S225-50-54 CL-6B Control Panel Retrofit Installation ...

1 1CL-6B Control Panel Retrofit Installation InstructionsVoltage RegulatorsService InformationS225-50-540512 Supersedes 05/081 Safety Information .. 2 Hazard Statement Definitions .. 2 Safety instructions .. 2 Product Information .. 3 Introduction .. 3 Acceptance and Initial Inspection .. 3 Handling and Storage .. 3 Quality Standards .. 3 Installation Procedures Kit 57A64327900A, CL-6B Control Panel in Cooper Box, Dead Front .. 4 Installation Procedures Kit 57A64327900B, CL-6B Control Panel in Cooper Box, Not Dead Front .. 5 Installation Procedures Kit 57A64327900C, CL-6B Control Panel in Siemens Box .. 6 Installation Procedures Kit 57A64327900D, CL-6B Control Panel in General Electric Box with Fork-Type Terminal .. 9 Installation Procedures Kit 57A64327900E, CL-6B Control Panel in General Electric box with Pin-Type Terminal .. 12 Installation Procedures Kit 57A64327900F, CL-6B Control Panel in Howard Box.

2 14 ContentsFigure 1. CL-6B regulator Control panels in various Control instructions in this manual are not intended as a sub stitute 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:n Is thoroughly familiar with these Is trained in industry-accepted high- and low-voltage safe operating practices and Is trained and authorized to energize, de-energize, clear, and ground power distribution Is trained in the care and use of protective equipment such as flash clothing, safety glasses, face shield, hard hat, rubber gloves, clampstick, hotstick, is important safety information. For safe Installation and operation of this equipment, be sure to read and understand all cautions and InstructionsFollowing are general caution and warning statements that apply to this equipment.

3 Additional statements, related to specific tasks and procedures, are located throughout the : 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.!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.!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.

4 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.!SAFETY FOR LIFEC ooper 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 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.

5 !SAFETYFOR LIFE!SAFETYFOR LIFESAFETY INFORmATIONThis manual may contain four types of hazard statements:DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious : Indicates a hazardous situation which, if not avoided, could result In death or serious : Indicates a hazardous situation which, if not avoided, could result in minor or moderate : Indicates a hazardous situation which, if not avoided, could result in equipment damage Statement Definitions!!! CL-6B Control Panel Retrofit Installation InstructionsIntroductionService Information S225-50-54 provides the instructions for retrofitting a CL-6B Control Panel on a Cooper Power Systems, Siemens Corporation, General Electric, or Howard Industries, Inc. 32-step voltage regulator. 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.

6 Read and understand the manuals detailing the Installation and operation of the regulator and the regulator Control used with the regulator. Refer to S225-11-1 CL-6 Series Control Installation , Operation, and Maintenance instructions for information on the CL-6B voltage regulator Control . Refer to S225-10-30 VR-32 Voltage Regulator with Quik-Drive Tap-Changer Installation , Operation, and Maintenance instructions for information on the Cooper Power Systems voltage regulator with Quik-Drive tap-changer. 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, please contact your Cooper Power Systems representative. Acceptance and Initial Inspection This kit is thoroughly inspected at the factory.

7 It is in good condition when accepted by the carrier for shipment. Upon receipt of the regulator kit, a thorough inspection should be made for damage, evidence of rough handling, or shortages. Should this initial inspection reveal evidence of rough handling, damage, or shortages, it should be noted on the bill of lading and a claim should immediately be made with the carrier. Also, notify your Cooper Power Systems and Storage Be careful during handing and storage of equipment to minimize the possibility of damage. If the regulator kit is not to be placed into immediate use, store the kit where the possibility of damage is StandardsISO 9001 Certified Quality Management SystemS225-50-54!SAFETYFOR LIFEPR oducT InFoRMATIon3!Follow these instructions to install the CL-6B in a CL-6A Control box on a Cooper Power Systems voltage regulator with a dead-front Tools: Screwdriver (standard) Backpanel tool (included in kit)Note: Verify all kit items are present before beginning Installation procedure.

8 1. Remove the existing Control . Refer to the appropriate voltage regulator Control manual for complete instructions on removing a Control . Refer to S225-11-1 VR-32 Voltage Regulators CL-6 Series Control Installation , Operation, and Maintenance instructions for information on the Cooper Power Systems CL-6 series voltage regulator Control . 2. Using a screwdriver, install the bracket (Item 1) on the Control box mounting tabs with screws (Item 2). Refer to Figure 2. 3. Slide the Cooper CL-6B Control Panel onto the existing hinge pins. 4. Plug the wiring harness connector into TB-2 on the backpanel. 5. Connect ground cable to back Panel . Refer to Figure 3. 6. Secure the Cooper CL-6B Control Panel to the bracket using the existing latch. 7. Refer to S225-11-1 CL-6 Series Control Installation , Operation, and Maintenance instructions for proper Control configuration and start up Control Panel Retrofit Installation Instructions4 Installation PRocEduRES KIT 57A64327900A CL-6B Control Panel In cooPER Box, dEAd FRonTFigure 2.

9 Control box bracket 3. Backpanel terminal board 1 Kit Parts Identification, Kit 57a64327900a*ItemDescriptionCooper Part #Qty1CL-6 adaptor bracket, Cooper box2092700A0011212-13-203-11 screw0800071095Z23 Backpanel tool, plastic A6130980011 * Use this kit with CL-6B Control Panel , Part # 57A6432690EA. Retain for future these instructions to install the CL-6B PRA in a CL-5 Control box on a Cooper Power Systems voltage regulator without a dead-front Tools: Screwdriver (standard) SVR tool (included in kit)Note: Verify all kit items are present before beginning Installation procedure. 1. Remove the existing Control . Refer to the appropriate voltage regulator Control manual for complete instructions on removing a Control . Refer to S225-11-1 VR-32 Voltage Regulators CL-6 Series Control Installation , Operation, and Maintenance instructions for information on the Cooper Power Systems CL-6 series voltage regulator Control .

10 2. Refer to S225-50-27, CL-6A Control Retrofit Connector Kit instructions for updating Control box for CL-6B Control . Pay particular attention to: Updating older 10-position terminal block to 18. Insure jumpers between 4 and 3 and 2 and 1 are in place. See Figure 6 in S225-50-27 S225-50-27, CL-6A Control Retrofit Connector Kit instructions . 3. Using a screwdriver, install the bracket (Item 2) on the Control box mounting tabs with screws (Item 3). Refer to Figure 2. 4. Disconnect the white connector from the side of the Panel to remove the strain relief and standard wiring harness from the CL-6B Control Panel . See Figure 4. 5. Install the new wiring harness assembly (Item 1) in the connectors located on the side of the CL-6B Control Panel . Refer to Figure 5. 6. Attach the strain relief device, removed in Step 3, to the wiring harness. Be careful to position the tie-wrap on the proper side of strain relief device.