regulator recloser and future C P S controls to be connected on the same communications loop from the RTU and each group of devices can be selected by a single message 255 Broadcast address All controls on the system listen and change as commanded with no return response if a mes sage is sent to address 255 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 65 Communications Port Baud Rate 0 2 invalid 1 5 The user may select the baud rate to which the CL 4C control system interfaces to the SCADA system The available baud rates are 1 300 BAUD 2 1200 BAUD 3 2400 BAUD 4 4800 BAUD 5 9600 BAUD The control is factory set for 4800 BAUD 2 18 VR 32 Regulator and CL 4C Control FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 66 Communications Port Handshake Mode 0 2 N A invalid 0 2
52. 7 8219 245 2107 32 3 STEPS 7620 13200 SER we AL Sr 8 95 1 250 0 2 TTCHSETTIWCS Pes IT TOM INDICATOR aiena tere n fetapa afie z 1 129 110 prec TAP Stance AMPERE RATING 750 AMPS em sev 82 d CANIT TON o p ri gt FILES MINERAL MAT contait LESS PC MANUF Figure 1 6 Nameplate 1 7 VR 32 Regulator and CL 4C Control Operational Check NOTE This operational check on the control should be used only with newly installed regulators For regulators already on line use the operational check on page 2 3 With the CL 4C control now set for basic operation an operational check should be performed as follows 1 Depress the 8 key to display the COMPENSATED VOLTAGE 2 Place the Control Switch in the MANUAL position 3 Lift up on the RAISE switch to activate a raise operation 4 Allow the tap changer to operate for five or six steps or enough steps to take the voltage above the in band voltage level 5 Now place the Control Switch in the AUTO position After the time delay period the control should cause the regulator to step down to within the top band edge Example 120V and a 2V B W 121 V top band edge This should be shown in the display 6 After the voltage is brought in band an
53. 8 Figure 2 1 SCADA relay and terminal strip 6071 Figure 5 4 Control cable 15 for remote mounting 6104 not shown 20 for remote mounting 6105 not shown 25 for remote mounting 6106 not shown 30 for remote mounting 6107 not shown Field installable accessories See page 5 1 for further information Control cabinet heater 9000 Figure 5 1 Fan cooling 9005 Figure 5 5 Auxiliary control cabinet and 9050 not shown hardware Long control cabinet and hardware 9054 not shown Accessories for data extraction Data Reader amp Software Kit 9076 Figure 5 2 Data Reader Assembly 9977 Figure 5 3 Motor Kits include motor capacitor and hardware When contact viewed from motor side of tap changer Current design has 10 conductors 12 conductor cables with required terminations are available for obsolete designs or to mount CL 4C on previous designs Contact factory service department for details See parts manual or contact factory service department other lengths available Contact factory service department 6 1 5225 10 4 COMPLETE BUSHING ASSEMBLY W HARDWARE Figure 6 1 High voltage bushing TERMINAL CAP TERMINAL CAP GASKET BUSHING PORCELAIN BUSHING GASKET CLAMP RING SPRING WASHER CONICAL SPRING WASHER ROD ASSEMBLY HEX JAM NUT MOTOR KIT 3014 REVERSING STATIONARY CONTACT RH 3004 REVERSING MAIN STATIONARY STATIONARY CONTACT
54. AMETER RANGE FACTORY SETTING 45 C T PRIMARY RATING 25 2000 C T RATING FOR THE REGULATOR The CL 4C is designed for 200 mA as the rated C T current and will meter to 400 mA 200 load with no loss of accuracy Ratio correction is performed by the software and consequently the C T primary rating must be entered The C T primary rating is available on the regulator nameplate Example If a C T ratio of 400 0 2 is indicated on the nameplate then 400 must be entered at Function Code 45 Table 2 5 sum marizes the C T primary ratings for all standard regulator ratings Perform the following steps to program the C T primary rating into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 45 ENTER 45 200 This is the C T primary rating for a 200A regulator CHANGE 45 Enter the desired value example 400 400 ENTER 45 400 The C T primary rating is now 400 amps TABLE 2 5 Current Tansformer Applications Regulator Current C T Ratings Primary Current 15 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 2 35 5225 10 4 SINGLE PHASE STEP VOLTAGE REGULATOR VR 32 55 65 RISE 60 HZ CLASS 167 187 8219 245 10 32 2 STEPS vars 1620 1 3200Y SER CU s AL or 95 waitin 250 00 2 UNTANKING T
55. C 100 4 200 S RSAA199200AA 170C 150 167 3338 RSM199333AA 770B kV 200 8 4005 RSAA199400AA 770B BIL 250 5008 RSAA199500AA 770B 335 667 S RSAA199667AA 660C 418 8335 RSAA199833AA 660C Note 5 following the kVA denotes station mount Spring drive 9280 and 170 Direct drive 770B and 660C 3 1 VR 32 Regulator and CL 4C Control DIVER MECHANISM Spring drive complete revolutions per tap change The motion of the geneva Two steel extension springs are arranged in a triangular con pinion turns a six tooth geneva gear a main drive shaft and a figuration to provide positive spring over center action to Scroll cam 180 degrees per tap change Each 180 degree move move the switch contacts The mechanism is adjusted for gt ment of the scroll cam operates one of two roller plates and smooth make and break contact action moves the corresponding main movable contacts 40 degrees The combination of geneva gearing and scroll cam characteristics DRIVE MECHANISM Direct drive results in a threestep wipe transfer wipe contact action The 770B and 660C tap changers employ drive mechanisms Attached to the main geneva gear drive shaft is a planetary based upon the same design principle and many components gt gear type mechanical stop which prevents contact motion beyond are interchangeable The motor turns a geneva pinion three the maximum raise and lower position Figure 3 1 Figure 3 2 928D spring drive tap changer 170C spr
56. DIFFERENTIAL VOLTAGE MOTOR VOLTAGE SENSING VOLTAGE VOLTAGE TEST TERMINALS 1 PORTIONS OF SCHEMATIC SHOWN IN DOTTED ENCLO SURE ARE LOCATED IN REGULATOR TANK Figure 2 20 VR 32 regulator and CL 4C Control with Differential P T wiring diagram CURRENT TRANSFORMER TOROIDAL COIL SOURCE BUSHING LOAD BUSHING SERIES WINDING DIFFERENTIAL POTENTIAL TRANSFORMER I TRPS LOCATED ON CHANGER TERMINAL BOARD UNDER OIL CONTROL WINDING 1 SOURCE LOAD BUSHING REMOVABLE GROUND ON SIDE OF CABINET 2 39 5225 10 4 LOWER SOURCE RAISE 1 1 I 2 20 CL4 REMOTE CIRCUIT VOLTAGE BOARD 1 l REDUCTION 1 TB2 1 9 1 l 1 1 19 1 1 1 1 1 1 AUTO MOTOR CURRENT ENABLE RELAYS SENSE COUPLER COUPLER 1 1 1 1 NEUTRRI a ee TEST BLOCKING EXTERNAL RELAY PROVISION n 74 EL 5 Ls PS E 6 93 INTERNAL SOURCE TR2 VM TB2 VS v7 gt TB2 G 1 INTERNAL REMOVABLE GROUND IN JUNCTION BOX 2 40 VR 32 Regulator and CL 4C Control Voltage Circuits All Cooper Power Systems VR 32 regulators have provisions for operation at system voltages lower than the nameplate rat ing as i
57. EAD CHANGE RESET VALUE LOW HIGH 76 Automatic Reduction Setting 1 0 2 0 0 0 0 10 0 Two levels of automatically activated voltage reduction are available with the CL 4C Control The percentage of voltage reduction to be performed at Automatic Level 1 is entered here Automatic activation for Level 1 occurs as a result of the load current exceeding the turn on threshold at Function Code 78 when Function Code 70 3 Automatic voltage reduction is overridden by remote voltage reduction See Voltage Reduction page 2 30 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 77 Automatic Reduction Setting 2 0 2 0 0 0 0 10 0 Two levels of automatically activated voltage reduction are available with the CL 4C Control The percentage of voltage reduction entered here is added to the value entered at Function Code 76 to provide the Automatic Level 2 reduction amount Example If Function Code is 76 2 5 and Function Code 77 is set to equal 3 0 then the Automatic Level 2 reduction will be 5 5 Automatic activation for Level 2 occurs as a result of the load current exceeding the turn on threshold at Function Code 79 when Function Code 70 3 Automatic voltage reduction is overridden by remote voltage reduction See Voltage Reduction
58. EGULATOR CONFIGURATION The CL 4C Control is set at the factory for connection to single phase systems or wye connected three phase systems If the regu lator is installed on a delta system it must be determined whether the regulator is leading or lagging and then the proper code must be entered 1 delta lagging or 2 delta leading Cooper Power Systems reference document R225 10 1 explains in detail the determination of the proper settings KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 41 ENTER 41 0 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 lagging 9225 10 4C SYSTEM LINE VOLTAGE Regulators shipped from the factory are usually set for the rated voltage and this value is entered into the control If the regulator is installed on any other system voltage this system voltage must be entered for proper operation KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 43 ENTER 43 7200 This is the system voltage for 7200V regulator CHANGE 43 Enter the desired value example 4800 4800 ENTER 43 4800 The system line voltage is now 4800 volts POTENTIAL TRANSFORMER RATIO The ratio to be entered into the control is the OVERALL POT RATIO as shown on the regulator nameplate for every applicable sys tem voltage for the particlualr regulator The P T ratio which corresponds to the regulator rated voltage is
59. ER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 08 Compensated Voltage Secondary v 0 This is the calculated voltage at the load center referred to the secondary This is based upon the resistive compensation setting Function Codes 4 or 54 reactive compensation setting Function Codes 5 or 55 and the load current flow This is the voltage that the regulator is regulating during either forward or reverse power flow FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER oF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 09 Load Current Primary A 0 This is the fundamental RMS current flowing in the primary circuit This parameter is scaled according to the CT primary rating which is entered at Function Code 45 FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 10 Load Voltage Primary kV kV 0 N A N A N A N A This is the fundamental RMS voltage referred to the primary which appears at the output load terminals of the regulator Since ratio correction is performed by the software this parameter is scaled according to the inputs at Function Code
60. ERSE MODE Function Code 56 1 Source P T is Required METERING Always operates in the reverse direction regard less of power flow direction If forward power occurs the meter ing functions remain on the source side of the regulator no forward demand readings will occur This mode is not intended to be used in applications where forward power flow is possible OPERATION Always operates in the reverse direction using the reverse settings at Function Codes 51 52 53 54 and 55 This allows operation down to zero current conditions since there is no reverse threshold involved A safeguard has been built into the control to prevent misoperation in the event for ward power flow does occur If more than 2 004 amps C T secondary forward current occurs the control idles on the last tap position held and the band edge indicators will turn off As the current flow returns to a level above this forward threshold normal forward operation resumes REVERSE FORWARD NORMAL REVERSE 7 TAP CHANGING OPERATIONS 25 INHIBITED _ a iy CURRENT LEVEL Figure 2 7 Locked reverse mode operation 2 26 VR 32 Regulator and CL 4C Control REVERSE IDLE MODE Function Code 56 2 Source P T Required for Metering only METERING A threshold level of 1 002A of the full load C T secondary current 200A is used in setting the power direction The metering will
61. Function Code 56 5 No Source P T is Required In recent years there has been a growing number of voltage regulator applications involving co generation by the utilities customers The co generation mode was developed for the Cooper Power System s control to satisfy the specialized needs of these applications Normally the desired operation of a regu lator installed on a feeder involving co generation is to regulate the voltage at the customer during times of power flow into the customer site and to regulate the voltage at the regulator on the same output side during power flow into the utility grid This is accomplished by simply not reversing the control sensing input voltage when reverse power is detected and by altering the line drop compensation settings to account for this change in power flow direction CUSTOMER SUBSTATION CO GENERAT ON SITE ar REGULATED VOLTAGE DURING FORWARD POWER FLOW REGULATED VOLTAGE DURING REVERSE POWER FLOW Figure 2 11 Co generation regulation points METERING Always operates in the forward direction except the load center voltage is calculated based upon the reverse line drop compensation settings Function Codes 54 and 55 when the fixed 1 reverse metering threshold is exceeded The REV PWR annunciator is turned on when this reverse threshold is crossed The forward line drop compensation settings Function Codes 4 and 5 are used when the current exceeds
62. G THE CL 4C CONTROL FOR SERVICE page 2 32 The voltage developed by the sensing winding is brought from the tap changer terminal board to the junction box terminal board through the control cable into the enclosure and termi nates at the knife switch labeled V1 Opening this knife switch provides a visible means of removing all power to the control and back panel thus allowing the operator to work safely on the control circuitry while the regulator is energized From the knife Switch the voltage is ratio corrected by the RCT as previously described Note also that a separation of sensing and motor circuits occurs at this transformer The motor circuit is routed directly to the control front panel whereas the sensing potential Figure 2 22 Back panel with optional is brought back to the top terminal strip through a series of remov able jumpers and then to the front panel This scheme allows for the complete interchangeability with all the prior CL series Controls and accompanying accessories Applications involving reverse power flow will have a second voltage source installed internal to the regulator to develop the source side regulator voltage which is needed during reverse operation A differential P T is utilized on Cooper Power System s Regulators for measuring the voltage across the series winding which is then used to develop the source side voltage The differ ential P T will have taps similar to the outp
63. G any CL 4C parameter However SCADA READ commands can occur under these conditions When mends can occur under these conditions When the security level is set back to 0 full SCADA control resumes The securi ty level is reset to O by either 1 turning the CL 4C display off or 2 after 30 minutes to no keypad activity the display automatically shuts off and the security is set to 0 at that time The specific communications parameters are listed in function codes 60 69 and are described more fully in the function code section beginning on page 2 17 NOTE When any of the func tion codes affecting communications are changed via the keypad the power to the CL 4C Control must be turned off and then back on to force these new communications parameters to be loaded into the optional protocol converter module 2 29 5225 10 4 Voltage Reduction An ideal application for system load management is at the dis tribution voltage regulator Voltage reduction capabilities within the regulator control permit it to trigger the regulator to reduce voltage during situations where power demands surpass the available capacity and where there are extraordinary peak loads The CL 4 Control is unique in its offering of three modes of voltage reduction LOCAL REMOTE and AUTOMATIC with remote override All modes operate for forward or reverse power flow conditions Voltage reduction can be overridden by the operat
64. GH 24 H L P kVA Load Demand Forward kVA 0 1 Reset This is the load kVA as demand value according to the demand time internal at Function Code 46 H maximum value since last reset L minimum value last reset and P present value Scroll to the L and P values FUNCTION FUNCTION UNIT SECURITY LEVEL KEY pue CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 25 H L P kVA Load Demand Forward kW 0 1 Reset This is the load kW as demand value according to the demand time internal at Function Code 46 maximum value since last reset L minimum value last reset and P present value Scroll to the L and P values FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 26 H L P kVAR Load Demand Forward kVAR 0 1 Reset This is the load as demand value according to demand time internal at Function Code 46 H maximum value since last reset L minimum value last reset and P present value Scroll to the L and P values FUNCTION FUNCTION UNIT SECURITY LEVEL ENTRY CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 27 H L P Maximum Boost Minimum Buck 0 1 Reset This is the highest percentage that the regulator
65. HITE JBB L GRN BLK NL NO ORANGE gt WHITE JBB NL RED BLK 1 WHITE TCB E3 WHITE JBB R BLUE T E WHITE TCB G WHITE 82 WHITE T F4 WHITE T 84 WHITE Figure 1 13 Internal wiring of spring drive regulator with series winding located on the source side m TCB 1 TC8 5 TAP CHANGER 51 112211 TERMINAL TRANSFORMER CONTROL WINDING m TAP CHANGER 7 48 MOTOR M HOLDING SWITCH HS 1 15 VR 32 Regulator and CL 4C Control JUNCTION BOX TERMINAL BOARD JBB TC8 E4 JBB C CURRENT TCc8 E CONTROL TRANSFORMER C BOTTOM FRAME TERMINAL BOARD TFG GROUND 8FG TCB E POSITION INDICATOR gt TAP CHANGER 1 BFG TERMINAL BOARD TCB zT Tg L top TRANSFORMER 77 FRAME GROUND TFG 1 7 CHANGER HOLDING SWITCH HS MOTOR M 6 LOWER RAISE 5 1 40 CA TCB 1 NEUTRAL LIGHT SWITCH NL CAM 4 6 MC 2 MOTOR CAPACITOR MC BFG WHITE 52 WHITE 51 WHITE HS 1 BLACK M 1 WHITE TCB 1 HS BLACK HS 2 BLUE M 2 BLUE TCB 1 NL ORANGE HS 3 RED M 3 RED TCB 4 BLUE JBB C1 WHITE MC 1 BLUE TCB 5 RED JBB C2 BLACK MC 2 RED TCB 6 WHITE JBB G WHITE NL C WHITE TCB 7 GREEN JBB HS ORANGE NL NC GREEN TCB E4 WHITE JBB
66. IAN soavon nes 1 17 Back panel signal circuit VR 32 Regulator and CL 4C Control Figure 2 1 CL 4C front panel COOPER POWER SYSTEMS NOOR McGRAW EDISON CL 4C REGULATOR CONTROL LCD Display Keypad Data Port INTERNAL EXTERNAL Power Switch Voltmeter Terminals External Power Terminals Panel Fuse 8 Dfflerential Voltage Fuse 9 Motor Fuse 10 Manual RAISE LOWER Switch 11 AUTO REMOTE OFF MANUAL Switch 12 Neutral Lamp Test Drag Hand Resel Switch 13 Neutral Indicating Light 9225 10 4C CL 4C REGULATOR CONTROL Section 2 INTRODUCTION The CL 4C Control This section of the manual fully describes the capabilities of this control The CL 4C Control is a full featured control which incorpo rates digital logic and microprocessor technology The CL 4C Control utilizes a keypad to simplify the setup of the basic con trol and its many built in accessory features An LCD screen displays the control settings accessory settings metering val ues and annunciator words The standard features of this control are Voltage Limiting Voltage Reduction Local and Remote Reverse Power Flow Detection and Operation Metering Data Port Communications Capability The voltage limiting and voltage reduction features are enhanced beyond those of the CL 2A Control The Reverse Power Flow featur
67. L GRN BLK NL NO ORANGE 2 WHITE JBB NL RED BLK T T1 WHITE TCB E3 WHITE JBB R BLUE T To WHITE TCB G WHITE T F4 WHITE TFG WHITE Figure 1 14 Internal wiring of direct drive regulator with series winding located on the load side 1 16 5225 10 4 TCB P TCB P 51 T4 T2 F4 DIFFERENTIAL POTENTIAL JUNCTION BOX TERMINAL BOARD JBB TRANSFORMER OPT TCB E J88 C 2 TERMINAL BOARD POSITION INDICATOR CURRENT TRANSFORMER C TCB E 2 TCB G 51 Eo Fy TRANSFORMER CONTROL WINDING HOLDING SWITCH HS 6 TCB 1 4 TC8 1 NEUTRAL LIGHT SWITCH NL RAISE LOWER 5 123 CHANGER TERMINAL BOARD TCB CHANGER MOTOR M MOTOR CAPACITOR MC DPT F4 WHITE JBB R BLUE T 81 WHITE DPT S4 WHITE JBB S5 WHITE TCB 1 HS BLACK DPT T4 WHITE JBB S4 WHITE TCB 1 NL ORANGE 2 WHITE M 1 WHITE TCB 4 BLUE HS 1 BLACK M 2 BLUE TCB 5 RED HS 2 BLUE M 3 RED TCB 6 WHITE HS 3 RED MC 1 BLUE TCB 7 GREEN JBB C1 WHITE MC 2 RED TCB E4 WHITE JBB C2 BLACK NL C WHITE WHITE JBB DHR ORG BLK NL NC GREEN TCB E3 WHITE JBB G WHITE NL NO ORANGE TCB G WHITE JBB HS O
68. LH CONTACT 3003 3002 Figure 6 2 Replacement parts for spring drive tap changers 928D and 170C MAIN MOVABLE CONTACT LH 3006 il 1 REVERSING MOVABLE CONTACT 3022 for 9280 3005 for 170C MAIN MOVABLE CONTACT RH 3007 VR 32 Regulator and CL 4C Control SHIELD 3068 N i REVERSING NEUTRAL M am CONTACT 3067 MOVABLE 3069 STATIONARY Y b ARCING 12 LI C CONTACT 1 3053 REVERSING STATIONARY CONTACT 3067 Figure 6 3 Replacement parts for direct drive tap changer 770B f nm 5 REVERSING NEUTRAL STATIONARY CONTACT 3027 MOTOR KIT 3031 REVERSING MOVABLE CONTACT ASSEMBLY 3035 FK STATIONARY fe C ARCING _ Ci CONTACT MAIN NEVEHSING MOVABLE STATIONARY CUNTACT CONTACT ASSEMBLY 3037 3029 Figure 6 4 Replacement for direct drive tap changer 660C 6 3 9225 10 4C NOTES 6 4 VR 32 Regulator and CL 4C Control APPENDIX Section 7 SERIAL NUMBERS numbers for Cooper Power System s regulators are coded in the following manner 91 Year of manufacture Z Factory location Z Zanesville A Month of Manufacture January February March April May June July August September October November December XX Arbitrary numbers and letters assigne
69. N NL NO ORANGE T F4 WHITE T T4 WHITE T T2 WHITE TCB E3 WHITE TCB G WHITE TCB P WHITE 2 WHITE TCB P3 WHITE Figure 1 16 Internal wiring of regulator with load winding on output side with differential potential transformer 1 18 5225 10 4 TO POSITION INDICATOR JBB G WHITE AND REGULATOR TANK JBB HS ORANGE RLS 1 BLUE gt p REMOVABLE IMPERA FOR ACCESSORIFS LLS 1 GREEN BLACK JBB NL RED BLACK JBB DHR ORANGE BLACK 52 BLACK JBB C2 GREEN JBB C4 RED 2 5 ORANGE TBg 1 BLUE TB2 R3 BLUE REMQVARBI TB2 L3 WHITE GREEN GROUND TBg 3 WHITE GREEN TBo NL WHITE RED 2 WHITE ORANGE 2 BLACK RCT4 120 BLACK SD4 1 VIOLET TB2 C3 GREEN RCT2 WHITE BROWN RCT4 BLACK TB7 Vg WHITE BROWN TBz7 V4 BLACK PD4 2 Vg WHITE BROWN PD4 2 V4 BLACK RCT2 COM WHITE TB4 C2 VIOLET 2 RED RCT41 COM WHITE TB7 G WHITE 2 WHITE BLACK TB4 V4 BLACK ADS TEN T PD4 2 RCT2 WHITE BROWN PD1 2 RCT4 BLACK TBg 4 WHITE TB4 R4 BLUE TB4 L4 WHITE GREEN TB2 G WHITE 2 WHITE BLUE TBg 5 WHITE BLUE TBi Vs BLACK RCT 1 127 WHITE BLACK 501 2 RED TB4 Ca GREEN TB4 Hs ORANGE TBy NL WHITE RED TB4 DHR WHITE ORANGE
70. NTROL AND DATA ACQUISITION SCADA SCADA is a supervisory system used by some utilities for remote control of their system SCADA may take on many forms from the single retrieval of a few analog values Such as voltage current power factor etc to remote control of the tap changer raise lower inhibit to complete remote control which allows everything to be performed remotely that could be performed at the regulator front panel Complete remote control can only be accomplished through a digital communi cations link The digital communications SCADA is discussed in the section labeled Communications on page 2 28 This section applies to regulator SCADA applications that have seen increased use on distribution systems Cooper Power Systems has prepared a connection scheme to accom modate various functions while at the same time protecting the equipment This scheme accommodates the following func tions 1 Remotely raise and lower the tap changer 2 Remotely block automatic operation 3 Remotely apply voltage reduction The basic requirement of the scheme is the use of the cur rent relay package The purpose of the current relay package is to prevent misapplication of any SCADA system and to work with the holding switch to make sure a tap change is completed once it is started The scheme uses a current relay to sense when the holding switch is closed Once the holding switch is closed the current relay contacts open and pre
71. OTAL GAL WEIGHT LBS WEIGHT LBS OIL REVERSING SWITCH EQUAL IZER REACTOR LIMIT SWITCH SETTINGS ON POSITION NOICATOR IBGCXGMEHCZULZIZLE Ono 160 195 120 100 CAUTION JUNCTION BOX DO NOT BYPASS UNLESS ON NEUTRAL POSITION RND 3 CONTROL SWITCH IS OFF READ INSTALLATION ANO VT FILLEO WITH MINERAL OIL THAT CONTAINED LESS OPERATING INSTRUCTIONS 5225 10 4 OR 5225 10 5 X THAN PPM PCB AT TIME OF MANUFACTURE Figure 2 17 Nameplate without Differntial installed F McGRAW EDISON COOPER POWER SYSTEMS VOLTAGE REGULATOR A McGRAW EDISON W EE POWER SYSTEMS MGR SINGLE PHASE STEP VOLTAGE REGULATOR VR 32 55 65 C RISE 60 HZ CLASS OA KVR167 187 219 245 RE 10 32 87 STEPS 7620 13200 SER CU s AL ser 95 250 0 2 UNTANK ING TOTAL GAL WEIGHT Les WEIGHT LBS OIL Loap CONTROL INTERNAL R C T TEST OVERALL POG TAP P T TERMINAL POT RATIO FOONTROL 4 VOLTAGE RATIO fear 60 1 120 4800 40 1 4160 2 40 1 ARRESTER CURRENT TRANSFORMER REVERSING SWITCH CONTROL WINDING O 2400 Estes 20 1 SERIES WINDING EQUALIZER WINDING TM OIL QN CHANGER LIMIT SWITCH SETTINGS TERMINAL BOARD ON POSITION INDICATOR SERIES INO ING REGULATION RANSF
72. R and NEUTRAL LIGHT MUST BOTH indicate neutral WARNING A regulator should be bypassed with the line energized ONLY if BOTH the position indi cator AND the neutral light indicate NEUTRAL If both do not indicate NEUTRAL the line should be de ener gized to avoid shorting part of the series winding WARNING Always use the CONTROL switch labeled AUTO REMOTE OFF MANUAL to oper ate the regulator not the POWER switch Failure to do so may result in the tap changer stepping off of neutral immediately upon being energized 1 8 9225 10 4C De energizing The Regulator Once it has been established that the regulator is on neu tral immediately proceed with the following steps 1 Turn the CONTROL switch to OFF 2 Turn control POWER switch to OFF 3 Open the V1 knife switch and V6 if present on the back panel Figure 1 5 4 Remove the 6A motor fuse 5 Close the BYPASS switch 6 Open the SOURCE S disconnect switch 7 Open the LOAD L disconnect switch 8 Open the SOURCE LOAD SL disconnect switch Delta application only 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 manu
73. RANGE T F4 WHITE 1 WHITE JBB L GRN BLK T T4 WHITE WHITE JBB NL RED BLK T T2 WHITE TCB P3 WHITE Figure 1 15 Internal wiring of regulator with series winding on input side with differential potential transformer 1 17 VR 32 Regulator and CL 4C Control JUNCTION BOX TERMINAL BOARD J8B DIFFERENTIAL POTENTIAL CURRENT TRANSFORMER C BOTTOM FRAME TFG GROUND TO CONTROL TERMINAL BOARD J8B C 05 110 INDICATOR 5 T4 T2 Fy SOURCE POTENTIAL TRANSFORMER CT HOLDING SWITCH HS TAP CHANGER TERMINAL BOARD TCB 9 TOP FRAME GROUND TFG 7 69 6 1 NEUTRAL SWITCH NL TAP CHANGER MOTOR LOWER RAISE fc g 5 1 TCB 4 MC 2 Y TCB 4 M 2 MOTOR CAPACITOR MC DPT F4 WHITE DPT S1 WHITE DPT T1 WHITE JBB R BLUE JBB S2 WHITE JBB S4 WHITE T 84 WHITE TCB 1 HS BLACK TCB 1 NL ORANGE WHITE M 1 WHITE TCB 4 BLUE HS 1 BLACK M 2 BLUE TCB 5 RED HS 2 BLUE M 3 RED TCB 6 WHITE HS 3 RED MC 1 BLUE TCB 7 GREEN JBB C1 WHITE MC 2 RED TCB E4 WHITE JBB C2 BLACK NL C WHITE TCB E WHITE JBB DHR ORG BLK JBB G WHITE JBB HS ORANGE JBB L GRN BLK JBB NL RED BLK NL NC GREE
74. RHRRRRRRERERRRERRRERRRERERRERRAREARERRAREERRRRRRRRRRRR 3 1 Introduction 444 1 3 Reversing Switch 3 1 Receiving ntn 1 3 Drive Mechanisms esee 3 2 INSPECTION e rn CE dE E mir 1 3 Contacts eee nee eene 3 3 AL oa 1 3 Operating Sequence 3 3 STORING icai iude ice t icon eene 1 3 TROUBLE SHOOTING GUIDE SECTION 4 Installation eere 1 3 Complete Regulator In Service 41 PRE INSTALLATION INSPECTION 1 3 EXTERNAL CHECK eese 4 1 SYSTEMS CONNECTIONS 1 3 DEFINING THE PROBLEM 4 1 MOUNTING ere e sue 1 4 SOT ME 1 AONO SERMOE s 15 POSITONINDONIORREPLACEMENT 43 OPERATIONAL CHECK PROGRAMMER 1 8 on ro a ra lon x Field Calibration Check 1 8 VOLTAGE CALIBRATION 43 Ramoval Erom Service 1 8 CURRENT CALIBRATION 4 3 DETERMINING NEUTRAL POSITION 1 8 ACCESSORIES SECTION 5 5 1 DE ENERGIZING THE REGULATOR p 1 9 SPARE PARTS SECTION 6 aRRERRRRRARRRRRRRRRRRRRRRRRR 6 1 Maintenance Program
75. TY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 60 Data Port Baud Rate 0 2 4 1 4 The microprocessor on the CL 4C Control has two communications channels each with selectable baud rates Baud rate is the number of bits per second of data that can be transferred Channel 1 is dedicated to the 9 pin Data Port located on the CL 4C Control front panel The available baud rates for channel 1 are 1 300 BAUD 2 1200 BAUD 3 2400 BAUD and 4 4800 BAUD To permit communications with the Cooper Power System s Data Reader data gathering device the Channel 1 baud rate has been factory set to 4800 i e Function Code 60 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 61 Interface Port Baud Rate 0 2 N A 5 1 5 The microprocessor on the CL 4C Control has two communications channels each with selectable baud rates Baud rate is the number of bits per second of data that can be transferred Channel 2 is dedicated to the communications interface card which mounts directly above the CL 4C main board set and com municates to SCADA systems The available baud rates for channel 2 are 1 300 BAUD 2 1200 BAUD 3 2400 BAUD 4 4800 BAUD and 5 15625 BA
76. UD To permit communications with the communications interface card apart of the SCADA system interface the Channel 2 baud rate must be set to 15625 BAUD i e Function Code 61 5 2 17 9225 10 4C FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 62 Channel 1 Status 0 The 4 microprocessor monitors the communications channels reports the status of the communications sessions The staus of the communications taking place on channel 1 Data Port is displayed here This is for imformation use only Status codes are listed with Function Code 63 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 63 Channel 2 Status 0 The CI 4C microprocessor monitors the communications channels and reports the status of the communications sessions The staus of the communications taking place on channel 2 communications interface card is displayed here This is for imfor mation use only Status codes for both Function Codes 62 and 63 are listed as follows 0 Valid message received 6 Checksum error in the received message 1 Control in local mode 7 Inv
77. ULATOR WILL OPERATE MANUALLY BUT NOT AUTOMATICALLY Diagnosing trouble A Measure voltage from VS to G on lower terminal board TB2 1 A measurement of approximately the set voltage setting at VS to G indicates that the problem is in the control 2 If there is no voltage present at VS to G the trouble is in the V1 disconnect or ratio correcting transformer of the rear signal circuit B If check A indicates that the trouble is in the control refer to Control Trouble Shooting below THE REGULATOR OPERATES MANUALLY BUT OPERATES INCORRECTLY WHEN SET ON AUTOMATIC Diagnosing trouble Run the regulator to the neutral position with the control switch Check for voltage between V4 and G on TB1 This is the sensing circuit supply voltage from the output of RCT1 on the rear panel If this voltage is more than 1096 above or below the programmed voltage level setting of the control then the source is beyond the range of the regulator An absence of voltage would indicate a wiring problem such as an opening somewhere in the control power supply If these checks are correct then the malfunction is probably in the control Refer to Control Trouble Shooting below Control Trouble Shooting At this point the problem has been determined to be in the con trol so the front panel should be taken out of the control cabinet and taken to a service bench for trouble shooting Figure 2 19 can be used to aid the trouble shooting process The panel co
78. URCE S disconnect switch Set the POWER switch to INTERNAL and the CONTROL switch to MANUAL Lift the RAISE LOWER switch to operate the tap changer two or three steps then depress the RAISE LOWER switch to return the tap changer to neutral position These steps verify the mechanism is functional When on neutral the NEUTRAL LAMP will glow and the position indicator will point to zero With the regulator in neutral position set the CONTROL switch to OFF set the POWER switch to OFF open the V1 knife switch back panel and V6 if present and remove the 6A motor fuse Close the LOAD L disconnect switch Open the BYPASS switch Replace the 6A motor fuse close the V1 knife switch and set the POWER switch to INTERNAL Go to Setting the CL 4C for Service page 1 6 PROCEDURE B REGULATOR BYPASS DISCONNECT SWITCH 1 2 3 Oo 11 Verify from the regulator nameplate that the control circuit is connected for the proper regulated load voltage Set the CONTROL switch to MANUAL and the POWER switch to EXTERNAL The knife switches on the back panel should be set with the V1 potential switch and V6 if present open pulled out and the C CT shorting switch closed pushed in See Figure 1 5 Apply 120 volts to the EXTERNAL SOURCE terminals if 120 volts is available If not proceed to Step 7 below Lift the RAISE LOWER switch to operate the tap changer two or three steps then depres
79. Voltage Regulators Cooper Power Systems Cooper Power System s VR 32 Regulator and CL 4C Control 12 Installation Operation and Maintenance Instructions 52 2 8 1 4 Parts Replacement Information Service Information CL 4C REGULATOR CONTROL SECTION 2 a xod a Introduction ILLE 2 2 amp 2 2 Pre Installation Operational Check 2 2 In Service Operational Check 2 3 Function Code Description 2 5 Differential Voltage cernere 2 25 n Accessory Operation eene 2 25 i DEMAND TASK 2 25 REVERSE POWER OPERATION 2 25 COMMUNICATIONS eren 2 28 VOLTAGE REDUCTION 2 30 VOLTAGE 2 31 System Protection Diagnostics 2 31 Security System 2 32 Setting the CL 4C Control for Service 2 32 m Control Syatem Design and Operation 2 37 Supervisory Control and Data Acquisition 2 43 Field Trial CL 4 Controls 2 45 VR 32 REGULATOR TAP CHANGER SECTION 3 TABLE OF CONTENTS Tap Changer Operation 3 1 VR 32 REGULATORS a SECTION 1 Motor n mARSERRRAREER BERSHRR
80. al mode of operation run the regulator several steps in the raise direction and then turn the control back to auto After the time delay programmed into the control expires the regulator should return within bandwidth which will normally be the same position you started from unless the incoming voltage is currently vary ing When this has been completed use the manual mode of operation to run the regulator several steps in the lower direction and then turn the control back to auto After the time delay the regulator should return back within band width If the regulator will not operate properly a substitute con trol can be tried before removing the unit from service Refer to the following sections for proper procedures on removing and replacing the CL 4C Control Since the usable life of a regulator is affected by its appli cation it may be desirable to periodically remove the regu lator 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 Removal of CL 4C Front Panel The CL 4C 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 acces sible The design of the control enclosure back panel and front panel enable
81. alid point type requested 2 Framing error in the received message 8 Invalid command received 3 Overrun error in the received message 9 Invalid point number specified 4 Noise error in the received message Channel inactive 5 Parity error in the received message FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 64 Control Communications Adress 0 2 N A invalid 0 32766 Cooper power Systems has developed advanced controls for various utilizing a common protocol see Communications page 2 28 Each control on the system can be uniquely addressed by the SCADA RTU The CL 4C Control SCADA address is entered here with a factory set address of 2 For existing protocol called DATA 2200 the device addresses and responses are as follows 0 Wild card address All controls on the system respond is a message is sent to address 0 In practice this requires a star configuration where each control has a dedicated line 1 200 Unique device address range Controls with addresses in this range uniquely respond when the paricular address is sent 201 254 Device type group address range The group address is dependent upon the device type For example the CL 4C Control is device type 1 and its group address is 255 1 254 Any message sent to address 254 causes all con nected CL
82. ample 122 2 1222 ENTER 01 122 2 The set voltage is now 122 2 volts C RANGE FACTORY SETTING 2 BANDWIDTH 1 0 6 0 2 0 The bandwidth is defined as that total voltage range around the voltage setting which the control will consider as a satisfied condi tion an example a 2 V bandwidth on a 120 V setting means the operational timer will not activate until the voltage is below 119V or above 121V When the voltage is in band the band edge indicators are off and the timer time delay is off so no relay clo sure can occur Selection of a small bandwidth will cause more tap changes to occur but will provide a more tightly regulated line Conversely a larger bandwidth results in fewer tap changes but at the expense of better regulation Selection of the bandwidth and time delay settings should be made recognizing the interdependence of these two parameters Perform the following steps to program the bandwidth into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION 2 ENTER 02 20 This is the bandwidth as shipped from the factory CHANGE 02 Enter the desired value Example 4 5 45 ENTER 02 45 The bandwidth is now 4 5 volts F C PARAMETER RANGE FACTORY SETTING 3 TIME DELAY 5 180 30 The time delay is the period of time in seconds that the control waits from the time when the voltage first goes out of band to the time when relay closure occurs If a rapid response is required a smal
83. ans that the parameter is reset to the present value 2 10 VR 32 Regulator and CL 4C Control FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER oF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 23 H Power Factor At Maximum kVA Demand Forward 0 A invalid N A N A This is the instantaneous power factor of the load at the time when the maximum kVA demand occured since last reset A This parameter is associated with the kVA demand and therefore cannot be reset independent of the kVA demand FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS CHANGE RESET VALUE LOW HIGH 23 L Power Factor At Minimum kVA Demand Forward 0 A invalid This is instantaneous power factor of the load the time when the minimum kVA demand occured since last reset A This parameter is associated with the kVA demand and therefore cannot be reset independent of the kVA demand FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HI
84. arly labeled Vin and Vdiff The software of the CL 4C Control then recognizes this differential source voltage as a source voltage and will function accordingly 2 25 9225 10 4C The CL 4C Control offers 6 different response characteris tics for reverse power detection and operation These charac teristics are user selectable by entering a particular code at Function Code 56 The six modes and their corresponding codes are 0 Locked Forward 1 Locked Reverse 2 Reverse Idle 3 Bi directional 4 Neutral Idle 5 Co generation This section will separately explain each mode of operation Since the CL 4C Control retains the reverse metered demand values separate from the forward metered values the metering will also be explained for each mode In determining power direction the CL 4C Control senses only the real component of the current and then determines tne current direction and magnitude in that direction When the conditions dictate a power reversal has occurred the following parameters assume new values and the control operation is affected accordingly OUTPUT VOLTAGE now sensed from what was previous ly the input transformer now sensed from what was previous ly the output transformer in the forward direction the current is used directly as measured In the re verse direction the current is scaled to reflect the ratio difference between the input and output side of the regu lator accordi
85. be forward until the current exceeds the 1 threshold in the reverse direction At this time the various parameters assume new values as previously described and the REV PWR annunciator turns on The con trol continues metering in reverse until the current exceeds the 1 threshold in the forward direction and then the parameter scaling reverts back to normal and the REV PWR annuncia tor urns off If the source or differential P T is not installed reverse metering will not be available but all other metering operations remain the same OPERATION The threshold for which the control switches operation is programmable at Function Code 57 over the range 1 to 5 of the rated C T secondary current When the real component of the current is above this threshold the con trol operates in the normal forward direction When current falls below this threshold all tap changing is inhibited The control idles on the last tap position held before the threshold was crossed The operational timer time delay is reset on any excursion below this threshold and the band edge indica tors turn off FORWARD NHIBI To 5 j 88 NORMAL FORWARD 1 OPERATIONS 4 Shy ds f E 2 1 5 F C 57 CURRENT LEVEL Figure 2 8 Reverse idle mode operation BI DIRECTIONAL MODE Function Code 56 3 Source P T is Required METERING A threshold level of 1 002A of the full load C T secondary current 200A is used in
86. ble However many of these values per tain to the operation of the accessories and are not needed for normal regulator operations This section aides in determining the correct values for the 10 settings needed for basic regulator operation A full detailed description of each of the accessories is given in the ACCESSORY OPERATION section page 2 25 along with set up instructions The ten basic parameters are PARAMETER F C PARAMETER 1 Set Voltage 41 Regulator Configuration 2 Bandwidth 42 Control Operating Mode 3 Time Delay 43 System Line Voltage 4 Line Compensation Resistance 44 Ratio 5 Line Compensation Reactance 45 C T Primary Rating The control must be energized to perform the programming This can be accomplished by applying 120 volts to the external source terminals and placing the power switch in the EXTER NAL position Alternately the regulator may be energized at line potential and the control switch placed in the INTERNAL posi tion 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 the Diagnostics Section of this manual page 2 31 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 s
87. ble from Cooper Power Systems Separate documents are available to describe the user information for these communications interface modules When a communications system is in place and active it can perform all functions which the operator may perform at the front panel To prevent the SCADA system from conflicting with local operator commands several measures have been taken 1 The SCADA system may be completely disabled by an ON OFF switch located on the fiber optic module on the control back panel When the switch is OFF the system is electrically disconnected from the CL 4C Control such that no READ WRITE or RESET commands can reach the control However if the control is in a loop system the loop is maintained even with the switch OFF NOTE IF THE SCADA SYSTEM HAD PLACED THE CONTROL IN THE INHIBIT TAP CHANGE MODE AUTOMATIC OPERA TION WILL REMAIN INHIBITED UNLESS THE OPERA TOR ACCESSES FUNCTION CODE 69 AND CHANGES THE STATE OF THIS CODE FROM 1 To 0 SEE FUNC TION CODE 69 DESCRIPTION ON PAGE 2 19 2 The control switch on the CL 4C front panel must be placed in the AUTO REMOTE position for remote tap change commands to be performed If this switch is in either the OFF or MANUAL position no tap changes can occur but normal READ WRITE and RESET commands from the SCADA system can be performed 3 When the local operator enters any security code level 1 2 or 3 the SCADA system is prevented from WRITING or RESETTIN
88. cent lower buck in 32 approximately 5 8 steps Cooper Power System s regulators are supplied with the following standard features Dual rated 55 65 C rise ADD AMP capabiilty Unit construction Sealed tank construction Pressure relief device High creep bushings with clamp type terminals MOV type external series arresters Shunt arrester mounting bosses Two nameplates Oil sight gauge Upper filter press connection Drain valve and oil sampling device The 65 C rise insulation system and the sealed tank con struction allow for a BONUS CAPACITY 12 above the 55 C normal 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 and is avail able when the ADD AMP feature is not in use All Cooper Power System s regulators are manufactured and tested to ANSI standard 57 15 The unit construction which suspends the internal assembly and the control enclosure form the cover allows for ease of inspection and maintenance There are three types of step voltage regulators source side series winding load side series winding and series transformer Cooper Power System s Regulators are usually equipped with an equalizer winding The nameplates locat ed on the tank and control box clarify the power circuit involved RECEIVING Inspection Prior to shipment the regulator is thoroughly tested and inspected at the factory Imme
89. coil assembly within the oil until inspection of the tap changer or other maintenance is complete Figure 1 7 Untanking Retanking The Regulator Retank the regulator as follows 1 Be sure the position indicator shows the present position of the tap changer If not remove the indicator cable in the junction box from the position indicator shaft after loosen ing the set screw Rotate the indicator shaft until the prop er position is reached then tighten the set screw Verify coordination of position indicator with tap changer in neu tral position control neutral light on 2 Check the gasket seat surfaces on the cover and tank and wipe clean Wipe the gasket and position it on the tank lip Loosen horizontal side channel bolts to insure proper seating of regulator in tank and cover seal 3 Raise the cover assembly and attached components over the tank Make certain of proper orientation 4 Lower the unit positioning the channels in the tank guides Guide the control cabinet onto its brackets 5 Seat the unit in the tank Tighten the cover clamps or bolts and replace the control mounting bolts NOTE Tap the cover with a rubber hammer around the edge to properly seal the gasket while tightening the cover band 6 Check and retighten horizontal side channel bolts through handhole if required Maintenance The following is the recommended maintenance program for a regulator that has been untanked 1 Check all connecti
90. ction page 2 30 2 21 5225 10 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 80 Voltage Limiting Mode 0 2 0 0 0 2 The CL 4C Control has built in voltage limiting capabilities for both a low voltage or high voltage condition The appropriate mode is activated by entering the corresponding code 0 Off 1 High limit active only 2 High and low limit active See Voltage Limiting page 2 31 FUNCTION FUNCTION UNIT SECURITY LEVEL REN ENTRY CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 81 High Voltage Limit v 0 2 130 0 120 0 135 0 The high voltage limit is programmed here n the voltage limiting function is activated Function Code 80 1 or 2 the control will prevent the output voltage of the Whe regulator from exceeding this value See Voltage Limiting page 2 31 FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 82 Low Voltage Limit v 0 2 105 0 105 0 120 0 The low voltage limit is programmed here When the voltage limiting function is activated Function Code 80 2 the control wil
91. cuit is brought to the top terminal board through a series of removable jumpers and then to the front panel for connection to the circuit board Once this current signal is delivered to the circuit board it is transformed into a voltage signal and con verted into a digital format for processing Motor Circuit The motor circuit power is brought from the 6A fuse to the cir cuit board through a set of back to back diodes to the AUTO MANUAL selector switch When this switch is set for automatic operation motor power is applied to the relays An appropriate relay closure then applies this power to the tap changer motor after first passing through the limit switch contacts in the posi tion indicator When the switch is set for manual operation the power is transferred to the momentary toggle switch labeled RAISE LOWER By actuating this switch in one direction or the other power is applied through the limit switch contacts directly to the tap changer motor completely bypassing the cir cuit board Also included as a part of the motor circuit is an alternate feed to the motor called the holding switch circuit Located on the tap changer is a single pole double throw switch which is driven by a cam operated off of the tap changing mechanism Motor rotation closes this switch one direction or the other and establishes a complete circuit for motor current until the rotation is complete and the cam drops out During the time the ho
92. d per factory work order 001 Serial number of unit on a given factory work order 001 999 ACIOnmoou 91Z A XXX 001 LIST OF TABLES The following is a list of all tables found in this document and the page on which they are located Table Number Table Title 1 1 ShuntArrester Application Data 1 2 ADD AMP Capabilities 1 12 2 1 VR 32 Tap Connections and Voltage Levels 2 4 2 2 Function Codes for CL 4C Control 2 5 2 3 Function Code Dependent Upon Differential Voltage 2 25 2 4 Security Codes 2 32 2 5 Current Transformer Applications 2 35 2 6 Function Codes For CL 4 Control Field Trial 2 45 3 1 Changer Model Application Chart 3 1 6 1 Spare parts 6 1 LIST OF SCHEMATIC DIAGRAMS Figure Description Page 1 3 Typical Connection Diagrams 1 4 1 9 Power Circuit Series Winding Located on the Source Side 1 13 1 10 Power Circuit Series Winding Located on the Load Side 1 14 1 11 Power Circuit Series Transformer 1 14 1 13 Internal Wiring of Spring Drive Regulator with Series Winding Located on the Source Side 1 15 1 14 Internal Wiring of Direct Drive Regulator with Series Winding Located on the Load Side 1 16 1 15 Internal Wiring of Regulator with Series Wind ing on the Input Side with Differential Potential Transformer 1 17 1 16 Internal Wiring of Regulator with Load Winding on the output Side
93. d tap changing has stopped move the Control Switch to the MANUAL position 7 Press down on the LOWER switch to activate a lower opera tion 8 Allow the tap changer to operate five or six steps or enough steps to take the voltage below the in band voltage level 9 Now place the Control Switch in the AUTO position After the time delay period the control should cause the regulator to step up to within the lower band edge Example 120V and a 2N B W 119V lower band edge This should be shown in the display This concludes the operational check of the CL 4C control and regulator 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 procedure described in the CONTROL TROUBLE SHOOTING section of this manual which is a laboratory process 1 Connect an accurate true RMS responding voltmeter such as the Fluke 8026B 8060A or 8062A multimeters to the VOLT METER 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 sligh
94. d to use this function This com munications feature will allow the user to perform virtually any function remotely which might otherwise be done locally at the regulator front panel If you ARE NOT using the communications capability skip to Step D If you ARE using the communications capability begin at Step A A To temporarily disconnectthe control from SCADA flip off the toggle switch located on the lower left of the back panel B To determine if automatic operation has been inhibited by SCADA look at Function Code 69 Regulation Blocking Status The codes are as follows O Normal Automatic operation 1 Automatic operation Inhibited NOTE If automatic operation is inhibited record the last position of the tap changer C If automatic operation is inhibited access security level 2 see page 2 32 When in security level 2 press FUNCTION 69 ENTER Now press CHANGE RESET and type 0 You are now in the normal automatic opera tion and can continue as directed in instructions D Connect an accurate true RMS responding voltmeter such as the Fluke 8026B 8060A or 8062A multimeters to the VOLTMETER terminals E 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 accom plished by accessing the keypad and keying FUNCTION 47 ENTER The voltage displayed is the voltage at the test terminals NOTE The CL
95. de at Function Code 99 Depress the following keys on the keypad FUNCTION 99 ENTER 321 23 ENTER The proper level of security is now activated 6 Access Function Code 47 by keying FUNCTION 47 ENTER 7 The display will show the voltage applied to the control This should correspond to the reading on the reference voltmeter If the CL 4C Control reading is significantly different greater than 3V error the calibration can be altered by key ing CHANGE and then entering the correct voltage as dis played on the reference meter followed by ENTER The volt age circuit is now calibrated Current Calibration 1 2 Connect an accurate true RMS responding ammeter such as the meters above in series with the current source Connect a stable 60 50 Hz current source with less than 596 harmonic content to the reference ammeter and to the cur rent input terminals C1 and C3 on fanning strip TB2 C1 is identified by a red wire and C3 is identified as the green wire To power the control connect a 120 vac voltage source to the EXTERNAL SOURCE terminals Place the power switch on EXTERNAL Adjust the current source to provide 200 amps to the control as read on the reference ammeter Before calibration can be performed security level 3 must be activated This is accomplished by entering the proper secu rity code at Function Code 99 Depress the following keys on the keypad FUNCTION 99 ENTER 32123 ENTER The
96. diately 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 immedi ately 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 regula tor must be lifted by means of a sling and spreader bar uti lizing the tankmounted lifting lugs which are shown in Figure 1 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 WARNING The cover may fracture if the cover mounted lifting eyes are used to fit the entire unit Lift the entire unit only with the tank mounted lifing lugs Storing If the regulator is not to be placed into immediate use it can be stored with minimal precautions Locate the unit where the possibil ity of mechanical damage is minimized INSTALLATION Pre installation Inspection Before connecting the regulator to the line make the following inspection 1 Check the oil sight gauge Look for visible sig
97. ds for the appropriate power direction are set to their corresponding instanta neous value and the integration algorithm begins according to the programmed demand interval at Function Code 46 3 At 15 minutes or the demand time interval whichever is longer the max min demand values begin to track the pre sent demand similar to drag hands All demand values are calculated continuously in the working memory RAM and the max min demands are also stored in the nonvolatile memory EEPROM every 15 minutes if a change has occurred This prevents loss of data during a power inter ruption or outage Notice that the provisions are made to reset any demand value by itself via the change reset key or all demands can be reset simultaneously by entering Function Code 38 Maximum H and minimum L values will be set to their corresponding present P demand value If the present demand is in an invalid state dash es the maximum and minimum values will also become invalid displaying dashes Two conditions cause the present demands to be invalid 1 The power has just been applied within the 3 minute freeze peri od or 2 the power flow has changed direction If the CL 4C Control is metering in the forward direction the reverse present demands will be invalid and if metering in the reverse direction the forward present demands will be invalid Reverse Power Operation Most voltage regulators are installed in circuits with well de
98. e 07 Source Voltage Secondary 3 Bi directional 08 Compensated Voltage Secondary 4 Neutral Idle 09 Load Current Primary 5 Co Generation 10 Load Voltage Primary kV 57 Reverse Threshold Value 2 11 Source Voltage Primary kV 12 Percent Regulation COMMUNICATIONS 13 Power factor 60 Data Port Baud Rate 2 14 kVA Load 61 Interface Port Baud Rate 2 15 kW Load 62 Channel 1 Status 16 kVAR Load 63 Channel 2 Status 17 Line Frequency 64 Conrol Communications Address 2 18 Voltage Harmonics 3 5 7 9 11 65 Communications Port Baud Rate 2 19 Current Harmonics 3 5 7 9 11 66 Communications Port Handshake Mode 2 67 Communications Port Resynch Time Chars 2 Forward Demand Metering 68 Communications Port Transmit Enable Delay 2 20 Load Voltage Demand H L P 1 69 REGULATION BLOCKING STATUS 2 21 Compensated Voltage Demand H L P 1 VOLTAGE REDUCTION 22 Load Current Demand H L P 1 70 Voltage Reduction Mode 2 23H Power Factor Max kVA Demand 0 Off 1 Local 2 Remote 23L Power Factor Min kVA 3 Automatic With Remote Override 24 kVA Load Demand H L P 1 71 Voltage Reduction In Effect Read Only 25 kW Load Demand H L P 1 72 Local Reduction 2 26 kVAR Load Demand H L P 1 73 Remote Reduction Setting 1 2 27 Max Boost Min Buck 1 74 Remote Reduction Setting 2 2 28 Max Buck Min Boost 1 75 Remote Reduction Setting 3 2 76 Automatic Reduction Setting 1 2 REVERSE DEMAND METERING 77 Automatic Reduction Setting 2 2 30 Load V
99. e motor operation 10 At the end of this pause if the voltage is still out of band another output is issued to close the RAISE relay thus starting another tap change sequence step 6 If the volt age is in band the LOW band indicator is turned off and the time delay timer is reset At all times the microproces sor is sampling the sensing voltage for a change of condi tions This sequence is altered slightly if the voltage averaging or time integrating mode of operation is selected These character istics are described in the section titled SETTING THE CL 4C CONTROL FOR SERVICE page 2 32 Manual In the manual mode of operation the power switch can be set on either INTERNAL or EXTERNAL and the control switch will be placed on MANUAL If the EXTERNAL position is chosen an external source must be applied through the terminals on the front panel Operation of the momentary toggle switch RAISE LOWER applies power through the position indicator limit switch contacts directly to the tap changer motor As the tap changer rotates the holding switch is closed as described in the preceding section 2 42 VR 32 Regulator and CL 4C Control step 6 Again this holding switch current is sensed by the cir cuit board and the operations counter is appropriately incre mented Function Code 0 Tap changes will continue to occur as long as the RAISE LOWER switch is closed and the limit switch is not opened SUPERVISORY CO
100. e not only detects reverse power flow but provides the capability of operating in one of six different modes An extensive number of instantaneous and demand metering values including instantaneous harmonic values and maxi mum minimum and present demand values can be displayed on the LCD screen Some reverse power flow operation modes and metering require an optional differential potential trans former All control settings and metering values can be copied to an optional Data Reader through the CL 4C Data Port for transfer to a personal computer This feature allows the CL 4C Control user to establish a data base of useful information An enhancement of the CL 4C Control over the CL 4B Control is its real time communications capability With the addition of two retrofittable circuit boards any CL 4C can com municate digitally with a SCADA system The heart of the CL 4C Control is a Motorola MC68HC11 8 bit microcomputer This powerful processor also contains 512 bytes of electrically erasable and programmable read only memory EEPROM The demand values and control settings are stored in this special memory to prevent their loss during a power outage Information stored in the EEPROM will be retained indefinitely with or without power applied To fully capitalize on the microprocessor capabilities a 12 bit analog to digital converter is used in the front end of the design to convert the analog voltage and current waveforms into di
101. ectrical equipment and they do not respond to the continuous fluctuations which occur on the line FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 47 Voltage Calibration v 0 3 N A B 110 0 130 0 The voltage which the CL 4C Control actually measures is displayed at Function Code 47 To calibrate this value is compared to a reference voltmeter and if different is changed to display the exact correct value Calibration is performed by the factory and should not be necessary in the field See Control Calibration page 4 3 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 48 Current Calibration mA 0 3 B 100 0 400 0 The voltage which the CL 4C Control actually measures in milli amps is displayed at Function Code 48 The CL 4C Control is designed for 200mA as the rated C T current and will meter to 400 mA 200 load with no loss of accuracy To calibrate this value is compared to a reference ammeter and if different is changed to display the exact correct value Calibration is performed by the factory and should not be necessary in the field See Control Calibration page 4 3 B Representati
102. ecurity to change operational settings has now been activated SECURITY CODES TABLE 2 4 Security Level Factory Programmed User Definable Code Range 0 No Code Required No Code Required 1 1234 1 9999 2 12121 10000 19999 3 32123 20000 32766 Read all parameters except diagnostics Function Codes 93 94 amp 95 and security Function Codes 96 97 amp 98 Read all parameters as described above and reset all demands Read all parameters as described above reset all demands and change any operational or setup parameter Read all parameters and reset or change any parameter Functions Available at the Active Code 2 32 VR 32 Regulator and CL 4C Control C PARAMETER RANGE FACTORY SETTING 1 SET VOLTAGE 100 0 135 0 120 0 The set voltage is the voltage level to which the control will regulate on the 120 volt base Since the CL 4C Control performs ratio correction in software this value will normally be set for 120 0 volts unless it is desired to operate at a voltage level higher or lower than nominal For proper operation the ratio correcting transformer located on the control back panel must also be set for the cor rect tap as shown by the regulator nameplate Perform the following steps to program the set voltage into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION 1 ENTER 01 120 0 This is the set voltage as shipped from the factory CHANGE 01 Enter the desired value ex
103. ems Inc 1 VR 32 Regulator and CL 4C Control 1 CLAMP TYPE TERMINALS 2 THREADED STUD BUSHING TERMINALS 3 MOV TYPE SERIES ARRESTER 4 BUSHINGS 5 UPPER FILTER PRESS CONNECTION 6 ARRESTER MOUNTING BOSSES 7 BALL TYPE OIL SIGHT GAUGE 8 PANEL TYPE RADIATORS 9 DRAIN VALVE amp OIL SAMPLING DEVICE 10 BOLT DOWN PROVISIONS 11 GROUND BOSSES 2 12 CONTROL 13 CONTROL ENCLOSURE 14 NAMEPLATES 2 15 POLE TYPE MOUNTING BRACKETS 16 ENCLOSURE SUPPORT BAR 17 CONTROL CABLE 18 REGULATOR LIFTING LUGS 19 POSITION INDICATOR 20 JUNCTION BOX 21 INTERNAL ASSEMBLY LIFTING LUGS 22 HANDHOLE COVER Figure 1 2 Features of the VR 32 Voltage Regulator DEFINITIONS OF ALERTS PLEASE READ THE FOLLOWING CAREFULLY AND HEED THE WARNINGS CAUTIONS AND NOTICES HEREIN WARNING A WARNING describes a potentially CAUTION A CAUTION describes a potentially hazardous situation which if not avoided could hazerdous situation which if not avoided could result in death or serious injury result in minor or moderate injury NOTICE A NOTICE describes a situation which if not avoided could result in damage to the equipment with no likelihood of personal injury 1 2 5225 10 4 VR 32 VOLTAGE REGULATORS Section 1 INTRODUCTION Cooper Power System s VR 32 feeder voltage regulators are regulating auto transformers They regulate line voltage from ten percent raise boost to ten per
104. eration Communications The CL 4C Control has the facilities for two communications channels One such channel is dedicated to the 9 pin subminia ture connector located on the control front panel labeled the Data Port The Data Port is designed to interface with the Cooper Power System s Data Reader a handheld battery operated data gathering device Figure 2 14 In five seconds the Data Reader collects all the data contained in the CL 4C Control data base for later transfer to an IBM compatible per sonal computer The Data Reader can read 100 such devices before its memory is filled to capacity A simple command on the PC erases the Data Reader to permit another read cycle This device and the PC based software are available from Cooper Power Systems Figure 2 14 Data Reader 2 28 VR 32 Regulator and CL 4C Control The Channel 1 baud rate is selectable at 300 1200 2400 and 4800 BAUD However to permit communications with the Cooper Power Systems Data Reader the Channel 1 baud rate is set at the factory to 4800 BAUD Communications Channel 2 is dedicated to the real time digital communications interface Like other advanced controls developed by Cooper Power Systems the CL 4C Control uti lizes a point structure data base This permits all parameters to be read changed or reset as appropriate through the SCADA system there by allowing the user to perform virtually any function remotely which mig
105. ered at Function Code 44 The CL 4C Control will then define the 124 9 volts output from the back panel ratio correction trans former as the 120 base voltage and 120v is displayed at Function Code 6 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 45 Current Transformer Primary Rating A 0 2 N A 100 25 2000 The CL 4C Control is designed for 200 mA as the rated current transformer C T current and will meter to 400mA 200 load with no loss of accuracy Ratio corection is performed by the software and consequently the C T primary rating must be entered The C T primary rating is available on the regulator nameplate and is summarized in Table 2 5 on page 2 35 for all regulaotr ratings Example A 7620 volt 328 amp regulator 250kVA would have a C T primary rating of 400A and this is entered at Function Code 45 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS CHANGE RESET VALUE LOW HIGH 46 Demand Time Interval min 0 2 N A 15 0 3 0 60 0 This is the time period which the demand integral is performed for all demand readings Function Codes 20 through 36 Demand readings are useful because they represent the values which produce actual heating effects in el
106. erse Power Operation page 2 25 2 16 VR 32 Regulator and CL 4C Control FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 56 Reverse Sensing Method 0 2 0 0 5 The CL 4C Control offers six different response characteristics for reverse power flow operation selectable by the user The six modes and their corresponding codes are 0 Locked Forward 1 Locked Reverse 2 Reverse Idle 3 Bi directional 4 Neutral Idle 5 Co generation See Reverse Power Operation page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 57 Reverse Threshold 0 2 2 1 5 This is the current threshold at which the CL 4C Control switches operation either from forward to reverse or reverse to foward This threshold is programmable as a percentage of the rated C T secondary current Example a 328 amp regulator utilizing a C T with a 400 amp primary rating and with a 3 threshold value would have a threshold of 6 mA 12 amps The metering of the CL 4C Control switches on a fixed 1 threshold completely independent from Function Code 57 See Reverse Power Operation page 2 25 FUNCTION UNIT SECURI
107. essory VR 32 Regulator and CL 4C Control SPARE PARTS Section 6 When ordering replacement parts or field installable acces sories for your Cooper Power Systems VR 32 step voltage regulator provide the following information 1 Regulator serial number found on control nameplate 2 Quantity of each part required Table 6 1 Spare Parts 3 Part code number of each part as shown in Table 6 1 4 Description of each part as shown in Table 6 1 Additional parts and installation information for tap changers is found in bulletin S225 10 2 Part Description Code No Reference Figure Bypass series arrester Figure 1 2 with mounting hardware Complete bushing assembly indicate if for S L or SL application Dry type 95 kV BIL and below Figure 6 1 Oil filled 150 kV BIL and above not shown Note oil filled bushings available only as complete assembly Dry type bushing components Terminal cap Figure 6 1 Terminal cap gasket Figure 6 1 Porcelain Figure 6 1 Bushing tank gasket Figure 6 1 Clamp w bolts Figure 6 1 Clamp spring Figure 6 1 Position indicator complete 4000 Figure 1 8 Position indicator glass cover 4001 Figure 1 8 Position indicator external 4004 not shown drive cable not used on regulators without junction box Position indicator internal drive not shown cable provide total length of old cable in inches 928D and 170C Spring drive tap changer
108. ey have the motor and gear train moving the contacts through a geneva gear pinion and scroll cam Direct drive tap changers are commonly applied above 219 amps Both the mid current Model 770B Figure 3 3 and high current Model 660C Figure 3 4 are rated 150 BIL See Table 3 1 for application chart of tap changer mod els MOTOR The motor for the spring drive tap changer is a capacitor run reversing gear motor suitable for operation at 120 volts ac sin glephase at 50 60 Hz An integral braking mechanism controls motor coast The motor for the direct drive tap changers is a capacitor start capacitor run high torque reversing gear motor rated 120 volts ac single phase at 50 60 Hz with an internal magnetically dis engaging brake mechanism All components are compatible with hot transformer oil and the windings are oil cooled The motors will carry locked rotor current for at least 3000 hours REVERSING SWITCH The reversing switch function changes the polarity of the tapped winding When the spring drive tap changer is in the neutral posi tion the reversing switch is open When the direct drive tap changer is in the neutral position the reversing movable contact is in contact with the lower reversing stationary contact VL The load current on all types is carried by the source bushing the reactor slip rings main movable contacts neutral stationary contact and the load bushing The reversing switch motion on the spring
109. fined power flow from source to load However some circuits have interconnections or loops in which the direction of power flow through the regulator may change For optimum utility system per formance a regulator installed on such a circuit should have the capability of detecting reverse power flow and of sensing and controlling the voltage regardless of the power flow direction The CL 4C Control has full reverse power capabilities but for fully automatic reverse operation the source voltage or source to load differential voltage must be supplied to the CL 4C Control in addition to the load voltage Regulators may be ordered direct from the factory with an internal source to load differential P T or an external source side P T may be installed in the field In either case a second Ratio Correcting Transformer RCT on the control back panel is required for proper correction of the source voltage regulators with factory installed differential P T s also have the second RCT installed at the factory Some field installations may require that a source voltage P T be used instead of a differential series winding P T which is the standard technique used on the Cooper Power Systems voltage regulator The CL 4C Control is designed such that it can be con figured for this application also This reconfiguration is accom plished by removing the beck shield and moving a soldered jumper from one set of terminal posts to another they are cle
110. gital signals A digital signal processing technique called Discrete Fourier Analysis is then performed on this data permitting extremely accurate resolution of both the voltage and current input signals It is the power of this technique which enables the CL 4C Control to do harmonic analysis to the 11th harmonic frequency as well as measurements for metering and control PRE INSTALLATION OPERATIONAL CHECK The CL 4C Control has the facilities for either manual or auto matic operation of the tap changer with either the internal source of power the regulator or an external source To per form an operational check of the control before installing the regulator follow these steps A Connect the three high voltage bushings together and ground them B Place the POWER switch in the OFF position and the CONTROL switch in the OFF position C Connect a variable 120 volt 50 60 Hz source to the EX TERNAL SOURCE terminals The grounded side of the external source must connect to the ground white termi nal on the control D Place the POWER switch in the EXTERNAL position E Move the CONTROL switch to MANUAL and depress and hold the RAISE LOWER momentary toggle switch Allow the tap changer to operate to 16L the 10 buck position F Hold up on the RAISE LOWER momentary toggle switch Allow the tap changer to operate to 16R the 10 boost position G Now place the Control switch in the AUTO REMOTE position H Adjust the va
111. h the kVA demand and therefore cannot be reset independent of the kVA demand An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 33 L Power Factor At Maximum kVA Demand Reverse 0 N A A invalid N A N A This is the instantaneous power factor of the load when the minimum kVA demand occured during reverse power flow since last reset A This parameter is associated with the kVA demand and therefore cannot be reset independent of the kVA demand An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 34 H L P kVA Load Demand Reverse kVA 0 1 Reset N A N A This is the load kVA during reverse power flow as a demand value according to the demand time interval at Function Code 46 H maximum value since last reset minimum value since last reset and P present value Scroll to the L
112. horting 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 7 Close the panel and tighten panel locking screws Untanking The Regulator 1 Manually run the tap changer to neutral if possible If not po Sible note position indicator reading before proceeding to untank 2 Remove the two mounting bolts holding the control cabinet to tank 3 Remove the series arrester Release internal pressure using the pressure relief device on the side of the regulator Free cover by removing clamping ring or cover bolts Attach sling or hooks with spreader bar Figure 1 7 to lifting eyes and raise the cover with the ahached core and coil assembly until the top of the coil is approximately one inch under oil The control cabinet should be guided to avoid snag ging during lifting af 1 9 VR 32 Regulator and CL 4C Control CAUTION Before untanking a fan cooled regu lator 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 It is recommended that the main core and coil assembly never be removed from the oil except when a winding failure occurs Blocking between the cover and tank lip should be employed to suspend the core and
113. ht otherwise be done locally at the regulator front panel All Cooper Power Systems advanced controls employ the same protocol for communications to the outside world This standard protocol is defined as DATA 2200 which is an 8 bit character oriented asynchronous for mat and is not proprietary The physical implementation of digital communications to the CL 4C is accomplished through an optional two board set consisting of a protocol converter module and a fiber optic transmitter receiver module The protocol converter mounts directly above the CL 4C main circuit board set on the front panel and plugs directly into it Its primary function is to pro vide the outside world with a suitable communications inter face to the CL 4C main control unit The system is designed such that this module can be easily added in the field The fiber optic transmitter receiver module mounts on the back panel of the control enclosure and also can be field installed It is connected to the protocol converter module through an eight conductor cable and connects into the SCADA system via two ST bayonet style fiber optic transmitter and receiver connectors The fiber optic communications medium was chosen because it has demonstrated clear supe riority to traditional RS232 cabling in terms of electrical isola tion and surge protection To interface to an RTU RS232 port a fiber optic to RS232 converter is used at the RTU This device is also availa
114. inal variable source to the EXTERNAL SOURCE terminals C Set the CONTROL switch on RAISE D Measure the voltage between terminals R and G on ter minal board The voltage reading should be approximate ly 120 volts act E Set the CONTROL switch on LOWER F Measure the voltage between terminals L and G on ter minal board The voltage reading should be approximate ly 120 volts act G If correct voltage readings are obtained in steps B and D above the trouble is in the regulator tank Refer to trou bleshooting section of S225 10 2 H If there is no voltage measurement in either step B or D the problem is in the limit switches inside the position indicator or the control cable 7 Check the continuity of the raise and lower limit switches The switches should be closed on all tap changer positions except for the set limit switch positions of the indicator dial To check the continuity A Remove position indicator green black lead from splice terminals B Place the meter lead on the disconnected lead and the other lead on terminal L of the junction box terminal board Then check continuity C If a continuity problem occurs refer to Position Indicator Replacement on page 4 3 D Remove the position indicator blue lead from the splice terminal E Place the meter lead on the disconnected lead and the other lead on terminal R of the junction box terminal board Check continuity F If a continuity problem occurs refer to Po
115. ing drive When the spring drive switch is in the neutral position and the control calls for a tap change the following events occur 1 Motor brake releases and motor starts 2 Motor holding switch closes assuring that one tap change will be completed 3 The up slope of sprocket cam engages a lip of the spool This lifts the pin in the pin cam and frees it from the hole in the actuator 4 A projection on the sprocket cam contacts a leg on the pin cam and both turn 5 Drive shaft which is attached to the pin cam begins to turn the crank arm and the springs begin to extend 6 Pin comes free from the lip on the spool and a spring pushes it against the surface actuator 7 Down slope of sprocket cam returns the spool to the start position 8 Pin drops into the hole in the actuator 180 degrees from the start position 9 At this point the crank arm is at top dead center and the springs are fully loaded Drive shaft and crank arm sprocket cam pin cam and actuator are locked together and con nected through the chain to the motor 10 Motor drives all parts beyond top dead center 11 Spring unloads instantaneously pulling pin cam and actuator through 180 degrees at high speed Pins on the actuator cause the contact drive sprocket to index one tap position 12 As the contact drive sprocket moves it imparts motion to the reversing switch segment and main movable contacts This action closes the reversing movable and rever
116. ing drive tap changer Figure 3 3 Figure 3 4 770B direct drive tap changer 660C direct drive tap changer 3 2 5225 10 4 CONTACTS Several connection conditions are satisfied by the variety of contact structures They are divided into arcing and non arcing The non arcing contacts consist of front and rear slip rings which serve as the connection point for opposite ends of the reactor windings and one end of the two main movable con tacts All contact surfaces are Electrical Tough Pitch ETP cop per and all joints are riveted bolted or brazed to maintain a high conductivity current path Contact pressure between mov ing points is maintained by steel leaf springs in the spring drive tap changers or by opposing steel compression springs in the direct drive tap changers The main movable contact is split to make contact on both surfaces of the slip ring and to resist sep aration in the event of high current surges There are several types of arcing contacts on a regulator tap changer They can be divided into two categories stationary and movable 1 The main stationary contacts are connected to the series winding taps The main movable contacts connect the slip rings to the main stationary contacts 2 The reversing stationary contacts are connected to oppo site ends of the series winding The reversing movable contacts connect the neutral stationary contacts and load bushing to the reversing stationary contac
117. ing has been completed 4 Consider upgrading controls to latest design CONSTRUCTION Surge Protection SERIES SURGE ARRESTER All VR 32 regulators are equipped with a bypass arrester con nected across the series winding between the source S and load L bushings This bypass arrester limits the voltage devel oped across the series winding during lightning strikes switching surges and line faults The series surge arrester can be seen in Figure 1 2 A MOV type series surge arrester of 2 2 kV offers series winding protection on all regulators except those rated over 14 400 volts which have a 3 4 5 kV MOV type series surge arrester SHUNT ARRESTERS A shunt arrester is an optional 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 L bushing and ground For additional protection a shunt arrester may also be installed between the S source bushing and ground 1 10 5225 10 4 For best results locate these arresters on the mounting pads provided on the tank near the bushing Ground the arrester and the regulator tank to the same ground connec tion using the shortest cable possible Shunt arrester appli cation data is listed in Table 1 1 TABLE 1 1 Shunt Arrester Application Data Nominal System Voltages Recommended volts MOV Regulator Shunt Voltage Delta or Multi G
118. it operates in either the forward or reverse directions and has the highest priority of all operating functions Voltage limiting is overridden only by the operator taking LOCAL con trol or by an interconnected SCADA system The purpose of the voltage limiter is to protect the consumer from abnormal high or low voltages resulting from 1 Abnormal loading of the feeder 2 Inaccurate regulator contro settings voltage level bandwidth and line drop compensation 3 Heavy loading by the first customer while there is a lead ing power factor on the feeder 4 Light loading at the first customer with heavy loading on the feeder at the same time The appropriate high and low limits for the output voltage can be programmed into the CL 4C Control at Function Codes 81 and 82 respectively The accessory is then activated by accessing Function Code 80 and entering the appropriate code for the desired operation 0 off 1 high voltage limit ing only and 2 both high and low limiting If low voltage limit ing only is desired Function Code 80 should be set for 2 to enable this limit and the value programmed into Function Code 81 for the high limit can be set to some extreme number such as 135 to prevent the high limit from activating The control has two response sensitivities If the output voltage exceeds either the high or low limit by three volts or more the CL 4C Control samples the voltage for two seconds and then taps immediatel
119. l differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 32 H L P Load Current Demand Reverse A 0 N A 1 Reset N A N A This is the load current during reverse flow as a demand value according to the demand time interval at Function Code 46 H maximum value since last reset L minimum value since last reset and P present value Scroll to the L and P values An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 A default value of Reset means that the parameter is reset to the present value 2 12 VR 32 Regulator and CL 4C Control FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 33 H Power Factor At Maximum kVA Demand Reverse 0 A invalid N A NAA This is the instantaneous power factor of the load when the maximum kVA demand occured during reverse power flow since last reset A This parameter is associated wit
120. l prevent the output voltage of the regulator from dropping below this value See Voltage Limiting page 2 31 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 89 Device Software Version 0 The version number of the software is displayed at Function Code 89 for information only This number cannot be changed via the keypad Present production CL 4C Controls contain version 4 01 software initial production contained version 1 01 2 01 amp 3 01 software f additional enhancements are performed new version numbers will be assigned to readily identify any device FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 90 Number of Defaults 0 N A This is a counter fro the number of parameters in the CL 4C Control operating system which have defaulted During normal operation this will be zero f any number other than zero is encountered all of the CL 4C Control settings must be examined to determine which has defaulted Then the setting s must be changed to the correct value s 2 22 VR 32 Regulator and CL 4C Control FUNCTION
121. lding switch is closed motor current is drawn through an input on the circuit board which permits the control to detect that a tap change is in process The microprocessor uses this information in its decision making process as described in the following section Two other unassociated circuits which share the 6A motor source are the drag hand reset and neutral light circuits The drag hand reset function is accomplished simply by operating a momentary toggle switch which applies power to the reset solenoid in the position indicator The neutral light is similarly actuated for test purposes and it is also energized from neu tral light switch located on the tap changer when in the neu tral tap position Control Operation Automatic In the automatic mode of operation the power switch will be set on INTERNAL and the control switch will be placed on AUTO The regulator is assumed energized from the primary circuit If the sequential mode of operation is selected the standard mode the control response is as follows 1 As the primary voltage moves to a level which represents an out of band condition the sensing voltage will corre spondingly reflect the same results on the 120V base Assuming the voltage dropped low a lower than nominal signal will appear at the printed circuit board input termi nals 12 and 13 2 The signal is transformed and converted into a digital format for use by the microprocessor 3 The microprocess
122. ler setting should be used If several devices on the same line are to be coordinated longer time delay settings may be required to allow the proper devices to operate in the desired sequence Proceeding from the source each device should have a longer time delay than the preceding device Perform the following steps to program the time delay into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION 3 ENTER 03 30 This is the time delay as shipped from the factory CHANGE 03 Enter the desired value example 49 49 ENTER 03 49 The time delay is now 49 seconds LINE COMPENSATION RESISTANCE AND REACTANCE SETTINGS Quite often regulators are installed some distance from the theoretical load center the location at which the voltage is to be regu lated This means the load will not be served at the desired voltage level due to the losses voltage drop on the line between the regulator and the load Furthermore as the load increases line losses also increase causing the lowest voltage condition to occur during the time of heaviest loading To provide the regulator with the capability to regulate at a projected load center manufacturers incorporate line drop compen sation elements in the controls This circuitry usually consists of a current source C T which produces a current proportional to the load current and resistive R and reactive X elements through which this current flows As the load increases the resulting C T curren
123. llustrated by Table 2 1 page 2 4 This is accomplished by providing a voltage sensing potential winding with taps which roughly correspond to the appropriate system voltages This source may be either a winding on the main core coil assembly or a separate potential transformer located on the output load side of the regulator The taps from this source are brought to a terminal board located on top of the tap changer assembly under oil see Figure 2 21 The connec tions are made with push on terminals and are easily accessed through the handhole im e Figure 2 21 Internal tap terminals The tapped potential winding cannot always provide adjust ment of the voltage fine enough for control purposes A tapped autotransformer is therefore used for fine voltage adjustment This transformer is referred to as the Ratio Correcting Transformer RCT and has taps at 104 110 115 120 127 133 volts It is located on the back panel in the control enclosure see Figure 2 22 To operate a regulator on a system other than its rating the appropriate selection must be made for the internal tap and RCT tap and the CL 4C Control must be pro grammed properly at Function Code 43 System Line Voltage and Function Code 44 P T Ratio The nameplate always pro vides all these values for the common system voltages which are applicable for the particular regulator see Figure 2 17 page 2 36 This is discussed in detail in section titled SETTIN
124. ltage Primary kV 61 Channel 2 Baud Rate 2 12 Load Current Secondary mA 13 Percent Regulation VOLTAGE REDUCTION OPTION 14 Power Factor Voltage Reduction Mode 2 15 kVA Load 1 Local 2 Remote 16 kW Load 3 Automatic With Remote Override 17 kVAR Load 71 Voltage Reduction In Effect 18 Line Frequency 72 Local Voltage Reduction 2 73 Remote Setting 1 2 FORWARD DEMAND METERING OPTION 74 Remote Setting 2 2 0 Load Voltage 1 75 Remote Setting 3 2 21 Load Center Voltage 1 76 Automatic Setting 1 2 22 Load Current 1 77 Automatic Setting 2 2 23H Power Factor Max kVA Demand 78 Current For Automatic 1 2 23L Power Factor Min kVA Demand 79 Current For Automatic 2 2 24 kVA Load 1 25 kW Load 1 VOLTAGE LIMITER OPTION 26 kVAR Load 1 Voltage Limiting Mode 2 0 Off 1 High Limit Only REVERSE DEMAND METERING OPTION 2 High and Low Limit 27 Load Voltage 1 81 High Voltage Limit 2 28 Load Center Voltage 1 82 Low Voltage Limit 2 29 Load Current 1 30H Power Factor Max kVA Demand WATCHDOG DIAGNOSTICS 301 Power Factor Min kVA Demand Number of Defaults 31 kVA Load 91 Self Test 32 kW Load 1 93 Number of EEPROM Corrections 3 33 kVAR Load 1 94 Number of Rests 3 95 Hardware Status System Code 3 34 Max Boost Min Buck 1 35 Max Buck Min Boost 1 SECURITY ACCESS Level 1 Security Code 3 36 Master Reset 97 Level 2 Security Code 3 98 Level 3 Security Code 3 37 Regulator Identification 2 99 Enter Security Code 3
125. ltage setting E If correct voltage readings are obtained in steps B and D above the trouble may be in the position indicator junction box or control cable Refer to the junction box trou bleshooting section on page 4 2 G If there is no voltage measurement in either step B or D make a corresponding measurement R3 to G and L3 to G on lower terminal board TB2 H If the voltages measured in Step G are approximately the set voltage setting then the fault is likely a loose connection or a faulty terminal swage between TB1 and TB2 If steps B D and do not provide voltage readings measure the voltage between VM and G on terminal board TB2 The reading should be approximately the set voltage setting J If Step measures correctly the trouble could be an open motor fuse power switch or control switch of the control K If Step does not yield a voltage measurement check the volt age between PD 1 V1 and ground G at the voltage discon nect knife switch 1 If approximately the set voltage setting is obtained the V1 disconnect or the ratio correcting transformer RCT1 of the rear panel signal circuit is probably faulty 2 voltage is not obtained the trouble is in the control cable junction box or regulator tank Refer to the junction box troubleshooting section on page 4 2 If the junction box checks are satisfactory the trouble is in the regulator tank See S225 10 2 for the trouble shooting method THE REG
126. m ponents are checked by using an external voltage of approxi mately 120 volts ac 60 50 Hz applied to the external source ter minals of the control To gain access to the front panel components first remove the back shield This is accomplished by removing the cable clamp attached to the shield side and then removing the four nuts which secure the shield to the front panel 1 Check the motor and panel fuses to ensure they have not blown 2 Connect the power source to the external source terminals observing the proper polarity Place the power switch on the EXTERNAL position 3 The CL 4C Regulator Control display should light If the dis play does not light measure the voltage on the printed circuit board terminals 12 to 13 expecting to measure approximately 120 volts act The circuit board terminals are identified as 1 through 15 from left to right 5225 10 4 4 the display does not light and no voltage is measured terminals 12 to 13 then the problem is probably in the power switch The power switch can be checked by mea suring the voltage from terminal 2 to ground terminal 5 to ground and terminal 8 to ground These measurements should equal the external voltage applied If not the power switch is defective 5 If the display does not light and voltage is measured at ter minals 12 to 13 then the circuit board is defective and must be returned to the factory for repair 6 the display does light b
127. m once the diagnostic routines are entered the first action taken by the CL 4C Control is to light all segments of the display This gives the operator an opportuni ty to observe the display for defective segments Activities are performed as follows 1 Non volatile memory is checked to ensure all locations can be written to and erased 2 The frequency detection circuitry is checked to verify a signal frequency between 45 and 65 Hz is being sampled 2 31 9225 10 4C 3 The interrupt line to the processor is checked to verify that it is functional 4 The multiplexor and analog to digital converter are checked to verify operation Critical parameters are checked to ensure validity The input differential voltage channel is checked for the pres ence of a signal 7 The output voltage channel is checked for the presence of a signal The duration of this test sequence is approximately 3 sec onds At completion the display will indicate PASS or FAIL dependent upon the test results The PASS message will remain in the display until the operator makes an entry through the keypad or 30 minutes if no keypad entry is made After 30 minutes the display will automatically be turned off The FAIL message remains in the display for approximately 15 minutes then the diagnostic routines are executed again The CL 4C Control will attempt to overcome the problem that dis abled it by going through this pr
128. m the back of the indicator C Turn the indicator shaft to center the hand at zero neutral D Reconnect the flexible shaft 16 Run the tap changer to both raise and lower extremes to check operation of the limit switches and coordination with holding switch 17 Run between position nine raise and nine lower to check neutral light and position indicator alignment Run sever al cycles 18 Should the alignment of the position indicator hand and the neutral light become unstable during this check an internal inspection of the tap changer and position indi cator shaft is required See S225 10 2 for instructions 19 Return the tap changer to the neutral position and dis connect the power supply 20 Replace the junction box cover 21 The unit may now be placed into service as outlined on page 1 5 following steps Voltage Calibration 1 Connect an accurate true RMS responding voltmeter to the voltmeter terminals This voltmeter should have a base accu racy of at least 0 196 with calibration traceable to the National Bureau of Standards 2 Connect a stable 60 50 Hz voltage source with less than 596 harmonic content to the external source terminals 3 Place the power switch on EXTERNAL 4 Adjust the voltage source to provide 120 0 volts to the control as read on the reference voltmeter 5 Before calibration can be performed security level 3 must be activated This is accomplished by entering the proper secu rity co
129. ng to this formula INPUT VOLTAGE LOAD CURRENT reverse load current forward load current input voltage secondary output voltage secondary where input voltage secondary and output voltage sec ondary are in the reverse direction kVA kW kVAR and BUCK BOOST are now calculated based upon the new metered reverse values LOCKED FORWARD MODE Function Code 56 0 No Source P T is Required METERING Always operates in the forward direction regard less of power flow direction If reverse power occurs the metering functions remain on the normal load side of the regu lator no reverse demand readings will occur This mode is not intended to be used in applications where reverse power flow is possible OPERATION Always operates in the forward direction This allows operation down to zero current conditions since there is no forward threshold involved A safeguard has been built into the control to prevent misoperation in the event reverse power flow does occur If more than 2 004 amps C T secondary reverse current occurs the control idles on the last tap position held and the band edge indicators will turn off As the current flow returns to a level above this reverse threshold normal for ward operation resumes REVERSE dea TAP CHANGING INHIBITED Figure 2 6 Locked forward mode operation FORWARD NORMAL FORWARD OPERATIONS NES 2 0 CURRENT LEVEL LOCKED REV
130. not be displayed or changed and calibration cannot be performed See Security System page 2 32 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 99 Enter Security Code 0 1 32766 This is function code location where security codes are entered for access to system The CL 4C Control is continually scanning Function Code 99 looking for a security code entry for any of the three security levels 2 24 VR 32 Regulator and CL 4C Control DIFFERENTIAL VOLTAGE Unless specifically ordered or required as a part of the speci fied operation most regulator designs will be without the inter nal differential voltage P T Without a differential voltage input several functions cannot be obtained and will indicate dashes when displayed Also Function Code 95 will display a 7 to indicate no input voltage The following function codes will be invalid TABLE 2 3 Function code dependent upon differential voltage Function Code Description 7 Secondary Source Voltage 11 Primary Source Voltage 12 Percent Regulation 6 16 Reverse Instantaneous Values 27 Maximum Boost Minimum Buck 28 Maximum Buck Minimum Boost 30 36 All Reverse Metered Demand Values If the parameters listed above are desired and the regu lator is not equipped
131. ns of oil leakage 2 Examine the series arrester for damage If damaged install a new arrester of the same voltage rating 3 Inspect the porcelain bushings for damage or leaking seals If there is a suspicion that moisture has entered the unit remove the handhole cover and inspect for evidence of moisture such as rust or watertracks in the oil If moisture has entered the tank dry the regulator and filter the oil before putting the unit in service The oil must test 26 kV minimum in a standard gap ASTM D 877 Be sure to properly replace the handhole cover CAUTION Do not subject tap changer to tempera tures above 150 F To do so may cause damage to the contact panels resulting in misalignment of the con tacts 4 If the regulator has been stored for some time test the dielectric strength of the oil according to ASTM D 877 5 The regulator may be energized at rated line voltage with caution and an operational check page 1 8 can be performed This procedure is optional 6 A Hi pot test may be done to insure adequate electrical clearanc es to ground This procedure is optional Systems Connections A regulator can regulate a single phase circuit or one phase of a three phase wye 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 delta circuit When connected in wye three regulators
132. nter is activated by detecting tap changer motor operation which is determined by sensing current flow in the holding switch circuit This technique has been employed in all previous CL regulator control designs The operations count is written into non volatile memory after every ten 10 counts In the event of a power outage the count will round back to the nearest ten 10 and then add five 5 to obtain the restored count when power recovers Example Count 218 After Power Loss Recovery 215 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 01 Set Voltage Forward v 0 2 120 0 100 0 135 0 The set voltage is the voltage level to which the control will regulate on 120 volt base during forward power flow FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 02 Bandwidth Forward v 0 2 2 0 1 0 6 0 The bandwidth is defined as that total voltage range around the voltage setting which the control will consider as a satisfied in band condition during forward power flow FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET
133. o 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 1 11 VR 32 Regulator and CL 4C Control TABLE 1 2 ADD AMP Capabilities Load Current Ratings amps Rated Rated Regulation Range Volts kVA 1096 8 3 4 7 1 290 6 1 4 25 25 100 112 110 120 135 160 50 200 224 220 240 270 320 75 300 336 330 360 405 480 100 400 448 440 480 540 640 2500 125 500 560 550 600 668 668 167 668 668 668 668 668 250 1000 1120 1000 1000 1000 1000 333 1332 1492 1332 1332 1332 1332 416 3 1665 1865 1665 1665 1665 1665 25 50 56 55 60 68 80 50 100 112 110 120 135 160 100 200 224 220 240 270 320 125 250 280 275 300 338 400 5000 167 334 374 367 401 451 534 250 500 560 550 600 668 668 333 668 668 668 668 668 416 3 833 900 833 833 833 833 38 1 50 56 55 60 68 80 57 2 75 84 83 90 101 120 76 2 100 112 110 120 135 160 114 3 150 168 165 180 203 240 167 219 245 241 263 296 350 7620 250 328 367 361 394 443 525 333 438 491 482 526 591 668 416 3 548 614 603 658 668 668 500 656 668 668 668 668 668 667 875 900 875 875 875 875 833 1093 1224 1093 1093 1093 1093 69 50 56 55 60 68 80 138 100 112 110 120 135 16 207 150 168 165 180 203 24 276 200 224 220 240 270 32 13800 414 300 336 330 360 405 48 500 362 405 398 434 489 579 552
134. oad current Function Code 9 See Figure 2 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 15 kW Load v 0 This is the total kilowatts true power consumed the load This is calculated by the product of the power factor Function Code 13 times the kVA load Function Code 14 See Figure 2 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 16 kVAR Load kVAR 0 N A N A N A N A N A This is the total kilovolt amperes reactive reactive power drawn by the load t is this reactive power which adds to losses on the line yet does not do any work Figure 2 4 a POWER FACTOR kVA kVAR we kW kVA cos 0 kW kVA sin Figure 2 4 Power triangle FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY CODE CODE PARAMETER TO TO TO DEFAULT LIMIT EXTENSION MEAS READ CHANGE VALUE LOW HIGH 17 Line Frequency Hz 0 This is the frequency of the power line as measured by the CL 4C Control The CL 4C Control is capable of operating on systems from 45 to 65 Hz with no loss
135. ocess continually until it receives operator attention The specific problem identified is indicated by a number that is displayed at Function 95 see page 2 23 for a description of these system codes Any system code other than 0 all systems good 6 invalid critical parameters or 7 no input voltage will require sending the CL 4C Control back to the factory for repair SECURITY SYSTEM The security system implemented on the CL 4C Control is structured into four 4 levels This permits selective access to the venous parameters as dictated by the active security level Three security access codes have been programmed into the CL 4C Control at the factory but may be changed by the user according to Table 2 4 This information is also shown on the Function Code Sheet bulletin 89024 Access into the system is accomplished simply by entering the appropriate security code at Function Code 99 NOTE If the Level 3 Code is changed by the user the new value should be recorded and kept in a safe place Loss of this code means that security codes cannot be displayed or changed diagnostic codes cannot be displayed or changed and calibra tion cannot be performed However all Security Codes may be down loaded to a Data Reader for analysis via special Cooper Power Systems Data Reader Software ou SETTING THE CL 4C CONTROL FOR SERVICE There a total of 41 parameters on the CL 4C Control which are user selecta
136. oltage Demand H L P 1 78 Percent Current For Automatic 1 2 31 Compensated Voltage Demand H L P 1 79 Percent Current For Automatic 2 2 32 Load Current Demand H L P 1 VOLTAGE LIMITER OPTION 33H Power Factor Max kVA Demand 80 Voltage Limiting Mode 2 33L Power Factor Min kVA Demand 0 Off 1 High Limit Active Only 34 kVA Load Demand H L P 1 2 High and Low Limits Active 35 kW Load Demand H L P 1 81 High Voltage Limit 2 36 kVAR Load Demand H L P 1 82 Low Voltage Limit 2 38 MASTER DEMAND RESET 1 WATCHDOG DIAGNOSTICS 90 Number of Defaults CONFIGURATION 91 Self Test 40 Regulator Identification 2 93 Number of EEPROM Corrections 3 41 Regulator Configuration 2 94 Number of Resets 3 0 1 Delta Lag 2 Delta Lead 95 System Status Code Read only 3 42 Control Operating Mode 2 0 All Systems Good 0 Sequential 1 EEPROM Write Failure 1 Time Integrating 2 Voltage Averaging 2 EEPROM Erase Failure 43 System Line Voltage 2 3 Frequency Detection Failure 44 Potential Transformer Ratio 2 4 No Sampling Interrupt 45 Current Transformer Primary Rating 2 5 Analog to digital Converter Failure 46 Demand Time Interval 2 6 Invalid Critical Parameters 7 No Source Voltage Detected CALIBRATION 8 No Output Voltage Detected 47 Voltage Calibration 3 9 Source amp Output Voltage Detected 48 Current Calibration 3 SECURITY ACCESS 96 Level 1 Security Code 3 97 Level 2 Security Code 3 KEY ENTRY ERROR CODES 98 Level 3 Security Code 3 If an error is
137. on These modes and their corresponding codes are 0 Sequential 1 Time Integrating 2 Voltage Averaging SEQUENTIAL This is the standard mode of response incorporated on all Cooper Power Systems CL series Regulator Controls When the load voltage goes out of band the time delay circuit is activated At the end of the time out a tap change is initiated Afler each tap change a 2 second pause occurs to permit the control to sample the voltage again This sequence continues until the voltage is brought into band at which time the timing circuit is reset Any time the voltage goes in band the timer is reset TIME INTEGRATING When the load voltage goes out of band the time delay circuit is activated At the end of the time out a tap change is initiat ed After each tap change a 2 second pause occurs to permit the control to sample the voltage again If the voltage is still out of band another tap change is performed This sequence continues until the voltage is brought into band When the voltage goes in band the timer is decremented at the rate of 1 1 seconds for every second elapsed until it reaches zero VOLTAGE AVERAGING When the load voltage goes out of band the time delay circuit is activated During this time delay period the microproces sor monitors and averages the instantaneous load voltage t then computes the number of tap changes required to bring the average voltage back to the set voltage level When the time delay period is
138. ons for tightness 2 Check all contacts for wear refer to S225 10 2 3 Avoid removing the main core and coil assembly from the oil except when a winding failure occurs Blocking between the cover and tank lip should be employed to suspend the core and coil assembly within the oil until inspection of the tap changer or other maintenance is complete 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 lifting apparatus fail If it is necessary to remove the main core and coil assembly from the oil the following steps should be followed A The tap changer must not be subjected to temperatures above 66 C 150 F It must be removed if the unit is baked at higher temperatures B If the 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 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 the entire internal assembly to soak in the oil for at least five days before energizing E Do not test the unit until either the vacuum processing or the soak
139. ontrols have Function Codes numbered as indicated in Table 2 6 The numbering of the function codes for the production controls was changed to more logically organize the data Table 2 6 Function Codes for CL 4C Control Field Trial Function codes 12 18 27 42 and 44 48 some instantaneous metered values all reverse demand metered values the master reset and the configuration parameters have changed However the normal operational parameters forward and reverse control settings voltage reduction and voltage limiter parameter num bers have not changed Function Codes which have changed are shown in parentheses in Table 2 6 SECURITY SECURITY FUNCTION FUNCTION LEVEL FUNCTION FUNCTION LEVEL CODE CHANGE RESET CODE CHANGE RESET FOWARD CONTROL SETTINGS REVERSE CONTROL SETTINGS OPTION 0 Operation Counter 51 Set Voltage 2 1 Set Voltage 2 52 Bandwidth 2 2 Bandwidth 2 53 Time Delay 2 3 Time Dealy 2 54 Line Compensation Resistance 2 4 Line Compensation Resistance 2 55 Line Compensation Reactance 2 5 Line Compensation Reactance 2 56 Reverse Sensing Method 2 O Locked Forward 1 Locked Reverse INSTANTANEOUS METERING OPTION 2 Reverse Idle 3 Non Latching 6 Load Voltage Secondary 4 Neutral Idle 5 Co Generation 7 Source Voltage Secondary 57 Reverse Threshold Value 2 8 Load Center Voltage Secondary 9 Load Current Primary COMMUNICATIONS 10 Load Voltage Primary kV Channel 1 Baud Rate 2 11 Source Vo
140. or recognizing the voltage condition as low and out of band issues an output which activates the LOW band indicator in the display and starts an internal timer which is equivalent to the time delay setting 4 During the time out period the voltage is continually sensed and sampled Should the voltage momentarily move into band the timer is reset 5 At the end of the time delay period the microprocessor issues an output which causes the RAISE relay coil to be energized 6 The tap changer motor begins to turn as a result of the relay closure and a cam on the tap changer closes the RAISE holding switch This now provides an alternate source for the motor current which passes through the input terminals 1 and 3 on the circuit board 7 The microprocessor now recognizes that current is flowing in the holding switch circuit and performs two actions 1 the operations counter is incremented and 2 the RAISE relay is de energized thus opening its contacts 8 As a result of the relay contacts opening the motor current is now carried solely by the holding switch circuit When the motor rotation is complete the holding switch opens as a result of the cam action and the motor stops 9 The microprocessor recognizes that the tap change is now complete by detecting that motor current is no longer flow ing through input terminals 1 and 3 A two second pause then occurs allowing the sensing voltage to stabilize from th
141. or taking local control by an interconnected SCADA system or by the voltage limiter accessory LOCAL Function Code 70 1 Local manual voltage reduction can be performed by select ing the local mode of operation Function Code 70 1 and then entering into Function Code 72 the amount of reduction required as a percentage of the set voltage This has the effect of lowering the set voltage of the control by that percentage i e the control now regulates to this reduced voltage level When voltage reduction is occurring regardless of the mode of activation LOCAL REMOTE or AUTOMATIC the V RED annunciator turns on and the percentage of reduction taking place is available for display at Function Code 71 Example If the regulator is set for 123V voltage seeing and 4 696 voltage reduction is required set Function Code 70 1 and program Function Code 72 4 6 The regulator will tap down 5 7 volts 4 696 of 123V immediately following the time delay period The V RED annunciator will be on and Function Code 71 will display 4 696 REMOTE Function Code 70 2 The CL 4C Control offers three levels of remote voltage reduc tion which may be selected through two customer input termi nals This is accomplished by first setting Function Code 70 2 and then activating either input 1 input 2 or both inputs simul taneously The percentage of reduction to be performed in each case is programmed into Function Codes 73 74 and 75 for
142. parts Replacement motor kit A 3014 Figure 6 2 with sprocket and pin Main movable contact right hand 3007 Figure 6 2 Main movable contact left hand 3006 Figure 6 2 Main stationary contact 3002 Figure 6 2 Reversing stationary contact 3004 Figure 6 2 right hand Reversing stationary contact left hand 3003 Figure 6 2 Reversing movable 3022 Figure 6 2 contact 928D Reversing movable 3005 Figure 6 2 contact 170C 770B Direct drive tap changer parts Replacement motor kit A 3031 Figure 6 4 use old shield Replacement motor shield 3068 Figure 6 3 Main or reversing 3059 Figure 6 3 movable contact Main stationary contact 30s3 Figure 6 3 Reversing stationary contact 3067 Figure 6 3 Reversing stationary neutral 3057 Figure 6 3 contact non arcing Part Description Code No Reterence Figure 66 Direct drive tap changer parts Replacement motor kit A 3041 Figure 6 4 Main movable contact 3029 Figure 6 4 Main stationary contact 3023 Figure 6 4 Reversing stationary contact 3037 Figure 6 4 Reversing stationary neutral 3027 Figure 6 4 contact non arcing Reversing movable contact 3036 Figure 6 4 e CLcontrol parts Complete CL 4C control 6505 not shown includes 6500 back panel cabinet no cable CL 4C front panel only 6500 Figure 2 1 includes all operational electronics of control Neutral light bulb 6051 Figure 2 1 Motor fuse 6A pack of 5 6047 Figure 2 1 Panel fuse 2A pack of 5 604
143. power flow 2 6 VR 32 Regulator and CL 4C Control FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 06 Load Voltage Secondary v 0 N A N A N A N A N A This is the fundamental RMS voltage referred to the secondary which appears at the output load terminals of the regulator Since ratio correction is performed by the software this parameter is scaled according to the inputs at Function Code 44 PT Ratio and Function Code 43 System Line Voltage FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 07 Source Voltage Secondary v 0 N A N A N A N A This is the fundamental RMS voltage referred to the secondary which appears the input source terminals of the regulator Since ratio correction is performed by the software this parameter is scaled according to the inputs at Function Code 44 PT Ratio and Function Code 43 System Line Voltage An optional differential or source voltage must be added to obtain this parameter Lack of this voltage will result in this para meter displaying dashed Refer to page 2 25 FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMET
144. proper level is now activated Access Function Code 48 by keying FUNCTION 48 ENTER The display will show the current applied to the control This should correspond to the reading on the reference ammeter If the CL 4C Control reading is significantly different greater than 6 milliamps error the calibration can be altered by keying CHANGE and then entering the correct current as displayed on the reference meter followed by ENTER The current circuit is now calibrated 9225 10 4C NOTES 4 4 VR 32 Regulator and CL 4C Control ACCESSORIES Section 5 HEATER ASSEMBLY The thermostatically controlled heater assembly Figure 5 1 is best used in high humidity areas The heater assembly contains an ON OFF toggle switch In the ON position the thermostat in the heater assembly will turn the heater on when the temperature falls below 85 F and off when the temperature exceeds 100 F For full details refer to S225 10 1 Supplement 2 HEATER Figure 5 1 Heater WC d v SESS N PNE m nee Figure 5 2 Data Reader and Software Kit DATA READER The optional hand held DATA READER allows the operator to copy all of the Function Code parameters from the CL 4C Control for transfer to a personal computer operation of the control is not affected by the DATA READER The DATA READER can store data from 100 different CL 4C Controls before
145. r Into Service Regulators can be placed in service without interrupting load continuity WARNING Closing the bypass switch with the tap changer off neutral will short circuit part of the series winding Before closing the bypass switch the regulator must be on NEUTRAL and the control switch set to OFF Procedure A should be followed when one bypass switch and two disconnect switches are used Procedure B should be followed when a regulator bypass disconnect switch is used Figure 1 5 Knife switches and TB1 with optional V6 knife switch and RCT2 CAUTION When installing a regulator solidly ground both the regulator tank AND the con trol Failure to do so may cause damage to the regu lator and or control due to current surges and may subject personnel to electrical shock A threaded stud is provided at the bottom of the control enclosure for grounding purposes PROCEDURE A ONE BYPASS SWITCH AND TWO DISCONNECT SWITCHES 1 2 3 12 Verify from the regulator nameplate that the control circuit is connected for the proper regulated load voltage Set the POWER switch to OFF and the CONTROL switch to OFF The knife switches on the back panel should be set with the V1 potential switch and V6 if present closed pushed in and the C CT shorting switch open pulled out See Figure 1 5 Close the SOURCE LOAD SL disconnect switch Delta appli cations only Close the SO
146. r source voltage must be added to obtain this parameter Lack of this voltage will result in this parame ter displaying dashes Refer to page 2 25 default value of Reset means that the parameter is reset to the present value 2 13 5225 10 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 38 Master Demand Reset 1 Entry of this code will reset all demand parameters Maximum H and minimum L values will be set to their corresponding present P demand value f the present demand is in an invalid stae dashes the maximum and minimum values will also become invalid displaying dashes FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 40 Regulator Configuration 0 2 N A 12345 1 32766 Provision is made for entry of a number to uniquely identify each CL 4C Control The serial number of the control as shown on the decal on the back of the front panel was entered at Function Code 40 at the factory However any other number within the limits defined above may be chosen instead This permits easy identification when data is collected via the Data Reader
147. ral light switch opens 8 Geneva pinion completes second revolution and continues to rotate 9 Geneva pinion drives the geneva gear main drive shaft and scroll cam through 60 degrees and produces final wipe action at the front main movable and reversing movable contacts 10 Motor holding switch opens 11 Motor brake engages 12 Motor stops Atap change from No 1 raise position to neutral will be accom plished as described except the geneva pinion will rotate clock wise The reversing movable contact will be transferred from the reversing stationary contact VR to the stationary contact VL VR 32 Regulator and CL 4C Control TROUBLE SHOOTING GUIDE Section 4 COMPLETE REGULATOR IN SERVICE WARNING When trouble shooting energized equipment caution should be taken to wear pro tective gear and to avoid personal contect with ener gized parts Failure to do so may cause serious injury or death External Check When service personnel arrive at what appears to be a mal functioning regulator it is advisable to examine the power con nections first For example verify that the source lead is con nected to the source bushing that the load lead is connected to the load bushing and that the source load lead is connect ed to the source load bushing Check other potential prob lems such as an open ground connection Defining The Problem Page 1 19 Figure 2 19 page 2 37 can be used while diag no
148. riable voltage source so the applied voltage is at least 5 volts above the control voltage setting Note that the HIGH band annunciator in the display will come on After the time delay period the control will issue LOWER tap change signals Check to ensure that the operations counter is registering tap changes by pressing the O key on the keypad Permit the tap changer to operate for ap proximately eight to ten steps SPECIFICATIONS A Physical size B Weight C Burden 120 V D Operating Temperature Range E Control System Accuracy F Metering Accuracy VOLTAGE INPUTS 2 output Voltage and Differential Source Voltage 80 170 volts a c 45 to 65 Hz with error not to exceed 0 5 of the reading under all conditions The CL 4C Control will withstand up to 170 volts without damage or loss of calibration CURRENT INPUT 0 0 400 amps a c 45 to 65 Hz with error not to exceed 0 6 0 0012 amps of the nominal full load current 0 200 amps under all conditions The CL 4C Control will withstand the short circuit rating of the regulator without damage or loss of calibration CALCULATED VALUES kVA kW kVAR 0 9999 with error not to exceed 1 under all conditions HARMONIC ANALYSIS Current and Voltage Harmonics 3 5 7 9 11 th harmonic frequencies with error not to exceed 5 under all conditions Basic accuracy of the device excluding P T ana C T errors 10 1 4 W 17 1 2 H 2 1 2 D 11 1 2 Ibs
149. riod of time in seconds that the control waits from the time when the voltage first goes out of band to the time when the relay closure occurs during reverse power flow See Reverse Power Operation page 2 25 FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 54 Line Compensation Resistance Reverse v 0 2 0 0 24 0 24 0 The resistive line drop compensation value is used to model the resistive line losses between the regulator and the theoretical load center The CL 4C Control uses this parameter in conjunction with the load current flow to calculate the compensated voltage displayed at Function Code 8 during the reverse power flow See Reverse Power Operation page 2 25 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 55 Line Compensation Reactance Reverse v 0 2 0 0 24 0 24 0 The reactive line drop compensation value is used to model the reactive line losses between the regulator and the theoretical load center The CL 4C Control uses this parameter in conjunction with the load current flow to calculate the compensated voltage displayed at Function Code 8 during the reverse power flow See Rev
150. rounded Arrester Rating Single Phase Wye Ratings 2500 4330Y 2400 2400 4160 2500 2500 4330 3 4160 4160 7200 5000 8660Y 4330 4330 7500 4800 4800 8320 6 5000 5000 8660 6900 6900 11950 7620 13200Y 7200 7200 12470 9 7620 7620 13200 7970 7970 13800 10 12000 12470 13800 13200 15 13800 14400 13800 23900 14400 24940Y 14400 24940 18 19920 34500GrdY 19920 34500 27 Position Indicator amp ADD AMP Capability The position indicator Figure 1 8 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 numbered 1 through 16 on each side of zero which designates neutral Drag hands indicate the maximum and minimum positions attained during raise and lower operations The drag hands are automatically reset around the position indicator hand by operating the drag hand reset switch on the control front panel Figure 1 8 Position Indicator The ADD AMP feature of VR 32 regulators allows increased cur rent capacity by reducing the regulation range This is accom plished by setting limit switches in the position indicator to prevent the tap changer from traveling beyond a set position in either raise or lower directions The limit switches have scales graduated in regulation and are adjustable to specific values of 5 6 1 4 7 1 2 8
151. s REGULATING ONE PHASE OF A THREE PHASE THREE WIRE CIRCUIT REGULATING A THREE PHASE THREE WIRE WYE OR DELTA CIRCUIT WITH TWO REGULATORS dress mnt cu wA e BYPASS NS NP SUMGE 1 ARRLSTL SS REGULATING A THREE PHASE THREE WIRE DELTA CIRCUIT WITH THREE REGULATORS NOTE Individual switches are shown for the bypass and dis connect 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 Mounting A regulator can be mounted on a pole crossarm plafform or elevating structure optional Regulators are normally provid ed with either pole mounting brackets or a station plafform according to the rating This information is available in Table 3 1 page 3 1 by noting the S Substation suffix to the kVA Cooper Power System s elevating structure Figure 1 4 can be used to simplify substation installation of regulators requir ing 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 lengths of 15 20 25 30 and 35 ft for intercon nection between the control and the regulator Figure 1 4 Elevating structure 9225 10 4C Placing A Regulato
152. s is the secondary output voltage of the regulator as a demand value according to the demand time interval at Function Code 46 H maximum value since last reset L minimum value last reset and P present value Scroll to the L and P values FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 21 H L P Compensated Voltage Demand Forward v 0 1 Reset This is the calculated secondary voltage the load center as a demand value according to the demand time interval at Function Code 46 The line compensation settings for resistance and reactance Function Codes 4 and 5 are used in this calculation H maximum value since last reset L minimum value last reset and P present value Scroll to the L and P values FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 22 H L P Load Current Demand Forward A 0 1 Reset This is load curent as demand value according to the demand time interval at Function Code 46 H maximum value since last reset minimum value last reset and P present value Scroll to L and P values default value of Reset me
153. s the RAISE LOWER switch to return the tap changer to neutral position These steps verify the mechanism is functional When on neutral the NEUTRAL LAMP will glow and the position indicator will point to zero Remove the 120 volts from the EXTERNAL SOURCE terminals With the regulator in neutral position set the CONTROL switch to OFF set the POWER switch to OFF and remove the 6A motor fuse Close the SOURCE LOAD SL disconnect switch Delta applications only Close the regulator bypass disconnect switch Replace the 6A motor fuse close the V1 knife switch and V6 if present open the C knife switch and set the POWER switch to INTERNAL Go to Setting the CL 4C for Service page 1 6 1 5 VR 32 Regulator and CL 4C Control Setting The Control for Service If the control has been previously set up skip to Operational Check page 1 8 If the control had not previously been set up before installing the regulator perform the following steps for basic operation set voltage bandwidth time delay resistive line compensa tion reactive line compensation regulator configuration system line voltage the P T ratio and the C T primary rating Additional instructions are also available in Section 2 starting at page 2 1 for turning on and setting up the various accessories With the control now energized the display should be showing PASS Be certain the control switch is in the OFF position To gain acces
154. s the voltage which the control is regulating This value takes into consideration the software ratio correction and any line drop com pensation being used Additionally if the regulator is equipped for reverse power operation the voltage displayed at Function Code 8 will be correct even during reverse power conditions The volt age measured at the test terminals however will reflect the input SOURCE voltage instead of the output LOAD voltage REMOVAL FROM SERVICE Determining Neutral Position WARNING Closing the bypass switch with the tap changer off neutral will short circuit part of the series winding Before closing the bypass switch the regulator must on NEUTRAL and the control switch set to OFF Return the regulator to neutral The regulator can be safely removed from service without interrupting load continuity only on the neutral position It is wise to employ more than one method to determine whether a regulator is on neutral To Return The Regulator To Neutral 1 Use the control to RAISE or LOWER the regulator until it is in the neutral position 2 When on NEUTRAL the NEUTRAL LAMP will light and the POSITION INDICATOR will point to zero 3 To stop the regulator on the neutral position the CONTROL switch should be turned to OFF during the switching opera tion from position 1 to position zero Switching to OFF prior to reaching the neutral position prevents overshoot 4 The POSITION INDICATO
155. s to the system for CHANGING parameters depress the following keys to activate the security system FUNCTION 99 ENTER 12121 ENTER The security system is now activated for changing operational settings SET VOLTAGE KEYS TO DEPRESS DISPLAY DESCRIPTION 1 ENTER 01 120 0 This is the set voltage as shipped from the factory CHANGE 01 Enter the desired value example 122 2 1222 ENTER 01 122 2 The set voltage is now 122 2 volts BANDWIDTH TO CHANGE KEYS TO DEPRESS DISPLAY DESCRIPTION 2 ENTER 02 20 This is the bandwidth as shipped from the factory CHANGE 02 Enter the desired value Example 4 5 45 ENTER 02 4 5 The bandwidth is now 4 5 volts TIME DELAY TO CHANGE KEYS TO DEPRESS DISPLAY DESCRIPTION 3 ENTER 03 30 This is the time delay as shipped from the factory CHANGE 03 Enter the desired value example 49 49 ENTER 03 49 The time delay is now 49 seconds LINE COMPENSATION RESISTANCE KEYS TO DEPRESS DISPLAY DESCRIPTION 4 ENTER 04 00 This is the resistive compensation as shipped from the factory CHANGE 04 Enter the desired value Example 8 5 85 ENTER 04 8 5 The resistive compensation is now 8 5 volts LINE COMPENSATION RESISTANCE TO CHANGE KEYS TO DEPRESS DISPLAY DESCRIPTION 5 ENTER 05 0 0 This is the reactive compensation as shipped from the factory CHANGE 05 Enter the desired value example 3 5 35 ENTER 05 3 5 The reactive compensation is now 3 5 volts R
156. set by the factory If the regulator is installed on any other system voltage the corresponding ratio must also be entered for proper operation KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 44 ENTER 44 60 0 This is the regulator configuration as shipped from the factory CHANGE 44 Enter the desired value Example 40 0 400 ENTER 44 40 0 The P T ratio is now 40 0 1 CURRENT TRANSFORMER PRIMARY RATING The CL 4C is designed for 200 mA as the rated C T current and will meter to 400 mA 200 load with no loss of accuracy Ratio correction is performed by the software and consequently the C T primary rating must be entered The C T primary rating is avail able on the regulator nameplate Example If a C T ratio of 250 0 2 is indicated on the nameplate then 250 must be entered at Function Code 45 Table 2 5 on page 2 35 summarizes the C T primary ratings for all standard regulator reatings Perform the following steps to program the C T primary rating into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION FUNCTION 45 ENTER 45 200 This is the C T primary rating for a 200A regulator CHANGE 45 Enter the desired value example 250 250 ENTER 45 250 The C T primary rating is now 250 amps The CL 4C Regulator Control is now set for basic operation C McGRAW EDISON v oret ee VOLTAGE REGULATOR SINGLE PHASE STEP VOLTAGE REGULATOR VA 32 55 65 C RISE HZ CLASS OA KVALG 7 18
157. shaft A In early 1986 this joint was changed to a set screw type coupling B Older equipment employed a cotter pin coupling 4 Disconnect the four leads from the junction box terminal board and open the two splice terminals to the control cable 5 Remove the three bolts holding the indicator to the junc tion box and slide the indicator free 6 Remove the gasket from the groove on the back of the indicator body 7 Clean the gasket surface of the junction box and the gas ket and groove on the new indicator 8 Place the gasket in the groove and insert the leads through the junction box wall align the holes and install the three bolts finger tight 9 Wrench tighten the bolts to evenly compress the gasket and bring the indicator body tight against the junction box 10 Connect the six leads to the terminal board and control cable leads per Figure 4 1 and secure all connections 11 Turn the indicator drive shaft to place the hand at the pre viously noted position 12 Slide the flexible shaft coupling over the indicator shaft and secure the joint 13 Position the wire to prevent snagging on the coupling or cotter pin Secure with the wraps 14 Connect a 120 volt ac external power supply to the control 15 Run the tap changer manually to verify alignment of the position indicator hand and the neutral light If correction is required A Stop the tap changer with the neutral light on B Disconnect the flexible shaft fro
158. sing station ary contacts and drives the main movable contact onto the adjacent main stationary contact Also the neutral light switch opens 13 Motor continues to turn the sprocket cam until the motor holding switch opens The gear motor output shaft has com pleted one revolution Should more than one tap change be required the foregoing sequence will be repeated except reversing switch portion until the control is satisfied or the limit switch in the position indicator is reached OPERATING SEQUENCE Direct drive When the switch is in neutral and the control calls for a tap change in the raise direction the following events occur 1 Motor brake releases and motor starts 2 Geneva pinion rotates counter clockwise to engage the geneva gear 3 Geneva pinion drives the geneva gear main drive shaft and scroll cam through 60 degrees and produces initial wipe action at the front main movable contact and reversing mov able contacts 4 Motor holding switch closes assuring that one tap change will be completed 5 Geneva pinion completes first revolution and continues to rotate 6 Geneva pinion drives the geneva gear through 60 degrees and the scroll cam and roller plates transfer the front main movable contacts from the neutral stationary contact N to the stationary contact No 1 Simultaneously the reversing movable contact is transferred from the reversing stationary contact VL to the stationary contact VR 7 Neut
159. sing the problem After the external power connections have been checked check the voltage disconnect knife switch V1 and V6 if pre sent and the current shorting knife switch C of the rear panel signal circuit in the control box Close the voltage dis connects if open Open shorting switch if closed Check for loose connections or burnt wiring Make sure ratio correcting transformer RCT1 is on the cor rect tap for the regulated voltage shown on the nameplate on the control box door Remove the motor and panel fuses from the control and check for continuity across each fuse Spares if needed are included with the control NOTICE Use only 350 volts ac slow blow ceramic fuses of the proper current rating Failure to do so may cause unnecessary fuse operation or insufficient protection of the regulator and control If the above checks do not identify the problem determine which of the following three categories best describes the mal function and follow the corresponding diagnostic steps THE REGULATOR WILL NOT OPERATE MANUALLY OR AUTOMATICALLY Diagnosing trouble A Set the CONTROL switch on RAISE B Measure the voltage between terminals R1 and G on termi nal board TB1 The voltage reading should be approximate ly the set voltage setting C Set the CONTROL switch on LOWER D Measure the voltage between terminals L and G on termi nal board TB1 The voltage reading should be approximate ly the set vo
160. sition Indicator Replacement on page 4 3 8 Check the reset solenoid of position indicator Push the DRAG HAND RESET switch while measuring the voltage between DHR and G on the terminal board The voltage reading should be approximately 120 volts ac and DRAG HANDS will reset A If 120 volts is read and drag hand will not reset refer to 1 Remove the regulator from service as stated on page 1 8 Position Indicator Replacement on page 4 3 2 Ground the three high voltage bushings B If 120 volts is not read refer to Control Trouble Shooting 3 Open V disconnect switch on rear panel of control cabinet on page 4 1 4 Remove junction box lid 5 Check the wiring on the junction box terminal board for loose connections burnt wiring or bad swage joints 6 A Setthe POWER switch to EXTERNAL HS OHG BLK CC ORG BLK CC RED AVAILABLE LEAD CC BLK FOR ACCESSORIES POSITION INDICATOR RLS BLU JUNCTION oor 1 7 BOX LOWER LIMIT 2452 TERMINAL SWITCH LLS 54 BHR BOARD 88 L GRN BLK I C wes CC GRN BLK 4 RAISE LIMIT 20 HS G SWITCH RLS 21 CC WHT BLK 4 M2 JBB R BLU L POS IND M LLS GRN BLK RESET T CC ORG SOLENOIDS JBB DHR ORG BLK CC RED BLK pe 5 J CC GRN fee CC WH RS WH 10 CONDUCTOR CABLE UU Figure 34 1 Junction box wiring diagram TO CONTROL 4 2 VR 32 Regulator and CL 4C Control Position Indicator Replacement
161. t NOTE The neutral stationary contact in the direct drive tap changer has both arcing and non arcing contact conditions All stationary contact bodies are made of ETP copper Copper tungsten inserts are brazed to the edges of the station ary contacts since those contacts are subject to damage from impact or arcing duty The main movable contacts are con structed of a coppertungsten The contacts are split to make contact on both sides of the stationary contacts This split resists separation in the event of high current surges The direct drive tap changer stationary contact body is cop per Copper tube spacers and steel bolts are employed to fas ten all parts and provide a high conductivity current path The reversing movable contacts are the same construction as the main movable contact The 660C direct drive tap changer employs a double set of reversing movable contacts and silver tungsten arcing ends to satisfy the high current rating Contact erosion is a function of many variables such as tap voltage load current power factor reactor design and tapped winding design Stationary contacts should be replaced before the arcing inserts erode to the point where there may be burning on the copper Movable contacts should be replaced when approxi mately 1 8 in of smooth rubbing surface remains Refer to S225 10 2 for complete information and typical erosion pat terns for the various stages of contact life OPERATING SEQUENCE Spr
162. t Regulation 13 Power Factor 14 kVA Load 15 kW Load 16 kVAR Load 17 Line Frequency 18 Voltage Harmonics 19 Current Harmonics FORWARD DEMAND METERING 20 Load Voltage Demand Forward 21 Compensated Voltage Demand Forward 22 Load Current Demand Forward 23H Power Factor Max kVA Demand Forward 23L Power Factor Min kVA Demand Forward 24 kVA Load Demand Forward 25 kW Load Demand Forward 26 kVAR Load Demand Forward 27 Max Boost Min Buck 28 Max Buck Min Boost REVERSE DEMAND METERING 30 Load Voltage Demand Reverse 31 Compensated Voltage Demand Reverse 32 Load Current Demand Reverse 33H Power Factor Max kVA Demand Reverse 33L Power Factor Min kVA Demand Reverse 34 kVA Load Demand Reverse 35 kW Load Demand Reverse 36 kVAR Load Demand Reverse 38 MASTER DEMAND RESET CONFIGURATION 40 Regulator Identification 41 Regulator Configuration 0 Wye 1 Delta Lag 2 Delta Lead 42 Control operating Mode 0 Sequential 1 Time Integrating 2 Voltage Averaging 43 System Line Voltage 44 Potential Transformer Ratio 45 Current Transformer Primary Rating 46 Demand Time Interval CALIBRATION 47 Voltage Calibration 48 Current Calibration 52 Bandwidth Reverse 53 Time Delay Reverse 54 Line Compensation Resistance Reverse 55 Line Compensation Reactance Reverse 56 Reverse Sensing Mode O Locked Forward 1 Locked Reverse 2 Reverse Idle 3 Bi directional 4 Neutral Idle 5 Co generation 57 Re
163. t flowing through these elements produces voltage drops which simulate the voltage drops on the primary line For the CL 4C Control the input current is sampled and is used in a computer algorithm which calculates the respective resis tive and reactive voltage drops based upon the line drop compensation values programmed into the control at Function Codes 4 and 5 or Function Codes 54 and 55 This is by far a more accurate and economical means of developing the compensated volt age To select the proper R and X values the user must know several factors about the line being regulated See reference docu ment R225 10 1 for assistance in this determination F C PARAMETER RANGE FACTORY SETTING 4 LINE COMPENSATION RESISTANCE 24 0 24 0 0 0 Perform the following steps to program the resistive compensation into the CL 4C Control KEYS TO DEPRESS DISPLAY DESCRIPTION 4 ENTER 04 00 This is the resistive compensation as shipped from the factory CHANGE 04 Enter the desired value Example 8 5 85 ENTER 04 8 5 The resistive compensation is now 8 5 volts 2 33 5225 10 4 C PARAMETER RANGE FACTORY SETTING 5 LINE COMPENSATION REACTANCE 24 0 24 0 0 0 Perform the following steps to program the reactive compenation into the CL 4C KEYS TO DEPRESS DISPLAY DESCRIPTION 5 ENTER 05 0 0 This is the reactive compensation as shipped from the factory CHANGE 05 Enter the desired value example 3 5 35
164. tly different because A The CL 4C metering and operation is based upon the RMS value of the 60 Hz 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 calculation of the RMS voltage This does not represent 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 6V out of 120V and still be considered to be incalibration The CL 4C 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 CL 4C control is designed to perform ratio correction 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 volt base voltage However there are some ratings in which this voltage is not fully corrected by the RCT Column 6 in Table 2 1 page 2 4 gives a general indication of these voltages but always refer to the nameplate which provides the specific information for the particu lar regulator The voltage displayed at Function Code 8 compensated voltage i
165. to occur as each parameter is accessed If one of the three values does not match the different value will be corrected to agree with the other two This will also be counted as an EEPROM correction and the number of EEPROM Corrections Function Code 93 will be increased by 1 If all three values are different a default value one that is chosen as a representative value and programmed into ROM will be used for that particular parameter If a setting parame ter defaults the Number of Defaults Function Code 90 will be increased by 1 Additionally when interrogated the param eter s that defaulted will display a d preceding the value to indicate it is a default The CL 4C Control will continue to operate using the default value s Three parameters cannot default to a predetermined value because no logical choice is possible The three parameters Regulator Configuration Function Code 41 System Line Voltage Function Code 43 and P T Ratio Function Code 44 will revert to an invalid status and will display dashes preceded by a 9 Anything dependent upon these values will cease to function and Function 95 will display a 6 to represent invalid critical parameters DIAGNOSTICS There are three events which force the CL 4C Control into the self diagnostic routines 1 The power is first turned on 2 oper ator entry of the Self Test Mode Function Code 91 or 3 MER TOSA detects a software proble
166. unction Code 8 Place the CONTROL switch on AUTO After the time delay period the regulator should step up to within the lower band edge Example 120v and 2v band width 119v lower band edge To assure that none of the control settings have defaulted the default counter Function Code 90 must be checked This is accomplished by keying FUNCTION 90 ENTER The num ber displayed should be zero If any number other than zero is displayed then all control settings will need to be examined to find the defaulted parameter and when located changed to its correct value A defaulted parameter will indicate d on the display If you ARE NOT using the communications capability you are finished with the in service operation check If you ARE using the communications capability continue as directed If you changed the control from the automatic operation inhib ited mode you will need to change it back To do this press FUNCTION 69 ENTER and type 1 You are now back in the automatic operation inhibit mode Place the tap changer back into the position you recorded ear lier Flip the toggle switch located on the lower left of the back panel back on You are now finished with the in service opera tional check 9225 10 4C Table 2 1 VR 32 Tap Connections and Voltage Levels Nominal Test Overall Regulator Single Ratio Adjusting Data Terminal Potential Voltage Phase Internal PT RCT Voltage Ratio
167. ut reports the FAIL message then the internal diagnostics have detected a problem The details of this internal process are described in the control section fabled SYSTEM PROTECTION DIAGNOSTICS page 2 31 The front panel circuits for the DRAG HAND RESET solenoid COMES and NEUTRAL LIGHT NL can be checked as follows Connect the ac volt meter from G to DHR on fanning strip TB2 identified as white wire G and white orange tracer DHR 2 Depress the DRAG HAND RESET toggle switch and observe approximately 120 volts on the voltmeter If no voltage is measured the switch is probably defective 3 Connect the ac voltmeter from G to NL on fanning strip TB2 identified as white wire G and white red tracer NL 4 Activate the NEUTRAL LAMP TEST toggle switch and observe approximately 120 volts on the voltmeter and note that the neutral light should come on If no voltage is mea sured and the light does not come on the switch is proba bly defective If voltage is measured but the light does not come on the lamp or lamp holder is defective Junction Box Trouble Shooting This section is used if the regulator will not operate manually Problem was isolated to junction box or regulator tank after checking out control on page 4 1 The junction box is composed of a terminal board the position indicator and the control box interconnections Refer to Figure 4 1 when the following steps are made B Apply a 60 50 Hz 120 volt ac nom
168. ut voltage P T These taps are also located on the tap changer terminal board The potential is then brought directly to the knife switch labeled V6 and then passes through a second RCT for ratio correction simi lar to that performed for V1 The ratio differential V6 voltage now labeled V7 is then routed to the control front panel On the front panel the three potentials Vs sensing voltage V7 differential voltage Vm motor voltage are all brought directly to the power switch The normal application would not have the V7 differential voltage installed In these cases the V7 terminal is connected to the Vs terminal on the control back panel and the CL 4C Control software then recognizes that the V7 voltage is not present The power switch has three positions INTERNAL OFF EXTERNAL The INTERNAL position powers the control from the regulator sensing winding and the EXTER NAL position permits an external 120V supply be used to operate the tap changer and control When the power switch is in the external position the internal supply is disconnected to prevent accidentally energizing the high voltage winding and bushings The external source terminals are prominently located adjacent to the voltmeter test terminals The voltmeter terminals allow the monitoring of the voltage that is applied to the circuit board which is the voltage output from the RCT and the voltage displayed at Function Code 47 on the CL 4C Control 2 41 92
169. ve calibration factors are programmed into ROM for use in the event the working memory experiences a default condition 2 15 9225 10 4C FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER oF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 51 Set Voltage Reverse v 0 2 120 0 100 0 135 0 The set voltage is the voltage level to which the control will regulate on 120 volt base during reverse power flow See Reverse Power Operation page 2 25 FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 52 Bandwidth Reverse v 0 2 2 0 1 0 6 0 The bandwidth is defined as that total voltage range around the set voltage which the control will consider as a satisfied in band condition during reverse power flow Example A band width of 3 volts and a set voltage of 120 volts will establish a low limit of 118 5 volts and a high limit of 121 5 volts See Reverse Power Operation page 2 25 FUNCTION FUNCTION UNIT SECURITY LEVEL KEY ENTRY LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 53 Time Delay Reverse sec 0 2 N A 30 5 180 The time delay is the pe
170. vent any further power from being applied to the motor except through the holding switch When the holding switch opens the current relay contacts close returning control of the tap changer to one of the operational methods of control AUTO MANUAL or SCADA Figure 2 24 shows the basic scheme and the function of the current relay This general scheme applies to all McGraw Edison CL regulator controls but the wiring changes necessary to achieve the scheme differ with the different controls The block ing contact shown in Figure 2 23 inhibits automatic operation of the regulator when the normally closed contact is opened VOLTAGE REDUCTION The use of voltage reduction is common with SCADA schemes Figure 2 25 shows a typical voltage reduction method The input voltage to the control is applied between V in and common The output voltage V out to common is applied to the sensing circuit If relay K is energized V out is greater than V in and when this increased voltage is applied the sensing circuit causes the con trol to lower voltage by the amount of increase Various levels of voltage reduction may be selected depending upon the number and value of each tap on the auto transformer The total range is usually 0 to 10 NoTE This discussion assumes that the Cooper Power Systems voltage reduction accessory is not being used and SCADA equipment is being connected directly to the bare CL 4C Control Refer to Figure 2 23 for proper
171. verse Threshold generation COMMUNICATIONS 60 Data Port Baud Rate 61 Interface Port Baud Rate 62 Channel 1 Status 63 Channel 2 Status 64 Control Communications Address 65 Communications Port Baud Rate 66 Communications Port Handshake Mode 67 Communications Port Resynch Time Characters 68 Communications Port Transmit Enable Delay 69 REGULATION BLOCKING STATUS VOLTAGE REDUCTION 70 VOLTAGE LIMITER 80 81 82 WATCHDOG DIAGNOSTICS 90 Number of Detaults 91 Self Test 93 Number of EEPROM Corrections 94 Number of Resets 95 System Status Code SECURITY ACCESS 96 Level 1 Secunty Code 97 Level 2 Secunty Code 98 Level 3 Security Code 99 Enter Security Code Voltage Reduction Mode O off 1 Local 2 Remote 3 Automatic With Remote override Reduction In Effect Local Voltage Reduction Remote Reduction Setting 1 Remote Reduction Setting 2 Remote Reduction Setting 3 Automatic Reduction Setting 1 Automatic Reduction Setting 2 Percent Current For Automatic 1 Percent Current For Automatic 2 Voltage Limiting Mode O off 1 High Limit Active only 2 High and Low Limits Active High Voltage Limit Low Voltage Limit 2 5 5225 10 4 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 00 Operation Counter 0 The operations cou
172. with Differential Potential Transformer 1 18 1 17 Rear Panel Signal Circuit 1 19 2 14 Co Generation Regulation Points 2 28 2 15 Voltage Reduction Customer Contact Points 2 30 2 19 VR 32 Regulator and CL 4C Control Wiring Diagram 2 37 2 20 VR 32 Regulator and CL 4C Control with D P T Control Wiring Diagram 2 39 2 23 SCADA Connections to CL 4C Control 2 43 2 24 SCADA Connections Basic Scheme 2 44 2 25 Typical User Provided Voltage Reduction Module 2 44 2 26 Voltage Reduction Customer Contact Points 2 44 4 1 Junction Box Wiring Diagram 4 2 SECURITY CODES The factory set security codes are as follows Security Security Level Code 0 No Code Required 1 1234 2 12121 3 32123 2 41 9225 10 4C SECURITY SECURITY FUNCTION FUNCTION LEVEL FUNCTION FUNCTION LEVEL CODE CHANGE RESET CODE CHANGE RESET FOWARD CONTROL SETTINGS REVERSE CONTROL SETTINGS OPTION 00 Operation Counter 51 Set Voltage Reverse 2 01 Set Voltage Forward 2 52 Bandwidth Reverse 2 02 Bandwidth Forward 2 53 Time Delay Reverse 2 03 Time Delay Forward 2 54 Line Compensation Resistance Reverse 2 04 Line Compensation Resistance Forward 2 55 Line Compensation Reactance Reverse 2 05 Line Compensation Reactance Forward 2 56 Reverse Sensing Method 2 0 Locked Forward INSTANTANEOUS METERING OPTION 1 Locked Reverse 06 Load Voltage Secondary 2 Reverse Idl
173. with Table 2 1 System Voltage 120 Control Voltage Internal PT Ratio RCT Tap Voltage Setting As an example consider a 13800V regulator installed 12470V system The calculation is 12470 X 120 125 Control 115 From Table 2 1 104 From Table 2 1 Voltage Setting To calculate overall Potential Ratio Function Code 44 System Voltage 12470 _ 99 7 Control Voltage Setting 125 2 4 VR 32 Regulator and CL 4C Control FUNCTION CODES All of the parameters control settings accessory settings metering values etc have been assigned a Function Code number The Function Codes are described in detail on pages 2 6 through 2 24 and will be found in numerical order The Function Codes are list ed in the table below METERING The metering parameters have been assigned Function Codes 06 through 38 Each is described in detail starting on page 2 6 Table 2 2 Function Codes For CL 4C Control FUNCTION FUNCTION CODE FUNCTION CODE FUNCTION FORWARD CONTROL SETTINGS REVERSE CONTROL SETTINGS 00 Operation Counter 51 Set Voltage Reverse 01 Set Voltage Forward 02 Bandwidith Forward 03 Time Delay Forward 04 Line Compensation Resistance Forward 05 Line Compensation Reactance Forward INSTANTANEOUS METERING 06 Load Voltage Secondary 07 Source Voltage Secondary 08 Compensated Voltage Secondary 09 Load Current Primary 10 Load Voltage Primary kV 11 Source Voltage Primary kV 12 Percen
174. y is 1234 Entry of this number at Function Code 99 permits the user to change reset only the parameters marked as Level 1 security demand readings See Security System page 2 32 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 97 Level 2 Security Code 3 3 N A 12121 1000 19999 The number to be used as the Level 2 security code is entered here The Level 2 code assigned at the factory is 12121 Entry of this number at Function Code 99 permits the user to change reset only the parameters marked as Level 2 security control settings configuration and Level 1 security code See Security System page 2 32 FUNCTION UNIT SECURITY LEVEL KEY ENTRY FUNCTION LIMIT CODE CODE PARAMETER OF TO TO TO DEFAULT EXTENSION MEAS READ CHANGE RESET VALUE LOW HIGH 98 Level 3 Security Code 3 3 N A 32123 2000 32766 The number to be used as the Level 3 security code is entered here The Level 3 code assigned at the factory is 32123 Entry of this number at Function Code 99 permits the user to change reset only any parameter NOTICE If the Level 3 code is changed by the user the new value should be recorded and kept in a safe place Loss of this code means that security codes cannot be displayed or changed diagnostic codes can
175. y to bring the voltage to the limit value If the output voltage exceeds either high or low limit by less than 3 volts the CL 4C Control samples the voltage for 10 seconds then taps to bring the voltage to the limit value The 10 second delay is used to prevent false responses to transient conditions The control uses the sequential method of tapping pausing two seconds between taps for voltage sampling when bringing the voltage back to the limit value HIGH and LOW annunciators in the display indicate when either limit is active A threshold of one volt is used for both limiting values to establish a grey zone around the limits When the output voltage is within this grey zone the control will not perform any tap changes which would take the output voltage closer to the limit If the voltage is directly on the edge of the grey zone the control will allow one tap change to permit the volt age to enter the zone by as much as 0 7 volts 127 HIGH VOLTAGE LIMIT F C 81 WWW SS J J 2 44 LL LL 126 EDGE OF HIGH GREY ZONE NORMAL RANGE OF OPERATION 120 VOLTAGE SETTING F C 1 OR 51 7ZZ 115V EDGE Ur LUW GREY ZUNE Lu lt 114V LOW VOLTAGE LIMIT F C 82 Figure 2 16 Voltage limiting grey zones SYSTEM PROTECTION All CL 4C Control inputs 15 are protected with metal oxide varistors MOVs and capacitors to prevent damage from line surges and high frequency transients This

S225-10-4C - Cooper Industries

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