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O & M Manual for the CHGEN Automatic Transfer Switch

1. GROUND BAR C BASE PLATE COMPONENT PART NUMBER ATS MODEL Contactor 8160A99G51 100 A Contactor 8160A99G52 200 A Generator Controller Board 8160A99G33 100 amp 200A Ground Bar 8160A99G55 100 amp 200A Load Shed Option 8160A99G36 100 amp 200A Lugs 8160A99G56 100A Lugs 8160A99G57 200 A Neutral Bar 8160A99G53 100 A Neutral Bar 8160A99G54 200 A Service Entrance Breaker 8160A99G41 100 A Service Entrance Breaker 8160A99G42 200 A Service Entrance Cover 8160A99G45 100 amp 200A Service Entrance Lugs 8160A99G643 100A Service Entrance Lugs 8160A99G44 200A Generator Breaker SE Only Option 8160A99G41 100A Generator Breaker SE Only Option 8160A99G42 200A Generator Breaker Lugs SE Only Option 8160A99G43 100A Generator Breaker Lugs SE Only Option 8160A99G44 200A SurgTel 8160A99G48 100 amp 200A SurgCable 8160A99G49 100 amp 200A TVSS Internal SE Only Option 8160A99G46 100 amp 200A TVSS External Standard or SE Option 8160A99G47 100 amp 200 A Wiring Harness 1 8160A99G34 100 amp 200 A Note 1 When replacing the wiring harness on the 100 A ATS the flag must be cut off the one white wire and replaced with the appropriate size ring terminal For more information visit www eaton com IBO01602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch A WARNING HIGH VOLTAGES ARE PRESENT IN AND AROUND TRANSFER SWITCH EQUIPMENT BEFORE ATTEMPTING TO REPLACE A
2. Figure 48 Location of the Generator Breaker Lugs Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to OFF position before attempting to replace the generator breaker s line side lugs Step 2 Remove the generator breaker from the ATS by following steps 1 through 5 in Section 6 4 1 10 Step 3 Working from the rear of the generator breaker remove the two 2 screws securing the lugs to the stabs using a Phillips screwdriver See fig 49 REI TT on lt fi AA Ses ure 49 Location of the Screws Securing the Lugs to the Stabs f Fig Step 4 Remove the lugs from the stabs Step 5 Slide the new lugs over the stabs until the holes in each are aligned www eaton com Instructional Booklet Page 30 Effective January 2008 Step 6 Secure the new lugs to the stabs using the hardware Step 7 Reinstall the generator breaker in the ATS by following the steps 6 through 10 in Section 6 4 1 10 Step 8 Apply utility Source 1 power and place the generator Source 2 control selector switch in the AUTO position after the generator breaker lugs have been replaced Test the system for proper functionality 6 4 1 13 Service Entrance Cover Service Entrance Breaker and Generator breaker Figure 50 Service Entrance Cover Installed on the ATS Door Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selecto
3. 200 A 100 A SE and 200 A SE CHGEN ATSs Step 3 Disconnect the Neutral N1 1 N Coil N Aux N C E Aux N C E Coil and E2 female flag connectors from the generator controller board Refer to the wiring diagram in Figure 20 for connection locations on the generator con troller board see Figure 25 Note All wires connected to the generator controller board are labeled to ease identification www eaton com Instructional Booklet Page 20 Board Step 4 Step 5 Step 6 Step 7 ay S ae I a 2 d Figure 25 Wires to Disconnect from the Generator Controller Effective January 2008 wy Rite i AS ey tae CAR yo TROEN gt AN Ar X Non rea AAE ee allan gi a ro NG p x a ke wy b SS t3 toe bs a el 2 int ee i Remove the two 2 screws securing the generator con troller board to the base plate using a blade screwdriver Remove the generator controller board Orient the new generator controller board as per the origi nal installation then align the controller board with the existing holes in the base plate Secure the new genera tor controller board to the base plate using the hardware supplied see Figure 23 or 24 Connect the Neutral N1 N2 N Coil N Aux N C E Aux N C E Coil and E2 female flag connectors to the new generator controller board Refer to the wiring diagram in Figure 20 for connection locations on the generator con troller board see Figure 25 Apply
4. Step 12 Secure the green yellow TVSS wire to a receptacle on the ground bar using a blade screwdriver see Figure 70 GREEN YELLOW WIRE Figure 70 TVSS Green Yellow Wire Connected to the Ground Bar Step 13 Using the wires cut from the red and black TVSS wires in Step 7 if long enough or 600 V 14 AWG wire make two 2 wire leads that will run from the TVSS fuse block to the male spade connectors at the utility lugs on the contactor see Figure 71 For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Figure 71 Connection Points at the TVSS Fuse Block and Utility Lugs Step 14 Remove the wiring harness connections at the male flag terminal at the N 1 utility lug Remove the crimp on female flag connector Strip 0 25 in 6 35 mm of insu lation from the end of the TVSS wire and the N 1 har ness wires Using the new crimp on female flag connector supplied connect the N 1 harness wires with one of the TVSS leads see Figure 71 Step 15 Repeat the process for the N 2 wires Step 16 Reconnect the N 1 and N 2 female flag connectors to the N 1 and N 2 male flag terminals at the utility lugs Step 17 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the internally mounted TVSS has been installed Test the system for proper functionality 7 3 SurgeTel Installation Not
5. a mI a sA An lt in EDN f nm hy N i NA Figure 28 Replacing the 200 A Neutral Bar Step 6 Secure the new neutral bar assembly to the base plate using the hardware supplied Step 7 If the neutral bar being replaced was grounded use the copper connector 10 32 x 0 625 in screw and 1 4 20 x 0 50 in bolt removed in Step 4 to ground the neutral bar to the base plate see Instruction Leaflet supplied with the grounding kit for more information Step 8 Connect the flag to the wire terminal on the back of the neutral bar IB01602014E For more information visit instructional Booklet Effective January 2008 Page 21 Step 9 Reconnect all wire cables to the neutral bar Step 10 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the SE neutral bar has been replaced Test the system for proper functionality 6 4 1 4 Ground Bar Note The 100 A ground and neutral bars are the same Refer to Figure 26 for the correct location Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the ground bar Step 2 Disconnect all wire cables from the ground bar Step 3 Remove the 1 5 in long screw at the top of the ground bar see Figure 29 using a Phillips screwdriver Figure 29 Replacing the Ground Bar Step 4 Remove the screw in the bl
6. originally closed in Step 1 of Section 5 2 NOTICE THIS WILL SIMULATE AN INTERRUPTION OF THE UTILITY SOURCE 1 POWER SOURCE Step 2 After a time delay the standby generator engine will start Step 3 The ATS Time Delay Normal Utility to Emergency Gen erator TDNE will begin to time after the generator engine begins to run After time out the solenoid will engage and the contactor will automatically switch from the UTILITY to the GENERATOR Source 2 position E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Step 4 Using a voltmeter measure the line to line and line to neu tral voltages across the generator line terminals to ensure that the generator emergency voltage is correct If neces sary make adjustments to the voltage regulator on the generator according to the manufacturer s recommenda tions to correct any voltage deviations The ATS will only respond to the correct voltage from the generator power source Step 5 Close the utility breaker described in Step 1 of Section 5 2 Step 6 The ATS Time Delay Emergency Generator to Normal Utility TDEN timer will begin timing and the solenoid will engage and automatically switch from the GENERA TOR to the UTILITY position and the generator will shut down For more information visit www eaton com IB01602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch SECTION 6 MAINTENANCE AND
7. 2 side of the contactor For more information visit www eaton com a Mi aly i E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch te sg Figure 45 Location of the Top Generator Breaker Mounting Screw Step 5 Step 6 Step 7 Step 8 Step 9 Remove the screw securing the top of the generator breaker to the mounting bracket using a blade screw driver or 0 25 in nut driver Remove the generator breaker from the ATS see Figure 45 Align the new generator breaker with the holes in the mounting bracket Loosely secure the top of the genera tor breaker to the mounting bracket using the hardware provided Firmly tighten the screw securing the top of the generator breaker to the mounting bracket Reconnect the jumpers between the generator breaker and the lugs at terminals E1 amp E2 on the generator Source 2 side of the contactor using the screws and hardware provided Reconnect the cables to the lugs on the line side of the generator breaker using the lug screws and 6mm allen wrench provided Step 10 Apply utility Source 1 power and place the generator selector switch in the AUTO position after the genera tor breaker has been replaced Test the system for proper functionality IBO1602014E E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch 6 4 1 11 Service Entrance Breaker Lugs 100 and 200A B e wine Y USE 7
8. CHGEN Automatic Transfer Switch Step 8 Next insert a blade screwdriver or 5 16 in socket or nut driver up through the load lug terminal hole and remove the hardware securing the two 2 generator lugs see Figure 39 Remove the generator lugs Figure 39 Replacing the 200 A Lugs For SE Switch skip this step Step 9 Remove the hardware securing the 2 utility lugs using a blade screwdriver or 5 16 in socket or nut driver Remove the utility lugs For SE switch skip this step Step 10 Place the new utility lugs on the utility bus so the anti turn protrusions fit in the holes see Figure 38 Once the lugs are in place secure them to the utility bus using one 1 screw and one 1 washer supplied Repeat the process of the second utility lug Ensure that no gaps are present between the lugs and bus Step 11 Place the new generator lugs on the generator bus so the anti turn protrusions fit in the holes see Figure 38 Once the lugs are in place secure them to the generator bus using one 1 screw and one 1 washer supplied Repeat the process of the second generator lug Ensure that no gaps are present between the lugs and bus Step 12 Secure each load lug to the detached load bus using one 1 screw and one 1 washer supplied Step 13 Slide the completed load bus extension back into the contactor and secure each extension using the four 4 Phillips screws see Figure 39 For SE switches only Step 14
9. COMPONENT REPLACEMENT 6 1 Introduction A WARNING HIGH VOLTAGES ARE PRESENT IN AND AROUND TRANSFER SWITCH EQUIPMENT BEFORE INSPECTING OR MAINTAINING THIS EQUIPMENT DISCONNECT THE LINE POWER FROM THE EQUIP MENT BEING SERVICED BY OPENING AND LOCKING OUT IF POSSI BLE THE NEXT HIGHEST DISCONNECT DEVICE FAILURE TO FOLLOW THIS PROCEDURE COULD CAUSE SEVERE PERSONAL INJURY AND OR DEATH In general ATS equipment is designed to be relatively mainte nance free under normal usage However because of the variabil ity of application conditions and the importance placed on GENERATOR BREAKER NOTE A E1 GENERATOR SUPPLY VOLTAGE OPTIONAL LOAD SHED LOAD ENABLE CONTACTS Figure 20 Wiring Diagram for the CHGEN ATS IB01602014E TRANSFER MECHANISM instructional Booklet Effective January 2008 Page 15 dependable operation by this type of equipment inspection and maintenance checks should be made on a regularly scheduled basis Since equipment maintenance will consist mainly of keep ing the equipment clean the frequency of maintenance will depend to a large extent on the cleanliness of its surroundings If a significant amount of dust or foreign matter is present a more frequent maintenance schedule should be followed It is suggested that visual inspections of the equipment be made on a regular basis not just during regularly scheduled periods Always be alert for an accumulation of dirt in and around the struct
10. and the E1 E2 terminals on the generator Source 2 side of the contactor must be removed Follow steps 1 through 4 in Sec tion 6 4 1 9 for 100A amp 200A Service Entrance breaker and steps 3 amp 4 in Section 6 4 1 10 for 100A amp 200A generator breaker Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the service entrance breaker Step 2 Disconnect all wire cables from the contactor Step 3 Note their location then disconnect the twelve 12 red wires from the contactor see Figure 33 Note All wires connected to the contactor are labeled to ease identification For SE ATSs only Step 4 Remove the hardware securing the utility bus extensions to the contactor and SE Breaker Remove the utility bus extension For all ATSs Step 5 Remove the four 4 screws securing the contactor to the base plate using a blade screwdriver or 0 25 in socket or nut driver Step 6 Remove the load lugs first by removing the four 4 Phil lips screws from the back of the contactor using a Phillips screwdriver The load bus extension and load lugs can now be removed by sliding it away from the contactor see Figure 39 Step 7 Remove each load lug from the load bus using a blade screwdriver or 5 16 in socket or nut driver For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the
11. g Return the transfer switch equipment to service Make certain all barriers are in place and the door is closed Re apply generator Source 2 and utility Source 1 power For more information visit www eaton com IB01602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch instructional Booklet Effective January 2008 Page 17 6 3 Maintenance Log DATE Example 01 01 05 ACTION Inspected and cleaned IBO1602014E For more information visit www eaton com Instructional Booklet Page 18 Effective January 2008 6 4 Component Replacement Certain components within the ATS are field replaceable Figure 21 identifies the field replaceable parts Table 4 lists the part GENERATOR CONTROLLER BOARD CONTACTOR As BAR UTILITY LUGS GENERATOR GROUND BAR LUGS x LOAD LUGS HARNESS ta BASE PLATE Figure 21 Field Replaceable Components Left 100 A Standard Right 200 A SE Table 4 Field Replaceable Components E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch numbers to use when ordering replacement components To order replacement components contact an authorized Eaton sales repre sentative HARNESS SERVICE ENTRANCE BREAKER GENERATOR CONTROLLER BOARD GENERATOR i BREAKER LUGS GENERATOR BREAKER
12. genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the service entrance breaker Step 2 Disconnect the cables from the lugs on the line side of the service entrance breaker using a 6mm allen wrench Step 3 Remove the two 2 bolts lock washers and flat washers securing the utility bus extension stabs between the con tactor and SE breaker Using a 7 16 in wrench nut driver or socket and ratchet remove the utility bus extension stabs see Figure 41 IBO1602014E instructional Booklet Effective January 2008 Page 27 Figure 41 Stab Connections at the Service Entrance Breaker Step 4 Remove the screw securing the top of the service entrance breaker to the mounting bracket using a blade screwdriver or 0 25 in nut driver Remove the service entrance breaker from the ATS see Figure 42 Figure 42 Location of the Top Service Entrance Breaker Mounting Screw Step 5 Align the new service entrance breaker with the holes in the mounting bracket and the contactor bus connections Note that the stabs of the service entrance breaker should be between mounting bracket red insulating blocks and the contactor bus connections Step 6 Loosely secure the top of the service entrance breaker to the mounting bracket using the hardware provided see Figure 42 Step 7 Align the utility lug extension stabs with the SE breaker and contactor Firmly secure the utility b
13. har ness and the white wire from the optional TVSS if Strip 0 25 in 6 35 mm of insulation from the end of each of the wires then crimp the supplied larger female r flag connector onto the wires Connect the female flag Figure 87 Load She connector to the male flag terminal on the neutral bar see Figure 86 Refer to the wiring diagram in Figure 20 for 7 connection locations for the load shed wires Step 4 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the load shed has been replaced Test the system for proper functionality d Wire Connected to the Normally OPEN Terminal on the Auxiliary Switch Note Terminals 1 through 12 on the load shed provide a number of options for taking advantage of the functionality of the load shed Refer to Figure 88 for a diagram illustrating the use of these terminals to take advantage of its functionality For more information visit www eaton com IB01602014E E Ten Cutler Hammer Instructional Booklet Effective January 2008 Page 41 O amp M Manual for the CHGEN Automatic Transfer Switch 1 N C 2 N C 3 N C 4 N C E ai a 5 N O 6 N O 7 N O 8 N O 9 Com 10 Com 11 Com 12 Com 13 14 Figure 88 Additional Connections at the Load Shed Step 5 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the load shed has been replaced Tes
14. ordered an optional TVSS the TVSS will be included with the CHGEN ATS but it is up to the installer to mount and wire the TVSS and associated fuse block See examples in Figures 6 and 7 and see Sections 7 1 and 7 2 for complete instruction for install ing the optional TVSS 1 2 4 Optional Load Shed Four sets of contacts are available and can be used to control large connected loads on the generator i e air conditioners hot tubs etc See Section 7 5 for complete instructions for installing the optional load shed VALT dSHD ENSET N a FAN Culler CHSP ULTRA Dia E Wy A O ie 2 Pole 120 240 VAC GOH WE E Cutler Hammer Circuit Breaker 200 Amp Figure 7 TVSS Mounted to the Outside of a Standard Enclosure 1 2 5 Optional Telephone and Cable Surge Protection The telephone line surge protection feature offers 4 pair telephone line protection The feature ships loose for customer mounting convenience See Section 7 3 The TV and satellite cable surge protection feature offers two 2 coaxial line protection cable satellite TV The feature ships loose roi ED for customer mounting convenience See Section 7 4 Figure 6 TVSS and Load Shed Mounted in an SE Enclosure IBO1602014E For more information visit www eaton com Instructional Booklet Page 6 Effective January 2008 1 3 Transfer Switch Catalog Number Identification ATS equipment catalog numbers provide a significant amou
15. replaced Test the sys tem for proper functionality 6 4 1 6 Wire Harness Figure 31 Replacing the Wire Harness Step 1 Turn the utility Source 1 power off and turn the generator Source 2 control selector switch to the OFF position before attempting to replace the wiring harness Step 2 Disconnect the installer connected control wiring from the utility sensing fuse block Step 3 Remove the Utility sensing fuses from the fuse block to gain access to the fuse block mounting screws see Fig ure 32 IBO1602014E E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch J coni eorna Ta scores Step 4 Remove the two 2 screws securing the utility sensing fuse block to the base plate using a blade screwdriver or 0 25 in nut driver see Figure 32 Step 5 Note their location then disconnect the twelve 12 red wires from the contactor Refer to the wiring diagram in Figure 20 for connection locations on the contactor see Figure 33 Note All wires connected to the contactor are labeled to ease identifica tion Ei JE COI M lt FUSEBLOCK K Figure 33 Wires to Disconnect from the Contactor Note If the load shed option has been installed in the ATS DO NOT remove the red wire running from the load shed to the auxiliary switch on the right side of the contactor IB01602014E instructional Booklet Effective January 2008 Page 23 Figure
16. switch in the AUTO position after the wiring harness has been replaced Test the system for proper functionality IB01602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch 6 4 7 7 Replacing the 100 A Lugs ar UTILITY EN _ te a Figure 37 Repiacihg ih 100 A TN Note If you are replacing the lugs in 100A SE ATS the service entrance breaker must be removed first Also jumpers between the generator breaker inside ATS and the E1 E2 terminals on the generator Source 2 side of the contactor must be removed Follow steps 1 through 4 in Sec tion 6 4 1 9 for 100A amp 200A Service Entrance breaker and steps 3 amp 4 in Section 6 4 1 10 for 100A amp 200A generator breaker Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the service entrance breaker Step 2 Step 3 Disconnect all wire cables from the contactor Note their location then disconnect the twelve 12 red wires from the contactor see Figure 33 Note All wires connected to the contactor are labeled to ease identification For SE ATSs only Step 4 Remove the hardware securing the utility bus extensions to the contactor and SE Breaker Remove the utility bus extension For All ATSs Step 5 Remove the four 4 screws securing the contactor to the base plate using a blade
17. the TVSS Step 1 Remove the screw in the middle of the back of the new SurgeCable using a Phillips head screwdriver Attach the auxiliary ground terminal strip provided to the back of the SurgeCable using the Phillips head screw just removed see Figure 81 Figure 78 SurgeCable Mounted Externally When the TVSS Is Internally Mounted in a SE ATS For more information visit www eaton com IB01602014E E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Auxiliary Ground Strip Mounted to the SurgeCable Figure 81 Step 2 Secure the SurgeCable to an acceptable mounting sur face near the ATS using the screws supplied Step 3 Connect the supplied ground wire to the auxiliary ground strip using the screw provided Step 4 Turn the utility Source 1 power off and turn the gener ator Source 2 control selector switch to the OFF position before attempting to connect the ground wire to the ATS Step 5 Route the ground wire into the ATS to the ground bar Secure the ground TVSS wire to a receptacle on the ground bar using a blade screwdriver Step 6 Apply utility Source 1 power and place the generator control selector switch in the AUTO position 7 4 3 Connecting the Cables to the SurgeCable Step 1 Reroute the coaxial cables to the SurgeCable Step 2 Connect the coaxial cables to the applicable In and Out terminals on the SurgeCable Note See the I
18. the event the utility power source fails and the generator power source does not appear the ATS remains connected to the utility power source until the generator power source does appear Conversely if connected to the generator power source and the generator power source fails while the utility power source is still unavail able the ATS remains connected to the generator power source ATSs automatically perform the transfer function and include three basic elements 1 Main contacts to connect and disconnect the load to and from the source of power 2 Solenoids to make the transfer of the main contacts from source to source 3 Intelligence supervisory circuits to constantly monitor the con dition of the power sources and thus provide the intelligence necessary for the switch and related circuit operation IBO1602014E For more information visit Instructional Booklet Effective January 2008 Page 3 1 2 1 Design Configuration The Eaton ATS is a rugged compact design that utilizes contac tors to transfer essential loads from one power source to another see Figure 3 The ATS contains suitable mechanical and electri cal interlock switches to eliminate the possibility of connecting the utility service to the generator output In addition a manual over ride lever is provided for the transfer function A WARNING DO NOT MANUALLY TRANSFER THE SWITCH WHILE UNDER LOAD Figure 3 CHGEN ATS 100 A 1 2 2 Optio
19. tion before attempting to replace the TVSS For more information visit www eaton com IB01602014E E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch 60H 40 C Circuit Breaker 200 Amp 120 240 VAC Figure 65 Note The length of the four 4 TVSS wires can affect the performance of the TVSS During installation the wires should be kept as short and as close to identical length as possible In keeping the length of the wires as equal as possible they should be braided to increase the effectiveness of the TVSS Step 6 Based on the following connection points and wire rout ing determine which TVSS wire s will be the longest WIRE COLOR CONNECTION POINT Red TVSS fuse block Black TVSS fuse block White ATS neutral bar Green Yellow ATS ground bar Cut all four 4 wires to the same length necessary to reach the furthest connection point Braid any excess wire length for the other connection points VuLin dSH Jawwep sanny t NLS J _ Figure 66 Braided TVSS Wires Step 7 The red and black wires from the TVSS are to be con nected to the terminals of the TVSS fuse block Strip 0 25 in 6 35 mm of insulation from the end of the wires Step 8 Connect the red and black TVSS wires to the TVSS fuse block as shown using a blade screwdriver see Figure 67 IBO1602014E instructional Booklet Effective January 2008 Page 35 Fuse Blo
20. utility Source 1 power and place the generator control selector switch in the AUTO position after the generator controller board has been replaced Test the system for proper functionality For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch 6 4 7 2 100 A Neutral Bar Note The 100 A ground and neutral bars are the same Refer to Figure 26 for the correct location Figure 26 100 A Neutral Bar Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the neutral bar Step 2 Disconnect all wire cables from the neutral bar Step 3 If the neutral bar has been grounded remove the 1 5 in screw that grounds the neutral bar to the base plate see Instruction Leaflet supplied with the grounding kit for more information Step 4 Remove the screw in the black base using a blade screw driver or 0 25 in socket or nut driver Remove the neu tral bar see Figure 27 Figure 27 Replacing the 100 A Neutral Bar Step 5 Remove the screw securing the white wire to the neutral bar using a blade screwdriver or 0 25 in socket or nut driver Step 6 Attach the white wire to the new neutral bar using the hardware supplied Step 7 Mount the neutral bar to the base plate using the hard ware supplied IBO1602014E E T N Cutler Hdam
21. 34 Optional Load Shed Wire Connected to the Auxiliary Switch on the Contactor Step 6 Disconnect the Neutral N1 N2 N Coil N Aux N C E Aux N C E Coil and E2 female connectors from the gen erator controller board Refer to the wiring diagram in Fig ure 20 for connection locations on the generator controller board see Figure 35 Note All wires connected to the generator controller board are labeled to ease identification Aie a SES eS i ie 2 HOS A CEON Figure 35 Wires to Disconnect from the Generator Controller Board MEC RS Step 7 Disconnect the white wire that runs from the generator controller board to the neutral bar On 100 A ATS use a blade screwdriver to remove the screw securing the white wire s ring terminal to the neutral bar Note If an optional load shed is installed in the 100 A ATS the screw securing the white wire to the neutral bar is also used to secure the red load shed wire The red load shed wire will have to be reattached to the neutral bar when the white wire in the new wiring harness is connected to the neutral bar later in this process On 200 A standard and SE ATSs remove the white wire from the flag connector on the neutral bar For more information visit www eaton com Instructional Booklet Page 24 Effective January 2008 Note If an optional load shed and or TVSS is installed in a 200 A standard or SE ATS the female flag connector is also used to connect the
22. 57 Ay kis E Figure 57 TVSS Red and Black Wires Connected to the TVSS Fuse Block Step 11 The white wire from the TVSS will be connected to the neutral bar Cut the white wire to a suitable length to connect to the neutral bar then strip 0 25 in 6 35 mm of insulation from the end of the wire Step 12 On 100 A standard ATSs secure the white TVSS wire to a receptacle on the neutral bar using a blade screw driver see Figure 58 Note On 200 A standard ATSs the white TVSS wire must be connected to the male flag receptacle on the neutral bar see Figure 59 Remove the female flag connector from the neutral bar Cut the female flag connector off of the white wire from the main wiring harness and the red wire from the optional load shed if installed Strip 0 25 in 6 35 mm of insulation from the white TVSS wire the white wire from the main wiring harness and red wire from the option load shed if installed Crimp the supplied female flag connector on the wires so they can be connected to the male flag terminal on the neutral bar IB01602014E Instructional Booklet Page 33 Effective January 2008 Valin dSH ETET N oD ke Danas _ Figure 59 TVSS White Wire Connected to the 200 A Neutral Bar Step 13 The green yellow wire from the TVS will be connected to the ground bar Cut the green yellow wire to a suit able length to connect to the ground bar then strip 0 25 in 6 35 mm of ins
23. ATSs are listed in File E38116 by Underwriters Laboratories Inc under Standard UL 1008 This standard covers the requirements for ATSs intended for use in ordinary locations to provide lighting and power as fol lows a In standby systems in accordance with article 702 of the National Electrical Code Eaton ATSs are available to meet NFPA 110 for standby power systems Eaton ATS equipment are listed for application by CSA In addi tion Eaton ATSs are listed in the Legacy File LR96245 Master Contract 163545 by Canadian Standards Association under Stan dard 22 2 178 1978 For more information visit www eaton com Instructional Booklet Page 8 Effective January 2008 SECTION 4 INSTALLATION AND WIRING 4 1 General Eaton ATSs are factory wired and tested Installation requires sol idly mounting the enclosed unit and connecting the power cables and the auxiliary pilot circuits Physical mounting procedures and power cable connections are covered in this section Once a transfer switch is properly installed and wired it should be mechanically and electrically checked for proper installation and operation The procedures for these initial mechanical and electri cal checks are outlined in Section 5 of this manual 1in 25 4mm_ Weight 26 lbs 11 8 kg Figure 8 For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch 4 2 Mounting Location Cho
24. Align the utility lug extension with the SE breaker and contactor Secure the utility bus extension to the SE breaker and contactor using the original hardware Note If you are replacing the lugs in a 200A SE ATS the service entrance breaker must be reinstalled at this time Also reconnect the jumpers between the generator breaker inside the ATS and the E1 E2 terminals on the generator Source 2 side of the contactor Follow steps 5 through 10 in Section 6 4 1 9 for 100A amp 200A Service Entrance breaker and steps 8 in Section 6 4 1 10 for 100A amp 200A generator breaker Step 15 Secure the contactor to the base plate using the four 4 screws supplied IBO1602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch Step 16 Reattach the twelve 12 red wires to the contactor Examine each wire to find the name then refer to Figure 33 for the correct connection point Step 17 Reconnect all wire cables to the contactor as per their original connections Step 18 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the service entrance breaker has been replaced Test the system for proper functionality 6 4 1 9 100 A and 200 A Service Entrance Breakers SERVICE ENTRANCE BREAKER GENERATOR BREAKER Figure 40 Service Entrance Breakers Installed 200 A SE ATSs Step 1 Turn the utility Source 1 power off and turn the
25. E TeN Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Instruction Booklet New Information Description Page IMEFOCGUIGION 2 4 2 5 cee Ge eee te oe se eee B S oe ee 2 Receiving Handling and Storage 000 eee eee 6 Equipment Description 2 0c eee ee ee et 7 Installation and Wiring 2 0 ee 8 Functional Testing 0 ce eee es 14 Maintenance and Component Replacement 15 Installing Optional Components 20002 eee 32 IB01602014E For more information visit www eaton com Instructional Booklet Page 2 Effective January 2008 A WARNING READ AND UNDERSTAND THE INSTRUCTIONS CONTAINED HEREIN AFTER 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 MAIN TENANCE PROCEDURES TO AVOID THESE VOLTAGES THE TRANSFER SWITCH EQUIPMENT COVERED BY THIS INSTRUC TION 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 SERI OUS BODILY INJURY AND OR PROPERTY DAMAGE ALL RESPON SIBLE PERSONNEL SHOULD LOCATE THE DOOR MOUNTED EQUIPMENT NAMEPLATE AND BE FAMILIAR WITH THE INFORMA TION PROVIDED ON THE NAMEPLATE A TYPICAL EQUIPMENT NAMEPLATE IS SHOWN IN FIGURE 1 Automatic
26. Instructional Booklet Page 14 Effective January 2008 SECTION 5 FUNCTIONAL TESTING A WARNING YOU ARE READY TO ENERGIZE THE EQUIPMENT VOLTAGES WITHIN THE ENCLOSURE ARE CAPABLE OF CAUSING SEVERE PER SONAL INJURY OR DEATH USE EXTREME CAUTION TO AVOID CONTACT WITH ENERGIZED EQUIPMENT 5 1 Preliminary Checks Step 1 Check all loads connected to the ATS to ensure that they are ready to be energized 5 2 Energize the Switch Step 1 Close the upstream utility Source 1 power source breaker or switch to connect the ATS to the utility power source voltage Step 2 If the ATS unit is not already in the UTILITY position the solenoid will engage and the contactor will automatically switch to the UTILITY position Step 3 Using a voltmeter measure the line to line and the line to neutral voltages across the utility line terminals to ensure the utility voltage is correct A WARNING CONTACT WITH ENERGIZED COMPONENTS WILL CAUSE ELECTRI CAL SHOCK CAPABLE OF PRODUCING SEVERE PERSONAL INJURY OR DEATH USE EXTREME CAUTION TO AVOID CONTACT WITH ENERGIZED COMPONENTS WHEN USING A METER FOR VOLTAGE CHECKS Step 4 Position the generator control selector switch located on the standby generator to the AUTO position Step 5 Close the upstream generator Source 2 power source breaker or switch to connect the ATS to the generator power supply source 5 3 Operational Checks Step 1 Open the upstream utility Source 1 breaker
27. Mounted TVSS Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to install the externally mounted TVSS Step 2 Determine the desired location for mounting the TVSS An existing 0 50 in 1 25 cm knockout can be used or a 0 50 in 1 25 cm hole can be drilled in the enclosure A CAUTION EXTREME CARE SHOULD BE TAKEN TO PROTECT THE ATS FROM DRILL CHIPS FILINGS AND OTHER CONTAMINANTS WHEN MAK ING THE TVSS MOUNTING HOLE TO PREVENT DAMAGE OR A FUTURE MALFUNCTION A CAUTION TO MEET APPLICABLE CODES AN EXTERNALLY MOUNTED TVSS MUST BE MOUNTED BELOW THE LEVEL OF THE BOTTOM LUGS LOAD LUGS OF THE CONTACTOR Figure 53 TVSS Must be Mounted Below the Level of the Load Lugs For more information visit E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Step 3 Remove the lock nut from the nipple of the TVSS Step 4 Feed the TVSS wires and mounting nipple through the knockout or hole drilled in the ATS enclosure Step 5 Secure the TVSS to the ATS enclosure using the lock nut removed in Step 3 Be sure to firmly secure the TVSS using an appropriate tool to fully tighten the lock nut see Figure 54 Figure 54 TVSS Secured to the ATS Enclosure Note The length of the four 4 TVSS wires can affect the performance of the TVSS During installation the wires should be kept as short and a
28. NY COMPONENT DISCONNECT THE LINE POWER FROM THE EQUIP MENT BEING SERVICED BY OPENING AND LOCKING OUT IF POSSI BLE THE NEXT HIGHEST DISCONNECT DEVICE FAILURE TO FOLLOW THIS PROCEDURE COULD CAUSE SEVERE PERSONAL INJURY AND OR DEATH ALWAYS TURN THE UTILITY SOURCE 1 POWER OFF AND TURN THE GENERATOR SOURCE 2 CONTROL SELECTOR SWITCH TO THE OFF POSITION BEFORE ATTEMPTING TO REPLACE ANY COM PONENTS NOTICE APPLY UTILITY SOURCE 1 POWER AND PLACE THE GENERATOR CONTROL SELECTOR SWITCH IN THE AUTO POSITION AFTER THE COMPONENT HAS BEEN REPLACED TEST THE SYSTEM FOR PROPER FUNCTIONALITY 6 4 1 Component Replacement Instructions 6 4 1 1 100 A and 200 A Controller Board Figure 22 Generator Controller Board Installed in the CHGEN ATS Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the generator controller board Step 2 Note the orientation of the generator controller board as it was mounted to the base plate at the factory see Figures 23 and 24 IBO1602014E For more information visit Instructional Booklet Page 19 Effective January 2008 EADE ar ewe A i Figure 23 Generator Controller Board as Mounted in a Standard 100 A CHGEN ATS Sr TS ACRE ae ie p a A ERIAN lt o aR LFP f t f Eas lI Figure 24 Generator Controller Board as Mounted in a Standard
29. PPLICATION OPER ATION OR MAINTENANCE OF THE EQUIPMENT IN ADDITION ONLY QUALIFIED PERSONS SHOULD BE PERMITTED TO PERFORM ANY WORK ASSOCIATED WITH THE EQUIPMENT ANY WIRING INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE FOL LOWED PRECISELY FAILURE TO DO SO COULD CAUSE PERMA NENT EQUIPMENT DAMAGE IBO1602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch 1 2 General Information ATSs are used to protect critical electrical loads against loss of power The load s utility Source 1 power source is backed up by a generator Source 2 power source An ATS is connected to both the utility and generator power sources and supplies the load with power from one of these two sources In the event that power is lost from the utility power source the ATS transfers the load to the generator power source Once the utility power is restored the load is automatically transferred back to the utility power source Figure 2 Generator Source 2 Utility Source 1 Figure 2 Typical Load Transfer Switch Contactor Schematic An intelligence system initiates the transfer when the utility power source fails or falls below a preset voltage An engine start is then initiated and the ATS transfers to the generator power source when sufficient generator voltage is available When the utility power source is restored the ATS automatically transfers back and the generator will shut down after a time delay In
30. Transfer Switch Cat No CHGEN100ATSRSE 2 04 GO No 1 1 Item 1 Volt 240 Wire 3 Amps 100 Hertz 60 Figure 1 Typical Automatic Transfer Switch Equipment Nameplate All possible contingencies that may arise during installation opera tion or maintenance and all details and variations of this equip ment do not purport to be covered by these instructions If further information is required by the purchaser regarding a partic ular installation application or maintenance activity please con tact an authorized Eaton sales representative or the installing contractor For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch SECTION 1 INTRODUCTION 1 1 Preliminary Comments and Safety Precautions This technical document is intended to cover most aspects associ ated with the installation application operation and maintenance of the CHGEN Automatic Transfer Switch ATS 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 pro ceeding If further information is required by the purchaser regard ing a particular installation application or maintenance activity please contact an authorized Eaton sales representative or the installing contractor 1 1 1 Warranty and Liability Information No warranties expressed or implied including warranties of fit ne
31. USE 60 75 C WIRE FOR 125 AMP LUGS FEED OPPOPSE BUS Figure 46 Location of the Service Entrance Breaker Lugs Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the service entrance r breaker s line side lugs Step 2 Remove the service entrance breaker from the ATS by fol lowing steps 1 through 4 in Section 6 4 1 9 Step 3 Working from the rear of the service entrance breaker remove the two 2 screws securing the lugs to the stabs using a Phillips screwdriver See fig 47 x ate amp K NEY i i EE Figure 47 Location of the Screws Securing the Lugs to the Stabs Step 4 Step 5 Remove the lugs from the stabs Slide the new lugs over the stabs until the holes in each are aligned Step 6 Secure the new lugs to the stabs using the hardware Step 7 Reinstall the service entrance breaker in the ATS by fol lowing Steps 5 through 10 in Section 6 4 1 9 IB01602014E For more information visit instructional Booklet Effective January 2008 Page 29 Step 8 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the service entrance breaker lugs have been replaced Test the system for proper functionality 6 4 1 12 Generator Breaker Lugs 100A and 200A C WIRE FOR 125 AMP USE 75 USE 60 75 C WIRE LUGS FEED OPPOReE gus
32. ack base using a blade screw driver or 0 25 in socket or nut driver see Figure 29 Remove the ground bar Step 5 Secure the new ground bar to the base plate using the hardware supplied Step 6 Insert the 1 5 in long screw into the top of the ground bar Use the hardware supplied if necessary Step 7 Reconnect all wire cables to the ground bar Step 8 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the ground bar has been replaced Test the system for proper functionality www eaton com Instructional Booklet Page 22 Effective January 2008 6 4 7 5 Replacing the Contactor Figure 30 Replacing the Contactor Note If you are replacing the contactor in a 100A or 200A SE ATS the service entrance breaker must be removed first Also jumpers between the generator breaker inside the ATS and the E1 E2 terminals on the genera tor Source 2 side of the contactor must be removed Follow steps 1 through 4 in Section 6 4 1 9 for 100A amp 200A Service Entrance breaker and steps 3 amp 4 in Section 6 4 1 10 for 100A amp 200A generator breaker Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the contactor Step 2 Note their location then disconnect the twelve 12 red wires from the contactor see Figure 30 Note All wires connected
33. at its destination undamaged and ready for installation The packing is designed to protect the internal components as well as the enclosure 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 site and ready to be installed When the ATS equipment reaches its destination the customer should inspect the shipping container for any obvious signs of rough handling and or external damage that occurred during trans portation Record any external and internal damage for reporting to the transportation carrier and to the Eaton sales representative once a thorough inspection is complete All claims should be as specific as possible and include the Shop Order and General Order numbers A shipping label affixed to the shipping container includes a vari ety of equipment and customer information such as General Order and Customer numbers Make certain that this information matches the other shipping paper information Each ATS enclosure is packaged in its own box Heavy duty card board sides surround the enclosure Do not discard the packing material until the equipment is ready for installation Once the top packaging is removed from the shipment the enclo sure door can be opened A plastic bag of documents will be found in the enclosure Important documents such as wiring dia grams and appropriate instruction leaflets are enclose
34. cal loads as possible 4 4 Power Cable Connection A WARNING POWER CONDUCTORS MAY HAVE VOLTAGE PRESENT THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH DE ENERGIZE ALL POWER OR CONTROL CIRCUIT CONDUCTORS TO BE CONNECTED TO THE ATS EQUIPMENT BEFORE BEGINNING TO WORK WITH THE CONDUCTORS AND OR TERMINATING THEM TO THE EQUIPMENT A CAUTION TO HELP PREVENT COMPONENT DAMAGE OR FUTURE MALFUNC TIONS USE EXTREME CARE TO KEEP CONTAMINANTS OUT OF THE ATS EQUIPMENT WHEN MAKING THE POWER CABLE CONNEC TIONS Test all power cables prior to connection to the unit to ensure that the conductors or cable insulation has not been damaged while being pulled into position Power cables are to be connected to solderless screw type lugs located on the automatic transfer switching devices Verify that the lugs supplied will accommodate the power cables being used Also verify that the cables comply with all local electrical codes Standard ATS equipment as supplied from the factory will accommodate the wire sizes shown in Table 2 Table 2 Wire Sizes for ATSs TRANSFER SWITCH CONTACTOR WIRE NUMBER OF CABLES AMP RATING SIZE RANGE PER PHASE 100 14 2 0 1 200 6 290 KCMIL 1 Carefully strip the insulation from the power cables to avoid nick ing or ringing of the conductor strands Prepare the stripped con ductor termination end by cleaning it with a wire brush If aluminum conductors are used apply an appropriate joint com pound to the
35. ck Step 9 The white wire from the TVSS will be connected to the neutral bar Cut the white wire to a suitable length to connect to the neutral bar then strip 0 25 in 6 35 mm of insulation from the end of the wire Step 10 On 100 A SE ATSs secure the white TVSS wire to a receptacle on the neutral bar using a blade screwdriver see Figure 68 Note On 200 A SE ATSs the white TVSS wire must be connected to the male flag receptacle on the neutral bar Remove the female flag connector from the neutral bar Cut the female flag connector off of the white wire from the main wiring harness and the red wire from the optional load shed if installed Strip 0 25 in 6 35 mm of insulation from the white TVSS wire the white wire from the main wiring harness and red wire from the optional load shed if installed Crimp the supplied female flag connector on the wires so they can be connected to the male flag terminal on the neutral bar see Figure 69 AT a 4 A N F oy K xe a Ii g Pe Ad NN 4 Figure 68 TVSS White Wire Connected to the 100 A Neutral Bar For more information visit www eaton com Instructional Booklet Page 36 Effective January 2008 VuLIn dSH jawwep sanny D Nel aj n Step 11 The green yellow wire from the TVS will be connected to the ground bar Cut the green yellow wire to a suit able length to connect to the ground bar then strip 0 25 in 6 35 mm of insulation from the end of the wire
36. clean conductor surface area CAUTION IMPROPER POWER CABLE CONNECTIONS CAN CAUSE EXCESSIVE HEAT AND SUBSEQUENT EQUIPMENT FAILURE Note Tighten the cable lugs to the torque identified on the label affixed to the unit s door IBO1602014E For more information visit instructional Booklet Effective January 2008 Page 11 Step 1 Connect cables as follows see Figures 13 and 14 and Table 2 e The utility Source 1 power cables to the utility lugs or SE breaker if installed e The generator Source 2 power cables to the generator lugs or generator breaker lugs for SE only e The customer load cables to the main distribution panel load lugs e The neutral cables to the neutral bar and e The ground wires to the ground bar UTILITY i LUGS Figure 13 Cable Connection Locations 100 A www eaton com Instructional Booklet Page 12 Effective January 2008 PD ES QO AN So SS Figure 14 Cable Connection Locations 200 A Step 2 The utility sensing fuse block is located at the bottom cen ter of the power panel and is used to supply 240 Vac to the generator See Figure 15 See Section 4 7 for more detailed information on connecting these inputs Figure 15 Utility Sensing Fuse Block Location Step 3 Tighten all cables and wiring to specifications For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch 4 5 Wi
37. ctrical connections Inspect for accumulated dirt loose hardware or physical damage Examine the primary insulation for evidence of cracking or overheating Overheating will show as discoloration melting or blistering of the conductor insulation or as pitting or melting of the con ductor surfaces due to arcing Inspect the secondary control connections for damage and control wiring for insulation integrity c Inspect the contactor for dust dirt soot grease moisture or corrosion Remove dust dirt soot grease moisture and corrosion contamination from the surface of the switching device using a dry soft lint free cloth dry soft bristle brush and vacuum cleaner Do not blow debris into the contactor If contamination is found look for the source and fix the prob lem d Check for material integrity uneven wear discoloration or loose hardware Severe material cracking will require replacement and loose hardware will need to be tightened e Check the terminals and connectors for looseness or signs of overheating Overheating will show as discoloration melting or blistering of the conductor insulation Connections that do not have signs of looseness or overheating should not be disturbed f Exercise the contactor if it is not often exercised while in operation This will permit the wiping If a switching device is used for frequent switching during normal operation this step can be dis action by the contacts regarded
38. d within the bag and should be filed in a safe place 2 2 Handling As previously mentioned ATS equipment is packaged in its own box Protect the equipment from impact at all times and do not double stack Once the equipment is at the installation site and ready to be installed the packaging material can be removed Refer to Section 4 of this manual for specific installation instruc tions 2 3 Storage Although well packaged this equipment is not suitable for outdoor storage 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 protec tive packaging material in place Protect the equipment at all times from excessive moisture construction dirt corrosive condi tions and other contaminants It is strongly suggested that the package protected equipment be stored in a climate controlled environment of 20 to 65 C 4 to 149 F with a relative humid ity of 80 or less Do not under any circumstance stack other equipment on top of an ATS equipment enclosure whether pack aged or not IBO1602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch SECTION 3 EQUIPMENT DESCRIPTION 3 1 Introduction The Eaton ATS is assembled and tested at the factory It is designed to be used in conjunction with standby power distribu tion equipment to provide an alternate source of
39. e The Eaton SurgeTel is designed to mount directly to the TVSS when it is externally mounted to the ATS enclosure see Figure 72 If the TVSS was installed inside the 100 A or 200 A SE ATS enclosure the SurgeTel MUST BE mounted outside the enclosure see Figure 73 See the Instruc tion Bulletin supplied with the SurgeTel for additional information Figure 72 SurgeTel Installed on the Externally Mounted TVSS IB01602014E E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch B o Figure 73 SurgeTel Mounted Externally When the TVSS Is Internally Mounted in a SE ATS 7 3 1 Attaching the SurgeTel to an Externally Mounted TVSS Step 1 Align the quick connector with the receptacle on the right side left side or bottom of the TVSS Slide the SurgeTel into the receptacle until completely seated see Figure 74 Note If the SurgeTel will be mounted to the TVSS no ground wire is required between the SurgeTel and ATS The TVSS ground will also ground the SurgeTel Note The SurgeTel can also be mounted to other Eaton surge protection devices that incorporate the quick connect feature r E eye onl TE ers vAN See PS E teens ioe iin x 4 idz gt lt s wri tars lt TESO Bun Wo CR Sa mae ts libs EE cee Figure 74 SurgeTel Mounted to the TVSS IBO1602014E instructional Booklet Effective January 2008 Page 37 7 3 2 Mounting the SurgeTel w
40. erator Source 2 power source to the utility Source 1 power source to allow the utility power source to stabilize before the transfer is initi ated Timing begins when the utility power source becomes available If the generator power source fails during timing the time delay is overridden and an immediate transfer to the utility power source will occur The TDEN timer is set for 10 sec onds Failsafe Failsafe refers to the condition whereby the ATS is connected to the generator Source 2 power source In the event that the generator power source fails and the utility Source 1 power source is available an immediate retransfer to the utility power source will occur 4 Time Delay Engine Cool off TDEC This feature allows the generator engine to run after the ATS returns to the utility Source 1 power source without load The generator will run for its time delay IBO1602014E Instructional Booklet Effective January 2008 Page 7 5B Undervoltage Sensing for Emergency Generator Source This feature enables the logic to constantly monitor the gen erator Source 2 power source The logic prevents transfer from the utility Source 1 power source to the generator power source until the generator power source has reached an acceptable operating voltage and frequency Dropout is set at 80 of nominal voltage and pickup is set at 90 of nominal voltage 26 Undervoltage Sensing for Normal Utility Source This feature e
41. he white wire with the load shed wire ring terminal and secure both to the neutral bar using the screw just removed see Figure 85 Refer to the wiring diagram in Figure 20 for connection locations for the load shed wires www eaton com Instructional Booklet Page 40 Effective January 2008 E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch E Cutler Hammer 3 J mhal a pm Circuit Breaker zma a 120 240VAC soke we F CSR 25k 200 Amp gt d 6 4 Figure 86 Load Shed Wire Connected to the Neutral Bar 200 A ATS Step 3 Connect one of the supplied wires to terminal 13 on the load shed see Figure 84 Route the wire from the load shed to the auxiliary switch on the right side of the con tactor Cut the wire to the proper length and strip 0 25 in 6 35 mm of insulation from the end of the wire Crimp the smaller female flag connector supplied onto the end of the wire Connect the female flag connector to the male flag terminal on the normally OPEN contact to the auxiliary switch see Figure 87 f Figure 85 Load Shed Wire Connected to the Neutral Bar LOAD WIRE NORMALLY OPEN _ i a installed Cut the load shed wire to the proper length COMMON On 200 A ATSs remove the female flag connector from the male flag terminal on the neutral bar Cut the female flag connector from the white wire in the main wiring
42. ice wire s to the Step 1 Align the quick connector with the receptacle on the right SurgeTel side left side or bottom of the TVSS Slide the SurgeCa ble into the receptacle until completely seated see Figure Step 2 Remove the cover from the SurgeTel 79 Step 3 Connect the telephone service wires to the SurgeTel con Note If the SurgeCable will be mounted to the TVSS no ground wire is nectors required between the SurgeCable and ATS The TVSS ground will also ground the SurgeCable Note See the Instruction Bulletin supplied with the SurgeTel for complete telephone wire connection information Note The SurgeCable can also be mounted to other Eaton surge protec tion devices that incorporate the quick connect feature Step 4 Check for a dial tone on a telephone connected to the system Step 5 Place and outgoing call and have someone call you back to ensure that the system is working 7 4 SurgeCable Installation Note The Eaton SurgeCable is designed to mount directly to the TVSS when it is externally mounted to the ATS enclosure see Figure 77 If the TVSS was installed inside the 100 A or 200 A SE ATS enclosure the Sur geTel MUST BE mounted outside the enclosure see Figure 78 See the Instruction Bulletin supplied with the SurgeTel for additional information Figure 79 SurgeCable Mounted to the TVSS 7 4 2 Mounting the SurgeCable with an Internally Mounted TVSS Figure 80 SurgeCable Installed Separate from
43. ill Eaton be responsible to the purchaser or user in contract in tort including negligence strict liability or otherwise for any special indirect incidental or conse quential 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 exist ing power facilities or claims against the purchaser or user by its customers resulting from the use of the information recommen dations and description contained herein Eaton Corporation Electrical Group 1000 Cherrington Parkway Moon Township PA 15108 United States 877 ETN CARE 877 386 2273 Eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch 2008 Eaton Corporation All Rights Reserved Printed in USA Publication No IBO1602014E TBGOO174 January 2008
44. ith an Internally Mounted TVSS A WARNING Hazardous Figure 75 SurgeTel Installed Separate from the TVSS Step 1 Remove the screw in the middle of the back of the new SurgeTel using a Phillips head screwdriver Attach the auxiliary ground terminal strip provided to the back of the SurgeTel using the Phillips head screw just removed see Figure 76 AUX GROUND TERMINAL STRIP y ooo a Figure 76 Auxiliary Ground Strip Mounted to the SurgeTel Step 2 Secure the SurgeTel to an acceptable mounting surface near the ATS using the screws supplied Step 3 Connect the supplied ground wire to the auxiliary ground strip using the screw provided Step 4 Turn the utility Source 1 power off and turn the gener ator Source 2 control selector switch to the OFF position before attempting to connect the ground wire to the ATS Step 5 Route the ground wire into the ATS to the ground bar Secure the ground TVSS wire to a receptacle on the ground bar using a blade screwdriver Step 6 Apply utility Source 1 power and place the generator control selector switch in the AUTO position For more information visit www eaton com Instructional Booklet _ E T N Cutler Hammer Page 38 Effective January 2008 O amp M Manual for the CHGEN Automatic Transfer Switch 7 3 3 Connecting the Phone Lines to the SurgeTel 7 4 1 Attaching the SurgeCable to an Externally Mounted TVSS Step 1 Route the telephone serv
45. mer O amp M Manual for the CHGEN Automatic Transfer Switch Step 8 If the neutral bar being replaced was grounded use the 1 5 in screw removed in Step 3 to ground the neutral bar to the base plate see Instruction Leaflet supplied with the grounding kit for more information Step 9 Reconnect all wire cables to the neutral bar Step 10 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the neutral bar has been replaced Test the system for proper functionality 6 4 7 3 200 A Neutral Bar Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to replace the SE neutral bar Step 2 Disconnect all wire cables from the neutral bar Step 3 Disconnect the flag from the wire terminal on the back of the neutral bar see Figure 28 Step 4 If the neutral bar has been grounded remove the 10 32 x 0 625 in screw that grounds the neutral bar to the base plate Also remove the 1 4 20 x 0 50 in bolt securing the copper connector to the bottom of the neu tral bar see Instructional Leaflet supplied with the grounding kit for more information Step 5 Remove the two 2 screws securing the neutral bar bracket to the base plate see Figure 28 using a blade screwdriver or 0 25 in socket or nut driver Remove the neutral bar wey w a v D Be X xX A Aas er Py ss X st
46. nables the logic to constantly monitor the util ity Source 1 power source The logic prevents transfer from the generator Source 2 power source to the utility power source until the utility power source has reached an accept able operating voltage Dropout is set at 80 of nominal voltage and pickup is set at 90 of nominal voltage 3 3 Optional Features The following is a list of optional features for the CHGEN ATS 36 Load Shed Four sets of contacts are available and can be used to con trol large connected loads on the generator i e air condi tioners hot tubs etc 37 Service Equipment Rated Transfer Switch This feature provides the label Suitable for use as Service Equipment and the features necessary to meet the require ments for the label 51H CHSPULTRA This feature provides a OKA 240 120VAC 1 Ohm surge device It can be mounted on the Source 1 line The feature ships loose for customer mounting convenience 51J Telephone Surge Protection The telephone line surge protection feature offers 4 pair tele phone line protection The feature ships loose for customer mounting convenience 51K Cable Surge Protection The TV and satellite cable surge protection feature offers 2 coaxial line protection cable satellite TV The feature ships loose for customer mounting convenience 3 4 Standards Eaton ATS equipment enclosed in NEMA 3R enclosures are listed for application by UL In addition Eaton
47. nal Service Entrance Feature The ATS can be ordered in either a standard or service entrance SE configuration When ordered as an SE integral overcurrent protection is built into the switch Therefore the ATS can be installed at the point of service entrance without the need for an upstream disconnect device Also the switch comes with a gener ator breaker on the generator Source 2 side of the contactor see Figure 5a and 5b The generator breaker can be switched OFF to prevent the transfer of power from the generator source to the load if the service entrance breaker is switched OFF manually Not an overload condition gt www eaton com Instructional Booklet _ E T N Cutler Hammer Page 4 Effective January 2008 O amp M Manual for the CHGEN Automatic Transfer Switch Figure 5b An SE ATS 200A Figure 5a An SE ATS 100A For more information visit www eaton com IB01602014E E TeN Cutler Hammer Instructional Booklet Enecive January 2008 Page 5 O amp M Manual for the CHGEN Automatic Transfer Switch The benefits of the SE configuration are e Combined service disconnect and over current protection in the ATS reduces the overall equipment and installation costs e Fewer components and power connections reduce maintenance requirements 1 2 3 Optional TVSS Surge Protection Transient voltage surge suppressor TVSS surge protection is available as an optional feature on all CHGEN ATSs If you have
48. nsfer to the utility CAUSE 1 The circuit breaker on the generator is open 2 The generator voltage is not acceptable 3 The generator breaker on the ATS unit is open SE only option 1 The service disconnect breaker is open 2 The utility voltage is not acceptable Instructional Booklet Effective January 2008 Page 31 CORRECTION 1 Reset the generator circuit breaker 2 Refer to the generator User s Manual 3 Turn ON the generator breaker on the ATS unit SE only option 1 Reset the service disconnect breaker 2 Wait for the utility voltage to return to normal The generator is still running after the transfer switch transfers to the utility IBO1602014E Engine cool down period For more information visit www eaton com The engine should stop after the cool down period Instructional Booklet Page 32 Effective January 2008 SECTION 7 INSTALLING OPTIONAL COMPONENTS 7 1 Installing the Optional TVSS Externally on a Standard or SE 100 A and 200 A ATS Note If you are installing a TVSS in a SE ATS it can be installed inter nally See Section 7 2 for detailed installation instructions Note Because of the size of the enclosure if you have either a 100 A or 200 A standard ATS the TVSS CANNOT be installed inside the enclosure It will have to be mounted on the outside of the enclosure in a suitable position see Figure 52 CHSP ULTRA Figure 52 Possible Location for and Externally
49. nstruction Bulletin supplied with the SurgeCable for addi tional connection information Step 3 After ensuring that all connections are tight turn on the protected equipment and check for proper functioning 7 5 Installing a Load Shed in a 100 A or 200 A CHGEN ATS The steps detailed in this section explain how to install a load shed ina 100 A or 200 A CHGEN ATS Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi tion before attempting to install the load shed Align the load shed with the existing holes near the top of the base plate directly above the contactor for standard ATSs see Figure 82 and directly below the neutral bar for SE ATSs see Figure 83 Secure the load shed to the base plate using the hardware supplied IBO1602014E For more information visit instructional Booklet Effective January 2008 Page 39 ON Figure 83 Load Shed Installed on the Base Plate of an SE ATS Step 2 Connect one of the supplied wires to terminal 14 on the load shed see Figure 84 Route the wire from the load shed to the neutral bar On 100 A ATSs cut the wire to the proper length strip 0 25 in 6 35 mm of insulation from the end of the wire then crimp the supplied ring ter minal onto the wire Using a blade screwdriver remove the screw securing the white wire of the main wiring har ness to the neutral bar Align the ring terminal of t
50. nt of relevant information pertaining to a specific piece of equipment The Catalog Number Identification Table see Table 1 provides the required interpretation information An example is offered to initially simplify the process The catalog number CHGEN1OOATSRSE describes an ATS Table 1 ATS Catalog Number Explanation POSITIONS 1 2 POSITION 3 5 POSITION 6 8 Manufacturer Type Ampere Rating Cutler Hammer CH Generator GEN 100 A 100 200 A 200 POSITION 9 11 POSITION 12 POSITION 13 14 Type Enclosure Service Entrance Automatic ATS NEMA 3R R Standard Blank Transfer Service EntranceSE Switch 1 4 Environmental and Operational Conditions Normally an ATS is applied indoors in an electrical equipment room It can also be used for normal outdoor applications with a Nema 3R enclosure where the equipment is subject to falling rain freezing temperatures and 95 humidity non condensing The ambient temperature range for operation is between 20 and 70 C 4 and 158 F Seismic With proper installation these transfer switches have a seismic capability which exceeds the worst case Zone 4 required levels per both the Uniform Building Code and the California Building Code For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch SECTION 2 RECEIVING HANDLING AND STORAGE 2 1 Receiving Every effort is made to ensure that the ATS equipment arrives
51. ose a location that offers a flat rigid mounting surface capa ble of supporting the weight of the enclosed ATS equipment see Figure 8 100 A Standard Figure 9 100 A SE Figure 10 200 A Standard or Figure 11 200 A SE Protect the transfer switch at all times against excessive moisture dust dirt lint and corrosive vapors Back View Showing Wall Mounting Dimensions 1 100 A Enclosure Mounting Holes Dimensions and Plan View of Standard CHGEN Automatic Transfer Switch in 100 A IB01602014E E TeN Cutler Hammer instructional Booklet Effective J 2008 Page 9 O amp M Manual for the CHGEN PORIV E e AMLAN age Automatic Transfer Switch 100A Enclosure Mounting Holes Ea Figure 9 Dimensions and Plan View of SE CHGEN Automatic Transfer Switch in 100 A AE 14 46 Back View Showing Wall Mounting Dimensions 200 A Enclosure Mounting Holes 5 35 M Figure 10 Dimensions and Plan View of Standard CHGEN Automatic Transfer Switch in 200 A 1 in 25 4 mm Weight 35 Ibs 15 9 ka 35 Weight 35 Ibs 15 9 kg 15 9 kg IB01602014E For more information visit www eaton com Instructional Booklet _ E T N Cutler Hammer Page 10 Effective January 2008 O amp M Manual for the CHGEN Automatic Transfer Switch 200A Enclosure Mounting Holes Figure 11 Dimensions and Plan View of SE CHGEN Automatic Transfer Switch in 200 A Check to ensure there are no pipes wires or o
52. power source and the transfer switch see Figure 17 When utility power returns the ATS will switch all power back to the utility panel and the genera tor will shut down IBO1602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch Non Critical Utility la Loads Source gt gt Watt Hour Meter Utility Panel Generator Note Source 2 With optional feature 37 this Transfer Switch is te intended as service Circuit Breaker entrance equipment typically included in Genset Critical Loads Emergency Distribution Panel Figure 17 Diagram of a Typical Installation Critical Loads Only In addition another typical installation for loads can be considered see Figure 18 Refer to Figure 19 for a loads connection dia gram Disconnect Switch F or Fuse Transfer Breaker Panel Control Wiring Generator Figure 18 Typical Installation of a Light Commercial ATS The switch 1 and generator 2 are connected to the power supply The ATS is located between the utility and the loads IB01602014E instructional Booklet Effective January 2008 Page 13 Utility Source 1 Generator Source 2 Circuit Breaker Circuit Breaker nN Watt Hour Meter poe Household Figure 19 Diagram of a Typical Installation All Loads 4 7 Utility Sensing Fuse Block Connection The gene
53. power to critical circuits in the event that the primary power source is interrupted This ATS monitors both utility Source 1 and generator Source 2 power sources and automatically transfers critical load circuits between the two sources depending on which source is available The utility power source is preferred and will remain connected to the switch if it is available 3 2 Features The following section describes the standard features in the CHGEN ATS Note The time delays are not adjustable 1 Time Delay Normal Utility to Emergency Generator TDNE This feature delays the transfer from the utility Source 1 power source to the generator Source 2 power source in order to override momentary utility power source outages and or fluctuations Timing begins when the generator power source becomes available Should the utility power source fail the generator will start up after its time delay The TDNE timer is set for 50 seconds 2 Time Delay on Engine Starting TDES This feature delays initiation of the generator engine start cir cuit in order to override momentary utility Source 1 power source outages and or fluctuations It does not affect the abil ity of the transfer switch to transfer from the utility power source to the generator Source 2 power source The TDES timer is dependent on the generator 3 Time Delay Emergency Generator to Normal Utility TDEN This feature delays the transfer from the gen
54. ptional load shed and or TVSS is installed in a 200 A standard or SE ATS the female flag connector is also used to connect the red load shed and white TVSS wires to the neutral bar Cut the female flag connec tor from the white wiring harness wire Strip 0 25 in 6 35 mm of insula tion from the white wiring harness wire red load shed wire and white TVSS wire Crimp the new female flag connector supplied onto the white and red wires then install the female flag connector on the male flag termi nal on the neutral bar See Figure 36 Step 11 Connect the Neutral N1 N2 N Coil N Aux N C E Aux N C E Coil and E2 female connectors to the gen erator controller board Refer to the wiring diagram in Figure 20 for connection locations on the generator con troller board see Figure 35 Step 12 Connect the twelve 12 red wires to the contactor at the locations noted before they were removed Refer to the wiring diagram in Figure 20 for connection locations on the contactor see Figure 33 Step 13 Align the utility sensing fuse block with the holes in the base plate from which the original fuse block was removed Secure the utility sensing fuse block to the base plate using the hardware supplied Step 14 Install the utility sensing fuses in the fuse block Step 15 Reconnect the control wiring removed in Step 2 to the utility sensing fuse block Step 16 Apply utility Source 1 power and place the generator control selector
55. r switch to the OFF posi tion before attempting to replace the service entrance cover Step 2 Open the service entrance cover door Step 3 Remove the three 3 screws securing the service entrance cover to the ATS door using a blade screw driver or 0 25 in nut driver see Figure 51 Remove the service entrance cover For more information visit www eaton com Step 4 Step 5 Step 6 Step 7 Figure 51 E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch SCREWS Location of the Service Entrance Cover Screws Open the new service entrance cover door and align it with the holes in the ATS door Secure the new service entrance cover to the ATS door using the hardware supplied Close the service entrance cover door Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the service entrance cover has been replaced Test the sys tem for proper functionality IBO1602014E E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch 6 5 Troubleshooting Table 5 contains troubleshooting information for the CHGEN ATS If a problem still exists after completing the troubleshooting proce dures contact an authorized Eaton sales representative Table 5 Troubleshooting Chart PROBLEM The automatic transfer switch does not transfer to the generator The automatic transfer switch does not tra
56. rator s 240 Vac utility sensing fuse block is located at the bottom center of the power panel of the ATS Figure 15 Prior to making the sensing inputs connection to the ATS set the generator control selector switch to the OFF position to prevent an unwanted engine start Connect the sensing wires to the fuse block These wires should be connected to the side of the fuse block with no existing wires See Section 6 Figure 20 for the wiring diagram 4 8 Preliminary Checks After the ATS enclosure is installed and power cables are con nected to the equipment thoroughly inspect the unit to ensure that no tools were left inside and that the cabinet is free of debris If necessary use a vacuum cleaner to remove any and all con struction or installation debris from the equipment Read and understand all labels on the equipment Review and understand the wiring diagrams supplied with the equipment Note any optional accessories that may have been furnished with this unit and review their operation Verify that the phase to phase line voltages of both the utility Source 1 and generator Source 2 power sources are the same and that they match the rated voltage as indicated on the ATS rat ings label A CAUTION SEVERE EQUIPMENT DAMAGE CAN RESULT IF THE UNIT IS NOT APPLIED AT PROPER VOLTAGE DO NOT ENERGIZE THE EQUIP MENT IF THE SUPPLY VOLTAGES DO NOT MATCH EQUIPMENT RATINGS LABEL For more information visit www eaton com
57. re the contactor to the base plate using the four 4 screws supplied For SE ATSs Step 12 Align the utility lug extension with the SE breaker and contactor Secure the utility bus extension to the SE breaker and contactor using the original hardware Note If you are replacing the lugs in a 100A SE ATS the service entrance breaker must be reinstalled at this time Also reconnect the jumpers between the generator breaker inside the ATS and the E1 E2 terminals on the generator Source 2 side of the contactor Follow steps 5 through 10 in Section 6 4 1 9 for 100A amp 200A Service Entrance breaker and steps 8 in Section 6 4 1 10 for 100A amp 200A generator breaker Step 13 Reattach the twelve 12 red wires to the contactor Examine each wire to find the name then refer to Figure 33 for the correct connection point Step 14 Reconnect all wire cables to the contactor as per their original connections Step 15 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the service entrance breaker has been replaced Test the system for proper functionality www eaton com Instructional Booklet Page 26 Effective January 2008 6 4 7 8 200 A LUGS Figure 38 Replacing the 200 A Lug Lug Location Note If you are replacing the lugs in 200A SE ATS the service entrance breaker must be removed first Also jumpers between the generator breaker inside the ATS
58. red load shed wire and white TVSS wire to the neutral bar Cut the red load shed and white TVSS wires as close to the connector as possible They will be reconnected later in this process see Figure 36 VuLin dSH sawwepuanny NLS r y Figure 36 White Wiring Harness Optional Red Load Shed and Optional White TVSS Wires Connected to a 100 A and 200 A Neutral Bars ae ee A y j h Ve oon ty d A rA io gt af i m z 7 7 es Y eaaa f j af ear N j r a Step 8 Remove the original wiring harness complete with the utility sensing fuse block from the ATS Step 9 Place the new wiring harness and utility sensing fuse block in the ATS Step 10 Connect the white wire to the neutral bar On 100 A ATS cut the female flag connector from the white wire Strip 0 25 in 6 35 mm of insulation from the wire then crimp the supplied ring terminal onto the wire Connect the wire to the neutral bar using a blade screwdriver to tighten the screw Note If an optional load shed is installed in the 100 A ATS the screw securing the white wire to the neutral bar is also used to secure the red load shed wire On 200 A standard or SE ATSs install the white wire female flag connector on the male flag terminal on the neutral bar For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Note If an o
59. ring A WARNING POWER CONDUCTORS AND SENSING WIRES MAY HAVE VOLTAGE PRESENT THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH DE ENERGIZE ALL POWER OR CONTROL CIRCUIT CONDUC TORS BEFORE BEGINNING TO PERFORM ANY WIRING ACTIVITY TO OR WITHIN THE ATS EQUIPMENT A CAUTION CHECK THE ATS EQUIPMENT NAMEPLATE FOR RATED VOLTAGE IT SHOULD BE THE SAME AS THE UTILITY SOURCE 1 AND GENER ATOR SOURCE 2 LINE VOLTAGES OPERATING THE EQUIPMENT ON IMPROPER VOLTAGE CAN CAUSE EQUIPMENT DAMAGE 4 6 Installation In a typical installation for critical loads see Figure 16 the ATS 1 and the generator 2 are connected to the power supply The ATS 1 and emergency distribution panel 3 receive utility Source 1 power from a dedicated breaker in the utility service panel 4 The ATS and emergency panel receive generator Source 2 power from the generator 2 Power from the utility feeds the utility panel Sensing Wires Figure 16 Typical Installation of a Light Commercial ATS The switch 1 and generator 2 are connected to the power sup ply The ATS is located between the emergency distribution 3 and the utility panel 4 When the utility power fails the ATS will sense the failure the generator will start and when sufficient generator voltage is avail able the ATS will switch all loads to the emergency panel All emergency loads will receive power from the generator A line breaker is required between the generator
60. s close to identical length as possible In keeping the length of the wires as equal as possible they should be braided to increase the effectiveness of the TVSS Step 6 Mount the TVSS fuse block to the existing holes on the ATS base plate using the hardware provided For stan dard 100 A and 200 A ATSs the mounting holes are directly above the contactor see Figure 55 lous voltage use severe Injury h st be properly you tum Figure 55 TVSS Fuse Block Mounted in a Standard ATS Step 7 Install the supplied fuses in the TVSS fuse block Step 8 Based on the following connection points and wire rout ing determine which TVSS wire s will be the longest WIRE COLOR CONNECTION POINT Red TVSS fuse block Black TVSS fuse block White ATS neutral bar Green Yellow ATS ground bar www eaton com IBO1602014E E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Cut all four 4 wires to the same length necessary to reach the furthest connection point Braid any excess wire length for the other connection points Se E E Ff oe z4 see gy _ Figure 56 Braided TVSS Wires Step 9 The red and black wires from the TVSS are to be con nected to the terminals of the TVSS fuse block Strip 0 25 in 6 35 mm of insulation from the end of the wires Step 10 Connect the red and black TVSS wires to the TVSS fuse block using a blade screwdriver see Figure
61. screwdriver or 0 25 in socket or nut driver Step 6 Remove the two 2 generator lugs and the two 2 load lugs using a blade screwdriver see Figure 37 IB01602014E For more information visit instructional Booklet Effective January 2008 Page 25 For SE ATSs Skip This Step Step 7 Once the load lugs have been removed insert a blade screwdriver up through the circular hole in the load lug bus and remove screws securing the two 2 generator lugs For SE switch skip this step Step 8 Place the new utility lugs on the utility bus so the anti turn protrusions fit in the holes Once the lugs are in place take one 1 supplied control wire terminal and hold it underneath the bus Using one 1 screw and one 1 washer supplied tighten the control wire terminal and lug to the utility bus Repeat the process of the second utility lug Ensure that no gaps are present between the lugs and bus Step 9 Place the new generator lugs on the generator bus Once the lugs are in place take one 1 supplied control wire terminal and hold it underneath the bus Using one 1 screw and one 1 washer supplied tighten the con trol wire terminal and lug to the generator bus Repeat the process of the second generator lug Ensure that no gaps are present between the lugs and bus Step 10 Secure the load lugs to the load bus using the hardware supplied Note The load lugs do not require control wire terminals Step 11 Secu
62. ss for a particular purpose of merchantability or warranties aris ing 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 capi tal loss of power additional expenses in the use of existing power facilities or claims against the purchaser or user by its cus tomers resulting from the use of the information and descriptions contained herein 1 1 2 Safety Precautions All safety codes standards and or regulations must be strictly observed in the installation application operation and mainte nance of this device A WARNING THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PRO CEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONAL 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 ENSURE THAT PERSONNEL ARE ALERT TO WARNINGS WHICH APPEAR THROUGHOUT THE DOCUMENT IN ADDITION CAUTIONS ARE ALL UPPER CASE AND BOLDFACE A CAUTION READ AND UNDERSTAND THE MATERIAL PRESENTED IN THIS DOC UMENT BEFORE ATTEMPTING INSTALLATION A
63. t the system for proper functionality IBO1602016E For more information visit www eaton com Instructional Booklet E T N Cutler Hammer Page 42 Effective January 2008 O amp M Manual for the CHGEN Automatic Transfer Switch Notes For more information visit www eaton com IBO1602016E E Ten Cutler Hammer Instructional Booklet Effective January 2008 Page 43 O amp M Manual for the CHGEN Automatic Transfer Switch Notes IBO1602016E For more information visit www eaton com Instructional Booklet Page 44 Effective January 2008 This instruction booklet is published solely for information pur poses and should not be considered all inclusive If further infor mation is required you should consult an authorized Eaton sales representative The sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between the parties This litera ture is not intended to and does not enlarge or add to any such contract The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the pur chaser and Eaton NO WARRANTIES EXPRESSED OR IMPLIED INCLUDING WAR RANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MER CHANTABILITY OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE ARE MADE REGARDING THE INFORMATION RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN In no event w
64. ther mounting haz With the enclosed ATS equipment unpacked and ready for mount ards in the immediate mounting area that could create a problem ing proceed with the following steps Carefully remove all packing material from the ATS enclosure at Step 1 Depress the padlockable catch at the bottom of the door the installation site Even though an equipment inspection was and slide the door downward see Figure 12 Open the performed when the equipment was received make another care door ful inspection of the enclosure and the ATS mechanism as the packing material is removed and the enclosure readied for mount ing Be especially alert for distorted metal loose wires or dam aged components 4 3 Mounting Procedure A CAUTION EXTREME CARE SHOULD BE TAKEN TO PROTECT THE ATS FROM DRILL CHIPS FILINGS AND OTHER CONTAMINANTS WHEN MAK ING THE CABLE ENTRY HOLES AND MOUNTING THE ENCLOSURE TO PREVENT COMPONENT DAMAGE OR A FUTURE MALFUNCTION NOTICE THE INSTALLATION MUST FULLY COMPLY WITH ALL APPLICABLE CODES STANDARDS AND REGULATIONS Figure 12 Location of the Door Latch For more information visit www eaton com IB01602014E E T N Cutler Hdammer O amp M Manual for the CHGEN Automatic Transfer Switch Step 2 Use the knockouts for cable entry and control wiring NOTICE GENERATOR CONTROL CIRCUIT WIRING MUST BE RUN SEPARATE FROM POWER CABLES Step 3 Mount the switch to a rigid structure as close to the elec tri
65. to the contactor are labeled to ease identification Step 3 Remove the four 4 screws securing the contactor to the base plate using a blade screwdriver or 0 25 in socket or nut driver Remove the contactor Step 4 Following the replacement steps for the 100 A or 200 A lugs see Sections 6 4 1 7 and 6 4 1 8 remove the lugs from the old contactor then install the lugs on the new contactor Step 5 Secure the contactor onto the base plate using the hard ware supplied Step 6 Reattach the twelve 12 red wires to the contactor Examine each wire to find the name then refer to Figure 30 for the correct connection point Step 7 Reconnect all wire cables to the contactor as per their original connections For more information visit www eaton com E T N Cutler Hammer O amp M Manual for the CHGEN Automatic Transfer Switch Note If you are replacing the contactor in a 100A or 200A SE ATS the service entrance breaker must be reinstalled at this time Also reconnect the jumpers between the generator breaker inside the ATS and the E1 E2 terminals on the generator Source 2 side of the contactor Follow steps 5 through 10 in Section 6 4 1 9 for 100A amp 200A Service Entrance breaker and steps 8 in Section 6 4 1 10 for 100A amp 200A generator breaker Step 8 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the service entrance breaker has been
66. ulation from the end of the wire Step 14 Secure the green yellow TVSS wire to a receptacle on the ground bar using a blade screwdriver see Figure 60 Figure 60 TVSS Green Yellow Wire Connected to the Ground Bar For more information visit gt www eaton com Instructional Booklet _ E T N Cutler Hammer Page 34 Effective January 2008 O amp M Manual for the CHGEN Automatic Transfer Switch Step 15 Using the wires cut from the red and black TVSS wires Step 2 Align the TVSS Mounting bracket with the existing holes in Step 7 if long enough or 600 V 14 AWG wire make in the back of the enclosure located above the base two 2 wire leads that will run from the TVSS fuse block plate Secure the mounting bracket to the enclosure to the male spade connectors at the utility lugs on the using the hardware provided and a flat blade screwdriver contactor see Figure 63 Step 16 Remove the wiring harness connections at the male flag terminal at the N 1 utility lug Remove the crimp on female flag connector Strip 0 25 in 6 35 mm of insu lation from the end of the TVSS wire and the N 1 har ness wires Using the new crimp on female flag connector supplied connect the N 1 harness wires with one of the TVSS leads see Figure 61 Figure 63 TVSS Mounting Bracket Secured to the Back of the Enclosure Step 3 Align the TVSS with the holes in the mounting bracket Secure the TVSS to the mounting brackets using the hard
67. ure loose parts and or hardware cracks and or discoloration to insulation and damaged or discolored components Figure 20 is the wiring diagram for the CHGEN ATS switch Note Only qualified and experienced personnel should attempt any diag nostic work using this diagram SERVICE ENTRANCE BREAKER NOTE A Ti J MAIN DISTRIBUTION PANEL LOAD UTILITY SUPPLY l N2 nN o_o _ UTILITY SENSING _ 240 VAC OPTIONAL TSS NOTES NOTE A UTILITY AND GENERATOR CIRCUIT BREAKERS TO BE CONNECTED WHEN SWITCH IS USED FOR SERVICE ENTRANCE APPLICATION For more information visit www eaton com Instructional Booklet E T N Cutler Hammer Page 16 Effective January 2008 O amp M Manual for the CHGEN Automatic Transfer Switch 6 2 Procedures A suggested maintenance procedure to be followed is outlined in Table 3 Table 3 Recommended Periodic Maintenance Procedures STEP ACTION a Make the transfer switch equipment safe for inspection and or maintenance Disconnect the line power from the equipment being serviced by opening next highest disconnect device Make certain that any accessory control power is switched off b Inspect the structure area for safety hazards or potential maintenance problems Inspect the area especially where the contactor is installed for any safety hazards including per sonal safety and fire hazards Exposure to certain chemical vapors can cause deterioration of the ele
68. us extension stabs to the SE Breaker and contactor using original hard ware Step 8 Firmly tighten the screw securing the top of the service entrance breaker to the mounting bracket Step 9 Reconnect the cables to the line side lugs on the service entrance breaker Step 10 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the service entrance breaker has been replaced Test the system for proper functionality For more information visit www eaton com Instructional Booklet Page 28 Effective January 2008 6 4 71 70 100A and 200A Generator Breakers SERVICE ENTRANCE BREAKER GENERATOR BREAKER Figure 43 Generator Breakers Installed 200A SE ATSs Step 1 Step 2 Step 3 Step 4 Figure 44 200A SE Generator Breaker Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to OFF position before attempting to replace the generator breaker Disconnect the cables from the lugs on the line side of the generator breaker using 6mm allen wrench Remove the four 4 bolts lock washers and flat washers securing the jumpers between the emergency lugs of the contactor and the load lugs of the generator breaker using a 7 16 in wrench or nut driver see Figure 43 amp 44 Disconnect the jumpers between the generator breaker and the lugs at terminals E1 amp E2 on the generator Source
69. ware provided and a flat blade screwdriver or 0 25 in nut driver Note that the TVSS wires should facing the ATS base plate and installed components see Figure 64 a Ys i E s i q gt atin ET P A Eee Figure 61 Connection Points at the TVSS Fuse Block and Utility Lugs Step 17 Repeat the process for the N 2 wires Step 18 Reconnect the N 1 and N 2 female flag connectors to the N 1 and N 2 male flag terminals at the utility lugs Step 19 Apply utility Source 1 power and place the generator control selector switch in the AUTO position after the externally mounted TVSS has been installed Test the system for proper functionality 7 2 Installing the TVSS Internally in a SE 100 A and 200 A ATS Note Even though there is ample room and existing mounting holes within an SE CHGEN ATS to install an optional TVSS it can also be mounted externally on the ATS If you want to externally mount the TVSS follow the instructions in Section 7 1 Step 4 Mount the TVSS fuse block to the existing holes on the ATS base plate using the hardware provided For 100 A and 200 A SE ATSs the holes are directly to the left of the contactor TEES Step 5 Install the supplied fuses in the TVSS fuse block see Fig ure 65 H NAA a De es ANY A 4 fi Figure 62 TVSS Installed Inside an SE ATS Step 1 Turn the utility Source 1 power off and turn the genera tor Source 2 control selector switch to the OFF posi

O & M Manual for the CHGEN Automatic Transfer Switch

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O &amp; M Manual for the CHGEN Automatic Transfer Switch

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O & M Manual for the CHGEN Automatic Transfer Switch