Rockwell Automation 1494V-DS30, 1494V-DSX200 User Manual
Bulletin 1494V Variable Depth Disconnect Switch Installation Instructions
(Cat 1494V-DS30; -DSX30 - Series D; 1494V-DS60; -DSX60 - Series D)
(Cat 1494V-DS100; -DSX100 - Series D; 1494V-DS200; -DSX200 - Series D)
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 2
Disconnect Switch Installation
-
- Disconnect Handle Installation
- Cutting Connecting Rod
Quick Installation Guide (continued) 3
Connecting Rod Installation
-
Connecting Rod Adjustment Procedure 4
Enclosure Without Handle Cutout 5
- Locate Handle
- Drill Handle Holes
Door Catch Mounting Bracket Installation 6
Disconnect Switch Installation 7
-
Locate Disconnect Switch
- Install Disconnect Switch
- Assemble and Install Line Terminal Guard
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
42052-116-01 (7)
Printed in U.S.A.
Bulletin 1494V Disconnect Switch Kit 15
Bulletin 1494V Disconnect Switch Kit Optional Accessory List 16
QUICK INSTALLATION GUIDE
Disconnect Switch Installation (Right hand installation shown. For left hand installation follow similar procedure.)
1
Use template A to locate handle holes on mounting plate.
4
TOP HANDLE HOLE
2
MEASURE TO
INSIDE OF THE
HOLD FLUSH
TO INSIDE
TOP OF ENCLOSURE
OF ENCLOSURE
TAPE
BOTTOM HANDLE HOLE
A
TOP OF ENCLOSURE
3
Disconnect Handle Installation
2
Install gasket.
1
MEASURE TO
INSIDE OF THE
A
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
TOP
BOTT
11
Overlay template B (30 A - 100 A) over A .
5
7
Overlay template C (200 A) over A .
3 - 1/16"
TOP
2 - 1/4"
2 - 1/4"
switch
HOLD FLUSH
4 - 11/16"
TO INSIDE
MEASURE TO
INSIDE OF THE
OF ENCLOSURE
Switch Mounting Holes
TOP OF ENCLOSURE
Center punch and drill (4) 11/64" holes for
tap-tite screws provided with
5 - 1/4"
BOTT
C
A
or
B
1
6
Center punch and
drill (4) holes
for thread forming
(TAP-TITE) screws
provided with switch.
11/64" Dia. (30A - 100A)
7/32" Dia (200A)
Install handle and spring bracket.
2 3
Install disconnect switch.
23 - 37 lb-in
(30A - 100A)
40 - 60 lb-in
(200A)
Install defeater lever.
Cutting Connecting Rod
3
Measure working depth of enclosure.
1
Mounting
Plate
Working Depth
(Inside Flange
of Enclosure to
Mounting Plate)
Enclosure
30-40 lb-in
7-11 lb-in
Measure, mark and
2
cut connecting rod.
Remove burrs
3
N
N minus 3-1/8"
(30A - 100A)
N minus 3-1/4"
(200A)
(2)
QUICK INSTALLATION GUIDE (CONTINUED)
Connecting Rod Installation
4
Verify that disconnect switch and handle are in "OFF"
1
position. (Switch blades will be visible)
Drive Bar
Rotate connecting rod into
drive bar (see table).
Switch Rating
30A - 60A - 100A
200A
Full Turns Engagement
2
10
13
Push rod down and verify if rod
is approximately 1/8" from
touching bottom of bolt head.
(If not, rotate rod up to 5 full
turns in either direction)
(200A)
Push down
4
3
(30A - 60A - 100A)
Pull up
1/8" Gap
Push rod down and
verify if rod is nearly
touching bottom of bolt
head. (If not, rotate rod
up to 5 full turns in
either direction)
Hitch Pin
Connecting
Rod
6
7
6
5
5
Primary Link
8a
Enclosure depth
8 in. or less
8b
Enclosure depth
greater than 8 in.
ATTENTION
CHECK FOR PROPER
OPERATION
(3)
Connecting Rod Adjustment Procedure
Drive Bar
Hitch Pin
"ON" Position
1
Move disconnect handle to the "ON" position.
If switch does not fully close, return handle to "OFF" position.
Remove link spring hitch pin and disengage the connectiong 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
Connecting
Rod
Primary Link
"OFF" Position
2
Move disconnect handle to the "OFF" position.
If switch does not fully open, return handle to "ON" position.
Remove hitch pin and link spring, then disengage the connectiong 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
(4)
Enclosure without Handle Cutout
● Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.
● Enclosures with a Flange Thickness 3/16" and greater use dimensions in alternate Mounting Kit 1494V-H3 to install disconnect
handle.
● Multi-Door Enclosures may require the need for a more rigid flange / mounting plate system, such as a Channel Support Kit. Use
dimensions in Channel Support Kit 1494V-H15, if handle is mounted on top of the channel.
Locate Handle
1
Drill Handle Holes
2
C
Right Hand Flange
C
B
A
B
A
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
200A
A
(min)
4 - 5/8"
6 - 1/16"
10 - 1/8"
(min)
1 - 1/8"
1 - 1/8"
1 - 1/8"
(2) .265 Dia. Holes
G
H
J
H
Enclosure Dimensions
B
C
(max)
1 - 1/16"
1 - 1/16"
1 - 1/16"
F
4 - 11/16"
4 - 11/16"
4 - 11/16"
(5)
F
G
1 - 9/16"
1 - 9/16"
1 - 9/16"
H
1"
1"
1"
J
7/8"
7/8"
7/8"
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 (1494F-P1, -M1 or -S1), 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 (1494F-P1, -M1 or -S1), 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.
Door Catch
Mounting Bracket
Top
Enclosure Door
Door Catch
Mounting Bracket
Door Catch
NEMA
SIZE
30A, 60A
100A
200A
C
E
TOP VIEW
A
(min)
4 - 5/8"
6 - 1/16"
10 - 1/8"
B
(min)
1 - 1/8"
1 - 1/8"
1 - 1/8"
B
C
D
B
Enclosure Dimensions
C
A
(max)
1 - 1/16"
1 - 1/16"
1 - 1/16"
D
1 - 5/8"
1 - 5/8"
1 - 5/8"
E
2 - 3/8"
2 - 3/8"
2 - 3/8"
Flange
Thickness
Enclosure
Base
F
4 - 11/16"
4 - 11/16"
4 - 11/16"
G
1 - 9/16"
1 - 9/16"
1 - 9/16"
B
A
Door Catch
K
H
1"
1"
1"
J
7/8"
7/8"
7/8"
C
E
Top Handle Hole
Door Catch
Mounting
Bracket
D
D
Door Catch
Mounting
Bracket
Right Hand Flange Left Hand Flange
(6)
Disconnect Switch Installation
Locate Disconnect Switch
1
FF
CC
HH HH
GG
AAAAAAAA
AA
BB BB
Top Handle Hole
AAAAAAAAAAAAAAAAAAAAAAEE
CC
FF
GG
Right Hand Flange Left Hand Flange
Panel Mounting Dimensions
Switch
Size
AA BB CC DD
EE
(4 Mounting Plate Holes)
FF
HH
DDDD
30A, 60A, 100A
200A
3-1/16" 2-1/2" 2-1/4" 5-1/4"
3-9/16" 3-9/16" 2" 8-1/4" 3-9/16" 4-1/4" 1-1/8"7/32" Dia.
3-1/16"
11/64" Dia.
2-1/4"GG----
This dimension can be 2-1/4" if necessary, to avoid interference with panel mounting studs in some 8 inch deep enclosures.
Install Disconnect Switch Assemble and Install Line Terminal Guard
2 3
23 - 37 lb-in (30A - 100A)
40 - 60 lb-in (200A)
LINE TERMINAL GUARD
LINE TERMINAL GUARD
(7)
Trailer Fuse Block Installation (Switch Rating 30A - 100A)
Trailer Fuse Block Location
1
Note: Not required for non-fusible disconnect switch applications.
30 Amp Trailer Fuse Block (1494V-FS30)
Amps Voltage Class Fuse
30
30
30
30
60
60
60
60
250
600
600
600
250
600
600
600
H/R
H/R
J
HRCII-C
H/R
H/R
J
HRCII-C
A
2-27/32"
5-5/8"
2-27/32"
4-3/16"
3-5/8"
6-1/8"
3"
4-3/16"
Torque (lb-in)Fuse
Block
23
Fuse
Clip
-
37 22-37 20-25 20-25
Lug to
Terminal
Wire
into Lug
A
2-1/4"
Amps Voltage Class Fuse
30
30
30
30
60
60
60
60
100
100
Amps Voltage Class Fuse
60
60
60
60
100
100
100
100
200
60 Amp Trailer Fuse Block (1494V-FS60)
A
Block
250
600
600
600
250
600
600
600
600
600
250
600
600
600
250
600
600
600
600
H/R
H/R
HRCII-C
H/R
H/R
HRCII-C
H/R
100 Amp Trailer Fuse Block (1494V-FS100)
H/R
H/R
HRCII-C
H/R
H/R
HRCII-C
2-27/32"
5-5/8"
2-27/32"
J
4-3/16"
3-5/8"
6-1/8"
J
J
J
J
J
3"
4-3/16"
4-15/16"
8-1/8"
A
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"
-
37
23
23
-
37 16-22 40-60 45-50
Block
23
-
37
23
-
37 16-22 90-110 150-165
Torque (lb-in)Fuse
Fuse
23-37 40-60 45-50
Lug to
Clip
Terminal
Torque (lb-in)Fuse
Fuse
22-37 90-110 150-165
Clip
Lug to
Terminal
Wire
into Lug
Wire
into Lug
Install Trailer Fuse Block
2
23 - 37 lb-in
(8)
Trailer Fuse Block Installation (Switch Rating 200A)
Trailer Fuse Block Location
1
Note: Not required for non-fusible disconnect switch applications.
Amps Voltage Class Fuse
100
100
100
100
200
200
200
200
B
400
250
600
600
600
250
600
600
600
600
200 Amp Trailer Fuse Block (1494V-FS200)
60
Fuse
Clip
16
16
Torque (lb-in)Fuse
-
22
-
22
Lug to
Terminal
175
H/R
H/R
J
HRCII-C
H/R
H/R
J
HRCII-C
J
B
5-7/8"
7-7/8"
4-5/8"
4-5/8"
6-3/4"
9-1/4"
5-3/8"
5-3/8"
6-1/4"
Block
40
-
Wire
into Lug
-
200 275-305
1 - 1/8"
Install Trailer Fuse Block
2
2"
40 - 60 lb-in
(9)
Switch Rating (30A, 60A Rating)
Fuse Clip Installation
1
2
23 - 37 lb-in
2
1
Phase Barrier Replacement Kit
1494F-PH2
NOTE: Fuse clips and lugs must be removed to add or replace phase barriers.
1 2
1
40392-098
2
CLICK
1
CLICK
2
40392-097
(10)
Loading...