Voltage Regulators COOPER POWER

SERIES
Effective January 2025
MN225008EN Supersedes June 2020

VR-32 and EVER-Tap™ Voltage Regulator

Installation, Operation, and Maintenance Instructions
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s
(“Eaton”) experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales
office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in
appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES
OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY
EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE
CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or
otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to
damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of
existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information,
recommendations and descriptions contained herein. The information contained in this manual is subject to change without
notice.

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 VR-32 and EVER-Tap™ Voltage Regulator

Contents
DISCLAIMER OF WARRANTIES AND LIMITATION MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OF LIABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II External Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 25
SAFETY FOR LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . IV Quik-Drive tap-changers . . . . . . . . . . . . . . . . . . . . . 26
EVER-Tap voltage regulator. . . . . . . . . . . . . . . . . . . 27
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . IV
Operational check . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Insulating fluid maintenance. . . . . . . . . . . . . . . . . . 28
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 EVER-Tap voltage regulator insulating fluid
Read this manual first. . . . . . . . . . . . . . . . . . . . . . . . 1 maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Additional information. . . . . . . . . . . . . . . . . . . . . . . . 1 Sampling insulating fluid. . . . . . . . . . . . . . . . . . . . . 29
Acceptance and initial inspection . . . . . . . . . . . . . . . 1 FR3 insulating fluid application. . . . . . . . . . . . . . . . 29
Handling and storage. . . . . . . . . . . . . . . . . . . . . . . . . 1 Untanking the regulator. . . . . . . . . . . . . . . . . . . . . . 29
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Retanking the regulator . . . . . . . . . . . . . . . . . . . . . 31
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Quality standards. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PRODUCT INFORMATION. . . . . . . . . . . . . . . . . . . . . 3 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . 32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . 32
Available options. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Regulator control reverse power flow test. . . . . . . 32
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Voltage regulator ratio test . . . . . . . . . . . . . . . . . . . 33
Pre-installation inspection . . . . . . . . . . . . . . . . . . . . . 5 Voltage regulator potential transformer ratio test. . 34
Systems connections . . . . . . . . . . . . . . . . . . . . . . . . 5 Regulator dry-out procedure. . . . . . . . . . . . . . . . . . 35
Nameplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Voltage regulator current test. . . . . . . . . . . . . . . . . 35
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Insulation resistance test . . . . . . . . . . . . . . . . . . . . 37
Placing regulator into service . . . . . . . . . . . . . . . . . . 9 Freeing a stalled tap-changer. . . . . . . . . . . . . . . . . 37

REMOVAL FROM SERVICE. . . . . . . . . . . . . . . . . . . 13 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Connections and voltage levels. . . . . . . . . . . . . . . . 39
CONSTRUCTION AND OPERATION. . . . . . . . . . . . 14
ADD-AMP capabilities. . . . . . . . . . . . . . . . . . . . . . . 41
Standard features, regulators with over-head
bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Position indicator and ADD-AMP capability . . . . . . 15
Surge protection . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Internal construction and wiring . . . . . . . . . . . . . . . 16
Quik-Drive tap-changers . . . . . . . . . . . . . . . . . . . . . 21
EVER-Tap™ voltage regulators . . . . . . . . . . . . . . . . 23
EVER-Tap important operational information. . . . . . 24

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VR-32 and EVER-Tap™ Voltage Regulator

! !
SAFETY
FOR LIFE
Safety for life SAFETY
FOR LIFE

Eaton meets or exceeds all applicable industry standards relating to product safety in its Cooper Power™ series products.
We actively promote safe practices in the use and maintenance of our products through our service literature, instructional
training programs, and the continuous efforts of all Eaton employees involved in product design, manufacture, marketing, and
service.
We strongly urge that you always follow all locally-approved safety procedures and safety instructions when working around
high-voltage lines and equipment, and support our “Safety For Life” mission.

Safety information
The instructions in this manual are not intended as a Safety instructions
substitute for proper training or adequate experience in the
safe operation of the equipment described. Only competent Following are general caution and warning statements that
technicians who are familiar with this equipment should apply to this equipment. Additional statements, related to
install, operate, and service it. specific tasks and procedures, are located throughout the
manual.
A competent technician has these qualifications:
• Is thoroughly familiar with these instructions. DANGER
• Is trained in industry-accepted high- and low-voltage safe Hazardous voltage. Contact with hazardous voltage will
operating practices and procedures. cause death or severe personal injury. Follow all locally-
approved safety procedures when working around high-
• Is trained and authorized to energize, de-energize, clear, and low-voltage lines and equipment. G103.3
and ground power distribution equipment.
• Is trained in the care and use of protective equipment WARNING
such as arc flash clothing, safety glasses, face shield,
hard hat, rubber gloves, clampstick, hotstick, etc. Before installing, operating, maintaining, or testing this
equipment, carefully read and understand the contents
Following is important safety information. For safe of this manual. Improper operation, handling, or
installation and operation of this equipment, be sure to read maintenance can result in death, severe personal injury,
and understand all cautions and warnings. and equipment damage. G101.0

Hazard Statement Definitions WARNING

This manual may contain four types of hazard statements: This equipment is not intended to protect human
life. Follow all locally-approved procedures and safety
practices when installing or operating this equipment.
DANGER Failure to comply can result in death, severe personal
Indicates an imminently hazardous situation which, if injury, and equipment damage. G102.1

not avoided, will result in death or serious injury.

WARNING
WARNING Power distribution and transmission equipment must
Indicates a potentially hazardous situation which, if not be properly selected for the intended application. It
avoided, could result in death or serious injury. must be installed and serviced by competent personnel
who have been trained and understand proper safety
procedures. These instructions are written for such
CAUTION personnel and are not a substitute for adequate training
Indicates a potentially hazardous situation which, if not and experience in safety procedures. Failure to properly
avoided, may result in minor or moderate injury. select, install, or maintain power distribution and
transmission equipment can result in death, severe
personal injury, and equipment damage.
NOTICE G122.2

Indicates a potentially hazardous situation which, if not

avoided, may result in equipment damage only.

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 VR-32 and EVER-Tap™ Voltage Regulator

Introduction Handling and storage

Eaton’s Service Information MN225008EN provides the Be careful during handing and storage of equipment to
installation, operation, and maintenance instructions for its minimize the possibility of damage. If the regulator will not
Cooper Power™ series VR-32 voltage regulator with the be placed into immediate service, it can be stored with
Quik-Drive™ tap-changer. It also contains this information minimal precautions. Store the unit where the possibility of
for the Eaton EVER-Tap™ voltage regulator with the mechanical damage is minimized.
VACUTAP™ RMV-SVR on-load tap-changer manufactured by
Maschinenfabrik Reinhausen™. Long-term storage
If a regulator is to be placed into long term storage the
Read this manual first following additional precautions may be taken prior to
placing the unit into service:
Read and understand the contents of this manual and
follow all locally approved procedures and safety practices • Sample the insulating fluid comparing it to the
before installing or operating this equipment. Read and parameters detailed in Table 5 (Envirotemp FR3) and
understand the manual detailing the installation and Table 6 (Mineral Oil). If the fluid does not meet the
operation of the control used with this regulator. Refer to standards, the fluid should be filtered or replaced. Refer
Service Information MN225003EN, CL-7 Voltage Control to “Insulating fluid maintenance” on page 28 for
Installation, Operation, and Maintenance Instructions, for more information.
information on the CL-7 series voltage regulator controls. • Perform an insulation resistance test on the unit.
Compare the test value to the initial manufacturing test
Additional information values available from VRSupport. Consult VRSupport
for information on acceptable test values and dry-out
These instructions cannot cover all details or variations in procedures.
the equipment, procedures, or processes described nor
provide directions for meeting every possible contingency The voltage regulator control may be stored long term in
during installation, operation, or maintenance. For additional the control box outdoors. However, long term storage of the
information, please contact the Voltage Regulator Support control in a climate-controlled environment prior to use is
group at (866) 975-7347 (from outside the U.S. and advisable.
Canada call +1 (262) 896-2591) or e-mail questions to
[email protected].

Acceptance and initial inspection

The regulator is thoroughly tested and inspected at the
factory. It is carefully calibrated, adjusted, and in good
condition when accepted by the carrier for shipment.
Upon receipt of the regulator shipment, before unloading, a
thorough inspection should be made for damage, evidence
of rough handling, or shortages. The position indicator,
junction box, arrester, radiators and bushings should all
be inspected for evidence of damage. Should this initial
inspection reveal evidence of rough handling, damage, or
shortages, it should be noted on the bill of lading and a
claim should immediately be made with the carrier. Also,
notify Eaton warranty via email at PS-WarrantyServices@
Eaton.com.

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VR-32 and EVER-Tap™ Voltage Regulator

WARNING Standards
Eaton’s Cooper Power series regulators are designed and
Equipment Damage. Lift the entire unit only with tank- tested in accordance with the following standards:
mounted lifting lugs. The cover may warp or fracture
and the tank may separate from the cover if the cover- IEEE Std C37.90.1-2012™ standard
mounted lifting eyes are used to lift the entire unit
causing death or severe personal injury and equipment IEEE Std C37.90.2-2004™ standard
damage. IEEE Std C57.13-2016™ standard
IEEE Std C57.15-2017™/IEC 60076-21:2018-12 standard
Lifting IEEE Std C37.91-2021™ standard
When lifting a voltage regulator using an overhead crane IEEE Std C57.131-2012™ standard
to unload, or for installation or deinstallation, it is strongly
recommended that the lift be made by means of a lifting EN 50081-2
strap and spreader bar utilizing the tank-mounted lifting
lugs; see Figure 3 on page 4 for the location of lifting EN 61000-4
lugs. Never lift the entire voltage regulator with the lifting IEC 60068-2
eyes on the cover. The lifting eyes are only to be used to
untank the internal assembly which is attached to the cover. IEC 60214-1
Whether lifting a voltage regulator with a lifting strap and IEC 610255-5
spreader bar or using a lifting strap without a spreader bar,
it is important to perform the lift as vertically as possible
to minimize the possibility of damage to the unit. The Quality standards
maximum angle from vertical of the lifting strap is to be
no more that 25°. The 25° maximum angle applies to both ISO 9001 Certified Quality Management System
2- and 4-lift lug tank designs. The clearance between
lifting straps and any cover-mounted components is to
be a minimum of 3 inches. It is recommended that the
series arrester be removed before lifting to eliminate the
possibility of clearance issues between the arrester and
lifting straps. See Figure 1 for a lifting diagram example.

Figure 1.  Lifting recommendations for lifting an entire

voltage regulator using the lifting lugs.

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Product information
Description
VR-32 and EVER-Tap single-phase step-voltage regulators
from Eaton operate to keep voltage levels within
programmed limits to improve power quality and are
compatible with SCADA and automation distribution
systems.
Available in pole-, platform-, and pad-mounted and
substation configurations, VR-32 voltage regulators are
suitable for three- or four-wire overhead and underground
systems. EVER-Tap voltage regulators are manufactured
primarily for installation in substations.
Eaton voltage regulators are regulating auto-transformers. Figure 2.  Quick connect/disconnect cable
They regulate rated voltage from 10% raise (boost) to 10%
lower (buck) in 32 approximately 5/8% steps.
The 65 °C rise insulation system and the sealed-tank Available options
construction allow for a bonus capacity 12% above the
55 °C nominal rating without loss of normal insulation Available options include:
life. The bonus capacity is stated on the nameplate. For • Extended-length control cable, lengths up to 120 feet
example, A 167/187 kVA rating indicates a nominal rating of
167 kVA and a bonus capacity rating of 187 kVA.
• Armored control cable
• Shielded control cable
Unit construction, which suspends the internal assembly
from the cover, allows for ease of inspection and • Adjustable galvanized-steel elevating structure
maintenance. • Supplemental external fusing to prevent damage from
Eaton manufactures four types of step-voltage regulators: reverse polarity connection to the external-source
source-side series winding (Type B), load-side series terminals
winding (Type A), series transformer (Type TX), and series • Shunt surge arresters
auto transformer (Type AX). Eaton voltage regulators • Insulating fluid 25°C level sight gauge
are usually equipped with an equalizer winding. The
nameplates located on the tank and control box define the • Insulating fluid thermometer with or without alarm
power circuit. contacts

Eaton voltage regulators are supplied with the following

• Insulating fluid level gauge with or without alarm
standard features: contacts
• Pressure and vacuum gauge with or without alarm
• CL-7 voltage regulator control (CE mark compliant) contacts
• Dual-rated 55/65 °C average winding rise • Gauges with 0-20 mA output for analog display of
• Measured load and source voltages temperature, pressure, and vacuum
• ADD-AMP™ capability • Rapid pressure-rise relay
• Sealed-tank construction • Stainless steel tank and cover
• Pressure relief device • Envirotemp™ FR3™ insulating fluid
• 18" minimum-creep bushings with clamp-type • Tank and control enclosure ground connectors
connectors • Alternate top-coat color
• MOV-type external series arrester • External stainless steel hardware
• Shunt-arrester mounting bosses • Stainless steel control enclosure
• Two aluminum, laser-etched nameplates • Stainless steel nameplates
• Critical insulating fluid level site gauge • Substation base, below 167 kVA
• Upper filter press connection • Pole-mounting brackets, on 333 kVA
• Drain valve and insulating fluid sampling device • Wildlife guards
• Internal differential potential transformer (IDPT) • 4-hole NEMA® spade bushing connectors
• Control cable quick connect/disconnect • IEEE/IEC Standard universal control cable interface

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VR-32 and EVER-Tap™ Voltage Regulator

MOV-type series arrester

Bushing
connectors
Junction box
Threaded-stud
bushing terminals
Hand-hole cover
Bushings

Cover
Lifting eyes for
untanking

Position indicator
Upper filter press
connection
Cover-ground strap

Shunt-arrester Regulator lifting lugs

mounting bosses

Ball-type 25 C° insulating
fluid level sight gauge
Control cable with
Quick-Disconnect plug

Laser-etched nameplate (2)

(second nameplate on
control enclosure door)
Lockable control enclosure

Tap-changer motor capacitor

CL-7 control

Control ground boss

Not shown:
• Automatic pressure-
relief device
• Pole-mounting bracket
(units up to 250 kVA)

Bolt-down provisions (4)

Substation base (available Ground pad

in units 167 kVA and above)
Drain valve and insulating
fluid sampling device

Figure 3.  External features of the VR-32 and EVER-Tap voltage regulator

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 VR-32 and EVER-Tap™ Voltage Regulator

Installation Systems connections

Pre-installation inspection WARNING

Before connecting the regulator to the line, make the Hazardous Voltage. Connect the “S” bushing to
following inspection: the source, the “L” bushing to the load. For Wye
connections, connect the “SL” bushing to neutral.
1. Check insulating fluid level sight gauge to insure that For Delta connections, connect the “SL” bushing to the
the fluid level is above the critical fluid level. Look for appropriate phase. Inaccurate connections may cause
visible signs of leaking insulating fluid. excessively high or low voltage on the load side of the
regulator and can cause death or severe personal injury
Note: The current standard location for the fluid sight
and equipment damage.
gauge is at the critical fluid level. Regulator
designs prior to 2018 placed the gauge at the A regulator can regulate a single-phase circuit or one phase
25°C insulating fluid level as a standard. Confirm of a three-phase wye (star) or delta circuit. Two regulators
the location of the gauge when checking the fluid connected phase-to-phase in open delta or three regulators
level. connected phase-to-phase in closed delta can regulate a
three-phase, three-wire circuit. When connected in wye,
Note: Insulating fluid level may not be visible in three regulators can regulate a three-phase, four-wire,
cold temperatures if the sight gauge is at the multi-grounded wye circuit. Three regulators should not
25°C fluid level. Move these units into a warm be connected directly in wye on three-phase, three-wire
environment before checking the fluid level. circuits because of the probability of neutral shift, unless
2. Examine series arrester for damage. If damaged, install the neutral is connected to the neutral of a wye-connected
a new arrester of same voltage rating. bank of distribution transformers or to the substation
transformer secondary neutral. Typical connection diagrams
3. Inspect porcelain bushings for damage or leaking seals. are illustrated in Figure 4 through Figure 8. Refer to “Shunt
arresters” on page 16 for information on shunt arrester
4. If moisture ingress into the tank is suspected, remove application.
the hand-hole cover and inspect for evidence of
moisture such as rust or water tracks in the insulating Note: In the typical connection diagrams (Figure 4
fluid. If moisture has entered the tank, dry regulator through Figure 8), individual switches are shown
and filter the insulating fluid before putting unit in for the bypass and disconnect functions. However,
service. See Table 5 and Table 6 (page 28) for a regulator-bypass-disconnect switch can be
insulating fluid test standards. Be sure to properly used in each phase to perform the bypassing and
replace hand-hole cover. disconnecting operations in sequence. Each of these
5. Check position indicator for damage. When cleaning the switches replaces one bypass and two disconnect
faceplate, do NOT use solvent or fuel. switches shown in the diagrams.
Source

6. If the regulator has been stored for some time, test the Ø

Load
dielectric strength of the insulating fluid according to N
Table 5 and Table 6 (page 28).
7. Regulator may be energized at rated voltage (with
caution); you can then perform the ”Operational
check” on page 28. This procedure is optional.
8. A high-potential test may be done to ensure adequate
electrical clearances to ground. This procedure is
optional.

Control
Box

Figure 4.  Regulating a single-phase circuit

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VR-32 and EVER-Tap™ Voltage Regulator

A
Source

Load
C
N

Control
Box

Figure 5.  Regulating one phase of a three-phase, four- Figure 6.  Regulating a three-phase, three-wire circuit
wire circuit regulator with two regulators (Open Delta)

A
Source

Load
C
N

Control Control Control

Box Box Box

Figure 7.  Regulating a three-phase, four-wire, multi-grounded wye (star) circuit with three regulators (Wye)

A
Source

Load

B
C

Control Control Control

Box Box Box

Figure 8.  Regulating a three-phase, three-wire circuit with three regulators (Closed Delta)

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Nameplates Mounting
Two anodized aluminum nameplates are provided as Regulators with over-head bushings can be mounted on
standard; refer to Figure 9 and Figure 10. One nameplate a pole, a cross-arm platform, or an elevating structure.
is placed on the regulator tank. The other is placed on the Regulators are normally provided with either pole-mounting
control box door. Nameplates provide information necessary brackets or a substation base according to their rating. An
for proper control function. Information such as CT ratio, elevating structure can be provided to simplify substation
PT ratio, regulator type, and tap-changer type can be found installation of regulators requiring a specific live part-to-
on the nameplates. When a control is delivered mounted ground clearance.
onto a regulator, the nameplate data will be programmed
into the control at the factory. It is recommended that The regulator control can be mounted on the regulator
this information be verified prior to placing the control and tank or at a point remote from the unit. Various lengths of
regulator into service. When calling Eaton for service or rubber-coated control cables are available up to 120 feet
support-related issues, have the catalog number and serial (36.6 meters).
number found on the nameplate for reference.

Figure 9.  Typical nameplate: Domestic 60-Hz design

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VR-32 and EVER-Tap™ Voltage Regulator

Figure 10.  Typical nameplate: International 50-Hz design

Figure 8. Typical nameplate, domestic 60 Hz design.

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 VR-32 and EVER-Tap™ Voltage Regulator

Placing regulator into service CAUTION

DANGER Equipment Damage. Only an AC power supply is to be
used to energize the control externally. Do not use a
TO PREVENT INJURY OR DEATH TO PERSONNEL AND DC-to-AC voltage inverter. Failure to comply can cause
DAMAGE TO EQUIPMENT, THE FOLLOWING STEPS excessive harmonics to be generated and result in
MUST BE PERFORMED PRIOR TO OPERATING THE damage to the control.
BYPASS SWITCH.

1. ALWAYS WEAR PROPER PERSONAL PROTECTIVE CAUTION

EQUIPMENT (PPE) when operating or servicing this
Equipment Damage. When connecting external power
equipment.
to the voltage regulator control, make sure the polarity
2. The regulator MUST be placed in the NEUTRAL of the power source is correct. Reverse polarity will
position. If all of the following indicators do not result in control and back-panel wiring damage.
confirm NEUTRAL, the regulator MUST NOT be
bypassed:
• The position indicator pointing to N (neutral). Refer to Service Information MN225003EN, CL-7
Voltage Control Installation, Operation, and Maintenance
• The neutral light on the regulator control Instructions, for information on the CL-7 series voltage
illuminated continuously and brightly. regulator control, including placing the control into service
• The control tap-position display indicating 0 and initial programming.
(zero).
As with all electrical equipment, proper grounding of a
• The voltage difference measured between the voltage regulator control box is essential. The voltage
S and L bushings to be less than 0.25% of the regulator control box must be grounded to the tank ground
system line voltage using a calibrated meter or pad or earth ground. A poor ground connection to the
the Eaton regulator control SAFE-TO-BYPASS control box can result in a hazard to operators and control
feature. malfunctions. Mounting a control box on the regulator tank
3. The tap changer motor MUST be disabled before does not ensure a proper ground because of the painted
performing the bypass operation to prevent surfaces of the tank and control box. A ground pad tapped
inadvertent operation of the tap changer motor. Use for 1/2"-13 UNC thread is provided on the side of the control
these steps to disable the motor: cabinet to be used for grounding.
• FIRST move the CONTROL FUNCTION switch After programming the control for basic operations, perform
(labeled AUTO/REMOTE-OFF-LOCAL MANUAL) a control operational check of manual and automatic
to the OFF position. Failure to do this FIRST may operations to complete the installation of the regulator.
result in the tap changer stepping off NETURAL Regulators can be placed into service without interrupting
immediately upon being energized. load continuity by installing bypass and disconnect
• Move the control power switch to OFF. switches.
• Remove the motor fuse. To perform an operational check and the switching
• On the panel behind the control, open the V1, V6 operations to install a regulator onto a system, use one of
and if present the V2 and V8 switches. the following procedures:
• Use Procedure A when employing one bypass switch
and two disconnect switches.

WARNING • Use Procedure B when employing a single-pull regulator

bypass-disconnect switch.
Hazardous Voltage. To protect personnel from surges
while operating the control, follow these control When energizing the control from an external source, make
enclosure grounding procedures: a) If the enclosure is sure to connect the power source with the correct polarity
attached to the regulator tank or is remote from the to avoid damage to the control. The line connection should
tank but only accessible with a ladder, connect the be made to the black terminal, neutral connected to white,
enclosure to the regulator-to-ground rod conductor; b) and green to ground. Use only a 120 Vac source unless the
If the enclosure is accessible by personnel standing on control is set up for 240 Vac. Controls set up for 240 Vac
the ground, connect the enclosure directly to a ground external source power will have a decal adjacent to the
mat and ground rod. Failure to comply can result in terminals and a step-down auto transformer in the control
severe personal injury or death. box.

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VR-32 and EVER-Tap™ Voltage Regulator

Procedure A: One bypass switch and two disconnect switches

1. Verify from regulator nameplate that control circuit is
connected for proper regulated system voltage.
2. Set POWER switch to OFF and CONTROL FUNCTION
switch to OFF.
3. The orange knife switches on back panel should be
properly set for operation:
• V1 for PT closed/pushed in.
• V6 for internal differential PT closed/pushed in.
• V2 (if present) for auxiliary power winding closed/
pushed in.
• V8 (if present) for EVER-Tap motor power closed/
Figure 11.  Typical CL-7 single-phase control back-panel
pushed in.
• C for CT shorting Open/pulled out.
4. Close source-load (SL) disconnect switch if available.
5. Close source (S) disconnect switch.
6. Set POWER switch to INTERNAL and CONTROL
FUNCTION switch to LOCAL MANUAL.
7. Lift raise-lower switch to operate tap-changer two or
three steps, then depress raise-lower switch to return
tap-changer to the neutral position; these steps verify
that the mechanism is functional. When on neutral,
the neutral light will glow continuously and position
indicator will point to zero or N for Neutral.

DANGER
TO PREVENT INJURY OR DEATH TO PERSONNEL AND
DAMAGE TO EQUIPMENT, THE FOLLOWING STEPS
MUST BE PERFORMED PRIOR TO OPERATING THE
BYPASS SWITCH.

1. ALWAYS WEAR PROPER PERSONAL PROTECTIVE

EQUIPMENT (PPE) when operating or servicing this
Figure 12.  Typical CL-7 control multi-phase back-panel equipment.
2. The regulator MUST be placed in the NEUTRAL
position. If all of the following indicators do not
confirm NEUTRAL, the regulator MUST NOT be
bypassed:
• The position indicator pointing to N (neutral).
• The neutral light on the regulator control
illuminated continuously and brightly.
• The control tap-position display indicating 0
(zero).
• The voltage difference measured between the
S and L bushings to be less than 0.25% of the
system line voltage using a calibrated meter or
the Eaton regulator control SAFE-TO-BYPASS
feature.

Figure 13.  Typical CL-7 control back-panel for an EVER-

Tap voltage regulator

10 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

3. The tap changer motor SHALL be disabled before 3. The orange knife switches on back panel should be
performing the bypass operation to prevent properly set for operation:
inadvertent operation of the tap changer motor. Use
these steps to disable the motor:
• V1 for PT closed/pushed in.
• FIRST move the CONTROL FUNCTION switch • V6 for internal differential PT closed/pushed in.
(labeled AUTO/REMOTE-OFF-LOCAL MANUAL) • V2 (if present) for auxiliary winding closed/pushed in.
to the OFF position. Failure to do this FIRST may
result in the tap changer stepping off NETURAL • V8 (if present) for EVER-Tap motor power closed/
immediately upon being energized. pushed in.
• Move the control power switch to OFF. • C for CT shorting Open/pulled out.
• Remove the motor fuse.
4. Apply 120 V (or 240 V if indicated by the decal on the
• On the panel behind the control, open the V1, V6 control) to external source terminals.
and if present the V2 and V8 switches.
5. Lift raise-lower switch to operate tap-changer two or
8. Confirm the voltage regulator has been placed in three steps, then depress raise-lower switch to return
neutral before proceeding by observing these four tap-changer to neutral position; these steps verify
indicators: that the mechanism is functional. When on neutral,
the neutral light will glow continuously and position
a. Neutral light is illuminated continuously and indicator will point to zero or N for Neutral.
brightly.
b. Tap-position indication on the control at FC 12 DANGER
displays 0 for neutral.
TO PREVENT INJURY OR DEATH TO PERSONNEL AND
c. Position indicator dial pointer is pointing directly at DAMAGE TO EQUIPMENT, THE FOLLOWING STEPS
N or 0 for neutral. MUST BE PERFORMED PRIOR TO OPERATING THE
BYPASS SWITCH.
d. Measure the voltage difference between the S
and L bushings using an approved voltmeter or 1. ALWAYS WEAR PROPER PERSONAL PROTECTIVE
the SAFE-TO-BYPASS feature on the CL-7 series EQUIPMENT (PPE) when operating or servicing this
control. The voltage should measure zero or very equipment.
close to zero.
2. The regulator MUST be placed in the NEUTRAL
9. With the regulator in neutral position, disable the motor position. If all of the following indicators do not
operation by taking the following steps: confirm NEUTRAL, the regulator MUST NOT be
bypassed:
a. Set the CONTROL FUNCTION switch to OFF.
• The position indicator pointing to N (neutral).
b. Set the POWER switch to OFF. • The neutral light on the regulator control
c. Open the V1 and V6 knife switches and, if present, illuminated continuously and brightly.
open the V2 and V8 switches. • The control tap-position display indicating 0
d. Remove the 6 Amp motor fuse. (zero).
• The voltage difference measured between the
10. Close load (L) disconnect switch. S and L bushings to be less than 0.25% of the
11. Open bypass switch. The regulator is now energized. system line voltage using a calibrated meter or
the Eaton regulator control SAFE-TO-BYPASS
12. Replace 6 A motor fuse, close the V1 and V6 knife feature.
switches and, if present, the V2 and V8 switches, and
3. The tap changer motor MUST be disabled before
set the POWER switch to INTERNAL.
performing the bypass operation to prevent
13. Refer to Service Information MN225003EN, CL-7 inadvertent operation of the tap changer motor. Use
Voltage Regulator Control Installation, Operation, and these steps to disable the motor:
Maintenance Instructions, for information on the CL-7 • FIRST move the CONTROL FUNCTION switch
series voltage regulator control, including placing the (labeled AUTO/REMOTE-OFF-LOCAL MANUAL)
control into service and initial programming. to the OFF position. Failure to do this FIRST may
result in the tap changer stepping off NETURAL
immediately upon being energized.
Procedure B: Regulator bypass-disconnect switch
• Move the control power switch to OFF.
1. Verify from regulator nameplate that control circuit is • Remove the motor fuse.
connected for proper regulated system voltage.
• On the panel behind the control, open the V1, V6
2. Set CONTROL FUNCTION switch to LOCAL MANUAL and if present the V2 and V8 switches.
and POWER switch to EXTERNAL.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 11

VR-32 and EVER-Tap™ Voltage Regulator

6. Confirm the voltage regulator has been placed in Setting the manual (hard) limit switches
neutral before proceeding by observing these four Note: Refer to “Position indicator and ADD-AMP
indicators:
capability” on page 15 for a complete discussion
a. Neutral light is illuminated continuously and of these features.
brightly.
Before setting the manual limit switches, be sure the new
b. Tap-position indication on the control at FC 12 settings will not conflict with the present tap-changer
displays 0 for neutral. position; see Figure 14. Do not set the switches below the
indicated tap-changer position. For example, if the main
c. Position indicator dial pointer is pointing directly at hand is at step 12 and the change to be made is from plus
N or 0 for neutral. or minus 10% (step 16) to plus or minus 5% (step 8), run
d. Measure the voltage difference between the S and the tap-changer back to step 7 or less, manually. Then set
L bushings. On a de-energized voltage regulator, the limit switches for plus or minus 5% regulation.
this can be done by applying a low voltage (for Limit switches should be set in anticipation of the maximum
example 120 Vac) between the S and SL bushings. deviation of primary voltage. For example, on a circuit
The measured voltage between the S and L where 7200 V is to be maintained, plus or minus 10% will
bushings should be zero or very close to zero. permit voltages between 6480 V and 7920 V to be regulated
Note: Operating the tap changer when applying effectively. For voltages outside this range, the regulator
120 Vac between the S and SL bushings will not be able to return the voltage to the preselected
will create a voltage change of 0.75 Vac level (7200 V). Five percent regulation would accommodate
circuit voltages between 6840 and 7560 V, maintaining 7200
between the S and L bushings for each
V for all voltages in this range.
step.
To set the limit switches:
7. Remove the voltage from external source terminals.
8. With regulator in the neutral position, set CONTROL 1. Unlatch the captive bezel and swing the cover open.
FUNCTION switch to OFF, set POWER switch to OFF, 2. Lift the limit-switch adjustment lever free of the detent
and remove 6 A motor fuse. and slide it to the new setting allowing the lever to
9. For Delta applications only: Close source-load (SL) snap into the detent stop.
disconnect switch. Note: If the ADD-AMP limits have been programmed
10. Close regulator bypass-disconnect switch. The regulator into the control (Soft ADD-AMP) and the limit
is now energized. switches have not been set, it is possible to
manually step the tap-changer beyond the Soft
11. Replace 6 A motor fuse, close the V1 and V6 knife ADD-AMP limit. If the unit is switched back
switches and, if present, the V2 and V8 switches, and
to automatic mode, the control will step the
set POWER switch to INTERNAL.
regulator back to within the Soft ADD-AMP limits
12. Refer to Service Information MN225003EN, CL-7 as set in the control.
Voltage Regulator Control Installation, Operation, and
Maintenance Instructions, for information on the CL-7
series voltage regulator control, including placing the
control into service and initial programming.

Figure 14.  Position indicator

12 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Removal from service WARNING

Before removing a regulator from service, the tap-changer Explosion Hazard. Bypass a regulator with the line
must be returned to the neutral position. Only a regulator energized only if the position indicator, the neutral
in the neutral position can be safely removed from service light, and the control tap position indicate neutral and
without interrupting load continuity. It is recommended to the voltage measured between the source and the load
use at least four methods to confirm the neutral position, as bushings using an approved voltmeter or CL-7 SAFE-
specified in step 2, below. TO-BYPASS feature is zero. If all indications of neutral
do not agree, the line should be de-energized to avoid
DANGER shorting part of the series winding and resultant high
circulating current. Failure to comply can result in death
TO PREVENT INJURY OR DEATH TO PERSONNEL AND or personal injury and equipment damage.
DAMAGE TO EQUIPMENT, THE FOLLOWING STEPS
MUST BE PERFORMED PRIOR TO OPERATING THE WARNING
BYPASS SWITCH.
Explosion Hazard. To ensure a complete tapping
1. ALWAYS WEAR PROPER PERSONAL PROTECTIVE operation when returning the tap-changer to the neutral
EQUIPMENT (PPE) when operating or servicing this position, the CONTROL FUNCTION switch must be
equipment. placed in the OFF position before the POWER switch is
2. The regulator MUST be placed in the NEUTRAL placed in the OFF position. Failure to comply can result
position. If all of the following indicators do not in the tap-changer stepping off of neutral immediately
confirm NEUTRAL, the regulator MUST NOT be upon being energized which can result in death or
bypassed: severe personal injury and equipment damage.
• The position indicator pointing to N (neutral).
• The neutral light on the regulator control To remove a regulator from service:
illuminated continuously and brightly.
1. Use the Raise/Lower switch to bring the regulator to
• The control tap-position display indicating 0 neutral position.
(zero).
Note: When in neutral, the Neutral light will be
• The voltage difference measured between the
continuously and brightly lit on the control front
S and L bushings to be less than 0.25% of the
panel and the position indicator will point to zero
system line voltage using a calibrated meter or
the Eaton regulator control SAFE-TO-BYPASS or N for Neutral.
feature. 2. Verify the neutral position of the regulator using each of
3. The tap changer motor MUST be disabled before these four methods:
performing the bypass operation to prevent a. Verify that the neutral indicator light on the
inadvertent operation of the tap changer motor. Use control is indicating the neutral position. Neutral is
these steps to disable the motor: indicated only when the light is continuously and
• FIRST move the CONTROL FUNCTION switch brightly illuminated.
(labeled AUTO/REMOTE-OFF-LOCAL MANUAL)
to the OFF position. Failure to do this FIRST may b. Verify that the tap position on the control indicates
result in the tap changer stepping off NETURAL neutral by using the Metering-PLUS™ Tap Position
immediately upon being energized. key or FC 12. When in neutral, these display “0”
(zero).
• Move the control power switch to OFF.
• Remove the motor fuse. c. Verify that the position indicator on the regulator
is pointing straight up, either to zero or to “N” for
• On the panel behind the control, open the V1, V6 Neutral.
and if present the V2 and V8 switches.
d. Using an approved voltmeter or CL-7 SAFE-TO-
BYPASS feature, verify that there is no voltage
difference between the source and load bushings.
IMPORTANT: Do not proceed to step 3 until you have
confirmed that the regulator is in the
Neutral position using all four methods
listed above.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 13

VR-32 and EVER-Tap™ Voltage Regulator

marked on the regulator cover adjacent to the bushings. The

WARNING S, L, and SL bushings are interchangeable with each other.
Explosion Hazard. After placing the regulator in the For regulators rated 1200 A and below, each bushing
neutral position for bypass switching, always disable includes a threaded 1.125"-12 UNF-2A stud. For regulators
the motor to prevent a tap change during bypassing rated 1201 A and above, each bushing includes a 1.5"-12
which can result in the tap-changer stepping off of UNF-2A stud. Connectors are not integral to the bushing.
neutral. Failure to comply can cause death or severe Refer to Table 1 for standard terminals.
personal injury and equipment damage.
The threaded studs and connectors of the standard
3. Disable the tap-changer motor to ensure that the terminals are plated bronze. Four-hole spade terminals are
tap-changer cannot inadvertently switch to an available as an option for all current ratings.
off-neutral position:
a. Place the CONTROL FUNCTION switch in the OFF Table 1.  Standard terminals
position.
Rating (A) Standard Terminals
b. Remove the motor fuse. 150 and below Clamp-type connectors for #6 to 250 MCM conductor
c. Place control POWER switch in the OFF position. 151-668 Clamp-type connectors for #6 to 800 MCM conductor
d. Open the V1 and V6 knife switches and, if present, 669-1200 4-hole spade
the V2 and V8 switches located on control back 1201 and above 4-hole spade
panel.
IMPORTANT: Do not proceed to step 4 until you Series arrester. All regulators are provided with an external
UltraSIL™ Polymer-Housed Evolution™ heavy-duty bypass
have disabled the tap-changer motor as
arrester connected across the series winding. For units
directed above.
rated less than 22 kV, the series arrester is rated 3 kV. For
4. De-energize the regulator: units rated 22 kV or larger, the series arrester is rated 6 kV.
a. Close the bypass switch. Insulating fluid level sight gauge. An insulating fluid level
sight gauge indicates fluid color and level at the critical fluid
b. Open the load (L) disconnect switch. levels.
c. Open the source (S) disconnect switch. Position indicator. An external, corrosion-resistant position
d. Open the source-load (SL) disconnect switch, if indicator indicates the tap-changer position. The polymer-
available. constructed position indicator is slanted downward at a
45-degree angle for ease-of-reading when the regulator is
Note: If a regulator single-pull bypass disconnect mounted above ground level.
is used in place of three separate switches,
Arrester mounting provisions. Stainless steel bosses are
step a, step b, and step c are carried out in one
provided for the mounting of lightning arresters adjacent to
operation.
the source (S), load (L), and source-load (SL) bushings. The
bosses are fully welded around their circumference.
Construction and operation Drain valve with sampler. All regulators have a 1" drain
valve with sampling device and a 1" upper filter press
Eaton’s Cooper Power series VR-32 and EVER-Tap voltage connection.
regulators are designed, manufactured, and tested in
accordance with IEEE Std C57.15-2017™/IEC 60076-21:2018- Hand-hole cover. A hand-hole on the cover of the regulator
12 standard. The regulators are rated and name-plated for provides access for inspection purposes and to access
55/65 °C average winding rise. terminals used to reconnect the regulator for operation at
system voltages as shown in Table 10 (page 39) and
Eaton voltage regulators are filled with ANSI® Type II Table 11 (page 40).
mineral oil per ASTM D-3487, containing less than 1 part
per million PCBs, at time of manufacture, as stated on the Mounting. Regulators rated 250 kVA and below are
regulator nameplate. Envirotemp™ FR3™ fluid is available provided with welded-on hanger brackets. Regulators rated
as an option. 167 kVA and above are provided with a base suitable for
securing them to a pad or elevating structure. All regulators
are capable of being secured to elevating structures.
Standard features, regulators with over-head Ground Provisions. Regulators without a substation base
bushings are provided with two stainless steel 1/2"–13 UNC welded
ground bosses located diagonally opposite from each other.
Bushings. The BIL rating of the bushings is compatible with Regulators with a substation base have two stainless steel
the BIL of the regulator, and all ratings, 250 kVA and below, ground pads located diagonally opposite from each other.
have bushings with a minimum creep distance of 18 inches. Each pad has two stainless steel 1/2"-13 UNC ground
The bushing designations (S, L, and SL) are permanently

14 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

provisions. All grounding provisions are located near the Table 2.  ADD-AMP adjustments
base of the regulator.
Regulation (%) Current (%)
Nameplates. Each regulator has two laser-etched
nameplates, one mounted on the control enclosure and the ± 10.0 100
other mounted on the regulator tank. The nameplates have ± 8.75 110
the manufacturer code and serial number bar-coded with ± 7.5 120
“3 of 9” coding with a 0.25" minimum height. ± 6.25 135
Pressure-relief device. A pressure-relief device vents at ± 5.0 160
approximately 5 psig.
Tank and Cover. The sealed-tank construction permits The position indicator (see Figure 3 and Figure 14) is
operation at 65 °C AWR without increasing the oxidation mounted on the junction box on the cover of the regulator
rate of the insulating fluid. and is directly connected to the tap-changer by a flexible
The external parts of the tank and control enclosure are drive shaft passing through the junction box and terminal
painted light gray, ANSI® 70 (Munsell 5BG7.0/0.4), and board via a sealing gland.
meet the coating and security requirements of IEEE Std The indicator face is graduated in steps. Drag hands
C57.12.28™-2014 and IEEE Std C57.12.31™-2010 standards. indicate the maximum and minimum positions attained
Also, the inside of the tank and bottom of the cover are during raise and lower operations. The drag hands are reset
primed and/or painted. around the main hand position by operating the drag-hand
An external electrical connection between the cover and reset switch on the control front panel.
tank allows the cover-suspended internal assembly and tank During forward power flow, the main hand of the position
to be grounded together to eliminate voltage differentials indicator will be to the right of the neutral position when
while energized. the regulator is boosting. During reverse power flow, the
Thermometer. Provisions for a tank thermometer are main hand will be to the left of the neutral position when
standard for all voltage regulators with substation bases the regulator is boosting.
(units 167 kVA and above).
The limit switches on the position indicator can be adjusted
Control cable. A multi-conductor neoprene 600 V, –50 °C to limit the maximum and minimum tap positions with
to 105 °C cable with disconnect plugs at each end provides possible settings of raise or lower 8, 10, 12, 14 or 16.
the connection between the internal circuitry of the voltage These limits correspond to percent regulation levels of 5,
regulator and the control. 6 1/4, 7 1/2, 8 3/4, and 10%. The five possible load current
ratings associated with the reduced regulation ranges
Current transformer. An automatic, solid-state CT shorting are summarized in Table 12 (page 41) and Table 13
device protects the internal CT from high voltages due (page 42). Higher regulation ranges are realized in closed
to the control cable being disconnected or cut while the delta application.
voltage regulator is energized.
Internal differential potential transformer (IDPT). The When using the limit switches, a detent stop at each
IDPT provide for a differential voltage measurement setting provides positive adjustment. Settings other than
between the S and L bushings. This measurement is used those stops are not recommended. The raise and lower
by the regulator control for reverse power regulation, SAFE- limits need not be the same value unless reverse power is
TO-BYPASS feature, and enhanced tap position tracking. possible. The regulator will stay within the ADD-AMP limits
set forth by the control or the position indicator, whichever
limit is of a lower regulation percentage.
Position indicator and ADD-AMP capability Note: If Soft ADD-AMP limits have been programmed into
Regulators rated below 668 A include an ADD-AMP the control and the position indicator limit switches
feature which permits additional current-carrying capacity have not been set, it is possible to manually step
at reduced voltage regulation range, as shown in Table 2, the tap-changer beyond these limits. If the unit is
but not to exceed 668 A. The ADD-AMP type adjustment switched back to automatic mode, the control will
is located inside the position-indicator faceplate to prevent step the regulator back to within the Soft ADD-AMP
inadvertent adjustment. In addition, a Soft ADD-AMP limits set in the control.
control feature allows adjustment by way of the keypad or
interface software. An optional ADD-AMP feature maximum
of 875 A is provided when specified for regulators rated Surge protection
438–668 A.
Series arrester
All Eaton voltage regulators are equipped with a bypass
arrester connected across the series winding between
the source (S) and load (L) bushings. This arrester limits
the voltage developed across the series winding during
lightning strikes, switching surges, and line faults. The
series surge arrester can be seen in Figure 3. A heavy-

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 15

VR-32 and EVER-Tap™ Voltage Regulator

duty MOV-type series surge arrester of 3 kV offers series A patterned, epoxy-coated insulation paper is used in
winding protection on all regulators except those rated all windings. Prior to assembly of the main core and
22,000 V and greater, which have a 6 kV MOV-type series coil assembly, the windings are baked with sufficient
surge arrester. mechanical pressure exerted on the sides of the coil
winding to maximize a complete bonding of the insulation
Shunt arresters to improve its short-circuit current withstand capabilities.
A shunt arrester is a recommended accessory on Eaton The main core and coil assemblies are of the shell-form
voltage regulators for protection of the shunt winding. The configuration. The series winding on the input (source) side
shunt arrester is a direct-connected arrester mounted on of the regulator (Figure 15) allows all windings (control,
the tank and connected between the bushing and ground shunt and series) to be located in one coil assembly. The
(earth). It is recommended that arresters be applied to all load voltage is monitored by the control winding.
non-grounded bushings. Regulators that have the series winding on the output
For best results, locate these arresters on the mounting (load) side (Figure 16) have a separate potential transformer
pads provided on the tank near the bushing. Connect installed on the load side in lieu of a control winding.
the arrester and the regulator tank to the same ground The control winding or separate potential transformer
connection using the shortest cable possible. Shunt (PT) supplies a voltage for the tap-changer motor and the
arrester application data is listed in Table 3. control sensing circuit. Additional taps are available in the
Table 3.  Typical shunt arrester application data a PT for line voltages other than rated voltage.

Recommended Recommended Most regulators, depending upon the rating, have an

Regulator MOV Shunt Regulator MOV Shunt equalizer winding. This winding improves contact life for
Voltage Arrester Voltage Arrester high-current applications.
Rating Ratings (kV) Rating Ratings (kV)
Figure 17 shows a typical regulator power circuit with a
2500 3 14400 18 series transformer. This design is utilized when the load
5000 6 15000 21 current rating exceeds the tap-changer rating. In this type
6600 9 19920 27 of design, the series transformer winding losses are a
function of the load alone and are independent of the tap
7620 10 22000 27 position. Because of this, limiting the range of voltage
8660 12 33000 36 regulation does not reduce losses and therefore the
11000 15 34500 36 ADD-AMP feature is not applicable.
13800 18 The bridging reactor is a core-form design, consisting of
a Contact factory for specific shunt arrestor application ratings. a coil on each leg of one core. The inside half of one coil
is connected to the outside half of the other coil and vice
versa, providing equal current in each half of the reactor
Internal construction and wiring winding.
Eaton regulators are designed such that they can be This interlacing of the two coils lowers the interwinding
partially or completely untanked for inspection and leakage reactance to a very low value. The reactor is
maintenance without disconnecting any internal electrical completely isolated from ground by stand-off insulators
or mechanical connections. External connections must since the reactor coil is at line voltage above ground. The
be disconnected. Regulators equipped with military reactor core, core clamps, and other associated parts
specification-style, quick-disconnect circular connector approach this level.
are also equipped with a solid-state automatic current-
transformer shorting device located in the junction box. The current transformer is a toroid, through which the load
current passes. It furnishes a current proportional to load
The Quik-Drive tap-changing mechanism is completely current for the line-drop compensator and metering features.
fluid-immersed. The tap-changer, in the manual position,
operates from –16L to +16R in less than 10 seconds. The tap-changer enables the regulator to provide regulation
in smooth, accurately proportioned steps at a controlled
Refer to “Quik-Drive tap-changers” on page 21 for speed that minimizes arcing and extends contact life.
more information. Figure 28 (page 43) and Figure 29 (page 44)
The holding switch circuit is an electrical feedback circuit illustrate the typical internal wiring schemes. Most of the
which monitors motor current. It is incorporated with the wiring is on the tap-changer itself. Molex® receptacles
tap-changer motor circuit and control to ensure accurate plugged into the junction block inside the junction box on
indication of tap position and operations counting. the cover connect the internal tank wiring to the position
indicator and control. The junction box wiring is shown in
The regulator main coil, reactor, and potential transformer Figure 31 (page 46). The connections are made to the
include thermally upgraded insulation to permit operation junction box terminal board using automative-style Molex®
up to 65 °C rise without loss of life to the insulating connectors. A legacy junction box wiring diagram is shown
system. At 65 °C rise, the regulator provides 12% extra in Figure 32 (page 47).
current capacity over the base 55 °C rise current rating.

16 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

VR VL

S L
1 2 3 4 5 6 7 8 N

Source Load

E3 C2 C1
E2 CONTROL
E1 V1
E G

SL

Figure 15.  Power circuit—series winding located on the source-side, ANSI® Type B

VR VL

S L
N 1 2 3 4 5 6 7 8

Source Load

E3 C2 C1
E2 CONTROL
E1 V1
E G

SL

Figure 16.  Power circuit—series winding located on the load-side, ANSI® Type A

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 17

VR-32 and EVER-Tap™ Voltage Regulator

S L

6
VR
5

4 E3 C2 C1
Source VL E2 Load
3 CONTROL

2 E1 V1

1 E G

SL

Figure 17.  Power circuit – series auto transformer, Type AX (similar characteristics to Type A)

S L

2 E3 C2 C1
Source 3 E2 Load
CONTROL
VL
4 E1 V1
5 E G
VR 6

SL

Figure 18.  Power circuit – series transformer, Type TX

18 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Voltage circuits Most voltage regulators are installed in circuits with well-
Eaton voltage regulators have provisions for operation at defined power flow from source to load. However, some
system voltages other than the nominal rating, as listed circuits have interconnections or loops in which the direction
in Table 10 (page 39) and Table 11 (page 40). This is of power flow through the regulator may change. For
accomplished by providing taps on the control winding or optimum utility system performance, a regulator installed on
PT. The taps are brought to a terminal board located on top such a circuit should have the capability of detecting reverse
of the tap-changer assembly, under the insulating fluid, and power flow and of sensing and controlling the voltage,
are marked E1, E2, or E3. (See Figure 19.) The connections regardless of the power flow direction. The CL-7 control has
are made with push-on terminals and are easily accessed full reverse power capabilities.
through the hand hole. Refer to Service Information MN225003EN, CL-7 Voltage
Regulator Control Installation, Operation, and Maintenance
Instructions, for more information on the CL-7 series
control, reverse power operation, and source-side voltage
calculation.
The three back-panel potentials (VS, sensing voltage; V7,
E Taps differential voltage; VM, motor and control power voltage)
are all brought directly to the control power switch. When
no IDPT is present, the V7 terminal is connected to the
VS terminal on the control back panel and the control
software then recognizes that a source-side voltage signal
is not present and a calculation is required to determine the
S-bushing voltage.
The power switch has three positions: INTERNAL, OFF,
and EXTERNAL. The internal position powers the control
and motor from the regulator sensing winding, and the
Figure 19.  PT tap terminals on a QD3 tap-changer external position permits an external supply for the same
purpose. When the power switch is in the external position,
For voltage regulators equipped with an internal differential the internal supply is disconnected to prevent accidentally
potential transformer (IDPT), “P” tap connections will back-feeding the high-voltage winding and bushings. The
be provided and located either on a separate voltage external-source terminals are prominently located adjacent
transformer or on the tap-changer terminal board. to the voltmeter test terminals.

The PT cannot always provide adjustment of the voltage fine The voltmeter terminals allow the monitoring of the voltage
enough for control or motor use. A tapped autotransformer that is applied to the control. This is the voltage output
is used for fine voltage adjustment. This transformer, the from the RCT and the voltage displayed at FC47 (Voltage
Ratio Correction Transformer (RCT), has input taps at 104, Calibration). During forward power flow, the voltage at these
110, 115, 120, 127, and 133 V. The output tap to the control terminals is the output voltage. During reverse power flow,
and motor is set as 120 V. The RCT is located on the control the voltage at these terminals is the source-side voltage.
back panel (see Figure 11 and Figure 12). From the 6 A fuse, the motor potential provides power
To operate a regulator on a system voltage other than its to the CONTROL FUNCTION switch, the drag-hand reset
nominal rating, the appropriate selection must be made solenoid, the neutral light, and the holding switch (alternate
for the PT, RCT, and IDPT taps and the control must be motor source) circuits.
programmed properly at Function Code (FC) 43 (System
Line Voltage), FC44 (Overall PT Ratio) and FC44 (Internal WARNING
PT Ratio). The nameplate provides settings for common
system voltages (see Figure 9 and Figure 10). Electrocution Hazard. Applying voltage to the voltmeter
terminals on some voltage regulator controls can back-
The internal voltage supply is brought from the tap-changer feed the voltage regulator potential transformer and
terminal board through the junction box and the control create high voltage on the bushings. When applying
cable, into the control box, terminating at the knife switch external power to the voltage regulator control, make
labeled V1. Units equipped with an IDPT will have a V6 sure to open the V1, V6, and if present, the V2 and V8
switch to interrupt this circuit. There may also be a V2 switches on the back panel, apply power to the external
switch to interrupt an auxiliary power winding and a V8 source terminals only and move the POWER switch to
switch provided on EVER-Tap units to interrupt the motor EXTERNAL.
power supply. Opening these knife switches provides a
visible means of removing all power to the control and
motor circuits. From the knife switch, the voltage is ratio
corrected by RCT as previously described.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 19

VR-32 and EVER-Tap™ Voltage Regulator

Current circuit Table 4.  Current transformer applications (50 & 60 Hz)
All Eaton voltage regulators are designed with an internal Regulator Current Ratings CT Primary Current
current transformer (CT) (see Figure 20) to provide a current
source for the line-drop compensation calculations, power 50 50
flow direction determination and for metering functions. 75 75
Table 4 provides the application information for the various 100 100
CTs used on Eaton regulators. These CTs provide 200 mA
output for the rated CT primary current. 150 150
167, 200 200
219, 231, 250 250
289, 300 300
328, 334, 347, 400 400
418, 438, 463, 500, 502 500
548, 578, 604, 656, 668 600
833, 875, 1000, 1093 1000
1332, 1503, 1665 1600
2800 3000

Motor circuit
The motor circuit power is brought from the 6 A fuse to
the circuit board through a set of back-to-back diodes to the
CONTROL FUNCTION 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 position indicator. When the switch
is set for manual operation, the power is transferred to
Figure 20.  Internal bushing-mounted current
the momentary toggle switch labeled RAISE/LOWER. By
transformer
actuating this switch in one direction or the other, power
is applied through the limit switch contacts, directly to the
The current developed by the CT is brought through the tap-changer motor, completely bypassing the control circuit
control cable and junction box, into the control box and board. This enables operation of the tap-changer in most
terminates at the knife switch labeled C. Closing the knife circumstances, even if the control cannot be powered up
switch provides a visible means of shorting the CT, thus fully.
allowing the operator to work safely on the current circuitry.
For additional safety measures, the V1, V2, V6, and V8 Also included as a part of the motor circuit is an alternate
knife switches should also be opened. For all regulators with feed to the motor called the holding switch circuit. Located
the quick-disconnect connector (Figure 2), an automatic on the tap-changer are switches which operate off of the
solid-state CT shorting device is located in the junction box. tap-changing mechanism. Motor rotation causes switch
This solid-state device will automatically short the CT when closure (one direction or the other) and establishes a
the cable is disconnected. complete circuit for motor current until the rotation is
complete and the cam drops out. During the time the
At the C switch, one side of the CT is connected to holding switch is closed, motor current is monitored by
the equipment ground and is also routed to the control way of an input on the control circuit board that permits
for termination on the circuit board. The “high” side of the control to detect that a tap change is in process.
the current circuit is brought to the top terminal board The microprocessor uses this information in its decision-
through two removable jumpers and then to the control for making process, as described under Control Operating
connection to the circuit board. Once this current signal is Modes in Service Information MN225003EN, CL-7 Voltage
delivered to the circuit board, it is transformed into a voltage Regulator Control Installation, Operation, and Maintenance
signal and converted into a digital format for processing. Instructions.
Two other circuits that share the 6 A motor source are
the drag-hand reset and neutral light circuits. The drag-
hand reset function is accomplished simply by operating
a momentary membrane switch, which applies power to
the reset solenoid in the position indicator. The neutral
light is energized from a neutral light switch located on the
tap-changer when in the neutral tap position.

20 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Quik-Drive tap-changers
Eaton offers three Quik-Drive tap-changer models (see
Figure 21, Figure 22, and Figure 23). Each device is sized
for a specific range of current and voltage applications and
share many similarities in their construction. The primary
benefits of Quik-Drive tap-changers are: direct motor drive
for simplicity and reliability; high-speed tap selection for
quicker serviceability; and proven mechanical life (one
million operations). Quik-Drive load tap-changers meet
IEEE® and IEC standards for mechanical, electrical, and
thermal performance.

Common Quik-Drive tap-changer features

• Neutral Light Switch – A switch is triggered to close by
the Reversing Switch Assembly or the Main Contact
Assembly to indicate to the Control that the tap-changer
is in the Neutral position.
• Holding Switch – A common holding switch assembly
driven by a pinion cam seals in motor power during a
tap-change until the operation is complete.
• Position Indicator Drive – A common indexing mechanism
Figure 22.  QD5 Quik-Drive tap-changer
is shared between the tap-changers for driving the
Position Indicator.
• Safety Switches – In addition to the limit switches in the
Position Indicator, microswitches are employed on the
tap-changers to interrupt power to the motor so that they
cannot be powered beyond the 16 Raise or 16 Lower
positions. These Safety Switches are triggered by a cam
that is driven from the Main Contact Assembly.
• Logic Switches (Back-Off Switches) – The Logic Switches
are used in parallel with the Safety Switches, based on
the polarity of the Reversing Switch, to ensure proper
operation of the tap-changer.

Figure 23.  QD8 Quik-Drive tap-changer

Figure 21.  QD3 Quik-Drive tap-changer

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 21

VR-32 and EVER-Tap™ Voltage Regulator

Quik-Drive tap-changer mechanism Contacts

A tap change is initiated by the Control. After some rotation Several connection conditions are satisfied by the variety
of the drive gear connected to the motor, a holding switch of contact structures. They are divided into arcing and
energizes the motor through a separate circuit until the non-arcing.
indexing motion is completed. The indexing occurs very
quickly. The total elapsed time to complete the action is The non-arcing contacts consist of front and rear slip rings,
approximately 250 milliseconds from the time the indexing which serve as the connection point for opposite ends of
signal is started by the control. Each full turn of the Geneva the reactor windings and one end of the two main movable
drive gear rotates the main Geneva/contact drive assembly contacts. All contact surfaces are Electrical Tough Pitch
one tap position, which is 20 degrees. (ETP) copper and all joints are riveted, bolted, or brazed to
maintain a high-conductivity current path. Contact pressure
between moving points is maintained by opposing steel
Reversing switch compression springs.
The reversing switch function changes the polarity of the There are several types of arcing contacts on a regulator
tapped winding. When a Quik-Drive tap-changer is in the tap-changer. They can be divided into two categories: main
neutral position, the reversing switch is open. and reversing.
The reversing switch motion on the Quik-Drive tap-changer • The main stationary contacts are connected to the series-
occurs as the main movable contacts enter or leave the winding taps. The main movable contacts connect the slip
neutral position. The Main Contact Assembly engages the rings to the main stationary contacts.
Reversing Switch either directly or through a linkage when
the main switch is in the neutral position. The first tap step • The reversing stationary contacts are connected to
in either direction rotates the Reversing Switch Assembly to opposite ends of the series winding. The reversing
engage the appropriate contacts. movable contacts connect the neutral stationary contacts
to the reversing stationary contacts.
Additionally, the Main Contact Assembly, or its drive, and
the Reversing Switch Arm provide a mechanical stop located All stationary contact bodies are made of ETP copper.
320° on either side of the neutral position so that the Copper-tungsten inserts are brazed to the edges of the
tap-changers cannot be moved past 16 Lower or 16 Raise. stationary contacts since those contacts are subject to
damage from impact or arcing duty. The main movable
Quik-Drive motors drive systems contacts are constructed of a copper-tungsten. The movable
contacts are split to make connection on both sides of the
Either an alternating current (AC) synchronous motor or stationary contacts. This split resists separation in the event
an induction motor is used on Quik-Drive tap-changers. of high-current surges.
The motors use a holding switch circuit that is activated
by a pinion cam closing holding switches as the motor The tap-changer stationary contact body is copper. The
begins to rotate. The holding switch is engaged throughout reversing movable contacts are the same construction as
the duration that the movable contacts are in motion to the main movable contact.
ensure that the tap change cycle is complete. Because of
Contact erosion is a function of many variables such as
differences in rotational speed and braking characteristics,
system parameters, regulated and unregulated voltages,
the AC synchronous motor uses a cam of different timing
line currents, power factor, voltage and current harmonics,
duration than the induction motor to activate the holding
and reactor and main core and coil designs.
switch. The cam on the AC synchronous motor is engaged
for 270° of rotation while the induction motor cam is Stationary contacts should be replaced before the arcing
engaged for 105° of rotation. inserts erode to the point where there may be burning on
the copper. Movable contacts should be replaced when
The AC synchronous motor utilizes a phase-shifting network,
approximately 1/8 inch of smooth surface remains.
consisting of a capacitor and a resistor, to operate properly
when powered by a single-phase source. This motor has
a permanent magnet rotor that arrests the inertia of the
system once power to the motor is removed; therefore, no
braking mechanism is required. The AC synchronous motor
uses a 12 µF capacitor for 60 Hz applications and a 15 µF
capacitor for 50 Hz applications.
The induction motors use a phase-shifting capacitor and
require a friction-type brake to stop the motor between tap
changes. Brakes use various means to interrupt the braking
action while the movable contacts are in motion so that full
motor torque is dedicated to completing the tap change.
The induction motors use a 50 µF capacitor for 50 and 60
Hz operation.

22 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Operating sequence EVER-Tap™ voltage regulators

When the tap-changer is in the neutral position and the The EVER-Tap voltage regulator utilizes a VACUTAP®
control calls for a tap change, the following events occur. RMV-SVR-I-2000 tap changer from Maschinenfabrik
1. The motor is energized and rotor begins to move. Reinhausen (see Figure 24). This tap changer is rated for an
industry-leading 1,000,000 operations before maintenance
2. The motor drives the Geneva drive. is required. A first inspection of the tap changer is
recommended after 500,000 operations. Inherent to the
3. The pin and roller on the Geneva drive gear enters a
vacuum interrupting design of this tap changer is that
slot on the main Geneva/contact drive assembly and
material and gas byproducts from tapping operations do
the main Geneva/contact drive assembly begins to
not accumulate in the dielectric fluid. This preserves a clean
index.
operating environment inside the voltage regulator tank,
4. The holding switch closes to ensure the tap change will prolongs tap changer contact and coil winding life, and
go to completion. The control opens the initial circuit. significantly extends maintenance intervals.
The motor is energized only by way of the holding
switch.
5. The reversing switch pin on the main Geneva/contact
drive assembly begins to drive the reversing switch
arm.
6. One of the two main interrupting movable contacts
slides out of engagement with the neutral stationary
contact and interrupts the circuit through that branch.
7. The reversing switch arm rotates, which causes the
reversing switch contacts to pivot. A bridge between
the neutral contact and a stationary contact connected
to one end of the series winding is thus established.
No arcing occurs across the reversing switch contacts.
When the reversing arm rotates, a logic switch is
triggered.
8. The main interrupting contacts slide over and onto
the number one stationary contact, making a bridging
position from contact N to contact 1 by way of the
reactor.
9. The pin on the Geneva drive gear exits the main
Geneva/contact drive assembly slot. The main Geneva/ Figure 24.  EVER-Tap voltage regulator’s RMV-SVR-I-2000
contact drive assembly stops moving and is rotationally tap changer
locked.
10. The holding switch opens and the motor is
de-energized. EVER-Tap® tap-changer and Motor drive unit
11. The magnetic rotor of the AC synchronous motor or The tap changer comprises four switch modules linked
the brake used with the AC induction motor stops the together through a common mechanism to synchronize the
Geneva drive gear at mid-travel. modules’ operations. The tap selector module and reversing
switch module share functional similarities with the Quik-
12. The elapsed time from step 1 to step 11 is Drive™ tap changers with the exception that arc-resistant
approximately 250 ms. materials are not required on the movable or stationary tap
selector contacts. The by-pass switch module (sometimes
13. If the control issues another signal to index in the same referred to as a “diverter switch”) works in coordination
direction, the same sequence is repeated except the with the vacuum interrupter module to interrupt current
reversing switch is not actuated. The reversing switch to the appropriate tap selector contact prior to switching.
does not move until the tap-changer is reversed and Arcing is contained within the vacuum interrupter, thus
stepped the opposite direction back to neutral. preserving the dielectric fluid of the voltage regulator.
14. If the tap-changer is switching from position 15 to
position 16, a normally closed limit switch is triggered ETMD-A motor drive unit
that is connected in parallel with the logic switch. Both
the limit switch and the logic switch open up, so that The tap changer is operated by a motor drive unit comprised
the control cannot make a tap change past position 16. of a motor, gearbox, position indicator linkage, and micro
switches for feedback to the voltage regulator control. Some
motor drive units require the control to be equipped with
an auxiliary actuator board to manage start, stop, and tap

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 23

VR-32 and EVER-Tap™ Voltage Regulator

limiting functions. Other motor drive units may be powered EVER-Tap important operational information
and controlled directly by the voltage regulator control. In
either case, the voltage regulator control is responsible for WARNING
initiating a tap change. The motor drive model will be listed
on the voltage regulator nameplate. For all EVER-Tap™ The user of this equipment should be properly trained
manufactured prior to 2020, the voltage regulator was in the operation of voltage regulators. Wiring and
supplied with the ETMD-A motor drive unit. Function Code operation of the EVER-TAP™ voltage regulator is
49 may be used to select the motor drive or tap changer different than other voltage regulators equipped with
model. CL-7 controls. Only attempt to commission and operate
an EVER-Tap™ voltage regulator after thoroughly
The CL-7 voltage regulator control utilizes an additional reading and understanding this document as well as the
actuator board for use with the ETMD-A motor drive unit voltage regulator and control manuals.
to power the tap changer. A 100 µF run capacitor and a 50
µF start capacitor are required for operation of the ETMD-A
with actuator board. Back panel wiring in the control box for EVER-TAP controls and control boxes
the ETMD-A is not compatible with Quik-Drive tap changers. Important information pertaining to a CL-7 control and
The CL-7 will trigger the actuator board to make a tap control box equipped for use with and EVER-Tap voltage
change. If limit switches are not tripped, the actuator board regulator:
energizes the motor. After some rotation of the drivetrain, • EVER-Tap control boxes should only be used on
an operating switch is engaged to signal that the motor is EVER-Tap™ voltage regulators. The ETMD-A motor
responding to the command. Failure to receive this signal drive unit requires a special motor drive control circuitry
within several seconds will cause the actuator board to and capacitor configuration that is different from that
abort the tap change. In approximately 2 seconds, under of Eaton’s Quik-Drive tap changers. The wiring of the
normal operating conditions, the operating switch will be back-panel inside the control box and the wire harness
released, triggering the actuator board to stop the motor to the control cable are not compatible with Quik-Drive
drive unit and signal to the control that the tap change is equipped voltage regulators.
complete.
• Use the CL-7 equipped with an actuator board only
with an ETMD-A motor drive unit on an EVER-Tap™
Operating sequence
voltage regulator. Undesirable performance and unsafe
Within the interval of time the motor drive unit is rotating, operating conditions may result if any other control
the tap changer mechanism drives different linkages to configuration is used.
sequence the switch modules’ operations. First, a bypass
switch opens causing all the load current of one movable • The actuator board interfaces with the motor drive to
contact to flow through the vacuum interrupter. Second, ensure proper actuation of the tap changer.
the vacuum interrupter opens, stopping current through the
movable contact. Third, the movable contact is moved from • The actuator board monitors position limit switches and
one stationary tap to the next tap without electrical arcing operation cycle switches.
because the current was previously interrupted. Fourth, the • Starting and stopping functionality is augmented by the
vacuum interrupter closes and current flow is reinitiated actuator board.
through the movable contact. Finally, the bypass switch
closes causing the load current to be shunted around the
vacuum interrupter. EVER-Tap Internal/external/auxiliary power
Important information pertaining to powering of the CL-7
Reversing switch control when operating an EVER-Tap voltage regulator:
The reversing switch function changes the polarity of the • Two separate internal power circuits exist for the actuator
tapped winding. When an EVER-Tap tap-changer is in the board and CL-7 sensing and power circuits.
neutral position through position 16 Raise, the reversing
switch is in position B. When the tap selector moves • The V1 knife switch powers the VS sensing circuit and
between the neutral position and position 1 Lower, the VM control power circuit.
reversing switch moves between position A and B. • The V8 knife switch powers the actuator board for the
tap changer motor drive.
• Do not short V1 to V8. V1 and V8 are both nominally
120V to ground, however V1 and V8 are opposite phase
resulting in a nominal 240V from V1 to V8.
• Select INTERNAL power on both the CL-7 front panel
and the auxiliary swing panel power switches.

• External power to the CL-7 control and actuator board to

control the RMV-SVR tap changer may be supplied using

24 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

the power input receptacle on the auxiliary swing panel • The actuator board is triggered from the first raise or
inside the control box. lower signal that it receives from the CL-7 and locks out
further input until the end of the tap change cycle, so a
• The control box must be properly grounded. brief actuation of the raise/lower switch in “MANUAL”
• For external power, use a 120 VAC source referenced mode is enough to start and complete a tap change.
to ground. • It is acceptable to hold the raise/lower switch in one
– The neutral terminal is internally connected to position if multiple tap changes are to be made in the
chassis ground. same direction.

– The power source must be capable of supplying • Before reversing the direction of operation of the tap
15 Amps. changer, wait for the completion of a tap change cycle.

• The power input receptacle works with a standard • Due to the longer tap change cycle and differences
NEMA 5-15R extension cord set with normal polarity. in the internal mechanism, the user will notice that
Reversed polarity will short the external power supply the position indicator pointer moves slowly from one
to ground. position to the next compared to the rapid motion
generated by a Quik-Drive tap changer.
• After connecting the power cord, select EXTERNAL
power on both the CL-7 front panel and the auxiliary • If the tap changer fails to operate with the actuator
swing panel power switches to power on the control. board in AUTO or MANUAL mode, check that all wire
harness connections are tight and check the 15A fuse on
• For permanent auxiliary power to the CL-7 control and the actuator board.
actuator board (for example, using substation power)
• In the unlikely event that the tap changer fails to
• Contact the factory for a supplemental wiring move when commanded and/or stalls between taps,
schematic. wait for approximately 10 seconds while the actuator
• Wiring changes will be required on the back panel board resets and then trigger the tap changer to move
to avoid back-feeding the voltage regulator from the in the opposite direction. If the tap changer fails to move
auxiliary power source. again as commanded, there is likely a mechanical jam in
the tap changer or motor drive unit. It is also possible that
the voltage supply and/or temperature are too low.
EVER-Tap with motor drive unit ETMD-A CL-7 control settings
• CL-7 firmware version 1.15.0 or later is required on the Maintenance
CL-7 front panel
• From the CL-7 front panel, use Function Code 49 and The usable life of a regulator will vary depending upon the
select “Eaton ETMD-A”. Alternatively, this setting may be application but in any case, will be extended by periodic
changed using ProView NXG software. inspections and maintenance. Inspection and maintenance
schedules will vary and can be different for the same
• For normal operation using the CL-7 control in AUTO voltage regulator design depending upon system conditions
or LOCAL mode, ensure the actuator board control and loading. The best predictor of future maintenance
switch is in the “AUTO” position. This switch is near the requirements are past experiences.
wire harness connector to the actuator board.
• Emergency manual operation of the tap changer
without a working CL-7 front panel can be performed External Inspection
by moving the actuator board control switch to the • Inspect ground connections to the control box and
“MANUAL” position. A second toggle switch near the tank; take precautions to safely repair and replace any
wire harness of the actuator board is used to manually damaged ground connections.
trigger the actuator board to command “Raise” and
“Lower” operations. • On units installed on wye configured systems, inspect
ground connections to SL bushings; deenergize any unit
• The tap changer actuator board can be disabled by with an ungrounded or poorly grounded SL bushing and
setting the control switch to the “OFF” position between repair the ground connection.
“AUTO” and “MANUAL”.
• From the CL-7 front panel, manual and automatic DANGER
operation is similar to that of a Quik-Drive operation.
For voltage regulators connected in a wye-connected
However, keep these things in mind:
system, an ungrounded SL bushing will be at line
• A complete tap change cycle is approximately 2 voltage. If the ground connection to an SL bushing
seconds under most operating conditions. Cold becomes disconnected, take steps to deenergize the
temperature, especially with a low voltage supply to voltage regulator and reconnect the ground connection.
the control/actuator board, may result in longer cycle Contact with an ungrounded SL bushing will cause
times. death or severe personal injury.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 25

VR-32 and EVER-Tap™ Voltage Regulator

• Inspect bushing for cracks, leaks and signs of Moveable contacts

overheating, replace as necessary. • Inspect the contacts for adequate contact surface area.
• Inspect the tank and metal surfaces for rust; remove rust • Run the tap-changer through all positions checking for
and touch up paint as needed. proper alignment with stationary contacts.
• Inspect the tank, cooling corrugate, and radiators for • Replace excessively worn contacts.
leaks; repair leaks and add insulating fluid if needed.
• Inspect arrestors for signs of failure and test for proper
operation; replace damaged or inoperable arresters. Reversing switch contacts and mechanism
• Inspect contacts for wear.
• Inspect control cables for insulation damage, replace as
needed. • Inspect mechanisms for damage.
• Inspect control cable connections for signs of corrosion; • Replace excessively worn contacts.
clean connections and reseal following instructions in
document MN225058EN.
Stationary contact board and moveable contact arm
• Inspect nameplates for readability; replace unreadable • Inspect for build-up of carbon on surfaces; wipe off any
nameplates. build-up with a rag.
• Inspect control box for leaks; identify cause of leak and • Inspect for signs of arcing or heat damage.
repair.
• Inspect the phenolic contact boards found on legacy
• Inspect pressure relief valve for cleanliness and proper tap-changers for scratches.
operation, clean or replace as necessary.
• Upgrade the phenolic moveable contact arm to the
• Inspect gauges for damage and serviceability, replace as polymer version for the legacy QD8 tap-changer.
necessary.
• Inspect position indicator lens; replace cloudy or damaged
Holding switch
lenses.
• Inspect for proper operation of the switch.
• Inspect position indicator apparatus; replace damaged or
unserviceable position indicators. • Inspect contact surfaces of holding switches on spring-
drive and direct-drive tap-changers for pitting and proper
• Inspect junction box and junction box cover for leaks, spacing as defined in the tap-changer manual.
repair and reseal as necessary.
• On units equipped with cooling fans, inspect fans Position indicator drive mechanism
for proper operation and damage; repair or replace
unserviceable fans and fan equipment.
• Check the position-indicator gears on the tap-changer for
signs of damage or loose parts.
Quik-Drive tap-changers • Check the drive cable for damage and signs of corrosion.
Quik-Drive tap changers are designed to provide many years
of trouble-free operation. If past maintenance requirements
are not known, a first inspection of the Quik-Drive General
tap-changer contacts and other mechanical components • Inspect for any signs of arcing between contact, contact
inside the tank should be performed after 10 years or boards, brackets, tap-changer mechanisms, and any other
100,000 operations. components inside the tank.
Inspection of components inside the tank and maintenance • Check hardware for tightness.
of voltage regulator mechanisms should include the items • Check the reactor tie-rods for tightness.
listed below. Any problems found should be resolved before
placing the units back into service. Consult the tap-changer
• Inspect the core and coil for insulation damage and heat
manuals listed below or contact the Voltage Regulator damage.
Support group at (866) 975-7347 (from outside the U.S. • Remove any loose debris.
and Canada call +1 (262) 896-2591) or e-mail questions to • Evaluate an insulating fluid sample and compare the
[email protected]. results to the requirements found in Table 5 and Table 6.

Stationary contacts
• Inspect the arcing tips for excessive erosion.
• Inspect the contact surface for pitting and scoring.
• Replace excessively worn contacts.

26 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Related manuals Moveable contacts

Review the following tap-changer manuals for additional • Run the tap-changer through all positions checking for
information on contact erosion and tap-changer proper alignment with stationary contacts.
maintenance requirements:
• Replace excessively worn contacts.
• MN225072EN, QD3 Quik-Drive Voltage Regulator
Tap-Changer Manual
• Signs of arcing indicate a malfunctioning vacuum
interrupter or tap changer mechanism.
• MN225012EN, QD5 Quik-Drive Voltage Regulator
Tap-Changer Manual
Reversing switch contacts and mechanism
• MN225011EN, QD8 Quik-Drive Voltage Regulator • Run the tap-changer between neutral and position 1
Tap-Changer Installation and Maintenance Instructions Lower checking for proper alignment with stationary
• S225-10-2, Spring-Drive and Direct-Drive Tap-Changer contacts.
Switches in VR-32 Operating, Maintenance, • Inspect contacts for wear.
Troubleshooting and Parts Replacement Instructions
• Inspect mechanisms for damage.

Duty Cycle Monitor (DCM)

Stationary contact board and moveable contact arms
Another useful indicator of the need for inspection
and maintenance for voltage regulators equipped with
• Inspect for build-up of carbon on surfaces; wipe off any
Quik-Drive tap changers is the DCM control feature. build-up with a rag.
Refer to Service Information MN225003EN, CL-7 Voltage • Inspect for signs of arcing or heat damage.
Regulator Control Installation, Operation, and Maintenance
Instructions, for more information on the DCM feature.
DCM will operate correctly only when a Quik-Drive General
tap-changer is paired with a CL-6 or later control and the • Inspect for any signs of arcing between contacts, contact
control has been programmed with the correct design boards, brackets, tap-changer mechanisms, and any other
specification number. components inside the tank.
• Check hardware for tightness.
EVER-Tap voltage regulator • Check the reactor tie-rods for tightness.
Consult the document MN225077EN (expected release • Inspect the core and coil for insulation damage and heat
date Q4, 2025), EVER-Tap Voltage Regulator Maintenance damage.
Instructions and the inspection recommendations below for
details on maintenance procedures. • Remove any loose debris.
• Evaluate an insulating fluid sample.
500,000 operation inspection
Position indicator drive mechanism
Vacuum interrupter • Check the position-indicator linkage on the motor drive for
• Check the contact erosion indicator. signs of damage or loose parts.
• Check the drive cable for damage and signs of corrosion.
Bypass contacts
• Inspect the contact surface for erosion. 1,000,000 operation maintenance

Stationary contacts General

• Inspect the contact surface for pitting and scoring. • Replace the vacuum interrupter and bypass contacts.
• Replace excessively worn contacts. • Repeat 500,000-operation inspection for all other
contacts and replace contacts as necessary.
• Signs of arcing indicate a malfunctioning vacuum
interrupter or tap changer mechanism. • Repeat the 500,000-operation inspection for all other
components.
• Inspect the tap changer mechanism and motor drive unit
for worn components including bearings, cams, pins, and
microswitches. Replace worn components.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 27

VR-32 and EVER-Tap™ Voltage Regulator

Duty Cycle Monitor (DCM) results would be to compare values between subsequent
This feature is not available for the EVER-Tap voltage tests. Unusually rapid buildup of gases from one test to
regulator. another could be a sign of internal problems. Contact the
Voltage Regulator Support group at (866) 975-7347 (from
outside the U.S. and Canada call +1 (262) 896-2591) or
Operational check e-mail questions to [email protected] for further
assistance in evaluating DGA results.
Proper operation of the regulator can be checked without
removing the unit from service. When performing periodic maintenance of voltage
regulators, insulating fluid characteristics should be
To perform an operational check: evaluated. See Table 5 and Table 6 for information on the
characteristics that would be part of the evaluation and the
1. Place the CONTROL FUNCTION switch in LOCAL
levels to be measured against. When the fluid fails to meet
MANUAL.
the requirements shown in the tables, steps should be
2. Manually run the regulator several steps in the raise taken to filter or replace the fluid. These steps should be
direction until the OUT-OF-BAND HIGH LED illuminates performed during normal maintenance intervals.
continuously.
3. Place the CONTROL FUNCTION switch in AUTO/
REMOTE. After the time delay expires, the regulator
EVER-Tap voltage regulator insulating fluid
should return to within the band edge and the OUT-OF- maintenance
BAND HIGH LED should go out. The EVER-Tap voltage regulator is equipped with an arc
4. Again place the CONTROL FUNCTION switch in LOCAL interrupter. The arc occurring during tapping operations
MANUAL. occurs inside of the vacuum bottle. As a result, the
dielectric fluid will not become contaminated in the same
5. Manually run the regulator several steps in the lower way as a conventional voltage regulator. Dissolved gas
direction until the OUT-OF-BAND LOW LED illuminates analysis results from an EVER-Tap voltage regulator can be
continuously. treated like the results from a conventional transformer or
OLTC.
6. Place the CONTROL FUNCTION switch in AUTO/
REMOTE. After the time delay expires, the regulator
should return to within the band edge and the OUT-OF-
BAND LOW LED should go out. Table 5.  Envirotemp™ FR3™ Fluid Characteristics
(natural ester a)
7. If the operations check does not complete successfully,
review the troubleshooting section of this manual Characteristic New Used
and refer to Service Information MN225003EN, CL-7 Dielectric Strength (kV) ASTM D1816:
Voltage Regulator Control Installation, Operation, and
2-mm gap ≥ 45 ≥ 40
Maintenance, for more instructions.
1-mm gap ≥ 25 ≥ 23
8. If further assistance is required, contact the Voltage
Interfacial Tension (mNm) ASTM D971-91 — —
Regulator Support group at (866) 975-7347 (from b
outside the U.S. and Canada call +1 (262) 896-2591) or Water (mg/kg) ASTM D1533 ≤ 300
e-mail questions to [email protected]. a Per IEEE Std C57.147™-2008 standard

b Recommended limit is application- and user-specific. Suggested limit would be the same
relative saturation limit used for mineral oil at a given temperature.
Insulating fluid maintenance
The operation of a conventional step voltage regulator
includes switching of a load tap-changer. Switching of this Table 6.  Mineral Oil Characteristics (Type II a)
tap-changer will result in a small amount of arcing during Characteristic New Used
each operation. This is different from a typical transformer
or voltage regulator equipped with a vacuum interrupter. Dielectric Strength (kV) ASTM D1816:
Under normal conditions, you would expect no internal 2-mm gap ≥ 45 ≥ 40
arcing in a transformer and as a result, elevated levels of 1-mm gap ≥ 25 ≥ 23
arcing gases are an indication of trouble. For conventional
voltage regulators, arcing occurs inside the tank on every Interfacial Tension (mNm) ASTM D971 ≥ 38 ≥ 25
tap change. As a result, it is expected that gas levels will Water (mg/kg) ASTM D1533 ≤ 20 ≤ 35
build up over time. a Per IEEE Std C57.106™-2006 standard

Because of the characteristic arcing of tap-changer contacts,

dissolved gas analysis (DGA) is only marginally useful when
evaluating insulating fluid from single-phase step voltage
regulators (SVR). There are no industry standards to evaluate
DGA results for an SVR. The best method of evaluating DGA

28 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Sampling insulating fluid Untanking the regulator

Care should be taken to ensure the best specimen
possible when sampling insulating fluid. Here are some CAUTION
recommendations: Equipment Misoperation. Do not subject tap-changer
• Check the insulating fluid level before and after sampling with phenolic contact boards to temperatures above
to insure that there is sufficient fluid in the tank to meet 150 °F (66 °C). To do so may cause damage to the
or exceed the critical oil level. contact panels, resulting in misalignment of the
contacts, and can cause personal injury and equipment
• Liquid samples must be drawn from the sampling valve damage.
located at the bottom of the voltage regulator tank.
• A sample of the liquid should be taken when the unit is CAUTION
warmer than the surrounding air to avoid condensation of
Equipment Damage. Before untanking a regulator that
moisture on the liquid.
contains a thermometer: (1) Lower the insulating fluid
• Relieve tank pressure or vacuum by operating the level below the thermometer, then; (2) Remove the
pressure relief valve before taking the sample. Care thermometer well. Failure to do so will result in damage
should be taken to wipe the valve clean and dry before to the thermometer well and can cause spillage of the
pulling the ring. insulating fluid when the internal assembly is lifted,
causing personal injury.
• Collect liquid into a large-mouth glass bottle that is clean
and dry.
CAUTION
• When sampling, a metal or non-rubber hose must be
used; oil will leach sulfur from rubber. Equipment Damage. Do not suspend the control
box using the control cable. The control cable is not
• Before collecting a sample, drain a sufficient amount of designed to support the weight of the control box.
fluid from the valve to ensure that the sample collected is The control box can fall, causing personal injury and
not from the valve, but from the bottom of the tank. equipment damage.
• Before collecting a sample, rinse the sampling bottle
three times with the liquid being sampled. Before untanking a voltage regulator, remove it from
service following the instructions found in this manual
• Do not permit the fluid to splash into sampling container; in “Removal from service” on page 13. Untanking is
splashing can introduce air and moisture into the fluid. performed in order to inspect the internal components and
• Test samples should be taken only after the fluid has perform maintenance. A voltage regulator can be partially
settled for at least 24 hours; longer for cold fluid. untanked for most routine maintenance and inspections. If
a more in-depth inspection or maintenance is needed, a full
untanking can also be performed.
WARNING
Steps for untanking:
Equipment damage, personal injury or death possible.
Do not lower fluid in tank below the critical fluid level. 1. Manually run the tap-changer to neutral. If that tap
Insufficient fluid risks unit failure, which could result in changer cannot be returned to neutral, record the
severe personal injury or death to exposed personnel. position indicator reading before proceeding so the
position indicator can be returned to the correct
position before retanking.
FR3 insulating fluid application 2. Disconnect the control cable from the bottom of the
Viscosity characteristics of FR3 necessitate a mechanism junction box (see Figure 2).
to inhibit tap-changer operations for low-temperature 3. Remove the series arrester to avoid damaging
applications. the arrester and bushings while lifting the internal
In such cases, a thermometer will be provided as a standard components.
feature. The thermometer will be configured to close a 4. Disconnect the cover ground strap (see Figure 1).
contact when insulating fluid temperatures reach -10 °C.
5. Release the tank pressure by pulling the ring on the
With the contact closed, auto operation will be inhibited. pressure-relief device located on the side of the tank.
The CL-7 control will illuminate the Auto Tap Blocked LED
and display Blocked: CL or Comm on the Metering-PLUS 6. Free the cover by removing the cover band or cover
Load Current screen. bolts.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 29

VR-32 and EVER-Tap™ Voltage Regulator

WARNING
The lifting eyes on the top of the voltage regulator are
to be used for untanking only. Attempting to lift the
entire voltage regulator using the lifting eyes could
cause the tank to separate from the cover and fall to
the ground. This could cause death, personal injury, or
property damage.

7. Attach lifting straps with a spreader bar to the lifting

eyes on top of the cover.

WARNING
Personal Injury. Do not rely on the lifting apparatus
when the internal assembly is lifted for inspection or
maintenance. Blocking should be placed between the
cover and the top of the tank when partially untanking
the voltage regulator to keep the assembly from falling,
which can cause death or severe personal injury and
equipment damage.

8. Lift the assembly:

a. For partial untanking: lift the assembly until the
top of the coil is approximately one inch under the
insulating fluid (see Figure 25).
b. For Full untanking: lift the assembly until the
bottom of the assembly clears the tank. The
assembly can be suspended for a period of time
until the oil dripping slows. The internal assembly
can then be placed on a drip tray. Make sure to
return the core and coil to oil within 4 hours.

Figure 25.  Untanking the voltage regulator

30 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Retanking the regulator 8. Check and retighten the horizontal, side-channel bolts
through the hand hole; torque to 50 ft-lbs (68 Nm).
Steps for retanking:
9. Properly reseal the hand-hole cover, being careful not to
1. If the core and coil assembly have been out of oil for damage the cover or the gasket.
more than 4 hours, the coil must be dried, as follows:
10. Connect the cover ground strap (see Figure 1).
a. Bake the unit at 100˚C (212˚F) for 24 hours.
11. Connect the control cable to the connector at the
Note: Units equipped with a phenolic tap-changer bottom of the junction box.
must be baked at a maximum temperature
of 66˚C (150˚F). 12. Pull a vacuum on the unit for at least one hour at
2 mm Hg (2 Torr) of vacuum or better after the unit is
Note: A unit can be rebaked a maximum of two completely refilled with fluid.
times over its life.
Note: If vacuum processing is not available, allow the
b. After baking, check all hardware for tightness. entire internal assembly to soak in fluid for at
c. Within four hours after baking, retank the unit and least 24 hours before energizing.
fill it with fluid.
Note: If baking is not possible or practical, see Leak Test
“Regulator dry-out procedure” on page 35 After retanking, a leak test is recommended to ensure that
for an alternative to baking. the cover is properly seal. To perform a leak test, take these
2. Verify that the position indicator shows the present steps:
position of the tap-changer. 1. Ensure that all appropriate plugs, valves, oil level
Note: If the position indicator is not showing the indicators, and thermometers are installed.
present position of the tap-changer, proceed as 2. Ensure that the outside areas of the tank, cover, cover
follows: band, bushings, plugs, valves, and position indicator
a. Remove the indicator cable in the junction box are free of oil.
box from the position indicator shaft after 3. Remove the pressure relief valve and in its place, install
loosening the set screw. a Schrader valve.
b. Rotate the indicator shaft until the proper 4. Apply dry nitrogen to the unit through the Schrader
position is reached; then tighten the set valve to a pressure shown in Table 7.
screw.
Table 7.  Tanks Pressures for Leak Testing
c. Verify coordination of the position indicator
with the tap-changer in the neutral position Minimum
(control neutral light on). lbs/psi Time (hours)

3. Check the gasket seat surfaces on the cover and tank, Round Tanks w/Radiators 10 1
and wipe clean. Wipe the gasket and position it on the Round and Square Tanks w/Corrugate (All 7 1
tank lip. Mild Steel Corrugate, Any Stainless Steel
Corrugate Less Than 12”)
4. Loosen the horizontal, side channel bolts to ensure Round and Square Tanks w/ Stainless Steel 5 2
proper seating of the regulator in the tank and proper Corrugate 12” or Larger
cover seal.
The unit is considered to have passed the leak test if the
5. Raise the cover assembly and attached components following requirements have been met:
over the tank. Make certain of proper orientation.
• No more than 0.5 psi pressure loss over the period
6. Lower the unit, rotating the channels counter-clockwise specified in Table 7.
into the tank guides.
• No oil leaks at the welded seams, radiators, and gasket
7. Seat the unit in the tank. Tighten the cover band surfaces above and below the oil line.
or bolts. Torque the cover band to 18 – 22 ft-lbs
(24.4 – 29.8 Nm). Make sure the ends of the cover If the unit does not pass the leak test, steps should be
band do not touch when fully tightened. Torque taken to reseal the tank cover or repair leaks as necessary.
the cover bolts on a square-tanked regulator to Be sure to replace the pressure relief valve after completing
24 – 26 ft-lbs (32.5 – 35.6 Nm). the test.
Note: On round tanks, tap the cover with a rubber
hammer around the edge to assist in providing a
good seal while tightening the cover band.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 31

VR-32 and EVER-Tap™ Voltage Regulator

Spare parts Troubleshooting

Ordering Information For troubleshooting instructions, refer to Service Information
MN225003EN, CL-7 Voltage Regulator Control Installation,
When ordering replacement parts or field-installation Operation, and Maintenance Instructions. The procedures
accessories for your Eaton voltage regulator, provide the in this section provide terminal markings for a single-phase
following information: control. If troubleshooting is being performed on a regulator
• Regulator serial number (found on nameplate) with a multi-phase control, the terminals corresponding
to the phase in question should be used. See Table 8 for
• Regulator catalog number (found on nameplate) assistance in identifying the correct terminals.
• Part number if known (not required) Table 8.  Single-phase and multi-phase control back-
• Photo of part is helpful panel markings
Single-Phase Multi-Phase Control Markings
• Description of each part
Control
• Quantity of each part required Markings VR1 VR2 VR3 Function

Refer to the following Service Information documents for V1 V1A V1B V1C Load-Side PT
information on Eaton’s Cooper Power series tap-changer V6 V6A V6B V6C Differential PT
maintenance and replacement parts: C CA CB CC CT Shorting Switch
• MN225072EN, QD3 Quik-Drive Voltage Regulator C2 - - - CT +
Tap-Changer Manual C3 - - - CT +
R1 R3 R-B R-C Motor Raise
• MN225012EN, QD5 Quik-Drive Voltage Regulator
Tap-Changer Manual L1 L3 L-B L-C Motor Lower
G G G G Ground
• MN225011EN, QD8 Quik-Drive Voltage Regulator
Tap-Changer Manual HS HS HSB HSC Holding Switch

For additional assistance, call the Voltage Regulator Support

line at (866) 975-7347 (calls from outside the U.S.:262-896-
2591) or e-mail questions to [email protected].

Regulator control reverse power flow test

Purpose
The purpose of this procedure is to test the voltage
regulator and control to ensure correct operation in
response to reverse power flow.

Required equipment
• Clamp-on ammeter
• Appropriate cable leads
• 2 – 120 V variable power supplies

Procedure

WARNING
Hazardous Voltage. This procedure must only be
performed on a regulator that has been removed from
service. Failure to comply can cause serious injury or
death.

1. Remove the unit from service as described in

“Removal from service” on page 13.

32 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

control REVERSE POWER LED does not illuminate, the

WARNING control is in the forward mode. Reversing the voltage
Hazardous Voltage. When troubleshooting energized source leads on the L and SL bushings should cause
equipment, protective gear must be worn to avoid the control panel REVERSE POWER LED to illuminate,
personal contact with energized parts. Failure to comply indicating the control is in the reverse power flow
can cause serious injury or death. mode.

2. Conduct this test with the regulator located in the

maintenance shop or other suitable location. Voltage regulator ratio test
Purpose
WARNING
The purpose of this test is to:
Hazardous Voltage. The regulator tank must be solidly
earth grounded. Failure to comply can cause severe • Confirm correct series winding tap-changer connections.
personal injury and equipment damage. • Identify an open or short-circuit in the series or shunt
windings.
3. Ground the regulator tank.
Required equipment
4. Connect a cable sized for the regulator rated current
between the S (Source) and the L (Load) bushings. • Voltmeter
• 2 - 120 V variable power supplies
5. Install a clamp-on ammeter on the cable between the S
and L bushings to verify the current during the test. Procedure
6. Open the V1, V6, and C, switches and, if present, also
open the V2 and V8 switches on the control assembly WARNING
back panel. Hazardous Voltage. This procedure must only be
performed on a regulator that has been removed from
CAUTION service. Failure to comply can cause serious injury or
death.
Equipment Damage. When connecting external power to
the voltage regulator control, make sure the polarity of 1. Remove the unit from service as described in
the power source is correct. Reverse polarity will result “Removal from service” on page 13.
in control damage. VR-T235.0
2. Connect a voltmeter between the L (Load) and SL
(Source-Load) bushings.
CAUTION
3. Use a variac to apply 120 Vac between the S (Source)
Equipment Damage. Only an AC power supply is to be and SL bushings.
used to energize the control externally. Do not use a
DC-to-AC voltage inverter. Failure to comply can cause
excessive harmonics to be generated and result in
CAUTION
damage to the control. VR-T204.1 Electrical Shock Hazard. Connecting an energized
variac to the bushings will expose the tester to 120 Vac.
7. Apply 120 Vac to the control EXTERNAL SOURCE Contact with the bushings will result in an electrical
terminals. For instruction on connecting the control shock.
to an external source, see Service Information
MN225003EN, CL-7 Voltage Regulator Control
Installation, Operation, and Maintenance Instructions. WARNING
8. Using the manual RAISE/LOWER switch, place the Electrical Shock Hazard. The V1, V2, V6, and V8
regulator on the 3 Raise position. (whichever are present) knife-blade switches must be
open when connecting external power to the control.
9. Check control settings and correct if necessary. Ensure With some controls, if 120 Vac is incorrectly applied to
that FC56 is set for bidirectional. This will allow the the voltmeter terminals and the switches remain closed,
control to function in both the forward and reverse rated voltage could be created on the bushings. Contact
power flow directions. with the bushings in such a case could result in death
10. Connect a variable source between the L and SL or serious injury.
(Source-Load) bushings and increase the applied
voltage until 50% of the current rating is reached: this CAUTION
should be around 55 V.
Incorrect connection of an external power source to
11. Depending on the polarity of the voltage applied to the the control or supply of an over-voltage will result in
L and SL bushings, the control will operate in either damage to the control panel.
the forward or reverse power flow direction. If the

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 33

VR-32 and EVER-Tap™ Voltage Regulator

4. Connect a separate 120 Vac supply to the EXTERNAL Note: On a type B regulator, the difference between
SOURCE terminals on the control front panel. Move the taps will be slightly less than calculated as
the control power switch to the EXTERNAL position to the regulator is tapped toward 16 Lower. This is
operate the tap-changer. normal and inherent in the design of the type B
regulator.
Note: For instruction on connecting the control to
an external source, see Service Information Questions about the described procedure may be directed
MN225003EN, CL-7 Voltage Regulator Control to the Voltage Regulator Support group at (866) 975-7347
Installation, Operation, and Maintenance (from outside the U.S. and Canada call +1 (262) 896-2591)
Instructions. or e-mail questions to [email protected].
5. Increase the voltage on the variac to 120 Vac. This will
provide 12 V on the series winding.
Voltage regulator potential transformer ratio test
120 Vac x 10% regulation = 12 V
Purpose
6. Calculate the change in volts per tap change as follows: The purpose of this test is to verify proper potential
transformer ratio.
series winding volts = 12 = 0.75 V per step
   16 steps 16 Required equipment
Note: If 160 Vac is applied between the S and SL • Voltmeter
bushings, the calculations in step 5 and step 6 are • 120 V variable power supply
computed, you will see that a 1.0 volt difference • Appropriate cable leads
between steps will result. Doing this will simplify • Calculator
the ratio check.
Procedure
Table 9.  Typical meter readings with 120 Vac
connected between the S and SL bushings
WARNING
Hazardous Voltage. This procedure must only be
Lower Raise
performed on a regulator that has been removed from
16L - 108.0 16R - 132.0 service. Failure to comply can cause serious injury or
15L - 108.75 15R - 131.25 death.
14L - 109.5 14R - 130.5
13L - 110.25 13R - 129.75 WARNING
12L - 111.0 12R - 129.0 Hazardous Voltage. When troubleshooting energized
11L - 111.75 11R - 128.25 equipment, protective gear must be worn to avoid
10L - 112.5 10R - 127.5 personal contact with energized parts. Failure to comply
9L - 113.25 9R - 126.75 can cause serious injury or death.
8L - 114.0 8R - 126.0 1. Remove the unit from service as described in
7L - 114.75 7R - 125.25 “Removal from service” on page 13.
6L - 115.5 6R - 124.5 2. Open the back-panel knife switch marked V1.
5L - 116.25 5R - 123.75
3. Note the correct PT ratio as given for the pinned Load
4L - 117.0 4R - 123.0
Volts on the nameplate under the Internal PT Ratio
3L - 117.75 3R - 122.25 column. The tap setting of the PT can be verified by
2L - 118.5 2R - 121.5 inspecting the tap-changer terminal board connection
1L - 119.25 1R - 120.75 through the hand-hole on the regulator cover. The
Neutral 120 tap-changer terminal board is located on the top of the
tap-changer under oil. The connection will be to E1, E2,
or E3 made by a wire from above the terminal board
7. Operate the tap-changer with the control switch marked E; this should correspond to the PT ratio for the
through all 32 steps from 16 Raise to 16 Lower. voltage pinned on the nameplate.
Record the voltmeter reading at each tap position. The
change in voltage should be almost the same between 4. With the regulator in the neutral position, connect 120
each step (± 0.10 volts). If a substantial difference in Vac between the S (Source) and the SL (Source Load)
any reading exists, then there is a problem with the bushings.
windings or their connection. Readings will be the 5. Using the formula below, determine the expected
same with or without the equalizer winding. output voltage of the PT.
Expected Voltage = 120 Vac/PT Ratio

34 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

6. Measure the voltage between the top of the V1

switch and the terminal strip ground marked G. The WARNING
expected voltage should equal the measured voltage. Hazardous Voltage. The regulator tank must be solidly
A significant difference between the expected and earth grounded. Failure to comply can cause severe
measured voltages indicates a problem with the PT or personal injury and equipment damage.
PT connection.
5. Ground the regulator tank.
6. Using a variac apply impedance voltage at 16 Raise
Regulator dry-out procedure between the S and L bushings. Raise the voltage until
rated current is read on the ammeter. Impedance
Purpose
voltage values may be obtained from the factory. For
The purpose of this procedure is to remove moisture assistance contact the Voltage Regulator Support
from the paper insulation, coil, and other components of a group at (866) 975-7347 (from outside the U.S. and
voltage regulator. Canada call +1 (262) 896-2591) or e-mail questions to
[email protected].
Required equipment and information
7. Let the regulator set in this condition for approximately
• Impedance voltage value obtained from factory 24 hours. This will drive the moisture out of the coil into
• 120 V variable power supply the insulating fluid.
• Cable lead jumper rated for nominal current
• Clamp-on ammeter 8. De-energize the regulator and drain the insulating fluid.
• Variable power supply sufficient to apply impedance voltage
• New insulating fluid 9. Refill with new insulating fluid.
• Insulation power factor test equipment 10. Check the results of the procedure by performing
an insulation power factor test after the regulator
Procedure temperature has stabilized to the ambient temperature.
WARNING
Hazardous Voltage. This procedure must only be Voltage regulator current test
performed on a regulator that has been removed from
service. Failure to comply can cause serious injury or Purpose
death. The purpose of this test is to confirm operation of the
current transformer (CT) and voltage regulator control
1. Remove the unit from service as described in current measurement.
“Removal from service” on page 13.
Note: When performing this test on units with a multi-
WARNING phase control, there will not be jumpers available,
as described in step 7, to facilitate connection of
Hazardous Voltage. The regulator will be energized with
load current present for the duration of the procedure. an ammeter. To connect the ammeter, the green
The regulator must be placed in a protected area, control cable wires connected to the top of the
preventing anyone from coming in contact with the CCA, CCB, and CCC switches (for VR1, VR2, and
unit. Failure to do so could result in injury or possible VR3 respectively) can be disconnected and then the
death. ammeter can be connected between the green wires
and the top of the switches.
2. Perform this procedure with the regulator located in
a protected area in the maintenance shop or other
suitable location. Required equipment
• 2 - 120 V variable power supply
3. Place regulator on the 16 Raise position using external • Cable lead jumper rated for nominal current
power. For instruction on connecting the control to an • Clamp-on ammeter
external source, see Service Information MN225003EN, • Small needle-nose pliers
CL-7 Voltage Regulator Control Installation, Operation, • Milli-ammeter
and Maintenance Instructions.
4. Place a jumper, rated for nominal current, between the Procedure
S (Source) and L (Load) bushings. A clamp-on ammeter
should be used to measure the current in the shorted WARNING
current path. Hazardous Voltage. This procedure must only be
performed on a regulator that has been removed from
service. Failure to comply can cause serious injury or
death.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 35

VR-32 and EVER-Tap™ Voltage Regulator

1. Remove the unit from service as described in tap-changer moves from Neutral to 16 Raise position.
“Removal from service” on page 13. The current will reach its maximum value at a specific
position dependent on the type and rating of the
WARNING regulator. Current reduces to zero when it reaches the
neutral position.
Hazardous Voltage. When troubleshooting energized
equipment, protective gear must be worn to avoid
personal contact with energized parts. Failure to comply
can cause serious injury or death.
2. Conduct this test with the regulator located in the
maintenance shop or other suitable location.

CAUTION
Equipment Damage. When connecting external power to
the voltage regulator control, make sure the polarity of
the power source is correct. Reverse polarity will result
in control damage.

CAUTION
Equipment Damage. Only an AC power supply is to be
used to energize the control externally. Do not use a
DC-to-AC voltage inverter. Failure to comply can cause
excessive harmonics to be generated and result in
damage to the control.
3. Use an external source to power the control and
enable tap-changer operation. See Service Information
MN225003EN, CL-7 Voltage Regulator Control
Installation, Operation, and Maintenance Instructions,
for detailed information on powering the control
externally.
4. Place a jumper, rated for nominal current, between the S
(Source) and L (Load) bushings. Use a clamp-on ammeter Figure 26.  Removing jumper between C2 and C3
to measure the current in the jumper during the test.

WARNING
Hazardous Voltage. The regulator tank must be solidly
earth grounded. Failure to comply can
cause severe personal injury and equipment damage.
5. Ground the regulator tank.
6. Close C knife switch on the back panel.
7. Remove the jumper from between the C2 and C3
terminals to the left of the V1 switch, on the back
panel. See Figure 26. Place a milli-ampere meter
between these terminals. See Figure 27.
8. Using a variable voltage source, place approximately
120 V between the L and SL (Source-Load) bushings
until a current value is shown on the clamp-on meter.
9. Open the knife switch C on the back panel. The milli-
ampere meter should indicate a current value based on
the CT ratio shown on the rating plate.
10. Run the voltage regulator through all of the tap Figure 27.  Milli-ammeter connection points
positions to check the continuity and reveal any
possible intermittent opens. The current indicated on
the clamp-on meter will increase or decrease as the

36 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Insulation resistance test 6. Using the variac on the tester, bring the voltage up to
the desired test level. Refer to the instructions provided
Purpose with the test equipment for guidelines on voltage test
The purpose of this procedure is to describe the proper levels.
connections and procedure when performing an insulation 7. Read the test value in mega-ohms; then compare the
power factor test on a voltage regulator. reading with the baseline reading:
Required Equipment • If the new reading is lower than the baseline
reading, further testing and evaluation of the
• 120 V variable power supply
insulation is recommended.
• Cable lead jumper rated for nominal current
• Insulation power factor test equipment • If the new reading is the same as or higher than
the baseline reading, no further testing is indicated.
Procedure

WARNING Freeing a stalled tap-changer

Hazardous Voltage. This procedure must only be Purpose
performed on a regulator that has been removed from
service. Failure to comply can cause serious injury or The purpose of this procedure is to free a tap-changer that
death. has experienced a mechanical jam that prevents operation.

1. Remove the unit from service as described in Required Equipment

“Removal from service” on page 13. • Voltmeter
2. Conduct this test with the regulator located in the • Terminal-board tool
maintenance shop or other suitable location. • Screwdriver (screw-type terminal boards only)

Note: The regulator tank must be isolated from ground Procedure

potential. 1. Confirm that a stall has occurred. If the tap-changer
is stalled between tap positions with the holding
CAUTION switch closed, a voltmeter placed between terminals
R1 and G or L1 and G on the back panel will read
Equipment Damage. When connecting external power to approximately 120 Vac. The terminal measuring 120 Vac
the voltage regulator control, make sure the polarity of will be the direction the tap-changer was moving
the power source is correct. Reverse polarity will result when stalling occurred. There will likely be a floating
in control damage. capacitive voltage in the other direction greater than
120 Vac. If there is little or no voltage in the other
CAUTION direction, it is likely that the motor capacitor has failed.
After determining the stall direction, the steps of this
Equipment Damage. Only an AC power supply is to be procedure can be used to reverse the direction of the
used to energize the control externally. Do not use a tap-changer to free the mechanism.
DC-to-AC voltage inverter. Failure to comply can cause
excessive harmonics to be generated and result in 2. Place the CONTROL FUNCTION switch in OFF
damage to the control. position.
3. Place the regulator in the 16 Lower position. Power 3. Place the POWER switch in OFF position.
the control using an external power source to enable
4. Close the C switch on the back panel of the control.
tap-changer operation. See Service Information
MN225003EN, CL-7 Voltage Regulator Control 5. Open the V1 disconnect switch on the back panel of
Installation, Operation, and Maintenance Instructions, the control, removing power from the control.
for detailed information on powering the control
externally. CAUTION
4. Place a jumper, rated for nominal current, tying all the Hazardous Voltage. The lead terminal “HS” could have
bushings together. 120 V present when disconnected from the terminal
Note: This test is very sensitive to contamination on board. Do not touch the lead terminal or allow the
the regulator bushings. Make sure to clean terminal to make contact with any surface. Failure to
the bushing surface of all debris and oxidation comply can cause personal injury or blow a fuse.
before preforming the test. 6. Disconnect the orange wiring harness lead from the
5. Close C knife switch on the back panel. HS terminal on the terminal board located on the
back panel; this removes power from the tap-changer
holding switch.

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 37

VR-32 and EVER-Tap™ Voltage Regulator

7. Close the V1 disconnect switch.

8. Place the POWER switch on INTERNAL.
9. Place the CONTROL FUNCTION switch on LOCAL
MANUAL.
10. Jog the RAISE/LOWER switch in the direction the
capacitive voltage was observed. This should allow the
tap-changer to free itself. Using the RAISE/LOWER
switch, run the tap-changer one or two steps. Inspect
the position indicator to verify that the indicating
pointer is directly over a tap position mark. If the
pointer is not directly over a tap position mark, jog the
RAISE/LOWER switch in the same direction as done
previously. This should put the pointer in the correct
position.
11. Place the CONTROL FUNCTION switch on OFF.
12. Place the POWER switch on OFF.
13. Open V1 disconnect switch.
14. Reconnect the orange lead to the HS terminal restoring
power to holding switch.
15. Close the V1 disconnect switch.
16. Open the C switch.
17. Place the POWER switch on INTERNAL.
18. Turn CONTROL FUNCTION control switch to LOCAL
MANUAL.
19. Using the RAISE/LOWER switch, step the regulator to
the neutral position.
20. Once the tap-changer stall has been freed, it is
recommended that the voltage regulator be removed
from service as soon as possible and evaluated to
determine the cause of the problem and perform
maintenance.
Refer to “Removal from service” on page 13
and Service Information MN225003EN, CL-7
Voltage Regulator Control Installation, Operation,
and Maintenance Instructions, for detailed service
information and safe bypassing instructions.

38 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Appendix
Connections and voltage levels
Table 10.  Tap connections & voltage levels (60 Hz) Table 10.  (continued)
Nominal Ratio-Adjusting Data Nominal Ratio-Adjusting Data
Regulator Single- Test Overall Regulator Single- Test Overall
Voltage Phase Internal PT RCT Terminal Potential Voltage Phase Internal PT RCT Terminal Potential
Rating Voltage Tap a Ratio Tap Voltage b Ratio b Rating Voltage Tap a Ratio Tap Voltage b Ratio b
1 2 3 4 5 6 7 1 2 3 4 5 6 7
2500 2500 – 20:1 120 125 20:1 34500 34500 E1/P1 287.5:1 120 120 287.5:1
2400 – 20:1 120 120 20:1 19920 E2/P2 165.5:1 120 120.5 165.5:1
5000 5000 E1/P1 40:1 120 125 40:1 a P taps are used with E taps only on regulators where an internal potential transformer is
4800 E1/P1 40:1 120 120 40:1 used in conjunction with the control winding to provide voltage supplies to the control.
4160 E1/P1 40:1 104 120 34.7:1 See nameplate for verification of this type of control supply.
b Test terminal voltage and overall potential ratio may vary slightly from one regulator to
2400 E2/P2 20:1 120 120 20:1
another. See the regulator nameplate for determining the exact values.
7620 8000 E1/P1 60:1 133 120.5 66.5:1
7970 E1/P1 60:1 133 120 66.5:1
7620 E1/P1 60:1 127 120 63.5:1
7200 E1/P1 60:1 120 120 60:1
6930 E1/P1 60:1 115 120.5 57.5:1
4800 E2/P2 40:1 120 120 40:1
4160 E2/P2 40:1 104 120 34.7:1
2400 E3/P3 20:1 120 120 20:1
13800 13800 E1/P1 115:1 120 120 115:1
13200 E1/P1 115:1 115 120 110.2:1
12470 E1/P1 115:1 104 120 99.7:1
12000 E1/P1 115:1 104 120 99.7:1
7970 E2/P2 57.5:1 133 120 63.7:1
7620 E2/P2 57.5:1 133 120 63.7:1
7200 E2/P2 57.5:1 120 120 57.5:1
6930 E2/P2 57.5:1 120 120 57.5:1
14400 14400 E1/P1 120:1 120 120 120:1
13800 E1/P1 120:1 115 120 115:1
13200 E1/P1 120:1 110 120 110:1
12000 E1/P1 120:1 104 115.5 104:1
7970 E2/P2 60:1 133 120 65.5:1
7620 E2/P2 60:1 127 120 63.5:1
7200 E2/P2 60:1 120 120 60:1
6930 E2/P2 60:1 150 120.5 57.5:1
19920 19920 E1/P1 166:1 120 120 166:1
17200 E1/P1 166:1 104 119.5 143.9:1
16000 E2/P2 120:1 133 120.5 133:1
15242 E2/P2 120:1 127 120 127:1
14400 E2/P2 120:1 120 120 120:1
7970 E3/P3 60:1 133 120 65.5:1
7620 E3/P3 60:1 127 120 63.5:1
7200 E3/P3 60:1 120 120 60:1

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 39

VR-32 and EVER-Tap™ Voltage Regulator

Table 11.  Tap connections & voltage levels (50 Hz)

Regulator Nominal Ratio-Adjusting Data Test Overall
Voltage Single-Phase Terminal Potential
Rating Voltage Internal Tap a PT Ratio RCT Tap Voltage b Ratio b
1 2 3 4 5 6 7
6600 6930 – 54.9:1 127 119.2 58.1:1
6600 – 54.9:1 120 120.1 54.9:1
6350 – 54.9:1 115 120.6 52.6:1
6000 – 54.9:1 110 119.2 50.4:1
5500 – 54.9:1 104 115.5 47.6:1
11000 11600 E1/P1 91.6:1 127 119.7 96.9:1
11000 E1/P1 91.6:1 120 120.1 91.6:1
10000 E1/P1 91.6:1 110 119.1 84.0:1
6930 E2/P2 55.0:1 127 119.1 58.2:1
6600 E2/P2 55.0:1 120 120.1 55.0:1
6350 E2/P2 55.0:1 115 120.6 52.7:1
6000 E2/P2 55.0:1 110 119.1 50.4:1
5500 E2/P2 55.0:1 104 115.5 47.6:1
15000 15000 E1/P1 120:1 120 125.0 120.0:1
14400 E1/P1 120:1 120 120.0 120.0:1
13800 E1/P1 120:1 115 120.0 115.0:1
13200 E1/P1 120:1 110 120.0 110.0:1
12000 E1/P1 120:1 104 115.4 104.0:1
11000 E2/P2 91.8:1 120 119.9 91.8:1
10000 E2/P2 91.8:1 110 118.9 84.1:1
6600 E3/P3 53.8:1 120 122.7 53.8:1
22000 22000 E1/P1 183.4:1 120 120.0 183.4:1
20000 E1/P1 183.4:1 110 119.0 168.1:1
19100 E1/P1 183.4:1 104 120.2 158.9:1
15000 E2/P2 122.3:1 120 122.7 122.3:1
12700 E2/P2 122.3:1 104 119.9 106.0:1
11000 E3/P3 91.7:1 120 120.0 91.7:1
10000 E3/P3 91.7:1 110 119.0 84.0:1
33000 33000 E1/P1 275.0:1 120 120.0 275.0:1
30000 E1/P1 275.0:1 110 119.0 252.1:1
22000 E2/P2 183.3:1 120 120.0 183.3:1
20000 E2/P2 183.3:1 110 119.0 168.1:1
11600 E3/P3 91.7:1 127 119.0 97.0:1
11000 E3/P3 91.7:1 120 120.0 91.7:1
10000 E3/P3 91.7:1 110 119.0 84.0:1
a P taps are used with E taps only on regulators where an internal potential 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.
b Test terminal voltage and overall potential ratio may vary slightly from one regulator to another. See the regulator
nameplate for determining the exact values.

40 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

ADD-AMP capabilities
Table 12.  ADD-AMP capabilities of 60 Hz ratings Table 12.  (continued)
Load Current Ratings (A) a Load Current Ratings (A) a
Regulation Range (Wye and Open Delta) Regulation Range (Wye and Open Delta)
± 10% ± 8.75% ± 7.5% ± 6.25% ± 5% ± 10% ± 8.75% ± 7.5% ± 6.25% ± 5%
Rated Rated Regulation Range (Closed Delta) Rated Rated Regulation Range (Closed Delta)
Volts kVA ± 15% ± 13.1% ± 11.3% ± 9.4% ± 7.5% Volts kVA ± 15% ± 13.1% ± 11.3% ± 9.4% ± 7.5%
2500 50 200 220 240 270 320 14400 72 50 55 60 68 80
75 300 330 360 405 480 144 100 110 120 135 160
100 400 440 480 540 640 288 200 220 240 270 320
125 500 550 600 668 668 333 231 254 277 312 370
167 668 668 668 668 668 416 289 318 347 390 462
250 1000 1000 1000 1000 1000 432 300 330 360 405 480
333 1332 1332 1332 1332 1332 500 347 382 416 468 555
416.3 1665 1665 1665 1665 1665 576 400 440 480 540 640
5000 25 50 55 60 68 80 667 463 509 556 625 668
50 100 110 120 135 160 720 500 550 600 668 668
100 200 220 240 270 320 833 578 636 668 668 668
125 250 275 300 338 400 19920 100 50.2 55 60 68 80
167 334 367 401 451 534 200 100.4 110 120 135 160
250 500 550 600 668 668 333 167 184 200 225 267
333 668 668 668 668 668 400 200.8 220 240 270 320
416.3 833 833 833 833 833 500 250 275 300 338 400
7620   b 38.1 50 55 60 68 80 667 335 369 402 452 536
57.2 75 83 90 101 120 833 418 460 502 564 668
76.2 100 110 120 135 160 1000 502 552 602 668 668
114.3 150 165 180 203 240 34500 172.5 50 55 60 68 80
167 219 241 263 296 350 345 100 110 120 135 160
250 328 361 394 443 525 517 150 165 180 203 240
333 438 482 526 591 668 690 200 220 240 270 320
416.3 548 603 658 668 668 a 55/65 °C rise rating on Eaton voltage regulators gives an additional 12% increase in
500 656 668 668 668 668 capacity if the tap-changer’s maximum current rating has not been exceeded. For loading
667 875 875 875 875 875 in excess of the above values, please contact the Voltage Regulator Support group at
(866) 975-7347 (from outside the U.S. and Canada call +1 (262) 896-2591) or e-mail
833 1093 1093 1093 1093 1093 questions to [email protected].
13800 69 50 55 60 68 80 b Regulators are capable of carrying current corresponding to rated kVA when operated at
138 100 110 120 135 160 7200 V.
207 150 165 180 203 240
276 200 220 240 270 320
414 300 330 360 405 480
500 362 398 434 489 579
552 400 440 480 540 640
667 483 531 580 652 668
833 604 664 668 668 668

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 41

VR-32 and EVER-Tap™ Voltage Regulator

Table 13.  ADD-AMP capabilities of 50 Hz ratings

Load Current Ratings (A) a
Regulation Range (Wye and Open Delta)
± 10% ± 8.75% ± 7.5% ± 6.25% ± 5%
Rated Rated Regulation Range (Closed Delta)
Volts kVA ± 15% ± 13.1% ± 11.3% ± 9.4% ± 7.5%
6600 33 50 55 60 68 80
66 100 110 120 135 160
99 150 165 180 203 240
132 200 220 240 270 320
198 300 330 360 405 480
264 400 440 480 540 640
330 500 550 600 668 668
396 600 660 668 668 668
11000 55 50 55 60 68 80
110 100 110 120 135 160
165 150 165 180 203 240
220 200 220 240 270 320
330 300 330 360 405 480
440 400 440 480 540 640
550 500 550 600 668 668
660 600 660 668 668 668
15000 75 50 55 60 68 80
150 100 110 120 135 160
225 150 165 180 203 240
300 200 220 240 270 320
450 300 330 360 405 480
600 400 440 480 540 640
750 500 550 600 668 668
16000 160 100 110 120 135 160
320 200 220 240 270 320
22000 110 50 55 60 68 80
220 100 110 120 135 160
330 150 165 180 203 240
440 200 220 240 270 320
660 300 330 360 405 480
880 400 440 480 540 640
33000 165 50 55 60 68 80
330 100 110 120 135 160
495 150 165 180 203 240
333 231 254 277 312 370
660 200 220 240 270 320
825 250 275 300 338 372
a 55/65 °C rise rating on Eaton voltage 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 contact the Voltage Regulator Support group at
(866) 975-7347 (from outside the U.S. and Canada call +1 (262) 896-2591) or e-mail
questions to [email protected].

42 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

Wiring diagrams

Figure 28.  Typical internal wiring of voltage regulators with a QD3 tap-changer

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 43

VR-32 and EVER-Tap™ Voltage Regulator

Figure 29.  Typical internal wiring of voltage regulators with QD5 and QD8 tap-changers

44 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 VR-32 and EVER-Tap™ Voltage Regulator

12 6
11 5
10 4
9 3
8 2
7 1

Figure 30.  Typical internal wiring of EVER-Tap voltage regulator tap changer

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 45

 RS-2 (WHT) JBB STUD (WHT) MOLEX 12-PIN MOLEX 12-PIN

46
RECEPTACLE [A] RECEPTACLE-INTERNAL
JUNC/BOX
3/8" MTG STUD B (RED/BLK) (RED/BLK)
1 6
POSITION INDICATOR B (ORG) (ORN)
2 5
B (LT BLU/BLK) (LT BLU/BLK)
D (GRN/BLK) LLS-2 (GRN/BLK) A (GRN/BLK) 3 4
LOWER LIMIT 1 1 B (BLK/WHT) (BLK/WHT)
1 2 C (GRN/BLK) RLS-2 (BLU) A (BLU) 4 3
SWITCH (LLS) 2 2 B (BLK) (BLK)
D (BLU) 5 2
MOLEX 2-PIN MOLEX 2-PIN B (WHT/BLK)
RAISE LIMIT 1 2 PLUG [D] RECEPTACLE [D] 6 1
SWITCH (RLS) C (BLU)
2 J/B 3/8" STUD (WHT) 7 12
P. I. RESET CT (WHT)
SOLENOID (RS) C (ORG/BLK) 8 11
CT PROTECTION D (GRN/BLK) (GRN/BLK)
1 JUNC/BOX CIRCUIT [CT] 9 10
3/8" MTG STUD D (BLU) (BLU)
10 9
CT-C1 (RED) (WHT)
11 8
CT-C2 (GRN) (BLK)
12 7

LLS-1 (GRN/BLK)
RS-1 (ORG/BLK)
A (LT BLU/BLK)

RLS-1 (BLU)
A (RED/BLK)

Figure 31.  Junction box wiring diagram

JUNCTION BOX TERMINAL BOARD [JBB]

A (BLK/WHT)
A (WHT/BLK)
A (BLK)
A (RED)
A (GRN)

A (ORG)
J/B 3/8" STUD (WHT)
STUD STUD
MOLEX 10-PIN CC (WHT)
MOLEX 3-PIN

1
VR-32 and EVER-Tap™ Voltage Regulator

2
3
5
7
8

4
6

1
2
3
10
RECEPTACLE [C] RECEPTACLE [B]

MOLEX 3-PIN MOLEX 10-PIN

1
9

2
3
5
7
8

4
6

1
2
3
10
PLUG [C] PLUG [B]
C2
C1

CC (BLK)

CC (BLU)
CC (RED)
CC (GRN)

CC (ORG)
CC (RED/BLK)

CC (GRN/BLK)
CC (ORG/BLK)
CC (BLK/WHT)
CC (WHT/BLK)

CC (LT BLU/BLK)
POS-7 (BLK)
POS-8 (WHT)

15
12
11
10
9
8
7
6
5
4
3
2
1
NUM
E

12-CONNECTION
C
C

L1
V6
V1

R1

NL

CABLE ASSY [CC]

HS
POS

DHR

GRD
GND

MC-2
MC-1
COLOR CHART

RED

BLUE
WHITE
BLACK

GREEN
COLOR
POS-9 (BLU)
POS-5 (ORG)

Installation, Operation, and Maintenance Instructions MN225008EN January 2025

ORANGE
POS-2 (BLK)

GROUND (WHT)
POS-6 (RED/BLK)

RED/BLACK
POS-3 (BLK/WHT)
POS-10 (GRN/BLK)
POS-4 (LT BLU/BLK)

BLACK/WHITE
WHITE/BLACK

GREEN/BLACK

LT BLUE/BLACK

GREEN/YELLOW
ORANGE/BLACK

TO CONTROL BOX
 VR-32 and EVER-Tap™ Voltage Regulator

RS-1 (ORG/BLK)
CC (ORG/BLK)
CC (RED)
CC (BLK)
RLS-2 (BLU)

POSITION INDICATOR JUNCTION BOX

CC (WHT/BLK)
TERMINAL BOARD
LOWER LIMIT
JBB-L (GRN/BLK)
S4 S2 (JBB)
1 2 DHR
SWITCH (LLS)
CC (GRN/BLK)
(RED)
R C1
JBB-R (BLU)
RAISE LIMIT 1 2 CC (BLU/BLK) S6 L
SWITCH (RLS)
CC (BLU) LLS-2 (GRN/BLK) (GREEN)
NL
POSITION 2 CC (BLK/WHT)
JBB-G (WHT) S7 C2
INDICATOR GROUND
RESET HS G
JBB-DHR (ORG) STUD
SOLENOID 1
(RS) M2

CC (ORG)
GROUND
CC (RED/BLK) STUD
CC (GRN)
CC (WHT)
RS-2 (WHT)

12 CONDUCTOR
CONTROL CABLE (CC)

TO CONTROL

Figure 32.  Legacy junction box wiring diagram

Installation, Operation, and Maintenance Instructions MN225008EN January 2025 47

VR-32 and EVER-Tap™ Voltage Regulator

MOTOR CC (RED/WHT)
CAPACITOR CC (GRN/WHT)
(NOTE 2)

CC (WHT/BLK)
CC (BLU/BLK)

CC (GRN)

CC (RED)
CC (BLK)
19 (RED)

17 (VIO)
(NOTE 3)
15 (WHT/GRN)

15 (WHT/GRN)

CC (ORG/BLK)
CC (GRN/BLK)

20 (WHT/BRN)
CC (RED/BLK)
13 (WHT/BLU)

13 (WHT/BLU)
CC (BLUE)

CC (WHT)

CC (ORG)
12 (WHT)

12 (WHT)

21 (WHT)
18 (GRN)

18 (GRN)
19 (RED)
14 (BLU)

14 (BLU)
10 (BLK)

16 (BLK)

16 (BLK)
11 (BLK)

17 (VIO)

1 1 1 1
(NOTE 1)
1
2 2 2 2
2 5

DHR
GND
NLG
NLP

VM
OC
104

120
120
127
133

BR

HS
VS
VS
110
110
115

C1
C3

R3

NL
BR

V9
V7
VS

20
21
22
32

L3
V2
V6
V1
R1
R2

C2
C3
V4

G
G
L1
L2
G
G

8
7
6
5
J
C

6
3
3 3 3 7 3
4
TB3
21 (WHT)
RCT (ORG)

RCT (GRN)
RCT (BRN)
RCT (RED)
RCT (BLK)

RCT (BLU)
RCT (YEL)
11 (BLK)

MOV 4 4 4 4

(NOTE 1)
20 (WHT/BRN)
10 (BLK)
COM

104

110

115

120

127

133

RCT1
TAP VOLTAGE

NOTES
1. LEAD 20 (WHT/BRN) CONNECTS VS TO V7 INSTEAD OF
V6-4 TO V7 WHEN A DIFFERENTIAL PT IS NOT PRESENT.
2. CONTROL CABLES CONTAINING 12 CONDUCTORS WILL
HAVE CAPACITOR WIRE COLORS OF BLUE/BLACK AND
BLACK/WHITE.
CONTROL
3. TO RECONFIGURE THE RCT CONNECTION MOVE THE CABLE
WIRE WITH THE WHITE TAG. (CC)

Figure 33.  Standard back panel signal circuit

48 Installation, Operation, and Maintenance Instructions MN225008EN January 2025

 TB3
133
T
133 RCT (BLU) 127 A
127 RCT (GRN) P
120 RCT (YEL) 120
120 11 (BLK) V
115 RCT (ORG) 115 O
110 RCT (RED) L

MOTOR
110 110 T
RCT (BRN)
BRAKING
104

10 (BLK)
A
G RCT (BLK) 104 G
G 12 (WHT)

CAPACITOR
CAPACITOR
E
BR 13 (WHT/BLU) COM
R1 AB (GRN/WHT)
R2 14 (BLU)

Figure 34.  EVER-Tap back panel signal circuit

L1 AB (RED/BLK)
L2 15 (WHT/GRN)
V4 11 (BLK)

RCT
VS 16 (BLK)
C2 17 (VIO)
C3 18 (GRN)

4
3
2
1
V1 CC (BLK)
AB (BLU/WHT)

AB (RED/WHT)
AB (RED/WHT)

6
5
AB (GRN/WHT)
CC (RED/WHT)

CC (GRN/WHT)

19 (RED)

4
7 3
2
1
C CC (GRN)
8 17 (VIO)
7 CC (RED)
6
5 AB (YEL) AB (WHT)
J
V9
(CC)
CABLE

V7 20 (WHT/BRN)
CONTROL

AB (WHT)
MOV
BR 13 (WHT/BLU)
3
2

GND
G 12 (WHT)
4
4 3
1 2
1

V2 CC (BLU/BLK)
G CC (WHT)
4
3
2
1

VS 20 (WHT/BRN) V6 CC (WHT/BLK)
VS 16 (BLK)
4
3
2
1

V8 CC (BLK/WHT)
VM
C1 19 (RED) AB (BLU) RLS CC (BLU)
C3 18 (GRN) AB (RED) LLS CC (GRN/BLK)
HS AB (ORG) OCI CC (ORG)
(AB)

3
2
1

R3 14 (BLU) AB (BLK) ABP

ACTUATOR

L3 15 (WHT/GRN)
NL CC (RED/BLK)
BOARD HARNESS

DHR CC (ORG/BLK)

Installation, Operation, and Maintenance Instructions MN225008EN January 2025

49
VR-32 and EVER-Tap™ Voltage Regulator
 !
SAFETY
FOR LIFE

Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com

Eaton’s Power Systems Division

2300 Badger Drive
Waukesha, WI 53188
United States
Eaton.com/cooperpowerseries

© 2025 Eaton
All Rights Reserved
Eaton is a registered trademark.
Printed in USA For Eaton‘s Cooper Power series product
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