Voltage Regulators Service Information S225-50-12 Back Panel Upgrade 10- to 18-Position Terminal Strip Installation Instructions Contents Product Information������������������������������������������������������ 1 Parts Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tools Required������������������������������������������������������������ 1 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3 Product Information Introduction Item 1 Figure 1. 18-Position Terminal Strip Replacement Assembly. Service Information S225-50-12 contains instructions for upgrading voltage regulator back panels from a 10-position to 18-position terminal strip. This upgrade is necessary to accommodate a CL4 and CL5 series control replacing a CL1, CL2, or CL2A control. ! Item 2 Item 3 Item 4 Item 5 Item 6 Read This Manual First Read and understand the contents of this manual and follow all locally approved procedures and safety practices before installing or operating this equipment. Additional Information These instructions cannot cover all details or variations in the equipment, procedures, or processes described nor provide directions for meeting every possible contingency during installation, operation, or maintenance. For additional information, contact your Cooper Power Systems representative. Acceptance and Initial Inspection Each 18-position terminal strip assembly is in good condition when accepted by the carrier for shipment. Upon receipt, inspect the shipping container for signs of damage. Unpack the 18-position terminal strip assembly and inspect it thoroughly for damage incurred during shipment. If damaged is discovered, file a claim with the carrier immediately. Handling and Storage Be careful during handling and storage of the 18-position terminal strip assembly to minimize the possibility of damage. If the assembly is to be stored for any length of time prior to installation, provide a clean, dry storage area. Standards ISO 9001:2008 Certified Quality Management System December 1999 • New Issue Figure 2. PARTS SUPPLIED Item Number Description Qty 1 18-Position Terminal Strip Assembly 1 2 10-32x3/8 Stainless Steel Machine Screw 1 3 #10 Split Lock Washer 1 4 6-32x3/8 Stainless Steel Machine Screw 1 5 #6 Split Lock Washer 1 6 .203x.437 Round Br. Washer 1 Tools Required Description Qty Screwdriver (Standard) 1 Phillips-Head Screwdriver 1 1/4 inch Nut-Driver 1 ! WARNING: Hazardous voltage. Electric power must be off to the control panel and back panel below the knife switches before performing the installation operations. Failure to do so may result in death or serious injury. 1 Back Panel 10- to 18-Position Terminal Strip Upgrade 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 sub­s titute for proper training or adequate experience in the safe operation of the equipment described. Only competent technicians, who are familiar with this equipment should install, operate and service it. A competent technician has these qualifications: nIs thoroughly familiar with these instructions. nIs trained in industry-accepted high- and low-voltage safe operating practices and procedures. nIs trained and authorized to energize, de-energize, clear, and ground power distribution equipment. nIs 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 understand all cautions and warnings. 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. ! DANGER: ! WARNING: Hazardous voltage. Contact with high voltage will cause death or severe personal injury. Follow all locally approved safety procedures when working around high- and low-voltage lines and equipment. 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. Hazard Statement Definitions This manual may contain four types of hazard statements: ! DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury. ! WARNING: Indicates a hazardous situation which, if not avoided, could result In death or serious injury. ! CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Caution: Indicates a hazardous situation which, if not avoided, could result in equipment damage only. 2 ! 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. ! 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 understand 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. ! S225-50-12 SAFETY FOR LIFE installation procedures SAFETY Removing 10-Position Terminal Strip 1. If the regulator and or control is energized perform the following steps before installing the upgrade. 2. Open the V1 and V6 (if present) knife-blade switches on the back panel. Close the C knife-blade switch to short the CT. See Figure 1. In some of the earlier regulators, the C shorting switch must to be pulled open in order to short the CT. 3. Locate the orange HS lead. Remove the HS lead terminal from the lower row of screws on TB1. 4. Performing the steps above will isolate the TB2 circuits. Orange HS Lead TB1 C Switch Wiring Harness TB2 10Position Terminal Strip Figure 3. Label Bar Mounting Screw Label Bar Mounting Screw Label Bar Control Faning Strip Figure 4. Adhesive Protector Figure 5. 2. Use a standard screwdriver and remove the two screws and spacers to remove the terminal board label bar. See Figure 4. 3. Use a standard screwdriver and remove the control fanning strip from the bottom row of screws on TB2. See Figure 4. Remove the control panel from the control box hinges. 4. Remove the control wiring harness terminals from the top of TB2. See Figures 3 and 4. 5. Use a standard screwdriver to remove the TB2 terminal board mounting screws, there could be as many as four screws. See Figure 4. Installation of 18-Position Terminal Strip V Switch TB2 Mounting Screw 1. TB2 is the 10-position terminal strip located at the bottom of the back panel. See Figure 3. TB2 Mounting Screw 1. Once the 10-position terminal board is removed from the back panel, remove the adhesive protector from the back side of the 18-position terminal strip assembly. See Figure 5. 2. Locate, center and place the 18-position terminal strip assembly on to the back panel with the white wire and metal jumper at the top. See Figure 6. The new terminal strip assembly should be placed in the same location as the old 10-position terminal strip. The DHR label should be located on the right hand side of the back panel with the terminal strip assembly installed. 3. Using a 1/4 inch nut-driver remove the nut and lockwasher on the label bar on the DHR end of the terminal board. Loosen the nut on the opposite end of the label bar. Remove the label bar from the terminal board stud on the DHR end. See Figure 7. 4. Wire the back panel wiring harness to the new TB2 terminal strip. The table below shows the wiring color code and label location for each lead. Color Code Terminal Label White G Black VS White/Black VM Red C1 Green C3 Orange HS Blue R3 White/Green L3 White/Red NL White/Orange DHR 5. Replace the label bar back onto the terminal board stud. Replace the lockwasher and nut and tighten the 1/4 inch nuts on both ends of the terminal board using a nut-driver. 6. Place the new control on the control box hinges. 3 Back Panel 10- to 18-Position Terminal Strip Upgrade Installation Instructions 7. Using either a standard or phillips-head screwdriver, loosen all 18 terminal board screws on the bottom row of the terminal board. White Lead Metal Jumper DHR 8. Place the control fanning strip on the bottom row of screws. The white/orange wire on the fanning strip should be located on the DHR terminal. See Figure 8. 9. Tighten all 18 screws on the fanning strip. 10. Connect the green ground lead on the control panel to the back panel. From the items supplied, select the appropriate hardware to be used for connecting the ground lead. See Figure 9. Figure 6. 11. Reconnect the orange HS lead back on to the terminal labeled HS on TB1. See Figure 5. Terminal Board Stud 12. To energize the front panel, the V knife-blade switches must be closed and the C knife-blade switch placed in the open operating position. Information Notes 1. The white jumper lead must be connected from J to G on TB2. 2. A metal jumper must be connected between terminals BR and G. This jumper must be in place for automatic operation. Another method to inhibit automatic operation is by setting FC 69 to Blocked. DHR Figure 7. 3. In a CL-1 series control the VM, motor supply, supplied by RCT2, means that your VM lead on TB2 will be coming from the terminal board at RCT2. Control Grounding Lead and Terminal 4. If you are replacing a CL-1 series control and the regulator is set up for reverse power flow and you want to use the present setup, which would include an internal differential PT and a third RCT. You must connect a lead from the terminal board on RCT 3 to TB2-V7 and remove the auxiliary reverse power flow panel. Control Fanning Strip 5. If you are replacing a CL-2 or CL-2A front panel and the regulator is set up for reverse power flow, and you want to use the present setup, that would include an internal differential PT and a second ratio correction transformer (RCT2). You must connect a lead from the terminal board on RCT2 to TB2-V7 and remove the auxiliary reverse power flow panel. 6. When replacing a CL-1, CL-2, CL-2A or CL-4 series control panels with a CL-5C, CL-5C you do not need to use the internal differential PT or RCTs for reverse power flow. Refer to the CL-5C or CL-5 series control manual, S225-10-10 for instruction on setting up for reverse power flow operations. White/Orange Wire Figure 8. Control Ground Lead Connection to Back Panel Figure 9. ! SAFETY FOR LIFE © 2010 Cooper Industries. All Rights Reserved. Cooper Power Systems is a valuable trademark of Cooper Industries in the U.S. and other countries. You are not permitted to use the Cooper Trademarks without the prior written permission of Cooper Industries. S2255012 Rev. 0 4 2300 Badger Drive Waukesha, WI 53188 USA www.cooperpower.com