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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.
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.
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.
Bulletin 1494F Disconnect Switch and Accessory Kits for Bulletins 502, 502L, 506, 512, 522, 532, 542, 572, 1232X, 1272 and 1282
NEMA Starter
Size(s)
1494F-D301494F-D60
1494F-D1001494F-D200
0 - 1234
30 Amp Switch60 Amp Switch
100 Amp Switch200 Amp Switch
1494F-M11494F-P11494F-S1
0 - 40 - 40 - 4
5-1/2" Painted Metal Handle5-1/2" Molded Handle
5-1/2" Stainless Steel Handle
1494F-FS301494F-FS60
1494F-FS1001494F-FS200
0 - 1234
30 Amp Fuse Block60 Amp Fuse Block
100 Amp Fuse Block200 Amp Fuse Block
1494F-MS361494F-MS1001494F-MS200
0 - 234
30 / 60 Amp Mechanism100 Amp Mechanism200 Amp Mechanism
1495-N501495-N511495-N561495-N57
1494F-PH2
1494F-PH31494F-PH4
30 / 60 Amp Phase Barrier
100 Amp Phase Barrier200 Amp Phase Barrier
0 - 2
34
0 - 34
0 - 34
Fuse CoverFuse Cover
Fuse Cover with DoorFuse Cover with Door
(Included)1494R-N11494R-N21494R-N3
1401-N411401-N42
1401-N431401-N441401-N451401-N501401-N511401-N521401-N531401-N54
0 - 20 - 3
0 - 33-43-40 - 20 - 20 - 23-43-4
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
0-1234
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
Disconnect Kit Catalog No. Description
Bulletin 1494F Disconnect Switch and Accessory Kits2
Publication 1494F-IN012D-EN-E - January 2013 42052-042-01 DIR 42052-042 (Version 04)
Operating Mechanism and Handle Installation
2
65
43
1
23-37 lb-in
7-11 lb-in
1
1
2
3
2
1
3
2
3
3Bulletin 1494F Disconnect Switch and Accessory Kits
Publication 1494F-IN012D-EN-E - January 2013 42052-042-01 DIR 42052-042 (Version 04)
2
3 4
1
22 - 37 lb-in (30A - 100A)40 - 60 lb-in (200A)
Disconnect Switch Installation
LINE TERMINAL GUARD
LINE TERMINAL GUARD
IF PRESENT
DISCARD (2)
THREAD-FORM
SCREWS
Bulletin 1494F Disconnect Switch and Accessory Kits4
Publication 1494F-IN012D-EN-E - January 2013 42052-042-01 DIR 42052-042 (Version 04)
Trailer Fuse Block Installation
2. Tighten the (2) screws to 23 - 37 lb-in (30A - 100A) or 40 - 60 lb-in (200A)
30/60 Amp Disconnect Switch
and Trailer Fuse Block on a
NEMA Size 0…2 Combination Starter
Orientation "A"
(Bottom Holes)
Orientation "B"
(Bottom Holes)
100 Amp Disconnect Switch
and Trailer Fuse Block on a
NEMA Size 3 Combination Starter
Position
161337234
Orientation
BABBAAABB
Amps
3030303060606060
100
Voltage
250600600600250600600600600
Fuse Class
H/RH/R
JHRCII-C
H/RH/R
JHRCII-C
J
Position
216368475
Orientation
BBAAABAAA
Amps
60606060
100100100100200
Voltage
250600600600250600600600600
Fuse Class
H/RJ
H/RHRCII-C
H/RH/R
JHRCII-C
J
200 Amp Disconnect Switch
and Trailer Fuse Block on a
NEMA Size 4 Combination Starter
Position
36115722
Amps
100100100100200200200200
Voltage
250600600600250600600600
Fuse Class
H/RH/R
JHRCII-C
H/RH/R
JHRCII-C
Position 1
Position 2
Position 3
Position 4
Position 5
Position 6
Position 7
Position 8Position 9
Note: Not required for non-fusible disconnect switch applications.
1. Refer to the figures and chart below to determine the position on the mounting plate and the orientation ofthe trailer fuse block.
5Bulletin 1494F Disconnect Switch and Accessory Kits
Publication 1494F-IN012D-EN-E - January 2013 42052-042-01 DIR 42052-042 (Version 04)
Determine which part attaches to the disconnect by referring to the table below and the part number that isimprinted on the side of the phase barrier:
Amp
Rating
30/60100200
Phase Barrier
Catalog Number
1494F-PH21494F-PH31494F-PH4
Part Number
(Attached to Disconnect)
40392-09740392-099
Part Number
(Attached to Fuse Block)
40392-09840392-100
1 2
43
22 - 37 lb-in
Click
Click
Phase Barrier and Fuse Clip Installation (Switch Rating 30, 60 Amp)
11
2
1
2
2
Bulletin 1494F Disconnect Switch and Accessory Kits6
Publication 1494F-IN012D-EN-E - January 2013 42052-042-01 DIR 42052-042 (Version 04)
32
1
54
Click
Click
Phase Barrier and Fuse Clip Installation (Switch Rating 100 Amp)
16 - 22 lb-in
22 - 37 lb-in
1
2
1
2
2
2
1
1
Switch Phase Barrier
600V H - RFuse Clip Size and Class
600V H - R600V H - R250V H - R
60 A100 A200 A200 A
250V H - RFuse Clip Size and Class
600V J250V H - R600V J
60 A60 A100 A100 A
600V J200 A
1
21
2
Trailer Block Phase Barrier
7Bulletin 1494F Disconnect Switch and Accessory Kits
Publication 1494F-IN012D-EN-E - January 2013 42052-042-01 DIR 42052-042 (Version 04)
3 4
Phase Barrier and Fuse Clip Installation (Switch Rating 200 Amp)
1
2
Click 1
2
Click
4
1
3
3
2
16 - 22 lb-in
16 - 22 lb-in
22 - 37 lb-in
42052-042-01DIR 42052-042 (Version 04)
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Publication 1494F-IN012D-EN-E - January 2013
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.
Testing of Disconnect Switch1. Verify that both the disconnect switch and the disconnect handle are in the OFF position. (the disconnect switch can be moved into the OFF position by moving the crossbar downward so that the blades are exposed)
2. To test that the disconnect switch and the mechanism are properly aligned. Verify that the disconnect switch can be turned on by moving the defeater lever downward and moving the disconnect handle to
the ON position (the blades should enter the disconnect switch arc hood).
3. Verify that the disconnect switch can be turned off by moving the disconnect handle to the OFF position (the blades should exit the disconnect switch arc hood).
Fuse Cover Installation
Size 0 - 3
Size 4
200 A, 600 V, Class H, R Fuses
30 A, 60 A, 100 A Non-Fused30 A, 250 V, Class H, R Fuses30 A, 600 V, Class H, R Fuses60 A, 250 V, Class H, R Fuses60 A, 600 V, Class H, R Fuses
100 A, 600 V, Class H, R Fuses100 A, 250 V, Class H, R Fuses200 A, 250 V, Class H, R Fuses200 A, 600 V, Class J Fuses
Cat 1495-N58
Non-Fused
200 A, 250 V, Class H, R Fuses
200 A, 600 V, Class H, J, R Fuses
1
2
2
1
1
1
Click
2
3
3
Click
CONFIDENTIAL AND PROPRIETARY INFORMATION. THIS DOCUMENT CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF
ROCKWELL AUTOMATION, INC. AND MAY NOT BE USED, COPIED OR DISCLOSED TO OTHERS, EXCEPT WITH THE AUTHORIZED WRITTEN
PERMISSION OF ROCKWELL AUTOMATION, INC.
Sheet
Size Ver
Of 11
A 0110000021667Dr. DateG. USHAKOW 3-21-13
SPECIFICATIONS FOR 8 PAGE INSTRUCTION SHEET8-1/2” W x 5-1/2” H - FINAL FOLD
MATERIALSIZE
FOLD
TWO SIDES PRINTEDBODY STOCK WHITE
BODY INK BLACK8-1/2" W x 5-1/2" H
FLAT
17" W x 11" H
Page Layout
8 - 1/2"8 - 1/2"
17" 17"
Front SidePage 1
Back SidePage 2
Front SidePage 8
Back SidePage 7
Front Side
Saddle Stitched Saddle Stitched
Page 3
Back SidePage 4
Front SidePage 6
Back SidePage 5
8 - 1/2"8 - 1/2"
Final Fold
5-1/2”
8-1/2”
11"
Note: After folding---Printed in (Country where printed), part number(s) and barcode (when used) should be visible.
* The printing vendor may change the instruction sheet files to show the correct country.
PN-123456DIR 10000000000 (Version 00)Printed in U.S.A.
BARCODE