Fundamentals of ATS

Lesson 1: Introduction to ATS

Objectives

Identify an Automatic Transfer Switch

Describe the main components and basic
construction of an ATS

Describe the purpose of the ATS Controller

Describe the purpose of the Switch Actuator

Summarize the basic ATS cycle

List the types of different switch types

Describe the different ATS applications
What is a Transfer Switch?
Basic Transfer Switch Construction

U Source 1
Switch
Source 1
Customer’s
Shared Load
Bus
L
ATS

Source 2 Source 2
Switch
G
Powered by Source 1

G
Powered by Source 2

G
Basic Transfer Switch Construction

U Source 1
Switch
Source 1
Connections Customer’s
Load
Shared
Bus
L
Source 2
Source 2 Switch
Connections

G
ATS Controller

U
Inputs

ATS
Control
Outputs L

G
Switch Actuator

ATS
Control
L

Switch
Actuator
G
 ReTransfer
Power Relays Power Relay
from Utility

to Load
ATS
Control

from Genset

Transfer Power Relay

Automatic Transfer Switch

Source 1
Fails

Shutdown Detect
Source 2 Failure

ReTransfer Start
Load to Source 1 Source 2

Source 1 Monitor
Returns Source 2

Transfer Load
to Source 2
Types of Transfer Switches

Open Transition

Closed Transition

Bypass Isolation

Breaker Based
Open Transition

“Break”…

…before “Make”
Closed Transition

Both switches
can be closed at
the same time
Bypass Isolation

Bypass
Transfer

OT
ATS
Breaker Based

Utility Breaker

Genset Breaker
Applications

Utility to Genset

Utility to Utility

Genset to Genset
Utility to Genset

G
Utility to Utility

U1

U2
Genset to Genset (Prime Power)

G1

G2
Genset to Genset (Dual Standby)

U Util to Gen
ATS

G1 L

Gen to Gen
ATS

G2
Summary

In this lesson you have learned to:

– Identify an Automatic Transfer Switch
– Describe the main components and basic construction of an
ATS
– Describe the purpose of the ATS Controller
– Describe the purpose of the Switch Actuator
– Summarize the basic ATS cycle
– List the types of different switch types
– Describe the different ATS applications
Lesson 2: ATS Safety
Objectives

Describe the Responsibility of the employee

Identify the Authorization levels

Determine Approach Boundaries
– Shock Hazard
– Arc Flash Hazard

Determine Appropriate PPE for work on energized
Automatic Transfer Switches

Identify specific transfer switch hazards
Introduction

This module is not intended to be a qualifying NFPA

70E safety course

Every Cummins employee is responsible for his/her
own safety
– Follow safe practices and procedures
– Work only when properly trained
– De-energize, lock and tag-out
– Wear correct PPE
– Maintain training
Authorization Levels

Authorized

Qualified

Unqualified
Electrical Safe Work Condition
Energized Work Permit
Electrical Shock
Shock Approach Boundaries

Limited Approach

Exposed, Restricted Approach

energized
conductor
Prohibited Approach
Approach Boundary Distances

Voltage L-L Limited Restricted Prohibited

Approach Approach Approach
Boundary Boundary Boundary

50 – 300 V 3’ – 6” Avoid Contact Avoid Contact

301 – 750 V 3’ – 6” 1’ – 0” 0’ – 1”
Arc Flash/Blast
Arc Flash Boundary

Arc Flash
Boundary
Exposed,
energized
conductor
Labeling of Equipment

Nominal
Voltage

Hazard/Risk
Category
Approach
Boundaries
Flash
Boundary
Standard Personal Protective Equipment

Safety Glasses

Hearing Protection

8 cal/cm2 clothing
Leather Safety
Shoes
Rubber Insulating Gloves

Leather Protector
Rubber Insulating Glove
Arc Flash PPE Hazard/Risk Categories

H/R Cat 0 H/R Cat 1 H/R Cat 2

Arc Clothing Natural/Non 4 cal/cm2 8 cal/cm2

Melting

Safety Glasses Yes Yes Yes

Hearing Protection Yes Yes Yes

Leather Gloves Yes Yes Yes

Leather Shoes Yes Yes Yes

AR Face Shield No Yes Yes

Hard Hat No Yes Yes

AR Balaclava No No Yes
Table 130.7(C)
Boundaries
 Typical ATS Energized Components
Utility Power Lugs

Utility/Genset
Sensing

Load
Lugs

Power
Relays

Genset Power Lugs

Jack/Plug
Insulated Tools
Proper Meter Selection
Summary

In this lesson you have learned to:

– Describe the Responsibility of the employee
– Identify the Authorization levels
– Determine Approach Boundaries
• Shock Hazard
• Arc Flash Hazard
– Determine Appropriate PPE for work on energized
Automatic Transfer Switches
– Identify specific transfer switch hazards
Lesson 3: ATS Controls
Objectives

Describe the purpose of an ATS Control

Identify the typical Inputs to an ATS Control

Identify the typical Outputs from an ATS control

Describe the Time Delays used by ATS controls

Describe monitoring and sensing parameters
Introduction
ATS Controller

S1 Sensing Open S1

Outputs
S2 Sensing Open S2

S1 Position Inputs ATS Close S1

Controller
S2 Position Close S2
Inhibits S2 Start
Source 1 Power Sensing
from Utility

Source 1 Sensing
(All Phases)

to Load
ATS
Control

from Genset
Source 2 Power Sensing
from Utility

to Load
ATS
Control

Source 2 Sensing

from Genset
Source Sensing w/ PTs
from Utility

Source 1 Sensing PT

to Load
ATS
Control

Source 2 Sensing PT

from Genset
 Pickup

Nominal Voltage

Pickup Setting
Voltage

Source determined
acceptable

Time
 Dropout

Nominal Voltage

Dropout Setting
Voltage

Source determined
unacceptable

Time
Remote Start
Rmt. St.
Relay

ATS
Control
Position Sensing
Source 1 from Utility
Pos. Switch

S1 Position

to Load
ATS
Control

S2 Position

Source 2
Pos. Switch from Genset
Switch Control
from Utility
Power
Relays

Open S2
Close S1

to Load
ATS
Control

Close S2
Open S1

Switching
Mechanism

from Genset
 Display

Util. Avail Util. Connect Gen. Connect Gen. Avail

Display LEDs

Typical ATS Display

Operator Input

Util. Avail Util. Connect Gen. Connect Gen. Avail

Test Exercise Override

Test/Exercise
from Utility
Rmt. St.
Relay

to Load
ATS
Control
Time Delays

TDES

TDNE
ATS

TDPT Control

TDEN

TDEC

TDEL
Phase Rotation from Utility
A B C

to Load

A B C
Synchronizing
Transfer/ReTransfer Inhibit
from Utility

to Load
ATS
Control

Transfer ReTransfer
Inhibit Inhibit from Genset
Summary

In this lesson you have learned to:

– Describe the purpose of an ATS Control
– Identify the typical Inputs to an ATS Control
– Identify the typical Outputs from an ATS control
– Describe the Time Delays used by ATS controls
– Describe monitoring and sensing parameters
Lesson 4: ATS Mechanisms
Objectives

Describe the different Switch Types used in CPG

transfer switches

Describe the different types of Switch Actuators used
in CPG transfer switches

Describe the purpose of Power Relays

Describe the purpose of Auxiliary Switches
Introduction

Switch
Auxiliary Actuator
Switches

Switch
Mechanism

Power Relays
Switch Mechanism Types

Load Interrupter

Cassette Contactor

Electrically Operated Breaker
 Load Interrupter
Source Lugs Arc Chute

A B C N

Contact
Cross
Bar

Load Lugs

Spring Mechanism
Arc Chutes (Load Interrupter)
Cassette Contactor (OHPC/CHPC)
Source 1 From Source 1
Opening Cam (Stationary)

Movable
Contacts

Contact
Closing
Springs
To Load

From Source 2
Source 2 (Stationary)
Opening Cam
Electrically Operated Breaker (PLT)
Switch Actuators

Solenoid

Linear Motor

Charge Motor/Tensioned Springs
Solenoid
Solenoid
Shaft

Solenoid
Housing

Coil
Typical Solenoid Mechanism
Linear Motor

Motor
Shaft

Coil
A
Linear
Motor
Housing

Coil
B

Typical Linear Motor Mechanism

Charge Motor/Tensioned Springs
Tensioned
Springs
Trigger Solenoid

Charging/Rewind Motor
Power Relays

Relays

Contactors
Relays
Movable, Hinged
Contact Coil

Normally
Closed Common Three-pole

Normally
Open
Contactors
Power Relays

Contactors

Relays
Auxiliary Switches
Summary

In this lesson you learned to:

– Describe the different Switch Types used in CPG transfer
switches
– Describe the different types of Switch Actuators used in
CPG transfer switches
– Describe the purpose of Power Relays
– Describe the purpose of Auxiliary Switches
Lesson 5: Basic Sequence of
Operation
Objectives

Describe the Normal Operating conditions of an OT

Automatic Transfer Switch

Demonstrate the operations required to Transfer the
OT ATS from Utility to Genset

Demonstrate the operations required to ReTransfer
the OT ATS from Genset back to Utility

Sequence the Time Delays used by the ATS control
 Introduction
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Normal
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Loss of Utility
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 TDES
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Start Genset
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Genset Available
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 TDNE
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Open from Utility
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 TDPT
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Close to Genset
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Monitor Utility
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Utility Returns
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 TDEN
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 TDEL
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Open from Genset
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 TDPT
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Close to Utility
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 TDEC
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
 Shutdown Genset
U
Utility Voltage
Utility Position

Open S2

Power Relays
ATS Control

Close S1
Close S2 L
Open S1

Genset Position
Genset Voltage
Rmt St

G
Summary

In this lesson you have learned to:

– Describe the Normal Operating conditions of an OT
Automatic Transfer Switch
– Demonstrate the operations required to Transfer the OT
ATS from Utility to Genset
– Demonstrate the operations required to ReTransfer the OT
ATS from Genset back to Utility
– Sequence the Time Delays used by the ATS control
Lesson 6: EC Hardware
Objectives

Identify the main components of the EC transfer

switch control

Identify and explain the function of the LED’s and
Pushbuttons on the EC control panel

Identify and explain the function of each of the
terminal blocks on the EC control panel
Exterior of EC Transfer Switch

OTEC Control
Panel

Optional Cover
Guard
 EC Control Panel

Configuration
LEDs

Indicator
LEDs

Pushbuttons
Configuration LEDs

Function
Indicator
LEDs

Value
Indicator
LEDs
ATS Status LEDs

Util. Genset
Available Available
LED LED

Util. Genset
Connected Connected
LED LED
Pushbuttons

Set Exercise
Test
Override
Inside of the Door
EC Control
Panel

GTEC

OTEC
Rear View of EC Control Panel
P5

P4

Serial No

P3

Configuration
Switch
P3 – Voltage Sensor Inputs
P4 - Inputs
Terminal Block P5 - Outputs
Summary

In this lesson you have learned to:

– Identify the main components of the EC transfer switch
control
– Identify and explain the function of the LED’s and
pushbuttons on the EC control panel
– Identify and explain the function of each of the terminal
blocks on the EC control panel
Lesson 7: EC Features
Objectives

Describe how the EC Control monitors Utility and

Genset Power

Describe why the EC Control initiates Time Delays

Initiate an Exercise

Initiate a Test

Describe the purpose of Phase Check/Return to
TDPT
Utility Sensing

Sensor Available Set

Description Points
Undervoltage 95%
Pickup 90%
(% of Nominal)
90%
Undervoltage 85%
Dropout
(% of Nominal) 80%
70%

L1 L2 L3
Genset Sensing

Sensor Description Set Point

Undervoltage Pickup 90%
(% of Nominal)
Undervoltage Dropout 75%
(% of Nominal)
Underfrequency Pickup 90%
(% of Nominal)
Underfrequency 85%
Dropout
(% of Nominal)

L1 L3
Control Power
Ground B+ Input
 Test

Test
LED

Test Pushbutton
Exercise

Set Exercise Pushbutton Exercise LED

EC Time Delays

Time Delay Engine Start

Time Delay Normal to Emergency

Time Delay Program Transition

Time Delay Emergency to Normal

Time Delay Elevator Pretransfer

Time Delay Engine Cooldown
Phase Check Sensor/Return to TDPT

Both Sources must

be available
Summary

In this lesson you have learned to:

– Describe how the EC control monitors Utility and Genset
Power
– Describe why the EC control initiates Time Delays
– Initiate an Exercise
– Initiate a Test
– Describe the purpose of Phase Check/Return to TDPT
Lesson 8: EC Configuration
 Objectives

Demonstrate how to put the EC control into

configuration mode

Identify the function and value being configured
by deciphering the indicator LEDs

Change the function being configured

Change the value of the function

Save the configuration

129 3/26/2015 Cummins Confidential

Configuration Mode

Configuration
Switch
Front Panel Indicator LEDs

Function
Indicator LEDs Value
Indicator LEDs
Configurable Functions in Service Manual
 Configuring the EC Control

Test Pushbutton Override

Pushbutton
133 3/26/2015 Cummins Confidential
Saving Configuration

Configuration
Switch
Summary

In this lesson you have learned to:

– Illustrate how to put the EC control into configuration mode
– Identify the function and value being configured by
deciphering the indicator LEDs
– Change the function being configured
– Change the value of the function
– Save the configuration
Lesson 9: EC Sequence of Operation
Objectives

Describe the EC ATS controls inputs and outputs

during Transfer from Utility to Genset

Describe the EC ATS controls inputs and outputs
during Retransfer from Genset to Utility
Introduction
Normal Operating Conditions
S1 S2

Utility
Sensing
Loss of Utility
S1 S2

Utility
Sensing
Start Genset Rmt St

S1 S2

Utility
Sensing
Genset Available Rmt St

S1 S2

Utility
Sensing
Gen
Sensing
Open from Utility Rmt St
Open
S1 S2 S1

Utility
Sensing
Gen
Sensing
Close to Genset Rmt St
Open Close
S1 S2 S1 S2

Utility
Sensing
Gen
Sensing
Utility Returns Rmt St

S1 S2

Utility
Sensing
Gen
Sensing
TDEN/TDEL Rmt St
Elev.
S1 S2 Relay

Utility
Sensing
Gen
Sensing
Open from Genset Rmt St
Open
S1 S2 S2

Utility
Sensing
Gen
Sensing
Close to Utility Rmt St
Close Open
S1 S2 S1 S2

Utility
Sensing
Gen
Sensing
Shutdown Genset
S1 S2

Utility
Sensing
Gen
Sensing
Summary

In this lesson you have learned to

– Describe the EC ATS controls inputs and outputs during
Transfer from Utility to Genset
– Describe the EC ATS controls inputs and outputs during
Retransfer from Genset to Utility
Lesson 10: OT Hardware
Objectives

Identify the major components of the OT 40-1200A

Mechanism

Describe the function of each piece of hardware of
the OT 40-1200A Mechanism

Repair/Replace commonly repaired components
Introduction Inside the
Cabinet

ATS
Door
Inside of the Door Components

Power S1 Switch
Relays

J1 and J2
Power Relays

K1

K2

K3
J1 and J2

J1

J2
S1 Switch
S1 Switch
 Inside of the Cabinet Components
Utility Connections
Utility Auxiliary
Utility Side
Switches
Contacts

Crossbar
TB1
Linear Motor
Capacitor

CB1 Load
Connections
Mechanical
Interlock
TB2
Genset
Contacts

Genset Connections
Genset Auxiliary
Switches
Utility Auxiliary Switches

S2 S3 S4 S5
Genset Auxiliary Switches

S6 S7 S8 S9

Genset Auxiliary Switches

TB1
TB2
Linear Motor
CB1
Motor Starting Capacitor
Summary

In this lesson you learned to:

– Identify the major components of the OT 40-1200A
Mechanism
– Describe the function of each piece of hardware of the OT
40-1200A Mechanism
– Repair/Replace commonly repaired components
Lesson 11: OT Sequence of
Operation
 Objectives

List the main signals sent to the ATS control by the

OT mechanism

Describe the signals sent by the ATS control to the
OT mechanism for operation

Describe the sequence of operation of the OT
transfer switch and what signals are present at any
point in the sequence

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 Introduction
Utility Aux Switches Utility Sensing

S1
K1 Switch

K2

S2
K3 J1 Switch
J2

Genset Aux Switches Genset Sensing

Linear Motor
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 Normal Operating Conditions

K1

K2

K3 J1

J2

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 Loss of Utility

K1

K2

K3 J1

J2

171 3/26/2015 Cummins Confidential

 Genset Available

K1

K2

K3 J1

J2

172 3/26/2015 Cummins Confidential

 Open from Utility

K1

K2

K3 J1

J2

173 3/26/2015 Cummins Confidential

 Close to Genset

K1

K2

K3 J1

J2

174 3/26/2015 Cummins Confidential

 Utility Returns

K1

K2

K3 J1

J2

175 3/26/2015 Cummins Confidential

 Open from Genset

K1

K2

K3 J1

J2

176 3/26/2015 Cummins Confidential

 Close to Utility

K1

K2

K3 J1

J2

177 3/26/2015 Cummins Confidential

 Shutdown Genset

K1

K2

K3 J1

J2

178 3/26/2015 Cummins Confidential

 Summary

In this lesson you learned to:

– List the main signals sent to the ATS control by the OT
mechanism
– Describe the signals sent by the ATS control to the OT
mechanism for operation
– Describe the sequence of operation of the OT transfer
switch and what signals are present at any point in the
sequence

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Lesson 12: GT Hardware
Objectives

Identify the major components of the GT 20-500A

Mechanism

Describe the function of each piece of hardware of
the GT 20-500A Mechanism

Repair/Replace commonly repaired components
Introduction

Control Utility Connections

Fuses
GT Mechanism

Power
Relays Position
Switches

Customer Load
Terminal Connections
Block

Genset
Mechanism Connections
Control
Source/Load Connections
Utility Connections

Genset Connections

Load Connections
Power Relays

K1

K2

K3

K4
Utility Auxiliary Contact

ASW1
Genset Auxiliary Contact

BSW1
TB-1
Control Fuses

FM1

FM2

FM3

FM4

FS1

FS2

FB
Switch Indicators Utility Switch
Indicator

Genset Switch
Indicator
Manual Operation

Manual Trip Source Select

Switch Switch

Manual Operation Handle

GT Mechanism Control
Summary

In this lesson you have learned to:

– Identify the major components of the GT 20-500A
Mechanism
– Describe the function of each piece of hardware of the GT
20-500A Mechanism
– Repair/Replace commonly repaired components
Lesson 13 - GT Sequence of
Operation
Objectives

List the main signals sent to the ATS control by the

GT mechanism

Describe the signals sent by the ATS control to the
GT mechanism for operation

Describe the sequence of operation of the GT
transfer switch and what signals are present at any
point in the sequence
 Introduction Utility Sensing
Indicators

K1 ON

K2

K3
OFF

K4

GT Control Genset
Wiring Sensing
Normal Operating Conditions

ON

OFF
Loss of Utility

ON

OFF
Genset Available

ON

OFF
Open from Utility

OFF

OFF
Close to Genset

OFF

ON
Utility Returns

OFF

ON
Open from Genset

OFF

OFF
Close to Utility

ON

OFF
Shutdown Genset

ON

OFF
Summary

In this lesson you have learned to:

– List the main signals sent to the ATS control by the GT
mechanism
– Describe the signals sent by the ATS control to the GT
mechanism for operation
– Describe the sequence of operation of the GT transfer
switch and what signals are present at any point in the
sequence
Lesson 14: GATRR Approach to
Troubleshooting
 5 Step Troubleshooting Approach

Gather

Analyze

Test

Repair

Retest

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 Gather

Gather information and speak with the operator

Determine the symptom of the faulty transfer switch
– Will not transfer, retransfer, nuisance starting, etc.

Perform a visual inspection of the overall area to
ensure that it will be safe to perform an operation
check (JSA)

Check for the following:
– Electrical damage to contacts or components
– Loose wiring
– Indicator LED’s
– Fault/Event history

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 Gather cont.

Test the transfer switch to replicate the problem

Write down all symptoms outside of normal operation

If the switch is still displaying the problem, move on
to the next step
– For correct operation of a transfer switch, you need the
following
• Voltage/Frequency sensing
• Position Sensing
• Power available to transfer/retransfer

DOCUMENT!

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 Analyze

Isolate the System
– Narrow Down the possibilities by system
– Remove customer wiring
– If it doesn’t transfer, does it retransfer?

START WITH THE BASICS
– Genset doesn’t start?
• Remote Start wiring, Genset problem, TDES
– Switch doesn’t transfer?
• Genset voltage, inhibit(s), K2/K3, TDNE
– Switch doesn’t retransfer?
• Utility voltage, inhibit(s), K1/K3, TDEN
– Genset doesn’t shutdown?
210 • Remote Start
3/26/2015 wiring,
Cummins TDEN
Confidential
 Test

Test the Likely Problem Components

– Test components in order of likeliness based on
troubleshooting trees and symptoms that are present

Perform Manufacturers Recommended Test

Can the component be fixed or does it need to be
replaced?

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 Repair

Perform Repair
– Make sure to check with customer

Double check that the component to be replaced is
the problem component
– Ensure the test performed was done correctly and the
proper solution was reached

Ensure that the proper procedures are followed
based on the manufacturing guidelines

DOCUMENT!

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 Retest

Test the transfer switch to ensure that the problem is

fixed

Perform entire sequence – genset start, transfer,
retransfer, genset shutdown

If the transfer switch still doesn’t operate correctly, is
it displaying the same symptom(s)?
– Are there multiple faults

DOCUMENT! Ensure proper documentation for all
worked performed is completed

213 3/26/2015 Cummins Confidential

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