Bulletin 1494V Variable Depth Disconnect Switch Installation Instructions
(Cat 1494V-DS600 - Series D)
WARNING
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.
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 2
-
Disconnect Switch Installation
- Disconnect Handle Installation
- Cutting Connecting Rod
Quick Installation Guide (continued) 3
Connecting Rod Installation
-
Connecting Rod Adjustment Procedure 4
Enclosure Without Handle Cutout 5
- Locate Handle
- Drill Handle Holes
Door Catch Mounting Bracket Installation 6
Disconnect Switch Installation 7
-
Locate Disconnect Switch
- Install Disconnect Switch
- Assemble and Install Line Terminal Guard
Conversion from Right Hand to Left Hand Operation 8
Trailer Fuse Block Installation 9
Fuse Clip Installation 10
Bulletin 1494V Disconnect Switch Kit 11
Bulletin 1494V Disconnect Switch Kit Optional Accessory List 12
42052-183-01
DIR 42052-183 (Version 03)
Printed in U.S.A.
QUICK INSTALLATION GUIDE
Disconnect Switch Installation (Right hand installation shown. For left hand installation follow similar procedure.)
1
Use template D to locate handle holes on mounting plate.
4
2
OLE
TOP HANDLE H
MEASURE TO
INSIDE OF THE
HOLD FLUSH
TO INSIDE
TAPE
TOP OF ENCLOSURE
D
OF ENCLOSURE
BOTTOM HANDL
3
E HOLE
INSIDE OF THE
TOP OF ENCLOSURE
D
Disconnect Handle Installation
2
Install gasket.
1
MEASURE TO
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
TOP
BOTT
11
2 3
Overlay template F (600 A) over D .
5
8-1/4"
4-1/8"
HOLD FLUSH
MEASURE TO
INSIDE OF THE
OF ENCLOSURE
TOP OF ENCLOSURE
Switch Mounting Holes
Center punch and drill (4) 9/32" holes for #5/16-18 thread
forming (TAP-TITE) screws provided with switch
15"
A
Disconnect Switch Hole Location Template (600A)
RIGHT Hand Installation
(Use opposite side for left hand installation)
6
Center punch
F
)
1
5-01 (
8
.
A
-1
S.
2
.
U
n
i
d
e
4205
int
r
P
and drill (4) holes
for 5/16-18 thread forming
screws provided with switch.
9/32" Dia.
Install handle and spring bracket.
TO INSIDE
Install disconnect switch.
7
/16"
1
2-
6-5/8"
TOP
6-1/2"
BOTT
90 -130 lb-in
Install defeater lever.
60-80 lb-in
IMPORTANT:
Apply grease to O-Ring
7-11 lb-in
to retain into handle groove.
Cutting Connecting Rod (Cut (2) Connecting Rods; first rod connects the handle to the switch, second rod provides
3
stiffening for the enclosure flange)
Measure working depth of enclosure.
1
Mounting
Plate
Enclosure
Working Depth
(Inside Flange
of Enclosure to
Mounting Plate)
Measure, mark and
2
cut (2) connecting rods.
N
N minus 3-3/4"
Remove burrs.
3
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DIR 42052-183 (Version 03)
(2)
QUICK INSTALLATION GUIDE (CONTINUED)
Connecting Rod Installation
4
First rod connects the handle to the switch
Verify that disconnect switch and handle are in "OFF"
1
position. (Switch blades will be visible)
3
Pull rod up and verify if
rod is 1/2" away from
touching bottom of
spring bracket. (If not,
rotate rod accordingly)
4
O
P
E
N
Rotate connecting rod into
drive bar 15 turns.
2
Connecting
Rod
5
Drive Bar
Hitch Pin
6
Primary Link
1/2"
Clearance
7
8
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DIR 42052-183 (Version 03)
Second rod provides stiffening for the enclosure flange
11
150 - 200 lb-in
9
10
ATTENTION: CHECK FOR PROPER OPERATION
(3)
Connecting Rod Adjustment Procedure
2
Drive Bar
Hitch Pin
Connecting
Rod
6
5
Primary Link
"ON" Position
1
Move disconnect handle to the "ON" position.
Ê
If switch does not fully close, return handle to "OFF" position.
Ê
Remove link spring hitch pin and disengage the connectiong rod from the primary link.
Ê
Turn connecting rod counter-clockwise (1 or more) full turns.
Ê
Re-engage connecting rod in primary link of handle, insert hitch pin and re-test
Ê
Repeat Ê - Ê as necessary.
Ê
Re-install link spring
Ê
"OFF" Position
2
Move disconnect handle to the "OFF" position.
Ê
If switch does not fully open, return handle to "ON" position.
Ê
Remove hitch pin and link spring, then disengage the connectiong rod from the primary link.
Ê
Turn connecting rod clockwise (1 or more) full turns.
Ê
Re-engage connecting rod in primary link of handle, insert hitch pin and re-test.
Ê
Repeat Ê - Ê as necessary.
Ê
Re-install link spring
Ê
42052-183-01
DIR 42052-183 (Version 03)
(4)
Enclosure without Handle Cutout
L Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.
Locate Handle
1
1 - 1/8" Max.
1 - 3/8" Min.
1 - 3/8" Min.
1 - 1/8" Max.
Drill Handle Holes
2
18 - 3/16" Min.
18 - 3/16" Min.
Top Handle Hole
Right Hand Flange Left Hand Flange
(2) .328 Dia. Holes
Top Handle Hole
5/16"
42052-183-01
DIR 42052-183 (Version 03)
Square corners or up to 1/4" radius
1/4"
(5)
1/2"
5 - 1/2"
6 - 1/2"
Door Catch Bracket Installation
Right hand installation shown (for left hand installation follow similar procedures)
Door Catch Mounting Bracket:
L Provided with projections for welding.
L Projections can also be used as a guide for drilling holes.
L Can be used as a template to drill corresponding holes in the enclosure door.
L User to supply the hardware for fastening the bracket.
LFasteners must provide the degree of ingress protection for the environmental rating of the enclosure.
L The bracket hardware must be inaccessible to unauthorized personnel.
L Dimension K (3/4" to 1")
L When using large disconnect handle kit only (1494F-M2 or -S2), use door catch provided with handle kit.
L 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")
L When using large disconnect handle kit only (1494F-M2 or -S2), use door catch (40492-080-02) which can be ordered
from factory.
L 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
C
E
TOP VIEW
NEMA
SIZE
600A
18 - 3/16"
B
A
22 - 37 lb-in
Flange
Thickness
C
D
B
Enclosure Dimensions
A
(min)
B
(min)
1 - 3/8"
Top Handle Hole
C
(max)
1 - 5/8"
Door Catch
K
Enclosure
Base
DE
3 - 3/4"1 - 1/8"
C
B
A
E
Door Catch
Mounting
Bracket
Right Hand Flange Left Hand Flange
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DIR 42052-183 (Version 03)
Door Catch
Mounting
D
D
(6)
Bracket
Disconnect Switch Installation
Locate Disconnect Switch
1
CC
AAAAAAAA
AA
EE
AAAAAAAA
CC
DD
FF
BB BB
Top Handle Hole
GG
GG
Right Hand Flange Left Hand Flange
Panel Mounting Dimensions
Switch
Size
600A
AA BB CC DD
2 - 1/16" 8 - 1/4"6 - 5/8" 15" 2 - 1/16" 8 - 1/4"9/32" Dia.
EE
(4 Mounting Plate Holes)
FF
GG
FF
DD
Install Disconnect Switch
2
90 - 130 lb-in
Line Terminal Guard
3
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DIR 42052-183 (Version 03)
(7)
Conversion from Right Hand to Left Hand Operation (If Required)
Remove drive mechanism from right side of switch
1
(3) 5/16 - 18 Hex Head Screws
Rotate crossbar to closed position.
2
Reinstall drive mechanism
3
on left side of switch
42052-183-01
DIR 42052-183 (Version 03)
90 -130 lb-in
(8)
Trailer Fuse Block Installation (Switch Rating 400A)
Trailer Fuse Block Location
1
(400A Class H, J, R Fuses)
Note: Not required for non-fusible disconnect switch applications.
2
Trailer Fuse Block Location
(600A Class J Fuses)
8-1/4"
6-3/4"
A
3-15/16"
Amps Voltage Class Fuse
400
400
400
250
600
600
3/16"
2-13/16"
400 Amp Trailer Fuse Block (1494V-FSV400)
H/R
H/R
J
A
1-3/4"
4-1/4"
1-1/8"
3-3/16"
3"
6-3/4"
22-37
Clip
Torque (lb-in)Fuse
Fuse
Block
90-130
Lug to
Terminal
175
-
200 275-305
Wire
into Lug
8-1/4"
6-3/4"
A
3/8"
3-15/16"
2-13/16"
600 Amp Trailer Fuse Block (1494V-FS600)
Amps Voltage Class Fuse
3-3/16"
3"
6-3/4"
A
Bolt
4-3/8"600 250 / 600 J
300-350
Torque (lb-in)Fuse
Fuse
Block
90-130
Lug to
Terminal
175
-
200 275-305
Wire
into Lug
Trailer Fuse Block Location
3
(600A - 250V / 600V Class H, R Fuses)
Note: Refer to instructions provided with separately mounted fuse blocks (Catalog Numbers 1491-N621 and 1491-R621).
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DIR 42052-183 (Version 03)
(9)
Fuse Clip Installation (Switch Rating 600A)
400A Fuses (Class H, J, R) 600A Fuses (Class J)
300 - 350 lb-in
1
40 - 55 lb-in
2
2
1
600A Fuses (Class H, R)
300 - 350 lb-in
4
3
Note: Refer to instructions provided with separately mounted fuse blocks (Catalog Numbers 1491-N621 and 1491-R621).
42052-183-01
DIR 42052-183 (Version 03)
(10)
Bulletin 1494V Disconnect Switch Kit
Disconnect Kit
Switch
Handle
Connecting
Rod
Catalog Number and Description
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)
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"
Fuse
Block
Fuse
Clips
Mounted with Switch
1494V-FSV400 (400A Class H, J, R)
1494V-FS600 (600A Class J)
Separately Mounted
1491-N621 (600A Class H)
1491-R621 (600A Class R)
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 separately
mounted fuse blocks Cat. Nos.1491-N621
and 1491-R621
42052-183-01
DIR 42052-183 (Version 03)
(11)
Bulletin 1494V Disconnect Switch Optional Accessory List
Optional Accessories
(Installation Instructions
Included with Accessory Kits)
Electrical
Interlock
Catalog Number and Description
Switch with Right Hand Mechanism
1495-N34 (1-N.O./N.C.) *
1495-N35 (2-N.O./N.C.) *
*Requires Adapter Kit 1495-N36
Auxiliary
Contact
Lug
Connectors
595-A (1-N.O.) (600A) *
595-B (1-N.C.) (600A) *
*Requires Adapter Kit 595-N1
Switch and Fuse Block
1494R-N10
(CU Wire (2) - #1/0 -350 MCM)
(600A or 400A Fuse Block)
(3 per kit)
1494R-N12
(CU Wire (1) - #1/0 -500 MCM)
(600A or 400A Fuse Block)
(3 per kit)
Separately Mounted Fuse Blocks
1494R-N11
(CU Wire (2) - #1/0 -350 MCM)
(600A)
(2 per kit)
Switch
Rating
Fuse
Class
Fuse Clip
Rating
250V 600V
Cat No.
42052-183-01
DIR 42052-183 (Version 03)
Printed in U.S.A.
Fuse
Cover
with Door
Available only for R.H. mounted
disconnect switch.
600A ----
Non-Fusible 1495-N61
H, J, R600A 1495-N61
Ê Switch with right hand mechanism
ÊSwitch with left hand mechanism
400A 400A
600A 600AJ600A 1495-N61
600A 600AH,R600A N/A
----
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