Installation Instructions
Bulletin 1494F Disconnect Switch and Accessory Kits for Bulletins 502, 502L,
506, 512, 522, 1232X and 1494G
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.
Disconnect Kit
42052-105-01
DIR 42052-105 (Version 03)
Publication 1494F-IN014C-EN-E - January 2013
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Cat No.
Description
NEMA Starter
Size(s)
1494F-MS400
400 Amp Mechanism
5
1494F-M2
1494F-S2
7-1/2" Painted Metal Handle
7-1/2" Stainless Steel Handle
5
5
1494F-D400
400 Amp Switch
5
1494F-FS400
400 Amp Fuse Block
5
1401-N46
1401-N45
1401-N54
1401-N55
Fuse Clip, Class H, J, 400A - 250V, 400A - 600V
Fuse Clip, Class H, J, 200A-250V, 200A-600V
Fuse Clip, Class R, 200A-250V, 200A-600V
Fuse Clip, Class R, 400A-250V, 400A-600V
5
5
5
5
1494R-N14
Lug Connector: Wire Size (2) #1/0 - 250 MCM
5
1494R-N15
Lug Connector: Wire Size #4 ... 500 MCM
5
1494F-PH5
400 Amp Phase Barrier
5
1495-N68
Fuse Cover with Door
5
2
Bulletin 1494F Disconnect Switch and Accessory Kits
Operating Mechanism and Handle Installation
1
2
2
IMPORTANT: Apply grease to O-Ring
seal to retain into handle groove.
1
60 - 80 lb-in
3
4
8 lb-in
Publication 1494F-IN014C-EN-E - January 2013
42052-105-01 DIR 42052-105 (Version 03)
Bulletin 1494F Disconnect Switch and Accessory Kits
Operating Mechanism and Handle Installation (Cont’d)
5
1
2
Disconnect Switch Installation
1
2
IMPORTANT: Move operating handle to “ON” position
after assembly to ensure the proper engagement of the
disconnect switch cross bar to the handle operating
mechanism.
90 - 130 lb-in
LINE TERMINAL GUARD
Publication 1494F-IN014C-EN-E - January 2013
42052-105-01 DIR 42052-105 (Version 03)
3
4
Bulletin 1494F Disconnect Switch and Accessory Kits
Trailer Fuse Block Installation
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 of
the trailer fuse block.
400 Amp Disconnect Switch
and Trailer Fuse Block on a
NEMA Size 5 Combination Starter
Position 1
Position 2
Position 3
Position 4
Position 5
Position 6
Position
Amps
Voltage
Fuse Class
3
5
1
4
6
2
200
200
200
400
400
400
250
600
600
250
600
600
H/R
H/R
J
H/R
H/R
J
90 - 130 lb-in
Publication 1494F-IN014C-EN-E - January 2013
42052-105-01 DIR 42052-105 (Version 03)
Bulletin 1494F Disconnect Switch and Accessory Kits
5
Phase Barrier and Fuse Clip Installation
Amp
Rating
400
Phase Barrier
Catalog Number
1494F-PH5
400 Amp Rating
1
2
1
1
2
2
Click
3
4
200A Clips
16 - 22 lb-in
400A Clips
22 - 37 lb-in
2
1
200A Clips
22 - 37 lb-in
400A Clips
40 - 50 lb-in
Publication 1494F-IN014C-EN-E - January 2013
42052-105-01 DIR 42052-105 (Version 03)
Fuse Cover Installation
Cat 1495-N68
Non-Fused
200 A, 250 V, Class H, R Fuses
200 A, 600 V, Class H, J, R Fuses
400 A, 250 V, Class H, R Fuses
400 A, 600 V, Class H, J, R Fuses
1
2
2
1
Click
Testing of Disconnect Switch
1. 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 (counter-clockwise) 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).
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Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication 1494F-IN014C-EN-E - January 2013
42052-105-01
DIR 42052-105 (Version 03)
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
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