If power is going into a disconnect switch, but power is not coming out of the disconnect switch with the rotary handle in the "On" position, the disconnect switch may not have been assembled properly.
During standard installations, the disconnect switch (portion inside of the control panel) is separated from the rotary handle (portion outside of the control panel). This is done to remove the inner portion to more easily terminate the incoming power wires into the top of the disconnect. The procedure to do this is below. The most common cause of issues is that the rotary handle is not in the "Off" position during step 4, so take everything apart and walk through the complete process from the beginning.
1. Before working on a disconnect switch, ensure that the rotary handle is set to the Off position and the power from the breaker is turned off.
2. Separate the rotary handle from the disconnect switch inside of the control panel by pressing down the orange "upside-down U" piece.
3. Pull the disconnect switch away from the rotary handle and land the incoming L1, L2, and L3 (if applicable) wires on the top of the disconnect.
4. Ensuring that the rotary handle is in the OFF position, reconnect the disconnect switch to the rotary handle and press down on the orange "upside-down U" piece to lock the two components back together.
5. If the rotary handle was not in the OFF position when the disconnect was disassembled or reassembled, it is possible for the shaft on the disconnect to become misaligned. Ensure that the disconnect switch is in the Off position by verifying that the black switch on the side of the disconnect switch is to the left as circled below.
The shaft has one corner that is "shaved" that must be in the upper-right position when reassembling the switch in the Off position.
If the disconnect shaft is misaligned, gently turn it back to the proper orientation with a pair of pliers as shown in the below video. Repeat step 4 once this is done.
Double-check that the receiving hole on the inside of the rotary handle is in the proper orientation as well. The hole should have a "shaved" corner in the upper-left corner to coincide with the "shaved" corner on the upper-right of the disconnect shaft.
6. If the disconnect switch is removed without pressing down on the orange "Upside down U" piece in step 2, it is possible for the shaft on the disconnect switch to be stuck to the inside of the rotary handle as shown in the below picture. Use pliers to remove it from the rotary handle and re-insert it into the disconnect switch, ensuring the proper orientation of the "shaved" corner.
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