Power topic #7012 | Technical information from Cummins Power Generation Inc.

Guidelines for ATS selection:

How to choose the right transfer solution
for your power application.
> White Paper
By Gary Olson, Director, Power Systems Development
Transfer switch equipment is available in a
variety of types, with a wide array of features.
Selecting the appropriate transfer switch
for a specic application requires a clear
understanding of site needs and application
restraints. This paper discusses the various
types of power transfer equipment that are
available, along with their advantages and
disadvantages, so that a more informed
selection can be made.
Transfer switches are at the heart of an emergency
power system, providing a dependable power transfer
between the utility and emergency standby generator,
or between other types of power sources and facility
loads. When the normal power source fails (usually the
utility), transfer switches detect the loss of power, send
a start signal to the standby generator and then connect
the generator to the facilitys loads when the generator
has achieved proper frequency and voltage. In cases of
utility failure when the emergency power source is not
operating, electrical service to a facilitys loads will be
lost for a period of approximately 10 seconds while the
generator set starts unless there is an uninterruptible
power supply (UPS) serving loads in the system to
bridge the power gap while the generator set starts,
reaches the proper parameters, and the automatic
transfer switch transfers.
When transferring between two live sources, such as
when normal power has returned or during generator
set test/exercise periods, a system designer can select
different types of transfer switches to minimize or even
eliminate the electrical disturbance to critical loads.
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One might expect that the type of transfer switch

selected is primarily a function of reliability, but in some
cases selection is simply based on convenience. In
general, minimizing the disturbance that can occur
when switching between sources will increase the
cost of a transfer switch. It costs more to completely
eliminate the switching disturbance, and the added
complexity can have negative impacts on the
reliability of the transfer device and even the generator
equipment. So, whether the application is a simple
standby power system in a home, a large emergency
system in a hospital protecting the lives of patients,
or standby service to a data center handling millions
of dollars in transactions, a careful consideration of
the balance between cost, reliability and the quality of
power provided to critical loads is necessary to select
the most appropriate transfer switch equipment.
Types of transfer equipment
Transfer switch equipment can be categorized into four
general groups:
Open-transition transfer devices: Open the connected
source before closing the new source, causing a total
power interruption for a short period of time;
Fast closed-transition transfer devices: Operate
like an open-transition transfer switch when a source
has failed, but will parallel the two sources for 100
milliseconds or less and then disconnect when both
sources are available, so a total interruption of power
is avoided;
Soft closed-transition devices: Operate like an
open transition transfer switch when a source has
failed, but when transferring between live sources
Power topic #7012 | Page 2
will actively synchronize the sources, then connect
them together and ramp load to the new source.
This results in a transfer that provides the minimum
disturbance to the loads; and
Sub-cycle transfer devices: Open and then re-close
on the new source in less than one-quarter of an
electrical cycle. The resultant interruption is so short
that most load devices arent affected by it. They are
used primarily in UPS systems and only occasionally
with a generator set. These devices are very expensive
in relation to mechanical switches and are typically
protected with fuses. They are also more complex than
mechanical switches and are considered by some to
be less reliable. This type of transfer device will not be
further discussed in this paper.
Open-transition transfer switches
Open-transition transfer switches provide a break-
before-make switching action. They are specically
designed to transfer power between utility and onsite
power systems. The connection to one source is
opened before the connection to the second source
is closed. (See Figure 1) Mechanical interlocks that
positively prevent interconnection of sources in
automatic and manual modes are commonly used.
Open-transition transfer switches are the most
commonly used type of transfer switch and are used
in all types of applications. By design, they neither
require nor allow generator set paralleling with
the utility service. (See Figure 2) Typical customer
applications include basic standby power systems
for small businesses, hotels, small manufacturing
and commercial buildings that can tolerate brief
interruptions during monthly power system testing and
retransfer to the utility after an outage.
Advantages of using conventional open-transition
transfer switches are:
Lowest-cost automatic power transfer option available
due to the simplicity of the controls and mechanism
needed and the simplicity of the interface to the
generator set.
Most reliable option available, again due to simplicity,
and the fact that there is no external utility protection
or generator equipment needed.
Most designs incorporate a mechanical interlock that
positively prevents inadvertent utility paralleling.
The disadvantage of open-transition transfer systems
is that during retransfer from the emergency generator
to the utility following restoration of normal power or
during system testing a xed open time is needed
to allow the arc developed on opening the contacts to
decay. Typically this time requirement is approximately
ve electrical cycles. In applications with a high
percentage of inductive loads (motors, transformers,
etc.), open-transition transfer switches need added
functionality to control the speed of operation of the
mechanical switch and keep the contacts open for
Figure 2 - Open-transition transfer switch
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Figure 1
Loads powered
by genset
Utility
Service
To
Loads
Power From
Genset
Utility
Service
Generator
Set
Utility
Service
Generator
Set
Power From
Utility
To
Loads
Generator
Set
Transfer
sequence
Loads powered
by utility
1 2 3
OPEN TRANSITION
Power topic #7012 | Page 3
one-half to three seconds to allow time for the residual
voltage in inductive load devices to decay. This feature
is called programmed transition or delayed transfer.
Some other open-transition transfer switch designs
utilize phase angle monitoring between sources to
initiate switching between sources when they are
synchronized to minimize the transfer time between live
sources. These are suitable for small motor applications
where the largest motors served by the transfer switch
are not more than 20 horsepower.
Fast closed-transition transfer switches
Fast closed-transition transfer switches provide a
make-before-break switching action and utilize
a momentary paralleling of both sources (<100
milliseconds) during the transfer period. Closed-
transition transfer switches utilize a control system
similar to that of open-transition transfer switches and
are connected to the generator set in a similar way.
Closed-transition transfer switches require a mechanism
that is capable of being operated in open-transition
sequence when switching from a failed source to a
live source, and a closed-transition sequence when
transferring between two live sources. Many closed-
transition transfer switches do not include mechanical
interlocking of sources, making it possible, especially
in manual operation modes, to manually parallel the
sources. This can be very damaging to the power
sources or the transfer equipment. Closed-transition
switching mechanisms are more complex and
expensive than open-transition transfer switches.
While fast closed-transition transfer devices switch from
sources without a total interruption, there is generally a
disturbance in power supplied to the loads due to the
sudden load change on the source. This is particularly
true when transferring a load from the utility to the
generator set. In general, in order to prevent disruptive
transients, fast closed-transition transfer switches must
be transferred sequentially, and each switch load should
be limited to less than 25 percent of the standby rating
of the generator set.
Many closed-transition transfer switches utilize passive
synchronizing typically composed of a sync check
device (also called a permissive relay or phase band
monitor) to sense the phase relationship between
the two live power sources and allow interconnection
of the sources only when they are synchronized. The
synchronizing is termed passive because there is no
direct control over the generator set frequency. Instead,
it relies on changes in the loads or difference in the
frequency of the sources to induce phase angle matching
of the sources. As the loads on the system change, and
the speed of the genset changes, the two power sources
will eventually drift toward synchronism. The transfer is
timed and signaled to occur so that when both sources
are close together, they are synchronized at the instant
when the generator set is interconnected with the utility.
Paralleling of the sources occurs for a xed time (not
more than one-tenth of a second). The short duration
of the paralleling makes it unnecessary to add more
complex controls to control load on the generator set
while paralleled with the utility grid. (See Figure 3)

Advantages of closed-transition transfer switches with
passive synchronizing are:
Lowest-cost non-load-break system, due to
simplicity of controls and lack of generator set
governor synchronizing controls.
They prevent momentary breaks in power during
generator set testing and when closing back to a
restored utility source. Splitting the loads into small
portions and controlling the sequence of their transfer
will minimize disruptive transients.
Disadvantages of this equipment are:
The overlap time is very brief, so voltage and
frequency transients will be imposed on the system
which may be just as disruptive as a short total
interruption, especially upon switching to the
generator set.
If facility loads are very stable, the two power
systems may require an objectionably long time to
synchronize. This failure mode may be intermittent,
Power From
Genset
Power From
Utility
Loads powered
by genset
Utility
Service
To
Loads
Utility
Service
Generator
Set
Utility
Service
Generator
Set
To
Loads
Generator
Set
Transfer
sequence
Loads powered
by utility
1 2 3
CLOSED TRANSITION
Figure 3
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Power topic #7012 | Page 4
since it depends on site loading variations to provide
the frequency change necessary to induce changes
in the phase relationship between the on-site power
system and the utility.
Generator sets used with this equipment may
be subjected to abnormal stresses due to poor
synchronizing accuracy. The premature damage to
the excitation system due to imprecise paralleling with
the utility does not necessarily occur at the instant of
paralleling, and may cause failure of the generator set
under emergency conditions.
Generator sets used with this equipment should
be provided with protection against out-of-phase
paralleling, as well as reverse power and reverse kVAR
protection, so that failure to isolate the sources does
not cause catastrophic damage to the generator set.
Since the closed-transition transfer switch is a utility
paralleling device, and some failure modes of closed-
transition transfer devices can result in sustained
operation in parallel with the utility service, some utility
service providers require protection of their systems
from these effects. Common requirements include
reverse power relays and/or fail-to-disconnect timers.
No closed-transition transfer device should be operated
in closed-transition mode without specic written
permission from the local utility service provider.
Some authorities may interpret the National Electric
Code as requiring the use of protective relaying and
other devices when using closed-transition transfer
switches. See NFPA 76 (National Electrical Code),
article 705 for more details.
Closed-transition transfer switches
with active synchronizing
Some fast closed-transition transfer switches
incorporate an active synchronizing function in the
control so that failures to synchronize can be avoided.
One source of fast closed-transition devices with
active slip frequency synchronizing is Cummins Power
Generation. A PowerCommand closed-transition
transfer switch can incorporate active synchronizing
and also contains an algorithm for adjusting the timing
of the closing of the mechanical contacts in order to
compensate for wear.
Advantages of closed-transition transfer switches with
active synchronizing include:
Synchronizing is more accurate and power transfers
occur more rapidly.
They prevent synchronizing delays in facilities with
very stable loads.
They prevent momentary breaks in power during
generator set testing and when closing back to a
restored utility source.
Disadvantages include:
Similar to other fast closed-transition transfer devices,
except that failure to synchronize is avoided.
Soft closed-transition transfer switches
Soft closed-transition transfer systems use an
automatic synchronizer that forces the generator set to
synchronize with the utility service, closes the generator
to the utility and then gradually transfers the facility
loads to the generator. Transfer time is adjustable
and can vary from a few seconds to several minutes,
depending on facility needs and utility requirements.
On retransfer, a similar process occurs, allowing the
genset load to be gradually reduced before dropping off
the bus. As a result, the typical disturbances in voltage
and frequency are eliminated for all practical purposes.
Because this type of system is often used in situations
where the generator set(s) are connected at the top
of a distribution system for example, powering the
entire building the switching mechanisms can be
low- or medium-voltage power circuit breakers.
Typical applications include standby power systems
for large businesses, resort complexes, data centers,
government centers or facilities participating in
interruptible or load-shedding programs in conjunction
with their utilities.
The advantage of this system is that voltage and
frequency disruptions during the transfer process are
kept to an absolute minimum. The process results in
power transfer between sources that is imperceptible to
nearly any load. Also, since the on-site power system
is actively synchronized to the utility service, other
weaknesses of other closed-transition systems, such
as failure to synchronize and the potential for alternator
damage, are also minimized.
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Power topic #7012 | Page 5
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Design challenges include incorporating code-compliant
emergency power systems and providing effective
ground fault detection and protection equipment. These
challenges can be managed, but require consideration
early in the system design to allow effective integration
into a system.
Disadvantages are cost related, due to the additional
equipment required in the system. These disadvantages
include:
Since interconnection time with the utility is usually
longer than with some other systems, utility-required
protective relaying equipment may be more extensive
than with other systems, and the approval process will
generally take longer.
Active synchronizing functions and import/export
controls for kW and kVAR are required in the system,
which can add cost. These systems are considerably
less expensive than they have been in the past due
to advances in microprocessor-based controls for
generator sets and integration of functions into
simpler control systems.
Figure 5 - Bypass/isolation transfer switch
Bypass/isolation transfer switches
Most of the transfer systems described in this paper can
be provided with bypass/isolation capability. (See Figure 4)
A bypass/isolation provision allows the power-carrying
mechanisms in a transfer switch to be bypassed and
isolated without interrupting power to the facility. This
allows the automatic transfer switch to be conveniently
repaired or maintained.
As may be expected, these provisions are often specied
in systems where the equipment is critical to operation
of the facility or protecting life, and when the equipment
loads are in active service 24 hours a day. The most
common applications for bypass switches are serving
UPS equipment in data centers and healthcare facilities.
While the bypass/isolation capability provides a valuable
function, it does add signicant cost to the transfer
system, particularly in the larger sizes of the device
(more than 1,000 amps). Transfer switches with bypass/
isolation capability typically take up considerably more
space in a facility, and often require both front and rear
access for installation and maintenance. (See Figure 5)
Figure 4
BYPASS/ISOLATION TRANSFER
FROM
UTILITY
FROM
GENSET
TO
LOADS
ATS BYPASS
ATS connected to normal
source and bypass open
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(3/08) CPE-249
Conclusions and recommendations
The most desirable choice of equipment for a specic
application will depend on two major factors: 1)
equipment costs; and 2) the magnitude and duration
of the voltage and frequency deviation the facility can
tolerate. As a general trend, facilities of all sizes are
identifying more and more critical loads that must have
continuous power, and more facilities than ever are
installing generator backup systems that will carry the
entire facility. This trend leads to more closed-transition
transfer systems, because the incremental cost of the
closed-transition functions is a relatively small increase
to the overall system cost.
Gary Olson has been an employee
of Cummins Power Generation since
1977. He holds a B.S. in Mechanical
Engineering from Iowa State University
and an MBA from the University of St.
Thomas. His current responsibilities
About the author
include research relating to on-site power applications,
technical product support for on-site power system
equipment, and contributing to organizations working on
codes and standards. He also manages an engineering
group dedicated to developing the next generation of
power systems.
Before choosing a system for a particular facility,
work with a consulting engineer and power system
supplier to consider all possible power transfer options
to meet system performance and cost optimization
requirements. When contemplating closed-transition
systems, consultation with the utility will be required to
meet the utilitys interconnection regulations.
For additional technical support, please contact your
local Cummins Power Generation distributor. To locate
your distributor, visit http://www.cumminspower.com/.