1 Cutler-Hammer I.B. ATS-RT03 Instructions for Cutler-Hammer Residential Automatic Transfer Switch Effective March, 1999 Supersedes I.B. ATS-RT02 dated October, 1998
3 I.B. ATS-RT03 Page iii! WARNING READ AND UNDERSTAND THE INSTRUCTIONS CONTAINED HEREINAFTER BEFORE ATTEMPTING TO UNPACK, ASSEMBLE, OPERATE OR MAINTAIN THIS EQUIPMENT. HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCH ENCLOSURES THAT CAN CAUSE DEATH OR SEVERE PERSONAL INJURY. FOLLOW PROPER INSTALLATION, OPERATION AND MAINTENANCE PROCEDURES TO AVOID THESE VOLTAGES. TRANSFER SWITCH EQUIPMENT COVERED BY THIS INSTRUCTION BOOK IS DESIGNED AND TEST- ED TO OPERATE WITHIN ITS NAMEPLATE RAT- INGS. OPERATION OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL RESULTING IN DEATH, SERIOUS BODILY INJURY AND/OR PROPERTY DAMAGE. ALL RESPONSIBLE PERSON- NEL SHOULD LOCATE THE DOOR MOUNTED EQUIPMENT NAMEPLATE AND BE FAMILIAR WITH THE INFORMATION PROVIDED ON THE NAME- PLATE. A TYPICAL EQUIPMENT NAMEPLATE IS SHOWN IN FIGURE 1. Automatic Transfer Switch Cutler-Hammer E Cat No: RTHEFDA20100WSU 9/95 GO No: 1/1 Item: 1 Poles: 2 Amps: 100 Volt: 240 Phase: 1 Hertz: 60 Wire: 3 Figure 1 Typical Automatic Transfer Switch Equipment Nameplate All possible contingencies which 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 further information is desired by purchaser regarding his particular installation, operation or maintenance of particular equipment, contact a Cutler-Hammer representative.
4 Page iv I.B. ATS-RT03 TABLE OF CONTENTS SECTION 1: INTRODUCTION Page 1.1 Preliminary Comments and Safety Precautions Warranty and Liability Information Safety Precautions General Information Design Configuration Transfer Switch Catalog Number Identification...2 SECTION 2: RECEIVING, HANDLING AND STORAGE 2.1 Receiving Handling Storage...4 SECTION 3: EQUIPMENT DESCRIPTION 3.1 Introduction Options Standards...5 SECTION 4: INSTALLATION AND WIRING 4.1 General Mounting Location Mounting Procedure Power Cable Connections Wiring Installation Engine Start Connection Preliminary Checks...9 SECTION 5: FUNCTIONAL TESTING 5.1 Preliminary Checks Energize the Switch Operational Checks...12
5 I.B. ATS-RT03 Page v SECTION 6: TESTING AND PROBLEM SOLVING Page 6.1 General Plant Exerciser Timer Timer Programming Timing Delays...13 SECTION 7: MAINTENANCE 7.1 Introduction Procedures...14
6 Page vi I.B. ATS-RT03 LIST OF FIGURES Figure Title Page 1-1 Typical Load Transfer Switch (circuit breaker type) Schematic Typical Residential Automatic Transfer Switch Dimensions and Plan View of Residential Automatic Transfer Switch (30-150A) Dimensions and Plan View of Residential Automatic Transfer Switch (200A) Typical installation of a residential or light duty automatic transfer switch Diagram of Typical Installation Plant Exerciser Timer Panel-mounted Timing Relay Wiring Diagram for Residential Automatic Transfer Switch VAC Application Wiring Diagram for Residential Automatic Transfer Switch VAC Applications...16 LIST OF TABLES Table Title Page 1.1 Transfer Switch Catalog Number Explanation Wire Size for Automatic Transfer Switch Periodic Maintenance Procedures...17
7 I.B. ATS-RT03 Page 1 SECTION 1: INTRODUCTION 1.1 PRELIMINARY COMMENTS AND SAFETY PRECAUTIONS This technical document is intended to cover most aspects associated with the installation, application, operation and maintenance of the Residential Automatic Transfer Switch. It is provided as a guide for authorized and qualified personnel only. Please refer to the specific WARNING and CAUTION in Section before proceeding. If further information is required by the purchaser regarding a particular installation, application or maintenance activity, a Cutler-Hammer representative should be contacted WARRANTY AND LIABILITY INFORMATION No 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 regarding the information, recommendations and descriptions contained herein. In no event will Cutler-Hammer be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information and descriptions contained herein SAFETY PRECAUTIONS COMPLETELY READ AND UNDERSTAND THE MATE- RIAL PRESENTED IN THIS DOCUMENT BEFORE ATTEMPTING INSTALLATION, OPERATION OR APPLICATION OF THE EQUIPMENT. IN ADDITION, ONLY QUALIFIED PERSONS SHOULD BE PERMIT- TED TO PERFORM ANY WORK ASSOCIATED WITH THE EQUIPMENT. ANY WIRING INSTRUCTIONS PRE- SENTED IN THIS DOCUMENT MUST BE FOLLOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT EQUIPMENT DAMAGE. 1.2 GENERAL INFORMATION Transfer switches are used to protect critical electrical loads against loss of power. The load s normal power source is backed up by a secondary (emergency) power source. A transfer switch is connected to both the normal and emergency power sources and supplies the load with power from one of these two sources. In the event that power is lost from the normal power source, the transfer switch transfers the load to the secondary (emergency) power source. Transfer can be automatic or manual, depending upon the type of transfer switch equipment being used. Once normal power is restored, the load is automatically or manually transferred back to Normal Source! CAUTION Emergency Source All safety codes, safety standards and/or regulations must be strictly observed in the installation, operation and maintenance of this device.! WARNING THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PROCEDURAL STEPS IN THIS DOCU- MENT ARE FOR PERSONNEL SAFETY AND PRO- TECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE OF A TYPICAL WARNING LABEL HEAD- ING IS SHOWN ABOVE TO FAMILIARIZE PERSON- NEL WITH THE STYLE OF PRESENTATION. THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERT TO WARNINGS, WHICH APPEAR THROUGH- OUT THE DOCUMENT. IN ADDITION, CAUTIONS ARE ALL UPPER CASE AND BOLDFACE. Load Figure 1-1 Typical Load Transfer Switch (circuit breaker type) Schematic
8 Page 2 I.B. ATS-RT03 the normal power source, again depending upon the type of transfer equipment being used (Figure 1-1). In automatic transfer switch equipment, the switch s intelligence system initiates the transfer when normal power fails or falls below a preset voltage. If the emergency power source is a standby generator, the transfer switch initiates generator starting and transfers to the emergency power source when sufficient generator voltage is available. When normal power is restored, the transfer switch automatically transfers back and initiates engine shutdown. In the event the normal power source fails and the emergency power source does not appear, the automatic transfer switch remains connected to the normal power source until the emergency power source does appear. Conversely, if connected to the emergency power source and the emergency power source fails while the normal power source is still unavailable, the automatic transfer switch remains connected to the emergency power source. Automatic transfer switches automatically perform the transfer function, and include three basic elements: (1) Main contacts to connect and disconnect the load to and from the source of power. (2) A mechanism to make the transfer of the main contacts from source to source. (3) Intelligence/supervisory circuits to constantly monitor the condition of the power sources and thus provide the intelligence necessary for the switch and related circuit operation DESIGN CONFIGURATION The Cutler-Hammer transfer switch is a rugged, compact design that utilizes molded case switches to transfer essential loads from one power source to another (Figure 1-2). Molded case switches are interlocked to prevent both switches from being closed at the same time. Mounting the enclosure is simple using top and bottom mounting flanges with elongated mounting holes. 1.3 TRANSFER SWITCH CATALOG NUMBER IDEN- TIFICATION Transfer switch equipment catalog numbers provide a significant amount of relevant information pertaining to a specific piece of equipment. The Catalog Number Identification Table (Table 1.1) provides the required interpretation information. An example is offered to initially simplify the process. Example: Catalog Number (circled numbers correspond to position headings in Table 1.1) ➀ to ➁➂ ➃ ➄ to ➅ ➆ ➇ ➈ to ➉ RT H E FD A B S U Table 1.1 Transfer Switch Catalog Number Explanation Positions 1-2 Position 3 Position 4 Positions 5-6 Basic Switching Device Control Switching Device Orientation Panel Device Residential RT Horizontal H Electromechanical E HFD Cutler-Hammer Series C FD Position 7 Position 8 Positions 9-12 Position 13 Position 14 Position 15 Switching Device Number Ampere Voltage/ Arrangement of Poles Rating Frequency Enclosure Listing Fixed Mount Molded Case A Two 2 ➀ 30A VAC/60Hz A NEMA 1 S UL Listed U Switches Three 3 ➁ 70A VAC/60Hz B NEMA 3R R 100A VAC/60Hz W 150A A 0200 ➀ ➁ Only available with 120 or 240 volt systems (60 Hz Only) Only available with 208 volt systems (60 Hz Only)
9 I.B. ATS-RT03 Page 3 The catalog number RTHEFDA30100BSU describes an automatic transfer switch with the switching devices mounted horizontally in the enclosure. The intelligence represented by the control panel is electromechanical logic. The frame is for 100 amp service, and the switch is a 3-pole, fixed mount molded case switch. The continuous current rating of this equipment is 100 amperes and applicable at 208 VAC, 60Hz. The transfer switch equipment is enclosed in a NEMA 1 enclosure and listed for UL applications. Figure 1-2 Typical Residential Automatic Transfer Switch (30-150A)
10 Page 4 I.B. ATS-RT03 SECTION 2: RECEIVING, HANDLING, AND STORAGE 2.1 RECEIVING Every effort is made to ensure that the transfer switch equipment arrives at its destination undamaged and ready for installation. Packing is designed to protect internal components as well as the enclosure. Care should be exercised, however, to protect the equipment from impact at all times. Do not remove protective packaging until the equipment is ready for installation. When transfer switch equipment reaches its destination, the customer should inspect the shipping container for any obvious signs of rough handling and/ or external damage that occurred during transportation. Record any external and internal damage for reporting to the transportation carrier and Cutler-Hammer, once a thorough inspection is complete. All claims should be as specific as possible and include Shop Order and General Order numbers. A shipping label affixed to the shipping container includes a variety of equipment and customer information, such as General Order number and Customer Number. Make certain that this information matches other shipping paper information. Each transfer switch enclosure is bolted through its top and bottom mounting flanges to a rigid wooden pallet. The pallet is open at two ends for movement by a forklift. Heavy duty cardboard sides surround the enclosure and are further supported with reinforced cardboard corner posts. An egg crate design cardboard protector covers the entire top of the enclosure with additional cardboard protectors over the indicating light panel and operating handle. A heavy duty cardboard lid covers the entire opening. The shipment is secured and further protected with shrink wrap. Do not discard the packing material until the equipment is ready for installation. Once the top packaging is removed from the shipment, the enclosure door can be opened. A plastic bag of documents will be found in the enclosure, usually attached to the inside of the door. Important documents, such as test reports, wiring diagrams, appropriate instruction leaflets and a warranty registration card, are enclosed within the bag and should be filed in a safe place. 2.2 HANDLING As previously mentioned, transfer switch equipment is packaged for forklift movement. Protect the equipment from impact at all times and do not double stack. Once the equipment is in the installation location and ready to be installed, packaging material can be removed. Once the enclosure is unbolted from the wooden pallet, it can be hand moved to its installation position. Be careful not to damage the top or bottom enclosure mounting flanges. Refer to Section 4 of this manual for specific installation instructions. 2.3 STORAGE Although well packaged, this equipment is not suitable for storage outdoors. The equipment warranty will not be applicable if there is evidence of outdoor storage. If the equipment is to be stored indoors for any period of time, it should be stored with its protective packaging material in place. Protect the equipment at all times from excessive moisture, construction dirt, corrosive conditions, and other contaminants. It is strongly suggested that the package-protected equipment be stored in a climate-controlled environment of -20 C to 65 C with a relative humidity of 80 percent or less. Do not under any circumstance, stack other equipment on top of a transfer switch equipment enclosure, whether packaged or not.
11 I.B. ATS-RT03 Page 5 SECTION 3: EQUIPMENT DESCRIPTION 3.1 INTRODUCTION The Cutler-Hammer Residential Automatic Transfer Switch is assembled and tested at the factory. It is designed to be used in conjunction with standby power distribution equipment to provide an alternate source of power to critical circuits in the event that a primary power source is interrupted. This switch monitors both normal and standby power sources and automatically transfers critical load circuits between the two sources depending upon which source is available. The normal source is preferred and will remain connected to the switch if it is available. 3.2 OPTIONS A variety of switch options are available to meet a wide variety of application requirements. Individual options or option combinations permit a switch to be tailored to individual needs. Options are numbered with an associated description. More detailed selections that must be made within a specific option are lettered. 1. Time Delay Normal to Emergency (TDNE) This option delays the transfer from the normal power source to the emergency power source in order to override momentary normal power source outages and/or fluctuations. Timing begins when the emergency power source becomes available. It does not affect initiation of the engine start circuit. Should the normal power source fail, the engine start contact will immediately close and, if connected to an engine generator, will initiate an engine start-up. The timer is user-adjustable from 3 seconds to 60 seconds. This option is labeled TDNE. 2. Time Delay on Engine Starting (TDES) This option is used only where the emergency power source is an engine generator. It delays initiation of the engine start circuit in order to override momentary normal power source outages and/or fluctuations. It does not affect the ability of the transfer switch to transfer from the normal power source to the emergency power source. The timer is user adjustable from 0.5 seconds to 15 seconds. This option is labeled TDES. 2B. Adjustable 0.5 to 15 seconds 2C. Adjustable 4 to 120 seconds 3. Time Delay Emergency to Normal (TDEN) This option delays transfer from the emergency power source to the normal power source to allow the normal power source to stabilize before the transfer is initiated. Timing begins when the normal source becomes available. If the emergency power source fails during timing, the time delay is overridden and an immediate transfer to the normal power source will occur. The timer is useradjustable from 24 seconds to 480 seconds. This option is labeled TDEN. 5D. Under Voltage Sensing for Emergency Source This option enables the logic to constantly monitor the emergency power source. The logic prevents transfer from normal power source to the emergency power source until the emergency power source has reached an acceptable operating voltage. 23. Plant Exerciser A digital 7-day timer provides automatic testing at preselected intervals at least once each week. 23C. Without load interruption 23D. By simulation of power failure 3.3 STANDARDS Cutler-Hammer transfer switch equipment enclosed in a NEMA 1 enclosure is listed for application by UL and UL-C. In addition, Cutler-Hammer automatic transfer switches are listed in File E38116 by Underwriters Laboratories, Inc. under Standard UL This standard covers requirements for automatic transfer switches intended for use in ordinary locations to provide lighting and power as follows: a. In emergency systems, in accordance with articles 517 and 700 in the National Electrical Code, ANSI/NFPA 70 and the National Fire Protection Association No. 76A and/or b. In standby systems, in accordance with article 702 of the National Electrical Code and/or c. In legally required standby systems in accordance with article 701 of the National Electrical Code. Cutler-Hammer automatic transfer switches are available to meet NFPA110 for emergency and standby power systems, and NFPA99 for health care facilities when ordered with the appropriate options. Since Cutler-Hammer automatic transfer switches use specially designed molded case switches as the main power switching contacts, these devices must also be listed under the additional UL Standard Underwriters laboratories uses two basic types of listing programs label service and re-examination.
12 Page 6 I.B. ATS-RT03 UL1087 employ a label service listing program which requires an extensive follow-up testing program for listed devices. Standard UL1008 for automatic transfer switches lists devices under the reexamination program which only requires a continual physical reexamination of the components used in the product to ensure consistency with the originally submitted device. Follow-up testing is not required by UL1008. Representative production samples of molded case switches and molded case circuit breakers used in Cutler-Hammer automatic transfer switches are subjected to a complete test program identical to the originally submitted devices on an ongoing periodic basis per UL1087. The frequency of such a re-submittal can be as often as every quarter for a low ampere device. Any failure during one of these periodic re-submittals could result in a loss of the valued UL listing mark.
13 I.B. ATS-RT03 Page 7 SECTION 4: INSTALLATION AND WIRING 4.1 GENERAL Transfer switches are factory wired and tested. Installation requires solidly mounting the enclosed unit and connecting power cables and auxiliary pilot circuits. Physical mounting procedures and power cable connections are covered in this section. Once a transfer switch is properly installed and wired, it should be mechanically and electrically checked for proper installation and operation. The procedures for these initial mechanical and electrical checks are outlined in Section 5 of this instruction manual. 4.2 MOUNTING LOCATION Choose a location that offers a flat, rigid mounting surface capable of supporting the weight of the enclosed transfer switch equipment (Figure 4-1, A or Figure 4-2, 200A). Avoid locations that are moist, hot, or dusty, however, there are enclosure designs available for special environments. If there are any doubts as to location suitability, discuss it with your Cutler-Hammer representative. Check to make certain that there are no pipes, wires, or other mounting hazards in the immediate mounting area that could create a problem..078 (2 mm) 4.84 (123 mm) (0.5m) (0.26 m).078 (2 mm) 4.84 (123 mm) (0.5m) (0.26 m) (0.68m) (0.44m) m) (0.75m) (0.707m) (0.69m) Front View Dimensions Weight 90lbs. (41kg.) 1.25 (38mm).22 (6mm) 7.73 (196mm) 8.35 (212mm) (0.75m) m) Front View Dimensions Weight 100 lbs. (46kg.) 1.25 (38mm).22 (6mm) (211mm) (288mm) Plan View Dimensions Plan View Dimensions Figure 4-1 Dimensions and Plan View of Residential Automatic Transfer Switch (30-150A) Figure 4-2 Dimensions and Plan View of Residential Automatic Transfer Switch (200A)
14 Page 8 I.B. ATS-RT03 Carefully remove all packing material from the transfer switch at the mounting location. Even though an equipment inspection was made when the equipment was received, make another careful inspection of the enclosure and the enclosed transfer switch as packing material is removed and the enclosure readied for mounting. Be especially alert for distorted metal, loose wires or damaged components. 4.3 MOUNTING PROCEDURE! CAUTION EXTREME CARE SHOULD BE TAKEN TO PROTECT THE TRANSFER SWITCH FROM DRILL CHIPS, FIL- INGS AND OTHER CONTAMINANTS WHEN MAKING THE CABLE ENTRY HOLES AND MOUNTING THE ENCLOSURE TO PREVENT COMPONENT DAMAGE OR A FUTURE MALFUNCTION. With the enclosed transfer switch equipment unpacked and ready for mounting, proceed with these steps: Step 1: The transfer switch enclosure door is hinge mounted with removable hinge pins. To simplify the mounting procedure and avoid damage, carefully remove the door and put it in a safe place until mounting is complete. Step 2: Install required mounting bolt anchors and the two upper mounting bolts in the mounting surface. Step 3: Gently lift the enclosure and guide the teardrop-shaped holes in the upper mounting flange over the upper mounting bolts, but do not completely tighten the bolts. Step 4: While still supporting the enclosure, install the two lower mounting bolts in the lower mounting flange, but do not completely tighten. Use shims, if required, to prevent deformation of the enclosure when the mounting surface is distorted. Step 5: Tighten all four mounting bolts after any required shimming is completed. Step 6: Double check to ensure that all packing and shipping material has been removed. 4.4 POWER CABLE CONNECTIONS! WARNING POWER CONDUCTORS MAY HAVE VOLTAGE PRE- SENT THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. DE-ENERGIZE ALL POWER OR CONTROL CIRCUIT CONDUCTORS TO BE CON- NECTED TO THE TRANSFER SWITCH EQUIPMENT BEFORE BEGINNING TO WORK WITH THE CON- DUCTORS AND/OR TERMINATING THEM TO THE EQUIPMENT.! CAUTION USE OF CABLE LUGS, NOT DESIGNED FOR THE TRANSFER SWITCH MAY CAUSE HEATING PROB- LEMS. BREAKER LUGS ONLY MOUNT TO THE BREAKER, WHILE TRANSFER SWITCH LUGS MOUNT TO BOTH THE BREAKER AND THE BUS- BAR BEHIND THE BREAKER. FOR INSTALLATION INSTRUCTIONS, REFER TO THE INSTRUCTION LEAFLET SUPPLIED FOR THE SPECIFIC LUGS.! CAUTION TO HELP PREVENT COMPONENT DAMAGE OR FUTURE MALFUNCTIONS, USE EXTREME CARE TO KEEP CONTAMINANTS OUT OF THE TRANSFER SWITCH EQUIPMENT WHEN MAKING POWER CABLE CONNECTIONS. Test all power cables prior to connection to the unit to ensure that conductors or cable insulation has not been damaged while being pulled into position. Power cables are to be connected to solderless screw type lugs located on the transfer switch switching devices. Verify that the lugs supplied will accommodate the power cables being used. Also verify that the cables Table 4.1 Wire Size for Automatic Transfer Switch Transfer Switch Number of Amp Rating Wire Size Range Cables per Phase #14-3/ #6-300MCM 1
15 I.B. ATS-RT03 Page 9 comply with local electrical codes. Standard transfer switch equipment, as supplied from the factory, will accommodate the wire sizes shown in Table 4.1. Carefully strip insulation from the power cables to avoid nicking or ringing of the conductor strands. Prepare the stripped conductor termination end by cleaning it with a wire brush. If aluminum conductors are used, apply an appropriate joint compound to the clean conductor surface area. IMPROPER POWER CABLE CONNECTIONS CAN CAUSE EXCESSIVE HEAT AND SUBSEQUENT EQUIPMENT FAILURE. Tighten cable lugs to the torque identified on the label affixed to the unit immediately adjacent to the lugs. 4.5 WIRING POWER CONDUCTORS AND CONTROL WIRING MAY HAVE VOLTAGE PRESENT THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. DE-ENER- GIZE ALL POWER OR CONTROL CIRCUIT CONDUC- TORS BEFORE BEGINNING TO PERFORM ANY WIRING ACTIVITY TO OR WITHIN THE TRANSFER SWITCH EQUIPMENT. CHECK THE TRANSFER SWITCH EQUIPMENT NAMEPLATE FOR RATED VOLTAGE. IT SHOULD BE THE SAME AS THE NORMAL AND EMERGENCY LINE VOLTAGES. OPERATING THE EQUIPMENT ON IMPROPER VOLTAGE CAN CAUSE EQUIPMENT DAMAGE. 4.6 INSTALLATION! CAUTION! WARNING! CAUTION In a typical installation (Figure 4-3), the automatic transfer switch (ATS) (1) and the generator (2) are connected to the residential power supply. The ATS (1) and emergency distribution panel (3) receive normal power from a dedicated breaker in the utility service panel (4). The ATS and emergency panel receive emergency power from the generator (2). Power from the utility feeds the utility panel. When normal power fails, the ATS will sense the failure, start the generator, and switch all loads to the emergency panel. All emergency loads will receive power from the generator. A line breaker is required between the emergency source (generator) and the transfer switch (Figure 4-4). When normal power returns, the ATS will switch all power back to the utility and shut down the generator. 4.7 ENGINE START CONNECTION The engine control contact connections are located on the lower right of the intelligence portion of the ATS. NOTE: Prior to making the engine start connection to the switch, set the engine generator controls selector switch in the OFF position to prevent an unwanted engine start. Connect the engine start wires to the red terminal blocks marked 51 and 52. A contact closes between these terminal blocks when an engine start signal is provided by the ATS logic. The wiring diagram (Figure 7-1) provides additional engine start connection information. 4.8 PRELIMINARY CHECKS After the ATS enclosure is installed and power cables are connected to the equipment, thoroughly inspect the unit to ensure that no tools were left inside and that the cabinet is free of debris. If necessary, use a vacuum cleaner to remove any and all construction or installation debris from the equipment. Read and understand all labels on the equipment. Review and understand the wiring diagrams supplied with the equipment. Note any optional accessories that may have been furnished with this unit and review their operation. Verify that the phase-to-phase line voltages of both the normal and emergency power sources are the same and that they match rated voltage as indicated on the ATS ratings label.! CAUTION SEVERE EQUIPMENT DAMAGE CAN RESULT IF UNIT IS NOT APPLIED AT PROPER VOLTAGE. DO NOT ENERGIZE EQUIPMENT IF SUPPLY VOLT- AGES DO NOT MATCH EQUIPMENT RATINGS LABEL. CONTACT THE FACTORY FOR INSTRUC- TIONS TO MODIFY THE VOLTAGE RATING IN THE FIELD.
16 Page 10 I.B. ATS-RT03 Figure 4-3 Typical installation of a residential or light duty automatic transfer switch. The switch (1) and generator (2) are connected to the power supply. The automatic transfer switch is located between the emergency distribution (3) and the utility panel (4)
18 Page 12 I.B. ATS-RT03 SECTION 5: FUNCTIONAL TESTING! WARNING YOU ARE READY TO ENERGIZE THE EQUIPMENT. VOLTAGES WITHIN THE ENCLOSURE ARE CAPA- BLE OF CAUSING SEVERE PERSONAL INJURY OR DEATH. USE EXTREME CAUTION TO AVOID CONTACT WITH ENERGIZED EQUIPMENT. 5.1 PRELIMINARY CHECKS Step 1: Pre-set all time delays (as supplied) as noted in the adjustment instruction (Section 6). Step 2: Check all loads connected the ATS to ensure that they are ready to be energized. 5.2 ENERGIZE THE SWITCH Step 1: Close the upstream normal source breaker or switch to connect the ATS to the normal source voltage. Step 2: If the ATS unit is not already in the NORMAL position, the motorized transfer mechanism will engage and automatically switch to the NOR- MAL position. Step 3: Using a voltmeter, measure line-to-line and line-to-neutral voltages across the normal line terminals to ensure normal voltage is correct.! WARNING CONTACT WITH ENERGIZED COMPONENTS WILL CAUSE ELECTRICAL SHOCK CAPABLE OF PRO- DUCING SEVERE PERSONAL INJURY OR DEATH. USE EXTREME CAUTION TO AVOID CONTACT WITH ENERGIZED COMPONENTS WHEN USING A METER FOR VOLTAGE CHECKS. Step 4: Position the engine control selector switch located on the standby engine generator to the AUTOSTART position. (It may also be labeled REMOTE START.) Step 5: Close the upstream emergency source breaker or switch to connect the ATS to the emergency supply source. 5.3 OPERATIONAL CHECKS Step 1: Open the upstream normal breaker originally closed in Step 2 of Section 5.2. NOTICE This will simulate an interruption of the normal power source. Step 2: After a brief time delay (if the ATS is equipped with Time Delay Engine Start option), the standby engine generator will start. Step 3: If supplied, the ATS Time Delay Normal to Emergency (TDNE) will begin to time after the engine begins to run and the emergency voltage relay picks up (if supplied). After time out (or instantaneously if no TDNE is supplied), the motorized transfer mechanism will engage and automatically switch from the NORMAL to EMERGENCY position. Step 4: Using a voltmeter, measure line-to-line and line-to-neutral voltages across the emergency line terminals to ensure that the emergency voltage is correct. If necessary, make adjustments to the voltage regulator on the generator according to the manufacturer s recommendations to correct any voltage deviations. The ATS will only respond to correct voltage from the emergency source. Step 5: Close the normal breaker described in Step 1. Step 6: If supplied, the ATS Time Delay Emergency to Normal (TDEN) relay will begin timing after a time-out (or instantaneously if no TDEN is supplied), and the motorized transfer mechanism will engage and automatically switch from the EMERGENCY to NORMAL position and the generator will shut down. NOTICE Although not offered as an option on this ATS, some engine generator controls may be equipped with a Time Delay Engine Cool-Off feature that keeps the engine running for a pre-set time after transfer to normal. Contact the generator manufacturer for verification.
19 I.B. ATS-RT03 Page 13 SECTION 6: ADJUSTMENTS 6.1 GENERAL Certain devices, such as the sensing relays and timers, need to be set and/or calibrated prior to placing the transfer switch equipment into service. The devices furnished with the equipment will be the same or similar to those described in this section. Adjustments should be made as instructed for the devices supplied. 6.2 PLANT EXERCISER TIMER Option 23, described in Section 3.5, is a plant exerciser. The plant exerciser is a 7-day timer switch used to exercise the engine driven generator. After power-up, press the Reset button before setting the time or programming. This will clear the memory of all data from testing and handling. 6.3 TIMING DELAYS NOTICE Agastat Time Delay Relays used on Options 1, 2B, 2C, and 3 are adjustable by rotating the dial or via screwdriver adjustment pots (Figure 6-2) TIMER PROGRAMMING The FM/1 digi 20 incorporates a 7-day time base, permitting each day of the week to be uniquely programmed (Figure 6-1). For convenience, Block Programming is also provided. This allows up to seven days to be grouped together if the ON and OFF times are the same. The timer displays in AM/PM format. When setting the hours, attention must be given to whether it is AM or PM. Figure 6-2 Panel-mounted Timing Relay Figure 6-1 Plant Exerciser Timer
20 Page 14 I.B. ATS-RT03 SECTION 7: MAINTENANCE 7.1 INTRODUCTION! WARNING HIGH VOLTAGES ARE PRESENT IN AND AROUND TRANSFER SWITCH EQUIPMENT. BEFORE INSPECTING OR MAINTAINING THIS EQUIPMENT, DISCONNECT LINE POWER FROM THE EQUIPMENT BEING SERVICED BY OPENING AND LOCKING OUT, IF POSSIBLE, THE NEXT HIGHEST DISCON- NECT DEVICE. FAILURE TO FOLLOW THIS PROCE- DURE COULD CAUSE PERSONAL INJURY AND/OR DEATH. In general, transfer switch equipment is designed to be relatively maintenance free under normal usage. However, because of the variability of application conditions and the importance placed on dependable operation by this type of equipment, inspection and maintenance checks should be made on a regularly scheduled basis. Since equipment maintenance will consist mainly of keeping the equipment clean, the frequency of maintenance will depend, to a large extent, on the cleanliness of the surroundings. If a significant amount of dust or foreign matter is present, a more frequent maintenance schedule should be followed. It is suggested that visual inspections of the equipment be made on a regular basis, not just during regularly scheduled periods. Always be alert for an accumulation of dirt in and around the structure, loose parts and/or hardware, cracks and/or discoloration to insulation, and damaged or discolored components. Figures 7-1 and 7-2 are the wiring diagrams for the residential automatic transfer switch. Only qualified and experienced personnel should attempt any diagnostic work using this diagram. 7.2 PROCEDURES A suggested maintenance procedure to follow is outlined in Table 7.1.
21 I.B. ATS-RT03 Page 15 Figure 7-1 Wiring Diagram for Residential Automatic Transfer Switch VAC Applications
22 Page 16 I.B. ATS-RT03 Figure 7-2 Wiring Diagram for Residential Automatic Transfer Switch - Applications VAC
23 I.B. ATS-RT03 Page 17 Table 7.1 Periodic Maintenance Procedures Step Action a. Make transfer switch equipment safe for Disconnect line power from equipment being serviced by inspection and/or maintenance. opening next highest disconnect device. Make certain that any accessory control power is switched off. b. Inspect structure area for safety hazards or Inspect area, especially where molded case switching potential maintenance problems. devices are installed, for any safety hazards, including personnel safety and fire hazards. Exposure to certain chemical vapors can cause deterioration of electrical connections. Inspect for accumulated dirt, loose hardware or physical damage. Examine primary insulation for evidence of cracking or overheating. Overheating will show as discoloration, melting, or blistering of conductor insulation, or as pitting or melting of conductor surfaces due to arcing. Inspect secondary control connections for damage, and control wiring for insulation integrity. c. Inspect molded case switching devices for dust, Remove dust, dirt, soot, grease, moisture and corrosion dirt, soot, grease, moisture or corrosion. contamination from the surface of the switching device using a dry soft lint-free cloth, dry soft bristle brush and vacuum cleaner. Do not blow debris into circuit breaker or nearby breaker structure. If contamination is found, look for the source and fix the problem. d. Check for material integrity, uneven wear, Severe material cracking will require replacement and discoloration or loose hardware. loose hardware will need to be tightened. e. Check terminals and connectors for looseness Overheating will show as discoloration, melting, or or signs of overheating. blistering of conductor insulation. Connections that do not have signs of looseness or overheating should not be disturbed. f. Exercise the molded case switching devices If a switching device is used for frequent switching during if they are not often exercised while in normal operation, this step can be disregarded. operation. This will permit wiping action by the contacts. g. Return transfer switch equipment to service. Make certain all barriers are in place and doors closed. Re-apply secondary and primary power.
24 Page 18 I.B. ATS-RT03
26 I.B. ATS-RT03 This instruction booklet is published solely for information purposes and should not be considered all inclusive. If further information is required, you should consult Cutler-Hammer. Sale of product shown in this literature is subject to terms and conditions outlined in appropriate Cutler- Hammer selling policies or other contractual agreement between the parties. This literature is not intended to and does not enlarge or add to any such contract. The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and Cutler-Hammer. NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PAR- TICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEAL- ING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Cutler-Hammer be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and description contained herein. Cutler-Hammer Moon Township, Pennsylvania U.S.A. (ISI) Style 5715B77H03 Printed in U.S.A.
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