Voltage Regulators

Service Information
QD3/T350 Motor Replacement Kit
Kit Number 57A63675100B S225-50-35
Contents TOOLS REQUIRED
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description Qty
Parts Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Crimper 1
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Motor Removal Instructions . . . . . . . . . . . . . . . . . . . . . 1 Diagonal Cutters 1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Phillips Screw Driver 1
New Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Standard Screw Driver 1
Allen Wrench 1/8 inch 1
Allen Wrench 5/32 inch 1
Allen Wrench 3/16 inch 1
GENERAL 9/16 Socket 1

The purpose of this replacement kit is to provide the parts Ratchet 1

and installation instructions for replacing the motor on a QD3 Needle Nose Pliers 1
Quik Drive Tap Changer.
PARTS SUPPLIED Motor Removal Instructions
Item Part Number Description Qty Step 1
1 TAA114651003 Ring Terminal 3 1. Remove the internal position indicator shaft from the
2 TAA136263002 Cable Tie 3
tap changer indicator drive tube. See Figure 2.
3 TAA136263001 Cable Tie 4
4 0692044A060 Creep Insulation Tube 6 inches
5 0800073199Z "E" Clip 1 Internal
6 2291846A01 Motor 1 Flex Shaft

Item 6

Tap Changer
Internal Drive Tube
Item 4 Item 1
Item 5

Figure 2.
Internal flex shaft
Item 3
Item 2
Figure 1.
Kit parts

These instructions do not claim to cover all details or variations in the equipment, procedure, or process described, nor to provide
directions for meeting every contingency during installation, operation, or maintenance. When additional information is desired to satisfy
a problem not covered sufficiently for the user’s purpose, please contact your Cooper Power Systems sales engineer.

August 2006 • New Issue 1

Printed in U.S.A.
600 A 35 kV Class BT-TAP™ Connector System 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 Safety Instructions
sub stitute for proper training or adequate experience
in the safe operation of the equipment described. Following are general caution and warning statements that
Only competent technicians, who are familiar with apply to this equipment. Additional statements, related to
this equipment should install, operate and service it. specific tasks and procedures, are located throughout the
A competent technician has these qualifications: manual.
 Is thoroughly familiar with these instructions. DANGER: Hazardous voltage. Contact with
 Is trained in industry-accepted high- and low-voltage high voltage will cause death or severe personal
safe operating practices and procedures. injury. Follow all locally approved safety procedures
 Is trained and authorized to energize, de-energize, clear,
when working around high- and low-voltage lines and
equipment.
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. WARNING: Before installing, operating,
maintaining, or testing this equipment, carefully
Following is important safety information. For safe read and understand the contents of this manual.
installation and operation of this equipment, be sure to Improper operation, handling or maintenance can
read and understand all cautions and warnings. result in death, severe personal injury, and equipment
damage.

Hazard Statement Definitions WARNING: This equipment is not intended to

This manual may contain four types of hazard protect human life. Follow all locally approved
statements: procedures and safety practices when installing or
operating this equipment. Failure to comply may
DANGER: Indicates an imminently hazardous result in death, severe personal injury and equipment
situation which, if not avoided, will result in death damage.
or serious injury.
WARNING: Indicates a potentially hazardous
situation which, if not avoided, could result In WARNING: Power distribution equipment must
death or serious injury. be selected for the intended application. It must
be installed and serviced by competent personnel
CAUTION: Indicates a potentially hazardous who have been trained and understand proper safety
situation which, if not avoided, may result in procedures. These instructions are written for such
minor or moderate injury. personnel and are not a substitute for adequate training
and experience in safety procedures. Failure to properly
CAUTION: Indicates a potentially hazardous situation select, install or maintain this equipment can result in
which, if not avoided, may result in equipment damage death, severe personal injury, and equipment damage.
only.

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SAFETY
FOR LIFE S225-50-35

2. Use a pair of diagonal side cutters and cut and remove 4. Using a 1/8 inch Allen wrench, remove the three
the cable ties from the control winding hard insulation button Allen head screws fastening the motor bracket
tube and tap changer top bracket assembly. See to the tap changer assembly. See Figure 5.
Figure 3.

1/8 inch Allen

Cable Tie
Head Screws

Figure 3. Figure 5.
Control cable fastening. Motor bracket fasteners.

5. Using a Phillips screwdriver, loosen and remove the

blue motor lead terminal from the tap changer larger
3. Use a 9/16 inch socket and ratchet to loosen and terminal board terminal position 2, red lead from
remove the nut and carriage bolt fastening the tap terminal position 6 and the white ground lead from
changer bracket to the regulator side channel. See terminal position G. See Figure 6.
Figure 4.

White Ground Lead Terminal G

Blue Lead Terminal 2

Carriage
Bolt Nut

Red Lead Terminal 6

Figure 6.
Figure 4. Motor wiring to terminal board.
Tap changer and side channel fastener.

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QD3/T350 Motor Replacement Kit Number 57A63675100B

6. Using a pair of diagonal side cutters, cut and remove 9. Lift the top bracket clearing the position indicator tube
the two cable ties fastening the motor wires to the main and the main wiring harness. See Figure 9.
harness. See Figure 7.
Position Indicator Drive Tube
7. Using a pair of diagonal side cutters, cut and remove
the two medium cable ties fastening the motor harness
and main wiring harness to the tap changer top terminal
board. See Figure 7.

Main Wiring Harness Cable Tie

Main Wiring Harness
Motor Wiring Cable Ties

Tap Changer Top Bracket

Figure 9.
Tap changer top bracket.
Motor Wiring Insulation Cable Tie

Figure 7.
Motor wiring cable ties. 10. Lift the motor and gear assembly out of the tap changer
assembly and place on a work surface.
11. Use a pair of needle nose pliers and remove the "E" clip
fastening the motor gear to the motor shaft. See Figure
8. Use a 5/32 inch Allen wrench and remove the two 10.
button Allen head screws mounting the top tap changer
bracket to the tap changer. See Figure 8.

E-Clip

5/32 inch Allen Head Screws

Figure 10.
Motor gears and retaining clip.

Figure 8.
Tap changer bracket fastening.

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SAFETY
FOR LIFE S225-50-35

12. To remove the gear from the motor, use a standard New Motor Assembly
screw driver to pry the gear off of the motor shaft. Place
the screwdriver between the motor and the gear. Pry 14. Place the red, blue, and white motor leads through item
the gear forward until the gear clears the shaft. See #4 creep insulation.
Figure 11. 15. Position the motor onto the motor mount bracket so
that the motor leads are on the side where there are
two mounting ears. See Figure 13.

Motor Bracket Mounting Ears

Motor Gear

Motor Motor

Motor Leads

Figure 11.
Motor and gear.
Figure 13.
Motor bracket alignment.

13. Using a 3/16 inch Allen wrench, loosen and remove the
Allen button head screws fastening the bracket to the
motor. See Figure 12. 16. Fasten the motor mount bracket onto the motor using
four button Allen head 3/16 inch screws and tighten
with a 3/16 inch Allen wrench.
3/16 inch Allen Head Screws 17. Place the motor gear onto the motor shaft with the hex
nut to the outside. See Figure 14.

Gear Hex Nut

Figure 12.
Motor bracket.

Figure 14.
Motor gear placement.

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QD3/T350 Motor Replacement Kit Number 57A63675100B

18. Using a pair of needle nose pliers, press the "E" clip 21. Position the top bracket so that the position indicator
over the motor shaft grove. The center "E" Clip point drive tube and main wiring harness is through the
must be on the flat surface of the motor shaft. See bracket holes. Align the bracket and motor mounting
Figure 15. holes. See Figure 17.

Position Indicator Drive Tube

E-Clip Shift Flat Surfaces

Main Wiring Harness

Figure 17.
Terminal board bracket alignment.
Figure 15.
E-Clip placement.

22. Place the 1/8 inch button Allen head screws into the
19. With the motor leads to the outside, place the motor right side and right top of the plate. The bottom right
gear between the tap changer sections. The motor screw also requires a flat washer. See Figure 18. Use
gear must match up with the pinion drive gear. See a 1/8 inch Allen wrench and tighten the connection
Figure 16. between the motor bracket and the front plate.

Motor and Gear

Motor Mounting Screws

Motor Leads

Figure 16. Figure 18.

Motor replacement. Motor bracket fasteners.

20. Place one drop of locktite on each motor button Allen

head screw thread (1/8).

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SAFETY
FOR LIFE S225-50-35

23. Place the 5/32 inch button Allen head screws in the 28. Place the insulation paper tubing and motor wires in
top bracket and front plate, tightening with a 5/32 Allen the bracket slots at the end of the bracket above the
wrench. See Figure 19. motor and cable tie with one item #3. See Figure 21.
29. Bundle with plastic cable ties the main wiring harness
insulator tube to the bracket with one cable tie, item #3.
See Figure 21.

Motor Harness Tie

5/32 inch Button Allen Head Screws

Motor Insulation Tie

Figure 19.
Terminal board bracket fastening. Main Harness Tie

Figure 21.
Wiring insulation fastening.
24. The inside 1/8 inch motor mounting button head screw
may be easier to start after tightening the 5/32 inch
button Allen head screws.
25. Crimp a ring tongue terminal item #1 to each of the mo- 30. Place the carriage bolt into the square hole of the tap
tor wires after cutting and stripping to fit. changer top bracket. Place the 9/16 nut onto the bolt
through the side channel and tighten with the socket
26. Connect the blue motor wire to post 2 of the large ter-
and ratchet. See Figure 4.
minal board, connect the red wire to past 6, and the
white wire to the ground post G. See Figure 20. 31. Place the control winding hard tubing insulation against
the tap changer top bracket and bundle with plastic
cable ties with item #3. See Figure 3.

White "G" Post

Red Post 6

Blue Post 2

Figure 20.
Terminal board wiring.

27. Use two cable ties item #2, to fasten the motor leads to
the main wiring harness.

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QD3/T350 Motor Replacement Kit Number 57A63675100B

1045 Hickory Street

Pewaukee, WI 53072
© 2006 Cooper Power Systems, Inc. or its affiliates www.cooperpower.com

MC
08/06
Printed on Recycled Paper