The Mechanical (Type) Voltage Regulator
The mechanical type voltage regulator has the greatest number of different names often reflecting their means of operation and/or purpose:
6.1 Tap Changing Voltage Operation
6.2 Magnetic Induction Voltage Regulator Operation
6.3 Mechanical Voltage Regulator Characteristics – Power Quality vs Line Drop
6.4 Mechanical Voltage Regulator Advantages & Disadvantages
· Mechanical tap changing regulator
|
· Electromechanical voltage regulator
|
· Tap changer
|
· Electromechanical voltage stabilizer
|
· Tap-switching voltage regulator
|
· Motorized variable transformer
|
· Servo voltage regulator
|
· Magnetic induction voltage regulator
|
· Servo voltage stabilizer
|
· Magnetic induction voltage stabilizer
|
· Motorized variac
|
· Motor-driven variable autotransformer
|
· Variable autotransformer
|
· Line voltage regulator
|
· Line drop compensator
|
· On load tap changer
|
· LDC
|
· OLTC
|
· Step voltage regulator
|
· Auto-boost regulator
|
This type of voltage regulator has been in use for more than 50 years and has seen refinements throughout the years primarily with advances in control technology and servo drive systems. This type of voltage regulator dominates the electric utility market and is the most popular type outside of North America for power quality applications. As more electronics are deployed in industrial settings worldwide, the mechanical voltage regulator is being displaced by the electronic voltage regulator.
While the mechanical voltage regulator comes in a broad variety of designs they all share the characteristics of having one or more servomotors to physically move some component(s) within the unit. The purpose of this movement is to affect voltage regulation by changing the turns ratio or magnetic coupling of a transformer. Included in this type of voltage regulator are devices for power quality control as well as devices used by electric utilities for correcting voltage (line) drop in distribution lines (see Power Quality versus Line Drop Compensation below).
The two primary methods of operation used by mechanical voltage regulators are: (A) by changing the turns ratio, or (B) by altering the magnetic induction between the primary and secondary coils of a transformer by physically changing their orientation.
The two primary methods of operation used by mechanical voltage regulators are: (A) by changing the turns ratio, or (B) by altering the magnetic induction between the primary and secondary coils of a transformer by physically changing their orientation.
Contents of this section:
6 The Mechanical (Type) Voltage Regulator 6.1 Tap Changing Voltage Operation
6.2 Magnetic Induction Voltage Regulator Operation
6.3 Mechanical Voltage Regulator Characteristics – Power Quality vs Line Drop
6.4 Mechanical Voltage Regulator Advantages & Disadvantages
6.1 Tap Changing Voltage Regulator Operation
Simply said, when a transformer has an equal number of winding turns on the primary (input) and secondary (output), the input and output voltage should be equal. By adding or subtracting the number of turns on the secondary, the output voltage can be changed – up or down, respectively. Rather than physically changing the number of turns, the turns ratio can be altered by changing the location of the physical connection to the secondary. Transformers often have multiple locations (known as “taps”) for connection to the secondary to adjust the output voltage.
The mechanical tap changing voltage regulator utilizes contactors or brushes along with some type of motorized drive system to change the taps on the secondary of the transformer. A simplified diagram is shown at the right. The controller monitors the output voltage and operates the drive system to change taps until the output voltage is within the proper range. There are many variations on this type of arrangement.6.2 Magnetic Induction Voltage Regulator Operation
Another means of changing output voltage in a transformer is to alter the physical orientation of the primary and secondary relative to each other. In a transformer the primary windings produce a magnetic flux field that induces current to flow in the secondary windings. Physically repositioning the windings of the secondary within the flux field can change the amount of current induced and the output voltage.
The magnetic induction voltage regulator (or servo induction voltage regulator) changes the orientation of the transformer secondary relative to the magnetic field rather than changing taps. The magnetic induction voltage regulator may look like an electric motor having the primary windings in a cylindrical, stationary configuration (stator) and the secondary windings (rotor) inside the primary wrapped around a shaft that is supported by bearings. Unlike a motor, the secondary of the servo induction voltage regulator rotates back and forth in an arc less than 360 degrees to alter the output voltage. Like a tap switching voltage regulator, a controller measures the output voltage and uses a servomotor drive to adjust the degree of rotation of the rotor to achieve the desired output voltage.
In both, tap switching and servo induction voltage regulators, the control mechanisms range from simple analog devices to microprocessor-based controls with onboard data acquisition and communication capabilties. Falling costs, high accuracy, solidstate designs and programability favor increased use of digital controls, however analog controls can be very inexpensive and tolerant of higher temperatures.
6.3 Mechanical Voltage Regulator Characteristics – Power Quality vs Line Drop
Mechanical voltage regulators for power quality and utility line drop compensation (LDC) function in similar manners but they differ substantially in application:
Power Quality AVR
|
Utility AVR
| |
Type:
|
Tap switch or magnetic induction
|
Tap switch
|
Size (kVA):
|
1 to 1,500
|
500 to 3,500+
|
Nominal Voltages:
|
< 600 V
|
Up to 34.5 kV
|
Input Voltage Range:
|
+20% to -20%
|
+10% to -10%
|
Output Regulation:
|
1% to 3%
|
0.6% to 2.5%
|
Phase:
|
Single or three
|
Single or three
|
Voltage Step Up/Down:
|
Yes
|
Yes
|
Cooling Media:
|
Air
|
Oil
|
Location:
|
Indoor/Outdoor
|
Outdoor
|
Efficiency:
|
> 95%
|
> 95%
|
The primary differences between power quality and utility applications are the range of input voltage regulation and voltage levels, but there are other, less obvious, differences including the terms used for these units.
For power quality applications the mechanical AVR goes by names such as: electromechanical voltage regulator or stabilizer, mechanical tap changing voltage regulator, tap switching voltage regulator, motorized variable transformer, motorized variac, magnetic induction voltage regulator or stabilizer, servo voltage regulator or stabilizer, motor-driven variable autotransformer and variable autotransformer.
Mechanical AVRs for power quality applications operate at low voltage to match the voltage of the equipment being protected and also have a larger input voltage range to account for voltage fluctuations from the utility as well as voltage fluctuations in the end user’s facility. For power quality applications, the mechanical tap switching or servo induction voltage regulator usually comes as a completely assembled package.
The mechanical tap changing voltage regulator used by electric utilities often goes by names such as: line drop compensator (LDC), on-load tap changer (OLTC), step voltage regulator, auto-boost regulator or mechanical tap changer.
The on-load tap changer is easily the most common type used by electric utilities. OLTCs typically differ from the power quality version in that they operate at medium to high voltage, usually have relatively finer regulating steps (5/8% per step) and the tap changing mechanisms and controls are often purchased as “add-ons” for a tapped transformer. The sensors for voltage measurement may be miles down the distribution or transmission line and relay signals to the OLTC upstream to affect voltage changes.
The utility line drop compensator typically includes sophisticated controls to delay tap changing for a variety of reasons such as: avoiding tap changing during momentary fluctuations and to coordinate tap changing with other LDCs in series downstream. Because access to an oil-filled, line drop compensator is difficult and costly, these units will have more elaborate provisions for testing, self-cleaning and adjustment. Magnetic or servo induction voltage regulators are rarely used by electric utilities.
6.4 Mechanical Voltage Regulator Advantages & Disadvantages
Advantages
The advantages of mechanical AVRs, either tap changing or magnetic induction type, vary by design but generally include:
The advantages of mechanical AVRs, either tap changing or magnetic induction type, vary by design but generally include:
- Very accurate output voltage regulation
- Wide choice of kVA rating, voltage and configuration
- Easily applicable to outdoor application
- High tolerance to system faults and overload
- High tolerance to power factor and frequency deviations
- Good line isolation
- Relatively inexpensive
In addition to these advantages, the servo induction voltage regulator also provides a very smooth output voltage compared to the discrete switching that occurs in tap changers.
Disadvantages
- Mechanical drive components, brushes and contractors require regular maintenance and/or replacement
- Frequent overloads can damage brushes
- Speed of voltage correction correct may not be fast enough for electronic loads
Tap switching voltage regulators tend to have higher maintenance requirements than magnetic induction units since the magnetic induction voltage regulator has few or no brushes or contactors to wear out. With either type, the maintenance requirements are directly related to frequency of voltage correction – the more it moves the more maintenance will be required.
Because maintenance on utility, oil-filled on-load tap changers can be quite expensive, they often have time delays and other capability built into their controls to minimize the frequency of tap changing. These units typically have recommended overhaul intervals ranging from 500,000 to 1,000,000 operations.
In power quality applications, it would be counterproductive to have delays or other limitations on the operation of tap switching or servo induction voltage regulators. Fortunately, these units are usually air-cooled, smaller in size and relatively accessible compared to the utility OLTC.
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