Installation Instructions
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
(Cat 1494U-D30; 1494U-D60; 1494U-D100; Series A)
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.
Tools Needed: 7/16" Nut Driver, 5/16" Nut Driver, Hammer, Center Punch, File, T27 Torx Driver, Phillips Screwdriver, 11/64" Drill Bit, Needlenose Pliers
Table of Contents Page
Installation Guide............................................................................................................................................................................. 2
Rod and Cable Operated Disconnect Switch Location.................................................................................................. 2
Rod Operated Switch Installation.......................................................................................................................................... 3
Handle Installation.................................................................................................................................................................. 3
Connecting Rod Installation................................................................................................................................................ 3
Rod Adjustment Procedure................................................................................................................................................. 4
Cable Operated Switch Installation...................................................................................................................................... 5
Handle and Cable Mechanism Installation..................................................................................................................... 5
Cable to Switch Mechanism Installation......................................................................................................................... 6
Cable Adjustment Procedure.............................................................................................................................................. 7
Enclosure Without Handle Cutout............................................................................................................................................. 8
Door Catch Bracket Installation.................................................................................................................................................. 9
Trailer Fuse Block and Phase Barrier Installation................................................................................................................10
Auxiliary Contact Installation.....................................................................................................................................................11
Line Terminal Adapter Installation..........................................................................................................................................12
Electrical Interlock Installation..................................................................................................................................................12
Fuse Clip and Fuse Installation.................................................................................................................................................13
Protective Cover Installation.....................................................................................................................................................14
Bulletin 1494U Disconnect Switch Component Accessory List....................................................................................15
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
2
Rod and Cable Operated Disconnect Switch Location
Disconnect Switch Location and Installation
1
A) For Rod Operated Switches, follow steps 1 - 5 below.
B) For Cable Operated Switches, follow steps 3 - 5 below.
IMPORTANT: When locating the 30A, 60A and 100A 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 eciency of the cable system, create additional drag and friction within the cable conduit and possibly decrease
system life.
1 Measure top hole of handle on enclosure.
2 Use template PN-254969 to locate handle holes on mounting plate.
Lay template on enclosure back plate. Align using the top hole on
Measure hole center to side of enclosure: _______
paper and measurements taken from step .
Measure hole center to top of enclosure: _______
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3 Tape template down.
Center punch and drill (4)
11/64" holes for thread
forming (TAP-TITE) screws
provided with switch.
4 Install Disconnect Switch. 5 Install Line Terminal Guard.
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23-37 lb-in
(2.6-4.2 N-m)
7/16" Nut Driver
Wiring Diagrams
Single Phase AC Three Phase AC Direct Current
L1 L2 L3
T1 T2 T3
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
L1 L2 L3
T1 T2 T3
L1 L2 L3
T1 T2 T3
Rod Operated Switch Installation
1494U Handle Installation
1
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
3
1 Install gasket. 2 Install spring bracket and handle.
TIP: Move handle to
“ON” position to help
align handle and bracket.
Return handle to “OFF”
position once connected.
30-40 lb-in
(3.4-4.5 N-m)
Spring
Bracket
Cutting Connecting Rod
2
3 Install defeater lever.
7-11 lb-in
(0.8-1.2 N-m)
1 Measure working depth of enclosure. 2 Measure, mark and cut connecting rod. 3 Remove burrs.
Mounting
Plate
Connecting Rod
1494U-R1
Enclosure
Working Depth
(Inside Flange
of Enclosure to
Mounting Plate)
30A - 60A - 100A Disconnect Switches
Enclosure Working Depth “N”
6-1/2"
Min.
N
Max.
19"
N minus 3"
For enclosures with a working depth greater than 19"
but less than 23", use connecting rod kit 1494V-RA4.
Defeater
Lever
Connecting Rod Installation
3
1 Verify that disconnect switch and handle are in “OFF” position
(Switch blades will be visible).
Drive Bar
2
2
Rotate connecting rod
into drive bar (11) full
turns.
See steps and for final rod alignment.
2
2
3
4
3
Ensure that the handle is
in the full “OFF” position.
Align threaded rod
toward handle and,
4
if needed, rotate
counterclockwise
until ears engage the
primary link slots.
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
4
Rod Operated Switch Installation (Cont’d)
Connecting Rod Installation (Cont’d)
3
5 Engage ears of connecting rod into slots of handle link. 7 Install spring to handle link.
Connecting
6
5
6 Install hitch pin
through ears of
connecting rod.
Rod Adjustment Procedure
Rod
Hitch Pin
6
5
Primary Link
8 Install other side of spring
to handle bracket.
7
8
ATTENTION
CHECK FOR PROPER
OPERATION
Adjustment Procedure if switch does not
turn "ON".
1. Move handle to “ON” position.
2. If switch does not fully close, return handle to
"OFF" position.
3. Remove link spring and hitch pin to disengage
the connecting rod from the primary link.
4. Turn connecting rod counter-clockwise (1 or
more) full turns.
5. Re-engage connecting rod in primary link of
handle, insert hitch pin and re-test.
6. Repeat steps 1 - 5 as necessary.
7. Re-install link spring.
Adjustment Procedure if switch does not
turn "OFF".
1. Move handle to “OFF” position.
2. If switch does not fully open, return handle to
"ON" position.
3. Remove link spring and hitch pin to disengage
the connecting rod from the primary link.
4. Turn connecting rod clockwise (1 or more) full
turns.
5. Re-engage connecting rod in primary link of
handle, insert hitch pin and re-test.
6. Repeat steps 1 - 5 as necessary.
7. Re-install link spring.
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
Cable Operated Switch Installation
1494U Handle and Cable Mechanism Installation
1
Enclosures with Right Flange
1a Install spring to handle link.
90°
Enclosures with Left Flange
2a
Connect handle link to lever pin.
3
Install handle nuts and hitch pin.
30 - 40 lb-in
(3.4 - 4.5 N-m)
5
OFF
2b
1b
Install spring to handle link.
Connect handle link to lever pin..
90°
4 Install other end of spring to cable mechanism bracket
using needlenose pliers.
5 Install defeater lever.
3
Install handle nuts and hitch pin.
OFF
30 - 40 lb-in
(3.4 - 4.5 N-m)
7-11 lb-in
(0.8-1.2 N-m)
Defeater
Lever
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
6
Cable Operated Switch Installation (Cont’d)
Cable to Switch Mechanism Installation
2
IMPORTANT: Verify that the cable assembly does not interfere with any mechanical and moving parts. Keep the cable conduit a minimum of 1/2" from all heat sources and current carrying
terminals, fuses, transformers, etc.
IMPORTANT: When locating the 30A, 60A and 100A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and the handle mechanism is not less
than 6 inches.
1 Locate switch as to not pinch the cable or create
a bend less than 6" in diameter.
NOTE:
All bends must be
greater than 6" in
6" Diameter Min
diameter.
Do Not Pinch Cable
1 Tighten cable nuts onto switch
bracket.
Check for one
washer on each
side of the switch
bracket.
30-35 lb-in
(3.4-4 N-m)
2 Use washer and hitch pin to attach cable
pivot to switch mechanism cable slot.
Install pin as
shown. Do
not push past
second bend
on clip.
3 Remove drive bar for rod operation, washer
and hitch pin; discard.
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
Cable Adjustment Procedure
1 Move handle to “ON” position. 2 Remove cable pivot hitch pin and washer. 3 Push cable pivot out of handle bracket.
7
4 Return handle to “OFF” position. 5 (a) ADJUSTMENT PROCEDURE IF
6 Return handle to “ON” position and insert
cable pivot back into mechanism.
SWITCH DOES NOT FULLY CLOSE
Unscrew cable pivot ONE full turn
counter-clockwise to extend cable.
7 Re-install cable pivot washer and hitch pin. 8 Confirm switch operates properly and
5
(b) ADJUSTMENT PROCEDURE IF
SWITCH DOES NOT FULLY OPEN
Turn cable pivot ONE full turn
clockwise to shorten cable.
repeat steps 5-7 if necessary.
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
8
Enclosure without Handle Cutout
• Some Enclosures with hinged flange panels may require additional flange support brackets to stiffen panel.
Consult your local enclosure manufacturer.
Locate Handle
1
Right Hand Flange
Drill Handle Holes
2
C
B
A
B
A
C
Top Handle Hole
Left Hand Flange
Top Handle Hole
To make slot drill (3) 1/2" diameter holes and remove burrs
NEMA
SIZE
30A, 60A
100A
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
A
(min)
4 - 5/8"
6 - 1/16"
(min)
1 - 1/4"
(2) .265 Dia. Holes
G
H
J
H
Enclosure Dimensions
B
C
(max)
F
4 - 11/16"G1 - 9/16"
F
H
1"
J
7/8"1 - 3/32"
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
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.
• 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.
9
Door Catch
Mounting Bracket
(2.5-4.2 N-m)
22-37 lb-in
E
Top
TOP VIEW
Enclosure Door
Flange
Thickness
Door Catch
Mounting
Bracket
Door Catch
C
Enclosure
Base
D
B
Enclosure Dimensions
NEMA
SIZE
30A, 60A
100A
C
B
A
A
(min)
4 - 5/8"
6 - 1/16"
B
(min)
1 - 1/4"
Top Handle Hole
C
(max)
DE
1 - 5/8"
2 - 3/8"1 - 3/32"
B
A
C
E
K
Door Catch
Mounting
Bracket
D
D
Door Catch
Mounting
Bracket
Right Hand Flange Left Hand Flange
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Fuse
Phase
Barrier
Amps
Volts
Class
30
250
H/R**30
600
H/RB30
600
J
**
30
600
HRCII-C
A
60
250
H/R
A
60
600
H/RB60
600
J**60
600
HRCII-C
A
100
250
H/R
C
100
600
H/R
D
100
600JB
100
600
HRCII-C
B
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
10
Trailer Fuse Block and Phase Barrier Installation
1 Trailer Fuse Block Location
“Z”
2 Snap phase barrier off to desired length as shown in table above.
D
C
B
A
3 Slide phase barriers into fuse block and click in place.
DIM
“Z”
(in)
1.791
4.585
1.791
3.024
2.622
5.122
1.976
3.024
5.636
7.636
4.449
4.402
**Phase barrier not required.
4 Slide phase barriers into left channels on switch.
Click
5 Fasten fuse block to panel.
23-37 lb-in
(2.6-4.2 N-m)
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Auxiliary Contact Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
11
1
2
CLICK
0.32"
(8 mm)
1
#18 - #12 AWG
(0.75-2.5 mm²)
6-8 lb-in
(0.7-0.9 N-m)
2
Auxiliary Contact Wire Routing
Wire routing channels
Wire tie-down points
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
30…60 1494U-LA36
(1) 14 AWG … 2 AWG (Cu)
(1) 12 AWG … 2 AWG (Al)
(2) 14 AWG … 10 AWG (Cu)
(2) 12 AWG … 10 AWG (Al)
100 1494U-LA100
(1) 14 AWG … 1/ 0 AWG (Cu)
(1) 12 AWG … 1/0 AWG (Al)
(2) 12 AWG … 4 AWG (Cu-Al)
30...100 1494U-LM31 Multi -po rt
(1) 14 AWG … 4 AWG (Cu)
(1) 12 AWG … 4 AWG (Al)
(2*) 10 AWG (Cu - Al)
30…60 1494U-LC36
(1) 14 AWG … 4 AWG (Cu)
(2*) 14 AWG … 8 AWG (Cu)
(4) 16 AWG (Cu)
100 1494U- LC100 (1) 8 AWG... 1/0 AWG (C u)
Lug Ki t
Lug
Description
Wire Range
Switch
Rating
(A)
Lug
Material
Single Port
Single Port
Wire
Material
Cu
Cu Only
Al
Cu or Al
Lug
1494U-LA36 1494U-LA100 1494U-LM31 1494U-LC36 1494U-LC100
Wire Gauge (AWG)
1/0…2 - - -
4…6 35
825
10…14 20
Torque (in-lbs)
50
45
45
120
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
12
Lug Connectors
*Wire pairs must be same size and material.
Lug to
Terminal
Torque
40-60 l b-i n
(4.5-6.8 N-m)
Wire Torque
Line Terminal Adapter Installation
Load Side
Line Side
Lug Adapter Kit
Catalog
Number
1494U-ALT31 30A/60A/100A
Disconnect
Switch
Rating (Size)
Adapter
Torque
50 lb-in
(5.6 N-m)
Torque
25 lb-in
(2.8 N-m)
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Wire Clamp
Adapter
Wire Lug
Wire Clamp
Wire 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
Electrical Interlock Installation
1
2
25 lb-in
(2.8 N-m)
Fuse Clip and Fuse Installation
30A/60A Fuse Clip Installation 30A/60A Fuse Installation
23-37 lb-in
(2.6-4.2 N-m)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
13
100A Fuse Clip Installation 100A Fuse Installation
23-37 lb-in
(2.6-4.2 N-m)
18-22
lb-in
(2-2.5 N-m)
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
14
Protective Cover Installation
1 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 ensure
engagement.
5 Ensure flange on left side of cover has snapped under fuse block.
4 Press center of cover tight to mounting plate to engage notch in right
side of cover with switch bracket.
6 Optional: Install high-vibration application screw in bottom slot.
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Component
Cat No.
Switch and Mechanism
1494U-D30 (30A)
1494U-D60 (60A)
1494U-D100 (100A)
Includes:
Line Side Lugs
Line Side Shield (Field Installed)
Load Side Lugs (Field Installed)
1494U-AL36 (30A/60A) (Pkg Qty 3)
1494U-AL100 (100A) (Pkg Qty 3)
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-R1 (30A-100A)
Enclosure Working Depth: 6-1/2” to 19”
Fuse Clip Kits (Pkg Qty 6):
1494U-FC302J (30A 250V Class J)
1494U-FC302R (30A 250V Class R)
1494U-FC30J (30A 600V Class J)
1494U-FC60J (60A 600V Class J)
1494U-FC100J (100A 600V Class J)
1494U-FC30R (30A 600V Class R)
1494U-FC60R (60A 600V Class R)
1494U-FC100R (100A 600V Class R)
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
Bulletin 1494U Disconnect Switch Component Accessory List
Disconnect Switch and Mechanism
(1494U-D30 shown)
Handle
15
(1494U-HM1 shown)
Connecting Rod
Cable-Operated Handle Mechanism
Fuse Block
(1494U-F30 shown)
Fuse Clip Kits
(1494U-FC30J shown)
Publication 1494U-IN001G-EN-P - November 2015 PN-335193 DIR 10001182729 (Version 06)
Cable Handle Mechanism:
1494U-C313 (3 ft. Cable)
1494U-C314 (4 ft. Cable)
1494U-C315 (5 ft. Cable)
1494U-C316 (6 ft. Cable)
1494U-F30 (30A)
1494U-F60 (60A)
1494U-F100 (100A)
Includes:
Phase Barriers
1494U-PB31 (Field Installed) (Pkg Qty 2)
Bulletin 1494U Disconnect Switch Component Accessory List (Cont’d)
Auxillary Contacts
1494U-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
1494U-LC36 (30A - 60A)
1494U-LC100 (100A)
(Pkg Qty 3)
Multiport Lugs
1494U-LM31 (30A - 100A)
(Pkg Qty 3)
Line Terminal Adapters
1494U-ALT31 (Pkg Qty 2)
250V
600V
30/60/100A
Non-
Fusible
30A
30A
30A
60A
100A
30A
60A
100A
Component Cat No.
1494U-LA36 (30A - 60A)
1494U-LA100 (100A)
(Pkg Qty 3)
(1494U-LA100 shown)
(1494U-LC100 shown)
Phase Barriers
1494U-PB31 (Pkg Qty 2)
Fuse Cover
Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page
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.
Switch
Rating
Fuse
Class
H,J
R
H,J
H,J
H,J
R
R
R
Fuse Clip Rating
----
----
30A
30A
----
----
----
----
----
----
----
----
30A
60A
100A
30A
60A
100A
1494U-FC302J
1494U-FC302R
1494U-FC30J
1494U-FC60J
1494U-FC100J
1494U-FC30R
1494U-FC60R
1494U-FC100R
Fuse Clip
Cat No.
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Fuse Cover
Cat No.
1494U-PC1
1494U-PC2
Publication 1494U-IN001G-EN-P - November 2015
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
DIR 10001182729 (Version 06)
PN-335193
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