Page 1
Bulletin 1494C Cable Operated Disconnect Switch Kit (400A)
Installation Instructions
(Cat 1494C- _ _ _ Series 2 : 400A)
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.
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.
Table of Contents Page
Quick Installation Guide
- Disconnect Switch Installation 2,3
- Disconnect Handle Installation 3
- Assemble and Install Line Terminal Guard 4
- Cable Mechanism Installation 4
- Connecting Rod Adjustment Procedure 5
Enclosure Without Handle Cutout 6
- Locate Handle
- Drill Handle Holes
Door Catch Mounting Bracket Installation 7
Trailer Fuse Block Installation (400A) 8
Phase Barrier Replacement (400A)
9
Fuse Clip Installation (400A) 10
Bulletin 1494C Cable Operated Disconnect Switch Kit Components 11
Bulletin 1494C Cable Operated Disconnect Switch Kit Optional Accessory List
12
Page 2
QUICK INSTALLATION GUIDE
IMPORTANT: When locating the 400A 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.
Disconnect Switch Installation
1
Switch
Size
400A
AA BB CC DD
2" 11" 4-3/4" 1-3/8"
Locate switch with right hand mechanism
1a
Panel Mounting Dimensions
EE
9/32" Dia.
(4) Mounting Plate Holes
Minimum Bend Diameter
FF
16" Dia.
EE
DD
AA
BB
CC
Enclosure with Right Hand Flange
AA
FF
Locate switch with left hand mechanism
1b
EE
EE
DD
AA
BB
CC
FF
Enclosure with Left Hand Flange
AA
EE
BB
DD
CC
FF
FF
BB
DD
CC
Enclosure with Right Hand Flange Enclosure with Left Hand Flange
(2)
Page 3
Disconnect Switch Installation (Cont'd)
1
Assemble disconnect switch to cable switch
2
mechanism
90 - 130 lb-in (400A)
Thread forming
screws
provided with
disconnect switch.
Disconnect Switch with
Right Hand Cable Mechanism
(shown)
Assemble disconnect switch assembly to mounting plate
3
Thread forming
screws
provided with cable
90 - 130 lb-in
(400A)
mechanism.
Install rubber handle on line terminal guard Install the line terminal guard on disconnect switch
4
LINE TERMINAL GUARD
Disconnect Handle Installation
2
Install gasket
1 2 3
Install handle and mechanism bracket
5
LINE TERMINAL G
UAR
D
Install defeater lever
NOTE: Apply grease from
capsule to gasket or groove
to retain gasket to handle.
(Right Hand
Flange Mounted
Shown)
60 - 80 lb-in
7-11 lb-in
(3)
Page 4
Cable Mechanism Installation
3
Verify that disconnect switch and handle are in "ON" position.
1
(Switch blades will not be visible)
Rotate connecting rod (clockwise) into drive bar until it
2
begins to exit the drive bar (approximately 18 full turns).
Align connecting rod with primary link
3
Connecting
Rod
Primary Link
(4)
Page 5
Cable Mechanism Installation (Cont'd)
3
Install hitch pin clip Turn disconnect handle "OFF" and
5 6
Hitch Pin Clip
install handle mechanism spring
Connecting Rod Adjustment Procedure
4
"ON" Position
Move disconnect handle to the "ON" position.
➊
If switch does not fully close, return handle to "OFF" position.
➋
Remove link spring hitch pin and disengage the connecting rod from the primary link.
➌
Turn connecting rod counter-clockwise (1 or more) full turns.
➍
Re-engage connecting rod in primary link of handle, insert hitch pin and re-test
➎
Repeat ➊ -
➏
Re-install link spring.
➐
"OFF" Position
Move disconnect handle to the "OFF" position.
➊
If switch does not fully open, return handle to "ON" position.
➋
Remove hitch pin and link spring, then disengage the connecting rod from the primary link.
➌
Turn connecting rod clockwise (1 or more) full turns.
➍
Re-engage connecting rod in primary link of handle, insert hitch pin and re-test.
➎
Repeat ➊ - ➎ as necessary.
➏
Re-install link spring.
➐
as necessary.
➎
ATTENTION: CHECK FOR PROPER OPERATION. Upon completion of
the installation instructions, no further adjustment of the cable mechanism is
required.
(5)
Page 6
Enclosure without Handle Cutout
● Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.
Locate Handle
1
Drill Handle Holes
2
1-1/8"
Right Hand Flange Left Hand Flange
1-3/8"
14-3/8" 14-3/8"
Top Handle Hole
(2) .328 Dia. Holes
1-3/8"
1-1/8"
Top Handle Hole
Square corners or
up to 1/4" radius
(6)
1/2"
1/4"
5/16"
5-1/2"
6-1/2"
Page 7
Door Catch Bracket Installation
Right 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.
●
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 Catch
Mounting Bracket
Top
Enclosure Door
Door Catch
Mounting Bracket
Door Catch
1-1/8" 1-1/8"
3-3/4"
TOP VIEW
1-3/8"
14-3/8"
1 - 1/8"
1 - 5/8"
-
1
3/8"
Flange
Thickness
Enclosure
Base
1-3/8"
Door Catch
K
14-3/8"
3-3/4"
Top Handle Hole
Door Catch
Mounting
Bracket
1-5/8"
1-5/8"
Door Catch
Mounting
Bracket
(7)
Right Hand Flange Left Hand Flange
Page 8
Trailer Fuse Block Installation (Switch Rating 400A)
Trailer Fuse Block Location
1
Note: Refer to the figures and chart below to determine the location on the mounting plate for the trailer fuse block.
(Not required for non-fusible disconnect switch applications.)
1494V-FS400
Amps Voltage Class Fuse
200
200
200
200
400
400
400
400
A
400 Amp Trailer Fuse Block (1494V-FS400)
Torque (lb-in)Fuse
Fuse
Clip
16
-
22 175-200 275-305
-
37 175-200 275-305
22
250
600
600
600
250
600
600
600
H/R
H/R
J
HRCII-C
H/R
H/R
J
HRCII-C
A
7-11/16"
10-3/16"
6-3/8"
6-3/8"
8-11/16"
11-11/16"
7-3/16"
8-11/16"
Block
-
90
-
90
130
130
Lug to
Terminal
Wire
into Lug
4 - 3/4"
Install Trailer Fuse Block
2
1494V-FS400
(See Table )
(8)
Page 9
Phase Barrier Replacement Kit (Switch Rating 400A)
1494F-PH5
1
20 - 30 lb-in
3
2
CLICK
4
Terminal Adapter Installation - Conversion from Fusible to Non-Fusible (Switch Rating 400A)
90 - 110 lb-in
1
35 - 50 lb-in
3
175 - 200 lb-in
2
(9)
Page 10
Fuse Clip Installation (Switch Rating 400A)
Switch for Right Hand Mechanism
1
200A Fuse Clips
400A Fuse Clips
16 - 22 lb-in
22 - 37 lb-in
Switch for Left Hand Mechanism
1
200A Fuse Clips
400A Fuse Clips
2
2
16 - 22 lb-in
22 - 37 lb-in
1
1
Switch for Right Hand Mechanism
2
200A Fuse Clips
400A Fuse Clips
23 - 37 lb-in
40 - 55 lb-in
1
Switch for Left Hand Mechanism
2
2
1
2
200A Fuse Clips
400A Fuse Clips
23 - 37 lb-in
40 - 55 lb-in
(10)
Page 11
Bulletin 1494C Cable Operated Disconnect Switch Kit Components
Disconnect Switch Kit
Handle
Switch
Cable
Mechanism
Cat No.
1494F-M2 (7-1/2" Painted Metal) (400A - 600A)
1494F-S2 (7-1/2" Stainless Steel) (400A - 600A)
Switch for Right Hand Mechanism
1494F-D400 (400A)
Switch for Left Hand Mechanism
1494F-DX400 (400A)
Cable with Right Hand Mechanism
1494C-CM9: 400A (4 Ft Cable)
1494C-CM10: 400A (5 Ft Cable)
1494C-CM11: 400A (6 Ft Cable)
1494C-CM12: 400A (10 Ft Cable)
Cable with Left Hand Mechanism
1494C-CMX9: 400A (4 Ft Cable)
1494C-CMX10: 400A (5 Ft Cable)
1494C-CMX11: 400A (6 Ft Cable)
1494C-CMX12: 400A (10 Ft Cable)
Fuse
Block
Fuse
Clips
1494V-FS400 (400A)
1401-N45 (Class H,J, 200A - 250V, 200A - 600V)
1401-N46 (Class H,J, 400A - 250V, 400A - 600V)
1401-N54 (Class R, 200A - 250V, 200A - 600V)
1401-N55 (Class R, 400A - 250V, 400A - 600V)
(11)
Page 12
Bulletin 1494C Cable Operated Disconnect Switch Kit Optional Accessory List
Optional Accessories
(Installation Instructions
Not Included)
Electrical
Interlock
Switch with
Right Hand Mechanism
1495-N43 (1-N.O./N.C.) (200A - 400A)
1495-N44 (2-N.O./N.C.) (200A - 400A)
Switch with
Left Hand Mechanism
1495-N41 (1-N.O./N.C.) (400A)
1495-N42 (2-N.O./N.C.) (400A)
Cat No.
Auxiliary
Contact
Auxiliary
Contact
Adapter Kit
Wire Lug
Connectors
Phase
Barrier
1495-N8 (1-N.O.) (30A - 400A)
1495-N9 (1-N.C.) (30A - 400A)
1495-N25 (200A - 400A)
(Required only for switch with
Left Hand Mechanism)
1494R-N14
(CU Wire Size (2 ) - #1/0 - 250 MCM (400A)
1494R-N15
(CU Wire Size #4.......500 MCM (400A)
1494F-PH5 (400A)
42052-155-01 (2)
Printed in U.S.A.
Fuse
Cover
with Door
Switch
Rating
400A
400A
Fuse
Class
H, J, R
H, J, R
➀ Switch with right hand mechanism
➁ Switch with left hand mechanism
Fuse Clip
Rating
250V 600V
200A
200A
400A
400A
---- ----Non-Fusible
200A
200A
400A
400A
---- ----Non-Fusible
Cat No.
1495-N68➀
1495-N63➁
Loading...