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Cooper S225-10-30, Installation, Operation And Maintanance Instructions

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Cooper S225-10-30 Installation, Operation And Maintanance Instructions Download Page 28

VR-32 Voltage Regulator Installation, Operation, and Maintenance Instructions

28

Figure 25 . 

Replacement parts for the Quik-Drive tap-changer QD-3 .

TC-LTC PI drive gear kit

Motor kit

Motor resistor

PI cam

Main stationary contact

Reversing stationary contact

Main movable contact assembly

Reversing movable contact

Quik-Drive holding switch assembly

Summary of Contents for S225-10-30

Page 1: ...unting 8 Placing Regulator into Service 10 Setting the Manual Limit Switches 12 Removal from Service 13 Construction and Operation 14 Standard Pole Mounted Regulator External Features 14 Position Indicator and ADD AMP Capabilities 15 Surge Protection 15 Internal Construction and Wiring 16 Quik Drive Tap Changers 20 Maintenance 23 Periodic Inspection 23 Untanking the Regulator 24 Retanking the Regu...

Page 2: ... Definitions This manual may contain four types of hazard statements DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate in...

Page 3: ... bushings should all be inspected for evidence of damage Should this initial inspection reveal evidence of rough handling damage or shortages it should be noted on the bill of lading and a claim should immediately be made with the carrier Also notify your Cooper Power Systems representative Handling and Storage Be careful during handing and storage of equipment to minimize the possibility of damag...

Page 4: ...it Cooper Power Systems regulators are supplied with the following standard features Dual rated 55 65 C rise ADD AMP capability Sealed tank construction Pressure relief device 18 minimum creep bushings with clamp type connectors MOV type external series arrester Shunt arrester mounting bosses Two aluminum laser etched nameplates Oil sight gauge Upper filter press connection Drain valve and oil sam...

Page 5: ...s Drain Valve and Oil Sampling Device Control with Tap Changer Motor Capacitor Junction Box Hand Hole Cover Cover Position Indicator Automatic Pressure Relief Device Control Cable with Quick Disconnect Plug Lockable Control Enclosure Bolt Down Provisions 4 Internal Assembly Lifting Eyes Upper Filter Press Connection Regulator Lifting Lugs Shunt Arrester Mounting Bosses Laser Etched Nameplates 2 se...

Page 6: ...ase to phase in closed delta can regulate a three phase three wire circuit When con nected in wye three regulators can regulate a three phase four wire multi grounded wye circuit Three regulators should not be connected directly in wye on three phase three wire circuits because of the probability of neutral shift unless the neutral is connected to the neutral of a wye connected bank of distributio...

Page 7: ...nnects Bypass Switches A B C S L 1 2 SL SL Load Source S L Figure 7 Regulating a three phase four wire multi grounded wye star circuit with three regulators Wye Series Arrester Shunt Arrester Disconnects Bypass Switch Bypass Switch Bypass Switch A B C N 1 2 3 SL SL SL Load Source S L S L S L Figure 8 Regulating a three phase three wire circuit with three regulators Closed Delta Shunt Arrester Disc...

Page 8: ...erial number found on the nameplate in order for the factory to reference the proper drawings and support information Mounting A regulator can be mounted on a pole a cross arm plat form or an elevating structure Regulators are normally provided with either pole mounting brackets or a substa tion base according to their rating An elevating structure can be provided to simplify substation installati...

Page 9: ... S225 10 30 SAFETY FOR LIFE Figure 10 Typical nameplate international 50 Hz design WAN22B2006AN 0737XXXXXX 692 1384 490 QD5 ...

Page 10: ...erating the control follow these control enclosure grounding procedures a If the enclosure is attached to the regulator tank or is remote from the tank but only accessible with a ladder connect the enclosure to the regulator to ground rod conductor b If the enclosure is accessible by personnel standing on the ground connect the enclosure directly to a ground mat and ground rod Failure to comply ca...

Page 11: ...tallation Operation and Maintenance Instructions for information on the CL 6 voltage regulator control including placing the control into service and initial programming Procedure B Regulator Bypass Disconnect Switch 1 Verify from regulator nameplate that control circuit is connected for proper regulated system voltage 2 Set control switch to MANUAL and power switch to EXTERNAL 3 Knife switches on...

Page 12: ...t voltages between 6480 V and 7920 V to be regulated effectively For voltages outside this range the regulator will not be able to return the voltage to the preselected level 7200 V Five percent regulation would accommodate circuit voltages between 6840 and 7560 V maintaining 7200 V for all voltages in this range To set the limit switches follow this procedure 1 Unlatch the captive bezel and swing...

Page 13: ...n source load SL disconnect switch if available NOTE If a regulator bypass disconnect is used in place of three separate switches steps 5 6 and 7 are carried out in one operation 13 S225 10 30 SAFETY FOR LIFE WARNING Explosion Hazard To stop the reg ulator on the neutral position the CONTROL FUNCTION switch should be returned to Off during the switching operation from positions 1R or 1L to positio...

Page 14: ...ct the regulator for operation at system voltages as shown in Tables 11 and 12 see Appendix Regulators rated 250 kVA and below are provided with welded on hanger brackets Regulators rated 167 kVA and above are provided with a base suitable for securing them to a pad or elevating structure All regulators are capable of being secured to elevating structures Regulators without a substation base are p...

Page 15: ...etent stop at each set ting provides positive adjustment Settings other than those stops are not recommended The raise and lower limits need not be the same value unless reverse power is possible The regulator will stay within the ADD AMP limits set forth by the control or the position indicator whichever limit is of a lower regulation percentage NOTE If the ADD AMP limits have been programmed int...

Page 16: ...re 13 allows all windings control shunt and series to be located in one coil assembly The load voltage is monitored by the control winding Regulators that have the series winding on the output load side Figure 14 have a separate potential transform er installed on the load side in lieu of a control winding The control winding or separate potential transformer sup plies a voltage for the tap change...

Page 17: ...anger itself The terminal board inside the junction box on the cover connects the internal tank wiring to the posi tion indicator and control The junction box wiring is shown in Figure 28 see Appendix 17 S225 10 30 SAFETY FOR LIFE Figure 15 Power circuit series transformer similar characteristics to Type A S SL L N 1 2 3 4 5 6 7 8 G G V1 C2 C1 E1 E2 E3 JBB G JBB S2 C O N T R O L Source VL VR Sourc...

Page 18: ...is ratio corrected by RCT1 as previ ously described The motor circuit is routed directly to the control front panel and the sensing potential is brought back to the top terminal strip through a series of removable jumpers and then to the front panel This scheme allows for the complete interchangeability with all the prior CL series controls and accompanying accessories Most voltage regulators are ...

Page 19: ... Circuit The motor circuit power is brought from the 6 A fuse to the circuit board through a set of back to back diodes to the control auto manual switch When this switch is set for automatic operation motor power is applied to the relays An appropriate relay closure then applies this power to the tap changer motor after first passing through the limit switch contacts in the position indicator Whe...

Page 20: ...Quik Drive tap changer is in the neutral position the reversing switch is open The reversing switch motion on the Quik Drive tap changer occurs as the main movable contacts enter or leave the neutral position The Main Contact Assembly engages the Reversing Switch either directly or through a linkage when the main switch is in the neutral position The first tap step in either direction rotates the ...

Page 21: ...onnect the neutral stationary con tacts to the reversing stationary contacts All stationary contact bodies are made of ETP copper Copper tungsten inserts are brazed to the edges of the stationary contacts since those contacts are subject to damage from impact or arcing duty The main movable contacts are constructed of a copper tungsten The mov able contacts are split to make connection on both sid...

Page 22: ...ontacts When the reversing arm rotates a logic switch is trig gered 8 The main interrupting contacts slide over and onto the number one stationary contact making a bridging position from contact N to contact 1 by way of the reactor 9 The pin on the Geneva drive gear exits the main Geneva contact drive assembly slot The main Geneva contact drive assembly stops moving and is rotationally locked 10 T...

Page 23: ... expires the regulator should return to band edge When this has been completed use the manual mode of operation to run the regulator several steps in the lower direction and then switch the control back to auto After the time delay the regulator should return to band edge If the regulator will not operate properly a substitute control can be tried before removing the unit from service Refer to Ser...

Page 24: ...m bly is available for operating an untanked regulator from the mounted control cabinet if the connection cable is not long enough Contact customer service for avail ability VR 32 Voltage Regulator Installation Operation and Maintenance Instructions 24 Figure 21 Untanking the voltage regulator WARNING Personal Injury Do not rely on the lifting apparatus when the internal assembly is lifted for ins...

Page 25: ...nd hole cover 9 Connect control cable to connector at the bottom of the junction box A If the unit is out of fluid more than four hours it must be rebaked at 66 C 150 F A unit can be rebaked a maximum of two times over its life B Within four hours after bake the unit should be retanked and filled with fluid C Retighten all hardware as needed It is recommended that a vacuum be pulled on the unit fo...

Page 26: ...or the Quik Drive tap changer QD 8 Quik Drive holding switch assembly Motor Chain Brake assembly Right hand reversing stationary contact Main reversing contact Left hand reversing stationary contact Main stationary contact Left hand movable contact Reversing movable contacts contact Right hand movable contact ...

Page 27: ...uik Drive tap changer QD 5 Quik Drive holding switch assembly Motor Brake assembly Right hand reversing stationary contact Left hand reversing stationary contact Main stationary contact Neutral stationary contact Main movable contact assembly Reversing movable contact ...

Page 28: ...ions 28 Figure 25 Replacement parts for the Quik Drive tap changer QD 3 TC LTC PI drive gear kit Motor kit Motor resistor PI cam Main stationary contact Reversing stationary contact Main movable contact assembly Reversing movable contact Quik Drive holding switch assembly ...

Page 29: ...e a corresponding measurement R3 to G and L3 to G on lower terminal board TB2 7 If the voltages measured in Step 6 are approximately the set voltage value then the fault is likely a loose con nection or a faulty terminal between TB1 and TB2 8 If Steps 2 4 and 6 do not provide voltage readings measure the voltage between VM and G on terminal board TB2 The reading should approximate the set voltage ...

Page 30: ...tch Check for voltage between V4 and G on TB1 This is the sensing circuit supplying voltage from the output of RCT1 on the rear panel If this voltage is more than 10 above or below the programmed voltage level setting of the control then the source is beyond the range of the regulator An absence of voltage would indicate a wiring problem such as an open somewhere in the control power supply If the...

Page 31: ...the indica tor will not display and the voltage will not regulate 2 Check FC 57 Reverse Current Sense Threshold and Load Current Metering PLUS If the load current is less then the reverse threshold current the indicators will not work and the regulator will not regulate 3 Check the polarity of the current transformer If the polarity is reversed the band indicators will not dis play Junction Box Tr...

Page 32: ...ry Output Voltage Does Not Match the Voltmeter Test Terminal Voltage When the output voltage at FC 6 is several volts different from what the voltmeter test terminals read check and verify the following function codes and settings for proper setting per the name plate 1 Verify FC 43 System Line Voltage Load Voltage is set per nameplate value 2 Verify FC 44 Overall PT Ratio is set per nameplate 3 V...

Page 33: ...e proper level is now activated 7 Access Function Code 48 Current Calibration Function 48 Enter 8 The display will show the current applied to the control This should correspond to the reading on the reference ammeter If the control reading is significantly differ ent greater than 0 6 mA error the calibration can be altered by pressing Edit then entering the correct cur rent as displayed on the re...

Page 34: ...rmation S225 11 1 CL 6 Series Control Installation Operation and Maintenance Instructions No Neutral Sync Signal Control not installed on regulator This most often occurs when powering up a control on a workbench The No Neutral Sync Signal means the con trol did not have a neutral signal during the self test during power up This can occur because there is no 120 V signal present on the neutral lig...

Page 35: ... Installation Operation and Maintenance Instructions Position Indicator Replacement 1 Verify that the tap changer is in neutral via the neutral light of the control and visual inspection of the tap changer If the position indicator does not also show neutral refer to instructions in Service Information S225 10 2 Regulator Tap Changer Operation and Maintenance 2 Remove the unit from service as outl...

Page 36: ... and proceed to check the proper movement and alignment of the PI 18 Index the PI to the 2 R position the scribe line on the coupling should be located ccw of the 12 o clock mark If the scribe line is inside the notch proceed to step 19 If the scribe line is outside of the ccw band notch of the PI back hub loosen the brass coupling set screws and rotate the coupling while holding the flex shaft un...

Page 37: ... on the polarity of the voltage applied to the L and SL bushings the control will operate in either the forward or reverse power flow direction If the control LCD annunciator does not indicate REV PWR the control is in the forward mode Reversing the voltage source leads on the L and SL bushings should cause the control panel Reverse Power LED to light indicating the control is in the reverse power...

Page 38: ...oltmeter reading at each tap position The change in voltage should be almost the same between each step 0 10 V If a substantial difference in any reading exists then there is a problem with the wind ings or their connection CAUTION Equipment Damage Be mindful of polar ity when using an external source Polarity reversal will result in control damage VR T201 0 CAUTION Equipment Damage Only an ac pow...

Page 39: ... and voltage source 4 Place a jumper rated for nominal current between the source S and the load L bushings A clamp on ammeter should be used to measure the current in the shorted current path 5 Ground the regulator tank 6 Using a variac apply impedance voltage at 16 raise to the source S and load SL bushings Raise the voltage until rated current is read on the ammeter Impedance voltages may be ob...

Page 40: ...nd voltage source 4 Place a jumper rated for nominal current tying all the bushings together 5 Close knife switch C on the back panel 6 Using the variac on the tester bring the voltage up to the desired test level Refer to the tester manufacturer instructions for guidelines on voltage test levels 7 Read the test value in mega ohms 8 Compare the reading with the baseline reading When a lower readin...

Page 41: ... Manual switch on Manual 10 Jog the Raise Lower switch in the direction the capacitive voltage was observed This should allow the tap changer to free itself Using the Raise Lower switch run the tap changer one or two steps Inspect the position indicator to verify that the indicating pointer is directly over a tap position mark If the pointer is not directly over a tap position mark jog the Raise L...

Page 42: ...nature of voltage regulators and the changing voltage at their out put terminals there is a voltage difference between the two units connected in parallel The method described below is designed to limit the circulating current to avoid overload ing of the equipment voltage regulators and transformers connected in the circulating loop Negative Reactance Method The current that will circulate in the...

Page 43: ...ircuit where screw terminals are present Procedure 1 Identify the raise R and lower L circuits coming into the control box from the regulator 2 Place a momentary short circuit across the raise and lower leads to discharge any residual capacitive volt age that may be in the motor circuit 3 Connect temporary capacitor leads Connect the tem porary capacitor leads across the raise R and lower L circui...

Page 44: ...00 42 12 Refer to the regulator nameplate for the BIL and refer to Table 8 or 9 to determine the correct ac potential voltage Starting at zero volts increase the voltage to the specified level within 15 seconds 13 The potential voltage is to be applied for 60 seconds The following may indicate a failure A A sudden increase in test circuit current B An indication of smoke and bubbles C An audible s...

Page 45: ...ng Voltage Internal PT RCT Tap Ratio Tap 1 2 3 4 5 6 7 6600 6930 54 9 1 127 119 2 58 1 1 6600 54 9 1 120 120 1 54 9 1 6350 54 9 1 115 120 6 52 6 1 6000 54 9 1 110 119 2 50 4 1 5500 54 9 1 104 115 5 47 6 1 11000 11600 E1 P1 91 6 1 127 119 7 96 9 1 11000 E1 P1 91 6 1 120 120 1 91 6 1 10000 E1 P1 91 6 1 110 119 1 84 0 1 6930 E2 P2 55 0 1 127 119 1 58 2 1 6600 E2 P2 55 0 1 120 120 1 55 0 1 6350 E2 P2 ...

Page 46: ... 8 220 240 270 320 500 250 275 300 338 400 667 335 369 402 452 536 833 418 460 502 564 668 1000 502 552 602 668 668 172 5 50 55 60 68 80 34500 345 100 110 120 135 160 517 150 165 180 203 240 690 200 220 240 270 320 Table 12 ADD AMP Capabilities of 60 Hz Ratings Load Current Ratings A Rated Rated Regulation Range Wye and Open Delta Volts kVA 10 8 75 7 5 6 25 5 Regulation Range Closed Delta 15 13 1 ...

Page 47: ... T2 T3 TCB1 G WHT TCB1 2 BLU TCB2 G WHT M T1 WHT M T3 RED M T2 BLU NL C WHT NL NO ORG RBS NC BLU BLK RLR NC BLU BLK RLL NO RED BLK LBS NC RED BLK RLR C BLU WHT RBS C BLU WHT RHS NO BLU RLL C RED WHT LBS C RED WHT LHS NO RED LHS C BLK RHS C BLK JBB S7 GRN WHT JBB R BLU JBB NL RED BLK JBB L GRN BLK JBB HS ORG T S1 WHT JBB S2 WHT TCB1 G WHT TCB1 7 BLU WHT TCB1 9 RED WHT TCB1 12 ORG TCB1 13 WHT TCB1 6...

Page 48: ...OTOR FUSE MOV METAL OXIDE VARISTOR MR MOTOR RESISTOR NL NEUTRAL LIGHT NLC NEUTRAL LIGHT CAPACITOR NLS NEUTRAL LIGHT SWITCH PD POTENTIAL OPENING DEVICE PF PANEL FUSE PS POWER SWITCH RCT RATIO CORRECTION TRANSFORMER RLS RAISE LIMIT SWITCH POSITION INDICATOR RLS RAISE LOGIC SWITCH TAP CHANGER RSS RAISE SAFETY SWITCH SCP SHORT CIRCUIT PROTECTION SD CURRENT SHORTING DEVICE TB CONTROL TERMINAL BOARD TCB...

Page 49: ... SUPERVISORY JBB G J4 7 TB2 G JBB S6 JBB S7 TB2 6 TB2 5 TB2 7 TB2 8 GRN J4 13 J4 2 J4 17 J4 10 J4 1 J4 16 SOURCE SOURCE EXTERNAL INTERNAL J4 11 12 6 3 J4 12 J4 14 5 4 OFF 2 11 1 10 C NC NC C C NC NC C EST MF PROVISION GROUND IN JUNCTION BOX INTERNAL VTT LLS RLS HSR HSL MC NLS IRS SENSE COUPLER CURRENT BLOCKING RELAY COUPLER ENABLE AUTO TRIACS CIRCUIT BOARD CL6 ACCESSORIES JUMPERS REMOVABLE FOR REM...

Page 50: ...995 and IEEE Standard C57 131 1995 are trademarks of the Institute of Electrical and Electronics Engineers Inc 1045 Hickory Street Pewaukee WI 53072 USA www cooperpower com SAFETY FOR LIFE Figure 28 Junction box wiring diagram Position Indicator Reset Solenoid RS Raise Limit Switch RLS Lower Limit Switch LLS JBB L GRN BLK 2 1 2 1 CC GRN BLK JBB R BLU CC BLU JBB G WHT JBB DHR ORG CC WHT BLK RLS 2 B...

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