Top 37 How To Bypass Internal Voltage Regulator Top Answer Update

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Contents

Can you run without a voltage regulator?

The voltage regulator turns the raw energy of the ATV’s stator to the right amount of energy the battery can use. If you continue to ride your ATV without a voltage regulator, you will damage other parts.

Can you run an alternator without a voltage regulator?

Without a voltage regulator, an alternator may put out up to 250 volts. This is enough to destroy the car’s battery and electrical system. The voltage regulator is usually found inside or on the back of the alternator case.

What is bypass voltage regulator?

A system having voltage regulator bypass means provides a means for preventing a voltage regulator to be bypassed in a power system when the difference between a load side voltage of the voltage regulator and a source side voltage of the voltage regulator is not below a certain threshold or substantially small.

What are the symptoms of a faulty regulator rectifier?

Key Signs to Look For

You won’t have any trouble diagnosing the faulty regulator rectifier if the battery is the cause. You’ll note signs right away like poor starts, fluctuating meter readings, and dimmed headlights. around 13 volts, the bike will start to drain the battery.

What happens without a voltage regulator?

The voltage regulator in your vehicle is in charge of keeping the right amount of electrical power flowing consistently to certain parts of your car. This means if the voltage regulator is broken, the components in your electrical system might only work erratically or not at all.

Do you need a voltage regulator with a one wire alternator?

As you might assume, the concept behind a one-wire alternator is that there is a single wire used to connect the alternator to the battery. The voltage regulator is internal, and there are no other wires that need to be connected to your electrical system.

What device is used to bypass a regulator?

S&C Regulator Bypass Switches are used to bypass and isolate voltage regulators for maintenance. They’re also suitable for bypassing and isolating other devices, such as the current transformers of primary metering equipment.

Which of these is an appliance used for voltage regulation?

Many simple DC power supplies regulate the voltage using either series or shunt regulators, but most apply a voltage reference using a shunt regulator such as a Zener diode, avalanche breakdown diode, or voltage regulator tube.

How do I test a voltage regulator with a multimeter?

Follow these steps to test your voltage regulator:

Step 1: Set The Multimeter To Voltage. Ensure your multimeter is on the voltage setting. …
Step 2: Connect The Multimeter To Your Battery. …
Step 3: Check The Multimeter. …
Step 4: Turn Your Vehicle On. …
Step 5: Rev The Engine. …
Step 6: Check The Multimeter Again.

Will a motorcycle run without a voltage regulator?

Super Moderator. Your voltage regualtor is needed to keep a charge on your battery. Your battery would die without it.

Can a motorcycle run without regulator?

It won’t damage anything to run without a working reg/rec. The issue is that you’ll have a very limited range, so the engine might die on you at any time; typically not while riding under load, but rather when you go to idle to come to a stop.

What does a ski doo voltage regulator do?

A snowmobile with a battery and electric start have a RECTIFIER to change the AC voltage off of the generator to DC. A snowmobile without a battery has an AC lighting system. The regulator in an AC lighting system typically dumps any voltage above 15 volts to gound…. thus limiting it to about 15 volts.

How do you test a snowmobile voltage regulator?

The only way to test them is to put an AC signal that is higher than the rated voltage and measure it. Regulators with a red wire for charging the battery simply have a diode to create a pulsing DC signal for the battery.

Alternator Internal Regulator to External Regulator Conversion – Sort Of

Can You Ride an ATV Without the Voltage Regulator? – ATV MAN

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Table of Contents:

What Does the Voltage Regulator Do for an ATV

How to Know if your ATV has a Bad Voltage Regulator

The Cost of a Voltage Regulator Replacement

Some notes on ATV batteries relative to voltage regulators

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Can You Ride an ATV Without the Voltage Regulator? – ATV MAN

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Table of Contents:

Do You Have a Bad Voltage Regulator

1 What Does a Voltage Regulator Do

Can You Ride an ATV Without the Voltage Regulator? – ATV MAN

Riding an ATV can be exhilarating, but not so much when your voltage regulator has left the ATV with little power. This can be extremely frustrating when you are ready to be out on the open road.

Can you ride an ATV without the voltage regulator? While you may be able to temporarily operate an ATV without a voltage regulator, you should not do so. The voltage regulator turns the raw energy of the ATV’s stator to the right amount of energy the battery can use. If you continue to ride your ATV without a voltage regulator, you will damage other parts.

If you are having issues with your voltage regulator, you need to quick riding and get it check out by someone who knows what they are looking at. Without proper energy from the battery, your ATV will no longer be operable. Your voltage regulator does a lot for your ATV that you should read on about.

What Does the Voltage Regulator Do for an ATV?

Your voltage regulator turns the alternative current (AC) into a direct current (DC). This ensures that your battery gets just the right amount of power at any time. The majority of this power makes your ATV run properly and without any sputtering.

Should you ride your ATV without a voltage regulator, your battery will become overcharged. This would mean that all of the AC energy is being concentrated on the battery and does not flow to the other components of your ATV that need power.

As your battery continues to handle this much power, it will start to weaken and and eventually die completely. When your voltage regulator starts to have issues, your ATV will not seem as powerful as it should.

However, we all know there are many reasons your ATV can lose power. Because of that, there are other problems that you should look out for on your ATV that will suggest that your voltage regulator is starting to fail.

How to Know if your ATV has a Bad Voltage Regulator?

Spotting the signs of a failing voltage regulator will help you to fix the problem sooner. Because the voltage regulator helps bring a steady flow of power to each part of the ATV, there are different clues to spot when the voltage regulator begins failings.

The signs of a failing ATV voltage regulator include the following:

Your ATV is overloaded with power: The AC energy that starts when you turn your ATV on goes straight through the voltage regulator. The voltage then exceeds the limit for the ATV, causing problems with other electrical parts.

Your ATV doesn’t run as strongly: The ATV will become slower as you try to push it harder. You may think there is a problem with the engine, but more than likely it is the regulator.

Your ATV lights start to dim: Your lights may flicker, or they just dim so they are not as bright as usual. Again, you will be tempted to change the bulbs, but it is best to look at the regulator to make sure it is not a bigger issue.

Your ATV’s battery stops working: The end result of a bad voltage regulator is a dead battery. There could be other reasons as to why your battery is dead, but a dead batter is the main sign of your regulator not functioning properly. One sign that often means you have a voltage regulator issue is that you find your battery to be swollen.

If you see any of these signs showing up, you should take immediate action. Early detection can help prevent the burnout of other electrical parts that will cost more to replace. So, how do you test your ATV voltage regulator to make sure that it is working properly before you buy a replacement?

How Do You Test a Voltage Regulator On an ATV?

Testing your voltage regulator is a simple task, but you can also hire a professional if you are not comfortable with it.

Going along with the regulator, you will hear the word, “rectifier.” A rectifier moves hand-in-hand with the regulator, as it is responsible for changing the three-phase AC energy into DC. The regulator then takes that DC energy and keeps it where it needs to be to not overcharge the ATV and the battery.

To test your regulator you will need:

A Digital multimeter with a Diode Check (This is an inexpensive one we like)

(This is an inexpensive one we like) Your ATV’s service manual

Here are the following steps to take to test your voltage regulator:

Take your digital multimeter and change the setting to do a diode check.

Next, determine if your ATV uses a single or three-phase regulator. If it is a single-phase regulator, there will be one wire. If your ATV has a three-phase regulator, there will be three different colored wires.

This part is important as you do not want to electrocute yourself. Make sure that your ATV is completely turned off and once you have done this, you are now able to remove the regulator from your ATV.

You need to perform a forward bias test on your regulator. Take the leads from your digital multimeter and check once more to determine that it is on the diode check.

Attach your leads to your regulator. The negative lead will be attached to the positive line on the regulator, which is usually the color red.

Attach your positive lead to the regulator’s biggest line. This line will have multiple connections for you to test. This will show you where your regulator is faulty.

When you apply the positive lead to one of the connectors, your multimeter should read between, .300 to .500 volts DC.

If you have received an OL on your digital multimeter, this stands for “Open Line.” The connector that gives this reading is unable to receive any power. AC energy is running right past it, unfiltered. This means it is time to replace your regulator.

The Cost of a Voltage Regulator Replacement

The cost of the voltage regulator part itself can range from $15 to $250 on Amazon. The price you pay will depend on what model of ATV you have and the manufacturer of the part you choose.

If you are not comfortable replacing the voltage regulator, any ATV repair shop should be able to handle it. On top of the part, you should count on paying at least $100 to $300 for the labor.

Should the regulator be located on the inside of the alternator, you should expect to pay on the higher end of the labor cost range. If it is located on the outside of the alternator, you will not have to pay so much.

Overall, your total cost to replace this piece should be no more than $500. Even though dealerships often charge more, you should explore other options if they want much more than that.

Some notes on ATV batteries relative to voltage regulators

If the voltage regulator is causing your battery to go bad, you can often see swelling in the battery. Because the regulator is not steadying the flow of energy, the battery is taking more power in than it is designed for. Make sure to be careful when removing the swollen battery from your ATV.

Once your voltage regulator has fried your ATV battery, you will have to pick a new one. An ATV uses a flooded acid-battery or an Absorbed Glass Mat batteries. The Absorbed Glass Mat batteries are stronger than the flooded acid-lead batteries.

If you are just simply riding around in your ATV and not having to do any heavy handling, then the flooded battery would be your best option. It is low-cost, but they can begin to become messy if you start to ride a bit rougher.

The Absorbed Glass Mat battery is made for rougher riding. As you would expect, it will cost slightly more than a flooded battery. However, they do not spill and can be charged faster than the flooded batteries.

If you have questions about buying a new battery for your ATV, you will want to check out our much more comprehensive battery guide.

How to Test Your Alternator’s Voltage Regulator

Dan Ferrell writes about DIY car maintenance and repair. He has certifications in Automation and Control Technology and Technical Writing.

Do You Have a Bad Voltage Regulator?

Symptoms of a bad voltage regulator may include:

High voltage output

Low voltage output, sometimes

No voltage output

Lights dim or flicker

Faulty high-beam headlamp bulbs

Engine working erratically (weak or flickering ignition system)

Adding water to the battery frequently

Growing corrosion around battery terminals and top

Dead battery

Battery or check engine light indicator lit on dashboard

Keep in mind that some of these symptoms may come from loose or corroded charging system connections.

Therefore, Make Sure to Check for:

clean and tight battery connections,

good battery cables,

good engine and chassis ground connections and wires,

battery clean and in good operating condition (have it tested, if necessary), and

drive or serpentine belt not worn and with proper tension.

These preliminary checks will help you eliminate the most common charging system problems.

Index 1. What Does a Voltage Regulator Do? 2. Voltage Regulator Test a. Checking Wires Using Voltage Drop b. Voltage Regulator Bypass Test c. Voltage Regulator Adjustment d. Testing a Contact-point Voltage Regulator 3. Voltage Regulator Replacement

Check the battery and charging circuit to make sure they are not interfering with charging system operation. Photo in the Public Domain.

1. What Does a Voltage Regulator Do?

Basically, the voltage regulator controls field current through the rotor, inside the alternator, in order to control alternator output.

Without a voltage regulator, an alternator may put out up to 250 volts. This is enough to destroy the car’s battery and electrical system.

The voltage regulator is usually found inside or on the back of the alternator case. Increasingly, though, late-model vehicle have the engine control module (ECM) regulating alternator voltage output through a special circuit.

Older models used an electro-mechanical, external voltage regulator, mounted somewhere in the engine compartment.

On a computer controlled charging system, the electronic or powertrain control module can monitor system operation, cut off charging output if voltage levels are too high, and trigger diagnostic trouble codes. This is part of a fail-safe-circuit in the computer, and can greatly help you diagnose system problems and describe potential faults.

Check Your Alternator Parameters Always check the charging system specifications for your particular vehicle model to correctly interpret your system test results. Different models have different specifications for the voltage regulator.

Use a digital multimeter to check voltage regulator operation and charging circuit voltage drop. Photo courtesy of Emilian Robert Vico on Wikimedia.

2. Voltage Regulator Test

Charging voltage can vary between 13.5 and 14.8 volts, depending on ambient temperature.

In a nice, 70 F (21 C) day, you can expect a voltage regulator charging your car’s battery at about 14.2 volts. And the higher the temperature, the lower the charging voltage.

This test is a simple procedure to check alternator voltage regulator output. You need a digital multimeter for this test.

Set the parking brake and shift the transmission to Neutral (manual) or Park (automatic). Set your multimeter to DC Voltage and select the 20 Volts in the scale. Connect the meter’s red lead to the battery’s positive (+) post and the meter’s black lead to the battery’s negative (-) post. Notice the open-circuit voltage of the battery. Your battery should be at about 12.6 volts, 12.4 volts minimum; otherwise, charge the battery and continue with this test. Now, ask an assistant to start the engine and run it at 1500 rpm. Take a note of your voltmeter reading.

A good output voltage should be about 2 volts higher than your battery open-circuit voltage. Consult your vehicle repair manual, if necessary, to check the correct specifications for your particular model.

If you noticed an output voltage reading below 13 volts right after starting the engine, there could be a charging system problem. Conduct a voltage drop test as described in the following subsection 1. Checking Wires Using Voltage Drop.

If the output voltage reading is 16 volts or higher, there’s an overcharging problem. This usually indicates a bad voltage regulator.

If voltage seems to fluctuate during your test, switch your voltmeter to the AC voltage scale and take another output voltage reading with the engine still running. This time, connect your meter’s red lead to the B+ terminal on the back of the alternator, and the meter’s black lead to battery negative (-). Usually, the presence of 0.25 AC volts means a leaking diode that requires replacing the alternator. But some manufacturers recommend replacing the alternator if 0.50 AC volts is detected. However, if you have noticed engine performance issues, this might be the problem. Consult your vehicle repair manual for acceptable diode leak rate, if necessary.

If your output voltage is within specifications, continue with this test:

With the engine running, increase engine speed to 2000 rpm. Turn on the headlights, AC, defogger, and other high current accessories you may have. Take a note of your voltmeter reading.

The voltage output reading should be about 0.5 volts higher than your battery’s open circuit voltage.

Most voltage regulators are calibrated to output between 13.5 and 15.5 charging volts on a fully charged battery at normal temperature with no accessories or lights on. Consult the specifications in your vehicle repair manual for your particular application.

Keep in mind that a worn or loose drive belt and other vehicle operating conditions like high temperatures can affect how the voltage regulator operates.

When your test shows a steady or intermittent high or low voltage output, the voltage regulator is possibly bad. Most voltage regulators fail by allowing a high voltage output, though. However, before going any further, check that all the connections to the alternator and battery are good and clean as described in the next section.

a. Checking Wires Using Voltage Drop

A quick way to examine the wires and connections in the charging system is to check for voltage drops.

Set your voltmeter to 2 volts. Start the engine and let it idle. Measure for voltage across individual wires and connections in the charging system. If there’s voltage over 0.2 volts in any wire or connection, check for corroded, damaged or loose wires. When fixing wires and connections, aim for a voltage drop of less than 0.1 volts or 0.

This post on charging system voltage drop tests walks you in more detail through the steps. Pay special attention to the ground side of the charging system which can cause trouble for the voltage regulator.

If the charging circuit connections are good, continue with the following tests. You can check whether your voltage regulator is at fault through a regulator bypass test, as described in the following section.

The following video gives you a charging system check overview that you can follow as well to test your charging system, if necessary.

b. Voltage Regulator Bypass Test

On many alternators (except those with computer voltage regulation), you can bypass the voltage regulator to test whether your voltage regulator or some other component (alternator or charging circuit) is at fault.

There could be several ways to bypass the voltage regulator, depending on the charging system configuration for your particular vehicle model. Your voltage regulator may be connected to the power side of the circuit (type-B circuit) or the ground side (type-A circuit). Consult your repair manual.

If the rear of your alternator has a ‘test tab’, you need to short this tab to the alternator frame using a screwdriver while checking voltage output at the battery with the engine running.

On other systems, you may need to connect the battery and field terminals using a jumper wire while checking voltage output at the battery with the engine running.

If your car’s charging system is controlled through the computer, you may need a scan tool to check voltage regulation.

On modern Chrysler vehicles, most likely the computer regulates alternator output voltage. Depending on its particular configuration, you may test charging output by grounding the corresponding field terminal, or applying battery voltage to the appropriate terminal (on B-circuit types, 2002 and newer).

Follow These Precautions:

During your test, keep all electrical accessories off before starting the engine.

Disconnect the jumper wires once your digital multimeter reads charging voltage.

Turn off the engine.

Consult the vehicle repair manual for your particular model to conduct this test, if necessary.

When the voltage regulator is bypassed, you should see maximum voltage output.

If voltage output remains at a normal level, most likely the voltage regulator is faulty.

If voltage output remains at the same level (low, for example) as in your initial test (Section II, step 6), most likely you have a faulty alternator.

The next video shows you how to test an external voltage regulator and how to bypass it.

c. Voltage Regulator Adjustment

Some alternators with an old configuration allow adjusting of the voltage regulator. On these units, you can find a small adjusting screw on the voltage regulator.

Connect your voltmeter across the battery posts. Set the Parking brake. Shift the transmission to Neutral (manual) or to Park (automatic). Start the engine and let it idle. Turn off any accessories, if necessary. Check battery charging voltage. Turn the adjusting screw using a small screwdriver to adjust charging voltage to specifications.

Refer to your vehicle repair manual to make sure you have an adjustable voltage regulator, locate the adjusting screw, and set voltage output to specifications.

Old type DC generators and early vehicle charging systems used a contact-point type voltage regulator. Basically, it consisted of a coil, a set of points and resistors to control alternator voltage and current output. These regulators were replaced by electronic or solid-state voltage regulators.

Still, there might be some vehicles on the road today fitted with this type of regulator.

Usually, the contact points in the regulator are the ones to cause trouble after many miles of service due to wear or pitting.

To repair a contact-point voltage regulator:

File, test and adjust the regulator points, as necessary.

If still, voltage output is out of specifications, replace the regulator.

Refer to the repair manual for your particular vehicle make and model.

If necessary, replace the voltage regulator or install a new alternator. Photo courtesy of Phasmatisnox on Wikipedia.

3. Voltage Regulator Replacement

To replace it, remove the voltage regulator from the back, or inside, of the alternator. Consult your vehicle repair manual for the procedure for your particular model.

If you don’t have the manual yet, you can buy a relatively inexpensive copy online through Amazon. Haynes manuals come with step-by-step procedures for many maintenance, troubleshooting and component replacement projects you can do at home. So you’ll recoup your small investment soon.

Some vehicle models use alternators with internal voltage regulation. You’ll need to replace the alternator, if voltage regulation has failed.

The same goes for computer-controlled voltage regulation. When the voltage-regulator circuit fails, most likely you’ll need to replace the Powertrain Control Module (PCM).

Probably your voltage regulator passed the tests. However, you still may suspect a problem in the system. In this case, this other post will help you check the charging system in your car.

This content is accurate and true to the best of the author’s knowledge and is not meant to substitute for formal and individualized advice from a qualified professional.

Questions & Answers

Question: When you wrote, “Without a voltage regulator, an alternator may put out up to 250 volts,” is that referring to when a car is on the highway or a racecourse?

Answer: It was referring to how much the alternator may put out if it didn’t have a regulator.

Question: Is there a more simple solution for the “over voltage” problem from the alternator regulator? For example, can we not put another filter (voltage regulator) after the alternator to keep the voltage between 12 to 14.5 volts?

Answer: If the original internal regulator failed, usually you can replace the unit with an OEM part. It’s calibrated for your specific application. External regulators require different wiring set up to work.

© 2019 Dan Ferrell

Systems and Methods for Bypassing a Voltage Regulator

Description:

TECHNICAL FIELD

The present disclosure relates generally to bypassing a voltage regulator in a power system. More specifically, the present disclosure relates to preventing a voltage regulator from being bypassed when certain safe bypass conditions are not met.

BACKGROUND

The practice of bypassing a regulator is fairly common. Bypassing is done in order to avoid power disruptions when installing or removing a regulator from service. If it is not done properly, i.e.—the regulator is bypassed while the tap changer is not in the neutral position (commonly referred to as “Bypass off Neutral”), serious damage can result. When the tap changer is not in the neutral position, a voltage exists between the source and load bushings of the regulator. Bypassing the regulator creates a short circuit between the source and load bushings through the bypass switch. If the series winding has not been taken out of the circuit by moving the tap changer to the neutral position, the voltage across the source and load bushings can drive a very large current through the regulator series winding and bypass switch. This large current can burn insulation, create arcing, melt windings, and lead to a rupture of the regulator tank. Because of the typically small number of series turns involved, the ratio of series turns to shunt turns can be very small. This means that even though a very large bypass current is flowing in the series winding, a much smaller current is reflected into the shunt winding. This current can be near or below rated load current. As a result, upstream protection may, be unable to detect the situation until a ground fault occurs. Therefore, the protective equipment upstream of the device often cannot sense and/or cannot respond quickly enough to prevent the failure from becoming catastrophic.

Traditionally, the method for ensuring a safe bypass operation is a manual process in which the user is recommended to verify that the regulator tap changer is in the neutral position and no voltage differential is present between the load and source sides of the bypass switch and voltage regulator. Typically, such verification includes four possible methods: 1) verify that a neutral indicator light on the control is indicating the neutral position; 2) verify that the tap position display on the regulator control interface indicates the neutral position; 3) verify that the mechanical position indicator on the regulator is in the neutral position; and 4) verify by measurement that there is no voltage difference between the source and load bushing. Such methods are typically dependent upon the observation, judgment, knowledge, and conscientiousness of the user. Thus, such existing methods can be prone to human error.

SUMMARY

In an example embodiment, a system with voltage regulator bypass includes a voltage regulator, a bypass switch coupled to the voltage regulator, and between a source and a load, the bypass switch comprising a first state and a second state. In the first state, the bypass switch electrically couples the source to the voltage regulator and the voltage regulator to the load, establishing a conductive path between the source and load via the voltage regulator.

In the second state, the bypass switch electrically couples the source directly to the load, bypassing the voltage regulator. The system further includes a bypass switch controller coupled to the bypass switch, wherein the bypass switch controller controls whether the bypass switch is put into the first state or the second state, and a voltage regulator controller coupled to the bypass switch controller and the voltage, regulator, wherein the voltage regulator controller prevents the bypass switch controller from putting the bypass switch into the second state unless one or, more bypass conditions are met.

In another example embodiment, a voltage regulator bypass controller includes a logic controller configured to couple to a bypass switch controller, wherein the bypass switch controller is coupled, to and controls a bypass switch. When the logic controller is coupled to the bypass controller, the logic controller prevents the bypass switch controller from actuating the bypass switch unless one or more bypass conditions are met.

In another example embodiment, a method of bypassing a voltage regulator includes receiving a plurality of inputs from a voltage regulator, and determining if a bypass condition has been met based on at least the inputs from the voltage regulator. If it is determined that the bypass condition is met, then permit a bypass switch controller to actuate a bypass switch and put the voltage regulator into a bypassed state. If it is determined that the bypass condition is not met, then prevent the bypass switch controller from actuating a bypass switch. The method further includes, preventing the voltage regulator from being put into the bypassed state.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the example embodiments of the present disclosure and the advantages thereof, reference is now made to the following description in conjunction with the accompanying drawings in, which:

FIG. 1 illustrates an example block diagram of a system with voltage regulator bypassing means, in accordance with certain example embodiments;

FIG. 2 illustrates an example schematic diagram of certain elements of the system of FIG. 1, in accordance with certain example embodiments; and

FIG. 3 illustrates an example logic diagram for determining a safe bypass condition, in accordance with certain example embodiments.

FIG. 4 illustrates an example method for determining whether a bypass switch control may actuate a bypass switch in accordance with certain example embodiments.

The drawings illustrate only example embodiments of the disclosure and are therefore not to be considered limiting of its scope, as the disclosure may admit to other equally effective embodiments. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of example embodiments of the present disclosure. Additionally, certain dimensions may be exaggerated to help visually convey such principles.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Embodiments of the disclosure are directed to systems and methods for bypassing a voltage regulator in a power system when the voltage regulator is in a neutral state and no voltage differential exists between source and load bushings of the voltage regulator. In the description, well known components, methods, and/or processing techniques are omitted or briefly described so as not to obscure the disclosure. As used herein, the “disclosure” refers to any one of the embodiments described herein and any equivalents, but is not limiting to the embodiments described herein. Furthermore, reference to various feature(s) of the “disclosure” is not to suggest that all embodiments must include the referenced feature(s). The following description of example embodiments refers to the attached drawings.

Turning now, to the drawings, in which like numerals indicate like elements throughout, example embodiments of the disclosure are described in detail.

Turning to FIG. 1, an example power system 100 includes a voltage regulator 108, a bypass switch 104, a bypass switch control 110, and a voltage regulator control 112. In an example embodiment, the bypass switch 104 is coupled to a power source 102 and a load 106. The bypass switch 104 is also coupled to the voltage regulator 108. In an example embodiment, the bypass switch is operable in at least two modes, an on mode and an off mode. The off mode (also called normal mode) is generally applied when the power system 100 is operating normally, and the voltage regulator 108 is to be coupled between the power source 102 and the load 106, thereby regulating voltage delivered to the load 106. Specifically, when the bypass switch 104 is in the off mode, the bypass switch 104 electrically couples the power source 102 to the voltage regulator 108, and the voltage regulator 108 to the load 106. Further, in an example embodiment, when the bypass switch 104 is in the off mode, the power source 102 and load 106 are not coupled directly to each other, and power provided from the power source 102 goes through the voltage regulator 108, and a regulated voltage is provided to the load 106 from the voltage regulator 108. When the bypass switch 104 is in the on mode, the voltage regulator 108 is bypassed and the power source 102 is directly coupled to the load 104. Thus, power from the power source 102 is provided directly to the load 106 without going through, or being regulated by, the voltage regulator 108.

In the example embodiment shown in FIG. 1, the bypass switch 104 is further communicatively coupled to the bypass switch control 110. In an example embodiment, the bypass switch control 110 controls the mode of the bypass switch 104 by sending a bypass control signal to the bypass switch 104, which puts the bypass switch 104 into the off mode or the on mode. The bypass switch control 110 is further communicatively coupled to the voltage regulator control 112, which is communicatively coupled to the voltage regulator 108.

In an example embodiment, the bypass switch control 110 is locked from putting the bypass switch 104 into the on mode if the voltage regulator is not in a neutral state, as determined by the voltage regulator controller 112. Specifically, an output signal from the voltage regulator controller 112 is sent to the bypass switch control 110. The output signal is an indication of whether the voltage regulator is in a neutral state. When the voltage regulator is in the neutral state, there is effectively no voltage difference between the voltage provided to the voltage regulator 108 from the power source 102 and the voltage provided to the load 106 from the voltage regulator 108. Thus, if the voltage regulator 108 were to be bypassed, there would be effectively no voltage difference between the power source 102 and the load 106, and thus, generally no harmful current surge.

An output signal 116b is generated by the voltage regulator controller 112 in response to one or more voltage measurements at the voltage regulator 108. Specifically, if, it is detected that the voltage regulator 108 is in the neutral state, the voltage regulator controller 112 sends a signal to the bypass switch control 110 which unlocks the bypass switch control 110, allowing it to put the bypass switch 104 into the on mode, thereby bypassing the voltage regulator 108. However, if it is detected that the voltage regulator 108 is not in the neutral state, the voltage regulator controller 112 sends a signal to the bypass switch control which locks the bypass switch control. When the bypass switch control 110 is locked, it is generally unable to put the bypass switch 104 into the on mode, and the voltage regulator 108 cannot be bypassed. Thus, in general, the voltage regulator 108 can only be bypassed when the voltage regulator 108 is in the neutral state. Various voltage measurement circuits and methods are employable for detecting the neutral state of the voltage regulator 108 in addition to those disclosed herein. In certain example embodiments, in order for the voltage regulator controller 112 to make a neutral determination of the voltage regulator 108, one or more additional conditions must be met, a subset of which is detailed below.

FIG. 2 illustrates a schematic representation of the power system 100 according to an example embodiment of the present disclosure. Turning to FIG. 2, an example embodiment of the power system 100 includes the voltage regulator 108, a logic controller 256, the bypass switch control 110, the bypass switch 104, the power source 102, and the load 106. In certain example embodiments, the power system 100 may not include the power source 102 and/or the load 106, as certain embodiments of the power system 100 are configured to be coupled to and decoupled from various loads and power sources.

In an example embodiment, the voltage regulator 108 includes a differential potential transformer 202, a potential transformer 204, an auto-transformer 206, and a tap changer 208. In an example embodiment, the auto-transformer 206 is the combination of a shunt winding 212 and a series winding 214. The series winding 214 includes a plurality of taps, and the shunt winding 212 has a fixed ratio to a control winding 210. The tap changer 208 includes movable contacts 220 and stationary contacts 216 individually connected to taps, of the series winding 214. In an example embodiment, the series winding 214 is physically located outside of the tap changer 208. The movable contacts 220 are configured to make contact with one or two of the stationary contacts 216 at a time, thereby effectuating a variable number of windings in the series winding 214. The stationary contacts 216 includes a neutral contact 218, which effectively bypasses the series winding 214. Thus, when the movable contacts 220 are coupled to the neutral contact, no portion of the series winding 214 is, connected between the source and load bushings 232, 230, and the voltage regulator is in the neutral state. Specifically, the series winding 214 and the neutral contact 218 are coupled to the load bushing 230, and the movable contacts 220 is coupled to the source bushing 232. The load bushing 230 is coupled to the load via the bypass switch 104 and the source bushing 232 is coupled to the power source 102 via the bypass switch 104. When the movable contacts 220 are coupled to the neutral contact 218, the load 106 is coupled to the power source 102 via the bypass switch, without going through any windings 214. Thus, the voltage provided at the power source 102 is effectively the same as the voltage provided at the load 106, and the voltage regulator 108 is in the neutral position.

The movable contacts 220 can be further coupled to a preventative autotransformer 222 or other form of impedance to prevent a short circuit condition when the movable contacts 220 are bridging across taps 216 at different electrical potentials. In an example embodiment, the preventative autotransformer 222 is located outside of the tap changer 208. In certain example embodiments, the tap changer 208 also includes a polarity switch 226. The polarity switch 226 is used to couple the load bushing 230 to either a first end 215a of the series windings 214 or a second end 215b of the series winding 214, which determines whether the series windings 214 has an additive or subtractive effect on the voltage.

In certain example embodiments, further detection of the voltage regulator 108 being in the neutral state employs the differential potential transformer 202 and/or the potential transformer 204. In certain example embodiments, the signals of differential potential transformers 202 coupled in the circuit are used to detect the neutral state. In certain example embodiments, the differential potential transformer 202 is used to measure the voltage difference across the source-side, or source bushing 232, of the voltage regulator and the load-side, or load bushing 230, of the voltage regulator. The measured voltage difference by the logic controller 256 and a neutral state determination is made by the logic controller 256. Specifically, if the measured voltage difference is below a set threshold, it is an indication the voltage regulator 108 is in the neutral state. Conversely, if the measured voltage difference is not below the threshold, then it is an indication that the voltage regulator 108 is not in the neutral state. The voltages at the source bushing 232 and the load bushing 230 of the voltage regulator can also be measured separately against a reference point, for instance, by using the control winding 210 and the potential transformer 204, and comparing the values.

It should be noted that FIG. 2 illustrates an example embodiment which includes several measurement means that can be used to detect that the voltage regulator 108 is in the neutral state. Specifically, in certain example embodiments, a subset of the measurement means illustrated in FIG. 2 are used to detect that the voltage regulator 108 is in the neutral state. For example, in an example embodiment, a differential signal which is used to detect neutral position is generated by the differential potential transformer 202. In another example embodiment, the detected differential signal between two potential transformers 210 and 204 connected between the source and the load, respectively, is used to determine the neutral state. In other words, in alternate embodiments not all of the measurement means illustrated in FIG. 2 will necessarily be present.

In certain example embodiments, the voltage regulator 108 is, a type A voltage regulator, in which the shunt winding 212 is coupled to the source 102. In such an embodiment, the system 100 includes the differential potential transformer 202, through which a neutral state can be detected. In certain example embodiments, the voltage regulator 108 is a type B voltage regulator, in which the shunt winding 212 is coupled to the load 106, and the control winding 210 to monitor the voltage on the load 106. In such an embodiment, the potential transformer 204 may not be included in the system 100.

In certain example embodiments, the tap changer 208 also includes a neutral position switch 224. The neutral position switch 224, is typically triggered when the neutral tap 218 is selected and coupled to the movable contacts 220. The neutral position switch 224, when triggered, provides a signal to the logic controller 256 indicative of the neutral tap 218 being selected. In certain example embodiments, the power system 100 includes a neutral position indicator light 234. The indicator light 234 may be powered directly from the neutral position switch 224 or from the logic controller 256, and lights up when the tap changer 208, and thus voltage regulator 108, is in the neutral state.

Under normal operating conditions (i.e., when the bypass switch 104 is in the off mode), the bypass switch 104 connects the power source 102 to the source bushing 232 through a source disconnect contact 236. The load 106 is connected to the load bushing 230 through a load disconnect contact 238. The bypass switch 104 further includes a bypass contact 240. The bypass contact 240 is coupled between the load 106 and the power source 102 such that when the bypass contact 240 is open, the load 106 is not electrically coupled to the power source 102 via the bypass contact 240. When the bypass contact 240 is closed, the load 106 is directly electrically coupled to the power source 102 via the bypass contact 240. Thus, in order to prevent a short circuit across the series winding 214, the bypass contact 240 remains open while the regulator is in service (i.e., not bypassed). In an example embodiment, the source disconnect contact 236, the load disconnect contact 238 and the bypass contact 240 may or may not be ganged together to operate through a single actuator 242. Specifically, the actuator 242, when operated on, either opens the disconnect contacts 236, 238 and closes the bypass contacts 240, or closes the disconnect contacts 236, 238 and opens the bypass contacts 240. In certain example embodiments, the actuator 242 is a mechanized actuator. In certain other example embodiments, the actuator 242 is an electrical switch.

In an example embodiment in which the actuator 242 is a mechanized actuator, the actuator 242 is controlled by the bypass switch controller 110. The bypass switch controller 110 includes a control switch 248, a power supply 246, and a safety relay 250. Specifically, in an example embodiment, the control switch 248, the safety relay 250, and the power supply 246 are coupled serially with the actuator 242. Thus, the actuator 242 is powered by the power supply 246, and actuated, when the control switch 248 and the safety relay 250 are both in the closed position. If either of the control switch 248 and the safety relay 250 are open, then an open circuit occurs and the actuator 242 is not powered. In certain, example embodiments, the default state of the actuator 242 is a normal state, in which the load disconnect contact 238 and the source disconnect contact 236 are closed and the bypass contact 240 is open (i.e., voltage regulator not bypassed). When actuator 242 goes into a bypass state when it is powered, the load disconnect contact 238 and source disconnect contact 236 are opened and the bypass contact 240 is closed. Thus, in an example embodiment, both the control switch 248 and the safety relay have to be closed, or activated, for the actuator to be put into the bypass state.

The control switch 248 is activated when it is determined, either automatically or by, a user, that the voltage regulator 108 is to be bypassed and the load 106 is to be directly coupled to the power source 102. Thus, in certain example embodiments, the control switch 248 is coupled to and/or follows a button or the like or a user interface. In certain example embodiments, the control switch 248 is coupled to and/or responds to a signal from a processor or controller. In an example embodiment, the safety relay 250 is controlled by the logic controller 256. Specifically, the logic controller 256 generates a safe output signal when the controller detects that one or more safe bypass conditions are met. The safe output signal is sent to the safety relay 250 and activates the safety relay 250 to be a closed circuit component. Thus, when the control switch 248 is activated (i.e., closed), the circuit is completed and the actuator 242 is actuated. In an example embodiment, the safety relay 250 is disabled (i.e., open) by default when the controller 112 does not detect that bypass conditions are met and thus does not send the safe output signal to the safety relay 250. Thus, the safety relay 250 remains open when bypass conditions are not met, and the actuator 242 cannot be activated even if the control switch 248 is enabled. The safety relay 250 described herein is an example actuator 242 hocking mechanism. Various other implementations of an actuator 242 locking mechanism which disables the actuator 242 from being activated even when then control switch 248 is activated are applicable and considered to be within the scope of the disclosure.

As discussed above, in certain example embodiments, the logic controller 256 enables the safety relay 250 when one or more bypass conditions are met. The bypass conditions are determined from one or more of various inputs 252 to the logic controller 256. Most crucially, the logic controller 256 should verify, that the voltage across the load and source sides of a regulator bypass switch 104 is sufficiently small to eliminate the chance of a short circuit through the bypass switch 104 and voltage regulator 108. One method of verification of such is to utilize a differential potential transformer 202 or a similar measurement device to directly measure the difference in potential between the load bushing 230 and the source bushing 232. Another method of verification is to measure the voltages at the source and load sides of the voltage regulator 108 separately against a reference point, for example, using the control winding 210 and the potential, transformer 204, and comparing the values. Additionally, resistive dividers, capacitive dividers, and other commonly used voltage measurement means may be similarly used. Additionally, in certain example embodiments, when the voltage regulator 108 is currently being bypassed, the bypass switch 104 also cannot be switched out of the bypass position without proper output from the voltage regulator 108.

In certain example embodiments, in addition to detecting that the source and load voltages 232, 230 are substantially similar, certain other bypass conditions may be required to be met prior to determining that a safe bypass condition exists. For example, one such bypass condition is that the neutral position switch 224 is triggered, indicating that the movable contacts 220 of the tap changer 208 are positioned on the neutral tap 218. Further, another such bypass condition may be verification that a voltage regulator controller 112 is in an off-line mode so that voltage regulator 108 may, not switch tap positions 214 until placed online. In certain example embodiments, the power supply 246 and/or the control switch 248 are also communicatively coupled to the logic controller 256 to prevent bypassing if all safety requirements are not met. Further, in certain example embodiments, a timer or remote control could be incorporated into the logic controller 256 to allow personnel to be in a remote/secure, location when the bypass switch 104 is operated. Additionally, in certain example embodiments, the bypass switch 104 includes a bypass position switch 258. The bypass position switch 258 is linked to the bypass contacts 240 and provides feedback to the logic controller 256 and/or the voltage regulator controller 112 regarding the position of the bypass contacts 240. Thus, the voltage regulator controller 112 is inhibited from switching tap positions 214 unless the bypass contacts 240 are open. In certain example embodiments, the logic controller 256 and the voltage regulator controller 112 are separate controllers that are communicatively coupled. In certain other example embodiments, the logic controller 256 and the voltage regulator controller 112 are one and the same. In certain example embodiments, the bypass switch controller 110, the logic controller 112, and the voltage regulator controller 256, or any subset thereof, are implemented together as one subsystem. For example, in an embodiment, the bypass switch controller 110 and the voltage regulator controller 256 are activated by the logic controller 112, and the bypass switch controller 110 operates the bypass switch 104.

FIG. 3 illustrates an example logic diagram 300 for establishing a safe bypass condition in the controller 112 or 256. In an example embodiment, in order to establish a safe bypass condition, and allow bypassing of the voltage regulator 108, several measurements or states are measured and/or detected. In an example embodiment, such measurements or states include a first percentage threshold 302, a second percentage threshold 304, an input voltage module status 306, a tap changer module status 308, a control function switch off status 310, a control power switch internal status 312, and an output voltage module status 314. In an example embodiment, such measurements or states are expressed in binary logic (i.e., yes/condition met or no/condition not met). Specifically, with regard to the first percentage threshold 302 input, if the measured difference between the source voltage and the load voltage is higher than 0.4%, a logic ON is achieved. Otherwise, the input is a logic OFF. Likewise, with regard to the second percentage threshold 304, if the measured difference between the source voltage and the load voltage is lower than −0.4%, then a logic ON is achieved. With regard to the input voltage module status 306, if no input voltage into the power system 100 is detected, a logic ON is achieved. Next, each of these three outputs are put through respective NOT gates 316a, 316b, 316c such that their logic states are flipped. The outputs of the NOT gates 316a, 316b, 316c are then put through a first AND, gate 318a. Thus, in order for the first AND gate 318a to produce a logic ON, the difference between the source voltage must not be higher than 0.4% (block 302), the difference between the source voltage must not be lower than −0.4% (block 304), and there must be input voltage detected (block 306). Thus, an ON state at the first AND gate 318a is indicative of a set of bypass conditions being met. In certain example embodiments, the first AND gate 318a is also tied to a user-defined LED which lights up when the AND gate 318a is in the ON state.

A second AND gate 318b receives a state input from the first AND gate 318a as well as the tap changer module status 308 and the control switch off status 310. Specifically, for the second AND gate 318b to produce an ON output, the first AND gate 318a must be ON, the tap changer neutral switch (block 308) must be closed, producing an ON output, and the control switch (block 310) must be off, producing an ON output.

The output of the second AND gate 318b is sent to an OR gate 320 along with the output of a third AND gate 318c. In order for the third AND gate 318c to produce an ON state, a control power switch of the voltage regulator 108 must be in an internal position (block 312) and no output voltage (block 314) from the control winding 210 is detected. In certain example embodiments, the control power switch of the voltage regulator 108 is either in the internal position or an external position. The internal position is an indication that the potential transformer sensing inputs 202, 204, and 210 are being received internally under normal operation. The external position is an indication that the potential transformer sensing inputs 202, 204, and 210 are not receiving power internally. In order to provide any operation of the voltage regulator 108 when it is bypassed, the voltage regulator 108 must be coupled to an external supply for control and motor power. Thus, an ON state at the control power internal status 312 is indicative of the needed potential transformer signals being online. The third AND gate 318c is in the ON state when there is no output voltage detected at the control winding 210 and the voltage regulator 108 is receiving proper potential transformer signals. Typically, when both of these conditions are met, it is an indication that the power system 100 is not powered or the power source 102 is not providing any power, and there is no voltage in the power system 100.

In an example embodiment, an ON output at the OR gate 320 is generally an indication that the overall safe bypass conditions are met, and the safety relay 250 is enabled, allowing the voltage regulator 108 to be bypassed if needed. Thus, in order for the OR gate 320 to be in an ON state, at least one of the second AND gate 318b and the third AND, gate 318c must be in the ON state. If the power system 100 is detected to be unpowered and no voltage is provided, the safety relay 250 is enabled. On the other hand, if conditions 302, 304, 306, 308, and 310, which generally relate to ensuring that the tap changer 208 is in the neutral position 218 and the voltage difference between the load side 230 and the source side 232 is below a certain threshold, indicate the presence of power or voltage, then the safety relay 250 will not be enabled and the voltage regulator 108 cannot be bypassed. In certain example embodiments, a subset of such conditions may be employed and additional conditions may be employed.

In FIG. 4, an example method 400 is illustrated for determining whether a bypass switch control 110 may actuate a bypass switch 104. In alternate embodiments other methods may be used for determining whether a bypass switch control may actuate a bypass switch. Referring now to FIGS. 1 through 4, in step 405 of example method 400, a logic controller 256 receives inputs from the voltage regulator 108. For example, the received inputs can include whether an input voltage is detected at the voltage regulator, a measured difference between the source voltage and the load voltage, a status of the tap changer neutral switch, and a status of a control switch. In step 410 of example method 400, the logic controller 256 determines based on the received inputs whether the bypass condition is met. For example, in one embodiment, all of the inputs received must satisfy a certain condition in order for the bypass condition to be met. In alternate embodiments, the logic controller 256 may only require that certain received inputs satisfy certain conditions in order for the bypass condition to be met. If the bypass condition is met in step 410, the logic controller 256 permits the bypass switch control 110 to actuate the bypass switch 104 in step 415. Alternatively, if the bypass condition is not met, the logic controller 256 causes the bypass switch control 110 to be disabled thus preventing actuation of the bypass switch 104.

In certain example embodiments, the power system 100 includes a built-in bypass switch controller 110 and/or the logic controller 256. In certain example embodiments, the bypass switch controller 110 and/or the logic controller 256 are made as stand-alone devices that retro-fitted onto existing power systems or used interchangeably with more than one Although embodiments of the present disclosure have been described herein in power system.

Although embodiments of the present disclosure have been described herein in detail, the descriptions are by way of example. The features of the disclosure described herein are representative and, in alternative embodiments, certain features and elements may be added or omitted. Additionally, modifications to aspects of the embodiments described herein may be made by those skilled in the art without departing from the spirit and scope of the present disclosure defined in the following claims, the scope of which are to be accorded the broadest interpretation so as to encompass modifications and equivalent structures.

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