Allen-Bradley A Series Installation Instructions Manual

Brand: Allen-Bradley

Model: A Series

Type: Installation Instructions Manual

This manual is also suitable for

1494U-D200

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 .

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.

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 eciency of the cable system, create additional drag and friction within the cable conduit and possibly

decrease system life.

Universal Disconnect Switch Installation Instructions (200A)

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1494U Handle Installation

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.

Dis

nnec

ocatio

emp

0A)

-47

(

)

Rod Operated Switch Installation (Cont’d)

Cutting Connecting Rod

1 Measure working depth of enclosure. 2 Measure, mark and cut connecting rod. 3 Remove burrs.

Enclosure

Working Depth

(Inside Flange

of Enclosure to

Mounting Plate)

Mounting

Plate

N minus 3-1/8"

Connecting Rod Installation

1 Verify that disconnect switch and handle are in “OFF” position

(Switch blades will be visible).

Drive Bar

Rotate connecting rod

into drive bar 9-10 full

turns.

Align threaded rod

toward handle and,

if needed, rotate

counterclockwise

until ears engage the

primary link slots.

Connecting

Rod

Hitch Pin

Handle Link

5 Engage ears of connecting rod into slots of handle link. 7 Install spring to handle link.

See steps and for final rod alignment.

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)

ATTENTION: CHECK FOR PROPER OPERATION.

If not operating properly, go to Rod Operated

Adjustment Procedure.

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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

Connect handle link to lever pin.

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)

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

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.

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.

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)

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.

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.

Adjustment Procedure if switch does not turn "ON". Adjustment Procedure if switch does not turn "OFF".

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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"

7/8"

• 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

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)

Right hand flange shown. Mirror for left hand flange.

Locate Handle Drill Handle Holes

1 2

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Trailer Fuse Block and Phase Barrier Installation

Fuse

DIM

"Z"

(in)

Trim

Phase

Barrier

Amps Voltage Class

100 250 H/R

100 600 H/R E

100 250/600 J

100 600

HRCII-C

200 250/600 J* D

200 250/600

200 250

H/R

200 600 H/R

200

600 HRCII-C

*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

6-1/8

4-3/4

6-1/8

8-5/8

4-3/4

Lug Connectors

Universal Disconnect Switch Installation Instructions (200A)

"Z"

4 - 3/4"

Thread forming

screws

90-130 lb-in

10-15 Nm

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

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*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)

Direct Mount for J Fuses

Publication 1494U-IN007B-EN-P - July 2018

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)

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

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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)

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)

6-1/2"

200A Disconnect Switches

Enclosure Working Depth

Min.

19"

Max.

1494U-R1

Connecting Rod

6-1/2" 23"1494V-RA4

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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)

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

EEE Yönetmeliğine Uygundur.

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Trademarks not belonging to Rockwell Automation are property of their respective companies.

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