Rockwell Automation 1494F-N30, 1494F-N60, 1494F-N100, 1494F-N200 User Manual

Bulletin 1494F Fixed Depth Disconnect Switch Installation Instructions

(Cat 1494F-N30; -N60; -N100; -N200) (Series B)

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

Enclosure with Pre-Drilled Handle Cutout 2

Install Disconnect Switch

-

- Install Disconnect Switch Standoffs

Enclosure without Pre-Drilled Handle Cutout

Locate Handle

-

3

- Drill Handle Holes

Enclosure Requiring Door Catch Mounting Bracket

4

Fuse Block Adapter Plate Installation (Switch Rating 30A - 60A - 100A) 5, 6

Fuse Block Adapter Plate Installation (Switch Rating 200A) 7

Phase Barrier Replacement Kit and Fuse Clip Installation (

Switch Rating 30A - 60A) 8

Phase Barrier Replacement Kit and Fuse Clip Installation (

Switch Rating 100A) 9

Phase Barrier Replacement Kit (

Switch Rating 200A) 10

Fuse Clip Installation (

Switch Rating 200A)

11

Dimensions 12

Fuse Clip Installation (200A)

Installation--Vault Hardware Latching (1494F-L1)

12

13

Installation-- Vault Hardware Latching (1494F-L2, -L3, -L4) 14

Testing Vault Hardware Latching and Enclosure Seal 15

Installation-- Vault Hardware Latching (Non Pre-Drilled Enclosures) 16, 17

Bulletin 1494F Disconnect Switch Kits 18

Bulletin 1494F Disconnect Switch Kit Optional Accessory List 19

42052-195-01

DIR 10000075001 (Version 00)

Printed in U.S.A.

Enclosure with Pre-Drilled Handle Cutout

Option 1

Install Disconnect Switch (Left-hand installation unavailable.)

1

Option 2

35-45 lb-in

Install Disconnect Switch Standoffs

2

Standoffs & Bolts to be Provided by User or Enclosure Manufacturer

42052-195-01 DIR 10000075001 (Version 00)

23-37 lb-in

Standoffs & Bolts to be Provided by User or Enclosure Manufacturer

(2)

Enclosure without Pre-Drilled Handle Cutout

Locate Handle

1

Option 1

C

B

Option 2

F

E

NEMA

SIZE

30A, 60A

100A

200A

Drill Handle Holes

2

ENCLOSURE FLANGE

HANDLE CUT-OUT

15/32”

A

(min)

2-3/4"

4-1/4"

8-1/4"

Option 1

(2) .265” Dia. Holes

B

(min)

1 - 3/16"

9/16”

13/16”

5/8” Min.

C

(min)

1 - 1/16"

FLANGE MOUNTED

COVER PLATE

1 - 1/8”

A

D

5/8” Min.

Enclosure Flange Cut-Out Dimensions (Option 2)Enclosure Flange Cut-Out Dimensions (Option 1)

NEMA

SIZE

30A, 60A

100A

200A

D

(min.)

3

4-1/2"

8-1/2"

E

(min.)

1 - 3/16"

F

(min.)

1 - 1/16"

Option 2

FLANGE MOUNTED

COVER PLATE

1 - 1/8”

9/16”

13/16”

9/16”

ENCLOSURE FLANGE

HANDLE CUT-OUT

1-1/8”

9/16”

13/32”

(4) .203” Dia. Holes

7 - 3/16”

27/32”

21/32”

8 - 1/2”

1 - 5/16”

42052-195-01 DIR 10000075001 (Version 00)

1/4”

6-3/8”

25/32”

1 - 3/16”

8”

1 - 9/16”

9-1/8”

(3)

7-3/16”

13/32”

21/32”

1-5/16”

1 - 3/16”

8”

6-3/8”

1/4”

25/32”

1 - 9/16”

8”

9-1/8”

Enclosure Requiring Door Catch Bracket Right-hand installation shown with or without enclosure door vault hardware (Left-hand installation unavailable)

Door Catch Mounting Bracket:

L Provided with projections for welding. L Projections can also be used as a guide for drilling holes. L Can be used as a template to drill corresponding holes in the enclosure door. L User to supply the hardware for fastening the bracket. L The bracket hardware must be inaccessible to unauthorized personnel. L Fasteners must provide the degree of ingress protection for the environmental rating of the enclosure.

Dimension K (3/4" to 1")

L When installed in any size enclosure without door vault hardware, use door catch provided with disconnect switch kit. L When installed in small and intermediates size enclosures (15 inches to 40 inches) using door vault hardware kits

(1494F-L1, 1494F-L2 and 1494F-L3), use door catch with pivot lever provided with disconnect switch kit. Discard the door catch supplied with the door vault hardware kit.

Dimension K (1-1/8" to 1-3/8")

L When installed in large enclosure using door vault hardware kit (1494F-L4), use the door catch assembly with the pivot lever included with the disconnect switch. Discard the door catch supplied with the door vault hardware kit.

Mounting Bracket

Enclosure Door

Door Catch

Mounting Bracket

Door Catch

Option 1

C

E

Door Catch

TOP VIEW

Top

Door Catch (used without door vault hardware kits)

Flange

Thickness

C

K

Enclosure

Base

D

B

Option 2

H

B

A

K

G

F

Door Catch

Mounting

Bracket

Enclosure Dimensions

NEMA

SIZE

30A, 60A

100A

200A

42052-195-01 DIR 10000075001 (Version 00)

A

(min)

2 - 3/4"

4 - 1/4"

8 - 1/4"

B

(min)

1 - 3/16"

C

(max)

1 - 1/16"

Door Catch

Mounting

Bracket

H

(max)

1 - 1/16"

J

2 - 1/8"

K

3 - 9/16"

D

Enclosure Dimensions

D

2 - 1/8"

E

3 - 13/16"

NEMA

SIZE

30A, 60A

100A

200A

F

(min)

3"

4 - 1/2"

8 - 1/2"

G

(min)

1 - 3/16"

(4)

Fuse Block Adapter Plate Installation (Switch Rating 30A - 60A - 100A)

30 Amp Fuse Block Adapter Plate Kit (1494F-F30)

1

Fuse

Amps

30 30 30 30 60 60 60 60

Voltage Class

250 600 600 600 250 600 600 600

H/R H/R

HRCII-C

H/R H/R

HRCII-C

Position D

J

6 2 6 3 4 1 5 3

2 - 13/16”

5 - 5/8”

2 - 13/16”

4

-

3/16” 3 - 5/8” 6 - 1/8”

3”

4 - 3/16”

Hardware Torque (lb-in)

30 60

Fuse Block Adapter Kit

Fuse

Clip

Lug to

Terminal

into Lug

40-60 22-37 20-25 20-25

Wire

Fuse

Amps

6”

4 - 5/16”

1 - 3/16”

15/16”

(Option 2)

(Option 1)

(3) - 9/32 Dia.

1

2

3

4

D

5

6

60 Amp Fuse Block Adapter Plate Kit (1494F-F60)

Fuse

Amps Voltage Class Position

30 30 30 30 60 60 60

60 100 100 100

250 600 600 600 250 600 600 600 250 600 600

H/R H/R

J

HRCII-C

H/R H/R

J

HRCII-C

H/R

J

H/R

8 3 8 5 6 2 7 5 2 4 1

Hardware Torque (lb-in)

30 60

100

Fuse Block Adapter Kit

Fuse

Clip

Terminal

40-60 22-37 40-60 45-50

40-60 16-22 40-60 45-50

Fuse

Amps

Lug to

D

2 - 13/16”

5 - 5/8”

2 - 13/16”

4 - 3/16”

3

-

5/8”

6

-

1/8”

3”

4 - 3/16”

6 - 1/8”

4 - 15/16”

8 - 1/8”

Wire

into Lug

6”

4

-

5/16”

1

-

3/16”

15/16”

(Option 2)

(Option 1)

(3) - 9/32 Dia.

1

2

3

4

D

5

6

7

8

42052-195-01 DIR 10000075001 (Version 00)

(5)

Fuse Block Adapter Plate Installation (Switch Rating 30A - 60A - 100A) - (Cont’d)

a

100 Amp Fuse Block Adapter Plate Kit (1494F-F100)

100 Amp Trailer Fuse Block (1494F-F100)

Fuse

Amps Voltage Class

60 60 60

60 100 100 100 100 200

Fuse

Amps

100

200

60

250 600 600 600 250 600 600 600 600

Fuse Block

Adapter Kit

H/R

J

H/R

HRCII-C

H/R H/R

J

HRCII-C

J

Hardware Torque (lb-in)

40-60 22-37 90-110 150-165

40-60 16-22 90-110 150-165

Fuse

Clip

7 8 3 6 3 1 5 2 4

Lug to

Terminal

DPosition

4 - 3/16”

3 - 9/16” 6 - 11/16” 4 - 11/16” 6 - 11/16” 8 - 11/16”

5

-

1/2”

7 - 9/16”

6

-

1/4”

Wire

into Lug

6”

D

4 - 5/16”

1

-

3/16”

15/16”

(Option 2)

(Option 1)

(3) - 9/32 Di

1

2

3

4

5

6

7

8

2 3

40 - 60 lb-in

Standoffs & Bolts to be Provided by User or Enclosure Manufacturer

42052-195-01 DIR 10000075001 (Version 00)

(6)

Fuse Block Adapter Plate Installation (Switch Rating 200A)

200 Amp Fuse Block Adapter Plate Kit (1494F-F200)

1

200 Amp Trailer Fuse Block (1494F-F200)

Fuse

Amps Voltage Class

100 100 100 100 200 200 200 200 400

Fuse

Amps

100 200

400

250 600 600 600

HRCII-C 250 600 600 600

HRCII-C 600

Fuse Block Adapter Kit

40-60 16-22 160-190 275-305

Position

Fuse

Clip

5 2 7 7 3 1 6 6 4

Terminal

Lug to

5 - 7/8” 7 - 7/8” 4 - 5/8” 4

6 - 3/4” 9 - 1/4” 5 - 3/8” 5 - 3/8” 6

-

H/R H/R

J

H/R H/R

J

Hardware Torque (lb-in)

D

5/8”

1/4”

into Lug

Wire

8 - 3/16”

D

1

2

3

4

5

6

7

400A J

200A J

100A J

4 - 23/32”

1 - 3/16”

(Option 2)

15/16”

(Option 1)

(3) - 9/32 Dia.

2

40 - 60 lb-in

3

Standoffs & Bolts to be Provided by User or Enclosure Manufacturer

42052-195-01 DIR 10000075001 (Version 00)

(7)

Phase Barrier Replacement Kit (Switch Rating 30A - 60A) 1494F-PH2

1 2

1

2

Disconnect Switch

Phase Barrier

Part No. 40392-097

30 Amp Disconnect Switch and Fuse Block Shown

Fuse Block Phase Barrier Part No. 40392-098

Fuse Clip Installation (Switch Rating 30A - 60A)

1

23 - 37 lb-in

2

CLICK

1

CLICK

2

Class R Fuses Shown

42052-195-01 DIR 10000075001 (Version 00)

Class R Fuse Clips Shown

1

30 Amp Disconnect Switch and Fuse Block Shown

(8)

Phase Barrier Replacement Kit (Switch Rating 100A)

R

1494F-PH3

Switch Phase Barrier

Trailer Block Phase Barrier

1

2

CLICK

Fuse Clip Size and Class

60 A 100 A 200 A 200 A

600V H - R 600V H - R 600V H - R 250V H - R

2

Fuse Clip Size and Class

60 A

1

60 A 100 A 100 A

250V H - R 600V J 250V H - R 600V J

600V J200 A

1

CLICK

3

1

2

Fuse Clip Installation (Switch Rating 100 Amp)

1

16 - 22 lb-in

2

CLICK

1

CLICK

2

100 Amp Class Fuses Shown

2

23 - 37 lb-in

42052-195-01 DIR 10000075001 (Version 00)

1

(9)

Phase Barrier Replacement Kit (Switch Rating 200A) 1494F-PH4

1

2

5

40 - 60 lb-in

3

2

CLICK

4

1

2

3

CLICK

42052-195-01 DIR 10000075001 (Version 00)

(10)

Fuse Clip Installation (Switch Rating 200A)

1

16 - 22 lb-in

2

1

Fuse Clip Installation (Switch Rating 200A) for 400A Class J Fuses (Cat. No. 1401-N171)

23 - 37 lb-in

2

1

2

16 - 22 lb-in

2

150 - 200 lb-in

1

42052-195-01 DIR 10000075001 (Version 00)

(11)

Dimensions

Spacers / Standoffs

Provided by

User or

Enclosure

Manufacturer

H

(Min)

J Q

Non-Fusible Disconnect Switch

R

E

D

Fusible Disconnect Switch

A

B

1-1/8”

M

C

F

1/4”

K LG

(2) - 9/32 Dia.

Spacers / Standoffs

Provided by

User or

Enclosure

Manufacturer

Switch

Size

H

(Min)

J

ABC EFGH

R

Q

E

D

See Fuse Block

Adapter Plate Section

See Fuse Block

Adapter Plate Section

(Min)

A

B

1-1/8”

N

P

JD

KMNPQRL

M

C

F

1/4”

K LG

(3) - 9/32 Dia.

30A

60A

100A

200A

9 - 3/16”

9

-

3/16”

-

9

3/16”

5/8”

4

-

5/16”

4

-

5/16”

-

5/16”

4

-

3/4”

4

42052-195-01

DIR 10000075001 (Version 00)

1

-

1/8”

1

-

1/8”

-

1/8”

1

-

5/32”

1

-

8

6”

3/16”

3/8”

1

-

9/16”

2”

10

-

29/32”

1/2”

8

9

-

1/2”

3/4”

6

-

7/8”

6-

7/8”

-

1/8”

8

-

1/8”7/16”

8

8”

8 - 1/2”

8”

8

8”

8

8”

15/16”

3 - 21/32”

15/16”

3

-

1/2”

-

1/2”

-

1/2”

-

21/32”

-

21/32”

-

3

3/4”

7

-

5/16”

-

5/16”

-

5/16”

-

1/2”

5

3”

-

7/16”

3”

5

-

7/16”

3”

-

7/16”

5

-

3”1 - 5/16”

7/16”

5

(12)

Installation--

)

Vault Hardware Latching (1494F-L1) - Top and Side Latching

(40 Inches Maximum Enclosure Height)

1

Latching rod may be supplied by enclosure manufacturer

2

Drive-Lok Pin

1

(Optional screw and nut included with kit)

3 4

3

40 - 60 lb-in

Gasket to be installed inside door.

40 - 60 lb-in

1

Optional number of

1

150 - 200 lb-in

2

shims used (0 - 3).

More shims, more

gasket compression

23 - 37 lb-in

2

23 - 37 lb-in

3

23 - 37 lb-in

Assemble door catch and defeater lever actuator in center of slots. (Parts included with the disconnect switch). Adjustment may be required (up or down

1

for interlocking to work properly.

42052-195-01 DIR 10000075001 (Version 00)

(13)

Installation--

c

f

Vault Hardware Latching (1494F-L2, -L3) -

(40 Inches Maximum Enclosure Height-1494F-L2) (60 Inches Maximum Enclosure Height-1494F-L2, -L3)

Top and Bottom Latching or Top, Side and Bottom Latching

Vault Hardware Latching (1494F-L4 for Large Enclosures) -

(84 Inches Maximum Enclosure Height)

1

3

2

Latching rod may be

supplied by

enclosure manufacturer

1

Drive-Lok Pin (Optional screw and nut included with kit)

Top, Side and Bottom Latching

4

Drive-Lok Pin

(Optional screw and

nut included with kit)

2

3

4

3

40 - 60 lb-in

3

23 - 37 lb-in

Gasket to be installed inside door.

Assemble door cat and defeater lever actuator in center o slots. (Parts include with the disconnect switch). Adjustment may be required (up or dow

1

for interlocking to work properly.

40 - 60 lb-in

1

3

40 - 60 lb-in

2

150 - 200 lb-in

23 - 37 lb-in

Optional number

of shims used

(0 - 3). More shims, more gasket

compression

2

23 - 37 lb-in

42052-195-01 DIR 10000075001 (Version 00)

(14)

Installation-- Vault Hardware Latching (Non Pre-Drilled Enclosures)

2

Option 2Option 1

1 - 3/8”

1

-

1/8”

9/16”

(1494F-L1)

-

1/4”

3

G

(Min)

(1494F-L2,

1494F-L4)

H *

(Min)

C

(Min)

J *

(Min)

C + 1/16” *

(Min)

4 - 3/4”

Bracket

Guide

Bracket

2 - Holes

9/32” Dia.

3 - 1/4”

2 - 3/8”

13/16”

2 - Holes

13/32” Dia.

Guide

1 - 3/8”

B

1/4”

A

D

F

E

(Min)

1/4”

3/4” Dia.

B

M

Guide Bracket

Door Catch Bracket

(1494F-L1, 1494F-L2)

E + 3 - 1/2”

(1494F-L4)

-

3/8”

E + 3

N

Guide Bracket

M

3/4”

5/16”

N

3/4”

6 - Holes

+.000

.193” Dia.

-.003

3/8”

K

L

1/2”

2 - Holes #10-32

5/16”

3/8”

(1494F-L1, 1494F-L

G minus 3/4”

(1494F-L4)

-

G minus 1

1/8”

(1494-L2)

H minus 3/4”

(1494-L4)

H minus 1 - 1/8”

* Non applicable for 1494F-L1

Vault Hardware

Kits

Switch

Size

AB C

(Min)

E

(Min)

FG

(Min)H(Min)

J

(Min)

KLD

M

N

Small and Intermediate Enclosures

4

-

1/2”

1494F-L1 * 1494F-L2 * 1494F-L3 *

30A

60A

100A

200A

3

-

3

-

3

-

3

7/8”

3/8”

3

-

1/16”

-

1/8”

2

3

-

1/16”

2 - 1/8”

-

1/16”

3

-

3

1/16”

-

1/8”

2

-

1/8”

3

-

13/16”

-

1/2”

4

3

-

13/16”

-

1/2”

4

-

1/2”

-

3

-

3

13/16”

18

23 - 25/32”

13”

14”

-

7/8”

8

-

1/8”

8

-

1/8”

-

1/8”

8

-

1/8”

8

5”

1/2”

5”

1/2”

5”

1/2”

5”

1/2”

1/4”

11/16”

1/2”

Large Enclosures

5”

3

-

13/16”

13 - 1/8”

5”

3

-

5”

-

3

5”

-

3

13/16”

13

18

23 - 13/32”

-

13/16”

9

-

5/8”

-

13/16”

-

1/2”

-

13/16”

9

-

13/16”

9

6”

5/8”

5/16”

1-1/4”

3/4”

1494F-L4 *

30A

60A

100A

200A

1/2”

4”

1/2”

3 - 3/4”

3

-

3/4”

-

3/4”

3

-

3/4”

3

2

-

1/8”

2

-

1/8”

-

1/8”

2

-

1/8”

2

* When using 1494F-L1, -L2, -L4 vault hardware kits with Series A 1494F-N30, 1494F-NF30, 1494F-N60, 1494F-NF60, 1494F-N100, 1494F-NF100, 1494D-N4, 1494D-N5, 1494M-N30, 1494M-NF30, 1494M-N60, 1494M-NF60, 1494M-N100 or 1494M-NF100 it may be necessary to order adapter 1494F-N13. (Required for Hoffman A22 Series B or later enclosures.)

42052-195-01 DIR 10000075001 (Version 00)

(15)

Testing Vault Hardware Latching and Enclosure Seal

Close door against enclosure base. The door handle should

1 2

be in the 6 o’clock position in line with the length of the door when fully latched and the enclosure is sealed.

Turn release screw counterclockwise and hold screw in that position to release initial catch from beneath enclosure flange.

Handle should rotate clockwise to approximately the 9 o’clock

3 4

position under spring action. The locking bars should have retracted from top and bottom of door and center latch cleared right hand flange.

Reclose door against enclosure base. Turn door handle counterclockwise to the 6 o’clock position. You should hear two distinct clicks as you turn the handle. Handle should remain in this position.

“Click”

42052-195-01 DIR 10000075001 (Version 00)

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Testing Vault Hardware Latching and Enclosure Seal (Cont’d)

Return to Step 3 to open door. Close the

5 6

door on the base and turn the handle to the 6 o’clock position. Door should be sealed securely to the enclosure base.

Close the door and turn the door handle counterclockwise until the first “click” is heard. Move the disconnect handle to the ON position (do not force). If the disconnect handle can be moved, the defeater lever actuator is properly adjusted. Continue rotating door handle to fully closed position (6’oclock).

“Click”

Move defeater lever actuator upward to allow disconnect handle to be turned to on position later.

Move door catch downward to allow operation of handle relative to door latching handle sooner.

42052-195-01 DIR 10000075001 (Version 00)

(17)

Bulletin 1494F Disconnect Switch Kit

Disconnect Kit

Disconnect Switch and Handle

with Mechanism

Fuse Block

with Adapter Plate

Cat No.

Switch and Handle with Right Hand Mechanism (Non-Fusible and Fusible) 1494F-N30 (30A) 1494F-N60 (60A) 1494F-N100 (100A) 1494F-N200 (200A)

1494F-F30 (30A) 1494F-F60 (60A) 1494F-F100 (100A) 1494F-F200 (200A)

42052-195-01 DIR 10000075001 (Version 00)

Fuse Clips

1401-N41 (Class H, 30A - 250V) 1401-N42 (Class H,J, 30A - 600V, Class H, 60A-250V) 1401-N43 (Class H,J, 60A - 600V) 1401-N44 (Class H,J, 100A-250V, 100A-600V) 1401-N45 (Class H,J, 200A-250V, 200A-600V) 1401-N50 (Class R, 30A - 250V) 1401-N51 (Class R, 30A - 600V, 60A-250V) 1401-N52 (Class R, 60A - 600V) 1401-N53 (Class R, 100A - 250V, 100A-600V) 1401-N54 (Class R, 200A-250V, 200A-600V) 1401-N171 (Class J, 400A-250V / 600V)

(18)

Bulletin 1494F Disconnect Switch Optional Accessory List

Optional Accessories

(Installation Instructions

Included with Accessory Kits)

Electrical

Interlock

Terminal

Adapter Kit

Use with Switch with Right Hand Mechanism 1495-N34 (1-N.O./N.C.) (30A - 60A - 100A) 1495-N35 (2-N.O./N.C.) (30A - 60A - 100A) 1495-N43 (1-N.O./N.C.) (200A) 1495-N44 (2-N.O./N.C.) (200A)

1494R-N16 (30A) 1494R-N17 (60A) 1494R-N18 (100A) 1494R-N19 (200A)

Cat No.

Line Side

Cover

Auxiliary

Contact

Lug

Connectors

Phase

Barrier

Fuse

Cover

with Door

1495-N80 (30A - 60A - 100A) 1495-N81 (200A)

1495-N8 (1-N.O.) (30A - 60A - 100A - 200A) 1495-N9 (1-N.C.) (30A - 60A - 100A - 200A)

Low Energy 1495-N8X (1-N.O.) (30A - 60A - 100A - 200A) 1495-N9X (1-N.C.) (30A - 60A - 100A - 200A)

(Saddle Clamps Included) (CU Wire Size #14 . . #8 AWG) (30A)

1494R-N1 (CU Wire Size #14 . . #4 AWG) (60A)

1494R-N2 (CU Wire Size #8 . . #1/0 AWG) (100A)

1494R-N3 (CU Wire Size #6 . . #4/0 AWG) (200A)

1494F-PH2 (30A - 60A) 1494F-PH3 (100A) 1494F-PH4 (200A)

Switch Rating

30A 30A 60A 30A 60A 60A

100A

30A 60A

100A

200A

Fuse

Class

Non-Fusible

H, R H, R

J

J Non-Fusible Non-Fusible

H, R H, R

J

H, R

J

Non-Fusible

H, J, R

J

Fuse Clip

Rating

250V 600V

----

30A

----

60A

----

30A

60A

----

30A

----

60A

100A

200A

----

200A

400A

Cat No.

1495-N64

1495-N65

1495-N66

1495-N67

42052-195-01 DIR 10000075001 (Version 00)

(19)

42052-195-01

DIR 10000075001 (Version 00)

Print in U.S.A.