Bulletin 494C Cable Operated Disconnect Switch Kit (600A) Installation Instructions (Cat 494C- _ Series : 600A) 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. 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. Table of Contents Page Quick Installation Guide - Disconnect Switch Installation,3 - Disconnect Handle Installation 3 - Cable Mechanism Installation 4 - Connecting Rod Adjustment Procedure 5 Conversion from Right Hand to Left Hand Operation 6 Enclosure Without Handle Cutout 7 - Locate Handle - Drill Handle Holes Door Catch Mounting Bracket Installation 8 Trailer Fuse Block Installation (600A) 9 Fuse Clip Installation (600A) 0 Bulletin 494C Cable Operated Disconnect Switch Kit Components Bulletin 494C Cable Operated Disconnect Switch Kit Optional Accessory List 405-90-0 () Printed in U.S.A.
QUICK INSTALLATION GUIDE IMPORTANT: When locating the 600A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and handle mechanism is not less than 6 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 /" from all heat sources and current carrying terminals, fuses, transformers, etc. Disconnect Switch Installation a Locate switch with right hand mechanism 8-/4" 5" 8-/4" 5" (4) - 9/3" Dia. Mounting Holes (4) - 9/3" Dia. Mounting Holes 6" Dia. Minimum Enclosure with Right Hand Flange 6" Dia. Minimum Enclosure with Left Hand Flange b Locate switch with left hand mechanism 5" 8-/4" 5" 8-/4" (4) - 9/3" Dia. Mounting Holes (4) - 9/3" Dia. Mounting Holes 6" Dia. Minimum 6" Dia. Minimum Enclosure with Right Hand Flange Enclosure with Left Hand Flange ()
Disconnect Switch Installation (Cont'd) Rotate crossbar to closed position. 3 Assemble the cable mechanism bracket to the disconnect switch. 90-30 lb-in 4 Turn the connecting rod clockwise (approximately 9-0 5 turns) until jam nuts touch drive bar Turn the connecting rod counter-clockwise (less than turn) until hole in threaded rod aligns with hole in cable mechanism lever. Drive Bar Threaded Rod Jam Nuts Cable Mechanism Lever (3)
Disconnect Switch Installation (Cont'd) 6 Attach threaded rod to cable mechanism lever. 7 Assemble disconnect switch assembly to mounting plate. Threaded Rod 90-30 lb-in 90-30 lb-in 90-30 lb-in Cable Mechanism Lever (4) - 5/6-8 thread forming screws provided with disconnect switch. Disconnect Handle Installation Install gasket. Install handle and mechanism bracket. 3 Install defeater lever. 60-80 lb-in (Right Hand Flange Mounted Shown) 7- lb-in NOTE: Apply grease from capsule to gasket or groove to retain gasket to handle. 3 Cable Mechanism Installation Verify that disconnect switch and handle are in the "ON" position. Rotate connecting rod (clockwise) into drive bar until it begins to exit the drive bar (approximately 8 full turns). C L O S E D (4)
3 Cable Mechanism Installation (Cont'd) 3 Align connecting rod with primary link. 4 Install hitch pin clip Hitch Pin Clip Connecting Rod Primary Link 5 Turn disconnect handle "OFF" and install handle mechanism spring. 4 Connecting Rod Adjustment Procedure "ON" Position ➊ 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 ( 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" Position ➊ Move disconnect handle to the "OFF" position. If switch does not fully open, return handle to "ON" position. ➋ ➌ Remove hitch pin and link spring, then disengage the connecting rod from the primary link. ➍ Turn connecting rod clockwise ( 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. ATTENTION: CHECK FOR PROPER OPERATION. Upon completion of the installation instructions, no further adjustment of the cable mechanism is required. (5)
Conversion from Right Hand to Left Hand Operation (If Required) IMPORTANT: Switch conversion to left-hand operation requires left-hand cable mechanism. Remove drive mechanism from right side of switch (3) - 5/6-8 Hex Head Screws with disconnect switch in the "OFF" position. Rotate crossbar to closed position. 3 Reinstall drive mechanism on left side of switch ATTENTION: With switch in the "CLOSED" position, drive mechanism should align with crossbar. 90-30 lb-in (6)
Enclosure without Handle Cutout Enclosures with a Flange Thickness less than 3/6" use dimensions below to install disconnect handle. Locate Handle -/8" -/8" -3/8" -3/8" 8-3/6" 8-3/6" Top Handle Hole Right Hand Flange Left Hand Flange Drill Handle Holes ().38 Dia. Holes Top Handle Hole 5/6" /" /4" 5-/" 6-/" Square corners or up to /4" radius (7)
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. 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 ") When using large disconnect handle kit only (494F-M or -S), use door catch provided with handle kit. When using large disconnect handle kit and small door hardware kits (494V-L, -LL, -L or -LL), use door catch provided with door hardware kit. Dimension K (-/8" to -3/8") When using large disconnect handle kit and large door hardware kits (494V-L3 or -LL3), use door catch provided with door hardware kit. Door Catch Mounting Bracket Top TOP VIEW Door Catch Enclosure Door Door Catch Mounting Bracket Flange Thickness K Door Catch - /8" - 5/8" - 3/8" Enclosure Base -/8" -/8" -3/8" -3/8" 8-3/6" 8-3/6" 3-3/4" 3-3/4" Top Handle Hole Door Catch Mounting Bracket -5/8" -5/8" Door Catch Mounting Bracket Right Hand Flange (8) Left Hand Flange
Trailer Fuse Block Installation (Switch Rating 600A) Note: Not required for non-fusible disconnect switch applications. Trailer Fuse Block Location (400A Class H, J, R Fuses) Trailer Fuse Block Location (600A Class J Fuses) 8-/4" 8-/4" 6-3/4" 6-3/4" A 3/6" 3-3/6" A 3/8" 3" 3-5/6" 3-5/6" -3/6" 3" Note: Terminal bolts need to be moved from disconnect switch load terminals to fuse block. -3/6" 3" 6-3/4" 6-3/4" Amps Voltage Class Fuse Clip 400 400 400 400 Amp Trailer Fuse Block (494V-FSV400) Fuse Torque (lb-in) A Fuse Lug to Block Terminal 50 600 600 H/R H/R J -3/4" 4-/4" -/8" Wire into Lug -37 90-30 75-00 75-305 Fuse 600 Amp Trailer Fuse Block (494V-FS600) Torque (lb-in) A Fuse Lug to Block Terminal Amps Voltage Class Fuse Bolt Wire into Lug 600 50 / 600 J 4-3/8" 300-350 90-30 75-00 75-305 3 Trailer Fuse Block Location (600A - 50V / 600V Class H, R Fuses) Note: Refer to instructions provided with separately mounted fuse blocks (Catalog Numbers 49-N6 and 49-R6). (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 3 600A Fuses (Class H, R) Note: Refer to instructions provided with separately mounted fuse blocks (Catalog Numbers 49-N6 and 49-R6). (0)
Bulletin 494C Cable Operated Disconnect Switch Kit Components Disconnect Switch Kit Cat No. Switch with Right Hand Mechanism 494V-DS600 (600A) Convertible in the field for Left Hand operation Switch Handle 494F-M (7-/" Painted Metal) (400A / 600A) 494F-S (7-/" Stainless Steel) (400A / 600A) Cable Mechanism Cable with Right Hand Mechanism 494C-CM3: 600A (4 Ft Cable) 494C-CM4: 600A (5 Ft Cable) 494C-CM5: 600A (6 Ft Cable) 494C-CM6: 600A (0 Ft Cable) Cable with Left Hand Mechanism 494C-CMX3: 600A (4 Ft Cable) 494C-CMX4: 600A (5 Ft Cable) 494C-CMX5: 600A (6 Ft Cable) 494C-CMX6: 600A (0 Ft Cable) Mounted with Switch 494V-FSV400 (400A Class H, J, R) 494V-FS600 (600A Class J) Fuse Block Separately Mounted 49-N6 (600A 50V / 600V Class H) 49-R6 (600A 50V / 600V Class R) 400A Fuses 40-N46 (Class H, J, 400A-50V, 400A-600V) 40-N55 (Class R, 400A-50V, 400A-600V) Fuse Clips 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.49-N6 and 49-R6 ()
Bulletin 494C Cable Operated Disconnect Switch Kit Optional Accessory List Optional Accessories (Installation Instructions Included with Accessory Kits) Catalog Number and Description Electrical Interlock Switch with Right Hand Mechanism 495-N34 (-N.O./N.C.) * 495-N35 (-N.O./N.C.) * *Requires Adapter Kit 495-N36 Auxiliary Contact 595-A (-N.O.) (600A) * 595-B (-N.C.) (600A) * *Requires Adapter Kit 595-N Switch and Fuse Block 494R-N0 (CU Wire () - #/0-350 MCM) (600A or 400A Fuse Block) (3 per kit) Lug Connectors 494R-N (CU Wire () - #/0-500 MCM) (600A or 400A Fuse Block) (3 per kit) Separately Mounted Fuse Blocks 494R-N (CU Wire () - #/0-350 MCM) (600A) ( per kit) Switch Rating Fuse Class Fuse Clip Rating 50V 600V Cat No. Fuse Cover with Door 600A Non-Fusible ---- ---- 495-N6 600A H, J, R 400A 400A 495-N6 600A J 600A 600A 495-N6 Available only for R.H. mounted disconnect switch. 600A H,R 600A 600A N/A 405-90-0 () Printed in U.S.A.