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AUTOMATIC TRANSFER
SWITCHES
Automatic Transfer Switches Application and Installation Guide
Foreword
This section of the Application and Installation Guide generally describes wide-
ranging requirements and options for Caterpillar Automatic Transfer Switches
(ATS). Additional engine and generator systems, components and dynamics
are covered in other sections of this Application and Installation Guide.
Information and data related to specific ATS models is available from
a variety of sources. Refer to the overall introduction of this guide for
additional references.
Systems and components described in this guide may not be available
or applicable for every ATS. Refer to the Product Specification Sheets for
specific options and compatibility. While much of the content of this guide
is applicable to all ATS, the primary focus of this guide is on the North
American ATS market.
Section Contents
1. Introduction....................................................................... 8
1.1. Transfer Switch Basics ................................................ 8
1.1.1. Non-Automatic (Manual) Transfer Switch ............... 9
1.1.2. Manually Operated Non-Automatic ......................... 9
1.1.3. Manually Initiated, Electrically Operated.................. 9
1.1.4. Automatic Transfer Switch.................................. 10
2. Transfer Switch Components ............................................ 10
2.1. Power Switching Device ............................................ 10
2.1.1. Types of Power Switching Devices ...................... 10
2.1.1.1. Contactors.................................................. 11
2.1.1.2. Circuit Breakers........................................... 11
2.1.1.2.1. Molded Case Switch ........................................11
2.1.1.2.2. Insulated Case Switch......................................12
2.1.1.3. Static Transfer Switch ................................. 12
2.2. Transfer Mechanism .................................................. 12
2.2.1. Manually Operated ............................................. 12
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2.2.2. Electrically Operated ........................................... 12
2.2.2.1. Single Solenoid ........................................... 13
2.2.2.2. Dual Solenoid.............................................. 13
2.2.2.3. Unidirectional Gear Motor............................. 13
2.2.2.4. Twin Stored Energy ..................................... 14
2.2.2.5. Linear Motor ............................................... 15
2.2.3. Control Power.................................................... 16
2.2.4. Controls Logic.................................................... 16
3. Design Criteria ................................................................. 16
3.1. Current Ratings ......................................................... 16
3.1.1. Inrush Current.................................................... 18
3.1.2. Interrupt Current ................................................ 18
3.1.3. Continuous Current ............................................ 19
3.1.4. Withstand Fault Current ...................................... 20
3.1.5. Protecting the Main Contacts .............................. 21
3.2. Manual Operating Handles.......................................... 22
3.2.1. Specifications .................................................... 23
3.2.2. Manual Operation Under Load Dangers ................. 23
3.3. Safeguards ............................................................... 24
3.4. Summary ................................................................. 24
4. Controls .......................................................................... 24
4.1. Voltage Sensing ........................................................ 24
4.1.1. Under-voltage .................................................... 25
4.1.2. Over-voltage ...................................................... 25
4.2. Frequency Sensing .................................................... 26
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5.1.1.5. Momentary Paralleling.................................. 33
5.1.1.6. Motor Load Shedding Delayed Reconnection .. 34
5.1.2. Electronic Variable Frequency Drives (VFDs) ......... 34
6. Switching The Neutral Conductor ...................................... 35
6.1.1. Grounded vs. Ungrounded Neutrals ...................... 36
6.1.2. Three Pole Transfer Switches .............................. 39
6.1.3. Four Pole Transfer Switches ................................ 42
6.1.4. Fourth Pole and UL Requirements......................... 43
7. Sizing Automatic Transfer Switches................................... 44
7.1.1. Loads................................................................ 45
7.1.2. Voltage Rating ................................................... 45
7.1.3. Solid or Switched Neutral.................................... 45
7.1.4. Continuous Current Rating .................................. 46
7.1.4.1. Example ..................................................... 46
7.1.5. Overload and Fault Current Withstand Ratings....... 46
7.1.6. Overcurrent Protection ........................................ 47
7.2. Enclosure Ratings...................................................... 47
7.2.1. Non-Hazardous Locations .................................... 47
7.2.2. Hazardous Locations........................................... 51
7.2.3. NEMA Enclosure Type Numbers vs.
IEC Enclosure Classification Designations ....................... 52
7.3. Transfer Switch Configurations................................... 53
7.3.1. Open Transition.................................................. 54
7.3.2. Delayed Transition Transfer Switches ................... 55
7.3.2.1. Application Information ................................ 55
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9. Standards, Testing & Maintenance..................................... 68
9.1. Standards and Ratings ............................................... 68
9.1.1. The National Electric Code .................................. 68
9.1.2. Underwriters Laboratories, Inc. (UL) .................... 69
9.1.3. Canadian Standards Association (CSA)................. 69
9.1.4. International Electrotechnical Commission (IEC) ..... 69
9.1.5. National Fire Protection Association ..................... 69
9.1.6. National Electrical Manufacturers Association........ 70
9.1.7. American National Standards Institute .................. 70
9.1.8. Institute of Electrical and Electronic Engineers ....... 70
9.1.9. International Building Code .................................. 70
9.2. Testing .................................................................... 71
10. Controls Testing Standards ............................................. 71
10.1. Maintenance ........................................................... 71
10.1.1. Inspection and Cleaning .................................... 71
10.1.2. Servicing ......................................................... 72
11. Glossary of Terms .......................................................... 72
12. Appendices ................................................................... 77
12.1. Bibliography............................................................ 77
12.2. Systems Data Sheet Example: .................................. 78
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Automatic Transfer Switches Application and Installation Guide
1. Introduction
Modern utility systems are generally reliable but human error or the
uncertainty of weather can and does call for emergency or standby power
availability. These systems are found in a wide range of environments,
including industrial, commercial, office, military, remote, medical, malls,
public safety, academic or scientific sites. In all cases, safety as to personnel
or destructive fires and outages must be designed in and accounted for.
While emergency power can be supplied by multiple utility services or by
on-site power generation, on-site generator sets will provide the maximum
control and reliability. Whether with a second utility source or on-site
generation, a means must be provided to transmit power to the loads from
either source, and transfer the loads from one source to the other, such as
an Automatic Transfer Switch (ATS).
An ATS is defined as: a device used to switch a power supply from normal
to emergency when a power failure occurs.
The seven major functions of an ATS are:
1. Carry current continuously,
2. Detect power failures,
3. Initiate emergency source,
4. Transfer load,
5. Sense restoration of normal,
6. Re-transfer load to normal,
7. Withstand and close-in on fault currents.
ATSs are used for both low voltage (LV) and medium voltage (MV)
applications. Low voltage is classified as 0-1kV and medium voltage is
classified as 1kV 15kV, 15kV and above is not discussed in this guide.
LV ATSs are designed to fulfill Underwriter Laboratories (UL), Inc. standards
contained in UL-1008.
While many of the concepts discussed in this guide are applicable to
the International market, the focus of this guide is on the North American
ATS market.
permits critical loads to continue
1.1. Transfer Switch Basics
running or begin running again,
A transfer switch is a critical
once the transfer is made. After
component of any standby power
the normal source of power is once
system. When the normal (preferred)
again available, the transfer switch
source of power is lost, the transfer
transfers back to the normal source
switch transfers from the normal
from the emergency source.
source of power to the emergency
(alternate) source of power. This
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Operation of the transfer switch to operate them. Since the non-
from normal to emergency and back automatic transfer switches are part
to normal can be a manual type of the emergency power supply
operation or an automatic type system, they should have the same
operation. It depends on the type or UL 1008 electrical ratings as the
configuration of the transfer switch ATSs feeding the more critical loads.
equipment. If loads are critical, an For these reasons, only switches
ATS will most likely be used to specifically designed for manual
ensure the fastest possible transfer. transfer applications should be
A hospital operating room is an considered.
example of a critical load. An ATS There are two types of non-ATSs:
might also be used when operators
are not conveniently available who Manually operated non-automatic,
could make a manual transfer. If Manually initiated, electrically
loads are not quite as critical, but still operated.
cannot go for any extended period
of time without power, a manual 1.1.2. Manually Operated
transfer switch could be used. Non-Automatic
Manually operated non-automatic
1.1.1. Non-Automatic (Manual) transfer switches provide all the
Transfer Switch mechanics to effect the transfer
Transferring loads can be done from source to source. The actual
with a manually operated device, transfer of power, however, is
also referred to as a non-automatic accomplished by true hand operation
transfer switch. In such applications, of the transfer switch mechanism.
operating personnel should be readily In many installations where
available and the load is not of a non-critical loads are being served,
critical nature requiring immediate specifications may call for manual
restoration of power. A refrigeration or non-automatic transfer switches.
plant is an example of a less critical This method may be used because
need. While the refrigeration plant operating personnel are present and
could not live with an extended the loads are not of a critical nature
power outage, it may be able to requiring unattended operation.
tolerate a brief down time while
a manual transfer is made. 1.1.3. Manually Initiated,
Electrically Operated
From a very simplistic standpoint,
Manually initiated, electrically
double-throw knife switches and
operated non-automatic transfer
safety switches have been used as
switches are similar to the manually
manual transfer switches. Because
operated version just described
these devices are marginal
except that an electrical operation
adaptations, lack a high degree
feature is added to the switch. The
of reliability, and the restricted
switch electrically transfers power
operation requirements can be
when a pushbutton, usually mounted
abused; personnel are reluctant
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Based upon the type of power tripping element. Circuit breaker
switching device, there are actually type transfer switches can be further
three basic types of power switching categorized by their construction
devices available in the ATS market methodology as either molded case
today: switches or insulated case switches.
Contactor type switches, 2.1.1.2.1. Molded Case Switch
Circuit breaker type switches, A molded case switch is a molded
case circuit breaker without a thermal
Static transfer switches. trip element. Molded case switches
2.1.1.1. Contactors are often used when a circuit requires
Contactor type transfer switches a compact, high capacity disconnect
are widely considered the most device. Supply of a trip element
frequently specified type of ATS and (making it a circuit breaker) is an
are designed to limit the number of option. The contacts and arc chutes
operating parts to accomplish the of the switch are completely enclosed
required transfer between alternate in an insulated housing. These
sources. While referred to as switching devices can be designed to
contactor type transfer switches, meet a number of UL requirements for
this type of switch does not use molded case circuit breakers, molded
motor starting/lighting contactors. case switches and ATSs. Considering
the wide range of standards the
The standard transfer switch must
circuit breaker type transfer switch
be designed to prevent two sources
can meet, they can serve as a viable
(a normal source and emergency
alternative to the contactor type
source) from being connected to a
device.
load simultaneously. In the case of
the contactor type switch, this is Typically, molded case switching
accomplished through the use of an devices are oversized for the
electrically operated, mechanically ampacity of the transfer switch.
held contact operation, which will For example, an 800 ampere molded
be described in more detail in case switch type transfer switch
Section 2.2. uses 1200 ampere switching
devices. Thus the contacts are likely
2.1.1.2. Circuit Breakers
to be larger in the molded case
Circuit breaker type transfer
switch design than the contacts used
switches are another popular and
in a contactor type of equal rating.
effective means of transferring
load between alternate sources. The molded case switching
In the case of automatic transfer device is normally used with smaller
application, the term circuit ampacity transfer switches
breaker is actually misleading. (e.g. < 1600 amps). It provides
The transfer medium is actually a for self-protection with a fixed
switch and not a circuit breaker. instantaneous trip setting feature
By definition, a switch is a circuit and will interrupt a fault current
breaker which does not include a at or above its preset level.
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operator to initiate operation. Manual transfer of a single
Through the use of a controls solenoid operated transfer switch
package and pre-programmed is possible, but requires all power
operating conditions, the mechanism to be disconnected to the solenoid.
is automatically set in motion when Manual transfer is accomplished
the programmed operating through the use of a metal rod. The
conditions are met. metal rod is typically not attached
to the switch permanently.
There are five primary types of
transfer mechanisms used with Single solenoid type transfer
transfer switches: switches are typically used on lower
amperage rated transfer switches
1. Single solenoid,
(typically on switches 400Amp
2. Dual solenoid, and less).
3. Unidirectional gear motor,
2.2.2.2. Dual Solenoid
4. Twin stored energy, In the case of the dual solenoid
5. Linear motor. switch, which is also used in
contactor type transfer switches,
2.2.2.1. Single Solenoid
a solenoid-operated actuator is
The single solenoid type transfer
assigned to independently operate
mechanism, employed on contactor
each set of source contacts. One
type switches, utilizes an electrical
solenoid serves to close the normal
solenoid with an integrally mounted
source contacts, while the second
actuator. The solenoid is directly
solenoid serves to close the
connected to line voltage.
emergency source contacts.
In an emergency condition, the
Dual solenoid type transfer
solenoid is energized, causing the
switches are typically used on higher
actuator to extend and rotate the
amperage rated transfer switches
mechanically linked cam. As the cam
(typically on switches greater than
rotates, the contact arm (which is
400Amps).
connected to the cam via a
connecting yoke) is caused to move 2.2.2.3. Unidirectional Gear Motor
from the normal source position to This type of mechanism transfers
the emergency source position. This between power sources through the
results in contact connection to the use of a unidirectional motor-driven
emergency (standby power) source. mechanical device. Rigid shafts or
arms are linked to the motor through
Upon restoration of the normal
a ratchet type device or gears. The
source, the solenoid is de-energized,
rotary motion created by the motor
causing the actuator to retract and
is converted to linear motion. The
rotate the cam in the opposite
linear motion moves the rigid shafts
direction, resulting in contact
or arms to operate the switching
connection at the emergency
devices, such as the operating
(standby power) source.
handles on molded case switches.
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Figure 2 Insulated Case Design Utilizing a Twin Stored Energy Mechanism
with Protective Cover Removed for Clarity
When insulated case switches are which the load is transferred. In
used as the switching devices, each addition, the closing and opening
device can be manually opened and functions can be electrically and
closed through the use of manual automatically performed.
buttons located on the front of the 2.2.2.5. Linear Motor
device. If required, the switching The linear motor mechanism is
devices can also be configured to basically a coil with an operating
be electrically closed and opened. shaft running through the coil. The
The closing springs can be manually operating shaft which causes the
charged using a front mounted main contacts to operate is not an
manual charging handle. integral part of the coil. Since the
If it is not desirable to perform the linear motor electric operator is
functions just described manually connected directly to the full line
or the transfer switch is to be fully voltage, the circuit requires the use
automatic, electrically operated of capacitors. This creates
switching devices are available. difficulties when voltage rating
changes are required. This type of
This means that the closing springs
switch cannot be operated manually
are automatically charged, as
and cannot be manually switched
required, through the use of a small
under full load. In fact, the motor
integrally mounted electric motor. The
drive circuit must be disconnected
motor is energized from the source to
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distribution network, four design consideration in the design of the
criteria related to current carrying switch and when applying it into
capability must be taken into a specific EPS.
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interrupted when the switch transfers
from one source to another:
Wide arc gaps,
Arc chutes and arc quenching
grids.
The arc gap (see Figure 5) is the
distance from the stationary contact
to the movable contact when the
movable contact is fully opened.
The arc gap must be wide enough
to draw out the arc and provide time
to extinguish it. Transfer time should
be a minimum of 20 msec to ensure Figure 6 Arc Quenching
that the arc is extinguished. As a
point of reference, a high speed 3.1.3. Continuous Current
solenoid actuated drive typically A transfer switch must
ensures contact transfer in continuously carry current to critical
100 msec or less. loads. Current flows through the
transfer switch during both normal
and emergency conditions. Unlike
other equipment used in EPS
applications, a transfer switch is
expected to provide continuity of
power to the load, uninterrupted,
for multiple generations. Other
emergency equipment may only be
required to provide power for the
duration of a power outage. During
this continual period of usage, the
transfer switch is exposed to fault
Figure 5 Arc Gap currents, repetitive switching while
In addition to wide arc gaps, arc powering various types of loads and
quenching grids (see Figure 6), adverse environmental conditions.
consisting of arc chutes are often The switch must be designed such
used to break up the arc as it is that these factors do not cause
drawn into them by the magnetic excessive temperature rise, detract
field created when the arc forms. from reliable operation or require a
substantial amount of maintenance.
In order to achieve these
objectives, the contact temperature
rise of a transfer switch must be
well below that established for an
eight-hour rated device. Additionally,
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adequate radiating surfaces, protective device clears
along with high-contact the fault, a time delay is
pressures, to keep heating incorporated into the control
to a minimum. Larger transfer circuit.
switches often utilize segmented The control current will prevent
contacts that provide multiple application of control voltage to
paths for current flow through the switch operator until a minimum
the main contacts. This feature acceptable value for proper transfer
extends the life of the contact has developed.
by reducing the amount of heat
generated during operation. For additional information on
withstand rating terms and
3. Life of the contact is also calculations, see Appendix 12.2:
extended through the prevention Systems Data Sheet Example.
of arcing on the main contacts
by the use of arcing contacts. 3.1.5. Protecting the Main
This is discussed in further detail Contacts
in section 3.1.5 preventing the The main contacts of the transfer
main contacts. switch can be prematurely worn
4. Delay in Transfer It is down and damaged by the arcs
necessary to account for the created when transferring from a live
voltage drop that is normally source. Arc runners and arc chutes
experienced with large fault are often employed to drive the arc,
currents. The design must ensure created during this transfer, out
that the voltage drop does not away from the main contacts.
cause the switch to be As soon as the arc is formed during
automatically transferred while the transfer operation, it is drawn
the switch is carrying the fault away from the current-carrying area
current. To ensure that this does of the main contacts by an arc
not occur, the following design runner. The damaging effects of the
criteria should be met: arc are absorbed by the arcing tip at
A mechanically held the top of the arc runner, and away
mechanism to prevent opening from the current-carrying area of the
during a fault condition, and a movable contact.
time delay to override In larger-size switches, separate
momentary dips in voltage. arcing contacts are often used
The mechanically held (Figure 7). When the switch begins
mechanism assures that the to transfer, the main contacts open
switch will not transfer until first while the arcing contacts remain
control voltage is applied to closed (Figure 8). Since the main
the transfer switch operator. contacts are opening under load, an
To prevent energizing the arc is formed between the arcing
operator until the overcurrent contacts. The stationary arcing
contact serves to draw the arc away
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purposes and must be so labeled. operation while under full load, a
When an internal handle is used, few of these are explained below:
contacts must be protected and
It is possible to close a transfer
both mechanical and electrical
switch into a generator, which is
hazards must be considered. UL
attempting to crank, thereby
clearly states that power should
forcing the emergency generator
be removed from the unit prior to
source to bog down as it
servicing on all manufacturers
attempts to assume full load prior
internal operators. An internal
to reaching proper voltage and
removable operating handle that
speed.
is listed by UL in accordance with
UL1008 standards for safety should Manually transferring fault
be provided. currents in excess of switch
rating would create a danger for
3.2.1. Specifications anyone operating the manual
Some specifications have handle of any transfer switch.
been issued that add restrictive,
Manually operating the switch
unnecessary, and potentially
with overload currents present of
dangerous requirements for
six times switch rating unless the
manual handles.
contacts are protected in
The requirements issued state: enclosed arc chambers.
The manual handle shall provide Manual operation by unauthorized
the same contact-to-contact personnel could disconnect
transfer speed as the electrical critical loads.
operator to prevent flashover; Manual operation of a switch that
The manual handle shall be has malfunctioned without first
externally operable. determining the reason for that
malfunction and whether manual
These specifications described
operation is safe.
are restrictive because they are
design features centered on one Manually operating the switch
manufacturers guide specifications. without disconnecting the
They are unnecessary for the proper electrical operator, causing the
and safe operation of an ATS; and mechanism to drive back against
they are potentially dangerous the person operating the switch.
because all safeguards are not If the handle is external, additional
considered. dangers may exist:
3.2.2. Manual Operation Under Increased possibility of
Load Dangers unauthorized persons operating
There are many possible dangers the switch,
present when attempting to Possibility of a moving handle
conduction manual transfer switch (during automatic operation)
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its availability. Single phase sensing acceptable for the transfer switch
is used on single-phase sources, contacts to close on the source
while sensing on three-phase and connect the load.
systems may be one of the following: 2. Dropout setting The dropout
Single-phase on normal and (or differential) setting determines
emergency sources, the voltage that the control will
consider unacceptable and initiate
Three-phase on normal source
a transfer operation towards the
and single-phase on emergency
emergency source
source,
The pickup and dropout settings
Three-phase on normal and
may be fixed or adjustable
emergency sources.
depending on the control type:
Single-phase sensing on a three-
phase system would only be 1. If fixed, typically the pickup
recommended in applications where setting will be 85% of the nominal
possible loss of a single phase would system voltage and the dropout
not cause problems with the differential setting will be fixed at
connected load equipment. 75% of the pickup setting;
2. If adjustable, the pickup setting
Controls utilize this voltage sensing
range is typically 85 to 100% of
capability to determine either an
nominal system voltage and the
under-voltage or over-voltage
dropout range is 75 to 98% of
condition of the normal and
the pickup setting.
emergency sources.
The under-voltage sensors include
4.1.1. Under-voltage a time delay before the controls
ATS controls utilize under-voltage initiate a time delay start. This time
sensors to continuously monitor delay allows the control to ignore
both the normal source and very brief voltage dips that may
emergency power sources. Under result from short-circuit faults and
normal operating conditions, the re-closure operation, etc. Under-
controller identifies the normal voltage sensing time delay can either
source as the preferred source of be fixed, typically at 0.5 seconds, or
power and will not permit the load adjustable, typically from 0.1 to
to be disconnected from both 1.0 seconds.
sources simultaneously when either
or both are acceptable. 4.1.2. Over-voltage
As with under-voltage, two settings
Under-voltage sensing uses two are used for over-voltage sensing:
parameters for determination of
source condition and required switch 1. Pickup setting determines
action: the voltage that the control
will consider acceptable for the
1. Pickup setting The pickup transfer switch contacts to close
setting determines the voltage
that the control will consider
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applications, the controls should 4.4. Engine Start Contact
include a time delay on transfer to Controls must include a contact
emergency that is adjustable from that signals the engine controls to
zero to one minute. start when the normal power fails.
4.3.1. Time Delay Normal to
4.5. ATS Testing
Emergency (TDNE) Periodic testing is necessary to
Provides a time delay when maintain the emergency power
transferring from the normal source system in good condition. Therefore,
to the emergency source. Timing controls are equipped with a
begins when the emergency source manually operated switch to
becomes available. Permits simulate a normal source failure.
controlled transfer of the load
circuit to the emergency source. The controls described here are
standard and meet most of the
4.3.2. Time Delay Engine Start application needs for ATSs. A
(TDES) number of other controls are
Provides a time delay of the signal available to handle specific needs:
to initiate the engine/generator start
cycle in order to override momentary
4.5.1. Test Switch/Pushbutton
ATSs should be provided with a
power outages or voltage
test button that simulates a loss of
fluctuations of the normal source.
the normal power source. All
4.3.3. Time Delay Emergency programmed time delays (TDNE,
to Normal (TDEN) TDEN, etc.) will be performed as
Provides a time delay of the re- part of the test. Engine run time of
transfer operation to permit the test is equal to the plant
stabilization of the normal source. exerciser programmed set point.
Timing begins when the normal All tests are failsafe protected.
source becomes available. If the If one of the optional test operators
emergency source fails during is chosen, then the standard test
timing, then re-transfer is immediate pushbutton is disabled.
overriding the time delay. Programmable set points include:
4.3.4. Time Delay Engine Load or no load testing, or
Cooldown (TDEC) disabled,
Provides a time delay of the signal Engine run time is equal to the
to initiate the engine/generator stop plant exerciser setting.
cycle after the re-transfer operation.
This allows the engine/generator to 4.5.1.1. 2-Position Test Selector
cooldown by running unloaded. Switch (TSS)
Timing begins on completion of the Provides a 2-position, maintained
re-transfer cycle. contact selector switch marked
Auto and Test. The test is a load
test and will continue until the TSS is
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terminal unit (RTU) in supervisory Modbus card. This address enables
control and data acquisition (SCADA) the master to distinguish between
systems. the various slaves on the network.
It also allows the master device to
Versions of the Modbus protocol
send a query command to the
exist for serial port (e.g. Modbus
addressed slave. When the
RTU) and Ethernet (e.g. Modbus
addressed slave receives this
TCP). Some ATS products include
command it will send back an
optional Modbus RTU network cards
appropriate response to the master.
which reside on the back of the
controller board and are part of the LonWorks is a control network
controller assembly. The purpose of that is used in a myriad of
this card is to allow the controller to applications, including factory
be available on a Modbus network as automation, process control,
a slave device. This allows a master building networks and vehicle
device, such as a programmable logic networks. LonWorks allows up to
controller (PLC), to obtain information 32,000 devices in a peer-to-peer
from the controller and have that configuration and also provides
information available for control, a complete set of network
data acquisition and monitoring. management functions. The
LonWorks data link is a proprietary
Every Modbus network consists
form of CSMA/CD over twisted pair,
of one master device and at least
coax and fiber. Some manufacturers
one slave device. All devices on the
produce adapters which allow
network are daisy-chained using a
connection to the Internet via
twisted pair cable, with each slave
Ethernet or dial up modems.
device assigned a unique address
which is a factory default for each
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control system is a system that is result in over currents that can blow
placed on top of a real time control fuses or trip circuit breakers.
system to control a process that is
external to the SCADA system.
5.1.1. Motor Protection
Alternatives
The SCADA system can utilize Four different control methods can
either the Modbus connection or the be employed to address these
Ethernet connection to monitor and problems:
control the switchgear and ATS.
5.1.1.1. In-Phase Monitor
4.6.4. Annunciator Panels This feature compares the phase
With various transfer switches angle between both sources of
scattered throughout a facility, a power and prevents transfer until
remote annunciator panel provides the two are approximately in phase
the simplest form of remote (within a self adjusting range). When
indication and control of multiple the two voltages are within the
ATSs. These panels are available desired phase angle and approaching
from various manufacturers in the zero phase angle, the in-phase
standard and custom configurations monitor signals the transfer switch to
with a host of available options. operate and reconnection of the load
These options include the ability to takes place. The in-phase monitor,
remotely test, monitor the position, used with transfer switches that
indicate source availability and operate within 10 cycles can be used
bypass time delays for individual to safely transfer motors without
Transfer Switches. exceeding normal starting currents.
Advantages:
The advantages of using an in-phase
monitor when transferring large motor
and/or transformer loads are:
Permits the motor to continue to
run with little disturbance to the
electrical system and the process
that is being controlled by the
motor;
A standard double throw transfer
Figure 11 Remote Annunciator switch can be used with the
addition of the in-phase monitor.
5. Motor Load Transfer
Some loads, especially large three- 5.1.1.2. Motor Load Disconnect
phase motors greater than 50 HP, Control Circuit
receive severe mechanical stress if Motor disconnect control circuits
power is transferred out of phase may also be used to transfer motor
while the motor is still rotating. Also, loads. These circuits should not be
back EMF generated by a motor can used if the motors cannot be
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the bulk of the load being controlled 5.1.1.4. Description and Operation
consists of large motors and/or The delayed transition transfer
transformers. Further, many UPS switch functions as discussed below:
manufacturers strongly recommend Upon failure or reduction of the
the use of delayed transition type normal source, and the availability
transfer switches to ensure proper of the emergency source, the drive
operation and sequencing of their solenoid is energized and pulls the
equipment. The delayed transition main contacts out of the normal
feature allows a typical UPS system position and locks them mechanically
sufficient delay to recognize a power in the open transition position.
failure and transfer to batteries,
acknowledge the return of input An adjustable time delay is then
power and allow the rectifier to walk- energized. After the preset time
on to the new source, reducing any has elapsed, the drive solenoid is
transfer anomalies. energized and pulls the main contacts
out of the transition position and
Advantages: locks them mechanically in the
The advantages of using delayed emergency closed position. The
transition when transferring large emergency power source is now
motor and/or transformer loads are: feeding the load. When the voltage
Consistent operation under all sensing detects the restoration of the
conditions, including manual normal source for a predetermined
(pushbutton) operation; time period, the drive solenoid is
energized and pulls the main contacts
Operation is totally independent
from the emergency position and
of the synchronism of the power
locks them mechanically in the open
sources, eliminating the need for transition position. After the preset
in-phase monitors or extensive time delay has elapsed, the drive
motor disconnect control wiring solenoid is energized and pulls the
between the transfer switch and main contacts out of the open
motor control centers;
transition position and locks them
The delayed transition function mechanically in the normal closed
adapts itself for use in multiple position. The normal power source
generator systems and paralleling is now feeding the load.
systems to permit load shedding
5.1.1.5. Momentary Paralleling
by switching the main contacts
Closed transition switches combine
to a center-off or disconnected
delayed transition operation during a
position;
source failure with a control system
Allows typical UPS systems to that allows momentary paralleling
function properly while switching (100 ms) of two acceptable sources,
between line input sources. thereby limiting the impact of
transfer on the load. Reference the
section on closed transition transfer
(Section 7.3.3) for further details.
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This particular problem can be load carrying contacts. The use of
only partly solved by conventional the fourth pole to switch the neutral
in-phase transfer or other load is less commonly understood.
disconnect arrangements, because Questions of when to switch the
other extraneous interruptions of neutral or not in standby power
power will also confuse the VFD systems must be answered in light
voltage sensing circuitry. of NEC 230-95 and NFPA 70-2005.
These standards refer to ground
Some systems include high speed
fault protection requirements.
voltage sensing circuitry that detects
momentary power outages and The safety and advantages of
shuts down the VFD entirely. Upon Ground Fault Protection (GFP) can
reapplication of voltage, the SCRs only be realized if proper grounding
go from an off condition to a soft and consideration of neutral
start current-limiting startup that switching is taken. When neutral
automatically protects the solid switching is dictated, then the
state switching devices. determination of fourth pole contact
ratings, synchronization, reliability
When other provisions are lacking,
and integration with GFP must be
the motor load disconnect control
taken into account. Since April 1989
circuit can be considered for transfer
UL has required more stringent test
of SCR controlled loads for the VFDs
conformance of the neutral pole and
and other loads such as used by
this has a bearing on the designers
communications companies. The
choices for standby power systems.
contact, which must be integrated
by the VFD manufacturer, simply These switches are made in two,
signals the SCR control to power three- and four-pole versions. The
down before transfer and permits use of a transfer switch in traditional
a soft restart after transfer. As two- or three-pole applications, as
indicated above, such controls may pertains to automatic voltage sensing
protect the SCRs during a power of normal source failure and the
interruption when the transfer commands to start and cut over to a
switch is operating, but offer standby source, is straightforward.
no protection when the power Typically these installations are two-
interruption is extraneous to the pole for single phase and three-pole
transfer switch. for three phase circuits. The neutral
may or may not require switching
6. Switching the Neutral which would dictate an additional
Conductor pole on the transfer switch. The
neutral and its relation to grounding,
Automatic transfer and bypass
in terms of safety to personnel and
switches are made in two-, three-
equipment for standby systems,
and four- pole versions. The two-
must first be understood.
and three- pole varieties are
generally understood as to usage
and ampere/voltage rating of the
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though is the capacitive coupling
that always exists between system
conductors and ground. Because of
the danger to personnel and possible
damage to equipment and property,
should there be leakage to ground
due to shorts or high impedance
paths, the NEC decrees that certain
grounding practices and detection of
these faults be designed into systems.
Figure 16 Transient Overvoltage Due to
Ground Fault Interruption on Ungrounded
System (May Cause Other Faults to Occur
on System)
In addition, an ungrounded neutral
system developing a fault to ground
may go unnoticed until a second
ground fault causes a line-to-line
fault which can be of major
proportions (Figure 17).
These ungrounded systems
Figure 15 Ungrounded System
Capacitively Coupled to Ground are designed into critical industrial
processes that cannot afford tripping
The utilities generally provide
of protective devices should a
power to large users via three phase
ground fault develop. Such a
grounded wye distribution. The
condition could shut down
power transformer feeding the user
operations or parts of processes
will have its neutral grounded. For a
that could result in an explosion or
system having a neutral conductor
loss of product being processed.
that is not grounded, the possibility
of destructive transient voltages
appearing from line to ground during
switching of a circuit having a line to
ground fault is very likely (Figure 16).
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Zero Sequence detects vector
unbalance of current sum in each
phase and the neutral. Outputs if
not zero;
Residual Connected uses 3 or
4 CTs and 4 time relays. Any
leakage to ground will output a
signal;
Source Ground detects current
flow through system grounding
conductor, which is connected
between neutral and ground.
None of these methods are totally
without problems. Proper operation
requires that detection will monitor
all fault currents to ground. Should Figure 19 Multiple Grounding of Neutral
there be multiple grounding of the Allows Fault Current to Flow Back Through
neutral, it is possible that proper Neutral via Paths A&B (Flow via C
operation of the GFP device will not is Outside GFP Sensor)
monitor the total fault (Figure 19). 6.1.2. Three Pole Transfer
Therefore, it is important to ensure Switches
that grounding of the neutral not take A correctly grounded standby
place at multiple locations so as to generator system including the
create unintended paths and defeat transfer switch is shown in Figure 20.
the GFP sensor. The NEC further
Note that a three-pole transfer
limits neutral grounding via the
switch is used and the generator set
separately derived system rule.
does not have its neutral grounded
That is, a system source such as a
at the generator although the
transformer or a generator can have
housing is grounded.
its neutral grounded at only one
place. The correct place to ground Should a fault develop to ground
the service neutral is at the main only one path exists and the GFP
panelboard or switchboard. It is not sensor would signal the unbalance.
permitted to be grounded at other Since the neutral is common to both
points. the normal and standby sources, the
generator is not considered
separately derived. Under this
scheme the neutral is not grounded
at the housing.
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Figure 21 Generator Set Grounded to Neutral at Housing Neutral Bus Isolated
from Housing of Transfer Switch
Yet another problem with a generator set ground path. This
generator neutral ground is shown also will fool the GFP sensor into
in Figure 22. In this case the neutral monitoring less fault current than
current can divide and return via the may be flowing.
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Figure 23 Use of a 4 Pole Transfer Switch to Permit Grounding of Generator Set at Site
A designer has the tools to now 6.1.4. Fourth Pole and UL
configure a standby system as Requirements
either separately derived or not. As of April 1989, UL 1008
If the system needs are for not required that the fourth pole of
grounding the generator set at its a transfer switch be tested and
site then a three-pole transfer proven to have ratings equal to
switch with a solid neutral should its phase contacts if not of the
be employed. If the generator set same construction. And that bus
needs to be grounded at its site spacing is closer to line than its
then a four-pole transfer switch line-to-line spacing or it has a
must be designed into the system. different means of support for its
This will ensure that the neutral is neutral bus. That means that the
switched, isolating the normal or neutral contact must be capable
utility supply. of withstand and close into fault
Lastly, should the designer decide ratings at least equal to the phase
to switch the neutral, consideration contacts. The fact is not all
to contact ratings and performance transfer switches employing a
should be taken into account. fourth pole are constructed in
like fashion.
There exist four pole switches
that utilize contacts:
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The main points to be considered 7.1.2. Voltage Rating
are as follows: An ATS is unique in the electrical
Loads, distribution system in that it is one
of the few electrical devices that
Voltage rating,
may have two unsynchronized
Continuous current rating, power sources connected to it.
Overload and fault current This means that the voltages
withstand ratings, impressed on the insulation may
actually be as high as 960 volts on
Type of overcurrent protective
a 480-volt ac system. A properly
device ahead of transfer
designed transfer switch will
switch.
provide sufficient spacings and
7.1.1. Loads insulation to meet these increased
Loads, as applied to ATSs, are voltage stresses.
classified by UL 1008, as (1) total For this reason, the spacings in
system loads, (2) motor load, transfer switches should not be
(3) electric discharge lamp loads, less than those shown in Table
(4) resistive loads, (5) incandescent 22.1 of UL 1008, regardless of
lamp loads. what type of component may be
UL requires marking of transfer used as part of the transfer switch.
switches to indicate the type of For the purposes of this guide, the
load they are capable of handling. voltage ratings will be limited to
The marking total systems loads low voltage applications where
indicates that the transfer switch transfer switches are rated 600
can be used for any combination of volts or less. Common ac voltage
the loads described above under ratings of ATSs are typically 120,
(2) through (5). However, the 208, 240, 480 or 600 volts, single
incandescent load shall not exceed or three-phase. Standard
30% of the total load unless the frequencies are 50 or 60 hertz.
transfer switch is specifically Transfer switches may also be
marked as suitable to transfer a provided for other voltages, when
higher percentage of incandescent required.
lamps. Most transfer switches are
rated for transfer of total system 7.1.3. Solid or Switched
loads, though some may be marked Neutral
resistance only, tungsten only, etc. For three phase applications, it
or a combination of these markings. is necessary to choose between
The burden on the system designer three pole and four pole transfer
is lessened when he chooses switches.
switches listed and rated for total
Three pole switches represent
system loads.
a solid neutral where four pole
switches represent a switched
neutral. Two pole transfer
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continuous duty rating transfer For a sample withstand current
switch can be used. rating see Section 12.2.
7.1.6. Overcurrent Protection 7.2. Enclosure Ratings
Since transfer switches are often The National Electric
subjected to currents of short Manufacturers Association
duration exceeding the continuous (NEMA) provides standards
duty rating, the ability of the for enclosures to ensure safe
transfer switch to handle higher operation under various
currents is measured by its overload conditions. Two major categories
and withstand current ratings. of classification are for switchgear
The overload rating refers to the in non-hazardous locations and
ability of a transfer switch to those in hazardous locations.
handle normal inrush currents 7.2.1. Non-Hazardous
encountered in switching lighting,
Locations
transformer, and motor loads.
In non-hazardous locations
Generally an ATS should have a
the specific enclosure types,
minimum overload rating 15 times
their applications, and the
the continuous duty rating for .
environmental conditions they
5 second. The withstand current
are designed to protect against,
rating pertains to the ability of an
when completely and properly
ATS to withstand the magnetic
installed, are as follows (see
and thermal stresses of high fault
Figure 24 and Figure 25):
currents until the fault is cleared by
an overcurrent protective device. Type 1 Enclosures constructed
The overcurrent protective device for indoor use to provide a degree
is usually located external to the of protection to personnel against
transfer switch although there are access to hazardous parts and to
transfer switches that do include provide a degree of protection to
integral overcurrent protection. the equipment inside the enclosure
To differentiate between the two, against ingress of solid foreign
one recognized standard defines objects (falling dirt).
the following type designation: Type 1A is similar to Type 1,
Transfer switch; Type A means but also includes gasketing
an ATS that does not employ material. Type 1A is not officially
integral overcurrent devices recognized but is often included in
specifications.
Transfer switch, Type B means
an ATS that employs integral Type 2 Enclosures constructed
overcurrent devices. for indoor use to provide a degree
of protection to personnel against
UL 1008 includes minimum
access to hazardous parts; to
requirements for withstand current
provide a degree of protection to
ratings.
the equipment inside the enclosure
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of protection with respect to personnel against access to
harmful effects on the equipment hazardous parts; to provide a
due to the ingress of water degree of protection to the
(dripping and light splashing). equipment inside the enclosure
against ingress of solid foreign
Type 6 Enclosures constructed
objects (falling dirt and circulating
for either indoor or outdoor use
dust, lint, fibers, and flyings); and
to provide a degree of protection
to provide a degree of protection
to personnel against access to
with respect to harmful effects on
hazardous parts; to provide a
the equipment due to the ingress
degree of protection to the
of water (dripping and light
equipment inside the enclosure
splashing).
against ingress of solid foreign
objects (falling dirt); to provide a Type 12K Identical to Type 12
degree of protection with respect with the addition of being
to harmful effects on the constructed with knockouts.
equipment due to the ingress of Type 13 Enclosures constructed
water (hose-directed water and the for indoor use to provide a degree
entry of water during occasional of protection to personnel against
temporary submersion at a limited access to hazardous parts; to
depth); and to remain undamaged provide a degree of protection to
by the external formation of ice on the equipment inside the enclosure
the enclosure. against ingress of solid foreign
Type 6P Identical to Type 6 but objects (falling dirt and circulating
also provides an additional level dust, lint, fibers, and flyings); to
of protection against corrosion, provide a degree of protection
ingress of water (occasional with respect to harmful effects on
prolonged submersion), and the equipment due to the ingress
protection against the external of water (dripping and light
formation of ice on the enclosure. splashing); and to provide a degree
of protection against the spraying,
Type 12 Enclosures constructed
splashing, and seepage of oil and
without knockouts for indoor use to
non-corrosive coolants.
provide a degree of protection to
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Figure 24 Comparison of Specific Applications of Enclosures
for Indoor Non-Hazardous Locations (NEMA 250-2003)
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Figure 25 Comparison of Specific Applications of Enclosures
for Outdoor Non-Hazardous Locations (NEMA 250-2003)
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indicates the degree of protection Type numbers in this standard to
provided by the enclosure with the IEC enclosure classification
respect to persons and solid foreign designations. The enclosure type
objects entering the enclosure. numbers meet or exceed the test
The second numeral indicates the requirements for the associated
degree of protection provided by IEC Classification; for this reason
the enclosure with respect to the Figure 27 cannot be used to
harmful ingress of water. convert from IEC classifications
to enclosure Type numbers.
Figure 27 provides an equivalent
conversion from the enclosure
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Example: The type of switch would a way that the power output is
be one of the three types just outlined broken (interrupted) before the
(non-automatic manual/electrical or transfer to the new source is made.
automatic). The application could call There is a definite break in power as
for the switch to perform in a certain the load is taken off one source and
way to accomplish its function. This connected to another. While this type
means the switch must be configured of transfer is simple, the time delay
to do the job. The logic might be between break and make creates an
configured in a certain way, the unacceptable power interruption for
switch might be physically configured critical loads, such as computers. For
in a certain way, or it could be a this reason, the OTT configuration is
combination of the two. Even though more appropriate for less critical
the switch is configured a certain way applications.
for the application, it might be a non- Typically, this type of switch
automatic type or an automatic type uses voltage sensors and time delay
switch. These things are dependent circuitry to activate the operation
upon the specific design. All switch of the switching mechanism in the
designs do not offer all the same desired sequence. With ATSs, the
choices. In addition, previous logic controls the operation. Whether
discussions centered around fixed the switch is transferring to the
switching devices. emergency source or retransferring
If insulated case switches or to the normal source, it operates in
insulated case circuit breakers are the same sequence, break-before-
used as the main switching devices, make (Figure 28)
drawout switching devices may also
be available. The transfer switch
can, therefore, be configured as
fixed or drawout.
The rest of this section will present
brief explanations of a number of
different switch configurations:
Open transition,
Delayed transition,
Closed transition,
Maintenance bypass/bypass
isolation,
Service entrance. Figure 28 Open Transition Operation
(Break-Before-Make Operation No Center
7.3.1. Open Transition Off Position)
An Open Transition Transfer (OTT)
switch is also called a break-before-
make switch. It is configured in such
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7.3.2. Delayed Transition source, reducing any transfer
Transfer Switches anomalies.
As previously explained, a delayed 7.3.2.1. Application Information
transition transfer switch, also When transferring large motors,
referred to by some manufacturers UPS systems and/or transformers
as a programmed transition between two sources of power
feature, provides an adjustable time that have the potential to be
delay after the opening of the closed unsynchronized, consideration
contacts and before the closing of must be given to the elimination
the open contacts for transferring or reduction of transients.
large motor and/or transformer
These may occur when loads are
loads. This delayed transition time
disconnected from the first power
allows for motors to coast down and
source and immediately connected
transformer fields to decay, thus
to the second source.
allowing inductive loads to be re-
energized after transfer with only When a running motor is suddenly
normal inrush starting currents. disconnected from its power source,
the residual voltage developed due
The delayed transition design is an
to generator action will decrease in
effective method of handling these
amplitude and frequency as the
applications and can be utilized as
motor slows down. Depending on
an alternative to a standard transfer
the type number and application of
switch equipped with an in-phase
the motors involved, the decaying
monitor.
action may take a considerable
The delayed transition transfer amount of time.
switch is ideally suited for pumping
Similarly when a transformer is
stations, sewage treatment plants,
disconnected from the line, time is
hospital X-ray equipment, or
required for its magnetic field to
wherever the bulk of the load being
collapse. Release of stored energy in
controlled consists of large motors
the transformer generates a surge
and/or transformers.
even though the two power sources
Further, many UPS manufacturers are in synchronism when a transfer
strongly recommend the use of is initiated. The transient caused by
delayed transition type transfer the momentary high current flow
switches to ensure proper operation described above can exceed the
and sequencing of their equipment. instantaneous trip settings of
The delayed transition switch allows protective devices in the system
a typical UPS system sufficient delay and can be severe enough to trip
to recognize a power failure and circuit breakers cause damage to
transfer to batteries, acknowledge motor shafts couplings, etc.
the return of input power and allow
One solution to this problem is to
the rectifier to walk-on to the new
introduce a delay in the transition
between two live sources.
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are sensitive to even the 30-100
millisecond outage experienced during
a typical transfer switch operation.
In addition to these applications,
opportunities for peak shaving and
utility incentive rates may be passed
over because of the inability to
accept the short power interruptions
inflicted during operation.
The closed transition transfer
switch, also known as a make-before-
break switch, is designed for such
applications. With this feature, there
is no interruption in power to the load
during transfer operations when both
power sources are available. Figure 30 CTT Switch Used for
Emergency Source Testing (Make-Before-
These products utilize the same Break Operation)
switching technology as that NOTE: P Position indicates both sources paralleled
previously described, combined with for 6 cycles
the capability to transfer in a closed 7.3.3.1. Description and Operation
transition mode when both sources Generally speaking, closed transition
are within preset parameters. Utilizing switches have two basic modes of
a high-speed drive system, the operation. During a failure of one
overlap of the normal and emergency source or an out of specification
sources is less than 100 msec. When condition, the switch operates as a
one source is not within specified standard delayed transition switch.
limits, such as during a power failure, This sequence allows clear separation
the closed transition switch operates of an unreliable source from an
in an open transition mode. available one.
Closed transition operation takes
place when both sources are within
preset voltage and frequency
parameters and the phase angle
differential is less than five degrees.
The closed transition sequence may
be initiated by the test switch, a
load exerciser clock, peak shaving
controls or special utility incentive
rate signals.
When a transfer signal is received
from one of the above mentioned
methods, the engine generator set
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In some non-critical emergency Figure 31 shows the physical
power systems, it is possible to layout of a bypass isolation transfer
disconnect the power feeders from switch with the manually operated
the ATS and electrically isolate the bypass-isolation switch mounted
switch for servicing. Yet, there above the ATS. The switches are
are many critical systems where completely interconnected requiring
interruption of power is not only the normal source, emergency
permissible. In hospital source and load cable connections.
communication systems, data Once installed, no cables need to
processing centers, airports, etc., be removed to isolate the transfer
power disruption is not permitted. switch module for maintenance
For these systems, the use of a or inspection. The ATS may be
bypass-isolation switch with the withdrawn for testing or maintenance
transfer switch is essential and often without disturbing the load.
required by code. Bypass-Isolation
Transfer Switches are designed to
meet the requirements for the
inspection and/or maintenance
of the transfer switch without
power interruption.
7.3.4.1. Construction
The bypass-isolation transfer
switch consists of two major
modules; the ATS and the bypass-
isolation switch.
The ATS module is of identical
construction and functionality
as that previously described. The
switch may be designed to operate
in an open transition, delayed
transition or closed transition mode. Figure 31 Bypass Isolation and
Automatic Transfer Switches
The bypass section is a basic
Transfer switch provided with a 7.3.4.1.1. Automatic Transfer Switch
quick make/quick break manual The transfer switch module of a
load transfer handle and a control/ bypass isolation transfer switch has
interlock system consisting of both three positions:
mechanical and electrical interlocks. 1. Automatic: The transfer switch
The bypass should be equipped with is carrying the load, and the
normal failure sensing and a time bypass switch is in the open
delay to start the engine automatically position. This is the normal
if the ATS has been removed for operating position;
service and a failure occurs.
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ATS operator, Make-before-break the second
Disconnect switch off, type of switch operation does not
interrupt power to the load during
ATS in normal position,
the procedure (reference Figure
ATS in emergency position. 34). This is accomplished by
means of a mechanical interlock
between the automatic and
bypass switches.
Care should be taken in the
selection of a bypass isolation
switch to understand the type of
switch operation that is required
for the specific application.
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7.3.4.4. Service Entrance Rated the way it remains until the utility
Service Entrance Rated (SER) takes care of the problem and
transfer switches combine the restores power. A number of
functions of the automatic switching facilities, such as water, wastewater
device with a utility circuit breaker, treatment, pumping station and many
which serves as a disconnect other industrial facilities cannot
device. The SER must meet all NEC tolerate the loss of commercial
requirements for installation as power. An emergency power source
service entrance equipment. is necessary at any of these facilities
to protect against commercial power
Service entrance rated transfer
interruptions. In such a situation, it
switches generally are installed at
becomes necessary to have an ATS
facilities that have a single utility
as close as possible to the point
feed and a single emergency power
where commercial power enters the
source. A circuit breaker serves as
facility, the service entrance. The
the utility disconnect and links are
reason most likely is that every load
provided to connect both neutral
at the facility is critical, and must
and ground conductors.
continue functioning, even though
Service entrance is the point where commercial power is lost.
power supplied by a utility enters
There are two approaches that can
a facility.
be used for the installation of ATS
Just look at the point where power equipment:
enters a house from the local utility
and goes directly into a load center, Contactor type ATS installation,
probably mounted on a basement Breaker transfer pair ATS
wall. The incoming power line first installation.
goes to a main disconnect, probably 7.3.4.5. Contactor Type SER
a circuit breaker. From there it A contactor type ATS installation
breaks down into many different would normally be installed
circuits through any number of immediately downstream of the
smaller circuit breakers to supply service disconnect devices of both
power throughout the house. the utility and standby (emergency)
Industrial facilities, for example, are power supplies (Figure 35). This may
no different, just on a larger scale. not be the optimum installation
When there is a loss of power from location, but it is the best that can
the utility at a house, everything be done with conventional ATS
electrical stops functioning. That is equipment.
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Figure 35 Contactor Type ATS Service Entrance Installation
7.3.4.6. Breaker Transfer Pair SER disconnect devices and their
A breaker transfer pair ATS respective power interconnections.
installation using circuit breaker type This means the ATS is installed
disconnects, such as the SPB, and a directly at the point of service
service entrance option eliminates entrance (Figure 36).
the need for separate upstream
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to power a load, the load distribution
must be prioritized and segregated.
In the event of a utility source
outage, the UPS will continue to
power the priority 1 loads. The ATS
will signal the generator sets to start.
As soon as a generator set has
started, the breaker to the bus bar
is closed and the priority 1 loads
are switched from the utility source
to the generator. Once a second
generator has started, it is
synchronized to the bus bar, and
the ATS connected to the priority 2
Figure 38 loads switches from utility source to
generator set power. This process is
8.1.4. Multiple Generator
continued until all generator sets are
Set/Switchgear/ATS synchronized on the bus and all loads
A simplified multiple generator are powered by the generator sets.
set/switchgear/ATS system is
shown in Figure 39. In the event
that multiple generators are required
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are not likely to be jointly affected generator sets or combinations of
by system disturbances, it can be the two.
advantageous to provide an ATS
8.1.7.1. Multiple Utility/Single
for switching if there is a failure Generator Set
in one of the utility power sources. When the primary source
Since the utility is constantly fails, the master transfer switch
supplying power, there would connects the load to the secondary
not be the startup delay that is utility. Should the secondary
experienced with a generator set utility source also fail, the engine
backup system. generator will start and the source
There may still be times during selector transfer switch will
which both utility power sources connect the load to the generator
fail; therefore, certain codes set when it reaches proper
(Hospitals) require backup operating parameters (Figure 42).
generator sets. In this application, the unit is
The controls for a utility/utility utility preferred. That is, if either
ATS are similar to a utility/ utility source becomes available,
generator set ATS except there the logic of the system will transfer
is no start/stop signal. the load to the available utility and
then shut down the generator set
until the next utility failure.
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9. Standards, Testing
& Maintenance
9.1. Standards and Ratings
9.1.1. The National Electric
Code
Figure 43 Single Utility/Multiple The National Electric Code (NEC)
Generator Sets Logic Scheme 1 provides guidance for safe and
proper installation of equipment
8.1.7.2.2. Logic Scheme 2
required for emergency and legally
The second logic scheme
required standby power systems.
operates in a similar mode.
It also contains rules for those
However, the user is supplied with
standby systems that are installed
a prime generator set selector
for the convenience of operations
switch, which causes only one of
in a facility (optional standby
the sets to start on utility failure
systems). Finally, it also deals with
and act as the primary standby
those systems operated in parallel
unit. Either unit may be so
with the electric utility and is
selected. If the primary unit does
capable of delivering energy
not assume the load within a
back to the utility source.
preset period (usually 10 seconds),
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9.1.2. Underwriters 9.1.4. International
Laboratories, Inc. (UL) Electrotechnical
UL 1008 is the Standard for Commission (IEC)
Safety Transfer Switch Equipment Transfer switches should IEC listed
and serves as the prevailing under standard 947 Low Voltage
standard for the transfer switch Switchgear and Control Gear
market in the United States. The and are suitable for installation in
requirements found in this standard applications where the prevailing
cover automatic, non-automatic standard is the IEC, found primarily
(manual), and by-pass/isolation outside of North America
transfer switches intended for use
in ordinary locations to provide for 9.1.5. National Fire Protection
lighting and power Association
The National Fire Protection
UL1008 is applicable to
Association (NFPA) provides a
equipment rated at 600 Volts or
number of very important and
less and includes standards related
applicable standards:
to the construction, performance,
testing, rating and marking of NFPA 70 National Electrical
transfer switches. When choosing Code (NEC), developed by NFPA,
an ATS it is critical to ensure that provides guidance for the proper
it is listed under UL 1008. installation of equipment required
for emergency systems, legally
Additionally, circuit breaker type
required standby systems and
transfer switches utilizing molded
optional standby systems. It
and insulated case switches or
also contains rules for systems
circuit breakers as the main power
intended for operation in parallel
switching contacts, may also be
with utility and capable of
listed under two additional
providing power back to the utility;
standards:
NFPA 99 Standard for
UL 1087 Standard for molded
Healthcare Facilities; addresses
case switches, the requirements for emergency
UL 489 Standard for circuit systems in health care facilities;
breakers. NFPA 101 Life Safety Code;
9.1.3. Canadian Standards identifies the features necessary
Association (CSA) to minimize danger to life from
CSA C22.2 No 178 Automatic fire and provides guidelines to
Transfer Switches; Industrial where emergency lighting is
Products is the prevailing essential;
standard for transfer switches NFPA 110 Standard for
sold and applied in Canada. Emergency and Standby Power
Systems; provides performance
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9.2. Testing recommended to ensure proper
A manual operator handle is operation.
provided with the transfer switch
for maintenance purposes only.
10. Controls Testing
Manual operation of the switch Standards
must be checked before it is Controls are to be factory tested
operated electrically. It is important in accordance with the following
to note that both power sources standards:
must be disconnected before
IEEE 472 (ANSI C37.90A),
manual operation of the switch.
EN55022 Class B (CISPR 11)
Manual operation is conducted by (Exceeds EN55011 & MILSTD
inserting the handle and operating 461 Class 3),
the transfer switch between the
source 1 and source 2 positions. EN61000:
The transfer switch should operate o EN61000-4-2 (Level 4),
smoothly without binding. Return o EN61000-4-3,
the switch to source 1 position, (ENV50140) 10v/m,
remove the handle, and return it
o EN61000-4-4,
to the holder provided.
o EN61000-4-5, IEEE
After completing the inspection, C62.41 (1.2 X 50ms,
cleaning and servicing of the 5 & 8 kV),
transfer switch, reinstall the switch
cover, and close and lock the o EN61000-4-6
cabinet door. Reclose the circuit (ENV50141),
breakers feeding the utility and o EN61000-4-11.
generator sources to the switch.
10.1. Maintenance
Initiate the electrical transfer test A preventive maintenance
by activating the test switch. After program will insure high reliability
programmed delay times, the and long life for a transfer switch.
controller will send an engine start The preventive maintenance
signal and the switch will complete program for any transfer switch
its transfer by closing into source 2. should include the following items:
Deactivating the test switch will 10.1.1. Inspection and
start retransfer to source 1. The
switch will complete its retransfer
Cleaning
The switch should be inspected
following programmed time delays,
for any accumulation of dust, dirt,
allowing the engine generator to
run unloaded for a preset cool or moisture, and should be cleaned
by vacuuming or wiping with a dry
down period.
cloth or soft brush. Do not use a
Per the NEC, Articles 700 & 701, blower since debris may become
a periodic test of the transfer lodged in the electrical and
switch under load conditions is
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device protecting the circuit and Continuous Current: The amount
the load. of current a device can carry
constantly at 60 cycles without
Bypass Isolation Switch: A
exceeding the temperature rise,
manually operated device used in
according to ANSI charts.
conjunction with a transfer switch
to provide a means of directly Drawout: A type of circuit breaker
connecting load conductors to a that can be moved into or out of its
power source and of disconnecting structure without unbolting, often
the transfer switch. on a racking mechanism.
Circuit Breaker Type Switch: Delayed Transition Transfer: Type
Transfer switches known as the of open transition transfer whereby
circuit breaker type use specially an ATS is equipped with a center
designed switching devices that off position in addition to the
are typically molded/insulated case Normal and Emergency positions,
switches. A molded case switch is which allows for motors to coast
like a molded case circuit breaker down and transformer fields to
without magnetic or thermal trip decay, prior to re-energizing.
elements and does not trip on Electrically Operated: A
overload or faults. Used when a version of the manually operated
compact, high capacity disconnect mechanism, but is electrically
is needed, and is held to a more operated. Operating personnel must
rigorous testing standard than the be present to initiate the operation.
contactor type.
Electrically Operated Non-
Closed Transition Transfer: Automatic Transfer: Switch similar
Transfer between emergency power to the manually operated version
sources whereby power is main- except that an electrical operation
tained to the load throughout the feature is added to the switch. The
transfer process (make-before-break). switch electrically transfers power
Closing Rating: The RMS when a pushbutton, generally
symmetrical current a transfer mounted on the enclosure, is
switch can safely close into and activated. Can also be operated
conduct during short circuit manually.
conditions. Emergency Power: Also called
Contactor Type Transfer Switch: alternate, back-up and critical
Transfer switches that use a power. If there is a normal power
contactor type design. The source failure, emergency power
contactor type switches do not can be supplied as an additional
use motor starting/lighting type source from the utility or an on site
contactors. In fact, contactor type generation, from an engine-
transfer switches used circuit generator set for example.
breaker design contacts, arc
chutes and arcing horns.
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equipment, raceways, and other Legally Required Standby
enclosures to the service System: A system legally required
equipment, the service power and classified by government
source ground, or both. jurisdiction. These systems are
intended to automatically supply
Grounding Electrode: A device
power to selected loads, other
that establishes an electrical
than those already classified as
connection to the earth.
emergency. Transfer time from the
Grounding Electrode Conductor: normal source to the emergency
The conductor used to connect the source cannot exceed 60 seconds.
grounding electrode(s) to the (Refrigeration, Communications,
equipment grounding conductor, Smoke removal, Sewage disposal,
to the grounded conductor, or to Industrial processes).
both, at the service, at each
Logic Panels: Provides the
building or structure where
intelligence/supervisory logic
supplied by a feeder(s) or branch
circuits necessary for the switch
circuit(s), or at the source of a
and related circuit operations.
separately derived system.
There are three forms;
In-phase Monitor: a device that Electromechanical Relay, Solid
monitors the relative phase angle State, Microprocessor-based.
between the two power sources
Manually Operated Non-
serving a transfer switch. This device
Automatic Transfer Switch: Provide
is used with the controls of an ATS
all the mechanics to effect the
as a permissive control to allow
transfer from source to source. The
transfer between the two power
actual transfer or power, however,
sources only upon the condition of
is accomplished by true hand
the two sources achieving a near
operation of the transfer switch.
synchronous condition.
Manual Transfer Switch: See
In Sight From (Within Sight From,
Non-Automatic transfer switch.
Within Sight): Where this Code
specifies that one equipment shall Neutral Conductor: The
be in sight from, within sight conductor that is intended to be so
from, or within sight, and so energized, that in the normal steady
forth, of another equipment, the state, the voltages from every other
specified equipment is to be visible conductor to the neutral conductor
and not more than 15 m (50 ft) are definitely related and usually
distant from the other. equal in amplitude.
Interrupting Rating: Also Neutral Ground: Neutral Ground
Ampere Interrupting Capacity refers to the connection between
(AIC), the highest current at rated neutral and ground. When a neutral-
voltage that a device is intended to to-ground connection is properly
interrupt under standard test made in accordance with the the
conditions. NEC , the voltage between any
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intended to constitute the main at their free ends to the appropriate
control and cutoff of the supply. main terminals or lines of a system.
Short Circuit: An overcurrent Transfer Switch: An automatic or
resulting from a fault of negligible nonautomatic device for transferring
impedance between live conductors one or more load conductor
having a difference in potential connections from one power source
under normal operating conditions. to another.
Standby Power: A power source Trip Unit Device: A device which
other than that used everyday. trips the operating mechanism in
Usually refers to a power used with case of a short circuit or overload
optional or alternative systems. condition.
Stored Energy: A mechanism Twin Stored Energy: A type of
used to overcome inherent forces mechanism which utilizes insulated
opposed to the insulated switch case and switches with true two
(circuit breaker) closing process, step stored energy mechanisms as
which stores energy until it is the switching devices. The stored
needed to help open the breaker. energy provides the mechanical
motion to open and close the two
SCADA Supervisory Control
sets of main contacts
And Data Acquisition: A system
that collects data from various Withstand Rating: the RMS
components within a factory, symmetrical current a transfer
power plant or in other remote switch can safely conduct during
locations and then consolidates short circuit conditions.
this data at a central processor
which controls the components 12. Appendices
and manages the data.
12.1. Bibliography
System Ground: A connection The following information is
to ground from one of the current provided as an additional reference
carrying conductors of a to subjects discussed in this manual.
distribution circuit or of an interior
wiring scheme. The following publications are
available for order through your
System Neutral Ground: A Caterpillar dealer.
connection to ground from the
neutral point or points of a circuit, Note: The information that is
transformer, rotating machine or contained in the listed publications
system. The neutral point or a is subject to change without notice.
system is that point which has the Note: Refer to this publication, the
same potential as the point of respective product data sheet, and
junction of a group of equal to the appropriate Operation and
nonreactive resistances if connected Maintenance Manual for product
application recommendations.
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personnel or equipment damage for units up to 150 amps; note the
may result. A clear understanding three cycle rating on 150 amp and
of the interrelationship between below units is optional as UL has
protective devices, transfer switch determined that all breakers in this
and system needs is necessary for size clear in less than 1.5 cycles).
a well-designed installation. Some The Umbrella or Any Breaker
basic information on withstand rating is therefore the actual UL
rating terms and calculations requirement and definition of the
follows the enclosed rating chart. ATS industry 3 cycle (or 1.5 as
noted) withstand and closing rating,
Underwriters Laboratories (UL) is
and should not to be confused with
the independent testing body that
additional, non UL 1008 labeled
has developed the standard UL
withstand only tests.
1008 which all major transfer
switch manufacturers test to. UL The following pages include the
lists products that have successfully UL certified ratings and specific
passed a battery of witnessed tests, breaker coordination charts,
including the withstand and close withstand rating data and
into fault tests described herein. additional specific information.
Manufacturers that complete these The consulting engineer must
tests are then permitted to label keep in mind that unless a transfer
their products with the UL mark. switch bears an umbrella breaker
approval for use with any molded
UL made significant changes in
case breaker, care must be taken
April of 1989 regarding the labeling
to assure that the breaker specified
requirements of transfer switches.
for the installation have an equal or
Prior to that date there had been
shorter trip time when compared to
concern over coordination with
the listed devices. This would limit
some protective devices. UL clarified
the application of the switch to
the labeling procedure and now
projects within the scope of its
allows for three rating categories.
specific breaker listing.
Current limiting fuse,
In addition to this factor, many
Specific class (trip time) of transfer switch manufacturers
molded case breaker, perform additional withstand tests
Umbrella or Any Breaker on selected products. These
ratings that take into account additional tests may be either for
all types of molded and a higher current valve or a longer
insulated case circuit breakers. duration than their standard UL
Listed ratings. The consultant must
These tests are performed for determine the applicability of these
a duration of 3 cycles on units tests and take careful note of the
225 amps and greater, and for fact that these levels are normally
1.5 cycles on 40-150 amp units not UL labeled ratings.
(with an optional 3 cycle duration
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Certified Withstand and Closing Ratings in Symmetrical RMS Amperes at 480 Volts AC
Switches Rated for W isthstand and Closing Current Ratings per UL 1008
Withstand and Any
Specific Coordinated
Closing Ratings when Breaker
Breaker Rating
Coordinated with any Rating
UL 1008 Minimum
Max
Model Switch UL 1008
Max. Max Circuit Max Max
Rating Ratings
Fuse Size Circuit Breaker Circuit Circuit
Amps Amps Size Amps Amps
Amps
TS1 40 50 200,000 400 30,000 10,000 5,000
TS1 80 100 200,000 400 30,000 10,000 5,000
TS1 100 125 200,000 400 30,000 10,000 5,000
TS1 150 200 200,000 400 30,000 10,000 10,000
TS1 200 300 200,000 400 30,000 10,000 10,000
TS1 225 300 200,000 800 50,000 35,000 10,000
TS1 260 350 200,000 800 50,000 35,000 10,000
TS1 400 600 200,000 800 50,000 35,000 10,000
TS 600 750 200,000 800 65,000 50,000 12,000
TS 800 1,200 200,000 1,200 65,000 50,000 16,000
TS 1,000 1,250 200,000 1,600 85,000 50,000 20,000
TS 1,200 1,500 200,000 1,600 85,000 50,000 24,000
TS 1,600 2,000 200,000 2,500 100,000 100,000 32,000
TS 2,000 2,500 200,000 2,500 100,000 100,000 40,000
TS 3,000 4,000 200,000 4,000 100,000 100,000 60,000
TS 4,000 6,000 200,000 5,000 100,000 100,000 80,000
BTS1 100 125 200,000 800 50,000 35,000 5,000
BTS1 150 200 200,000 800 50,000 35,000 10,000
BTS1 225 300 200,000 800 50,000 35,000 10,000
BTS1 260 350 200,000 800 50,000 35,000 10,000
BTS1 400 600 200,000 800 50,000 35,000 10,000
BTS 600 750 200,000 800 65,000 50,000 12,000
BTS 800 1,000 200,000 1,600 85,000 50,000 16,000
BTS 1,000 1,250 200,000 1,600 85,000 50,000 20,000
BTS 1,200 1,500 200,000 1,600 85,000 50,000 24,000
BTS 1,600 2,500 200,000 2,500 100,000 100,000 32,000
BTS 2,000 2,500 200,000 2,500 100,000 100,000 40,000
BTS 3,000 4,000 200,000 4,000 100,000 100,000 60,000
BTS 4,000 6,000 200,000 5,000 100,000 100,000 80,000
TSD1 40 50 200,000 150 50,000 35,000 5,000
TSD1 80 100 200,000 150 50,000 35,000 5,000
TSD1 100 125 200,000 150 50,000 35,000 5,000
TSD1 150 200 200,000 400 50,000 35,000 10,000
TSD1 225 300 200,000 400 50,000 35,000 10,000
TSD1 260 350 200,000 400 50,000 35,000 10,000
TSD1 400 600 200,000 800 50,000 35,000 10,000
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SECTION 2 DEFINITIONS AND f. Available Peak Current
CALCULATIONS Maximum possible short-
1. Purpose circuit current that may exist
Many questions arise when in a system without
comparing WCR to the system protective devices;
fault current rating. Too often a g. Peak Let Through Current
switch is rated by a manufacturer Maximum instantaneous
in one set of WCR terms and the current through the
available system fault currents protective device during the
described with a different set of total clearing time;
terms. h. Withstand Current Rating
The purpose of this paper is to The rating that defines the
outline the different ways switches ability of the switch to
may be rated (WCR) and systems withstand the thermal and
are measured. electromagnetic effects of
2. Basic Definitions short circuit currents for a
a. RMS Current The Root set period of time;
Mean Square which is the i. Withstand and Closing Rating
effective value of an UL 1008 test for a transfer
alternating current. It is switchs ability to close into
equal to 0.707 of the peak and withstand a fault current.
current for a sine wave. This These are the ratings which
is the value referred to when will actually appear on the UL
people say current; label of the product.
b. Peak Current The Note: For diagrams of typical
instantaneous maximum current wave forms, see Figure 45
value of current the peak and Figure 46.
current of a sine wave is 3. Available Fault Current
1.414 times its RMS value; Available fault current information
c. Symmetrical Current The can often b supplied by the utility
alternating current which is company. If this information is not
symmetrical around the zero available, approximate fault current
axis of the sine wave; can be calculated by knowing the
d. Asymmetrical Current The transformer impedance (usually 2
alternating current which is to 5% of full load ampere rating of
not symmetrical around the the transformer).
zero axis; For a single phase system,
e. Peak Fault Current The transformer let through current is:
instantaneous maximum
current value that occurs
after the start of a fault in Where Z is transformer impedance
any phase; in percent divided by 100.
For three phase systems:
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4. Comparison of Terms
The following values have all been
used to describe identical circuit
Example: 500 kVA transformer
conditions:
2.5% Impedance 480 Volts, 3
a. Available short circuit current
phase
RMS 120,000 amps;
b. Peak Let Through Current
(1/2 cycle) 30,000 amps;
This figure is somewhat lower c. Peak Asymmetrical Current
if a long run of cable introduces 56,000 amps;
substantial additional impedance. d. Peak Symmetrical Current
Available fault current determine 40,000 amps;
the rating that a transfer must e. Withstand Rating 3 cycles
meet. RMS 28,000 amps.
Figure 45
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Figure 46
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LEBQ8107-00 2007 Caterpillar Printed in U.S.A.
All rights reserved.