Universal Disconnect Switch Installation Instructions (400A) · Universal Disconnect Switch...

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

Line Terminal Guard Installation...................................................................................................................................................................................................8

Lug Installation....................................................................................................................................................................................................................................8

Line Terminal Adapter Installation...............................................................................................................................................................................................8

Trailer Fuse Block Installation.........................................................................................................................................................................................................9

Direct Mount Fuse Installation..................................................................................................................................................................................................9

Fuse Clip Installation...................................................................................................................................................................................................................10

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

Bulletin 1494U Disconnect Switch Kit Optional Accessory List.......................................................................................................................................11

Universal Disconnect Switch Installation Instructions (400A)(Cat 1494U-D400; Series A)

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 Installation1

Rod Operated Switch Installation

2 Universal Disconnect Switch Installation Instructions (400A)

Install gasket.

60-80 lb-in6.8-9.0 Nm

Install handle and spring bracket.

Use template D to locate handle holes on mounting plate. Overlay template E (400 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.

NN m

inus 3-3/4"Enclosure

Working Depth(Inside Flange of Enclosure toMounting Plate)

MountingPlate

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-Ringto retain into handle groove.

7-11 lb-in0.79-1.2 Nm

6D

HOLD FLUSH

TO INSID

E

OF ENCLOSUREMEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP HANDLE H

OLE

BOTTOM HANDLE H

OLE

TAPE HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

D

113

2

4

90-130 lb-in10-15 Nm

Handle Installation2

Cutting Connecting Rod3

A

HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

2

4 - 3/4

5 - 1/2

5

6-1/2

11

Switch M

ounting H

oles

Center punch and drill

(4) 1

1/32" holes fo

r thread

forming (T

AP-TITE) screws provided w

ith switc

h

42052-158-01 (1)

Printed in

U.S.A.

E

Disconnect Switc

h Hole Locatio

n Template (400A)

RIGHT H

and Installa

tion

(Use opposite

side for le

ft hand in

stallatio

n)

Center punch and drill(4) 9/32" dia. holes forthread forming screwsprovided with switch.

Publication 1494U-IN006C-EN-P - August 2019

3Universal Disconnect Switch Installation Instructions (400A)

Connecting Rod InstallationFirst rod connects the handle to the switch

4

ATTENTION: CHECK FOR PROPER OPERATION.If not operating properly, go to Connecting RodAdjustment Procedure.

Second rod provides stiffening for the enclosure flange and mounting panel

150-200 lb-in17-23 Nm

Verify that disconnect switch and handle are in "OFF" position. (Switch blades will be visible)

Drive Bar

1

2

Rotate connecting rod into drive bar 9-10 turns.

43

Rotate rod to adjust.Adjust to create minimal gap with spring bracket.

ZeroClearance

8

7ConnectingRod

Hitch Pin

Handle Link

5

6

9

10

11

Stiffening Rod

Top View



2 3

1 Assemble the cable mechanism bracket to the disconnect switch.

Rotate connecting rod into drive bar 9-10 turns. Attach connecting rod to cable mechanism.

90-130 lb-in10-15 Nm

1/2"

Fully seat boltprior to attachingnut.

1

2

ConnectingRod

Cable MechanismLever

90-130 lb-in10-15 Nm

9/16"

5/16"

Lubricate

90-130 lb-in10-15 Nm

Cable Operated Mechanism Installation1IMPORTANT: 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 400A 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.

Connecting Rod



3 Assemble disconnect switch assembly to mounting plate.

Handle Mechanism Installation4

Handle InstallationInstall gasket.1 2 3

3

7-11 lb-in0.79-1.2 Nm

Install handle and mechanism bracket. Install defeater lever.

(Right HandFlange MountedShown)

60-80 lb-in6.8-9.0 Nm

1 Operate disconnect switch and verify that the handle and switch are in the "ON" position.

2 Align connecting rod with handle link.

11"

1/2"

Locate Switch. Use template Ewhere desired.

1

2

A

HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

2

4 - 3/4

5 - 1/2

5

6-1/2

11

Switch M

ounting H

oles

Center punch and drill

(4) 1

1/32" holes fo

r thread

forming (T

AP-TITE) screws provided w

ith switc

h

42052-158-01 (1)

Printed in

U.S.A.

E

Disconnect Switc

h Hole Locatio

n Template (400A)

RIGHT H

and Installa

tion

(Use opposite

side for le

ft hand in

stallatio

n)

IMPORTANT:Apply grease to O-Ringto retain into handle groove.

ConnectingRod

HandleLink

90-130 lb-in10-15 Nm

4-3/4"

2"

Cable Operated Switch Installation2

10" Diameter Min.Do not pinch cable.

Center punch and drill(4) 9/32" dia. holes forthread forming screwsprovided with switch.

(4) - 5/16-18 threadforming screws




43

ATTENTION: CHECK FOR PROPER OPERATION.

Handle Mechanism Installation (Cont'd)3Turn 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.

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".

Rod Operated Adjustment Cable Operated Adjustment

Hitch Pin Clip

Drive Bar

Door Catch Bracket InstallationRight 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.


Door CatchMounting

Bracket

14-3/8"

1-3/8"1-1/8"

3-3/4"

1-5/8"

TopHandle

Hole

Squarecornersor up to

1/4" radius

(2) .328" Dia.Holes

1/4"

1/2"6-1/2"

5-1/2"

5/16"

Enclosure without Handle Cutout• Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.

5-1/2"

11"

2"

4-3/4"

1-3/8"

(4) 9/32" Dia.Holes

5"

Locate Disconnect SwitchLocate Handle Drill Handle Holes1 2 3

Right hand flange shown. Mirror for left hand flange.

1-1/8"

1-3/8"

Enclosure Door

Flange Thickness K

1-5/8"

Enclosure Base

TOP VIEW

Door CatchMounting

Bracket

Door CatchMounting Bracket

Door Catch

Top

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


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.


Line Terminal Guard Installation

Assemble and Install Line Terminal Guard

LINE TERMINAL GUARD

LINE TERMINAL GUARD1

2

Lug Installation

175-200 lb-in20-23 Nm

1Line Terminal Adapter Installation

Torque Range

1494R-N19

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 KitWireCatalog

Number

Wire Clamp

Adapter175-200 lb-in

20-23 Nm



Trailer Fuse Block Installation

Trailer Fuse Block Location (400A Class H, J, R Fuses)

A

4 - 3/4"

400 Amp Trailer Fuse Block (1494U-F400)

Torquelb-in(Nm)Fuse

7-11/16"10-3/16"6-3/8"6-3/8"

10"8-11/16"11-11/16"7-3/16"8-11/16"

200200200200400400400400400

250600600600600250600600600

H/RH/R

JHRCII-C

J*H/RH/R

JHRCII-C

90-130(10-15)

22-37(2.5-4.2)

16-22(1.8-2.5)

175-200(20-23)

275-305(31-34)

Amps Voltage Class FuseClip

AFuseBlock

Lug toTerminal

Wireinto Lug

Direct Mount Fuse Installation400A Fuses (Class J Only)

*Direct Mount

N/A

Thread forming screws

1

2

Cut phase barriers along line.

175-200 lb-in20-23 Nm



Fuse Clip Installation400A Fuses (Class H, J, R)

1 2

1

2

1

2

16-22 lb-in1.8-2.5 Nm22-37 lb-in2.5-4.2 Nm

200A Fuse Clips

400A Fuse Clips

23-37 lb-in2.6-4.2 Nm40-55 lb-in4.5-6.2 Nm

200A Fuse Clips

400A Fuse Clips

Protective Cover Installation

23-5/8"

8-1/2"

3-3/8"11/16"

Punch and drill (4) 11/64" pilot holes. 21

1

2

Install (4) mounting screws to hang cover.Fasten cover screws.

8-1/2"Publication 1494U-IN006C-EN-P - August 2019


Bulletin 1494U Disconnect Switch Kit Optional Accessory List

Disconnect Switch Kit

Handle

Switch

ConnectingRod

FuseBlock

FuseClips

Catalog Number and Description

1494U-D400

1494F-M2 (7-1/2" Painted Metal) (400A / 600A)1494F-S2 (7-1/2" Stainless Steel) (400A / 600A)

1494U-F400

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"

1494U-C44: 4 Ft Cable1494U-C45: 5 Ft Cable1494U-C46: 6 Ft Cable

CableMechanism

1401-N45 (Class H,J, 200A - 250V, 200A - 600V)1401-N46 (Class H,J, 400A - 250V, 400A - 600V)1401-N54 (Class R, 200A - 250V, 200A - 600V)1401-N55 (Class R, 400A - 250V, 400A - 600V)

Set of(2) rods


PN-475448DIR 10003527458 (Version 02)

Copyright © 2019 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.


Bulletin 1494U Disconnect Switch Kit Optional Accessory List

Catalog Number and Description

ElectricalInterlock

AuxiliaryContact

AluminumLugs

Optional Accessories

1495-N43 (1-N.O./N.C.)1495-N44 (2-N.O./N.C.)

1495-N8 (1-N.O.)1495-N9 (1-N.C.)

ProtectiveCover

LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)1494R-N14

Wire

275 LB-INCU ONLY (2) 1/0…250 MCM

*Special Purpose Not For General Use

CopperLugs

LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)1494U-LA400

Wire

275 LB-INAL / CU (2) 1/0…300 MCM

LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)1494U-LM400*

FOR LOADSIDE ONLY

Wire

35 LB-INAL / CU

(12) 8…425 LB-IN (12) 820 LB-IN (12) 14…10

MultiportLugs

LineTerminalAdapters

1494R-N19(Pkg Qty 6)

1494U-PC400

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.

CONFIDENTIAL AND PROPRIETARY INFORMATION. THIS DOCUMENT CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF

ROCKWELL AUTOMATION, INC. AND MAY NOT BE USED, COPIED OR DISCLOSED TO OTHERS, EXCEPT WITH THE AUTHORIZED WRITTEN

PERMISSION OF ROCKWELL AUTOMATION, INC.

Sheet

Size Ver

Of 11

A 0110000021669Dr. DateG. USHAKOW 03-21-13

MATERIALSIZE

FOLD

TWO SIDES PRINTEDBODY STOCK WHITE

BODY INK BLACK8-1/2" W x 11" H

FLAT

17" W x 11" H

Page Layout

8 - 1/2"

17"

Front SidePage 12

Back SidePage 11

Front SidePage 1

Back SidePage 2

Front Side

Saddle Stitched

Page 3

Back SidePage 4

Front SidePage 10

Back SidePage 9

Front SidePage 5

Back SidePage 6

Front SidePage 8

Back SidePage 7

SPECIFICATIONS FOR12 PAGE INSTRUCTION SHEET8-1/2” W x 11” H - FINAL FOLD

8 - 1/2" 8 - 1/2"

17"

8 - 1/2" 8 - 1/2"

17"

8 - 1/2"

Final Fold

11”8-1/2”

11"

Note: After folding---Printed in (Country where printed*), part number(s) and barcode (when used) should be visible.

* The printing vendor may change the instruction sheet files to show the correct country.

PN-123456DIR 10000000000 (Version 00)Printed in U.S.A.

BARCODE

Universal Disconnect Switch Installation Instructions (400A) · Universal Disconnect Switch...

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