Eaton S225-50-6 Retrofit 12-Conductor Cable Installation Instructions
Advertisement
Advertisement
Voltage Regulators
Retrofit 12-Conductor Cable Installation Instructions
Item 12
Junction box installation parts
Item 18
Item 4
Item 1
Item 2
Control box installation parts
Item 16
Item 19
Control cable
Control cable detail
Item 7
Item 11
Item 10
Item 9
Item 5
Item 6
Item 15
Item 17
Item 3
Item 8
Item 13
Item 24
Item 23
Nut Gasket
Washer
Figure 1.
Kit parts and control cable.
Note: The control cable is sold as a separate item. Refer to
Table 2 for standard control cable lengths. The control cable length is determined by the control box option selected.
Contents
Safety Information .................................................. 2
Hazard Statement Definitions .................................
2
Safety Instructions ..................................................
2
Product Information ...............................................
3
Introduction ............................................................
3
Acceptance and Initial Inspection ...........................
3
Handling and Storage ..............................................
3
Quality Standards ...................................................
3
Service Information
S225-50-6
Table 1
Kit Parts Identification
12
15
17
9
10
11
5
6
3
4
7
Junction Box:
Item
1
2
18
Control Box:
Item
8
13
16
19
Description
Flat washer
Hex nut
Lockwasher
CT protector
Lead assembly (Green)
Lead assembly (Red)
Cable assembly
Nut
Washer
Gasket
Cable tie fastener
Lead assembly (White)
Machine screw #8-32
Adhesive-backed tie fastener
Description
Control box cable assembly
Pipe-coupling plug
Self-locking cable tie fastener
Mounting base
Installation Procedures .........................................
4
Junction Box Cable Removal .................................
4
Quick-Disconnect Cable, Junction Box Installation .
5
Control Box Cable Removal ...................................
7
Quick-Disconnect Cable, Control Box Installation ...
8
1
1
3
1
1
1
2
1
1
1
1
1
Qty
1
1
4
3
Qty
1
1
August 2008 • Supersedes 1/99
2
Retrofit 12-Conductor Cable Installation Instructions
!
SAFETY
FOR LIFE
SAFETY FOR LIFE
!
SAFETY
FOR LIFE
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 INFORMATION
The instructions in this manual are not intended as a substitute for proper training or adequate experi ence in the safe operation of the equipment described.
Only competent technicians, who are familiar with this equipment should install, operate, and service it.
Safety Instructions
Following are general caution and warning statements that apply to this equipment. Additional statements, related to specific tasks and procedures, are located throughout the manual.
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.
DaNGeR: Hazardous voltage. Contact with hazardous voltage will cause death or severe personal injury. Follow all locally approved safety procedures when working around high- and low-voltage lines and equipment.
G103.3
• Is trained in the care and use of protective equipment such as flash clothing, safety glasses, face shield, hard hat, rubber gloves, hotstick, etc.
Following is important safety information. For safe installation and operation of this equipment, be sure to read and under stand all cautions and warnings.
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.
G101.0
Hazard Statement 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: 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.
G102.1
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 injury.
CaUTION: Indicates a potentially hazardous situation which, if not avoided, may 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 under stand 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.
G122.3
!
SAFETY
FOR LIFE
S225-50-6
PROducT INFORMATION
Introduction
Service Information S225-50-6 provides the instructions for retrofitting a hard-wired Cooper Power Systems or
McGraw-Edison VR-32 voltage regulator with quickdisconnect cables. The quick-disconnect cables can be retrofitted on any McGraw-Edison or Cooper Power
Systems regulator with a junction assembly on the cover assembly.
Acceptance and Initial Inspection
This kit is thoroughly inspected at the factory. It is in good condition when accepted by the carrier for shipment.
Upon receipt of the regulator kit, a thorough inspection should be made for damage, evidence of rough handling, or shortages. 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.
Read This Manual First
Read and understand the contents of this manual and follow all locally approved procedures and safety prac tices before installing or operating this equipment. Read and understand the manuals detailing the installation and operation of the regulator and the regulator control used with the regulator. Refer to S225-10-30 VR-32
Voltage Regulator with Quik-Drive Tap-Changer Installation,
Operation, and Maintenance Instructions for information on the Cooper Power Systems voltage regulator with Quik-
Drive tap-changer. Refer to S225-11-1 CL-6 Series Control
Installation, Operation, and Maintenance Instructions for information on the CL-6 voltage regulator control.
Handling and Storage
Be careful during handing and storage of equipment to minimize the possibility of damage. If the regulator kit is not to be placed into immediate use, store the kit where the possibility of damage is minimized.
Quality Standards
ISO 9001:2000 Certified Quality Management System
Additional Information
These instructions cannot cover all details or variations in the equipment, procedures, or process described nor pro vide directions for meeting every possible contingency dur ing installation, operation, or maintenance. For additional information, please contact your Cooper Power Systems representative.
3
4
Retrofit 12-Conductor Cable Installation Instructions
INSTALLATION PROcEduRES
WaRNING: Hazardous Voltage. This procedure must only be performed on a regulator that has been removed from service. Failure to comply can cause serious injury or death.
VR-T224.0
3.
Using a standard screwdriver, remove all control cable and position indicator lead connections from the round terminal block JBB located in the back of the junction box. Refer to Figure 2.
4.
Using a pair of needle-nose pliers, disconnect the position indicator and control cable, green/black leads, from the male terminal with insulation sleeve. Refer to
Figure 2.
Remove the regulator from service before installing this kit. Only a regulator in the neutral position can be safely removed from service without interrupting load continu ity. It is recommended to use more than one method to determine the neutral position. Refer to the appropri ate voltage regulator manual for complete instructions on removing from service. Refer to S225-10-30 VR-32
Voltage Regulator with Quik-Drive Tap-Changer Installation,
Operation, and Maintenance Instructions for information on the Cooper Power Systems voltage regulator with Quik-
Drive tap-changer.
5.
Using a pair of needle-nose pliers, disconnect the blue lead from the position indicator and control cable.
6.
Using a pair of diagonal cutters, cut the tie fasteners and separate the position indicator and control cable leads. Refer to Figure 2.
Ground stud
Required Tools:
• Screwdriver (Standard)
• Diagonal cutter
• Needle-nose pliers
• 3/8" Wrench or nut driver
• 1 1/4" Open-end wrench
• 1 3/8" Open-end wrench
• Allen wrench
• Crescent wrench
Cable grip
Gasket
Washer
Figure 3.
Cable grip and ground stud.
Junction Box cable Removal
1.
Using a standard screwdriver, remove the junction box cover.
2.
Using an Allen wrench, remove the external flex shaft from the output shaft of the position indicator. Refer to
Figure 2.
7.
Using a 1 1/4" wrench, remove the cable grip nut inside the junction box. Refer to Figure 3.
8.
Remove the cable grip and control cable from the junc tion box.
JBB terminal block
Position indicator and control cable leads
Allen screws
Figure 2.
Junction box and control cable leads.
!
SAFETY
FOR LIFE
S225-50-6
Quick-disconnect cable, Junction
Box Installation
There are two procedures for installing the junction box quick-disconnection cable assembly. Refer to Figure 3.
Procedure 1: for junction boxes that have a ground stud on the back surface inside of the junction box.
Procedure 2: for junction boxes without a ground stud on the inside surface of the junction box.
Procedure 1: Junction Box cable
Installation
1.
Locate gasket (Item 11) and remove adhesive protec tive backing on one of the gaskets. Place the gasket around the cable entrance hole with the adhesive side down on the inside of the junction box. Refer to
Figure 3.
2.
Locate the second gasket (Item 11). The adhesive must be against the metal surface of the under side of the junction box around the cable entrance hole. Remove the protective backing and place the gasket with the slot offset 90° from the slot of the gasket in step 1.
3.
Place the lead side of the cable assembly (Item 7) through the cable entrance hole from the under side of the junction box.
4.
Place washer (Item 10) over the cable assembly leads and down against the gasket. Refer to Figure 3.
5.
Place nut (Item 9) over the cable assembly leads and start the nut on to the threads. Using a 1 1/4" openend wrench, tighten the nut down until snug. Refer to
Figure 3.
6.
Leads from the cable assembly and position indicator have ring tongue terminals. Connect leads from cable assembly and position indicator to C
Table 1.
1
and C
2
on the terminal block on the inside of the junction box; refer to
Table 1
10-Conductor Connections
Lead Color
White (Gounds)
Orange/Black
Connector
G
DHR
Black
Red
Green
Blue
Green/Black
Red/Black
Orange
Blue/Black
White/Black*
S
2
C 1
C 2
R
L
NL
HS
M
2
S
4
* White/Black lead is connected to S4 when an internal dif ferential PT is being used. Otherwise tie back and insulate the terminal.
7.
Connect green lead (Item 5) to C
2
and red lead (Item 6) to C
1
on the terminal block on the inside of the junction box.
8.
Using a pair of needle-nose pliers, connect the control cable and position indicator leads with push-on con nectors on to the clear insulated male connector. Refer to Figure 4 and Table 2.
Table 2
Push-On Connections
A
Position Indicator
Green/Black
Blue
B to Control Cable to Green/Black to Blue
Push-on connector
Figure 4.
Push-on connectors.
CT protector
Push-on connector
9.
On the back side of the junction box, remove the ground stud nut and white ground lead.
Figure 5.
CT Protector, side view.
Allen screw
Ground bracket
Screw
10.
Using the L-shaped bracket, place CT Protector
(Item 4) on to the ground stud. Refer to Figure 5.
11.
Place the ring tongue terminal of the ground lead over the stud followed by the nut and tighten. Refer to
Figure 4.
5
Retrofit 12-Conductor Cable Installation Instructions
TB 2
TB 1
Ground bracket
Procedure 2: Junction Box cable
Installation
In this option installing the junction box cable assembly is the same except for step 8 in option 1. In this case of an older regulator that does not have a ground stud on the back surface inside of the junction box, use the following process to assemble the CT Protector.
1.
Replace the grounding screw on the bottom of the CT
Protector grounding bracket (Item 4) with the #8-32 SS machine screw (Item 17). Refer to Figure 5.
Figure 6.
CT Protector, top view.
12.
Connect green lead push-on connector (Item 5) to CT protector (Item 4) at TB1. Connect red lead push-on connector (Item 6) on to CT Protector (Item 4) at TB2.
Refer to Figure 6.
13.
Using three cable tie fasteners (Item 12), tie the control cable leads and position indicator lead so that they are clear of interference with the external flex shaft.
14.
Verify that the position indicator pointer is on zero.
Place the external flex shaft on the output shaft of the position indicator and tighten the Allen screws with an
Allen wrench.
15.
Replace the junction box cover after inspecting that all connections are correct.
Figure 5.
CT Protector, side view.
Ground bracket
Screw
2.
Place the ring tongue terminal of the lead assembly
(Item 15) between the head of the screw and the ground pad on the CT Protector and tighten the screw.
CT protector and adhesive back for tie fastener
Figure 7.
Tie-fastener placement.
3 . Remove the adhesive protector on the adhesivebacked tie fastener (Item 18). Locate and place in the center on the inside surface of the back of the junction box with the fastener running parallel to the bottom of the box. Refer to Figure 7.
4.
Finish the junction box assembly step 9 through step 12 as stated for Procedure 1.
6
!
SAFETY
FOR LIFE
S225-50-6
Control Box Cable Removal
1.
Open the control cabinet and swing open the front panel.
2.
Using a pair of diagonal cutters, cut the tie fasteners holding the control cable leads to the mounting bases on the back panel. Refer to Figure 8.
TB 1
C switch
Control cable
4.
Using a 3/8" nut driver, remove the black lead from the top of V
1
knife blade switch . Remove the green lead from the top of the C knife blade switch and the red lead from the bottom of the C switch. Remove the white/black lead from the top of V
6
. Remove blue/black lead from the top of V 2 .
Cable grip
1 3/8" nut
V
1
switch
V
6
switch
Tie fastener
Figure 8.
Control cable leads.
3.
Using a standard screwdriver, remove the control cable leads on TB1. Refer to Table 3 for the control cable lead color and connector identification.
Table 3
Control Cable Connections
Lead Color
White
Orange
Blue
Green/Black
Red/Black
Orange/Black
Connector ID
G
HS
R
1
L
1
NL
DHR
Figure 9.
Cable grip.
5.
Use a 1 3/8" open-end wrench to remove the cable grip on the top of the control box. Refer to Figure 9.
6.
Remove the control cable from the control box.
7
Retrofit 12-Conductor Cable Installation Instructions
Quick-Disconnect Cable, Control
Box Installation
There are three options in installing the control retrofit cable in the control box. Determine which option is appropriate for the application; this will determine the cable length.
Option 1: Control Box, Bottom Entrance
Bottom entrance using the left hand knockout in the bot tom of the control box.
Option 2: Control Box, Side Entrance
Side entrance using one of the two knockouts on the right side of the control box.
Option 3: Control Box, Top Entrance
Top entrance that requires cutting a 1 5/16 inch diameter hole in the top of the control box.
The internal control box cable is designed extra long to allow for fitting a long box. The same internal control cable is used in all three options and requires that the excess lead length be shaped and tied in place with cable tie fas teners (Item 16).
The electrical connections are all the same in all three con trol box entrance options. The customer determines which option is best for their own application when deciding on which quick-disconnect control cable length to be used when retrofitting.
Standard quick-disconnect cable lengths are 19", 27", 31",
34", 40", 40", 46", 54", 6', 15', 20', 25', 30', 35', 40', 45', and 60'.
Determine the appropriate quick-disconnect cable to use to connect the junction box and the control box for
Option 1, Option 2, or Option 3.
Option 1: Control Box, Bottom Entrance
Measure the distance from the bottom side of the junc tion box to the bottom edge of the control box and add eight inches; select the nearest cable length. As a rule, the cable should never have a radius less than two times the diameter of the cable.
Note: The distance between the bottom of the junction box and the bottom of the control box is dependant on where the customer is planning to fasten the control box.
Option 2: Control Box, Side Entrance
Measure the distance from the bottom side of the junction box to either the top or bottom knockout on the right side of the control box and add eight inches; select the nearest cable length . The radius of the cable should never be less than two times the cable diam eter.
Note: The distance between the bottom of the junction box and the knockout is dependant on the location where the customer is planning to fasten the control box.
Option 3: Control Box, Top Entrance
Measure the distance from the bottom side of the junc tion box to the top of the control and select the nearest length.
Note: The distance between the bottom of the junction box and the top of the control box is dependent on the location where the customer is planning to fasten the control box.
Quick-disconnect cable, control Box
Assembly
1.
Connect the cable assembly-control box (Item 8) to the back panel. Refer to Figure 9.
2.
The control cable has two different connector types.
One end is a male connector that connects into the junction box. The other connector is a female con nector that connects to the control box. Remove the nut and washer from the female connector end of the cable.
3.
Place the external threaded connector through the entrance hole in the control box. The rubber gasket on the connector should be on the outside surface of the control box.
4.
From the inside of the control box, place the washer over the connector threads, then start and tighten the cable connector nut.
8
!
SAFETY
FOR LIFE
S225-50-6
1
Motor Capacitor
2
Cable Assembly,
Control Box
JBB-S
6
JBB-S
7
JBB-HS
JBB-G RLS-1
LLS-1 JBB-DHR
JBB-NL
G G HS R
1
R
1
L
1
L
1
NL
D
H
R
V
S
V
5
V
5
V
4
V
7
G G R
2
L
2
R
4
L
4
C
2
C
4
C
4
C
3
TB
1
JBB-C
1
JBB-S
4 JBB-S
2
1
PD
2
2
1
PD
2
1
1 2
SD
(C)
1
3 4
JBB-C
2
TB
2
-C
2
RCT
1
-120
TB
1
RCT
2
-G
-G SD
1
-2 TB
2
-C
3
RCT
2
RCT
1
TB
2
-C
1
PD
2
-2
TB
2
-V
7
RCT
TB
1
1
-G
-G
PD
1
-2
TB
1
-V
4
RCT
TB
8
2
-G
-4
133
127
120
115
110
104
G
133
127
120
115
110
104
G
RCT
2
RCT
1
1 2 3 4 5 6 7 TB
8
TB
2
-G
RCT
2
TB
8
-5
-120 TB
8
-4
TB
2
-J
TB
1
-VS
SD
1
-3
TB
1
-C
TB
1
-HS
3
TB
TB
1
-R
1
1
-L
1
TB
1
TB
-NL
1
-DHR
8 7 6 5 J V
9
V
7
BR G G V
S
V
S
V
M
C
1
C
3
HS R
3
L
3
NL DHR TB
2
Figure 10.
Control back-panel wiring.
9
Retrofit 12-Conductor Cable Installation Instructions
5.
Align the key slot of control box cable assembly (Item 8) with the key guide in the control cable connector.
6.
Insert the control box cable in to the control cable and tighten the cable fastener. Refer to Figures 10, 11, and
12 for the three entrance options.
7.
After installing the control box retrofit cable assembly and the control cable, shape the excess leads in the control box and secure using the self-locking cable tie fasteners (Item 16), three mounting bases (Item 19), three 32 x .375 machine screws (Item 6), and three #6 spit lockwashers. Refer to Figures 11, 12 and 13.
8.
After the old cable assembly is removed from the con trol box, there is an open hole in the top of the control box. Refer to Figures 14 and 15. Application of sealing compound to the threads of pipe coupling (Item 13) is recommended. Using a Crescent wrench, tighten the pipe plug.
Figure 14.
Control box coupling without pipe plug.
Pipe plug
Figure 11. bottom entry.
Figure 15.
Control box coupling with pipe plug.
Figure 12.
Side entry.
Figure 13.
Top entry.
10
!
SAFETY
FOR LIFE
S225-50-6
11
Retrofit 12-Conductor Cable Installation Instructions
!
SAFETY
FOR LIFE
©2008 Cooper US, Inc.
Crescent, Edison, and McGraw are valuable trademarks of Cooper US., Inc., in the U.S. and other countries. You are not permitted to use the Cooper
Trademarks without the prior written consent of Cooper US., Inc.
12
2300 Badger Drive
Waukesha, WI 53188 USA www.cooperpower.com

Public link updated
The public link to your chat has been updated.
Advertisement