Allen-Bradley 1494U-D400 Installation Instructions Manual

1494U-D400
Allen-Bradley
Brand
Allen-Bradley
Model
1494U-D400
Type
Installation Instructions Manual

Allen-Bradley 1494U-D400 is a versatile disconnect switch designed for safe and efficient isolation of electrical circuits. With a current rating of 400A, it's ideal for industrial and commercial applications. Installation is simplified with clear instructions and necessary tools. The switch features a robust construction with a durable enclosure, ensuring reliable operation in demanding environments. Its compact design allows for easy integration into existing electrical systems. Additionally, the 1494U-D400 offers various mounting options for flexible installation.

Allen-Bradley 1494U-D400 is a versatile disconnect switch designed for safe and efficient isolation of electrical circuits. With a current rating of 400A, it's ideal for industrial and commercial applications. Installation is simplified with clear instructions and necessary tools. The switch features a robust construction with a durable enclosure, ensuring reliable operation in demanding environments. Its compact design allows for easy integration into existing electrical systems. Additionally, the 1494U-D400 offers various mounting options for flexible installation.

Table of Contents Page
Rod Operated Switch Installation................................................................................................................................................................................................. 2
Switch Installation..........................................................................................................................................................................................................................2
Handle Installation.........................................................................................................................................................................................................................2
Cutting Connecting Rod..............................................................................................................................................................................................................2
Connecting Rod Installation.......................................................................................................................................................................................................3
Cable Operated Mechanism Installation...................................................................................................................................................................................4
Cable Operated Switch Installation.........................................................................................................................................................................................5
Handle Installation.........................................................................................................................................................................................................................5
Handle Mechanism Installation.................................................................................................................................................................................................5
Connecting Rod Adjustment Procedure....................................................................................................................................................................................6
Enclosure without Handle Cutout................................................................................................................................................................................................7
Door Catch Bracket Installation.....................................................................................................................................................................................................7
Line Terminal Guard Installation...................................................................................................................................................................................................8
Lug Installation....................................................................................................................................................................................................................................8
Line Terminal Adapter Installation...............................................................................................................................................................................................8
Trailer Fuse Block Installation.........................................................................................................................................................................................................9
Direct Mount Fuse Installation..................................................................................................................................................................................................9
Fuse Clip Installation...................................................................................................................................................................................................................10
Protective Cover Installation........................................................................................................................................................................................................10
Bulletin 1494U Disconnect Switch Kit Optional Accessory List.......................................................................................................................................11
Universal Disconnect Switch Installation Instructions (400A)
(Cat 1494U-D400; Series A)
Tools Needed: 1/2" Socket, 5/16" Allen Wrench, Hammer, Center Punch, File, Flat Head Screwdriver, Phillips Screwdriver, 9/32" Drill Bit, Needlenose Pliers, Hacksaw
Installation Instructions
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.
Switch Installation
1
Rod Operated Switch Installation
2
Universal Disconnect Switch Installation Instructions (400A)
Install gasket.
60-80 lb-in
6.8-9.0 Nm
Install handle and spring bracket.
Use template D to locate handle holes on mounting plate.
Overlay template E (400 A) over D .
Install defeater lever.
Cut (2) Connecting Rods; first rod connects the handle to the switch, second rod provides
stiffening for the enclosure flange and mounting panel. Installation of both rods is required.
N
N minus 3-3/4
"
Enclosure
Working Depth
(Inside Flange
of Enclosure to
Mounting Plate)
Mounting
Plate
Measure working depth of enclosure.
Measure, mark and
cut (2) connecting rods.
5
1
1
2
Remove burrs.
3
2 3
Install disconnect switch.
7
IMPORTANT:
Apply grease to O-Ring
to retain into handle groove.
7-11 lb-in
0.79-1.2 Nm
6
D
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
MEASURE TO
INSIDE OF THE
TOP OF ENCLOSURE
TOP HANDLE HOLE
BOTTOM HANDLE HOLE
TAPE
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
MEASURE TO
INSIDE OF THE
TOP OF ENCLOSURE
TOP
BOTT
D
11
3
2
4
90-130 lb-in
10-15 Nm
Handle Installation
2
Cutting Connecting Rod
3
A
HOLD FLUSH
TO INSIDE
OF ENCLOSURE
MEASURE TO
INSIDE OF THE
TOP OF ENCLOSURE
TOP
BOTT
2
4 - 3/4
5 - 1/2
5
6-1/2
11
Switch Mounting Holes
Center punch and drill (4) 11/32" holes for thread
forming (TAP-TITE) screws provided with switch
4205
2-15
8
-01
(1
)
Pr
i
nted
in
U
.S.A.
E
Disconnect Switch Hole Location Template (400A)
RIGHT Hand Installation
(Use opposite side for left hand installation)
Publication 1494U-IN006A-EN-P - March 2018
Center punch and drill
(4) 9/32" dia. holes for
thread forming screws
provided with switch.
3
Universal Disconnect Switch Installation Instructions (400A)
Connecting Rod Installation
First rod connects the handle to the switch
4
ATTENTION: CHECK FOR PROPER OPERATION.
If not operating properly, go to Connecting Rod
Adjustment Procedure.
Second rod provides stiffening for the enclosure flange and mounting panel
150-200 lb-in
17-23 Nm
Verify that disconnect switch and handle are in "OFF"
position. (Switch blades will be visible)
Drive Bar
1
2
Rotate connecting rod into
drive bar 9-10 turns.
4
3
Rotate rod to adjust.
Adjust to create minimal
gap with spring bracket.
Zero
Clearance
8
7
Connecting
Rod
Hitch Pin
Handle Link
5
6
9
10
11
Stiffening Rod
Publication 1494U-IN006A-EN-P - March 2018
Top View
4
Universal Disconnect Switch Installation Instructions (400A)
2 3
1
Assemble the cable mechanism bracket to the disconnect switch.
Rotate connecting rod into drive bar 9-10 turns. Attach connecting rod to cable mechanism.
90-130 lb-in
10-15 Nm
1/2"
Fully seat bolt
prior to attaching
nut.
1
2
Connecting
Rod
Cable
Mechanism
Lever
90-130 lb-in
10-15 Nm
9/16"
5/16"
Lubricate
90-130 lb-in
10-15 Nm
Cable Operated Mechanism Installation
1
IMPORTANT: Verify that the cable assembly does not interfere with any mechanical and moving parts. Keep the cable conduit away from all heat sources and current carrying terminals,
fuses, transformers, etc.
IMPORTANT: When locating the 400A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and the handle mechanism is not less than 10 inches.
Publication 1494U-IN006A-EN-P - March 2018
Connecting Rod
5Universal Disconnect Switch Installation Instructions (400A)
3
Assemble disconnect switch assembly to mounting plate.
Handle Mechanism Installation
4
Handle Installation
Install gasket.
1 2 3
3
7-11 lb-in
0.79-1.2 Nm
Install handle and mechanism bracket.
Install defeater lever.
(Right Hand
Flange Mounted
Shown)
60-80 lb-in
6.8-9.0 Nm
1
Operate disconnect switch and verify that the handle and
switch are in the "ON" position.
2
Align connecting rod with handle link.
11"
1/2"
Locate Switch. Use template E
where desired.
1
2
A
HOLD
F
LUSH
T
O INSID
E
OF E
NC
L
OSURE
MEASU
R
E TO
INSIDE
OF TH
E
TOP OF
ENCLOS
UR
E
TOP
B
OTT
2
4
-
3/
4
5 - 1/2
5
6-1/2
11
Switch Mounting Hole
s
Center punch an
d
d
r
i
ll (4) 11/
32
"
ho
les fo
r t
h
read
fo
rmi
n
g
(TAP-
T
ITE) scre
ws
provi
d
ed
wi
th
s
witch
4
20
5
2
-
1
58
-
0
1
(
1
)
P
r
i
n
t
e
d
i
n
U
.
S
.
A
.
E
Dis
connect Sw
i
tc
h
Hole
L
oca
t
i
on
T
em
p
l
a
te
(4
00
A
)
RIGHT H
an
d In
stallation
(U
se
o
ppo
s
it
e
si
de
f
o
r
le
ft
h
a
nd i
nstallation)
IMPORTANT:
Apply grease to O-Ring
to retain into handle groove.
Connecting
Rod
Handle
Link
90-130 lb-in
10-15 Nm
4-3/4"
2"
Cable Operated Switch Installation
2
Publication 1494U-IN006A-EN-P - March 2018
10" Diameter Min.
Do not pinch cable.
Center punch and drill
(4) 9/32" dia. holes for
thread forming screws
provided with switch.
(4) - 5/16-18 thread
forming screws
6
Universal Disconnect Switch Installation Instructions (400A)
4
3
ATTENTION: CHECK FOR PROPER OPERATION.
Handle Mechanism Installation (Cont'd)
3
Turn disconnect handle "OFF" and install handle
mechanism spring.
Connecting Rod Adjustment Procedure
Move disconnect handle to the "ON" position.
If switch does not fully close, return handle to "OFF" position.
Remove link spring and hitch pin to disengage the connecting
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.
Install hitch pin clip.
1
2
3
4
5
6
7
1
5
Move disconnect handle to the "OFF" position.
If switch does not fully close, return handle to "ON" position.
Remove link spring and hitch pin to disengage the connecting 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.
1
2
3
4
5
6
7
1
5
Adjustment Procedure if switch does not turn "ON". Adjustment Procedure if switch does not turn "OFF".
Rod Operated Adjustment Cable Operated Adjustment
Hitch Pin Clip
Drive Bar
Publication 1494U-IN006A-EN-P - March 2018
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 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.
7Universal Disconnect Switch Installation Instructions (400A)
Door Catch
Mounting
Bracket
14-3/8"
1-3/8"
1-1/8"
3-3/4"
1-5/8"
Top
Handle
Hole
Square
corners
or up to
1/4" radius
(2) .328" Dia.
Holes
1/4"
1/2"
6-1/2"
5-1/2"
5/16"
Enclosure without Handle Cutout
• Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.
5-1/2"
11"
2"
4-3/4"
1-3/8"
(4) 9/32" Dia.
Holes
5"
Locate Disconnect Switch
Locate Handle Drill Handle Holes
1 2 3
Right hand flange shown. Mirror for left hand flange.
1-1/8"
1-3/8"
Enclosure Door
Flange
Thickness
K
1-5/8"
Enclosure
Base
TOP VIEW
Door Catch
Mounting
Bracket
Door Catch
Mounting Bracket
Door Catch
Top
22-37 lb-in
(2.5-4.2 N-m)
Publication 1494U-IN006A-EN-P - March 2018
Dimension K (3/4" to 1")
• When using large disconnect handle kit only (1494F-M2 or -S2), use door catch provided with handle kit.
• When using large 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 large disconnect handle kit and large door hardware kits (1494V-L3 or -LL3), use door catch provided with
door hardware kit.
8
Universal Disconnect Switch Installation Instructions (400A)
Line Terminal Guard Installation
Assemble and Install Line Terminal Guard
L
I
N
E
T
ERM
I
NAL
GUA
R
D
LI
NE TER
MI
N
AL
GU
ARD
1
2
Lug Installation
175-200 lb-in
20-23 Nm
1
Line Terminal Adapter Installation
Torque Range
1494R-
N19
25 lb-in
(2.8 N-m)
(1) 14-10 STR/SOL
(1) 8 STR
(2) 14 SOL/SOL
(2) 14 STR/STR
(2) 12 SOL/SOL
(2) 12 STR/STR
(2) 10 SOL/SOL
(2) 10 STR/STR
(2) 8 STR/STR
Lug Adapter Kit
Wire
Catalog
Number
Wire Clamp
Adapter
175-200 lb-in
20-23 Nm
Publication 1494U-IN006A-EN-P - March 2018
9Universal Disconnect Switch Installation Instructions (400A)
Trailer Fuse Block Installation
Trailer Fuse Block Location
(400A Class H, J, R Fuses)
A
4 - 3/4"
400 Amp Trailer Fuse Block (1494U-F400)
Torque
lb-in
(Nm)
Fuse
7-11/16"
10-3/16"
6-3/8"
6-3/8"
10"
8-11/16"
11-11/16"
7-3/16"
8-11/16"
200
200
200
200
400
400
400
400
400
250
600
600
600
600
250
600
600
600
H/R
H/R
J
HRCII-C
J*
H/R
H/R
J
HRCII-C
90-130
(10-15)
22
-
37
(2.5-4.2)
16-22
(1.8-2.5)
175
-
200
(20-23)
275
-
305
(31-34)
Amps Voltage Class Fuse
Clip
A
Fuse
Block
Lug to
Terminal
Wire
into Lug
Direct Mount Fuse Installation
400A Fuses (Class J Only)
*Direct Mount
N/A
Thread forming
screws
1
2
Cut phase barriers along line.
175-200 lb-in
20-23 Nm
Publication 1494U-IN006A-EN-P - March 2018
10
Universal Disconnect Switch Installation Instructions (400A)
Fuse Clip Installation
400A Fuses (Class H, J, R)
1
2
1
2
1
2
16-22 lb-in
1.8-2.5 Nm
22-37 lb-in
2.5-4.2 Nm
200A Fuse Clips
400A Fuse Clips
23-37 lb-in
2.6-4.2 Nm
40-55 lb-in
4.5-6.2 Nm
200A Fuse Clips
400A Fuse Clips
Protective Cover Installation
23-5/8"
8-1/2"
3-3/8"
11/16"
Punch and drill (4) 11/64" pilot holes.
2
1
1
2
Install (4) mounting screws to hang cover.
Fasten cover screws.
8-1/2"
Publication 1494U-IN006A-EN-P - March 2018
Bulletin 1494U Disconnect Switch Kit Optional Accessory List
Disconnect Switch Kit
Handle
Switch
Connecting
Rod
Fuse
Block
Fuse
Clips
Catalog Number and Description
1494U-D400
1494F-M2 (7-1/2" Painted Metal) (400A / 600A)
1494F-S2 (7-1/2" Stainless Steel) (400A / 600A)
1494U-D400
1494V-RB3 (Standard) (400A / 600A)
Enclosure Working Depth: 9-1/2" to 10"
1494V-RB4 (Extended) (400A / 600A)
Enclosure Working Depth: 9-1/2" to 23"
1494U-C44: 4 Ft Cable
1494U-C45: 5 Ft Cable
1494U-C46: 6 Ft Cable
Cable
Mechanism
11Universal Disconnect Switch Installation Instructions (400A)
1401-N45 (Class H,J, 200A - 250V, 200A - 600V)
1401-N46 (Class H,J, 400A - 250V, 400A - 600V)
1401-N54 (Class R, 200A - 250V, 200A - 600V)
1401-N55 (Class R, 400A - 250V, 400A - 600V)
Set of
(2) rods
Publication 1494U-IN006A-EN-P - March 2018
PN-475448
DIR 10003527458 (Version 00)
Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Publication 1494U-IN006A-EN-P - March 2018
Bulletin 1494U Disconnect Switch Kit Optional Accessory List
Catalog Number and Description
Electrical
Interlock
Auxiliary
Contact
Aluminum
Lugs
Optional Accessories
1495-N43 (1-N.O./N.C.)
1495-N44 (2-N.O./N.C.)
1495-N8 (1-N.O.)
1495-N9 (1-N.C.)
Protective
Cover
LUGS (Pkg Qty 3)
TYPE TORQUE GAUGE (AW G)
1494R-N14
Wire
275 LB-INCU ONLY
(2) 1/0…250 MCM
*Special Purpose Not For General Use
Copper
Lugs
LUGS (Pkg Qty 3)
TYPE TORQUE GAUGE (AW G)
1494U-LA400
Wire
275 LB-INAL / CU
(2) 1/0…300 MCM
LUGS (Pkg Qty 3)
TYPE TORQUE GAUGE (AW G)
1494U-LM400*
FOR LOAD
SIDE ONLY
Wire
35 LB-IN
AL / CU
(12) 8…4
25 LB-IN (12) 8
20 LB-IN (12) 14…10
Multiport
Lugs
Line
Terminal
Adapters
1494R-N19
(Pkg Qty 6)
1494U-PC400
EEE Yönetmeliğine Uygundur.
Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page.
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Allen-Bradley 1494U-D400 Installation Instructions Manual

1494U-D400
Allen-Bradley
Brand
Allen-Bradley
Model
1494U-D400
Type
Installation Instructions Manual

Allen-Bradley 1494U-D400 is a versatile disconnect switch designed for safe and efficient isolation of electrical circuits. With a current rating of 400A, it's ideal for industrial and commercial applications. Installation is simplified with clear instructions and necessary tools. The switch features a robust construction with a durable enclosure, ensuring reliable operation in demanding environments. Its compact design allows for easy integration into existing electrical systems. Additionally, the 1494U-D400 offers various mounting options for flexible installation.

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