Rockwell Automation 1494C User Manual
Bulletin 1494C Cable Operated Disconnect Switch Kit (30A - 200A)
Installation Instructions
(Cat 1494C- _ _ _ Series 2 : 30A, 60A, 100A and 200A)
WARNING
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.
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 2,3
- Disconnect Handle Installation 3
- Assemble and Install Line Terminal Guard 4
- Cable Mechanism Installation 4
- Connecting Rod Adjustment Procedure 5
Enclosure Without Handle Cutout 6
- Locate Handle
- Drill Handle Holes
Door Catch Mounting Bracket Installation 7
Trailer Fuse Block Installation (30A, 60A, 100A) 8
Trailer Fuse Block Installation (200A) 9
Fuse Clip Installation and Phase Barrier Replacement (30A, 60A) 10
Fuse Clip Installation and Phase Barrier Replacement (100A) 11
Fuse Clip Installation (200A)
12
Fuse Clip Installation (Switch Rating 200A) for 400A Class J Fuses 13
Phase Barrier Replacement (200A) 14
Bulletin 1494C Cable Operated Disconnect Switch Kit Components 15
Bulletin 1494C Cable Operated Disconnect Switch Kit Optional Accessory List
16
42052-123-01 (3)
Printed in U.S.A.
QUICK INSTALLATION GUIDE
NOTICE
When locating the 30A, 60A and 100A switch, verify that the minimum diameter for the loop of the cable between the switch
mechanism and handle mechanism is not less than 12 inches.
When locating the 200A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and
handle mechanism is not less than 16 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.
NOTICE
Disconnect Switch Installation
1
1a
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.
Switch
Size
30A, 60A, 100A
200A
Locate switch with right hand mechanism
AA
EE
DD
BB
Panel Mounting Dimensions
AA BB CC DD
2-1/4" 5-1/4" 2-1/4" ----
2" 8-1/4" 4-1/4" 1-1/8"
EE
11/64" Dia.
7/32" Dia.
EE
DD
(4) Mounting Plate Holes
Minimum Bend Diameter
FF
12" Dia.
16" Dia.
AA
BB
CC
Enclosure with Right Hand Flange
Locate switch with left hand mechanism
1b
EE
BB
CC
FF
FF
Enclosure with Left Hand Flange
AA
DD
CC
BB
EE
AA
DD
CC
FF
FF
Enclosure with Right Hand Flange Enclosure with Left Hand Flange
(2)
Disconnect Switch Installation (Cont'd)
1
Assemble disconnect switch to cable switch
2
mechanism
23 - 37 lb-in (30A - 100A)
40 - 60 lb-in (200A)
Thread forming
screws
provided with
disconnect switch.
Disconnect Switch with
Right Hand Cable Mechanism
(shown)
Assemble disconnect switch assembly to mounting plate
3
23 - 37 lb-in
(30A - 100A)
40 - 60 lb-in
(200A)
Thread forming
screws
provided with cable
mechanism.
Install rubber handle on line terminal guard Install the line terminal guard on disconnect switch
4
LINE TERMIN
AL GUA
RD
Disconnect Handle Installation
2
Install gasket
1 2 3
Install handle and mechanism bracket
5
LINE TERMINAL GUA
RD
Install defeater lever
30-40 lb-in
(Right Hand
Flange Mounted
Shown)
7-11 lb-in
(3)
Cable Mechanism Installation
3
Verify that disconnect switch and handle are in "ON" position.
1
(Switch blades will not be visible)
Rotate connecting rod (clockwise) into drive bar until it
2
bottoms out
Rotate connecting rod (counter-clockwise):
3
30A - 60A - 100A (1) full turn
200A (3) full turns
Align connecting rod with primary link
4
Connecting
Rod
Primary Link
(4)
Cable Mechanism Installation (Cont'd)
3
Install hitch pin clip Turn disconnect handle "OFF" and
5 6
Hitch Pin Clip
install handle mechanism spring
Connecting Rod Adjustment Procedure
4
"ON" Position
Move disconnect handle to the "ON" position.
➊
If switch does not fully close, return handle to "OFF" position.
➋
Remove link spring hitch pin and disengage the connecting rod from the primary link.
➌
Turn connecting rod counter-clockwise (1 or more) full turns.
➍
Re-engage connecting rod in primary link of handle, insert hitch pin and re-test
➎
Repeat ➊ -
➏
Re-install link spring.
➐
"OFF" Position
Move disconnect handle to the "OFF" position.
➊
If switch does not fully open, return handle to "ON" position.
➋
Remove hitch pin and link spring, then disengage the connecting rod from the primary link.
➌
Turn connecting rod clockwise (1 or more) full turns.
➍
Re-engage connecting rod in primary link of handle, insert hitch pin and re-test.
➎
Repeat ➊ - ➎ as necessary.
➏
Re-install link spring.
➐
as necessary.
➎
ATTENTION: CHECK FOR PROPER OPERATION. Upon completion of
the installation instructions, no further adjustment of the cable mechanism is
required.
(5)
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