ATS - Design Manual Caterpillar

APPLICATION AND INSTALLATION GUIDE
AUTOMATIC TRANSFER
SWITCHES
Automatic Transfer Switches Application and Installation Guide
Foreword
This section of the Application and Installation Guide generally describes wide-
ranging requirements and options for Caterpillar Automatic Transfer Switches
(ATS). Additional engine and generator systems, components and dynamics
are covered in other sections of this Application and Installation Guide.
Information and data related to specific ATS models is available from
a variety of sources. Refer to the overall introduction of this guide for
additional references.
Systems and components described in this guide may not be available
or applicable for every ATS. Refer to the Product Specification Sheets for
specific options and compatibility. While much of the content of this guide
is applicable to all ATS, the primary focus of this guide is on the North
American ATS market.
Section Contents
1. Introduction....................................................................... 8
1.1. Transfer Switch Basics ................................................ 8
1.1.1. Non-Automatic (Manual) Transfer Switch ............... 9
1.1.2. Manually Operated Non-Automatic ......................... 9
1.1.3. Manually Initiated, Electrically Operated.................. 9
1.1.4. Automatic Transfer Switch.................................. 10
2. Transfer Switch Components ............................................ 10
2.1. Power Switching Device ............................................ 10
2.1.1. Types of Power Switching Devices ...................... 10
2.1.1.1. Contactors.................................................. 11
2.1.1.2. Circuit Breakers........................................... 11
2.1.1.2.1. Molded Case Switch ........................................11
2.1.1.2.2. Insulated Case Switch......................................12
2.1.1.3. Static Transfer Switch ................................. 12
2.2. Transfer Mechanism .................................................. 12
2.2.1. Manually Operated ............................................. 12
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2.2.2. Electrically Operated ........................................... 12
2.2.2.1. Single Solenoid ........................................... 13
2.2.2.2. Dual Solenoid.............................................. 13
2.2.2.3. Unidirectional Gear Motor............................. 13
2.2.2.4. Twin Stored Energy ..................................... 14
2.2.2.5. Linear Motor ............................................... 15
2.2.3. Control Power.................................................... 16
2.2.4. Controls Logic.................................................... 16
3. Design Criteria ................................................................. 16
3.1. Current Ratings ......................................................... 16
3.1.1. Inrush Current.................................................... 18
3.1.2. Interrupt Current ................................................ 18
3.1.3. Continuous Current ............................................ 19
3.1.4. Withstand Fault Current ...................................... 20
3.1.5. Protecting the Main Contacts .............................. 21
3.2. Manual Operating Handles.......................................... 22
3.2.1. Specifications .................................................... 23
3.2.2. Manual Operation Under Load Dangers ................. 23
3.3. Safeguards ............................................................... 24
3.4. Summary ................................................................. 24
4. Controls .......................................................................... 24
4.1. Voltage Sensing ........................................................ 24
4.1.1. Under-voltage .................................................... 25
4.1.2. Over-voltage ...................................................... 25
4.2. Frequency Sensing .................................................... 26
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4.2.1. Normal Source Monitoring and Protection ............. 26

4.2.2. Emergency Source Monitoring and Protection........ 26
4.3. Time Delays.............................................................. 26
4.3.1. Time Delay Normal to Emergency (TDNE) ............. 27
4.3.2. Time Delay Engine Start (TDES)........................... 27
4.3.3. Time Delay Emergency to Normal (TDEN) ............. 27
4.3.4. Time Delay Engine Cooldown (TDEC) ................... 27
4.4. Engine Start Contact ................................................. 27
4.5. ATS Testing ............................................................. 27
4.5.1. Test Switch/Pushbutton...................................... 27
4.5.1.1. 2-Position Test Selector Switch (TSS) ........... 27
4.5.1.2. 3-Position Test Selector Switch (TPSS) ......... 28
4.5.1.3. 4-Position Test Selector Switch (FPSS).......... 28
4.6. Communications ....................................................... 28
4.6.1. Ethernet ............................................................ 28
4.6.2. Modbus............................................................. 28
4.6.3. Remote Monitoring and Control ........................... 30
4.6.4. Annunciator Panels............................................. 31
5. Motor Load Transfer......................................................... 31
5.1.1. Motor Protection Alternatives .............................. 31
5.1.1.1. In-Phase Monitor ......................................... 31
5.1.1.2. Motor Load Disconnect Control Circuit .......... 31
5.1.1.3. Timed Center-Off Position
(Delayed Transition) .............................................. 32
5.1.1.4. Description and Operation ............................ 33
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5.1.1.5. Momentary Paralleling.................................. 33
5.1.1.6. Motor Load Shedding Delayed Reconnection .. 34
5.1.2. Electronic Variable Frequency Drives (VFDs) ......... 34
6. Switching The Neutral Conductor ...................................... 35
6.1.1. Grounded vs. Ungrounded Neutrals ...................... 36
6.1.2. Three Pole Transfer Switches .............................. 39
6.1.3. Four Pole Transfer Switches ................................ 42
6.1.4. Fourth Pole and UL Requirements......................... 43
7. Sizing Automatic Transfer Switches................................... 44
7.1.1. Loads................................................................ 45
7.1.2. Voltage Rating ................................................... 45
7.1.3. Solid or Switched Neutral.................................... 45
7.1.4. Continuous Current Rating .................................. 46
7.1.4.1. Example ..................................................... 46
7.1.5. Overload and Fault Current Withstand Ratings....... 46
7.1.6. Overcurrent Protection ........................................ 47
7.2. Enclosure Ratings...................................................... 47
7.2.1. Non-Hazardous Locations .................................... 47
7.2.2. Hazardous Locations........................................... 51
7.2.3. NEMA Enclosure Type Numbers vs.
IEC Enclosure Classification Designations ....................... 52
7.3. Transfer Switch Configurations................................... 53
7.3.1. Open Transition.................................................. 54
7.3.2. Delayed Transition Transfer Switches ................... 55
7.3.2.1. Application Information ................................ 55
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7.3.3. Closed Transition ............................................... 56
7.3.3.2. Application Information ................................ 58
7.3.3.3. Soft Load ................................................... 58
7.3.4. Transfer/Bypass-Isolation Switches ...................... 58
7.3.4.1. Construction ............................................... 59
7.3.4.1.1. Automatic Transfer Switch ...............................59
7.3.4.1.2. Bypass-Isolation Switch....................................60
7.3.4.2. Interlocks and Indicators .............................. 60
7.3.4.3. Load Transition ........................................... 61
7.3.4.4. Service Entrance Rated ................................ 62
7.3.4.5. Contactor Type SER .................................... 62
7.3.4.6. Breaker Transfer Pair SER............................. 63
8. Transfer Switch Applications............................................. 63
8.1.1. On Generator Set Configurations.......................... 64
8.1.2. Utility/Generator Set ATS.................................... 64
8.1.3. Generator Set/ATS/UPS ...................................... 64
8.1.4. Multiple Generator Set/Switchgear/ATS................ 65
8.1.5. Gen to Gen ATS................................................. 66
8.1.6. Utility to Utility ATS ........................................... 66
8.1.7. Multi-Source Switching Systems.......................... 67
8.1.7.1. Multiple Utility/Single Generator Set .............. 67
8.1.7.2. Single Utility/Multiple Generator Sets............. 67
8.1.7.2.1. Logic Scheme 1 ..............................................68
8.1.7.2.2. Logic Scheme 2 ..............................................68
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9. Standards, Testing & Maintenance..................................... 68
9.1. Standards and Ratings ............................................... 68
9.1.1. The National Electric Code .................................. 68
9.1.2. Underwriters Laboratories, Inc. (UL) .................... 69
9.1.3. Canadian Standards Association (CSA)................. 69
9.1.4. International Electrotechnical Commission (IEC) ..... 69
9.1.5. National Fire Protection Association ..................... 69
9.1.6. National Electrical Manufacturers Association........ 70
9.1.7. American National Standards Institute .................. 70
9.1.8. Institute of Electrical and Electronic Engineers ....... 70
9.1.9. International Building Code .................................. 70
9.2. Testing .................................................................... 71
10. Controls Testing Standards ............................................. 71
10.1. Maintenance ........................................................... 71
10.1.1. Inspection and Cleaning .................................... 71
10.1.2. Servicing ......................................................... 72
11. Glossary of Terms .......................................................... 72
12. Appendices ................................................................... 77
12.1. Bibliography............................................................ 77
12.2. Systems Data Sheet Example: .................................. 78
Information contained in this publication may be considered confidential. Discretion

is recommended when distributing. Materials and specifications are subject to change
without notice.
CAT, CATERPILLAR, their respective logos, Caterpillar Yellow and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of
Caterpillar and may not be used without permission.
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1. Introduction
Modern utility systems are generally reliable but human error or the
uncertainty of weather can and does call for emergency or standby power
availability. These systems are found in a wide range of environments,
including industrial, commercial, office, military, remote, medical, malls,
public safety, academic or scientific sites. In all cases, safety as to personnel
or destructive fires and outages must be designed in and accounted for.
While emergency power can be supplied by multiple utility services or by
on-site power generation, on-site generator sets will provide the maximum
control and reliability. Whether with a second utility source or on-site
generation, a means must be provided to transmit power to the loads from
either source, and transfer the loads from one source to the other, such as
an Automatic Transfer Switch (ATS).
An ATS is defined as: a device used to switch a power supply from normal
to emergency when a power failure occurs.
The seven major functions of an ATS are:
1. Carry current continuously,
2. Detect power failures,
3. Initiate emergency source,
4. Transfer load,
5. Sense restoration of normal,
6. Re-transfer load to normal,
7. Withstand and close-in on fault currents.
ATSs are used for both low voltage (LV) and medium voltage (MV)
applications. Low voltage is classified as 0-1kV and medium voltage is
classified as 1kV 15kV, 15kV and above is not discussed in this guide.
LV ATSs are designed to fulfill Underwriter Laboratories (UL), Inc. standards
contained in UL-1008.
While many of the concepts discussed in this guide are applicable to
the International market, the focus of this guide is on the North American
ATS market.
permits critical loads to continue
1.1. Transfer Switch Basics
running or begin running again,
A transfer switch is a critical
once the transfer is made. After
component of any standby power
the normal source of power is once
system. When the normal (preferred)
again available, the transfer switch
source of power is lost, the transfer
transfers back to the normal source
switch transfers from the normal
from the emergency source.
source of power to the emergency
(alternate) source of power. This
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Operation of the transfer switch to operate them. Since the non-
from normal to emergency and back automatic transfer switches are part
to normal can be a manual type of the emergency power supply
operation or an automatic type system, they should have the same
operation. It depends on the type or UL 1008 electrical ratings as the
configuration of the transfer switch ATSs feeding the more critical loads.
equipment. If loads are critical, an For these reasons, only switches
ATS will most likely be used to specifically designed for manual
ensure the fastest possible transfer. transfer applications should be
A hospital operating room is an considered.
example of a critical load. An ATS There are two types of non-ATSs:
might also be used when operators
are not conveniently available who Manually operated non-automatic,
could make a manual transfer. If Manually initiated, electrically
loads are not quite as critical, but still operated.
cannot go for any extended period
of time without power, a manual 1.1.2. Manually Operated
transfer switch could be used. Non-Automatic
Manually operated non-automatic
1.1.1. Non-Automatic (Manual) transfer switches provide all the
Transfer Switch mechanics to effect the transfer
Transferring loads can be done from source to source. The actual
with a manually operated device, transfer of power, however, is
also referred to as a non-automatic accomplished by true hand operation
transfer switch. In such applications, of the transfer switch mechanism.
operating personnel should be readily In many installations where
available and the load is not of a non-critical loads are being served,
critical nature requiring immediate specifications may call for manual
restoration of power. A refrigeration or non-automatic transfer switches.
plant is an example of a less critical This method may be used because
need. While the refrigeration plant operating personnel are present and
could not live with an extended the loads are not of a critical nature
power outage, it may be able to requiring unattended operation.
tolerate a brief down time while
a manual transfer is made. 1.1.3. Manually Initiated,
Electrically Operated
From a very simplistic standpoint,
Manually initiated, electrically
double-throw knife switches and
operated non-automatic transfer
safety switches have been used as
switches are similar to the manually
manual transfer switches. Because
operated version just described
these devices are marginal
except that an electrical operation
adaptations, lack a high degree
feature is added to the switch. The
of reliability, and the restricted
switch electrically transfers power
operation requirements can be
when a pushbutton, usually mounted
abused; personnel are reluctant
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on the switchs enclosure, is An ATS consists of the following

pushed. If necessary, the switch basic elements:
can also be manually operated.
Power switching device the
1.1.4. Automatic Transfer purpose is to transfer the
Switch physical load connection between
The most convenient and reliable emergency power sources.
method to transfer power is with an Transfer mechanism purpose is
ATS. In general, the ATS includes to cause the transfer of the main
controls to detect when a power contacts between emergency
failure occurs, and triggers other sources.
controls to start the engine when Control power the purpose of
the emergency power source is a control power is to supply power
generator set. When the generator to the transfer mechanism, which
set reaches the proper voltage and causes transfer of the power
frequency, the switch transfers load switching device.
circuits from the normal source to
Controls the purpose of ATS
the emergency source.
controls is to monitor normal and
When the normal source is once emergency power sources and to
again ready to supply power, the initiate the transfer between
switch retransfers the load circuits sources, as appropriate.
to the normal source. It also triggers
Enclosure the purpose of the
controls to shut down the generator
enclosure is to house the ATS
set. The standard operation
components and to protect them
performed by the ATS each time
from site environmental
there is a power failure and power
conditions.
restoration is:
Engine starting, 2.1. Power Switching
Transfer to generator, Device
The purpose of the power
Retransfer to normal,
switching device is to transfer the
Engine shutdown. physical load connection between
alternate power sources.
2. Transfer Switch
Components 2.1.1. Types of Power
ATSs contain basic elements, each Switching Devices
performing specific functions. All While the titles are slightly
transfer switches do not carry out misleading, it is often stated that
these functions in the same way. there are two basic types of transfer
Included is a summary of those basic switch designs: contactor type
functions, with a description of the transfer switches and circuit
various means used to accomplish breaker type transfer switches.
those functions.
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Based upon the type of power tripping element. Circuit breaker
switching device, there are actually type transfer switches can be further
three basic types of power switching categorized by their construction
devices available in the ATS market methodology as either molded case
today: switches or insulated case switches.
Contactor type switches, 2.1.1.2.1. Molded Case Switch
Circuit breaker type switches, A molded case switch is a molded
case circuit breaker without a thermal
Static transfer switches. trip element. Molded case switches
2.1.1.1. Contactors are often used when a circuit requires
Contactor type transfer switches a compact, high capacity disconnect
are widely considered the most device. Supply of a trip element
frequently specified type of ATS and (making it a circuit breaker) is an
are designed to limit the number of option. The contacts and arc chutes
operating parts to accomplish the of the switch are completely enclosed
required transfer between alternate in an insulated housing. These
sources. While referred to as switching devices can be designed to
contactor type transfer switches, meet a number of UL requirements for
this type of switch does not use molded case circuit breakers, molded
motor starting/lighting contactors. case switches and ATSs. Considering
the wide range of standards the
The standard transfer switch must
circuit breaker type transfer switch
be designed to prevent two sources
can meet, they can serve as a viable
(a normal source and emergency
alternative to the contactor type
source) from being connected to a
device.
load simultaneously. In the case of
the contactor type switch, this is Typically, molded case switching
accomplished through the use of an devices are oversized for the
electrically operated, mechanically ampacity of the transfer switch.
held contact operation, which will For example, an 800 ampere molded
be described in more detail in case switch type transfer switch
Section 2.2. uses 1200 ampere switching
devices. Thus the contacts are likely
2.1.1.2. Circuit Breakers
to be larger in the molded case
Circuit breaker type transfer
switch design than the contacts used
switches are another popular and
in a contactor type of equal rating.
effective means of transferring
load between alternate sources. The molded case switching
In the case of automatic transfer device is normally used with smaller
application, the term circuit ampacity transfer switches
breaker is actually misleading. (e.g. < 1600 amps). It provides
The transfer medium is actually a for self-protection with a fixed
switch and not a circuit breaker. instantaneous trip setting feature
By definition, a switch is a circuit and will interrupt a fault current
breaker which does not include a at or above its preset level.
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2.1.1.2.2. Insulated Case Switch 2.2. Transfer Mechanism

Transfer switches also use The purpose of the transfer
insulated case type switching mechanism is to switch the main
devices. Testing for these type contacts of the power switching
devices is rigorous and covers a device between two power sources.
broad scope just like the molded Example: consider a double-throw
case type switch. Unlike the molded knife switch to be one type of power
case type device, the insulated case switching device. The arm of the
type switching device can be operator who actuates the handle
provided without any type of of the knife switch serves as the
trip unit. This is true because the Transfer Mechanism.
insulated case type device has
very high withstand and endurance Transfer mechanisms can be
ratings. In addition, the insulated classified by the way in which
case type switch is available in a they are activated. Those methods
drawout configuration, which lends include:
itself to certain specialty transfer Manual operation,
switch configurations.
Electrical operation.
2.1.1.3. Static Transfer Switch
In some site applications, where 2.2.1. Manually Operated
the emergency power system is Manually operated mechanisms
required to supply solid-state require operating personnel to
equipment, such as in a data center, perform a function by hand, such as
traditional power transfer devices directly operating a manual handle.
are incapable of transferring loads Operation of the handle results in
within the required time frame. the power switching device being
transferred from one source position
The static transfer switch provides to the emergency source position.
a faster load transfer (typically It is important to recognize that
of a cycle), than the traditional UL1008 regulates the conditions
ATS, which ensures uninterrupted under which ATSs may be operated
operation of sensitive electronic manually. For additional information
equipment. In this instance, load regarding the use of manual
retransfer to the preferred input operating handles please reference
source is virtually instantaneous. Section 3.2.
Silicon controlled rectifiers (SCRs)
are the means by which the static 2.2.2. Electrically Operated
transfer switch transfers power, Electrically operated mechanisms
which allows for the improved are powered by motors or solenoids.
transfer times. The electrical operator may be
initiated manually (typically via
This type of switching is typically a pushbutton) or automatically.
used when both sources are utilities
or one source is an Uninterruptible Automatically operated
Power Supply (UPS). mechanisms do not require an
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operator to initiate operation. Manual transfer of a single
Through the use of a controls solenoid operated transfer switch
package and pre-programmed is possible, but requires all power
operating conditions, the mechanism to be disconnected to the solenoid.
is automatically set in motion when Manual transfer is accomplished
the programmed operating through the use of a metal rod. The
conditions are met. metal rod is typically not attached
to the switch permanently.
There are five primary types of
transfer mechanisms used with Single solenoid type transfer
transfer switches: switches are typically used on lower
amperage rated transfer switches
1. Single solenoid,
(typically on switches 400Amp
2. Dual solenoid, and less).
3. Unidirectional gear motor,
2.2.2.2. Dual Solenoid
4. Twin stored energy, In the case of the dual solenoid
5. Linear motor. switch, which is also used in
contactor type transfer switches,
2.2.2.1. Single Solenoid
a solenoid-operated actuator is
The single solenoid type transfer
assigned to independently operate
mechanism, employed on contactor
each set of source contacts. One
type switches, utilizes an electrical
solenoid serves to close the normal
solenoid with an integrally mounted
source contacts, while the second
actuator. The solenoid is directly
solenoid serves to close the
connected to line voltage.
emergency source contacts.
In an emergency condition, the
Dual solenoid type transfer
solenoid is energized, causing the
switches are typically used on higher
actuator to extend and rotate the
amperage rated transfer switches
mechanically linked cam. As the cam
(typically on switches greater than
rotates, the contact arm (which is
400Amps).
connected to the cam via a
connecting yoke) is caused to move 2.2.2.3. Unidirectional Gear Motor
from the normal source position to This type of mechanism transfers
the emergency source position. This between power sources through the
results in contact connection to the use of a unidirectional motor-driven
emergency (standby power) source. mechanical device. Rigid shafts or
arms are linked to the motor through
Upon restoration of the normal
a ratchet type device or gears. The
source, the solenoid is de-energized,
rotary motion created by the motor
causing the actuator to retract and
is converted to linear motion. The
rotate the cam in the opposite
linear motion moves the rigid shafts
direction, resulting in contact
or arms to operate the switching
connection at the emergency
devices, such as the operating
(standby power) source.
handles on molded case switches.
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The unidirectional motor is energized operating handle. The operating

from the source to which the load is handle, whether it is ratcheted or
to be transferred. This type of rotated, produces the linear motion
transfer mechanism can also be required to operate the switching
operated manually, often through devices.
the use of an integrally mounted
Figure 1 Circuit Breaker Type ATS with Unidirectional Gear Motor

2.2.2.4. Twin Stored Energy the main contacts of the two
This type of mechanism utilizes switching devices prevents both
insulated case switches with true sets of main contacts from being
two-step stored energy mechanisms closed simultaneously. Except for
as the switching devices (Figure 2). the mechanical interlock, the
The stored energy mechanism switching device and the transfer
provides the required mechanical mechanism are automatically
motion to open and close the two provided in the form of the one
sets of main contacts. A rigid device, the insulated case switch.
mechanical interlock between
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Figure 2 Insulated Case Design Utilizing a Twin Stored Energy Mechanism
with Protective Cover Removed for Clarity
When insulated case switches are which the load is transferred. In
used as the switching devices, each addition, the closing and opening
device can be manually opened and functions can be electrically and
closed through the use of manual automatically performed.
buttons located on the front of the 2.2.2.5. Linear Motor
device. If required, the switching The linear motor mechanism is
devices can also be configured to basically a coil with an operating
be electrically closed and opened. shaft running through the coil. The
The closing springs can be manually operating shaft which causes the
charged using a front mounted main contacts to operate is not an
manual charging handle. integral part of the coil. Since the
If it is not desirable to perform the linear motor electric operator is
functions just described manually connected directly to the full line
or the transfer switch is to be fully voltage, the circuit requires the use
automatic, electrically operated of capacitors. This creates
switching devices are available. difficulties when voltage rating
changes are required. This type of
This means that the closing springs
switch cannot be operated manually
are automatically charged, as
and cannot be manually switched
required, through the use of a small
under full load. In fact, the motor
integrally mounted electric motor. The
drive circuit must be disconnected
motor is energized from the source to
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prior to manual operation. The logic or solid state logic. Normally,

motor drive circuit must also be microprocessor-based logic comes in
reconnected before the switch will the form of a self-contained unit that
function. The manual operating can be mounted on the enclosure
handle is a separate loose tool. door (Figure 3). The biggest
differences between microprocessor
2.2.3. Control Power logic from one manufacturer to
The ATS receives power to
another are the features available
transfer from the source to which
and ease of use.
it is transferring the loads. For
example, if the switch is going to
transfer from the failed normal
source (e.g. utility) to a live
emergency source (e.g. diesel
generator set), the power to make
the switch transfer must come
from the output of the diesel
generator set.
Voltage must be provided to the
transfer switch components that
require power to operate
solenoids, control relays and
controller. This voltage is typically
provided through internally mounted
transformers, which must match the
application voltage.
2.2.4. Controls Logic
The purpose of the ATS controls Figure 3 Caterpillar microprocessor-
logic is to monitor both the normal based controller
and emergency power sources and
to initiate and control transfer 3. Design Criteria
between those emergency power The primary purpose of an ATS is
sources. The logic panel, included as to transfer loads between alternate
part of a transfer switch, provides power sources. This section will
intelligence supervisory circuits to outline the various design criteria
constantly monitor the condition of that are taken into consideration in
the power sources and thus provide the design of a transfer switch.
the intelligence necessary for the
switch and related circuit operation. 3.1. Current Ratings
In a typical emergency power
Microprocessor-based logic system (EPS), ATSs are located in
provides a far more comprehensive that portion of the distribution bus
list of capabilities to the ATS world that feeds branch circuits (see
than previously available with relay Figure 4). Due to its location in the
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distribution network, four design consideration in the design of the
criteria related to current carrying switch and when applying it into
capability must be taken into a specific EPS.
Figure 4 Emergency Power System (EPS) with

Automatic Transfer Switches Feeding Branch Circuits
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3.1.1. Inrush Current to weld. In order to accomplish this,

When the transfer switch closes the contacts must be designed with
onto the emergency power source, some minimum level of bounce
the contacts can be subject to and be constructed with sufficient
a large surge of current. The thermal capacity to prevent welding.
magnitude of that surge depends One means of meeting these criteria
on the load, which is placed upon is by constructing the contacts of
the switching device at the moment the switch with a silver alloy.
of transfer. Loads specifically 3.1.2. Interrupt Current
addressed by UL 1008 include When the contacts of a transfer
motors, electric-discharge lamps, switch go from one source to
electric-heating loads, and tungsten- another, an arc is drawn from the
filament lamp loads. source the contacts are leaving.
Due to the relatively low resistance The higher the voltage and the
of a tungsten-filament lamp when it lower the power factor, the longer
is cold, the initial current drawn by the duration of the arc. This arc
the lamp may be as high as 17 must be extinguished before the
times what it draws during normal contacts connect to the other source
operation, with the inrush lasting or there can be a short circuit from
up to 14 cycles. Unless a transfer one source to the other. If the arc is
switch has been specifically not extinguished, serious damage
designed, tested and labeled can occur.
otherwise, it may not be used to
switch loads having greater than When the switch transfers to the
30 percent of its total consisting emergency source from the normal
of tungsten-filament lamp loads. source, the current interruption can
be zero. The transfer switch can also
Motor loads can add up to 6 times be called upon to interrupt full load
their rated current to the load placed currents at full voltage under test
on a transfer switch switching conditions. One of the most critical
between alternate power supplies, times occur if a motor is drawing
under normal circumstances. locked rotor current at the instant
However, the transfer switch must of transfer.
be designed to handle switching to
a power source, which is not in When the switch retransfers from
phase with the residual voltage or the emergency to the normal source,
counter electromotive force (CEMF) it is normally required to interrupt
created by motor. This can result in the emergency source current at full
an inrush current of up to 15 times voltage. An adequately designed
the normal operating current. switch must interrupt the arc from
both the normal and the emergency
When closing onto loads with high sources at all current levels.
inrush currents, the contacts of the
transfer switch must not be allowed Two means are often used to
ensure that the arc is properly
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interrupted when the switch transfers
from one source to another:
Wide arc gaps,
Arc chutes and arc quenching
grids.
The arc gap (see Figure 5) is the
distance from the stationary contact
to the movable contact when the
movable contact is fully opened.
The arc gap must be wide enough
to draw out the arc and provide time
to extinguish it. Transfer time should
be a minimum of 20 msec to ensure Figure 6 Arc Quenching
that the arc is extinguished. As a
point of reference, a high speed 3.1.3. Continuous Current
solenoid actuated drive typically A transfer switch must
ensures contact transfer in continuously carry current to critical
100 msec or less. loads. Current flows through the
transfer switch during both normal
and emergency conditions. Unlike
other equipment used in EPS
applications, a transfer switch is
expected to provide continuity of
power to the load, uninterrupted,
for multiple generations. Other
emergency equipment may only be
required to provide power for the
duration of a power outage. During
this continual period of usage, the
transfer switch is exposed to fault
Figure 5 Arc Gap currents, repetitive switching while
In addition to wide arc gaps, arc powering various types of loads and
quenching grids (see Figure 6), adverse environmental conditions.
consisting of arc chutes are often The switch must be designed such
used to break up the arc as it is that these factors do not cause
drawn into them by the magnetic excessive temperature rise, detract
field created when the arc forms. from reliable operation or require a
substantial amount of maintenance.
In order to achieve these
objectives, the contact temperature
rise of a transfer switch must be
well below that established for an
eight-hour rated device. Additionally,
2007 Caterpillar
the quality of contact must be A transfer switch must be capable

sustained through proper contact of withstanding the available fault
design. Arcing contacts prevent or current at its location in the system
minimize arcing at the main contacts until the overcurrent protective device
that would cause contact erosion clears the fault. The system designer
and affect the ability of the switch should determine the available RMS
to carry current continuously. symmetrical fault current at the
transfer switch location, the X/R
A transfer switch is capital
ratio, voltage and types of protective
investment equipment; therefore, the
devices (current limiting fuse, molded
ability to perform without overheating
case breaker or power breaker) before
should not be limited to new or
a properly rated transfer switch can
unused switches. For this reason
be selected.
most government agencies require a
complete temperature test be A number of factors account for
performed after the endurance test. high withstand current ratings of
transfer switches, including the
3.1.4. Withstand Fault Current following:
Transfer switches must be
designed to withstand the magnetic 1. Blow-on contacts In many
stresses and dissipate the heat switching devices, the
energy from high fault currents. electromagnetic fields that
Withstand current ratings (WCR) surround the current-carrying
vary depending on the switch size conductor act to force the
and type. Transfer switches should contacts to separate. Since these
have withstand and close-in current electromagnetic forces increase
ratings based on the available fault exponentially with current, it can
current at its location in the system be anticipated that if not properly
and the type of overcurrent device designed, the contacts may
to be used. To properly evaluate separate during short-circuit
application and coordination of currents due to the magnetic
transfer switches with protective effects.
devices, a system short-circuit 2. Heat The amount of heat
calculation should be made to generated at the transfer switch
determine the symmetrical fault is proportional to the resistance
current magnitude and the reactance of the parts that carry the current
to resistance (X/R) ratio at each through the switch, multiplied by
point of application. As the X/R ratio the square of the current. To
increases, both the fault withstand- provide the thermal capacity
ability of a transfer switch and the needed to cope with this heat,
fault interrupting capacity of an the cross section of the current-
overcurrent protective device carrying parts must be of
become more critical. substantial magnitude to keep the
resistance at a reasonable value.
It is also necessary to provide
2007 Caterpillar
adequate radiating surfaces, protective device clears
along with high-contact the fault, a time delay is
pressures, to keep heating incorporated into the control
to a minimum. Larger transfer circuit.
switches often utilize segmented The control current will prevent
contacts that provide multiple application of control voltage to
paths for current flow through the switch operator until a minimum
the main contacts. This feature acceptable value for proper transfer
extends the life of the contact has developed.
by reducing the amount of heat
generated during operation. For additional information on
withstand rating terms and
3. Life of the contact is also calculations, see Appendix 12.2:
extended through the prevention Systems Data Sheet Example.
of arcing on the main contacts
by the use of arcing contacts. 3.1.5. Protecting the Main
This is discussed in further detail Contacts
in section 3.1.5 preventing the The main contacts of the transfer
main contacts. switch can be prematurely worn
4. Delay in Transfer It is down and damaged by the arcs
necessary to account for the created when transferring from a live
voltage drop that is normally source. Arc runners and arc chutes
experienced with large fault are often employed to drive the arc,
currents. The design must ensure created during this transfer, out
that the voltage drop does not away from the main contacts.
cause the switch to be As soon as the arc is formed during
automatically transferred while the transfer operation, it is drawn
the switch is carrying the fault away from the current-carrying area
current. To ensure that this does of the main contacts by an arc
not occur, the following design runner. The damaging effects of the
criteria should be met: arc are absorbed by the arcing tip at
A mechanically held the top of the arc runner, and away
mechanism to prevent opening from the current-carrying area of the
during a fault condition, and a movable contact.
time delay to override In larger-size switches, separate
momentary dips in voltage. arcing contacts are often used
The mechanically held (Figure 7). When the switch begins
mechanism assures that the to transfer, the main contacts open
switch will not transfer until first while the arcing contacts remain
control voltage is applied to closed (Figure 8). Since the main
the transfer switch operator. contacts are opening under load, an
To prevent energizing the arc is formed between the arcing
operator until the overcurrent contacts. The stationary arcing
contact serves to draw the arc away
2007 Caterpillar
from the main contacts, with the arc

being pulled into the arc chutes.
This design serves to extend the
life of the contact by protecting the
main contacts, which are designed
to continuously carry current, but
not designed to take the punishment
from the arcs.
Figure 9 Arc Being Drawn into

the Arc Chutes
3.2. Manual Operating

Handles
Manufacturers of ATSs have
Figure 7 Main Contacts and Arcing
Contacts Closed provided manual operating handles
for many years. The reasons for
providing a handle for an ATS
Additional criteria: include:
Prevent simultaneous closure of Installation: For use during
normal and emergency source, installation to manually place
Powered from the live source, the switch in the proper position.
Convenience to maintain. Maintenance: For periodic
inspections and maintenance to
verify the mechanical operation
of the switch and for ease of
contact inspection.
Emergency Operation: To switch
from a dead source to a live
source if the electrical operator
has failed.
In the first two cases, the manual
operator is used on dead sources.
In the third case, it is used to switch
from a dead source to a live source.
Figure 8 Main Contacts Open While
Arcing Contacts Remain Closed UL1008 permits an external
operating handle or an internal
operating handle. The internal
handle is designed for maintenance
2007 Caterpillar
purposes and must be so labeled. operation while under full load, a
When an internal handle is used, few of these are explained below:
contacts must be protected and
It is possible to close a transfer
both mechanical and electrical
switch into a generator, which is
hazards must be considered. UL
attempting to crank, thereby
clearly states that power should
forcing the emergency generator
be removed from the unit prior to
source to bog down as it
servicing on all manufacturers
attempts to assume full load prior
internal operators. An internal
to reaching proper voltage and
removable operating handle that
speed.
is listed by UL in accordance with
UL1008 standards for safety should Manually transferring fault
be provided. currents in excess of switch
rating would create a danger for
3.2.1. Specifications anyone operating the manual
Some specifications have handle of any transfer switch.
been issued that add restrictive,
Manually operating the switch
unnecessary, and potentially
with overload currents present of
dangerous requirements for
six times switch rating unless the
manual handles.
contacts are protected in
The requirements issued state: enclosed arc chambers.
The manual handle shall provide Manual operation by unauthorized
the same contact-to-contact personnel could disconnect
transfer speed as the electrical critical loads.
operator to prevent flashover; Manual operation of a switch that
The manual handle shall be has malfunctioned without first
externally operable. determining the reason for that
malfunction and whether manual
These specifications described
operation is safe.
are restrictive because they are
design features centered on one Manually operating the switch
manufacturers guide specifications. without disconnecting the
They are unnecessary for the proper electrical operator, causing the
and safe operation of an ATS; and mechanism to drive back against
they are potentially dangerous the person operating the switch.
because all safeguards are not If the handle is external, additional
considered. dangers may exist:
3.2.2. Manual Operation Under Increased possibility of
Load Dangers unauthorized persons operating
There are many possible dangers the switch,
present when attempting to Possibility of a moving handle
conduction manual transfer switch (during automatic operation)
2007 Caterpillar
injuring someone standing or The ATS has been designed with

walking near the switch, operator safety and load protection
Complete disregard of the in mind. External load break
potential hazards, service manual handles on ATSs ignore
difficulties and operational many aspects of those proven
problems induced by manual design principles.
operation.
4. Controls
3.3. Safeguards Controls serve to make transfer
The following safeguards are switches automatic. In an
recommended for manual handle emergency power system with a
transfer switches: generator set as the emergency
source of power, ATS controls are
Fully enclosed arc chambers
designed to detect a power failure of
provide protection to the operator
the normal source and to signal the
against arcing, and also prevent
generator set to start. When the
flashover;
generator set reaches the proper
The handle is long and well voltage and frequency, the controls
isolated from electrical or signal the switch to transfer from
mechanical hazards; the normal source to the generator
Proper instructions and labels are set. When the normal source is
provided on the switch to assure available and ready to supply power
safe operation; again, the controls detect that return
and signal the switch to retransfer to
The handle is designed to operate
the normal source. In order to carry
the product within required UL
out these functions, the following
guidelines.
time delays and components are
3.4. Summary frequently specified and supplied
The internal handle, with the with the ATS controller:
proper instructions and safeguards Voltage sensing,
as listed, provides a safe and
Frequency sensing,
dependable operating system.
Time delays,
It is recommended that
specifications include provide a Engine control contacts,
manual handle for manual operation Test switch,
of the transfer switch during Communications.
maintenance.
It is strongly suggested that
4.1. Voltage Sensing
operating personnel are made To detect a power failure, voltage
familiar with proper procedures for sensing of the normal source is
manual transfer and that all factors required. Voltage sensing on at least
be considered before this operation a single phase of the emergency
is performed. source is also needed to determine
2007 Caterpillar
its availability. Single phase sensing acceptable for the transfer switch
is used on single-phase sources, contacts to close on the source
while sensing on three-phase and connect the load.
systems may be one of the following: 2. Dropout setting The dropout
Single-phase on normal and (or differential) setting determines
emergency sources, the voltage that the control will
consider unacceptable and initiate
Three-phase on normal source
a transfer operation towards the
and single-phase on emergency
emergency source
source,
The pickup and dropout settings
Three-phase on normal and
may be fixed or adjustable
emergency sources.
depending on the control type:
Single-phase sensing on a three-
phase system would only be 1. If fixed, typically the pickup
recommended in applications where setting will be 85% of the nominal
possible loss of a single phase would system voltage and the dropout
not cause problems with the differential setting will be fixed at
connected load equipment. 75% of the pickup setting;
2. If adjustable, the pickup setting
Controls utilize this voltage sensing
range is typically 85 to 100% of
capability to determine either an
nominal system voltage and the
under-voltage or over-voltage
dropout range is 75 to 98% of
condition of the normal and
the pickup setting.
emergency sources.
The under-voltage sensors include
4.1.1. Under-voltage a time delay before the controls
ATS controls utilize under-voltage initiate a time delay start. This time
sensors to continuously monitor delay allows the control to ignore
both the normal source and very brief voltage dips that may
emergency power sources. Under result from short-circuit faults and
normal operating conditions, the re-closure operation, etc. Under-
controller identifies the normal voltage sensing time delay can either
source as the preferred source of be fixed, typically at 0.5 seconds, or
power and will not permit the load adjustable, typically from 0.1 to
to be disconnected from both 1.0 seconds.
sources simultaneously when either
or both are acceptable. 4.1.2. Over-voltage
As with under-voltage, two settings
Under-voltage sensing uses two are used for over-voltage sensing:
parameters for determination of
source condition and required switch 1. Pickup setting determines
action: the voltage that the control
will consider acceptable for the
1. Pickup setting The pickup transfer switch contacts to close
setting determines the voltage
that the control will consider
2007 Caterpillar
on the source and connect the 4.2.1. Normal Source

load; Monitoring and Protection
2. Dropout setting determines Provides monitoring and protection
the voltage that the control will based on source 1 frequency set
consider unacceptable and initiate points.
a transfer operation towards the
emergency source.
4.2.2. Emergency Source
Monitoring and Protection
Again, the pickup and dropout
Provides monitoring and protection
settings may be fixed or adjustable
based on the source 2 voltage
depending on the control type:
and/or frequency set points.
If fixed, typically the pickup
setting will be 85% of the 4.3. Time Delays
nominal system voltage and the Several time delays are provided;
dropout differential setting will the first time delay overrides any
be fixed at 75% of the pickup momentary normal source outages
setting; that would cause false engine starts
and switch transfers. This delay
If adjustable, the dropout setting
must be short enough so that the
range is typically 105 to 110%
emergency source can be connected
of nominal system voltage while
within code required time periods.
the pickup setting range is
The typical range is 0 to 6 seconds.
typically 103 to 105% of nominal
voltage. The pickup setting or Another time delay is needed to be
restore value must be set sure that when the normal source is
below the dropout or fail restored, it is a sustained restoration
setting. Typically, by a minimum and ready to assume the load. This
of 2% below the dropout value. delay is normally adjustable from
The over-voltage sensors also zero to 30 minutes. The controls
include a time delay before signaling should bypass this time delay in
the control to begin the start time returning to the normal source if
delay. This time delay prevents the emergency source fails and the
initiation of the start time delay normal source is available.
under spurious over-voltage A time delay is often provided to
conditions caused by any number allow the engine to run unloaded for
of system events such as static, cooldown before the controls shut it
lightning or breaker closures. down. In a power failure, it is usually
Typically, this time delay is adjust- desirable to have the load transferred
able from 0.5 to 120 seconds. to the engine generator set as soon
as it reaches proper voltage and
4.2. Frequency Sensing frequency. However, there are times
Controls are also equipped to when it is desired to sequence
sense the frequency of both the various transfer switches onto the
normal and emergency sources. generator set. Therefore, for these
2007 Caterpillar
applications, the controls should 4.4. Engine Start Contact
include a time delay on transfer to Controls must include a contact
emergency that is adjustable from that signals the engine controls to
zero to one minute. start when the normal power fails.
4.3.1. Time Delay Normal to
4.5. ATS Testing
Emergency (TDNE) Periodic testing is necessary to
Provides a time delay when maintain the emergency power
transferring from the normal source system in good condition. Therefore,
to the emergency source. Timing controls are equipped with a
begins when the emergency source manually operated switch to
becomes available. Permits simulate a normal source failure.
controlled transfer of the load
circuit to the emergency source. The controls described here are
standard and meet most of the
4.3.2. Time Delay Engine Start application needs for ATSs. A
(TDES) number of other controls are
Provides a time delay of the signal available to handle specific needs:
to initiate the engine/generator start
cycle in order to override momentary
4.5.1. Test Switch/Pushbutton
ATSs should be provided with a
power outages or voltage
test button that simulates a loss of
fluctuations of the normal source.
the normal power source. All
4.3.3. Time Delay Emergency programmed time delays (TDNE,
to Normal (TDEN) TDEN, etc.) will be performed as
Provides a time delay of the re- part of the test. Engine run time of
transfer operation to permit the test is equal to the plant
stabilization of the normal source. exerciser programmed set point.
Timing begins when the normal All tests are failsafe protected.
source becomes available. If the If one of the optional test operators
emergency source fails during is chosen, then the standard test
timing, then re-transfer is immediate pushbutton is disabled.
overriding the time delay. Programmable set points include:
4.3.4. Time Delay Engine Load or no load testing, or
Cooldown (TDEC) disabled,
Provides a time delay of the signal Engine run time is equal to the
to initiate the engine/generator stop plant exerciser setting.
cycle after the re-transfer operation.
This allows the engine/generator to 4.5.1.1. 2-Position Test Selector
cooldown by running unloaded. Switch (TSS)
Timing begins on completion of the Provides a 2-position, maintained
re-transfer cycle. contact selector switch marked
Auto and Test. The test is a load
test and will continue until the TSS is
2007 Caterpillar
returned to the Automatic position. Off The automatic transfer

The TSS is failsafe protected. controller and engine start
contact are disabled. A white
4.5.1.2. 3-Position Test Selector
pilot light is provided to indicate
Switch (TPSS)
that the FPSS is in the Off
Provides a 3-position, maintained
position.
contact selector switch marked
Auto, Test, and Off. The 4.6. Communications
TPSS is failsafe protected. Transfer Emergency power systems and
switch operation is determined by their associated distribution are vital
the switch position. Transfer switch links within any installation. The ATS
operations are as follows: is an integral part of many systems.
Auto Automatic operation Various means of communicating
mode; ATS parameters are available
Test A Load test is predominately being; annunciator
performed until the switch is panels and communication devices,
moved to another position; which allow the ATS to communicate
with a customers SCADA or
Off The automatic transfer Building Management System
controller and engine start (BMS).
contact are disabled. A white
pilot light is provided to indicate 4.6.1. Ethernet
that the FPSS is in the Off Ethernet is a large, diverse family
position. of frame-based computer networking
technologies that operates at many
4.5.1.3. 4-Position Test Selector
speeds for local area networks
Switch (FPSS)
(LANs).
Provides a 4-position, maintained
contact selector switch marked For switchgear it provides a way for
Auto, Test, Engine Start, individuals to remotely monitor and/or
and Off. The FPSS is failsafe control the switchgear with a PC.
protected. Transfer switch operation
4.6.2. Modbus
is determined by the switch position.
Modbus is a serial communications
Transfer switch operations are as
protocol published by Modicon for
follows:
use with its programmable logic
Auto Automatic operation controllers (PLCs). Due, in part, to the
mode; fact that it is an open protocol and
Test A Load test is charges no royalties, it has become
performed until the switch is the standard communications protocol
moved to another position; used in industry to connect electronic
devices. This protocol allows for
Engine Start A no-Load test
communication between multiple
is performed until the switch is
devices connected to the same
moved to another position;
network and is often used to connect
a supervisory computer with a remote
2007 Caterpillar
terminal unit (RTU) in supervisory Modbus card. This address enables
control and data acquisition (SCADA) the master to distinguish between
systems. the various slaves on the network.
It also allows the master device to
Versions of the Modbus protocol
send a query command to the
exist for serial port (e.g. Modbus
addressed slave. When the
RTU) and Ethernet (e.g. Modbus
addressed slave receives this
TCP). Some ATS products include
command it will send back an
optional Modbus RTU network cards
appropriate response to the master.
which reside on the back of the
controller board and are part of the LonWorks is a control network
controller assembly. The purpose of that is used in a myriad of
this card is to allow the controller to applications, including factory
be available on a Modbus network as automation, process control,
a slave device. This allows a master building networks and vehicle
device, such as a programmable logic networks. LonWorks allows up to
controller (PLC), to obtain information 32,000 devices in a peer-to-peer
from the controller and have that configuration and also provides
information available for control, a complete set of network
data acquisition and monitoring. management functions. The
LonWorks data link is a proprietary
Every Modbus network consists
form of CSMA/CD over twisted pair,
of one master device and at least
coax and fiber. Some manufacturers
one slave device. All devices on the
produce adapters which allow
network are daisy-chained using a
connection to the Internet via
twisted pair cable, with each slave
Ethernet or dial up modems.
device assigned a unique address
which is a factory default for each
2007 Caterpillar
Figure 10 ATS Remote Monitoring Software Screens
4.6.3. Remote Monitoring program, usually configured in

a hierarchical manner, to control,
and Control
monitor and manage all the
There are two types of remote
equipment installed in the building.
monitoring systems which are
Customers frequently integrate the
typically used: isolated monitoring
monitoring and control of their
and system/group monitoring.
emergency power system
Isolated monitoring systems are components with their BMS.
systems which monitor a single
To accomplish this integration,
product. These systems are variable
a means by which to communicate
dependant on individual
electric power systems (EPS)
manufacturers.
parameters to their system is
The system/group monitoring required. Typically a dedicated PLC
systems most commonly used are on the switchgear master controls
the Building Management System is used for integrating with the BMS.
(BMS) and Supervisory Control and
SCADA
Data Acquisition (SCADA) described
Supervisory Control and Data
below.
Acquisition (SCADA) systems are
Building Management System typically used to perform data
Building Management System collection and control at the
(BMS) is a computer software supervisory level. The supervisory
2007 Caterpillar
control system is a system that is result in over currents that can blow
placed on top of a real time control fuses or trip circuit breakers.
system to control a process that is
external to the SCADA system.
5.1.1. Motor Protection
Alternatives
The SCADA system can utilize Four different control methods can
either the Modbus connection or the be employed to address these
Ethernet connection to monitor and problems:
control the switchgear and ATS.
5.1.1.1. In-Phase Monitor
4.6.4. Annunciator Panels This feature compares the phase
With various transfer switches angle between both sources of
scattered throughout a facility, a power and prevents transfer until
remote annunciator panel provides the two are approximately in phase
the simplest form of remote (within a self adjusting range). When
indication and control of multiple the two voltages are within the
ATSs. These panels are available desired phase angle and approaching
from various manufacturers in the zero phase angle, the in-phase
standard and custom configurations monitor signals the transfer switch to
with a host of available options. operate and reconnection of the load
These options include the ability to takes place. The in-phase monitor,
remotely test, monitor the position, used with transfer switches that
indicate source availability and operate within 10 cycles can be used
bypass time delays for individual to safely transfer motors without
Transfer Switches. exceeding normal starting currents.
Advantages:
The advantages of using an in-phase
monitor when transferring large motor
and/or transformer loads are:
Permits the motor to continue to
run with little disturbance to the
electrical system and the process
that is being controlled by the
motor;
A standard double throw transfer
Figure 11 Remote Annunciator switch can be used with the
addition of the in-phase monitor.
5. Motor Load Transfer
Some loads, especially large three- 5.1.1.2. Motor Load Disconnect
phase motors greater than 50 HP, Control Circuit
receive severe mechanical stress if Motor disconnect control circuits
power is transferred out of phase may also be used to transfer motor
while the motor is still rotating. Also, loads. These circuits should not be
back EMF generated by a motor can used if the motors cannot be
2007 Caterpillar
deenergized, even momentarily, line, time is required for its magnetic

during the transfer of power sources. field to collapse. Release of stored
energy in the transformer generates
This load control disconnects a
a surge even though the two power
large motor via its control circuit
sources are in synchronism when a
for an adjustable period of time prior
transfer is initiated. The transient
to transfer in either direction.
caused by the momentary high
For switching multiple motors, current flow described above can
the motor disconnect contact with exceed the instantaneous trip
staged restart disconnects the settings of protective devices in the
motors prior to transfer and brings system and can be severe enough to
them back on line sequentially. trip circuit breakers, cause damage
A62 Sequential Motor Load to motor shafts, couplings, etc.
Disconnect Circuit: Normally closed Another solution to this problem is
set of auxiliary contacts that open to introduce a delay in the transition
0-60 seconds prior to transfer, after between two live sources. Transfer
transfer, or both in either direction switches equipped with a delayed
then re-close in timed sequence transition feature provide an
after transfer. adjustable time delay after the
5.1.1.3. Timed Center-Off Position opening of the closed contacts and
(Delayed Transition) before the closing of the open
When transferring large motors, contacts for transferring large motor
UPS systems and/or transformers and/or transformer loads. This delayed
between two sources of power transition time allows for motors to
that have the potential to be coast down and transformer fields to
unsynchronized, consideration decay, thus allowing inductive loads
must be given to the elimination or to be re-energized after transfer with
reduction of transients. These may only normal inrush starting currents.
occur when loads are disconnected The delayed transition design is an
from the first power source and effective method of handling these
immediately connected to the applications and can be utilized as an
second source. alternative to a standard transfer
switch equipped with an in-phase
When a running motor is suddenly monitor.
disconnected from its power source,
the residual voltage developed due Delayed transition switches can
to generator action will decrease in also be used for load shedding of
amplitude and frequency as the selected circuits or other applications
motor slows down. Depending on which require a means to disconnect
the type number and application of the load from either source.
the motors involved, the decaying The delayed transition transfer
action may take a considerable switch is ideally suited for pumping
amount of time. Similarly when a stations, sewage treatment plants,
transformer is disconnected from the hospital X-ray equipment, or wherever
2007 Caterpillar
the bulk of the load being controlled 5.1.1.4. Description and Operation
consists of large motors and/or The delayed transition transfer
transformers. Further, many UPS switch functions as discussed below:
manufacturers strongly recommend Upon failure or reduction of the
the use of delayed transition type normal source, and the availability
transfer switches to ensure proper of the emergency source, the drive
operation and sequencing of their solenoid is energized and pulls the
equipment. The delayed transition main contacts out of the normal
feature allows a typical UPS system position and locks them mechanically
sufficient delay to recognize a power in the open transition position.
failure and transfer to batteries,
acknowledge the return of input An adjustable time delay is then
power and allow the rectifier to walk- energized. After the preset time
on to the new source, reducing any has elapsed, the drive solenoid is
transfer anomalies. energized and pulls the main contacts
out of the transition position and
Advantages: locks them mechanically in the
The advantages of using delayed emergency closed position. The
transition when transferring large emergency power source is now
motor and/or transformer loads are: feeding the load. When the voltage
Consistent operation under all sensing detects the restoration of the
conditions, including manual normal source for a predetermined
(pushbutton) operation; time period, the drive solenoid is
energized and pulls the main contacts
Operation is totally independent
from the emergency position and
of the synchronism of the power
locks them mechanically in the open
sources, eliminating the need for transition position. After the preset
in-phase monitors or extensive time delay has elapsed, the drive
motor disconnect control wiring solenoid is energized and pulls the
between the transfer switch and main contacts out of the open
motor control centers;
transition position and locks them
The delayed transition function mechanically in the normal closed
adapts itself for use in multiple position. The normal power source
generator systems and paralleling is now feeding the load.
systems to permit load shedding
5.1.1.5. Momentary Paralleling
by switching the main contacts
Closed transition switches combine
to a center-off or disconnected
delayed transition operation during a
position;
source failure with a control system
Allows typical UPS systems to that allows momentary paralleling
function properly while switching (100 ms) of two acceptable sources,
between line input sources. thereby limiting the impact of
transfer on the load. Reference the
section on closed transition transfer
(Section 7.3.3) for further details.
2007 Caterpillar
5.1.1.6. Motor Load Shedding Emergency source overloading

Delayed Reconnection prevention methods are:
Motor load shedding delayed
Transfer switches with individual
reconnection refers to methods used
time delay circuits on transfer
to prevent overloading the emergency
to emergency;
source during a normal power outage.
On-site generator sets are often used Transfer switches with signal
as the emergency source of power. circuit for definite disconnection
Such generator sets often have of a single load prior to transfer
limited capability to supply the total and reconnection after transfer;
inrush and starting currents of the Transfer switches as indicated
connected load. For economical in the previous point, but with
purposes, generator sets are multi-signal circuits to sequence
commonly sized to provide full load several loads onto the generator.
current plus a limited motor starting
capability. In such cases, it becomes
5.1.2. Electronic Variable
essential to delay reconnection of Frequency Drives (VFDs)
some of the loads when transferring Special consideration should be
from the normal power source to the given to systems that utilize VFDs
on-site generator. to control motor operation. These
electronic devices often consist
Article 517 of the NEC requires of SCR assemblies to change the
that the equipment system load voltage and frequency applied to the
(primarily motor load) transfer motor to vary its torque and speed.
switches in hospitals be equipped
with time delay relays that will delay With some VFDs, interruption of
transfer of the connected load to the input, whether it is caused by
the generator set. The purpose is transfer switch operation or other
to assure that the more important momentary power outages, causes
emergency system loads are the device to see a low voltage
connected first and established input. To maintain motor speed,
within ten seconds of failure. The some control sensors immediately
transfer switches feeding the motors change the conduction angle of the
are then sequentially transferred to controlling SCRs to compensate for
the generator set. Another reason low line condition. The result is that
for load shedding is the need to upon immediate reapplication of
power down certain loads, such power, the controlling SCRs are
as those utilizing SCRs, to avoid turned fully on, causing a severe
damage to, or failure of, such current inrush. This current inrush is
components during transfer. of such a magnitude that protective
Following are various solutions devices such as fuses can blow, or
in use today to help solve these the SCRs themselves can be
problems by adding circuit features irreparably damaged.
to transfer switches.
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This particular problem can be load carrying contacts. The use of
only partly solved by conventional the fourth pole to switch the neutral
in-phase transfer or other load is less commonly understood.
disconnect arrangements, because Questions of when to switch the
other extraneous interruptions of neutral or not in standby power
power will also confuse the VFD systems must be answered in light
voltage sensing circuitry. of NEC 230-95 and NFPA 70-2005.
These standards refer to ground
Some systems include high speed
fault protection requirements.
voltage sensing circuitry that detects
momentary power outages and The safety and advantages of
shuts down the VFD entirely. Upon Ground Fault Protection (GFP) can
reapplication of voltage, the SCRs only be realized if proper grounding
go from an off condition to a soft and consideration of neutral
start current-limiting startup that switching is taken. When neutral
automatically protects the solid switching is dictated, then the
state switching devices. determination of fourth pole contact
ratings, synchronization, reliability
When other provisions are lacking,
and integration with GFP must be
the motor load disconnect control
taken into account. Since April 1989
circuit can be considered for transfer
UL has required more stringent test
of SCR controlled loads for the VFDs
conformance of the neutral pole and
and other loads such as used by
this has a bearing on the designers
communications companies. The
choices for standby power systems.
contact, which must be integrated
by the VFD manufacturer, simply These switches are made in two,
signals the SCR control to power three- and four-pole versions. The
down before transfer and permits use of a transfer switch in traditional
a soft restart after transfer. As two- or three-pole applications, as
indicated above, such controls may pertains to automatic voltage sensing
protect the SCRs during a power of normal source failure and the
interruption when the transfer commands to start and cut over to a
switch is operating, but offer standby source, is straightforward.
no protection when the power Typically these installations are two-
interruption is extraneous to the pole for single phase and three-pole
transfer switch. for three phase circuits. The neutral
may or may not require switching
6. Switching the Neutral which would dictate an additional
Conductor pole on the transfer switch. The
neutral and its relation to grounding,
Automatic transfer and bypass
in terms of safety to personnel and
switches are made in two-, three-
equipment for standby systems,
and four- pole versions. The two-
must first be understood.
and three- pole varieties are
generally understood as to usage
and ampere/voltage rating of the
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6.1.1. Grounded vs.

Ungrounded Neutrals
The NEC differentiates between
system and equipment grounding.
A system ground (Figure 12) is a
connection to ground from one of
the current-carrying conductors of
a distribution circuit or of an interior
wiring scheme.
Figure 13 Equipment Ground

Ungrounded Neutral
A system neutral ground (Figure 14)
is a connection to ground from the
neutral point or points of a circuit,
transformer, rotating machine or
system. The neutral point of a system
is that point which has the same
potential as the point of junction
of a group of equal non-reactive
resistances if connected at their free
ends to the appropriate main terminals
or lines of the system.
Figure 12 System Ground on an

Ungrounded System
An equipment ground (Figure 13)
is a connection to ground from one
or more of the non-current-carrying
metal parts of the wiring system or
of apparatus connected to the
system. As used in this sense, the
term "equipment" includes all such
metal parts as metal conduits, metal
raceways, metal armor of cables,
outlet boxes, cabinets, switch Figure 14 System Neutral Ground
boxes, motor frames and metal
An ungrounded system (Figure 15)
enclosures of motor controllers.
features no intentional connection
between the system conductors and
ground. What is easily forgotten
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though is the capacitive coupling
that always exists between system
conductors and ground. Because of
the danger to personnel and possible
damage to equipment and property,
should there be leakage to ground
due to shorts or high impedance
paths, the NEC decrees that certain
grounding practices and detection of
these faults be designed into systems.
Figure 16 Transient Overvoltage Due to
Ground Fault Interruption on Ungrounded
System (May Cause Other Faults to Occur
on System)
In addition, an ungrounded neutral
system developing a fault to ground
may go unnoticed until a second
ground fault causes a line-to-line
fault which can be of major
proportions (Figure 17).
These ungrounded systems
Figure 15 Ungrounded System
Capacitively Coupled to Ground are designed into critical industrial
processes that cannot afford tripping
The utilities generally provide
of protective devices should a
power to large users via three phase
ground fault develop. Such a
grounded wye distribution. The
condition could shut down
power transformer feeding the user
operations or parts of processes
will have its neutral grounded. For a
that could result in an explosion or
system having a neutral conductor
loss of product being processed.
that is not grounded, the possibility
of destructive transient voltages
appearing from line to ground during
switching of a circuit having a line to
ground fault is very likely (Figure 16).
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rated 1000 amperes or more

(Figure 18).
Figure 17 Undergrounded Neutral Figure 18 Source Featuring Grounded

System Developing Second Fault to Ground Neutral at Transformer and Service
A system featuring neutral Entrance with GFP Sensor
grounding has many advantages The reason behind this requirement
over the ungrounded system. was awareness that sustained arcing
That is: on grounded 480Y/277 volt systems
could be very damaging.
Greater safety for personnel and
equipment, The selection of 1000 amperes
Increased service reliability, or more for ground fault protection
was made with the belief that
Lower operating and maintenance smaller overcurrent devices with
expense, long trip times of 1000 amperes
Reduced magnitude transients, or less would probably clear an
Simplified ground-fault location. arcing ground fault in sufficient
time to limit damage. A designer
The NEC requires that ground
could under this rule, choose as
fault protection must be used for all
many as six 800 amperes mains
solidly grounded wye services. This
in a 480Y/277 volt switchboard
requirement first appeared in the NEC
(4800 amps of service) without
in 1971 (230-95). It stated, Ground
having to install ground fault
fault protection of equipment shall be
protection.
provided for solidly grounded wye
electrical services of more than Ground fault protection equipment
150 volts to ground, but not is designed to detect phase to
exceeding 600 volts phase to phase ground faults ignoring overloads
for each service disconnecting means and phase-to-phase faults. Three
methods of detection are employed:
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Zero Sequence detects vector
unbalance of current sum in each
phase and the neutral. Outputs if
not zero;
Residual Connected uses 3 or
4 CTs and 4 time relays. Any
leakage to ground will output a
signal;
Source Ground detects current
flow through system grounding
conductor, which is connected
between neutral and ground.
None of these methods are totally
without problems. Proper operation
requires that detection will monitor
all fault currents to ground. Should Figure 19 Multiple Grounding of Neutral
there be multiple grounding of the Allows Fault Current to Flow Back Through
neutral, it is possible that proper Neutral via Paths A&B (Flow via C
operation of the GFP device will not is Outside GFP Sensor)
monitor the total fault (Figure 19). 6.1.2. Three Pole Transfer
Therefore, it is important to ensure Switches
that grounding of the neutral not take A correctly grounded standby
place at multiple locations so as to generator system including the
create unintended paths and defeat transfer switch is shown in Figure 20.
the GFP sensor. The NEC further
Note that a three-pole transfer
limits neutral grounding via the
switch is used and the generator set
separately derived system rule.
does not have its neutral grounded
That is, a system source such as a
at the generator although the
transformer or a generator can have
housing is grounded.
its neutral grounded at only one
place. The correct place to ground Should a fault develop to ground
the service neutral is at the main only one path exists and the GFP
panelboard or switchboard. It is not sensor would signal the unbalance.
permitted to be grounded at other Since the neutral is common to both
points. the normal and standby sources, the
generator is not considered
separately derived. Under this
scheme the neutral is not grounded
at the housing.
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Figure 20 Correctly Grounded Standby Power Source

Figure 21 depicts the division of portion would return outside the
current that would occur in the GFP sensor.
event of a ground fault. Some
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Figure 21 Generator Set Grounded to Neutral at Housing Neutral Bus Isolated
from Housing of Transfer Switch
Yet another problem with a generator set ground path. This
generator neutral ground is shown also will fool the GFP sensor into
in Figure 22. In this case the neutral monitoring less fault current than
current can divide and return via the may be flowing.
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Figure 22 Neutral Current Returning to Ground (Partial Current Outside GFP)

In all of the previous cases, the grounded without compromising the
three-pole transfer switch must have NEC. That is, the generator set can
contact structures that are able to be wired as a separately derived
withstand the fault currents for the system by grounding the neutral
time that is taken before sensing and at the generator set as long as the
the protective devices clear the neutral is no longer solid through the
circuit. Transfer switches that are transfer switch. This of course infers
properly designed will have relatively that neutral be switched at the same
high withstand and close into fault time as the phases. This scheme will
current values for this demanding also insure GFP operation as
work. Also in the above cases the intended. Figure 23 shows a four-
neutral current carrying line was pole transfer switch wired with
solidly connected and not switched. a generator set having its neutral
Should the designer want to ground grounded at the housing. In this
the generator and still adhere to wiring the neutral return path is
code and avoid the problems of deliberately open for ground return
split return paths and improper currents by the transfer switch
GFP sensing the use of a four-pole contacts. This will also avoid
transfer switch is called for. nuisance tripping in the case of
an unbalanced load. In effect, the
6.1.3. Four Pole Transfer generator set is now completely
Switches isolated from the utility service
Four pole switches are employed and presents an effective and safe
to ensure that the generator can be alternative to solid neutral lines.
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Figure 23 Use of a 4 Pole Transfer Switch to Permit Grounding of Generator Set at Site
A designer has the tools to now 6.1.4. Fourth Pole and UL
configure a standby system as Requirements
either separately derived or not. As of April 1989, UL 1008
If the system needs are for not required that the fourth pole of
grounding the generator set at its a transfer switch be tested and
site then a three-pole transfer proven to have ratings equal to
switch with a solid neutral should its phase contacts if not of the
be employed. If the generator set same construction. And that bus
needs to be grounded at its site spacing is closer to line than its
then a four-pole transfer switch line-to-line spacing or it has a
must be designed into the system. different means of support for its
This will ensure that the neutral is neutral bus. That means that the
switched, isolating the normal or neutral contact must be capable
utility supply. of withstand and close into fault
Lastly, should the designer decide ratings at least equal to the phase
to switch the neutral, consideration contacts. The fact is not all
to contact ratings and performance transfer switches employing a
should be taken into account. fourth pole are constructed in
like fashion.
There exist four pole switches
that utilize contacts:
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Of different amperage (lower) leaving the neutral connected to

capacity than the phases, the normal power source.
That do not actuate by the same There exists some debate over
means as the phase contacts, synchronizing the timing of the
That have bus supports differing fourth pole. For those transfer
from the phase supports, switches having all contacts
actuated by a common shaft, the
That have bus structures with
neutral will swing in harmony with
closer spacing than phase to
the phase contacts. In fact, if the
phase spacing,
neutral leads the phase contacts by
That have synchronizing an amount to ensure make first,
characteristics differing from break last, then the possibility of
phase contact make-break transient voltages during switching
timing. is diminished or eliminated.
Since all transfer switches For those switches employing a
must comply with and meet the separate actuating means for the
requirements for UL 1008, a neutral, the possibility of timing
designer must examine the ratings differences are much greater.
and specifications of a four-pole These switches employ the
transfer switch should the system overlapping contact arrangement,
call for switching the neutral. which adds to complexity. Four-
At a minimum, the designer pole transfer switches with
should ensure that all four poles common shafts change position
are equally rated as to carrying, rapidly enough to minimize any
withstand, close into fault currents currents due to transients.
and voltage. Although the subject of another
The designer should also ascertain discussion, the more recent
that bus supports, spacings, and attention to third harmonic current
actuating means are identical for all appearing on the neutral and its
contacts. The aspect of actuating attendant emphasis on having
means can be critical. greater contact capability, the need
for reliable fourth pole operation
If all contacts are actuated by a
is even more pronounced.
common shaft, there can be no
question of a neutral never having 7. Sizing Automatic
been switched while the phases
were. There are switches that have Transfer Switches
fourth pole contacts actuated by Serious attention to, and careful
means other than the main phase selection of, an ATS is important
contact shaft. Interesting results to ensure maximum reliability and
are obtained by transferring the adequate capability under both
phases to standby power and normal and emergency conditions.
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The main points to be considered 7.1.2. Voltage Rating
are as follows: An ATS is unique in the electrical
Loads, distribution system in that it is one
of the few electrical devices that
Voltage rating,
may have two unsynchronized
Continuous current rating, power sources connected to it.
Overload and fault current This means that the voltages
withstand ratings, impressed on the insulation may
actually be as high as 960 volts on
Type of overcurrent protective
a 480-volt ac system. A properly
device ahead of transfer
designed transfer switch will
switch.
provide sufficient spacings and
7.1.1. Loads insulation to meet these increased
Loads, as applied to ATSs, are voltage stresses.
classified by UL 1008, as (1) total For this reason, the spacings in
system loads, (2) motor load, transfer switches should not be
(3) electric discharge lamp loads, less than those shown in Table
(4) resistive loads, (5) incandescent 22.1 of UL 1008, regardless of
lamp loads. what type of component may be
UL requires marking of transfer used as part of the transfer switch.
switches to indicate the type of For the purposes of this guide, the
load they are capable of handling. voltage ratings will be limited to
The marking total systems loads low voltage applications where
indicates that the transfer switch transfer switches are rated 600
can be used for any combination of volts or less. Common ac voltage
the loads described above under ratings of ATSs are typically 120,
(2) through (5). However, the 208, 240, 480 or 600 volts, single
incandescent load shall not exceed or three-phase. Standard
30% of the total load unless the frequencies are 50 or 60 hertz.
transfer switch is specifically Transfer switches may also be
marked as suitable to transfer a provided for other voltages, when
higher percentage of incandescent required.
lamps. Most transfer switches are
rated for transfer of total system 7.1.3. Solid or Switched
loads, though some may be marked Neutral
resistance only, tungsten only, etc. For three phase applications, it
or a combination of these markings. is necessary to choose between
The burden on the system designer three pole and four pole transfer
is lessened when he chooses switches.
switches listed and rated for total
Three pole switches represent
system loads.
a solid neutral where four pole
switches represent a switched
neutral. Two pole transfer
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switches are typically used for be selected. In addition the power

single-phase applications. For factor of the motor is assumed
more information see section 6 to be .85 and the efficiency is
assumed to be .90.
7.1.4. Continuous Current
Rating Motor
hp 746
An ATS current rating is FullLoad =
determined very simply by adding PF EFF V 3
Current
up the total amps required; i.e.
kW 1000
lights, heating, and motors. When I=
sizing an ATS, motor full load V 3 power _ factor
currents only are considered.
Momentary surges caused by 300kW _ lightning _ load I =
300x1000
= 360amps
loads such as lighting or motors 480 x1.732x1.0
450x1000
450kW _ lightning _ load I = = 541amps
can be ignored. Select a transfer 480 x1.732x1.0
200x 746
switch rating that is either equal 200hp _ motor _ load I = = 235amps
.85 x.9 x 480x 3
to or greater than the calculated Total _ Load = 1136amps
continuous current and rated for
the class of connected load (i.e.
tungsten lamp). Sometimes it is 7.1.5. Overload and Fault
desirable to select a size of transfer Current Withstand
switch, which is the same as the Ratings
overcurrent device ahead of it on The protective device within the
the normal side. Although this service entrance switchgear on the
many not be necessary, it is a normal source (circuit breaker or
convenience which will allow for fuse) protects the downstream
the addition of future loads while apparatus, including the ATS.
remaining within the capacity of However, if a fault condition
the system. develops between the ATS and
7.1.4.1. Example the load, the ATS could be
Select an ATS for use in a three- required to handle currents well
phase, 480-volt, 60 Hz system for beyond its continuous rating.
use with the following three-phase Under a fault condition when
balanced load. the switch closed and on normal
300 kW lighting load, service, an ATS be required to
450 kW heating load, withstand the energy let the
normal service protective device
200 hp motor load.
while device interrupts the fault.
Select a transfer switch with The maximum current of an ATS
a rating closest to, but greater in this fault condition called the
than the total load current. In this withstand rating. To obtain a
example, a 1200-amp transfer withstand rating; a higher
switch rated 480 volts would
2007 Caterpillar
continuous duty rating transfer For a sample withstand current
switch can be used. rating see Section 12.2.
7.1.6. Overcurrent Protection 7.2. Enclosure Ratings
Since transfer switches are often The National Electric
subjected to currents of short Manufacturers Association
duration exceeding the continuous (NEMA) provides standards
duty rating, the ability of the for enclosures to ensure safe
transfer switch to handle higher operation under various
currents is measured by its overload conditions. Two major categories
and withstand current ratings. of classification are for switchgear
The overload rating refers to the in non-hazardous locations and
ability of a transfer switch to those in hazardous locations.
handle normal inrush currents 7.2.1. Non-Hazardous
encountered in switching lighting,
Locations
transformer, and motor loads.
In non-hazardous locations
Generally an ATS should have a
the specific enclosure types,
minimum overload rating 15 times
their applications, and the
the continuous duty rating for .
environmental conditions they
5 second. The withstand current
are designed to protect against,
rating pertains to the ability of an
when completely and properly
ATS to withstand the magnetic
installed, are as follows (see
and thermal stresses of high fault
Figure 24 and Figure 25):
currents until the fault is cleared by
an overcurrent protective device. Type 1 Enclosures constructed
The overcurrent protective device for indoor use to provide a degree
is usually located external to the of protection to personnel against
transfer switch although there are access to hazardous parts and to
transfer switches that do include provide a degree of protection to
integral overcurrent protection. the equipment inside the enclosure
To differentiate between the two, against ingress of solid foreign
one recognized standard defines objects (falling dirt).
the following type designation: Type 1A is similar to Type 1,
Transfer switch; Type A means but also includes gasketing
an ATS that does not employ material. Type 1A is not officially
integral overcurrent devices recognized but is often included in
specifications.
Transfer switch, Type B means
an ATS that employs integral Type 2 Enclosures constructed
overcurrent devices. for indoor use to provide a degree
of protection to personnel against
UL 1008 includes minimum
access to hazardous parts; to
requirements for withstand current
provide a degree of protection to
ratings.
the equipment inside the enclosure
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against ingress of solid foreign against the external formation of

objects (falling dirt); and to provide ice on the enclosure.
a degree of protection with respect Type 3SX Identical to Type 3
to harmful effects on the but also provides additional
equipment due to the ingress of protection against corrosion and
water (dripping and light splashing). sleet, ensuring the external
Type 3 Enclosures constructed mechanism(s) remain operable
for either indoor or outdoor use when ice laden.
to provide a degree of protection Type 4 Enclosures constructed
to personnel against access to for either indoor or outdoor use
hazardous parts; to provide a to provide a degree of protection
degree of protection to the to personnel against access to
equipment inside the enclosure hazardous parts; to provide a
against ingress of solid foreign degree of protection to the
objects (falling dirt and windblown equipment inside the enclosure
dust); to provide a degree of against ingress of solid foreign
protection with respect to harmful objects (falling dirt and windblown
effects on the equipment due to dust); to provide a degree of
the ingress of water (rain, sleet, protection with respect to harmful
snow); and to remain undamaged effects on the equipment due to
by the external formation of ice the ingress of water (rain, sleet,
on the enclosure. snow, splashing water, and hose
Type 3R Identical to Type 3 directed water); and to remain
except Type 3R does not protect undamaged by the external
against ingress of solid foreign formation of ice on the enclosure.
objects and may be ventilated. Type 4X Identical to Type 4 but
Type 3S Identical to Type 3 with also provides an additional level
additional protection against sleet, of protection against corrosion
ensuring the external mechanism(s) (usually by incorporating stainless
remain operable when ice laden. steel or nonmetallic composites)
and against the external formation
Type 3X Identical to Type 3 with
of ice on the enclosure.
an additional level of protection
against corrosion and against the Type 5 Enclosures constructed
external formation of ice on the for indoor use to provide a degree
enclosure. of protection to personnel against
access to hazardous parts; to
Type 3RX Identical to Type 3
except Type 3RX does not protect
the equipment inside the enclosure
against ingress of solid foreign
objects, may be ventilated, and
objects (falling dirt and settling
provides an additional level of
airborne dust, lint, fibers, and
protection against corrosion and
flyings); and to provide a degree
2007 Caterpillar
of protection with respect to personnel against access to
harmful effects on the equipment hazardous parts; to provide a
due to the ingress of water degree of protection to the
(dripping and light splashing). equipment inside the enclosure
Type 6 Enclosures constructed
objects (falling dirt and circulating
for either indoor or outdoor use
dust, lint, fibers, and flyings); and
to provide a degree of protection
to provide a degree of protection
to personnel against access to
with respect to harmful effects on
hazardous parts; to provide a
the equipment due to the ingress
degree of protection to the
of water (dripping and light
equipment inside the enclosure
splashing).
objects (falling dirt); to provide a Type 12K Identical to Type 12
degree of protection with respect with the addition of being
to harmful effects on the constructed with knockouts.
equipment due to the ingress of Type 13 Enclosures constructed
water (hose-directed water and the for indoor use to provide a degree
entry of water during occasional of protection to personnel against
temporary submersion at a limited access to hazardous parts; to
depth); and to remain undamaged provide a degree of protection to
by the external formation of ice on the equipment inside the enclosure
the enclosure. against ingress of solid foreign
Type 6P Identical to Type 6 but objects (falling dirt and circulating
also provides an additional level dust, lint, fibers, and flyings); to
of protection against corrosion, provide a degree of protection
ingress of water (occasional with respect to harmful effects on
prolonged submersion), and the equipment due to the ingress
protection against the external of water (dripping and light
formation of ice on the enclosure. splashing); and to provide a degree
of protection against the spraying,
splashing, and seepage of oil and
without knockouts for indoor use to
non-corrosive coolants.
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Figure 24 Comparison of Specific Applications of Enclosures
for Indoor Non-Hazardous Locations (NEMA 250-2003)
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for Outdoor Non-Hazardous Locations (NEMA 250-2003)
7.2.2. Hazardous Locations as Class I, Division 1, Groups A, B,

Manufacturers who specialize C, or D as defined in NFPA 70.
in hazardous location equipment Type 8 Enclosures constructed
should be used for consultation for either indoor or outdoor use
when selecting equipment for in hazardous (classified) locations
hazardous locations. that is classified as Class I,
In hazardous locations, when Division 1, Groups A, B, C, and D
completely and properly installed as defined in NFPA 70.
and maintained, Type 7 and 10 Type 9 Enclosures constructed
enclosures are designed to contain for indoor use in hazardous
an internal explosion without (classified) locations classified as
causing an external hazard. Type 8 Class II, Division 1, Groups E, F,
enclosures are designed to prevent or G as defined in NFPA 70.
combustion through the use of
oil-immersed equipment. Type 9
to meet the requirements of the
enclosures are designed to prevent
Mine Safety and Health
the ignition of combustible dust.
Administration, 30 CFR, Part 18.
for indoor use in hazardous
(classified) locations classified
2007 Caterpillar
Figure 26 summarizes the additional protection is needed

requirements for enclosures in from Figure 24 or Figure 25, a
hazardous locations. combination-type enclosure is
If the enclosure in a hazardous needed
location is to be outdoors or .

for Indoor Hazardous Locations (NEMA 250-2003)
7.2.3. NEMA Enclosure such as moisture, corrosive vapors,

fungus, or vermin. The NEMA
Type Numbers vs. IEC
Standard for Enclosures for
Enclosure Classification Electrical Equipment does test for
Designations environmental conditions such as
IEC Publication 60529, corrosion, rust, icing, oil, and
Classification of Degrees coolants. For this reason and
of Protection Provided by because the test and evaluations
Enclosures, provides a system for other characteristics are not
for specifying the enclosures of identical, the IEC enclosure
electrical equipment on the basis classification designations cannot be
of the degree of protection exactly equated with the enclosure
provided by the enclosure. Type numbers in this standard.
IEC 60529 does not specify The IEC designation consists
degrees of protection against of the letters IP followed by two
mechanical damage of equipment, numerals. The first numeral
risk of explosions, or conditions
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indicates the degree of protection Type numbers in this standard to
provided by the enclosure with the IEC enclosure classification
respect to persons and solid foreign designations. The enclosure type
objects entering the enclosure. numbers meet or exceed the test
The second numeral indicates the requirements for the associated
degree of protection provided by IEC Classification; for this reason
the enclosure with respect to the Figure 27 cannot be used to
harmful ingress of water. convert from IEC classifications
to enclosure Type numbers.
Figure 27 provides an equivalent
conversion from the enclosure
Figure 27 IEC Enclosure Classification

A shaded block in the A column indicates that the NEMA enclosure type
exceeds the requirements for the respective IEC 60529 IP first character
designation. The IP first character designation is the protection against
access to hazardous parts and solid foreign objects.
A shaded block in the B column indicates that the NEMA enclosure type
exceeds the requirements for the respective IEC 60529 IP second character
designation. The IP second character designation is the protection against
the ingress of water.
7.3. Transfer Switch Automatic.

This section will concentrate on
Configurations transfer switches with different
Three basic types of transfer
configurations. In most instances
switches have been discussed up to
that means the switch performs in
this point:
a certain manner for a specific type
Non-automatic (manually application. There is a difference
operated), between a transfer switch type and
Non-automatic (electrically its configuration.
operated),
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Example: The type of switch would a way that the power output is
be one of the three types just outlined broken (interrupted) before the
(non-automatic manual/electrical or transfer to the new source is made.
automatic). The application could call There is a definite break in power as
for the switch to perform in a certain the load is taken off one source and
way to accomplish its function. This connected to another. While this type
means the switch must be configured of transfer is simple, the time delay
to do the job. The logic might be between break and make creates an
configured in a certain way, the unacceptable power interruption for
switch might be physically configured critical loads, such as computers. For
in a certain way, or it could be a this reason, the OTT configuration is
combination of the two. Even though more appropriate for less critical
the switch is configured a certain way applications.
for the application, it might be a non- Typically, this type of switch
automatic type or an automatic type uses voltage sensors and time delay
switch. These things are dependent circuitry to activate the operation
upon the specific design. All switch of the switching mechanism in the
designs do not offer all the same desired sequence. With ATSs, the
choices. In addition, previous logic controls the operation. Whether
discussions centered around fixed the switch is transferring to the
switching devices. emergency source or retransferring
If insulated case switches or to the normal source, it operates in
insulated case circuit breakers are the same sequence, break-before-
used as the main switching devices, make (Figure 28)
drawout switching devices may also
be available. The transfer switch
can, therefore, be configured as
fixed or drawout.
The rest of this section will present
brief explanations of a number of
different switch configurations:
Open transition,
Delayed transition,
Closed transition,
Maintenance bypass/bypass
isolation,
Service entrance. Figure 28 Open Transition Operation
(Break-Before-Make Operation No Center
7.3.1. Open Transition Off Position)
An Open Transition Transfer (OTT)
switch is also called a break-before-
make switch. It is configured in such
2007 Caterpillar
7.3.2. Delayed Transition source, reducing any transfer
Transfer Switches anomalies.
As previously explained, a delayed 7.3.2.1. Application Information
transition transfer switch, also When transferring large motors,
referred to by some manufacturers UPS systems and/or transformers
as a programmed transition between two sources of power
feature, provides an adjustable time that have the potential to be
delay after the opening of the closed unsynchronized, consideration
contacts and before the closing of must be given to the elimination
the open contacts for transferring or reduction of transients.
large motor and/or transformer
These may occur when loads are
loads. This delayed transition time
disconnected from the first power
allows for motors to coast down and
source and immediately connected
transformer fields to decay, thus
to the second source.
allowing inductive loads to be re-
energized after transfer with only When a running motor is suddenly
normal inrush starting currents. disconnected from its power source,
the residual voltage developed due
The delayed transition design is an
to generator action will decrease in
effective method of handling these
amplitude and frequency as the
applications and can be utilized as
motor slows down. Depending on
an alternative to a standard transfer
the type number and application of
switch equipped with an in-phase
the motors involved, the decaying
monitor.
action may take a considerable
The delayed transition transfer amount of time.
switch is ideally suited for pumping
Similarly when a transformer is
stations, sewage treatment plants,
disconnected from the line, time is
hospital X-ray equipment, or
required for its magnetic field to
wherever the bulk of the load being
collapse. Release of stored energy in
controlled consists of large motors
the transformer generates a surge
and/or transformers.
even though the two power sources
Further, many UPS manufacturers are in synchronism when a transfer
strongly recommend the use of is initiated. The transient caused by
delayed transition type transfer the momentary high current flow
switches to ensure proper operation described above can exceed the
and sequencing of their equipment. instantaneous trip settings of
The delayed transition switch allows protective devices in the system
a typical UPS system sufficient delay and can be severe enough to trip
to recognize a power failure and circuit breakers cause damage to
transfer to batteries, acknowledge motor shafts couplings, etc.
the return of input power and allow
One solution to this problem is to
the rectifier to walk-on to the new
introduce a delay in the transition
between two live sources.
2007 Caterpillar
The advantages of using delayed emergency closed position. The

transition when transferring large emergency power source is now
motor and/or transformer loads are: feeding the load.
Consistent operation under all When the voltage sensing detects
conditions, including manual the restoration of the normal source
(pushbutton) operation; for a predetermined time period, the
Operation is totally independent drive solenoid is energized and pulls
of the synchronism of the power the main contacts from the
sources, eliminating the need for emergency position and locks them
in-phase monitors or extensive mechanically in the open transition
motor disconnect control wiring position. After the preset time delay
between the transfer switch and has elapsed, the drive solenoid is
motor control centers; energized and pulls the main contacts
out of the open transition position and
The delayed transition function locks them mechanically in the normal
adapts itself for use in multiple closed position. The normal power
generator systems and paralleling source is now feeding the load.
systems to permit load shedding
by switching the main contacts
to a center-off or disconnected
position;
Allows typical UPS systems to
function properly while switching
between line input sources.
7.3.2.2. Description and Operation
The operation of a delayed
transition transfer switch is identical
to the previously mentioned open
transition type with the exception of
the drive mechanism. Upon failure or
reduction of the normal source, and Figure 29 Delayed Transition Operation
the availability of the emergency (Break-Before-Make Operation
source, the drive solenoid is with Center Off Position)
energized and pulls the main NOTE: N Position indicates
Neither Source connected
contacts out of the normal position
and locks them mechanically in the 7.3.3. Closed Transition
open transition position. Since the ATS is the single link
between utility and emergency
An adjustable time delay is then
power, operation and testing of the
energized. After the preset time
ATS may be a cause of concern for
has elapsed, the drive solenoid is
many users. Loads such as electronic
energized and pulls the main contacts
equipment, UPS systems, HID
out of the transition position and
lighting, motor starters, etc.,
locks them mechanically in the
2007 Caterpillar
are sensitive to even the 30-100
millisecond outage experienced during
a typical transfer switch operation.
In addition to these applications,
opportunities for peak shaving and
utility incentive rates may be passed
over because of the inability to
accept the short power interruptions
inflicted during operation.
The closed transition transfer
switch, also known as a make-before-
break switch, is designed for such
applications. With this feature, there
is no interruption in power to the load
during transfer operations when both
power sources are available. Figure 30 CTT Switch Used for
Emergency Source Testing (Make-Before-
These products utilize the same Break Operation)
switching technology as that NOTE: P Position indicates both sources paralleled
previously described, combined with for 6 cycles
the capability to transfer in a closed 7.3.3.1. Description and Operation
transition mode when both sources Generally speaking, closed transition
are within preset parameters. Utilizing switches have two basic modes of
a high-speed drive system, the operation. During a failure of one
overlap of the normal and emergency source or an out of specification
sources is less than 100 msec. When condition, the switch operates as a
one source is not within specified standard delayed transition switch.
limits, such as during a power failure, This sequence allows clear separation
the closed transition switch operates of an unreliable source from an
in an open transition mode. available one.
Closed transition operation takes
place when both sources are within
preset voltage and frequency
parameters and the phase angle
differential is less than five degrees.
The closed transition sequence may
be initiated by the test switch, a
load exerciser clock, peak shaving
controls or special utility incentive
rate signals.
When a transfer signal is received
from one of the above mentioned
methods, the engine generator set
2007 Caterpillar
is started and allowed to reach rated o A 24 VDC shunt trip circuit

voltage and frequency. The control is suggested on one of the
system compares the phase angle feeder breakers, normally
of the two power sources and when the generator feeder.
the proper relationship is reached, the Power for this trip circuit
emergency drive solenoid is energized and alarm system backup is
and the emergency main contacts are typically supplied from the
closed and locked mechanically. engine starting batteries or
an equivalent source.
The normal drive solenoid is then
energized; the utility main contacts 7.3.3.3. Soft Load
are opened and mechanically locked When conditions are most
in this position. sensitive to generator voltage drop
or frequency dips, a variation of the
The overlap time of the two sources
closed transition method of transfer,
is less than 100 ms. Retransfer from
which further combines the attributes
a generator set to the utility source is
of a closed transition transfer
also performed in the closed transition
switch with generator paralleling
mode. If, however, a generator failure
switchgear. By employing automatic
occurs, the unit will revert to standard
synchronizing, active loading controls
delayed transition operation.
and a greater interconnect (parallel)
7.3.3.2. Application Information time; a soft-loaded/closed transition
Closed transition switches require transfer can be accomplished.
a momentary (less than 100 ms)
Note that this method of transfer
paralleling of the standby source
interconnects the utility and generator
with the utility. This usually
sources for a longer period (seconds
requires the owner to obtain
rather than cycles), and greater
approval of the installation by
coordination with the local utility
the utility;
company is necessary. Typically,
The purpose of a closed more sophisticated protective
transition switch is to prevent the relaying schemes will be required.
momentary outages that occur
during transfer of a standard unit. 7.3.4. Transfer/Bypass-Isolation
This technology is not a substitute Switches
for a UPS system as it does Though designed to give
not provide stored energy consistent operation, the ATS must
capability but rather acts in be periodically maintained to ensure
a complementary fashion; proper operation and system
System application requirements reliability.
(requirements may vary based on Maintenance of the entire system
manufacturer): is called for in the National Electrical
o The generator set must be Code Article 700-4, NEMA Standard
provided with a stable ICS2-447 and in NFPA 99.
isochronous governor;
2007 Caterpillar
In some non-critical emergency Figure 31 shows the physical
power systems, it is possible to layout of a bypass isolation transfer
disconnect the power feeders from switch with the manually operated
the ATS and electrically isolate the bypass-isolation switch mounted
switch for servicing. Yet, there above the ATS. The switches are
are many critical systems where completely interconnected requiring
interruption of power is not only the normal source, emergency
permissible. In hospital source and load cable connections.
communication systems, data Once installed, no cables need to
processing centers, airports, etc., be removed to isolate the transfer
power disruption is not permitted. switch module for maintenance
For these systems, the use of a or inspection. The ATS may be
bypass-isolation switch with the withdrawn for testing or maintenance
transfer switch is essential and often without disturbing the load.
required by code. Bypass-Isolation
Transfer Switches are designed to
meet the requirements for the
inspection and/or maintenance
of the transfer switch without
power interruption.
7.3.4.1. Construction
The bypass-isolation transfer
switch consists of two major
modules; the ATS and the bypass-
isolation switch.
The ATS module is of identical
construction and functionality
as that previously described. The
switch may be designed to operate
in an open transition, delayed
transition or closed transition mode. Figure 31 Bypass Isolation and
Automatic Transfer Switches
The bypass section is a basic
Transfer switch provided with a 7.3.4.1.1. Automatic Transfer Switch
quick make/quick break manual The transfer switch module of a
load transfer handle and a control/ bypass isolation transfer switch has
interlock system consisting of both three positions:
mechanical and electrical interlocks. 1. Automatic: The transfer switch
The bypass should be equipped with is carrying the load, and the
normal failure sensing and a time bypass switch is in the open
delay to start the engine automatically position. This is the normal
if the ATS has been removed for operating position;
service and a failure occurs.
2007 Caterpillar
2. Test: The bypass switch is The bypass isolation design requires

closed and feeding the load. The no additional load break contacts,
transfer switch has control power which cause load interruption during
and may be operated for test bypass-isolation functions. The
purposes via the test switch bypass isolation switch contacts
on the enclosure door; are out of the system current path
3. Isolate: The transfer switch is except during actual bypass
withdrawn from all power and operation. Therefore, they are not
ready for maintenance. The constantly exposed to the destructive
bypass switch serves the load. effects of potential fault currents.
The ATS is installed on a draw-out The normal, emergency and load
mechanism, with electrical and are connected between the ATS and
mechanical interlocks for secure the bypass-isolation switch through
removal after load bypass. solidly braced isolating contacts that
Additionally, the control/logic panel are open when the transfer switch
is mounted on the enclosure door is isolated. All current carrying
and connected by a wire harness components provide high withstand
and multi-pin disconnect plugs. The current ratings in excess of those
transfer switch and/or the control specified in UL 1008 standards.
panel may be tested, isolated and 7.3.4.2. Interlocks and Indicators
removed for maintenance without Bypass-isolation transfer
load interruption. switches should be supplied
7.3.4.1.2. Bypass-Isolation Switch with all necessary electrical and
The bypass-isolation switch mechanical interlocks to prevent
module is the same basic design as improper sequence of operation as
the transfer switch module and thus well as the necessary interlocking
has the same electrical ratings. circuit for engine starting integrity.
Manually operated, it features high Further, a bypass isolation switch
speed, quick make/quick break should be furnished with a detailed
contact action. The bypass-isolation step-by-step operating instruction
switch has three basic positions: plate as well as the following
1. Automatic: Normal bypass additional indications:
contacts open, emergency Normal source available,
bypass contacts open;
Emergency source available,
2. Bypass Normal: Normal bypass
Bypass switch in normal position,
contacts closed, emergency
bypass contacts open; Bypass switch in emergency
3. Bypass Emergency: Normal position,
bypass contacts open, ATS in test position,
emergency bypass contacts ATS isolated,
closed;
ATS inhibit,
2007 Caterpillar
ATS operator, Make-before-break the second
Disconnect switch off, type of switch operation does not
interrupt power to the load during
ATS in normal position,
the procedure (reference Figure
ATS in emergency position. 34). This is accomplished by
means of a mechanical interlock
between the automatic and
bypass switches.
Care should be taken in the
selection of a bypass isolation
switch to understand the type of
switch operation that is required
for the specific application.
Figure 32 Bypass-Isolation Diagnostic

Indicating Lights
7.3.4.3. Load Transition
With the automatic transfer and
bypass-isolation switches set for
automatic operation, power comes
from the source 1 (utility), through
the automatic transfer section and
to the loads.
Figure 33 Break-Before-Make Bypass
In testing or servicing the bypass Arrangement
isolation switch, the bypass switch
must be manually moved from the
bypass position to either the source
1 or source 2 position.
Two basic types of load transition
features are found in contactor type
bypass-isolation switches:
Break-before-make this type
of switch operation momentarily
interrupts power to the load
during the bypass procedure
(reference Figure 33);
Figure 34 Make-Before Break
2007 Caterpillar
7.3.4.4. Service Entrance Rated the way it remains until the utility
Service Entrance Rated (SER) takes care of the problem and
transfer switches combine the restores power. A number of
functions of the automatic switching facilities, such as water, wastewater
device with a utility circuit breaker, treatment, pumping station and many
which serves as a disconnect other industrial facilities cannot
device. The SER must meet all NEC tolerate the loss of commercial
requirements for installation as power. An emergency power source
service entrance equipment. is necessary at any of these facilities
to protect against commercial power
Service entrance rated transfer
interruptions. In such a situation, it
switches generally are installed at
becomes necessary to have an ATS
facilities that have a single utility
as close as possible to the point
feed and a single emergency power
where commercial power enters the
source. A circuit breaker serves as
facility, the service entrance. The
the utility disconnect and links are
reason most likely is that every load
provided to connect both neutral
at the facility is critical, and must
and ground conductors.
continue functioning, even though
Service entrance is the point where commercial power is lost.
power supplied by a utility enters
There are two approaches that can
a facility.
be used for the installation of ATS
Just look at the point where power equipment:
enters a house from the local utility
and goes directly into a load center, Contactor type ATS installation,
probably mounted on a basement Breaker transfer pair ATS
wall. The incoming power line first installation.
goes to a main disconnect, probably 7.3.4.5. Contactor Type SER
a circuit breaker. From there it A contactor type ATS installation
breaks down into many different would normally be installed
circuits through any number of immediately downstream of the
smaller circuit breakers to supply service disconnect devices of both
power throughout the house. the utility and standby (emergency)
Industrial facilities, for example, are power supplies (Figure 35). This may
no different, just on a larger scale. not be the optimum installation
When there is a loss of power from location, but it is the best that can
the utility at a house, everything be done with conventional ATS
electrical stops functioning. That is equipment.
2007 Caterpillar
Figure 35 Contactor Type ATS Service Entrance Installation
7.3.4.6. Breaker Transfer Pair SER disconnect devices and their
A breaker transfer pair ATS respective power interconnections.
installation using circuit breaker type This means the ATS is installed
disconnects, such as the SPB, and a directly at the point of service
service entrance option eliminates entrance (Figure 36).
the need for separate upstream
Figure 36 Breaker Transfer Pair ATS Service Entrance Installation

2. Utility/generator set ATS,
8. Transfer Switch
3. Generator set/ATS/UPS,
Applications
There are six common transfer 4. Multiple generator
schemes, which will be discussed: set/switchgear/ATS,
1. On generator set configurations,
2007 Caterpillar
5. Generator set to generator

set ATS,
6. Utility to utility ATS,
7. Multi-source switching systems.
8.1.1. On Generator Set
Configurations
The on generator set configuration
represents the most basic automatic
transfer scheme. It performs similar
functions to the utility/generator
set ATS. The on generator set
configuration, otherwise known as
the automatic mains failure feature
of a generator set controller, is Figure 37
designed to operate the generating
8.1.3. Generator Set/ATS/UPS
set automatically in event of utility
An Uninterruptible Power Supply
failure, supply power to the load,
(UPS) system is an assembly of
and shut down the generator when
equipment used with electrical
the main power is restored.
loads sensitive to power source
This configuration is typically disturbances or that require absolute
used outside of North America continuity of power. The UPS stores
in areas not subject to UL1008. energy for the purpose of providing
8.1.2. Utility/Generator Set ATS power during short duration power
outages and load switching
The most common application of
operations. The UPS continually
an ATS is use as a utility/generator
conditions power and when the
set interface. Upon a loss of the
normal power source is not
normal source (utility), the ATS
available, the UPS provides power
signals the generator set to start and
to the critical load until the standby
switches the transfer mechanism
power generation can come on-line.
to the emergency power source
(generator set). When normal power In conjunction with an ATS, the
is restored, the ATS switches to the UPS is positioned between the ATS
normal power source and signals and the load (Figure 38) and will
the generator set to shut down perform its function until the ATS
(see Figure 37). switches the load to the emergency
power source.
2007 Caterpillar
to power a load, the load distribution
must be prioritized and segregated.
In the event of a utility source
outage, the UPS will continue to
power the priority 1 loads. The ATS
will signal the generator sets to start.
As soon as a generator set has
started, the breaker to the bus bar
is closed and the priority 1 loads
are switched from the utility source
to the generator. Once a second
generator has started, it is
synchronized to the bus bar, and
the ATS connected to the priority 2
Figure 38 loads switches from utility source to
generator set power. This process is
8.1.4. Multiple Generator
continued until all generator sets are
Set/Switchgear/ATS synchronized on the bus and all loads
A simplified multiple generator are powered by the generator sets.
set/switchgear/ATS system is
shown in Figure 39. In the event
that multiple generators are required
2007 Caterpillar
Figure 39 Multiple Generator Set/ATS/UPS
8.1.5. Gen to Gen ATS

In a generator set to generator
set system, the ATS operates
two generator sets, one being
an emergency power source
to the other, running at alternate
times to power the load.
The system is similar to a
utility/generator set arrangement
except that the control system
is set to switch load from one
generator to the other after
a preset time, in addition to Figure 40
performing emergency switching 8.1.6. Utility to Utility ATS
operations. If a utility has the ability
to provide multiple service
connections over separate lines
from separate supply points which
2007 Caterpillar
are not likely to be jointly affected generator sets or combinations of
by system disturbances, it can be the two.
advantageous to provide an ATS
8.1.7.1. Multiple Utility/Single
for switching if there is a failure Generator Set
in one of the utility power sources. When the primary source
Since the utility is constantly fails, the master transfer switch
supplying power, there would connects the load to the secondary
not be the startup delay that is utility. Should the secondary
experienced with a generator set utility source also fail, the engine
backup system. generator will start and the source
There may still be times during selector transfer switch will
which both utility power sources connect the load to the generator
fail; therefore, certain codes set when it reaches proper
(Hospitals) require backup operating parameters (Figure 42).
generator sets. In this application, the unit is
The controls for a utility/utility utility preferred. That is, if either
ATS are similar to a utility/ utility source becomes available,
generator set ATS except there the logic of the system will transfer
is no start/stop signal. the load to the available utility and
then shut down the generator set
until the next utility failure.
Figure 42 Multiple Utility Single

Figure 41
Generator Transfer Scheme
8.1.7. Multi-Source Switching 8.1.7.2. Single Utility/Multiple
Systems Generator Sets
Multiple source switching In lieu of a second utility source,
systems are designed to switch these applications include the use
a single load between multiple of a second generator set to
available sources of power. These serve as standby power to the
sources may be multiple utilities, load. Two different logic schemes
are typically utilized in this
2007 Caterpillar
application, depending on facility the secondary unit will be started

requirements. and the load transferred to it.
8.1.7.2.1. Logic Scheme 1 The primary unit remains the first
In this scenario, both engine standby set and if it successfully
generator sets are started when a starts and maintains operating
utility failure occurs and the load is parameters, the load will be
connected to the first available transferred to it and the secondary
generator set. The second set will unit will be shut down until the
run on a standby timer for a period next failure.
of 5 minutes to verify that the first
set will continue to run and then
shut down.
If the connected generator set
fails, the second set will restart
and assume the load until utility
restoration.
Figure 44 Single Utility/Multiple

Generator Sets Logic Scheme 2
9. Standards, Testing
& Maintenance
9.1. Standards and Ratings
9.1.1. The National Electric
Code
Figure 43 Single Utility/Multiple The National Electric Code (NEC)
Generator Sets Logic Scheme 1 provides guidance for safe and
proper installation of equipment
8.1.7.2.2. Logic Scheme 2
required for emergency and legally
The second logic scheme
required standby power systems.
operates in a similar mode.
It also contains rules for those
However, the user is supplied with
standby systems that are installed
a prime generator set selector
for the convenience of operations
switch, which causes only one of
in a facility (optional standby
the sets to start on utility failure
systems). Finally, it also deals with
and act as the primary standby
those systems operated in parallel
unit. Either unit may be so
with the electric utility and is
selected. If the primary unit does
capable of delivering energy
not assume the load within a
back to the utility source.
preset period (usually 10 seconds),
2007 Caterpillar
9.1.2. Underwriters 9.1.4. International
Laboratories, Inc. (UL) Electrotechnical
UL 1008 is the Standard for Commission (IEC)
Safety Transfer Switch Equipment Transfer switches should IEC listed
and serves as the prevailing under standard 947 Low Voltage
standard for the transfer switch Switchgear and Control Gear
market in the United States. The and are suitable for installation in
requirements found in this standard applications where the prevailing
cover automatic, non-automatic standard is the IEC, found primarily
(manual), and by-pass/isolation outside of North America
transfer switches intended for use
in ordinary locations to provide for 9.1.5. National Fire Protection
lighting and power Association
The National Fire Protection
UL1008 is applicable to
Association (NFPA) provides a
equipment rated at 600 Volts or
number of very important and
less and includes standards related
applicable standards:
to the construction, performance,
testing, rating and marking of NFPA 70 National Electrical
transfer switches. When choosing Code (NEC), developed by NFPA,
an ATS it is critical to ensure that provides guidance for the proper
it is listed under UL 1008. installation of equipment required
for emergency systems, legally
Additionally, circuit breaker type
required standby systems and
transfer switches utilizing molded
optional standby systems. It
and insulated case switches or
also contains rules for systems
circuit breakers as the main power
intended for operation in parallel
switching contacts, may also be
with utility and capable of
listed under two additional
providing power back to the utility;
standards:
NFPA 99 Standard for
UL 1087 Standard for molded
Healthcare Facilities; addresses
case switches, the requirements for emergency
UL 489 Standard for circuit systems in health care facilities;
breakers. NFPA 101 Life Safety Code;
9.1.3. Canadian Standards identifies the features necessary
Association (CSA) to minimize danger to life from
CSA C22.2 No 178 Automatic fire and provides guidelines to
Transfer Switches; Industrial where emergency lighting is
Products is the prevailing essential;
standard for transfer switches NFPA 110 Standard for
sold and applied in Canada. Emergency and Standby Power
Systems; provides performance
2007 Caterpillar
requirements for emergency and 9.1.7. American National

standby power systems. Standards Institute
9.1.6. National Electrical The American National Standards
Manufacturers Institute (ANSI) is a private
nonprofit organization that oversees
Association the development of voluntary
The National Electrical
consensus standards for products,
Manufacturers Association
services, processes, systems, and
(NEMA) is a US based association
personnel in the United States.
which defines standards for
The organization also coordinates
many commonplace electrical U.S. standards with international
interconnects, as well as outlining standards so that American
manufacturing standards for
products can be used worldwide.
electrical products, such as various
grades of electrical enclosures. 9.1.8. Institute of Electrical
NEMA ICS 10 Industrial Control and Electronic Engineers
and Systems: AC Transfer The Institute of Electrical and
Equipment Part 2: Static AC Electronics Engineers (IEEE) is an
Transfer Equipment; Applies to international non-profit, professional
static automatic and static non- organization for the advancement
automatic transfer equipment of technology related to electricity.
without cross-connection of 9.1.9. International Building
sources during transfer or
Code
retransfer, with or without bypass
The International Building
isolation switches rated 600 volts
Code (IBC), developed by the
AC or less, not exceeding
International Code Council
6000 amps, for use on single-
(ICC), has been widely adopted
phase and polyphase AC circuits.
throughout the United States. The
This standards publication code contains safety concepts,
provides practical information structural, and fire and life safety
concerning ratings, construction, provisions covering various topics
test, performance, and of building design including seismic
manufacture of industrial control engineering provisions for the
equipment. These standards are design of new buildings.
used by the electrical industry to
In compliance with the
provide guidelines for the
requirements of IBC-2003,
manufacture and proper application
Caterpillar Transfer switches have
of reliable products and equipment
been certified by a 3rd party agency
and to promote the benefits of
and have demonstrated the
respective manufacturing and
capability of operating (transferring)
widespread product availability.
during a simulated seismic event.
This standard has superseded
NEMA ICS2-447.
2007 Caterpillar
9.2. Testing recommended to ensure proper
A manual operator handle is operation.
provided with the transfer switch
for maintenance purposes only.
10. Controls Testing
Manual operation of the switch Standards
must be checked before it is Controls are to be factory tested
operated electrically. It is important in accordance with the following
to note that both power sources standards:
must be disconnected before
IEEE 472 (ANSI C37.90A),
manual operation of the switch.
EN55022 Class B (CISPR 11)
Manual operation is conducted by (Exceeds EN55011 & MILSTD
inserting the handle and operating 461 Class 3),
the transfer switch between the
source 1 and source 2 positions. EN61000:
The transfer switch should operate o EN61000-4-2 (Level 4),
smoothly without binding. Return o EN61000-4-3,
the switch to source 1 position, (ENV50140) 10v/m,
remove the handle, and return it
o EN61000-4-4,
to the holder provided.
o EN61000-4-5, IEEE
After completing the inspection, C62.41 (1.2 X 50ms,
cleaning and servicing of the 5 & 8 kV),
transfer switch, reinstall the switch
cover, and close and lock the o EN61000-4-6
cabinet door. Reclose the circuit (ENV50141),
breakers feeding the utility and o EN61000-4-11.
generator sources to the switch.
10.1. Maintenance
Initiate the electrical transfer test A preventive maintenance
by activating the test switch. After program will insure high reliability
programmed delay times, the and long life for a transfer switch.
controller will send an engine start The preventive maintenance
signal and the switch will complete program for any transfer switch
its transfer by closing into source 2. should include the following items:
Deactivating the test switch will 10.1.1. Inspection and
start retransfer to source 1. The
switch will complete its retransfer
Cleaning
The switch should be inspected
following programmed time delays,
for any accumulation of dust, dirt,
allowing the engine generator to
run unloaded for a preset cool or moisture, and should be cleaned
by vacuuming or wiping with a dry
down period.
cloth or soft brush. Do not use a
Per the NEC, Articles 700 & 701, blower since debris may become
a periodic test of the transfer lodged in the electrical and
switch under load conditions is
2007 Caterpillar
mechanical components and cause

damage.
11. Glossary of Terms
Ampacity: The current, in
Remove the transfer switch amperes, that a conductor or
barriers and check the condition of equipment can carry continuously
the contacts. Any surface deposits under the conditions of use without
must be removed with a clean exceeding its temperature ratings.
cloth (do not use emery cloth or a
ANSI: American National
file). If the contacts are pitted or
Standards Institute
worn excessively, they should be
replaced. A general inspection of Arcing: The effect generated
mechanical integrity should be when electrical current bridges the
made to include loose, broken air gap between two contacts or
or badly worn parts. conductors
10.1.2. Servicing Arc Chute: A structure affording

All worn or inoperative parts are a confined space or passageway,
to be replaced using factory lined with arc resisting material,
recommended replacement parts. into or through which, an arc is
Please refer to the applicable directed to extinction.
replacement parts manual for Arcing Contacts: The contacts of
specific part information and a switching device on which the
ordering procedures. arc is drawn after the main
The operating mechanism of the contacts have parted.
transfer switch must be lubricated Arc Splitter: Arc splitters are
in accordance with factory typically metallic plates used to split
recommended lubricant. Please the arc into series arcs. This process
consult ATS O&M Manual for effectually raises arc voltage above
guidance in choosing the system voltage allowing the arc to
appropriate lubricant. The lubricant be extinguished quickly.
applied at the factory provides
Automatic Transfer Switch
adequate lubrication for the lifetime
(ATS): A device that automatically
of the switch. Should debris
transfers a common load from a
contaminate the mechanism, clean
normal supply to an emergency
and apply additional lubricant.
supply in the event of failure of the
CDT battery replacement: Lithium normal supply, and automatically
batteries may last up to 10 years, returns the load to the normal
however it is recommended that supply when the normal supply is
battery replacement be included in restored.
a 3-5 year service cycle. The
Back-up Power: See Emergency
battery maintains the exerciser
Power
memory only and does not
otherwise affect the operation. Branch Circuit: The circuit
between the final Overcurrent
2007 Caterpillar
device protecting the circuit and Continuous Current: The amount
the load. of current a device can carry
constantly at 60 cycles without
Bypass Isolation Switch: A
exceeding the temperature rise,
manually operated device used in
according to ANSI charts.
conjunction with a transfer switch
to provide a means of directly Drawout: A type of circuit breaker
connecting load conductors to a that can be moved into or out of its
power source and of disconnecting structure without unbolting, often
the transfer switch. on a racking mechanism.
Circuit Breaker Type Switch: Delayed Transition Transfer: Type
Transfer switches known as the of open transition transfer whereby
circuit breaker type use specially an ATS is equipped with a center
designed switching devices that off position in addition to the
are typically molded/insulated case Normal and Emergency positions,
switches. A molded case switch is which allows for motors to coast
like a molded case circuit breaker down and transformer fields to
without magnetic or thermal trip decay, prior to re-energizing.
elements and does not trip on Electrically Operated: A
overload or faults. Used when a version of the manually operated
compact, high capacity disconnect mechanism, but is electrically
is needed, and is held to a more operated. Operating personnel must
rigorous testing standard than the be present to initiate the operation.
contactor type.
Electrically Operated Non-
Closed Transition Transfer: Automatic Transfer: Switch similar
Transfer between emergency power to the manually operated version
sources whereby power is main- except that an electrical operation
tained to the load throughout the feature is added to the switch. The
transfer process (make-before-break). switch electrically transfers power
Closing Rating: The RMS when a pushbutton, generally
symmetrical current a transfer mounted on the enclosure, is
switch can safely close into and activated. Can also be operated
conduct during short circuit manually.
conditions. Emergency Power: Also called
Contactor Type Transfer Switch: alternate, back-up and critical
Transfer switches that use a power. If there is a normal power
contactor type design. The source failure, emergency power
contactor type switches do not can be supplied as an additional
use motor starting/lighting type source from the utility or an on site
contactors. In fact, contactor type generation, from an engine-
transfer switches used circuit generator set for example.
breaker design contacts, arc
chutes and arcing horns.
2007 Caterpillar
Emergency System: A system Ground: A conducting

legally required and classified by connection, whether intentional or
government jurisdiction. Applies accidental, between an electrical
when loss of the normal power circuit or equipment and the earth
source would be a hazard to safety or some conducting body that
or human life. Intended to serves in place of the earth.
automatically supply illumination Grounded Effectively:
and/or power to designated areas Intentionally connected to earth
and equipment. Characterized through a ground connection or
by a transfer time of less than connections of sufficiently low
10 seconds. impedance and having sufficient
Enclosure: A case or housing current-carrying capacity to prevent
used to protect the contained the buildup of voltages that may
conductor or equipment against result in undue hazards to
external conditions and to prevent connected equipment or to persons.
operating personnel from Grounded, Solidly: Connected to
accidentally contacting live parts. ground without inserting any
Equipment Ground: A connection resistor or impedance device.
to ground from one or more of the Grounded Conductor: A system
non-current carrying metal parts of or circuit conductor that is
the wiring system or of electric intentionally grounded.
equipment connected to the system.
Ground Fault Protection: A
Equipment Grounding Conductor: system intended to provide
The conductor used to connect the protection of equipment from
non-current carrying metal parts of damaging line-to-ground fault
equipment, raceways, and other currents by operating to cause a
enclosures to the service disconnecting means to open all
equipment, the service power ungrounded conductors of the
source ground, or both. faulted circuit. This protection is
Emergency Power Supply System provided at current levels less than
(EPSS): Provides a source of those required to protect conductors
electrical power of required capacity, from damage through the operation
reliability and quality to loads for a of a supply circuit overcurrent device.
length of time and within a specified Grounding Conductor: A
time following loss or failure of the conductor used to connect
normal power supply (as specified in equipment or the grounded circuit
NFPA 110 Chapter 4). of a wiring system to a grounding
Feeder Circuit: All circuit electrode or electrodes.
conductors between the service Grounding Conductor, Equipment:
equipment (or the generator The conductor used to connect the
switchboard) and the final branch non-current carrying metal parts of
circuit Overcurrent device.
2007 Caterpillar
equipment, raceways, and other Legally Required Standby
enclosures to the service System: A system legally required
equipment, the service power and classified by government
source ground, or both. jurisdiction. These systems are
intended to automatically supply
Grounding Electrode: A device
power to selected loads, other
that establishes an electrical
than those already classified as
connection to the earth.
emergency. Transfer time from the
Grounding Electrode Conductor: normal source to the emergency
The conductor used to connect the source cannot exceed 60 seconds.
grounding electrode(s) to the (Refrigeration, Communications,
equipment grounding conductor, Smoke removal, Sewage disposal,
to the grounded conductor, or to Industrial processes).
both, at the service, at each
Logic Panels: Provides the
building or structure where
intelligence/supervisory logic
supplied by a feeder(s) or branch
circuits necessary for the switch
circuit(s), or at the source of a
and related circuit operations.
separately derived system.
There are three forms;
In-phase Monitor: a device that Electromechanical Relay, Solid
monitors the relative phase angle State, Microprocessor-based.
between the two power sources
Manually Operated Non-
serving a transfer switch. This device
Automatic Transfer Switch: Provide
is used with the controls of an ATS
all the mechanics to effect the
as a permissive control to allow
transfer from source to source. The
transfer between the two power
actual transfer or power, however,
sources only upon the condition of
is accomplished by true hand
the two sources achieving a near
operation of the transfer switch.
synchronous condition.
Manual Transfer Switch: See
In Sight From (Within Sight From,
Non-Automatic transfer switch.
Within Sight): Where this Code
specifies that one equipment shall Neutral Conductor: The
be in sight from, within sight conductor that is intended to be so
from, or within sight, and so energized, that in the normal steady
forth, of another equipment, the state, the voltages from every other
specified equipment is to be visible conductor to the neutral conductor
and not more than 15 m (50 ft) are definitely related and usually
distant from the other. equal in amplitude.
Interrupting Rating: Also Neutral Ground: Neutral Ground
Ampere Interrupting Capacity refers to the connection between
(AIC), the highest current at rated neutral and ground. When a neutral-
voltage that a device is intended to to-ground connection is properly
interrupt under standard test made in accordance with the the
conditions. NEC , the voltage between any
2007 Caterpillar
metal part of the electrical system neutral pole that is switched in an

to the earth will be zero volts. overlapping fashion with the main
phase poles. Commonly, the
Non-Automatic Transfer Switch:
neutral pole is operated to close
A device operated manually by
the neutral before opening phase
a physical action, or electrically by
poles and maintain the two source
a remote control, for transferring a
neutrals connected until after the
common load between a normal
phase poles have been switched.
and emergency supply.
Pole: that portion of a device
Normal Power: The power source
associated exclusively with one
used every day in non-emergency
electrically separated conducting
situations. Also called the preferred
path of the main circuit of the
source.
device.
On-site Generation Power: Power
Preferred Source: See Normal
produced by the user, typically from
Power
an engine generator set (generator
set), located in their facility. Program(med) Transition: see
Delayed Transition Transfer
Open Transition Transfer: A
method of switching the load Separately Derived System: A
between sources, where power to premises wiring system whose
the load is intentionally interrupted power is derived from a source of
during switching (Break-before- electric energy or equipment other
Make). than a service. Such systems have
no direct electrical connection,
Optional Standby System:
including a solidly connected
Intended to protect public or
grounded circuit conductor, to
private property or facilities, where
supply conductors originating in
life and safety do not depend on
another system.
the systems performance.
Generally, on-site generated power Service: The conductors and
is supplied to selected loads equipment for delivering electric
automatically or manually. There is energy from the serving utility to
no time limit associated with the the wiring system of the premises
transfer. (Commercial buildings, served.
Farms, Residences) Service (Rated) Equipment: The
Overcurrent: Any current in necessary equipment, usually
excess of the rated current of consisting of a circuit breaker(s)
equipment or the ampacity of a or switch(es) and fuse(s) and their
conductor. It may result from accessories, connected to the load
overload, short circuit, or ground end of service conductors to a
fault. building or other structure, or an
otherwise designated area, and
Overlapping Neutral Pole: In a
four-pole switch, the fourth or
2007 Caterpillar
intended to constitute the main at their free ends to the appropriate
control and cutoff of the supply. main terminals or lines of a system.
Short Circuit: An overcurrent Transfer Switch: An automatic or
resulting from a fault of negligible nonautomatic device for transferring
impedance between live conductors one or more load conductor
having a difference in potential connections from one power source
under normal operating conditions. to another.
Standby Power: A power source Trip Unit Device: A device which
other than that used everyday. trips the operating mechanism in
Usually refers to a power used with case of a short circuit or overload
optional or alternative systems. condition.
Stored Energy: A mechanism Twin Stored Energy: A type of
used to overcome inherent forces mechanism which utilizes insulated
opposed to the insulated switch case and switches with true two
(circuit breaker) closing process, step stored energy mechanisms as
which stores energy until it is the switching devices. The stored
needed to help open the breaker. energy provides the mechanical
motion to open and close the two
SCADA Supervisory Control
sets of main contacts
And Data Acquisition: A system
that collects data from various Withstand Rating: the RMS
components within a factory, symmetrical current a transfer
power plant or in other remote switch can safely conduct during
locations and then consolidates short circuit conditions.
this data at a central processor
which controls the components 12. Appendices
and manages the data.
12.1. Bibliography
System Ground: A connection The following information is
to ground from one of the current provided as an additional reference
carrying conductors of a to subjects discussed in this manual.
distribution circuit or of an interior
wiring scheme. The following publications are
available for order through your
System Neutral Ground: A Caterpillar dealer.
connection to ground from the
neutral point or points of a circuit, Note: The information that is
transformer, rotating machine or contained in the listed publications
system. The neutral point or a is subject to change without notice.
system is that point which has the Note: Refer to this publication, the
same potential as the point of respective product data sheet, and
junction of a group of equal to the appropriate Operation and
nonreactive resistances if connected Maintenance Manual for product
application recommendations.
2007 Caterpillar
LEXX0801 9. Learning Module 29:

Systems Data Sheet UL Transfer Switch Equipment,
Withstand and Closing Ratings for Eaton/Cutler - Hammer
CTS/CTG Series Automatic 12.2. Systems Data Sheet
Transfer Switches (ATS)
LEXX0603
Example:
SECTION 1 THE PURPOSE OF
Systems Data Sheet Manual TESTING AND UNIT RATINGS
Handles for Automatic Transfer 1. Introduction
Switches (ATS) Automatic transfer switches have
1. On-Site Power Generation: A been subjected to an extensive
Reference Book, Electrical test program to show that they
Generating Systems comply with and exceed UL 1008
Association, 1990 standards as well as the various
2. Enclosures for Electrical performance specifications used by
Equipment, National Electrical most government agencies and
Manufacturers Association, major electrical engineers through-
NEMA Standard 250-2003 out the world. The primary test to
assure the dependability of an
3. Standard for Health Care
automatic transfer switch is its
Facilities, National Fire Protection
ability to close into and withstand
Association, NFPA 99, 2005
high fault currents. The purpose of
4. Standard for Emergency and this publication is to provide basic
Standby Power Systems, information on withstand ratings
National Fire Protection and to document the ratings the
Association NFPA 110, 2005 ATSs holds under UL 1008. NFPA
5. Standard for Electrical Safety No. 110 (emergency and standby
Requirements for Employee power systems) requires that the
Workplaces, National Fire capacity and rating of automatic
Protection Association, NFPA transfer switches be adequate to
70 2005, 2005 withstand the thermal and
6. Nash, Hugh O. Jr., Ground electromagnetic effects of short
Fault Protection and the Problem circuit currents that may arise in
of Nuisance Tripping of Critical the electrical system. It is
Feeders IEEE CH2581-7/88 important to be able to compare
properly the withstand current
7. D. Beeman, Industrial Power rating (WCR) of the switch to the
Systems Handbook McGraw- available short circuit (fault)
Hill, 1955 current of the system until the
8. A. Freund, Double the Neutral protective device clears the fault.
and Derate the Transformer
If a transfer switch does not have
Or Else! E C & M, Dec. 1988
adequate withstand capability
system failure, fire, injury to
2007 Caterpillar
personnel or equipment damage for units up to 150 amps; note the
may result. A clear understanding three cycle rating on 150 amp and
of the interrelationship between below units is optional as UL has
protective devices, transfer switch determined that all breakers in this
and system needs is necessary for size clear in less than 1.5 cycles).
a well-designed installation. Some The Umbrella or Any Breaker
basic information on withstand rating is therefore the actual UL
rating terms and calculations requirement and definition of the
follows the enclosed rating chart. ATS industry 3 cycle (or 1.5 as
noted) withstand and closing rating,
Underwriters Laboratories (UL) is
and should not to be confused with
the independent testing body that
additional, non UL 1008 labeled
has developed the standard UL
withstand only tests.
1008 which all major transfer
switch manufacturers test to. UL The following pages include the
lists products that have successfully UL certified ratings and specific
passed a battery of witnessed tests, breaker coordination charts,
including the withstand and close withstand rating data and
into fault tests described herein. additional specific information.
Manufacturers that complete these The consulting engineer must
tests are then permitted to label keep in mind that unless a transfer
their products with the UL mark. switch bears an umbrella breaker
approval for use with any molded
UL made significant changes in
case breaker, care must be taken
April of 1989 regarding the labeling
to assure that the breaker specified
requirements of transfer switches.
for the installation have an equal or
Prior to that date there had been
shorter trip time when compared to
concern over coordination with
the listed devices. This would limit
some protective devices. UL clarified
the application of the switch to
the labeling procedure and now
projects within the scope of its
allows for three rating categories.
specific breaker listing.
Current limiting fuse,
In addition to this factor, many
Specific class (trip time) of transfer switch manufacturers
molded case breaker, perform additional withstand tests
Umbrella or Any Breaker on selected products. These
ratings that take into account additional tests may be either for
all types of molded and a higher current valve or a longer
insulated case circuit breakers. duration than their standard UL
Listed ratings. The consultant must
These tests are performed for determine the applicability of these
a duration of 3 cycles on units tests and take careful note of the
225 amps and greater, and for fact that these levels are normally
1.5 cycles on 40-150 amp units not UL labeled ratings.
(with an optional 3 cycle duration
2007 Caterpillar
Certified Withstand and Closing Ratings in Symmetrical RMS Amperes at 480 Volts AC
Switches Rated for W isthstand and Closing Current Ratings per UL 1008
Withstand and Any
Specific Coordinated
Closing Ratings when Breaker
Breaker Rating
Coordinated with any Rating
UL 1008 Minimum
Max
Model Switch UL 1008
Max. Max Circuit Max Max
Rating Ratings
Fuse Size Circuit Breaker Circuit Circuit
Amps Amps Size Amps Amps
Amps
TS1 40 50 200,000 400 30,000 10,000 5,000
TS1 80 100 200,000 400 30,000 10,000 5,000
TS1 100 125 200,000 400 30,000 10,000 5,000
TS1 150 200 200,000 400 30,000 10,000 10,000
TS1 200 300 200,000 400 30,000 10,000 10,000
TS1 225 300 200,000 800 50,000 35,000 10,000
TS1 260 350 200,000 800 50,000 35,000 10,000
TS1 400 600 200,000 800 50,000 35,000 10,000
TS 600 750 200,000 800 65,000 50,000 12,000
TS 800 1,200 200,000 1,200 65,000 50,000 16,000
TS 1,000 1,250 200,000 1,600 85,000 50,000 20,000
TS 1,200 1,500 200,000 1,600 85,000 50,000 24,000
TS 1,600 2,000 200,000 2,500 100,000 100,000 32,000
TS 2,000 2,500 200,000 2,500 100,000 100,000 40,000
TS 3,000 4,000 200,000 4,000 100,000 100,000 60,000
TS 4,000 6,000 200,000 5,000 100,000 100,000 80,000
BTS1 100 125 200,000 800 50,000 35,000 5,000
BTS1 150 200 200,000 800 50,000 35,000 10,000
BTS1 225 300 200,000 800 50,000 35,000 10,000
BTS1 260 350 200,000 800 50,000 35,000 10,000
BTS1 400 600 200,000 800 50,000 35,000 10,000
BTS 600 750 200,000 800 65,000 50,000 12,000
BTS 800 1,000 200,000 1,600 85,000 50,000 16,000
BTS 1,000 1,250 200,000 1,600 85,000 50,000 20,000
BTS 1,200 1,500 200,000 1,600 85,000 50,000 24,000
BTS 1,600 2,500 200,000 2,500 100,000 100,000 32,000
BTS 2,000 2,500 200,000 2,500 100,000 100,000 40,000
BTS 3,000 4,000 200,000 4,000 100,000 100,000 60,000
BTS 4,000 6,000 200,000 5,000 100,000 100,000 80,000
TSD1 40 50 200,000 150 50,000 35,000 5,000
TSD1 80 100 200,000 150 50,000 35,000 5,000
TSD1 100 125 200,000 150 50,000 35,000 5,000
TSD1 150 200 200,000 400 50,000 35,000 10,000
TSD1 225 300 200,000 400 50,000 35,000 10,000
TSD1 260 350 200,000 400 50,000 35,000 10,000
TSD1 400 600 200,000 800 50,000 35,000 10,000
2007 Caterpillar
SECTION 2 DEFINITIONS AND f. Available Peak Current
CALCULATIONS Maximum possible short-
1. Purpose circuit current that may exist
Many questions arise when in a system without
comparing WCR to the system protective devices;
fault current rating. Too often a g. Peak Let Through Current
switch is rated by a manufacturer Maximum instantaneous
in one set of WCR terms and the current through the
available system fault currents protective device during the
described with a different set of total clearing time;
terms. h. Withstand Current Rating
The purpose of this paper is to The rating that defines the
outline the different ways switches ability of the switch to
may be rated (WCR) and systems withstand the thermal and
are measured. electromagnetic effects of
2. Basic Definitions short circuit currents for a
a. RMS Current The Root set period of time;
Mean Square which is the i. Withstand and Closing Rating
effective value of an UL 1008 test for a transfer
alternating current. It is switchs ability to close into
equal to 0.707 of the peak and withstand a fault current.
current for a sine wave. This These are the ratings which
is the value referred to when will actually appear on the UL
people say current; label of the product.
b. Peak Current The Note: For diagrams of typical
instantaneous maximum current wave forms, see Figure 45
value of current the peak and Figure 46.
current of a sine wave is 3. Available Fault Current
1.414 times its RMS value; Available fault current information
c. Symmetrical Current The can often b supplied by the utility
alternating current which is company. If this information is not
symmetrical around the zero available, approximate fault current
axis of the sine wave; can be calculated by knowing the
d. Asymmetrical Current The transformer impedance (usually 2
alternating current which is to 5% of full load ampere rating of
not symmetrical around the the transformer).
zero axis; For a single phase system,
e. Peak Fault Current The transformer let through current is:
instantaneous maximum
current value that occurs
after the start of a fault in Where Z is transformer impedance
any phase; in percent divided by 100.
For three phase systems:
2007 Caterpillar
4. Comparison of Terms
The following values have all been
used to describe identical circuit
Example: 500 kVA transformer
conditions:
2.5% Impedance 480 Volts, 3
a. Available short circuit current
phase
RMS 120,000 amps;
b. Peak Let Through Current
(1/2 cycle) 30,000 amps;
This figure is somewhat lower c. Peak Asymmetrical Current
if a long run of cable introduces 56,000 amps;
substantial additional impedance. d. Peak Symmetrical Current
Available fault current determine 40,000 amps;
the rating that a transfer must e. Withstand Rating 3 cycles
meet. RMS 28,000 amps.
Figure 45
2007 Caterpillar
Figure 46
2007 Caterpillar
2007 Caterpillar
LEBQ8107-00 2007 Caterpillar Printed in U.S.A.
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APPLICATION AND INSTALLATION GUIDE

4.2.1. Normal Source Monitoring and Protection ............. 26

7.3.2.2. Description and Operation ............................ 56

Information contained in this publication may be considered confidential. Discretion

on the switchs enclosure, is An ATS consists of the following

2.1.1.2.2. Insulated Case Switch 2.2. Transfer Mechanism

The unidirectional motor is energized operating handle. The operating

Figure 1 Circuit Breaker Type ATS with Unidirectional Gear Motor

prior to manual operation. The logic or solid state logic. Normally,

Figure 4 Emergency Power System (EPS) with

3.1.1. Inrush Current to weld. In order to accomplish this,

the quality of contact must be A transfer switch must be capable

from the main contacts, with the arc

Figure 9 Arc Being Drawn into

3.2. Manual Operating

injuring someone standing or The ATS has been designed with

on the source and connect the 4.2.1. Normal Source

returned to the Automatic position. Off The automatic transfer

Figure 10 ATS Remote Monitoring Software Screens

4.6.3. Remote Monitoring program, usually configured in

deenergized, even momentarily, line, time is required for its magnetic

5.1.1.6. Motor Load Shedding Emergency source overloading

6.1.1. Grounded vs.

Figure 13 Equipment Ground

Figure 12 System Ground on an

rated 1000 amperes or more

Figure 17 Undergrounded Neutral Figure 18 Source Featuring Grounded

Figure 20 Correctly Grounded Standby Power Source

Figure 22 Neutral Current Returning to Ground (Partial Current Outside GFP)

Of different amperage (lower) leaving the neutral connected to

switches are typically used for be selected. In addition the power

against ingress of solid foreign against the external formation of

7.2.2. Hazardous Locations as Class I, Division 1, Groups A, B,

Figure 26 summarizes the additional protection is needed

Figure 26 Comparison of Specific Applications of Enclosures

7.2.3. NEMA Enclosure such as moisture, corrosive vapors,

Figure 27 IEC Enclosure Classification

7.3. Transfer Switch Automatic.

The advantages of using delayed emergency closed position. The

is started and allowed to reach rated o A 24 VDC shunt trip circuit

2. Test: The bypass switch is The bypass isolation design requires

Figure 32 Bypass-Isolation Diagnostic

Figure 36 Breaker Transfer Pair ATS Service Entrance Installation

5. Generator set to generator

Figure 39 Multiple Generator Set/ATS/UPS

8.1.5. Gen to Gen ATS

Figure 42 Multiple Utility Single

application, depending on facility the secondary unit will be started

Figure 44 Single Utility/Multiple

requirements for emergency and 9.1.7. American National

mechanical components and cause

10.1.2. Servicing Arc Chute: A structure affording

Emergency System: A system Ground: A conducting

metal part of the electrical system neutral pole that is switched in an

LEXX0801 9. Learning Module 29:

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