ATTENTION - RockwellAutomation.com · Disconnect Switch Installation (Cont'd) (4) - 5/16-18 thread forming screws provided with disconnect switch. 7 1 6 Attach threaded rod to cable

Table of Contents Page

Quick Installation Guide - Disconnect Switch Installation 2,3 - Disconnect Handle Installation 3 - Cable Mechanism Installation 4 - Connecting Rod Adjustment Procedure 5

Conversion from Right Hand to Left Hand Operation 6

Enclosure Without Handle Cutout 7 - Locate Handle - Drill Handle Holes

Door Catch Mounting Bracket Installation 8

Trailer Fuse Block Installation (600A) 9

Fuse Clip Installation (600A) 10

Bulletin 1494C Cable Operated Disconnect Switch Kit Components 11 Bulletin 1494C Cable Operated Disconnect Switch Kit Optional Accessory List 12

ATTENTION: The following procedures are critical to the proper operation of the disconnect handle and switch. Failure to follow these steps can result in damage to the equipment and/or serious injury or death to the operator.

BULLETIN 1494C (600A) CABLE OPERATED DISCONNECT SWITCH KIT INSTALLATION

INSTRUCTION SHEET

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

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DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

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G. Ushakow 7-30-077-30-07

7-30-07

M. JutzJ. Koziczkowski

ATTENTION: To prevent electrical shock, disconnect from power source before installing or servicing. Follow NFPA 70E requirements. Install in suitable enclosure. Keep free from contaminants.

Bulletin 1494C Cable Operated Disconnect Switch Kit (600A)Installation Instructions(Cat 1494C- _ _ _ Series 2 : 600A)

42052-190-01 (1)Printed in U.S.A.

THIS DRAWING IS THE PROPERTY OFROCKWELL AUTOMATION, INC.

OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,USED OR DISCLOSED FOR ANY PURPOSEEXCEPT AS AUTHORIZED IN WRITING BY

ROCKWELL AUTOMATION, INC.

1 13

QUICK INSTALLATION GUIDE

Disconnect Switch Installation

Enclosure with Right Hand Flange Enclosure with Left Hand Flange

Enclosure with Right Hand Flange Enclosure with Left Hand Flange

(2)

1

IMPORTANT: When locating the 600A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and handle mechanism is not less than 16 inches.Any reduction to the diameter of the bend loop for the cable will reduce the efficiency of the cable system, and create additional drag and friction within the cable conduit.

IMPORTANT: Verify that the cable assembly does not interfere with any mechanical and moving parts. Keep the cable conduit a minimum of 1/2" from all heat sources and current carrying terminals, fuses, transformers, etc.

Locate switch with right hand mechanism

8-1/4"

15"

(4) - 9/32" Dia.Mounting Holes

8-1/4"

15"


1a

Locate switch with left hand mechanism1b

16" Dia. Minimum 16" Dia. Minimum

16" Dia. Minimum16" Dia. Minimum

8-1/4"

15"


8-1/4"

15"


2 13


INSTRUCTION SHEET

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(3)

2

4 5

3


INSTRUCTION SHEET

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Disconnect Switch Installation (Cont'd)

Rotate crossbar to closed position. Assemble the cable mechanism bracket to the disconnect switch.

Turn the connecting rod clockwise (approximately 9 - 10 turns) until jam nuts touch drive bar

Turn the connecting rod counter-clockwise (less than 1 turn) until hole in threaded rod aligns with hole in cable mechanism lever.

Drive Bar

Jam Nuts

1

90 - 130 lb-in

ThreadedRod

Cable Mechanism Lever

90 - 130 lb-in

(4)

Disconnect Switch Installation (Cont'd)

(4) - 5/16-18 threadforming screws provided with

disconnect switch.

7

1Assemble disconnect switch assembly to mounting plate.6 Attach threaded rod to cable mechanism lever.


INSTRUCTION SHEET

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Cable Mechanism Installation3

NOTE: Apply grease from capsule to gasket or grooveto retain gasket to handle.

Disconnect Handle Installation

Install gasket.1 2 3

2

7-11 lb-in

Install handle and mechanism bracket. Install defeater lever.

(Right HandFlange MountedShown)

60 - 80 lb-in

1 Verify that disconnect switch and handle are in the "ON" position.

2 Rotate connecting rod (clockwise) into drive bar until it begins to exit the drive bar (approximately 18 full turns).

1

2

ThreadedRod

Cable Mechanism Lever

90 - 130 lb-in

90 - 130 lb-in

CLOSED

(5)

3

5

4

ATTENTION: CHECK FOR PROPER OPERATION. Upon completion of the installation instructions, no further adjustment of the cable mechanism is required.

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INSTRUCTION SHEET

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Cable Mechanism Installation (Cont'd)3Align connecting rod with primary link.

Turn disconnect handle "OFF" and install handle mechanism spring.

Connecting Rod Adjustment Procedure4"ON" Position➊ Move disconnect handle to the "ON" position.

➋ If switch does not fully close, return handle to "OFF" position.

➌ Remove link spring hitch pin and disengage the connecting rod from the primary link.

➍ Turn connecting rod counter-clockwise (1 or more) full turns.

➎ Re-engage connecting rod in primary link of handle, insert hitch

pin and re-test

➏ Repeat ➊ - ➎ as necessary.

➐ Re-install link spring.

"OFF" Position➊ Move disconnect handle to the "OFF" position.

➋ If switch does not fully open, return handle to "ON" position.

➌ Remove hitch pin and link spring, then disengage the connecting rod from the primary link.

➍ Turn connecting rod clockwise (1 or more) full turns.

➎ Re-engage connecting rod in primary link of handle, insert hitch pin and re-test.

➏ Repeat ➊ - ➎ as necessary.

➐ Re-install link spring.

Install hitch pin clip Hitch Pin Clip

ConnectingRod

Primary Link

(6)

1

2

3

90 -130 lb-in

Remove drive mechanism from right side of switch(3) - 5/16 - 18 Hex Head Screws with disconnect switchin the "OFF" position.

Rotate crossbar to closed position.

Reinstall drive mechanism on left side of switch

Conversion from Right Hand to Left Hand Operation (If Required)

IMPORTANT: Switch conversion to left-hand operation requires left-hand cable mechanism.

ATTENTION: With switch in the "CLOSED" position, drive mechanism should align with crossbar.


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(7)

Enclosure without Handle Cutout

1

Top Handle Hole

Top Handle Hole

Square corners orup to 1/4" radius

Locate Handle

Right Hand Flange Left Hand Flange

(2) .328 Dia. Holes

1/4"

1/2"

Drill Handle Holes2

● Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.

6-1/2"5-1/2"

5/16"

18-3/16" 18-3/16"

1-3/8" 1-3/8"1-1/8" 1-1/8"

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INSTRUCTION SHEET

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(8)

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INSTRUCTION SHEET

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Door Catch Bracket Installation Right hand installation shown (for left hand installation follow similar procedures)

Top Handle Hole

Door CatchMounting

Bracket

Door CatchMountingBracket

Right Hand Flange Left Hand Flange

1 - 1/8"

1 - 3/8"

Enclosure Door Flange Thickness K

1 - 5/8"

Enclosure Base

TOP VIEW

Door Catch Mounting Bracket:● Provided with projections for welding.● Projections can also be used as a guide for drilling holes.● Can be used as a template to drill corresponding holes in the enclosure door. ● User to supply the hardware for fastening the bracket. ● Fasteners must provide the degree of ingress protection for the environmental rating of the enclosure. ● The bracket hardware must be inaccessible to unauthorized personnel.

Dimension K (3/4" to 1")● When using large disconnect handle kit only (1494F-M2 or -S2), use door catch provided with handle kit.● When using large disconnect handle kit and small door hardware kits (1494V-L1, -LL1, -L2 or -LL2), use door catch provided with door hardware kit.

Dimension K (1-1/8" to 1-3/8")● When using large disconnect handle kit and large door hardware kits (1494V-L3 or -LL3), use door catch provided with door hardware kit.

Door CatchMounting Bracket

Door CatchMounting Bracket

Door Catch

Door Catch

Top

18-3/16"

1-3/8" 1-3/8"1-1/8" 1-1/8"

18-3/16"

3-3/4"

1-5/8"

3-3/4"

1-5/8"

(9)

Trailer Fuse Block Installation (Switch Rating 600A)Note: Not required for non-fusible disconnect switch applications.

Note: Terminal bolts need to be moved from disconnect switch load terminals to fuse block.

Note: Refer to instructions provided with separately mounted fuse blocks (Catalog Numbers 1491-N621 and 1491-R621).

1 2Trailer Fuse Block Location (400A Class H, J, R Fuses)

Trailer Fuse Block Location (600A Class J Fuses)

3 Trailer Fuse Block Location (600A - 250V / 600V Class H, R Fuses)

400 Amp Trailer Fuse Block (1494V-FSV400)

Torque (lb-in)Fuse

1-3/4"4-1/4"1-1/8"

400400400

250600600

H/RH/R

J90-13022-37 175-200 275-305

Amps Voltage Class FuseClip

AFuseBlock

Lug toTerminal

Wireinto Lug

Torque (lb-in)Fuse

4-3/8"600 250 / 600 J 90-130300-350 175-200 275-305

Amps Voltage Class FuseBolt

AFuseBlock

Lug toTerminal

Wireinto Lug

600 Amp Trailer Fuse Block (1494V-FS600)

A

8-1/4"

6-3/4"

6-3/4"

2-13/16" 3"

3-3/16"3/16"

3"

A

6-3/4"

2-13/16"

3-15/16" 3-15/16"

8-1/4"

6-3/4"

3"3/8"

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(10)

Fuse Clip Installation (Switch Rating 600A)

40 - 55 lb-in

400A Fuses (Class H, J, R) 600A Fuses (Class J)

600A Fuses (Class H, R)

2

1

4

3

2

Note: Refer to instructions provided with separately mounted fuse blocks (Catalog Numbers 1491-N621 and 1491-R621).

300 - 350 lb-in

300 - 350 lb-in

1


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(11)

Disconnect Switch Kit Cat No.

Cable with Right Hand Mechanism1494C-CM13: 600A (4 Ft Cable)1494C-CM14: 600A (5 Ft Cable)1494C-CM15: 600A (6 Ft Cable)1494C-CM16: 600A (10 Ft Cable)

Cable with Left Hand Mechanism1494C-CMX13: 600A (4 Ft Cable)1494C-CMX14: 600A (5 Ft Cable)1494C-CMX15: 600A (6 Ft Cable)1494C-CMX16: 600A (10 Ft Cable)

CableMechanism

Bulletin 1494C Cable Operated Disconnect Switch Kit Components

Handle

Switch

Switch with Right Hand Mechanism 1494V-DS600 (600A)

Convertible in the field for Left Hand operation

1494F-M2 (7-1/2" Painted Metal) (400A / 600A)1494F-S2 (7-1/2" Stainless Steel) (400A / 600A)

FuseBlock

FuseClips

Mounted with Switch

1494V-FSV400 (400A Class H, J, R)1494V-FS600 (600A Class J)

400A Fuses

1401-N46 (Class H, J, 400A-250V, 400A-600V)1401-N55 (Class R, 400A-250V, 400A-600V)

600A Fuses

Class J - Bolts directly to switch and fuse block (no clips required)

Class H, R - Fuse clips included with separatelymounted fuse blocks Cat. Nos.1491-N621 and 1491-R621

Separately Mounted

1491-N621 (600A 250V / 600V Class H)1491-R621 (600A 250V / 600V Class R)


INSTRUCTION SHEET

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42052-190-01 (1)Printed in U.S.A.

Catalog Number and Description

ElectricalInterlock

AuxiliaryContact

LugConnectors

Optional Accessories(Installation Instructions

Included with Accessory Kits)

Switch with Right Hand Mechanism 1495-N34 (1-N.O./N.C.) *1495-N35 (2-N.O./N.C.) *

*Requires Adapter Kit 1495-N36

595-A (1-N.O.) (600A) *595-B (1-N.C.) (600A) *

*Requires Adapter Kit 595-N1

FuseCover

with Door

Switch and Fuse Block

1494R-N10 (CU Wire (2) - #1/0 - 350 MCM) (600A or 400A Fuse Block)(3 per kit)

1494R-N11 (CU Wire (1) - #1/0 - 500 MCM) (600A or 400A Fuse Block)(3 per kit)

1494R-N12 (CU Wire (2) - #1/0 - 350 MCM) (600A)(2 per kit)

SwitchRating

FuseClass

Fuse ClipRating

Cat No.

250V 600V

400A 400AH, J, R600A 1495-N61

600A ---- ----Non-Fusible 1495-N61

Separately Mounted Fuse Blocks

Available only for R.H. mounted disconnect switch.

600A 600AJ600A 1495-N61

600A 600AH,R600A N/A


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Bulletin 1494C Cable Operated Disconnect Switch Kit Optional Accessory List

Documents

ATTENTION - RockwellAutomation.com · Disconnect Switch Installation (Cont'd) (4) - 5/16-18 thread forming screws provided with disconnect switch. 7 1 6 Attach threaded rod to cable