O & M Manual For Up To 400 Amps (600 Vac Max) ATC-300 /ATC .

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O & M Manual for up to 400 amps (600 Vac Max)ATC-300 /ATC-900 Contactor Open/Closed Transition Fixedand Dual Drawout Bypass Isolation Automatic Transfer SwitchInstruction BookletDescriptionPageIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Receiving, Handling, and Storage . . . . . . . . . . . . . . .Equipment Description. . . . . . . . . . . . . . . . . . . . . . .Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . .Operation of the Bypass Isolation Transfer Switch . . .Draw-out, Racking-in, and Removal of ATS Contactor .Testing and Problem Solving . . . . . . . . . . . . . . . . . .Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Renewal Parts Guide . . . . . . . . . . . . . . . . . . . . . . . .ATC-300 Controlled ATS Quick Start Instructions . .IB0140018EN. 3. 8. 9.1727313538384042For more information visit: www.eaton.com

Instructional BookletPage 2Effective: March 2015Up to 400 amps (600 Vac Max) ATC-300 /ATC-900 Contactor Open/ClosedTransition Fixed and Dual Drawout Bypass Isolation Automatic Transfer SwitchWARNINGNOTICEREAD AND UNDERSTAND THE INSTRUCTIONS CONTAINED HEREINAFTER BEFORE ATTEMPTING TO UNPACK, ASSEMBLE, OPERATE,OR MAINTAIN THIS EQUIPMENT.WHILE ENERGIZED, AN ARC FLASH AND SHOCK HAZARD EXISTS.CONSULT NFPA 70E, OSHA AND OTHER APPLICABLE REQUIREMENTS PERTAINING TO OPERATOR SAFETY PRIOR TO SERVICINGEQUIPMENT. ALL WORK ASSOCIATED WITH SUCH ELECTRICALEQUIPMENT SHOULD BE PERFORMED ONLY BY A QUALIFIED/COMPETENT PERSON AS DEFINED BY APPLICABLE REGULATION WHOSHOULD ALSO FOLLOW ALL APPLICABLE PROTECTIVE CLOTHINGSYSTEM REQUIREMENTS AND REVIEW APPROPRIATE HAZARDASSESSMENT AND ENERGY CONTROL PRECAUTIONS AND PROCEDURES. FAILURE TO FOLLOW THIS WARNING COULD LEAD TODEATH OR SEVERE INJURY.TRANSFER SWITCH EQUIPMENT COVERED BY THIS INSTRUCTIONBOOK IS DESIGNED AND TESTED TO OPERATE WITHIN ITS NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAYCAUSE THE EQUIPMENT TO FAIL RESULTING IN DEATH, SERIOUSBODILY INJURY, AND/OR PROPERTY DAMAGE. ALL RESPONSIBLEPERSONNEL SHOULD LOCATE THE DOOR MOUNTED EQUIPMENTNAMEPLATE AND BE FAMILIAR WITH THE INFORMATION PROVIDEDON THE NAMEPLATE. A TYPICAL EQUIPMENT NAMEPLATE ISSHOWN IN FIGURE 1.A FINAL INSPECTION OF THE EQUIPMENT SHOULD BE PERFORMEDPRIOR TO ENERGIZING THE TRANSFER SWITCH.Step 1: Remove any dirt or debris that may have collected duringshipment or installation. NEVER use high pressure blowing air. This could drive dirt or other foreign objects intoelectrical or mechanical components which could causedamage. Use an industrial quality vacuum cleaner toremove any dirt or foreign objects.Step 2: Be certain all cable connections are correct and that thephase rotation of both sources match.Step 3: Inspect the engine start connections and verify the correct connection of all control wires.Step 4: Check all programmable setpoints and adjust as necessary. In addition, adjust any optional accessories asrequired.Step 5: Be certain that the actual lug torque values are in keepingwith the requirements outlined in this instruction book toinsure the integrity of power connections.Step 6: Check to be sure that all covers and barriers are properlyinstalled and fastened.Automatic Transfer SwitchSwitchEPoles: 33Poles:Phase: 33Phase:Cat No:CatGO No:GOItemItemBIC8C3X31200XSUBIC 60Volt:Volt:Wire:Wire:9/092/111of11of1ALL POSSIBLE CONTINGENCIES WHICH MAY ARISE DURING INSTALLATION, OPERATION, OR MAINTENANCE, AND ALL DETAILS ANDVARIATIONS OF THIS EQUIPMENT DO NOT PURPORT TO BE COVERED BY THESE INSTRUCTIONS. IF FURTHER INFORMATION ISDESIRED BY THE PURCHASER REGARDING HIS PARTICULAR INSTALLATION, OPERATION, OR MAINTENANCE OF PARTICULAR EQUIPMENT, CONTACT AN EATON REPRESENTATIVE.480480VACVAC44Figure 1. Typical Automatic Transfer Switch EquipmentNameplate.For more information visit: www.eaton.comIB140018EN

Instructional BookletEffective: March 2015Up to 400 amps (600 Vac Max) ATC-300 /ATC-900 Contactor Open/ClosedTransition Fixed and Dual Drawout Bypass Isolation Automatic Transfer SwitchSection 1: IntroductionWARNING1.1 Preliminary Comments and Safety PrecautionsThis technical document is intended to cover most aspects associated with the installation, application, operation, and maintenanceof ATC-900 controlled contactor based transfer switch equipmentwith ratings from usually 100 through 400 amperes (A). It is provided as a guide for authorized and qualified personnel only.Please refer to the specific WARNING and CAUTION in Section1.1.2 before proceeding. If further information is required by thepurchaser regarding a particular installation, application, or maintenance activity, contact an Eaton representative. For informationassociated with the control, refer to the separate instruction bookpertaining to the logic package installed in the switch.1.1.1 Warranty and Liability InformationNo warranties, expressed or implied, including warranties of fitness for a particular purpose of merchant-ability, or warrantiesarising from course of dealing or usage of trade, are made regarding the information, recommendations and descriptions containedherein. In no event will Eaton be responsible to the purchaser oruser in contract, in tort (including negligence), strict liability orotherwise for any special, indirect, incidental or consequentialdamage or loss whatsoever, including but not limited to damage orloss of use of equipment, plant or power system, cost of capital,loss of power, additional expenses in the use of existing powerfacilities, or claims against the purchaser or user by its customersresulting from the use of the information and descriptions contained herein.1.1.2 Safety PrecautionsAll safety codes, safety standards, and/or regulations must bestrictly observed in the installation, operation, and maintenance ofthis device.Page 3THE CLOSED TRANSITION PRODUCT CONTAINS A SPECIAL CONTACT ARRANGEMENT (OVERLAPPING CONTACTS). MISUSE CANRESULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR PROPERTYDAMAGE.1.2 General InformationTransfer switches are used to protect critical electrical loadsagainst loss of power. The Source 1 power source of the load isbacked-up by a Source 2 power source. A transfer switch is connected to both the Source 1 and Source 2 power sources and supplies the load with power from one of these two sources. In theevent that power is lost from the Source 1 power source, thetransfer switch transfers the load to the Source 2 power source.This open transition transfer can be automatic or manual, depending upon the type of transfer switch equipment being used. OnceSource 1 power is restored, the load is automatically or manuallytransferred back to the Source 1 power source, again dependingupon the type of transfer equipment being used (Figure 2).In addition, the closed transition feature may be applied where it isdesirable to avoid any momentary power interruptions. Althoughthe closed transition switch is not a substitute for an uninteruptable power source (UPS), it does eliminate power interruptions toloads except to those caused by power sources or equipmentexternal to the transfer switch. If both sources are acceptable asdetermined by the ATC-900 controller. A make-before-breaktransfer is performed during a transfer test or retransfer operationusing the bypass contactor momentarily.Source 2Source 1WARNINGTHE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PROCEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONNEL SAFETYAND PROTECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLEOF A TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TOFAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION.THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERT TOWARNINGS, WHICH APPEAR THROUGHOUT THE DOCUMENT. INADDITION, CAUTIONS ARE ALL UPPER CASE AND BOLDFACE.CAUTIONDO NOT ATTEMPT TO SERVICE OR PERFORM MAINTENANCE ONEQUIPMENT WHILE IT IS ENERGIZED. FAILURE TO FOLLOW THISWARNING COULD LEAD TO DEATH OR SEVERE INJURY. ALWAYSVERIFY THAT NO VOLTAGE IS PRESENT ON EQUIPMENT PRIOR TOSERVICING. WHILE ENERGIZED, AN ARC FLASH AND SHOCK HAZARD EXISTS. CONSULT NFPA 70E AND OSHA GUIDELINES FOROPERATOR SAFETY PRIOR TO OPERATING, INSPECTING OR SERVICING EQUIPMENT.LoadFigure 2. Typical Load Transfer Switch (Switching Device Type)Schematic. One Three Position, Closed on Source 1, ContactorShown.IB140018ENFor more information visit: www.eaton.com

Instructional BookletPage 4Effective: March 2015Up to 400 amps (600 Vac Max) ATC-300 /ATC-900 Contactor Open/ClosedTransition Fixed and Dual Drawout Bypass Isolation Automatic Transfer Switch1.2.1 Transfer Switch TypesOpen/closed transition bypass isolation type automatic transferswitches consist of four basic elements.1. Main contacts to connect and disconnect the load to and fromthe source of power.2. Intelligence/supervisory circuits to constantly monitor the condition of the power sources and thus provide the intelligencenecessary for the switch and related circuit operation.3. A transfer mechanism to effect the transfer of the main contacts from source to source.4. Voltage selection, bypass selection, and transformer panel.The Fixed Bypass Isolation Switch and the Dual Drawout Switchboth shown in Figure 3 are designed for applications where maintenance, inspection, and testing must be performed while maintaining continuous power to the load. This is typically required incritical life support systems and standby power situations callingfor safe system maintenance with no power disruptions. Such adesign allows for the quick removal of the ATS switching devicesfor inspection, maintenance, or replacement.The Eaton transfer switch is a rugged, compact design utilizingpower contactors to transfer essential loads from one powersource to another. Open transition switching devices are interlocked to prevent both switching devices from being closed at thesame time.The switching devices are in a compact vertical arrangement. Thelogic can be easily disconnected from the switching device without disturbing critical connections. The enclosure is free standing,and is seismic approved. The terminals are mounted in the rear ofthe switch for front access, permitting rear, top, bottom, or sidecable entrance. The terminals also can be mounted on the top orbottom or any assortment of that with the dual draw-out typeswitch.The switching devices have a high withstand rating (Table 1). Figure 4 shows the schematic of the Bypass Isolation Switch. Thereare two contactors that enable the transfer as a bypass in an openor closed transition. The unit can also be operated as a redundantswitch with the controller being full activated with the primary(ATS) or redundant (Bypass) switch. There is not a need to movethe Bypass contactor to the ATS slot if the ATS contactor isremoved for a dual redundant switch to operate. The Bypass (top)will be a switch although only as an open ATS not a closed ATS.1.2.2 Design ConfigurationFigure 3.Typical Fixed Bypass (left) and Dual Drawout with Contactor removed.For more information visit: www.eaton.comIB140018EN

Instructional BookletEffective: March 2015Up to 400 amps (600 Vac Max) ATC-300 /ATC-900 Contactor Open/ClosedTransition Fixed and Dual Drawout Bypass Isolation Automatic Transfer SwitchBYPASSSOURCE 1SOURCE 1AVAILABLERRBYPASSSOURCE 2(4)(3)LOADSOURCE 2AVAILABLEGG(1)ATSSOURCE 1Page 5RED AND GREEN LAMPS(2)ATSSOURCE 2SHOWN ASNORMAL OPERATIONFigure 4. Typical Bypass Isolation Switch Schematic Dual Drawout Shown.Table 1. Fixed Bypass Withstand Ratings.UL 1008 WITHSTAND AND CLOSE-ON RATINGS (KA)400 and below480 VOLTS480 VOLTS600 VOLTS600 eaker30,00050,00022,00035,000200 and belowAt a Test Voltage of 240V the Any Breaker is 35kAFuse test at 600V @ 200KATested in accordance with UL1008.Eaton transfer switch will coordinate with a power switching device short time rating. Contact factory for details.See specific breaker listing for all current breakers listed per rev:7 of UL1008 specification.IB140018ENFor more information visit: www.eaton.com

Instructional BookletPage 6Effective: March 2015Up to 400 amps (600 Vac Max) ATC-300 /ATC-900 Contactor Open/ClosedTransition Fixed and Dual Drawout Bypass Isolation Automatic Transfer Switch1.3 Draw-out Switching Devices1.3.2 Draw-out Switching DevicesThe ATS draw-out switching device is a design having three positions with the compartment door closed (LOCKED IN, ISOLATED,REMOVED). Figure 6 shows the contactor fully disconnected fromthe transfer switch. It is ready for removal. The ATS draw-outswitching device is equipped with both primary and secondary disconnects to provide for the draw-out functioning. The primarycontacts (Figure 7) are the S1, S2, and load contacts. The secondary contacts are the control and feedback contacts. The secondary connector is on the top of the contactor and is somewhatfloating for easy racking-in. The operating mechanism is electrically operated and also has a mechanical operation if required inan emergency. When removed, the ATS switching device can beinspected, tested, and minor maintenance performed. The insideof the compartment can also be inspected with the ATS switchingdevice withdrawn. Caution must be taken as there is voltage onthe run-backs (copper) in the back of the cell once the contactor isremoved.All switching devices are 100% rated, Underwriters Laboratories(UL) 1008 listed, and are built and tested in an ISO 9002 certifiedfacility to applicable NEMA, ANSI, IEEE, and UL standards.The main difference between the ATS and the Bypass versions ofthe switching devices (contactors) used in the bypass isolationtransfer switch is that the Bypass contractor could be fixed withno slides enabling it to be drawn out. Figure 5 shows the two contactors in the switch. The bottom is the ATS contactor and thetop is the bypass contactor. The ATS contactor will do nearly allof the current transfer for the loads during the life of the switch.The ATS contactor switching device is mounted with safety interlocks, in a "slide" mechanism, allowing the switching device to be“drawn-out” for service, maintenance, and/or replacement. TheBypass device is either a fixed type contractor or drawout type.BYPASSWARNINGBYPASSDO NOT ATTEMPT TO PERFORM MAINTENANCE OR SERVICEEQUIPMENT WHILE IT IS ENERGIZED. FAILURE TO FOLLOW THISWARNING COULD LEAD TO DEATH OR SEVERE INJURY. ALWAYSVERIFY THAT NO VOLTAGE IS PRESENT ON EQUIPMENT PRIOR TOSERVICING. WHILE ENERGIZED, AN ARC FLASH AND SHOCK HAZARD EXISTS. CONSULT NFPA 70E AND OSHA GUIDELINES FOROPERATOR SAFETY PRIOR TO SERVICING OR OPERATING EQUIPMENT.ATSATSFigure 6. Draw-out Switching Device Fully Extended (Removed)from the Transfer Switch's Runbacks.Figure 5. Switching Devices Installed in the Transfer Switch,Bypass fixed option shown on top and drawout ATS on thebottom.For more information visit: www.eaton.comIB140018EN

Instructional BookletEffective: March 2015Up to 400 amps (600 Vac Max) ATC-300 /ATC-900 Contactor Open/ClosedTransition Fixed and Dual Drawout Bypass Isolation Automatic Transfer SwitchPage 71.4 Transfer Switch Catalog Number IdentificationSecondary ContactsTransfer switch equipment catalog numbers provide a significantamount of relevant information that pertains to a particular pieceof equipment. The catalog number identification table (Table 2)provides the required interpretation information. An example foran open transition switch is offered to initially simplify the process.Example: Catalog Number (circled numbers correspond to positionheadings in Table 2).1 to 2345 to 6BIC C3789 to 12BI C 9 C3 X 3 0400 X S UOrientationC ContactorEnclosureMechanismSwitchE Draw-outX FixedNumberof Poles2 2 pole3 3 pole4 4 poleLogic3 ATC-300 9 ATC-900Amperes0040 40A0080 80A0100 100A0150 150A0200 200A0225 225A0260 260A0400 400A1.5 Environmental Conditions1.5.1 Operational ConditionsNormally, an ATS is applied indoors in an electrical equipmentroom. In the appropriate enclosure, it can be used for outdoorapplications where the equipment is subject to falling rain, freezing temperatures, and no greater than 90% humidity (non-condensing). The ambient temperature range for operation isbetween -20 and 60 C (-4 to 140 F). A 100 watt heater may berequired for heating or condensation.IB140018EN15X 3 0400 X S UTable 2. Transfer Switch Catalog Number Explanation.C3 3 Position14The catalog number BIC9C3X30400XSU describes a fixed bypassisolation transfer switch with the switching devices mounted vertically in the enclosure. The intelligence, represented by the ATC900 is a microprocessor-based logic package. The contactor isused as the switching device and is a 3-pole for each source. Thecontinuous current rating of this equipment is 400A and is applicable at 480 Vac, 60 Hz. The transfer switch equipment isenclosed in a NEMA 1 enclosure and is listed for UnderwritersLaboratories (UL) and Canadian Standards Association (CSA)applications. Seismic is also qualified.Figure 7. Three Pole Primary Connections on the ATS SwitchingDevice, Secondary Connections on Top.TypeBI BypassIsolationOpenTransitionCB BypassIsolationClosedTransition13For more information visit: www.eaton.comVoltageA 120V, 60HzB 208V, 60HzE 600V, 60HzG 220V, 50HzH 380V, 50HzK 600V, 50HzM 230V, 50HzN 401V, 50HzO 415V, 50HzW 240V, 60HzX 480V, 60HzZ 365V, 50HzS NEMA 1J NEMA 12R NEMA 3RCertificationU UL ListedR UL Recognized

Instructional BookletPage 8Effective: March 2015Up to 400 amps (600 Vac Max) ATC-300 /ATC-900 Contactor Open/ClosedTransition Fixed and Dual Drawout Bypass Isolation Automatic Transfer Switch1.6 GlossarySection 2: Receiving, Handling, and StorageWith respect to their use within this document and as they relateto transfer switch and controller operation, the following terminology is defined.2.1 ReceivingAvailableA source is defined as “available” when it is within its undervoltage/overvoltage/ underfrequency/overfrequency (if applicable) setpoint ranges for the nominal voltage and frequency setting.BypassTo transfer to another contactor, same source, with no powerinterruption.ConnectedConnected is defined as when the input is shorted by an externalcontact or connection.Failed or FailsA source is defined as “failed” when it is outside of the applicablevoltage and frequency setpoint ranges for the nominal voltage andfrequency setting for a time exceeding 0.5 seconds after the timedelay emergency fail (TDEF) time delays expires.FailsafeFailsafe is a feature that prevents disconnection from the onlyavailable power source and also forces a transfer or re-transferoperation to the only available power source.Re-TransferRe-transfer is defined as a change of the load connection from theSource 2 to the Source 1.Source 1Source 1 is the primary source (normal source, normal powersource, or normal).Source 2Source 2 is the secondary source (emergency source, emergencypower source, emergency, standby, or backup source).Source 1: Failed or FailsSource 1 is defined as “failed” when it is outside of its undervoltage/overvoltage/ underfrequency/overfrequency (if applicable) setpoint ranges for the nominal voltage and frequency setting.Source 2: Failed or FailsSource 2 is defined as “failed” when it is outside of its undervoltage/overvoltage/ underfrequency/overfrequency (if applicable) setpoint ranges for the nominal voltage and frequency setting for atime exceeding 0.5 seconds after the Time Delay Emergency Fail(TDEF) time delay expires.TransferTransfer is defined as a change of the load connection from theSource 1 to the Source 2 power source.TripDevice is not connected to Source 1/ or Source 2.Device is open.UnconnectedUnconnected is defined as when the input is not shorted by anexternal contact or connection.Every effort is made to ensure that the transfer switch equipmentarrives at its destination undamaged and ready for installation.Crating and

ated with the installation, appli cation, operation, and maintenance of ATC-900 controlled contactor based transfer switch equipment with ratings from usually 100 through 400 amperes (A). It is pro-vided as a guide for authorized and qualified personnel only. Please refer to the specific WARNING and CAUTION in Section 1.1.2 before proceeding.

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