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MOVEABLE

ARCING

CONTACT

MOVEABLE

ARCING

CONTACT

NEW CONTACTS

END OF CONTACT LIFE STAGE

Contact erosion is a function of many variables such as tap voltage load current and

power factor reactor design and tapped winding design. MEPS employs both equalizer

and conventional windings which will produce the typical erosion patterns above.

INTERMEDIATE STAGE

STATIONARY

CONTACT

STATIONARY

CONTACT

EROSION

NEW CONTACTS

ARCING

INSERT

ARCING

INSERT

EROSION HAS PROGRESSED TO A POINT WHERE

BURNING CAN OCCUR ON COPPER

CONVENTIONAL

WINDING PATTERN

EQUALIZER

WINDING PATTERN

MINIMUM OF ORIGINAL

CONTACT SURFACE REMAINS

Figure 16. Contact life stages.

Contact erosion patterns

Copper

QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS

MN225012EN March 2016

Summary of Contents for QD5

Page 1: ...QD5 Quik Drive voltage regulator tap changer manual COOPER POWER SERIES Voltage Regulators MN225012EN Effective March 2016 Supersedes S225 12 2 February 2013...

Page 2: ...SS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON THE CONTENTS O...

Page 3: ...erating sequence 4 MAINTENANCE SERVICE AND TROUBLESHOOTING 5 QD5 TAP CHANGER SCHEMATIC 10 QD5 TAP CHANGER TORQUE REGUIREMENTS 13 QD5 TAP CHANGER REVERSING MOVABLE CONTACT ASSEMBLY KIT 5740785B72ER 19...

Page 4: ...orking around high voltage lines and equipment and support our Safety For Life mission Safety information DANGER Hazardous voltage Contact with hazardous voltage will cause death or severe personal in...

Page 5: ...o 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...

Page 6: ...hich will affect the operation of the tap changer Special fixtures are used to assemble the holding switch assembly to ensure that alignment gap setting requirements are met Motor capacitor The QD5 ta...

Page 7: ...stationary contact at all times The main stationary contacts bolt to collector rings The collector rings insert between a set of button contacts that are able to hold a continuous current path throug...

Page 8: ...are use to provide a safety switch circuit to prevent the tap changer from tapping beyond 16R and 16L acting as a fail safe to the mechanical stop The switches enable the tap changer to step back fro...

Page 9: ...ator Figure 10 Tap changer front view Control Winding Terminal Board Holding Switch Assembly Drive Pinion Cam Main Stationary Contact Safety Switches PI Drive Face Geneva Gear Brake Assembly Main Term...

Page 10: ...ionary 2 Stationary 1 Main Stationary Contact VL Reversing Stationary Contact Neutral Stationary VR Reversing Stationary Contact 8 Stationary 4 Stationary Reversing Neutral Stationary Contact 6 QD5 QU...

Page 11: ...r Brake Assembly Raise Safety Switch Neutral Switch Lower Safety Switch Reversing Segment Actuator Drive Sprocket Gear Logic Switches Chain 7 QD5 QUIK DRIVE TAP CHANGER INSTALLATION AND MAINTENANCE IN...

Page 12: ...rive frame with Geneva gear Geneva Gear Reversing Segment Actuator Movable Contact Actuator Finger Drive Sprocket Gear 8 QD5 QUIK DRIVE TAP CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN...

Page 13: ...Contact Main Movable Contacts Main Stationary Contact 1 Movable Contact Insulator Arm VR Stationary Contact Neutral Main Stationary Contact Main Stationary Contact 8 Inner Collector Ring Outer Collec...

Page 14: ...QD5 tap changer schematic Figure 15 QD5 wiring schematic 10 QD5 QUIK DRIVE TAP CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

Page 15: ...l produce the typical erosion patterns above INTERMEDIATE STAGE STATIONARY CONTACT STATIONARY CONTACT EROSION EROSION NEW CONTACTS ARCING INSERT ARCING INSERT EROSION HAS PROGRESSED TO A POINT WHERE B...

Page 16: ...shown in Figures 21 and 22 must definitely be replaced The figures below show actual contacts after various stages of contact erosion New contacts Figure 17 QD5 tap changer movable contact Figure 18 Q...

Page 17: ...ure 24 Front drive torque requirements 30 40 in lbs 3 4 4 5 Nm 4 5 in lbs 0 5 0 6 Nm 180 192 in lbs 20 3 21 6 Nm 12 18 in lbs 1 4 2 0 Nm Stationary Contact Reversing Stationary Contact 80 90 in lbs 9...

Page 18: ...e 26 Motor pivot stud and locknut torque requirements 18 20 lb in 5 2 2 Nm 180 192 lb in 20 2 21 6 Nm Figure 27 Geneva gear torque requirements 65 75 in lbs 7 5 8 5 Nm 14 QD5 QUIK DRIVE TAP CHANGER IN...

Page 19: ...e tap changer Parts supplied Item Part Number Description Qty 1 0740785B72 Reversing Movable Contact 1 Tools required Ratchet Wrench 3 8 inch Socket 7 16 inch Socket 9 16 inch Deep well Socket 1 4 inc...

Page 20: ...7 16 wrench loosen and remove both bushing mounting bolts See Figure 32 4 Remove the bushing from the reversing movable contact shaft See Figure 32 Figure 31 Bushing Figure 30 Removal of actuator arm...

Page 21: ...Use a 9 16 wrench to loosen and remove the nuts and flat washers from both of the reversing neutral stationary contacts on the back of the tap changer contact panel See Figure 36 Figure 34 Removal of...

Page 22: ...actuator shaft into the new reversing movable contact assembly See Figure 39 13 Place the reversing movable contact into the mounting slot in the tap changer front panel aligning the movable contact...

Page 23: ...act panel Align the movable contact assembly so that the reversing movable tube aligns with and goes through the hole in the contact panel At this point the stationary contact and movable contact shou...

Page 24: ...ent arm onto the reversing actuator shaft Align the square portion of the shaft with the square hole in the arm If needed place a screwdriver through the movable contact tube and push the shaft forwar...

Page 25: ...Figure 51 Figure 50 Neutral stationary contact position for main movable contacts Figure 51 Neutral position for reversing movable Reversing Movable Contact Reversing Neutral Stationary Contact 21 Pla...

Page 26: ...e holding switch actuator See Figure 52 Figure 52 Neutral position for position indicator pinion cam and holding switch Pinion Cam Holding Switch Actuator 22 QD5 QUIK DRIVE TAP CHANGER INSTALLATION AN...

Page 27: ...tion procedure Removing existing contact assembly Note N Retain all hardware 1 Hold the reversing movable contact assembly to prevent it from moving Using a 9 16 wrench loosen and remove the reversing...

Page 28: ...mounting screws See Figures 58 and 59 Figure 57 Removing reversing movable contact bushing Bushing Reversing Movable Contact Tap Changer Plate Figure 58 Logic switch removal Reversing Logic Switch Mo...

Page 29: ...ovable contact assemble disengages from the reversing neutral stationary contact and remove it from the tap changer See Figure 63 10 Remove the reversing neutral stationary contact assembly from the t...

Page 30: ...able contact assembly until the middle button contact is fully engaged in the center of the reversing stationary contact blade See Figure 66 4 Slide the stationary and movable contact assembly toward...

Page 31: ...reversing segment arm onto the reversing actuator shaft Align the square portion of the shaft with the square hole in the arm If needed place a screwdriver through the movable contact tube and push th...

Page 32: ...her components are aligned in the neutral position 2 Confirm that the regulator is in the neutral position A Main movable contacts are located on the neutral stationary contact which is located at the...

Page 33: ...ding switch actuator See Figure 76 Figure 75 Neutral position for reversing movable Reversing Movable Contact Reversing Neutral Stationary Contact Figure 76 Neutral position for position indicator pin...

Page 34: ...to Service Information MN225026EN General The purpose of this replacement kit is to provide the parts and installation instructions for replacing the main stationary contacts on a QD5 Quik Drive tap...

Page 35: ...o be replaced 7 When the movable contacts are located on the stationary contact to be replaced the movable contacts must be moved Place a 3 8 socket onto the rear shaft of the motor See Figure 82 Usin...

Page 36: ...neutral position A Main movable contacts are located on the neutral stationary contact which is located at the 11 o clock position and under the reversing switch movable contact assembly See Figure 83...

Page 37: ...y contact assembly kit number 5791646A25 Refer to Service Information MN225027EN General The purpose of this replacement kit is to provide the parts and installation instructions for replacement of th...

Page 38: ...ered edge is facing in the wrong direction the stationary VR contact is being used See Figure 90 6 Place a flat washer and nut on each stud Use a 9 16 socket and ratchet to tighten the nuts on each co...

Page 39: ...the neutral position A Main movable contacts are located on the neutral stationary contact which is located at the 11 o clock position and under the reversing switch movable contact assembly See Figur...

Page 40: ...contact will begin to move QD5 tap changer VR reversing stationary contact assembly kit number 5791646A27 Refer to Service Information MN225028EN General The purpose of this replacement kit is to pro...

Page 41: ...stationary contact If the tapered edge is facing in the wrong direction the stationary VL contact is being used See Figure 99 6 Place a flat washer and nut on each stud Use a 9 16 socket and ratchet t...

Page 42: ...embly See Figure 101 B The reversing movable contact is located on the reversing neutral stationary contact See Figure 102 Figure 101 Neutral stationary contact Neutral Stationary Contact Main Movable...

Page 43: ...ench 1 4 inch Socket 3 8 inch Socket Phillips Head Screwdriver 2 Standard Blade Screwdriver Diagonal Cutters Loctite 243 Threadlocker External Snap Ring Pliers 0 200 in lbs 0 25 Nm Torque Wrench Crimp...

Page 44: ...shown in Figure 109 remove the motor pivot stud lock nut with a 9 16 socket on a ratchet Pull the motor off of the motor pivot stud make sure the Belleville washer stays on the motor pivot stud and d...

Page 45: ...nd sprocket Refer to Figure 112 Remove the motor from the tap changer assembly 9 Remove the four screws securing the motor to the motor mounting plate using a 1 4 socket on a ratchet Remove the motor...

Page 46: ...e motor replacement kit Do not fully tighten Make sure the motor wires are extending out of the top right of the motor when looking at the motor from the sprocket end Refer to Figure 116 Using a torqu...

Page 47: ...nting hole in the motor mounting plate Secure the motor mounting plate to the motor pivot stud with the locknut removed in Step 6 Refer to Figures 118 and 119 Using a torque wrench with a 9 16 socket...

Page 48: ...he end of each wire Crimp a supplied ring tongue connector to the end of each wire making sure the wire is fully inserted into the ring tongue connector The wire should not stick out of the connector...

Page 49: ...act which is located at the 11 o clock position and under the reversing switch movable contact assembly See Figure 125 B The reversing movable contact is located on the reversing neutral stationary co...

Page 50: ...rocedure 1 The tap changer should be secured to a bench before starting the replacement procedure if the tap changer has been removed from the unit 2 The tap changer should be in the neutral position...

Page 51: ...ft in place during this procedure Refer to Figures 133 and 134 7 Push the main shaft from the threaded end partially through the steel front plate of the tap changer so that the retaining ring on the...

Page 52: ...back of the molded panel Pull the contact rings out of the button contacts and remove the movable contact panel assembly Refer to Figure 138 11 Remove the three button head screws nuts and washers th...

Page 53: ...between the contact ring and the movable contact panel and align the holes Insert the three button head screws from the contact ring side of the assembly so the screw heads secure the contact ring in...

Page 54: ...ion it against the movable contact panel Refer to Figure 146 18 Line up the main shaft with the hole in the Geneva gear Push the shaft through Geneva gear until the threaded end of the shaft reaches t...

Page 55: ...aft the remainder of the way through the hole in the steel plate Secure the steel shaft to the steel panel using the 1 2 13 lock nut Use a 5 8 open end wrench to hold the steel shaft while securing th...

Page 56: ...locker to the two actuator finger bolts and then install the actuator finger It may be necessary to reposition the movable contact insulator arm if the holes do not quite line up See Figure 152 25 Pla...

Page 57: ...holding switch actuator See Figure 155 Figure 155 Neutral position for position indicator pinion cam and holding switch Pinion Cam Holding Switch Actuator 53 QD5 QUIK DRIVE TAP CHANGER INSTALLATION A...

Page 58: ...This page is intentionally left blank 54 QD5 QUIK DRIVE TAP CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

Page 59: ...This page is intentionally left blank 55 QD5 QUIK DRIVE TAP CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

Page 60: ...I 53188 Eaton com cooperpowerseries 2016 Eaton All Rights Reserved Printed in USA Publication No MN2225012EN March 2016 SAFETY FOR LIFE Eaton is a registered trademark All trademarks are property of t...

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