Cooper QD3 Service Information

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Page 1

Voltage Regulators

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

Service Information

S225-12-1

Figure 1A.

QD3 Tap-changer.

Contents

Safety Information � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2 Product Information � � � � � � � � � � � � � � � � � � � � � � � � � � � 3 Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7 Part Kit Instructions��18 QD3/T350 Main Moveable Contact Assembly Kit � � � 19 Kit Number 5741325B04 QD3/T350 Main Moveable Contact Assembly Kit � � � 32 Kit Number 5741325B04 QD3/T350 Motor Replacement Kit ��40 Kit Number 57A63675100B QD3/T350 Motor Resistor Replacement Kit ��46 Kit Number 5791844A01 QD3/T350 PI Drive Cam Replacement Kit ��49 Kit Number 5740783B21

Figure 1B.

QD3 Tap-changer.

QD3/T350 Reversing Stationary ��51 Contact Assembly Kit Number 5791822A02 QD3/T350 Reversing Moveable Contact and ��60 Neutral Stationary Contact Assembly Kit, Kit Number 5741325B03 QD3/T350 TC-LTC P.I. Drive Face Gear Kit ��72 Kit Number 5740787B11 QD3/T350 Quick Drive Holding Switch ��74 Assembly Kit, Kit Number 574074B04

August 2012 • Supersedes 6/09

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

FOR LIFE

SAFETY

Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively promote safe practices in the use and maintenance of our products through our service literature, instructional training programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture, marketing and service.

We strongly urge that you always follow all locally approved safety procedures and safety instructions when working around highvoltage lines and equipment and support our “Safety For Life” mission.

SAFETY FOR LIFE

SAFETY

SAFETY INFORMATION

The instructions in this manual are not intended as a sub stitute for proper training or adequate experience in the safe operation of the equipment described. Only competent technicians, who are familiar with this equipment should install, operate and service it.

A competent technician has these qualiﬁcations:

Is thoroughly familiar with these instructions.

Is trained in industry-accepted high- and low-voltage

safe operating practices and procedures.

Is trained and authorized to energize, de-energize, clear,

and ground power distribution equipment.

Is trained in the care and use of protective equipment

such as ﬂash clothing, safety glasses, face shield, hard hat, rubber gloves, clampstick, hotstick, etc.

Following is important safety information. For safe installation and operation of this equipment, be sure to read and understand all cautions and warnings.

Hazard Statement Definitions

This manual may contain four types of hazard statements:

Safety Instructions

Following are general caution and warning statements that apply to this equipment. Additional statements, related to specic tasks and procedures, are located throughout the manual.

DANGER:

Hazardous voltage. Contact with high voltage will cause death or severe personal injury. Follow all locally approved safety procedures when working around high- and low-voltage lines and equipment.

WARNING:

Before installing, operating, maintaining, or testing this equipment, carefully read and understand the contents of this manual. Improper operation, handling or maintenance can result in death, severe personal injury, and equipment damage.

WARNING:

DANGER:

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING:

This equipment is not intended to protect human life. Follow all locally approved procedures and safety practices when installing or operating this equipment. Failure to comply may result in death, severe personal injury and equipment damage.

Indicates a hazardous situation which, if not avoided, could result In death or serious injury.

CAUTION:

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION: Indicates a hazardous situation which, if not avoided, could result in equipment damage only.

WARNING:

Power distribution and transmission equipment must be properly selected for the intended application. It must be installed and serviced by competent personnel who have been trained and understand proper safety procedures. These instructions are written for such personnel and are not a substitute for adequate training and experience in safety procedures. Failure to properly select, install or maintain power distribution and transmission equipment can result in death, severe personal injury, and equipment damage.

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S225-12-1

PRODUCT INFORMATION

Introduction

The QD3 Quik-Drive™ tap-changer combines 50 years of experience with the latest technology, providing the most advanced and reliable Voltage Regulator tap-changer. Cooper Power Systems provides the proven value customers have come to expect. By using advanced thermal set material rather than phenolic material, Cooper Power Systems has been able to design a product that has the strength for the most demanding applications as well as increasing the tracking resistance within the parts. By simplifying the bridging within the tap-changer, Cooper was able to simplify the contact design and at the same time improve product life. The QD3 tap-changer incorporates Cooper Power Systems exclusive holding switch circuit, which has set the standard for tap-changer tracking reliability.

The Cooper Power Systems QD3 Quik-Drive tap-changer provides endless possibilities when used with the control technology, starting with the CL-6A control, with applications such as Preventative Maintenances Tapping (PMT™), Duty Cycle Monitor, and TIME-ON-TAP™ features.

Instructions

These instructions apply to Distribution Voltage Regulators. Read these instructions carefully before attempting to use the voltage regulator.

The equipment covered by these instructions should be operated and serviced only by competent personnel familiar with good safety practices. These instructions are written for such personnel and are not intended as a substitute for adequate training and experience in safe procedures for this type of equipment.

The text of this instruction includes information concerning hazards to safety, which are common to all regulators. This safety hazard information is offered for guidance when installing and operating the descriptive matter to aid in preventing damage to the equipment and to advise of possible hazards to personnel. When reading this text, the meaning and content of these statements should be understood and followed carefully.

General

S225-12-1 covers operating, maintenance and replacement instructions for the QD3 Quik-Drive tap-changer in Cooper Power Systems VR-32 voltage regulators. The QD3 tap-changer in 2005 replaced the spring drive tapchangers for Cooper Power Systems low current application single-phase voltage regulators. Replacing the spring drive model 928, 95 KV BIL and model 170, 150 KV BIL tap-changers. The QD3 tap-changer as like the spring drive tap-changer are use on voltage regulators with load rating up to 219 Amps. The QD3 tap-changer is also rated for voltage regulator up to 219 Amps 150 KV BIL.

Motor

S225-12-1 covers operating, maintenance. The QD3 Quik-Drive tap-changer uses an AC Synchronous Motor that shaft speed is synchronous with the line voltage frequency. The motor has rapid stating and stopping, stopping with a minimal coast when the motor in de-energized without the need for a mechanical brake. The motor runs at an exact speed with no variation with load or voltage using a permanent magnet rotor to hold the motor shaft in position when the motor is de-energized. Since the connection between the rotor and stator is magnetic, the motor can be stalled without damage. The motor operates in both clockwise and counter-clockwise directions. A resistor and capacitor is required for starting and providing a phase-shifting network to operate the motor

CAUTION:

Do not operate the motor in air for excessive time or overheating and failure may result.

Figure 2.

Motor.

Motor Resistance

To measure the motor resistance of each motor directional winding, see the following:

Motor Ground “White Lead” to “Blue Lead”

Raise = 27.5 ohms

Motor Ground “White lead” to “Red Lead”

Lower = 27.5 ohms

Raise “Blue Lead” to Lower “Red Lead” = 54 ohms

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

Motor Capacitors

The QD3 tap-changer uses two different motor capacitors depending on whether the tap-changer is being used with 50 Hz or 60 Hz power. The motor capacitor is not part of the tap-changer assembly. The capacitor for regulators supplied with a QD3 tap-changer will be found in the voltage regulator control box assembly.

Capacitor Size

Power Size Rating

50 Hertz 15 ufd 440 Vac 100 °C

60 Hertz 12 ufd 440 Vac 100 °C

It is important to use the correct size capacitor with the QD3 tap-changer hanger. For example: If a 12 ufd is used on a tap-changer that is being applied to a 50 Hz system, the tap action of the tap change can be affected by the number of steps taken and the directional operation of the tap-changer. The same can occur if a 15 ufd is used for a 12 ufd on a 60 Hz system. Other problems can occur if smaller or larger capacitors are used in place of the speciﬁed capacitor size. It is always recommended to use the motor capacitor supplied by the manufacture of the tap-changer and voltage regulators.

Holding Switch

The QD3 tap-changer uses a micro-switch assembly for the holding switch instead of a three-blade contact holding switch assembly that was used on the spring drive tap-changer assembly. The micro-switch assembly eliminates the need and requirements for making adjustments in the alignment and gape settings when working on or around the holding switch assembly.

All Cooper Power System tap-changers are equipped with a holding switch to assure that a tap-changer in process is completed. This switch also provides a repetitive and accurate opening action causing the motor to stop the drive components with correct alignment. A signal from the holding switch activates the operations counter and prevents time delay reset during a tap change. The holding switch is operated by a pinion cam causing the holding switch lever to close in on either the raise or lower micro-switches. If a holding switch needs to be worked on due to problems with one of the two micro-switches, the micro-switch should not be replaced with a new one. The complete assembly needs to be replaced with a micro-switch assembly from the factory. Replacement of the micro-switch can cause problems with the assembly and tap-changer. Special ﬁxtures are used for the assembly to prevent alignment gap setting requirements.

QD3 Motor Resistor

Figure 3.

Motor resistor.

Resistor Size:

40 Ohm

100 Watt

The motor resistor on the QD3 tap-changer is used for proper phasing of the motor. An open resistor, resistor connection, or different size resistor will affect operation of the motor. Either of these conditions can cause the motor to take more tap steps then required as well as causing the motor to run or start to run in the opposite direction.

Actuator

Lever

Micro Switch

Figure 4.

Holding switch assembly.

Micro Switch

CAUTION:

Operating the QD3 Tap-Changer in air for an excessive amount of time, or if operating continues without pulsing, will cause the resistor to become hot to the touch. Overheating can be a harasser causing injury if touched and can affect the operation of the tap-changer motor.

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S225-12-1

Contacts

All moveable and main stationary contacts employ copper-tungsten copper alloy tips at points subjected to arcing duty. Contact points not subjected to arcing employ a combination of EPT copper to provide a high conductivity current path. Moveable contacts are split to make contact on both sides of mating parts and resist separation during high current surges. Contact pressure is maintained by steel compression springs.

Tungsten Copper Arcing Tips

The main moveable contact assembly consists of the main Geneva Gear, and two sets of contacts. One contact of each mates with the main stationary contact and a button contact. This mates and has constant contact with a collector ring.

Figure 7.

Reversing stationary contact.

The receiving stationary contact is used in two positions, VL and VR, and sees less operating duty than the main stationary contacts. The reversing stationary contacts do not utilize tungsten alloy arcing tips. The reversing stationary contact is symmetrical and can be use for either the VL or VR positions.

Figure 5.

Main stationary contact.

The main stationary contact has two arcing tips, one on each side. Each arcing tip is composed of tungsten copper alloy. Tungsten is used to help reduce the erosion of the contacts due to arcing. The main stationary contact is used for stationary contacts tap 1 through 8.

Actuator Lever

Moveable Contact Button Contacts

Moveable Contacts

Reversing Switch

The reversing switch changes the polarity of the tapped winding. When the QD3 Quik-Drive tap-changer is in the neutral position; the reversing switch is open (not making contact with either of the reversing stationary contacts). In the open position, the reversing switch is not in the load current circuit.

The reversing switch motion on the QD3 tap-changer occurs as the main moveable contact enters or leaves the neutral position. The main moveable contact assembly has a pivot roller located between the two moveable contacts. The pivot roller is engaged in a pivot slot in the reversing switch moveable contact assembly when the main moveable contacts are in the neutral position. The ﬁrst tap step rotates the reversing moveable contact assembly, causing the reversing switch moveable contacts to engage the reversing stationary contact. This will be either the VL or VR reversing stationary contacts.

QD3 tap-changer reversing switches may be exposed to arcing duty. The main Geneva/contact drive assembly and the reversing switch arm provide a mechanical stop located approximately 320 degrees on either side of neutral.

Figure 6.

Main moveable contact assembly.

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

Neutral Main Stationary Contact

Figure 8.

Reversing switch moveable contact assembly.

Reversing Moveable Assembly Neutral Pivot Slot

Reversing Segment

Reversing Moveable Button Contact

Figure 9.

Reversing switch moveable contact assembly.

The reversing moveable contact assembly consists of the reversing segment, neutral main stationary contact, and reversing moveable contact. The reversing moveable button-contact makes or engages the reversing stationary contacts as the tap-changer is moved off of the Neutral Position. The other end of the moveable contact has a button contact that stays engaged with the neutral stationary contact at all times.

If the neutral stationary contact is in need of being replaced, the complete reversing switch moveable contact assembly should be replaced.

Micro-Switchs

Micro-switches are use for the holding switch, reversing logic, neutral indication, and taping limit logic switches.

Two sets of normally closed switches are used to provide a safety switch circuit to prevent the tap-changer from trying to tap beyond 16R and 16L. This assists the mechanical stop. These two switches allow the tapchanger to reverse in the opposite direction when the mechanical stop is reached, causing the holding switch to become closed.

The micro switches used are rated for –40°C to 130°C, 5 mp 125/250 Vac rating. The switches are designed to exceed one million operations at QD3 tap-changer current.

Housing, Geneva, Gears, Cams and Bearings

Housing, geneva, gears, cams and bearings are constructed of reinforced thermoplastic engineered grade polymer providing these characterizes.

 •Transformeroilcompatible

 •Envirotemp™FR3™uidcompatible

 •Highheatresistancewithanoperating

temperature over 200 °C

 •Highmechanicalstrength

 •Highelectricalcreepresistance

 •Moldedpartreducesnumberoftotaltap

changer parts

 •Lowerwaterabsorptionandpowerfactorthanphenolicboard

 •Goodmechanicalcreepresistance

 •Corrosionresistant

 •Highdielectricstrength

 •Goodwearresistance

 •Highchemicalresistance

 •Sometypicalapplicationsinclude:

  •Under-hoodhightemperatureautomotive

applications such as engine manifolds

  •Electricalapplicationssuchascircuitbreakersand

stand-off insulators

  •Hightemperaturelightingapplications

QD3 Drive Mechanism

Once a tap change is initiated, a holding switch energizes the motor through a separate circuit until the indexing motion is completed. The indexing occurs very fast. The total elapsed time to complete the action is approximately 270 milliseconds from the time the indexing signal is started by the control. The motor turns a Geneva drive gear that is coupled to the motor shaft. Each full turn of the Geneva drive gear rotates the main Geneva/contact drive assembly 20°C. The moving contacts are assembled directly to the main Geneva/contact drive assembly. This direct connection achieves accurate indexing of the contacts.

The permanent magnet rotor arrests the inertia of the system once the tap change is completed and the power is removed from the motor. A safety switch circuit and a backup mechanical stop prevents rotation of the main Geneva/contact drive assembly beyond the maximum position.

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S225-12-1

INSTALLATION

QD3 Operating Sequence

When the tap-changer is in the neutral position and the control calls for a tap change, the following events occur:

1. The motor is energized and begins to turn using 120V power supplied by the control.

2. The motor gear drives the Geneva drive gear.

3. The pin on the Geneva drive gear enters a slot on

the main Geneva/contact drive assembly and the main Geneva/contact drive assembly begins to index.

4. The holding switch closes to ensure the tap change will go to completion. The control removes the initial 120V power. The motor is now energized only through the hooding switch (also 120V).

5. The reversing switch pin on the main Geneva/contact drive assembly begins to drive the reversing switch arm.

6. One of the two main interrupting moveable contacts slides out of engagement with the neutral stationary contact and interrupts the circuit through that branch.

7. The reversing switch arm rotates, which causes the reversing switch contacts to pivot. A bridge between the neutral contact and a stationary contact connected to one end of the series winding is thus established. NO arcing occurs across the reversing switch contacts. When the reversing arm rotates, a ﬁnger on the reversing switch arm engages a normally closed logic switch that determines whether the tap-changer is raising or lowering the voltage.

8. The main interrupting contacts slide over and onto the number one stationary contact, making a bridging position from contact N to contact 1 through the reactor.

9. The pin on the Geneva drive gear exits the main Geneva/contact drive assembly slot. The Geneva/ contact drive assembly stops moving and rotation is all locked.

10. The holding switch opens and de-energizes the motor. The magnetic rotor in the motor stops all motion.

11. The motor shaft has completed a 120-degree turn. The elapsed time from step 1 to step 13 is approximately 270 ms.

12. If the control issues another signal to index in the same direction, the same sequence is repeated except the reversing switch is not actuated. The reversing switch does not move until the tap-changer is reversed and stepped the opposite direction back in neutral.

13. If the tap-changer is switching from position 15 to position 16, a normally closed limit switch is engaged that is connected in parallel with the logic switch. With both the logic and the limit switches activated, the control cannot provide power to the motor to index the tap-changer past the 16 position. The tap-changer can be indexed back to the 15 position.

MAINTENANCE, SERVICE, AND TROUBLESHOOTING

The following outlines maintenance procedures relating to the QD3 voltage regulator tap-changer and components. Before any internal or external maintenance is performed, the regulator must be removed from service.

It is necessary to open the regulator for inspection of the tap-changer. It is also necessary and recommended to remove the QD3 tap-changer from the regulator to perform inspections and repairs to moveable and stationary contacts. This section provides procedures for removing and replacing various components of the tap-changer with replacement kits.

Before removing the voltage regulator from service for maintenance, refer the Removal From Service section of the voltage regulator manual S225-10-30.

Troubleshooting and service functions of the QD3 / T350 tap-changer are performed with the regulator un-tanked and the tap-changer removed from the regulator.

Page 8

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

Control Winding

Terminal Board

Position Indicator Drive Tube

Neutral Position Micro Switch

Reversing Lower Micro Switch

PI Drive Face Geneva Gear

Raise & Lower Tap Limit Switches

Reversing Raise Micro Switch

Holding Switch Assembly

Drive Pinion Cam

Motor Resistor

Figure 10.

Tap-changer front view.

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S225-12-1

Terminal Board

Motor

#7 Stationary

#6 Stationary

#8 Stationary

VR Reversing Stationary Contact

Neutral Stationary

VL Reversing Stationary Contact

#1 Main Stationary Contact

#5 Stationary

#4 Stationary

#2 Stationary

#3 Stationary

Tapchanger Mounting Base

Figure 11.

Back side of QD3 Tap-changer.

Page 10

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

Figure 12.

QD3 wiring schematic.

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Contact Erosion Patterns

S225-12-1

Figure 13.

Contact life stages.

Contact Inspection

Tap-changer contacts are exposed to a combination of electrical, mechanical, and thermal conditions that result in deterioration. Erosion at the points subjected to arcing duty is the most visible indication of wear. Figure 13 illustrates typical contact erosion patterns resulting from normal service. Contact at the end-of-life stage shown in Figures16 and 19 must deﬁnitely be replaced. The following ﬁgures show the actual contact after varies stage of contact erosion.

Page 12

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

New Contacts

Figure 14.

QD3 moveable contact.

Intermediate Life Stage

Figure 15.

QD3 moveable contact.

End of Contact Life Stage

Figure 17.

QD3 stationary contact.

Figure 18.

QD3 stationary contact edge.

Figure 16.

QD3 moveable contact, end of life.

Figure 19.

QD3 stationary contact edge, end of life.

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QD3/T350 Torque Requirements

60-70 lb.-in. Back panel tap connections; Taps 1 thru 8, N- Neutral, VR, VL All 6 P1 and P2 connections.

60-70 lb.-in. All 6 P1 & P2 connections

6.779-7.908 Nm

S225-12-1

60-70 lb.-in.

6.779-7.908 Nm

60-70 lb.-in. Tap connections N and 1 thru 8

6.779-7.908 Nm

50-60 lb.-in. Button Head socket head or Allen head screws, six locations

5060 lb.in.

5.6496.779 Nm

50-60 lb.-in.

5.649-6.779 Nm

50-60 lb.-in.

5.649-6.779 Nm

Figure 20.

Connect panel connections.

50-60 lb.-in.

5.649-6.779 Nm

Figure 21.

Front and back panel connections.

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

100-110 lb.-in. Motor Bracket to Motor Fastener Torque

100-110 lb.-in.

11.298-12.428 Nm

100-110 lb.-in.

11.298-12.428 Nm

22-28 lb.-in. Motor to Front Panel Torque

12-18 lb.-in. Holding Switch Assembly to Front Panel Fastener Torque

12-18 lb.-in. Tap Position Lob Cover to Front Panel Fastener Torque

24-32 oz.-in. Raise, Lower, and Neutral Micro Switch to Front Panel Fastener Torque

22-28 oz.-in. Position Indicator Drive Assembly to Front Panel Fastener Torque

Figure 22.

Motor mount bracket.

24-32 oz.-in. .169-.255 Nm

12-18 lb.-in.

1.355-2.033 Nm

12-18 lb.-in.

1.355-2.033 Nm

22-28 lb.-in.

2.485-3.163 Nm

12-18 lb.-in.

1.355-2.033 Nm

12-18 lb.-in.

1.355-2.033 Nm

Figure 23.

Front panel component torques.

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22-28 lb.-in. Motor Resistor clips to tap-changer base mounting hardware torque

24-32oz.-in. Tap Position raise and lower limit micro switch mounting hardware torque

S225-12-1

24-32oz.-in. .169-.255 Nm

22-28 lb.-in.

2.485-3.163 Nm

Figure 24.

Front panel component torques.

18-20 lb.- in. Tap-Changer Terminal Board Mounting Hardware Torque

18-20 lbs.-in.

2.033-2.259 Nm

24-32oz.-in. .169-.255 Nm

22-28 lb.-in.

2.485-3.163 Nm

1820 lbs.in.

2.0332.259 Nm

Figure 25.

Tap-changer terminal board fastener torques.

18-20 lbs.-in.

2.033-2.259 Nm

Page 16

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 Neutral Position

Neutral Switch

Actuator Arm

Tap position Indicator

Holding Switch Assembly

Lob Pointer

Figure 26.

Neutral Position.

When identifying if the tap-changer is in the neutral position without being on a voltage regulator, check the following:

1. Actuator Arm has the “N” (center switch) switch

depressed causing the neutral switch to apply a 120V source to light the neutral light on the control panel.

2. The tap position lob pointer is pointing at “N” on the

tap position indicator.

3. The Pinion Cam point is over the white holding switch

lever and is pointing in the three o’clock position.

Holding Switch Lever

Pinior Cam

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QD3/T350 Replacement Part Kit Pictures

Figure 27.

Main moveable contact assembly 5741325B04.

S225-12-1

Figure 30.

Motor resistor replacement kit 5791844A01.

Figure 28.

Main stationary contact assembly 5791822A01.

Figure 29.

Motor replacement kit 57A63675100B.

Figure 31.

P.I. Drive cam replacement kit 5740783B21.

Figure 32.

TC-LTC P.I. Drive face gear kit 5740787B11.

Page 18

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

PART KIT INSTRUCTIONS

Figure 33.

Reversing moveable contact and neutral stationary contact assembly kit 5741325B03.

The following instructions are documents/sections of this manual that supply guidance and instructions for replacing various parts of the QD3 tap-changer and for making repairs or for servicing the tap-changer.

Document Numbers and Descriptions

S225-50-35 QD3/T350 Motor Replacement Kit

S225-50-37 QD3/T350 Motor Resistor Replacement Kit

S225-50-40 QD3/T350 PI Drive Cam Replacement Kit

S225-50-41 QD3/T350 Main Stationary Contact Assembly Kit

S225-50-42 QD3/T350 Main Moveable Contact Assembly Kit

S225-50-43 QD3/T350 Reversing Stationary Contact Assembly

S225-50-44 QD3/T350 Reversing Moveable Contact and Neutral Stationary Contact Assembly Kit

S225-50-45 QD3/T350 TC-LTC. PI. Drive Face Gear Kit

S225-50-20 Quik Drive holding Switch Assembly Kit

Figure 34.

Reversing stationary contact assembly 5791822A02.

Figure 35.

Holding switch 5740794B04

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S225-12-1

QD3/T350 MAIN MOVEABLE CONTACT ASSEMBLY KIT

Kit 5741325B04

Refer to Service Information S225-50-42

GENERAL

The purpose of this replacement kit is to provide the parts and installation instructions for replacing the main stationary contacts on a QD3 Quik-Drive Tap-changer.

This installation instruction is made up of four different procedure sections:

Tap-changer Removal from Voltage Regulator

QD3/T350 Tap-changer Assembly Separation

Main Moveable and Neutral Stationary Contact Removal and Re-assembly

Tap-changer Re-assembly

TABLE 1

Parts Supplied

Item Part Number Description Qty

1 2241325B04 Main Moveable Neutral

Contact Assembly

TABLE 2

Tools Required

Description Qty

Needle Nose Pliers 1

9/16 inch Deep Well Socket 1

3/8 inch Drive Ratchet Wrench 1

5/32 Allen Wrench 1

Phillips Head Screwdriver Size 1 Point 1

Diagonal Cutters 1

Phillips Head Screwdriver 1

Standard Screwdriver 1

Torque Wrench inch pounds 1

PRODUCT INFORMATION

Introduction

Cooper Power Systems QD3/T350 Main Moveable Contact Assembly Kit and installation instructions gives customers the ability and guidance to replace the main moveable contacts during maintenance cycles when contact erosion has occurred to the point of needing replacement.

Additional Information

These instructions cannot cover all details or variations in the equipment, procedures, or process described nor provide directions for meeting every possible contingency during installation, operation, or maintenance. For additional information, contact your representative.

Acceptance and Initial Inspection

Each moveable contact board is in good condition when

accepted by the carrier for shipment. Upon receipt,

inspect the shipping container for signs of damage. Unpackthemoveablecontactboardandinspectitthoroughly for damage incurred during shipment. If damage is discovered, ﬁle a claim with the carrier immediately.

Handling and Storage

Be careful during handling and storage of the moveable contact board to minimize the possibility of damage. If the moveable contact board is to be stored for any length of time prior to installation, provide a clean, dry storage area.

Standards

ISO 9001 Certiﬁed Quality Management System

Page 20

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

INSTALLATION PROCEDURE

Tap-Changer Removal from Voltage Regulator

Cable Tie

Figure 36.

Kit part.

1. Remove the internal position indicator shaft from the

tap-changer indicator drive tube. (See Figure 37.)

Internal

Flex Shaft

Tapchanger Internal Drive Tube

Figure 37.

Internal ﬂex shaft.

Figure 38.

Control cable fastening.

Use a 9/16 inch socket and ratchet to loosen and

remove the nut and carriage bolt fastening the tapchanger bracket to the regulator side channel. (See Figure 39.)

Carriage Bolt Nut

2. Usingapairofdiagonalsidecutters,cutandremove

the cable-ties from the control winding hard insulation tube and tap-changer top bracket assembly. (See

Figure 38.)

Figure 39.

Tap-changer and side channel fastener.

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4. UsingaPhillipsheadscrewdriver,loosenandremove

the TCB terminal board leads from the 14 position terminal board located on the top right of the QD3 tap-changer. (See Figure 40.)

TABLE 3

Lead Color and Termination Points

Lead Color TCB Connection

Blue/White 1

Green/White 5

Blue 9

Green 10

Orange 11

Red/Black 13

White G

S225-12-1

White Position G

Red/Black Position 13

Orange Position 11

Green Position 10

Blue Position 9

Green/White Position 5

Blue/White Position 1

Figure 40.

TCB lead color and termination points.

5. Use a Phillips head screwdriver and needle nose

pliers to disconnect the white E control winding leads and P leads, if available, from the seven position terminal board located on the left top of the tapchanger. (See Figure 41.)

Control Winding E Lead and P Lead, if Available,

Connections.

Figure 41.

E & P lead connections.

6. Use a deep well 9/16 inch socket with a ratchet

or a 9/16 inch wrench to loosen and remove all lead connections from the back of the tap-changer contact board. (See Figure 42.)

CAUTION:

Do not remove lead ties from lead bundles holding the tap leads in a certain position. Try to keep from moving the lead bundles from normal position. Doing so can result possibly in de-electric failures.

Tap Lead Connections

TABLE 4

Lead Marker and Terminal Board ID

Lead Marker Terminal Board ID

E Could be on either E1, E2, or E3

E1 E1

E2 E2

E3 E3

P If available, could be on either P1, P2,

or P3

P1 P1

P2 P2

P3 P3

Reactor P1 & P2 Connections

Figure 42.

Tap leads and reactor connections.

Page 22

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

7. Remove the mounting bolts fastening the tap-changer- mounting bracket to the top core clamp. (See Figure

43.) Remove the tap-changer from the regulator and place on a work surface.

Mounting Hardware

Figure 43.

Tap-changer to core clamp fastening hardware.

2. UsingaPhillipsheadscrewdriver,loosenandremove

the three mounting screws fastening the position indicator micro switch hub to the front of the tapchanger assembly. (See Figure 45.)

Screws

Position Indicator Hub

Figure 45.

Position indicator hub.

QD3/T350 Tap-changer Assembly Separation

1. After removing the tap-changer from the regulator assembly, use a Phillips head one point screwdriver to loosen and remove the six screws mounting the Reversing Lower, Raise and Neutral switch located in the upper left corner of the tap-changer assembly. (See Figure 44.)

Neutral

Screws

Raise

Lower

3. Remove the tapping indicator position lob pointer from the tap-changer. The lob may have to be pried a little to be removed. (See Figure 46.)

Position Indicator Hub

Figure 46.

Position indicator hub.

Figure 44.

Lower, raise and neutral logic switches.

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4. Disconnect and remove the blue and red strip leads from the 40-ohm resistor. These connections are push-on connections. (See Figure 47.)

40Ohm Resistor

Blue/Red Leads

Figure 47.

40-Ohm resistor connections.

5. Lay the tap-changer assembly flat on a work surface with the tap contact studs down on the surface.

6. Usinga5/32Allenwrenchloosenandremovethetwo

pan head Allen screws from the tap-changer-mounting bracket. (See Figure 48.)

7. Usinga5/32Allenwrench,loosenandremovethepan

head Allen screws fastening the front drive assembly section and the contact panel assembly section together. (See Figure 49.)

Screws

Figure 49.

Drive panel and contact panel fastening.

8. Lift the front drive assembly off of the contact assembly and set aside. (See Figure 50.)

Bracket Fastening Screws

Figure 48.

Tap-changer bracket mounting.

Drive Assembly

Contact Panel

Figure 50.

Tap-changer sections.

Page 24

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

Main Moveable Contact Removal and Re-assembly

Removing Main Moveable and Geneva Assembly

1. Use a 9/16 wrench or a deep well 9/16 socket and

ratchet, loosen and remove the number one main stationary contact stud mounting nut, lock washer, and flat washer. (See Figure 51.)

Stationary One Contact

3. By hand, rotate the main moveable contact and Geneva gear assembly so that the moveable contact is in the stationary one contact position. (See Figure53.)

Contact Panel

P2 Connection

Six P1 & P2 Connection Studs

P1 Connection

Figure 51.

Removal of stationary contact.

2. Remove stationary contact one from the contact assembly board. (See Figure 52.)

Stationary Contact One Position

Moveable Contacts

Moveable Contact Assembly

Figure 53.

P1 and P2 connections.

4. Use a 9/16 wrench or deep well 9/16 socket and

ratchet to remove the six nuts, lock washer, and flat washer fastening the P1 and P2 slip ring studs to the contact panel located in the center back of the stationary contact panel. (See Figure 53.)

5. Facing the Main moveable contact and Geneva gear assembly, pull forward removing the main contact assembly and P1 and P2 slip ring assemblies for the contact board assembly. (See Figure 54.)

Moveable Contact Assembly

P1 & P2 Studs

Slip Rings

Figure 52.

Moveable contacts.

Figure 54.

Moveable contact dis-assembly.

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6. Remove the P1 and P2 slip ring from the moveable contact and Geneva Gear Assembly by lifting the ring stud assembly upward on the opposite side of the moveable contact button. To help in identifying the slip ring see Figure 56. Slide the slip ring out of from between the moveable contact button. (See Figure

55.) Repeat this process for the second slip ring stud assembly.

P1 & P2 Slip Rings

Installing New Main Moveable and Geneva Assembly

7. Place one of the Slip Ring Studs (see Figure 57)

assemblies over the hub of the moveable contact and Geneva gear assembly (see Figure 58). When putting the slip ring on the Geneva gear, angle the ring so that the ring can be inserted between the moveable contact buttons on the lower left hand moveable contact. (See Figure 58.)

Hub

Moveable Contacts

Figure 55.

Slip ring removal.

Figure 56.

Slip ring.

Figure 57.

Moveable contact assembly.

Slip Ring

Moveable Contact Buttons

Figure 58.

Slip ring & moveable contact assembly.

Page 26

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

8. Place the second slip ring stud assembly over the first ring assembly studs and the Geneva hub. Angle the ring assembly so that the ring can be inserted between the button contacts on the right hand upper moveable

contact. (See Figure 59.)

Second Slip Ring

First Slip Ring

Figure 59.

Slip ring and moveable contact assembly.

10. Align the stud of the slip rings with the mounting holes in the contact panel. The studs on the slip ring that is between the left hand lower button contact (Figure

61) will go into the holes that have the higher shoulder spacer as part of the contact panel. (See Figure 62.)

Left Hand Button Contact

Figure 61.

Stud positioning.

9. Align the moveable contact and Geneva gear assembly so that the moveable contacts align up where the number one stationary contact has been removed. (See Figure 60.)

Moveable Contact

Assembly

Stationary Contact One Position

Stationary Contact Assembly

Figure 60.

Contact panel and moveable contact assembly.

Raised Shoulder Mounting Holes for Slip Rings

Figure 62.

Raised shoulder mounting.

11. You may need to rotate the slip ring assemblies in the bottom contact to make the proper alignment.

12. Press the moveable and Geneva contact assembly to insert the studs.

13. You may find that after starting the studs the moveable and Geneva contact assembly will need to be rotated to position the moveable contact so that the contacts are not interfering with other stationary contacts during the installation.

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14. Rotate the main moveable contact Geneva gear assembly onto the neutral stationary contact located under the reversing switch assembly. (See Figure 63.)

Neutral Position

Moveable Contact Assembly

Reversing Moveable Contact Assembly

Figure 63.

Neutral position.

15. Place a flat brass flat washer, external tooth lock washer, and 3/8 nut on each of the P1 and P2 slip ring studs and tighten with a 9/16 wrench or socket and ratchet. Torque the nut on the studs to 60-70 poundinch (6.779-7.908 Nm).

16. Replace the number 1 stationary contact by inserting the contact stud into the contact-mounting hole in the contact panel. The contact position number is located on the contact panel. (See Figure 64.)

Tap-changer Re-Assembly

1. Lay the contact panel assembly section flat on a table surface. (See Figure 65.)

Stationary Contact Panel Assembly

Figure 65.

Stationary contact panel assembly.

2. Place and align the tap-changer drive assembly section on top of the contact panel assembly. (See Figure 66.)

Stationary Contact One

Figure 64.

Stationary contact one assembly.

17. Place a brass flat washer, external tooth lock washer, and nut on the number 1 stationary contact stud. Tighten and torque the hardware 60-70 pound-inch (6.779-7.908 Nm).

Drive Panel Assembly

Figure 66.

Tap-changer Sections.

Page 28

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

3. Align the center hub of the main moveable contact assembly with the center hole in the tap-changer drive assembly. (See Figures 67 and 68.)

Main Moveable Contact Assembly

Hub

Stationary Contact Assembly

Figure 67.

Contact assembly and main moveable contacts.

4. Press both of the tap-changer assembly sections together and stand up-right. (See Figure 69.)

Contact Panel

Drive Panel Assembly

Drive Assembly Panel

Center Hole

Figure 68.

Drive assembly panel.

Figure 69.

View of panel assembly.

Insert four pan head Allen screws into the tapchanger assemblies. Two screws will mount the two tap-changer assemblies and the terminal block bracket at the top of the tap-changer. The other two screws are inserted in the mounting holes along both side centers of the tap-changer. (See Figure 70.)

Screws

Figure 70.

Panel assembly fastening.

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6. Place the mounting bracket (see Figure 71) to the base of the tap-changer assembly and fasten with two pan head hex screw and tighten with a 5/32 Allen Wrench. (See Figure 72.)

Figure 71.

Tap-changer mounting bracket.

7. Place the neutral position pointer lob (see Figure 73) into the main moveable contact hub located in the lower front center of the drive assembly panel. (See Figure 74.)

Lob

Figure 73.

Position indicator lob.

Fastening Screws

Figure 72.

Bracket fastening.

Lob

Figure 74.

Lob placement.

Page 30

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

8. Fasten the tap position switch assembly to the front of the drive panel assembly with three pan head Phillip screws. (See Figure 75.)

Position Switch Assembly

Screws

Figure 75.

Position switch assembly.

9. Position the position actuator arm between the center position and L by rotating the pinion counter clockwise. (See Figure 76.) This will allow for mounting the micro switches without interference with the micro switch arms.

10. Place and fasten the reversing logic and neutral logic micro switches on the upper left of the drive assembly panel. The micro switch with a blue white striped wire and blue black striped wire is located on the R position. The micro switch with a red white striped wire and red black striped wire is located on the L position. The micro switch with an orange wire and a white wire is located on the center position between the R and L position. (See Figure 77.)

R Switch

Neutral

Actuator Arm

L Switch

Figure 77.

Logic switch positioning.

Actuator

L Switch

Figure 76.

Switch actuator position.

R Switch

Pinion

11. Rotate the pinion back clockwise until the arm in Figure 77 is in the center and the neutral switch is depressed.

12. Connect the blue wires with red stripes to the 40-ohm resistor by pushing the female connector onto the resistor terminals. (See Figure 78.)

Resistor

Blue/Red Leads

Figure 78.

Resistor connections.

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13. Check and set the tap-changer for neutral position. The tap-changer can be set for any tap position by rotating the pinion cam in either the clockwise or counter clockwise direction. For rotating to the neutral position, the reversing logic switch actuator must be in the center with the neutral switch arm depressed. The tap position lob must have the pointer pointing at N. The pinion cam point is pointing at the three o’clock position over the holding switch lever arm. The holding

switch is open. (See Figure 79.)

Reversing Logic Switch

Pinion Cam Pointing at three o'clock

S225-12-1

Tap Position Lob Pointing at N

Holding Switch Open

Figure 79.

Neutral position.

Re-assembly of Tap-changer to Voltage Regulator Assembly

1. Once the tap-changer has been re-assembled, reverse the process in the procedure titled “Tap-changer Removal from Voltage Regulator” at the beginning of these instructions.

Page 32

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 Main Moveable Contact Assembly Kit Kit 5741325B04

Refer to Service Information S225-50-41

GENERAL

The purpose of this replacement procedure is to provide the parts and installation instructions for replacing the main stationary contacts on a QD3 Quik-Drive Tap-changer.

This installation instruction is made up of four different procedure sections:

Tap-changer Removal from Voltage Regulator

QD3/T350 Tap-changer Assembly Separation

Main Stationary Contact Removal and Re-Assembly

Tap-changer Re-assembly

TABLE 5

Parts Supplied

Item Part Number Description Qty

1 0791822A01 Main Stationary Contact 1

Acceptance and Initial Inspection

Each Stationary Contact Assembly is in good condition

whenacceptedbythecarrierforshipment.Uponreceipt,

inspect the shipping container for signs of damage.

Unpackthe Stationary Contact Assembly and inspect it

thoroughly for damage incurred during shipment. If damage is discovered, ﬁle a claim with the carrier immediately.

Handling and Storage

Be careful during handling and storage of the Stationary Contact Assembly to minimize the possibility of damage. If the moveable contact board is to be stored for any length of time prior to installation, provide a clean, dry storage area.

Standards

ISO 9001 Certiﬁed Quality Management System

TABLE 6

Tools Required

Description Qty

Needle Nose Pliers 1

9/16 inch Deep Well Socket 1

5/32 Allen Wrench 1

Phillips Head Screwdriver size 1 point 1

Diagonal Cutters 1

Phillips Head Screwdriver 1

Standard Screwdriver 1

Torque Wrench inch pounds 1

3/8 inch Drive Ratchet Wrench 1

PRODUCT INFORMATION

Introduction

The QD3/T350 Main Stationary Contact Assembly Kit and installation instructions gives customers the ability and guidance to replace the stationary contact during maintenance cycles when contact erosion has occurred to the point of needing replacement.

Additional Information

Kit part figure.

INSTALLATION PROCEDURE

Tap-Changer Removal from Voltage Regulator

1. Remove the internal position indicator shaft from the tap-changer indicator drive tube. (See Figure 80.)

Internal Flex Shaft

TapChanger Internal Drive Tube

Figure 80.

Internal flex shaft.

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2. Use a pair of diagonal side cutters to cut and

remove the cable-ties from the control winding hard insulation tube and tap-changer top bracket assembly. (See Figure 81.)

Cable Tie

4. Use a Phillips head screwdriver to loosen and

remove the TCB terminal board leads from the 14 position terminal board located on the top right of the QD3 tap-changer. (See Figure 83.)

TABLE 7

Lead Color and Termination Points

Lead Color TCB Connection

Blue/White 1

Green/White 5

Blue 9

Green 10

Orange 11

Red/Black 13

White G

White Position G

Red/Black Position 13

Orange Position 11

Blue Position 9

Green Position 10

Figure 81.

Control cable fastening.

3. Use a 9/16 inch socket and ratchet to loosen and

remove the nut and carriage bolt fastening the tapchanger bracket to the regulator side channel. (See Figure 82.)

Carriage Bolt Nut

Figure 82.

Tap-changer and side channel fastener.

Green/White Position 5

Blue/White Position 1

Figure 83.

TCB lead color and termination points.

5. Use a Phillips head screwdriver and needle nose

pliers to disconnect the white E control winding leads, and P leads if available, from the seven position terminal board located on the left top of the

tap-changer. See Figure 84. Control winding E lead and (P lead if available) Connections. The E lead will have E lead ID markers

and the P leads if available will have P lead markers.

TABLE 8

Lead Marker and Terminal Board ID

Lead Marker Terminal Board ID

E Could be on either E1, E2, or E3

E1 E1

E2 E2

E3 E3

P If available could be on either P1, P2, or P3

P1 P1

P2 P2

P3 P3

Page 34

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

7. Remove the mounting bolts fastening the tapchanger mounting bracket to the top core clamp. See (Figure

86.) Remove the tapchanger from the regulator and place on a work surface.

Mounting Hardware

Figure 84.

E & P lead connections.

6. Use a deep well 9/16 inch socket with ratchet or a 9/16 inch wrench to loosen and remove all lead connections from the back of the tapchanger contact

board. (See Figure 85.)

CAUTION:

Do not remove lead ties from lead bundles holding the tap leads in a certain position. Try to keep from moving the lead bundles from normal position. Doing so can result, possibly, in de-electric failures.

Tap Lead Connections

Figure 86.

Tap-changer to core clamp fastening hardware.

QD3/T350 Tap-Changer Assembly Separation

1. After removing the tapchanger from the regulator

assembly, use a Phillips one point screwdriver to loosen and remove the six screws mounting the Reversing Lower, Raise and Neutral switch located in the upper left corner of the tapchanger assembly. (See Figure 87.)

Neutral

Reactor P1 & P2 Connections

Figure 85.

Tap leads and reactor connections.

Screws

Raise

Lower

Figure 87.

Lower, raise, and neutral logic switches.

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2. Use a Phillips head screwdriver to loosen and remove the three mounting screws fastening the position indicator micro switch hub to the front of the tapchanger assembly. (See Figure 88.)

Screws

Position Indicator Hub

Figure 88.

Position indicator hub.

3. Remove the tapping indicator position lob pointer from the tapchanger. The lob may have to be pried a little to be removed. (See Figure 89.)

5. Lay the tapchanger assembly at on a work surface with the tap contact studs down on the surface.

6. Use a 5/32 Allen wrench to loosen and remove the two pan head Allen screws from the tapchangermounting bracket. (See Figure 91.)

Bracket Fasten Screws

Figure 91.

Tap-changer bracket mounting.

7. Using a 5/32 Allen wrench loosen and remove the pan head Allen screws fastening the front drive assembly section and the contact panel assembly section together. (See Figure 92.)

Indicator Position Lob

Figure 89.

Indicator position lob.

4. Disconnect and remove the blue and red strip leads from

the 40ohm resistor. These connections are pushon connection. (See Figure 90.)

40Ohm Resistor

Blue/Red Leads

Screws

Figure 92.

Driver panel and contact panel fastening.

Figure 90.

40 Ohm resistor connections.

Page 36

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

8. Lift the front drive assembly off of the contact assembly

and set aside. (See Figure 93.)

Drive Assembly

Contact Panel

Figure 93.

Driver panel and contact panel fastening.

Main Stationary Contact Removal and Re-Assembly.

1. Use a 9/16 wrench or a deep well 9/16 socket and ratchet, loosen and remove the brass nut on the stationary contact that is to be removed, remove the external tooth lock washer and brass at washer. (See Figure 94.)

2. Push the contact stud through the mounting hole in the contact panel. (See Figure 95.)

Stationary Contacts

Figure 95.

Stationary contacts.

Flat Washer External Tooth Lock Washer Nut

Stationary Contacts

Figure 94.

Stationary contact fasteners.

3. Remove the stationary contact from the contact panel.

4. Insert the new stationary contact stud through the

mounting hole for that number of stationary contact. Make sure that the stationary contact is aligned for proper tting in the contact board assembly. (See Figure

96.)

5. Place a brass at washer, external tooth lock washer, and nut onto the stationary contact stud. Tighten and torque the hardware to 6070 poundinch (6.7797.908 Nm) torque.

6. The above process is used for each of the eight station- ary contacts on the QD3 contact panel.

QD3 has eight main stationary contacts all labeled with

the tap number on the contact panel.

Tap-Changer Re-Assembly

1. Lay the contact panel assembly section at on a table surface. (See Figure 96.)

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Stationary Contact Panel Assemble

Figure 96.

Stationary contact panel assembly.

2. Place and align the tapchanger drive assembly section on top of the contact panel assembly. (See Figure 97.)

S225-12-1

Center Hole

Drive Panel Assembly

Figure 97.

Tap-changer sections.

3. Align the center hub of the main moveable contact assembly with the center hole in the tapchanger drive assembly. (See Figures 98 and 99.)

Hub

Figure 99.

Drive assembly panel.

4. Press both of the tapchanger assembly sections together and stand upright. (See Figure 100.)

Contact Panel

Drive Panel Assembly

Stationary Contact Assembly

Man Moivable Contact Assembly

Figure 98.

Contact assembly and main moveable contacts.

Figure 100.

View of panel assembly.

Page 38

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

5. Insert four pan head Allen screws into the tapchanger

assemblies. Two screws will mount the two tapchanger assemblies and the terminal block bracket at the top of the tapchanger. The other two screws are inserted in the mounting holes along both side centers of the tap changer. (See Figure 101.)

Screws

Figure 101.

Panel assembly fastening.

6. Place the mounting bracket (see Figure 102) to the base of the tapchanger assembly and fasten with two pan head hex screw and tighten with a 5/32 Allen Wrench. (See Figure 103.)

7. Place the neutral position pointer lob, see (Figure 104), into the main moveable contact hub located in the lower front center of the drive assembly panel. (See Figure

105.)

Figure 104.

Position indicator lob.

Lob

Figure 102.

Tap-changer mounting bracket.

Fastening Screws

Figure 103.

Bracket fastening.

Figure 105.

Lob placement.

8. Fasten the tap position switch assembly to the front of the drive panel assembly with three pan head Phillip screws. (See Figure 106.)

Position Switch Assembly

Screws

Figure 106.

Position switch assembly.

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9. Position the position actuator arm between the center

position and L by rotating the pinion counter clockwise. (See Figure 107.) This will allow for mounting the micro switches without interference with the micro switch arms.

R Switch

S225-12-1

Actuator

Pinion

L Switch

Figure 107.

Switch actuator position.

10. Place and fasten the reversing logic and neutral logic

micro switches on the upper left of the drive assembly panel. The micro switch with a blue white striped wire and blue black striped is located on the R position. The micro switch with a red white striped wire and red black striped wire is located on the L position. The micro switch with an orange wire and a white wire is located on the center position between the R and L position. (See Figure 108.)

Resistor

Blue/Red Leads

Figure 109.

Resistor connections.

13. Check and set the tapchanger for neutral position. The tapchanger can be set for any tap position by rotating the pinion cam in either the clockwise or counter clockwise direction. For neutral position the reversing logic switch actuator must be in the center with the neutral switch arm depressed. The tap position lob must have the pointer pointing at N. The pinion cam point is pointing at the three o’clock position over the holding switch lever arm. The holding switch is open. (See Figure 110.)

Reversing Logic Switch

R Switch

Neutral

Actuator Arm

L Switch

Figure 108.

Logic switch positioning.

11. Rotate the pinion back clockwise until the arm in Figure 108 is in the center and the neutral switch is depressed.

12. Connect the blue wires with red strips to the 40 ohm resistor by pushing the female connector on to the resistor terminals. (See Figure 109.)

Pinion Cam Pointing at three o'clock

Tap Position Lob Pointing at N

Holding Switch Open

Figure 110.

Neutral positioning.

Re-Assembly of Tap-Changer to Voltage Regulator Assembly

1. Once the tapchanger has been reassembled, reverse

the process in the procedure titled “Tapchanger Removal from Voltage Regulator” at the beginning of the installation instructions.

Page 40

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 MOTOR REPLACEMENT KIT KIT NUMBER 57A63675100B

Refer to Service Information S2255035

GENERAL

The purpose of this replacement kit is to provide the parts and installation instructions for replacing the motor on a QD3 Quik Drive Tapchanger.

TABLE 9

Parts Supplied

Item Part Number Description Qty

1 TAA114651003 Ring Terminal 3

2 TAA136263002 Cable Tie 3

3 TAA136263001 Cable Tie 4

4 0692044A060 Creep Insulation Tube 6 inches

5 0800073199Z "E" Clip 1

6 2291846A01 Motor 1

TABLE 10

Tools Required

Description Qty

Crimper 1

Diagonal Cutters 1

Phillips Screw Driver 1

Standard Screw Driver 1

Allen Wrench 1/8 inch 1

Allen Wrench 5/32 inch 1

Allen Wrench 3/16 inch 1

9/16 Socket 1

Ratchet 1

Needle Nose Pliers 1

Motor Removal Instructions

1. Remove the internal position indicator shaft from the tapchanger indicator drive tube. (See Figure 112.)

Item 4

Item 3

Figure 111. Kit parts.

Item 2

Item 5

Item 6

Item 1

Internal Flex Shaft

Tapchanger Internal Drive Tube

Figure 112. Internal flex shaft.

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2. Use a pair of diagonal side cutters and cut and remove the cable ties from the control winding hard insulation tube and tapchanger top bracket assembly. (See Figure 113.)

Cable Tie

4. Using a 1/8 inch Allen wrench, remove the three button Allen head screws fastening the motor bracket to the tapchanger assembly. (See Figure 115.)

1/8 inch Allen Head Screws

Figure 115.

Motor bracket fasteners.

5. Using a Phillips screwdriver, loosen and remove the

blue motor lead terminal from the tapchanger larger terminal board terminal position 2, red lead from terminal position 6 and the white ground lead from terminal position G. (See Figure 116.)

Figure 113.

Control cable fastening.

3. Use a 9/16 inch socket and ratchet to loosen and

remove the nut and carriage bolt fastening the tap changer bracket to the regulator side channel. (See Figure 114.)

Carriage Bolt

Nut

White Ground Lead Terminal G

Blue Lead Terminal 2

Red Lead Terminal 6

Figure 116. Motor wiring to terminal board.

Figure 114. Tap-changer and side channel fastener.

Page 42

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

6. Using a pair of diagonal side cutters, cut and remove the two cable ties fastening the motor wires to the main harness. (See Figure 117.)

7. Using a pair of diagonal side cutters, cut and remove the two medium cable ties fastening the motor harness and main wiring harness to the tapchanger top terminal board. (See Figure 117.)

Motor Wiring Cable Ties

Main Wiring Harness Cable Tie

Motor Wiring Insulation Cable Tie

Figure 117.

Motor wiring cable ties.

8. Use a 5/32 inch Allen wrench and remove the two button Allen head screws mounting the top tapchanger bracket to the tapchanger. See Figure 118.

9. Lift the top bracket clearing the position indicator tube and the main wiring harness. (See Figure 119.)

Position Indicator Drive Tube

Main Wiring Harness

Tapchanger

Figure 119.

Tap-changer top bracket.

10. Lift the motor and gear assembly out of the tapchanger assembly and place on a work surface.

11. Use a pair of needle nose pliers and remove the "E" clip fastening the motor gear to the motor shaft. (See Figure

120.)

5/32 inch Allen Head Screws

Figure 118. Tap-changer bracket fastening.

EClip

Figure 120. Motor gears and retaining clip.

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12. To remove the gear from the motor, use a standard screw driver to pry the gear off of the motor shaft. Place the screwdriver between the motor and the gear. Pry the gear forward until the gear clears the shaft. (See Figure121.)

Motor Gear

Motor

Figure 121.

Motor and gear.

13. Using a 3/16 inch Allen wrench, loosen and remove the Allen button head screws fastening the bracket to the motor. (See Figure 122.)

3/16 inch Allen Head Screws

New Motor Assembly

14. Place the red, blue, and white motor leads through item #4 creep insulation.

15. Position the motor onto the motor mount bracket so that the motor leads are on the side where there are two mounting ears. (See Figure 123.)

Motor Bracket Mounting Ears

Motor

Motor Leads

Figure 123.

Motor and bracket alignment.

16. Fasten the motor mount bracket onto the motor using four button Allen head 3/16 inch screws and tighten with a 3/16 inch Allen wrench.

17. Place the motor gear onto the motor shaft with the hex nut to the outside. (See Figure 124.)

Figure 122. Motor bracket.

Gear Hex Nut

Figure 124. Motor gear placement.

Page 44

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

18. Using a pair of needle nose pliers, press the "E" clip over the motor shaft grove. The center "E" Clip point must be on the at surface of the motor shaft. (See Figure 125.)

Shift Flat Surfaces

EClip

Figure 125.

E-Clip placement.

19. With the motor leads to the outside, place the motor gear between the tapchanger sections. The motor gear must match up with the pinion drive gear. (See Figure126.)

20. Place one drop of locktite on each motor button Allen head screw thread (1/8).

21. Position the top bracket so that the position indicator drive tube and main wiring harness is through the bracket holes. Align the bracket and motor mounting holes. (See Figure 127.)

Position Indicator Drive Tube

Main Wiring Harness

Figure 127.

Terminal board bracket alignment.

22. Place the 1/8 inch button Allen head screws into the right side and right top of the plate. The bottom right screw also requires a at washer. (See Figure 128.) Use a 1/8 inch Allen wrench and tighten the connection between the motor bracket and the front plate.

Figure 126.

Motor placement.

Motor and Gear

Motor Mounting Screws

Motor Leads

Figure 128. Motor bracket fasteners.

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23. Place the 5/32 inch button Allen head screws in the top bracket and front plate, tightening with a 5/32 Allen wrench. (See Figure 129.)

5/32 inch Button Allen Head Screws

Figure 129.

Terminal board bracket fastening.

24. The inside 1/8 inch motor mounting button head screw may be easier to start after tightening the 5/32 inch button Allen head screws.

25. Crimp a ring tongue terminal item #1 to each of the motor wires after cutting and stripping to t.

26. Connect the blue motor wire to post 2 of the large terminal board, connect the red wire to past 6, and the white wire to the ground post G. (See Figure 130.)

27. Use two cable ties item #2, to fasten the motor leads to the main wiring harness.

28. Place the insulation paper tubing and motor wires in the bracket slots at the end of the bracket above the motor and cable tie with one item #3. (See Figure 131.)

29. Bundle with plastic cable ties the main wiring harness insulator tube to the bracket with one cable tie, item #3. (See Figure 131.)

Motor Harness Tie

Motor Insulation Tie

Main Harness Tie

Figure 131.

Wiring insulation fastening.

30. Place the carriage bolt into the square hole of the tap changer top bracket. Place the 9/16 nut onto the bolt through the side channel and tighten with the socket and ratchet. (See Figure 114.)

Red Post 6

White "G" Post

Figure 130. Terminal board wiring.

31. Place the control winding hard tubing insulation against the tapchanger top bracket and bundle with plastic cable ties with item #3. (See Figure 113.)

Blue Post 2

Page 46

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 MOTOR RESISTOR REPLACEMENT KIT

KIT NUMBER 5791844A01

Refer to Service Information S2255037

GENERAL

The purpose of this replacement kit is to provide the parts and installation instructions for replacing the motor resistor on a QD3 Quik Drive Tapchanger.

TABLE 11

Parts Supplied

Item Part Number Description Qty

1 2291844A01 T350TCHL 100 15N 40 ohm

5% Resistor

Resistor Removal Instructions

1. Using a pair of needle nose pliers, remove the push on connections from each end of the resistor. The colors for the resistor wires are blue/red. (See Figure 133.)

Blue/Red Wire

Pushon Connections

Figure 133.

Resistor connectors.

Figure 132.

Kit parts.

TABLE 12

Tools Required

Description Qty

Allen Wrench 1/8 inch 1

243 Locktite 1

Needle Nose Pliers 1

2. Use a 1/8 inch Allen wrench and remove the button head screw from one resistor mounting clips. (See Figure 134.)

Button Head Screw and Resistor Clip

Figure 134. Removing resistor clip fasteners.

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3. Remove the mounting clip from the resistor. (See Figure

135.)

Resistor Mounting Clip

Motor Resistor

Figure 135.

Resistor clip removed.

4. Work the resistor off of the second mounting clip by rotating the resistor clockwise and counter clockwise while pulling on the resistor.

Resistor Installation

5. Push the new resistor onto the mounting clip that is fastened to the lower tapchanger mounting bracket. The resistor terminals must be pointing upward. (See Figure 136.)

6. Press the loose mounting clip into the open end of the resistor. (See Figure 137.)

Resistor Mounting Clip

Resistor

Figure 137.

Installing resistor clip.

7. Align the mounting clip along the slotted mounting hole up with the mounting hole in the tapchanger's lower mounting bracket.

8. Fasten the resistor mounting clip with the button head Allen screw after placing a drop of 243 Locktite on the screw threads and tighten with a 1/8 inch Allen wrench. (See Figure 138.)

Resistor Terminals

Resistor

Figure 136. Installing new resistor.

Resistor Mounting Clip

Resistor Clip Fasten Screw

Figure 138. Fastening resistor assembly.

Page 48

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

9. Push the blue/red wire pushon connectors onto each of the terminals on each end of the resistor. (See Figure

139.)

Resistor Wire Connections

Figure 139.

Resistor lead connectors.

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QD3/T350 PI DRIVE CAM REPLACEMENT KIT

Kit Number 5740783B21

GENERAL

The purpose of this replacement kit is to provide the parts and installation instructions for replacing the PI Drive Cam on a QD3 Quik Drive Tapchanger.

TABLE 13

Parts Supplied

Item Part Number Description Qty

1 2240783B21 PI Drive Cam 1

2 2291652A06 Sprocket Key 1

3 0891663A09 PI Cam Wave

Washer

TABLE 14

Tools Required

Description Qty

Phillips Screw Driver 1

243 Locktite 1

PI Cam Removal

1. If possible, rotate the PI Cam so that the point of the cam is pointing toward the holding switch actuator. (See Figure 141.) The PI Cam can be easily rotated by hand.

2. Hold the PI Cam so that the cam does not rotate. Use a Phillips screwdriver and loosen and the mounting screw. (See Figure 141.)

PI Cam Mounting Screw

Holding Switch Actuator

Figure 141.

PI cam and holding switch actuator.

PI Cam

Item 1

Figure 140.

Kit parts.

3. Pull the cam forward removing the cam from the tap changer drive shaft. (See Figure 142.)

Drive Shaft

Item 1

Figure 142.

Tap-changer drive shaft.

Page 50

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

4. Remove the Sprocket Key from the PI Cam slot. (See Figure 143.)

PI Cam

Sprocket Key

Figure 143.

PI cam and sprocket key.

5. Remove the PI Cam Wave Washer that is located between the PI Cam and the front surface of the tap changer. (See Figure 144.)

Wave Washer

PI Cam Assembly

6. Place the new PI Cam wave washer over the shaft. (See Figure 145.)

7. Place either the new sprocket key or the original sprocket key in the slot of the new PI Cam.

8. Align the new PI Cam up so that the sprocket key matches up with the key slot in the shaft. Insert the sprocket key in the slot between the shaft and the PI Cam.

9. Rotate the PI Cam point so it is pointing at the actuator located on the holding switch. (See Figure 145.) The large radius end of the cam should be match with the radius arc of the PT Drive Geneva Gear. (See Figure

145.)

Large Cam Radius

PI Drive Geneva Gear

Sprocket

Holding Switch

Cam Point

Figure 144.

PI cam wave washers.

Figure 145.

PI cam assembly.

10. Place the washer over the PI Cam fastening screw.

11. Place a drop of 243 Locktite on to the screw threads.

Place the screw into the tapped hole on the shaft and hold the PI Drive Cam so it does not rotate while tighten with a Phillips Screw Driver.

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QD3/T350 REVERSING STATIONARY CONTACT ASSEMBLY

Instructions Kit Number 5791822A02

Refer to Service Information S2255043

GENERAL

The purpose of this replacement kit is to provide the parts and installation instruction for replacing the reversing stationary contacts on a QD3 Quik Drive Tapchanger. The VR and VL reversing stationary contacts are symmetrical; therefore, one stationary contact can be used either for the VR or the VL stationary.

This installation instruction is made up of four different procedures sections:

Tapchanger Removal from Voltage Regulator

QD3/T350 Tapchanger Assembly Separation

Reversing Stationary Contact Removal and Reassembly

Tapchanger Reassembly

TABLE 16

Tools Required

Description Qty

Needle Nose Pliers 1

9/16 inch Deep Well Socket 1

3/8 inch Drive Ratchet Wrench 1

5/32 Allen Wrench 2

Phillips Head Screwdriver Size 1 Point

Diagonal Cutters 1

Phillips Head Screwdriver 1

Standard Screwdriver 1

Torque Wrench inch pounds 1

3/8 inch drive 0200 lbin (025 Nm) torque wrench

TABLE 15

Parts Supplied

Item Part Number Description Qty

1 2291844A01 T350TCHL 100 15N

40 ohm 5% Resistor

Figure 146. Kit part.

Page 52

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

Tap-Changer R emoval F rom Voltage Regulator

1. Remove the internal position indicator shaft from the tap changer indicator drive tube. (See Figure 147.)

Internal Flex Shaft

Tapchanger Internal Drive Tube

Figure 147.

Internal flex shaft.

2. Use a pair of diagonal side cutters to cut and remove the cableties from the control winding hard insulation tube and tapchanger top bracket assembly. (See Figure

148.)

3. Use a 9/16 inch socket and ratchet to loosen and remove the nut and carriage bolt fastening the tap changer bracket to the regulator side channel. (See Figure 149.)

Carriage Bolt Nut

Figure 149.

Tap-changer and side channel fastener.

4. Use a Phillips head screwdriver to loosen and remove the TCB terminal board leads from the 14 position terminal board located on the top right of the QD3 tap changer. (See Figure 150.)

TABLE 17

Lead Color and Termination Points

Cable Tie

Lead Color TCB Connection

Blue/White 1

Green/White 5

Blue 9

Green 10

Orange 11

Red/Black 13

White G

White Position G

Red/Black Position 13

Green/White Position 5

Orange Position 11

Blue Position 9

Green Position 10

Blue/White Position 1

Figure 148. Control cable fastening.

Figure 150. TCB lead color and termination points.

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5. Use a Phillips head screwdriver and needle nose pliers to disconnect the white E control winding leads, and P leads if available, from the seven position terminal board located on the left top of the tapchanger. (See Figure

151.)

Control winding E lead and (P lead if available) Connections.

The E lead will have E lead ID markers and the P leads if available will have P lead markers.

TABLE 18

Lead Marker and Terminal Board ID

S225-12-1

Tap Lead Connections

Lead Marker Terminal Board ID

E Could be on either E1, E2, or E3

E1 E1

E2 E2

E3 E3

P If available could be on either P1, P2, or

P1 P1

P2 P2

P3 P3

Reactor P1 & P2 Connections

Figure 152.

Tap leads and reactor connections.

7. Remove the mounting bolts fastening the tapchanger mounting bracket to the top core clamp. (See Figure

153.) Remove the tapchanger from the regulator and place on a work surface.

Mounting Hardware

Figure 151.

E & P lead connections.

6. Use a deep well 9/16 inch socket with ratchet or a 9/16 inch wrench to loosen and remove all lead connections from the back of the tapchanger contact board. (See Figure 152.)

Figure 153. Tap-changer to core clamp fastening hardware.

CAUTION:

Page 54

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 Tap-Changer Assembly Separation

1. After removing the tapchanger from the regulator

assembly, use a Phillips one point screwdriver to loosen and remove the six screws mounting the Reversing Lower, Raise and Neutral switch located in the upper left corner of the tapchanger assembly. (See Figure 154.)

Neutral

Screws

Raise

Lower

3. Remove the tapping indicator position lob pointer from the tapchanger. The lob may have to be pried a little to be removed. (See Figure 156.)

Indicator Position

Figure 156.

Indicator position lob.

4. Disconnect and remove the blue and red strip leads from the 40ohm resistor. These connections are push on connection. (See Figure 157.)

Figure 154.

Lower, raise and neutral logic switches.

2. Use a Phillips head screwdriver to loosen and remove the three mounting screws fastening the position indicator micro switch hub to the front of the tapchanger assembly. (See Figure 155.)

Screws

Position Indicator

Figure 155. Position indicator hub.

40 Ohm Resistor

Blue/Red Leads

Figure 157. 40 Ohm resistor connections.

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5. Lay the tapchanger assembly at on a work surface with the tap contact studs down on the surface.

6. Using a 5/32 Allen wrench loosen and remove the two pan head Allen screws from the tapchangermounting bracket. (See Figure 158.)

Bracket Fasten Screws

Figure 158.

Tap-changer bracket mounting.

7. Use a 5/32 Allen wrench to loosen and remove the pan head Allen screws fastening the front drive assembly section and the contact panel assembly section together. (See Figure 159.)

8. Lift the front drive assembly off of the contact assembly and set aside. (See Figure 160.)

Drive Assembly

Figure 160.

Tap-changer sections.

Reversing Stationary Contact Removal and Re-Assembly

1. The main moveable stationary contact must be locat-

ed on the neutral stationary contact located under the reversing moveable contact arm. The reversing moveable contact buttons must be located in the center space between the VR and VL stationary contacts. (See Figure 161.)

Reversing Stationary Contact VR

Screws

Figure 159. Drive panel and contact panel fastening.

Contact Panel

Reversing Moveable Contact

Reversing Stationary Contact VL

Neutral Position

Figure 161.

Reversing stationary and reversing moveable.

2. If not, by hand rotate the main moveable contact assembly so that statement in step one is true.

3. The VR and VL stationary contact are reversible, or one can be use for the other.

Page 56

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

4. Using a 9/16 wrench, or 9/16 socket and ratchet loosen and remove the nut, external lock washer, and at wash for the VR and/or VL stationary contact. (See Figure

162.)

VR Stationary Contact Fastening Hardware

VL Stationary Contact Fastening Hardware

Figure 162.

VL and VR fastening hardware.

Tap-Changer Re-Assembly

1. Lay the contact panel assembly section at on a table

surface. (See Figure 164.)

Stationary Contact Panel

Figure 164.

Stationary contact panel assembly.

2. Place and align the tapchanger drive assembly section on top of the contact panel assembly. (See Figure165.)

5. Push the stationary contact stud through the contact panel removing the stationary contact from the contact panel. (See Figure 163.)

6. Place stationary contacts in either VR or VL position or both. (See Figure 163.)

7. Place a at brass washer, external tooth lock washer, and nut on the stationary contact stud. Tighten and torque to 6070 poundinch torque (6.7797.908 Nm).

Stationary Contact

Drive Panel Assembly

Figure 165. Tap-changer sections.

Figure 163. Stationary contact removal.

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3. Align the center hub of the main moveable contact assembly with the center hole in the tapchanger drive assembly. (See Figures 166 & 167.)

Hub

Main Moveable Contact

Stationary Contact

Figure 166.

Contact assembly and main moveable contacts.

4. Press both of the tapchanger assembly sections together and stand upright. (See Figure 168.)

Contact Panel

Drive Panel

Center Hole

Figure 167. Drive assembly panel.

Drive Assembly Panel

Figure 168.

Tap-changer sections.

5. Insert four pan head Allen screws into the tapchanger

Screws

Figure 169. Panel assembly fastening.

Page 58

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

6. Place the mounting bracket, (see Figure 170), to the base of the tapchanger assembly and fasten with two pan head hex screw and tighten with a 5/32 Allen Wrench. (See Figure 171.)

Drive Panel

Figure 170.

Tap-changer mounting bracket.

Lob

Figure 173.

Lob placement.

8. Fasten the tap position switch assembly to the front of the drive panel assembly with three pan head Phillip screws. (See Figure 174.)

Position Switch

Screws

Fastening Screws

Figure 171.

Bracket fastening.

7. Place the neutral position pointer lobe, (see Figure 172), into the main moveable contact hub located in the lower front center of the drive assembly panel. (See Figure 173. )

Lob

Figure 172. Position lob indicator.

Figure 174.

Lob placement.

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9. Position the position actuator arm between the center position and L by rotating the pinion counter clockwise. (See Figure 175.) This will allow for mounting the micro switches without interference with the micro switch arms.

Pinion

Actuator

L Switch

Figure 175.

Switch actuator position.

10. Place and fasten the reversing logic and neutral logic micro switch on the upper left of the drive assembly panel. The micro switch with a blue white striped wire and blue black striped is located on the R position. The micro switch with a red white striped wire and red black striped wire is located on the L position. The micro switch with an orange wire and a white wire is located on the center position between the R and L position. (See Figure 176.)

R Switch

12. Connect the blue wires with red strips to the 40ohm resistor by pushing the female connector on to the resistor terminals. (See Figure 177.)

Resistor

Blue/Red Leads

Figure 177.

Resistor connections.

13. Check and set the tapchanger for neutral position. The

tapchanger can be set for any tap position by rotating the pinion cam in either the clockwise or counter clockwise direction. For neutral position the reversing logic switch actuator must be in the center with the neutral switch arm depressed. The tap position lob must have the pointer pointing at N. The pinion cam point is pointing at the three o’clock position over the holding switch lever arm. The holding switch is open. (See Figure 178.)

Reversing Logic Switch

Pinion Cam Pointing at Three o'clock

Neutral

Actuator Arm

L Switch

Figure 176.

Logic switch positioning.

11. Rotate the pinion back clockwise until the arm in Figure 176 is in the center and the neutral switch is depressed.

Tap Position Lob Pointing at N

Figure 178.

Neutral position.

Holding Switch Open

Re-Assembly of Tap-changer to Voltage Regulator Assembly

Once the tapchanger has been reassembled, reverse the process in the procedure titled “Tapchanger Removal from Voltage Regulator” at the beginning of these installation instructions.

Page 60

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 REVERSING MOVEABLE CONTACT AND NEUTRAL STATIONARY CONTACT ASSEMBLY KIT

Kit Number 5741325B03

Refer to Service Information S2255044

GENERAL

The purpose of this replacement procedure is to provide the instructions for replacing the main stationary contacts on a QD3 Quik Drive Tapchanger.

This installation instruction is made up of four different procedure sections:

Tapchanger Removal from Voltage Regulator

QD3/T350 Tapchanger Assembly Separation

Reversing Moveable and Neutral Stationary Contact Removal and Reassembly

Tapchanger Reassembly

INSTALLATION PROCEDURE

Figure 179.

Kit part Item 1.

TABLE 19

Parts Supplied

Item Part Number Description Qty

1 5741325B03 Reversing Moveable

Neutral Stationary Contact Assembly

TABLE 20

Tools Required

Description Qty

Needle Nose Pliers 1

9/15 inch Deep Well socket 1

3/8 inch Drive Ratchet Wrench 1

5/32 Allen Wrench 1

Phillips Head Screwdriver Size 1 Point 1

Diagonal Cutters 1

Phillips Head Screwdriver 1

Standard Screwdriver 1

Torque Wrench inch pounds 1

Figure 180. Kit part Item 1.

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Tap-changer Removal from Voltage Regulator

1. Remove the internal position indicator shaft from the tapchanger indicator drive tube. (See Figure 181.)

Internal Flex

Tapchanger Internal Drive Tube

Figure 181.

Internal flex shaft.

2. Use a pair of diagonal side cutters cut and remove the cableties from the control winding hard insulation tube and tapchanger top bracket assembly. (See Figure

182.)

Cable Tie

3. Use a 9/16 inch socket and ratchet to loosen and

remove the nut and carriage bolt fastening the tap changer bracket to the regulator side channel. (See Figure 183.)

Carriage Bolt Nut

Figure 183.

Tap-changer and side channel fastener.

4. Using a Phillips head screwdriver, loosen and remove the TCB terminal board leads from the 14 position terminal board located on the top right of the QD3 tap changer. (See Figure 184.)

TABLE 21

Lead Color and Termination Points

Lead Color TCB Connection

Blue/White 1

Green/White 5

Blue 9

Green 10

Orange 11

Red/Black 13

White G

Figure 182. Control cable fastening.

White Position G

Red/Black Position 13

Orange Position 11

Blue/White Position 9

Figure 184. TCB lead color and termination points.

Green Position 10

Blue Position 9

Green/White Position 9

Page 62

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

5. Use a Phillips head screwdriver and needle noise pliers to disconnect the white E control winding leads and P leads if available from the seven position terminal board located on the left top of the tapchanger. (See Figure

185.)

Control Winding E Lead and (P Lead if Available) Connections

The E lead will have E lead ID markers and the P

leads, if available, will have P lead markers.

TABLE 22

Lead Marker and Terminal Board ID

Lead Marker Terminal Board ID

E Could be on either E1, E2, or E3

E1 E1

E2 E2

E3 E3

P If available, could be on either P1,

P2, or P3

P1 P1

P2 P2

P3 P3

Tap Lead Connections

Reactor P1 & P2 Connections

Figure 186.

Tap leads and reactor connections.

7. Remove the mounting bolts fastening the tapchanger mounting bracket to the top core clamp. (See Figure

187.) Remove the tapchanger from the regulator and place on a work surface.

Figure 185.

E & P lead connections.

6. Use a deep well 9/16 inch socket with ratchet or a 9/16 inch wrench to loosen and remove all lead connections from the back of the tapchanger contact board. (See Figure 186.)

Mounting Hardware

Figure 187. Tap-changer to core clamp fastening hardware.

CAUTION:

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QD3/T350 Tap-Changer Assembly Separation

8. After removing the tapchanger from the regulator assembly, use a Phillips head one point screwdriver too loosen and remove the six screws mounting the Reversing Lower, Raise and Neutral switch located in the upper left corner of the tapchanger assembly. (See Figure 188.)

Neutral

Screws

Raise

Lower

Figure 188.

Lower, raise and neutral logic switches.

10. Remove the tapping indicator position lob pointer from the tapchanger. The lob may have to be pried a little to be removed. (See Figure 190.)

Indicator Position Lob

Figure 190.

Indicator position lob.

11. Disconnect and remove the blue and red strip leads from the 40Ohm resistor. These connections are pushon connections. (See Figure 191.)

9. Using a Phillips head screwdriver, loosen and remove the three mounting screws fastening the position indicator micro switch hub to the front of the tapchanger assembly. (See Figure 189.)

Screws

Position Indicator Hub

Figure 189. Position indicator hub.

40 Ohm Resistor

Blue/Red Leads

Figure 191.

40 Ohm resistor connections.

12. Lay the tapchanger assembly flat on a work surface with the tap contact studs down on the surface.

Page 64

QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

13. Using a 5/32 Allen wrench loosen and remove the two pan head Allen screws from the tapchangermounting bracket. (See Figure 192.)

Bracket Fastening Screws

Figure 192.

Tap-changer bracket mounting.

14. Using a 5/32 Allen wrench, loosen and remove the pan head Allen screws fastening the front drive assembly section and the contact panel assembly section together. (See Figure 193.)

15. Lift the front drive assembly off of the contact assembly and set aside. (See Figure 194.)

Drive Assembly

Contact Panel

Figure 194.

Tap-changer sections.

Reversing Moveable and Neutral Stationary Contact Removal and Re-assembly

1. Use a 9/16 wrench or a deep well 9/16 socket and ratchet, loosen and remove the brass nut on stationary contact one, remove the external tooth lock washer and flat washer. (See Figure 195.)

Screws

Figure 193. Drive panel and contact panel fastening.

Stationary Contact Eight

Figure 195. Stationary contacts.

Stationary Contact One

Fastening Hardware

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2. Push the contact stud through the mounting hole in the contact panel. (See Figure 196.)

Stationary Contact

Figure 196.

Stationary contact removal.

4. Use a 9/16 wrench or deep well 9/16 socket and ratchet to remove the six nuts, lock washer, and flat washer fastening the P1 and P2 slip ring studs to the contact panel located in the center back of the stationary contact panel. (See Figure 198.)

P1 & P2 Stud Fastening Hardware

3. By hand, rotate the main moveable contact and Geneva gear assembly so that the moveable contact is in the stationary one contact position. (See Figure 197.)

Contact One Position

Main Moveable Contact Assembly

Moveable Contact

Figure 198.

P1 and P2 stud hardware removal.

5. Facing the main moveable contacts and Geneva gear assembly, pull forward removing the main contact assembly and P1 and P2 slip ring assemblies from the contact board assembly. (See Figure 199.)

Main MoveP1 & P2 Slip Rings

able

and

Geneva Gear

Assembly

Contact Board Assembly

Figure 197. Positioning of moveable contacts.

Figure 199. Separating moveable contacts.

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

6. Rotate the reversing switch assembly, if not already rotated, so that the contact buttons are in the center space between the VR and VL stationary contacts as though in the neutral position. (See Figure 200.)

Contact Button

Reversing Stationary Contacts

Moveable Reversing

Neutral

Switch

Figure 200.

Positioning of moveable reversing switch.

7. Using a 9/16 wrench, or 9/16 socket and ratchet loosen and remove the mounting nut on the stud of the reversing switch assembly. The reversing switch assembly stud is located between the reversing stationary contacts VR and VL on the stationary contact assembly on the contact panel. (See Figure 201.)

Moveable Reversing Switch Hardware

8. Pull out on the reversing moveable contact assembly removing form the contact panel. (See Figure 202.)

Contact Panel

Neutral

Moveable Reversing

Stationary Contact

Switch

Figure 202.

Removal of moveable reversing switch.

9. Install the reversing switch assembly with the contact buttons located between the VR and VL stationary contacts. (See Figure 200.)

10. Place the brass flat washer, external tooth lock washer and nut onto the reversing switch assembly stud. Tighten and torque the hardware to 6070 poundinch torque (6.7797.908 Nm).

11. Rotate the reversing switch assembly so that the button contacts are on the VR reversing stationary contact. (See Figure 203.) To identify the VR stationary contact look for the ID marking on the contact panel.

Reversing Moveable Contact

VL Reversing Stationary Contact

Button

VR Reversing Stationary Contact

Figure 201. Moveable reversing switch hardware.

Reversing Moveable Contact Assembly

Figure 203. Reversing moveable contact positioning.

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12. Align the Moveable Contact and Geneva Gear Assembly so that the moveable contacts align to where the number one stationary contact has been removed. (See Figure

204.)

S225-12-1

Higher Mounting Shoulders

Moveable Contact Assembly

Stationary Contact Position One

Figure 204.

Moveable contact re-assembly.

13. Align the studs of the slip rings with the mounting holes in the contact panel. The studs on the slip ring that is between the left hand lower button contact will go into the holes that have the high shoulder spacer as part of the contact panel. (See Figures 205 and 206.)

P1 and P2 Slip Ring Studs

Higher Mounting Shoulders

Figure 206.

P1 and P2 mounting holes.

14. You may need to rotate the slip ring assemblies in the button contact to make the proper alignment.

15. Press on the moveable and Geneva contact assembly to insert the studs.

16. You may find that after starting the studs, the moveable and Geneva contact assembly will need to be rotated to position the moveable contact so that the contacts are not interfering with other stationary contacts during the installation.

17. Rotate the main moveable contact Geneva gear assembly onto the neutral stationary contact, located under the reversing switch assembly, locating the reversing moveable so that the button contact is between VR &VL stationaries. (See Figure 207.)

Moveable Contact Button

Slip Ring

Figure 205. Slip ring P1 and P2 studs.

Moveable Contact Assembly

Neutral

Reversing Moveable

Stationary Contact

Contact Button

Figure 207.

Positioning of reversing moveable contacts.

18. Place a flat brass flat washer, external tooth lock washer,

and 3/8 nut on each of the P1 and P2 slip ring studs and tighten with a 9/16 wrench or socket and ratchet. Torque the nut on the studs to 6070 poundsinch (6.7797.908 Nm).

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

19. Replace the number 1 stationary contact by inserting the contact stud into the contactmounting hole in the contact panel. The contact position number is located on the contact panel. (See Figure 208.)

Stationary Contact Assembly

Figure 208.

P1 and P2 mounting holes.

20. Place a brass flat washer, external tooth lock washer, and nut on the number 1 stationary contact stud. Tighten and torque the hardware 6070 poundinch (6.7797.908 Nm).

2. Place and align the tapchanger drive assembly section on top of the contact panel assembly. (See Figure

210.)

Drive Panel Assembly

Figure 210.

Tap-changer sections.

3. Align the center hub of the main moveable contact assembly with the center hole in the tapchanger drive assembly. (See Figures 211 and 212.)

Main Moveable

Hub

Contact Assembly

Tap-changer Re-assembly

1. Lay the contact panel assembly section flat on a table

surface. (See Figure 209.)

Stationary Contact Panel Assembly

Figure 209. Stationary contact panel assembly.

Stationary Contract Assembly

Figure 211. Contact assembly and main moveable contacts.

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S225-12-1

5. Insert four pan head Allen screws into the tapchanger assemblies. Two screws will mount the two tapchanger assemblies and the terminal block bracket at the top of the tapchanger. The other two screws are inserted in the mounting holes along both side centers of the tap changer. (See Figure 214.)

Screws

Center Hole

Figure 212.

Drive assembly panel.

4. Press both of the tapchanger assembly sections together and standupright. (See Figure 213.)

Contact Panel

Drive Panel Assembly

Figure 214.

Panel assembly fastening.

6. Place the mounting bracket, (see Figure 215), to the base of the tapchanger assembly and fasten with two pan head hex screw and tighten with a 5/32 Allen Wrench. (See Figure 216.)

Contact Panel

Figure 213. View of panel assembly.

Figure 215. Tap-changer mounting bracket.

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

8. Fasten the tapposition switch assembly to the front

of the drive panel assembly with three pan head Phillip screws. (See Figure 219.)

Position Switch Assembly

Fastening Screws

Figure 216.

Bracket fastening.

7. Place the neutral position pointer lob, (see Figure 217), into the main moveable contact hub located in the lower front center of the drive assembly panel. (See Figure

218. )

Lob

Figure 217.

Position indicator lob.

Screws

Figure 219.

Position switch assembly.

9. Position the position actuator arm between the center

position and L by rotating the pinion counter clockwise. (See Figure 220.) This will allow for mounting the micro switches without interference with the micro switch arms.

Pinion

Actuator

Lob

Figure 218. Lob placement.

L Switch

Figure 220. Lob placement.

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S225-12-1

R Switch

Neutral

Actuator Arm

13. Check and set the tapchanger for neutral position. The tapchanger can be set for any tap position by rotating the pinion cam in either the clockwise or counter clockwise direction. For rotating to the neutral position, the reversing logic switch actuator must be in the center with the neutral switch arm depressed. The tap position lob must have the pointer pointing at N. The pinion cam point is pointing at the three o’clock position over the holding switch lever arm. The holding switch is open. (See Figure 223.)

Reversing Logic Switch

Tap Position Lob Pointing at N

Pinion Cam Pointing at Three o'clock

Holding Switch Open

Figure 221.

Logic switch positioning.

11. Rotate the pinion back clockwise until the arm in Figure 221 is in the center and the neutral switch is depressed.

12. Connect the blue wires with red strips to the 40ohm resistor by pushing the female connector onto the resistor terminals. (See Figure 222.)

Resistor

Blue/Red Leads

Figure 223.

Logic switch positioning.

Re-assembly of Tap-changer to Voltage Regulator Assembly

1. Once the tapchanger has been reassembled, reverse the process in the procedure titled “Tapchanger Removal from Voltage Regulator” at the beginning of these installation instructions.

Figure 222. Resistor connections.

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 TC-LTC P.I. DRIVE FACE GEAR KIT

Kit Number 5740787B11

Refer to Service Information S2255045

GENERAL

The purpose of this replacement kit is to provide the parts and installation instructions for replacing the PI Drive Face Gear on a QD3 Quik Drive Tapchanger.

TABLE 23

Parts Supplied

Item Part Number Description Qty

1 2240787B11 TCLTC P.I. Drive Face Gear 1

2 0800073184Z Retainer Ring 1

TABLE 24

Tools Required

INSTALLATION PROCEDURE

PI Gear Removal

1. Place a narrow blade standard screwdriver in the slots

of the retainer ring allowing the retainer ring to be pried off the shaft. (See Figure 226.)

Retainer Ring Slots

Figure 226.

Retainer ring removal.

Retainer Ring

P.I. Drive Gear

Description Qty

Standard Narrow Blade Screw Drive 1

Needle Nose Pliers 1

Standard Wireman Pliers 1

Item 2

Item 1

2. Remove the retainer ring.

Slide the P.I. Drive Gear off of the shaft. (See Figure

227.)

P.I. Drive Gear

Shaft

Figure 224 (Above) and 225 (Below). Kit parts.

Figure 227. P.I. drive gear and shaft.

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4. Slide the new P.I. Drive Gear onto the shaft matching up the gear teeth of the P.I. Drive Gear and the teeth of the miter gear. (See Figure 228.)

P.I. Drive Gear

Miter Gear Teeth

P.I. Drive Gear

Figure 228.

Gear teeth.

5. Use a pair of pliers, either needle nose or wireman pliers, and press the retainer ring over the shaft with the retainer ring located in the shaft groove. (See Figures 229 and 230.)

S225-12-1

Retainer Ring

Figure 229.

Retainer ring fastening.

P.I. Drive Gear

Retainer Ring Shaft

Shaft

Figure 230. Retainer ring in place.

Retainer Ring

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

QD3/T350 QUICK DRIVE HOLDING SWITCH ASSEMBLY KIT

Kit Number 574074B04

GENERAL

The purpose of this installation instruction is for replacing the holding switch on a QD3 Quik Drive Tapchanger.

TABLE 25

Parts Supplied

Item Part Number Description Qty

1 2240794B04 Holding Switch 1

2 0800073409Z #832 Machine

Screw

TABLE 26

Tools Required

INSTRUCTIONS

Removing Holding Switch

1. Using a pair of pliers remove the four leads form the

holding switch assembly. Facing the holding switch you will nd the wires by color. (See Figure 232.)

Top Micro Switch

Black wire on top terminal post (com post) Blue wire on center terminal post (No. 2 post) Bottom terminal post, vacant (No. 3 post)

Bottom Micro Switch

Top terminal post, vacant (No. 3 post) Red wire on center terminal post (No. 2 post) Black wire on bottom terminal post (com post)

Mounting Screws

Black Wire

Blue Wire

Top Switch

Description Qty

Pliers 1

Phillips Screwdriver 1

Standard Flat Blade Screwdriver 1

Allen Wrench 9/64 inch 1

Figure 231. Kit part.

Red Wire

Bottom Switch

Figure 232.

Holding switch connections.

2. Use either a Phillips screwdriver, standard at blade

screwdriver or an Allen wrench and remove the four screws fasten the holding switch in place. Earlier Quik Drive tapchangers were built using pan head and Phillip screws. (See Figure 232.)

Black Wire

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Installation of Holding Switch

3. Place the holding switch assembly on to the QD3 tap changer with the nylon actuator located at the 3 o’clock position or just to he right of the pinion cam. (See Figure

233.)

Actuator

S225-12-1

Figure 233.

Pinion and actuator location.

Using a 9/64 Allen wrench place and tighten the four

mounting screws. (See Figure 232.)

5. Connect the wires on to the holding switch assembly.

(See Figure 232.)

Top Micro Switch

Black wire on top terminal post (com post) Blue wire on center terminal post (No. 2 post) Bottom terminal post, vacant (No. 3 post)

Bottom Micro Switch

Top terminal post, vacant (No. 3 post) Red wire on center terminal post (No. 2 post) Black wire on bottom terminal post (com post)

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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual

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Cooper QD3 Service Information

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Frequently Asked Questions

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