FOR LIFE 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 pro- grams, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture, mar- keting and service.
Raise “Blue Lead” to Lower “Red Lead” = 54 ohms 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.
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It is important to use the correct size capacitor with the holding switch is operated by a pinion cam causing the QD3 tap-changer hanger. For example: If a 12 ufd is used holding switch lever to close in on either the raise or lower on a tap-changer that is being applied to a 50 Hz sys- micro-switches.
The reversing switch changes the polarity of the tapped Main stationary contact. winding. When the QD3 Quik-Drive tap-changer is in the neutral position; the reversing switch is open (not making The main stationary contact has two arcing tips, one on contact with either of the reversing stationary contacts).
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Contact 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 con- structed of reinforced thermoplastic engineered grade polymer providing these characterizes.
S225-10-30. formed, the regulator must be removed from service. Troubleshooting and service functions of the QD3 / T350 It is necessary to open the regulator for inspection of the tap-changer are performed with the regulator un-tanked tap-changer.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual Control Winding Terminal Board Position Indicator Drive Tube Neutral Position Reversing Raise Micro Switch Micro Switch Holding Switch Reversing Lower Assembly Micro Switch PI Drive Face Geneva Gear Drive Pinion Cam Motor Resistor Raise & Lower Tap Limit Switches Figure 10.
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#8 Stationary VR Reversing Stationary Contact Terminal Board Motor Neutral Stationary #7 Stationary VL Reversing Stationary Contact #1 Main Stationary Contact #6 Stationary #2 Stationary #5 Stationary #3 Stationary #4 Stationary Tapchanger Mounting Base Figure 11. Back side of QD3 Tap-changer.
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S225-12-1 SAFETY FOR LIFE Contact erosion Patterns 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 arc- ing duty is the most visible indication of wear. Figure 13 illustrates typical contact erosion patterns resulting from normal service.
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QD3 moveable contact. QD3 stationary contact. Intermediate Life Stage Figure 15. Figure 18. QD3 moveable contact. QD3 stationary contact edge. end of Contact Life Stage Figure 16. Figure 19. QD3 moveable contact, end of life. QD3 stationary contact edge, end of life.
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S225-12-1 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. 6.779-7.908 Nm 60-70 lb.-in. All 6 P1 & P2 connections 6.779-7.908 Nm 60-70 lb.-in.
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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.
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S225-12-1 SAFETY FOR LIFE 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 24-32oz.-in. 24-32oz.-in. .169-.255 Nm .169-.255 Nm 22-28 lb.-in. 22-28 lb.-in. 2.485-3.163 Nm 2.485-3.163 Nm Figure 24.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual QD3/T350 Neutral Position Neutral Switch Holding Switch Assembly Actuator Arm Tap position Indicator Holding Switch Lever Pinior Cam Lob Pointer Figure 26. Neutral Position. When identifying if the tap-changer is in the neutral posi-...
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S225-12-1 SAFETY FOR LIFE QD3/T350 Replacement Part Kit Pictures Figure 30. Motor resistor replacement kit 5791844A01. Figure 27. Main moveable contact assembly 5741325B04. Figure 28. Figure 31. Main stationary contact assembly 5791822A01. P.I. Drive cam replacement kit 5740783B21. Figure 29.
PART KIT INSTRUCTIONS The following instructions are documents/sections of this manual that supply guidance and instructions for replac- ing various parts of the QD3 tap-changer and for making repairs or for servicing the tap-changer. D o c u m e n t...
PRODUCT INFORMATION CONTACT ASSeMBLy KIT Introduction Kit 5741325B04 Cooper Power Systems QD3/T350 Main Moveable Con- tact Assembly Kit and installation instructions gives cus- tomers the ability and guidance to replace the main move- Refer to Service Information S225-50-42 able contacts during maintenance cycles when contact erosion has occurred to the point of needing replacement.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual INSTALLATION PROCeDURe Ta p - C h a n g e r R e m o v a l f r o m Voltage Regulator Cable Tie Figure 36. Kit part. 1. Remove the internal position indicator shaft from the tap-changer indicator drive tube.
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S225-12-1 SAFETY FOR LIFE 4. Using a Phillips head screwdriver, loosen and remove 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...
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 7. Remove the mounting bolts fastening the tap-changer- 2. Using a Phillips head screwdriver, loosen and remove mounting bracket to the top core clamp. (See Figure the three mounting screws fastening the position indicator micro switch hub to the front of the tap- 43.) Remove the tap-changer from the regulator and...
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S225-12-1 SAFETY FOR LIFE 4. Disconnect and remove the blue and red strip leads 7. Using a 5/32 Allen wrench, loosen and remove the pan from the 40-ohm resistor. These connections are head Allen screws fastening the front drive assembly push-on connections. (See Figure 47.) section and the contact panel assembly section together.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual Main Moveable Contact Removal 3. By hand, rotate the main moveable contact and Geneva gear assembly so that the moveable contact is and Re-assembly in the stationary one contact position. (See Figure 53.) Removing Main Moveable and Geneva Assembly 1.
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S225-12-1 SAFETY FOR LIFE 6. Remove the P1 and P2 slip ring from the moveable Installing New Main Moveable and Geneva contact and Geneva Gear Assembly by lifting the ring Assembly stud assembly upward on the opposite side of the 7.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 8. Place the second slip ring stud assembly over the first 10. Align the stud of the slip rings with the mounting holes ring assembly studs and the Geneva hub. Angle the in the contact panel. The studs on the slip ring that...
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S225-12-1 SAFETY FOR LIFE Tap-changer Re-Assembly 14. Rotate the main moveable contact Geneva gear assembly onto the neutral stationary contact located 1. Lay the contact panel assembly section flat on a table under the reversing switch assembly. (See Figure 63.) surface.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 4. Press both of the tap-changer assembly sections 3. Align the center hub of the main moveable contact together and stand up-right. (See Figure 69.) assembly with the center hole in the tap-changer drive assembly.
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S225-12-1 SAFETY FOR LIFE 6. Place the mounting bracket (see Figure 71) to the 7. Place the neutral position pointer lob (see Figure 73) base of the tap-changer assembly and fasten with into the main moveable contact hub located in the two pan head hex screw and tighten with a 5/32 Allen lower front center of the drive assembly panel.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 8. Fasten the tap position switch assembly to the front of 10. Place and fasten the reversing logic and neutral logic the drive panel assembly with three pan head Phillip micro switches on the upper left of the drive assembly screws.
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S225-12-1 SAFETY FOR LIFE 13. Check and set the tap-changer for neutral position. The tap-changer can be set for any tap position by rotating the pinion cam in either the clockwise or counter clockwise direction. For rotating to the neutral position, the reversing logic switch actuator must be in the center with the neutral switch arm depressed.
The purpose of this replacement procedure is to pro- Handling and Storage vide the parts and installation instructions for replac- ing the main stationary contacts on a QD3 Quik-Drive Be careful during handling and storage of the Station- Tap-changer. ary Contact Assembly to minimize the possibility of dam- age.
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TCB terminal board leads from the 14 hard insulation tube and tap-changer top bracket position terminal board located on the top right of the assembly. (See Figure 81.) QD3 tap-changer. (See Figure 83.) TABLE 7 Lead Color and Termination Points Lead Color...
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 7. Remove the mounting bolts fastening the tapchanger mounting bracket to the top core clamp. See (Figure 86.) Remove the tapchanger from the regulator and place on a work surface. Mounting Hardware Figure 84.
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S225-12-1 SAFETY FOR LIFE 2. Use a Phillips head screwdriver to loosen and remove 5. Lay the tapchanger assembly flat on a work surface the three mounting screws fastening the position indi- with the tap contact studs down on the surface. cator micro switch hub to the front of the tapchanger 6.
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Washer Nut 6. The above process is used for each of the eight station- ary contacts on the QD3 contact panel. QD3 has eight main stationary contacts all labeled with the tap number on the contact panel. Tap-Changer Re-Assembly Stationary 1.
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S225-12-1 SAFETY FOR LIFE Stationary Contact Panel Assemble Center Hole Figure 96. Stationary contact panel assembly. 2. Place and align the tapchanger drive assembly section on top of the contact panel assembly. (See Figure 97.) Figure 99. Drive assembly panel. Drive Panel Assembly 4.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 5. Insert four pan head Allen screws into the tapchanger 7. Place the neutral position pointer lob, see (Figure 104), assemblies. Two screws will mount the two tapchanger into the main moveable contact hub located in the lower assemblies and the terminal block bracket at the top of front center of the drive assembly panel.
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S225-12-1 SAFETY FOR LIFE 9. Position the position actuator arm between the center position and L by rotating the pinion counter clockwise. (See Figure 107.) This will allow for mounting the micro switches without interference with the micro switch arms. R Switch Pinion Actuator...
Standard Screw Driver Allen Wrench 1/8 inch Allen Wrench 5/32 inch The purpose of this replacement kit is to provide the parts and installation instructions for replacing the motor on a QD3 Allen Wrench 3/16 inch Quik Drive Tapchanger. 9/16 Socket...
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S225-12-1 SAFETY FOR LIFE 2. Use a pair of diagonal side cutters and cut and remove 4. Using a 1/8 inch Allen wrench, remove the three button the cable ties from the control winding hard insulation Allen head screws fastening the motor bracket to the tube and tapchanger top bracket assembly.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 6. Using a pair of diagonal side cutters, cut and remove 9. Lift the top bracket clearing the position indicator tube the two cable ties fastening the motor wires to the main and the main wiring harness. (See Figure 119.) harness.
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S225-12-1 SAFETY FOR LIFE New Motor Assembly 12. To remove the gear from the motor, use a standard screw driver to pry the gear off of the motor shaft. Place 14. Place the red, blue, and white motor leads through item the screwdriver between the motor and the gear.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 21. Position the top bracket so that the position indicator 18. Using a pair of needle nose pliers, press the "E" clip over drive tube and main wiring harness is through the bracket the motor shaft grove. The center "E" Clip point must be holes.
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S225-12-1 SAFETY FOR LIFE 23. Place the 5/32 inch button Allen head screws in the 27. Use two cable ties item #2, to fasten the motor leads to top bracket and front plate, tightening with a 5/32 Allen the main wiring harness. wrench.
QD3 Quik-Drive Voltage Regulator Tap-Changer Manual Resistor Removal Instructions QD3/T350 MOTOR ReSISTOR RePLACeMeNT KIT 1. Using a pair of needle nose pliers, remove the push on connections from each end of the resistor. The colors for the resistor wires are blue/red. (See Figure 133.) KIT NUMBeR 5791844A01 Refer to Service Information S2255037...
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S225-12-1 SAFETY FOR LIFE 3. Remove the mounting clip from the resistor. (See Figure 6. Press the loose mounting clip into the open end of the 135.) resistor. (See Figure 137.) Resistor Mounting Clip Resistor Mounting Clip Motor Resistor Resistor Figure 135.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 9. Push the blue/red wire pushon connectors onto each of the terminals on each end of the resistor. (See Figure 139.) Resistor Wire Connections Figure 139. Resistor lead connectors.
(See Figure 141.) The purpose of this replacement kit is to provide the parts and installation instructions for replacing the PI Drive Cam PI Cam on a QD3 Quik Drive Tapchanger. Mounting Screw PI Cam TABLE 13 Parts Supplied...
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual PI Cam Assembly 4. Remove the Sprocket Key from the PI Cam slot. (See Figure 143.) 6. Place the new PI Cam wave washer over the shaft. (See Figure 145.) 7. Place either the new sprocket key or the original sprocket key in the slot of the new PI Cam.
The purpose of this replacement kit is to provide the parts Standard Screwdriver and installation instruction for replacing the reversing sta- tionary contacts on a QD3 Quik Drive Tapchanger. The Torque Wrench inch pounds VR and VL reversing stationary contacts are symmetrical;...
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TCB terminal board leads from the 14 position ter- the cableties from the control winding hard insulation minal board located on the top right of the QD3 tap tube and tapchanger top bracket assembly. (See Figure changer. (See Figure 150.) 148.)
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S225-12-1 SAFETY FOR LIFE 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 151.) Tap Lead Connections Control winding E lead and (P lead if available) Connections.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual QD3/T350 Tap-Changer Assembly 3. Remove the tapping indicator position lob pointer from the tapchanger. The lob may have to be pried a little to Separation be removed. (See Figure 156.) 1. After removing the tapchanger from the regulator assembly, use a Phillips one point screwdriver to loos-...
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S225-12-1 SAFETY FOR LIFE 5. Lay the tapchanger assembly flat on a work surface 8. Lift the front drive assembly off of the contact assembly with the tap contact studs down on the surface. and set aside. (See Figure 160.) 6.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 4. Using a 9/16 wrench, or 9/16 socket and ratchet loosen Tap-Changer Re-Assembly and remove the nut, external lock washer, and flat wash 1. Lay the contact panel assembly section flat on a table for the VR and/or VL stationary contact.
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S225-12-1 SAFETY FOR LIFE 3. Align the center hub of the main moveable contact 4. Press both of the tapchanger assembly sections togeth- assembly with the center hole in the tapchanger drive er and stand upright. (See Figure 168.) assembly. (See Figures 166 & 167.) Contact Panel Drive Panel Main Moveable...
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 6. Place the mounting bracket, (see Figure 170), to the base of the tapchanger assembly and fasten with two pan head hex screw and tighten with a 5/32 Allen Wrench. (See Figure 171.) Drive Panel Figure 173.
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S225-12-1 SAFETY FOR LIFE 9. Position the position actuator arm between the center 12. Connect the blue wires with red strips to the 40ohm resistor by pushing the female connector on to the resis- position and L by rotating the pinion counter clockwise. (See Figure 175.) This will allow for mounting the micro tor terminals.
QD3 Quik-Drive Voltage Regulator Tap-Changer Manual QD3/T350 ReVeRSING INSTALLATION PROCeDURe MOVeABLe CONTACT AND NeUTRAL STATIONARy CONTACT ASSeMBLy KIT Kit Number 5741325B03 Refer to Service Information S2255044 GENERAL The purpose of this replacement procedure is to provide the instructions for replacing the main stationary contacts on a QD3 Quik Drive Tapchanger.
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2. Use a pair of diagonal side cutters cut and remove the the TCB terminal board leads from the 14 position cableties from the control winding hard insulation tube terminal board located on the top right of the QD3 tap and tapchanger top bracket assembly. (See Figure changer. (See Figure 184.) 182.)
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 5. Use a Phillips head screwdriver and needle noise pliers to disconnect the white E control winding leads and P Tap Lead leads if available from the seven position terminal board Connections located on the left top of the tapchanger. (See Figure 185.)
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S225-12-1 SAFETY FOR LIFE QD3/T350 Tap-Changer Assembly 10. Remove the tapping indicator position lob pointer from the tapchanger. The lob may have to be pried a little to Separation be removed. (See Figure 190.) 8. After removing the tapchanger from the regulator...
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 13. Using a 5/32 Allen wrench loosen and remove the two 15. Lift the front drive assembly off of the contact assembly pan head Allen screws from the tapchangermounting and set aside. (See Figure 194.) bracket.
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S225-12-1 SAFETY FOR LIFE 2. Push the contact stud through the mounting hole in the 4. Use a 9/16 wrench or deep well 9/16 socket and ratchet contact panel. (See Figure 196.) to remove the six nuts, lock washer, and flat washer fastening the P1 and P2 slip ring studs to the contact panel located in the center back of the stationary contact panel.
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 6. Rotate the reversing switch assembly, if not already 8. Pull out on the reversing moveable contact assembly rotated, so that the contact buttons are in the center removing form the contact panel. (See Figure 202.) space between the VR and VL stationary contacts as though in the neutral position.
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S225-12-1 SAFETY FOR LIFE 12. Align the Moveable Contact and Geneva Gear Assembly so that the moveable contacts align to where the number one stationary contact has been removed. (See Figure 204.) Moveable Higher Contact Mounting Assembly Shoulders Higher Mounting Shoulders Stationary Contact...
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 19. Replace the number 1 stationary contact by inserting 2. Place and align the tapchanger drive assembly section the contact stud into the contactmounting hole in the on top of the contact panel assembly. (See Figure contact panel.
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S225-12-1 SAFETY FOR LIFE 5. Insert four pan head Allen screws into the tapchanger assemblies. Two screws will mount the two tapchanger assemblies and the terminal block bracket at the top of the tapchanger. The other two screws are inserted in the mounting holes along both side centers of the tap...
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QD3 Quik-Drive Voltage Regulator Tap-Changer Manual 8. Fasten the tapposition switch assembly to the front of the drive panel assembly with three pan head Phillip screws. (See Figure 219.) Position Switch Assembly Screws Fastening Screws Figure 216. Bracket fastening. 7. Place the neutral position pointer lob, (see Figure 217), Figure 219.
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S225-12-1 SAFETY FOR LIFE 10. Place and fasten the reversing logic and neutral logic 13. Check and set the tapchanger for neutral position. micro switches on the upper left of the drive assembly The tapchanger can be set for any tap position by panel.
Retainer Ring GENERAL Slots The purpose of this replacement kit is to provide the parts and installation instructions for replacing the PI Drive Face Gear on a QD3 Quik Drive Tapchanger. P.I. Drive Gear TABLE 23 Parts Supplied Item Part Number...
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S225-12-1 SAFETY FOR LIFE 4. Slide the new P.I. Drive Gear onto the shaft matching up the gear teeth of the P.I. Drive Gear and the teeth of the miter gear. (See Figure 228.) P.I. Drive Gear Miter Gear Teeth P.I.
The purpose of this installation instruction is for replacing Top terminal post, vacant (No. 3 post) the holding switch on a QD3 Quik Drive Tapchanger. Red wire on center terminal post (No. 2 post) Black wire on bottom terminal post (com post)
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SAFETY FOR LIFE Installation of Holding Switch 3. Place the holding switch assembly on to the QD3 tap changer with the nylon actuator located at the 3 o’clock position or just to he right of the pinion cam. (See Figure 233.)
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