Voltage Regulators
Service Information
Left-Hand Lower Limit Switch Replacement
Kit 5792236A02 for Polymer Position Indicator
S225-50-34
Contents
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . .
Removing Existing Left-Hand Lower Limit Switch. . .
Installing New Left-Hand Lower Limit Switch . . . . . .
Testing Installation and Operation . . . . . . . . . . . . . . .
1
2
3
3
5
7
PRODUCT INFORMATION
Introduction
Service Information S225-50-34 provides instructions for
use with Kit 5792236A02.
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 kit.
Additional Information
These instructions cannot cover all details or variations
in the equipment, procedures, or process 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 kit is completely assembled, tested, and inspected
at the factory. It is in good condition when accepted by
the carrier for shipment. Upon receipt, inspect the shipping
container for signs of damage. Unpack the kit and inspect
it thoroughly for damage incurred during shipment. If damage is discovered, file a claim with the carrier immediately.
Figure 1.
Left-hand lower limit switch assembly.
Product Description
Kit 5792236A02 is designed for replacement of the lefthand lower limit switch and slider arm in a polymer position
indicator. Refer to Table 1 for the kit part list.
Tools Required
•Phillips Screwdriver
•Needle-Nose Pliers
•AC Volt Meter or Multimeter
TABLE 1
Kit 5792236A02 Part List
Item
Part
Number
Description
Qty
1
5792236A02
Left-Hand Lower Limit Switch 1
Assembly
Handling and Storage
Be careful during handling and storage of the kit to minimize the possibility of damage. If the kit is to be stored for
any length of time prior to installation, provide a clean, dry
storage area.
Standards
ISO 9001:2000 Certified Quality Management System
March 2006 • New Issue
Printed in U.S.A.
1
Left-Hand Lower Limit Switch Kit 5792236A02 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 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:
•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.
•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 understand all cautions and warnings.
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: 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.
2
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: 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
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
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: Power distribution 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 equipment can result
in death, severe personal injury, and equipment damage.
G122.2
S225-50-34
INSTALLATION PROCEDURES
Removing Existing Left-Hand Lower
Limit Switch
3.Remove and retain the drag-hand reset solenoid module from the position indicator face. See Figure 4.
1.Unlatch the hasp on the right-hand side of the polymer position indicator to open the main cover. See
Figure 2.
Position
indicator face
Drag-hand reset
solenoid module
Hasp
Figure 4.
Module removal.
Figure 2.
Main cover hasp.
2.Using a standard screwdriver, remove and retain the
thumbscrew on the drag-hand reset solenoid module.
See Figure 3.
Drag-hand
reset solenoid
module
Thumbscrew
Figure 3.
Solenoid module fastening thumbscrew.
3
Left-Hand Lower Limit Switch Kit 5792236A02 Installation Instructions
4.Note the two wires that are connected to the solenoid
with push-on terminals: an orange/black wire is connected to the inside terminal of the solenoid and a
white wire is connected to the outside terminal. See
Figure 5.
Number
dial
Screws
Solenoid terminals
White, ground
wire
Orange/black
wire
Figure 5.
Solenoid terminals.
Figure 6.
Number dial fastening.
9.Remove and retain the position indicator Geneva Gear/
Pointer. See Figure 7.
CAUTION: Hazardous Voltage. The orange/black
wire can have voltage potential if the drag-hand
reset circuit is closed. Caution should be taken to
prevent shorting the reset orange/black with the ground
white wire or touching the orange/black wire terminal.
Check the voltage potential between the orange/black
wire and the white wire before disconnecting the wires
from the solenoid. If voltage potential is present, deenergize the regulator and refer to the regulator manual
for troubleshooting. Failure to comply can cause
personal injury and equipment damage.
Note:
The Geneva Gear/Pointer is not fastened into the
position indicator; it will lift out from the position indicator housing.
Lower limit
switch and
Slider A02
5.Measure the voltage between the wire terminations
with a voltmeter. Under normal conditions, no voltage should be present. If voltage potential is present,
de-energize the regulator. Refer to the regulator installation, operation, and maintenance manual for further
troubleshooting to determine the cause of voltage
potential on these leads. Do not proceed when voltage
potential is present.
6.Using a pair of needle-nose pliers, remove the orange/
black and the white wires from the terminals on the
solenoid module. Remove and retain the solenoid module from the position indicator.
7.Remove and retain the three Phillips screws fastening
the number dial to the position indicator. See Figure 6.
8.Remove and retain the number dial.
Green/black wires
and terminals
Geneva
gear/pointer
Figure 7.
Geneva Gear/Pointer and wiring.
10.Identify the lower limit switch in the position indicator.
The lower limit switch has green/black wires connected
to the microswitch terminals. The yellow lower slider is
marked with A02 engraved in the slider. See Figure 7.
11.Using a pair of needle-nose pliers, disconnect the
green/black wire female connector from the microswitch male terminal.
12.Remove the A02 yellow lower slider from the position
indicator.
4
S225-50-34
Installing New Left-Hand Lower
Limit Switch
1.Verify that the new left-hand microswitch and slider is
the correct part by verifying that the slider is engraved
with A02.
2.Using a pair of needle-nose pliers, connect the green/
black wire female terminal to each of the new raise A02
limit switch terminals. See Figure 7.
5.Replace the number dial in the position indicator,
aligning the mounting holes in the dial with the position
indicator base.
The letter "N" must be aligned over the elongated slot
at the 12 o'clock position. See Figure 9.
The yellow pointer must be aligned with "N" neutral.
See Figure 10.
Pointer
Neutral "N"
Indicator
Figure 10.
Pointer and neutral "N" alignment.
16 L
position
Figure 8.
Positioning of left-hand limit switch and slider
assembly, shown with number dial for reference.
3.Locate the lower limit switch at the 16 L position. See
Figure 8.
4.Replace the Geneva Gear/Pointer into the position
indicator housing. Align the yellow pointer with the slot
at the 12 o'clock position. See Figure 9.
6.Using a Phillips screwdriver, replace and tighten the
Phillips screws in the number dial.
7.Make the wire connections to the retained drag-hand
reset solenoid.
Connect the orange/black wire to the inside terminal
post on the drag-hand reset solenoid.
Connect the white wire onto the outside terminal post
of the drag-hand reset solenoid. See Figure 11.
Solenoid
terminals
12 o'clock
position slot
White, ground
wire
Pointer
Orange/black
wire
Figure 11.
Solenoid terminal connections.
Figure 9.
Pointer alignment.
5
Left-Hand Lower Limit Switch Kit 5792236A02 Installation Instructions
8.Open up the drag hands on the module so that the
drag hands will fall on the proper sides of the indicator
pointer and pointer stop. See Figure 12.
Pointer
10.Align the solenoid plunger of the retained drag-hand
reset solenoid module with the cutout slot in the position indicator housing. See Figures 14 and 15.
Pointer stop
Solenoid reset
plunger
Drag hands
Figure 12.
Drag-hand positioning.
Figure 14.
Solenoid reset plunger.
9.Set the lower limit switch to 16 L and the raise limit
switch 16 R; this will make it easier to insert the draghand reset solenoid. See Figure 13.
Cutout slot
Lower limit
switch
Raise limit
switch
Figure 15.
Solenoid plunger cutout slot.
11.Insert the drag-hand reset solenoid module into the
position indicator housing.
Figure 13.
Limit switch positions.
6
12.Align the screw threads of the retained thumbscrew
with the screw mounting hole threads, press down on
the module, and tighten the thumbscrew.
S225-50-34
Testing Installation and Operation
1.Test the limit switch by positioning the left-hand lower
limit to 8, 10, 12, or 14 L and tap the tap-changer so
that the pointer is at the limit switch setting. When the
limit switch is working properly, the tap-changer will not
step beyond the limit setting.
2.After testing the limit setting, tap the tap-changer back
to neutral. Depress the drag-hand reset switch on the
control panel. The drag hands should return to the
indicator pointer.
7
Left-Hand Lower Limit Switch Kit 5792236A02 Installation Instructions
© 2006 Cooper Power Systems, Inc., or its affiliates.
8
1045 Hickory Street
Pewaukee, WI 53072 USA
www.cooperpower.com