Bul. 140U
Q and M-Frame Circuit Breakers
Instruction Leaflet for Drilling and Assembling
Rotary Handle Mechanism
!
WARNING
DO NOT ATTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT IS ENERGIZED. DEATH, SEVERE PERSONAL INJURY, OR
SUBSTANTIAL PROPERTY DAMAGE CAN RESULT
FROM CONTACT WITH ENERGIZED EQUIPMENT.
ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT
BEFORE PROCEEDING WITH THE TASK, AND
ALWAYS FOLLOW GENERALLY ACCEPTED SAFETY PROCEDURES.
THE ALLEN-BRADLEY CORPORATION IS NOT
LIABLE FOR THE MISAPPLICATION OR MISINSTALLATION OF ITS PRODUCTS.
The user is cautioned to observe all recommendations,
warnings and cautions relating to the safety of personnel and equipment as well as all general local health
and safety laws, codes and procedures.
The recommendations and information contained herein
are based on Allen-Bradley's experience and judgment, but should not be considered to be all-inclusive or
covering every application or circumstance which may
arise. If any questions arise, contact Allen-Bradley for
further information or instructions.
1-0 DESCRIPTION
The Allen-Bradley general purpose rotary handle
mechanism is suitable for use with NEMA 1, 3R, 12 and
4, 4x fabricated enclosures. For NEMA 4 and 4x enclosures the rotary handle is labeled and gasketed for these
applications. It is designed for use with
Q-Frame and M-Frame Circuit Breakers, Molded Case
Switches and HMCP’s up to 800 amps (Figure 1-1).
Required for a standard application are the operating
handle, shaft, and mechanism.
Figure 1-1 Handle Mechanism Assembly (Q-Frame
Shown
operate. It may be padlocked in the OFF position utilizing
3 padlocks (.312 Max).
The standard label in the operating handle indicates ON/
Tripped/OFF/Open/Reset. To fulfill international requirements, an alternate handle may be ordered which indicates (1)/Tripped/(O)/Open/Reset.
To meet the various enclosure depths, four variable depth
shafts are offered (6", 12", 16", and 24"). Each shaft
includes a support brace to ensure proper alignment. In
addition, the 16" and 24" extra long shafts include an
adjustable support bracket.
The rotary handle mechanism is Underwriters
Laboratories, Inc. listed for field installation.
The standard mechanism located on the breaker does
include means for internally locking the breaker in the
"OFF" position with up to 3 padlocks each with a maximum diameter of .312".
The operating handle has been designed to meet NFPA
79 requirements. It may be mounted in either the horizontal or vertical direction. The handle was ergonomically
designed with extra clearance for a "gloved hand" to
As an option, an auxiliary switch is offered so that the
control panel builder may electrically indicate the status of
the breaker. This accessory would be mounted on the
mechanism and comes with 24" pigtail leads.
40752-073(1) Effective 6/02
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2-0 INSTALLATION INSTRUCTIONS
The installation procedure consists of: drilling and modifying customer enclosure; installing the circuit breaker
and operating assembly; assembling the shaft to the
operating assembly, and handle assembly to the enclosure cover; testing function of installed handle mechanism. To install the handle mechanism, perform the following steps:
!
WARNING
WHEN INSTALLING A NEW HANDLE MECHANISM,
OR A NEW CIRCUIT BREAKER AND HANDLE
MECHANISM IN AN EXISTING ELECTRICAL SYSTEM, MAKE SURE THERE IS NO VOLTAGE PRESENT WHERE WORK IS TO BE PERFORMED. SPECIAL ATTENTION SHOULD BE PAID TO REVERSE
FEED APPLICATIONS TO ENSURE NO VOLTAGE IS
PRESENT. THE VOLTAGES IN ENERGIZED EQUIPMENT CAN CAUSE DEATH OR SEVERE PERSONAL
INJURY.
2. Turn breaker off. Remove and discard (4) cover
screws on line and load end where mechanism
mounts.
3. Mount circuit breaker to enclosure using the four (4)
1.5" long screws from hardware kit.
4. Mount mechanism onto circuit breaker, ensuring
slide plate is engaged with circuit breaker handle.
For Q-Frame, insert two (2) 2.500" long screws and
lockwashers through mechanism with spacer into
line side of the breaker cover and two (2) 2.125"
long screws and lockwashers through mechanism
into load side of the breaker cover. For M-Frame,
insert four (4) 2.125" long screws and lockwashers
through mechanism into breaker cover (omit spacer)..
Figure 2-2.
Q
Figure 2-2 Breaker/Mechanism Assembly
2-2 Installation of Shaft to Operating Assembly
1. Measure panel depth "D" then determine shaft
length by subtracting 4-1/4" from this dimension.
LD
MDL
A
10.750
16.000
B
5.614
8.302
C
9.531
14.750
D
5.052
7.677
E
3.062
5.687
Figure 2-1 Drill & Tapping Plan for Q-Frame Breaker
2-1 Installation of Circuit Breaker and Operating
Assembly
1. Determine position for circuit breaker in
enclosure. Drill and tap circuit breaker mounting
holes in enclosure mounting surface as shown in
Figure 2-1.
40752-073(1) Effective 6/02
2. Mark shaft measuring length beginning at the
pointed end and cut to correct length (Figure 2-3).
3. If adjustable support extension is being used
(designed for 16" and 24" shaft lengths), install
loosely at this time. Remove screws from extension
and use to attach to shaft support bracket.
4. Place square end of shaft into square opening of
die cast pivot link on the operating mechanism to
the circuit breaker. Ensure pin is in shaft correctly
oriented with respect to anticipated handle position
(vertical or horizontal handle placement, see
Figure 2-4).
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Table 2.1 Correction Factor Table
Correction
Distance
From
Hinge
Flat Hinge
Offset Hinge
4
3/16”
9/16”
5
5/32”
7/16”
6
1/8”
11/32”
7
3/32”
9/32”
8
3/32”
1/4”
9
3/32”
7/32”
10
1/16”
3/16”
11
1/16”
3/16”
12
1/16”
5/32”
Figure 2-3 Cutting Shaft to Length and Collar to Shaft
5. Take set screw and shaft collar from hardware kit
and insert set screw into shaft collar. Place square
end of shaft through shaft support bracket then
through shaft collar and into square opening of die
cast pivot link on the operating mechanism attached
to the circuit breaker, as shown in Figure 2-2.
Position shaft collar lightly against the underside of
the shaft support collar and torque set screw
between 28-30 in-lbs.
6. For vertical and horizontal handle mounting orientation, see Figure 2-5.
7. If adjustable support extension is being used,
tighten securely at this time.
2-3 Installation of Handle Assembly onto Enclosure
Cover
1. To determine where to drill the enclosure door
cover, close the cover with moderate force in order
to cause the point of the shaft to scratch/mark the
paint on the inside of the door.
2. Prior to drilling the 1.50" diameter hole in the cover
door, use correction factor per Table 2.1. Correction
should be made from mark on door (step 1) towards
hinge. Drill 1.50" Dia. hole.
40752-073(1) Effective 6/02
Figure 2-4 Handle Orientation
3. After the hole is drilled, close enclosure cover
allowing the shaft to stick through the opening.
Check this dimension per Figure 2-3.
4. Close enclosure door. Place gasket/template
supplied in hardware kit or cut out the dotted
line of the shaft outline provided in Figure 4-1.
Place the template over the shaft ensuring the
text/wording is facing outward. With the use
of your fingers remove any play by rotating
the shaft in a clockwise motion. Align the
template cutout with the shaft profile and mark
the handle mounting holes. Drill (4) .281"
(7.0 mm) diameter holes.
Page 4
5. Carefully remove the inner portion of the gasket/
template keeping the outer gasket ring and place it
between the handle assembly and door. If this
installation is a NEMA 4 or 4X use the neoprene
gasket supplied with the hardware kit. Loosely
drive the four 1/4-20 x 0.5 screws through both the
door and gasket from the inside of the enclosure
door cover and into the handle assembly. Tighten
evenly. For International handle styles, the handle
mounting hardware is similar to the M6 x 1 x 12
mm screw if misplaced.
6. With power isolated from the circuit breaker, test
function of installed handle mechanism in the
following manner:
a. Close enclosure door. Switch handle mechanism
to ON.
b. Check the handle mechanism switches circuit
breaker to ON position and that enclosure door can
not be opened.
c.
Switch handle mechanism to OFF Position.
d. Check that handle mechanism switches circuit
breaker to OFF position and that enclosure door
cannot be opened.
e. Turn handle to OPEN position and ensure door
opens.
f.
Close enclosure door. Switch handle mechanism/circuit breaker to ON.
g. Turn interlock defeater counter clockwise with a
flat-blade screwdriver.
h. Open enclosure door.
i.
Press Push-to-Trip Button in the circuit breaker
trip unit with a small flat-blade screwdriver to trip.
40752-073(1) Effective 6/02
Figure 2-5 New Handle on Door
Page 5
Fig. 4-1
Full Size Drill Template
40752-073(1) Effective 6/02
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40752-073(1) Effective 6/02
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40752-073(1) Effective 6/02
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40752-073(1) Effective 6/02
Printed in U.S.A./TQC
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