Allen-Bradley HL Selector Switches Installation Instructions

Allen-Bradley HL Selector Switches are designed for use in NEMA Type 7 and 9 enclosures. They offer robust construction for demanding environments and are compatible with a range of panel sizes. The switches feature a locking screw for secure mounting and adjustable nut for precise positioning. They are suitable for both new installations and replacement applications.

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INSTALLATION INSTRUCTIONS 800HL-EMP POTENTIOMETER
FOR NEMA TYPE 7 [3/8&quot; (9.5) TO 2-1/2&quot; (50.8) PANELS]
AND TYPE 9 [7/32&quot; (7.2) TO 2-1/2&quot; (50.8) PANELS] &Auml;
WARNING
To avoid damage to equipment or injury to personnel, electrical power
must be off before and during installation and maintenance.
Maintain &frac12;&quot; (12.7) minimum clearance through air between
current-carrying parts and enclosure.
ADJUSTING NUT
SET SCREWS
1/16&quot; (1.6) HEX WRENCH
TIGHTEN TO 4 &plusmn; 1/2 LB-IN
ADAPTER RING
HOUSING
PANEL
SECURING RING
SHAFT
&Aacute;&Acirc;
KNOB
MOUNTING RING
MOUNTING BUSHING
LEGEND PLATE
Figure 1
LOCKING SCREW
Installation: See Figure 1 for illustrated assembly.
1. Place securing ring and/or adjusting nut as supplied on unit and thread unit into panel until bushing extends
approximately 11/32&quot; (8.7) [4 to 5 threads], past front of panel - 9/32&quot; (7.1) [3 to 4 threads] if a legend plate is not to be
used, see Figure 3.
2. To secure unit, rotate to a position which provides electrical clearance and tighten adjusting nut and/or locking screw.
Where two units are mounted adjacently, arrange securing rings to avoid interference.
3.
When Installing in a metal enclosure, maintain 1/2” (12.7) minimum
WARNING
clearance through air between current carrying parts enclosure.
4. Place legend plate, if to be used, over mounting bushing.
5. Assemble mounting ring adapter and tighten.
6. Rotate shaft counterclockwise to stop.
7. Position knob on shaft aligning white indexer on knob with &quot;min.&quot; increment marking on legend plate.
8. Tighten the two set screws in the knob to 4 &plusmn; &frac12; lb.-in. with a 1/16&quot; (1.6) hex wrench.
9. Install mounting ring and tighten. Allen-Bradley Catalog No. 800T-N3 wrench is available for this operation.
Replacing Potentiometer: See Figure 3 for illustrated assembly.
NOTE 1: Refer to nameplate on housing for original potentiometer resistance.
NOTE 2: Unit need not be removed from enclosure to replace potentiometer.Potentiometer Removal:
1. Remove the two screws on the rear of the housing and pull the housing (see Figure 3) from the bushing.
2. Disconnect the three wire leads from the potentiometer terminals.
3. Loosen the two set screws in the shaft adapter with a 1/16&quot; (1.6) hex wrench and remove shaft adapter from
potentiometer shaft.
4. Remove nut, lockwasher and mounting plate.
Potentiometer Installation:
1. Remove mounting ring leaving mounting ring adapter in place. Allen-Bradley Catalog No. 800T-N3 wrench is available
for this operation.
2. Loosen the two set screws in the knob with a 1/16&quot; (1.6) hex wrench and remove knob.
3. Rotate shaft so that it extends .40 &plusmn; .01 (10.2 &plusmn; .2) from bushing.
4. Before installing potentiometer bend the three terminals 80&deg; -90&deg; and remove nut and lockwasher from bushing (see
Figure 2).
5. Install mounting plate, printed side facing outward, over potentiometer shaft aligning locating tab on potentiometer
with slot in mounting plate.
6. Tighten nut and lockwasher on potentiometer shaft and bend locating tab to fit mounting plate.
7. Insert wire leads onto the potentiometer terminals making sure the leads identified as 1, 2 and 3 are attached to the
correspondingly identified potentiometer terminals. (See Figure 3 for terminal identification.) If the potentiometer
housing does not have wires with terminal lugs, cut and strip the wires and solder the wire end to the appropriate
potentiometer terminal.
40060-303-01 Ver (06)
Printed in U.S.A
8. Rotate potentiometer clockwise to stop.
9. Place shaft adapter onto potentiometer shaft. Rotate shaft adapter to orient slot in shaft adapter with roll pin in shaft
while holes in diaphragm and mounting plate are in line with holes in mounting bushing.
10. Tighten the two set screws in the shaft adapter to 4 &plusmn; &frac12; lb.-in. with a 1/16&quot; (1.6) hex wrench.
11. Line up holes in housing, mounting plate, and mounting bushing and push the unit into the mounting bushing.
12. Secure by threading in the two screws from the rear of the potentiometer housing.
13. Rotate shaft counterclockwise to stop.
14. Position knob on shaft aligning white indexer on knob with &quot;min.&quot; increment marking on legend plate.
15. Tighten the two set screws in the knob to 4 &plusmn; &frac12; lb.-in. with a 1/16&quot; (1.6) hex wrench.
16. Install mounting ring and tighten. Allen-Bradley Catalog No. 800T-N3 wrench is available for this operation.
 Enclosure must comply with U.L. standards 698 and 1203 and CSA standard C22.2 No. 30 for Class I Groups B, C and
D hazardous locations or C22.2 No. 25 for Class II Groups E, F and G hazardous locations. For Class I locations, a
suitable seal fitting is required within 18 inches.
 Hole size to be .958 (24.3 &Oslash;) to .970 diameter (24.6 &Oslash;) &frac34;-14NPSM tap.
 Apply grease from capsule (supplied) to threads of &frac34;-14NPSM hole before assembling units into panel and to the
threads of the lens assembly.
 For standard length units (Bul. 800H), maximum panel
KNOB
thickness is 1” (25.4). From 3/4” (9.5) to 23/32” (18.3)
securing ring is used as shown, without adjusting nut.
SET SCREWS
MOUNTING
1/16&quot; (1.6) HEX WRENCH
Securing ring is reversed when panel thickness is from
RING
11/32 (8.7) IF
TIGHTEN TO 4 &plusmn; 1/2 LB-IN
23/32” (18.3) to 29/32” (23) and eliminated between 29/32”
LEGEND PLATE
MOUNTING RING
IS
TO
BE
USED
(23) and 1” (25.4).
ADAPTER
9/32 (7.1) IF
 For long barrel units (Bul. 800H), maximum panel thicknes
SHAFT
PLATE
is 21/2” (63.5). For panels above 2” (50.8) but not exceeding LEGEND
IS NOT TO BE USED
40 &plusmn; .01 (10.2 &plusmn; 2)
LEGEND
21/2” (63.5) remove and discard securing ring and tighten
PLATE
device with adjusting nut only.
ENCLOSURE
 For Class I Group B application, 5/8&quot; (15.9) minimum panel
thickness is required.
ROLL PIN
SECURING RING
Power Rating:
Maximum power (P) = 2 watts provided maximum working
LOCKING SCREW
MOUNTING
voltage is not exceeded.
BUSHING
ADJUSTING NUT
Maximum working voltage (EMAX) shall not exceed 300 volts
(RMS or DC) or as determined by EMAX=&Ouml;PR, R = resistance,
SET SCREWS
SHAFT ADAPTER
1/16&quot; (1.6) HEX WRENCH
whichever is less. See Table 1 for power derating with respect
TIGHTEN TO 4 &plusmn; 1/2 LB-IN
DIAPHRAGM
to rotation for rheostat application.
Table 1
Power derating with respect to rotation
for rheostat application
Multiplying
Percent
Wattage
Rotation
Rating By
100
1.00
90
.99
80
.98
70
.96
60
.93
50
.89
40
.81
30
.68
20
.49
10
.23
0
.11
NUT AND LOCKWASHER
POTENTIOMETER SHAFT
PRINTED SIDE
LOCATING TAB
MOUNTING PLATE
POTENTIOMETER
POTENTIOMETER
TERMINAL
TERMINAL
IDENTIFICATION
WIRE LEAD
HOUSING
MOUNTING
SCREW
MOUNTING
SCREW
80&deg; - 90&deg;
Figure 3
25
40060-303-01 Ver (06)
Printed in U.S.A
Figure 2
Rockwell Automation,
1201 South Second Street,
Milwaukee, WI 53204-2496 USA,
Tel: (1)414.382.2000, Fax:(1)414.382.4444
NOTE:
WIRE RANGE:
18-14 AWG (0.5-2.5mm2)
TIGHTENING TORQUE:
6-7lb.in (0.7-0.8 Nm)
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Key features

NEMA Type 7 & 9 enclosures
Adjustable nut
Locking screw
Potentiometer replacement
Legend plate compatibility
Power derating table

Frequently asked questions

This switch is compatible with NEMA Type 7 panels ranging from 3/8” (9.5) to 2-1/2” (50.8) and Type 9 panels ranging from 7/32” (7.2) to 2-1/2” (50.8).

To replace a potentiometer, you need to follow a multi-step process, including removing the housing, disconnecting the wires, loosening set screws, and removing the shaft adapter. Then, install a new potentiometer, aligning the tabs, tightening the nut and lockwasher, connecting the wires, and reassembling the housing. You can find detailed instructions in the viewed document.

The locking screw should be tightened to 4 ± ½ lb.-in with a 1/16” (1.6) hex wrench.