Rockwell Automation 1494U-D30, 1494U-D60, 1494U-D100 User Manual

Installation Instructions

Bulletin 1494U 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

Fuse Clip and Fuse Installation.................................................................................................................................................13

Protective Cover Installation.....................................................................................................................................................14

Bulletin 1494U Disconnect Switch Component Accessory List....................................................................................15

PN-224754

DIR 10001182729 (Version 01)

Printed in U.S.A.

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.

NOTICE

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.

When locating the 30A, 60A and 100A cable operated switch, verify that the minimum diameter for the loop of the cable

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 .

1

Measure hole center to top of enclosure: _______

2-7/8

1-3/4

ead

1-13/16

r

or th

used

2
e
l

Switch Mounting Holes

AP-TITE) sc
er punch and drill (4) 11/64" holes f
t

(T

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C
forming

empl

ation T

oc
Variable Depth Disconnect S
Hole L

ews pro
r

ate (30A - 60A - 100A

vided with switch

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Ho
or Step
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Ste
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and align by u
top hole
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from Step 1

Step 3
down, pu
holes

54969

0

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Measure ho

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Measure h

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top of enc

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losure ba

surements taken

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on
ti
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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.

23 - 37 lb-in

7/16” Nut Driver

Wiring Diagrams

Single Phase AC Three Phase AC Direct Current

L1 L2 L3

L1 L2 L3

L1 L2 L3

T1 T2 T3

PN-224754

DIR 10001182729 (Version 01)

T1 T2 T3

T1 T2 T3

(2)

Rod Operated Switch Installation

Handle Installation

1

1 Install gasket. 2 Install spring bracket and handle.

30 - 40 lb-in

Spring
Bracket

Cutting Connecting Rod

2

3 Install defeater lever.

7 - 11 lb-in

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.

PN-224754
DIR 10001182729 (Version 01)

(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.

PN-224754
DIR 10001182729 (Version 01)

(4)

Cable Operated Switch Installation

Handle and Cable Mechanism Installation

1

1 Install gasket. 2 Connect handle link to lever pin. 3 Install hitch pin through handle link.

TIP: Move handle to

“ON” position to help
connect handle link
to lever pin. Return
handle to “OFF”
position once
connected.

4 Verify handle is in “OFF” position.

6 Install spring to handle link.

6

5 Install handle nuts.

30 - 40 lb-in

8 Install defeater lever.

7

7 Install other end of spring to cable mechanism bracket

using needlenose pliers.

PN-224754
DIR 10001182729 (Version 01)

7 - 11 lb-in

Defeater
Lever

(5)