Rockwell Automation 1494V-DSxx 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
Bulletin 1494V Disconnect Switch Kit 15
Bulletin 1494V Disconnect Switch Kit Optional Accessory List 16
PN-47400
DIR 10000056505 (Version 00)
Printed in U.S.A.
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
OLE
TOP HANDLE H
HE
MEASURE TO
INSIDE OF T
HOLD FLUSH
TO INSIDE
TOP OF ENCLOSURE
OF ENCLOSURE
TAPE
BOTTOM HANDLE H
A
Disconnect Handle Installation
2
Install gasket.
1
2
TOP
OLE
HOLD FLUSH
TO INSIDE
OSURE
MEASURE TO
INSIDE OF THE
OF ENCLOSURE
TOP OF ENCL
BOTT
3
A
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
HE
HOLD FLUSH
4 - 11/16"
TO INSIDE
MEASURE TO
NCLOSURE
INSIDE OF T
OF ENCLOSURE
Switch Mounting Holes
TOP OF E
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
Connecting
Rod
Standard
Extended
N
Catalog
Number
1494V-RA3
1494V-RA4
30-40 lb-in
Measure, mark and
2
cut connecting rod.
N minus 3-1/8"
(30A - 100A)
N minus 3-1/4"
(200A)
30A - 60A - 100A Disconnect Switches
“N”
Min.
6 - 3/4"
6 - 3/4"
21 - 5/8"
Max.
9 - 1/8"
7-11 lb-in
Remove burrs
3
200A Disconnect Switches
“N”
Min.
8 - 1/2"
8 - 1/2"
Max.
10 - 1/4"
22 - 3/4"
PN-47400
DIR 10000056505 (Version 00)
(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
PN-47400
DIR 10000056505 (Version 00)
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
PN-47400
DIR 10000056505 (Version 00)
(4)
Enclosure without Handle Cutout
L Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.
L Enclosures with a Flange Thickness 3/16" and greater use dimensions in alternate Mounting Kit 1494V-H3 to install disconnect
handle.
L 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
PN-47400
DIR 10000056505 (Version 00)
A
(min)
4 - 5/8"
6 - 1/16"
10 - 1/8"
(2) .265 Dia. Holes
H
J
H
Enclosure Dimensions
B
(min)
1 - 1/8"
1 - 1/8"
1 - 1/8"
C
(max)
1 - 1/16"
1 - 1/16"
1 - 1/16"
(5)
4 - 11/16"
4 - 11/16"
4 - 11/16"
G
F
F
G
1 - 9/16"
1 - 9/16"
1 - 9/16"
H
1"
1"
1"
J
7/8"
7/8"
7/8"
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