1 9

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1 1004063

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REVISIONAUTHORIZATION

DR.

CHKD.

APPD.

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

G. Ushakow 9-10-039-10-03

9-10-03M. JutzJ. Koziczkowski

ATTENTION: To prevent electrical shock, disconnect from power source before installing or servicing. Install in suitable enclosure. Keep free from contaminants.

Bulletin 1494V Variable Depth, Flange Operated Disconnect Switch Kits for 30 and 60 Amperes (Series A), 100 and 200 Amperes (Series B or Series C Switches)

Components Cat No. DescriptionSwitch Rating

(Amps)

1494V-DS301494V-DS601494V-DS1001494V-DS200

30 Amp Switch60 Amp Switch100 Amp Switch200 Amp Switch

1494F-M11494F-P11494F-S1

5-1/2" Painted Metal Handle5-1/2" Molded Handle5-1/2" Stainless Steel Handle

1494V-FS301494V-FS601494V-FS1001494V-FS200

3060

100200

30 Amp Fuse Block60 Amp Fuse Block100 Amp Fuse Block200 Amp Fuse Block

3060

100200

30...200

1494V-RA3

1494V-RA4

Standard Connecting RodEnclosure Working Depth: 6-3/4" to 9-1/8" Extended Connecting RodEnclosure Working Depth: 9-1/8" to 21-5/8"

3060

100200

(Included)1494R-N11494R-N21494R-N3

Lug Connector: Wire Size #14 . . . #8 AWGLug Connector: Wire Size #14 . . . #4 AWGLug Connector: Wire Size #14 . . . #1/0 AWGLug Connector: Wire Size #6 . . . #4/0 AWG

1495-N59

1495-N60

Fuse Cover with Door(only for Right-Hand Installation)

1401-N411401-N42

1401-N431401-N441401-N451401-N501401-N511401-N521401-N531401-N54

3030 - 60

60100-200100-200

3030 - 60

60100-200

Fuse Clip, Class H, 30A - 250VFuse Clip, Class H,J, 30A - 600V,Class H, 60A-250VFuse Clip, Class H,J, 60A - 600VFuse Clip, Class H,J, 100A-250V, 100A-600VFuse Clip, Class H,J, 200A-250V, 200A-600VFuse Clip, Class R, 30A - 250VFuse Clip, Class R, 30A - 600V, 60A-250VFuse Clip, Class R, 60A - 600VFuse Clip, Class R, 100A - 250V, 100A-600VFuse Clip, Class R, 200A-250V, 200A-600V

Fuse Cover with Door(only for Right-Hand Installation)

200

100-200

30...200

595-A

595-B

(1) N.O. Auxiliary Contact

(1) N.C. Auxiliary Contact30...200

30...100

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1 1004063

42052-064OF

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REVISIONAUTHORIZATION

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APPD.

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

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

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

2 9

Handle Installation

4

1

3

7-11 lb-in

Door CatchMounting

Bracket

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

and remove burrs

E

D

Door CatchMountingBracket

Locate Handle

Right Hand Flange Left Hand Flange

(2) .265 Dia. HolesDrill Handle Holes

D

BC

C

B

A

C

B

A

E

5

2

F

G

H

J

HDoor Catch

Mounting Bracket

Door Catch

Enclosure Door

D

Enclosure Base

Locate Door Catch

Install Defeater Lever Install Gasket

(2)

Notes:A) Enclosures with a Flange Thickness less than 3/16" use dimensions above.B) Enclosures with a Flange Thickness 3/16" and greater use dimensions in Mounting Kit 1494V-H3.C) Multi-Door Enclosures use dimensions in Channel Support Kit 1494V-H4, if handle is mounted atop channel.D) The door catch mounting bracket is provided with projections for welding; however, holes can be drilled in the bracket using the projections for locating hole centers. After proper location, use the bracket as a template and drill corresponding holes in the enclosure door. Fasten the bracket with hardware supplied by user. If properly assembled, the hardware should not be accessible for tampering with by unauthorized personnel.

1 - 5/8"

D

1 - 5/8"

1 - 5/8"

E

2 - 11/32"

2 - 11/32"

2 - 11/32"

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 - 3/32"

C(max)

1 - 3/32"

1 - 3/32"

B(min)

29/32"

29/32"

29/32"

A(min)

4 - 5/8"

5 - 13/16"

10 - 1/8"

NEMASIZE

30A, 60A

200A

100A

3 9

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1 1004063

42052-064OF

N/A

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N/A

REVISIONAUTHORIZATION

DR.

CHKD.

APPD.

DATE

DATE

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

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

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

RectangularMetal Plate

MovableBlades

Insert the rectangular metal plate provided with the hardware kit into the crossbar end slot on the right-hand side as shown below.

ATTENTION: Do not attempt to change the position of the drive mechanism after removal from the disconnect assembly. Use the rectangular metal plate to rotate the crossbar from the "OFF" position to the full "ON" positiom.

Remove the rectangular metal plate and discard, (not required for switch operation.)Position the drive mechanism assembly as shown below and install the (4) screws.

Rotate the crossbar assembly in a clockwise direction to the "ON" position (blades fully engaged - not visible). (Use any convenient adjustable wrench or pliers to aid in rotating the crossbar & moveable blades.)

With the disconnect switch in the "OFF" position, (blades visible) loosen and remove the (4) screws.Remove the drive mechanism from the right-hand side of the disconnect switch.Save the (4) 1/4-20 pan head screws shown below.

Disconnect Switch Installation

Conversion from Right-Hand Installation to Left-Hand Installation

1

2 3

54

RectangularMetal Plate

Moveable Blades

40-60 lb-in

3 - 29/64" 1 - 27/32" 1 - 31/32" 4 - 21/64" 1" 3 - 15/16" (4) #10-32 2 - 37/64"

AA BB CC DDNEMASIZE

30A, 60A,100A

3 - 53/64" 2 - 63/64" 2 - 23/64" 4 - 59/64" 1 - 7/64" 4 - 23/32" (4) 1/4-20 2 - 61/64"200A

EE FF GG HH

BB BB

CC

DD DDEE EE

FF

AAAAAAAAAAAAAAAAAAAAAAGG AAAAAAAAAAAAAAAAAAAAAACCAAAAAAAAAAAA

FF

LocateDisconnect Switch

Right Hand Flange Left Hand Flange

HH HH

(3)

1 Install Trailer Block

2 Install Fuse Clips

30A ....... 60A 100A ....... 200A

3 Install Wire Lugs to Terminals 4 Install Wire to Lugs

4 9

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1 1004063

42052-064OF

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REVISIONAUTHORIZATION

DR.

CHKD.

APPD.

DATE

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

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

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

Trailer Fuse Block and Fuse Clip Installation

Y

Z X

Q

R

R

40 lb-in

10 - 15 lb-in

T

S

1

2

2

3

4

V

W

(4)

1

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1 1004063

42052-064OF

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N/A

N/A

REVISIONAUTHORIZATION

DR.

CHKD.

APPD.

DATE

DATE

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

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

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

5 9

Trailer Fuse Fuse Fuse Block Fuse Clip Lug to Wire toSwitch Fuse Fuse Block Clip Block Mtg. Screw Mtg. Screw Terminal LugRating Rating Fuse Catalog Catalog V W X Y Z Mounting Torque Torque Torque Torque

TermScrew

(Amps) Amps/Volts Class Number Number inches inches inches inches inches Hole lb-ins. lb-ins. lb-ins. lb-ins.

30A, 250V 1494V-FS30 1401-N41 2-1/4 1-13/16 1-31/32 31/32 9/16

30A, 250V 1494V-FS30 1401-N50 2-1/4 1-13/16 1-31/32 31/32 9/16

30A, 600V 1494V-FS30 1401-N42 2-1/4 1-13/16 1-31/32

30A, 600V 1494V-FS30 1401-N42 2-1/4 1-13/16 1-31/3230

30A, 600V 1494V-FS30 1401-N51 2-1/4 1-13/16 1-31/32 #10-32

60A, 250V 1494V-FS30 1401-N42 2-1/4 1-13/16 1-31/32

60A, 250V 1494V-FS30 1401-N51 2-1/4 1-31/32

60A, 600V 1494V-FS30 1401-N43 2-1/4 1-31/32

60A, 600V 1494V-FS30 1401-N43 2-1/4 1-31/32

60A, 600V 1494V-FS30 1401-N52 2-1/4 1-31/32

60A, 250V 1494V-FS60 2-1/4 1-31/32

60A, 600V 1494V-FS60 2-1/4 1-31/32

60A, 600V 1494V-FS60 2-1/4 1-31/32

60A, 600V 1494V-FS60 2-1/4 1-31/32

1494V-FS60 2-1/4 1-31/32#10-32

1494V-FS60 2-1/4 1-31/32 1-21/64

60A, 600V 1494V-FS60 2-1/4 1-31/32 1-21/6460

60A, 600V

60A, 600V

60A, 600V

1494V-FS60 2-1/4 1-31/32 3-53/64

60A, 600V 1494V-FS60 2-1/4 1-31/32 11/16

100A, 600V 2-1/4 1-31/32 5-13/16 #10-32

100A, 600V 1494V-FS60 2-1/4 1-31/32 5-13/16

60A, 600V 1494V-FS100 1401-N43 2-1/8 1-31/32 6-17/64

#10-32

60A, 600V 1494V-FS100 1401-N52 2-1/8 1-11/16 1-31/32 6-17/64

#10-32

100

100A, 600V 1494V-FS200 1401-N44 1-41/64 1-1/4 2-23/64

100A, 600V 1494V-FS200 1401-N44 1-41/64 1-1/4 2-23/64

100A, 600V 1494V-FS200 1401-N53 1-41/64 1-1/4 2-23/64

200A, 250V 1494V-FS200 1401-N45 1-41/64 1-1/4 2-23/64

200 1/4-20

200A, 600V 1494V-FS200 1401-N45 1-41/64 1-1/4 2-23/64

(5)

H

J

R

H

J

H

R

8-35/64

5-19/64

8-35/64

7-27/64

6-3/64

H

R

H

R

H

J

1401-N41

1401-N50

1401-N42

1401-N42

1401-N51

1401-N42

1401-N51

1401-N43

1401-N43

1401-N44

1401-N53

6-5/8

6-7/32

6-5/8

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-13/16

1-11/16

1-47/64

1-47/64

4-15/64

1-3/32

6-7/32

3-47/64

31/32

3-47/64

1-47/64

1-47/64

4-15/64

1-3/32

4-15/64

31/32

31/32

3-47/64

31/32

3-47/64

3-21/64

9/16

3-21/64

1-11/32

1-11/32

3-27/32

23/32

3-27/32

9/16

9/16

3-11/32

1-11/32

3-11/32

6-53/64

3-37/64

6-53/64

5-43/64

4-21/64

H

R

H

J

30A, 600V 1494V-FS30 1401-N42 2-1/4 1-13/16 1-31/32 31/32 9/16J

R

H

R

H

J

R

H

R

H

J

R

3030

3030

20

30

2030

30

30

40

#5/16/2415090

20 #3/8-24275175

#1/4-284550

#10-322030

100A, 600V 1494V-FS60 2-1/4 1-31/32 2-9/16J 1401-N44 2-31/32 1-13/16

100A, 250V 1494V-FS60 2-1/4 1-31/32 3-27/32R 1401-N53 1-13/16 4-1/4

1494V-FS60

60A, 600V 1494V-FS60 2-1/4 1-31/32 3-53/64R 1401-N52 1-13/16 4-15/64

1494V-FS60 2-1/4 1-31/32 3-27/32100A, 250V H 1401-N44 1-13/16 4-1/4

60A, 600V

**

**

* FUSE BOLTS DIRECTLY TO THE SWITCH AND FUSE BLOCK TERMINALS**FUSE ADAPTER KIT CATALOG NUMBER 1401-N170 REQUIRED.

** 1494V-FS100 1401-N43 2-1/8 1-11/16 1-31/32 4-63/64 J 5-3/8

100A, 250V 1494V-FS100 1401-N44 2-1/8 1-11/16 1-31/32H 4-5/8 4-15/64

100A, 250V 1494V-FS100 1401-N53 2-1/8 1-11/16 1-31/32R 4-5/8 4-15/64

100A, 250V 1494V-FS100 1401-N44 2-1/8 1-11/16 1-31/32H 6-5/8 6-15/64

100A, 600V 1494V-FS100 1401-N44 2-1/8 1-11/16 1-31/32J 3-3/8 2-63/64

100A, 600V 1494V-FS100 1401-N53 2-1/8 1-11/16 1-31/32R 6-5/8 6-15/64

400A, 600V 1494V-FS200 1401-N46 1-41/64 1-1/4 2-23/64 1/4-20J 8-17/32 6-13/64 17540

200A, 600V 1494V-FS200 1401-N54

*

*

1-41/64 1-1/4 2-23/64R 9-59/64 8-13/64

200A, 600V 1494V-FS200 1401-N45 1-41/64 1-1/4 2-23/64H 9-59/64 8-13/64

200A, 250V 1494V-FS200 1401-N54 1-41/64 1-1/4 2-23/64R 7-27/64 5-43/64

200A, 600V 1494V-FS100 1401-N45 7/16 1-11/16 1-31/32J 4-1/8 3-47/64 #10-32 9030

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1 1004063

42052-064OF

N/A

N/A

N/A

REVISIONAUTHORIZATION

DR.

CHKD.

APPD.

DATE

DATE

DATE

E - DOC

LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

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

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

6 9

1

2 3

ConnectingRod Min. Max.

"N"

Standard

Extended

Catalog Number

1494V-RA3

1494V-RA4

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

9-1/8" 21-5/8"

Connecting Rod Installation

Right Hand Operation

Connecting Rod Adjustment Procedure

N

EnclosureWorking Depth

(Flange toMounting Plate)

N - 3"

Front

Install connecting rod in mechanism and thread in clockwise (12) full turns

Place the disconnect handle in the "OFF" position. Insert the ears of rod into the primary link of the handle and install the hitch pin as shown below

4 5"ON" Position

a) Move disconnect handle to the "ON" position.

b) If switch does not fully close, return handle to "OFF" position.

c) Remove hitch pin and disengage the connectiong rod from the primary link.

d) Turn connecting rod counter-clockwise (1) full turn.

e) Re-engage connecting rod in primary link of handle, insert hitch pin and re-test

f) Repeat 4a - 4e as necessary.

"OFF" Position

g) Move disconnect handle to the "OFF" position.

h) If switch does not fully open, return handle to "ON" position.

j) Remove hitch pin and disengage the connectiong rod from the primary link.

k) Turn connecting rod clockwise (1) full turn.

l) Re-engage connecting rod in primary link of handle, insert hitch pin and re-test

m) Repeat 5g - 5l as necessary.

(6)

1004063

AlignArrows

Auxiliary Contact Installation

Click

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1

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REVISIONAUTHORIZATION

DR.

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

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

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

7 9

6

Left Hand Operation

7

1 2

Place the disconnect handle in the "ON" position. Insert the ears of rod into the primary link of the handle and install the hitch pin as shown below.

Install connecting rod in mechanism and thread in clockwise (9) full turns.

(7)

Connecting Rod Adjustment Procedure

8 9"ON" Position

a) Move disconnect handle to the "ON" position.

b) If switch does not fully close, return handle to "OFF" position.

c) Remove hitch pin and disengage the connectiong rod from the primary link.

d) Turn connecting rod counter-clockwise (1) full turn.

e) Re-engage connecting rod in primary link of handle, insert hitch pin and re-test

f) Repeat 4a - 4e as necessary.

"OFF" Position

g) Move disconnect handle to the "OFF" position.

h) If switch does not fully open, return handle to "ON" position.

j) Remove hitch pin and disengage the connectiong rod from the primary link.

k) Turn connecting rod clockwise (1) full turn.

l) Re-engage connecting rod in primary link of handle, insert hitch pin and re-test

m) Repeat 5g - 5l as necessary.

Important: Before installing auxiliary contact, disconnect switch must be in "Off" position.

DISCONNECT SWITCH AND ACCESSORYINSTALLATION INSTRUCTION SHEET

1 1004063

42052-064OF

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LOCATION: MILWAUKEE, WISCONSIN U.S.A.

B-vertical.ai

DWG.SIZE

SHEET

B

1 2 3 4 5 6 7 8

A

B

C

D

E

F

G

H

REFERENCE

DIMENSIONS APPLY BEFORESURFACE TREATMENT

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

.XX:

.XXX:

ANGLES:

42052

THIS DRAWING IS THE PROPERTY OFROCKWELL INTERNATIONAL CORPORATION

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

ROCKWELL INTERNATIONAL CORPORATION

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

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

8 9

Fuse Cover Installation

30 A ... 100 A Non-Fused30 A, 250 V, Class H, R Fuses30 A, 600 V, Class J Fuses60 A, 250 V, Class H, R Fuses60 A, 600 V, Class J Fuses100 A, 600 V, Class J Fuses

100 A, 600 V, Class H, R Fuses

30 A, 600 V, Class H, R Fuses60 A, 600 V, Class H, R Fuses100 A, 250 V, Class H, R Fuses200 A, 600 V, Class J Fuses

1

1

2

2

42052-064-01 (1)Printed in U.S.A.

200 A

30 A ... 100 A

2

2

200 A Non-Fused100 A, 250 V, Class H, R Fuses100 A, 600 V, Class H, J, R Fuses200 A, 250 V, Class H, R Fuses200 A, 600 V, Class H, J, R Fuses400 A, 600 V, Class J Fuses