Eaton Cutler-Hammer DS200EK1 Auxiliary Contact Kit Instruction Manual

1. Introduction

This manual provides essential information for the safe and effective installation and operation of the Eaton Cutler-Hammer DS200EK1 Auxiliary Contact Kit. This kit is designed as an electrical interlock with a 1 Normally Open (NO) and 1 Normally Closed (NC) contact configuration, intended for use with various switches, excluding 30-100A DG models.

Please read these instructions thoroughly before proceeding with installation or operation to ensure proper functionality and safety.

2. Safety Information

CAUTION: Always turn off power ahead of the switch or device before performing any work on this unit or associated equipment. Failure to do so may result in serious injury or death.

• Ensure all local and national electrical codes are followed during installation.
• Installation should only be performed by qualified personnel.
• Verify that the power source is completely disconnected and locked out before beginning work.
• Use appropriate personal protective equipment (PPE).

3. Setup and Installation

The following steps outline the installation procedure for the DS200EK1 Auxiliary Contact Kit. Refer to the accompanying images for visual guidance.

1. Turn off power: Ensure power to the device is completely off.
2. Switch position: Turn the main switch to the "off" position.
3. Pre-wire the electrical interlock: Connect the necessary wiring to the auxiliary contact kit. Ensure correct polarity for 'IN' and 'OUT' connections (A to A, B to B).
4. Remove line shield: If a line shield is present on the main switch, remove it.
5. Position the interlock: Carefully position the pre-wired electrical interlock into the main switch mechanism. Ensure that control wires are clear and away from moving parts. Tighten the two screws to fasten the interlock securely to the mechanism.
6. Check mechanical operation: Before energizing circuits, manually operate the main switch several times (off, on, off) to verify the mechanical operation of the auxiliary contact. Confirm the kit is installed properly.
7. Replace line shield: If removed in Step 4, replace the line shield.
8. Close cover: Securely close the cover of the main switch enclosure.
9. Apply power: Power can now be safely applied to the system.

Figure 1: Detailed assembly instructions for the DS200EK1 Auxiliary Contact Kit, outlining the nine steps for installation.

Figure 2: Front view of the Cutler-Hammer auxiliary contact kit, showing the 'OUT' and 'IN' terminals (A and B) and the 'MUST BE SAME POLARITY' instruction. Model number NO. 10316H89 is visible, indicating a component within the DS200EK1 kit.

Figure 3: Side view of the auxiliary contact kit, illustrating its physical form factor and mounting bracket, which attaches to the main switch mechanism.

4. Operating Principles

The DS200EK1 Auxiliary Contact Kit functions as an electrical interlock, providing additional contact points (1 Normally Open and 1 Normally Closed) that operate in conjunction with the main switch. When the main switch changes state (e.g., from OFF to ON), the auxiliary contacts also change their state, allowing for control circuit applications such as signaling, interlocking, or remote indication.

• Normally Open (NO) Contact: This contact is open when the main switch is in its default (usually OFF) position and closes when the main switch is operated.
• Normally Closed (NC) Contact: This contact is closed when the main switch is in its default (usually OFF) position and opens when the main switch is operated.

Ensure that the control circuit connected to these auxiliary contacts is designed to handle the specified voltage and current ratings of the kit.

5. Maintenance

The Eaton Cutler-Hammer DS200EK1 Auxiliary Contact Kit is designed for reliable operation with minimal maintenance. However, periodic inspection is recommended to ensure continued performance and safety.

• Visual Inspection: Periodically inspect the auxiliary contact kit and its wiring for any signs of damage, wear, loose connections, or corrosion.
• Connection Integrity: Ensure all screw terminals remain tight. Loose connections can lead to overheating or intermittent operation.
• Cleanliness: Keep the area around the auxiliary contact free from dust, dirt, and moisture, which can interfere with electrical contacts.
• Functional Check: During routine system checks, verify that the auxiliary contacts operate correctly in response to the main switch's action.

WARNING: Always disconnect power before performing any maintenance or inspection.

6. Troubleshooting

If the auxiliary contact kit is not functioning as expected, consider the following troubleshooting steps:

• No Contact Change:
  • Verify that the kit is correctly installed and mechanically engaged with the main switch.
  • Check for any obstructions preventing the auxiliary contacts from operating.
• Intermittent Operation:
  • Inspect all wiring connections for tightness and proper insulation.
  • Check for signs of corrosion or damage on the terminals or contacts.
• Incorrect Polarity:
  • Ensure that the 'IN' and 'OUT' connections (A to A, B to B) are correctly wired as indicated on the unit.
• No Power to Control Circuit:
  • Confirm that the control circuit itself is receiving power and that any associated fuses or circuit breakers are intact.

If issues persist after performing these checks, contact a qualified electrician or Eaton technical support for further assistance.

7. Specifications

Figure 4: Packaging label for the DS200EK1 Auxiliary Contact Kit, confirming the model number and 1 N.O. - N.C. configuration.

Figure 5: Close-up of the packaging label, indicating compatibility with 30-100 A Heavy Duty & Double Throw switches and 200-1200 A General Duty, Heavy Duty & Double Throw switches.

8. Warranty and Support

The Eaton Cutler-Hammer DS200EK1 Auxiliary Contact Kit comes with a warranty to ensure product quality and customer satisfaction.

• Warranty Period: 1 Year from the Date of Installation or 18 Months from the Date of Shipment, whichever comes first.

For technical support, warranty claims, or further inquiries, please contact Eaton customer service or visit the official Eaton website. Ensure you have your product model number (DS200EK1) and purchase details available when seeking support.