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
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FOR LIFE
FOR LIFE
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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
highvoltage 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:
n
Is thoroughly familiar with these instructions.
n
Is trained in industry-accepted high- and low-voltage
safe operating practices and procedures.
n
Is trained and authorized to energize, de-energize, clear,
and ground power distribution equipment.
n
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
specic 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.
2
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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SAFETY
FOR LIFE
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
3
QD3 Quik-Drive Voltage Regulator Tap-Changer Manual
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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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SAFETY
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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.
5
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.
•Transformeroilcompatible
•Envirotemp™FR3™uidcompatible
•Highheatresistancewithanoperating
temperature over 200 °C
•Highmechanicalstrength
•Highelectricalcreepresistance
•Moldedpartreducesnumberoftotaltap
changer parts
•Lowerwaterabsorptionandpowerfactorthanphenolicboard
•Goodmechanicalcreepresistance
•Corrosionresistant
•Highdielectricstrength
•Goodwearresistance
•Highchemicalresistance
•Sometypicalapplicationsinclude:
•Under-hoodhightemperatureautomotive
applications such as engine manifolds
•Electricalapplicationssuchascircuitbreakersand
stand-off insulators
•Hightemperaturelightingapplications
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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SAFETY
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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
120V 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 120V power. The motor is now energized only
through the hooding switch (also 120V).
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.
7
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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SAFETY
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S225-12-1
Terminal Board
Motor
#7 Stationary
P2
#6 Stationary
#8 Stationary
VR Reversing
Stationary
Contact
Neutral Stationary
VL Reversing
Stationary
Contact
#1 Main
Stationary
Contact
P1
#5 Stationary
#4 Stationary
#2 Stationary
#3 Stationary
Tapchanger
Mounting Base
Figure 11.
Back side of QD3 Tap-changer.
9
QD3 Quik-Drive Voltage Regulator Tap-Changer Manual
Figure 12.
QD3 wiring schematic.
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SAFETY
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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
Figures16 and 19 must definitely be replaced. The following figures show the actual contact after varies stage
of contact erosion.
11
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.
12
Figure 19.
QD3 stationary contact edge, end of life.
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SAFETY
FOR LIFE
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
5060 lb.in.
5.6496.779 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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SAFETY
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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
1820 lbs.in.
2.0332.259 Nm
Figure 25.
Tap-changer terminal board fastener torques.
18-20 lbs.-in.
2.033-2.259 Nm
15
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 120V
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.
17
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
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.
Unpackthemoveablecontactboardandinspectitthoroughly 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
19
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
Tapchanger
Internal Drive
Tube
Figure 37.
Internal flex shaft.
Figure 38.
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 39.)
Carriage Bolt Nut
2. Usingapairofdiagonalsidecutters,cutandremove
the cable-ties from the control winding hard insulation
tube and tap-changer top bracket assembly. (See
Figure 38.)
20
Figure 39.
Tap-changer and side channel fastener.
!
!
SAFETY
FOR LIFE
4. UsingaPhillipsheadscrewdriver,loosenandremove
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
E1
E3
E2
G
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.
21
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. UsingaPhillipsheadscrewdriver,loosenandremove
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.
22
!
SAFETY
FOR LIFE
S225-12-1
4. Disconnect and remove the blue and red strip leads
from the 40-ohm resistor. These connections are
push-on connections. (See Figure 47.)
40Ohm 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. Usinga5/32Allenwrenchloosenandremovethetwo
pan head Allen screws from the tap-changer-mounting
bracket. (See Figure 48.)
7. Usinga5/32Allenwrench,loosenandremovethepan
head Allen screws fastening the front drive assembly
section and the contact panel assembly section
together. (See Figure 49.)
Screws
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.
23
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