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GEI-101448

System SM-3 Step Voltage Regulator Control Replacement of Control Cabinet on GE Voltage Regulators

SM-3 Upgrade – Control Cabinet Installation Overview

OR

SM-3

ML-32

Installation of SM-3 with old ML-32/VR-1 plug on GE voltage regulator.

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VR-1

GEI-101448 WARNINGS, CAUTIONS, AND NOTES AS USED IN THIS PUBLICATION WARNINGS Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other conditions that could cause personal injury are present in this equipment or may be associated with its use. Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment.

CAUTIONS Caution notices are used for situations in which equipment might be damaged if care is not taken.

NOTES Notes call attention to information that is especially significant to understanding and operating the equipment. This document is based on information available at the time of its publication. While efforts have been made to ensure accuracy, the information contained herein does not cover all details or variations in hardware and software, nor does it provide for every possible contingency in connection with installation, operation, and maintenance. Features may be described herein that are not present in all hardware and software systems. GE Industrial Systems assumes no obligation of notice t o holders of this document with respect to changes subsequently made. GE Industrial Systems makes no representation or warranty, expressed, implied, or statutory, with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warrantees of merchantability or fitness for purpose shall apply.

©Copyright 2001 GE Company All Rights Reserved

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SM-3 Upgrade – Control Cabinet Table of Contents Chapter 1 – Introduction General Instructions....................................................................................................................1 Recommended Tools........................................................................................................1 Model Verification......................................................................................................................1 Precautions..................................................................................................................................2

Chapter 2 – Control Installation Remove the Old Control ..............................................................................................................3 Mounting the New Control .........................................................................................................3

Chapter 3 – Control Pretesting ........................................................................................................5 Chapter 4 – Control Programming SM-3 Basic Programming Procedure...........................................................................................7 Suggested Items to Program ........................................................................................................7

Chapter 5 – Return to Service ..........................................................................................................8 Chapter 6 – Connection Diagrams ................................................................................................9

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SM-3 Upgrade – Control Cabinet List of Figures 1. ML-32 voltage regulator, built between 1966 and 1984............................................................................1 2. VR-1 voltage regulator, built from 1984 to the present............................................................................1 3. Replacement SM-3 control.....................................................................................................................2 4. Removing the old control. ....................................................................................................................3 5. Control cabinet grounded to the tank. ..................................................................................................3 6. Control connected to the position indicator. .........................................................................................3 7. Nameplate connection chart. ................................................................................................................4 8. Voltage select jumper on the power disconnect circuit board.................................................................4 9. Measuring the current transformer impedance. ..................................................................................5 10. Measurement points (pins 5 and 7) on the circuit board.......................................................................5 11. Motor capacitor disconnected in the control cabinet..............................................................................5

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SM-3 Upgrade – Control Cabinet Chapter 1 – Introduction WARNING: The voltage regulator must be deenergized before beginning any procedures to replace the control system.

General Instructions Installation and replacement of voltage regulator controls must only be done by qualified and competent technicians, who are familiar with safety procedures and the proper installation, operation, and maintenance of voltage regulators. These instructions are provided for use by such personnel and are not intended as a substitute for adequate training and experience in safe operation and installation of the equipment. Safe installation and operation requires a careful review and adherence to procedures and warnings as listed in Installation – Operation – Maintenance, as found in GEH-5858, for type VR-1 single-phase voltage regulators. Particular attention to safety precautions as shown in warning blocks is required. Carefully follow instructions about dissipating static charges, releasing pressure from the tank, grounding of terminals and tank, and de-energizing the regulator before disconnecting from electrical connection or removing components. Equipment must not be energized until the following steps have been taken: • Proper jumper connections have been verified according to the new nameplate and connection diagram. • The control and current transformer shorting device in the control are connected.

Cable

Figure 1. ML-32 voltage regulator, built between 1966 and 1984.

Cable

Recommended Tools You should have the following tools available before beginning this procedure: • Socket set • Combination wrench set • Multimeter • Step ladder

Model Verification Verify that the model of voltage regulator to be upgraded is either an ML-32, picture in Figure 1, or a VR-1, pictured in Figure 2. The installation process for an ML-32 is described in Chapter 2 and for a VR-1 i n Chapter 3. Verify that the control cable on the replacement control, as shown in Figure 3, is long enough to replace the cable indicated in Figure 1 or 2, as appropriate.

Figure 2. VR-1 voltage regulator, built from 1984 to the present.

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SM-3 Upgrade – Control Cabinet Chapter 1 – Introduction

Cable

Figure 3. Replacement SM-3 control.

Precautions Be sure to observe the following warnings during the conversion process. WARNING: De-energize the regulator and take precautions to ensure a safe working environment before beginning this procedure.

WARNING: Always release any pressure in the tank (which may accumulate due to the loading cycle or to ambient-temperature change) by slowly loosening the hand hole-cover band. Do not attempt to remove the cover or hand hole until the pressure has been released.

WARNING: To protect against the possibility of back energizing the regulator when energizing the control from an external source, short and ground all three bushings before applying external power to the control.

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SM-3 Upgrade – Control Cabinet Chapter 2 – Control Installation

Remove the Old Control Ground Strap

1. Remove the grounding cable attached to the side of the old control, if present. 2. Remove the old control. (Figure 4.) a. Disconnect the plug at the bottom of the position indicator. b. Remove the hardware attaching the control to the regulator. c. Remove the top bolt last, while supporting the weight of the control.

Figure 5. Control cabinet grounded to the tank.

Disconnect Plug at Bottom of Position Indicator

Top Bolt on Control

Figure 6. Control connected to the position indicator. 5. Replace the nameplates on the regulator and control cabinet. If there is no nameplate mounting bracket on the regulator, find a flat spot on the regulator or form the nameplate to the curvature of the tank. Use double-sided tape to mount the new nameplate to the side of the regulator. Be sure to clean the tank mounting location to insure good adhesion.

Figure 4. Removing the old control.

Mounting the New Control

6. Check the nameplate connection chart, shown i n Figure 7. Verify that the internal voltage supply jumper, shown in Figure 8, is positioned correctly on the power disconnect circuit board. To change the jumper, remove the power disconnect circuit board and reposition the jumper as indicated on the nameplate connection chart. Replace the power disconnect board.

3. Mount the new control at the position of the old control. Ground the control cabinet externally to the tank using the ground stud on the exterior of the control cabinet with the ground strap provided, as shown in Figure 5. If there was an external ground on the old cabinet, reattach it to the cabinet also. 4. Connect the new control to the position indicator. Plug the connector on the cable from the new control to the bottom of the position indicator, as shown in Figure 6.

CAUTION: The jumper must be set for the system voltage where the regulator is used. Failure to set the jumper correctly could destroy the control due to overvoltage. 3

SM-3 Upgrade – Control Cabinet Chapter 2 – Control Installation

Read voltage select jumper settings.

Select proper voltage rating and put pin in hole.

Figure 7. Nameplate connection chart. CAUTION: Do not make connections based on the nameplate shown in Figure 7. It is a typical example and may not be correct for your application. Consult the nameplate on the regulator or control for the correct connections.

Voltage Jumper

Figure 8. Voltage select jumper on the power disconnect circuit board.

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SM-3 Upgrade – Control Cabinet Chapter 3 – Control Pretesting Use the following procedure to verify that the n e w control is functioning properly. 1. Current transformer resistance tests. Verify that the current transformer connection is valid by measuring the impedance of the CT from inside the voltage control, as illustrated in Figure 9. a. Remove the power disconnect circuit board from the holder by pressing the ejection ears on the circuit board. b. Disconnect the 24-pin connector that goes to the front control panel. c. Replace the board and measure the resistance between pins 5 and 7 of the circuit board (pin 1 is to the right), as shown in Figure 10. The value is the impedance of the CT, which should be between 10 to 100 ohms. d. If the impedance is satisfactory, remove the power disconnect board from the control, reconnect the 24-pin control connector, then replace the board.

Pin 7

Pin5

Figure 10. Measurement points (pins 5 and 7) on the circuit board. 2. Disconnect the motor capacitor in the control cabinet. The control cabinet is equipped with a motor capacitor. The capacitor is connected into the circuit but must be disconnected, as shown i n Figure 11, since there is a motor capacitor inside the regulator that is still connected. If the motor capacitor inside the regulator fails, the predominant failure mode is open. Untank the regulator and replace the capacitor inside the regulator. Operation of the regulator can then be restored by reconnecting the motor capacitor i n the control cabinet.

Capacitor Leads Disconnected and Tied Back

Figure 11. Motor capacitor disconnected in the control cabinet. NOTE: If the internal capacitor fails and the external one is connected, the motor will not be able to restart if a limit switch is activated, because the limit switch will disconnect the capacitor. As a temporary measure, it is recommended that the limit switches be set at 14 lower and 14 raise, so that the motor can be restarted by moving the limit switch to 16 position. Be sure to have the motor control switch set to run the regulator towards neutral.

Figure 9. Measuring the current transformer impedance.

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SM-3 Upgrade – Control Cabinet Chapter 3 – Control Pretesting 3. Verify manual operation. Apply external power (120 Vac, 60 Hz) to the control power supply test studs to verify that the motor operates in manual and that the neutral indicator and operation counter work correctly. Be sure to return the regulator to Neutral (Neutral indicator on control front panel ON) before disconnecting external power and turn the control off.

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SM-3 Upgrade – Control Cabinet Chapter 4 – Control Programming

SM-3 Basic Programming Procedure

The • • • •

1. Select the item or parameter to be modified. Use the front-panel menu and navigation buttons i n the diamond to bring the item to be changed into the display.

following are the parameters to be set: CT primary amps from the nameplate Regulator current rating from the nameplate PT primary volts from the nameplate Position determination algorithm: Set to DEAD RECK

2. Switch to the soft buttons immediately below the display, then press the CHANGE button. 3. Press the PROGRAM push button located on the left side of the control. 4. Use the soft push buttons to change the parameter value. • Press SAVE to update the parameter to the n e w value. • Press QUIT to abort the change.

Suggested Items to Program Basic Regulation Settings • Voltage level 120 volts • Band width 2.0 volts • Time delay 30 seconds Options Settings • LDC Optional • FHP On High limit = 2 volts above V Level + Max LDC Low limit = 2 volts below V Level • Data Logger linear or expanded Sample rate User’s choice • Clock (under Data Logger) Time in Data Logger Date in Data Logger Data Settings Use the following procedure to program the data settings (under Configuration): 1. Go to CONFIGURATION on the REGULATOR menu. 2. Press the NEXT soft key until the parameter to be programmed is found. 3. Press CHANGE. 4. Press the PROGRAM button on the side of the control. 5. Press SHIFT and INCR as needed to change the display to the new setting. 6. Press SAVE.

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SM-3 Upgrade – Control Cabinet Chapter 5 – Return to Service WARNING: A voltage regulator may destroy itself and property or personnel nearby if it is not at NEUTRAL when a connection is made between the SOURCE and LOAD bushing (commonly referred to as bypassing).

WARNING: Do not energize the regulator unless the tank is properly grounded. See the instruction book provided with the regulator for more details. The following procedure is used to prepare the regulator for return to service. A source of control voltage is required, with no connection to the LOAD bushing. 1. External 120 Vac may be used if it is connected to the CONTROL POWER SUPPLY test studs. If the high-voltage switches allow, an alternate method to power the control is to close the connection to the SOURCE bushing only. There must not be any connection between the highvoltage SOURCE and LOAD bushing if this i s done. 2. Place the Motor Control switch to manual. 3. Run the regulator to Neutral and check that the Neutral Indicator on the front panel comes on. Run regulator to 1 Raise and 1 Lower to insure that the Neutral Indicator is only on at Neutral. 4. Place the Raise/Lower switch to OFF . 5. Place the Internal/External power supply switch to OFF. 6. Disconnect the power source. 7. The regulator is now ready to be energized. Consult the instruction manual supplied with the regulator for more information.

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SM-3 Upgrade – Control Cabinet Chapter 6 – Connection Diagrams

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SM-3 Upgrade – Control Cabinet Chapter 6 – Connection Diagrams

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SM-3 Upgrade – Control Cabinet Chapter 6 – Connection Diagrams

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SM-3 Upgrade – Control Cabinet Chapter 6 – Connection Diagrams

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g GE Industrial Systems General Electric Company 7000 West Bert Kouns Industrial Loop., Shreveport, LA 71129 GEI101448

R01

0201

© 2001 General Electric Company