GenInterlock EAT-CH200A

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Summary

Safety Precautions

General Warning

Emphasizes that only qualified personnel should work on the panel box and follow NEC regulations.

Installation Guide

Step 1: Panel Preparation

Disassemble interlock, place bottom plate above top left breaker and mark holes.

Step 2: Panel Cover Removal

Turn off the main breaker and remove the panel cover.

Step 3: Drilling Holes

Drill holes on the panel cover as marked with a 3/16 drill bit and clean burs.

Step 4: Plate Installation

Install bottom and top plates with screws, thread lock, and retaining nuts.

Step 5: Generator Breaker Installation

Install the 2-pole Generator breaker on the top left and apply the Generator Warning Sticker.

Step 6: Zip Tie Application

Create a loop with zip ties, secure around top breakers, tighten and trim as needed.

Step 7: Final Cover Re-installation

Re-install the panel cover and verify the proper operation of the interlock mechanism.

Step 8: Label Placement

Place the Generator start-up procedure and CAUTION labels on the panel box and meter pan.

Critical Operational Warnings

Do not turn on MAIN and GENERATOR breakers simultaneously; follow safety protocols.

Disclaimer and Support

States disclaimer on misuse/improper installation and provides contact information.

This document describes the installation and operation of the EAT-CH200A generator interlock kit, designed for Eaton / Cutler Hammer 150 and 200 Amp CH Series panels manufactured before 2019. The primary function of this interlock kit is to ensure the safe operation of a generator in conjunction with a main electrical panel by preventing both the main breaker and the generator breaker from being in the "ON" position simultaneously. This is a critical safety feature that prevents backfeeding the utility grid, which can be extremely dangerous for utility workers and can damage electrical equipment. The interlock mechanism physically prevents one breaker from being switched on if the other is already on, thereby enforcing a safe operating procedure.

The kit is specifically designed for main breakers that are 150 or 200 amp single-handle, with a horizontal throw from left (ON) to right (OFF). The generator breaker is intended to be installed in the top left side, occupying two positions within the panel. The installation process is detailed and requires careful attention to ensure proper functionality and safety.

Installation Process:

The installation begins with disassembling the interlock kit. The bottom plate, which has holes, is positioned above the top left breaker. This plate should be parallel to the left top breaker and touch the edge of the right top breaker. These positions are then marked on the panel cover.

Next, it is crucial to turn off the main breaker before proceeding with any further steps. This is a fundamental safety precaution to prevent electrical shock during the installation. Once the main breaker is off, the panel cover can be safely removed.

The marked holes on the panel cover are then drilled using a supplied 3/16 drill bit. After drilling, it is important to remove any burrs from the drilled holes to ensure a smooth surface and proper fit of the interlock components.

The interlock components are then assembled onto the panel cover. Screws are inserted from the rear of the cover, followed by the installation of the bottom plate and then the top plate (which is slotted). Thread lock is applied to the screws, and retaining nuts are installed to secure the components. During this step, it is essential to verify that the interlock mechanism allows for proper movement, ensuring that it can freely slide to engage and disengage the breakers as intended.

A 2-pole generator breaker is then installed in the top left side of the panel. A "Generator Warning Sticker" is placed on this generator breaker to clearly identify its function and associated safety warnings.

To further secure the wiring and maintain an organized panel, zip ties are used. These zip ties are combined to form a loop and are installed around the top set of breakers in the panel, as depicted in the provided images. They are pulled tight around the breakers to secure them, and any excess zip tie material is trimmed. Additionally, a "Warning label" is installed next to the release tab on the zip tie at the generator breaker, reinforcing safety instructions.

Operational Features and Safety:

Once the physical installation is complete, the panel cover is re-installed. Before energizing the system, it is critical to verify the proper operation of the interlock. This involves a series of checks:

Main breaker ON, generator breaker OFF: In this state, the generator breaker CAN NOT be turned on. This confirms that the interlock prevents the generator from being active when the main power is supplied.
Generator breaker ON, main breaker OFF: In this state, the main breaker CAN NOT be turned on. This confirms that the interlock prevents the main power from being active when the generator is supplying power.

It is also important to verify that the inside of the panel cover is not touching any breakers. If there is contact, the panel cover's top and bottom screws should be adjusted to ensure proper clearance.

Finally, a "Generator start-up procedure label" is placed on the panel box, and a "CAUTION label" is placed on the panel box and the electric meter pan. These labels provide crucial information for safe operation and alert users to potential hazards.

Key Usage Features:

The core usage feature of this interlock kit is its ability to enforce a strict safety protocol: the main and generator breakers should NEVER be able to be turned on at the same time. This mechanical interlock is a passive safety device that relies on physical barriers to prevent unsafe conditions.

Maintenance Features:

While the document does not explicitly detail "maintenance features" in the traditional sense (e.g., lubrication schedules), it emphasizes critical aspects related to the ongoing safety and functionality of the device:

Qualified Personnel Requirement: A prominent warning states: "Only qualified personnel should be working on the panel box. An amateur should NEVER open the panel box." This highlights that any inspection, adjustment, or troubleshooting of the interlock or the electrical panel must be performed by individuals with the necessary training and expertise. This is the most significant "maintenance" instruction, as it dictates who is authorized to interact with the device.
Regular Verification: The instruction to "Verify proper operation of interlock" after re-installing the panel cover implies a need for periodic checks. While not explicitly stated as a recurring maintenance task, the initial verification process serves as a model for how one might confirm the continued proper functioning of the interlock over time. Any time the panel cover is removed or the electrical system is serviced, the interlock's functionality should be re-verified.
Immediate Action for Malfunction: A critical instruction states: "If for any reason the interlock does not function properly, DO NOT USE and contact us immediately." This is a crucial maintenance directive. It mandates that if the interlock fails to perform its safety function (i.e., if both breakers can be turned on simultaneously, or if the generator breaker can be turned on with the panel cover removed), the system must be immediately taken out of service, and professional assistance must be sought. This proactive approach prevents potentially dangerous situations.
Adherence to Codes: The instruction to "Please follow all rules and regulations of the National Electric Code" is a broad but essential maintenance and operational guideline. It implies that the installation and ongoing use of the interlock must always comply with current electrical safety standards, which may include requirements for periodic inspections or specific maintenance procedures for electrical equipment.

In summary, the EAT-CH200A generator interlock kit is a vital safety device designed to prevent hazardous conditions when integrating a generator with a main electrical panel. Its installation requires precision and adherence to safety protocols, and its continued safe operation relies on strict adherence to usage guidelines and immediate action if any malfunction is detected, always emphasizing that only qualified personnel should handle electrical work.