Universal Disconnect Switch Installation …...4 Install Disconnect Switch. 5 Install Line Terminal...

Universal Disconnect Switch Installation Instructions (200A)(Cat 1494U-D200; Series A)

Tools Needed: 5/16", 3/8" & 7/16" Nut Drivers, Hammer, Center Punch, File, Flat Screwdriver, Phillips Screwdriver, 7/32" 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.

Table of Contents Page

Rod and Cable Operated Disconnect Switch Location........................................................................................................................................................ 2

Rod Operated Switch Installation.................................................................................................................................................................................................2

Handle Installation.........................................................................................................................................................................................................................2

Cutting Connecting Rod..............................................................................................................................................................................................................3

Connecting Rod Installation.......................................................................................................................................................................................................3

Cable Operated Switch Installation.............................................................................................................................................................................................4

Handle and Cable Mechanism Installation...........................................................................................................................................................................4

Cable to Switch Mechanism Installation................................................................................................................................................................................4

Rod Operated Adjustment Procedure........................................................................................................................................................................................5

Cable Operated Adjustment Procedure.....................................................................................................................................................................................5

Enclosure without Handle Cutout................................................................................................................................................................................................6

Door Catch Bracket Installation.....................................................................................................................................................................................................6

Trailer Fuse Block Installation.........................................................................................................................................................................................................7

Fuse Clip and Fuse Installation..................................................................................................................................................................................................8

Auxiliary Contact Installation.........................................................................................................................................................................................................9

Auxiliary Contact Wire Routing.....................................................................................................................................................................................................9

Line Terminal Adapter Installation...............................................................................................................................................................................................9

Electrical Interlock Installation.......................................................................................................................................................................................................9

Protective Cover Installation........................................................................................................................................................................................................10

Bulletin 1494U Disconnect Switch Component Accessory List......................................................................................................................................11

1 Measure top hole of handle on enclosure.

Measure hole center to side of enclosure: _______

Measure hole center to top of enclosure: _______

2 Use template C to locate handle holes on mounting plate. Laytemplate on enclosure mounting plate. Align using the top hole onpaper and measurements taken from step .1

3 Tape template down.Center punch and drill (4)7/32" holes for threadforming screws providedwith switch.

4 Install Disconnect Switch. 5 Install Line Terminal Guard.

40-60 lb-in(4.5-6.8 N-m)

7/16"NutDriver

Disconnect Switch Location and Installation A) For Rod Operated Switches, follow steps 1 - 5 below. B) For Cable Operated Switches, follow steps 3 - 5 below.

1Rod and Cable Operated Disconnect Switch Location

IMPORTANT: When locating the 200A cable operated 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, create additional drag and friction within the cable conduit and possibly

decrease system life.

Universal Disconnect Switch Installation Instructions (200A)2

Publication 1494U-IN007B-EN-P - July 2018

1494U Handle Installation1Rod Operated Switch Installation

1 Install gasket. 2 Install spring bracket and handle.

30-40 lb-in(3.4-4.5 N-m)

SpringBracket

3 Install defeater lever.

7-11 lb-in(0.8-1.2 N-m)

DefeaterLever

TIP: Move handle to“ON” position to helpalign handle and bracket.Return handle to “OFF”position once connected.

Disconnect Switch H

ole Locatio

n Tem

plate (2

00A)

PN-475436

DIR10003527327 (Version 00)

Copyright ©

2018 Rockwell Automation, In

c. All R

ights Reserved. Prin

ted in USA.

C

Rod Operated Switch Installation (Cont’d)

Cutting Connecting Rod21 Measure working depth of enclosure. 2 Measure, mark and cut connecting rod. 3 Remove burrs.

N

EnclosureWorking Depth(Inside Flangeof Enclosure toMounting Plate)

MountingPlate

N minus 3-1/8"

Connecting Rod Installation31 Verify that disconnect switch and handle are in “OFF” position

(Switch blades will be visible).Drive Bar

2 Rotate connecting rodinto drive bar 9-10 fullturns.

2

Align threaded rodtoward handle and,if needed, rotatecounterclockwiseuntil ears engage theprimary link slots.3

4

ConnectingRod

Hitch Pin

Handle Link

5

6

5 Engage ears of connecting rod into slots of handle link. 7 Install spring to handle link.

7

8

See steps and for final rod alignment.23 24

6 Install hitch pinthrough ears ofconnecting rod.

8 Install other side of springto handle bracket.

Ensure thatthe handleis in the full“OFF” position.

Universal Disconnect Switch Installation Instructions (200A) 3

ATTENTION: CHECK FOR PROPER OPERATION.If not operating properly, go to Rod OperatedAdjustment Procedure.


Cable Operated Switch Installation

1 Tighten cable nuts onto switch bracket.

3 Assemble washers (2) and hitch pin to attach cable pivot to switch mechanism cable slot.

NOTE: Ensure there is one washer on each side of the switch bracket.

Install pin as shown.Do not push pastsecond bend on clip.

75-90 lb-in(8.5-10.2 N-m)

1494U Handle and Cable Mechanism InstallationEnclosures with Right Flange

1

1 Connect handle link to lever pin. 2 Install handle nuts and hitch pin. 3 Install defeater lever.

30-40 lb-in(3.4-4.5 N-m)

OFF


7-11 lb-in(0.8-1.2 N-m)

DefeaterLever


6" DiameterMin.

2 Ensure switch is located as to not pinch the cable or create a bend less than 6" indiameter.

Cable to Switch Mechanism Installation2

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.

1 2

ATTENTION: CHECK FOR PROPER OPERATION.If not operating properly, go to Cable OperatedAdjustment Procedure.

3/8" (9.5mm)Top of thread totop of upper nut.

Handle Link

Lever Pin

SwitchBracket

Cable Operated Adjustment Procedure

1 Move handle to “ON” position. 2 Remove hitch and clevis pins. 3 Return handle to “OFF” position.

4 (a) ADJUSTMENT PROCEDURE IF SWITCHDOES NOT FULLY CLOSE.Unscrew clevis ONE full turn counter-clockwise to extend cable.

4 5 Return handle to “ON” position. Reinstallclevis, clevis pin and hitch pin.

6 Confirm switch operates properly andrepeat steps 2-5, if necessary.

(b) ADJUSTMENT PROCEDURE IF SWITCHDOES NOT FULLY OPEN.Turn clevis ONE full turn clockwise toshorten cable.


Rod Operated 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.

123

45

67

1 5

Move disconnect handle to the "OFF" position.

If switch does not fully close, 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.

123

45

67

1 5

Adjustment Procedure if switch does not turn "ON". Adjustment Procedure if switch does not turn "OFF".


Clevis

Clevis Pin

Hitch Pin

Enclosure without Handle Cutout

To make slot, drill (3)1/2" diameter holesand remove burrs.

Top Handle Hole

(2) .265 Dia. Holes

1-1/4" MIN.1-3/32 MAX.

10-1/8"MIN.

4-11/16"

1-9/16"

1"

7/8"

1"

• Some Enclosures with hinged flange panels may require additional flange support brackets to stiffen panel. Consult your local enclosure manufacturer.

Door Catch Bracket InstallationRight hand installation shown (for left hand installation follow similar procedures)

Door CatchMounting

Bracket

2-3/8"

1-5/8"

1-3/32"

1-1/4"

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 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 small disconnect handle kit only (1494U-HP1, -HM1 or -HS1), use door catch provided with handle kit.• When using small 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 small disconnect handle kit only (1494U-HP1, -HM1 or -HS1), use door catch (40492-080-02) which can be ordered from factory. • When using small 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

Top

22-37 lb-in(2.5-4.2 N-m)


Right hand flange shown. Mirror for left hand flange.

Locate Handle Drill Handle Holes1 2


Trailer Fuse Block and Phase Barrier Installation

FuseDIM"Z"(in)

TrimPhaseBarrierAmps Voltage Class

100 250 H/R C100 600 H/R E100 250/600 J A100 600 HRCII-C A200 250/600 J* D200 250/600 J B200 250 H/R D200 600 H/R -200 600 HRCII-C B

*Direct Mounting

1 Trailer Fuse Block Location 2 Trim phase barrier to desired length as shown in the table in Step .

3 Slide phase barriers into left channels on switch.

4-1/46-1/4

44

6-1/84-3/46-1/88-5/84-3/4

Lug Connectors


"Z"

4 - 3/4"

Thread forming screws

90-130 lb-in10-15 Nm

A

BC

D

E

1

Kit Description MaterialTorque to Terminal

Wire Range (AWG)

Wire MaterialWire into

Lug Torque1494U-LC200 Single Port Cu Cu Only

1494U-LA200 Single Port

1494U-LM200* Multi-Port 14…445 lb-in

(5.1 N-m)

90-105lb-in

(10.2-11.9N-m)

275 lb-in(31.1 N-m)

Cu or AlAl

WireLug

6…250 MCM


*Load Side Only

Fuse Clip and Fuse Installation

Fuse Clip Installation Fuse Installation

23-37 lb-in(2.6-4.2 N-m)

18-22 lb-in(2-2.5 N-m)


Direct Mount for J Fuses


2

2

1

1

40-60 lb-in(4.5-6.8 N-m)

Auxiliary Contact Installation

Line Terminal Adapter Installation

Wire Clamp Range

(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

6-8 lb-in(0.7-0.9 N-m)

0.32"(8 mm)

#18 - #12 AWG(0.75-2.5 mm²)

Wire routing channel

Wire tie-down points

Electrical Interlock Installation


2

CLICK

Wire Clamp25 lb-in(2.8 N-m)

Adapter90-105 lb-in(10.2-11.9 N-m)

WireLug

NOTE:

USE ADAPTER ON

LINE SIDE ONLY


1

1

2

Auxiliary Contact Wire Routing

25 lb-in(2.8 N-m)

Range Torque

6.9-10.4 lb-in(.78-1.18 N-m)

Wire

18-12 AWG

Protective Cover Installation1 Position cover in front of switch as shown. Remove line side

shield.2 Spread sides apart at bottom to fit around fuse block.

3 Rotate cover up and slide top sides into tracks shown on switch.Push in until fully inserted and pull cover down slightly to ensureengagement.

4 Press center of cover tight to mounting plate to engage notch in rightside of cover with switch bracket.

5 Ensure flange on left side of cover has snapped under fuse block.

6 Install screw in bottom slot.



Bulletin 1494U Disconnect Switch Component Accessory List

Component Cat No.

1494U-D200

1494U-HM1 (5-1/2” Painted Metal) (30A - 200A)1494U-HP1 (5-1/2” Molded Plastic) (30A - 200A)1494U-HS1 (5-1/2” Stainless Steel) (30A - 200A)

1494U-F200

Fuse Clip Kits (Pkg Qty 6):1401-N44 (Class H, J, 100A-250V, 100A-600V)1401-N45 (Class H, J, 200A-250V, 200A-600V)1401-N53 (Class R, 100A-250V, 100A-600V)1401-N54 (Class R, 200A-250V, 200A-600V)

Fuse Clip Kits

Fuse Block

Connecting Rod

Cable-Operated Handle Mechanism

1494U-C24 (4 ft. Cable)1494U-C25 (5 ft. Cable)1494U-C26 (6 ft. Cable)

Handle

Disconnect Switch and Mechanism

(1494U-HM1 shown)


6-1/2"

200A Disconnect Switches

Enclosure Working Depth

Min.19"

Max.1494U-R1

Connecting Rod

6-1/2" 23"1494V-RA4


Bulletin 1494U Disconnect Switch Component Accessory List (Cont’d)

Auxiliary Contacts1494U-NO (1 N.O.)1494U-NC (1 N.C.)

1494U-NOLV (1 N.O. Low Level)1494U-NCLV (1 N.C. Low Level)

Aluminum Lugs

Copper Lugs

Multiport Lugs

Line Terminal Adapters

1494U-ALT200 (Pkg Qty 2)

Phase Barriers

1494U-PB200

Protective Cover

PN-475447DIR 10003527449 (Version 01)

Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Component Cat No.

1494U-PC200

1494U-LM200 (Pkg Qty 3)

1494U-LC200 (Pkg Qty 3)

1494U-LA200 (Pkg Qty 3)


EEE Yönetmeliğine Uygundur.

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Universal Disconnect Switch Installation …...4 Install Disconnect Switch. 5 Install Line Terminal...

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