Eaton Automatic Transfer Switch, Molded Case Type, Open Transition, ATC-300+/ATC-900 Controller, 30-1000A Maintenance Manual

O & M Manual for the EATON ATC-300+/900
Breaker Based Transfer Switch
Instruction Booklet
Description
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .
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 Instructions
IB140042EN
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Instructional Booklet
Page 2
Effective: May 2015
ATC-300/ 900 Breaker Based Transfer Switch
Section 1:
WARNING
1.1 Preliminary Comments and Safety Precautions
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 TESTED TO OPERATE WITHIN ITS NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY
CAUSE THE EQUIPMENT TO FAIL RESULTING IN DEATH, SERIOUS
BODILY INJURY, AND/OR PROPERTY DAMAGE. ALL RESPONSIBLE
PERSONNEL SHOULD LOCATE THE DOOR MOUNTED EQUIPMENT
NAMEPLATE AND BE FAMILIAR WITH THE INFORMATION PROVIDED
ON THE NAMEPLATE. A TYPICAL EQUIPMENT NAMEPLATE IS
SHOWN IN FIGURE 1.
Automatic Transfer Switch
E
Cat No:
GO No:
Item
Introduction
ATV3KDA20225WRU
XYZ0123
1
2/04
1/1
This technical document is intended to cover most aspects associated 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
the 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 the
installing contractor.
1.1.1 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 Eaton 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.
1.1.2 Safety Precautions
Poles: 2
Phase: 1
Amps:
Hertz:
225
60
Volt:
Wire:
240
3
All safety codes, safety standards, and/or regulations must be
strictly observed in the installation, operation, and maintenance of
this device.
Figure 1. Typical Automatic Transfer Switch (ATS) Equipment
Nameplate.
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 further
information is desired by the purchaser regarding a particular
installation, operation, or maintenance of particular equipment,
please contact an authorized Eaton Sales Representative or the
installing contractor.
WARNING
THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PROCEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONNEL
SAFETY AND PROTECTION OF EQUIPMENT FROM DAMAGE. AN
EXAMPLE OF A TYPICAL WARNING LABEL HEADING IS SHOWN
ABOVE TO FAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION. THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERT
TO WARNINGS, WHICH APPEAR THROUGHOUT THE DOCUMENT.
IN ADDITION, WARNINGS AND CAUTIONS ARE ALL UPPER CASE
AND BOLDFACE.
CAUTION
COMPLETELY 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 PERFORM
ANY WORK ASSOCIATED WITH THIS EQUIPMENT. ANY WIRING
INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE FOLLOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT EQUIPMENT DAMAGE.
For more information visit: www.eaton.com
IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
1.2 General Information
Transfer switches are used to protect critical electrical loads
against loss of power. The load’s Source 1 power source is
backed 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 the
event that power is lost from Source 1, the transfer switch transfers the load to the Source 2 power source. This transfer can be
automatic or manual, depending upon the type of transfer switch
equipment being used. Once Source 1 power is restored, the load
is automatically or manually transferred back to the Source 1
power source, again depending upon the type of transfer equipment being used (Figure 2).
Source 2
Page 3
source until the Source 2 power source does appear. Conversely,
if connected to the Source 2 power source and the Source 2
power source fails while the Source 1 power source is still
unavailable, the ATS remains connected to the Source 2 power
source.
ATSs automatically perform the transfer function, and include
three basic elements:
1. Main contacts to connect and disconnect the load to and from
the power source.
2. A mechanism to transfer 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.
1.2.1 Design Configuration
The Eaton ATS is a rugged, compact design that uses molded
case switches and/or circuit breakers to transfer essential loads
from 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 being
closed at the same time.
Source 1
Load
Figure 2. Typical Load Transfer Switch (Circuit Breaker Type)
Schematic.
In ATS equipment, the switch’s intelligence system initiates the
transfer when the Source 1 power fails, falls below, or rises above
a preset voltage. If the Source 2 power source is a standby generator, the ATS initiates generator startup and transfers to the
Source 2 power source when sufficient generator voltage is available. 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
IB140042EN
Figure 3. Typical Power Panel for 225-1200 A Models (Deadfront
Covers Removed).
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Instructional Booklet
Page 4
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 compact, 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 Controller. Door or individual panel removal is achieved without disturbing 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 mounting holes, along with power panel positioning bolts and pre-tapped
inserts, insure proper power panel mounting after the initial enclosure installation or when switching from top to bottom or bottom
to top entry. Refer to Section 4 for specific mounting and modification 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
Fuse Rating Type
600 Vac
30-100
150
150-225
225
100
100
100
100
65
65
65 (240 Vac)
65
25
25
25
25
200
400
400
400
J, T
J, T
J, T
J, T
200
200
200
200
300
400
600
100
100
100
65
65
65
25
25
25
400
600
1200
J, T
J, T
J, T
200
200
200
800
1000
65
65
50
50
25
25
1600
1600
L
L
200
200
 4 pole 480 Vac are rated 35 kA
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IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
1.3 ATS Catalog Number Identification
Transfer switch equipment catalog numbers provide a significant
amount of relevant information that pertains to a particular piece
of equipment. The Catalog Number Identification Table (Table 2)
provides the required interpretation information. An example is
offered here to initially simplify the process.
Example: Catalog Number (circled numbers correspond to position
headings in Table 2):
1 to 2
3
4
5 to 6
7
8
9 to 12
13
14
15
AT
V
3
KD
A
2
0225
W
R
U
Page 5
The catalog number ATV3KDA20225WRU describes an ATS with
the switching devices mounted vertically in the enclosure. The
intelligence represented by the control panel is the ATC-300+.
The Eaton Series C Type HKD is used as the switching device and
is in the form of a 2-pole molded case switch on each source. The
continuous current rating of this equipment is 225 A and applicable at 240 Vac, 60 Hz. The transfer switch equipment is enclosed
in a NEMA 3R enclosure and is listed for UL applications.
Table 2. Transfer Switch Catalog Number Explanation
POSITIONS 1 TO 2
POSITION 3
POSITION 4
POSITIONS 5 TO 6
BASIC
DEVICE
SWITCHING DEVICE
ORIENTATION
CONTROL
PANEL
SWITCHING
DEVICE
Automatic Transfer Switch
AT
Vertical
Horizontal
POSITION 7
SWITCHING DEVICE
ARRANGEMENT
Fixed Mount Molded Case
A
Switches Both Power Sources
V1
H2
ATC-300+
ATC-900
Controller
POSITION 8
POSITIONS 9 TO 12
POSITION 13
NUMBER
OF POLES
AMPERE
RATING
VOLTAGE/
FREQUENCY
Two
2
HFD
HKD
HLD
HMDL
NB
HND3
POSITION 14
ENCLOSURE
600 Vac/60 Hz
E
Type 12
J
480 Vac/60 Hz
X
Type 3R
R
240 Vac/60 Hz
W
Open
K
150 A – 0150
208 Vac/60 Hz
B
225 A – 0225
120 Vac/60 Hz
A
Circuit Breaker Source 1 Power Source,
300 A – 0300
220 Vac/50 or 60 Hz G
Molded Case Switch Source 2
400 A – 0400
600 Vac/50 Hz
K
Power Source
600 A – 0600
415 Vac/50 Hz
O
Four
Circuit Breakers Both Power Sources
Fixed Mount Molded Case
Fixed Mount Molded Case
C
D
4
800 A – 0800
401 Vac/50 Hz
N
Switch Source 1 Power Source,
1000 A – 1000
380 Vac/50 Hz
H
Molded Case Circuit Breaker
1200 A – 1200
365 Vac/50 Hz
Z
230 Vac/50 Hz
M
Source 2 Power Source
Notes: 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, both
power sources.
1.4 Environmental Conditions
1.4.1 Seismic
With proper installation, and by including the appropriate optional
feature that includes specially designed cleats (optional feature
#42), the 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 than 90% humidity (non-condensing). The ambient temperature range for operation is between -20
and 70°C (-4 to 158°F).
IB140042EN
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FD
KD
LD
MD
NB
ND
LISTING
30 A – 0030
70 A – 0070
B
Eaton Series C
Eaton Series C
Eaton Series C
Eaton
Eaton
Eaton Series C
POSITION 15
100 A – 0100
Fixed Mount Molded Case
Three 3
3
9
*UL/CSA Listing U
No Listing
X
Instructional Booklet
Page 6
Effective: May 2015
ATC-300/ 900 Breaker Based Transfer Switch
1.5 Glossary
With respect to their use within this document and as they
relate to transfer switch and controller operation, the following terminology is defined.
Available
A 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.
Connected
Connected is defined as when the input is shorted by an
external contact or connection.
Failed or Fails
A source is defined as “failed” when it is outside of the applicable voltage and frequency setpoint ranges for the nominal
voltage and frequency setting for a time exceeding 0.5 seconds after the time delay emergency fail (TDEF) time delays
expires.
Failsafe
Failsafe is a feature that prevents disconnection from the only
available power source and also forces a transfer or re-transfer operation to the only available power source.
Re-Transfer
Re-transfer is defined as a change of the load connection
from the Source 2 to the Source 1.
Source 1
Source 1 is the primary source (normal source, normal power
source, or normal).
Source 2
Source 2 is the secondary source (emergency source, emergency power source, emergency, standby, or backup source).
Source 1: Failed or Fails
Source 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 Fails
Source 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 a time exceeding 0.5 seconds after the Time Delay
Emergency Fail (TDEF) time delay expires.
Transfer
Transfer is defined as a change of the load connection from
the Source 1 to the Source 2 power source, except when
specifically used as “Transfer to Neutral”.
Transfer to Neutral
Transfer to Neutral is defined as when the load circuits are
disconnect from both the Source 1 and Source 2 power
sources.
Unconnected
Unconnected is defined as when the input is not shorted by
an external contact or connection.
Section 2:
Storage
Receiving, Handling, and
2.1 Receiving
Every effort is made to ensure that the ATS 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 the protective packaging until the equipment is ready
for installation.
When the ATS 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 Eaton, once
a thorough inspection is complete. All claims should be as
specific as possible and include the 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 remove or 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, and appropriate instruction leaflets, are
enclosed within the bag and should be filed in a safe place.
2.2 Handling
As previously mentioned, ATS equipment is packaged for
forklift movement. Protect the equipment from impact at all
times and DO NOT double stack.
Once the equipment is at the installation location and ready
to 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. Be
careful not to damage the top or bottom enclosure mounting
flanges. Refer to Section 4 of this manual for specific installation instructions.
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IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
2.3 Storage
Section 3:
Although well packaged, this equipment is not suitable for outdoor
storage. 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.
3.1 General
It is strongly suggested that the package-protected equipment 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 packaged or not.
3. The microprocessor-based Controller.
Page 7
Equipment Description
The ATS consists of three basic panels:
1. The power panel;
2. The voltage selection and transformer panel; and
These panels are interconnected via connector plugs and mounted
in an enclosure (Figure 6).
POWER PANEL
CONTROLLER
VOLTAGE SELECTION
AND TRANSFORMER
PANEL
Figure 6. Three Basic Panels of the ATS (225-1200 A).
3.2 Power Panel
The power panel is used for making load, power, and neutral connections. The main contacts and the transfer mechanism are all
on one steel frame (Figures 7 and 8).
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Page 8
Effective: May 2015
ATC-300/ 900 Breaker Based Transfer Switch
3.2.1 Steel Base Plate
The steel base plate design (225-1200 A models only) permits the
power panel to be moved vertically within the enclosure to accommodate top or bottom cable entry. Elongated holes on either side
of the base plate ensure proper positioning. The bottom set of
elongated holes positions the power panel higher in the enclosure,
thus permitting bottom cable entry. The top set of elongated
holes positions the power panel lower in the enclosure for top
cable entry. Section 4 discusses equipment mounting and load
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 classes
of loads, open or enclosed.
Figure 7. Typical Power Panel for 225-1200 A Models.
Figure 8. Typical Power Panel for 30-150 A Models.
Figure 9. Mounted Molded Case Switches with the Transfer
Mechanism Removed for Clarity (225-1200 A Models).
In addition, they have high dielectric strength, heavy-duty switching, high-withstand capabilities, and high interruption capacity.
The switching devices are mechanically and electrically interlocked to prevent the two sets of main contacts from being closed
simultaneously. The load side contacts of each switching device
are joined with a bus bar assembly to form a common load terminal location, either top or bottom (Figures 10 and 11).
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Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
GROUND
CONNECTIONS
EMERGENCY LINE
CONNECTIONS
NEUTRAL BOND
(FOR SERVICE
ENTRANCE)
EMERGENCY POWER
SOURCE SWITCHING
DEVICE
NORMAL LINE
CONNECTIONS
PIVOT
BOLT
MANUAL OPERATOR
KNOB
NORMAL POWER
SOURCE SWITCHING
DEVICE
BRAKE RELEASE
LEVER
TRANFER
MECHANISM
LOAD
CONNECTIONS
NEUTRAL
ASSEMBLY
Figure 10. Typical (30-150 A) Horizontal Design Transfer Switch Equipment (Door Open).
IB140042EN
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Page 9
Instructional Booklet
Page 10
Effective: May 2015
ATC-300/ 900 Breaker Based Transfer Switch
LOAD LUGS (TOP ENTRY)
POWER PANEL
GROUND
CONNECTIONS
NORMAL POWER
SOURCE MOLDED
CASE SWITCH
NEUTRAL
CONNECTIONS
MANUAL
OPERATING
HANDLE
INDICATOR
WHEEL
TRANSFER
MECHANISM
MOTOR BRAKE
BOARD
EMERGENCY POWER SOURCE
MOLDED CASE SWITCH
Figure 11. Typical (225-1200 A) Vertical Design Transfer Switch Equipment (Door Open and Deadfront Cover Removed).
3.2.3 Transfer Mechanism (225-1200 A)
The transfer mechanism transfers between power sources
through a motor-driven, ratchet-type operation. A rotational
motion is created on an indicator wheel by the ratchet’s operation. 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).
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ATC-300/900 Breaker Based Transfer Switch
Page 11
A solid steel shield (Deadfront Cover) attached to the ratchet
assembly permits viewing of the rotary switch position indicator
while restricting access to other parts of the power panel (Figure
12).
Figure 13. North American Market Voltage Selection Terminals
(Shown Connected to the 120 Vac Taps).
Figure 12. Vertical Design ATS Equipment with Deadfront Cover
in Place Over the Power Panel (225-1200 A)
3.2.4 Transfer Mechanism (30-150 A)
This mechanism transfers between power sources using a motordriven arm that connects to a lever that operates both the Source
1 and Source 2 switches (Figure 8).
3.3 Voltage Selection
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 transformers and installing them on the primary taps
for the desired voltage. Taps are provided for 120 to 600 Vac to
satisfy any required North American market application voltage.
The factory default position is 600 Vac.
CAUTION
WHEN CHANGING THE SELECTED VOLTAGE, THE POWER MUST BE
REMOVED FROM THE ATS AND THE WIRES MUST BE MOVED ON THE
TAPS OF BOTH TRANSFORMERS.
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Page 12
Effective: May 2015
ATC-300/ 900 Breaker Based Transfer Switch
3.3.2 International Voltage Selection (208, 220, 240,
380, 415, and 600 V - 50-60 Hz)
.
The International market voltage selection panel is a multi-tap,
enclosed transformer mounted in the enclosure (Figure 14).
Seven front accessible voltages taps from 208 to 600 Vac satisfy
any required International market application voltage. A quickchange capability from one voltage to another is provided by a
small disconnect plug. The factory default position is 600 VAC.
Figure 15A. ATC-300+.
Figure 14. International Market Vertical Design Voltage Selection
Panel with Voltage Being Selected.
3.4 ATC-300 and ATC-900 Controllers
The Controller panel provides the intelligence and supervisory circuits which constantly monitor the condition of both the Source 1
and Source 2 power sources, thus providing the required intelligence for transfer operations (see Figures 15A and 15B). Detailed
information for controller operation is presented in separate documents:
• ATC-300+ Instruction Book (IB01602009E); and
• ATC-900 Instruction Book (IB140012EN).
• For current metering, there is a DCT module available that
attaches on to the back of the ATC-900. The DCT also serves
as a 24VDC input for backup power to the controller, to keep
communications functioning during power outages. See the
ATC-900 instruction booklet for more information.
• I/O Modules are available that will increase inputs and outputs
(4 in and 4 out per module) if additional I/Os are required. See
the ATC-900 instruction booklet for more information.
Figure 15B. ATC-900.
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Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
3.5 Features
Page 13
5H. Phase Reversal
A variety of standard and optional features are available for Eaton
ATSs. All features or combinations of features may not be available on specific ATSs. All features and/or accessories are Underwriters Laboratories (UL) listed unless noted.
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 source will
be considered “Unavailable.
3.5.1 Standard Features
For a 3-phase delta source, this feature should be turned off
via the PHASE REV setpoint.
The following is a list of the standard features for the ATC-300+
and the ATC-900 Controlled ATS. There are other options available, see the controller IB supplied. Customer Order Engineering
(COE) may also be applied to the switch, see the drawings for
those options.
1.
Time Delay Normal to Emergency (TDNE)
This feature provides a time delay when transferring from the
Source 1 to the Source 2 power source. Timing begins
when Source 2 becomes available. It permits controlled
transfer of the load circuit to Source 2.
2.
Adjustable Undervoltage:
Dropout: 50 - 97% of nominal
Pickup: (Dropout +2%) to 99% of nominal
5K.3-Phase Overvoltage/Overfrequency
Adjustable Overvoltage:
Dropout: 105 - 120% of nominal
Pickup: 103% to (Dropout –2%) of nominal
Time Delay on Engine Starting (TDES)
This feature provides a time delay of the signal to initiate the
engine/generator start cycle in order to override momentary
power outages or voltage fluctuations of Source 1.
3.
5J. 3-Phase Undervoltage and Underfrequency Protection
Adjustable Overfrequency:
Dropout: 103 - 110% of nominal
Pickup: 101% to (Dropout -1Hz) of nominal
5L.
Time Delay Emergency to Normal (TDEN)
For a 3-phase wye source, this feature monitors phase voltage ratios. Voltage unbalance (%) is calculated as the difference between the maximum and minimum phase voltage,
divided by the minimum phase voltage. User-selectable setpoints are available for dropout and pickup unbalance settings (minimum 2% differential). Dropout is adjustable from
5 to 20%. Pickup is adjustable from 3 to (Dropout –2%). A
setpoint for user-selectable time delay from 10 to 30 seconds is provided. The factory default setpoints are: 5%
dropout, 3% pickup, and 30 seconds time delay. A userselectable setpoint for enable and disable is also provided.
This feature provides a time delay of the re-transfer operation to permit stabilization of Source 1. Timing begins when
Source 1 becomes available. If Source 2 fails during timing,
then re-transfer is immediate overriding the time delay.
4.
Time Delay for Engine Cool-down (TDEC)
This feature provides a time delay of the signal to initiate the
engine/generator stop cycle after the re-transfer operation.
This allows the engine/generator to cool down by running
unloaded. Timing begins on completion of the re-transfer
cycle.
5,
When an unbalance condition is detected on Source 2, the
Unbalance Timer (TD UNBAL) starts timing. After TD
UNBAL times out, Source 2 is declared “failed”.
Source 2 Monitoring and Protection
This feature provides monitoring and protection based on the
Source 2 voltage and/or frequency setpoints. All feature 5
functions are “failsafe” operations.
5B, 26B. Phase Undervoltage and Underfrequency Protection
Adjustable Undervoltage & Underfrequency
5C, 26C. Phase Overvoltage/Overfrequency
Adjustable Overvoltage & Overfrequency
5D, 26D. Phase Undervoltage
Adjustable Undervoltage
5E, 26E. Phase Overvoltage
Adjustable Overvoltage
Source 2 3-Phase Voltage Unbalance
For a 3-phase delta source, this feature should be turned off
via the VOLT UNBAL setpoint.
6.
Test Operators
Eaton ATSs are provided with a Test Pushbutton that simulates a loss of the Source 1 power source as standard (Feature 6B). All programmed time delays (TDNE, TDEN, etc.)
will be performed as part of the Test. Engine run time of the
Test is equal to the Plant Exerciser (Feature 23) programmed
setpoint. All Tests are Failsafe protected.
6B. Test Pushbutton
Programmable Setpoints include:
1. Load or No Load Testing, or Disabled
2. Engine run time equal to the plant exerciser setting
5F, 26F. 3-Phase Undervoltage
Adjustable Undervoltage
5G, 26G. 3-Phase Overvoltage
Adjustable Overvoltage
IB140042EN
For more information visit: www.eaton.com
Instructional Booklet
Page 14
7.
Effective: May 2015
ATC-300/ 900 Breaker Based Transfer Switch
Time Delay Emergency Fail (TDEF)
This feature provides a time delay that prevents a connected
Source 2 power source from being declared “Failed” in order
to override momentary generator fluctuations. If the Source
2 power source remains in the failed state then, 0.5 seconds
after the TDEF timer expires, the transfer switch will proceed
with the programmed sequence for retransfer. This time
delay is only implemented when the Source 2 power source
is a generator.
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.
This feature provides a contact that indicates if the power
switching device is in the “Open” or “Closed” position.
15E. Source 1 Position Indication Contact
This feature provides 1 dry form “C” contact that indicates
the position of the Source 1 power switching device.
Adjustable 0 - 6 Seconds
8.
Time Delay Bypass Pushbutton
15F. Source 2 Position Indication Contact
This feature provides a way (by pushing the Help and Step
pushbutton simultaneously) to bypass the TDNE (Feature 1)
and/or TDEN (Feature 2) time delays. The Time Delay
Bypass function, when activated by pushing the Help and
Step pushbutton simultaneously, will reduce any or all of the
programmed time delay to zero.
This feature provides 1 dry form “C” contact that indicates
the position of the Source 2 power switching device.
23.
This feature provides one set of pushbuttons to bypass the
TDEN time delay. The ATC-900 has the feature that all of
the timers can be bypassed.
8D. Bypass TDNE
23K. Plant Exerciser Selectable – Disabled/1/7/14/28 Day Interval
This feature provides for automatic test operation of the
generator. Available test cycles are daily, 7, 14, or 28 days
with duration equal to the programmed engine test time.
This feature provides one set of pushbuttons to bypass the
TDNE time delay. The ATC-900 has the feature that all of
the timers can be bypassed.
Programmable setpoints allow for selection of three test
cycles:
12. Power Source Annunciation
This feature provides LEDs to give switch position and power
source availability indications.
•
•
•
Switch Position
Provides LEDs to indicate the switch position.
12C. Source 1 - Source Connected
Plant Exerciser (PE)
This feature provides a means for automatic testing of the
engine generator set or standby power system. All programmed time delays will be performed during plant exerciser operations. The ATC-900 has two independent
exercisers.
8C. Bypass TDEN
Engine Start/Run Only (No Load);
Exercise with Load Transfer; or
Disabled
This is a “Failsafe” operation.
26.
This feature provides a green LED that, when lit, indicates
the load is connected to Source 1.
Source 1 - Monitoring and Protection
This feature provides Source 1 monitoring and protection
functions. If the Source 1 power supply fails, then the
ATC-300 will begin the sequence of operations necessary
to transfer the load circuit to the Source 2 power source.
All Feature 26 monitoring and protection functions are “failsafe” operations.
12D. Source 2 - Source Connected
This feature provides a red LED that, when lit, indicates the
load is connected to Source 2.
26D. Go to Source 2
Power Source Availability
This feature provides the capability for an external contact
opening to initiate a load power transfer to the Source 2
power source. This includes starting the engine/generator,
performing the programmed time delays, and the transfer
operation. Re-transfer will occur when the external contact
is closed or under a “failsafe” condition. A connection point
on the controller for the connection of an external contact is
included.
Provides LEDs to indicate if a power source is available.
LEDs may be integral or separate from the controller.
12G. Source 1 - Available
For the ATC-300+, this feature provides a white LED that,
when lit, indicates Source 1 is available. For the ATC-900,
form C output relays are available.
12H. Source 2 - Available
29.
For the ATC-300+, this feature provides an amber LED
that, when lit, indicates Source 2 is available. For the ATC900, form C output relays are available.
14.
Switch Position Indication Contact
Relay Auxiliary Contacts
Alternate Transfer Modes of Operation
Provides standard or optional transfer modes, mode selection devices, and operational methods for Transfer
Switches.
29A. Automatic Operation
14G. Source 1 Present: Provides two (2) normally open and two
(2) normally closed contacts. The relay is energized when
Source 1 is available.
Provides fully automatic transfer, re-transfer, and engine/
generator startup and shutdown operations.
For more information visit: www.eaton.com
IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
32.
Delayed Transition Transfer Modes for Open Transition
Transfer Switches
This feature provides delayed transition transfer modes for
an open transition transfer switch. Often used in systems
with inductive loads, a delayed transition transfer switch
may prevent or reduce inrush currents due to out of phase
switching of inductive loads.
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 Protection on the Source 2 Power
Switching Device
This feature provides integral overcurrent protection on the
Source 2 power switching device.
32A. Time Delay Neutral
This feature provides a time delay in the neutral position
during the transfer and re-transfer operations during which
both Source 1 and Source 2 are disconnected from the load
circuit. The time delay is programmable and is the same for
both transfer and re-transfer operations.
Adjustable 0 - 120 Seconds
35.
42.
This feature provides integral overcurrent protection on the
Source 1 power switching device.
18.
3.5.2 Optional Features
The following is a partial list of the optional features. There are
many other options available, check with sales or the instruction
booklets for the controllers for a full set. All features or combinations of features may not be available on specific ATSs
A single ammeter is a true RMS sensing device that displays
single phase current only
The ammeter can be mounted on Source 1, Source 2, or
load. The meter can also be configured for 1, 2, or 3-phase
sensing by supplying one meter per phase for Source 1,
Source 2, or load. Ammeters for both Source 1 and Source
2 can also be grouped together.
21.
21A. Optional Power Cable Connection Terminals
This feature provides alternate power cable connection terminals. Consult Eaton for available optional terminal sizes.
29.
29G. Automatic/Manual Operation with Selector Switch
This feature provides a 2-position selector switch (labeled
Auto/Manual) that permits selection of the automatic or
manual transfer operation mode. When in the “Auto” position, the transfer switch operates with fully automatic transfer, re-transfer, and engine/generator start up and shut
down operations. When in the “Manual” position, manual
start-up of the engine/generator and manual transfer are
required (see Section 5 for manual operation of the transfer
switch). Manual shutdown of the engine/generator are also
required. The selector switch for manual operation is provided.
Available only with integral Overcurrent Protection (Feature
16). (Shown on Automatic Transfer Controller Display.)
12LM. Source 1 and/or 2 Tripped (Requires Feature 16) Via the
controller's display.
The Automatic Transfer Controller display will read “Lockout” if the Source 1 circuit breaker is in the “tripped” position.
Integral Overcurrent Protection
This feature provides thermal-magnetic overcurrent protection integral to the power switching device(s). All Feature
16 options include a “Lockout” function. If the power
switching breaker trips on an overcurrent condition, then
“Lockout” is displayed on the Automatic Transfer Controller
display and automatic operation is prevented until the appropriate source is manually reset.
IB140042EN
Alternate Transfer Modes of Operation
Provides standard or optional transfer modes, mode selection devices, and operational methods for Transfer
Switches.
Overcurrent Trip Indication
16.
Optional Power Cable Connection Terminals
Eaton Transfer Switches are provided as standard with
Source 1, Source 2, and Load Circuit solderless screw-type
terminals for power cable connection. Alternate terminal
wire sizes may be available dependant on transfer switch
type and ampere rating.
Power Source Annunciation
This feature provides LEDs to give switch position and
power source availability indications.
Metering
The ATC-900, with the DCT module, integrated metering is
available with appropriate CTs. Meters can also be applied
to the switch if the ATC-300+ is used.
Seismic Certification
This feature provides a Seismic certified Transfer Switch
with certificate for application in Seismic Zone 4 under the
California Building Code, the Uniform Building Code, and
BOCA.
12.
16N. Integral Overcurrent Protection on the Source 1 Power
Switching Device
Pre-Transfer, Post-Transfer, Pre & Post TransferSignal
This feature provides a signal to a remote device prior to a
re-transfer operation. It provides one Form “C” contact
(NO/NC) for interface with other equipment (typically elevator controls). The contacts close/open on a timed basis
prior to transfer in either direction. After TDNE/TDEN times
out, this relay closes and the Pre-transfer Timer (TPRE)
starts timing. After the TPRE times out, the transfer proceeds by starting the TDN timer if enabled. The pre-transfer relay opens after the transfer is complete. The ATC-900
have Pre and Post transfers outputs available. The ATC300+ has only the Pre-transfer. Check the Controller IBs
for more information.
Page 15
Note:Transfer switches with Feature 29G MUST be labeled as NonAutomatic Transfer Switch Equipment.
37.
Service Equipment Rated Transfer Switch
This feature provides the label “Suitable for use as Service
Equipment” and the features necessary to meet the requirements for the label. It includes the service disconnect with
visible indication and neutral assembly with removable link.
Features 16B or 16N must be selected separately.
For more information visit: www.eaton.com
Instructional Booklet
Page 16
Effective: May 2015
ATC-300/ 900 Breaker Based Transfer Switch
37A. Service Equipment Rated Transfer Switch Without Ground
Fault Protection (30 – 1000 A)
This feature provides Service Equipment rating for an application that does not require ground fault protection.
37B. Service Equipment Rated Transfer Switch With Ground Fault
Protection (800 – 1000 A)
This feature provides Service Equipment rating for an application that requires ground fault protection.
38.
3.6 Enclosure
The rugged steel ATS enclosure is supplied with three door
hinges, regardless of enclosure size. They ensure proper support
of the door and door mounted devices (Figure 16). The hinges
have removable hinge pins to facilitate door removal. Certain procedures, such as switch mounting, are simplified with the door
removed. The doors are supplied as standard with pad-lockable
latches.
Stainless Steel Covers
Provides an added level of security by providing a pad
lockable stainless steel cover for use with standard transfer switch controllers and/or associated device panels.
These covers function with Eaton Eaton’s ATC series controllers and device panels. The covers are designed for
NEMA 1, 3R, 4X, and 12 applications.
39.
Feeder Breakers
39A.
Two 200 A Feeder Breakers
This feature provides two (2) 200 A feeder breakers for
the 200 A ATH3 transfer switch.
39B.
Three 200 A Feeder Breakers
This feature provides three (3) 200 A feeder breakers for
the 300 A ATH3 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. Surge Device
This feature gives protection for surge current capacity rating. There are many ratings available with the most popular being 50kA and 100kA, up to 480VAC. It provides a
low impedance surge path to ground while supporting the
rated voltage. It has LED indication.
Figure 16. Typical Type 1 Enclosure (Door Closed).
The door is used to mount a variety of lights, switches, and pushbuttons, depending upon the options required for a particular ATS.
All lights and switches are mounted in the plastic door-mounted
panel.
For more information visit: www.eaton.com
IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
The rear of the enclosure is supplied with teardrop shaped holes in
the top and bottom mounting flanges to facilitate mounting. It is
also supplied with two positioning bolts and various pre-tapped
inserts to insure proper positioning of the power panel anytime the
power panel must be repositioned to accommodate a different
cable entry position. Cable entry holes are the responsibility of
the customer.
ATS enclosures and all internal steel mounting plates, such as the
power panel mounting plate, go through a pretreatment cleaning
system prior to painting to ensure a durable finish.
The standard ATS enclosure is NEMA 1 Type for general use.
However, a variety of enclosures are available to address almost
any environmental circumstance (see Table 3).
Table 3. Transfer Switch Equipment Enclosures
NEMA TYPE
DESIGN
Open
Indoor
PROTECTION
1
Indoor
Enclosed Equipment
3R
Outdoor
Rain, Ice Formation
4/4X
Outdoor
Hose Down,
Non-corrosive
12
Indoor
Dust, Dirt and
Non-Corrosive Liquids
Page 17
3.7 Standards
Eaton ATS equipment, enclosed in any of the enclosures listed in
Table 3, is listed for application by UL and ULC. In addition, Eaton
ATSs are listed in File E38116 by Underwriters Laboratories, Inc.
under Standard UL 1008. 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.
Eaton ATSs are available to meet NFPA 110 for emergency and
standby power systems, and NFPA 99 for health care facilities
when ordered with the appropriate options.
Since Eaton ATSs use specially designed molded case switches or
circuit breakers the main power switching contacts, these devices
must also be listed under the additional UL Standards 1087 and
489. UL uses two basic types of listing programs - label service
and reexamination.
UL1087 and 489 employs a label service listing program which
requires an extensive follow-up testing program for listed devices.
Standard UL 1008 for ATSs lists devices under the reexamination
program which only require 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 UL 1008.
Representative production samples of molded case switches and
molded case circuit breakers used in Eaton ATSs are subjected to
a complete test program identical to the originally submitted
devices on an ongoing, periodic basis per UL 1087 and 489. The
frequency of such a re-submittal can be as often as every quarter
for a low ampere device.
IB140042EN
For more information visit: www.eaton.com
Instructional Booklet
Page 18
Effective: May 2015
Section 4:
Installation and Wiring
ATC-300/ 900 Breaker Based Transfer Switch
4.3 Mounting Procedure
4.1 General
Eaton ATSs 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. All other required
wiring or electrical connection references are covered in a separate Customer Wiring Booklet packaged with the ATS.
Locate the wiring schematic, review it, and keep it readily available for reference purposes during installation and testing. Once
an ATS 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 6 of this instruction manual.
NOTICE
TO FACILITATE THE PROCEDURES DESCRIBED IN THIS SECTION,
THE SOLID STEEL SHIELD OVER THE POWER PANEL SHOULD BE
REMOVED. THE SHIELD IS ATTACHED TO THE RATCHET ASSEMBLY WITH FOUR SCREWS. REMOVE THE FOUR SCREWS AND
SHIELD UNTIL THE PROCEDURES ARE COMPLETED.
WARNING
BE CERTAIN THAT THE SOLID STEEL POWER PANEL SHIELD IS
PROPERLY INSTALLED BEFORE THE TRANSFER SWITCH EQUIPMENT IS PUT INTO SERVICE. THE SHIELD PROVIDES PROTECTION
FROM DANGEROUS VOLTAGES AT THE LINE AND LOAD TERMINALS WHEN THE EQUIPMENT IS IN OPERATION. FAILURE TO DO
SO COULD RESULT IN PERSONAL INJURY OR DEATH.
CAUTION
SINCE THE ENCLOSED ATS MUST BE LIFTED INTO PLACE FOR
MOUNTING, BE CERTAIN THAT ADEQUATE RESOURCES ARE
AVAILABLE FOR LIFTING TO AVOID PERSONNEL INJURIES OR
EQUIPMENT DAMAGE.
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 notice that the power panel has two sets
of mounting holes. One set positions the power panel for top
entry of cables and one set for bottom entry. This will be covered
in more detail in Section 4.4.
Eaton ATS equipment is assembled and supplied as standard for
top entry (see Figure 17), although equally adaptable to bottom
entry. Cable entry holes are not part of the enclosure when
shipped from the factory and must be provided in the field, either
before or after mounting the enclosure.
CAUTION
EXTREME CARE SHOULD BE TAKEN TO PROTECT THE TRANSFER
SWITCH FROM DRILL CHIPS, FILINGS, AND OTHER CONTAMINANTS
WHEN MAKING THE CABLE ENTRY HOLES. EXTREME CARE
SHOULD ALSO BE TAKEN WHEN MOUNTING THE ENCLOSURE TO
PREVENT COMPONENT DAMAGE OR A FUTURE MALFUNCTION.
4.2 Mounting Location
Choose a location that offers a flat, rigid mounting surface capable of supporting the weight of the enclosed ATS equipment. For
standard ATSs, avoid locations that are moist, hot, or dusty.
However, Eaton offers optional enclosure designs that can be
used in special environments. If there are any doubts as to a location’s suitability, discuss them with your Eaton 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.
Carefully remove all packing material from the ATS at the mounting location. Even though an equipment inspection should have
been made when the equipment was received, make another careful inspection of the enclosure and the enclosed ATS components
as the packing material is removed and the enclosure readied for
mounting. Be especially alert for distorted metal, loose wires, or
damaged components.
Figure 17. Typical (30-150 A) Horizontal Design ATS Equipment
(Door Open).
For more information visit: www.eaton.com
IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
With the enclosed ATS equipment unpacked and ready for mounting, proceed with the following steps.
Step 1: The ATS enclosure door is hinge mounted with removable
hinge pins. To simplify the mounting procedure and avoid
damaging the door-mounted controller, it is strongly suggested that the door be carefully removed and put it in a
safe place until mounting is complete. To remove the
door, open the door and disconnect the power connectors
(J7) at the back of the ATC-300 or the ATC-900 controller. Remove the wire ties securing the harness to the
inside of the door. Carefully remove the hinge pins then
the door from the enclosure.
Step 2: Install the required upper and lower mounting bolt
anchors and the two upper mounting bolts in the mounting surface.
Step 3: Gently lift the enclosure and guide the teardrop holes in
the upper mounting flange over the upper mounting
bolts. Do not completely tighten the bolts at this time.
Step 4: While still supporting the enclosure, install the two lower
mounting bolts in the lower mounting 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.
4.4 Load Lug Location
This section applies only to the 255-1200 A switches. The load
lugs for the 30-150 A switch are fixed.
ATS equipment is supplied from the factory with the load terminal
lugs at the top. If the load lugs are to be repositioned to the bottom, do it at this time before wiring the unit or making power
cable connections.
WARNING
F THE LOAD LUG LOCATION IS BEING CHANGED ON ALREADY
INSTALLED TRANSFER SWITCH EQUIPMENT, MAKE SURE THAT
THE SOURCE 1, SOURCE 2, AND OTHER POWER SOURCES CONNECTED TO THE EQUIPMENT ARE DE-ENERGIZED. HAZARDOUS
VOLTAGES ARE PRESENT INSIDE ATS EQUIPMENT THAT CAN
CAUSE SEVERE PERSONAL INJURY OR DEATH.
With the solid steel shield removed, proceed with the following
steps for bottom feed load termination. Refer to Figure 19 for
transfer switch component names and locations.
Step 5: Tighten all four mounting bolts after any required shimming is completed.
Electrical
Unit Status
ATC-300
Available
Source 1
Connected
Load
Available
Connected
Source 2
Help
Engine
Test
Lamp
Test
Step
Enter
Bypass
TDNE / TDEN
ase
ase
Alarm
Reset
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.
IB140042EN
Page 19
For more information visit: www.eaton.com
Instructional Booklet
Page 20
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
LOAD LUGS (TOP ENTRY)
POWER PANEL
GROUND
CONNECTIONS
NORMAL POWER
SOURCE MOLDED
CASE SWITCH
NEUTRAL
CONNECTIONS
MANUAL
OPERATING
HANDLE
INDICATOR
WHEEL
TRANSFER
MECHANISM
MOTOR BRAKE
BOARD
EMERGENCY POWER SOURCE
MOLDED CASE SWITCH
Figure 19. Typical (225-1200 A) Vertical Design Transfer Switch Equipment (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).
For more information visit: www.eaton.com
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Instructional Booklet
ATC-300/900 Breaker Based Transfer Switch
Page 21
NEUTRAL TO
NEUTRAL
ASSEMBLY
JUMPER
GROUND
CONNECTION
NEUTRAL BOND
(FOR SERVICE
ENTRANCE)
NEUTRAL
ASSEMBLY
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).
IB140042EN
Effective: May 2015
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Instructional Booklet
Page 22
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
Step 2: Remove the bolt that bonds the neutral strap to the rear of
the enclosure, if it is in place.
Step 3: Remove the four bolts that secure the power panel in the
enclosure. Depending 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 20. Location of the P1, P2, and P3 Connector Plugs for
ATSs with the North American Market Transformer Panel.
Figure 22. Power Panel Removed from the Enclosure (with the
Transfer Mechanism Removed for Clarity - 225-1200 A Models).
NOTICE
AT THIS POINT, TAKE THE TIME TO REFER TO FIGURE 23 AND
BECOME FAMILIAR WITH THE INSIDE REAR OF THE ENCLOSURE
AND THE POWER PANEL MOUNTING PROVISIONS AVAILABLE FOR
BOTH TOP AND BOTTOM ENTRY. IT WILL FACILITATE REINSTALLATION OF THE POWER PANEL.
Figure 21. Location of the P1, P2, and P3 Connector Plugs for
ATSs with the International Market Transformer Panel.
Step 4: Remove the operating mechanism from the front of the
power panel by removing the six bolts holding the mechanism in position. The molded case switches or optional
circuit breakers should not be removed (Figure 23).
For more information visit: www.eaton.com
IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
NOTICE
THE REAR-MOUNTED LOAD LUGS, DIP-INSULATED BUS BARS,
STANDOFF INSULATORS, GLASS POLYESTER PHASE BARRIERS,
AND METAL MOUNTING BRACKET ARE DESIGNED TO BE REMOVED
AS ONE LOAD LUG ASSEMBLY (FIGURE 23).
Page 23
Step 7: Turn the load lug assembly 180° with the lugs at the bottom and remount the assembly by reversing the procedures described in Steps 5 and 6. The mounting bracket
will now be bolted to the bottom of the power panel.
Make certain that all glass polyester phase barriers are in
place and positioned properly in the grooves. When making any bolted connection to the bus, comply with the
torque requirements as outlined in Table 4.
Table 4. Bolted Bus Connection Torque Requirements.
POWER PANEL
SWITCHING DEVICE
TORQUE
FT-LB (NM)
Type FD
10 (14)
Type KD
20 (27)
Type LD
25 (34)
Type MD
25 (34)
Type ND
25 (34)
Type NB
25 (34)
Step 8: Remount the operating mechanism to the front of the
power panel with the six bolts removed 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 against the back of
the enclosure, replace and tighten the four mounting
bolts removed previously in Step 3.
Step 11: If applicable, attach the neutral strap, removed in Step 2,
to the back of the enclosure through the upper bonding
hole.
Step 12: Reconnect the P1, P2, and P3 connector plugs that were
disconnected in Step 1.
4.5 Power Cable Connections
WARNING
Figure 23. Mounted Load Lug Assembly (225-1200 A Models).
Step 5: The load lug assembly is removed by first removing the
four, six, or eight bolts securing the pieces of insulated
bus to the back of the power panel. The number of
mounting bolts depends upon whether 2-, 3-, or 4-pole
devices are installed. Mounting bolts are accessed
through holes in the load end of the molded case switches
or optional circuit breakers.
Step 6: Remove the four bolts holding the mounting bracket to the
upper rear portion of the power panel. The load lug
assembly can now be removed as one unit. Note that
there are grooves in the back of the power panel and in
the mounting bracket that keep the polyester phase barriers in their proper positions.
IB140042EN
POWER CONDUCTORS MAY HAVE VOLTAGE PRESENT THAT CAN
CAUSE SEVERE PERSONAL INJURY OR DEATH. DE-ENERGIZE ALL
POWER OR CONTROL CIRCUIT CONDUCTORS TO BE CONNECTED
TO THE ATS EQUIPMENT BEFORE BEGINNING TO WORK WITH THE
CONDUCTORS AND/OR TERMINATING THEM TO THE EQUIPMENT.
WARNING
USE OF CABLE LUGS NOT DESIGNED FOR THE ATS MAY CAUSE
HEATING PROBLEMS. 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.
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Instructional Booklet
Page 24
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
4.6 Wiring
CAUTION
TO HELP PREVENT COMPONENT DAMAGE OR FUTURE MALFUNCTIONS, 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 OF POWER PANEL. DO NOT ROUTE THE POWER
CABLES BEHIND OR TO THE LEFT OF THE POWER PANEL. RUNNING
THE CABLES BEHIND OR TO THE LEFT OF THE POWER PANEL
COULD INTERFERE WITH THE PROPER OPERATION OF THE TRANSFER SWITCH.
Test all power cables prior to connection to the unit to ensure that
the conductors or cable insulation have not been damaged while
being pulled into position.
Power cables are to be connected to solderless screw type lugs
located on the ATS switching devices. Refer to the separate Customer Wiring Booklet supplied with the ATS equipment for power
termination. Verify that the lugs supplied will accommodate the
power cables being used. Also verify that the cables comply with
local electrical codes. Standard ATS equipment, as supplied from
the factory, will accommodate the wire sizes shown in Table 5.
Carefully strip the 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.
WARNING
POWER CONDUCTORS AND CONTROL WIRING MAY HAVE VOLTAGE PRESENT THAT CAN CAUSE SEVERE PERSONAL INJURY OR
DEATH. DEENERGIZE ALL POWER OR CONTROL CIRCUIT CONDUCTORS BEFORE BEGINNING TO PERFORM ANY WIRING ACTIVITY TO
OR WITHIN THE ATS EQUIPMENT.
Power sources, load conductors, and control wiring should be
connected to locations as indicated in the Customer Wiring Booklet supplied with the ATS equipment.
CAUTION
ENSURE THE ATS VOLTAGE IS SET CORRECTLY. IT SHOULD BE
THE SAME AS THE SOURCE 1 AND SOURCE 2 LINE VOLTAGES.
OPERATING THE EQUIPMENT ON IMPROPER VOLTAGE CAN CAUSE
EQUIPMENT DAMAGE.
Once the ATS equipment has been installed and wired, perform
the initial mechanical and electrical procedures as outlined in Section 6 to verify that the equipment is installed and operating properly.
NOTICE
REMEMBER TO REATTACH THE SOLID STEEL POWER PANEL SHIELD
TO THE RATCHET ASSEMBLY AFTER COMPLETING ANY OF THE
PROCEDURES DESCRIBED IN THIS SECTION.
WARNING
IMPROPER POWER CABLE CONNECTIONS CAN CAUSE EXCESSIVE
HEAT AND SUBSEQUENT EQUIPMENT FAILURE.
Tighten the cable lugs to the torque identified on the label affixed
to the door of the unit.
Table 5. Transfer Switch Equipment Wire Sizes
TRANSFER SWITCH AMPERE RATING
WIRE SIZE RANGES
NUMBER OF CABLES PER PHASE
30-100
#14-3/0
1
75 (167)
150
#6-300KCMIL
1
75 (167)
225-300
#3-350KCMIL
1
75 (167)
400
#3-350KCMIL
2
75 (167)
600 (3P)
#1-500KCMIL
2
75 (167)
600 (4P)
3/0-400KCMIL
3
75 (167)
800-1200
3/0-500KCMIL
4
75 (167)
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TERMINAL TEMPERATURE RATING °C (°F)
IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
Page 25
4.7 Engine Start Connection
The engine control contact connections are located on the controllers of the ATS. It is always worthwhile to check the drawings in
order to connect the engine start contacts since there may have
been special wiring requested or the contacts may have been
wired to terminal blocks. The engine start terminals are marked 13
and 14 on J-5 connector on the ATC-300+ Controller (see Figure
24A). For the ATC-900 (Figure 24B) the contacts are on J15 4 &
5. See the individual 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.
NOTICE
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. IT IS RECOMMENDED THAT CONTROL WIRING,
SUCH AS THE ENGINE START WIRES, BE RUN IN A SEPARATE CONDUIT FROM THE POWER CABLES.
MODBUS
Feature
Figure 24B. ATS Rear View of ATC-900 Controller with DCT Module Attached.
Figure 24A. ATS Rear View of ATC-300+ Controller.
IB140042EN
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Instructional Booklet
Page 26
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
4.8 Voltage Selection Adjustments
Certain devices, such as the Voltage Selection Panel, sensing
relays, and timers, need to be set and/or calibrated prior to placing
the ATS equipment in service. Adjustments for controller are
described in the separate instructional document dedicated to the
specific controller being used. Voltage selection adjustments are
described in this section.
CAUTION
BE SURE THAT THE CORRECT VOLTAGE IS SELECTED TO MATCH
THE SYSTEM VOLTAGE. AN IMPROPER SELECTION AND/OR CONNECTION COULD RESULT IN EQUIPMENT DAMAGE.
4.8.1 North American Market Voltage Selection Panels (120,
208, 240, 480, and 600 V, - 60 Hz)
Vertical and Horizontal Design Voltage Selection
The North American market Voltage Selection Panel consists of
multi-tap transformers, contained in a steel case mounted in the
enclosure. The cover has “teardrop” holes for the screws to allow
easy access to the transformers. To change the voltage from the
factory default 600 Vac, follow the steps detailed below.
Step1: Loosen the four screws 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 transformers and installed them on the taps for the desired
voltage (Figure 25). Note that only one wire per transformer is moved since the second wire is the zero reference.
Figure 25. North American Market Voltage Selection Panel with
Voltage Being Selected.
Step 3: Reinstall the cover and tighten the four screws.
4.8.2 International Market Power Panels (208, 220, 240,
380, 415, and 600 V - 50-60 Hz)
Vertical Design Voltage Selection
CAUTION
WHEN CHANGING THE VOLTAGE, ONE WIRE MUST BE MOVED ON
THE PRIMARY TAPS OF BOTH TRANSFORMERS.
The vertical design transfer switch is furnished with a multi-tap
Voltage Selection Panel to the right of the power panel. Seven
front accessible taps from 208 to 600 Vac are provided (Figure
26). A small disconnect plug is provided to change from one voltage to another. The transfer switch is shipped with the plug in
the 600 Vac position.
Horizontal Design Voltage Selection
Horizontal design transfer switches are furnished with an adjustable line voltage plug and receptacles below the power panel. To
change the line voltage, insert the plug in the desired receptacle
(Figure 26). The transfer switch is shipped with the plug in the
600 Vac position.
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IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
Page 27
Figure 26. Line Voltage Plug and Receptacles for Horizontal
Design.
4.9 Terminal Block Wire Installation and Removal
Proceed with the following steps and associated figures to install
or remove terminal block wiring.
Step 1: Figure 27 shows two tension clamp terminal blocks.
There is a large one and small one, but the operation is
the same for both. A small tool, such as a screwdriver,
will be pushed into the square hole next to the wire hole
and a wire will be inserted into the larger circular hole on
the outer edge.
TOOL HOLE
Figure 28. Screwdriver Inserted in the “Tool” Hole.
Step 3: Once the screwdriver is in place, obtain a stripped wire
(strip about 1/4 in.) and insert it into the larger circular
wire hole as shown in Figure 29. Push the wire in until it
can go no further.
WIRE HOLE
Figure 29. Wire Inserted in the “Wire” Hole.
Figure 27. Tension Clamp 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.
IB140042EN
Step 4: While holding the wire in place, pull the screwdriver out.
The wire will now be held securely in the terminal block.
Pull on the wire to insure that it is correctly inserted into
the clamp.
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Instructional Booklet
Page 28
Effective: May 2015
Section 5:
Operation
ATC-300 /900 Breaker Based Transfer Switch
5.2 Manual Operation (225-1200 A)
5.1 General
An ATS provides main contacts to connect and disconnect the
load to and from the Source 1 and Source 2 power sources (Section 3.2.2). Each transfer mechanism provides the mechanical
motion required to open and close the mechanically interlocked
main contacts (Section 3.2.3).
Note that the transfer mechanisms for the two types of ATSs
described in this booklet (30-150 A and 225-1200 A) are different
for both the manual and automatic modes.
The manual operating handle can be used to create the rotational
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 interlocking 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).
NOTICE
IF AN ATS WITH ANY TYPE OF ELECTRICAL OPERATING CAPABILITIES IS TO BE OPERATED UTILIZING THE MANUAL OPERATING
HANDLE, IT IS STRONGLY RECOMMENDED THAT THE TRANSFER
MOTOR CIRCUIT FIRST BE ISOLATED. THIS IS ACCOMPLISHED BY
UNPLUGGING THE (P3) PLUG MARKED MOTOR DISCONNECT (FIGURE 31). ANY ATTEMPT TO USE THE MANUAL OPERATING HANDLE WITHOUT FIRST ISOLATING THE MOTOR CIRCUIT CAUSES AN
AUTOMATIC TRANSFER.
I
P3
Figure 31. ATS Manual Operating Handle in Use (225-1200 A
Models).
Figure 30.Motor Disconnect P3 must be disconnected.
Figure 32. Indicator Wheel Mounted in the Switch with Motor
Under the Wheel (225-1200 A Models).
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Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
Page 29
Figure 34. Switch Being Manually Operated (30-150 A Model).
5.4 Automatic Transfer
Figure 33. Indicator Wheel in Neutral Position (225-1200 A
Models).
The three distinct switch positions or contact conditions are:
Source 1: The contacts associated with the Source 1 power
source are closed and the Source 2 power source contacts are open.
Neutral:
The contacts associated with both the Source 1 and
Source 2 power sources are open. This position allows
for load circuit maintenance.
Source 2: The contacts associated with the Source 1 power
source are open and the Source 2 power source contacts are closed.
To manually operate the ATS, the manual operating handle is
ratcheted until the desired switch position is indicated on the indicator wheel. The operating handle, no matter what design or type
of switch operation, is always electrically "dead" and the indicator
wheel free-wheels should a particular switch have a motor and be
capable of electrical operation. This feature ensures no operator
problems should the switch automatically operate while the manual handle is being used.
5.3 Manual Operation (30 - 150 A)
To operate the breaker manually, or if the breaker trips, unplug P3
from S3 to disconnect the motor circuit (Figure 35). Turn and
hold the break release lever to “HOLD FOR MANUAL OPERATION”
position, and then rotate the manual operator knob in either direction to move the ATS into the desired position. Let go of the
brake release lever for “AUTOMATIC OPERATION” after P3 and
S3 are reconnected.
The operating sequence of an ATS is dictated by the switch's
standard features and selected options. Operation of an ATS during Source 1 power source failure and Source 1 power source restoration 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 suggested that you become familiar with
additional options selected with the particular ATS and their effect
on the normal operation of an ATS.
5.4.1 Source 1 Power Source Failure
Standard Source 1 power source failure is defined as a reduction
or loss of voltage. If this occurs, the sequence of operation is as
follows.
1. Failure of Source 1 is detected by the controller intelligence.
2. When the controller detects a failure, the engine contacts
close (after delay if programmed) and start the engine-driven
generator.
3. When the Source 2 voltage reaches its operation rating, the
K2 relay closes, starting the transfer operation. This operating sequence opens the Source 1 switch and closes the
Source 2 switch.
4. The load is now transferred to the Source 2 power source.
5.4.2 Source 1 Power Source Restoration
1. A return to the Source 1 power source begins when the voltage in all phases of a three-phase sensing unit, or phase-tophase in a single sensing unit, is restored to a preset value.
2. At the present voltage, the controller will cause the K1 relay
to change state. This starts the return to the Source 1 power
source and Source 1 transfer switch operation.
3. During this sequence, the Source 2 power source switch is
opened and the Source 1 power source switch is closed.
4. Simultaneously, the engine cool-down timer initiates the shut
down of the engine driven generator.
5. Transfer of the load back to the Source 1 power source is
now complete.
IB140042EN
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Instructional Booklet
Page 30
Effective: May 2015
Section 6:
Testing and Problem Solving
ATC-300 /900 Breaker Based Transfer Switch
6.1 Testing
After the ATS equipment is initially installed or during planned outages, the installation should be tested to ensure that all equipment
operates properly. This attention to detail will help avoid unexpected malfunctions. Mechanical and/or electrical tests should be
performed as described in this section.
The frequency of subsequent testing should be based on recommendations of the Genset manufacturer. Use the test pushbutton
to check the electrical operation of the switch.
Step 3: With the emergency generator in the OFF position, close
the Source 2 power source upstream protective device,
assuming such a device used.
NOTICE
AT THIS POINT, AND PRIOR TO MAKING ANY ATTEMPT TO ENERGIZE THE ATS EQUIPMENT, THE ENGINE-DRIVEN GENERATOR
SHOULD BE OPERATED. IF NECESSARY, THE VOLTAGE REGULATOR ON THE GENERATOR SHOULD BE ADJUSTED ACCORDING TO
THE MANUFACTURER’S RECOMMENDATIONS. THE ATS EQUIPMENT WILL RESPOND ONLY TO THE RATED VOLTAGE AND FREQUENCY PROGRAMMED INTO THE CONTROLLER.
Step 4: Close any generator engine-start controls opened as a
result of actions taken in Step 4, Section 6.1.2.
WARNING
HIGH VOLTAGES ASSOCIATED WITH OPERATIONAL TRANSFER
SWITCH EQUIPMENT PRESENT A SHOCK HAZARD THAT CAN
CAUSE SEVERE PERSONAL INJURY OR DEATH. USE EXTREME CAUTION TO AVOID TOUCHING ELECTRICAL CONNECTIONS WHENEVER
INSPECTING OR TESTING THE EQUIPMENT.
IN ADDITION, IMPROPER OPERATION OF THE GENERATOR SET
PRESENTS A HAZARD THAT CAN CAUSE SEVERE PERSONAL
INJURY OR DEATH. OBSERVE ALL SAFETY PRECAUTIONS IN YOUR
GENERATOR SET OPERATIONS AND INSTALLATION MANUALS.
6.1.1 Mechanical and/or Electrical Testing
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 terminals.
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 Section 6.1.3, Step 1.
Step 2: Initiate an automatic transfer operation from the Source 1
to the Source 2 power source by pressing the <Engine
Test> pushbutton two times.
Note:The ATC-300 Controller provides the capability to set the Engine Test
function to:
NOTICE
SINCE FEATURE 4 (TIME DELAY ENGINE COOL-OFF), AS DESCRIBED
IN SECTION 3, IS A STANDARD FEATURE, AN ENGINE START SIGNAL
WILL BE PRESENT FOR A PERIOD OF TIME WHEN THE SWITCH IS
FIRST ENERGIZED. THE PERIOD OF TIME IS EQUAL TO THE TIMER
SETTING. TO AVOID STARTING THE ENGINE DURING THIS TIME
PERIOD, TURN THE GENERATOR CONTROLS TO THE OFF POSITION.
Energize the ATS equipment as described in Sections 6.1.2
through 6.1.6. Insure that all safety precautions are taken and
that all WARNINGS and CAUTIONS are observed.
6.1.2 No Voltage Steps
With no voltage available on either power source, proceed as follows.
Step 1: Check to make sure that both the Source 1 and Source 2
power switching devices are in the OPEN position. The
switching devices can be put into the OPEN position
using of the manual operating handle, stopping in the
NEUTRAL position.
Step 2: The generator engine start controls should be in the OFF
position to prevent an undesired start.
Step 3: Ensure that the ATS has been set to the proper applied
system voltage (See Section 4.8).
Step 4: Check all ATS loads to ensure that they are ready to be
energized.
1.
No Load Engine Test;
2.
Load Engine Test; or
3.
Disabled.
The factory default is set to:
1.
Load Engine Test
a. After the Time Delay Engine Starting (TDES) has timed out,
the engine should start, run, and build up to normal voltage
and frequency.
b. The transfer switch will transfer to the Source 2 power
source (the Source 1 switching device opens and Source 2
switching device closes) after the Time Delay Normal to
Emergency (TDNE) times out.
Step 3: Initiate an automatic transfer operation back to the Source
1 power source by pressing the <Engine Test> pushbutton one time.
1. After the Time Delay Emergency to Normal timer (TDEN)
has timed out, the transfer switch will transfer back to
the Source 1 power source (the Source 2 switching
device opens and the Source 1 switching device closes).
2. The Time Delay for Engine Cool-Off (TDEC - Feature 4)
will allow the engine to run unloaded for a preset time
after transfer to the Source 1 power source is completed.
6.1.3 Connecting the Power Sources
Step 1: Close the Source 1 power source upstream protection
device. The Source 1 power switching device should
close
Step 2: Connect the engine start battery cable.
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IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
6.1.5 Alternate Tests
1. Alternate operational tests may be possible depending upon
the options provided with any given ATS. Refer to the schematic diagram provided with the ATS equipment, along with
the specification nameplate, to determine the exact options
provided.
Section 7:
Adjustments
7.1 General
Refer to I.B. 01602009E, supplied with the ATS for ATC-300
Controller adjustments and programming.
2. If you attempt to manually operate the ATS with the Source 1
power source connected and available, the ATC-300 logic will
cycle the ATS back to the Source 1 power source since it is
the preferred source. The ATS was designed with this safety
feature in case a manual transfer is attempted while the
switch is in automatic mode and under load.
6.2 Problem Solving
WARNING
HAZARDOUS VOLTAGES IN AND AROUND ATS EQUIPMENT DURING
THE PROBLEM SOLVING PROCESS CAN CAUSE SEVERE PERSONAL
INJURY AND/OR DEATH. AVOID CONTACT WITH ANY VOLTAGE
SOURCE WHILE PROBLEM SOLVING.
WARNING
ONLY PROPERLY TRAINED PERSONNEL, FAMILIAR WITH THE ATS
EQUIPMENT AND ITS ASSOCIATED EQUIPMENT, SHOULD BE PERMITTED TO PERFORM THE PROBLEM SOLVING FUNCTION. IF AN INDIVIDUAL 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 equipment 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 correctly. See the appropriate Instruction Booklet: ATC-300+
Instruction Book (IB01602009E) and ATC-900 Instruction Book
(IB140012EN). The IB is included with this IB.
If a problem persists after having completed the problem solving
procedure, contact a Eaton representative for further assistance.
When calling for assistance, the following is the minimum information required to properly address the need:
1. GO Number from the label;
2. Catalog number of ATS;
3. Actual location of the ATS (type of facility, address, etc.);
4. Company name and name and position of individual representing company;
5. Basic description of the situation as it exists; and
6. Any results of the problem solving steps taken and/or readings taken.
Eaton Care for assistance
877-386-2273 option 2, option 4, and then option 3
IB140042EN
Page 31
For more information visit: www.eaton.com
Instructional Booklet
Page 32
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
Section 8:
Maintenance
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 equipment’s surroundings. If a significant amount of dust or foreign matter is
present, a more frequent maintenance schedule should be followed.
8.1 Introduction
WARNING
HIGH VOLTAGES ARE PRESENT IN AND AROUND ATS EQUIPMENT.
BEFORE INSPECTING OR MAINTAINING THIS EQUIPMENT, DISCONNECT THE LINE POWER FROM, THEN LOCK OUT, IF POSSIBLE, THE
NEXT HIGHEST DISCONNECT DEVICE. FAILURE TO FOLLOW THIS
PROCEDURE COULD CAUSE SEVERE PERSONAL INJURY AND/OR
DEATH.
It is suggested that visual inspections of the equipment be made
on a regular basis, not just during 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.
In general, ATS 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
8.2 Procedures
A suggested maintenance procedure is outlined in Table 6.
Table 6. Periodic Maintenance Procedures
STEP
ACTION
a. Make the ATS equipment safe for inspection and/or maintenance.
Disconnect the line power from equipment being serviced by opening the next highest disconnect device. Make certain that any accessory control power is switched off by disconnecting 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 physical damage.
Examine the 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 the secondary control connections for damage and the control wiring for insulation integrity.
c.Inspect the molded case switching devices for dust, dirt, soot, grease, moisture, or corrosion.
Remove dust, dirt, soot, grease, moisture, and 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 the 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, discoloration, or loose hardware.
Severe material cracking will require replacement and loose hardware will need to be
tightened.
e.Check the terminals and connectors for looseness or signs of overheating.
Overheating will show as discoloration, melting, or blistering of the conductor insulation.
Connections that do not have signs of looseness or overheating should not be disturbed.
f.Exercise the molded case switching devices if they are not often exercised while in operation.
This will permit a “wiping” action by the contacts.
If a switching device is used for frequent switching during normal operation, this step can
be disregarded.
g.Return the ATS equipment to service.
Make certain all barriers are in place and doors closed. Reapply secondary and primary
power.
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IB140042EN
Instructional Booklet
ATC-300/900 Breaker Based Transfer Switch
Section 9:
Effective: May 2015
Page 33
Renewal Parts Guide
9.1 General
Refer to Figure 36A and B for assistance with selecting and ordering selected ATS renewal parts. For more information please see
Renewal Parts Publication (RP01603002E).
Example: To order the transformer panel for an ATH3FDA30150XSU transfer switch, order Catalog Number as shown in
Figures 36 B.
COMPLETE POWER PANEL PLEASE NOTE THE ORIGINAL
CATALOG NUMBER OF
TRANSFER SWITCH, AS IT IS
REQUIRED TO COMPLETE THE
CATALOG NUMBER OF A
POWER PANEL.
EXAMPLE: ATV3KDA30300WSU
ATH3FDB20200BSU
VERTICAL POWER PANEL CAT#:
PPV3KDA30300XKU
NOTE THAT THE SECOND TO
THE LAST CHARACTER WILL
ALWAYS BE A “K” WHEN
ORDERING A REPLACEMENT
POWER PANEL.
HORIZONTAL POWER PANEL
CAT#: PPH3FDB20200BKU
(NOT SHOWN)
Figure 36A Typical ATC-300 Controlled Breaker Based ATS.
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Instructional Booklet
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Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
ATC-900 CONTROLLER-BREAKER TYPE
(TDN)-CAT# 8160A90G07
WIRE HARNESS (ATH3/ATV3)
DOMESTIC SWITCH-CAT# 68C8097G03
INTERNATIONAL SWITCH-CAT# 68C8097G01
AG SWITCH-CAT# 68C8097G02
100W SPACE HEATER
DOMESTIC/INTERNATIONAL SWITCH-CAT# 8160A41G52
AG SWITCH-CAT# 8160A41G53
TRANSFORMER PANEL
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
Figure 36B. Typical Controlled Breaker Based ATS.
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IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
Page 35
Section 10: ATC-300 Controlled ATS
Quick Start Instructions
WARNING
THESE QUICK START INSTRUCTIONS ARE NOT A COMPLETE
SOURCE OF INFORMATION ON THE ATC-300 CONTROLLED ATS
EQUIPMENT. INSTALLATION SHOULD NOT BE STARTED UNTIL THE
ENTIRE INSTRUCTION BOOK HAS BEEN REVIEWED AND UNDERSTOOD. FAILURE TO FOLLOW THE FULL INSTRUCTIONS CAN
RESULT IN DEATH, SEVERE PERSONAL INJURY, OR PROPERTY
DAMAGE.
WARNING
Electrical
Unit Status
ATC-300
Available
Source 1
Connected
Load
Available
Connected
Source 2
Help
Engine
Test
Lamp
Test
THESE QUICK START INSTRUCTIONS ARE PROVIDED FOR USE
ONLY BY TECHNICIANS HIGHLY FAMILIAR AND EXPERIENCED WITH
ATC-300 CONTROLLED ATS EQUIPMENT INSTALLATION, SET UP,
AND TESTING. IT IS STRONGLY SUGGESTED THAT THE FULL
INSTRUCTIONS BE FOLLOWED FOR ALL INSTALLATIONS, SET UP,
AND TESTING.
Step
Enter
Bypass
TDNE / TDEN
ase
ase
Alarm
Reset
Step 1: Mount the ATS on a flat rigid surface (Figure 37). Shim if
necessary. For seismic mounting requirements, check the
main instruction sections of this manual.
Shim if Necessary
Figure 37. Mounting Details.
Step 2: Install the power cables. Cables must be sized and
installed per National Electrical Code, refer to NFPA70.
The cables must be sized within the specified cable size
range on the side of the cable connectors.
Connect the cables and torque to the correct value indicated on
the label near the lugs in the following order:
1. Load Cables* (T1, T2, T3);
2. Source 1 or Utility Supply (N1, N2, N3); and
3. Source 2 or Generator Supply (E1, E2, E3).
For 4 pole transfer switches, connect the load cables (TN), Source
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).
IB140042EN
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Instructional Booklet
Page 36
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
LOAD LUGS
(TOP ENTRY)
NEUTRAL
CONNTECTIONS
POWER PANEL
NORMAL
POWER
SOURCE
MOLDED
CASE SWITCH
MANUAL
OPERATING
HANDLE
LOCKOUT
INDICATOR
WHEEL
TRANSFER
MECHANISM
VOLTAGE
SELECTION
PANEL
(DOMESTIC)
MOTOR
BRAKE
BOARD
EMERGENCY POWER SOURCE
MOLDED CASE SWITCH
Figure 38. 300 A, 3-Pole, ATS Interior Components.
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IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
Page 37
Unit Status
ATC-300
Available
Source 1
Connected
Load
Available
Connected
Source 2
Figure 39. Horizontal Power Panel
Step 3: Turn the generator OFF at the generator control panel.
This will prevent unexpected activation of the generator.
Step 4: Connect the Engine Generator Start wires as shown in
Section 4.7. This contact is CLOSED whenever the
engine generator is needed, and should be connected to a
generator controller. NEVER connect directly to a starter
solenoid or ignition system. See the Genset manufacturer
instruction leaflet for recommended wire sizes and location procedures.
Step 5: Apply Utility (Source 1) power. If the switch is properly
applied for the system voltage ordered, the display should
work 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.
IB140042EN
Engine
Test
Help
Step
Lamp
Test
Enter
Bypass
TDNE / TDEN
se
se
Alarm
Reset
Figure 40. ATC-300+Controller (Utility Supplying Load)
Step 6: To view the setpoints, press the <Step/Enter> pushbutton and enter the Password.
Note: The factory default Password is 0300. Once all installation and testing is complete, the Password should be changed by authorized personnel to a unique Password for the equipment.
After entering the password, press the <Step/Enter>
pushbutton until the VIEW SETPOINTS menu appears.
Select YES. Press the <Step/Enter> pushbutton to
scroll through the setpoints (Figures 41 through 42 and
the controller's instruction booklet).
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Instructional Booklet
Page 38
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
Utility - Generator Transfer Switch
Source 1 is available
Close Source 1
(Energize K1)
Source 1 is powering the load
No
Source 1 becomes unavailable
(or Engine Test, Plant Exercise, Go To Emergency)
Is Source 1
Available?
TDES timer times out
Yes
TDEN timer times out
Send "Engine Start" signal
(Energize Gen Start relay)
Sends pretransfer signal
TPRE timer times out
No
Open Source 2
(Energize K1)
Is Source 2
Available?
Close Source 1
(Energize K1)
Yes
TDNE timer times out
Source 1 is powering the load
Sends pretransfer signal
TPRE timer times out
(If Source 1 is Available)
Open Source 1
(Energize K2)
TDEC timer times out
Remove "Engine Start" signal
(De-energize Gen Start relay)
Close Source 2
(Energize K2)
Source 2 is powering the load
Figure 41.Utility - Generator Transfer Switch
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IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
Page 39
Dual Utility Transfer Switch
Source 1 is available
Close Source 1
(Energize K1)
Source 1 is powering the load
Source 1 becomes unavailable
(or Go To Emergency)
No
No
Is Source 2
Available?
Yes
TDNE timer times out
Sends pretransfer signal
TPRE timer times out
(If Source 1 is Available)
Open Source 1
(Energize K2)
Close Source 2
(Energize K4)
Is Source 1
Available?
Yes
TDEN timer times out
Sends pretransfer signal
TPRE timer times out
Open Source 2
(Energize K1)
Close Source 1
(Energize K3)
Source 1 is powering the load
Source 2 is powering the load
Figure 42. Dual Utility Transfer Switch
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Instructional Booklet
Page 40
Effective: May 2015
ATC-300 /900 Breaker Based Transfer Switch
Step 7: To change or add a setpoint, select Yes when the
“Change Setpoints” message appears on the screen. Use
the <Step/Enter> pushbutton to step through the setpoints.
Use the <Increase> and <Decrease> pushbuttons to
change the setpoint.
When finished scrolling through and changing the desired
setpoints, answer Yes when the “Save Setpoints?” question appears on the screen. The display will return to the
default screen.
Step 9: Initiate a Load Test from the front panel of the ATC-300
(Figure 44). This may be done by setting the engine test
setpoint to:
1 Load Test
then saving the setpoints. Once the engine test setpoint
has been changed and saved, press the <Engine Test>
pushbutton twice. The generator should start, the ATS
should transfer and run on the generator for the set test
interval, then proceed to a TDEN countdown 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 system. Voltage measurements should be taken phase to
phase and phase to neutral. A load test will cause a
momentary power outage during transfer.
Unit Status
ATC-300
Available
Source 1
Connected
Load
Available
Connected
Source 2
HELP
STEP
Unit Status
INCREASE
ATC-300
Available
Source 1
Connected
Load
Available
DECREASE
ENGINE
TEST
Engine
Test
Help
Step
Lamp
Test
Enter
se
se
Alarm
Reset
Bypass
TDNE / TDEN
LAMP TEST
Connected
Source 2
BYPASS ENTER
TDNE/TDEN
ALARM RESET
Engine
Test
Figure 43. ATC-300 Pushbuttons
Help
Step
Lamp
Test
Enter
WARNING
THE GENERATOR SHOULD BE MANUALLY STARTED AND THE OUTPUT CHECKED AND VERIFIED BEFORE PROCEEDING TO STEP 8. IF
IMPROPER VOLTAGE/FREQUENCY IS APPLIED TO THE LOAD, THE
ATS MAY BE DAMAGED.
Step 8: Manually start the engine generator at the generator controller (Figure 43). Check that the generator is running
and the Source 2 Available amber LED is lit. Press the
<Step/Enter> pushbutton, step through the phase voltages, frequency, and message display. If the source message indicates that the source is Good, shut down the
generator and place the Genset controller in the Autooperating position. If the message indicates a problem
with the source, the setpoints should be reviewed and the
generator checked for proper voltage and frequency output.
Bypass
TDNE / TDEN
se
se
Alarm
Reset
Figure 44. ATC-300.
Step 10: ATH3/ATV3 Controlled ATS Power Failure Test - Initiate
a Load Test by simulating an actual power failure.
1. This should be done by opening the upstream breaker
or fused disconnect switch.
2. If the ATS is Service Equipment Rated with no
upstream disconnect, use the Source 1 Control Circuit Fused Disconnect to simulate a power failure
(Figure 45).
The Source 1 Control Circuit Fused Disconnect can
be found in one of two places. The first would be
located directly beside the Source 1 breaker. The
second would be located on the transformer panel/
customer connection panel. The Source 1 Control
Circuit Fused Disconnect is the disconnect marked
Source 1. The disconnect switch should be in the
ON position for Source 1 operation. Turning the
switch to the OFF position will simulate a Source 1
power outage.
For more information visit: www.eaton.com
IB140042EN
Instructional Booklet
Effective: May 2015
ATC-300/900 Breaker Based Transfer Switch
Page 41
3.The generator should start and the ATS should transfer 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 complete, 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
Figure 45. Source 1 Control Disconnect in the ON Position.
IB140042EN
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Instructional Booklet
Page 42
ATC-300/900 Breaker Based Transfer Switch
Effective: May 201 5
This instruction booklet is published solely for information purposes and should not be considered all-inclusive. If further information is required, you should consult Eaton.
Sale of the product(s) shown in this literature is subject to terms
and conditions outlined in appropriate Eaton selling policies or
other contractual agreements 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 Eaton.
NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR 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 Eaton 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.
CSA is a registered trademark of the Canadian Standards Association. National Electrical Code and NEC are registered trademarks
of the National Fire Protection Association, Quincy, Mass. NEMA
is the registered trademark and service mark of the National Electrical Manufacturers Association. Uniform Building Code (UBC) is
a trademark of the International Conference of Building Officials
(ICBO). UL is a federally registered trademark of Underwriters Laboratories Inc.
Eaton
Electrical Sector
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Cleveland, OH 44122
United States
877-ETN CARE (877-386-2273)
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© 2015 Eaton
All Rights Reserved
Printed in USA
Publication No. IB140042E/TBG01220
May 2015

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