O & M Manual for the EATON ATC-300 /900Breaker Based Transfer SwitchInstruction BookletDescriptionPageIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . .Receiving, Handling, and Storage . . . . . . . . . . . .Equipment Description. . . . . . . . . . . . . . . . . . . .Installation and Wiring . . . . . . . . . . . . . . . . . . .Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .Testing and Problem Solving . . . . . . . . . . . . . . .Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .Renewal Parts Guide . . . . . . . . . . . . . . . . . . . .ATC-300 Controlled ATS Quick Start InstructionsIB140042EN.26718283031323335For more information visit: www.eaton.com
Instructional BookletPage 2Effective: May 2015ATC-300/ 900 Breaker Based Transfer SwitchSection 1:WARNING1.1 Preliminary Comments and Safety PrecautionsREAD AND UNDERSTAND THE INSTRUCTIONS CONTAINED HEREINAFTER BEFORE ATTEMPTING TO UNPACK, ASSEMBLE, OPERATE, ORMAINTAIN THIS EQUIPMENT.HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCHENCLOSURES THAT CAN CAUSE DEATH OR SEVERE PERSONALINJURY. FOLLOW PROPER INSTALLATION, OPERATION, AND MAINTENANCE PROCEDURES TO AVOID THESE VOLTAGES.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.Automatic Transfer SwitchECat No:GO his technical document is intended to cover most aspects associated with the installation, application, operation, and maintenanceof the Automatic Transfer Controller (ATC-300) Controlled ATSwith ratings from 30 through 1000 amperes (A). It is provided asa guide for authorized and qualified personnel only. Please refer tothe specific WARNING and CAUTION in Section 1.1.2 before proceeding. If further information is required by the purchaser regarding a particular installation, application, or maintenance activity,please contact an authorized Eaton sales representative or theinstalling contractor.1.1.1 Warranty and Liability InformationNo warranties, expressed or implied, including warranties of fitness for a particular purpose of merchantability, or warranties arising from course of dealing or usage of trade, are made regardingthe 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 PrecautionsPoles: 2Phase: 1Amps:Hertz:22560Volt:Wire:2403All safety codes, safety standards, and/or regulations must bestrictly observed in the installation, operation, and maintenance ofthis device.Figure 1. Typical Automatic Transfer Switch (ATS) EquipmentNameplate.All possible contingencies that may arise during installation, operation, or maintenance, and all details and variations of this equipment do no purport to be covered by these instructions. If furtherinformation is desired by the purchaser regarding a particularinstallation, operation, or maintenance of particular equipment,please contact an authorized Eaton Sales Representative or theinstalling contractor.WARNINGTHE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PROCEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONNELSAFETY AND PROTECTION OF EQUIPMENT FROM DAMAGE. ANEXAMPLE OF A TYPICAL WARNING LABEL HEADING IS SHOWNABOVE TO FAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION. THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERTTO WARNINGS, WHICH APPEAR THROUGHOUT THE DOCUMENT.IN ADDITION, WARNINGS AND CAUTIONS ARE ALL UPPER CASEAND BOLDFACE.CAUTIONCOMPLETELY READ AND UNDERSTAND THE MATERIAL PRESENTED IN THIS DOCUMENT BEFORE ATTEMPTING INSTALLATION,OPERATION, OR APPLICATION OF THE EQUIPMENT. IN ADDITION,ONLY QUALIFIED PERSONS SHOULD BE PERMITTED TO PERFORMANY WORK ASSOCIATED WITH THIS EQUIPMENT. ANY WIRINGINSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE FOLLOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT EQUIPMENT DAMAGE.For more information visit: www.eaton.comIB140042EN
Instructional BookletEffective: May 2015ATC-300/900 Breaker Based Transfer Switch1.2 General InformationTransfer switches are used to protect critical electrical loadsagainst loss of power. The load’s Source 1 power source 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 the two sources. In theevent that power is lost from Source 1, the transfer switch transfers the load to the Source 2 power source. This transfer can beautomatic or manual, depending upon the type of transfer switchequipment being used. Once Source 1 power is restored, the loadis automatically or manually transferred back to the Source 1power source, again depending upon the type of transfer equipment being used (Figure 2).Source 2Page 3source until the Source 2 power source does appear. Conversely,if connected to the Source 2 power source and the Source 2power source fails while the Source 1 power source is stillunavailable, the ATS remains connected to the Source 2 powersource.ATSs automatically perform the transfer function, and includethree basic elements:1. Main contacts to connect and disconnect the load to and fromthe power source.2. A mechanism to transfer the main contacts from source tosource.3. Intelligence/supervisory circuits to constantly monitor the condition of the power sources and thus provide the intelligencenecessary for the switch and related circuit operation.1.2.1 Design ConfigurationThe Eaton ATS is a rugged, compact design that uses moldedcase switches and/or circuit breakers to transfer essential loadsfrom one power source to another (Figures 3 [225-1200 A] and 4[30-150 A]). Molded case switches are mechanically and electrically interlocked to prevent both switching devices from beingclosed at the same time.Source 1LoadFigure 2. Typical Load Transfer Switch (Circuit Breaker Type)Schematic.In ATS equipment, the switch’s intelligence system initiates thetransfer when the Source 1 power fails, falls below, or rises abovea preset voltage. If the Source 2 power source is a standby generator, the ATS initiates generator startup and transfers to theSource 2 power source when sufficient generator voltage is available. When Source 1 power is restored, the ATS automaticallytransfers back and initiates generator shutdown. In the event theSource 1 power source fails and the Source 2 power source doesnot appear, the ATS remains connected to the Source 1 powerIB140042ENFigure 3. Typical Power Panel for 225-1200 A Models (DeadfrontCovers Removed).For more information visit: www.eaton.com
Instructional BookletPage 4Effective: May 2015ATC-300 /900 Breaker Based Transfer SwitchFigure 4. Typical Power Panel for 30-150 A Models (DeadfrontCover Installed).Molded case switches and the associated transfer mechanismsare mounted vertically to save space in the assembly. The compact, vertical configuration uses a positive, metallic transfer andinterlocking system between the molded case switches.The Eaton ATS was designed with easy installation and simplifiedmaintenance in mind. Three main panels compromise the transferswitch design:1. Power panel;2. Voltage selection and transformer panel (if required); and3. Controller.Figure 5. Vertical Design Transfer Switch with the DeadfrontCover in Place Over the Power Panel (225-1200 A).Each panel is independently mounted with interconnecting wiringterminated at the connector receptacles on the ATC-300 Controller. Door or individual panel removal is achieved without disturbing critical connections by removing the connectors from thereceptacles and cutting the wire ties that secure the wires to thedoor.Mounting the enclosure is simple using top and bottom mountingflanges with elongated (teardrop) mounting holes. These mounting holes, along with power panel positioning bolts and pre-tappedinserts, insure proper power panel mounting after the initial enclosure installation or when switching from top to bottom or bottomto top entry. Refer to Section 4 for specific mounting and modification details.Table 1. Withstand RatingsUL 1008 WITHSTAND AND CLOSE-ON RATINGS (kA)SwitchRatingAmperesUL 1008 3-Cycle“Any Breaker” RatingRating When UsedWith Upstream Fuse240 Vac480 Vac600 VacMaximumFuseFuse Rating Type600 Vac30-100150150-225225100100100100656565 (240 Vac)6525252525200400400400J, TJ, TJ, TJ, T200200200200300400600100100100656565 2525254006001200J, TJ, TJ, T2002002008001000656550 50 252516001600LL200200 4 pole 480 Vac are rated 35 kAFor more information visit: www.eaton.comIB140042EN
Instructional BookletEffective: May 2015ATC-300/900 Breaker Based Transfer Switch1.3 ATS Catalog Number IdentificationTransfer 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 isoffered here to initially simplify the process.Example: Catalog Number (circled numbers correspond to positionheadings in Table 2):1 to 2345 to 6789 to 12131415ATV3KDA20225WRUPage 5The catalog number ATV3KDA20225WRU describes an ATS withthe switching devices mounted vertically in the enclosure. Theintelligence represented by the control panel is the ATC-300 .The Eaton Series C Type HKD is used as the switching device andis in the form of a 2-pole molded case switch on each source. Thecontinuous current rating of this equipment is 225 A and applicable at 240 Vac, 60 Hz. The transfer switch equipment is enclosedin a NEMA 3R enclosure and is listed for UL applications.Table 2. Transfer Switch Catalog Number ExplanationPOSITIONS 1 TO 2POSITION 3POSITION 4POSITIONS 5 TO 6BASICDEVICESWITCHING tic Transfer SwitchATVerticalHorizontalPOSITION 7SWITCHING DEVICEARRANGEMENTFixed Mount Molded CaseASwitches Both Power SourcesV1H2ATC-300 ATC-900ControllerPOSITION 8POSITIONS 9 TO 12POSITION 13NUMBEROF LNBHND3POSITION 14ENCLOSURE600 Vac/60 HzEType 12J480 Vac/60 HzXType 3RR240 Vac/60 HzWOpenK150 A – 0150208 Vac/60 HzB225 A – 0225120 Vac/60 HzACircuit Breaker Source 1 Power Source,300 A – 0300220 Vac/50 or 60 Hz GMolded Case Switch Source 2400 A – 0400600 Vac/50 HzKPower Source600 A – 0600415 Vac/50 HzOFourCircuit Breakers Both Power SourcesFixed Mount Molded CaseFixed Mount Molded CaseCD4800 A – 0800401 Vac/50 HzNSwitch Source 1 Power Source,1000 A – 1000380 Vac/50 HzHMolded Case Circuit Breaker1200 A – 1200365 Vac/50 HzZ230 Vac/50 HzMSource 2 Power SourceNotes: 1 Vertical orientation (225-1200 A)2 Horizontal orientation (30-150 A)3 Consult factory for availability.*CSA will only be applied to molded case switches, bothpower sources.1.4 Environmental Conditions1.4.1 SeismicWith proper installation, and by including the appropriate optionalfeature that includes specially designed cleats (optional feature#42), the ATSs have a seismic capability which exceeds the worstcase Zone 4 required levels, per both the Uniform Building Codeand the California Building Code.1.4.2 Operational ConditionsNormally, an ATS is applied indoors in an electrical equipmentroom. In the appropriate enclosure, it can be used for outdoorapplications were the equipment is subject to falling rain, freezingtemperatures, and no greater than 90% humidity (non-condensing). The ambient temperature range for operation is between -20and 70 C (-4 to 158 F).IB140042ENFor more information visit: www.eaton.comFDKDLDMDNBNDLISTING30 A – 003070 A – 0070BEaton Series CEaton Series CEaton Series CEatonEatonEaton Series CPOSITION 15100 A – 0100Fixed Mount Molded CaseThree 339*UL/CSA Listing UNo ListingX
Instructional BookletPage 6Effective: May 2015ATC-300/ 900 Breaker Based Transfer Switch1.5 GlossaryWith respect to their use within this document and as theyrelate to transfer switch and controller operation, the following terminology is defined.AvailableA source is defined as “available” when it is within its undervoltage/overvoltage/ underfrequency/overfrequency (if applicable) setpoint ranges for the nominal voltage and frequencysetting.ConnectedConnected is defined as when the input is shorted by anexternal contact or connection.Failed or FailsA source is defined as “failed” when it is outside of the applicable voltage and frequency setpoint ranges for the nominalvoltage and frequency setting for a time exceeding 0.5 seconds after the time delay emergency fail (TDEF) time delaysexpires.FailsafeFailsafe is a feature that prevents disconnection from the onlyavailable power source and also forces a transfer or re-transfer operation to the only available power source.Re-TransferRe-transfer is defined as a change of the load connectionfrom the Source 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, emergency power 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 frequencysetting.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 frequencysetting for a time exceeding 0.5 seconds after the Time DelayEmergency Fail (TDEF) time delay expires.TransferTransfer is defined as a change of the load connection fromthe Source 1 to the Source 2 power source, except whenspecifically used as “Transfer to Neutral”.Transfer to NeutralTransfer to Neutral is defined as when the load circuits aredisconnect from both the Source 1 and Source 2 powersources.UnconnectedUnconnected is defined as when the input is not shorted byan external contact or connection.Section 2:StorageReceiving, Handling, and2.1 ReceivingEvery effort is made to ensure that the ATS equipmentarrives at its destination undamaged and ready for installation. Packing is designed to protect internal components aswell as the enclosure. Care should be exercised, however, toprotect the equipment from impact at all times. Do notremove the protective packaging until the equipment is readyfor installation.When the ATS equipment reaches its destination, the customer should inspect the shipping container for any obvioussigns of rough handling and/or external damage that occurredduring transportation. Record any external and internal damage for reporting to the transportation carrier and Eaton, oncea thorough inspection is complete. All claims should be asspecific as possible and include the Shop Order and GeneralOrder numbers.A shipping label affixed to the shipping container includes avariety of equipment and customer information, such as General Order Number and Customer Number. Make certain thatthis information matches other shipping paper information.Each transfer switch enclosure is bolted through its top andbottom mounting flanges to a rigid wooden pallet. The palletis open at two ends for movement by a forklift. Heavy-dutycardboard sides surround the enclosure and are further supported with reinforced cardboard corner posts. An egg cratedesign cardboard protector covers the entire top of the enclosure with additional cardboard protectors over the indicatinglight panel and operating handle. A heavy-duty cardboard lidcovers the entire opening. The shipment is secured and further protected with shrink-wrap. Do not remove or discardthe packing material until the equipment is ready for installation.Once the top packaging is removed from the shipment, theenclosure door can be opened. A plastic bag of documentswill be found in the enclosure, usually attached to the insideof the door. Important documents, such as test reports, wiring diagrams, and appropriate instruction leaflets, areenclosed within the bag and should be filed in a safe place.2.2 HandlingAs previously mentioned, ATS equipment is packaged forforklift movement. Protect the equipment from impact at alltimes and DO NOT double stack.Once the equipment is at the installation location and readyto be installed, packaging material can be removed and discarded. Once the enclosure is unbolted from the wooden pallet, it can be hand moved to its installation position. Becareful not to damage the top or bottom enclosure mountingflanges. Refer to Section 4 of this manual for specific installation instructions.For more information visit: www.eaton.comIB140042EN
Instructional BookletEffective: May 2015ATC-300/900 Breaker Based Transfer Switch2.3 StorageSection 3:Although well packaged, this equipment is not suitable for outdoorstorage. The equipment warranty will not be applicable if there isevidence of outdoor storage. If the equipment is to be storedindoors for any period of time, it should be stored with its protective packaging material in place. Protect the equipment at alltimes from excessive moisture, construction dirt, corrosive conditions, and other contaminants.3.1 GeneralIt is strongly suggested that the package-protected equipment bestored in a climate-controlled environment with temperatures from-30 to 85 C (-22 to 185 F) and with a relative humidity of 80%or less. DO NOT, under any circumstance, stack other equipmenton top of a transfer switch equipment enclosure, whether packaged or not.3. The microprocessor-based Controller.Page 7Equipment DescriptionThe ATS consists of three basic panels:1. The power panel;2. The voltage selection and transformer panel; andThese panels are interconnected via connector plugs and mountedin an enclosure (Figure 6).POWER PANELCONTROLLERVOLTAGE SELECTIONAND TRANSFORMERPANELFigure 6. Three Basic Panels of the ATS (225-1200 A).3.2 Power PanelThe power panel is used for making load, power, and neutral connections. The main contacts and the transfer mechanism are allon one steel frame (Figures 7 and 8).IB140042ENFor more information visit: www.eaton.com
Instructional BookletPage 8Effective: May 2015ATC-300/ 900 Breaker Based Transfer Switch3.2.1 Steel Base PlateThe steel base plate design (225-1200 A models only) permits thepower panel to be moved vertically within the enclosure to accommodate top or bottom cable entry. Elongated holes on either sideof the base plate ensure proper positioning. The bottom set ofelongated holes positions the power panel higher in the enclosure,thus permitting bottom cable entry. The top set of elongatedholes positions the power panel lower in the enclosure for topcable entry. Section 4 discusses equipment mounting and loadlug location in detail.3.2.2 Main ContactsThis ATS incorporates Eaton-type molded case switches. Themain contacts connect and disconnect the load to and from thedifferent power sources. High-withstand molded case switchesare the main contacts for the Source 1 and Source 2 powersources in standard switch ATSs (Figure 9 and Section 3.7).These continuous duty transfer switches are rated for all classesof loads, open or enclosed
ated with the installation, application, operation, and maintenance of the Automatic Transfer Controller (ATC-300) Controlled ATS with ratings from 30 through 1000 amperes (A). It is provided as a guide for authorized and qualified personnel only. Please refer to
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