Cutler-Hammer O & M Manual for Cutler-Hammer Drawout SPB ...€¦ · 7.4.1 Normal Bypass to...

IB01602003E

Effective November 2002

Cutler-Hammer

O & M Manual for Cutler-Hammer Drawout SPBTransfer Switches

IB01602003E Page iii

Effective 11/02

All possible contingencies which may arise during installation, operation or maintenance, and all details andvariations of this equipment do not purport to be covered by these instructions. If further information isdesired by purchaser regarding his particular installation, operation or maintenance of particular equipment,contact a Cutler-Hammer representative.

READ AND UNDERSTAND THE INSTRUCTIONSCONTAINED HEREINAFTER BEFORE ATTEMPTINGTO UNPACK, ASSEMBLE, OPERATE OR MAINTAINTHIS EQUIPMENT.

HAZARDOUS VOLTAGES ARE PRESENT INSIDETRANSFER SWITCH ENCLOSURES THAT CANCAUSE DEATH OR SEVERE PERSONAL INJURY.FOLLOW PROPER INSTALLATION, OPERATIONAND MAINTENANCE PROCEDURES TO AVOIDTHESE VOLTAGES.

! WARNING TRANSFER SWITCH EQUIPMENT COVERED BYTHIS INSTRUCTION BOOK IS DESIGNED AND TEST-ED TO OPERATE WITHIN ITS NAMEPLATE RAT-INGS. OPERATION OUTSIDE OF THESE RATINGSMAY CAUSE THE EQUIPMENT TO FAIL RESULTINGIN DEATH, SERIOUS BODILY INJURY AND/ORPROPERTY DAMAGE. ALL RESPONSIBLE PERSON-NEL SHOULD LOCATE THE DOOR MOUNTEDEQUIPMENT NAMEPLATE AND BE FAMILIAR WITHTHE INFORMATION PROVIDED ON THE NAME-PLATE. A TYPICAL EQUIPMENT NAMEPLATE ISSHOWN IN FIGURE 1.

Figure 1 Typical Automatic Transfer Switch Equipment Nameplate

Cutler-Hammer

Automatic Transfer Switch

ECat No: ATVISPE32000XSU 11/02

GO No: 1 of 1

Item: 1

Poles: 3 Amps: 2000 Volt: 480

Phase: 3 Hertz: 60 Wire: 4

A final inspection of the equipment should be per-formed prior to energizing the transfer switch:

Step 1: Remove any dirt or debris that may havecollected during shipment or installation. NEVERuse high pressure blowing air. This could drive dirtor other foreign objects into electrical or mechani-cal components which could cause damage. Usean industrial quality vacuum cleaner to remove anydirt or foreign objects.

Step 2: Be certain all cable connections are correctand that the phase rotation of both sources match.

Step 3: Inspect engine start connections and verifythe correct connection of all control wires.

Step 4: Check all programmable setpoints andadjust as necessary. In addition, adjust any option-al accessories as required.

Step 5: Be certain that actual lug torque values arein keeping with the requirements outlined in theinstruction book to insure the integrity of powerconnections.

Step 6: Check to be sure that all covers and barriersare properly installed and fastened.

NOTICE

IB01602003EPage iv

Effective 11/02

TABLE OF CONTENTS

PAGESECTION 1: INTRODUCTION

1.1 Preliminary Comments and Safety Precautions..................................................................................................11.1.1 Warranty and Liability Information..........................................................................................................11.1.2 Safety Precautions .................................................................................................................................1

1.2 General Information.............................................................................................................................................11.2.1 Transfer Switch Types............................................................................................................................21.2.2 Design Configuration..............................................................................................................................2

1.3 Transfer Switch Catalog Number Identification ...................................................................................................4

SECTION 2: RECEIVING, HANDLING AND STORAGE

2.1 Receiving.............................................................................................................................................................62.2 Handling ..............................................................................................................................................................62.3 Storage ...............................................................................................................................................................6

SECTION 3: EQUIPMENT DESCRIPTION

3.1 General ...............................................................................................................................................................73.2 Power Panel ........................................................................................................................................................7

3.2.1 Main Contacts ........................................................................................................................................73.2.2 Switch Interlocks (Open Transition Only) ...............................................................................................83.2.3 Drawout Interlocks..................................................................................................................................83.2.4 Transfer Mechanism...............................................................................................................................83.2.5 Drawout Mechanism...............................................................................................................................9

3.3 Voltage Selection Panel ......................................................................................................................................93.4 Logic Panel..........................................................................................................................................................93.5 Neutrals ...............................................................................................................................................................93.6 Features ............................................................................................................................................................103.7 Enclosure .........................................................................................................................................................123.8 Standards ..........................................................................................................................................................13

SECTION 4: INSTALLATION AND WIRING

4.1 General .............................................................................................................................................................144.2 Mounting Location .............................................................................................................................................144.3 Unpackaging and Inspection .............................................................................................................................144.4 Mounting Procedure ..........................................................................................................................................144.5 Power Cable Connections.................................................................................................................................154.6 Voltage Selection Adjustment ..........................................................................................................................164.7 Mounting Switching Device in the Drawout Mechanism....................................................................................164.8 Wiring .............................................................................................................................................................16

4.8.1 Engine Start Connection ......................................................................................................................164.8.2 Alarm Contacts (Closed Transition Only) .............................................................................................16

SECTION 5: OPERATION

5.1 General .............................................................................................................................................................195.2 Automatic Transfer Switch ................................................................................................................................19

IB01602003E Page v

Effective 11/02

PAGESECTION 6: DRAWOUT MECHANISM

6.1 Drawout Interlock ..............................................................................................................................................216.2 Switch Position ..................................................................................................................................................216.3 Rotation on the Drawout....................................................................................................................................216.4 Operational Check for Drawout Mechanism......................................................................................................22

SECTION 7: OPERATION OF BYPASS ISOLATION TRANSFER SWITCH

7.1 Operator Panel ..................................................................................................................................................237.2 Automatic Operation..........................................................................................................................................237.3 Bypassing the Transfer Switch..........................................................................................................................24

7.3.1 Normal to Normal Bypass ....................................................................................................................247.3.2 Emergency to Emergency Bypass .......................................................................................................247.3.3 Normal to Emergency Bypass (Open Transition Only) ........................................................................277.3.4 Emergency to Normal Bypass (Open Transition Only) ........................................................................27

7.4 Manual Operation when in Bypass Mode..........................................................................................................287.4.1 Normal Bypass to Emergency Bypass .................................................................................................287.4.2 Emergency Bypass to Normal Bypass .................................................................................................28

SECTION 8: TESTING AND PROBLEM SOLVING

8.1 Testing .............................................................................................................................................................298.2 Problem Solving ................................................................................................................................................29

8.2.1 Transfer Switch Appears Inoperative ...................................................................................................308.2.2 Transfer Switch will not Automatically Transfer to Normal ...................................................................308.2.3 Transfer Switch will not Automatically Transfer to Emergency ............................................................308.2.4 Transfer Switch will not Automatically Recharge Switches ..................................................................31

SECTION 9: MAINTENANCE

9.1 Introduction........................................................................................................................................................329.2 Procedures ........................................................................................................................................................329.3 Cover Removal and Replacement ....................................................................................................................34

9.3.1 NEMA 1 Cover Removal and Replacement .........................................................................................349.3.2 NEMA 3R Cover Removal and Replacement ......................................................................................36

LIST OF FIGURES

Figure Title Page

1-1 Typical Load Transfer Switch (circuit breaker type) Schematic.................................................................21-2 Typical Bypass Isolation Switch ................................................................................................................31-3 Typical Bypass Isolation Switch Schematic...............................................................................................31-4 Typical Drawout Transfer Switch with Deadfront Attached........................................................................4

3-1 Typical Power Panel (Open Transition Only).............................................................................................73-2 Insulated Case Circuit Breaker (Closed Transition Shown).......................................................................73-3 Terminal Connections for a Typical Drawout Transfer Switch (800-2000A Closed Transition Shown).....83-4 Drawout Mechanism (Closed Transition Shown).......................................................................................93-5 Voltage Selection Panel (Engine Start Contacts Identified) ......................................................................93-6 ATC-600/ATC-800...................................................................................................................................10

IB01602003EPage vi

Effective 11/02

LIST OF FIGURES

Figure Title Page

3-7 Neutral SE with Ground Fault ..................................................................................................................103-8 Solid Neutral ............................................................................................................................................103-9 Charger Mounting Dimensions in Inches (mm) .......................................................................................113-10 Typical Switch Enclosure.........................................................................................................................12

4-1 Seismic Tested and Approved Product Mounting Instructions ................................................................174-2 Drawout Stationary ..................................................................................................................................184-3 Secondary Control Block Contact Opening .............................................................................................184-4 Correct Placement ...................................................................................................................................18

5-1 Pumping Handle Charges Stored Energy Mechanism ............................................................................195-2 Close Switch by Pushing Close Button (Open Transition Only) ..............................................................195-3 Switching Device Closing Precautions (Closed Transition Only).............................................................20

6-1 Drawout with Socket Wrench...................................................................................................................216-2 Drawout Pulled Forward for Inspection....................................................................................................216-3 Drawout Rotated Out for Inspection ........................................................................................................22

7-1 Bypass Isolation Switch...........................................................................................................................237-2a Transfer from Normal Switching Device to Normal Bypass Switching Device, Steps 1-4 .......................257-2b Transfer from Normal Switching Device to Normal Bypass Switching Device, Steps 5-8 .......................26

9-1 Screw Removal........................................................................................................................................349-2 Slowly Tilting Cover Away .......................................................................................................................349-3 Lifting Cover Free ....................................................................................................................................349-4 Lifting Cover into Enclosure Frame .........................................................................................................359-5 Pushing Cover Fully into Enclosure Frame .............................................................................................359-6 Replacing Screws....................................................................................................................................359-7 Screw Removal........................................................................................................................................369-8 Inserting Tabs into Screw Holes..............................................................................................................369-9 Pulling Cover Out.....................................................................................................................................369-10 Cover Against Frame...............................................................................................................................379-11 Inserting Tabs into Screw Holes..............................................................................................................379-12 Sliding Cover Flange Under Roof Flange................................................................................................379-13 Pushing Bottom of Cover in Place...........................................................................................................389-14 Replacing Screws and Sealing Washers.................................................................................................38

10-1 Air Filter Replacement Kit ........................................................................................................................3910-2 Padlockable Handle Replacement Kit .....................................................................................................39

LIST OF TABLES

Table Title Page

1.1 Withstand Ratings......................................................................................................................................3

1.2 Transfer Switch Catalog Number Explanation...........................................................................................5

3.1 Transfer Switch Equipment Enclosures...................................................................................................12

4.1 Wire Size for Available Power Cable Connections..................................................................................16

9.1 Periodic Maintenance Procedures...........................................................................................................33

IB01602003E Page 1

Effective 11/02

SECTION 1: INTRODUCTION

1.1 PRELIMINARY COMMENTS AND SAFETYPRECAUTIONS

This technical document is intended to cover mostaspects associated with the installation, application,operation and maintenance of transfer switch equipmentwith ratings from 600 through 4000 amperes, except forthe specific logic used to control the equipment. It is pro-vided as a guide for authorized and qualified personnelonly. Please refer to the specific WARNING and CAU-TION in Section 1.1.2 before proceeding. If further infor-mation is required by the purchaser regarding a particu-lar installation, application or maintenance activity, aCutler-Hammer representative should be contacted. Forinformation associated with the control, refer to the sep-arate instruction book pertaining to the logic packageinstalled in the switch.

1.1.1 WARRANTY AND LIABILITY INFORMATION

No warranties, expressed or implied, including war-ranties of fitness for a particular purpose of merchant-ability, or warranties arising from course of dealing orusage of trade, are made regarding the information, rec-ommendations and descriptions contained herein. In noevent will Cutler-Hammer be responsible to the purchas-er or user in contract, in tort (including negligence), strictliability or otherwise for any special, indirect, incidentalor consequential damage or loss whatsoever, includingbut not limited to damage or loss of use of equipment,plant or power system, cost of capital, loss of power,additional expenses in the use of existing power facili-ties, or claims against the purchaser or user by its cus-tomers resulting from the use of the information anddescriptions contained herein.

1.1.2 SAFETY PRECAUTIONS

All safety codes, safety standards and/or regulationsmust be strictly observed in the installation, operationand maintenance of this device.

THE WARNINGS AND CAUTIONS INCLUDED ASPART OF THE PROCEDURAL STEPS IN THIS DOCU-MENT ARE FOR PERSONNEL SAFETY AND PRO-TECTION OF EQUIPMENT FROM DAMAGE. ANEXAMPLE OF A TYPICAL WARNING LABEL HEAD-ING IS SHOWN ABOVE TO FAMILIARIZE PERSON-

NEL WITH THE STYLE OF PRESENTATION. THISWILL HELP TO INSURE THAT PERSONNEL AREALERT TO WARNINGS, WHICH APPEAR THROUGH-OUT THE DOCUMENT. IN ADDITION, CAUTIONSARE ALL UPPER CASE AND BOLDFACE.

COMPLETELY READ AND UNDERSTAND THE MATE-RIAL PRESENTED IN THIS DOCUMENT BEFOREATTEMPTING INSTALLATION, OPERATION ORAPPLICATION OF THE EQUIPMENT. IN ADDITION,ONLY QUALIFIED PERSONS SHOULD BE PERMIT-TED TO PERFORM ANY WORK ASSOCIATED WITHTHE EQUIPMENT. ANY WIRING INSTRUCTIONS PRE-SENTED IN THIS DOCUMENT MUST BE FOLLOWEDPRECISELY. FAILURE TO DO SO COULD CAUSEPERMANENT EQUIPMENT DAMAGE.

THE CLOSED TRANSITION PRODUCT CONTAINS ASPECIAL CONTACT ARRANGEMENT (OVERLAP-PING CONTACTS). MISUSE CAN RESULT IN DEATH,SEVERE PERSONAL INJURY AND/OR PROPERTYDAMAGE.

1.2 GENERAL INFORMATION

Transfer switches are used to protect critical electricalloads against loss of power. The normal power sourceof the load is backed-up by a secondary (emergency)power source. A transfer switch is connected to boththe normal and emergency power sources and suppliesthe load with power from one of these two sources(Figure 1-1).

In the event that power is lost from the normal powersource, the transfer switch transfers the load to the sec-ondary (emergency) power source. Transfer can beautomatic or manual, depending upon the type of trans-fer switch equipment being used. Once normal power isrestored, the load is automatically or manually trans-ferred back to the normal power source, again depend-ing upon the type of transfer equipment being used(Figure 1-1).

In addition, the Cutler-Hammer Closed TransitionTransfer Switch, may be applied where it is desirable toavoid any momentary power interruptions. Although theclosed transition switch is not a substitute for a UPS, itdoes eliminate power interruptions to loads except tothose caused by power sources or equipment external

! WARNING

! CAUTION

! WARNING

IB01602003EPage 2

Effective 11/02

to the transfer switch. If both sources are acceptable asdetermined by the IQ Transfer logic, a make-before-break transfer is performed during a transfer test orretransfer operation.

1.2.1 TRANSFER SWITCH TYPES

There are 4 types of transfer switch equipment:

Automatic Transfer SwitchAutomatic transfer switches automatically perform thetransfer function. They consist of three basic elements:

(1) Main contacts to connect and disconnect the loadto and from the source of power.

(2) Intelligence/supervisory circuits to constantly moni-tor the condition of the power sources and thus pro-vide the intelligence necessary for the switch andrelated circuit operation.

(3) A transfer mechanism to effect the transfer of themain contacts from source to source.

Basic Transfer Switch (Power Panel)The basic transfer switch is designed for use with cus-tomer furnished logic. It is similar in design to the auto-matic version except the intelligence circuit (logic panel)and voltage selection panel are omitted. All controldevices are the customer’s responsibility.

Non-Automatic Transfer Switch (ElectricallyOperated)

Non-Automatic Transfer Switches are manually initiated,electrically operated devices for applications whereautomatic load transfer is not required.

Bypass Isolation Transfer Switch

The bypass isolation switch is designed for applicationswhere maintenance, inspection and testing must be per-formed while maintaining continuous power to the load(Figures 1-2 and 1-3). This is typically required in criti-cal life support systems and standby power situationscalling for safe system maintenance with no power dis-ruptions. Such a design allows for the quick removal ofthe different switching devices for inspection, mainte-nance or replacement.

The automatic transfer switch, non-automatic transferswitch (electrically operated) and bypass isolation trans-fer switch are the available types for the configurationdescribed in this manual.

Operation of the automatic transfer switch and thebypass isolation switch are only discussed in this manu-al (Sections 5 and 7 respectively).

1.2.2 DESIGN CONFIGURATION

The Cutler-Hammer transfer switch is a rugged, compactdesign utilizing insulated case switches or insulated casecircuit breakers to transfer essential loads from onepower source to another. Open transition switchingdevices are interlocked to prevent both switching devicesfrom being closed at the same time. The versatile design,in addition to standard transfer functions, offers an option-al integral thermal and short circuit protection in either orboth switching devices.

The switching devices are in a compact vertical arrange-ment. The logic can be easily disconnected from theswitching device without disturbing critical connections.The enclosure is free standing, and, by using the special-ly supplied cleats, the switch is seismic approved (Option42). The terminals are mounted in the rear of the switch,permitting rear, top, bottom or side cable or bus barentrance.

The switching devices have a high withstand rating (Table 1.1). The high-speed, stored-energy switch-ing mechanism guarantees a transfer time of less than 5 cycles.

Figure 1-1 Typical Load Transfer Switch (circuit break-er type) Schematic

NormalSource

EmergencySource

Load

IB01602003E Page 3

Effective 11/02

Figure 1-3 Typical Bypass Isolation Switch SchematicFigure 1-2 Typical Bypass Isolation Switch

Table 1.1 Withstand Ratings

Rating When Used with Upstream Circuit Breker Rating When Used with Upstream Fuse

Transfer Switch 240V 480V 600V Maximum Fuse 600V max.Amp Rating (kA) (kA) (kA) Fuse Rating Type (kA)

800 65 50 ➁➂➃ 25 1200/1600 L 100/2001000 65 50 ➁➂➃ 25 1600 L 2001200 85 65 ➃ 85 2000 L 2001600 100 100 85 3000 L 2002000 100 100 85 3000 L 2002500 100 100 85 4000 L 2003000 100 100 85 4000 L 2004000➀ 100 100 85 5000 L 200

Tested in accordance with UL1008.Cutler-Hammer Drawout SPB Transfer Switch will coordinate with a power circuit breaker short time rating.Contact factory for details➀ Available in 3-pole only.➁ 4-pole units are rated 35kA.➂ 65 kAIC for mini-SPB.➃ 100 kAIC for SPB with Option 17C.

IB01602003EPage 4

Effective 11/02

1.3 TRANSFER SWITCH CATALOG NUMBER IDENTIFICATION

Transfer switch equipment catalog numbers provide asignificant amount of relevant information that pertainsto a particular piece of equipment. The catalog numberidentification table (Table 1.2) provides the requiredinterpretation information. An example for an open tran-sition switch is offered to initially simplify the process.

Example: Catalog number (circled numbers correspondto position headings in Table 1.2):

The catalog number ATVISPE31000XSU describes anautomatic transfer switch with the switching devicesmounted vertically in the enclosure. The intelligencerepresented by the ATC-600/ATC-800 is a microproces-sor-based logic package. The System Power Breaker(SPB) is used as the switching device and is a 3-poleinsulated case switch for each source. The continuouscurrent rating of this equipment is 1000 amperes andapplicable at 480 VAC, 60Hz. The transfer switch equip-ment is enclosed in a NEMA 1 enclosure and is UL list-ed.

➀ to ➁ ➂ ➃ ➄ to ➅ ➆ ➇ ➈ to ➉

AT V I SP E 3 1000 X S U

12 13 14 15

IB01602003E Page 5

Effective 11/02

Position 7 Position 8 Positions 9-12 Position 13 Position 14 Position 15

Switching Device Number Ampere Voltage/ EnclosureArrangement of Poles Rating Frequency Type Listing

Drawout Insulated Case E Two 2 0600 120VAC/60Hz A No Enclosure K UL Listed U

Switches both Sources Three 3 0800 208VAC/60Hz B Type 1 S

Four 4 1000 600VAC/60Hz E Type 3R R➀

Drawout Insulated Case F 1200 220VAC/50 or 60Hz G Type 4 L

Breakers both Sources 1600 380VAC/50Hz H Type 4X D

2000 600VAC/50Hz K Type 12 J

Drawout Insulated Case G 2500 230VAC/50Hz M

Breaker Normal Source, 3000 401VAC/50Hz N

Insulated Switch 4000 415VAC/50Hz O

Emergency Source 240VAC/60Hz W

480VAC/60Hz X

Drawout Insulated Case H 365VAC/50Hz Z

Switch Normal Source,Insulated BreakerEmergency Source

➀ Not available in bypass isolation (BI) versions.

Positions 1-2 Position 3 Position 4 Positions 5-6

Switching DeviceConfiguration Orientation Control Panel Switching Device

Automatic Transfer Switch AT Vertical V ATC-600 I SPB Systems Power Breaker SP

Bypass IsolationTransfer Switch BI

Non-Automatic TransferSwitch (Electrically Operated) NT

Basic Transfer Switch(Power Panel Only) PP

Closed Transition AutomaticTransfer Switch CT ATC-800 I

Table 1.2 Transfer Switch Catalog Number Explanation

IB01602003EPage 6

Effective 11/02

SECTION 2: RECEIVING, HANDLING ANDSTORAGE

2.1 RECEIVING

Every effort is made to insure that transfer switch equip-ment arrives at its destination undamaged and ready forinstallation. Crating and packing is designed to protectinternal components as well as the enclosure. Transferswitch enclosures are skid mounted and suited for forklift movement. Care should be exercised, however, toprotect the equipment from impact at all times. Do notremove protective packaging until the equipment isready for installation.

When transfer switch equipment reaches its destination,the customer should inspect the shipping container forany obvious signs of rough handling and/or externaldamage incurred during the transportation phase.Record any external and internal damage observed forreporting to the transportation carrier and Cutler-Hammer, once a thorough inspection is completed. Allclaims should be as specific as possible and includeshop order and general order numbers.

A shipping label is affixed to the top of the shipping con-tainer which includes a variety of equipment and cus-tomer information, such as General Order Number(GO#) and Catalog Number (Cat#). Make certain thatthis information matches other shipping paper informa-tion.

Each transfer switch enclosure is bolted to a rigid wood-en pallet. The pallet is open at two ends for movementby a fork lift. The shipment is secured and further pro-tected with shrink wrap. Do not discard the packingmaterial until the equipment is ready for installation.

A plastic bag of documents will be found within theenclosure, usually attached to the inside of the door.Important documents, such as test reports, wiring dia-grams, appropriate instruction leaflets and a warrantyregistration card, are enclosed within the bag andshould be filed in a safe place.

2.2 HANDLING

As previously mentioned, transfer switch equipment ispackaged for fork lift movement. Protect the equipmentfrom impact at all times and do not double stack. Oncethe equipment is in the installation location and ready tobe installed, packaging material can be removed. Oncethe enclosure is unbolted from the wooden pallet, theequipment can be installed using the lifting provisionlocated on the top of the structure. Be careful not todamage the top or bottom enclosure mounting flanges.Refer to Section 4 of this manual for specific installationinstructions.

2.3 STORAGE

Although well packaged, this equipment is not suitablefor storage outdoors. The equipment warranty will notbe applicable if there is evidence of outdoor storage. Ifthe equipment is to be stored indoors for any period oftime, it should be stored with its protective packagingmaterial in place. Protect the equipment at all times fromexcessive moisture, construction dirt, corrosive condi-tions and other contaminants. It is strongly suggestedthat the package protected equipment be stored in a cli-mate controlled environment of -20° to 85° with a rela-tive humidity of 80% or less. Do not, under any circum-stances, stack other equipment on top of a transferswitch equipment enclosure, whether packaged or not.

IB01602003E Page 7

Effective 11/02

SECTION 3: EQUIPMENT DESCRIPTION

3.1 GENERAL

This Cutler-Hammer transfer switch equipment is avail-able in three different configurations:• Automatic Transfer Switch • Non-Automatic Transfer Switch (Electrically Operated)

(open transition only) • Bypass Isolation Transfer Switch

Refer to Section 1 for a discussion of all types. Eachtransfer switch is usually supplied in an enclosure,although unmounted sub-assemblies can be supplied formounting by the customer. The enclosed automatictransfer switch is the only specific type that will be dis-cussed in this section.

The enclosed automatic transfer switch consists of three

basic panels interconnected through connector plugsand mounted in an enclosure:

• Power Panel • Voltage Selection Panel • Logic Panel

- ATC-600 (open transition only)- ATC-800 (closed transition only)

The components comprising the three panels are installedin accordance with the specific requirements of the circuitbeing controlled. Each transfer switch is, therefore, tailor-made to a specific application.

3.2 POWER PANEL

The power panel consists of a means for making load,power, and neutral connections. The main contacts andthe transfer mechanism are all on one steel frame(Figure 3-1). The actual power connections are shownin Figure 3-3.

3.2.1 MAIN CONTACTS

The main contacts connect and disconnect the load toand from the different power sources. High withstandinsulated case switches are the main contacts for theNormal and Emergency power sources in standard,unmodified automatic transfer switches. Optional inte-gral thermal and short circuit protection in either or bothswitching devices is available (Figure 3-2 and Section3.6). These continuous duty devices are rated for allclasses of loads. In addition, they have high dielectricstrength, heavy-duty switching and withstand capabili-ties, and high interrupting capacity.

Figure 3-1 Typical Power Panel(Open Transition Shown)

Figure 3-2 Insulated Case Circuit Breaker(Closed Transition Shown)

IB01602003EPage 8

Effective 11/02

3.2.2 SWITCH INTERLOCKS (OPEN TRANSITIONONLY)

Cutler-Hammer transfer switches are mechanically andelectrically interlocked to prevent the two sets of maincontacts from being closed simultaneously.

3.2.3 DRAWOUT INTERLOCKS

The standard closed transtition ATS is not providedwith a mechanical interlock. All bypass switchingdevices are mechanically interlocked to the drawoutmechanism to ensure that the switching device isalways open when connecting or disconnecting it fromthe line and load stabs when in the bypass mode.

All open transition switching devices are mechanicallyinterlocked to the drawout mechanism to ensure that theswitching device is always open when connecting or dis-connecting it from the line and load stabs.

LIFTING THE PADLOCK LATCH WHILE ATTEMPT-ING TO RACK THE SWITCH IN OR OUT WHEN THESWITCH CONTACTS ARE CLOSED WILL CAUSETHE SWITCH TO OPEN.

The switching device will close only in the DISCON-NECT, TEST, and CONNECT positions. The switchingdevice will not close in the WITHDRAW position.

3.2.4 TRANSFER MECHANISM

The transfer switch uses Cutler-Hammer SPB-type insu-lated case circuit breakers and insulated case switcheswith a stored-energy mechanism (Figure 3-2). An elec-trical operator automatically recharges the mechanismafter the switching device has been closed, and an indi-cator on the switch shows whether it is in the OPEN orCLOSED position and the status of the stored energymechanism.

Figure 3-3 Terminal Connections for a Typical Drawout Transfer Switch (800-2000A Closed Transition Shown)

! CAUTION

NormalConnections

LoadConnections

EmergencyConnections

NeutralConnections(solid neutral

shown)

GroundConnections

Rear View

Side View

IB01602003E Page 9

Effective 11/02

The switching device is closed by energizing a solenoidthat releases the spring mechanism. A shunt trip willopen the switching device if energized.

3.2.5. DRAWOUT MECHANISM

The drawout mechanism is described in detail in Section6 (Figure 3-4).

3.3 VOLTAGE SELECTION PANEL

The voltage selection panel is a multi-tap-enclosedtransformer mounted in the enclosure (Figure 3-5).Seven front-accessible voltage taps from 208 to 600volts AC satisfy most required application voltages. Aquick change capability from one voltage to another isprovided by a small disconnect plug.

3.4 LOGIC PANEL

The logic panel provides the intelligence and superviso-ry circuits which constantly monitor the condition of bothnormal and emergency power sources thus providingthe required intelligence for transfer operations (Figure3-6). Detailed information is presented in a separatedocument:• ATC-600 Instruction Book (open transition only)• ATC-800 Instruction Book (closed transition only)

3.5 NEUTRALS

All 2-pole and 3-pole transfer switches are equippedwith 100-percent-rated neutral connections (Figures3-7 and 3-8). Different lug configurations are available,Option 21A.

Figure 3-4 Drawout Mechanism (Closed Transition Shown)

Figure 3-5 Voltage Selection Panel (Engine StartContacts Identified)

IB01602003EPage 10

Effective 11/02

3.6 FEATURES

Switch options, which are not part of the logic scheme,are available to meet a variety of other applicationrequirements. Options are numbered with an associat-ed description. More detailed selections that must bemade within a specific option are lettered. For availableoptions associated with the logic scheme, refer to thespecific logic document associated with the type of logicselected.

Options are Underwriters Laboratories, Inc. listed,except as noted, when supplied on UL ListedSwitches. If an option is selected that is Not ULListed, the switch Will Not Have A UL Label.

Not all options are available for all transfer switchconfigurations. If in doubt, check Price List 29-920for the availability of options for a specific transferswitch design. The option numbers used here corre-spond to the numbers used in the price list.

14. Relay Auxiliary Contacts

Provides Form “C” relay auxiliary contacts.

C. Source 1 Available: Provides 4 Form “C” relay auxil-iary contacts. The relay is energized when Source1 is available.

D. Source 2 Available: Provides 4 Form “C” relay auxil-iary contacts. The relay is energized when Source2 is available.

16. Integral Overcurrent ProtectionProvides thermal-magnetic overcurrent protection inte-gral to the power switching device(s). All Feature 16options include a “Lockout” function. If the power switch-ing breaker trips on an overcurrent condition then“Lockout” is displayed on the Automatic Transfer SwitchController display and automatic operation is preventeduntil the appropriate source is manually reset.

NOTICE

NOTICE

Figure 3-6 ATC-600/ATC-800

Figure 3-7 Neutral SEwith Ground Fault

Figure 3-8 Solid Neutral

ATC-600

ATC-800

LoadConnections

GroundConnections

SourceConnections

LoadConnections

SourceConnections

GroundConnections

IB01602003E Page 11

Effective 11/02

B. Both Power Source Switching Devices: Providesintegral overcurrent protection on both Source 1 and Source 2 power switching devices.

E. Source 2 Power Switching Device: Provides inte-gral overcurrent protection on the Source 2 powerswitching device.

N. Source 1 Power Switching Device: Provides inte-gral overcurrent protection on the Source 1 powerswitching device.

17C. High Withstand Power Switching DevicesProvides power switching devices with a higher with-stand rating on fixed mounted SPB type transfer switch-es 800A - 1200A.

18. Metering and Commnications

The IQ Family of microprocessor-based multi-functionmonitoring and display devices features the latest tech-nological advances in metering and communicationscapabilities. Feature 18 metering options include allrequired external devices (CT’s etc.) for a fully function-ing metering system.

O. IQ Analyzer - Source 1 Line Side Metering: Providesan IQ Analyzer for monitoring the Source 1 line sidecircuit.

P. IQ Analyzer - Source 2 Line Side Metering: Providesan IQ Analyzer for monitoring the Source 2 line sidecircuit.

Q. IQ Analyzer with Selector Switch for Source 1 orSource 2 Line Side Metering: Provides an IQAnalyzer with a source selector switch for monitor-ing the Source 1 or Source 2 line side circuit.

R. IQ DP-4000 - Source 1 Line Side Metering:Provides an IQ DP-4000 for monitoring the Source 1line side circuit.

S. IQ DP-4000 - Source 2 Line Side Metering:Provides an IQ DP-4000 for monitoring the Source 2line side circuit.

T. IQ DP-4000 with Selector Switch for Source 1 orSource 2 Line Side Metering: Provides an IQ DP-4000 with a source selector switch for monitoringthe Source 1 or Source 2 line side circuit.

20A. Rear Bus Connections

Provides Source 1, Source 2 and Load Circuit rearaccessable bus stabs with provision for bus bar connec-tion.

21A. Optional Power Cable Connection Terminals

Provides alternate power cable connection terminals.Consult Cutler-Hammer for available optional terminalsizes.

24. Battery Charger Provides an automatic battery charger for engine crank-ing batteries. Requires a separate 100-135Vac, 60Hzcustomer supplied power source.

C. Battery Charger with 12Vdc Output: Provides anautomatic battery charger with 12Vdc, 5 amp out-put.

D. Battery Charger with 24Vdc Output: Provides anautomatic battery charger with 12Vdc, 5 amp out-put.

When supplied, the battery charger is provided in a sep-arate wall mounted enclosure (Figure 3-9). Separateinstructions and wiring information are provided with thecharger for installation purposes.

A separate 120 VAC control power supply isrequired for the battery charger input. No connec-tions between the transfer switch and battery charg-er should be made.

NOTICE

6.13 (156)

9.50 (241)

7.50 (191)

7.38 (187)

Figure 3-9 Charger Mounting Dimensions in Inches(mm)

8.88 (223)

8.25 (208)

5.25 (132)7.25 (182)

IB01602003EPage 12

Effective 11/02

34. Logic Extender Cable

Provides logic extender cables with connectors whichpermit remote mounting of the Automatic TransferController in non-standard applications.

A. 48 inch (1219 mm): Provides logic extension cablewith connectors.

B. 72 inch (1829 mm): Provides logic extension cablewith connectors.

C. 96 inch (2438 mm): Provides logic extension cablewith connectors.

D. 120 inch (3048 mm): Provides logic extension cablewith connectors.

E. 144 inch (3658 mm): Provides logic extension cablewith connectors.

Special lengths are available. Contact Cutler-Hammer.

37. Service Entrance Rated Transfer Switch

Provides the label “Suitable for use as ServiceEquipment” and the features necessary to meet therequirements for the label. Includes service disconnectwith visible indication and neutral assembly with remov-able link. Feature 16B or 16N must be selected sepa-rately.

A. Service Equipment Rated Transfer Switch withoutGround Fault Protection: Provides ServiceEquipment rating for an application that does notrequire ground fault protection.

B. Service Equipment Rated Transfer Switch withGround Fault Protection: Provides ServiceEquipment rating for an application that requiresground fault protection.

41. Space Heater with ThermostatProvides a space heater and adjustable thermostat.External control power is not required.

A. Space Heater with Thermostat - 100 Watts:Provides 100 watt space heater with an adjustablethermostat.

B. Space Heater with Thermostat - 200 Watts:Provides 200 watt space heater with an adjustablethermostat.

C. Space Heater with Thermostat - 400 Watts:Provides 400 watt space heater with an adjustablethermostat.

42. Seismic Certification

Provides a Seismic certified Transfer Switch with certifi-cate for application is Seismic Zone 4 under the CaliforniaBuilding Code, the Uniform Building Code and BOCA.

3.7 ENCLOSURE

The rugged steel switch enclosure is supplied with threedoor hinges, regardless of enclosure size, to insureproper support of the door and door mounted devices.The hinges have removable hinge pins to facilitate doorremoval. The doors are supplied as standard with a key

NEMA Design ProtectionType

1 Indoor Enclosed Equipment

3R Outdoor Rain, Ice Formation

4/4X Indoor/Outdoor Dust, Rain, Splashing, Water,

Corrosion Resistant

12 Indoor Dust, Dirt and Non-corrosive

Liquids

Table 3.1 Transfer Switch Equipment Enclosures

IB01602003E Page 13

Effective 11/02

lockable handle. Cable entry holes are the customer’sresponsibility.

The door is used to mount a variety of lights, switchesand pushbuttons, depending upon the options requiredfor a particular switch. All switch doors are supplied witha heavy duty plastic accessory panel in place, whetheror not external devices are required. When lights, push-buttons or switches are required, they are normally mounted in the plastic door mounted panel. Models of2500 amperes and higher have two doors (Figures 4-1and 4-2).

Transfer switch enclosures and all internal steel mount-ing plates, such as the power panel mounting plate, gothrough a pre-treatment cleaning system prior to paint-ing to insure a durable finish. Should the enclosurebecome scratched and in need of touch up paint, useANSI61.

The standard switch enclosure is NEMA Type 1 for gen-eral indoor use (Table 3.1).

3.8 STANDARDS

Cutler-Hammer transfer switch equipment is listed forapplication by UL, and are certified to meet CanadianStandards by Underwriters Laboratories Inc. (CUL),except for Bypass Isolation units. In addition, Cutler-Hammer Automatic Transfer Switches are listed in FileE38116 by Underwriters Laboratories, Inc. underStandard UL 1008. This standard covers requirementsfor automatic transfer switches intended for use in ordi-nary locations to provide for lighting and power as fol-lows:

a. In emergency systems, in accordance with articles517 and 700 in the National Electrical Code,ANSI/NFPA 70 and the National Fire ProtectionAssociation No. 76A and/or

b. In stand-by systems, in accordance with article 702of the National Electrical Code and/or

c. In legally required stand-by systems in accordancewith article 701 of the National Electrical Code.

Cutler-Hammer Automatic Transfer Switches are avail-able to meet NFPA 110 for emergency and stand-bypower systems, and NFPA 99 for health care facilitieswhen ordered with the appropriate options.

Since Cutler-Hammer Automatic Transfer Switches uti-lize specially designed switches and/or circuit breakersas the main power switching contacts, these devicesmust also be listed under the additional UL Standards489 and 1087. Underwriters Laboratories utilize two

basic types of listing programs: a) Label service b) Re-examination. UL489 and UL1087 employ a label servicelisting program which requires an extensive follow-uptesting program for listed devices. Standard UL1008 forautomatic transfer switches lists devices under the re-examination program which only requires a continualphysical re-examination of the components used in theproduct to insure consistency with the originally submit-ted device. Follow-up testing is not required by UL1008.

Representative production samples of switches and cir-cuit breakers used in Cutler-Hammer Automatic TransferSwitches are subjected to a complete test program identi-cal to the originally submitted devices on an ongoing peri-odic basis per UL489 and UL1087. The frequency of sucha re-submittal can be as often as every quarter for a lowampere device.

IB01602003EPage 14

Effective 11/02

SECTION 4: INSTALLATION AND WIRING

4.1 GENERAL

Transfer switches are factory wired and tested.Installation requires solidly mounting the enclosed unitand connecting power cables and auxiliary pilot circuits.Physical mounting procedures and power cable connec-tions are covered in this section. All other requiredwiring or electrical connection references are covered ina separate Customer Wiring Diagrams packed withthe transfer switch. Locate the wiring booklet, review it,and keep it readily available for reference purposes dur-ing installation and testing. Once a transfer switch isproperly installed and wired, it should be mechanicallyand electrically checked for proper installation and oper-ation. The procedures for these initial mechanical andelectrical checks are outlined in Section 6 of this instruc-tion manual.

BE CERTAIN THAT THE SOLID STEEL POWERPANEL SHIELD IS PROPERLY INSTALLED BEFORETRANSFER SWITCH EQUIPMENT IS PUT INTO SER-VICE. THE SHIELD PROVIDES PROTECTION FROMDANGEROUS VOLTAGES AT THE LINE AND LOADTERMINALS WHEN THE EQUIPMENT IS IN OPERA-TION. FAILURE TO DO SO COULD RESULT IN PER-SONAL INJURY OR DEATH.

4.2 MOUNTING LOCATION

Choose a location that offers a flat, rigid mounting sur-face capable of supporting the weight of the enclosedtransfer switch equipment. Avoid locations that aremoist, hot, or dusty. Enclosure designs are, however,available for special environments. If there are anydoubts as to location suitability, discuss it with yourCutler-Hammer representative.

Check to make certain that there are no pipes, wires, orother hazards in the immediate area that could create aproblem. The panels provide ample room for rear cableentry from top, bottom, and sides. At no time shouldcable be routed to retard the action of relays or coverthe logic in a way that restricts adjustments. Maintainproper electrical clearances between live metal partsand grounded metal.

For installation and maintenance purposes, the primaryand secondary sources must have an overcurrent pro-tective device upstream of the transfer switch, unlessovercurrent protection is integral to the switch.

Dimensions of the transfer switch are an important con-sideration in determining proper location selection.

4.3 UNPACKAGING AND INSPECTION

SINCE THE ENCLOSED TRANSFER SWITCH MUSTBE LIFTED INTO PLACE FOR MOUNTING, BE CER-TAIN THAT ADEQUATE RESOURCES ARE AVAIL-ABLE FOR LIFTING TO AVOID PERSONNELINJURIES OR EQUIPMENT DAMAGE.

Cable entry holes are not part of the enclosure whenshipped from the factory and must be provided in thefield, either before or after mounting the enclosure.Proceed with the following four steps:

Step 1: Carefully uncrate the transfer switch. If dam-age is visible, please contact your local Cutler-Hammer sales representative or the factory at800-354-2070.

Step 2: Open the door and visually verify that there areno broken or damaged components or evi-dence of distorted metal or loose wires as aresult of rough handling.

Step 3: A label on the baseplate provides specifica-tions for your transfer switch. Verify that thesespecifications comply with your requirements.

Step 4: Remove any braces or packing used to protectthe transfer switch or internal components dur-ing shipping.

EXTREME CARE SHOULD BE TAKEN TO PROTECTTHE TRANSFER SWITCH FROM DRILL CHIPS, FIL-INGS, AND OTHER CONTAMINANTS WHEN MAK-ING THE CABLE ENTRY HOLES AND MOUNTINGTHE ENCLOSURE TO PREVENT COMPONENT DAM-AGE OR A FUTURE MALFUNCTION.

4.4 MOUNTING PROCEDURE

With the enclosed transfer switch equipment unpackedand ready for mounting, proceed with the following steps:

Step 1 : Mounting and cabling access is best providedby removing side and rear covers (when applic-

! WARNING

! CAUTION

! CAUTION

IB01602003E Page 15

Effective 11/02

able). See Section 7.3 for cover removalinstructions.

Step 2 : Gently maneuver the switch into its locationusing all of the supplied lift brackets.

Step 3 : Bolt the enclosure to the base. Use separatecleats (Option 42 only) if Seismic UBC Zone 4certification is desired (Figure 4-1), and securewith 1/2-13 UNC Grade 5 hex bolts.

Step 4 : Tighten bolts to 50 ft-lbs (68 Nm).

Step 5 : Double check to ensure that all packing andshipping material has been removed.

4.5 POWER CABLE CONNECTIONS

POWER CONDUCTORS MAY HAVE VOLTAGE PRE-SENT THAT CAN CAUSE SEVERE PERSONALINJURY OR DEATH. DE-ENERGIZE ALL POWER ORCONTROL CIRCUIT CONDUCTORS TO BE CON-NECTED TO THE TRANSFER SWITCH EQUIPMENTBEFORE BEGINNING TO WORK WITH THE CON-DUCTORS AND/OR TERMINATING THEM TO THEEQUIPMENT.

USE OF CABLE LUGS NOT DESIGNED FOR THETRANSFER SWITCH MAY CAUSE HEATING PROB-LEMS. BREAKER LUGS ONLY MOUNT TO THEBREAKER, WHILE TRANSFER SWITCH LUGSMOUNT TO BOTH THE BREAKER AND THE BUSBAR BEHIND THE BREAKER. FOR INSTALLATIONINSTRUCTIONS, REFER TO THE INSTRUCTIONLEAFLET SUPPLIED FOR THE SPECIFIC LUGS.

TO HELP PREVENT COMPONENT DAMAGE ORFUTURE MALFUNCTIONS, USE EXTREME CARE TOKEEP CONTAMINANTS OUT OF THE TRANSFERSWITCH EQUIPMENT WHEN MAKING POWERCABLE CONNECTIONS.

Proceed with the following steps:

Step 1: Verify that the line and load cables comply withapplicable electrical codes.

Step 2: Verify that transfer switch rated current andvoltage (see identification plate on the intelli-gence panel of transfer switch) agree with sys-tem current and voltage.

Step 3: After the transfer switch is mounted, provideconduit or cable openings as required. Ensurethat no metal filings contaminate the transferswitch components.

Step 4: Test all power cables before connecting to theunit to insure that conductors or cable insula-tion have not been damaged while being pulledinto position.

Step 5: Carefully strip insulation from the powercables. Avoid nicking or ringing of the conduc-tor strands. Prepare the stripped conductor ter-mination end by cleaning it with a wire brush. Ifaluminum conductors are used, apply anappropriate joint compound to the clean con-ductor surface area. Refer to Figure 3-3 forapproximate locations of power connections.

Power cables are to be connected to solderless screwtype lugs located on the transfer switch switchingdevices. Refer to the separate Customer WiringDiagrams supplied with the transfer switch equipmentfor power termination. Verify that the lugs supplied willaccommodate the power cables being used. Also verifythat the cables comply with local electrical codes.Standard transfer switch equipment, as supplied fromthe factory, will accommodate the wire sizes shown inTable 4.1.

IMPROPER POWER CABLE CONNECTIONS CANCAUSE EXCESSIVE HEAT AND SUBSEQUENTEQUIPMENT FAILURE.

Step 6: Tighten cable lugs to the torque identified onthe label affixed to the unit immediately adja-cent to the lugs.

Step 7: Make necessary connections of options usingwiring diagrams supplied with the unit.

Step 8: Connect engine start wires to the red terminalblocks marked 51 and 52.

! WARNING

! CAUTION

! CAUTION

! CAUTION

IB01602003EPage 16

Effective 11/02

4.6 VOLTAGE SELECTION ADJUSTMENT

Certain devices, such as the Voltage Selection Panel,sensing relays and timers, need to be set and/or cali-brated prior to placing the transfer switch equipment intoservice. Adjustments for logic devices are described inthe separate instructional document dedicated to thespecific logic being used. Voltage selection adjustmentsare described here.

BE SURE THAT THE CORRECT VOLTAGE ISSELECTED TO MATCH THE SYSTEM VOLTAGE. ANIMPROPER SELECTION AND/OR CONNECTIONCOULD RESULT IN EQUIPMENT DAMAGE.

4.7 MOUNTING SWITCHING DEVICE IN THE DRAWOUT MECHANISM

When mounting the switching device in the drawoutmechanism, ensure that the extension rails are pulledout to full extension, and that the tape has beenremoved from the secondary control block contact open-ings (Figures 4-2 and 4-3).

Use a wide strap attached to an overhead crane for lift-ing the switch. Tilt the switching device forward and slipthe strap underneath, placing it between the two draw-out wheels on each side. Steady the sides of the switch-ing device as the crane lifts it to ensure that it does notslip off the strap. Lower all four wheels onto the top ofthe switching device extension rails (Figure 4-7). Thefront wheels on the switching device will fit into a depres-sion at the front of the rails, and it will rest there securely.

Remove the strap. It will slide out between the switchingdevice and the extension rails. A molded escutcheon onthe switching device cell door is for mounting the labelfor the indexing lever. This label indicates the position ofthe switch. With the cell door in place attach theescutcheon to the outside of the enclosure door.

Place the switching device in the TEST position. Peel thebacking off the label that indicates the position of the switch-ing device and place it on the escutcheon so that the testposition indicator lines up correctly with the indexing lever.

4.8 WIRING

POWER CONDUCTORS AND CONTROL WIRINGMAY HAVE VOLTAGE PRESENT THAT CAN CAUSESEVERE PERSONAL INJURY OR DEATH. DE-ENER-GIZE ALL POWER OR CONTROL CIRCUIT CONDUC-TORS BEFORE BEGINNING TO PERFORM ANYWIRING ACTIVITY TO OR WITHIN THE TRANSFERSWITCH EQUIPMENT.

Power sources, load conductors and control wiringshould be connected to locations as indicated in theCustomer Wiring Diagrams supplied with the transferswitch equipment.

4.8.1 ENGINE START CONNECTION

The engine control contact connections are located onthe lower right of the transformer panel of the ATS(Figure 3-5). The engine control contact connections ofbypass isolation units are located in the rear of theenclosure (51A, 52A). NOTE: Prior to making the enginestart connection to the switch on bypass isolation units,set the engine generator controls selector switch in theOFF position to prevent an unwanted engine start.Connect the engine start wires to the red terminal blocksmarked 51 and 52 or 51A and 52A for bypass isolation units. A contact closes between these terminal blockswhen an engine start signal is provided by the ATSlogic.

4.8.2 ALARM CONTACTS (CLOSED TRANSITIONONLY)

Closed transition only automatic transfer switches areprovided with 4 N.O. and 4 N.C. contacts (KA) forremote alarming. These contacts are energized whenthe TDUP (Time Delay Utility Parallel) times out (presetby user). The TDUP timer starts timing when bothsources are paralleled. Refer to the IQ Transfer instruc-tion book for additional alarms.

Table 4.1 Wire Size for Available Power Cable Connections

! CAUTION

Switch Cables RangeRating Per Wiring Size(Amps) Phase

800-2000 8 4/0-500 MCM800-2000 6 500-750 MCM2500-3000 12 4/0-500 MCM2500-3000 9 500-750 MCM4000 16 4/0-500 MCM4000 12 500-750 MCM

! CAUTION

IB01602003E Page 17

Effective 11/02

These cleats must be

ATVISP, NTVSSP

Figure 4-1 Seismic Tested and Approved Product Mounting Instructions

Seismic Tested and Approved Product Mounting Instructions

In all cases, the unit must be mounted per the outline drawing. Inaddition, the floor-mounted units must use the provided cleats.These cleats must be placed between the head of the bolt and thesheet metal enclosure. It is also necessary to use 0.5-13UNC Grade5 or better hex head bolts. These bolts are to be torqued to 50 ft. lbs.(68 Nm).

IB01602003EPage 18

Effective 11/02

Figure 4-3 Secondary Control Block Contact Opening

Figure 4-4 Correct Placement

Figure 4-2 Drawout Stationary

IB01602003E Page 19

Effective 11/02

SECTION 5: OPERATION

5.1 GENERAL


A transfer switch provides main contacts to connect anddisconnect the load to and from the normal and emer-gency power sources (Paragraph 3.2.1). A stored-energytype transfer mechanism provides the mechanical motionrequired to open and close the main contacts (Paragraph3.2.5 and Figure 3-2).

Each switch can be manually operated. Before a switch-ing device can be closed, the stored energy mechanismmust be charged by pumping the handle (Figure 5-1).

In the closed transition product a single switchingdevice can be manually closed by following the instruc-tions detailed in Figure 5-3. An indicator window showswhether the switch is open or closed.

The open transition switching device can be closed bypushing the close button (Figure 5-2). The other switch-ing device is prevented from closing through a rigidmechanical interlock(Paragraph 3.2.2). An indicatorwindow shows whether the switch is open or closed.

If a transfer switch with any type of electrical operat-ing capabilities is to be operated manually utilizing

the manual operating handle, it is strongly recom-mended that the transfer control circuit first be iso-lated. This is accomplished by disconnecting thelogic from the power panel panel. If, however, atransfer switch is supplied with a four-positionselector switch (Option 6H), it can be turned to theoff position, making it unnecessary to unplug thelogic. In the case of the automatic transfer switchdesign, any attempt to operate the manual handlewithout first isolating the control circuit causes anautomatic transfer.

5.2 AUTOMATIC TRANSFER SWITCH

The operating sequence of an automatic transfer switchis dictated by the switch’s standard features and select-ed options. Operation of an automatic transfer switchduring normal power source failure, normal powersource restoration and performing tests is described inthe associated Controller Instruction Booklet.

Figure 5-1 Pumping Handle Charges Stored EnergyMechanism (Closed Transition Shown)

NOTICE

! WARNING

Figure 5-2 Close Switch by Pushing Close Button(Open Transition Shown)

IB01602003EPage 20

Effective 11/02

Figure 5-3 Switching Device Closing Precautions (Closed Transition Only)

! WARNING

OVERLAPPING CONTACTSAlternate and Normal Sources

must be Synchronized

7805C60H02

THIS PRODUCT CONTAINS A SPECIAL CON-TACT ARRANGEMENT (OVERLAPPING CON-TACTS). MISUSE CAN RESULT IN DEATH,SEVERE PERSONAL INJURY OR PROPERTYDAMAGE.

(THIS LABEL IS APPLIED TO THE DEAD FRONTCOVER.)

Do Not Use WithoutReading Manual

Operating Instructions

MANUAL CLOSE BUTTON

! WARNING

Manual Operation Instructions

1. Disconnect Logic Connectors2. Open both switching devices3. Verify “OPEN” flags4. Verify source availability5. Close switching device on available

source by inserting a small tool in center of “Manual Close Button” labelon switching device.

7805C60H01

THESE INSTRUCTIONS ONLY PERTAIN TOMANUALLY CLOSING A SINGLE SWITCHINGDEVICE. ATTEMPTING TO CLOSE BOTHSWITCHING DEVICES CAN CAUSE SEVEREINJURY OR DEATH.

(THIS LABEL IS APPLIED TO THE DEAD FRONTCOVER.)

Attempting to close bothswitching devices simultaneouslycan cause severe injuryor death.

Follow Manual Operation Instructions Below

FOLLOW THE INSTRUCTIONSOUTLINED IN THE NEXTWARNING LABEL.

(THIS LABEL IS APPLIED TOTHE COVER OF THE MANUALCLOSE BUTTON ON EACHSWITCHING DEVICE.)

IB01602003E Page 21

Effective 11/02

SECTION 6: DRAWOUT MECHANISM

6.1 DRAWOUT INTERLOCK

The transfer switch is mechanically interlocked to thedrawout mechanism to ensure that the switching deviceis always open when connecting or disconnecting it fromthe line and load stabs.

LIFTING THE PADLOCK LATCH WHILE ATTEMPT-ING TO RACK IN OR OUT THE SWITCHING DEVICEWHEN THE SWITCH CONTACTS ARE CLOSED WILLRESULT IN THE SWITCHING DEVICE OPENING.THIS WILL RESULT IN A LOSS OF POWER TO THELOAD.

The switching device will close in the DISCONNECTED,TEST, and CONNECTED positions. POWER WILL BEDELIVERED FROM A POWER SOURCE TO THELOAD ONLY WHEN THE SWITCHING DEVICE IS INTHE CONNECTED POSITION. The switching devicewill not close in the WITHDRAWN position.

6.2 SWITCH POSITION

The drawout mechanism has four positions: Connected,Test, Disconnected and Withdrawn. They are achievedby lifting the padlock latch and inserting a 3/4-inch sock-et wrench (Figure 6-1). Clockwise motion moves theswitch towards the CONNECTED position.Counterclockwise will move the switch towards theWITHDRAWN position.

The socket wrench must be removed and the drawoutmechanism in an operational position for the switchingdevice to operate.

CONNECTED

The switch is fully connected to the primary stabs andsecondary contacts.

With both switches in this position the transferswitch is fully operational.

TEST

The switch is not connected to the primary stabs, but is connected to the secondary contacts.

DISCONNECTED

Both primary stabs and the secondary contacts are disconnected.

WITHDRAW

The switch may be removed from the cassette.

6.3 ROTATION ON THE DRAWOUT

If the switching device needs to be rotated on the draw-out for inspection, the deadfront shield must first be

! CAUTION NOTICE

Figure 6-1 Drawout with Socket Wrench Figure 6-2 Drawout Pulled Forward for Inspection

IB01602003EPage 22

Effective 11/02

removed. The shield should be removed while theswitching device is in the DISCONNECT position,before it is pulled into the WITHDRAWN position. Beforebeginning the rotation, ensure that the switching deviceis fully withdrawn, with the front wheels in the depres-sion in the front of the extension rails.

Lift the front of the switch so that the front wheels are offthe extension rails, and pull it forward (Figure 6-2) Continue pulling forward on the switching device untilthe back wheels move into the depression at the end ofthe extension rails where the front wheels were situated.

As the switching device is turned, be careful of the com-partment opening. Do not lift or put pressure on the sec-ondary control contract block assembly on the back ofthe switch. Turn it by holding the top or bottom (Figure6-3)

NEVER RETURN THE TRANSFER SWITCH TO SER-VICE WITHOUT INSTALLING THE DEADFRONTSHIELD.

Return the switching device to the desired position.Replace the deadfront shield when the switch is in theDISCONNECT position.

6.4 OPERATIONAL CHECK FOR DRAWOUT MECH-ANISM

Ensure that the wiring is clear of all obstructions.Rack the switch to the DISCONNECT position. Visuallyverify that the secondary contacts are apart. Manuallycharge and close the switching device.

Rack the switching device to the TEST position. Ensurethat the tab falls into the slot of the indicator wheel onthe right side of the moveable mechanism. Verify thatthe switching device opens when the padlock is raised.

Visually verify that the secondary contacts are connect-ed. Check for electrical continuity by energizing thecontrol circuit and operating switching device.

Rack the switching device to the CONNECT position.Visually verify that the secondary contacts remain con-nected.

Rack the switching device to the DISCONNECT posi-tion. Visually verify that the secondary contacts areapart.

! CAUTIONFigure 6-3 Drawout Rotated Out for Inspection

IB01602003E Page 23

Effective 11/02

SECTION 7: OPERATION OF BYPASS ISO-LATION TRANSFER SWITCH

7.1 OPERATOR PANEL

The design of this transfer switch allows quick removalof the different switching devices for inspection or main-tenance, or if required, quick replacement.

The bypass isolation switch has two operator panelswith switches and lights (Figure 7-1). The followingdescriptions are for those features that are standardwith the bypass isolation switch. Additional features aredescribed in the options section.

The left control panel has the following standard fea-tures:

1. Light to indicate if the normal source is available.

2. Light to indicate if the emergency source is avail-able.

3. Light to indicate if the NORMAL position is ener-gized, that is, the normal switching device in theautomatic transfer switch is closed.

4. Light to indicate if the EMERGENCY position isenergized, that is, the emergency switching devicein the automatic transfer switch is closed.

5. Push-to-test button allows testing of the transferswitch. Pushing the button will simulate a power fail-ure, causing the transfer switch to start the transfersequence. If the push button is held down, thetransfer switch will transfer the load to the emer-gency switch. Releasing the button will restore regu-lar power.

6. Three-position selector switch to control the genera-tor:AUTO — The intelligence circuit of the transfer switch will start the generator if the normal power source is not available.

OFF — The intelligence circuit of the transfer switch will not be able to start the generator, which eliminates nuisance starts during maintenance.

RUN — The generator will run regardless of the availability of the normal power source.

The right control panel has the following standard fea-tures:

1. Light to indicate if the normal switching device is

isolated (only if the normal switching device isracked out).

2. Light to indicate if the emergency switching deviceis isolated (only if the emergency switching device isracked out).

3. Light to indicate if the normal bypass switchingdevice is closed.

4. Light to indicate if the emergency bypass switchingdevice is closed.

7.2 AUTOMATIC OPERATION

The intelligence/supervisory circuits on Cutler-Hammertransfer switches constantly monitor the condition ofboth the normal and emergency power sources. These

Figure 7-1 Bypass Isolation Switch

IB01602003EPage 24

Effective 11/02

circuits automatically initiate an immediate transfer ofpower from the normal to the emergency source whenthe power source fails or the voltage level drops below apreset value. Transfer back to the normal power sourceis automatic upon return of the normal power source.

Monitoring the power source is always performed on theline side of the power source to which the switch is con-nected. The normal power source is the preferredsource and the transfer switch will always seek thissource when it is available.

7.3 BYPASSING THE TRANSFER SWITCH


7.3.1 NORMAL TO NORMAL BYPASS

The normal switching device can be bypassed and iso-lated by the following sequence (Figure 7-2):

1. Move the generator selector switch to the OFF posi-tion to avoid nuisance starts.

2. Remove the key from the emergency switchingdevice by turning it counterclockwise while pushingup on the lever next to the key interlock. This willlock the emergency switching device to prevent itfrom closing.

3. Insert the key in the normal bypass switching deviceand turn it clockwise, which will release the lever tothe left of the key interlock. This will unlock the nor-mal bypass switching device.

4. Close the normal bypass switch manually. The nor-mal bypassed light will illuminate.

5. Open and rack out the normal switching device (seeSection 6). The normal isolated light will illuminate.The normal position energized light will no longer beilluminated.

6. Inspect and/or perform maintenance on the normal switching device.

7. Rack in the normal switching device (see Section 6).The normal switching device will automaticallyrecharge and close when it is in the CONNECT

position. The normal isolated light will no longer beilluminated, but the NORMAL position energizedlight will be illuminated.

8. Open the normal bypass switch. The normalbypassed light will no longer be illuminated.

9. Remove the key from the normal bypass switch byturning the key counterclockwise while pushing upon the lever next to the key interlock. This will lockthe normal bypass switch to prevent it from closing.

10. Insert the key in the emergency switch and turn thekey clockwise, which will release the lever to the leftof the key interlock. This will unlock the emergencyswitching device.

11. The normal switching device is now back in automatic operation.

7.3.2 EMERGENCY TO EMERGENCY BYPASS

The emergency switching device can be bypassed andisolated by the following sequence:

1. Move the generator selector switch to the RUN posi-tion to avoid losing power.

2. Remove the key from the normal switching deviceby turning the key counterclockwise while pushingup on the lever next to the key interlock. This willlock the normal switching device and prevent it fromclosing.

3. Insert the key in the emergency bypass switchingdevice and turn the key clockwise to release thelever to the left of the key interlock. This will unlockthe emergency bypass switching device

4. Close the emergency bypass switching device man-ually. The emergency bypass light will illuminate.

5. Open and rack out the emergency switching device(see Section 6). The emergency isolated light willilluminate, and the emergency position energizedlight will no longer be illuminated.

6. Inspect and/or perform maintenance on the emer-gency switching device.

7. Rack in the emergency switching device (seeSection 6). The emergency switching device willautomatically recharge and close when in the CON-NECT position. The emergency isolated light will nolonger be illuminated, and the emergency positionenergized light will illuminate.

! WARNING

IB01602003E Page 25

Effective 11/02

Rack out andInspect/Maintain

Switch

Place GeneratorIn OFF Position

Cutler-Hammer

Digitrip 3000Operational

High Load

CommunicationsTrip

Time OvercurrentCurve ShapePickup (x In)

Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes

Settings/Test Time/Trip Cause

TestProgram

Test

Pickup (x In)Instantaneous

Short DelayAmp Demand

I

Cutler-Hammer

PhasePhase Phase

Phase

Ground

Digitrip 3000Operatio

High

CommunTime OvercurrentCurve Shape

Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Cutler-Hammer


High Load

CommunicationsTrip


Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes


TestProgram

Test



I

Cutler-Hammer

PhasePhase Phase

Phase

Ground


High


Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Cutler-Hammer


High Load

CommunicationsTrip


Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes


TestProgram

Test



I

Cutler-Hammer

PhasePhase Phase

Phase

Ground


High


Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Cutler-Hammer


High Load

CommunicationsTrip


Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes


TestProgram

Test



I

Cutler-Hammer

PhasePhase Phase

Phase

Ground


High


Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Figure 7-2a Transfer from Normal Switching Device to Normal Bypass Switching Device, Steps 1-4

IB01602003EPage 26

Effective 11/02

Rack NormalSwitch back

into itslocation

Switch willautomatically

close

Cutler-Hammer


High Load

CommunicationsTrip


Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes


TestProgram

Test



I

Cutler-Hammer

PhasePhase Phase

Phase

Ground


High


Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Cutler-Hammer


High Load

CommunicationsTrip


Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes


TestProgram

Test



I

Cutler-Hammer

PhasePhase Phase

Phase

Ground


High


Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Cutler-Hammer


High Load

CommunicationsTrip


Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes


TestProgram

Test



I

Cutler-Hammer

PhasePhase Phase

Phase

Ground


High


Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Cutler-Hammer


High Load

CommunicationsTrip


Time Multiplier

Pickup (x In)Time

Program

Phase

Ground

I

I

I

RMS Amperes


TestProgram

Test



I

Cutler-Hammer

PhasePhase Phase

Phase

Ground


High


Pickup (x In)

Time Multiplier

Time

Program

Phase

Ground

RMS


Short Delay

Figure 7-2b Transfer from Normal Switching Device to Normal Bypass Switching Device, Steps 5-8

IB01602003E Page 27

Effective 11/02

8. Open the emergency bypass switch. The emer-gency bypassed light will no longer be illuminated.

9. Remove the key from the emergency bypass switchby turning the key counterclockwise while pushing upon the lever next to the key interlock. This will lock theemergency bypass switch and prevent it from closing.

10. Insert the key in the normal switch and turn it clock-wise to release the lever to the left of the key inter-lock. This will unlock the normal switch.

11. The normal switch is now back in automatic opera-tion.

7.3.3 NORMAL TO EMERGENCY BYPASS(OPEN TRANSITION ONLY)

The normal switch can be isolated and bypassed by thefollowing sequence:

1. Move the generator selector switch to the RUN posi-tion because the load needs to be energized fromthe emergency source.

2. Make sure that the emergency source is available.

3. Remove the key from the normal switch by turning thekey counterclockwise while pushing up on the levernext to the key interlock. This will open the normalswitching device and thus the normal position ener-gized light will no longer be illuminated. The normalswitching device is now locked to prevent it from clos-ing.

4. Close the emergency bypass switching device manu-ally. The emergency bypassed light will be illuminat-ed.

5. Open and rack out the normal switching device (seeSection 6). The normal isolated light will illuminate.

6. Inspect and/or perform maintenance on the normalswitching device.

7. Rack in the normal switching device (see Section 6).The normal switching device will automaticallyrecharge when it is in the CONNECT position. Thenormal isolated light will no longer be illuminated.

8. Open the emergency bypass switching device. Theemergency bypassed light will no longer be illuminat-ed.

9. Remove the key from the emergency bypass switch-ing device by turning the key counterclockwise whilepushing up on the lever next to the key interlock. This

will lock the emergency bypass switching device toprevent it from closing.

10. Insert the key in the normal switching device and turnthe key clockwise, which will release the lever to theleft of the key interlock. This will unlock the normalswitching device.

11. The normal switching device is now back in automaticoperation.

7.3.4 EMERGENCY TO NORMAL BYPASS(OPEN TRANSITION ONLY)

The emergency switching device can be bypassed andisolated by the following sequence:

1. Encure that the normal power is available since theload will be energized from the normal source.

2. Move the generator selector switch to the OFF posi-tion to avoid nuisance starting of the generator whilework is being performed on the emergency switch-ing device.

3. Remove the key from the emergency switching deviceby turning the key counterclockwise while pushing upon the lever next to the key interlock. This will openthe emergency switching device and thus the emer-gency position energized light will no longer be illumi-nated. The emergency switching device is nowlocked to prevent it from closing.

4. Insert the key in the normal bypass switching deviceand turn it clockwise to release the lever to the left ofthe key interlock. This will unlockthe normal bypassswitching device.

5. Close the normal bypass switching device manually.The normal bypassed light will illuminate.

6. Rack out the emergency switching device (seeSection 6). The emergency isolated light will illumi-nate.

7. Inspect and/or perform maintenance on the emer-gency switching device.

8. Rack in the emergency switching device (see Section6). The emergency isolated light will no longer be illu-minated.

9. Open the normal bypass switching device. The nor-mal bypassed light will no longer be illuminated.

10. Remove the key from the normal bypass switching

IB01602003EPage 28

Effective 11/02

device by turning the key counterclockwise whilepushing up on the lever next to the key interlock.This will lock the normal bypass switching deviceand prevent it from closing.

11. Insert the key in the emergency switching deviceand turn it clockwise to release the lever to the leftof the key interlock. This will unlock the emergencyswitching device, which will automatically recharge.

12. The switching device is now back in automatic oper-ation.

7.4 MANUAL OPERATION WHEN IN BYPASS MODE

7.4.1 NORMAL BYPASS TO EMERGENCY BYPASS

When the transfer switch is set to normal bypass, it canbe transferred to emergency bypass by the followingsequence:

1. Move the generator selector switch to the RUN posi-tion.

2. Remove the key from the normal switching deviceby turning it counterclockwise while pushing up onthe lever next to the key interlock. The normalswitching device is now locked and prevented fromclosing.

3. Insert the key in the emergency bypass switchingdevice and turn it clockwise to release the lever tothe left of the key interlock. This will unlock theemergency bypass switching device.

4. Open the normal bypass switching device. The nor-mal bypassed light will no longer be illuminated.

5. Close the emergency bypass switching device man-ually and the emergency bypassed light will illumi-nate.

7.4.2 EMERGENCY BYPASS TO NORMAL BYPASS

When the transfer switch is set to emergency bypass itcan be transferred to the normal bypass switchingdevice by the following sequence:

1. Remove the key from the emergency switchingdevice by turning it counterclockwise while pushingup on the lever next to the key interlock. The emer-gency switching device is now locked and preventedfrom closing.

2. Insert the key in the normal bypass switching deviceand turn it clockwise to release the lever to the left

of the key interlock. This will unlock the normalbypass switching device.

3. Open the emergency bypass switching device andthe emergency bypassed light will no longer be illu-minated.

4. Close the normal bypass switching device manuallyand the normal bypassed light will illuminate.

5. Move the generator selector switch to the OFF position.

IB01602003E Page 29

Effective 11/02

SECTION 8: TESTING AND PROBLEMSOLVING

8.1 TESTING

After transfer switch equipment is initially installed or dur-ing planned outages, the installation should be tested toinsure that all equipment operates properly. This attentionto detail will help to avoid unexpected malfunctions.Mechanical and/or electrical tests should be performed.

The frequency of subsequent testing should be basedon recommendations of the generator set manufacturer.Use the test pushbutton to check the electrical operationof the switch. IF A TEST SWITCH IS PROVIDED,ALWAYS RETURN THE SWITCH TO THE AUTOPOSITION AFTER THE TEST IS COMPLETE.

HIGH VOLTAGES ASSOCIATED WITH OPERA-TIONAL TRANSFER SWITCH EQUIPMENT PRESENTA SHOCK HAZARD THAT CAN CAUSE SEVEREPERSONAL INJURY OR DEATH. USE EXTREMECAUTION TO AVOID TOUCHING ELECTRICAL CON-NECTIONS WHENEVER INSPECTING OR TESTINGTHE EQUIPMENT.

IN ADDITION, IMPROPER OPERATION OF THE GEN-ERATOR SET PRESENTS A HAZARD THAT CANCAUSE SEVERE PERSONAL INJURY OR DEATH.OBSERVE ALL SAFETY PRECAUTIONS IN YOURGENERATOR SET OPERATIONS AND INSTALLA-TION MANUALS.

For mechanical operations, refer to Section 5 in thisinstruction book. Refer to the applicable logic instruc-tion book for electrical testing.

8.2 PROBLEM SOLVING

HAZARDOUS VOLTAGES IN AND AROUND TRANS-FER SWITCH EQUIPMENT DURING THE PROBLEMSOLVING PROCESS CAN CAUSE PERSONALINJURY AND/OR DEATH. AVOID CONTACT WITHANY VOLTAGE SOURCE WHILE PROBLEM SOLV-ING.

ONLY PROPERLY TRAINED PERSONNEL FAMILIARWITH THE TRANSFER SWITCH EQUIPMENT ANDITS ASSOCIATED EQUIPMENT SHOULD BE PERMIT-TED TO PERFORM THE PROBLEM SOLVING FUNC-TION. IF AN INDIVIDUAL DOES NOT FEEL QUALI-FIED TO PERFORM THE PROBLEM SOLVING FUNC-TION, THE INDIVIDUAL SHOULD NOT ATTEMPT TOPERFORM ANY OF THESE PROCEDURES.

A basic problem solving effort is the first step to takeprior to calling for assistance. Frequently, the effort willsuccessfully address most problems encountered. Mostproblem solving procedures are outlined in the instruc-tion manual unique to the type of logic being used. Inaddition, several problem solving procedures are pre-sented here which are specific to the type of switches orcircuit breakers used in this equipment.

If a problem persists after having completed the problemsolving procedure, contact a Cutler-Hammer represen-tative for further assistance. When calling for assis-tance, the following is the minimum information requiredto properly address the need:

1. Shop Order Number (SO#) or General OrderNumber (GO#) of transfer switch, plus related ItemNumber

2. Catalog and/or Style Number of transfer switch

3. Actual location of transfer switch (type of facility,address, etc.)

4. Company name

5. Name and position of individual representing com-pany

6. Basic description of situation as it exists

7. Any results of problem solving steps taken and/orreadings taken

THIS CLOSED TRANSITION PRODUCT CONTAINS ASPECIAL CONTACT ARRANGEMENT (OVERLAP-PING CONTACTS). MISUSE CAN RESULT IN DEATH,SEVERE PERSONAL INJURY AND/OR PROPERTYDAMAGE.

! WARNING

! WARNING

! WARNING

! WARNING

IB01602003EPage 30

Effective 11/02

8.2.1 TRANSFER SWITCH APPEARS INOPERATIVE

Step 1: Verify that all plugs and sockets are properly interconnected.

Step 2: Verify that the correct system voltage appearsat NORMAL switch. Measure the voltage at thebreaker lugs.

Step 3: Verify that the voltage selection plug is in the proper position to match the system voltage.

Step 4: Look for any obviously burned components. Determine the cause and rectify, if possible. Replace defective components after the cause is determined.

Step 5: For closed transition, refer to Figure 5-2 for manual operating instructions. Verify whether or not the system voltage now appears on the load terminals.

If YES: Proceed to check logic for problems in respective logic instruction book.

If NO: Check all power connections andthe switching mechanism.

Step 5: For open transition, press the push-to-close button on the normal switching device. Verify whether or not the system voltage now appears on the load terminals.

If YES: Proceed to check logic for problems in respective logic instruction book.

If NO: Check all power connections andthe switching mechanism.

8.2.2 TRANSFER SWITCH WILL NOT AUTOMATI-CALLY TRANSFER TO NORMAL

Step 1: Check for proper line voltage on N1, N2, N3.

Step 2: Is the normal switching device charged?

If YES: Continue with other procedures.

If NO: Go through section 8.2.4 first beforecontinuing.

Step 3: Is the emergency switch OPEN?

If YES: Proceed to Step 5.

If NO: Proceed to Step 4.

Step 4: Measure voltage between terminals A9 and A8on the emergency switching device (shunt trip).Does the voltage measure 120 VAC ±10 volts?Record reading.

If YES: Check shunt trip in emergency switch

If NO: Check wiring to A9 and A8.

Step 5: Measure voltage between terminals A1 and A2on the normal switching device (spring releasecoil). Does the voltage measure 120 VAC ±10 volts? Record reading.

If YES: Check spring release coil in normalswitching device.


8.2.3 TRANSFER SWITCH WILL NOT AUTOMATI-CALLY TRANSFER TO EMERGENCY

Step 1: Check for proper line voltage on E1, E2, E3.

Step 2: Is the emergency switching device charged?

If YES: Continue with other procedures.

If NO: Go through Section 8.2.4 first beforecontinuing.

Step 3: Is the normal switching device OPEN?

If YES: Proceed to Step 5.

If NO: Proceed to Step 4.

Step 4: Measure voltage between terminals A9 and A8 on the normal switching device (shunt trip). Does the voltage measure 120 VAC ± 10 volts?

If YES: Check shunt trip in normal switch


Step 5: Measure voltage between terminals A1 and A2on the emergency switching device (spring release coil). Does the voltage measure 120 VAC ± 10 volts? Record reading.

If YES: Check spring release coil in emergencyswitch.

If NO: Check wiring to A1 and A2..

IB01602003E Page 31

Effective 11/02

8.2.4 TRANSFER SWITCH WILL NOT AUTOMATI-CALLY RECHARGE SWITCHES

Step 1: Measure the voltage between the terminals A6 and A2 on the switching device that does not automatically recharge. Does the voltage read120 VAC ± 10 volts? Record reading.

If YES: Check electrical operator inside the switching device.

If NO: Verify wiring to A6 and A2.

Step 2: If problem persists contact Cutler-Hammer.

IB01602003EPage 32

Effective 11/02

SECTION 9: MAINTENANCE

9.1 INTRODUCTION

HIGH VOLTAGES ARE PRESENT IN AND AROUNDTRANSFER SWITCH EQUIPMENT. BEFOREINSPECTING OR MAINTAINING THIS EQUIPMENT,DISCONNECT LINE POWER FROM THE EQUIPMENTBEING SERVICED BY OPENING AND LOCKINGOUT, IF POSSIBLE, THE NEXT HIGHEST DISCON-NECT DEVICE. FAILURE TO FOLLOW THIS PROCE-DURE COULD CAUSE PERSONAL INJURY AND/ORDEATH.


In general, transfer switch equipment is designed to berelatively maintenance free under normal usage. How-ever, because of the variability of application conditionsand the importance placed on dependable operation bythis type of equipment, inspection and maintenancechecks should be made on a regularly scheduled basis.Since equipment maintenance will consist mainly ofkeeping the equipment clean, the frequency of mainte-nance will depend, to a large extent, on the cleanlinessof the surroundings. If a significant amount of dust orforeign matter is present, a more frequent maintenanceschedule should be followed.

It is suggested that visual inspections of the equipmentbe made on a regular basis, not just during regularlyscheduled periods. Always be alert for an accumulationof dirt in and around the structure, loose parts and/orhardware, cracks and/or discoloration to insulation, anddamaged or discolored components.

9.2 PROCEDURES

A suggested maintenance procedure to follow is out-lined in Table 9.1.

! WARNING

! WARNING

IB01602003E Page 33

Effective 11/02

Table 9.1 Periodic Maintenance Procedures

a. Make transfer switch equipment safe for Disconnect line power from equipment being serviced by inspection and/or maintenance. opening next highest disconnect device. Make certain that

any accessory control power is switched off and logic plugs disconnected.

b. Inspect structure area for safety hazards or Inspect area, especially where switching devices are potential maintenance problems. installed, for any safety hazards, including personnel

safety and fire hazards. Exposure to certain chemical vapors can cause deterioration of electrical connections.

Inspect for accumulated dirt, loose hardware or physical damage.

Examine primary insulation for evidence of cracking or overheating. Overheating will show as discoloration, melting, or blistering of conductor insulation, or as pitting or melting of conductor surfaces due to arcing.

Inspect secondary control connections for damage, and control wiring for insulation integrity.

c. Inspect switching devices for dust, dirt, soot, Remove dust, dirt, soot, grease, moisture and corrosion grease, moisture or corrosion. contamination from the surface of the switching device

using a dry soft lint-free cloth, dry soft bristle brush and vacuum cleaner. Do not blow debris into circuit breaker or nearby breaker structure. If contamination is found, look for the source and fix the problem.

d. Check for material integrity, uneven wear, Severe material cracking will require replacement anddiscoloration or loose hardware. loose hardware will need to be tightened.

e. Check terminals and connectors for looseness Overheating will show as discoloration, melting, oror signs of overheating. blistering of conductor insulation.

Connections that do not have signs of looseness or overheating should not be disturbed.

f. Exercise the switching devices if they are If a switching device is used for frequent switching during not often exercised while in operation. This normal operation, this step can be disregarded.will permit wiping action by the contacts.

g. Inspect NEMA 3R filters for blockage or For NEMA 3R enclosed transfer switches with venting, contamination check that air filters are clean and uncompromised.

Replace filters as necessary (Cat. # TSAFDO)

h. Return transfer switch equipment to service. Make certain all barriers are in place and doors closed.Re-apply secondary and primary power.

Step Action

IB01602003EPage 34

Effective 11/02

9.3 COVER REMOVAL AND REPLACEMENT

Many of the maintenance procedures outlined in Table9.1 require the removal and replacement of side andrear covers. For all NEMA 1 enclosed transfer switches,see Section 9.3.1 for cover removal and replacementinstructions. For 600-2000A NEMA 3R enclosed trans-fer switches, see Section 9.3.2. For 2500-4000A NEMA3R enclosed transfer switches, rear access is providedvia double doors. Side access is not provided.

9.3.1 NEMA 1 COVER REMOVAL ANDREPLACEMENT

A 3/8” wrench is required to perform this procedure.

Cover Removal

Step 1: Locate the screws used to secure the cover to the frame and remove them with the 3/8” wrench. Remove the top screws last while holding the cover in place (Figure 9-1).

Step 2: Hold the bottom of the cover in place with your foot and allow the top of the cover to slowly tilt away from the enclosure frame (Figure 9-2).

Step 3: Move your hands around to the sides and lift thecover free (Figure 9-3).

Figure 9-1 Screw Removal

Figure 9-2 Slowly Tilting Cover Away

Figure 9-3 Lifting Cover Free

IB01602003E Page 35

Effective 11/02

Cover Replacement

Step 1: Grasp the cover at the sides and lift the bottomof the cover into the enclosure frame (Figure 9-4). Holdthe bottom of the cover in place with your foot.

Step 2: Move your hands around to the front and pushthe cover fully into the enclosure frame (Figure 9-5).

Step 3: Replace the cover screws, taking care not tocross-thread the screws into the frame (Figure 9-6).Tighten to 8 ft lbs. Do not over tighten.

Figure 9-5 Pushing Cover Fully into Enclosure Frame

Figure 9-6 Replacing ScrewsFigure 9-4 Lifting Cover into Enclosure Frame

IB01602003EPage 36

Effective 11/02

9.3.2 NEMA 3R COVER REMOVAL ANDREPLACEMENT

A 3/8” wrench is required to perform this procedure.

Cover Removal

Step 1: Locate the screws used to secure the cover to the frame and remove them with the 3/8” wrench (Figure 9-7). Make sure that the sealingwashers remain on the screws during removal.

Step 2: Locate the cover lifting handles (provided with the equipment) and insert the tabs into the screw holes (Figure 9-8).

Step 3: Grasp the cover lifting handles and pull the cover out until the lower flange of the cover clears the lower cross member. Lower the cover to the ground (Figure 9-9). The cover is now free to be moved as required.

Figure 9-8 Inserting Tabs into Screw Holes

Figure 9-9 Pulling Cover OutFigure 9-7 Screw Removal

IB01602003E Page 37

Effective 11/02

Cover Replacement

Step 1: Place the cover against the frame (Figure 9-10).

Step 2: Locate the cover lifting handles (provided with the equipment) and insert the tabs into the screw holes (Figure 9-11).

Step 3: Grasp the cover lifting handles and pull up, sliding the upper cover flange under the roof flange (Figure 9-12). When the lower cover flange clears the top of the lower cross member, push the bottom of the cover in place (Figure 9-13).

Step 4: Replace the cover screws and selaing washers,taking care not to cross-thread the screws into the frame (Figure 9-14). Tighten to 8 ft lbs. Do not over tighten.

Figure 9-10 Cover Against Frame

Figure 9-11 Inserting Tabs into Screw Holes

Figure 9-12 Sliding Cover Flange Under Roof Flange

Slide UpUnderRoof Flange

IB01602003EPage 38

Effective 11/02

Figure 9-13 Pushing Bottom of Cover in Place Figure 9-14 Replacing Screws and Sealing Washers

Slide UpUnderRoof Flange

Push In Place

IB01602003E Page 39

Effective 11/02

SECTION 10: RENEWAL PARTS GUIDE

10.1 GENERAL

Refer to Figures 10-1 and 10-2 for assistance withselecting and ordering selected transfer switch renewalparts.

Example: To order the Air Filter Replacement Kit for anATVISPB31200XRU transfer switch, order CatalogNumber TSAFDO as shown in Figure 10-1.

Figure 10-1 Air Filter Replacement Kit (Fixed Mount)(Catalog Number TSAFDO)

Figure 10-2 Padlockable Handle Replacement Kit(Catalog Number TSDHPZFS)

IB01602003EPage 40

Effective 11/02

IB01602003E

Cutler-HammerPittsburgh, Pennsylvania U.S.A.

Effective 11/02 (ISI)Style IB01602003E H01Printed in U.S.A.

This instruction booklet is published solely for informa-tion purposes and should not be considered all inclu-sive. If further information is required, you should con-sult Cutler-Hammer.

Sale of product shown in this literature is subject toterms and conditions outlined in appropriate Cutler-Hammer selling policies or other contractual agreementbetween the parties. This literature is not intended toand does not enlarge or add to any such contract. Thesole source governing the rights and remedies of anypurchaser of this equipment is the contract between thepurchaser and Cutler-Hammer.

NO WARRANTIES, EXPRESSED OR IMPLIED,INCLUDING WARRANTIES OF FITNESS FOR A PAR-TICULAR PURPOSE OR MERCHANTABILITY, ORWARRANTIES ARISING FROM COURSE OF DEAL-ING OR USAGE OF TRADE, ARE MADE REGARDINGTHE INFORMATION, RECOMMENDATIONS ANDDESCRIPTIONS CONTAINED HEREIN. In no eventwill Cutler-Hammer be responsible to the purchaser oruser in contract, in tort (including negligence), strict lia-bility or otherwise for any special, indirect, incidental orconsequential damage or loss whatsoever, including butnot limited to damage or loss of use of equipment, plantor power system, cost of capital, loss of power, addition-al expenses in the use of existing power facilities, orclaims against the purchaser or user by its customersresulting from the use of the information, recommenda-tions and description contained herein.

Date post:	08-Oct-2020
Category:	Documents
Upload:	others
View:	2 times
Download:	0 times

Cutler-Hammer O & M Manual for Cutler-Hammer Drawout SPB ...€¦ · 7.4.1 Normal Bypass to...

Documents