Allen-Bradley D Series Installation Instructions Manual

Allen-Bradley
Brand
Allen-Bradley
Model
D Series
Type
Installation Instructions Manual

This manual is also suitable for

Table of Contents Page
Rod Operated Switch Installation................................................................................................................................................................................................. 2
Switch Installation..........................................................................................................................................................................................................................2
Handle Installation.........................................................................................................................................................................................................................2
Cutting Connecting Rod..............................................................................................................................................................................................................2
Connecting Rod Installation.......................................................................................................................................................................................................3
Cable Operated Mechanism Installation...................................................................................................................................................................................4
Cable Operated Switch Installation.........................................................................................................................................................................................5
Handle Installation.........................................................................................................................................................................................................................5
Handle Mechanism Installation.................................................................................................................................................................................................5
Connecting Rod Adjustment Procedure....................................................................................................................................................................................6
Enclosure without Handle Cutout................................................................................................................................................................................................7
Door Catch Bracket Installation.....................................................................................................................................................................................................7
Conversion from Right Hand to Left Hand Operation (If Required).................................................................................................................................8
Line Terminal Guard Installation...................................................................................................................................................................................................8
Line Terminal Adapter Installation...............................................................................................................................................................................................8
Trailer Fuse Block Installation (400A Fuses)..............................................................................................................................................................................9
Trailer Fuse Block Installation (600A Fuses)............................................................................................................................................................................10
Bulletin 1494V/U Disconnect Switch Optional Accessory List.........................................................................................................................................11
Universal Disconnect Switch Installation Instructions (600A)
(Cat 1494V-DS600; Series D)
Tools Needed: 1/2" Socket, 5/16" Allen Wrench, Hammer, Center Punch, File, Flat Head Screwdriver, Phillips Screwdriver, 9/32" Drill Bit, Needlenose Pliers, Hacksaw
Installation Instructions
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.
Installation, adjustments, putting into service, use, assembly, disassembly, and maintenance shall be carried out by suitably trained personnel in accordance with applicable code of
practice. In case of malfunction or damage, no attempts at repair should be made. The product should be returned to the manufacturer for repair. Do not dismantle the product.
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.
Switch Installation
1
Rod Operated Switch Installation
2
Universal Disconnect Switch Installation Instructions (600A)
A
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
MEASURE TO
INSIDE OF THE
TOP OF ENCLOSURE
TOP
BOTT
Install gasket.
60-80 lb-in
6.8-9.0 Nm
Install handle and spring bracket.
Use template D to locate handle holes on mounting plate.
Overlay template F (600 A) over D .
Install defeater lever.
Cut (2) Connecting Rods; first rod connects the handle to the switch, second rod provides
stiffening for the enclosure flange and mounting panel. Installation of both rods is required.
N
N minus 3-3/4
"
Enclosure
Working Depth
(Inside Flange
of Enclosure to
Mounting Plate)
Mounting
Plate
Measure working depth of enclosure.
Measure, mark and
cut (2) connecting rods.
5
1
1
2
Remove burrs.
3
2 3
Install disconnect switch.
7
IMPORTANT:
Apply grease to O-Ring
to retain into handle groove.
7-11 lb-in
0.79-1.2 Nm
6
D
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
MEASURE TO
INSIDE OF THE
TOP OF ENCLOSURE
TOP HANDLE HOLE
BOTTOM HANDLE HOLE
TAPE
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
MEASURE TO
INSIDE OF THE
TOP OF ENCLOSURE
TOP
BOTT
D
11
3
2
4
90-130 lb-in
10-15 Nm
8-1/4"
4-1/8"
6-5/8"
15"
2-
1
/16"
6-1/2"
42052-
1
8
5-01 (
1
)
P
rin
ted
in U.
S.A.
F
Disconnect Switch Hole Location Template (600A)
RIGHT
Hand Installation
(Use opposite side for left hand installation)
Switch Mounting Holes
Center punch and drill (4) 9/32" holes for #5/16-18 thread
forming (TAP-TITE) screws provided with switch
Center punch and drill
(4) 9/32" dia. holes for
thread forming screws
provided with switch.
Handle Installation
2
Cutting Connecting Rod
3
Publication 1494V-IN028A-EN-P - March 2018
3
Universal Disconnect Switch Installation Instructions (600A)
Connecting Rod Installation
First rod connects the handle to the switch
4
ATTENTION: CHECK FOR PROPER OPERATION.
If not operating properly, go to Connecting Rod
Adjustment Procedure.
8
Second rod provides stiffening for the enclosure flange and mounting panel
4
3
Rotate rod to adjust.
Adjust to create 1/2"
gap with spring
bracket.
1/2"
Clearance
7
Connecting
Rod
Hitch Pin
Handle Link
5
6
9
10
11
150-200 lb-in
17-23 Nm
Stiffening Rod
Publication 1494V-IN028A-EN-P - March 2018
Drive Bar
2
Rotate connecting rod into
drive bar 9-10 turns.
O
P
E
N
Verify that disconnect switch and handle are in "OFF"
position. (Switch blades will show “OPEN”)
1
Top View
4
Universal Disconnect Switch Installation Instructions (600A)
2
3
1
Assemble the cable mechanism bracket to the disconnect switch.
Rotate connecting rod into drive bar approximately
9 - 10 turns.
Turn the connecting rod counter-clockwise (less than 1 turn)
until hole in threaded rod aligns with hole in cable mechanism
lever.
90-130 lb-in
10-15 Nm
Connecting
Rod
Cable
Mechanism
Lever
4
Attach connecting rod to cable mechanism lever.
1
2
Connecting
Rod
Cable
Mechanism
Lever
90-130 lb-in
10-15 Nm
1/2"
9/16"
5/16"
Fully seat bolt
prior to attaching
nut.
Lubricate
90-130 lb-in
10-15 Nm
Cable Operated Mechanism Installation
1
Publication 1494V-IN028A-EN-P - March 2018
IMPORTANT: Verify that the cable assembly does not interfere with any mechanical and moving parts. Keep the cable conduit away from all heat sources and current carrying terminals,
fuses, transformers, etc.
IMPORTANT: When locating the 600A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and the handle mechanism is not less than 10 inches.
5Universal Disconnect Switch Installation Instructions (600A)
A
HOL
D FLUSH
TO I
N
SIDE
OF
ENCLOS
URE
MEASURE T
O
INSIDE
O
F TH
E
T
OP OF
E
NCLOS
UR
E
TOP
B
OT
T
Locate Switch. Use template F
where desired.
1
2
8-
1
/
4"
4
-1/8"
6-5/8
"
1
5"
2-
1/16
"
6-1/2"
42
05
2
-
1
85
-
01
(
1
)
P
r
in
t
e
d
i
n
U.S
.
A
.
F
D
is
c
onne
c
t S
w
i
tch H
ole Loc
a
ti
o
n T
e
m
pl
a
t
e
(60
0
A
)
RIG
H
T
Hand Install
ation
(
Us
e
opp
osite
s
ide for
le
ft ha
nd ins
ta
l
la
t
i
o
n)
Sw
i
t
ch M
ounting Holes
C
e
nte
r
punch a
nd drill (4)
9
/3
2
" hole
s
for
#
5
/1
6
-1
8
t
hr
e
a
d
for
ming
(T
A
P
-TIT
E)
s
c
r
e
ws
prov
ided wit
h swit
ch
(4) - 5/16-18 thread
forming screws
3
Assemble disconnect switch assembly to mounting plate.
Handle Mechanism Installation
4
Handle Installation
Install gasket.
1 2 3
3
7-11 lb-in
0.79-1.2 Nm
Install handle and mechanism bracket.
Install defeater lever.
(Right Hand
Flange Mounted
Shown)
60-80 lb-in
6.8-9.0 Nm
1
Operate disconnect switch and verify that the handle and switch
are in the "ON" position.
C
L
O
S
E
D
2
Align connecting rod with handle link.
Connecting
Rod
Handle Link
1/2"
8-1/4"
15"
1/2"
90-130 lb-in
10-15 Nm
10" Diameter Min.
Do not pinch cable.
IMPORTANT:
Apply grease to O-Ring
to retain into handle groove.
Cable Operated Switch Installation
2
Publication 1494V-IN028A-EN-P - March 2018
Center punch and drill
(4) 9/32" dia. holes for
thread forming screws
provided with switch.
6
Universal Disconnect Switch Installation Instructions (600A)
4
3
ATTENTION: CHECK FOR PROPER OPERATION.
Handle Mechanism Installation (Cont'd)
4
Turn disconnect handle "OFF" and install handle
mechanism spring.
Connecting Rod Adjustment Procedure
Move disconnect handle to the "ON" position.
If switch does not fully close, return handle to "OFF" position.
Remove link spring and hitch pin to disengage the connecting
rod from the primary link.
Turn connecting rod counter-clockwise (1 or more) full turns.
Re-engage connecting rod in primary link of handle, insert hitch
pin and re-test.
Repeat - as necessary.
Re-install link spring.
Install hitch pin clip
Hitch Pin
Clip
Drive Bar
1
2
3
4
5
6
7
1
5
Move disconnect handle to the "OFF" position.
If switch does not fully open, return handle to "ON" position.
Remove link spring and hitch pin to disengage the connecting
rod from the primary link.
Turn connecting rod clockwise (1 or more) full turns.
Re-engage connecting rod in primary link of handle, insert hitch pin and
re-test.
Repeat - as necessary.
Re-install link spring.
1
2
3
4
5
6
7
1
5
Adjustment Procedure if switch does not turn "ON". Adjustment Procedure if switch does not turn "OFF".
Rod Operated Adjustment Cable Operated Adjustment
Publication 1494V-IN028A-EN-P - March 2018
7Universal Disconnect Switch Installation Instructions (600A)
Door Catch
Mounting
Bracket
18-3/16"
1-3/8"
1-1/8"
3-3/4"
1-5/8"
Top
Handle
Hole
Square
corners
or up to
1/4" radius
(2) .328 Dia.
Holes
1/4"
1/2"
6-1/2"
5-1/2"
5/16"
Locate Disconnect Switch
Enclosure without Handle Cutout
• Enclosures with a flange thickness less than 3/16" use dimensions below to install disconnect handle.
Locate Handle
Right hand flange shown. Mirror for left hand flange.
Drill Handle Holes
8-1/4" 2-1/16"
6-5/8"
Ø9/32"
15"
8-1/4"
1 2 3
Publication 1494V-IN028A-EN-P - March 2018
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 in the enclosure door.
•
• User to supply the hardware for fastening the bracket.
• The bracket hardware must be inaccessible to unauthorized personnel.
• Fasteners must provide the degree of ingress protection for the environmental rating of the enclosure.
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.
1-1/8"
1-3/8"
Enclosure Door
Flange
Thickness
K
1-5/8"
Enclosure
Base
TOP VIEW
Door Catch
Mounting
Bracket
Door Catch
Mounting Bracket
Door Catch
Top
22-37 lb-in
(2.5-4.2 N-m)
8
Universal Disconnect Switch Installation Instructions (600A)
1
2
3
90-130 lb-in
10-15 Nm
Remove drive mechanism
from right side of switch
(3) - 5/16 - 18 Hex Head Screws
with disconnect switch
in the "OFF" position.
Rotate crossbar to closed or "on" position.
Reinstall drive mechanism on left side of switch
Conversion from Right Hand to Left Hand Operation (If Required)
IMPORTANT: Switch conversion to left-hand operation requires left-hand cable mechanism.
ATTENTION: With switch in the "CLOSED" position,
drive mechanism should align with crossbar.
Line Terminal Guard Installation
90-130 lb-in
10-15 Nm
1
2
6-10 lb-in
0.68-1.1 Nm
Line Terminal Adapter Installation
Torque Range
1494U-
ALT600
25 lb-in
(2.8 N-m)
(1) 14-10 STR/SOL
(1) 8 STR
(2) 14 SOL/SOL
(2) 14 STR/STR
(2) 12 SOL/SOL
(2) 12 STR/STR
(2) 10 SOL/SOL
(2) 10 STR/STR
(2) 8 STR/STR
Lug Adapter Kit
Wire
Catalog
Number
Publication 1494V-IN028A-EN-P - March 2018
Wire
Clamp
Adapter
9Universal Disconnect Switch Installation Instructions (600A)
Trailer Fuse Block Installation (400A Fuses)
Note: Terminal bolts need to be
moved from disconnect switch
load terminals to fuse block.
Trailer Fuse Block Location
(400A Class H, J, R Fuses)
A
8-1/4"
6-3/4"
6-3/4"
2-13/16"
3"
3-3/16"
3/16"
3-15/16"
40-55 lb-in
4.5-6.2 Nm
400A Fuses (Class H, J, R)
2
1
Fuse Installation
400 Amp Trailer Fuse Block (1494V-FSV400)
Torque
lb-in
(Nm)
Fuse
1-3/4"
4-1/4"
1-1/8"
400
400
400
250
600
600
H/R
H/R
J
90-130
(10-15)
22
-
37
(2.5-4.2)
175
-
200
(20-23)
275
-
305
(31-34)
Amps Voltage Class Fuse
Clip
A
Fuse
Block
Lug to
Terminal
Wire
into Lug
Publication 1494V-IN028A-EN-P - March 2018
10
Universal Disconnect Switch Installation Instructions (600A)
Trailer Fuse Block Installation (600A Fuses)
Trailer Fuse Block Location
(600A Class J Fuses)
3"
A
6-3/4"
2-13/16"
3-15/16"
8-1/4"
6-3/4"
3"
3/8"
600A Fuses (Class J)
4
3
2
300-350 lb-in
34-40 Nm
1
Fuse Clip Installation
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).
300-350 lb-in
34-40 Nm
600 Amp Trailer Fuse Block (1494V-FS600)
Torque
lb-in
(Nm)
Fuse
4-3/8"600 250/600 J
90-130
(10-15)
300-350
(34-40)
175
-
200
(20-23)
275
-
305
(31-34)
Amps Voltage Class Fuse
Bolt
A
Fuse
Block
Lug to
Terminal
Wire
into Lug
Publication 1494V-IN028A-EN-P - March 2018
Bulletin 1494V/U Disconnect Switch Optional Accessory List
Disconnect Kit
Handle
Switch
Connecting
Rod
Fuse
Block
Fuse
Clips
Catalog Number and Description
Switch with Right Hand Mechanism
1494V-DS600
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)
Mounted with Switch
1494V-FSV400 (400A Class H, J, R)
1494V-FS600 (600A Class J)
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
Separately Mounted
1491-N621 (600A Class H)
1491-R621 (600A Class R)
1494U-C64: 4 Ft Cable
1494U-C65: 5 Ft Cable
1494U-C66: 6 Ft Cable
Cable
Mechanism
11Universal Disconnect Switch Installation Instructions (600A)
Publication 1494V-IN028A-EN-P - March 2018
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"
Set of
(2) rods
PN-475449
DIR 10003527463 (Version 00)
Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Publication 1494V-IN028A-EN-P - March 2018
Bulletin 1494V/U Disconnect Switch Optional Accessory List
Catalog Number and Description
Electrical
Interlock
Auxiliary
Contact
Aluminum
Lugs
Optional Accessories
(Installation Instructions
Included with Accessory Kits)
Switch with Right Hand Mechanism
1495-N34 (1-N.O./N.C.)*
1495-N35 (2-N.O./N.C.)*
*Requires Adapter Kit 1495-N36
595-A (1-N.O.)*
595-B (1-N.C.)*
*Requires Adapter Kit 595-N1
Protective
Cover
with Door
Switch
Rating
Fuse
Class
Fuse Clip
Rating
Cat No.
250V 600V
400A 400A
H, J, R600A 1495-N61
600A ----
----
Non-Fusible 1495-N61
600A 600AJ600A 1495-N61
600A 600AH,R600A N/A
LUGS (Pkg Qty 3)
TYPE TORQUE GAUGE (AW G)
1494R-N10
1494R-N11*
1494R-N12
Wire
325 LB-INCU ONLY
(2) 1/0…350 MCM
*For Separately Mounted Fuse Blocks (2 per kit)
*Special Purpose Not For General Use
Copper
Lugs
(1) 1/0…500 MCM
LUGS (Pkg Qty 3)
TYPE TORQUE GAUGE (AW G)
1494U-LA600
Wire
325 LB-INAL / CU
(2) 1/0…500 MCM
LUGS (Pkg Qty 3)
TYPE TORQUE GAUGE (AW G)
1494U-LM600*
FOR LOAD
SIDE ONLY
Wire
35 LB-IN
AL / CU
(12) 6…4
25 LB-IN (12) 8
20 LB-IN
(12) 14…10
Multiport
Lugs
Line
Terminal
Adapters
1494U-ALT600
(Pkg Qty 2)
EEE Yönetmeliğine Uygundur.
Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page.
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Allen-Bradley D Series Installation Instructions Manual

Allen-Bradley
Brand
Allen-Bradley
Model
D Series
Type
Installation Instructions Manual
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