Cutler-Hammer Flex Shaft User manual

I.L. 15606C
File 29-000
Effective February 2001 Supersedes I.L. 15606B dated October 1997
Cutler-Hammer
Instructions for Drilling and Assembling Flex ShaftTM Handle Mechanism for
L, M, MDL, N, and R-Frame Series C Circuit Breakers, Molded Case
Switches, and HMCP’s
DO NOT ATTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT IS ENER-
GIZED. SEVERE PERSONAL INJURY, DEATH, 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.
CUTLER-HAMMER 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 person-
nel and equipment as well as all general local health
and safety laws, codes and procedures.
The recommendations and information contained herein
are based on Cutler-Hammer's experience and judg-
ment, but should not be considered to be all-inclusive or
covering every application or circumstance which may
arise. If any questions arise, contact Cutler-Hammer for
further information or instructions.
!
WARNING GENERAL INFORMATION
The Shaft handle mechanism provides a means of exter-
nally operating the circuit breaker and can be applied to
enclosures of varying heights and depths. The handle
can be used with NEMA 1, 3R, and 12 enclosure applica-
tions, plus NEMA 4 and 4x applications, depending on
the accessory components selected. An operating han-
dle, flexible shaft, and mechanism are required for stan-
dard applcation. Three lengths of shafts are available for
use with the range of depths of various enclosures (4’, 5’,
and 6’). When selecting the length of the Flexible Shaft,
ensure Minimum Bending Radius of 5 inches is main-
tained to operate properly. The flex shaft assembly is
Underwriters Laboratories, Inc. listed under UL File
E64983.
WHEN INSTALLING A NEW HANDLE MECHANISM,
OR A NEW CIRCUIT BREAKER AND HANDLE
MECHANISM IN AN EXISTING ELECTRICAL SYS-
TEM, MAKE SURE THERE IS NO VOLTAGE PRE-
SENT WHERE WORK IS TO BE PERFORMED. SPE-
CIAL ATTENTION SHOULD BE PAID TO REVERSE
FEED APPLICATIONS TO ENSURE NO VOLTAGE IS
PRESENT. THE VOLTAGE IN ENERGIZED EQUIP-
MENT CAN CAUSE DEATH OR SEVERE PERSONAL
INJURY.
Figure 1-1 Pivot Bracket and Outer Handle Mechanism Assembly
!
WARNING

I.L. 15606C
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Effective 2/01
Figure 1-2 LD, MDL, ND, RD Mechanism Assembly

INSTALLATION
1. Remove the two 1/4-20 x 5/8" screws and
lockwashers from the outer handle mechanism.
Place each screw and lockwasher though the pivot
bracket assembly Thread the retaining washers
enclosed in the parts kit onto the 1/4-20 x 5/8"
screws. See Figure 1-1.
2. Connect the actuator link from the outer handle
mechanism on the pivot bracket assembly Mount
the pivot bracket assembly to the enclosure and
outer handle mechanism by securing the mounting
hardware. Attach the E-Ring supplied in the parts kit
to the actuator link. See Figure 1-1.
3. Drill and tap the mounting holes for the circuit
breaker. See breaker frame instruction leaflet for the
drilling pattern.
Note: Be certain that there is a 5 inch minimum
clearance between the load end of the breaker and
wall of the enclosure for the flex shaft.
4. Mount breaker's Line end to enclosure using the
mounting hardware supplied in the hardware kit.
5. Attach the base plate and mounting hardware to the
load end of the circuit breaker per the following
breaker frames:
LD: Attach the base plate and Load end of the breaker
to enclosure using the 1/4-20x4.75" screws and lock-
washers enclosed. See Figure 1-2 for illustration.
M: Attach the Load end of the breaker to the enclosure
using hardware frame parts kit. Attach the base plate to
the Load end cover on the (M) type breaker. The load
end cover screws are replaced with the (2) 10-32x2"
screws and lockwashers enclosed. (Not shown in Figure
1-2).
MDL: Attach the load end of the breaker to the enclo-
sure using hardware from the hardware kit. Attach the
base plate to the load end cover of the breaker. The
load end cover screws are replaced with the (2) #8-
32x2.25" screws, #8 lockwashers, and mounting
sleeves enclosed. See Figure 1-2 for illustration.
ND: Attach the Load end of the breaker to the enclosure
using hardware from the hardware kit. Attach the base
plate to the circuit breaker using the 1/4-2Ox3.5" screws
and 1/4" lockwashers enclosed in the parts kit at the
load end of the breaker after removing the (2) load
cover screws located between the trip unit and the two
load end mounting holes. See Figure 1-2 for illustration.
I.L. 15606C Page 3
Effective 2/01
RD: Attach the Load end of the breaker to the enclosure
using the hardware from the hardware kit. Attach the
base plate to the circuit breaker using the 1/4- 20x3.75"
screws and 1/4" lockwashers enclosed in the parts kit at
the load end of the breaker. See Figure 1-2 for illustra-
tion.
Note: Prior to Dec. 1994: The Breaker mounting
hardware for Line end and Load end mounting
(except LD) were in the appropriate breaker frame
mounting hardware kit. The mounting hardware is
now included in the hardware parts enclosed.
6. Place the outer handle mechanism in the full ON
position and the circuit breaker in the ON position.
You must Release Cover interlock to move handle
to ON position. Place the handle extension assem-
bly onto the breaker handle and secure as shown
on Figure 1-2.
Note: LD and MD use clamp type assembly: ND and
RD use a through bolt for handle attachment from
the hardware kit.
7. Locate bulk head nuts of the flexible shaft over the
groove of the base plate and tighten.
8. Actuate the outer handle positions (ON, OFF,
RESET). If minor adjustments are necessary, refer
to the following adjustment checklist and Figure 1-2.
Install appropriate door hardware (supplied); as
referenced on Figure 1-3.
ADJUSTMENT CHECKLIST
Situation:
Breaker turns ON and OFF, but will not RESET when
tripped.
Adjustment:
Loosen the 1/4-28 adjusting nut that is closest to the
black cap and turn towards the cap about 1.5-2 turns.
Retighten the adjusting nut that is on the end of the
shaft to the handle extension and inner adjusting nut.
Recheck for the ON, OFF and RESET position. If not
successful, repeat procedure. If still not successful, and
the adjusting nut is bottomed out onto the shaft, loosen
the bulk head nuts, and shift the cable towards the Load
end of the breaker. Re-tighten the bulk head nuts.
Recheck for the ON, OFF and RESET position. If not
successful, repeat the beginning steps.

I.L. 15606C
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Effective 2/01
Situation:
Breaker resets after tripping, but does not turn ON.
Adjustment:
Loosen the 1/4-28 adjusting nut that is located on the
end of the shaft and turn towards the end of the shaft
about 1/5-2 turns. Re-tighten the adjusting nut that is
closest to the black cap to the handle extension and the
outing adjusting nut. Re-check for the ON, OFF and
RESET position. If not successful, and the adjusting nut
on the end of the shaft is two threads from the end,
loosen the bulk head nuts, and shift the cable towards
the line end of the breaker. Re-tighten the bulk head
nuts. Re-check for the ON, OFF and RESET position. If
not successful, repeat the beginning steps.
If any other adjustment problems should arise, contact
your local Cutler-Hammer representative.

I.L. 15606C Page 5
Effective 2/01
Figure 1-3 Flange Drilling Plan For Handle and Interlock Blade Mounting Dimensions
AMT-Vari-Depth Handle Mechanisms (Dimensions in Inches)
Outline and Drilling Plans
For Enclosure Door Interlock Assembly

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I.L. 15606C Page 7
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Cutler-Hammer
Pittsburgh, PA 15220
Effective 2/01 (ISI)
Style 6648C76H04
Printed in U.S.A.
I.L. 15606C
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