1 2 3 4 5 6 7 8 warning - rockwellautomation.com · 2011. 2. 28. · 1 - 5/8" d 1 - 5/8"...

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

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.

BULLETIN 1494V VARIABLE DEPTH DISCONNECT SWITCHINSTALLATION INSTRUCTION SHEET

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REVISIONAUTHORIZATION

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

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DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

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G. Ushakow 6-25-086-25-08

6-25-08

M. JutzJ. Koziczkowski

To prevent electrical shock, disconnect from power source before installing or servicing. Follow NFPA 70E requirements. Install in suitable enclosure. Keep free from contaminants.

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)

THIS DRAWING IS THE PROPERTY OFROCKWELL AUTOMATION, INC.

OR ITS SUBSIDIARIES AND MAY NOT BE COPIED,USED OR DISCLOSED FOR ANY PURPOSEEXCEPT AS AUTHORIZED IN WRITING BY

ROCKWELL AUTOMATION, INC.

1 17

6 1021282

7 1032142

WARNING

WARNING

42052-116-01 (7)Printed in U.S.A.

A

HOLD FLUSH

TO INSID

E

OF ENCLOSUREMEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP HANDLE H

OLE

BOTTOM HANDLE H

OLE

Disconnect Handle Installation

Disconnect Switch Installation (Right hand installation shown. For left hand installation follow similar procedure.)1

2

Install gasket.

30-40 lb-in

Install handle and spring bracket.

Use template A to locate handle holes on mounting plate. Overlay template B (30 A - 100 A) over A .

Overlay template C (200 A) over A .

7-11 lb-in

Install defeater lever.

Cutting Connecting Rod

N

EnclosureWorking Depth(Inside Flange of Enclosure toMounting Plate)

MountingPlate

Measure working depth of enclosure.

3

Measure, mark and cut connecting rod.

N minus 3-1/8"

(30A - 100A)

N minus 3-1/4"

(200A)

23 - 37 lb-in(30A - 100A)

40 - 60 lb-in(200A)

TAPE HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

2

4

A

11

5

1

1 2 Remove burrs3

2 3

Install disconnect switch.7

6

1

3

A

HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

Bor C

2 - 1/4"

5 - 1/4"

2 - 1/4"

4 - 11/16"

3 - 1/16"

Switch M

ounting H

oles

Center punch and drill

(4) 1

1/64" holes fo

r

tap-tite screws provided with

switch

Center punch and drill (4) holesfor thread forming (TAP-TITE) screws provided with switch. 11/64" Dia. (30A - 100A)7/32" Dia (200A)


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QUICK INSTALLATION GUIDE

(2)

Connecting Rod Installation4Verify that disconnect switch and handle are in "OFF" position. (Switch blades will be visible)

Drive Bar

Pull up

(30A - 60A - 100A)

1

2

Rotate connecting rod into drive bar (see table).

34

Enclosure depth8 in. or less

Enclosure depth greater than 8 in.

CHECK FOR PROPEROPERATION

ATTENTION

7

8b8a

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)

(200A)

Push down

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)

1/8" Gap

Switch Rating

30A - 60A - 100A

200A

Full Turns Engagement

10

13


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QUICK INSTALLATION GUIDE (CONTINUED)

(3)

ConnectingRod

Hitch Pin

Primary Link

5

6

5

6

(4)

Connecting Rod Adjustment Procedure

"ON" Position 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

"OFF" Position 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.



1

2

ConnectingRod

Hitch Pin

Primary Link

Drive Bar


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Enclosure without Handle Cutout

1

To make slot drill (3) 1/2" diameter holes and remove burrs

Top Handle Hole

Top Handle Hole

Locate Handle

Right Hand Flange

Enclosure Dimensions

Left Hand Flange

(2) .265 Dia. Holes

Drill Handle Holes

BC

A

C

B

A

2

F

G

H

J

H

(5)

● Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.● Enclosures with a Flange Thickness 3/16" and greater use dimensions in alternate Mounting Kit 1494V-H3 to install disconnect handle.● 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.

F

4 - 11/16"

4 - 11/16"

4 - 11/16"

G

1 - 9/16"

1 - 9/16"

1 - 9/16"

H

1"

1"

1"

J

7/8"

7/8"

7/8"1 - 1/16"

C(max)

1 - 1/16"

1 - 1/16"

B(min)

1 - 1/8"

1 - 1/8"

1 - 1/8"

A(min)

4 - 5/8"

6 - 1/16"

10 - 1/8"

NEMASIZE

30A, 60A

200A

100A

6 1021282

5 17

- - - - - - -

Door Catch Bracket Installation Right hand installation shown (for left hand installation follow similar procedures)

Top Handle Hole

Door CatchMounting

Bracket

E

D

Door CatchMountingBracket

Right Hand Flange Left Hand Flange

D

BC

A

C

B

A

E

(6)

C

B

Enclosure Door Flange Thickness K

D

Enclosure Base

TOP VIEW

Door Catch Mounting Bracket:● Provided with projections for welding.● Projections can also be used as a guide for drilling holes.● Can be used as a template to drill corresponding 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 (1494F-P1, -M1 or -S1), 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 (1494F-P1, -M1 or -S1), 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.


1 - 5/8"

D

1 - 5/8"

1 - 5/8"

E

2 - 3/8"

2 - 3/8"

2 - 3/8"

F

4 - 11/16"

4 - 11/16"

4 - 11/16"

G

1 - 9/16"

1 - 9/16"

1 - 9/16"

H

1"

1"

1"

J

7/8"

7/8"

7/8"1 - 1/16"

C(max)

1 - 1/16"

1 - 1/16"

B(min)

1 - 1/8"

1 - 1/8"

1 - 1/8"

A(min)

4 - 5/8"

6 - 1/16"

10 - 1/8"

NEMASIZE

30A, 60A

200A

100A

6 17


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ROCKWELL AUTOMATION, INC.6 1021282

Door CatchMounting Bracket


Door Catch

Door Catch

Top

Disconnect Switch Installation

3-1/16" 2-1/2" 2-1/4" 5-1/4"

AA BB CC DD

3-1/16"

EE

2-1/4"

GG

----

HH

11/64" Dia.

FF(4 Mounting Plate Holes)

Locate Disconnect Switch


(7)

SwitchSize

30A, 60A, 100A

This dimension can be 2-1/4" if necessary, to avoid interference with panel mounting studs in some 8 inch deep enclosures.

3-9/16" 3-9/16" 2" 8-1/4" 3-9/16" 4-1/4" 1-1/8"7/32" Dia.200A

BB BB

DDDD

AAAAAAAAAAAAAAAAAAAAAAEEAAAAAAAACC

GG

HH HH

CC

FF FF

AA

GG

Panel Mounting Dimensions

1

Install Disconnect Switch Assemble and Install Line Terminal Guard

23 - 37 lb-in (30A - 100A)40 - 60 lb-in (200A)

LINE TERMINAL GUARD

LINE TERMINAL GUARD

2 3


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7 17

Top Handle Hole

(8)

Trailer Fuse Block Installation (Switch Rating 30A - 100A)

Note: Not required for non-fusible disconnect switch applications. 1

2

23 - 37 lb-in

Trailer Fuse Block Location

Install Trailer Fuse Block

30 Amp Trailer Fuse Block (1494V-FS30)

Torque (lb-in)Fuse

23-37

2-27/32"5-5/8"

2-27/32"4-3/16"3-5/8"6-1/8"

3"4-3/16"

3030303060606060

250600600600250600600600

H/RH/R

JHRCII-C

H/RH/R

JHRCII-C

22-37 90-110 150-165

23-37 22-37 20-25 20-25

23-37 16-22 90-110 150-165

Amps Voltage Class FuseBlock

AFuseClip

Lug toTerminal

Wireinto Lug


Torque (lb-in)Fuse

23-37

2-27/32"5-5/8"

2-27/32"4-3/16"3-5/8"6-1/8"

3"4-3/16"4-15/16"8-1/8"

3030303060606060100100

250600600600250600600600600600

H/RH/R

JHRCII-C

H/RH/R

JHRCII-C

JH/R

23-37 40-60 45-50

23-37 16-22 40-60 45-50


AFuseClip

Lug toTerminal

Wireinto Lug


Torque (lb-in)Fuse

4-3/16"3-9/16"6-11/16"4-11/16"6-11/16"8-11/16"5-1/2"7-9/16"6-1/4"

60606060100100100100200

250600600600250600600600600

H/RJ

H/RHRCII-C

H/RH/R

JHRCII-C

J


AFuseClip

Lug toTerminal

Wireinto Lug

A

2-1/4"


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8 17

(9)

2 Install Trailer Fuse Block

1 - 1/8"

Trailer Fuse Block Installation (Switch Rating 200A)


40 - 60 lb-in



Torque (lb-in)Fuse

40-60

5-7/8"7-7/8"4-5/8"4-5/8"6-3/4"9-1/4"5-3/8"5-3/8"6-1/4"

100100100100200200200200400

250600600600250600600600600

H/RH/R

JHRCII-C

H/RH/R

JHRCII-C

J

16-22

16-22

175-200 275-305


BFuseClip

Lug toTerminal

Wireinto Lug

B

2"

9 17


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Switch Rating (30A, 60A Rating) Fuse Clip Installation

Phase Barrier Replacement Kit 1494F-PH2

NOTE: Fuse clips and lugs must be removed to add or replace phase barriers.

1 2

21

23 - 37 lb-in

(10)

1

1

2

2

1

2

40392-098

40392-097

CLICK

CLICK

10 17


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2

1

3


Switch Phase Barrier

Fuse Clip Installation (Switch Rating 100 Amp)

1 2

16 - 22 lb-in

600V H - RFuse Clip Size and Class

600V H - R600V H - R250V H - R

60 A100 A200 A200 A


600V J250V H - R600V J

60 A60 A100 A100 A

600V J200 A

23 - 37 lb-in

(11)

2

1

1

1

1

2 12

1

22

Trailer Block Phase Barrier

2

CLICK

CLICK


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ROCKWELL AUTOMATION, INC.1021282

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(12)

Fuse Clip Installation (Switch Rating 200A)

1

2

1

2

23 - 37 lb-in

16 - 22 lb-in

23 - 37 lb-in

Switch for Right Hand Mechanism Switch for Left Hand Mechanism


16 - 22 lb-in

1

2

1

2

1 2 1 2

12 17


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(13)


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Fuse Clip Installation (Switch Rating 200A) for 400A Class J Fuses (Cat. No. 1401-N171)

2 2Switch with Right Hand Mechanism Switch with Left Hand Mechanism

1 1

16 - 22 lb-in

Switch with Right Hand Mechanism Switch with Left Hand Mechanism

1

2

1

216 - 22 lb-in

150 - 200 lb-in

150 - 200 lb-in

Use of 400A fuses will void the UL listing of this product.NOTICE

(14)

Phase Barrier Replacement Kit (Switch Rating 200A) 1494F-PH4

1

2

40 - 60 lb-in

1

1

23

2

4

3

CLICK

CLICK


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15 17

6 1021282

Bulletin 1494V Disconnect Switch Kit

Disconnect Kit

Handle

Switch

ConnectingRod

FuseBlock

FuseClips

Cat No.

Switch with Right Hand Mechanism 1494V-DS30 (30A)1494V-DS60 (60A)1494V-DS100 (100A)1494V-DS200 (200A)

Switch with Left Hand Mechanism 1494V-DSX30 (30A)1494V-DSX60 (60A)1494V-DSX100 (100A)1494V-DSX200 (200A)

1494F-M1 (5-1/2" Painted Metal) (30A - 200A)1494F-P1 (5-1/2" Molded) (30A - 200A)1494F-S1 (5-1/2" Stainless Steel) (30A - 200A)

1494V-FS30 (30A)1494V-FS60 (60A)1494V-FS100 (100A)1494V-FS200 (200A)

1401-N41 (Class H, 30A - 250V)1401-N42 (Class H,J, 30A - 600V, Class H, 60A-250V)1401-N43 (Class H,J, 60A - 600V)1401-N44 (Class H,J, 100A-250V, 100A-600V)1401-N45 (Class H,J, 200A-250V, 200A-600V)

1401-N50 (Class R, 30A - 250V)1401-N51 (Class R, 30A - 600V, 60A-250V)1401-N52 (Class R, 60A - 600V)1401-N53 (Class R, 100A - 250V, 100A-600V)1401-N54 (Class R, 200A-250V, 200A-600V)1401-N171 (Class J, 400A-250V / 600V)

1494V-RA3 (Standard) (30A - 100A)Enclosure Working Depth: 6-3/4" to 9-1/8"1494V-RA3 (Standard) (200A)Enclosure Working Depth: 8-1/2" to 10-1/4"

1494V-RA4 (Extended)(30A - 100A)Enclosure Working Depth: 6-3/4" to 21-5/8"1494V-RA4 (Extended) (200A)Enclosure Working Depth: 8-1/2" to 23-3/4"


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42052-116-01 (7)Printed in U.S.A.




16 17

6 1021282

Bulletin 1494V Disconnect Switch Optional Accessory List

ElectricalInterlock

AuxiliaryContact

AuxiliaryContact

Adapter Kit

ChannelSupport Kit

LugConnectors

Optional Accessories(Installation Instructions

Included with Accessory Kits)Cat No.

Switch with Right Hand Mechanism 1495-N34 (1-N.O./N.C.) (30A - 100A) 1495-N35 (2-N.O./N.C.) (30A - 100A)1495-N43 (1-N.O./N.C.) (200A)1495-N44 (2-N.O./N.C.) (200A)

Switch with Left Hand Mechanism 1495-N37 (1-N.O./N.C.) (30A - 100A)1495-N38 (2-N.O./N.C.) (30A - 100A)1495-N39 (1-N.O./N.C.) (200A)1495-N40 (2-N.O./N.C.) (200A)

1495-N8 (1-N.O.) (30A - 200A)1495-N9 (1-N.C.) (30A - 200A)

1495-N24 (30A - 100A)(Required only for Switch with Left HandMechanism)


1494V-H15 (30A - 200A)

FuseCover

with Door

PhaseBarrier

1494F-PH2 (30A / 60A)1494F-PH3 (100A)1494F-PH4 (200A)

(Included) (CU Wire Size #14 . . #8 AWG) (30A)

1494R-N1 (CU Wire Size #14 . . #4 AWG) (60A)

1494R-N2 (CU Wire Size #8 . . #1/0 AWG) (100A)


SwitchRating

FuseClass

Fuse ClipRating

Cat No.

30A30A60A30A60A60A100A

----30A60A30A60A--------

250V 600V

------------30A60A--------

Non-FusibleH, RH, R

JJ

Non-FusibleNon-Fusible

--------

100A

30A60A100A

H, RH, R

J

30A60A100A

100A 100AH, R100A

200A 200AH, J, R200A

200A 200AH, J, R

1495-N64

1495-N65

1495-N66

1495-N67

1495-N62

Switch with right hand mechanism Switch with left hand mechanism

200A

17"

8.50" 8.50"

FRONT SIDEPAGE 2

FRONT SIDEPAGE 15

BACK SIDEPAGE 1

BACK SIDEPAGE 16

FRONT SIDEPAGE 4

FRONT SIDEPAGE 13

BACK SIDEPAGE 3

BACK SIDEPAGE 14

FRONT SIDEPAGE 6

FRONT SIDEPAGE 11

BACK SIDEPAGE 5

BACK SIDEPAGE 12

FRONT SIDEPAGE 8

FRONT SIDEPAGE 9

BACK SIDEPAGE 7

BACK SIDEPAGE 10

17 17


5 1020139

6

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


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DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

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PARTNO. MATERIALCHG.

CHAR. SIZEFLAT FOLD

-01 7

TWO SIDES PRINTED

17" W x 11" H 8-1/2" W x 11" HBODY STOCK WHITE

BODY INK BLACKSTAPLED

1021282

A

HOLD FLUSH

TO INSID

E

OF ENCLOSUREMEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP HANDLE H

OLE

BOTTOM HANDLE H

OLE

Disconnect Handle Installation

Disconnect Switch Installation (Right hand installation shown. For left hand installation follow similar procedure.)1

2

Install gasket.

30-40 lb-in

Install handle and spring bracket.

Use template A to locate handle holes on mounting plate. Overlay template B (30 A - 100 A) over A .

Overlay template C (200 A) over A .

7-11 lb-in

Install defeater lever.

Cutting Connecting Rod

N

EnclosureWorking Depth(Inside Flange of Enclosure toMounting Plate)

MountingPlate

Measure working depth of enclosure.

3

Measure, mark and cut connecting rod.

N minus 3-1/8"

(30A - 100A)

N minus 3-1/4"

(200A)

23 - 37 lb-in(30A - 100A)

40 - 60 lb-in(200A)

TAPE HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

2

4

A

11

5

1

1 2 Remove burrs3

2 3

Install disconnect switch.7

6

1

3

A

HOLD FLUSH

TO INSID

E

OF ENCLOSURE

MEASURE TO

INSID

E OF THE

TOP OF ENCLOSURE

TOP

BOTT

Bor C

2 - 1/4"

5 - 1/4"

2 - 1/4"

4 - 11/16"

3 - 1/16"

Switch M

ounting H

oles

Center punch and drill

(4) 1

1/64" holes fo

r

tap-tite screws provided with

switch

Center punch and drill (4) holesfor thread forming (TAP-TITE) screws provided with switch. 11/64" Dia. (30A - 100A)7/32" Dia (200A)


5 1020139

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

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REFERENCE



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- - - - - - - - - - - - - -- - - - - - -

- - - - - - -- - - - - - -- - - - - - -




2 17

6 1021282

7 1032142

QUICK INSTALLATION GUIDE

(2)

Connecting Rod Installation4Verify that disconnect switch and handle are in "OFF" position. (Switch blades will be visible)

Drive Bar

Pull up

(30A - 60A - 100A)

1

2

Rotate connecting rod into drive bar (see table).

34

Enclosure depth8 in. or less

Enclosure depth greater than 8 in.

CHECK FOR PROPEROPERATION

ATTENTION

7

8b8a

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)

(200A)

Push down

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)

1/8" Gap

Switch Rating

30A - 60A - 100A

200A

Full Turns Engagement

10

13


5 1020139

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

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- - - - - - - - - - - - - -- - - - - - -

- - - - - - -- - - - - - -- - - - - - -




3 17

6 1021282

7 1032142

QUICK INSTALLATION GUIDE (CONTINUED)

(3)

ConnectingRod

Hitch Pin

Primary Link

5

6

5

6

(4)

Connecting Rod Adjustment Procedure

"ON" Position 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



"OFF" Position 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.



1

2

ConnectingRod

Hitch Pin

Primary Link

Drive Bar


5 1020139

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

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- - - - - - - - - - - - - -- - - - - - -

- - - - - - -- - - - - - -- - - - - - -




4 17

6 1021282

7 1032142


5 1020139

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

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Enclosure without Handle Cutout

1

To make slot drill (3) 1/2" diameter holes and remove burrs

Top Handle Hole

Top Handle Hole

Locate Handle

Right Hand Flange


Left Hand Flange

(2) .265 Dia. Holes

Drill Handle Holes

BC

A

C

B

A

2

F

G

H

J

H

(5)

● Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.● Enclosures with a Flange Thickness 3/16" and greater use dimensions in alternate Mounting Kit 1494V-H3 to install disconnect handle.● 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.

F

4 - 11/16"

4 - 11/16"

4 - 11/16"

G

1 - 9/16"

1 - 9/16"

1 - 9/16"

H

1"

1"

1"

J

7/8"

7/8"

7/8"1 - 1/16"

C(max)

1 - 1/16"

1 - 1/16"

B(min)

1 - 1/8"

1 - 1/8"

1 - 1/8"

A(min)

4 - 5/8"

6 - 1/16"

10 - 1/8"

NEMASIZE

30A, 60A

200A

100A

6 1021282

5 17

- - - - - - -

Door Catch Bracket Installation Right hand installation shown (for left hand installation follow similar procedures)

Top Handle Hole

Door CatchMounting

Bracket

E

D

Door CatchMountingBracket


D

BC

A

C

B

A

E

(6)

C

B

Enclosure Door Flange Thickness K

D

Enclosure Base

TOP VIEW

Door Catch Mounting Bracket:● Provided with projections for welding.● Projections can also be used as a guide for drilling holes.● Can be used as a template to drill corresponding 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 (1494F-P1, -M1 or -S1), 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 (1494F-P1, -M1 or -S1), 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.


1 - 5/8"

D

1 - 5/8"

1 - 5/8"

E

2 - 3/8"

2 - 3/8"

2 - 3/8"

F

4 - 11/16"

4 - 11/16"

4 - 11/16"

G

1 - 9/16"

1 - 9/16"

1 - 9/16"

H

1"

1"

1"

J

7/8"

7/8"

7/8"1 - 1/16"

C(max)

1 - 1/16"

1 - 1/16"

B(min)

1 - 1/8"

1 - 1/8"

1 - 1/8"

A(min)

4 - 5/8"

6 - 1/16"

10 - 1/8"

NEMASIZE

30A, 60A

200A

100A

6 17


5 1020139

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE



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Door Catch

Door Catch

Top

Disconnect Switch Installation

3-1/16" � 2-1/2" 2-1/4" 5-1/4"

AA BB CC DD

3-1/16"

EE

2-1/4"

GG

----

HH

11/64" Dia.

FF(4 Mounting Plate Holes)

Locate Disconnect Switch


(7)

SwitchSize

30A, 60A, 100A

� This dimension can be 2-1/4" if necessary, to avoid interference with panel mounting studs in some 8 inch deep enclosures.

3-9/16" 3-9/16" 2" 8-1/4" 3-9/16" 4-1/4" 1-1/8"7/32" Dia.200A

BB BB

DDDD

AAAAAAAAAAAAAAAAAAAAAAEEAAAAAAAACC

GG

HH HH

CC

FF FF

AA

GG

Panel Mounting Dimensions

1

Install Disconnect Switch Assemble and Install Line Terminal Guard

23 - 37 lb-in (30A - 100A)40 - 60 lb-in (200A)

LINE TERMINAL GUARD

LINE TERMINAL GUARD

2 3


5 1020139

6

7 1032142

1011282

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE



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42052

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7 17

Top Handle Hole

(8)

Trailer Fuse Block Installation (Switch Rating 30A - 100A)


2

23 - 37 lb-in


Install Trailer Fuse Block


Torque (lb-in)Fuse

23-37

2-27/32"5-5/8"

2-27/32"4-3/16"3-5/8"6-1/8"

3"4-3/16"

3030303060606060

250600600600250600600600

H/RH/R

JHRCII-C

H/RH/R

JHRCII-C

22-37 90-110 150-165

23-37 22-37 20-25 20-25

23-37 16-22 90-110 150-165


AFuseClip

Lug toTerminal

Wireinto Lug


Torque (lb-in)Fuse

23-37

2-27/32"5-5/8"

2-27/32"4-3/16"3-5/8"6-1/8"

3"4-3/16"4-15/16"8-1/8"

3030303060606060100100

250600600600250600600600600600

H/RH/R

JHRCII-C

H/RH/R

JHRCII-C

JH/R

23-37 40-60 45-50

23-37 16-22 40-60 45-50


AFuseClip

Lug toTerminal

Wireinto Lug


Torque (lb-in)Fuse

4-3/16"3-9/16"6-11/16"4-11/16"6-11/16"8-11/16"5-1/2"7-9/16"6-1/4"

60606060100100100100200

250600600600250600600600600

H/RJ

H/RHRCII-C

H/RH/R

JHRCII-C

J


AFuseClip

Lug toTerminal

Wireinto Lug

A

2-1/4"


5 1020139

6 1021282

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE



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42052

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---------------------------------------




8 17

(9)

2 Install Trailer Fuse Block

1 - 1/8"

Trailer Fuse Block Installation (Switch Rating 200A)


40 - 60 lb-in



Torque (lb-in)Fuse

40-60

5-7/8"7-7/8"4-5/8"4-5/8"6-3/4"9-1/4"5-3/8"5-3/8"6-1/4"

100100100100200200200200400

250600600600250600600600600

H/RH/R

JHRCII-C

H/RH/R

JHRCII-C

J

16-22

16-22

175-200 275-305


BFuseClip

Lug toTerminal

Wireinto Lug

B

2"

9 17


5 1020139

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE



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Switch Rating (30A, 60A Rating) Fuse Clip Installation


NOTE: Fuse clips and lugs must be removed to add or replace phase barriers.

1 2

21

23 - 37 lb-in

(10)

1

1

2

2

1

2

40392-098

40392-097

CLICK

CLICK

10 17


5 1020139

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE



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42052

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2

1

3


Switch Phase Barrier

Fuse Clip Installation (Switch Rating 100 Amp)

1 2

16 - 22 lb-in


600V H - R600V H - R250V H - R

60 A100 A200 A200 A


600V J250V H - R600V J

60 A60 A100 A100 A

600V J200 A

23 - 37 lb-in

(11)

2

1

1

1

1

2 12

1

22

Trailer Block Phase Barrier

2

CLICK

CLICK


5 1020139

6

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

G

REFERENCE



.XX:

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11 17



ROCKWELL AUTOMATION, INC.1021282

------------- --------------------------

---------------------------------------

(12)

Fuse Clip Installation (Switch Rating 200A)

1

2

1

2

23 - 37 lb-in

16 - 22 lb-in

23 - 37 lb-in



16 - 22 lb-in

1

2

1

2

1 2 1 2

12 17


5 1020139

6 1021282

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

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REFERENCE



.XX:

.XXX:

ANGLES:

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(13)


5 1020139

6 1021282

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

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REFERENCE



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13 17




Fuse Clip Installation (Switch Rating 200A) for 400A Class J Fuses (Cat. No. 1401-N171)

2 2Switch with Right Hand Mechanism Switch with Left Hand Mechanism

1 1

16 - 22 lb-in

Switch with Right Hand Mechanism Switch with Left Hand Mechanism

1

2

1

216 - 22 lb-in

150 - 200 lb-in

150 - 200 lb-in

Use of 400A fuses will void the UL listing of this product.NOTICE

(14)

Phase Barrier Replacement Kit (Switch Rating 200A) 1494F-PH4

1

2

40 - 60 lb-in

1

1

23

2

4

3

CLICK

CLICK


5 1020139

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

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REFERENCE



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14 17

6 1021282

(15)


5 1020139

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

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REFERENCE



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15 17

6 1021282

Bulletin 1494V Disconnect Switch Kit

Disconnect Kit

Handle

Switch

ConnectingRod

FuseBlock

FuseClips

Cat No.

Switch with Right Hand Mechanism 1494V-DS30 (30A)1494V-DS60 (60A)1494V-DS100 (100A)1494V-DS200 (200A)

Switch with Left Hand Mechanism 1494V-DSX30 (30A)1494V-DSX60 (60A)1494V-DSX100 (100A)1494V-DSX200 (200A)

1494F-M1 (5-1/2" Painted Metal) (30A - 200A)1494F-P1 (5-1/2" Molded) (30A - 200A)1494F-S1 (5-1/2" Stainless Steel) (30A - 200A)

1494V-FS30 (30A)1494V-FS60 (60A)1494V-FS100 (100A)1494V-FS200 (200A)

1401-N41 (Class H, 30A - 250V)1401-N42 (Class H,J, 30A - 600V, Class H, 60A-250V)1401-N43 (Class H,J, 60A - 600V)1401-N44 (Class H,J, 100A-250V, 100A-600V)1401-N45 (Class H,J, 200A-250V, 200A-600V)

1401-N50 (Class R, 30A - 250V)1401-N51 (Class R, 30A - 600V, 60A-250V)1401-N52 (Class R, 60A - 600V)1401-N53 (Class R, 100A - 250V, 100A-600V)1401-N54 (Class R, 200A-250V, 200A-600V)1401-N171 (Class J, 400A-250V / 600V)

1494V-RA3 (Standard) (30A - 100A)Enclosure Working Depth: 6-3/4" to 9-1/8"1494V-RA3 (Standard) (200A)Enclosure Working Depth: 8-1/2" to 10-1/4"

1494V-RA4 (Extended)(30A - 100A)Enclosure Working Depth: 6-3/4" to 21-5/8"1494V-RA4 (Extended) (200A)Enclosure Working Depth: 8-1/2" to 23-3/4"


5 1020139

7 1032142

42052-116OF

N/A

N/A

N/A


DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC


B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

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REFERENCE



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42052-116-01 (7)Printed in U.S.A.




16 17

6 1021282

Bulletin 1494V Disconnect Switch Optional Accessory List

ElectricalInterlock

AuxiliaryContact

AuxiliaryContact

Adapter Kit

ChannelSupport Kit

LugConnectors

Optional Accessories(Installation Instructions

Included with Accessory Kits)Cat No.

Switch with Right Hand Mechanism 1495-N34 (1-N.O./N.C.) (30A - 100A) 1495-N35 (2-N.O./N.C.) (30A - 100A)1495-N43 (1-N.O./N.C.) (200A)1495-N44 (2-N.O./N.C.) (200A)

Switch with Left Hand Mechanism 1495-N37 (1-N.O./N.C.) (30A - 100A)1495-N38 (2-N.O./N.C.) (30A - 100A)1495-N39 (1-N.O./N.C.) (200A)1495-N40 (2-N.O./N.C.) (200A)

1495-N8 (1-N.O.) (30A - 200A)1495-N9 (1-N.C.) (30A - 200A)



1494V-H15 (30A - 200A)

FuseCover

with Door

PhaseBarrier

1494F-PH2 (30A / 60A)1494F-PH3 (100A)1494F-PH4 (200A)

(Included) (CU Wire Size #14 . . #8 AWG) (30A)

1494R-N1 (CU Wire Size #14 . . #4 AWG) (60A)



SwitchRating

FuseClass

Fuse ClipRating

Cat No.

30A30A60A30A60A60A100A

----30A60A30A60A--------

250V 600V

------------30A60A--------

Non-FusibleH, RH, R

JJ

Non-FusibleNon-Fusible

--------

100A

30A60A100A

H, RH, R

J

30A60A100A

100A 100AH, R100A

200A 200AH, J, R200A

200A 200AH, J, R

1495-N64

1495-N65

1495-N66

1495-N67

1495-N62

Switch with right hand mechanism Switch with left hand mechanism

200A

1 2 3 4 5 6 7 8 warning - rockwellautomation.com · 2011. 2. 28. · 1 - 5/8" d 1 - 5/8"...

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