Universal Disconnect Switch Installation Instructions (200A)
(Cat 1494U-D200; Series A)
Tools Needed: 5/16", 3/8" & 7/16" Nut Drivers, Hammer, Center Punch, File, Flat Screwdriver, Phillips Screwdriver, 7/32" 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.
Table of Contents Page
Rod and Cable Operated Disconnect Switch Location........................................................................................................................................................ 2
Rod Operated Switch Installation.................................................................................................................................................................................................2
Handle Installation.........................................................................................................................................................................................................................2
Cutting Connecting Rod..............................................................................................................................................................................................................3
Connecting Rod Installation.......................................................................................................................................................................................................3
Cable Operated Switch Installation.............................................................................................................................................................................................4
Handle and Cable Mechanism Installation...........................................................................................................................................................................4
Cable to Switch Mechanism Installation................................................................................................................................................................................4
Rod Operated Adjustment Procedure........................................................................................................................................................................................5
Cable Operated Adjustment Procedure.....................................................................................................................................................................................5
Enclosure without Handle Cutout................................................................................................................................................................................................6
Door Catch Bracket Installation.....................................................................................................................................................................................................6
Trailer Fuse Block Installation.........................................................................................................................................................................................................7
Fuse Clip and Fuse Installation..................................................................................................................................................................................................8
Auxiliary Contact Installation.........................................................................................................................................................................................................9
Auxiliary Contact Wire Routing.....................................................................................................................................................................................................9
Line Terminal Adapter Installation...............................................................................................................................................................................................9
Electrical Interlock Installation.......................................................................................................................................................................................................9
Protective Cover Installation........................................................................................................................................................................................................10
Bulletin 1494U Disconnect Switch Component Accessory List......................................................................................................................................11
1 Measure top hole of handle on enclosure.
Measure hole center to side of enclosure: _______
Measure hole center to top of enclosure: _______
2 Use template C to locate handle holes on mounting plate. Lay
template on enclosure mounting plate. Align using the top hole on
paper and measurements taken from step .
1
3 Tape template down.
Center punch and drill (4)
7/32" holes for thread
forming screws provided
with switch.
4 Install Disconnect Switch. 5 Install Line Terminal Guard.
40-60 lb-in
(4.5-6.8 N-m)
7/16"
Nut
Driver
Disconnect Switch Location and Installation
A) For Rod Operated Switches, follow steps 1 - 5 below.
B) For Cable Operated Switches, follow steps 3 - 5 below.
1
Rod and Cable Operated Disconnect Switch Location
IMPORTANT: When locating the 200A cable operated switch, verify that the minimum diameter for the loop of the cable 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 eciency of the cable system, create additional drag and friction within the cable conduit and possibly
decrease system life.
Universal Disconnect Switch Installation Instructions (200A)
2
Publication 1494U-IN007B-EN-P - July 2018
1494U Handle Installation
1
Rod Operated Switch Installation
1 Install gasket. 2 Install spring bracket and handle.
30-40 lb-in
(3.4-4.5 N-m)
Spring
Bracket
3 Install defeater lever.
7-11 lb-in
(0.8-1.2 N-m)
Defeater
Lever
TIP: Move handle to
“ON” position to help
align handle and bracket.
Return handle to “OFF”
position once connected.
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C
Rod Operated Switch Installation (Cont’d)
Cutting Connecting Rod
2
1 Measure working depth of enclosure. 2 Measure, mark and cut connecting rod. 3 Remove burrs.
N
Enclosure
Working Depth
(Inside Flange
of Enclosure to
Mounting Plate)
Mounting
Plate
N minus 3-1/8"
Connecting Rod Installation
3
1 Verify that disconnect switch and handle are in “OFF” position
(Switch blades will be visible).
Drive Bar
2
Rotate connecting rod
into drive bar 9-10 full
turns.
2
Align threaded rod
toward handle and,
if needed, rotate
counterclockwise
until ears engage the
primary link slots.
3
4
Connecting
Rod
Hitch Pin
Handle Link
5
6
5 Engage ears of connecting rod into slots of handle link. 7 Install spring to handle link.
7
8
See steps and for final rod alignment.
2
3
2
4
6 Install hitch pin
through ears of
connecting rod.
8 Install other side of spring
to handle bracket.
Ensure that
the handle
is in the full
“OFF” position.
Universal Disconnect Switch Installation Instructions (200A)
3
ATTENTION: CHECK FOR PROPER OPERATION.
If not operating properly, go to Rod Operated
Adjustment Procedure.
Publication 1494U-IN007B-EN-P - July 2018
Cable Operated Switch Installation
1 Tighten cable nuts onto switch bracket.
3 Assemble washers (2) and hitch pin to attach cable pivot to switch mechanism cable slot.
NOTE: Ensure there is one
washer on each side
of the switch bracket.
Install pin as shown.
Do not push past
second bend on clip.
75-90 lb-in
(8.5-10.2 N-m)
1494U Handle and Cable Mechanism Installation
Enclosures with Right Flange
1
1
Connect handle link to lever pin.
2
Install handle nuts and hitch pin. 3 Install defeater lever.
30-40 lb-in
(3.4-4.5 N-m)
OFF
Universal Disconnect Switch Installation Instructions (200A)
4
7-11 lb-in
(0.8-1.2 N-m)
Defeater
Lever
Publication 1494U-IN007B-EN-P - July 2018
6" Diameter
Min.
2 Ensure switch is located as to not pinch the cable or create a bend less than 6" in
diameter.
Cable to Switch Mechanism Installation
2
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.
1
2
ATTENTION: CHECK FOR PROPER OPERATION.
If not operating properly, go to Cable Operated
Adjustment Procedure.
3/8" (9.5mm)
Top of thread to
top of upper nut.
Handle Link
Lever Pin
Switch
Bracket
Cable Operated Adjustment Procedure
1 Move handle to “ON” position. 2 Remove hitch and clevis pins.
3 Return handle to “OFF” position.
4 (a) ADJUSTMENT PROCEDURE IF SWITCH
DOES NOT FULLY CLOSE.
Unscrew clevis ONE full turn counter-
clockwise to extend cable.
4
5 Return handle to “ON” position. Reinstall
clevis, clevis pin and hitch pin.
6 Confirm switch operates properly and
repeat steps 2-5, if necessary.
(b) ADJUSTMENT PROCEDURE IF SWITCH
DOES NOT FULLY OPEN.
Turn clevis ONE full turn clockwise to
shorten cable.
Universal Disconnect Switch Installation Instructions (200A)
5
Rod Operated 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.
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".
Publication 1494U-IN007B-EN-P - July 2018
Clevis
Clevis Pin
Hitch Pin
Enclosure without Handle Cutout
To make slot, drill (3)
1/2" diameter holes
and remove burrs.
Top Handle Hole
(2) .265 Dia. Holes
1-1/4" MIN.
1-3/32 MAX.
10-1/8"
MIN.
4-11/16"
1-9/16"
1"
7/8"
1"
• Some Enclosures with hinged flange panels may require additional flange support brackets to stiffen panel.
Consult your local enclosure manufacturer.
Door Catch Bracket Installation
Right hand installation shown (for left hand installation follow similar procedures)
Door Catch
Mounting
Bracket
2-3/8"
1-5/8"
1-3/32"
1-1/4"
Enclosure Door
Flange
Thickness
K
1-5/8"
Enclosure
Base
TOP VIEW
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.
Dimension K (3/4" to 1")
• When using small disconnect handle kit only (1494U-HP1, -HM1 or -HS1), 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 (1494U-HP1, -HM1 or -HS1), 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
Door Catch
Mounting Bracket
Door Catch
Top
22-37 lb-in
(2.5-4.2 N-m)
Universal Disconnect Switch Installation Instructions (200A)
6
Right hand flange shown. Mirror for left hand flange.
Locate Handle Drill Handle Holes
1 2
Publication 1494U-IN007B-EN-P - July 2018
Trailer Fuse Block and Phase Barrier Installation
Fuse
DIM
"Z"
(in)
Trim
Phase
Barrier
Amps Voltage Class
100 250 H/R
C
100 600 H/R E
100 250/600 J
A
100 600
HRCII-C
A
200 250/600 J* D
200 250/600
J
B
200 250
H/R
D
200 600 H/R
-
200
600 HRCII-C
B
*Direct Mounting
1 Trailer Fuse Block Location
2 Trim phase barrier to desired length as shown in the table in Step .
3 Slide phase barriers into left channels on switch.
4-1/4
6-1/4
4
4
6-1/8
4-3/4
6-1/8
8-5/8
4-3/4
Lug Connectors
Universal Disconnect Switch Installation Instructions (200A)
7
"Z"
4 - 3/4"
Thread forming
screws
90-130 lb-in
10-15 Nm
A
B
C
D
E
1
Kit Description Material
Torque to
Terminal
Wire Range
(AWG)
Wire Material
Wire into
Lug Torque
1494U-LC200 Single Port Cu Cu Only
1494U-LA200 Single Port
1494U-LM200* Multi-Port 14…4
45 lb-in
(5.1 N-m)
90-105
lb-in
(10.2-11.9
N-m)
275 lb-in
(31.1 N-m)
Cu or AlAl
WireLug
6…250 MCM
Publication 1494U-IN007B-EN-P - July 2018
*Load Side Only
Fuse Clip and Fuse Installation
Fuse Clip Installation Fuse Installation
23-37 lb-in
(2.6-4.2 N-m)
18-22 lb-in
(2-2.5 N-m)
Universal Disconnect Switch Installation Instructions (200A)
8
Direct Mount for J Fuses
Publication 1494U-IN007B-EN-P - July 2018
2
2
1
1
40-60 lb-in
(4.5-6.8 N-m)
Auxiliary Contact Installation
Line Terminal Adapter Installation
Wire Clamp Range
(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
6-8 lb-in
(0.7-0.9 N-m)
0.32"
(8 mm)
#18 - #12 AWG
(0.75-2.5 mm²)
Wire routing channel
Wire tie-down points
Electrical Interlock Installation
Universal Disconnect Switch Installation Instructions (200A)
9
2
CLICK
Wire Clamp
25 lb-in
(2.8 N-m)
Adapter
90-105 lb-in
(10.2-11.9 N-m)
Wire
Lug
NOTE:
USE ADAPTER ON
LINE SIDE ONLY
Publication 1494U-IN007B-EN-P - July 2018
1
1
2
Auxiliary Contact Wire Routing
25 lb-in
(2.8 N-m)
Range
Torque
6.9-10.4 lb-in
(.78-1.18 N-m)
Wire
18-12 AWG
Protective Cover Installation
1 Position cover in front of switch as shown. Remove line side
shield.
2 Spread sides apart at bottom to fit around fuse block.
3 Rotate cover up and slide top sides into tracks shown on switch.
Push in until fully inserted and pull cover down slightly to ensure
engagement.
4 Press center of cover tight to mounting plate to engage notch in right
side of cover with switch bracket.
5 Ensure flange on left side of cover has snapped under fuse block.
6 Install screw in bottom slot.
Universal Disconnect Switch Installation Instructions (200A)
10
Publication 1494U-IN007B-EN-P - July 2018
Bulletin 1494U Disconnect Switch Component Accessory List
Component Cat No.
1494U-D200
1494U-HM1 (5-1/2” Painted Metal) (30A - 200A)
1494U-HP1 (5-1/2” Molded Plastic) (30A - 200A)
1494U-HS1 (5-1/2” Stainless Steel) (30A - 200A)
1494U-F200
Fuse Clip Kits (Pkg Qty 6):
1401-N44 (Class H, J, 100A-250V, 100A-600V)
1401-N45 (Class H, J, 200A-250V, 200A-600V)
1401-N53 (Class R, 100A-250V, 100A-600V)
1401-N54 (Class R, 200A-250V, 200A-600V)
Fuse Clip Kits
Fuse Block
Connecting Rod
Cable-Operated Handle Mechanism
1494U-C24 (4 ft. Cable)
1494U-C25 (5 ft. Cable)
1494U-C26 (6 ft. Cable)
Handle
Disconnect Switch and Mechanism
(1494U-HM1 shown)
Universal Disconnect Switch Installation Instructions (200A)
11
6-1/2"
200A Disconnect Switches
Enclosure Working Depth
Min.
19"
Max.
1494U-R1
Connecting Rod
6-1/2" 23"1494V-RA4
Publication 1494U-IN007B-EN-P - July 2018
Bulletin 1494U Disconnect Switch Component Accessory List (Cont’d)
Auxiliary Contacts
1494U-NO (1 N.O.)
1494U-NC (1 N.C.)
1494U-NOLV (1 N.O. Low Level)
1494U-NCLV (1 N.C. Low Level)
Aluminum Lugs
Copper Lugs
Multiport Lugs
Line Terminal Adapters
1494U-ALT200 (Pkg Qty 2)
Phase Barriers
1494U-PB200
Protective Cover
PN-475447
DIR 10003527449 (Version 01)
Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Component Cat No.
1494U-PC200
1494U-LM200 (Pkg Qty 3)
1494U-LC200 (Pkg Qty 3)
1494U-LA200 (Pkg Qty 3)
Publication 1494U-IN007B-EN-P - July 2018
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