Voltage Regulators
Effective August 2014
New Issue
Quick connect assembly (QCA) 12-conductor retrofit kit
MN225002EN
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s
(“Eaton”) experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales
office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in
appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES
OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY
EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE
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 otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or
loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing
power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice.
ii
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Contents
SAFETY INFORMATION
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
PRODUCT INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Acceptance and Initial Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL
Parts Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SIEMENS CORPORATION/HOWARD INDUSTRIES 12-CONDUCTOR QCA INSTALLATION INSTRUCTIONS
Component Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
GENERAL ELECTRIC 12-CONDUCTOR QCA INSTALLATION INSTRUCTIONS
Component Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL ELECTRIC SM2/SM3 12-CONDUCTOR QCA INSTALLATION INSTRUCTIONS
Component Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
CL-7 CONTROL AND ENCLOSURE INSTALLATIONS
Option 1: Single-phase CL-7 Control and Enclosure for an Individual Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . .29
Option 2: Multi-phase CL-7 Control and Enclosure for Two to Three Single-Phase Voltage Regulators. . . . . . . . . . . . . .33
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
iii
!
Safety for life
SAFETY
FOR LIFE
!
SAFETY
FOR LIFE
Eaton’s 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 Eaton’s 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.
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.
• Is trained in the care and use of protective equipment
such as arc flash clothing, safety glasses, face shield, hard
hat, rubber gloves, clampstick, 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 a 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.
iv
DANGER
Hazardous voltage. Contact with hazardous voltage will
cause death or severe personal injury. Follow all locally
approved safety procedures when working around highand 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 can result in death, severe personal
injury and equipment damage.
G102.1
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.
G122.3
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Product information
Introduction
The purpose of the Quick Connect Assembly (QCA)
12-conductor retrofit kit provides the parts and installation
instruction for installing the QCA retrofit kit in other voltage
regulator manufacturer's (General Electric® (GE®), Howard
Industries®, Siemens Corporation®) control enclosures,
using them as junction boxes for the purpose of interfacing
with Eaton's Cooper Power Systems control/cabling
assembly.
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 process described nor
provide directions for meeting every possible contingency
during installation, operation, or maintenance. For additional
information, contact your representative.
Acceptance and initial inspection
Each kit 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.
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 Certified Quality Management System
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
1
General
Parts supplied
The parts supplied in this kit will depend on the voltage
regulator manufacturer's apparatus interface. The QCA
12-conductor retrofit kit can be used for one of the following
four interfaces.
Manufacturer
Part Number
Siemens Corporation
575044887B01
Howard Industries
575044887B01
GE
575044887B02
GE SM2/SM3
575044887B03
Description Qty.
QCA, 12conductor
1
The QCA retrofit kit is an application allowing for another
manufacturer's voltage regulating apparatus connected to
Eaton's Cooper Power Systems control assembly by using
the other manufacturer's control enclosure as a junction
box. The QCA retrofit kit is terminated within the existing
control enclosure, using the manufacturer's juncture for
their apparatus and control front panel termination point.
Existing control front panel is removed. Once the QCA
retrofit kit has been installed, Eaton's Cooper Power
Systems control assembly with 12-conductor control cable
connector can be interfaced with the circular receptacle end
of the QCA retrofit kit.
The QCA retrofit kit can be used for a single-phase
application or a multi-phase application (three single-phase
voltage regulators/one control).
This document is divided into three sections for installation
of the QCA retrofit kit.
Tools required
Siemens Corporation/Howard Industries
Item Number
Description
Qty.
1
Pliers
1
2
Wire Cutters
1
3
Standard Flat Head Screwdriver
1
4
Phillips #2 Screwdriver
1
5
3/8 inch Drive Drill
1
6
1-1/4 inch Open End Wrench
1
7
1-3/4 inch Open End Wrench
2
8
Nut Driver or Socket 3/8 inch
1
9
Hammer
1
10
Bi-metal Hole Saw
1
11
Chisel
1
12
3/8 inch Drive Ratchet
1
Application
GE
GE (SM2/SM3 module connector)
GE 12-conductor QCA, Part# 575044887B02
Siemens/Howard 12 conductor QCA,
Part# 575044887B01
GE SM2/SM3 12-conductor QCA, Part# 575044887B03
2
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Siemens Corporation/Howard Industries
12-conductor QCA installation instructions
Component parts
Item
Part Number
Description
Qty.
1
5044886B01
Juncture terminal board harness
12-conductor
1
2
5043000B01
QCA circular receptacle assembly
–EXT Cap 12
1
3
08A621282001
Washer
4
4
0537980C03
Gasket
2
5
A5481751
¾ -14 NPSM STL ZP NUT
1
6
0800069825Z
Cable tie adhesive back fastener
3
7
0800011079Z-2
Cable tie
5
Item 2
Item 1
Figure 1. Siemens/Howard 12-conductor QCA kit.
Feature
Item 4
The highlight of the Siemens/Howard 12-conductor QCA
retrofit kit is to transform the Siemens or Howard control
enclosures into junction boxes replacing their control panel
with Eaton's Cooper Power Systems control assembly
with interconnecting cord(s). The circular sealed receptacle
assembly (Item 2) shall exit preferably from the bottom
of the newly formed junction box. Eaton's Cooper Power
Systems 12-conductor cord connector inserts into the end
of this receptacle assembly.
The acceptable application involves a single regulator or
group of two or three regulators mounted on a common
platform or pole locating the replacement control assembly
at a remote location. This application also applies to
regulators in a substation located on the same pad next to
each other.
Item 5
Item 3
Figure 2. Washer, gaskets and nut.
Installation
Item 6
The following instructions provide guidelines in removing
the other manufacturer's control panel from their
enclosure, installing the QCA retrofit kit, and connecting
Eaton's Cooper Power Systems control assembly with
interconnecting cords.
1.
Energized regulator(s) shall be placed in the Neutral
Position verifying by using three forms of indication:
Neutral Light of control panel lit, Position Indicator
pointing to the Neutral Position, and by way of
monitoring between the Source and Load Bushings
indicating zero volts within meter tolerance.
2.
Bypass and de-energize the regulators.
3.
Swing open up the control panel allowing entry to the
back of the enclosure.
Item 7
Figure 3. Fasteners and cable ties.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
3
4.
Remove the two wing nuts against the male portion
of the juncture terminal board of the QCA harness
assembly located at the top inside of the enclosure.
See Figure 4.
Wing nut
8.
Remove the cabling provision at the bottom location of
the control enclosure as shown in Figure 6. If cabling
provision is not available use a bi-metal hole saw to
provide a 1-1/8 inch diameter opening at the bottom of
the control enclosure.
Wing nut
Figure 4. Apparatus/Control juncture terminal board.
5.
Disconnect the apparatus/control juncture terminal
board assembly as shown in Figure 5.
Bottom of
enclosure
Cabling provision
Figure 6. Control enclosure bottom access.
9.
Apparatus/control
juncture terminal
board assembly
Remove the Siemens/Howard QCA retrofit kit, as
seen in Figure 7, from the package and disconnect the
circular sealed receptacle assembly from the rest of
the QCA retrofit kit assembly. To disconnect the circular
sealed receptacle assembly, press down on the release
levers, as shown in Figure 8, of the two "Wire to Wire"
connectors and pull them apart.
Figure 5. Disconnected juncture terminal board
assembly.
6.
Disconnect and discard control panel ground wires
from ground posts on back of the control enclosure.
7.
Remove control panel from the hinges of the enclosure.
Figure 7. Siemens/Howard QCA retrofit kit.
4
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
11. From the kit, place one of the gaskets (Item 4), over the
QCA retrofit kit harness seating the gasket against the
QCA circular sealed receptacle assembly as shown in
Figure 10.
"Wire to Wire"
connector release
levers
Receptacle white
wire
Gasket
Lever clamp
terminal block
Circular sealed receptacle
assembly
Figure 8. "Wire to Wire" connector decoupling.
10. Pull up on the lever of the clamp terminal block
where the white wire of the receptacle assembly is
connected. See Figure 9. Pull this white wire from the
clamp terminal block.
Figure 10. QCA circular sealed receptacle assembly and
gasket.
12. From outside of enclosure insert the QCA circular
receptacle assembly with gasket through the opening
at the bottom of the control enclosure. See Figure 11.
QCA circular
sealed receptacle
Lever
Circular receptacle
assembly white
wire
Figure 11. QCA circular sealed receptacle location.
Figure 9. Lever clamp terminal block.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
5
13. Place second gasket (Item 4) over the inserted QCA
circular receptacle assembly on inside surface of
control enclosure. See Figure 12.
15. Place the nut (Item 5) over the QCA circular receptacle
assembly. See Figure 14.
Nut
Gasket
Figure 14. Receptacle assembly nut installation.
Figure 12. Receptacle assembly internal gasket
installation.
14. Place flat washer (Item 3) over the QCA circular
receptacle assembly with washer on top of previous
installed gasket. See Figure 13.
16. Secure QCA receptacle assembly by threading and
tightening down the provided internal nut with a 1-¼"
open face wrench while holding the outside portion of
the receptacle in place with a 1-¾" size wrench.
17. Connect the QCA male portion of the juncture terminal
board to the Siemens/Howard female portion located
at the top of the control enclosure. Make sure that the
terminal block halves are fully engaged with the wing
nut studs protruding through the male connector. See
Figure 15.
Washer
Wing nut studs
QCA harness
terminal board
Figure 13. Receptacle assembly internal washer
installation.
Figure 15. Installation of QCA juncture terminal board
harness.
6
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Siemens/Howard Terminals
QCA wiring harness Color Code
U12
Red/Black
P2
Black
C2
Green
E
White*
E1
Red
U2
White/Black
J
Blue
K
Green/Black
U10
Orange
U11
Orange/Back
Lever in
upright
position
CT protector
*Two white wires, harness white wire and CT Protector white wire.
18. Replace the two wing nuts onto the wing nut threaded
studs tightening down until the two terminal board
halves remain fully engaged. See Figure 16.
Figure 17. Open position of lever clamp terminal block.
Closed lever
White wire
Wing nuts
Circular receptacle
assembly
Figure 16. Wing nut installation.
Figure 18. Installation of white wire from receptacle.
19. Lift into the upright position one of the levers of the
clamp terminal block which has an available position
as shown in Figure 17. Insert fully the white wire from
the circular receptacle assembly into this position,
afterwards closing the lever as shown in Figure 18.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
7
20. Link together the two "Wire to Wire" connectors
between the circular receptacle assembly and the
juncture terminal board harness as shown in Figure 19.
Juncture terminal
board harness
Option 1.
Motor capacitor not available in the Siemens/Howard
control enclosure. The capacitor is mounted inside the
regulator tank on the tap-changer. Remove the shorter wires
(blue/black and black/white with the Push On terminals)
from the lever clamp terminal blocks shown in Figure 20. To
remove, lift the associated levers in the upmost position and
pull the wires out. Tie these wires to the QCA harness for
future use so they do not interfere with other terminations.
"Wire to Wire" connectors
Blue/Black
motor capacitor lead
Circular receptacle
assembly
Black/White motor
capacitor lead
Black/White
short lead
Lever clamp terminal
blocks
Figure 19. "Wire to Wire" connectors linked.
21. There are two additional wires off of the QCA retrofit
kit 12-conductor harness assembly, blue/black and
black/white wires. These wires are for connections with
tap-changer motor start capacitor mounted inside the
control enclosure. There are three options available for
use of these wires.
Blue/Black
short lead
Figure 20. External motor capacitor connections.
Option 2.
Motor capacitor available inside the Siemens/Howard
control enclosure and the capacitor is to be left
connected to the existing Siemens/Howard enclosure
circuitry. Remove the shorter wires (blue/black and black/
white with the Push On terminals) from the lever clamp
terminal blocks shown in Figure 20. To remove lift the
associated levers into the upmost position and pull the
wires out. Tie these wires to the QCA harness for future
use so they do not interfere with other terminations.
8
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Option 3.
The motor capacitor for Siemens/Howard tap-changer
relocated to inside of the Eaton's Cooper Power
Systems control enclosure. Remove the shorter wires
(blue/black and black/white with the Push On terminals)
from the lever clamp terminal blocks shown in Figure 20. To
remove lift the associated levers into the upmost position
and pull the wires out.
Remove from the motor capacitor terminals, the leads
coming from the electrical conduit between the control
enclosure and regulator cover junction box. Use a pair of
wire cutters to remove these capacitor terminals from
the capacitor leads. Strip back the insulation 3/16" on both
capacitor leads. Lift the lever on one of the QCA retrofit
kit lever clamp terminal blocks above the associated open
position. Insert one of the Siemens/Howard motor capacitor
leads fully into the open position and close the orange lever.
Repeat the same process for the other motor capacitor
lead. See Figure 21.
22. To help secure the QCA retrofit kit to the back of the
Siemens/Howard control enclosure, place one to three
tie fasteners (Item 6) as needed as shown in Figure 22.
Cable tie fasteners
Figure 22. Cable tie fasteners.
23. For each fastener insert a cable tie (Item 7) through the
slots in the fastener. Bring both ends of the cable tie
together and pull snugly, cutting off excess with wire
cutters. See Figure 23.
Siemens/
Howard motor
capacitor lead
Siemens/
Howard motor
capacitor lead
Blue/Black
motor
capacitor
lead
Lever clamp
terminal blocks
Black/White
motor capacitor
lead
Figure 21. Siemens/Howard motor capacitor lead
connections.
The motor capacitor leads from the QCA retrofit kit are color
coded: one wire is blue/black and the other is black/white.
There is no concern for polarity with these connections.
The connections are now completed for the Siemens/
Howard motor capacitor to be relocated or a new capacitor
installed inside the Eaton's Cooper Power Systems control
enclosure. For a multi-phase control application two or
three motor capacitors will be installed in the same control
enclosure in the proper location (VR1, VR2 and VR3) to
match up with the tap-changers they are intended for.
The location is important for a bank of different voltage
regulators.
Cable tie fasteners
Figure 23. Secured harness assembly.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
9
24. The male connector of Eaton's Cooper Power Systems
12-conductor cord connects to the QCA circular female
receptacle at the bottom of the GE control enclosure
shown in Figure 24. To connect the cord to the
receptacle, line up the keyway on the cord connector
with the keyway guide of the receptacle as shown in
Figure 25.
25. Insert the male connector of the cord into the QCA
female receptacle, pushing the connector into the
receptacle as far as possible. Tighten the male
connector nut several turns pushing the connector
further into the receptacle. Continue pushing and
tightening until the connector and receptacle are fully
engaged.
26. Refer to the CL-7 control and enclosure installations
section of this service manual following instructions
making wiring connections inside the Eaton's Cooper
Power Systems control enclosure specific for the
application selected.
Figure 24. Circular sealed receptacle.
Figure 25. Receptacle and connector assembly.
10
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
General Electric 12-conductor QCA
installation instructions
Component parts
Item
Part Number
Description
Qty
1
5044886B02
Juncture terminal board harness
12-conductor GE
1
2
5043000B01
QCA circular receptacle assembly
–EXT Cap 12
1
3
08A621282001
Washer
1
4
0537980C03
Gasket
2
5
A5481751
¾ -14 NPSM STL ZP NUT
1
6
0800069825Z
Cable tie adhesive back fastener
3
7
0800011079Z-2
Cable tie
5
Item 1
Item 2
Figure 26. GE 12-conductor QCA kit.
Feature
The highlight of the GE 12-conductor QCA retrofit kit is to
transform the GE control enclosures into junction boxes
replacing their control panel with Eaton's Cooper Power
Systems control assembly with interconnecting cord(s).
The circular sealed receptacle assembly (Item 2) will exit
preferably from the bottom of the newly formed junction
box. Eaton's Cooper Power Systems 12-conductor cord
connector inserts into the end of this receptacle assembly.
The acceptable application involves a single regulator or
group of two or three regulators mounted on a common
platform or pole locating the replacement control assembly
at a remote location. This application also applies to
regulators in a substation located on the same pad next to
each other.
Item 4
Item 5
Item 3
Figure 27. Washer, gaskets, and nut.
Installation
The following instructions provide guidelines in removing
the other manufacturer's control panel from their enclosure,
installing the QCA retrofit kit assembly, and connecting
Eaton's Cooper Power Systems control assembly with
interconnecting cords.
Item 6
Item 7
Figure 28. Fasteners and cable ties.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
11
1.
Energized regulator(s) shall be placed in the Neutral
Position verifying by using three forms of indication:
Neutral Light of the control panel lit, Position Indicator
pointing to the Neutral Position, and by way of
monitoring between the Source and Load Bushings,
indicating zero volts within meter tolerance.
2.
Bypass and de-energize the regulators.
3.
Swing open up the control panel allowing entry to the
back of the enclosure.
4.
Disconnect the GE wiring harness from the bottom half
of the two apparatus/control juncture terminal boards,
shown in Figure 29, located at the right top side at the
back of the enclosure.
5.
Disconnect and discard control panel ground wires
from ground posts on back of the control enclosure.
6.
Remove control panel from the hinges of the enclosure.
7.
Remove the cabling provision from the bottom location
of the control enclosure as shown in Figure 30. If
cabling provision is not available use a bi-metal hole
saw to provide a 1-1/8 inch diameter opening at the
bottom of control enclosure.
Bottom of
enclosure
1-1/8"
cabling
provision
GE enclosure wiring harness
Figure 30. Control enclosure bottom access.
8.
Remove the GE QCA retrofit kit, as shown in Figure
31, from the package and disconnect the circular
sealed receptacle assembly from the rest of the QCA
retrofit kit assembly. To disconnect the circular sealed
receptacle assembly, press down on the release levers
as shown in Figure 32, of the two "Wire to Wire"
connectors and pull them apart.
Figure 29. Apparatus/Control Juncture terminal boards.
Figure 31. GE QCA retrofit kit.
12
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
10. From the kit place one of the gaskets (Item 4) over the
QCA retrofit kit harness seating the gasket against the
QCA circular sealed receptacle assembly as shown in
Figure 34.
"Wire to Wire" connector
release levers
Gasket
Receptacle white
wire
Lever clamp
terminal block
Circular sealed
receptacle assembly
Figure 34. QCA circular sealed receptacle assembly and
gasket.
Figure 32. "Wire to Wire" connector decoupling.
9.
11. From outside of the enclosure insert the QCA circular
receptacle assembly with gasket through the opening
at the bottom of the control enclosure. See Figure 35.
Pull up on the lever on the clamp terminal block
where the white wire of the receptacle assembly is
connected. See Figure 33. Pull this white wire from the
clamp terminal block.
QCA circular
sealed
receptacle
Circular receptacle
assembly white
wire
Lever
Figure 35. QCA circular sealed receptacle location.
Figure 33. Lever clamp terminal block.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
13
12. Place second gasket (Item 4) over the inserted QCA
circular receptacle assembly on inside surface of the
control enclosure. See Figure 36.
14. Place the nut (Item 5) over the QCA circular receptacle
assembly. See Figure 38.
15. Secure QCA receptacle assembly by threading and
tightening down the provided internal nut with a 1-1/4"
open face wrench while holding the outside portion of
the receptacle in place with a 1-3/4" size wrench.
Gasket
Figure 36. Receptacle assembly internal gasket
installation.
13. Place flat washer (Item 3) over the QCA circular
receptacle assembly with washer on top of previously
installed gasket. See Figure 39.
Nut
Figure 38. Receptacle assembly nut installation.
Washer
Figure 37. Receptacle assembly internal washer
installation.
14
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
16. Connect the QCA retrofit kit assembly to the apparatus/
control juncture terminal boards located in the upper
right back side of the control enclosure. Connect this
end of the QCA assembly using the wire chart below.
GE Terminals (NN)
QCA Assembly
Color Wire Code
26
White
27
Blue
28
Green/Black
29
Orange/Black
30
Orange
31
Red /Black
32
White/Black
24
Red
23
Green
10
White
*20 Internal PT tap
Black 20, 21, or 22
Connection
Load Volts
Pot Ratio
Control
Volts
NN9 TO
I TO
7960
66.7:1
119.3
22
H5
7620
66.7:1
114.1
22
H5
7620
63.5:1
120.0
21
H5
7200
60:1
120.0
20
H5
5000
40:1
125.0
20
H4
4330
34.8:1
124.4
20
H3
2500
20:1
125
20
H2
18. Lift into the upright position one of the levers of the
clamp terminal block which has an available position
as shown in Figure 40. Insert fully the white wire from
the circular receptacle assembly into this position,
afterwards closing the lever as shown in Figure 41.
*21 Internal PT tap
Lever in upright
position
*22 Internal PT tap
** Terminal board mounting
threaded studs
White
* See Step 18 for information on connection.
** Two white harness wires fasten under mounting nuts on top terminal
board, one wire on each end of terminal board
White harness
wires
White
harness
wires
CT protector
Figure 40. Open position of lever clamp terminal block.
Figure 39. QCA retrofit kit harness termination on
apparatus/control juncture terminal boards.
17. When connecting the black wire from the QCA retrofit
kit wiring harness refer to the GE nameplate on the GE
control enclosure or apparatus to determine connection
for required regulated system voltage.
Note: The following is an example of GE Nameplate chart
covering required taps for specified system voltage.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
15
Closed lever
19. Link together the two "Wire to Wire" connectors
between the circular receptacle assembly and the
juncture terminal board harness as shown in Figure 42.
Juncture terminal
board harness
White wire
"Wire to Wire"
connectors
Circular
receptacle
assembly
Circular
receptacle
assembly
Figure 41. Installation of white wire from receptacle.
Figure 42. "Wire to Wire" linked.
20. There are two additional wires off of the QCA retrofit
kit 12-conductor harness assembly; blue/black and
black/white wires. These wires are for connections with
tap-changer motor start capacitor mounted inside the
control enclosure. There are three options available for
use of these wires.
16
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Option 1.
Option 2.
Motor capacitor not available in the GE control
enclosure. The capacitor is mounted inside the regulator
tank on the tap-changer. Remove the shorter wires (blue/
black and black/white with the Push on terminals) from the
lever clamp terminal blocks shown in Figure 43. To remove,
lift the associated levers in the upmost position and pull the
wires out. Tie these wires to the QCA harness for future
use so they do not interfere with other terminations.
Motor capacitor available inside the GE control
enclosure and the capacitor is to be left connected
to the existing GE enclosure circuitry. Remove the
shorter wires (blue/black and black/white with the Push
On terminals) from the lever clamp terminal blocks shown
in Figure 43. To remove, lift the associated levers into the
upmost position and pull the wires out. Tie these wires to
the QCA harness for future use so they do not interfere
with other terminations.
Blue-Black
motor capacitor
lead
Black/White motor
capacitor lead
Blue/Black short
lead
Black/White
short lead
Lever clamp
terminal blocks
Figure 43. External motor capacitor connections.
Option 3.
The motor capacitor for GE tap-changer relocated
to inside of Eaton's Cooper Power Systems control
enclosure. Remove the shorter wires (blue/black and black/
white with the Push On terminals) from the lever clamp
terminal blocks shown in Figure 43. To remove, lift the
associated levers into the upmost position and pull the
wires out.
Remove from the motor capacitor terminals, the leads
coming from the electrical cord between the control
enclosure and regulator position indicator. Use a pair of
wire cutters to remove these capacitor terminals from
the capacitor leads. Strip back the insulation 3/16" on both
capacitor leads. Lift the lever on one of the QCA retrofit
kit lever clamp terminal blocks above the associated open
position. Insert one of the GE motor capacitor leads fully
into the open position and close the orange lever. Repeat
the same process for the other motor capacitor lead. See
Figure 44.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
17
21. To help secure the QCA retrofit kit to the back of the
GE control enclosure, place one to three tie fasteners
(Item 6) as needed and shown in Figure 45.
GE motor leads
Blue/Black
motor
capacitor lead
Black/White
motor
capacitor lead
Lever clamp terminal blocks
Figure 44. GE motor capacitor lead connections.
The motor capacitor leads from the QCA retrofit kit are color
coded: one wire is blue/black and the other is black/white.
There is no concern for polarity with these connections. The
connections are now completed for the GE motor capacitor
to be relocated or a new capacitor installed inside Eaton's
Cooper Power Systems control enclosure. For a multiphase control application two or three motor capacitors will
be installed in the same control enclosure in the proper
location (VR1, VR2, or VR3) to match up with the tapchangers they are intended for. The location is important for
a bank of different voltage regulators.
Cable tie fasteners
Figure 45. Cable tie fasteners.
22. For each fastener insert a cable tie (Item 7) through the
slots in the fastener. Bring both ends of the cable tie
together and pull snugly, cutting off excess with wire
cutters. See Figure 46.
Cable ties
Figure 46. Secured harness assembly.
18
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
23. The male connector of Eaton's Cooper Power Systems
12-conductor cord connects to the QCA circular female
receptacle at the bottom of the GE control enclosure
shown in Figure 47. To connect the cord to the
receptacle, line up the keyway on the cord connector
with the keyway guide of the receptacle as shown in
Figure 48.
24. Insert the male connector of the cord into the QCA
female receptacle, pushing the connector into the
receptacle as far as possible. Tighten the male
connector nut several turns pushing the connector
further into the receptacle. Continue pushing and
tightening until the connector and receptacle are fully
engaged.
25. Refer to the CL-7 control and enclosure installations
section of this service manual following instructions
making wiring connections inside Eaton's Cooper
Power Systems control enclosure specific for the
application selected.
Figure 47. Circular sealed receptacle.
Figure 48. Receptacle and connector assembly.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
19
GE SM2/SM3 12-conductor QCA installation
instructions
Item 1
Component parts
Item
Part Number
Description
Qty
1
5044886B03
Junction terminal board harness
12-conductor
1
2
5043000B01
QCA circular receptacle assembly
–EXT Cap 12
1
3
08A621282001
Washer
1
4
0537980C03
Gasket
2
5
A5481751
¾ -14 NPSM STL ZP NUT
1
6
0800069825Z
Cable tie adhesive back fasteners
3
7
0800011079Z-2
Cable tie
5
Item 2
Figure 49. GE SM2/SM3 12-conductor QCA kit.
Feature
The highlight of the GE SM2/SM3 12-conductor QCA retrofit
kit is to transform the GE control enclosures into junction
boxes replacing the control panel with Eaton's Cooper
Power Systems control assembly with interconnecting
cord(s). The circular sealed receptacle assembly (Item 2)
shall exit preferably from the bottom of the newly formed
junction box. Eaton's Cooper Power Systems 12-conductor
cord connector inserts into the end of this receptacle
assembly.
The accepted application involves a single regulator or a
group of two or three regulators mounted on a common
platform or pole locating the replacement control assembly
at a remote location. This application also applies to
regulators in a substation located on the same pad next to
each other.
Item 5
Item 3
Item 4
Figure 50. Washer, gaskets, and nut.
Installation
The following instructions provide guidelines in removing
the other manufacturer's control panel from their
enclosure, installing the QCA retrofit kit, and connecting
Eaton's Cooper Power Systems control assembly with
interconnecting cords.
Item 6
Item 7
Figure 51. Fasteners and cable ties.
20
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
1.
Energized regulator(s) shall be placed in the Neutral
Position verifying by using three forms of indication:
Neutral Light of the control panel lit, Position Indicator
pointing to the Neutral Position, and by way of
monitoring between the Source and Load Bushings,
indicating zero volts within meter tolerance.
2.
Bypass and de-energize the regulators
3.
Swing open up the control panel allowing entry to the
back of the enclosure where the power disconnectcircuit board module is located, shown in Figure 52.
4.
To remove the power disconnect circuit board from
the rack, first press down on the right and left ejection
levers as shown in Figure 53. Secondly, slide downward
and out the circuit board from the rack as shown in
Figure 54.
5.
Detach the 24-pin connector, shown in Figure 54, of the
harness connected to the control panel.
Rack
Ejection lever
Figure 52. Power disconnect-circuit board module.
Figure 53. Releasing power disconnect-circuit board
module.
24-pin
harness
connector
Figure 54. Detached power disconnect-circuit board
module and harness assembly.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
21
6.
Disconnect the two pin control panel ground connector assembly from ground post on back of the control
enclosure.
7.
Remove control panel from the hinges of the enclosure.
8.
Remove the cabling provision from the bottom location
of the control enclosure as shown in Figure 55. If
cabling provision is not available use a bi-metal hole
saw to provide a 1-1/8 inch diameter opening at the
bottom of control enclosure.
"Wire to Wire" connector
release levers
Receptacle
white wire
Lever clamp
terminal block
1-1/8" cabling
provision
Bottom of
enclosure
Figure 55. Control enclosure bottom access.
Figure 57. "Wire to Wire" connector decoupling.
9.
Remove the GE SM2/SM3 QCA retrofit kit, as shown
in Figure 56, from the package and disconnect the
circular sealed receptacle assembly from the rest of
the QCA retrofit kit assembly. To disconnect the circular
sealed receptacle assembly, press down on the release
levers, as shown in Figure 57, of the two "Wire to Wire"
connectors and pull them apart.
10. Pull up on the lever on the clamp terminal block
where the white wire of the receptacle assembly is
connected. See Figure 58. Pull this white wire from the
clamp terminal block.
11. From the kit, place one of the gaskets (Item 4) over the
QCA retrofit kit harness seating the gasket against the
QCA circular sealed receptacle assembly as shown in
Figure 58.
Circular
receptacle
assembly
white wire
Lever
Figure 58. Lever clamp terminal block.
Figure 56. GE SM2/SM3 QCA kit.
22
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
12. From outside of the enclosure insert the QCA circular
receptacle assembly with gasket through the opening
at the bottom of the control enclosure. See Figure 60.
13. Place second gasket (Item 4) over the inserted QCA
circular receptacle assembly on inside surface of
control cabinet. See Figure 61.
Circular sealed
receptacle
assembly
Gasket
Figure 59. QCA circular sealed receptacle assembly and
gasket.
Gasket
QCA circular
sealed
receptacle
Figure 61. Receptacle assembly internal gasket
installation.
Figure 60. QCA circular sealed receptacle location.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
23
14. Place flat washer (Item 3) over the QCA circular
receptacle assembly with washer on top of previously
installed gasket. See Figure 62.
Washer
Figure 62. Receptacle assembly internal washer
installation.
15. Place the nut (Item 5) over the QCA circular receptacle
assembly. See Figure 63.
Nut
Figure 63. Receptacle assembly nut installation.
16. Secure QCA receptacle assembly by threading and
tightening down the provided internal nut with a 1-1/4"
open face wrench while holding the outside portion of
the receptacle in place with a 1-3/4" size wrench.
17. Both the 24-pin male power disconnect-circuit board
connector and the matching QCA female connector are
keyed for proper alignment. See Figure 64. Connect the
QCA wiring harness female pin connector to the power
disconnect-circuit board module as shown in Figure 65.
QCA female
module connector
24-Pin power disconnect-circuit board connector
Figure 64. Alignment of QCA and power disconnectcircuit board connectors.
24
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
19. Press the ejection levers upward toward the circuit
board module. These will ensure the connection of the
module with the apparatus/control juncture.
20. Lift into the upright position one of the levers of the
clamp terminal block which has an available position
as shown in Figure 67. Insert fully the white wire from
the circular receptacle assembly into this position,
afterwards closing the lever as shown in Figure 68.
Lever in upright
position
Figure 65. QCA harness and power disconnect-circuit
board module.
18. Engage the power disconnect-circuit board module to
the apparatus/control juncture by fully sliding assembly
upward into the rack located on the back of the
enclosure as shown in Figure 66.
CT Protector
Figure 67. Open position of lever clamp terminal block.
Closed lever
White wire
Apparatus/control juncture
Figure 66. Engaged power disconnect-circuit board
module assembly.
Circular
receptacle
assembly
Figure 68. Installation of white wire from receptacle.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
25
21. Link together the two "Wire to Wire" connectors
between the circular receptacle assembly and the
juncture terminal board harness as shown in Figure 69.
Power-disconnect
circuit board
module harness
22. There are two additional wires off of the QCA retrofit
kit 12-conductor harness assembly; blue/black wire and
black/white wires. These wires are for connections with
tap-changer motor start capacitor mounted inside the
control enclosure. There are three options available for
use of these wires.
"Wire to Wire"
connectors
Circular
receptacle
assembly
Figure 69. "Wire to Wire" connectors linked.
26
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Option 1.
Motor capacitor not available in the GE control
enclosure. The capacitor is mounted inside the regulator
tank on the tap-changer. Remove the shorter wires (blue/
black and black/white with the Push On terminals) from the
lever clamp terminal blocks shown in Figure 70. To remove,
lift the associated levers in the upmost position and pull the
wires out. Tie these wires to the QCA harness for future
use so they do not interfere with other terminations.
Blue/
black motor
capacitor lead
Black/
white motor
capacitor lead
Blue/black
short lead
into the open position and close the orange lever. Repeat
the same process for the other motor capacitor lead. See
Figure 71.
The motor capacitor leads from the QCA retrofit kit are color
coded: one wire is blue/black and the other is black/white.
GE motor
capacitor leads
Lever clamp
terminal
blocks
Black/white
short lead
Blue/black
motor
capacitor lead
Lever clamp
terminal
blocks
Figure 70. External motor capacitor connections.
Option 2.
Motor capacitor available inside the GE control
enclosure and the capacitor is to be left connected
to the existing GE enclosure circuitry. Remove the
shorter wires (blue/black and black/white with the Push
On terminals) from the lever clamp terminal blocks shown
in Figure 70. To remove, lift the associated levers into the
upmost position and pull the wires out. Tie these wires to
the QCA harness for future use so they do not interfere
with other terminations.
Black/white motor capacitor lead
Figure 71. GE motor capacitor lead connections.
There is not concern for polarity with these connections.
The connections are now completed for the GE motor
capacitor to be relocated or a new capacitor installed
inside Eaton's Cooper Power Systems control enclosure.
For a multi-phase control application two or three motor
capacitors will be installed in the same control enclosure in
the proper location (VR1, VR2, or VR3) to match up with the
tap-changers they are intended for. The location is important
for a bank of different voltage regulators.
Option 3.
The motor capacitor for GE tap-changer relocated
to inside of Eaton's Cooper Power Systems control
enclosure. Remove the shorter wires (blue/black and black/
white with the Push On terminals) from the lever clamp
terminal blocks shown in Figure 70. To remove, lift the
associated levers into the upmost position and pull the
wires out.
Remove from the motor capacitor terminals, the leads
coming from the electrical cord between the control
enclosure and regulator position indicator. Use a pair of
wire cutters to remove these capacitor terminals from
the capacitor leads. Strip back the insulation 3/16" on both
capacitor leads. Lift the lever on one of the QCA retrofit
kit lever clamp terminal blocks above the associated open
position. Insert one of the GE motor capacitor leads fully
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
27
23. To help secure the QCA retrofit kit to the back of the
GE control enclosure, place one to three tie fasteners
(Item 6) as needed and shown in Figure 72.
24. For each fastener insert a cable tie (Item 7) through the
slots in the fastener. Bring both ends of the cable tie
together and pull snugly, cutting off excess with wire
cutters. See Figure 73.
26. Insert the male connector of the cord into the QCA
female receptacle, pushing the connector further into
the receptacle as far as possible. Tighten the male
connector nut several turns pushing the connector
further into the receptacle. Continue pushing and
tightening until the connector and receptacle are fully
engaged.
Cable tie
fasteners
Figure 74. Circular sealed receptacle.
Figure 72. Cable tie fasteners.
Cable ties
Figure 75. Receptacle and connector assembly.
Figure 73. Secured harness assembly.
25. The male connector of Eaton's Cooper Power Systems
12-conductor cord connects to the QCA female
receptacle at the bottom of the GE control enclosure
shown in Figure 74. To connect the cord to the
receptacle, line up the keyway on the cord connector
with the keyway guide of the receptacle as shown in
Figure 75.
28
27. Refer to the CL-7 control and enclosure installations
section of this service manual following instructions
making wiring connections inside Eaton's Cooper
Power Systems control enclosure specific for the
application selected.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
CL-7 control and enclosure installations
Two options for CL-7 control and enclosure installations
are offered due to the availability of both the single-phase
and multi-phase version of the CL-7. As suspected there
is more involved in the installation of a multi-phase CL-7
control when interfacing with the Siemens, Howard or GE
voltage regulating apparatus. All required interface cords,
receptacles and connectors are provided for the installation.
Option 1: Single-phase CL-7 control and
enclosure for an individual voltage regulator
Introduction:
This section provides instructions for the application of a
single-phase CL-7 control and its enclosure with a Siemens,
GE or Howard voltage regulator. Additional steps are
provided to supplement the instructions given in previous
sections covering installations of QCA retrofit assembly kits
within the original control enclosures.
Installation instructions
1.
The following instructions cover the interconnecting
quick disconnect cord and associated components
installed within the CL-7 enclosure if not previously
installed at the factory.
2.
Remove the nut, flat washer, and gasket from the cord
receptacle end shown in Figure 76.
Gasket
Flat washer
Nut
Figure 76. Cord receptacle end and components.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
29
3.
With the gasket located around the outside of the entry
hole at the top of the control enclosure, insert the
threaded portion of the cord receptacle end as shown
in Figure 77.
5.
Align the keyway of the enclosure male connector,
shown in Figure 79, with the keyway of the cord
receptacle end.
Note: As an option the control cable can be inserted via
a bottom entry or side entry of the enclosure, by
removing a knockout. A plug would be required for
the unused top entry way.
Cord receptacle end
Gasket
Keyway
Enclosure entry way
Figure 77. Installation of cord receptacle end.
Figure 79. Enclosure male connector assembly.
4.
Fully insert cord receptacle end, placing the flat
washer and nut onto the threads within the enclosure
as shown in Figure 78. Using a 1-3/4 inch open face
wrench, tighten the nut securing the cord receptacle
end to the control enclosure.
Flat washer
Nut
Figure 78. Components installation.
30
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
6.
Push the male connector assembly fully as far as
possible onto the cord receptacle end while tightening
the knurled nut. Repeat this push and tightening
process until connection is fully tightened. See Figure
80.
8.
Relocate orange lead from "HS" position to position "5"
using the insertion tool shown in Figure 83.
Terminal #5
Figure 83. Position "5".
Figure 80. Installed cord receptacle and connector
assembly.
7.
Using the wire insertion tool supplied in the control
enclosure, shown in Figure 81, remove the orange lead
connected to the "HS" position of the terminal board at
the bottom of the rear panel shown in Figure 82.
Note: Relocation of the orange wire from position "HS" to
position "5" allows for the signal from the Operation
Counter switch circuit of the GE, Siemen's and
Howard's apparatus to properly increment a tap
position and operations count on the display of the
CL-7 control.
9.
For setting up the features and programming of the CL-7
control panel refer to Service Manual MN225003EN
(S225-70-1), CL-7 Voltage Regulator Control Installation,
Operation, and Maintenance Instructions.
10. If the GE, Siemens or Howard voltage regulator placed
their tap-changer motor capacitor within their control
enclosure, install the appropriate capacitor at the
provision available in the upper left corner of the CL-7
control enclosure as shown in Figure 84.
Figure 81. Wire insertion tool.
Orange
lead
"HS"
position
Figure 82. Removal of "HS" orange lead.
Figure 84. Motor capacitor mounting provision.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
31
11. Place the capacitor terminal boot on to the blue/
black and black/white wires from the male connector
assembly.
12. Push the blue/black and black/white wire terminals on
to the capacitor terminals as shown in Figure 85.
Capacitor
terminal
protector boot
Figure 85. Motor capacitor connections.
13. Place the capacitor protective boot over the capacitor
terminals and snap in place.
14. On the bottom left side of the CL-7 Control Panel a
recessed switch, shown in Figure 86, is placed in the
upward position for applications with Siemens, Howard
and GE voltage regulators for the purpose of handling
their Neutral light source signal.
Figure 86. Neutral light source switch.
32
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Option 2: Multi-phase CL-7 control and
enclosure for two to three single-phase
voltage regulators
2.
Remove the nuts, flat washers and gaskets from the
cord receptacle ends as shown in Figure 76.
3.
With the multi-phase control enclosure, depending on
the application, two to three entry ways are selected
for the cord receptacle ends. These entry ways are
available on the top, side and bottom of the enclosure.
These entry ways are identified as VR1, VR2, and VR3
with two of them shown in Figure 87.
Introduction:
This section provides instructions for the application
of a multi-phase CL-7 control and its enclosure with a
combination of two to three GE, Siemens or Howard
voltage regulators. Additional steps are provided to
supplement the instructions given in previous sections
covering installations of QCA retrofit assembly kits within
the original control enclosures.
VR1 and VR2 cord
receptacle entry
ways
Installation instructions:
1.
The following instructions cover the interconnecting
quick disconnect cords and associated components
installed within the CL-7 multi-phase enclosure if not
previously installed at the factory.
Figure 87. Enclosure entry ways.
4.
Locate gaskets around entry ways, outside of
enclosure, while inserting the threaded portion of the
cord receptacle ends. See Figure 77.
5.
Fully insert the cord receptacle ends, placing the
flat washers and nuts onto the threads within the
enclosure as shown in Figure 78. Using a 1-3/4" open
face wrench, tighten the nuts securing the cord
receptacle ends to the control enclosure.
6.
Select the identified CL-7 multi-phase control male
connector assemblies matching the identified cord
receptacle entry ways as shown in Figure 88.
Cord receptacle
end
Male connector
assembly
Figure 88. Coordination of receptacle and connector
assemblies.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
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7.
Align keyway of the enclosure male connector, shown
in Figure 89, with the keyway of the cord receptacle
end.
9.
If the GE, Siemens or Howard voltage regulators placed
their tap-changer motor capacitors within their control
enclosures, install the appropriate capacitors using the
provisions available in the upper left corner of the CL-7
control enclosure as shown in Figure 91. Match the
capacitor provisions with the same identifier as used
for the entry ways and male connector assemblies.
Keyway
Figure 89. Male connector assembly.
Figure 91. Multi-phase motor capacitor provisions.
8.
Push the male connector assemblies fully as far as
possible onto the cord receptacle ends while tightening
the knurled nuts. Repeat this push and tighten process
until connections are fully tightened. See Figure 90.
10. Place the capacitor terminal boots on to the blue/
black and black/white wires from the male connector
assemblies.
11. Push the blue/black and black/white wire terminals on
to the respective capacitor terminals.
Figure 90. Installed cord receptacle and connector
assembly.
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Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
12. Place the capacitor protective boots over the capacitor
terminals and snap them into place as shown in Figure
92.
14. Using the wire insertion tool supplied in the control
enclosure, shown in Figure 81, remove the orange lead
of the VR1 male connector assembly from the "HS"
position on the left side of the terminal board located at
the bottom of the rear panel, shown in Figure 94.
"HS"
Capacitor terminal
protective boot
Figure 92. Capacitor protective boots.
Figure 94. "HS" position.
13. The next steps involve relocating the holding switch
wiring for precise reaction with the Operations Counter
circuitry of the GE, Siemens and Howard voltage
regulators. Rewiring takes place with the large terminal
board shown in Figure 93.
15. Relocate this orange lead of the VR1 male connector
assembly to "5" position, twelve (12) positions to the
left of the "HS" position as shown in Figure 95.
Orange HS lead
Figure 93. Multi-phase terminal board.
Terminal #5
Figure 95. "5" position.
Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
35
16. Using the wire insertion tool remove the orange lead
of the VR2 male connector assembly from the "HSB"
position in the middle of the multi-phase terminal
board, shown in Figure 96.
18. Using the wire insertion tool remove the orange lead
of the VR3 male connector assembly from the "HSC"
position in the middle of the multi-phase terminal
board, shown in Figure 98.
"HSC" position
"HSB" position
Figure 96. "HSB" position.
17. Relocate this orange lead of the VR2 male connector
assembly to "J" position, adjacent to the right of the "5"
position as shown in Figure 97.
Figure 98. "HSC" position.
19. Relocate this orange lead of the VR3 male connector
assembly to "BR" position, three (3) positions to the
right of the "J" position as shown in Figure 99.
"J" position
"BR" position
Figure 99. "BR" position.
Figure 97. "J" position.
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Quick connect assembly (QCA) 12-conductor retrofit kit installation instructions MN225002EN August 2014 www.cooperpower.com
Multi-phase control panel setup and programming
20. For setting up the features and programming of the CL-7
control panel refer to Service Manual MN225003EN
(S225-70-1), CL-7 Voltage Regulator Control Installation,
Operation, and Maintenance Instructions.
21. On the bottom left side of the CL-7 multi-phase control
panel, three recessed switches shown in Figure 100,
are placed in their upward positions for applications
with Siemens, Howard and GE voltage regulators
for the purpose of handling their Neutral light source
signal. The top switch is identified as VR1, the middle
one is VR2, and the bottom one is VR3.
VR1
VR2
VR3
Figure 100. Multi-phase Neutral light source switches.
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!
SAFETY
FOR LIFE
Eaton
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Cleveland, OH 44122
United States
Eaton.com
Eaton’s Cooper Power Systems
Business
2300 Badger Drive
Waukesha, WI 53188
United States
cooperpower.com
© 2014 Eaton
All Rights Reserved
Printed in USA
Publication No. MN225002EN / August
2014
Eaton and Cooper Power Systems are
valuable trademarks of Eaton, in the U.S.
and other countries. You are not permitted
to use these trademarks without the prior
written consent of Eaton.
All other trademarks are property of their
respective owners.
For Eaton's Cooper Power
Systems CL-7 regulator
control product information,
call 1-877-277-4636 or visit:
www.cooperpower.com.