EE-40023
Revision 5 - April/2019
PREFACE
Upon receipt of TOSHIBA Regulator, you will receive not only the assurance of a Japanese technology, but also the care
of a stringent QUALITY control and the commitment with the environmental performance improvement.
We are sure this manual will guide you properly in order to get from your Regulator everything your design engineering
has specified.
OBSERVATION: After the equipment and its accessories delivery, make sure about the presence and integrity of all the
parts, checking the packing list. If any damage or missing part is observed, immediately notify Tsea Energia.
REMEMBER: Damages caused by handling and/or improper operations void the warranty signed in the agreement.
The information in this document is subjected to changes without previous notice. No part of this document can be
reproduced or transmitted in any way or through any means, electronic or mechanic, for any purpose, without prior
written authorization by Tsea Energia.
Tsea Energia may have patents, trademarks, copyright or any other intellectual property rights that comprise this
document content. Possession of this document does not warrant any right on such patents, trademarks, copyright or
other intellectual property rights, except the ones expressly mentioned in a license agreement, in written, by Tsea Energia
BASIC NORMATIVE REFERENCES:
- NBR 11809/1992: REGULADORES DE TENSÃO (VOLTAGE REGULATORS)
- ANSI C.57.15/1999: TERMINOLOGY, AND TEST CODE FOR STEP-VOLTAGE REGULATORS
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Sumário
1 - INTRODUCTION.................................................................................................................................................. 4
2 - BASIC SCHEME OF POWER TRANSMISSION AND DISTRIBUTION: ........................................................... 4
3 - FUNCTIONING PRINCIPLE................................................................................................................................ 4
3.1- Functioning as step-up transformer ................................................................................................................... 5
3.2- Functioning as down-up transformer ................................................................................................................... 5
4 - REGULATOR ASSEMBLY ................................................................................................................................... 5
4.1- Reactor functions ................................................................................................................................................ 6
4.1.1- Voltage splitter ......................................................................................................... 6
4.1.2- Do not allow the circuit interruption during switching ............................................................. 6
4.1.3- Limit circulating current .............................................................................................. 7
4.2 - Equalization coil ................................................................................................................................................ 9
5 - CONNECTION TYPES IN REGULATORS BANK ........................................................................................... 11
5.1 - Star Connection .............................................................................................................................................. 11
5.2- Delta Closed Connection ................................................................................................................................. 12
5.3- Delta Open Connection.................................................................................................................................... 14
6 - PREFERRED RATINGS 60 Hz STEP VOLTAGE REGULATORS ................................................................. 15
7- PREFERRED RATINGS 60 Hz STEP VOLTAGE REGULATORS .................................................................. 16
8 - REGULATOR SIZING ........................................................................................................................................ 17
9 - REGULATOR FUNCTIONING ........................................................................................................................... 17
10 - ADJUSTMENT OF THE LINE DROP EQUALIZER ........................................................................................ 18
10.1- Adjustment of drop line compensation for the types of regulator connections ............................................. 18
10.1.1- Monophasic connection ............................................................................................. 18
10.1.2 Star connection ....................................................................................................... 19
10.1.3 Triangle connection .................................................................................................. 20
11 - TRANSPORTATION OF SINGLE-PHASE VOLTAGE REGULATORS ........................................................... 25
11.1 - Objective ........................................................................................................................................................ 25
11.2- Packaging ....................................................................................................................................................... 25
11.3- Fastening ........................................................................................................................................................ 25
11.4- Check before Shipping .................................................................................................................................... 25
11.5- Type of Tractor Trailer or Truck ........................................................................................................................ 25
11.6- Transportation Documents and Reports ......................................................................................................... 25
11.7- Speed Limits: .................................................................................................................................................. 25
12 - INSPECTION AND MAINTENANCE OF SINGLE-PHASE VOLTAGE REGULATORS ................................... 25
12.1- Introduction .................................................................................................................................................... 25
12.2- Receipt............................................................................................................................................................ 26
12.3- Storage ........................................................................................................................................................... 26
12.4- Installation ...................................................................................................................................................... 26
12.4.1- To operate the regulator ............................................................................................. 26
12.4.2- Typical connections for single-phase regulators.................................................................. 27
12.4.3- Maneuver on regulators ............................................................................................ 31
12.5 - Installation ..................................................................................................................................................... 32
12.5.1 - By-pass lightning rod ............................................................................................... 32
12.5.2- Pressure relief valve ................................................................................................ 32
12.6 - REGULATOR MAINTENANCE ..................................................................................................................... 33
12.6.1- Periodical inspection ............................................................................................... 33
12.6.2- Internal inspection of the regulator .............................................................................. 36
12.6.3- Removal of the tank active part .................................................................................... 36
12.6.4. Equipment required for the inspection .......................................................................... 36
13 - EXTERNAL ELECTRO-MECHANICAL POSITIONS INDICATOR (ANALOGICAL) TB-I900 ...................... 37
13.1- GOAL .............................................................................................................................................................. 37
13.2- DESCRIPTION, FEATURES, AND FUNCTIONING ....................................................................................... 37
13.3- INSTALLATION AND MAINTENANCE: .......................................................................................................... 37
13.3.4- Dimensions ........................................................................................................... 38
14 – SPECIAL CARE WITH HANDLING, WASTE DISCARDED, AND LEAKAGES ASSOCIATED TO S VOLTAGE
REGULATORS..................................................................................................................................... 39
14.1- Goals ............................................................................................................................................................. 39
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14.2- Definitions ....................................................................................................................................................... 39
14.3- General Requirements.................................................................................................................................... 39
14.3.1- Integrated Management Policy Quality, Environment, Occupational Health and Safety .................. 39
14.3.2- Environmental Aspects ............................................................................................. 39
14.3.3- Waste Handling and Destination ................................................................................... 40
14.4- Legal Requirements and Other Requirements ................................................................................................ 41
14.5- Training, Awareness and Competence ........................................................................................................... 42
14.6- Communication............................................................................................................................................... 42
15 - DRAWINGS AND SPECIFIC INSTRUCTIONS ATTACHED. ........................................................................... 42
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1 - INTRODUCTION
The application of voltage regulators in the power distribution systems started in the 1940's, in developed countries, mainly in
the USA, due to its large territory, where the centers are spread in large areas far from the generation points and along with
it, the appearance of a huge amount of new electro-electronics, sensitive to voltage oscillations, made consumers complains
rise. Consumers started demanding good quality power distribution. Because of this, currently thousands of regulators are
installed in several points of the country, providing the consumption points with a proper voltage regulation and ensuring quality
to the power supply. This brings at least three benefits:
Consumer satisfaction;
Reduction of distribution losses;
Increase to the power supply company income.
Brazil presents some degree of similarity to the USA when it comes to territorial area, which makes viable the use of voltage
regulators. These have great acceptance by the power supply companies due to economic, simplicity, and versatility
reasons. Besides, today there are voltage regulators fully manufactured in Brazil, which eliminates the problems in obtaining
spare parts observed up to 1986, when such equipment was fully or partially (on load tap changer) imported from the USA.
2 - BASIC SCHEME OF POWER TRANSMISSION AND DISTRIBUTION:
1 - Generator
2 - Step-up Transformer
3 - Transmission line
4- Step-down substation
5 - Distribution network 6 - Monophasic Voltage
6- regulator up to 36 kV
7 - Distribution Transformer 8 - Consumer
3
5
FIGURE 1
4
1
2
6
7
8
3 - FUNCTIONING PRINCIPLE
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The working principle is similar to an autotransformer, that is, besides the magnetic coupling, between the primary and the
secondary, there is an electric coupling, as shown in the figure below:
B
PRIMARY
C
SECONDARY
FIGURE 2
There are two ways to perform electrical connection between the primary and the secondary, making the
autotransformer operate as a step-up or a step-down:
3.1- Functioning as step-up transformer
+
B
C 100 V
1100 V
1000 V
+
Voltage on load
FIGURE 3
3.2- Functioning as down-up transformer
+
B
C 100 V
900 V
1000 V
+
Voltage on load
FIGURE 4
It is the COILs polarity that determines the electrical connection to the autotransformer functioning as step-up or step- down.
Therefore, we are going to add a polarity reversal switch to the circuit, to enable the autotransformer to work as step-up or
step-down.
+
M
B
K
C
FIGURE 5
4 - REGULATOR ASSEMBLY
By adding taps to COIL “C”, then we have voltage steps.
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FIGURE 6
Therefore, if the load is connected to tap 1, and if we need to switch its connection to tap 2, we will have to interrupt the
circuit, i.e., de-energize the regulator.
In order to avoid this, the solution is to add a reactor to the circuit, since while the reactor ends (legs) move to tap 2, the
load supply is carried out through the other end of the reactor.
REACTOR
B
LOAD
M
K
C
CENTER
TAP
FIGURE 7
4.1- Reactor functions
Let's consider for better understanding the reactor circuit, a piece of COIL “C”.
4.1.1- Voltage splitter
Considering the reactor in position 0 (neutral):
REACTOR
0
A
LOAD
B
Vd
1
C
Vd
2
Vd= VOLTAGE STEPS
FIGURE 8
Now let's go to:
0
A
REACTOR
Vd/2
Vd/2
LOAD
Vd
1
C
B
Vd
2
FIGURE 9
Voltage applied to the reactor terminals is Vd, however the load voltage will increase or decrease in the Vd/2 rate, due to
the center tap, which explains the reactor being a voltage splitter.
4.1.2- Do not allow the circuit interruption during switching
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By analyzing the previous circuit, when “B” goes out from tap 0, and is moving to tap 1, the circuit energizing is made
through "A", without the circuit interruption.
4.1.3- Limit circulating current
0
REACTOR
1
C
Vd
Ic
2
FIGURE 10
When Vd voltage is applied to the reactor terminals, a circulating current takes place, Ic, this current shall be limited so
that excessive wear does not happen to the tap changer contacts and that their life cycle is preserved.
The determination of the circulating current limit in the reactor is based on the extinction of arc in a circuit, as shown in
the figure:
IL
"C" COIL
1
Vd
Vb
IR
Ic
Vb
2
REACTOR
VR
FIGURE 11
We have developed the following equations:
VR = 2Vb-Vd
IR = 1 IL-IC
2
From this point, these equations have been developed and the conclusion was the reactor shall be designed to:
IC = 50% IL
Tolerance for the circulating current Trial is from -20% to 0%.The reactor core has from 1 to 2 Gaps sized so that the
circulating current is established within the previous parameters.
These Gaps are filled with phonolite or premix. However, along the regulator's life cycle, the gap may increase or decrease
due to vibrations and/or temperature, and the current calibration may not correspond to the previous parameters:
Here is an example of the reactor recalibration:
- Regulator:
HCMR 60 Hz 138 kVA (1380 kVA) 13800 V ± 10% (32 steps) 100 A.
Project -
IC = 0.5 x 100 = 50 A with tolerance from -20% to 0% Field
7
-
Assuming: IC = 70 A
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Measuring the Gap = 2 x 10.5 = 21 mm
In order to recalibrate we take the direct proportion:
70 A
50 A
- 21 mm
-X
X = 15 mm --> 2 x 7,5mm
The reactor has the characteristic to enable the load current circulation, IL, free by it, not constituting impedance to this
current. This happens because of the center tap, which promotes the half IL circulation on one side of the reactor (A) and
the other IL half on the other side (B), as follows:
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Ic
IL
2
L
c
2
IL
CENTER TAP
L
2
Ic
IL
2
FIGURE 12
According to the figure above, we can see the magnetic flows,∅𝐿/2, created by the current,IL/2 become void, which, in an
inductive circuit means that the tension induced on the reactor coil due to the load current circulation, is zero:
4.2 - Equalization coil
Considering the circuits below:
Circuit A: Since there is no voltage applied on the
reactor, Ic = 0.
REACTOR
FIGURE 13
Circuit B: Since there is no voltage applied on the reactor, Ic = 0.
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REACTOR
FIGURE 14
The circulating current switching from zero (circuit A) to value 50% IL (circuit B) during the regulator switching times would
di
cause a high wear of the tap changer contacts due to the Ldt , i.e., the current variation rate from zero to 50% would be
high, which would cause the arc voltage to increase and, consequently, the arc potency.
In order to solve this problem and keep the circulating current in the reactor constantly at 50% IL, regardless of the tap
changer position, it is recommended to add the equalization coil to the reactor circuit, as shown below:
EQUALIZ. SPOOL
REACTOR
FIGURE 15
LOAD
REACTOR
The equalization coil is located in the active part of the regulator main transformer. This enables the coil to be an active
element, i.e., a voltage source in the reactor circuit, when it is in the condition of circuit “A”. Thus, by analyzing the following
circuit, we can see that the circulating current in this condition changes the direction, but it continues in module.
EQUALIZ. COIL
REACTOR
LOAD
REACTOR
FIGURE 16
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5 - CONNECTION TYPES IN REGULATORS BANK
5.1 - Star Connection
BY PASS SWITCH
SOURCE
A
B
C
C
A
B
Shunt arresteres
S
Series arresteres
SL
L
BY PASS SWITCH
C
B
L
O
A
D
B
S
SL
L
C
BY PASS SWITCH
B
C
N
S
SL
L
N
FIGURE 18
FIGURE 17
Assuming the regulators are stepping-up by +10%. The fasorial diagram would be:
FIGURE 19
Recommendation is that if the regulators bank is connected in star, then the power supply necessarily is also in star so that
the neutral current, due to possible load unbalances of the group, has the way closed to grounding, therefore to the power
supply.
Power supply
Regulators Bank
FIGURE 20
ALERT
It is recommended that the grounding resistor is lower than 20 ohms.
If the Power supply is in triangle and the regulators bank is in star form, the virtual neutral of the star connection will be
displaced in case of load unbalance, and the regulators bank will undergo a series of switching. Typically, some regulators
in the bank will go to the maximum step-up position and others to the maximum step-down position.
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5.2- Delta Closed Connection
BY PASS SWITCH
A
C
A
B
Shunt arresteres
S
Series arresteres
SL
L
BY PASS SWITCH
B
C
B
C
B
L
O
A
D
S
SL
L
BY PASS SWITCH
C
B
C
S
SL
FIGURE 21
L
FIGURE22
Assuming 13800 V regulators are stepping-up by +10%.
13800 x 0.1 = 1380
13800 V
FIGURE 23
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So:
𝑆𝑒𝑛 60° =
𝐶^′/1380
𝐶𝑜𝑠 60° =
𝐵′/1380
C’=1195
B’=690
)
80
13
0+
80
(13
A
1380
B'
C'
FIGURE 25
FIGURE 24
Thus:
A=
A = 15915 V
Regulation (%) = 15915 = 115 %
13800
CLOSED DELTA CONNECTION GROUP REGULATION IS ± 15%
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5.3- Delta Open Connection
A
C
BY PASS SWITCH
B
A
Shunt arresteres
S
Series arresteres
B
L
O
A
D
C
B
SL
L
BY PASS SWITCH
B
S
SL
L
C
C
FIGURE 26
FIGURE 27
Assuming 138 kVA 13800 V regulators are stepping-up by +10%.
POWER SUPPLY
FIGURE 28
VOLTAGE BETWEEN PHASES AT THE BANK OUTPUT = A
So:
Cos 60º = X' X'=690 1380
A = 13800 + 2X = 15180
Regulation (%) = 15180 = 110%
13800
FIGURE 29
OPEN DELTA CONNECTION GROUP REGULATION IS ± 10%
This is an advantageous connection when it comes to a cascade connection, with this, 2 regulators are placed in each
point of the cascade, therefore saving 1 regulator. It is recommended to use 3 and at most 4 regulators bank in cascade
due to possible overvoltage problems on the system when closing the reconnectors.
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6 - PREFERRED RATINGS 60 Hz STEP VOLTAGE REGULATORS
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7- PREFERRED RATINGS 60 Hz STEP VOLTAGE REGULATORS
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8 - REGULATOR SIZING
Through the table above we can show an example of how to size a regulator: Load: 10 MVA;
Regulation voltage: 13800 V;
Star power supply with grounding resistor below 20 Ohms; Star group connection.
For this, current is:
I = 10000 kVA = 418 A 3x1388 kV
Nominal voltage of the regulator should be: VN = 13800 = 7967 V
3
By analyzing the previous table, we chose regulator 333 kVA - 7620 V - 438 A, with additional voltage of 7967 V.
9 - REGULATOR FUNCTIONING
Voltage
regulator
control
FIGURE 31
Winding 1, called excitement winding (winding B), induces a tension on winding 2 (also known as tape or regulation
winding). In figure 31, TP4 (potential transformer) installed on the load side sends a signal to the voltage regulator control,
which places the reactor 3 A and B terminals on the proper position to maintain the load voltage constant. The polarity
reversal key shown in 6 will determine whether the regulator will increase or decrease the voltage, and its control is
performed by the regulator control. TC5 (current transformer) installed on the load side will send to the regulator control a
line loading signal, making it possible to compensate voltage drops that may occur in the system.
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LOAD
10 - ADJUSTMENT OF THE LINE DROP EQUALIZER
Regulator
Control
FIGURE 32
By using essential voltage equations, we can easily identify the voltage drop on the line referring to the control circuit,
which is provided by:
Where:
RL: Line resistance in ohms.
XL: Line reactance in ohms.
RC: Compensator resistance in volts. XC: Compensator reactance in volts IC: Primary nominal current of TC (A)
OBS.: For Toshiba regulators, the TC primary current is identical to the regulator nominal current. The TP ratio is provided
by:
RTP =
Nominal regulator tension
120
By observing the above equations (1) and (2), we have a common
factor
Ic
, which we will define as:
TP Ratio
FC: Line drop compensation factor
Note: This factor depends on the regulator plate data only.
10.1- Adjustment of drop line compensation for the types of regulator connections
10.1.1- Monophasic connection
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RL
XL
S
Ic
TP
LOAD
RL
XL
Ic
SL
FIGURE 33
Note: The FC adjustment in this connection depends on the grounding. Factor should be:
2.0: for ground-insulated system;
1.67: for system with neutral connected to the ground.
10.1.2 Star connection
SOURCE
A
B
C
C
B
C
L
O
A
D
B
C
B
N
FIGURE 34
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With the TP and the load voltage are the phase is the ground:
10.1.3 Triangle connection
A
C
B
B
C
L
O
A
D
B
C
C
B
FIGURE 35
As the TP voltage is between phases, and the load voltage is from phase to ground:
F
x1,73
TP
By considering the potency factor is equal to 1.0, we can state:
- The phase voltage of a monophasic system and the load current are in phase;
- The phase voltages for neutral in a multiple ground star connection system are in phase with the corresponding load
currents.
- The phase voltages for neutral in a triangle connection system are different by 30º related to the corresponding load
currents.
- Due to the difference between the voltage and the current in the triangle connection, it is necessary to correct the obtained
values for the line drop equalizer according to items 10.1.3.1 and 10.1.3.2 below:
10.1.3.1 - Closed triangle connection, considering:
V A, V B , V C
: Voltage between phases
VAN, VBN, VCN : Phase voltage for equivalent grounding
RL
: Line resistance (ohms)
XL
: Line reactance (ohms)
FP
: Potency factor = 1.0
20
IC
: Load current
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10.1.3.2- Delayed Regulator
We have:
A
NAMING:
VA
VAB = VA
VBC = VB
VCA = VC
VAN
B
WS
A
C
C
B
FIGURE 36
THIS PORTION REPRESENTS THE CORRECTION TO BE
INCREMENTED ON THE LINE DROP EQUALIZER.
FIGURE 37
By analyzing the previous figures, we can say that:
1 - Voltage between phases is advanced in 30, regarding the phase-neutral voltage of the corresponding phase.
2 - As the regulator is monophasic, i.e., the phase-neutral voltage is its reference, we can say the regulator is delayed.
Regarding the line drop equalizer circuit, we can state:
And it is easy to show that for determining the increment portion of the equalizer we just need to multiply the vector
module by the unitary with its difference. Then, we have:
(RC + jXC) x 1
+ 30º
(RC + jXC) x (+ 0.866 + j0.5)
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0.866RC + j 0.5RC + j 0.866XC - 0.5XC
So:
0.866R
0.5
0.866X
0.5
Where:
R’C: Rc correction C
X’C: Xc correction C
After R'c and X'c calculation, the positive values should be adjusted on the control's polarity key with positive polarity and
the negative values with negative polarity. However, TOSHIBA regulator control is programmed to automatically perform
the R'c and X'c values correction, since Rc and Xc values and the triangle connection transformation are previously set in
the control. (For more information, see the Voltage Regulator Control Manual).
10.1.3.3 - Advanced Regulator
A
Where:
VAN
VA
B
A
V BA = V B
V CB = V C
V AC = V A
WS
C
C
B
FIGURE 38
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We have to:
VC
A)
XL
N
VA
IC
E
AS
PH
IC(
RL
IC
VB
VA
FIGURE 39
By analyzing the previous figures, we can say that:
3 - Voltage between phases is delayed in 30, regarding the phase-neutral voltage of the corresponding phase.
4 - As the regulator is monophasic, i.e., the phase-neutral voltage is its reference, we can say the regulator is advanced.
5 - Thinking about the line drop equalizer circuit, we can state:
And it is easy to show that for determining the increment portion of the equalizer we just need to multiply the vector
module by the unitary with its difference. Then, we have:
(RC + jXC-)30º
x1
(RC + jXC) x (+ 0.866 - j0.5)
0.866RC - j 0.5RC + j 0.866XC + 0.5XC
Therefore: Where:
R’C: R correction
X’C: X correction
0.866
0.5
0.866
0.5
C
C
After R'c and X'c calculation, the positive values should be adjusted on the control's polarity key with positive polarity and
the negative values with negative polarity. However, TOSHIBA regulator control is programmed to automatically perform
R'c and X'c values correction, since Rc and Xc values and the triangle connection transformation are previously set in the
control. (For more information, see the Voltage Regulator Control Manual).
10.1.3.4- Open triangle connection
10.1.3.4.1- Connection with Phase "B" without regulator
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A
Where:
WS
B
VCB = VC
VAB = VA
B
C
A
VCN
VAN
C
VC
VA
Figure 40
It is possible to say that the phase "C" regulator is the advanced one and that the one of phase "A" is the delayed one. R'c
and X'c values are the same previously shown for the delayed and advanced regulator.
10.1.3.4.2- Connection with Phase "C" without regulator
A
C
Where:
WS
VAC = VA
VBC = VB
B
B
A
VAN
VBN
C
VB
VA
FIGURE 41
We can say that the phase "A" regulator is the advanced one and that the one of phase "B" is the delayed one. R'c and X'c
values are the same previously shown for the delayed and advanced regulators.
After R'c and X'c calculation, the positive values should be adjusted on the control's polarity key with positive polarity and
the negative values with negative polarity. However, TOSHIBA regulator control is programmed to automatically perform
R'c and X'c values correction, as the Rc and Xc values and the triangle connection transformation are previously set in the
control. (For more information, see the Voltage Regulator Control Manual).
We can say that in open triangle connections one regulator is delayed and the other is advanced. However, on site,
sometimes it is difficult to determine which regulator is delayed and which one is advanced to adjust the line drop equalizer
R and X values.
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11 - TRANSPORTATION OF SINGLE-PHASE VOLTAGE REGULATORS
11.1 - Objective
To better protect the equipment during shipping and transportation, the preventive measures in this manual shall be taken
for chocks.
11.2- Packaging
The regulator shall be packaged in a wooden box. The base and upper side of the regulator shall be well wedged to the
package in order to avoid its displacement during transportation.
11.3- Fastening
To avoid displacements during transportation, holders shall be placed on the bottom of the tractor trailer or truck. The
fastening on the upper side shall be performed by means of lashing to the hooks or the package.
11.4- Check before Shipping
The person in charge of the transportation shall confirm the items below before going leaving the site:
-Shipping condition
-Equipment condition
11.5- Type of Tractor Trailer or Truck
The tractor trailer or truck shall have a tachometer installed
ALERT
11.6- Transportation Documents and Reports
ALERT
They shall be kept for at least 3 years.
11.7- Speed Limits:
ALERT
Paved roads: Maximum 60 Km/h
Unpaved roads: Maximum 40 km/h
These limits shall be strictly observed.
Note: Non observance of these speed limits may cause the equipment warranty to be lost in case of any problem that may
be a result from such event to be detected.
12 - INSPECTION AND MAINTENANCE OF SINGLE-PHASE VOLTAGE REGULATORS
12.1- Introduction
TOSHIBA voltage regulator has been designed to provide good service on the line and to make its operation and
maintenance easier.
High quality materials and good manufacturing practices have been combined to offer the best regulator. Your regulator
has been carefully inspected and adjusted at the plant; however, for satisfactory operation it is important that its installation
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is excellent and maintenance is continuous.
This manual is designed to help you get a long-standing and cost-effective service for your regulator. Read this manual
before installing or operating your regulator.
12.2- Receipt
Upon your regulator delivery, carefully check each item in the invoice. In case that anything is missing, or if there is
something damaged, immediately contact the company responsible for the shipment and include the proper notes in the
invoice.
If necessary, contact Tsea Energia.
12.3- Storage
If the regulator is not operated immediately, it shall be kept in a protected area or outdoors without major concerns since
the control compartment and the inspection cover are well sealed.
12.4- Installation
TOSHIBA voltage regulators can be installed both in covered areas and outdoors, on platforms or poles, provided the
service condition limits established by NBR 11809 / ANSI C57.15 or the client's technical specification (whichever is most
strict) is observed.
12.4.1- To operate the regulator
12.4.1.1- Check the oil level through its own indicator.
12.4.1.2- Check the bushings porcelains.
WARNING
The bushings porcelain can be broken due to improper
handling or transportation.
12.4.1.3- Check the oil dielectric stiffness
(this will not be necessary if the unit is installed upon receipt and in good conditions). If the dielectric stiffness is
below 30 kV, it will be required to filter the oil before operating the regulator.
ALERT
Due to the viscosity of the insulating oil at low temperatures and the particularities of the tap changer's engine,
IS NOT recommended to perform external powering via control panel (tap changer via electronic control panel),
as well as the powering of the regulator itself, at an ambient temperature lower than -5°C. In case of the
ambient temperature being lower than -5°C, it is essential to raise, by external means, the temperature of the
insulating oil of the regulator before running any command on the tap changer( via external powering on the
control panel) or before the direct powering of the regulator.
12.4.1.4- Cause a short-circuit on the power supply, load, and neutral bushings
Measure the resistance (with MEGGER) between these bushings and the tank. The read values must be at least
2000 Mega Ohm at room temperature.
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NOTE:
1 - The bushings are identified according to terminology described in the table below, according to the client's interest.
This terminology will be clearly printed on the regulator cover.
TERMINOLOGY
INSULATOR
S
ANSI
ABNT
SOURCE
“S”
“F”
LOAD
“L”
“C”
NEUTRAL
“SL”
“FC”
L
S
SL
CONTROL
ENCLOSURE
Insulators placement on the regulator cover
2- If any one of the requirements previously described is not met, contact TSEA ENERGIA technical support by telephone
+55(31)3329-6060, +55(31)3329-6565 or email: exportsales@tseaenergia.com.br / falecom@toshiba.com.br
12.4.1.5- Review the drawings on the identification plate and on the control diagram.
WARNING
Check the voltage the Single-Phase Voltage Regulator is connected. In order to be
sure, follow the connections established on the regulator's identification plate.
12.4.2- Typical connections for single-phase regulators
Figures 42 to 45 describe the four basic connections for monophasic and triphasic systems, where regulation is
performed by monophasic regulators.
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BY PASS W ITCH
Shunt arresteres
S
Serie arrester
SL
L
N
FIGURE 42
SINGLE-PHASE VOLTAGE REGULATOR CONNECTION TO MONOPHASIC LINE.
BY PASS SWITCH
A
Shunt arresteres
S
Series arresteres
SL
L
BY PASS SWITCH
B
S
SL
C
L
Figure 43 OPEN DELTA
Two single-phase regulators connected to a triphasic line in open delta providing the system with 10%
of the regulation range on the 3 (three) phases.
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BY PASS SWITCH
A
Shunt arresteres
S
Series arresteres
SL
L
BY PASS SWITCH
B
S
SL
L
BY PASS SWITCH
C
S
SL
L
Figure 44- CLOSED DELTA
Three single-phase regulators connected to a triphasic line in closed delta providing the system
with 15% of the regulation range.
28
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BY PASS SWITCH
A
Shunt arresteres
S
Series arresteres
SL
L
BY PASS SWITCH
B
S
SL
L
BY PASS SWITCH
C
S
SL
L
N
FIGURE 45- STAR CONNECTION
Three single-phase regulators connected in star to a triphasic line with grounded neutral providing the
system with 10% of the regulation range.
28
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12.4.3- Maneuver on regulators
Installation and removal of the service regulator must follow the procedure below. Note: This procedure applies to
regulators with the TVC-MP control.
FIGURE 46
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12.5 - Installation
12.5.1 - By-pass lightning rod
All the regulators, standard model, are equipped with by-pass lightning rod, which shall be assembled between the
bushings of the power supply and load.
The by-pass lightning rod limits voltage through the winding, but it does not work as protection for the line to ground.
Protection against atmospheric discharges (Shunt Lightening rod): for higher protection of the regulator and the line,
proper voltage lightening rods must be installed between line and ground, one on the power supply side and the other
on the load side.
WARNING
Fuses: when they are used along with single-phase regulators, place them only on
the power supply terminals, never place them on the neutral or common terminal.
12.5.2- Pressure relief valve
Used to relieve the tank internal pressure, protecting it in case of high pressures due to problems on the active part of
the regulator.
ALERT
Check in the “Outer Dimensions” drawing, attached, what type of valve applies
to your regulator.
12.5.2.1- Functioning
When the tank internal pressure is higher than the relief valve operating pressure, the valve will automatically open,
releasing the pressure. When the tank internal pressure becomes lower than the operational pressure the valve will
close off sealing the tank.
Venting and sealing characteristics shall be as follows:
a) Venting pressure = 69 kPa (10 psig) ± 13 kPa (gage) (2 psig).
b) Resealing pressure = 6.9 kPa (gage) (1 psig) minimum.
c) Zero leakage from reseal pressure to –56 kPa (gage) (–8 psig).
d) Flow at 103 kPa (gage) (15 psig) = 16,5 l/s (35 standard cubic feet per minute), (SCFM)] minimum corrected
for air pressure of 101 kPa (14.7 psi) (absolute) and air temperature of 21 °C
12.5.2.2- Notifying abnormalities
If through a periodical inspection or in the standard operation any abnormality is identified, we ask you to notify the
event to Tsea Energia.
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12.6 - REGULATOR MAINTENANCE
12.6.1- Periodical inspection
ELECTRONIC CONTROL
Inspection
Clause
point
Check
Period
- Manual
actuation
- Maximum
and
minimum
block
1
Control
3 years
Reference
voltage
2
3
- Linear
temporiz
ation
- Automati
c
actuation
Rise and
Low
Procedure or checking
item
- Upon placing the
operation adjust in
“rise”, check if the
control rises the tap,
stopping at the set
block.
- Upon placing the
operation adjust in
“lowers”, check if the
control lows the tap,
stopping at the set
block.
With the regulator
energized, adjust: Ur=0V,
Ux= 0V. Check if the
“Voltmeter” output
voltage is equal (± 1V)
the reference after
stabilized.
- Varying the reference
adjustment for a higher
voltage than the one of
the network.
- Check if the motor
starts on the “Rise”
direction after the set
time.
- Varying the gross tune
for a lower voltage than
the one of the network.
- Check if the motor
starts on the “Low”
direction after the set
time.
33
Evaluation / Correction
According to the
operating instruction.
EE-40023
VOLTAGE REGULATOR
Clause Inspection
point
Check
Period
Bushings
Light-ening
rod
4
Accessories
Procedure or checked item
Evaluation /
Correction
1. Impurities accumulation
on the porcelains;
2. Oil leakage;
3. Terminals tightening.
1. Impurities accumulation;
2. Insulation endurance.
1. When the
contamination is
excessive, clean
with a cloth
soaked with
ammonia or
carbon
tetrachloride and
apply a
neutralizer.
Afterwards, wash
them
with fresh water
and dry with a
dry cloth;
2. When the
terminals are
loose, tighten
them.
- Glass display
replacement;
- Tightening of
indicator's body
or gasket
replacement.
- Tighten A, if the
leakage
persists, the
equipment shall
be removed
from service
3 years
Oil level
indicator
- Break on the glass display;
- Oil leakage.
Oil drain
valve
- Oil leakage.
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Clause
4
Inspection
point
Accessorie
s
Check
Control
box
Procedure or checked
Period item
3
-Water penetration
inside the box;
years
-Check the connection
of the multi cable to
the control box.
5
Accessorie
s
6
Tank outer
side
7
Insulating
oil
8
Miscellaneous
Position
Indicator
Switch
- Water penetration into
3 years the interior of an
external.
3 years - Check the general
condition of the
tank painting.
Dielec
tric
stiffn
ess
3
yea
rs
Abnormal
excitation
noise and
vibration
- All the procedures
shall be according to
Standard ABNT NBR
6869.
- Check the fixation
condition of the parts
connected to the tank.
Evaluation /
Correction
-In case of water
penetration,
replace the door
insulation
gaskets;
-Connection of
multi cable
loosen,
tighten it.
-Maintaining the
indicator.
-Remove
moisture in
the terminal
box.
- Restoration of
the outer
surface painting
shall be
performed
according to the
following
frequency:
1. The
equipment
installed in
industrial,
maritime and
polluted zones,
approximately
every 12
months.
2. The
equipment
installed in
atmosphere free
of pollution and
out of the
maritime coast,
approximately
every 3 years.
1. Satisfactory:
Higher than
26kV/2.5 mm;
2. To be
reconditioned:
Lower than
26kV/2.5 mm.
-Readjustment.
Contact Tsea
Energia at the
numbers:
(05531) 33296684
Email:
falecom@tseaenergia.com.br
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NOTES:
* After all the tests, the adjustments shall be placed as previously found.
* If there are no conditions to perform all the tests due to variations that they will cause on the load side, we suggest taking
the regulator out of service and closing the by-pass and the disconnection of the load side (Check handling procedure
instruction on control box cover), which allows testing all the relay functions, except the ones related to the line drop
compensation.
12.6.2- Internal inspection of the regulator
We recommend the internal inspection, together with the Tap Changer, observing in the Instruction it, the number of
operations, for inspection or maintenance.
Basically, the internal inspection consists of:
a)
Inspection on the Tap Changer, according to specific instruction for it.
b)
Inspection on Active Part (the entire structure with core, coil and e.tc).
* It is not required to perform any trials or checks unless an abnormal functioning condition is seen and, in such case,
Tsea Energia shall be notified. It is recommended to perform at least:
- Spirals relation check;
- Measurement of the electric resistance of the excitation and TAP’s windings;
- Visual inspection.
12.6.3- Removal of the tank active part
The removal of the tank active part shall be performed in a protected place, preferably with dust control, fully removing
it from the tank.
Procedures:
A)
Remove the cover fixing bolts;
B)
Remove all the fixing bolts and grounding of the control box to the regulator tank. The control box pulls out along
with the cover if necessary;
C)
The active part shall be removed from the tank by the suspension pad eyes on the cover. Upon inspection, check
if all the bolts, nuts and connections are well tightened;
D)
For each hour of exposure, the active part shall be submitted to two (2) hours of vacuum. Maximum 5 mmHg;
E)
After the vacuum period is concluded, the oil filling must start. When the oil level is complete, the vacuum can be
broken;
F)
Leave the regulator in rest for 12 hours before energizing it.
12.6.4. Equipment required for the inspection
12.6.4.1 – Instruments
A) Instrument to test the oil dielectric stiffness;
B) Device for spirals relation test;
C) Volt/ohm meter for calibration and test of the command device;
D) Megger for insulation tests;
E) Device for line current measurements.
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13 - EXTERNAL ELECTRO-MECHANICAL POSITIONS INDICATOR (ANALOGICAL) TB-I900
13.1- GOAL
Externally to the tank indicate by means of mechanical connection the position (tap) the on load tap changer is under voltage
single-phase regulators load. It still has functions that allow for controlling the operation range limit (load-bonus) and
indicators on the outer positions reached during an observance period (upper and lower tap).
Except when expressly indicated otherwise in the purchase order, aluminum boxes are provided with finishing painting in grey
Munsell N6.5 on both sides (internal and external).
13.2- DESCRIPTION, FEATURES, AND FUNCTIONING
The indicator shall always be assembled inclined in relation to the ground (45º), to make easier the indication pointers
visualization and to make possible to eliminate the humidity condensation; The bolts for fixation of the visor are in stainless
steel and with partial thread (BSP 3/16”) to avoid their fall during the operation for accessing the pointers and load-bonus
system.
It enables the control of the operation range limit through microswitch. Limiting, as predicted in operating standard of singlephase regulators, can be performed both sides of the tap changer (Raise or Lower). It is accessible in the inner side of the
visor by means of sliding keys, which have locking systems in pair positions from 8 to 16, both sides. Keys can be positioned
independently on both sides (ex.: +12 and -16, +14 / -10, etc). For the operating range regulation, the operator shall loose
the four bolts that attach the polycarbonate visor. The bolts are released the front visor without the need for their total
removal (this avoids the need to hold them or risks that they will fall during this operation). On the visor back side, there is
a bolt that allows its tilting in relation to the indicator's lower side, leaving the operator's hands free to work, thus, when
releasing the visor, it won't fall and will not demand the operator to hold it. Operating range limit keys are made of stainless
steel and painted in yellow. They are positioned by means of turning in relation to the display arc to the desired position.
When placing the keys at the desired pair positions, check their correct locking through “click” of the movement mechanism.
When placing it in the right position, the movement resistance increases, being possible to feel it during the adjustment.
Placement out of the locking position can cause improper functioning of the indicator.
13.3- INSTALLATION AND MAINTENANCE:
Open the front visor and place the operation range limit Keys (load-bonus) on the desired positions. Remember that the
relay must be appropriate to receive the microswitches signal for the correct operation of this functionality;
Perform the tap changer mechanical indication flexible cable connection to the inlet axis of the TB-I900 indicator. Remember
that the cable must be connected in order to obtain a correct indication of the position signalized on the TB-I900 visor and
the real position of the tap changer. This operation should be preferable performed in neutral position;
Perform a manual test, using the relay's outer supply in order to evaluate the behavior and proper cables connection.
Perform tests on reset and operation range limitation functions. Check if the system did not get heavy, causing the tap
changer dragging. Check if the assembling is correct with regards to the system's tightness. If everything is operating
properly, the regulator with TB-I900 indicator is ready to return to operation.
During its life cycle, TB-I900 does not need periodical maintenance, being only required its functional monitoring so that
adjustments can be performed in case of pointers misalignment.
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13.3.4- Dimensions
2
3
"A"
1
.8
R0
R0
.8
C0.5
Detalhe "G"
DESCRIPTION OF COMPONENTS:
1
FRONTAL ALUMINIUM CHILLED COVER
2
DISPLAY IN POLYCARBONATE
3
MECHANISM BOX ALUMINIUM CHILLED
VIEW "A"
The product may undergo changes due to changes in the manufacture processes, improvements or materials substitution
without previous notice.
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14 – SPECIAL CARE WITH HANDLING, WASTE DISCARDED, AND LEAKAGES ASSOCIATED TO S VOLTAGE
REGULATORS
14.1- Goals
Provide the necessary information for disposing wastes from potency transformers, distribution transformers, voltage
regulators and derivation reactors that may cause any impact to the environment, as well as measures to be taken in case of
leakage of oil, paint, solvent, etc. during transportation, reception, storage, and installation inspections.
14.2- Definitions
Environmental aspect: Activity, product or service that may interact with the environment in normal or risky situation. E.g. Gas
emissions, oil spillages. Aspect = causes.
Environmental impact: consequence of environmental aspects that result in the environmental change. Example: Air
contamination, ground water contamination. Impact = Aspect effect.
14.3- General Requirements
The TSEA ENERGIA, aware of its compromise with the sustainable development, and answering the expectations from
the customers and from society that are looking for products that do not attack the environment is investing in a permanent
way in the improvement of its acting related to the environment.
The TSEA ENERGIA in its continuous search of the development of its activities, products and services try to attend all the
legislation and it is introducing its environmental administration system in order to attend also the NBR ISO 14001 and
OHSAS 18001.
14.3.1- Integrated Management Policy Quality, Environment, Occupational Health and Safety
The TSEA ENERGIA, located in the city of Contagem, state of Minas Gerais, has the commitment to comply with the
needs of customers, shareholders, employees, partners and society, continuously improving its performance in the
manufacture of transformers and services rendering.
14.3.2- Environmental Aspects
Below we list the environmental aspects of transportation activities, receipt, storage and installation inspections for
voltage transformers, distribution transformers, voltage regulators, and derivation reactors.
14.3.2.1 - Significant Environmental Aspects
-Transformers, regulators, and reactors disposal,
-Insulating oil discarding;
-Oil barrels disposal;
-Paints and/or solvents discarding;
-Insulating oil leakage;
-Paints and/or solvents leakage.
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14.3.3- Waste Handling and Destination
- The equipment you are purchasing contains insulating oil inside. Oil spillage, once not contained, changes the soil and/or
water quality, harming the environment.
- Transformers, triphasic voltage regulators, and derivation reactors shall be installed within contention bases in order to
avoid, in case of leakage, soil and water contamination. The insulating oil contained in the equipment can be treated,
filtered and reused, or co-processed in mortar stoves. The metal part may be sent for casting companies.
14.3.3.1- Transformers, Regulators and Reactors Discarded
14.3.3.1.1- Metallic scraps
In general (silicon steel, copper, brass, carbon steel, aluminium). The metallic scraps must be selectively
discarded and send for recycling.
14.3.3.1.2- Porcelain:
It must be discarded as ordinary refuse in sanitary filled land.
14.3.3.2- Insulating Oil Discard
Direct it to barrels for later treatment or filtering and reuse or co-processing in mortar stoves, incineration or
discarded in Class I dump*.
14.3.3.3- Disposal of Insulating Oil Barrels
Barrels contaminated with oil shall be treated and reused. There are licensed companies that perform the proper
treatment and sell them.
14.3.3.4- Discarding Paints and Solvents
Direct them to co-processing in mortar stoves, incineration or Class I dump*.
14.3.3.5- Insulating Oil Leakage
14.3.3.5.1- Small insulating oil leakage
-Collect the leaked oil with the aid of rag, cloths or sawdust;
-Collect the residues and direct them for co-processing in mortar stoves, incineration or Class I dump*;
-In case of being able to collect the spilled oil, proceed according to item 13.3.3.2;
Note: In case of insulating oil leakage due to the actuation of the pressure relief valve, proceed according to item
13.3.3.2.
14.3.3.5.2- Major insulating oil leakage
-Immediately contain the oil using sandbags;
-Collect the oil into barrels or canisters;
-Proceed according to item 13.3.3.2.
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14.3.3.6- Paints, Solvents and Other Leakages
-Collect the leaked substance with the aid of rags, cloths or sawdust;
-Collect the residues and direct them to co-processing in mortar stoves, incineration or Class I dump*;
Note: In case of leakage, care must be taken regarding the generation of sparks, as the substances are flammable.
14.3.3.7- Discarding Cloths, Rags, Insulating Papers, Press Cardboard, Plastics, and Sawdust
Impregnate with Oil
Collect the residues and direct them to co-processing in mortar stoves, incineration or Class I dump*.
14.3.3.8- Discarding Wooden Packages
Collect and send to recycling or reuse as fuel in stoves, auto stoves, etc.
14.3.3.9- Discarding Plastic Used in Packages
Selectively collect and send to recycling.
14.3.3.10- Discarding Cardboard Used in Packages
Selectively collect and send to recycling.
14.3.3.11- Discarding Steel Protections
Selectively collect and send to recycling.
14.3.3.12- Discarding Gasket, Cork, Adhesive Tapes, Rubbers
Collect as garbage and send to sanitary dump.
14.3.3.13- Discarding Paints, Solvents Packages
Collect, send to recycling, reuse or send to sanitary dump.
14.3.3.14- Discarding of Oil Cleaning Filters
Collect and send to co-processing in mortar stoves, incineration or Class I dump*.
14.3.3.15- Noise
Check if it is according to federal or state environmental legislation, otherwise, perform maintenance to minimize
noise.
14.4- Legal Requirements and Other Requirements
When disposing a transformer, care must be taken to comply with the legislation in your State.
We communicate below the most important points of legislation regarding the equipment supplied by: TSEA ENERGIA
-Toxic wastes, as well as the ones that contain flammable (insulating oil), explosive, and other harmful substances, shall
undergo treatment and/or proper conditioning at the production site and comply with the conditions established by the
pollution control and environmental protection state agency.
-Garbage or wastes shall not be discharged in waterways, courses, lakes or ponds, except in case of the need to dispose
in artificial ponds, authorized by the pollution control and environmental protection state agency.
-It is forbidden to deposit, discard, unload, burry, infiltrate, or accumulate any types of waste on soil, except for the ones
whose disposal is made as established in specific projects of transportation and final destination, being forbidden the simple
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discharge or deposit in public or private property.
14.5- Training, Awareness and Competence
In case of subcontracting transportation, unloading, storage, and installation of the equipment, the information described
herein must be forwarded to the subcontractor in order to make it aware of:
-The importance of environmental policy;
-The significance of actual or potential environmental impacts, its activities and benefits to the environment resulting from
its performance improvement;
-The potential consequences of non-observance of the procedures described herein.
Personnel who perform tasks that may cause significant environmental impacts must be qualified, with proper education,
training and/or expertise.
14.6- Communication
In case of doubts regarding the waste disposal, please contact the Integrated Management Area for TSEA ENERGIA
Programs through telephone (+55 31) 3329-6557.
15 - DRAWINGS AND SPECIFIC INSTRUCTIONS ATTACHED.
Separately from this manual, you will also receive:
-Instructions manual for the voltage regulator control;
-Specific drawings applied to the regulator;
-Specific painting process to the regulator.
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