Eaton Bussmann Series Installation guide

Brand: Eaton

Model: Bussmann Series

Type: Installation guide

Installation manual 3A3749 Rev B

Effective October 2018

Supersedes July 2018

CCP2-FLC2-___ ﬂange-cable operating mechanism

HAZARD OF ELECTRIC SHOCK,

EXPLOSION OR ARC FLASH

MAY RESULT IN DEATH OR

SERIOUS INJURY

Working on or near energized circuits

poses a serious risk of electric

shock. De-energize all circuits before

installing or servicing this equipment

and follow all prescribed safety

procedures.

•

Do not install or perform maintenance on

equipment while it’s energized.

•

Death, severe personal injury or substantial

property damage can result from contact

with energized equipment. Always verify

that no voltage is present, and prescribed

safety and lockout/tagout procedures are

followed.

•

Eaton is not liable for the misapplication or

mis-installation of this product.

•

The user is cautioned to observe all

recommendations, warnings and cautions

relating to personnel and equipment safety,

as well as all general and local health and

safety laws, codes and procedures.

•

The recommendations and information

contained herein are based on 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

the Bussmann Division for further

information or instructions.

General information

These instructions cover the installation and

operation of the following Bussmann series flange

cable operating mechanisms installed on 2- or

3-pole versions of the fused 200 and 400 amp

Compact Circuit Protector (CCP2) switches, and

3-pole versions of the non-fused 200 and 400 amp

Compact Circuit Disconnect (CCD2) switches.

Catalog no. Description

NEMA

rating

CCP2-FLC2-36

36” Cable with painted

handle

1, 3R,

CCP2-FLC2-36X

36” Cable with chrome

handle

CCP2-FLC2-60

60” Cable with painted

handle

1, 3R,

CCP2-FLC2-60X

60” Cable with chrome

handle

CCP2-FLC2-120

120” Cable with painted

handle

1, 3R,

CCP2-FLC2-120X

120” Cable with chrome

handle

When installing the optional auxiliary contacts

(cat. no. CCP2-AUX-225) with the flange cable

operating mechanism, the auxiliary contacts must

be installed on the switch’s left side.

Contents

Description Page

General information 1

Required tools 2

Hardware contents 2

Installation and adjustment 2-5

Flange drilling pattern 6

Installation manual 3A3749 Rev B

Effective October 2018

CCP2-FLC2-___ ange-cable operating mechanism

Eaton.com/bussmannseries

Required tools

•

#1 phillips head screwdriver

•

1/4” blade screwdriver

•

Needle nose pliers

•

5/32” Allen wrench

•

3/8” open end wrench

•

7/16” open end wrench

•

(2) 11/16” open end wrenches

•

#8-32 tap and suitable drill bit

•

Electric drill

•

Hacksaw

•

Metal file

Before proceeding, please review flange cable kit contents to be

sure all parts are included. If any are missing, please contact your

local Bussmann series product representative.

Installation

Part 1 — Assemble operator mechanism onto switch

Step 1. Test fit the shaft into right side of switch by inserting until

fully seated (see Fig. 1-1). If shaft protrudes beyond the left side,

mark and trim shaft accordingly with hacksaw. Remove burrs with

metal file. Note: if mounting auxiliary contacts (cat. no. CCP2-

AUX-225) trim shaft sufficiently to permit inserting the auxiliary

contact’s mechanical drive - be careful not to trim shaft in excess

of what’s needed for the auxiliary contact to fully seat against the

switches left side.

Step 2. Place switch in ON position and insert shaft into the switch’s

right side until fully seated. Take care to align the shaft’s lever so that

it’s aligned with the switch handle position (see Fig. 1-2).

Step 3. Secure mechanism frame to the switch’s right side using

four 3.5 x 9 mm phillips head screws and torque to 12 lb-in (see Fig.

1-3).

Step 4. Mount support bracket to mechanism frame using the two

6-32 phillips head screws with 6-32 washers and 6-32 lock washers

and until hand tight (see Fig. 1-4).

Step 5. Assemble cable end to shaft lever with 1/4” shoulder bolt,

spring, two 1/4” washers and 1/4” locknut in order shown (see Fig.

1-5). Tighten nut until secure.

Step 6. Loosen cable adjustment nuts and washers sufficiently to

fully seat cable into the mechanism frame as shown in Fig. 1-6.

Hand tighten nuts until final adjustment (Part 2, Steps 8 through 10).

Step 7. Stretch the spring and insert its small end into the hole on

mechanism frame as shown in Fig 1-7.

Step 8. Install the switch following the instructions provided with

the product. Be sure the switch’s mounting position does not create

a minimum cable bending radius that is less than 4 inches.

Step 9. Once switch is installed, secure support bracket to the panel

wall by locating, drilling and tapping a 8-32 hole for the mounting

screw (see Fig. 1-8). Loosen screws holding the bracket to the

mechanism frame, position bracket, install the 8-32 screw and 8-32

washer and 8-32 lock washer, and tighten to the back panel wall.

Finish by tightening the two screws holding the support bracket to

the mechanism frame.

The switch/mechanism installation is now complete.

Proceed to handle installation.

Flange handle hardware

1x - 1/4" E-Ring

2x - 1/4" Lockwasher

1x - 1/4" Locknut washer

4x - 8-32 x .375" screw

1x - 1/4-20 x .625" Screw

2x - 1/4-20 x .875" Screw

1x - Adapter Link

1x - Handle spring

1x - Door hasp

1x - Interlock hook

mounting bracket

1x - Interlock hook - Short

1x - Interlock hook - Long

Operator mechanism hardware

Support bracket

Mechanism frame

Spring

Shaft/lever assembly

1x - 1/4" Shoulder bolt

2x - 1/4" Washer

1x - 1/4" Locknut

1x - 8-32 x 0.5" Screw

1x - 8-32 Washer

1x - 8-32 Lock washer

2x - 6-32 x 0.25" Screw

2x - 6-32 Washer

2x - 6-32 Lock washer

4x - 3.5 x 9mm Screw

Fig. 1-1. Test fit shaft.

Insert shaft into right side

of switch until fully seated.

If shaft protrudes, mark length

and trim to fit flush.

If also installing an auxiliary contact,

trim additional shaft to accommodate

auxiliary contact mechanical drive.

Fig. A Hardware contents

Installation manual 3A3749 Rev B

Effective October 2018

CCP2-FLC2-___ ange-cable operating mechanism

Eaton.com/bussmannseries

Fig. 1-7. Hook small end of spring into hole on mounting frame,

then long end onto the shoulder bolt, between the cable end and

the two washers.

Fig. 1-4. Mount support bracket to mechanism frame.

Fig. 1-2. Align shaft lever with switch handle.

Fig. 1-5. Assemble cable to shaft lever.

Fig. 1-6. Cable installation on mechanism frame.

Fig. 1-8. Installing support bracket to panel wall.

Insert shaft so

lever is aligned with

switch handle position.

Fig. 1-3. Secure mechanism frame to switch using four phillips head

screws.

Lock nut

Shaft level

Lockwashers

Cable end

Shoulder bolt

Loosen cable adjustment nuts and

place cable in mechanism frame

Second, pull long end of spring

forward and hook to shoulder

bolt between the cable end and

the two washers

First

, hook short end of spring

into the hole on the rear of the

mechanism frame

Adjust support bracket

so it’s flush with the panel

and tighten the two screws.

Insert 8-32 screw with washer and

lock washer into support bracket

and tighten.

Installation manual 3A3749 Rev B

Effective October 2018

CCP2-FLC2-___ ange-cable operating mechanism

Eaton.com/bussmannseries

Part 2 — Assemble flange handle onto enclosure

Refer to Fig 2-1, unless otherwise noted.

Step 1. Place the outer handle mechanism with attached gasket

over the enclosure cutout. (For cut-out dimensions, refer to Fig 3-1).

Insert the top 1/4-20 outer handle mechanism mounting screw and

lock washer through the enclosure and thread into the outer handle

mechanism for a few turns, but not all the way.

Step 2. Slide the toggle mechanism assembly over the top of the

handle mounting screw installed in Step 1. Insert the bottom outer

handle mechanism- mounting screw and lock washer through the

toggle mechanism bracket, through the enclosure, into the handle.

Step 3. Securely tighten both mounting screws.

Step 4. Insert the adapter link into the bell crank’s pin via the largest

hole on the link (see Fig. 2-3) Secure the adapter link by inserting the

E-ring into the slot on the bell crank pin.

Step 5. Rotate the bell crank towards the handle and rotate the

handle to the ON position. Align the adapter link and attach it to the

actuator link using the 1/4-20 pan head screw and nut. See Fig 2-4.

Step 6. Connect the spring’s long end through the adapter link’s

hole. Hook the spring’s shorter end into the tab on the lower portion

of the toggle mechanism. See Fig 2-5.

Step 7. Mount door interlock hasp to handle using two #8-32

SEMS screws. See Fig. 2-2. Hasp orientation may be modified per

customer requirements and enclosures.

Step 8. Close enclosure door and check operation of door interlock

hardware, adjust if necessary.

Step 9. Cycle handle ON and OFF to check switch operation. To

cycle the mechanism, either close door or defeat door interlock lever.

Step 9a. If switch cycles correctly, proceed to tighten cable

adjustment nuts on switch mechanism. If switch does not cycle ON

and OFF, proceed to Step 10.

Step 10. Adjust cable position by loosening cable adjustment nuts

on switch and repositioning the cable up or down until satisfactory

operation is obtained (see Fig. 2-6). Tighten cable adjustment nuts to

70 lb-in when finished with adjustment.

Adapter link

connects with

bell crank

Nut/lockwasher, 1/4-20

Handle mechanism

Door interlock hasp.

Orientation may be modified

depending on requirements

and enclosure.

Interlock hasp/hook

screws, 8-32 x 0.375”

(4 places, 2 on handle,

2 on door for hook)

1/4-20 x 0.625” bolt

Spring

Rotate handle

to ON positio

Assemble adapter

link to bell crank

and secure with E-ring

Line up holes by

rotating bell crank

and adapter link

Assemble adapter

link with bolt,

washer and nut

Line up holes by

rotating bell crank

and adapter link

Assemble adapter

link with bolt,

washer and nut

Outer handle

mechanism

mounting

screws,

1/4-20 0.875

(2 places)

1/4 lockwashers

(2 places)

Bell crank

Toggle mechanism

assembly

Enclosure

Outer handle

mechanism

NOTE:

Assemble these items

after handle is mounted

to the enclosure

Figure 2-1. Toggle mechanism and handle to enclosure.

Figure 2-2. Outer handle mechanism assembly.

Figure 2-3. Adapter link assembly to bell crank.

Figure 2-4. Adapter link assembly to actuator link.

Installation manual 3A3749 Rev B

Effective October 2018

CCP2-FLC2-___ ange-cable operating mechanism

Eaton.com/bussmannseries

Place long end of spring

through hole in

adapter link

Attach short end

of spring through

hole in tab of

toggle mechanism

Figure 2-5. Spring assembly to toggle mechanism.

Figure 2-6. Adjust switch operation by loosening cable adjustment

nuts and repositioning cable up or down.

Loosen cable adjustment nuts

and adjust up or down until

satisfactory ON/OFF operation

is achieved.

Tighten nuts when complete.

Installation manual 3A3749 Rev B

Effective October 2018

CCP2-FLC2-___ ange-cable operating mechanism

Eaton.com/bussmannseries

Upper hole

5.75” min

2.75” min

inside

1.9

Datum

2 clearance holes

in flange for

1/4-20 screws

0.56 ± 0.01

3.44

± 0.01

0.5

± 0.01

4.69

± 0.005

Datum

R = 0.25

1.62”

min

4.0

0.25

0.62

2.0

1.5

Fig. 3-1. Flange drilling pattern for handle and interlock blade

mounting.

The instructions for installation, testing, maintenance, or repair

herein are provided for the use of the product in general commercial

applications and may not be appropriate for use in nuclear

applications.

These instructions are published solely for information purposes

and should not be considered all-inclusive. If further information is

required, you should consult an authorized Bussmann series sales

representative.

The sale of the product shown in this literature is subject to the

terms and conditions outlined in appropriate Eaton selling policies

or other contractual agreement between the parties. This literature

is not intended to and does not enlarge or add to any such contract.

The sole source governing the rights and remedies of anyone

purchasing this equipment is the contract between the purchaser

and the Bussmann division.

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING

WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR

MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE

OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING

THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS

CONTAINED HEREIN.

In no event will Eaton be responsible to the purchaser or user in

contract, in tort (including negligence), strict liability or otherwise

for any special, indirect, incidental or consequential damage or loss

whatsoever, including but not limited to damage or loss of use of

equipment, plant or power system, cost of capital, loss of power,

additional expenses in the use of existing power facilities, or claims

against the purchaser or user by its customers resulting from the

use of the information, recommendations and description contained

herein.

Installation manual 3A3749 Rev B

Effective October 2018

CCP2-FLC2-___ ange-cable operating mechanism

Eaton.com/bussmannseries

Notes

CCP2-FLC2-___ ange-cable operating mechanism

Installation manual 3A3749 Rev B

Effective October 2018

Eaton and Bussmann are valuable trademarks

of Eaton in the U.S. and other countries. You

are not permitted to use the Eaton trademarks

without prior written consent of Eaton.

ANSI is a registered trademark of the

American National Standards Association

IEEE is a registered trademark of the Institute

of Electrical and Electronics Engineers

NEMA

is a registered trademark of the

National Electrical Mfgrs. Association

NFPA

is a registered trademark of the National

Fire Protection Association

is a registered trademark of the

Underwriters Laboratories, Inc.

Eaton

1000 Eaton Boulevard

Cleveland, OH 44122

Eaton.com

Bussmann Division

114 Old State Road

Ellisville, MO 63021

United States

Eaton.com/bussmannseries

Printed in USA

Publication No. 3A3749

October 2018

Eaton Bussmann Series Installation guide

Eaton Bussmann Series Installation guide

Eaton Bussmann Series Installation guide

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