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Reliance, FlexPak and WebPak are trademarks of Rockwell Automation.

250 Amp and 400 Amp AC Line Disconnect Kits

for FlexPak 3000 and WebPak 3000 Digital DC Drives

40 to 75 HP @ 230 VAC, 75 to 150 HP @ 460 VAC, 265 A @ 380 / 415 VAC

M/N 901FK1102, 901FK1112, 901FK1202, 901FK1212

Instruction Manual D2-3395-1

Product Description

This instruction manual describes optional AC input line disconnect kits that can be installed on

FlexPak

™ 3000 and WebPak™ 3000 Digital DC drives (40 to 75 HP @ 230 VAC, 75 to 150 HP @ 460 VAC,

265 A @ 380 / 415 VAC). Each kit includes a molded-case switch and mounting hardware. Kits used with

NEMA 1 enclosures also include a mounting bracket to provide through-the-door operation of the switch and a

locking bracket to allow a locking device to be used.

The kits provide a positive disconnect of all AC input leads for the FlexPak 3000 and WebPak 3000 drives.

The 40-60 / 75-125 HP @ 230 / 460 VAC disconnect is rated for 250 amps at 600 VAC. The 75 / 150 HP @

230 / 460 VAC disconnect is rated for 400 amps at 600 VAC. To comply with NEC codes, do not use either

disconnect for more than 85% of its rated amps.

A yellow test button on the front of the switch (at the lower right or lower left) can be used to check the switch’s

mechanical operation and for quick disconnect. When pressed, the test button immediately trips the switch

open. The test button is not accessible when the switch is mounted in a NEMA 1 enclosure.

Verifying the Kit Model Number Matches the Drive

The disconnect kits are rated for use with Reliance™

FlexPak 3000 and WebPak 3000 drives as shown in

table 1. To ensure a kit is properly rated for your application, use it only with Reliance FlexPak 3000 and

WebPak 3000 drives and only as listed in the table.

ATTENTION:Only qualified personnel familiar with the construction and operation of this

equipment and the hazards involved should install, adjust, operate, and/or service this equipment.

Read and understand this manual in its entirety before proceeding. Failure to observe this

precaution could result in severe bodily injury or loss of life.

ATTENTION:The user is responsible for conforming with all applicable local, national, and

international codes. Failure to observe this precaution could result in damage to, or destruction

of, the equipment.

Kit Model

Number

Current Rating @

40° C

Corresponding

Drive Horsepower/Voltage Rating Mounting

901FK1102 250 Amp 40-60 / 75-125 HP @ 230 / 460 VAC Chassis

901FK1112 250 Amp 40-60 / 75 -125 HP @ 230 / 460 VAC NEMA 1

901FK1202 400 Amp 75 / 150 HP @ 230 / 460 VAC, 265 A @380 / 415 VAC Chassis

901FK1212 400 Amp 75 / 150 HP @ 230 / 460 VAC, 265 A @380 / 415 VAC NEMA 1

Summary of content (11 pages)

PAGE 1
250 Amp and 400 Amp AC Line Disconnect Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives 40 to 75 HP @ 230 VAC, 75 to 150 HP @ 460 VAC, 265 A @ 380 / 415 VAC M/N 901FK1102, 901FK1112, 901FK1202, 901FK1212 Instruction Manual D2-3395-1 ! ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, and/or service this equipment. Read and understand this manual in its entirety before proceeding.
PAGE 2
Checking the Contents of the Kit Tables 2 and 3 list the contents of the AC Line Disconnect kits.
PAGE 3
Item Number 1 2 3 4A 4B 5 6 7 8 9 13 14 15 16 17 Models 901FK1202 (Chassis) and 901FK1212 (NEMA 1) Quantity Description 901FK1202 901FK1212 Reliance Part Number 400 A Disconnect Switch 1 1 65242-300FSX Disconnect Switch Panel 1 1 802274-218R Lift Bracket – 1 610274-54S Left Lock Bracket – 1 610274-57A Right Lock Bracket – 1 610274-58A Spacer – 4 610274-56A Bus Bar 3 – 610274-261A – 6 610274-260A M6 x 10 Self-tapping Screw 3 9 419062-100PJG M6 x 90 SHCS 4 – 419062-10AJY M6 x 120 SHCS 4 419062-10AJZ M6 Lockw
PAGE 4
Step 2. NEMA 1 kits only: Remove the drive’s plastic cover, and then remove the disconnect hole plug from the cover. Step 3. Refer to figure 1, View A for steps 3 through 6. Flip down the plastic line fuse cover. It is held in place over the fuses by a hook and loop fastener. Step 4. Disconnect the incoming power lines from the drive. Save the M10 fasteners. Step 5.
PAGE 5
b. Apply the label [Item 16] at the top front of the disconnect, as shown in figure 1, View B. c. Refer to figure 2 or figure 4. Connect the bus bars installed on terminals 181, 182, and 183 in step 6 to the disconnect switch’s load terminals. Use 1/4" fasteners for the 250 A disconnect or 3/8" fasteners for the 400 A disconnect [Items 13, 14, and 15]. Step 10. Torque the fasteners on the bus bars to the values listed in table 4. Fastener Size 1/4” 3/8” M10 Maximum Torque 7.46 Nm (66 in-lb) 26.
PAGE 6
Motor Terminal Panel Auxiliary Chassis Auxiliary Chassis Cover View A AC Line Disconnect Panel M5 Screws Label M6 Screws AC Line Disconnect View B Figure 1 – AC Line Disconnect Mounting Location 6 250 Amp and 400 Amp AC Line Disconnect Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives
PAGE 7
9 8 TYP. (4) PL. Figure 2 – 250 Amp Chassis-Mount Kit (M/N 901FK1102) 250 Amp and 400 Amp AC Line Disconnect Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives DETAIL "A" 1 2 17 SIDE VIEW SHOWING LINE FUSE CONNECTIONS END VIEW TYP. (3) PLACES 14 15 13 NUT SUPPLIED WITH LINE FUSE ASSY TYP.
PAGE 8
DETAIL "A" 1 9 8 TYP. (4) PL. Figure 3 – 250 Amp NEMA 1 Kit (M/N 901FK1112) 250 Amp and 400 Amp AC Line Disconnect Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives 17 2 7 TYP. (6) PL. SIDE VIEW SHOWING LINE FUSE CONNECTIONS END VIEW 4 TYP. (2) PLACES TYP. (3) PLACES NUT SUPPLIED WITH LINE FUSE ASSY 16 3 14 15 13 TYP.
PAGE 9
8 TYP. (4) PL. Figure 4 – 400 Amp Chassis-Mount Kit (M/N 901FK1202) 250 Amp and 400 Amp AC Line Disconnect Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives DETAIL "A" 1 2 17 SIDE VIEW SHOWING LINE FUSE CONNECTIONS END VIEW 16 NUT SUPPLIED WITH LINE FUSE ASSY 83 14 15 13 82 TYP. (3) PLACES 81 TYP.
PAGE 10
DETAIL "A" 9 8 TYP. (4) PL. 1 7 Figure 5 – 400 Amp NEMA 1 Kit (M/N 901FK1212 250 Amp and 400 Amp AC Line Disconnect Kits for FlexPak 3000 and WebPak 3000 Digital DC Drives 17 TYP. (6) PLACES 3 2 SIDE VIEW SHOWING LINE FUSE CONNECTIONS END VIEW 16 83 NUT SUPPLIED WITH LINE FUSE ASSY 4B 14 15 13 TYP. (3) PLACES 82 81 5 TYP. (4) PLACES 4A 6 TYP.
PAGE 11
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