Bulletin 1494V Variable Depth Disconnect Switch Installation Instructions

(Cat 1494V-DS600 - Series D)

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.

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.

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
1 Disconnect Switch Installation (Right hand installation shown. For left hand installation follow similar procedure.)

Use template D to locate handle holes on mounting plate. 5 Overlay template F (600 A) over D . 7 Install disconnect switch.

6"
1/1
2-

"

/8"
1/4
8-

4 4-
1/8
"

TO
P
6-5

2
H
US
FL IDE
TO LD S E
RE HE RE HO O IN UR read /2"
SU F T SU T OS 18 th 6-1
LE EA O O olC
L /16- h
LE
HO M IDE CL es
EHN r #5 sw
itc

ND
S N g
in s fo ith
HA
IN F E OntFhole ed w
P O Mou32" ovid
TO P h
itc ) 9/ s pr
TO Sw ill (4 rew
dr ) sc
d
an TITE TT
h
nc AP- BO
r pu (T
te ing
Cen form

TO "
RE HE RE 15

S N
SU F T SU
EA O O
M IDE CL
IN F E
US
H
FL IDE
LD INS RE P
A m
at
pl
e (6
00

onn)
A)

O HOTO SU TO
tio
n Te ti
llaallatio
P O ca
CL e Lo stainst
TO Hol In nd
EN HO
LE h d ft ha
anfor le
itc
OF N DL
E
ec
t Sw Hde
HA co
nn
HT site
si
M Dis
TTO RIG
op
po
TAPE

BO se
(U

H
US
FL IDE
TO LD S E

D 3 RE HE RE HO O IN UR
SU F T SU
EA O O
M IDE CL
S N
IN F E
O
OF
EN
T OS
CL 6
185A.
-01
(1)
F
P 52- U.S.

Center punch
in
420ted

TO
Prin

BO
TT

1
and drill (4) holes
D for 5/16-18 thread forming
screws provided with switch. 90 -130 lb-in
9/32" Dia.

2 Disconnect Handle Installation

1 Install gasket. 2 Install handle and spring bracket. 3 Install defeater lever.

60-80 lb-in

IMPORTANT:
Apply grease to O-Ring 7-11 lb-in
to retain into handle groove.

3 Cutting Connecting Rod (Cut (2) Connecting Rods; first rod connects the handle to the switch, second rod provides
stiffening for the enclosure flange)

1 Measure working depth of enclosure. 2 Measure, mark and 3 Remove burrs.

cut (2) connecting rods.

Mounting Enclosure
Working Depth
Plate N
(Inside Flange 4"
of Enclosure to 3 -3/
n us
Mounting Plate) mi
N

42052-183-01
DIR 42052-183 (Version 03) (2)
QUICK INSTALLATION GUIDE (CONTINUED)
4 Connecting Rod Installation
First rod connects the handle to the switch
1 Verify that disconnect switch and handle are in "OFF"
position. (Switch blades will be visible)

Pull rod up and verify if

rod is 1/2" away from
touching bottom of
3 spring bracket. (If not,
rotate rod accordingly)

2 Drive Bar

O
P
E
N

1/2"
Rotate connecting rod into Clearance
drive bar 15 turns.

Hitch Pin

Connecting 7
Rod
6

5
Primary Link 8

Second rod provides stiffening for the enclosure flange

11 150 - 200 lb-in

10

ATTENTION: CHECK FOR PROPER OPERATION

42052-183-01
DIR 42052-183 (Version 03) (3)
Connecting Rod Adjustment Procedure

2 Drive Bar

Hitch Pin

Connecting
Rod
6

5
Primary Link

1 "ON" Position
Ê 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

2 "OFF" Position
Ê 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
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 - 1/8" Max.

1 - 3/8" Min. 1 - 3/8" Min.

18 - 3/16" Min. 18 - 3/16" Min.

Top Handle Hole

Right Hand Flange Left Hand Flange

Drill Handle Holes

2 (2) .328 Dia. Holes
Top Handle Hole

5/16"

Square corners or up to 1/4" radius

5 - 1/2" 6 - 1/2"

1/2"

1/4"

42052-183-01
DIR 42052-183 (Version 03) (5)
 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
Top
Mounting Bracket

22 - 37 lb-in
TOP VIEW Door Catch

Enclosure Door Flange

Thickness K
Door Catch
Mounting Bracket
C
Enclosure
Door Catch
Base
D B

Enclosure Dimensions
NEMA A B C D E
SIZE (min) (min) (max)

600A 18 - 3/16" 1 - 3/8" 1 - 1/8" 1 - 5/8" 3 -3/4"

C C
B B

A A

E E

Top Handle Hole

Door Catch Door Catch

Mounting Mounting
Bracket Bracket
D
D

Right Hand Flange Left Hand Flange

42052-183-01
DIR 42052-183 (Version 03) (6)
Disconnect Switch Installation
1 Locate Disconnect Switch
CC AA A
EEA CC

FF FF

BB BB

DD DD

Top Handle Hole

GG GG

Right Hand Flange Left Hand Flange

Panel Mounting Dimensions
AA BB CC DD EE FF GG
Switch
(4 Mounting Plate Holes)
Size

600A 2 - 1/16" 6 - 5/8" 8 - 1/4" 15" 2 - 1/16" 9/32" Dia. 8 - 1/4"

2 Install Disconnect Switch 3 Line Terminal Guard

90 - 130 lb-in

42052-183-01
DIR 42052-183 (Version 03) (7)
Conversion from Right Hand to Left Hand Operation (If Required)

1 Remove drive mechanism from right side of switch

(3) 5/16 - 18 Hex Head Screws

2 Rotate crossbar to closed position.

3 Reinstall drive mechanism

on left side of switch

90 -130 lb-in

42052-183-01
DIR 42052-183 (Version 03) (8)
Trailer Fuse Block Installation (Switch Rating 400A)
1 Trailer Fuse Block Location
2 Trailer Fuse Block Location
(400A Class H, J, R Fuses) (600A Class J Fuses)
Note: Not required for non-fusible disconnect switch applications.

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

6-3/4" 6-3/4"
A 3-3/16" A 3-3/16"
3/16" 3/8"

3-15/16" 3-15/16"

2-13/16" 3" 2-13/16" 3"

6-3/4" 6-3/4"

400 Amp Trailer Fuse Block (1494V-FSV400) 600 Amp Trailer Fuse Block (1494V-FS600)
Fuse Torque (lb-in) Fuse Torque (lb-in)
A A
Amps Voltage Class Fuse Fuse Lug to Wire Amps Voltage Class Fuse Fuse Lug to Wire
Clip Block Terminal into Lug Bolt Block Terminal into Lug
400 250 H/R 1-3/4" 600 250 / 600 J 4-3/8" 300-350 90-130 175-200 275-305
400 600 H/R 4-1/4" 22-37 90-130 175-200 275-305
400 600 J 1-1/8"

3 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).

42052-183-01
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

40 - 55 lb-in

300 - 350 lb-in 4

600A Fuses (Class H, R)

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 Catalog Number and Description

Switch with Right Hand Mechanism

1494V-DS600 (600A)

Convertible in the field for Left Hand operation

Switch

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

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

1494V-RB3 (Standard) (400A / 600A)

Enclosure Working Depth: 9-1/2" to 10"
Connecting
Rod
1494V-RB4 (Extended)(400A / 600A)
Enclosure Working Depth: 9-1/2" to 23"

Mounted with Switch

1494V-FSV400 (400A Class H, J, R)

1494V-FS600 (600A Class J)

Fuse
Block 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)

Fuse 600A Fuses

Clips
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 Catalog Number and Description
Included with Accessory Kits)

Switch with Right Hand Mechanism

Electrical 1495-N34 (1-N.O./N.C.) *
Interlock 1495-N35 (2-N.O./N.C.) *

*Requires Adapter Kit 1495-N36

595-A (1-N.O.) (600A) *

Auxiliary 595-B (1-N.C.) (600A) *
Contact
*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
Lug (CU Wire (1) - #1/0 -500 MCM)
Connectors (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 Fuse Fuse Clip Cat No.

Rating Class Rating
250V 600V

Fuse
600A Non-Fusible ---- ---- 1495-N61
Cover
with Door

600A H, J, R 400A 400A 1495-N61

600A J 600A 600A 1495-N61

Available only for R.H. mounted 600A H,R 600A 600A N/A
disconnect switch.

Ê Switch with right hand mechanism

ÊSwitch with left hand mechanism

42052-183-01
DIR 42052-183 (Version 03)
Printed in U.S.A.