Eaton Electrical Magnum Transfer Switch User Manual
O & M Manual for the Fixed and
Drawout Magnum Transfer Switches
Instruction Booklet
New Information
Description Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Receiving, Handling, and Storage . . . . . . . . . . . . . . . . . . . . 10
Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drawout and Fixed Switching Devices . . . . . . . . . . . . . . . . 22
Operation of the Bypass Isolation Transfer Switch . . . . . . . . 25
Testing and Problem Solving . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Renewal Parts Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Instructional Booklet
Page 2 Effective: March 2007
WARNING
READ AND UNDERSTAND THE INSTRUCTION S CONTAINED HEREINAFTER BEFORE ATTEMPTING TO UNPACK, ASSEMBLE, OPERATE,
OR MAINTAIN THIS EQUIPMENT.
HAZARDOUS VOLTAGES ARE PRESENT INSIDE TRANSFER SWITCH
ENCLOSURES THAT CAN CAUSE DEATH OR SEVERE PERSONAL
INJURY. FOLLOW PROPER INSTALLATION, OPERATION, AND MAINTENANCE PROCEDURES TO AVOID THESE VOLTAGES.
TRANSFER SWITCH EQUIPMENT COVERED BY THIS I NSTRUCTION
BOOK IS DESIGNED AND TESTED TO OPERATE WITHIN ITS NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY
CAUSE THE EQUIPMENT TO FAIL RESULTING IN DEATH, SERIOUS
BODILY INJURY, AND/OR PROPERTY DAMAGE. ALL RESPONSIBLE
PERSONNEL SHOULD LOCATE THE DOOR MOUNTED EQUIPMENT
NAMEPLATE AND BE FAMILIAR WITH THE INFORMATION PROVIDED
ON THE NAMEPLATE. A TYPICAL EQUIPMENT NAMEPLATE IS
SHOWN IN FIGURE 1.
Fixed and Drawout Magnum Transfer Switches
Automatic Transfer Switch
E
Poles: 3 Amps: 3200 Volt: 120/600 VAC
Phase: 3 Hertz: 60 Wire: 4
Figure 1. Typical Automatic Transfer Switch Equipment Nameplate.
Cat No: ATVIMGB33200XRU 11/04
GO No: 1of1
Item 1
NOTICE
A FINAL INSPECTION OF THE EQUIPMENT SHOULD BE PERFORMED
PRIOR TO ENERGIZING THE TRANSFER SWITCH.
Step 1: Remove any dirt or debris that may have collected during
Step 2: Be certain all cable connections are correct and that the
Step 3: Inspect the engine start connections and verify the cor-
shipment or installation. NEVER use high pressure blowing air. This could drive dirt or other foreign objects into
electrical or mechanical components which could cause
damage. Use an industrial quality vacuum cleaner to
remove any dirt or foreign objects.
phase rotation of both sources match.
rect connection of all control wires.
Step 4: Check all programmable setpoints and adjust as neces-
sary. In addition, adjust any optional accessories as
required.
Step 5: Be certain that the actual lug torque values are in keeping
with the requirements outlined in the instruction book to
insure the integrity of power connections.
Step 6: Check to be sure that all covers and barriers are properly
installed and fastened.
ALL POSSIBLE CONTINGENCIES WHICH MAY ARISE DURI NG INSTALLATI ON, OPERATION, OR MAINTENANCE, AND ALL DETAILS AND VARIATIONS OF THIS EQUIPMENT DO NOT PURPORT TO BE COVERED BY THESE INSTRUCTIONS. IF FURTHER INFORMATION IS DESIRED BY THE
PURCHASER REGARDING HIS PARTICULAR INSTALLATION, OPERATION, OR MAINTENANCE OF PARTICULAR EQUIPMENT, CONTACT AN
EATON REPRESENTATIVE.
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Fixed and Drawout Magnum Transfer Switches
Instructional Booklet
Effective: March 2007 Page 3
Section 1: Introduction
1.1 Preliminary Comments and Safety Precautions
This technical document is intended to cover most aspects associated with the installation, application, operation, and maintenance
of transfer switch equipment with ratings from 800 through
3200 amperes (A), except for the specific logic used to control
the equipment. It is provided as a guide for authorized and qualified personnel only. Please refer to the specific WARNING and
CAUTION in Section 1.1.2 before proceeding. If further information is required by the purchaser regarding a particular installation,
application, or maintenance activity, contact an Eaton representative. For information associated with the control, refer to the separate instruction book pertaining to the logic package installed in
the switch.
1.1.1 Warranty and Liability Information
No warranties, expressed or implied, including warranties of fitness for a particular purpose of merchant-ability, or warranties
arising from course of dealing or usage of trade, are made regarding the information, recommendations and descriptions contained
herein. In no event will Eaton be responsible to the purchaser or
user in contract, in tort (including negligence), strict liability or
otherwise for any special, indirect, incidental or consequential
damage or loss whatsoever, including but not limited to damage or
loss of use of equipment, plant or power system, cost of capital,
loss of power, additional expenses in the use of existing power
facilities, or claims against the purchaser or user by its customers
resulting from the use of the information and descriptions contained herein.
WARNING
THE CLOSED TRANSITION PRODUCT CONTAINS A SPECIAL CONTACT ARRANGEMENT (OVERLAPPING CONTACTS). MISUSE CAN
RESULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR PROPERTY
DAMAGE.
1.2 General Information
Transfer switches are used to protect critical electrical loads
against loss of power. The Source 1 power source of the load is
backed-up by a Source 2 power source. A transfer switch is connected to both the Source 1 and Source 2 power sources and supplies the load with power from one of these two sources. In the
event that power is lost from the Source 1 power source, the
transfer switch transfers the load to the Source 2 power source.
This transfer can be automatic or manual, depending upon the
type of transfer switch equipment being used. Once Source 1
power is restored, the load is automatically or manually transferred back to the Source 1 power source, again depending upon
the type of transfer equipment being used (Figure 2).
In addition, the Eaton closed transition transfer switch may be
applied where it is desirable to avoid any momentary power interruptions. Although the closed transition switch is not a substitute
for an uninteruptable power source (UPS), it does eliminate power
interruptions to loads except to those caused by power sources or
equipment external to the transfer switch. If both sources are
acceptable as determined by the IQ Transfer logic, a make-beforebreak transfer is performed during a transfer test or retransfer
operation.
1.1.2 Safety Precautions
All safety codes, safety standards, and/or regulations must be
strictly observed in the installation, operation, and maintenance of
this device.
WARNING
THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PROCEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONNEL SAFETY
AND PROTECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE
OF A TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TO
FAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION.
THIS WILL HELP TO INSURE THAT PERSONNEL ARE ALERT TO
WARNINGS, WHICH APPEAR THROUGHOUT THE DOCUMENT. IN
ADDITION, CAUTIONS ARE ALL UPPER CASE AND BOLDFACE.
.
CAUTION
COMPLETELY READ AND UNDERSTAND THE MATERIAL PRESENTED
IN THIS DOCUMENT BEFORE ATTEMPTING INSTALLATION, OPERATION, OR APPLICATION OF THE EQUIPMENT. IN ADDITION, ONLY
QUALIFIED PERSONS SHOULD BE PERMITTED TO PERFO RM ANY
WORK ASSOCIATED WITH THE EQUIPMENT. ANY WIRING
INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE FOLLOWED PRECISELY. FAILURE TO DO SO COULD CAUSE PERMANENT EQUIPMENT DAMAGE.
1.2.1 Transfer Switch Types
There are four types of transfer switch equipment.
Automatic Transfer Switch
Automatic transfer switches (ATSs) automatically perform the
transfer function. They consist of three basic elements:
1. Main contacts to connect and disconnect the load to and from
the source of power.
2. Intelligence/supervisory circuits to constantly monitor the condition of the power sources and thus provide the intelligence
necessary for the switch and related circuit operation.
3. A transfer mechanism to effect the transfer of the main contacts from source to source.
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Instructional Booklet
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Fixed and Drawout Magnum Transfer Switches
Basic Transfer Switch (Power Panel)
The basic transfer switch is designed for use with customer furnished logic. It is similar in design to the automatic version,
except the intelligence circuit (logic panel) and voltage selection
panel are omitted. All control devices are the customer’s
responsibility.
Source 2
Source 1
The switching devices are in a compact vertical arrangement. The
logic can be easily disconnected from the switching device without disturbing critical connections. The enclosure is free standing,
and, by using the specially supplied cleats, the switch is seismic
approved (Option 42). The terminals are mounted in the rear of
the switch, permitting rear, top, bottom, or side cable or bus bar
entrance.
The switching devices have a high withstand rating (Table 1). The
high-speed, stored-energy switching mechanism guarantees a
transfer time of less than 5 cycles.
Load
Figure 2. Typical Load Transfer Switch (Switching Device Type)
Schematic.
Non-Automatic Transfer Switch (Electrically Operated)
Non-automatic transfer switches are manually initiated, electrically
operated devices for applications where automatic load transfer is
not required.
Bypass Isolation Transfer Switch
The bypass isolation switch is designed for applications where
maintenance, inspection, and testing must be performed while
maintaining continuous power to the load (Figures 3 and 4). This
is typically required in critical life support systems and standby
power situations calling for safe system maintenance with no
power disruptions. Such a design allows for the quick removal of
the different switching devices for inspection, maintenance, or
replacement.
The ATS, non-automatic transfer switch (electrically operated),
and bypass isolation transfer switch are the available types for the
configuration described in this manual.
Operation of the ATS and the bypass isolation switch only are discussed in this manual (Sections 5 and 7 respectively).
1.2.2 Design Configuration
The Eaton transfer switch is a rugged, compact design utilizing
insulated case switches or insulated case circuit breakers to transfer essential loads from one power source to another. Open transition switching devices are interlocked to prevent both switching
devices from being closed at the same time. The versatile design,
in addition to standard transfer functions, offers an optional integral thermal and short circuit protection in either or both switching
devices.
Figure 3.Typical Bypass Isolation Switch.
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Fixed and Drawout Magnum Transfer Switches
INCOMING
SOURCE 1
SOURCE 1
ISOLATED
ATS
SOURCE 1
SOURCE 1
BYPASS
Instructional Booklet
Effective: March 2007 Page 5
SOURCE 1
POSITION
A
SOURCE 1
AVAILABLE
SOURCE 2
ISOLATED
SOURCE 2
POSITION
ATS
SOURCE 2
LOAD
SOURCE 2
BYPASS
INCOMING
SOURCE 2
A
SOURCE 2
AVAILABLE
Figure 4.Typical Bypass Isolation Switch Schematic.
Table 1. Withstand Ratings
RATING WHEN USED WITH UPSTREAM CIRCUIT BREAKER RATING WHEN USED WITH UPSTREAM FUSE
Transfer Switch
Amp Rating
800 100 85
1000 100 85
1200 100 85
1600 100 85
2000 100 85
2500 100 85
3200 100 85
SOURCE 1
BYPASS
SOURCE 2
BYPASS
3 Cycle
600V
(kA)
30 Cycle
600V
(kA)
Tested in accordance with UL1008.
Eaton Drawout Magnum Transfer Switch will coordinate with a power switching device short time rating. Contact factory for details.
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1.3 Magnum Fixed and Drawout Switching Devices
1.3.1 General Magnum Switching Device
The Magnum switching devices used in the Magnum transfer
switches are air switching devices utilizing an electronic tripping
system. They are available in both fixed and drawout versions,
both of which are used in the Magnum transfer switch depending
on the specific transfer switch ordered.
Fixed and Drawout Magnum Transfer Switches
Figure 5. The Magnum Fixed Switching Device.
Figure 6. The Magnum Drawout Switching Device.
The Magnum transfer switches are available in the following configurations:
Table 2. Magnum Transfer Switch Configurations
NUMBER OF
SWITCHING DEVICES
2Fixed
2 Drawouts
4 Drawouts
All Magnum switching devices are 100% rated, Underwriters Laboratories (UL) listed, and are built and tested in an ISO 9002 certified facility to applicable NEMA, ANSI, IEEE, and UL standards.
For more information on Magnum switching devices, consult the
Magnum switching device manual supplied with the transfer
switch.
The main difference between the fixed and drawout versions of
the Magnum switching devices used in the Magnum transfer
switch is the mounting method. Fixed switching devices are
bolted directly into the transfer switch frame while drawout
switching devices are mounted in an extendable carriage within
the transfer switch, allowing the switching device to be “drawn
out” for service, maintenance, and/or replacement.
SWITCHING DEVICE
TYPE
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Fixed and Drawout Magnum Transfer Switches
Figure 7. Fixed Switching Device for the Magnum Transfer
Switch.
Instructional Booklet
Effective: March 2007 Page 7
Figure 9. Drawout Switching Device Fully Extended from the
Magnum Transfer Switch.
1.3.3 Magnum Fixed Switching Devices
The Magnum fixed type switching device differs from the drawout
version in that it has no levering device, primary disconnects, and
secondary disconnects.
Figure 8. Drawout Switching Device Installed in the Magnum
Transfer Switch.
1.3.2 Magnum Drawout Switching Devices
The Magnum drawout switching device is a design having three
positions with the compartment door closed (CONNECT, TEST,
DISCONNECT) and one position out of its compartment on the
extendable carriage rails (REMOVE). The Magnum drawout
switching device is equipped with both primary and secondary disconnects to provide for the drawout functioning. The operating
mechanism is a two-step, stored energy mechanism, either manually or electrically operated. When withdrawn on the extendable
carriage rails, Magnum switching devices can be inspected, accessory items added, and minor maintenance performed. The inside
of the compartment can also be inspected with the switching
device withdrawn on the extendable carriage rails.
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Figure 10. Primary and Secondary Connections on a Magnum
Fixed Switching Device.
PRIMARY CONNECTIONS
SECONDARY CONNECTIONS
Instructional Booklet
Page 8 Effective: March 2007
In addition, a fixed switching device does not have a standard feature to hold the switching device in a “trip-free” position.
Magnum fixed switching device terminals have holes for making
bolted horizontal primary bus connections. Adapters are available
for making vertical primary bus connections. Secondary connections can be made through standard terminal blocks or a special
connector compatible with the drawout switching device’s type
secondary connector. Both secondary connection devices are
mounted at the top front of the switching device.
The Magnum fixed switching devices have two mounting feet,
one on each side, to permit the switching device to be securely
mounted to the transfer switch frame. Each mounting foot has
two slotted mounting holes to facilitate mounting.
1.4 Transfer Switch Catalog Number Identification
Transfer switch equipment catalog numbers provide a significant
amount of relevant information that pertains to a particular piece
of equipment. The catalog number identification table (Table 3)
provides the required interpretation information. An example for
an open transition switch is offered to initially simplify the process.
Example: Catalog Number (circled numbers correspond to position
headings in Table 3).
Fixed and Drawout Magnum Transfer Switches
The catalog number ATVIMGB33200XRU describes an ATS with
the switching devices mounted vertically in the enclosure. The
intelligence, represented by the ATC-400/ATC-600/ATC-800, is a
microprocessor-based logic package. The Magnum Breaker is used
as the switching device and is a 3-pole molded case breaker for
each source. The continuous current rating of this equipment is
3200 A and is applicable at 480/277 Vac, 60 Hz. The transfer
switch equipment is enclosed in a NEMA 3R enclosure and is
listed for Underwriters Laboratories (UL) and Canadian Standards
Association (CSA) applications.
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Fixed and Drawout Magnum Transfer Switches
Table 3. Transfer Switch Catalog Number Explanation.
Magnum
Bypass, Automatic and Non-automatic
Transfer Switches
800-3200 Amperes
USING THE STYLE IDENTIFICATION GUIDE
The Style Identification Guide provides an ov erview of the ten basic style/feature
categories which generate the 15 digit Genswitch catalog number.
Instructional Booklet
Effective: March 2007 Page 9
TYPE
ORIENTATION
A
TYPE
Position1-2
AT = Automatic
CT = Closed Transition
BI = Bypass Transition
CB = Closed Transition/
Bypass Isolation
NT = Non Auto
①
Contact factory for availability
V
T
ORIENTATION
Position 3
V = Vertical
I G B 3 3200 RXU
LOGIC
Position 4
I = IQ Transfer
4 = ATC-400
E = Electro Mechanical
FRAME
LOGIC
M
FRAME
Position 5-6
Molded Cases
Magnum DS MG
①
SWITCH
Position 7
A = Fixed Mount,
Molded Case Switch (MCS Both)
B = Fixed Mount,
Molded Case Circuit Breaker (HCCB Both)
C = Fixed Mount,
MCCB Normal, MCS Emergency
D = Fixed Mount,
MCS Normal, MCCB Emergency
E = Drawout, MCS Both
F = Drawout, MCCB Both
G = Drawout, MCCB Normal,
MCS Emergency
H = Drawout, MCS Normal,
MCCB Emergency
SWITCH
POLES
AMPERES
Position 9-12
0200 = 200A
0300 = 300A
0400 = 400A
0600 = 600A
0800 = 800A
1000 = 1000A
1200 = 1200A
1600 = 1600A
2000 = 2000A
2500 = 2500A
3200 = 3200A
POLES
Position 8
2 = 2 Poles
3 = 3 Poles
4 = 4 Poles
AMPERE
RATING
ENCLOSURE
VOLTAGE
TYPE
ENCLOSURE
Position 14
K = Open
S = NEMA 1
R = NEMA 3R
T = Thru Door
Design
LISTING
LISTING
Position 15
U = UL Listed,
CSA Listed
VOLT AGE
Position 13
A = 120 V 60 Hz 3 Phase 3 Wire
B = 208/120 60 Hz 3 Phase 4 Wire
E = 600 V 60 Hz 3 Phase 3 Wire
E = 600 V 60 Hz 3 Phase 4 Wire
G = 220/127 V 50 Hz 3 Phase 4 Wire
G = 220/110 V 50/60 Hz 1 Phase 3 Wire
H = 380/220 V 50 Hz 3 Phase 4 Wire
K = 600 V 50 Hz 3 Phase 4 Wire
M = 230 V 50 Hz 3 Phase 3 Wire
M = 230 V 50 Hz 1 Phase 3 Wire
N = 401/230 V 50 Hz 3 Phase 4 Wire
O = 415/240 V 50 Hz 3 Phase 4 Wire
W = 240/120 V 60 Hz 1 Phase 3 Wire
W = 240 V 60 Hz 3 Phase 3 Wire
W = 240/120 V 60 Hz 3 Phase 4 Wire Hi-Leg
W = 230/115 V 60 Hz 1 Phase 3 Wire
X = 480 V 60 Hz 3 Phase 3 Wire
X = 480/277 V 60 Hz 3 Phase 4 Wire
X = 480/240 V 50 Hz 1 Phase 2 Wire
Z = 346/220 V 50 Hz 3 Phase 4 Wire
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Instructional Booklet
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Fixed and Drawout Magnum Transfer Switches
Section 2: Receiving, Handling, and Storage
2.1 Receiving
Every effort is made to ensure that the transfer switch equipment
arrives at its destination undamaged and ready for installation.
Crating and packing is designed to protect internal components as
well as the enclosure. Transfer switch enclosures are skid
mounted and suited for fork lift movement. Care should be exercised, however, to protect the equipment from impact at all times.
Do not remove the protective packaging until the equipment is at
the installation location and ready for installation.
When the transfer switch equipment reaches its destination, the
customer should inspect the shipping container for any obvious
signs of rough handling and/or external damage incurred during
transportation. Record any external and internal damage observed
for reporting to the transportation carrier and Eaton, once a thorough inspection is completed. All claims should be as specific as
possible and include the Shop Order and General Order numbers.
A shipping label is affixed to the top of the shipping container
which includes a variety of equipment and customer information,
such as General Order Number (GO #) and Catalog Number
(Cat #). Make certain that this information matches other shipping paper information.
Each transfer switch enclosure is bolted to a rigid wooden pallet.
The pallet is open at two ends for movement by a fork lift. The
shipment is secured and further protected with shrink wrap. Do
not discard the packing material until the equipment is ready for
installation.
A plastic bag of documents will be found within the enclosure,
usually attached to the inside of the door. Important documents,
such as test reports, wiring diagrams, and appropriate instruction
leaflets, are enclosed within the bag and should be filed in a safe
place.
Section 3: Equipment Description
3.1 General
This Eaton transfer switch equipment is available in four different
configurations:
• ATS (Closed and Open transition);
• Non-Automatic (Electrically Operated) (Open Transition Only);
• Bypass Isolation Transfer Switch (Open and Closed Transition);
and
• Power Panel.
Refer to Section 1 for a discussion of all four types. Each transfer
switch is usually supplied in an enclosure, although unmounted
sub-assemblies can be supplied for mounting by the customer.
The enclosed ATS is the only specific type that will be discussed
in this section.
2.2 Handling
As previously mentioned, the transfer switch equipment is packaged for fork lift movement. Protect the equipment from impact
at all times and DO NOT double stack. Once the equipment is at
the installation location and ready for installation, the packaging
material can be removed. Once the enclosure is unbolted from the
wooden pallet, it can be installed using the lifting provision located
on the top of the structure. Be careful not to damage the top or
bottom enclosure mounting flanges. Refer to Section 4 of this
manual for specific installation instructions.
2.3 Storage
Although well packaged, this equipment is not suitable for storage
outdoors. The equipment warranty will not be applicable if there
is evidence of outdoor storage. If the equipment is to be stored
indoors for any period of time, it should be stored with its protective packaging material in place. Protect the equipment at all
times from excessive moisture, construction dirt, corrosive conditions, and other contaminants.
It is strongly suggested that the package-protected equipment be
stored in a climate controlled environment of -20° to 85°C
(-4° to 185°F) with a relative humidity of 80% or less. DO NOT,
under any circumstances, stack other equipment on top of a transfer switch equipment enclosure, whether packaged or not.
Figure 11. Typical Power Panel (Open Transition Shown).
The enclosed ATS consists of three basic panels interconnected
through connector plugs and mounted in an enclosure:
• Power Panel;
• Voltage Selection Panel; and
• Logic Panel
•
ATC-600 (open transition only)
•
ATC-800 (closed transition only).
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Fixed and Drawout Magnum Transfer Switches
Instructional Booklet
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The components comprising the three panels are installed in accordance with the specific requirements of the circuit being controlled.
Each transfer switch is, therefore, tailor-made to a specific appl ication.
3.2 Power Panel
The power panel consists of a means for making load, power, and
neutral connections. The main contacts and the transfer mechanism are all on one steel frame (Figure 12). The actual power connections are shown in Figure 13.
3.2.3 Drawout Interlocks
The standard closed transition ATS is not provided with a
mechanical interlock. All bypass switching devices are mechanically interlocked to the drawout mechanism to ensure that the
switching device is always open when connecting or disconnecting it from the line and load stabs when in the bypass mode.
All open transition switching devices are mechanically interlocked
to the drawout mechanism to ensure that the switching device is
always open when connecting or disconnecting it from the line
and load stabs.
The switching device will close only in the DISCONNECT, TEST,
and CONNECT positions.
Figure 12. Insulated Case Switching Device.
3.2.1 Main Contacts
The main contacts connect and disconnect the load to and from
the different power sources. High withstand insulated case
switches are the main contacts for the Source 1 and Source 2
power sources in standard, unmodified ATSs. Optional integral
thermal and short circuit protection in either or both switching
devices is available (Section 3.6). These continuous duty devices
are rated for all classes of loads. In addition, they have high
dielectric strength, heavy-duty switching and withstand capabilities, and high interrupting capacity.
3.2.2 Switch Interlocks (Open Transition Only)
Eaton transfer switches are mechanically and electrically interlocked to prevent the two sets of main contacts from being closed
simultaneously.
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