Allen-Bradley 1494U-D400 Installation Instructions Manual
The Allen-Bradley 1494U-D400 is a 400A universal disconnect switch designed for various applications. It supports both rod-operated and cable-operated mechanisms, offering flexibility in installation and operation. The switch is compatible with various enclosure types and features a protective cover for added safety. It also integrates with fuses, fuse blocks, and optional accessories like electrical interlocks and auxiliary contacts.
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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.
4
2
TOP HANDLE HOLE
O
THE
MEASURE T
INSIDE OF
TOP OF ENCLOSURE
OF ENCLOSURE
BO
TT
OM HANDLE HOLE
D
3
TOP
O
THE
MEASURE T
INSIDE OF OF ENCLOSURE
TOP OF ENCLOSURE
BO
TT
D
2
Handle Installation
1 Install gasket.
2
5 - 1/2
TOP
5
11
O
THE h or thread
MEASURE T
INSIDE OF ws pr ovided with s h Mounting Holes
Switc
AP-TITE) scre
Center punc forming (T
TT
BO
6-1/2
A
Template (400A)
4 - 3/4 h Hole Location
(Use opposite side f
E inted
U
8-01
(1
4205
.S.A.
6
Center punch and drill
(4) 9/32" dia. holes for thread forming screws provided with switch.
2 Install handle and spring bracket.
90-130 lb-in
10-15 Nm
3 Install defeater lever.
60-80 lb-in
6.8-9.0 Nm
IMPORTANT:
Apply grease to O-Ring to retain into handle groove.
7-11 lb-in
0.79-1.2 Nm
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 cut (2) connecting rods.
3 Remove burrs.
Mounting
Plate
Enclosure
Working Depth
(Inside Flange of Enclosure to
Mounting Plate)
N
N minus 3-3/4
"
Publication 1494U-IN006A-EN-P - March 2018
Universal Disconnect Switch Installation Instructions (400A)
4
Connecting Rod Installation
First rod connects the handle to the switch
1 Verify that disconnect switch and handle are in "OFF" position. (Switch blades will be visible)
Rotate rod to adjust.
Adjust to create minimal gap with spring bracket.
3
4
3
2
Drive Bar
Zero
Clearance
Top View
Rotate connecting rod into drive bar 9-10 turns.
Connecting
Rod
Hitch Pin
6
7
5
Handle Link
8
Second rod provides stiffening for the enclosure flange and mounting panel
11
150-200 lb-in
17-23 Nm
9
Stiffening Rod
10
ATTENTION:
CHECK FOR PROPER OPERATION.
If not operating properly, go to Connecting Rod
Adjustment Procedure.
Publication 1494U-IN006A-EN-P - March 2018
4
1
Universal Disconnect Switch Installation Instructions (400A)
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.
Connecting Rod
3
Attach connecting rod to cable mechanism.
Lubricate
Connecting
Rod
90-130 lb-in
10-15 Nm
9/16"
90-130 lb-in
10-15 Nm 2
1
5/16"
Cable
Mechanism
Lever
Fully seat bolt prior to attaching nut.
Publication 1494U-IN006A-EN-P - March 2018
Universal Disconnect Switch Installation Instructions (400A)
2
Cable Operated Switch Installation
1 Locate Switch. Use template E where desired.
3 Assemble disconnect switch assembly to mounting plate.
2"
5
2
5 - 1/2
TOP
5
11
OF
MEASU h an d d
TITE) scre
(T
AP-
Center punc fo rmi ng
O
E
32
pr
E id s
HOLD
NC or t th
E
LOSURE
BOT
T
6-1/2
A
4
- 3/
4
H an d In
Tem
Loca tion stallation
Dis connect
(U se
Sw itc h
Hole
o ppo sit e si de
fo
RIGHT r le ft h and i
(4
00
A)
E
420
52 -1
U
58
.S
-0
.A
(1
Pr in d
2
Center punch and drill
(4) 9/32" dia. holes for thread forming screws provided with switch.
3
Handle Installation
1 Install gasket.
11"
90-130 lb-in
10-15 Nm
4-3/4"
(4) - 5/16-18 thread forming screws
2 Install handle and mechanism bracket.
10" Diameter Min.
Do not pinch cable.
3 Install defeater lever.
1/2"
60-80 lb-in
6.8-9.0 Nm
(Right Hand
Flange Mounted
Shown)
7-11 lb-in
0.79-1.2 Nm
IMPORTANT:
Apply grease to O-Ring to retain into handle groove.
4
Handle Mechanism Installation
1
Operate disconnect switch and verify that the handle and switch are in the "ON" position.
2
Align connecting rod with handle link.
Connecting
Rod
Handle
Link
Publication 1494U-IN006A-EN-P - March 2018
6 Universal Disconnect Switch Installation Instructions (400A)
3
Handle Mechanism Installation (Cont'd)
3
Install hitch pin clip.
4
Turn disconnect handle "OFF" and install handle mechanism spring.
Hitch Pin Clip
ATTENTION:
CHECK FOR PROPER OPERATION.
Connecting Rod Adjustment Procedure
Adjustment Procedure if switch does not turn "ON".
Adjustment Procedure if switch does not turn "OFF".
rod from the primary link.
pin and re-test.
-
5 as necessary.
from the primary link.
re-test.
-
5 as necessary.
Rod Operated Adjustment Cable Operated Adjustment
Drive Bar
Publication 1494U-IN006A-EN-P - March 2018
Universal Disconnect Switch Installation Instructions (400A)
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.
Holes
14-3/8"
3-3/4"
(4) 9/32" Dia.
Holes
5/16"
Top
Handle
Hole
5-1/2"
Door Catch
Mounting
Bracket
1/2"
1/4"
5-1/2"
6-1/2"
11"
1-5/8" Square corners or up to
1/4" radius
1-3/8"
4-3/4"
7
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
22-37 lb-in
(2.5-4.2 N-m)
Door Catch
Mounting
Bracket
Door Catch
1-1/8"
1-5/8" 1-3/8"
Enclosure
Base
Publication 1494U-IN006A-EN-P - March 2018
8 Universal Disconnect Switch Installation Instructions (400A)
Line Terminal Guard Installation
Assemble and Install Line Terminal Guard
1
LINE
TER
MI
NAL
GU
ARD
2
LIN
E
TERM
INAL
GUA
RD
Lug Installation
1
175-200 lb-in
20-23 Nm
Line Terminal Adapter Installation
Wire Clamp
Adapter
175-200 lb-in
20-23 Nm
Catalog
Number
1494R-
N19
Lug Adapter Kit
Wire
Torque
25 lb-in
(2.8 N-m)
Range
(1) 14-10 STR/SOL
(1) 8 STR
(2) 14 SOL/SOL
(2) 14 STR/STR
(2) 12 SOL/SOL
(2) 12 STR/STR
(2) 10 SOL/SOL
(2) 10 STR/STR
(2) 8 STR/STR
Publication 1494U-IN006A-EN-P - March 2018
Trailer Fuse Block Installation
Trailer Fuse Block Location
(400A Class H, J, R Fuses)
Universal Disconnect Switch Installation Instructions (400A)
Direct Mount Fuse Installation
400A Fuses (Class J Only)
1
Cut phase barriers along line.
9
A
Thread forming screws
4 - 3/4"
200
200
200
200
400
400
400
400
400
Fuse
400 Amp Trailer Fuse Block (1494U-F400)
Torque lb-in
(Nm)
A
Amps Voltage Class Fuse
Clip
Fuse
Block
Lug to
Terminal
Wire into Lug
250
600
600
600
600
250
600
600
600
H/R
H/R
J
HRCII-C
J*
H/R
H/R
J
HRCII-C
7-11/16"
10-3/16"
6-3/8"
6-3/8"
10"
8-11/16"
11-11/16"
7-3/16"
8-11/16"
16-22
(1.8-2.5)
N/A
22-37
(2.5-4.2)
90-130
(10-15)
175-200
(20-23)
275-305
(31-34)
*Direct Mount
2
Publication 1494U-IN006A-EN-P - March 2018
175-200 lb-in
20-23 Nm
10 Universal Disconnect Switch Installation Instructions (400A)
Fuse Clip Installation
400A Fuses (Class H, J, R)
1
200A Fuse Clips
400A Fuse Clips
16-22 lb-in
1.8-2.5 Nm
22-37 lb-in
2.5-4.2 Nm
2
2
200A Fuse Clips
400A Fuse Clips
23-37 lb-in
2.6-4.2 Nm
40-55 lb-in
4.5-6.2 Nm
2
1
1
Protective Cover Installation
1
Punch and drill (4) 11/64" pilot holes.
8-1/2"
11/16"
3-3/8"
2
Install (4) mounting screws to hang cover.
Fasten cover screws.
2
1
23-5/8"
8-1/2"
Publication 1494U-IN006A-EN-P - March 2018
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
Handle
1494F-M2 (7-1/2" Painted Metal) (400A / 600A)
1494F-S2 (7-1/2" Stainless Steel) (400A / 600A)
1494V-RB3 (Standard) (400A / 600A)
Enclosure Working Depth: 9-1/2" to 10"
Connecting
Rod
1494V-RB4 (Extended) (400A / 600A)
Enclosure Working Depth: 9-1/2" to 23"
Set of
(2) rods
Cable
Mechanism
1494U-C44: 4 Ft Cable
1494U-C45: 5 Ft Cable
1494U-C46: 6 Ft Cable
Fuse
Block
1494U-D400
Fuse
Clips
1401-N45 (Class H,J, 200A - 250V, 200A - 600V)
1401-N46 (Class H,J, 400A - 250V, 400A - 600V)
1401-N54 (Class R, 200A - 250V, 200A - 600V)
1401-N55 (Class R, 400A - 250V, 400A - 600V)
Publication 1494U-IN006A-EN-P - March 2018
Bulletin 1494U Disconnect Switch Kit Optional Accessory List
Optional Accessories Catalog Number and Description
Electrical
Interlock
1495-N43 (1-N.O./N.C.)
1495-N44 (2-N.O./N.C.)
Auxiliary
Contact
1495-N8 (1-N.O.)
1495-N9 (1-N.C.)
Copper
Lugs
LUGS (Pkg Qty 3)
1494R-N14
Wire
TYPE TORQUE GAUGE (AWG)
CU ONLY 275 LB-IN (2) 1/0…250 MCM
Aluminum
Lugs
LUGS (Pkg Qty 3)
1494U-LA400
Wire
TYPE TORQUE GAUGE (AWG)
AL / CU 275 LB-IN (2) 1/0…300 MCM
Multiport
Lugs
Line
Terminal
Adapters
LUGS (Pkg Qty 3)
1494U-LM400*
FOR LOAD
SIDE ONLY
Wire
TYPE TORQUE GAUGE (AWG)
AL / CU
35 LB-IN
25 LB-IN
20 LB-IN
(12) 8…4
(12) 8
(12) 14…10
*Special Purpose Not For General Use
1494R-N19
(Pkg Qty 6)
Protective
Cover
1494U-PC400
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.
EEE Yönetmeliğine Uygundur.
Publication 1494U-IN006A-EN-P - March 2018
PN-475448
DIR 10003527458 (Version 00)
Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

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Key features
- 400A current rating
- Suitable for indoor and outdoor use
- Robust construction
- Variety of mounting options
- Easy to install and maintain