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Eaton QD5 Manual

Eaton QD5 Manual

Quik-drive voltage regulator tap-changer
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Voltage Regulators
MN225012EN
QD5 Quik-Drive voltage regulator tap-changer manual
Effective March 2016
Supersedes S225-12-2 February 2013
COOPER POWER
SERIES

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  • Page 1 COOPER POWER Voltage Regulators SERIES Effective March 2016 MN225012EN Supersedes S225-12-2 February 2013 QD5 Quik-Drive voltage regulator tap-changer manual...
  • Page 2 CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to...

  • Page 3: Table Of Contents

    ....19 QD5 TAP-CHANGER REVERSING NEUTRAL STATIONARY CONTACT ASSEMBLY KIT 5791646A26 ..QD5 TAP-CHANGER MAIN STATIONARY CONTACT ASSEMBLY KIT 5791646A24 .

  • Page 4: Safety Information

    FOR LIFE FOR LIFE Eaton meets or exceeds all applicable industry standards relating to product safety in its Cooper Power™ series products. 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 Eaton employees involved in product design, manufacture, marketing, and service.

  • Page 5: Product Information

    “Blue Lead” Raise = 7 .2 ohms Motor Ground “ White Lead” to ” Red Lead” Lower = 7 .2 ohms Raise “Blue Lead” to Lower “Red Lead” = 13.9 ohms QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 6: Motor Capacitor

    Motor capacitor Holding switch The QD5 tap-changer motor uses a 50 μF , 440 Vac, and Eaton's tap-changers are equipped with a holding switch 100°C motor capacitor. The motor capacitor is not part of to assure that a tap-changer operation is completed. This the tap-changer assembly;...

  • Page 7: Contacts

    Main movable contacts Figure 7. Figure 8. Neutral reversing stationary. The set of reversing switch stationary contacts on the QD5 tap-changer consist of three individual stationary contacts, a VL-Reversing Stationary, a Reversing Neutral Stationary, and a VR-Reversing Raise Stationary contact. The reversing...

  • Page 8: Main Reversing Movable Contacts

    VL stationary contact. The reversing movable will be bridging the VL and VN when moving in the lower direction. Drive pinion cam returns to the open area opening the holding switch. 10. Tap Change is completed. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 9: Maintenance, Service And Troubleshooting

    PI Drive Face ary Contacts Geneva Gear Holding Switch Reversing Segment Assembly Actuator Arms Drive Pinion Cam Reversing Actuator Main Stationary Contact Safety Switches Neutral Switch Figure 10. Tap-changer front view. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 10 Contact VL -Reversing Stationary Contact #7 Stationary Neutral Stationary #1 Main Stationary Contact #6 Stationary #2 Stationary #3 Stationary #5 Stationary #4 Stationary Figure 11. Back side of QD5 tap-changer. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 11 Motor Chain Brake Assembly Logic Switches Drive Sprocket Gear Raise Safety Switch Reversing Segment Neutral Switch Actuator Lower Safety Switch Figure 12. Inside drive frame. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 12 Drive Sprocket Gear Geneva Gear Reversing Segment Actuator Movable Contact Actuator Finger Figure 13. Drive frame with Geneva gear. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 13 Stationary Contact VL Stationary Contact Main Stationary Contact #8 Main Movable Contacts Main Stationary Contact #1 Inner Collector Ring Movable Contact Insulator Arm Outer Collector Ring Figure 14. Inside contact assembly. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 14: Qd5 Tap-Changer Schematic

    QD5 tap-changer schematic Figure 15. QD5 wiring schematic. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 15 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. Figure 16. Contact life stages. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 16 Figure 19. QD5 tap-changer movable contact. Figure 20. QD5 tap-changer stationary contact. End of contact life stage Figure 21. QD5 tap-changer movable contact. Figure 22. QD5 tap-changer stationary contact edge. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 17: Qd5 Tap-Changer Torque Reguirements

    Figure 23. QD5 tap-changer stationary contact torque requirements. 30–40 in-lbs (3.4–4.5 Nm) 180–192 in-lbs (20.3–21.6 Nm) 12–18 in-lbs (1.4–2.0 Nm) 4–5 in-lbs (0.5–0.6 Nm) Figure 24. Front drive torque requirements. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 18 65–75 in-lbs (7.5–8.5 Nm) Figure 25. Motor to mounting bracket torque Figure 27. Geneva gear torque requirements. requirements. 180–192 lb-in (20.2–21.6 Nm) Figure 26. Motor pivot stud and locknut torque requirements. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 19 9/16 inch Deep-well Socket • 1/4 inch Wrench • Small Flat-blade Screwdriver or 5/32 inch Allen Wrench • Standard 8-inch Long Flat-blade Screwdriver • Torque Wrench in-lbs • Loctite ® 243™ Threadlocker • QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 20 See Figures 30 and 31. Reversing Bushing Actuator Reversing Actuator Shaft Figure 32. Removal of bushing. Figure 30. Removal of actuator arm. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 21 See Figure 36. Screw Reversing Sta- Logic Switch tionary Contact Hardware Figure 34. Removal of logic switch. Figure 36. Reversing neutral stationary contact. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 22 Slot Movable Contact Assembly Figure 38. Rotating of reversing movable contact. Figure 40. Reinstalling reversing movable contact. 10. Remove the reversing neutral stationary contact assembly from the tap-changer contact panel. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 23: Qd5 Tap-Changer Reversing Movable Contact Assembly Kit 5740785B72Er

    See Figure 42. Neutral Stationary Contact Movable Contact Assembly Neutral Stationary Studs Figure 44. Reinstalling neutral stationary and hardware. Figure 42. Engaging contacts. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 24 Tighten the bolts to a torque of 30–40 in-lbs (3.4–4.5 Nm). See Figure 46. Bushing Hardware Figure 48. Positioning the reversing movable with the bushing. Figure 46. Reinstalling bushing. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 25 B. The reversing movable contact is located on the reversing neutral stationary contact. See Figure 51. Reversing Neutral Stationary Contact Reversing Movable Contact Figure 51. Neutral position for reversing movable. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 26 C. The pinion cam is pointing to the right over the holding switch actuator. See Figure 52. Holding Switch Actuator Pinion Cam Figure 52. Neutral position for position indicator pinion cam and holding switch. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 27: Qd5 Tap-Changer Reversing Neutral Stationary Contact Assembly Kit 5791646A26

    Torque Wrench, in-lbs • Small flat-blade Screwdriver or 5/32 inch Allen Wrench • Reversing 8" Long flat-blade Screwdriver • Actuator ® Loctite 243™ Threadlocker • Figure 55. Reversing actuator arm removal. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 28 Remove the bushing from the reversing actuator shaft. See Figure 57 . Tap- Changer Plate Reversing Reversing Movable Logic Switch Contact Bushing Figure 57. Removing reversing movable contact bushing. Figure 59. Reversing logic switch removal. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 29 Movable Movable Contact Assembly Figure 63. Removing reversing movable contact. Figure 61. Reversing neutral stationary contact hardware. 10. Remove the reversing neutral stationary contact assembly from the tap-changer contact panel. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 30 Reversing Neutral Movable Stationery Contact Contact Button Contact Panel Reversing Movable Contact Tube Slot Figure 67. Stationary and movable contact alignment. Figure 65. Reassembly of neutral stationary and reversing movable. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 31 See Figures 71 and 72. Reversing Segment Arm 4-40x1.25 Screws Reversing Logic Switches Reversing Segment Gear Shaft Figure 71. Placement of reversing segment arm. Figure 69. Reversing logic switch mounting. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 32 Figure 74. Neutral position for main movable contacts. 10. Once the work has been completed, place the tap- changer in the neutral position. 3/8-16 Self- Locking Nut Reversing Segment Shaft Figure 73. Reversing segment fastening. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 33 C. The pinion cam is pointing to the right over the holding switch actuator. See Figure 76. Holding Switch Actuator Pinion Cam Figure 76. Neutral position for position indicator pinion cam and holding switch. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 34: Qd5 Tap-Changer Main Stationary Contact Assembly Kit 5791646A24

    Each QD5 tap-changer has nine main stationary contacts. Of these, eight are tap contacts and one is the neutral stationary contact. See Figure 78. Figure 79. Removal of contact hardware. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 35 Using a torque wrench, tighten the nuts to a torque of 80–90 in-lbs (9.0–10.2 Nm). See Figure 81. Washer Figure 81. Contact hardware installation. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 36 See Figure 85. Movable Contacts Figure 83. Neutral position for main movable contacts. Holding Switch Actuator Pinion Cam Figure 85. Neutral position for position indicator pinion cam and holding switch. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 37: Qd5 Tap-Changer Vl Reversing Stationary Contact Assembly Kit 5791646A25

    Torque Wrench in-lbs • rotation. 3/8 inch Socket • Installation procedure VL reversing stationary contact removal and installation Each QD5 tap-changer has one VL reversing stationary contact. See Figure 87 . QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 38 Remove the VL reversing stationary contact from the contact assembly panel. See Figure 90. Once the work has been completed, place the tap- changer in the neutral position. Tapered Edge Figure 90. VL reversing stationary contact removal. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 39 See Figure 94. Movable Contacts Figure 92. Neutral position for main movable contacts. Holding Switch Actuator Pinion Cam Figure 94. Neutral position for position indicator pinion cam and holding switch. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 40: Qd5 Tap-Change Vr Reversing Stationary Contact Assembly Kit 5791646A27

    Each QD5 tap-changer has one VR reversing stationary contact. Note that in the photo, the nylon separating bar has been removed. It is not necessary to remove the bar to perform these steps. See Figure 96. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 41 If the tapered edge is facing in the wrong direction, the stationary VL contact is being used. See Figure 99. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 42 Figure 101. Neutral stationary contact. B. The reversing movable contact is located on the reversing neutral stationary contact. See Figure 102. Reversing Neutral Stationary Reversing Movable Contact Figure 102. Neutral position for reversing movable. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 43: Qd5 Tap-Changer Motor Replacement Procedure Kit 57A63675100A

    3/8" socket on a ratchet until the tap-changer is in the neutral position. Contacts in the Neutral Position Figure 104. Tap-changer motor replacement kit. Figure 105. Neutral position. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 44 Refer to Figure 113. Motor Pivot Stud Blue Motor Wire Motor Pivot Terminal Board Lock Nut Red Motor Wire Belleville Washer Figure 107. Disconnection of wires. Figure 109. Motor pivot stud design. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 45 Remove the motor mounting plate from the old motor. Refer to Figure 113. Molded Back Panel Motor Motor Mounting Mounting Plate Screw Plate Figure 111. Removal of the motor. Figure 113. Removal of the motor plate. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 46 Figure 114, follow Step 14. Molded Back Panel Motor Relief Area Motor Chain Adjustment Bracket Outer Snap Ring Figure 115. Placement of the sprocket. Figure 117. Locating motor. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 47 Figure 118. Motor positioning. Fiber Washer Figure 120. Motor pivot bolt. Motor Pivot Bolt Motor Pivot Stud Lock Nut Hex Spacer Figure 119. Motor pivot stud. Figure 121. Placement of motor pivot bolt. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 48 1/16 (1.5 mm) of an inch. Attach the ring tongues to the motor connection points on the terminal board as described above. Refer to Figure 123. Figure 123. Wiring connections. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 49 Figure 125. Neutral stationary contact. B. The reversing movable contact is located on the reversing neutral stationary contact. See Figure 126. Reversing Neutral Stationary Reversing Movable Contact Figure 126. Neutral position for reversing movable. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...

  • Page 50: Qd5 Tap-Changer Main Movable Contact Replacement Kit 5740785B33

    129. If the tap-changer is not in the neutral position, turn the shaft on the back of the motor shaft using a 3/8" socket on a ratchet until the QD5 tap-changer is in the neutral position. Remove the number 1 stationary contact from the molded panel using a 9/16"...
  • Page 51 Using a 3/8” socket on a ratchet, rotate the shaft on the back of the motor to move the movable contacts into the space opened up when the number 1 stationary Nut on the end contact was removed. of the Main Shaft Main Shaft Figure 133.
  • Page 52 Refer to Figure 137 . washer under the nut. Movable Contact Assemblies Button Head Screw Figure 137. Removal of shaft. Figure 139. Movable contact removal from insulating arm and rings. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 53 Contact Button Contact Shunt Button Contact Spring Contact Ring Aligned with Button Contact Figure 143. Installing rings into P1 and P2. Figure 141. Installation of movable contacts and of rings. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 54 The Geneva gear should be rotating freely on the shaft. See Figures 147 and 148. Figure 145. Ring and P1 contacts. Figure 147. Geneva gear rotating freely on main shaft. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 55 See Figure 149. Neutral Stationary E-Clip Washer Movable Contact Aligned Figure 149. Locating of e-clip. Figure 151. Main movable contact aligned with neutral stationary for installation of the actuator finger. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 56 26. Reinstall the number 1 stationary contact and tighten Reversing the nuts to a torque of 80–90 in-lbs (9.0–10.2 Nm). Movable Contact Figure 154. Neutral position for reversing movable. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 57 C. The pinion cam is pointing to the right over the holding switch actuator. See Figure 155. Holding Switch Actuator Pinion Cam Figure 155. Neutral position for position indicator pinion cam and holding switch. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 58 This page is intentionally left blank. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 59 This page is intentionally left blank. QD5 QUIK-DRIVE TAP-CHANGER INSTALLATION AND MAINTENANCE INSTRUCTIONS MN225012EN March 2016...
  • Page 60 2300 Badger Drive Waukesha, WI 53188 Eaton.com/cooperpowerseries © 2016 Eaton All Rights Reserved Eaton is a registered trademark. For Eaton's Cooper Power series product Printed in USA information call 1-877-277-4636 or visit: Publication No. MN2225012EN All trademarks are property www.eaton.com/cooperpowerseries.

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