Installation Instructions

Universal Disconnect Switch Installation Instructions (400A)

(Cat 1494U-D400; 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: 1/2" Socket, 5/16" Allen Wrench, Hammer, Center Punch, File, Flat Head Screwdriver, Phillips Screwdriver, 9/32" Drill Bit, Needlenose Pliers, Hacksaw

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

2 Universal Disconnect Switch Installation Instructions (400A)

Rod Operated Switch Installation

1 Switch Installation
Use template D to locate handle holes on mounting plate. 5 Overlay template E (400 A) over D . 7 Install disconnect switch.

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1 Center punch and drill

(4) 9/32" dia. holes for
D
thread forming screws
90-130 lb-in
provided with switch. 10-15 Nm

2 Handle Installation
1 Install gasket. 2 Install handle and spring bracket. 3 Install defeater lever.

60-80 lb-in
6.8-9.0 Nm

IMPORTANT: 7-11 lb-in

Apply grease to O-Ring 0.79-1.2 Nm
to retain into handle groove.

3 Cutting Connecting Rod 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.

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

cut (2) connecting rods.

Mounting Enclosure
Working Depth 4"
Plate N -3/
(Inside Flange s3
nu
of Enclosure to mi
N
Mounting Plate)

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 Universal Disconnect Switch Installation Instructions (400A) 3

4 Connecting Rod Installation

First rod connects the handle to the switch
1 Verify that disconnect switch and handle are in "OFF"
Rotate rod to adjust.
position. (Switch blades will be visible)
Adjust to create minimal
gap with spring bracket.

4
3

2 Drive Bar

Zero
Clearance
Top View
Rotate connecting rod into
drive bar 9-10 turns.

Hitch Pin

Connecting 7
Rod
6

5
Handle Link

Second rod provides stiffening for the enclosure flange and mounting panel

150-200 lb-in
11 17-23 Nm
9
Stiffening Rod
10

ATTENTION: CHECK FOR PROPER OPERATION.

If not operating properly, go to Connecting Rod
Adjustment Procedure.

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4 Universal Disconnect Switch Installation Instructions (400A)

1 Cable Operated 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.
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.

1 Assemble the cable mechanism bracket to the disconnect switch.

1/2"

90-130 lb-in
10-15 Nm

2 Rotate connecting rod into drive bar 9-10 turns. 3 Attach connecting rod to cable mechanism.

Lubricate

90-130 lb-in
Connecting 10-15 Nm
Connecting Rod Rod
9/16"

90-130 lb-in
10-15 Nm 2
1
5/16"
Cable
Mechanism
Lever

Fully seat bolt

prior to attaching
nut.

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 Universal Disconnect Switch Installation Instructions (400A) 5

2 Cable Operated Switch Installation

1 Locate Switch. Use template E 3 Assemble disconnect switch assembly to mounting plate.
where desired. 2"

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4-3/4"

2 (4) - 5/16-18 thread

Center punch and drill forming screws 10" Diameter Min.
(4) 9/32" dia. holes for Do not pinch cable.
thread forming screws
90-130 lb-in
provided with switch.
10-15 Nm

3 Handle Installation
1 Install gasket. 2 Install handle and mechanism bracket. 3 Install defeater lever.

1/2" (Right Hand

Flange Mounted
Shown)
60-80 lb-in
7-11 lb-in
6.8-9.0 Nm
0.79-1.2 Nm

IMPORTANT:
Apply grease to O-Ring
to retain into handle groove.

4 Handle Mechanism Installation Connecting

Rod
1 Operate disconnect switch and verify that the handle and 2 Align connecting rod with handle link.
switch are in the "ON" position.

Handle
Link

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6 Universal Disconnect Switch Installation Instructions (400A)
3 Handle Mechanism Installation (Cont'd)
3 Install hitch pin clip.
Hitch Pin Clip
ATTENTION: CHECK FOR PROPER OPERATION.
Connecting Rod Adjustment Procedure
Adjustment Procedure if switch does not turn "ON".
1 Move disconnect handle to the "ON" position.
2 If switch does not fully close, return handle to "OFF" position.
3 Remove link spring and hitch pin to disengage the connecting
rod from the primary link.
4 Turn connecting rod counter-clockwise (1 or more) full turns.
5 Re-engage connecting rod in primary link of handle, insert hitch
pin and re-test.
6 Repeat 1 - 5 as necessary.
7 Re-install link spring.
Rod Operated Adjustment
Drive Bar
Publication 1494U-IN006C-EN-P - August 2019
4 Turn disconnect handle "OFF" and install handle
mechanism spring.
Adjustment Procedure if switch does not turn "OFF".
1 Move disconnect handle to the "OFF" position.
2 If switch does not fully close, return handle to "ON" position.
3 Remove link spring and hitch pin to disengage the connecting rod
from the primary link.
4 Turn connecting rod clockwise (1 or more) full turns.
5 Re-engage connecting rod in primary link of handle, insert hitch pin and
re-test.
6 Repeat 1 - 5 as necessary.
7 Re-install link spring.
Cable Operated Adjustment
 Universal Disconnect Switch Installation Instructions (400A) 7

Enclosure without Handle Cutout

• Enclosures with a Flange Thickness less than 3/16" use dimensions below to install disconnect handle.

1 Locate Handle 2 Drill Handle Holes 3 Locate Disconnect Switch

2" 5"
1-1/8"
1-3/8"

(2) .328" Dia.

14-3/8" Holes

3-3/4" (4) 9/32" Dia.

Holes
5/16"
Top
Handle 5-1/2"
Hole 1/2" 5-1/2"
Door Catch 6-1/2"
1/4"
Mounting 11"
Bracket

1-5/8" Square
corners 1-3/8"
or up to
1/4" radius

4-3/4"

Right hand flange shown. Mirror for left hand flange.

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.
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.

Door Catch
Mounting Bracket TOP VIEW
Enclosure Door
Top
Flange
Thickness K

Door Catch
Mounting 1-1/8"
22-37 lb-in Bracket
Enclosure
(2.5-4.2 N-m)
Door Catch Base
1-5/8" 1-3/8"

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8 Universal Disconnect Switch Installation Instructions (400A)

Line Terminal Guard Installation

Assemble and Install Line Terminal Guard

LIN
ET
ER
MIN
AL

1 G UA
RD

LIN
2
ET
ER
MIN
AL
GU
AR
D

Lug Installation Line Terminal Adapter Installation

1 Wire Clamp
175-200 lb-in Adapter
20-23 Nm 175-200 lb-in
20-23 Nm

Lug Adapter Kit

Catalog Wire
Number Torque Range
(1) 14-10 STR/SOL
(1) 8 STR
(2) 14 SOL/SOL
(2) 14 STR/STR
1494R- 25 lb-in
(2) 12 SOL/SOL
N19 (2.8 N-m)
(2) 12 STR/STR
(2) 10 SOL/SOL
(2) 10 STR/STR
(2) 8 STR/STR

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 Universal Disconnect Switch Installation Instructions (400A) 9

Trailer Fuse Block Installation Direct Mount Fuse Installation

400A Fuses (Class J Only)
Trailer Fuse Block Location
(400A Class H, J, R Fuses) 1 Cut phase barriers along line.

Thread forming
screws
4 - 3/4"

400 Amp Trailer Fuse Block (1494U-F400) 2

Torque
lb-in 175-200 lb-in
20-23 Nm
Fuse (Nm)
A
Amps Voltage Class Fuse Fuse Lug to Wire
Clip Block Terminal into Lug
200 250 H/R 7-11/16"
200 600 H/R 10-3/16" 16-22
200 600 J 6-3/8" (1.8-2.5)
200 600 HRCII-C 6-3/8" 90-130 175-200 275-305
400 600 J* 10" N/A (10-15) (20-23) (31-34)
400 250 H/R 8-11/16"
400 600 H/R 11-11/16" 22-37
400 600 J 7-3/16" (2.5-4.2)
400 600 HRCII-C 8-11/16"
*Direct Mount

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10 Universal Disconnect Switch Installation Instructions (400A)

Fuse Clip Installation

400A Fuses (Class H, J, R)
1 2 23-37 lb-in
16-22 lb-in 200A Fuse Clips
200A Fuse Clips 2.6-4.2 Nm
1.8-2.5 Nm
22-37 lb-in 40-55 lb-in
400A Fuse Clips 400A Fuse Clips
4.5-6.2 Nm
2.5-4.2 Nm
2
2

1 1

Protective Cover Installation

1 Punch and drill (4) 11/64" pilot holes. 2 Install (4) mounting screws to hang cover.
8-1/2" Fasten cover screws.
11/16" 3-3/8"
2

23-5/8"

8-1/2"
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 Universal Disconnect Switch Installation Instructions (400A) 11

Bulletin 1494U Disconnect Switch Kit Optional Accessory List

Disconnect Switch Kit Catalog Number and Description

1494U-D400

Switch

1494F-M2 (7-1/2" Painted Metal) (400A / 600A)

Handle 1494F-S2 (7-1/2" Stainless Steel) (400A / 600A)

1494V-RB3 (Standard) (400A / 600A)

Enclosure Working Depth: 9-1/2" to 10"
Connecting Set of
Rod (2) rods
1494V-RB4 (Extended) (400A / 600A)
Enclosure Working Depth: 9-1/2" to 23"

1494U-C44: 4 Ft Cable
Cable 1494U-C45: 5 Ft Cable
1494U-C46: 6 Ft Cable
Mechanism

Fuse 1494U-F400
Block

1401-N45 (Class H,J, 200A - 250V, 200A - 600V)

Fuse 1401-N46 (Class H,J, 400A - 250V, 400A - 600V)
Clips 1401-N54 (Class R, 200A - 250V, 200A - 600V)
1401-N55 (Class R, 400A - 250V, 400A - 600V)

Publication 1494U-IN006C-EN-P - August 2019

Bulletin 1494U Disconnect Switch Kit Optional Accessory List

Optional Accessories Catalog Number and Description

Electrical 1495-N43 (1-N.O./N.C.)

Interlock 1495-N44 (2-N.O./N.C.)

Auxiliary 1495-N8 (1-N.O.)

Contact 1495-N9 (1-N.C.)

Wire
LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)
Copper
1494R-N14 CU ONLY 275 LB-IN (2) 1/0…250 MCM
Lugs

Wire
LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)
Aluminum
1494U-LA400 AL / CU 275 LB-IN (2) 1/0…300 MCM
Lugs

Wire
LUGS (Pkg Qty 3) TYPE TORQUE GAUGE (AWG)
Multiport 1494U-LM400* 35 LB-IN (12) 8…4
Lugs FOR LOAD AL / CU 25 LB-IN (12) 8
SIDE ONLY 20 LB-IN (12) 14…10
*Special Purpose Not For General Use

Line
1494R-N19
Terminal
(Pkg Qty 6)
Adapters

Protective
1494U-PC400
Cover

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

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Publication 1494U-IN006C-EN-P - August 2019 DIR 10003527458 (Version 02)
Copyright © 2019 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.