bulletin 1494c cable operated disconnect switch...

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

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 (400A) CABLE OPERATED DISCONNECT SWITCH KIT INSTALLATION

INSTRUCTION SHEET

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REVISIONAUTHORIZATION

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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 12-3-0712-3-07

12-3-07

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 (400A)Installation Instructions(Cat 1494C- _ _ _ Series 2 : 400A)

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.

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1030857

2

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)

FFMinimum Bend Diameter

16" Dia.

FF

1

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.

FF

FF

FF

AA BB CC DD

EE(4) Mounting Plate Holes

Locate switch with right hand mechanism

SwitchSize

2" 11" 4-3/4" 1-3/8" 9/32" Dia.400A

Panel Mounting Dimensions

1a

Locate switch with left hand mechanism1b

BB

AA

DD

EE

CC

BB

AA

DD

EE

CC

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INSTRUCTION SHEET

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ROCKWELL AUTOMATION, INC. 10308572

BB

AA

DD

EE

CC

BB

AA

DD

EE

CC

Disconnect Switch with Right Hand Cable Mechanism

(shown)

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

(3)

Assemble disconnect switch to cable switch mechanism

Install rubber handle on line terminal guard Install the line terminal guard on disconnect switch

Assemble disconnect switch assembly to mounting plate

90 - 130 lb-in (400A)

LINE TERMINAL GUARD

90 - 130 lb-in (400A)

LINE TERMINAL GUARD

Disconnect Switch Installation (Cont'd)

Disconnect Handle Installation

Thread forming screws

provided with cable mechanism.

Thread forming screws provided with disconnect switch.

2

4

Install gasket1 2 3

5

3

2

1


INSTRUCTION SHEET

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7-11 lb-in

Install handle and mechanism bracket Install defeater lever

(Right HandFlange MountedShown)

10308572

60 - 80 lb-in

1

(4)

3

2


INSTRUCTION SHEET

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Cable Mechanism Installation3Verify that disconnect switch and handle are in "ON" position. (Switch blades will not be visible)

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

Align connecting rod with primary link

ConnectingRod

Primary Link

10308572

(5)

5 6

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

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Cable Mechanism Installation (Cont'd)3Install hitch pin clip Turn disconnect handle "OFF" and

install handle mechanism spring

Hitch Pin Clip

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.

10308572

(6)

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"

14-3/8" 14-3/8"

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


INSTRUCTION SHEET

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ROCKWELL AUTOMATION, INC.10308572

(7)

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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

10308572

14-3/8"

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

14-3/8"

3-3/4"

1-5/8"

3-3/4"

1-5/8"

(8)

1494V-FS400

1494V-FS400

Install Trailer Fuse Block2

Trailer Fuse Block Installation (Switch Rating 400A)

1 Trailer Fuse Block Location

400 Amp Trailer Fuse Block (1494V-FS400)Torque (lb-in)Fuse

90-130

90-130

7-11/16"10-3/16"6-3/8"6-3/8"

8-11/16"11-11/16"7-3/16"8-11/16"

200200200200400400400400

250600600600250600600600

H/RH/R

JHRCII-C

H/RH/R

JHRCII-C

16-22 175-200 275-305

22-37 175-200 275-305

Amps Voltage Class FuseBlock

AFuseClip

Lug toTerminal

Wireinto Lug

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.)

(See Table )

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A

4 - 3/4"

(9)

4

3

Phase Barrier Replacement Kit (Switch Rating 400A) 1494F-PH5

Terminal Adapter Installation - Conversion from Fusible to Non-Fusible (Switch Rating 400A)

175 - 200 lb-in

20 - 30 lb-in

90 - 110 lb-in

35 - 50 lb-in

CLICK

1

2

31

2

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INSTRUCTION SHEET

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ROCKWELL AUTOMATION, INC. 10308572

(10)

Fuse Clip Installation (Switch Rating 400A)

1

2

1

2

23 - 37 lb-in40 - 55 lb-in

200A Fuse Clips400A Fuse Clips

Switch for Right Hand Mechanism Switch for Left Hand Mechanism

Switch for Right Hand Mechanism Switch for Left Hand Mechanism

1

2

1

2

2

16 - 22 lb-in22 - 37 lb-in


16 - 22 lb-in22 - 37 lb-in


23 - 37 lb-in40 - 55 lb-in


1

2

1


INSTRUCTION SHEET

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(11)

Disconnect Switch Kit

Handle

Switch

FuseBlock

FuseClips

Cat No.

Switch for Right Hand Mechanism 1494F-D400 (400A)

Switch for Left Hand Mechanism 1494F-DX400 (400A)

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

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)

Cable with Right Hand Mechanism1494C-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 Mechanism1494C-CMX9: 400A (4 Ft Cable)1494C-CMX10: 400A (5 Ft Cable)1494C-CMX11: 400A (6 Ft Cable)1494C-CMX12: 400A (10 Ft Cable)

CableMechanism

Bulletin 1494C Cable Operated Disconnect Switch Kit Components


INSTRUCTION SHEET

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42052-155-01 (2)Printed in U.S.A.


INSTRUCTION SHEET

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ElectricalInterlock

AuxiliaryContact

AuxiliaryContact

Adapter Kit

Wire LugConnectors

Optional Accessories(Installation Instructions

Not Included)Cat No.

Switch withRight Hand Mechanism 1495-N43 (1-N.O./N.C.) (200A - 400A)1495-N44 (2-N.O./N.C.) (200A - 400A)

Switch withLeft Hand Mechanism 1495-N41 (1-N.O./N.C.) (400A)1495-N42 (2-N.O./N.C.) (400A)

1495-N8 (1-N.O.) (30A - 400A)1495-N9 (1-N.C.) (30A - 400A)

1495-N25 (200A - 400A)(Required only for switch withLeft Hand Mechanism)

FuseCover

with Door

1494R-N14(CU Wire Size (2 ) - #1/0 - 250 MCM (400A) 1494R-N15(CU Wire Size #4.......500 MCM (400A)

Bulletin 1494C Cable Operated Disconnect Switch Kit Optional Accessory List

PhaseBarrier 1494F-PH5 (400A)

SwitchRating

FuseClass

Fuse ClipRating

Cat No.

250V 600V

200A400A

200A400A

200A400A

200A400A

H, J, R400A

---- ----Non-Fusible

1495-N68➀

H, J, R

400A---- ----Non-Fusible

1495-N63➁

➀ Switch with right hand mechanism➁ Switch with left hand mechanism

bulletin 1494c cable operated disconnect switch...

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