Allen-Bradley 1494V Disconnect Switch (400/600A - Series A) Installation Instructions

1
2
3
A
4
5
6
7
8
Bulletin 1494V Variable Depth, Flange Operated Disconnect Switch Kits
for 400 and 600 Amperes (Series A) Switches
ATTENTION: To prevent electrical shock, disconnect from power source before installing or servicing. Install
in suitable enclosure. Keep free from contaminants.
Components
B
Cat No.
Description
Switch Rating
(Amps)
1494V-H2
1494V-R2
1494V-W2
7-1/2" Painted Metal Handle
7-1/2" Molded Handle
7-1/2" Stainless Steel Handle
400...600
1494V-DS400
1494V-DS600
400 Amp Switch
600 Amp Switch
400
600
1494V-RB1
Standard Connecting Rod (2 per kit)
Enclosure Working Depth: 9" to 9-1/4"
Extended Connecting Rod (2 per kit)
Enclosure Working Depth: 9" to 23"
400...600
1494V-FS400
1494V-FS600
1491-N621
1491-R621
400 Amp Fuse Block
600 Amp Fuse Block (Class J fuses only)
600A 250V/600V Class H
600A 250V/600V Class R
400...600
600
600
600
1401-N46
1401-N45
1401-N54
1401-N55
Fuse Clip, Class H, J, 400A - 250V, 400A - 600V
Fuse Clip, Class H,J, 200A-250V, 200A-600V
Fuse Clip, Class R, 200A-250V, 200A-600V
Fuse Clip, Class R, 400A-250V, 400A-600V
400...600
400
400
400
595-A
595-B
595-N1
(1) N.O. Auxiliary Contact
(1) N.C. Auxiliary Contact
Auxiliary Contact Adapter Kit
400...600
1494R-N10
Lug Connector: Wire Size (2) #1/0 - 350 MCM
400...600
1494R-N11
Lug Connector: Wire Size (2) #1/0 - 350 MCM
400...600
1494R-N12
Lug Connector: Wire Size #4. . .500 MCM
400
1495-N61
Fuse Cover with Door
(only for Right-Hand Installation)
400...600
L1
L2
L3
C
1494V-RB2
D
E
F
G
REFERENCE
REVISION
AUTHORIZATION
1
1006259
2
1025456
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
G. Ushakow
CHKD. M. Jutz
APPD. J. Koziczkowski
DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
12-13-06
12-13-06
12-13-06
DWG.
SIZE
B
SHEET
1
OF
8
42052-073
B-vertical.ai
1
2
3
4
5
6
7
8
A
Handle Installation
1
C
Locate Handle
C
B
B
A
A
E
E
B
Door Catch
Mounting
Bracket
Door Catch
Mounting
Bracket
D
D
Right Hand Flange
C
Left Hand Flange
NEMA
SIZE
A
(min)
B
(min)
C
(max)
D
E
F
G
H
J
K
L
M
400A
14 - 3/16"
29/32"
1 - 7/32"
1 - 5/8"
3 - 49/64"
6 - 1/2"
3"
5"
9/16"
1/2"
1/4"
3/4"
600A
18 - 3/16"
29/32"
1 - 7/32"
1 - 5/8"
3 - 49/64"
6 - 1/2"
3"
5"
9/16"
1/2"
1/4"
3/4"
DIMENSIONS NOT SUITABLE FOR 1494V-R2 HANDLE
2 Drill Handle Holes
3 Locate Door Catch Mounting Bracket
K
(2) - 21/64" Dia. Holes
L
Enclosure Door
J
Door Catch
Mounting Bracket
30 lb-in
G
D
H
F
Door Catch
M
Enclosure
Base
C
Square Corners or 1/4" R.
B
D
Notes:
A) Enclosures with a Flange Thickness less than 3/16" use dimensions above.
B) Enclosures with a Flange Thickness 3/16" and greater use dimensions in Mounting Kit 1494V-H6. This kit requires "B" dimension of 1-7/32" min.
C) For large enclosure use 1-1/8" "M" dimension, using large enclosure door hardware (1494V-L3, 1494V-LL3).
D) The door catch mounting bracket is provided with projections for welding; however, holes can be drilled in the bracket using the
projections for locating hole centers. After proper location, it may be used as a template and drill corresponding holes in the enclosure door.
Fasten the bracket with hardware supplied by user. If properly assembled, the hardware should not be accessible for tampering with by
unauthorized personnel.
E
5
4 Install Gasket
Install Handle to Flange
6
Important: Use grease from grease capsule to keep
o-ring seal in handle groove during installation.
Install Defeater Lever
(Note: After handle is mounted on the enclosure flange.)
7-11 lb-in
2
50-65 lb-in
1
F
(2)
G
REFERENCE
REVISION
AUTHORIZATION
1
1006259
2
1025456
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL INTERNATIONAL CORPORATION
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL INTERNATIONAL CORPORATION
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
2
OF 8
42052-073
B-vertical.ai
1
2
3
4
5
6
7
8
Disconnect Switch Installation
A
1 Locate
CC
AA
CC
GG
Disconnect
Switch
HH
HH
BB
BB
DD
B
DD
Right Hand Flange
C
Left Hand Flange
NEMA
SIZE
AA
BB
CC
DD
400A
2 - 5/64"
6 - 5/32" 8 - 17/64" 14 - 31/32" 2 - 5/64"
(4) 5/16-18
600A
2 - 5/64"
6 - 5/32" 8 - 17/64" 14 - 31/32" 2 - 5/64"
(4) 5/16-18
GG
HH
Conversion from Right-Hand Installation to Left-Hand Installation
2
With the disconnect switch in the "OFF" position, (blades visible)
loosen and remove the (3) hex head screws.
Remove the drive mechanism from the right-hand side of the
disconnect switch.
Save the (3) 5/16-18 hex head screws shown below.
D
3
Rotate the crossbar assembly to the "ON" position (blades fully
engaged - not visible).
(Use any convenient adjustable wrench to aid in rotating the
crossbar & moveable blades.
L3
L1
L2
L2
L1
L3
2
1
E
4
ATTENTION: Do not attempt to change the position of the
drive mechanism after removal from the disconnect assembly.
L3
L2
Position the drive mechanism assembly as shown below and install
the (3) 5/16-18 hex head screws.
L1
40-60 lb-in
2
F
1
(3)
G
REFERENCE
REVISION
AUTHORIZATION
1
1006259
2
1025456
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL AUTOMATION, INC.
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL AUTOMATION, INC.
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
3
OF
8
42052-073
B-vertical.ai
1
A
2
3
4
5
6
7
8
Trailer Fuse Block and Fuse Clip Installation
1 Install Trailer Block
2 Install Fuse Clips
B
Q
R
40 lb-in
Y
AA
V
Z
BB
CC
X
C
3 Install Wire Lugs to Terminals
3
S
2
L1
L2
L3
1
E
4
S
F
(4)
G
REFERENCE
REVISION
AUTHORIZATION
1
1006259
2
1025456
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL AUTOMATION, INC.
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL AUTOMATION, INC.
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
4
OF
8
42052-073
B-vertical.ai
1
A
2
3
4
5
6
7
8
4 Install Wire to Lugs
1
T
L1
L2
L3
3
B
8 lb-in
C
2
T
D
Switch
Rating
(Amps)
400
E
600
F
Fuse
Rating
(Amps/Volts)
Fuse
Class
Trailer
Fuse Block
Catalog
Number
Fuse
Clip
Catalog
Number
V
(inches)
200A, 250V
H
1494V-FS400
1401-N45
200A, 250V
R
1494V-FS400
1401-N54
200A, 600V
H
1494V-FS400
Q
R
S
T*
Z
(inches)
Fuse
Block
Mounting
Screw
Fuse Block
Mtg. Screw
Torque
(lb-ins.)
Fuse Clip
Mtg. Screw
Torque
(lb-ins.)
Lug to
Terminal
Torque
(lb-ins.)
Wire to
Lug
Torque
(lb-ins.)
Term
Screw
or
Stud
AA
(inches)
BB
(inches)
CC
(inches)
325
3-3/16
2-13/16
3
325
3-3/16
2-13/16
3
275
325
---
---
-----
X
(inches)
Y
(inches)
3/16
6-3/4
1-17/32
3-15/16
5/16-18
90-110
20
275
3/16
6-3/4
1-17/32
3-15/16
5/16-18
90-110
20
275
1401-N45
3/16
6-3/4
4-1/32
3-61/64
5/16-18
90-110
20
200A, 600V
R
1494V-FS400
1401-N54
3/16
6-3/4
4-1/32
3-61/64
5/16-18
90-110
20
275
325
200A, 600V
J
1494V-FS400
1401-N45
3/16
6-3/4
29/32
3-15/16
5/16-18
90-110
20
275
325
400A, 250V
H
1494V-FS400
1401-N46
3/16
6-3/4
2-11/16
3-15/16
5/16-18
90-110
30
275
400A, 250V
R
1494V-FS400
1401-N55
3/16
6-3/4
2-11/16
3-15/16
5/16-18
90-110
30
275
---
---
3-3/16
2-13/16
3
325
---
---
---
325
---
---
---
---
---
1/2-13
400A, 600V
H
1494V-FS400
1401-N46
3/16
6-3/4
5-11/16
3-15/16
5/16-18
90-110
30
275
325
---
400A, 600V
J
1494V-FS400
1401-N46
3/16
6-3/4
1-3/16
3-15/16
5/16-18
90-110
30
275
325
---
---
---
400A, 600V
R
1494V-FS400
1401-N55
3/16
6-3/4
5-11/16
3-15/16
5/16-18
90-110
30
275
325
---
---
---
400A, 250V
H
1494V-FS400
1401-N46
23/64
6-3/4
1-3/4
3-15/16
5/16-18
90-110
30
275
325
---
---
---
400A, 250V
R
1494V-FS400
1401-N55
23/64
6-3/4
1-3/4
3-15/16
5/16-18
90-110
30
275
325
---
---
---
400A, 600V
H
1494V-FS400
1401-N46
23/64
6-3/4
4-1/4
3-15/16
5/16-18
90-110
30
275
325
---
---
---
400A, 600V
J
1494V-FS400
1401-N46
23/64
6-3/4
1-3/32
3-15/16
5/16-18
90-110
30
275
325
---
---
---
400A, 600V
R
1494V-FS400
1401-N55
23/64
6-3/4
4-1/4
3-15/16
5/16-18
90-110
30
275
325
---
---
---
600A, 250V
H
1491-N621
(1)
---
---
---
---
5/16-18
60
---
275
325
---
---
---
600A, 250V
R
1491-R621
(1)
---
---
---
---
5/16-18
60
---
275
325
---
---
---
600A, 600V
H
1491-N621
(1)
---
---
---
---
5/16-18
60
---
275
325
---
---
---
600A, 600V
J
1494V-FS600
(2)
23/64
6-3/4
4-13/32
3-15/16
5/16-18
90-110
225
275
325
---
---
---
600A, 600V
R
1491-R621
(1)
---
---
---
---
5/16-18
60
---
275
325
---
---
---
1/2-13
* When lug kits 1494R-N10 & 1494R-N11 are used.
(5)
G
REFERENCE
REVISION
AUTHORIZATION
1
1006259
2
1025456
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL AUTOMATION, INC.
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL AUTOMATION, INC.
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
5
OF 8
42052-073
B-vertical.ai
1
2
3
4
5
6
7
8
A
Connecting Rod Installation
1
N
Enclosure
Working Depth
(Flange to
Mounting Plate)
Connecting
Rod
Catalog Number
Standard
Extended
"N"
Min.
Max.
1494V-RB1
9"
9-1/4"
1494V-RB2
9"
23"
N - 3"
B
Front
Right Hand Operation
2
a) Install connecting rod into the support rod bracket and
thread in clockwise (5) full turns
b) Install connecting rod into the drive bar mechanism
and thread in clockwise (9) full turns
C
3
a) Place the disconnect handle in the "OFF" position. Attach
the end of the connecting rod to the primary link of the handle
with two 1/4-20 x 1/2" slotted head screw assemblies and
tighten to 40 lb-in torque.
b) Attach the second connecting rod to the top of the spring
bracket with two 1/4-20 x 1/2" slotted head screw assemblies
and tighten to 40 lb-in torque.
c) Attach the two springs to the mechanism as shown below:
Spring
Bracket
Support Rod
Bracket
Connecting
Link
D
Drive Mechanism
Connecting Rod Adjustment Procedure
4 "ON" Position
E
5 "OFF" Position
a) Move disconnect handle to the "ON" position.
b) If switch does not fully close, return handle to "OFF"
position.
c) Loosen and remove the two 1/4-20 slotted hex head screw
assemblies that hold the connecting rod to the connecting link.
d) Turn connecting rod counter-clockwise (1) full turn.
e) Re-assemble the two 1/4-20 hex head assemblies and
tighten to 40 lb-in and re-test.
f) Repeat 4a - 4e as necessary.
g) Move disconnect handle to the "OFF" position.
h) If switch does not fully open, return handle to "ON" position.
j) Loosen and remove the two 1/4-20 slotted hex head screw
assemblies that hold the connecting rod to the connecting link.
k) Turn connecting rod clockwise (1) full turn.
l) Re-assemble the two 1/4-20 hex head assemblies and tighten
to 40 lb-in and re-test.
m) Repeat 5g - 5l as necessary.
F
(6)
G
REFERENCE
REVISION
AUTHORIZATION
1
1006259
2
1025456
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL AUTOMATION, INC.
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL AUTOMATION, INC.
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
6
OF 8
42052-073
B-vertical.ai
1
2
3
4
5
6
7
8
A
Left Hand Operation
6 a) Install connecting rod into the support rod bracket and
thread in clockwise (5) full turns
b) Install connecting rod into the drive bar mechanism and
thread in clockwise (9) full turns
7
a) Place the disconnect handle in the "ON" position. Attach the
end of the connecting rod to the primary link of the handle with
two 1/4-20 x 1/2" slotted head screw assemblies and tighten to
40 lb-in torque.
b) Attach the second connecting rod to the top of the spring
bracket with two 1/4-20 x 1/2" slotted head screw assemblies and
tighten to 40 lb-in torque.
c) Attach the two springs to the mechanism as shown below:
B
Spring
Bracket
Support Rod
Bracket
Connecting
Link
Drive
Mechanism
C
Connecting Rod Adjustment Procedure
8 "ON" Position
9 "OFF" Position
a) Move disconnect handle to the "ON" position.
b) If switch does not fully close, return handle to "OFF" position.
c) Loosen and remove the two 1/4-20 slotted hex head screw
assemblies that hold the connecting rod to the connecting link.
d) Turn connecting rod counter-clockwise (1) full turn.
e) Re-assemble the two 1/4-20 hex head assemblies and tighten to
40 lb-in and re-test.
f) Repeat 8a - 8e as necessary.
D
g) Move disconnect handle to the "OFF" position.
h) If switch does not fully open, return handle to "ON" position.
j) Loosen and remove the two 1/4-20 slotted hex head screw
assemblies that hold the connecting rod to the connecting link.
k) Turn connecting rod clockwise (1) full turn.
l) Re-assemble the two 1/4-20 hex head assemblies and tighten to
40 lb-in and re-test.
m) Repeat 9g - 9l as necessary.
Auxiliary Contact Installation
1
2
Auxiliary Contact Adapter
595-N1
L1
L2
E
L3
Auxiliary Contact
595-A, 595-B
40 lb-in
F
(7)
G
REFERENCE
REVISION
AUTHORIZATION
1
1006259
2
1025456
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL AUTOMATION, INC.
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL AUTOMATION, INC.
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
7
OF 8
42052-073
B-vertical.ai
1
2
3
4
5
6
7
8
Fuse Cover Installation
A
12
B
2
3
C
Removal
D
3
1
E
2
42052-073-01 (3)
F
Printed in U.S.A.
-01
G
3
PART CHG.
NO. CHAR.
TWO SIDES PRINTED
BODY STOCK WHITE
BODY INK BLACK
MATERIAL
1
1006259
2
1025456
4-1/4" W x 5-1/2" H
FLAT
FOLD
SIZE
REFERENCE
REVISION
AUTHORIZATION
17" W x 11" H
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
THIS DRAWING IS THE PROPERTY OF
ROCKWELL AUTOMATION, INC.
OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,
USED OR DISCLOSED FOR ANY PURPOSE
EXCEPT AS AUTHORIZED IN WRITING BY
ROCKWELL AUTOMATION, INC.
(DIMENSIONS IN INCHES)
TOLERANCES UNLESS
OTHERWISE SPECIFIED
.XX:
N/A
.XXX:
N/A
E - DOC
DISCONNECT SWITCH AND ACCESSORY KITS
INSTALLATION INSTRUCTION SHEET
H
LOCATION: MILWAUKEE, WISCONSIN U.S.A.
--------------CHKD. --------------APPD. --------------DR.
ANGLES:
42052
N/A
DATE
DATE
DATE
-------------------------------------------
DWG.
SIZE
B
SHEET
8
OF 8
42052-073
B-vertical.ai
">