Universal Disconnect Switch Installation Instructions (600A) · 4 Universal Disconnect Switch Installation Instructions (600A) 2 3 1 Assemble the cable mechanism bracket to the disconnect

Table of Contents Page

Rod Operated Switch Installation................................................................................................................................................................................................. 2

Switch Installation..........................................................................................................................................................................................................................2

Handle Installation.........................................................................................................................................................................................................................2

Cutting Connecting Rod..............................................................................................................................................................................................................2

Connecting Rod Installation.......................................................................................................................................................................................................3

Cable Operated Mechanism Installation...................................................................................................................................................................................4

Cable Operated Switch Installation.........................................................................................................................................................................................5

Handle Installation.........................................................................................................................................................................................................................5

Handle Mechanism Installation.................................................................................................................................................................................................5

Connecting Rod Adjustment Procedure....................................................................................................................................................................................6

Enclosure without Handle Cutout................................................................................................................................................................................................7

Door Catch Bracket Installation.....................................................................................................................................................................................................7

Conversion from Right Hand to Left Hand Operation (If Required).................................................................................................................................8

Line Terminal Guard Installation...................................................................................................................................................................................................8

Line Terminal Adapter Installation...............................................................................................................................................................................................8

Trailer Fuse Block Installation (400A Fuses)..............................................................................................................................................................................9

Trailer Fuse Block Installation (600A Fuses)............................................................................................................................................................................10

Bulletin 1494V/U Disconnect Switch Optional Accessory List.........................................................................................................................................11

Universal Disconnect Switch Installation Instructions (600A)(Cat 1494V-DS600; Series D)

Tools Needed: 1/2" Socket, 5/16" Allen Wrench, Hammer, Center Punch, File, Flat Head Screwdriver, Phillips Screwdriver, 9/32" Drill Bit, Needlenose Pliers, Hacksaw

Installation Instructions

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

contaminants.

Installation, adjustments, putting into service, use, assembly, disassembly, and maintenance shall be carried out by suitably trained personnel in accordance with applicable code of

practice. In case of malfunction or damage, no attempts at repair should be made. The product should be returned to the manufacturer for repair. Do not dismantle the product.

WARNING: 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.

Switch Installation1

Rod Operated Switch Installation

2 Universal Disconnect Switch Installation Instructions (600A)

A

HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

Install gasket.

60-80 lb-in6.8-9.0 Nm

Install handle and spring bracket.

Use template D to locate handle holes on mounting plate. Overlay template F (600 A) over D .

Install defeater lever.

Cut (2) Connecting Rods; first rod connects the handle to the switch, second rod provides stiffening for the enclosure flange and mounting panel. Installation of both rods is required.

NN m

inus 3-3/4"Enclosure

Working Depth(Inside Flange of Enclosure toMounting Plate)

MountingPlate

Measure working depth of enclosure. Measure, mark and cut (2) connecting rods.

5

1

1 2 Remove burrs.3

2 3

Install disconnect switch.7

IMPORTANT:Apply grease to O-Ringto retain into handle groove.

7-11 lb-in0.79-1.2 Nm

6D

HOLD FLUSH

TO INSID

E

OF ENCLOSUREMEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP HANDLE H

OLE

BOTTOM HANDLE H

OLE

TAPE HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

D

113

2

4

90-130 lb-in10-15 Nm

8-1/4"

4-1/8"

6-5/8"

15"

2-1/16"

6-1/2"

42052-185-01 (1)

Printed in

U.S.A.

F

Disconnect Switc

h Hole Location Template (6

00A)

RIGHT Hand In

stallatio

n

(Use opposite

side for le

ft hand in

stallatio

n)

Switch M

ounting Holes

Center punch and drill

(4) 9

/32" holes fo

r #5/16-18 th

read

forming (T

AP-TITE) screws provided w

ith switc

h

Center punch and drill(4) 9/32" dia. holes forthread forming screwsprovided with switch.

Handle Installation2

Cutting Connecting Rod3

Publication 1494V-IN028A-EN-P - March 2018

3Universal Disconnect Switch Installation Instructions (600A)

Connecting Rod InstallationFirst rod connects the handle to the switch

4

ATTENTION: CHECK FOR PROPER OPERATION.If not operating properly, go to Connecting RodAdjustment Procedure.

8

Second rod provides stiffening for the enclosure flange and mounting panel

43

Rotate rod to adjust. Adjust to create 1/2" gap with spring bracket.

1/2"Clearance

7ConnectingRod

Hitch Pin

Handle Link

5

6

9

10

11 150-200 lb-in17-23 Nm

Stiffening Rod


Drive Bar

2

Rotate connecting rod into drive bar 9-10 turns.

OPEN

Verify that disconnect switch and handle are in "OFF" position. (Switch blades will show “OPEN”)

1

Top View


2

3

1 Assemble the cable mechanism bracket to the disconnect switch. Rotate connecting rod into drive bar approximately9 - 10 turns.

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

90-130 lb-in10-15 Nm

ConnectingRod

Cable MechanismLever

4 Attach connecting rod to cable mechanism lever.

1

2

ConnectingRod

Cable MechanismLever

90-130 lb-in10-15 Nm

1/2"

9/16"

5/16"

Fully seat boltprior to attachingnut.

Lubricate

90-130 lb-in10-15 Nm

Cable Operated Mechanism Installation1


IMPORTANT: Verify that the cable assembly does not interfere with any mechanical and moving parts. Keep the cable conduit away from all heat sources and current carrying terminals,

fuses, transformers, etc.

IMPORTANT: When locating the 600A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and the handle mechanism is not less than 10 inches.


A

HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

Locate Switch. Use template F where desired.

1

2

8-1/4"

4-1/8"

6-5/8"

15"

2-1/16"

6-1/2"

42052-185-01 (1)

Printed in

U.S.A.

F

Disconnect Switc

h Hole Location Template (6

00A)

RIGHT Hand In

stallatio

n

(Use opposite

side for le

ft hand in

stallatio

n)

Switch M

ounting Holes

Center punch and drill

(4) 9

/32" holes fo

r #5/16-18 th

read

forming (T

AP-TITE) screws provided w

ith switc

h

(4) - 5/16-18 threadforming screws

3 Assemble disconnect switch assembly to mounting plate.

Handle Mechanism Installation4

Handle Installation

Install gasket.1 2 3

3

7-11 lb-in0.79-1.2 Nm

Install handle and mechanism bracket. Install defeater lever.

(Right HandFlange MountedShown)

60-80 lb-in6.8-9.0 Nm

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

CLOSED

2 Align connecting rod with handle link.

ConnectingRod

Handle Link

1/2"

8-1/4"

15"

1/2"

90-130 lb-in10-15 Nm

10" Diameter Min.Do not pinch cable.

IMPORTANT:Apply grease to O-Ringto retain into handle groove.

Cable Operated Switch Installation2


Center punch and drill(4) 9/32" dia. holes forthread forming screwsprovided with switch.


43

ATTENTION: CHECK FOR PROPER OPERATION.

Handle Mechanism Installation (Cont'd)4Turn disconnect handle "OFF" and install handle mechanism spring.

Connecting Rod Adjustment Procedure

Move disconnect handle to the "ON" position.

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

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

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

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

Repeat - as necessary.

Re-install link spring.

Install hitch pin clip Hitch PinClip

Drive Bar

123

45

67

1 5

Move disconnect handle to the "OFF" position.

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

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

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

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

Repeat - as necessary.

Re-install link spring.

123

45

67

1 5

Adjustment Procedure if switch does not turn "ON". Adjustment Procedure if switch does not turn "OFF".

Rod Operated Adjustment Cable Operated Adjustment



Door CatchMounting

Bracket

18-3/16"

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

3-3/4"

1-5/8"

TopHandle

Hole

Squarecornersor up to

1/4" radius

(2) .328 Dia.Holes

1/4"

1/2"6-1/2"

5-1/2"

5/16"

Locate Disconnect Switch

Enclosure without Handle Cutout• Enclosures with a flange thickness less than 3/16" use dimensions below to install disconnect handle.

Locate Handle

Right hand flange shown. Mirror for left hand flange.

Drill Handle Holes

8-1/4" 2-1/16"

6-5/8"

Ø9/32"

15"

8-1/4"

1 2 3


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

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

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.

1-1/8"

1-3/8"

Enclosure Door

Flange Thickness K

1-5/8"

Enclosure Base

TOP VIEW

Door CatchMounting

Bracket

Door CatchMounting Bracket

Door Catch

Top

22-37 lb-in(2.5-4.2 N-m)


1

2

3

90-130 lb-in10-15 Nm

Remove drive mechanismfrom right side of switch(3) - 5/16 - 18 Hex Head Screwswith disconnect switchin the "OFF" position.

Rotate crossbar to closed or "on" 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.

Line Terminal Guard Installation

90-130 lb-in10-15 Nm

1

26-10 lb-in

0.68-1.1 Nm

Line Terminal Adapter Installation

Torque Range

1494U-ALT600

25 lb-in(2.8 N-m)

(1) 14-10 STR/SOL(1) 8 STR

(2) 14 SOL/SOL(2) 14 STR/STR(2) 12 SOL/SOL(2) 12 STR/STR(2) 10 SOL/SOL(2) 10 STR/STR(2) 8 STR/STR

Lug Adapter KitWireCatalog

Number


WireClamp

Adapter


Trailer Fuse Block Installation (400A Fuses)

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

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

A

8-1/4"

6-3/4"

6-3/4"

2-13/16" 3"

3-3/16"3/16"

3-15/16"

40-55 lb-in4.5-6.2 Nm

400A Fuses (Class H, J, R)

2

1

Fuse Installation

400 Amp Trailer Fuse Block (1494V-FSV400)

Torquelb-in(Nm)Fuse

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

400400400

250600600

H/RH/R

J

90-130(10-15)

22-37(2.5-4.2)

175-200(20-23)

275-305(31-34)

Amps Voltage Class FuseClip

AFuseBlock

Lug toTerminal

Wireinto Lug



Trailer Fuse Block Installation (600A Fuses)

Trailer Fuse Block Location (600A Class J Fuses)

3"

A

6-3/4"

2-13/16"

3-15/16"

8-1/4"

6-3/4"

3"3/8"

600A Fuses (Class J)

4

3

2

300-350 lb-in34-40 Nm

1

Fuse Clip Installation

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

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

300-350 lb-in34-40 Nm

600 Amp Trailer Fuse Block (1494V-FS600)

Torquelb-in(Nm)Fuse

4-3/8"600 250/600 J 90-130(10-15)

300-350(34-40)

175-200(20-23)

275-305(31-34)

Amps Voltage Class FuseBolt

AFuseBlock

Lug toTerminal

Wireinto Lug


Bulletin 1494V/U Disconnect Switch Optional Accessory List

Disconnect Kit

Handle

Switch

ConnectingRod

FuseBlock

FuseClips

Catalog Number and Description

Switch with Right Hand Mechanism 1494V-DS600

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)

Mounted with Switch1494V-FSV400 (400A Class H, J, R)

1494V-FS600 (600A Class J)

400A Fuses1401-N46 (Class H, J, 400A-250V, 400A-600V)1401-N55 (Class R, 400A-250V, 400A-600V)

600A FusesClass 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 Mounted1491-N621 (600A Class H)1491-R621 (600A Class R)

1494U-C64: 4 Ft Cable1494U-C65: 5 Ft Cable1494U-C66: 6 Ft CableCable

Mechanism



1494V-RB3 (Standard) (400A / 600A)Enclosure Working Depth: 9-1/2" to 10"

1494V-RB4 (Extended) (400A / 600A)Enclosure Working Depth: 9-1/2" to 23"

Set of(2) rods

PN-475449DIR 10003527463 (Version 00)

Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.


Bulletin 1494V/U Disconnect Switch Optional Accessory List

Catalog Number and Description

ElectricalInterlock

AuxiliaryContact

AluminumLugs

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.)*595-B (1-N.C.)*

*Requires Adapter Kit 595-N1

ProtectiveCover

with Door

SwitchRating

FuseClass

Fuse ClipRating

Cat No.

250V 600V

400A 400AH, J, R600A 1495-N61

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

600A 600AJ600A 1495-N61

600A 600AH,R600A N/A

LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)1494R-N101494R-N11*1494R-N12

Wire

325 LB-INCU ONLY(2) 1/0…350 MCM

*For Separately Mounted Fuse Blocks (2 per kit)

*Special Purpose Not For General Use

CopperLugs

(1) 1/0…500 MCM

LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)1494U-LA600

Wire

325 LB-INAL / CU (2) 1/0…500 MCM

LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)1494U-LM600*

FOR LOADSIDE ONLY

Wire

35 LB-INAL / CU

(12) 6…425 LB-IN (12) 820 LB-IN (12) 14…10

MultiportLugs

LineTerminalAdapters

1494U-ALT600(Pkg Qty 2)

EEE Yönetmeliğine Uygundur.

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Sheet

Size Ver

Of 11

A 0110000021669Dr. DateG. USHAKOW 03-21-13

MATERIALSIZE

FOLD

TWO SIDES PRINTEDBODY STOCK WHITE

BODY INK BLACK8-1/2" W x 11" H

FLAT

17" W x 11" H

Page Layout

8 - 1/2"

17"

Front SidePage 12

Back SidePage 11

Front SidePage 1

Back SidePage 2

Front Side

Saddle Stitched

Page 3

Back SidePage 4

Front SidePage 10

Back SidePage 9

Front SidePage 5

Back SidePage 6

Front SidePage 8

Back SidePage 7

SPECIFICATIONS FOR12 PAGE INSTRUCTION SHEET8-1/2” W x 11” H - FINAL FOLD

8 - 1/2" 8 - 1/2"

17"

8 - 1/2" 8 - 1/2"

17"

8 - 1/2"

Final Fold

11”8-1/2”

11"

Note: After folding---Printed in (Country where printed*), part number(s) and barcode (when used) should be visible.

* The printing vendor may change the instruction sheet files to show the correct country.

PN-123456DIR 10000000000 (Version 00)Printed in U.S.A.

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Documents

Universal Disconnect Switch Installation Instructions (600A) · 4 Universal Disconnect Switch Installation Instructions (600A) 2 3 1 Assemble the cable mechanism bracket to the disconnect