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Installation Instructions
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A)
(Cat 1494U-D30; 1494U-D60; 1494U-D100; Series A)
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.
Tools Needed: 7/16" Nut Driver, 5/16" Nut Driver, Hammer, Center Punch, File, T27 Torx Driver, Phillips Screwdriver, 11/64" Drill Bit, Needlenose Pliers
Table of Contents
Installation Guide............................................................................................................................................................................. 2
Rod and Cable Operated Disconnect Switch Location.................................................................................................. 2
Rod Operated Switch Installation.......................................................................................................................................... 3
Handle Installation.................................................................................................................................................................. 3
Connecting Rod Installation................................................................................................................................................ 3
Rod Adjustment Procedure................................................................................................................................................. 4
Cable Operated Switch Installation...................................................................................................................................... 5
Handle and Cable Mechanism Installation..................................................................................................................... 5
Cable to Switch Mechanism Installation......................................................................................................................... 6
Cable Adjustment Procedure.............................................................................................................................................. 7
Enclosure Without Handle Cutout............................................................................................................................................. 8
Door Catch Bracket Installation.................................................................................................................................................. 9
Trailer Fuse Block and Phase Barrier Installation................................................................................................................10
Auxiliary Contact Installation.....................................................................................................................................................11
Line Terminal Adapter Installation..........................................................................................................................................12
Electrical Interlock Installation..................................................................................................................................................12
Fuse Clip and Fuse Installation.................................................................................................................................................13
Protective Cover Installation.....................................................................................................................................................14
Bulletin 1494U Disconnect Switch Component Accessory List....................................................................................15
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Summary of Contents for Allen-Bradley 30A
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Page 1: Table Of Contents
Installation Instructions Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) (Cat 1494U-D30; 1494U-D60; 1494U-D100; Series A) 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. -
Page 2: Installation Guide
B) For Cable Operated Switches, follow steps 3 - 5 below. IMPORTANT: When locating the 30A, 60A and 100A 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. -
Page 3: Rod Operated Switch Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Rod Operated Switch Installation 1494U Handle Installation Install gasket. Install spring bracket and handle. Install defeater lever. TIP: Move handle to “ON” position to help align handle and bracket. Return handle to “OFF”... -
Page 4: Rod Adjustment Procedure
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Rod Operated Switch Installation (Cont’d) Connecting Rod Installation (Cont’d) Engage ears of connecting rod into slots of handle link. Install spring to handle link. Hitch Pin Connecting Install hitch pin Primary Link through ears of connecting rod. -
Page 5: Cable Operated Switch Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Cable Operated Switch Installation 1494U Handle and Cable Mechanism Installation Enclosures with Right Flange Install spring to handle link. Connect handle link to lever pin. Install handle nuts and hitch pin. 30 - 40 lb-in (3.4 - 4.5 N-m) -
Page 6: Cable To Switch Mechanism Installation
IMPORTANT: Verify that the cable assembly does not interfere with any mechanical and moving parts. Keep the cable conduit a minimum of 1/2" from all heat sources and current carrying terminals, fuses, transformers, etc. IMPORTANT: When locating the 30A, 60A and 100A switch, verify that the minimum diameter for the loop of the cable between the switch mechanism and the handle mechanism is not less than 6 inches. -
Page 7: Cable Adjustment Procedure
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Cable Adjustment Procedure Move handle to “ON” position. Remove cable pivot hitch pin and washer. Push cable pivot out of handle bracket. Return handle to “OFF” position. (a) ADJUSTMENT PROCEDURE IF (b) ADJUSTMENT PROCEDURE IF... -
Page 8: Enclosure Without Handle Cutout
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Enclosure without Handle Cutout • Some Enclosures with hinged flange panels may require additional flange support brackets to stiffen panel. Consult your local enclosure manufacturer. Locate Handle Top Handle Hole Right Hand Flange... -
Page 9: Door Catch Bracket Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) 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. -
Page 10: Trailer Fuse Block And Phase Barrier Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Trailer Fuse Block and Phase Barrier Installation Trailer Fuse Block Location Fuse Phase “Z” Barrier Amps Volts Class (in) 1.791 4.585 1.791 HRCII-C 3.024 2.622 5.122 1.976 HRCII-C 3.024 5.636 “Z” 7.636 4.449... -
Page 11: Auxiliary Contact Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) 11 Auxiliary Contact Installation CLICK 0.32" (8 mm) #18 - #12 AWG (0.75-2.5 mm²) 6-8 lb-in (0.7-0.9 N-m) Auxiliary Contact Wire Routing Wire tie-down points Wire routing channels Publication 1494U-IN001H-EN-P - October 2016... -
Page 12: Line Terminal Adapter Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Lug Connectors Switch Lug to Wire Rating Lug Kit Wire Range Terminal Description Material Material Torque (1) 14 AWG … 2 AWG (Cu) (1) 12 AWG … 2 AWG (Al) 30…60 1494U-LA36 (2) 14 AWG …... -
Page 13: Fuse Clip And Fuse Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) 13 Fuse Clip and Fuse Installation 30A/60A Fuse Clip Installation 30A/60A Fuse Installation 23-37 lb-in (2.6-4.2 N-m) 100A Fuse Clip Installation 100A Fuse Installation 23-37 lb-in (2.6-4.2 N-m) 18-22 lb-in (2-2.5 N-m) -
Page 14: Protective Cover Installation
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Protective Cover Installation Position cover in front of switch as shown. Remove line side Spread sides apart at bottom to fit around fuse block. shield. Rotate cover up and slide top sides into tracks shown on switch. -
Page 15: Bulletin 1494U Disconnect Switch Component Accessory List
Universal Disconnect Switch Installation Instructions (30A, 60A, 100A) Bulletin 1494U Disconnect Switch Component Accessory List Component Cat No. Disconnect Switch and Mechanism Switch and Mechanism 1494U-D30 (30A) 1494U-D60 (60A) 1494U-D100 (100A) Includes: Line Side Lugs Line Side Shield (Field Installed) - Page 16 100A 1494U-FC100R Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page 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. PN-335193 Publication 1494U-IN001H-EN-P - October 2016 DIR 10001182729 (Version 07) Copyright ©...
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