Eaton Cutler-Hammer ATC-300 Operation And Maintenance Manual Download Page 4

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IB140042EN

Instructional Booklet

Page

Effective: May 2015

ATC-300 /900 Breaker Based Transfer Switch

Figure 4. Typical Power Panel for 30-150 A Models (Deadfront

Cover Installed).

Molded case switches and the associated transfer mechanisms

are mounted vertically to save space in the assembly. The com-

pact, vertical configuration uses a positive, metallic transfer and

interlocking system between the molded case switches.

The Eaton ATS was designed with easy installation and simplified

maintenance in mind. Three main panels compromise the transfer

switch design:

1. Power panel;

2. Voltage selection and transformer panel (if required); and

3. Controller.

Figure 5. Vertical Design Transfer Switch with the Deadfront

Cover in Place Over the Power Panel (225-1200 A).

Each panel is independently mounted with interconnecting wiring

terminated at the connector receptacles on the ATC-300 Control-

ler. Door or individual panel removal is achieved without disturb-

ing critical connections by removing the connectors from the

receptacles and cutting the wire ties that secure the wires to the

door.

Mounting the enclosure is simple using top and bottom mounting

flanges with elongated (teardrop) mounting holes. These mount-

ing holes, along with power panel positioning bolts and pre-tapped

inserts, insure proper power panel mounting after the initial enclo-

sure installation or when switching from top to bottom or bottom

to top entry. Refer to Section 4 for specific mounting and modifi-

cation details.

Table 1. Withstand Ratings

UL 1008 WITHSTAND AND CLOSE-ON RATINGS (kA)

Switch
Rating
Amperes

UL 1008 3-Cycle

“Any Breaker” Rating

Rating When Used

With Upstream Fuse

240 Vac 480 Vac

600 Vac

Maximum

Fuse Rating

Fuse

Type

600 Vac

30-100

150

150-225

225

100

65 (240 Vac)

200

400

J, T

200

300

400

600

100



400

600

1200

J, T

200

800

1000



1600

200



4 pole 480 Vac are rated 35 kA

Summary of Contents for Cutler-Hammer ATC-300

Page 1: ...ed Transfer Switch Instruction Booklet Description Page Introduction 2 Receiving Handling and Storage 6 Equipment Description 7 Installation and Wiring 18 Operation 28 Testing and Problem Solving 30 Adjustments 31 Maintenance 32 Renewal Parts Guide 33 ATC 300 Controlled ATS Quick Start Instructions 35 ...

Page 2: ... ing a particular installation application or maintenance activity please contact an authorized Eaton sales representative or the installing contractor 1 1 1 Warranty and Liability Information No warranties expressed or implied including warranties of fit ness for a particular purpose of merchantability or warranties aris ing from course of dealing or usage of trade are made regarding the informat...

Page 3: ...wer source when sufficient generator voltage is avail able When Source 1 power is restored the ATS automatically transfers back and initiates generator shutdown In the event the Source 1 power source fails and the Source 2 power source does not appear the ATS remains connected to the Source 1 power source until the Source 2 power source does appear Conversely if connected to the Source 2 power sou...

Page 4: ...0 Control ler Door or individual panel removal is achieved without disturb ing critical connections by removing the connectors from the receptacles and cutting the wire ties that secure the wires to the door Mounting the enclosure is simple using top and bottom mounting flanges with elongated teardrop mounting holes These mount ing holes along with power panel positioning bolts and pre tapped inse...

Page 5: ...ATSs have a seismic capability which exceeds the worst case Zone 4 required levels per both the Uniform Building Code and the California Building Code 1 4 2 Operational Conditions Normally an ATS is applied indoors in an electrical equipment room In the appropriate enclosure it can be used for outdoor applications were the equipment is subject to falling rain freezing temperatures and no greater t...

Page 6: ... made to ensure that the ATS equipment arrives at its destination undamaged and ready for installa tion 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 the protective packaging until the equipment is ready for installation When the ATS equipment reaches its destination the c...

Page 7: ...ent be stored 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 equipment on top of a transfer switch equipment enclosure whether pack aged or not Section 3 Equipment Description 3 1 General The ATS consists of three basic panels 1 The power panel 2 The voltage selection and transfo...

Page 8: ... lug location in detail 3 2 2 Main Contacts This ATS incorporates Eaton type molded case switches The main contacts connect and disconnect the load to and from the different power sources High withstand molded case switches are the main contacts for the Source 1 and Source 2 power sources in standard switch ATSs Figure 9 and Section 3 7 These continuous duty transfer switches are rated for all cla...

Page 9: ...ypical 30 150 A Horizontal Design Transfer Switch Equipment Door Open NORMAL POWER SOURCE SWITCHING DEVICE NORMAL LINE CONNECTIONS MANUAL OPERATOR KNOB BRAKE RELEASE LEVER NEUTRAL BOND FOR SERVICE NEUTRAL ASSEMBLY GROUND CONNECTIONS TRANFER MECHANISM EMERGENCY LINE CONNECTIONS EMERGENCY POWER SOURCE SWITCHING DEVICE PIVOT BOLT LOAD CONNECTIONS ENTRANCE ...

Page 10: ...otational motion is created on an indicator wheel by the ratchet s opera tion The indicator wheel is attached to rigid shafts that convert the rotary motion into vertical linear motion Opening and closing the switching devices is accomplished as a result of this vertical linear motion The transfer mechanism is mounted in front of the molded case switches Figure 6 NORMAL POWER SOURCE MOLDED CASE SW...

Page 11: ...on 3 3 1 North American Voltage Selection 120 208 240 480 and 600 V 60 Hz The North American market voltage selection panel consists of multi tap transformers contained in a steel case mounted in the enclosure Figure 13 The cover has teardrop holes for the screws to allow easy access to the transformers The voltage is selected by simply removing the wires from the default primary taps of both tran...

Page 12: ...ontrollers The Controller panel provides the intelligence and supervisory cir cuits which constantly monitor the condition of both the Source 1 and Source 2 power sources thus providing the required intelli gence for transfer operations see Figures 15A and 15B Detailed information for controller operation is presented in separate docu ments ATC 300 Instruction Book IB01602009E and ATC 900 Instruct...

Page 13: ...ge Overfrequency 5D 26D Phase Undervoltage Adjustable Undervoltage 5E 26E Phase Overvoltage Adjustable Overvoltage 5F 26F 3 Phase Undervoltage Adjustable Undervoltage 5G 26G 3 Phase Overvoltage Adjustable Overvoltage 5H Phase Reversal For a 3 phase wye source this feature monitors the phase sequence of the sources If a source does not have the same ABC or CBA sequence as the setpoint value that so...

Page 14: ...ce 1 Present Provides two 2 normally open and two 2 normally closed contacts The relay is energized when Source 1 is available 14H Source 2 Present Provides two 2 normally open and two 2 normally closed contacts The relay is energized when Source 2 is available 15 Switch Position Indication Contact This feature provides a contact that indicates if the power switching device is in the Open or Close...

Page 15: ... trips on an overcurrent condition then Lockout is displayed on the Automatic Transfer Controller display and automatic operation is prevented until the appro priate source is manually reset 16B Integral Overcurrent Protection on Both Power Source Switching Devices This feature provides integral overcurrent protection on both Source 1 and Source 2 power switching devices 16E Integral Overcurrent P...

Page 16: ... transfer switch 39C Four 200 A Feeder Breakers This feature provides four 4 200 A feeder breakers for the 400 A ATH3 transfer switch 41 Space Heater With Thermostat This feature provides a space heater and non adjustable thermostat External control power is not required 41A Space Heater With Thermostat 100 Watt This feature provides a 100 watt W space heater with a non adjustable thermostat 51xx ...

Page 17: ...I 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 arti cle 701 of the National Electrical Code Eaton ATSs are available to meet NFPA 110 for emergency and standby power systems and NFPA 99 for health care facilities when ordered with...

Page 18: ... enclosure readied for mounting Be especially alert for distorted metal loose wires or damaged components 4 3 Mounting Procedure All vertical design ATS equipment enclosures and power panels are of the same design Only the overall physical dimensions change Note that the enclosure is provided with four teardrop elongated mounting holes two in the top mounting flange and two in the bottom Also noti...

Page 19: ... flange Again do not completely tighten the bolts at this time Use shims if required to prevent deformation of the enclosure if the mounting surface is distorted Step 5 Tighten all four mounting bolts after any required shim ming is completed Figure 18 Typical Mounting of the ATS to a Mounting Surface Step 6 Double check to ensure that all packing and shipping materials have been removed 4 4 Load ...

Page 20: ...ipment Door Open and Deadfront Cover Removed Step 1 Disconnect the power panel from the rest of the transfer switch by unplugging the connector plugs P1 P2 and P3 Figures 20 and 21 NORMAL POWER SOURCE MOLDED CASE SWITCH GROUND CONNECTIONS MANUAL OPERATING HANDLE INDICATOR WHEEL TRANSFER MECHANISM MOTOR BRAKE BOARD EMERGENCY POWER SOURCE MOLDED CASE SWITCH NEUTRAL CONNECTIONS LOAD LUGS TOP ENTRY PO...

Page 21: ...aker Based Transfer Switch Figure 19A 4 Pole Neutral Bond for Service Entrance Step 1 Disconnect the power panel from the rest of the transfer switch by unplugging the connector plugs P1 P2 and P3 Figures 20 and 21 NEUTRAL ASSEMBLY GROUND CONNECTION NEUTRAL BOND FOR SERVICE ENTRANCE NEUTRAL TO NEUTRAL ASSEMBLY JUMPER ...

Page 22: ...ng upon the size of the panel it may be advisable to have assistance with the removal Once the power panel is free carefully move it to a solid work surface Figure 22 Figure 22 Power Panel Removed from the Enclosure with the Transfer Mechanism Removed for Clarity 225 1200 A Models Step 4 Remove the operating mechanism from the front of the power panel by removing the six bolts holding the mecha ni...

Page 23: ...moved previously in Step 4 Step 9 Position the power panel in the enclosure such that the two upper elongated holes one on either side of the power panel fit over the two positioning bolts located in the rear of the enclosure This will line up the four correct mounting holes in the power panel with the pre tapped inserts in the rear of the enclosure Step 10 With the power panel held securely again...

Page 24: ... and wired perform the initial mechanical and electrical procedures as outlined in Sec tion 6 to verify that the equipment is installed and operating prop erly CAUTION TO HELP PREVENT COMPONENT DAMAGE OR FUTURE MALFUNC TIONS USE EXTREME CARE TO KEEP CONTAMINANTS OUT OF THE ATS EQUIPMENT WHEN MAKING POWER CABLE CONNECTIONS CAUTION RUN THE POWER CABLE THROUGH THE GUTTER SPACE PROVIDED TO THE RIGHT O...

Page 25: ...dividual controller instruction booklets for more details The IB s are ATC 300 Instruction Book IB01602009E and ATC 900 Instruction Book IB140012EN A contact closes between these terminal when an engine start signal is provided by the Controller The wiring diagram provides additional engine start connection information Use the proper wire size as listed by the generator set Genset manufacturer Fig...

Page 26: ...ws securing the cover of the Voltage Selection Transformer case Slide the cover up then away from the case Step 2 Remove the wires from the primary taps of both trans formers and installed them on the taps for the desired voltage Figure 25 Note that only one wire per trans former is moved since the second wire is the zero refer ence WHEN CHANGING THE VOLTAGE ONE WIRE MUST BE MOVED ON THE PRIMARY T...

Page 27: ...lamp Terminal Blocks Step 2 Begin by inserting a small flathead screwdriver into the square tool hole with the flat surface of the screwdriver against the back wall of the hole see Figure 28 With a little bit of force push the screwdriver in on a slight angle toward the center of the clamp Be sure to slide it in until it clicks You will then see the clamp open in the wire hole Figure 28 Screwdrive...

Page 28: ...ional motion required to open and close the main contacts through a rigid mechanical interlocking system Figure 32 An indicator wheel attached to the operating handle and mechanical interlock ing system rotates with each movement of the handle to open and or close the main contacts Figures 33 Three distinct switch positions are provided and indicated visually on the indicator wheel Figure 34 Figur...

Page 29: ...operating sequence of an ATS is dictated by the switch s standard features and selected options Operation of an ATS dur ing Source 1 power source failure and Source 1 power source res toration will be described here with only standard options included on the switch Additional options as described in Section 3 can change sequences and timing depending upon the options selected It is strongly sugges...

Page 30: ...ontrols opened as a result of actions taken in Step 4 Section 6 1 2 Step 5 Where required use an accurate voltmeter to check phase to phase and phase to neutral voltages present at the transfer switch Source 1 Source 2 and or load termi nals 6 1 4 Operational Checks Step 1 Check to ensure that the Source 1 switching device is in the CLOSED position This should have been done in Sec tion 6 1 3 Step...

Page 31: ...ON IF AN INDI VIDUAL IS NOT QUALIFIED TO PERFORM THE PROBLEM SOLVING FUNCTION THE INDIVIDUAL SHOULD NOT ATTEMPT ANY OF THESE PROCEDURES Remember only qualified individuals familiar with the ATS equip ment and the system in which it is applied should attempt these problem solving procedures One of the most basic issues is not having the setpoints of the switch in the controller set up cor rectly Se...

Page 32: ...dis connecting all control plugs b Inspect the structure area for safety hazards or potential maintenance problems Inspect the area especially where molded case switching 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 physica...

Page 33: ...ple To order the transformer panel for an ATH3FDA30150XSU transfer switch order Catalog Number as shown in Figures 36 B Figure 36A Typical ATC 300 Controlled Breaker Based ATS REQUIRED TO COMPLETE THE COMPLETE POWER PANEL PLEASE NOTE THE ORIGINAL CATALOG NUMBER OF TRANSFER SWITCH AS IT IS CATALOG NUMBER OF A POWER PANEL EXAMPLE ATV3KDA30300WSU ATH3FDB20200BSU VERTICAL POWER PANEL CAT PPV3KDA30300X...

Page 34: ...AT 68C8097G01 DOMESTIC INTERNATIONAL SWITCH CAT 8160A41G52 AG SWITCH CAT 68C8097G02 AG SWITCH CAT 8160A41G53 DOMESTIC SWITCH ATH3 HORIZONTAL CAT 8885C45G35 DOMESTIC SWITCH ATV3 VERTICAL CAT 8885C45G34 INTERNATIONAL SWITCH ATH3 HORIZONTAL CAT 8885C45G31 INTERNATIONAL SWITCH ATV3 VERTICAL CAT 8885C45G30 AG SWITCH ATH3 HORIZONTAL CAT 8885C45G33 AG SWITCH ATV3 VERTICAL CAT 8885C45G32 100W SPACE HEATER...

Page 35: ...ource 1 or utility supply NN and Source 2 or generator supply EN Refer to Figure 38 for the location of all parts discussed in this document Load cables on switches using the vertical design MUST be connected and torqued BEFORE installing the SUPPLY cables Figures 38 and 39 WARNING THESE QUICK START INSTRUCTIONS ARE NOT A COMPLETE SOURCE OF INFORMATION ON THE ATC 300 CONTROLLED ATS EQUIPMENT INSTA...

Page 36: ... Based Transfer Switch Figure 38 300 A 3 Pole ATS Interior Components LOCKOUT LOAD LUGS TOP ENTRY NEUTRAL CONNTECTIONS MANUAL OPERATING HANDLE INDICATOR WHEEL TRANSFER MECHANISM MOTOR BRAKE BOARD EMERGENCY POWER SOURCE MOLDED CASE SWITCH VOLTAGE SELECTION PANEL DOMESTIC NORMAL POWER SOURCE MOLDED CASE SWITCH POWER PANEL ...

Page 37: ...rk and the Source 1 Available white LED should light Figure 40 Using a voltmeter check for proper system voltage on Source 1 and load terminals Check all phases on a 3 phase switch Voltage measurements should be taken phase to phase and phase to neutral Figure 40 ATC 300 Controller Utility Supplying Load Step 6 To view the setpoints press the Step Enter pushbut ton and enter the Password Note The ...

Page 38: ...xercise Go To Emergency TDES timer times out Send Engine Start signal Energize Gen Start relay Is Source 2 Available TDNE timer times out Open Source 1 Energize K2 Close Source 2 Energize K2 Source 2 is powering the load Is Source 1 Available TDEN timer times out Yes No No Yes Sends pretransfer signal TPRE timer times out If Source 1 is Available Open Source 2 Energize K1 Close Source 1 Energize K...

Page 39: ... Source 1 is powering the load Source 1 becomes unavailable or Go To Emergency Is Source 2 Available TDNE timer times out Open Source 1 Energize K2 Close Source 2 Energize K4 Source 2 is powering the load Is Source 1 Available TDEN timer times out Yes No No Yes Open Source 2 Energize K1 Close Source 1 Energize K3 Source 1 is powering the load Sends pretransfer signal TPRE timer times out If Source...

Page 40: ...n and return to Source 1 While the ATS is connected to Source 2 use a voltmeter to check for correct system voltage on the load terminals of the ATS Check all phases on a 3 phase sys tem Voltage measurements should be taken phase to phase and phase to neutral A load test will cause a momentary power outage during transfer Figure 44 ATC 300 Step 10 ATH3 ATV3 Controlled ATS Power Failure Test Initia...

Page 41: ...n 3 The generator should start and the ATS should trans fer to Source 2 4 After transfer close the upstream breaker or close the Source 1 Control Circuit Fused Disconnect The TDEN timer should begin counting and when com plete the ATS should transfer to Source 1 The TDEC should time out and shut the Source 2 power unit down Eaton Care for assistance 877 386 2273 option 2 option 4 and then option 3...

Page 42: ... RECOMMENDATIONS AND DESCRIPTIONS CON TAINED HEREIN In no event will Eaton be responsible to the pur chaser or user in contract in tort including negligence strict liability or otherwise for any special indirect incidental or conse quential 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 expens...

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