Allen-Bradley 1494V Flange Operated Circuit Breaker Kits (125A / 150A / 250A / 400A) Installation Instructions

1
2
3
A
4
5
6
7
8
Bulletin 1494V Variable Depth, Flange Operated Circuit Breaker Kits for 125A, 150A
250A and 400A Frame Sizes
ATTENTION: To prevent electrical shock, disconnect from power source before installing or servicing. Install
in suitable enclosure. Keep free from contaminants.
Components
Cat No.
1494F-M1
1494F-P1
1494F-S1
B
1494V-RA3
1494V-RA4
Switch Rating
(Amps)
Description
5-1/2" Painted Metal Handle
5-1/2" Molded Handle
5-1/2" Stainless Steel Handle
125A...400A
Standard Connecting Rod
Enclosure Working Depth: 6-3/4" to 9-1/8"
Extended Connecting Rod
Enclosure Working Depth: 9-1/8" to 23"
125A...400A
1494V-M41
Circuit breaker mechanism for use with
Allen-Bradley: 140U-H (MCCP), 140M-H (MCP)
Cutler-Hammer: EF, HMCPE
125A
1494V-M40
Circuit breaker mechanism for use with
Allen-Bradley: 140M-I (MPCP and MCP)
Cutler-Hammer: EHD, FD, FDB, FDC, HFD, HMCP
150A
1494V-M51
Circuit breaker mechanism for use with
Allen-Bradley: 140U-J (MCCB), 140M-J (MPCB and MCP)
Cutler-Hammer: EF
250A
C
1494V-M50
D
Circuit breaker mechanism for use with
Cutler-Hammer: JD, JDB, JDC, HJD, HMCP
250A
Circuit breaker mechanism for use with
Allen-Bradley: 140U-K (MCCB), 140M-K (MPCB and MCP)
Cutler-Hammer: KD, KDB, KDC, HKD, HMCP
1495-N8
(1) N.O. Auxiliary Contact
1495-N9
(1) N.C. Auxiliary Contact
1495-N21
Auxiliary Contact Adapter Kit
125A...150A
1495-N23
Auxiliary Contact Adapter Kit
250A...400A
TE
R
G MIN
UA
RD AL
1494V-M60
400A
N.O
.
125A...400A
E
F
42052-074-01 (1)
Printed in U.S.A.
G
REFERENCE
REVISION
AUTHORIZATION
1
1013923
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
CIRCUIT BREAKER AND ACCESSORY
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
G. Ushakow
CHKD. M. Jutz
APPD. J. Koziczkowski
DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
11-13-03
11-13-03
11-13-03
DWG.
SIZE
B
SHEET
1
OF
7
42052-074
B-vertical.ai
1
A
2
3
4
5
6
7
8
Handle Installation
1
C
Locate Handle
C
B
B
A
A
E
E
B
Door Catch
Mounting
Bracket
Door Catch
Mounting
Bracket
D
D
Right Hand-Flange
C
Left Hand-Flange
FRAME
SIZE
A
(min)
B
(min)
C
(max)
D
125A, 150A
3 - 1/2"
29/32"
1 - 3/32"
1 - 5/8"
250A
10 - 29/32"
29/32"
1 - 3/32"
400A
13 - 3/32"
29/32"
1 - 3/32"
E
F
G
H
J
2 - 11/32" 4 - 11/16" 1 - 9/16"
1"
7/8"
1 - 5/8"
2 - 11/32" 4 - 11/16" 1 - 9/16"
1"
7/8"
1 - 5/8"
2 - 11/32" 4 - 11/16" 1 - 9/16"
1"
7/8"
3 Locate Door Catch
2 Drill Handle Holes
(2) .265 Dia. Holes
Enclosure Door
G
Door Catch
Mounting Bracket
30 lb-in
H
To make slot drill
(3) 1/2" diameter holes
and remove burrs
D
F
J
Enclosure
Base
C
Door Catch
H
D
B
Notes:
A) Enclosures with a Flange Thickness less than 3/16" use dimensions above.
B) Enclosures with a Flange Thickness 3/16" and greater use dimensions in Mounting Kit 1494V-H3.
C) Multi-Door Enclosures use dimensions in Channel Support Kit 1494V-H4, if handle is mounted atop channel.
D) The door catch mounting bracket is provided with projections for welding; however, holes can be drilled in the bracket using the
projections for locating hole centers. After proper location, use the bracket as a template and drill corresponding holes in the
enclosure door. Fasten the bracket with hardware supplied by user. If properly assembled, the hardware should not be accessible for
tampering with by unauthorized personnel.
E
4
Install Defeater Lever
5
Install Gasket
6
Install Handle to Flange
7-11 lb-in
2
23-37 lb-in
1
F
(2)
G
REFERENCE
REVISION
AUTHORIZATION
1
1013923
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
CIRCUIT BREAKER AND ACCESSORY
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
2
OF 7
42052-074
B-vertical.ai
1
A
2
3
4
5
6
7
8
Circuit Breaker Mechanism Installation
1
2
1494V-M41
1494V-M51
(Only)
N
Enclosure
Working Depth
(Flange to
Mounting Plate)
2
Connecting
Rod
Catalog Number
Standard
Extended
"N"
Min.
Max.
1494V-RA3
6-3/4"
9-1/8"
1494V-RA4
9-1/8"
23"
N - 3"
1
B
16 - 22 lb-in
3
LL
3
Threaded Rod
C
4a Locate Circuit Breaker Mechanism (125A and 150A Frame Circuit Breakers)
CC
BB
AA
BB
AA
CC
D
EE
AA
DD
E
Right Hand-Flange
F
Left Hand-Flange
Frame
Size
AA
BB
CC
DD
EE
Wire
Bending
Space
Mechanism
Mounting
Hole (Tapped)
KK
Mechanism
Mounting
Hole (Tapped)
lb-in
125A
1/4"
2 - 7/64"
1 - 3/8"
4 - 1/2"
6
(4) - #8-32
20
150A
1/4"
2 - 7/64"
1 - 3/8"
4 - 1/2"
6
(4) - #8-32
20
(3)
G
REFERENCE
REVISION
AUTHORIZATION
1
1013923
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
CIRCUIT BREAKER AND ACCESSORY
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
3
OF
7
42052-074
B-vertical.ai
1
A
2
3
4
5
6
7
8
Circuit Breaker Mechanism Installation (Cont'd)
4b Locate Circuit Breaker Mechanism (250A and 400A Frame Circuit Breaker)
BB
CC
BB
MM
CC
MM
FF
GG
HH
B
AA
GG
HH
EE
EE
DD
DD
KK
KK
JJ
LL
LL
Right Hand-Flange
C
JJ
Left Hand-Flange
Frame
Size
AA
BB
CC
DD
EE
FF
GG
HH
LL
Mechanism
MM
Mounting
Wire
Bending Hole (Tapped)
JJ
Space
250A
13/16"
2 - 9/32"
1 - 3/8"
7 - 1/4"
-----
1 - 7/32"
-----
10 - 5/8"
2 - 31/32"
10
400A
-----
2 - 13/16" 1 -23/32"
-----
8 - 7/16"
1 - 13/32"
1/4"
10 - 3/4"
3 - 43/64"
12
Mechanism
Mounting
Hole (Tapped)
KK
Mechanism
Mounting
Hole (Tapped)
lb-in
(2) - #10-32
(4) - 1/4-20
60
(2) - #10-32
(4) - 1/4-20
60
6
5
D
2
16 - 20 lb-in
On
Off
Toggle
Adjustment
Plate
Toggle
Adjustment
Plate
UP
1
E
25 - 30 lb-in
3
15
0A
5A
12
125A / 150A
Circuit Breaker
250A / 400A
Circuit Breaker
F
(4)
G
REFERENCE
REVISION
AUTHORIZATION
1
1013923
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
CIRCUIT BREAKER AND ACCESSORY
INSTALLATION INSTRUCTION SHEET
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
4
OF
7
42052-074
B-vertical.ai
1
A
2
3
4
5
6
7
8
Circuit Breaker Installation (Cont'd)
7
8
2
2
3
B
1
4
1
3
Hitch Pin
C
Testing of Circuit Breaker
1. Verify that the circuit breaker can be turned on by moving the defeater lever downward and moving the disconnect
handle to the ON position.
2. If the circuit breaker does not turn on, loosen the (2) screws and adjust the toggle adjustment plates toward the line
terminals until the circuit breaker turns on when the disconnect handle is in the ON position. Tighten the (2) toggle
adjustment plate screws to 25 - 30 lb-in.
3. If the circuit breaker still can not be turned on unhook the spring, remove hitch pin and separate threaded rod and
handle link. Turn threaded rod one full turn counterclockwise. Reattach threaded rod and handle link, hitch pin and
spring. Repeat Step 1 and if necessary Step 2.
4. Verify that the circuit breaker can be turned off by moving the disconnect handle to the OFF position.
5. If the circuit breaker can not be turned off, loosen the (2) screws and adjust the toggle adjustment plates toward the
load terminals until the circuit breaker turns off when the disconnect handle is in the OFF position. Tighten the (2)
toggle adjustment plate screws to 25 - 30 lb-in.
6. If the circuit breaker still can not be turned off and if no adjustment of the threaded rod was made in Step 3 then
unhook the spring, separate threaded rod and handle link and remove hitch pin. Turn threaded rod one full turn
clockwise. Reattach threaded rod and handle link, hitch pin and spring. Repeat Step 4 and if necessary Step 5.
7. Verify that the circuit breaker can be reset after manually tripping when circuit breaker is in the ON position.
8. Manually trip the circuit breaker while in the ON position, then move the disconnect handle to the Off-Reset
position.
9. If the circuit breaker does not reset, loosen the (2) screws and adjust the toggle adjustment plates in small
increments toward the load terminals.
Note: Repeat this procedure until the circuit breaker can be reset.
Note: Do not adjust the toggle adjustment plate too far: this will prevent the disconnect handle from moving to the full OFFReset position.
10.Tighten the (2) adjustment plate screws to 25 - 30 lb-in.
11.Verify that the circuit breaker can still be turned on following the above steps.
Note: Twisting of the bail mechanism is acceptable when the handle is in the full ON or full OFF position.
D
E
F
(5)
G
REFERENCE
REVISION
AUTHORIZATION
1
1013923
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
CIRCUIT BREAKER AND ACCESSORY
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
5
OF 7
42052-074
B-vertical.ai
1
2
3
4
5
6
7
8
A
Auxiliary Installation
Safety Guards
5
On
Off
1
B
Bulletin 1495
Auxiliary
Contacts
Slot B
Slot A
Base
Assembly
3
Support
Bracket
Bail
4
Support
Plate
Bushings
Safety Guard
C
Cam
2
Bulletin 1495
Auxiliary
Contacts
1. Move the disconnect handle on the combination starter to the OFF position.
2. Fasten the cam and bushings to the bail with (2) flat washers, (2) lock washers, and (2) screws Tighten to 12 - 16 lb-in.
3. Fasten the base assembly to the support bracket with (2) screws. Tighten to 7 - 10 lb-in.
4. Attach the assembly from Step 3 to the ear on the support plate with (2) screws. Tighten to 7 - 10 lb-in.
5. Attach the auxiliary contact with the safety guard to the base assembly.
Note: If a single auxiliary contact is used, it must be positioned nearest the cam, in slot A shown above. A second auxiliary contact
would be positioned in slot B.
D
Testing of Auxiliary Contacts
1. Make sure the auxiliary contact and adapter kit (circuit breaker) have been installed in the proper position.
2. If the auxiliary contact (circuit breaker) is N.O., place the probes of the continuity tester across both terminals with the
disconnect handle in the OFF position; there should be no continuity.
3. Move the disconnect handle to the ON position and place the probes of the continuity tester across both terminals; there
should be continuity.
4. If the auxiliary contact (circuit breaker) is N.C., place the probes of the continuity tester across both terminals with the
disconnect handle in the OFF position; there should be continuity.
5. Move the disconnect handle to the ON position and place the probes of the continuity tester across both terminals; there
should be no continuity.
E
F
42052-074-01 (1)
Printed in U.S.A.
G
REFERENCE
REVISION
AUTHORIZATION
1
1013923
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
CIRCUIT BREAKER AND ACCESSORY
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
6
OF 7
42052-074
B-vertical.ai
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